DAQ-2025-001281

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February L9,2025
Utah Division of Air Quality
ATTN: Jay Morris, Section Manager
Small Source Compliance
150 North l-950 West
P. O. Box 744820
salt Lake city, Utah 84LL4-4820
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Re.: Hydro Extrusion USA, LLC
1550 N Hydro Way, Spanish Fork, UT 84560
40 CFR Part 53, Subpart RRR -
Semiannual Excess Emissions/Summary Report
Reoorti ns Period : 07 I Ot I 2024 th roueh t2 I 3L I 2024
Dear Sir:
Hydro Extrusion USA, LLC (Hydro) owns and operates a secondary aluminum production facility
(Facility) located in Spanish Fork, Utah. Hydro is subject to 40 CFR Part 63, Subpart RRR - National
Emission Standards for Hazardous Air Pollutants for Secondary Aluminum Production (Subpart RRR),
which requires that Hydro submit a Semiannual Report in accordance with 40 CFR 563.1516(b). As
allowed by 40 CFR 563.101(3Xvi) of Subpart A - General Provisions (Subpart A), the Summary Report is
being submitted. The attached Semiannual Report for the Subpart RRR affected sources at the Facility
is for the reporting period of OT lOt/2024 through t2/31./2O24.
As required bya0CFR 563.1516(b)(1)of Subpart RRR, both a Summary Reportand the Excess Emission
and Continuous Monitoring System Performance Report are being submitted. As allowed by 40 CFR
563.10(e)(3)(vii), the total duration of excess emissions during the reporting period was less than l"
percent of the total operating time for the reporting period. Continuous monitoring system (CMS)
downtime for the reporting period was also less than 5 percent of the total operating time for the
reporting period; therefore, the full Gaseous and Opacity Excess Emissions and Continuous Monitoring
System Performance Report is not being submitted.
lf you have any questions or require additional information, please contact me at (80L) 372-4782.
)
ydro
HSE Manager
Enclosures
CC: EPA Region Vlll, ATTN' Regional MACT Coordinator
File
Hydro Extrusions USA, LLC, Spanish Fork Operation - Summary Report
Secondary Aluminum MACT
19, February 2025
Summary Report - Gaseous and Opacity Excess Emission and
Continuous Monitoring System Performance
This Summary Report is provided to meet the requirements of 40 CFR 63.10(e) and 63.1516(b).
A. The company name and address of the affected source [63.10(eX3)(vi)(n]l:
Hydro Extrusion USA, LLC
(F/K/A Sapa Extrusions, lnc.)
Spanish Fork Operation
1550 N. Hydro Way
Spanish Fork, Utah 84660
B. ldentification of each hazardous air pollutant monitored at the affected source
[63.10(eX3XviXB)]:
Emission Point(s)HAP'(or HAP Surrogate) Monitoredl
Melting Furnace 21 X Organic HAP (dioxin/furan)
'HAP = Hazardous Air Pollutant1 Possible HAP emitted from Secondary Aluminum production facilities include: antimony (Sb) &
compounds, arsenic (As) & compounds (inorganic), cadmium (Cd) & compounds, chromium (Cr) &
compounds, dioxin/furans (D/F), hydrochloric acid (HCl), hydrogen fluoride (HF), lead (Pb) & compounds,
manganese (Mn) & compounds, mercury (Hg) & compounds, and nickel (Ni) & compounds. Area sources,
such as the Spanish Fork Operation, are required only to comply with emission limits and operating
requirements relating to Dioxin/Furans.
C. Beginning and ending dates of the reporting period [63.10(eX3XviXC)]:
Beginning:
Ending:
07-01-24
12-37-24
D. Brief description of regulated process units [63.10(eX3XviXD)l:
Hydro Extrusion USA, LLC - Spanish Fork Operation (Spanish Fork Operation) operates one
(1) 52.5-ton melter with an annual operating capacity of 153,300 tons (melter throughput).
This furnace processes clean charge materials; purchased aluminum scrap that is essentially
free of oils, lubricants, and coatings; internally generated saw chip briquettes; and
runaround scrap (internal runaround). The molten aluminum is cast into round ingots (logs)
of various diameters and lengths. No reactive fluxingtakes place in the furnace in question.
Hydro Extrusions USA, LLC, Spanish Fork Operation - Summary Report
Secondary Aluminum MACT
19, February 2025
Emissions from the melting furnace are discharged directly through a stack on furnace. No
add-on control devices are used.
Charge materials for the melting furnaces consist of aluminum pig, recycled scrap ingot
("RSl"), purchased scrap, internally generated runaround scrap, and saw chip briquettes.
The purchased scrap consists primarily of material from other extrusion, forging, and
fabricating operations. The quality of this material, in terms of oil and lubricants, is similar
to the internally generated scrap, however, purchased scrap may also contain painted
scrap. All purchased scrap is inspected to ensure consistencywith purchased scrap
specifications; painted scrap is separated and stored in dedicated bunkers. The maximum
amount of purchased scrap (not including RSI or painted scrap) used in a charge may be as
much as 7O0% of the charge weight. The maximum amount of coated (painted) or dirty
material in a charge is equalto or less than L0% of the total charge weight based on
performance testing conducted in March 2005. The maximum amount of saw chip
briquettes may not exceed 9.375 tons per charge. A full charge cycle typically lasts 3 to 3.5
hours. However, the charge cycle could be prolonged if a process upset prohibits the
molten metal from being transferred to the holding furnace. The maximum production rate
is approximately L4 tons per hour.
Molten metal from the melting furnace is transferred to a 47.5-ton holding furnace with an
annual operating capacity of approximately 125,000 tons. This uncontrolled, Group 1
furnace processes only clean charge transferred from the melting furnace. Alloying and
reactive fluxing takes place in the holding furnace with the addition of commercial alloying
metals and reactive salt flux. Addition of reactive salt flux is not used in all charges and is
only used for certain alloys approximately six charges per week. The facility records the
total reactive flux addition rate based on monitoring the weight of reactive flux per ton of
feed/cha rge per $53. 15 10(jX5).
The molten metal from the holding furnace is subsequently conveyed through an in-line
spinning nozzle inert flotation (SNIF)fluxer or "degasse(' prior to casting. The degasser uses
a mixture of a reactive gas (chlorine) and an inert gas (argon)to refine molten aluminum
prior to casting.
Both the holding furnace and the SNIF units are exempt from associated emission standards
under $63.1511(b) as an area source for HAP as well as 563.1512(eXZ) for receiving only
clean charge.
The molten aluminum is then transferred (tapped) to direct chill-type casters. ln this
process, water is used to coolthe molten aluminum into round ingots (logs of various
diameters and lengths. The logs are then used as the feed for the facility's extrusion
presses.
Hydro Extrusions USA, LLC, Spanish Fork Operation - Summary Report
Secondary Aluminum MACT
19, February 2025
Units Subject to 40 CFR 63 Subpart RRR
Source ID Regulatory
Classification
Average
Production Rate
Feed/Charge
Materials
Flux Type
Melting Furnace 21 Group 1 Furnace 52.5-ton/cycle Clean charge,
purchased scrap, saw
chip briquettes,
alloying materials
None
Holding Furnace Group 1 Furnace 47.5-ton/cycle Clean charge only Reactive
Salt
SNIF ln-Line Fluxer 47.5-ton/cycle Clean charge only Reactive
Bi-eas
E. The emission and operating parameter !imitations specified in the relevant standard(s)
[63.10(eX3XviXe)]:
Emission Unit Description Emission Limits Operating Parameter Limitations
Melting Furnace 2L DIF ls ug TEQ/Mg Al
Clean Charge Unrestricted
Purchased Scrap 90,000 Tons 1,2 month
rolling
Painted Purchased Scrap No more than 10% of
charse
Saw Chip Briquettes No more than 18,750
lbs/cha ree
Salt Flux None
Label Sources with
Limits and Operating
Parameters
N/A
Holding Furnace 21
Exempt due to Area
Source and Clean
Charge Only
Clean Charge U nrestricted
Salt Flux Solid Reactive
SNIF 21
Exempt due to Area
Source and Clean
Charge Only
Clean Charge U nrestricted
Flux ClzlAr Bi-Gas
Hydro Extrusions USA, LLC, Spanish Fork Operation - Summary Report
Secondary Aluminum MACT
19, February 2025
F. The monitoring equipment manufacturer(s) and mode! number(s)
[63.10(e)(3XviXr)]:
G. The date of the latest CMS certification or audit [63.10(e)(3XviXG)l
The following table summarizes the dates of the latest CMS calibration for each affected
source.
H. The total operating time of the affected source during the reporting period
[53.10(eX3XviXH)]:
Parameter Manufacturer Model Number Emission Unit(s) or Source(s)
Weight of each
charge and charge
component
Mettler Toledo lND280 Charge Chute
Scale Melting Furnace 21
Weight of each
charge and charge
component
Mettler Toledo Mettler Toledo
IND 310 Floor Scale Melting Furnace 21
Weight of each
charge and charge
component
Mettler Toledo lND780 Truck Scale Melting Furnace 21
Weight of alloying
material Mettler Toledo IND PBY Bench Scale Holding Furnace 21
Emission Unit lD Emission Unit
Description Continuous Monitoring Device lD
[ast
Calibration
Date
Meltine Furnace 21 Meltine Furnace Mettler Toledo IND 280 Charse Chute Scale 08/28/2024
Meltins Furnace 21 Meltine Furnace Mettler Toledo IND 780 Truck Scale 05/L3/2024
Melting Furnace 21 Melting Furnace Mettler Toledo IND 310 Floor Scale 0812812024
Holdine Furnace 21 Holdine Furnace Mettler Toledo IND PBA Bench Scale 08128/2024
Emission Unit No.Emission Unit Description Tota! Operating Time (hours)
Melting Furnace 21 Melting Furnace 3,479
Hydro Extrusions USA, LLC, Spanish Fork Operation - Summary Report
Secondary Aluminum MACT
19, February 2025
!. Emission data summary [63.10(eX3XviXI)]:
Emission testing for Dioxin/Furans was conducted on the regulated source, Melting Furnace
21, during the reporting period. The testing was conducted in the first week of October
2024 and the facility is awaiting the final testing report to submit to the State DAQ. The
affected units are uncontrolled; therefore, the Facility does not monitor control system
parameters.
J. CMS Performancesummary [63.10(e)(3)(vi](J)l:
The affected units are uncontrolled. Therefore, the Facility does not monitor control
system parameters. The following table summarizes continuous monitoring system
downtime during the reporting period:
K. Description of any changes in CMS processes, or controls since the last reporting period
[63.10(eX3l(viXK]l:
Total Duration of Downtime Breakdown of Cause(s) of CMS Downtime
:mission Unit
Description
Monitoring
Device/
Parameter
Total
Down-
time
(hours)
Percent oi
Source
Operating
Time
Monitoring
Equipment
Valfunction
Non-
monitoring
Equipment
Malfunction
aA/ac
Calibrations
Other
Known
Causes
Other
Unknown
Causes
Melting
Furnace 21
Mettler
Toledo
tND 280
Charge Chute
Sca le
0 700%o.o%o.o%o.o%o.o%o.o%
Vlelting
:urnace 2L
Mettler
Toledo
tND 780
Truck Scale
0 100%0.0%o.o%o.o%O.O o/o o.o%
Vlelting
:urnace 21
Vlettler
Ioledo
ND 319
:loor Scale
0 100%o.o%o.o%0.0%o.o%o.o%
tolding
:urnace 21
Vlettler
l-oledo
ND PBY
lench Scale
0 100%o.o%o.o%o.o%o.o%o.o%
Hydro Extrusions USA, LLC, Spanish Fork Operation - Summary Report
Secondary Aluminum MACT
19, February 2025
There were no changes in CMS processes or controls since the last reporting period.
(1). Results of performance tests conducted during reporting period [553.1516(bX3)]:
Emission testing for Dioxin/Furans was conducted on the regulated source, Melting Furnace
2!, duringthe reporting period. The testing was conducted in the first week of October
2024 and the facility is awaiting the final testing report to submit to the State DAQ.
The initial performance test results were submitted to the Utah Division of Air Quality on
July 26,2002 and were addressed to Sarah Malluche, Environmental Scientist. This initial
emission testing related only to Dioxin/Furans. No additional testing was performed during
this reporting period. ln accordance with $63.1511(e), repeattests are required everyfive
years for affected emissions units at secondary aluminum production facilities that are
major sources. The Hydro Extrusions USA, LLC, Spanish Fork Operation is an area source
and therefore, repeat tests are not required every five years.
(2). Certification for Group t holding furnace [563.1516(bX2Xiv)l:
This emission unit is exempt from emission standards under 563.15L1(b) and $63.1512(eX2)
due to the facility being an area source for HAPs and the emission unit processing only clean
charge.
(3). Certification for the SNIF [563.1s15(b)(2)(vi)]:
This emission unit is exempt from emission standards under 563.L511(b) and $63.1512(e)(2)
due to the facility being an area source for HAPs.
(4). Periods of Startup and Shutdown for the Group 1 Melting Furnace [553.1515(bX2Xvii)l:
During each startup and shutdown, no flux and no feed/charge were added to the emission
unit, and electricity, propane or natural gas were used as the sole source of heat or the
emission unit was not heated.
Hydro Extrusions USA, LLC, Spanish Fork Operation - Summary Report
Secondary Aluminum MACT
19, February 2025
Excess Emissions and Continuous Monitoring System (CMS)
Performance Report
This Excess Emission and CMS Performance Report is provided to meetthe requirements of 40
CFR 63.10(e) and 63.ls16(b).
A. The company name and address of the affected source:
Hydro Extrusion USA, LLC
(Formerly Sapa Extrusions, lnc.)
Spanish Fork Operation
1550 N. Hydro Way
Spanish Fork, Utah
B. Date and time identifying each operating period during which the CMS was inoperative except
for zero and high level checks:
The table below summarizes each period during which a CMS was inoperative during the
reporting period:
Emission Unit Description -
Monitoring Device/
Parameter Date Time Period
(Beein - End)
TotalTime CMS
lnoperative
(Hours: Minutes)
Nature of Repairs or
Adjustments Made to
CMS
None None None None None
No outages to report
C. The date and time identifying each operating period during which the CMS was out of control, as
defined in 53.8(cX8):
There were no CMS out-of-control periods during the reporting period.
D. The specific identification of each time period of excess emissions and parameter monitoring
exceedances that occurred during startups, shutdowns, and malfunctions (SSM) of the affected
source, as defined in 63.10(c)(7):
There were no excess emissions or parameter monitoring exceedances that occurred during
startups, shutdowns and malfunctions during the reporting period.
E. The specific identification of each time period of excess emissions and parameter monitoring
exceedances that occurred during periods other than startups, shutdowns, and malfunctions of
the affected source, as defined in 63.10(cX8):
Hydro Extrusions USA, LLC, Spanish Fork Operation - Summary Report
Secondary Aluminum MACT
19, February 2025
As allowed by 40 CFR 563.1O(eX3Xvii), the total duration of excess emissions and parameter
monitoring exceedances during the reporting period was less than 1 percent of the total
operating time for the reporting period.
ainted Purchases
ap No more than
LO% of charse bv Wt.
20%and 30% Purchased Painted
Scrap Charged During Stack Test
Trials
Hydro Extrusions USA, LLC, Spanish Fork Operation - Summary Report
Secondary Aluminum MACT
19, February 2025
Periodic Start-up, Shutdown and Malfunction (SSM) Report
This Start-up, Shutdown and Malfunction (SSM) Report is provided to meet the requirement of 40
cFR 563.L0(dxsxi).
A. The company name and address of the affected source:
Hydro Extrusion USA, LLC
(F lK/ ASapa Extrusions, lnc.)
Spanish Fork Operation
1550 N. Hydro Way
Spanish Fork, Utah 84660
B. Actions taken consistent with Startup, Shutdown and/or Malfunction:
The facility did not experience any startup, shutdown and/or malfunction events during the
reporting period that resulted in excess emissions.
Semiannual Compliance Report Certification Statement
[563. 10(eX3Xvi)(L), 553. ts 16(bX2Xvii)]
ln accordance with the requirements of 40 CFR 563.10(eX3)(vi)(L), I certify that, based on
information and belief formed after reasonable inquiry, the statements and information in this
Summary Report and the supporting enclosures are true, accurate and complete and that the
source has complied with the relevant standard which is 40 CFR Part 63 Subpart RRR - National
Emission Standards for Hazardous Air Pollutants for Secondary Aluminum Production.
Additionally, under 40 CFR 563.1516(b)(2)(vii), I certify that during each startup and shutdown,
no flux and no feed/charge were added to the emission unit, and electricity, propane or natural
gas were used as the sole source of heat or the emission unit was not heated for each affected
source choosing to demonstrate compliance during periods of startup and shutdown in
accordance with 563. 1513(fx1).
On behalf of Error! Reference source not found.:
The name, title, and signature of the responsible official
who is certifying the accuracy of the Three reports:
Brett Burninsham
Name of Responsible Official
The date of the report:
19th, Febru ary 2025
Operations Manager
Title of Responsible Official
19'h, Februgrv 2025.
Date
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sible Official
Hydro Extrusions USA, LLC, Spanish Fork Operation - Summary Report
Secondary Aluminum MACT
19, February 2025
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