OAQ Process Information Application PI-11 Foundry Smelting And Die Cast Operations {52551}

Indiana Department of Environmental Management Office of Air Quality Air Permit Application Page 1 of 11 PI-11 Instructions 10/2006 PROCESS INFORMATION: Foundry, Smelting & Die Cast Operations ­ INSTRUCTIONS Microsoft Word version of PI-11 Adobe PDF version of PI-11 The purpose of PI-11 (state form 52551) is to obtain detailed information about foundry, smelting, and die cast operations. Complete one form for each process (or group of identical processes). PI-11 is a required form for all air permit applications submitted to IDEM, OAQ. For the purposes of this form, the term "source" refers to the plant as a whole and NOT to the individual emissions units. If you do not provide the enough information to adequately describe the process, the application process may be stopped. If you have any questions, contact the Air Permit Reviewer of the Day (PROD) at (317) 233-0178 or 1-800-451-6027 extension 3-0178 (toll free call within Indiana). Part A: Elements of Foundry, Smelting & Die Cast Operations Part A identifies the processes related to foundries, smelting, and die cast operations and additional forms that may be needed. For each process listed, specify the form(s) attached. If a listed process is not applicable to the process, choose "N/A". If there is another process applicable beyond the listed items, specify the process under the "other" option, and identify any additional forms used to describe the process. 1. Process: a. Raw Material Storage and Handling: Use the PI-03 form to describe all storage and handling activities. b. Non-Metallic Mineral Processing (crushing and sizing of raw materials): Use the PI-18 form to describe the mineral processing activities. c. Ground Material Storage and Handling: Use the PI-03 form to describe all storage and handling activities. d. Pre-heater / Pre-calciner: To adequately describe the pre-heater or pre-calciner, complete the PI-02A to summarize the combustion units, Complete the PI-02B to describe each pre-heater or pre-calciner, complete the PI-02G to identify all the emission factors applicable to the process, and complete PI-02H to identify any federal rules that apply to the combustion unit. e. Fuel Type for Pre-heater / Pre-calciner: Complete the PI-02F form is a fuel other than natural gas is used. f. Furnace: To adequately describe the furnace, complete the PI-02A to summarize the combustion units, Complete the PI-02B to describe each furnace, complete the PI-02G to identify all the emission factors applicable to the process, and complete PI-02H to identify any federal rules that apply to the combustion unit. g. Fuel Type for Kiln: Complete the PI-02F form is a fuel other than natural gas is used. h. Non-Metallic Mineral Processing (crushing and sizing of clinker): Use the PI-18 form to describe the mineral processing activities. i. j. Shot Blasting: Use the PI-17 form to describe all blasting operations. Grinding: Use the PI-18 form to describe the mineral processing activities. k. Painting: Use the PI-19 form to describe all surface coating activities. l. Sand Reclamation: Most sand reclamation is achieved through an incineration process. To adequately describe the incineration process, complete the PI-02A to summarize the combustion units, Complete the PI-02B to describe each furnace, complete the PI-02G to identify all the emission factors applicable to the process, and complete PI-02H to identify any federal rules that apply to the combustion unit. If sand reclamation does not employ an incineration process, provide an explanation of the reclamation process. A PI-01 form may be needed to describe the process. 2. Form: PI-03: Storage and Handling of Bulk Material PI-02A: Combustion Unit Summary American LegalNet, Inc. www.FormsWorkflow.com Indiana Department of Environmental Management Office of Air Quality Air Permit Application Page 2 of 11 PI-11 Instructions 10/2006 PI-02B: Combustion ­ Boilers, Process Heaters, and Furnaces PI-02D: Combustion ­ Incinerators and Combustors PI-02F: Combustion ­ Fuel Use PI-02G: Combustion ­ Emission Factors PI-02H: Combustion ­ Federal Rule Applicability PI-17: Blasting Operations PI-18: Mineral Processing PI-19: Surface Coating and Printing Operations Part B: Operation Details Part B identifies the overall foundry process. 3. Final Products: Identify all final products of the foundry. 4. Type of Process: Specify the foundry process. If none of the listed categories or subcategories is applicable, specify the combustions type under the "other" option. Part C: Charge Handling Process Part C identifies the components associated with the charge handling process. Use additional forms as necessary 5. Unit ID: For each equipment or component type listed, provide the identification number(s) for the process unit(s). Please list each emission unit on a separate row, unless they are identical. Identical units must be of the same type, capacity, and installation date. The identification numbers listed on this form should correspond to the emissions unit identified on the Plant Layout and Process Flow diagrams. 6. Installation Date: For each emission unit listed, provide the date on which the unit was installed. If the exact date is not known, provide the month and year of the installation. If the unit has not yet been installed, provide the anticipated installation date. If the unit has been modified since the original installation, include the most recent modification date. 7. Material Handled: For each equipment or component type listed, identify the materials handled. 8. Maximum Charge Rate: Specify the maximum charge rate in tons per hour (ton/hr). 9. Is the Process Totally Enclosed in a building? Specify whether the process is totally enclosed in a building. 10. Air Pollutant: For each process identified, list each air pollutant emitted to the atmosphere during normal operation. If there are multiple pollutants for an process, use a new row for each pollutant. 11. Emission Factor: Provide the relevant emission factor including the appropriate units (e.g., lb/units, lbs/ton, lbs/gal, lbs/cf, etc.). 12. Source of Emission Factor: Provide the source of the emission factors. Common sources include AP-42, stack test data, engineering analysis. The United States Environmental Protection Agency (U.S. EPA) has developed a Clearinghouse for Inventories & Emission Factors containing AP-42 and other emission factors. Appendix A of AP-42 lists several common conversion factors that may be needed to calcu