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 463.14 - Operating requirements

Current through June 24, 2024
(1) SUMMARY.
(a) On and after the compliance date
				  established by s.
				  NR
				  463.115, the owner or operator shall operate all new
				  and existing affected sources and control equipment according to the
				  requirements in this section.
(b)
				  The owner or operator of an existing sweat furnace that meets the
				  specifications of s.
				  NR
				  463.13(6) shall operate the sweat
				  furnace and control equipment according to the requirements of this section on
				  and after the compliance date established by s.
				  NR
				  463.115.
(c) The owner or operator of a new sweat
				  furnace that meets the specifications of s.
				  NR
				  463.13(6) shall operate the sweat
				  furnace and control equipment according to the requirements of this section by
				  March 23, 2000 or upon startup, whichever is later.
(d) Operating requirements are summarized in
				  the following table.
Table 2
Summary of Operating Requirements for New and
					 Existing Affected Sources and Emission Units
Affected Source or Emission
								  Unit
Monitor Type, Operation,
								  Process
Operating Requirements
All affected sources and emission units with an
								  add-on air pollution control device
Emission capture and collection system
Design and install in accordance with Industrial
								  Ventilation: A Manual of Recommended Practice, incorporated by reference in s.
								  NR 484.11(2)
								  (d); operate in accordance with OM&M
								  plan. b
All affected sources and emission units subject
								  to production-based (lb/ton of feed) emission limits
								  a
Charge or feed weight or production weight
Operate a device that records the weight of each
								  charge; operate in accordance with OM&M plan.
								  b
Group 1 furnace, group 2 furnace, in-line fluxer,
								  scrap dryer, delacquering kiln or decoating kiln
Labeling
Identification, operating parameter ranges and
								  operating requirements posted at affected sources and emission units; control
								  device temperature and residence time requirements posted at scrap dryer,
								  delacquering kiln or decoating kiln.
Aluminum scrap shredder with fabric filter
Bag leak detector or
Continuous opacity monitor or
Visual emissions
Initiate corrective action within one hour of
								  alarm and complete in accordance with OM&M
								  planb; operate such that alarm does not sound more
								  than 5% of operating time in 6-month period.
Initiate corrective action within one hour of a
								  6-minute average opacity reading of 5% or more and complete in accordance with
								  OM&M plan. b
Initiate corrective action within one hour of any
								  observed visual emissions and complete in accordance with the OM&M
								  plan.b
Thermal chip dryer with afterburner
Afterburner operating temperature
Afterburner operation Feed material
Maintain average temperature for each 3-hr period
								  at or above average operating temperature during the performance test.
Operate in accordance with OM&M
								  plan.b
Operate using only unpainted aluminum
								  chips
Scrap dryer, delacquering kiln, decoating kiln
								  with afterburner and lime-injected fabric filter
Afterburner operating temperature
Afterburner operation Bag leak detector or
Continuous opacity monitor
Fabric filter inlet temperature
Lime injection rate
Maintain average temperature for each 3-hr period
								  at or above average operating temperature during the performance test.
Operate in accordance with OM&M
								  plan.b
Initiate corrective action within one hour of
								  alarm and complete in accordance with the OM&M
								  planb; operate such that the alarm does not sound
								  more than 5% of operating time in 6-month period.
Initiate corrective action within one hour of a
								  6-minute average opacity reading of 5% or more and complete in accordance with
								  the OM&M plan.b
Maintain average fabric filter inlet temperature
								  for each 3-hr period at or below average temperature during the performance
								  test +14 °C (+25 °F).
Maintain free-flowing lime in the feed hopper or
								  silo at all times for continuous injection systems; maintain feeder setting at
								  level established during the performance test for continuous injection
								  systems.
Sweat furnace with afterburner
Afterburner operating temperature
If a performance test was conducted, maintain
								  average temperature for each 3-hr period at or above average operating
								  temperature during the performance test; if a performance test was not
								  conducted, and afterburner meets specifications of s.
								  NR
								  463.13(6), maintain average
								  temperature for each 3-hr period at or above 1600 °F.
