40 CFR 63.1514 – Change of furnace classification
The requirements of this section are in addition to the other requirements of this subpart that apply to group 1 and group 2 furnaces.
(a) Changing from a group 1 controlled furnace processing other than clean charge to group 1 uncontrolled furnace processing other than clean charge. An owner or operator wishing to change operating modes must conduct performance tests in accordance with §§ 63.1511 and 63.1512 to demonstrate to the permitting authority for major sources, or the Administrator for area sources that compliance can be achieved under both modes. Operating parameters relevant to each mode of operation must be established during the performance test.
(1) Operators of major sources must conduct performance tests for PM, HCl and D/F, according to the procedures in § 63.1512(d) with the capture system and control device operating normally if compliance has not been previously demonstrated in this operating mode. Performance tests must be repeated at least once every 5 years to demonstrate compliance for each operating mode.
(i) Testing under this paragraph must be conducted in accordance with § 63.1511(b)(1) in the controlled mode.
(ii) Operating parameters must be established during these tests, as required by § 63.1511(g).
(iii) The emission factors for this mode of operation for use in the demonstration of compliance with the emission limits for SAPUs specified in § 63.1505(k) must be determined.
(2) Operators of major sources must conduct performance tests for PM, HCl, HF and D/F, according to the procedures in § 63.1512(e) without operating a control device if compliance has not been previously demonstrated for this operating mode. Performance tests must be repeated at least once every 5 years to demonstrate compliance for each operating mode.
(i) Testing under this paragraph must be conducted in accordance with § 63.1511(b)(1) in the uncontrolled mode.
(ii) Testing under this paragraph must be conducted with furnace emissions captured in accordance with the provisions of § 63.1506(c) and directed to the stack or vent tested.
(iii) Operating parameters representing uncontrolled operation must be established during these tests, as required by § 63.1511(g). For furnaces in batch (cyclic) operation, the number of tap-to-tap cycles (including zero, if none) elapsed using the feed/charge type, feed/charge rate and flux rate must be established as a parameter to be met before changing to uncontrolled mode. For furnaces in continuous (non-cyclic) operation, the time period elapsed (including no time, if none) using the feed/charge type, feed/charge rate and flux rate must be established as a parameter to be met before changing to uncontrolled mode.
(iv) The emission factors for this mode of operation for use in the demonstration of compliance with the emission limits for SAPUs specified in § 63.1505(k) must be determined.
(3) Operators of area sources must conduct performance tests for D/F, according to the procedures in § 63.1512(d) with the capture system and control device operating normally, if compliance has not been previously demonstrated for this operating mode.
(i) Testing under this paragraph must be conducted in accordance with § 63.1511(b)(1) in the controlled mode.
(ii) Operating parameters must be established during these tests, as required by § 63.1511(g).
(iii) The D/F emission factor for this mode of operation for use in the demonstration of compliance with the emission limits for SAPUs specified in § 63.1505(k) must be determined.
(4) Operators of area sources must conduct performance tests for D/F, according to the procedures in § 63.1512(e) without operating a control device, if compliance has not been previously demonstrated for this operating mode.
(i) Testing under this paragraph must be conducted in accordance with § 63.1511(b)(1).
(ii) Testing under this paragraph must be conducted with furnace emissions captured in accordance with the provisions of § 63.1506(c) and directed to the stack or vent tested.
(iii) Operating parameters representing uncontrolled operation must be established during these tests, as required by § 63.1511(g). For furnaces in batch (cyclic) operation, the number of tap-to-tap cycles (including zero, if none) elapsed using the feed/charge type, feed/charge rate and flux rate must be established as a parameter to be met before changing to uncontrolled mode. For furnaces in continuous (non-cyclic) operation, the time period elapsed (including no time, if none) using the feed/charge type, feed/charge rate and flux rate must be established as a parameter to be met before changing to uncontrolled mode.
