(1) BY WHAT DATE MUST I CONDUCT PERFORMANCE
TESTS AND OTHER INITIAL COMPLIANCE DEMONSTRATIONS?
(a) For a new or reconstructed affected
source, you shall meet the requirements of subds. 1. to 4.
1. All emission capture systems, add-on
control devices, and CPMS shall be installed and operating no later than the
applicable compliance date specified in s.
NR 465.31(4). Except for solvent
recovery systems for which you conduct liquid-liquid material balances
according to sub. (2) (j), you shall conduct a performance test of each capture
system and add-on control device according to subs. (5), (6) and (7) and
establish the operating limits required by s.
NR 465.33(3) no later than 180 days
after the applicable compliance date specified in s.
NR 465.31(4). For a solvent recovery
system for which you conduct liquid-liquid material balances according to sub.
(2) (j), you shall initiate the first material balance no later than the
applicable compliance date specified in s.
NR 465.31(4).
2. You shall develop and begin implementing
the work practice plan required by s.
NR 465.33(4) no later than the
compliance date specified in s.
NR 465.31(4).
3. You shall complete the initial compliance
demonstration for the initial compliance period according to the requirements
of sub. (2). The initial compliance period begins on the applicable compliance
date specified in s.
NR 465.31(4) and ends on the last day of
the 12th month following the compliance date. If the compliance date occurs on
any day other than the first day of a month, then the initial compliance period
extends through the end of that month plus the next 12 months. You shall
determine the mass of organic HAP emissions and mass of coatings solids used
each month and then calculate an organic HAP emission rate at the end of the
initial compliance period. The initial compliance demonstration includes the
results of emission capture system and add-on control device performance tests
conducted according to subs. (5), (6) and (7); results of liquid-liquid
material balances conducted according to sub. (2) (j); calculations according
to sub. (2) and supporting documentation showing that during the initial
compliance period the organic HAP emission rate was equal to or less than the
applicable emission limit in s.
NR 465.33(1); the operating limits
established during the performance tests and the results of the continuous
parameter monitoring required by sub. (9); and documentation of whether you
developed and implemented the work practice plan required by s.
NR 465.33(4).
4. You do not need to comply with the
operating limits for the emission capture system and add-on control device
required by s.
NR 465.33(3) until after you have
completed the performance tests specified in subd. 1. Instead, you shall
maintain a log detailing the operation and maintenance of the emission capture
system, add-on control device, and continuous parameter monitors during the
period between the compliance date and the performance test. You shall begin
complying with the operating limits for your affected source on the date you
complete the performance tests specified in subd. 1. The requirements in this
subdivision do not apply to solvent recovery systems for which you conduct
liquid-liquid material balances according to the requirements in sub. (2) (j).
(b) For an existing
affected source, you shall meet the requirements of subds. 1. to 3.
1. All emission capture systems, add-on
control devices and CPMS shall be installed and operating no later than the
applicable compliance date specified in s.
NR 465.31(4). Except for solvent
recovery systems for which you conduct liquid-liquid material balances
according to sub. (2) (j), you shall conduct a performance test of each capture
system and add-on control device according to the procedures in subs. (5), (6)
and (7) and establish the operating limits required by s.
NR 465.33(3) no later than the
compliance date specified in s.
NR 465.31(4). For a solvent recovery
system for which you conduct liquid-liquid material balances according to sub.
(2) (j), you shall initiate the first material balance no later than the
compliance date specified in s.
NR 465.31(4).
2. You shall develop and begin implementing
the work practice plan required by s.
NR 465.33(4) no later than the
compliance date specified in s.
NR 465.31(4).
3. You shall complete the initial compliance
demonstration for the initial compliance period according to the requirements
of sub. (2). The initial compliance period begins on the applicable compliance
date specified in s.
NR 465.31(4) and ends on the last day of
the 12th month following the compliance date. If the compliance date occurs on
any day other than the first day of a month, then the initial compliance period
extends through the end of that month plus the next 12 months. You shall
determine the mass of organic HAP emissions and mass of coatings solids used
each month and then calculate an organic HAP emission rate at the end of the
initial compliance period. The initial compliance demonstration includes the
results of emission capture system and add-on control device performance tests
conducted according to subs. (5), (6) and (7); results of liquid-liquid
material balances conducted according to sub. (2) (j); calculations according
to sub. (2) and supporting documentation showing that during the initial
compliance period the organic HAP emission rate was equal to or less than the
applicable emission limit in s.
NR 465.33(1); the operating limits
established during the performance tests and the results of the continuous
parameter monitoring required by sub. (9); and documentation of whether you
developed and implemented the work practice plan required by s.
NR 465.33(4).
