['Air Programs']
['Hazardous Air Pollutants']
12/23/2024
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Table 1 to Subpart ZZZZZ of Part 63 - Performance Test Requirements for New and Existing Affected Sources Classified as Large Foundries
As required in §63.10898(c) and (h), you must conduct performance tests according to the test methods and procedures in the following table:
| For. . . | You must. . . | According to the following requirements. . . |
|---|---|---|
| 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 §63.14). | ||
| 1. Each metal melting furnace subject to a PM or total metal HAP limit in §63.10895(c) | a. Select sampling port locations and the number of traverse points in each stack or duct using EPA Method 1 or 1A (40 CFR part 60, appendix A)
b. Determine volumetric flow rate of the stack gas using Method 2, 2A, 2C, 2D, 2F, or 2G (40 CFR part 60, appendix A) c. Determine dry molecular weight of the stack gas using EPA Method 3, 3A, or 3B (40 CFR part 60, appendix A). 1 d. Measure moisture content of the stack gas using EPA Method 4 (40 CFR part 60, A) e. Determine PM concentration using EPA Method 5, 5B, 5D, 5F, or 5I, as applicable or total metal HAP concentration using EPA Method 29 (40 CFR part 60, appendix A) | Sampling sites must be located at the outlet of the control device (or at the outlet of the emissions source if no control device is present) prior to any releases to the atmosphere.
i. Collect a minimum sample volume of 60 dscf of gas during each PM sampling run. The PM concentration is determined using only the front-half (probe rinse and filter) of the PM catch. ii. For Method 29, only the measured concentration of the listed metal HAP analytes that are present at concentrations exceeding one-half the quantification 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 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 §63.10898(d) for an individual furnace or Equation 2 of §63.10898(e) for the group of all metal melting furnaces at the foundry. | ||
| 2. Fugitive emissions from buildings or structures housing any iron and steel foundry emissions sources subject to opacity limit in §63.10895(e) | a. Using a certified observer, conduct each opacity test according to EPA Method 9 (40 CFR part 60, appendix A-4) and 40 CFR 63.6(h)(5) | i. The certified observer may identify a limited number of openings or vents that appear to have the highest opacities 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 Method 9 performance test, conduct visible emissions test by Method 22 (40 CFR part 60, appendix A-7). The test is successful if no visible emissions are observed for 90 percent of the readings over 1 hour. If VE is observed greater than 10 percent of the time over 1 hour, then the facility must conduct another performance test as soon as possible, but no later than 15 calendar days after the Method 22 test, using Method 9 (40 CFR part 60, appendix A-4) | i. The observer may identify a limited number of openings or vents that appear to have the highest visible emissions and perform 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 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 visible emissions test such that the observations are recorded during the PM or total metal HAP performance tests. | |
Table 2 to Subpart ZZZZZ of Part 63 - Procedures for Establishing Operating Limits for New Affected Sources Classified as Large Foundries
As required in §63.10898(k), you must establish operating limits using the procedures in the following table:
| For . . . | You must . . . |
|---|---|
| 1. Each wet scrubber subject to the operating limits in §63.10895(d)(1) for pressure drop and scrubber water flow rate. | Using the CPMS required in §63.10897(b), measure and record the pressure drop and scrubber water flow rate in intervals of no more than 15 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 precipitator subject to operating limits in §63.10895(d)(2) for voltage and secondary current (or total power input). | Using the CPMS required in §63.10897(c), measure and record voltage and secondary current (or total power input) in intervals of no more than 15 minutes during each PM or total metal 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. |
Table 3 to Subpart ZZZZZ of Part 63 - Applicability of General Provisions to New and Existing Affected Sources Classified as Large Foundries
| Citation | Subject | Applies to large foundry? | Explanation |
|---|---|---|---|
| 63.1 | Applicability | Yes | |
| 63.2 | Definitions | Yes | |
| 63.3 | Units and abbreviations | Yes | |
| 63.4 | Prohibited activities | Yes | |
| 63.5 | Construction/reconstruction | Yes | |
| 63.6(a) through (d) | Compliance applicability and dates | Yes | |
| 63.6(e) | Operating and maintenance requirements | No | This subpart specifies operating and maintenance requirements. |
| 63.6(f)(1) | Applicability of non-opacity emission standards | No | This subpart specifies applicability of non-opacity emission standards. |
| 63.6(f)(2) through (3) | Methods and finding of compliance with non-opacity emission standards | Yes | |
| 63.6(g) | Use of an alternative nonopacity emission standard | Yes | |
| 63.6(h)(1) | Applicability of opacity and visible emissions standards | No | This subpart specifies applicability of opacity and visible emission standards. |
| 63.6(h)(2) through (9) | Methods and other requirements for opacity and visible emissions standards | Yes | |
