**Subpart RRR —**  **National Emission Standards for Hazardous Air Pollutants for Secondary Aluminum Production** 

**General**

**§63.1500 Applicability.** 
(a) The requirements of this subpart apply to the owner or operator of each secondary aluminum production facility as def ined in §63.1503.
(b) The requirements of this subpart apply to the following affected sources, located at a secondary aluminum production facility that is a major source of hazardous air pollutants (HAPs) as defined in §63.2:
(1) Each new and existing alu minum scrap shredder;
(2) Each new and existing thermal chip dryer;
(3) Each new and existing scrap dryer/delacquering kiln/decoating kiln;
(4) Each new and existing group 2 furnace;
(5) Each new and existing sweat furnace;
(6) Each new and existing dross

- only furnace;(7) Each new and existing rotary dross cooler; and
(8) Each new and existing secondary aluminum processing unit.
(c) The requirements of this subpart pertaining to dioxin and furan (D/F) emissions and associated operating, monitoring, reporti ng and recordkeeping requirements apply to the following affected sources, located at a secondary aluminum production facility that is an area source of HAPs as defined in §63.2:
(1) Each new and existing thermal chip dryer;
(2) Each new and existing scrap dryer/delacquering kiln/decoating kiln;
(3) Each new and existing sweat furnace;
(4) Each new and existing secondary aluminum processing unit, containing one or more group 1 furnace emission units processing other than clean charge.
(d) The requirements o f this subpart do not apply to facilities and equipment used for research and development that are not used to produce a saleable product.
(e) If you are an owner or operator of an area source subject to this subpart, you are exempt from the obligation to obtain a permit under 40 CFR part 70 or 71, provided you are not requiredto obtain a permit under 40 CFR 70.3(a) or 71.3(a) for a reason other than your status as an area source under this subpart. Notwithstanding the previous sentence, you must continue to comply with the provisions of this subpart applicable to area

sources. (f) An aluminum die casting facility, aluminum foundry, or aluminum extrusion facility shall be considered to be an area source if it does not emit, or have the potential to emit

con sidering controls, 10 tons per year or more of any single listed HAP or 25 tons per year of any combination of listed HAP from all emission sources which are located in a contiguous area and under common control, without regard to whether or not such

sourc es are regulated under this subpart or any other subpart. In the case of an aluminum die casting facility, aluminum foundry, or aluminum extrusion facility which is an area source and is subject to regulation under this subpart only because it operates a t hermal chip dryer, no furnace operated by such a facility shall be deemed to be subject to the requirements of this subpart if it melts only clean charge, internal scrap, or customer returns.
[65 FR 15710, Mar. 23, 2000, as amended at 67 FR 79814, Dec. 30, 2002; 70 FR 75346, Dec. 19, 2005]**§63.1501 Dates.** 
(a) The owner or operator of an existing affected source must comply with the requirements of this subpart by March 24, 2003.
(b) Except as provided in paragraph (c) of this section, the owner or operator of a new affected source that commences construction or reconstruction after February 11, 1999 must comply with the requirements of this subpart by March 24, 2000 or upon startup, whichever is later.
(c) The owner or operator of any affected source which i s constructed or reconstructed at any existing aluminum die casting facility, aluminum foundry, or aluminum extrusion facility which otherwise meets the applicability criteria set forth in §63.1500 must comply with the requirements of this subpart by March 24, 2003 or upon startup, whichever is later.

( d) The owner or operator of an existing affected source must comply with the following requirements of this subpart by [DATE 90 DAYS FROM PUBLICATION OF THE FINAL RULE IN THE FEDERAL REGISTER]: § 63.1505 (a), ( i)(4), (k), (k)(1),(k)(2), (k)(3); § 63.1506 (a)(1), (a)(5), (c)(1),(g)(5), (k)(3), (m)(4),(n)(1); § 63.1510 ( a), (b), (b)(5),(b)(9), (d)(2), (f)(1)(ii), (i)(4), (j)(4), (n)(1), (o)(1), (o)(1)(ii), (s)(2)(iv), (t), (t)(2)(i), (t)(2)(ii), (t)(4), (t)(5); § 63. 1511(a), (b), (b)(1), (b)(6),(c)(9), (f)(6), (g)(5); § 63.1512 (e)(1), (e)(2),(e)(3), (e)(4), (e)(5), (h)(1), (h)(2), (j), (j)(1)(I, (j)(2)(i), (o)(1), (p), (p)(2); § 63.1513 (b), (b)(1), (e)(1), (e)(2), (e)(3); §63.1514; § 63.1516 (a), (b), (b) (1)(v), (b)(2)( iii), (b)(3), (c),(d); § 63.1517 (b)(16)(i), (b)(18), (c); § 63.1520.
[67 FR 59791, Sept. 24, 2002]

**§63.1502 Incorporation by reference.** 
(a) The following material is incorporated by reference in the corresponding sections noted. The incorporation by referenc e (IBR) of certain publications listed in the rule will be approved by the Director of the Office of the Federal Register as of the date of publication of the final rule in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. This material is incorporated as it exists on the date of approval:
(1) Chapters 3 and 5 of “Industrial Ventilation: A Manual of Recommended Practice,” American Conference of Governmental Industrial Hygienists, (23rd edition, 1998), IBR approved for §63.1506(c), and
(2) “Interim Procedur es for Estimating Risks Associated with Exposures to Mixtures of Chlorinated Dibenzo

- p - Dioxins and

-Dibenzofurans (CDDs and CDFs) and 1989 Update” (EPA/625/3

– 89/016). (3) “Industrial Ventilation: A Manual of Recommended Practice,” American Conference of G overnmental Industrial Hygienists, (27rd edition, 2010), IBR approved for §63.1506(c).
(b) The material incorporated by reference is available for inspection at the National Archives and Records Administration (NARA); and at the Air and Radiation Docket an d Information Center, U.S. EPA, 1200 Pennsylvania Ave., NW., Washington, DC. For information on the availability of this material at NARA, call 202

– 741

– 6030, or go to: http://www.archives.gov/federal_register/code_of_federal_regulat ions/ibr_locations.html. The material is also available for purchase from the following addresses:
(1) Customer Service Department, American Conference of Governmental Industrial Hygienists (ACGIH), 1330 Kemper Meadow Drive, Cincinnati, OH 45240

– 1634, telephone number (513) 742

– 2 020; and
(2) The National Technical Information Service (NTIS), 5285 Port Royal Road, Springfield, VA, NTIS no. PB 90

– 145756.

**§63.1503 Definitions.** Terms used in this subpart are defined in the Clean Air Act as amended (CAA), in §63.2, or in this section a s follows:

Add

- on air pollution control device means equipment installed on a process vent that reduces the quantity of a pollutant that is emitted to the air.

Affirmative defense means, in the context of an enforcement proceeding, a response or defense pu t forward by a defendant, regarding which the defendant has the burden of proof, and the merits of which are independently and objectively evaluated in a judicial or administrative proceeding.

Afterburner means an air pollution control device that uses

con trolled flame combustion to convert combustible materials to noncombustible gases; also known as an incinerator or a thermal oxidizer.
Aluminum scrap means fragments of aluminum stock removed during manufacturing ( i.e., machining), manufactured aluminum a rticles or parts rejected or discarded and useful only as material for reprocessing, and waste and discarded material made of aluminum.
Aluminum scrap shredder means a high speed or low speed unit that crushes, grinds, granulates, shears or breaks aluminum scrap into a more uniform size prior to processing or chargingto a scrap dryer/delacquering kiln/decoating kiln, or furnace. A bale breaker is not an aluminum scrap shredder.

Bale breaker means a device used to break apart a bale of aluminum scrap for f urther processing. Bale breakers are not used to crush, grind, granulate, shear or break aluminum scrap into more uniform size pieces.
Bag leak detection system means an instrument that is capable of monitoring particulate matter loadings in the exhaust of a fabric filter ( i.e., baghouse) in order to detect bag failures.
A bag leak detection system includes, but is not limited to, an instrument that operates on triboelectric, light scattering, light transmittance, or other effect to monitor relative partic ulate matter loadings.
Capture and collection system means the system of hood(s), duct system and fan used to collect a contaminant at or near its source, and for affected sources equipped with an air pollution control device, transport the contaminated ai r to the air cleaning device.
Chips means small, uniformly

- sized, unpainted pieces of aluminum scrap, typically below 11/4inches in any dimension, primarily generated by turning, milling, boring, and machining of aluminum parts.Clean charge means furnace charge materials, including molten aluminum; T

- bar; sow; ingot; billet; pig; alloying elements; aluminum scrap known by the owner or operator to be entirely free of paints, coatings, and lubricants; uncoated/unpainted aluminum chips that have been thermall y dried or treated by a centrifugal cleaner; aluminum scrap dried at 343 °C (650 °F) or higher; aluminum scrap delacquered/decoated at 482 °C (900 °F) or higher, and runaround scrap. Anodized aluminum that contains dyes or sealants with organic compounds i s not clean charge.

Cover flux means salt added to the surface of molten aluminum in

a group 1 or group 2 furnace, without agitation of the molten aluminum, for the purpose of preventing oxidation. Any flux added to a rotary furnace or other furnace that u ses a molten metal pump or other device to circulate the aluminum is not a cover flux. Any reactive flux cannot be a cover flux.

Customer returns means any aluminum product which is returned by a customer to the aluminum company that originally manufacture d the product prior to resale of the product or further distribution in commerce, and which contains no paint or other solid coatings ( i.e., lacquers).
D/F means dioxins and furans.Dioxins and furans means tetra

- , penta

- , hexa

- , and octachlorinated diben zo dioxins and furans.

Dross means the slags and skimmings from aluminum melting and refining operations consisting of fluxing agent(s), impurities, and/or oxidized and non

- oxidized aluminum, from scrap aluminum charged into the furnace.

Dross

- only furnace means a furnace, typically of rotary barrel design, dedicated to the reclamation of aluminum from dross formed during melting, holding, fluxing, or alloying operations carried out in other process units. Dross and salt flux are the sole feedstocks to this type of furnace.

Emission unit means a group 1 furnace or in

- line fluxer at a secondary aluminum production facility.

Fabric filter means an add

- on air pollution control device used to capture particulate matter by filtering gas streams through filter me dia; also known as a baghouse.
Feed/charge means, for a furnace or other process unit that operates in batch mode, the total weight of material (including molten aluminum, T

- bar, sow, ingot, etc.) and alloying agents that enter the furnace during an operat ing cycle. For a furnace or other process unit that operates continuously, feed/chargemeans the weight of material (including molten aluminum, T

- bar, sow, ingot, etc.) and alloying agents that enter the process unit within a specified time period ( e.g., a time period equal to the performance test period). The feed/charge for a dross only furnace includes the total weight of dross and solid flux.
Fluxing means refining of molten aluminum to improve product quality, achieve product specifications, or reduce material loss, including the addition of solvents to remove impurities (solvent flux); and the injection of gases such as chlorine, or chlorine mixtures, to remove magnesium (demagging) or hydrogen bubbles (degassing). Fluxing may be performed in the furn ace or outside the furnace by an in

- line fluxer.

Furnace hearth means the combustion zone of a furnace in which the molten metal is contained.
Group 1 furnace means a furnace of any design that melts, holds, or processes aluminum that contains paint, lubr icants, coatings, or other foreign materials with or without reactive fluxing, or processes clean charge with reactive fluxing.
Group 2 furnace means a furnace of any design that melts, holds, or processes only clean charge and that performs no fluxing or performs fluxing using only nonreactive, non

- HAP

- containing/non

-HAP

- generating gases or agents. Pots used to transport metal to customers are not furnaces.

HCl means , for the purposes of this subpart, emissions of hydrogen chloride that serve as a surroga te measure of the total emissions of the HAPs hydrogen chloride, hydrogen fluoride and chlorine
.

HF means hydrogen fluoride.

In

- line fluxer means a device exterior to a furnace, located in a transfer line from a furnace, used to refine (flux) molten alumin um; also known as a flux box, degassing box, or demagging box.
Internal scrap means all aluminum scrap regardless of the level of contamination which originates from castings or extrusions produced by an aluminum die casting facility, aluminum foundry,

or aluminum extrusion facility, and which remains at all times within the control of the company that produced the castings or extrusions.

Lime means calcium oxide or other alkaline reagent.

Lime

- injection means the continuous addition of lime upstream of

a f abric filter.Melting/holding furnace means a group 1 furnace that processes only clean charge, performs melting, holding, and fluxing functions, and does not transfer molten aluminum to or from another furnace except for purposes of alloy changes, off

sp ecification product drains, or maintenance activities.
Operating cycle means for a batch process, the period beginning when the feed material is first charged to the operation and ending when all feed material charged to the operation has been processed. F or a batch melting or holding furnace process, operating cycle means the period including the charging and melting of scrap aluminum and the fluxing, refining, alloying, and tapping of molten aluminum (the period from tap

- to

- tap).

PM means, for the purpose s of this subpart, emissions of particulate matter that serve as a measure of total particulate emissions and as a surrogate for metal HAPs contained in the particulates, including but not limited to, antimony, arsenic, beryllium, cadmium, chromium, cobalt , lead, manganese, mercury, nickel, and selenium.
Pollution prevention means source reduction as defined under the Pollution Prevention Act of 1990 ( e.g., equipment or technology modifications, process or procedure modifications, reformulation or redesign of products, substitution of raw materials, andimprovements in housekeeping, maintenance, training, or inventory control), and other practices that reduce or eliminate the creation of pollutants through increased efficiency in the use of raw materials, e nergy, water, or other resources, or protection of natural resources by conservation.
Reactive fluxing means the use of any gas, liquid, or solid flux (other than cover flux) that results in a HAP emission. Argon and nitrogen are not reactive and do not pr oduce HAP.

Reconstruction means the replacement of components of an affected source or emission unit such that the fixed capital cost of the new components exceeds 50 percent of the fixed capital cost that would be required to construct a comparable new af fected source, and it is technologically and economically feasible for the reconstructed source to meet relevant standard(s) established in this subpart. Replacement of the refractory in a furnace is routine maintenance and is not a reconstruction. The rep air and replacement of in

- line fluxer components ( e.g., rotors/shafts, burner tubes, refractory, warped steel) is considered to be routine maintenance and is not considered a reconstruction. In

- line fluxers are typically removed to a maintenance/repair ar ea and are replaced with repaired units. The replacement of an existing in

- line fluxer with a repaired unit is not considered a reconstruction.Residence time means, for an afterburner, the duration of time required for gases to pass through the afterburn er combustion

zone. Residence time is calculated by dividing the afterburner combustion zone volume in cubic feet by the volumetric flow rate of the gas stream in actual cubic feet per second. The combustion zone volume includes the reaction chamber of the afterburner in which the waste gas stream is exposed to the direct combustion flame and the complete refractory lined portion of the furnace stack up to the measurement thermocouple.
Rotary dross cooler means a water

- cooled rotary barrel device that accel erates cooling of dross.
Runaround scrap means scrap materials generated on

- site by aluminum casting, extruding, rolling, scalping, forging, forming/stamping, cutting, and trimming operations and that do not contain paint or solid coatings. Uncoated/unpain ted aluminum chips generated by turning, boring, milling, and similar machining operations may be clean charge if they have been thermally dried or treated by a centrifugal cleaner, but are not considered to be runaround scrap.
Scrap dryer/delacquering ki ln/decoating kiln means a unit used primarily to remove various organic contaminants such as oil, paint, lacquer, ink, plastic, and/or rubber from aluminum scrap(including used beverage containers) prior to melting , or that separates aluminum foil from pa per and plastic in scrap
. Secondary aluminum processing unit (SAPU). An existing SAPU means all existing group 1 furnaces and all existing in

- line fluxers within a secondary aluminum production facility. Each existing group 1 furnace or existing in

- line fl uxer is considered an emission unit within a secondary aluminum processing unit. A new SAPU means any combination of individual group 1 furnaces and in

- line fluxers within a secondary aluminum processing facility which either were constructed or reconstruc ted after February 11, 1999, or have been permanently redesignated as new emission units pursuant to §63.1505(k)(6). Each of the group 1 furnaces or in

- line fluxers within a new SAPU is considered an emission unit within that secondary aluminum processing unit. A secondary aluminum production facility may have more than one new SAPU . Secondary aluminum production facility means any establishment using clean charge, aluminum scrap, or dross from aluminum production, as the raw material and performing one or more of the following processes: scrap shredding, scrap drying/delacquering/decoating, thermal chip drying, furnace operations ( i.e., melting, holding, sweating, refining, fluxing, or alloying), recovery of aluminum from dross, in

- linefluxing, or dross c ooling. A secondary aluminum production facility may be independent or part of a primary aluminum production facility. For purposes of this subpart, aluminum die casting facilities, aluminum foundries, and aluminum extrusion facilities are not considered t o be secondary aluminum production facilities if the only materials they melt are clean charge, customer returns, or internal scrap, and if they do not operate sweat furnaces, thermal chip dryers, or scrap dryers/delacquering kilns/decoating kilns. The det ermination of whether a facility is a secondary aluminum production facility is only for purposes of this subpart and any regulatory requirements which are derived from the applicability of this subpart, and is separate from any determination which may be made under other environmental laws and regulations, including whether the same facility is a “secondary metal production facility” as that term is used in 42 U.S.C. §7479(1) and 40 CFR 52.21(b)(1)(i)(A) (“prevention of significant deterioration of air qua lity”).

Sidewell means an open well adjacent to the hearth of a furnace with connecting arches between the hearth and the open well through which molten aluminum is circulated between the hearth, where heat is applied by burners, and the open well, which i sused for charging scrap and solid flux or salt to the furnace, injecting fluxing agents, and skimming dross.

Sweat furnace means a furnace used exclusively to reclaim aluminum from scrap that contains substantial quantities of iron by using heat to separ ate the low

- melting point aluminum from the scrap while the higher melting

- point iron remains in solid form.
Tap means the end of an operating cycle when processed molten aluminum is poured from a furnace.

TEQ means the international method of expressing t oxicity equivalents for dioxins and furans as defined in “Interim Procedures for Estimating Risks Associated with Exposures to Mixtures of Chlorinated Dibenzo

- p - Dioxins and

- Dibenzofurans (CDDs and CDFs) and 1989 Update” (EPA

– 625/3

– 89

– 016), available from the National Technical Information Service (NTIS), 5285 Port Royal Road, Springfield, Virginia 22161, NTIS no. PB 90

– 145756.

THC means, for the purposes of this subpart, total hydrocarbon emissions that also serve as a surrogate for the emissions of organi c HAP compounds.Thermal chip dryer means a device that uses heat to evaporate oil or oil/water mixtures from unpainted/uncoated aluminum chips. Pre

- heating boxes or other dryers which are used solely to remove water from aluminum scrap are not considered to be thermal chip dryers for purposes of this subpart.

