Secondary Aluminum Production Industry Maximum Achievable Control Technology (MACT) Training

1. Secondary AluminumProduction Industry Maximum Achievable Control Technology (MACT) Training 40 CFR Part 63 Subpart RRR

2. Secondary aluminum plants recover aluminum from scrap such as beverage cans, foundry returns, other aluminum scrap, and dross. Air toxics are released from preprocessing operations

3. such asaluminum scrap shredding, thermal chip drying, scrap drying/decoating/ delacquering; and furnace operations (i.e., melting, holding, refining, fluxing, or alloying).

5. Secondary Aluminum Production Facility Any establishment using clean charge, post-consumer aluminum scrap, aluminum ingots, aluminum foundry returns, dross from

6. aluminum production, or molten aluminum as the raw material and performing one or more of the following processes:

7. Scrap shredding Scrap drying/delacquering/decoating Thermal chip drying Furnace operations In-line fluxing Dross cooling

8. Example Secondary Aluminum Facility

10. Secondary Aluminum Sectors • Secondary aluminum companies • Sweat furnace operators • May include die casters & foundries

11. Estimated Number of Secondary Aluminum Sources Potentially Affected • Approximately 400 (86 major) • 320 die casting companies • 1500 foundries • 1650 sweat furnaces

13. Types of Hazardous Air Pollutants (HAP’s) Emitted • Organic HAP’s (e.g. benzene, styrene, dioxins, and furans)

14. Inorganic gaseous HAP’s (e.g. hydrogen chloride, hydrogen flouride, and chlorine) • Particulate HAP metals (e.g. arsenic, lead, and chromium)

16. History of Secondary Aluminum Production National Emission Standards for Hazardous Air Pollutants (NESHAP) • NESHAP was proposed, 2/11/99

17. History Cont’d.: • Final rule was promulgated, 3/23/00 • Direct final rule; amendments, 6/14/02 • Final rule; amendments, 9/24/02 • Final rule amendments 12/30/03

19. Regulated Entities under Current Rule • Facilities that perform secondary smelting and alloying of aluminum

20. Secondary aluminum production facility affected sources collocated at: • Aluminum sheet, plate, and foil manufacturing facilities • Aluminum extruded product manufacturing facilities

21. Other aluminum rolling and drawing facilities • Primary aluminum production facilities • Aluminum die casting facilities • Aluminum foundry facilities

23. Regulated HAPs • Particulate matter emissions (PM) (surrogate for HAP metals) • Total hydrocarbon (THC) emissions - surrogate for HAP organics)

24. Hydrogen chloride (HCl) emissions - a HAP and a surrogate for inorganic HAP’s including hydrogen fluoride (HF) and chlorine (Cl2)

25. Dioxin and furan emissions at secondary aluminum production facilities that are major or area sources

27. Projected Environmental Benefits • Reduce HAP emissions by about 12,420 tons/year, a 70% reduction from current levels • Reduce HCl emissions by 12,370 tons/year, a 73% reduction

28. Projected Environmental Benefits (Continued) • Reduce metal emissions by 40 tons/year, a 60% reduction • Reduce dioxin/furan emissions by 0.88 pounds/year, a 79% reduction

29. Projected Environmental Benefits (Continued) • Reduce polycyclic organic matter emissions by 10 tons/year, a 25% reduction • Reduce PM emissions by 3,185 tons/year, a 30% reduction

31. Rule Requirements • Emission standards and operating requirements • Monitoring and compliance provisions • Notifications, reports, and records

33. Applicability and Description of Affected Units§63.1500

34. Applicability and Description of Affected Units • Secondary aluminum production operations • Affected sources Secondary Aluminum Website: http://www.epa.gov/ttn/uatw/alum2nd.html

36. Secondary Aluminum NESHAPS Applicability Flowcharts

42. Secondary Aluminum Production Operations • Preprocessing of scrap aluminum (size reduction, removal of oils, coatings, and other contaminants)

43. Furnace operations (melting, in-furnace fluxing/refining, tapping) • Additional refining (in-line fluxing) • Cooling of dross

45. Processing of Scrap Aluminum • Crushing, shredding, and grinding • Drying • Heating in a dryer or kiln • Heating in a sweat furnace

46. Crushing, Shredding, and Grinding To reduce the size of scrap aluminum Emissions: Particulate matter (PM) and HAP metals generated as dust from coatings & other contaminants

47. Chip Dryers To reduce the size of scrap aluminum Emissions: Particulate matter (PM) & HAP metals generated as dust from coatings and other contaminants

48. Applicability and Description of Affected Units • Secondary aluminum production operations • Affected sources

50. Secondary Aluminum Production Operations • Preprocessing of scrap aluminum (size reduction, removal of oils, coatings, and other contaminants)