ERJviErthe-jj_-jSOURCE 8/30/10 Mr. Conrad

Chin USEPA

Office

of Air Quality Planning

and Standards 109 T.W. Alexander

Drive Research

Triangle

Park,

NC 27711 Dear

Mr. Chin, Please

find enclosed

requested information

from USEPA’s Information

Collection Request

for Ferroalloys

Production Manufacturing.

Eramet

Marietta

Inc

has classified

as Business Confidential

sections

2A,

2B,

2D,

and

2E

of this request as they pertain

to technologies

and processes

developed

by our company.

These sections

have

been forwarded

to Mr. Roberto

Morales

as instructed

in Enclosure one

of the

ICR. One omission

from

this request

is

a copy

of the Title

V renewable

application

for Eramet

Marietta

Inc.

Ohio

EPA

has

not

yet provided

this document

for submittal. Please

contact

me

with

any questions

regarding

this matter

at (740)

374-1

366. Sincerely, John Hughes Environmental

Engineer Eramet

Marietta

Inc. (740) 374-1366CcMsChristinaWiegOEPA-SEDOIR\\1II\l\RIIINiIi)Iii)\I\kIII\01111)4T{}fl.i)IIIliiiirIi—iIijII11)11(1III11(iIIII41)14pl6aEPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTSENCLOSURE1INFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTSThisinformationcollectionrequestisbeingconductedbytheEnvironmentalProtectionAgency’s(EPA)OfficeofAirandRadiation(OAR)toassisttheEPAAdministratorindevelopingemissionstandardsforFerroalloysProductionManufacturingEmissionPointsunderCleanAirAct(CAA)section112.ThesurveyisbeingsentundertheauthorityofSection114oftheCAA.BACKGROUND:Thisinformationrequest(Enclosure1)istobecompletedforoperationsthatcompriseferroalloysproductionateachfacilityoperatedbyyourcompanywhichislocatedwithintheUnitedStates.Theferroalloysproductionsourcecategoryincludesanyfacilityengagedinproducingferroalloyssuchasferrosilicon,siliconmetal,silicomanganese,ferromanganese,ferronickel,andferrochromium.Thesourcecategoryalsoincludesproductionofcalciumcarbide.Ferroalloysproductionincludes,butisnotlimitedto,thefollowingunitoperations:oreunloading,orestorage,sintering,crushing,weigh-feeding,smelting,tapping,casting,andscreening.CAAsection114(a)statesthattheAdministratormayrequireanyowneroroperatorsubjecttoanyrequirementofthisActto:(A)Establishandmaintainsuchrecords;(B)makesuchreports;(C)install,use,andmaintainsuchmonitoringequipment,andusesuchauditprocedures,ormethods;(D)samplesuchemissions(inaccordancewithsuchproceduresormethods,atsuchlocations,atsuchintervals,duringsuchperiods,andinsuchmannerastheAdministratorshallprescribe);(E)keeprecordsoncontrolequipmentparameters,productionvariablesorotherindirectdatawhendirectmonitoringofemissionsisimpractical;(F)submitcompliancecertificationsinaccordancewithsection114(a)(3);and(G)providesuchotherinformationastheAdministratormayreasonablyrequire.TherearetwoaspectstothisCAAsection114informationcollectionrequest.Thefirstcomponentoftheinformationcollectioninvolvesasurveyrequestinginformationonexistingemissionpoints.Thesecondcomponentrequiresownerstoconducttesting.Thetestingrequirementsaresetforthinthecoverletterofthispacket(CAAsection114letter)aswellasEnclosure2.DIRECTIONS:XAllrecipientsmustcompleteandreturnthissurveybyJuly30,2Q10.XYouarenotexpectedtogeneratenewinformationfortheattachedsurvey(Enclosure1).XPleaseanswerallquestionsunlessnotapplicabletoyourfacilityoroperations,inwhichcasenotethatthequestionisnotapplicable.Allinformationshouldbeforthe2009reportingyear(unlessotherwisenoted).4/21/2010EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTSXPleaseidentifyclearlyanyresponse(s)thatyouconsidertobeconfidentialbusinessinformation(CBI).Anyresponsesnotsoidentifiedwillbeincludedinapubliclyavailabledatabase.RefertoEnclosures3,4,5,and6formoreinformationonthetreatmentofCBIandalistofinformationyoumaybeaskedtosubmitlatertosubstantiateaclaimofconfidentiality.Pleasedonotlabelanentireresponse“confidential”ifonlycertainportionsconsistoftradesecretinformation.Ifyouwish,youmaysubmitaconfidentialandanon-confidentialversion.Inordertoavoidduplicatedataandkeepalldataforaparticularfacilitytogether,werequestthatyousubmitallofthedatarequestedfromyourfacilityinthesameway.Tosubmityourdata,mailaCDorDVDcontaininganelectroniccopyofallrequestedfilestotheEPAaddressbelow:U.S.EnvironmentalProtectionAgencyOfficeofAirQualityPlanningandStandardsU.S.EPAMailroom(D243-02)Attn:Mr.ConradChin109T.W.AlexanderDriveResearchTrianglePark,NC27711Iftheprocessdataorotherinformationyouareprovidingisconsideredconfidential,pleasecreateaseparateCDorDVDcontainingonlytheconfidentialportionofyourdataorprepareacopyofthehardcopymaterialscontainingonlythepagesthatincludetheinformationyouconsiderconfidential.Clearlymarkthediskand/ormaterialswiththewords“ConfidentialBusinessInformation.”SendtheseconfidentialfilesunderseparatecovertotheattentionofMr.RobertoMoralesatthefollowingaddress:U.S.EnvironmentalProtectionAgencyOfficeofAirQualityPlanningandStandardsU.S.EPAMailroom(C404-02)Attn:Mr.RobertoMorales,DocumentControlOfficer109T.W.AlexanderDriveResearchTrianglePark,NC27711Forthesecurityofyourdata,EPArecommendssendingyourconfidentialfilestoMr.MoralesviaRegisteredU.S.Mailusingreturnreceiptrequested,FederalExpress,orothermethodforwhichsomeonemustprovideasignatureuponreceipt.Donotelectronicallytransmitconfidentialbusinessinformation(CBI)toEPA.E-mailandfacsimilearenotsecureformsofcommunicationandshouldneverbeusedtotransmitCBI.Ifyouhaveanyquestionsregardingthisrequest,pleasecontactMr.ConradChinate-mailchin.conrad(epa.qovPleasenotethatyouaretoprovideaseparateresponsepackageforeachfacilityinyourcompanywithferroalloyproductionoperations.Copiesofthisquestionnaireshouldbemadeforadditionalfacilities.PLEASERETURNTHISSURVEYNOLATERTHANJULY30,20104/21/2010EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTSCONFIDENTIALBUSINESSINFORMATION(CBI):PleaseindicateifanyCBIisincludedinthissurveyresponse:1YesLJNoPARTI.OWNERINFORMATION1.NameofLegalOwner:ErametSAa.Address:16705Riverviewb.City:Mariettac.State:Ohiod.Zip:45750e.County:Washington2.Completestreetaddressoffacility(physicallocation):a.Address:16705StateRoute7Southb.City:Mariettac.State:Ohiod.Zip:45750e.County:Washington3.MailingAddress(ifdifferentfromFacilityStreetAddress):a.Address:P.O.Box299b.City:Mariettac.State:Ohiod.Zip:45750e.County:Washington4.FacilityContact:a.Name(FirstName,LastName):JohnHughesb.Title:EnvironmentalEngineerc.TelephoneNumber:(740)374-1366Extd.FaxNumber:(740)374-1305e.E-mail:john.hughes(äerametgroup.corn4/21/201()EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTS5.FacilityDescription:a.Briefdescriptionofthefacility:(e.g.,ferroalloyproductionoperationsandanyotheroperationslocatedon-site.)FerroalloyProduction.b.Dun&BradstreetNo:07-462-7592c.SARATRIFacilityID(fromFormR):4575OLKMMTYOUTEd.NumberofFacilityEmployees:Numberofemployeesassociatedwithferroalloyproductionoperationsatthefacility(answermaybegivenusingthefollowingranges:0-100;101-250;251-500;501-750;751-1,000;1,001-1,500;and>1,500.)Includetemporaryemployeesiftheyareasignificantfractionofyourtotalnumberofemployees.101-250e.NumberofCorporateEmployees:Approximatenumberofemployeesofthebusinessenterprisethatownsthisplant,includingwhereapplicable,theparentcompanyandallsubsidiaries,branches,andunrelatedestablishmentsownedbytheparentcompany16000f.NAICSCode(s):(Seehttp://www.census.qov/epcd/www/naics.html)Primary:331112Other:g.Isthelegalownerasmallentity?DYDNUnknown44/21/2010EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTSh.OperatingHours(Mostcommonoperatinghoursforthemajorityoftheyear)hours/day:shifts/day:days/wk:weeks/yr:243752MajorSource6.GeographicCoordinatesofCenterofPlant:EitherlatitudeandlongitudeorUTMcoordinateswithzone.Latitudeandlongitudeshouldbeprovidedindecimaldegrees,with6digitstorightofdecimalpoint,andanindicationoftheassociateddatum(ifavailable,likelyNAD27,NAD83,orWGS84.)a.latitudeandlongitude:39.37251781.523150b.UTMcoordinates:454937.9East,4358247.0North,Zone177.RegulatoryRequirements(IndicateanyFederalorStateairemissionstandards,suchastheNSPS,whichareapplicabletoyourfacility)40CFRPart60,subpartZ,StandardsofPerformanceforFerroalloysProduction40CFRPart63,subpartXXX,NationalEmissionStandardsforHazardousAirPollutantsfromFerroalloysProduction:FerromanganeseandSilicomanganeseLI40CFRPart63,subpartDDDDD,NationalEmissionStandardsforHazardousAirPollutantsforIndustrial/Commercial/InstitutionalBoilersandProcessHeaters40CFRPart63,subpartYYYYYY,NationalEmissionStandardsforHazardousAirPollutantsforAreaSources:FerroalloysProductionFacilitiesElOthers(pleaseidentify):8.FacilityClassificationforhazardousairpollutants(HAP)IfyouhaveanairoperatingpermitissuedunderTitleVoftheCleanAirAct,indicatetheclassificationofyourfacilityElSyntheticMinorSourceMinor/AreaSource9.PermitConditionsIfanyoftheferroalloysproductionoperationsatyourfacilityaresubjecttoStateorlocalairpermitlimits,pleaseprovideacopyofyouroperatingpermit.IfyouhaveaTitleVpermitanditisnotavailableonline,pleaseprovideacopyofit.IfyourTitleVpermitisstillpending,pleaseprovideacopyofyourpermitapplication4/21/2010EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTS10.ListofEnclosedItemsListtheitemssubmittedwiththesurveyresponse(e.g.,permits,block-flowdiagrams,pipingandinstrumentationdiagrams,testreports,samplinganalyses,exceedencereports),andprovideanidentificationcodeforeachitem(e.g.,attachment1)IdentificationcodeDescriptionofitemsubmittedwithsurveyresponseAttachment1TitleVPermitApplicationAttachment2Attachment3ProcessFlowDiagramsStartup,Shutdown,andMalfunctionPlanPARTII.GENERALFACILITYINFORMATIONProcessSummaryCompletetheProcessSummaryinTable2Afor2009(unlessyoucanjustifyselectionofanalternatebaseyear)forallunitoperationsatyourplantthatarecoveredbytheferroalloyssourcecategory.Theseincludestorageandhandlingofrawmaterialsandproducts.CompleteTable2Bwithdetailedinformationforeachfurnace,andcompleteTable2Cwithdetailsoftappingoperationsforeachfurnace.2.ProcessFlowDiagramForeachunitoperationidentifiedinTable2A,provideaprocessflowdiagramthatincludesallsourcesofairemissions(e.g.,stackemissions,processfugitiveemissions,andotherfugitiveemissions[includingfugitivedustemissions]).Alsoincludeallassociatedairpollutioncontroldevices.AsimpleexampleisincludedinAppendixB.Pleasenotethatitonlyrepresentsaportionofthediagramthatatypicalfacilityshouldsubmit.AlsoincludeallactivitiesthatgenerateHAPemissions,includingthestorage,transfer,handling,andprocessingofthematerials,andwastewaterandsolidwastehandling.Indicateallfeedstocks,products,andemissionsthatcontainHAP.Usethesameterminology/codesinidentifyingunitoperationsandemissionspointsinthisfigureasyouwillusefortherestofthissurvey.SeeAppendixAforEPA’slistofHAPs.64/21/2010EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTS3.RawMaterialsCompletethesummaryofrawmaterialsused,inTable2D.Includeallthecomponentsincludedinfurnacechargesforallproducts,andindicatehowmuchofeachwasconsumedin2009.Foreachrawmaterial,indicatethepercentageoftotalconsumptionusedforeachendproduct.If2009wasnotarepresentativeyear,datafromanotheryearmaybeusedifanexplanationisprovided.ForeachmaterialpotentiallycontainingmetalHAP,providedetailedinformationonoriginandcomposition,includinganypotentialforvariability(e.g.,forscrapmetal.)Describethefactorsthatareimportantintheselectionoftherawmaterial.4.ProductsandProductHandlingA.CompletethesummaryofproductsandproductionvolumeinTable2E.Listtheproducts,co-products,andby-productsidentifiedintheprocessflowdiagramandindicatehowmuchofeachwasproducedineachofthelast5years.B.Ifproductioninrecentyearsisnotconsistentorrepresentativeofnormalplantoperations,orifyouexpecttomakechangestotheplantthatwillaffectproduction,pleaseexplain:2009dataprovidedunlessotherwisenoted.C.Provideabriefnarrativedescriptionofpost-tappingproducthandlingandprocessingoperations,includingstorage,conveyance,andanyoperationsperformedonproducts:Productiscastuntilsolid-transportedtostoragebyscoop,transportedtocrushingandsizingbyscoop.aftersizingtransportedtobinstorage.Productisloadedbyscoopintotruckfordeliverytocustomer.PARTIll.VENTILATION,CAPTUREANDCONTROLSYSTEMSCaptureandControlSummaryCompleteTable3AsummarizingventilationIcaptureforanyairpollutionventilationIcaptureequipmentassociatedwiththeprocesseslistedinTable2A,(withtheexceptionofcaptureforfurnacesandtapping.)Fugitiveemissionsfromfurnaceandtappingoperationsshouldbeincludedhere.2.PrimaryandTappingCaptureForeachfurnacereportedasoperational(orsoontobeoperational)prepareacopyofTable3Bdetailingcaptureofprimaryandtappingemissionswithinformationregardinghoods,enclosures,curtains,etc.whichcaptureemissionsfromthefurnacesurface(primaryemissions)andfromthetaphole(tappingandancillaryoperations).Providediagramsandbriefdescriptionstofullyexplainconfigurations.74/21/2010EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTS3.ControlDeviceDetailsCompleteTable3Cwithinformationonanyairpollutioncontrolequipment.Emissionspointsexhaustingtothesamecontroldevicemaybegrouped.Ifyouhaveanydatashowinganyvariationincontroldeviceefficiencyovertime,pleaseattachit.4.LadlePost-ProcessingCaptureandControlDoyouperformanypost-tapladleprocessing?1YesNoIfyes,pleaseprovideanarrativedescriptionoftheprocessanddetailsofanyassociatedcaptureandcontrolequipment.SomeofproductFeMnisrefinedtoproducemediumorlowcarbonFeMn.CapturesystemisMORBaghouse.5.OtherEmissionReductionsDescribeanyworkpracticesorpollutionpreventionmeasuresyouhaveimplementedwhichresultinHAPreductions.PleaseprovideanydataorcalculationsyouhavewhichquantifythereductionsNone.PARTIV.MONITORINGSYSTEMSMonitoringSummaryCompleteTable4Awithdetailsofroutineparametermonitoringperformedforcontroldeviceperformanceindicators.Emissionpointsforwhichmonitoringperformedissimilarmaybegrouped.Makecopiesofthetableasneeded.ProvidedetailsforanyopacitymonitoringinTable4B,includinguncontrolledemissionpoints,suchasroofvents.2.VisibleEmissionsMonitoringTestReportsIfyouconductroutinevisibleemissions(Method22orMethod9)monitoringofthefurnacebuildingroofmonitorand/orcontroldeviceoutlettodemonstratecompliancewiththesubpartYYYYYYareasourcestandards,submitcopiesofthecompliancereportsforthelast12months(ifapplicable).PARTV.HAZARDOUSAIRPOLLUTANT(HAP)EMISSIONS1.PointSourceModelingDataForeachemissionpointthatisapointsource(e.g.,stackfrombaghouse),completeTables5A(forcontrolledemissionpoints)and5B(foruncontrolledemissionpoints)indicatingthelatitudeandlongitudecoordinates,height,diameter,velocityofflow,temperatureoftheoutputstream,andnatureoftheemissions(i.e.,continuousorvariedovertime).Iftheemissionsarevaried,indicatehowtheemissionsvaryovertimeifknown.84/2I’2010EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTS2.Non-PointModelingDataForeachemissionpointthatisanonpointsource(e.g.,fugitiveemissions),completeTable5C.Eachnonpointsourceshouldbedefinedasarectangulararea.ForTable5C,indicatethesouthwestcornerlatitudeandlongitudecoordinatesofthedefinednonpointsourcearea,thereleaseheight,lengthandwidthdimensions,angleofrotation,andnatureoftheemissions.NotesonModelingData:Coordinates:Forgeographiccoordinates,provideeitherlatitudeandlongitudeorUTMcoordinateswithzone.Latitudeandlongitudeshouldbeprovidedindecimaldegrees,with6digitstorightofdecimalpoint,andanindicationoftheassociatedNAD(NorthAmericanDatum,EitherNAD27orNAD83.Ifleftblank,NAD83willbeassumed.)Latitude:measureindecimaldegreesoftheangulardistanceonameridiannorthorsouthoftheequator.Positive(+)datapointforNAmerica.Include(+)sign,Ex.+78.123456.Forpointsourcesthisrepresentsthecenterofthesource;forfugitivesourcesthisisthesouthwestcornerifthefugitiveangleiszero,orthewesternmostcornerifthefugitiveangleisgreaterthanzero.Longitude:measureindecimaldegreesoftheangulardistanceonameridianeastorwestoftheprimemeridian.Negative(-)datapointforNAmerica.Include(-)sign,Ex.-123.234561.Forpointsourcesthisrepresentsthecenterofthesource;forfugitivesourcesthisisthesouthwestcornerifthefugitiveangleiszero,orthewesternmostcornerifthefugitiveangleisgreaterthanzero.AngleofRotation:Angleofrotationspecifiestherotationofthesourcefromnorth(intheclockwisedirection).Thelocationcoordinates(UTMorlatitudeandlongitude)shouldreflectthesouthwestcorneroftheareasource.Thex-dimensionshouldreflectthelengthofthesourceintheeasterlydirection,orinthesoutheasterlydirectionifthesourceisrotated.They-dimensionshouldreflectthelengthinthenortherlydirection,orthenortheasterlydirectionifthesourceisrotated.3.SpeciatedHAPandTotalParticulateMatter(PM)EmissionsCompleteTables5Dand5EforeachemissionpointindicatedinTables5A,5B,and5C.Foreachemissionpoint,indicatethetotalactualandallowableemissionsandconcentrationofeachindividualHAPemitted(seeAppendixAforEPA’slistofHAP5),andthetotalactualandallowableemissionsandconcentrationofparticulatematter.Provideexplanationsforthebasisofspeciatedemissions.Identifytheappropriateemissionpointsusingthesameterminology/codesyouusedinpreparingtheprocessflowdiagram(s)forSection11-2,above.4.HAPinEmissionStreamsCompleteTable5Fforeachemissionpointandprocess,withcapture,control,andemissionsinformationforeachemissionstreamidentifiedinTables5A,5B,and5C,withthefollowingconsiderations:C)4/21/2010EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTS1.Columns1-3and11-13ofTable5Fmustbecompletedforallsources;2.Completecolumns4-7ofTable5Fforallsourceswithcapturesystems(e.g.,hoods);3.Completecolumns8-10ofTable5Fforallsourceswithairpollutioncontrolsystems(e.g.,baghouses);4.ProvideHAPdataonlyforthoseHAPsidentifiedinTable50,above;5.IthasbeenassumedthatHAPwillbeprimarilyinparticulateform.IfsignificantvolatileHAPareemitted,includethemincolumn13,withanoteoftheunitsused.Provideexplanationsforthebasisofspeciatedemissions.6.ForthoseemissionpointsfromunitswithResourceConservationandRecoveryAct(RCRA)PartBpermits,itisnotnecessarytocompleteTable5Fforwastewaterandsolidwastehandlingoperations.5.EmissionTestData1.Encloseanypreviouslyconductedtestreports,chlorinecontentofcoalanalyses,orbaghousedustanalysesconductedtodetermineifyourfacilityisamajorsource.2.Enclosesummariesoftestreportsfromanyemissiontestsconductedonferroalloysproductionprocessesandairpollutioncontroldevices(APCD5)sincetheyear2003.Summariesshouldinclude:•Pollutantsandemissionratesmeasured;•Thetestmethodorprocedureused;•Informationonactualferroalloyproductionprocessconditionsatthetimethemeasurementsweremade;•IfthetestswereconductedonoutletstreamsofAPCD5,theAPCDoperatingconditions;and•Anyanalysesthathavebeenperformedoncompositionofbaghousecatch.6.CalculationsandTestReportsForcalculationsbasedonemissionfactors,materialbalances,orengineeringprinciples,submitastep-bystepdescriptionofthecalculations,includingassumptionsused,andabriefrationaleforthevalidityofthecalculationmethodused.Iftestreportsarelistedasthebasisforemissionsestimatesorcapturesystemandcontroldeviceefficiencies,includecopiesoftheemissiontestresults(asdescribedabove.)PARTVI.COSTDATA1.FabricFilterCosts104/21/2010

# EPA INFORMATION

COLLECTION

REQUEST

FOR FERROALLOYS

PRODUCTION MANUFACTURING

EMISSION

POINTS Complete

Table

6A providing

annual

costs

for operating

and maintaining

EAF fabric

filter control

devices

(i.e., positive pressure baghouses). 2. Scrubber

Costs Complete

Table

68 providing

annual

costs

for operating

and maintaining

EAF

wet scrubbers. PART

VII. STARTUP

AND SHUTDOWN Please

provide

the following information

for operations

during

startup

and shutdown.

Attach additional

pages

if necessary. 1. Startup

and Shutdown Information A. Please

indicate

number

of times

over

the

last three

years

that shutdown

and start-up event

has occurred:

11 B. Complete

Table

7 for each shutdown

and start-up

event occurring

over

the

last three

years. 2. Procedures List what procedures

are followed

or any activities

that occur

during

startup

and shutdown. Refer

to Attachment

3- 

# Startup, Shutdown

and Malfunction

Plan. 3. Emissions

Profile Is the emission

profile

of the process

units different

during

startup

and shutdown

than during

normal operating conditions?

