Terms used in this subpart are defined in the Clean Air Act, in Sec. 63.2, and in this section.
Annual metal melt capacity means the lower of the total metal melting furnace equipment melt rate capacity assuming 8,760 operating hours per year summed for all metal melting furnaces at the foundry or, if applicable, the maximum permitted metal melt production rate for the iron and steel foundry calculated on an annual basis. Unless otherwise specified in the permit, permitted metal melt production rates that are not specified on an annual basis must be annualized assuming 24 hours per day, 365 days per year of operation. If the permit limits the operating hours of the furnace(s) or foundry, then the permitted operating hours are used to annualize the maximum permitted metal melt production rate.
Annual metal melt production means the quantity of metal melted in a metal melting furnace or group of all metal melting furnaces at the iron and steel foundry in a given calendar year. For the purposes of this subpart, metal melt production is determined on the basis on the quantity of metal charged to each metal melting furnace; the sum of the metal melt production for each furnace in a given calendar year is the annual metal melt production of the foundry.
Bag leak detection system means a system that is capable of continuously monitoring relative particulate matter (dust) loadings in the exhaust of a baghouse to detect bag leaks and other upset conditions. A bag leak detection system includes, but is not limited to, an instrument that operates on triboelectric, electrodynamic, light scattering, light transmittance, or other effect to continuously monitor relative particulate matter loadings.
Binder chemical means a component of a system of chemicals used to bind sand together into molds, mold sections, and cores through chemical reaction as opposed to pressure.
Capture system means the collection of components used to capture gases and fumes released from one or more emissions points and then convey the captured gas stream to a control device or to the atmosphere. A capture system may include, but is not limited to, the following components as applicable to a given capture system design: Duct intake devices, hoods, enclosures, ductwork, dampers, manifolds, plenums, and fans.
Chlorinated plastics means solid polymeric materials that contain chlorine in the polymer chain, such as polyvinyl chloride (PVC) and PVC copolymers.
Control device means the air pollution control equipment used to remove particulate matter from the effluent gas stream generated by a metal melting furnace.
Cupola means a vertical cylindrical shaft furnace that uses coke and forms of iron and steel such as scrap and foundry returns as the primary charge components and melts the iron and steel through combustion of the coke by a forced upward flow of heated air.
Deviation means any instance in which an affected source or an owner or operator of such an affected source:
(1) Fails to meet any requirement or obligation established by this subpart including, but not limited to, any emissions limitation (including operating limits), management practice, or operation and maintenance requirement;
(2) Fails to meet any term or condition that is adopted to implement an applicable requirement in this subpart and that is included in the operating permit for any iron and steel foundry required to obtain such a permit; or
(3) Fails to meet any emissions limitation (including operating limits) or management standard in this subpart during startup, shutdown, or malfunction, regardless of whether or not such failure is permitted by this subpart.
Electric arc furnace means a vessel in which forms of iron and steel such as scrap and foundry returns are melted through resistance heating by an electric current flowing through the arcs formed between the electrodes and the surface of the metal and also flowing through the metal between the arc paths.
Electric induction furnace means a vessel in which forms of iron and steel such as scrap and foundry returns are melted though resistance heating by an electric current that is induced in the metal by passing an alternating current through a coil surrounding the metal charge or surrounding a pool of molten metal at the bottom of the vessel.
Exhaust stream means gases emitted from a process through a conveyance as defined in this subpart.
Foundry operations mean all process equipment and practices used to produce metal castings for shipment. Foundry operations include: Mold or core making and coating; scrap handling and preheating; metal melting and inoculation; pouring, cooling, and shakeout; shotblasting, grinding, and other metal finishing operations; and sand handling.
Free liquids means material that fails the paint filter liquids test by EPA Method 9095B, Revision 2, November 1994 (incorporated by reference--see Sec. 63.14). That is, if any portion of the material passes through and drops from the filter within the 5-minute test period, the material contains free liquids.
Fugitive emissions means any pollutant released to the atmosphere that is not discharged through a system of equipment that is specifically designed to capture pollutants at the source, convey them through ductwork, and exhaust them using forced ventilation. Fugitive emissions include pollutants released to the atmosphere through windows, doors, vents, or other building openings. Fugitive emissions also include pollutants released to the atmosphere through other general building ventilation or exhaust systems not specifically designed to capture pollutants at the source.
Furfuryl alcohol warm box mold or core making line means a mold or core making line in which the binder chemical system used is that system commonly designated as a furfuryl alcohol warm box system by the foundry industry.
Iron and steel foundry means a facility or portion of a facility that melts scrap, ingot, and/or other forms of iron and/or steel and pours the resulting molten metal into molds to produce final or near final shape products for introduction into commerce. Research and development facilities, operations that only produce non-commercial castings, and operations associated with nonferrous metal production are not included in this definition.
Large foundry means, for an existing affected source, an iron and steel foundry with an annual metal melt production greater than 20,000 tons. For a new affected source, large foundry means an iron and steel foundry with an annual metal melt capacity greater than 10,000 tons.
Mercury switch means each mercury-containing capsule or switch assembly that is part of a convenience light switch mechanism installed in a vehicle.
Metal charged means the quantity of scrap metal, pig iron, metal returns, alloy materials, and other solid forms of iron and steel placed into a metal melting furnace. Metal charged does not include the quantity of fluxing agents or, in the case of a cupola, the quantity of coke that is placed into the metal melting furnace.
Metal melting furnace means a cupola, electric arc furnace, electric induction furnace, or similar device that converts scrap, foundry returns, and/or other solid forms of iron and/or steel to a liquid state. This definition does not include a holding furnace, an argon oxygen decarburization vessel, or ladle that receives molten metal from a metal melting furnace, to which metal ingots or other material may be added to adjust the metal chemistry.
Mold or core making line means the collection of equipment that is used to mix an aggregate of sand and binder chemicals, form the aggregate into final shape, and harden the formed aggregate. This definition does not include a line for making greensand molds or cores.
Motor vehicle means an automotive vehicle not operated on rails and usually is operated with rubber tires for use on highways.
Motor vehicle scrap means vehicle or automobile bodies, including automobile body hulks, that have been processed through a shredder. Motor vehicle scrap does not include automobile manufacturing bundles, or miscellaneous vehicle parts, such as wheels, bumpers, or other components that do not contain mercury switches.
Nonferrous metal means any pure metal other than iron or any metal alloy for which an element other than iron is its major constituent in percent by weight.
On blast means those periods of cupola operation when combustion (blast) air is introduced to the cupola furnace and the furnace is capable of producing molten metal. On blast conditions are characterized by both blast air introduction and molten metal production.
Responsible official means responsible official as defined in Sec. 63.2.
Scrap preheater means a vessel or other piece of equipment in which metal scrap that is to be used as melting furnace feed is heated to a temperature high enough to eliminate volatile impurities or other tramp materials by direct flame heating or similar means of heating. Scrap dryers, which solely remove moisture from metal scrap, are not considered to be scrap preheaters for purposes of this subpart.
Scrap provider means the person (including a broker) who contracts directly with an iron and steel foundry to provide motor vehicle scrap. Scrap processors such as shredder operators or vehicle dismantlers that do not sell scrap directly to a foundry are not scrap providers.
Scrubber blowdown means liquor or slurry discharged from a wet scrubber that is either removed as a waste stream or processed to remove impurities or adjust its composition or pH.
Small foundry means, for an existing affected source, an iron and steel foundry that has an annual metal melt production of 20,000 tons or less. For a new affected source, small foundry means an iron and steel foundry that has an annual metal melt capacity of 10,000 tons or less.
Total metal HAP means, for the purposes of this subpart, the sum of the concentrations of compounds of antimony, arsenic, beryllium, cadmium, chromium, cobalt, lead, manganese, mercury, nickel, and selenium as measured by EPA Method 29 (40 CFR part 60, appendix A-8). Only the measured concentration of the listed analytes that are present at concentrations exceeding one-half the quantitation limit of the analytical method are to be used in the sum. If any of the analytes are not detected or are detected at concentrations less than one-half the quantitation limit of the analytical method, the concentration of those analytes will be assumed to be zero for the purposes of calculating the total metal HAP for this subpart. Sec. Table 1 to Subpart ZZZZZ of Part 63--Performance Test Requirements
for New and Existing Affected Sources Classified as Large Foundries
As required in Sec. 63.10898(c) and (h), you must conduct performance tests according to the test methods and procedures in the following table: ------------------------------------------------------------------------
According to the
For. . . You must. . . following
requirements. . .------------------------------------------------------------------------1. Each metal melting a. Select sampling Sampling sites must
furnace subject to a PM or port locations and be located at the
total metal HAP limit in the number of outlet of the
Sec. 63.10895(c). traverse points in control device (or
each stack or duct at the outlet of
using EPA Method 1 the emissions
or 1A (40 CFR part source if no
60, appendix A). control device is
b. Determine present) prior to
volumetric flow any releases to the
rate of the stack atmosphere.
gas using Method 2, i. Collect a minimum
2A, 2C, 2D, 2F, or sample volume of 60
2G (40 CFR part 60, dscf of gas during
appendix A). each PM sampling
c. Determine dry run. The PM
molecular weight of concentration is
the stack gas using determined using
EPA Method 3, 3A, only the front-half
or 3B (40 CFR part (probe rinse and
60, appendix A).\1\. filter) of the PM
d. Measure moisture catch.
content of the ii. For Method 29,
stack gas using EPA only the measured
Method 4 (40 CFR concentration of
part 60, A). the listed metal
e. Determine PM HAP analytes that
concentration using are present at
EPA Method 5, 5B, concentrations
5D, 5F, or 5I, as exceeding one-half
applicable or total the quantification
metal HAP limit of the
concentration using analytical method
EPA Method 29 (40 are to be used in
CFR part 60, the sum. If any of
appendix A). the analytes are
not detected or are
detected at
concentrations less
than one-half the
quantification
limit of the
analytical method,
the concentration
of those analytes
is assumed to be
zero for the
purposes of
calculating the
total metal HAP.
iii. A minimum of
three valid test
runs are needed to
comprise a PM or
total metal HAP
performance test.
iv. For cupola metal
melting furnaces,
sample PM or total
metal HAP only
during times when
the cupola is on
blast.
v. For electric arc
and electric
induction metal
melting furnaces,
sample PM or total
metal HAP only
during normal melt
production
conditions, which
may include, but
are not limited to
the following
operations:
Charging, melting,
alloying, refining,
slagging, and
tapping.
vi. Determine and
record the total
combined weight of
tons of metal
charged during the
duration of each
test run. You must
compute the process-
weighted mass
emissions of PM
according to
Equation 1 of Sec.
63.10898(d) for an
individual furnace
or Equation 2 of
Sec. 63.10898(e)
for the group of
all metal melting
furnaces at the
foundry.2. Fugitive emissions from a. Using a certified i. The certified
buildings or structures observer, conduct observer may
housing any iron and steel each opacity test identify a limited
foundry emissions sources according to EPA number of openings
subject to opacity limit in Method 9 (40 CFR or vents that
Sec. 63.10895(e). part 60, appendix A- appear to have the
4) and 40 CFR highest opacities
63.6(h)(5). and perform opacity
observations on the
identified openings
or vents in lieu of
performing
observations for
each opening or
vent from the
building or
structure.
Alternatively, a
single opacity
observation for the
entire building or
structure may be
performed, if the
fugitive release
points afford such
an observation.
ii. During testing
intervals when PM
or total metal HAP
performance tests,
if applicable, are
being conducted,
conduct the opacity
test such that the
opacity
observations are
recorded during the
PM or total metal
HAP performance
tests.
b. As alternative to i. The observer may
Method 9 identify a limited
performance test, number of openings
conduct visible or vents that
emissions test by appear to have the
Method 22 (40 CFR highest visible
part 60, appendix A- emissions and
7). The test is perform
successful if no observations on the
visible emissions identified openings
are observed for 90 or vents in lieu of
percent of the performing
readings over 1 observations for
hour. If VE is each opening or
observed greater vent from the
than 10 percent of building or
the time over 1 structure.
hour, then the Alternatively, a
facility must single observation
conduct another for the entire
performance test as building or
soon as possible, structure may be
but no later than performed, if the
15 calendar days fugitive release
after the Method 22 points afford such
test, using Method an observation.
9 (40 CFR part 60, ii. During testing
appendix A-4). intervals when PM
or total metal HAP
performance tests,
if applicable, are
being conducted,
conduct the visible
emissions test such
that the
observations are
recorded during the
PM or total metal
HAP performance
tests.------------------------------------------------------------------------\1\ You may also use as an alternative to EPA Method 3B (40 CFR part 60,
appendix A), the manual method for measuring the oxygen, carbon
dioxide, and carbon monoxide content of exhaust gas, ANSI/ASME PTC
19.10-1981, ``Flue and Exhaust Gas Analyses'' (incorporated by
reference--see Sec. 63.14).
Sec. Table 2 to Subpart ZZZZZ of Part 63--Procedures for Establishing
Operating Limits for New Affected Sources Classified as Large Foundries
As required in Sec. 63.10898(k), you must establish operating limits using the procedures in the following table: ------------------------------------------------------------------------
For. . . You must. . .------------------------------------------------------------------------1. Each wet scrubber subject Using the CPMS required in Sec.
to the operating limits in 63.10897(b), measure and record the
Sec. 63.10895(d)(1) for pressure drop and scrubber water flow
pressure drop and scrubber rate in intervals of no more than 15
water flow rate. minutes during each PM or total metal
HAP test run. Compute and record the
average pressure drop and average
scrubber water flow rate for all the
valid sampling runs in which the
applicable emissions limit is met.2. Each electrostatic Using the CPMS required in Sec.
precipitator subject to 63.10897(c), measure and record voltage
operating limits in Sec. and secondary current (or total power
63.10895(d)(2) for voltage input) in intervals of no more than 15
and secondary current (or minutes during each PM or total metal
total power input). HAP test run. Compute and record the
minimum hourly average voltage and
secondary current (or total power input)
from all the readings for each valid
sampling run in which the applicable
emissions limit is met.------------------------------------------------------------------------
Sec. Table 3 to Subpart ZZZZZ of Part 63--Applicability of General
Provisions to New and Existing Affected Sources Classified as Large
Foundries
As required in Sec. 63.10900(a), you must meet each requirement in the following table that applies to you: ----------------------------------------------------------------------------------------------------------------
Applies to large
Citation Subject foundry? Explanation----------------------------------------------------------------------------------------------------------------63.1................................ Applicability.......... Yes.63.2................................ Definitions............ Yes.63.3................................ Units and abbreviations Yes.63.4................................ Prohibited activities.. Yes.63.5................................ Construction/ Yes.
reconstruction.63.6(a)-(g)......................... Compliance with Yes.
standards and
maintenance
requirements.63.6(h)............................. Opacity and visible Yes.
emissions standards.63.6(i)(i)-(j)...................... Compliance extension Yes.
and Presidential
compliance exemption.63.7(a)(3), (b)-(h)................. Performance testing Yes.
requirements.63.7(a)(1)-(a)(2)................... Applicability and No Subpart ZZZZZ specifies
performance test dates. applicability and
performance test
dates.63.8(a)(1)-(a)(3), (b), (c)(1)- Monitoring requirements Yes.
(c)(3), (c)(6)-(c)(8), (d), (e),
(3), (c)(6)-(c)(8), (d), (e),
(f)(1)-(f)(6), (g)(1)-(g)(4).
(1)-(f)(6), (g)(1)-(g)(4).
63.8(a)(4).......................... Additional monitoring No.
requirements for
control devices in
Sec. 63.11.63.8(c)(4).......................... Continuous monitoring No.
system (CMS)
requirements.63.8(c)(5).......................... Continuous opacity No.
monitoring system
(COMS) minimum
procedures.63.8(g)(5).......................... Data reduction......... No.63.9................................ Notification Yes.
requirements.63.10(a), (b)(1)-(b)(2)(xii) - Recordkeeping and Yes.
(b)(2)(xiv), (b)(3), (d)(1)-(2), reporting requirements.
(2)(xiv), (b)(3), (d)(1)-(2), reporting requirements.
(xiv), (b)(3), (d)(1)-(2), reporting requirements.
(e)(1)-(2), (f).63.10(c)(1)-(6), (c)(9)-(15)........ Additional records for No.
(1)-(2), (f).63.10(c)(1)-(6), (c)(9)-(15)........ Additional records for No.
continuous monitoring
systems.63.10(c)(7)-(8)..................... Records of excess Yes.
emissions and
parameter monitoring
exceedances for CMS.63.10(d)(3)......................... Reporting opacity or Yes.
visible emissions
observations.63.10(e)(3)......................... Excess emissions Yes.
reports.63.10(e)(4)......................... Reporting COMS data.... No.63.11............................... Control device No.
requirements.63.12............................... State authority and Yes.
delegations.63.13-63.16......................... Addresses of State air Yes.
pollution control
agencies and EPA
regional offices.
Incorporation by
reference.
Availability of
information and
confidentiality.
Performance track
provisions.---------------------------------------------------------------------------------------------------------------- Sec. Table 4 to Subpart ZZZZZ of Part 63--Compliance Certifications for
New and Existing Affected Sources Classified as Large Iron and Steel
Foundries
As required by Sec. 63.10900(b), your notification of compliance status must include certifications of compliance according to the following table: ------------------------------------------------------------------------
Your notification of compliance status
required by Sec. 63.9(h) must include
For. . . this certification of compliance, signed
by a responsible official:------------------------------------------------------------------------Each new or existing affected ``This facility has prepared, and will
source classified as a large operate by, written material
foundry and subject to scrap specifications for metallic scrap
management requirements in according to Sec. 63.10885(a)(1)'' and/
Sec. 63.10885(a)(1) and/or or ``This facility has prepared, and
(2). will operate by, written material
specifications for general iron and
steel scrap according to Sec.
63.10885(a)(2).''Each new or existing affected ``This facility has prepared, and will
source classified as a large operate by, written material
foundry and subject to specifications for the removal of
mercury switch removal mercury switches and a site-specific
requirements in Sec. plan implementing the material
63.10885(b). specifications according to Sec.
63.10885(b)(1)'' and/or ``This facility
participates in and purchases motor
vehicles scrap only from scrap providers
who participate in a program for removal
of mercury switches that has been
approved by the EPA Administrator
according to Sec. 63.10885(b)(2) and
have prepared a plan for participation
in the EPA approved program according to
Sec. 63.10885(b)(2)(iv)'' and/or ``The
only materials from motor vehicles in
the scrap charged to a metal melting
furnace at this facility are materials
recovered for their specialty alloy
content in accordance with Sec.
63.10885(b)(3) which are not reasonably
expected to contain mercury switches''
and/or ``This facility complies with the
requirements for scrap that does not
contain motor vehicle scrap in
accordance with Sec. 63.10885(b)(4).''Each new or existing affected ``This facility complies with the no
source classified as a large methanol requirement for the catalyst
foundry and subject to Sec. portion of each binder chemical
63.10886. formulation for a furfuryl alcohol warm
box mold or core making line according
to Sec. 63.10886.''Each new or existing affected ``This facility operates a capture and
source classified as a large collection system for each emissions
foundry and subject to Sec. source subject to this subpart according
63.10895(b). to Sec. 63.10895(b).''Each existing affected source ``This facility complies with the PM or
classified as a large total metal HAP emissions limit in Sec.
foundry and subject to Sec. 63.10895(c) for each metal melting
63.10895(c)(1). furnace or group of all metal melting
furnaces based on a previous performance
test in accordance with Sec.
63.10898(a)(1).''Each new or existing affected ``This facility has prepared and will
source classified as a large operate by an operation and maintenance
foundry and subject to Sec. plan according to Sec. 63.10896(a).''
63.10896(a).
Each new or existing (if ``This facility has prepared and will
applicable) affected source operate by a site-specific monitoring
classified as a large plan for each bag leak detection system
foundry and subject to Sec. and submitted the plan to the
63.10897(d). Administrator for approval according to
Sec. 63.10897(d)(2).''------------------------------------------------------------------------ Subpart AAAAAA [Reserved] Subpart BBBBBB_National Emission Standards for Hazardous Air Pollutants for Source Category: Gasoline Distribution Bulk Terminals, Bulk Plants,
and Pipeline Facilities
Source: 73 FR 1933, Jan. 10, 2008, unless otherwise noted.
What This Subpart Covers