Wisconsin Administrative Code
Department of Natural Resources
NR 400-499 - Environmental Protection - Air Pollution Control
Chapter NR 422 - Control Of Organic Compound EmissionsFrom Surface Coating, Printing And Asphalt Surfacing Operations
Section NR 422.143 - Lithographic printing - part 2
Universal Citation: WI Admin Code ยง NR 422.143
Current through August 26, 2024
(1) APPLICABILITY.
(a) This section applies to the owner or
operator of a printing facility that operates a lithographic printing press and
meets all of the following criteria:
1. The
facility has actual VOC emissions from all lithographic printing presses,
including related lithographic cleaning activities and fountain solution use at
the facility, before consideration of controls, equal to or greater than 3 tons
on a 12-consecutive month rolling basis.
2. The facility meets any of the following
criteria:
a. The facility is located in
Kenosha, Milwaukee, Ozaukee, Racine, Sheboygan, Washington, or Waukesha
County.
b. The facility is
constructed or modified on or after July 1, 2019, and is located in Kewaunee or
Manitowoc county.
c. The facility
is located in any area designated as a moderate, serious, severe, or extreme
ozone nonattainment area.
d. The
facility is located in any area formerly designated as a moderate, serious,
severe, or extreme ozone nonattainment area that has subsequently been
redesignated to attainment, except for any facility subject to s.
NR 422.142.
(am) When determining the VOC emissions for
applicability under this subsection, the VOC emissions shall include the
emissions from the use of inks, fountain solutions, and cleaning solutions, as
defined in s.
NR 422.02(14m).
(1m) RETENTION FACTORS AND CAPTURE EFFICIENCIES. For purposes of determining VOC emissions from offset lithographic printing operations, the following retention factors and capture efficiencies may be used:
(a) A 20% VOC
retention factor for heatset inks printed on absorptive substrates, meaning 80%
of the VOC in the ink is emitted during the printing process and is available
for capture and control by an add-on pollution control device.
(b) A 95% VOC retention factor for sheet-fed
and non-heatset web inks printed on absorptive substrates, meaning 5% of the
VOC in the ink is emitted during the printing process.
(c) A 50% VOC retention factor for cleaning
solution VOC in shop towels where the composite partial vapor pressure of the
VOC in the cleaning solution is less than 10 mm of Hg at 20°C (68°F)
and the cleaning solution and contaminated shop towels are kept in closed
containers, meaning 50% of the VOC used on the shop towels is emitted during
the cleaning process.
(d) A 100%
VOC capture efficiency for inks. All the VOC in the ink that is not retained is
assumed to be volatilized in the press dryer. Capture efficiency testing for
heatset dryers is not required if it is demonstrated that pressure in the dryer
is negative relative to the surrounding press room and the airflow is into the
dryer.
(e) A 70% VOC capture
efficiency for fountain solutions containing alcohol substitutes.
(f) A 40% VOC capture efficiency for
automatic blanket or roller wash, as defined in s.
NR 422.02(7c), where the VOC composite
partial vapor pressure of the automatic blanket or roller wash is less than 10
mm of Hg at 20°C (68°F).
(2) EXEMPTIONS. All of the following exemptions apply to lithographic printing operations affected by this section:
(a) Up to 110 gallons of cleaning solutions,
on a 12-consecutive month rolling basis, that do not meet the low VOC composite
partial vapor pressure or low VOC content requirements as stated in this
section, are exempt from the requirements of this section.
(b) The fountain solution VOC content
requirements in sub. (3) (b) do not apply to sheet-fed presses with a maximum
sheet size of up to 11 inches by 17 inches or to any lithographic press with a
total fountain solution reservoir of less than one gallon.
(c) The printing of books on a heatset
lithographic press is exempt from the requirements of sub. (3) (a).
(d) Heatset lithographic presses with a
maximum web width of up to 22 inches are exempt from the requirements of sub.
(3) (a).
(3) EMISSION LIMITATIONS.
(a)
Dryer
exhaust.
1. On and after May 1,
2010, no owner or operator of a heatset web lithographic printing press may
operate, or cause, allow or permit the operation of a lithographic press that
has maximum theoretical emissions of VOCs, from the dryer, equal to or greater
than 25 tons per year from heatset inks, unless the owner or operator installs
and operates an emission control device and meets the applicable emission
limitation as follows:
a. If the emission
control device was first installed prior to May 1, 2010, the owner or operator
shall reduce VOC emissions from the lithographic press dryer exhaust by 90% by
weight as carbon, minus methane and ethane, or maintain a maximum dryer exhaust
outlet VOC concentration of 20 ppmv, as carbon, minus methane and
ethane.
b. If the emission control
device was first installed after May 1, 2010, the owner or operator shall
reduce VOC emissions from the lithographic press dryer exhaust by 95% by weight
as carbon, minus methane and ethane, or maintain a maximum dryer exhaust outlet
VOC concentration of 20 ppmv, as carbon, minus methane and ethane.
