EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUCTION MANUFACTURING EMISSION POINTS



### 1 4/21/2010 

# ENCLOSURE 1

INFORMATION COLLECTION REQUEST FOR FERROALLOY

S PRODUCTION MANUFACTURING EMISSION POINTS

This information collection request is being conducted by the Environmental Protection Agency’s (EPA) Office of Air and Radiation (OAR) to assist the EPA Administrator in developing emission standards for Ferroalloy s Production Manufacturing Emission Points under Clean Air Act (CAA) section 112 . The survey is being sent under the authority of Section 114 of the C AA

.
BACKGROUND:

This information reques t (Enclosure 1) is to be completed for operations that comprise ferroalloys production at each facility operated by your company which is located within the United States. The ferroalloys production source category includes any facility engaged in produci ng ferroalloys such as ferrosilicon, silicon metal, silicomanganese, ferromanganese, ferronickel, and ferrochromium. The source category also includes production of calcium carbide. Ferroalloys production includes, but is not limited to, the following un it operations: ore unloading, ore storage, sintering, crushing, weigh

- feeding, smelting, tapping, casting, and screening.
CAA section 114(a) states that the Administrator may require any owner or operator subject to any requirement of this Act to:
(A) Es tablish and maintain such records; (B) make such reports; (C) install, use, and maintain such monitoring equipment, and use such audit procedures, or methods; (D) sample such emissions (in accordance with such procedures or methods, at such locations, at s uch intervals, during such periods, and in such manner as the Administrator shall prescribe); (E) keep records on control equipment parameters, production variables or other indirect data when direct monitoring of emissions is impractical; (F) submit compl iance certifications in accordance with section 114(a)(3); and (G) provide such other information as the Administrator may reasonably require.
There are two aspects to this CAA section 114 information collection request. The first component of the inform ation collection involves a survey requesting information on existing emission points . The second component requires owners to conduct testing. The testing requirements are set forth in the cover letter of this packet (CAA section 114 letter) as well as Enclosure 2.

DIRECTIONS:

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

.

C Y ou are not expected to generate new information for the attached survey (Enclosure 1).

C Please answer all questions unless not applicable to your facility or operations, in which case note that the question is not applicable. All information should be for the 2009 reporting year (unless otherwise noted)

.EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUCTION MANUFACTURING EMISSION POINTS



### 2 4/21/2010 C Please identify clearly any response(s) that you consider to be confidential business information (CBI). Any responses not so identified will be included in a publicly available database. Refer to Enclosures 3, 4, 5, and 6 for more information on the treatment of CBI and a list of information you may be asked to submit later to substantiate a claim of conf identiality. Please do not label an entire response “confidential” if only certain portions consist of trade secret information. If you wish, you may submit a confidential and a non

- confidential version.
In order to avoid duplicate data and keep all data for a particular facility together, we request that you submit all of the data requested from your facility in the same way. To submit your data, m ail a CD or DVD containing an electronic copy of all requested files to the EPA address below:

U.S. Enviro nmental Protection Agency Office of Air Quality Planning and Standards U.S. EPA Mailroom (D243

- 02) Attn: Mr. Conrad Chin 109 T.W. Alexander Drive Research Triangle Park, NC 27711
If the process data or other information you are providing is considered c onfidential, please create a separate CD or DVD containing only the confidential portion of your data or prepare a copy of the hard copy materials containing only the pages that include the information you consider confidential. Clearly mark the disk and/o r materials with the words “Confidential Business Information.” Send these confidential files under separate cover to the attention of Mr. Roberto Morales at the following address:
U.S. Environmental Protection Agency Office of Air Quality Planning and St andards U.S. EPA Mailroom (C404

- 02) Attn: Mr. Roberto Morales, Document Control Officer

109 T.W. Alexander Drive Research Triangle Park, NC 27711
For the security of your data, EPA recommends sending your confidential files to Mr. Morales via Registered U.S. Mail using return receipt requested, Federal Express, or other method for which someone must provide a signature upon receipt. Do not electronically transmit confidential business information (CBI) to EPA. E

- mail and facsimile are not secure forms o f communication and should never be used to transmit CBI.
If you have any questions regarding this request, please contact Mr. Conrad Chin at e

- mail chin.conrad@epa.gov

PLEASE RETURN THIS SURVEY NO LATER THAN JULY 30 , 2010 Please note that you are to provide a separate response package for each facility in your company with ferroalloy production operations. Copies of this

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



### 3 4/21/2010 

## CONFIDENTIAL BUSINESS INFORMATION (CBI) :

Please indicate if any CBI is included in this survey response 

## : q Yes 

# : No

PART I. OWNER INFORMATION

1. Name of Legal Owner: Felman Production, Inc.

a. Address: 4442 Graham Stati on Road b. City: Letart
c. State: West Virginia d. Zip: 25253 e. County: Mason

2. Complete street address of facility (physical location):
a. Address: 4442 Graham Station Road b. City: Letart
c. State: We st Virginia d. Zip: 25253 e. County: Mason

3

. Mailing Address (if different from Facility Street Address) :
a. Address: Route 3 Box 127 b. City: Letart
c. State: West Virginia d. Zip: 25253 e. County: Mason

4

. Facility Contact: a. Name (First Name, Last Name): Paul Pigott
b. Title: EHS Manager c. Telephone Number: ( 304 ) 882

- 1181

_ Ext 257
d. Fax Number: ( 304 ) 675

- 0079

_ e. E

- mail: safety@fpiwv.comEPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUCTION MANUFACTURING EMISSION POINTS



### 4 4/21/2010 5. Facility Description:

a. Brief des cription of the facility : (e.g., ferroalloy production operations and any other operations located on

- site.)

__ Manufacturing of manganese and silicon based ferroalloys.

_________________ ___

___________________________________________________ ___________________

_____________________________________________________________________

_____________________________________________________________________

b. Dun & Bradstreet No: N/A

c

. SARA TRI Facility ID (from Form R): 25265FLMNPUSR T6

d . Number of Facility Employees : Number of employees associated with ferroalloy production operations at the facility (answer may be given using the following ranges: 0

- 100; 101

- 250; 251

- 500; 501

- 750;
751

- 1,000; 1,001

- 1,500; and >1,5 00

. ) Include temporary employees if they are a significant f raction of your total number of employees.

__ 251

- 500

________________________________________________________________

e

. Number of Corporate Employees : Approximate number of employees of the business enterprise that owns this plant, including where applicable, the parent company and all subsidiaries, branches, and unrelated establishments owned by the parent company

___ Unknown

__________________________________________ _____________________

f

. NAICS Code(s): (See http://www.census.gov/epcd/www/naics.html ) Primary: 33112
Other: 331492

g. Is the legal owner a small entity? 

## q Y 

# : N 

## q UnknownEPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUCTION MANUFACTURING EMISSION POINTS



### 5 4/21/2010 h

. Operating Hours (Most common operating hours for the majority of the year) hours/day: 24 shifts/day: 3 days/wk: 7 weeks/yr: 52

6

. Geog raphic Coordinates of Center of Plant: Either latitude and longitude or UTM coordinates with zone . L atitude and longitude should be provided in decimal degrees, with 6 digits to right of decimal point

, and an indication of the associated datum (if availab le, likely NAD27

, NAD83 , or WGS84

. )

a. latitude and longitude : b. UTM coordinates : 419.73 km Easting

– 4312.468 km Northing

– Zone 17

7. Regulatory Requirements (Indicate any Federal or State air emission standar ds, such as the NSPS, which are applicable to your facility)
40 CFR Part 60, subpart Z, Standards of Performance for Ferroalloys Production



# : 40 CFR Part 63, subpart XXX, National Emis sion Standards for Hazardous Air Pollutants from Ferroa lloys Production: Ferromanganese and Silicomanganese
40 CFR Part 63, subpart DDDDD, National Emission Standards for Hazardous Air Pollutants for Industrial/Commercial/Institutional Boilers and Process Heaters

40 CFR Part 63, subpart YYYYYY, National Emission Standards for Hazardous Air Pollutants for Area Sources: Ferroalloys Production Facilities



# : Others (please identify): 45CSR6, 45CSR7, 45CSR10, 45CSR11, 45CSR30, 40CFR Part 61, 40CFR Part 82 subpart F

8

. Facility Classification for hazardous air pollutants (HAP) If you have an air operating permit issued under Title V of the Clean Air Act, indicate the classification of your facility



# : Major Source
Synt hetic Minor Source

Minor/Area Source

9

. Permit Conditions If any of the ferroalloys production operations at your facility are subject to State or local air permit limits, please provide a copy of your operating permit. I f you have a Title VEPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUCTION MANUFACTURING EMISSION POINTS



### 6 4/21/2010 permit and it is not available online, please provide a copy of it. If your Title V permit is still pending, please provide a copy of your permit application

10

. List of Enclosed Items List the items submitted with the survey re sponse (e.g., permits, block

- flow diagrams, piping and instrumentation diagrams, test reports, sampling analyses, exceedence reports), and provide an identification code for each item (e.g., attachment 1)

Identification code Description of item submitted with survey response Attachment 1 Process Flow Diagram



### PART I I . GENERAL FACILITY INFORMATION

1

. Process Summary Complete the Process Summary in Table 2A for 2009 (unless you can justify selection of an alte rnate base year) for all unit operations at your plant that are covered by the ferroalloys source category. These include storage and handling of raw materials and products. Complete Table 2B with detailed information for each furnace, and complete Table 2C with details of tapping operations for each furnace.

