Facility DEC ID: 6405800003

 PERMIT

 Under the Environmental Conservation Law (ECL)

IDENTIFICATION INFORMATION

Permit Type: Air Title V Facility

Permit ID: 6-4058-00003/00365

Effective Date: 09/01/2002 Expiration Date: 09/01/2007

Permit Issued To: ALCOA INC

201 ISABELLA ST

PITTSBURGH, PA 15212-5858

 

Contact: JAMES M SHAW

ALCOA INC

PO BOX 150

MASSENA, NY 13662-0150

(315) 764-4126

Facility: ALCOA MASSENA OPERATIONS (WEST PLANT)

PARK AVENUE EAST

MASSENA, NY 13662

Contact: JAMES M SHAW

ALCOA INC

PO BOX 150

MASSENA, NY 13662-0150

(315) 764-4126

Description:

By acceptance of this permit, the permittee agrees that the permit is contingent upon strict compliance

with the ECL, all applicable regulations, the General Conditions specified and any Special Conditions

included as part of this permit.

Permit Administrator: BRIAN D FENLON

 STATE OFFICE BLDG

 317 WASHINGTON ST

 WATERTOWN, NY 13601-3787

Authorized Signature: _________________________________ Date: ___ / ___ / _____

FINAL
Facility DEC ID: 6405800003

Notification of Other State Permittee Obligations

Item A: Permittee Accepts Legal Responsibility and Agrees to Indemnification

The permittee expressly agrees to indemnify and hold harmless the Department of Environmental

Conservation of the State of New York, its representatives, employees, and agents ("DEC") for all

claims, suits, actions, and damages, to the extent attributable to the permittee's acts or omissions

in connection with the permittee's undertaking of activities in connection with, or operation and

maintenance of, the facility or facilities authorized by the permit whether in compliance or not in

compliance with the terms and conditions of the permit. This indemnification does not extend to

any claims, suits, actions, or damages to the extent attributable to DEC's own negligent or

intentional acts or omissions, or to any claims, suits, or actions naming the DEC and arising

under article 78 of the New York Civil Practice Laws and Rules or any citizen suit or civil rights

provision under federal or state laws.

Item B: Permittee's Contractors to Comply with Permit

The permittee is responsible for informing its independent contractors, employees, agents and 

assigns of their responsibility to comply with this permit, including all special conditions while

acting as the permittee's agent with respect to the permitted activities, and such persons shall

be subject to the same sanctions for violations of the Environmental Conservation Law as

those prescribed for the permittee.

Item C: Permittee Responsible for Obtaining Other Required Permits

The permittee is responsible for obtaining any other permits, approvals, lands, easements and

rights-of-way that may be required to carry out the activities that are authorized by this

permit.

Item D: No Right to Trespass or Interfere with Riparian Rights

This permit does not convey to the permittee any right to trespass upon the lands or interfere

with the riparian rights of others in order to perform the permitted work nor does it authorize

the impairment of any rights, title, or interest in real or personal property held or vested in a

person not a party to the permit.

FINAL
Facility DEC ID: 6405800003

LIST OF CONDITIONS

 

DEC GENERAL CONDITIONS

General Provisions

Facility Inspection by the Department

Relationship of this Permit to Other Department Orders and Determinations

Applications for Permit Renewals and Modifications

Permit Modifications, Suspensions and Revocations by the Department

Facility Level

Submission of Applications for Permit Modification or Renewal -REGION 6 

HEADQUARTERS

 DEC Permit Conditions

Page 1 of 3 FINAL
Facility DEC ID: 6405800003

 DEC GENERAL CONDITIONS

 **** General Provisions  

n0 For the purpose of your Title V permit, the following section contains state-only enforcable

 terms and conditions

GENERAL CONDITIONS - Apply to ALL Authorized Permits.

Condition 1: Facility Inspection by the Department

Applicable State Requirement: ECL 19-0305.

Item 1.1:

The permitted site or facility, including relevant records, is subject to inspection at reasonable hours and 

intervals by an authorized representative of the Department of Environmental Conservation (the 

Department) to determine whether the permittee is complying with this permit and the ECL. Such 

representative may order the work suspended pursuant to ECL 71-0301 and SAPA 401(3).

Item 1.2:

The permittee shall provide a person to accompany the Department's representative during an inspection 

to the permit area when requested by the Department.

Item 1.3:

A copy of this permit, including all referenced maps, drawings and special conditions, must be available 

for inspection by the Department at all times at the project site or facility. Failure to produce a copy of 

the permit upon request by a Department representative is a violation of this permit.

Condition 2: Relationship of this Permit to Other Department Orders and Determinations

Applicable State Requirement: ECL 3-0301.2(m)

Item 2.1:

Unless expressly provided for by the Department, issuance of this permit does not modify, supersede or 

rescind any order or determination previously issued by the Department or any of the terms, conditions or 

requirements contained in such order or determination.

Condition 3: Applications for Permit Renewals and Modifications

Applicable State Requirement: 6NYCRR 621.13

Item 3.1:

The permittee must submit a separate written application to the Department for renewal, modification or 

transfer of this permit. Such application must include any forms or supplemental information the 

Department requires. Any renewal, modification or transfer granted by the Department must be in 

writing.

Item 3.2:

The permittee must submit a renewal application at least 180 days before expiration of permits for Title V 

Facility Permits, or at least 30 days before expiration of permits for State Facility Permits. 

Item 3.3:

Permits are transferrable with the approval of the department unless specifically prohibited by the statute, 

 DEC Permit Conditions

Page 2 of 3 FINAL
Facility DEC ID: 6405800003

regulation or another permit condition. Applications for permit transfer should be submitted prior to actual 

transfer of ownership.

Condition 4: Permit Modifications, Suspensions and Revocations by the Department

Applicable State Requirement: 6NYCRR 621.14

Item 4.1:

The Department reserves the right to modify, suspend, or revoke this permit in accordance with 6NYCRR 

Part 621. The grounds for modification, suspension or revocation include:

a) materially false or inaccurate statements in the permit application or supporting papers;

b) failure by the permittee to comply with any terms or conditions of the permit;

c) exceeding the scope of the project as described in the permit application;

d) newly discovered material information or a material change in environmental conditions, 

relevant technology or applicable law or regulations since the issuance of the existing permit;

e) noncompliance with previously issued permit conditions, orders of the commissioner, any 

provisions of the Environmental Conservation Law or regulations of the Department 

related to the permitted activity.

 

 ** ** Facility Level  

Condition 5: Submission of Applications for Permit Modification or Renewal -REGION 6 

HEADQUARTERS

Applicable State Requirement: 6NYCRR 621.5(a)

Item 5.1:

Submission of applications for permit modification or renewal are to be submitted to:

NYSDEC Regional Permit Administrator 

Region 6 Headquarters

Division of Environmental Permits

State Office Building, 317 Washington Street

Watertown, NY 13601-3787

(315) 785-2245

 DEC Permit Conditions

Page 3 of 3 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Permit Under the Environmental Conservation Law (ECL)

 ARTICLE 19: AIR POLLUTION CONTROL - TITLE V PERMIT

 

IDENTIFICATION INFORMATION

Permit Issued To: ALCOA INC

201 ISABELLA ST

PITTSBURGH, PA 15212-5858

 

Contact: JAMES M SHAW

ALCOA INC

PO BOX 150

MASSENA, NY 13662-0150

(315) 764-4126

Facility: ALCOA MASSENA OPERATIONS (WEST PLANT)

PARK AVENUE EAST

MASSENA, NY 13662

Contact: JAMES M SHAW

ALCOA INC

PO BOX 150

MASSENA, NY 13662-0150

(315) 764-4126

Authorized Activity By Standard Industrial Classification Code:

3334 - PRIMARY ALUMINUM

3354 - ALUMINUM EXTRUDED PRODUCTS

 Air Pollution Control Permit Conditions

Page 1 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

LIST OF CONDITIONS

 

FEDERALLY ENFORCEABLE CONDITIONS

Facility Level

1 Surface Coating Exemption

2 Emission Unit Definition

3 Recordkeeping and reporting of compliance monitoring

4 Monitoring, Related Recordkeeping, and Reporting Requirements.

5 Compliance Certification 

6 Compliance Certification 

7 Non Applicable requirements

8 Required Emissions Tests - Facility Level

9 Compliance Certification 

10 Recordkeeping requirements

11 Compliance Certification 

12 Compliance Certification 

13 Compliance Certification 

14 Compliance Certification 

15 Compliance Certification 

16 Equipment Specifications for Cold Cleaning Batch Degreasing

17 Compliance Certification 

18 Compliance Certification 

19 Compliance Certification 

20 Incorporation by Reference

21 Compliance Provisions - Test Plan

22 Compliance Certification 

23 Reference test methods for TF and POM emissions

24 Alternative test methods for TF or POM emissions

25 Accidental release provisions.

26 Recycling and Emissions Reduction

Emission Unit Level

27 Emission Point Definition By Emission Unit

28 Process Definition By Emission Unit

29 Compliance Certification (EU=A-00001,EP=F078A,Proc=HT2,ES=AF78A)

30 Compliance Certification (EU=A-00001,EP=F078B,Proc=HT2,ES=AF78B)

31 Compliance Certification (EU=A-00002,Proc=FAB)

32 Compliance Certification (EU=A-00002,Proc=MRS)

33 Compliance Certification (EU=A-00002,Proc=MRS)

34 Corrective Action

35 Corrective Action

36 Corrective Action

37 Corrective Action

38 General Provisions

39 Compliance Certification (EU=B-00001)

40 Compliance Certification (EU=B-00001,Proc=OIL)

41 Compliance Certification (EU=B-00001,Proc=OIL)

 Air Pollution Control Permit Conditions

Page 2 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

42 Records retention

43 Sulfur in fuel exception reporting

44 Compliance Certification (EU=B-00001,Proc=OIL)

45 Sampling, compositing, and analysis of fuel samples

46 Compliance Certification (EU=B-00001,Proc=OIL)

47 Compliance Certification (EU=B-00001,Proc=OIL,ES=B0001)

48 Compliance Certification (EU=B-00001,Proc=OIL,ES=B0002)

49 Compliance Certification (EU=B-00001,Proc=OIL,ES=B0003)

50 Compliance Certification (EU=B-00001,Proc=OIL,ES=B0004)

51 Compliance Certification (EU=B-00001,EP=00001,Proc=GAS)

52 Compliance Certification (EU=B-00001,EP=00001,Proc=OIL)

53 Compliance Certification (EU=B-00001,EP=00002,Proc=GAS)

54 Compliance Certification (EU=B-00001,EP=00002,Proc=OIL)

55 Compliance Certification (EU=C-00001)

56 Compliance Certification (EU=C-00001)

57 Compliance Certification (EU=C-00001)

58 Compliance Certification (EU=C-00001,Proc=CD1,ES=C029B)

59 Compliance Certification (EU=C-00001,Proc=CD1,ES=C029B)

60 Compliance Certification (EU=C-00001,EP=I0029,Proc=CD1)

61 Compliance Certification (EU=C-00001,EP=I0029,Proc=CD1)

62 Compliance Certification (EU=C-00001,EP=I0030,Proc=CM1,ES=C0030)

63 Compliance Certification (EU=C-00002)

64 Compliance Certification (EU=C-00002)

65 Compliance Certification (EU=C-00002)

66 Compliance Certification (EU=C-00002)

67 Compliance Certification (EU=C-00002,Proc=CD2)

68 Compliance Certification (EU=C-00002,Proc=CD2)

69 Compliance Certification (EU=C-00002,Proc=CD2,ES=C044B)

70 Compliance Certification (EU=C-00002,Proc=CD2,ES=C044B)

71 Compliance Certification (EU=D-00001,Proc=PRT)

72 Compliance Certification (EU=D-00001,Proc=PRT)

73 method 24 40 CFR 60

74 samples

75 Compliance Certification (EU=D-00001,Proc=PRT)

76 Compliance Certification (EU=D-00001,Proc=PRT)

77 Compliance Certification (EU=D-00001,Proc=PRT,ES=DF073)

78 Compliance Certification (EU=M-00001)

79 Compliance Certification (EU=M-00001)

80 Compliance Certification (EU=M-00001)

81 Compliance Certification (EU=M-00001)

82 Calculation of Secondary Aluminum Processing Unit PM emissions

83 Compliance Certification (EU=M-00001)

84 Compliance Certification (EU=M-00001)

85 Compliance Certification (EU=M-00001)

86 Compliance Certification (EU=M-00001)

87 Testing of Representative Emission Units

88 Compliance Certification (EU=M-00001)

89 Compliance Certification (EU=M-00001)

 Air Pollution Control Permit Conditions

Page 3 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

90 Performance Test/Compliance Demonstration Requirements and

Procedures - Feed/Charge Weight Measurement.

91 Compliance Certification (EU=M-00001)

92 Equations for Determining Compliance - Secondary Aluminum 

Processing Unit

93 Compliance Certification (EU=M-00001)

94 Compliance Certification (EU=M-00001)

95 Compliance Certification (EU=M-00001,EP=I003C,Proc=MHS,ES=M003C)

96 Compliance Certification (EU=M-00001,EP=I024F,Proc=MHA,ES=M024F)

97 Compliance Certification (EU=M-00002)

98 Compliance Certification (EU=M-00002)

99 Compliance Certification (EU=M-00002)

100 Compliance Certification (EU=M-00002)

101 Calculation of Secondary Aluminum Processing Unit PM emissions

102 Compliance Certification (EU=M-00002)

103 Compliance Certification (EU=M-00002)

104 Compliance Certification (EU=M-00002)

105 Compliance Certification (EU=M-00002)

106 Testing of Representative Emission Units

107 Compliance Certification (EU=M-00002)

108 Compliance Certification (EU=M-00002)

109 Performance Test/Compliance Demonstration Requirements and

Procedures - Feed/Charge Weight Measurement.

110 Compliance Certification (EU=M-00002)

111 Equations for Determining Compliance - Secondary Aluminum 

Processing Unit

112 Compliance Certification (EU=M-00002)

113 Compliance Certification (EU=M-00002)

114 General requirements

115 Compliance Certification (EU=P-00001,Proc=PWS)

116 Compliance Certification (EU=S-00001,Proc=POT)

117 Compliance Certification (EU=S-00001,Proc=POT)

118 Compliance Certification (EU=S-00001,Proc=POT)

119 Performance Test Requirements - Previous Control Device Tests

120 Potline TF emission rate calculation

121 Procedure to determine weights

122 Calculation of aluminum production rate

123 Selection of monitoring parameters - potlines and anode bake furnaces

124 Selection of monitoring parameters - redetermining operating limits

125 Compliance Certification (EU=S-00001,Proc=POT)

126 Reduced sampling frequency - contents of request letter

127 Reduced sampling frequency request - contents of the 

approved alternative requirement

128 Compliance Certification (EU=S-00001,Proc=POT)

129 Compliance Certification (EU=S-00001,Proc=POT)

130 Compliance Certification (EU=S-00001,Proc=POT)

131 Corrective action procedures

132 Exceedances

 Air Pollution Control Permit Conditions

Page 4 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

133 Compliance Certification (EU=S-00001,Proc=POT)

134 Accuracy and calibration requirements

135 Alternative operating parameters

136 Definition of potline in Method 14

137 Installation of manifolds for potlines subject to Method 14

138 Performance test reports

139 Startup, shutdown, and malfunction plan and reports

140 Startup, shutdown, and malfunction plan and reports

141 Compliance Certification (EU=S-00001,Proc=POT)

142 Compliance Certification (EU=S-00001,Proc=POT)

143 Compliance Certification (EU=S-00001,Proc=POT)

144 Compliance Certification (EU=S-00001,Proc=POT)

145 Compliance Certification (EU=S-00001,Proc=POT)

146 Compliance Certification (EU=S-00002,Proc=BAK)

147 Compliance Certification (EU=S-00002,Proc=BAK)

148 Performance Test Requirements - Previous Control Device Tests

149 Compliance Certification (EU=S-00002,Proc=BAK)

150 Compliance Certification (EU=S-00002,Proc=BAK)

151 Calculation of anode bake furnace TF emission rate

152 Calculation of anode bake furnace POM emission rate

153 Procedure to determine weights

154 Determination of rate of green anode introduction into furnace

155 Selection of monitoring parameters - potlines and anode bake furnaces

156 Selection of monitoring parameters - redetermining operating limits

157 Compliance Certification (EU=S-00002,Proc=BAK)

158 Compliance Certification (EU=S-00002,Proc=BAK)

159 Compliance Certification (EU=S-00002,Proc=BAK)

160 Compliance Certification (EU=S-00002,Proc=BAK)

161 Compliance Certification (EU=S-00002,Proc=BAK)

162 Corrective action procedures

163 Exceedances

164 Compliance Certification (EU=S-00002,Proc=BAK)

165 Accuracy and calibration requirements

166 Alternative operating parameters

167 Performance test reports

168 Startup, shutdown, and malfunction plan and reports

169 Startup, shutdown, and malfunction plan and reports

170 Compliance Certification (EU=S-00002,Proc=BAK)

171 Compliance Certification (EU=S-00002,Proc=BAK)

172 Compliance Certification (EU=S-00002,Proc=BAK)

173 Compliance Certification (EU=S-00002,Proc=BAK)

174 Compliance Certification (EU=S-00002,Proc=BAK)

175 Compliance Certification (EU=S-00002,EP=S0078,Proc=BAK,ES=SS078)

176 Compliance Certification (EU=S-00002,EP=S0078,Proc=BAK,ES=SS078)

177 Emission Limits for Existing Sources - Paste Production Plants

178 Initial compliance provisions for paste production plants

179 Selection of monitoring parameters - paste production plants

180 Selection of monitoring parameters - redetermining operating limits

 Air Pollution Control Permit Conditions

Page 5 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

181 Compliance Certification (EU=S-00003)

182 Compliance Certification (EU=S-00003)

183 Compliance Certification (EU=S-00003)

184 Corrective action procedures

185 Exceedances

186 Accuracy and calibration requirements

187 Alternative operating parameters

188 Startup, shutdown, and malfunction plan and reports

189 Startup, shutdown, and malfunction plan and reports

190 Compliance Certification (EU=S-00003)

191 Compliance Certification (EU=S-00003)

192 Compliance Certification (EU=S-00003)

193 Compliance Certification (EU=S-00003)

194 Compliance Certification (EU=S-00003)

195 Compliance Certification (EU=S-00003,EP=S0100)

196 Compliance Certification (EU=S-00004,Proc=M01,ES=SS017)

197 Compliance Certification (EU=S-00004,Proc=M16)

198 Compliance Certification (EU=S-00005,Proc=PST)

199 Compliance Certification (EU=W-00001,Proc=WWT)

200 Compliance Certification (EU=W-00001,Proc=WWT)

STATE ONLY ENFORCEABLE CONDITIONS

Facility Level

201 Contaminant List

202 Unavoidable noncompliance and violations

203 Compliance Demonstration

204 Emissions other than total fluorides

205 Air pollution prohibited

206 Compliance Demonstration

207 Compliance Demonstration

208 Compliance Demonstration

Emission Unit Level

209 Compliance Demonstration

210 Compliance Demonstration

211 Compliance Demonstration

212 Compliance Demonstration

213 Compliance Demonstration

3355 - ALUMINUM ROLLING & DRAWING NEC

Permit Effective Date: 09/01/2002 Permit Expiration Date: 09/01/2007

 Air Pollution Control Permit Conditions

Page 6 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

FEDERALLY ENFORCEABLE CONDITIONS

** ** Facility Level  

NOTIFICATION OF GENERAL PERMITTEE OBLIGATIONS

The items listed below are not subject to the annual compliance certification

 requirements under Title V. Permittees may also have other obligations

under regulations of general applicability.

Item A: Sealing - 6NYCRR Part 200.5

The Commissioner may seal an air contamination source to 

prevent its operation if compliance with 6 NYCRR Chapter 

III is not met within the time provided by an order of the

Commissioner issued in the case of the violation. 

Sealing means labeling or tagging a source to notify any 

person that operation of the source is prohibited, and 

also includes physical means of preventing the operation 

of an air contamination source without resulting in 

destruction of any equipment associated with such source, 

and includes, but is not limited to, bolting, chaining or 

wiring shut control panels, apertures or conduits 

associated with such source.

No person shall operate any air contamination source 

sealed by the Commissioner in accordance with this section

unless a modification has been made which enables such 

source to comply with all requirements applicable to such 

modification.

Unless authorized by the Commissioner, no person shall 

remove or alter any seal affixed to any contamination 

source in accordance with this section.

Item B: Acceptable Ambient Air Quality - 6NYCRR Part 200.6

 

Notwithstanding the provisions of 6 NYCRR Chapter III, 

Subchapter A, no person shall allow or permit any air 

contamination source to emit air contaminants in 

quantities which alone or in combination with emissions 

from other air contamination sources would contravene any 

applicable ambient air quality standard and/or cause air 

pollution. In such cases where contravention occurs or may

occur, the Commissioner shall specify the degree and/or 

method of emission control required.

Item C: Maintenance of Equipment - 6NYCRR Part 200.7

 

Any person who owns or operates an air contamination 

 Air Pollution Control Permit Conditions

Page 7 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

source which is equipped with an emission control device 

shall operate such device and keep it in a satisfactory 

state of maintenance and repair in accordance with 

ordinary and necessary practices, standards and 

procedures, inclusive of manufacturer's specifications, 

required to operate such device effectively.

Item D: Unpermitted Emission Sources - 6NYCRR Part 201-1.2

 

If an existing emission source was subject to the 

permitting requirements of 6NYCRR Part 201 at the time of 

construction or modification, and the owner and/or 

operator failed to apply for a permit for such emission 

source then the following provisions apply:

(a) The owner and/or operator must apply for a permit for 

such emission source or register the facility in 

accordance with the provisions of Part 201.

(b) The emission source or facility is subject to all 

regulations that were applicable to it at the time of 

construction or modification and any subsequent 

requirements applicable to existing sources or 

facilities.

Item E: Emergency Defense - 6NYCRR Part 201-1.5

 

An emergency constitutes an affirmative defense to an 

action brought for noncompliance with emissions 

limitations or permit conditions for all facilities in New

York State.

(a) The affirmative defense of emergency shall be 

demonstrated through properly signed, contemporaneous 

operating logs, or other relevant evidence that:

(1) An emergency occurred and that the facility owner 

and/or operator can identify the cause(s) of the 

emergency;

(2) The equipment at the permitted facility causing the 

emergency was at the time being properly operated;

(3) During the period of the emergency the facility owner

and/or operator took all reasonable steps to minimize 

levels of emissions that exceeded the emission standards, 

or other requirements in the permit; and

(4) The facility owner and/or operator notified the 

Department within two working days after the event 

occurred. This notice must contain a description of the 

 Air Pollution Control Permit Conditions

Page 8 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

emergency, any steps taken to mitigate emissions, and 

corrective actions taken.

(b) In any enforcement proceeding, the facility owner 

and/or operator seeking to establish the occurrence of an 

emergency has the burden of proof.

(c) This provision is in addition to any emergency or 

upset provision contained in any applicable requirement.

Item F: Recycling and Salvage - 6NYCRR Part 201-1.7

 

Where practical, any person who owns or operates an air 

contamination source shall recycle or salvage air 

contaminants collected in an air cleaning device according

to the requirements of 6 NYCRR.

Item G: Prohibition of Reintroduction of Collected Contaminants 

to the Air - 6NYCRR Part 201-1.8

No person shall unnecessarily remove, handle, or cause to

be handled, collected air contaminants from an air 

cleaning device for recycling, salvage or disposal in a 

manner that would reintroduce them to the outdoor 

atmosphere.

Item H: Public Access to Recordkeeping for Title V Facilities - 

6NYCRR Part 201-1.10(b)

The Department will make available to the public any 

permit application, compliance plan, permit, and 

monitoring and compliance certification report pursuant to

Section 503(e) of the Act, except for information entitled

to confidential treatment pursuant to 6NYCRR Part 616 - 

Public Access to records and Section 114(c) of the Act.

Item I: Proof of Eligibility for Sources Defined as Exempt 

Activities - 6 NYCRR Part 201-3.2(a)

The owner and/or operator of an emission source or unit 

that is eligible to be exempt, may be required to certify 

that it operates within the specific criteria described in

6 NYCRR Subpart 201-3. The owner or operator of any such 

emission source must maintain all required records on-site

for a period of five years and make them available to 

representatives of the Department upon request. 

Department representatives must be granted access to any 

facility which contains emission sources or units subject 

to 6 NYCRR Subpart 201-3, during normal operating hours, 

for the purpose of determining compliance with this and 

any other state and federal air pollution control 

 Air Pollution Control Permit Conditions

Page 9 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

requirements, regulations, or law.

Item J: Proof of Eligibility for Sources Defined as Trivial 

Activities - 6 NYCRR Part 201-3.3(a)

The owner and/or operator of an emission source or unit 

that is listed as being trivial in 6 NYCRR Part 201 may be

required to certify that it operates within the specific 

criteria described in 6 NYCRR Subpart 201-3. The owner or

operator of any such emission source must maintain all 

required records on-site for a period of five years and 

make them available to representatives of the Department 

upon request. Department representatives must be granted 

access to any facility which contains emission sources or 

units subject to 6 NYCRR Subpart 201-3, during normal 

operating hours, for the purpose of determining compliance

with this and any other state and federal air pollution 

control requirements, regulations, or law.

Item K: Timely Application for the Renewal of Title V Permits - 6

NYCRR Part 201-6.3(a)(4)

Owners and/or operators of facilities having an issued 

Title V permit shall submit a complete application at 

least 180 days, but not more than eighteen months, prior 

to the date of permit expiration for permit renewal 

purposes.

Item L: Certification by a Responsible Official - 6 NYCRR Part 

201-6.3(d)(12)

Any application, form, report or compliance certification

required to be submitted pursuant to the federally 

enforceable portions of this permit shall contain a 

certification of truth, accuracy and completeness by a 

responsible official. This certification shall state that 

based on information and belief formed after reasonable 

inquiry, the statements and information in the document 

are true, accurate, and complete.

Item M: Requirement to Comply With All Conditions - 6 NYCRR Part 

201-6.5(a)(2)

The permittee must comply with all conditions of the 

Title V facility permit. Any permit non-compliance 

constitutes a violation of the Act and is grounds for 

enforcement action; for permit termination, revocation and

reissuance, or modification; or for denial of a permit 

renewal application.

Item N: Permit Revocation, Modification, Reopening, Reissuance or

Termination, and Associated Information Submission 

 Air Pollution Control Permit Conditions

Page 10 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Requirements - 6 NYCRR Part 201-6.5(a)(3)

This permit may be modified, revoked, reopened and 

reissued, or terminated for cause. The filing of a request

by the permittee for a permit modification, revocation and

reissuance, or termination, or of a notification of 

planned changes or anticipated noncompliance does not stay

any permit condition.

Item O: Providing Information Upon Request - 6 NYCRR Part 

201-6.5(a)(4)

The permittee shall furnish to the Department, within a 

ard reasonable time, any information that the Department may 

request in writing to determine whether cause exists for 

modifying, revoking and reissuing, or terminating the 

permit or to determine compliance with the permit. The 

permittee shall also, on request, furnish the Department 

with copies of records required to be kept by the permit. 

Where information is claimed to be confidential, the 

permittee may furnish such records directly to the 

Administrator along with a claim of confidentiality.

Item P: Cessation or Reduction of Permitted Activity Not a 

Defense - 6NYCRR Part 201-6.5(a)(5)

It shall not be a defense for a permittee in an 

enforcement action to claim that a cessation or reduction 

in the permitted activity would have been necessary in 

order to maintain compliance with the conditions of this 

permit.

Item Q: Property Rights - 6 NYCRR Part 201-6.5(a)(6)

 

This permit does not convey any property rights of any 

sort or any exclusive privilege.

Item R: Fees - 6 NYCRR Part 201-6.5(a)(7)

 

The owner and/or operator of a stationary source shall 

pay fees to the department consistent with the fee 

schedule authorized by 6 NYCRR Subpart 482-2.

Item S: Right to Inspect - 6 NYCRR Part 201-6.5(a)(8)

 

Upon presentation of credentials and other documents, as 

may be required by law, the permittee shall allow the 

Department or an authorized representative to perform the 

following:

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

i. Enter upon the permittee's premises where the permitted

facility is located or emissions-related activity is 

conducted, or where records must be kept under the 

conditions of the permit;

ii. Have access to and copy, at reasonable times, any 

records that must be kept under the conditions of the 

permit;

iii. Inspect, at reasonable times, any facilities, 

equipment (including monitoring and air pollution control 

equipment), practices, or operations regulated or required

under the permit; and

iv. As authorized by the Act, sample or monitor, at 

reasonable times, substances or parameters for the purpose

of assuring compliance with the permit or applicable 

requirements.

Item T: Severability - 6 NYCRR Part 201-6.5(a)(9)

 

If any provisions, parts or conditions of this permit are

found to be invalid or are the subject of a challenge, the

remainder of this permit shall continue to be valid.

Item U: Progress Reports and Compliance Schedules - 6 NYCRR Part 

201-6.5(d)(5)

Progress reports consistent with an applicable schedule 

of compliance must be submitted at least semiannually on a

calendar year basis, or at a more frequent period if 

specified in the applicable requirement or by the 

Department elsewhere in this permit. These reports shall

be submitted to the Department within 30 days after the 

end of a reporting period. Such progress reports shall 

contain the following:

i. Dates for achieving the activities, milestones, or 

compliance required in the schedule of compliance, and 

dates when such activities, milestones or compliance were 

achieved; and

ii. An explanation of why any dates in the schedule of 

compliance were not or will not be met, and any preventive

or corrective measures adopted.

Item V: Off Permit Changes - 6 NYCRR Part 201-6.5(f)(6)

 

No permit revision will be required for operating changes

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

that contravene an express permit term, provided that such

changes would not violate applicable requirements as 

defined under this Part or contravene federally 

enforceable monitoring (including test methods), 

recordkeeping, reporting, or compliance certification 

permit terms and conditions. Such changes may be made 

without requiring a permit revision, if the changes are 

not modifications under any provisions of Title I of the 

Act and the changes do not exceed the emissions allowable 

under the permit (whether expressed therein as a rate of 

emissions or in terms of total emissions) provided that 

the facility provides the Administrator and the Department

with written notification in advance of the proposed 

changes within a minimum of 7 days as required by 6 NYCRR 

§201-6.5(f)(6).

Item W: Permit Shield - 6 NYCRR Part 201-6.5(g)

 

All permittees granted a Title V facility permit shall be

covered under the protection of a permit shield, except as

provided under 6 NYCRR Subpart 201-6. Compliance with the

conditions of the permit shall be deemed compliance with 

any applicable requirements as of the date of permit 

issuance, provided that such applicable requirements are 

included and are specifically identified in the permit, or

the Department, in acting on the permit application or 

revision, determines in writing that other requirements 

specifically identified are not applicable to the major 

stationary source, and the permit includes the 

determination or a concise summary thereof. Nothing herein

shall preclude the Department from revising or revoking 

the permit pursuant to 6 NYCRR Part 621 or from exercising

its summary abatement authority. Nothing in this permit 

shall alter or affect the following:

i. The ability of the Department to seek to bring suit on 

behalf of the State of New York, or the Administrator to 

seek to bring suit on behalf of the United States, to 

immediately restrain any person causing or contributing to

pollution presenting an imminent and substantial 

endangerment to public health, welfare or the environment 

to stop the emission of air pollutants causing or 

contributing to such pollution;

ii. The liability of a permittee of the Title V facility 

for any violation of applicable requirements prior to or 

at the time of permit issuance;

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

iii. The applicable requirements of Title IV of the 

Act;

iv. The ability of the Department or the Administrator to 

obtain information from the permittee concerning the 

ability to enter, inspect and monitor the facility.

Item X: Reopening for Cause - 6 NYCRR Part 201-6.5(i)

 

This Title V permit shall be reopened and revised under 

any of the following circumstances:

i. If additional applicable requirements under the Act 

become applicable where this permit's remaining term is 

three or more years, a reopening shall be completed not 

later than 18 months after promulgation of the applicable 

requirement. No such reopening is required if the 

effective date of the requirement is later than the date 

on which this permit is due to expire, unless the original

permit or any of its terms and conditions has been 

extended by the Department pursuant to the provisions of 

Part 201-6.7 and Part 621.

ii. The Department or the Administrator determines that 

the permit contains a material mistake or that inaccurate 

statements were made in establishing the emissions 

standards or other terms or conditions of the 

permit.

iii. The Department or the Administrator determines that 

the Title V permit must be revised or reopened to assure 

compliance with applicable requirements.

iv. If the permitted facility is an "affected source" 

subject to the requirements of Title IV of the Act, and 

additional requirements (including excess emissions 

requirements) become applicable. Upon approval by the 

Administrator, excess emissions offset plans shall be 

deemed to be incorporated into the permit.

 Proceedings to reopen and issue Title V facility permits 

shall follow the same procedures as apply to initial 

permit issuance but shall affect only those parts of the 

permit for which cause to reopen exists.

 Reopenings shall not be initiated before a notice of such

intent is provided to the facility by the Department at 

least thirty days in advance of the date that the permit 

 Air Pollution Control Permit Conditions

Page 14 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

is to be reopened, except that the Department may provide

a shorter time period in the case of an emergency.

Item Y: Required Emission Tests - 6 NYCRR Part 202-1.1

 

An acceptable report of measured emissions shall be 

submitted, as may be required by the Commissioner, to 

ascertain compliance or noncompliance with any air 

pollution code, rule, or regulation. Failure to submit a 

report acceptable to the Commissioner within the time 

stated shall be sufficient reason for the Commissioner to 

suspend or deny an operating permit. Notification and 

acceptable procedures are specified in 6NYCRR Part 202-1.

Item Z: Visible Emissions Limited - 6 NYCRR Part 211.3

Except as permitted by a specific part of this Subchapter

and for open fires for which a restricted burning permit 

has been issued, no person shall cause or allow any air 

contamination source to emit any material having an 

opacity equal to or greater than 20 percent (six minute 

average) except for one continuous six-minute period per 

hour of not more than 57 percent opacity.

Item AA: Open Fires - 6 NYCRR Part 215

No person shall burn, cause, suffer, allow or permit the 

burning in an open fire of garbage, rubbish for salvage, 

or rubbish generated by industrial or commercial 

activities.

Item BB: Permit Exclusion - ECL 19-0305

The issuance of this permit by the Department and the 

receipt thereof by the Applicant does not and shall not be

construed as barring, diminishing, adjudicating or in any 

way affecting any legal, administrative or equitable 

rights or claims, actions, suits, causes of action or 

demands whatsoever that the Department may have against 

the Applicant for violations based on facts and 

circumstances alleged to have occurred or existed prior to

the effective date of this permit, including, but not 

limited to, any enforcement action authorized pursuant to 

the provisions of applicable federal law, the 

Environmental Conservation Law of the State of New York 

(ECL) and Chapter III of the Official Compilation of the 

Codes, Rules and Regulations of the State of New York 

(NYCRR). The issuance of this permit also shall not in any

way affect pending or future enforcement actions under the

Clean Air Act brought by the United States or any person.

 Air Pollution Control Permit Conditions

Page 15 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item CC: Federally Enforceable Requirements - 40 CFR 70.6(b)

All terms and conditions in this permit required by the 

Act or any applicable requirement, including any 

provisions designed to limit a facility's potential to 

emit, are enforceable by the Administrator and citizens 

under the Act. The Department has, in this permit, 

specifically designated any terms and conditions that are 

not required under the Act or under any of its applicable 

requirements as being enforceable under only state 

regulations.

FEDERAL APPLICABLE REQUIREMENTS

The following conditions are subject to annual compliance certification requirements

for Title V permits only.

Condition 1: Surface Coating Exemption

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 201-3.2(c)(17)

Item 1.1:

The following activity is exempt from permitting requirements, but must be included in the Title V permit 

application: Surface coating and related operations which uses less than 25 gallons per month of coating 

materials (paints) and cleaning solvents, combined, subject to the following: 

(i) the facility is located outside of any severe ozone non attainment area; and

(ii) all abrasive cleaning and surface coating operations are performed in an enclosed building where 

such operations are exhausted into appropriate emission control devices.

 

Condition 2: Emission Unit Definition

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 201-6.

Item 2.1:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: A-00001

Emission Unit Description: 

PROCESS HEATERS TREAT SOLID ALUMINUM AND 

EMIT SMALL QUANTITIES OF PROCESS EMISSIONS 

DUE TO RESIDUALS ON THE ALUMINUM. 

EMISSIONS CO-MINGLE WITH 

PRODUCTS-OF-COMBUSTION (POC) FROM NATURAL 

GAS BURNERS.

Building(s): 131

 Air Pollution Control Permit Conditions

Page 16 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

140

222

234

Item 2.2:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: A-00002

Emission Unit Description: 

INSIGNIFICANT SHOP SOURCES.

Building(s): 131

140

Item 2.3:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: B-00001

Emission Unit Description: 

FOUR VIRTUALLY IDENTICAL PACKAGE BOILERS 

FIRING EITHER NATURAL GAS OR #6 FUEL OIL.

Building(s): 216A

Item 2.4:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: C-00001

Emission Unit Description: 

CHIP DRYER #1 WITH ASSOCIATED CONTROL 

EQUIPMENT (CYCLONE AND AFTERBURNER) AND 

CHIP MELTER #1.

Building(s): 221

Item 2.5:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: C-00002

Emission Unit Description: 

CHIP DRYER #2 WITH ASSOCIATED CONTROL 

EQUIPMENT (CYCLONE AND THERMAL OXIDIZER) 

AND CHIP MELTER #2.

Building(s): 221

Item 2.6:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: D-00001

Emission Unit Description: 

MISCELLANEOUS POINT SOURCES.

 Air Pollution Control Permit Conditions

Page 17 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Building(s): 140

220

222

Item 2.7:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: F-00001

Emission Unit Description: 

ALCOA ENGINEERED PRODUCTS (AEP) FUGITIVES.

Building(s): 131

140

220

222

Item 2.8:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: M-00001

Emission Unit Description: 

ALUMINUM MELTING AND HOLDING FURNACES. 

ALL FURNACES ARE REVERBERATORY, CENTER 

CHARGED. FURNACE CHARGE MOLTEN ALUMINUM, 

CLEAN SCRAP, ALLOYING INGREDIENTS AND SALT.

 NO GAS FLUXING IS DONE IN ANY FURNACE.

Building(s): 221

Item 2.9:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: M-00002

Emission Unit Description: 

IN-LINE FILTERB BOX FLUXING UNITS USE A 

MIXTURE OF ARGON AND CHLORINE GAS TO PURIFY

MOLTEN ALUMINUM AS IT IS BEING CAST INTO 

INGOTS OR ROD. TYPICALLY THERE IS ONE 

FILTERBOX PER FURNACE, AND MULITPLE 

FURNACES/FILTERBOXES SERVE A SINGLE CASTING

COMPLEX. WI THIN A CASTING COMPLEX, THESE 

FILTERBOXES CAN BE EXHAUSTED TOGETHER OR 

INDIVIDUALLY, HOWEVER, ONLY ONE FILTER BOX 

IS FLUXING AT ANY TIME SINCE THERE IS ONLY 

ONE CASTING APPARATUS PER COMPLEX. THUS 

ONLY ONE FILTERBOX EMISSION SOURCE AND 

POINT REPRESENTS A LL FILTERBOXES IN A 

SINGLE CASTING COMPLEX.

Building(s): 221

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Page 18 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item 2.10:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: P-00001

Emission Unit Description: 

This emission unit consists of all the parts washers in 

the facility.

Item 2.11:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: S-00001

Emission Unit Description: 

ONE POTLINE OF ELECTROLYTIC CELLS AND 

ASSOCIATED CONTROL EQUIPMENT. THIS POTLINE

IS CATEGORIZED AS A CENTER WORK PREBAKE-1 

(CWPB-1) AS DESCRIBED IN THE DEFINITIONS 

SECTION OF EPA'S PRIMARY ALUMINUM MACT 

REGULATIONS. THE PERMIT TO CONSTRUCT WAS 

ISSUED IN NOVEMBER 1973.

Building(s): 401

402

Item 2.12:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: S-00002

Emission Unit Description: 

ANODE BAKING FURNACE AND ASSOCIATED 

ALUMINA INJECTION DRY SCRUBBER.

Building(s): 351

Item 2.13:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: S-00003

Emission Unit Description: 

PASTE PRODUCTION PLANT AND ASSOCIATED COKE

INJECTION SCRUBBER.

Building(s): 354C

Item 2.14:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: S-00004

Emission Unit Description: 

MATERIAL HANDLING OPERATIONS FOR ALUMINA, 

CARBON AND OTHER MISCELLANEOUS SOLID 

MATERIALS. EACH ARE CONTROLLED BY A FABRIC

FILTER TO LIMIT PARTICULATE EMISSIONS TO 

 Air Pollution Control Permit Conditions

Page 19 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

THE ENVIRONMENT.

Building(s): 332

344

351

354B

354C

378

380

435

440A

440E

440H

441

441C

446A

446B

446C

469

Item 2.15:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: S-00005

Emission Unit Description: 

COAL TAR PITCH UNLOADING AND STORAGE. 

INCLUDES FUGITIVES FROM THE PITCH UNLOADING

PUMPS AND PITCH RECIRCULATING PUMPS.

Building(s): 352B

352F

Item 2.16:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: S-00006

Emission Unit Description: 

SMELTING AND ANODE PLANT FUGITIVES 

EXCEPTING POTLINE FUGITIVES (THE POTLINE 

FUGITIVES ARE REGULATED UNDER PRIMARY 

ALUMINUM MACT REGULATIONS).

Building(s): 314

332

350

0351

352B

370

372

374

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Page 20 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

376

380

Item 2.17:

The facility is authorized to perform regulated processes under this permit for:

Emission Unit: W-00001

Emission Unit Description: 

WASTEWATER TREATMENT OPERATIONS.

Building(s): 79C

Condition 3: Recordkeeping and reporting of compliance monitoring

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 201-6.5(c)

Item 3.1:

The following information must be included in any required compliance monitoring records and reports:

(i) The date, place, and time of sampling or measurements;

(ii) The date(s) analyses were performed;

(iii)The company or entity that performed the analyses;

(iv) The analytical techniques or methods used including quality assurance and quality control procedures 

if required;

(v) The results of such analyses including quality assurance data where required; and

(vi) The operating conditions as existing at the time of sampling or measurement.

Any deviation from permit requirements must be clearly identified in all records and reports. Reports 

must be certified by a responsible official, consistent with Section 201-6.3 of this Part 201.

 

Condition 4: Monitoring, Related Recordkeeping, and Reporting 

Requirements.

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 201-6.5(c)(2)

Item 4.1:

Compliance monitoring and recordkeeping shall be conducted according to the terms and conditions 

contained in this permit and shall follow all quality assurance requirements found in applicable 

regulations. Records of all monitoring data and support information must be retained for a period of at 

least 5 years from the date of the monitoring, sampling, measurement, report, or application. Support 

information includes all calibration and maintenance records and all original strip-chart recordings for 

continuous monitoring instrumentation, and copies of all reports required by the permit. 

 Air Pollution Control Permit Conditions

Page 21 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

 

Condition 5: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 201-6.5(c)(3)(ii)

Item 5.1:

The Compliance Certification activity will be performed for the Facility.

Item 5.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

To meet the requirements of this facility permit with 

respect to reporting, the permittee must:

Submit reports of any required monitoring at a minimum 

frequency of every 6 months, based on a calendar year 

reporting schedule. These reports shall be submitted to 

the Department within 30 days after the end of a reporting

period. All instances of deviations from permit 

requirements must be clearly identified in such reports. 

All required reports must be certified by the responsible 

official for this facility.

Notify the Department and report permit deviations and 

incidences of noncompliance stating the probable cause of 

such deviations, and any corrective actions or preventive 

measures taken. Where the underlying applicable 

requirement contains a definition of prompt or otherwise 

specifies a time frame for reporting deviations, that 

definition or time frame shall govern. Where the 

underlying applicable requirement fails to address the 

time frame for reporting deviations, reports of deviations

shall be submitted to the permitting authority based on 

the following schedule:

(1) For emissions of a hazardous air pollutant or a 

toxic air pollutant (as identified in an applicable 

regulation) that continue for more than an hour in excess 

of permit requirements, the report must be made within 24 

hours of the occurrence.

(2) For emissions of any regulated air pollutant, 

excluding those listed in paragraph (1) of this section, 

that continue for more than two hours in excess of permit 

requirements, the report must be made within 48 

 Air Pollution Control Permit Conditions

Page 22 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

hours.

(3) For all other deviations from permit requirements, 

the report shall be contained in the 6 month monitoring 

report required above.

(4) This permit may contain a more stringent reporting 

requirement than required by paragraphs (1), (2) or (3) 

above. If more stringent reporting requirements have been

placed in this permit or exist in applicable requirements 

that apply to this facility, the more stringent reporting 

requirement shall apply.

If any of the above conditions are met, the source must 

notify the permitting authority by telephone during normal

business hours at the Regional Office of jurisdiction for 

0 this permit, attention Regional Air Pollution Control 

Engineer (RAPCE) according to the timetable listed in 

paragraphs (1) through (4) of this section. For 

deviations and incidences that must be reported outside of

normal business hours, on weekends, or holidays, the DEC 

Spill Hotline phone number at 1-800-457-7362 shall be 

used. A written notice, certified by a responsible 

official consistent with 6 NYCRR Part 201-6.3(d)(12), must

be submitted within 10 working days of an occurrence for 

deviations reported under (1) and (2). All deviations 

reported under paragraph (1) through (4) of this section 

must also be identified in the 6 month monitoring report 

required above.

If the permittee seeks to have a violation excused as 

provided in 201-1.4, the permittee shall report such 

violations as required under 201-1.4(b). However, in no 

case may reports of any deviation be on a less frequent 

basis than those described in paragraphs (1) though (4) 

above. In order to have a violation of a federal 

regulation (such as a new source performance standard or 

national emissions standard for hazardous air pollutants) 

excused, the specific federal regulation must provide for 

an affirmative defense during start-up, shutdowns, 

malfunctions or upsets. 

In the case of any condition contained in this permit 

with a reporting requirement of "Upon request by 

regulatory agency" the permittee shall include in the 

semiannual report, a statement for each such condition 

that the monitoring or recordkeeping was performed as 

required or requested and a listing of all instances of 

 Air Pollution Control Permit Conditions

Page 23 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

deviations from these requirements.

In the case of any emission testing performed during the 

previous six month reporting period, either due to a 

request by the Department, EPA, or a regulatory 

requirement, the permittee shall include in the semiannual

report a summary of the testing results and shall indicate

whether or not the Department or EPA has approved the 

results.

All semiannual reports shall be submitted to the 

Administrator (or his or her representative) as well as 

two copies to the Department (one copy to the regional air

pollution control engineer (RAPCE) in the regional office 

and one copy to the Bureau of Compliance Monitoring and 

Enforcement (BCME) in the DEC central office). Mailing 

addresses for the above referenced persons are contained 

in the monitoring condition for 6 NYCRR Part 201-6.5(e), 

contained elsewhere in this permit.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 6: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 201-6.5(e)

Item 6.1:

The Compliance Certification activity will be performed for the Facility.

Item 6.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Requirements for compliance certifications with terms and

conditions contained in this facility permit include the 

following:

i. Compliance certifications shall contain:

- the identification of each term or condition of the 

permit that is the basis of the certification;

- the compliance status;

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

- whether compliance was continuous or intermittent;

- the method(s) used for determining the compliance status

of the facility, currently and over the reporting period 

consistent with the monitoring and related recordkeeping 

and reporting requirements of this permit;

- such other facts as the Department may require to 

determine the compliance status of the facility as 

specified in any special permit terms or conditions; 

and

- such additional requirements as may be specified 

elsewhere in this permit related to compliance 

certification.

ii. The responsible official must include in the annual 

certification report all terms and conditions contained in

this permit which are identified as being subject to 

certification, including emission limitations, standards, 

or work practices. That is, the provisions labeled herein

as "Compliance Certification" are not the only provisions 

of this permit for which an annual certification is 

required.

iii. Compliance certifications shall be submitted 

annually. Certification reports are due 30 days after the

anniversary date of four consecutive calendar quarters. 

The first report is due 30 days after the calendar quarter

that occurs just prior to the permit anniversary date, 

unless another quarter has been acceptable by the 

Department.

iv. All compliance certifications shall be submitted to 

the Administrator (or his or her representative) as well 

as two copies to the Department (one copy to the regional 

air pollution control engineer (RAPCE) in the regional 

office and one copy to the Bureau of Compliance Monitoring

and Enforcement (BCME) in the DEC central office). Please

send annual compliance certifications to Chief of the 

Stationary Source Compliance Section, the Region 2 EPA 

representative for the Administrator, at the following 

address:

USEPA Region 2

Air Compliance Branch

290 Broadway

New York, NY 10007-1866

The address for the RAPCE is as follows:

 Air Pollution Control Permit Conditions

Page 25 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

State Office Building

317 Washington Street

Watertown, NY 13601-3787

The address for the BCME is as follows:

NYSDEC 

Bureau of Compliance Monitoring

and Enforcement

625 Broadway

Albany, NY 12233-3258

Monitoring Frequency: ANNUALLY

Reporting Requirements: ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due on the same day each year

 

Condition 7: Non Applicable requirements

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 201-6.5(g)

Item 7.1:

This section contains a summary of those requirements that have been specifically identified as being not 

applicable to this facility and/or emission units, emission points, processes and/or emission sources within 

this facility. The summary also includes a justification for classifying any such requirements as nonapplicable.

6NYCRR 212.4(c)

Emission Unit: M00001

Reason: This emission unit will be complying with the PM emission 

limits contained in the Secondary Aluminum Production 

NESHAP (40 CFR Part 63 Subpart RRR) and thus is exempt 

from the PM limits contained in 6 NYCRR Part 212.4(c) as 

allowed by 6 NYCRR Part 212.5(d).

6NYCRR 212.4(c)

Emission Unit: M00002

Reason: This emission unit will be complying with the PM emission 

limits contained in the Secondary Aluminum Production 

NESHAP (40 CFR Part 63 Subpart RRR) and thus is exempt 

from the PM limits contained in 6 NYCRR Part 212.4(c) as 

allowed by 6 NYCRR Part 212.5(d).

6NYCRR 225-1.7(b)

Emission Unit: B00001 Process: OIL

Reason: The requirement for a SO2 CEMS does not apply since Alcoa 

meets the exception contained in 6 NYCRR Part 

 Air Pollution Control Permit Conditions

Page 26 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

225-1.7(b)(2) by virtue of performing the sampling and 

recordkeeping contained in the permit condition cited 6 

NYCRR Part 225-1.8(a).

6NYCRR 228.1(a)

Emission Unit: A00002 Emission Point: F0031 Process: MRS Source: AF031

Reason: This source is exempt from permitting requirements per 6 

NYCRR Part 201-3.3(c)(45). As such the VOC RACT 

requirements of 6 NYCRR Part 228 for surface coating 

processes do not apply.

6NYCRR 228.1(a)

Emission Unit: A00002 Emission Point: F0065 Process: MRS Source: AF065

Reason: This source is exempt from permitting requirements per 6 

NYCRR Part 201-3.3(c)(45). As such the VOC RACT 

requirements of 6 NYCRR Part 228 for surface coating 

processes do not apply.

Condition 8: Required Emissions Tests - Facility Level

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 202-1.1

Item 8.1:

An acceptable report of measured emissions shall be submitted, as required by the commissioner, to 

ascertain compliance or noncompliance with any air pollution code, rule, or regulation.

 

Condition 9: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 202-2.1

Item 9.1:

The Compliance Certification activity will be performed for the Facility.

Item 9.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Emission statements shall be submitted on or before April

15th each year for emissions of the previous calendar 

p0 year.

Monitoring Frequency: ANNUALLY

Reporting Requirements: ANNUALLY (CALENDAR)

Reports due by April 15th for previous calendar year

 Air Pollution Control Permit Conditions

Page 27 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Condition 10: Recordkeeping requirements

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 202-2.5

Item 10.1:

(a) The following records shall be maintained for at least five years:

(1) a copy of each emission statement submitted to the department; and

(2) records indicating how the information submitted in the emission statement was 

determined, including any calculations, data, measurements, and estimates used.

(b) These records shall be made available at the facility to the representatives of the department 

upon request during normal business hours.

 

Condition 11: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.

Item 11.1:

The Compliance Certification activity will be performed for the Facility.

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 11.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

All sources that employ control devices to limit 

particulate emissions, shall be monitored and maintained 

according to the Operation and Maintenance (O & M) plan 

submitted and approved by the Department in order to 

insure proper operation and control. The O & M plan shall 

be considered a "living" document and will be changed and 

improved over time. Each change shall be submitted to the 

department for approval. Exceedances of the proper 

operating limits shall be reported semi-annually. Records 

shall be maintained for a minimum of five years. 

Compliance testing will be done upon request from the 

Department.

 Air Pollution Control Permit Conditions

Page 28 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Reference Test Method: EPA Method 5

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 12: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.4(c)

Item 12.1:

The Compliance Certification activity will be performed for the facility:

The Compliance Certification applies to:

Emission Unit: A-00002

Emission Unit: S-00004

Emission Unit: A-00001

Process: EPH

Emission Unit: A-00001

Process: HMO

Emission Unit: A-00001

Process: HT1

Emission Unit: C-00001

Process: CD1

Emission Unit: C-00001

Process: CM1

Emission Unit: D-00001

Process: ALB

Emission Unit: D-00001

Process: SKD

Emission Unit: S-00002

Process: BAK

Emission Unit: A-00001

Process: HT2 Emission Source: AF014

Emission Unit: A-00001

 Air Pollution Control Permit Conditions

Page 29 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Process: HT2 Emission Source: AF015

Emission Unit: A-00001

Process: HT2 Emission Source: AF02A

Emission Unit: A-00001

Process: HT2 Emission Source: AF02B

Emission Unit: C-00002

Process: CD2 Emission Source: C0044

Emission Unit: C-00002

Process: CM2 Emission Source: C0045

Emission Unit: S-00003 Emission Point: S0100

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 12.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

Emissions of solid particulates are limited to less than 

0.050 grains of particulates per cubic foot of exhaust gas

expressed at standard conditions on a dry gas basis. 

Compliance testing shall be conducted upon request from 

the department.

Upper Permit Limit: 0.050 grains per dscf

Reference Test Method: EPA Method 5

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

i0Condition 13: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.6(a)

Item 13.1:

The Compliance Certification activity will be performed for the facility:

The Compliance Certification applies to:

 Air Pollution Control Permit Conditions

Page 30 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Unit: S-00004

Emission Unit: S-00005

Emission Unit: S-00003 Emission Point: S0100

Emission Unit: A-00001

Process: EPH

Emission Unit: A-00001

Process: HMO

Emission Unit: A-00001

Process: HT1

Emission Unit: D-00001

Process: ALB

Emission Unit: D-00001

Process: CCT

Emission Unit: D-00001

Process: SKD

Emission Unit: A-00001

Process: HT2 Emission Source: AF014

Emission Unit: A-00001

Process: HT2 Emission Source: AF015

Emission Unit: A-00001

Process: HT2 Emission Source: AF02A

Emission Unit: A-00001

Process: HT2 Emission Source: AF02B

Emission Unit: W-00001

Emission Unit: C-00001

Process: CD1

Emission Unit: C-00002

Process: CD2

Emission Unit: F-00001

Process: FB1

Emission Unit: F-00001

 Air Pollution Control Permit Conditions

Page 31 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Process: FB2

Emission Unit: F-00001

Process: FB3

Emission Unit: F-00001

Process: FC1

Emission Unit: F-00001

Process: FC2

Emission Unit: A-00002

Emission Unit: M-00001

Emission Unit: M-00002

Emission Unit: C-00001

Process: CM1

Emission Unit: C-00002

Process: CM2

Emission Unit: F-00001

Process: FC3

Emission Unit: S-00006

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 13.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

No person will cause or allow emissions having an average

opacity during any six consecutive minutes of 20 percent 

or greater from any process emission source, except only 

the emission of uncombined water. The department reserves 

the right to perform or require the performance of a 

method 9 opacity evaluation at any time during facility 

operation.

Upper Permit Limit: 20 percent

Reference Test Method: EPA Method 9

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

 Air Pollution Control Permit Conditions

Page 32 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 14: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.10(c)(1)

Item 14.1:

The Compliance Certification activity will be performed for the facility:

The Compliance Certification applies to:

Emission Unit: A-00001

Process: HMO

Emission Unit: S-00001

Process: POT

Emission Unit: A-00001 Emission Point: I0014

Emission Unit: A-00001 Emission Point: I015A

Emission Unit: A-00001 Emission Point: I015B

Emission Unit: A-00001 Emission Point: F0075

Emission Unit: A-00001 Emission Point: F0076

Emission Unit: A-00001 Emission Point: F074A

Emission Unit: A-00001 Emission Point: F074B

Emission Unit: A-00001 Emission Point: F0014

Emission Unit: A-00001 Emission Point: F0015

Emission Unit: A-00001 Emission Point: F001A

Emission Unit: A-00001 Emission Point: F001B

Emission Unit: A-00001 Emission Point: F001C

Emission Unit: A-00001 Emission Point: F001D

Emission Unit: A-00001 Emission Point: F001E

Emission Unit: A-00001 Emission Point: F002A

 Air Pollution Control Permit Conditions

Page 33 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Unit: A-00001 Emission Point: F002B

Emission Unit: A-00001 Emission Point: I0026

Emission Unit: A-00001 Emission Point: I0027

Emission Unit: A-00001 Emission Point: I0043

Emission Unit: A-00001 Emission Point: I0046

Emission Unit: M-00001 Emission Point: I001A

Emission Unit: M-00001 Emission Point: I001B

Emission Unit: M-00001 Emission Point: I001C

Emission Unit: M-00001 Emission Point: I001D

Emission Unit: M-00001 Emission Point: I0034

Emission Unit: M-00001 Emission Point: I0035

Emission Unit: M-00001 Emission Point: I003A

Emission Unit: M-00001 Emission Point: I003C

Emission Unit: M-00001 Emission Point: I024C

Emission Unit: M-00001 Emission Point: I024D

Emission Unit: A-00002 Emission Point: F0067

Regulated Contaminant(s):

CAS No: 0NY210-00-0 OXIDES OF NITROGEN

Item 14.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

The emission rate potential of oxides of nitrogen (NOx) 

from each emission point shall remain less than 3.0 pounds

per hour. A reasonably available control technology (RACT)

analysis is not required for emission points with NOx 

emission rate potentials less than 3.0 pounds per hour at 

facilities located outside the lower Orange County and New

York City metropolitan areas. Compliance testing shall be 

 Air Pollution Control Permit Conditions

Page 34 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

conducted upon request from the Department.