(c) You are not required to conduct an
initial performance test to determine capture efficiency or destruction
efficiency of a capture system or control device if you receive approval to use
the results of a performance test that has been previously conducted on that
capture system or control device. Any previous tests shall meet the conditions
described in subds. 1. to 3.
1. The previous
test shall have been conducted using the methods and conditions specified in
this subchapter.
2. Either no
process or equipment changes shall have been made since the previous test was
performed, or the owner or operator shall be able to demonstrate that the
results of the performance test, with or without adjustments, reliably
demonstrate compliance despite process or equipment changes.
3. Either the required operating parameters
were established in the previous test or sufficient data were collected in the
previous test to establish the required operating parameters.
(2) HOW DO I
DEMONSTRATE INITIAL COMPLIANCE?
(a)
General. You may use the emission rate with add-on controls
option for any coating operation, for any group of coating operations in the
affected source, or for all of the coating operations in the affected source.
You may include both controlled and uncontrolled coating operations in a group
for which you use this option. You shall use either the compliant material
option in s.
NR 465.33(2) (a) or the emission rate
without add-on controls option in s.
NR 465.33(2) (b) for any coating
operation in the affected source for which you do not use the emission rate
with add-on controls option. To demonstrate initial compliance, the coating
operations for which you use the emission rate with add-on controls option
shall meet the applicable emission limits in s.
NR 465.33(1), (3) and (4). You shall
conduct a separate initial compliance demonstration for each general use,
thermoplastic olefin, automotive lamp and assembled on-road vehicle coating
operation, unless you are demonstrating compliance with a predominant activity
or facility-specific emission limit as provided in s.
NR 465.33(1) (c). If you are
demonstrating compliance with a predominant activity or facility-specific
emission limit, you shall demonstrate that all coating operations included in
the predominant activity determination or calculation of the facility-specific
emission limit comply with that limit. You shall meet all the requirements of
this subsection. When calculating the organic HAP emission rate according to
this subsection, do not include any coatings, thinners or other additives, or
cleaning materials used on coating operations for which you use the compliant
material option or the emission rate without add-on controls option. You do not
need to re-determine the mass of organic HAP in coatings, thinners or other
additives, or cleaning materials that have been reclaimed onsite, or reclaimed
off-site if you have documentation showing that you received back the exact
same materials that were sent off-site, and reused in the coatings operations
for which you use the emission rate with add-on controls option. If you use
coatings, thinners or other additives, or cleaning materials that have been
reclaimed on-site, the amount of each used in a month may be reduced by the
amount of each that is reclaimed. That is, the amount used may be calculated as
the amount consumed to account for materials that are reclaimed.
(b)
Compliance with operating
limits. Except as provided in sub. (1)(a) 4., and except for solvent
recovery systems for which you conduct liquid-liquid material balances
according to the requirements of par. (j), you shall establish and demonstrate
continuous compliance during the initial compliance period with the operating
limits required by s.
NR 465.33(3), using the procedures
specified in subs. (8) and (9).
(c)
Compliance with work practice
requirements. You shall develop, implement and document your
implementation of the work practice plan required by s.
NR 465.33(4) during the initial
compliance period, as specified in s.
NR 465.35(3).
(d)
Compliance with emission
limits. You shall follow the procedures in pars. (e) to (n) to
demonstrate compliance with the applicable emission limit in s.
NR 465.33(1) for each affected source in
each sub-category.
(e)
Determine the mass fraction of organic HAP, density, volume
used, and mass fraction of coating solids. Follow the procedures
specified in s.
NR 465.37(2) (a) to (d) to determine the
mass fraction of organic HAP, density and volume of each coating, thinner and
other additive, and cleaning material used during each month; and the mass
fraction of coating solids for each coating used during each month.
(f)
Calculate the total mass of
organic HAP emissions before add-on controls. Using Equation 1 of s.
NR 465.37(2), calculate the total mass
of organic HAP emissions before add-on controls from all coatings, thinners and
other additives, and cleaning materials used during each month in the coating
operation or group of coating operations for which you use the emission rate
with add-on controls option.
(g)
Calculate the organic HAP emission reduction for each controlled
coating operation. Determine the mass of organic HAP emissions reduced
for each controlled coating operation during each month. The emission reduction
determination quantifies the total organic HAP emissions that pass through the
emission capture system and are destroyed or removed by the add-on control
device. Use the procedures in par. (h) to calculate the mass of organic HAP
emission reduction for each controlled coating operation using an emission
capture system and add-on control device other than a solvent recovery system
for which you conduct liquid-liquid material balances. For each controlled
coating operation using a solvent recovery system for which you conduct a
liquid-liquid material balance, use the procedures in par. (j) to calculate the
organic HAP emission reduction.
