Wisconsin Administrative Code › Department of Natural Resources › NR 400-499 - Environmental Protection - Air Pollution Control › Chapter NR 463 - National Emission Standards For Hazardous Air Pollutants For Metals Treating And Processing › Subchapter II - Secondary Aluminum Production › Section NR 463.15 - Monitoring requirements

Current through June 24, 2024
(1) SUMMARY. On and
				  after the compliance date established by s.
				  NR
				  463.115, the owner or operator of a new or existing
				  affected source or emission unit shall monitor all control equipment and
				  processes according to the requirements in this section. Monitoring
				  requirements for each type of affected source and emission unit are summarized
				  in the following table.
Table 3
Summary of Monitoring Requirements for New and Existing
					 Affected Sources and Emission Units
Affected Source and Emission
								  Unit
Monitor Type, Operation,
								  Process
Monitoring Requirements
All affected sources and emission units with an
								  add-on air pollution control device
Emission capture and collection system
Annual inspection of all emission capture,
								  collection, and transport systems to ensure that systems continue to operate in
								  accordance with Industrial Ventilation: A Manual of Recommended Practice,
								  incorporated by reference in s.
								  NR 484.11(2)
								  (d).
All affected sources and emission units subject
								  to production-based, lb/ton of feed or charge, emission limits.
								  a
Feed charge weight
Record weight of each feed or charge, weight
								  measurements device of other procedure accuracy of
								  ±1%b-; calibrate according to manufacturers
								  specifications, or at least once every 6 months
Group 1 furnace, group 2 furnace inline fluxer,
								  scrap dryer, delacquering kiln or decoating kiln
Labeling
Check monthly to confirm that labels are intact
								  and legible
Aluminum scrap shredder with fabric filter
Bag leak detector or
Install and operate in accordance with "Fabric
								  Filter Bag Leak Detection Guidance."c; Record
								  voltage output from bag leak detector.
Continuous opacity monitor or
Design and install in accordance with PS-1;
								  collect data in accordance with subpart A of 40 CFR part 63; determine and
								  record 6-minute block averages.
Visual emissions
Conduct and record results of 30-minute daily
								  test in accordance with Method 9 in Appendix A to 40 CFR part 60, incorporated
								  by reference in s.
								  NR
								  484.04(13).
Thermal Chip dryer with afterburner
Afterburner operating temperature
Continuous measurement device to meet
								  specifications in s. NR 463.15(7) (a); record average temperature for each
								  15-minute block; determine and record 3-hr block averages.
Afterburner operation
Annual inspection of afterburner internal parts;
								  complete repairs in accordance with the OM&Md
								  plan.
Feed or charge material
Record identity of each feed or charge; certify
								  feed or charge materials ever 6 months
Scrap dryer, delacquering kiln or decoating kiln
								  with afterburner and lime injected fabric filter
Afterburner operating temperature
Continuous measurement device to meet
								  specifications in s. NR 463.15(7) (a); record temperature for each 15-minute
								  block; determine and record 3-hr block averages.
Afterburner operation
Annual inspection of afterburner internal parts;
								  complete repairs in accordance with the OM&Md
								  plan.
Bag leak detector or
Install and operate in accordance with "Fabric
								  Filter Bag Leak Detection Guidance"c; record voltage
								  output from bag leak detector.
Continuous opacity monitor
Design and install in accordance with PS-1;
								  collect data in accordance with subpart A of 40 CFR part 63; determine and
								  record 6-minute block averages.
Lime injection rate
For continuous injection systems; inspect each
								  feed hopper or silo every 8 hr to verify that lime is free-flowing; record
								  results of each inspection. If blockage occurs, inspect every 4 hr for 3 days;
								  return to 8-hr inspections if corrective action results in no further blockage
								  during the 3-day period; record feeder setting daily.
Fabric filter inlet temperature
Continuous measurement device to meet
								  specifications in s. NR 463.15(8) (b); record temperatures in 15-minute block
								  averages; determine and record 3-hr blockage averages.
Sweat furnace with after burner
Afterburner operating temperature
Continuous measurement device to meet
								  specifications in s. NR 463.15(8) (a); record temperature in 15-minute block
								  averages; determine and record 3-hr block average.
Afterburner operation
Annual inspection of afterburner internal parts;
								  complete repairs in accordance with the OM&Md
								  plan.