Three

- day, 24

- hour rolling average means daily calculations of the average 24

- hour emission rate (lbs/ton of feed/charge), over the 3 most recent consecutive 24

- hour periods, for a secondary aluminum processing unit.
Total reactive chlorine flux injection rate means the sum of the total weight of chlorine in the gaseous or liquid reactive flux and the total weight of chlorine in the solid reactive chloride flux, divided by the total weight of feed/cha rge, as determined by the procedure in §63.1512(o).
[65 FR 15710, Mar. 23, 2000, as amended at 67 FR 79814, Dec. 30, 2002; 69 FR 18803, Apr. 9, 2004; 69 FR 53984, Sept. 3, 2004; 70 FR 57517, Oct. 3, 2005]

**§63.1504 [Reserved]** 
**Emission Standards and Operatin g Requirements** 

**§63.1505 Emission standards for affected sources and emission**  **units.**(a) Summary. (1) The owner or operator of a new or existing affected source must comply at all times with each applicable limit in this section , including periods of startu p and shutdown . Table 1 to this subpart summarizes the emission standards for each type of source.
(2) For a new or existing affected sources subject to an emissions limit in paragraphs (b) through (j) of this section expressed in units of pounds per ton o f feed, or μg TEQ or ng TEQ per Mg of feed, calculate your emissions during periods of startup and shutdown by dividing your measured emissions in lb/hr or μg/hr or ng/hr by the appropriate feed rate in tons/hr or Mg/hr from your most recent or current per formance test.
(b) Aluminum scrap shredder. On and after the compliance date established by §63.1501, the owner or operator of an aluminum scrap shredder at a secondary aluminum production facility that is a major source must not discharge or cause to be d ischarged to the atmosphere:
(1) Emissions in excess of 0.023 grams (g) of PM per dry standard cubic meter (dscm) (0.010 grain (gr) of PM per dry standard cubic foot (dscf)); and
(2) Visible emissions (VE) in excess of 10 percent opacity from any PM add

- on air pollution control device if a continuousopacity monitor (COM) or visible emissions monitoring is chosen as the monitoring option.
(c) Thermal chip dryer. On and after the compliance date established by §63.1501, the owner or operator of a thermal chi p dryer must not discharge or cause to be discharged to the atmosphere emissions in excess of:
(1) 0.40 kilogram (kg) of THC, as propane, per megagram (Mg) (0.80 lb of THC, as propane, per ton) of feed/charge from a thermal chip dryer at a secondary alumin um production facility that is a major source; and
(2) 2.50 micrograms (μg) of D/F TEQ per Mg (3.5 × 10 −5 gr per ton) of feed/charge from a thermal chip dryer at a secondary aluminum production facility that is a major or area source.
(d) Scrap dryer/delacq uering kiln/decoating kiln. On and after the compliance date established by §63.1501:
(1) The owner or operator of a scrap dryer/delacquering kiln/decoating kiln must not discharge or cause to be discharged to the atmosphere emissions in excess of:
(i) 0.0 3 kg of THC, as propane, per Mg (0.06 lb of THC, as propane, per ton) of feed/charge from a scrap dryer/delacqueringkiln/decoating kiln at a secondary aluminum production facility that is a major source;
(ii) 0.04 kg of PM per Mg (0.08 lb per ton) of feed /charge from a scrap dryer/delacquering kiln/decoating kiln at a secondary aluminum production facility that is a major source;
(iii) 0.25 μg of D/F TEQ per Mg (3.5 × 10 −6 gr of D/F TEQ per ton) of feed/charge from a scrap dryer/delacquering kiln/decoating kiln at a secondary aluminum production facility that is a major or area source; and
(iv) 0.40 kg of HCl per Mg (0.80 lb per ton) of feed/charge from a scrap dryer/delacquering kiln/decoating kiln at a secondary aluminum production facility that is a major source. (2) The owner or operator of a scrap dryer/delacquering kiln/decoating kiln at a secondary aluminum production facility that is a major source must not discharge or cause to be discharged to the atmosphere visible emissions in excess of 10 percent opacity from any PM add

- on air pollution control device if a COM is chosen as the monitoring option.
(e) Scrap dryer/delacquering kiln/decoating kiln: alternative limits. The owner or operator of a scrap dryer/ delacquering kiln/decoating kiln may choose to comply with the emissionlimits in this paragraph (e) as an alternative to the limits in paragraph (d) of this section if the scrap dryer/delacquering kiln/decoating kiln is equipped with an afterburner having a design residence time of at least 1 secon d and the afterburner is operated at a temperature of at least 760 °C (1400 °F) at all times. On and after the compliance date established by §63.1501:
(1) The owner or operator of a scrap dryer/delacquering kiln/decoating kiln must not discharge or cause to be discharged to the atmosphere emissions in excess of:
(i) 0.10 kg of THC, as propane, per Mg (0.20 lb of THC, as propane, per ton) of feed/charge from a scrap dryer/delacquering kiln/decoating kiln at a secondary aluminum production facility that is a major source;
(ii) 0.15 kg of PM per Mg (0.30 lb per ton) of feed/charge from a scrap dryer/delacquering kiln/decoating kiln at a secondary aluminum production facility that is a major source;
(iii) 5.0 μg of D/F TEQ per Mg (7.0 × 10 −5 gr of D/F TEQ per to n) of feed/charge from a scrap dryer/delacquering kiln/decoating kiln at a secondary aluminum production facility that is a major or area source; and(iv) 0.75 kg of HCl per Mg (1.50 lb per ton) of feed/charge from a scrap dryer/delacquering kiln/decoating kiln at a secondary aluminum production facility that is a major source.
(2) The owner or operator of a scrap dryer/ delacquering kiln/decoating kiln at a secondary aluminum production facility that is a major source must not discharge or cause to be disc harged to the atmosphere visible emissions in excess of 10 percent opacity from any PM add

- on air pollution control device if a COM is chosen as the monitoring option.
(f) Sweat furnace. The owner or operator of a sweat furnace shall comply with the emissi on standard of paragraph (f)(2) of this section.
(1) The owner or operator is not required to conduct a performance test to demonstrate compliance with the emission standard of paragraph (f)(2) of this section, provided that, on and after the compliance da te of this rule, the owner or operator operates and maintains an afterburner with a design residence time of 0.8 seconds or greater and an operating temperature of 1600 °F or greater.
(2) On and after the compliance date established by §63.1501, the owner or operator of a sweat furnace at a secondary aluminum production facility that is a major or area source must notdischarge or cause to be discharged to the atmosphere emissions in excess of 0.80 nanogram (ng) of D/F TEQ per dscm (3.5×10 −10 gr per dscf) at 11 percent oxygen (O 2 ).
(g) Dross

- only furnace. On and after the compliance date established by §63.1501, the owner or operator of a dross

- only furnace at a secondary aluminum production facility that is a major source must not discharg e or cause to be discharged to the atmosphere:
(1) Emissions in excess of 0.15 kg of PM per Mg (0.30 lb of PM per ton) of feed/charge.
(2) Visible emissions in excess of 10 percent opacity from any PM add

- on air pollution control device if a COM is chosen as the monitoring option.
(h) Rotary dross cooler. On and after the compliance date established by §63.1501, the owner or operator of a rotary dross cooler at a secondary aluminum production facility that is a major source must not discharge or cause to be discharged to the atmosphere:
(1) Emissions in excess of 0.09 g of PM per dscm (0.04 gr per dscf).(2) Visible emissions in excess of 10 percent opacity from any PM add

- on air pollution control device if a COM is chosen as the monitoring option.
(i) Group 1 furnace. The owner or operator of a group 1 furnace must use the limits in this paragraph to determine the emission standards for a SAPU.
(1) 0.20 kg of PM per Mg (0.40 lb of PM per ton) of feed/charge from a group 1 furnace, that is not a melting/holdi ng furnace processing only clean charge, at a secondary aluminum production facility that is a major source;
(2) 0.40 kg of PM per Mg (0.80 lb of PM per ton) of feed/charge from a group 1 melting/holding furnace processing only clean charge at a secondary aluminum production facility that is a major source;
(3) 15 μg of D/F TEQ per Mg (2.1 × 10 −4 gr of D/F TEQ per ton) of feed/charge from a group 1 furnace at a secondary aluminum production facility that is a major or area source. This limit does not apply if the furnace processes only clean charge; and
(4) 02.0 kg or HF per Mg (0.40 lb of HF per ton) of feed/charge from an uncontrolled group 1 furnace and 0.20 kg of HCl per Mg (0.40 lb of HCl per ton) of feed/charge or, if the furnace isequipped with an add

- on air pollution control device, 10 percent of the uncontrolled HCl emissions, by weight, for a group 1 furnace at a secondary aluminum production facility that is a major source.
(5) The owner or operator of a group 1 furnace at a secondary aluminum production facility that is a major source must not discharge or cause to be discharged to the atmosphere visible emissions in excess of 10 percent opacity from any PM add

- on air pollution control device if a COM is chosen as the monitoring option.
(6) The owner or operator may determine the emission standards for a SAPU by applying the group 1 fur nace limits on the basis of the aluminum production weight in each group 1 furnace, rather than on the basis of feed/charge.
(7) The owner or operator of a sidewell group 1 furnace that conducts reactive fluxing (except for cover flux) in the hearth, or th at conducts reactive fluxing in the sidewell at times when the level of molten metal falls below the top of the passage between the sidewell and the hearth, must comply with the emission limits of paragraphs (i)(1) through (4) of this section on the basis of the combined emissions from the sidewell and the hearth.(j) In

- line fluxer. Except as provided in paragraph (j)(3) of this section for an in

- line fluxer using no reactive flux material, the owner or operator of an in

- line fluxer must use the limits in this paragraph to determine the emission standards for a SAPU.
(1) 0.02 kg of HCl per Mg (0.04 lb of HCl per ton) of feed/charge;
(2) 0.005 kg of PM per Mg (0.01 lb of PM per ton) of feed/charge.
(3) The emission limits in paragraphs (j)(1) and (j)(2) of t his section do not apply to an in

- line fluxer that uses no reactive flux materials.
(4) The owner or operator of an in

- line fluxer at a secondary aluminum production facility that is a major source must not discharge or cause to be discharged to the atmosp here visible emissions in excess of 10 percent opacity from any PM add

- on air pollution control device used to control emissions from the in

line fluxer, if a COM is chosen as the monitoring option.
(5) The owner or operator may determine the emission stan dards for a SAPU by applying the in

- line fluxer limits on the basis ofthe aluminum production weight in each in

- line fluxer, rather than on the basis of feed/charge.
(k) Secondary aluminum processing unit. On and after the compliance date established by § 63.1501, the owner or operator must comply with the emission limits calculated using the equations for PM , and HCl and HF in paragraphs (k)(1) and (2) of this section for each secondary aluminum processing unit at a secondary aluminum production facility t hat is a major source. The owner or operator must comply with the emission limit calculated using the equation for D/F in paragraph (k)(3) of this section for each secondary aluminum processing unit at a secondary aluminum production facility that is a maj or or area
source. (1) The owner or operator must not discharge or allow to be discharged to the atmosphere any 3

- day, 24

- hour rolling average emissions of PM in excess of:

Where,L tiPM = The PM emission limit for individual emission unit i in paragraph (i)(1) and (2) of this section for a group 1 furnace or in paragraph (j)(2) of this section for an in

- line fluxer;

T ti = The mass of feed/charge for 24 hours rate for individual emission unit I i ; and

L cPM = The daily PM emission limit for the secondary aluminum processing unit which is used to calculate the 3

- day, 24

- hour PM emission limit applicable to the SAPU
.

Note: In

- line fluxers using no reactive flux materials can not be included in this calculation since they are not subject to the PM limit.
(2) The owner or operator must not discharge or allow to be discharged to the atmosphere any 3

- day, 24

- hour rolling average emissions of HCl or HF in excess of:



## ( ) ( ) 2) Eq. ( T T L L n
1 i ti n
1 i ti tiHCl/HF cHCl/HF 

# ∑ ∑

=

= ×

=Where,

L tiHCl /HF = The HCl emission limit for individual emission unit i in paragraph (i)(4) of this section for a group 1 furnace or in paragraph (j)(1) o f this section for an in

- line fluxer; or the HF emission limit for individual emission unit i in paragraph (i)(4) of this section for an uncontrolled group 1 furnace and

L cHCl /HF = The daily HCl or HF emission limit for the secondary aluminum processing un it which is used to calculate the 3

- day, 24

- hour HCL or HF emission limit applicable to the SAPU
.

Note: Only uncontrolled group 1 furnaces are included I this HF limit calculation and i I n - line fluxers using no reactive flux materials cannot be included in this calculation since they are not subject to the HCl limit.
(3) The owner or operator must not discharge or allow to be discharged to the atmosphere any 3

- day, 24

- hour rolling average emissions of D/F in excess of:

Where,L tiD/F = The D/F emission limit for individual emission unit i in paragraph (i)(3) of this section for a group 1 furnace; and

L cD/F = The daily D/F emission limit for the secondary aluminum proces sing unit which is used to calculate the 3

- day, 24

- hour D/F emission limit applicable to the SAPU
. Note: Clean charge furnaces cannot be included in this calculation since they are not subject to the D/F limit.
(4) The owner or operator of a SAPU at a seco ndary aluminum production facility that is a major source may demonstrate compliance with the emission limits of paragraphs (k)(1) through (3) of this section by demonstrating that each emission unit within the SAPU is in compliance with the applicable emi ssion limits of paragraphs (i) and (j) of this section.
(5) The owner or operator of a SAPU at a secondary aluminum production facility that is an area source may demonstrate compliance with the emission limits of paragraph (k)(3) of this section by demons trating that each emission unit within the SAPU is in compliance with the emission limit of paragraph (i)(3) of this section.
(6) With the prior approval of the responsible permitting authority, an owner or operator may redesignate any existinggroup 1 fur nace or in

- line fluxer at a secondary aluminum production facility as a new emission unit. Any emission unit so redesignated may thereafter be included in a new SAPU at that facility. Any such redesignation will be solely for the purpose of this MACT stand ard and will be irreversible.
[65 FR 15710, Mar. 23, 2000, as amended at 67 FR 59792, Sept. 24, 2002; 67 FR 79816, Dec. 30, 2002; 70 FR 57517, Oct. 3, 2005]

**§63.1506 Operating requirements.** 
(a) Summary. (1) On and after the compliance date established by § 63.1501, the owner or operator must operate all new and existing affected sources and control equipment according to the requirements in this section. The affected sources, and their associated control equipment, listed in §63.1500(c)(1)through(4) of this subpart that are located at a secondary aluminum production facility that is an area source are subject to the operating requirements of paragraphs (b), (c), (d), (f), (g), (h), (m), (n), and (p) of this section.
(2) The owner or operator of an existing sw eat furnace that meets the specifications of §63.1505(f)(1) must operate the sweat furnace and control equipment according to the requirements of this section on and after the compliance date of this standard.(3) The owner or operator of a new sweat furna ce that meets the specifications of §63.1505(f)(1) must operate the sweat furnace and control equipment according to the requirements of this section by March 23, 2000 or upon startup, whichever is later.
(4) Operating requirements are summarized in Table 2 to this subpart.
(5) At all times, the owner or operator must operate and maintain any affected source, including associated air pollution control equipment and monitoring equipment, in a manner consistent with safety and good air pollution control pract ices for minimizing emissions. Determination of whether such operation and maintenance procedures are being used will be based on information available to the Administrator which may include, but is not limited to, monitoring results, review of operation a nd maintenance procedures, review of operation and maintenance records, and inspection of the source.
(b) Labeling. The owner or operator must provide and maintain easily visible labels posted at each group 1 furnace, group 2 furnace, in

- line fluxer and sc rap dryer/delacquering kiln/decoating kiln that identifies the applicable emission limits and means of compliance, including:(1) The type of affected source or emission unit ( e.g., scrap dryer/delacquering kiln/decoating kiln, group 1 furnace, group 2 fu rnace, in

- line fluxer).
(2) The applicable operational standard(s) and control method(s) (work practice or control device). This includes, but is not limited to, the type of charge to be used for a furnace ( e.g ., clean scrap only, all scrap, etc.), flux materials and addition practices, and the applicable operating parameter ranges and requirements as incorporated in the OM&M plan.
(3) The afterburner operating temperature and design residence time for a scrap dryer/delacquering kiln/decoating kiln.
(c) C apture/collection systems. For each affected source or emission unit equipped with an add

- on air pollution control device, the owner or operator must:
(1) Design and install a system for the capture and collection of emissions to meet the engineering stand ards for minimum exhaust rates as published by the American Conference of Governmental Industrial Hygienists in chapters 3 and 5 of “Industrial Ventilation: A Manual of Recommended Practice” 23 rd or 27 th edition (ACGIH Guidelines) (incorporated by referenc e in §63.1502 of this subpart);(2) Vent captured emissions through a closed system, except that dilution air may be added to emission streams for the purpose of controlling temperature at the inlet to a fabric filter; and
(3) Operate each capture/collecti on system according to the procedures and requirements in the OM&M plan.
(d) Feed/charge weight. The owner or operator of each affected source or emission unit subject to an emission limit in kg/Mg (lb/ton) or μg/Mg (gr/ton) of feed/charge must:
(1) Except as provided in paragraph (d)(3) of this section, install and operate a device that measures and records or otherwise determine the weight of feed/charge (or throughput) for each operating cycle or time period used in the performance test; and
(2) Operate each weight measurement system or other weight determination procedure in accordance with the OM&M plan.
(3) The owner or operator may chose to measure and record aluminum production weight from an affected source or emission unit rather than feed/charge w eight to an affected source or emission unit, provided that:(i) The aluminum production weight, rather than feed/charge weight is measured and recorded for all emission units within a SAPU; and
(ii) All calculations to demonstrate compliance with the emis sion limits for SAPUs are based on aluminum production weight rather than feed/charge weight.
(e) Aluminum scrap shredder. The owner or operator of a scrap shredder with emissions controlled by a fabric filter must operate a bag leak detection system, or a continuous opacity monitor, or conduct visible emissions observations.
(1) If a bag leak detection system is used to meet the monitoring requirements in §63.1510, the owner or operator must:
(i) Initiate corrective action within 1

- hour of a bag leak detec tion system alarm and complete the corrective action procedures in accordance with the OM&M plan.
(ii) Operate each fabric filter system such that the bag leak detection system alarm does not sound more than 5 percent of the operating time during a 6

- month block reporting period. In calculating this operating time fraction, if inspection of the fabric filter demonstrates that no corrective action is required, no alarm time is counted. If corrective action isrequired, each alarm shall be counted as a minimu m of 1 hour. If the owner or operator takes longer than 1 hour to initiate corrective action, the alarm time shall be counted as the actual amount of time taken by the owner or operator to initiate corrective action.
(2) If a continuous opacity monitoring system is used to meet the monitoring requirements in §63.1510, the owner or operator must initiate corrective action within 1

- hour of any 6

- minute average reading of 5 percent or more opacity and complete the corrective action procedures in accordance wit h the OM&M plan.
(3) If visible emission observations are used to meet the monitoring requirements in §63.1510, the owner or operator must initiate corrective action within 1

- hour of any observation of visible emissions during a daily visible emissions tes t and complete the corrective action procedures in accordance with the OM&M plan.
(f) Thermal chip dryer. The owner or operator of a thermal chip dryer with emissions controlled by an afterburner must:
(1) Maintain the 3

- hour block average operating temper ature of each afterburner at or above the average temperature established during the performance test.(2) Operate each afterburner in accordance with the OM&M plan.
(3) Operate each thermal chip dryer using only unpainted aluminum chips as the feedstock.
(g) Scrap dryer/delacquering kiln/decoating kiln. The owner or operator of a scrap dryer/delacquering kiln/decoating kiln with emissions controlled by an afterburner and a lime

- injected fabric filter must:
(1) For each afterburner,
(i) Maintain the 3

- hour block average operating temperature of each afterburner at or above the average temperature established during the performance test.
(ii) Operate each afterburner in accordance with the OM&M plan.
(2) If a bag leak detection system is used to meet the fabr ic filter monitoring requirements in §63.1510,
(i) Initiate corrective action within 1

- hour of a bag leak detection system alarm and complete any necessary corrective action procedures in accordance with the OM&M plan.
(ii) Operate each fabric filter syste m such that the bag leak detection system alarm does not sound more than 5 percent of the operating time during a 6

- month block reporting period. Incalculating this operating time fraction, if inspection of the fabric filter demonstrates that no correctiv e action is required, no alarm time is counted. If corrective action is required, each alarm shall be counted as a minimum of 1 hour. If the owner or operator takes longer than 1 hour to initiate corrective action, the alarm time shall be counted as the ac tual amount of time taken by the owner or operator to initiate corrective action.
(3) If a continuous opacity monitoring system is used to meet the monitoring requirements in §63.1510, initiate corrective action within 1

- hour of any 6

- minute average readin g of 5 percent or more opacity and complete the corrective action procedures in accordance with the OM&M plan.
(4) Maintain the 3

- hour block average inlet temperature for each fabric filter at or below the average temperature established during the perform ance test, plus 14 °C (plus 25 °F).
(5) For a continuous injection device, maintain free

- flowing lime in the hopper to the feed device at all times and maintain the lime feeder setting at or above the same level established during the performance test.
(h) Sweat furnace. The owner or operator of a sweat furnace with emissions controlled by an afterburner must:(1) Maintain the 3

- hour block average operating temperature of each afterburner at or above:
(i) The average temperature established during the perfo rmance test; or
(ii) 1600 °F if a performance test was not conducted, and the afterburner meets the specifications of §63.1505(f)(1).
(2) Operate each afterburner in accordance with the OM&M plan.
(i) Dross

- only furnace. The owner or operator of a dross

- on ly furnace with emissions controlled by a fabric filter must:
(1) If a bag leak detection system is used to meet the monitoring requirements in §63.1510,
(i) Initiate corrective action within 1

- hour of a bag leak detection system alarm and complete the cor rective action procedures in accordance with the OM&M plan.
(ii) Operate each fabric filter system such that the bag leak detection system alarm does not sound more than 5 percent of the operating time during a 6

- month block reporting period. In calculatin g this operating time fraction, if inspection of the fabric filter demonstrates that no corrective action is required, no alarm time is counted. If corrective action isrequired, each alarm shall be counted as a minimum of 1 hour. If the owner or operator takes longer than 1 hour to initiate corrective action, the alarm time shall be counted as the actual amount of time taken by the owner or operator to initiate corrective action.
(2) If a continuous opacity monitoring system is used to meet the monitoring requirements in §63.1510, initiate corrective action within 1

- hour of any 6

- minute average reading of 5 percent or more opacity and complete the corrective action procedures in accordance with the OM&M plan.
(3) Operate each furnace using dross and salt fl ux as the sole feedstock.
(j) Rotary dross cooler. The owner or operator of a rotary dross cooler with emissions controlled by a fabric filter must:
(1) If a bag leak detection system is used to meet the monitoring requirements in §63.1510,
(i) Initiate co rrective action within 1

- hour of a bag leak detection system alarm and complete the corrective action procedures in accordance with the OM&M plan.
(ii) Operate each fabric filter system such that the bag leak detection system alarm does not sound more than 5 percent of theoperating time during a 6

- month block reporting period. In calculating this operating time fraction, if inspection of the fabric filter demonstrates that no corrective action is required, no alarm time is counted. If corrective action is required, each alarm shall be counted as a minimum of 1 hour. If the owner or operator takes longer than 1 hour to initiate corrective action, the alarm time shall be counted as the actual amount of time taken by the owner or operator to initiate correctiv e action.
(2) If a continuous opacity monitoring system is used to meet the monitoring requirements in §63.1510, initiate corrective action within 1 hour of any 6

- minute average reading of 5 percent or more opacity and complete the corrective action proced ures in accordance with the OM&M plan.
(k) In

- line fluxer. The owner or operator of an in

- line fluxer with emissions controlled by a lime

- injected fabric filter must:
(1) If a bag leak detection system is used to meet the monitoring requirements in §63.151 0,
(i) Initiate corrective action within 1

- hour of a bag leak detection system alarm and complete the corrective action procedures in accordance with the OM&M plan.(ii) Operate each fabric filter system such that the bag leak detection system alarm does n ot sound more than 5 percent of the operating time during a 6

- month block reporting period. In calculating this operating time fraction, if inspection of the fabric filter demonstrates that no corrective action is required, no alarm time is counted. If cor rective action is required, each alarm shall be counted as a minimum of 1 hour. If the owner or operator takes longer than 1 hour to initiate corrective action, the alarm time shall be counted as the actual amount of time taken by the owner or operator to initiate corrective action.
(2) If a continuous opacity monitoring system is used to meet the monitoring requirements in §63.1510, initiate corrective action within 1 hour of any 6

