Document ID: EPA-HQ-OAR-2010-0544-0076
Agency: epa
Document Type: Supporting & Related Material
Title: 
Posted Date: 2012-02-14T05:00Z

Enclosure 1

Information Collection Request for Secondary Aluminum Production

National Emission Standards for Hazardous Air Pollutants (NESHAP) 

Part A.  Facility Information

1. 	Name and address of legal OWNER of the facility:

	

	

	

2. 	Name and address of legal OPERATOR of the facility, if different
from the legal OWNER

	

	

	

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

a. 	Address:  	

b. 	City: 	

c. 	State: 	

d. 	Zip: 	

e. 	County: 	

4. 	Provide mailing address of the facility if different from physical
location: 

a. 	Address: 	

b. 	City: 	

c. 	State: 	

d. 	Zip: 	

5. 	Facility contact able to answer technical questions about the
completed survey

a. 	Name (First Name, Last Name): 	

b. 	Title: 	

c. 	Telephone number:  ___________________________   ext. 	

d. 	Fax number: 	

e. 	E-mail: 	

f.	If the facility is permanently closed or is not subject to 40 CFR
part 63, subpart RRR, please complete this page, sign below and send
this page certified mail to the non-CBI address listed on the
instruction sheet by XXX,  

I certify that this facility is permanently closed or is not subject to
the National Emission Standards for Hazardous Air Pollutants for
Secondary Aluminum Production as defined in 40 CFR part 63, subpart RRR.

	

(Print Name)              (Title)                  (Signature of
Responsible Official)		(Date)

A Responsible Official can be the president, vice-president, secretary,
or treasurer of the company that owns the facility, owner of the
facility, plant manager, plant engineer or supervisor.

6. 	What is the facility size classification for hazardous air pollutant
(HAP) emissions? 

(CHECK one)

EPA Major Source of Hazardous Air Pollutants (HAP):			

EPA Area source (based on potential to emit) of HAP			

EPA Area source (Synthetic Minor) of HAP					

7. 	Facility NAICS codes

Note: The primary NAICS code represents the line of business that
generates the most income for the facility

a.	Primary NAICS code	 

b.	Other facility NAICS codes: ______________, ______________,	

8. 	Company Size – (CHECK one)

Note:  Approximate average number of all employees (worldwide) of the
business enterprise that owns this facility, including where applicable,
the parent company and all subsidiaries, branches, and unrelated
establishments owned by the parent company:  If your company has a
primary NAICS code that does not begin with “331---,” please also
include your average annual sales receipts $___________

(How to calculate average annual receipts and average employment of a
firm can be found in 13 CFR § 121.104 and 13 CFR § 121.106,
respectively).

___ ≤ 50

___ 51-100

___ 101-500

___ 501-750

___ 751-1000

___ >1000

9. 	Facility Size – (CHECK one)

Note:  Approximate average number of all employees at facility in
location identified in question #3 above.

___ ≤ 50

___ 51-100

___ 101-500

___ 501-750

___ 751-1000

___ >1000

10.	Is the legal owner a small entity as defined by the Regulatory
Flexibility Act?  

	(CHECK one)     ___ Yes___ No

	Note:  For private businesses, small entity is defined for each NAICS
of the owning entity based on number of employees and/or company
revenue.  The NAICS codes used for Secondary Aluminum production are
331312, 331314, 331315, 331316, 331319, 331521, 331524 and various codes
used for operations with Sweat Furnaces.  The small business size
standards for NAICS subsectors are located at the following link:  
HYPERLINK
"http://www.sba.gov/contractingopportunities/officials/size/table/index.
html" 
http://www.sba.gov/contractingopportunities/officials/size/table/index.h
tml 

11.	Federal and State rule/permit coverage.  (CHECK all that apply to
this facility). 

___  Subpart RRR  (Secondary Aluminum)

____ Diecasting Operations

____ Foundry

____ Extruder

___  Subpart LL  (Primary Aluminum)

_________________________________  Other (SPECIFY rule name and subpart)

_________________________________  Other (SPECIFY rule name and subpart)

New Source Performance Standards (NSPS)

_________________________________  (SPECIFY rule name and subpart)
_________________________________  (SPECIFY rule name and subpart)

Title V ______________________  (SPECIFY the basis for your Title V
permit) 

State Air Toxics:

_________________________________  (SPECIFY rule name and subpart)

_________________________________  (SPECIFY rule name and subpart)

Other MACT (e.g., Metal Coil Surface Coatings MACT):
___________________________ 

Other MACT: ___________________________ (SPECIFY emission unit and rule)

________________________________________________________________________
_  

12.	Normal Facility Production Hours:

	Hours/day: ___________________

	Shifts/day: ___________________

	Days/week: __________________

	Weeks/year: __________________

13.	Total amount of aluminum produced in 2009.  If 2009 is not
representative of normal operations, please provide information for a
representative year (2004 or later) and specify the year. 

		Year

		Tons of aluminum produced

	Amount of total charge to the facility used to produce the amount of
aluminum reported 	in question #13:  

		Tons of charge 

15. 	Approximately what percentage of the facility’s total charge (in
#14 above) is considered clean charge? 

		Percent (%)

16.  	Please provide a copy of a schematic of the plant layout for
equipment subject to subpart RRR, control devices, and discharge stacks
associated with these units.  Label the schematic with the unit IDs,
control device IDs, and stack IDs, which should also match the unit IDs,
control device IDs, and stack IDs used to respond to later questions. 
Please properly identify units that are permanently “out of service”
or not yet installed.