Upper Permit Limit: 3.0 pounds per hour

Reference Test Method: EPA Method 7

Monitoring Frequency: SINGLE OCCURRENCE

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 15: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.10(c)(1)

Item 15.1:

The Compliance Certification activity will be performed for the facility:

The Compliance Certification applies to:

Emission Unit: A-00001 Emission Point: F0014

Emission Unit: A-00001

Process: HT1

Emission Unit: A-00001 Emission Point: F0015

Emission Unit: A-00001 Emission Point: F002A

Emission Unit: A-00001 Emission Point: F002B

Emission Unit: S-00005

Process: PUN

Emission Unit: W-00001

Process: OWT

Emission Unit: W-00001

Process: WWT

Emission Unit: F-00001

Emission Unit: A-00002 Emission Point: F0067

Regulated Contaminant(s):

CAS No: 0NY998-00-0 VOC

Item 15.2:

Compliance Certification shall include the following monitoring:

 Air Pollution Control Permit Conditions

Page 35 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

The emission rate potential of Volatile Organic Compounds

(VOCs) from each emission point shall remain less than 3.0

pounds per hour. A reasonably available control technology

(RACT) analysis is not required for emission points with 

VOC emission rate potentials less than 3.0 pounds per hour

at facilities located outside the lower Orange County and 

New York City metropolitan areas. Compliance testing shall

be conducted upon request from the Department.

Upper Permit Limit: 3.0 pounds per hour

Reference Test Method: EPA Method 7E

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 16: Equipment Specifications for Cold Cleaning Batch 

Degreasing

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 226.

Item 16.1:

A. Equipment specifications: 

1. A cover shall be provided which can be operated easily.

2. The drainage facility shall be internal (under cover), if practical.

3. A control system that limits VOC emissions to those achievable with equipment having a freeboard 

ratio greater than or equal to 0.7, or a water cover where the solvent is insoluble in and heavier than 

water, where the solvent being used has a vapor pressure greater than 33mm Hg at 38oC (100oF) or 

where the solvent is heated above 50oC (120oF)

B. Operating requirements:

1. Clean parts shall be drained at least 15 seconds or until dripping ceases. 

C. General requirements: 

No person shall conduct solvent metal cleaning unless:

1. Solvent is stored in covered containers and waste solvent is transferred or disposed of in such a 

manner that less than 20 percent of the waste solvent (by weight) can evaporate into the atmosphere.

2. Equipment used in solvent metal cleaning is maintained to minimize leaks and fugitive emissions.

3. Equipment used in solvent metal cleaning displays a conspicuous summary of proper operating 

procedures consistent with minimizing emissions of volatile organic compounds.

 Air Pollution Control Permit Conditions

Page 36 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

4. Equipment covers are closed when the solvent metal cleaning unit is not in service.

5. A record of solvent consumption shall be maintained for each year and made available to the 

commissioner or his representative upon request.

Condition 17: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.3(a)

Item 17.1:

The Compliance Certification activity will be performed for the facility:

The Compliance Certification applies to:

Emission Unit: A-00001 Emission Point: F078A

Emission Unit: A-00001 Emission Point: F078B

Emission Unit: A-00001 Emission Point: FC01A

Emission Unit: A-00001 Emission Point: FC01B

Emission Unit: A-00001 Emission Point: FC01C

Emission Unit: A-00001 Emission Point: FC01D

Emission Unit: A-00001 Emission Point: FC01E

Emission Unit: B-00001

Process: OIL Emission Source: B0001

Emission Unit: B-00001

Process: OIL Emission Source: B0002

Emission Unit: B-00001

Process: OIL Emission Source: B0003

Emission Unit: B-00001

Process: OIL Emission Source: B0004

Emission Unit: B-00001 Emission Point: 00001

Process: GAS

Emission Unit: B-00001 Emission Point: 00002

Process: GAS

Item 17.2:

Compliance Certification shall include the following monitoring:

 Air Pollution Control Permit Conditions

Page 37 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

No owner or operator of a combustion installation shall 

emit greater than 20 percent opacity except for one six 

minute period per hour, not to exceed 27 percent, based 

upon the six minute average in reference test method 9 in 

appendix A of 40 CFR 60. Testing shall be conducted upon 

request from the Department.

Parameter Monitored: OPACITY

Upper Permit Limit: 20 percent

Reference Test Method: EPA Method 9

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: 6-MINUTE AVERAGE (METHOD 9)

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 18: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-2.4(g)(3)

Item 18.1:

The Compliance Certification activity will be performed for the facility:

The Compliance Certification applies to:

Emission Unit: A-00001 Emission Point: F078A

Emission Unit: A-00001 Emission Point: F078B

Emission Unit: A-00001 Emission Point: FC01A

Process: HT1

Emission Unit: A-00001 Emission Point: FC01B

Process: HT1

Emission Unit: A-00001 Emission Point: FC01C

Process: HT1

Emission Unit: A-00001 Emission Point: FC01D

Process: HT1

Emission Unit: A-00001 Emission Point: FC01E

Process: HT1

Regulated Contaminant(s):

 Air Pollution Control Permit Conditions

Page 38 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

CAS No: 0NY210-00-0 OXIDES OF NITROGEN

Item 18.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

A RACT analysis is not necessary for sources that emit 

less than 3 lbs per hour of oxides of nitrogen. Testing 

shall be conducted upon request from the department to 

ensure compliance.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 19: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 257-8.

Item 19.1:

The Compliance Certification activity will be performed for the Facility.

Regulated Contaminant(s):

CAS No: 068188-85-2 FLUORIDES

Item 19.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Standards. a) Total Fluorides, part per million (ppm), 

dry weight basis (as F) in and on forage for consumption 

for grazing ruminants. Average concentration shall be less

than the following in all levels:

 (1) For growing season (not to exceed six 

consecutive months)-40 ppm

 (2) For any 60 day period- 60 ppm

 (3) For any 30 day period- 80 

ppm

Measurement. (a) Total Fluorides in and on forage is 

determined by fusion of a representative sample by the 

Schoniger flash oxygen combustion method and analysis by 

specific ion electrode or other methods acceptable to the 

commissioner.

 Air Pollution Control Permit Conditions

Page 39 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Alcoa shall continue Fluoride testing and reporting in 

accordance with the" Work/Quality Assurance Project PlanSampling and Anlysis for Fluoride in Vegetation" dated 

May 5, 1999.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 20: Incorporation by Reference

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.841, Subpart LL

Item 20.1:

 (a) The following material is incorporated by reference in the corresponding sections noted. This 

incorporation by reference was approved by the Director of the Federal Register on October 7, 1997, in

accordance with 5 U.S.C. 552(a) and 1 CFR Part 51. These materials are incorporated as they exist on the 

date of approval, and notice of any change in the materials will be published in the Federal Register.

Revisions to ``Industrial Ventilation: A Manual of Recommended Practice'' (22nd ed.) are applicable only 

after publication of a document in the Federal Register to amend subpart LL to require use of the new 

information.

 (1) Chapter 3, ``Local Exhaust Hoods'' and Chapter 5, ``Exhaust System Design Procedure'' of 

``Industrial Ventilation: A Manual of Recommended Practice,'' American Conference of 

Governmental Industrial Hygienists, 22nd edition, 1995, IBR approved for 40 CFR Part 

63.843(b) and 40 CFR Part 63.844(b); and

 (2) ASTM D 2986-95A, Standard Practice for Evaluation of Air Assay Media by the 

Monodisperse DOP (Dioctyl Phthalate) Smoke Test, IBR approved for section 7.1.1 of Method 

315 in appendix A to 40 CFR Part 63.

 (b) The materials incorporated by reference are available for inspection at the Office of the Federal 

Register, 800 North Capitol Street NW., Suite 700, 7th Floor, Washington, DC, and at the Air and

Radiation Docket Center, U.S. EPA, 401 M Street, SW., Washington, DC. The materials also are 

available for purchase from one of the following addresses:

 (1) Customer Service Department, American Conference of Governmental Industrial Hygienists 

(ACGIH), 1330 Kemper Meadow Drive, Cincinnati, Ohio 45240, telephone number (513) 742-

2020; or

 (2) American Society for Testing and Materials, 100 Bar Harbour Drive, West Conshohocken, 

Pennsylvania 19428, telephone number (610) 832-9500.

 

 Air Pollution Control Permit Conditions

Page 40 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Condition 21: Compliance Provisions - Test Plan

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(b), Subpart LL

Item 21.1: 

The owner or operator shall prepare a site-specific test plan prior to the initial performance test according 

to the requirements of 40 CFR Part 63.7(c). The test plan must include procedures for conducting the 

initial performance test and for subsequent performance tests required in 40 CFR Part 63.848 for 

emission monitoring. In addition to the information required by 40 CFR Part 63.7, the test plan shall 

include:

(1) Procedures to ensure a minimum of three runs are performed annually for the primary 

control system for each source;

(2) For a source with a single control device exhausted through multiple stacks, procedures to 

ensure that at least three runs are performed annually by a representative sample of the stacks

satisfactory to the applicable regulatory authority;

(3) For multiple control devices on a single source, procedures to ensure that at least one run is 

performed annually for each control device by a representative sample of the stacks satisfactory to the

applicable regulatory authority;

(4) Procedures for sampling single stacks associated with multiple anode bake furnaces;

(8) Procedures for establishing the frequency of testing to ensure that at least one run is 

performed before the 15th of the month, at least one run is performed after the 15th of the month, and that 

there are at least 6 days between two of the runs during the month, or that secondary emissions are 

measured according to an alternate schedule satisfactory to the applicable regulatory authority.

 

Condition 22: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848, Subpart LL

Item 22.1:

The Compliance Certification activity will be performed for the facility:

The Compliance Certification applies to:

Emission Unit: S-00001

Process: POT

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

 Air Pollution Control Permit Conditions

Page 41 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

CAS No: 0NY505-00-0 40 CFR 63 SUBPART LL - POM

CAS No: 068188-85-2 FLUORIDES

Item 22.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator shall install, operate, calibrate, and

maintain a continuous parameter monitoring system for each

emission control device. The owner/operator shall submit 

for approval by the New York State DEC a description of 

the parameter(s) to be monitored, the operating limits, 

and the monitoring frequency to ensure that the control 

device is being properly operated and maintained. An 

explanation of the criteria used for selection of the 

parameter(s), the operating limits, and the monitoring 

frequency, including how these relate to emission control 

also shall be submitted to the New York State DEC.

Reference Test Method: EPA 13A or ALT, 315

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 23: Reference test methods for TF and POM emissions

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.849(a), Subpart LL

Item 23.1:

The owner/operator shall use the following reference methods to determine compliance with the 

applicable emission limits for TF and POM emissions:

1) Method 1 in Appendix A to part 60 for sample and velocity traverses;

2) Method 2 in Appendix A to part 60 for velocity and volumetric flow rate;

3) Method 3 in Appendix A to part 60 for gas analysis;

4) Method 13A or 13B in Appendix A to part 60, or an approved alternative, for the concentration of TF 

where stack or duct emission are sampled;

5) Method 13A or 13B and Method 14 or 14A in Appendix A to part 60 or an approved alternative 

method for the concentration of TF where emissions are sampled from roof monitors not employing wet 

roof scrubbers;

6) Method 315 in Appendix A to part 63 or an approved alternative method for the concentration of POM 

where stack or duct emissions are sampled; and 

 Air Pollution Control Permit Conditions

Page 42 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

7) Method 315 in Appendix A to part 63 and Method 14 in Appendix A to part 60 or an approved 

alternative method for the concentration of POM where emissions are sampled from roof monitors not 

employing wet roof scrubbers.

 

Condition 24: Alternative test methods for TF or POM emissions

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.849(e), Subpart LL

Item 24.1:

The owner/operator may use an alternative test method for TF or POM emissions providing:

1) The owner/operator has already demonstrated the equivalency of the alternative method for a specific 

plant and has received previous approval from the Administrator or the New York State DEC for TF or 

POM measurements using the alternative methods; or

2) The owner/operator demonstrates to the satisfaction of the New York State DEC that the results from 

the alternative method meet the criteria specified in §§63.848(d)(1) and (d)(3) through (d)(6). The results 

from the alternative method shall be based on simultaneous sampling using the alternative method and the 

following reference methods:

For TF, Methods 13 and 14 or Method 14A in appendix A to part 60, or for POM, Method 315 in 

appendix A to part 63 and Method 14 in appendix A to part 60.

 

Condition 25: Accidental release provisions.

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 68.

Item 25.1:

If a chemical is listed in Tables 1,2,3 or 4 of 40 CFR §68.130 is present in a process in quantities greater 

than the threshold quantity listed in Table 1, the following requirements will apply:

a) The owner or operator shall comply with the provisions of 40 CFR Part 68 and;

b) The owner or operator shall submit (if not previously submitted) one of the following if such quantities 

are present at the time of permit issuance:

1) A compliance schedule for meeting the requirements of 40 CFR Part 68 by the date provided in 40 

CFR §68.10(a) or,

2) A certification statement that the source is in compliance with all requirements of 40 CFR Part 68, 

including the registration and submission of the Risk Management Plan. Information should be submitted 

to:

USEPA Region 2

Air Compliance Branch

290 Broadway

 Air Pollution Control Permit Conditions

Page 43 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

New York, NY 10007-1866

ATTN: Accidental Release Program contact

 

Condition 26: Recycling and Emissions Reduction

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 82, Subpart F

Item 26.1:

The permittee shall comply with all applicable provisions of 40 CFR Part 82.

 

** ** Emission Unit Level  

Condition 27: Emission Point Definition By Emission Unit

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 201-6.

Item 27.1:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: A-00001

Emission Point: F0014

Height (ft.): 41 Diameter (in.): 25

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 140

Emission Point: F0015

Height (ft.): 48 Diameter (in.): 25

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 140

Emission Point: F001A

Height (ft.): 50 Diameter (in.): 24

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: F001B

Height (ft.): 50 Diameter (in.): 24

rd NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: F001C

Height (ft.): 50 Diameter (in.): 24

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: F001D

Height (ft.): 50 Diameter (in.): 24

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

 Air Pollution Control Permit Conditions

Page 44 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Point: F001E

Height (ft.): 50 Diameter (in.): 24

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: F002A

Height (ft.): 47 Diameter (in.): 21

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 140

Emission Point: F002B

Height (ft.): 47 Diameter (in.): 21

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 140

Emission Point: F0075

Height (ft.): 47 Diameter (in.): 12

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: F0076

Height (ft.): 46 Diameter (in.): 21

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: F074A

Height (ft.): 45 Diameter (in.): 12

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: F074B

Height (ft.): 45 Diameter (in.): 12

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: F078A

Height (ft.): 42 Diameter (in.): 24

Building: 140

Emission Point: F078B

Height (ft.): 42 Diameter (in.): 24

Building: 140

Emission Point: FC01A

Height (ft.): 50 Diameter (in.): 10

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: FC01B

Height (ft.): 50 Diameter (in.): 24

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: FC01C

Height (ft.): 50 Diameter (in.): 24

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

 Air Pollution Control Permit Conditions

Page 45 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Point: FC01D

Height (ft.): 50 Diameter (in.): 24

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: FC01E

Height (ft.): 50 Diameter (in.): 10

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: I0014

Height (ft.): 52 Diameter (in.): 42

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 234

Emission Point: I0026

Height (ft.): 62 Diameter (in.): 54

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 222

Emission Point: I0027

Height (ft.): 62 Diameter (in.): 54

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 222

Emission Point: I0043

Height (ft.): 52 Diameter (in.): 54

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 222

Emission Point: I0046

Height (ft.): 62 Diameter (in.): 54

Building: 222

Emission Point:n0I015A

Height (ft.): 52 Diameter (in.): 42

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 234

Emission Point: I015B

Height (ft.): 52 Diameter (in.): 42

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 234

Item 27.2:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: A-00002

Emission Point: F0031

Height (ft.): 20 Diameter (in.): 24

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: F0062

Height (ft.): 10 Length (in.): 12 Width (in.): 12

 Air Pollution Control Permit Conditions

Page 46 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 140

Emission Point: F0063

Height (ft.): 8 Diameter (in.): 7

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: F0064

Height (ft.): 30 Diameter (in.): 12

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: F0065

Height (ft.): 7 Diameter (in.): 12

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Emission Point: F0067

Height (ft.): 26 Diameter (in.): 8

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 131

Item 27.3:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: B-00001

Emission Point: 00001

Height (ft.): 60 Diameter (in.): 96

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 216A

Emission Point: 00002

Height (ft.): 60 Diameter (in.): 96

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 216A

Item 27.4:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: C-00001

Emission Point: I0029

Height (ft.): 52 Diameter (in.): 36

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 221

Emission Point: I0030

Height (ft.): 73 Diameter (in.): 42

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 221

Item 27.5:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: C-00002

 Air Pollution Control Permit Conditions

Page 47 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Point: I0044

Height (ft.): 74 Diameter (in.): 36

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 221

Emission Point: I0045

Height (ft.): 74 Diameter (in.): 44

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 221

Item 27.6:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: D-00001

Emission Point: F0042

Height (ft.): 57 Diameter (in.): 19

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 140

Emission Point: I0016

Height (ft.): 52 Diameter (in.): 42

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 220

Emission Point: I0042

Height (ft.): 50 Diameter (in.): 22

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 222

Item 27.7:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: M-00001

Emission Point: I001A

Height (ft.): 67 Diameter (in.): 32

Building: 221

Emission Point: I001B

Height (ft.): 67 Diameter (in.): 32

Building: 221

Emission Point: I001C

Height (ft.): 68 Diameter (in.): 20

Building: 221

Emission Point: I001D

Height (ft.): 68 Diameter (in.): 20

Building: 221

Emission Point: I0034

 Air Pollution Control Permit Conditions

Page 48 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Height (ft.): 74 Diameter (in.): 32

Building: 221

Emission Point: I0035

Height (ft.): 74 Diameter (in.): 32

Building: 221

Emission Point: I003A

Height (ft.): 67 Diameter (in.): 33

Building: 221

Emission Point: I003C

Height (ft.): 67 Diameter (in.): 79

Building: 221

Emission Point: I024C

Height (ft.): 74 Diameter (in.): 50

Building: 221

Emission Point: I024D

Height (ft.): 74 Diameter (in.): 50

Building: 221

Emission Point: I024F

Height (ft.): 82 Diameter (in.): 79

Building: 221

Item 27.8:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: M-00002

Emission Point: 10036

Height (ft.): 52 Diameter (in.): 9

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 221

Emission Point: 1024E

Height (ft.): 46 Diameter (in.): 8

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 221

Emission Point: I001E

Height (ft.): 67 Diameter (in.): 42

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 221

Emission Point: I003E

Height (ft.): 48 Diameter (in.): 8

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 221

 Air Pollution Control Permit Conditions

Page 49 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item 27.9:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: S-00001

Emission Point: SA398

Height (ft.): 78 Diameter (in.): 48

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 401

Item 27.10:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: S-00002

Emission Point: S0078

Height (ft.): 105 Diameter (in.): 84

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 351

Emission Point: SS078

Height (ft.): 105 Diameter (in.): 84

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 351

Item 27.11:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: S-00003

Emission Point: S0100

Height (ft.): 111 Diameter (in.): 42

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 354C

Item 27.12:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: S-00004

Emission Point: S0015

Height (ft.): 19 Length (in.): 12 Width (in.): 12

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 332

Emission Point: S0016

Height (ft.): 23 Length (in.): 12 Width (in.): 12

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 332

Emission Point: S0017

Height (ft.): 62 Diameter (in.): 25

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 332

 Air Pollution Control Permit Conditions

Page 50 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Point: S0038

Height (ft.): 15 Diameter (in.): 33

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 354B

Emission Point: S0041

Height (ft.): 42 Diameter (in.): 15

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 441

Emission Point: S0043

Height (ft.): 91 Diameter (in.): 15

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 441C

Emission Point: S0046

Height (ft.): 79 Diameter (in.): 10

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 446A

Emission Point: S0047

Height (ft.): 79 Diameter (in.): 10

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 446B

Emission Point: S0048

Height (ft.): 79 Diameter (in.): 10

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 446C

Emission Point: S0049

Height (ft.): 106 Diameter (in.): 15

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 354C

Emission Point: S0050

Height (ft.): 106 Diameter (in.): 15

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 354C

Emission Point: S0051

Height (ft.): 106 Diameter (in.): 13

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 354C

Emission Point: S0052

Height (ft.): 106 Diameter (in.): 21

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 354C

Emission Point: S0053

Height (ft.): 106 Diameter (in.): 13

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 354C

Emission Point: S0060

Height (ft.): 105 Diameter (in.): 16

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 354C

 Air Pollution Control Permit Conditions

Page 51 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Point: S0061

Height (ft.): 105 Diameter (in.): 9

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 354C

Emission Point: S0083

Height (ft.): 5 Diameter (in.): 21

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 344

Emission Point: S0086

Height (ft.): 22 Diameter (in.): 15

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 440A

Emission Point: S0090

Height (ft.): 4 Length (in.): 13 Width (in.): 11

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 378

Emission Point: S0092

Height (ft.): 63 Length (in.): 22 Width (in.): 19

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 440E

Emission Point: S0093

Height (ft.): 166 Length (in.): 18 Width (in.): 24

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 440E

Emission Point: S0095

Height (ft.): 28 Length (in.): 23 Width (in.): 19

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 351

Emission Point: S0102

Height (ft.): 27 Diameter (in.): 52

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 469

Emission Point: S023B

Height (ft.): 35 Diameter (in.): 52

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 380

Emission Point: S23AA

Height (ft.): 40 Diameter (in.): 75

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 435

Emission Point: S23AC

Height (ft.): 17 Diameter (in.): 27

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 435

Item 27.13:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: S-00005

 Air Pollution Control Permit Conditions

Page 52 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Point: S0073

Height (ft.): 37 Diameter (in.): 8

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 352B

Emission Point: S0077

Height (ft.): 37 Diameter (in.): 8

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 352B

Emission Point: S0088

Height (ft.): 28 Diameter (in.): 12

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 352F

Emission Point: S0089

Height (ft.): 28 Diameter (in.): 12

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 352F

Emission Point: S073A

Height (ft.): 37 Diameter (in.): 8

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 352B

Item 27.14:

The following emission points are included in this permit for the cited Emission Unit:

Emission Unit: W-00001

Emission Point: F0068

Height (ft.): 40 Diameter (in.): 3

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 79C

Emission Point: F0069

Height (ft.): 41 Diameter (in.): 14

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 79C

Emission Point: F0070

Height (ft.): 41 Diameter (in.): 12

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 79C

Emission Point: F0071

Height (ft.): 41 Diameter (in.): 10

NYTMN (km.): 4977. NYTME (km.): 508.9 Building: 79C

Condition 28: Process Definition By Emission Unit

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 201-6.

Item 28.1:

 Air Pollution Control Permit Conditions

Page 53 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: A-00001

Process: EPH Source Classification Code: 2-02-002-02

Process Description: 

TWO (2) 6500 TON PRESS PRE-HEATS AND ONE 

(1) 5300 TON PRESS PRE-HEAT FURNACE. EACH 

USES MULTIPLE DIRECT FIRE NATURAL GAS 

BURNERS.

Emission Source/Control: AI014 - Process

Emission Source/Control: AI15A - Process

Emission Source/Control: AI15B - Process

Item 28.2:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: A-00001

Process: HMO Source Classification Code: 2-02-002-02

Process Description: 

FOUR (4) HOMOGENIZING HEAT TREAT FURNACES.

 EACH USES MULTIPLE DIRECT FIRE NATURAL GAS

BURNERS. CHEMICAL ADDITIVE PREVENTS 

OXIDATION OF SURFACE OF METAL AND PRODUCES 

INCIDENTAL HYDROGEN FLUORIDE EMISSIONS AS A

BY-PRODUCT.

Emission Source/Control: AI026 - Process

Emission Source/Control: AI027 - Process

Emission Source/Control: AI043 - Process

Emission Source/Control: AI046 - Process

Design Capacity: 30 million Btu per hour

Item 28.3:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: A-00001

Process: HT1 Source Classification Code: 2-02-002-02

Process Description: 

#30, 31, 32, 33, 34, 35, 36, 37, 38 HEAT 

TREAT FURNACES PROCESS EXHAUST. EACH 

FURNACE EXHAUSTS THROUGH THEIR OWN EMISSION

POINT. #32-36 FURNACES ARE INDIRECTLY 

FIRED AND HAVE SEPARATE COMBUSTION 

 Air Pollution Control Permit Conditions

Page 54 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

EXHAUSTS. RESIDUAL OIL ON ALUMINUM 

PRODUCES SLIGHT VOC EMISSION. CHEMICAL 

ADDITIVE PREVENTS OXIDATION OF SURFACE OF 

METAL AND PRODUCES INCIDENTAL HYDROGEN 

FLUORIDE EMISSION AS A BY-PRODUCT.

Emission Source/Control: AFC1A - Combustion

Emission Source/Control: AFC1B - Combustion

Emission Source/Control: AFC1C - Combustion

Emission Source/Control: AFC1D - Combustion

Emission Source/Control: AFC1E - Combustion

Emission Source/Control: AF01A - Process

Emission Source/Control: AF01B - Process

Emission Source/Control: AF01C - Process

Emission Source/Control: AF01D - Process

Emission Source/Control: AF01E - Process

Emission Source/Control: AF075 - Process

Emission Source/Control: AF076 - Process

Emission Source/Control: AF74A - Process

Emission Source/Control: AF74B - Process

Item 28.4:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: A-00001

Process: HT2 Source Classification Code: 2-02-002-02

Process Description: 

HEAT TREAT FURNACES #13, #14 AND #15 ARE 

INDIRECT FIRED NATURAL GAS FURNACES WHERE 

THE PRODUCTS OF COMBUSTION EXHAUST THROUGH 

EMISSION POINT (EP) F078A. THE FURNACE IS 

EXHAUSTED THROUGH EP F0014. HEAT TREAT 

FURNACES #16, #17 AND #18 HAVE A SIMILAR 

ARRANGEMENT WHERE THE PRODUCTS OF 

COMBUSTION EXHAUST THROUGH EP F078B AND THE

 Air Pollution Control Permit Conditions

Page 55 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

FURNACE EXHAUST THROUGH EP F0015. FURNACE 

PROCESS EMISSIONS CONSIST OF RESIDUAL 

DRAWING LUBE FROM THE BARS WHICH ARE 

COMBUSTED AND VAPORIZED DURING THE 

BEGINNING OF THE HEAT TREAT PROCESS. 

CHEMICAL ADDITIVES PREVENT THE OXIDATION OF

SURFACE METAL. THIS ADDITIVE PRODUCES 

INCIDENTAL HYDROGEN FLUORIDE AS A 

BY-PRODUCT. NUMBER 23 AND 24 AGE ANNEAL 

FURNACES ARE EACH EXHAUSTED THROUGH THEIR 

OWN EMISSION POINTS. THESE FURNACES ARE 

DIRECT FIRED, NATURAL GAS AND RESIDUAL OIL 

ON THE ALUMINUM PRODUCES SLIGHT VOC 

EMISSIONS.

Emission Source/Control: AF014 - Process

Emission Source/Control: AF015 - Process

Emission Source/Control: AF02A - Process

Emission Source/Control: AF02B - Process

Emission Source/Control: AF78A - Process

Emission Source/Control: AF78B - Process

Item 28.5:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: A-00002

Process: FAB Source Classification Code: 2-02-002-02

Process Description: 

Small crucible located in the Fabricating Shop used 

occasionally to melt lead, lead bismuth, zinc or tin 

babbit. Cruce heated by natural gas fired burner.

Emission Source/Control: AF062 - Process

Item 28.6:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: A-00002

Process: MRS Source Classification Code: 2-02-002-02

Process Description: 

THREE (3) SMALL NATURAL GAS OVENS AND TWO 

(2) MAINTENANCE PAINTING ROOMS USED IN 

MAINTENANCE SHOPS. THE BAKE OVEN AND DRYING

 Air Pollution Control Permit Conditions

Page 56 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

OVEN ARE USED TO DRY PARTS WASHED WITH A 

WATER BASED SOLUTION, AND OCCASIONALLY TO 

CURE MOTOR COILS COATED WITH VARNISH.

