401 KAR 61:165. Existing primary aluminum reduction plants

Link to law: http://www.lrc.ky.gov/kar/401/061/165.htm
Published: 2015

Subscribe to a Global-Regulation Premium Membership Today!

Key Benefits:

Subscribe Now
      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.