2. Process Flow Diagram For each unit operation identified in Table 2A , prov ide a process flow diagram that includes all sources of air emissions (e.g., stack emissions, process fugitiv e emissions, and other fugitive emissions [including fugitive dust emissions]). A lso include all associated air pollution control devices.

A simple example is included in Appendix B. Please note that it only represents a portion of the diagram that a ty pical facility should submit.
Also include all activities that generate HAP emissions, including the storage, transfer, handling, and processing of the materials, and wastewater and solid waste handling. Indicate all feedstocks, products, and emission s that contain HAP.
Use the same terminology/codes in identifying unit operations and emissions points in this figure as you will use for the rest of this survey. See Appendix A for EPA’s list of HAPs.EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUCTION MANUFACTURING EMISSION POINTS



### 7 4/21/2010 3. Raw Materials Complete the summary of raw materials used, in Table 2D . Include all the components included in furnace charges for all products, and indicate how much of each was consumed in 2009. For each raw material, indicate the percentage of total consumption used for each end product. I f 2009 was not a representative year, data from another year may be used if an explanation is provided.
For each material potentially containing metal HAP, provide detailed information on origin and composition, including any potential for variability ( e.g., for scrap metal.) Describe the factors that are important in the selection of the raw material.

4. Products and Product Handling A. Complete the summary of products and production volume in Table 2E . List the products, co
- products, and by

- product s identified in the process flow diagram and indicate how much of each was produced in each of the last 5 years.

B. If production in recent years is not consistent or representative of normal plant operations, or if you expect to make changes to the plan t that will affect production, please explain :

_____ N/A

______________________________________________________________

______________________________________________________________________

_____________________________________________________________________ _

______________________________________________________________________

C. Provide a brief narrative description of post

- tapping product handling and processing operations, including storage, conveyance, and any o perations performed on products: Molten metal is separated from the slag and is poured into cooling chills. Once the product has cooled, it is broken apart. Next, the broken pieces are ran through a crusher and the final product is stored in bins awaiting shipment.



### PART I I I

. VENTILATION, CA PTURE AND CONTROL SYSTEMS

1. Capture and Control Summary Complete Table 3A summarizing ventilation / captur e for any air pollution ventilation / capture equipment associated with the processes listed in Table 2A, ( with the exception of capture for furnac es and tapping.) Fugitive emissions from furnace and tapping operations should be included here.

2. Primary and Tapping Capture For each furnace reported as operational (or soon to be operational) prepare a copy of Table 3B detailing capture of primary and tapping emissions with information regarding hoods, enclosures, curtains, etc. which capture emissions from the furnace surface (primary emissions) and from the tap hole (tapping and ancillary operations).
Provide diagrams and brief descriptions t o fully explain configurations.EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUCTION MANUFACTURING EMISSION POINTS



### 8 4/21/2010 3. Control Device Details Complete Table 3C with information on any air pollution contro l equipment . Emissions points exhausting to the same control device may be grouped . If you have any data showing any variation in control device efficiency over time, please attach it.

4. Ladle Post

- Processing Capture and Control Do you perform any post

- tap ladle processing? 

##  ̋ Yes 

## q No

If yes, please provide a narrative description of the process and details of any associ ated capture and control equipment.

_ Preheated hoods an d a ventilation system are used.

_ _____________________________________________________________________

______________________________________________________________________

__________________________ ____________________________________________

______________________________________________________________________ 5. Other Emission Reductions Describe any work practices or pollution prevention measures you have implemented which result in HAP reductio ns

. Please provide any data or calculations you have which quantify the reductions

_ N/A

__________________________________________________________________

______________________________________________________________________

_______________________________ _______________________________________

______________________________________________________________________


### PART IV

. MONITORING SYSTEMS

1. Monitoring Summary Complete Table 4A with details of routine parameter monitoring performed for control device performance indicators. Emission points for which monitoring performed is similar may be grouped. Make copies of the table as needed. Provide details for any opacity monitoring in Table 4B , including uncontrolled emission points, such as roof vents.

2. Visible Emissions Monitoring Test Reports If you conduct routine visible emissions (Method 22 or Method 9) monitoring of the furnace building roof monitor and/or control device outlet to demonstrate compliance with the subpart YYYYYY area source standards , submit copies of the compliance reports for the last 12 months (if applicable).



### PART V

. HAZARDOUS AIR POLLUTANT (HAP) EMISSIONS

1

. Point Source Modeling Data For each emission point that is a point source (e.g., stack from baghouse), complete Tables 5A (for controlled emission points) and 5B (for uncontrolled emission points) indicating the latitude and longitude coordinates, height, diameter, velocity of flow, temperature of the output stream, and nature of the emissions (i.e., continuous or varied over time). If the emissions are varied, indicate how the emissions vary over time if known.EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUCTION MANUFACTURING EMISSION POINTS



### 9 4/21/2010 2

. Non

- Point Modeling Data For each emission point that is a nonpoint source (e.g., fugitive emissions), complete Table 5C. Each nonpoint source should be defi ned as a rectangular area. For Table 5C , indicate the southwest corner latitude and longitude coordinates of the defined nonpoint source area, the release height, length and width dimensions, angle of rotation, and nature of the emissions.

3

. Speciated HAP and Total Particulate Matter (PM) Emissions Complete Tabl es 5D and 5E for each emission point indicated in Tables 5A , 5B , and 5C . For each emission point, indicate the total actual and allowable emissions and concentrati on of each individual HAP emitted (see Appendix A for EPA’s list of HAPs), and the total actual and allowable emissions and concentration of particulate matter. Provide explanations for the basis of speciated emissions. Identify the appropriate emission points using the same terminology/codes you used in preparing the process flow diagram(s) for Section II

- 2 , above.

4

. HAP in Emission Streams Notes on Modeling Data:

Coordinates: For geographic coordinates, provide e ither latitude and longitude or UTM coordinates with zone . L atitude and longitude should be provided in decimal degrees, with 6 digits to right of decimal point

, and an indication of the associated NAD (North American Datum, Either NAD27 or NAD83. If left blank, NAD83 will be assumed

. )

Latitude : measure in decimal degrees of the angular distance on a meridian north or south of the equator. Positive (+) data point for N America. Include (+) sign, Ex. +78.123456. For point sources this represents the center of the source; for fugitive sources this is the southwest corner if the fugitive angle is zero, or the western most corner if the fugitive angle is greater than zero.
Longitude: measure in decimal degrees of the an gular distance on a meridian east or west of the prime meridian. Negative (

- ) data point for N America. Include (

- ) sign, Ex.

- 123.234561. For point sources this represents the center of the source; for fugitive sources this is the southwest corner if the fugitive angle is zero, or the western most corner if the fugitive angle is greater than zero.
Angle of Rotation: A ngle of rotation specifies the rotation of the source from north (in the clockwise direction).The location coordinates (UTM or latitude a nd longitude) should reflect the southwest corner of the area source. The x

- dimension should reflect the length of the source in the easterly direction, or in the southeasterly direction if the source is rotated. The y

- dimension should reflect the length in the northerly direction, or the northeasterly direction if the source is rotated.EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUCTION MANUFACTURING EMISSION POINTS



### 10 4/21/2010 Complete Table 5 F for each emission point and process, with capture, control, and emissions information for each emission stream identified in Tables 5A, 5B, and 5C, with the following considerations:

1. Columns 1

- 3 and 11

- 13 of Table 5 F must be completed for all sources;

2. Complete columns 4

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

3

. Complete columns 8

- 10 of Table 5 F for all sources wit h air pollution control systems (e.g., baghouses);

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

5. It has been assumed that HAP w ill be primarily in particulate form. If significant volatile HAP are emitted, include them in column 13, with a note of the units used. Provide explanations for the basis of speciated emissions.

6. For those emission points from units with Resource Co nservation and Recovery Act (RCRA) Part B permits, it is not necessary to complete Table 5 F for wastewater and solid waste handling operations. 5

. Emission Test Data

1. Enclose any previously conducted test reports, chlorine content of coal analyses, or baghouse dust analyses conducted to determine if your facility is a major source.

2. Enclose summaries of test reports from any emission tests conducted on ferroalloys production processes and air pollution control devices (APCDs) since the year 2003.

Summaries should include:

• Pollutants and emission rates measured;

• The test method or procedure used;
• Information on actual ferroalloy production process conditions at the time the measurements were made;

• If the tests were conducted on outlet streams of APCDs, the APCD operating conditions; and
• Any analyses that have been performed on composition of baghouse catch.

6

. Calculations and Test Reports For calculations based on emission factors, material balances, or engineering principles, submit a step

- by step description of the calculations, including assumptions used, and a brief rationale for the validity of the calculation method used. If test reports are listed as the basis for emissions estimates or capture system and control device efficiencies, include copies of the emission test results (as described above.)EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUCTION MANUFACTURING EMISSION POINTS



### 11 4/21/2010 PART VI

. COST DATA

1. Fabric Filter Costs Complete Table 6A providing annual costs for operating and maintaining EAF fabric filter control devices (i.e., positive pres sure baghouses).

