Presentation is loading. Please wait.

Presentation is loading. Please wait.

Secondary Aluminum Production Industry Maximum Achievable Control Technology (MACT) Training 40 CFR Part 63 Subpart RRR.

Similar presentations


Presentation on theme: "Secondary Aluminum Production Industry Maximum Achievable Control Technology (MACT) Training 40 CFR Part 63 Subpart RRR."— Presentation transcript:

1 Secondary Aluminum Production Industry Maximum Achievable Control Technology (MACT) Training 40 CFR Part 63 Subpart RRR

2 Secondary aluminum plants recover aluminum from scrap such as beverage cans, foundry returns, other aluminum scrap, and dross. Air toxics are released from preprocessing operations

3 such as aluminum scrap shredding, thermal chip drying, scrap drying/decoating/ delacquering; and furnace operations (i.e., melting, holding, refining, fluxing, or alloying).

4

5 Secondary Aluminum Production Facility Any establishment using clean charge, post-consumer aluminum scrap, aluminum ingots, aluminum foundry returns, dross from

6 aluminum production, or molten aluminum as the raw material and performing one or more of the following processes:

7 Scrap shredding Scrap shredding Scrap drying/delacquering/decoating Scrap drying/delacquering/decoating Thermal chip drying Thermal chip drying Furnace operations Furnace operations In-line fluxing In-line fluxing Dross cooling Dross cooling

8 Example Secondary Aluminum Facility

9

10 Secondary Aluminum Sectors Secondary aluminum companies Secondary aluminum companies Sweat furnace operators Sweat furnace operators May include die casters & foundries May include die casters & foundries

11 Estimated Number of Secondary Aluminum Sources Potentially Affected Approximately 400 (86 major) Approximately 400 (86 major) 320 die casting companies 320 die casting companies 1500 foundries 1500 foundries 1650 sweat furnaces 1650 sweat furnaces

12

13 Types of Hazardous Air Pollutants (HAPs) Emitted Organic HAPs (e.g. benzene, Organic HAPs (e.g. benzene, styrene, dioxins, and furans) styrene, dioxins, and furans)

14 Inorganic gaseous HAPs (e.g. hydrogen chloride, hydrogen flouride, and chlorine)Inorganic gaseous HAPs (e.g. hydrogen chloride, hydrogen flouride, and chlorine) Particulate HAP metals (e.g. arsenic, lead, and chromium)Particulate HAP metals (e.g. arsenic, lead, and chromium)

15

16 History of Secondary Aluminum Production National Emission Standards for Hazardous Air Pollutants (NESHAP) NESHAP was proposed, 2/11/99NESHAP was proposed, 2/11/99

17 History Contd.: Final rule was promulgated, 3/23/00Final rule was promulgated, 3/23/00 Direct final rule; amendments, 6/14/02Direct final rule; amendments, 6/14/02 Final rule; amendments, 9/24/02Final rule; amendments, 9/24/02 Final rule amendments 12/30/03Final rule amendments 12/30/03

18

19 Regulated Entities under Current Rule Facilities that perform secondary smelting and alloying of aluminumFacilities that perform secondary smelting and alloying of aluminum

20 Secondary aluminum production facility affected sources collocated at:Secondary aluminum production facility affected sources collocated at: Aluminum sheet, plate, and foil manufacturing facilitiesAluminum sheet, plate, and foil manufacturing facilities Aluminum extruded product manufacturing facilitiesAluminum extruded product manufacturing facilities

21 Other aluminum rolling and drawing facilitiesOther aluminum rolling and drawing facilities Primary aluminum production facilitiesPrimary aluminum production facilities Aluminum die casting facilitiesAluminum die casting facilities Aluminum foundry facilitiesAluminum foundry facilities

22

23 Regulated HAPs Particulate matter emissions (PM) (surrogate for HAP metals)Particulate matter emissions (PM) (surrogate for HAP metals) Total hydrocarbon (THC) emissions - surrogate for HAP organics)Total hydrocarbon (THC) emissions - surrogate for HAP organics)

24 Hydrogen chloride (HCl) emissions - a HAP and a surrogate for inorganic HAPs including hydrogen fluoride (HF) and chlorine (Cl 2 )Hydrogen chloride (HCl) emissions - a HAP and a surrogate for inorganic HAPs including hydrogen fluoride (HF) and chlorine (Cl 2 )

