Final Rule Established for Iron and Steel MACT.In August, the administrator of the U.S. EPA EPA eicosapentaenoic acid. EPA abbr. eicosapentaenoic acid EPA, n.pr See acid, eicosapentaenoic. EPA, n. signed the final rule establishing the National Emissions Standards for Hazardous Air Pollutants The National Emissions Standards for Hazardous Air Pollutants (NESHAPS) are emissions standards set by the United States EPA for an air pollutant not covered by NAAQS that may cause an increase in fatalities or in serious, irreversible, or incapacitating illness. (NESHAP NESHAP National Emission Standards for Hazardous Air Pollutants (US EPA) ) from iron and steel foundries (referred to as the MACT MACT Maximum Achievable Control Technology MACT Maximum Available Control Technology MACT Men of All Colors Together MACT Minnesota Association of Community Theatres MACT Maulana Azad College of Technology (Bhopal, India) standards). The AFS A distributed file system for large, widely dispersed Unix and Windows networks from Transarc Corporation, now part of IBM. It is noted for its ease of administration and expandability and stems from Carnegie-Mellon's Andrew File System. AFS - Andrew File System 10E MACT Ad-hoc Committee worked with EPA to modify many of the requirements from its proposed rule (issued in December December: see month. ), including the elimination of two key controversial provisions. For example, the 200 ft/min capture velocity requirement on all local exhaust hoods Noun 1. exhaust hood - metal covering leading to a vent that exhausts smoke or fumes hood covering - an artifact that covers something else (usually to protect or shelter or conceal it) range hood - exhaust hood over a kitchen range was replaced by language directing foundries to follow good engineering practices in the design of the system. A chart summarizing the requirements of the MACT standards for iron and steel foundries is shown on p. 13. A larger version of the same chart is available at www.moderncasting.com. A copy of the final rule is posted on the AFS website, www.afsinc.org See .org. (networking) org - The top-level domain for organisations or individuals that don't fit any other top-level domain (national, com, edu, or gov). Though many have .org domains, it was never intended to be limited to non-profit organisations. RFC 1591. . If you have any questions, contact Gary Gary, city (1990 pop. 116,646), Lake co., NW Ind., a port of entry on Lake Michigan; inc. 1909. Gary was founded by the U.S. Steel Corporation, which purchased the land in 1905 and landscaped it for a city. Mother, AFS, at 800/537-4237 x228.
Iron and Steel MACT Rule Synopsis (download a larger version at
www.moderncasting.com)
Final rule signed August 29, 2003
Emission Emission Limit or Comment
Source Work Practice
Standard
Cupolas Existing PM limit of 0.006
Cupolas gr/dscf or total
metal HAP of
0.0005 gr/dscf
New Cupolas PM limit of 0.002
gr/dscf or total
metal HAP of
0.0002 gr/dscf
All new & VOHAP limit of 20 Afterburners at 130OF (15
existing Cupolas ppmv (corrected to min. avg.) Accommodations
10% 02) for start-up and off blast
time)
Electric Melting Furnaces
Existing Induction PM limit of 0.005
& Electric Arc gr/dscf or total
Furnaces metal HAP of
0.0004 gr/dscf
New Induction PM limit of 0.001
Furnaces gr/dscf or total
metal HAP of
0.00008 gr/dscf
New Electric PM limit of 0.002
Arc Furnaces gr/dscf or total
metal HAP of
0.0002 gr/dscf
All Melting Furnaces
Scrap Certifica- Supplier Certification: No
tion or post-consumer automotive
scrap, oily turnings,
plastics, mercury switches,
lead or organic liquids.
Scrap Selection Supplier certifies no Hg
and Inspection switches or Pb components
Program and foundry inspects all
incoming scrap according to
written diagram and proce-
dures. Also restrictions on
oil and free liquids.
