EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010 

# ENCLOSURE 1

INFORMATION COLLECTION REQUEST FOR FERROALLOY

S 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 Ferroalloy s Production Manufacturing Emission Points under Clean Air Act (CAA) section 112 . The survey is being sent under the authority of Section 114 of the C AA

.

BACKGROUND:

This information reques t (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 produci ng 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 un it 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) Es tablish 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 s uch 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 compl iance 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 inform ation 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

.

 Y ou 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)

.EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010  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 conf identiality. 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, m ail a CD or DVD containing an electronic copy of all requested files to the EPA address below:

U.S. Enviro nmental 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 c onfidential, 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/o r 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 St andards 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 o f 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 facilit y in your company with ferroalloy production operations. Copies of this

questionnaire should be made for additional facilities.EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010 

## 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. A ddress:
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:EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010 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 f raction of your total number of employees.

__________________________________________________________________

e

. Number of Corporate Employees : Approximate number of employees of th e 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 

##  UnknownEPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010 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 P lant: Either latitude and longitude or UTM coordinates with zone . L atitude 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 standar ds, 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 Emis sion 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 pr ovide a copy of your permit applicationEPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010 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 p rovide an identification code for each item (e.g., attachment 1)

Identification code Description of item submitted with survey response



### PART I I . GENERAL FACILITY INFORMATION

1

. Process Summary Complete t he 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 product s. 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 , prov ide a process flow diagra m that includes all sources of air emissions (e.g., stack emissions, process fugitive emissions, and other fugitive emissions [including fugitive dust emissions]). A lso 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 ty pical facility should submit.

Also include all activities that generate HAP emissions, including the storage, transfer, handling, and processing of the materials, and w astewater 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.EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010 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 detai led 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 product s 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 rep resentative 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 operatio ns, including storage, conveyance, and any o perations performed on products:

______________________________________________________________________

______________________________________________________________________

______________________________________ ________________________________

______________________________________________________________________



### PART I I I

. VENTILATION, CAPTURE AND CONTROL SYSTEMS

1. Capture and Control Summary Complete Table 3A summarizing ventilation / captur e for any air pol lution 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 Capt ure 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 s urface (primary emissions) and from the tap hole (tapping and ancillary operations).

Provide diagrams and brief descriptions to fully explain configurations.EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010 3. Control Device Details Complete Table 3C with information on any air pollution contro l 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? 

##  Y es 

##  N o

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 p ollution 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 monitorin g 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 emis sion 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.EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010 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 widt h dimensions, angle of rotation, and nature of the emissions.

3

. Speciated HAP and Total Particulate Matter (PM) Emissions Complete Tabl es 5D and 5E for each emission point indicated in Tables 5A

, 5B , and 5C . For each emi ssion 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 explanat ions 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 5 F for each emissio n 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 5 F must be completed for all sources; Notes on Modeling Data:

Coordinates: For geographic coordinates, provide e ither latitude and longitude or UTM coordinates with zone . L atitude 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 : me asure 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 p oint 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: A ngle 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

- dimensi on 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

.EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010 2. Complete c olumns 4

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

3. Complete columns 8

- 10 of Table 5 F for all sources wit h 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 sp eciated 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 5 F for wastewater and solid waste handling operations. 5

. Emission Test Data

1. Enclos e 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 produc tion 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 calculat ions 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 lis ted 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 operat ing and maintaining EAF fabric filter control devices (i.e., positive pressure baghouses).EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010 2. Scrubber Costs Complete Table 6B providing annual costs for operating and maintaining EAF wet
scrubbers.



### PART VII

. STARTUP AND SHUTDOWN

Please pr ovide the following information for operatio ns 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 a ctivities 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 t o 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 sh utdown and why. Please also provide any information that supports your response to this question.)

______________________________________________________________________

______________________________________________________________________

________________ ______________________________________________________

______________________________________________________________________

______________________________________________________________________

____________________________________________________________ __________

______________________________________________________________________

______________________________________________________________________EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010 4

. Test Data

Do you have test data that show emissions during startup or shutdown? 

##  Y es 

##  N o

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
Ar e 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? 

##  Y es 

##  N o



### PART VIII

. MISCELLANEOUS

1. Future Plans Describe any future work practice or pollution prevention measures you are considering which may result in emission reductions.

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010 2

. New Source Review If any cont rol 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 du st 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 fac tors 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.