17.  	Please provide all of the pertinent information listed below. 
Please provide electronic copies, if available, and indicate items
provided below.  

(CHECK all that apply):

□	Title V permit

□	State Air Operating permit 

□	Pending air permit applications (except for state and Title V
renewal applications)

□	Performance test reports (submit most recent test reports for each
subpart RRR related process). This includes any test data on air
emission sources, e.g. HF testing, bag house dust analyses, etc., not
previously submitted to our office under a section 114 request.

□	Emission inventory reports (reporting years should be the same as
the years selected for this survey)

□	Most recent Consent decree or order for air related issues 

□	Notice(s) of air operating permit violations for the past 3 years

□	Startup, shutdown, and malfunction (SSM) plan

□	Operating, maintenance, and monitoring plan (OM&M)

Part B.  Facility Equipment Regulated under Subpart RRR (Secondary
Aluminum NESHAP)

Please provide the information below for all equipment at your facility:

18.  	Regulated Equipment List

Unit Identification Numbers 

(Unit ID No.)	Unit ID No. as Designated in Title V or State Operating
Permit*	Subpart RRR Equipment	Do You Have This Equipment at the
Facility?

(Y or N)	Add-on Controls

(Y or N)	Operating in 2009?

(Y or N)

If “No,” list last year of operation

Aluminum Scrap Shredder 

	Thermal Chip Dryer 

	Scrap Dryer/Delacquering/Decoating Kiln 

	Group 1 Furnace-Clean charge only**

	Group 1 Furnace-Handling other than clean charge**

	Group 2 Furnace**

	In-line Fluxer 

	Dross-only Furnace

	Rotary Dross Cooler

	Sweat Furnace

	

* Please complete this column if ID numbers used in this form are
different from those in the permit.

** Please indicate which of the Group 1 or Group 2 furnaces listed above
that have side wells or scrap wells.

Part C.  Charge Rates and Controls Used for Major Sources Subpart RRR
MACT 

Please provide the information below for all regulated equipment at your
facility; Use information for this section from whichever year (2004 or
later) is representative of the highest emissions per ton of production.
_________ (please specify year)

For purposes of this section, “Maximum Capacity” of a unit is
defined as the unit’s potential to process charge or produce aluminum
at its maximum rate on mass/time basis.  If your permit limits the
throughput or output of the unit, then that permitted amount may be used
to calculate the maximum capacity.

19. 	For Each Scrap Shredder 

Unit ID No.	Amount of Charge (tons/yr)	Maximum Capacity of Unit 

(tons/yr)	Charge Rate During Most Recent Performance Test (lbs/hr)*
Control Device

Type	Device 

ID No.

	

20.  	For Each Thermal Chip Dryer

Unit ID

No.	Amount of Chips Charged (tons/yr)	Maximum Capacity of Unit

(tons chips/yr)	Charge Rate During Most Recent Performance Test
(lbs/hr)*	Control Device

Type	Device

ID No.

	

* If more than one performance test was conducted to demonstrate
operation with different types of charge, please enter the maximum
charge rate.  If a test on a representative unit was conducted to
demonstrate compliance for similar units, please enter the charge rate
during the test used to demonstrate compliance for untested units. 

21.  	For Each Scrap Dryer/Delacquering Kiln/Decoating Kiln  

Unit ID

No.	Amount of Charge (tons/yr)	Maximum Capacity of Unit

(tons/yr)	Charge Rate During Most Recent Performance Test (lbs/hr)*
Control Device**

Type	Device

ID No.

**If the kiln is equipped with an afterburner operated at a minimum of
760°C (1400°F), with a design residence time of 1 second minimum,
enter the control device ID Nos. here: _______________

22.  	For Each Dross Only Furnace

Unit ID No.	Amount of Dross Charged (tons/yr)	Maximum Capacity of Unit

(tons dross/yr)	Charge Rate During Most Recent Performance Test
(lbs/hr)*	Control Device

Type	Device

ID No.

23.  	For Each Rotary Dross Cooler

Unit ID No.	Amount of Dross Charged (tons/yr)	Maximum Capacity of Unit

(tons dross/yr)	Charge Rate During Most Recent Performance Test
(lbs/hr)*	Control Device

Type	Device

ID No.

* If more than one performance test was conducted to demonstrate
operation with different types of charge, please enter the maximum
charge rate.  If a test on a representative unit was conducted to
demonstrate compliance for similar units, please enter the charge rate
during the test used to demonstrate compliance for untested units. 

24. 	For Each Group 1 Furnace

Unit ID No.	Amount of Charge

(tons/yr)	Only Clean Charge (yes/no)	Maximum Capacity of Unit

(tons/yr)	Charge Rate During Most Recent Performance Test (lbs/hr)*
Control Device

	Type	Device ID No.

25.  	For Each Group 2 Furnace

Unit ID No.	Amount of Charge (tons/yr)	Maximum Capacity of Unit 

(tons/yr)	Charge Rate During Most Recent Performance Test (lbs/hr)*
Control Device

Type	Device ID No.

26.  	For Each In-line Fluxer 

Unit ID No.	Amount of Charge (tons/yr)	Maximum Capacity of Unit

(tons/yr)	Maximum Number of Times the Unit Can Run in a 24-hr Period
Charge Rate During Most Recent Performance Test (lbs/hr)*	Control Device

	Type	Device ID No.

