Wis. Admin. Code Department of Natural Resources NR 463.14

Current through November 25, 2024

Section NR 463.14 - Operating requirements

(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 plan^b; 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 plan^b; 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 plan^c	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.

(2) LABELING. The owner or operator shall provide and maintain easily visible labels posted at each group 1 furnace, group 2 furnace, in-line fluxer, scrap dryer, delacquering kiln and decoating kiln that identify the applicable emission limits and means of compliance, including all of the following:

(a) The type of affected source or emission unit, such as a scrap dryer, delacquering kiln or decoating kiln, group 1 furnace, group 2 furnace or in-line fluxer.

(b) The applicable operational standards and control methods, including work practice or control device. This includes the type of charge to be used for a furnace, including clean scrap only, all scrap, or other, flux materials and addition practices, and the applicable operating parameter ranges and requirements as incorporated in the operations maintenance and monitoring plan required by s. NR 463.15(2).

(c) The afterburner operating temperature and design residence time for a scrap dryer, delacquering kiln or decoating kiln.

(3) CAPTURE AND COLLECTION SYSTEMS. For each affected source or emission unit equipped with an add-on air pollution control device, the owner or operator shall do all of the following:

(a) Design and install a system for the capture and collection of emissions to meet the engineering standards for minimum exhaust rates as published by the American Conference of Governmental Industrial Hygienists in chapters 3 and 5 of Industrial Ventilation: A Manual of Recommended Practice, incorporated by reference in s. NR 484.11(2) (d).

(b) Vent captured emissions through a closed system, except that dilution air may be added to emission streams for the purpose of controlling temperature at the inlet to a fabric filter.

(c) Operate each capture and collection system according to the procedures and requirements in the operation, maintenance and monitoring (OM&M) plan.

(4) FEED OR CHARGE WEIGHT. The owner or operator of each affected source or emission unit subject to an emission limit in kg/Mg (lb/ton) or mg/Mg (gr/ton) of feed or charge shall comply with both pars. (a) and (b).

(a) Except as provided in par. (c), install and operate a device that measures and records or otherwise determine the weight of feed or charge (or throughput) for each operating cycle or time period used in the performance test.

(b) Operate each weight measurement system or other weight determination procedure in accordance with the OM&M plan.

(c) The owner or operator may chose to measure and record aluminum production weight from an affected source or emission unit rather than feed or charge weight to an affected source or emission unit, provided that both of the following conditions are met:

1. The aluminum production weight, rather than feed or charge weight is measured and recorded for all emission units within a SAPU.

2. All calculations to demonstrate compliance with the emission limits for SAPUs are based on aluminum production weight rather than feed or charge weight.

(5) ALUMINUM SCRAP SHREDDER. The owner or operator of a scrap shredder with emissions controlled by a fabric filter shall operate a bag leak detection system or a continuous opacity monitor or conduct visible emissions observations.

(a) If a bag leak detection system is used to meet the monitoring requirements in s. NR 463.15, the owner or operator shall do all of the following:

1. Initiate corrective action within one hour of a bag leak detection system alarm and complete the corrective action procedures in accordance with the OM&M plan.

2. Operate each fabric filter system such that the bag leak detection system alarm does not sound more than 5% of the operating time during a 6-month block reporting period. In calculating this operating time fraction, if inspection of the fabric filter demonstrates that no corrective action is required, no alarm time shall be counted. If corrective action is required, each alarm shall be counted as a minimum of one hour. If the owner or operator takes longer than one hour to initiate corrective action, the alarm time shall be counted as the actual amount of time taken by the owner or operator to initiate corrective action.

(b) If a continuous opacity monitoring system is used to meet the monitoring requirements in s. NR 463.15, the owner or operator shall initiate corrective action within one hour of any 6-minute average reading of 5% or more opacity and complete the corrective action procedures in accordance with the OM&M plan.

(c) If visible emission observations are used to meet the monitoring requirements in s. NR 463.15, the owner or operator shall initiate corrective action within one hour of any observation of visible emissions during a daily visible emissions test and complete the corrective action procedures in accordance with the OM&M plan.