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



### PART VII

. STARTUP AND SHUTDOWN

Please provide the following information for operatio ns during startup and shutdown. Attach ad ditional pages if necessary.

1. Startup and Shutdown Information

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

- up event has occurred: Unknown

____________ ______________________ B. Complete Table 7 for each shutdown and start

- up event occurring over the last three years.

2

. Procedures

List what procedures are followed or any activities that occur during startup and shutdown. Unknown

__________________

_____________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________ 3

. Emissions Profile

Is the emission profile of the process units different during startup and shutdown than during normal operating conditions? Is there a temporary change to the emission profile of the furnace when starting a new furnace, one with a cleaned

- out hearth, or one with a cold hearth after a long shutdown? (If the answer is yes, please explain, in detail, how emissions are different during or after startup and shutdown and why. Please also provide any information that supports your respons e to this question.) No______

______________________________________________________________

______________________________________________________________________

______________________________________________________________________

________________________ ______________________________________________

______________________________________________________________________

______________________________________________________________________

_____________________________________________________________________ _

______________________________________________________________________EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUCTION MANUFACTURING EMISSION POINTS



### 12 4/21/2010 4

. Test Data

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

## q Yes 

##  ̋ No
If yes, when did you conduct such testing and why?

___________________ ___________________________________________________

______________________________________________________________________

______________________________________________________________________

_________________________________________________________________ _____

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

______________________________________________________________________

______________________________________________________________________

_____________________________________________ _________________________

______________________________________________________________________

Were the tests associated with a routine startup or shutdown?

__ ____________________________________________________________________

______________________ ________________________________________________

______________________________________________________________________

______________________________________________________________________

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

5. Startup and Shutdown Plan Please submit a copy of your start

- up and shutdown plan if you are required to develop
one.

6. Startup and Shutdown Reports Ar e you required to submit periodic and immediate start

- up and shutdown reports ( either stand

- alone or contained within the periodic excess emissions report) to your permitting authority? 

##  ̋ Y

es 

## q N oEPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUCTION MANUFACTURING EMISSION POINTS



### 13 4/21/2010 PART VIII

. MISCELLANEOUS

1. Future Plans Describe any future work practice or pollution prevention measures you are considering which may result in emission reductions. Modifications to the Fugitive Dust Plan are being made as needed. This continues to keep the facility operating under the best known work practices and standards to reduce emissions. Update s and modification s t o existing crusher baghouses and to current furnace baghouses in the future may also help to reduce emissions.

___________________________________________________________



### 2. New Source Review If any cont rol or process change you have performed w as instituted as a result of new source review requirements pursuant to 40 CFR Part 51, Subpart I, Review of New Sources and Modifications, provide the date at which the lowest achievable emission rate (LAER) came into effect:

_ N/A

________________________ __________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

3

. Fugitive Dust Sources Fugitive dust sources discharge particles to the atmosphere due to wind or mechanical inducement such as vehicle traffic, and may include plant roadways, yard areas, and outdoor material storage and transfer operations.

Describ e any measures that are employed by your facility to control fugitive dust from such sources. Include description of any written fugitive dust control plans, and any recordkeeping activities associated with fugitive dust control. See Attachment 1

- Fugit ive Dust P lan

________________________________________________ ___________________ ___

_____________________________________________________________________ _

______________________________________________________________________

________________________________ ______________________________________

___________________________________________________________________ ___

4. Other Issues Describe any factors not addressed in the above questions that might serve to distinguish your facility from others in this sour ce category for purposes of developing a separate source category or subcategory and maximum available control technology (MACT) standards. N/A

___________________________________________________________________

_____________________________________________ _________________________

______________________________________________________________________

______________________________________________________________________EPA INFORMATION COLLECTION REQUEST FOR FERROALLOY S PRODUCTION MANUFACTURING EMISSION POINTS



### 14 4/21/2010Ferroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 2. PLANT OPERATIONS Table 2A : Summary of Ferroalloy Production Unit Operations Include all operations referred to in attached process flow diagram

hr/d d/yr Electric Arc Furnace EAF1 16 350 500,000 800,000 Electric Arc Furnace #2 001-01 24 259 34,887 88,476 Electric Arc Furnace #5 001-02 24 308 25,978 43,800 Electric Arc Furnace #7 001-03 24 329 29,371 43,800

* Crushing and Screening #1 009-01 24 365 19,394 175,200 Crushing and Screening #2 009-02 24 365 66,028 175,200

* - Unit did not operate in 2009. Data used is from 2008.

(a) Please use the same ID as used in the process flow diagram. (b) Provide production in appropriate units e.g., tons/yr. Reporting year should be 2009 unless otherwise indicated. Operating Cycle Name of Unit Operations Using and/or Emitting HAP Maximum Annual Production

(tons/yr) Unit Operation Process Diagram ID (a) Average Annual Production (b) (tons/yr)

Sample row is shaded, and shows one representative unit operation. Include all unit operations at your facility in your response.Ferroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 2B : Furnace Information Fill out a copy of this form for each furnace Furnace Process Diagram ID (a) Primary Product (b) Actual Production of primary product 2009 (days/year) Actual Production of primary product 2009 (tons/year) Average Production of primary product (tons/hr) Maximum Production of primary product (tons/hr) Secondary Product (b) Actual Production of secondary product 2009 (days/year) N/A Actual Production of secondary product 2009 (tons/year) N/A Average Production of secondary product (tons/hr) N/A Maximum Production of secondary product (tons/hr) N/A Furnace Design Rotating furnace? Height (ft) 37 Diameter (ft) 17.224 Age of Furnace (yrs) Original capital cost of furnace ($) Remaining economic life (yrs) Average operating rating (MW) Design Rating (MW) Annual Operation (hr/yr) Description of upgrades made to furnace Year(s) upgrade was made (a) Please use the same ID as used in the process flow diagram. (b) If multiple products are produced in a furnace, please indicate percentage of total furnace production. See sample page for example response 2010 SiMn (100%)

N/A

Furnace Dimensions Yes ( ) No (X)

43

Unknown 1 10.1

Unknown

001-01

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

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 2. PLANT OPERATIONS

18

Hydraulic system to model valving and controls 32 5981.5 262.3 34887Table 2B : Furnace Information Fill out a copy of this form for each furnace Furnace Process Diagram ID (a) Primary Product (b) Actual Production of primary product 2009 (days/year) Actual Production of primary product 2009 (tons/year) Average Production of primary product (tons/hr) Maximum Production of primary product (tons/hr) Secondary Product (b) Actual Production of secondary product 2009 (days/year) N/A Actual Production of secondary product 2009 (tons/year) N/A Average Production of secondary product (tons/hr) N/A Maximum Production of secondary product (tons/hr) N/A Furnace Design Rotating furnace? Height (ft) 31 Diameter (ft) 14.5 Age of Furnace (yrs) Original capital cost of furnace ($) Remaining economic life (yrs) Average operating rating (MW) Design Rating (MW) Annual Operation (hr/yr) Description of upgrades made to furnace Year(s) upgrade was made (a) Please use the same ID as used in the process flow diagram. (b) If multiple products are produced in a furnace, please indicate percentage of total furnace production. See sample page for example response N/A Yes ( ) No (X) Furnace Dimensions

35

Unknown 20

N/A 20 7461 Unknown 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 2. PLANT OPERATIONS

001-02 SiMn (100%)

N/A

Open (X) Sealed ( ) Semi or Mixed Sealed ( ) 311.25 25978 2 5Table 2B : Furnace Information Fill out a copy of this form for each furnace Furnace Process Diagram ID (a) Primary Product (b) Actual Production of primary product 2009 (days/year) Actual Production of primary product 2009 (tons/year) Average Production of primary product (tons/hr) Maximum Production of primary product (tons/hr) Secondary Product (b) Actual Production of secondary product 2009 (days/year) N/A Actual Production of secondary product 2009 (tons/year) N/A Average Production of secondary product (tons/hr) N/A Maximum Production of secondary product (tons/hr) N/A Furnace Design Rotating furnace? Height (ft) 31 Diameter (ft) 14.5 Age of Furnace (yrs) Original capital cost of furnace ($) Remaining economic life (yrs) Average operating rating (MW) Design Rating (MW) Annual Operation (hr/yr) Description of upgrades made to furnace Year(s) upgrade was made (a) Please use the same ID as used in the process flow diagram. (b) If multiple products are produced in a furnace, please indicate percentage of total furnace production. See sample page for example response N/A Yes ( ) No (X) Furnace Dimensions

33

Unknown 18

N/A 20 7926.7 Unknown 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 2. PLANT OPERATIONS

001-03 SiMn (100%)

N/A

Open (X) Sealed ( ) Semi or Mixed Sealed ( ) 5 3 29371 330.3Ferroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 2C : Furnace Tapping Information Make additional copies as needed. Unit Operation Process Diagram ID (a) Brief narrative description of tapping process Frequency of Tapping Duration of typical Tapping Event TAP-2 Carbon plug is removed and product is tapped into ladle 12 times daily 25 min

TAP-5 Carbon plug is removed and product is tapped into ladle 12 times daily 25 min

TAP-7 Carbon plug is removed and product is tapped into ladle 12 times daily 25 min

(a) Please use the same ID as used in the process flow diagram. Sample row is shaded



### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS
SECTION 2. PLANT OPERATIONSFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 2D : Summary of Raw Materials Add others as necessary, include units for each.
Raw Material

(by product) Annual Consumption (tons) Origin and Composition Associated Products (% of total for each)
Coke 41455 Unknown 

### SiMn (100%) Manganese Ore 168706 Unknown 

### SiMn (100%)
Quartz 45222 Unknown 

### SiMn (100%) Scrap 420 Unknown 

### SiMn (100%)
Electode Paste 3093 Unknown 

### SiMn (100%)

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 2. PLANT OPERATIONSFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 2E : Summary of Products & Production Volume Add other products as necessary, include units for each.