(h)
Calculate the organic HAP emission reduction for each controlled
coating operation not using liquid-liquid material balance. Use the
equations in this paragraph to calculate the organic HAP emission reduction for
each controlled coating operation using an emission capture system and add-on
control device other than a solvent recovery system for which you conduct
liquid-liquid material balances. You shall assume zero efficiency for the
emission capture system and add-on control device for any period of time a
deviation specified in sub. (4) (c) or (d) occurs in the controlled coating
operation, including a deviation during a period of startup, shutdown or
malfunction, unless you have other data indicating the actual efficiency of the
emission capture system and add-on control device and the use of these data is
approved by the department.
Note: The calculation applies the emission capture system
efficiency and add-on control device efficiency to the mass of organic HAP
contained in the coatings, thinners and other additives, and cleaning materials
that are used in the coating operation served by the emission capture system
and add-on control device during each month. Equation 1 treats the materials
used during a deviation as if they were used on an uncontrolled coating
operation for the time period of the deviation.
See
Image
where:
HC is the mass of organic HAP
emission reduction for the controlled coating operation during the month, kg
(lb)
AC is the total mass of organic HAP
in the coatings used in the controlled coating operation during the month, kg
(lb), as calculated in Equation 1A of this subsection
BC is the total mass of organic HAP
in the thinners and other additives used in the controlled coating operation
during the month, kg (lb), as calculated in Equation 1B of this
subsection
CC is the total mass of organic HAP
in the cleaning materials used in the controlled coating operation during the
month, kg (lb), as calculated in Equation 1C of this subsection
Rw is the total mass of organic HAP
in waste materials sent or designated for shipment to a hazardous waste TSDF
for treatment or disposal during the compliance period, kg (lb), determined
according to s.
NR 465.37(2) (e) 2. You may assign a
value of zero to Rw if you do not wish to use this
allowance.
HUNC is the total mass of organic
HAP in the coatings, thinners and other additives, and cleaning materials used
during all deviations specified in sub. (4) (c) and (d) that occurred during
the month in the controlled coating operation, kg (lb), as calculated in
Equation 1D of this subsection
CE is the capture efficiency of the emission capture system
vented to the add-on control device, percent. Use the test methods and
procedures specified in subs. (5) and (6) to measure and record capture
efficiency.
DRE is the organic HAP destruction or removal efficiency of
the add-on control device, percent. Use the test methods and procedures in
subs. (5) and (7) to measure and record the organic HAP destruction or removal
efficiency.
See
Image
where:
AC is the total mass of organic HAP
in the coatings used in the controlled coating operation during the month, kg
(lb)
Volc,i is the total volume of
coating, i, used during the month, liters (gallons)
Dc,i is the density of coating, i,
kg per liter (lb per gallon)
Wc,i is the mass fraction of organic
HAP in coating, i, kg per kg (lb per lb). For reactive adhesives, use the mass
fraction of organic HAP that is emitted as determined using the method in 40
CFR part 63, Subpart PPPP, Appendix A, incorporated by reference in s.
NR 484.04(24r).
m is the number of different coatings used
See
Image
where:
BC is the total mass of organic HAP
in the thinners or other additives used in the controlled coating operation
during the month, kg (lb)
Volt,j is the total volume of
thinner or other additive, j, used during the month, liters (gallons)
Dt,j is the density of thinner or
other additive, j, kg per liter (lb per gallon)
Wt,j is the mass fraction of organic
HAP in thinner or other additive, j, kg per kg (lb per lb). For reactive
adhesives, use the mass fraction of organic HAP that is emitted as determined
using the method in 40 CFR part 63, Subpart PPPP, Appendix A, incorporated by
reference in s.
NR 484.04(24r).
n is the number of different thinners and other additives
used
See
Image
where:
CC is the total mass of organic HAP
in the cleaning materials used in the controlled coating operation during the
month, kg (lb)
Vols,k is the total volume of
cleaning material, k, used during the month, liters (gallons)
Ds,k is the density of cleaning
material, k, kg per liter (lb per gallon)
Ws,k is the mass fraction of organic
HAP in cleaning material, k, kg per kg (lb per lb)
p is the number of different cleaning materials used
See
Image
where:
HUNC is the total mass of organic
HAP in the coatings, thinners and other additives, and cleaning materials used
during all deviations specified in sub. (4)(c) and (d) that occurred during the
month in the controlled coating operation, kg (lb)
Volh is the total volume of coating,
thinner or other additives, or cleaning material, h, used in the controlled
coating operation during deviations, liters (gallons)
Dh is the density of coating,
thinner or other additives, or cleaning material, h, kg per liter (lb per
gallon)
Wh is the mass fraction of organic
HAP in coating, thinner or other additives, or cleaning material, h, kg (lb) of
organic HAP per kg (lb) of coating. For reactive adhesives, use the mass
fraction of organic HAP that is emitted as determined using the method in 40
CFR part 63, Subpart PPPP, Appendix A, incorporated by reference in s.
