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OAQ PROCESS INFORMATION APPLICATION PI-11: Foundry, Smelting & Die Cast Operations
State Form 52551 (R / 1-07)

INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENT

IDEM ­ Office of Air Quality ­ Permits Branch 100 N. Senate Ave., MC 61-53 Indianapolis, IN 46204-2251 Telephone: (317) 233-0178, or Toll Free: 1-800-451-6027 x30178 (within Indiana) Facsimile Number: (317) 232-6749 www.idem.IN.gov/permits/air/index.html

NOTES:

· · ·

The purpose of this form is to obtain detailed information about foundry, smelting and die cast operations. Complete one form for each process unit (or group of identical units). Detailed instructions for this form are available online at

www.idem.IN.gov/permits/air/apps/instructions/pi11instructions.doc .
All information submitted to IDEM will be made available to the public unless it is submitted under a claim of confidentiality. Claims of confidentiality must be made at the time the information is submitted to IDEM, and must follow the requirements set out in 326 IAC 17.1-4-1. Failure to follow these requirements exactly will result in your information becoming a public record, available for anyone to inspect and photocopy.

PART A: Foundry, Smelting & Die Cast Processes Part A identifies processes that are related foundries, smelting, and die casting and additional forms that may be needed. 1. Process a. Raw Material Storage and Handling b. Non-Metallic Mineral Processing (crushing and sizing of raw materials) c. Ground Material Storage and Handling d. Pre-heater / Pre-calciner e. Fuel Type for pre-heater / pre-calciner (If other than Natural Gas) f. Furnace Use the form listed for the specified processes. Check all that apply. This form is included for raw materials unloading / storage: This form is included for the raw materials processing: PI-03 PI-18 N/A N/A

This form is included for the raw mills storage / handling: This form is included for the pre-heater: Submit form if fuel other than Natural Gas used in the preheater:

PI-03 PI-02

N/A N/A

PI-02F These forms are included for the furnace: PI-02A PI-02B PI-02G PI-02H

N/A N/A N/A N/A N/A N/A N/A

g. Fuel Type for Kiln (If other than Natural Gas) h. Non-Metallic Mineral Processing (crushing and sizing of clinker) i. j. Shot Blasting Grinding

Submit form if fuel other than Natural Gas used in the kiln: This form is included for processing:

PI-02F PI-18

This form is included for shot blasting: This form is included for grinding: This form is included for painting:

PI-23 PI-18 PI-19

N/A N/A N/A N/A

k. Painting l. Sand Reclamation

This form is included for the incineration process: PI-02 If the sand reclamation is not an incineration process, explain the process:

m. Other process(es)

This form is included for (specify process):

N/A

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Page 1 of 10

Indiana Department Of Environmental Management Office Of Air Quality State Form 52551 (R / 1-07)

Process Information ­ Foundry, Die Casting, and Smelter Operations FORM PI-11 Page 2 of 10

PART B: Operation Details Part B identifies the overall foundry process. 2. Final Products: (check all that apply) Billets Other (specify) Bars Castings Ingots Molten Metal

3. Type of Process: Check all that apply. Foundry: Smelting: Aluminum Die Casting PART C ­ Charge Handling Process Part B identifies the components associated with the charge handling process. Use additional forms as necessary. 4. Unit ID 5. Installation Date 6. Material Handled 7. Maximum Charge Rate (tons/hr) 8. Is the Process Totally Enclosed in a Building? Yes No Yes Yes Yes Yes No No No No Aluminum Gray Iron Aluminum Brass Steel Lead Copper Other (specify) Other (specify) Ductile Iron

This following section identifies all emission factors used to calculate air emissions from sand handling.
9. Air Pollutant: Particulate Matter (PM) Particulate Matter less than 10m (PM10) Particulate Matter less than 2.5m (PM2.5) Other (specify): 10. Emission Factor
value units

11. Source of Emission Factor
(If not using AP-42, include calculations)

AP-42 AP-42 AP-42 AP-42

Other Other Other Other

N/A N/A N/A N/A

12. Add-On Control Technology: Identify all control technologies used for this unit, and attach completed CE-01 (unless "none"). None Baghouse / Fabric Filter ­ Attach CE-02. Electrostatic Precipitator ­ Attach CE-04. Reduction ­ Attach CE-09 Cyclone ­ Attach CE-03. Absorption / Wet Collector / Scrubber ­ Attach CE-05. Other (specify): ­ Attach CE-10.

13. Control Techniques: Identify all control techniques used for this unit.

14. Process Limitations / Additional Information: Identify any acceptable process limitations. Attach additional information if necessary.

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Indiana Department Of Environmental Management Office Of Air Quality State Form 52551 (R / 1-07)

Process Information ­ Foundry, Die Casting, and Smelter Operations FORM PI-11 Page 3 of 10

PART D ­ Sand Handling Information Part D identifies all the components associated with the sand handling. Use additional forms as necessary. 15. Does your process include sand handling? 16. Unit ID 17. Installation Date Yes No
If yes, complete the rest of this section. If no, proceed to the next section.

18. Sand Throughput Rate (tons of sand per hour)

This following section identifies all emission factors used to calculate air emissions from sand handling.
19. Air Pollutant: Particulate Matter (PM) Particulate Matter less than 10m (PM10) Particulate Matter less than 2.5m (PM2.5) Other (specify): 20. Emission Factor
value units

21. Source of Emission Factor
(If not using AP-42, include calculations)

AP-42 AP-42 AP-42 AP-42

Other Other Other Other

N/A N/A N/A N/A

22. Add-On Control Technology: Identify all control technologies used for this unit, and attach completed CE-01 (unless "none"). None Baghouse / Fabric Filter ­ Attach CE-02. Electrostatic Precipitator ­ Attach CE-04. Reduction ­ Attach CE-09 Cyclone ­ Attach CE-03. Absorption / Wet Collector / Scrubber ­ Attach CE-05. Other (specify): ­ Attach CE-10.

23. Control Techniques: Identify all control techniques used for this unit.

24. Process Limitations / Additional Information: Identify any acceptable process limitations. Attach additional information if necessary.

This space is intentionally left blank.

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Indiana Department Of Environmental Management Office Of Air Quality State Form 52551 (R / 1-07)

Process Information ­ Foundry, Die Casting, and Smelter Operations FORM PI-11 Page 4 of 10

PART E ­ Mold Making Process Information Part E identifies all process components associated with Mold Making. Use additional sheets as necessary. 25. Does your production process include a process for making sand molds? 26. Number of Mold Making Process Lines: 27. Unit ID 28. Installation
Date

Yes No

If yes, complete the rest of this section. If no, proceed to the next section.

29. Capacity
(tons sand per hr)

30. Type of Binder
(for mold making)

31. Amount of Binder Used
(lb of binder per lb of sand)

32. % VOC in
Binder
(include MSDS)

This following section identifies all emission factors used to calculate air emissions from Mold Making.
33. Air Pollutant: 34. Emission Factor
value units

35. Source of Emission Factor
(If not using AP-42, include calculations)

Carbon Monoxide (CO) Lead (Pb) Nitrogen Oxides (NOX) Particulate Matter (PM) Particulate Matter less than 10m (PM10) Particulate Matter less than 2.5m (PM2.5) Sulfur Dioxide (SO2) Volatile Organic Compounds (VOC) Hazardous Air Pollutants (HAP) (specify): Other (specify):

AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42

Other Other Other Other Other Other Other Other Other Other

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

36. Add-On Control Technology: Identify all control technologies used for this unit, and attach completed CE-01 (unless "none"). None Baghouse / Fabric Filter ­ Attach CE-02. Electrostatic Precipitator ­ Attach CE-04. Oxidizer / Incinerator ­ Attach CE-06. Condenser ­ Attach CE-08. Other (specify): Cyclone ­ Attach CE-03. Absorption / Wet Collector / Scrubber ­ Attach CE-05. Adsorber ­ Attach CE-07. Reduction ­ Attach CE-09. ­ Attach CE-10.

37. Control Techniques: Identify all control techniques used for this unit.

38. Process Limitations / Additional Information: Identify any acceptable process limitations. Attach additional information if necessary.

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Indiana Department Of Environmental Management Office Of Air Quality State Form 52551 (R / 1-07)

Process Information ­ Foundry, Die Casting, and Smelter Operations FORM PI-11 Page 5 of 10

PART F ­ Core Mixing Process Information Part F identifies the process components associated with Core Mixing. Use additional sheets as necessary. 39. Does your production process include a core-mixing process? 40. Number of Core Mixing Process Lines: 41. Core
Mixer Unit ID

Yes No

If yes, complete the rest of this section. If no, proceed to the next section.

42. Installation
Date

43. Core Mixer
Capacity
(tons sand per hour)

44. Type of Binder
(for core making)

45. Amount of Binder Used
(lb of binder per lb of sand)

46. % VOC in
Binder
(include MSDS)

This following section identifies all emission factors used to calculate air emissions from the Core Mixer.
47. Air Pollutant: Carbon Monoxide (CO) Lead (Pb) Nitrogen Oxides (NOX) Particulate Matter (PM) Particulate Matter less than 10m (PM10) Particulate Matter less than 2.5m (PM2.5) Sulfur Dioxide (SO2) Volatile Organic Compounds (VOC) Worst Case HAP (specify): Other (specify): 48. Emission Factor
value units

49. Source of Emission Factor
(If not using AP-42, include calculations)

AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42

Other Other Other Other Other Other Other Other Other Other

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

50. Add-On Control Technology: Identify all control technologies used for this unit, and attach completed CE-01 (unless "none"). None Baghouse / Fabric Filter ­ Attach CE-02. Electrostatic Precipitator ­ Attach CE-04. Oxidizer / Incinerator ­ Attach CE-06. Condenser ­ Attach CE-08. Other (specify): Cyclone ­ Attach CE-03. Absorption / Wet Collector / Scrubber ­ Attach CE-05. Adsorber ­ Attach CE-07. Reduction ­ Attach CE-09. ­ Attach CE-10.

51. Control Techniques: Identify all control techniques used for this unit.

52. Process Limitations / Additional Information: Identify any acceptable process limitations. Attach additional information if necessary.

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Indiana Department Of Environmental Management Office Of Air Quality State Form 52551 (R / 1-07)

Process Information ­ Foundry, Die Casting, and Smelter Operations FORM PI-11 Page 6 of 10

PART G ­ Core Making Process Information Part G identifies the process components associated with the Core Machine. Use additional sheets as necessary. 53. Does your production process include a core-making process? 54. Core
Machine Unit ID

Yes No

If yes, complete the rest of this section. If no, proceed to the next section.

55. Installation
Date

56. Type of
Core Making Process

57. Core Making
Capacity
(tons of cores per hour)

58. Type of
Catalyst
(for core making)

59. Amount of
Catalyst Used
(lb of catalyst per lb of sand)

60. % VOC in
Catalyst
(include MSDS)

This following section identifies all emission factors used to calculate air emissions from the Core Machine.
61. Air Pollutant: Carbon Monoxide (CO) Lead (Pb) Nitrogen Oxides (NOX) Particulate Matter (PM) Particulate Matter less than 10m (PM10) Particulate Matter less than 2.5m (PM2.5) Sulfur Dioxide (SO2) Volatile Organic Compounds (VOC) Worst Case HAP (specify): Other (specify): 62. Emission Factor
value units

63. Source of Emission Factor
(If not using AP-42, include calculations)

AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42

Other Other Other Other Other Other Other Other Other Other

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

64. Add-On Control Technology: Identify all control technologies used for this unit, and attach completed CE-01 (unless "none"). None Baghouse / Fabric Filter ­ Attach CE-02. Electrostatic Precipitator ­ Attach CE-04. Oxidizer / Incinerator ­ Attach CE-06. Condenser ­ Attach CE-08. Other (specify): Cyclone ­ Attach CE-03. Absorption / Wet Collector / Scrubber ­ Attach CE-05. Adsorber ­ Attach CE-07. Reduction ­ Attach CE-09. ­ Attach CE-10.

65. Control Techniques: Identify all control techniques used for this unit.

66. Process Limitations / Additional Information: Identify any acceptable process limitations. Attach additional information if necessary.

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Indiana Department Of Environmental Management Office Of Air Quality State Form 52551 (R / 1-07)

Process Information ­ Foundry, Die Casting, and Smelter Operations FORM PI-11 Page 7 of 10

PART H ­ Core Dip Tank Information Part H identifies the process components associated with the Core Dip Tank. Use additional sheets as necessary. 67. Does your production process include a core-dip tank? 68. Dip Tank
Unit ID

Yes No

If yes, complete the rest of this section. If no, proceed to the next section.

69. Installation
Date

70. Dip Tank
Capacity
(specify units)

71. Amount of Core
Wash Used
(lb of core wash per lb of sand)

72. % VOC in Core
Wash
(include MSDS)

73. Core Oven ID
(use Form PI-02 to describe this unit)

This following section identifies all emission factors used to calculate air emissions from the Core Dip Tank.
74. Air Pollutant: Carbon Monoxide (CO) Lead (Pb) Nitrogen Oxides (NOX) Particulate Matter (PM) Particulate Matter less than 10m (PM10) Particulate Matter less than 2.5m (PM2.5) Sulfur Dioxide (SO2) Volatile Organic Compounds (VOC) Worst Case HAP (specify): Other (specify): 75. Emission Factor
value units

76. Source of Emission Factor
(If not using AP-42, include calculations)

AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42

Other Other Other Other Other Other Other Other Other Other

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

77. Add-On Control Technology: Identify all control technologies used for this unit, and attach completed CE-01 (unless "none"). None Baghouse / Fabric Filter ­ Attach CE-02. Electrostatic Precipitator ­ Attach CE-04. Oxidizer / Incinerator ­ Attach CE-06. Condenser ­ Attach CE-08. Other (specify): Cyclone ­ Attach CE-03. Absorption / Wet Collector / Scrubber ­ Attach CE-05. Adsorber ­ Attach CE-07. Reduction ­ Attach CE-09. ­ Attach CE-10.

78. Control Techniques: Identify all control techniques used for this unit.

79. Process Limitations / Additional Information: Identify any acceptable process limitations. Attach additional information if necessary.

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Indiana Department Of Environmental Management Office Of Air Quality State Form 52551 (R / 1-07)

Process Information ­ Foundry, Die Casting, and Smelter Operations FORM PI-11 Page 8 of 10

PART I ­ Refining, Inoculation & Magnesium Treatment & Alloying Information Part I identifies any additives to the process to change the properties of the metals. Use additional sheets as necessary. 80. Does your production process use a REFINING procedure? 81. Flux type 82. Flux amount
(lb flux per lb metal)

Yes No

If yes, provide the information about flux. If no, proceed to the section about inoculation.

83. Frequency of process
(% of time refining is used)

84. Does your production process use an INOCULATION procedure? 85. Inoculant type 86. Inoculant amount
(lb inoculant per lb metal)

Yes No

If yes, provide the information about the inoculants. If no, proceed to the section about magnesium treatment.

87. Frequency of process
(% of time inoculant is used)

88. Does your production process use a MAGNESIUM (Mg) TREATMENT procedure? 89. Location of Magnesium Treatment Process 90. Unit Where Magnesium Process Occurs 91. Unit ID

Yes No

If yes, provide the information about magnesium treatment. If no, proceed to the section about Dross Cooling.

Furnace 92. Installation Date

Other (specify): 93. Magnesium amount
(lb Mg per lb metal)

94. Does your production process use DROSS COOLING? 95. Type of Dross Cooling: Dross Coolers Open Vats Dross Coolers Open Vats Dross Coolers Open Vats Dross Coolers Open Vats 96. Dross usage
(tons dross/hr)

Yes No

If yes, complete the rest of this section. If no, proceed to the next section.

97. Unit ID

98. Installation Date

99. Number of Coolers / Vats

100. Volume of each Cooler / Vat

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Indiana Department Of Environmental Management Office Of Air Quality State Form 52551 (R / 1-07)

Process Information ­ Foundry, Die Casting, and Smelter Operations FORM PI-11 Page 9 of 10

PART J ­ Pouring/Casting, Cooling and Shakeout Details Part J identifies the Pouring/Casting, Cooling, and Shakeout process lines. Use additional sheets as necessary. 101. Line / Unit ID 102. Installation Date 103. Capacity
(tons of metal per hr) (tons of sand per hour)

104. VOC emitted
(lb per hour, lb per cast)

105. PM emitted

106. HAP emitted

(lb per hour, lb per cast) (lb per hour, lb per cast)

107. Air Pollutant: Carbon Monoxide (CO) Lead (Pb) Nitrogen Oxides (NOX) Particulate Matter (PM) Particulate Matter less than 10m (PM10) Particulate Matter less than 2.5m (PM2.5) Sulfur Dioxide (SO2) Volatile Organic Compounds (VOC) Worst Case HAP (specify): Other (specify):

108. Emission Factor
value units

109. Source of Emission Factor
(If not using AP-42, include calculations)

AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42 AP-42

Other Other Other Other Other Other Other Other Other Other

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

110. Add-On Control Technology: Identify all control technologies used for this unit, and attach completed CE-01 (unless "none"). None Baghouse / Fabric Filter ­ Attach CE-02. Electrostatic Precipitator ­ Attach CE-04. Oxidizer / Incinerator ­ Attach CE-06. Condenser ­ Attach CE-08. Other (specify): Cyclone ­ Attach CE-03. Absorption / Wet Collector / Scrubber ­ Attach CE-05. Adsorber ­ Attach CE-07. Reduction ­ Attach CE-09. ­ Attach CE-10.

111. Control Techniques: Identify all control techniques used for this unit.

112. Process Limitations / Additional Information: Identify any acceptable process limitations. Attach additional information if necessary.

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Indiana Department Of Environmental Management Office Of Air Quality State Form 52551 (R / 1-07)

Process Information ­ Foundry, Die Casting, and Smelter Operations FORM PI-11 Page 10 of 10

PART K: Federal Rule Applicability Part K identifies any federal rules that apply to the process. 113. Is a New Source Performance Standard (NSPS) applicable to this source?
If yes, identify the affected emission units and attach a completed FED-01 for each rule that applies.

114. Unit ID Yes No

40 CFR Part 60, Subpart L 40 CFR Part 60, Subpart M 40 CFR Part 60, Subpart LL 40 CFR Part 60, Subpart OOO 40 CFR Part 60, Subpart UUU

Secondary Lead Smelters Brass and Bronze Production Plants Metallic Mineral Processing Plants Non-Metallic Mineral Processing Plants Calciners and Dryers in Mineral Industries 116. Unit ID Yes No

115. Is a National Emission Standard for Hazardous Air Pollutants (NESHAP) applicable to this source? If yes, identify the affected emission units and attach a
completed FED-01 for each rule that applies.

40 CFR Part 63, Subpart EEEE 40 CFR Part 63, Subpart MMMM 40 CFR Part 63, Subpart RRR 40 CFR Part 63, Subpart X

Iron and Steel Foundries Miscellaneous Metal Parts and Products Secondary Aluminum Secondary Lead Smelter

117. Non-Applicability Determination: Provide an explanation If the process unit appears subject to a rule (based on the rule title or the source category), but the rule will not apply.