Product 2005 (tons/yr) 2006 (tons/yr) 2007 (tons/yr) 2008 (tons/yr) 2009 (tons/yr) 

### 50% Ferrosilicon 75% Ferrosilicon Silicon Metal Calcium Carbide Ferromanganese Silicomanganese 0 8602 47504 61044 90237 

### Silifume Other (List): EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS

SECTION 2. PLANT OPERATIONSFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 

### Table 3A: Air Pollution Ventilation/Capture System Parameters (Excluding Furnaces) Make additional copies as needed. Emission Point (a,b) Emission Point (a,b) Emission Point (a,b) Emission Point (a,b) Emission Point (a,b) DH2 DH5 DH7 Local Ventilation System used: Airflow (scfm) Fan ( ) ( ) ( ) ( ) ( ) Other (Specify) ( )____________ ( )____________ ( )____________ ( )____________ ( )____________ Building Ventilation Airflow (scfm) Building Identification ( ) ( ) ( ) ( ) ( ) Open Roof Monitor - Natural Ventilation (X) (X) (X) ( ) ( ) Other (Specify) ( )____________ ( )____________ ( )____________ ( )____________ ( )____________ Enclosure or Hood Design: Airflow (scfm) Complete Enclosure ( ) ( ) ( ) ( ) ( ) Closed Hood ( ) ( ) ( ) ( ) ( ) Canopy or Suspended Hood ( ) ( ) ( ) ( ) ( ) Distance of hood from source Other (Specify) ( )____________ ( )____________ ( )____________ ( )____________ ( )____________ Airflow Control System: Air Curtain ( ) ( ) ( ) ( ) ( ) Drop Curtain Baffling ( ) ( ) ( ) ( ) ( ) Curtain or Baffling Material ( ) ( ) ( ) ( ) ( ) Ductwork ( ) ( ) ( ) ( ) ( ) Other (Specify) ( )____________ ( )____________ ( )____________ ( )____________ ( )____________ (a) Please use the same ID as used in the process flow diagram.

Sample column is shaded Ventilation/Capture System 

## EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 3. CAPTURE & CONTROL

(b) Emissions points using the same capture systems may be grouped. Different emission points using the same capture system may be sent to the same control device, and/or a single emission point may send emissions to 2 or more capture systems (control devices).Ferroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 3B: Primary & Tapping Emissions from Electric Arc Furnaces- Capture Details Furnace specific information (complete worksheet for each furnace).

001-01

Hood Dimensions (ft) (a) Circular Hood Diameter (ft) 17.224 Depth (ft) Unknown (b) Rectangular Hood Length (ft) N/A Width (ft) N/A Depth (ft) N/A 8 Temperature of fume entering hood (°F) 900 Volumetric flow rate entering hood (scfm) Unknown Unknown

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

Yes ( ) No (X)

N/A

How is the enclosure constructed? N/A Wire mesh ( ) N/A Chain curtain ( ) N/A Ceramic curtain ( ) N/A

Hydraulic door ( ) N/A Other ( ) Describe --> N/A N/A N/A Standard best practice implementation

90

N/A

(a) Please use the same ID as used in the process flow diagram See sample page for example response If Yes, percent of total area surrounded by enclosure ( e.g ., 60% of hood circumference)

Dimensions of openings in enclosure (ft) Distance between top of furnace and curtain (ft) Describe measures taken to ensure proper operation of ventilation system ( e.g ., periodic or continuous monitoring of volumetric flowrate in ductwork downstream of capture hoods, fan power consumption and pressure drop across fans, systematic inspection and maintenance, others)

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

Is there an enclosure ( e.g. , curtain or door panels around the furnace) Distance between top of furnace and hood (ft) Primary Emissions Capture

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

If Yes, describe factors which cause variation in flow rate Cooled 7 section roof/hood section with 4+ pull offs for removing emmissions to the baghouse. It's constructed of sheet,tube and angle steel and stainless steel Narrative description of furnace hood configuration

Please attach diagrams if available 

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

SECTION 3. CAPTURE & CONTROL

Furnace Process Diagram ID (a)

Airflow Control: Describe other airflow control and ventilation systems associated with the furnace. Include building ventilation (roof vents, etc.) and other airflow control systems (air curtains, drop curtain baffling, etc.)Ferroalloys Production Manufacturing Emission Points Survey Page 16 10/21/2011 

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

SECTION 3. CAPTURE & CONTROL

Hood Dimensions (ft) (a) Circular Hood Diameter (ft) Depth (ft) (b) Rectangular Hood Length (ft) 16 Width (ft) 8.5 Depth (ft) Unknown 0.25 3 Unknown 6 8 Temperature of fume entering hood (°F) Unknown

Volumetric flow rate entering hood (scfm) Unknown Unknown

Yes (X) No ( ) Unknown

N/A

30

N/A

N/A

(a) Please use the same ID as used in the process flow diagram. See sample page for example response If you do not use curtains on or surrounding the hood controlling primary emissions, do you anticipate any problems in installing and using them? If so, please describe.

If you do not have a dedicated tap hood, do you anticipate any problems in installing and using such a hood? If so, please describe. Please describe the design basis upon which the flow rate was determined

If Yes, describe factors which cause variation in flow rate

Describe measures taken to ensure proper operation of ventilation system ( e.g ., periodic or continuous monitoring of volumetric flowrate in ductwork downstream of capture hoods, fan power consumption and pressure drop across fans, systematic inspection and maintenance, others) Best estimate of % capture achieved (based on visual estimates)

Other Capture Related Information (use additional pages if needed) Does this flow rate vary? Clam shell style hood separated in center with duct work and forced air fan to pull emissions off to the baghouse. Please attach diagrams if available Tapping Emissions Capture Table 3B: (Continued) Primary & Tapping Emissions from Electric Arc Furnaces - Capture Details

Distance between ladle and bottom of hood (ft) Diameter of ladle tapped product is poured into (ft) Narrative description of tap hood configuration

Tap hole diameter (ft) Distance between center of tap hole and hood (ft) Distance between center of tap hole and bottom of hood (ft)Ferroalloys Production Manufacturing Emission Points Survey Page 17 10/21/2011 

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

SECTION 3. CAPTURE & CONTROL
Table 3B: Primary & Tapping Emissions from Electric Arc Furnaces- Capture Details Furnace specific information (complete worksheet for each furnace).

001-02

Hood Dimensions (ft) (a) Circular Hood Diameter (ft) 14.5 Depth (ft) Unknown (b) Rectangular Hood Length (ft) N/A Width (ft) N/A Depth (ft) N/A 8 Temperature of fume entering hood (°F) 900 Volumetric flow rate entering hood (scfm) Unknown Unknown

Does this flow rate vary? Yes (X) No ( ) Unknown Yes ( ) No (X)
N/A

How is the enclosure constructed? N/A Wire mesh ( ) N/A Chain curtain ( ) N/A Ceramic curtain ( ) N/A

Hydraulic door ( ) N/A Other ( ) Describe --> N/A N/A N/A Standard best practice implementation

90
N/A

(a) Please use the same ID as used in the process flow diagram See sample page for example response Distance between top of furnace and curtain (ft) Describe measures taken to ensure proper operation of ventilation system ( e.g ., periodic or continuous monitoring of volumetric flowrate in ductwork downstream of capture hoods, fan power consumption and pressure drop across fans, systematic inspection and maintenance, others) Best estimate of % capture achieved (based on visual estimates)
Airflow Control: Describe other airflow control and ventilation systems associated with the furnace. Include building ventilation (roof vents, etc.) and other airflow control systems (air curtains, drop curtain baffling, etc.) Distance between top of furnace and hood (ft)

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

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

Dimensions of openings in enclosure (ft) Furnace Specifications Furnace Process Diagram ID (a) Primary Emissions Capture Narrative description of furnace hood configuration Cooled 7 section roof/hood section with 4+ pull offs for removing emmissions to the baghouse. It's constructed of sheet,tube and angle steel and stainless steel Please attach diagrams if availableFerroalloys Production Manufacturing Emission Points Survey Page 18 10/21/2011 

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

SECTION 3. CAPTURE & CONTROL

Hood Dimensions (ft) N/A (a) Circular Hood Diameter (ft) N/A Depth (ft) N/A (b) Rectangular Hood Length (ft) 16 Width (ft) 8.5 Depth (ft) Unknown 0.25 3 Unknown 6 8 Temperature of fume entering hood (°F) Unknown Volumetric flow rate entering hood (scfm) Unknown

Unknown

Yes (X) No ( ) Unknown

N/A

30

N/A

N/A

(a) Please use the same ID as used in the process flow diagram. See sample page for example response Best estimate of % capture achieved (based on visual estimates)
Other Capture Related Information (use additional pages if needed) If you do not use curtains on or surrounding the hood controlling primary emissions, do you anticipate any problems in installing and using them? If so, please describe.

