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 440.57 - Industrial surface coating: large appliances
Universal Citation: WI Admin Code ยง NR 440.57
Current through August 26, 2024
(1) APPLICABILITY AND DESIGNATION OF AFFECTED FACILITY.
(a) The
provisions of this section apply to each surface coating operation in a large
appliance surface coating line.
(b)
Any facility under par. (a) that commences construction, modification or
reconstruction after December 24, 1980, is subject to the requirements of this
section.
(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. "Applied
coating solids" means the coating solids that adhere to the surface of the
large appliance part being coated.
2. "Coating application station" means that
portion of the large appliance surface coating operation where a prime coat or
a topcoat is applied to large appliances parts or products (e.g., dip tank,
spray booth or flow coating unit).
3. "Curing oven" means a device that uses
heat to dry or cure the coatings applied to large appliance parts or
products.
4. "Electrodeposition" or
"EDP" means a method of coating application in which the large appliance part
or product is submerged in a tank filled with coating material suspended in
water and an electrical potential is used to enhance deposition of the material
on the part or product.
5.
"Flashoff area" means the portion of a surface coating line between the coating
application station and the curing oven.
6. "Large appliance part" means any organic
surface-coated metal lid, door, casing, panel or other interior or exterior
metal part or accessory that is assembled to form a large appliance product.
Parts subject to in-use temperatures in excess of 250°F are not included in
this definition.
7. "Large
appliance product" means any organic surface-coated metal range, oven,
microwave oven, refrigerator, freezer, washer, dryer, dishwasher, water heater
or trash compactor manufactured for household, commercial or recreational
use.
8. "Large appliance surface
coating line" means that portion of a large appliance assembly plant engaged in
the application and curing of organic surface coatings on large appliance parts
or products.
9. "Organic coating"
means any coating used in a surface coating operation, including dilution
solvents, from which VOC emissions occur during the application or the curing
process. For the purpose of this section, powder coatings are not included in
this definition.
10. "Powder
coating" means any surface coating that is applied as a dry powder and is fused
into a continuous coating film through the use of heat.
11. "Spray booth" means the structure housing
automatic or manual spray application equipment where a coating is applied to
large appliance parts or products.
12. "Surface coating operation" means the
system on a large appliance surface coating line used to apply and dry or cure
an organic coating on the surface of large appliance parts or products. 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.
13. "Transfer efficiency"
means the ratio of the amount of coating solids deposited onto the surface of a
large appliance part or product to the total amount of the coating solids
used.
14. "VOC content" means the
proportion of a coating that is volatile organic compounds (VOCs), expressed as
kilograms of VOCs per liter of coating solids.
15. "VOC emissions" means the mass of
volatile organic compounds (VOCs), expressed as kilograms of VOCs per liter of
applied coating solids, emitted from a 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
concentration of VOCs in a gas stream leaving a control device and entering the
atmosphere (parts per million by volume, as carbon).
2. Cb is the concentration of VOCs in a gas
stream entering a control device (parts per million by volume, as
carbon).
3. Cf is the concentration
of VOCs in a gas stream emitted directly to the atmosphere (parts per million
by volume, as carbon).
4. Dc is the
density of coating (or input stream), as received (kilograms per
liter).
5. Dd is the density of a
VOC solvent added to coatings (kilograms per liter).
6. Dr is the density of a VOC solvent
recovered by an emission control device (kilograms per liter).
7. E is the VOC destruction efficiency of a
control device (fraction).
8. F is
the proportion of total VOCs emitted by an affected facility that enters a
control device (fraction).
9. G is
the volume-weighted average mass of VOCs in coatings consumed in a calendar
month per unit volume of applied coating solids (kilograms per
liter).
10. Lc is the volume of
coating consumed, as received (liters).
11. Ld is the volume of 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 VOC solvent added to
coatings (kilograms).
15. Mo is the
mass of VOCs in coatings consumed, as received (kilograms).
16. Mr is the mass of VOCs recovered by an
emission control device (kilograms).
17. Qa is the volumetric flow rate of a gas
stream leaving a control device and entering the atmosphere (dry standard cubic
meters per hour).
18. Qb is the
volumetric flow rate of a gas stream entering a control device (dry standard
cubic meters per hour).
19. Qf is
the volumetric flow rate of a gas stream emitted directly to the atmosphere
(dry standard cubic meters per hour).
20. R is the overall VOC emission reduction
achieved for an affected facility (fraction).
21. T is the transfer efficiency
(fraction).
22. Vs is the
proportion of solids in a coating (or input stream), as received (fraction by
volume).
23. Wo is the proportion
of VOCs in a coating (or input stream), as received (fraction by
weight).
(3) STANDARD FOR VOLATILE ORGANIC COMPOUNDS. On and after the date on which the performance test required by s. NR 440.08 is completed, no owner or operator of an affected facility subject to the provisions of this section may discharge or cause the discharge of VOC emissions that exceed 0.90 kilogram of VOCs per liter of applied coating solids from any surface coating operation on a large appliance surface coating line.
(4) PERFORMANCE TEST AND COMPLIANCE PROVISIONS.
(a) Section
NR 440.08(4) and
(6) does 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 paragraph.
1. An owner
or operator shall use the following procedures for an affected facility that
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 coating
manufacturer or by 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 coating
manufacturer to determine the VOC content of coatings 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 coatings 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. Except as provided in subd. 1. d., the
weighted average of the total mass of VOCs consumed per unit volume of coatings
solids applied each calendar month shall be determined as follows:
1) Calculate the mass of VOCs consumed (Mo+
Md) during the calendar month for each affected facility by the following
equation:
(SLdj Ddj 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 calender month
m is the number of different VOC solvents added to coatings during the calendar month
2) Calculate the total volume of coatings
solids used (Ls) in the calendar month for each affected facility by the
following equation:
where:
n is the number of different coatings used during the calendar month
3) Select
the appropriate transfer efficiency from Table 1. If the owner or operator can
demonstrate to the satisfaction of the department that transfer efficiencies
other than those shown are appropriate, the department shall approve their use
on a case-by-case basis. Transfer efficiencies for application methods not
listed 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 method | Transfer efficiency (Tk) | |
| a) | Air atomized spray............ | 0.40 |
| b) | Airless spray ................ | 0.45 |
| c) | Manual electrostatic spray ...... | 0.60 |
| d) | Flow coat ................... | 0.85 |
| e) | Dip coat .................... | 0.85 |
| f) | Nonrotational automatic electrostatic spray ................ | 0.85 |
| g) | Rotating head automatic electrostatic spray ................ | 0.90 |
| h) | 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:
where:
n is the number of coatings (or input streams) used
m is the number of application methods used
4) 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:
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
VOCs discharged to the atmosphere per unit volume of coating solids applied (N)
is equal to or less than 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 coating 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 this subparagraph. 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 this subparagraph 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:
where:
n is the number of gas streams entering the control device
p 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:
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 applied coating solids (G) during
each calendar month for each affected facility using the equations in subd. 1.
a. 1), 2), 3) if applicable, and 4).
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 equal to or less
than 0.90 kilogram per liter of applied coating solids, the affected facility
is in compliance.
3. An
owner or operator shall use the following procedure for any affected facility
that uses a control device for VOC recovery (e.g., carbon adsorber) to comply
with the applicable emission limits 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 applied coating solids (G)
during each calendar month for each affected facility using the equations in
subd. 1. a. 1), 2), 3) if applicable, and 4).
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:
d.
Calculate the volume-weighted average mass of VOCs emitted to the atmosphere
(N) for each calendar month for each affected facility using equation in subd.
2. c.
e. If the volume-weighted
average mass of VOCs emitted to the atmosphere for each calendar month (N) is
equal to or less than 0.90 kilogram per liter of applied coatings solids, the
affected facility is in compliance. Each monthly calculation is considered a
performance test.
(5) MONITORING OF EMISSIONS AND OPERATIONS.
(a) The owner or operator of an affected
facility that 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 as prescribed below:
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.
(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) (b) 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
Reference Method 24 of 40 CFR part 60, Appendix A, incorporated by reference in
s.
NR 440.17, or supplied by the coating manufacturer, and
the minimum transfer efficiency of any coating application equipment used
during the month.
3. For each
affected facility where compliance is achieved through 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 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 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 use of thermal incineration, each 3-hour period of coating operation
during which the average temperature of the device was more than 28°C
(50°F) 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 of coating operation during which the average temperature
recorded immediately before the catalyst bed is more than 28°C (50 °F)
below the average temperature at the same location during the most recent
performance test at which destruction efficiency was determined as specified
under sub. (4). Additionally, all 3-hour periods of coating operation 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) shall be recorded.
3. For thermal and catalytic incinerators, if
no periods as described in subd. 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 formulation data supplied by the coating manufacturer to determine
the VOC content of a coating. In the event of dispute, Method 24 shall be the
reference method. For determining compliance only, results of Method 24
analyses of waterborne coatings shall be adjusted as described in sectio n 12.6
of Method 24.
Note: Procedures to determine VOC emissions are provided in sub. (4).
2. Method 25 for
the measurement of the VOC concentration in the gas stream vent.
3. Method 1 for sample and velocity
traverses.
4. Method 2 for velocity
and volumetric flow rate.
5. Method
3 for gas analysis.
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 a one-liter sample
taken into a one-liter container at a point where the sample will be
representative of the coating material.
(c) For Method 25 of 40 CFR part 60, Appendix
A, incorporated by reference in s.
NR 440.17(1), the sample time for each
of 3 runs shall be at least 60 minutes and the minimum sample volume shall be
at least 0.003 dscm (0.1 dscf) 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 sampling of representative stacks on a case-by-case
basis if the owner or operator can demonstrate to the satisfaction of the
department that the testing of representative stacks would yield results
comparable to those that would be obtained by testing all stacks.
Disclaimer: These regulations may not be the most recent version. Wisconsin may have more current or accurate information. We make no warranties or guarantees about the accuracy, completeness, or adequacy of the information contained on this site or the information linked to on the state site. Please check official sources.
This site is protected by reCAPTCHA and the Google
Privacy Policy and
Terms of Service apply.