Emission Source/Control: AF031 - Process

Emission Source/Control: AF063 - Process

Emission Source/Control: AF064 - Process

Emission Source/Control: AF065 - Process

Emission Source/Control: AF067 - Process

Item 28.7:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: B-00001

Process: GAS Source Classification Code: 2-02-002-02

Process Description: 

FOUR VIRTUALLY IDENTICAL BOILERS CAPABLE 

OF BURNING NATURAL GAS.

Emission Source/Control: B0001 - Combustion

Emission Source/Control: B0002 - Combustion

Emission Source/Control: B0003 - Combustion

Emission Source/Control: B0004 - Combustion

Item 28.8:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: B-00001

Process: OIL Source Classification Code: 1-02-004-01

Process Description: 

FOUR VIRTUALLY IDENTICAL BOILERS CAPABLE 

OF BURNING NO. 6 FUEL OIL.

Emission Source/Control: B0001 - Combustion

Emission Source/Control: B0002 - Combustion

Emission Source/Control: B0003 - Combustion

Emission Source/Control: B0004 - Combustion

 Air Pollution Control Permit Conditions

Page 57 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item 28.9:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: C-00001

Process: CD1 Source Classification Code: 3-04-001-09

Process Description: 

CHIP DRYER #1 DRIES ALUMINUM MACHINING 

CHIPS WITH HEATED AIR.

Emission Source/Control: C029A - Control

Control Type: SINGLE CYCLONE

Emission Source/Control: C029B - Control

Control Type: DIRECT FLAME AFTERBURNER

Emission Source/Control: C0029 - Process

Item 28.10:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: C-00001

Process: CM1 Source Classification Code: 3-04-001-03

Process Description: 

CHIP MELTER #1 MELTS CLEAN ALUMINUM 

MACHINING CHIPS.

Emission Source/Control: C0030 - Process

Item 28.11:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: C-00002

Process: CD2 Source Classification Code: 3-04-001-09

Process Description: 

CHIP DRYER #2 DRIES ALUMINUM MACHINING 

CHIPS HEATED WITH AIR.

Emission Source/Control: C044A - Control

Control Type: MULTIPLE CYCLONE W/O FLY ASH INJECTION

Emission Source/Control: C044B - Control

Control Type: THERMAL OXIDATION

Emission Source/Control: C0044 - Process

Item 28.12:

This permit authorizes the following regulated processes for the cited Emission Unit:

 Air Pollution Control Permit Conditions

Page 58 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Unit: C-00002

Process: CM2 Source Classification Code: 3-04-001-03

Process Description: 

CHIP MELTER #2 MELTS CLEAN ALUMINUM 

MACHINING CHIPS.

Emission Source/Control: C0045 - Process

Item 28.13:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: D-00001

Process: ALB Source Classification Code: 3-03-001-99

Process Description: ALUMINUM BURNISHER

Emission Source/Control: DFF42 - Control

Control Type: CENTRIFUGAL

Emission Source/Control: DF142 - Process

Item 28.14:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: D-00001

Process: CCT Source Classification Code: 3-03-001-99

Process Description: 

EMULSIFIED OIL AND WATER SYSTEM FOR THE 

CONTINUOUS CASTER.

Emission Source/Control: DII42 - Process

Item 28.15:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: D-00001

Process: PRT Source Classification Code: 3-04-001-99

Process Description: 

FABRICATED ALUMINUM BARS PASS THROUGH AN 

ENCLOSED SPRAY CHAMBER WHERE A CLEAR 

PROTECTIVE COATING IS APPLIED TO THE BASE 

METAL. THE COATING IS TRANSPARENT AND USES

THE UNDERCOAT ALUMINUM AS A REFLECTIVE 

BASE. EMISSIONS PASS THROUGH A MIST 

COLLECTOR AND VENT INSIDE THE BUILDING.

Emission Source/Control: DF073 - Process

Item 28.16:

 Air Pollution Control Permit Conditions

Page 59 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: D-00001

Process: SKD Source Classification Code: 3-04-001-07

Process Description: 

SKIM AND DROSS AREA USED FOR PASSIVE 

COOLING OF SKIM AND DROSS.

Emission Source/Control: DI016 - Control

Control Type: FABRIC FILTER

Emission Source/Control: DI116 - Process

Item 28.17:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: F-00001

Process: FB1 Source Classification Code: 3-03-001-05

Process Description: 

FUGITIVES FROM THE BULL BLOCK. PROCESS 

APPLIES HIGH BOILING POINT (GREATER THAN 

300F) SOLVENT TO SLIGHTLY HOT METAL TO 

ADHERE METAL TO BLOCK. VOC EMISSIONS ARE 

INLCUDED ON THE ANNUAL EMISSIONS 

STATEMENT.

Emission Source/Control: FFFB1 - Process

Item 28.18:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: F-00001

Process: FB2 Source Classification Code: 3-03-001-99

Process Description: 

FUGITIVES FROM THE INK JET PRINTER. 

METHYL ETHYL KETONE (MEK) USED AS A CARRIER

SOLVENT. MEK EMISSIONS ARE INCLUDED ON THE

ANNUAL EMISSIONS STATEMENT.

Emission Source/Control: FFFB2 - Process

Item 28.19:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: F-00001

Process: FB3 Source Classification Code: 2-88-888-01

Process Description: 

FUGITIVES FROM WAX DIPPING AND AIR DRYING 

 Air Pollution Control Permit Conditions

Page 60 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

COILS. WAX IS MIXED WITH WATER AND 

HEATED,THUS DOES NOT HAVE A HIGH, VOC 

CONTENT. VOC EMISSIONS INCLUDED ON ANNUAL 

EMISSIONS STATEMENT.

Emission Source/Control: FFFB3 - Process

Item 28.20:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: F-00001

Process: FC1 Source Classification Code: 2-88-888-01

Process Description: 

FUGITIVES FROM THE ROD OILER ASSOCIATED 

WITH THE CONTINUOUS CASTER. VOC EMISSIONS 

WILL BE INCLUDED ON THE ANNUAL EMISSIONS 

STATEMENT.

Emission Source/Control: FIFC1 - Process

Item 28.21:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: F-00001

Process: FC2 Source Classification Code: 2-88-888-01

Process Description: 

FUGITIVES FROM THE AUTOMATIC LATHE. VOC 

EMISSIONS WILL BE INCLUDED ON THE ANNUAL 

EMISSIONS STATEMENT.

Emission Source/Control: FIFC2 - Process

Item 28.22:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: F-00001

Process: FC3 Source Classification Code: 3-03-001-99

Process Description: 

TWO (2) MOLD SHOP BAKE OVENS. SMALL OVEN 

IS USED TO VOLATILIZE OIL IMPREGNATED IN 

GRAPHITE RINGS. EMISSIONS VENT INTO THE 

MILL AND ESTIMATED TO BE INSIGNIFICANT.

Emission Source/Control: FIFC3 - Process

Item 28.23:

This permit authorizes the following regulated processes for the cited Emission Unit:

 Air Pollution Control Permit Conditions

Page 61 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Unit: M-00001

Process: MHA Source Classification Code: 3-04-001-99

Process Description: 

MOLTEN ALUMINUM MELTING AND HOLDING 

FURNACES. CURRENTLY, THESE FURNACES ARE 

NOT PERMITTED TO USE SALT FLUXES.

Emission Source/Control: M001A - Process20

Emission Source/Control: M001B - Process

Emission Source/Control: M024C - Process

Emission Source/Control: M024D - Process

Emission Source/Control: M024F - Process

Item 28.24:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: M-00001

Process: MHS Source Classification Code: 3-04-001-99

Process Description: 

MOLTEN ALUMINUM MELTING AND HOLDING 

FURNACES WHICH ARE PERMITTED TO USE SALT 

FLUXES AT THE TIME OF TITLE V APPLICATION 

SUBMISSION. ALL FURNACES ARE 

REVERBERATORY, CENTER CHARGED. NO GAS 

FLUXING IS DONE IN ANY FURNACE.

Emission Source/Control: M001C - Process

Emission Source/Control: M001D - Process

Emission Source/Control: M0034 - Process

Emission Source/Control: M0035 - Process

Emission Source/Control: M003A - Process

Emission Source/Control: M003C - Process

Item 28.25:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: M-00002

Process: FBA Source Classification Code: 3-04-001-04

Process Description: 

 Air Pollution Control Permit Conditions

Page 62 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

IN-LINE FILTERBOX FLUXING UNITS USE A 

MIXTURE OF ARGON AND CHLORINE GAS TO PURIFY

MOULTEN ALUMINUM AS IT IS BEING CAST INTO 

INGOTS OR ROD. TYPICALLY THERE IS ONE 

FILTERBOX PER FURNACE, AND MULTIPLE 

FURNACES/FILTERBOXES SERVE AS A SINGLE 

CASTING COMPLEX. WITHIN A CASTING COMPLEX.

THESE FILTERBOXES CAN BE EXHAUSTED TOGETHER

OR INDIVIDUALLY, HOWEVER, ONLY ONE 

FILTERBOX IS FLUXING AT ANY TIME SINCE 

THERE IS ONLY ONE CASTING APPARATUS PER 

COMPLEX. THUS, ONLY ONE FILTERBOX EMISSION

SOURCE AND POINT REPRESENTS ALL FILTERBOXES

IN A CASTING COMPLEX.

Emission Source/Control: M001E - Process

Emission Source/Control: M0036 - Process

Emission Source/Control: M003E - Process

Emission Source/Control: M024E - Process

Item 28.26:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: P-00001

Process: PWS Source Classification Code: 4-01-003-35

Process Description: 

This process consists of all the cold cleaning parts 

washers.

Emission Source/Control: PARTS - Process

Item 28.27:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00001

Process: POT Source Classification Code: 3-03-001-01

Process Description: 

ELECTROLYTIC REDUCTION OF ALUMINA INTO 

ALUMINUM. THIS POTLINE IS CATEGORIZED AS A

CENTER WORK PREBAKE-1 (CWPB-1) AS DESCRIBED

IN THE DEFINITIONS SECTION OF EPA'S PRIMARY

ALUMINUM MACT REGULATIONS.

Emission Source/Control: SA398 - Control

Control Type: SCRUBBER - DRY ALUMINA INJECTION

 Air Pollution Control Permit Conditions

Page 63 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Source/Control: SS198 - Process

Item 28.28:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00002

Process: BAK Source Classification Code: 3-03-001-05

Process Description: 

ANODE BAKING FURNACE AND ASSOCIATED 

ALUMINA INJECTION DRY SCRUBBER.

Emission Source/Control: SS78S - Control

Control Type: SCRUBBER - DRY ALUMINA INJECTION

Emission Source/Control: SS078 - Process

Item 28.29:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00003

Process: GMS Source Classification Code: 3-03-003-99

Process Description: 

PASTE PRODUCTION PLANT AND ASSOCIATED COKE

INJECTION SCRUBBER.

Emission Source/Control: SS100 - Control

Control Type: SCRUBBER - DRY COKE INJECTION

Emission Source/Control: SS099 - Process

Item 28.30:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M01 Source Classification Code: 3-03-003-12

Process Description: 

BUILDING 332 DUST COLLECTION EQUIPMENT 

INCLUDES A STUB HOLE CLEANER WHICH USES AIR

TO BLOW COKE DUST OUT OF STUB HOLES. 

PROCESS M01 ALSO INCLUDES TWO SMALL 

INDUCTION FURNACES USED FOR MELTING IRON, 

AND ANTHRACITE COAL HANDLING AND STORAGE.

Emission Source/Control: SS015 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS016 - Control

 Air Pollution Control Permit Conditions

Page 64 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Control Type: FABRIC FILTER

Emission Source/Control: SS017 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS415 - Process

Item 28.31:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M02 Source Classification Code: 3-09-005-00

Process Description: 

ELECTRIC WELDER USED TO WELD ALUMINUM, 

COPPER, AND STEEL TOGETHER. WELD IS 

PRODUCED UNDER HIGH CURRENT AND HYDRAULIC 

PRESSURE.

Emission Source/Control: SS083 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS483 - Process

Item 28.32:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M03 Source Classification Code: 3-03-003-12

Process Description: PACKED COKE DRILLED OUT OF ANODE STUB HOLES.

Emission Source/Control: SS095 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS495 - Process

Item 28.33:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M04 Source Classification Code: 3-03-001-04

Process Description: DRY SCRUBBER ALUMINA LOADING AND UNLOADING AREA.

Emission Source/Control: SS090 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS490 - Process

Item 28.34:

 Air Pollution Control Permit Conditions

Page 65 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M05 Source Classification Code: 3-03-001-05

Process Description: ROUGH CLEANING OF SPENT ANODES.

Emission Source/Control: S23AB - Control

Control Type: FABRIC FILTER

Emission Source/Control: 423AB - Process

Item 28.35:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M06 Source Classification Code: 3-04-022-10

Process Description: 

BATH HANDLING, CRUSHING AND CRUCIBLE 

DIGGING OPERATIONS.

Emission Source/Control: S23AA - Control

Control Type: FABRIC FILTER

Emission Source/Control: S23AC - Control

Control Type: FABRIC FILTER

Emission Source/Control: 423AA - Process

Item 28.36:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M07 Source Classification Code: 3-03-001-04

Process Description: 

TRANSFER POINT IN BUILDING 441 FOR TWO 

ALUMINA BELT CONVEYORS.

Emission Source/Control: SS041 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS441 - Process

Item 28.37:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M08 Source Classification Code: 3-03-003-12

Process Description: BUTT CRUSHING.

 Air Pollution Control Permit Conditions

Page 66 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Source/Control: SS038 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS438 - Process

Item 28.38:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M09 Source Classification Code: 3-03-001-05

Process Description: 

ANODE BUTT STORAGE, STORAGE FILLING, 

AGGREGATE BLENDING, COKE CRUSHING, STORAGE 

DISCHARGE, BALL MILL CLASSIFYING, AND 

INTERMEDIATE CLASSIFYING.

Emission Source/Control:0 SS049 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS050 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS051 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS052 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS053 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS060 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS061 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS449 - Process

Item 28.39:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M10 Source Classification Code: 3-03-001-04

Process Description: STORAGE TANK 440A AND 440B FLUIDIZER FOR ALUMINA

Emission Source/Control: SS086 - Control

 Air Pollution Control Permit Conditions

Page 67 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Control Type: FABRIC FILTER

Emission Source/Control: SS486 - Process

Item 28.40:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M11 Source Classification Code: 3-03-001-04

Process Description: 

TRACK HOPPER DUST COLLECTOR FOR ALUMINA 

UNLOADING AND ALUMINA AIRLIFT TOWER DUST 

COLLECTOR.

Emission Source/Control: SS092 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS093 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS492 - Process

Item 28.41:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M12 Source Classification Code: 3-03-001-04

Process Description: 

TRANSFER POINT 441C SERVES ST441C AND THE 

TRANSFER OF ALUMINA TO ST441B.

Emission Source/Control: SS043 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS443 - Process

Item 28.42:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M13 Source Classification Code: 3-03-001-04

Process Description: 

ALUMINA TRANSFER POINT 446A FROM REACTORS 

TO STORAGE TANKS.

Emission Source/Control: SS046 - Control

Control Type: FABRIC FILTER

 Air Pollution Control Permit Conditions

Page 68 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Source/Control: SS446 - Process

Item 28.43:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M14 Source Classification Code: 3-03-001-04

Process Description: 

ALUMINA TRANSFER POINT 446B FROM REACTORS 

TO STORAGE TANKS.

Emission Source/Control: SS047 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS447 - Process

Item 28.44:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M15 Source Classification Code: 3-03-001-04

Process Description: 

ALUMINA TRANSFER POINT 446C FROM REACTORS 

TO STORAGE TANKS.

Emission Source/Control: SS048 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS448 - Process

Item 28.45:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00004

Process: M16 Source Classification Code: 3-03-003-12

Process Description: 

POT DIGGING AND SPENT POTLINING HANDLING 

OPERATIONS CONTROLLED BY A FABRIC FILTER TO

LIMIT PARTICULATE EMISSIONS TO THE 

ENVIRONMENT.

Emission Source/Control: SS102 - Control

Control Type: FABRIC FILTER

Emission Source/Control: SS402 - Process

Item 28.46:

This permit authorizes the following regulated processes for the cited Emission Unit:

 Air Pollution Control Permit Conditions

Page 69 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Unit: S-00005

Process: PST Source Classification Code: 3-03-003-12

Process Description: 

0 COAL TAR PITCH INCLUDES A SINGLE EMISSION 

POINT (EP) SERVING EACH OF TWO COAL TAR 

PITCH STORAGE TANKS, AND FUGITIVES 

INCLUDING BUT NOT LIMITED TO THOSE 

ASSOCIATED WITH THE PITCH RECIRCULATING 

PUMPS LOCATED IN BUILDING 352F.

Emission Source/Control: SS088 - Process

Emission Source/Control: SS089 - Process

Emission Source/Control: SSFP2 - Process

Item 28.47:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00005

Process: PUN Source Classification Code: 3-03-003-12

Process Description: 

COAL TAR PITCH UNLOADING INCLUDES A SINGLE

EMISSION POINT (EP) SERVING EACH OF TWO 

RAILCAR UNLOADING STATIONS, AND FUGITIVES 

INCLUDING BUT NOT LIMITED TO THOSE 

ASSOCIATED WITH THE PITCH UNLOADING PUMPS. 

SOME OF THESE FUGITIVES ARE EXHAUSTED 

THROUGH THE BUILDING VENTILATOR DESIGNATED 

AS EP S073A.

Emission Source/Control: SS073 - Process

Emission Source/Control: SS077 - Process

Emission Source/Control: SSFP1 - Process

Item 28.48:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00006

Process: FA1 Source Classification Code: 3-03-003-12

Process Description: 

TOTAL SUSPENDED SOLID (I.E. PARTICULATE) 

FUGUTIVES FROM COKE UNLOADING.

Emission Source/Control: SSFA1 - Process

 Air Pollution Control Permit Conditions

Page 70 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item 28.49:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00006

Process: FA2 Source Classification Code: 3-03-003-12

Process Description: 

TOTAL SUSPENDED SOLID (I.E. PARTICULATE) 

FUGITIVES FROM COKE STORAGE AND HANDLING.

Emission Source/Control: SSFA2 - Process

Item 28.50:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00006

Process: FA3 Source Classification Code: 3-03-001-05

Process Description: 

TOTAL SUSPENDED SOLID (I.E. PARTICULATE) 

FUGITIVES FROM CLAMSHELL BUCKET OPERATIONS 

IN THE ANODE BAKING FURNACE ROOM.

Emission Source/Control: SSFA3 - Process

Item 28.51:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00006

Process: FAC Source Classification Code: 3-03-001-05

Process Description: 

WHEN SPENT ANODES ARE PLACED IN BUILDING 

380 AND 376 TO COOL, THERE ARE FUGITIVE 

EMISSIONS FROM PASSIVE ANODE COOLING. SOME

HYDROGEN FLUORIDE IS EMITTED AS A RESULT OF

THE RESIDUAL BATH ON THE ANODES. EMISSIONS

ARE INCLUDED ON THE ANNUAL EMISSIONS 

STATEMENT.

Emission Source/Control: SSFAC - Process

Item 28.52:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: S-00006

Process: FSM Source Classification Code: 3-03-003-99

Process Description: 

SEAM MIX OPERATIONS INCLUDE: LOW 

TEMPERATURE PITCH UNLOADING AND STORAGE, 

 Air Pollution Control Permit Conditions

Page 71 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

THE MIXING OF PITCH, ANTHRACITE COAL AND 

LIQUID METHYLNAPTHALENE, AND THE PLACING OF

FINAL PRODUCT IN BAGS. FUGITIVE EMISSIONS 

CONSIST OF POLYCYCLIC ORGANIC MATTER.

Emission Source/Control: SSFSM - Process

Item 28.53:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: W-00001

Process: OWT Source Classification Code: 3-03-001-99

Process Description: 

TREATMENT OF MISCELLANEOUS OILY 

WASTEWATERS USING A PRECOATE VACUUM FILTER.

 VACUUM EXHAUST IS THE EMISSION POINT.

Emission Source/Control: W0068 - Process

Item 28.54:

This permit authorizes the following regulated processes for the cited Emission Unit:

Emission Unit: W-00001

Process: WWT Source Classification Code: 3-03-001-99

Process Description: 

WASTEWATER TREATMENT CONSISTS OF CHEMICAL 

PRE-TREATMENT, AND BIOLOGICAL TREATMENT.

0

Emission Source/Control: W0069 - Control

Control Type: SODIUM-ALKALI SCRUBBING

Emission Source/Control: W0070 - Process

Emission Source/Control: W0071 - Process

Condition 29: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.3(a)

Item 29.1:

The Compliance Certification activity will be performed for:

Emission Unit: A-00001 Emission Point: F078A

Process: HT2 Emission Source: AF78A

Item 29.2:

Compliance Certification shall include the following monitoring:

 Air Pollution Control Permit Conditions

Page 72 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

No owner or operator of a combustion installation shall 

emit greater than 20 percent opacity except for one six 

minute period per hour, not to exceed 27 percent, based 

upon the six minute average in reference test method 9 in 

Appendix A of 40 CFR 60.

Parameter Monitored: OPACITY

Upper Permit Limit: 20 percent

Reference Test Method: EPA RM 9

Averaging Method: 6-MINUTE AVERAGE (METHOD 9)

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 30: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.3(a)

Item 30.1:

The Compliance Certification activity will be performed for:

Emission Unit: A-00001 Emission Point: F078B

Process: HT2 Emission Source: AF78B

Item 30.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

No owner or operator of a combustion installation shall 

emit greater than 20 percent opacity except for one six 

minute period per hour, not to exceed 27 percent, based 

upon the six minute average in reference test method 9 in 

Appendix A of 40 CFR 60.

Parameter Monitored: OPACITY

Upper Permit Limit: 20 percent

Reference Test Method: EPA RM 9

Averaging Method: 6-MINUTE AVERAGE (METHOD 9)

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 31: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

 Air Pollution Control Permit Conditions

Page 73 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Applicable Federal Requirement: 6NYCRR 212.4(a)

Item 31.1:

The Compliance Certification activity will be performed for:

Emission Unit: A-00002

Process: FAB

Regulated Contaminant(s):

CAS No: 007439-92-1 LEAD

Item 31.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

As required by 6 NYCRR Part 212.4(a) lead has been issued

an environmental rating of A. The emission rate potential 

of lead from this process source shall remain less than 1 

pound per hour. Compliance testing shall be conducted upon

request from the Department.

Upper Permit Limit: 1.0 pounds per hour

Reference Test Method: EPA RM 29

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 32: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.4(a)

Item 32.1:

The Compliance Certification activity will be performed for:

Emission Unit: A-00002

Process: MRS

Regulated Contaminant(s):

CAS No: 000050-00-0 FORMALDEHYDE

Item 32.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

 Air Pollution Control Permit Conditions

Page 74 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Monitoring Description: 

As required by 6 NYCRR Part 212.4(a) formaldehyde has 

been issued an environmental rating of A. The emission 

rate potential of formaldehyde from the emission sources 

in this process shall remain less than 

1 pound per hour. Compliance testing shall be conducted 

upon request from the Department.

Upper Permit Limit: 1.0 pounds per hour

Reference Test Method: EPA RM 18

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 33: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.4(a)

Item 33.1:

The Compliance Certification activity will be performed for:

Emission Unit: A-00002

Process: MRS

Regulated Contaminant(s):

CAS No: 000067-56-1 METHYL ALCOHOL

Item 33.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

As required by 6 NYCRR Part 212.4(a) methanol has been 

issued an environmental rating of B. The emission rate 

potential of methanol from the emission sources in this 

process shall remain less than 10 pounds per hour. 

Compliance testing shall be done upon request from the 

Department.

Upper Permit Limit: 10 pounds per hour

Reference Test Method: EPA RM 18

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

 Air Pollution Control Permit Conditions

Page 75 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 34: Corrective Action

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.6(a)

Item 34.1:

This Condition applies to Emission Unit: B-00001

 

Item 34.2:

Any facility found in violation of the provisions of this Part shall not cause, permit, or allow the operation 

of the affected stationary combustion installation unless: 

(1) it is equipped with approved emission control equipment;

(2) it is rehabilitated or upgraded in an approved manner; or

(3) the fuel is changed to an acceptable type.

Condition 35: Corrective Action

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.6(b)

Item 35.1:

This Condition applies to Emission Unit: B-00001

 

Item 35.2:

The commissioner may seal such stationary combustion installation so as to prevent any operation if the 

conditions of paragraphs 6 NYCRR Part 227-1.6(a)(1)-(3) are not met within the time provided by the 

order of final determination issued in the case of the violation. 

 

Condition 36: Corrective Action

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.6(c)

Item 36.1:

This Condition applies to Emission Unit: B-00001

 

Item 36.2:

No person shall cause, permit, or allow the operation of any affected stationary combustion installation 

sealed by the commissioner in accordance with 6 NYCRR Part 227-1.6.

 

Condition 37: Corrective Action

Effective between the dates of 09/01/2002 and 09/01/2007

 Air Pollution Control Permit Conditions

Page 76 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Applicable Federal Requirement: 6NYCRR 227-1.6(d)

Item 37.1:

This Condition applies to Emission Unit: B-00001

 

Item 37.2:

No person except the commissioner or his representatives shall remove, tamper with or destroy any seal 

affixed to any stationary combustion installation in accordance with 6 NYCRR Part 227-1.6. 

Condition 38: General Provisions

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.7

Item 38.1:

This Condition applies to Emission Unit: B-00001

 

Item 38.2:

(a) Emission data. Any person who owns or operates a stationary combustion installation 

described in 6 NYCRR Part 227-1 shall provide pertinent data concerning emissions when so requested 

by the commissioner. 

 (b) Test methods. Sampling, compositing and analysis of fuel samples shall be carried out in 

accordance with the most recent ASTM standard methods or equivalent methods acceptable to the 

commissioner.

 

Condition 39: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-2.4(b)(1)

Item 39.1:

The Compliance Certification activity will be performed for:

Emission Unit: B-00001

Regulated Contaminant(s):

CAS No: 0NY210-00-0 OXIDES OF NITROGEN

Item 39.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

In order to comply with the NOx RACT requirements of 6 

NYCRR Part 227-2 each of the four boilers in this emission

unit shall not exceed an emission rate of 0.30 pounds per 

million Btu per hour.

 Air Pollution Control Permit Conditions

Page 77 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Parameter Monitored: OXIDES OF NITROGEN

Upper Permit Limit: 0.30 pounds per million Btus

Reference Test Method: EPA RM 7E

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: ONCE / BATCH OR MONITORING OCCURRENCE

Condition 40: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 225-1.2(d)

Item 40.1:

The Compliance Certification activity will be performed for:

Emission Unit: B-00001

Process: OIL

Regulated Contaminant(s):

CAS No: 007446-09-5 SULFUR DIOXIDE

Item 40.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

Sulfur content of Number 6 fuel oil used in this process 

shall not exceed 1.5% by weight.

Process Material: NUMBER 6 OIL

Parameter Monitored: SULFUR CONTENT

Upper Permit Limit: 1.5 percent by weight

Monitoring Frequency: PER DELIVERY

Averaging Method: MAXIMUM - NOT TO BE EXCEEDED AT ANY 

 TIME (INSTANTANEOUS/DISCRETE OR GRAB)

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 41: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 225-1.7(c)

Item 41.1:

The Compliance Certification activity will be performed for:

 Air Pollution Control Permit Conditions

Page 78 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Unit: B-00001

Process: OIL

Item 41.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Part 225-1.7(c) requires that measurements must be made 

daily of the rate of each fuel burned. The gross heat 

content and ash content of each fuel burned must be 

determined at least once each week. This information 

must be retained by the source owner for a period of five 

years.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 42: Records retention

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 225-1.7(d)

Item 42.1:

This Condition applies to Emission Unit: B-00001

Process: OIL

 

Item 42.2:

Data collected pursuant to 6 NYCRR Part 225-1.7 must be tabulated and summarized in a form 

acceptable to the commissioner, and must be retained for at least three years. The source owner must 

furnish such records and summaries upon request of the commissioner.

 

Condition 43: Sulfur in fuel exception reporting

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 225-1.7(e)

Item 43.1:

This Condition applies to Emission Unit: B-00001

Process: OIL

 

Item 43.2:

Source owners subject to 6 NYCRR Part 225-1.7 must submit a written report of the fuel sulfur content 

excceding the applicable sulfur-in-fuel limitation, or of measured emissions exceeding the applicable 

equivalent emission rate, and the nature and cause of such excesses if known, for the calendar quarter.