NR 484.04(24r).
q is the number of different coatings, thinners and other
additives, and cleaning materials used
(j)
Calculate the organic HAP
emission reduction for each controlled coating operation using liquid-liquid
material balances. For each controlled coating operation using a
solvent recovery system for which you conduct liquid-liquid material balances,
calculate the organic HAP emission reduction by applying the volatile organic
matter collection and recovery efficiency to the mass of organic HAP contained
in the coatings, thinners and other additives and cleaning materials that are
used in the coating operation or operations controlled by the solvent recovery
system during each month. Perform a liquid-liquid material balance for each
month as specified in subds. 1. to 6. Calculate the mass of organic HAP
emission reduction by the solvent recovery system as specified in subd. 7.
1. For each solvent recovery system, install,
calibrate, maintain and operate according to the manufacturer's specifications,
a device that indicates the cumulative amount of volatile organic matter
recovered by the solvent recovery system each month. The device shall be
initially certified by the manufacturer to be accurate to within 2.0 % of the
mass of volatile organic matter recovered.
2. For each solvent recovery system,
determine the mass of volatile organic matter recovered for the month, based on
measurement with the device required in subd. 1.
3. Determine the mass fraction of volatile
organic matter for each coating, thinner and other additive and cleaning
material used in the coating operation or operations controlled by the solvent
recovery system during the month, kg (lb) of volatile organic matter per kg
(lb) of coating. You may determine the volatile organic matter mass fraction
using Method 24 in 40 CFR part 60, Appendix A, incorporated by reference in s.
NR 484.04(13), or an EPA approved
alternative method, or you may use information provided by the manufacturer or
supplier of the coating. In the event of any inconsistency between information
provided by the manufacturer or supplier and the results of Method 24 or an
approved alternative method, the test method results will take precedence
unless, after consultation, you demonstrate to the satisfaction of the
department that the formulation data are correct.
4. Determine the density of each coating,
thinner or other additive and cleaning material used in the coating operation
or operations controlled by the solvent recovery system during the month, kg
per liter (lb per gallon), according to s.
NR 465.37(2) (c).
5. Measure the volume of each coating,
thinner and other additive and cleaning material used in the coating operation
or operations controlled by the solvent recovery system during the month,
liters (gallons).
6. Each month,
calculate the solvent recovery system's volatile organic matter collection and
recovery efficiency using the following equation:
See
Image
where:
RV is the volatile organic matter
collection and recovery efficiency of the solvent recovery system during the
month, percent
MVR is the mass of volatile organic
matter recovered by the solvent recovery system during the month, kg
(lb)
Voli is the volume of coating, i,
used in the coating operation controlled by the solvent recovery system during
the month, liters (gallons)
Di is the density of coating, i, kg
per liter (lb per gallon)
WVc,i is the mass fraction of
volatile organic matter for coating i, kg (lb) of volatile organic matter per
kg (lb) of coating. For reactive adhesives, use the mass fraction of organic
HAP that is emitted as determined using the method in 40 CFR part 63, Subpart
PPPP, Appendix A, incorporated by reference in s.
NR 484.04(24r).
Volj is the volume of thinner or
other additive, j, used in the coating operation controlled by the solvent
recovery system during the month, liters (gallons)
Dj is the density of thinner or
other additive, j, kg per liter (lb per gallon)
WVt,j is the mass fraction of
volatile organic matter for thinner or other additive, j, kg (lb) of volatile
organic matter per kg (lb) of thinner or other additive. For reactive
adhesives, use the mass fraction of organic HAP that is emitted as determined
using the method in 40 CFR part 63, Subpart PPPP, Appendix A, incorporated by
reference in s.
NR 484.04(24r).
Volk is the volume of cleaning
material, k, used in the coating operation controlled by the solvent recovery
system during the month, liters (gallons)
Dk is the density of cleaning
material, k, kg per liter (lb per gallon)
WVs,k is the mass fraction of
volatile organic matter for cleaning material, k, kg (lb) of volatile organic
matter per kg (lb) of cleaning material
m is the number of different coatings used in the coating
operation controlled by the solvent recovery system during the month
n is the number of different thinners and other additives
used in the coating operation controlled by the solvent recovery system during
the month
p is the number of different cleaning materials used in the
coating operation controlled by the solvent recovery system during the
month
7. Calculate the mass
of organic HAP emission reduction for the coating operation or operations
controlled by the solvent recovery system during the month, using the following
equations:
See
Image
where:
HCSR is the mass of organic HAP
emission reduction for the coating operation controlled by the solvent recovery
system using a liquid-liquid material balance during the month, kg (lb)
ACSR is the total mass of organic
HAP in the coatings used in the coating operation controlled by the solvent
recovery system, kg (lb), calculated using Equation 3A of this
subsection
BCSR is the total mass of organic
HAP in the thinners and other additives used in the coating operation
controlled by the solvent recovery system, kg (lb), calculated using Equation
3B of this subsection
CCSR is the total mass of organic
HAP in the cleaning materials used in the coating operation controlled by the
solvent recovery system, kg (lb), calculated using Equation 3C of this
subsection
RV is the volatile organic matter
collection and recovery efficiency of the solvent recovery system, percent,
from Equation 2 of subd. 6.