Is there

a temporary

change

to the emission

profile of the furnace

when starting

a new furnace,

one

with

a cleaned-out

hearth,

or one

with

a cold hearth

after

a long shutdown?

(If the answer

is yes, please

explain,

in detail,

how emissions

are different

during

or after startup

and shutdown

and

why. Please

also provide

any information

that supports

your response

to this question.) Facility

has

no test

data

to indicate

the emission

profile

is different

during

startup

and shutdown.

11 4/2I/2010EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTS4TestDataDoyouhavetestdatathatshowemissionsduringstartuporshutdown?IIYesNoIfyes,whendidyouconductsuchtestingandwhy?NotApplicable.Whatwerethetestconditionsatthetimeoftesting?NotApplicable.Werethetestsassociatedwitharoutinestartuporshutdown?NotApplicable.Pleasesubmitanytestdatayouhavecollectedduringanystartuporshutdown.5.StartupandShutdownPlanPleasesubmitacopyofyourstart-upandshutdownplanifyouarerequiredtodevelopone.6.StartupandShutdownReportsAreyourequiredtosubmitperiodicandimmediatestart-upandshutdownreports(eitherstand-aloneorcontainedwithintheperiodicexcessemissionsreport)toyourpermittingauthority?E1YesDNoPARTVIII.MISCELLANEOUS1.FuturePlansDescribeanyfutureworkpracticeorpollutionpreventionmeasuresyouareconsideringwhichmayresultinemissionreductions.NewbaghouseonEAC#1Furnacetoreplaceagingscrubbers.124/21/2010

# EPA INFORMATION

COLLECTION

REQUEST

FOR FERROALLOYS

PRODUCTION MANUFACTURING

EMISSION

POINTS 2.

New Source

Review If any control

or process

change

you have performed

was instituted

as

a result

of new source

review requirements

pursuant

to

40 CFR

Part

51, Subpart

I, Review of New Sources

and Modifications,

provide

the date

at which

the lowest achievable

emission

rate (LAER)

came

into effect: Not Applicable. 3. Fugitive

Dust Sources Fugitive

dust sources discharge

particles

to the atmosphere

due

to wind

or mechanical inducement

such

as vehicle

traffic,

and

may include

plant roadways,

yard areas,

and outdoor

material

storage

and transfer operations. Describe

any measures

that

are employed

by your facility

to control

fugitive

dust

from such sources.

Include description

of any written

fugitive

dust control

plans,

and

any recordkeeping

activities associated

with fugitive

dust control. Roads

and storage

pile areas

are inspected

and watered

as needed. 4.

Other

Issues Describe

any factors

not addressed

in the above questions

that might

serve

to distinguish

your facility

from others

in this source category

for purposes

of developing

a separate

source category

or subcategory

and maximum

available

control technology (MACT) standards. None.

13 4/2

1/20

10Submitted

to Mr. Roberto

Morales

as CBI (Confidential

Business Information)

Page

15EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTSAPPENDIXA:EPA’sLISTOFHAZARDOUSAIRPOLLUTANTS(HAP)CASNumberChemicalNameAntimonyCompoundsArsenicCompounds(inorganicincludingarsine)BerylliumCompoundsCadmiumCompoundsChromiumCompoundsCobaltCompoundsCokeOvenEmissionsCyanideCompoundsGlycolethersLeadCompoundsManganeseCompoundsMercuryCompoundsFinemineralfibersNickelCompoundsPolycyclicOrganicMatterRadionuclides(includingradon)SeleniumCompounds5714711-Dimethylhydrazine790051,1,2-Trichloroethane793451,1,22-Tetrachloroethane961281,2-Dibromo-3-chloropropane1226671,2-Diphenylhydrazine1068871,2-Epoxybutane755581,2-Propylenimine(2-Methylaziridine)N/A1,2,3,4,5,6-Hexachlorocyclohexane(allstereoisomers,includinglindane)1208211,2,4-Trichlorobenzene10699013-Butadiene54275613-Dichloropropene112071413-Propanesultone1064671,4-Dichlorobenzene12391114-Dioxane(1,4-Diethyleneoxide)539632-Acetylaminofluorene5322742-Chloroacetophenone794692-Nitropropane5408412,24-Trimethylpentane17460162378-Tetrachlorodibenzo-p-dioxin9475724-D(2,4-DichlorophenoxyaceticAcid)(includingsaltsandesters)512852,4-Dinitrophenol12114224-Dinitrotoluene5848492,4-Toluenediisocyanate959542,45-Trichlorophenol8806224,6-Trichlorophenol414/21/2010EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTSCASNumberChemicalName919413,3-Dichlorobenzidine1199043,3’-Dimethoxybenzidine1199373,3-Dimethylbenzidine926714-Aminobiphenyl601174-Dimethylaminoazobenzene929334-Nitrobiphenyl1000274-Nitrophenol1011444,4-Methylenebis(2-chloroaniline)10177944-Methylenedianiline1016884,4’-Methylenediphenyldiisocyanate(MDI)5345214,6-Dinitro-o-cresol(includingsalts)75070Acetaldehyde60355Acetamide75058Acetonitrile98862Acetophenone107028Acrolein79061Acrylamide79107Acrylicacid107131Acrylonitrile107051Allylchloride62533Aniline1332214Asbestos71432Benzene(includingbenzenefromgasoline)92875Benzidine98077Benzotrichloride100447Benzylchloride57578beta-Propiolactone92524Biphenyl117817Bis(2-ethylhexyl)phthalate(DEHP)542881Bis(chloromeyj)ether75252Bromoform156627Calciumcyanamide105602Caprolactam(Removed6/18/9661FR30816)133062Captan63252Carbaryl75150Carbondisulfide56235Carbontetrachloride463581Carbonylsulfide120809Catechol133904Chloramben57749Chlordane7782505Chlorine79118Chloroaceticacid108907Chlorobenzene510156Chlorobenzilate67663Chloroform424/21’2O1()EPA INFORMATION

COLLECTION

REQUEST

FOR FERROALLOYS

PRODUCTION MANUFACTURING

EMISSION

POINTS CAS Number

Chemical

Name 107302

Chloromethyl

methyl

ether 126998

Chloroprene 1319773 Cresol/Cresylicacid(mixedisomers) 98828

Cumene 3547044

DDE(1

1 -dichloro-2,2-bis(p-chlorophenyl)ethylene) 334883

Diazomethane 132649

Dibenzofuran 84742 Dibutylphthalate 1

1 1444 Dichloroethylether(Bis[2-chloroethyl]ether) 62737

Dichlorvos 111422 Diethanolamine 64675

Diethylsulfate 131

113 Dimethylphthalate 77781 Dimethylsulfate 79447 Dimethylcarbamoylchloride 106898 Epichlorohydrin(I-Chloro-2,

3-epoxypropane) 140885

Ethylacrylate 51796 Ethylcarbamate(Urethane) 75003 Ethylchloride(Chloroethane) 100414

Ethylbenzene 107062 Ethylenebichloride(1

,2-Dichloroethane) 106934 Ethylenedibromide(Dibromoethane) 107211

Ethylene

glycol 75218

Ethylene

oxide 96457

Ethylene

thiourea 151564 Ethyleneimine(Aziridine) 75343 Ethylidenedichloride(1

1 -Dichloroethane) 50000 Formaldehyde 76448

Heptachlor 118741 Hexachlorobenzene 87683 Hexachlorobutadiene 77474 Hexachlorocyclopentadiene 67721 Hexachloroethane 822060 Hexamethylenediisocyanate 680319 Hexamethylphosphoramide 110543

Hexane 302012

Hydrazine 7647010 Hydrochloricacid (HydrogenChloride) 7664393 Hydrogenfluoride

(Hydrofluoricacid) 123319

Hydroguinone 78591

Isophorone 58899

Lindane 108394

m-Cresol 108383

m-Xylene 108316

Maleic anhydride 67561

Methanol

9.._, 4/21/2010

# EPA INFORMATION

COLLECTION

REQUEST

FOR FERROALLOYS

PRODUCTION MANUFACTURING

EMISSION

POINTS CAS Number

Chemical

Name 72435

Methoxychlor 74839 Methylbromide(Bromomethane) 74873 Methylchloride(Chloromethane) 71556 Methylchloroform(

1,1

1 -Trichloroethane) 78933 Methylethylketone(2-Butan

one) 74884 Methyliodide(Iodomethane) 108101 Methylisobutylketone(Hexone) 624839 Methylisocyanate 80626 Methylmethacrylate 1634044 Methyltert-butylether 75092 Methylenechloride(Dichloromethane) 60344 Methylhydrazine 684935 N-Nitroso-N-methylurea 62759 N-Nitrosodimethylamine 59892 N-Nitrosomorpholine 91203

Naphthalene 98953

Nitrobenzene 121697 N,N-Dimethylaniline 68122 N,N-Dimethylformamide 90040

o-Anisidine 95487

o-Cresol 95534

o-Toluidine 95476

o-Xylene 106445

p-Cresol 106503 p-Phenylenediamine 106423

p-Xylene 56382

Parathion 82688 Pentachloronitrobenzene(Quintobenzene) 87865 Pentachlorophenol 108952

Phenol 75445

Phosgene 7803512

Phosphine 7723140

Phosphorus 85449 Phthalicanhydride 1336363 Polychlorinatedbiphenyls(Aroclors) 123386 Propionaldehyde 114261 Propoxur(Baygon) 78875 Propylenebichloride(1

2-Dichioropropane) 75569 Propyleneoxide 91225

Quinoline 106514 Quinone(p-Benzoguinone) 100425

Styrene 96093

Styreneoxide 127184 Tetrachloroethylene(Perchloroethylene) 7550450 Titaniumtetrachloride 108883

Toluene

44 4/21/201()

# EPA INFORMATION

COLLECTION

REQUEST

FOR FERROALLOYS

PRODUCTION MANUFACTURING

EMISSION

POINTS CAS Number

Chemical

Name 95807 Toluene-2,4-diamine 8001352 Toxaphene(chlorinatedcamphene) 79016 Trichloroethylene 121448

Triethylamine 1582098

Trifluralin 108054

Vinylacetate 593602

Vinylbromide 75014

Vinylchloride 75354 Vinylidenechloride(1

1 -Dichloroethylene) 1330207 Xylenes(mixedisomers)

45 4/21/2010

# EPA INFORMATION

COLLECTION

REQUEST

FOR FERROALLOYS

PRODUCTION MANUFACTURING

EMISSION

POINTS APPENDIX

B: SAMPLE RESPONSES

FOR INFORMATION

REQUEST I. Sample

Process

Flow Diagram STACK

1

4 BAGHOUSE

1

Z

SI-tiI



# LEGEND:

4EI1ISSIONSTREAM/-(i) 

# FUGITIVES

1

I—, 

# HOOD______CONTROLDEVICE 

# A

AEMISSIONPOINTID 

# EAF1I



# COOL1

IPRODUCTIONUNiTCAPTURESYSTEMOR 

# ELECTRIC

ARC

TAPPING

1

COOLINGDEVICE 

# FURNACE

1

Figure

1: Sample

Process

Flow Diagram (Note:

For illustration

only,

not

a complete

sample) II. Example

narrative responses

for Table

3B Primary Emissions

Capture Furnace

3 has

a suspended

circular

canopy

hood

for capturing

furnace emissions.

The hood

is constructed

of 1/4’ carbon

steel material.

Both furnace emissions

and tapping emissions

are ducted

to baghouse

number

3. The branch

duct

size

is eight

feet

in diameter

while

the main duct

to the baghouse

is ten

feet

in diameter.

A schematic

for

the hood configuration

is attached. The canopy

hood

is enclosed

by

a refractory

ceramic

fiber curtain suspended

in

a two inch-wide frame

to minimize

fugitive emissions.

A series

of panels

were omitted

to create

an approximately

15-foot-wide

opening

for furnace

access.

The curtain

is

on

a monorail

that permits

the opening

to

be rotated

so that

the furnace

can

be charged

and stoked

from various points

around

the furnace.

A damper

located downstream

of the canopy

hood

is used

to adjust the draft applied

and consequently

flow

rate. Tapping Emissions

Capture Tapping emissions

are captured

by

a square side-draft

tapping

hood located

above

the

tap hole. The hood

was modified

a year

ago

with

two slotted openings

to improve

the capture efficiency Both

the tapping emission

and furnace emissions

are ducted

to baghouse

number

3. The 46 4i’21/2010

# EPA INFORMATION

COLLECTION

REQUEST

FOR FERROALLOYS

PRODUCTION MANUFACTURING

EMISSION

POINTS branch

duct

size

is four

feet

in diameter

and

is joined

with

the main

duct.

A schematic

for

the hood configuration

is attached.

This

hood

has damper openings

and

can

be opened

and closed as needed

to accomplish

capture

of tapping

fume

as

it occurs. Ill. Notes

on Modeling Parameters

for Positive Pressure Baghouses For positive pressure baghouses,

height

should

be listed

as the height

of the roof monitor

above ground.

Velocity

may

be taken

from

past

test reports. Equivalent

diameter

of rectangular

cross sections

may

be calculated

using Equation

1-1 from USEPA

Method

1:‘‘i=



# 1.-



# 1-1 47 4/21/2010ManufacturingEmissionPointsSection2A,PlantOperationsSubmittedtoMr.RobertoMoralesasCBI(ConfidentialBusinessInformation)Page15Manufacturing

Emission

Points Section

2

B, Plant Operations Submitted

to Mr. Roberto

Morales

as CBI (Confidential

Business Information)

Page

15

# Table

2C: Furnace

Tapping Information Make additional

copies

as needed. Unit Operation

Duration

of Process

Brief narrative description

of Frequency

of typical Tapping Diagram

ID

(a)

tapping

process

Tapping

Event TAP1

Carbon

plug

is removed

and

4 times

daily

15

mm product

is tapped

into ladle P901

Carbon

plug removed/tapped

in

12

15-20 minutes ladle P908

Carbon

plug removed/tapped

in

12

15-20 minutes ladle P909

Carbon

plug removed/tapped

in

12

15-20 minutes ladle (a) Pase

use

the same

ID

as used

in the process

flow diagram. Sample

row

is shaded Ferroalloys

Production Manufacturing

Emission

Points

Survey Page

20 EPA INFORMATION

COLLECTION

REQUEST

FOR FERROALLOYS PRODUCTION MANUFACTURING

EMISSION

POINTS SECTICN:2. .:pLANiQpETIO4S

H::

8/13/2010Manufacturing

Emission

Points Section

2D, Plant Operations Submitted

to Mr. Roberto

Morales

as CBI (Confidential

Business Information)

Page

15

# Manufacturing

Emission

Points Section

2E, Plant Operations Submitted

to Mr. Roberto

Morales

as CBI (Confidential

Business Information)

Page

15

# EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS

SECTION 3. CAPTURE & CONTROL

Table 3A: Air Pollution VentilationlCapture System Parameters (Excluding Furnaces)

Make additional cooies as needed.

Emission Point Emission Point Emission Point Emission Point Emission Point Emission Point

(ab) (a,b) (ab) (ab) (ab) (a,b)

VentilationlCapture System E4

Local Ventilation System used: P917E1 P917-E2 P917-E3

Airflow (scfm) 

# Fan(X) () () () () ()

Other (Specify) 

# ( ) ( ) ( ) ( ) (

Building Ventilation

Airflow (scfm)

Building Identification 

# ( ) ( ) ( ) ( ) (

Open Roof Monitor

- 

# Natural Ventilation 

# ( ) ( x 

# ) ( x 

# ) ( x 

# ) (

Other (Specify) (X) 3 powered roof 

# (

)______________ 

# (

)_____________ 

# (

)_____________ 

# (

ventilators

Enclosure or Hood Design:

Airflow (scfm) 44,254 46,026 57,249

Complete Enclosure 

# ( ) ( ) ( ) ( ) (

Closed Hood 

# ( ) ( ) ( ) ( ) (

Canopy or Suspended Hood (X) 

# ( x) 

# ( x) 

# ( x) 

# (

Distance of hood from source

Other (Specify) 

# ( ) ( 

# ) ( ) ( 

# ) (

Airflow Control System:



# Air Curtain ( ) ( ) ( ) ( ) ( ) (

Drop Curtain Bafflingj( 

# ) ( ) ( ) ( ) (

Curtain or Baffling Material 

# ( ) ( ) ( ) ( ) ( )

Ductwork(X) (x) (x) (x) 

# ( ) (

Other (Specify)I 

# ( ) ( 

# ) ( ) ( ) ( )

(a) Please use the same ID as used in the process flow diagram.

(b) Emissions points using the same capture systems may be grouped. Different emission points using the same capture system may be sent to the same control device,

and/or a single emission point may send emissions to 2 or more capture systems (control devices).

Sample column is shaded

Ferroalloys Production Manufacturing Emission Points Survey

Page 27 8/13/2010

# ::EPA INFORMATICN COLLECTION REQUEST 

# FORFEROALLOYSPRODUCTION MANUFACTLJ:R1NG 

# EM15S1ON:FQ1NT:S

SECTION 3 CAPTURE & 

# CONTROL

Table 3A: Air Pollution Ventilation/Capture System Parameters (Excluding Furnaces)

Make additional cooies as needed.

Emission Point Emission Point Emission Point Emission Point Emission Point Emission Point

(ab) (a,b) (ab) (a,b) (a,b) (ab)

Ventilation/Capture System E4

Local Ventilation System used: F014-E3 F014-E4a F014-E4

Airflow (scfm)

Fan(X) (x) (x) (x) 

# ( ) ( )

Other (Specify) 

# ( ) ( ) ( ) ( )

(__________________ 

# Building Ventilation

Airflow (scfm)

Building Identification 

# ( ) ( ) ( ) ( ) (

Open Roof Monitor

- 

# Natural Ventilation 

# ( ) ( x 

# ) ( x) 

# ( x) 

# (

Other (Specify) (X) 3 powered roof 

# (

)______________ 

# (

)______________ 

# (

)______________ 

# (

ventilators

Enclosure or Hood Design:

Airflow (scfm) 12,048 23,970 19,097

Complete Enclosure 

# ( ) ( ) ( ) ( ) (

Closed Hood 

# ( ) ( ) ( ) ( ) (

Canopy or Suspended Hood (X) 

# ( x) 

# ( x) 

# ( x) 

# (

Distance of hood from source

Other (Specify) 

# ( ) ( ) ( ) ( ) (

Airflow Control System:

Air Curtain 

# ( ) ( ) ( ) ( ) ( )

Drop Curtain Bafflingf( 

# ) ( ) ( ) ( ) ( )

Curtain or Baffling Material 

# ( ) ( ) ( ) ( ) ( )

Ductwork(X) (x) (x) (x) 

# ( ) ( )

Other (Specify)j 

# ( ) ( ) ( ) ( ) ( )

(a) Please use the same ID as used in the process flow diagram.

(b) Emissions points using the same capture systems may be grouped. Different emission points using the same capture system may be sent to the same control device,

and/or a single emission point may send emissions to 2 or more capture systems (control

Sample column s shaded

Ferroalloys Production Manufacturing Emission Points Survey

Page 28 8/13/2010EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTSSECTION3CAPTURE&CONTROLTable3B:Primary&TappingEmissionsfromElectricArcFurnaces-CaptureDetailsFurnacespecificinformation(completeworksheetforeachfurnace).FurnaceSpecificationsFurnaceProcessDiagramID(a)P901-EAF#1PrimaryEmissionsCapture___________________________________________________________________NarrativedescriptionoffurnacehoodconfigurationThehoodiswatercooledandcontainsthree5’by6’ductoff-takeseachpulling1/3ofthehoodthroughmultipleopeningsEstimatedintakeflowis180000Pleaseattachdiagramsifavailableacfm.C31HoodDimensions(ft)(a)CircularHoodDiameter(ft)3775ejJth(ft)(b)RectangularHoodLength(if)NotApplicableWidth(ft)NotApplicableDepth(if)NotApplicableDistancebetweentopoffurnaceandhood(if)4Temperatureoffumeenteringhood(‘F)246(cfm)OO0acfrnPleasedescribethedesignbasisuponwhichtheflowratewasExitflowratedetermined___________________________________________________________________DoesIhflowratevary?YLLNi)IfYes,describefactorswhichcausevariationinflowrateTemperatureandFurnaceBlows.Isthereanenclosure(eg.,curtainordoorpanelsaroundthefurnace)Yes(x)NoIfYes,percentoftotalareasurroundedbyenclosuree.g60%ofhood30%circumference)____________________________________________________________________________Howistheenclosureconstructed?WiremeshChaincurtainCeramiccurtainHydraulicdoor(Other(x)Describe-->SheetMetalDimensionsofopeningsinenclosure(if)NotApplicableDistancebetweentopoffurnaceandcurtain(if)NotApplicableDescribemeasurestakentoensureproperoperationofventilationMonitoringoffanmotoramps,pressuredropofscrubbers,andvisualsystem(e.g.,periodicorcontinuousmonitoringofvolumetricflowrateinobservations,Preventativemaintenanceandsystematicinspections.ductworkdownstreamofcapturehoods,fanpowerconsumptionandpressuredropacrossfans,systematicinspectionanBestestimateof%captureachieved(basedonvisualestimates)9950%AirflowControlDescribeotherairflowcontrolandventilationsystemsBuildinghasroofmonitorsassociatedwiththefurnace.Includebuildingventilation(roofvents,etc.)andotherairflowcontrolsystems(aircurtains,dropcurtainbaffling,etc.)(a)PleaseusethesameIDasusedintheprocessflowdiagramSeesamplepageforexampleresponseFerroalloysProductionManufacturingEmissionPointsSurveyPage298113/2010EPALNFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTSSECTION3CAPTURE&CONTROLTable3B:(Continued)Primary&TappingEmissionsfromElectricArcFurnaces-CaptureDetailsITappingEmissionsCaptureNarrativedescriptionoftaphoodconfigurationTapholehoodislocated5feetabovetapholeandcollecteddustisductedtobaghousethroughahoodthathastwosetsof10slotsmeasuring3-1/4by7PleaseattachdiagramsifavailableHoodDimensions(if)(a)CircularHoodDiameter(if)NotApplicableifpth(ftNotApphcab(b)RectangularHoodLength(if)19Width(if)9Depth(ft)2Tapholediameter(ft)0.5Distancebetweencenteroftapholeandhood(if)6Distancebetweencenteroftapholeandbottomofhood(0)6Diameterofladletappedproductispouredinto(0)8Distancebetweenladleandbottomofhood(if)10Temperatureoffumeenteringhood(SF)120vomwrenterwighooLscfm7(100PleasedescribethedesignbasisuponwhichtheflowratewasStackexitflowrate.determinedDoestF-sflowratevary?YeSFJ(x)IfYes,describefactorswhichcausevariationinflowrateDescribemeasurestakentoensureproperoperationofventilationVisualObservationBestestimateof%captureachieved(basedonvisualestimates)99%OtherCaptureRelatedInformation(useadditionalpagesifneeded)IfyoudonotusecurtainsonorsurroundingthehoodcontrollingprimaryChaincurtainswouldinterferewithstokersusedtodistributemixonthefurnace.emissions,doyouanticipateanyproblemsininstallingandusingthem?Ifso,pleasedescribe.Ifyoudonothaveadedicatedtaphood,doyouanticipateanyproblemsTaphoodpresent.ininstallingandusingsuchahood?Ifso,pleasedescribe.(a)[-‘leaseusethesameIDasusedintheprocessflowdiagram.SeesamplepageforexampleresponseFerroalloysProductionManufacturingLmissionPointsSurveyPage308/13/2010•

