EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

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ENCLOSURE 1

INFORMATION COLLECTION REQUEST FOR

FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

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 maintain 

such 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 existing 

emission 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: 

 All recipients must complete and return this survey by July 30, 2010.

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

 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). 
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MANUFACTURING EMISSION POINTS

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 Please identify clearly any response(s) that you consider to be confidential 

business information (CBI). Any responses not so identified will be included in a 

publicly available database. Refer to Enclosures 3, 4, 5, and 6 for more information on 

the treatment of CBI and a list of information you may be asked to submit later to 

substantiate a claim of confidentiality. Please do not label an entire response 

“confidential” if only certain portions consist of trade secret information. If you 

wish, you may submit a confidential and a non-confidential version.

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 other 

method 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 secure 

forms 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.gov

PLEASE RETURN THIS SURVEY NO LATER THAN JULY 30, 2010

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.
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MANUFACTURING EMISSION POINTS

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CONFIDENTIAL BUSINESS INFORMATION (CBI): 

Please indicate if any CBI is included in this survey response: Yes No

PART I. OWNER INFORMATION

1. Name of Legal Owner: 

a. Address: 

b. City: 

c. State: 

d. Zip: 

e. County: 

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

a. Address: 

b. City: 

c. State: 

d. Zip: 

e. County: 

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

a. Address: 

b. City: 

c. State: 

d. Zip: 

e. County: 

4. Facility Contact:

a. Name (First Name, Last Name): 

b. Title: 

c. Telephone Number: ( ) _Ext

d. Fax Number: ( ) _

e. E-mail: 
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5. Facility Description:

a. Brief description of the facility:

 (e.g., ferroalloy production operations and any other operations located on-site.)

 _______________________________________________________________________

______________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

b. Dun & Bradstreet No: 

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

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.

__________________________________________________________________

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

__________________________________________________________________

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

 Primary: 

 Other: 

g. Is the legal owner a small entity? Y N Unknown
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h. Operating Hours (Most common operating hours for the majority of the year)

 hours/day: 

 shifts/day: 

 days/wk: 

 weeks/yr: 

6. Geographic Coordinates of Center of Plant:

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

a. latitude and longitude: 

b. UTM coordinates: 

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 Production

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

Pollutants from Ferroalloys Production: Ferromanganese and Silicomanganese

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

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

Major Source

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
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10. List of Enclosed Items

List the items submitted with the survey response (e.g., permits, block-flow diagrams, 

piping and instrumentation diagrams, test reports, sampling analyses, exceedence 

reports), and provide an identification code for each item (e.g., attachment 1)

Identification code Description of item submitted with survey response

PART II. GENERAL FACILITY INFORMATION

1. 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 all 

associated 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.
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3. Raw Materials

Complete the summary of raw materials used, in Table 2D. Include all the components 

included in furnace charges for all products, and indicate how much of each was 

consumed in 2009. For each raw material, indicate the percentage of total consumption 

used for each end product. If 2009 was not a representative year, data from another 

year may be used if an explanation is provided. 

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: 

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

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

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

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

PART III. VENTILATION, CAPTURE AND CONTROL SYSTEMS

1. Capture and Control Summary

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

capture equipment associated with the processes listed in Table 2A,( with the exception 

of capture for furnaces and tapping.) Fugitive emissions from furnace and tapping 

operations 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.
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3. Control Device Details

Complete Table 3C with information on any air pollution control equipment. Emissions 

points exhausting to the same control device may be grouped. If you have any data 

showing any variation in control device efficiency over time, please attach it.

4. Ladle Post-Processing Capture and Control

Do you perform any post-tap ladle processing? Yes No 

If yes, please provide a narrative description of the process and details of any 

associated capture and control equipment.

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

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

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

PART IV. MONITORING SYSTEMS

1. Monitoring Summary

Complete Table 4A with details of routine parameter monitoring performed for control 

device performance indicators. Emission points for which monitoring performed is 

similar 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 compliance 

with 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 the 

latitude and longitude coordinates, height, diameter, velocity of flow, temperature of the 

output stream, and nature of the emissions (i.e., continuous or varied over time). If the 

emissions are varied, indicate how the emissions vary over time if known.
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2. Non-Point Modeling Data

For each emission point that is a nonpoint source (e.g., fugitive emissions), complete Table 

5C. Each nonpoint source should be defined as a rectangular area. For Table 5C, indicate 

the southwest corner latitude and longitude coordinates of the defined nonpoint source area, 

the release height, length and width dimensions, angle of rotation, and nature of the 

emissions. 

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 and 

concentration of each individual HAP emitted (see Appendix A for EPA’s list of HAPs), 

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 II-2, above.

4. HAP in Emission Streams

Complete Table 5F for each emission point and process, with capture, control, and 

emissions information for each emission stream identified in Tables 5A, 5B, and 5C, 

with the following considerations:

1. Columns 1-3 and 11-13 of Table 5F must be completed for all sources;

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 the 

western 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 the 

western 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.
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2. Complete columns 4-7 of Table 5F for all sources with capture systems (e.g., hoods);

3. Complete columns 8-10 of Table 5F for all sources with air pollution control systems 

(e.g., baghouses);

4. Provide HAP data only for those HAPs identified in Table 5D, 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, or

baghouse 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 (APCDs) 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 APCDs, 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

Complete Table 6A providing annual costs for operating and maintaining EAF 

fabric filter control devices (i.e., positive pressure baghouses).
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2. Scrubber Costs

Complete Table 6B providing annual costs for operating and maintaining EAF wet 

scrubbers.

PART VII. STARTUP AND SHUTDOWN

Please provide the following information for operations during startup and 

shutdown. Attach additional pages if necessary.

1. Startup and Shutdown Information

A. Please indicate number of times over the last three years that shutdown and start-up 

 event has occurred: __________________________________

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. 

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

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.)