See
Image
where:
ACSR is the total mass of organic
HAP in the coatings used in the coating operation controlled by the solvent
recovery system during the month, kg (lb)
Volc,i is the total volume of
coating, i, used during the month in the coating operation controlled by the
solvent recovery system, liters (gallons)
Dc,i is the density of coating, i,
kg per liter (lb per gallon)
Wc,i is the mass fraction of organic
HAP in coating, i, kg (lb) of organic HAP per kg (lb) of coating. For reactive
adhesives, use the mass fraction of organic HAP that is emitted as determined
using the method in 40 CFR part 63, Subpart PPPP, Appendix A, incorporated by
reference in s.
NR 484.04(24r).
m is the number of different coatings used
See
Image
where:
BCSR is the total mass of organic
HAP in the thinners and other additives used in the coating operation
controlled by the solvent recovery system during the month, kg (lb)
Volt,j is the total volume of
thinner or other additive, j, used during the month in the coating operation
controlled by the solvent recovery system, liters (gallons)
Dt,j is the density of thinner or
other additive, j, kg per liter (lb per gallon)
Wt,j is the mass fraction of organic
HAP in thinner or other additive, j, kg (lb) of organic HAP per kg (lb) of
thinner or other additive. For reactive adhesives, use the mass fraction of
organic HAP that is emitted as determined using the method in 40 CFR part 63,
Subpart PPPP, Appendix A, incorporated by reference in s.
NR 484.04(24r).
n is the number of different thinners and other additives
used
See
Image
where:
CCSR is the total mass of organic
HAP in the cleaning materials used in the coating operation controlled by the
solvent recovery system during the month, kg (lb)
Vols,k is the total volume of
cleaning material, k, used during the month in the coating operation controlled
by the solvent recovery system, liters (gallons)
Ds,k is the density of cleaning
material, k, kg per liter (lb per gallon)
Ws,k is the mass fraction of organic
HAP in cleaning material, k, kg (lb) of organic HAP per kg (lb) of cleaning
material
p is the number of different cleaning materials used
(k)
Calculate
the total mass of coating solids used. Determine the total mass of
coating solids used which is the combined mass of coating solids for all the
coatings used during each month in the coating operation or group of coating
operations for which you use the emission rate with add-on controls option,
using Equation 2 of s.
NR 465.37(2).
(L)
Calculate the mass of organic HAP
emissions for each month. Determine the mass of organic HAP emissions
during each month, using the following equation:
See
Image
where:
HHAP is the total mass of organic
HAP emissions for the month, kg (lb)
He is the total mass of organic HAP
emissions before add-on controls from all the coatings, thinners and other
additives, and cleaning materials used during the month, kg (lb), determined
according to par. (f)
Hc,i is the total mass of organic
HAP emission reduction for controlled coating operation, i, not using a
liquid-liquid material balance, during the month, kg (lb), from Equation 1 of
this subsection
HCSR,j is the total mass of organic
HAP emission reduction for coating operation j, controlled by a solvent
recovery system using a liquid-liquid material balance, during the month, kg
(lb), from Equation 3 of this subsection
q is the number of controlled coating operations not
controlled by a solvent recovery system using a liquid-liquid material
balance
r is the number of coating operations controlled by a
solvent recovery system using a liquid-liquid material balance
(m) Calculate the organic HAP
emission rate for the compliance period. Determine the organic HAP emission
rate for the compliance period using the following equation:
See
Image
where:
Hannual is the organic HAP emission
rate for the compliance period, kg (lb) of organic HAP emitted per kg (lb) of
coating solids used
HHAP,y is the organic HAP emissions
for month, y, kg (lb), determined according to Equation 4 of this
subsection
Mst,y is the total mass of coating
solids used during month, y, kg (lb), from Equation 2 of s.
NR 465.37(2)
y is the number of the month in the compliance
period
n is the number of full or partial months in the compliance
period. For the initial compliance period, n equals 12 if the compliance date
falls on the first day of a month; otherwise n equals 13. For all following
compliance periods, n equals 12.