EC

10

N.: RE

ES MANUFACTURING

EMISSIONPOINTSSECTION3CAPTURE& CONTROLTable38:Primary&TappingEmissionsfromElectricArcFurnaces-CaptureDetailsFurnacespecificinformation(completeworksheetforeachfurnace).FurnaceSpecificationsFurnaceProcessDiagramID(a)

P908-EAF#12PrimaryEmissionsCapture___________________________________________________________________NarrativedescriptionoffurnacehoodconfigurationHoodhasmultipleopeningstodistributethehoodpull.Thereisa4openingbetweenthefurnaceandhoodtoallowforstoking.PleaseattachdiagramsifavailableHoodDimensions(H)(a)CircularHoodDiameter(H)37.33ejJthft)8(b)RectangularHoodLength(ft)NotApplicableWidth(H)NotApplicableDepth(H)NotApplicableDistancebetweentopoffurnaceandhood(H)4Temperatureoffumeenteringhood(“F)170Vokimetricflowrateenteringhoo(scfm0PleasedescribethedesignbasisuponwhichtheflowratewasExitflowatscrubberstack.determinedDoestNsflowratevary?Yes()No(x)IfYes,describefactorswhichcausevariationinflowrateNotApplicableIsthereanenclosure(eg..curtainordoorpanelsaroundthefurnace)Yes(x)NoIfYes.percentoftotalareasurroundedbyenclosureeg,60%ofhood20%circumference)_____________________________________________________________________________Howistheenclosureconstructed?WiremeshChaincurtainCeramiccurtainHydraulicdoorOther

(x)Describe-->SheetMetalDimensionsofopeningsinenclosure(H)NotApplicableDistancebetweentopoffurnaceandcurtain(ft)NotApplicableDescribemeasurestakentoensureproperoperationofventilationMonitoringoftanmotoramps,scrubberpressuredrop,andvisualobservations.system(ag.,periodicorcontinuousmonitoringofvolumetricflowrateinPreventativemaintenanceandsystematicinspections.ductworkdownstreamofcapturehoods,fanpowerconsumptionandpressuredropacrossfans,systematicinspectionanBestestimateof%captureachieved(basedonvisualestimates)99.50%4irflowControlDescribeotherairflowcontrolandventilationsystemsBuildinghasroofmonitors.associatedwiththefurnace.Includebuildingventilation(roofvents,etc.)andotherairflowcontrolsystems(aircurtains,dropcurtainbaffling,etc.)(a)PleaseusethesameIDasusedintheprocessflowdiagramSeesamplepageforexampleresponseFerroalloysProductionManufacturingEmissionPointsSurveyPage318/13/2010EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTSSECTION3CAPTURE&CONTROLTable38:(Continued)Primary&TappingEmissionsfromElectricArcFurnaces-CaptureDetailsTaooinaEmissionsCaotureNarrativedescriptionoftaphoodconfigurationTapholehoodisa6’by20rectangularshapedhoodwith15evenlyspacedslots.Collectedfumeisductedtoascrubber.PleaseattachdiagramsifavailableHoodDimensions(if)(a)CircularHoodDiameter(if)NotApplicableep!(ttlNotApplicab(b)RectangularHoodLength(if)6Width(ft)20Depth(if)NotApplicableTapholediameter(if)0.5Distancebetweencenteroftapholeandhood(if)Distancebetweencenteroftapholeandbottomofhood(ft)Diameterofladletappedproductispouredinto(ft)8Distancebetweenladleandbottomofhood(if)15Temperatureoffumeenteringhood(°F)Vcumetricflowrateenteringhoo

cstmPleasedescribethedesignbasisuponwhichtheflowratewasEstimateddeterminedDoesthisflowratvary?YUNo(x)IfYes,describefactorswhichcausevariationinflowrateNotApplicableDescribemeasurestakentoensureproperoperationofventilationVisualobservation.Bestestimateof%captureachieved(basedonvisualestimates)99%OtherCaptureRelatedInformation(useadditionalpagesifneeded)IfyoudonotusecurtainsonorsurroundingthehoodcontrollingprimaryChaincurtainswouldinterferewithstokersusedtodistributemixonthefurnace.emissions,doyouanticipateanyproblemsininstallingandusingthem?Ifso,pleasedescribeIfyoudonothaveadedicatedtaphood,doyouanticipateanyproblemsTaphoodpresent.ininstallingandusingsuchahood?Ifso,pleasedescribe(a)PleaseusethesameIDasusedintheprocessflowdiagram.SeesamplepageforexampleresponseFerroalloysProductionManufacturingEmissionPointsSurveyPage328/13/2010:::::::.::::.::::MANUFACTURINGEMISSIONPOINTSSECTION3CAPTURE&CONTROLTable3B:Primary&TappingEmissionsfromElectricArcFurnaces-CaptureDetailsFurnacespecificinformation(completeworksheetforeachfurnace).FurnaceSpecificationsFurnaceProcessDiagramID(a)1P909-EAF#18PrimaryEmissionsCaptureNarrativedescriptionoffurnacehoodconfigurationFurnace#18isasemi-sealedfurnace.EmissionsfromthefurnacearecapturedunderthcoverwhichcompletelyenclosesthefurnacesexceptforanopeningPleaseattachdiagramsifavailablearoundeachelectrodetofeedmixtothefurnace.Make-upairintakeontheeastsideofthecoverandfumeofflakeonthewestsideofthecover.Asmuchas11000scfrncanbedrawnfromunderthecovertowetventurisystem.HoodDimensions(if)(a)CircularHoodDiameter(if)NotApplicableqpth(if3NotAp,plicab(b)RectangularHoodLength(if)NotApplicableWidth(if)NotApplicableDepth(if)NotApplicableDistancebetweentopoffurnaceandhood(if)NotApplicableTemperatureoffumeenteringhood(CF)135Vcumetricflowrateentenghoo(scfmioPleasedescribethedesignbasisuponwhichtheflowratewasExitflowatscrubberstack.determinedDoesthisfiowratevary?jj)q)IfYes,describefactorswhichcausevariationinflowrateNotApplicableIsthereanenclosure(e.g.,curtainordoorpanelsaroundthefurnace)Yes()No(xIfYespercentoftotalareasurroundedbyenclosureeg.50%ofhoodNotApplicablecircumference)Howistheenclosureconstructed?NotApplicableWiremeshChaincurtainCeramiccurtainHydraulicdoorOther()Describe-->Dimensionsofopeningsinenclosure(if)NotApplicableDistancebetweentopoffurnaceandcurtain(if)NotApplicableDescribemeasurestakentoensureproperoperationofventilationMonitorpressuredrop.motoramps,visualobservations,preventativesystem(e.g.,periodicorcontinuousmonitoringofvolumetricflowrateinmaintenance,andsystematicinspections.ductworkdownstreamofcapturehoods,fanpowerconsumptionandpressuredropacrossfans,systematicinspectionandmaintenance,others)Bestestimateof%captureachieved(basedonvisualestimates)99,50%AirflowControl:DescribeotherairflowcontrolandventilationsystemsBuildinghasroofmonitors.FugitiveemissionsescapingthefurnacesareventedassociatedwiththefurnaceIncludebuildingventilation(roofvents,etc.)totheatmosphereby4draftstacks.andotherairflowcontrolsystems(aircurtains,dropcurtainbaffling,etc.)(a)PleaseusethesameIDasusedintheprocessflowdiagramSeesamplepaqeforexampleresponseFerroalloysProductionManufacturingEmissionPointsSurveyPage338/13/2010EPA INFORMATION

COLLECTION

REQUEST

FOR FERROALLOYS

PRODUCTION MANUFACTURING

EMISSION

POINTS SECTION

3 CAPTURE

& CONTROL Table

3B: (Continued)

Primary

& Tapping Emissions

from Electric

Arc Furnaces- Capture

Details Tapping Emissions

Capture Narrative description

of tap hood configuration

Rectangular

hood located

above taphole Please

attach diagrams

if available Hood Dimensions

(ft) (a) Circular

Hood

Diameter

(tt)

Not Applicable epthtft)

ppb (b) Rectangular

Hood

Length

(ft)

8 Width

(ft)

6 Depth

(ft)

Not Applicable Tap

hole diameter

(ft)

0.5 Distance

between

center

of tap hole

and hood

(ft)

6 Distance

between

center

of tap hole

and bottom

of hood

(5)

6 Diameter

of ladle tapped

product

is poured

into

(5)

8 Distance

between

ladle

and bottom

of hood

(ft)

10 Temperature

of fume entering

hood

(F)

Unknown Vcurnetrlc

flow

rate entering

hoo

(scfm

unkno Please describe

the design

basis

upon

which

the

flow

rate

was

N/A determined Does

tNs

flow

rate vary?

iJ9__Q_) If Yes, describe

factors

which

cause variation

in flow

rate Describe measures

taken

to ensure

proper operation

of ventilation

Visual observation

during

tapping Best estimate

of

% capture achieved

(based

on visual estimates)

99 Other Capture

Related Information

(use additional

pages

if needed) If you

do

not

use curtains

on

or surrounding

the hood controlling

primary

N/A emissions,

do you anticipate

any problems

in installing

and using them? If so, please describe. If you

do

not have

a dedicated

tap hood,

do you anticipate

any problems

N/A in installing

and using

such

a hood?

If so, please describe. (a) Please

use

the same

ID

as used

in the process

flow diagram. See sample

page

for example

response

Ferroalloys

Production Manufacturing

Emission

Points

Survey Page

34

8/13/2010I.MANUFACTURINGEMISSIONPOINTSSECTION3CAPTURE&CONTROLTable3B:Primary&TappingEmissions-CaptureDetailsSAMPLE-DONOTUSETHISPAGEFurnacespecificinformation(completeworksheetforeachfurnace).FurnaceProcessDiagramID(a)IEAF1PrimaryEmissionsCapture________________________________________________________________NarrativedescriptionoffurnacehoodconfigurationSeeExampleinAppendixBPleaseattachdiagramsifavailableHoodDimensions(ft)(a)CircularHoodDiameter(ft)15epth(ft6(b)RectangularHoodLength(ft)Width(ft)Depth_(ft)___________________________________________________________Distancebetweentopoffurnaceandhood(ft)15TemperatureoffumeenteringhoodF)500VoIymcowrateentennghoo(cr)19QQ2.0*—.-——PleasedescribethedesignbasisuponwhichtheflowratewasEngineeringestimate(Calculationsshouldbeattached))determined________________________________________________________________________Doesthisflowratevary9Yes(NoX)—IfYes,describefactorswhichcausevariationinflowrateIsthereanenclosure(e.g.,curtainordoorpanelsaroundthefurnace)Yes(X)NoIfYes,percentoftotalareasurroundedbyenclosure(e.g.,60%ofhood70%circumference)____________________________________________________________________Howistheenclosureconstructed?WiremeshChaincurtainCeramiccurtain(XHydraulicdoorOther()Describe-->Dimensionsofopeningsinenclosure(ft)15Distancebetweentopoffurnaceandcurtain(ft)5DescribemeasurestakentoensureproperoperationofventilationMonthlymaintenance,continuousmonitoringofvolumetricflowrateinductworksystem(e.g.,periodicorcontinuousmonitoringofvolumetricflowrateindownstreamfromhood.ductworkdownstreamofcapturehoods,fanpowerconsumptionandpressuredropacrossfans.systematicinspectionandiriairileiiariceothers)Bestestimateof%captureachieved(basedonvisualestimates)90%AirflowControl.DescribeotherairflowcontrolandventilationsystemsRootventsassociatedwiththefurnaceIncludebuildingventilation(roofvents.etc.)andotherairflowcontrolsystems(aircurtainsdropcurtainbaffling.etc.)FerroalloysProductionManufacturingEmissionPointsSurveyPage35FurnaceSpecifications8/13/2010EPAINFORMATION CCLLEC11.ON..REQUE:.:STF0MANUFACTURINGEMISSIONPOINTSSECTION3CAPTURE&CONTROLTable3B:(Continued)Primary&TappingEmissions-CaptureDetailsTappingEmissionsCapture________________________________________________________________NarrativedescriptionoftaphoodconfigurationSeeExampleinAppendixBPleaseattachdiagramsifavailableHoodDimensions(H)(a)CircularHoodDiameter(ft)15e2t?(tt6(b)RectangularHoodLength(tt)Width(H)Depth_(ft)_______________________________________________________________________Tapholediameter(ft)3Distancebetweencenteroftapholeandhood(ft)10Distancebetweencenteroftapholeandbottomofhood(ft)6Diameterofladletappedproductispouredinto(ft)10Distancebetweenladleandbottomofhood(H)5Temperatureoftumeenteringhood(F)500(scfmioooooPleasedescribethedesignbasisuponwhichtheflowratewasEngineeringestimate(Calculationsshouldbeattached))determinedDoevary7Ye(Jo(jIfYes,describefactorswhichcausevariationinflowrateDescribemeasurestakentoensureproperoperationofventilationMonthlymaintenanceBestestimateof%captureachieved(basedonvisualestimates)50%OtherCaptureRelatedInformationfuseadditionalpaqesifneeded)___________________________________________________________________Ifyoudonotusecurtainsonorsurroundingthehoodcontrollingprimaryemissions,doyouanticipateanyproblemsininstallingandusingthem2Ifso.pleasedescribe.Ifyoudonothaveadedicatedtaphood,doyouanticipateanyproblemsinnstailingandusingsuchahood?Ifso,pleasedescribe.(a)PleaseusethesameIDasusedintheprocessflowdiagram.FerroalloysProductionManufacturingEmissionPointsSurveyPage368/13/2010rroiilcy Pruducicrn Manufacturing

Emiccii,ri

Points

Su

vsv

8it 312010 Pago

38 (a) Please

use

the same

lOgs

used

in the process

flow diagram IbI Emissions

points

using

the same control systems

may

be grouped

Different

emission

points

using

the same capture

system

may

be sent

to the same control

device,

avdlor

a single emission

point

may

send emissions

to

2

or more capture

systems

(control

devices) (C) Provide documentation

of the basis

for equipment

parameters

)oev’gn

actual

etc) )d) Provide

copies

of estimation workshents

or other docurrtentation

of the basis

for emission

estimatesEPAINFORMATIONCOLLECTable4A:AirPollutionControlDeviceParameterMIncludeallparametersoractivitieswhicharemonitoredorforwhichrecordsa:ControlSystem&PerformanceIndicatingParametersMonitored(abc)BaghouseEmissionPoints:P901-92,P9091F012-E2,P917-El,P917-E2,P917-E3,F014E3,F014-E4,F014-E4A.PressureDifferentialAcrossBaghousInletGasTemperaturTemperatureDitterentisExhaustGasFlowRatCleaningMechanismOperatioFanCurrenInspections&MaintenancFerroalloysProduclionManufacturingEmissionPointsSurveyPage39YesNoandVisibleEmissionsmonitorinc’shouldbedetailedinTable481-requencyorOutletPMConcentration(CEM--.BagLeakDetectorxPressureDifferentialAcrossCellOther)P901-BHI-ElecironicPLCwithstriprecorderP917-El.92,E3andF014-E394,E4A-MagnahelicgaugemanuallyreadandrecordedP909/FOl2-E2recordedlhroughcomputermonitoringsystem,manualrecordsalsomaintainedInchesWaterContinuousx0x5x50controlDeviceID:ScrubberEmissionPoints:P901-El,P908-El,P909-ElPressureDitferentiahasWaterontinuouonitoredbycomputersystem.LiquidFlowRatxGasFlowRatexScrubberInletGasTemperaturaagreesFContinuousMonitoredbycomputersystem-ScrubberOutletGasTemperaturxMakeup/blowdownratScrubberLiquidSolidsContenx—ScrubberLiquidp1x—NeutralizingChemicalFeedRatScrubberLiquidSpecificGravit0Other)(—ontroIDeviceID:ElectrostaticPrecipitatorEmissionPoints:OutletPMConcentratioiSecondaryCoronaPower(Current&Voltagi(SparkRatePrimaryPower(Current&Voltage-InletGasTemperatur:GasFlowRateRapperOperatiorFieldsinOperatioiInletWaterFlowRate(WetTypeFlushWaterSolidsContent(WetTypeOther(—ControlDeviceID:CycloneEmissionPoints:InletVelocityorInletGasFlowRat—___________PressureDifferentiaInletGasTemperatunOther(Makecopiesasneeded(a)PleaseusethesameIDasusedintheprocess110wdiagram(b)Providedocumentationofthebasinforequipmentparameters(designactualetc(c(ProvidecopiesofestimationworksheetsorotherdocumentationofIhebasisforemissionestimatesSeesamplepageforexamplerespoirse8/1312010Makecopiesasneeded(a)PleaseusethesameIDasusedintheprocessflowdiagram(b)Providedocumentationofthebasisforequipmentparameters(design,actual,etc(C)ProvidecopiesofestimationworKsheetsorotherdocunientatiunofthebasisforemissionestimatesFerroalioysProduciionManufacturingEmissisePointsSurveyPage40EPAINFORMATIONCOLLECTIONREQUESTFORFERROALLOYSPRODUCTIONMANUFACTURINGEMISSIONPOINTSSECTION4MONITORINGTable4A:AirPollutionControlDeviceParameterMonitoring(Includesectionsasneeded)SAMPLE-DONOTUSETHISPAGEIncludeallparametersoractivAeswhich--forwhichrecordsaremaintainedOoacitvandVisibleEmissionsmonitorinoshouldbedetailedinTable4RMonitored?UnitsFrequencyofControlSystem&PerformanceIndicatingParametersMonitored(abc)YesNoMeasuredMonitoringMonitoringMethodDescribeQualityAssuranceControlDevice:BaghousoEmissionPoints:El,E2,E3OutletPMConcentration(CEM)X.,BagLeakDetectorsXContinuousContinuousmonitot’RegularmaintenancePressureDifferentialAcrossCellsXPressureDillerentialAcrossBaghouseXinH20ContinOtisCordwiuousmonitor...RegutarmaintenanceInletGasTemperatureXdeyFContinuouCot,s.tiocegularmaintenanceTemperatureDrfterenffalX.—.—.ExhaustGasFlowRateXCleaningMechanismOperationX—FanCurrentXInspections&MaintenanceXMawrlenancerecordsmaintainedVisibleEmissionsMonilonng(Method9OpacityorMethod22yE)tXpercentDailyMethod22Other)ControlDevice:ScrubberEmissionPoints:PressureDifferentialLiquidFlowRateGasFlowRateScrubberInletGasTemperatureScrubberOutletGasTemperatureMakeupiblowdownrateScrubberLiquidSolidsContent——ScrubberLiquidpH—NeutralizingChemicolFeedRate—ScrubberLiquidSpecificGravity——Other(-ControlDevice:ElectrostaticPrecipitatorEmissionPoints:OutletPMConcenloalion.SecondaryCoronaPower(Current&Voltage)SparkRatePrwnaryPower(Current&Voltage)InlelGasTemperatureGasFlowRale-RapperOperationFieldsinOperationInletWaterFlowRate(WetType)FlushWaterSolidsContent(WetType)OilierControlDevice:CycloneEmissionPoints:InletVelocityorInletGasFlowRatePressureDifferentialInletGasTemperatureOtherin1t312010EPA JNFQRMA’OON

CO .ECTI0P ROUEET

FOR FERROAtLOYS

PRODUCTION MANUFACTURING

EMffi$O POINTS SECTiON

4 MONITORING Table

40 OpeoltyNisible

Emissions

Monitoring

information

Frequency

of lsnaolto

or Visible Emissions

Monitonine

Moniforino

Method

Moniforina

Describe

Oootitu A,.ursne. bmflees

Pefef (el_El____________________— EPA Morhnd

22

Ca.7— Continuous

Cpoooy Montonng

CCVI—— Cooboucus

Emission Montoning

ICEMi— Other)________________________

I Opacity

or VE LimW

for the Egaseree

Point

(if any)

Plo

ass note

unts

E Easini

CYty Aoerage

Opacity

orVE obsessed

ten brie Emission

Point (Please

note

units

% EmissnooPoiot(o(:

P901-El endPgbl-E2— MorhodonrMnthod2

ioiAypioanis—

— Continuous

opoo 1 y Monitoring

)CCr nnnpyinanio CsnhnaousEmnsoionMonhonioglChMnuvlspput 0 s.___— panoulsi.smosions

from

ins steaks and

Vi

any s.aios higosa

eE tremfris Other)____________________________

i—-

Etnb

onnnu

Ytt(s C.nOosi.s 20u OpsniiyaseO-minaoeags sen.nndvnniesmonnnkisnePOregeiO oengeniannino

or ins

iap nnia

1000 onus

rr 00(01121

Viu.Oi.

nE sh.ll

rei esn.edao%aeanryase-nisassrsa enneni

.5 ninuid.d

fry

mis 1000

000 iC.OP(

20% ceanry

as fr-rOe nurings inaymm.d20%ossrinna Cli

p

IA

oi

VA

Ln

iii

1w thin Amiosion

Point

(it any( (Pin-ann

note

units

A

hr €iVfPriErnaVl(— V-u.

np-

Cu

dy

nn

VP observed

ron

rhic Eminnion

Point (Pleannnctiul Emission

Point(a(

P900-Er— MitbndhniMnthnd2

s 9 ndty105b Cortinunus

CA

coy Mnnitonng

(CCV

PA Ary(i&hh Cun-i-.unuoEmiuniuinrdonlnririg(CEPninrVoVir.b— yaynnnsnkeeaisnop.iainginnniuki and reisnnoisibia

muss noooinrfrs Cinnr

I

I eannnreini—

edy nyuninevnnirinnno 2n%Oesniryansf-min

ansnau. senenr

aniline bonena

raps, pouing

sr.4 neygen

lancing

or ire

ran

hnis

1000 274n-rr-OryO(lO(

disi0s

PE .0.5

nor eenesddO%opsonns.