(iv) The D/F emission factor for this mode of operation for use in the demonstration of compliance with the emission limits for SAPUs specified in § 63.1505(k) must be determined.
(5) To change modes of operation from uncontrolled to controlled, the owner or operator must perform the following, before charging scrap to the furnace that exceeds the contaminant level established for uncontrolled mode:
(i) Change the label on the furnace to reflect controlled operation;
(ii) Direct the furnace emissions to the control device;
(iii) Turn on the control device and begin lime addition to the control device at the rate established for controlled mode; and
(iv) Ensure the control device is operating properly.
(6) To change modes of operation from controlled to uncontrolled, the owner or operator must perform the following, before turning off or bypassing the control device:
(i) Change the label on the furnace to reflect uncontrolled operation;
(ii) Charge scrap with a level of contamination no greater than that used in the performance test for uncontrolled furnaces for the number of tap-to-tap cycles that elapsed (or, for continuously operated furnaces, the time elapsed) before the uncontrolled mode performance test was conducted; and
(iii) Decrease the flux addition rate to no higher than the flux addition rate used in the uncontrolled mode performance test.
(7) In addition to the recordkeeping requirements of § 63.1517, the owner or operator must maintain records of the nature of each mode change (controlled to uncontrolled, or uncontrolled to controlled), the time the change is initiated, and the time the exhaust gas is diverted from control device to bypass or bypass to control device.
(b) Changing from a group 1 controlled furnace processing other than clean charge to a group 1 uncontrolled furnace processing clean charge. An owner or operator wishing to change operating modes must conduct performance tests in accordance with §§ 63.1511 and 63.1512 to demonstrate to the permitting authority for major sources, or the Administrator for area sources that compliance can be achieved in both modes. Operating parameters relevant to each mode of operation must be established during the performance test.
(1) Operators of major sources must conduct performance tests for PM, HCl and D/F, according to the procedures in § 63.1512(d) with the capture system and control device operating normally if compliance has not been previously demonstrated in this operating mode. Performance tests must be repeated at least once every 5 years to demonstrate compliance for each operating mode.
(i) Testing under this paragraph must be conducted in accordance with § 63.1511(b)(1) in the controlled mode.
(ii) Operating parameters must be established during these tests, as required by § 63.1511(g).
(iii) The emission factors for this mode of operation for use in the demonstration of compliance with the emission limits for SAPUs specified in § 63.1505(k) must be determined.
(2) Operators of major sources must conduct performance tests for PM, HCl, HF and D/F, according to the procedures in § 63.1512(e) without operating a control device if compliance has not been previously demonstrated for this operating mode. Performance tests must be repeated at least once every 5 years to demonstrate compliance for each operating mode.
(i) Testing under this paragraph may be conducted at any time after operation with clean charge has commenced.
(ii) Testing under this paragraph must be conducted with furnace emissions captured in accordance with the provisions of § 63.1506(c) and directed to the stack or vent tested.
(iii) Operating parameters representing uncontrolled operation must be established during these tests, as required by § 63.1511(g). For furnaces in batch (cyclic) operation, the number of tap-to-tap cycles (including zero, if none) elapsed using the feed/charge type, feed/charge rate and flux rate must be established as a parameter to be met before changing to uncontrolled mode. For furnaces in continuous (non-cyclic) operation, the time period elapsed (including no time if none) using the feed/charge type, feed/charge rate and flux rate must be established as a parameter to be met before changing to uncontrolled mode.
(iv) Emissions of D/F during this test must not exceed 1.5 µg TEQ/Mg of feed/charge.
(v) The emission factors for this mode of operation for use in the demonstration of compliance with the emission limits for SAPUs specified in § 63.1505(k), must be determined.
(3) Operators of area sources must conduct performance tests for D/F, according to the procedures in § 63.1512(d) with the capture system and control device operating normally, if compliance has not been previously demonstrated for this operating mode.
(i) Testing under this paragraph must be conducted in accordance with § 63.1511(b)(1).
