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 440.74 - Polymeric coating of supporting substrates facilities
Universal Citation: WI Admin Code ยง NR 440.74
Current through August 26, 2024
(1) APPLICABILITY AND DESIGNATION OF AFFECTED FACILITY.
(a) The
affected facility to which the provisions of this section apply is each coating
operation and any onsite coating mix preparation equipment used to prepare
coatings for the polymeric coating of supporting substrates.
(b) Any affected facility for which the
amount of VOC used is less than 95 Mg per 12-month period is subject only to
the requirements of subs. (5) (b), (8) (b) and (c). If the amount of VOC used
is 95 Mg or greater per 12-month period, the facility is subject to all the
requirements of this section. Once a facility has become subject to the
requirements of this section it will remain subject to those requirements
regardless of changes in annual VOC use.
(c) This section applies to any affected
facility for which construction, modification or reconstruction begins after
April 30, 1987, except for the facilities specified in par. (d).
(d) This section does not apply to the
following:
1. Coating mix preparation
equipment used to manufacture coatings at one plant for shipment to another
plant for use in an affected facility or for sale to another company for use in
an affected facility;
2. Coating
mix preparation equipment or coating operations during those times they are
used to prepare or apply waterborne coatings so long as the VOC content of the
coating does not exceed 9% by weight of the volatile fraction;
3. Web coating operations that print an image
on the surface of the substrate or any coating applied on the same printing
line that applies the image.
(2) DEFINITIONS, SYMBOLS AND CROSS-REFERENCE TABLES.
(a) All terms used in this section
not defined as follows have the meaning given to them in s.
NR 440.02.
1. "Coating
applicator" means any apparatus used to apply a coating to a continuous
substrate.
2. "Coating mix
preparation equipment" means all mixing vessels in which solvent and mixing
vessels in which solvent and other materials are blended to prepare polymeric
coatings.
3. "Coating operation"
means any coating applicators, flashoff areas and drying ovens located between
a substrate unwind station and a rewind station that coats a continuous web to
produce a substrate with a polymeric coating. If the coating process does not
employ a rewind station, the end of the coating operation is after the last
drying oven in the process.
4.
"Common emission control device" means a device controlling emissions from an
affected coating operation as well as from any other emission source.
5. "Concurrent" means the period of time in
which construction of an emission control device serving an affected facility
is commenced or completed, beginning 6 months prior to the date that
construction of the affected facility commences and ending 2 years after the
date that construction of the affected facility is completed.
6. "Control device" means any apparatus that
reduces the quantity of a pollutant emitted to the air.
7. "Cover" means, with respect to coating mix
preparation equipment, a device that fits over the equipment opening to prevent
emission of volatile organic compounds from escaping.
8. "Drying oven" means a chamber within which
heat is used to dry a surface coating; drying may be the only process or one of
multiple processes performed in the chamber.
9. "Equivalent diameter" means 4 times the
area of an opening divided by its perimeter.
10. "Flashoff area" means the portion of a
coating operation between the coating applicator and the drying oven where VOC
begins to evaporate from the coated substrate.
11. "Natural draft opening" means any opening
in a room, building or total enclosure that remains open during operation of
the facility and that is not connected to a duct in which a fan is installed.
The rate and direction of the natural draft across such an opening is a
consequence of the difference in pressure on either side of the wall or barrier
containing the opening.
12.
"Nominal 1-month period" means a calendar month or, if established prior to the
performance test, a similar monthly time period, for example, 30-day month or
accounting month.
13. "Onsite
coating mix preparation equipment" means those pieces of coating mix
preparation equipment located at the same plant as the coating operation they
serve.
14. "Polymeric coating of
supporting substrates" means a web coating process that applies elastomers,
polymers or prepolymers to a supporting web other than paper, plastic film,
metallic foil or metal coil.
15.
"Substrate" means the surface to which a coating is applied.
16. `Temporary enclosure` means a total
enclosure that is constructed for the sole purpose of measuring the fugitive
VOC emissions from an affected facility.
17. "Total enclosure" means a structure that
is constructed around a source of emissions and operated so that all VOC
emissions are collected and exhausted through a stack or duct. With a total
enclosure, there will be no fugitive emission, only stack emissions. The drying
oven itself may be part of the total enclosure.
18. "Vapor capture system" means any device
or combination of devices designed to contain, collect and route solvent vapors
released from the coating mix preparation equipment or coating
operation.
19. "VOC in the applied
coating" means the product of Method 24 VOC analyses or formulation data, if
those data are demonstrated to be equivalent to Method 24 results, and the
total volume of coating fed to the coating applicator.
20. "VOC used" means the amount of VOC
delivered to the coating mix preparation equipment of the affected facility,
including any contained in premixed coatings or other coating ingredients
prepared off the plant site, for the formulation of polymeric coatings to be
applied to supporting substrates at the coating operation, plus any solvent
added after initial formulation is complete, for example, dilution solvents
added at the coating operation. If premixed coatings that require no mixing at
the plant site are used, "VOC used" means the amount of VOC delivered to the
coating applicators of the affected facility.
21. "Volatile organic compounds" or "VOC"
means any organic compounds that participate in atmospheric photochemical
reactions; or that are measured by a reference method, an equivalent method, an
alternative method or that are determined by procedures specified under any
section.
22. "Waterborne coating"
means a coating which contains more than 5 weight percent water in its volatile
fraction.