0-min.osisg rAtIO).

20% onanlrn

as 6-nm so.sagsriomfrsioermennni llnCfrRM

t052(

Oeanuy

as

a 0-mm sns,aae nnsysece.d2000naimm. dnnnasn000-nonneniodsoi000eo Cpaoily

on

VE

Lim

I mr

this Eminsion

Point

(ir any

( (PIn

cnn-

nntn

units

&

ba jncFPshls52(aJ( Aonragn

Cpinio

on AEnbnerveytoiihvEmin_nPet(P.nasnnote

n Emlssionnoint(a)P909-Er——— MithrdoniMoihnd2

9yCPnp(hn Conimnumonin

Cp.indy tituinloriry

(CCI nniuppnrno Cent nnon Emission Monitoring

(CEM tiniuyyinnbis Other—

•cnntenuy

ni

Asnmnu

N rVPndhinimrn 20%Dosniiyasan-ninaoeiaue nnar-rn-nn(o(Ctl

Vmeib

• PP olmnli

nni ranennas

cinviOrd

bonnie (uconron rr-ortyy.

20%

0 eanno

as On Iannn000

oral. onanino

an

as Cpaoty

or

Oh

Lmm

r mr

thin Emiuoinn

Pint

or uiiy

( (PIn

inn note

onto

&

ha spurner

inciyfl— Aonragn

Cpan

tyor

Ph ohs.

end

too

hi-. Ann,sinn

Pont

IPI nine

non.n

On Emission

Peinl

(a) P909iFOt2-E2

Method

9

or fntnrhna

2 nnnnyyinnn Contnnunin

Cpnnmiy Monitoring

(CCV (ooppmnnnie Cotinonun

Ennnninn Miinrnninp

(CEM rr!Aeniynr.e—— Cthnn I________________

eui.nn

pn

on

i

-

n

Arenni

n.y Curd

tm inawn •nsnspa

1000

erun mmml

p

- on PEarafnnisroesduounoaniinn

0 Opandy

or VP LimI

br

this Emission

Point

(ii any

I

1 PI nine

notn

unls

&

be rVKIOAE2MIJ!nAPV(—— Aoeraoe

Cpaoyy

or

PP observed

tor

thin Emission

Pu

or (PA

ice

note

u-

ii AmlsalonPolet(a(Pn17-Er.P917-E2.P902-E3—

— Mi thud

0

on Mothod

C nnuuypis.s—— Cool n0005 Cy.nniiy Monyonny

CCV noruonnno——

—— ConAnuovs Enn-sninnr.rmn,iror.rg(CE1

nn!9 00 nnrl.— usdnnnsoksonhsnsnsnasnarenu.s.0. sear

en •nnoisiOa

rogose

no Oemms Crhen(___________________

nEnmoynnA-—-

Oj Paibis

no

or V 0 nios

duo snarn

or 220%eoesiosaan-oa.. as.iag.

loon arar—rr-0n101

VisiOns nosinarnorsepssdao%a

eseen

55

e nile ae.naaeseuserasciesidsdbn Cynony

on yE LimO

ion

this Ennsnnn

ConI

(it

my ((Please

onlo

onto

&

0 myjndo nE4hir7-cftn(—

—— Au-nape

Coanno

or VEobnnin

id

ron thin

Em

ion Point (Pmnasn

cute

on

rI Emission

Poinl

(a) Ford-E3,

rota-Ed

Fora

Edo Mnlpodyyrr.ritbnd2 5 muty 0 pmt,n

o

— PAir nouns

Cy

in

to Munnnr

ny (CCV

rio

°pp

P etA—

— Cnntniuiiun

Enninni

on Monunning

(CAM

lip tm yno(°nfr. anenuianyooioiero 5 essnonomrns Crhor(

rvtmnnoPJdrPC._

Peyu._._., nyimnChysYErrrte, 5 0n Pieuis

PP emfrsgoss

&isr

sins”

nor rrnssa

20% eesruy

sea a-mn •neeseel0005ass-rr-Onisi.

VisOs en .y&i rorseossa

ae% eeas.ne

ass me assraesseoserssr000sdse Op nnityw

hA pimy

u ihiu Emission

Point

(ii any

H

e eon

note

units

& by inpjnpopEpppp4jjoj._ Pin

un

Cm

pAy urVE observed

ton this Em-esion

Point Pleasenotnu 1 el

In.

in—

lie -n—n

iO

as used

in thn process

tow d-oyram San

pie

now ssrodnd

P..un

01.ReleaseParametersforRiskModeling(bc)EmissionPointID.CoordinatesHeightDiameterVelocityTemp.a1LatLongNAD(d)mmmisKP901-El(1)39.370311-81.52031437.52.4137,000acfm333P901-E2(1)39.370162-81.52132329.31.475,000acfm322P908-El(1)39.369026-81.52564637.52.4169,500acfm333P909-El(1)39.367997-81.52896233.50,510,500acfm314P909/F012-E2(1)39.36881-81.52719113.4(2)3X15175,000acfm394P917-El(1)39.368387-81.52550791.2244216acfmAmbientP917-E2(1)39.368387-8152550791.2245642acfrnAmbientP917-E3(1)39.368387-81.52550791.4657539acfmAmbientF014-E3(1)39.36954-81.521677180.6612,229acfmAmbientF014-E4(1)39.369847-81.52094718.609119,565acfmAmbientF014-E4A(1)39.369648-81.521441180.924,188acfmAmbient(a)PleaseusethesameIDasusedintheprocessflowdiagram(b)ForeachHAPemissionpointdefinedintheprocessflowdiagram,entertheapplicableinformationFerroalloysProductionManufacturingEmissionPointsSurveyPage42UnitOperationNameandProcessDiaqramID(a):8/13/2010UnitOperationNameandProcessDiagramID(a):ReleaseParametersforRiskModeling(b)EmissionPointReasonforCoordinatesHeightDiameterVelocityTemp.ID(a)ReleasePointLatLongNAD(c)mmmisKP909-E3a(1)DraftStack39.367997-81.5289623350.6637,000acfm303P909-E3b(1)DraftStack39.367997-81.52896233.50.6635,500acfm303P909-E3c(1)DraftStack39.367997-81.52896233.50.6531,000acfm303P909-E3d(1)DraftStack39.367997-81.52896233.50.6528,000acfm303(a)PleaseusethesameIDasusedintheprocessflowdiagram(b)ForeachHAPemissionpointdefinedintheprocessflowdiagram,entertheapplicableinformationFerroalloysProductionManufacturingEmissionPointsSurveyPage43..imissioflParameMakeadditionalcopiesofthistableforeachunitoperationidentifiedinTable2Aandyourprocessflowdiagram8/13/2010le5C:EmissionPOTModelingParameters(NonpointSources:MakeadditionalcopiesofthistableforeachunitoOeratjonidentifiedinTable2AandyourprocessflowParametersforRiskMoj1rReleaseHeightDimensionofSourceLatLorn(m)X(length,m)y(width,3.897701-77.03103N39.22.287W081.3111:1470Pile4171(2)N39.22.329W081.3117l1430Pile4251(2)N39.22.324W081.312011WGS841660Pile4252(2)N39.22.320W081.31211436Pile4247(2)N39.22.305W081.31:1445Pile9301/9302(2)N39.22.303W081.31:1445Pile4246(2)N39.22.300W081.31216ile1060(2)N39.22.278W081.312i1540ile1119(2)N39.22.240W081.3135180Pile209(2)N39.22.300W081.31:470Pile8300(2)N39.22.296W081.31512Pile1320(2)N39.22.293W081.31321530Pile1321(2)N39.22.290W081.313311560Pile4180(2)N39.22.283W081.3112Pile1023(2)N39.22.242W081.3125180Pile512(2)N39.22.239W081.31615Pile1100(2)N39.22.220W081.31.25180ile218(2)N39.22280W081.313711845ile592(2)N39.22.262W081.314422065Pile1055(2)N39.22.232W081.314625180Pile555(2)N39.22.252W081.3146l2050Pile566(2)N39,22.244W081.315025120Pile407(2)N39.22.204W081.31442075Pile408(2)N39.22191W081.3146212075Pile409(2)N39.22.184W081.3148l75(b)ForeachHAPemissionpointdefinedintheprocessflowdiagram,entertheapplicableinformation(c)NohAmericanDatum.EitherNAD27orNAD83.Ifleftblank,NAD83willbeassumed(d)Dimensionofsourcereferstotheareadefinedasaflonpointsourceemission(e.g.,openairdustpile)(e)angleofrotationspecifiestherotationofthesourcefromnorth(intheclockwisedirection)SamplerowisshadedFerroalloysProductionManufacturingEmissionPointsSurveyPage448/13/2010MANUFACTURINGEMISSIONPOINTSSECTION5HAPEMISSiONSTable5C:EmissionPointModelingParameters(NonpointSources)MakeadditionalcopiesofthistableforeachunitoperationidentifiedinTable2AandyourprocessflowdiaqramUnitOperationNameandProcessDiagramID(a):..ReleaseParametersforRiskModeling(b)EmissionReleaseHeightDimensionofSource(d)AngleofRotation(e)oins(a)LatLongNAD(c)(m)x(length,m)y(width,m)(degrees)E738.897701-77.036625NAD2710302012.5Pile558(2)N39.22.182W081.31494WGS8425807590Pile1031(2)N39.22.220W081.31.505WGS84207510090Pile511(2)N39.22.180W081.31.556WGS84830590Pile569(2)N39.22.164W081.31.584WGS8412554090Pile4215(2)N39.22.148W081.31.692WGS8415504090Pile1322(2)N39.22.137W081.31.714WGS8415404090Pi1e4230(2)N39.22.106W081.31.785WGS8415804590Pi1e4232(2)N39.22.099W081.31.803WGS84151008290Pile232(2)N39.22.020W081.31.781WGS84122308890Pile448(2)N39.22.017W081.31.765WGS8410453090Pile445(2)00WGS8400090Pile645(2)N39.22.024W081.31.736WGS84151607590Pile648(2)N39.22.026W081.31.712WGS8410854590Pile332(2)N39.22.023W08131.692WGS84615890Pile385(2)N39.22.029W081.31.663WGS8458890Pile339(2)00WGS8400090Pile723(2)N39.22.091W081.31.501WGS8415474590Gchute(2)N39.22.999W081.31.861WGS8415753090Pile4214(2)N39.22.063W081.31.846WGS8410501690Pile3999(2)N39.22.086W081.31767WGS841420012590F007-F1(1)39.369946-81.52122633.590F008-F1(1)39.369059-81.52468133.590F009-F1(1)39.368022-81.52832933.590(a)PleaseusethesameIDasusedintheprocessflowdiagram(b)ForeachHAPemissionpointdefinedintheprocessflowdiagram,entertheapplicableinformation(c)NorthAmericanDatum.EitherNAD27orNAD83.Ifleftblank,NAD83willbeassumed(d)Dimensionofsourcereferstotheareadefinedasanonpointsourceemission(e.g.,openairdustpile)(e)angleofrotationspecifiestherotationofthesourcefromnorth(intheclockwisedirection)SamplerowisshadedFerroalloysProductionManufacturingEmissionPointsSurveyPage458/13/2010I::F’:.J.J

.t#WJ

:Jb.Ih.W.

POINTS SECTION

5 HAP EMISSIONS Table

5D: Speciated

HAP Emissions- Actual

and Allowable Make additional

copies

of this table

for each

unit operation

identified

in Table

2A

and your process

flow diagram Unit Operation

Name

and Process

Diaqram

lD(a): Emission

Point

HAP Emissions

(b) Actual

HAP Emissions

Allowable

HAP Emissions Emission

Point

ID

(a)

HAP Emitted

Actual

HAP

Actual

HAP

Basis

for Allowable

HAP Allowable

HAP

Basis

for Allowable Emissions

Concentration

Emissions

Emissions

Concentration

Limit Estimate tpy

ppm

tpy

ppm El

Manganese

150

0.05

tesldala

200

0.1 WV23709-IV-(d) El

Lead

0 02

0 0001

test

data

003

0.0005

WV 23709-

lV-(d) E2

Manganese

200

0.1

calculated

250

0.2

WV 23709-

IV-(d) E2

Lead

0.05

0 0008

calculated

0.08

0.001

WV 23709-

lV-(d) June

2007

Test P901-E1/P9o1-E2

Manganese

1 96 lb/hr

Not Applicable

Oats

Not Applicable

Not Applicable

Not Applicable Oclober

2008

Test P901-El/P901-E2

Manganese

1 535

lb/hr NotApplicable

Data

NotApplicabte

NotApplicable

NotApplicable Test

data

prior

to furnace

rebuild P908-El

Manganese

2.22

lb/hr

Not Applicable

(March

2009)

Not Applicable

Not Applicable

Not Applicable Tesi

data

after furnace

rebuild (2010).

Report

not P908-El

Manganese

0.57

lb/hr

Not Applicable

yet final.

Not Applicable

Not Applicable

Not Applicable June

2009 P901-El

Lead

003

lb/hr

Not Applicable

Engineering

Test

Not Applicable

Not Applicable

Not Applicable June

2009 P909-El

Lead

0.02

lb/hr

Not Applicable

Engineering

Test

Not Applicable

Not Applicable

Not Applicable (al l-ftease

use

the samu

ID

as Used

fl the process

flow diagram (b(

For each

HAP emission

point defined

in Ihe process

flow diagram,

enter

the applicable

information Sample

rows

are shaded

and illustrate

where

two

or more

HAP

are emitted

from

a single emission

point. Ferroalloys

Production Manufacturing

Emission

Points

Survey Page

46 DA

afHr InArfrsKI

(rI

I cr*TI(M

iirr

COItAI

t tV DDflhtIrrI1

Ml A

rTI lIMt MIWiM 8/13/2010EPAINFORMATIONCOU.ECTJQNREQUESTFORFERROAUOY$PRODUCTIONMANUFACTURINGEMISSIONPOINTSSECTION5HAPEMI5SIONSTable5E:TotalParticulateMatter(PM)Emissions-ActualandAllowableMakeadditionalcopiesofthistableforeachunitoperationidentifiedinTable2AandyourprocessflowdiagramUnitOperationNameandProcessDiagramID(a(:EmissionPointPMEmissions(b)ActualPMEmissionsAllowablePMEmissionsEmissionPointTotalActualPMActualPMTotalAllowablePMAllowablePMID(a)EmissionsConcentrationBasisforEmissionsConcentrationBasisforAllowable(peremissionpoint)(peremissionpoint)Emissions(peremissionpoint)(peremissionpoiflt)Limitgr/dscfEstimategr/dscft3’brspecifyl(orspecify(El21300322TestData3000.05/tN23709-IV-(a(E24000.0625Calculated5000.075WV23709-IV-(a)359lbs/hrP901-ElandSubmittedtoConradu2fiMWonE2ChinJuly2010NotApplicable-NotApplicableNotApplicableSilicomanganese40CFR631652(b)P901-Eland272lbs/hr025MWE2NotApplicableNotApplicableNotApplicableNotApplicableonSilicomanganese40CFR63.1652(b)298lbs/hrP901-Eland>22MWonE2NotApplicableNotApplicableNotApplicableNotApplicableFerromanganese40CFR63.1652(b)P901-Eland217lbs/hr022MWE2NotApplicableNotApplicableNotApplicableNotApplicableonFerromanganese40CFR63.1652)b)359lbs/hrSubmittedtoConrad.-2SMVVonP908-ElChinJuly2010NotAeplicableNotApplicableNotApplicableSilicomanganese40CFR63.1652)b)272lbs/hr225MWP908-ElNotApplicableNotApplicableNotApplicableNotApplicableonSilicomanganese40CFR63.1652)b)298lbslnr22MWonP908-ElNotApplicableNotApplicableNotApplicableNotApplicableFerromanganese40CFR63.1652)b)217lbs/hr222MWP908-ElNotApplicableNotApplicableNotApplicableNotApplicableonFerromanganese40CFR631652(b)SubmittedtoConrad247lbs/hronP909-ElChinJuly2010NotApplicableNotApplicableNotApplicableFerromanganese40CFR631654)a))1-3)P909/FOI2-E2NotApplicableNotApplicableNotApplicableNotApplicable003gr/dscf40CFR63.1652(d)P917-ElNotApplicableNotApplicableNotApplicableNotApplicable003gr/dscf40CFRS3.1652)e)(2)P917-E2NotApplicableNotApplicableNotApplicableNotApplicable003gr/dscf40CFR63.1652(e)(2)P917-E3NotApplicableNotApplicableNotApplicableNotApplicable003gr/dscf40CFR631652(e))2)ProcessNotFO14-E3OperatingNotApplicableNotApplicableNotApplicable003gr/dscf40CFR63.1652(e)(2)ProcessNotFO14-E4OperatingNotApplicableNotApplicableNotApplicable003gr/dscf40CFR63.1652(e)(2)ProcessNotF0l4-E4AOperatingNotApplicableNotApplicableNotApplicable003gr/dscf40CFR63.1652(e)(2)(a)PleaseusethesameIDasusedintheprocessflowdiagram)b(ForeachHAPemissionpointdetnedintheprocessSowdiagram.entertheapplicableinformationSamplerowsareshadedFerroalloysProductionManufacturingEmissionPointsSurveyPage478/13/2010

# EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSIQN POINTS

SECTION 5 HAP EMISSIONS

Table 5F: HAP Concentrations in Emission Streams



# 1 2 

# I 3 4 

# I 5 6 

# I 7 8 

# I 9 

# I 10 11 12 13

Emission Point & Process ID Caoture Control Outlet Stream

Concentration of Total Particulate

Unit Operation Emissions to Capture Control Flow Rate of Emitted HAP Concentration in

Emission Point ID Process Capture System or Capture Basis for Reported System Efficiency Basis for Reported Stream (scfm Igr/dscf or specify( Particulate Matter

(at Unit Operation Name (b( Diagram ID (a) Device and ID (a) Efficiency (%t Efficiency (c) (%))d( Control Device and ID (a 1%) Control Efficiency (C) 

# or specily) (dl Iwl %( Ice)

El Electric Arc Furnace 1 EAF 1 Hood ICS1) 80% Estimate 60% F-abnc Filler )BH1 ( 99% Mfg Design Val

El Electric Arc Furnace 2 EAF2 i-food ICS2) 80% Estimate 40% i-abric Fitter )BH1( 99% Mlg Design Val

P901-SCR1 and P901-

P901 -El EAF #1 P901 Hood (P901-CS1 

# 1 99 5 Estimate 100 SCR2 99 Title V Application 1 53,723 21.24 lbs/hr Not available

P901 -E2 EAF #1 

# P90 Hood iP9Ol -CS2( 99 Estimate 100 P901 -BH1 99 Title V Application 71.240 0.96 lbs/hr Not available

Hoods (P906-CS1. P908-SCR1 and P908-

P908-El EAF #12 P908 P908-CS2t 995 Estimate 100 SCR2 98 Title V Application 143.950 819 lbs/hr Not available

P909-El EAF #18 P909 Hood (P909-CSl1 995 Estimate 100 P909-SCR1 997 Title V Application 8,364 7.61 lbs/hr Not available

Hoods IP909-CS2,

P909/F012-E2 EAF #18 P909/FOl 2 F012-CS3( 995 Estimate 00 MOR-BH 99 Titte V Application 224.012 0.003 gr/dscf Not available

P917-El C2P Crusn/Size P917 Hood (P917-CS1 1 99 Estimate 100 P9l7-BH1 98.01 Title V Application 44.253 0.022 gr/dscf Not avavabte

Hoods (P917-CS3.

P917-E2 C2P Crush/Size P917 P917-CS4( 99 Estimate 100 P917-6H2 9801 Title VApplicalion 46.026 0 022 gr/dscI Not available

P917-E3 C2P Crush/Size P917 Hood (P917-CS2( 99 Estimate 100 P917-8H3 9801 Title VApplication 57,249 0 022 gr/dscf Not available

F014-E3 C7P Crush/Size P014 Hood (F014-CS1) 99 Estimate 100 F014-BH3 99 Title V Application 12.048 0.03 gr/dscf Not available

F014-E4 C7P Crush/Size F014 Hood (F014-CS3( 99 Estimate 100 F014-BH4 99 Title V Application 19,097 003 gr/dscf Not available

F014-E4A C7P Crush/Size F014 Hood (F014-CS2( 99 Estimate 100 F014-BH4A 99 Title V Application 23.970 0.03 gr/dscf Not available



# (a) Please 

# use the same ID as used in the process flow diagram.

(b) For example, furnace or tapping fugitives, crushing, mixing, handling, loading/unloading

(c) Please provide copies of estimation worksheets and any other relevant documentation to document basis for estimates

(d) If the emission point is one of multiple points contributing to an emission stream, indicate the percentage of total stream emissions.

(e) Provide speciated data where available, It has been assumed that most HAP are present in particulate form. If significant volatile HAP are present, include them here with notation of units.

Sample rows are shaded, and illustrate a situation where 

# two unit operations are directed through a common control device

Ferroatloys Production Manutacturing Emission Points Survey

Page 49 8/13/2010

# Ferroalloys Production Manufacturing emission Points Survey

Page 50 

# EPA 

# INFORMATION COILECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING 

# EMISSION POINTS

SCTION6 COSTOATA

Table 6A: Fabric Filter Costs (make additional copies as needed)

Provide annual costs for operating and maintaining the EAF fabric filter control devices (i.e., positive pressure baghouses).

Other Costs

New bags (maintenance, Total Annual

Monitoring, Reporting, & (or other parts, waste disposal, etc., Operating Costs

Control Device ID (a) Type of bags Labor Cost Recordkeeping please specify) please specify) Electricity (2009)

P901-BH1(2007) Same as 3C 7673.00 Unknown 17,886.00 Unknown 25559.00

MOR-BH(2008) Same as 3C 90157.00 Unknown 127,545.00 Unknown 217702.00

P917-BH1(2009) Same as 3C 5849.00 Unknown 7734.00 Unknown 13583.00

P917-BH2(2009) Same as 3C 4545.00 Unknown 7734.00 Unknown 12279.00

P917-BH3(2009) Same as 3C 4969.00 Unknown 9950.00 Unknown 14919.00

F014-BH3 Same as 3C Not Operating Unknown Unknown

F014-BH4 Same as 3C Not Operating Unknown Unknown

F014-BH4A Same as 3C Not Operating Unknown Unknown

(a) Please use the same ID as used in the process flow diagram.