(ii) Operating parameters must be established during these tests, as required by § 63.1511(g).
(iii) The D/F emission factor for this mode of operation for use in the demonstration of compliance with the emission limits for SAPUs specified in § 63.1505(k) must be determined.
(4) Operators of area sources must conduct performance tests for D/F, according to the procedures in § 63.1512(e) without operating a control device if compliance has not been previously demonstrated for this operating mode.
(i) Testing under this paragraph must be conducted at any time after operation with clean charge has commenced and must be conducted in accordance with § 63.1511(b)(1) and under representative conditions expected to produce the highest level of D/F in the uncontrolled mode.
(ii) Testing under this paragraph must be conducted with furnace emissions captured in accordance with the provisions of § 63.1506(c) and directed to the stack or vent tested.
(iii) Operating parameters representing uncontrolled operation must be established during these tests, as required by § 63.1511(g). For furnaces in batch (cyclic) operation, the number of tap-to-tap cycles elapsed (including zero, if none) using the feed/charge type, feed/charge rate and flux rate must be established as a parameter to be met before changing to uncontrolled mode. For furnaces in continuous (non-cyclic) operation, the time period elapsed (including no time, if none) using the feed/charge type, feed/charge rate and flux rate must be established as a parameter to be met before changing to uncontrolled mode.
(iv) Emissions of D/F during this test must not exceed 1.5 µg TEQ/Mg of feed/charge.
(5) To change modes of operation from uncontrolled to controlled, the owner or operator must perform the following, before charging scrap to the furnace that exceeds the contaminant level established for uncontrolled mode:
(i) Change the label on the furnace to reflect controlled operation;
(ii) Direct the furnace emissions to the control device;
(iii) Turn on the control device and begin lime addition to the control device at the rate established for controlled mode; and
(iv) Ensure the control device is operating properly.
(6) To change modes of operation from controlled to uncontrolled, the owner or operator must perform the following, before turning off or bypassing the control device:
(i) Change the label on the furnace to reflect uncontrolled operation;
(ii) Charge clean charge for the number of tap-to-tap cycles that elapsed (or, for continuously operated furnaces, the time elapsed) before the uncontrolled mode performance test was conducted; and
(iii) Decrease the flux addition rate to no higher than the flux addition rate used in the uncontrolled mode performance test.
(7) In addition to the recordkeeping requirements of § 63.1517, the owner or operator must maintain records of the nature of each mode change (controlled to uncontrolled, or uncontrolled to controlled), the time the furnace operating mode change is initiated, and the time the exhaust gas is diverted from control device to bypass or from bypass to control device.
(c) Changing from a group 1 controlled or uncontrolled furnace to a group 2 furnace. An owner or operator wishing to change operating modes must conduct performance tests in accordance with §§ 63.1511 and 63.1512 to demonstrate to the permitting authority for major sources, or the Administrator for area sources that compliance can be achieved under both modes and establish the number of cycles (or time) of operation with clean charge and no reactive flux addition necessary before changing to group 2 mode. Operating parameters relevant to group 1 operation must be established during the performance test.
(1) Operators of major sources must conduct performance tests for PM, HCl and D/F (and HF for uncontrolled group 1 furnaces) according to the procedures in § 63.1512 if compliance has not been previously demonstrated for the operating mode. Controlled group 1 furnaces must conduct performance tests according to the procedures in § 63.1512(d) with the capture system and control device operating normally. Uncontrolled group 1 furnaces must conduct performance tests according to the procedures in § 63.1512(e) without operating a control device. Performance tests must be repeated at least once every 5 years to demonstrate compliance for each operating mode.
(i) Testing under this paragraph must be conducted in accordance with § 63.1511(b)(1) in both modes.
(ii) Operating parameters must be established during these tests, as required by § 63.1511(g).
(iii) The emission factors for this mode of operation for use in the demonstration of compliance with the emission limits for SAPUs specified in § 63.1505(k) must be determined.