* If more than one performance test was conducted to demonstrate
operation with different types of charge, please enter the maximum
charge rate.  If a test on a representative unit was conducted to
demonstrate compliance for similar units, please enter the charge rate
during the test used to demonstrate compliance for untested units. 

27.  	For Each Sweat Furnace

Unit ID No.	Amount of Charge (tons/yr)	Maximum Capacity of Unit

(tons/yr)	Charge Rate During Most Recent Performance Test (lbs/hr)*
Control Device**

Type	Device ID No.

* If more than one performance test was conducted to demonstrate
operation with different types of charge, please enter the maximum
charge rate.  If a test on a representative unit was conducted to
demonstrate compliance for similar units, please enter the charge rate
during the test used to demonstrate compliance for untested units.

** If the sweat furnace is equipped with an afterburner operated at a
minimum of 1600°F, with a design residence time of 0.8 second minimum,
enter the control device ID here: _____________

28.  	For Each Secondary Aluminum Processing Unit (SAPU) Using Emissions
Averaging (as per section 63.1505(k))

a. 	Complete this table if your facility chose to measure compliance
using the weight of the feed/charge.

SAPU Unit

ID No.	Unit Nos. from Questions #24 and #26 making up the SAPU(s)	SAPU
Type?

N=New

E=Existing	Amount of Feed/Charge (tons/year)	Percent Clean Charge
(approximate)

b. 	Complete this table if your facility chose to measure compliance
using the weight of the aluminum produced.

SAPU Unit ID No.	Unit Nos. from Questions #24 and #26 making up the
SAPU(s)	SAPU Type?

N=New

E=Existing	Amount of Aluminum Produced (tons/year)	Percent Clean Charge
(approximate)

Part D.  Charge Rates and Controls Used for Area Sources Subpart RRR
MACT

Please provide the information below for all regulated equipment at your
facility; Use information for this section from 2004 or later, whichever
year is representative of the highest emissions per ton of production.
_________ (please specify year)

For purposes of this section, “Maximum Capacity” of a unit is
defined as the unit’s potential to process charge or produce aluminum
at its maximum rate on mass/time basis.  If your permit limits the
throughput or output of the unit, then that permitted amount may be used
to calculate the maximum capacity.

29. 	For Each Thermal Chip Dryer

Unit

ID No.	Amount of Chips Charged

(tons/yr)	Maximum Capacity of Unit (tons/yr)	Charge Rate During Most
Recent Performance Test (lbs/hr)*	Control Device

Type	Device ID No.

* If more than one performance test was conducted to demonstrate
operation with different types of charge, please enter the maximum
charge rate.  If a test on a representative unit was conducted to
demonstrate compliance for similar units, please enter the charge rate
during the test used to demonstrate compliance for untested units. 

30.  	For Each Scrap Dryer/Delacquering Kiln/Decoating Kiln

Unit 

ID No.	Amount of Charge (tons/yr)	Maximum

Capacity of Unit (tons/yr)	Charge Rate During Most Recent Performance
Test (lbs/hr)*	Control Device**

Type	Device ID No.

**If the kiln is equipped with an afterburner operated at a minimum of
760°C (1400°F), with a design residence time of 1 second minimum,
enter the control device ID Nos. here: ________________ 

31.  	For Each Group 1 Furnace

Unit ID

No.	Amount of Charge (tons/yr)	Only Clean Charge (yes/no)	Maximum
Capacity of Unit (tons/yr)	Charge Rate During Most Recent Performance
Test (lbs/hr)*	Control Device

	Type	Device ID No.

* If more than one performance test was conducted to demonstrate
operation with different types of charge, please enter the maximum
charge rate.  If a test on a representative unit was conducted to
demonstrate compliance for similar units, please enter the charge rate
during the test used to demonstrate compliance for untested units. 

32.  	For Each Sweat Furnace

Unit ID No.	Amount of Charge (tons/yr)	Maximum Capacity of Unit

(tons/yr)	Charge Rate During Most Recent Performance Test (lbs/hr)*
Control Device**

Type	Device ID

** If the sweat furnace is equipped with an afterburner operated at a
minimum of 1600°F, with a design residence time of 0.8 second minimum,
enter the control device ID here: _____________

33.  	For Each In-line Fluxer  

Unit ID No.	Amount of Charge (tons/yr)	Maximum Capacity of Unit

(tons/yr)	Maximum Number of Times the Unit Can Run in a 24-hr Period
Charge Rate During Most Recent Performance Test (lbs/hr)*	Control Device

	Type	Device ID No.

* If more than one performance test was conducted to demonstrate
operation with different types of charge, please enter the maximum
charge rate.  If a test on a representative unit was conducted to
demonstrate compliance for similar units, please enter the charge rate
during the test used to demonstrate compliance for untested units.

34.  	Each Secondary Aluminum Processing Unit (SAPU) Using Emissions
Averaging (as per section 63.1505(k))

a.	Complete this table if your facility chose to measure compliance
using the weight of the feed/charge.

SAPU Unit

ID No.	Unit ID Nos. from Questions #31 and #33 making up the SAPU(s)
SAPU Type?

N=New

E=Existing	Amount of Feed/Charge (tons/year)	Percent Clean Charge
(approximate)

b. 	Complete this table if your facility chose to measure compliance
using the weight of the aluminum produced.

