Wisconsin Administrative Code, Subchapter II, Section NR 440.48 - Surface coating of metal furniture | Wisconsin Administrative Code

(1) APPLICABILITY AND DESIGNATION OF AFFECTED FACILITY.

(a) The affected facility to which the provisions of this section apply is each metal furniture surface coating operation in which organic coatings are applied.

(b) This section applies to each affected facility identified in par. (a) on which construction, modification or reconstruction is commenced after November 28, 1980.

(c) Any owner or operator of a metal furniture surface coating operation that uses less than 3,842 liters of coating (as applied) per year and keeps purchase or inventory records or other data necessary to substantiate annual coating usage shall be exempt from all other provisions of this section. These records shall be maintained at the source for a period of at least 2 years.

(2) DEFINITIONS AND SYMBOLS.

(a) As used in this section, terms not defined in this paragraph have the meanings given in s. NR 440.02.

1. "Bake oven" means a device which uses heat to dry or cure coatings.

2. "Dip coating" means a method of applying coatings in which the part is submerged in a tank filled with the coatings.

3. "Electrodeposition" or "EDP" means a method of applying coatings in which the part is submerged in a tank filled with the coatings and in which an electrical potential is used to enhance deposition of the coatings on the part.

4. "Electrostatic spray application" means a spray application method that uses an electrical potential to increase the transfer efficiency of the coatings.

5. "Flashoff area" means the portion of a surface coating operation between the coating application area and bake oven.

6. "Flow coating" means a method of applying coatings in which the part is carried through a chamber containing numerous nozzles which direct unatomized streams of coatings from many different angles onto the surface of the part.

7. "Organic coating" means any coating used in a surface coating operation, including dilution solvents, from which volatile organic compound emissions occur during the application or the curing process. For the purpose of this section, powder coatings are not included in this definition.

8. "Powder coating" means any surface coating which is applied as a dry powder and is fused into a continuous coating film through the use of heat.

9. "Spray application" means a method of applying coatings by atomizing and directing the atomized spray toward the part to be coated.

10. "Surface coating operation" means the system on a metal furniture surface coating line used to apply and dry or cure an organic coating on the surface of the metal furniture part or product. The surface coating operation may be a prime coat or a topcoat operation and includes the coating application station or stations, flashoff area and curing oven.

11. "Transfer efficiency" means the ratio of the amount of coating solids deposited onto the surface of a part or product to the total amount of coating solids used.

12. "VOC content" means the proportion of a coating that is volatile organic compounds (VOCs), expressed as kilograms of VOCs per liter of coating solids.

13. "VOC emissions" means the mass of volatile organic compounds (VOCs), expressed as kilograms of VOCs per liter of applied coating solids, emitted from a metal furniture surface coating operation.

(b) As used in this section, symbols not defined in this paragraph have the meanings given in s. NR 440.03.

1. Ca is the VOC concentration in each gas stream leaving the control device and entering the atmosphere (parts per million by volume, as carbon).

2. Cb is the VOC concentration in each gas stream entering the control device (parts per million by volume, as carbon).

3. Cf is the VOC concentration in each gas stream emitted directly to the atmosphere (parts per million by volume, as carbon).

4. Dc is the density of each coating, as received (kilograms per liter).

5. Dd is the density of each diluent VOC solvent (kilograms per liter).

6. Dr is the density of VOC solvent recovered by an emission control device (kilograms per liter).

7. E is the VOC destruction efficiency of the control device (fraction).

8. F is the proportion of total VOCs emitted by an affected facility that enters the control device (fraction).

9. G is the volume-weighted average mass of VOCs in coatings consumed in a calendar month per unit volume of coating solids applied (kilograms per liter).

10. Lc is the volume of each coating consumed, as received (liters).

11. Ld is the volume of each diluent VOC solvent added to coatings (liters).

12. Lr is the volume of VOC solvent recovered by an emission control device (liters).

13. Ls is the volume of coating solids consumed (liters).

14. Md is the mass of diluent VOC solvent consumed (kilograms).

15. Mo is the mass of VOCs in coatings consumed as received (kilograms).

16. Mf is the mass of VOCs recovered by an emission control device (kilograms).

17. N is the volume-weighted average mass of VOC emissions to the atmosphere per unit volume of coating solids applied (kilograms per liter).

18. Qa is the volumetric flow rate of each gas stream leaving the control device and entering the atmosphere (dry standard cubic meters per hour).

19. Qb is the volumetric flow rate of each gas stream entering the control device (dry standard cubic meters per hour).

20. Qf is the volumetric flow rate of each gas stream emitted directly to the atmosphere (dry standard cubic meters per hour).