If you do not have a dedicated tap hood, do you anticipate any problems in installing and using such a hood? If so, please describe. Diameter of ladle tapped product is poured into (ft) Distance between ladle and bottom of hood (ft)

Please describe the design basis upon which the flow rate was determined Does this flow rate vary? If Yes, describe factors which cause variation in flow rate

Describe measures taken to ensure proper operation of ventilation system ( e.g ., periodic or continuous monitoring of volumetric flowrate in ductwork downstream of capture hoods, fan power consumption and pressure drop across fans, systematic inspection and maintenance, others) Narrative description of tap hood configuration Clam shell style hood separated in center with duct work and forced air fan to pull emissions off to the baghouse.

Please attach diagrams if available

Tap hole diameter (ft) Distance between center of tap hole and hood (ft) Distance between center of tap hole and bottom of hood (ft) Table 3B: (Continued) Primary & Tapping Emissions from Electric Arc Furnaces - Capture Details Tapping Emissions CaptureFerroalloys Production Manufacturing Emission Points Survey Page 19 10/21/2011 

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

SECTION 3. CAPTURE & CONTROL
Table 3B: Primary & Tapping Emissions from Electric Arc Furnaces- Capture Details Furnace specific information (complete worksheet for each furnace).

001-03

Hood Dimensions (ft) (a) Circular Hood Diameter (ft) 14.5 Depth (ft) Unknown (b) Rectangular Hood Length (ft) N/A Width (ft) N/A Depth (ft) N/A 8 Temperature of fume entering hood (°F) 900 Volumetric flow rate entering hood (scfm) Unknown Unknown Does this flow rate vary? Yes (X) No ( ) Unknown Yes ( ) No (X)
N/A

How is the enclosure constructed? N/A Wire mesh ( ) N/A Chain curtain ( ) N/A Ceramic curtain ( ) N/A

Hydraulic door ( ) N/A Other ( ) Describe --> N/A N/A N/A
Standard best practice implementation

90

N/A

(a) Please use the same ID as used in the process flow diagram See sample page for example response Best estimate of % capture achieved (based on visual estimates)

Airflow Control: Describe other airflow control and ventilation systems associated with the furnace. Include building ventilation (roof vents, etc.) and other airflow control systems (air curtains, drop curtain baffling, etc.) If Yes, describe factors which cause variation in flow rate Is there an enclosure ( e.g. , curtain or door panels around the furnace) If Yes, percent of total area surrounded by enclosure ( e.g ., 60% of hood circumference)

Dimensions of openings in enclosure (ft) Distance between top of furnace and curtain (ft)
Describe measures taken to ensure proper operation of ventilation system ( e.g ., periodic or continuous monitoring of volumetric flowrate in ductwork downstream of capture hoods, fan power consumption and pressure drop across fans, systematic inspection and maintenance, others) Primary Emissions Capture Narrative description of furnace hood configuration Cooled 7 section roof/hood section with 4+ pull offs for removing emmissions to the baghouse. It's constructed of sheet,tube and angle steel and stainless steel

Please attach diagrams if available

Distance between top of furnace and hood (ft)

Please describe the design basis upon which the flow rate was Furnace Specifications Furnace Process Diagram ID (a)Ferroalloys Production Manufacturing Emission Points Survey Page 20 10/21/2011 

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

SECTION 3. CAPTURE & CONTROL

Hood Dimensions (ft) (a) Circular Hood Diameter (ft) Depth (ft) (b) Rectangular Hood Length (ft) 16 Width (ft) 8.5 Depth (ft) Unknown 0.25 3 Unknown 6 8 Temperature of fume entering hood (°F) Unknown Volumetric flow rate entering hood (scfm) Unknown Unknown

Yes (X) No ( ) Unknown

N/A

30

N/A

N/A

(a) Please use the same ID as used in the process flow diagram. See sample page for example response If you do not have a dedicated tap hood, do you anticipate any problems in installing and using such a hood? If so, please describe. Does this flow rate vary? If Yes, describe factors which cause variation in flow rate

Describe measures taken to ensure proper operation of ventilation system ( e.g ., periodic or continuous monitoring of volumetric flowrate in ductwork downstream of capture hoods, fan power consumption and pressure drop across fans, systematic inspection and maintenance, others) Best estimate of % capture achieved (based on visual estimates)
Other Capture Related Information (use additional pages if needed) If you do not use curtains on or surrounding the hood controlling primary emissions, do you anticipate any problems in installing and using them? If so, please describe. Tap hole diameter (ft) Distance between center of tap hole and hood (ft) Distance between center of tap hole and bottom of hood (ft) Diameter of ladle tapped product is poured into (ft) Distance between ladle and bottom of hood (ft)

Please describe the design basis upon which the flow rate was determined Table 3B: (Continued) Primary & Tapping Emissions from Electric Arc Furnaces - Capture Details Tapping Emissions Capture Narrative description of tap hood configuration Clam shell style hood separated in center with duct work and forced air fan to pull emissions off to the baghouse.

Please attach diagrams if availableFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 

### Table 3C: Air Pollution Control Equipment Parameters (Include sections as needed) Copy sections as needed Emission Point (a,b) Emission Point (a,b) Emission Point (a,b) Emission Point (a,b) Emission Point (a,b)

001-01 001-02 001-03 009-01 / 009-02 009-03 / 009-04 / 009-05

Control Device ID: Baghouse Actual / 0002 Actual / 0003 Actual / 0004 Actual / 000D / 000E / 0006 Actual / 000F / 0008 Date installed/rebuilt 1973 1973 1973 1952 1968/ 1980

Manufacturer/Model Number American Air Filter American Air Filter American Air Filter Wheelabrator (D,6), American Air Filter (E) American Air Filter (F), Norblo (8) Original installed cost (capital cost plus installation cost) Unknown Unknown Unknown Unknown Unknown Gas Inlet Temp. (deg F) 209 293 230 N/A N/A Maximum operating temperature (deg F) 330 330 330 70 70

Bag material, weight, & coating Polyester, 6oz., N/A Polyester, 6oz., N/A Polyester, 6oz., N/A Polyester, 6oz., N/A Polyester, 6oz., N/A

Cleaning method & frequency Reversed Air / Weekly Reversed Air / Weekly Reversed Air / Weekly Shaker Shaker Air to cloth ratio (acfm/sqft) 2.05 2.05 2.05 Unknown Unknown Number of compartments 11 7 7 2 2 Number of bags per compartment 256 256 256 256 256 Pressure drop across baghouse (in H2O) 8"-12" 8"-12" 8"-12" 3"-7" 3"-7" Pressure drop across cells (in H2O) (-) 2" - 8" (-) 2" - 8" (-) 2" - 8" (-) 2" - 8" (-) 2" - 8" Positive or negative pressure baghouse? Positive Positive Positive Positive Positive Positive pressure baghouse dilution air flowrate (dscf) 278423 239891 130063 Unknown Unknown Stack opacity (%) 10.8% 0.0% 0.4% 0.0% 0.0% Design collection efficiency 99.5% 99.5% 99.5% 99.5% 99.5% Measured collection efficiency 99.5% 99.5% 99.5% 99.5% 99.5% Controlled particulate emissions (gr/dscf) 0.001 0.001 0.002 0.005 0.002 Amount of particulate collected (lb/mo or specify) 1483.2 lb/mo 2556.0 lb/mo 4024.8 lb/mo 237.6 lb/mo 118.1 lb/mo Describe what is done with collected baghouse dust Stockpiled Stockpiled Stockpiled Stockpiled Stockpiled Control Device ID: Scrubber Type of Scrubber (Venturi, packed bed, impingement, other (specify)) Year installed Manufacturer/Model Number Original installed cost (capital cost plus installation cost) Gas Inlet Temp. (deg F) Gas Outlet Temp. (deg F) Pressure drop (in H2O) Liquid-to-gas ratio (gal/10^3 acfm) Inlet scrubbing liquor pH % solids Type of alkali added (if any) Rate (lbs/gal) Effluent scrubbing liquor pH Wastewater generation rate (gal/min) HAP composition of wastewater (mg/l) Mist eliminator  Ye s  No What is done with the sludge? Design collection efficiency Measured collection efficiency Controlled particulate emissions (gr/dscf) Control Device ID: Electrostatic Precipitator N/A Year installed Manufacturer/Model Number Original installed cost (capital cost plus installation cost) Gas Inlet Temp. (deg F) Particle resistivity (ohm-centimeter) Specific collection area (ft^2/1,000 acfm) Conditioning agents used (sulfur trioxide, sodium componds, etc.) Stack opacity (%) Design collection efficiency Measured collection efficiency Controlled particulate emissions (gr/dscf) Control Device ID: Mechanical Collectors N/A Type of collector (e.g., Multicyclone) Number of collectors Range of particle size (μm) Gas flowrate (acfm @ deg F) Overall pressure drop (in H2O) Stack opacity (%) Design collection efficiency Measured collection efficiency Controlled particulate emissions (gr/dscf) Control Device ID: Other (Incinerators, Flares, etc.) N/A Include items as appropriate Type of device Year installed Manufacturer/Model Number Original installed cost (capital cost plus installation cost) Gas flowrate (acfm @ deg F) Overall pressure drop (in H2O) Stack opacity (%) Design collection efficiency Measured collection efficiency Controlled particulate emissions (gr/dscf) Other Parameters (fill in as needed) Other __________________________ Units___________ Other __________________________ Units___________ Other __________________________ Units___________ Other __________________________ Units___________ Other __________________________ Units___________ (a) Please use the same ID as used in the process flow diagram.

