401 KAR 61:165.
Existing primary aluminum reduction plants.
RELATES TO: KRS
224.20-100, 224.20-110, 224.20-120
STATUTORY AUTHORITY:
KRS 224.10-100
NECESSITY, FUNCTION,
AND CONFORMITY: KRS 224.10-100 requires the Environmental and Public Protection
Cabinet to prescribe administrative regulations for the prevention, abatement,
and control of air pollution. This administrative regulation provides for the
control of emissions from existing primary aluminum reduction plants.
Section 1.
Applicability. (1) The provisions of this administrative regulation shall apply
to each affected facility which means each potroom group within a primary
aluminum reduction plant commenced before the classification date defined
below.
(2) A physical
change in, or change in the method of operation of, each potroom group within a
primary aluminum reduction plant in conformance with the change from this
administrative regulation, as effective November 5, 1981, to this
administrative regulation, as effective October 1, 1984, shall not be a
modification; provided, that the potroom group within a primary aluminum
reduction plant was an affected facility at the time of the physical or
operational change.
Section 2.
Definitions. As used in this administrative regulation, all terms not defined
herein shall have the meaning given them in 401 KAR 50:010.
(1) "Primary
aluminum reduction plant" means any source manufacturing aluminum by
electrolytic reduction.
(2)
"Potroom" means a building unit which houses a group of electrolytic
cells in which aluminum is produced.
(3) "Potroom
group" means an uncontrolled potroom, a potroom which is controlled
individually, or a group of potrooms or potroom segments ducted to a common
control system.
(4) "Roof
monitor" means that portion of the roof of a potroom where gases not
captured at the cell exit from the potroom.
(5) "Total
fluorides" and "gaseous fluorides" means elemental fluorine and
all fluoride compounds, as measured and distinguished by reference methods
specified in Section 7 or equivalent or alternative methods.
(6) "Primary
control system" means an air pollution control system designed to remove
gaseous and particulate fluorides from exhaust gases which are captured at the
cell.
(7)
"Classification date" means October 23, 1974.
(8) "Dry
scrubbing plant" means each primary aluminum reduction plant with a
primary control system which operates in a manner whereby potroom group gases
flow through a reaction bed consisting of alumina prior to being treated by dry
removal methods for particulate emissions control. The resulting reaction bed
products are then used as feed to the potroom group electrolytic reduction
cells.
(9) "Start-up
cell" means an electrolytic reduction cell which is initially devoid of
any materials other than carbon cathodes and anodes. Such a cell undergoes a
prebake period by passing electrical current through anodes resting on the
cathode floor, then has the necessary electrolyte and aluminum added, such that
it will produce aluminum.
(10) "Sick
cell" means an electrolytic reduction cell which has lost its proper heat
balance, cannot maintain a solid crust, and must be removed from the primary
control system to receive corrective attention.
(11) "Normal
potroom operations" means any potroom activity and includes uncaptured
cell gases resulting from start-up cells, cell tapping, anode changing, ore
additions, or any other potroom operation but does not include operations due
to sick cells.
(12) "State
Implementation Plan" means the most recently prepared plan or revision
thereof required by Section 110 of the Clean Air Act which has been approved by
the U.S. EPA.
Section 3. Standard
for Visible Emissions. On and after the date on which the performance test
required to be conducted by 401 KAR 61:005 is completed, no owner or operator
subject to the provisions of this administrative regulation shall cause to be
discharged into the atmosphere:
(1) From any potroom
roof monitor any gases which exhibit ten (10) percent opacity or greater during
normal potroom operation except start-up cells;
(2) From any potroom
roof monitor section directly above sick cells or start-up cells any gases
which exhibit forty (40) percent opacity or greater;
(3) From any dry
scrubbing plant primary control system any gases which exhibit ten (10) percent
opacity or greater; or
(4) From any primary
aluminum reduction plant other than a dry scrubbing plant primary control
system any gases which exhibit twenty-five (25) percent opacity or greater.
Section 4. Standard
for Fluorides. (1) On and after the date on which the performance test required
to be conducted by 401 KAR 61:005 is completed, the owner or operator subject
to the provisions of this administrative regulation shall:
(a) For a dry
scrubbing plant cause to be discharged into the atmosphere no gases which
contain total fluorides in excess of one and nine-tenths (1.9) lb/ton of
aluminum produced except that emissions between one and nine-tenths (1.9)
lb/ton and two and five-tenths (2.5) lb/ton will be considered in compliance if
the owner or operator demonstrates to the cabinet's satisfaction that exemplary
operation and maintenance procedures were used with respect to the emission
control system and that proper control equipment was operating at the affected
facility during the performance test.
(b) For any primary
aluminum reduction plant other than a dry scrubbing plant cause to be
discharged into the atmosphere through each potroom roof monitor no gases which
contain gaseous fluorides in excess of 3.25 lb/hr.
(c) For a primary
aluminum reduction plant other than a dry scrubbing plant cause to be
discharged into the atmosphere from any primary control system no gases which
contain gaseous fluorides in excess of one (1.0) lbs/ton of aluminum produced
except that any such plant may cause to be discharged into the atmosphere gases
which contain gaseous fluorides not exceeding 290 lb/hr providing that a State
Implementation Plan allowing such emissions has been approved by the U.S. EPA.
The minimum stack height for the primary control system shall be 400 feet.
(2) In the event of
a recorded violation of the fluoride standard prescribed in 401 KAR 53:010, the
cabinet shall require that remedial measures be initiated from the source(s)
responsible for causing said violation.