SAPU Unit

ID No.	Unit ID Nos. from Questions #31 and #33 making up the SAPU(s)
SAPU Type?

N=New

E=Existing	Amount of Aluminum Produced (tons/year)	Percent Clean Charge
(approximate)

35. 	Please complete this table for any scrap shredder, group 2
furnace, in-line fluxer, dross-only furnace, or rotary dross 	cooler
present at your facility.

Unit

ID No.	Type of Equipment	Maximum Capacity* (tons/year)	What Type of
Control Device, if Any is Used?	Height of Stack or Discharge (ft)
Discharge	Exit Gas Temperature (degrees F)	Latitude**	Longitude**	Flow
Rate (SCFM)

	Diameter (ft)	Area 

(sq. ft.)

Maximum	Minimum

 

	 

	 

	 	 

	 	 	 	 	 

 

	 	 

	 	 	 	 	 

 

	 	 

	 	 	 	 	 

* For purposes of this section, “Maximum Capacity” of a unit is
defined as the unit’s potential to process charge or produce aluminum
at its maximum rate on mass/time basis.  If your permit limits the
throughput or output of the unit, then that permitted amount may be used
to calculate the maximum capacity.

** Longitude and Latitude should be specified out to 6 decimal places.
If coordinates are not known, please provide a scaled site diagram, with
a latitude/longitude reference point, indicating stack locations.

Part E.  Emissions and Limits for Subpart RRR Sources and Non-Subpart
RRR Sources

Please provide the information below for all equipment at your facility;
Use information for this section from 2004 or later, whichever year is
representative of the highest emissions per ton of production. _________
(please specify year)

For purposes of this section, “Maximum Capacity or Maximum
Allowable” of a unit is defined as the unit’s potential to process
charge or produce aluminum at its maximum rate on mass/time basis.  If
your permit limits the throughput or output of the unit, then that
permitted amount may be used to calculate the maximum capacity.

36.	a. Please list all regulated pollutant emissions from equipment
subject to 40 CFR 63, subpart RRR. 

Unit

ID No.	Emissions Unit Name	Emissions of Regulated RRR Pollutants Based
on Performance Tests	Control Device

(from Part C or D above)	List Dates of the Applicable Compliance Tests 

PM

(lbs./ton)	D/F**

(grain/ton)	HCl (lbs./ton)	Total Hydrocarbons (THC) (lbs./ton)	Device
Type*	Unit

ID No.

	

* If you comply with subpart RRR requirements for sweat furnaces by
controlling your afterburner residence time, enter “AB/RT” in the
table.

**Please include dioxin/furan congeners.  Use additional lines to break
these out, if necessary.

	b. Please list all other HAP emissions from equipment subject to 40
CFR 63, subpart RRR. (Please include fugitive emissions.) 

Equipment/Process Description	Unit ID No.	List Each Individual HAP	CAS#
Emission Rate (lbs./yr)	Maximum Allowable (lbs./yr)	Maximum Allowable
(lbs./hr)	Emission Factor Type**

c. Please list estimated HAP emissions from collocated sources that are
not regulated under 40 CFR 63, subpart RRR. (Please include fugitive
emissions.) Do not include Primary Aluminum Sources. Gas fired equipment
(such as preheater boxes and annealing furnaces, etc.) not regulated
under 40 CFR 63, subpart RRR may be combined into a single entry.

Equipment/Process Description	Unit ID No.	List Each Individual HAP*	CAS#
Emission Rate* (lbs./yr)	Maximum Allowable (lbs./yr)	Maximum Allowable
(lbs./hr)	Emission Factor Type**

* Copies of test data reports for your HAP emissions from non-subpart
RRR sources are not required.  HAP emissions data previously submitted
for Primary Aluminum, is not required.  Please include all others HAP
emissions.

** Emission Factor Type:

1= Emissions calculated based on source test or other emissions
measurements.

2= Emissions calculated based on material balance using engineering
knowledge of the process.

3= Emissions calculated based on AP-42 or EPA 450/2-90-011 or other EPA
emission factor.

4= Emissions calculated by engineering judgement. (Approved by the State
agency)

5= Emissions calculated based on a state or local agency emission
factor.

Part F.  Detailed Control Device and Emission Release Information for
Subpart RRR MACT Sources and Other Collocated Sources Emitting Hazardous
Air Pollutants (HAP)

Use information for this section from 2004 or later, whichever year is
representative of the highest emissions per ton of production. _________
(please specify year)

37 	a.  Add-on air pollution control devices (use multiple lines if the
same control device is used to control more than one pollutant).

Please provide the information below for subpart RRR MACT sources.

Control Devices	Units

Controlled

Device Type*	Device

ID No.	Pollutant Controlled	Capture Efficiency (if known) (percent)
Control Device Efficiency 

(if known)

(percent)	Overall Efficiency (if known) (percent)	Methods Used for
Determining Capture &  Control  Efficiencies**(a-c)	Type(s) of Unit	Unit

ID No.

* For example, afterburner, lime coated fabric filter, etc.

