Wis. Admin. Code Department of Natural Resources NR 463.15

Current through November 25, 2024

Section NR 463.15 - Monitoring requirements

(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.

(3) LABELING. The owner or operator shall inspect the labels for each group 1 furnace, group 2 furnace, in-line fluxer, scrap dryer, delacquering kiln and decoating kiln at least once per calendar month to confirm that posted labels as required by the operational standard in s. NR 463.14(2) are intact and legible.

(4) CAPTURE AND COLLECTION SYSTEM. The owner or operator shall do both of the following:

(a) Install, operate and maintain a capture and collection system for each affected source and emission unit equipped with an add-on air pollution control device.

(b) Inspect each capture and collection and closed vent system at least once each calendar year to ensure that each system is operating in accordance with the operating requirements in s. NR 463.14(3) and record the results of each inspection.

(5) FEED OR CHARGE WEIGHT. The owner or operator of an 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 install, calibrate, operate and maintain a device to measure and record the total weight of feed or charge to, or the aluminum production from, the affected source or emission unit over the same operating cycle or time period used in the performance test. Feed or charge or aluminum production within SAPUs shall be measured and recorded on an emission unit-by-emission unit basis. As an alternative to a measurement device, the owner or operator may use a procedure acceptable to the department to determine the total weight of feed or charge or aluminum production to the affected source or emission unit.

(a) The weight measurement device or procedure shall have an accuracy of ± 1% of the weight being measured. The owner or operator may apply to the department for approval to use a device of alternative accuracy if the required accuracy cannot be achieved as a result of equipment layout or charging practices. A device of alternative accuracy may not be approved unless the owner or operator provides assurance through data and information that the affected source will meet the relevant emission standard.

(b) The owner or operator shall verify the calibration of the weight measurement device in accordance with the schedule specified by the manufacturer, or if no calibration schedule is specified, at least once every 6 months.

(6) FABRIC FILTERS AND LIME-INJECTED FABRIC FILTERS. The owner or operator of an affected source or emission unit using a fabric filter or lime-injected fabric filter to comply with the requirements of this subchapter shall install, calibrate, maintain and continuously operate a bag leak detection system as required in par. (a) or a continuous opacity monitoring system as required in par. (b). The owner or operator of an aluminum scrap shredder shall install and operate a bag leak detection system as required in par. (a), install and operate a continuous opacity monitoring system as required in par. (b), or conduct visible emission observations as required in par. (c).

(a) The requirements of this paragraph apply to the owner or operator of a new or existing affected source or existing emission unit using a bag leak detection system.

1. The owner or operator shall install and operate a bag leak detection system for each exhaust stack of a fabric filter.

2. Each triboelectric bag leak detection system shall be installed, calibrated, operated and maintained according to the Fabric Filter Bag Leak Detection Guidance, EPA, OAQPS, September 1997, incorporated by reference in s. NR 484.05(10). Other bag leak detection systems shall be installed, operated, calibrated, and maintained in a manner consistent with the manufacturer's written specifications and recommendations.

3. The bag leak detection system shall be certified by the manufacturer to be capable of detecting PM emissions at concentrations of 10 milligrams per actual cubic meter (0.0044 grains per actual cubic foot) or less.

4. The bag leak detection system sensor shall provide output of relative or absolute PM loadings.

5. The bag leak detection system shall be equipped with a device to continuously record the output signal from the sensor.

6. The bag leak detection system shall be equipped with an alarm system that shall sound automatically when an increase in relative PM emissions over a preset level is detected. The alarm shall be located where it is easily heard by plant operating personnel.

7. For positive pressure fabric filter systems, a bag leak detection system shall be installed in each baghouse compartment or cell. For negative pressure or induced air fabric filters, the bag leak detector shall be installed downstream of the fabric filter.

8. Where multiple detectors are required, the system's instrumentation and alarm may be shared among detectors.

9. The baseline output shall be established by adjusting the range and the averaging period of the device and establishing the alarm set points and the alarm delay time.

10. Following initial adjustment of the system, the owner or operator may not adjust the sensitivity or range, averaging period, alarm set points, or alarm delay time except as detailed in the OM&M plan. In no case may the sensitivity be increased by more than 100% or decreased more than 50% over a 365-day period unless the adjustment follows a complete fabric filter inspection which demonstrates that the fabric filter is in good operating condition.