(n) Compliance demonstration. The organic HAP
emission rate for the initial compliance period, calculated using Equation 5 of
this subsection, shall be less than or equal to the applicable emission limit
for each sub-category in s.
NR 465.33(1) or the predominant activity
or facility-specific emission limit allowed in s.
NR 465.33(1) (c). You shall keep all
records as required by s.
NR 465.35(3)
and (4). As part of the notification of
compliance status required by s.
NR 465.35(1), you shall identify the
coating operations for which you used the emission rate with add-on controls
option and submit a statement that the coating operations were in compliance
with the emission limits in s.
NR 465.33(1) during the initial
compliance period because the organic HAP emission rate was less than or equal
to the applicable emission limit in s.
NR 465.33(1), and you achieved the
operating limits required by s.
NR 465.33(3) and the work practice
standards required by s.
NR 465.33(4).
(4) HOW DO I DEMONSTRATE CONTINUOUS
COMPLIANCE WITH THE EMISSION LIMITS?
(a) To
demonstrate continuous compliance with the applicable emission limit in s.
NR 465.33(1), the organic HAP emission
rate for each compliance period, determined according to the procedures in sub.
(2), shall be equal to or less than the applicable emission limit in s.
NR 465.33(1). A compliance period
consists of 12 months. Each month after the end of the initial compliance
period described in sub. (1) is the end of a compliance period consisting of
that month and the preceding 11 months. You shall perform the calculations in
sub. (2) on a monthly basis using data from the previous 12 months of
operation. If you are complying with a facility-specific emission limit under
s.
NR 465.33(1) (c) 2., you shall also
perform the calculation using Equation 1 in s.
NR 465.33(1) (c) 2. on a monthly basis
using the data from the previous 12 months of operation.
(b) If the organic HAP emission rate for any
12-month compliance period exceeded the applicable emission limit in s.
NR 465.33(1), this is a deviation from
the emission limit for that compliance period that shall be reported as
specified in s.
NR 465.35(1)
(c) 6. and (2) (a) 7.
(c) You shall demonstrate continuous
compliance with each operating limit required by s.
NR 465.33(3) that applies to you, as
specified in Table 1 of this subchapter, when the coating line is in operation.
If an operating parameter is out of the allowed range specified in Table 1, you
shall do both of the following:
1. Report as
a deviation from the operating limit as specified in s.
NR 465.35(1)
(c) 6. and (2) (a) 7.
2. Assume that the emission capture system
and add-on control device were achieving zero efficiency during the time period
of the deviation, unless you have other data indicating the actual efficiency
of the emission capture system and add-on control device and the use of these
data is approved by the department.
(d) You shall meet the requirements for
bypass lines in sub. (9) (b) for controlled coating operations for which you do
not conduct liquid-liquid material balances. If any bypass line is opened and
emissions are diverted to the atmosphere when the coating operation is running,
this is a deviation that shall be reported as specified in s.
NR 465.35(1)
(c) 6. and (2) (a) 7. For the purposes of
completing the compliance calculations specified in sub. (2) (h), you shall
treat the materials used during a deviation on a controlled coating operation
as if they were used on an uncontrolled coating operation for the time period
of the deviation as indicated in Equation 1 of sub. (2).
(e) You shall demonstrate continuous
compliance with the work practice standards in s.
NR 465.33(4). If you did not develop a
work practice plan, or you did not implement the plan, or you did not keep the
records required by s.
NR 465.35(3)
(i) 8., this is a deviation from the work
practice standards that shall be reported as specified in s.
NR 465.35(1)
(c) 6. and (2) (a) 7.
(f) As part of each semiannual compliance
report required in s.
NR 465.35(2), you shall identify the
coating operations for which you used the emission rate with add-on controls
option. If there were no deviations from the emission limits specified in s.
NR 465.33(1), you shall submit a
statement that you were in compliance with the emission limits during the
reporting period because the organic HAP emission rate for each compliance
period was less than or equal to the applicable emission limit in s.
NR 465.33(1), and you achieved the
operating limits required by s.
NR 465.33(3) and the work practice
standards required by s.
NR 465.33(4) during each compliance
period.
(g) During periods of
startup, shutdown or malfunction of the emission capture system, add-on control
device or coating operation that may affect emission capture or control device
efficiency, you shall operate in accordance with the startup, shutdown and
malfunction plan required by s.
NR 465.34(1)
(c).
(j) You shall maintain records as specified
in s.
NR 465.35(3)
and (4).
(6) HOW DO I DETERMINE THE
EMISSION CAPTURE SYSTEM EFFICIENCY? You shall use the procedures and test
methods in this subsection to determine capture efficiency as part of the
performance test required by sub. (1).