8/13/2010

# EPA INFORMATI

Monitoring,

Reporting, & Other costs Control Device ID (a) Labor Cost Recordkeeping Electricity Water Waste Disposal (specify)Parts Total Annual Costs

P901-SCR1 123405.00 

# $ 200,000.00 $725,000.00* 55340.00 1,103,745.00 P901-SCR2 12340500 

# $ 200,000.00 $725,000.00* 55340.00 1.10374500 P908-SCR1 (2007) 62275.00 

# $ 200,000.00 $725,000.00* 14261 .00** 1,001,53600 P908-SCR2 (2007) 62275.00 

# $ 200,000.00 $725,000.00* 14261 QQ** 1,001,536.00 P909-SCR1 (2008) 88721.00 

# $ 200,000.00 $725,000.00* 357523.00 1,371,244.00

(a) Please use the same ID as used in the process flow diagram.

Ferroalloys Production Manufacturing Emission Points Survey

Page 48 Table 6B: Scrubber Costs

- 

# Provide annual costs for operating and maintaining the EAF scrubber control devices

8/13/2010

# iaoie I: 

# startup ana nutdwn information (Make additional copies as needed)

Any monitoring

data or control

Was event covered by system parameter

contingency plan for Estimated PM Basis for monitoring

Unit Operation Permit conditions controlling emissions? emissions during emissions collected during

Process ID (a) Date and Description of event exceeded Duration of event (hours) (YIN) event (pounds) estimate event? (YIN)

EAF1 07112/2006 Emergency Shutdown WV 23709- IV-(d) 3 V 127 Emission Factor Y

P901 2/23/2007 Furnace burnthrough Not Applicable 250 Y Not Applicable Not Applicable N

P901 3/8/2007 Furnace burnthrough Not Applicable 511 Y Not Applicable Not Applicable N

P901 616/2007 Arced ceiling panel on A-Phase Not Applicable 38 V Not Applicable Not Applicable N

P909 9/9/2007 Mini-outage Not Applicable 140 Y Not Applicable Not Applicable N

10/20/2007 Down due to arcing 

# @ C phase

P901 lifting cylinder Not Applicable 24 V Not Applicable Not Applicable N

P901 3/30/2008 Major re-build Not Applicable 1148 Y Not Applicable Not Applicable N

P901 6/30/2008 Re-build Not Applicable 427 V Not Applicable Not Applicable N

P908 11/16/2008 Outage Not Applicable 88 Y Not Applicable Not Applicable N

P901 12/19/2008 Mini-outage Not Applicable 73 Y Not Applicable Not Applicable N

8/14/2009 Replace ribbon flexes in buss

P901 runs Not Applicable 52 V Not Applicable Not Applicable N

P908 3/11/2009 Shutdown due to Economy Not Applicable Not Applicable V Not Applicable Not Applicable N

(a) Please use the same ID as used in the process flow diagram.

Sample row is shaded

Ferroalloys Production Manufacturing Emission Points Survey

Page 15 V. 

# SECTION RThFAND SHUTDOWM.

.



# 8/13/2010ATTACHMENT#1TITLEVAPPLICATIONATTACHMENT#2PROCESSFLOWDIAGRAMSP901-El Stack 1 Stack EAF1 Tapi

____ Electric Arc Furnace 1 (P901) Primary emission capture is by a suspended circular canopy hood above the furnace as described in table 3B. Primary emissions are directed to wet scrubbers. Tapping emissions are collected by a hood located above the taphole and directed to a baghouse.

P901 Stack

F007-F1 Roof Monitor rs

_________ If Producing Std FeMn MOR Casting Crushing If producing SiMnP908 CS1 I EAF12 Tapi 1

_________ Electric Arc Furnace 12 (P908) Primary emission capture is by a suspended circular canopy hood above the furnace as described in table 3B. Primary emissions are directed to wet scrubbers.

P908-El F007 Fl

Stack 1 Roof Monitor

_________ MOR I

- CastingFURNACE #18 BUILDING 36 _99o81Fo12 ® 4-

__ ___ ENE

_ Drafl S1aus E3b c Ed F1 rs__

_ ff I I

od Tap 1 Casting Reaction / FURNACE #18 ls

Bins Ladle /

____________ unner r EAF#18

___________ le__/ F009_Cas Reaction / Tapping Ladle Pouring Slag Separation : FOl 2 MOR Ladle Transfer Ladle Transport Metal from #12 Furnace

EAC#18 (P909) MOR (F012) Furnace #18 is a semi-sealed furnace with a wet scrubber collecting primary emissions from under the cover of the furnace. Tapping emissions

are collected and ducted to the MOR baghouse. Metal from Furnace #18 and Furnace #12 are poured into a reaction ladle and further processed at the MOR (F012). The MOR fume is collected by a hood and ducted to MOR baghouse. (*) P909C2P Crushing/Sizing (P917)

Roof Monitor ,‘P917-’. ‘ 5 cs3 -,

-- P917- CS4 4-

Jaw Crusher -‘P917.’ ‘CS2 / P917

rusher Screen Box ... Screen Box Product bin Product bin Fines bin Emissions are captured at transfer points and ducted to baghouse.BulkhandlingC7PCrushing/Sizing/Packing(F014)Emissionsbeginningatthecrusherarecollectedattransferpointsandductedtobaghousest#3BaghouseStorage!Loading__0RawMaterial4Truckunloadingat4deliveredtostoragejtruckfortransportto—*mixhouse.areabytruckjMixHouseStoragePiles-(F002)RawMaterialisdeliveredbytrucktostoragepilearea.Afrontendloaderloadstherawmaterialonatruckwhichtransportsthematerialtothemixhouse.ATTACHMENT

#3 STARTUPISHUTDOWNIMALFUNCTION

PLANSSectionNo:SOPIssueDate:Rev.Date:START-UP/SHUTDOWN/MALFUNCTIONActticr:PLANFOR#1FURNACEPage:1or1.0PURPOSEANDSCOPE:ThecorcoseandscoreofthisproceouteissoassureDraperoperationariddocumentationofthefurnaceorocess,Laprcnebaqnouse,andventuriscruober;andtocoinplvvithallapplicablerequlrementsoftheEPA,TitleV,aridMAlTstandards.Thisprocessconsistsofanopenfurnaceandassociateddustcontrolequipment.TheemissionsfromthisprocessarecontrolledbyaventuriwetscrubberthatcollectsfumebyuseofahoodsuspendedabovethefurnaceandabaghousewhichcontrolsfumefromthetappIngofthefurnace.2.0OPERATIONANDMAINTENANCEREQUIREMENTSAtalltimes,includingperiodsofstartup,shutdown,aridmalfunction,ownersoroperatorsshalloperateandmaintaintheaffectedsource,includingassociatedairpollutioncontrolequipment,inamannerconsistentwithgoodairpollutioncontrolpracticesforminimizingemissionsatleasttothelevelsrecuiredbyallrelevantstandards.Anytimethefurnaceordustcontrolequipmentisshu:downorrestarted,theseproceduresroastbefollowedanddocumentedintheTitleV/SSMP/MaintenanceF:.ecordSheetlocatedintheoperationssupervisorsoffice.3.0DESCRIPTION:3.1Start—up:Furnace#1VenturiScrubbersystem3.1.1StartupofVenturiScrubbingSystemwillbeperformedperElrametMariettaHECPProcedureHECP—lOl—08andErametTrainingManualappendix1,section(3.1.2)AND(3.1.3)3.l.l.a.OperationalchecksaredefinedinReferenceManual#12((TitledVenturiGasCleaningSystem)(Section3.1.1through3.l.9HErametTrainingandTechnicalManual12.3.l.l.b.RecordthestartupdataofthedustcollectorontheTitleV/MACTInspectionRecordsheetlocatedintheOperationsSupervisorsoffice.3.1.2StartupofFurnace#1willbeperformedperErametMariettaIncHECP101—25andEramet’stechnicalandtrainingmanual.3.1.2.a.EnsurepropermixlevelsareinfurnacE-tocinirsozetunoanci.3.l.2.b.VsuayIc-osforemissionstramthedischaroeorthestacas.3.l.2.ci.Reccrdthestartuprimeoftheorocess:ntheTitleV/SSMP/Maintenance_RecordSheetlocateaintheoperationssmcersisorsoffIce.rZSac::iou:t:crriace3.2.1Shutdownof[urnacewillbeperformedperErametMariettaSOP101-25.3.2.2VenturidustcollectoroperatesuntilfumingstopsSTARTUP/SHUTDOWN/MALFUNCTIONPLANFOR#1FURNACESectionNo:SOSIssuehate:Rev.Date:Author:Page:2of3.2.3RecordthetimeofshurcuurrinmeTitleV/ISVP:iia:rrtenanceRecordSrree:locatedintheoperatirusupercisorsofice3.3Shutdown:Ventor:Scrubber3.3.1.ShutdownofVenturiScrubberwillbecerformedperHECP101—Ct.3.3.2.Recordthei:imeUtsbutdownonthe_TitleV/SSIIP/Maintenance_Record_Sheetlocatedintheoperationssupervisorsoffice3.4Startup:TapholeBaghouseCollector3.4.1Startuparidshutdownofthetepholebaghousewillbeperformedaccordingto3505101-09.3.4.2.Recordthetimeofanyrnalfur:criorrorrepairsonTitleV/SSMP/MaintenanceRecordSheetlocatedintheOperationsupervisorsoffice.3.4.3RecordeachnormalstartupandshutdownoftapholefumecollectingfanduringthetappingofthefurnaceontheBaghouseCheckSheet.4.0STANDARD/EXPECTEDENDRESULT:4.ITheexpectedendresultissafeoperationofthefurnace,baghouse,andventuriand100%complIancewithrhoEramet’aTitleVPermitandthePACTstandard.5.0DEVIATIONANDCORRECTIVEACTION:5.1.Seeattachment“A”TitledFurnace#1SSMP5.2Seeattachment“B”TitleFurnace#1TapholeFumeCollector6.0RESPONSIBILITYFORIMPLEMENTATION:6.1TheShiftSupervisorisresponsibletoassurethatthisprocedureisimplementedexactlyaswritten.6.2TheDepartmentManagerordesigneeisresponsibletoconductaprocedureassessmentofthisprocedureannually.7.0RECORDEPINGREQUIREMENTS:TheEnvironmentalDepartmentmustbenotifiedimmediatelyitamalfunctionoccursthatcausesanexceedanceofSrialirwableparameterthatisnotaddressedinthisSOP.AnyexceedancenotspecificallylistedinthisSOPandaddressedperthecorrectiveactionslistedinthisSOP,:irusthereportedtoOEPAwithin(2)dayswithaftilow—opletterdetalirigtheeventwithin(7)days.STARTUP/SHUTDOWN/MALFUNCTIONPLANFOP.#1FURNACESectronNo:SO?issueDate:Rev.Date:AthtrPage:3ofAllrocitorrg:epuo:s,excessenssic•rsn):eo,andallmaintenanceactivityperformedontheOtiarcollectormustberecordedandsenttotheenvironmentaldeorccercwithin(2)daysoftheer.dofeachmonth.TheStartup—Shutdown—MalfunctionPlanaridMaintenancePlanmustbekeptforthelifeofthedustcollectorandtheprocess.Changestotheprocessorcontrolequipmentwillrequiretheplantobeupdatedtoreflectthesechanges.TherecordkeepingrequiredbythisSOPisforatermof(5)years.TheserecordsmustbemadeavailabletotheEPAattheirrequest.8.0APPROVAlS:DeptManagerEnvironmentalManager,QualityAssurance9.0SYSTEMSCONNECTIONS:None10.0ATTACTh’NTS:TitleV/MACTInspectionRecordSheetTitleV/MACTComplianceRecordSheetAPPENDIX“A”FURNACE#1SSMPProblerns(P)andCorrectiveActions(CA)5.0DEVIATIONANDCORRECTIVEACTION:Whenanon—standardconditionoccurs.theproceduremustbefollowedandDocumented.NotifytheShiftSupervisor/PlantForemanimmediately.IMalfunctions/Non—Conformance:•I(P)Completelossofpowertoplant,furnaceorscrubbers1.2(CA)Uponlossofpower.followGuidein1’LC151arid15U.Whenpowerisrestored.followstartupprocedureforscrubbersoutlinedinErametTrainingaridTechnicalManual#1.Afterscrubbersareoperating.commencestartupoffurnaceper1-IECP101-25aridSOP101-217forstartupoffurnace1.3(P)Fantripcausedbyhighvibration1.4(CA)LockoutfanperHECP101-08.Cleanandbalancefun,startupperHECP101-08aridTechnicalManual#12.1.5(P)Fantripnotcausedbyhighvibration1.6(CA)Checkallothermonitoringdevicesthatcouldcausetrip.Checkallpowersourcesforproblems.Whenrepaired.startupperHECP101-08andTechnicalManual#12.1.7(P)Fandampercontrolsnotoperating.1.8(CA)Checkelectricalandmechanicalcomponentsofcontrolsystemandrepairallyproblemfound.1.9(P)Recirculatingpumpfailureornowatertofixeddisc.1.10(CA)Switchtosparepumpandrepairpumpthatfailed.Checklinesforblockage.Removeanyblockagefound.1.11(P)Motorfailureonfalls..12(CA)LockfanoutperHECP101-08andreplacemotor.1.13(P)Fanbearingormotorcouplingfailure.1.14(CA)LockfanoutperHECP101-08andreplacefanbearingormotorcoupling.1.15(P)Lossofcoolingwatertofanbearings.1.16(CA)Checkwaterlineforbreakorblockage.Checkstrainerforblockage.Checkwaterssupplysourceforpumpfailureormajorbreakinsupplyline..17(P)Holeinscrubberfanhousingorductfromfurnacetoscrubberfan.1.18(CA)Weldpatchoverhole.1.19(P)Failureofscrubberfanimpellerorshaft.1.20(CA)Repairorreplaceimpellerorshaft.1.21(P)Possiblefurnaceprocessinterruptions:1.21.1Scheduledmaintenanceoutagesforroutinerepairs1.21.2Waterleaksonfurnacecoolingatersystem.1.21.3Electricalproblenis(i.e.arcing,controlpower,monitoringequipmentoncriticalcomponenents.1.21,4Coolingwatersupplyfailure.1.21.5Changingoutofstokingmachinesorrepairinginplace1.21.6Cleaningofoperatingdeck1.21.7Soundingofelectrodes1.21.8Electrodestubbingorbreaking1.21.9Failureofhydraulicsystemforheadmovementandslippingsystem1.21.10Mixchuteleakingmix1.21.11Changingoftransformervoltagesettings1.21.12Checkingforsuspectedwaterleaks1.21.13Scheduledplantpoweroutageforcleaningandelectricalcheck.2

I

4 Power curtailment

horn electrical

supply compans I .2

I. 15 Furnace

trip

due

to blow 1 .2

I

16 Plant shutdown

due

to evacuation 1.22 (CA)Fxceptlhr

1.21.5,

1.21.6,

1.21.7.

1.21.8,.

1.21.10.

1.21.11 .1.21.12,

1.21.13, 1.21.14,1.21.15,

and

I .21.16,

the above

itemsVs ould

he repaired

through

the Maintenance

Empact

Work

Order System I .23 (P)l/mittine

visible emissions

tiom

stack 1.24

(CA)

adjust electrodes

to lower position

if needed 1 .24.

I Add

mix

to furnace

and stoke

mix

in I .24.2Check/adjust

scrubber parameters

for proper

settings 1.25

(P) Furnace

shell

burn through 1.26 (CA)Furnace

shell

to

be repaired I .27 (P)Plugging

tiirrmace

taphole

by hand

when

Bailey plugging

unit malfunctioning 1.28 (CA)Repair

plugging

gun 1 .29

(P) Water

leaks

in pressure

rings

or bottom

shields. 1.30

(CA) Furnace

off

line

and evaluate

extent

of water

leak.

If required, remove/repair pressure

rings

or bottom

shields.

*See

Note *Note_

The water

leaks

in the pressure

rings

on Furnace

I resulted

in

a non compliant

emission test

in November

2006.

‘Jo prevent

a re-occurrence

of this pressure

ring failure,

the following procedures

are now

in place. (I)

A Production

Preventive Maintenance

Work

order

will automatically

be generated

every 8 weeks

to inspect

the pressure

rings

and bottom

shields.

Erarnet

will maintain

the record. (2)

The furnace operator

will check

daily

the water

level

in the closed

loop system.

Any significant

loss

of water

will initiate

a visual inspection

of the pressure

rings

for leaks.APPENDIX“B”FURNACE#1TapholeFumeCollectorSSN’IPProblems(P)andCorrectiveActions(CA)1.DEVIATIONANDCORRECTIVEACTION:Whenanon—standardconditionoccurs,theproceduremusthefollowedand1)ocumented.NotifytheShiftSupervisor/PlantForemanimmediately.Malfunctions/Non-Conformance:1.(P)Lossofpowertofanmotor.1.1.(CA)Checkwiringandpowersourceforwiringproblemorblownfuses.2.(P)MotorBad2.1.1.(CA)ReplaceMotor3.(P)LowMotorAmpsorwillnotcomeuptospeed3.1.1.(CA)Checkdampercontrolsystemelectricalandmechanical4.(P)Motorwillnotstart4.11.(CA)Checkelectricalcontrolsystem5.(P)Bagsfullofdust5.1.1.(CA)Checkelectricalandmechanicalpartsofcleaningsystem6.(P)Holeinbagsorbagsmissing6.1.1.(CA)Replacebags7.(P)Compartmentsfulloffume7.1.1.(CA)Checkaugerfeedscrewsystem8.(P)Augerfeedscrewnotturning8.1.1.(CA)Checkmotor.beltsandcoupling9.(P)Discnotsealing9.1.1.(CA)Checkifdiscbrokenorlooseonshaft10.(P)Bagcollasped10.1.1.(CA)Replacewirecagesthatgoinsidebagsii.(P)Holeorcrackinductworkorbaghouse11.1.1.(CA)Weldpatchoncrackorhole12.(P)Lossoflowairsupplytobaghouse12.11.(CA)Checkairsystemforpluggedline,solenoids,valvesforproperoperationorlossofplantair.13(P)Compartmentdoesnotseal13.1.1.(CA)Checkdoorlatchesandrubberseal.Repairifneeded

# U)

[U U)

U) 

# a

to

Cl)



# 0

I-I

Ii 

# 0

Cl) 

# in

Cl) 

# C)

0 

# N

a

0

10



# in

I-I



# 0



# I 

# I Cl)

‘Ti

Cr)



# H s-—) 

# U) Cc- U) U) U) 

# C0F-QJDJ0>

. . 

# it UCDH-Cfll1c-C 

# U) U) 

# U F- U) 

# U 

# OOU)UNU

• it hi CCictCD OOU U) U) 

# U- U) U) it 

# HCDH-U)(lU)U) 

# 0 I 

# U-U)OH-CDF- 

# U) U) 

# U Iii U) U) U) 

# U) U) U) U) U 

# U) U- U CT)

r— 

# U hi U 

# it U !Cfl Chic-I- U)pic-t 

# U) U)hi -itDic-I 

# U U- U)F- U) I— 

# (OQJ H U) U)HCP 

# Uc-DU-Url-H c-I- c-I- 

# U) UT• U)hi -S-U 

# CDU000c-rU-OU U U- U-

-—- 

# U) U) U) c-I- H H 

# U CD it CD CD U- H- I-I 

# CD )j 0 hi U)U- U-c-I-U- 

# U- c-I-U HQCPUUI H U U- U- U flU) 

# U- U H-c-I-U) U U-h-iUH

# UU H- U) 

# XU U- H-(nU-CD c-U 

# U— U U-Co 

# < U-i 0 C U Qc-r-U-Q 

# U-H U 0 c-cD itCT) H

# U flit U)Xit 

# CD 0 

# U OU)P-JU U I—v 

# (I-U U (I) 

# U) —U) 

# CD UU-UU-U0U)U c-I- c-LI 

# 00 0 U- (flU) itCDOU)c-I-U)U)U) I--I, U) 

# CPU U hi cD—U- 

# 0<(ID H<O -OCD c-I— 

# U 

# CD hiU) 

# U U U U) UU- U) 

# CD U-hi 

# 1 t3—CD hiCDU) U- U) U-H-, U0U-OU- C) c-c C) U) U- 

# U CD CU U Di 

# U CD U) c-I- U) 0 0 U) U) c-I- 

# U) H

- 

# H- CD U-c-I 

# -< 

# U) U [jYQ 

# H-I-I-hi hc-U- H-H-Ic-U) H-CDD 

# U) U it hi 

# U-IC) CPU-hi U-U-U U-hi 

# <C U-U) U)0I-iLO (I) U 7)(D U) 

# U- UCD c-l-HQ H-Hit 

# UH CD 0<hiUUDi U U- -CD 

# 0 U) U-- H- U-H-H- CD CD FI-UCPUW 

# itU) 1 

# flU 

# 0 U 

# U-— OCJ)c-t ci) 

# 0 U-U) c-I- 

# U-CDUU)OOCDU 

# 0 

# U Qc-I- DLI U CPU) 

# UI-c-U- (flU- U-fl U- (DU-itCDc-I-0 U 

# hi H- hO c-I-U) UCUCD CPU[I) hih- hi U) 

# U-i- I--I

# U

‘ 

# U) CDU (DC 

# H- DUHUUc-tU0 

# 0 U) c-I

# 0

—- 

# Cc-U U)—U 

# U) U CO U)Uv--UCDUU-U) U) cc-U hi UI H- U-CUc-I- (flI-i U)I-Y 

# U) C)U- itUO U 

# (Ti 

# U- U- U) it it 

# U) U U U) U) CD C)] 

# --

0 U U 

# U) 

# U hi 

# U cD CD v— (DU) 

# (OH-hi UCD 

# (flU U UU-flUH 1 U0 U Ic-I

# U CD U 

# hiUct CU-U- fl-U 

# U itOhiitOCDH-it it 

# U) FitU) H- 

# < U-TO <c-I-C U-U-U I TO H-UCUUU)CD CD CD 

# U U 

# it U-CD H-CPU) U-H-r- U)U) 

# TO 0CTOU- U-c-I-lc 

# D) hi c—itt) CI) U)

— 

# UU- 

# H-U-H- fl-U) CD UUU-U-UH-Djc Hi 

# 0 H- 

# U) U 

# U) 0! U Cl 0 ci) 

# U U) CI) hi U] CD CD U H 

# U) H Ci 

# U 

# 0 U0 0 UCD -)(TJ 

# U CD c-I- 

# CDhihi000hi

c- hi U- it U- LU U) hi C)) 0 it U) U) 

# U- U) U U U) c-r 

# U) I-—- CD it 

# it 

# U it 

# U 

# hi Hi (PU 

# U) 

# —c-U U) U-CDH-UUUitU H- CD (Dc-I- CD U0 0 ZUH- CC) U)U-U• H-c-)U-U)c 

# U) 

# 0 U-U- Hi U hi h-TiCo0 

# U itUU 

# U c-I- 

# CD N CD CD hi 

# H- 

# U--U HiCDh-tc UCC) 

# U-H- CD hiH-U H

—r- 

# U) 0 0 U CD H-C) UUCo U-U) 

# U <CU-it Uc--UU U U 

# U-U) 

# U itU) fl0c-r U—CD U) H

# U ci)U-Hiit hi U H it I-I 

# U hi U- U) Hi 

# CU U 

# it it Hi 

# U-

c— 

# HU- it C CPU) U-CD —CD 

# hiTO o!U-Q. CDCPCDc-I U C)] CPU U- hi H-U c-LICnhi 

# CPU hi!CD0 

# U CU- cO hi itCD 

# 0 0 U-hi UU- U)CDCD 

# U U 

# U H-UI-to 

# U H-U LU H- 

# U-U- Don 

# U UU) HU U 

# U CD U Ui 

# U U-U 

# UU 

# UI-hi CPU •c-U c-I-cD 

# 0c-- UU-U)U it CD 

# U H- 

# CD CO—I (Dc-I- H-CD hi HcitO H-U 

# 0 c-I- 

# U0 U U 

# c-I- C) Hr-v NiH-hi 

# U-U-U U) U U it 

# UU 0 U-CU hiD H-Cl) 

# U-UCU U 

# CU CO 

# it 0 CPU- U)0 U U-hi 

# fl<cU 

# U-CD U U-c-IU U-it OH- U)U- H-U CP-CD Chit hi 

# U)U- hi 

# U U flU) 

# C U-CD CUU 

# U-On H- (DCD ci) H- 

# U-CU CPU- U)U H-U) C)it 

# c-I-U-U-U 

# CD hi CD U- H-U r-rfl 

# U) 

# U U-UU 

# U it 

# <i 

# ! U) HN 

# CD it U) 

# ci) 

# U) H hi U) H- U) 

# it --t-

- 

# 0 

# U H- 

# Cl 

# 0 CD it CT) U H- it 

# U U it it 

# H- 

# CD hi —U) 

# CUhi Cc-CD 

# U itUC 0U) N it H- 

# —U) 

# U U)U- UCDUU Cl] 

# —lCD it CD 

# it 00 [CD U-EU U’ itUh—itD 

# 0 U U- 

# U U hi— U-hi 0 c-I-U-it 

# U) 

# U) CL —ci 

# U— CPU —it it U-H 

# 0 U U) 

# U-iit 

# U H H- 

# U CU 0 0 

# U H- 

# 0 U) h-U)U) U 

# U U- CDU- (Dc--- CD 

# U-CD 0 HU)U- it H

# 0 CD itit —it H-UI ititcC) 

# U) H-fl 

# U U- U) U) 

# U-CD U-U I OH 

# 0 ci) H CD c-I- 

# CD 

# 0 0 

# U U- H- 

# U- U) 

# CD 

# ci) U U) 

# U it 

# U- UU

. 