(b) The requirements of this paragraph apply to the owner or operator of a new or existing affected source or an existing emission unit using a continuous opacity monitoring system.

1. The owner or operator shall install, calibrate, maintain and operate a continuous opacity monitoring system to measure and record the opacity of emissions exiting each exhaust stack.

2. Each continuous opacity monitoring system shall meet the design and installation requirements of Performance Specification 1 in Appendix B to 40 CFR part 60, incorporated by reference in s. NR 484.04(21).

(c) The requirements of this paragraph apply to the owner or operator of a new or existing aluminum scrap shredder who conducts visible emission observations. The owner or operator shall do both of the following:

1. Perform a visible emissions test for each aluminum scrap shredder using a certified observer at least once a day according to the requirements of Method 9 in Appendix A to 40 CFR part 60, incorporated by reference in s. NR 484.04(13). Each Method 9 test shall consist of 5 6-minute observations in a 30-minute period.

2. Record the results of each test required under subd. 1.

(7) AFTERBURNER. The requirements of this subsection apply to the owner or operator of an affected source using an afterburner to comply with the requirements of this subchapter.

(a) The owner or operator shall install, calibrate, maintain, and operate a device to continuously monitor and record the operating temperature of the afterburner consistent with the requirements for continuous monitoring systems in s. NR 460.07(3).

(b) The temperature monitoring device shall meet each of the following performance and equipment specifications:

1. The temperature monitoring device shall be installed at the exit of the combustion zone of each afterburner.

2. The monitoring system shall record the temperature in 15-minute block averages and determine and record the average temperature for each 3-hour block period.

3. The recorder response range shall include zero and 1.5 times the average temperature established according to the requirements in s. NR 463.163(13).

4. The reference method shall be a National Institute of Standards and Technology calibrated reference thermocouple-potentiometer system or alternate reference, subject to approval by the department.

(c) The owner or operator shall conduct an inspection of each afterburner at least once a year and record the results. At a minimum, an inspection and resulting steps shall include all of the following:

1. Inspection of all burners, pilot assemblies, and pilot sensing devices for proper operation and clean pilot sensor.

2. Inspection for proper adjustment of combustion air.

3. Inspection of internal structures, such as baffles, to ensure structural integrity.

4. Inspection of dampers, fans, and blowers for proper operation.

5. Inspection for proper sealing.

6. Inspection of motors for proper operation.

7. Inspection of combustion chamber refractory lining and cleaning and replacement of lining as necessary.

8. Inspection of afterburner shell for corrosion and hot spots.

9. Documentation, for the burn cycle that follows the inspection, that the afterburner is operating properly and any necessary adjustments have been made.

10. Verification that the equipment is maintained in good operating condition.

11. Following an equipment inspection, completion of all necessary repairs in accordance with the requirements of the OM&M plan.

(8) FABRIC FILTER INLET TEMPERATURE. The requirements of this subsection apply to the owner or operator of a scrap dryer, delacquering kiln or decoating kiln or a group 1 furnace using a lime-injected fabric filter to comply with the requirements of this subchapter.

(a) The owner or operator shall install, calibrate, maintain and operate a device to continuously monitor and record the temperature of the fabric filter inlet gases consistent with the requirements for continuous monitoring systems in s. NR 460.07(3).

(b) The temperature monitoring device shall meet each of the following performance and equipment specifications:

1. The monitoring system shall record the temperature in 15-minute block averages and calculate and record the average temperature for each 3-hour block period.

2. The recorder response range shall include zero and 1.5 times the average temperature established according to the requirements in s. NR 463.163(14).

3. The reference method shall be a National Institute of Standards and Technology calibrated reference thermocouple-potentiometer system or alternate reference, subject to approval by the department.

(9) LIME INJECTION. The requirements of this subsection apply to the owner or operator of an affected source or emission unit using a lime-injected fabric filter to comply with the requirements of this subchapter.

(a) The owner or operator of a continuous lime injection system shall verify that lime is always free-flowing by one of the following methods:

1. Inspecting each feed hopper or silo at least once each 8-hour period and recording the results of each inspection. If lime is found not to be free-flowing during any of the 8-hour periods, the owner or operator shall increase the frequency of inspections to at least once every 4-hour period for the next 3 days. The owner or operator may return to inspections at least once every 8-hour period if corrective action results in no further blockages of lime during the 3-day period.