23. "Web coating" means
the coating of products, such as fabric, paper, plastic film, metallic foil,
metal coil, cord and yarn, that are flexible enough to be unrolled from a large
roll; and coated as a continuous substrate by methods including, but not
limited to, knife coating, roll coating, dip coating, impregnation, rotogravure
and extrusion.
(b) The
nomenclature used in this section has the following meanings:
1. "Ak" means the area of each natural draft
opening (k) in a total enclosure, in square meters.
2. "Caj" means the concentration of VOC in
each gas stream (j) exiting the emission control device, in parts per million
by volume.
3. "Cbi" means the
concentration of VOC in each gas stream (i) entering the emission control
device, in parts per million by volume.
4. "Cdi" means the concentration of VOC in
each gas stream (i) entering the emission control device from the affected
coating operation, in parts per million by volume.
5. "Cfk" means the concentration of VOC in
each uncontrolled gas stream (k) emitted directly to the atmosphere from the
affected coating operation, in parts per million by volume.
6. "Cgv" means the concentration of VOC in
the gas stream entering each individual carbon absorber vessel (v), in parts
per million by volume. For purposes of calculating the efficiency of the
individual absorber vessel, Cgv may be measured in the carbon adsorption
system's common inlet duct prior to the branching of individual inlet
ducts.
7. "Chv" means the
concentration of VOC in the gas stream exiting each individual carbon absorber
vessel (v), in parts per million by volume.
8. "E" means the control device efficiency
achieved for the duration of the emission test, expressed as a
fraction.
9. "F" means the VOC
emission capture efficiency of the vapor capture system achieved for the
duration of the emission test, expressed as a fraction.
10. "FV" means the average inward face
velocity across all natural draft openings in a total enclosure, in meters per
hour.
11. "Hv" means the individual
carbon absorber vessel (v) efficiency achieved for the duration of the emission
test, expressed as a fraction.
12.
"Hsys" means the carbon adsorption system efficiency calculated when each
absorber vessel has an individual exhaust stack.
13. "Mci" means the total mass (kg) of each
coating (i) applied to the substrate at an affected coating operation during a
nominal 1-month period as determined from facility records.
14. "Mr" means the total mass (kg) of VOC
recovered for a nominal 1-month period.
15. "Qaj" means the volumetric flow rate of
each gas stream (i) exiting the emission control device, in dry standard cubic
meters per hour when Method 18 or 25 is used to measure VOC concentration or in
standard cubic meters per hour (wet basis) when Method 25A is used to measure
VOC concentration.
16. "Qbi" means
the volumetric flow rate of each gas stream (i) entering the emission control
device, in dry standard cubic meters per hour when Method 18 or 25 is used to
measure VOC concentration or in standard cubic meters per hour (wet basis) when
Method 25A is used to measure VOC concentration.
17. "Qdi" means the volumetric flow rate of
each gas stream (i) entering the emission control device from the affected
coating operation, in dry standard cubic meters per hour when Method 18 or 25
is used to measure VOC concentration or in standard cubic meters per hour (wet
basis) when Method 25A is used to measure VOC concentration.
18. "Qfk" means the volumetric flow rate of
each uncontrolled gas stream (k) emitted directly to the atmosphere from the
affected coating operation, in dry standard cubic meters per hour when Method
18 or 25 is used to measure VOC concentration or in standard cubic meters per
hour (wet basis) when Method 25A is used to measure VOC
concentration.
19. "Qgv" means the
volumetric flow rate of the gas stream entering each individual carbon adsorber
vessel (v), in dry standard cubic meters per hour when Method 18 or 25 is used
to measure VOC concentration or in standard cubic meters per hour (wet basis)
when Method 25A is used to measure VOC concentration. For purposes of
calculating the efficiency of the individual adsorber vessel, the value of Qgv
can be assumed to equal the value of Qgv measured for that adsorber
vessel.
20. "Qhv" means the
volumetric flow rate of the gas stream exiting each individual carbon adsorber
vessel (v), in dry standard cubic meters per hour when Method 18 or 25 is used
to measure VOC concentration or in standard cubic meters per hour (wet basis)
when Method 25A is used to measure VOC concentration.
21. "Qin i" means the volumetric flow rate of
each gas stream (i) entering the total enclosure through a forced makeup air
duct, in standard cubic meters per hour (wet basis).
22. "Qout j" means the volumetric flow rate
of each gas stream (j) exiting the total enclosure through an exhaust duct or
hood, in standard cubic meters per hour (wet basis).
23. "R" means the overall VOC emission
reduction achieved for the duration of the emission test, expressed as a
fraction.
24. "RSi" means the total
mass (kg) of VOC retained on the coated substrate after oven drying or
contained in waste coating for a given combination of coating and
substrate.
25. "Woi" means the
weight fraction of VOC in each coating (i) applied at an affected coating
operation during a nominal 1-month period as determined by Method 24.
(c) Tables 1A and 1B present a
cross reference of the affected facility status and the relevant subsections of
the regulation.