# I-— U-) 

# U 0 CD CD 

# -U- U- ‘i

C) U

(0 UUU)

H 

# U H



# U- H- Ccc

U-U) 

# U-UI-DC

CD CD I-I



# c-U-U

it. Cl;



# UU



# U HU

itI



# U

0(00

H-U (fl



# U) H-

,—- 

# CD I-fl U)

flU 

# it

it HU

C_n 

# 0



# U-i-CD

0 

# U-U U

itCD

U 

# U-U

U I-U



# U 0U) hi

Hi 

# hi 

# U

OU

U U I-)



# CPU

it U

CUP)



# O U

U-CD

—S



# UCDU



# UU



# U cc U)OO

CD U C)



# U- it H



# CD 0 it



# U

H-U)



# CPU 

# 0-U-U--

0 U

U U-I-Ic



# CD U) U

itCP 

# 0

U-- 

# 0

CDUU



# CDit

itO hi

U itO



# C U)



# H

# CPU

U U 

# U- c--]



# H-Dit

H

# 0 CD

I—



# U 

# U U)

U- CD 

# U- 

# U) U U

U) 

# itU)

U) 

# Di 

# 0

O itU



# U H- 

# (D



# TOO

U)UU

CD U



# O 0

hi

CT) U



# Q c-f 

# C) 

# U-ito

H- (P 

# I-C

hi I-C



# UU0

U U Nc



# it 

# U it



# U0UCD Hit 

# U)

I-to



# U-CO

mU-U

U(D

(c-U 

# U

I-; 

# U

?c-hi



# -Cl H-

H- 

# <C U



# c-i-CD

H-U 

# it

ID ito

H



# Li

H-U



# U



# U Cii U

U-UI-I



# CD



# CU

U- I-i

CTh lI-i C

I-i 

# U)

“CD

U U

CPU-C



# U- U-U)

U- CD

U ithi



# U 

# OP]



# 0- it



# U

- 

# H



# ‘OO

U) U



# <CU



# 0-



# U

H

# U) Co HI 

# U)

U U(DCI]U



# -cC I-fl 

# 0 (DO’ Cit

“CC 

# C(H

bUD 

# 0

U-U-U



# itU

U c-I-U 

# “(DO

U) 

# U)



# 0

I-fl



# 0

itSTARTUP/SHUTDOWN/MALFUNCTIONPLANFOR#12FURNACESectionNo:SOPIssueDate:Rev.Date:Author:Page:2of3.2.3RecordthetimeofshutdownonLheTitleV/MACT_SSMP/Maintenance_Recordsheetlocatedintheoperationssupervisorsoffice.3.3Shutdown:VenturiScrubber3.3.1.ShutdownofVenturiScrubberwillbeperformedperHECP102—07.3.3.2.RecordtherimeofshutdownontheTitleV/MACTSSMP/MaintenanceRecordsheetlocatedintheoperationssupervisorsoffice4.0STANDARD/EXPECTEDENDRESULT:4.1Theexpectedendresultissafeoperationofthefurnaceandventuriand100%compliancewiththeErainet’sTitleVPermitandtheMASTstandard.5.0DEVIATIONANDCORRECTIVEACTION:5.1SeeAttachment“A”TitledFurnace#12SSMP6.0RESPONSIBILITYFORIMPLEMENTATION:6.1TheShiftSupervisorisresponsibletoassurethatthisprocedureisimplementedexactlyaswritten.6.2TheDepartmentManagerordesigneeisresponsibletoconductaprocedureassessmentofthisprocedureannually.7.0RECORDEPINGREQUIREMENTS:TheEnvironmentalDepartmentmustbenotifiedimmediatelyifamalfunctionoccursthatcausesanexceedanceofanallowableparameterthatisnotaddressedinthisSOP.AnyexceedancenotspecificallylistedinthisSOPandaddressedperthecorrectiveactionslistedinthisSOP,mustbereportedtoOEPAwithin(2)dayswithafollow-upletterdetailingtheeventwithin(7)days.Allmonitoringreports,excessemissionsnoted,andallmaintenanceactivityperforinecionthedustcollectormustberecordedandsenttotheenvironmentaldepartmentwithin(2)daysoftheendofeachmonth.TheStartup—Shutdown—MalfunctionPlanandMaintenancePlanmustbekeptforthelifeofthedustcollectorandtheprocess.Changestotheprocessorcontrolequipmentwillrequiretheplantobeupdatedtoreflectthesechanges.TherecordkeepingrequiredbythisSOPisforatermof(5)years.TheserecordsmustbemadeavailabletotheEPAattheirrequest.8,0APPROVALS:STARTUP!SHUTDOWN/MALFUNCTIONPLANFOR#12FURNACESectionDo:SOPssoeDate:Rev.Date:Athor:Page:3ofDeptManagerEnvironmentalManagei,aaliLyAssetanne9.0SYSTEMSCONNECTIONS:Nerie10.0ATTACI-Th’SNTS:TitleV/MACESSt/P/MalntenanceRecordSheetTitleV/MACEComplianceRecordSheetAPPENDIX“A”FURNACE#12SSMPProbleins(P)andCorrectiveActions(CA)5.DEVIATIONANI)CORRECTIVEACTION:Whenanon—standardconditionoccurs,theprocedureniustbefollowedandDocumented.NotifvtheShiftSupervisor’PlantForemanimmediately.IMalfunctions/Non-Conformance:•I(P)Completelossofpowertoplant,furnaceorscrubbers1.2(CA)Uponlossofpower,followGuideinTLC151and15G.Whenpowerisrestored,followstartupprocedureforscrubbersoutlinedinErametTrainingandTechnicalManual#12.AfterscrLlbbersareoperating,commencestartupoffurnaceperHECP102-01andSOP102-029forstartupoffurnace.1.3(P)Fantripcausedbyhighvibration1.4(CA)LockoutfanperHECP102-07.Cleanandbalancefan,startupperI-IECP102-07andTechnicalManual#12.1.5(P)Fantripnotcausedbyhighvibration1.6(CA)Checkallothermonitoringdevicesthatcouldcausetrip.Checkallpowersourcesforproblems.Whenrepaired,startupperHECP102-07andTechnicalManual#12.1.7(P)Fandampercontrolsnotoperating.1.8(CA)Checkelectricalandmechanicalcomponentsofcontrolsystemandrepairanyproblemfound.1.9(P)Recirculatingpumpfailureornowatertotaxeddisc.1.10(CA)Switchtosparepumpandrepairpumpthatfoiled.Checklinesforblockage.Removeanyblockagefound.1.11(P)Motorfailureonfans.1.l2(CA)Lockfanoutper1-{ECP102-07andreplacemotor.1.13(P)Fanbearingormotorcouplingfailure.I.14(CA)LockfanoutperHECP102-07andreplacefanbearingormotorcoupling.1.15(P)Lossofcoolingwatertofanbearings.1.I6(CA)Checkwaterlineforbreakorblockage.Checkstrainerforblockage.Checkwatersupplyssourceforpumpfailureormajorbreakinsupplyline.•I7(P)Holeinscrubberfanhousingorductfromfurnacetoscrubberfan.1.18(CA)Weldpatchoverhole.19(P)Failureofscrubberfanimpellerorshaft.I.20(CA)Repairorreplaceimpellerorshaft.1.21(P)Possihlefurnaceprocessinterruptions:1.21.IScheduledmaintenanceoutagesforroutinerepairs1.21.2Waterleaksonfurnacecoolingwatersystem.1.2I.3Electricalproblems(i.e.arcing,controlpower,monitoringequipmentoncriticalcomponents.etc.I.21.1Coolingwatersupplyfailure.1.21.5Changingoutofstokingmachinesorrepairinginplace1.21.6Cleaningofoperatingdeck1.21.7SoundingofelectrodesI.21.8Electrodestubbingorbreaking1.21.9Failureofhdraulicsystemforheadmovementandslippings\stem1.21.10Mi\chuteleakingniixI.21.IIChangingoftransformervoltagesettings1.21.12Checkingforsuspectedwaterleaks1.21.13Scheduledplantpoweroutageforcleaning&electricalcheck1.21.14Powercurtailmentfromelectricalsupplycompany1.21.15FurnacetripduetofurnaceblowI.21.16Plantshutdownduetoevactiation1.22(CA)Exceptfor1.21.5,1.21.6,1.21.7,121.10.1.21.15,and1.21.16theaboveitemsrepairedthroughtheMaintenanceEmpactWorkOrderSystem.23(P)Emittingvisibleemissionsfromstack1.24(CA)adjustelectrodestolowerpositionifneededI.24.IAddmixtofurnaceandstokemixinI.24.2Check/adjustscrtibberparametersforpropersettings1.25(P)Furnaceshellburnthrough1.26(CA)Furnaceshelltoherepaired1.27(P)PluggingfurnacetapholebyhandwhenBaileypluggingunitmalfunctioning1.28(CA)RepairplugginggunSectionNo;SOPIssueDate;Rev.Date;START-UP/SHUTDOWN/MALFUNCTIONAuthor;PLANFOR#18FURNACEPage;1of1.0PURPOSEANDSCOPE;ThepurcoseandscopeofthisprocedureistoassureproperoperationandcocI:nenatror.ofthefurocceprocesssrdventuriscrcaner;andtocomplywithallapplicablerequiren.eritsoftheEPA,TitleV,aridMACIstandards.Thisprocessconsistsofasari-sealfurnaceandassociateddus::controlequipment.Theemissior:sfromthicprocessarecontrolledbyaventuriwetscrubberthatcollectsemissionsfromunderthecoverofthefurnace.2.0OPERATIONANDMAINTENANCEREQUIREMENTSAtalltimes,includingperiodsofstartup,shutdown,andmalfunction,ownersoroporatorsshalloperateancmarntaintheaftectedsource,rncludingassocratecairpollutioncontrolequipment,inamannerconsistentwithgoodairpoilutioncontrolpracticestotminimizingemissionsatleasttotheievelsrequiredbyalreievantstandards.Anytinethefurnaceorventuriscrubberisshutdown,orrestarted,theseproceduresmustbefoliowodanddocumentedontheSSMPMaintenanceRecordSheettcatedinNo.18FurnaceControlRoom.3.0DESCRIPTION;3.1Start—up;No.18FurnaceVenturiScrubbersystem3.1.1StartupufVenturiScrubbingSystemwillbeperformedperErametMariettaRECPProcedureNECP—l03—243.l.l.a.OperationsaredefinedinReferenceManual#13(TitledVenturiGasCleaningSystem—Section6.6.5.4jErametTrainingandTechnicalManual3.l.1.b.RecordthestartupdataofthedustcollectorontheSSMPMaintenanceRecordsheetlocatedinNo.18FurnaceControlRoom3.1.2StartupofFurnace#18willbeperformedperSrametMarietta,IncSOP—103—019.3.1.2.a.Ensurepropermixlevelsareinfurnacetominimizefuming.3.l.2.b.Visuallylookforemissionsfromthedischargeofthestacks.3.l.2.o.RecordthestartuptimeoftheprocessontheSSMPMaintenanceRecordsheetlocatedInNo.18FurnaceControlRoom.3.2Shutdown;No.18Furnace3.2.1ShutduwnoffurnacewillbepertormedperErametMariettaSOP103-090.3.2.ienturihostooiertoroperalesuntIlfumzngstoos3.2.3PeoorhthetimeotshutdownonSSNPMaintenanceRerordsheetloua:edNo.18FurrareCnntrrPoom.STARTUP/SHUTDOWN/MALFUNCTIONPLANFOR#18FURNACESectIonNo:SOPIssueDate:Rev.Date:Author:Page:2of3.3Stdosn:VenturiScrubber3.3.1.ShutdownofVenturiScrubberwillbeperformedD’erDECS103—24.3.3.2.Rc.cordthetimeofsnutzdownontheSS1iPMaintenanceRecordsheEtlocatedinNo.18FurnaceControlRoom4.0STANDARD/EXPECTEDENDRESULT:4.1Theexpectedendresultissafeorerationofthefurnaceandventuriand100%compliancewiththeErarr.eI’sTitleVPermitandtheMACTstariciard.5.0DEVIATIONANDCORRECTIVEACTION:5.1SeeApendix“A”titledFurnace#18SSM?6.0RESPONSIBILITYFORIMPLENTATION:6.1TheShiftSupervisor/PlantForemanisresponsibletoassurethatthisprocedureisimplementedexactlyaswritten.6.2TheDepartmentManagerordesigneeisresponsibletoconductaprocedureassessmentofthisprocedureannually.7.0RECORDIEPINGREQUIRENTS:TheEnvironmentalDepartmentmustbenotifiedimmediatelyifamalfunctionoccursthatcausesanexceedariceofanallowableparameterthatisnotaddressedinthisSOPorguidancedocument.AnyexceedaricenotspecificallylistedinthisSOP/guidancedocumentaridaddressedperthecorrectiveactionslistedinthisSOP,mustbereportedtoOEPAwithin(2)dayswithafollow-upletterdetailingtheeventwithin(7)days.Allmonitoringreports,excessemissionsnoted,andallmaintenanceactivityperformedonthedustcollectormustberecordedandsenttotheenvironmentaldepartmentwithin(2)daysoftheendofeachmonth.TheStartup—Shutdown--MalfunctionPlanandMaintenancePlanmustbekeptforthelifeofthedustcollectoraridtheprocess.Changestotheprocessorcontroleciu:pmentwillrequiretheplantohoupdatedtoreflectthesechanges.TherecordkeepingrequiredbythisSOPisforatermof(5)years.TheserecordsmusthemadeavailabletotheEPAattheirrequest.8.0APPROVALS:DepiManagerEnviron:uentaiManager,QualityAssuranceSTARTUP/ SHUTDOWN/MALFtJNCT

ION PLAN

FOR

#18 FURNACE

Section

No:

SOP Issue

Date: Rev.

Date: A;thor: Page: 9.0 SYSTEMS CONNECTIONS: 1. I-IECP-103-24:

#18 Purriace 2. Reference

Manual

#13: Venturi

Sas (leaning

tystent— Section

6.6.5.4.

in Eramet Training

and Technical

Manual 3. SOP—103—619:

Recovery

Pro:r.

Scent

inn

No.

8 Furnace 10.0 ATTACFNTS: A)

SSMP Maintenance

Record

Sheet B) Apperithx

“A”

: Furnace

#18

55MBAPPENDIX‘IA”FURNACE#18SS1PProblems(P)andCorrectiveActions(CA)5MDEVIATIONANDCORRECTIVEACTION:Whenanon-standardconditionoccurs,theproceduremusthefollowedandDocumented.NotifytheShiftSupervisor/PlantForemanimmediately.5IMalfunctions/Non—Conformance:5.1.1(P)Completelossofpowertoplant,furnaceorscrubber.1.1(CA)Uponlossofpower,followHECP103-04.Whenpowerisrestored,followstartupprocedureforventuriscrubbingsystemoutlinedinErametTrainingandTechnicalManual#13.Afterscrubberisoperating,commencestartupoffurnaceperHECP103-04andSop103-019ftrstarttipoffurnace.1.2(P)Scrubbertripcausedbyhighvibration.1.3(CA)LockoutscrubberperHECP103-24.Switchtobackupscrubber.StartupperHECP103-24andTechnicalManual#13.Cleanandbalancemalfunctioningscrubber..1.4(P)Scrubbertripnotcausedbyhighvibration.1.5(CA)Checkallothermonitoringdevicesthatcouldcausetrip.Checkallpowersourcesforproblems.Whenrepairedorbackupplacedinservice,startupperIIECP103-24andTechnicalManual#13..1.6(P)Scrubberdampercontrolsnotoperating..1.7(CA)Checkelectricalandmechanicalcomponentsofcontrolsystemandrepairanyproblemfound..1.8(P)Pumpfailureornowatertoscrubbersystem..1.9(CA)Contactwatersupplysourceandrequestrepairpumpthatfailedorswitchtobackup.Checklinesforblockage.Removeanyblockagefound..1.10(P)Motorfailureonscrubbers..1.11(CA)LockoutscrubberperHECP103-24.Switchtobackupscrubber.StartupperHECP103-24andTechnicalManual#13.Replacemotorofinalfunctioningscrubber..1.12(P)Scrubberbearing,coupling,orgearboxfailure..1.13LockoutscrubberperHECP103-24.Switchtobackupscrubber.StailupperHECP103-24andTechnicalManual#13.Replacemalfunctioningscrubberbearingorcouplingorgearboxasneeded..1.14(P)Lossofcoolingwatertoscrubberbearings..1.15(CA)Checkwaterlineforbreakorblockage.Checkstrainerforblockage.Checkwatersupplysourceforpumpfailureormajorbreakinsupplyline..1.16(P)Holeinscrubberhousingorductfromfurnacetoscrubber..1.17(CA)Weldpatchoverhole.(P)Failureofscrubberimpellerorshaft..1.19(CA)L.ockoutscrtibberper1{ECP103-24.SwitchtobackupscrubberRepairorreplacemalfunctioningimpellerorshaft..1.20(P)Possiblefurnaceprocessinterruptions:.1.20.1ScheduledmaintenanceoutagesforroutinerepairsI.20.2Waterleaksonfurnacecoolingwatersystem,•I.20.3Electricalproblems(i.e.arcing,controlpower.monitoringequipmentoncriticalcomponents,etc..I.20.4Coolingwatersupplyfailure.•I.20.5Shovinginofmixbanks•1.20.6Cleaningofoperatingdeck•I.20.7Soundingofelectrodes•1.20.8ElectrodestubbingorbreakingFailureofhydraulicsstemforheadmoementandslippingsystem5.2.21.OMixchuteleakingmix5.2.21.IIChangingoftranslormervoltagesettings5.2.21.12CheckinvtbrsuspectLdaterleaks5.2.21.I3Scheduledplantpoweroutageforcleaningandcheckingplantelectricalsystem5.2.21.14Powercurtailmentfromelectricalsupplycompany5.2.22(CA)Exceptfor5.2.21.6,5.2.21.7,5.2.21.8,5.2.21.11,5.2.21.12.5.2.21.13and5.21.2.14,theaboveitemswouldherepairedthroughtheMaintenancekmnpactWorkOrderSystem5.2.23(P)Emittingvisibleemissionsfromstack5,2.24(CA)adjustelectrodestolowerpositionifneededAddmixtofurnaceCheck/adjustscrubberparametersforpropersettings5.2.25(P)Fornaceshellburnthrough5.2.26(CA)Furnaceshelltoberepaired5.2.27(P)PluggingfurnacetapholebyhandwhenBaileypluggingunitmalfunctioning5.2.28(CA)RepairplugginggunSectionNo:SOPIssueDate:Rev.Date:START-UP/SHUTDO/MALFUNCTIONAuthor:PLANFORMORPROCESSPage:1of1.0PURPOSEANDSCOPE:r1hEpurposeandscopeofthiscrocedureistoassureproperoperationanddocumentationoftheNORprocessandbaghouse;andto;umplywithallapplicablerequirementsoftheSPA,TitleV,aridMACTstandards.Thisprocessc:ortsistsofaManganeseOxygenReduction(NOR)processanddustcont.rolequiernerit.TheemissionsfromthisprocessarecontrolledbyabaghousewhichcontrolsfumefronttheNORprocessbymeansofasuspendedhoodabovetheladle.2.0OPERATIONANDMAINTENANCEREQUIRENTSAtalltimes,includingperiodsofstartup,shutdown,andmalfunction,ownersoroperatorsshalloperateandmaintaintheaffectedsource,includingassociatedairpollutioncontrolequipment,inamannerconsistentwithgoodairpollutioncontrolpracticesforminimizingemissionsatleasttothelevelsrequiredbyallrelevantstandards.AnytimetheNORprocess/dustcontrolequipmentisshutdownorrestarted,theseproceduresmustbefollowedanddocumentedontheSSMPMaintenanceRecordSheetlocatedintheNORControlRoom.3.0DESCRIPTION:3.1Start—up:ManganeseOxygenReduction(NOR)Process/Baghouse3.1.1StartupofNORProcess/BaghousewillbeperformedperHECP-103-02.3.1.2OperationalchecksaredefinedbytheNORBaghouseChecksheet.3.1.3RecordthestartupdataofthedustcollectorontheSSMPMaintenanceRecordSheetlocatedintheNORControlRoom.3.2Shutdown:MORprocess/Baghouse3.2.1ShutdownoftheMORwillbeperformedperHECP-l03-02.3.2.2NORBaghousewilloperateuntilfumingstops.3.2.3RecordthetimeofshutdownontheSSMPMaintenanceRecordSheetlocatedintheNORControlRoom.4.0STANDARD/EXPECTEDENDRESULT:4.1TheexpectedendresultissafeoperationoftheNORprocessandBaghouseand100%compliancewiththeEramet’sTitleVPermitandtheMACTstandard.5.0DEVIATIONANDCORRECTIVEACTION:5.1SeeAppendix“A”titled11CRProcess/BaghouseSSNP6.0RESPONSIBILITYFORIMPLEMENTATION:6.1TheShiftSupervisorisresponsibletoassurethatthisprocedureisrmplementedexactlyaswritten.STARTUP!SHUTDOWN/MALFUNCTIONPLANFORMORPROCESSSectionSo:SOPIssueDate:Rev.Date:Author:Page:2of6.2TheDepartIrerrManagerordesigneeisresponsibletoconductaproceroureassessmentofthisprocedureannuaLly.7.0RECORDEPINGREQUIREtNTS:TheEnvironmentalDepartmentroustbenotifiedimmediatelyifamalfunctionoccursthatcausesanexceedanceofanallowableparameterthatisnotaddressedinthisSOP.AnvexceedancerrotspecificallylistedinthisSOPandaddressedperthecorrectiveactionslistedinthisSOP,mustbereportedtoOEPAwithin(2)dayswithafoliow—upletterdetailingtheeventwithin(7)days.Allmonitoringreports,excessemissionsnoted,andallmaintenanceactivityperformedonthedustcollectormustberecordedandsenttotheenvironmentaldepartmentwithin(2)daysoftheendofeachmonth.TheStartup—Shutdown—7lalfurmcticnPlanandMaintenancePlanmustbekeptforthelifeofthedustcollectorandtheprocess.Changestotheprocessorcontrolequipmentwillrequiretheplantobeupdatedtoreflectthesechanges.TherecordkeepingrequiredbythisSOPisforatermof(5)years.TheserecordsmustbemadeavailabletotheEPAatt:heirrequest.8.0APPROVALS:DeptManagerEnvironmentalManager,QualityAssurance9.0SYSTEMSCONNECTIONS:1.HECP—103—02:Reaction/CastingFans10.0ATTAC-Th’NTS:A)SSMPMaintenanceRecordSheetB)MORPachouseCireckaheetC)Appenidix‘A”:MOEProcess/BaghouseSSVPINOSAhowDcc.d:575-Version:3Phnted:2010-04-13byJohnHughesIDcc.status:ApprovedIN0sAhowSOP-143-460:C2P#2DustCollector-SSMPAjthor:DaveBaflantyrieApproveddate:2009-09I621:44Approvedby:DaveBallantynaSOP-143-460:SHEPERSONALPROTECTIVEEQUIPMENTEMIStandardPPEisrequiredforperformingthetasksdescribedHowever,Glovesarerecommended,andHearingProtectionisC2PCrusherSoundBarrierCurtainswhilethecrutdn.qsystemisPURPOSEANDSCOPE:1PROCEDUREDESCRIPTIONThepurposeandscopeofthisprocedureeproperoperationandJawCrusherprocessand#2DustCector,andtomtallapplicablerequirer———k5,andMACTstandards.TheC2PawCrrocessonsistsoftwocrushvibratinggrizzlyfeeder,and7(yen)nveyorbe.Theemissionsfromthisibyabaghousewithvariouspupints.Alldustisollecdtoadusthopper.IVIRONMENTALPOLlY:Attimes,includingeriodofstartup,shutdown,andmalfunction,operatorsoftheC2PJawCrherpressand#2stCIlectorshalloperateandmaintaintheprocess,includingassociatedaollutiocontrolquipent,inamannerconsistentwithgoodairpollutioncontrolpracticesforminiingesistoleastthelevelsrequiredbyallrelevantstandards.StartTonthe#2collect.ThisisdonfromtHMIlocatedinthecontrolroom.IftheentirecrushersysteistobetartedthendustcIlectorwillstartautomaticallythroughthePLCandHMI.NOTE:#2DustcollectorInotnwhenallcrushedproductisgoingtoproductconveyor#1only.1.2ThedischargerotaryvalveswIIautmaticallystartthroughthePLCwhenthedustollectorsarestarted.NOThedustcollectdiscargerotaryvalvearecontinuouslymonitoredbytheC.Ifeithperanfailtostart,thefanwillnotstart.1.3VisuaokforemissfromthedischargeofthestackandrecorddailyontheTitle5/MACTInspecionecordsheet(APPENDIX143-A)locatedinthecrushercontrolroom.iepressuredroprangeforthebaghouseis0.6-3.0inchesofwater.ThepressurereadoutislocatedontheSouthlegofthebaghouse.RecordthereadingIpectionRecordsheet.fthestartupdataofthedustcollectorontheInspectionRecordsheet.Iftherearenovisibleemissionsandthedifferentialpressureiswithintheacceptablerange,itisassumedthatthecleaningmechanismisoperatingcorrectly..6RecordthestartuptimeoftheprocessontheTitle5IMACTComplianceRecordsheet(APPENDIX143-B)locatedinthecrushercontrolroom.NOTE:Anytimethereisadustcollectorshutdownorbreakdown,theaboveStart-upproceduremustbefollowedanddocumentedininkasdescribedabove.ThisincludesStart-upandshLltdownatthebeginningandendofshift.Protectiveequipment:C2P#2DUSTCOLLECTORSTARTUP,SHUTDOWN,MAINTENANCEPLANThepurposeandscopeofthisprocedureistoassureproperoperationanddocumentationoftheC2PJawCrusherprocessandDustCollector.procedure.workingwithintheoftheC2PEPA’sTitlea1.41.5Pvge1of3INOSAhowDcc.id.575-Vervor3Printed2010-04-13byJohu-uiçj:es.._.Doc,statusApproved I

hoAuthorDaveBaflautynL SOP-143-460:

C2P

#2 Dust Collector- SS1PApproveddate2009-09-162144Approvedby:DaveBallaritynePROCEDUREDESCRIPTION(Continued)2Shutdown:2.1TurnoffthedustcollectorusingthePLCfrmheHMIlocatedinthecrushercontrolroom.2.2RecordthetimeofshutdownontheCompliacRecordsheetlocatedinthecrushercontrolroom.3CollectorIBaghouseMaintenance&Preveninance3.1Monthly-VisualInspecnsomsystem.isillincludeavisualInspectionofthehoodsandductwrkisualinsetionoftheextenrofthebaghouse,visualinspectionofthedifferentialgagluing,andaisualinspectionofthepulsejetcleaningmechanismRecordtheresultsoftinectntheEMPACSystemPreventiveMaintenanceWorkOrder.3.2Quarterl-Vspeonofgsndcages.Openplenumofbaghouseforinspeo.RecordtreItsofipectionintheEMPACSystemPreventiveMainennceWorkOrde3.3Seminnat-Inspectionoffaforwearandcorrosion.Recordtheresultsoftheta::::ntheEMPACyemPreventiveMaintenanceWorkOrder.4.1Start-upandhutdownofthedustcollectionsystemmustbedoneatthebeginningandendofeachshused.ItshouldbenotedontheComplianceRecordsheetinthecrushercontrolroo2tencedoneonthedustcollectormustbedocumentedintheEMPACSystemyeMaintenanceWorkOrder.Allnon-PMworkshouldalsobedocumentedontheComplianceRecordsheetlocatedinthecrushercontrolroom.Paqe2of3INOSAhowDec.id:575-VCrSLO3Printed:2010-04-13byJohnHughes



# IDcc.status:Approved 

# NOSAhOW

SQP-143-460:

C2P

#2 Dust Collector- 

# SSI4PAUthor.Daus[3aHaniyne



# IApproveddate2009-09-1621:44App-vJby:Davedaliar.tyneSTANDARDIEXPECTEDENDRESULTTheexpectedendresultissafeoperationofthedustcollectorand100%compliancewiththeEPAsTitle5PermitandtheMACTstandard.ODEVIATIONANDCORRECTIVEACTIONDustCollectorFanFailure.Verifypowerison.laceFanMotor.electricalcontrols.cebearings.cebelts.FORIMPLEMENTATIONibilityofthePackingSupervisortoassurethatthisprocedureisimplementedresponsibilityoftheDepartmentManagertoconductaprocedureassessmentofthisprocedureannually. 

# %SYSTEMCONNECTIONS1APPENDIX143-ATitle5/MACTInspectionRecordSheet2.APPENDIX143-B:Title5/MACTComplianceRecordSheet1.Whenanonstandardconditionoccurs,theproceduremustbeactionstakendocumented.Whena“No-Gosituationoccursshutdownimmediatelyandthenon-conformancemustbePackingSupervisor/PlantForemanimmediately.2AnymalfunctionsfoLindorcorrectiveactionsrequired,willbeprioritytocompletetherepairsinatimelymanner,AllmalfunctiontactionswillbereportedtotheEnvironmentalDepartmentintwo(2)andtheconditionsand 

# ),theequipmentmustbe3Malfunctions/Non-conformance:3.1Emittingvisibledustfromstack.No-Go-Usefluorescentpowdertoleakdetec-Replacebags,cagesorrepgifis3.2Pluggedorbrokendust-Patch,repairor-3.3HighDifferentialPr-Verifypowerison.-VerifyPDBlower-Changebags.3.4LowDifferentialPressure-Verowens-erifyFanisoperatiregacitherearenoieckductsforholeCheckbagsforholesorCheckbaghouseintegrityleaks,b-Go3.6BaghdischargeI-Verifyp-i._-Replacemotor.-Rep/repIacegeardrive.-Rete1htibq/replacebelt.PrirIri,,-electricalcontrols.written.Page3o13INOSAhowDoc,id:574-Version:2Printc.2010-04-13byJohnHLiçJhCSDoc.statusApprovedINOSA110’3SOP-143-450:C2P#3DustCollector-SSMPAuthor,DavehalantyneApproveddate:2009-09-1621:43Approvedby.DaveBel[antyneLwPERSONALPTEIEEQUIPMENTEMIStandardPPErequirecforpertorrningthetasksdescnbedHoweverGlovesarerecommendedandH:arirgi.2jotectionisreqiPROCEDUREDESCRIPTION________________Thepurposeandscopeofthisproceduraproperoperationand-‘3C2PDuOCeiieuWr“‘JawCrusherprocessand#3DustCctor,andtomtallapplicabler5,andMACTstandardsTheC2PawCrocessonsistsoftwo—vibratinggnzzlyfeeder,and7(yen)nveyorbeThemissionsfromthis—byabaghousewithvariouspupmisAlldustisollecdtoadusthopper.ENVIRONMENTALPOLlY:Ataimes,includingpdodofstartup,shutdown,andmalfunction,operatorsoftheC2PJawCrherpressand#3StCIlectorshalloperateandmaintaintheprocess,includingassociatedaiollutiocontrolquipnt,inamannerconsistentwithgoodairpollutioncontrolpracticesforminiingeamstoleastthelevelsrequiredbyallrelevantstandards1Start-.1Tonthe#3collectThisisdonfromHMIlocatedinthecontrolroomIftheentirecrushersystestobetartedthendustcHectorwillstartautomaticallythroughthePLCandHMINOTE:#3Dustcollectorwnotrnwhenallcrushedprocuctisgoingtoproductconveyor#1onlyI2ThedischargerotaryvalveswiautmaticallystartthroughthePLCwhenthedustolleclorsarestartedNOThedustcollectdiscrgerotaryvalvearecontinuouslymonitoredbythePLCitheroionfaostart,thefanwillnotstart1.3VisuaokforemissfromthedischargeofthestackandrecorddailyontheTitle5IMACTInspecionecordsheet(APPENDIX143-A)locatedinthecrushercontrolroomaptablepressuredroprangeforthebaghouseis0.6-3.0inchesofwaterThepressurereadoutislocatedontheSouthlegofthebaghouse.RecordthereadingmctmonRecordsheet‘thestartupdataofthedustcollectorontheInspectionRecordsheet::IftherearenovisibleemissionsandthedifferentialpressureiswithintheacceptablerangeitisassumedthatthecleaningmechanismisoperatingzorrecfljRecordtnestatuptimeoftheprocessontheTitle5MACTComplianceRecorosheet,AENDlX43-3)locatedinthecrushercontrolroomNOTE:AnytimethereisaOustcollectorshutdownorbreakoowntheaboveStart-upproedjremustbefollowedanddocumentedininkasdescrbedaboveThisincludesStart-uoandshuldosnatthebeginningandendofsh’tr’,33.1of3Protectiveequipment:SOP-:4345rJ.PrJILPO5EANDSCOPE:C2P3DjsrC0L.EC0R-SATUP,LOUIDOWN,rlAiN’rErAncEPLANThepurposeandscopeofthisprocedureisTOassureproperoperatioc.anddocumentationofIDeC2PJaWCrusherprocessaid3DustCollector.oftheC2PEPA’sTitlea1.415.1,INOSAhowDot.d:574Version:2Pr:nted:2D1DO4-13by]ohriHughesDcc.status:ApprovedINOSASOP-143-450:C2P#3DustCollector-SSI4PAuthor.DaveBahantyneApproveddate:2OO9-O91621.43Approvedby:DeveBaflantynePROCEDUREDESCRIPTION(Continued)2.Shutdown:2.1TurnoffthedustcollectorusingthePLCfrmheHMIlocatedinthecrushercontrolroom.2.2RecordthetimeofshutdownontheCompliacRecordsheetlocatedinthecrushercontrolroom.3.Collector!BaghouseMaintenance&Prevensinnance3.1Monthly-Visualinspecnsomsystem.isillincludeavisualinspectionofthehoodsandductwrkisualinsetionoftheexterirofthebaghouse,visualinspectionofthedifferentialgagluing,andaisualinspectionofthepulsejetcleaningmechanism.RecordtheresultsoftinactntheEMPACSystemPreventiveMaintenanceWorkOrder.3.2Quarterl-Vspeonofgsndcages.Openplenumofbaghouseforinspeio.RecordtreItsofipectionintheEMPACSystemPreventiveMainennceWorkOrde3.3Seminnal-Inspectionoffaforwearandcorrosion.RecordtheresultsofthetheEMPACyemPreventiveMaintenanceWorkOrder.4.1Start-upandhutdownofthedustcollectionsystemmustbedoneatthebeginningandendofeachshused.ItshouldbenotedontheComplianceRecordsheetinthecrushercontrolroo2tencedoneonthedustcollectormustbedocumentedintheEMPACSystemyeMaintenanceWorkOrder.Allnon-PMworkshouldalsobedocumentedontheComplianceRecordsheetlocatedinthecrushercontrolroom.Page2of3INOSAhowDoc.id:574-Verson:2Printed:2010-04-13byJohnHughesDoc.status:ApprovedINOSISOP-143-450:C2P#3DustCollector-SSI4PAuthor:DavebahantyneApproveddate:2009-09-1621:4JApprovedby.DaveEaIIriryne3.4LowDifferentialPressure-Verower-erifvFanistherearenockductsforholeCheckbagsforholesorICheckbaghouseintegrityDustCollectorFanFailure.NiVerifypowerison.:eFanMotorelectricalcontrols.bearings.belts.STANDARDIEXPECTEDENDRESULTTheexpectedendresultissafeoperationofthedustcollectorand100%compliancewiththeEPA’sTitle5PermitandtheMACTstandard.DEVIATIONANDCORRECTIVEACTION1.Whenanonstandardconditionoccurs,theproceduremustbeactionstakendocumented.Whena“No-Go”situationoccursshutdownimmediatelyandthenonconformancemustbePackingSupervisor/PlantForemanimmediately.2.Anymalfunctionsfoundorcorrectiveactionsrequired,willbeadcprioritytocompletetherepairsinatimelymanner.AllmalfunctiontactionswillbereportedtotheEnvironmentalDepartmentintwo(2)andtheconditionsandbedaysorless.3.Malfunctions/Nonconformance:3.1Emittingvisibledustfromstack.No-Go-Usefluorescentpowdertoleakdetect-Replacebags,cagesorrenairi3.2Pluggedorbrokendust-Patch,repairorclearI3.3HighDifferential-Verifypowerison.-VerifyPDBlower-Changebags.isoperatingcorrectly.3.6Bagh’sdischarge-Verifypo—i-Replacemotor.-Rep/replacegeardrive.-Reteitiç/replacebelt.-Ppnir/reIniceelectricalcontrols.SILITYFORIMPLEMENTATIONponsibilityofthePackingSupervisortoassurethatthisprocedureisimplementedwritten.theresponsibilityoftheDepartmentManagertoconductaprocedureassessmentofthisprocedureannually.5SYSTEMCONNECTIONS1.APPENDIX143-ATitle5/MACTInspectionRecordSheet2.APPENDIX143-B:Title5/MACTComplianceRecordSheetPaoe3of5INOSAhowDcc.id576Veron:3Printed:2010-04-13byJohnHughesiDcc.status:ApprovedNOSASOP-143-470:C2P#1DustCollectorSSMPAuthorDaveBallantyrieIApproveddate:20U9OfDl621:44Approvedby:DaveBallantyneSOP-143-470:nt-However,Glovesarerecommended,andHIlII,C2PCrusherSoundBarrierCurtainswhilethiPROCEDUREDESCRIPTIONC2PD,otCoiie,torThepurposeandscopeofthis‘JawCrusherprocessand#1Di.5,andMACTstandardsThevibratinggrizzlyfeeder,byabaghousewithvanPURPOSEANDSCOPE:ENVIRONMENTALPOLICY:ofstartup,shutdown,andmalfunction,operatorsoftheC2PJawCrushectorshalloperateandmaintaintheprocess,includingassociatedairp,inamannerconsistentwithgoodairpollutioncontrolpracticesforminimizinemissionoatleastthelevelsrequiredbyallrelevantstandards.rt-up:1.1Turnonthe#1dustcoctor.isisdonefrotheIlocatedinthecontrolroom.Iftheentirecrushersystemisbeatedthen#1dcollectorwillstartautomaticallythroughthePLCandHMI.1.ThedischargerotaryvalvesIIautmaticallystartthroughthePLCwhenthedustcollectorsarestarted.TE:ThedustcollectorschgerotaryvalvearecontinuouslymonitoredbythePLC.Ifeitheropationalltostart,thefanwillnotstart.1.3uallyloosionsfrmthedischargeofthestackandrecorddailyontheTitle5/MAInspectionRecorheet(APPENDIX143-A)locatedinthecrushercontrolroom.1.4Theacceptablepressuredroprangeforthebaghouseis0.6-3.0inchesofwater.ThediffqçentialpressurereadoutislocatedontheSouthlegofthebaghouse.RecordthereadingontheN,ospectionRecordsheet.testartupdataofthedustcollectorontheInspectionRecordsheet.Iftherearenovisibleemissionsandthedifferentialpressureiswithintheacceptablerange,itisassumedthatthecleaningmechanismisoperatingcorrectly.thestartuptimeoftheprocessontheTitleVIMACTComplianceRecordsheet(APPENDIX143-B)locatedinthecrushercontrolroom.NOTE:Anytimethereisadustcollectorshutdownorbreakdown,theaboveStart-upproceduremustbefollowedanddocumentedininkasdescribedabove.ThisincludesStart-upandshutdownatthebeginningandendofshift.Protectiveequipment:C2P#1DUSTCOLLECTOR-STARTUP,SHUTDOWN,MAINTENANCEPLANThepurposeandscopeofthisprocedureistoassureproperoperationanddocumentationofheC2PJawCrusherprocessandiiDustCollector.SHEPERSONALPROTECTIVEEQUIPMENTEMIStandardPPEisrequiredforperformingthetasksdescribedwithijrocedure.isienworkingwithintheroperationanddocuntatioftheC2PIapplicablerequirementftheA’sTitlensistsoftwocrushers,tworenboxes,amissionsfromthisprocessarecontrolleddtoadusthopper.1.5Page1of3INOSAhowDoc.id:576-Version:3Printed:2010-04-13byJohnHughesIN0SADoc.status.ApprovedSOP143470C2P1DustCollectorSSivlPAthoraeBaa’reAnorosedcete:z.U9-Uv-62:44Approveddy:DaveBaliantynePROCEDUREDESCRIPTION(Continued)2Shutdown:2.1TurnoffthedustcollectorusingthePLCftheHMIlocatedinthecrushercontrolroom2.2RecordthetimeofshutdownontheCompIinteRecordsheetlocatednthecrushercontrolroom.3.Collector/BaghouseMaintenancePreventaIamnarice3.1Monthly-Visualinspeoorlesomsystem.iillincludeavisualinspectionofthehoodsandductrvisualinsehonoftheexteriorofthebaghouse,visualinspectionofthedifferentialgageurnng,anaisualinspectionofthepulsejetcleaningmechanism.RecordtheresultsofthinsontheEMPACSystemPreventiveMaintenanceWorkOrder.3.2Quarter-sualinectnofbsdcages.Openplenumofbaghouseforinspeio.RecordtheestsofthspectionintheEMPACSystemPreventiveMainnnceWorkOrder.inofateeofthe.1Start-upandtdownofthedustcollectionsystemmustbedoneatthebeginningandendofeacsftused.ItshouldbenotedontheComplianceRecordsheetinthecrushercontrolrom.4.2mnancedoneonthedustcollectormustbedocumentedintheEMPACSystemPreventiveMaintenanceWorkOrder.Allnon-PMworkshouldalsobedocumentedontheComplianceRecordsheetlocatedinthecrushercontrolroom.Page2of3r—

jAIiow

Dot t576Versom

3

Ponted: 2O1CQ4-13

by John Hughes Dot, status Approved SOP-143-470:

C2P

#1 Dust Collector- SSMP

Vea’15

2144 Approved

by: Dave baPlantyne STANDARD

I EXPECTED

END RESULT The expected

end result

is safe operation

of the dust collector

and 1000/o compliance

with

the EPAs Title

5 Permit

and

the MACT standard. o DEVIATION

AND CORRECTIVE

ACTION 1. When

a nonstandard

condition

occurs,

the procedure

must

be folio

d and

the conditions

and actions

taken documented.

When

a “No-Go”

situation

occurs

(

e

b low),

the equipment

must

be shutdown immediately

and

the nonconformance

must

be correc

d

b

ore start-up.

Notify

the Packing Supervisor?

Plant Foreman immediately. 3.4 Low Differential

Pressure- Veify-pSfl- Sdrifs,

Fan

is there

are

no heck

ducts

for hole Check

bags

for holes

or- Check baghouse

integrity Dust Collector

Fan Failure.