- minute average reading of 5 percent or more opacity and complete the correc tive action procedures in accordance with the OM&M plan.
(3) For a continuous injection system, maintain free

- flowing lime in the hopper to the feed device at all times and maintain the lime feeder setting at or above the same level established during the performance test.
(4) Maintain the total reactive chlorine flux injection rate for each operating cycle or time period used in the performance testat or below the average rate established during the performance
test.
(l) In

- line fluxer using no reactive f lux material. The owner or operator of a new or existing in

- line fluxer using no reactive flux materials must operate each in

- line fluxer using no reactive flux materials.
(m) Group 1 furnace with add

- on air pollution control devices. The owner or operator of a group 1 furnace with emissions controlled by a lime

- injected fabric filter must:
(1) If a bag leak detection system is used to meet the monitoring requirements in §63.1510, the owner or operator must:
(i) Initiate corrective action within 1 hour of a bag leak detection system alarm.
(ii) Complete the corrective action procedures in accordance with the OM&M plan.
(iii) Operate each fabric filter system such that the bag leak detection system alarm does not sound more than 5 percent of the operating tim e during a 6

- month block reporting period. In calculating this operating time fraction, if inspection of the fabric filter demonstrates that no corrective action is required, no alarm time is counted. If corrective action isrequired, each alarm shall be c ounted as a minimum of 1 hour. If the owner or operator takes longer than 1 hour to initiate corrective action, the alarm time shall be counted as the actual amount of time taken by the owner or operator to initiate corrective action.
(2) If a continuous o pacity monitoring system is used to meet the monitoring requirements in §63.1510, the owner or operator
must: (i) Initiate corrective action within 1 hour of any 6

- minute average reading of 5 percent or more opacity; and
(ii) Complete the corrective action procedures in accordance with the OM&M plan.
(3) Maintain the 3

- hour block average inlet temperature for each fabric filter at or below the average temperature established during the performance test, plus 14 °C (plus 25 °F).
(4) For a continuous lime inj ection system, maintain free

flowing lime in the hopper to the feed device at all times and maintain the lime feeder setting at or above the same level established during the performance test.
(5) Maintain the total reactive chlorine flux injection rate fo r each operating cycle or time period used in the performance testat or below the average rate established during the performance
test. (6) Operate each sidewell furnace such that:
(i) The level of molten metal remains above the top of the passage between the sidewell and hearth during reactive flux injection, unless emissions from both the sidewell and the hearth are included in demonstrating compliance with all applicable emission limits.
(ii) Reactive flux is added only in the sidewell, unless emissions from both the sidewell and the hearth are included in demonstrating compliance with all applicable emission limits.
(n) Group 1 furnace without add

- on air pollution control devices. The owner or operator of a group 1 furnace (including a group 1 furnace t hat is part of a secondary aluminum processing unit) without add

- on air pollution control devices must:
(1) Maintain the total reactive chlorine flux injection rate and fluorine addition rate for each operating cycle or time period used in the performance test at or below the average rate established during the performance test.
(2) Operate each furnace in accordance with the work practice/pollution prevention measures documented in the OM&Mplan and within the parameter values or ranges established in the OM&M plan.
(3) Operate each group 1 melting/holding furnace subject to the emission standards in §63.1505(i)(2) using only clean charge as the feedstock.
(o) Group 2 furnace. The owner or operator of a new or existing group 2 furnace must:
(1) Operate each furnace using only clean charge as the feedstock.
(2) Operate each furnace using no reactive flux.
(p) Corrective action. When a process parameter or add

- on air pollution control device operating parameter deviates from the value or range established duri ng the performance test and incorporated in the OM&M plan, the owner or operator must initiate corrective action. Corrective action must restore operation of the affected source or emission unit (including the process or control device) to its normal or us ual mode of operation as expeditiously as practicable in accordance with good air pollution control practices for minimizing emissions. Corrective actions taken must include follow

- up actions necessary to return the process or control device parameterleve l(s) to the value or range of values established during the performance test and steps to prevent the likely recurrence of the cause of a deviation.
[65 FR 15710, Mar. 23, 2000, as amended at 67 FR 59792, Sept. 24, 2002; 67 FR 79816, Dec. 30, 2002; 69 FR 5 3984, Sept. 3, 2004]

**§§63.1507 -**  **63.1509 [Reserved]** 
**Monitoring and Compliance Requirements**

**§63.1510 Monitoring requirements.** 
(a) Summary. On and after the compliance date established by §63.1501, the owner or operator of a new or existing affected

source or emission unit must monitor all control equipment and processes according to the requirements in this section. Monitoring requirements for each type of affected source and emission unit are summarized in Table 3 to this subpart. Area sources are subject to monitoring requirements for those affected sources listed in §63.1500(c)(1)

- (4)of this subpart, and associated control equipment as required by paragraphs (b) through (k), (n) through (q), and (s) through (w) of this section, including but not limited to:(1) T he operation, maintenance and monitoring plan required in paragraph (b) of this section pertaining to each affected source listed in §63.1500(c)(1)

- (4) of this subpart, (2) T he labeling requirements described in paragraph (c) of this section pertainin g to group 1 furnaces processing other than clean charge, and scrap dryer/delacquering kiln/decoating kilns, (3) T he requirements for capture and collection described in paragraph (d) of this section for each controlled affected source listed in §63.1500(c )(1)

- (4) of this subpart, (4) T he feed charge weight monitoring requirements described in paragraph (e) of this section applicable to group 1 furnaces processing other than clean charge, scrap dryer/delacquering kiln/decoating kilns and thermal chip dryers , (5) T he bag leak detect ion system requirements described in paragraph (f) of this section applicable to all bag leak detect ion systems installed on fabric filters and lime injected fabric filters used to control each affected source listed in §63.1500(c) (1)

- (4) of this subpart, (6) T he requirements for afterburners described in paragraph (g) of this section applicable to sweat furnaces, thermal chip dryers, and scrap dryer/delacquering kiln/decoating kilns, (7) T he requirements for monitoring fabric filte r inlet temperature described in paragraph (h) of this section for all lime injected fabric filters used to control group 1 furnacesprocessing other than clean charge, sweat furnaces and scrap dryer/delacquering kiln/decoating kilns, (8) T he requirements for monitoring lime injection described in paragraph (i) of this section applicable to all lime injected fabric filters used to control emissions from group 1 furnaces processing other than clean charge, thermal chip dryers, sweat furnaces and scrap dryer/ delacquering kiln/decoating kilns, (9) T he requirements for monitoring total reactive flux injection described in paragraph (j) of this section for all group 1 furnaces processing other than clean charge, (10) T he requirements described in paragraph (k) o f this section for thermal chip dryers, (11) T he requirements described in paragraph (n) of this section for controlled group 1 sidewell furnaces processing other than clean charge, (12) T he requirements described in paragraph (o) of this section for uncon trolled group 1 sidewell furnaces processing other than clean charge, (13) T he requirements described in paragraph (p) of this section for scrap inspection programs for uncontrolled group 1 furnaces , (14) T he requirements described in paragraph (q) of this section for monitoring scrap contamination level for uncontrolled group 1 furnaces,(15) T he requirements described in paragraph (s) of this section for secondary aluminum processing units, limited to compliance with limits for emissions of D/F from group 1 furnaces processing other than clean charge, (16) T he requirements described in paragraph (t) of this section for secondary aluminum processing units limited to compliance with limits for emissions of D/F from group 1 furnaces processing other than clea n charge, (17) T he requirements described in paragraph (u) of this section for secondary aluminum processing units limited to compliance with limits for emissions of D/F from group 1 furnaces processing other than clean charge, (18) T he requirements descri bed in paragraph (v) of this section for alternative lime addition monitoring methods applicable to lime coated fabric filters used to control emissions from group 1 furnaces processing other than clean charge, thermal chip dryers, sweat furnaces and scrap dryer/delacquering kiln/decoating kilns, and (19) The requirements described in paragraph (w) of this section for approval of alternate methods for monitoring group 1 furnaces processing other than clean charge, thermal chip dryers, scrap dryer/delacqueri ng kiln/decoating kilns and sweat furnaces and associated control devices for the control of D/F emissions.(b) Operation, maintenance, and monitoring (OM&M) plan. The owner or operator must prepare and implement for each new or existing affected source an d emission unit, a written operation, maintenance, and monitoring (OM&M) plan. The owner or operator of an existing affected source must submit the OM&M plan to the responsible permitting authority no later than the compliance date established by §63.1501( a). The owner or operator of any new affected source must submit the OM&M plan to the responsible permitting authority within 90 days after a successful initial performance test under §63.1511(b), or within 90 days after the compliance date established by §63.1501(b) if no initial performance test is required. The plan must be accompanied by a written certification by the owner or operator that the OM&M plan satisfies all requirements of this section and is otherwise consistent with the requirements of this subpart. The owner or operator must comply with all of the provisions of the OM&M plan as submitted to the permitting authority, unless and until the plan is revised in accordance with the following procedures. If the permitting authority determines at an y time after receipt of the OM&M plan that any revisions of the plan are necessary to satisfy the requirements of this section or this subpart, the owner or operator must promptly make all necessary revisions and resubmit the revised plan. If the owner or operator determines that any other revisions of the OM&M plan are necessary, suchrevisions will not become effective until the owner or operator submits a description of the changes and a revised plan incorporating them to the permitting authority
. The ow ner or operator must not begin operating under the revised plan until approval is received or until after 60 days, whichever is

sooner. Each plan must contain the following information:
(1) Process and control device parameters to be monitored to determin e compliance, along with established operating levels or ranges, as applicable, for each process and control device.
(2) A monitoring schedule for each affected source and emission unit.
(3) Procedures for the proper operation and maintenance of each
proce ss unit and add

- on control device used to meet the applicable emission limits or standards in §63.1505.
(4) Procedures for the proper operation and maintenance of monitoring devices or systems used to determine compliance, including:
(i) Calibration and ce rtification of accuracy of each monitoring device, at least once every 6 months, according to the manufacturer's instructions; and(ii) Procedures for the quality control and quality assurance of continuous emission or opacity monitoring systems as require d by the general provisions in subpart A of this part.
(5) Procedures for monitoring process and control device parameters, including lime injection rates, procedures for annual inspections of afterburners, and if applicable, the procedure to be used for d etermining charge/feed (or throughput) weight if a measurement device is not used.
(6) Corrective actions to be taken when process or operating parameters or add

- on control device parameters deviate from the value or range established in paragraph (b)(1) o f this section, including:
(i) Procedures to determine and record the cause of any deviation or excursion, and the time the deviation or excursion began and ended; and
(ii) Procedures for recording the corrective action taken, the time corrective action wa s initiated, and the time/date corrective action was completed.
(7) A maintenance schedule for each process and control device that is consistent with the manufacturer's instructions and recommendations for routine and long

- term maintenance.(8) Documentat ion of the work practice and pollution prevention measures used to achieve compliance with the applicable emission limits and a site

- specific monitoring plan as required in paragraph (o) of this section for each group 1 furnace not equipped with an add

- on air pollution control device.
(9) Procedures to be followed when changing furnace classification under the provisions of §63.1514.
(c) Labeling. The owner or operator must inspect the labels for each group 1 furnace, group 2 furnace, in

- line fluxer and scr ap dryer/delacquering kiln/decoating kiln at least once per calendar month to confirm that posted labels as required by the operational standard in §63.1506(b) are intact and legible.
(d) Capture/collection system. The owner or operator must:
(1) Install, operate, and maintain a capture/collection system for each affected source and emission unit equipped with an add

on air pollution control device; and
(2) Inspect each capture/collection and closed vent system at least once each calendar year to ensure tha t each system is operating in accordance with the operating requirements in §63.1506(c) and record the results of each inspection. This inspection shall include a volumetric flow rate measurementtaken at a location in the ductwork downstream of the hoods which will be representative of the actual volumetric flow rate without the interference of leaks, the introduction of ambient air for cooling, or other ducts manifolded from other hoods. The measurement shall be performed using EPA Reference Methods 1 and 2 in appendix A to 40 CFR part 60.
(e) Feed/charge weight. The owner or operator of an affected source or emission unit subject to an emission limit in kg/Mg (lb/ton) or μg/Mg (gr/ton) of feed/charge must install, calibrate, operate, and maintain a devi ce to measure and record the total weight of feed/charge to, or the aluminum production from, the affected source or emission unit over the same operating cycle or time period used in the performance test. Feed/charge or aluminum production within SAPUs mu st be measured and recorded on an emission unit

- by

- emission unit basis. As an alternative to a measurement device, the owner or operator may use a procedure acceptable to the applicable permitting authority to determine the total weight of feed/charge or

a luminum production to the affected source or emission unit.
(1) The accuracy of the weight measurement device or procedure must be ±1 percent of the weight being measured. The owner or operator may apply to the permitting agency for approval to use a devic e of alternative accuracy if the required accuracy cannotbe achieved as a result of equipment layout or charging practices. A device of alternative accuracy will not be approved unless the owner or operator provides assurance through data and information that the affected source will meet the relevant emission standard.
(2) The owner or operator must verify the calibration of the weight measurement device in accordance with the schedule specified by the manufacturer, or if no calibration schedule is specif ied, at least once every 6 months.
(f) Fabric filters and lime

- injected fabric filters. The owner or operator of an affected source or emission unit using a fabric filter or lime

- injected fabric filter to comply with the requirements of this subpart must i nstall, calibrate, maintain, and continuously operate a bag leak detection system as required in paragraph (f)(1) of this section or a continuous opacity monitoring system as required in paragraph (f)(2) of this section. The owner or operator of an aluminu m scrap shredder must install and operate a bag leak detection system as required in paragraph (f)(1) of this section, install and operate a continuous opacity monitoring system as required in paragraph (f)(2) of this section, or conduct visible emission o bservations as required in paragraph (f)(3) of this section.(1) These requirements apply to the owner or operator of a new or existing affected source or existing emission unit using a bag leak detection system.
(i) The owner or operator must install and operate a bag leak detection system for each exhaust stack of a fabric filter.
(ii) Each bag leak detection system must be installed, calibrated, operated, and maintained according to the manufacturer’s operating instructions. Each triboelectric bag leak de tection system must be installed, calibrated, operated, and maintained according to the “Fabric Filter Bag Leak Detection Guidance,” (September 1997). This document is available from the U.S. Environmental Protection Agency; Office of Air Quality Planning and Standards; Emissions, Monitoring and Analysis Division; Emission Measurement Center (MD

– 19), Research Triangle Park, NC 27711. This document also is available on the Technology Transfer Network (TTN) under Emission Measurement Technical Information (EM TIC), Continuous Emission Monitoring. Other bag leak detection systems must be installed, operated, calibrated, and maintained in a manner consistent with the manufacturer's written specifications and recommendations.
(iii) The bag leak detection system mu st be certified by the manufacturer to be capable of detecting PM emissions atconcentrations of 10 milligrams per actual cubic meter (0.0044 grains per actual cubic foot) or less.
(iv) The bag leak detection system sensor must provide output of relative o r absolute PM loadings.
(v) The bag leak detection system must be equipped with a device to continuously record the output signal from the sensor.
(vi) The bag leak detection system must be equipped with an alarm system that will sound automatically when a n increase in relative PM emissions over a preset level is detected. The alarm must be located where it is easily heard by plant operating personnel.
(vii) For positive pressure fabric filter systems, a bag leak detection system must be installed in each b aghouse compartment or cell. For negative pressure or induced air fabric filters, the bag leak detector must be installed downstream of the fabric filter.
(viii) Where multiple detectors are required, the system's instrumentation and alarm may be shared am ong detectors.
(ix) The baseline output must be established by adjusting the range and the averaging period of the device and establishing the alarm set points and the alarm delay time.(x) Following initial adjustment of the system, the owner or operator must not adjust the sensitivity or range, averaging period, alarm set points, or alarm delay time except as detailed in the OM&M plan. In no case may the sensitivity be increased by more than 100 percent or decreased more than 50 percent over a 365

- day per iod unless such adjustment follows a complete fabric filter inspection which demonstrates that the fabric filter is in good operating condition.
(2) These requirements apply to the owner or operator of a new or existing affected source or an existing emiss ion unit using a continuous opacity monitoring system.
(i) The owner or operator must install, calibrate, maintain, and operate a continuous opacity monitoring system to measure and record the opacity of emissions exiting each exhaust stack.
(ii) Each cont inuous opacity monitoring system must meet the design and installation requirements of Performance Specification 1 in appendix B to 40 CFR part 60.
(3) These requirements apply to the owner or operator of a new or existing aluminum scrap shredder who condu cts visible emission observations. The owner or operator must:(i) Perform a visible emissions test for each aluminum scrap shredder using a certified observer at least once a day according to the requirements of Method 9 in appendix A to 40 CFR part 60. E ach Method 9 test must consist of five 6

- minute observations in a 30

- minute period; and
(ii) Record the results of each test.
(g) Afterburner. These requirements apply to the owner or operator of an affected source using an afterburner to comply with the r equirements of this subpart.
(1) The owner or operator must install, calibrate, maintain, and operate a device to continuously monitor and record the operating temperature of the afterburner consistent with the requirements for continuous monitoring system s in subpart A of this part.
(2) The temperature monitoring device must meet each of these performance and equipment specifications:
(i) The temperature monitoring device must be installed at the exit of the combustion zone of each afterburner.
(ii) The mo nitoring system must record the temperature in 15

- minute block averages and determine and record the average temperature for each 3

- hour block period.(iii) The recorder response range must include zero and 1.5 times the average temperature established acc ording to the requirements in §63.1512(m).
(iv) The reference method must be a National Institute of Standards and Technology calibrated reference thermocouple

potentiometer system or alternate reference, subject to approval by the Administrator.
(3) The o wner or operator must conduct an inspection of each afterburner at least once a year and record the results. At a minimum, an inspection must include:
(i) Inspection of all burners, pilot assemblies, and pilot sensing devices for proper operation and clean pilot sensor;
(ii) Inspection for proper adjustment of combustion air;
(iii) Inspection of internal structures ( e.g., baffles) to ensure structural integrity;
(iv) Inspection of dampers, fans, and blowers for proper operation;
(v) Inspection for proper s ealing;
(vi) Inspection of motors for proper operation;(vii) Inspection of combustion chamber refractory lining and clean and replace lining as necessary;
(viii) Inspection of afterburner shell for corrosion and/or hot spots;
(ix) Documentation, for the b urn cycle that follows the inspection, that the afterburner is operating properly and any necessary adjustments have been made; and
(x) Verification that the equipment is maintained in good operating condition.
(xi) Following an equipment inspection, all n ecessary repairs must be completed in accordance with the requirements of the OM&M plan.
(h) Fabric filter inlet temperature. These requirements apply to the owner or operator of a scrap dryer/delacquering kiln/decoating kiln or a group 1 furnace using a l ime

- injected fabric filter to comply with the requirements of this subpart.
(1) The owner or operator must install, calibrate, maintain, and operate a device to continuously monitor and record the temperature of the fabric filter inlet gases consistent wit h the requirements for continuous monitoring systems in subpart A of this part.(2) The temperature monitoring device must meet each of these performance and equipment specifications:
(i) The monitoring system must record the temperature in 15

- minute block averages and calculate and record the average temperature for each 3

- hour block period.
(ii) The recorder response range must include zero and 1.5 times the average temperature established according to the requirements in §63.1512(n).
(iii) The reference method must be a National Institute of Standards and Technology calibrated reference thermocouple

potentiometer system or alternate reference, subject to approval by the Administrator.
(i) Lime injection. These requirements apply to the owner or operator o f an affected source or emission unit using a lime

injected fabric filter to comply with the requirements of this subpart.
(1) The owner or operator of a continuous lime injection system must verify that lime is always free

- flowing by either:
(i) Inspectin g each feed hopper or silo at least once each 8

- hour period and recording the results of each inspection. If lime is found not to be free

- flowing during any of the 8

- hourperiods, the owner or operator must increase the frequency of inspections to at least once every 4

- hour period for the next 3 days. The owner or operator may return to inspections at least once every 8 hour period if corrective action results in no further blockages of lime during the 3

- day period; or
(ii) Subject to the approval of the pe rmitting agency, installing, operating and maintaining a load cell, carrier gas/lime flow indicator, carrier gas pressure drop measurement system or other system to confirm that lime is free

- flowing. If lime is found not to be free

- flowing, the owner or op erator must promptly initiate and complete corrective action, or
(iii) Subject to the approval of the permitting agency, installing, operating and maintaining a device to monitor the concentration of HCl at the outlet of the fabric filter. If an increase i n the concentration of HCl indicates that the lime is not free

- flowing, the owner or operator must promptly initiate and complete corrective action.
(2) The owner or operator of a continuous lime injection system must record the lime feeder setting once ea ch day of operation.
(3) An owner or operator who intermittently adds lime to a lime coated fabric filter must obtain approval from the permitting authority for a lime addition monitoring procedure. Thepermitting authority will not approve a monitoring pr ocedure unless data and information are submitted establishing that the procedure is adequate to ensure that relevant emission standards will be met on a continuous basis.
(4) At least once per month, verify that the lime injection rate in pound per hour ( lb/hr) is no less than 90 percent of the lime injection rate used to demonstrate compliance during your performance test.
(j) Total reactive flux injection rate. These requirements apply to the owner or operator of a group 1 furnace (with or without add

- on air pollution control devices) or in

- line fluxer. The owner or operator must: (1) Install, calibrate, operate, and maintain a device to continuously measure and record the weight of gaseous or liquid reactive flux injected to each affected source or emiss ion unit.
(i) The monitoring system must record the weight for each 15