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________
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4. Test Data

Do you have test data that show emissions during startup or shutdown? Yes No 

If yes, when did you conduct such testing and why?

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

What were the test conditions at the time of testing? . 

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

Were the tests associated with a routine startup or shutdown? 

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

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 permitting 

authority? Yes No 

PART VIII. MISCELLANEOUS

1. Future Plans

Describe any future work practice or pollution prevention measures you are 

considering which may result in emission reductions.

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________
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2. New Source Review

If any control or process change you have performed was instituted as a result of 

new source review requirements pursuant to 40 CFR Part 51, Subpart I, Review 

of New Sources and Modifications, provide the date at which the lowest 

achievable emission rate (LAER) came into effect:

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

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.

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

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.

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________
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EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

SECTION 2. PLANT OPERATIONS

Table 2A : Summary of Ferroalloy Production Unit Operations

Include all operations referred to in attached process flow diagram

hr/d d/yr

Electric Arc Furnace EAF1 16 350 500,000 800,000

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

(b) Provide production in appropriate units e.g., tons/yr. 

Reporting year should be 2009 unless otherwise indicated.

Operating Cycle

Name of Unit Operations Using 

and/or Emitting HAP

Maximum Annual 

Production 

(tons/yr)

Unit Operation 

Process 

Diagram ID (a)

Average Annual 

Production (b) 

(tons/yr)

Sample row is shaded, and shows one representative unit operation. Include all unit operations at your facility in your 

response.

Ferroalloys Production Manufacturing Emission Points Survey

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Table 2B : Furnace Information

Fill out a copy of this form for each furnace

Furnace Process Diagram ID (a)

Primary Product (b)

Actual Production of primary product 2009 (days/year)

Actual Production of primary product 2009 (tons/year)

Average Production of primary product (tons/hr)

Maximum Production of primary product (tons/hr)

Secondary Product (b)

Actual Production of secondary product 2009 (days/year)

Actual Production of secondary product 2009 (tons/year)

Average Production of secondary product (tons/hr)

Maximum Production of secondary product (tons/hr)

Furnace Design

Rotating furnace?

Height (ft)

Diameter (ft)

Age of Furnace (yrs)

Original capital cost of furnace ($)

Remaining economic life (yrs)

Average operating rating (MW)

Design Rating (MW)

Annual Operation (hr/yr)

Description of upgrades made to furnace

Year(s) upgrade was made

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

(b) If multiple products are produced in a furnace, please indicate percentage of total furnace production.

See sample page for example response

Open ( ) Sealed ( ) Semi or Mixed Sealed ( )

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

SECTION 2. PLANT OPERATIONS

Furnace Dimensions

Yes ( ) No ( )

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Table 2B : Furnace Information SAMPLE - DO NOT USE THIS PAGE

Fill out a copy of this form for each furnace

Furnace Process Diagram ID (a)

Primary Product (b)

Actual Production of primary product 2009 (days/year) 350

Actual Production of primary product 2009 (tons/year) 300,000

Average Production of primary product (tons/hr) 54

Maximum Production of primary product (tons/hr) 86

Secondary Product (b)

Actual Production of secondary product 2009 (days/year)

Actual Production of secondary product 2009 (tons/year)

Average Production of secondary product (tons/hr)

Maximum Production of secondary product (tons/hr)

Furnace Design

Rotating furnace?

Height (ft) 20

Diameter (ft) 10

Age of Furnace (yrs)

Original capital cost of furnace ($) $75,000

Remaining economic life (yrs)

Average operating rating (MW) 15

Design Rating (MW)

Annual Operation (hr/yr)

Description of upgrades made to furnace

Year(s) upgrade was made

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

(b) If multiple products are produced in a furnace, please indicate percentage of total furnace production.

See sample page for example response

75% Ferrosilicon (100%)

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

SECTION 2. PLANT OPERATIONS

EAF1

Open ( X ) Sealed ( ) Semi or Mixed Sealed ( )

Yes ( ) No ( X )

20

5600

Furnace Dimensions

35

>10

Ferroalloys Production Manufacturing Emission Points Survey

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Table 2C : Furnace Tapping Information

Make additional copies as needed.

Unit Operation 

Process 

Diagram ID (a)

Brief narrative description of 

tapping process

Frequency of 

Tapping

Duration of 

typical Tapping 

Event

TAP1 Carbon plug is removed and 

product is tapped into ladle

4 times daily 15 min

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

Sample row is shaded

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PRODUCTION MANUFACTURING EMISSION POINTS

SECTION 2. PLANT OPERATIONS

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Table 2D : Summary of Raw Materials

Add others as necessary, include units for each.

Raw Material 

(by product)

Annual Consumption

(tons) Origin and Composition Associated Products

(% of total for each)

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POINTS

SECTION 2. PLANT OPERATIONS

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Table 2D : Summary of Raw Materials SAMPLE - DO NOT USE THIS PAGE

Add others as necessary, include units for each.

Raw Material 

(by product) Annual Consumption Origin and Composition Units Associated Products(% of total for each)

Scrap Iron 150,000 automotive industry scrap, 

93% Fe Tons FeSi 50% (25%), 

FeSi 75% (75%)

Coke 80,000 Carbon Products, 

Wheeling WV Tons FeSi 50% (25%), 

FeSi 75% (75%)

Sand 75,000 Appalachian Mine, 

Wheeling WV Tons FeSi 50% (25%), 

FeSi 75% (75%)

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SECTION 2. PLANT OPERATIONS

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Table 2E : Summary of Products & Production Volume

Add other products as necessary, include units for each.

Product

2005

(tons/yr)

2006

(tons/yr)

2007

(tons/yr)

2008

(tons/yr)

2009

(tons/yr)

50% Ferrosilicon

75% Ferrosilicon

Silicon Metal

Calcium Carbide

Ferromanganese

Silicomanganese

Silifume

Other (List):

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING 

EMISSION POINTS

SECTION 2. PLANT OPERATIONS

Ferroalloys Production Manufacturing Emission Points Survey

 Page 21 4/21/2010
Table 3A: Air Pollution Ventilation/Capture System Parameters (Excluding Furnaces)

Make additional copies as needed.

