Emissions limitations, work practice standards and operation and maintenance requirements

Emissions limitations, work practice standards and operation and maintenance requirements. (1) What emission limits must I meet? (a) You shall meet each of the following emission limits or standards that applies to you: 1. For each electric arc metal melting furnace, electric induction metal melting furnace or scrap preheater at an existing iron and steel foundry, as described in s. NR 463.21 (3) (c) , you may not discharge emissions through a conveyance to the atmosphere that exceed either the limit for particulate matter (PM) in subd. 1. a. or the limit for total metal HAP in subd. 1. b. : a. 0.005 gr/dscf of PM. b. 0.0004 gr/dscf of total metal HAP. 2. For each cupola metal melting furnace at an existing iron and steel foundry, as described in s. NR 463.21 (3) (c) , you may not discharge emissions through a conveyance to the atmosphere that exceed either the limit for PM in subd. 2. a. or the limit for total metal HAP in subd. 2. b. : a. 0.006 gr/dscf of PM. b. 0.0005 gr/dscf of total metal HAP. 3. For each cupola metal melting furnace or electric arc metal melting furnace at a new iron and steel foundry, as described in s. NR 463.21 (3) (d) , you may not discharge emissions through a conveyance to the atmosphere that exceed either the limit for PM in subd. 3. a. or, alternatively, the limit for total metal HAP in subd. 3. b. : a. 0.002 gr/dscf of PM. b. 0.0002 gr/dscf of total metal HAP. 4. For each electric induction metal melting furnace or scrap preheater at a new iron and steel foundry, as described in s. NR 463.21 (3) (d) , you may not discharge emissions through a conveyance to the atmosphere that exceed either the limit for PM in subd. 4. a. or, alternatively, the limit for total metal HAP in subd. 4. b. : a. 0.001 gr/dscf of PM. b. 0.00008 gr/dscf of total metal HAP. 5. For each pouring station at an existing iron and steel foundry, as described in s. NR 463.21 (3) (c) , you may not discharge emissions through a conveyance to the atmosphere that exceed either the limit for PM in subd. 5. a. or, alternatively, the limit for total metal HAP in subd. 5. b. : a. 0.010 gr/dscf of PM. b. 0.0008 gr/dscf of total metal HAP. 6. For each pouring area or pouring station at a new iron and steel foundry, as described in s. NR 463.21 (3) (d) , you may not discharge emissions through a conveyance to the atmosphere that exceed either the limit for PM in subd. 6. a. or, alternatively, the limit for total metal HAP in subd. 6. b. : a. 0.002 gr/dscf of PM. b. 0.0002 gr/dscf of total metal HAP. 7. For each building or structure housing any emissions source at the iron and steel foundry, you may not discharge any fugitive emissions to the atmosphere that exhibit opacity greater than 20% averaged over 6 minutes except for one 6-minute average per hour that does not exceed 27% opacity. 8. For each cupola metal melting furnace at a new or existing iron and steel foundry, you may not discharge emissions of volatile organic hazardous air pollutants (VOHAP) through a conveyance to the atmosphere that exceed 20 parts per million by volume (ppmv) corrected to 10% oxygen. 9. As an alternative to the work practice standard in sub. (2) (e) for a scrap preheater at an existing iron and steel foundry or in sub. (2) (f) for a scrap preheater at a new iron and steel foundry, as described in s. NR 463.21 (3) (d) , you may not discharge emissions of VOHAP through a conveyance to the atmosphere that exceed 20 ppmv. 10. For one or more automated conveyor and pallet cooling lines that use a sand mold system, or one or more automated shakeout lines that use a sand mold system, at a new iron and steel foundry, as described in s. NR 463.21 (3) (d) , you may not discharge emissions of VOHAP through a conveyance to the atmosphere that exceed a flow-weighted average of 20 ppmv. 11. For each triethylamine (TEA) cold box mold or core making line at a new or existing iron and steel foundry, you shall meet either the emission limit in subd. 11. a. or the emission standard in subd. 11. b. : a. You may not discharge emissions of TEA through a conveyance to the atmosphere that exceed 1 ppmv, as determined when scrubbing with fresh acid solution. b. You shall reduce emissions of TEA from each TEA cold box mold or core making line by at least 99%, as determined when scrubbing with fresh acid solution. (b) You shall meet each of the following operating limits that applies to you: 1. You shall install, operate and maintain a capture and collection system for all emission sources subject to an emission limit or standard for VOHAP or TEA in par. (a) 8. to 11. in accordance with both of the following: a. Each capture and collection system shall meet accepted engineering standards, such as those published by the American Conference of Governmental Industrial Hygienists. b. You shall operate each capture system at or above the lowest value or settings established as operating limits in your operation and maintenance plan. 2. You shall operate each wet scrubber applied to emissions from a metal melting furnace, scrap preheater, pouring area or pouring station subject to an emission limit for PM or total metal HAP in par. (a) 1. to 6. to insure that the 3-hour average pressure drop and scrubber water flow rate does not fall below the minimum levels established during the initial or subsequent performance test. 3. You shall operate each combustion device applied to emissions from a cupola metal melting furnace subject to the emission limit for VOHAP in par. (a) 8. to insure that the 15-minute average combustion zone temperature does not fall below 1,300ºF. Periods when the cupola is off blast and for 15 minutes after going on blast from an off blast condition are not included in the 15-minute average. 