- minute block period, during which reactive fluxing occurs, over the same operating cycle or time period used in the performance
test. (ii) The accuracy of the weight measurement device must be ±1 percent of the weight of the reactive component of the fluxbeing measured. The owner or operator may apply to the permitting authority for permission to use a weight measurement device of alternative accuracy in cases where the reactive flux fl ow rates are so low as to make the use of a weight measurement device of ±1 percent impracticable. A device of alternative accuracy will not be approved unless the owner or operator provides assurance through data and information that the affected source w ill meet the relevant emission standards.
(iii) The owner or operator must verify the calibration of the weight measurement device in accordance with the schedule specified by the manufacturer, or if no calibration schedule is specified, at least once ever y 6 months.
(2) Calculate and record the gaseous or liquid reactive flux injection rate (kg/Mg or lb/ton) for each operating cycle or time period used in the performance test using the procedure in §63.1512(o).
(3) Record, for each 15

- minute block period d uring each operating cycle or time period used in the performance test during which reactive fluxing occurs, the time, weight, and type of flux for each addition of:
(i) Gaseous or liquid reactive flux other than chlorine; and(ii) Solid reactive flux.
(4) Calculate and record the total reactive flux injection rate for each operating cycle or time period used in the performance test using the procedure in §63.1512(o). For solid flux that is added intermittently, record the amount added for each operating
cy cle or time period used in the performance test using the procedures in §63.1512(o)
. (5) The owner or operator of a group 1 furnace or in

- line fluxer performing reactive fluxing may apply to the Administrator for approval of an alternative method for monit oring and recording the total reactive flux addition rate based on monitoring the weight or quantity of reactive flux per ton of feed/charge for each operating cycle or time period used in the performance test. An alternative monitoring method will not be approved unless the owner or operator provides assurance through data and information that the affected source will meet the relevant emission standards on a continuous basis.
(k) Thermal chip dryer. These requirements apply to the owner or operator of a t hermal chip dryer with emissions controlled by an afterburner. The owner or operator must:
(1) Record the type of materials charged to the unit for each operating cycle or time period used in the performance test.(2) Submit a certification of compliance w ith the applicable operational standard for charge materials in §63.1506(f)(3) for each 6

- month reporting period. Each certification must contain the information in §63.1516(b)(2)(i).
(l) Dross

- only furnace. These requirements apply to the owner or operato r of a dross

- only furnace. The owner or operator must:
(1) Record the materials charged to each unit for each operating cycle or time period used in the performance test.
(2) Submit a certification of compliance with the applicable operational standard for charge materials in §63.1506(i)(3) for each 6

- month reporting period. Each certification must contain the information in §63.1516(b)(2)(ii).
(m) In

- line fluxers using no reactive flux. The owner or operator of an in

- line fluxer that uses no reactive flux materials must submit a certification of compliance with the operational standard for no reactive flux materials in §63.1506(l) for each 6

- month reporting period. Each certification must contain the information in §63.1516(b)(2)(vi).
(n) Sidewell group 1 f urnace with add

- on air pollution control devices. These requirements apply to the owner or operator of asidewell group 1 furnace using add

- on air pollution control devices. The owner or operator must:
(1) Record in an operating log for each charge tap of a sidewell furnace whether that the level of molten metal was above the top of the passage between the sidewell and hearth during reactive flux injection, unless the furnace hearth was also equipped with an add

- on control device. If visual inspection of th e molten metal level is not possible, the molten metal level must be determined using physical measurement methods.
(2) Submit a certification of compliance with the operational standards in §63.1506(m)( 7 6 ) for each 6

- month reporting period. Each certifica tion must contain the information in §63.1516(b)(2)(iii).
(o) Group 1 furnace without add

- on air pollution control devices. These requirements apply to the owner or operator of a group 1 furnace that is not equipped with an add

- on air pollution control dev ice.
(1) The owner or operator must develop, in consultation with the responsible permitting authority, a written site

- specific monitoring plan. The site

- specific monitoring plan must be submitted to the permitting authority as part of the OM&M plan. The s ite

- specific monitoring plan must contain sufficientprocedures to ensure continuing compliance with all applicable emission limits and must demonstrate, based on documented test results, the relationship between emissions of PM, HCl, (and, for uncontrolle d group 1 furnaces, HF) and D/F and the proposed monitoring parameters for each pollutant. Test data must establish the highest level of PM, HCl, (and, for uncontrolled group 1 furnaces, HF) and D/F that will be emitted from the furnace. This may be determ ined by conducting performance tests and monitoring operating parameters while charging the furnace with feed/charge materials containing the highest anticipated levels of oils and coatings and fluxing at the highest anticipated rate. If the permitting aut hority determines that any revisions of the site

- specific monitoring plan are necessary to meet the requirements of this section or this subpart, the owner or operator must promptly make all necessary revisions and resubmit the revised plan to the permitti ng authority.
(i) The owner or operator of an existing affected source must submit the site

- specific monitoring plan to the applicable permitting authority for review at least 6 months prior to the compliance date.
(ii) The permitting authority will review and approve or disapprove a proposed plan, or request changes to a plan, based on whether the plan contains sufficient provisions to ensurecontinuing compliance with applicable emission limits and demonstrates, based on documented test results, the relat ionship between emissions of PM, HCl, (and, for uncontrolled group 1 furnaces, HF) and D/F and the proposed monitoring parameters for each pollutant. Test data must establish the highest level of PM, HCl, (and, for uncontrolled group 1 furnaces, HF) and D/ F that will be emitted from the furnace. Subject to permitting agency approval of the OM&M plan, this may be determined by conducting performance tests and monitoring operating parameters while charging the furnace with feed/charge materials containing the highest anticipated levels of oils and coatings and fluxing at the highest anticipated rate.
(2) Each site

- specific monitoring plan must document each work practice, equipment/design practice, pollution prevention practice, or other measure used to meet t he applicable emission standards.
(3) Each site

- specific monitoring plan must include provisions for unit labeling as required in paragraph (c) of this section, feed/charge weight measurement (or production weight measurement) as required in paragraph (e) of this section and flux weight measurement as required in paragraph (j) of this section.(4) Each site

- specific monitoring plan for a melting/holding furnace subject to the clean charge emission standard in §63.1505(i)(3) must include these requirements:
(i) The owner or operator must record the type of feed/ charge (
e.g ., ingot, thermally dried chips, dried scrap, etc.) for each operating cycle or time period used in the performance test; and
(ii) The owner or operator must submit a certification of

com pliance with the applicable operational standard for clean charge materials in §63.1506(n)(3) for each 6

- month reporting period. Each certification must contain the information in §63.1516(b)(2)(iv).
(5) If a continuous emission monitoring system is includ ed in a site

- specific monitoring plan, the plan must include provisions for the installation, operation, and maintenance of the system to provide quality

- assured measurements in accordance with all applicable requirements of the general provisions in subpa rt A of this part.
(6) If a continuous opacity monitoring system is included in a site

- specific monitoring plan, the plan must include provisions for the installation, operation, and maintenance of the system to provide quality

- assured measurements in acco rdance with all applicable requirements of this subpart.(7) If a site

- specific monitoring plan includes a scrap inspection program for monitoring the scrap contaminant level of furnace feed/charge materials, the plan must include provisions for the demons tration and implementation of the program in accordance with all applicable requirements in paragraph (p) of this section.
(8) If a site

- specific monitoring plan includes a calculation method for monitoring the scrap contaminant level of furnace feed/charg e materials, the plan must include provisions for the demonstration and implementation of the program in accordance with all applicable requirements in paragraph (q) of this section.
(p) Scrap inspection program for group 1 furnace without add

- on air pollu tion control devices. A scrap inspection program must include:
(1) A proven method for collecting representative samples and measuring the oil and coatings content of scrap samples;
(2) A scrap inspector training program;
(3) An established correlation bet ween visual inspection and physical measurement of oil and coatings content of scrap samples;(4) Periodic physical measurements of oil and coatings content of randomly

- selected scrap samples and comparison with visual inspection results;
(5) A system for assuring that only acceptable scrap is charged to an affected group 1 furnace; and
(6) Recordkeeping requirements to document conformance with plan requirements.
(q) Monitoring of scrap contamination level by calculation method for group 1 furnace without add

- on air pollution control devices. The owner or operator of a group 1 furnace dedicated to processing a distinct type of furnace feed/charge composed of scrap with a uniform composition (such as rejected product from a manufacturing process for which th e coating

- to

- scrap ratio can be documented) may include a program in the site

- specific monitoring plan for determining, monitoring, and certifying the scrap contaminant level using a calculation method rather than a scrap inspection program. A scrap contam inant monitoring program using a calculation method must include:
(1) Procedures for the characterization and documentation of the contaminant level of the scrap prior to the performance test.(2) Limitations on the furnace feed/charge to scrap of the same composition as that used in the performance test. If the performance test was conducted with a mixture of scrap and clean charge, limitations on the proportion of scrap in the furnace feed/charge to no greater than the proportion used during the performan ce test. (3) Operating, monitoring, recordkeeping, and reporting requirements to ensure that no scrap with a contaminant level higher than that used in the performance test is charged to the furnace.
(r) Group 2 furnace. These requirements apply to the own er or operator of a new or existing group 2 furnace. The owner or operator must: (1) Record a description of the materials charged to each furnace, including any nonreactive, non

- HAP

- containing/non

- HAP

generating fluxing materials or agents.
(2) Submit a c ertification of compliance with the applicable operational standard for charge materials in §63.1506(o) for each 6

- month reporting period. Each certification must contain the information in §63.1516(b)(2)(v).(s) Site

- specific requirements for secondary al uminum processing units. (1) An owner or operator of a secondary aluminum processing unit at a facility must include, within the OM&M plan prepared in accordance with §63.1510(b), the following information:
(i) The identification of each emission unit in t he secondary aluminum processing unit;
(ii) The specific control technology or pollution prevention measure to be used for each emission unit in the secondary aluminum processing unit and the date of its installation or application;
(iii) The emission limi t calculated for each secondary aluminum processing unit and performance test results with supporting calculations demonstrating initial compliance with each applicable emission limit;
(iv) Information and data demonstrating compliance for each emission un it with all applicable design, equipment, work practice or operational standards of this subpart; and
(v) The monitoring requirements applicable to each emission unit in a secondary aluminum processing unit and the monitoringprocedures for daily calculati on of the 3

- day, 24

- hour rolling average using the procedure in §63.1510(t).
(2) The SAPU compliance procedures within the OM&M plan may not contain any of the following provisions:
(i) Any averaging among emissions of differing pollutants;
(ii) The inclus ion of any affected sources other than emission units in a secondary aluminum processing unit;
(iii) The inclusion of any emission unit while it is shutdown;

or (iv) The inclusion of any periods of startup or , shutdown, or malfunction in emission calculati ons. (3) To revise the SAPU compliance provisions within the OM&M plan prior to the end of the permit term, the owner or operator must submit a request to the applicable permitting authority containing the information required by paragraph (s)(1) of this

s ection and obtain approval of the applicable permitting authority prior to implementing any revisions.
(t) Secondary aluminum processing unit. Except as provided in paragraph (u) of this section, the owner or operator must calculate and record the 3

- day, 2 4

- hour rolling averageemissions of PM, HCl, (for uncontrolled group 1 furnaces, HF) and D/F for each secondary aluminum processing unit on a daily basis. To calculate the 3

- day, 24

- hour rolling average, the owner or operator must:
(1) Calculate and record the total weight of material charged to each emission unit in the secondary aluminum processing unit for each 24

- hour day of operation using the feed/charge weight information required in paragraph (e) of this section. If the owner or operator chooses to comply on the basis of weight of aluminum produced by the emission unit, rather than weight of material charged to the emission unit, all performance test emissions results and all calculations must be conducted on the aluminum production weight basis.
(2) Multiply the total feed/charge weight to the emission unit, or the weight of aluminum produced by the emission unit, for each emission unit for the 24

- hour period by the emission rate (in lb/ton of feed/charge) for that emission unit (as determined during the performance test) to provide emissions for each emission unit for the 24

- hour period, in pounds.
(i) Where no performance test has been conducted, for a particular emission unit, because the owner of operator has, with the approval of the permitting a uthority, chosen todetermine the emission rate of an emission unit by testing a representative unit, in accordance with §63.1511(f), the owner of operator shall use the emission rate determined from the representative unit in the SAPU emission rate calcul ation required in §63.1510(t)(4). (ii) If the owner or operator has not conducted performance tests for HCl and HF for an uncontrolled group 1 furnace or for HCL for an in

- line fluxer, in accordance with the provisions of §63.1512(d)(3), (e)(3), or (h)(2), the calculation required in §63.1510(t)(4) to determine SAPU

- wide HCl and HF emissions shall be made under the assumption that all chlorine

- containing reactive flux added to the emission unit is emitted as HCl and all fluorine

- containing reactive flux add ed to the emission unit is emitted as HF.
(3) Divide the total emissions for each SAPU for the 24

- hour period by the total material charged to the SAPU, or the weight of aluminum produced by the SAPU over the 24

- hour period to provide the daily emission r ate for the SAPU.
(4) Compute the 24

- hour daily emission rate using Equation 4:Where,

E day = The daily PM, HCl, or D/F and, for uncontrolled group 1 furnaces, HF emission rate for the secondary aluminum processing unit for the 24

- hour period;

T i = The total amount of feed, or aluminum produced, for emission unit i for the 24

- hour period (tons or Mg);

ER i = The measured emission rate for emission unit i as determined in the performance test (lb/ton or μg/Mg of feed/charge); and
n = The number of emission units in the secondary aluminum processing unit.
(5) Calculate and record the 3

- day, 24

- hour rolling average for each pollutant each day by summing the daily emission rates for each pollutant over the 3 most recent consecutive days and dividing by 3
. The SAPU is in compliance with an applicable emission limit if the 3

- day, 24

- hour rolling average for each pollutant is no greater than the applicable SAPU emission limit d etermined in accordance with §63.1505(k)(1)

- (3).
(u) Secondary aluminum processing unit compliance by individual emission unit demonstration. As an alternative to the procedures of paragraph (t) of this section, an owner or operator may demonstrate, throug h performance tests, that each individualemission unit within the secondary aluminum production unit is in compliance with the applicable emission limits for the emission unit.
(v) Alternative monitoring method for lime addition. The owner or operator of a lime

- coated fabric filter that employs intermittent or noncontinuous lime addition may apply to the Administrator for approval of an alternative method for monitoring the lime addition schedule and rate based on monitoring the weight of lime added per to n of feed/charge for each operating cycle or time period used in the performance test. An alternative monitoring method will not be approved unless the owner or operator provides assurance through data and information that the affected source will meet the relevant emission standards on a continuous basis.
(w) Alternative monitoring methods. If an owner or operator wishes to use an alternative monitoring method to demonstrate compliance with any emission standard in this subpart, other than those alternativ e monitoring methods which may be authorized pursuant to §63.1510(j)(5) and §63.1510(v), the owner or operator may submit an application to the Administrator. Any such application will be processed according to the criteria and procedures set forth in para graphs (w)(1) through (6) of this section.(1) The Administrator will not approve averaging periods other than those specified in this section.
(2) The owner or operator must continue to use the original monitoring requirement until necessary data are subm itted and approval is received to use another monitoring procedure.
(3) The owner or operator shall submit the application for approval of alternate monitoring methods no later than the notification of the performance test. The application must contain the information specified in paragraphs (w)(3) (i) through (iii) of this section:
(i) Data or information justifying the request, such as the technical or economic infeasibility, or the impracticality of using the required approach;
(ii) A description of the proposed alternative monitoring requirements, including the operating parameters to be monitored, the monitoring approach and technique, and how the limit is to be calculated; and
(iii) Data and information documenting that the alternative monitoring requi rement(s) would provide equivalent or better assurance of compliance with the relevant emission standard(s).(4) The Administrator will not approve an alternate monitoring application unless it would provide equivalent or better assurance of compliance wit h the relevant emission standard(s). Before disapproving any alternate monitoring application, the Administrator will provide:
(i) Notice of the information and findings upon which the intended disapproval is based; and
(ii) Notice of opportunity for the o wner or operator to present additional supporting information before final action is taken on the application. This notice will specify how much additional time is allowed for the owner or operator to provide additional supporting information.
(5) The owne r or operator is responsible for submitting any supporting information in a timely manner to enable the Administrator to consider the application prior to the performance test. Neither submittal of an application nor the Administrator's failure to approve or disapprove the application relieves the owner or operator of the responsibility to comply with any provisions of this subpart.
(6) The Administrator may decide at any time, on a case

- by

- case basis, that additional or alternative operating limits, or alt ernative approaches to establishing operating limits, arenecessary to demonstrate compliance with the emission standards of this subpart.
[65 FR 15710, Mar. 23, 2000, as amended at 67 FR 59792, Sept. 24, 2002; 67 FR 79816, Dec. 30, 2002; 69 FR 53984, Sept . 3, 2004]

**§63.1511 Performance test/compliance demonstration general**  **requirements.**
(a) Site

- specific test plan. Prior to conducting any performance test required by this subpart, the owner or operator must prepare a site

- specific test plan which satisfies all of the requirements, and must obtain approval of the plan pursuant to the procedures, set forth in §63.7(c ). Performance tests shall be conducted under such conditions as the Administrator specifies to the owner or operator based on representative
per formance of the affected source for the period being tested. Upon request, the owner or operator shall make available to the Administrator such records as may be necessary to determine the conditions of performance tests.
(b) Initial performance test. Foll owing approval of the site

specific test plan, the owner or operator must demonstrate initial compliance with each applicable emission, equipment, work practice, or operational standard for each affected sourceand emission unit, and report the results in the notification of compliance status report as described in §63.1515(b). The owner or operator of any existing affected source for which an initial performance test is required to demonstrate compliance must conduct this initial performance test no later than the date for compliance established by §63.1501(a). The owner or operator of any new affected source for which an initial performance test is required must conduct this initial performance test within 90 180 days after the date for compliance establis hed by §63.1501(b). Except for the date by which the performance test must be conducted, the owner or operator must conduct each performance test in accordance with the requirements and procedures set forth in §63.7(c). Owners or operators of affected sour ces located at facilities which are area sources are subject only to those performance testing requirements pertaining to D/F. Owners or operators of sweat furnaces meeting the specifications of §63.1505(f)(1) are not required to conduct a performance test
. (1) The performance test must be conducted with scrap containing the highest level of contamination, at the highest rate of production and using the highest reactive fluxing rate while an air pollution control device is operating. Any subsequent performa nce tests for the purposes of establishing new orrevised parametric limits shall be allowed upon pre

- approval from the permitting authorities as specified in the site

specific test plan. These new parametric settings shall be used to demonstrate complianc e for the period being tested. owner or operator must conduct each test while the affected source or emission unit is operating at the highest production level with charge materials representative of the range of materials processed by the unit and, if appl icable, at the highest reactive fluxing rate.
(2) Each performance test for a continuous process must consist of 3 separate runs; pollutant sampling for each run must be conducted for the time period specified in the applicable method or, in the absence of a specific time period in the test method, for a minimum of 3 hours.
(3) Each performance test for a batch process must consist of three separate runs; pollutant sampling for each run must be conducted over the entire process operating cycle.
(4) Where mu ltiple affected sources or emission units are exhausted through a common stack, pollutant sampling for each run must be conducted over a period of time during which all affected sources or emission units complete at least 1 entire process operating cycle o r for 24 hours, whichever is shorter.(5) Initial compliance with an applicable emission limit or standard is demonstrated if the average of three runs conducted during the performance test is less than or equal to the applicable emission limit or standard
. (6) Apply paragraphs (b)(1) through (5) of this section for each pollutant separately if a different production rate, charge material or , if applicable, reactive fluxing rate would apply and thereby result in a higher expected emissions rate for that pol lutant.
(c) Test methods. The owner or operator must use the following methods in appendix A to 40 CFR part 60 to determine compliance with the applicable emission limits or standards:
(1) Method 1 for sample and velocity traverses.
(2) Method 2 for veloci ty and volumetric flow rate.
(3) Method 3 for gas analysis.
(4) Method 4 for moisture content of the stack gas.
(5) Method 5 for the concentration of PM.
(6) Method 9 for visible emission observations.
(7) Method 23 for the concentration of D/F.(8) Method 25A for the concentration of THC, as propane.
(9) Method 26A for the concentration of HCl and HF . Where a lime

- injected fabric filter is used as the control device to comply with the 90 percent reduction standard, the owner or operator must measure the fa bric filter inlet concentration of HCl at a point before lime is introduced to the system.
(d) Alternative methods. The owner or operator may use an alternative test method, subject to approval by the Administrator.
(e) Repeat tests. The owner or operator of new or existing affected sources and emission units located at secondary aluminum production facilities that are major sources must conduct a performance test every 5 years following the initial performance test.
(f) Testing of representative emission u nits. With the prior approval of the permitting authority, an owner or operator may utilize emission rates obtained by testing a particular type of group 1 furnace which is not controlled by any add

- on control device, or by testing an in

- line flux box whic h is not controlled by any add

- on control device, to determine the emission rate for other units of the same type at the same facility. Such emission test results may only be considered tobe representative of other units if all of the following criteria a re satisfied:
(1) The tested emission unit must use feed materials and charge rates which are comparable to the emission units that it represents; (2) The tested emission unit must use the same type of flux materials in the same proportions as the emission units it represents;
(3) The tested emission unit must be operated utilizing the same work practices as the emission units that it represents;
(4) The tested emission unit must be of the same design as the emission units that it represents; and
(5) The te sted emission unit must be tested under the highest load or capacity reasonably expected to occur for any of the emission units that it represents.
(6) All 3 separate runs of a performance test must be conducted on the same unit.
(g) Establishment of monit oring and operating parameter values. The owner or operator of new or existing affected sources and emission units must establish a minimum or maximum operatingparameter value, or an operating parameter range for each parameter to be monitored as required by §63.1510 that ensures compliance with the applicable emission limit or standard. To establish the minimum or maximum value or range, the owner or operator must use the appropriate procedures in this section and submit the information required by §63.15 15(b)(4) in the notification of compliance status report. The owner or operator may use existing data in addition to the results of performance tests to establish operating parameter values for compliance monitoring provided each of the following condition s are met to the satisfaction of the applicable permitting authority:
(1) The complete emission test report(s) used as the basis of the parameter(s) is submitted.
(2) The same test methods and procedures as required by this subpart were used in the test.
( 3) The owner or operator certifies that no design or work practice changes have been made to the source, process, or emission control equipment since the time of the report.
(4) All process and control equipment operating parameters required to be monitore d were monitored as required in this subpart and documented in the test report.(5) If the owner or operator wants to conduct a new performance test and establish different operating parameter values, they must meet the requirements in paragraphs (g)(1) th rough (4) of this section and submit a revised site specific test plan and receive approval in accordance with paragraph (a) of this section.
(h) Testing of commonly