Emission Point 

(a,b)

Emission Point 

(a,b)

Emission Point 

(a,b)

Emission Point 

(a,b)

Emission Point 

(a,b)

Emission Point 

(a,b)

E4

Local Ventilation System used:

Airflow (scfm)

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

Other (Specify) ( )____________ ( )____________ ( )____________ ( )____________ ( )____________ ( )____________

Building Ventilation

Airflow (scfm)

Building Identification ( ) ( ) ( ) ( ) ( ) ( )

Open Roof Monitor - Natural Ventilation ( ) ( ) ( ) ( ) ( ) ( )

Other (Specify) (X) 3 powered roof 

ventilators

( )____________ ( )____________ ( )____________ ( )____________ ( )____________

Enclosure or Hood Design:

Airflow (scfm)

Complete Enclosure ( ) ( ) ( ) ( ) ( ) ( )

Closed Hood ( ) ( ) ( ) ( ) ( ) ( )

Canopy or Suspended Hood (X) ( ) ( ) ( ) ( ) ( )

Distance of hood from source

Other (Specify) ( )____________ ( )____________ ( )____________ ( )____________ ( )____________ ( )____________

Airflow Control System:

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

Drop Curtain Baffling ( ) ( ) ( ) ( ) ( ) ( )

Curtain or Baffling Material ( ) ( ) ( ) ( ) ( ) ( )

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

Other (Specify) ( )____________ ( )____________ ( )____________ ( )____________ ( )____________ ( )____________

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

Sample column is shaded

Ventilation/Capture System

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS

SECTION 3. CAPTURE & CONTROL

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

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

Ferroalloys Production Manufacturing Emission Points Survey

 Page 22 4/21/2010
Table 3B: Primary & Tapping Emissions from Electric Arc Furnaces- Capture Details

Furnace specific information (complete worksheet for each furnace).

Hood Dimensions (ft)

(a) Circular Hood Diameter (ft)

Depth (ft)

(b) Rectangular Hood Length (ft)

Width (ft)

Depth (ft)

Temperature of fume entering hood (°F)

Volumetric flow rate entering hood (scfm)

Does this flow rate vary? Yes ( ) No ( )

Yes ( ) No ( )

How is the enclosure constructed?

Wire mesh ( )

Chain curtain ( )

Ceramic curtain ( )

Hydraulic door ( )

Other ( ) Describe -->

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

See sample page for example response

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

SECTION 3. CAPTURE & CONTROL

Furnace Process Diagram ID (a)

Airflow Control: Describe other airflow control and ventilation systems 

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

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

Furnace Specifications

Is there an enclosure (e.g. , curtain or door panels around the furnace)

Distance between top of furnace and hood (ft)

Primary Emissions Capture

Please describe the design basis upon which the flow rate was 

determined

If Yes, describe factors which cause variation in flow rate

Narrative description of furnace hood configuration 

Please attach diagrams if available

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

circumference)

Dimensions of openings in enclosure (ft)

Distance between top of furnace and curtain (ft)

Describe measures taken to ensure proper operation of ventilation 

system (e.g ., periodic or continuous monitoring of volumetric flowrate in 

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)

Table 3B: (Continued) Primary & Tapping Emissions from Electric Arc Furnaces - Capture Details

Ferroalloys Production Manufacturing Emission Points Survey

 Page 23 4/21/2010
EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

SECTION 3. CAPTURE & CONTROL

Hood Dimensions (ft)

(a) Circular Hood Diameter (ft)

Depth (ft)

(b) Rectangular Hood Length (ft)

Width (ft)

Depth (ft)

Temperature of fume entering hood (°F)

Volumetric flow rate entering hood (scfm)

Yes ( ) No ( )

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

See sample page for example response

Distance between ladle and bottom of hood (ft)

Diameter of ladle tapped product is poured into (ft)

Narrative description of tap hood configuration 

Tap hole diameter (ft)

Distance between center of tap hole and hood (ft)

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

Please attach diagrams if available

Tapping Emissions Capture

Table 3B: (Continued) Primary & Tapping Emissions from Electric Arc Furnaces - Capture Details

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

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 

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

Please describe the design basis upon which the flow rate was 

determined

If Yes, describe factors which cause variation in flow rate

Describe measures taken to ensure proper operation of ventilation 

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

Other Capture Related Information (use additional pages if needed)

Does this flow rate vary?

Ferroalloys Production Manufacturing Emission Points Survey

 Page 24 4/21/2010
Table 3B: Primary & Tapping Emissions - Capture Details SAMPLE - DO NOT USE THIS PAGE

Furnace specific information (complete worksheet for each furnace).

EAF1

Hood Dimensions (ft)

(a) Circular Hood Diameter (ft) 15

Depth (ft) 6

(b) Rectangular Hood Length (ft)

Width (ft)

Depth (ft)

15

Temperature of fume entering hood (°F) 500

Volumetric flow rate entering hood (scfm) 100,000

Engineering estimate (Calculations should be attached))

Does this flow rate vary? Yes ( ) No ( X )

Yes ( X ) No ( )

70%

How is the enclosure constructed?

Wire mesh ( )

Chain curtain ( )

Ceramic curtain ( X )

Hydraulic door ( )

Other ( ) Describe -->

15

5

Monthly maintenance, continuous monitoring of volumetric flowrate in ductwork 

downstream from hood.