21. R is the overall VOC emission reduction achieved for an affected facility (fraction).

22. T is the transfer efficiency (fraction).

23. Vs is the proportion of solids in each coating (or input stream) as received (fraction by volume).

24. Wo is the proportion of VOCs in each coating (or input stream) as received (fraction by weight).

(3) STANDARD FOR VOLATILE ORGANIC COMPOUNDS (VOC).

(a) On and after the date on which the initial performance test required to be conducted by s. NR 440.08(1) is completed, no owner or operator subject to the provisions of this section may cause the discharge into the atmosphere of VOC emissions from any metal furniture surface coating operation in excess of 0.90 kilogram of VOC per liter of coating solids applied.

(4) PERFORMANCE TESTS AND COMPLIANCE PROVISIONS.

(a) Section NR 440.08(4) and (6) do not apply to the performance test procedures required by this section.

(b) The owner or operator of an affected facility shall conduct an initial performance test as required under s. NR 440.08(1) and thereafter a performance test each calendar month for each affected facility according to the procedures in this subsection.

(c) The owner or operator shall use the following procedures for determining monthly volume-weighted average emissions of VOCs in kilograms per liter of coating solids applied (G).

1. An owner or operator shall use the following procedures for any affected facility which does not use a capture system and control device to comply with the emissions limit specified under sub. (3). The owner or operator shall determine the composition of the coatings by formulation data supplied by the manufacturer of the coating or by an analysis of each coating, as received, using Method 24 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17(1). The department may require the owner or operator who uses formulation data supplied by the manufacturer of the coating to determine the VOC content of coating using Method 24. The owner or operator shall determine the volume of coating and the mass of VOC solvent used for thinning purposes from company records on a monthly basis. If a common coating distribution system serves more than one affected facility or serves both affected and existing facilities, the owner or operator shall estimate the volume of coating used at each facility by using the average dry weight of coating and the surface area coated by each affected and existing facility or by other procedures acceptable to the department.

a. Calculate the volume-weighted average of the total mass of VOCs consumed per unit volume of coating solids applied (G) during each calendar month for each affected facility, except as provided under subds. 2. and 3. Each monthly calculation shall be considered a performance test. Except as provided in subd. 1. d., the volume-weight average of the total mass of VOCs consumed per unit volume of coating solids applied (G) each calendar month shall be determined by the following procedures.

1) Calculate the mass of VOCs used (Mo+ Md) during each calendar month for each affected facility by the following equation:

See PDF for diagram

) (S) LdjDdj will be zero if no VOC solvent is added to the coatings, as received.)

where:

n is the number of different coatings used during the calendar month

m is the number of different diluent VOC solvents used during the calendar month

2) Calculate the total volume of coating solids used (Ls) in each calendar month for each affected facility by the following equation:

See PDF for diagram

where:

n is the number of different coatings used during the calendar month.

Select the appropriate transfer efficiency from Table 1. If the owner or operator can demonstrate to the satisfaction of the department that other transfer efficiencies other than those shown are appropriate, the department shall approve their use on a case-by-case basis. Transfer efficiency values for application methods not listed below shall be determined by the department on a case-by-case basis. An owner or operator shall submit sufficient data for the department to judge the accuracy of the transfer efficiency claims.

Table 1

Transfer Efficiencies

Application methods	Transfer efficiency (T)
a)	Air atomized spray	0.25
b)	Airless spray	0.25
c)	Manual electrostatic spray	0.60
d)	Nonrotational automatic electrostatic spray	0.70
e)	Rotating head electrostatic spray (manual and automatic)	0.80
f)	Dip coat and flow coat	0.90
g)	Electrodeposition	0.95

Where more than one application method is used within a single surface coating operation the owner or operator shall determine the composition and volume of each coating applied by each method through a means acceptable to the department and compute the weighted average transfer efficiency by the following equation:

See PDF for diagram

where:

n is the number of coatings used

p is the number of application methods used

3) Calculate the volume-weighted average mass of VOCs consumed per unit volume of coating solids applied (G) during the calendar month for each affected facility by the following equation:

See PDF for diagram

b. Calculate the volume-weighted average of VOC emissions to the atmosphere (N) during the calendar month for each affected facility by the following equation:

N = G

c. Where the volume-weighted average mass of VOC discharged to the atmosphere per unit volume of coating solids applied (N) is less than or equal to 0.90 kilogram per liter, the affected facility is in compliance.

d. If each individual coating used by an affected facility has a VOC content, as received, which when divided by the lowest transfer efficiency at which the coating is applied, results in a value equal to or less than 0.90 kilogram per liter, the affected facility is in compliance provided no VOCs are added to the coatings during distribution or application.