- ducted units within a secondary aluminum processing unit. When group 1 furnaces and/or in

- line fluxers are included in a single existing SAPU or new SAPU, and the emissions from more than one emission unit within that existing SAPU or new SAPU are manifolded to a single control device, compliance for all units within the SAPU is demonstrated if the total measured emissions from all controlled and uncontrolled units in the SAPU do not exceed the emission limits calculated for that SAPU based on the applicable equation in §63.1505(k).
(i) Testing of commonly

- ducted units not within a secondary alu minum processing unit. With the prior approval of the permitting authority, an owner or operator may do combined performance testing of two or more individual affected sources or emission units which are not included in a single existing SAPU or new SAPU, but whose emissions are manifolded to a single control device. Any such performance testing of commonly

- ducted units must satisfy the following basic requirements:(1) All testing must be designed to verify that each affected source or emission unit indivi dually satisfies all emission requirements applicable to that affected source or emission unit;
(2) All emissions of pollutants subject to a standard must be tested at the outlet from each individual affected source or emission unit while operating under t he highest load or capacity reasonably expected to occur, and prior to the point that the emissions are manifolded together with emissions from other affected sources or emission units;
(3) The combined emissions from all affected sources and emission unit s which are manifolded to a single emission control device must be tested at the outlet of the emission control device;
(4) All tests at the outlet of the emission control device must be conducted with all affected sources and emission units whose emission s are manifolded to the control device operating simultaneously under the highest load or capacity reasonably expected to occur; and
(5) For purposes of demonstrating compliance of a commonly

ducted unit with any emission limit for a particular type of pol lutant, the emissions of that pollutant by the individualunit shall be presumed to be controlled by the same percentage as total emissions of that pollutant from all commonly

- ducted units are controlled at the outlet of the emission control device.
[65 FR 15710, Mar. 23, 2000, as amended at 67 FR 59792, Sept. 24, 2002; 67 FR 79817, Dec. 30, 2002]

**§63.1512 Performance test/compliance demonstration requirements**  **and procedures.**
(a) Aluminum scrap shredder. The owner or operator must conduct performance tests to measure PM emissions at the outlet of the control system. If visible emission observations is the selected monitoring option, the owner or operator must record visible emission observations from each exhaust stack for all consecutive 6

- minute periods du ring the PM emission test according to the requirements of Method 9 in appendix A to 40 CFR part 60.
(b) Thermal chip dryer. The owner or operator must conduct a performance test to measure THC and D/F emissions at the outlet of the control device while th e unit processes only unpainted aluminum chips.(c) Scrap dryer/delacquering kiln/decoating kiln. The owner or operator must conduct performance tests to measure emissions of THC, D/F, HCl, and PM at the outlet of the control device.
(1) If the scrap dryer /delacquering kiln/decoating kiln is subject to the alternative emission limits in §63.1505(e), the average afterburner operating temperature in each 3

- hour block period must be maintained at or above 760 °C (1400 °F) for the
test.
(2) The owner or operato r of a scrap dryer/delacquering kiln/decoating kiln subject to the alternative limits in §63.1505(e) must submit a written certification in the notification of compliance status report containing the information required by §63.1515(b)(7).
(d) Group 1 furn ace with add

- on air pollution control devices. (1) The owner or operator of a group 1 furnace that processes scrap other than clean charge materials with emissions controlled by a lime

- injected fabric filter must conduct performance tests to measure emissi ons of PM and D/F at the outlet of the control device and emissions of HCl at the outlet (for the emission limit) or the inlet and the outlet (for the percent reduction standard).(2) The owner or operator of a group 1 furnace that processes only clean cha rge materials with emissions controlled by a lime

injected fabric filter must conduct performance tests to measure emissions of PM at the outlet of the control device and emissions of HCl at the outlet (for the emission limit) or the inlet and the outlet ( for the percent reduction standard).
(3) The owner or operator may choose to determine the rate of reactive flux addition to the group 1 furnace and assume, for the purposes of demonstrating compliance with the SAPU emission limit, that all reactive flux a dded to the group 1 furnace is emitted. Under these circumstances, the owner or operator is not required to conduct an emission test for HCl.
(4) The owner or operator of a sidewell group 1 furnace that conducts reactive fluxing (except for cover flux) in the hearth, or that conducts reactive fluxing in the sidewell at times when the level of molten metal falls below the top of the passage between the sidewell and the hearth, must conduct the performance tests required by paragraph (d)(1) or (d)(2) of this section, to measure emissions from both the sidewell and the hearth.
(e) Group 1 furnace (including melting holding furnaces) without add

- on air pollution control devices. In the site

- specificmonitoring plan required by §63.1510(o), the owner or operator of a group 1 furnace (including a melting/holding furnaces) without add

- on air pollution control devices must include data and information demonstrating compliance with the applicable emission limits.
(1) If the group 1 furnace processes other than clean c harge material, the owner or operator must conduct emission tests to measure emissions of PM, HCl, HF and D/F at the furnace exhaust outlet.
(2) If the group 1 furnace processes only clean charge, the owner or operator must conduct emission tests to simult aneously measure emissions of PM and HCl and HF. at the furnace exhaust outlet
. A D/F test is not required. Each test must be conducted while the group 1 furnace (including a melting/holding furnace) processes only clean charge.
(3) The owner or operator may choose to determine the rate of reactive flux addition to the group 1 furnace and assume, for the purposes of demonstrating compliance with the SAPU emission limit, that all reactive flux added to the group 1 furnace is emitted. Under these circumstanc es, the owner or operator is not required to conduct an emission test for HCl or HF .(4) When testing an existing uncontrolled furnace, the owner or operator must comply with the requirements of either paragraph (e)(4)(i) or paragraph (e)(4)(ii) of this se ction at the next required performance test. (i) Install hooding that meets ACGIH Guidelines, or (ii) Assume a 67 percent capture efficiency for the furnace exhaust (i.e., multiply emissions measured at the furnace exhaust outlet by 1.5) if hooding does no t meet ACGIH Guidelines. If the source fails to demonstrate compliance using the 67 percent capture efficiency assumption, the owner or operator must re

- test with a hood that meets the ACGIH Guidelines within 90 days, or petition the permitting authority t hat such hoods are impracticable and propose testing procedures that will minimize fugitive emissions. (5) When testing a new uncontrolled furnace the owner or operator must either: (i) Install hooding that meets ACGIH Guidelines, or (ii) Petition the pe rmitting authority that such hoods are impracticable and propose testing procedures that will minimize fugitive emissions.(f) Sweat furnace. Except as provided in §63.1505(f)(1), the owner or operator must measure emissions of D/F from each sweat furnace at the outlet of the control device.
(g) Dross

- only furnace. The owner or operator must conduct a performance test to measure emissions of PM from each dross

- only furnace at the outlet of each control device while the unit processes only dross and salt flu x as the sole feedstock.
(h) In

- line fluxer. (1) The owner or operator of an in

- line fluxer that uses reactive flux materials must conduct a performance test to measure emissions of HCl and PM or otherwise demonstrate compliance in accordance with paragrap h (h)(2) of this section. If the in

- line fluxer is equipped with an add

- on control device, the emissions must be measured at the outlet of the control device.
(2) The owner or operator may choose to limit the rate at which reactive chlorine flux is added t o an in

- line fluxer and assume, for the purposes of demonstrating compliance with the SAPU emission limit, that all chlorine in the reactive flux added to the in

- line fluxer is emitted as HCl. Under these circumstances, the owner or operator is not require d to conduct an emission test for HCl. If the owner or operator of any in

- line flux box which has no ventilation ductwork manifolded to any outlet oremission control device chooses to demonstrate compliance with the emission limit for HCl by limiting use of reactive chlorine flux and assuming that all chlorine in the flux is emitted as HCl, compliance with the HCl limit shall also constitute compliance with the emission limit for PM, and no separate emission test for PM is required. In this case, the owner or operator of the unvented in

- line flux box must utilize the maximum permissible PM emission rate for the in

- line flux boxes when determining the total emissions for any SAPU which includes the flux box.
(i) Rotary dross cooler. The owner or operator mus t conduct a performance test to measure PM emissions at the outlet of the control device.
(j) Secondary aluminum processing unit. The owner or operator must conduct performance tests as described in paragraphs (j)(1) through (3) of this section. The result s of the performance tests are used to establish emission rates in lb/ton of feed/charge for PM and HCl and HF and μg TEQ/Mg of feed/charge for D/F emissions from each emission unit. These emission rates are used for compliance monitoring in the calculatio n of the 3

- day, 24

- hour rolling average emission rates using the equation in §63.1510(t). A performance test is required for:(1) Each group 1 furnace processing only clean charge to measure emissions of PM and either:
(i) Emissions of HCl or HF (for the e mission limit s ); or
(ii) The mass flow rate of HCl at the inlet to and outlet from the control device (for the percent reduction standard).
(2) Each group 1 furnace that processes scrap other than clean charge to measure emissions of PM and D/F and either:
(i) Emissions of HCl or HF (for the emission limit s ); or
(ii) The mass flow rate of HCl at the inlet to and outlet from the control device (for the percent reduction standard).
(3) Each in

- line fluxer to measure emissions of PM and HCl.
(k) Feed/charge we ight measurement. During the emission test(s) conducted to determine compliance with emission limits in a kg/Mg (lb/ton) format, the owner or operator of an affected source or emission unit, subject to an emission limit in a kg/Mg (lb/ton) of feed/charge f ormat, must measure (or otherwise determine) and record the total weight of feed/charge to the affected source or emission unit for each of the three test runs and calculate and record the total weight. An owner or operator that chooses to demonstrate comp liance on the basis of thealuminum production weight must measure the weight of aluminum produced by the emission unit or affected source instead of the feed/charge weight.
(l) Continuous opacity monitoring system. The owner or operator of an affected sou rce or emission unit using a continuous opacity monitoring system must conduct a performance evaluation to demonstrate compliance with Performance Specification 1 in appendix B to 40 CFR part 60. Following the performance evaluation, the owner or operator must measure and record the opacity of emissions from each exhaust stack for all consecutive 6

- minute periods during the PM emission test.
(m) Afterburner. These requirements apply to the owner or operator of an affected source using an afterburner to comp ly with the requirements of this subpart.
(1) Prior to the initial performance test, the owner or operator must conduct a performance evaluation for the temperature monitoring device according to the requirements of §63.8.
(2) The owner or operator must us e these procedures to establish an operating parameter value or range for the afterburner operating temperature.(i) Continuously measure and record the operating temperature of each afterburner every 15 minutes during the THC and D/F performance tests;
(i i) Determine and record the 15

- minute block average temperatures for the three test runs; and
(iii) Determine and record the 3

- hour block average temperature measurements for the 3 test runs.
(n) Inlet gas temperature. The owner or operator of a scrap drye r/delacquering kiln/decoating kiln or a group 1 furnace using a lime

- injected fabric filter must use these procedures to establish an operating parameter value or range for the inlet gas temperature. (1) Continuously measure and record the temperature at t he inlet to the lime

- injected fabric filter every 15 minutes during the HCl and D/F performance tests;
(2) Determine and record the 15

- minute block average temperatures for the 3 test runs; and
(3) Determine and record the 3

- hour block average of the

recor ded temperature measurements for the 3 test runs.(o) Flux injection rate. The owner or operator must use these procedures to establish an operating parameter value or range for the total reactive chlorine flux injection rate.
(1) Continuously measure and record the weight of gaseous or liquid reactive flux injected for each 15 minute period during the HCl , HF and D/F tests, determine and record the 15

- minute block average weights, and calculate and record the total weight of the gaseous or liquid reactive flux for the 3 test runs;
(2) Record the identity, composition, and total weight of each addition of solid reactive flux for the 3 test runs;
(3) Determine the total reactive chlorine flux injection rate by adding the recorded measurement of the total weig ht of chlorine in the gaseous or liquid reactive flux injected and the total weight of chlorine in the solid reactive flux using Equation 5:

Where,

W t = Total chlo rine usage, by weight;

F 1 = Fraction of gaseous or liquid flux that is chlorine;

W 1 = Weight of reactive flux gas injected;F 2 = Fraction of solid reactive chloride flux that is chlorine (
e.g., F = 0.75 for magnesium chloride; and

W 2 = Weight of solid reactiv e flux;
(4) Divide the weight of total chlorine usage (W t ) for the 3 test runs by the recorded measurement of the total weight of feed for the 3 test runs; and
(5) If a solid reactive flux other than magnesium chloride is used, the owner or operator must d erive the appropriate proportion factor subject to approval by the applicable permitting authority.
(p) Lime injection. The owner or operator of an affected source or emission unit using a lime

- injected fabric filter system must use these procedures during the HCl and D/F tests to establish an operating parameter value for the feeder setting for each operating cycle or time period used in the performance test.
(1) For continuous lime injection systems, ensure that lime in the feed hopper or silo is free

- flo wing at all times; and
(2) Record the feeder setting and lime injection rate for the 3 test runs. If the feed rate setting and lime injection rates varies var y during the runs, determine and record the average feed rate and lime injection rate from the 3 r uns.(q) Bag leak detection system. The owner or operator of an affected source or emission unit using a bag leak detection system must submit the information described in §63.1515(b)(6) as part of the notification of compliance status report to document c onformance with the specifications and requirements in §63.1510(f).
(r) Labeling. The owner or operator of each scrap dryer/delacquering kiln/decoating kiln, group 1 furnace, group 2 furnace and in

- line fluxer must submit the information described in §63.1 515(b)(3) as part of the notification of compliance status report to document conformance with the operational standard in §63.1506(b).
(s) Capture/collection system. The owner or operator of a new or existing affected source or emission unit with an add

- o n control device must submit the information described in §63.1515(b)(2) as part of the notification of compliance status report to document conformance with the operational standard in §63.1506(c).
[65 FR 15710, Mar. 23, 2000, as amended at 67 FR 79817, D ec. 30, 2002; 69 FR 53984, Sept. 3, 2004]

**§63.1513 Equations for determining compliance.** (a) THC emission limit. Use Equation 6 to determine compliance with an emission limit for THC:

Where,
E = Emission rate of measured pollutant, kg/Mg (lb/ton) of feed;
C = Measured volume fraction of pollutant, ppmv;
MW = Molecular weight of measured pollutant, g/g

- mole (lb/lb

mole): THC (as propane) = 44.11;
Q = Volumetric flow rate of exhaust gases, dscm/hr (dscf/hr);

K 1 = Conversion factor, 1 kg/1,000 g (1 lb/lb);

K 2 = Conversion factor, 1,000 L/m 3 (1 ft 3 /ft 3 );

M v = Molar volume, 24.45 L/g

- mole (385.3 ft 3 /lb

- mole); and
P = Production rate, Mg/hr (ton/hr).
(b) PM, HCl , HF and D /F emission limits. (1) Use Equation 7 of this section to determine compliance with an emission limit for
PM , or HCl or HF :Where:

E = Emission rate of PM , or HCl or HF , kg/Mg (lb/ton) of feed;

C = Concentration of PM , or HCl or HF , g/dscm (gr/dscf);
Q = Volumetric flow rate of exhaust gases, dscm/hr (dscf/hr);

K 1 = Conversion factor, 1 kg/1,000 g (1 lb/7,000 gr); and
P = Production rate, Mg/hr (ton/hr).
(2) Use Equ ation 7A of this section to determine compliance with an emission limit for D/F:

Where:
E = Emission rate of D/F, μg/Mg (gr/ton) of feed;
C = Concentration of D/F , μg/dscm (gr/dscf);
Q = Volumetric flow rate of exhaust gases, dscm/hr (dscf/hr); and
P = Production rate, Mg/hr (ton/hr).(c) HCl percent reduction standard. Use Equation 8 to determine compliance with an HCl percent reduction standard:

Where,

%R = Percent reduction of the control device;

L i = Inlet loading of pollutant, kg/Mg (lb/ton); and

L o = Outlet loading of pollutant, kg/Mg (lb/ton).
(d) Conversion of D/F mea surements to TEQ units. To convert D/F measurements to TEQ units, the owner or operator must use the procedures and equations in “Interim Procedures for Estimating Risks Associated with Exposures to Mixtures of Chlorinated Dibenzo

- p - Dioxins and

- Dibenzofur ans (CDDs and CDFs) and 1989 Update” (EPA

– 625/3

– 89

– 016), incorporated by reference in §63.1502 of this subpart, available from the National Technical Information Service (NTIS), 5285 Port Royal Road, Springfield, Virginia, NTIS no. PB 90

– 145756.
(e) Second ary aluminum processing unit. Use the procedures in paragraphs (e)(1), (2), and (3) or the procedure in paragraph(e)(4) of this section to determine compliance with emission limits for a secondary aluminum processing unit.
(1) Use Equation 9 to compute th e mass - weighted PM emissions for a secondary aluminum processing unit. Compliance is achieved if the mass

- weighted emissions for the secondary aluminum processing unit (E cPM ) is less than or equal to the emission limit for the secondary aluminum processing unit (L cPM ) calculated using Equation 1 in §63.1505(k).

Where,

E cPM = The mass

- weighted PM emissions for the secondary aluminum processing unit;

E tiPM = Measured P M emissions for individual emission unit i;

T ti = The average feed rate for individual emission unit i during the operating cycle or performance test period , or the sum of the average feed rates for all emission units in the group of

co - controlled emission unit I ; andn=The number of emission units , and groups of co

- controlled emissions units in the secondary aluminum processing unit.
(2) Use Equation 10 to compute the aluminum mass

- weighted HCl or HF emissions for the secondary aluminum processing unit. Com pliance is achieved if the mass

- weighted emissions for the secondary aluminum processing unit (E cHCl /HF ) is less than or equal to the emission limit for the secondary aluminum processing unit (L cHCl /HF ) calculated using Equation 2 in §63.1505(k).



## ( ) ( ) ) 10 (Eq. T T E n
1 i ti n
1 i ti / cHCl/HF 

# ∑ ∑

=

= ×

= HF tiHCl E

Where,

E cHCl /HF = The mass

- weighted HCl or HF emissions for the secondary aluminum processing unit; and

E tiHCl /HF = Measured HCl or HF emissions for i ndividual emission unit i.(3) Use Equation 11 to compute the aluminum mass

- weighted D/F emissions for the secondary aluminum processing unit. Compliance is achieved if the mass

- weighted emissions for the secondary aluminum processing unit is less than or equal to the emission limit for the secondary aluminum processing unit (L cD/F ) calculated using Equation 3 in §63.1505(k).