2. Subject to the approval of the department, installing, operating and maintaining a load cell, carrier gas or lime flow indicator, carrier gas pressure drop measurement system or other system to confirm that lime is free-flowing. If lime is found not to be free-flowing, the owner or operator shall promptly initiate and complete corrective action.

3. Subject to the approval of the department, installing, operating and maintaining a device to monitor the concentration of HCl at the outlet of the fabric filter. If an increase in the concentration of HCl indicates that the lime is not free-flowing, the owner or operator shall promptly initiate and complete corrective action.

(b) The owner or operator of a continuous lime injection system shall record the lime feeder setting once each day of operation.

(c) An owner or operator who intermittently adds lime to a lime coated fabric filter shall obtain approval from the department for a lime addition monitoring procedure. The department may not approve a monitoring procedure unless data and information are submitted establishing that the procedure is adequate to ensure that relevant emission standards will be met on a continuous basis.

(10) TOTAL REACTIVE FLUX INJECTION RATE. The requirements of this subsection apply to the owner or operator of a group 1 furnace or in-line fluxer. The owner or operator shall meet pars. (a) to (d) or apply for approval of an alternate method under par. (e):

(a) Install, calibrate, operate and maintain a device to continuously measure and record the weight of gaseous or liquid reactive flux injected to each affected source or emission unit.

1. The monitoring system shall record the weight for each 15-minute block period, during which reactive fluxing occurs, over the same operating cycle or time period used in the performance test.

2. The weight measurement device shall be accurate to ± 1% of the weight of the reactive component of the flux being measured. The owner or operator may apply to the department for permission to use a weight measurement device of alternative accuracy in cases where the reactive flux flow rates are so low as to make the use of a weight measurement device of ±1% impracticable. A device of alternative accuracy may not be approved unless the owner or operator provides assurance through data and information that the affected source will meet the relevant emission standards.

3. The owner or operator shall verify the calibration of the weight measurement device in accordance with the schedule specified by the manufacturer, or if no calibration schedule is specified, at least once every 6 months.

(b) Calculate and record the gaseous or liquid reactive flux injection rate (kg/Mg or lb/ton) for each operating cycle or time period used in the performance test using the procedure in s. NR 463.163(15).

(c) Record, for each 15-minute block period during each operating cycle or time period used in the performance test during which reactive fluxing occurs, the time, weight and type of flux for each addition of the following:

1. Gaseous or liquid reactive flux other than chlorine.

2. Solid reactive flux.

(d) Calculate and record the total reactive flux injection rate for each operating cycle or time period used in the performance test using the procedure in s. NR 463.163(15).

(e) At their discretion, apply to the department for approval of an alternative method for monitoring and recording the total reactive flux addition rate based on monitoring the weight or quantity of reactive flux per ton of feed or charge for each operating cycle or time period used in the performance test. An alternative monitoring method may not be approved unless the owner or operator provides assurance through data and information that the affected source will meet the relevant emission standards on a continuous basis.

(11) THERMAL CHIP DRYER. The requirements of this subsection apply to the owner or operator of a thermal chip dryer with emissions controlled by an afterburner. The owner or operator shall do both of the following:

(a) Record the type of materials charged to the unit for each operating cycle or time period used in the performance test.

(b) Submit a certification of compliance with the applicable operational standard for charge materials in s. NR 463.14(6) (c) for each 6-month reporting period. Each certification shall contain the information in s. NR 463.18(2) (b) 1.

(12) DROSS-ONLY FURNACE. The requirements of this subsection apply to the owner or operator of a dross-only furnace. The owner or operator shall do both of the following:

(a) Record the materials charged to each unit for each operating cycle or time period used in the performance test.

(b) Submit a certification of compliance with the applicable operational standard for charge materials in s. NR 463.14(9) (c) for each 6-month reporting period. Each certification shall contain the information in s. NR 463.18(2) (b) 2.

(13) IN-LINE FLUXERS USING NO REACTIVE FLUX. The owner or operator of an in-line fluxer that uses no reactive flux materials shall submit a certification of compliance with the operational standard for no reactive flux materials in s. NR 463.14(12) for each 6-month reporting period. Each certification shall contain the information in s. NR 463.18(2) (b) 6.