Section 5. Standard
for Particulate Emissions. On and after the date on which the performance test
required to be conducted by 401 KAR 61:005 is completed, no owner or operator
subject to the provisions of this administrative regulation shall cause to be
discharged into the atmosphere from any primary aluminum reduction plant other
than a dry scrubbing plant primary control system any gases which contain
particulate emissions in excess of 0.010 gr/scf. Addition of dilution air shall
not constitute compliance.
Section 6.
Monitoring of Operations. (1) The owner or operator of any primary aluminum
reduction plant other than a dry scrubbing plant subject to the provisions of
this administrative regulation shall install, calibrate, maintain, and operate
monitoring devices which can be used to determine daily the weight of the
aluminum produced. The weighing devices shall have an accuracy of plus or minus
five (5) percent over their operating range.
(2) The owner or
operator of any primary aluminum reduction plant other than a dry scrubbing
plant shall maintain a record of daily production rates of aluminum, raw
material feed rates, and cell or potline voltages.
(3) The owner or
operator of any affected facility shall install, use, and maintain ambient air
monitoring equipment in accordance with such methods as the cabinet shall
prescribe; establish and maintain records of same; and make periodic emission
reports at intervals prescribed by the cabinet.
Section 7. Test
Methods and Procedures. (1) Reference methods as defined in Appendix A of 40
CFR 60 or as otherwise specified, filed by reference in 401 KAR 50:015, except
as provided for in 401 KAR 50:045, shall be used to determine compliance with
the standards prescribed in Section 3, 4 and 5 as follows:
(a) For sampling
emissions from stacks:
1. Reference Method
13A or 13B for the concentration of total fluoride and the associated moisture
content;
2. Reference Method
1 for sample and velocity traverses;
3. Reference Method
2 for velocity and volumetric flow rate;
4. Reference Method
3 for gas analysis; and
5. Reference Method
5 for particulate emissions.
(b) For sampling
emissions from roof monitors not employing stacks or pollutant collection
systems:
1. Reference Method
14 and Kentucky Method 130 for the concentration of gaseous fluorides and
associated moisture content;
2. Reference Method
1 for sample and velocity traverses;
3. Reference Method
2 and Reference Method 14 for velocity and volumetric flow rate; and
4. Reference Method
3 for gas analysis.
(c) For opacity
determination: Reference Method 9.
(2) For Reference
Method 13A or 13B, 14, and Kentucky Method 130, the sampling time for each run
shall be at least eight (8) hours for any potroom sample, and the minimum
sample volume shall be six and eight-tenths (6.8) dscm (240 dscf) for any
potroom sample except that shorter sampling times or smaller volumes, when
necessitated by process variables or other factors, may be approved by the
cabinet.
(3) The air
pollution control system for each affected facility shall be constructed so
that volumetric flow rates and total fluoride emissions can be accurately
determined using applicable methods specified under subsection (1) of this
section.
(4) The rate of
aluminum production is determined by dividing 720 hours into the weight of
aluminum tapped from the affected facility during a period of thirty (30) days
prior to and including the final run of a performance test.
(5) For each run for
any plant with an emission limitation expressed in lbs/ton of aluminum
produced, potroom group emissions expressed in kg/metric ton of aluminum
produced shall be determined using the equation in Appendix A of this
administrative regulation.
(6) For any sampling
harness which does not comply with Reference Method 14 in Appendix A to 40 CFR
60, as amended on June 30, 1980, the cabinet shall prescribe such sampling
procedures as it deems appropriate.
Section 8.
Compliance Timetable. (1) The owner or operator of an affected facility shall
be required with respect to start-up cell and sick cell emissions to achieve
compliance with this administrative regulation no later than February 1, 1982,
except as provided for under Section 9 of this administrative regulation.
(2) The owner or
operator of an affected facility shall be required with respect to the primary
removal system to achieve final compliance no later than February 1, 1981.
Section 9. Variance.
To allow for technological and economic circumstances unique to a source,
variation from the visible emission standard for sick or start-up cells
specified in Section 3(2) of this administrative regulation shall be granted by
the cabinet when supported by adequate technical and economic documentation
reasonably acceptable to the cabinet. (7 Ky.R. 384; Am. 478; eff. 1-7-81; 8 Ky.R.
164; eff. 11-5-81; 11 Ky.R. 574; eff. 10-1-84; 1461; eff. 6-4-85; TAm eff.
8-9-2007.)
APPENDIX
A TO 405 KAR 61:165
EQUATION
FOR POTROOM GROUP EMISSIONS
Where:
EP =
Primary control system emissions of gaseous fluorides in kg/metric ton of
aluminum produced at any plant other than a dry scrubbing plant.
= Potroom group
emissions of total fluorides in kg/metric ton of aluminum produced at dry
scrubbing plants.
C = For dry
scrubbing plants, concentration of total fluorides in mg/dscm as determined by
Reference Method 13A or 13B, or Reference Method 14 as applicable.
= For plants other
than dry scrubbing plants, concentration of gaseous fluorides as determined by
Kentucky Method 130.
Q = Volumetric flow
rate of the effluent gas stream in dscm/hour as determined by Reference Method
2 and/or Reference Method 14, as applicable.
10-6 =
Conversion factor for mg to kg.
M = Rate of aluminum
production in metric ton/hour as determined by Section 7(4).
(CQ)1 =
Product of C and Q for measurements of primary control system effluent gas
streams.
(CQ)2 =
Product of C and Q for measurements of roof monitor effluent gas stream at dry
scrubbing plants. (CQ)2 shall be equal to zero for any plant other
than a dry scrubbing plant.