 

Condition 44: Compliance Certification

 Air Pollution Control Permit Conditions

Page 79 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 225-1.8(a)

Item 44.1:

The Compliance Certification activity will be performed for:

Emission Unit: B-00001

Process: OIL

Item 44.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

THE PERMITTEE SHALL RETAIN FUEL OIL 

SUPPLIER CERTIFICATIONS FOR EACH SHIPMENT

OF OIL RECEIVED. SUCH CERTIFICATIONS 

SHALL CONTAIN, AS A MINIMUM: SUPPLIER 

NAME, DATE OF SHIPMENT, QUANTITY SHIPPED,

OIL SULFUR CONTENT, AND THE METHOD USED 

TO DETERMINE THE SULFUR CONTENT. SUCH 

CERTIFICATIONS SHALL BE AVAILABLE FOR 

INSPECTION BY, OR SUBMITTAL TO, NYSDEC 

UPON REQUEST.

Monitoring Frequency: PER DELIVERY

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 45: Sampling, compositing, and analysis of fuel samples

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 225-1.8(d)

Item 45.1:

This Condition applies to Emission Unit: B-00001

Process: OIL

 

Item 45.2:

All sampling, compositing, and analysis of fuel samples, taken to determine compliance with 6 NYCRR 

Part 225-1, must be done in accordance with methods acceptable to the commissioner.

 

Condition 46: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.4(b)

Item 46.1:

 Air Pollution Control Permit Conditions

Page 80 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

The Compliance Certification activity will be performed for:

Emission Unit: B-00001

Process: OIL

Item 46.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator of a stationary combustion 

installation which utilizes a continuous opacity 

monitoring system (COMS) shall include the following in 

their quarterly excess emission reports:

1) Magnitude, date, and time of each exceedence;

2) For each period of excess emissions, specific 

identification of the cause and corrective action 

taken;

3) Date, time, and duration of each period of COMS 

downtime, and the corrective action for each period of 

downtime;

4) Total time the COMS is required to record data during 

the reporting period;

5) The total number of exceedences and the duration of 

exceedences expressed as a percentage of the total time in

which the COMS are required to record data; and

6) Such other requirements as the Department may deem 

necessary in order to enforce Article 19 of the 

Environmental Conservation Law (ECL).

Reporting Requirements: QUARTERLY (CALENDAR)

Reports due 60 days after the reporting period.

The initial report is due 11/29/02.

Subsequent reports are due every 3 calendar month(s).

Condition 47: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.3(a)

Item 47.1:

The Compliance Certification activity will be performed for:

 Air Pollution Control Permit Conditions

Page 81 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Unit: B-00001

Process: OIL Emission Source: B0001

Item 47.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

No owner or operator of a combustion installation shall 

emit greater than 20 percent opacity except for one six 

minute period per hour, not to exceed 27 percent, based 

upon the six minute average utilizing a continuous opacity

monitor (COM).

Parameter Monitored: OPACITY

Upper Permit Limit: 20 percent

Reference Test Method: EPA Meth 9

Monitoring Frequency: CONTINUOUS

Averaging Method: 6 MINUTE AVERAGE

Reporting Requirements: QUARTERLY (CALENDAR)

Reports due 60 days after the reporting period.

The initial report is due 11/29/02.

Subsequent reports are due every 3 calendar month(s).

Condition 48: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.3(a)

Item 48.1:

The Compliance Certification activity will be performed for:

Emission Unit: B-00001

Process: OIL Emission Source: B0002

Item 48.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

No owner or operator of a combustion installation shall 

emit greater than 20 percent opacity except for one six 

minute period per hour, not to exceed 27 percent, based 

upon the six minute average utilizing a continuous opacity

monitor (COM).

 Air Pollution Control Permit Conditions

Page 82 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Parameter Monitored: OPACITY

Upper Permit Limit: 20 percent

Reference Test Method: EPA Meth 9

Monitoring Frequency: CONTINUOUS

Averaging Method: 6 MINUTE AVERAGE

Reporting Requirements: QUARTERLY (CALENDAR)

Reports due 60 days after the reporting period.

The initial report is due 11/29/02.

Subsequent reports are due every 3 calendar month(s).

Condition 49: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.3(a)

Item 49.1:

The Compliance Certification activity will be performed for:

Emission Unit: B-00001

Process: OIL Emission Source: B0003

Item 49.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

0 No owner or operator of a combustion installation shall 

emit greater than 20 percent opacity except for one six 

minute period per hour, not to exceed 27 percent, based 

upon the six minute average utilizing a continuous opacity

monitor (COM).

Parameter Monitored: OPACITY

Upper Permit Limit: 20 percent

Reference Test Method: EPA Meth 9

Monitoring Frequency: CONTINUOUS

Averaging Method: 6 MINUTE AVERAGE

Reporting Requirements: QUARTERLY (CALENDAR)

Reports due 60 days after the reporting period.

The initial report is due 11/29/02.

Subsequent reports are due every 3 calendar month(s).

Condition 50: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.3(a)

 Air Pollution Control Permit Conditions

Page 83 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item 50.1:

The Compliance Certification activity will be performed for:

Emission Unit: B-00001

Process: OIL Emission Source: B0004

Item 50.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

No owner or operator of a combustion installation shall 

emit greater than 20 percent opacity except for one six 

minute period per hour, not to exceed 27 percent, based 

upon the six minute average utilizing a continuous opacity

monitor (COM).

Parameter Monitored: OPACITY

Upper Permit Limit: 20 percent

Reference Test Method: EPA Meth 9

Monitoring Frequency: CONTINUOUS

Averaging Method: 6 MINUTE AVERAGE

Reporting Requirements: QUARTERLY (CALENDAR)

Reports due 60 days after the reporting period.

The initial report is due 11/29/02.

Subsequent reports are due every 3 calendar month(s).

Condition 51: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.3(a)

Item 51.1:

The Compliance Certification activity will be performed for:

Emission Unit: B-00001 Emission Point: 00001

Process: GAS

Item 51.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

No owner or operator of a combustion installation shall 

emit greater than 20 percent opacity except for one six 

 Air Pollution Control Permit Conditions

Page 84 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

minute period per hour, not to exceed 27 percent, based 

upon the six minute average in reference test method 9 in 

Appendix A of 40 CFR 60.

Parameter Monitored: OPACITY

Upper Permit Limit: 20 percent

Reference Test Method: EPA RM 9

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: 6-MINUTE AVERAGE (METHOD 9)

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 52: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227.2(b)(1)

Item 52.1:

The Compliance Certification activity will be performed for:

Emission Unit: B-00001 Emission Point: 00001

Process: OIL

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 52.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

Particulate emission limit for a stationary combustion 

installation firing oil. The owner or operator shall 

complete the following once per term of this permit:

1) submit, to the Department, an acceptable protocol for 

the testing of particulate emission limit cited in this 

condition,

2) perform a stack test, based upon the approved test 

protocol, to determine compliance with the particulate 

emission limit cited in this condition, and

3) all records shall be maintained at the facility for a 

minimum of five years.

Parameter Monitored: PARTICULATES

Upper Permit Limit: 0.10 pounds per million Btus

 Air Pollution Control Permit Conditions

Page 85 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Reference Test Method: Method 5

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 53: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227-1.3(a)

Item 53.1:

The Compliance Certification activity will be performed for:

Emission Unit: B-00001 Emission Point: 00002

Process: GAS

Item 53.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

No owner or operator of a combustion installation shall 

emit greater than 20 percent opacity except for one six 

minute period per hour, not to exceed 27 percent, based 

upon the six minute average in reference test method 9 in 

Appendix A of 40 CFR 60.

Parameter Monitored: OPACITY

Upper Permit Limit: 20 percent

Reference Test Method: EPA RM 9

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: 6-MINUTE AVERAGE (METHOD 9)

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 54: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 227.2(b)(1)

Item 54.1:

The Compliance Certification activity will be performed for:

 Air Pollution Control Permit Conditions

Page 86 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Unit: B-00001 Emission Point: 00002

Process: OIL

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 54.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

Particulate emission limit for a stationary combustion 

installation firing oil. The owner or operator shall 

complete the following once per term of this permit:

1) submit, to the Department, an acceptable protocol for 

the testing of particulate emission limit cited in this 

condition,

2) perform a stack test, based upon the approved test 

protocol, to determine compliance with the particulate 

emission limit cited in this condition, and

3) all records shall be maintained at the facility for a 

minimum of five years.

Parameter Monitored: PARTICULATES

Upper Permit Limit: 0.10 pounds per million Btus

Reference Test Method: Method 5

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 55: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 231-2.2(d)(3)

Item 55.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00001

Regulated Contaminant(s):

 Air Pollution Control Permit Conditions

Page 87 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

CAS No: 0NY998-00-0 VOC

Item 55.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

The emission rate of volatile organic compounds (VOC) 

from this emission unit shall not exceed 9.1 pounds per 

hour.

Upper Permit Limit: 9.1 pounds per hour

Reference Test Method: METHOD 25A

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: ONCE / BATCH OR MONITORING OCCURRENCE

Condition 56: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 231-2.2(d)(3)

Item 56.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00001

Regulated Contaminant(s):

CAS No: 0NY210-00-0 OXIDES OF NITROGEN

Item 56.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

The emission rate of nitrogen oxides (NOx) from this 

emission unit shall not exceed 9.1 pounds per hour.

Upper Permit Limit: 9.1 pounds per hour

Reference Test Method: METHOD 7E

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: ONCE / BATCH OR MONITORING OCCURRENCE

Condition 57: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

 Air Pollution Control Permit Conditions

Page 88 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Applicable Federal Requirement: 40CFR 52.21(i)(1), Subpart Ar

Item 57.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00001

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 57.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

The emission rate of particulate matter (PM) from this 

emission unit shall not exceed 5.6 pounds per hour.

Upper Permit Limit: 5.6 pounds per hour

Reference Test Method: METHOD 5

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: ONCE / BATCH OR MONITORING OCCURRENCE

Condition 58: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.10(c)(4)(i)

Item 58.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00001

Process: CD1 Emission Source: C029B

Regulated Contaminant(s):

CAS No: 0NY998-00-0 VOC

Item 58.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

Owner shall determine compliance with the VOC RACT 

requirements of 6 NYCRR Part 212.10(c)(4)(i) by performing

 Air Pollution Control Permit Conditions

Page 89 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

a stack test on the exhaust gas emissions of emission 

control C029B and comparing that to the inlet VOC 

concentration as determined by the following method:

 Inlet VOC = (%residual lube on chips) x (tons 

chips processed during test)

 Overall removal efficiency = [(inlet VOC) - 

(exhaust gas VOC from test)/(inlet VOC)] x 100

Parameter Monitored: VOC

Lower Permit Limit: 81 percent reduction by weight

Reference Test Method: EPA RM 18 or 25A

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Averaging Method: 1-HOUR AVERAGE

Reporting Requirements: ONCE / BATCH OR MONITORING OCCURRENCE

Condition 59: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.11(b)(1)

Item 59.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00001

Process: CD1 Emission Source: C029B

Regulated Contaminant(s):

CAS No: 0NY998-00-0 VOC

Item 59.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

Owners and/or operators of any source equipped with a 

thermal incinerator for emissions control equipment must 

install a continuous monitor and data recorder for exhaust

gas temperature. The continuous monitor must be operated 

at all times when the associated process equipment is 

operating except during any quality assurance and routine 

maintenance activities. The Continuous Monitoring System 

(CMS) will be operated and maintained according to a CMS 

Operation and Maintenance (CMS O&M) Plan that will be 

submitted to the Department for review and approval. The 

 Air Pollution Control Permit Conditions

Page 90 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

CMS O&M Plan will be updated as needed and any changes 

will be submitted to the Department for approval. 

In order to ensure Process CD1 maintains 81% destruction 

of VOC, the afterburner (emission control C029B) must be 

operated with a minumum exhaust gas temperature of 1200 

degrees Fahrenheit.

Parameter Monitored: TEMPERATURE

Lower Permit Limit: 1200 degrees Fahrenheit

Monitoring Frequency: CONTINUOUS

Averaging Method: 2-HOUR BLOCK AVERAGE

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 60: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.4(a)

Item 60.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00001 Emission Point: I0029

Process: CD1

Regulated Contaminant(s):

CAS No: 000630-08-0 CARBON MONOXIDE

Item 60.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

Carbon Monoxide emissions from the facility were given an

environmental rating of "C". Measured emissions at 

emission point I0029 (#1 Chip Dryer) were 13.3 pounds per 

hour which requires 70% control or Best Available Control 

Technology (BACT). A BACT analysis shall be submitted 

within 120 days of the permit issue date to show 

compliance with 212.5(d). 

Upper Permit Limit: 10.0 pounds per hour

Reference Test Method: EPA method 10

 Air Pollution Control Permit Conditions

Page 91 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Averaging Method: 1-HOUR AVERAGE

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 61: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.4(a)

Item 61.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00001 Emission Point: I0029

Process: CD1

Regulated Contaminant(s):

CAS No: 000111-42-2 ETHANOL, 2,2'-IMINOBISItem 61.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

As required by 6 NYCRR Part 212.4(a) diethanolamine has 

been issued an environmental rating of B. The emission 

rate potential of diethanolamine from each emission source

in this process shall remain less than 10 pounds per hour.

Emission testing shall be conducted upon request from the 

Department.

Upper Permit Limit: 10.0 pounds per hour

Reference Test Method: EPA RM 18

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 62: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.10(c)(3)

Item 62.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00001 Emission Point: I0030

Process: CM1 Emission Source: C0030

 Air Pollution Control Permit Conditions

Page 92 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Regulated Contaminant(s):

CAS No: 0NY210-00-0 OXIDES OF NITROGEN

Item 62.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The NOx RACT compliance plan submitted to NYSDEC in 1994 

determined control of NOx was not technically or 

economically feasible at that time. The current equipment 

configuration meets NOx RACT.

Reference Test Method: EPA RM 7E

Monitoring Frequency: SINGLE OCCURRENCE

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 63: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.10(f)

Item 63.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00002

Regulated Contaminant(s):

CAS No: 0NY210-00-0 OXIDES OF NITROGEN

Item 63.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Operation of the chip dryer and melter (emission sources 

C0044 & C0045) with low NOx burners and staged air 

combustion is considered RACT for the purposes of 6 NYCRR 

Part 212.10(f).

Reference Test Method: EPA RM 7E

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Condition 64: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 231-2.2(d)(3)

Item 64.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00002

Regulated Contaminant(s):

CAS No: 0NY210-00-0 OXIDES OF NITROGEN

Item 64.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

The emission rate of nitrogen oxides (NOx) from this 

emission unit shall not exceed 9.1 pounds per hour.

Upper Permit Limit: 9.1 pounds per hour

Reference Test Method: METHOD 7E

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

f0 Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: ONCE / BATCH OR MONITORING OCCURRENCE

Condition 65: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 231-2.2(d)(3)

Item 65.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00002

Regulated Contaminant(s):

CAS No: 0NY998-00-0 VOC

Item 65.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

The emission rate of volatile organic compounds (VOC) 

from this emission unit shall not exceed 9.1 pounds per 

 Air Pollution Control Permit Conditions

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hour.

Upper Permit Limit: 9.1 pounds per hour

Reference Test Method: METHOD 25A

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: ONCE / BATCH OR MONITORING OCCURRENCE

Condition 66: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 52.21(i)(1), Subpart A

Item 66.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00002

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 66.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

The emission rate of particulate matter (PM) from this 

emission unit shall not exceed 3.4 pounds per hour.

Upper Permit Limit: 3.4 pounds per hour

Reference Test Method: METHOD 5

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: ONCE / BATCH OR MONITORING OCCURRENCE

Condition 67: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.4(a)

Item 67.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00002

Process: CD2

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Regulated Contaminant(s):

CAS No: 000630-08-0 CARBON MONOXIDE

Item 67.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

As required by 6 NYCRR Part 212.4(a) carbon monoxide (CO)

has been issued an environmental rating of C. The emission

rate potential of carbon monoxide from each emission 

source in this process shall remain less than 10 pounds 

per hour. Compliance testing shall be conducted upon 

request from the Department.

Upper Permit Limit: 10.0 pounds per hour

Reference Test Method: EPA RM 10

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 68: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.4(a)

Item 68.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00002

Process: CD2

Regulated Contaminant(s):

CAS No: 000111-42-2 ETHANOL, 2,2'-IMINOBISItem 68.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

As required by 6 NYCRR Part 212.4(a) diethanolamine has 

been issued an environmental rating of B. The emission 

rate potential of diethanolamine from each emission source

in this process shall remain less than 10 pounds per hour.

Emission testing shall be conducted upon request from the 

Department.

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Upper Permit Limit: 10.0 pounds per hour

Reference Test Method: EPA RM 18

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 69: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.10(c)(4)(i)

Item 69.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00002

Process: CD2 Emission Source: C044B

Regulated Contaminant(s):

CAS No: 0NY998-00-0 VOC

Item 69.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

Owner shall determine compliance with the VOC RACT 

requirements of 6 NYCRR Part 212.10(c)(4)(i) by performing

a stack test on the exhaust gas emissions of emission 

control C044B and comparing that to the inlet VOC 

concentration as determined by the following method:

 Inlet VOC = (%residual lube on chips) x (tons 

chips processed during test)

 Overall removal efficiency = [(inlet VOC) - 

(exhaust gas VOC from test)/(inlet VOC)] x 100

Parameter Monitored: VOC

Lower Permit Limit: 81 percent

Reference Test Method: EPA RM 18 or 25A

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Averaging Method: 1-HOUR AVERAGE

Reporting Requirements: ONCE / BATCH OR MONITORING OCCURRENCE

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Condition 70: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.11(b)(1)

Item 70.1:

The Compliance Certification activity will be performed for:

Emission Unit: C-00002

Process: CD2 Emission Source: C044B

Regulated Contaminant(s):

CAS No: 0NY998-00-0 VOC

Item 70.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

Owners and/or operators of any source equipped with a 

thermal incinerator for emissions control equipment must 

install a continuous monitor and data recorder for exhaust

gas temperature. The continuous monitor must be operated 

at all times when the associated process equipment is 

operating except during any quality assurance and routine 

maintenance activities. The Continuous Monitoring System 

(CMS) will be operated and maintained according to a CMS 

Operation and Maintenance (CMS O&M) Plan that will be 

submitted to the Department for review and approval within

90 days of issuance of the permit. The CMS O&M Plan will 

be updated as needed and any changes will be submitted to 

the Department for approval. 

In order to ensure Process CD2 maintains an acceptable 

level of VOC reduction, the thermal incinerator (emission 

control C044B) must be operated with a minimum exhaust gas

temperature of 1400 degrees Fahrenheit.

Parameter Monitored: TEMPERATURE

Lower Permit Limit: 1400 degrees Fahrenheit

Monitoring Frequency: CONTINUOUS

Averaging Method: 2-HOUR BLOCK AVERAGE

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

 Air Pollution Control Permit Conditions

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Condition 71: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 228.2

Item 71.1:

The Compliance Certification activity will be performed for:

Emission Unit: D-00001

Process: PRT

Regulated Contaminant(s):

CAS No: 0NY998-00-0 VOC

Item 71.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

For all surface coatings subject to 6NYCRR Part 228, the 

VOC content (as applied, minus water and exempt VOC), must

be less than or equal to the limit specified in Table 1 or

Table 2 for the respective surface that is coated.

The VOC content of a coating, as applied, is calculated as

follows:

(VOC)a= (Dc)a { [(Wv)a - (Ww)a- (We)a)] / [ 1- [(Vw)a + 

(Ve)a] ] } 

Where: 

(VOC)a = VOC content of "as applied" coating, expressed as

a mass of VOC in pounds, per gallon of coating, in 

gallons, minus water and exempt VOC

(Dc)a= Coating density as applied, in pounds per 

gallon

(Wv)a= The weight fraction of total volatiles in the 

coating, as applied

(Ww)a= The weight fraction of water in the coating, as 

applied

(Vw)a= The volume fraction of water in the coating, as 

applied

(We)a= The weight fraction of exempt VOCs in the coating, 

as applied

(Ve)a= The volume fraction of exempt VOCs in the coating, 

as applied

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Reference Test Method: Method 24 (40CFR60)

Averaging Method: MAXIMUM - NOT TO BE EXCEEDED AT ANY 

 TIME (INSTANTANEOUS/DISCRETE OR GRAB)

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 72: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 228.5(a)

Item 72.1:

The Compliance Certification activity will be performed for:

Emission Unit: D-00001

Process: PRT

Item 72.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

 Certification from the coating supplier/manufacturer 

which verifies the parameters used to determine the actual

VOC content of the as applied coating, for each coating 

used at the facility, must be maintained and, upon 

request, be provided to the departments representative. 

In addition, purchase, usage and/or production records of 

the coating material, including solvents, must be 

maintained and, upon request, be submitted to the 

department. Records must be maintained at the facility 

for a period of five years.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 73: method 24 40 CFR 60

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 228.5(b)

Item 73.1:

This Condition applies to Emission Unit: D-00001

Process: PRT

 

Item 73.2:

Acceptable analytical methods for determining the volatile content, water content, density, volume of 

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

solids and weight of solids of surface coatings are presented in appendix A, method 24, of 40 CFR 60.

Condition 74: samples

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 228.5(d)

Item 74.1:

This Condition applies to Emission Unit: D-00001

Process: PRT

 

Item 74.2:

Representatives of the department shall be permitted, during reasonable business hours, to obtain 

coating samples for the purpose of determining compliance.

Condition 75: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 228.7

Item 75.1:

The Compliance Certification activity will be performed for:

Emission Unit: D-00001

Process: PRT

Regulated Contaminant(s):

CAS No: 0NY998-00-0 VOC

Item 75.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: WORK PRACTICE INVOLVING SPECIFIC 

 OPERATIONS

Monitoring Description: 

Clear coats used for the surface coating of miscellaneous

metal parts and products may contain a maximum of 4.3 

pounds of volatile organic compounds per gallon of coating

(minus water and excluded VOC) as applied.

Work Practice Type: PARAMETER OF PROCESS MATERIAL

Process Material: CLEAR COATINGS - MISCELLANEOUS METAL PARTS

Parameter Monitored: VOC CONTENT

Upper Permit Limit: 4.3 pounds per gallon

Reference Test Method: Method 24 (40CFR60)

Monitoring Frequency: SINGLE OCCURRENCE

Averaging Method: MAXIMUM - NOT TO BE EXCEEDED AT ANY 

 TIME (INSTANTANEOUS/DISCRETE OR GRAB)

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Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 76: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 228.10

Item 76.1:

The Compliance Certification activity will be performed for:

Emission Unit: D-00001

Process: PRT

Regulated Contaminant(s):

CAS No: 0NY998-00-0 VOC

Item 76.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

No owner or operator of a facility subject to 6NYCRR Part

228 shall:

(a) use open containers to store or dispose of cloth or 

paper impregnated with VOC and/or solvents that are used 

for surface preparation, cleanup, or coating 

removal;

(b) store in open containers spent or fresh VOC and/or 

solvents to be used for surface preparation, cleanup, or 

coating removal;

(c) use VOC and/or solvents to cleanup spray equipment 

unless equipment is used to collect the cleaning compounds

and to minimize their evaporation to the 

atmosphere;

(d) use open containers to store or dispense surface 

coatings and/or inks unless production, sampling, 

maintenance , or inspection procedures require operational

access. This provision does not apply to the actual 

device or equipment designed for the purpose of applying a

coating material to a substrate; or

(e) use open containers to store or dispose of spent 

surface coatings, spent VOCs and/or solvents.

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The surface coating operations shall be inspected daily to

determine if there are any open containers present. Open 

containers, if found, shall be covered.

Monitoring Frequency: DAILY

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 77: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 228.4

Item 77.1:

The Compliance Certification activity will be performed for:

Emission Unit: D-00001

Process: PRT Emission Source: DF073

Item 77.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

No person shall cause or allow emissions to the outdoor 

atmosphere having an average opacity of 20 percent or 

greater for any consecutive six-minute period from any 

emission source subject to 6NYCRR Part 228.

The Department reserves the right to perform or require 

the performance of a Method 9 opacity evaluation

Parameter Monitored: OPACITY

Upper Permit Limit: 20 percent

Reference Test Method: EPA RM 5

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: 6-MINUTE AVERAGE (METHOD 9)

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 78: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.5(d)

Item 78.1:

The Compliance Certification activity will be performed for:

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Unit: M-00001

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 78.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The particulate matter (PM) emissions from this emission 

unit, are subject to the Federal National Emission 

Standards for Hazardous Air Pollutants in 40 CFR part 63 

Subpart RRR, which satisfy the requirements of Part 

212.5(d) for PM emissions as long as the source owner 

continues to demonstrate that the emission unit is in 

compliance with the respective Federal requirements 

contained in this permit. Compliance testing shall be 

conducted upon request from the department.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 79: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1506(d), Subpart RRR

Item 79.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001

Item 79.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator of each affected source or emission

unit subject to an emission limit in kg/Mg (lb/ton) of 

feed/charge must:

(1) Except as provided in paragraph (3) of this 

condition, install and operate a device that measures and 

records or otherwise determine the weight of feed/charge 

(or throughput) for each operating cycle or time period 

used in the emissions test; and

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(2) Operate each weight measurement system or other 

weight determination procedure in accordance with the 

manufacturer's recommendations.

(3) The owner or operator may chose to measure and record

aluminum production weight from an affected source or 

emission unit rather than feed/charge weight to an 

affected source or emission unit, provided that: 

(i) The aluminum production weight, rather than 

feed/charge weight is measured and recorded for all 

emission units within a SAPU; and

(ii) All calculations to demonstrate compliance with the

emission limits for SAPUs are based on aluminum production

weight rather than feed/charge weight.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 80: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1506(p), Subpart RRR

Item 80.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001

Item 80.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

When a process parameter or add-on air pollution control 

device operating parameter deviates from the value or 

range established during the emissions test, the owner or 

operator must initiate corrective action. Corrective 

action must restore operation of the affected source or 

emission unit (including the process or control device) to

its normal or usual mode of operation as expeditiously as 

practicable in accordance with good air pollution control 

practices for minimizing emissions. Corrective actions 

taken must include follow-up actions necessary to return 

the process or control device parameter level(s) to the 

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value or range of values established during the emissions 

test and steps to prevent the likely recurrence of the 

cause of a deviation.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 81: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1510(e), Subpart RRR

Item 81.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001

Item 81.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator of an affected source or emission 

unit subject to an emission limit in kg/Mg (lb/ton) or 

ug/Mg (gr/ton) of feed/charge must install, calibrate, 

operate, and maintain a device to measure and record the 

total weight of feed/charge to, or the aluminum production

from, the affected source or emission unit over the same 

operating cycle or time period used in the initial 

emissions test. Feed/charge or aluminum production within 

SAPUs must be measured and recorded on an emission 

unit-by-emission unit basis. As an alternative to a 

measurement device, the owner or operator may use a 

procedure acceptable to the applicable permitting 

authority to determine the total weight of feed/charge or 

aluminum production to the affected source or emission 

unit.

 (1) The accuracy of the weight measurement device or 

procedure must be ±5 percent of the weight being measured.

The owner or operator may apply to the permitting agency 

for approval to use a device of alternative accuracy if 

the required accuracy cannot be achieved as a result of 

equipment layout or charging practices. A device of 

alternative accuracy will not be approved unless the owner

or operator provides assurance through data and 

information that the affected source will meet the 

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relevant emission standard.

 (2) The owner or operator must verify the calibration

of the weight measurement device in accordance with the 

schedule specified by the manufacturer, or if no 

calibration schedule is specified, at least once every 6 

months.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 82: Calculation of Secondary Aluminum Processing Unit PM 

emissions

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1510(t), Subpart RRR

Item 82.1:

This Condition applies to Emission Unit: M-00001

 

Item 82.2:

Except as provided in paragraph 40 CFR Part 63.1510(u), the owner or operator must calculate and 

record the 3-day, 24-hour rolling average emissions of PM for each secondary aluminum processing unit 

on a daily basis. To calculate the 3-day, 24-hour rolling average, the owner or operator must:

 (1) 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/charge weight information 

required in paragraph (e) of this section. 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 must be conducted on the aluminum 

production weight basis.

 (2) Multiply the total feed/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/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.

 (3) 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.

 (4) Compute the 24-hour daily emission rate using the equation below:

 

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

E

T ER

T

day

i i

i

n

i

i

= n

× =

=

∑

∑

( )

1

1

 

Where,

Eday = The daily PM emission rate for the secondary aluminum processing unit for the 24-hour period;

Ti = The total amount of feed, or aluminum produced, for emission unit i for the 24-hour period (tons);

ERi = The measured emission rate for emission unit i as determined in the performance test (lb/ton or 

μg/Mg of feed/charge); and

n = The number of emission units in the secondary aluminum processing unit.

 (5) Calculate and record the 3-day, 24-hour rolling average of PM each day by summing the daily 

emission rates for each pollutant over the 3 most recent consecutive days and dividing by 3.