(14) SIDEWELL GROUP 1 FURNACE WITH ADD-ON AIR POLLUTION CONTROL DEVICES. The requirements of this subsection apply to the owner or operator of a sidewell group 1 furnace using add-on air pollution control devices. The owner or operator shall do both of the following:

(a) Record in an operating log for each charge of a sidewell furnace that the level of molten metal was above the top of the passage between the sidewell and hearth during reactive flux injection, unless the furnace hearth was also equipped with an add-on control device.

(b) Submit a certification of compliance with the operational standards in s. NR 463.14(13) (f) for each 6-month reporting period. Each certification shall contain the information in s. NR 463.18(2) (b) 3.

(15) GROUP 1 FURNACE WITHOUT ADD-ON AIR POLLUTION CONTROL DEVICES.

(a) The requirements of this paragraph apply to the owner or operator of a group 1 furnace that is not equipped with an add-on air pollution control device.

1. The owner or operator shall develop, in consultation with the department, a written site-specific monitoring plan. The site-specific monitoring plan shall be submitted to the department as part of the OM&M plan. The site-specific monitoring plan shall contain sufficient procedures to ensure continuing compliance with all applicable emission limits and shall demonstrate, based on documented test results, the relationship between emissions of PM, HCl and D&F and the proposed monitoring parameters for each pollutant. Test data shall establish the highest level of PM, HCl and D&F that will be emitted from the furnace. This emission level may be determined by conducting performance tests and monitoring operating parameters while charging the furnace with feed or charge materials containing the highest anticipated levels of oils and coatings and fluxing at the highest anticipated rate. If the department determines that any revisions of the site-specific monitoring plan are necessary to meet the requirements of this subchapter, the owner or operator shall promptly make all necessary revisions and resubmit the revised plan to the department.

2. The site-specific monitoring plan shall contain all of the following as applicable:

a. Each site-specific monitoring plan shall document each work practice, equipment and design practice, pollution prevention practice or other measure used to meet the applicable emission standards.

b. Each site-specific monitoring plan shall include provisions for unit labeling as required in sub. (3), feed or charge weight measurement, or production weight measurement, as required in sub. (5) and flux weight measurement as required in sub. (10).

c. Each site-specific monitoring plan for a melting and holding furnace subject to the clean charge emission standard in s. NR 463.13(9) (c) shall include requirements that the owner or operator record the type of feed or charge, such as ingot, thermally dried chips, dried scrap, or other, for each operating cycle or time period used in the performance test, and that the owner or operator submit a certification of compliance with the applicable operational standard for clean charge materials in s. NR 463.14(14) (c) for each 6-month reporting period. Each certification shall contain the information in s. NR 463.18(2) (b) 4.

d. If a continuous emission monitoring system is included in a site-specific monitoring plan, the plan shall include provisions for the installation, operation and maintenance of the system to provide quality-assured measurements in accordance with all applicable requirements of the general provisions of ch. NR 460.

e. If a continuous opacity monitoring system is included in a site-specific monitoring plan, the plan shall include provisions for the installation, operation and maintenance of the system to provide quality-assured measurements in accordance with all applicable requirements of this subchapter.

f. If a site-specific monitoring plan includes a scrap inspection program for monitoring the scrap contaminant level of furnace feed or charge materials, the plan shall include provisions for the demonstration and implementation of the program in accordance with all applicable requirements in sub. (16).

g. If a site-specific monitoring plan includes a calculation method for monitoring the scrap contaminant level of furnace feed or charge materials, the plan shall include provisions for the demonstration and implementation of the program in accordance with all applicable requirements in sub. (17).

3. The owner or operator of an existing affected source shall submit the site-specific monitoring plan to the department for review at least 6 months prior to the compliance date.

(b) The department shall review and approve or disapprove a proposed site-specific monitoring plan, or request changes to a plan, based on whether the plan contains sufficient provisions to ensure continuing compliance with applicable emission limits and demonstrates, based on documented test results, the relationship between emissions of PM, HCl and D&F and the proposed monitoring parameters for each pollutant. Test data shall establish the highest level of PM, HCl and D&F that will be emitted from the furnace. Subject to department approval of the OM&M plan, this may be determined by conducting performance tests and monitoring operating parameters while charging the furnace with feed or charge materials containing the highest anticipated levels of oils and coatings and fluxing at the highest anticipated rate.