** Control & Capture Efficiency 

      a = Testing (specify method)

      b = Manufacturer's Specifications

      c = Engineering Estimate

Please provide any additional information concerning the Control
Devices:
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________


	b.  Add-on air pollution control devices (use multiple lines if the
same control device is used to control more than one pollutant).  (Do
not include Primary Aluminum Sources)

	

Please provide the information below for sources not subject to subpart
RRR MACT: 

Control Devices	Units

Controlled

Device Type*	Device

ID No.	Pollutant Controlled	Capture Efficiency (if known) (percent)
Control Device Efficiency 

(if known)

(percent)	Overall Efficiency (if known) (percent)	Methods Used for
Determining Capture &  Control  Efficiencies**(a-c)	Type(s) of Unit	Unit

ID No.

* For example, afterburner, lime coated fabric filter, etc.

** Control & Capture Efficiency 

      a = Testing (specify method)

      b = Manufacturer's Specifications

      c = Engineering Estimate

Please provide any additional information concerning the Control
Devices:

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
____________________________________38. 	a.  For each stack/control
device exhaust point, please provide the following information, if
known, related to the information in Item #37a above.  (Subpart RRR MACT
Sources.)

Unit

ID No.	What Control Devices are Vented at this Point? 	Height of stack
or discharge (ft)	Discharge	Exit Gas Temperature (degrees F)	Latitude*
Longitude*	Flow Rate (SCFM)

	Diameter (ft)	Area (sq. ft.)

Maximum	Minimum

 	 

 	 	 

	 	 	 	 	 

 	 	 

	 	 	 	 	 

	* Longitude and Latitude should be specified out to 6 decimal places.
If coordinates are not known, please provide a scaled site diagram, with
a latitude/longitude reference point, indicating stack locations.

	b.  For each stack/control device exhaust point, please provide the
following information, if known, related to the information in Item #37b
above.  (Non-Subpart RRR MACT Sources.) Do not include Primary Aluminum
Sources. If emissions from gas fired equipment were combined in question
#36c and discharged through different stacks, please estimate the
fraction of the discharge emitted through each stack.  

Unit

ID No.	What Control Devices are Vented at this Point? 	Height of stack
or discharge (ft)	Discharge	Exit Gas Temperature (degrees F)	Latitude*
Longitude*	Flow Rate (SCFM)

	Diameter (ft)	Area (sq. ft.)

Maximum	Minimum

 	 

 	 	 

	 	 	 	 	 

 	 	 

	 	 	 	 	 

	* Longitude and Latitude should be specified out to 6 decimal places.
If coordinates are not known, please provide a scaled site diagram, with
a latitude/longitude reference point, indicating stack locations.

39.	a.  For each exhaust point/stack not associated with a control
device for Subpart RRR MACT Sources, please provide the following
information:

Unit

ID No.	What Control Devices are Vented at this Point?	Height of Stack or
Discharge (ft)	Discharge	Exit Gas Temperature (degrees F)	Latitude*
Longitude*	Flow Rate (SCFM)

	Diameter (ft)	Area 

(sq. ft.)

Maximum	Minimum

 	 

 	 	 

	 	 	 	 	 

 	 	 

	 	 	 	 	 

 	 	 

	 	 	 	 	 

* Longitude and Latitude should be specified out to 6 decimal places. 
If coordinates are not known, please provide a scaled site diagram,
indicating stack locations.

	b.  For each exhaust point/stack not associated with a control device
for Non-Subpart RRR MACT Sources, please provide the following
information:  (Do not include Primary Aluminum Sources.)

Unit

ID No.	What Control Devices are Vented at this point?	Height of Stack or
Discharge (ft)	Discharge	Exit Gas Temperature (degrees F)	Latitude*
Longitude*	Flow Rate (SCFM)

	Diameter (ft)	Area 

(sq. ft.)

Maximum	Minimum

 	 

 	 	 

	 	 	 	 	 

 	 	 

	 	 	 	 	 

 	 	 

	 	 	 	 	 

* Longitude and Latitude should be specified out to 6 decimal places. 
If coordinates are not known, please provide a scaled site diagram,
indicating stack locations.

40.  	For each affected source listed in [Section B, above], identify
the date(s) of latest NESHAP compliance testing. 

Date Tested	Emission Unit	Test Method Used	Pollutant(s) Tested	Emission
Rate (Specify Units)

	Unit Type	Unit ID No.

	

For each Group 1 furnace for which a performance test was conducted:

Furnace ID*

ID of other furnaces for which this test was used to determine
representative emission rates  

Is this furnace operated continuously or batch-by-batch?

Does the furnace process metal other than clean charge?

How many runs were included in the test?

What was the length of each performance test run?

How many minutes during each run was the charging door open?

What steps were taken during the test to minimize air emissions escaping
from the furnace doors, etc.?

What period of time during each run was metal tapped from the furnace?

Is this a sidewell (scrapwell) furnace?

Is this a melting or holding furnace?

* Where two or more co-controlled furnaces were tested simultaneously,
list all furnace IDs.



For each sidewell (scrapwell) furnace 

Furnace ID

Was reactive flux used in the sidewell, hearth, both, or neither?

Was the level of molten metal maintained above the top of the passage
between the sidewell and hearth continuously?

Was the level of molten metal maintained above the top of the passage
between the sidewell and hearth during periods of reactive fluxing?

How was the molten metal level monitored?

For each Group 1 furnace that is not ducted to a control device:

Furnace ID

Is the furnace equipped with a hood or other type of enclosure as part
of the emissions collection system?

If yes, please describe.

What steps were taken during the test to minimize emissions from the
furnace doors, etc.?

Were visible emissions monitored during the performance test?

Were visible emissions observed during the performance test?