Scrap Preheater
Existing Scrap PM limit of 0.005
Preheaters gr/dscf or total
metal HAP of
0.0004 gr/dscf
a) VOHAP limit of Implies afterburner if not
20 ppmv (good b) of c),
engineering cap-
ture system or
b) Direct contact if not direct contact =
gas-fired pre- afterburner
heater or
c) Scrap Certifi-
cation
New Scrap PM limit of 0.001
Preheaters gr/dscf or total
metal HAP of
0.0008 gr/dscf
VOHAP limit of 20 Possible afterburner, if
ppmv (good engi- not heavy flame penetration
neering capture or scrap certification
system) or scrap
certification
Pouring
Existing Pouring PM limit of 0.010 If existing emissions dis-
Stations gr/dscf or total charged to the atmosphere
metal HAP of through a "conveyance)
0.0008 gr/dscf
New Pouring PM limit of 0.002 If emissions discharged to
Stations or gr/dscf or total the atmosphere through a
pouring areas metal HAP of "conveyance"
0.0002 gr/dscf
Mold Vent Light- Mold vents sponta- Contains procedures for
Off neously ignite or igniting mold vents at
they are manually pouring stations and areas
ignited if it is determined that
they do not spontaneously
ignite.
Fugitive Emissions Building opacity Applies to all building
from a building 20% opacity, openings (desired to mo-
or structure except for one nitor uncollected pouring,
6-min period per cooling & shakeout)
hour that does not
exceed 27%
opacity.
Cooling and Shakeout Emissions must be captured.
Now Cooling and VOHAP limit to 20 For automated conveyor and
Shakeout lines ppmv (flow pallet lines that use sand
weighted average) mold systems or automated
shakeout lines that use
sand mold systems
Written Plans
Operation & Describes capture Also must contain many
Maintenance Plan and control details of system, inclu-
systems, lists ding damper settings, gauge
system parameters settings, test points, etc.
appropriate to
evaluate perfor-
mance and esta-
blishes operating
limit for those
parameters. The
plan also must
include require-
ments for system
inspections, PM
procedures (with
schedules), and
procedures for
corrective
actions. Bag leak
detectors required
on all collection
devices with PM
limits.
Mold Vent Light Contains procedures for
Off (Part of O & M igniting mold vents at
Plan) pouring stations and
pouring areas if it is
determined that they do not
spontaneously ignite.
Start-up, Shutdown Must meet require-
& Malfunction Plan ments of 9
[section] 63.6 (e)
of NESHAP General
Provisions (68 FR
32586, May 30,
2003)
Scrap Selection & See above, under
Inspection Plan "All Melting
Furnaces"
Furan warm box No methanol, as
mold of core listed in the MSDS
making (applies to
catalyst portion
only)
Triethylamine (TEA) Control discharge
coldbox mold or of scrubber to 1
core production ppmv TEA or de-
(new or existing monstrate a 99%
facilities) control efficiency
(as determined
with fresh acid
solution)
Emission Emission Limit or Monitoring
Source Work Practice Requirements
Standard
Cupolas Existing PM limit of 0.006 Broken bag detectors,
Cupolas gr/dscf or total P, etc. (Note 1)
metal HAP of