 

Condition 83: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1511(a), Subpart RRR

Item 83.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001

Item 83.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Prior to conducting an emissions test required by this 

permit, the owner or operator must prepare and submit a 

site-specific test plan meeting the requirements in 6 

NYCRR Part 202-1.2 and 202-1.3. Such plan shall be 

submitted to the Department within 90 days of issuance of 

this permit. Testing of the subject source must occur 

within 90 days of Department approval of the site-specific

test plan.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

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Condition 84: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1511(b), Subpart RRR

Item 84.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001

Item 84.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Following approval of the site-specific test plan, the 

owner or operator must demonstrate initial compliance with

each applicable emission, equipment, work practice, or 

operational standard for each affected source and emission

unit, and report the results to the Department within 90 

days of achieving initial compliance. The owner or 

operator must conduct each emissions test according to the

requirements of the general provisions in 40 CFR 63 

subpart A and subpart RRR. 

(1) The owner or operator must 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 flux 

rate.

(2) Each emissions test for a continuous process must 

consist of 3 separate runs; pollutant sampling for each 

run must 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.

(3) Each emissions test for a batch process must consist 

of three separate runs; pollutant sampling for each run 

must be conducted over the entire process operating 

cycle.

(4) Where multiple affected sources or emission units are

exhausted through a common stack, pollutant sampling for 

each run must be conducted over a period of time during 

which all affected sources or emission units complete at 

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least 1 entire process operating cycle or for 24 hours, 

whichever is shorter.

(5) Initial compliance with an applicable emission limit 

or standard is demonstrated if the average of three runs 

conducted during the initial emissions test is less than 

or equal to the applicable emission limit or standard.

Reference Test Method: EPA RM 5

Monitoring Frequency: SINGLE OCCURRENCE

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 85: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1511(c), Subpart RRR

Item 85.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001

Item 85.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator must use the following methods in 

appendix A to 40 CFR part 60 to determine compliance with 

the applicable emission limits or standards:

(1) Method 1 for sample and velocity traverses.

(2) Method 2 for velocity and volumetric flow 

rate.

(3) Method 3 for gas analysis.

(4) Method 4 for moisture content of the stack 

gas.

(5) Method 5 for the concentration of PM.

(6) Method 9 for visible emission observations.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 Air Pollution Control Permit Conditions

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 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 86: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1511(e), Subpart RRR

Item 86.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001

Item 86.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator of new or existing emission units 

located at secondary aluminum production facilities that 

are major sources must conduct an emissions test every 5 

years following the initial emissions test.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 87: Testing of Representative Emission Units

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1511(f), Subpart RRR

Item 87.1:

This Condition applies to Emission Unit: M-00001

 

Item 87.2:

With the approval of the permitting authority, a single representative or similar group 1 furnace or in-line 

fluxer which is not controlled by an add-on control device may be tested to determine the emission rate of 

all like affected sources at a facility provided that:

(1) The tested emission unit must use identical feed/charge and flux materials in the same 

proportions as the emission units that it represents;

(2) The tested emission unit is subject to the same work practices and the emission units that it 

represents;

(3) The tested emission unit is of the same design as the emission units that it represents;

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(4) 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;

(5) At least one of each different style of emission unit at the facility is tested; and

(6) All add-on control devices are tested.

 

Condition 88: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1511(g), Subpart RRR

Item 88.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001

Item 88.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Establishment of monitoring and operating parameter 

values. The owner or operator of new or existing emission 

units must establish a minimum or maximum operating 

parameter value, or an operating parameter range for each 

parameter to be monitored, as required by this permit, 

that ensures compliance with the applicable emission limit

or standard. To establish the minimum or maximum value or 

range, the owner or operator must use the appropriate 

procedures in this section and submit the information 

required by 40 CFR Part 63.1515(b)(4), to the Department .

The owner or operator may use existing data in addition to

the results of emissions tests to establish operating 

parameter values for compliance monitoring provided each 

of the following conditions are met to the satisfaction of

the applicable permitting authority:

(1) The complete emission test report(s) used as the 

basis of the parameter(s) is submitted.

(2) The same test methods and procedures as required by 

this subpart were used in the test.

(3) 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.

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(4) All process and control equipment operating 

parameters required to be monitored were monitored as 

required in this subpart and documented in the test 

report.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 89: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1512(j), Subpart RRR

Item 89.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 89.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator must conduct emission tests as 

described below. The results of the emission tests are 

used to establish emission rates in lb/ton of feed/charge 

for PM from each emission unit. These emission rates are 

used for compliance monitoring in the calculation of the 

3-day, 24-hour rolling average emission rates using the 

equation in 40 CFR Part 63.1510(t). An emissions test is 

required for:

(1) Each group 1 furnace that processes scrap other than 

clean charge to measure emissions of PM.

 

(2) Each in-line fluxer to measure emissions of PM.

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 90: Performance Test/Compliance Demonstration Requirements and

Procedures - Feed/Charge Weight Measurement.

Effective between the dates of 09/01/2002 and 09/01/2007

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Applicable Federal Requirement: 40CFR 63.1512(k), Subpart RRR

Item 90.1:

This Condition applies to Emission Unit: M-00001

 

Item 90.2:

Feed/charge weight measurement. During the emission test(s) 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/charge format, must measure (or otherwise 

determine) and record the total weight of feed/charge to the affected source or emission unit for each of 

the three 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 must measure the weight of 

aluminum produced by the emission unit or affected source instead of the feed/charge weight.

 

Condition 91: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1513(b), Subpart RRR

Item 91.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001

Item 91.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Use the Equation below to determine the 

emission rate of PM from the emission 

unit:

 C x Q x K1

E = -------------- 

 

P

Where,

E = Emission rate of PM, kg/Mg (lb/ton) 

of feed;

C = Concentration of PM, g/dscm 

(gr/dscf);

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Q = Volumetric flow rate of exhaust 

gases, dscm/hr (dscf/hr);

K1 = Conversion factor, 1 kg/1,000 g (1 

lb/7,000 gr); and

P = Production rate, Mg/hr (ton/hr).

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 92: Equations for Determining Compliance - Secondary Aluminum 

Processing Unit

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1513(e), Subpart RRR

Item 92.1:

This Condition applies to Emission Unit: M-00001

 

Item 92.2:

Use the procedure below to determine compliance with emission limits for a secondary aluminum 

processing unit.

(1) Use the equation below to compute the mass-weighted PM emissions for a secondary 

aluminum processing unit. Compliance is achieved if the mass-weighted emissions for the secondary 

aluminum processing unit ECPM is less than or equal to the emission limit for the secondary aluminum 

processing unit LCPM calculated using Equation 1 in 40 CFR Part 63.1505(k).

 

E

E T

T

C

ti ti

i

n

ti

i

n P M

P M

=

× =

=

∑

∑

( )

( )

1

1 

Where,

ECPM = The mass-weighted PM emissions for the secondary aluminum processing unit;

EtiPM = Measured PM emissions for individual emission unit i;

Tti = The average feed rate for individual emission unit i during the operating cycle or performance test 

period; and

n=The number of emission units in the secondary aluminum processing unit.

 

Condition 93: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

 Air Pollution Control Permit Conditions

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Applicable Federal Requirement: 40CFR 63.1517(b)(7), Subpart RRR

Item 93.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001

Item 93.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

For each emission unit subject to an emission standard in

kg/Mg (lb/ton) of feed/charge, records of feed/charge (or 

throughput) weights for each operating cycle or time 

period used in the emissions test.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 94: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1517(b)(17), Subpart RRR

Item 94.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001

Item 94.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

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.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

 Air Pollution Control Permit Conditions

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Condition 95: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.10(c)(3)

Item 95.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001 Emission Point: I003C

Process: MHS Emission Source: M003C

Regulated Contaminant(s):

CAS No: 0NY210-00-0 OXIDES OF NITROGEN

Item 95.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Operation of the of the #15 melting and holding furnace 

with low NOx burners is considered RACT for the purposes 

of 6 NYCRR Part 212.10(c)(3).

Reference Test Method: EPA RM 7E

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 96: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.10(c)(3)

Item 96.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00001 Emission Point: I024F

Process: MHA Emission Source: M024F

Regulated Contaminant(s):

CAS No: 0NY210-00-0 OXIDES OF NITROGEN

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Item 96.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Operation of the of the #32 melting and holding furnace 

with low NOx burners is considered RACT for the purposes 

of 6 NYCRR Part 212.10(c)(3).

Reference Test Method: EPA RM 7E

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 97: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.5(d)

Item 97.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00002

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 97.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The particulate matter (PM) emissions from this emission 

unit, are subject to the Federal National Emission 

Standards for Hazardous Air Pollutants in 40 CFR part 63 

Subpart RRR, which satisfy the requirements of Part 

212.5(d) for PM emissions as long as the source owner 

continues to demonstrate that the emission unit is in 

compliance with the respective Federal requirements 

contained in this permit. Compliance testing shall be 

conducted upon request from the Department.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

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 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 98: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1506(d), Subpart RRR

Item 98.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00002

Item 98.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator of each affected source or emission

unit subject to an emission limit in kg/Mg (lb/ton) of 

feed/charge must:

(1) Except as provided in paragraph (3) of this 

condition, install and operate a device that measures and 

records or otherwise determine the weight of feed/charge 

(or throughput) for each operating cycle or time period 

used in the emissions test; and

(2) Operate each weight measurement system or other 

weight determination procedure in accordance with the 

manufacturer's recommendation.

(3) The owner or operator may chose to measure and record

aluminum production weight from an affected source or 

emission unit rather than feed/charge weight to an 

affected source or emission unit, provided that: 

(i) The aluminum production weight, rather than 

feed/charge weight is measured and recorded for all 

emission units within a SAPU; and

(ii) All calculations to demonstrate compliance with the

emission limits for SAPUs are based on aluminum production

weight rather than feed/charge weight.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

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Condition 99: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1506(p), Subpart RRR

Item 99.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00002

Item 99.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

When a process parameter or add-on air pollution control 

0 device operating parameter deviates from the value or 

range established during the emissions test, the owner or 

operator must initiate corrective action. Corrective 

action must restore operation of the affected source or 

emission unit (including the process or control device) to

its normal or usual mode of operation as expeditiously as 

practicable in accordance with good air pollution control 

practices for minimizing emissions. Corrective actions 

taken must include follow-up actions necessary to return 

the process or control device parameter level(s) to the 

value or range of values established during the emissions 

test and steps to prevent the likely recurrence of the 

cause of a deviation.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 100: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1510(e), Subpart RRR

Item 100.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00002

Item 100.2:

Compliance Certification shall include the following monitoring:

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Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator of an affected source or emission 

unit subject to an emission limit in kg/Mg (lb/ton) or 

ug/Mg (gr/ton) of feed/charge must install, calibrate, 

operate, and maintain a device to measure and record the 

total weight of feed/charge to, or the aluminum production

from, the affected source or emission unit over the same 

operating cycle or time period used in the initial 

emissions test. Feed/charge or aluminum production within 

SAPUs must be measured and recorded on an emission 

unit-by-emission unit basis. As an alternative to a 

measurement device, the owner or operator may use a 

procedure acceptable to the applicable permitting 

authority to determine the total weight of feed/charge or 

aluminum production to the affected source or emission 

unit.

 (1) The accuracy of the weight measurement device or 

procedure must be ±5 percent of the weight being measured.

The owner or operator may apply to the permitting agency 

for approval to use a device of alternative accuracy if 

the required accuracy cannot be achieved as a result of 

equipment layout or charging practices. A device of 

alternative accuracy will not be approved unless the owner

or operator provides assurance through data and 

information that the affected source will meet the 

relevant emission standard.

 (2) The owner or operator must verify the calibration

of the weight measurement device in accordance with the 

schedule specified by the manufacturer, or if no 

calibration schedule is specified, at least once every 6 

months.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 101: Calculation of Secondary Aluminum Processing Unit PM 

emissions

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1510(t), Subpart RRR

Item 101.1:

This Condition applies to Emission Unit: M-00002

 

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Item 101.2:

Except as provided in paragraph 40 CFR Part 63.1510(u), the owner or operator must calculate and 

record the 3-day, 24-hour rolling average emissions of PM for each secondary aluminum processing unit 

on a daily basis. To calculate the 3-day, 24-hour rolling average, the owner or operator must:

 (1) 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/charge weight information 

required in paragraph (e) of this section. 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 must be conducted on the aluminum 

production weight basis.

 (2) Multiply the total feed/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/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.

 (3) 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.

 (4) Compute the 24-hour daily emission rate using the equation below:

 

E

T ER

T

day

i i

i

n

i

i

= n

× =

=

∑

∑

( )

1

1

 

Where,

Eday = The daily PM emission rate for the secondary aluminum processing unit for the 24-hour period;

Ti = The total amount of feed, or aluminum produced, for emission unit i for the 24-hour period (tons);

ERi = The measured emission rate for emission unit i as determined in the performance test (lb/ton or 

μg/Mg of feed/charge); and

n = The number of emission units in the secondary aluminum processing unit.

 (5) Calculate and record the 3-day, 24-hour rolling average of PM each day by summing the daily 

emission rates for each pollutant over the 3 most recent consecutive days and dividing by 3.

 

Condition 102: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1511(a), Subpart RRR

 Air Pollution Control Permit Conditions

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Item 102.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00002

Item 102.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Prior to conducting an emissions test required by this 

permit, the owner or operator must prepare and submit a 

site-specific test plan meeting the requirements in 6 

NYCRR Part 202-1.2 and 202-1.3. Such plan shall be 

submitted to the Department within 90 days of issuance of 

this permit. Testing of the subject source must occur 

within 90 days of Department approval of the site-specific

test plan.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 103: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1511(b), Subpart RRR

Item 103.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00002

Item 103.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Following approval of the site-specific test plan, the 

owner or operator must demonstrate initial compliance with

each applicable emission, equipment, work practice, or 

operational standard for each affected source and emission

unit, and report the results to the Department within 90 

days of achieving initial compliance. The owner or 

operator must conduct each emissions test according to the

requirements of the general provisions in subpart A of 

this part and this subpart. 

 Air Pollution Control Permit Conditions

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(1) The owner or operator must 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.

(2) Each emissions test for a continuous process must 

consist of 3 separate runs; pollutant sampling for each 

run must 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.

(3) Each emissions test for a batch process must consist 

of three separate runs; pollutant sampling for each run 

must be conducted over the entire process operating 

cycle.

(4) Where multiple affected sources or emission units are

exhausted through a common stack, pollutant sampling for 

each run must be conducted over a period of time during 

which all affected sources or emission units complete at 

least 1 entire process operating cycle or for 24 hours, 

whichever is shorter.

(5) Initial compliance with an applicable emission limit 

or standard is demonstrated if the average of three runs 

conducted during the initial emissions test is less than 

or equal to the applicable emission limit or standard.

Reference Test Method: EPA RM 5

Monitoring Frequency: SINGLE OCCURRENCE

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 104: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1511(c), Subpart RRR

Item 104.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00002

Item 104.2:

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator must use the following methods in 

appendix A to 40 CFR part 60 to determine compliance with 

the applicable emission limits or standards:

(1) Method 1 for sample and velocity traverses.

(2) Method 2 for velocity and volumetric flow 

rate.

(3) Method 3 for gas analysis.

(4) Method 4 for moisture content of the stack 

gas.

(5) Method 5 for the concentration of PM.

(6) Method 9 for visible emission observations.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 105: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1511(e), Subpart RRR

Item 105.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00002

Item 105.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator of new or existing emission units 

located at secondary aluminum production facilities that 

are major sources must conduct an emissions test every 5 

years following the initial emissions test.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

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Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 106: Testing of Representative Emission Units

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1511(f), Subpart RRR

Item 106.1:

This Condition applies to Emission Unit: M-00002

 

Item 106.2:

With the approval of the permitting authority, a single representative or similar group 1 furnace or in-line 

fluxer which is not controlled by an add-on control device may be tested to determine the emission rate of 

all like affected sources at a facility provided that:

(1) The tested emission unit must use identical feed/charge and flux materials in the same 

proportions as the emission units that it represents;

(2) The tested emission unit is subject to the same work practices and the emission units that it 

represents;

(3) The tested emission unit is of the same design as the emission units that it represents;

(4) 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;

(5) At least one of each different style of emission unit at the facility is tested; and

(6) All add-on control devices are tested.

 

Condition 107: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1511(g), Subpart RRR

Item 107.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00002

Item 107.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Establishment of monitoring and operating parameter 

values. The owner or operator of new or existing emission 

units must establish a minimum or maximum operating 

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

parameter value, or an operating parameter range for each 

parameter to be monitored, as required by this permit, 

that ensures compliance with the applicable emission limit

or standard. To establish the minimum or maximum value or 

range, the owner or operator must use the appropriate 

procedures in this section and submit the information 

required by 40 CFR Part 63.1515(b)(4), to the Department .

The owner or operator may use existing data in addition to

the results of emissions tests to establish operating 

parameter values for compliance monitoring provided each 

of the following conditions are met to the satisfaction of

the applicable permitting authority:

(1) The complete emission test report(s) used as the 

basis of the parameter(s) is submitted.

(2) The same test methods and procedures as required by 

this subpart were used in the test.

(3) 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.

(4) All process and control equipment operating 

parameters required to be monitored were monitored as 

required in this subpart and documented in the test 

report.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 108: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1512(j), Subpart RRR

Item 108.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00002

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 108.2:

Compliance Certification shall include the following monitoring:

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator must conduct emission tests as 

described below. The results of the emission tests are 

used to establish emission rates in lb/ton of feed/charge 

for PM from each emission unit. These emission rates are 

used for compliance monitoring in the calculation of the 

3-day, 24-hour rolling average emission rates using the 

equation in 40 CFR Part 63.1510(t). An emissions test is 

required for:

(1) Each group 1 furnace that processes scrap other than 

clean charge to measure emissions of PM.

 

(2) Each in-line fluxer to measure emissions of PM.

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 109: Performance Test/Compliance Demonstration Requirements and

Procedures - Feed/Charge Weight Measurement.

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1512(k), Subpart RRR

Item 109.1:

This Condition applies to Emission Unit: M-00002

 

Item 109.2:

Feed/charge weight measurement. During the emission test(s) 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/charge format, must measure (or otherwise 

determine) and record the total weight of feed/charge to the affected source or emission unit for each of 

the three 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 must measure the weight of 

aluminum produced by the emission unit or affected source instead of the feed/charge weight.

 

Condition 110: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1513(b), Subpart RRR

Item 110.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00002

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item 110.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Use the Equation below to determine the 

emission rate of PM from the emission 

unit:

 C x Q x K1

E = -------------- 

 

P

Where,

E = Emission rate of PM, kg/Mg (lb/ton) 

of feed;

C = Concentration of PM, g/dscm 

(gr/dscf);

Q = Volumetric flow rate of exhaust 

gases, dscm/hr (dscf/hr);

K1 = Conversion factor, 1 kg/1,000 g (1 

lb/7,000 gr); and

P = Production rate, Mg/hr (ton/hr).

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 111: Equations for Determining Compliance - Secondary Aluminum 

Processing Unit

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1513(e), Subpart RRR

Item 111.1:

This Condition applies to Emission Unit: M-00002

 

Item 111.2:

Use the procedure below to determine compliance with emission limits for a secondary aluminum 

processing unit.

(1) Use the equation below to compute the mass-weighted PM emissions for a secondary 

aluminum processing unit. Compliance is achieved if the mass-weighted emissions for the secondary 

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aluminum processing unit ECPM is less than or equal to the emission limit for the secondary aluminum 

processing unit LCPM calculated using Equation 1 in 40 CFR Part 63.1505(k).

 

E

E T

T

C

ti ti

i

n

ti

i

n P M

P M

=

× =

=

∑

∑

( )

( )

1

1 

Where,

ECPM = The mass-weighted PM emissions for the secondary aluminum processing unit;

EtiPM = Measured PM emissions for individual emission unit i;

Tti = The average feed rate for individual emission unit i during the operating cycle or performance test 

period; and

n=The number of emission units in the secondary aluminum processing unit.

 

Condition 112: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1517(b)(7), Subpart RRR

Item 112.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00002

Item 112.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

For each emission unit subject to an emission standard in

kg/Mg (lb/ton) of feed/charge, records of feed/charge (or 

throughput) weights for each operating cycle or time 

period used in the emissions test.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 113: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.1517(b)(17), Subpart RRR

 Air Pollution Control Permit Conditions

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Item 113.1:

The Compliance Certification activity will be performed for:

Emission Unit: M-00002

Item 113.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

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.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 114: General requirements

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 226.2

Item 114.1:

This Condition applies to Emission Unit: P-00001

Process: PWS

 

Item 114.2:

No person shall conduct solvent metal cleaning unless:

(1) Solvent is stored in covered containers and waste solvent is transferred or disposed of in such a 

manner that less than 20 percent of the waste solvent, by weight, can evaporate into the atmosphere;

(2) Equipment used in solvent metal cleaning is maintained to minimize leaks and fugitive emissions;

(3) Equipment used in solvent metal cleaning displays a conspicuous summary of proper operating 

procedures consistent with minimizing emissions of volatile organic compounds; and

(4) Equipment covers are closed when the solvent metal cleaning unit is not in service.

(5) A record of solvent consumption shall be maintained for each year and made available to the 

commissioner or his representative upon request.

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Condition 115: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 226.3(a)

Item 115.1:

The Compliance Certification activity will be performed for:

Emission Unit: P-00001

Process: PWS

Item 115.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Except where otherwise permitted by the commissioner, the

following devices are required by a source owner 

conducting solvent metal cold cleaning degreasing: 

 (1) A cover shall be provided which can be 

operated easily. 

 (2) The drainage facility shall be internal 

(under cover), if practical. 

 (3) A control system that limits VOC emissions 

to those achievable with equipment having a freeboard 

ratio greater than or equal to 0.7, or a water cover where

the solvent is insoluble in and heavier than water, where 

the solvent being used has a vapor pressure greater than 

33mm Hg at 38° C (100° F) or where the solvent is heated 

above 50° C (120°F). 

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

46 Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 116: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.9(d)

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item 116.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00001

Process: POT

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 116.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The following equation shall be used to determine 

permissible solid particulate emissions (based on process 

weight:

for sources up to 100,000 lb/hr - E = 0.024P^(0.67); 

where:

E - is the permissible emission rate, and

P - is process weight in lb/hr.

Reference Test Method: EPA Method 5

Monitoring Frequency: MONTHLY

Averaging Method: ANNUAL MAXIMUM ROLLED MONTHLY

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 117: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.843(a)(1)(i), Subpart LL

Item 117.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00001

Process: POT

Regulated Contaminant(s):

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

CAS No: 068188-85-2 FLUORIDES

Item 117.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator shall not discharge or cause to be 

discharged into the atmosphere any emissions of Total 

Fluorides (TF) in excess of the applicable limit 

below:

 - 1.9 lb/ton of aluminum produced for each 

CWPB1 potline;

Monitoring Frequency: MONTHLY

Averaging Method: CALENDAR MONTH AVERAGE

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 118: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(d)(1), Subpart LL

Item 118.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00001

Process: POT

Regulated Contaminant(s):

CAS No: 068188-85-2 FLUORIDES

Item 118.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

The initial performance test and all subsequent 

performance tests shall be conducted in accordance with 

the requirements of the general provisions in 40 CFR Part 

63 Subpart A, the approved test plan, and the procedures 

in 40 CFR Part 63.847.

For each potline, the owner or operator shall measure and 

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

record the emission rate of TF exiting the outlet of the 

primary control system for each potline and the rate of 

secondary emissions exiting through each roof monitor. 

Using the equation in 40 CFR Part 63.847(e)(1), the owner 

or operator shall compute and record the average of at 

least three runs each month for secondary emissions and at

least three runs each year for the primary control system 

to determine compliance with the applicable emission 

limit. Compliance is demonstrated when the emission rate 

of TF is equal to or less than the applicable emission 

limit in 40 CFR Part 63.843(a)(1).

Parameter Monitored: FLUORIDES

Upper Permit Limit: 1.9 pounds per ton

Reference Test Method: EPA RM 13B or ALT

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 119: Performance Test Requirements - Previous Control Device 

Tests

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(d)(3), Subpart LL

Item 119.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 119.2:

If the owner or operator has performed more than one test of primary emission control device(s) for a 

potline or for a bake furnace during the previous consecutive 12 months, the average of all runs 

performed in the previous 12-month period shall be used to determine the contribution from the primary

emission control system.

 

Condition 120: Potline TF emission rate calculation

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(e)(1), Subpart LL

Item 120.1:

This Condition applies to Emission Unit: S-00001

Process: POT

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

 

Item 120.2:

The owner/operator shall determine compliance with the applicable TF emission limits by computing the 

emission rate (Ep) of TF from each potline using the following equation (Equation 1):

Ep= [(Cs1 x Qsd)1 + (Cs2 x Qsd)2]/(PxK)

Where:

Ep=emission rate of TF from a potline, kg/Mg (lb/ton);

Cs1=concentration of TF from the primary control system, mg/dscm (mg/dscf);

Qsd=volumetric flowrate of effluent gas corresponding to the appropriate subscript location, dscm/hr 

(dscf/min);

Cs2=concentration of TF as measured for roof monitor emissions, mg/dscm (mg/dscf);

P=aluminum production rate Mg/hr (ton/hr);

K=conversion factor, 106 mg/kg (453,600 mg/lb);

1= subscript for primary control system effluent gas; and

2=subscript for secondary control system or roof monitor effluent gas

 

Condition 121: Procedure to determine weights

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(e)(5), Subpart LL

Item 121.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 121.2:

The owner/operator shall determine compliance with the applicable TF and POM emission limits by 

determining the weight of the aluminum tapped from the potline and the weight of the green anode 

material placed in the anode bake furnace using the monitoring devices required in §63.848(j).

 

Condition 122: Calculation of aluminum production rate

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(e)(6), Subpart LL

Item 122.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 122.2:

The owner/operator shall determine compliance with the applicable TF and POM emission limits by 

determining the aluminum production rate (P). This shall be done by dividing the number of hours in the 

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calendar month into the weight of aluminum tapped from the potline during the calendar month that 

includes the three runs of a performance test.

 

Condition 123: Selection of monitoring parameters - potlines and anode 

bake furnaces

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(h)(1), Subpart LL

Item 123.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 123.2:

The owner/operator shall determine the operating limits and monitoring frequency for each control device 

that is to be monitored as required in §63.848(f). For potlines and anode bake furnaces, the 

owner/operator shall determine upper and/or lower operating limits, as appropriate, for each monitoring 

device for the emission control system from the values recorded during each of the runs performed during 

the initial performance test and from historical data from previous performance tests conducted by the 

methods specified in subpart LL.

 

Condition 124: Selection of monitoring parameters - redetermining 

operating limits

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(h)(3), Subpart LL

Item 124.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 124.2:

The owner/operator shall determine the operating limits and monitoring frequency for each control device 

that is to be monitored as required in §63.848(f). The owner/operator may redetermine the upper and/or 

lower operating limits, as appropriate, based on historical data or other information and submit an 

application to the New York State DEC to change the applicable limit(s). The redetermined limits shall 

become effective upon approval by the New York State DEC.

 

Condition 125: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(a), Subpart LL

Item 125.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00001

Process: POT

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Regulated Contaminant(s):

CAS No: 068188-85-2 FLUORIDES

Item 125.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

Using the procedures in §63.847 and in the approved test 

plan, the owner/operator shall monitor emissions of TF 

from each potline by conducting monthly performance tests.

 The owner/operator shall compute and record the monthly 

average from at least three runs for secondary emissions 

and the previous 12-month average of all runs for the 

primary control system to determine compliance with the 

applicable emission limit. The owner/operator must 

include all valid runs in the monthly average. The 

duration of each run for secondary emissions must 

represent a complete operating cycle.

Parameter Monitored: FLUORIDES

Upper Permit Limit: 1.9 pounds per ton

Reference Test Method: EPA RM 13B or ALT

Monitoring Frequency: MONTHLY

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 126: Reduced sampling frequency - contents of request letter

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(e)(1), Subpart LL

Item 126.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 126.2:

The owner/operator may submit a written request to the New York State DEC to establish an alternative 

testing requirement to reduce the sampling of secondary TF emissions from potlines from monthly to 

quarterly. In the request, the owner/operator shall provide information and data demonstrating, to the 

satisfaction of the New York State DEC, that secondary emissions of TF from potlines have low 

variability during normal operations using the following procedures:

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1) Submit data from 24 consecutive months of sampling that show the average TF emissions are less than 

60 percent of the applicable limit and that no monthly performance test in the 24 months of sampling 

exceeds 75 of the applicable limit; or

2) Submit data and a statistical analysis that the New York State DEC may evaluate based on the approach 

sued in "Primary Aluminum: Statistical Analysis of Potline Fluoride Emissions and Alternative Sampling 

Frequency" (EPA-450-86-012, October 1986).

 

Condition 127: Reduced sampling frequency request - contents of the 

approved alternative requirement

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(e)(2), Subpart LL

Item 127.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 127.2:

The owner/operator may submit a written request to the New York State DEC to establish an alternative 

testing requirement to reduce the sampling of secondary TF emissions from potlines from monthly to 

quarterly.