(2) While in compliance with the operating requirements of § 63.1506(o) for group 2 furnaces, operators of major sources must conduct performance tests for PM, HCl, HF and D/F, according to the procedures in § 63.1512(e) without operating a control device if compliance has not been previously demonstrated for this operating mode. Performance tests must be repeated at least once every 5 years to demonstrate compliance for each operating mode.
(i) Testing under this paragraph may be conducted at any time after the furnace has commenced operation with clean charge and without reactive flux addition.
(ii) Testing under this paragraph must be conducted with furnace emissions captured in accordance with the provisions of § 63.1506(c) and directed to the stack or vent tested.
(iii) Owners or operators must demonstrate that emissions are no greater than:
(A) 1.5 µg D/F (TEQ) per Mg of feed/charge;
(B) 0.040 lb HCl or HF per ton of feed/charge; and
(C) 0.040 lb PM per ton of feed/charge.
(iv) The number of tap-to-tap cycles, or time elapsed between starting operation with clean charge and no reactive flux addition and the group 2 furnace performance test must be established as an operating parameter to be met before changing to group 2 mode.
(3) Operators of area sources must conduct a performance tests for D/F, according to the procedures in § 63.1512 if compliance has not been previously demonstrated for the operating mode. Controlled group 1 furnaces must conduct performance tests according to the procedures in § 63.1512(d) with the capture system and control device operating normally. Uncontrolled group 1 furnaces must conduct performance tests according to the procedures in § 63.1512(e) without operating a control device.
(i) The performance tests must be conducted in accordance with § 63.1511(b)(1) under representative conditions expected to produce the highest expected level of D/F in the group 1 mode.
(ii) Operating parameters must be established during these tests, as required by § 63.1511(g).
(iii) The D/F emission factor for this mode of operation, for use in the demonstration of compliance with the emission limits for SAPUs specified in § 63.1505(k) must be determined.
(4) While in compliance with the operating requirements of § 63.1506(o) for group 2 furnaces, operators of area sources must conduct performance tests for D/F, according to the procedures in § 63.1512(e) without operating a control device if compliance has not been previously demonstrated for this operating mode.
(i) Testing under this paragraph may be conducted at any time after the furnace has commenced operation with clean charge, and without reactive flux addition.
(ii) Testing under this paragraph must be conducted with furnace emissions captured in accordance with the provisions of § 63.1506(c) and directed to the stack or vent tested.
(iii) Owners or operators must demonstrate that emissions are no greater than 1.5 µg D/F (TEQ) per Mg of feed/charge.
(iv) The number of tap-to-tap cycles, or time elapsed between starting operation with clean charge and no reactive flux and the group 2 furnace performance tests must be established as an operating parameter to be met before changing to group 2 mode.
(5) To change modes of operation from a group 2 furnace to a group 1 furnace, the owner or operator must perform the following before adding other than clean charge and before adding reactive flux to the furnace:
(i) Change the label on the furnace to reflect group 1 operation;
(ii) Direct the furnace emissions to the control device, if it is equipped with a control device;
(iii) If the furnace is equipped with a control device, turn on the control device and begin lime addition to the control device at the rate established for group 1 mode; and
(iv) Ensure the control device is operating properly.
(6) To change mode of operation from a group 1 furnace to group 2 furnace, the owner or operator must perform the following, before turning off or bypassing the control device:
(i) Change the label on the furnace to reflect group 2 operation;
(ii) Charge clean charge for the number of tap-to-tap cycles that elapsed (or, for continuously operated furnaces, the time elapsed) before the group 2 performance test was conducted; and,
(iii) Use no reactive flux.
(7) In addition to the recordkeeping requirements of § 63.1517, the owner or operator must maintain records of the nature of each mode change (controlled or uncontrolled to group 2), the time the change is initiated, and the time the exhaust gas is diverted from control device to bypass or from bypass to control device.