Table 1A. - Cross Referenceab
|
Status |
Standard |
Compliance Provisions - sub. (4) |
|
A. Coating operation: |
||
|
1. If projected VOC use is < 95 Mg/yr |
Sub. (1) (b): Monitor VOC use |
Not applicable |
|
2. If projected VOC use is >= 95 Mg/yr |
Sub. (3) (b) 1.: Reduce VOC emissions to the atmosphere from the coating operation by at least 90% or: sub. (3) (b) 2.: Install, operate and maintain a total enclosure around the coating operation and vent the captured VOC emissions from the total enclosure to a control device that is at least 95% efficient. |
(a) 1., (a) 2., (a) 3. or (a) 4., (b), (e) |
|
B. Coating mix preparation equipment: |
||
|
1. If projected VOC use is >= 95 Mg/yr but < 130 Mg/yr. |
Sub. (3) (c) 3.: a. Install, operate and maintain a cover on each piece of affected equipment; or |
(d), (e) |
|
b. install operate and maintain a cover on each piece of affected equipment and vent VOC emissions to a VOC control device. |
||
|
2. If projected VOC use is >= 130 Mg/yr but there is no concurrent construction of a control device. |
Sub. (3) (c) 2.: a. Install, operate and maintain a cover on each piece of affected equipment; or |
(d) |
|
b. install operate and maintain a cover on each piece of affected equipment and vent VOC emissions to a VOC control device. |
||
|
3. If projected VOC use is >= 130 Mg/yr and there is concurrent construction of a control device. |
Sub. (3) (c) 1.: Install, operate and maintain a cover on each piece of affected equipment and vent VOC emissions from the covered equipment to a 95% efficient control device while preparation of the coating is taking place within the vessel. |
(c), (e) |
aThis table is presented for the convenience of the user and is not intended to supersede the language of the regulation. For the details of the requirements, refer to the text of the regulation.
bRefer to Table 1B to determine which paragraphs of subs. (5), (6) and (8) correspond to each compliance provision (sub. (4)).
Table 1B. - Cross Reference
| Compliance Provisions - sub. (4) | Test Methods- sub. (6) | Category/ Equipmenta | Monitoring Requirements- sub. (5) | Reporting and Recordkeeping Requirements- sub. (8) |
| A. Coating Operation: | ||||
| (a) 1. - Gaseous emission test for coating operations not using carbon adsorption beds with individual exhausts. | (b)-(g) | General,CA, CO, TI, CI, PE, TE | (a), (i), (j), (k), (c) 1., (d), (e), (f), (g) | (a), (d) 7., (f), (g), (h), (d) 1., (d) 2. a., (d) 3., (d) 4., (d) 5., (d) 6. |
| (a) 2. - Gaseous emission test for coating operations using carbon adsorption beds with individual exhausts. | (b)-(g) | General, CA, PE, TE | (a), (i), (j), (k), (c) 2., (g) | (a), (d) 7., (f), (g), (h), (d) 1. b., (d) 2. b., (d) 6. |
| (a) 3. - Monthly liquid material balance - can be used only when a VOC recovery device controls only those emissions from one affected coating operation. | (a) | VOC recovery | (i), (k) | (e), (f), (g), (h) |
| (a) 4. - Short-term (3 to 7 day) liquid material balance -may be used as an alternative to sub. (4) (a) 3. | (a) | General, CA, CO, PE,TE | (a), (i), (j), (k), (c) 1., (c) 2., (d), (g) | (a), (d) 7., (f), (g), (h), (d) 1., (d) 2., (d) 3., (d) 6. |
| (b) - Alternative standard for coating operation -demonstrate use of approved total enclosure and emissions vented to a 95% efficient control device. | (b)-(g) | General, CA, CO, TI, CI, PE,TE | (a), (i), (j), (k), (c) 1., (c) 2., (d), (e), (f), (h) | (a), (d) 7., (f), (g), (h), (d) 1., (d) 2., (d) 3., (d) 4., (d) 5., (d) 6. |
| B. Coating mix preparation equipment: | ||||
| (c) - Standard for equipment servicing a coating operation with concurrent construction of a control device that uses at least 130 Mg/yr of VOC - demonstrates that covers meeting specifications are installed and used properly; procedures detailing proper use are posted; the mix equipment is vented to a 95% efficient control device. | (b) - (g) | General, CA, TI, CI | (a), (i), (j), (k), (c) 1., (c) 2., (e), (f) | (a), (d) 7., (f), (g), (h), (d) 1., (d) 2., (d) 4., (d) 5. |
| (d) - Standard for equipment servicing a coating operation that does not have concurrent construction of a control device but uses at least 130 Mg/yr of VOC or for equipment serving a coating operation that uses < 130 Mg/yr but 95 Mg/yr of VOC - demonstrate that covers meeting specifications are installed and used properly; procedures detailing proper use are posted; the mix equipment is vented to a control device (optional). | No other requirements apply. | - | - | - |
aCA denotes carbon adsorber; CO denotes condenser; TI denotes thermal incinerator; CI denotes catalytic incinerator; PE denotes partial enclosure; TE denotes total enclosure
(3) STANDARDS FOR VOLATILE ORGANIC COMPOUNDS.
(a) Each owner or
operator of an affected facility that is subject to the requirements of this
section shall comply with the emissions limitations in this subsection on and
after the date on which the initial performance test required by s.
NR 440.08 is
completed, but not later than 60 days after achieving the maximum production
rate at which the affected facility will be operated or 180 days after initial
startup, whichever dates comes first.
(b) For the coating operation, each owner or
operator of an affected facility shall either:
1. Reduce VOC emissions to the atmosphere
from the coating operation by at least 90% ("emission reduction" standard);
or
2. Install, operate and maintain
a total enclosure around the coating operation and vent the captured VOC
emissions from the total enclosure to a control device that is at least 95%
efficient (alternative standard).
(c) For the onsite coating mix preparation
equipment of an affected facility, the owner or operator shall comply with the
following requirements, as applicable:
1. For
an affected facility that has concurrent construction of a control device and
uses at least 130 Mg of VOC per 12-month period, the owner or operator shall
install, operate and maintain a cover on each piece of affected coating mix
preparation equipment and vent VOC emissions from the covered mix equipment to
a 95% efficient control device while preparation of the coating is taking place
within the vessel.
2. For an
affected facility that does not have concurrent construction of a control
device but uses at least 130 Mg of VOC per 12-month period, the owner or
operator shall either:
a. Install, operate
and maintain a cover on each piece of affected coating mix preparation
equipment; or
b. Install, operate
and maintain a cover on each piece of affected coating mix preparation
equipment and vent VOC emissions to a VOC control device.
3. For an affected facility that uses at
least 95 Mg but less than 130 Mg of VOC per 12-month period, the owner or
operator shall either:
a. Install, operate
and maintain a cover on each piece of affected coating mix preparation
equipment; or
b. Install, operate
and maintain a cover on each piece of affected coating mix preparation
equipment and vent VOC emissions to a VOC control device.
(4) COMPLIANCE PROVISIONS.
(a) To demonstrate compliance
with the emission reduction standard for coating operations specified in sub.
(3) (b) 1., the owner or operator of the affected facility shall use one of the
following methods.
1. For coating operations
not using carbon adsorption beds with individual exhausts the following gaseous
emission test method is applicable when the emissions from any affected coating
operation are controlled by a control device other than a fixed-bed carbon
adsorption system with individual exhaust stacks for each adsorber vessel. The
owner or operator using this method shall comply with the following procedures:
a. Construct the vapor capture system and
control device so that all gaseous volumetric flow rates and total VOC
emissions can be accurately determined by the applicable test methods and
procedures specified in sub. (6) (b) to (g);
b. Determine capture efficiency from the
coating operation by capturing, venting and measuring all VOC emissions from
the coating operation. During a performance test, the owner or operator of an
affected coating operation located in an area with other sources of VOC shall
isolate the coating operation emissions from all other sources of VOC by one of
the following methods:
1) Build a temporary
enclosure, as defined in sub. (2) (a) and conforming to the requirements of
par. (b) 1., around the affected coating operation. The temporary enclosure
shall be constructed and ventilated, through stacks suitable for testing, so
that it has minimal impact on performance of the capture system; or
2) Shut down all other sources of VOC and
continue to exhaust fugitive emissions from the affected coating operation
through any building ventilation system and other room exhausts such as those
on drying ovens. All such ventilation air shall be vented through stacks
suitable for testing because the VOC content in each shall be
determined.
c. Operate
the emission control device with all emission sources connected and
operating.
d. Determine the
efficiency (E) of the control device by Equation 1:
e.
Determine the efficiency (F) of the vapor capture system by Equation 2:
f. For
each affected coating operation subject to sub. (3) (b) 1. (emission reduction
standard for coating operations), compliance is demonstrated if the product of
(E) (F) is equal to or greater than 0.90.
2. For coating operations using carbon
adsorption beds with individual exhausts the following gaseous emission test
method is applicable when emissions from any affected coating operation are
controlled by a fixed-bed carbon adsorption system with individual exhaust
stacks for each adsorber vessel. The owner or operator using this method shall
comply with the following procedures:
a.
Construct the vapor capture system and control device so that each volumetric
flow rate and the total VOC emissions can be accurately determined by the
applicable test methods and procedures specified in sub. (6) (b) to
(g);
b. Assure that all VOC
emissions from the coating operation are segregated from other VOC sources and
that the emissions can be captured for measurement, as described in sub. (4)
(a) 1. b. 1) and 2);
c. Operate
the emission control device with all emission sources connected and
operating;
d. Determine the
efficiency (Hv) of each individual adsorber vessel (v) using Equation 3:
e.
Determine the efficiency of the carbon adsorption system (Hsys) by computing
the average efficiency of the adsorber vessels as weighted by the volumetric
flow rate (Qhv) of each individual adsorber vessel (v) using Equation 4:
f.
Determine the efficiency (F) of the vapor capture system using Equation
(2).
g. For each affected coating
operation subject to sub. (3) (b) 1. (emission reduction standard for coating
operations), compliance is demonstrated if the product of (Hsys) (F) is equal
to or greater than 0.90.
3. The monthly liquid material balance method
can be used only when a VOC recovery device controls only those emissions from
one affected coating operation. It may not be used if the VOC recovery device
controls emissions from any other VOC emission sources. When demonstrating
compliance by this method, s.
NR 440.08(6) does not apply. The owner
or operator using this method shall comply with the following procedures to
determine the VOC emission reduction for each nominal 1-month period:
a. Measure the amount of coating applied at
the coating applicator. This quantity shall be determined at a time and
location in the process after all ingredients, including any dilution solvent,
have been added to the coating or appropriate adjustments shall be made to
account for any ingredients added after the amount of coating has been
determined:
b. Determine the VOC
content of all coatings applied using the test method specified in sub. (6)
(a). This value shall be determined at a time and location in the process after
all ingredients, including any dilution solvent, have been added to the coating
or appropriate adjustments shall be made to account for any ingredients added
after the VOC content in the coating has been determined;
c. Install, calibrate, maintain and operate,
according to the manufacturer's specifications, a device that indicates the
cumulative amount of VOC recovered by the control device over each nominal
1-month period. The device shall be certified by the manufacturer to be
accurate to within "2.0%;
d.
Measure the amount of VOC recovered; and
e. Calculate the overall VOC emission
reduction (R) for each and every nominal 1-month period using Equation 5.