Where,

E cD/F = The mass

- weighted D/F emi ssions for the secondary aluminum processing unit; and

E tiD/F = Measured D/F emissions for individual emission unit , or group of co

- controlled emission units i.
(4) As an alternative to using the equations in paragraphs (e)(1), (2), and (3) of this section, the owner or operator may demonstrate compliance for a secondary aluminum processing unit by demonstrating that each existing group 1 furnace is in compliance with the emission limits for a new group 1 furnace in §63.1505(i) and that each existing in

- line fluxer is incompliance with the emission limits for a new in

- line fluxer in §63.1505(j).
[65 FR 15710, Mar. 23, 2000, as amended at 69 FR 53984, Sept. 3, 2004]
**§63.1514 Change of Furnace Classification.** The requirements of this section are in addition to the other requirement of this subpart that apply to group 1 and group 2 furnaces.
(a) Changing from a group 1 controlled furnace processing other than clean charge to group 1 uncontrolled furnace processing other than clean charge
. An owner or operator wishing to change operating modes must conduct performance tests to demonstrate to the regulatory authority that compliance can be achieved under both modes. Operating parameters relevant to each mode of operation must be established during the performance test. (1) Operators of major sources must conduct performance tests for PM, HCl and D/F, according to the procedures in §63.1512(d) with the capture system and control device operating normally. Performance tests must be repeated at least once every 5 y ears to demonstrate compliance for each operating mode.(i) The performance tests must be conducted with the scrap containing the highest level of contamination expected to be processed, at the highest throughput expected and using the highest rate of reac tive flux injection expected to be processed in controlled mode. (ii)Parameters for capture, flux rate, and lime injection must be established during these tests. (iii) The emission factors for this mode of operation, for use in the demonstration of compli ance with the emission limits for SAPUs specified in §63.1505(k) must be determined. (2) Operators of major sources must conduct additional performance tests for PM, HCl, HF and D/F, according to the procedures in §63.1512(e) without operating a control de vice. Performance tests must be repeated at least once every 5 years to demonstrate compliance with each operating mode. (i) Testing under this paragraph may be conducted at any time after the furnace has completed 1 or more charge to tap cycles, or 24 ope rating hours with scrap of the highest level of contamination expected to be processed in uncontrolled mode. (ii) Testing under this paragraph must be conducted with furnace emissions captured in accordance with the provisions of §63.1512(e)(4) and directe d to the stack or vent tested.(iii) Parameters for capture and flux rate must be established during these tests. (iv) The emission factors for this mode of operation, for use in the demonstration of compliance with the emission limits for SAPUs specified in §63.1505(k) must be determined. (3) Operators of area sources must conduct performance tests for D/F, according to the procedures in §63.1512(d) with the capture system and control device operating normally. (i) The performance tests must be conducted w ith the scrap containing the highest level of contamination expected to be processed, at the highest throughput expected to be processes and using the highest rate of reactive flux expected to be injected in controlled mode. (ii) Parameters for capture, fl ux rate, and lime injection must be established during these tests. (iii) The emission factors for this mode of operation, for use in the demonstration of compliance with the emission limits for SAPUs specified in §63.1505(k) must be determined. (4) Operat ors of area sources must conduct performance tests for D/F, according to the procedures in §63.1512(e) without operating a control device.(i) Testing under this paragraph may be conducted at any time after the furnace has completed 1 or more charge to tap cycles, or 24 operating hours with scrap of the highest level of contamination expected to be processed in uncontrolled mode. (ii) Testing under this paragraph must be conducted with furnace emissions captured in accordance with the provisions of §63.1506 (c) and directed to the stack or vent tested. (iii) Parameters for capture and flux rate must be established during these tests. In addition, the number of cycles of furnace operation with scrap of the highest level of contamination expected to be processe d in uncontrolled mode that elapsed prior to the performance test(s) conducted in uncontrolled mode is established as a parameter. (iv) The D/F emission factor for this mode of operation, for use in the demonstration of compliance with the emission limits for SAPUs specified in §63.1505(k) must be determined. (5) To change modes of operation from uncontrolled to controlled, the owner or operator must, before charging scrap to the furnace that exceeds the contaminant level established for uncontrolled mode, (i) Change the label on the furnace to reflect controlled operation,(ii) Direct the furnace emissions to the control device, and (iii) Begin lime addition to the control device at the rate established for controlled mode. (6) To change modes of operation from controlled to uncontrolled, the owner or operator must, before turning off or bypassing the control device, (i) Change the label on the furnace to reflect controlled operation, (ii) Charge scrap with a level of contamination no greater than that used in the performance test for uncontrolled furnaces for the number of charge to tap cycles that elapsed with scrap of a contamination level no higher than that used in the uncontrolled mode performance test(s), and (iii) Decrease the flux addition rate to n o higher than the flux addition rate used in the uncontrolled mode performance test. (7) In addition to the recordkeeping requirements of §63.1517, the owner or operator must maintain records of the nature of each mode change (controlled to uncontrolled, o r uncontrolled to controlled), the time the change is initiated, and the time the exhaust gas is diverted from control device to bypass or bypass to control device.(b) Changing from a group 1 controlled furnace processing other than clean charge to a gro up 1 uncontrolled furnace processing clean charge . An owner or operator wishing to operate under controlled mode with other than clean charge and uncontrolled mode with clean charge must conduct performance tests to demonstrate to the delegated regulatory authority that compliance can be achieved in both modes. Operating parameters relevant to each mode of operation must be established during the performance test. (1) Operators of major sources must conduct performance tests for PM, HCl and D/F, according to the procedures in §63.1512 with the capture system and control device operating normally. Performance tests must be repeated at least once every 5 years to demonstrate compliance for each operating mode. (i) The performance tests must be conducted with the scrap containing the highest level of contamination expected to be processed, at the highest throughput expected to be processed and using the highest rate of reactive flux injection expected in controlled mode. (ii) Parameters for capture, flux rate, and lime injection must be established during these tests.(iii) The emission factors for this mode of operation, for use in the demonstration of compliance with the emission limits for SAPUs specified in §63.1505(k) must be determined. (2) Operators of m ajor sources must conduct performance tests for PM, HCl and D/F, according to the procedures in §63.1512 without operating a control device. Performance tests must be repeated at least once every 5 years to demonstrate compliance for each operating mode.
( i) Testing under this paragraph may be conducted at any time after the furnace has completed 1 or more charge to tap cycles with clean charge. (ii) Testing under this paragraph must be conducted with furnace emissions captured in accordance with the provis ions of §63.1506(c) and directed to the stack or vent tested. (iii) Parameters for capture and flux rate must be established during these tests. (iv) Emissions of D/F during this test must not exceed 1.5 μg TEQ/Mg of feed/charge processed, or this mode of operation is not allowed. (v) The emission factors for PM, HCl and HF for this mode of operation, for use in the demonstration of compliance with theemission limits for SAPUs specified in §63.1505(k) must be determined. (3) Operators of area sources must conduct additional performance tests for D/F, according to the procedures in §63.1512 with the capture system and control device operating normally. (i) The performance tests must be conducted with the scrap containing the highest level of contamination ex pected to be processed, at the highest throughput expected to be processed and using the highest rate of reactive flux injection expected in controlled mode. (ii) Parameters for capture, flux rate, and lime injection must be established during these tests. (iii) The D/F emission factor for this mode of operation, for use in the demonstration of compliance with the emission limits for SAPUs specified in §63.1505(k) must be determined. (4) Operators of area sources must conduct additional performance tests fo r D/F, according to the procedures in §63.1512(e) without operating a control device. (i) Testing may be conducted at any time after the furnace has completed 1 or more charge to tap cycles with scrap of the highest level of contamination expected to be pr ocessed inuncontrolled mode at the highest throughput expected to be processed in uncontrolled mode. (ii) Testing under this paragraph must be conducted with furnace emissions captured in accordance with the provisions of §63.1506(c) and directed to the s tack or vent tested. (iii) Parameters for flux rate must be established during these tests. In addition the number of cycles of furnace operation with scrap of the highest level of contamination expected to be processed in uncontrolled mode that elapsed pr ior to the performance test(s) conducted in uncontrolled mode is established as a parameter. (iv) The D/F emission factor for this mode of operation, for use in the demonstration of compliance with the emission limits for SAPUs specified in §63.1505(k) mus t be determined. (5) To change modes of operation from uncontrolled to controlled, the owner or operator must, before charging scrap to the furnace that exceeds the contaminant level established for uncontrolled mode, (i) Change the label on the furnace to reflect controlled operation, (ii)Direct the furnace emissions to the control device, and(iii) Begin lime addition to the control device at the rate established for controlled mode. (6) To change modes of operation from controlled to uncontrolled, the ow ner or operator must, before turning off or bypassing the control device, (i) Change the label on the furnace to reflect controlled operation, (ii) Charge clean charge for the number of charge to tap cycles that elapsed before the uncontrolled mode perfor mance test was conducted, and (iii) Decrease the flux addition rate to no higher than the flux addition rate used in the uncontrolled mode performance test. (7) In addition to the recordkeeping requirements of §63.1517, the owner or operator must maintain records of the nature of each mode change (controlled to uncontrolled, or uncontrolled to controlled), the time the furnace operating mode change is initiated, and the time the exhaust gas is diverted from control device to bypass or bypass to control devi ce. (c) Changing from a group 1 controlled or uncontrolled furnace to a group 2 furnace . An owner or operator wishing to change operating modes must conduct additional performance tests to demonstrate to the delegated regulatory authority thatcompliance can be achieved under group 1 mode and establish the number of cycles of operation with clean charge and no reactive flux addition necessary to elapse before changing to group 2 mode. Operating parameters relevant to group 1 operation must be established during the performance test. (1) Operators of major sources must conduct additional performance tests for PM, HCl, HF and D/F, according to the procedures in §63.1512. Controlled group 1 furnaces must conduct performance tests with the capture system and control device operating normally. Performance tests must be repeated at least once every 5 years to demonstrate compliance for each operating mode. (i) The performance tests must be conducted with scrap containing the highest level of contamination expec ted to be processed, at the highest throughput expected to be processed and using the highest rate of reactive flux expected to be injected in controlled mode. (ii) Parameters for throughput, capture, flux rate, and lime injection must be established durin g these tests. (iii) The emission factors for this mode of operation, for use in the demonstration of compliance with the emission limits for SAPUs specified in §63.1505(k) must be determined.(2) While in compliance with the operating requirements of §63. 1506(o) for group 2 furnaces, operators of major sources must conduct additional performance tests for PM, HCl, HF and D/F, according to the procedures in §63.1512(e) without operating a control device. Performance tests must be repeated at least once ever y 5 years to demonstrate compliance for each operating mode. (i) Testing under this paragraph may be conducted at any time after the furnace has completed 1 or more charge

- to

- tap cycles, or 24 operating hours with clean charge, and without reactive flux ad dition. (ii) Testing under this paragraph must be conducted with furnace emissions captured in accordance with the provisions of §63.1506(c) and directed to the stack or vent tested. (iii) Owners or operators must demonstrate that emissions are no greater than: (A) 1.5 μg D/F (TEQ) per ton of feed/charge, (B) 0.04 lb HCl or HF per ton of feed/charge, and (C) 0.04 lb PM per ton of feed/charge. (iv) The number of charge

- to

- tap cycles, or operating hours elapsed before the group 2 furnace performance tests wer econducted is established as an operating parameter to be met before changing to group 2 mode. (3) Operators of area sources must conduct an additional performance test for D/F, according to the procedures in §63.1512. Controlled group 1 furnaces must con duct performance tests with the capture system and control device operating normally. (i) The performance test must be conducted with the scrap containing the highest level of contamination expected to be processed, at the highest throughput expected to be processed and using the highest rate of reactive flux expected to be injected in group 1 mode. (ii) Parameters for throughput, flux rate, and lime injection must be established during these tests. (iii) If the furnace is equipped with a control device
par ameter(s) for capture must be established. (iv) The D/F emission factor for this mode of operation, for use in the demonstration of compliance with the emission limits for SAPUs specified in §63.1505(k) must be determined. (4) While in compliance with the operating standards of §63.1506(o) for group 2 furnaces, operators of area sources mustconduct an additional performance test for D/F, according to the procedures in §63.1512(e), without operating a control device. (i) Testing under this paragraph may be conducted at any time after the furnace has completed 1 or more charge

- to

- tap cycles, or 24 operating hours with clean charge, and without reactive flux addition. (ii) Testing under this paragraph must be conducted with furnace emissions captured in accord ance with the provisions of §63.1506(c) and directed to the stack or vent tested. (iii) Owners or operators must demonstrate that emissions are no greater than 1.5 μg D/F (TEQ) per ton of feed/charge. (iv) The number of charge

- to

- tap cycles, or operating h ours elapsed before the group 2 furnace performance tests were conducted is established as an operating parameter to be met before changing to group 2 mode. (5) To change modes of operation from a group 1 furnace to a group 2 furnace, the owner or operator must (i) discontinue addition of other than clean charge; (ii) discontinue addition of reactive flux; (iii) change the label on the furnace to reflect group 2 operation;(iv) and if the furnace is equipped with a control device, allow the number of cycle s of operation established in paragraph (c) of this section to elapse before turning off the control device or diverting emissions from the control device. In addition control device parameters related to lime addition, capture, and inlet temperature must be maintained during this period. (6) To change mode of operation from a group 2 furnace to group 1 furnace, the owner or operator must change the label to reflect group 1 operation. If a control device is required for group 1 operation, the owner or ope rator must direct the emissions to the control device and maintain control device parameters related to lime addition, capture, and inlet temperature. (d) Changing from a group 1 controlled or uncontrolled furnace to group 2 furnace, for tilting reverberat ory furnaces capable of completely removing furnace contents between batches. An owner or operator of a tilting reverberatory furnace capable of completely removing furnace contents between batches, wishing to change operating modes, must conduct additiona l performance tests to demonstrate that compliance can be achieved under group 1 mode. Operating parameters relevant to group 1 operation must be established during the performance test.(1) Operators of major sources must conduct additional performance tests for PM, HCl, HF and D/F, according to the procedures in §63.1512. Controlled group 1 furnaces must conduct performance tests with the capture system and control device operating normally. The performance tests must be conducted with the scrap contain ing the highest level of contamination expected to be processed, at the highest throughput expected to be processed and using the highest rate of reactive flux expected to be injected in controlled mode. Performance tests must be repeated at least once eve ry 5 years to demonstrate compliance for each operating mode. (i) Parameters for throughput, capture, flux rate, and lime injection must be established during these tests. (ii) The emission factors for this mode of operation, for use in the demonstration o f compliance with the emission limits for SAPUs specified in §63.1505(k) must be determined. (2) Operators of area sources must conduct an additional performance test for D/F, according to the procedures in §63.1512. Operators of controlled group 1 furnace s must conduct performance tests with the capture system and control device operating normally. Performance tests must be repeated at least once every 5 years to demonstrate compliance for each operating mode.(i) The performance test must be conducted wi th the scrap containing the highest level of contamination expected to be processed, at the highest throughput expected to be processed and using the highest rate of reactive flux injection expected in group 1 mode. (ii) Parameters for throughput, flux rat e, and lime injection must be established during these tests. (iii) If the furnace is equipped with a control device parameter(s) for capture must be established. (iv) The D/F emission factor for this mode of operation, for use in the demonstration of comp liance with the emission limits for SAPUs specified in §63.1505(k) must be determined. (3) To change modes from group 1 to group 2 the operator must: (i) Completely remove all aluminum from the furnace; (ii) Change the furnace label; (iii) Use only clean c harge; and (iv) Use no reactive flux; (4) To change modes from group 2 to group 1 the owner or operator must, before charging other than clean charge and before adding reactive flux to the furnace;(i) Change the label on the furnace to reflect group 1
ope ration, (ii) Direct the furnace emissions to the control device, if any, and, (iii) Begin lime addition to the control device, if any. (5) In addition to the recordkeeping requirements of §63.1517, the owner or operator must maintain records of the nature of each mode change (group 1 to group 2, or group 2 to group 1), the time the change is initiated, and, if the furnace is equipped with a control device, the time the exhaust gas is diverted from control device to bypass or bypass to control device.
(e) F requency of changing furnace operating mode. Changing furnace operating mode and reversion to the previous mode, as provided in paragraphs (a) through (d) of this section may not be done more frequently than once every 6 months, except that controlled furn aces may change operating modes (and revert to prechange operating mode) without restriction on frequency, when the air pollution control device must be shut down for planned maintenance.

**§63.1514 [Reserved]** **Notifications, Reports, And Records**

**§63.1515 Not**  **ifications.**
(a) Initial notifications. The owner or operator must submit initial notifications to the applicable permitting authority as described in paragraphs (a)(1) through (7) of this section.
(1) As required by §63.9(b)(1), the owner or operator must provide notification for an area source that subsequently increases its emissions such that the source is a major source subject to the standard.
(2) As required by §63.9(b)(3), the owner or operator of a new or reconstructed affected source, or a source t hat has been reconstructed such that it is an affected source, that has an initial startup after the effective date of this subpart and for which an application for approval of construction or reconstruction is not required under §63.5(d), must provide not ification that the source is subject to the standard.
(3) As required by §63.9(b)(4), the owner or operator of a new or reconstructed major affected source that has an initial startup after the effective date of this subpart and for which an application fo r approval of construction or reconstruction is required by §63.5(d) must provide the following notifications:(i) Intention to construct a new major affected source, reconstruct a major source, or reconstruct a major source such that the source becomes a major affected source;
(ii) Date when construction or reconstruction was commenced (submitted simultaneously with the application for approval of construction or reconstruction if construction or reconstruction was commenced before the effective date of th is subpart, or no later than 30 days after the date construction or reconstruction commenced if construction or reconstruction commenced after the effective date of this subpart);
(iii) Anticipated date of startup; and
(iv) Actual date of startup.
(4) As r equired by §63.9(b)(5), after the effective date of this subpart, an owner or operator who intends to construct a new affected source or reconstruct an affected source subject to this subpart, or reconstruct a source such that it becomes an affected source subject to this subpart, must provide notification of the intended construction or reconstruction. The notification must include all the information required for an application for approval of construction or reconstruction as required by §63.5(d). For ma jor sources, the application forapproval of construction or reconstruction may be used to fulfill these requirements.
(i) The application must be submitted as soon as practicable before the construction or reconstruction is planned to commence (but no soo ner than the effective date) if the construction or reconstruction commences after the effective date of this subpart; or
(ii) The application must be submitted as soon as practicable before startup but no later than 90 days after the effective date of thi s subpart if the construction or reconstruction had commenced and initial startup had not occurred before the effective date.
(5) As required by §63.9(d), the owner or operator must provide notification of any special compliance obligations for a new

sourc e. (6) As required by §63.9(e) and (f), the owner or operator must provide notification of the anticipated date for conducting performance tests and visible emission observations. The owner or operator must notify the Administrator of the intent to conduct a performance test at least 60 days before the performance test is scheduled; notification of opacity or visible emission observations for a performance test must beprovided at least 30 days before the observations are scheduled to take place.
(7) As req uired by §63.9(g), the owner or operator must provide additional notifications for sources with continuous emission monitoring systems or continuous opacity monitoring systems.
(b) Notification of compliance status report. Each owner or operator of an exis ting affected source must submit a notification of compliance status report within 60 days after the compliance date established by §63.1501(a). Each owner or operator of a new affected source must submit a notification of compliance status report within 9 0 days after conducting the initial performance test required by §63.1511(b), or within 90 days after the compliance date established by §63.1501(b) if no initial performance test is required. The notification must be signed by the responsible official who must certify its accuracy. A complete notification of compliance status report must include the information specified in paragraphs (a)(1) through (10) of this section. The required information may be submitted in an operating permit application, in an am endment to an operating permit application, in a separate submittal, or in any combination. In a State with an approved operating permit program where delegation of authority under section 112(l) of the CAA has not been requested or approved, the owner oroperator must provide duplicate notification to the applicable Regional Administrator. If an owner or operator submits the information specified in this section at different times or in different submittals, later submittals may refer to earlier submittals instead of duplicating and resubmitting the information previously submitted. A complete notification of compliance status report must include:
(1) All information required in §63.9(h). The owner or operator must provide a complete performance test report for each affected source and emission unit for which a performance test is required. A complete performance test report includes all data, associated measurements, and calculations (including visible emission and opacity tests).
(2) The approved site

- spec ific test plan and performance evaluation test results for each continuous monitoring system (including a continuous emission or opacity monitoring system).
(3) Unit labeling as described in §63.1506(b), including process type or furnace classification and operating requirements.
(4) The compliant operating parameter value or range established for each affected source or emission unit with supporting documentation and a description of the procedure used to establish the value ( e.g., lime injection rate, to tal reactivechlorine flux injection rate, afterburner operating temperature, fabric filter inlet temperature), including the operating cycle or time period used in the performance test.
(5) Design information and analysis, with supporting documentation, d emonstrating conformance with the requirements for capture/collection systems in §63.1506(c).
(6) If applicable, analysis and supporting documentation demonstrating conformance with EPA guidance and specifications for bag leak detection systems in §63.1510 (f).
(7) Manufacturer's specification or analysis documenting the design residence time of no less than 1 second for each afterburner used to control emissions from a scrap dryer/delacquering kiln/decoating kiln subject to alternative emission standards in §63.1505(e).
(8) Manufacturer's specification or analysis documenting the design residence time of no less than 0.8 seconds and design operating temperature of no less than 1,600 °F for each afterburner used to control emissions from a sweat furnace that is not subject to a performance test.(9) The OM&M plan (including site

- specific monitoring plan for each group 1 furnace with no add

- on air pollution control device).
(10) Startup, shutdown, and malfunction plan, with revisions.
[65 FR 15710, Mar. 23, 200 0, as amended at 67 FR 59793, Sept. 24, 2002; 67 FR 79818, Dec. 30, 2002]

**§63.1516 Reports.** 
(a) [Reserved] Startup, shutdown, and malfunction plan/reports. The owner or operator must develop a written plan as described in §63.6(e)(3) that contains specifi c procedures to be followed for operating and maintaining the source during periods of startup, shutdown, and malfunction, and a program of corrective action for malfunctioning process and air pollution control equipment used to comply with the standard. T he owner or operator shall also keep records of each event as required by §63.10(b) and record and report if an action taken during a startup, shutdown, or malfunction is not consistent with the procedures in the plan as described in §63.6(e)(3). In additi on to the information required in §63.6(e)(3), the plan must include:(1) Procedures to determine and record the cause of the malfunction and the time the malfunction began and ended; and
(2) Corrective actions to be taken in the event of a malfunction of a process or control device, including procedures for recording the actions taken to correct the malfunction or minimize emissions.
(b) Excess emissions/summary report. The owner or operator of a major or area source must submit semiannual reports accordin g to the requirements in §63.10(e)(3). Except, the owner or operator must submit the semiannual reports within 60 days after the end of each 6

- month period instead of within 30 days after the calendar half as specified in §63.10(e)(3)(v). When no deviation s of parameters have occurred, the owner or operator must submit a report stating that no excess emissions occurred during the reporting period.
(1) A report must be submitted if any of these conditions occur during a 6

- month reporting period:
(i) The corr ective action specified in the OM&M plan for a bag leak detection system alarm was not initiated within 1 hour.(ii) The corrective action specified in the OM&M plan for a continuous opacity monitoring deviation was not initiated within 1 hour.
(iii) The c orrective action specified in the OM&M plan for visible emissions from an aluminum scrap shredder was not initiated within 1 hour.
(iv) An excursion of a compliant process or operating parameter value or range ( e.g., lime injection rate or screw feeder

se tting, total reactive chlorine flux injection rate, afterburner operating temperature, fabric filter inlet temperature, definition of acceptable scrap, or other approved operating parameter).
(v) An action taken during a startup, shutdown, or malfunction

w as not consistent with the procedures in the plan as described in §63.6(e)(3). [Reserved}
(vi) An affected source (including an emission unit in a secondary aluminum processing unit) was not operated according to the requirements of this subpart.
(vii) A de viation from the 3

- day, 24

- hour rolling average emission limit for a secondary aluminum processing unit.(2) Each report must include each of these certifications, as applicable:
(i) For each thermal chip dryer: “Only unpainted aluminum chips were used as feedstock in any thermal chip dryer during this reporting period.”
(ii) For each dross