90%

Roof vents

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

SECTION 3. CAPTURE & CONTROL

Distance between top of furnace and curtain (ft)

Describe measures taken to ensure proper operation of ventilation 

system (e.g ., periodic or continuous monitoring of volumetric flowrate in 

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)

Airflow Control: Describe other airflow control and ventilation systems 

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

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

Distance between top of furnace and hood (ft)

Please describe the design basis upon which the flow rate was 

determined

If Yes, describe factors which cause variation in flow rate

Is there an enclosure (e.g. , curtain or door panels around the furnace)

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

circumference)

Dimensions of openings in enclosure (ft)

Furnace Specifications

Furnace Process Diagram ID (a)

Primary Emissions Capture

Narrative description of furnace hood configuration See Example in Appendix B

Please attach diagrams if available

Ferroalloys Production Manufacturing Emission Points Survey

 Page 25 4/21/2010
EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

SECTION 3. CAPTURE & CONTROL

Hood Dimensions (ft)

(a) Circular Hood Diameter (ft) 15

Depth (ft) 6

(b) Rectangular Hood Length (ft)

Width (ft)

Depth (ft)

3

10

6

10

5

Temperature of fume entering hood (°F) 500

Volumetric flow rate entering hood (scfm) 100,000

Engineering estimate (Calculations should be attached))

Yes ( ) No ( X )

Monthly maintenance

50%

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

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

Other Capture Related Information (use additional pages if needed)

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

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 

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

Diameter of ladle tapped product is poured into (ft)

Distance between ladle and bottom of hood (ft)

Please describe the design basis upon which the flow rate was 

determined

Does this flow rate vary?

If Yes, describe factors which cause variation in flow rate

Describe measures taken to ensure proper operation of ventilation 

Narrative description of tap hood configuration See Example in Appendix B

Please attach diagrams if available

Tap hole diameter (ft)

Distance between center of tap hole and hood (ft)

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

Table 3B: (Continued) Primary & Tapping Emissions - Capture Details

Tapping Emissions Capture

Ferroalloys Production Manufacturing Emission Points Survey

 Page 26 4/21/2010
Table 3C: Air Pollution Control Equipment Parameters (Include sections as needed)

Copy sections as needed

Emission Point 

(a,b)

Emission Point 

(a,b)

Emission Point 

(a,b)

Emission Point 

(a,b)

Emission Point 

(a,b)

Control Device ID: Baghouse

Date installed/rebuilt

Manufacturer/Model Number

Original installed cost (capital cost plus installation cost)

Gas Inlet Temp. (deg F)

Maximum operating temperature (deg F)

Bag material, weight, & coating

Cleaning method & frequency

Air to cloth ratio (acfm/sqft)

Number of compartments

Number of bags per compartment

Pressure drop across baghouse (in H2O)

Pressure drop across cells (in H2O)

Positive or negative pressure baghouse?

Positive pressure baghouse dilution air flowrate (dscf)

Stack opacity (%)

Design collection efficiency

Measured collection efficiency

Controlled particulate emissions (gr/dscf)

Amount of particulate collected (lb/mo or specify) 

Describe what is done with collected baghouse dust

Control Device ID: Scrubber

Type of Scrubber 

(Venturi, packed bed, impingement, other (specify))

Year installed

Manufacturer/Model Number

Original installed cost (capital cost plus installation cost)

Gas Inlet Temp. (deg F)

Gas Outlet Temp. (deg F)

Pressure drop (in H2O)

Liquid-to-gas ratio (gal/10^3 acfm)

Inlet scrubbing liquor

pH

% solids

Type of alkali added (if any)

Rate (lbs/gal)

Effluent scrubbing liquor

pH

Wastewater generation rate (gal/min)

HAP composition of wastewater (mg/l)

What is done with the sludge?

Design collection efficiency

Measured collection efficiency

Controlled particulate emissions (gr/dscf)

Control Device ID: Electrostatic Precipitator

Year installed

Manufacturer/Model Number

Original installed cost (capital cost plus installation cost)

Gas Inlet Temp. (deg F)

Particle resistivity (ohm-centimeter)

Specific collection area (ft^2/1,000 acfm)

Conditioning agents used (sulfur trioxide, sodium componds, etc.)

Stack opacity (%)

Design collection efficiency

Measured collection efficiency

Controlled particulate emissions (gr/dscf)

Control Device ID: Mechanical Collectors

Type of collector (e.g., Multicyclone)

Number of collectors

Range of particle size (μm)

Gas flowrate (acfm @ deg F)

Overall pressure drop (in H2O)

Stack opacity (%)

Design collection efficiency

Measured collection efficiency

Controlled particulate emissions (gr/dscf)

Control Device ID: Other (Incinerators, Flares, etc.)

Include items as appropriate

Type of device

Year installed

Manufacturer/Model Number

Original installed cost (capital cost plus installation cost)

Gas flowrate (acfm @ deg F)

Overall pressure drop (in H2O)

Stack opacity (%)

Design collection efficiency

Measured collection efficiency

Controlled particulate emissions (gr/dscf)

Other Parameters (fill in as needed)

Other __________________________ Units___________

Other __________________________ Units___________

Other __________________________ Units___________

Other __________________________ Units___________

Other __________________________ Units___________

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

(c) Provide documentation of the basis for equipment parameters (design, actual, etc.)

(d) Provide copies of estimation worksheets or other documentation of the basis for emission estimates.