(a)
Assuming 100% capture efficiency. You may assume the capture
system efficiency is 100% if both of the conditions in subds. 1. and 2. are
met.
1. The capture system meets the criteria
in Method 204 in 40 CFR part 51, Appendix M, incorporated by reference in s.
NR 484.04(9), for a PTE and directs all
the exhaust gases from the enclosure to an add-on control device.
2. All coatings, thinners and other additives
and cleaning materials used in the coating operation are applied within the
capture system; coating solvent flash-off, curing and drying occurs within the
capture system; and the removal or evaporation of cleaning materials from the
surfaces they are applied to occurs within the capture system.
Note: For example, this criterion is not met if parts enter
the open shop environment when being moved between a spray booth and a curing
oven.
(b)
Measuring capture efficiency. If the capture system does not
meet both of the conditions in par. (a), then you shall use one of the 3
protocols described in pars. (c), (d) and (e) to measure capture efficiency.
The capture efficiency measurements use TVH capture efficiency as a surrogate
for organic HAP capture efficiency. For the protocols in pars. (c) and (d), the
capture efficiency measurement shall consist of 3 test runs. Each test run
shall be at least 3 hours duration or the length of a production run, whichever
is longer, up to 8 hours. For the purposes of this test, a production run means
the time required for a single part to go from the beginning to the end of the
production, which includes surface preparation activities and drying and curing
time.
(c)
Liquid-to-uncaptured-gas protocol using a temporary total enclosure or
building enclosure. The liquid-to-uncaptured-gas protocol compares the
mass of liquid TVH in materials used in the coating operation to the mass of
TVH emissions not captured by the emission capture system. You shall use a
temporary total enclosure or a building enclosure and the procedures in subds.
1. to 6. to measure emission capture system efficiency when using the
liquid-to-uncaptured-gas protocol.
1. Either
use a building enclosure or construct an enclosure around the coating operation
where coatings, thinners and other additives, and cleaning materials are
applied, and all areas where emissions from these applied coatings and
materials subsequently occur, such as flash-off, curing and drying areas. The
areas of the coating operation where capture devices collect emissions for
routing to an add-on control device, such as the entrance and exit areas of an
oven or spray booth, shall also be inside the enclosure. The enclosure shall
meet the applicable definition of a temporary total enclosure or building
enclosure in Method 204 in 40 CFR part 51, Appendix M, incorporated by
reference in s.
NR 484.04(9).
2. Use Method 204A or 204F in 40 CFR part 51,
Appendix M, incorporated by reference in s.
NR 484.04(9), to determine the mass
fraction of TVH liquid input from each coating, thinner and other additive and
cleaning material used in the coating operation during each capture efficiency
test run. To make the determination, substitute TVH for each occurrence of the
term volatile organic compounds (VOC) in the methods.
3. Use Equation 1 in this subsection to
calculate the total mass of TVH liquid input from all the coatings, thinners
and other additives and cleaning materials used in the coating operation during
each capture efficiency test run:
See
Image
where:
TVHused is the mass of liquid TVH in
materials used in the coating operation during the capture efficiency test run,
kg (lb)
TVHi is the mass fraction of TVH in
coating, thinner or other additive or cleaning material, i, that is used in the
coating operation during the capture efficiency test run, kg (lb) of TVH per kg
(lb) of material
Voli is the total volume of coating,
thinner or other additive or cleaning material, i, used in the coating
operation during the capture efficiency test run, liters (gallons)
Di is the density of coating,
thinner or other additive or cleaning material, i, kg (lb) of material per
liter (gallon) of material
n is the number of different coatings, thinners and other
additives, and cleaning materials used in the coating operation during the
capture efficiency test run
4. Use Method 204D or 204E in 40 CFR part 51,
Appendix M, incorporated by reference in s.
NR 484.04(9), to measure the total mass
of TVH emissions that are not captured by the emission capture system. They are
measured as they exit the temporary total enclosure or building enclosure
during each capture efficiency test run. To make the measurement, substitute
TVH for each occurrence of the term VOC in the methods.
a. Use Method 204D in 40 CFR part 51,
Appendix M, incorporated by reference in s.
NR 484.04(9), if the enclosure is a
temporary total enclosure.
b. Use
Method 204E in 40 CFR part 51, Appendix M, incorporated by reference in s.
NR 484.04(9), if the enclosure is a
building enclosure. During the capture efficiency measurement, all organic
compound emitting operations inside the building enclosure, other than the
coating operation for which capture efficiency is being determined, shall be
shut down, but all fans and blowers shall be operating normally.