| 63.6(i) through (j) | Compliance extension and Presidential compliance exemption | Yes | |
| 63.7(a)(1) through (2) | Applicability and performance test dates | No | This subpart specifies applicability and performance test dates. |
| 63.7(a)(3) through (4) | Administrators rights to require a performance test and force majeure provisions | Yes | |
| 63.7(b) through (d) | Notification of performance test, quality assurance program, and testing facilities | Yes | |
| 63.7(e)(1) | Performance test conditions | No | This subpart specifies performance test conditions. |
| 63.7(e)(2) through (4), (f) through (h) | Other performance testing requirements | Yes | |
| 63.8(a)(1) through (3), (b), (c)(1)(ii), (c)(2) through (3), (c)(6) through (8), (d)(1) through (2) | Monitoring requirements | Yes | |
| 63.8(a)(4) | Additional monitoring requirements for control devices in §63.11 | No | |
| 63.8(c)(1)(i), (c)(1)(iii) | Operation and maintenance of continuous monitoring systems | No | Not necessary in light of other requirements of §63.8 that apply. |
| 63.8(c)(4) | Continuous monitoring system (CMS) requirements | No | |
| 63.8(c)(5) | Continuous opacity monitoring system (COMS) minimum procedures | No | |
| 63.8(d)(3) | Quality control program | No | This subpart specifies records that must be kept associated with site-specific performance evaluation test plan. |
| 63.8(e), (f)(1) through (6), (g)(1) through (4) | Performance evaluations and alternative monitoring | Yes | |
| 63.8(g)(5) | Data reduction | No | |
| 63.9 | Notification requirements | Yes. | Except for opacity performance tests. |
| 63.10(a), (b)(1), (b)(2)(xii) through (xiv), (b)(3), (d)(1) through (4), (e)(1) through (2), (f) | Recordkeeping and reporting requirements | Yes | |
| 63.10(b)(2)(i) through (xi) | Malfunction and CMS records | No | |
| 63.10(c) | Additional records for CMS | No | This subpart specifies records requirements. |
| 63.10(d)(5) | Periodic startup, shutdown, and malfunction reports | No | |
| 63.10(e)(3) | Excess emissions reports | No | This subpart specifies reporting requirements. |
| 63.10(e)(4) | Reporting COMS data | No | |
| 63.11 | Control device requirements | No | |
| 63.12 | State authority and delegations | Yes | |
| 63.13(a) | Reporting to EPA regional offices | Yes | Except: reports and notifications required to be submitted to CEDRI meet this obligation through electronic reporting. |
| 63.13(b) through 63.16 | Addresses of state air pollution control agencies. Incorporation by reference. Availability of information and confidentiality. Performance track provisions | Yes |
[85 FR 56105, Sept. 10, 2020]
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 §63.10900(b), your notification of compliance status must include certifications of compliance according to the following table:
| For. . . | Your notification of compliance status required by §63.9(h) must include this certification of compliance, signed by a responsible official: |
|---|---|
| Each new or existing affected source classified as a large foundry and subject to scrap management requirements in §63.10885(a)(1) and/or (2) | “This facility has prepared, and will operate by, written material specifications for metallic scrap according to §63.10885(a)(1)” and/or “This facility has prepared, and will operate by, written material specifications for general iron and steel scrap according to §63.10885(a)(2).” |
| Each new or existing affected source classified as a large foundry and subject to mercury switch removal requirements in §63.10885(b) | “This facility has prepared, and will operate by, written material specifications for the removal of mercury switches and a site-specific plan implementing the material specifications according to §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 §63.10885(b)(2) and have prepared a plan for participation in the EPA approved program according to §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 §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 §63.10885(b)(4).” |
| Each new or existing affected source classified as a large foundry and subject to §63.10886 | “This facility complies with the no methanol requirement for the catalyst portion of each binder chemical formulation for a furfuryl alcohol warm box mold or core making line according to §63.10886.” |
| Each new or existing affected source classified as a large foundry and subject to §63.10895(b) | “This facility operates a capture and collection system for each emissions source subject to this subpart according to §63.10895(b).” |
| Each existing affected source classified as a large foundry and subject to §63.10895(c)(1) | “This facility complies with the PM or total metal HAP emissions limit in §63.10895(c) for each metal melting furnace or group of all metal melting furnaces based on a previous performance test in accordance with §63.10898(a)(1).” |
| Each new or existing affected source classified as a large foundry and subject to §63.10896(a) | “This facility has prepared and will operate by an operation and maintenance plan according to §63.10896(a).” |
| Each new or existing (if applicable) affected source classified as a large foundry and subject to §63.10897(d) | “This facility has prepared and will operate by a site-specific monitoring plan for each bag leak detection system and submitted the plan to the Administrator for approval according to §63.10897(d)(2).” |
Source: 73 FR 252, Jan. 2, 2008, unless otherwise noted.
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