25 Dioxin and furan emissions at secondary aluminum production facilities that are major or area sourcesDioxin and furan emissions at secondary aluminum production facilities that are major or area sources

26

27 Projected Environmental Benefits Reduce HAP emissions by about 12,420 tons/year, a 70% reduction from current levelsReduce HAP emissions by about 12,420 tons/year, a 70% reduction from current levels Reduce HCl emissions by 12,370 tons/year, a 73% reductionReduce HCl emissions by 12,370 tons/year, a 73% reduction

28 Projected Environmental Benefits (Continued) Reduce metal emissions by 40 tons/year, a 60% reductionReduce metal emissions by 40 tons/year, a 60% reduction Reduce dioxin/furan emissions by 0.88 pounds/year, a 79% reductionReduce dioxin/furan emissions by 0.88 pounds/year, a 79% reduction

29 Projected Environmental Benefits (Continued) Reduce polycyclic organic matter emissions by 10 tons/year, a 25% reductionReduce polycyclic organic matter emissions by 10 tons/year, a 25% reduction Reduce PM emissions by 3,185 tons/year, a 30% reductionReduce PM emissions by 3,185 tons/year, a 30% reduction

30

31 Rule Requirements Emission standards and operating requirementsEmission standards and operating requirements Monitoring and compliance provisionsMonitoring and compliance provisions Notifications, reports, and recordsNotifications, reports, and records

32

33 Applicability and Description of Affected Units § Applicability and Description of Affected Units §

34 Applicability and Description of Affected Units Secondary aluminum production Secondary aluminum production operations operations Affected sources Affected sources Secondary Aluminum Website:

35

36 Secondary Aluminum NESHAPS Applicability Flowcharts

37

38

39

40

41

42 Secondary Aluminum Production Operations Preprocessing of scrap aluminum (size reduction, removal of oils, coatings, and other contaminants) Preprocessing of scrap aluminum (size reduction, removal of oils, coatings, and other contaminants)

43 Furnace operations (melting, in- furnace fluxing/refining, tapping)Furnace operations (melting, in- furnace fluxing/refining, tapping) Additional refining (in-line fluxing)Additional refining (in-line fluxing) Cooling of drossCooling of dross

44

45 Processing of Scrap Aluminum Crushing, shredding, and grinding Crushing, shredding, and grinding Drying Drying Heating in a dryer or kiln Heating in a dryer or kiln Heating in a sweat furnace Heating in a sweat furnace

46 Crushing, Shredding, and Grinding To reduce the size of scrap aluminum To reduce the size of scrap aluminum Emissions: Particulate matter (PM) Emissions: Particulate matter (PM) and HAP metals generated as dust and HAP metals generated as dust from coatings & other contaminants from coatings & other contaminants

47 Chip Dryers To reduce the size of scrap aluminum To reduce the size of scrap aluminum Emissions: Particulate matter (PM) Emissions: Particulate matter (PM) & HAP metals generated as dust from & HAP metals generated as dust from coatings and other contaminants coatings and other contaminants

48 Applicability and Description of Affected Units Secondary aluminum production operations Secondary aluminum production operations Affected sourcesAffected sources

49

50 Secondary Aluminum Production Operations Preprocessing of scrap aluminum (size reduction, removal of oils, coatings, and other contaminants)Preprocessing of scrap aluminum (size reduction, removal of oils, coatings, and other contaminants)

51 Furnace operations (melting, in- furnace fluxing/refining, tapping)Furnace operations (melting, in- furnace fluxing/refining, tapping) Additional refining (in-line fluxing) Additional refining (in-line fluxing) Cooling of dross Cooling of dross

52 Preprocessing of Scrap Aluminum Crushing, shredding, and grindingCrushing, shredding, and grinding DryingDrying Heating in a dryer or kilnHeating in a dryer or kiln Heating in a sweat furnaceHeating in a sweat furnace

53 Crushing, Shredding, and Grinding To reduce the size of scrap aluminumTo reduce the size of scrap aluminum Emissions: Particulate matter (PM) and HAP metals generated as dust from coatings and other contaminantsEmissions: Particulate matter (PM) and HAP metals generated as dust from coatings and other contaminants

54 Chip Dryers Evaporates oil and moisture from uncoated aluminum chips & boringsEvaporates oil and moisture from uncoated aluminum chips & borings Generally operate at temperatures ranging between 300 o F to 750 o FGenerally operate at temperatures ranging between 300 o F to 750 o F Emissions: Organic HAPs including dioxins and furansEmissions: Organic HAPs including dioxins and furans

55 Scrap Dryers/Delacquering Kilns/Decoating Kilns Remove coatings and other contaminants that may be present in scrap prior to melting (e.g., oil, grease, lubricants, lacquers, rubber, and plastic laminates)Remove coatings and other contaminants that may be present in scrap prior to melting (e.g., oil, grease, lubricants, lacquers, rubber, and plastic laminates)

56 Heat scrap to exit temperature of 1000 ° FHeat scrap to exit temperature of 1000 ° F Emissions: Inorganic HAPs including particulate metal HAPs and hydrogen chloride and organic HAPs including dioxins and furans Emissions: Inorganic HAPs including particulate metal HAPs and hydrogen chloride and organic HAPs including dioxins and furans

57 Charging End of Delacquering Kilns

58 Discharge End of Delacquering Kilns

59 Sweat Furnaces Reclaim aluminum from scrap with high levels of ironReclaim aluminum from scrap with high levels of iron Operate in batch mode at a temperature high enough to melt the aluminum but not the ironOperate in batch mode at a temperature high enough to melt the aluminum but not the iron

60 Molten aluminum can be cast into sows, ingots, or T-bars used as feedstock for melting and refining furnacesMolten aluminum can be cast into sows, ingots, or T-bars used as feedstock for melting and refining furnaces Emissions: Dioxins and furansEmissions: Dioxins and furans

61 Sweat Furnace Charging

62 Sweat Furnace

63 Uncontrolled Sweat Furnace 1

64 Uncontrolled Sweat Furnace 2

65 Furnace Operations MeltingMelting Fluxing/refiningFluxing/refining TappingTapping

66 Melting Begins with charging of scrap into furnace Begins with charging of scrap into furnace Chemistry of molten bath adjusted by adding selected scrap or alloying agents (e.g., silicon)Chemistry of molten bath adjusted by adding selected scrap or alloying agents (e.g., silicon)

67 Charging Sidewell Furnace

68 Fluxing Done to refine molten aluminum to improve product quality, achieve product specifications, or reduce material lossDone to refine molten aluminum to improve product quality, achieve product specifications, or reduce material loss

69 Fluxes may be added to remove impurities and reduce aluminum oxidationFluxes may be added to remove impurities and reduce aluminum oxidation May be performed in the furnace or outside the furnace by an in- line fluxerMay be performed in the furnace or outside the furnace by an in- line fluxer

70 Fluxing Processes Addition of salts (cover flux)Addition of salts (cover flux) Addition of solventsAddition of solvents Injection of gasses (demagging and degassing)Injection of gasses (demagging and degassing)

71 Process Furnaces Refractory-lined metal vessels heated by oil, gas, or electricity that are used to melt scrapRefractory-lined metal vessels heated by oil, gas, or electricity that are used to melt scrap

72 Types include melting, holding, and refining furnacesTypes include melting, holding, and refining furnaces Charging of scrap can be done from the side, front, or top of the furnaceCharging of scrap can be done from the side, front, or top of the furnace

73 Examples of Process Furnaces Top charging and front charging furnacesTop charging and front charging furnaces

74 Sidewell melting furnace – a furnace with an open well adjacent to the hearth used for charging scrap & solid flux or salt to the furnace, injecting fluxing agents, & skimming drossSidewell melting furnace – a furnace with an open well adjacent to the hearth used for charging scrap & solid flux or salt to the furnace, injecting fluxing agents, & skimming dross

75 Transferring Molten Aluminum to Holding Furnace

76 Sidewell Furnace

77 Examples of Process Furnaces - Continued Induction furnaces – heating mechanism is electric energyInduction furnaces – heating mechanism is electric energy Reverberatory furnaces – typically gasReverberatory furnaces – typically gas

78 Process Furnace Emissions HAP emissions from scrap and fluxing agents include:HAP emissions from scrap and fluxing agents include: Particulate metal HAPs Particulate metal HAPs Hydrogen chloride Hydrogen chloride Dioxins and furans Dioxins and furans

79 Dross-only Furnaces Typically rotary barrel-designed furnaces dedicated to reclamation of aluminum from dross formed during melting, holding, alloying, or fluxing operations carried out in other process unitsTypically rotary barrel-designed furnaces dedicated to reclamation of aluminum from dross formed during melting, holding, alloying, or fluxing operations carried out in other process units

80 Dross-only Furnaces Contd. Dross and salt flux are sole feedstocksDross and salt flux are sole feedstocks Emissions: Particulate matter including metal HAPsEmissions: Particulate matter including metal HAPs

81 In-line Fluxing Fluxing performed in a device exterior to furnace, located in a transfer line from furnaceFluxing performed in a device exterior to furnace, located in a transfer line from furnace Involves injection of chlorine, argon, nitrogen, or other gases to achieve desired metal purityInvolves injection of chlorine, argon, nitrogen, or other gases to achieve desired metal purity

82 In-line Fluxing - Continued Found primarily at facilities that manufacture high quality aluminum or in facilities with no other means of degassingFound primarily at facilities that manufacture high quality aluminum or in facilities with no other means of degassing Emissions: Hydrogen chloride and particulate matterEmissions: Hydrogen chloride and particulate matter

83 Tapping Transferring molten metal from melting furnace to molds or to a ladleTransferring molten metal from melting furnace to molds or to a ladle

84 Cooling of Dross Dross - slags and skimmings from melting and refining consisting of fluxing agents, impurities, and/or oxidized and non-oxidized aluminumDross - slags and skimmings from melting and refining consisting of fluxing agents, impurities, and/or oxidized and non-oxidized aluminum

85 Cooling of Dross - Continued Accomplished in rotating, water- cooled drumsAccomplished in rotating, water- cooled drums Sole feedstock to dross-only furnacesSole feedstock to dross-only furnaces Emissions: Particulate matter including metal HAPsEmissions: Particulate matter including metal HAPs

86 Rotary Dross Cooler

87

88 Affected Sources at Major Sources of HAPs - § Each new and existing:Each new and existing: –Aluminum scrap shredder –Thermal chip dryer –Scrap dryer/delacquering kiln/decoating kiln

89 Each new and existing group 2 furnace:Each new and existing group 2 furnace: –Melts, holds, or processes only clean charge, and –Performs no fluxing, or –Performs fluxing using only non- reactive, non-HAP-containing/non- HAP-generating gases or agents

90 Each new and existing:Each new and existing: –Sweat furnace –Dross-only furnace –Rotary dross cooler

91 Each new and existing secondary aluminum processing unit (SAPU)Each new and existing secondary aluminum processing unit (SAPU) –Group 1 furnace: processes non- clean charge; or processes clean charge with reactive fluxing

92 –Combination of all group 1 furnaces and all in-line fluxers within a secondary aluminum production facility

93

94 Secondary Aluminum Processing Units (SAPU) Existing SAPU – all existing group 1 furnaces and all existing in-line fluxersExisting SAPU – all existing group 1 furnaces and all existing in-line fluxers

95 New SAPU – any combination of new group 1 furnaces and new in-line fluxers constructed after 2/11/99New SAPU – any combination of new group 1 furnaces and new in-line fluxers constructed after 2/11/99 Group 1 furnaces and in-line fluxers are emission units within an existing or new SAPUGroup 1 furnaces and in-line fluxers are emission units within an existing or new SAPU

96

97 Affected Sources at Area Sources of HAPs Emission limits for dioxins and furans and associated operating, monitoring, reporting, and recordkeeping requirements apply to affected sources located at area sourcesEmission limits for dioxins and furans and associated operating, monitoring, reporting, and recordkeeping requirements apply to affected sources located at area sources

98 Affected Sources at Area Sources of HAPs Contd. Each new and existing:Each new and existing: –Thermal chip dryer –Scrap dryer/delacquering kiln/decoating kiln

99 Affected Sources at Area Sources of HAPs Contd. –Sweat furnace –SAPUwith one or more group 1 furnace emission units processing other than clean charge

100

101 Affected Sources Does not include aluminum die casters, foundries, or extruders that:Does not include aluminum die casters, foundries, or extruders that: –Melt only clean charge and materials generated within the facility or returned clean materials originally from facility, and

102 Affected Sources Contd. –Do not operate a thermal chip dryer, sweat furnace, or scrap dryer/delacquering kiln/decoating kiln

103

104 Clean Charge Molten aluminumMolten aluminum T-bar, sow, ingot, billet, pigT-bar, sow, ingot, billet, pig Alloying elementsAlloying elements Uncoated/unpainted thermally dried chipsUncoated/unpainted thermally dried chips

105 Clean Charge - continued Scrap dried at 650 °FScrap dried at 650 °F Scrap delacquered/decoated at 900° FScrap delacquered/decoated at 900° F oil-, lubricant-free unpainted/uncoated gates and risersoil-, lubricant-free unpainted/uncoated gates and risers

106 Clean Charge - continued Oil- & lubricant-free unpainted/uncoated scrap, shapes, or products that have not been processed in such a way that causes contaminationOil- & lubricant-free unpainted/uncoated scrap, shapes, or products that have not been processed in such a way that causes contamination

107 Clean Charge - continued Runaround scrapRunaround scrap Customer returns (clean material which contain no paint or other solid coatings)Customer returns (clean material which contain no paint or other solid coatings)

108

109 Runaround Scrap Scrap generated on-site or returned that does not contain paint or solid coatingScrap generated on-site or returned that does not contain paint or solid coating Machining chips that have not been dried 650° F, or by equivalent non- thermal drying method, are not runaroundMachining chips that have not been dried 650° F, or by equivalent non- thermal drying method, are not runaround

110

111 Emission Standards and Operating Requirements § and § Emission Standards and Operating Requirements § and §

112 Emission Standards and Operating Requirements Emission Standards § Secondary Aluminum Website: requirement_tables.html

113 Pollutants Regulated PM – surrogate for particulate metal HAPsPM – surrogate for particulate metal HAPs THC – surrogate for gaseous organic HAPsTHC – surrogate for gaseous organic HAPs D/F – limits apply to a major or area sourceD/F – limits apply to a major or area source HCl – HAP & surrogate for chlorine & HFHCl – HAP & surrogate for chlorine & HF OpacityOpacity

114

115 Format of Emission Standard Emission limitsEmission limits Mass per unit (lb/ton) of feed/charge (or production)Mass per unit (lb/ton) of feed/charge (or production) Concentration (gr/dscf)Concentration (gr/dscf) Percentage reductionPercentage reduction

116 Format of Emission Standard - Continued Emission limitsEmission limits D/F in units of TEQD/F in units of TEQ International method of expressing toxicity equivalents for D/FInternational method of expressing toxicity equivalents for D/F

117 Format of Emission Standard - Continued Except for D/F, apply to major sources onlyExcept for D/F, apply to major sources only Apply to all new and existing affected sources and emission unitsApply to all new and existing affected sources and emission units

118

119 Opacity Limit Sources with a PM add-on air pollution control device -- monitored with a continuous opacity monitor (COM)Sources with a PM add-on air pollution control device -- monitored with a continuous opacity monitor (COM)

120 Opacity Limit Contd. Aluminum scrap shredders monitored with a COM, or monitored by visible emissions:Aluminum scrap shredders monitored with a COM, or monitored by visible emissions: Opacity limit = 10 percent Opacity limit = 10 percent

121

122 Aluminum Scrap Shredders grain (gr) of PM per dry standard cubic foot (dscf)0.010 grain (gr) of PM per dry standard cubic foot (dscf)

123

124 Thermal Chip Dryers 0.80 lb of total hydrocarbon emissions (THC) per ton of feed0.80 lb of total hydrocarbon emissions (THC) per ton of feed 2.50 micrograms of dioxins and furans (D/F) toxicity equivalents (TEQ) per megagram (Mg) of feed2.50 micrograms of dioxins and furans (D/F) toxicity equivalents (TEQ) per megagram (Mg) of feed

125 Thermal Chip Dryers Contd. D/F limit for units at major or area sourcesD/F limit for units at major or area sources

126

127 Scrap Dryers/Delacquering Kilns/Decoating Kilns 0.08 lb PM per ton of feed0.08 lb PM per ton of feed 0.80 lb HCl per ton of feed0.80 lb HCl per ton of feed 0.06 lb THC per ton of feed0.06 lb THC per ton of feed 0.25 micrograms of D/F TEQ per Mg of feed0.25 micrograms of D/F TEQ per Mg of feed

128 Scrap Dryers/Delacquering Kilns/Decoating Kilns – Alternate Limit Applies if afterburner has a design residence time 1 second, and operates at a temperature 1400 o FApplies if afterburner has a design residence time 1 second, and operates at a temperature 1400 o F 0.30 lb PM per ton of feed0.30 lb PM per ton of feed

129 Scrap Dryers/Delacquering Kilns/Decoating Kilns – Alternate Limit Contd lb HCl per ton of feed1.50 lb HCl per ton of feed 0.20 lb THC per ton of feed0.20 lb THC per ton of feed 5.0 micrograms D/F TEQ per Mg of feed5.0 micrograms D/F TEQ per Mg of feed

130

131 Sweat Furnaces 0.80 nanograms D/F TEQ per dry standard cubic meter (dscm) at 11 percent oxygen0.80 nanograms D/F TEQ per dry standard cubic meter (dscm) at 11 percent oxygen No test required if sweat furnace has afterburner with design residence timeNo test required if sweat furnace has afterburner with design residence time 2 seconds and operates at 1600 o F 2 seconds and operates at 1600 o F

132

133 Dross-only Furnaces 0.30 lb PM per ton of feed0.30 lb PM per ton of feed

134

135 In-line Fluxers Limits are used to calculate the standard applicable to secondary aluminum processing units (SAPU)Limits are used to calculate the standard applicable to secondary aluminum processing units (SAPU) 0.04 lb HCl per ton of feed0.04 lb HCl per ton of feed 0.01 lb PM per ton of feed0.01 lb PM per ton of feed

136 In-line Fluxers With No Reactive Fluxing No HCl and PM limits applyNo HCl and PM limits apply Work practice – no reactive fluxingWork practice – no reactive fluxing

137

138 Rotary Dross Coolers 0.04 gr of PM per dscf0.04 gr of PM per dscf

139

140 Clean Furnaces (Group 2) No emission limitsNo emission limits Work practices – clean charge only and no reactive fluxing – or elseWork practices – clean charge only and no reactive fluxing – or else

141

142 Group 1 Melting/Holding Furnaces (Clean Charge Only) Limits are used to calculate the standard applicable to secondary aluminum processing units (SAPU)Limits are used to calculate the standard applicable to secondary aluminum processing units (SAPU) 0.80 lb PM per ton of feed0.80 lb PM per ton of feed

143 Group 1 Melting/Holding Furnaces (Clean Charge Only) – Contd lb HCl per ton of feed, or 10 percent of the HCl upstream of an add-on control device0.40 lb HCl per ton of feed, or 10 percent of the HCl upstream of an add-on control device No D/F limit for clean charge furnaces – and only clean charge can be usedNo D/F limit for clean charge furnaces – and only clean charge can be used

144 Group 1 Furnaces Limits are used to calculate the standard applicable to secondary aluminum processing units (SAPU)Limits are used to calculate the standard applicable to secondary aluminum processing units (SAPU) 0.40 lb PM per ton of feed0.40 lb PM per ton of feed

145 Group 1 Furnaces Contd lb HCl per ton of feed, or 10 percent of the HCl upstream of an add-on control device0.40 lb HCl per ton of feed, or 10 percent of the HCl upstream of an add-on control device 15.0 micrograms of D/F TEQ per Mg of feed15.0 micrograms of D/F TEQ per Mg of feed

146

147 Group 1 Furnaces (Clean Charge Only) Limits are used to calculate the standard applicable to secondary aluminum processing units (SAPU)Limits are used to calculate the standard applicable to secondary aluminum processing units (SAPU) 0.40 lb PM per ton of feed0.40 lb PM per ton of feed

148 0.40 lb HCl per ton of feed, or 10 percent of the HCl upstream of an add-on control device0.40 lb HCl per ton of feed, or 10 percent of the HCl upstream of an add-on control device No limit on D/F – clean charge onlyNo limit on D/F – clean charge only

149

150 Sidewell Group 1 Furnace If reactive fluxing (except cover flux) is doneIf reactive fluxing (except cover flux) is done -In the hearth, or -In the sidewell when metal level falls below top of passage between sidewell and hearth, then

151 Sidewell Group 1 Furnace Contd. Then, limits for sidewell apply for combined hearth & sidewell emissionsThen, limits for sidewell apply for combined hearth & sidewell emissions

152

153 Secondary Aluminum Processing Units (SAPU) No 3-day, 24-hour rolling average emissions of PM, HCl, or D/F in excess of the production-weighted emission limit for all units in the SAPUNo 3-day, 24-hour rolling average emissions of PM, HCl, or D/F in excess of the production-weighted emission limit for all units in the SAPU

154 Secondary Aluminum Processing Units (SAPU) Contd. SAPU may comply by demonstrating compliance of each emission unit with its applicable emission limitSAPU may comply by demonstrating compliance of each emission unit with its applicable emission limit

155

156 Emission Standards and Operating Requirements - Continued Operating Requirements §

157 Capture/Collection Systems All sources and emission units with an add-on air pollution control device (APCD):All sources and emission units with an add-on air pollution control device (APCD):

158 Design and install a capture and collection system in accordance with American Conference of Governmental Industrial Hygienists (ACGIH) guidelinesDesign and install a capture and collection system in accordance with American Conference of Governmental Industrial Hygienists (ACGIH) guidelines

159 Industrial Ventilation: A Manual of Recommended PracticeIndustrial Ventilation: A Manual of Recommended Practice - Chapter 3: Local Exhaust Hoods - Chapter 5: Exhaust System Design Procedure Design Procedure

160 Vent captured emissions through a closed system (except dilution air fabric filter temperature control)Vent captured emissions through a closed system (except dilution air fabric filter temperature control) Operate in accordance with operation, maintenance, and monitoring (OM&M) planOperate in accordance with operation, maintenance, and monitoring (OM&M) plan

161

162 Feed/Charge Weight Measurement All sources and emission units subject to production-based (lb/ton of feed) emission limits:All sources and emission units subject to production-based (lb/ton of feed) emission limits: - Operate a device that records - Operate a device that records the weight each charge, or the weight each charge, or production weight production weight

163 Operate in accordance with OM&M planOperate in accordance with OM&M plan May use production basis instead of feed if:May use production basis instead of feed if: Production is measured for all Production is measured for all emission units within a SAPU emission units within a SAPU

164 All emission limit compliance calculations for SAPUs are based on productionAll emission limit compliance calculations for SAPUs are based on production

165

166 Labeling Post visible labels at each:Post visible labels at each: - group 1 furnace - group 2 furnace - in-line fluxer - scrap dryer/delacquering kiln/decoating kiln

167 Labels identify emission limits and means of compliance, including:Labels identify emission limits and means of compliance, including: -Type of source or emission unit - Applicable operational standards and control methods and control methods - Afterburner operating temperature and residence time and residence time

168

169 Affected Sources and Emission Units with Fabric Filters Scrap shreddersScrap shredders Scrap dryer/delacquering kiln/decoating kilnScrap dryer/delacquering kiln/decoating kiln Dross-only furnaceDross-only furnace Rotary dross coolerRotary dross cooler In-line fluxerIn-line fluxer

170 Group 1 furnaceGroup 1 furnace Must operate a bag leak detection system or continuous opacity monitorMust operate a bag leak detection system or continuous opacity monitor Except scrap shredders may alternatively choose to monitor VEExcept scrap shredders may alternatively choose to monitor VE

171

172 Fabric Filter with Bag Leak Detector Initiate corrective action within 1 hour of alarmInitiate corrective action within 1 hour of alarm Follow OM&M planFollow OM&M plan Operate so that alarm does not sound more than 5% of operating time in 6-month periodOperate so that alarm does not sound more than 5% of operating time in 6-month period

173

174 Fabric Filter with COM Initiate corrective action within 1 hour of a 6-minute average opacity 5%Initiate corrective action within 1 hour of a 6-minute average opacity 5% Complete corrective actions in accordance with OM&M planComplete corrective actions in accordance with OM&M plan

175 Aluminum Scrap Shredder with Fabric Filter – VE Alternative Initiate corrective action within 1 hr of any observed VEInitiate corrective action within 1 hr of any observed VE Complete corrective action in accordance with OM&M planComplete corrective action in accordance with OM&M plan

176 Thermal Chip Dryer with Afterburner Maintain average operating temperature for each 3-hr period average operating temperature during performance testMaintain average operating temperature for each 3-hr period average operating temperature during performance test

177 Operate afterburner in accordance with OM&M planOperate afterburner in accordance with OM&M plan Operate dryer using only unpainted aluminum chipsOperate dryer using only unpainted aluminum chips

178

179 Scrap Dryer/Delacquering Kiln/Decoating Kiln - Afterburner and Lime- injected Fabric Filter

180 Maintain afterburner average operating temperature for each 3- hr period than average operating temperature from performance testMaintain afterburner average operating temperature for each 3- hr period than average operating temperature from performance test

181 Operate afterburner in accordance with OM&M planOperate afterburner in accordance with OM&M plan Maintain average fabric filter inlet temperature for each 3-hr period average temperature during performance test (+ 25 o F)Maintain average fabric filter inlet temperature for each 3-hr period average temperature during performance test (+ 25 o F)

182 For continuous lime injection systems:For continuous lime injection systems: Maintain free-flowing lime in the hopper or silo at all timesMaintain free-flowing lime in the hopper or silo at all times Maintain lime feeder at setting established during performance testMaintain lime feeder at setting established during performance test

183

184 Sweat Furnace with Afterburner If performance tested, maintain each 3-hr. average temperature operating temperature of performance testIf performance tested, maintain each 3-hr. average temperature operating temperature of performance test

185 If not tested, afterburner design residence time must be 2 seconds and operate at 1600 o FIf not tested, afterburner design residence time must be 2 seconds and operate at 1600 o F Existing sweat furnaces must meet operating requirements by the compliance dateExisting sweat furnaces must meet operating requirements by the compliance date

186 New sweat furnaces must meet operating requirements by March 23, 2000 or upon startup, whichever is laterNew sweat furnaces must meet operating requirements by March 23, 2000 or upon startup, whichever is later Operate in accordance with OM&M planOperate in accordance with OM&M plan

187

188 Dross-only Furnace with Fabric Filter Must have bag leak detector or COMMust have bag leak detector or COM Operate using only dross as feed materialOperate using only dross as feed material

189

190 In-line Fluxer with Lime- injected Fabric Filter For continuous lime injection systems:For continuous lime injection systems: - Maintain free-flowing lime in the - Maintain free-flowing lime in the hopper or silo at all times for hopper or silo at all times for continuous injection systems continuous injection systems

191 - Maintain lime feeder at setting established during performance established during performance test test Maintain reactive flux injection rate performance test rate for each operating cycle or time period used in performance testMaintain reactive flux injection rate performance test rate for each operating cycle or time period used in performance test

192

193 In-line Fluxer Using No Reactive Flux Material Use no reactive fluxUse no reactive flux

194

195 Group 1 Furnace with Lime- injected Fabric Filter Maintain average fabric filter inlet temperature for each 3-hr period average temperature during performance test (+ 25 o F)Maintain average fabric filter inlet temperature for each 3-hr period average temperature during performance test (+ 25 o F)

196 Maintain reactive flux injection rate at or below performance test rate for each furnace cycleMaintain reactive flux injection rate at or below performance test rate for each furnace cycle

197 For continuous injection systems:For continuous injection systems: Maintain free-flowing lime in the Maintain free-flowing lime in the hopper or silo at all times hopper or silo at all times Maintain lime feeder at setting established during performance testMaintain lime feeder at setting established during performance test

198 For sidewell furnaces:For sidewell furnaces: - Operate so level of molten aluminum - Operate so level of molten aluminum is above the top of passage between is above the top of passage between sidewell and hearth during reactive sidewell and hearth during reactive flux injection, unless hearth is also flux injection, unless hearth is also controlled controlled

199 For sidewell furnaces Contd.:For sidewell furnaces Contd.: Add reactive flux only to sidewell of the furnace unless the hearth is also controlledAdd reactive flux only to sidewell of the furnace unless the hearth is also controlled

200

201 Group 1 Furnace Without Add-on Controls Maintain reactive flux injection rate performance test rate for each operating cycle or time period used in performance testMaintain reactive flux injection rate performance test rate for each operating cycle or time period used in performance test

202 Operate furnace within range of charge materials, contaminant levels, and parameter values established in site-specific monitoring planOperate furnace within range of charge materials, contaminant levels, and parameter values established in site-specific monitoring plan Use only clean charge (melting/holding furnace)Use only clean charge (melting/holding furnace)

203

204 Site-specific Monitoring Plan For group 1 furnaces without control devices - OM&M plan must include a section that documents work practices and pollution prevention measures, including procedures for scrap inspectionFor group 1 furnaces without control devices - OM&M plan must include a section that documents work practices and pollution prevention measures, including procedures for scrap inspection

205 Site-specific monitoring plan and testing to demonstrate adequacy of the monitoring plan must be developed in coordination with, and approved by, the permitting authoritySite-specific monitoring plan and testing to demonstrate adequacy of the monitoring plan must be developed in coordination with, and approved by, the permitting authority

206

207 Clean (Group 2) Furnace Use only clean chargeUse only clean charge Use no reactive fluxUse no reactive flux


Download ppt "Secondary Aluminum Production Industry Maximum Achievable Control Technology (MACT) Training 40 CFR Part 63 Subpart RRR."

Similar presentations


Ads by Google