For each Group 1 furnace that is ducted to a control device:

Furnace ID

Is the furnace equipped with a capture system to limit fugitive
emissions?

If yes, please describe.

Are visible emissions present during charging?

What, if any, monitoring and inspection is conducted to minimize leakage
from the duct leading to the control device?

What steps were taken during the test to minimize air emissions escaping
from the furnace doors, etc.?

For each thermal chip dryer, scrap dryer/delacquering kiln/decoating
kiln, sweat furnace, dross only furnace and rotary dross cooler:

Equipment ID & Type

Is this unit equipped with a hood or other capture devices as part of
the emissions collection system?

If yes, please describe.

Were visible emissions monitored during the performance test?

Were visible emissions observed during the performance test?

Are visible emissions present during loading and unloading of the unit?

What steps were taken during the test to minimize air emissions escaping
from the furnace doors, etc.?

41.  For affected sources at your facility subject to subpart RRR that
are ducted to add-on control devices:

	a. Are these sources equipped with capture systems designed and
installed 	in accordance with the standard (i. e. sections 3 and 5 of
the ACGIH manual)?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
_________

	b. What design parameters were measured to confirm this?
________________________
________________________________________________________________________
________________________________________________________________________
______

	c. What, if any, modifications to the capture systems of existing
sources were made to demonstrate compliance with this standard (e.g.
extending hoods, increasing exhaust rate, modifying operating
procedures, etc.)? ___________________________________________

________________________________________________________________________
________________________________________________________________________
______

	d. Were there any problems that were encountered during the permitting
process or operation of your facility due to the way the rule is written
in subpart RRR? _____________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
_________

Part G.  Facility Operations 

42.  	General Questions for Subpart RRR MACT Sources

a.	What type of pretreatment (including, but not limited to air drying,
centrifugal drying, etc.) takes places to get the charge ready for
processing? 

	

b.	Do you track the amount of aluminum produced as well as the amount of
charge? 

	

c.	Could you develop and report your emission rates in terms of amount
of emissions per unit of aluminum produced?  If not, what prevents you
from doing so?

	

d.	How do you ensure that the molten metal in the sidewell furnace
remains above the top of the passage between the sidewell and the hearth
during reactive fluxing?

	

43.	Fluxing for Subpart RRR MACT Sources

a.	What fluxes were used during the representative year used in Part F? 
Please attach MSDS for each flux:  

Flux Identification	Flux Still in Use?

(Yes or No)	Reactive = R 

Non-reactive = N	Mass Used (lbs./yr)	Furnace or In-line Fluxer ID in
which Flux was Used	Purpose 

(e.g., cover, degassing, demagging, etc.)

	

b.	If you have sidewell (scrapwell) furnaces, did you use reactive flux
in the sidewell and the hearth?  If so, did you test emissions from
both sources?

	

c.	Do you use different types or quantities of flux for different flux
applications?  If so, how do the procedures differ?

	

d.	What are your flux rate operating and monitoring procedures?

	

e.	Do you have any hydrogen fluoride emissions data for Subpart RRR MACT
Sources? If so, please provide the data reports or other supporting data
for the following:

__________    Maximum tons/yr of hydrogen fluoride emissions 

__________    Pounds of hydrogen fluoride emitted per ton of charge
(lbs. HF/ton charge)

__________    Maximum lbs./hr of hydrogen fluoride emitted

__________    What fraction of the fluorine content of the flux used was
emitted as either HF, F2, or particulate fluoride (%)? 

44.  	Alternative controls, monitoring, or operating conditions for
Subpart RRR MACT Sources

a.	Please provide details for any alternative control devices (e.g.
control devices other than fabric filters, lime-coated fabric filters,
or afterburners), monitoring (including particulate matter or HCl
continuous emissions monitors), or operating conditions at this facility
for equipment regulated under 40 CFR 63, subpart RRR.

	

	

For the control technologies identified in question 44a above, please
provide cost information: 

Unit ID No.	Control Device	Total Capital Investment	Total Annual
Operating and Maintenance Costs	Base Year for Operating Costs

	Type/Description	Device ID. No.

	

b.	Have you injected activated carbon or other type of carbon for HAP
control (excluding research efforts)?  What barriers do you envision to
adding carbon injection to fabric filters for HAP control (check as many
as apply)? 

     □     Cost of activated carbon 

     □     Creates problems with disposal of material collected by
baghouse

     □     Other (specify):
____________________________________________

c.	Do you use catalytic filters for dioxin control (e.g.,  HYPERLINK
"http://www.donaldson.com/en/industrialair/literature/051754.pdf"
http://www.donaldson.com/en/industrialair/literature/051754.pdf )? 

	

	d.	Do you have any plans to install any new higher efficiency rated
control devices or have any pending applications to add on any new
controls?  If so, please specify and include any copies of pending
permit applications as requested in Part A, item #17.

	_______________________________________________________________________
________________________________________________________________________
________________________________________________________________

	e.	Do you have any plans to use any alternative monitoring or operating
conditions?  If so, please provide details:

	_______________________________________________________________________
________________________________________________________________________
________________________________________________________________

45. 	Pollution prevention for Subpart RRR MACT sources

A.  Describe any procedures or work practice standards used at your
facility to prevent or reduce emissions of Hazardous Air Pollutants
(HAP). (As opposed to controlling pollution after it is formed).