An approved alternative requirement must include a test schedule and the method to be used to measure 

emissions for performance tests.

 

Condition 128: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(f)(1), Subpart LL

Item 128.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00001

Process: POT

Regulated Contaminant(s):

CAS No: 068188-85-2 FLUORIDES

Item 128.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator shall install, operate, calibrate, and

maintain a continuous parameter monitoring system for each

emission control device. The owner/operator shall submit 

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

for approval by the New York State DEC a description of 

the parameter(s) to be monitored, the operating limits, 

and the monitoring frequency to ensure that the control 

device is being properly operated and maintained. An 

explanation of the criteria used for selection of the 

parameter(s), the operating limits, and the monitoring 

frequency, including how these relate to emission control 

also shall be submitted to the New York State 

DEC.

Except as provided in §63.848(l), for dry alumina 

scrubbers, a device for the measurement of air flow shall 

be installed, monitored and recorded in accordance with 

the parametric monitoring plan.

Reference Test Method: 4075-TF

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 129: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(f)(1), Subpart LL

Item 129.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00001

Process: POT

Regulated Contaminant(s):

CAS No: 068188-85-2 FLUORIDES

Item 129.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator shall install, operate, calibrate, and

maintain a continuous parameter monitoring system for each

20emission control device. The owner/operator shall submit 

for approval by the New York State DEC a description of 

the parameter(s) to be monitored, the operating limits, 

and the monitoring frequency to ensure that the control 

device is being properly operated and maintained. An 

explanation of the criteria used for selection of the 

parameter(s), the operating limits, and the monitoring 

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frequency, including how these relate to emission control 

also shall be submitted to the New York State 

DEC.

Except as provided in §63.848(l), for dry alumina 

scrubbers, a device for the measurement of alumina flow 

shall be installed, monitored and recorded in accordance 

with the parametric monitoring plan.

Reference Test Method: 4075-TF

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 130: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(g), Subpart LL

Item 130.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00001

Process: POT

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 130.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator shall visually inspect the exhaust 

stack(s) of each control device on a daily basis for 

evidence of any visible emissions indicating abnormal 

operation.

Monitoring Frequency: DAILY

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 131: Corrective action procedures

Effective between the dates of 09/01/2002 and 09/01/2007

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Applicable Federal Requirement: 40CFR 63.848(h), Subpart LL

Item 131.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 131.2:

If a monitoring device for a primary control device measures an operating parameter outside the limit(s) 

established pursuant to §63.847(h), or if visible emissions indicating abnormal operation are observed 

from the exhaust stack of a control device during a daily inspection, the owner/operator shall initiate the 

corrective action procedures identified in the startup, shutdown, and malfunction plan within 1 hour. 

Failure to initiate the corrective action procedures within 1 hour or to take the necessary corrective actions 

to remedy the problem is a violation.

 

Condition 132: Exceedances

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(i), Subpart LL

Item 132.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 132.2:

If the limit for a given operating parameter associated with monitoring a specific control device is 

exceeded six times in any semiannual reporting period, then any subsequent exceedance in that reporting 

period is a violation. For the purpose of determining the number of exceedances, no more than one 

exceedance shall be attributed in any given 24-hour period.

 

Condition 133: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(j), Subpart LL

Item 133.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00001

Process: POT

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

Item 133.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Monitoring Description: 

The owner/operator of a new or existing potline or anode 

bake furnace shall install, operate, and maintain a 

monitoring device to determine the daily weight of 

aluminum produced and the weight of green anode material 

placed in the anode bake furnace. The weight of green 

anode material may be determined by monitoring the weight 

of all anodes or by monitoring the number of anodes placed

in the furnace and determining an average weight from 

measurements of a representative sample of anodes.

Monitoring Frequency: DAILY

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 134: Accuracy and calibration requirements

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(k), Subpart LL

Item 134.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 134.2:

The owner/operator shall submit recommended accuracy requirement to the New York State DEC for 

review and approval. All monitoring devices required by §63.848 must be certified by the owner/operator 

to meet the accuracy requirements and must be calibrated in accordance with the manufacturer's 

instructions.

 

Condition 135: Alternative operating parameters

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(l), Subpart LL

Item 135.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 135.2:

The owner/operator may monitor alternative control device operating parameters subject to prior written 

approval by the New York State DEC.

 

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Condition 136: Definition of potline in Method 14

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.849(c), Subpart LL

Item 136.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 136.2:

Except as provided in §63.845(g)(1), references to "potroom" or "potroom group" in Method 14 in 

appendix A to part 60 shall be interpreted as "potline" for the purposes of subpart LL.

 

Condition 137: Installation of manifolds for potlines subject to Method 

14

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.849(d), Subpart LL

Item 137.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 137.2:

For sampling using Method 14 in Appendix A to part 60, the owner/operator shall install one Method 14 

manifold per potline in a potroom that is representative of the entire potline, and this manifold shall meet 

the installation requirements specified in section 2.2.1 of Method 14 in appendix A to part 60.

 

Condition 138: Performance test reports

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(b), Subpart LL

Item 138.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 138.2:

The owner/operator shall report the results of the initial performance test as part of the notification of 

compliance status required in §63.850(a)(6). Except as provided in §63.850(d), the owner/operator shall 

submit a summary of all subsequent performance tests to the New York State DEC on an annual basis.

 

Condition 139: Startup, shutdown, and malfunction plan and reports

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(c)(1), Subpart LL

Item 139.1:

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 139.2:

The owner/operator shall develop and implement a written plan as described in §63.6(e)(3) that contains 

specific procedures to be followed for operating the source and maintaining the source during periods of 

startup, shutdown, and malfunction and a program of corrective action for malfunctioning process and 

control systems used to comply with the standard. The plan does not have to be submitted with the permit 

application or included in the operating permit. The New York State DEC may review the plan upon 

request. In addition to the information required in §63.6(e)(3), the plan shall include procedures, 

including corrective actions, to be followed if a monitoring device measures an operating parameter 

outside the limit(s) established under §63.847(h), or if visible emissions from an exhaust stack indicating 

abnormal operation of a control device are observed by the owner/operator during the daily inspection 

required in §63.848(g).

 

Condition 140: Startup, shutdown, and malfunction plan and reports

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(c)(2), Subpart LL

Item 140.1:

This Condition applies to Emission Unit: S-00001

Process: POT

 

Item 140.2:

The owner/operator shall develop and implement a written plan as described in §63.6(e)(3) that contains 

specific procedures to be followed for operating the source and maintaining the source during periods of 

startup, shutdown, and malfunction and a program of corrective action for malfunctioning process and 

control systems used to comply with the standard. The plan does not have to be submitted with the permit 

application or included in the operating permit. The New York State DEC may review the plan upon 

request. In addition to the information required in §63.6(e)(3), the plan shall include records of each event 

as required by §63.10(b) and the owner/operator shall 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 

§63.6(e)(3)(iv).

 

Condition 141: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(d), Subpart LL

Item 141.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00001

Process: POT

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item 141.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

As required in §63.10(e)(3), the owner/operator shall 

submit a report (or a summary report) if measured 

emissions are in excess of the applicable standard. The 

report shall contain the information specified in 

§63.10(e)(3)(v) and be submitted semiannually unless 

quarterly reports are required as a result of excess 

emissions.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 142: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(e)(1), Subpart LL

Item 142.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00001

Process: POT

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

Item 142.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator shall maintain files of all 

information (including all reports and notifications) 

required by §63.10(b) and by Subpart LL. Records must be 

retained 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 

must be retained at the facility. The remaining 3 years 

of records may be retained offsite.

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 143: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(e)(2), Subpart LL

Item 143.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00001

Process: POT

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

Item 143.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator may retain records on microfilm, on a 

computer, on computer disks, on magnetic tape, or on 

microfiche.

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 144: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(e)(3), Subpart LL

Item 144.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00001

Process: POT

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

Item 144.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator may report required information on 

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

paper or on a labeled computer disc using commonly 

available and compatible computer software.

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 145: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(e)(4), Subpart LL

Item 145.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00001

Process: POT

Item 145.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

In addition to the general records required by §63.10(b),

the owner/operator shall maintain records of the following

information:

1) Daily production rate of aluminum;

2) A copy of the startup, shutdown, and malfunction 

plan;

3) Records supporting a request for reduced sampling of 

potlines;

4) Records, such as a checklist or the equivalent, 

demonstrating that the daily visual inspection of the 

exhaust stack for each control device has been performed 

as required in §63.848(g), including the results of each 

inspection;

5) Records documenting the corrective actions taken when 

the limit(s) for an operating parameter established under 

§63.847(h) were exceeded, or when visible emissions 

indicating abnormal operation were observed from a control

device stack during a daily inspection required under 

§63.848(g);

6) Records documenting the portion of TF that is measured 

as particulate matter and the portion that is measured as 

 Air Pollution Control Permit Conditions

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gaseous when the particulate and gaseous fractions are 

quantified separately using an approved test method.

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 146: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.843(c)(1), Subpart LL

Item 146.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 068188-85-2 FLUORIDES

Item 146.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator shall not discharge or cause to be 

discharged into the atmosphere any emissions of TF in 

excess of the limit specified below:

 - TF shall not exceed 0.20 lb/ton of green 

anode.

Reference Test Method: EPA Method 13A

Monitoring Frequency: ANNUALLY

Averaging Method: CALENDAR YEAR AVERAGE

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 147: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.843(c)(2), Subpart LL

Item 147.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Process: BAK

Regulated Contaminant(s):

CAS No: 0NY505-00-0 40 CFR 63 SUBPART LL - POM

Item 147.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner or operator shall not discharge or cause to be 

discharged into the atmosphere any emissions of POM in 

excess of the limit specified below:

 - POM shall not exceed 0.18 lb/ton of green 

anode.

Reference Test Method: EPA Method 315

Monitoring Frequency: ANNUALLY

Averaging Method: CALENDAR YEAR AVERAGE

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 148: Performance Test Requirements - Previous Control Device 

Tests

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(d)(3), Subpart LL

Item 148.1:

This Condition applies to Emission Unit: S-00002

Process: BAK

 

Item 148.2:

If the owner or operator has performed more than one test of primary emission control device(s) for a 

potline or for a bake furnace during the previous consecutive 12 months, the average of all runs 

performed in the previous 12-month period shall be used to determine the contribution from the primary

emission control system.

 

Condition 149: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(d)(4), Subpart LL

Item 149.1:

The Compliance Certification activity will be performed for:

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 0NY505-00-0 40 CFR 63 SUBPART LL - POM

Item 149.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

The initial performance test and all subsequent 

performance tests shall be conducted in accordance with 

the requirements of the general provisions in 40 CFR Part 

63 Subpart A, the approved test plan, and the procedures 

in 40 CFR Part 63.847.

For each anode bake furnace, the owner or operator shall 

measure and record the emission rate of POM exiting the 

exhaust stack(s) of the primary emission control system 

for each anode bake furnace. Using the equation in 40 CFR 

Part 63.847(e)(4), the owner or operator shall compute and

record the average of at least three runs each year to 

determine compliance with the applicable emission limit 

for POM. Compliance is demonstrated when the emission rate

of POM is equal to or less than the applicable POM 

emission limit in 40 CFR Part 63.843(c)(2).

n0 Parameter Monitored: 40 CFR 63 SUBPART LL - POM

Upper Permit Limit: 0.18 pounds per ton

Reference Test Method: EPA RM 315

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 150: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(d)(4), Subpart LL

Item 150.1:

The Compliance Certification activity will be performed for:

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 068188-85-2 FLUORIDES

Item 150.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

The initial performance test and all subsequent 

performance tests shall be conducted in accordance with 

the requirements of the general provisions in 40 CFR Part 

63 Subpart A, the approved test plan, and the procedures 

in 40 CFR Part 63.847.

For each anode bake furnace, the owner or operator shall 

measure and record the emission rate of TF exiting the 

exhaust stack(s) of the primary emission control system 

for each anode bake furnace. Using the equation in 40 CFR 

Part 63.847(e)(3), the owner or operator shall compute and

record the average of at least three runs each year to 

determine compliance with the applicable emission limit 

for TF. Compliance is demonstrated when the emission rate 

of TF is equal to or less than the applicable TF emission 

limit in 40 CFR Part 63.843(c)(1).

Parameter Monitored: FLUORIDES

Upper Permit Limit: 0.20 pounds per ton

Reference Test Method: EPA RM 13B or ALT

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 151: Calculation of anode bake furnace TF emission rate

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(e)(3), Subpart LL

Item 151.1:

This Condition applies to Emission Unit: S-00002

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Process: BAK

 

Item 151.2:

The owner/operator shall determine compliance with the applicable TF emission limits by computing the 

emission rate (Eb) from each anode bake furnace using the following equation (Equation 2):

Eb= (Cs x Qsd) / (Pb x K)

Eb=emission rate of TF, kg/mg (lb/ton) of green anodes produced;

Cs=concentration of TF, mg/dscm (mg/dscf);

Qsd=volumetric flowrate of effluent gas, dscm/hr (dscf/hr);

Pb=quantity of green anode material placed in the furnace, mg/hr (ton/hr); and

K = conversion factor, 106 mg/kg (453,600 mg/lb)

 

Condition 152: Calculation of anode bake furnace POM emission rate

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(e)(4), Subpart LL

Item 152.1:

This Condition applies to Emission Unit: S-00002

Process: BAK

 

Item 152.2:

The owner/operator shall determine compliance with the applicable POM emission limits by computing 

the emission rate (Eb) from each anode bake furnace using the following equation (Equation 2):

Eb= (Cs x Qsd) / (Pb x K)

Eb=emission rate of POM, kg/mg (lb/ton) of green anodes produced;

Cs=concentration of POM, mg/dscm (mg/dscf);

Qsd=volumetric flowrate of effluent gas, dscm/hr (dscf/hr);

Pb=quantity of green anode material placed in the furnace, mg/hr (ton/hr); and

K = conversion factor, 106 mg/kg (453,600 mg/lb)

 

Condition 153: Procedure to determine weights

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(e)(5), Subpart LL

Item 153.1:

This Condition applies to Emission Unit: S-00002

Process: BAK

 

Item 153.2:

The owner/operator shall determine compliance with the applicable TF and POM emission limits by 

 Air Pollution Control Permit Conditions

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determining the weight of the aluminum tapped from the potline and the weight of the green anode 

material placed in the anode bake furnace using the monitoring devices required in §63.848(j).

 

Condition 154: Determination of rate of green anode introduction into 

furnace

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(e)(7), Subpart LL

dItem 154.1:

This Condition applies to Emission Unit: S-00002

Process: BAK

 

Item 154.2:

The owner/operator shall determine compliance with the applicable TF and POM emission limits by 

calculating the rate that green anode material is introduced into the anode bake furnace. This shall be 

determined by dividing the number of operating hours in the calendar month into the weight of green 

anode material used during the calendar month in which the performance test was conducted.

 

Condition 155: Selection of monitoring parameters - potlines and anode 

bake furnaces

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(h)(1), Subpart LL

Item 155.1:

This Condition applies to Emission Unit: S-00002

Process: BAK

 

Item 155.2:

The owner/operator shall determine the operating limits and monitoring frequency for each control device 

that is to be monitored as required in §63.848(f). For potlines and anode bake furnaces, the 

owner/operator shall determine upper and/or lower operating limits, as appropriate, for each monitoring 

device for the emission control system from the values recorded during each of the runs performed during 

the initial performance test and from historical data from previous performance tests conducted by the 

methods specified in subpart LL.

 

Condition 156: Selection of monitoring parameters - redetermining 

operating limits

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(h)(3), Subpart LL

Item 156.1:

This Condition applies to Emission Unit: S-00002

Process: BAK

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

 

Item 156.2:

The owner/operator shall determine the operating limits and monitoring frequency for each control device 

that is to be monitored as required in §63.848(f). The owner/operator may redetermine the upper and/or 

lower operating limits, as appropriate, based on historical data or other information and submit an 

application to the New York State DEC to change the applicable limit(s). The redetermined limits shall 

become effective upon approval by the New York State DEC.

 

Condition 157: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(c), Subpart LL

Item 157.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 0NY505-00-0 40 CFR 63 SUBPART LL - POM

Item 157.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

Using the procedures in §63.847 and in the approved test 

plan, the owner/operator shall monitor POM emissions from 

each anode bake furnace on an annual basis. The 

owner/operator shall compute and record the annual average

of POM emissions from at least three runs to determine 

compliance with the applicable emission limits. The 

owner/operator must include all valid runs in the annual 

average.

Parameter Monitored: 40 CFR 63 SUBPART LL - POM

Upper Permit Limit: 0.18 pounds per ton

Reference Test Method: EPA METHOD 315

Monitoring Frequency: ANNUALLY

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 158: Compliance Certification

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(c), Subpart LL

Item 158.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 068188-85-2 FLUORIDES

Item 158.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

Using the procedures in §63.847 and in the approved test 

plan, the owner/operator shall monitor TF emissions from 

each anode bake furnace on an annual basis. The 

owner/operator shall compute and record the annual average

of TF emissions from at least three runs to determine 

compliance with the applicable emission limits. The 

owner/operator must include all valid runs in the annual 

average.

Parameter Monitored: FLUORIDES

Upper Permit Limit: 0.20 pounds per ton

Monitoring Frequency: ANNUALLY

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 159: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(f)(1), Subpart LL

Item 159.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002

Process: BAK

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Regulated Contaminant(s):

CAS No: 068188-85-2 FLUORIDES

Item 159.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator shall install, operate, calibrate, and

maintain a continuous parameter monitoring system for each

emission control device. The owner/operator shall submit 

for approval by the New York State DEC a description of 

the parameter(s) to be monitored, the operating limits, 

and the monitoring frequency to ensure that the control 

device is being properly operated and maintained. An 

explanation of the criteria used for selection of the 

parameter(s), the operating limits, and the monitoring 

frequency, including how these relate to emission control 

also shall be submitted to the New York State 

DEC.

Except as provided in §63.848(l), for dry alumina 

scrubbers, a device for the measurement of air flow shall 

be installed, monitored and recorded in accordance with 

the parametric monitoring plan.

Reference Test Method: 4075-TF

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 160: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(f)(1), Subpart LL

Item 160.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 068188-85-2 FLUORIDES

Item 160.2:

Compliance Certification shall include the following monitoring:

 Air Pollution Control Permit Conditions

Page 157 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator shall install, operate, calibrate, and

maintain a continuous parameter monitoring system for each

emission control device. The owner/operator shall submit 

for approval by the New York State DEC a description of 

the parameter(s) to be monitored, the operating limits, 

and the monitoring frequency to ensure that the control 

device is being properly operated and maintained. An 

explanation of the criteria used for selection of the 

parameter(s), the operating limits, and the monitoring 

frequency, including how these relate to emission control 

also shall be submitted to the New York State 

DEC.

Except as provided in §63.848(l), for dry alumina 

scrubbers, a device for the measurement of alumina flow 

shall be installed, monitored and recorded in accordance 

with the parametric monitoring plan.

Reference Test Method: 4075-TF

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 161: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(g), Subpart LL

Item 161.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 161.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator shall visually inspect the exhaust 

stack(s) of each control device on a daily basis for 

evidence of any visible emissions indicating abnormal 

operation.

 Air Pollution Control Permit Conditions

Page 158 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Monitoring Frequency: DAILY

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 162: Corrective action procedures

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(h), Subpart LL

Item 162.1:

This Condition applies to Emission Unit: S-00002

Process: BAK

 

Item 162.2:

If a monitoring device for a primary control device measures an operating parameter outside the limit(s) 

established pursuant to §63.847(h), or if visible emissions indicating abnormal operation are observed 

from the exhaust stack of a control device during a daily inspection, the owner/operator shall initiate the 

corrective action procedures identified in the startup, shutdown, and malfunction plan within 1 hour. 

Failure to initiate the corrective action procedures within 1 hour or to take the necessary corrective actions 

to remedy the problem is a violation.

 

Condition 163: Exceedances

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(i), Subpart LL

Item 163.1:

This Condition applies to Emission Unit: S-00002

Process: BAK

 

Item 163.2:

If the limit for a given operating parameter associated with monitoring a specific control device is 

exceeded six times in any semiannual reporting period, then any subsequent exceedance in that reporting 

period is a violation. For the purpose of determining the number of exceedances, no more than one 

exceedance shall be attributed in any given 24-hour period.

 

Condition 164: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(j), Subpart LL

Item 164.1:

The Compliance Certification activity will be performed for:

 Air Pollution Control Permit Conditions

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

Item 164.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator of a new or existing potline or anode 

bake furnace shall install, operate, and maintain a 

monitoring device to determine the daily weight of 

aluminum produced and the weight of green anode material 

placed in the anode bake furnace. The weight of green 

anode material may be determined by monitoring the weight 

of all anodes or by monitoring the number of anodes placed

in the furnace and determining an average weight from 

measurements of a representative sample of anodes.

Monitoring Frequency: DAILY

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 165: Accuracy and calibration requirements

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(k), Subpart LL

Item 165.1:

This Condition applies to Emission Unit: S-00002

Process: BAK

 

Item 165.2:

The owner/operator shall submit recommended accuracy requirement to the New York State DEC for 

review and approval. All monitoring devices required by §63.848 must be certified by the owner/operator 

to meet the accuracy requirements and must be calibrated in accordance with the manufacturer's 

instructions.

 

Condition 166: Alternative operating parameters

Effective between the dates of 09/01/2002 and 09/01/2007

 Air Pollution Control Permit Conditions

Page 160 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Applicable Federal Requirement: 40CFR 63.848(l), Subpart LL

Item 166.1:

This Condition applies to Emission Unit: S-00002

Process: BAK

 

Item 166.2:

The owner/operator may monitor alternative control device operating parameters subject to prior written 

approval by the New York State DEC.

 

Condition 167: Performance test reports

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(b), Subpart LL

Item 167.1:

This Condition applies to Emission Unit: S-00002

Process: BAK

 

Item 167.2:

The owner/operator shall report the results of the initial performance test as part of the notification of 

compliance status required in §63.850(a)(6). Except as provided in §63.850(d), the owner/operator shall 

submit a summary of all subsequent performance tests to the New York State DEC on an annual basis.

 

Condition 168: Startup, shutdown, and malfunction plan and reports

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(c)(1), Subpart LL

Item 168.1:

This Condition applies to Emission Unit: S-00002

Process: BAK

 

Item 168.2:

The owner/operator shall develop and implement a written plan as described in §63.6(e)(3) that contains 

specific procedures to be followed for operating the source and maintaining the source during periods of 

startup, shutdown, and malfunction and a program of corrective action for malfunctioning process and 

control systems used to comply with the standard. The plan does not have to be submitted with the permit 

application or included in the operating permit. The New York State DEC may review the plan upon 

request. In addition to the information required in §63.6(e)(3), the plan shall include procedures, 

including corrective actions, to be followed if a monitoring device measures an operating parameter 

outside the limit(s) established under §63.847(h), or if visible emissions from an exhaust stack indicating 

abnormal operation of a control device are observed by the owner/operator during the daily inspection 

required in §63.848(g).

 

Condition 169: Startup, shutdown, and malfunction plan and reports

Effective between the dates of 09/01/2002 and 09/01/2007

 Air Pollution Control Permit Conditions

Page 161 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Applicable Federal Requirement: 40CFR 63.850(c)(2), Subpart LL

Item 169.1:

This Condition applies to Emission Unit: S-00002

Process: BAK

 

Item 169.2:

The owner/operator shall develop and implement a written plan as described in §63.6(e)(3) that contains 

specific procedures to be followed for operating the source and maintaining the source during periods of 

startup, shutdown, and malfunction and a program of corrective action for malfunctioning process and 

control systems used to comply with the standard. The plan does not have to be submitted with the permit 

application or included in the operating permit. The New York State DEC may review the plan upon 

request. In addition to the information required in §63.6(e)(3), the plan shall include records of each event 

as required by §63.10(b) and the owner/operator shall 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 

§63.6(e)(3)(iv).

 

Condition 170: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(d), Subpart LL

Item 170.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

Item 170.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

As required in §63.10(e)(3), the owner/operator shall 

submit a report (or a summary report) if measured 

emissions are in excess of the applicable standard. The 

report shall contain the information specified in 

§63.10(e)(3)(v) and be submitted semiannually unless 

quarterly reports are required as a result of excess 

emissions.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

 Air Pollution Control Permit Conditions

Page 162 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 171: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(e)(1), Subpart LL

Item 171.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

Item 171.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator shall maintain files of all 

information (including all reports and notifications) 

required by §63.10(b) and by Subpart LL. Records must be 

retained 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 

must be retained at the facility. The remaining 3 years 

of records may be retained offsite.

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 172: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(e)(2), Subpart LL

Item 172.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

Item 172.2:

 Air Pollution Control Permit Conditions

Page 163 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator may retain records on microfilm, on a 

computer, on computer disks, on magnetic tape, or on 

microfiche.

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 173: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(e)(3), Subpart LL

Item 173.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

Item 173.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator may report required information on 

paper or on a labeled computer disc using commonly 

available and compatible computer software.

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 174: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(e)(4), Subpart LL

Item 174.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002

0 Process: BAK

Item 174.2:

Compliance Certification shall include the following monitoring:

 Air Pollution Control Permit Conditions

Page 164 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

In addition to the general records required by §63.10(b),

the owner/operator shall maintain records of the following

information:

1) Daily production rate of green anode material placed in

the anode bake furnace;

2) A copy of the startup, shutdown, and malfunction 

plan;

3) Records, such as a checklist or the equivalent, 

demonstrating that the daily visual inspection of the 

exhaust stack for each control device has been performed 

as required in §63.848(g), including the results of each 

inspection;

4) Records documenting the corrective actions taken when 

the limit(s) for an operating parameter established under 

§63.847(h) were exceeded, or when visible emissions 

indicating abnormal operation were observed from a control

device stack during a daily inspection required under 

§63.848(g);

5) Records documenting the portion of TF that is measured 

as particulate matter and the portion that is measured as 

gaseous when the particulate and gaseous fractions are 

quantified separately using an approved test method.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 175: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.10(c)(3)

Item 175.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002 Emission Point: S0078

Process: BAK Emission Source: SS078

Regulated Contaminant(s):

CAS No: 0NY998-00-0 VOC

 Air Pollution Control Permit Conditions

Page 165 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item 175.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

Control of VOC emissions from this source were shown to 

be technically infeasible in the RACT analysis submitted 

to the Department in September of 1998. The Alumina dry 

scrubber will continue to be operated and reported under 

the guidelines of 40 CFR 63 Subpart LL for Primary 

Aluminum Production.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 176: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.10(c)(3)

Item 176.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00002 Emission Point: S0078

Process: BAK Emission Source: SS078

Regulated Contaminant(s):

CAS No: 0NY210-00-0 OXIDES OF NITROGEN

Item 176.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The NOx RACT Compliance Plan submitted to NYSDEC in 1994 

determined that control of NOx is not technically feasible

due to the nature and configuration of the anode bake 

furnace burners. Thus the current equipment configuration 

is considered RACT. Monitoring consists of 

re-certification that the fuel used during the previous 

reporting period was natural gas.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

 Air Pollution Control Permit Conditions

Page 166 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 177: Emission Limits for Existing Sources - Paste Production 

Plants

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.843(b), Subpart LL

Item 177.1:

This Condition applies to Emission Unit: S-00003

 

Item 177.2:

The owner or operator shall install, operate, and maintain equipment to capture and control POM 

emissions from each paste production plant.

(1) The emission capture system shall be installed and operated to meet the generally accepted 

engineering standards for minimum exhaust rates as published by the American Conference of 

Governmental Industrial Hygienists in Chapters 3 and 5 of ``Industrial Ventilation: A Handbook of 

Recommended Practice'' (incorporated by reference in Sec. 63.841 of this part); and

(2) Captured emissions shall be routed through a closed system to a dry coke scrubber.

 

Condition 178: Initial compliance provisions for paste production plants

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(f), Subpart LL

Item 178.1:

This Condition applies to Emission Unit: S-00003

 

Item 178.2:

Initial compliance with the standards for existing and new paste production plants in §§63.843(b) and 

63.844(b) will be demonstrated through site inspection(s) and review of site records by the applicable 

regulatory authority.

 

Condition 179: Selection of monitoring parameters - paste production 

plants

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(h)(2), Subpart LL

Item 179.1:

This Condition applies to Emission Unit: S-00003

 

Item 179.2:

The owner/operator shall determine the operating limits and monitoring frequency for each control device 

that is to be monitored as required in §63.848(f). For a paste production plant, the owner/operator shall 

 Air Pollution Control Permit Conditions

Page 167 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

specify and provide the basis or rationale for selecting parameters to be monitored and the associated 

operating limits for the emission control device.

 

Condition 180: Selection of monitoring parameters - redetermining 

operating limits

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.847(h)(3), Subpart LL

Item 180.1:

This Condition applies to Emission Unit: S-00003

 

Item 180.2:

The owner/operator shall determine the operating limits and monitoring frequency for each control device 

that is to be monitored as required in §63.848(f). The owner/operator may redetermine the upper and/or 

lower operating limits, as appropriate, based on historical data or other information and submit an 

application to the New York State DEC to change the applicable limit(s). The redetermined limits shall 

become effective upon approval by the New York State DEC.