0.0005 gr/dscf
New Cupolas PM limit of 0.002 Broken bag detectors,
gr/dscf or total P, etc. (Note 1)
metal HAP of
0.0002 gr/dscf
All new & VOHAP limit of 20 Afterburner
existing Cupolas ppmv (corrected to temperature
10% 02) (continuous)
Electric Melting Furnaces
Existing Induction PM limit of 0.005 Broken bag detectors,
& Electric Arc gr/dscf or total P, etc. (Note 1)
Furnaces metal HAP of
0.0004 gr/dscf
New Induction PM limit of 0.001 Broken bag detectors,
Furnaces gr/dscf or total P, etc. (Note 1)
metal HAP of
0.00008 gr/dscf
New Electric PM limit of 0.002 Broken bag detectors,
Arc Furnaces gr/dscf or total P, etc. (Note 1)
metal HAP of
0.0002 gr/dscf
All Melting Furnaces
Scrap Certifica-
tion or
Scrap Selection Written plan with
and Inspection heavy on-going
Program documentation
Scrap Preheater
Existing Scrap PM limit of 0.005 Broken bag detectors,
Preheaters gr/dscf or total P, etc. (Note 1)
metal HAP of
0.0004 gr/dscf
a) VOHAP limit of
20 ppmv (good
engineering cap-
ture system or
b) Direct contact
gas-fired pre-
heater or
c) Scrap Certifi-
cation
New Scrap PM limit of 0.001 Broken bag detectors,
Preheaters gr/dscf or total P, etc. (Note 1)
metal HAP of
0.0008 gr/dscf
VOHAP limit of 20
ppmv (good engi-
neering capture
system) or scrap
certification
Pouring
Existing Pouring PM limit of 0.010 Broken bag detectors,
Stations gr/dscf or total P, etc. (Note 1)
metal HAP of
0.0008 gr/dscf
New Pouring PM limit of 0.002 Broken bag detectors,
Stations or gr/dscf or total P, etc. (Note 1)
pouring areas metal HAP of
0.0002 gr/dscf
Mold Vent Light- Mold vents sponta- Documentation required.
Off neously ignite or
they are manually
ignited
Fugitive Emissions Building opacity Formal opacity readings
from a building 20% opacity,
or structure except for one
6-min period per
hour that does not
exceed 27%
opacity.
Cooling and Shakeout
Now Cooling and VOHAP limit to 20 Continuous Emissions
Shakeout lines ppmv (flow Monitoring
weighted average) (CEMS) required
Written Plans
Operation & Describes capture Routine documented
Maintenance Plan and control inspections,
systems, lists
system parameters
appropriate to
evaluate perfor-
mance and esta-
blishes operating
limit for those
parameters. The
plan also must
include require-
ments for system
inspections, PM
procedures (with
schedules), and
procedures for
corrective
actions. Bag leak
detectors required
on all collection
devices with PM
limits.
Mold Vent Light Documentation required.
Off (Part of O & M
Plan)
Start-up, Shutdown Must meet require-
& Malfunction Plan ments of 9
[section] 63.6 (e)
of NESHAP General
Provisions (68 FR
32586, May 30,
2003)
Scrap Selection & See above, under
Inspection Plan "All Melting
Furnaces"
Furan warm box No methanol, as
mold of core listed in the MSDS
making (applies to
catalyst portion
only)
Triethylamine (TEA) Control discharge Scrubber parameters,
coldbox mold or of scrubber to 1 including pH and liquid
core production ppmv TEA or de- flow. PH <4.5 measured
(new or existing monstrate a 99% at end of shift.