(6) THERMAL CHIP DRYER. The owner or operator of a thermal chip dryer with emissions controlled by an afterburner shall do all of the following:

(a) Maintain the 3-hour block average operating temperature of each afterburner at or above the average temperature established during the performance test.

(b) Operate each afterburner in accordance with the OM&M plan.

(c) Operate each thermal chip dryer using only unpainted aluminum chips as the feedstock.

(7) SCRAP DRYER, DELACQUERING KILN OR DECOATING KILN. The owner or operator of a scrap dryer, delacquering kiln or decoating kiln with emissions controlled by an afterburner and a lime-injected fabric filter shall meet pars. (a), (d) and (e) and either par. (b) or (c) as applicable:

(a) For each afterburner, do both of the following:

1. Maintain the 3-hour block average operating temperature of each afterburner at or above the average temperature established during the performance test.

2. Operate each afterburner in accordance with the OM&M plan.

(b) If a bag leak detection system is used to meet the fabric filter monitoring requirements in s. NR 463.15, do both of the following:

1. Initiate corrective action within one hour of a bag leak detection system alarm and complete any necessary corrective action procedures in accordance with the OM&M plan.

(c) If a continuous opacity monitoring system is used to meet the monitoring requirements in s. NR 463.15, initiate corrective action within one hour of any 6-minute average reading of 5% or more opacity and complete the corrective action procedures in accordance with the OM&M plan.

(d) Maintain the 3-hour block average inlet temperature for each fabric filter at or below the sum of the average temperature established during the performance test, plus 14°C (25°F).

(e) For a continuous injection device, maintain free-flowing lime in the hopper to the feed device at all times and maintain the lime feeder setting at the same level established during the performance test.

(8) SWEAT FURNACE. The owner or operator of a sweat furnace with emissions controlled by an afterburner shall do both of the following:

(a) Maintain the 3-hour block average operating temperature of each afterburner at or above one of the following, as appropriate:

1. The average temperature established during the performance test.

2. 871°C (1600°F) if a performance test was not conducted, and the afterburner meets the specifications of s. NR 463.13(6).

(b) Operate each afterburner in accordance with the OM&M plan.

(9) DROSS-ONLY FURNACE. The owner or operator of a dross-only furnace with emissions controlled by a fabric filter shall meet par. (c) and either par. (a) or (b) as appropriate:

(a) If a bag leak detection system is used to meet the monitoring requirements in s. NR 463.15, do both of the following:

1. Initiate corrective action within one hour of a bag leak detection system alarm and complete the corrective action procedures in accordance with the OM&M plan.

(b) If a continuous opacity monitoring system is used to meet the monitoring requirements in s. NR 463.15, initiate corrective action within one hour of any 6-minute average reading of 5% or more opacity and complete the corrective action procedures in accordance with the OM&M plan.

(c) Operate each furnace using dross and salt flux as the sole feedstock.

(10) ROTARY DROSS COOLER. The owner or operator of a rotary dross cooler with emissions controlled by a fabric filter shall do one of the following:

(a) If a bag leak detection system is used to meet the monitoring requirements in s. NR 463.15, do both of the following:

1. Initiate corrective action within one hour of a bag leak detection system alarm and complete the corrective action procedures in accordance with the OM&M plan.

(11) IN-LINE FLUXER. The owner or operator of an in-line fluxer with emissions controlled by a lime-injected fabric filter shall meet pars. (c) and (d) and either par. (a) or (b) as applicable:

(a) If a bag leak detection system is used to meet the monitoring requirements in s. NR 463.15, do both of the following:

1. Initiate corrective action within one hour of a bag leak detection system alarm and complete the corrective action procedures in accordance with the OM&M plan.

(c) For a continuous injection system, maintain free-flowing lime in the hopper to the feed device at all times and maintain the lime feeder setting at the same level established during the performance test.

(d) Maintain the total reactive chlorine flux injection rate for each operating cycle or time period at or below the average rate established during the performance test for the operating cycle or time period.