___ ___________________________________________________________________

______________________________________________________________________

______________________________________________________________________

_________________________________________________ _____________________EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010

### 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 Page 15 4/21/2010Table 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 ( )

Ferroalloys Production Manufacturing Emission Points Survey Page 16 4/21/2010Table 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 Page 17 4/21/2010Table 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 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS
PRODUCTION MANUFACTURING EMISSION POINTS

SECTION 2. PLANT OPERATIONS

Ferroalloys Production Manufacturing Emission Points Survey Page 18 4/21/2010Table 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) 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION
POINTS

SECTION 2. PLANT OPERATIONS

Ferroalloys Production Manufacturing Emission Points Survey Page 19 4/21/2010Table 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%) EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS

SECTION 2. PLANT OPERATIONS

Ferroalloys Production Manufacturing Emission Points Survey Page 20 4/21/2010Table 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 4/21/2010Table 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 4/21/2010Table 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 4/21/2010Table 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 4/21/2010Table 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 4/21/2010Table 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 4/21/2010Table 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 Describe Quality Assurance Monitoring Method Monitored? Units

Measured

Ferroalloys Production Manufacturing Emission Points Survey Page 29 4/21/2010Table 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

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

Monitoring

Ferroalloys Production Manufacturing Emission Points Survey Page 30 4/21/2010Table 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

Monitoring Method Describe Quality Assurance Opacity or Visible Emissions Monitoring Frequency of Monitoring

Ferroalloys Production Manufacturing Emission Points Survey Page 31 4/21/2010Table 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 4/21/2010Table 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 4/21/2010Table 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 4/21/2010Table 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

Ferroalloys Production Manufacturing Emission Points Survey Page 35 4/21/2010Table 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

Ferroalloys Production Manufacturing Emission Points Survey Page 36 4/21/2010Table 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. Capture Control Emission Point & Process ID Outlet Stream

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS
SECTION 5. HAP EMISSIONS

Ferroalloys Production Manufacturing Emission Points Survey Page 37 4/21/2010Table 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

Ferroalloys Production Manufacturing Emission Points Survey Page 38 4/21/2010Table 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

Ferroalloys Production Manufacturing Emission Points Survey Page 39 4/21/2010Table 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

Ferroalloys Production Manufacturing Emission Points Survey Page 40 4/21/2010EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



### 41
4/21/2010 APPENDIX A :

EPA's LIST OF HAZARDOUS AIR POLLUTANTS (HAP)



### CAS
Number Chemical Name

Antimony Compounds Arsenic Compoun ds (inorganic including arsine) Beryllium Compounds Cadmium Compounds Chromium Compounds
Cobal t 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 Co mpounds

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

- Hexachl orocyclohexane(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

- TrichlorophenolEPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



### 42
4/21/2010 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 Ace tophenone

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

562 35 Carbon tetrachloride

463581 Carbonyl sulfide

120809 Catechol

133904 Chloramben

57749 Chlordane

7782505 Chlorine

79118 Chloroaceticacid

108907 Chlorobenzene

510156 Chlorobenzilate

67663 ChloroformEPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



### 43
4/21/2010 CAS
Number Chemical Name

107302 Chloromethyl methyl ether

126998 Chloro prene
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 Dichlorvo s
111422 Diethanolamine

64675 Diethylsulfate

131113 Dimethylphthalate

77781 Dimethylsulfate

79447 Dimethylcarbamoylchloride

106898 Epichlorohydrin(l

- Chloro

- 2,3

- epoxypropane)

140885 Ethylacrylate

51796 Ethylcarbamate(Urethane)

75003 Ethylchloride(C hloroethane)

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 H ydrazine

7647010 Hydrochloricacid (HydrogenChloride)

7664393 Hydrogenfluoride (Hydrofluoricacid)

123319 Hydroquinone

78591 Isophorone

58899 Lindane

108394 m

- Cresol

108383 m

- Xylene

108316 Maleic anhydride

67561 MethanolEPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



### 44
4/21/2010 CAS
Number Chemical Name

72435 Methoxychlor

74839 M ethylbromide(Bromomethane)

74873 Methylchloride(Chloromethane)

71556 Methylchloroform(1,1,1

- Trichloroethane)

78933 Methylethylketone(2

- Butanone)

74884 Methyliodide(Iodomethane)

108101 Methylisobutylketone(Hexone)

624839 Methylisocyanate

80626 Methyl methacrylate

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

- Dimethyl aniline

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 Propyleneoxid e
91225 Quinoline

106514 Quinone(p

- Benzoquinone)

100425 Styrene

96093 Styreneoxide

127184 Tetrachloroethylene(Perchloroethylene)

7550450 Titaniumtetrachloride

108883 TolueneEPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



### 45
4/21/2010 CAS
Number Chemical Name

95807 Toluene

- 2,4

- diamine

8001352 Toxaphene(chlorinatedcamphene)

79016 T richloroethylene

121448 Triethylamine

1582098 Trifluralin

108054 Vinylacetate

593602 Vinylbromide

75014 Vinylchloride

75354 Vinylidenechloride(1,1

- Dichloroethylene)

1330207 Xylenes(mixedisomers)EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



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4/21/2010EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



### 47
4/21/2010 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 3 B

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

a pproximately 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 impro ve the capture efficiency.EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUC TION MANUFACTURING EMISSION POINTS



### 48
4/21/2010 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 ha s 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 r oof monitor above ground. Velocity may be taken from past test reports. Equivalent diameter of rectangular cross

sections may be calculated using E quation 1

- 1 from USEPA Method 1: