Section 226.100  Severability

 

If any Section, subsection, or clause of this Part is found invalid, that finding shall not affect the validity of this Part as a whole or any Section, subsection, or clause not found invalid.

 

Section 226.105  Scope and Organization

 

a)         This Part sets standards and limitations for emissions of lead from stationary sources.

 

b)         Notwithstanding the provisions of this Part, the air quality standards contained in 35 Ill. Adm. Code 243 must not be violated.

 

Section 226.110  Abbreviations and Acronyms

 

The following abbreviations and acronyms are used in this Part:

 

Act                  Illinois Environmental Protection Act, 415 ILCS 5

CPMP             continuous parametric monitoring plan

CDMP             control device monitoring plan

fpm                  feet per minute

FV                   facial velocity

gr/dscf             grains per dry standard cubic foot

Hg                   mercury

m/hr                 meters per hour

mg/l                 milligrams per liter

OSHA             Occupational Safety & Health Administration

Pb                    lead

USEPA           United States Environmental Protection Agency

 

Section 226.115  Definitions

 

The following definitions apply for the purposes of this Part.  Unless otherwise defined in this Section or a different meaning for a term is clear from its context, all terms not defined in this Part shall have the meaning given them in the Act and in 35 Ill. Adm. Code 211.

 

"Agency" means the Illinois Environmental protection Agency.

 

"Agglomerating furnace" means a furnace used to melt into a solid mass flue dust that is collected from a baghouse.

 

"Alloy" means a mixture or metallic solid solution composed of 2 or more elements.

 

"Alloying" means the process of combining or mixing metals or other substances in molten form for the purpose of producing a particular alloy.

 

"Alloying and refining kettle" means an open-top vessel that is heated from below and contains molten lead for the purpose of alloying and refining the lead.  These kettles include, but are not limited to, pot furnaces, receiving kettles, and holding kettles.

 

"Battery breaking area" means the source location at which lead-acid batteries are broken, crushed, disassembled, or separated into components.

 

"Casting" means the process of transferring molten lead-containing metal to a mold.

 

"Dross" means solid impurities removed from molten lead in lead kettles.

 

"Dryer" means a chamber that is heated and that is used to remove moisture from lead-bearing materials other than lead shot.

 

"Existing lead emission unit" means a lead emission unit in existence before January 1, 2015 at a nonferrous metal production facility.

 

"Housekeeping activities" means regular cleaning or maintenance activities conducted to reduce fugitive emissions from production areas.

 

"Induction furnace" means an electrical furnace used for heating metal by electromagnetic induction.

 

"Lead" means elemental lead or alloys in which the predominant component is lead (i.e., lead being more prevalent than any other single component).

 

"Lead-bearing scrap" or "lead-containing material" or "lead-containing metal" or "lead-containing wastes" or "lead particulate" means scrap or material or metal or wastes or particulate with a lead content equal to or greater than 5 mg/l as measured by EPA Method 1311, incorporated by reference in Section 226.120.

 

"Lead emission unit" means any process that emits lead, including, but not limited to, battery breaking areas; material handling areas; dryers and dryer areas; channel furnaces and channel furnace areas; coreless furnaces and coreless furnace areas; reverberatory furnaces and reverberatory furnace areas; rotary furnaces and rotary furnace areas; agglomerating furnaces and agglomerating furnace areas; kettles and casting areas; lead taps, slag taps, and molds during tapping; and areas where dust from fabric filters, sweepings, or used fabric filters are processed.

 

"Lead kettle" means a vessel that is heated from below and is used for the purpose of melting refined lead. 

 

"Lead tap" means the pouring hole though which molten lead flows from a kettle or furnace.

 

"Leak detection system" means an instrument that is capable of monitoring relative particulate matter (dust) loadings in the exhaust of a particulate control in order to detect leaks in the particulate control.  A leak detection system includes, but is not limited to, an instrument that operates on triboelectric, light scattering, transmittance, or other effect to monitor relative particulate matter loadings.

 

"Materials handling area" means any area in which lead-containing materials (including, but not limited to, broken battery components, flue dust, and dross) are handled in between process steps. These areas may include, but are not limited to, areas in which lead-bearing scrap, lead-containing materials, lead-containing metal, or lead-containing wastes are prepared.

 

"Materials storage area" means any area in which lead-containing materials (including, but not limited to, broken battery components, flue dust, and dross) are stored in between process steps.  These areas may include, but are not limited to, areas in which lead-bearing scrap, lead-containing materials, lead-containing metal, or lead-containing wastes are stored in open piles, bins, or tubs.

 

"Mold cooling" means the process of cooling a mold containing hot metal by direct contact of the mold, but not the hot metal itself, with cooling water or other liquids.

 

"Natural draft opening" means any permanent opening, including doors and windows, in a total enclosure that remains open during operation of the lead emissions unit in the enclosure or enclosures and is not connected to a duct in which a fan is installed.

 

"New lead emission unit" means a lead emission unit constructed on or after January 1, 2015, at a nonferrous metal production facility.

 

"Nonferrous metal" means a metal that is not an iron or steel alloy; these metals may include alloys of aluminum, copper, lead, and zinc.

 

"Nonferrous metal production facility" means any source that is alloying, refining, or casting nonferrous metal or manufacturing nonferrous metal products, and where the source includes lead in their alloys or products by design.

 

"Production area" means an indoor space at a nonferrous metal production facility where lead emission units are operated.

 

"Quenching" means the process of cooling hot metal other than lead shot by direct contact of the metal with cooling water or other liquids.

 

"Refined lead" means a material composed of lead alloys of a specified composition from an onsite or offsite lead refining operation.

 

"Refining" means the process of removing impurities or oxides from a metal or metal alloy.

 

"Reverberatory furnace" means a refractory-lined furnace that uses one or more flames to heat the walls and roof of the furnace and lead-bearing scrap to such a temperature that lead compounds are chemically reduced to elemental lead metal.

 

"Rotary furnace" or "rotary reverberatory furnace" means a furnace consisting of a refractory-lined chamber that rotates about a horizontal axis and that uses one or more flames to heat the walls of the furnace and lead-bearing scrap to such a temperature that lead compounds are chemically reduced to elemental lead metal.

 

"Section Manager" means Manager of Agency's Bureau of Air, Compliance Section.

 

"Slag tap" means the pouring hole through which slag is removed from a kettle or furnace.

 

"Tap" means the pouring hole through which molten metal flows from a kettle or furnace.

 

"Tapping" means opening the tap.

 

"Total enclosure" means a complete enclosure with walls and a roof  designed to minimize exposure to the elements and to maximize containment of emissions from one or more lead emission units and that meets the following performance standards: the average facial velocity of air flowing into the enclosure through all natural draft openings during operation of lead emission units in each total enclosure in any one hour period must be at least 200 fpm (3,600 m/hr) or average negative pressure value of 0.007 inches of water (0.013 mm Hg) must be maintained inside the enclosure over any one hour period. 

 

"Valid test run" means a completed test run conducted in accordance with a testing protocol submitted to the Agency, as required under Section 226.175(f).

 

Section 226.120  Incorporations by Reference

 

The following materials are incorporated by reference.  These incorporations do not include any later amendments or editions.

 

a)         75 FR 71033-01, Air Quality Designations for the 2008 Lead (Pb) National Ambient Air Quality Standards (November 22, 2010).

 

b)         76 FR 72097-01, Air Quality Designations for the 2008 Lead (Pb) National Ambient Air Quality Standards (November 22, 2011).

 

c)         40 CFR 60, appendix A, Method 29 (2012).

 

d)         40 CFR 60, appendix A, Methods 1, 1A (2012).

 

e)         40 CFR 60, appendix A, Methods 2, 2A, 2C, and 2D (2012).

 

f)         40 CFR 60, appendix A, Methods 3, 3A (2012).

 

g)         40 CFR 60, appendix A, Method 4 (2012).

 

h)         40 CFR 60, appendix A, Method 12 (2012).

 

i)          USEPA's Emission Measurement Center Guideline Document (GD-042), Preparation and Review of Site-Specific Emission Test Plans, Revised March 1999.

 

j)          40 CFR 260.11(c)(3)(v) and 261, Method 1311 (2012).

 

k)         OSHA.  The following method from the Occupational Safety & Health Administration, Methods Development Team, Industrial Hygiene Chemistry Division, OSHA Salt Lake Technical Center, Sandy UT 84070-6406, (801) 233-4900: OSHA Method 1006 (approved January 2005).

 

Section 226.125  Applicability

 

The provisions of this Part apply to all nonferrous metal production facilities located in the following areas in Illinois designated nonattainment for the 2008 lead National Ambient Air Quality Standards by USEPA:

 

            a)         Part of Madison County, specifically the area bounded by Granite City Township and Venice Township, 75 FR 71033-01 (November 22, 2010), as incorporated by reference in Section 226.120; and

 

b)         Part of Cook County, specifically, the area bounded             by Damen Avenue on the west, Roosevelt Road on the north, the Dan Ryan Expressway on the east, and the Stevenson Expressway on the south, 76 FR 72097-01 (November 22, 2011), as incorporated by reference in Section 226.120.

 

Section 226.130  Compliance Date

 

a)         For an existing lead emission unit that is subject to this Part, compliance with these requirements by an owner or operator of the unit is required by no later than January 1, 2015.

 

b)         For a new lead emission unit that is subject to this Part, compliance with these requirements by an owner or operator of the unit is required by the date on which the unit initially begins operation.

 

Section 226.140  Lead Emission Standards

 

a)         For all alloying and refining kettles located at a source subject to this Part (see Section 226.125), each lead emission unit must be:

 

1)         Equipped with a capture system (including covers, hoods, ducts, and fans) that is vented to a control device for lead particulates.  The emissions of lead into the atmosphere from each control device must not exceed 0.0010 gr/dscf; and

 

2)         Operated in a total enclosure pursuant to Section 226.155.  The entire gas stream collected by each total enclosure must only be ducted to a control device such that the emissions of lead into the atmosphere from each control device must not exceed 0.00010 gr/dscf. 

 

b)         For reverberatory furnaces or rotary furnaces located at a source subject to this Part (see Section 226.125), each lead emission unit must be:

 

1)         Equipped with a capture system (including hoods, ducts, and fans) that is vented to a control device for lead particulates.  The emissions of lead into the atmosphere from each control device must not exceed 0.00010 gr/dscf; and 

 

2)         Operated in a total enclosure pursuant to Section 226.155.  The entire gas stream collected by each total enclosure must only be ducted to a control device such that the emissions of lead into the atmosphere from each control device must not exceed 0.00010 gr/dscf. 

 

c)         Notwithstanding the provisions for total enclosure in subsections (a) and (b), any emissions of lead exiting an uncontrolled stack during quenching or mold cooling operations must not exceed 0.00010 gr/dscf.  Quenching operations shall be limited to no more than 6 hours per associated unit in any 24 hour period.

 

d)         For induction furnaces located at a source subject to this Part (see Section 226.125), each lead emission unit must be equipped with a capture system (including hoods, ducts, and fans) that is vented to a control device for lead particulates.  The emissions of lead into the atmosphere from each control device must not exceed 0.000010 gr/dscf.

 

e)         For all other furnaces, lead kettles, or any other operation subject to this Part (see Section 226.125), but not subject to subsection (a), (b), or (d), each lead emission unit must be equipped with a capture system (including ducts, fans, and hoods or covers) that is vented to a control device for lead particulates.  The emissions of lead into the atmosphere from each control device must not exceed 0.00010 gr/dscf. 

 

f)         Any source subject to the requirements of this Part (see Section 226.125) must operate pursuant to a lifetime operating permit, a federally enforceable State operating permit, a Clean Air Act Permit Program permit, or conditions within a construction permit.

 

Section 226.150  Operational Monitoring for Control Device

 

a)         The owner or operator of a lead emission unit subject to this Part must install, maintain, and operate parametric monitoring equipment that consists of a pressure differential system to measure the pressure drop across each control device required by Section 226.140.  Data from this instrumentation must be recorded as follows:

 

1)         Data must be automatically recorded every minute during operation of any lead emission unit subject to Section 226.140(a) or (b).

 

2)         Data must be recorded at least once every 8 hours during operation of any lead emission unit subject to Section 226.140(d) or (e).

 

3)         If the control device used to control lead emission units subject to Section 226.140(a) or (b) is the same as the control device used to control other lead emission units subject to Section 226.140(d) or (e), the requirements in subsection (a)(1) apply to the control device.

 

b)         The owner or operator of a lead emission unit subject to this Part and using a baghouse or other filter system to control units subject to the total enclosure requirements of Section 226.155 must install, maintain, and operate parametric monitoring equipment that consists of a leak detection system.  The leak detection system must be installed at the outlet of the baghouse or other filter system.

 

c)         The owner or operator of a lead emission unit subject to this Part must develop and maintain a Control Device Monitoring Plan.  The CDMP must be submitted for review and approval to the Section Manager by the compliance date specified in Section 226.130 and within 30 days after any changes are made to the plan. The CDMP must be amended by the owner or operator of a lead emission unit subject to this Part as necessary to ensure that it is kept current.

 

d)         The CDMP must include procedures to investigate and determine the cause of changes in pressure that could indicate a leak or other problem and, if applicable, every alarm from the leak detection system.  The procedures must also include a means to determine appropriate corrective actions and preventative measures to address the pressure changes and to avoid future alarms.  The owner or operator of a lead emission unit subject to this Part must operate and maintain each pressure differential system and each leak detection system according to the CDMP at all times.

 

Section 226.155  Total Enclosure

 

a)         An owner or operator of a lead emission unit subject to this Part must install, maintain, and operate one or more total enclosures to minimize fugitive emissions from the operations listed in subsections (a)(1) through (6) at all times that the applicable lead emission unit in the total enclosure is operating or housekeeping activities are being performed.  The total enclosure must meet the requirements specified in subsections (b) through (e).

 

1)         Battery breaking areas.

 

2)         Dryer and dryer areas, including transition pieces, charging hoppers, chutes, and skip hoists conveying any lead-containing material.

 

3)         Reverberatory furnaces or rotary furnaces charging any lead-containing material and the associated reverberatory furnace areas or rotary furnace areas, including any associated lead taps, slag taps, and molds during processing. 

 

4)         Alloying and refining kettles and associated areas, including any associated lead taps, slag taps, and molds during processing. 

 

5)         Areas where dross, dust from fabric filters, sweepings, or used fabric filters are handled, except for areas where all such materials are in closed, leak-proof containers at all times.

 

6)         Material handling areas for any lead-containing materials.  The following areas are exempt from the total enclosure requirements unless the areas listed also contain operations listed in subsections (a)(1) through (5):

 

A)        Those areas where refined lead is melted and cast;

 

B)        Those areas where spent refractory brick is stored in closed containers prior to and after crushing;

 

C)        Those areas where ladle repairs take place; or

 

D)        Those areas where lead-bearing scrap is sorted and handled, if the area is enclosed and equipped with a capture system ducted to a control device subject to the requirements of Section 226.140(e) during all sorting and handling activities and if the scrap is stored in closed containers at all other times.

 

b)         An owner or operator of a lead emission unit subject to this Part must duct the gas stream collected by each total enclosure to a control device that meets the applicable requirements of Section 226.140.

 

c)         The total enclosure must be maintained and operated with an inward flow of air through all natural draft openings while the lead emission unit applicable to the operation listed in subsection (a) in the total enclosure is operating.  The average facial velocity of air flowing into the enclosure through all natural draft openings during operation of lead emission units in each total enclosure in any one hour period must be at least 200 fpm (3,600 m/hr) or an average negative pressure value of 0.007 inches of water (0.013 mm Hg) must be maintained inside the enclosure over any one hour period.

 

d)         The total enclosure required by subsection (a) must be maintained at any opening, including, but not limited to, vents, windows, passages, doorways, bay doors, and roll-ups while lead emission units in the total enclosure or enclosures are operating, except as needed for temporary access to conduct manufacturing operations (e.g., during load-in and load-out of materials or passage of personnel or equipment).

 

e)         The total enclosure must be free of cracks, gaps, corrosion, or other deterioration that could cause or result in dust being emitted to the atmosphere through those openings, except that the total area of all natural draft openings must not exceed 5 percent of the surface area of the total enclosure's walls, floor, and ceiling.

 

Section 226.160  Operational Measurement for Total Enclosure

 

a)         An owner or operator of a lead emission unit subject to the total enclosure requirement of Section 226.155 must measure the total area of all natural draft openings and the total surface area of the total enclosure.

 

b)         An owner or operator of a lead emission unit subject to the total enclosure requirement of Section 226.155 must measure the facial velocity of air flowing through all natural draft openings using the following equation while any lead emission unit applicable to the operation listed in Section 226.155(a) is operating.  Values for Q_o and Q_I must be obtained by means of testing pursuant to subsection (b)(1) or monitoring pursuant to subsection (b)(2):

 

 

Where:

 

Q0	=	the sum of volumetric flow from all gas streams exiting the total enclosure through the control device.
QI	=	the sum of the volumetric flow from all gas streams into the total enclosure through a forced makeup air duct; zero if there is no forced makeup air into the total enclosure.
An	=	total area of all natural draft openings in the total enclosure.

 

1)         An owner or operator of a lead emission unit subject to the total enclosure requirement of Section 226.155 must conduct testing to determine the values for Q_o and Q_I at the same time as any emissions testing is conducted pursuant to Section 226.175; or

 

2)         An owner or operator of a lead emission unit subject to the total enclosure requirement of Section 226.155 must install, maintain, and operate a flow monitor at the outlet of each control device required by Section 226.140 to measure the volumetric flow from all gas streams exiting the total enclosure through the control device (or the final control device emitting to the atmosphere if the source has more than one control device in series). This volumetric flow data must be monitored and automatically recorded every minute.

 

c)         As an alternative to compliance with the requirements of subsection (b), an owner or operator of a lead emission unit subject to the total enclosure requirement of Section 226.155 must install, operate, and maintain instrumentation to monitor the pressure differential between the interior and exterior of the enclosure, measured in inches of water, to demonstrate compliance with the differential pressure requirements in Section 226.155(c).  This instrumentation must be located and designed to operate in accordance with all of the requirements of subsections (c)(1) through (6):

 

1)         An owner or operator of a total enclosure that has a total ground surface area of 10,000 square feet or more must install and maintain a minimum of one building digital differential pressure monitoring system at each of the following 3 walls in each total enclosure:

 

A)        The leeward wall.

 

B)        The windward wall.

 

C)        An exterior wall that connects the leeward and windward wall at a location defined by the intersection of a perpendicular line between a point on the connecting wall and a point on its furthest opposite exterior wall, and intersecting within plus or minus 10 meters of the midpoint of a straight line between the 2 other monitors specified. The midpoint monitor must not be located on the same wall as either of the other 2 monitors.

 

2)         An owner or operator of a total enclosure that has a total ground surface area of less than 10,000 square feet must install and maintain a minimum of one building digital differential pressure monitoring system at the leeward wall of each total enclosure.

 

3)         Each digital differential pressure monitoring system must be certified by the manufacturer to be capable of measuring and displaying negative pressure in the range of 0.001 to 0.11 inches of water (0.002 to 0.2 mm Hg) with a minimum accuracy of plus or minus 0.001 inches of water (0.002 mm Hg).

 

4)         Each digital differential pressure monitoring system must be equipped with a continuous recorder.

 

5)         Each digital differential pressure monitoring system must be calibrated in accordance with manufacturer's specifications at least once every 12 calendar months or more frequently if recommended by the manufacturer.

 

6)         Each digital differential pressure monitoring system must be equipped with a backup, uninterruptible power supply to ensure continuous operation of the monitoring system during a power outage.

 

d)         An owner or operator of a lead emission unit subject to the total enclosure requirement of Section 226.155 must develop and maintain a Continuous Parametric Monitoring Plan containing the information required in subsection (d)(1), (2), or (3).  The CPMP must be submitted for review and approval to the Section Manager by the compliance date specified in Section 226.130 and within 30 days after any changes are made to the plan.  The CPMP must be amended by the owner or operator of a lead emission unit subject to this Part as necessary to ensure that it is kept current.  The owner or operator of a lead emission unit subject to this Part must conduct monitoring in accordance with the CPMP at all times.

 

1)         If electing to comply with the facial velocity requirement in Section 226.155(c) using the total enclosure measurement method in subsection (b)(1), the CPMP must contain the information required by subsections (d)(1)(A) through (D).

 

A)        The CPMP must identify the operating parameters to be monitored on an ongoing basis to ensure that the facial velocity measured during the most recent compliance test is maintained, explain why those parameters are appropriate for demonstrating ongoing compliance, and identify the specific monitoring procedures for each parameter.

 

B)        The CPMP must specify limits or ranges of values of the operating parameters listed pursuant to subsection (d)(1)(A) that demonstrate compliance with the facial velocity requirements in Section 226.155(c).  These limits or ranges must represent the conditions indicative of proper operation and maintenance of the facial velocity through all natural draft openings during operation of lead emission units in each total enclosure.

 

C)        The CPMP must specify data to be recorded to demonstrate compliance with the facial velocity requirements in Section 226.155(c), as well as the recording frequency and methodology.

 

D)        The CPMP must specify the information to be reported to the Agency to demonstrate compliance with the facial velocity requirements in Section 226.155(c). This information must include, but is not limited to, all information to be submitted as part of the semiannual reports required by Section 226.185(n), as well as the reporting frequency. 

 

2)         If electing to comply with the facial velocity requirement in Section 226.155(c) using the total enclosure monitoring method in subsection (b)(2), the CPMP must contain the information required by subsections (d)(2)(A) through (C).

 

A)        The CPMP must specify limits or ranges of values of the sum of volumetric flow from all gas streams exiting the total enclosure through the control device and the sum of the volumetric flow from all gas streams into the total enclosure through a forced makeup air duct. These limits or ranges must represent the conditions indicative of proper operation and maintenance of the facial velocity through all natural draft openings during operation of lead emission units in each total enclosure.

 

B)        The CPMP must specify data to be recorded to demonstrate compliance with the facial velocity requirements in Section 226.155(c), as well as the recording frequency and methodology.

 

C)        The CPMP must specify the information to be reported to the Agency to demonstrate compliance with the facial velocity requirements in Section 226.155(c). This information must include, but is not limited to, all information to be submitted as part of the semiannual reports required by Section 226.185(n), as well as the reporting frequency. 

 

3)         If electing to comply with the average differential pressure requirement in Section 226.155(c) using the total enclosure measurement method in subsection (c), the CPMP must contain the information required by subsections (d)(3)(A) through (C).

 

A)        The CPMP must identify the locations and design of each differential pressure monitoring instrumentation demonstrating compliance with the requirements of subsection (c) to ensure that the average differential pressure is measured properly, explain why those locations are appropriate for demonstrating ongoing compliance, and provide a schedule for instrumentation calibration.

 

B)        The CPMP must specify data to be recorded to demonstrate compliance with the average differential pressure requirements in Section 226.155(c), as well as the recording frequency and methodology.

 

C)        The CPMP must specify the information to be reported to the Agency to demonstrate compliance with the average differential pressure requirements in Section 226.155(c). This information must include, but is not limited to, all information to be submitted as part of the semiannual reports required by Section 226.185(n), as well as the reporting frequency.

 

e)         The owner or operator of a lead emission unit subject to this Part electing to change the total enclosure measurement method for an existing lead emission unit subject to the total enclosure requirements of Section 226.155 must notify the Section Manager of the measurement method by which the owner or operator will comply with the requirements of this Section.  The notification must include an updated CPMP complying with the appropriate requirements for the new measurement method and must occur at least 30 days prior to changing the method.

 

Section 226.165  Inspection

 

a)         An owner or operator of a lead emission unit subject to this Part must inspect control devices for the control of lead particulate at least once per month.  The inspections of control devices must include all structures that comprise the infrastructure of the affected control device and other structures that are necessary for the affected control device to function in its intended capacity. 

 

b)         An owner or operator of a lead emission unit subject to this Part must inspect all total enclosures for proper operation and physical integrity at least once per month.

 

c)         An owner or operator of a lead emission unit subject to this Part must maintain and repair any control device and total enclosure, including all structures that comprise the infrastructure of the affected control device and total enclosure, as necessary to ensure proper and compliant operation.

 

Section 226.170  Lead Fugitive Dust Operating Program

 

a)         An owner or operator of a lead emission unit subject to this Part must operate at all times according to a lead fugitive dust operating program that describes in detail the measures that are implemented to minimize lead fugitive dust emissions from the areas, activities, or events listed in subsections (a)(1) through (7):

 

1)         Source roadways;

 

2)         Source buildings housing lead emission units;

 

3)         Battery storage areas;

 

4)         Equipment maintenance for equipment used in connection with the processing or handling of lead-containing materials;

 

5)         Material storage and material handling areas for lead-containing materials, excluding areas where only finished products are stored or handled;

 

6)         Spillage of lead-containing material; and

 

7)         Sorting or handling of lead-bearing scrap subject to Section 226.155(a)(6)(D).

 

b)         An owner or operator of a lead emission unit subject to this Part must develop and maintain a lead fugitive dust operating program.  The lead fugitive dust operating program must be submitted for review and approval to the Section Manager by the compliance date specified in Section 226.130 and within 30 days after any changes are made to the program.  The lead fugitive dust operating program must be amended by the owner or operator of a lead emission unit subject to this Part as necessary to ensure that it is kept current.  The owner or operator of a lead emission unit subject to this Part must operate according to the lead fugitive dust operating program at all times.

 

c)         The measures specified in the lead fugitive dust operating program must, at a minimum, include the requirements specified in subsections (c)(1) through (8).

 

1)         The lead fugitive dust operating program must meet all requirements of 35 Ill. Adm. Code 212.Subpart K.

 

2)         Cleanings must be performed by wet wash or by a vacuum cleaner equipped with a filter rated by the manufacturer to achieve at least 99.97 percent capture efficiency for 0.3 micron particles in a manner that does not generate fugitive dust. When performing cleanings by wet wash, a wet sweeper must employ a water flush followed by sweeping.  Cleanings must be performed at the following frequencies:

 

A)        Cleanings must be performed at least once every 24 hour period that a lead emission unit in an associated production area is operating and immediately before termination of negative pressure in any total enclosure required by Section 226.155 for all production areas.

 

B)        Cleanings of scrap sorting and handling areas subject to Section 226.155(a)(6)(D) must be performed directly after sorting or handling is completed and before shutdown of the required capture and control equipment.

 

C)        Cleanings must be performed at least once every 7 calendar days for all areas where lead-containing wastes generated from housekeeping activities are stored, disposed of, recovered, or recycled.

 

D)        Cleanings of all areas must be performed no later than one hour after detection of any accidental release of dust containing lead.

 

3)         All areas within the property boundaries subject to vehicle traffic must be paved and must be cleaned at least once every 7 calendar days to remove dust or other accumulated material from paved areas within the property boundaries. The cleaning must be performed using a vacuum truck with a filter rated by the manufacturer to achieve at least 99.97 percent capture efficiency for 0.3 micron particles, or a wet sweeper, or a combination thereof.  Limited access and limited use roadways such as unpaved roads to remote locations on the property are exempt from this requirement if they are used infrequently (no more than one round trip per day).

 

4)         Broken batteries must only be stored in a total enclosure.  Any battery storage areas that are not located in a total enclosure must be inspected at least once every 7 calendar days.  Within 72 hours after identification, any broken batteries must be moved to a total enclosure and all residue from broken batteries must be collected and the area must be cleaned.

 

5)         All maintenance activities that could generate dust containing lead must be performed in a manner that minimizes emissions of dust, including, but not limited to, the use of a vacuum cleaner equipped with a filter rated by the manufacturer to achieve at least 99.97 percent capture efficiency for 0.3 micron particles or the use of wet suppression sufficient to prevent dust formation.

 

6)         All collected dross and dust must be stored and transported within closed conveyor and storage systems or in closed, leak-proof containers.  All other lead-containing material must be contained and covered for transport outside of a total enclosure in a manner that minimizes spillage or dust formation.  The transport outside of a total enclosure of scrap metal, spent refractory brick, ladles, and finished product must be addressed in the lead fugitive dust operating program so as to minimize the spillage of lead-containing material or the formation of dust.

 

7)         Replacement of control equipment filter bags must be conducted in the manner specified in this subsection (c)(7).  All vacuuming referenced in this subsection (c)(7) must be performed by a vacuum cleaner equipped with a filter rated by the manufacturer to achieve at least 99.97 percent capture efficiency for 0.3 micron particles:

 

A)        Used filter bags must be rolled-up and placed into sealed plastic bags or barrels prior to removal from the filter unit;

 

B)        The filter unit floors, the dirty and clean plenum side, must be vacuumed of dust residues immediately following removal activity;

 

C)        The ground surface in and around the filter unit must be vacuumed immediately following the complete installation of new filter bags to remove any and all dust residue; and

 

D)        In those instances in which filter bag replacement requires more than one operational day, the requirements of subsection (c)(7)(C) must be completed just prior to the end of each operational day.

 

8)         Measures, including, but not limited to, those specified in subsections (c)(1) through (7) must be implemented to minimize the tracking of dust containing lead out of the total enclosure by personnel or by equipment used in handling the material.

 

d)         All grounds on any source subject to this Part must be paved or oiled, or have sufficient groundcover planted, to minimize the amount of wind-blown dust leaving the property.

 

e)         The applicability of this Part to the owner or operator of a lead emission unit does not exempt the owner or operator from compliance with the applicable requirements in 35 Ill. Adm. Code 212.

 

Section 226.175  Emissions Testing

 

a)         For an existing lead emission unit that is subject to this Part, testing of lead emissions at control devices required by Section 226.140 must be conducted by January 1, 2015.

 

b)         Testing Completed Prior to January 1, 2015

 

1)         The owner or operator of an existing lead emission unit that is subject to this Part and that performed all testing necessary to demonstrate compliance with Section 226.140 prior to January 1, 2015 is not required to retest pursuant to subsection (a) if:

 

A)        On or after January 1, 2011, the owner or operator of an existing lead emission unit that is subject to this Part performed all testing necessary to demonstrate compliance with Section 226.140;

 

B)        The owner or operator submitted the results of the tests to the Agency, and the tests were not rejected by the Agency;

 

C)        The same capture system and control device or devices tested under subsection (b)(1)(A) are still being used by the subject lead emission unit; and

 

D)        The owner or operator complies with all recordkeeping and reporting requirements in Section 226.185(i).

 

2)         Nothing in this subsection (b), however, shall limit the ability of the Agency or the USEPA to require that the owner or operator perform testing pursuant to subsection (e).

 

c)         For a new lead emission unit that is subject to this Part, testing of lead emissions at control devices required by Section 226.140 must be conducted within 60 days after achieving maximum operating rate, but no later than 180 days after initial startup of the new lead emission unit in accordance with this Section.

 

d)         The owner or operator of a lead emission unit subject to this Part must have subsequent emissions tests conducted at least once every 5 years.  The owner or operator of a lead emission unit that tested prior to January 1, 2015, in accordance with subsection (b) must use the original test date as the beginning of this 5-year period.

 

e)         When, as determined by the Agency or USEPA, it is necessary to conduct testing to demonstrate compliance with Section 226.140, the owner or operator of a lead emission unit subject to this Part must, at his or her own expense, have the test conducted in accordance with the applicable test methods and procedures specified in this Section within 90 days after receipt of a notice to test from the Agency or USEPA, unless that notice specifies an alternative testing deadline.

 

f)         The owner or operator of a lead emission unit subject to the emissions testing requirements of this Section must conduct all tests for lead required by subsections (a) through (e) in accordance with subsections (g) through (m). 

 

g)         The owner or operator of a lead emission unit required to test pursuant to subsection (a), (c), (d), or (e) must submit a testing protocol as described in USEPA's Emission Measurement Center Guideline Document (GD-042), as incorporated by reference in Section 226.120, to the Agency, directed to the Section Manager, at least 45 days prior to a scheduled emissions test.  Upon written request directed to the Section Manager, the Agency may, in its sole discretion, waive the 45-day requirement. A waiver is only effective if it is provided in writing by the Section Manager or his or her designee.

 

h)         Notification of a scheduled emissions test must be submitted to the Agency in writing, directed to the Section Manager, at least 30 days prior to the expected date of the emissions test and, again, 5 days prior to the testing.  Upon written request directed to the Section Manager, the Agency may, in its sole discretion, waive the 30-day requirement or the 5-day requirement. A waiver is only effective if it is provided in writing by the Section Manager or his or her designee.

 

i)          If, after the 30-days' notice for an initially scheduled test is sent, there is a delay (e.g., due to operational problems) in conducting the test as scheduled, the owner or operator of the lead emission unit must notify the Agency's Bureau of Air, Compliance Section as soon as practicable of the delay in the original test date, either by providing at least 7 days' notice of the rescheduled date of the test or by arranging a new test date with the Agency by mutual agreement.

 

j)          Not later than 60 days after the completion of the test, the owner or operator of a lead emission unit required to test pursuant to subsection (a), (c), (d), or (e) must submit the results of the test to the Agency, directed to the Section Manager.

 

k)         The owner or operator of a lead emission unit subject to the emissions testing requirements of this Section must conduct tests for lead emissions using 40 CFR 60, subpart A, and appendix A, Methods 1 (1 or 1A), 2 (2, 2A, 2C, or 2D), 3 (3 or 3A), and 4, and Method 12 or 29, as incorporated by reference in Section 226.120, or other alternative USEPA methods approved by the Agency. 

 

l)          Each emissions test must be in accordance with all of the following requirements:

 

1)         Method 12 or 29 must be used to determine compliance with the lead emission standard in Section 226.140;

 

2)         The minimum sample volume must be 0.85 dry standard cubic meters (30 dry standard cubic feet);

 

3)         The minimum sampling time must be 60 minutes for each run.  Consistent with the averaging and compliance requirements of this subsection (l), at least 3 runs must be performed and the arithmetic average of 3 valid runs must be used to determine compliance;

 

4)         The following procedure must be used to average emissions of tests results for any compliance determination:

 

A)        The average of the emissions test results must be determined by the arithmetic average of 3 valid test run results, as long as the test runs are conducted in conformance with the provisions of an approved testing protocol as required by subsection (g).

 

B)        Notwithstanding subsection (l)(4)(A), if the owner or operator of a lead emission unit elects to perform more than 3 test runs, then the average must be calculated based upon the results of all valid test runs.

 

C)        Notwithstanding subsection (l)(4)(A), in the event that a sample is accidentally lost or conditions occur in which one of the test runs must be discontinued because of forced shutdown, failure of an irreplaceable portion of the sample train, extreme meteorological conditions, malfunction, or other dissimilar or non-representative circumstances, upon the owner's or operator's documentation of the existence of any of the circumstances set forth in this subsection (l)(4)(C) and verification by the Section Manager or his or her designee that the conditions existed, compliance may be determined by using the arithmetic average of the test results of all remaining valid test runs; however, a minimum of 2 valid test runs is required to determine compliance;

 

5)         Each test for lead emissions must be conducted during conditions representative of maximum lead emissions; and

 

6)         If an owner or operator of a lead emission unit does not meet the criteria for averaging of subsection (l)(4), then each individual valid test run must meet the applicable limitation in order to demonstrate compliance.

 

m)        The owner or operator of any lead emission unit for which emissions are vented from an uncontrolled stack to the atmosphere must test those emissions in accordance with the requirements of this Section or calculate the emissions by means of collecting area time-weighted average lead samples and analyzing those samples through the use of OSHA Method 1006, as incorporated by reference in Section 226.120.  If an owner or operator of a lead emission unit subject to this Part elects to calculate lead emissions from an uncontrolled stack, the calculations must be completed at least once every 5 years.

 

Section 226.185  Recordkeeping and Reporting

 

a)         An owner or operator of a lead emission unit subject to this Part must keep and maintain all records used to demonstrate initial compliance and ongoing compliance with the requirements of this Part.

 

1)         Except as otherwise provided under this Part, copies of the records must be submitted by the owner or operator of the source to the Agency within 30 days after receipt of a written request by the Agency.

 

2)         The owner or operator must keep and maintain all records required by this Section at the source for at least 5 years from the date the document is created and must make all records available to the Agency for inspection and copying upon request.

 

b)         Notification of the initial startup of any new lead emission unit subject to this Part must be submitted to the Section Manager no later than 30 days after initial startup.

 

c)         The owner or operator of a lead emission unit subject to this Part must maintain records that demonstrate compliance with the requirements of this Part, as applicable, that include the following:

 

1)         Calendar date of the record;

 

2)         Reports for all applicable emissions tests for lead conducted on the lead emission unit, including the date of the test and the results;

 

3)         The date, time, and duration of any malfunction in the operation of any lead emission unit, any lead emission unit's control equipment, or any emissions monitoring equipment subject to this Part if the malfunction could cause an increase in emissions.  The records must include a description of the malfunction, the probable cause of the malfunction, the date and nature of the corrective action taken, and any preventative action taken to avoid future malfunctions;

 

4)         A log of all inspections, cleanings, maintenance, and repair activities performed on a lead emission unit's control equipment. The records must document the performance of the inspection, including the date of the inspection and the observed condition and operation of the control equipment. The records must also include the date and nature of the cleaning and the maintenance and repair activities performed on the lead emission unit's control equipment;

 

5)         Records, including the date and nature of all pavement cleanings, and any reason for not cleaning pavement (e.g., equipment breakdown);

 

6)         The date, time, and quantity of any spillage of dust containing lead.  The records must include the date, time, and nature of the cleaning activity in response to the spill;

 

7)         A log of all battery storage inspection activities, including the date of the inspection, a description of any broken batteries discovered during the inspections, and the date and nature of any required cleaning activities to control dust;

 

8)         A log of all maintenance activities that could generate dust containing lead.  The log must include the date of the maintenance activity, a description of the maintenance activity, and those measures implemented to minimize emissions of dust; and

 

9)         A log of the hours of operation for all quenching operations.

 

d)         The owner or operator of a lead emission unit subject to this Part must maintain records to demonstrate compliance with Section 226.150(a) and (b).

 

e)         The owner or operator of a lead emission unit subject to this Part must maintain the CDMP required by Section 226.150(c).  Records must be maintained demonstrating compliance with the CDMP.

 

f)         The owner or operator of a lead emission unit subject to this Part must maintain records of changes in pressure that could indicate a leak or other problem and, if applicable, every alarm from the leak detection system.  A log must be maintained of all investigations into the cause of the pressure changes and, if applicable, every alarm from the leak detection system, and any maintenance and repair activities performed as a result of the investigation.  The records must also include the date of each aforementioned activity.  Records must be maintained in order to demonstrate compliance with Section 226.150(d).

 

g)         The owner or operator of a lead emission unit subject to this Part must maintain records demonstrating compliance with the lead fugitive dust operating program and with the activities required by Section 226.170.

 

h)         The owner or operator of a lead emission unit subject to this Part must maintain records that include the following information for each period when the affected emission unit operated without the lead emission unit's control equipment for lead and had the potential for emissions:

 

1)         The date, time, and duration of the outage;

 

2)         The length of time that the affected lead emission unit subject to this Part operated uncontrolled before required control measures were in place or the affected lead emission unit was shut down (to resume operations only after required control measures were in place) and an explanation why the time the affected lead emission unit operated uncontrolled was not shorter, including a description of any mitigation measures that were implemented;

 

3)         A discussion of the probable cause of the outage of the control equipment; and

 

4)         A discussion of the date and nature of any preventative measures taken to avoid future outage.

 

i)          The owner or operator of a lead emission unit subject to this Part must maintain records demonstrating compliance with Section 226.175.

 

j)          The owner or operator of a lead emission unit subject to this Part must maintain a log of all inspections of control devices for the control of lead particulate.  The records must document the date of the inspection, the observed condition and operation of the control devices, and the date and nature of any corrective action taken.  Records must be maintained demonstrating compliance with Sections 226.165(a) and (c).

 

k)         The owner or operator of a lead emission unit subject to this Part must maintain a log of all inspections of any total enclosures and source structures.  The records must document the date of the inspection, the observed condition and operation of the total enclosure, and the date and nature of any corrective action taken. Records must be maintained demonstrating compliance with Sections 226.155(e), 226.160(a), and 226.165(b) and (c).

 

l)          The owner or operator of a lead emission unit subject to this Part must maintain records that include any data or information necessary to demonstrate compliance with the CPMP, including, but not limited to, records demonstrating compliance with Sections 226.155(c) and 226.160. 

 

m)        The owner or operator of a lead emission unit subject to this Part must notify the Section Manager within 5 days after discovery of deviations from any of the requirements of this Part or any exceedance of an applicable emission limitation.  At a minimum, and in addition to any permitting obligations, these notifications must include a description of the deviations, a discussion of the possible cause of the deviations, any corrective actions, and any preventative measures taken.

 

n)         The owner or operator of a lead emission unit subject to this Part must submit semiannual reports to the Section Manager.  The reports must include all monitoring reports summarizing monitoring as required by this Part, as well as summaries of all instances of deviations from the requirements of this Part.  For the January through June monitoring period, the owner or operator shall submit the monitoring report by July 31 of that year.  For the July through December monitoring period, the owner or operator shall submit the monitoring report by January 31 of the following year.  All reports must be certified by a responsible official that the information submitted is complete, true, and accurate.