Dross-only furnace with fabric filter
Bag leak detector or
Install and operate in accordance with "Fabric
								  Filter Bag Leak Detection Guidance"c; record output
								  voltage from bag leak detector.
Continuous opacity monitor
Design and install in accordance with PS-1;
								  collect data in accordance with subpart A of 40 CFR part 63; determine and
								  record 6-minute block averages.
Feed or charge material
Record identify of each feed or charge; certify
								  charge materials every 6 months.
Rotary dross cooler with fabric filter
Bag leak detector or
Install and operate in accordance with "Fabric
								  Filter Bag Leak Detection Guidance"c; record output
								  voltage from bag leak detector.
Continuous opacity monitor
Design and install in accordance with PS-1;
								  collect data in accordance with subpart A of 40 CFR part 63; determine and
								  record 6-minute block averages.
In-Line fluxer with lime-injected fabric
								  filter
Flux materials
Record flux material; certify every 6 months for
								  no reactive flux.
Bag leak detector or
Install and operate in accordance with "Fabric
								  Filter Bag Leak Detection Guidance"c; record output
								  voltage from bag leak detector.
Continuous opacity monitor
Design and install in accordance with PS-1;
								  collect data in accordance with subpart A of 40 CFR part 63; determine and
								  record 6-minute block averages.
Reactive flux injection rate
Weight measurement device accuracy of ±1%;
								  calibrate according to manufacturers specifications or at least once every 6
								  months; record time, weight and type of reactive flux added or injected for
								  each 15-minute block period while reactive fluxing occurs; calculate and record
								  total reactive flux injection rate for each operating cycle or time period used
								  in performance test; or
Alternative flux injection rate determination
								  procedure per s. NR 463.15(10) (e).
Lime injection rate
For continuous injection systems; inspect each
								  feed hopper or silo every 8 hr to verify that lime is free-flowing; record
								  results of each inspection. If blockage occurs, inspect every 4 hr for 3 days;
								  return to 8-hr inspections if corrective action results in no further blockage
								  during the 3-day period.e
In-line fluxer using no reactive flux
Flux materials
Record flux materials; certify every 6 months for
								  no reactive flux.
Group 1 furnace with lime injected fabric
								  filter
Bag leak detector or
Install and operate in accordance with "Fabric
								  Filter Bag Leak Detection Guidance"c; record output
								  voltage from bag leak detector.
Continuous opacity monitor
Design and install in accordance with PS-1;
								  collect data in accordance with subpart A of 40 CFR part 63; determine and
								  record 6-minute block averages.
Lime injection rate
For continuous injection systems; inspect each
								  feed hopper or silo every 8 hr to verify that lime is free-flowing; record
								  results of each inspection. If blockage occurs, inspect every 4 hr for 3 days;
								  return to 8-hr inspections if corrective action results in no further blockage
								  during the 3-day period; record feeder setting daily.
Reactive flux injection rate
Weight measurement device accuracy of
								  ±1%b, calibrate every 3 months; record weight
								  and type of reactive flux added or injected for each 15-minute block period
								  while reactive fluxing occurs; calculate and record total reactive flux
								  injection rate for each operating cycle or time period used in performance
								  test; or Alternative flux rate injection rate determination procedure per s. NR
								  463.15(10) (e).
Group 1 furnace with lime injected fabric filter
								  (Continued)
Fabric filter inlet temperature
Continuous measurement device to meet
								  specifications in s. NR 463.15(8) (b); record temperatures in 15-minute block
								  averages; determine and record 3-hour block averages
Maintain molten aluminum level in sidewell
								  furnace
Maintain aluminum level operating log; certify
								  every 6 months.
Group 1 furnace without add-on controls
Fluxing molten aluminum level in sidewell
								  furnace
Maintain flux addition operating log; certify
								  every 6 months.
Reactive flux injection rate
Weight measurement device accuracy of ±1%;
								  calibrate according to manufacturers specifications or at least once every 6
								  months; record time, weight and type of reactive flux added or injected for
								  each 15-minute block period while reactive fluxing occurs; calculate and record
								  total reactive flux injection rate for each operating cycle or time period used
								  in performance test.
OM&Md plan
								  approved by the department
Demonstration of site-specific monitoring
								  procedures to provide data and show correlation of emissions across the range
								  of charge and flux materials and furnace operating parameters.