(c) Provide documentation of the basis for equipment parameters (design, actual, etc.) (d) Provide copies of estimation worksheets or other documentation of the basis for emission estimates. See sample page for example response (b) Emissions points using the same control systems may be grouped. Different emission points using the same capture system may be sent to the same control device, and/or a single emission point may send emissions to 2 or more capture systems (control devices).



## EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 3. CAPTURE & CONTROL

Control System & Parameters (c,d)

N/AFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 4A: Air Pollution Control Device Parameter Monitoring (Include sections as needed) Include all parameters or activities which are monitored or for which records are maintained. Opacity and Visible Emissions monitoring should be detailed in Table 4B.

Yes No Control Device ID: Baghouse Emission Points: BH2, BH5, BH7, BH1S, BH2S Outlet PM Concentration (CEM) X gr/dscf 1 / Year Method 5D Record Keeping Bag Leak Detectors X Pressure Differential Across Cells X H2O 1 / Day Continuous Monitor Regular Maintenance Pressure Differential Across Baghouse X Inlet Gas Temperature X deg F 1 / Day Continuous Monitor Regular Maintenance Temperature Differential X deg F 1 / Day Continuous Monitor Exhaust Gas Flow Rate X dscfm 1 / Year Method 2 Record Keeping Cleaning Mechanism Operation X 1 / Week Visual Record Keeping Fan Current X amperes 1 / Shift Continuous Monitor Record Keeping Inspections & Maintenance X 1 / Quarter Maintenance Records Maintained Other (_VE Observation_______________________________) X % 1 / Day Method 9 Record Keeping Control Device ID: Scrubber Emission Points: N/A Pressure Differential Liquid Flow Rate

Gas Flow Rate Scrubber Inlet Gas Temperature Scrubber Outlet Gas Temperature Makeup/blowdown rate Scrubber Liquid Solids Content Scrubber Liquid pH Neutralizing Chemical Feed Rate Scrubber Liquid Specific Gravity Other (_____________________________________________________) Control Device ID: Electrostatic Precipitator Emission Points: N/A Outlet PM Concentration Secondary Corona Power (Current & Voltage) Spark Rate Primary Power (Current & Voltage) Inlet Gas Temperature Gas Flow Rate Rapper Operation Fields in Operation Inlet Water Flow Rate (Wet Type) Flush Water Solids Content (Wet Type) Other (_____________________________________________________) Control Device ID: Cyclone Emission Points: N/A Inlet Velocity or Inlet Gas Flow Rate Pressure Differential Inlet Gas Temperature Other (_____________________________________________________) Make copies as needed. (a) Please use the same ID as used in the process flow diagram (b) Provide documentation of the basis for equipment parameters (design, actual, etc.) (c) Provide copies of estimation worksheets or other documentation of the basis for emission estimates. See sample page for example response 

## EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 4. MONITORING

Control System & Performance Indicating Parameters Monitored (a,b,c) Frequency of Monitoring Describe Quality Assurance Monitoring Method Monitored? Units MeasuredFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 

### Table 4B: Opacity/Visible Emissions Monitoring Information Make copies as needed

Emission Point (a)_ BH2

______________________________________ Method 9 or Method 22 Method 22 1 / shift Record Keeping Continuous Opacity Monitoring (COM) Continuous Emission Monitoring (CEM) Other (______________________________) Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis) 0% Average Opacity or VE observed for this Emission Point (Please note units) 0% Emission Point (a)_ BH5

______________________________________ Method 9 or Method 22 Method 22 1 / shift Record Keeping Continuous Opacity Monitoring (COM) Continuous Emission Monitoring (CEM) Other (______________________________) Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis) 0% Average Opacity or VE observed for this Emission Point (Please note units) 0% Emission Point (a)_ BH7

______________________________________ Method 9 or Method 22 Method 22 1 / shift Record Keeping Continuous Opacity Monitoring (COM) Continuous Emission Monitoring (CEM) Other (______________________________) Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis) 0% Average Opacity or VE observed for this Emission Point (Please note units) 0% Emission Point (a)_ BH1S

_____________________________________ Method 9 or Method 22 Method 22 1 / shift Record Keeping Continuous Opacity Monitoring (COM) Continuous Emission Monitoring (CEM) Other (______________________________) Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis) 0% Average Opacity or VE observed for this Emission Point (Please note units) 0% Emission Point (a)_ BH2S

_____________________________________ Method 9 or Method 22 Method 22 1 / shift Record Keeping Continuous Opacity Monitoring (COM) Continuous Emission Monitoring (CEM) Other (______________________________) Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis) 0% Average Opacity or VE observed for this Emission Point (Please note units) 0% Emission Point (a)_ DH2

______________________________________ Method 9 or Method 22 Method 9 1 / year Record Keeping Continuous Opacity Monitoring (COM) Continuous Emission Monitoring (CEM) Other (______________________________) Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis) 20% Average Opacity or VE observed for this Emission Point (Please note units) 10.8% Emission Point (a)_ DH5

______________________________________ Method 9 or Method 22 Method 9 1 / year Record Keeping Continuous Opacity Monitoring (COM) Continuous Emission Monitoring (CEM) Other (______________________________) Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis) 20% Average Opacity or VE observed for this Emission Point (Please note units) 5.5% Emission Point (a)_ DH7

______________________________________ Method 9 or Method 22 Method 9 1 / year Record Keeping Continuous Opacity Monitoring (COM) Continuous Emission Monitoring (CEM) Other (______________________________) Opacity or VE Limit for this Emission Point (if any.) (Please note units & basis) 20% Average Opacity or VE observed for this Emission Point (Please note units) 0.4% (a) Please use the same ID as used in the process flow diagram Sample row is shaded 

## EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 4. MONITORING

Monitoring Method Describe Quality Assurance Opacity or Visible Emissions Monitoring Frequency of MonitoringFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 5A: Controlled Emission Point Modeling Parameters (Point Sources) Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Height Diameter Velocity Temp. Lat Long NAD (d ) m m m/s K BH2 38.958308 -81.927558 NAD83 25.908 3.6576 0.411 335.6

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information (c) See notes in Appendix B regarding modeling parameters for positive pressure baghouses. (d) North American Datum. Either NAD27 or NAD83. If left blank, NAD83 will be assumed Emission Point ID (a) Unit Operation Name and Process Diagram ID(a): 001-01 Release Parameters for Risk Modeling (b,c) 

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

CoordinatesFerroalloys Production Manufacturing Emission Points Survey Page 16 10/21/2011 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 5. HAP EMISSIONS Table 5A: Controlled Emission Point Modeling Parameters (Point Sources) Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Height Diameter Velocity Temp. Lat Long NAD (d ) m m m/s K BH5 38.958571 -81.927117 NAD83 25.908 2.80416 0.558 321.09

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information (c) See notes in Appendix B regarding modeling parameters for positive pressure baghouses. (d) North American Datum. Either NAD27 or NAD83. If left blank, NAD83 will be assumed Unit Operation Name and Process Diagram ID(a): 001-02

Emission Point ID (a) Release Parameters for Risk Modeling (b,c) CoordinatesFerroalloys Production Manufacturing Emission Points Survey Page 17 10/21/2011 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 5. HAP EMISSIONS Table 5A: Controlled Emission Point Modeling Parameters (Point Sources) Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Height Diameter Velocity Temp. Lat Long NAD (d ) m m m/s K BH7 38.958805 -81.926700 NAD83 25.908 2.80416 0.561 335.57

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information (c) See notes in Appendix B regarding modeling parameters for positive pressure baghouses. (d) North American Datum. Either NAD27 or NAD83. If left blank, NAD83 will be assumed Unit Operation Name and Process Diagram ID(a): 001-03

Emission Point ID (a) Release Parameters for Risk Modeling (b,c) CoordinatesFerroalloys Production Manufacturing Emission Points Survey Page 18 10/21/2011 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 5. HAP EMISSIONS Table 5A: Controlled Emission Point Modeling Parameters (Point Sources) Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Height Diameter Velocity Temp. Lat Long NAD (d ) m m m/s K BH1S 38.957957 -81.925265 NAD83 10.668 0.368808 19.22 281.58

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information (c) See notes in Appendix B regarding modeling parameters for positive pressure baghouses. (d) North American Datum. Either NAD27 or NAD83. If left blank, NAD83 will be assumed Unit Operation Name and Process Diagram ID(a): 009-01

Emission Point ID (a) Release Parameters for Risk Modeling (b,c) CoordinatesFerroalloys Production Manufacturing Emission Points Survey Page 19 10/21/2011 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 5. HAP EMISSIONS Table 5A: Controlled Emission Point Modeling Parameters (Point Sources) Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Height Diameter Velocity Temp. Lat Long NAD (d ) m m m/s K BH2S 38.957891 -81.925391 NAD83 10.668 0.560832 10.99 299.72