________________________________________________________________________
______

________________________________________________________________________
______

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________

________________________________________________________________________
______

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
__________________

Part H.  Startup and Shutdown for Subpart RRR MACT Sources

46.  For each startup and shutdown event for which you did not follow
your Startup/Shutdown plan or that resulted in an exceedance of any
applicable emission limitation during the past 2 years, please provide
the requested information in the table below.  If this information is
contained in periodic and immediate SSM reports (either stand-alone or
contained within the periodic excess emissions report) submitted to your
permitting authority, you may submit copies of those reports instead. 
Please provide any emissions data during startup or shutdown, if
available.  

Startup/Shutdown*

Description of the event, including identification of the emissions
source or sources [unit ID(s)] associated with the startup or shutdown

Was any permit condition exceeded and, if so, what permit condition was
exceeded?

Was the event covered by any contingency plan for controlling emissions
during startup or shutdown events and, if so, whether the plan was
followed; if the plan was not followed, why not?

Typical duration of an event

Actions taken to minimize emissions during the event, including the use
of any backup control systems

Estimates or measurements, if any, of emissions during the event; if you
did not have the ability to quantify emissions during the event, please
explain why

For affected sources ducted to afterburners, did any startups or
shutdowns take place while the afterburner was not operating, or
operating outside of the operating temperature established during the
performance test?

For affected sources ducted to control devices and monitored by
continuous opacity monitors, did opacity exceed 10% during any startup
or shutdown events?

List performance test data collected during each period of startup or
shutdown, the test method used for each event; when the testing was
conducted and why; the test conditions at the time of testing; and
whether the tests were associated with a routine startup or shutdown

*Startup:  the commencement of operation of an affected source or
portion of an affected source for any purpose; Shutdown:  the cessation
of operation of an affected source or portion of an affected source for
any purpose

47.  Are there any types of startup or shutdown events that you have
been able to eliminate: if so, please describe the type of event and
explain how these events were eliminated?

48.  Optional:  Please recommend a standard that would apply during
startup and/or shutdown.  Describe the type of event (e.g., defining the
beginning and duration of a start-up period and similarly for a
shutdown) to which the standard would apply; the recommended standard
(this could be an emission limitation, work practice, or operational
standard) that would apply during the period; the basis for the
recommended standard; why and how the standard would minimize emissions
during the event; and how compliance would be determined and/or
monitored. 

Part I.  Criteria Air Pollutants (CAP) for subpart RRR MACT sources and
non-subpart RRR MACT sources 

Please provide the information below for all regulated equipment at your
facility; Use information for this section from 2004 or later, whichever
year has the highest production rate._________(please specify year)

49.	a.  CAP emissions by unit for each emission unit subject to 40 CFR
63, subpart RRR MACT sources. (Please include fugitive emissions.)

Unit

ID No.	Emission

Unit	CAP Emissions*

(tons per year)

Lead	VOC	PM	PM10	PM2.5	CO	SOx	NOx

* Please provide any test data along with this section for sources
subject to 40 CFR 63, subpart RRR MACT sources.

	b.  Please list estimated CAP emissions from collocated sources at your
facility that are not regulated under 40 CFR 63, subpart RRR. (Please
include fugitive emissions, but not emissions from Primary Aluminum
sources.)  Test reports are not required to be submitted for sources not
subject to 40 CFR 63, subpart RRR.

Unit

ID No.	Emission

Unit	CAP Emissions 

(tons per year)

Lead	VOC	PM	PM10	PM2.5	CO	SOx	NOx

	

50.  	Control devices used for CAP emission control for Subpart RRR
MACT sources & Non-Subpart RRR MACT sources (Excluding Primary Aluminum)

Control Device ID	Type of Device	ID(s) of Units Controlled	Pollutants
Controlled	Control Efficiency (%)

Part J.  Energy Usage

  

51.  Please list total annual energy consumption.  

Combustion Units (Exclude Emergency Combustion Equipment)	Unit	Unit	Unit
Unit	Unit

Process Unit ID:

	Equipment ID:

	Type of Combustion Equipment:

	Year Built:

	Number of Operating Hours per Year:

	Design Capacity (Heat Input) (MMBtu/hr):

	Fuel Type:

	Heat Release Rate (Btu/scf):

	Is the unit subject to NSPS?

	If yes, indicate the year:

	Start-up Fuel/Material

	Start-up fuel:

	Typical Start-up fuel amount (specify units)

	Typical length of time for start-up (hours):

	Higher heating value (HHV):

	



Fuels/Materials Combusted During Production (include solid, liquid, and
gas waste streams)

Fuel #1 usage: (specify units)

Hours used per year:

Higher heating value (HHV):

Fuel #2 usage: (specify units)

Hours used per year:

Higher heating value (HHV):

Fuel # 3 usage: (specify units)

Hours used per year:

Higher heating value (HHV):

  

Please note:  In the excel version this chart will be vertical and allow
for facility totals, if individual unit information is not known.

52.  Are any Cogeneration units listed above, if so please list the unit
and describe the process for each?
________________________________________________________________________
_________________

________________________________________________________________________
_________________

________________________________________________________________________
_________________

53.	Electricity Usage

Normal Operating Annual Electricity Usage	Year	Total Facility Usage 

(Specify Unit of Measurement)

K.  Miscellaneous Information

54.   What specific improvements or rule changes would you like to see
that would help your facility with compliance or better rule
interpretation?