See sample page for example response

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

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

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION 

POINTS

SECTION 3. CAPTURE & CONTROL

Control System & Parameters (c,d)

Ferroalloys Production Manufacturing Emission Points Survey

 Page 27 4/21/2010
Table 3C: Air Pollution Control Equipment Parameters (Include sections as needed)

Copy sections as needed

Emission Point 

(a,b)

Emission Point 

(a,b)

Emission Point 

(a,b)

Emission Point 

(a,b)

Emission Point 

(a,b)

E1 E2 E2

Control Device ID: Baghouse BH1 (100%) BH1 (40%) BH2 (60%)

Date installed/rebuilt 2005 2005 1990 (rebuilt)

Manufacturer/Model Number Bagmaster 500 Bagmaster 500 Bagmaster 250

Original installed cost (capital cost plus installation cost) $200,000 $200,000 $125,000

Gas Inlet Temp. (deg F) 300 300 300

Maximum operating temperature (deg F) 500 500 500

Bag material, weight, & coating Nomex, 16 oz Nomex, 16 oz Nomex, 16 oz

Cleaning method & frequency shakers shakers shakers

Air to cloth ratio (acfm/sqft) 2 2 2

Number of compartments 25 25 25

Number of bags per compartment 8 8 8

Pressure drop across baghouse (in H2O) 2 2 2

Pressure drop across cells (in H2O) 8 8 8

Positive or negative pressure baghouse? 2 2 2

Positive pressure baghouse dilution air flowrate (dscf) Negative Negative Negative

Stack opacity (%) 2% 2% 2%

Design collection efficiency 99.9% 99.9% 99.9%

Measured collection efficiency 99.99% 99.99% 99.99%

Controlled particulate emissions (gr/dscf) 0.00322 gr/dscf 0.00322 gr/dscf 0.00322 gr/dscf

Amount of particulate collected (lb/mo or specify) 2,300 lb/mo 2,300 lb/mo 2,300 lb/mo

Describe what is done with collected baghouse dust Sold as product Sold as product Sold as product

Control Device ID: Scrubber

Type of Scrubber 

(Venturi, packed bed, impingement, other (specify))

Year installed

Manufacturer/Model Number

Original installed cost (capital cost plus installation cost)

Gas Inlet Temp. (deg F)

Gas Outlet Temp. (deg F)

Pressure drop (in H2O)

Liquid-to-gas ratio (gal/10^3 acfm)

Inlet scrubbing liquor

pH

% solids

Type of alkali added (if any)

Rate (lbs/gal)

Effluent scrubbing liquor

pH

Wastewater generation rate (gal/min)

HAP composition of wastewater (mg/l)

What is done with the sludge?

Design collection efficiency

Measured collection efficiency

Controlled particulate emissions (gr/dscf)

Control Device ID: Electrostatic Precipitator

Year installed

Manufacturer/Model Number

Original installed cost (capital cost plus installation cost)

Gas Inlet Temp. (deg F)

Particle resistivity (ohm-centimeter)

Specific collection area (ft^2/1,000 acfm)

Conditioning agents used (sulfur trioxide, sodium componds, etc.)

Stack opacity (%)

Design collection efficiency

Measured collection efficiency

Controlled particulate emissions (gr/dscf)

Control Device ID: Mechanical Collectors

Type of collector (e.g., Multicyclone)

Number of collectors

Range of particle size (μm)

Gas flowrate (acfm @ deg F)

Overall pressure drop (in H2O)

Stack opacity (%)

Design collection efficiency

Measured collection efficiency

Controlled particulate emissions (gr/dscf)

Control Device ID: Other (Incinerators, Flares, etc.)

Include items as appropriate

Type of device

Year installed

Manufacturer/Model Number

Original installed cost (capital cost plus installation cost)

Gas flowrate (acfm @ deg F)

Overall pressure drop (in H2O)

Stack opacity (%)

Design collection efficiency

Measured collection efficiency

Controlled particulate emissions (gr/dscf)

Other Parameters (fill in as needed)

Other __________________________ Units___________

Other __________________________ Units___________

Other __________________________ Units___________

Other __________________________ Units___________

Other __________________________ Units___________

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

(c) Provide documentation of the basis for equipment parameters (design, actual, etc.)

(d) Provide copies of estimation worksheets or other documentation of the basis for emission estimates.

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

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

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION 

POINTS

SECTION 3. CAPTURE & CONTROL

Control System & Parameters (c,d)

Ferroalloys Production Manufacturing Emission Points Survey

 Page 28 4/21/2010
Table 4A: Air Pollution Control Device Parameter Monitoring (Include sections as needed)

Include all parameters or activities which are monitored or for which records are maintained. Opacity and Visible Emissions monitoring should be detailed in Table 4B.

Yes No

Control Device ID: Baghouse

Emission Points:

Outlet PM Concentration (CEM)

Bag Leak Detectors

Pressure Differential Across Cells

Pressure Differential Across Baghouse

Inlet Gas Temperature

Temperature Differential

Exhaust Gas Flow Rate

Cleaning Mechanism Operation

Fan Current

Inspections & Maintenance

Other (_____________________________________________________)

Control Device ID: Scrubber 

Emission Points:

Pressure Differential

Liquid Flow Rate

Gas Flow Rate

Scrubber Inlet Gas Temperature

Scrubber Outlet Gas Temperature

Makeup/blowdown rate

Scrubber Liquid Solids Content

Scrubber Liquid pH

Neutralizing Chemical Feed Rate

Scrubber Liquid Specific Gravity

Other (_____________________________________________________)

Control Device ID: Electrostatic Precipitator

Emission Points:

Outlet PM Concentration

Secondary Corona Power (Current & Voltage)

Spark Rate

Primary Power (Current & Voltage)

Inlet Gas Temperature

Gas Flow Rate

Rapper Operation

Fields in Operation

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 Rate

Pressure Differential

Inlet Gas Temperature

Other (_____________________________________________________)

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 documentation of the basis for emission estimates.

See sample page for example response

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS

SECTION 4. MONITORING

Control System & Performance Indicating Parameters Monitored (a,b,c)

Frequency of 

Monitoring Monitoring Method Describe Quality Assurance

Monitored? Units 

Measured

Ferroalloys Production Manufacturing Emission Points Survey

 Page 29 4/21/2010
Table 4A: Air Pollution Control Device Parameter Monitoring (Include sections as needed) SAMPLE - DO NOT USE THIS PAGE

Include all parameters or activities which are monitored or for which records are maintained. Opacity and Visible Emissions monitoring should be detailed in Table 4B.

