ÿWPCÊ   IPDÛPÇ!˜dšYÌI´ ¬„|à8r¢hƒÂPýéIL]˜ˆÄšoÉàosãò£õ„<¡Û^_·aêÜoËFB°Ú£tWþîì;ÝØ€eóêLfÁªO¥ñ‰ü¥b9.‘·Šƒä¶RoùYQ‰ ¹rËm×ó#Ï¿ˆjM{TÔ2ÂÙ Ú^Ç8†@òœK‚`9ßjIäDAP\°nyÎÈ£}—Ì.)µ)o<œ” 6F.¼J"uù†bŠT¬HO[zEô%IØ8óùÜÈ…¼mm¿bŒG½ ù}„ƒ»æÔ¨Ns’Nçñ.ùè ŠF_8œ\K!yFÏÐÉeÚ}*HiJ”ǤVÅ–EßßñR§r©d¿ð's6>åJ:Ö¢±³h¡öî™qòq$ÐŒ(sµä‡%•ÇŠ*àÏ&þávz¤Klª× 4À¹6èOùÜ<Üòœ+[B½ÑŠV,Tßzt¼ë.bò±Á6L£òp J[§xó‰q1XW´óæ3M0$˯‹äpÔ’!©cøm >kàß=ãaë9Í01>b WœãˆEuvÜjÆH,¿–¢Æë_ݱT* Þ /[ ¯€è9£w>ÚäMN1÷!ž$"#!ÜUNý %K 0(QByO»w 4(N7^ 9 0DEO‰Ø Ú mæ æ 0lý 0Di i i i i i i i i i i i i i B­ ˜HP LaserJet 6L,ð,,,,,ð0(ÈhH  Z ‹6Times New Roman RegularX($¡¡C:\WINDOWS\TEMPLATE\STANDARD.WPT EÝ ƒ ¯'ÝÝ  ÝÔ_ÔÒe°Òà0 ½ à e%ä,,3|x y‰%ä(3¯$§§Ý ƒ!ÝÝ  Ý EÝ ƒ ¯'ÝÝ  ÝÔ_ÔÒe°Òà0 ½ à Ý ƒüÝ$Ýà  àòòÚ  Ú1Ú  ÚóóÝ  ÝÔ_ÔPost„consumer€scrap€aluminum€is€any€aluminum€product€or€intermediate€which€has€beenÐ ° Ðdiscarded€by€consumers€after€use.€€Examples€would€be€broken€ladders,€discarded€storm€doors€andÏwindows,€old€gutters,€empty€cans,€broken€or€otherwise€unusable€auto€engine€and€body€parts,Ïhome€and€building€siding€or€inside€panels€in€demolition€waste,€electrical€wire,€and€demolishedÏmobile€home€siding€and€parts.€€Post„industrial€scrap,€which€includes€dross€from€smelting€andÏrefining€and€any€other€scraps€that€are€too€dirty€or€too€far€out€of€specification€to€recycle€directlyÏback€into€product€manufacturing€process,€is€added€to€post„consumer€scrap€for€recovery€byÏsecondary€smelters.ÿU‹ÿÀÀÀ((3üÝ$¤¤Ý ƒ!ÝÝ  Ýà  àòòÚ  Ú0Ú  Úóó(#Ã$òòÚ  Ú0Ú  Úóó dÝ ƒ!ÝÝ  ÝÔ_ÔÔ_ÔÑ‹ÈÑñ ñÖ€ÿÿÖñ ññ ñÖ€ ÿÿÖñ ñòòà  àà ` àà ¸ àà  àà h àóóDecember€4,€1998òòÐ ' Ðà  àÌMEMORANDUMÌóóÌSUBJECT:à0 ` àTreatment€of€Aluminum€Die€Casting€Operations€for€the€Purposes€of€New€SourceÐ × ° ÐReview€ApplicabilityÐ ` (#` (# ÐÖ€ìÖÌTO:à0  àà0` (#(#àAddresseesЛ t` (#` (# ÐÌFROM:à0 ` àThomas€C.€Ô_ÔCurranÔ_Ô,€€DirectorÐsL ` (#` (# Ðà  àà ` àInformation€Transfer€and€Program€Integration€Division€(MD„12)ÌÌà  àThe€purpose€of€this€memorandum€is€to€provide€guidance€in€making€case„by„caseÏdeterminations€of€whether€die€casting€plants€should€be€categorized€generally€as€secondaryÏaluminum€recovery€plants€or€whether€the€processing€steps€within€a€die€casting€plant€might€beÏconsidered€as€a€secondary€aluminum€support€facility.€€This€is€in€response€to€a€request€by€theÏNorth€American€Die€Casting€Association€(Ô_ÔNADCAÔ_Ô)€for€guidance€on€the€issue€of€whetherÏaluminum€die€casting€facilities€are€secondary€metal€production€plants€under€the€Prevention€ofÏSignificant€Deterioration€(Ô_ÔPSDÔ_Ô)€regulations.€€Such€guidance€has€bearing€on€the€classification€ofÏaluminum€die€casting€facilities€as€major€sources€for€the€reason€that€secondary€metal€productionÏplants€are€subject€to€a€100„tons„per„year€major€source€threshold€rather€than€the€250„tons„per„yearÏthreshold€applicable€to€many€other€types€of€sources.€€This€memorandum€contains€EPAððs€analysisÏof€the€issues€raised€by€Ô_ÔNADCAÔ_Ôððs€request.ÌÌà  àThe€EPA€agrees€with€Ô_ÔNADCAÔ_Ô€that€aluminum€die€casting€facilities€typically€need€not€beÏconsidered€secondary€metal€production€plants.€€€As€a€general€matter,€aluminum€die€castingÏfacilities€do€not€use€the€feedstock,€do€not€engage€in€the€elaborate€processes,€and€do€not€produceÏthe€end€products€that€are€characteristic€of€facilities€engaged€in€secondary€aluminum€recovery.