(d) Changing from a group 1 controlled or uncontrolled furnace to group 2 furnace, for tilting reverberatory furnaces capable of completely removing furnace contents between batches. An owner or operator of a tilting reverberatory furnace capable of completely removing furnace contents between batches who wishes to change operating modes must conduct performance tests in accordance with §§ 63.1511 and 63.1512 to demonstrate to the permitting authority for major sources, or the Administrator for area sources that compliance can be achieved under group 1 modes. Operating parameters relevant to group 1 operation must be established during the performance test.
(1) Operators of major sources must conduct performance tests for PM, HCl, and D/F (and HF for uncontrolled furnaces) according to the procedures in § 63.1512 if compliance has not been previously demonstrated for this operating mode. Controlled group 1 furnaces must conduct performance tests with the capture system and control device operating normally if compliance has not been previously demonstrated for the operating mode. Controlled group 1 furnaces must conduct performance tests according to the procedures in § 63.1512(d) with the capture system and control device operating normally. Uncontrolled group 1 furnaces must conduct performance tests according to the procedures in § 63.1512(e) without operating a control device. Performance tests must be repeated at least once every 5 years to demonstrate compliance for each operating mode.
(i) Testing under this paragraph must be conducted in accordance with § 63.1511(b)(1) in both modes.
(ii) Operating parameters must be established during these tests, as required by § 63.1511(g).
(iii) The emission factors for this mode of operation for use in the demonstration of compliance with the emission limits for SAPUs specified in § 63.1505(k), must be determined.
(2) Operators of area sources must conduct performance tests for D/F according to the procedures in § 63.1512 if compliance has not been previously demonstrated for this operating mode. Controlled group 1 furnaces must conduct performance tests according to the procedures in § 63.1512(d) with the capture system and control device operating normally. Uncontrolled group 1 furnaces must conduct performance tests according to the procedures in § 63.1512(e) without operating a control device.
(i) The performance test must be conducted in accordance with § 63.1511(b)(1) under representative conditions expected to produce the highest expected level of D/F in the group 1 mode.
(ii) Operating parameters must be established during these tests, as required by § 63.1511(g).
(iii) The D/F emission factor for this mode of operation for use in the demonstration of compliance with the emission limits for SAPUs specified in § 63.1505(k) must be determined.
(3) To change modes of operation from a group 1 furnace to a group 2 furnace, the owner or operator must perform the following before turning off or bypassing the control device:
(i) Completely remove all aluminum from the furnace;
(ii) Change the label on the furnace to reflect group 2 operation;
(iii) Use only clean charge; and
(iv) Use no reactive flux.
(4) To change modes of operation from a group 2 furnace to a group 1 furnace, the owner or operator must perform the following before adding other than clean charge and before adding reactive flux to the furnace:
(i) Change the label on the furnace to reflect group 1 operation;
(ii) Direct the furnace emissions to the control device, if it is equipped with a control device;,
(iii) If the furnace is equipped with a control device, turn on the control device and begin lime addition to the control device at the rate established for group 1 mode; and
(iv) Ensure the control device is operating properly.
(5) In addition to the recordkeeping requirements of § 63.1517, the owner or operator must maintain records of the nature of each mode change (group 1 to group 2, or group 2 to group 1), the time the furnace operating mode change is initiated, and, if the furnace is equipped with a control device, the time the exhaust gas is diverted from control device to bypass or from bypass to control device.
(e) Limit on frequency of changing furnace operating mode. (1) A change in furnace operating mode, which consists of changing from one furnace operating mode to another and subsequently back to the initial operating mode, as provided in paragraphs (a) through (d) of this section, may not be done more frequently than 4 times in any 6-month period unless you receive approval from the permitting authority or Administrator for additional changes pursuant to paragraph (e)(2).
(2) If additional changes are needed, the owner or operator must apply in advance to the permitting authority, for major sources, or the Administrator, for area sources, for approval of the additional changes in operating mode.