Note: With regard to use of the phrase "first installed" in this paragraph, the first installation date for a control device does not change if the device is later moved to a new location. For example, if a brand new control device first installed in 1992 is moved to a new location in 1998, the first installation date is still 1992.
2. If a combined dryer and control device is
a part of the press design, a 100% capture at the control inlet may be assumed
for purposes of meeting the emission reduction limits in subd. 1.
(b)
Fountain
solutions.
1. `Heatset web presses.'
On and after May 1, 2010, any person who owns or operates a heatset web
lithographic printing press shall use a fountain solution which has a VOC
content, as applied, of no more than one of the following:
a. 1.6% by weight if the fountain solution
contains any restricted alcohol and is not refrigerated to 60°F or
less.
b. 3.0% by weight if the
fountain solution contains any restricted alcohol and is refrigerated to
60°F or less.
c. 5.0% by weight
if the fountain solution contains no restricted alcohol.
2. `Non-heatset web presses.' On and after
May 1, 2010, any person who owns or operates a non-heatset web lithographic
printing press shall use a fountain solution which contains no restricted
alcohol and which has a VOC content, as applied, of no more than 5.0% by
weight.
3. `Sheet-fed presses.' On
and after May 1, 2010, any person who owns or operates a sheet-fed lithographic
printing press shall, use a fountain solution which has a VOC content, as
applied, of no more than one of the following:
a. 5.0% by weight.
b. 8.5% by weight if the fountain solution is
refrigerated to 60°F or less.
(c)
Cleaning solutions.
Except as provided in sub. (2) (a), no owner or operator of a lithographic
printing press may cause, allow, or permit the use of a cleaning solution
unless the cleaning solution has a VOC content less than 70% by weight or has a
composite partial vapor pressure of less than or equal to 10 mm of Hg at
68°F.
(4) WORK PRACTICES.
(a) On and after November 1, 2009,
the owner or operator of a lithographic press subject to this subsection shall
store all solvents, solvent solutions and any applicator moistened with
solvents or solvent solutions that are used in cleaning operations related to
lithographic printing in covered non-absorbent, non-leaking containers, except
when filling or emptying the container.
(5) MONITORING REQUIREMENTS.
(a) The owner or operator of any lithographic
printing press shall monitor, at least once each 8-hour shift, the temperature
of each fountain solution reservoir for any fountain solution subject to sub.
(3) (b) 1. b. or 3. b.
(b) The
owner or operator of any lithographic printing press subject to the VOC control
device requirements of sub. (3) (a) shall comply with all of the following
monitoring requirements:
1. Install and
operate continuous temperature monitoring and recording equipment that measures
and records any of the following temperature of the control device at least
once every 15 minutes:
a. The combustion
chamber or minimum operating temperature for thermal oxidizers.
b. The catalytic bed inlet temperature for
catalytic oxidizers.
2.
Meet the instrument requirements in s.
NR 439.055(3) (a) and (4) for the
temperature monitoring devices.
3.
Maintain the 3-hour average temperature at or above any of the following levels
when the associated printing press is in operation:
a. 50°F below the minimum operating
temperature specified by the manufacturer for regenerative thermal
oxidizers.
b. 50°F below the
average temperature measured during the most recent emission test that
demonstrated compliance for all other type of oxidizers.
4. For catalytic oxidizers, inspect the
catalyst bed material annually for general catalyst condition and any signs of
potential catalyst depletion. The owner or operator shall also collect a
representative sample of the catalyst from the catalytic oxidizer, in
accordance with manufacturer's recommendations, and have it tested to evaluate
the catalyst's capability to continue to function at or above the required
control efficiency. An evaluation of the catalyst bed material shall be
conducted whenever the results of the inspection indicate signs of potential
catalyst depletion or poor catalyst condition based on manufacturer's
recommendations, but not less than once per year.
5. Perform maintenance for the control
devices in accordance with manufacturer's recommendations.
(6) RECORDKEEPING REQUIREMENTS. In addition to the applicable recordkeeping requirements in s. NR 439.04, the owner or operator of any lithographic printing press shall collect and record the applicable information specified in this subsection. The information shall be maintained at the facility for a minimum of 5 years and shall be made available to an authorized department representative at any time during normal working hours. The information required is all of the following:
(a) For a
heatset web lithographic printing press using a control device, all of the
following:
1. Temperature monitoring data for
the control device in accordance with sub. (5) (b) 1. for each day of
operation.
2. A log or record of
any time when the control device or control device monitoring equipment is
offline while the associated printing line is in operation.
3. A maintenance log for the control device
and control device monitoring equipment detailing all maintenance performed and
including the dates and duration of any outages.
4. Annual inspection results for catalytic
oxidizers.
(b) For
fountain solutions monitored under sub. (5), the fountain solution reservoir
temperature for each 8-hour shift of operation.
(c) For each fountain solution used, the
percent by weight VOC content as applied, and the CAS number and chemical name
of each restricted alcohol.
(d) For
each cleaning solution prepared, the percent by weight VOC content or the VOC
composite partial vapor pressure for the cleaning solution prepared.
(e) For each month of operation, the volume
of all cleaning solutions used that do not meet either of the emission
limitations in sub. (3) (c).
(7) COMPLIANCE TESTING.
(a) The owner or operator of a heatset web
lithographic printing press shall demonstrate compliance with the appropriate
destruction efficiency or emission rate in sub. (3) (a) by performing
compliance emission tests on each control device. The initial emission tests
shall be performed by the compliance deadline in sub. (8) (am). Each emission
test shall follow the methods and procedures listed in s.
NR 439.07. Method 18, 25 or 25A in 40 CFR part 60,
Appendix A, incorporated by reference in s.
NR 484.04(16), (19) and (20), shall be
used to determine the VOC concentration at the sampling points. When
determining the VOC concentration, the probe shall be heated during testing to
at least the exhaust gas stream temperature.
(b) The owner or operator of a heatset web
lithographic printing press shall perform the compliance emission tests
required under par. (a) according to one of the following applicable test
schedules:
1. Any facility with allowable VOC
emissions from lithographic printing presses of 100 tons or more per year shall
perform an emission test that demonstrates compliance with sub. (3) (a) every
24 months. Each biennial test shall be performed within 90 days of the
anniversary date of the initial emission test or an alternate date approved by
the department. The testing exceptions listed in s.
NR 439.075(4) may apply to this test
schedule.
2. Any facility with
allowable VOC emissions from lithographic printing presses of less than 100
tons per year shall perform an initial emission test that demonstrates
compliance with sub. (3) (a).
(c) The VOC content of the as-applied
fountain solutions and cleaning solutions shall be determined by any of the
following methods:
1. The method referred to
in s.
NR 439.06(3) (j).
2. If diluted prior to use, a calculation
shall be performed for VOC content that combines the method referred in s.
NR 439.06(3) (j) for the concentrated
materials used to prepare the as-applied fountain solution or cleaning
solution, and the proportions in which they are mixed to make the as-applied
fountain solution or cleaning solution.
(d) The VOC composite partial vapor pressure
of each cleaning solution shall be determined by any of the following methods:
1. If diluted prior to use, calculate the VOC
composite vapor pressure of the as-applied solvent by using the formula for
"VOC composite vapor pressure" as follows:
a.
Determine the identity and quantity of each compound in a blended organic
solvent.
b. Determine the vapor
pressure of each pure VOC component.
c. Calculate the VOC composite partial
pressure of the solvent by using the formula for "VOC composite partial
pressure." For the purpose of this calculation, the blended solvent shall be
assumed to be an ideal solution where "Raoult's Law" applies. The partial vapor
pressures of each compound at 68°F shall be used in the formula. The VOC
composite partial pressure shall be calculated as follows:
where:
Wi is the weight of the "i"th VOC compound, in grams.
Ww is the weight of water, in grams.
We is the weight of exempt compound, in grams.
MWi is the molecular weight of the "i"th VOC compound, in grams per gram-mole.
MWw is the molecular weight of water, in grams per gram-mole.
MWe is the molecular weight of the "e"th exempt compound, in grams per gram-mole.
PPc is the VOC composite vapor pressure at 68°F, in mm Hg.
VPi is the vapor pressure of the "i"th VOC compound at 68°F, in mm Hg.
2. If not diluted prior to use, the owner or
operator shall use formulation information provided by the supplier, such as a
safety data sheet (SDS) or equivalent information from the supplier, as long as
it is based on results determined in accordance with the procedure in subd.
1.
(8) COMPLIANCE SCHEDULE AND CERTIFICATION REQUIREMENTS.
(am) The owner or operator of a heatset web
lithographic printing press that is installed after July 1, 2019, shall perform
a compliance emission test within 180 days after installation of the press and
shall submit to the department no later than 60 days after the test written
certification that the press is in compliance with the applicable requirements
of sub. (3) and a demonstration of compliance in accordance with subs. (6),
(7), and (8).
(bm) The owner or
operator of any lithographic printing press, other than a heatset web press,
that is installed after July 1, 2019, shall submit to the department, no later
than 180 days after installation of the press, written certification that the
press is in compliance with the applicable requirements of sub. (3) and a
demonstration of compliance in accordance with subs. (6), (7), and (8).
(c) Facilities subject to this
section and located in an area described under sub. (1) (a) 2. c., shall comply
with the applicable requirements of this section by the following deadlines:
1. Facilities that were initially constructed
in an area described in sub. (1) (a) 2. c., prior to the effective date of its
designation as moderate, serious, severe, or extreme ozone nonattainment, shall
comply with applicable requirements within 180 days of the effective date of
designation.
2. Facilities that
were initially constructed in an area described in sub. (1) (a) 2. c., after
the area has been designated as moderate, serious, severe, or extreme ozone
nonattainment, shall comply with applicable requirements upon
startup.
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