(16) SCRAP INSPECTION PROGRAM FOR GROUP 1 FURNACE WITHOUT ADD-ON AIR POLLUTION CONTROL DEVICES. A scrap inspection program shall include all of the following:

(a) A proven method for collecting representative samples and measuring the oil and coatings content of scrap samples.

(b) A scrap inspector training program.

(c) An established correlation between visual inspection and physical measurement of oil and coatings content of scrap samples.

(d) Periodic physical measurements of oil and coatings content of randomly-selected scrap samples and comparison with visual inspection results.

(e) A system for assuring that only acceptable scrap is charged to an affected group 1 furnace.

(f) Recordkeeping requirements to document conformance with plan requirements.

(17) MONITORING OF SCRAP CONTAMINATION LEVEL BY CALCULATION METHOD FOR GROUP 1 FURNACE WITHOUT ADD-ON AIR POLLUTION CONTROL DEVICES. The owner or operator of a group 1 furnace dedicated to processing a distinct type of furnace feed or charge composed of scrap with a uniform composition, such as rejected product from a manufacturing process for which the coating-to-scrap ratio can be documented, may include a program in the site-specific monitoring plan for determining, monitoring and certifying the scrap contaminant level using a calculation method rather than a scrap inspection program. A scrap contaminant monitoring program using a calculation method shall include all of the following:

(a) Procedures for the characterization and documentation of the contaminant level of the scrap prior to the performance test.

(b) Limitations on the scrap in the furnace feed or charge to scrap of the same composition as that used in the performance test. If the performance test was conducted with a mixture of scrap and clean charge, limitations on the proportion of scrap in the furnace feed or charge to no greater than the proportion used during the performance test.

(c) Operating, monitoring, recordkeeping and reporting requirements to ensure that no scrap with a contaminant level higher than that used in the performance test is charged to the furnace.

(18) GROUP 2 FURNACE. The requirements of this subsection apply to the owner or operator of a new or existing group 2 furnace. The owner or operator shall do both of the following:

(a) Record a description of the materials charged to each furnace, including any nonreactive, non-HAP-containing, non-HAP-generating fluxing materials or agents.

(b) Submit a certification of compliance with the applicable operational standard for charge materials in s. NR 463.14(15) for each 6-month reporting period. Each certification shall contain the information in s. NR 463.18(2) (b) 5.

(19) SITE-SPECIFIC REQUIREMENTS FOR SECONDARY ALUMINUM PROCESSING UNITS.

(a) An owner or operator of a secondary aluminum processing unit at a facility shall include, within the OM&M plan prepared in accordance with sub. (2), all of the following information:

1. The identification of each emission unit in the secondary aluminum processing unit.

2. The specific control technology or pollution prevention measure to be used for each emission unit in the secondary aluminum processing unit and the date of its installation or application.

3. The emission limit calculated for each secondary aluminum processing unit and performance test results with supporting calculations demonstrating initial compliance with each applicable emission limit.

4. Information and data demonstrating compliance for each emission unit with all applicable design, equipment, work practice or operational standards of this subchapter.

5. The monitoring requirements applicable to each emission unit in a secondary aluminum processing unit and the monitoring procedures for daily calculation of the 3-day, 24-hour rolling average using the procedure in sub. (20).

(b) The SAPU compliance procedures within the OM&M plan may not contain any of the following provisions:

1. Any averaging among emissions of differing pollutants.

2. The inclusion of any affected sources other than emission units in a secondary aluminum processing unit.

3. The inclusion of any emission unit while it is shut down.

4. The inclusion of any periods of startup, shutdown or malfunction in emission calculations.

(c) To revise the SAPU compliance provisions within the OM&M plan prior to the end of the permit term, the owner or operator shall submit a request to the department containing the information required by par. (a) and obtain approval of the department prior to implementing any revisions.

(20) SECONDARY ALUMINUM PROCESSING UNIT. Except as provided in sub. (21), the owner or operator shall calculate and record the 3-day, 24-hour rolling average emissions of PM, HCl and D&F for each secondary aluminum processing unit on a daily basis. To calculate the 3-day, 24-hour rolling average, the owner or operator shall do all of the following:

(a) Calculate and record the total weight of material charged to each emission unit in the secondary aluminum processing unit for each 24-hour day of operation using the feed or charge weight information required in sub. (5). If the owner or operator chooses to comply on the basis of weight of aluminum produced by the emission unit, rather than weight of material charged to the emission unit, all performance test emissions results and all calculations shall be conducted on the aluminum production weight basis.