Yes No

Control Device: Baghouse 

Emission Points: E1, E2, E3

Outlet PM Concentration (CEM) X

Bag Leak Detectors X Continuous Continuous monitor Regular maintenance

Pressure Differential Across Cells X

Pressure Differential Across Baghouse X in H2O Continuous Continuous monitor Regular maintenance

Inlet Gas Temperature X deg F Continuous Continuous monitor Regular maintenance

Temperature Differential X

Exhaust Gas Flow Rate X

Cleaning Mechanism Operation X

Fan Current X

Inspections & Maintenance X Maintenance records maintained

Visible Emissions Monitoring (Method 9 opacity or Method 22 VE) 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

Makeup/blowdown rate

Scrubber Liquid Solids Content

Scrubber Liquid pH

Neutralizing Chemical Feed Rate

Scrubber Liquid Specific Gravity

Other (_____________________________________________________)

Control Device: Electrostatic Precipitator

Emission Points:

Outlet PM Concentration

Secondary Corona Power (Current & Voltage)

Spark Rate

Primary Power (Current & Voltage)

Inlet Gas Temperature

Gas Flow Rate

Rapper Operation

Fields in Operation

Inlet Water Flow Rate (Wet Type)

Flush Water Solids Content (Wet Type)

Other (_____________________________________________________)

Control Device: Cyclone

Emission Points:

Inlet Velocity or Inlet Gas Flow Rate

Pressure Differential

Inlet Gas Temperature

Other (_____________________________________________________)

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 documentation of the basis for emission estimates.

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS

SECTION 4. MONITORING

Control System & Performance Indicating Parameters Monitored (a,b,c) Monitoring Method Describe Quality Assurance

Monitored Units 

Measure

Frequency of 

Monitoring

Ferroalloys Production Manufacturing Emission Points Survey

 Page 30 4/21/2010
Table 4B: Opacity/Visible Emissions Monitoring Information 

Make copies as needed

Emission Point (a)__E1____________________________________

EPA Method 22 Daily

Continuous Opacity Monitoring (COM)

Continuous Emission Monitoring (CEM)

Other (______________________________)

Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis) 0 VE

Average Opacity or VE observed for this Emission Point (Please note units) 0%

Emission Point (a)__________________________________________

Method 9 or Method 22

Continuous Opacity Monitoring (COM)

Continuous Emission Monitoring (CEM)

Other (______________________________)

Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis)

Average Opacity or VE observed for this Emission Point (Please note units)

Emission Point (a)__________________________________________

Method 9 or Method 22

Continuous Opacity Monitoring (COM)

Continuous Emission Monitoring (CEM)

Other (______________________________)

Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis)

Average Opacity or VE observed for this Emission Point (Please note units)

Emission Point (a)__________________________________________

Method 9 or Method 22

Continuous Opacity Monitoring (COM)

Continuous Emission Monitoring (CEM)

Other (______________________________)

Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis)

Average Opacity or VE observed for this Emission Point (Please note units)

Emission Point (a)__________________________________________

Method 9 or Method 22

Continuous Opacity Monitoring (COM)

Continuous Emission Monitoring (CEM)

Other (______________________________)

Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis)

Average Opacity or VE observed for this Emission Point (Please note units)

Emission Point (a)__________________________________________

Method 9 or Method 22

Continuous Opacity Monitoring (COM)

Continuous Emission Monitoring (CEM)

Other (______________________________)

Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis)

Average Opacity or VE observed for this Emission Point (Please note units)

Emission Point (a)__________________________________________

Method 9 or Method 22

Continuous Opacity Monitoring (COM)

Continuous Emission Monitoring (CEM)

Other (______________________________)

Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis)

Average Opacity or VE observed for this Emission Point (Please note units)

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

Sample row is shaded

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION 

POINTS

SECTION 4. MONITORING

Opacity or Visible Emissions Monitoring Monitoring Method Describe Quality Assurance

Frequency of 

Monitoring

Ferroalloys Production Manufacturing Emission Points Survey

 Page 31 4/21/2010
Table 5A: Controlled Emission Point Modeling Parameters (Point Sources)

Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Height Diameter Velocity Temp.

Lat Long NAD(d) m m m/s K

(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

Emission Point 

ID (a)

Unit Operation Name and Process Diagram ID(a):

Release Parameters for Risk Modeling (b,c)

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

SECTION 5. HAP EMISSIONS

Coordinates

Ferroalloys Production Manufacturing Emission Points Survey

 Page 32 4/21/2010
Table 5B: Uncontrolled Emission Point Modeling Parameters (Point Sources)

Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Height Diameter Velocity Temp.

Lat Long NAD(c) m m m/s K

(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

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING 

EMISSION POINTS

SECTION 5. HAP EMISSIONS

Unit Operation Name and Process Diagram ID(a):

Emission Point 

ID (a)

Release Parameters for Risk Modeling (b) Reason for 

Release Point Coordinates

Ferroalloys Production Manufacturing Emission Points Survey

 Page 33 4/21/2010
Table 5C: Emission Point Modeling Parameters (Nonpoint Sources)

Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Release Height

Lat Long NAD(c) (m) x (length, m) y (width, m)

E7 38.897701 -77.036625 NAD27 10 30 20 12.5

(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

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

SECTION 5. HAP EMISSIONS

Unit Operation Name and Process Diagram ID (a):

Emission 

Points (a)

Release Parameters for Risk Modeling (b)

Dimension of Source (d) Angle of Rotation (e)

(degrees)

Coordinates

Ferroalloys Production Manufacturing Emission Points Survey

 Page 34 4/21/2010
Table 5D: Speciated HAP Emissions - Actual and Allowable

Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Actual HAP 

Emissions

Actual HAP 

Concentration

Allowable HAP 

Emissions

Allowable HAP 

Concentration

tpy ppm tpy ppm

E1 Manganese 150 0.05 test data 200 0.1 WV 23709 - IV-(d) 

E1 Lead 0.02 0.0001 test data 0.03 0.0005 WV 23709 - IV-(d)

E2 Manganese 200 0.1 calculated 250 0.2 WV 23709 - IV-(d)

E2 Lead 0.05 0.0008 calculated 0.08 0.001 WV 23709 - IV-(d)

(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

Sample rows are shaded and illustrate where two or more HAP are emitted from a single emission point.