facilities) control efficiency
(as determined
with fresh acid
solution)
Emission Emission Limit or Compliance
Source Work Practice Demonstration
Standard
Cupolas Existing PM limit of 0.006 Initial compliance stack
Cupolas gr/dscf or total test (Note 2) repeated at
metal HAP of least every
0.0005 gr/dscf
New Cupolas PM limit of 0.002 Initial compliance stack
gr/dscf or total test (Note 2) repeated at
metal HAP of least every 5 yr
0.0002 gr/dscf
All new & VOHAP limit of 20 Initial compliance stack
existing Cupolas ppmv (corrected to test (Note 3) repeated
10% 02) at least every 5 yr
Electric Melting Furnaces
Existing Induction PM limit of 0.005 Initial compliance stack
& Electric Arc gr/dscf or total test (Note 2) repeated
Furnaces metal HAP of at least every 5 yr
0.0004 gr/dscf
New Induction PM limit of 0.001 Initial compliance stack
Furnaces gr/dscf or total test (Note 2) repeated at
metal HAP of least every 5 yr
0.00008 gr/dscf
New Electric PM limit of 0.002 Initial compliance stack
Arc Furnaces gr/dscf or total test (Note 2) repeated
metal HAP of at least every 5 yr
0.0002 gr/dscf
All Melting Furnaces
Scrap Certifica-
tion or
Scrap Selection Certify that plan has
and Inspection been prepared
Program
Scrap Preheater
Existing Scrap PM limit of 0.005 Initial compliance stack
Preheaters gr/dscf or total test (Note 2) repeated at
metal HAP of least every 5 yr
0.0004 gr/dscf
a) VOHAP limit of Initial compliance stack
20 ppmv (good test (Note 3) Certify
engineering cap- direct flame contact type
ture system or
b) Direct contact
gas-fired pre-
heater or
c) Scrap Certifi-
cation
New Scrap PM limit of 0.001 Start-up performance
Preheaters gr/dscf or total testing (Note 2) repeated
metal HAP of at least every 5 yr
0.0008 gr/dscf
VOHAP limit of 20 Initial compliance stack
ppmv (good engi- test (Note 3) Certify that
neering capture plan has been prepared
system) or scrap
certification
Pouring
Existing Pouring PM limit of 0.010 Initial compliance stack
Stations gr/dscf or total test (Note 2) repeated
metal HAP of at least every 5 yr
0.0008 gr/dscf
New Pouring PM limit of 0.002 Start-up performance
Stations or gr/dscf or total testing (Note 7) repeated
pouring areas metal HAP of at least every S yr
0.0002 gr/dscf
Mold Vent Light- Mold vents sponta- Certify that plan has
Off neously ignite or been prepared
they are manually
ignited
Fugitive Emissions Building opacity Initial opacity reading
from a building 20% opacity, (Note 4) repeated every
or structure except for one 6 months thereafter
6-min period per
hour that does not
exceed 27%
opacity.
Cooling and Shakeout
Now Cooling and VOHAP limit to 20 Start-up performance
Shakeout lines ppmv (flow stack test
weighted average)
Written Plans
Operation & Describes capture Certify list plan has been
Maintenance Plan and control prepared and that the
systems, lists foundry will operate
system parameters equipment according to
appropriate to the plan. Semiannual
evaluate perfor- deviation reports.
mance and esta-
blishes operating
limit for those
parameters. The
plan also must
include require-
ments for system
inspections, PM
procedures (with
schedules), and
procedures for
corrective
actions. Bag leak
detectors required
on all collection
devices with PM
limits.
Mold Vent Light Certify that plan has been
Off (Part of O & M prepared. Semiannual com-
Plan) pliance certification
stating that the procedures
have been followed.
Start-up, Shutdown Must meet require-
& Malfunction Plan ments of 9
[section] 63.6 (e)
of NESHAP General
Provisions (68 FR
32586, May 30,
2003)
Scrap Selection & See above, under Certify trial plan has been
Inspection Plan "All Melting prepared (if plan is
Furnaces" required).