 

Condition 181: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(f)(2), Subpart LL

Item 181.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00003

Regulated Contaminant(s):

CAS No: 0NY505-00-0 40 CFR 63 SUBPART LL - POM

Item 181.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator shall install, operate, calibrate, and

maintain a continuous parameter monitoring system for each

emission control device. The owner/operator shall submit 

for approval by the New York State DEC a description of 

the parameter(s) to be monitored, the operating limits, 

and the monitoring frequency to ensure that the control 

device is being properly operated and maintained. An 

explanation of the criteria used for selection of the 

parameter(s), the operating limits, and the monitoring 

frequency, including how these relate to emission control 

also shall be submitted to the New York State 

 Air Pollution Control Permit Conditions

Page 168 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

DEC.

Except as provided in §63.848(l), for dry coke scrubbers, 

a device for the measurement of air flow shall be 

installed, monitored and recorded in accordance with the 

parametric monitoring plan.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 182: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(f)(2), Subpart LL

Item 182.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00003

Regulated Contaminant(s):

CAS No: 0NY505-00-0 40 CFR 63 SUBPART LL - POM

Item 182.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator shall install, operate, calibrate, and

maintain a continuous parameter monitoring system for each

emission control device. The owner/operator shall submit 

for approval by the New York State DEC a description of 

the parameter(s) to be monitored, the operating limits, 

and the monitoring frequency to ensure that the control 

device is being properly operated and maintained. An 

explanation of the criteria used for selection of the 

parameter(s), the operating limits, and the monitoring 

frequency, including how these relate to emission control 

also shall be submitted to the New York State 

DEC.

Except as provided in §63.848(l), for dry coke scrubbers, 

a device for the measurement of coke flow shall be 

installed, monitored and recorded in accordance with the 

parametric monitoring plan.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 Air Pollution Control Permit Conditions

Page 169 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 183: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(g), Subpart LL

Item 183.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00003

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 183.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator shall visually inspect the exhaust 

stack(s) of each control device on a daily basis for 

evidence of any visible emissions indicating abnormal 

operation.

Monitoring Frequency: DAILY

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 184: Corrective action procedures

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(h), Subpart LL

Item 184.1:

This Condition applies to Emission Unit: S-00003

 

Item 184.2:

If a monitoring device for a primary control device measures an operating parameter outside the limit(s) 

established pursuant to §63.847(h), or if visible emissions indicating abnormal operation are observed 

from the exhaust stack of a control device during a daily inspection, the owner/operator shall initiate the 

corrective action procedures identified in the startup, shutdown, and malfunction plan within 1 hour. 

Failure to initiate the corrective action procedures within 1 hour or to take the necessary corrective actions 

to remedy the problem is a violation.

 

 Air Pollution Control Permit Conditions

Page 170 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Condition 185: Exceedances

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(i), Subpart LL

Item 185.1:

This Condition applies to Emission Unit: S-00003

 

Item 185.2:

If the limit for a given operating parameter associated with monitoring a specific control device is 

exceeded six times in any semiannual reporting period, then any subsequent exceedance in that reporting 

period is a violation. For the purpose of determining the number of exceedances, no more than one 

exceedance shall be attributed in any given 24-hour period.

 

Condition 186: Accuracy and calibration requirements

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(k), Subpart LL

Item 186.1:

This Condition applies to Emission Unit: S-00003

 

Item 186.2:

The owner/operator shall submit recommended accuracy requirement to the New York State DEC for 

review and approval. All monitoring devices required by §63.848 must be certified by the owner/operator 

to meet the accuracy requirements and must be calibrated in accordance with the manufacturer's 

instructions.

 

Condition 187: Alternative operating parameters

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.848(l), Subpart LL

Item 187.1:

This Condition applies to Emission Unit: S-00003

 

Item 187.2:

The owner/operator may monitor alternative control device operating parameters subject to prior written 

approval by the New York State DEC.

 

Condition 188: Startup, shutdown, and malfunction plan and reports

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(c)(1), Subpart LL

Item 188.1:

This Condition applies to Emission Unit: S-00003

 

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Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item 188.2:

The owner/operator shall develop and implement a written plan as described in §63.6(e)(3) that contains 

specific procedures to be followed for operating the source and maintaining the source during periods of 

startup, shutdown, and malfunction and a program of corrective action for malfunctioning process and 

control systems used to comply with the standard. The plan does not have to be submitted with the permit 

application or included in the operating permit. The New York State DEC may review the plan upon 

request. In addition to the information required in §63.6(e)(3), the plan shall include procedures, 

including corrective actions, to be followed if a monitoring device measures an operating parameter 

outside the limit(s) established under §63.847(h), or if visible emissions from an exhaust stack indicating 

abnormal operation of a control device are observed by the owner/operator during the daily inspection 

required in §63.848(g).

 

Condition 189: Startup, shutdown, and malfunction plan and reports

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(c)(2), Subpart LL

Item 189.1:

This Condition applies to Emission Unit: S-00003

 

Item 189.2:

The owner/operator shall develop and implement a written plan as described in §63.6(e)(3) that contains 

specific procedures to be followed for operating the source and maintaining the source during periods of 

startup, shutdown, and malfunction and a program of corrective action for malfunctioning process and 

control systems used to comply with the standard. The plan does not have to be submitted with the permit 

application or included in the operating permit. The New York State DEC may review the plan upon 

request. In addition to the information required in §63.6(e)(3), the plan shall include records of each event 

as required by §63.10(b) and the owner/operator shall 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 

§63.6(e)(3)(iv).

 

Condition 190: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(d), Subpart LL

Item 190.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00003

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

Item 190.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

 Air Pollution Control Permit Conditions

Page 172 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Monitoring Description: 

As required in §63.10(e)(3), the owner/operator shall 

submit a report (or a summary report) if measured 

emissions are in excess of the applicable standard. The 

report shall contain the information specified in 

§63.10(e)(3)(v) and be submitted semiannually unless 

quarterly reports are required as a result of excess 

emissions.

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 191: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(e)(1), Subpart LL

Item 191.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00003

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

Item 191.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator shall maintain files of all 

information (including all reports and notifications) 

required by §63.10(b) and by Subpart LL. Records must be 

retained 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 

must be retained at the facility. The remaining 3 years 

of records may be retained offsite.

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 192: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(e)(2), Subpart LL

 Air Pollution Control Permit Conditions

Page 173 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item 192.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00003

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

Item 192.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator may retain records on microfilm, on a 

computer, on computer disks, on magnetic tape, or on 

microfiche.

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 193: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(e)(3), Subpart LL

Item 193.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00003

Regulated Contaminant(s):

CAS No: 0NY100-00-0 HAP

Item 193.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The owner/operator may report required information on 

paper or on a labeled computer disc using commonly 

available and compatible computer software.

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 194: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 63.850(e)(4), Subpart LL

 Air Pollution Control Permit Conditions

Page 174 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item 194.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00003

Item 194.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

In addition to the general records required by §63.10(b),

the owner/operator shall maintain records of the following

information:

1) A copy of the startup, shutdown, and malfunction 

plan;

2) Records of design information for paste production 

plant capture systems;

3) Records, such as a checklist or the equivalent, 

demonstrating that the daily visual inspection of the 

exhaust stack for each control device has been performed 

as required in §63.848(g), including the results of each 

inspection;

4) Records documenting the corrective actions taken when 

the limit(s) for an operating parameter established under 

§63.847(h) were exceeded, or when visible emissions 

indicating abnormal operation were observed from a control

device stack during a daily inspection required under 

§63.848(g).

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 195: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.10(f)

Item 195.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00003 Emission Point: S0100

Regulated Contaminant(s):

 Air Pollution Control Permit Conditions

Page 175 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

CAS No: 0NY998-00-0 VOC

Item 195.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

This source must be operated in such a manner to achieve 

an overall volatile organic compound (VOC) removal 

efficiency of at least 81%. For the purposes of 

determining compliance with this condition emissions of 

polycyclic organic matter (POM) shall be included in the 

total VOC emissions from the source.

Lower Permit Limit: 81 percent

Reference Test Method: 18 or 25A and 315

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 196: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.3(b)

Item 196.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00004

Process: M01 Emission Source: SS017

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 196.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

Emissions of solid particulates are limited to less than 

0.150 grains of particulates per cubic foot of exhaust 

gas, expressed at standard conditions on a dry gas basis. 

Compliance testing will be conducted at the discretion of 

the Department.

 Air Pollution Control Permit Conditions

Page 176 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Parameter Monitored: PARTICULATES

Upper Permit Limit: 0.15 grains per dscf

Reference Test Method: EPA Method 5

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 197: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 40CFR 52.21(i)(1), Subpart A

Item 197.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00004

Process: M16

Regulated Contaminant(s):

CAS No: 0NY075-00-0 PARTICULATES

Item 197.2:

Compliance Certification shall include the following monitoring:

Capping: Yes

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

Particulate emissions from this emission source shall not

exceed 15 tons during any 12 month period. Source owner 

must maintain records that demonstrate compliance with 

this emission limit. Records should include: any stack 

test reports, the number of hours the spent potliner 

handling is being performed, the number of hours that the 

baghouse is not in operation while spent potliner handling

is occurring, and information that shows the baghouse is 

being operated with the manufacturer's specifications for 

pressure drop and air/cloth ratio.

Upper Permit Limit: 15 tons per year

Reference Test Method: EPA RM 5

Monitoring Frequency: ONCE DURING THE TERM OF THE PERMIT

Averaging Method: ANNUAL MAXIMUM ROLLED MONTHLY

 Air Pollution Control Permit Conditions

Page 177 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 198: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.10(c)(1)

Item 198.1:

The Compliance Certification activity will be performed for:

Emission Unit: S-00005

Process: PST

Regulated Contaminant(s):

CAS No: 0NY998-00-0 VOC

Item 198.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The emission rate potential of volatile organic compound 

(VOC) from each emission point in this process shall 

remain less than 3.0 pounds per hour. A reasonably 

available control technology (RACT) analysis is not 

required for emission points with VOC emission rate 

potentials less than 3.0 pounds per hour at facilities 

located outside of the Lower Orange County and New York 

City metropolitan areas.

While unloading pitch from rail cars the vent from the 

tank receiving the pitch must be vented to the other pitch

storage tank which must be empty. The empty tank will in 

effect be a condenser for the semi-volatile pitch fumes 

emitted during the pitch rail car unloading. Failure to 

operate this process in this manner may cause VOC 

emissions greater than 3.0 pounds per hour.

Reference Test Method: EPA RM 18 or 25A

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

 Air Pollution Control Permit Conditions

Page 178 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

Condition 199: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.4(a)

Item 199.1:

The Compliance Certification activity will be performed for:

Emission Unit: W-00001

Process: WWT

Regulated Contaminant(s):

CAS No: 000074-90-8 HYDROCYANIC ACID

Item 199.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

As required by 6 NYCRR Part 212.4(a) hydrogen cyanide has

been issued an environmental rating of A. The emission 

rate potential of hydrogen cyanide from each emission 

source in this process shall remain less than 1 pound per 

hour. Compliance testing shall be conducted upon request 

from the Department.

Upper Permit Limit: 1.0 pounds per hour

Reference Test Method: EPA Method 18

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: 1-HOUR AVERAGE

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 200: Compliance Certification

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable Federal Requirement: 6NYCRR 212.4(a)

Item 200.1:

The Compliance Certification activity will be performed for:

Emission Unit: W-00001

Process: WWT

Regulated Contaminant(s):

 Air Pollution Control Permit Conditions

Page 179 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

CAS No: 007664-41-7 AMMONIA

Item 200.2:

Compliance Certification shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

As required by 6 NYCRR Part 212.4(a) ammonia has been 

issued an environmental rating of C. The emission rate 

potential of ammonia from each emission source in this 

process shall remain less than 10 pounds per hour. 

Compliance testing shall be conducted upon request from 

the Department.

Upper Permit Limit: 10 pounds per hour

Reference Test Method: EPA CTM-027

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

 Air Pollution Control Permit Conditions

Page 180 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

 STATE ONLY ENFORCEABLE CONDITIONS

 ** ** Facility Level  

NOTIFICATION OF GENERAL PERMITTEE OBLIGATIONS

 This section contains terms and conditions which are not federally enforceable. Permittees may also

have other obligations under regulations of general applicability

Item A: General Provisions for State Enforceable Permit Terms and

Condition - 6 NYCRR Part 201-5

Any person who owns and/or operates stationary sources 

shall operate and maintain all emission units and any 

required emission control devices in compliance with all 

applicable Parts of this Chapter and existing laws, and 

shall operate the facility in accordance with all 

criteria, emission limits, terms, conditions, and 

standards in this permit. Failure of such person to 

properly operate and maintain the effectiveness of such 

emission units and emission control devices may be 

sufficient reason for the Department to revoke or deny a 

permit.

The owner or operator of the permitted facility must 

maintain all required records on-site for a period of five

years and make them available to representatives of the 

Department upon request. Department representatives must 

be granted access to any facility regulated by this 

Subpart, during normal operating hours, for the purpose of

determining compliance with this and any other state and 

federal air pollution control requirements, regulations or

law.

STATE ONLY APPLICABLE REQUIREMENTS

The following conditions are state only enforceable and are not subject to annual

 compliance certification requirements for Title V permits.

Condition 201: Contaminant List

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable State Requirement: ECL 19-301.

Item 201.1:

Emissions of the following contaminants are subject to contaminant specific requirements in this 

permit(emission limits, control requirements or compliance monitoring conditions).

 Air Pollution Control Permit Conditions

Page 181 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

CAS No: 0NY505-00-0

Name: 40 CFR 63 SUBPART LL - POM

CAS No: 007664-41-7

Name: AMMONIA

CAS No: 000630-08-0

Name: CARBON MONOXIDE

CAS No: 000463-58-1

Name: CARBONYL SULFIDE

CAS No: 007782-50-5

Name: CHLORINE

CAS No: 000111-42-2

Name: ETHANOL, 2,2'-IMINOBISCAS No: 068188-85-2

Name: FLUORIDES

CAS No: 000050-00-0

Name: FORMALDEHYDE

CAS No: 0NY100-00-0

Name: HAP

CAS No: 000074-90-8

Name: HYDROCYANIC ACID

CAS No: 007647-01-0

Name: HYDROGEN CHLORIDE

CAS No: 007664-39-3

Name: HYDROGEN FLUORIDE

CAS No: 007439-92-1

Name: LEAD

CAS No: 000067-56-1

Name: METHYL ALCOHOL

CAS No: 0NY210-00-0

Name: OXIDES OF NITROGEN

CAS No: 0NY075-00-0

Name: PARTICULATES

 Air Pollution Control Permit Conditions

Page 182 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

CAS No: 007446-09-5

Name: SULFUR DIOXIDE

CAS No: 0NY998-00-0

Name: VOC

Condition 202: Unavoidable noncompliance and violations

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable State Requirement: 6NYCRR 201-1.4

Item 202.1:

At the discretion of the commissioner a violation of any applicable emission standard for necessary 

scheduled equipment maintenance, start-up/shutdown conditions and malfunctions or upsets may be 

excused if such violations are unavoidable. The following actions and recordkeeping and reporting 

requirements must be adhered to in such circumstances.

(a) The facility owner and/or operator shall compile and maintain records of all equipment 

maintenance or start-up/shutdown activities when they can be expected to result in an exceedance of any 

applicable emission standard, and shall submit a report of such activities to the commissioner's 

representative when requested to do so in writing or when so required by a condition of a permit issued 

for the corresponding air contamination source except where conditions elsewhere in this permit which 

contain more stringent reporting and notification provisions for an applicable requirement, in which case 

they supercede those stated here. Such reports shall describe why the violation was unavoidable and shall 

include the time, frequency and duration of the maintenance and/or start-up/shutdown activities and the 

identification of air contaminants, and the estimated emission rates. If a facility owner and/or operator is 

subject to continuous stack monitoring and quarterly reporting requirements, he need not submit reports 

for equipment maintenance or start-up/shutdown for the facility to the commissioner's representative.

(b) In the event that emissions of air contaminants in excess of any emission standard in 6 NYCRR 

Chapter III Subchapter A occur due to a malfunction, the facility owner and/or operator shall report such 

malfunction by telephone to the commissioner's representative as soon as possible during normal working 

hours, but in any event not later than two working days after becoming aware that the malfunction 

occurred. Within 30 days thereafter, when requested in writing by the commissioner's representative, the 

facility owner and/or operator shall submit a written report to the commissioner's representative 

describing the malfunction, the corrective action taken, identification of air contaminants, and an estimate 

of the emission rates. These reporting requirements are superceded by conditions elsewhere in this 

permit which contain reporting and notification provisions for applicable requirements more stringent 

than those above.

(c) The Department may also require the owner and/or operator to include in reports described 

under (a) and (b) above an estimate of the maximum ground level concentration of each air contaminant 

emitted and the effect of such emissions depending on the deviation of the malfunction and the air 

contaminants emitted.

(d) In the event of maintenance, start-up/shutdown or malfunction conditions which result in 

emissions exceeding any applicable emission standard, the facility owner and/or operator shall take 

appropriate action to prevent emissions which will result in contravention of any applicable ambient air 

 Air Pollution Control Permit Conditions

Page 183 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

quality standard. Reasonably available control technology, as determined by the commissioner,. shall be 

applied during any maintenance, start-up/shutdown or malfunction condition subject to this paragraph.

(e) In order to have a violation of a federal regulation (such as a new source performance standard or 

national emissions standard for hazardous air pollutants) excused, the specific federal regulation must 

provide for an affirmative defense during start-up, shutdowns, malfunctions or upsets.

 

Condition 203: Compliance Demonstration

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable State Requirement: 6NYCRR 209.

Item 203.1:

The Compliance Demonstration activity will be performed for the facility:

The Compliance Demonstration applies to:

Emission Unit: S-00001

Process: POT

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 0NY505-00-0 40 CFR 63 SUBPART LL - POM

CAS No: 068188-85-2 FLUORIDES

Item 203.2:

Compliance Demonstration shall include the following monitoring:

Monitoring Type: RECORD KEEPING/MAINTENANCE PROCEDURES

Monitoring Description: 

The more stringent requirements of 40 CFR 63 subpart LL 

apply to the emissions of Fluorides, Polycyclic Organic 

Matter (POMs) and opacity at this facility. As long as the

facility is in compliance with the requirements in subpart

LL, then it is in compliance with the requirements of 6 

NYCRR part 209. See subpart LL requirements for monitoring

and reporting frequencies.

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: AS REQUIRED - SEE MONITORING DESCRIPTION

Condition 204: Emissions other than total fluorides

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable State Requirement: 6NYCRR 209.4

 Air Pollution Control Permit Conditions

Page 184 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Item 204.1:

Emissions of air contaminants other than total fluorides from any air contamination source in a primary 

aluminum reduction plant are regulated by all other applicable Parts of this Subchapter. 

Condition 205: Air pollution prohibited

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable State Requirement: 6NYCRR 211.2

Item 205.1:

No person shall cause or allow emissions of air contaminants to the outdoor atmosphere of such quantity, 

characteristic or duration which are injurious to human, plant or animal life or to property, or which 

unreasonably interfere with the comfortable enjoyment of life or property. Notwithstanding the existence 

of specific air quality standards or emission limits, this prohibition applies, but is not limited to, any 

particulate, fume, gas, mist, odor, smoke, vapor, pollen, toxic or deleterious emission, either alone or in 

combination with others.

Condition 206: Compliance Demonstration

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable State Requirement: 6NYCRR 212.4(a)

Item 206.1:

The Compliance Demonstration activity will be performed for the facility:

The Compliance Demonstration applies to:

Emission Unit: A-00001

Process: HMO

Emission Unit: A-00001

Process: HT1

Emission Unit: A-00001

Process: HT2 Emission Source: AF014

Emission Unit: A-00001

Process: HT2 Emission Source: AF015

Emission Unit: A-00001

Process: HT2 Emission Source: AF02A

Emission Unit: A-00001

Process: HT2 Emission Source: AF02B

Regulated Contaminant(s):

CAS No: 007664-39-3 HYDROGEN FLUORIDE

Item 206.2:

 Air Pollution Control Permit Conditions

Page 185 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Compliance Demonstration shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

As required by 6 NYCRR 212.4(a), Hydrogen Fluoride has 

been issued an environmental rating of "B". The emission 

rate potential of Hydrogen Fluoride from each of these 

emission sources shall remain less than 10 pounds per 

hour. Compliance testing shall be conducted upon request 

from the Department.

Upper Permit Limit: 10 pounds per hour

Reference Test Method: method 4075-TF

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 207: Compliance Demonstration

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable State Requirement: 6NYCRR 212.4(a)

Item 207.1:

The Compliance Demonstration activity will be performed for the facility:

The Compliance Demonstration applies to:

Emission Unit: C-00002

Process: CD2

Emission Unit: M-00001

Emission Unit: M-00002

Emission Unit: C-00001

Process: CD1

Regulated Contaminant(s):

CAS No: 007647-01-0 HYDROGEN CHLORIDE

Item 207.2:

Compliance Demonstration shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

As required by 6 NYCRR 212.4(a), Hydrogen Chloride has 

been issued an environmental rating of "B". The emission 

 Air Pollution Control Permit Conditions

Page 186 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

rate potential of Hydrogen Chloride from each of these 

emission sources shall remain less than 10 pounds per 

hour.

Upper Permit Limit: 10 pounds per hour

Reference Test Method: EPA method 26

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

20 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 208: Compliance Demonstration

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable State Requirement: 6NYCRR 212.5(d)

Item 208.1:

The Compliance Demonstration activity will be performed for the facility:

The Compliance Demonstration applies to:

Emission Unit: S-00001

Process: POT

Emission Unit: S-00002

Process: BAK

Regulated Contaminant(s):

CAS No: 000463-58-1 CARBONYL SULFIDE

CAS No: 000630-08-0 CARBON MONOXIDE

CAS No: 007446-09-5 SULFUR DIOXIDE

Item 208.2:

Compliance Demonstration shall include the following monitoring:

Monitoring Type: WORK PRACTICE INVOLVING SPECIFIC 

 OPERATIONS

Monitoring Description: 

Where a source owner can demonstrate to the satisfaction 

of the commissioner that he will apply best available 

control technology (BACT), the commissioner may specify a 

less restrictive permissible emission rate, emission 

standard or degree of air cleaning for such source than 

required under this Part provided that the less 

restrictive requirement is equivalent to that which can be

achieved through the application of best available control

technology.

 Air Pollution Control Permit Conditions

Page 187 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Carbon Monoxide (CO), Carbonyl Sulfide (COS), and Sulfur 

Dioxide (SO2) emissions from the anode bake furnace and 

the potline shall be controlled according to the BACT 

analysis submitted to the Department July 9, 2001 and 

approved by Albany staff. 

The specification of % sulfur by weight in the coke used 

at the plant shall be lowered from 3% to 2.5% on an annual

average basis rolled monthly. The sulfur content shall be 

determined from vendor test data for each delivery of 

coke. The current annual average and any excursions above 

the limit shall be reported semiannually on a calendar 

year basis. 

Work Practice Type: PARAMETER OF PROCESS MATERIAL

Process Material: COKE

Parameter Monitored: SULFUR

Upper Permit Limit: 2.5 percent by weight

Monitoring Frequency: MONTHLY

Averaging Method: AVERAGING METHOD - SEE MONITORING 

 DESCRIPTION

Reporting Requirements: SEMI-ANNUALLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 1/30/03.

Subsequent reports are due every 6 calendar month(s).

 ** ** Emission Unit Level ****

Condition 209: Compliance Demonstration

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable State Requirement: 6NYCRR 227-1.4(a)

Item 209.1:

The Compliance Demonstration activity will be performed for:

Emission Unit: B-00001

Process: OIL

Item 209.2:

Compliance Demonstration shall include the following monitoring:

Monitoring Type: MONITORING OF PROCESS OR CONTROL 

 DEVICE PARAMETERS AS SURROGATE

Monitoring Description: 

Any person who owns a stationary combustion installation 

 Air Pollution Control Permit Conditions

Page 188 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

(excluding gas turbines), with a total maximum heat input 

capacity exceeding 250 million Btu per hour shall install,

operate in accordance with manufacturer's instructions, 

and properly maintain, accurate instruments satisfying the

criteria in appendix B of title 40, part 60 of the Code of

Federal Regulations, or approved by the commissioner on an

individual case basis, for continuously monitoring and 

recording opacity, and when sulfur dioxide continuous 

monitoring is required by Part 225 of this Title, for 

continuously monitoring and recording either the percent 

oxygen or carbon dioxide in the flue gases from such 

installations at all times that the combustion 

installation is in service. Where gas is the only fuel 

burned, monitoring and recording of opacity is not 

required.

Parameter Monitored: OPACITY

Upper Permit Limit: 20 percent

Reference Test Method: Apendix B, 40 CFR 60

Monitoring Frequency: CONTINUOUS

Averaging Method: 6 MINUTE AVERAGE

Reporting Requirements: QUARTERLY (CALENDAR)

Reports due 30 days after the reporting period.

The initial report is due 10/30/02.

Subsequent reports are due every 3 calendar month(s).

Condition 210: Compliance Demonstration

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable State Requirement: 6NYCRR 212.4(a)

Item 210.1:

The Compliance Demonstration activity will be performed for:

Emission Unit: C-00001 Emission Point: I0029

Process: CD1

Regulated Contaminant(s):

CAS No: 007446-09-5 SULFUR DIOXIDE

Item 210.2:

Compliance Demonstration shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

As required by 6 NYCRR Part 212.4(a) sulfur dioxide (SO2)

has been issued an environmental rating of B. The emission

rate potential of sulfur dioxide from each emission source

 Air Pollution Control Permit Conditions

Page 189 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

in this process shall remain less than 10 pounds per hour.

Compliance testing shall be conducted upon request from 

the Department.

Upper Permit Limit: 10.0 pounds per hour

Reference Test Method: EPA RM 6C

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 211: Compliance Demonstration

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable State Requirement: 6NYCRR 212.4(a)

Item 211.1:

The Compliance Demonstration activity will be performed for:

Emission Unit: C-00002

Process: CD2

Regulated Contaminant(s):

CAS No: 007446-09-5 SULFUR DIOXIDE

Item 211.2:

Compliance Demonstration shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

As required by 6 NYCRR Part 212.4(a) sulfur dioxide (SO2)

has been issued an environmental rating of B. The emission

rate potential of sulfur dioxide from each emission source

in this process shall remain less than 10 pounds per hour.

Compliance testing shall be conducted upon request from 

the Department.

Upper Permit Limit: 10.0 pounds per hour

Reference Test Method: EPA RM 6C

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: AVERAGING METHOD AS PER REFERENCE TEST

 METHOD INDICATED

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 212: Compliance Demonstration

Effective between the dates of 09/01/2002 and 09/01/2007

 Air Pollution Control Permit Conditions

Page 190 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

Applicable State Requirement: 6NYCRR 212.4(a)

Item 212.1:

The Compliance Demonstration activity will be performed for:

Emission Unit: M-00001

Regulated Contaminant(s):

CAS No: 007782-50-5 CHLORINE

Item 212.2:

Compliance Demonstration shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

As required by 6 NYCRR Part 212.4(a) chlorine has been 

issued an environmental rating of B. The emission rate 

potential of chlorine from each emission source in this 

emission unit shall remain less than 10 pounds per hour. 

Compliance testing shall be conducted upon request from 

the Department.

Upper Permit Limit: 10.0 pounds per hour

Reference Test Method: EPA RM 18

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: 1-HOUR AVERAGE

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

Condition 213: Compliance Demonstration

Effective between the dates of 09/01/2002 and 09/01/2007

Applicable State Requirement: 6NYCRR 212.4(a)

Item 213.1:

The Compliance Demonstration activity will be performed for:

Emission Unit: M-00002

Regulated Contaminant(s):

CAS No: 007782-50-5 CHLORINE

Item 213.2:

Compliance Demonstration shall include the following monitoring:

Monitoring Type: INTERMITTENT EMISSION TESTING

Monitoring Description: 

 Air Pollution Control Permit Conditions

Page 191 of 192 FINAL
Permit ID: 6-4058-00003/00365 Facility DEC ID: 6405800003

As required by 6 NYCRR Part 212.4(a) chlorine has been 

issued an environmental rating of B. The emission rate 

potential of chlorine from each emission source in this 

emission unit shall remain less than 10 pounds per hour. 

Compliance testing shall be conducted upon request from 

the Department.

Upper Permit Limit: 10.0 pounds per hour

Reference Test Method: EPA RM 18

Monitoring Frequency: AS REQUIRED - SEE MONITORING 

 DESCRIPTION

Averaging Method: 1-HOUR AVERAGE

Reporting Requirements: UPON REQUEST BY REGULATORY AGENCY

 Air Pollution Control Permit Conditions

Page 192 of 192 FINAL