(b) Multiply the total feed or charge weight to the emission unit, or the weight of aluminum produced by the emission unit, for each emission unit for the 24-hour period by the emission rate, in lb/ton of feed or charge, for that emission unit, as determined during the performance test, to provide emissions for each emission unit for the 24-hour period, in pounds.

(c) Divide the total emissions for each SAPU for the 24-hour period by the total material charged to the SAPU, or the weight of aluminum produced by the SAPU over the 24-hour period, to provide the daily emission rate for the SAPU.

(d) Compute the 24-hour daily emission rate using Equation 4:

See Image

where:

E_day is the daily PM, HCl, or D&F emission rate for the secondary aluminum processing unit for the 24-hour period

T_i is the total amount of feed, or aluminum produced, for emission unit i for the 24-hour period (tons or Mg)

ER _i is the measured emission rate for emission unit i as determined in the performance test (lb/ton or mg/Mg of feed or charge)

n is the number of emission units in the secondary aluminum processing unit

(e) Calculate and record the 3-day, 24-hour rolling average for each pollutant each day by summing the daily emission rates for each pollutant over the 3 most recent consecutive days and dividing by 3.

(21) SECONDARY ALUMINUM PROCESSING UNIT COMPLIANCE BY INDIVIDUAL EMISSION UNIT DEMONSTRATION. As an alternative to the procedures of sub. (20), an owner or operator may demonstrate, through performance tests, that each individual emission unit within the secondary aluminum production unit is in compliance with the applicable emission limits for the emission unit.

(22) ALTERNATIVE MONITORING METHOD FOR LIME ADDITION. The owner or operator of a lime-coated fabric filter that employs intermittent or noncontinuous lime addition may apply to the department for approval of an alternative method for monitoring the lime addition schedule and rate based on monitoring the weight of lime added per ton of feed or charge for each operating cycle or time period used in the performance test. An alternative monitoring method may not be approved unless the owner or operator provides assurance through data and information that the affected source will meet the relevant emission standards on a continuous basis.

(23) ALTERNATIVE MONITORING METHODS. If an owner or operator wishes to use an alternative monitoring method to demonstrate compliance with any emission standard in this subchapter, other than those alternative monitoring methods which may be authorized pursuant to subs. (10) (e) and (22), the owner or operator may submit an application to the department. Any application shall be processed according to the criteria and procedures in pars. (a) to (f).

(a) The department may not approve averaging periods other than those specified in this section.

(b) The owner or operator shall continue to use the original monitoring requirement until necessary data are submitted and approval is received to use another monitoring procedure.

(c) The owner or operator shall submit the application for approval of alternate monitoring methods no later than the notification of the performance test. The application shall contain all the information specified in subds. 1. to 3.:

1. Data or information justifying the request, such as the technical or economic infeasibility, or the impracticality of using the required approach.

2. A description of the proposed alternative monitoring requirements, including the operating parameters to be monitored, the monitoring approach and technique, and how the limit is to be calculated.

3. Data and information documenting that the alternative monitoring requirements would provide equivalent or better assurance of compliance with the relevant emission standards.

(d) The department may not approve an alternate monitoring application unless it would provide equivalent or better assurance of compliance with the relevant emission standards. Before disapproving any alternate monitoring application, the department shall provide both of the following:

1. Notice of the information and findings upon which the intended disapproval is based.

2. Notice of opportunity for the owner or operator to present additional supporting information before final action is taken on the application. This notice shall specify how much additional time is allowed for the owner or operator to provide additional supporting information.

(e) The owner or operator is responsible for submitting any supporting information in a timely manner to enable the department to consider the application prior to the performance test. Neither submittal of an application nor the department's failure to approve or disapprove the application relieves the owner or operator of the responsibility to comply with any provisions of this subchapter.

(f) The department may decide at any time, on a case-by-case basis, that additional or alternative operating limits, or alternative approaches to establishing operating limits, are necessary to demonstrate compliance with the emission standards of this subchapter.

Wis. Admin. Code Department of Natural Resources NR 463.15

CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09; corrections in (11) (b), (14) (b) and (18) (b) made under s. 13.92(4) (b) 7, Stats., Register December 2008 No. 636.