Unit Operation Name and Process Diagram ID(a):

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING 

EMISSION POINTS

SECTION 5. HAP EMISSIONS

Emission Point HAP Emissions (b)

HAP Emitted

Actual HAP Emissions Allowable HAP Emissions 

Emission Point 

ID (a) Basis for 

Emissions 

Estimate

Basis for Allowable 

Limit

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Table 5E: Total Particulate Matter (PM) Emissions - Actual and Allowable

Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Total Actual PM 

Emissions 

(per emission point)

Actual PM 

Concentration 

(per emission point)

Total Allowable PM 

Emissions 

(per emission point)

Allowable PM 

Concentration 

(per emission point)

tpy gr/dscf 

(or specify) tpy gr/dscf (or specify)

E1 213 0.0322 Test Data 300 0.05 WV 23709 - IV-(a) 

E2 400 0.0625 Calculated 500 0.075 WV 23709 - IV-(a) 

(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

Sample rows are shaded 

Allowable PM Emissions 

Basis for 

Emissions 

Estimate

Basis for Allowable 

Limit

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING 

EMISSION POINTS

SECTION 5. HAP EMISSIONS

Unit Operation Name and Process Diagram ID(a):

Emission Point 

ID (a)

Emission Point PM Emissions (b)

Actual PM Emissions

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Table 5F: HAP Concentrations in Emission Streams

1 2 3 4 5 6 7 8 9 10 11 12 13

Emission 

Point ID (a)

Unit Operation Name 

(b)

Unit 

Operation 

Process 

Diagram ID 

(a)

Capture System 

or Device and ID 

(a)

Capture 

Efficiency 

(%)

Basis for 

Reported 

Efficiency (c)

Concentration of 

Emissions to 

Capture System

(%)(d)

Control Device and 

ID (a)

Control 

Efficiency 

(%)

Basis for Reported 

Control Efficiency 

(c )

Flow Rate 

of Stream 

(scfm or 

specify)

Total 

Particulate 

Emitted 

(gr/dscf or 

specify) (d)

HAP Concentration 

in Particulate 

Matter (wt %) 

(c,e)

E1 Electric Arc Furnace 1 EAF1 Hood (CS1) 80% Estimate 60% Fabric Filter (BH1) 99% Mfg Design Val.

E1 Electric Arc Furnace 2 EAF2 Hood (CS2) 80% Estimate 40% Fabric Filter (BH1) 99% Mfg Design Val.

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

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

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

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

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

Sample rows are shaded, and illustrate a situation where two unit operations are directed through a common control device.

Emission Point & Process ID Capture Control Outlet Stream

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SECTION 5. HAP EMISSIONS

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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).

Control Device ID (a) Type of bags Labor Cost

Monitoring, Reporting, & 

Recordkeeping

New bags 

(or other parts, 

please specify)

Other Costs 

(maintenance, 

waste disposal, etc., 

please specify) Electricity

Total Annual 

Operating Costs 

(2009)

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

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS

SECTION 6. COST DATA

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Table 6B: Scrubber Costs (Make additional copies as needed)

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

Control Device ID (a) Labor Cost

Monitoring, 

Reporting, & 

Recordkeeping Electricity Water Waste Disposal

Other costs 

(specify) Total Annual Costs

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

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS

SECTION 6. COST DATA

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Table 7: Startup and Shutdown Information (Make additional copies as needed)

Unit Operation 

Process ID (a) Date and Description of event

Permit conditions 

exceeded Duration of event (hours)

Was event covered by 

contingency plan for 

controlling emissions? 

(Y/N)

Estimated PM 

emissions during 

event (pounds)

Basis for 

emissions 

estimate

Any monitoring 

data or control 

system parameter 

monitoring 

collected during 

event? (Y/N)

EAF1 07/12/2006 Emergency Shutdown WV 23709 - IV-(d) 3 Y 127 Emission Factor Y

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

Sample row is shaded

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS

SECTION 7. STARTUP AND SHUTDOWN

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APPENDIX A: 

EPA's LIST OF HAZARDOUS AIR POLLUTANTS (HAP)

CAS 

Number Chemical Name

Antimony Compounds

Arsenic Compounds (inorganic including arsine)

Beryllium Compounds

Cadmium Compounds

Chromium Compounds

Cobalt Compounds

Coke Oven Emissions

Cyanide Compounds

Glycol ethers

Lead Compounds

Manganese Compounds

Mercury Compounds

Fine mineral fibers

Nickel Compounds

Polycyclic Organic Matter

Radionuclides (including radon)

Selenium Compounds

57147 1,1-Dimethylhydrazine

79005 1,1,2-Trichloroethane

79345 1,1,2,2-Tetrachloroethane

96128 1,2-Dibromo-3-chloropropane

122667 1,2-Diphenylhydrazine

106887 1,2-Epoxybutane

75558 1,2-Propylenimine(2-Methylaziridine)

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

120821 1,2,4-Trichlorobenzene

106990 1,3-Butadiene

542756 1,3-Dichloropropene

1120714 1,3-Propanesultone

106467 1,4-Dichlorobenzene

123911 1,4-Dioxane(1,4-Diethyleneoxide)

53963 2-Acetylaminofluorene

532274 2-Chloroacetophenone

79469 2-Nitropropane

540841 2,2,4-Trimethylpentane

1746016 2,3,7,8-Tetrachlorodibenzo-p-dioxin

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

51285 2,4-Dinitrophenol

121142 2,4-Dinitrotoluene

584849 2,4-Toluenediisocyanate

95954 2,4,5-Trichlorophenol

88062 2,4,6-Trichlorophenol
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CAS 