Furan warm box No methanol, as
mold of core listed in the MSDS
making (applies to
catalyst portion
only)
Triethylamine (TEA) Control discharge Initial compliance stack
coldbox mold or of scrubber to 1 test repeated at
core production ppmv TEA or de- least every 5 yr
(new or existing monstrate a 99%
facilities) control efficiency
(as determined
with fresh acid
solution)
Emission Emission Limit or Compliance
Source Work Practice Date
Standard
Cupolas Existing PM limit of 0.006 3 yr from
Cupolas gr/dscf or total 5 yr rule publication
metal HAP of
0.0005 gr/dscf
New Cupolas PM limit of 0.002 At start-up
gr/dscf or total of new cupola
metal HAP of
0.0002 gr/dscf
All new & VOHAP limit of 20 3 yr for existing
existing Cupolas ppmv (corrected to cupolas, at start-up
10% 02) for new cupolas
Electric Melting Furnaces
Existing Induction PM limit of 0.005 3 yr from
& Electric Arc gr/dscf or total rule publication
Furnaces metal HAP of
0.0004 gr/dscf
New Induction PM limit of 0.001 At start-up for
Furnaces gr/dscf or total new furnaces
metal HAP of
0.00008 gr/dscf
New Electric PM limit of 0.002
Arc Furnaces gr/dscf or total
metal HAP of
0.0002 gr/dscf
All Melting Furnaces
Scrap Certifica- 1 yr from rule
tion or publication
Scrap Selection 1 yr from rue
and Inspection publication
Program
Scrap Preheater
Existing Scrap PM limit of 0.005 3 yr from rule
Preheaters gr/dscf or total publication
metal HAP of
0.0004 gr/dscf
a) VOHAP limit of 3 yr from rule publication
20 ppmv (good 3 yr from rule publication
engineering cap- 1 yr from rule publication
ture system or
b) Direct contact
gas-fired pre-
heater or
c) Scrap Certifi-
cation
New Scrap PM limit of 0.001 At start-up of
Preheaters gr/dscf or total new preheaters
metal HAP of
0.0008 gr/dscf
VOHAP limit of 20 1 yr from rule publication
ppmv (good engi-
neering capture
system) or scrap
certification
Pouring
Existing Pouring PM limit of 0.010 3 yr from rule
Stations gr/dscf or total publication
metal HAP of
0.0008 gr/dscf
New Pouring PM limit of 0.002 At start-up for
Stations or gr/dscf or total new lines
pouring areas metal HAP of
0.0002 gr/dscf
Mold Vent Light- Mold vents sponta- 3 yr from rule publication
Off neously ignite or
they are manually
ignited
Fugitive Emissions Building opacity 3 yr from rule publication
from a building 20% opacity,
or structure except for one
6-min period per
hour that does not
exceed 27%
opacity.
Cooling and Shakeout
Now Cooling and VOHAP limit to 20 At start-up
Shakeout lines ppmv (flow
weighted average)
Written Plans
Operation & Describes capture 3 yr from rule publication
Maintenance Plan and control
systems, lists
system parameters
appropriate to
evaluate perfor-
mance and esta-
blishes operating
limit for those
parameters. The
plan also must
include require-
ments for system
inspections, PM
procedures (with
schedules), and
procedures for
corrective
actions. Bag leak
detectors required
on all collection
devices with PM
limits.
Mold Vent Light 3 yr from rule publication
Off (Part of O & M
Plan)
Start-up, Shutdown Must meet require- 3 yr from rule publication
& Malfunction Plan ments of 9
[section] 63.6 (e)
of NESHAP General
Provisions (68 FR
32586, May 30,
2003)
Scrap Selection & See above, under 1 yr from rule publication
Inspection Plan "All Melting
Furnaces"
Furan warm box No methanol, as
mold of core listed in the MSDS
making (applies to
catalyst portion
only)
Triethylamine (TEA) Control discharge 3 yr from rule publication
coldbox mold or of scrubber to 1
core production ppmv TEA or de-
(new or existing monstrate a 99%
facilities) control efficiency
(as determined
with fresh acid
solution)
Note (1): Continuous Parametric Monitoring System (CPMS) required.
Implies continuous readings available, but does not mandate continuous
record. Recording frequency to be described in O & M Plan.
Note (2): To determine compliance with the metal HAP emissons limits.
EPA Method 1 through 4, and either Method 5, 5B, 5D, 5F or 5I, as
applicaple (to measure PM) a Method 29 (to measure total meal HAP) are
required.
Note (3): To determine compliance with the organic HAP limits, use EPA
Method 18 to measure VOHAP, Method 25 to measure total gaseous
non-methane (TBNMO) as hexane, or Method 25A to measure total organic
compounds (TOC) as hexane.
Note (4): To measure opacity, use EPA Method 9.
Compiled by Jim White, Grede Foundries, Inc. Reviewed by AFS MAHC
Steering Committee.
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