2. An owner or operator shall use the following procedures for any affected facility that uses a capture system and a control device that destroys VOCs (e.g., incinerator) to comply with the emission limit specified under sub. (3).

a. Determine the overall reduction efficiency (R) for the capture system and control device. For the initial performance test the overall reduction efficiency (R) shall be determined as prescribed in subd. 2. a. 1), 2) and 3). In subsequent months, the owner or operator may use the most recently determined overall reduction efficiency (R) for the performance test providing control device and capture system operating conditions have not changed. The procedure in subd. 2. a. 1), 2) and 3) shall be repeated when directed by the department or when the owner or operator elects to operate the control device or capture system at conditions different from the initial performance test.

1) Determine the fraction (F) of total VOCs emitted by an affected facility that enters the control device using the following equation:

See PDF for diagram

where:

n is the number of gas streams entering the control device

m is the number of gas streams emitted directly to the atmosphere

2) Determine the destruction efficiency of the control device (E) using values of the volumetric flow rate of each of the gas streams and the VOC content (as carbon) of each of the gas streams in and out of the device by the following equation:

See PDF for diagram

where:

n is the number of gas streams entering the control device

m is the number of gas streams leaving the control device and entering the atmosphere

3) Determine overall reduction efficiency (R) using the following equation:

R = EF

b. Calculate the volume-weighted average of the total mass of VOCs per unit volume of coating solids applied (G) during each calendar month for each affected facility using equations in subd. 1. a. 1), 2) and 3).

c. Calculate the volume-weighted average of VOC emissions to the atmosphere (N) during each calendar month by the following equation:

N = G (1-R)

d. If the volume weighted average mass of VOCs emitted to the atmosphere for each calendar month (N) is less than or equal to 0.90 kilogram per liter of coating solids applied, the affected facility is in compliance. Each monthly calculation is a performance test.

3. An owner or operator shall use the following procedure for any affected facility which uses a control device that recovers the VOCs (e.g., carbon adsorber) to comply with the applicable emission limit specified under sub. (3).

a. Calculate the total mass of VOCs consumed - (Mo + Md) and the volume-weighted average of the total mass of VOCs per unit volume of coating solids applied (G) during each calendar month for each affected facility using equations in subd. 1. a. 1), 2) and 3).

b. Calculate the total mass of VOCs recovered (Mr) during each calendar month using the following equation:

Mr = LrDr

c. Calculate overall reduction efficiency of the control device (R) for each calendar month for each affected facility using the following equation:

R= Mr/ Mo+ Md

d. Calculate the volume-weighted average mass of VOCs emitted to the atmosphere (N) for each calendar month for each affected facility using the equation in subd. 2. c.

e. If the weighted average mass of VOCs emitted to the atmosphere for each calendar month (N) is less than or equal to 0.90 kilogram per liter of coating solids applied, the affected facility is in compliance. Each monthly calculation is a performance test.

(5) MONITORING OF EMISSIONS AND OPERATIONS.

(a) The owner or operator of an affected facility which uses a capture system and an incinerator to comply with the emission limits specified under sub. (3) shall install, calibrate, maintain and operate temperature measurement devices according to the following procedures:

1. Where thermal incineration is used, a temperature measurement device shall be installed in the firebox. Where catalytic incineration is used, a temperature measurement device shall be installed in the gas stream immediately before and after the catalyst bed.

2. Each temperature measurement device shall be installed, calibrated and maintained according to the manufacturer's specifications. The device shall have an accuracy of the greater of 0.75% of the temperature being measured expressed in degrees Celsius or " 2.5°C.

3. Each temperature measurement device shall be equipped with a recording device so that a permanent continuous record is produced.

(b) The owner or operator of an affected facility which uses a capture system and a solvent recovery system to comply with the emission limits specified under sub. (3) shall install the equipment necessary to determine the total volume of VOC solvent recovered daily.

(6) REPORTING AND RECORDKEEPING REQUIREMENTS.

(a) The reporting requirements of s. NR 440.08(1) apply only to the initial performance test. Each owner or operator subject to the provisions of this section shall include the following data in the report of the initial performance test required under s. NR 440.08(1):

1. Except as provided in subd. 2., the volume-weighted average mass of VOCs emitted to the atmosphere per volume of applied coating solids (N) for a period of one calendar month from each affected facility.

2. For each affected facility where compliance is determined under the provisions of sub. (4) (c) 1. d., a list of the coatings used during a period of one calendar month, the VOC content of each coating calculated from data determined using Method 24 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17(1), or supplied by the manufacturer of the coating, and the minimum transfer efficiency of any coating application equipment used during the month.