Emissions during startups and shutdowns are to be included when determining R
because startups and shutdowns are part of normal operation for this source
category.
If the value of Ri is equal to or greater than 0.90, compliance with sub. (3) (b) 1. is demonstrated.
1) The value of RSi is zero unless the owner
or operator submits the following information to the administrator for approval
of a measured value of RSi, that is greater than zero but less than or equal to
6% by weight of the liquid VOC applied:
a)
Measurement techniques; and
b)
Documentation that the measured value of RSi, exceeds zero but is less than or
equal to 6% by weight of the liquid VOC applied.
2) For those facilities not subject to subd.
3. e. 1), the value of RSi is zero unless the owner or operator submits the
following information to the administrator for approval of a measured value of
RSi that is greater than 6% by weight of the liquid VOC applied:
a) Measurement techniques;
b) Documentation that the measured value of
RSi exceeds 6% by weight of the liquid VOC applied; and
c) Either documentation of customer
specifications requiring higher values or documentation that the desired
properties of the product make necessary for RSi to exceed 6% by weight of the
liquid VOC applied and that such properties cannot be achieved by other
means.
3) The
measurement techniques of subd. 3. e. 1) a) and 2) a) shall be submitted to the
department for approval.
f. The point at which Mr is to be measured
shall be established when the compliance procedures are approved. The
presumptive point of measurement shall be prior to separation/purification; a
point after separation/purification may be adopted for enhanced convenience or
accuracy.
4. Short-term
liquid material balance. This method may be used as an alternative to the
monthly liquid material balance described in subd. 3. The owner or operator
using this method shall comply with the following procedures to determine VOC
emission reduction for a 3 to 7 day period and shall continuously monitor VOC
emissions as specified in sub. (5).
a. Use
the procedures described in subd. 3. a. through f. to determine the overall
emission reduction, R. Compliance is demonstrated if the value of R is equal to
or greater than 0.90.
b. The number
of days for the performance test is to be based on the affected facility's
representative performance consistent with the requirements of s.
NR 440.08(3). Data demonstrating that
the chosen test period is representative shall be submitted to the department
for approval.
(b) Each owner or operator of an affected
coating operation subject to the standard specified in sub. (3) (b) 2. shall:
1. Demonstrate that a total enclosure is
installed. The total enclosure shall either be approved by the department in
accordance with the provisions of
40 CFR
60.746 or meet the requirements in subd. 1.
a. to f. as follows:
a. The only openings in
the enclosure are forced makeup air and exhaust ducts and natural draft
openings such as those through which raw materials enter and exit the coating
operation;
b. Total area of all
natural draft openings does not exceed 5% of the total surface are of the total
enclosure's walls, floor and ceiling;
c. All access doors and windows are closed
during normal operation of the enclosed coating operation, except for brief,
occasional openings to accommodate process equipment adjustments. If openings
are frequent or if the access door or window remains open for a significant
amount of time during the process operation, it shall be considered a natural
draft opening. Access doors used routinely by workers to enter and exit the
enclosed area shall be equipped with automatic closure devices;
d. Average inward face velocity (FV) across
all natural draft openings is a minimum of 3,600 meters per hour as determined
by the following procedures:
1) Construct all
forced makeup air ducts and all exhaust ducts so that the volumetric flow rate
in each can be accurately determined by the test methods and procedures
specified in sub. (6) (c) and (d). Volumetric flow rates shall be calculated
without the adjustment normally made for moisture content; and
2) Determine FV by Equation 6:
e. The air passing through all natural draft
openings flows into the enclosure continuously. If FV is less than or equal to
9,000 meters per hour, the continuous inward airflow shall be verified by
continuous observation using smoke tubes, streamers, tracer gases or other
means approved by the department over the period that the volumetric flow rate
tests required to determine FV are carried out. If FV is greater than 9,000
meters per hour, the direction of airflow through the natural draft openings
shall be presumed to be inward at all times without verification.
f. All sources of emissions within the
enclosure shall be a minimum of 4 equivalent diameters away from each natural
draft opening.
2.
Determine the control device efficiency using Equation (1) or Equations (3) and
(4), as applicable and the test methods and procedures specified in sub. (6)
(b) to (g).
3. Compliance is
demonstrated if the installation of a total enclosure is demonstrated and the
value of E determined from Equation (1) or the value of Hsys determined from
Equations (3) and (4), as applicable, is equal to or greater than
0.95.
(c) To demonstrate
compliance with sub. (3) (c) 1., standard for coating mix preparation equipment
servicing a coating operation with concurrent construction of a control device
that uses at least 130 Mg per year of VOC, each owner or operator of affected
coating mix preparation equipment shall demonstrate that:
1. Covers meeting the following
specifications have been installed and are being used properly:
a. Cover shall be closed at all times except
when adding ingredients, withdrawing samples, transferring the contents or
making visual inspection when such activities cannot be carried out with cover
in place. Activities shall be carried out through ports of the minimum
practical size;
b. Cover shall
extend at least 2 centimeters beyond the outer rim of the opening or shall be
attached to the rim;
c. Cover shall
be of such design and construction that contact is maintained between cover and
rim along the entire perimeter;
d.
Any breach in the cover, such as a slit for insertion of a mixer shaft or port
for addition of ingredients, shall be covered consistent with subd. 1. a. to c.
when not actively in use. An opening sufficient to allow safe clearance for a
mixer shaft is acceptable during those periods when the shaft is in place; and
e. A polyethylene or nonpermanent
cover may be used provided it meets the requirements of subd. 1. b. to d. A
cover may not be reused after once being removed.
2. Procedures detailing the proper use of
covers, as specified in subd. 1. a., have been posted in all areas where
affected coatings mix preparations equipment is used;
3. The coating mix preparation equipment is
vented to a control device while preparation of the coating is taking place
within the vessel; and
4. The
control device efficiency, E or Hsys as applicable, determined using Equation
(1) or Equations (3) and (4), respectively and the test methods and procedures
specified in sub. (6) (b) to (g) is equal to or greater than
0.95.
(d) To demonstrate
compliance with sub. (3) (c) 2., standard for coating mix preparation equipment
servicing a coating operation that does not have concurrent construction of a
control device but uses at least 130 Mg of VOC per year, or sub. (3) (c) 3.,
standard for coating mix preparation equipment servicing a coating operation
that uses at least 95 Mg but less than 130 Mg of VOC per year, each owner or
operator of affected coating mix preparation equipment shall demonstrate upon
inspection that:
1. Covers satisfying the
specifications in par. (c) 1. a. to e. have been installed and are being
properly operated and maintained; and
2. Procedures detailing the proper use of
covers, as specified in par. (c) 1. a., have been posted in all areas where
affected coating mix preparation equipment is used.
3. Owners or operators meeting the standard
specified in sub. (3) (c) 2. b. or 3. b. shall also demonstrate that the
coating mix preparation equipment is vented to a control device.
(e) If a control device other than
a carbon adsorber, condenser or incinerator is used to control emissions from
an affected facility, the necessary operating specifications for that device
shall be approved by the administrator. An example of such a device is a
flare.
(5) MONITORING REQUIREMENTS.
(a) Each owner or operator of
an affected facility shall install and calibrate all monitoring devices
required under the provisions of this subsection according to the
manufacturer's specifications, prior to the initial performance test in
locations such that representative values of the monitored parameters will be
obtained. The parameters to be monitored shall be continuously measured and
recorded during each performance test.
(b) Each owner or operator of an affected
facility that uses less that 95 Mg of VOC per year and each owner or operator
of an affected facility subject to the provisions specified in sub. (3) (c) 3.
shall:
1. Make semiannual estimates of the
projected annual amount of VOC to be used for the manufacture of polymeric
coated substrate at the affected coating operation in that year; and
2. Maintain records of actual VOC
use.
(c) Each owner or
operator of an affected facility controlled by a carbon adsorption system and
demonstrating compliance by the procedures described in sub. (4) (a) 1., 2.,
(b) or (c), which include control device efficiency determinations, or sub. (4)
(a) 4., short-term liquid material balance, shall carry out the monitoring
provisions of subd. 1. or 2., as appropriate.
1. For carbon adsorption systems with a
common exhaust stack for all the individual adsorber vessels, install,
calibrate, maintain and operate, according to the manufacturer's
specifications, a monitoring device that continuously indicates and records the
concentration level of organic compounds in either the control device outlet
gas stream or in both the control device inlet and outlet gas streams. The
outlet gas stream shall be monitored if the percent increase in the
concentration level of organic compounds is used as the basis for reporting, as
described in sub. (8) (d) 1. a. The inlet and outlet gas streams shall be
monitored if the percent control device efficiency is used as the basis for
reporting, as described in sub. (8) (d) 2. a.
2. For carbon adsorption systems with
individual exhaust stacks for each adsorber vessel, install, calibrate,
maintain and operate, according to the manufacturer's specifications, a
monitoring device that continuously indicates and records the concentration
level of organic compounds in the outlet gas stream for a minimum of one
complete adsorption cycle per day for each adsorber vessel. The owner or
operator may also monitor and record the concentration level of organic
compounds in the common carbon adsorption system inlet gas stream or in each
individual carbon adsorber vessel inlet stream. The outlet gas streams shall be
monitored if the percent increase in the concentration level of organic
compounds is used as the basis for reporting, as described in sub. (8) (d) 1.
b. In this case, the owner or operator shall compute daily a 3-day rolling
average concentration level of organics in the outlet gas stream from each
individual adsorber vessel. The inlet and outlet gas streams shall be monitored
if the percent control device efficiency is used as the basis for reporting, as
described in sub. (8) (d) 2. b. In this case, the owner or operator shall
compute daily a 3-day rolling average efficiency for each individual adsorber
vessel.
(d) Each owner
or operator of an affected facility controlled by a condensation system and
demonstrating compliance by the test methods described in sub. (4) (a) 1., 2.,
(b) or (c), which include control device efficiency determinations, or sub. (4)
(a) 4., short-term liquid material balance, shall install, calibrate, maintain
and operate, according to the manufacturer's specifications, a monitoring
device that continuously indicates and records the temperature of the condenser
exhaust stream.
(e) Each owner or
operator of an affected facility controlled by a thermal incinerator and
demonstrating compliance by the test methods described in sub. (4) (a) 1., 2.,
(b) or (c), which include control device efficiency determinations, shall
install, calibrate maintain and operate, according to the manufacturer's
specifications, a monitoring device that continuously indicates and records the
combustion temperature of the incinerator. The monitoring device shall have an
accuracy within " 1% of the temperature being measured in Celsius
degrees.
(f) Each owner or operator
of an affected facility controlled by a catalytic incinerator and demonstrating
compliance by the test methods described in sub. (4) (a) 1., 2., (b) or (c),
which include control device efficiency determinations, shall install,
calibrate maintain and operate, according to the manufacturer's specifications,
a monitoring device that continuously indicates and records the gas temperature
both upstream and downstream of the catalyst bed. The monitoring device shall
have an accuracy within " 1% of the temperature being measured in Celsius
degrees.
(g) Each owner or operator
of an affected facility who demonstrates compliance by the test methods
described in sub. (4) (a) 1. or 2., which include vapor capture system
efficiency determinations, or sub. (4) (a) 4., short-term liquid material
balance, shall submit a monitoring plan for the vapor capture system to the
department for approval. This plan shall identify the parameter to be monitored
as an indicator of vapor capture system performance, for example, the amperage
to the exhaust fans or duct flow rates, and the method for monitoring the
chosen parameter. The owner or operator shall install, calibrate, maintain and
operate, according to the manufacturer's specifications, a monitoring device
that continuously indicates and records the value of the chosen
parameter.
(h) Each owner or
operator of an affected facility who demonstrates compliance as described in
sub. (4) (b) shall follow the procedures described in par. (g) to establish a
monitoring system for the total enclosure.
(i) Each owner or operator of an affected
facility shall record time periods of mixing or coating operations when the
emission control device is malfunctioning or not in use.
(j) Each owner or operator of an affected
facility shall record time periods of mixing or coating operations when each
monitoring device is malfunctioning or not in use.
(k) Records of the measurements and
calculations required in subs. (4) and (5) shall be retained for at least 2
years following the date of the measurements and calculations.
(6) TEST METHODS AND PROCEDURES. Methods in Appendix A of 40 CFR part 60, incorporated by reference in s. NR 440.17, except as provided under s. NR 440.08(2), shall be used to determine compliance as follows:
(a) Method 24 is used
to determine the VOC content in coatings. If it is demonstrated to the
satisfaction of the administrator that coating formulation data are equivalent
to Method 24 results, formulation data may be used. In the event of any
inconsistency between a Method 24 test and a facility's formulation data, the
Method 24 test will govern. For Method 24, the coating sample shall be a
1-liter sample collected in a 1-liter container at a point in the process where
the sample will be representative of the coating applied to the substrate, that
is, the sample shall include any dilution solvent or other VOC added during the
manufacturing process. The container shall be tightly sealed immediately after
the sample is collected. Any solvent or other VOC added after the sample is
taken shall be measured and accounted for in the calculations that use Method
24 results.
(b) Method 25 shall be
used to determine VOC concentrations from incinerator gas streams. Alternative
Methods (18 or 25A), may be used as explained in the applicability section of
Method 25 in cases where use of Method 25 is demonstrated to be technically
infeasible. The owner or operator shall submit notice of the intended test
method to the department for approval along with the notification of the
performance test required under s.
NR 440.08(4). Except as indicated in
subds. 1. and 2., the test shall consist of 3 separate runs, each lasting a
minimum of 30 minutes.
1. When the method is
to be used in the determination of the efficiency of a fixed-bed carbon
adsorption system with a common exhaust stack for all the individual adsorber
vessels pursuant to sub. (4) (a) 1., (b) or (c), the test shall consist of 3
separate runs, each coinciding with one or more complete system rotations
through the adsorption cycles of all the individual adsorber vessels.
2. When the method is to be used in the
determination of the efficiency of a fixed-bed carbon adsorption system with
individual exhaust stacks for each adsorber vessel pursuant to sub. (4) (a) 2.,
(b) or (c), each adsorber vessel shall be tested individually. Each test shall
consist of 3 separate runs, each coinciding with one or more complete
adsorption cycles.
(c)
Method 1 or 1A is used for sample and velocity traverses;
(d) Method 2, 2A, 2C or 2D is used for
velocity and volumetric flow rates;
(e) Method 3 is used for gas
analysis;
(f) Method 4 is used for
stack gas moisture;
(g) Methods 2,
2A 2C or 2D; 3; and 4 shall be performed as applicable at least twice during
each test run.
Note: Under 40 CFR 60.746, if, in the administrator's judgment, an alternative means of emission limitation will achieve a reduction in emissions of VOC from any emission point subject to sub. (3) (c) at least equivalent to that required by sub. (3) (b) 2. or (3) (c), respectively, the administrator will publish in the Federal Register a notice permitting the use of the alternative means. The administrator may condition permission on requirements that may be necessary to ensure operation and maintenance to achieve the emission reduction as specified in sub. (3) (b) 2. or (3) (c), respectively. Any such notice shall be published only after public notice and an opportunity for a public hearing. Any person seeking permission under 40 CFR 60.746 shall submit to the administrator either results from an emission test that accurately collects and measures all VOC emissions from a given control device or an engineering evaluation that accurately determines such emissions.
(8) REPORTING AND RECORDKEEPING REQUIREMENTS.
(a) For each affected facility subject to the
requirements of sub. (3) (b) and (c), the owner or operator shall submit the
performance test data and results to the department as specified in s.
NR 440.08(1). In addition, the average
values of the monitored parameters measured at least every 15 minutes and
averaged over the period of the performance test shall be submitted with the
results of all performance tests.
(b) Each owner or operator of an affected
facility subject to the provisions specified in sub. (3) (c) 3. and claiming to
use less than 130 Mg of VOC in the first year of operation and each owner or
operator of an affected facility claiming to use less than 95 Mg of VOC in the
first year of operation shall submit to the department a material flow chart
indicating projected VOC use. The owner or operator shall also submit actual
VOC use records at the end of the initial year.