Nc Verify

power

is on. ce

Fan Motor. ir electrical

controls. ice bearings. ice belts. discharge

faili- Verify po2ei-4.- Replace

motor.- Rep/replace

gear

drive.- Retefitibq/replace

belt.- RenIsir/rplace

electrical

controls. FOR IMPLEMENTATION ibility

of the Packing Supervisor

to assure

that

this procedure

is implemented 2.j..ifhe responsibility

of the Department

Manager

to conduct

a procedure assessment

of this procedure

annually. % SYSTEM CONNECTIONS 1. APPENDIX

143-A:

Title

5/ MACT Inspection

Record

Sheet 2. APPENDIX

143-B:

Title

5

/ MACT Compliance

Record

Sheet

the highest 2. Any malfunctions

found

or corrective

actions required,

will

be. priority

to complete

the repairs

in

a timely manner.

All malfunctions actions

will

be reported

to the Environmental

Department

in two

(2) 3. Malfunctions

/ Non-conformance: 3.1 Emitting

visible

dust

from

stack.

No-Go- Use fluorescent

powder

to leak detect

fi- Replace

bags,

cages

or 3.2 Plugged

or broken

dust- Patch,

repair

or clear 3.3 High Differential- Verify

power

is on.- Verify

PD Blower- Change

bags.

is operating

correctly. leaks. 3.6

b-Go written.

Page

3 of

3

jPURPOSEANDSCOPE:ThepurposeendscopeofthisprocedureistoassureproperoperationanddocumentationofheC7PCrushmgandScreeningrocessand#4ADustCollector.EMIStandardPPEisrequiredforperformingthetasksdescribedwithithisprocedure.However,Glovesarerecommended,andHearirotectionisrequredhenworkingintheVicinityoftheC7PCrusherwhilethecrushingaternisopeCPROCEDUREDESCRIPTIONThepurposeandscopeofthisprocedureeproperoperationandcumentionoftheC7PCrushingandScreeningprocessan4ADustColler;andtomeetallappliclereqementsoftheEPA’sTitle5,andMACTstanrds.CrusgandScreeningand#DusthectorprocessconsistsoftheSouthssCStation.eemisionsfromthisprocessaronliedbyabaghousewithvariouspickuointENVIRONMENTALPOLlY:Attimes,includingeriodofstartup,shutdown,andmalfunction,operatorsoftheC7PCrushiandSeningand#ADtCollectorprocessshalloperateandmaintaintheprocess,includingsociatairpollionntrolequipment,inamannerconsistentwithgoodairpollutioncontrolpracticesrminiiemisIonstoatleastthelevelsrequiredbyallrelevantstandards.1.Start-.1Tnonpowere#4AstcollectordPL1.Turnonthedustcollecrfan.1.3ThedustcollectorisoperatdbyPLC.Thecleaningmechanismisa“Cleanondemand”system.Airpulsesayotbeheardwhenthedustcollectorisstarted.1.VisuallylookforemissionsfrmthdischargeofthestackandrecorddailyontheTitle5MACTInspectionRecordseet(PPENDTX143-A)locatedinthecrushershanty.1.Theessuredropforthaghuseis4.0-10.0inchesofwater.ThedifferentialressuredoutistedotheNorthlegofthebaghouse.RecordthereadingontheInectionRecordsheet.1.6Theacceptaeceaningpressurerangeis75-90psi.Thegageisnexttothedifferentialpressurereadoutontheairregulator.RecordthereadingontheInspectionsheet.startupdataofthedustcollectorontheInspectionRecordsheet.Itisassumedthatiftherearenovisibleemissions,thecleaningairpressureisacceptableandthedifferentialpressureisacceptable,thecleaningmechanismisoperatingcorrectlyRecordthestartuptimeoftheprocessontheTitle5/MACTComplianceRecordsheet(APPENDIX143-B)locatedinthecrushershanty.NOTE:Anytimethereisadustcollectorshutdownorbreakdown,theaboveStart-LipproceduremustbefollowedanddocumentedininkasdescribedaboveThisincludesStart-upandshutdownatthebeginningandendofshift.INOSAhowDoc.id:622-Version:2Printed:2010-08-13byJohnHughesDot.status:ApprovedINOSAh0WSOP-143-420:C7P#4ADustCollector-SSI4P62143Apr:nr’uciby:DaveBallnntyreProtectiveequipment:SOP-143-420:C7P#4AOUSTCOLLECTOR-SSNPSHEPERSONALPROTECTIVEEQUIPMENT1.7Paqel0f4jNOSAhowDoc.id:622-Version:2Printed:2010-08-13byJohnHughesII0SADon,status:ApprovedhowSOP-143-420:C7P#4ADustCollector-SSPAtho,DaveBallantyneApproveddate:200909-1621:4,3Approvedby.DaveBallantynePROCEDUREDESCRIPTION(Continued)2Shutdown:2.1Turnoffthedustcollectorfan2.2Turnoffthedustcollector2.3Recordthetimeofshutdownoompliancecrdsheet,3.CollectorIBaghouseMaintenae&ventativeMa’tennce3.1Monthly-Visualinsptiforleakfrmsystem.Thiwillincludeavisualinspectionofthehoodsandductork,isualipctionoftheexteriorofthebaghouse,visualinspectionofthedifferentialgage.RerdesuitsoftheinspectionintheEMPACSystemPreventiveMaintenanceorkrr,3.2Quarter-‘-speionagsndcages.Openplenumofbaghouseforinspelo-RecordtreItsofipectionintheEMPACSystemPreventiveMainennceWorkOrde3.3Semianal-Inspectionofaforwearandcorrosion,RecordtheresultsofthetheEMPACyemPreventiveMaintenanceWorkOrder,4.1Start-upandhutdownofthedustcollectionsystemmustbedoneatthebeginningandendofeachshused.ItshouldbenotedontheComplianceRecordsheetinthecrushershanty..3-teancedoneonthedustcollectormustbedocumentedintheEMPACSystemyeMaintenanceWorkOrder,Allnon-PMworkshouldalsobedocumentedontheComplianceRecordsheetlocatedinthecrushershanty.Page2of4INOSAhowDcc.id:&22-Vcrsor.:2Pri”ted:2013-08-13byJohnHcghesDoc.srat.s:Arove I I\I

c’i5j1howAjthor:SOP-143-420:C7P4ADUStCollector-SSI4PApcvddate201tO102-3A;:).‘o:y:DaveBalarryi’eCSTANDARDIEXPECTEDENDRESULTTheexpectedendresultissafeoperationofthedustcollectorand1QQ%compliancewiththeEPA’sTitle5PermitandtheMACTstandard.3.4HighDifferential-Vejpowerison..5LowDifferential-Verifypowerison.-VerifyFanisopen-Verifythegageis-Verifythereareno-Checkductsforhole-Checkbagsforholes-Checkbaghouseisedischargefailure.No-GorubberdiaphraminDischargevalve.TensionrodsinDischargevalve.SIBILITYFORIMPLEMENTATIONresponsibilityofthePackingSupervisortoassurethatthisprocedureisimplementedaswritten.2.ItistheresponsibilityoftheDepartmentManagertoconductaprocedureassessmentofthisprocedureannually.SYSTEMCONNECTIONS1.APPENDIX143-A;Title5/MACTInspectionRecordSheetDEVIATIONANDCORRECTIVEACTIONandtheconditionsbelow),theequipmentbeforestart-upNotify1.Whenanon-standardconditionoccurs,thisproceduremustbeandactionstakendocumented.Whena“No-Go”situationcccimustbeshutdownimmediatelyandthenon-conformancemustthePackingSupervisor/PlantForemanimmediately.2.Anymalfunctionsfoundorcorrectiveactionsrequired,willbeaddrprioritytocompletetherepairsinatimelymanner.AllmalfuncticactionswillbereportedtotheEnvironmentalDepartmentwithin3.Malfunctions/Non-conformance;3.1Emittingvisibledustfromstack.No-Go-Usefluorescentpowdertole-Replacebags,cagesorpairsteel-Checkwater3.2Pluggedor-Patch,3.3Plugged-Openchuteorinplumbingtogage.lesandleaks.jo-Go•Ft-eFanMc-llr-e+rtalcontrols.-Repair/replacebearings.belts.Rcto3of1LNOSAhowoc,id:622-Vers.on:2Printed:2010-08-13byJohnHughes SDcc.stCtLs:Ayr,jonIR!RAhowII’MUIiSOP143420C7P4ADustCollectorSS‘\I,rDa’eLtIc2t3A2cvOdhy:)aveBaHanlyre2Title5/MACTComplianceRecordSheetPae4of4INOSAhowDoc.Id:553-‘Jerson.2Prnted20L0-08-t3byJohnHughesDoc.status:App:oven 1 NOSA’ 10 ’ 5

SQP-143-410:

C/P

#3 Dust Collector- SSMP2t42Apgruvdby.D#veBartyrreSOP-t43-410:NOTE:Thedustcollectormonitoredbyazerstart.PURPOSEANOSCOPE:NOTE:Anytimethereisadustcollectorshutdownorbreakdown,theaboveStart-upproceduremustbefollowedanddocumentedininkasdescribedabove.ThisincludesStart-upandShutdownatthebeginningandendofshiftProtectiveequipment: 0C7P#3DUSTCOLLECTOR-STARTUP,SHUTDOWN,MAINTENANCEPLANSHEPERSONALPROTECTIVEEQUIPMENTThepurposeandscopeofthisprocedureistoassureproperoperatlosanddocumentationoftheC7PJawCrusherprocessand3DustCollector.EMIStandardPPEisrequiredforperformingthetasksdescribedwiththiprocedure.However,Glovesarerecommended,andHearingProtectionisreqi.iredhenworkinginthevicinityoftheC7PCrusherwhilethecrushingsyrating.PROCEDUREDESCRIPTIONThepurposeandscopeofthisprocedureistoassureproperoperationanocumeationoftheC7PJawCrusherprocessand#3DustCoilor,andtoeetallapplicablerequireantsoeEPA’sTitle5,andMACTstandards.TheC7PwCrusherproceconsistsofacrusher,aillaryhperandboxdumper.Theemissionsbyabaghousewithvauspicppoints.ofStartup,shutdown,andmalfunction,tctorshalloperateandmaintaintheinamannerconsistentwithgoodairstthelevelsrequiredbyallrelevantENVIRONMENTALPCoperatorsoftheC7PJaw,process,includingassociepollutioncontrolpracticesforstandards.1.Start-up:1.12TonpowertothefdustoiltheTurnonthedustcolleconWaterSprays1.61.7willnotrusherlookforemissiop(fromthedischargeofthestackandrecorddailyontheTitle5Isheet(APPENDIX143-A)locatedinthecrushercontrolroom.lepressuredroprangeforthebaghouseis2.0-5.0inchesofwater.TheiipressurereadoutislocatedontheSouthlegofthebaghouse.Recordthereading;pectionRecordsheet.IstartupdataofthedustcollectorontheInspectionRecordsheet.Iftherearenovisibleemissionsandthedifferentialpressureiswithintheacceptablerange.ftisassumedthatthecleaningmechanismisoperatingcorrectly.RecordthestartuptimeoftheprocessontheTitle5/MACTComplianceRecordsheet(APPENDIX143-B)locatedinthecrushercontrolroom.Pajelof4INOSAhowDcc.d:553-Version.2Pnnted:2010-08-13byJohnHughesIDcc.status:ApprovedINOSASQP-143-410:C7P#3DustCollector-SSNPAuthor:DavedantyneApproveddste:2009-09-1621:42IApprocedby:DaveBaharityneGPROCEDUREDESCRIPTION(Continued)2.Shutdown:2.1Turnoffthedustcollectorfan.2.2Turnofftheconveyorsunderthedustcollector.2.3Turnoffthedustcollector.2.4Turnoffwatersprays.2.5RecordthetimeofshutdoonthomplianceRecdset(APPENDIX143-B)locatedinthecrushersnty3.Collector!BaghouseM-tence&PreyntyeMaintenance3.1Monthly-Visualinspeionleafrsystem.Thiswillincludeavisualinspectionofthehoodsandductwork,uasptionoftheexteriorofthebaghouse,visualinspectionofthediffereplumbindiscnnectionofthezerospeedswitchontherotaryvalvetoverifyesystemintecksanvisIinspectionoftheshakercleaningmechanism.Rerdresultsthe-spectiointhEMPACSystemPreventiveMaintenanceWorkOrer3.2uaerly-Visualinspectinobagsandcages.Openplenumofbaghouseforspetion.RecordtheresItsftheinspectionintheEMPACSystemPreventiveMinteanceWorkOrder.SeminuaInspectiofnforwearandcorrosion.RecordtheresultsoftheinspectiointheACystemPreventiveMaintenanceWorkOrder.4.DataCollection:4.1Start-upndhutdownofthedustcollectionsystemmustbedoneatthebeginningandendofechhiftused.ItshouldbenotedontheComplianceRecordsheetinthecrusherchant-4.2AllintenancedoneonthedustcollectormustbedocumentedintheEMPACSystemreventiveMaintenanceWorkOrder.Allnon-PMworkshouldalsobedocumentedontheComplianceRecordsheetlocatedinthecrushershanty.Page2of4LIN0sOwDocci:53Vvrsoci:2P’tcd:2020-08-13byJohnHuQhesDoc.status:Approved I NOSAI10W

SOP-143-410:

C7P

#3 Dust Collector- SS[4P2142AljprOvedby:DaveBahvntynvOSTANDARD/EXPECTEDENDRESULTTheexpectedendresultissafeoperationoftheoustcollectorand100%compliancewiththeEPA’sTitle5PermitandtheMACTstandardoDEVIATIONANDCORRECTIVEACTION1Whenanon-standardconditionoccurs,theproceduremustbefoedandtheconditionsandactionstakendocumented.Whena“No-Go’situationocc(sebelow),theequipmentmustbeshutdownimmediatelyandthenon-conformancemustbecoectebeforestart-up.NotifythePackingSupervisorIPlantForemanimmediately.2.Anymalfunctionsfoundorcorrectiveactionsrequired,willbeaddssewiththehighestprioritytocompletetherepairsinatimelymanner.Allmalfunctions,devitionsandcorrectiveactionswillbereportedtotheEnvironmentalDepartmentintwo(2)orkidaysorless.3.MalfunctionsINon-conformance:3.5DustCollectorFanFaili-Verifypowerison.ReplaceFanMotor.irelectrical

>3.6Bagr-Verifypowerison.Iplacemotor.ar/replacegeardrive.lacebelt.electricalcontrols.SYSTEMCONNECTIONS1.APPENDIX143-A:Title5/MACTInspectionRecordSheet2APPENDIX143-B:Title5/MACTComplianceRecordSheetPage3.1Emittingvisibledustfromstack.No-Go-Usefluorescentpowdertole-Replacebags,cagesorpairsteel-Checkwatersprayc32Pluggedorbrc-Patch,repair.3.3HighDifferenti-Verifypoweris-VerifyShakerM-Changebags.ectly.3).No-Go-Verifythe-Verifythereare-Checkductsfor:-Checkbagsforholes-Checkbaghouse

mtgage.holesandleaks,efailure.No-GoFORIMPLEMENTATIONsponsibilityofthePackingSupervisortoasscrethatthisprocedureisimplementedexaaswritten.ItistheresponsibilityoftheDepartmentManagertoconductaprocedureassessmentofthisprocedureannually.INOSAhowDoc.d:553-Verson2Printed:2010-08-13byJohnHughesDoc.status:ApprovedINOSAh0SOP-143-410:C7P#3DustCollector-SSMPA00rDavetlsl:antyneApproveddate:2009-09-t621:42Approvedby:DaveBallantynePage4of4INOSAhowE)oci552-‘ersor2Pric’Led:2010-OS-tOflyohrcHughes INOSA)b0wSOP-143-400:C7P4DustCollector-SSI4PApprovedcute.2009-09-1521:v2Approvedby:DaveSallantyreS°P-143-400,PURPOSEANDSCOPE:Protectiveequipment:C7P#4DUSTCOLLECTOR-STARTUP,SHUTDOWN,MAINTENANCEPLANThepurposeandscopeofthisprocedureistoassureproperoperationanddocumentationoftheC7PCrushingandScreening,processand#4DustCollector.tationoftheC7PementsoftheorprocessolledbyThedustcollectorisoperatebyaLC.ThecleaningmechanismisaCleanondemandsystem.Airpulsesnayn)tbeheardwhenthedustcollectorisstarted.isuallylookforemissionstr,hmth4dischargeofthestackandrecorddailyontheTitle5TInspectionENDIX143-A)locatedinthecrushershanty.rangeforthebaghouseis5.0-10.0inchesofwater.TheislocatedontheNorthlegofthebaghouse.Recordthereadingsheet.acceptablecleaningpressurerangeis75-90psi.ThegageisnexttothepressurereadoutontheairregulatorRecordthereadingontheInspection‘thestartupdataofthedustcollectorontheInspectionRecordsheet.Ifthepressuredropandcleaningpressureareintheaboverangesandtherearenovisibleemissions;then.itisassumedthatthecleaningairpressureandthedifferentialpressureareacceptableandthecleaningmechanismisoperatingcorrectly.1.9RecordthestartuptimeoftheprocessontheTitle5/MACTComplianceRecordsheet(APPENDIX143-B)locatedinthecrushershanty.NOTE:Anytimethereisadustcollectorshutdownorbreakdown,theabovestart-upproceduremustbefollowedanddocumentedininkasdescribedabove,Thisincludesstart-upandshutdownatthebeginningandendofshift.procedure.vhenworkingintheseaPERSONALPROTECTIVEEQUIPMENTEMIStandardPPEsrequiredforperformingthetasksdescribedwithHowever.Glovesarerecommended,andHearingProtectionisreqivicinityoftheC7PCrusherwhilethecrushingsys)aeJaorating.PROCEDUREDESCRIPTIONThepurposeandscopeofthisprocedureistoassureproperCrushingandScreeningprocessand#4otor;andtomeetallappiEPA’sTitle5,andMACTstandards.eC7PCrushiandScreeningand#4consistsofcrushers,screentiissionsfromthisproabaghousewithvariousplcENVIRONMENTALPOLIC1operatorsoftheC7PCruEmaintaintheprocess,inchgoodairpollutioncontrolpracticrelevantstandards.1.Start-up:‘ofstartup,shutdown,andmalfunction,DustCollectorshalloperateandIequipment,inamannerconsistentwithtoatleastthelevelsrequiredbyallontheTurnonthedustcolctor.1.0onth1.71.8wet.Psgelof4tive Maintenance: system.

This

will include

a visual inspection

of of the exterior

of the baghouse,

visual inspection

of ection

of the zero speed

switch

on

the rotary

valve results

of the inspection

in the EMPAC

System bags

and cages.

Open plenum

of baghouse

for the EMPAC

System Preventive Maintenance

Work

Order. r for wear

and corrosion.

Record inspection

in the EMPAC nce Work

Order. nutdown

of the dust collection

system

must

be done

at the beginning

and ift used.

It should

be noted

on

the Compliance

Record

sheet

in the crusher nance

done

on

the dust collector

must

be documented

in the EMPAC

System ntive Maintenance

Work

Order.

All non-PM

work should

also

be documented

on

the Compliance

Record

sheet (APPENDIX

143-B)

located

in the crusher

shanty, INOSAhow

Doc.

id:

552- Version:

2

Pririted:2010-O8-13

by John Huqhes I NOSAh0W

SOP-143-400:

C7P

4 Dust Collector- SSI4P

WfltD:vC6aIIaPtye t,nj-oven

date:

U.•

lo

2.

:..2 ApyrOved

by: D:ve BHr:ty:’ % PROCEDURE

DESCRIPTION

(Continued) 2. Shutuown: 2.1

Turn

off

the dust collector

fan 2.2

Turn

off

the conveyors

under

the dust collector 2.3

Turn

off

the dust collector.

5

/ MAm

•ance Record

sheet shanty.

N 2.4 Record

the time

of shutd (APPEND

IX 143-B)

bc 3. Collector?

Baghouse

Ma1.r 3.1 Monthly- Visual

ir the hoods

an the

di to Pre 3.2

Page2ot4Version

2

Pri’

ted: 2010-08-23

Lv John Finches Doc walLs. A:)prOvCS I It

c

how—

Author

Dave FiaHntyne SOP-143-400.

C/P

#4 Dust Collector

SSMP

Approved

date

21)09

0916

21:42 Appc.vvd

by: Dave Baliantyne STANDARD

I EXPECTED

END RESULT The expected

end result

is safe operation

of the dust collector

and

100% compliance

with

the EPAs Title

5 Permit

and

the MACT standard DEVIATION

AND CORRECTIVE

ACTION oIIector

I Fan

Mc- Re4oteieaCcontrols,- Repair/replace

bearings.- Jlace

belts. RESPONSIBILITY

FOR IMPLEMENTATION 1.

It

is the responsibility

of the Packing Supervisor

to assure

that

this procedure

is implemented exactly

as written. 2

It

is the responsibility

of the Department

Manager

to conduct

a procedure assessment

of this

Notify 1. When

a non-standard

condition

occurs,

this procedure

must

be and actions

taken documented

When

a “No-Go”

situation

occi must

be shutdown immediately

and

the non-conformance

must

I the Packing Supervisor

/ Plant Foreman immediately 2.

Any malfunctions

found

or corrective

actions required,

will

be priority

to complete

the repairs

in

a timely manner.

All malfunctic actions

will

be reported

to the Environmental

Department

within 3. Malfunctions

/ Non-conformance:

and

the conditions and corrective 3.1 Emitting

visible

dust

from

stack.

No-Go.- Use fluorescent

powder

to leajdect

filter section.- Replace

bags,

cages 3.2 Plugged

or broken- Patch,

repair 3.3 Plugged- Open

chute 3.4 High Differential- Verify

power

is on.- Verify

PLC

us cleaning —VTnig

air- Change

bags. Low Differential- Verify

power

is on.- Verify

Fan

is open- Verify

the gage

is- Verify

there

are

no holi- Check

ducts

for hole

or- Check

bags

for holes- Check baghouse

gage. leaks. Go ise discharge

failure.

No-Go power

is on. motor. eplace

gear

drive. ‘Retention/replace

belt.- Repair/replace

electrical

controls.- Repair/replace

diaphragm

in discharge

valve- Check tension

rods

in diaphragm

valvwINOSAhowDcc.id:552-Version:2Printed:2010-08-13byJobsHughesDcc.status:ApprovedINOSAi43-4OO:C/P#4DustCollector-SSMP1hrDaveBalantyiieApproveddate:2009-Op-lb21:42Approvedby:DaveBatcrityneprocedureannually.SYSTEMCONNECTIONS.tAPPENDIX143-A.Title5/MACTInspectionRecordAPPENDIX143-B:Title5/MACTComplianceRecordPage4oi4