- only furnace: “Only dross and salt flux were used as the charge materials in any dross

- only furnace during this reporting period.”
(iii) For each sidewell group 1 furnac e with add

- on air pollution control devices: “Each furnace was operated such that the level of molten metal remained above the top of the passage between the sidewell and hearth during reactive fluxing, and reactive flux, except for cover flux, was added o nly to the sidewell or to a furnace hearth equipped with an add

- on air pollution control device for PM, HCl, HF and D/F emissions during this reporting period.”
(iv) For each group 1 melting/holding furnace without add

- on air pollution control devices and using pollution prevention measures that processes only clean charge material: “Each group 1 furnace without add

- on air pollution control devices subject to emission limits in §63.1505(i)(2) processed only clean charge during this reporting period.”(v) Fo r each group 2 furnace: “Only clean charge materials were processed in any group 2 furnace during this reporting period, and no fluxing was performed or all fluxing performed was conducted using only nonreactive, non

- HAP

- containing/non

- HAP

generating fluxi ng gases or agents, except for cover fluxes, during this reporting period.”
(vi) For each in

- line fluxer using no reactive flux: “Only nonreactive, non

- HAP

- containing, non

- HAP

- generating flux gases, agents, or materials were used at any time during this re porting period.”
(3) The owner or operator must submit the results of any performance test conducted during the reporting period, including one complete report documenting test methods and procedures, process operation, and monitoring parameter ranges

or v alues for each test method used for a particular type of emission point tested.
(i) Within 60 days after the date of completing each performance test (defined in §63.2) as required by this subpart you must transmit the results of the performance tests requ ired by this subpart to EPA’s WebFIRE database by using the Compliance and Emissions Data Reporting Interface (CEDRI) that is accessed through EPA’s Central Data Exchange (CDX)(www.epa.gov/cdx).Performance test data must be submitted in the file format
ge nerated through use of EPA’s Electronic Reporting Tool (ERT) (see http://www.epa.gov/ttn/chief/ert/index.html ) . Only data collected using test methods on the ERT website are subject to this requirement for submitting reports electronically to WebFIRE. Owne rs or operators who claim that some of the information being submitted for performance tests is confidential business information (CBI) must submit a complete ERT file including information claimed to be CBI on a compact disk or other commonly used electro nic storage media (including, but not limited to, flash drives) to EPA. The electronic media must be clearly marked as CBI and mailed to U.S. EPA/OAPQS/CORE CBI Office, Attention: WebFIRE Administrator, MD C404

- 02, 4930 Old Page Rd., Durham, NC 27703. The same ERT file with the CBI omitted must be submitted to EPA via CDX as described earlier in this paragraph. At the discretion of the delegated authority, you must also submit these reports, including the confidential business information, to the delegated authority in the format specified by the delegated authority. (ii) All reports required by this subpart not subject to the requirements in paragraphs (1)(i) and (ii) of this section must be sent to the Administrator at the appropriate address listed in §6 3.13. The Administrator or the delegated authority mayrequest a report in any form suitable for the specific case (e.g., by commonly used electronic media such as Excel spreadsheet, on CD or hard copy). The Administrator retains the right to require submi ttal of reports subject to paragraph (1)(i) and (ii) of this section in paper format.
(c) Annual compliance certifications. For the purpose of annual certifications of compliance required by 40 CFR part 70 or 71, the owner or operator of a major or area so urce subject to this subpart must certify continuing compliance based upon, but not limited to, the following conditions:
(1) Any period of excess emissions, as defined in paragraph (b)(1) of this section, that occurred during the year were reported as req uired by this subpart; and
(2) All monitoring, recordkeeping, and reporting requirements were met during the year.
(d) If there was a malfunction during the reporting period, the owner or operator must submit a report that includes the number, duration, an d a brief description for each type of malfunction which occurred during the reporting period and which caused or may have caused any applicable emission limitation to be exceeded. The report must also include a description of actions taken by an owner or operator during a malfunction of anaffected source to minimize emissions in accordance with §§63.1506(a)(5) and 63.1520(a)(8), including actions taken to correct a malfunction.
[65 FR 15710, Mar. 23, 2000, as amended at 69 FR 53984, Sept. 3, 2004; 71 FR 20461, Apr. 20, 2006]

**§63.1517 Records** 
(a) As required by §63.10(b), the owner or operator shall maintain files of all information (including all reports and notifications) required by the general provisions and this subpart.
(1) The owner or operator must retain each record for at least 5 years following the date of each occurrence, measurement, maintenance, corrective action, report, or record. The most recent 2 years of records must be retained at the facility. The remaining 3 years of records may be ret ained off site.
(2) The owner or operator may retain records on microfilm, computer disks, magnetic tape, or microfiche; and
(3) The owner or operator may report required information on paper or on a labeled computer disk using commonly available and
EPA

- c ompatible computer software.(b) In addition to the general records required by §63.10(b), the owner or operator of a new or existing affected source (including an emission unit in a secondary aluminum processing unit) must maintain records of:
(1) For eac h affected source and emission unit with emissions controlled by a fabric filter or a lime

- injected fabric filter:
(i) If a bag leak detection system is used, the number of total operating hours for the affected source or emission unit during each 6

- month reporting period, records of each alarm, the time of the alarm, the time corrective action was initiated and completed, and a brief description of the cause of the alarm and the corrective action(s) taken.
(ii) If a continuous opacity monitoring system is used, records of opacity measurement data, including records where the average opacity of any 6

- minute period exceeds 5 percent, with a brief explanation of the cause of the emissions, the time the emissions occurred, the time corrective action was initiat ed and completed, and the corrective action taken.
(iii) If an aluminum scrap shredder is subject to visible emission observation requirements, records of all Method 9 observations, including records of any visible emissions during a 30

- minute daily test, with a brief explanation of the cause ofthe emissions, the time the emissions occurred, the time corrective action was initiated and completed, and the corrective action taken.
(2) For each affected source with emissions controlled by an afterburner:
(i) Records of 15

- minute block average afterburner operating temperature, including any period when the average temperature in any 3

- hour block period falls below the compliant operating parameter value with a brief explanation of the cause of the excursion an d the corrective action taken; and
(ii) Records of annual afterburner inspections.
(3) For each scrap dryer/delacquering kiln/decoating kiln and group 1 furnace, subject to D/F and HCl emission standards with emissions controlled by a lime

- injected fabric filter, records of 15

- minute block average inlet temperatures for each lime

injected fabric filter, including any period when the 3

- hour block average temperature exceeds the compliant operating parameter value +14 °C (+25 °F), with a brief explanation of the cause of the excursion and the corrective action taken.
(4) For each affected source and emission unit with emissions controlled by a lime

- injected fabric filter:(i) Records of inspections at least once every 8

- hour period verifying that lime is prese nt in the feeder hopper or silo and flowing, including any inspection where blockage is found, with a brief explanation of the cause of the blockage and the corrective action taken, and records of inspections at least once every 4

- hour period for the subse quent 3 days. If flow monitors, pressure drop sensors or load cells are used to verify that lime is present in the hopper and flowing, records of all monitor or sensor output including any event where blockage was found, with a brief explanation of the cau se of the blockage and the corrective action taken;
(ii) If lime feeder setting is monitored, records of daily inspections of feeder setting, including records of any deviation of the feeder setting from the setting used in the performance test, with a bri ef explanation of the cause of the deviation and the corrective action taken.
(iii) If lime addition rate for a noncontinuous lime injection system is monitored pursuant to the approved alternative monitoring requirements in §63.1510(v), records of the tim e and mass of each lime addition during each operating cycle or time period used in the performance test and calculations of the average lime addition rate (lb/ton of feed/charge).(5) For each group 1 furnace (with or without add

- on air pollution control devices) or in

- line fluxer, records of 15

- minute block average weights of gaseous or liquid reactive flux injection, total reactive flux injection rate and calculations (including records of the identity, composition, and weight of each addition of gaseous , liquid or solid reactive flux), including records of any period the rate exceeds the compliant operating parameter value and corrective action taken.
(6) For each continuous monitoring system, records required by §63.10(c).
(7) For each affected source a nd emission unit subject to an emission standard in kg/Mg (lb/ton) of feed/charge, records of feed/charge (or throughput) weights for each operating cycle or time period used in the performance test.
(8) Approved site

- specific monitoring plan for a group 1 furnace without add

- on air pollution control devices with records documenting conformance with the plan.
(9) Records of all charge materials for each thermal chip dryer, dross

- only furnace, and group 1 melting/holding furnaces without air pollution contro l devices processing only clean charge.(10) Operating logs for each group 1 sidewell furnace with add

on air pollution control devices documenting conformance with operating standards for maintaining the level of molten metal above the top of the passage between the sidewell and hearth during reactive flux injection and for adding reactive flux only to the sidewell or a furnace hearth equipped with a control device for PM, HCl, and D/F emissions.
(11) For each in

- line fluxer for which the owner or operator has certified that no reactive flux was used:
(i) Operating logs which establish that no source of reactive flux was present at the in

- line fluxer;
(ii) Labels required pursuant to §63.1506(b) which establish that no reactive flux may be used at the in

- li ne fluxer; or
(iii) Operating logs which document each flux gas, agent, or material used during each operating cycle.
(12) Records of all charge materials and fluxing materials or agents for a group 2 furnace.
(13) Records of monthly inspections for proper unit labeling for each affected source and emission unit subject to labeling requirements.(14) Records of annual inspections of emission capture/collection and closed vent systems.
(15) Records for any approved alternative monitoring or test procedure.
( 16) Current copy of all required plans, including any revisions, with records documenting conformance with the applicable plan, including:
(i) Startup, shutdown, and malfunction plan [Reserved] ; (ii) OM&M plan; and
(iii) Site

- specific secondary aluminum pro cessing unit emission plan (if applicable).
(17) For each secondary aluminum processing unit, records of total charge weight, or if the owner or operator chooses to comply on the basis of aluminum production, total aluminum produced for each 24

- hour period and calculations of 3

- day, 24

- hour rolling average emissions.
(18) For each malfunction for which the owner or operator chooses to claim coverage under the affirmative defense provisions, the owner or operator must maintain the following records;(i) Reco rds of the occurrence and duration of each malfunction of operation (i.e., process equipment) or the air pollution control equipment and monitoring equipment. (ii) Records of actions taken during periods of malfunction to minimize emissions in accordance w ith §§63.1506(a)(5) and 63.1520(a)(8) , including corrective actions to restore malfunctioning process and air pollution control and monitoring equipment to its normal or usual manner of operation. (c) All reports required by this subpart not subject to the requirements in paragraph (b) of this section must be sent to the Administrator at the appropriate address listed in §63.13. If acceptable to both the Administrator and the owner or operator of a source, these reports may be submitted on electronic media. The Administrator retains the right to require submittal of reports subject to paragraph (b) of this section in paper format.
[65 FR 15710, Mar. 23, 2000, as amended at 67 FR 79818, Dec. 30, 2002]

**Other**

**§63.1518 Applicability of general provisions.** The re quirements of the general provisions in subpart A of this part that are applicable to the owner or operator subject to the requirements of this subpart are shown in appendix A to this subpart.

**§63.1519 Implementation and enforcement.** 
(a) This subpart can b e implemented and enforced by the U.S. EPA, or a delegated authority such as the applicable State, local, or Tribal agency. If the U.S. EPA Administrator has delegated authority to a State, local, or Tribal agency, then that agency, in addition to the U.S. EPA, has the authority to implement and enforce this regulation. Contact the applicable U.S. EPA Regional Office to find out if this subpart is delegated to a State, local, or Tribal agency.
(b) In delegating implementation and enforcement authority of th is regulation to a State, local, or Tribal agency under subpart E of this part, the authorities contained in paragraph (c) of this section are retained by the Administrator of U.S. EPA and cannot be transferred to the State, local, or Tribal agency.
(c) Th e authorities that cannot be delegated to State, local, or Tribal agencies are as specified in paragraphs (c)(1) through (4) of this section.(1) Approval of alternatives to the requirements in §§63.1500 through 63.1501 and 63.1505 through 63.1506.
(2) App roval of major alternatives to test methods for under §63.7(e)(2)(ii) and (f), as defined in §63.90, and as required in this subpart.
(3) Approval of major alternatives to monitoring under §63.8(f), as defined in §63.90, and as required in this subpart.
(4 ) Approval of major alternatives to recordkeeping and reporting under §63.10(f), as defined in §63.90, and as required in this subpart.
[68 FR 37359, June 23, 2003]

**§63.1520 [Reserved]** 
**§63.1520 Affirmative defense for violation**  **of emission limit during mal**  **function.** In response to an action to enforce the standards set forth in this subpart, you may assert an affirmative defense to a claim for civil penalties for violations of such standards that are caused by malfunction, as defined at §63.2. Appropriate pe nalties may be assessed, however, if you fail to meet your burden of proving all of the requirements in the affirmativedefense. The affirmative defense shall not be available for claims for injunctive relief. (a) To establish the affirmative defense in an y action to enforce such a limit, you must timely meet the notification requirements in paragraph (b) of this section, and must prove by a preponderance of evidence that: (1) The excess emissions: (i) Were caused by a sudden, infrequent and unavoidable fai lure of air pollution control and monitoring equipment, process equipment, or a process to operate in a normal or usual manner; and (ii) Could not have been prevented through careful planning, proper design or better operation and maintenance practices; an d (iii) Did not stem from any activity or event that could have been foreseen and avoided, or planned for. (iv) Were not part of a recurring pattern indicative of inadequate design, operation, or maintenance; and (2) Repairs were made as expeditiously as p ossible when the applicable emission limitations were being exceeded. Off

- shift and overtime labor were used, to the extent practicable to make these repairs; and (3) The frequency, amount and duration of the excess emissions (including any bypass) were mi nimized to the maximum extent practicable during periods of such emissions; and(4) If the excess emissions resulted from a bypass of control equipment or a process, then the bypass was unavoidable to prevent loss of life, personal injury, or severe proper ty damage; and (5) All possible steps were taken to minimize the impact of the excess emissions on ambient air quality, the environment and human health; and (6) All emissions monitoring and control systems were kept in operation if at all possible, consis tent with safety and good air pollution control practices; and (7) All of the actions in response to the excess emissions were documented by properly signed, contemporaneous operating logs; and (8) At all times, the affected source was operated in a manner consistent with good practices for minimizing emissions; and (9) A written root cause analysis has been prepared, the purpose of which is to determine, correct, and eliminate the primary causes of the malfunction and the excess emissions resulting from th e malfunction event at issue. The analysis shall also specify, using best monitoring methods and engineering judgment, the amount of excess emissions that were the result of the malfunction. (b) Reports . The owner or operator seeking to assert an affirmati ve defense shall submit a written report to theAdministrator within 45 days of the initial occurrence of the violation of the standards in this subpart , which may be the end of any applicable averaging period, to demonstrate, with all necessary supporting documentation, that it has met the requirements set forth in paragraph ( a ) of this section. The owner or operator may seek an extension of this deadline for up to 30 additional days by submitting a written request to the Administrator before the expiratio n of the 45 day period. Until a request for an extension has been approved by the Administrator, the owner or operator is subject to the requirement to submit such report within 45 days of the initial occurrence of the violation
. **Table 1 to Subpart RRR of Part 63**  **— Emission Standards for New and**  **Existing Affected Sources Affected source/Emission unit**  **Pollutant Limit**  **Units**All new and exi s ting affected sources and emission units that are controlled with a PM add

- on control device and that choose to monitor with a COM; and all new and existing aluminum scrap shredders that choose to monitor with a COM or to monitor visible emissions Opacity 10 Percent

New and existing aluminum scrap shredder PM 0.01 Gr/dscf
New and existing thermal c hip dryer THC 0.8 lb/ton of feed D/F a 2.5 ug TEQ/Mg of feed New and existing scrap dryer/delacquering kiln/decoating kiln

or PM 0.08 lb/ton of feed

HCl 0.8 lb/ton of feed THC 0.06 lb/ton of feed D/F b 0.25 ug TEQ/Mg of feed Alternative limits if afterburner has a design residence time of at le a st 1 second and oper a tes a t a temperature of at least 1400 F PM 0.3 lb/ton of feed HCl 1.5 lb/ton of feed THC 0.2 lb/ton of feed D/F a 5 ug TEQ/Mg of feed New or existing sweat furnace D/F a 0.8 ng TEQ/ dscm @ 11% O2 b New or existing dross

- only furnace PM 0.3 lb/ton of feed
New or existing in

- line fluxer HCL 0.04 lb/ton of feed

PM 0.01 lb/ton of feed New and existing in

- line fluxer with no reactive No limit work practice: no reactive fluxin gfluxing New and existing rotary dross cooler PM 0.04 gr/dscf
New and existing clean furnace (Group 2) No limit Work practices: clean charge only and no reactive fluxing
New and existing group 1 melting/holding fur nac e (processing only clean charge) c PM 0.8 l b/ton of feed HCL 0.4 lb/ton of feed
HF 0.4 lb/ton of feed

or 10 percent of the HCl upstream of the add

- on control device New and existing group 1 furnace c PM 0.4 lb/ton of feed HCL 0.4 lb/ton of feed
HF 0.4 lb/ton of feed

or 10 perc ent of the HCl upstream of the add

- on control device D/F b 15 ug/TEQ/Mg of feed New and existing group 1 furnace with clean charge only c PM 0.4 lb/ton of feed HCL 0.4 lb/ton of feed
HF 0.4 lb/ton of feed

or 10 percent of the HCl upstream of th e add

- on control device D/F a No limit Clean charge onlyNew and existing secondary aluminum process i ng unit a,d (consists of all existing group 1 furnaces and existing in

- line flux boxes at the facility, or all simultaneously constructed new group 1 furn aces and new in

- lie fluxers) PM e 

# ( ) ( ) ) 1 (Eq. T T L L n
1 i ti n
1 i ti ti C PM

PM 

## ∑ ∑

=

= ×

=

HCl or HF f 

### ( ) ( ) 2) Eq. ( T T L L n
1 i ti n
1 i ti tiHCl/HF cHCl/HF 

## ∑ ∑

= = ×

=

D/F g ( ) ( ) 3) (Eq. T T L L n
1 i ti n
1 i ti tiD/F cD/F 

### ∑ ∑

=

= ×

=

a D/F limit applies to a unit at a major or area sour c e.
b Sweat furnaces equipped with afterburners meeting the s pec ifications of §63.1505(f)(1) are not required to conduct a perfor ma n ce test.

d These limits are also used to calculate the limits applicable to secondary aluminum processing units.

d Equation defin i tions: L iPM = the PM emission limit for individual emission unit i in the secondary aluminum processing unit [kg/Mg (lb/t on) of feed]; T i = the feed rate for individual emission unit i in the secondary aluminum processing unit; L tPM = the overall PM emission limit for the secondary aluminum processing unit [kg/Mg (lb/Ton of feed)]; L iHCL /HF = the HCL or HF emission limit for individual emission unit i in the secondary aluminum processing unit [kg/Mg (lb/Ton) of feed]; L tHCl /HF = the overall HCl or HF emission limit for the secondary aluminum processing unit [kg/Mg (lb/ton) of feed]; L iD/F = the D/F emission limit for individu al emission unit i [μg TEQ/Mg (gr TEQ/ton) of feed]; L tD/F = the overall D/F emission limit for the secondary aluminum processing unit [μg TEQ/Mg (gr TEQ/Ton) o f feed]; n = the number of units in the secondary aluminum processing unit. (Need to check. Thes e are slightly different that what is in the text of the rule)

e In

- line fluxers using no reactive flux materials cannot be included in this calculation since they are not subject to the PM limit.f In

- line fluxers using no reactive flux materials cannot be included in this calculation since they are not subject to the HCL and HF limits.

g Clean charge furnaces cannot be included in this calculation since they are not subject to the D/F limit.