(c) Each owner or operator of an affected
facility subject to the provisions of sub. (3) (c) 3. and initially using less
that 130 Mg of VOC per year and each owner or operator of an affected facility
initially using less than 95 Mg of VOC per year shall:
1. Record semiannual estimates of projected
VOC use and actual 12-month VOC use;
2. Report the first semiannual estimate in
which projected annual VOC use exceeds the applicable cutoff; and
3. Report the first 12-month period in which
the actual VOC use exceeds the applicable cutoff.
(d) Each owner or operator of an affected
facility demonstrating compliance by the methods described in sub. (4) (a) 1.,
2., 4., (b) or (c) shall maintain records and submit quarterly reports to the
department documenting the following:
1. For
those affected facilities monitoring only the carbon adsorption system outlet
concentration levels of organic compounds, the periods, during actual coating
operations, specified in subd. 1. a. or b., as applicable.
a. For carbon adsorption systems with a
common exhaust stack for all the individual adsorber vessels, all periods of 3
consecutive system rotations through the adsorption cycles of all the
individual adsorber vessels during which the average value of the concentration
level of organic compounds in the common outlet gas stream is more the 20%
greater than the average value measured during the most recent performance test
that demonstrated compliance.
b.
For carbon adsorption systems with individual exhaust stacks for each adsorber
vessel, all 3-day rolling averages for each adsorber vessel when the
concentration level of organic compounds in the individual gas stream is more
than 20% greater than the average value for that adsorber vessel measured
during the most recent performance test that demonstrated compliance.
2. For those affected facilities
monitoring both the carbon adsorption system inlet and outlet concentration
levels of organic compounds, the periods, during actual coating operations,
specified in subd. 2. a. or b., as applicable.
a. For carbon adsorption systems with a
common exhaust stack for all the individual adsorber vessels, all periods of 3
consecutive adsorption cycles of all the individual adsorber vessels during
which the average carbon adsorption system efficiency falls below the
applicable level as follows:
1) For those
affected facilities demonstrating compliance by the performance test method
described in sub. (4) (a) 1., the value of E determined using Equation (1)
during the most recent performance test that demonstrated compliance.
2) For those affected facilities
demonstrating compliance by the performance test described in sub. (4) (a) 4.,
the average value of the system efficiency measured with the monitor during the
most recent performance test that demonstrated compliance.
3) For those affected facilities
demonstrating compliance pursuant to sub. (4) (b) or (c), 0.95.
b. For carbon adsorption systems
with individual exhaust stacks for each adsorber vessel, all 3-day rolling
averages for each adsorber vessel during which the average carbon adsorber
vessel efficiency falls below the applicable level as follows:
1) For those affected facilities
demonstrating compliance by the performance test method described in sub. (4)
(a) 2., (b) or (c), the value of Hv determined using Equation (3) during the
most recent performance test that demonstrated compliance.
2) For those affected facilities
demonstrating compliance by the performance test described in sub. (4) (a) 4.,
the average efficiency for that adsorber vessel measured with the monitor
during the most recent performance test that demonstrated compliance.
3. For those affected
facilities monitoring condenser exhaust gas temperature, all 3-hour periods,
during actual coating operations, during which the average exhaust temperature
is 5 or more Celsius degrees above the average temperature measured during the
most recent performance test that demonstrated compliance;
4. For those affected facilities monitoring
thermal incinerator combustion exhaust gas temperature, all 3-hour periods,
during actual coating operations, during which the average combustion
temperature of the device is more than 28 Celsius degrees below the average
combustion temperature of the device during the most recent performance test
that demonstrated compliance;
5.
For those affected facilities monitoring catalytic incinerator catalyst bed
temperature, all 3-hour periods, during actual coating operations, during which
the average gas temperature immediately before the catalyst bed is more than 28
Celsius degrees below the average gas temperature during the most recent
performance test that demonstrated compliance and all 3-hour periods, during
actual coating operations, during which the average gas temperature difference
across the catalyst bed is less than 80% of the average gas temperature
difference during the most recent performance test that demonstrated
compliance;
6. For each affected
facility monitoring a total enclosure pursuant to sub. (5) (h) or vapor capture
system pursuant to sub. (5) (g), all 3-hour periods, during actual coating
operations, during which the average total enclosure or vapor capture system
monitor readings vary by 5% or more from the average value measured during the
most recent performance test that demonstrated compliance.
7. Each owner or operator of an affected
coating operation not required to submit reports under subds. 1. to 6. because
no reportable periods have occurred shall submit semiannual statements
clarifying this fact.
(e) Each owner or operator of an affected
coating operation, demonstrating compliance by the test methods described in
sub. (4) (a) 3., liquid-liquid material balance, shall submit the following:
1. For months of compliance, semiannual
reports to the department stating that the affected coating operation was in
compliance for each 1-month period; and
2. For months of noncompliance, quarterly
reports to the department documenting the 1-month amount of VOC contained in
the coatings, the 1-month amount of VOC recovered and the percent emission
reduction for each month.
(f) Each owner or operator of an affected
coating operation, either by itself or with associated coating mix preparation
equipment, shall submit the following with the reports required under pars. (d)
and (e):
1. All periods during actual mixing
or coating operations when a required monitoring device, if any, was
malfunctioning or not operating; and
2. All periods during actual mixing or
coating operations when the control device was malfunctioning or not
operating.
(g) The
reports required under pars. (b) to (e) shall be postmarked within 30 days of
the end of the reporting period.
(h) Records required in this subsection shall
be retained for at least 2 years.
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.
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