4. You shall operate each combustion device applied to emissions from a scrap preheater subject to the emission limit for VOHAP in par. (a) 9. or from a TEA cold box mold or core making line subject to the emission limit for TEA in par. (a) 11. to insure that the 3-hour average combustion zone temperature does not fall below the minimum level established during the initial or subsequent performance test. 5. You shall operate each wet acid scrubber applied to emissions from a TEA cold box mold or core making line subject to the emission limit for TEA in par. (a) 11. to insure both of the following: a. The 3-hour average scrubbing liquid flow rate does not fall below the minimum level established during the initial or subsequent performance test. b. The 3-hour average pH of the scrubber blowdown, as measured by a continuous parameter monitoring system (CPMS), does not exceed 4.5 or the pH of the scrubber blowdown, as measured once every 8 hours during process operations, does not exceed 4.5. (c) If you use a control device other than a baghouse, wet scrubber, wet acid scrubber or combustion device, you shall prepare and submit a monitoring plan. The monitoring plan is subject to approval by the department and shall contain all of the following: 1. A description of the device. 2. Test results collected in accordance with s. NR 463.25 (3) verifying the performance of the device for reducing emissions of PM, total metal HAP, VOHAP or TEA to the levels required by this subchapter. 3. A copy of the operation and maintenance plan required by sub. (3) (b) . 4. A list of appropriate operating parameters that will be monitored to maintain continuous compliance with the applicable emissions limitations. 5. Operating parameter limits based on monitoring data collected during the performance test. (2) What work practice standards must I meet? (a) For each segregated scrap storage area, bin or pile, you shall either comply with the certification requirements in par. (b) or prepare and implement a plan for the selection and inspection of scrap according to the requirements in par. (c) . You may have certain scrap subject to par. (b) and other scrap subject to par. (c) at your facility, provided the scrap remains segregated until being aggregated to make up the charge for the furnace. (b) If you elect to meet this paragraph as allowed under par. (a) , you shall prepare, and operate at all times according to, a written certification that the foundry purchases and uses only metal ingots, pig iron, slitter or other materials that do not include post-consumer automotive body scrap, post-consumer engine blocks, post-consumer oil filters, oily turnings, lead components, mercury switches, plastics or free organic liquids, as defined in s. NR 463.22 (16) . Any post-consumer engine blocks, post-consumer oil filters or oily turnings that are processed and cleaned, to the extent practicable, such that the materials do not include lead components, mercury switches, plastics or free organic liquids may be included in this certification. (c) If you elect to meet this paragraph as allowed under par. (a) , you shall prepare and operate at all times according to a written plan for the selection and inspection of iron and steel scrap to minimize, to the extent practicable, the amount of organics and HAP metals in the charge materials used by the iron and steel foundry. This scrap selection and inspection plan is subject to approval by the department. You shall keep a copy of the plan onsite and readily available to all plant personnel with materials acquisition or inspection duties. You shall provide a copy of the material specifications to each of your scrap vendors. Each plan shall include all of the following information: 1. A materials acquisition program to limit organic contaminants according to the following requirements as applicable: a. For scrap charged to a scrap preheater, electric arc metal melting furnace or electric induction metal melting furnaces, specifications for scrap materials to be depleted, to the extent practicable, of the presence of used oil filters, plastic parts and organic liquids, and a program to ensure the scrap materials are drained of free liquids. b. For scrap charged to a cupola metal melting furnace, specifications for scrap materials to be depleted, to the extent practicable, of the presence of plastic, and a program to ensure the scrap materials are drained of free liquids. 2. A materials acquisition program specifying that the scrap supplier remove accessible mercury switches from the trunks and hoods of any automotive bodies contained in the scrap and remove accessible lead components such as batteries and wheel weights. You shall obtain and maintain onsite a copy of the procedures used by the scrap supplier for either removing accessible mercury switches or for purchasing automobile bodies that have had mercury switches removed, as applicable. 3. Procedures for visual inspection of a representative portion, but not less than 10%, of all incoming scrap shipments to ensure the materials meet the specifications. The inspection procedures shall do all of the following: a. Identify the locations where inspections are to be performed for each type of shipment. Inspections may be performed at the scrap supplier’s facility. The selected locations shall provide a reasonable vantage point, considering worker safety, for visual inspection. b. Include recordkeeping requirements for the documentation of each visual inspection including the results. c. Include provisions for rejecting or returning entire or partial scrap shipments that do not meet specifications and limiting purchases from vendors whose shipments fail to meet specifications for more than 3 inspections in one calendar year. d. If the inspections are performed at the scrap supplier’s facility, include an explanation of how the periodic inspections ensure that not less than 10% of scrap purchased from each supplier is subject to inspection. (d) For each furan warm box mold or core making line in a new or existing iron and steel foundry, you shall use a binder chemical formulation that does not contain methanol as a specific ingredient of the catalyst formulation as determined by the material safety data sheet. This requirement does not apply to the resin portion of the binder system.