€€ÌÌà  àWhile€€information€supplied€by€Ô_ÔNADCAÔ_Ô€indicates€that€some€die€casting€facilities€employÏcertain€process€steps€similar€to€those€employed€by€secondary€metal€production€facilities,€EPAÏagrees€with€Ô_ÔNADCAÔ_Ô€that€these€process€steps€are€distinguishable€in€most€cases.€€In€exceptionalÏcases,€the€process€steps€that€cannot€be€distinguished€from€secondary€metal€production€meet€theÏcriteria€for€a€ð ðnestedðð€support€facility€that€by€itself€is€subject€to€the€100„tons„per„year€majorÏsource€threshold.€€Finally,€it€is€possible€that€a€die€casting€facility€could€be€integrated€with€aÏsecondary€aluminum€recovery€process€to€such€an€extent€that€the€principal€products€or€activitiesÏwould€constitute€a€secondary€metal€production€plant.€€The€analysis€that€follows€discusses€theÏcritical€factors€that€should€be€evaluated€in€determining€whether€a€die€casting€facility€satisfies€theÏrather€specific€and€unique€qualifications€of€being€a€secondary€aluminum€recovery€plant€or€ifÏcertain€process€steps€constitute€a€ð ðnestedðð€secondary€aluminum€recovery€support€facility.€€€Ð  *ô#' ÐÌÌà  àThe€policies€set€forth€in€this€document€are€not€judicially€Ô_ÔreviewableÔ_Ô.€€They€do€not€changeÏexisting€EPA€regulations,€are€intended€solely€as€guidance,€do€not€represent€final€agency€action,Ïand€cannot€be€relied€upon€to€create€rights€enforceable€by€any€party.€€Further,€this€guidance€is€notÏintended€to€reverse€or€supersede€any€case„by„case€determination€made€previously€by€an€EPAÏRegional€Office,€State€or€local€permitting€authority.ÌÌà  àThe€Regional€Offices€should€send€this€memorandum€to€the€States€within€their€jurisdiction.€ÏQuestions€concerning€specific€issues€and€cases€should€be€directed€to€the€appropriate€RegionalÏOffice.€€The€Regional€Office€staff€may€contact€Mr.€Dennis€Ô_ÔCrumplerÔ_Ô€of€the€IntegratedÏImplementation€Group€at€(919)€541„0871€if€they€have€any€questions.€€This€document€is€availableÏon€the€Ô_ÔTTNÔ_Ô€Web€at€http://www.epa.gov/ttn/nsr/poly_gui.html.€€Users€unfamiliar€with€this€webÏsite€may€obtain€help€by€calling€the€Ô_ÔTTNÔ_Ô€help€line€€at€(919)541-5384.ÌÌAddressees:ÌDirector,€Office€of€Ecosystem€Protection,€Region€I€€€ÌDirector,€Division€of€Environmental€Planning€and€Protection,€Region€IIÌDirector,€Air€Protection€Division,€Region€IIIÌDirector,€Air,€Pesticides,€and€Ô_ÔToxicsÔ_Ô€Management€Division,€Region€IVÌDirector,€Air€and€Radiation€Division,€Region€V€ÌDirector,€Multimedia€Planning€and€Permitting€Division,€Region€VI€ÌDirector,€Air,€Ô_ÔRCRAÔ_Ô,€and€Ô_ÔToxicsÔ_Ô€Division,€Region€VIIÌAssistant€Regional€Administrator,€Office€of€Partnership€and€Regulatory€Assistance,€Region€VIIIÌDirector,€Air€Division,€Region€IX€ÌDirector,€Office€of€Air,€Region€XÌÐ  ¨ø ÐÔ_Ôò òÓ  ÓThe€EPAððs€Analysis€of€Die€Casting€OperationsÐ ° Ѐand€Information€Supplied€by€the€North€American€Die€Casting€AssociationÌó óÓLÓÌò òShould€die€casting€operations€be€classified€as€secondary€metal€production€plants?ó ó€€Ð tÄ ÐÌà  àOur€analysis€suggests€that€die€casting€operations€generally€need€not€be€classified€asÏsecondary€metal€production€plants.€€In€most€cases,€the€processes€and€products€of€the€two€types€ofÏoperations€are€sufficiently€distinct€to€warrant€this€determination.ÌÌà  àThe€Standard€Industrial€Classification€(SIC)€Code€Manual€provides€the€starting€point€forÏdetermining€which€pollutant„emitting€activities€should€be€considered€as€part€of€the€same€industrialÏgrouping€for€the€purposes€of€defining€a€stationary€source.€€The€exact€term€ð ðsecondary€metalÏproduction€plant,ðð€which€is€identified€€in€Section€169€of€the€Clean€Air€Act€as€an€industrial€sourceÏcategory€that€is€subject€to€a€100„ton„per„year€major€source€threshold,€does€not€appear€in€the€SICÏCode€Manual.€€The€SIC€Code€Manual€does€list,€however,€the€category€"Secondary€Metal€andÏRefining€of€Nonferrous€Metals."€€This€category€includes€sources€primarily€engaged€in€recoveringÏnonferrous€metals€and€alloys€from€new€and€used€scrap€and€dross€or€in€producing€alloys€fromÏpurchased€refined€metals.€€ÌÌà  àThe€SIC€Code€Manual€does€not€give€a€detailed€technical€description€of€the€process€that€isÏused€in€secondary€metals€recovery.€€To€gain€a€better€description€of€the€secondary€aluminumÏprocess,€we€consulted€the€technical€literature,€including€the€òòMcGraw„Hill€Encyclopedia€of€ScienceÐ ` Ðand€Technologyóó€and€òòCompilation€of€Air€Pollution€Emission€Factors,€Fifth€edition€(AP„42)€SectionÐ üL Ð12.8óó.€€From€these€references,€we€found€that€conventional€secondary€aluminum€processing€includesÐ è8 Ðthe€following€steps:€€receiving€every€conceivable€kind€of€post„consumer€scrap€and€recyclableÏwaste€aluminum׃×Ý ƒ#ÃÝòòÚ  Ú1Ú  ÚóóÝ  Ý×  ×;€drying€the€scrap;€shredding€or€grinding;€and€burning€off€organic€and€otherÐ À Ðvolatile€residues€such€as€paint€or€oil;€and€sweating€and€decanting€to€separate€the€aluminum€fromÏother€metals€in€the€scrap.€€Most€secondary€aluminum€processes€use€a€reverberatory€furnace€toÏsweat€or€decant€the€scrap,€but€crucible€furnaces€can€also€be€used€for€small,€batch€operations.€ÏAfter€the€preliminary€separation,€the€molten€aluminum€still€contains€a€significant€amount€ofÏalloyed€metals.€€These€metals€are€removed€by€smelting€while€still€in€the€reverberatory€furnace.€ÏDuring€this€part€of€the€process,€the€molten€mixture€is€ð ðfluxedðð€with€chloride€salts€and/or€chlorineÏgas€to€separate€undesirable€metals€(ð ðdemaggingðð)€and€impurities.€€Fluxing€rates€are€typically€in€theÏrange€of€5„7€percent€of€the€mass€of€aluminum€that€is€smelted.€€Hydrogen€gas€is€removedÏ(degassed)€by€bubbling€an€inert€gas€through€the€melt.€€After€Ð   $\" Ðimpurities€are€removed,€certain€metals€or€minerals€are€added€to€bring€product€characteristics€orÏquality€back€to€customer€specification.€€The€process€concludes€with€a€final€filtration,€followed€byÏcasting€the€recovered€aluminum€into€ingots,€block€(called€billets),€bars,€and€shot.€€ÌÌà  àDie€casting€involves€melting€metal€and€then€forcing€it€with€pressure€into€molds€through€aÏseries€of€channels€and€vents€to€form€aluminum€parts€and€products.€€To€obtain€detailed€informationÏregarding€the€die€casting€process,€EPA€met€with€NADCA€and€some€of€its€members.€€EPAððsÏRegion€V€staff€also€obtained€additional€information€during€a€visit€to€a€die€casting€facility.€€€FromÏthis,€it€appears€that€the€typical€die€casting€facility€uses€high€quality€metal€of€a€specified€alloy€andÏpurity€as€feedstock,€in€the€form€of€ingots€or€billets,€which€are€brought€into€the€plant€at€ready„to„¼cast€quality.€€The€feedstock€is€melted€in€a€furnace€(of€various€types,€but€most€typically€aÏreverberatory€furnace).€€As€much€as€1€percent€by€weight€of€a€purifying€flux€is€added€to€theÏfurnace€prior€to€receiving€the€charge€to€control€oxidation€and€to€maintain€alloy€specifications.€ÏOnce€the€metal€is€heated€and€exposed€to€air€in€the€furnace,€a€small€amount€of€€molten€metalÏoxidizes€to€form€dross€that€floats€to€the€surface.€€The€dross€is€skimmed€off€or€filtered€from€theÏmolten€metal€and€sold€to€smelters.€€The€molten€aluminum€may€also€be€degassed€of€hydrogen€byÏinjecting€nitrogen€or€argon€gas€into€the€melt.€Trimmings€from€cast€parts,€turnings€from€drillingÏand€milling€the€castings,€and€defective€castings€or€quality€rejects€are€recycled€to€the€furnace.€ÌÌà  àIn€addition€to€the€use€of€ingots€or€billets€for€feedstock,€some€die€casting€facilities€purchaseÏreturns€from€other€facilities€in€the€die€casting€industry.€€Where€the€composition€of€the€returns€canÏbe€specified€and€controlled€contractually,€die€casters€can€incorporate€recyclable€alloy€gradeÏaluminum€into€their€feed€without€extensive€fluxing€or€alloying.€€As€a€result,€such€inter„facilityÏtransfers€of€recyclable€alloy€grade€aluminum€have€no€different€effect€on€the€die€casting€facilityððsÏoperations€than€the€processing€of€its€own€in„house€returns.€€In€contrast,€few€die€casters€generateÏfeedstock€from€post„consumer€scrap€or€unspecified€aluminum€scrap€from€junk€dealers€because€ofÏquality€control€concerns.€ÌÌà  àWith€respect€to€plant€output,€die€casters€produce€a€marketable€aluminum€part€or€product.€ÏA€facility€may€temporarily€cast€aluminum€into€intermediate€forms,€such€as€sows€(large€roundÏblocks),€for€the€purpose€of€storing€its€residual€process€raw€material€when€equipment€is€shut€downÏfor€maintenance€or€repair.€€This€intermediate€is€not€sold€but€fed€back€to€the€process€upon€restart.Ìà  àÌà  àAs€the€above€description€illustrates,€conventional€secondary€aluminum€recovery€plants€andÏdie€casting€facilities€differ€in€several€respects.€€Die€casters€do€not€typically€produce€feedstock€fromÏpost„consumer€or€unspecified€aluminum€scrap.€€As€a€result,€most€die€casters€do€not€engage€in€aÏnumber€of€the€cleaning€and€pretreatment€steps€typical€of€secondary€aluminum€recovery€such€as€Ïpyrolitic€cleaning,€sweating,€and€thermal€separation.€€Die€casters€also€use€a€relatively€smallÏamount€of€flux„„less€than€one€percent€by€weight€of€the€processed€aluminum„„primarily€to€removeÏproducts€of€oxidation€in€the€melt€rather€than€to€remove€large€portions€of€undesirable€metals.€€ÏFinally,€die€casters€produce€a€marketable€aluminum€part€or€product€rather€than€an€intermediateÏform€of€feedstock€such€as€billets,€bars€or€ingots€for€sale€to€or€use€by€mills€that€perform€rolling,Ïextrusion,€drawing€forging€or€casting.€€ÌÌÔ_ÔÐ  @-(, Ðà  àAs€a€result€of€this€analysis,€EPA€will€presume€that€a€die€casting€facility€is€not€engaged€inÏsecondary€aluminum€production€as€a€òòprimary€activityóó€as€long€as€two€conditions€are€met:€€(1)€theÐ œì Ðfacility€uses€feedstock€such€as€ingots,€billets,€bars,€sows€or€shot€(or€even€as€molten€metal)€that€isÏof€a€specified€alloy€and€purity€or€scrap€from€other€industrial€facilities€for€which€the€quality€isÏspecified€and€guaranteed€by€contract€and€for€which€little€fluxing€or€alloying€is€required;€and€(2)Ïthe€facility€does€not€produce€intermediate€forms€of€feedstock€(ingots,€billets,€bars,€shot,€sows,Ïetc.)€for€sale€or€for€use€by€other€facilities.€€ÌÌà  àIf€a€plant€produces€cast€aluminum€parts€but€uses€post„consumer€or€unspecified€aluminumÏscrap€as€a€feedstock,€it€will€be€a€closer€question€whether€the€plantððs€primary€activity€is€secondaryÏaluminum€recovery.€€The€quality€and€origin€of€the€post„consumer€or€unspecified€aluminum€scrap,€Ïthe€use€of€thermal€cleaning€or€separation,€as€well€as€the€amount€used€relative€to€the€amount€ofÏspecified„grade€alloy€feedstock,€will€have€some€bearing€on€whether€secondary€aluminum€recoveryÏis€the€primary€activity.ÌÌò òÔ& œ ÔDoes€the€die€casting€facility€utilize€steps€that€would€be€considered€secondary€aluminumÐ „Ô  Ðprocessing€as€a€support€facility?€ÌÌó óà  àNotwithstanding€a€determination€that€a€facilityððs€òòprimaryóó€activity€is€òònotóó€secondaryÐ H˜ ÐaluminumÔ'œ„k3Ô€recovery,€the€use€of€any€post„consumer€or€unspecified€aluminum€scrap€would€result€in€aÏdetermination€that€certain€operations€at€a€die€casting€facility€should€be€considered€a€ð ðnestedððÏsecondary€aluminum€support€facility.€€When€determining€whether€a€source€contains€a€nestedÏsecondary€aluminum€support€facility,€the€specific€process€steps€of€which€would€be€subject€to€aÏ100€Ô_ÔtpyÔ_Ô€major€source€threshold,€a€source's€end€product€is€not€necessarily€a€determining€factor.ÌÌà  àThe€EPA€addressed€this€issue€in€the€context€of€secondary€aluminum€recovery€at€a€finishingÏmill€in€a€July€28,€1989€memorandum€concerning€Golden€Aluminum€from€William€B.€Hathaway,ÏDivision€Director,€Air,€Toxic€and€Radiation,€EPA€Region€6,€to€Steve€Ô_ÔSpawÔ_Ô€of€the€Texas€AirÏControl€Board.€€The€EPAððs€position€was€reaffirmed€in€subsequent€letters€of€July€20,€1990,€fromÏRobert€E.€Ô_ÔHanneschlagerÔ_Ô€to€Jeff€Ô_ÔCivinsÔ_Ô€and€again€in€a€September€3,€1991€letter€from€William€G.ÏRosenberg€to€Carol€Dinkins.€€With€respect€to€the€Golden€Aluminum€facility,€EPA€found€that€theÏsource,€even€though€it€produced€a€specific€end„product€other€than€aluminum€ingot€or€block,€alsoÏengaged€in€recovering€aluminum€from€used,€scrap€aluminum€that€was€collected€from€outside€theÏfacility,€with€a€process€that€included€several€classical€secondary€metal€process€steps€identifiedÏabove.€€Those€secondary€metals€process€steps€were€determined€to€be€a€nested€support€activityÏthat€was€subject€to€the€major€source€threshold€of€100€tons€per€year€specified€by€Congress€in€theÏClean€Air€Act.ÌÌà  àThe€EPA€will€presume€that€the€recycling€steps€at€a€die€casting€facility€do€not€constituteÏsecondary€metals€production€in€a€support€facility€capacity€only€under€narrow€circumstances.€€ThatÏis,€if€the€facility€recycles€only€in„house€returns€with€original€feedstock€and€uses€the€simple€melting,Ïfluxing€and€degassing€process€steps€described€above,€then€EPA€will€presume€that€the€facility€doesÏnot€engage€in€secondary€aluminum€recovery.€€In„house€returns€of€specified€quality€Ð  h+¸&* Ðthat€are€purchased€by€contract€from€other€die€casting€facilities€also€satisfy€the€feedstock€criteriaÏfor€this€presumption.€€In€any€case€where€this€presumption€is€rebutted,€the€total€emissions€from€allÏthe€recycling€steps€must€be€compared€against€the€100„ton„per„year€major€source€threshold.