(12) IN-LINE FLUXER USING NO REACTIVE FLUX MATERIAL. The owner or operator of a new or existing in-line fluxer using no reactive flux materials shall operate each in-line fluxer using no reactive flux materials.

(13) GROUP 1 FURNACE WITH ADD-ON AIR POLLUTION CONTROL DEVICES. The owner or operator of a group 1 furnace with emissions controlled by a lime-injected fabric filter shall meet pars. (c) to (f) and either par. (a) or (b) as applicable:

(a) If a bag leak detection system is used to meet the monitoring requirements in s. NR 463.15 do all of the following:

1. Initiate corrective action within one hour of a bag leak detection system alarm.

2. Complete the corrective action procedures in accordance with the OM&M plan.

3. Operate each fabric filter system such that the bag leak detection system alarm does not sound more than 5% of the operating time during a 6-month block reporting period. In calculating this operating time fraction, if inspection of the fabric filter demonstrates that no corrective action is required, no alarm time shall be counted. If corrective action is required, each alarm shall be counted as a minimum of one hour. If the owner or operator takes longer than one hour to initiate corrective action, the alarm time shall be counted as the actual amount of time taken by the owner or operator to initiate corrective action.

(b) If a continuous opacity monitoring system is used to meet the monitoring requirements in s. NR 463.15, do both of the following:

1. Initiate corrective action within one hour of any 6-minute average reading of 5% or more opacity.

2. Complete the corrective action procedures in accordance with the OM&M plan.

(c) Maintain the 3-hour block average inlet temperature for each fabric filter at or below the sum of the average temperature established during the performance test, plus 14°C (25°F).

(d) For a continuous lime injection system, maintain free-flowing lime in the hopper to the feed device at all times and maintain the lime feeder setting at the same level established during the performance test.

(e) Maintain the total reactive chlorine flux injection rate for each operating cycle or time period at or below the average rate established during the performance test for the operating cycle or time period.

(f) Operate each sidewell furnace such that both of the following are met:

1. The level of molten metal remains above the top of the passage between the sidewell and hearth during reactive flux injection, unless emissions from both the sidewell and the hearth are included in demonstrating compliance with all applicable emission limits.

2. Reactive flux is added only in the sidewell, unless emissions from both the sidewell and the hearth are included in demonstrating compliance with all applicable emission limits.

(14) GROUP 1 FURNACE WITHOUT ADD-ON AIR POLLUTION CONTROL DEVICES. The owner or operator of a group 1 furnace, including a group 1 furnace that is part of a secondary aluminum processing unit, without add-on air pollution control devices shall do all of the following:

(a) Maintain the total reactive chlorine flux injection rate for each operating cycle or time period at or below the average rate established during the performance test for the operating cycle or time period.

(b) Operate each furnace in accordance with the work practice and pollution prevention measures documented in the OM&M plan and within the parameter values or ranges established in the OM&M plan.

(c) Operate each group 1 melting and holding furnace subject to the emission standards in s. NR 463.13(9) (b) using only clean charge as the feedstock.

(15) GROUP 2 FURNACE. The owner or operator of a new or existing group 2 furnace shall do both of the following:

(a) Operate each furnace using only clean charge as the feedstock.

(b) Operate each furnace using no reactive flux.

(16) CORRECTIVE ACTION. When a process parameter or add-on air pollution control device operating parameter deviates from the value or range established during the performance test and incorporated in the OM&M plan, the owner or operator shall initiate corrective action. Corrective action shall restore operation of the affected source or emission unit, including the process or control device, to its normal or usual mode of operation as expeditiously as practicable in accordance with good air pollution control practices for minimizing emissions. Corrective actions taken shall include follow-up actions necessary to return the process or control device parameter level to the value or range of values established during the performance test and steps to prevent the likely recurrence of the cause of a deviation.

Wis. Admin. Code Department of Natural Resources NR 463.14

CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09; corrections in (1) (b), (c), (d) and (8) (a) 2. made under s. 13.92(4) (b) 7, Stats., Register December 2008 No. 636.