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information (c) See notes in Appendix B regarding modeling parameters for positive pressure baghouses. (d) North American Datum. Either NAD27 or NAD83. If left blank, NAD83 will be assumed Unit Operation Name and Process Diagram ID(a): 009-02

Emission Point ID (a) Release Parameters for Risk Modeling (b,c) CoordinatesFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 5B: Uncontrolled Emission Point Modeling Parameters (Point Sources) Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Height Diameter Velocity Temp. Lat Long NAD ( c) m m m/s K

DH2 Excess emissions produced from tapping process 38.957307 -81.927784 NAD83 24.384 4.6 Ambient Air Flow Ambient Air Flow

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information (c) North American Datum. Either NAD27 or NAD83. If left blank, NAD83 will be assumed



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

Unit Operation Name and Process Diagram ID(a): 001-01

Emission Point ID (a) Release Parameters for Risk Modeling (b) Reason for Release Point CoordinatesFerroalloys Production Manufacturing Emission Points Survey Page 16 10/21/2011 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 5. HAP EMISSIONS Table 5B: Uncontrolled Emission Point Modeling Parameters (Point Sources) Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Height Diameter Velocity Temp. Lat Long NAD ( c) m m m/s K

DH5 Excess emissions produced from tapping process 38.957781 -81.926727 NAD83 18.288 4.6 Ambient Air Flow Ambient Air Flow

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information (c) North American Datum. Either NAD27 or NAD83. If left blank, NAD83 will be assumed Unit Operation Name and Process Diagram ID(a): 001-02

Emission Point ID (a) Reason for Release Point Release Parameters for Risk Modeling (b) CoordinatesFerroalloys Production Manufacturing Emission Points Survey Page 17 10/21/2011 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 5. HAP EMISSIONS Table 5B: Uncontrolled Emission Point Modeling Parameters (Point Sources) Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Height Diameter Velocity Temp. Lat Long NAD ( c) m m m/s K

DH7 Excess emissions produced from tapping process 38.958043 -81.926275 NAD83 18.288 4.6 Ambient Air Flow Ambient Air Flow

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information (c) North American Datum. Either NAD27 or NAD83. If left blank, NAD83 will be assumed Emission Point ID (a) Reason for Release Point Release Parameters for Risk Modeling (b) Coordinates Unit Operation Name and Process Diagram ID(a): 001-03Ferroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 5C: Emission Point Modeling Parameters (Nonpoint Sources) Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Release Height Lat Long NAD (c) (m) x (length, m) y (width, m) E7 38.897701 -77.036625 NAD27 10 30 20 12.5 OS1 (Quartzite) 38.958534 -81.927551 NAD83 16.58 41.97 41.97 45 OS2 (Mn Ore) 38.958895 -81.926992 NAD83 21.37 54.11 54.11 45 OS3 (Coke) 38.95881 -81.92747 NAD83 25.18 58.14 58.14 45

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information (c) North American Datum. Either NAD27 or NAD83. If left blank, NAD83 will be assumed (d) Dimension of source refers to the area defined as a nonpoint source emission (e.g., open air dust pile) (e) angle of rotation specifies the rotation of the source from north (in the clockwise direction) Sample row is shaded 

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

Unit Operation Name and Process Diagram ID (a): 001-01, 001-02, 001-03

Emission Points (a) Release Parameters for Risk Modeling (b) Dimension of Source (d) Angle of Rotation (e) (degrees) CoordinatesFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 5D: Speciated HAP Emissions - Actual and Allowable Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Actual HAP Emissions Actual HAP Concentration Allowable HAP Emissions Allowable HAP Concentration

tpy ppm tpy ppm E1 Manganese 150 0.05 test data 200 0.1 WV 23709 - IV-(d) E1 Lead 0.02 0.0001 test data 0.03 0.0005 WV 23709 - IV-(d) E2 Manganese 200 0.1 calculated 250 0.2 WV 23709 - IV-(d) E2 Lead 0.05 0.0008 calculated 0.08 0.001 WV 23709 - IV-(d) BH2 ANTIMONY 0.000586 Unknown Calculated No Limit No Limit Grandfathered BH2 ARSENIC 0.00355 Unknown Calculated No Limit No Limit Grandfathered BH2 BERYLLIUM 0.0000627 Unknown Calculated No Limit No Limit Grandfathered BH2 CADMIUM 0.00266 Unknown Calculated No Limit No Limit Grandfathered BH2 CHROMIUM 0.00218 Unknown Calculated No Limit No Limit Grandfathered BH2 COBALT 0.000289 Unknown Calculated No Limit No Limit Grandfathered BH2 LEAD 0.179 Unknown Calculated No Limit No Limit Grandfathered BH2 MANGANESE 12.26 Unknown Calculated No Limit No Limit Grandfathered BH2 MERCURY 0.0000435 Unknown Calculated No Limit No Limit Grandfathered BH2 NICKEL 0.000942 Unknown Calculated No Limit No Limit Grandfathered BH2 SELENIUM 0.00698 Unknown Calculated No Limit No Limit Grandfathered

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information Sample rows are shaded and illustrate where two or more HAP are emitted from a single emission point. Unit Operation Name and Process Diagram ID(a): 001-01 

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

Emission Point HAP Emissions (b)

HAP Emitted Actual HAP Emissions Allowable HAP Emissions Emission Point ID (a) Basis for Emissions

Estimate Basis for Allowable LimitFerroalloys Production Manufacturing Emission Points Survey Page 16 10/21/2011 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 5. HAP EMISSIONS Table 5D: Speciated HAP Emissions - Actual and Allowable Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Actual HAP Emissions Actual HAP Concentration Allowable HAP Emissions Allowable HAP Concentration
tpy ppm tpy ppm E1 Manganese 150 0.05 test data 200 0.1 WV 23709 - IV-(d) E1 Lead 0.02 0.0001 test data 0.03 0.0005 WV 23709 - IV-(d) E2 Manganese 200 0.1 calculated 250 0.2 WV 23709 - IV-(d) E2 Lead 0.05 0.0008 calculated 0.08 0.001 WV 23709 - IV-(d) BH5 ANTIMONY 0.000436 Unknown Calculated No Limit No Limit Grandfathered BH5 ARSENIC 0.00264 Unknown Calculated No Limit No Limit Grandfathered BH5 BERYLLIUM 0.0000467 Unknown Calculated No Limit No Limit Grandfathered BH5 CADMIUM 0.00198 Unknown Calculated No Limit No Limit Grandfathered BH5 CHROMIUM 0.00162 Unknown Calculated No Limit No Limit Grandfathered BH5 COBALT 0.000215 Unknown Calculated No Limit No Limit Grandfathered BH5 LEAD 0.133 Unknown Calculated No Limit No Limit Grandfathered BH5 MANGANESE 9.13 Unknown Calculated No Limit No Limit Grandfathered BH5 MERCURY 0.0000324 Unknown Calculated No Limit No Limit Grandfathered BH5 NICKEL 0.000701 Unknown Calculated No Limit No Limit Grandfathered BH5 SELENIUM 0.0052 Unknown Calculated No Limit No Limit Grandfathered

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information Sample rows are shaded and illustrate where two or more HAP are emitted from a single emission point. Unit Operation Name and Process Diagram ID(a): 001-02

Emission Point ID (a) Emission Point HAP Emissions (b)

HAP Emitted Actual HAP Emissions Allowable HAP Emissions

Basis for Emissions

Estimate Basis for Allowable LimitFerroalloys Production Manufacturing Emission Points Survey Page 17 10/21/2011 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 5. HAP EMISSIONS Table 5D: Speciated HAP Emissions - Actual and Allowable Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Actual HAP Emissions Actual HAP Concentration Allowable HAP Emissions Allowable HAP Concentration
tpy ppm tpy ppm E1 Manganese 150 0.05 test data 200 0.1 WV 23709 - IV-(d) E1 Lead 0.02 0.0001 test data 0.03 0.0005 WV 23709 - IV-(d) E2 Manganese 200 0.1 calculated 250 0.2 WV 23709 - IV-(d) E2 Lead 0.05 0.0008 calculated 0.08 0.001 WV 23709 - IV-(d) BH7 ANTIMONY 0.000493 Unknown Calculated No Limit No Limit Grandfathered BH7 ARSENIC 0.00299 Unknown Calculated No Limit No Limit Grandfathered BH7 BERYLLIUM 0.0000528 Unknown Calculated No Limit No Limit Grandfathered BH7 CADMIUM 0.00224 Unknown Calculated No Limit No Limit Grandfathered BH7 CHROMIUM 0.00183 Unknown Calculated No Limit No Limit Grandfathered BH7 COBALT 0.000244 Unknown Calculated No Limit No Limit Grandfathered BH7 LEAD 0.151 Unknown Calculated No Limit No Limit Grandfathered BH7 MANGANESE 10.32 Unknown Calculated No Limit No Limit Grandfathered BH7 MERCURY 0.0000366 Unknown Calculated No Limit No Limit Grandfathered BH7 NICKEL 0.000793 Unknown Calculated No Limit No Limit Grandfathered BH7 SELENIUM 0.00588 Unknown Calculated No Limit No Limit Grandfathered

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information Sample rows are shaded and illustrate where two or more HAP are emitted from a single emission point. Unit Operation Name and Process Diagram ID(a): 001-03

Emission Point ID (a) Emission Point HAP Emissions (b)

HAP Emitted Actual HAP Emissions Allowable HAP Emissions

Basis for Emissions

Estimate Basis for Allowable LimitFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 5E: Total Particulate Matter (PM) Emissions - Actual and Allowable Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Total Actual PM Emissions (per emission point) Actual PM Concentration (per emission point) Total Allowable PM Emissions (per emission point) Allowable PM Concentration (per emission point)

tpy gr/dscf (or specify) tpy gr/dscf (or specify) E1 213 0.0322 Test Data 300 0.05 WV 23709 - IV-(a) E2 400 0.0625 Calculated 500 0.075 WV 23709 - IV-(a) BH2 9.02 0.001 Test Data No Limit No Limit Grandfathered

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information Sample rows are shaded Allowable PM Emissions

Basis for Emissions

Estimate Basis for Allowable Limit 

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

Unit Operation Name and Process Diagram ID(a): 001-01

Emission Point ID (a) Emission Point PM Emissions (b) Actual PM EmissionsFerroalloys Production Manufacturing Emission Points Survey Page 16 10/21/2011 

## EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 5. HAP EMISSIONS Table 5E: Total Particulate Matter (PM) Emissions - Actual and Allowable Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Total Actual PM Emissions (per emission point) Actual PM Concentration (per emission point) Total Allowable PM Emissions (per emission point) Allowable PM Concentration (per emission point)
tpy gr/dscf (or specify) tpy gr/dscf (or specify) E1 213 0.0322 Test Data 300 0.05 WV 23709 - IV-(a) E2 400 0.0625 Calculated 500 0.075 WV 23709 - IV-(a) BH5 15.55 0.001 Test Data No Limit No Limit Grandfathered

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information Sample rows are shaded Unit Operation Name and Process Diagram ID(a): 001-02

Emission Point ID (a) Emission Point PM Emissions (b) Actual PM Emissions Allowable PM Emissions

Basis for Emissions

Estimate Basis for Allowable LimitFerroalloys Production Manufacturing Emission Points Survey Page 17 10/21/2011 

## EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 5. HAP EMISSIONS Table 5E: Total Particulate Matter (PM) Emissions - Actual and Allowable Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Total Actual PM Emissions (per emission point) Actual PM Concentration (per emission point) Total Allowable PM Emissions (per emission point) Allowable PM Concentration (per emission point)
tpy gr/dscf (or specify) tpy gr/dscf (or specify) E1 213 0.0322 Test Data 300 0.05 WV 23709 - IV-(a) E2 400 0.0625 Calculated 500 0.075 WV 23709 - IV-(a) BH7 24.48 0.002 Test Data No Limit No Limit Grandfathered

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information Sample rows are shaded Unit Operation Name and Process Diagram ID(a): 001-03

Emission Point ID (a) Emission Point PM Emissions (b) Actual PM Emissions Allowable PM Emissions

Basis for Emissions

Estimate Basis for Allowable LimitFerroalloys Production Manufacturing Emission Points Survey Page 18 10/21/2011 

## EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 5. HAP EMISSIONS Table 5E: Total Particulate Matter (PM) Emissions - Actual and Allowable Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Total Actual PM Emissions (per emission point) Actual PM Concentration (per emission point) Total Allowable PM Emissions (per emission point) Allowable PM Concentration (per emission point)
tpy gr/dscf (or specify) tpy gr/dscf (or specify) E1 213 0.0322 Test Data 300 0.05 WV 23709 - IV-(a) E2 400 0.0625 Calculated 500 0.075 WV 23709 - IV-(a) BH1S 1.45 0.005 Test Data No Limit 0.03 40CFR 63 sub. XXX

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information Sample rows are shaded Unit Operation Name and Process Diagram ID(a): 009-01

Emission Point ID (a) Emission Point PM Emissions (b) Actual PM Emissions Allowable PM Emissions

Basis for Emissions

Estimate Basis for Allowable LimitFerroalloys Production Manufacturing Emission Points Survey Page 19 10/21/2011 

## EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 5. HAP EMISSIONS Table 5E: Total Particulate Matter (PM) Emissions - Actual and Allowable Make additional copies of this table for each unit operation identified in Table 2A and your process flow diagram

Total Actual PM Emissions (per emission point) Actual PM Concentration (per emission point) Total Allowable PM Emissions (per emission point) Allowable PM Concentration (per emission point)
tpy gr/dscf (or specify) tpy gr/dscf (or specify) E1 213 0.0322 Test Data 300 0.05 WV 23709 - IV-(a) E2 400 0.0625 Calculated 500 0.075 WV 23709 - IV-(a) BH2S 2.16 0.009 Test Data No Limit 0.03 40CFR 63 sub. XXX

(a) Please use the same ID as used in the process flow diagram (b) For each HAP emission point defined in the process flow diagram, enter the applicable information Sample rows are shaded Unit Operation Name and Process Diagram ID(a): 009-02

Emission Point ID (a) Emission Point PM Emissions (b) Actual PM Emissions Allowable PM Emissions

Basis for Emissions

Estimate Basis for Allowable LimitFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 5F: HAP Concentrations in Emission Streams



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

Emission Point ID (a) Unit Operation Name (b) Unit Operation

Process Diagram ID (a) Capture System or Device and ID (a) Capture Efficiency (%) Basis for Reported Efficiency (c) Concentration of Emissions to Capture System (%)(d) Control Device and ID (a) Control Efficiency (%) Basis for Reported Control Efficiency (c ) Flow Rate of Stream

(scfm or specify) Total Particulate

Emitted (gr/dscf or specify) (d) HAP Concentration in Particulate Matter (wt %) (c,e) E1 Electric Arc Furnace 1 EAF1 Hood (CS1) 80% Estimate 60% Fabric Filter (BH1) 99% Mfg Design Val. E1 Electric Arc Furnace 2 EAF2 Hood (CS2) 80% Estimate 40% Fabric Filter (BH1) 99% Mfg Design Val.

BH2 Electric Arc Furnace 2 001-01 Hood (H2B) 90% Estimate 80% Fabric Filter (BH2) 99% Mfg Design Val. 450353 0.001 21.69%

BH5 Electric Arc Furnace 5 001-02 Hood (H5A) 90% Estimate 80% Fabric Filter (BH5) 99% Mfg Design Val. 405639 0.001 21.69%

BH7 Electric Arc Furnace 7 001-03 Hood (H7A) 90% Estimate 80% Fabric Filter (BH7) 99% Mfg Design Val. 389094 0.002 21.69%

BH1S Sizing System 1 009-01 Hood (HS1C) 90% Estimate 80% Fabric Filter (BH1S) 99% Mfg Design Val. 7968 0.005 0%

BH2S Sizing System 2 009-02 Hood (HS2C) 80% Estimate 80% Fabric Filter (BH2S) 99% Mfg Design Val. 7127 0.002 0%

(a) Please use the same ID as used in the process flow diagram. (b) For example; furnace or tapping fugitives, crushing, mixing, handling, loading/unloading (c ) Please provide copies of estimation worksheets and any other relevant documentation to document basis for estimates -- AP-42 Baghouse Control Efficiency (d) If the emission point is one of multiple points contributing to an emission stream, indicate the percentage of total stream emissions. (e) Provide speciated data where available. It has been assumed that most HAP are present in particulate form. If significant volatile HAP are present, include them here with notation of units. Sample rows are shaded, and illustrate a situation where two unit operations are directed through a common control device. Capture Control Emission Point & Process ID Outlet Stream 

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 5. HAP EMISSIONSFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 6A: Fabric Filter Costs (make additional copies as needed) Provide annual costs for operating and maintaining the EAF fabric filter control devices (i.e., positive pressure baghouses).

Control Device ID (a) Type of bags Labor Cost Monitoring, Reporting, & Recordkeeping New bags (or other parts, please specify) Other Costs (maintenance, waste disposal, etc., please specify) Electricity Total Annual Operating Costs (2009) BH2 Polyester Unknown Unknown Unknown Unknown Unknown Unknown BH5 Polyester Unknown Unknown Unknown Unknown Unknown Unknown BH7 Polyester Unknown Unknown Unknown Unknown Unknown Unknown BH1S Polyester Unknown Unknown Unknown Unknown Unknown Unknown BH2S Polyester Unknown Unknown Unknown Unknown Unknown Unknown

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

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 6. COST DATAFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 6B: Scrubber Costs (Make additional copies as needed) Provide annual costs for operating and maintaining the EAF scrubber control devices

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

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

### EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 6. COST DATAFerroalloys Production Manufacturing Emission Points Survey Page 15 10/21/2011 Table 7: Startup and Shutdown Information (Make additional copies as needed)

Unit Operation Process ID (a) Date and Description of event Permit conditions exceeded Duration of event (hours) Was event covered by contingency plan for controlling emissions? (Y/N) Estimated PM emissions during

event (pounds) Basis for emissions

estimate Any monitoring data or control system parameter monitoring collected during

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

(a) Please use the same ID as used in the process flow diagram. Sample row is shaded 

## EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS SECTION 7. STARTUP AND SHUTDOWNERSGERSG