**Table 2 to Subpart RRR of Part 63 —**  **Summary of Operating Requ**  **irements for New and Existing Affected Sources and Emission Units** 

**Affected**

**source/emission unit Monitor**  **type/operation/process Operating requirements**  All affected sources and emission units with an add

- on air pollution control device Emission capture and collection system Design and install in accordance with Industrial Ventilation: A Handbook of Recommended Practice; 23 rd or 27 th edition; operate in accordance with OM&M plan. b All affected sources and emission units subject to production

- based (lb/ton of feed) emission limits a Charge/feed weight or Production weight Operate a device that records the weight of each charge; Operate in accordance with OM&M plan. b Group 1 furnace, group 2 furnace, in

line fluxer and scrap dryer/delacquering kiln/decoating kil n Labeling Identification, operating parameter ranges and operating requirements posted at affected sources and emission units; control device temperature and residence time requirements posted at scrap dryer/delacquering kiln/decoating kiln. Aluminum scr ap shredder with fabric filter Bag leak detector or Initiate corrective action within 1

- hr of alarm and complete in accordance with OM&Mplan b ; operate such that alarm does not sound more than 5% of operating time in 6

- month period. COM or Initiate cor rective action within 1

- hr of a 6

- minute average opacity reading of 5% or more and complete in accordance with OM&M plan. b VE Initiate corrective action within 1

- hr of any observed VE and complete in accordance with the OM&M plan. b Thermal chip dryer with afterburner Afterburner operating temperature Maintain average temperature for each 3

- hr period at or above average operating temperature during the performance test. Afterburner operation Operate in accordance with OM&M plan. b Feed material O perate using only unpainted aluminum chips. Scrap dryer/delacquering kiln/decoating kiln with afterburne r and lime

- injected fabric filter Afterburner operating temperature Maintain average temperature for each 3

- hr period at or above average operating tem perature during the performance test. Afterburner operation Operate in accordance with OM&M plan. b Bag leak detector or Initiate corrective action within 1

- hr of alarm and complete in accordance with the OM&M plan; b operate such that alarm does not sound more than 5% of operating time in 6

- month period.COM Initiate corrective action within 1

- hr of a 6

- minute average opacity reading of 5% or more and complete in accordance with the OM&M plan. b Fabric filter inlet temperature Maintain average fabric filter inlet temperature for each 3

- hr period at or below average temperature during the performance test +14 °C (+25 °F). Lime injection rate Maintain free

- flowing lime in the feed hopper or silo at all times for continuous injection systems; m aintain feeder setting at level established during the performance test for continuous injection systems. Sweat furnace with afterburner Afterburner operating temperature If a performance test was conducted, maintain average temperature for each 3

- hr peri od at or above average operating temperature during the performance test; if a performance test was not conducted, and afterburner meets specifications of §63.1505(f)(1), maintain average temperature for each 3

- hr period at or above 1600 °F. Afterburne r operation Operate in accordance with OM&M plan. b Dross

- only furnace with fabric filter Bag leak detector or Initiate corrective action within 1

- hr of alarm and complete in accordance with the OM&M plan; b operate such that alarm does not sound more than 5 % ofoperating time in 6

- month period. COM Initiate corrective action within 1

- hr of a 6

- minute average opacity reading of 5% or more and complete in accordance with the OM&M plan. b Feed/charge material Operate using only dross as the feed material
. Rotary dross cooler with fabric filter Bag leak detector or Initiate corrective action within 1

- hr of alarm and complete in accordance with the OM&M plan; b operate such that alarm does not sound more than 5% of operating time in 6

- month period. COM I nitiate corrective action within 1

- hr of a 6

- minute average opacity reading of 5% or more and complete in accordance with the OM&M plan. b In

- line fluxer with lime

- injected fabric filter (including those that are part of a secondary aluminum processing uni t) Bag leak detector or Initiate corrective action within 1

- hr of alarm and complete in accordance with the OM&M plan; b operate such that alarm does not sound more than 5% of operating time in 6

- month period. COM Initiate corrective action within 1

- hr o f a 6

- minute average opacity reading of 5% or more and complete in accordance with the OM&M plan. b Lime injection rate Maintain free

- flowing lime in the feed hopper or silo at all times for continuous injectionsystems; maintain feeder setting at level established during performance test for continuous injection systems. Reactive flux injection rate Maintain reactive flux injection rate at or below rate used during the performance test for each operating cycle or time period used in the performance test. In

- line fluxer (using no reactive flux material) Flux materials Use no reactive flux.

Group 1 furnace with lime

- injected fabric filter (including those that are part of a secondary of aluminum processing unit). Bag leak detector or Initiate correct ive action within 1

- hr of alarm; operate such that alarm does not sound more than 5% of operating time in 6

- month period; complete corrective action in accordance with the OM&M plan. b COM Initiate corrective action within 1

- hr of a 6

- minute average opa city reading of 5% or more; complete corrective action in accordance with the OM&M plan. b Fabric filter inlet temperature Maintain average fabric filter inlet temperature for each 3

- hour period at or below average temperature during the performance tes t +14 °C (+25 °F). Reactive flux injection rate Maintain reactive flux injection rate (kg/Mg) (lb/ton) at or below rate used during the performance test for each furnace cycle. Lime injection rate Maintain free

- flowinglime in the feed hopper or si lo at all times for continuous injection systems; maintain feeder setting at level established at performance test for continuous injection systems. Maintain molten aluminum level Operate sidewell furnaces such that the level of molten metal is above t he top of the passage between sidewell and hearth during reactive flux injection, unless the hearth is also controlled. Fluxing in sidewell furnace hearth Add reactive flux only to the sidewell of the furnace unless the hearth is also controlled. Grou p 1 furnace without add

- on controls (including those that are part of a secondary aluminum processing unit) Reactive flux injection rate Maintain reactive flux injection rate (kg/Mg) (lb/ton) at or below rate used during the performance test for each opera ting cycle or time period used in the performance test. Site

- specific monitoring plan c Operate furnace within the range of charge materials, contaminant levels, and parameter values established in the site

- specific monitoring plan. Feed material (m elting/holding furnace) Use only clean charge.

Clean (group 2) furnace Charge and flux materials Use only clean charge. Use no reactive flux. Furnaces that will be idle for at least 24 hours and will burn clean fuel only, will not receive new Associated fans, hoods and APCD may be temporarily turned off.charge, fl ux or alloying material Before charging resumes, all associated fans, hoods and APCD must be turned on and operated continuously.

a Thermal chip dryers, scrap dryers/delacquering kilns/decoati ng kilns, dross

only furnaces, in

- line fluxers and group 1 furnaces including melting/holding furnaces.

b OM&M plan

— Operation, maintenance, and monitoring plan.

c Site

- specific monitoring plan. Owner/operators of group 1 furnaces without control devices must include a section in their OM&M plan that documents work practice and pollution prevention measures, including procedures for scrap inspection, by which compliance is achieved with emission limits and process or feed parameter

- based operating requirements . This plan and the testing to demonstrate adequacy of the monitoring plan must be developed in coordination with and approved by the permitting authority.

d APCD

– Air pollution control device.

[65 FR 15710, Mar. 23, 2000, as amended at 67 FR 79818, Dec. 3 0, 2002; 69 FR 53984, Sept. 3, 2004] **Table 3 to Subpart RRR of Part 63 —**  **Summary of Monitoring Requirements for New and Existing Affected Sources and Emission**  **Units**

**Affected source/Emission unit**  **Monitor type/Operation/Process**  **Monitoring requirements**
All aff ected sources and emission units with an add

- on air pollution control device Emission capture and collection system Annual inspection of all emission capture, collection, and transport systems to ensure that systems continue to operate in accordance with A CGIH standards. Inspection includes volumetric flow rate measurements. All affected sources and emission units Feed/charge weight Record weight of each feed/charge, weightsubject to production

- based (lb/ton of feed/charge) emission limits a measurement de vice or other procedure accuracy of ±1% b ; calibrate according to manufacturers specifications, or at least once every 6 months. Group 1 furnace, group 2 furnace, in

line fluxer, and scrap dryer/delacquering kiln/decoating kiln Labeling Check monthly to co nfirm that labels are intact and legible.

Aluminum scrap shredder with fabric filter Bag leak detector or Install and operate in accordance with manufacturer’s operating instructions. “ Fabric Filter Bag Leak Detection Guidance” c ; record voltage output from bag leak detector
. COM or Design and install in accordance with PS

– 1; collect data in accordance with subpart A of 40 CFR part 63; determine and record 6

- minute block averages. VE Conduct and record results of 30

- minute daily test in accordance wi th Method 9. Thermal chip dryer with afterburner Afterburner operating temperature Continuous measurement device to meet specifications in §63.1510(g)(1); record average temperature for each 15

- minute block; determine and record 3

- hr block averages. A fterburner operation Annual inspection of afterburner internal parts; complete repairs in accordance with the OM&M plan. Feed/charge material Record identity of each feed/charge; certify feed/charge materials every 6 months.Scrap dryer/delacquering k iln/decoating kiln with afterburner and lime

- injected fabric filter Afterburner operating temperature. Continuous measurement device to meet specifications in §63.1510(g)(1); record temperature for each 15

- minute block; determine and record 3

- hr block aver ages. Afterburner operation Annual inspection of afterburner internal parts; complete repairs in accordance with the OM&M plan. Bag leak detector or Install and operate in accordance with manufacturer’s operating instructions. “Fabric Filter Bag Lea k Detection Guidance c ; record voltage output from bag leak detector. COM Design and Install in accordance with PS

– 1; collect data in accordance with subpart A of 40 CFR part 63; determine and record 6

- minute block averages. Lime injection rate For continuous injection systems, inspect each feed hooper or silo every 8 hours to verify that lime is free flowing; record results of each inspection. If blockage occurs, inspect every 4 hours for 3 days; return to 8

- hour inspections if corrective action res ults in no further blockage during 3

- day period, record feeder setting daily
. Verify monthly that lime injection rate is no less than 90 percent of the rate used during the compliance demonstration test.Fabric filter inlet temperature. Continous measu rement device to meet specifications in §63.1510(h)(2); record temperatures in 15

- minute block averages; determine and record 3

- hr block averages. Sweat furnace with afterburner Afterburner operating temperature Continuous measurement device to meet speci fications in §63.1510(g)(1); record temperatures in 15

- minute block averages; determine and record 3

- hr block averages. Afterburner operation Annual inspection of afterburner internal parts; complete repairs in accordance with the OM&M plan. Dross

- onl y furnace with fabric filter Bag leak detector or Install and operate in accordance with manufacturer’s operating instructions. “Fabric Filter Bag Leak Detection Guidance” c ; record output voltage from bag leak detector. COM Design and install in accorda nce with PS

– 1; collect data in accordance with subpart A of 40 CFR part 63; determine and record 6

- minute block averages. Feed/charge material Record identity of each feed/charge; certify charge materials every 6 months. Rotary dross cooler with fabri c filter Bag leak detector or Install and operate in accordance with manufacturer’s operating instructions. “Fabric Filter Bag Leak Detection Guidance” c ; record output voltage from bag leakdetector. COM Design and install in accordance with PS

– 1; colle ct data in accordance with subpart A of 40 CFR part 63; determine and record 6

- minute block averages. In

- line fluxer with lime

- injected fabric filter Bag leak detector or Install and operate in accordance with manufacturer’s operating instructions. “Fabric Filter Bag Leak Detection Guidance” c ; record output voltage from bag leak detector. COM Design and install in accordance with PS

– 1; collect data in accordance with subpart A of 40 CFR part 63; determine and record 6

- minute block averages Reactive flux injection rate Weight measurement device accuracy of ±1% b ; calibrate according to manufacturer's specifications or at least once every 6 months; record time, weight and type of reactive flux added or injected for each 15

- minute block period while reac tive fluxing occurs; calculate and record total reactive flux injection rate for each operating cycle or time period used in performance test; or Alternative flux injection rate determination procedure per §63.1510(j)(5). For solid flux added intermittentl y, record the amount added for each operating cycle or time period used in theperformance test. Lime injection rate For continuous injection systems, record feeder setting daily and inspect each feed hopper or silo every 8 hrs to verify that lime is f ree - flowing; record results of each inspection. If blockage occurs, inspect every 4 hrs for 3 days; return to 8

- hour inspections if corrective action results in no further blockage during 3

- day period. d Verify monthly that the lime injection rate is no les s than 90 percent of the rate used during the compliance demonstration test. In

- line fluxer using no reactive flux Flux materials Record flux materials; certify every 6 months for no reactive flux. Group 1 furnace with lime

- injected fabric filter Bag lea k detector or Install and operate in accordance with with manufacturer’s operating instructions. “Fabric Filter Bag Leak Detection Guidance” c ; record output voltage from bag leak detector. COM Design and install in accordance with PS

– 1; collect data in accordance with subpart A of 40 part CFR 63; determine and record 6

- minute block averages. Lime injection rate For continuous injection systems, record feeder setting daily and inspect each feed hopper or silo every 8 hours to verify that lime is free

- flowing; record results of each inspection. If blockage occurs, inspect every 4hours for 3 days; return to 8

- hour inspections if corrective action results in no further blockage during 3

- day period. d Verify monthly that the lime injection rate is no less than 90 percent of the rate used during the compliance demonstration test. Reactive flux injection rate Weight measurement device accuracy of ±1% b ; calibrate every 3 months; record weight and type of reactive flux added or injected for each 15

- minute b lock period while reactive fluxing occurs; calculate and record total reactive flux injection rate for each operating cycle or time period used in performance test; or Alternative flux injection rate determination procedure per §63.1510(j)(5). For solid fl ux added intermittently, record the amount added for each operating cycle or time period used in the performance test. Fabric filter inlet temperature Continuous measurement device to meet specifications in §63.1510(h)(2); record temperatures in 15

- min ute block averages; determine and record 3

- hour block averages. Maintain molten aluminum level in sidewell furnace Maintain aluminum level operating log; certify every 6 months
. If visual inspection of molten metal level is not possible, use physical m easurement methods.Group 1 furnace without add

- on controls Fluxing in sidewell furnace hearth Maintain flux addition operating log; certify every 6 months. Reactive flux injection rate Weight measurement device accuracy of +1% b ; calibrate according t o manufacturers specifications or at least once every six months; record weight and type of reactive flux added or injected for each 15

- minute block period while reactive fluxing occurs; calculate and record total reactive flux injection rate for each oper ating cycle or time period used in performance test
. For solid flux added intermittently, record the amount added for each operating cycle or time period used in the performance test OM&M plan (approved by permitting agency) Demonstration of site

speci fic monitoring procedures to provide data and show correlation of emissions across the range of charge and flux materials and furnace operating parameters. Feed material (melting/holding furnace) Record type of permissible feed/charge material; certify charge materials every 6 months. Clean (group 2) furnace Charge and flux materials Record charge and flux materials; certify every 6 months for clean charge and no reactive flux.

a Thermal chip dryers, scrap dryers/delacquering kilns/decoating kilns, dro ss only furnaces, in

- line fluxers and group 1 furnaces or melting/holding furnaces.

b Permitting agency may approve measurement devices of alternative accuracy, for example in cases where flux rates are very low and costs of meters of specified accuracy are prohibitive; or where feed/charge weighing devices ofspecified accuracy are not practicable due to equipment layout or charging practices.

c Non

- triboelectric bag leak detectors must be installed and operated in accordance with manufacturers' specificatio ns.

d Permitting agency may approve other alternatives including load cells for lime hopper weight, sensors for carrier gas pressure, or HCl monitoring devices at fabric filter outlet. [65 FR 15710, Mar. 23, 2000, as amended at 69 FR 53985, Sept. 3, 2004] **A ppendix A to Subpart RRR of Part 63**  **— General Provisions**  **Applicability to Subpart RRR**

**Citation Requirement**  **Applies to RRR**  **Comment** §63.1(a)(1)

– (4) General Applicability Yes. §63.1(a)(5) No [Reserved]. §63.1(a)(6)

– (8) Yes. §63.1(a)(9) No [Reserved]. §63.1(a) (10)

– (14) Yes. §63.1(b) Initial Applicability Determination Yes EPA retains approval authority. §63.1(c)(1) Applicability After Standard Established Yes. §63.1(c)(2) Yes §63.1500(e) exempts area sources subject to this subpart from the obli gation to obtain Title V operating permits. §63.1(c)(3) No [Reserved]. §63.1(c)(4)

– (5) Yes. §63.1(d) No [Reserved].§63.1(e) Applicability of Permit Program Yes. §63.2 Definitions Yes Additional definitions in §63.1503. §63.3 Units and Abbreviat ions Yes §63.4(a)(1)

– (3) Prohibited Activities Yes. §63.4(a)(4) No [Reserved] §63.4(a)(5) Yes. §63.4(b)

– (c) Circumvention/ Severability Yes. §63.5(a) Construction and Reconstruction

— Applicability Yes.

§63.5(b)(1) Existing, New, Reconstructed S ources — Requirements Yes.

§63.5(b)(2) No [Reserved]. §63.5(b)(3)

– (6) Yes. §63.5(c) No [Reserved]. §63.5(d) Application for Approval of Construction/ Reconstruction Yes.

§63.5(e) Approval of Construction/ Reconstruction Yes. §63.5(f) Approval of Construction/Reconstructi on Based on State Review Yes.

§63.6(a) Compliance with Standards and Maintenance

— Applicability Yes.

§63.6(b)(1)

– (5) New and Reconstructed Sources

— Dates Yes. §63.6(b)(6) No [Reserved]. §63.6(b)(7) Yes.§63.6(c)(1) Existi ng Sources Dates Yes §63.1501 specifies dates. §63.6(c)(2) Yes. §63.6(c)(3)

– (4) No [Reserved]. §63.6(c)(5) Yes. §63.6(d) No [Reserved]. 63.6(e)(1)(i) No. See §63.1506(a)(5) for general duty requirement. Any other cross reference to §63.6(3)(1)( i) in any other general provision incorporated by reference shall be treated as a cross reference to §63.1506(a)(5). 63.6(e)(1)(ii ) No.

§63.6(e)(1)

– (2) Operation & Maintenance Requirements Yes §63.1510 requires plan. 63.6(e)(2)) Yes. §63.6(e)(3) St artup and , Shutdown , and Malfunction Plan Yes No . §63.6(f) Compliance with Emission Standards Yes.
§63.6(f)(1) Compliance with Emission Standards No.

§63.6(f)(2) Compliance with Emission Standards Yes.

§63.6(g) Alternative Standard No §63.6(h) Com pliance with Yes.Opacity/VE Standards §63.6(h)(1) Compliance with Opacity/VE Standards No.

§63.6(h)(2)

- Compliance with Opacity/VE Standards Yes.

§63.6(i)(1)

– (14) Extension of Compliance Yes. §63.6(i)(15) No [Reserved]. §63.6(i)(16) Yes. §63. 6(j) Exemption from Compliance Yes. §63.7(a)

– (h) Performance Test Requirements

Applicability and Dates Yes Except §63.1511 establishes dates for initial performance tests. §63.7(b) Notification Yes. §63.7(c) Quality Assurance/Test Plan Yes. §63.7(d) Testing Facilities Yes. §63.7(e) Conduct of Tests Yes. §63.7(e)(1) Conduct of Tests No. See 63.1511(a). §63.7(e)(2) Conduct of Tests Yes. §63.7(f) Alternative Test Method Yes. §63.7(g) Data Analysis Yes. §63.7(h) Waiver of Tests Yes. §63.8(a) (1) Monitoring Requirements

— Applicability Yes. §63.8(a)(2) Yes. §63.8(a)(3) No [Reserved] §63.8(a)(4) Yes §63.8(b) Conduct of Monitoring Yes. §63.8(c)(1)

– CMS Operation and Yes.(3) Maintenance 63.8(c)(1)(i) No See 63.1506(a)(5) for general d uty requirement. 63.8(c)(1)(ii ) Yes.

§63.8(c)(1)(i ii) CMS Operation and Maintenance NO.

§63.8(c)(4)

– (8) Yes. §63.8(d) (3) Quality Control Yes. Except for last sentence which refers to an SSM plan. SSM plans are no require. §63.8(e) CMS Performance Evaluation Yes. §63.8(f)(1)

– (5) Alternative Monitoring Method No §63.1510(w) includes provisions for monitoring alternatives. §63.8(f)(6) Alternative to RATA Test Yes. §63.8(g)(1) Data Reduction Yes. §63.8(g)(2) No §63.1512 requires five 6

- minute averages for an aluminum scrap shredder. §63.8(g)(3)

– (5) Yes. §63.9(a) Notification Requirements

— Yes.Applicability §63.9(b) Initial Notifications Yes. §63.9(c) Request for Compliance Extension Yes. §63.9(d) New Source Notification for Special Co mpliance Requirements Yes.

63.9(e) Notification of Performance Test Yes. §63.9(f) Notification of VE/Opacity Test Yes. §63.9(g) Additional CMS Notifications Yes. §63.9(h)(1)

– (3) Notification of Compliance Status Yes Except §63.1515 establishes date s for notification of compliance status reports. §63.9(h)(4) No [Reserved]. §63.9(h)(5)

– (6) Yes. §63.9(i) Adjustment of Deadlines Yes. §63.9(j) Change in Previous Information Yes. §63.10(a) Recordkeeping/Reporting

— Applicability Yes. §63.10(b) G eneral Requirements Yes §63.1517 includes additional requirements. §63.10(b)(1) General Requirements Yes See 63.1517 includes additional requirements §63.10(b)(2)( i), (ii), (iv) and (v) General Requirements No See 63.1517(b)(18) for recordkeeping of occurrence and duration of malfunctions andrecordkeeping of actions taken during malfunction §63.10(b)(2)( iii) and (vi) to (ix) General Requirements Yes See 63.1517 includes additional requirements §63.10(c)(1) Additional CMS Recor dkeeping Yes. §63.10(c)(2)

– (4) No [Reserved]. §63.10(c)(5) Yes. §63.10(c)(6) Yes. §63.10(c)(7)

– (8) Yes. §63.10(c)(9) No [Reserved]. §63.10(c)(10)

- (11) No. See 63.1517(b)(18) for recordkeeping of malfunctions. §63.10(c)(14 ) Yes.
§63.10(c )(15) General Requirements No §63.10(d)(1) General Reporting Requirements Yes. §63.10(d)(2) Performance Test Results Yes. §63.10(d)(3) Opacity or VE Observations Yes. §63.10(d)(4)

– (5) Progress Reports/Startup, Shutdown, and Malfunction Reports Yes N o .
§63.10(e)(1)

– (2) Additional CMS Reports Yes. §63.10(e)(3) Excess Emissions/CMS Performance Reports Yes Reporting deadline given in §63.1516. §63.10(e)(4) COMS Data Reports Yes.§63.10(f) Recordkeeping/Reporting Waiver Yes. §63.11(a)

– (b) Control Device Requirements No Flares not applicable. §63.12(a)

– (c) State Authority and Delegations Yes. EPA retains authority for applicability determinations. §63.13 Addresses Yes. §63.14 Incorporation by Reference Yes Chapters 3 and 5 of ACGIH Industrial V entilation Manual for capture/collection systems; and Interim Procedures for Estimating Risk Associated with Exposure to Mixtures of Chlorinated Dibenzofurans (CDDs and CDFs) and 1989 Update (incorporated by reference in §63.1502). §63.15 Availability of Information/Confidentiali ty Yes.

[65 FR 15710, Mar. 23, 2000, as amended at 67 FR 59793, Sept. 24, 2002; 67 FR 79818, Dec. 30, 2002; 69 FR 53986, Sept. 3, 2004; 70 FR 75346, Dec. 19, 2005]