Number Chemical Name

91941 3,3'-Dichlorobenzidine

119904 3,3'-Dimethoxybenzidine

119937 3,3'-Dimethylbenzidine

92671 4-Aminobiphenyl

60117 4-Dimethylaminoazobenzene

92933 4-Nitrobiphenyl

100027 4-Nitrophenol

101144 4,4'-Methylenebis(2-chloroaniline)

101779 4,4'-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 Acrylonitrile

107051 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(chloromethyl)ether

75252 Bromoform

156627 Calcium cyanamide

105602 Caprolactam(Removed6/18/96,61FR30816)

133062 Captan

63252 Carbaryl

75150 Carbon disulfide

56235 Carbon tetrachloride

463581 Carbonyl sulfide

120809 Catechol

133904 Chloramben

57749 Chlordane

7782505 Chlorine

79118 Chloroaceticacid

108907 Chlorobenzene

510156 Chlorobenzilate

67663 Chloroform
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MANUFACTURING EMISSION POINTS

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CAS 

Number Chemical Name

107302 Chloromethyl methyl ether

126998 Chloroprene

1319773 Cresol/Cresylicacid(mixedisomers)

98828 Cumene

3547044 DDE(1,1-dichloro-2,2-bis(p-chlorophenyl)ethylene)

334883 Diazomethane

132649 Dibenzofuran

84742 Dibutylphthalate

111444 Dichloroethylether(Bis[2-chloroethyl]ether)

62737 Dichlorvos

111422 Diethanolamine

64675 Diethylsulfate

131113 Dimethylphthalate

77781 Dimethylsulfate

79447 Dimethylcarbamoylchloride

106898 Epichlorohydrin(l-Chloro-2,3-epoxypropane)

140885 Ethylacrylate

51796 Ethylcarbamate(Urethane)

75003 Ethylchloride(Chloroethane)

100414 Ethylbenzene

107062 Ethylenebichloride(1,2-Dichloroethane)

106934 Ethylenedibromide(Dibromoethane)

107211 Ethylene glycol

75218 Ethylene oxide

96457 Ethylene thiourea

151564 Ethyleneimine(Aziridine)

75343 Ethylidenedichloride(1,1-Dichloroethane)

50000 Formaldehyde

76448 Heptachlor

118741 Hexachlorobenzene

87683 Hexachlorobutadiene

77474 Hexachlorocyclopentadiene

67721 Hexachloroethane

822060 Hexamethylenediisocyanate

680319 Hexamethylphosphoramide

110543 Hexane

302012 Hydrazine

7647010 Hydrochloricacid (HydrogenChloride)

7664393 Hydrogenfluoride (Hydrofluoricacid)

123319 Hydroquinone

78591 Isophorone

58899 Lindane

108394 m-Cresol

108383 m-Xylene

108316 Maleic anhydride

67561 Methanol
EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

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CAS 

Number Chemical Name

72435 Methoxychlor

74839 Methylbromide(Bromomethane)

74873 Methylchloride(Chloromethane)

71556 Methylchloroform(1,1,1-Trichloroethane)

78933 Methylethylketone(2-Butanone)

74884 Methyliodide(Iodomethane)

108101 Methylisobutylketone(Hexone)

624839 Methylisocyanate

80626 Methylmethacrylate

1634044 Methyltert-butylether

75092 Methylenechloride(Dichloromethane)

60344 Methylhydrazine

684935 N-Nitroso-N-methylurea

62759 N-Nitrosodimethylamine

59892 N-Nitrosomorpholine

91203 Naphthalene

98953 Nitrobenzene

121697 N,N-Dimethylaniline

68122 N,N-Dimethylformamide

90040 o-Anisidine

95487 o-Cresol

95534 o-Toluidine

95476 o-Xylene

106445 p-Cresol

106503 p-Phenylenediamine

106423 p-Xylene

56382 Parathion

82688 Pentachloronitrobenzene(Quintobenzene)

87865 Pentachlorophenol

108952 Phenol

75445 Phosgene

7803512 Phosphine

7723140 Phosphorus

85449 Phthalicanhydride

1336363 Polychlorinatedbiphenyls(Aroclors)

123386 Propionaldehyde

114261 Propoxur(Baygon)

78875 Propylenebichloride(1,2-Dichloropropane)

75569 Propyleneoxide

91225 Quinoline

106514 Quinone(p-Benzoquinone)

100425 Styrene

96093 Styreneoxide

127184 Tetrachloroethylene(Perchloroethylene)

7550450 Titaniumtetrachloride

108883 Toluene
EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

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CAS 

Number Chemical Name

95807 Toluene-2,4-diamine

8001352 Toxaphene(chlorinatedcamphene)

79016 Trichloroethylene

121448 Triethylamine

1582098 Trifluralin

108054 Vinylacetate

593602 Vinylbromide

75014 Vinylchloride

75354 Vinylidenechloride(1,1-Dichloroethylene)

1330207 Xylenes(mixedisomers)
EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

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MANUFACTURING EMISSION POINTS

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APPENDIX B: 

SAMPLE RESPONSES FOR INFORMATION REQUEST 

I. Sample Process Flow Diagram

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-wlde 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. 
EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

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Both the tapping emission and furnace emissions are ducted to baghouse number 3. The 

branch duct size is four feet in diameter and is joined with the main duct. A schematic for the 

hood configuration is attached. This hood has damper openings and can be opened and closed 

as needed to accomplish capture of tapping fume as it occurs.

III. Notes on Modeling Parameters for Positive Pressure Baghouses

For positive pressure baghouses, height should be listed as the height of the roof monitor above 

ground. Velocity may be taken from past test reports. Equivalent diameter of rectangular crosssections may be calculated using Equation 1-1 from USEPA Method 1: