EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

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4/21/2010

ENCLOSURE 1

INFORMATION COLLECTION REQUEST FOR

FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

This information collection request is being conducted by the Environmental Protection

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

emission standards for Ferroalloys Production Manufacturing Emission Points under Clean Air 

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

BACKGROUND:

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

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

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

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

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

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

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

screening.

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

any requirement of this Act to:

(A) Establish and maintain such records; (B) make such reports; (C) install, use, and maintain 

such monitoring equipment, and use such audit procedures, or methods; (D) sample such

emissions (in accordance with such procedures or methods, at such locations, at such intervals, 

during such periods, and in such manner as the Administrator shall prescribe); (E) keep records 

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

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

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

require.

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

component of the information collection involves a survey requesting information on existing 

emission points. The second component requires owners to conduct testing. The testing

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

Enclosure 2. 

DIRECTIONS: 

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

C You 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). 
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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 confidentiality. Please do not label an entire response

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

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

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

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

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

address below:

U.S. Environmental Protection Agency

Office of Air Quality Planning and Standards

U.S. EPA Mailroom (D243-02)

Attn: Mr. Conrad Chin

109 T.W. Alexander Drive

Research Triangle Park, NC 27711

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

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

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

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

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

Roberto Morales at the following address:

U.S. Environmental Protection Agency

Office of Air Quality Planning and Standards

U.S. EPA Mailroom (C404-02)

Attn: Mr. Roberto Morales, Document Control Officer

109 T.W. Alexander Drive

Research Triangle Park, NC 27711

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

Morales via Registered U.S. Mail using return receipt requested, Federal Express, or other 

method for which someone must provide a signature upon receipt. Do not electronically 

transmit confidential business information (CBI) to EPA. E-mail and facsimile are not secure 

forms of communication and should never be used to transmit CBI.

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

chin.conrad@epa.gov

PLEASE RETURN THIS SURVEY NO LATER THAN JULY 30, 2010

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

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

questionnaire should be made for additional facilities.
EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

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CONFIDENTIAL BUSINESS INFORMATION (CBI): 

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

PART I. OWNER INFORMATION

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

a. Address: 4442 Graham Station 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: West 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.com
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5. Facility Description:

a. Brief description of the facility:

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

 __ Manufacturing of manganese and silicon based ferroalloys.____________________

______________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

b. Dun & Bradstreet No: N/A

c. SARA TRI Facility ID (from Form R): 25265FLMNPUSRT6

d. Number of Facility Employees:

 Number of employees associated with ferroalloy production operations at the facility 

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

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

significant fraction of your total number of employees.

__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? qY :N qUnknown
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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. Geographic Coordinates of Center of Plant:

Either latitude and longitude or UTM coordinates with zone. Latitude and longitude should 

be provided in decimal degrees, with 6 digits to right of decimal point, and an indication of 

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

a. latitude and longitude: 

b. UTM coordinates: 419.73 km Easting – 4312.468 km Northing – Zone 17

7. Regulatory Requirements

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

applicable to your facility)

40 CFR Part 60, subpart Z, Standards of Performance for Ferroalloys Production

:

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

Pollutants from Ferroalloys Production: Ferromanganese and Silicomanganese

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

Pollutants for Industrial/Commercial/Institutional Boilers and Process Heaters

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

Pollutants for Area Sources: Ferroalloys Production Facilities

:

Others (please identify): 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

Synthetic Minor Source

Minor/Area Source

9. Permit Conditions

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

air permit limits, please provide a copy of your operating permit. If you have a Title V 
EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

MANUFACTURING EMISSION POINTS

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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 response (e.g., permits, block-flow diagrams, 

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

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

Identification code Description of item submitted with survey response

Attachment 1 Process Flow Diagram

PART II. GENERAL FACILITY INFORMATION

1. Process Summary

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

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

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

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

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

2. Process Flow Diagram

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

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

and other fugitive emissions [including fugitive dust emissions]). Also include all 

associated air pollution control devices.

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

portion of the diagram that a typical facility should submit.

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

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

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

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

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

HAPs.
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MANUFACTURING EMISSION POINTS

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3. Raw Materials

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

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

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

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

year may be used if an explanation is provided. 

For each material potentially containing metal HAP, provide detailed information on 

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

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

4. Products and Product Handling

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

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

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

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

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

please explain: 

_____N/A______________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

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

operations, including storage, conveyance, and any operations 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 III. VENTILATION, CAPTURE AND CONTROL SYSTEMS

1. Capture and Control Summary

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

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

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

operations should be included here.

2. Primary and Tapping Capture

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

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

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

(primary emissions) and from the tap hole (tapping and ancillary operations). 

Provide diagrams and brief descriptions to fully explain configurations.
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3. Control Device Details

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

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

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

4. Ladle Post-Processing Capture and Control

Do you perform any post-tap ladle processing?  ̋Yes qNo 

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

associated capture and control equipment.

_Preheated hoods and a ventilation system are used. 

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

5. Other Emission Reductions

Describe any work practices or pollution prevention measures you have implemented 

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

quantify the reductions

_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.
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2. Non-Point Modeling Data

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

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

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

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

emissions. 

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

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

5C. For each emission point, indicate the total actual and allowable emissions and 

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

and the total actual and allowable emissions and concentration of particulate matter. 

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

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

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

4. HAP in Emission Streams

Notes on Modeling Data: 

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

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

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

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

assumed.)

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

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

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

fugitive sources this is the southwest corner if the fugitive angle is zero, or the 

western most corner if the fugitive angle is greater than zero.

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

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

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

fugitive sources this is the southwest corner if the fugitive angle is zero, or the 

western most corner if the fugitive angle is greater than zero. 

Angle of Rotation: Angle of rotation specifies the rotation of the source from north 

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

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

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

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

northerly direction, or the northeasterly direction if the source is rotated.
EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

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

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

with the following considerations:

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

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

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

(e.g., baghouses);

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

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

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

Provide explanations for the basis of speciated emissions.

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

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

solid waste handling operations.

5. Emission Test Data

1. Enclose any previously conducted test reports, chlorine content of coal analyses, or

baghouse dust analyses conducted to determine if your facility is a major source.

2. Enclose summaries of test reports from any emission tests conducted on ferroalloys 

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

Summaries should include:

• Pollutants and emission rates measured;

• The test method or procedure used;

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

measurements were made;

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

conditions; and 

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

6. Calculations and Test Reports

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

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

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

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

include copies of the emission test results (as described above.)
EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION 

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PART VI. COST DATA

1. Fabric Filter Costs

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

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

2. Scrubber Costs

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

scrubbers.

PART VII. STARTUP AND SHUTDOWN

Please provide the following information for operations during startup and 

shutdown. Attach additional pages if necessary.

1. Startup and Shutdown Information

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

 event has occurred: 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 response to this question.)

No____________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________
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4. Test Data

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

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

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

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

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

Were the tests associated with a routine startup or shutdown? 

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

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

5. Startup and Shutdown Plan

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

one. 

6. Startup and Shutdown Reports

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

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

authority?  ̋Yes qNo 
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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. Updates and modifications to existing crusher baghouses and to current 

furnace baghouses in the future may also help to reduce emissions. 

___________________________________________________________ 

2. New Source Review

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

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

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

achievable emission rate (LAER) came into effect:

_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. 

Describe any measures that are employed by your facility to control fugitive dust from 

such sources. Include description of any written fugitive dust control plans, and any 

recordkeeping activities associated with fugitive dust control.

See Attachment 1 - Fugitive Dust Plan

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

4. Other Issues

Describe any factors not addressed in the above questions that might serve to 

distinguish your facility from others in this source category for purposes of developing a 

separate source category or subcategory and maximum available control technology 

(MACT) standards.

N/A___________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________
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Ferroalloys 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

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Table 2B : Furnace Information

Fill out a copy of this form for each furnace

Furnace Process Diagram ID (a)

Primary Product (b)

Actual Production of primary product 2009 (days/year)

Actual Production of primary product 2009 (tons/year)

Average Production of primary product (tons/hr)

Maximum Production of primary product (tons/hr)

Secondary Product (b)

Actual Production of secondary product 2009 (days/year) 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 

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SECTION 2. PLANT OPERATIONS

18

Hydraulic system to model valving and controls

32

5981.5

262.3

34887
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) 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 

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SECTION 2. PLANT OPERATIONS

001-02

SiMn (100%)

N/A

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

311.25

25978

2

5
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) 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

330.3
Ferroalloys 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 OPERATIONS
Ferroalloys 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 OPERATIONS
Ferroalloys 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 OPERATIONS
Ferroalloys 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 available
Ferroalloys 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 Capture
Ferroalloys 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 available
Ferroalloys 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/A
Ferroalloys 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 Monitoring Method Describe Quality Assurance

Monitored? Units 

Measured
Ferroalloys 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

Opacity or Visible Emissions Monitoring Monitoring Method Describe Quality Assurance

Frequency of 

Monitoring
Ferroalloys 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

Coordinates
Ferroalloys 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)

Coordinates
Ferroalloys 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)

Coordinates
Ferroalloys 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)

Coordinates
Ferroalloys 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)

Coordinates
Ferroalloys 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 Coordinates
Ferroalloys 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)

Coordinates
Ferroalloys 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): 001-03
Ferroalloys 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)

Coordinates
Ferroalloys 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 

Limit
Ferroalloys 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 

Limit
Ferroalloys 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 

Limit
Ferroalloys 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 Emissions
Ferroalloys 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 

Limit
Ferroalloys 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 

Limit
Ferroalloys 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 

Limit
Ferroalloys 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 

Limit
Ferroalloys 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.

Emission Point & Process ID Capture Control Outlet Stream

EPA INFORMATION COLLECTION REQUEST FOR FERROALLOYS PRODUCTION MANUFACTURING EMISSION POINTS

SECTION 5. HAP EMISSIONS
Ferroalloys 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 DATA
Ferroalloys 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 DATA
Ferroalloys 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 SHUTDOWN
ERSG
ERSG