Attachment A.	Definitions for subpart RRR MACT sources

Afterburner means an air pollution control device that uses controlled
flame combustion to convert combustible materials to noncombustible
gases; also known as an incinerator or a thermal oxidizer. 

Aluminum scrap means fragments of aluminum stock removed during
manufacturing (i.e., machining), manufactured aluminum articles or parts
rejected or discarded and useful only as material for reprocessing, and
waste and discarded material made of aluminum.

Aluminum scrap shredder means a unit that crushes, grinds, or breaks
aluminum scrap into a more uniform size prior to processing or charging
to a scrap dryer/delacquering kiln/decoating kiln, or furnace.  A bale
breaker is not an aluminum scrap shredder. 

Clean charge means furnace charge materials, including molten aluminum;
T-bar; sow; ingot; billet; pig; alloying elements; aluminum scrap known
by the owner or operator to be entirely free of paints, coatings, and
lubricants; uncoated/unpainted aluminum chips that have been thermally
dried or treated by a centrifugal cleaner; aluminum scrap dried at 343
°C (650 °F) or higher; aluminum scrap delacquered/ decoated at 482 °C
(900 °F) or higher, and runaround scrap

Cover flux means salt added to the surface of molten aluminum in a group
1 or group 2 furnace, without agitation of the molten aluminum, for the
purpose of preventing oxidation.

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

Group 1 furnace means a furnace of any design that melts, holds, or
processes aluminum that contains paint, lubricants, coatings, or other
foreign materials with or without reactive fluxing, or processes clean
charge with reactive fluxing.

Group 2 furnace means a furnace of any design that melts, holds, or
processes only clean charge and that performs no fluxing or performs
fluxing using only nonreactive, non-HAP-containing/non-HAP-generating
gases or agents.

In-line fluxer means a device exterior to a furnace, located in a
transfer line from a furnace, used to refine (flux) molten aluminum;
also known as a flux box, degassing box, or demagging box. 

Melting/holding furnace, or melter/holder, means a group 1 furnace that
processes only clean charge, performs melting, holding, and fluxing
functions, and does not transfer molten aluminum to or from another
furnace.

Rotary dross cooler means a water-cooled rotary barrel device that
accelerates cooling of dross.  

Runaround scrap means scrap materials generated on-site by aluminum
casting, extruding, rolling, scalping, forging, forming/stamping,
cutting, and trimming operations and that do not contain paint or solid
coatings. Uncoated/unpainted aluminum chips generated by turning,
boring, milling, and similar machining operations may be clean charge if
they have been thermally dried or treated by a centrifugal cleaner, but
are not considered to be runaround scrap.

Scrap dryer/delacquering kiln/decoating kiln means a unit used primarily
to remove various organic contaminants such as oil, paint, lacquer, ink,
plastic, and/or rubber from aluminum scrap (including used beverage
containers) prior to melting.

Secondary aluminum processing unit (SAPU):  an existing SAPU means all
existing group 1 furnaces and all existing in-line fluxers within a
secondary aluminum production facility.  Each existing group 1 furnace
or existing in-line fluxer is considered an emission unit within a
secondary aluminum processing unit.  A new SAPU means any combination of
group 1 furnaces and in-line fluxers which are simultaneously
constructed after February 11, 1999.  Each of the group 1 furnaces or
in-line fluxers within a new SAPU is considered an emission unit within
that secondary aluminum processing unit.

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

Sweat furnace means a furnace used exclusively to reclaim aluminum from
scrap that contains substantial quantities of iron by using heat to
separate the low-melting point aluminum from the scrap while the higher
melting-point iron remains in solid form.

Thermal chip dryer means a device that uses heat to evaporate water,
oil, or oil/water mixtures from unpainted/uncoated aluminum chips.

Appendix B

Section 112(b) List of Hazardous Air Pollutants (HAP)

U.S. Code Title 42, Chapter 85, Subchapter 1, Part A, § 7412

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瑹↵؀Nickel Compounds

0 	Polycyclic Organic Matter 4

0 	Radionuclides (including radon) 5

0 	Selenium Compounds

NOTE: For all listings above which contain the word “compounds” and
for glycol ethers, the following applies: Unless otherwise specified,
these listings are defined as including any unique chemical substance
that contains the named chemical (i.e., antimony, arsenic, etc.) as part
of that chemical’s infrastructure.

1 XCN where X = H or any other group where a formal dissociation may
occur. For example KCN or Ca(CN)2.

2 Includes mono- and di- ethers of ethylene glycol (except for ethylene
glycol monobutyl ether (CAS Number 111–76–2), diethylene glycol, and
triethylene glycol R–(OCH2CH2)n–OR where

n = 1, 2, or 3

R = alkyl or aryl groups

R = R, H, or groups which, when removed, yield glycol ethers with the
structure: R–(OCH2CH)n–OH. Polymers are excluded from the glycol
category.

3 Includes mineral fiber emissions from facilities manufacturing or
processing glass, rock, or slag fibers (or other mineral derived fibers)
of average diameter 1 micrometer or less.

4 Includes organic compounds with more than one benzene ring, and which
have a boiling point greater than or equal to 100°C.

5 A type of atom which spontaneously undergoes radioactive decay.

 See “Definitions” in Attachment 1 at the end of this survey for
explanation of these terms. For the purposes of this survey, scrap wells
and wells of similar function as the side well shall be considered a
sidewell.

NESHAP for Secondary Aluminum (40 CFR part 63, subpart RRR)

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