Feed material - melting and holding
								  furnace
Record type of permissible feed or charge
								  material; certify charge materials every 6 months.
Clean group 2 furnace
Charge and flux materials
Record charge and flux materials; certify every 6
								  months for clean charge and no reactive flux.
a Thermal chip dryers, scrap dryers, delacquering kilns,
					 dross-only furnaces, in-line fluxers and group 1 furnaces or melting and
					 holding furnaces
b The department may approve measurement devices of
					 alternative accuracy, for example in cases where flux rates are very low and
					 costs of meters of specified accuracy are prohibitive; or where feed or charge
					 weighing devices of specified accuracy are not practicable due to equipment
					 layout or charging practices.
c Non-turboelectric bag leak detectors shall be installed
					 and operated in accordance with manufacturers' specifications.
d OM&M plan- Operation, maintenance, and monitoring
					 plan.
e The department may approve of other alternatives
					 including load cells for lime hopper weight, sensors for carrier gas pressure,
					 or HCl monitoring devices of fabric filter outlet.
(2) OPERATION, MAINTENANCE, AND MONITORING
				  PLAN. The owner or operator shall prepare and implement for each new or
				  existing affected source and emission unit, a written operation, maintenance
				  and monitoring (OM&M) plan. The owner or operator of an existing affected
				  source shall submit the OM&M plan to the department no later than the
				  compliance date established by s.
				  NR
				  463.115(1). The owner or operator of
				  any new MACT source subject to this subchapter shall submit the OM&M plan
				  to the department within 90 days after a successful initial performance test
				  under s.
				  NR
				  463.16(2) or within 90 days after the
				  compliance date established by s.
				  NR
				  463.115(2) if no initial performance
				  test is required. The plan shall be accompanied by a written certification by
				  the owner or operator that the OM&M plan satisfies all requirements of this
				  section and is otherwise consistent with the requirements of this subchapter.
				  The owner or operator shall comply with all of the provisions of the OM&M
				  plan as submitted to the department, unless and until the plan is revised in
				  accordance with the following procedures. If the department determines at any
				  time after receipt of the OM&M plan that any revisions of the plan are
				  necessary to satisfy the requirements of this subchapter, the owner or operator
				  shall promptly make all necessary revisions and resubmit the revised plan. If
				  the owner or operator determines that any other revisions of the OM&M plan
				  are necessary, the revisions may not become effective until the owner or
				  operator submits a description of the changes and a revised plan incorporating
				  them to the department. Each plan shall contain all of the following
				  information:
(a) Process and control device
				  parameters to be monitored to determine compliance, along with established
				  operating levels or ranges, as applicable, for each process and control
				  device.
(b) A monitoring schedule
				  for each affected source and emission unit.
(c) Procedures for the proper operation and
				  maintenance of each process unit and add-on control device used to meet the
				  applicable emission limits or standards in s.
				  NR
				  463.13.
(d) Procedures for the proper operation and
				  maintenance of monitoring devices or systems used to determine compliance,
				  including the following:
1. Calibration and
				  certification of accuracy of each monitoring device, at least once every 6
				  months, according to the manufacturer's instructions.
2. Procedures for the quality control and
				  quality assurance of continuous emission or opacity monitoring systems as
				  required by the general provisions in ch. NR 460.
(e) Procedures for monitoring process and
				  control device parameters, including procedures for annual inspections of
				  afterburners, and if applicable, the procedure to be used for determining
				  charge or feed or throughput weight if a measurement device is not
				  used.
(f) Corrective actions to be
				  taken when process or operating parameters or add-on control device parameters
				  deviate from the value or range established in par. (a), including the
				  following:
1. Procedures to determine and
				  record the cause of a deviation or excursion, and the time the deviation or
				  excursion began and ended.
2.
				  Procedures for recording the corrective action taken, the time corrective
				  action was initiated, and the time and date corrective action was
				  completed.
(g) A
				  maintenance schedule for each process and control device that is consistent
				  with the manufacturer's instructions and recommendations for routine and
				  long-term maintenance.
(h)
				  Documentation of the work practice and pollution prevention measures used to
				  achieve compliance with the applicable emission limits and a site-specific
				  monitoring plan as required in sub. (15) for each group 1 furnace not equipped
				  with an add-on air pollution control device.