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. Thesesections 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 EngineerEramet Marietta Inc.

(740) 374-1366

Cc Ms Christina WiegOEPA-SEDO

IR\\1I I \l\RII I Ni Ii) Iii )\ I\kII I \ 01111 )4T{} fl.i)

III liii irI i—iIij II 11)11(1 III 11 ( iIIII 41)1 4

pl6a
This information collection request is being conducted by the Environmental Protection

Agency’s (EPA) Office of Air and Radiation (OAR) to assist the EPA Administrator in developing

emission standards for Ferroalloys Production Manufacturing Emission Points under Clean Air

Act (CAA) section 112. The survey is being sent under the authority of Section 114 of the CAA.

BACKGROUND:

This information request (Enclosure 1) is to be completed for operations that comprise

ferroalloys production at each facility operated by your company which is located within the

United States. The ferroalloys production source category includes any facility engaged in

producing ferroalloys such as ferrosilicon, silicon metal, silicomanganese, ferromanganese,

ferronickel, and ferrochromium. The source category also includes production of calcium

carbide. Ferroalloys production includes, but is not limited to, the following unit operations: ore

unloading, ore storage, sintering, crushing, weigh-feeding, smelting, tapping, casting, and

screening.CAA section 114(a) states that the Administrator may require any owner or operator subject to

any requirement of this Act to:

(A) Establish and maintain such records; (B) make such reports; (C) install, use, and maintainsuch monitoring equipment, and use such audit procedures, or methods; (D) sample such

emissions (in accordance with such procedures or methods, at such locations, at such intervals,during such periods, and in such manner as the Administrator shall prescribe); (E) keep records

on control equipment parameters, production variables or other indirect data when direct

monitoring of emissions is impractical; (F) submit compliance certifications in accordance with

section 114(a)(3); and (G) provide such other information as the Administrator may reasonably

require.

There are two aspects to this CAA section 114 information collection request. The first

component of the information collection involves a survey requesting information on existingemission points. The second component requires owners to conduct testing. The testing

requirements are set forth in the cover letter of this packet (CAA section 114 letter) as well as

Enclosure 2.DIRECTIONS:

X All recipients must complete and return this survey by July 30, 2Q10.

X You are not expected to generate new information for the attached survey (Enclosure 1).

X Please answer all questions unless not applicable to your facility or operations, in which

case note that the question is not applicable. All information should be for the 2009

reporting year (unless otherwise noted).

4/21/2010
In order to avoid duplicate data and keep all data for a particular facility together, we

request that you submit all of the data requested from your facility in the same way. To submit

your data, mail a CD or DVD containing an electronic copy of all requested files to the EPA

address below:

U.S. Environmental Protection Agency

Office of Air Quality Planning and Standards

U.S. EPA Mailroom (D243-02)

Attn: Mr. Conrad Chin

109 T.W. Alexander Drive

Research Triangle Park, NC 27711

If the process data or other information you are providing is considered confidential,

please create a separate CD or DVD containing only the confidential portion of your data or

prepare a copy of the hard copy materials containing only the pages that include the information

you consider confidential. Clearly mark the disk and/or materials with the words “Confidential

Business Information.” Send these confidential files under separate cover to the attention of Mr.

Roberto Morales at the following address:

U.S. Environmental Protection Agency

Office of Air Quality Planning and Standards

U.S. EPA Mailroom (C404-02)

Attn: Mr. Roberto Morales, Document Control Officer

109 T.W. Alexander Drive

Research Triangle Park, NC 27711

For the security of your data, EPA recommends sending your confidential files to Mr.

Morales via Registered U.S. Mail using return receipt requested, Federal Express, or othermethod for which someone must provide a signature upon receipt. Do not electronically

transmit confidential business information (CBI) to EPA. E-mail and facsimile are not secureforms of communication and should never be used to transmit CBI.

If you have any questions regarding this request, please contact Mr. Conrad Chin at e-mail

chin.conrad(epa.qov

Please note that you are to provide a separate response package for each

facility in your company with ferroalloy production operations. Copies of this

questionnaire should be made for additional facilities.

PLEASE RETURN THIS SURVEY NO LATER THAN JULY 30, 2010

4/21/2010
PART I. OWNER INFORMATION

1. Name of Legal Owner: Eramet SA

a. Address: 16705 Riverview

b. City: Marietta

c. State: Ohio

d. Zip: 45750e. County: Washington

2. Complete street address of facility (physical location):

a. Address: 16705 State Route 7 South

b. City: Marietta

c. State: Ohio

d. Zip: 45750

e. County: Washington

3. Mailing Address (if different from Facility Street Address):

a. Address: P.O. Box 299

b. City: Marietta

c. State: Ohio

d. Zip: 45750

e. County: Washington

4. Facility Contact:

a. Name (First Name, Last Name): John Hughes

b. Title: Environmental Engineer

c. Telephone Number: (740) 374-1366 Ext

d. Fax Number: (740) 374-1305e. E-mail: john. hughes(äerametgroup. corn

4/21/201()
b. Dun & Bradstreet No: 07-462-7592

c. SARA TRI Facility ID (from Form R): 4575OLKMMTYOUTE

d. Number of Facility Employees:

Number of employees associated with ferroalloy production operations at the facility

(answer may be given using the following ranges: 0-100; 101-250; 251-500; 501-750;

751-1,000; 1,001-1,500; and >1,500.) Include temporary employees if they are a

significant fraction of your total number of employees.

10 1-250

e. Number of Corporate Employees:

Approximate number of employees of the business enterprise that owns this plant,

including where applicable, the parent company and all subsidiaries, branches,and unrelated establishments owned by the parent company

16000

f. NAICS Code(s): (See http://www.census.qov/epcd/www/naics.html)

Primary: 331112

Other:

g. Is the legal owner a small entity? DY DN Unknown

4

4/21/2010
Major Source

6. Geographic Coordinates of Center of Plant:

Either latitude and longitude or UTM coordinates with zone. Latitude and longitude shouldbe provided in decimal degrees, with 6 digits to right of decimal point, and an indication of

the associated datum (if available, likely NAD27, NAD83, or WGS84.)

a. latitude and longitude: 39.372517 81.523150

b. UTM coordinates: 454937.9 East, 4358247.0 North, Zone 17

7. Regulatory Requirements

(Indicate any Federal or State air emission standards, such as the NSPS, which are

applicable to your facility)

40 CFR Part 60, subpart Z, Standards of Performance for Ferroalloys Production40 CFR Part 63, subpart XXX, National Emission Standards for Hazardous Air

Pollutants from Ferroalloys Production: Ferromanganese and Silicomanganese

LI 40 CFR Part 63, subpart DDDDD, National Emission Standards for Hazardous Air

Pollutants for Industrial/Commercial/Institutional Boilers and Process Heaters

40 CFR Part 63, subpart YYYYYY, National Emission Standards for Hazardous Air

Pollutants for Area Sources: Ferroalloys Production Facilities

El Others (please identify):8. Facility Classification for hazardous air pollutants (HAP)

If you have an air operating permit issued under Title V of the Clean Air Act, indicate the

classification of your facility

El Synthetic Minor Source

Minor/Area Source

9. Permit Conditions

If any of the ferroalloys production operations at your facility are subject to State or local

air permit limits, please provide a copy of your operating permit. If you have a Title V

permit and it is not available online, please provide a copy of it. If your Title V permit is

still pending, please provide a copy of your permit application

4/21/2010
Attachment 3

Startup, Shutdown, and Malfunction Plan

PART II. GENERAL FACILITY INFORMATION

Process Summary

Complete the Process Summary in Table 2A for 2009 (unless you can justify selection

of an alternate base year) for all unit operations at your plant that are covered by the

ferroalloys source category. These include storage and handling of raw materials and

products. Complete Table 2B with detailed information for each furnace, and complete

Table 2C with details of tapping operations for each furnace.

2. Process Flow Diagram

For each unit operation identified in Table 2A, provide a process flow diagram that

includes all sources of air emissions (e.g., stack emissions, process fugitive emissions,

and other fugitive emissions [including fugitive dust emissions]). Also include allassociated air pollution control devices.

A simple example is included in Appendix B. Please note that it only represents a

portion of the diagram that a typical facility should submit.

Also include all activities that generate HAP emissions, including the storage, transfer,

handling, and processing of the materials, and wastewater and solid waste handling.

Indicate all feedstocks, products, and emissions that contain HAP.

Use the same terminology/codes in identifying unit operations and emissions points in

this figure as you will use for the rest of this survey. See Appendix A for EPA’s list of

HAPs.

6

4/21/2010
For each material potentially containing metal HAP, provide detailed information on

origin and composition, including any potential for variability (e.g., for scrap metal.)

Describe the factors that are important in the selection of the raw material.

4. Products and Product Handling

A. Complete the summary of products and production volume in Table 2E. List the

products, co-products, and by-products identified in the process flow diagram and

indicate how much of each was produced in each of the last 5 years.

B. If production in recent years is not consistent or representative of normal plant

operations, or if you expect to make changes to the plant that will affect production,

please explain:

2009 data provided unless otherwise noted.

C. Provide a brief narrative description of post-tapping product handling and processing

operations, including storage, conveyance, and any operations performed on products:

Product is cast until solid-transported to storage by scoop, transported to crushing and

sizing by scoop. after sizing transported to bin storage. Product is loaded by scoop into

truck for delivery to customer.

PART Ill. VENTILATION, CAPTURE AND CONTROL SYSTEMS

Capture and Control Summary

Complete Table 3A summarizing ventilation I capture for any air pollution ventilation I

capture equipment associated with the processes listed in Table 2A,( with the exceptionof capture for furnaces and tapping.) Fugitive emissions from furnace and tappingoperations should be included here.

2. Primary and Tapping Capture

For each furnace reported as operational (or soon to be operational) prepare a copy of

Table 3B detailing capture of primary and tapping emissions with information regarding

hoods, enclosures, curtains, etc. which capture emissions from the furnace surface

(primary emissions) and from the tap hole (tapping and ancillary operations).Provide diagrams and brief descriptions to fully explain configurations.

7

4/21/2010
Do you perform any post-tap ladle processing? 1Yes NoIf yes, please provide a narrative description of the process and details of any

associated capture and control equipment.Some of product FeMn is refined to produce medium or low carbon FeMn. Capturesystem is MOR Baghouse.

5. Other Emission Reductions

Describe any work practices or pollution prevention measures you have implemented

which result in HAP reductions. Please provide any data or calculations you have which

quantify the reductions

None.

PART IV. MONITORING SYSTEMS

Monitoring Summary

Complete Table 4A with details of routine parameter monitoring performed for controldevice performance indicators. Emission points for which monitoring performed issimilar may be grouped. Make copies of the table as needed. Provide details for any

opacity monitoring in Table 4B, including uncontrolled emission points, such as roof

vents.

2. Visible Emissions Monitoring Test Reports

If you conduct routine visible emissions (Method 22 or Method 9) monitoring of the

furnace building roof monitor and/or control device outlet to demonstrate compliancewith the subpart YYYYYY area source standards, submit copies of the compliance

reports for the last 12 months (if applicable).

PART V. HAZARDOUS AIR POLLUTANT (HAP) EMISSIONS

1. Point Source Modeling Data

For each emission point that is a point source (e.g., stack from baghouse), complete Tables

5A (for controlled emission points) and 5B (for uncontrolled emission points) indicating thelatitude and longitude coordinates, height, diameter, velocity of flow, temperature of theoutput stream, and nature of the emissions (i.e., continuous or varied over time). If theemissions are varied, indicate how the emissions vary over time if known.

8

4/2 I’20 10
Notes on Modeling Data:

Coordinates: For geographic coordinates, provide either latitude and longitude or

UTM coordinates with zone. Latitude and longitude should be provided in decimal

degrees, with 6 digits to right of decimal point, and an indication of the associated

NAD (North American Datum, Either NAD27 or NAD83. If left blank, NAD83 will be

assumed.)

Latitude: measure in decimal degrees of the angular distance on a meridian north

or south of the equator. Positive (+) data point for N America. Include (+) sign,

Ex. +78.123456. For point sources this represents the center of the source; for

fugitive sources this is the southwest corner if the fugitive angle is zero, or thewestern most corner if the fugitive angle is greater than zero.

Longitude: measure in decimal degrees of the angular distance on a meridian east

or west of the prime meridian. Negative (-) data point for N America. Include (-) sign,

Ex. -123.234561. For point sources this represents the center of the source; for

fugitive sources this is the southwest corner if the fugitive angle is zero, or thewestern most corner if the fugitive angle is greater than zero.Angle of Rotation: Angle of rotation specifies the rotation of the source from north

(in the clockwise direction).The location coordinates (UTM or latitude and longitude)

should reflect the southwest corner of the area source. The x-dimension should

reflect the length of the source in the easterly direction, or in the southeasterly

direction if the source is rotated. The y-dimension should reflect the length in the

northerly direction, or the northeasterly direction if the source is rotated.

3. Speciated HAP and Total Particulate Matter (PM) Emissions

Complete Tables 5D and 5E for each emission point indicated in Tables 5A, 5B, and

5C. For each emission point, indicate the total actual and allowable emissions andconcentration of each individual HAP emitted (see Appendix A for EPA’s list of HAP5),and the total actual and allowable emissions and concentration of particulate matter.

Provide explanations for the basis of speciated emissions. Identify the appropriate

emission points using the same terminology/codes you used in preparing the process

flow diagram(s) for Section 11-2, above.

4. HAP in Emission Streams

Complete Table 5F for each emission point and process, with capture, control, andemissions information for each emission stream identified in Tables 5A, 5B, and 5C,

with the following considerations:

C)

4/21/2010
4. Provide HAP data only for those HAPs identified in Table 50, above;

5. It has been assumed that HAP will be primarily in particulate form. If significant

volatile HAP are emitted, include them in column 13, with a note of the units used.

Provide explanations for the basis of speciated emissions.

6. For those emission points from units with Resource Conservation and Recovery Act

(RCRA) Part B permits, it is not necessary to complete Table 5F for wastewater and

solid waste handling operations.

5. Emission Test Data

1. Enclose any previously conducted test reports, chlorine content of coal analyses, orbaghouse dust analyses conducted to determine if your facility is a major source.2. Enclose summaries of test reports from any emission tests conducted on ferroalloys

production processes and air pollution control devices (APCD5) since the year 2003.

Summaries should include:

• Pollutants and emission rates measured;• The test method or procedure used;

• Information on actual ferroalloy production process conditions at the time the

measurements were made;

• If the tests were conducted on outlet streams of APCD5, the APCD operating

conditions; and

• Any analyses that have been performed on composition of baghouse catch.

6. Calculations and Test Reports

For calculations based on emission factors, material balances, or engineering principles,

submit a step-by step description of the calculations, including assumptions used, and a

brief rationale for the validity of the calculation method used. If test reports are listed as

the basis for emissions estimates or capture system and control device efficiencies,

include copies of the emission test results (as described above.)

PART VI. COST DATA

1. Fabric Filter Costs

1 0

4/21/2010
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/2010
If yes, when did you conduct such testing and why?Not Applicable.

What were the test conditions at the time of testing?

Not Applicable.

Were the tests associated with a routine startup or shutdown?

Not Applicable.

Please submit any test data you have collected during any startup or shutdown.

5. Startup and Shutdown Plan

Please submit a copy of your start-up and shutdown plan if you are required to develop

one.

6. Startup and Shutdown Reports

Are you required to submit periodic and immediate start-up and shutdown reports (either

stand-alone or contained within the periodic excess emissions report) to your permittingauthority? E1Yes DNo

PART VIII. MISCELLANEOUS

1. Future Plans

Describe any future work practice or pollution prevention measures you are

considering which may result in emission reductions.

New baghouse on EAC #1 Furnace to replace aging scrubbers.

12

4/21/2010
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 10
(Confidential Business Information) Page 15
Arsenic Compounds (

g

g 

)

Beryllium Compounds

Cadmium CompoundsChromium CompoundsCobalt Compounds

Coke Oven EmissionsCyanide CompoundsGlycol ethers

Lead Compounds

Manganese CompoundsMercury Compounds

Fine mineral fibers

Nickel Compounds

Polycyclic Organic MatterRadionuclides (including radon)Selenium Compounds

57147 1 1-Dimethylhydrazine79005 1,1 ,2-Trichloroethane

79345 1,1,22-Tetrachloroethane96128 1,2-Dibromo-3-chloropropane

122667 1 ,2-Diphenylhydrazine106887 1 ,2-Epoxybutane

75558 1 ,2-Propylenimine(2-Methylaziridine)

N/A 1 ,2,3,4,5,6-Hexachlorocyclohexane(allstereoisomers,includinglindane)

120821 1,2,4-Trichlorobenzene106990 1 3-Butadiene

542756 1 3-Dichloropropene

1120714 1 3-Propanesultone

106467 1 ,4-Dichlorobenzene123911 1 4-Dioxane(1 ,4-Diethyleneoxide)

53963 2-Acetylaminofluorene

532274 2-Chloroacetophenone

79469 2-Nitropropane

540841 2,24-Trimethylpentane

1746016 2378-Tetrachlorodibenzo-p-dioxin

94757 24-D(2,4-DichlorophenoxyaceticAcid)(includingsaltsandesters)

51285 2,4-Dinitrophenol

121142 24-Dinitrotoluene

584849 2,4-Toluenediisocyanate

95954 2,45-Trichlorophenol

88062 24,6-Trichlorophenol

41

4/21/2010
92933 4

Nitrobiphenyl

100027 4-Nitrophenol

101144 4,4-Methylenebis(2-chloroaniline)

101779 44-Methylenedianiline

101688 4,4’-Methylenediphenyldiisocyanate(MDI)

534521 4,6-Dinitro-o-cresol(includingsalts)

75070 Acetaldehyde

60355 Acetamide

75058 Acetonitrile

98862 Acetophenone

107028 Acrolein

79061 Acrylamide

79107 Acrylicacid

107131 Acrylonitrile107051 Allylchloride

62533 Aniline

1332214 Asbestos

71432 Benzene(includingbenzenefromgasoline)

92875 Benzidine

98077 Benzotrichloride

100447 Benzylchloride

57578 beta-Propiolactone

92524 Biphenyl

117817 Bis(2-ethylhexyl)phthalate(DEHP)

542881 Bis(chloromeyj)ether

75252 Bromoform

156627 Calcium cyanamide

105602 Caprolactam(Removed6/1 8/9661 FR3081 6)133062 Captan

63252 Carbaryl

75150 Carbon disulfide56235 Carbon tetrachloride

463581 Carbonyl sulfide

120809 Catechol

133904 Chloramben

57749 Chlordane

7782505 Chlorine

791 18 Chloroaceticacid

108907 Chlorobenzene

510156 Chlorobenzilate

67663 Chloroform

42

4/21’2O1()
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 oxide96457 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
y

(

)

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()
y

593602 Vinylbromide

75014 Vinylchloride

75354 Vinylidenechloride(1 1 -Dichloroethylene)

1330207 Xylenes(mixedisomers)

45

4/21/2010
BAGHOUSE 1 Z SI-ti

I LEGEND:

4 EI1ISSION STREAM

/- (i) FUGITIVES 1 I

—,

HOOD

CONTROL DEVICE

A A EMISSION POINT ID

EAF1 I COOL1 I PRODUCTION UNiT

CAPTURE SYSTEM OR

ELECTRIC ARC TAPPING 1 COOLING DEVICE

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
sections may be calculated using Equation 1-1 from USEPA Method 1:

‘ ‘i

=

1. -

1-1

47

4/21/2010
Submitted to Mr. Roberto Morales as CBI

(Confidential Business Information) Page 15
Submitted to Mr. Roberto Morales as CBI

(Confidential Business Information) Page 15
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

8/13/2010
Submitted to Mr. Roberto Morales as CBI

(Confidential Business Information) Page 15
Submitted to Mr. Roberto Morales as CBI

(Confidential Business Information) Page 15
EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURIN

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 Emiss

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

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 se

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 
::EPA INFORMATICN COLLECTION REQUEST FORFEROALLOYSPRODUCTION MANUFACTLJ:R1

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 Emiss

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

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 se

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 
Please attach diagrams if available acfm.C31

Hood Dimensions (ft)

(a) Circular Hood Diameter (ft) 3775

ejJth(ft)

(b) Rectangular Hood Length (if) Not Applicable

Width (ft) Not Applicable

Depth (if) Not Applicable

Distance between top of furnace and hood (if) 4

Temperature of fume entering hood (‘F) 246

(cfm) OO0acfrn

Please describe the design basis upon which the flow rate was Exit flow rate

determined 

Does Ih flow rate vary? YLLNi)If Yes, describe factors which cause variation in flow rate Temperature and Furnace Blows.

Is there an enclosure (e g. , curtain or door panels around the furnace) Yes (x) No

If Yes, percent of total area surrounded by enclosure e.g 60% of hood 30%

circumference) 

How is the enclosure constructed?

Wire mesh

Chain curtain

Ceramic curtain

Hydraulic door(

Other ( x ) Describe --> Sheet Metal

Dimensions of openings in enclosure (if) Not ApplicableDistance between top of furnace and curtain (if) Not ApplicableDescribe measures taken to ensure proper operation of ventilation Monitoring of fan motor amps, pressure drop of scrubbers, and visual

system (e.g., periodic or continuous monitoring of volumetric flowrate in observations, Preventative maintenance and systematic inspections.

ductwork downstream of capture hoods, fan power consumption and

pressure drop across fans, systematic inspection an

Best estimate of % capture achieved (based on visual estimates) 9950%Airflow Control Describe other airflow control and ventilation systems Building has roof monitors

associated with the furnace. Include building ventilation (roof vents, etc.)and other airflow control systems (air curtains, drop curtain baffling, etc.)

(a) Please use the same ID as used in the process flow diagramSee sample page for example response

Ferroalloys Production Manufacturing Emission Points Survey

Page 29 8113/2010
Hood Dimensions (if)

(a) Circular Hood Diameter (if) Not Applicable

ifpth(ft Not Apphcab

(b) Rectangular Hood Length (if) 19

Width (if) 9

Depth (ft) 2

Tap hole diameter (ft) 0.5

Distance between center of tap hole and hood (if) 6Distance between center of tap hole and bottom of hood (0) 6Diameter of ladle tapped product is poured into (0) 8

Distance between ladle and bottom of hood (if) 10

Temperature of fume entering hood (SF) 120

vomwrenterwighoo Lscfm 7(100

Please describe the design basis upon which the flow rate was Stack exit flow rate.

determined

Does tF-s flow rate vary? YeSFJ(x)If Yes, describe factors which cause variation in flow rate

Describe measures taken to ensure proper operation of ventilation Visual ObservationBest 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 Chain curtains would interfere with stokers used to distribute mix on the furnace.

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 Tap hood present.

in installing and using such a hood? If so, please describe.

(a) [-‘lease use the same ID as used in the process flow diagram.

See sample page for example response

Ferroalloys Production Manufacturing Lmission Points Survey

Page 30 8/13/2010
Please attach diagrams if available

Hood Dimensions (H)

(a) Circular Hood Diameter (H) 37.33

ejJthft) 8

(b) Rectangular Hood Length (ft) Not Applicable

Width (H) Not Applicable

Depth (H) Not Applicable

Distance between top of furnace and hood (H) 4

Temperature of fume entering hood (“F) 170

Vokimetric flow rate entering hoo (scfm 0

Please describe the design basis upon which the flow rate was Exit flow at scrubber stack.

determined

Does tNs flow rate vary? Yes()No(x)

If Yes, describe factors which cause variation in flow rate Not Applicable

Is there an enclosure (e g.. curtain or door panels around the furnace) Yes (x) No

If Yes. percent of total area surrounded by enclosure e g , 60% of hood 20%

circumference)

How is the enclosure constructed?

Wire mesh

Chain curtain

Ceramic curtain

Hydraulic door

Other ( x) Describe --> Sheet Metal

Dimensions of openings in enclosure (H) Not Applicable

Distance between top of furnace and curtain (ft) Not Applicable

Describe measures taken to ensure proper operation of ventilation Monitoring of tan motor amps, scrubber pressure drop, and visual observations.

system (a g., periodic or continuous monitoring of volumetric flowrate in Preventative maintenance and systematic inspections.ductwork downstream of capture hoods, fan power consumption and

pressure drop across fans, systematic inspection an

Best estimate of % capture achieved (based on visual estimates) 99.50%

4irflow Control Describe other airflow control and ventilation systems Building has roof monitors.

associated with the furnace. Include building ventilation (roof vents, etc.)

and other airflow control systems (air curtains, drop curtain baffling, etc.)

(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 31 8/13/2010
Hood Dimensions (if)(a) Circular Hood Diameter (if) Not Applicable

ep!(ttl Not Applicab

(b) Rectangular Hood Length (if) 6

Width (ft) 20

Depth (if) Not Applicable

Tap hole diameter (if) 0.5

Distance between center of tap hole and hood (if)

Distance between center of tap hole and bottom of hood (ft)

Diameter of ladle tapped product is poured into (ft) 8

Distance between ladle and bottom of hood (if) 15

Temperature of fume entering hood (°F)

Vcumetric flow rate entering hoo cstm

Please describe the design basis upon which the flow rate was Estimated

determined

Does this flow rat vary? YUNo(x)

If Yes, describe factors which cause variation in flow rate Not Applicable

Describe measures taken to ensure proper operation of ventilation Visual observation.

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 Chain curtains would interfere with stokers used to distribute mix on the furnace.

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 Tap hood present.

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 32 8/13/2010
Please attach diagrams if available around each electrode to feed mix to the furnace. Make-up air intake on the east side of the cover and fume offlake on the west side of the cover. As much as

11000 scfrn can be drawn from under the cover to wet venturi system.

Hood Dimensions (if)

(a) Circular Hood Diameter (if) Not Applicable

qpth(if3 Not Ap,plicab

(b) Rectangular Hood Length (if) Not Applicable

Width (if) Not Applicable

Depth (if) Not Applicable

Distance between top of furnace and hood (if) Not Applicable

Temperature of fume entering hood (CF) 135

Vcumetric flow rate ente ng hoo (scfm io

Please describe the design basis upon which the flow rate was Exit flow at scrubber stack.

determined

Does thisfi ow rate vary? jj)q)

If Yes, describe factors which cause variation in flow rate Not ApplicableIs there an enclosure (e.g. , curtain or door panels around the furnace) Yes ( ) No ( x

If Yes percent of total area surrounded by enclosure e g. 50% of hood Not Applicable

circumference)How is the enclosure constructed? Not Applicable

Wire mesh

Chain curtain

Ceramic curtain

Hydraulic door

Other ( ) Describe -->

Dimensions of openings in enclosure (if) Not ApplicableDistance between top of furnace and curtain (if) Not ApplicableDescribe measures taken to ensure proper operation of ventilation Monitor pressure drop. motor amps, visual observations, preventative

system (e.g., periodic or continuous monitoring of volumetric flowrate in maintenance, and systematic inspections.ductwork downstream of capture hoods, fan power consumption and

pressure drop across fans, systematic inspection and maintenance,

others)

Best estimate of % capture achieved (based on visual estimates) 99,50%

Airflow Control: Describe other airflow control and ventilation systems Building has roof monitors. Fugitive emissions escaping the furnaces are vented

associated with the furnace Include building ventilation (roof vents, etc.) to the atmosphere by 4 draft stacks.and other airflow control systems (air curtains, drop curtain baffling, etc.)

(a) Please use the same ID as used in the process flow diagramSee sample paqe for example response

Ferroalloys Production Manufacturing Emission Points Survey

Page 33 8/13/2010
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) 6Diameter 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 8/13/2010
Please attach diagrams if availableHood Dimensions (ft)

(a) Circular Hood Diameter (ft) 15

epth(ft 6

(b) Rectangular Hood Length (ft)

Width (ft)

Depth_(ft)

Distance between top of furnace and hood (ft) 15

Temperature of fume entering hood F) 500

VoIymcowrateentennghoo (cr) 19QQ2.0 *—.-— —

Please describe the design basis upon which the flow rate was Engineering estimate (Calculations should be attached))

determined

Does this flow rate vary 9 Yes(NoX)

—

If Yes, describe factors which cause variation in flow rateIs there an enclosure (e.g., curtain or door panels around the furnace) Yes (X) NoIf Yes, percent of total area surrounded by enclosure (e.g., 60% of hood 70%

circumference) 

How is the enclosure constructed?

Wire mesh

Chain curtain

Ceramic curtain (X

Hydraulic door

Other ( ) Describe -->

Dimensions of openings in enclosure (ft) 15Distance between top of furnace and curtain (ft) 5Describe measures taken to ensure proper operation of ventilation Monthly maintenance, continuous monitoring of volumetric flowrate in ductwork

system (e.g., periodic or continuous monitoring of volumetric flowrate in downstream from hood.ductwork downstream of capture hoods, fan power consumption andpressure drop across fans. systematic inspection and iriairileiiariceothers)

Best estimate of % capture achieved (based on visual estimates) 90%

Airflow Control. Describe other airflow control and ventilation systems Root vents

associated with the furnace Include building ventilation (roof vents. etc.)and other airflow control systems (air curtains drop curtain baffling. etc.)

Ferroalloys Production Manufacturing Emission Points Survey

Page 35

8/13/2010
Hood Dimensions (H)

(a) Circular Hood Diameter (ft) 15

e2t?(tt 6

(b) Rectangular Hood Length (tt)

Width (H)

Depth_(ft) 

Tap hole diameter (ft) 3

Distance between center of tap hole and hood (ft) 10

Distance between center of tap hole and bottom of hood (ft) 6Diameter of ladle tapped product is poured into (ft) 10Distance between ladle and bottom of hood (H) 5

Temperature of tume entering hood ( F) 500

(scfm iooooo

Please describe the design basis upon which the flow rate was Engineering estimate (Calculations should be attached))

determined

Doevary7 Ye(Jo(j

If Yes, describe factors which cause variation in flow rate

Describe measures taken to ensure proper operation of ventilation Monthly maintenance

Best estimate of % capture achieved (based on visual estimates) 50%

OtherCaptureRelated Information

fuse additionalpaqes ifneeded) 

If you do not use curtains on or surrounding the hood controlling primary

emissions, do you anticipate any problems in installing and using them 2

If so. please describe.

If you do not have a dedicated tap hood, do you anticipate any problems

in nstailing and using such a hood? If so, please describe.

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

Ferroalloys Production Manufacturing Emission Points Survey

Page 36 8/13/2010

rroiilcy Pruducicrn Manufacturing Emiccii,ri Points Su vsv

8it 312010 Pago 38

(a) Please use the same lOgs used in the process flow diagram

control

IbI Emissions

device,

points using the same control systems may be grouped Different emission points using the same capture system may be sent to the same 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 estimates
Pressure Differential Across Baghous

Inlet Gas Temperatur

Temperature Ditterentis

Exhaust Gas Flow Rat

Cleaning Mechanism Operatio

Fan Curren

Inspections & Maintenanc

Ferroalloys Produclion Manufacturing Emission Points Survey

Page 39

Other)

P917-El. 92, E3 and F014-E3 94,E4A - Magnahelic gauge manually

read and recorded

P909/FOl 2-E2 recorded lhrough

computer monitoring system, manual

x Inches Water Continuous records also maintained0x

5

x

5

0

control Device ID: ScrubberEmission Points: P901-El, P908-El, P909-El

Pressure Ditferentia has Water ontinuou onitored by computer system.

Liquid Flow Rat x

Gas Flow Rate x

Scrubber Inlet Gas Temperatur a agrees F Continuous Monitored by computer system - Scrubber Outlet Gas Temperatur x

Makeup/blowdown rat

Scrubber Liquid Solids Conten x — Scrubber Liquid p1 x — Neutralizing Chemical Feed Rat

Scrubber Liquid Specific Gravit 0

Other) ( — ontroI Device ID: Electrostatic Precipitator

Emission Points:

Outlet PM Concentratioi

Secondary Corona Power (Current & Voltagi ( Spark Rate

Primary Power (Current & Voltage - Inlet Gas Temperatur:

Gas Flow Rate

Rapper Operatior

Fields in Operatioi

Inlet Water Flow Rate (Wet Type

Flush Water Solids Content (Wet Type

Other( — Control Device ID: Cyclone

Emission Points:

Inlet Velocity or Inlet Gas Flow Rat —___________

Pressure Differentia

Inlet Gas Temperatun

Other(

Make copies as needed

(a) Please use the same ID as used in the process 110w diagram(b) Provide documentation of the basin for equipment parameters (design actual etc

(c( Provide copies of estimation worksheets or other documentation of Ihe basis for emission estimatesSee sample page for example respoirse

8/1312010
Make copies as needed

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

(b) Provide documentation of the basis for equipment parameters (design, actual, etc(C) Provide copies of estimation worKsheets or other docunientatiun of the basis for emission estimates

Ferroalioys Produciion Manufacturing Emissise Points Survey

Page 40

Exhaust Gas Flow Rate X

Cleaning Mechanism Operation X — Fan Current X

Inspections & Maintenance X Mawrlenance records maintained

Visible Emissions Monilonng (Method 9 Opacity or Method 22 yE)t X percent Daily Method 22

Other)

Control Device: Scrubber

Emission Points:

Pressure Differential

Liquid Flow Rate

Gas Flow Rate

Scrubber Inlet Gas Temperature

Scrubber Outlet Gas Temperature

Makeupiblowdown rate

Scrubber Liquid Solids Content — — Scrubber Liquid pH — Neutralizing Chemicol Feed Rate — Scrubber Liquid Specific Gravity — — Other( -

Control Device: Electrostatic Precipitator

Emission Points:

Outlet PM Concenloalion .

Secondary Corona Power (Current & Voltage)

Spark Rate

Prwnary Power (Current & Voltage)

Inlel Gas Temperature

Gas Flow Rale - Rapper Operation

Fields in Operation

Inlet Water Flow Rate (Wet Type)

Flush Water Solids Content (Wet Type)

Oilier

Control Device: Cyclone

Emission Points:

Inlet Velocity or Inlet Gas Flow Rate

Pressure Differential

Inlet Gas Temperature

Otheri

n1t312010
_________________ 

—-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 s9ndty105b Cortinunus CA coy Mnnitonng (CCV PA Ary(i&hh Cun-i-.unuoEmiuniuinrdonlnririg(CEPninrVoVir.b

—

yaynnnsnkeeaisnop.iainginnniuki

Cinnr and reisnnoisibia muss noooinrfrs 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

Aonragn

on VE Lim I mr this Eminsion Point (ir any ( (PIn cnn- nntn units & ba jncFPshls52(aJ( 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% 0eanno 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 IPInine 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 tminawn

•nsnspa 1000 erun mmml p - on PEarafnnisroesduounoaniinn 0

Opandy or VP LimI br this Emission Point (ii any I 1PI nine notn unls & be rVKIOAE2MIJ!nAPV(

—

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

Aoeraoe Cpaoyy or PP observed tor thin Emission Pu or (PA ice note u- ii

Mi thud — — 0 on Mothod C nnuuypis.s Cool n0005 Cy.nniiy Monyonny — — CCV noruonnno

ConAnuovs Enn-sninnr.rmn,iror.rg(CE1 nn!9 00nnrl. — — ——

usdnnnsoksonhsnsnsnasnarenu.s.0. —

Crhen(___________________ searen •nnoisiOa rogose no Oemms nEnmoynnA - —- Oj

Paibis no or V0nios duo snarnor

220%eoesiosaan-oa..

as.iag. loon arar—rr-0n101 VisiOns

nosinarnorsepssdao%a eseen 55 e

Cynony on yE LimO ion nile ae.naaeseuserasciesidsdbn 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 5muty 0pmt,no

—

PAir nouns Cy in to Munnnr ny (CCV rio °pp P etA Cnntniuiiun Enninni on Monunning — — (CAM liptm yno(°nfr.

anenuianyooioiero 5essnonomrns Crhor( rvtmnnoPJdrPC._

Pieuis

Peyu._._., nyimnChysYErrrte, 50n

PP emfrsgoss &isr sins” nor

rrnssa 20% eesruy sea a-mn

•neeseel0005ass-rr-Onisi. VisOs

en .y&i rorseossa ae% eeas.ne ass

Op nnityw hA pimy me assraesseoserssr000sdse 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
P901 -El (1) 39.370311 -81.520314 37.5 2.4 137,000 acfm 333 P901 - E2 (1) 39.370162 -81.521323 29.3 1.4 75,000 acfm 322 P908 - El (1) 39.369026 -81 .525646 37.5 2.4 169,500 acfm 333 P909- El (1) 39.367997 -81.528962 33.5 0,5 10,500 acfm 314

P909/F012 -E2 (1) 39.36881 -81.527191 13.4 (2) 3X15 175,000 acfm 394 P917 -El (1) 39.368387 -81 .525507 9 1.22 44216 acfm Ambient

P917 - E2 (1) 39.368387 -81 525507 9 1.22 45642 acfrn AmbientP917 -E3 (1) 39.368387 -81.525507 9 1.46 57539 acfm AmbientF014 - E3 (1) 39.36954 -81 .521677 18 0.66 12,229 acfm Ambient F014 -E4 (1) 39.369847 -81 .520947 18.6 091 19,565 acfm Ambient F014 - E4A (1) 39.369648 -81.521441 18 0.9 24,188 acfm Ambient

(a) Please use the same ID as used in the process flow diagram(b) For each HAP emission point defined in the process flow diagram, enter the applicable information

Ferroalloys Production Manufacturing Emission Points Survey

Page 42

8/1 3/2010
P909 - E3a (1) Draft Stack 39.367997 -81.528962 33 5 0.66 37,000 acfm 303

P909 - E3b (1) Draft Stack 39.367997 -81.528962 33.5 0.66 35,500 acfm 303P909 -E3c(1) Draft Stack 39.367997 -81 .528962 33.5 0.65 31,000 acfm 303P909 -E3d (1) Draft Stack 39.367997 -81.528962 33.5 0.65 28,000 acfm 303

(a) Please use the same ID as used in the process flow diagram(b) For each HAP emission point defined in the process flow diagram, enter the applicable information

Ferroalloys Production Manufacturing Emission Points Survey

Page 43

8/13/2010
3.897701 (m) X (length, m) y (width, -77.03 10 N39.22.287 W081.3111: 3 14 Pile 4171 (2) N39.22.329 W081.3117l 70 14 Pile 4251 (2) N39.22.324 W081.31201 1 30 WGS84 16 Pile 4252 (2) N39.22.320 W081.3121 60 14 Pile 4247 (2) N39.22.305 W081.31: 36 14 Pile 9301/9302 (2) N39.22.303 W081.31: 45 14 Pile4246(2) N39.22.300 W081.312 45 ile 1060 (2) 16 N39.22.278 W081.312i 15 ile 1119 (2) N39.22.240 W081.313 40 5 Pile 209 (2) N39.22.300 W081.31: 180 4 Pile 8300 (2) N39.22.296 W081.31 70 5 Pile 1320 (2) N39.22.293 W081.3132 12 15 Pile 1321 (2) N39.22.290 W081.31 30 331 15 Pile 4180 (2) N39.22.283 W081.31 60 Pile 1023 12 (2) N39.22.242 W081.31 25 Pile 512 (2) N39.22.239 W081.31 180 6 Pile 1100 (2) N39.22.220 W081.31. 15 25 ile 218 (2) N39.22 180 280 W081.31 371 18 ile 592 (2) N39.22.262 W081.31442 45 20 Pile 1055 (2) N39.22.232 W081.3146 65 25 Pile 555 (2) N39.22.252 W081.3146l 180 20 Pile 566 (2) N39,22.244 W081.31 50 50 25 Pile 407 (2) N39.22.204 W081.3144 120 20 Pile 408 (2) N39.22 75 191 W081.31462 1 20 Pile 409 (2) N39.22.184 W081.3148l 75

75

(b) For each HAP emission point defined in the process flow diagram, enter the applicable information

(d)

(c) Noh

Dimension

American

of source

Datum. Either NAD27 or NAD83. If left blank, NAD83 will be assumed refers to the area defined as a flonpoint source emission (e.g., open air dust pile) Sample (e) anglerowof rotation is shadedspecifies the rotation of the source from north (in the clockwise direction)

Ferroalloys Production Manufacturing Emission Points Survey Page 44

8/13/2010
Release Height Dimension of Source (d) Angle of Rotation (e)

oin s (a) Lat Long NAD(c) (m) x (length, m) y (width, m) (degrees)

E7 38.897701 -77.036625 NAD27 10 30 20 12.5

Pile 558 (2) N39.22.182 W081.31494 WGS84 25 80 75 90

Pile 1031 (2) N39.22.220 W081.31.505 WGS84 20 75 100 90

Pile 511 (2) N39.22.180 W081.31.556 WGS84 8 30 5 90

Pile 569 (2) N39.22.164 W081.31.584 WGS84 12 55 40 90Pile 4215 (2) N39.22.148 W081.31.692 WGS84 15 50 40 90Pile 1322 (2) N39.22.137 W081.31.714 WGS84 15 40 40 90

Pi1e4230(2) N39.22.106 W081.31.785 WGS84 15 80 45 90Pi1e4232(2) N39.22.099 W081.31.803 WGS84 15 100 82 90

Pile 232 (2) N39.22.020 W081.31.781 WGS84 12 230 88 90

Pile 448 (2) N39.22.017 W081.31.765 WGS84 10 45 30 90

Pile 445 (2) 0 0 WGS84 0 0 0 90

Pile 645 (2) N39.22.024 W081.31.736 WGS84 15 160 75 90

Pile 648 (2) N39.22.026 W081.31.712 WGS84 10 85 45 90

Pile 332 (2) N39.22.023 W08131.692 WGS84 6 15 8 90Pile 385 (2) N39.22.029 W081 .31.663 WGS84 5 8 8 90

Pile 339 (2) 0 0 WGS84 0 0 0 90Pile 723 (2) N39.22.091 W081.31.501 WGS84 15 47 45 90

Gchute (2) N39.22.999 W081.31.861 WGS84 15 75 30 90Pile 4214 (2) N39.22.063 W081.31.846 WGS84 10 50 16 90

Pile 3999 (2) N39.22.086 W081.31767 WGS84 14 200 125 90

F007-F1 (1) 39.369946 -81.521226 33.5 90

F008-F1 (1) 39.369059 -81.524681 33.5 90F009-F1 (1) 39.368022 -81.528329 33.5 90

(a) Please use the same ID as used in the process flow diagram(b) For each HAP emission point defined in the process flow diagram, enter the applicable information

(c) North American Datum. Either NAD27 or NAD83. If left blank, NAD83 will be assumed

(d) Dimension of source refers to the area defined as a nonpoint source emission (e.g., open air dust pile)(e) angle of rotation specifies the rotation of the source from north (in the clockwise direction)

Sample row is shaded

Ferroalloys Production Manufacturing Emission Points Survey

Page 45 8/13/2010
El Manganese 

py ppm tpy ppm El Lead 150 0.05 tesldala 200 0.1 WV23709-IV-(d)

E2 Manganese

0

200

02 0 0001 test data 003 0.0005 WV 23709- lV-(d)

E2 Lead 0.05 0.1 calculated 250 0.2 WV 23709- IV-(d) 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

8/13/2010
El 213 0 0322 Test Data 300 0.05 /tN 23709- IV-(a(E2 400 0.0625 Calculated 500 0.075 WV 23709 - IV-(a)

35 9 lbs/hr

P901-El and Submitted to Conrad u2fiMWon

E2 Chin July2010 Not Applicable - Not Applicable Not Applicable Silicomanganese 40CFR63 1652(b)P901-El and 272 lbs/hr 025MW

E2 Not Applicable Not Applicable Not Applicable Not Applicable on Silicomanganese 40CFR63. 1652(b)

29 8 lbs/hr

P901-El and >22MWonE2 Not Applicable Not Applicable Not Applicable Not Applicable Ferromanganese 40CFR63.1652(b)

P901-El and 21 7 lbs/hr 022MWE2 Not Applicable Not Applicable Not Applicable Not Applicable on Ferromanganese 40CFR63.1652)b)

35 9 lbs/hr

Submitted to Conrad .-2SMVVon

P908-El Chin July2010 Not Aeplicable Not Applicable Not Applicable Silicomanganese 40CFR63.1652)b)

27 2 lbs/hr 225MW

P908-El Not Applicable Not Applicable Not Applicable Not Applicable on Silicomanganese 40CFR63.1652)b)

29 8 lbslnr

22MW on

P908-El Not Applicable Not Applicable Not Applicable Not Applicable Ferromanganese 40CFR63.1652)b)

21 7 lbs/hr 222MW

P908-El Not Applicable Not Applicable Not Applicable Not Applicable on Ferromanganese 40CFR63 1652(b)

Submitted to Conrad 247 lbs/hr on

P909-El Chin July 2010 Not Applicable Not Applicable Not Applicable Ferromanganese 40CFR63 1654)a))1-3)

P909/FO I 2-E2 Not Applicable Not Applicable Not Applicable Not Applicable 0 03 gr/dscf 40CFR63. 1652(d)P917-El Not Applicable Not Applicable NotApplicable NotApplicable 003 gr/dscf 40 CFRS3.1652)e)(2)

P91 7-E2 Not Applicable Not Applicable Not Applicable Not Applicable 003 gr/dscf 40 CFR63.1652(e)(2)P91 7-E3 Not Applicable Not Applicable Not Applicable Not Applicable 003 gr/dscf 40 CFR63 1652(e))2) Process Not

FO 1 4-E3 Operating Not Applicable Not Applicable Not Applicable 0 03 gr/dscf 40 CFR63. 1 652(e)(2)

Process Not

FO 1 4-E4 Operating Not Applicable Not Applicable Not Applicable 0 03 gr/dscf 40 CFR63. 1 652(e)(2)

Process Not

F0l4-E4A Operating Not Applicable Not Applicable Not Applicable 003 gr/dscf 40 CFR63.1652(e)(2)

(a) Please use the same ID as used in the process flow diagram)b( For each HAP emission point det ned in the process Sow diagram. enter the applicable informationSample rows are shaded

Ferroalloys Production Manufacturing Emission Points Survey

Page 47 8/13/2010
EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSIQN POI

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 

Emission Point & Process ID Caoture Control 

Concentration of 

Unit Operation Emissions to Capture Control Flow 

Emission Point ID Process Capture System or Capture Basis for Reported System Efficiency Basis for Reported Stre

(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 

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 

P901 -E2 EAF #1 P90 Hood iP9Ol -CS2( 99 Estimate 100 P901 -BH1 99 Title V Application 7

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

P908-El EAF #12 P908 P908-CS2t 995 Estimate 100 SCR2 98 Title V Application 1

P909-El EAF #18 P909 Hood (P909-CSl1 995 Estimate 100 P909-SCR1 997 Title V Application 

Hoods IP909-CS2,

P909/F012-E2 EAF #18 P909/FOl 2 F012-CS3( 995 Estimate 00 MOR-BH 99 Titte V Application 2

P917-El C2P Crusn/Size P917 Hood (P917-CS1 1 99 Estimate 100 P9l7-BH1 98.01 Title V Application 4

Hoods (P917-CS3.

P917-E2 C2P Crush/Size P917 P917-CS4( 99 Estimate 100 P917-6H2 9801 Title VApplicalion 4

P917-E3 C2P Crush/Size P917 Hood (P917-CS2( 99 Estimate 100 P917-8H3 9801 Title VApplication 5

F014-E3 C7P Crush/Size P014 Hood (F014-CS1) 99 Estimate 100 F014-BH3 99 Title V Application 1

F014-E4 C7P Crush/Size F014 Hood (F014-CS3( 99 Estimate 100 F014-BH4 99 Title V Application 1

F014-E4A C7P Crush/Size F014 Hood (F014-CS2( 99 Estimate 100 F014-BH4A 99 Title V Application 2

(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 uni

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 
Ferroalloys Production Manufacturing emission Points Survey

Page 50

EPA INFORMATION COILECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING 

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, 

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

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

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

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

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

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

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

F014-BH3 Same as 3C Not Operating Unknown 

F014-BH4 Same as 3C Not Operating Unknown 

F014-BH4A Same as 3C Not Operating Unknown 

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

Monitoring,

Reporting, & 

Control Device ID (a) Labor Cost Recordkeeping Electricity Water Waste Disposal (s

P901-SCR1 123405.00 $ 200,000.00 $725,000.00* 

P901-SCR2 12340500 $ 200,000.00 $725,000.00* 

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

P908-SCR2 (2007) 62275.00 $ 200,000.00 $725,000.00* 

P909-SCR1 (2008) 88721.00 $ 200,000.00 $725,000.00* 

(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
iaoie I: startup ana nutdwn information (Make additional copies as needed)

Was event covered by 

contingency plan for Estimated PM 

Unit Operation Permit conditions controlling emissions? emissions during 

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

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

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

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

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

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

10/20/2007 Down due to arcing @ C phase

P901 lifting cylinder Not Applicable 24 V Not Applicable 

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

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

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

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

8/14/2009 Replace ribbon flexes in buss

P901 runs Not Applicable 52 V Not Applicable 

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

(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. 
ATTACHMENT #1

TITLE

V APPLICATION
ATTACHMENT #2

PROCESS FLOW DIAGRAMS
1-El

k

Tapi

ace 1 (P901)

y a suspended circular canopy hood above the furnace as described in table 3B.

d to wet scrubbers.

ed by a hood located above the taphole and directed to a baghouse.

Stack

P901 F007-F1

Roof Monitor

If Producing Std FeMn

MOR

Casting Crushing

If producing SiMn
I

EAF12 Tapi

1

ectric Arc Furnace 12 (P908)

ion capture is by a suspended circular canopy hood above the furnace as described in table 3B.

ions are directed to wet scrubbers.

08-El

F007 Fl

ck 1

Roof Monitor

MOR

I -

Casting
NG 36 _99o81Fo12

4-

__ ___

Ed

F1

rs__

_

ff I I

od

Tap 1 Casting

Reaction /

18

ls

Bins

Ladle

/

unner r

le__/ F009_Cas Reaction / Tapping Ladle Pouring

Slag Separation : FOl 2 MOR

Ladle Transfer

Ladle Transport

Metal from #12 Furnace

furnace with a wet scrubber collecting primary emissions from under the cover of the furnace. Tapping emissions

e MOR baghouse. Metal from Furnace #18 and Furnace #12 are poured into a reaction ladle and further processed at the MOR

lected by a hood and ducted to MOR baghouse. 
Sizing (P917)

Roof Monitor

‘5cs3

,‘P917-’.

-,

--

CS4

P917-

4-

rusher

Screen Box ... Screen Box

Product bin Product bin Fines bin

t transfer points and ducted to baghouse.
Bulk handling

C7P Crushing/Sizing/Packing (F014)Emissions beginning at the crusher are collected at transfer points and ducted to baghouses

#3

Baghouse

Storage!

Loading
Raw Material 4 Truck unloading at 4

delivered to storage jtruck for transport to —* mix house.area by truck jMix House

Storage Piles - (F002)Raw Material is delivered by truck to storage pile area.

A front end loader loads the raw material on a truck which transports the material to the mix house.
ATTACHMENT #3

STARTUPISHUTDOWNIMALFUNCTION PLANS
, 

p

q

, a

d venturi scruober;

and to coinpl v vi th all applicable requl rements of the EPA, Title V, arid MAlT

standards.

This process consists of an open furnace and associated dust controlequipment. The emissions from this process are controlled by a venturi wetscrubber that collects fume by use of a hood suspended above the furnace and a

baghouse which controls fume from the tappIng of the furnace.

2.0 OPERATION AND MAINTENANCE REQUIREMENTS

At all times, including periods of startup, shutdown, arid malfunction, owners

or operators shall operate and maintain the affected source, including

associated air pollution control equipment, in a manner consistent with good

air pollution control practices for minimizing emissions at least to thelevels recuired by all relevant standards.

Anytime the furnace or dust control equipment is shu:down or restarted, theseprocedures roast be followed and documented in the TitleV/SSMP/Maintenance

F:.ecord Sheet located in the operations supervisors office.

3.0 DESCRIPTION:

3. 1 Start—up: Furnace #1 Venturi Scrubber system

3.1.1 Startup of Venturi Scrubbing System will be performed per Elramet

Marietta HECP Procedure HECP—lOl—08 and Eramet Training Manual appendix

1, section (3.1.2) AND (3.1.3)

3.l.l.a. Operational checks are defined in Reference Manual #12

((Titled Venturi Gas Cleaning System) (Section 3.1.1 through

3.l.9HEramet Training and Technical Manual 12.

3.l.l.b. Record the startup data of the dust collector on the Title

V/MACT Inspection Record sheet located in the Operations

Supervisors office.

3.1.2 Startup of Furnace #1 will be performed per Eramet Marietta Inc

HECP 101—25 and Eramet’s technical and training manual.

3. 1 . 2. a. Ensure proper mix levels are in furnacE- to cinirsoze tunoanci.

3.l.2.b.Vsuay Ic-os for emissions tram the discharoe or the stacas.

3.l.2.ci. Reccrd the startup rime of the orocess :n the

TitleV/SSMP/Maintenance_Record Sheet locatea in the operations

smcersisors offIce.

rZ Sac::iou:t:crriace

3.2.1 Shutdown of [urnace will be performed per Eramet Marietta SOP 101-25.3.2.2 Venturi dust collector operates until fuming stops
3. 3 Shutdown: Vent or: Scrubber

3.3. 1 . Shutdown of Venturi Scrubber will be cer formed per HECP 101—Ct.

3.3.2. Record the i:ime Ut sbutdown on the_TitleV/SSIIP/Maintenance_Record_Sheet

located in the operations supervisors office

3.4 Startup: Taphole Baghouse Collector

3.4.1 Startup arid shutdown of the tephole baghouse will be performed

according to 3505 101-09.

3.4.2. Record the time of any rnalfur:criorr or repairs on

TitleV/SSMP/Maintenance Record Sheet located in the

Operation supervisors office.

3.4.3 Record each normal startup and shutdown of taphole fume collecting fan

during the tapping of the furnace on the Baghouse Check Sheet.

4.0 STANDARD/EXPECTED END RESULT:

4 . I The expected end result is safe operation of the furnace, baghouse, and

venturi and 100% complIance with rho Eramet’ a Title V Permit and the PACT

standard.

5.0 DEVIATION AND CORRECTIVE ACTION:

5.1. See attachment “A” Titled Furnace #1 SSMP

5.2 See attachment “B” Title Furnace #1 Taphole Fume Collector

6.0 RESPONSIBILITY FOR IMPLEMENTATION:

6. 1 The Shift Supervisor is responsible to assure that this procedure is

implemented exactly as written.

6. 2 The Department Manager or designee is responsible to conduct a procedure

assessment of this procedure annually.

7.0 RECORDEPING REQUIREMENTS:

The Environmental Department must be notified immediately it a malfunction occurs

that causes an exceedance of Sri alirwable parameter that is not addressed in thisSOP. Any exceedance not specifically listed in this SOP and addressed per the

corrective actions listed in this SOP, :irust he reported to OEPA within (2) days witha fti low—op letter deta lirig the event within (7) days.
y

per formed on the Otiar collector must be recorded and sent to the environmentaldeorccerc within (2) days of the er.d of each month.

The Startup—Shutdown—Malfunction Plan arid Maintenance Plan must be kept for the life

of the dust collector and the process. Changes to the process or control equipment

will require the plan to be updated to reflect these changes.

The recordkeeping required by this SOP is for a term of (5) years. These records

must be made available to the EPA at their request.

8.0 APPROVAlS:

Dept Manager Environmental Manager, Quality Assurance

9.0 SYSTEMS CONNECTIONS:

Non e

10.0 ATTACTh’NTS:

Title V/MACT Inspection Record Sheet

Title V/MACT Compliance Record Sheet
p

y

I Malfunctions/Non—Conformance:

• I (P)Complete loss of power to plant, furnace or scrubbers

1.2 (CA) Upon loss of power. follow Guide in 1’LC 151 arid 15 U. When power is restored.

follow start up procedure for scrubbers outlined in Eramet Training arid Technical

Manual #1. After scrubbers are operating. commence start up of furnace per 1-IECP 101-

25 arid SOP 101-2 17 for start up of furnace

1 .3 (P)Fan trip caused by high vibration

1.4 (CA)Lock out fan per HECP 101-08. Clean and balance fun, start up per HECP 101-08

arid Technical Manual #12.

1.5 (P)Fan trip not caused by high vibration

1.6 (CA)Check all other monitoring devices that could cause trip. Check all power sources for

problems. When repaired. start up per HECP 10 1-08 and Technical Manual #12.

1 .7 (P)Fan damper controls not operating.

1.8 (CA)Check electrical and mechanical components of control system and repair ally

problem found.

1 .9 (P)Recirculating pump failure or no water to fixed disc.

1.10 (CA)Switch to spare pump and repair pump that failed.Check lines for blockage.

Remove any blockage found.

1.11 (P)Motor failure on falls.

.12 (CA)Lock fan out per HECP 101-08 and replace motor.

1.13 (P)Fan bearing or motor coupling failure.1 .14 (CA)Lock fan out per HECP 101-08 and replace fan bearing or motor coupling.

1.1 5 (P)Loss of cooling water to fan bearings.

1. 16 (CA)Check water line for break or blockage.Check strainer for blockage. Check water s

supply source for pump failure or major break in supply line.

.17 (P)Hole in scrubber fan housing or duct from furnace to scrubber fan.

1.18 (CA)Weld patch over hole.

1.19 (P)Failure of scrubber fan impeller or shaft.

1 .20 (CA)Repair or replace impeller or shaft.1 .2 1 (P)Possible furnace process interruptions:

1.21. 1 Scheduled maintenance outages for routine repairs

1.21.2 Water leaks on furnace cooling ater system.1.21.3 Electrical problenis (i.e.arcing, control power, monitoring equipment on

critical componenents.

1.21,4 Cooling water supply failure.

1.21 .5 Changing out of stoking machines or repairing in place

1 .21 .6 Cleaning of operating deck

1 .21.7 Sounding of electrodes1.21.8 Electrode stubbing or breaking

1.21.9 Failure of hydraulic system for head movement and slipping system

1.21.10 Mix chute leaking mix

1.21.11 Changing of transformer voltage settings1.21.12 Checking for suspected water leaks

1.21 .13 Scheduled plant power outage for cleaning and electrical check
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.
When a non—standard condition occurs, the procedure must he followed and

1)ocumented. Notify the Shift Supervisor/Plant Foreman immediately.

Malfunctions/Non-Conformance:

1. (P)Loss of power to fan motor

.1.1. (CA) Check wiring and power source for wiring problem or blown fuses.

2. (P)Motor Bad

2.1 .1. (CA) Replace Motor

3. (P)Low Motor Amps or will not come up to speed

3. 1 . 1. (CA) Check damper control system electrical and mechanical

4. (P)Motor will not start

4. 1 1. (CA) Check electrical control system

5. (P)Bags full of dust

5.1.1. (CA) Check electrical and mechanical parts of cleaning system

6. (P)Hole in bags or bags missing

6.1.1. (CA) Replace bags

7. (P)Compartments full of fume

7.1 . 1. (CA) Check auger feed screw system

8. (P)Auger feed screw not turning

8. 1. 1. (CA) Check motor. belts and coupling

9. (P)Disc not sealing

9.1 .1. (CA) Check if disc broken or loose on shaft

10. (P)Bag collasped

1 0. 1 . 1. (CA) Replace wire cages that go inside bags

ii. (P)Hole or crack in duct work or baghouse

11.1 .1. (CA) Weld patch on crack or hole

12. (P)Loss of low air supply to baghouse

12.1 1. (CA) Check air system for plugged line, solenoids, valves for proper

operation or loss of plant air.

13 (P)Compartment does not seal

13.1.1. (CA) Check door latches and rubber seal. Repair if needed
U)

[U

U)

U)

a

to

Cl) 0

I-I

Ii

Na0

10

in

I-I 0I

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) HU flit U)Xit CD

0U 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

1t3—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--IU

‘ U) CDU (DC H- DUHUUc-tU0

0 U) c-I0 —- 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-IU 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) HU 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)

UU 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 H0 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-UU 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 itOC U)

HCPUU

U 

H

H

U

U- 

U) 

U) 

U) 

O 

U 

TO

U)U

CD 

hi

CT)

Q 

U

H- 

hi 

U

U 

it

U0

it U

I-t

U-

mU

(c-U

I-; 

?c

-Cl 

H- 

c-i-C

H-U 

ID 

U 

U-U

CU 

CTh 

U

CP

U- 

U- 

U 

U 

0- 

U 

‘O

<
p

p

3 . 3 Shutdown: Venturi Scrubber

3.3.1. Shutdown of Venturi Scrubber will be performed per HECP 102—07.

3.3.2. Record the rime of shutdown on the Title V/MACTSSMP/Maintenance

Record sheet located in the operations supervisors office

4.0 STANDARD/EXPECTED END RESULT:

4.1 The expected end result is safe operation of the furnace and venturi and 100%

compliance with the Erainet’s Title V Permit and the MAST standard.

5.0 DEVIATION AND CORRECTIVE ACTION:

5.1 See Attachment “A” Titled Furnace #12 SSMP

6.0 RESPONSIBILITY FOR IMPLEMENTATION:

6.1 The Shift Supervisor is responsible to assure that this procedure is

implemented exactly as written.

6.2 The Department Manager or designee is responsible to conduct a procedure

assessment of this procedure annually.

7.0 RECORDEPING REQUIREMENTS:

The Environmental Department must be notified immediately if a malfunction occurs

that causes an exceedance of an allowable parameter that is not addressed in this

SOP. Any exceedance not specifically listed in this SOP and addressed per thecorrective actions listed in this SOP, must be reported to OEPA within (2) days with

a follow-up letter detailing the event within (7) days.

All monitoring reports, excess emissions noted, and all maintenance activityperforineci on the dust collector must be recorded and sent to the environmentaldepartment within (2) days of the end of each month.

The Startup—Shutdown—Malfunction Plan and Maintenance Plan must be kept for the life

of the dust collector and the process. Changes to the process or control equipment

will require the plan to be updated to reflect these changes.The recordkeeping required by this SOP is for a term of (5) years. These records

must be made available to the EPA at their request.

8,0 APPROVALS:
Dept Manager Environmental Manage i , aa liLy Asset anne

9.0 SYSTEMS CONNECTIONS:

N erie

10.0 ATTACI-Th’SNTS:

Title V/MACE SSt/P/Malntenance Record Sheet

Title V/MACE Compliance Record Sheet
I Malfunctions/Non-Conformance:

• I (P)Complete loss of power to plant, furnace or scrubbers

1.2 (CA) Upon loss of power, follow Guide in TLC 151 and 15 G. When power is restored, follow start

up procedure for scrubbers outlined in Eramet Training and Technical Manual #12. After

scrLlbbers are operating, commence start up of furnace per HECP 102-01 and SOP 102-029 for

start up of furnace.

1.3 (P)Fan trip caused by high vibration

1.4 (CA)Lock out fan per HECP 102-07. Clean and balance fan, start up per I-IECP 102-07 and

Technical Manual #12.

1 .5 (P)Fan trip not caused by high vibration

1.6 (CA)Check all other monitoring devices that could cause trip. Check all power sources for

problems. When repaired, start up per HECP 102-07 and Technical Manual #12.

1 .7 (P)Fan damper controls not operating.1.8 (CA)Check electrical and mechanical components of control system and repair any problem found.

1.9 (P)Recirculating pump failure or no water to taxed disc.1 .1 0(CA)Switch to spare pump and repair pump that foiled. Check lines for blockage. Remove any

blockage found.

1.1 1(P)Motor failure on fans.

1.l2(CA)Lock fan out per 1-{ECP 102-07 and replace motor.

1.1 3(P)Fan bearing or motor coupling failure.I .14(CA)Lock fan out per HECP 102-07 and replace fan bearing or motor coupling.

1.15(P)Loss of cooling water to fan bearings.

1. I 6(CA)Check water line for break or blockage. Check strainer for blockage. Check water supply s

source for pump failure or major break in supply line.

• I 7(P)Hole in scrubber fan housing or duct from furnace to scrubber fan.

1.1 8(CA)Weld patch over hole.

19(P)Failure of scrubber fan impeller or shaft.

I .20(CA)Repair or replace impeller or shaft.

1 .21 (P)Possihle furnace process interruptions:

1.21. I Scheduled maintenance outages for routine repairs

1.21.2 Water leaks on furnace cooling water system.

1 .2 I .3 Electrical problems (i.e.arcing, control power, monitoring equipment on critical

components. etc.

I .21 .1 Cooling water supply failure.

1.21.5 Changing out of stoking machines or repairing in place1.21.6 Cleaning of operating deck1.21.7 Sounding of electrodes

I .21.8 Electrode stubbing or breaking

1.21.9 Failure of h draulic system for head movement and slipping s\stem1.21.10 Mi\ chute leaking niixI .21 . II Changing of transformer voltage settings

1.21. 12 Checking for suspected water leaks

1 .21 .13 Scheduled plant power outage for cleaning & electrical check

1 .21 .14 Power curtailment from electrical supply company
(

)

g

1 .26 (CA)Furnace shell to he repaired1.27 (P)Plugging furnace taphole by hand when Bailey plugging unit malfunctioning1.28 (CA)Repair plugging gun
p

p

y 

applicable requiren.erits of the EPA, Title V, arid MACI standards.

This process consists of a sari-seal furnace and associated dus:: control equipment.

The emissior:s from thic process are controlled by a venturi wet scrubber thatcollects emissions from under the cover of the furnace.

2.0 OPERATION AND MAINTENANCE REQUIREMENTS

At all times, including periods of startup, shutdown, and mal function, owners or

oporators shall operate anc marntain the aftected source, rncluding assocratec air

pollution control equipment, in a manner consistent with good air poilution control

practices tot minimizing emissions at least to the ievels required by al reievant

standards. Anytine the furnace or venturi scrubber is shutdown, or restarted, these

procedures must be foliowod and documented on the SSMP Maintenance Record Sheettcated in No. 18 Furnace Control Room.

3.0 DESCRIPTION;

3.1 Start—up; No. 18 Furnace Venturi Scrubber system

3.1.1 Startup uf Venturi Scrubbing System will be performed per Eramet

Marietta RECP Procedure NECP—l03—24

3.l.l.a. Operations are defined in Reference Manual #13 (Titled

Venturi Gas Cleaning System — Section 6.6.5.4jEramet

Training and Technical Manual

3.l.1.b. Record the startup data of the dust collector on the SSMP

Maintenance Record sheet located in No. 18 Furnace Control

Room

3.1.2 Startup of Furnace #18 will be performed per Sramet Marietta, Inc SOP—

103—019.

3.1.2.a. Ensure proper mix levels are in furnace to minimize fuming.

3.l.2.b. Visually look for emissions from the discharge of the stacks.

3.l.2.o. Record the startup time of the process on the SSMP Maintenance

Record sheet located In No. 18 Furnace Control Room.

3.2 Shutdown; No. 18 Furnace

3.2.1 Shutduwn of furnace will be pertormed per Eramet Marietta SOP 103-090.

3. 2.i enturi host ooiertor operales untIl fumzng stoos

3.2.3 Peoorh the time ot shutdown on SSNP Maintenance Rerord sheet loua:ed

No. 18 Furrare Cnntrr Poom.
3.3.1. Shutdown of Venturi Scrubber will be performed D’er DECS 103—24.

3.3.2 .Rc. cord the time of snutzdown on the SS1iP Maintenance Record sheEt

located in No. 18 Furnace Control Room

4.0 STANDARD/EXPECTED END RESULT:

4 . 1 The expected end result is safe oreration of the furnace and venturi and 100%

compliance with the Erarr.eI’s Title V Permit and the MACT stariciard.

5.0 DEVIATION AND CORRECTIVE ACTION:

5. 1 See Apendix “A” titled Furnace #18 SSM?

6.0 RESPONSIBILITY FOR IMPLENTATION:

6.1 The Shift Supervisor/Plant Foreman is responsible to assure that this

procedure is implemented exactly as written.

6.2 The Department Manager or designee is responsible to conduct a procedure

assessment of this procedure annually.

7.0 RECORDIEPING REQUIRENTS:

The Environmental Department must be notified immediately if a malfunction occurs

that causes an exceedarice of an allowable parameter that is not addressed in this

SOP or guidance document. Any exceedarice not specifically listed in thisSOP/guidance document arid addressed per the corrective actions listed in this SOP,

must be reported to OEPA within (2) days with a follow-up letter detailing the event

within (7) days.

All monitoring reports, excess emissions noted, and all maintenance activityperformed on the dust collector must be recorded and sent to the environmental

department within (2) days of the end of each month.

The Startup—Shutdown--Malfunction Plan and Maintenance Plan must be kept for the lifeof the dust collector arid the process. Changes to the process or control eciu:pment

will require the plan to ho updated to reflect these changes.The recordkeeping required by this SOP is for a term of (5) years. These records

must he made available to the EPA at their request.

8.0 APPROVALS:

Depi Manager Environ:uentai Manager, Quality Assurance
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 55MB
y 

p

y

5 I Malfunctions/Non—Conformance:

5. 1.1 (P)Complete loss of power to plant, furnace or scrubber.1.1 (CA) Upon loss of power, follow HECP 103-04. When power is restored,

follow start up procedure for venturi scrubbing system outlined in Eramet

Training and Technical Manual #13. After scrubber is operating, commence startup of furnace per HECP 103-04 and Sop 103-019 ftr start tip of furnace

.1.2 (P)Scrubber trip caused by high vibration.1.3 (CA)Lock out scrubber per HECP 103-24. Switch to backup scrubber. Start up

per HECP 103-24 and Technical Manual #13. Clean and balance malfunctioningscrubber.

.1.4 (P)Scrubber trip not caused by high vibration.1.5 (CA)Check all other monitoring devices that could cause trip. Check all power

sources for problems. When repaired or backup placed in service, start up per

IIECP 103-24 and Technical Manual #13.

.1.6 (P)Scrubber damper controls not operating..1.7 (CA)Check electrical and mechanical components of control system and repair

any problem found.

.1.8 (P)Pump failure or no water to scrubber system..1.9 (CA)Contact water supply source and request repair pump that failed or switch

to backup. Check lines for blockage. Remove any blockage found.

.1.10 (P)Motor failure on scrubbers..1.11 (CA) Lock out scrubber per HECP 103-24. Switch to backup scrubber. Start up

per HECP 103-24 and Technical Manual #13. Replace motor ofinalfunctioning

scrubber.

.1.12 (P)Scrubber bearing, coupling, or gear box failure..1.13 Lock out scrubber per HECP 103-24. Switch to backup scrubber. Stail up per

HECP 103-24 and Technical Manual #13. Replace malfunctioning scrubber

bearing or coupling or gearbox as needed.

.1.14 (P)Loss of cooling water to scrubber bearings.

.1.15 (CA)Check water line for break or blockage. Check strainer for blockage. Check

water supply source for pump failure or major break in supply line.

.1.16 (P)Hole in scrubber housing or duct from furnace to scrubber..1.17 (CA)Weld patch over hole.

(P)Failure of scrubber impeller or shaft.

.1.19 (CA) L.ock out scrtibber per 1{ECP 103-24. Switch to backup scrubber Repair or

replace malfunctioning impeller or shaft.

.1.20 (P)Possible furnace process interruptions:

.1 .20.1 Scheduled maintenance outages for routine repairs

I .20.2 Water leaks on furnace cooling water system,

• I .20.3 Electrical problems (i.e.arcing, control power. monitoring equipment on

critical components, etc..

I .20.4 Cooling water supply failure.

• I .20.5 Shoving in of mix banks• 1.20.6 Cleaning of operating deck
pp

y 

p

y

5.2.22(CA)Except for 5.2.21.6, 5.2.21.7, 5.2.21.8, 5.2.21.11, 5.2.21.12.

5.2.21 .13 and 5.2 1 .2. 14, the above items would he repaired through

the Maintenance kmnpact Work Order System

5.2.23(P)Emitting visible emissions from stack5,2.24(CA) adjust electrodes to lower position if needed

Add mix to furnace

Check/adjust scrubber parameters for proper settings

5.2.25(P)Fornace shell burn through5.2.26(CA)Furnace shell to be repaired5.2.27(P)Plugging furnace taphole by hand when Bailey plugging unit malfunctioning

5.2.28(CA)Repair plugging gun
p

g

; 

;

p

y 

pp

requirements of the SPA, Title V, arid MACT standards.

This process c:ortsists of a Manganese Oxygen Reduction (NOR) process and dust cont.rolequiernerit. The emissions from this process are controlled by a baghouse whichcontrols fume front the NOR process by means of a suspended hood above the ladle.

2. 0 OPERATION AND MAINTENANCE REQUIRENTS

At all times, including periods of startup, shutdown, and malfunction, owners or

operators shall operate and maintain the affected source, including associated air

pollution control equipment, in a manner consistent with good air pollution controlpractices for minimizing emissions at least to the levels required by all relevant

standards. Anytime the NOR process / dust control equipment is shutdown or

restarted, these procedures must be followed and documented on the SSMP MaintenanceRecord Sheet located in the NOR Control Room.

3.0 DESCRIPTION:

3.1 Start—up: Manganese Oxygen Reduction (NOR) Process / Baghouse

3.1.1 Startup of NOR Process / Baghouse will be performed per HECP-103-02.

3.1.2 Operational checks are defined by the NOR Baghouse Checksheet.3.1.3 Record the startup data of the dust collector on the SSMP Maintenance

Record Sheet located in the NOR Control Room.

3.2 Shutdown: MOR process / Baghouse

3.2.1 Shutdown of the MOR will be performed per HECP-l03-02.

3.2.2 NOR Baghouse will operate until fuming stops.3.2.3 Record the time of shutdown on the SSMP Maintenance Record Sheet located

in the NOR Control Room.

4.0 STANDARD/EXPECTED END RESULT:

4.1 The expected end result is safe operation of the NOR process and Baghouse and

100% compliance with the Eramet’s Title V Permit and the MACT standard.

5.0 DEVIATION AND CORRECTIVE ACTION:

5.1 See Appendix “A” titled 11CR Process / Baghouse SSNP

6.0 RESPONSIBILITY FOR IMPLEMENTATION:

6.1 The Shift Supervisor is responsible to assure that this procedure is

rmplemented exactly as written.
g

p

p

assessment of this procedure annuaLly.

7.0 RECORDEPING REQUIREtNTS:

The Environmental Department roust be notified immediately if a malfunction occursthat causes an exceedance of an allowable parameter that is not addressed in this

SOP .Anv exceedance rrot specifically listed in this SOP and addressed per thecorrective actions listed in this SOP, must be reported to OEPA within (2) days with

a foliow—up letter detailing the event within (7) days.

All monitoring reports, excess emissions noted, and all maintenance activity

performed on the dust collector must be recorded and sent to the environmental

department within (2) days of the end of each month.

The Startup—Shutdown—7lalfurmcticn Plan and Maintenance Plan must be kept for the life

of the dust collector and the process. Changes to the process or control equipment

will require the plan to be updated to reflect these changes.

The recordkeeping required by this SOP is for a term of (5) years. These records

must be made available to the EPA at t:heir request.

8.0 APPROVALS:

Dept Manager Environmental Manager, Quality Assurance

9.0 SYSTEMS CONNECTIONS:

1. HECP—103—02: Reaction / Casting Fans

10.0 ATTAC-Th’NTS:

A) SSMP Maintenance Record Sheet

B) MOR Pachouse CireckaheetC)Appenidix ‘A”: MOE Process / Baghouse SSVP
SHE PERSONAL PROTECTIVE EQUIPMENT

EMI Standard PPE is required for performing the tasks described

However, Gloves are recommended, and Hearing Protection isC2P Crusher Sound Barrier Curtains while the crutdn.q system is

1 PROCEDURE DESCRIPTION

The purpose and scope of this procedure e proper operation andJaw Crusher process and #2 Dust C ector, and to m tall applicable requirer

—

— —k 5, and MACT standards. The C2P aw Cr rocess onsists of two crush

vibrating grizzly feeder, and 7 ( yen) nveyor be . The emissions from this iby a baghouse with various p up ints. All dust is ollec d to a dust hopper.

IVIRONMENTAL POLl Y: At times, including eriod of startup, shutdown, and malfunction,

operators of the C2P Jaw Cr her pr ess and #2 st C Ilector shall operate and maintain theprocess, including associated a ollutio control quip ent, in a manner consistent with good airpollution control practices for mini ing e si s to least the levels required by all relevantstandards.

Start

T on the #2 collect . This is don from t HMI located in the control room. If the

entire crusher syste is to be tarted then dust c Ilector will start automatically through

the PLC and HMI.

NOTE: #2 Dust collector I not n when all crushed product is going to product

conveyor #1 only.

1.2 The discharge rotary valves w II aut matically start through the PLC when the dust

ollectors are started.

NO The dust collect disc arge rotary valve are continuously monitored by the

C. If eith pera n fail to start, the fan will not start.

1.3 Visua ok for emis s from the discharge of the stack and record daily on the Title 5 /

MACT Inspec ion ecord sheet (APPENDIX 143-A) located in the crusher control room.

ie pressure drop range for the baghouse is 0.6 - 3.0 inches of water. The

pressure readout is located on the South leg of the baghouse. Record the reading

Ipection Record sheet.

fthe startup data of the dust collector on the Inspection Record sheet.

If there are no visible emissions and the differential pressure is within the

acceptable range, it is assumed that the cleaning mechanism is operating correctly.

.6 Record the startup time of the process on the Title 5 I MACT Compliance Record sheet

(APPENDIX 143-B) located in the crusher control room.NOTE: Anytime there is a dust collector shutdown or breakdown, the above Start-up

procedure must be followed and documented in ink as described above.Thisincludes Start-up and shLltdown at the beginning and end of shift.

procedure.

working within the

of the C2P

EPA’s Title

a

1.4

1.5

Pvge 1 of3
3 Collector I Baghouse Maintenance & Preven in ance

3.1 Monthly - Visual Inspec n s om system. is ill include a visual Inspection of

the hoods and ductw rk isual ins e tion of the exten r of the baghouse, visual inspection of

the differential gag lu ing, and a isual inspection of the pulse jet cleaning mechanism

Record the results oft in ect n the EMPAC System Preventive Maintenance Work

Order.

3.2 Quarterl -V spe on of gs nd cages. Open plenum of baghouse for

inspe o . Record t re Its of i pection in the EMPAC System PreventiveMain en nce Work Orde

3.3 Semi nn at - Inspection of fa forwear and corrosion. Record the results of the

ta

::::n

the EMPAC y em Preventive Maintenance Work Order.

4.1 Start-up and hutdown of the dust collection system must be done at the beginning and

end of each sh used. It should be noted on the Compliance Record sheet in the crusher

control roo

2 te nce done on the dust collector must be documented in the EMPAC System

ye Maintenance Work Order. All non-PM work should also be documented on the

Compliance Record sheet located in the crusher control room.

Paqe2of3
Dust Collector Fan Failure.

Verify power is on.

lace Fan Motor.

electrical controls.

ce bearings.

ce belts.

FOR IMPLEMENTATION

ibility of the Packing Supervisor to assure that this procedure is implemented

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

actions taken documented. When a 

No-Go situation occurs

shutdown immediately and the non-conformance must be

Packing Supervisor / Plant Foreman immediately.

2 Any malfunctions foLind or corrective actions required, will be

priority to complete the repairs in a timely manner, All malfunctiontactions will be reported to the Environmental Department in two (2)

), the equipment must be

3 Malfunctions / Non-conformance:

3.1 Emitting visible dust from stack. No-Go - Use fluorescent powder to leak detec - Replace bags, cages or repgifis3.2 Plugged or broken dust - Patch, repair or -

3.3 High Differential Pr

- Verify power is on. - Verify PD Blower - Change bags.

3.4 Low Differential Pressure

- Ver owens - erify Fan is operatir

ega ci

there are no

ieck ducts for hole

Check bags for holes or

Check baghouse integrity leaks,

3.6 Bagh discharge I b-Go - Verify p-i._ - Replace motor. - Rep/repIace gear drive. -Rete 1htibq/replace belt.

PrirIri,,- electrical controls.

written.

Page 3o13
Lw PERSONAL P TEIE EQUIPMENT

EMI Standard PPErequirec for pertorrning the tasks descnbed

However Gloves are recommended and H:arirgi.2jotection is reqi

PROCEDURE DESCRIPTION 

The purpose and scope of this procedur a proper operation and

-‘3 C2P DuO CeiieuWr “‘ Jaw Crusher process and #3 Dust C ctor, and to m t all applicable r

5, and MACT standards The C2P aw C rocess onsists of two — vibrating gnzzly feeder, and 7 ( yen) nveyor be The missions from this — by a baghouse with various p up mis All dust is ollec d to a dust hopper.

ENVIRONMENTAL POLl Y: At a imes, including p dod of startup, shutdown, and malfunction,

operators of the C2P Jaw Cr her pr ess and #3 St C Ilector shall operate and maintain theprocess, including associated ai ollutio control quip nt, in a manner consistent with good air

pollution control practices for mini ing e am s to least the levels required by all relevant

standards

1 Start-

.1 T on the #3 collect This is don from HMI located in the control room If the

entire crusher syste s to be tarted then dust c Hector will start automatically throughthe PLC and HMI

NOTE: #3 Dust collectorw not r n when all crushed procuct is going to product

conveyor #1 only

I 2 The discharge rotary valves wi aut matically start through the PLC when the dust

olleclors are started

NO The dust collect disc rge rotary valve are continuously monitored by the PLC

ither o ion fa o start, the fan will not start

1.3 Visua ok for emis s from the discharge of the stack and record daily on the Title 5 I

MACT Inspec ion ecord sheet (APPENDIX 143-A) located in the crusher control room

aptable pressure drop range for the baghouse is 0.6 - 3.0 inches of water The

pressure readout is located on the South leg of the baghouse. Record the reading

mctmon Record sheet

‘the startup data of the dust collector on the Inspection Record sheet

:: If there are no visible emissions and the differential pressure is within the

acceptable range it is assumed that the cleaning mechanism is operating zorrecflj

Record tne statup time of the process on the Title 5 MACT Compliance Recoro sheet

,AENDlX 43-3) located in the crusher control room

NOTE: Anytime there is a Oust collector shutdown or breakoown the above Start-up

proedjre must be followed and documented in ink as descrbed above Thisincludes Start-uo and shuldosn at the beginning and end of sh’t

r’, 33.1 of 3

of the C2P

EPA’s Title

a

1.4

15

.1,
3. Collector! Baghouse Maintenance&Preven sin nance

3.1 Monthly -Visual inspec n s om system. is ill include a visual inspection of

the hoods and ductw rk isual ins e tion of the exteri r of the baghouse, visual inspection ofthe differential gag lu ing, and a isual inspection of the pulse jet cleaning mechanism.

Record the results oft in act n the EMPAC System Preventive Maintenance WorkOrder.

3.2 Quarterl -V spe on of gs nd cages. Open plenum of baghouse for

inspe io . Record t re Its of i pection in the EMPAC System PreventiveMain en nce Work Orde

3.3 Semi nn al - Inspection of fa for wear and corrosion. Record the results of the

the EMPAC y em Preventive Maintenance Work Order.

4.1 Start-up and hutdown of the dust collection system must be done at the beginning and

end of each sh used. It should be noted on the Compliance Record sheet in the crushercontrol roo

2 te nce done on the dust collector must be documented in the EMPAC System

ye Maintenance Work Order. All non-PM work should also be documented on the

Compliance Record sheet located in the crusher control room.

Page2of3
3.4 Low Differential Pressure - Ver ower

- erifv Fan is

there are no

ck ducts for hole

Check bags for holes or ICheck baghouse integrity

Dust Collector Fan Failure. Ni

Verify power is on.

:e Fan Motor

electrical controls.

bearings.belts.

actions taken documented. When a 

No-Go

situation occurs

shutdown immediately and the nonconformance must be

Packing Supervisor / Plant Foreman immediately.

2. Any malfunctions found or corrective actions required, will be adc

priority to complete the repairs in a timely manner. All malfunctiont

actions will be reported to the Environmental Department in two (2)

be

days or less.

3. Malfunctions / Nonconformance:

3.1 Emitting visible dust from stack. No-Go - Use fluorescent powder to leak detect - Replace bags, cages orrenairi

3.2 Plugged or broken dust

- Patch, repair or clear I

3.3 High Differential - Verify power is on. - Verify PD Blower - Change bags. is operating correctly.

3.6 Bagh’s discharge

- Verify po—i - Replace motor. - Rep/replace gear drive. - Reteitiç/replace belt.

- Ppnir/reInice electrical controls.

S ILITY FOR IMPLEMENTATION

ponsibility of the Packing Supervisor to assure that this procedure is implemented

written.

the responsibility of the Department Manager to conduct a procedure assessment of this

procedure annually.

5 SYSTEM CONNECTIONS

1. APPENDIX 143-A Title 5/ MACT Inspection Record Sheet

2. APPENDIX 143-B: Title 5/ MACT Compliance Record Sheet

Paoe 3 of 5
n

t - However, Gloves are recommended, and H I lII

,C2P Crusher Sound Barrier Curtains while thi

PROCEDURE DESCRIPTION

C2P D,ot Coiie,tor The purpose and scope of this

‘Jaw Crusher process and #1 Di

. 5, and MACT standards The

vibrating grizzly feeder,by a baghouse with vanENVIRONMENTAL POLICY: of startup, shutdown, and malfunction,

operators of the C2P Jaw Crush ector shall operate and maintain the

process, including associated air p , in a manner consistent with good air

pollution control practices for minimizin emission o at least the levels required by all relevantstandards.

rt-up:

1.1 Turn on the #1 dustco ctor. is is done fro the I located in the control room. If the

entire crusher system is be at ed then #1 d collector will start automatically through

the PLC and HMI.

1. The discharge rotary valves II aut matically start through the PLC when the dust

collectors are started.

TE: The dust collector sch ge rotary valve are continuously monitored by the

PLC. If either op ation all to start, the fan will not start.

1.3 ually loo sions fr m the discharge of the stack and record daily on the Title 5 /

MA Inspection Recor heet (APPENDIX 143-A) located in the crusher control room.

1.4 The acceptable pressure drop range for the baghouse is 0.6 - 3.0 inches of water. The

diffqçential pressure readout is located on the South leg of the baghouse. Record the readingon theN,ospection Record sheet.

te startup data of the dust collector on the Inspection Record sheet.

If there are no visible emissions and the differential pressure is within the

acceptable range, it is assumed that the cleaning mechanism is operating correctly.

the startup time of the process on the Title VIMACT Compliance Record sheet

(APPENDIX 143-B) located in the crusher control room.

NOTE: Anytime there is a dust collector shutdown or breakdown, the above Start-up

procedure must be followed and documented in ink as described above. Thisincludes Start-up and shutdown at the beginning and end of shift.

SHE PERSONAL PROTECTIVE EQUIPMENT

EMI Standard PPE is required for performing the tasks described withi jrocedure.

is ien working within the

r operation and docu ntatio f the C2P

I applicable requirement f the A’s Title

nsists of two crushers, two r en boxes, a

missions from this process are controlled

d to a dust hopper.

1.5

Page 1 of3
3. Collector / Baghouse Maintenance Preventa I am narice

3.1 Monthly -Visual inspe o or le s om system. i ill include a visual inspection of

the hoods and duct r visual ins e hon of the exterior of the baghouse, visual inspection of

the differential gage urn ng, an a isual inspection of the pulse jet cleaning mechanism.

Record the results of th ins o n the EMPAC System Preventive Maintenance Work

Order.

3.2 Quarter - sual in ect n of b s d cages. Open plenum of baghouse for

inspe io . Record the es ts of th spection in the EMPAC System PreventiveMain n nce Work Order.

in

ofa

te e

of the

.1 Start-up and tdown of the dust collection system must be done at the beginning and

end of eac s ft used. It should be noted on the Compliance Record sheet in the crusher

control ro m.

4.2 m nance done on the dust collector must be documented in the EMPAC System

Preventive Maintenance Work Order. All non-PM work should also be documented on the

Compliance Record sheet located in the crusher control room.

Page2of3
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 j
EMI Standard PPE is required for performing the tasks described withi this procedure.

However, Gloves are recommended, and Heari rotection is requred hen working in the

Vicinity of the C7P Crusher while the crushing a tern is ope

C PROCEDURE DESCRIPTION

The purpose and scope of this procedure e proper operation and cumen tion of the C7P

Crushing and Screening process an 4A Dust Colle r; and to meet all applic le req ements of

the EPA’s Title 5, and MACT stan rds. Crus g and Screening and # Dust hector

process consists of the South ss C Station. e emi sions from this process ar on lied by a

baghouse with various picku oint

ENVIRONMENTAL POLl Y: At times, including eriod of startup, shutdown, and malfunction,

operators of the C7P Crushi and S ening and # A D t Collector process shall operate andmaintain the process, including sociat air poll ion ntrol equipment, in a manner consistent withgood air pollution control practices r mini i emis Ions to at least the levels required by allrelevant standards.

1. Start-

.1 T n on power e #4A st collector d PL

1. Turn on the dust collec r fan.

1.3 The dust collector is operat d by PLC. The cleaning mechanism is a “Clean on

demand” system. Air pulses ay ot be heard when the dust collector is started.

1. Visually look for emissions fr m th discharge of the stack and record daily on the Title 5

MACT Inspection Record s eet ( PPENDTX 143-A) located in the crusher shanty.

1. The essure drop forth agh use is 4.0 - 10.0 inches of water. The differential

ressure dout is ted o the North leg of the baghouse. Record the reading on the

In ection Record sheet.

1.6 The accepta e c eaning pressure range is 75 - 90 psi. The gage is next to the

differential pressure readout on the air regulator. Record the reading on the Inspection

sheet.

startup data of the dust collector on the Inspection Record sheet.

It is assumed that if there are no visible emissions, the cleaning air pressure is

acceptable and the differential pressure is acceptable, the cleaning mechanism isoperating correctly

Record the startup time of the process on the Title 5 / MACT Compliance Record sheet

(APPENDIX 143-B) located in the crusher shanty.NOTE: Anytime there is a dust collector shutdown or breakdown, the above Start-Lip

procedure must be followed and documented in ink as described above Thisincludes Start-up and shutdown at the beginning and end of shift.

SHE PERSONAL PROTECTIVE EQUIPMENT

1.7

Paqel 0f4
2.3 Record the time of shutdown o omplianc ec rd sheet,

3. Collector I Baghouse Maintena e & ventative Ma’ ten nce

3.1 Monthly -Visual insp ti for leak fr m system. Thi will include a visual inspection of

the hoods and duct ork, isual i p ction of the exterior of the baghouse, visual inspectionof the differential gage. Re rd e suits of the inspection in the EMPAC System

Preventive Maintenance ork r r,

3.2 Quarter - ‘ - spe ion a gs nd cages. Open plenum of baghouse for

inspe lo - Record t re Its of i pection in the EMPAC System Preventive

Main en nce Work Orde

3.3 Semi an al - Inspection o fa forwear and corrosion, Record the results of the

the EMPAC y em Preventive Maintenance Work Order,

4.1 Start-up and hutdown of the dust collection system must be done at the beginning and

end of each sh used. It should be noted on the Compliance Record sheet in the crushershanty.

.3 - te ance done on the dust collector must be documented in the EMPAC System

ye Maintenance Work Order, All non-PM work should also be documented on the

Compliance Record sheet located in the crusher shanty.

Page2of4
3.4 High Differential - Vejpower is on.

.5 Low Differential - Verify power is on. - Verify Fan is open - Verify the gage is - Verify there are no - Check ducts for hole - Check bags for holes

- Check baghouse

ise discharge failure. No-Go

rubber diaphram in Discharge valve.

Tension rods in Discharge valve.

SIBILITY FOR IMPLEMENTATION

responsibility of the Packing Supervisor to assure that this procedure is implemented

as written.

2. It is the 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

below), the equipment

before start-up Notify

and actions taken documented. When a “No-Go” situation cccimust be shutdown immediately and the non-conformance must

the Packing Supervisor / Plant Foreman immediately.

2. Any malfunctions found or corrective actions required, will be addr

priority to complete the repairs in a timely manner. All malfunctic

actions will be reported to the Environmental Department within

3. Malfunctions / Non-conformance;

3.1 Emitting visible dust from stack. No-Go - Use fluorescent powder to le - Replace bags, cages or pair steel

- Check water

3.2 Plugged or - Patch,

3.3 Plugged - Open chute or

in plumbing to gage.

les and leaks.

• Ft jo-Go - e Fan Mc - llr-e+ rtal controls. - Repair/replace bearings.

belts.

Rcto 3 of 1
Pae4of4
NOTE: The dust collector

monitored by a zer

start.

NOTE: Anytime there is a dust collector shutdown or breakdown, the above Start-up

procedure must be followed and documented in ink as described above. This

includes Start-up and Shutdown at the beginning and end of shift

SHE PERSONAL PROTECTIVE EQUIPMENT

EMI Standard PPE is required for performing the tasks described with thi procedure.

However, Gloves are recommended, and Hearing Protection is reqi. ired hen working in the

vicinity of the C7P Crusher while the crushing sy rating.

PROCEDURE DESCRIPTION

The purpose and scope of this procedure is to assure proper operation an ocume ation of the C7P

Jaw Crusher process and #3 Dust Coil or, and to eet all applicable require ants o e EPA’s Title

5, and MACT standards. The C7P w Crusher proce consists of a crusher, a illary h per and box dumper. The emissions by a baghouse with va us pic p points.

of Startup, shutdown, and malfunction,

tctor shall operate and maintain the

in a manner consistent with good air

st the levels required by all relevant

ENVIRONMENTAL PC

operators of the C7P Jaw,

process, including associe

pollution control practices forstandards.

1. Start-up:

1.1 2T on power to thef dust

oil the

Turn on the dust collec

on Water Sprays

1.6

1.7

will not

rusher

look for emissiop(from the discharge of the stack and record daily on the Title 5

I sheet (APPENDIX 143-A) located in the crusher control room.

le pressure drop range for the baghouse is 2.0 - 5.0 inches of water. The

ii pressure readout is located on the South leg of the baghouse. Record the reading

;pection Record sheet.

I startup data of the dust collector on the Inspection Record sheet.

If there are no visible emissions and the differential pressure is within the

acceptable range. ft is assumed that the cleaning mechanism is operating correctly.

Record the startup time of the process on the Title 5/MACT Compliance Record sheet

(APPENDIX 143-B) located in the crusher control room.

Pajelof4
2.3 Turn off the dust collector.

2.4 Turn off water sprays.2.5 Record the time of shutdo on th ompliance Rec d s et (APPENDIX 143-B)

located in the crusher s nty

3. Collector! Baghouse M - te nce & Prey nt ye Maintenance

3.1 Monthly -Visual inspe ion lea fr system. This will include a visual inspection of

the hoods and ductwork, ua sp tion of the exterior of the baghouse, visual inspection ofthe differe plumbin disc nnection of the zero speed switch on the rotary valve toverify e system inte cks an vis I inspection of the shaker cleaning mechanism.

Re rd results the - spectio in th EMPAC System Preventive Maintenance Work

Or er

3.2 ua erly -Visual inspecti n o bags and cages. Open plenum of baghouse for

spe tion. Record the res Its f the inspection in the EMPAC System Preventive

M inte ance Work Order.

Semi nua Inspecti of n for wear and corrosion. Record the results of the

inspectio in the AC ystem Preventive Maintenance Work Order.

4. Data Collection:

4.1 Start-up nd hutdown of the dust collection system must be done at the beginning and

end of e ch hift used. It should be noted on the Compliance Record sheet in the crusherchant - 4.2 All intenance done on the dust collector must be documented in the EMPAC System

reventive Maintenance Work Order. All non-PM work should also be documented on the

Compliance Record sheet located in the crusher shanty.

Page2of4
and actions takendocumented. When a “No-Go’ situation occ (s e below), the equipment must

be shutdown immediately and the non-conformance must be co ecte before start-up. Notify thePacking Supervisor I Plant Foreman immediately.

2. Any malfunctions found or corrective actions required, will be add sse with the highest

priority to complete the repairs in a timely manner. All malfunctions, devi tions and corrective

actions will be reported to the Environmental Department in two (2) orki days or less.

3. Malfunctions I Non-conformance:

3.5 Dust Collector Fan Faili - Verify power is on.

Replace Fan Motor.

ir electrical

>

3.6 Bagr - Verify power is on.

Iplace motor.

ar/replace gear drive.

lace belt.

electrical controls.

SYSTEM CONNECTIONS

1. APPENDIX 143-A: Title 5 / MACT Inspection Record Sheet

2 APPENDIX 143-B: Title 5 / MACT Compliance Record Sheet

Page

3.1 Emitting visible dust from stack. No-Go - Use fluorescent powder to le - Replace bags, cages or pair steel - Check water sprayc

3 2 Plugged or brc - Patch, repair.

3.3 High Differenti - Verify power is

- Verify Shaker M - Change bags. ectly.

3). No-Go - Verify the

- Verify there are - Check ducts for: - Check bags for holes - Check baghouse mt gage. holes and leaks,

e failure. No-Go

FOR IMPLEMENTATION

sponsibility of the Packing Supervisor to asscre that this procedure is implemented

exa as written.

It is the responsibility of the Department Manager to conduct a procedure assessment of this

procedure annually.
Page4of4
tation of the C7P

ements of the

or process

olled by

The dust collector is operate by aLC. The cleaning mechanism is a Clean on

demand system. Air pulses nay n)t be heard when the dust collector is started.

isually look for emissions tr,hm th4 discharge of the stack and record daily on the Title 5

T Inspection ENDIX 143-A) located in the crusher shanty.

range for the baghouse is 5.0 - 10.0 inches of water. The

is located on the North leg of the baghouse. Record the reading

sheet.

acceptable cleaning pressure range is 75 - 90 psi. The gage is next to the

pressure readout on the air regulator Record the reading on the Inspection

‘the startup data of the dust collector on the Inspection Record sheet.

If the pressure drop and cleaning pressure are in the above ranges and there are

no visible emissions; then. it is assumed that the cleaning air pressure and thedifferential pressure are acceptable and the cleaning mechanism is operating

correctly.

1.9 Record the startup time of the process on the Title 5/MACT Compliance Record sheet

(APPENDIX 143-B) located in the crusher shanty.NOTE: Anytime there is a dust collector shutdown or breakdown, the above start-up

procedure must be followed and documented in ink as described above, Thisincludes start-up and shutdown at the beginning and end of shift.

procedure.

vhen working in the

sea PERSONAL PROTECTIVE EQUIPMENT

EMI Standard PPE s required for performing the tasks described with

However. Gloves are recommended, and Hearing Protection is reqi

vicinity of the C7P Crusher while the crushing sys)aeJaorating.

PROCEDURE DESCRIPTION

The purpose and scope of this procedure is to assure proper

Crushing and Screening process and #4 o tor; and to meet all appi

EPA’s Title 5, and MACT standards. e C7P Crushi and Screening and #4consists of crushers, screent iissions from this pro

a baghouse with various plcENVIRONMENTAL POLIC1

operators of the C7P CruEmaintain the process, inch

good air pollution control practicrelevant standards.

1. Start-up:

‘of startup, shutdown, and malfunction,

Dust Collector shall operate and

I equipment, in a manner consistent with

to at least the levels required by all

on the

Turn on the dust col

ctor.

1.0

on th

1.7

1.8

wet.

Psgelof4
tive 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,

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

toPre

3.2

Page2ot4
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

s, 

s 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 valvw
Page4oi4