3. For each affected facility where compliance is achieved through the use of an incineration system, the following additional information shall be reported:

a. The proportion of total VOCs emitted that enters the control device (F).

b. The VOC reduction efficiency of the control device (E).

c. The average combustion temperature or the average temperature upstream and downstream of the catalyst bed, and

d. A description of the method used to establish the amount of VOCs captured and sent to the incinerator.

4. For each affected facility where compliance is achieved through the use of a solvent recovery system, the following additional information shall be reported:

a. The volume of VOC solvent recovered (Lr), and

b. The overall VOC emission reduction achieved (R).

(b) Following the initial performance test, the owner or operator of an affected facility shall identify, record, and submit a written report to the department every calendar quarter of each instance in which the volume-weighted average of the total mass of VOC's emitted to the atmosphere per volume of applied coating solids (N) is greater than the limit specified under sub. (3). If no such instances have occurred during a particular quarter, a report stating this shall be submitted to the department semiannually.

(c) Following the initial performance test, the owner or operator of an affected facility shall identify, record, and submit at the frequency specified in s. NR 440.07(3) the following:

1. Where compliance with sub. (3) is achieved through the use of thermal incineration, each 3-hour period when metal furniture is being coated during which the average temperature of the device was more than 28°C below the average temperature of the device during the most recent performance test at which destruction efficiency was determined as specified under sub. (4).

2. Where compliance with sub. (3) is achieved through the use of catalytic incineration, each 3-hour period when metal furniture is being coated during which the average temperature of the device immediately before the catalyst bed is more than 28°C below the average temperature of the device immediately before the catalyst bed during the most recent performance test at which destruction efficiency was determined as specified under sub. (4). Additionally, when metal furniture is being coated, all 3-hour periods during which the average temperature difference across the catalyst bed is less than 80% of the average temperature difference across the catalyst bed during the most recent performance test at which destruction efficiency was determined as specified under sub. (4) will be recorded.

3. For thermal and catalytic incinerators, if no periods as described in subds. 1. and 2. occur, the owner or operator shall state this in the report.

(d) Each owner or operator subject to the provisions of this section shall maintain at the source, for a period of at least 2 years, records of all data and calculations used to determine VOC emissions from each affected facility. Where compliance is achieved through the use of thermal incineration each owner or operator shall maintain at the source daily records of the incinerator combustion chamber temperature. If catalytic incineration is used, the owner or operator shall maintain at the source daily records of the gas temperature, both upstream and downstream of the incinerator catalyst bed. Where compliance is achieved through the use of a solvent recovery system, the owner or operator shall maintain at the source daily records of the amount of solvent recovered by the system for each affected facility.

(7) TEST METHODS AND PROCEDURES.

(a) The reference methods in 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17, except as provided under s. NR 440.08(2) shall be used to determine compliance with sub. (3) as follows:

1. Method 24, or coating manufacturer's formulation data for use in the determination of VOC content of each batch of coating as applied to the surface of the metal parts but in case of an inconsistency between the Method 24 results and the formulation data, the Method 24 results will govern,

2. Method 25 for the measurement of VOC concentration,

3. Method 1 for sample and velocity traverses,

4. Method 2 for velocity and volumetric flow rate,

5. Method 3 for gas analysis, and

6. Method 4 for stack gas moisture.

(b) For Method 24 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17, the coating sample shall be at least a one liter sample in a one liter container taken at a point where the sample will be representative of the coating material as applied to the surface of the metal part.

(c) For Method 25 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17, the minimum sampling time for each of 3 runs shall be 60 minutes and the minimum sample volume shall be 0.003 dry standard cubic meters except that shorter sampling times or smaller volumes, when necessitated by process variables or other factors, may be approved by the department.

(d) The department shall approve testing of representative stacks on a case-by-case basis if the owner or operator can demonstrate to the satisfaction of the department that testing of representative stacks yields results comparable to those that would be obtained by testing all stacks.

Wisconsin Administrative CodeDepartment of Natural ResourcesNR 400-499 - Environmental Protection - Air Pollution ControlChapter NR 440 - Standards of performance for new stationary sourcesSubchapter II - Standards of PerformanceSection NR 440.48 - Surface coating of metal furniture

Wisconsin Administrative Code
Department of Natural Resources
NR 400-499 - Environmental Protection - Air Pollution Control
Chapter NR 440 - Standards of performance for new stationary sources
Subchapter II - Standards of Performance
Section NR 440.48 - Surface coating of metal furniture