Afterburner operation
Operate in accordance with OM&M
								  plan.b
Dross-only furnace with fabric filter
Bag leak detector or
Initiate corrective action within one hour of
								  alarm and complete in accordance with the OM&M
								  plan;b operate such that alarm does not sound more
								  than 5% of operating time in 6-month period.
Continuous opacity monitor
Initiate corrective action within one hour of a
								  6-min-utes average opacity reading of 5% or more and complete in accordance
								  with the OM&M plan.b
Feed or charge material
Operate using only dross as the feed
								  material.
Rotary dross cooler with fabric filter
Bag leak detector or
Initiate corrective action within one hour of
								  alarm and complete in accordance with the OM&M
								  plan;b operate such that alarm does not sound more
								  than 5% of operating time in 6-month period.
Continuous opacity monitor
Initiate corrective action within one hour of a
								  6-minute average opacity reading of 5% or more and complete in accordance with
								  the OM&M plan.b
In-line fluxer with lime-injected fabric filter,
								  including those that are part of a secondary aluminum processing unit
Bag leak detector
Initiate corrective action within one hour of
								  alarm and complete in accordance with OM&M
								  plan;b operate such that alarm does not sound more
								  than 5% or of operating time in a 6-month period.
Continuous opacity monitor
Initiate corrective action within one hour of
								  6-minute average opacity reading of 5% or more and complete in accordance with
								  the OM&M plan.b
Lime injection rate
Maintain free-flowing lime in the feed hopper or
								  silo at all times for continuous injection systems; maintain feeder setting at
								  level established during performance test for continuous injection
								  systems.
Reactive flux injection rate
Maintain reactive flux injection rate at or below
								  rate used during the performance test for each operating cycle or time period
								  used in the performance test.
In-line fluxer using no reactive flux
Flux material
Use no reactive flux
Group 1 furnace with lime-injected fabric filter,
								  including those that are part of a secondary aluminum processing unit
Bag leak detector or
Initiate corrective action within one hour of
								  alarm; operate such that alarm does not sound more than 5% of operating time in
								  6-month period; complete corrective action in accordance with the OM&M
								  plan.b
Continuous opacity monitor
Initiate corrective action within one hour of a
								  6-minute average opacity reading of 5% or more; complete corrective action in
								  accordance with the OM&M plan.b
Fabric filter inlet temperature
Maintain average fabric filter inlet temperature
								  for each 3-hour period at or below average temperature during the performance
								  test +14°C (+25 °F)
Reactive flux injection rate
Maintain reactive flux injection rate (lb/ton) at
								  or below the rate used during the performance test for each furnace
								  cycle.
Lime injection rate
Maintain free-flowing lime in the feed hopper or
								  silo at all times for continuous injection systems; maintain feeder setting at
								  level established at performance test for continuous injection systems.
Maintain molten aluminum level
Operate sidewell furnaces such that the level of
								  molten metal is above the top of the passage between sidewell and hearth during
								  reactive flux injection unless the hearth is also controlled.
Fluxing in sidewell furnace hearth
Add reactive flux only to the sidewell of the
								  furnace unless the hearth is also controlled
Group 1 furnace without add-on controls,
								  including those that are part of a secondary aluminum processing unit
Reactive flux injection
Site-specific monitoring
								  planc
Maintain reactive flux injection rate (lb/ton) at
								  or below rate used during the performance test for each operating cycle or time
								  period used in the performance test.
Operate furnace within the range of charge
								  materials, contaminant levels, and parameter values established in the
								  site-specific monitoring plan
Feed material, melting and holding furnace
Use only clean charge
Clean group 2 furnace
Charge and flux materials
Use only clean charge. Use no reactive
								  flux.
a Thermal chip dryers, scrap dryers, delacquering kilns,
					 dross-only furnaces, in-line fluxers and group 1 furnaces including melting and
					 holding furnaces.
b OM&M plan- Operation, maintenance, and monitoring
					 plan.
c Site-specific monitoring plan. Owners and operators of
					 group 1 furnaces without control devices shall include a section in their
					 OM&M plan that documents work practices and pollution prevention measures,
					 including procedures for scrap inspection, by which compliance is achieved with
					 emission limits and process or feed parameter-based operating requirements.
					 This plan and the testing to demonstrate adequacy of the monitoring plan shall
					 be developed in coordination with and approved by the department.