5. For each capture efficiency
test run, determine the percent capture efficiency of the emission capture
system using the following equation:
See
Image
where:
CE is the capture efficiency of the emission capture system
vented to the add-on control device, percent
TVHused is the total mass of TVH
liquid input used in the coating operation during the capture efficiency test
run, kg (lb)
TVHuncaptured is the total mass of
TVH that is not captured by the emission capture system and that exits from the
temporary total enclosure or building enclosure during the capture efficiency
test run, kg (lb)
6.
Determine the capture efficiency of the emission capture system as the average
of the capture efficiencies measured in the 3 test runs.
(d)
Gas-to-gas protocol using a
temporary total enclosure or a building enclosure. The gas-to-gas
protocol compares the mass of TVH emissions captured by the emission capture
system to the mass of TVH emissions not captured. You shall use a temporary
total enclosure or a building enclosure and the procedures in subds. 1. to 5.
to measure emission capture system efficiency when using the gas-to-gas
protocol.
1. Either use a building enclosure
or construct an enclosure around the coating operation where coatings, thinners
and other additives and cleaning materials are applied, and all areas where
emissions from these applied coatings and materials subsequently occur, such as
flash-off, curing and drying areas. The areas of the coating operation where
capture devices collect emissions generated by the coating operation for
routing to an add-on control device, such as the entrance and exit areas of an
oven or a spray booth, shall also be inside the enclosure. The enclosure shall
meet the applicable definition of a temporary total enclosure or building
enclosure in Method 204 in 40 CFR part 51, Appendix M, incorporated by
reference in s.
NR 484.04(9).
2. Use Method 204B or 204C in 40 CFR part 51,
Appendix M, incorporated by reference in s.
NR 484.04(9), to measure the total mass
of TVH emissions captured by the emission capture system during each capture
efficiency test run as measured at the inlet to the add-on control device. To
make the measurement, substitute TVH for each occurrence of the term VOC in the
methods.
a. The sampling points for the
Method 204B or 204C in 40 CFR part 51, Appendix M, incorporated by reference in
s.
NR 484.04(9), measurement shall be
upstream from the add-on control device and shall represent total emissions
routed from the capture system and entering the add-on control
device.
b. If multiple emission
streams from the capture system enter the add-on control device without a
single common duct, then the emissions entering the add-on control device shall
be simultaneously measured in each duct and the total emissions entering the
add-on control device shall be determined.
3. Use Method 204D or 204E in 40 CFR part 51,
Appendix M, incorporated by reference in s.
NR 484.04(9), to measure the total mass
of TVH emissions that are not captured by the emission capture system. They are
measured as they exit the temporary total enclosure or building enclosure
during each capture efficiency test run. To make the measurement, substitute
TVH for each occurrence of the term VOC in the methods.
a. Use Method 204D in 40 CFR part 51,
Appendix M, incorporated by reference in s.
NR 484.04(9), if the enclosure is a
temporary total enclosure.
b. Use
Method 204E in 40 CFR part 51, Appendix M, incorporated by reference in s.
NR 484.04(9), if the enclosure is a
building enclosure. During the capture efficiency measurement, all organic
compound emitting operations inside the building enclosure, other than the
coating operation for which capture efficiency is being determined, shall be
shut down, but all fans and blowers shall be operating normally.
4. For each capture efficiency
test run, determine the percent capture efficiency of the emission capture
system using the following equation:
See
Image
where:
CE is the capture efficiency of the emission capture system
vented to the add-on control device, percent
TVHcaptured is the total mass of TVH captured by the
emission capture systems measured at the inlet to the add-on control device
during the emission capture efficiency test run, kg (lb)
TVHuncaptured is the total mass of TVH that is not captured
by the emission capture system and that exits from the temporary total
enclosure or building enclosure during the capture efficiency test run, kg
(lb)
5. Determine the
capture efficiency of the emission capture system as the average of the capture
efficiencies measured in the 3 test runs.
(e) Alternative capture efficiency protocol.
As an alternative to the procedures specified in pars. (c) and (d) and subject
to the approval of the department, you may determine capture efficiency using
any other capture efficiency protocol and test method that satisfies the
criteria of either the DQO or LCL approach as described in 40 CFR part 63,
Subpart KK, Appendix A, incorporated by reference in s.
NR 484.04(24).
(7) HOW DO I DETERMINE THE ADD-ON CONTROL
DEVICE EMISSION DESTRUCTION OR REMOVAL EFFICIENCY? You shall use the procedures
and test methods in this subsection to determine the add-on control device
emission destruction or removal efficiency as part of the performance test
required by sub. (1). You shall conduct 3 test runs as specified in s.
NR 460.06(4)
(c), and each test run shall last at least
one hour.
(a) For all types of add-on control
devices, use the test methods specified in subds. 1. to 5.
1. Method 1 or 1A in 40 CFR part 60, Appendix
A, incorporated by reference in s.
NR 484.04(13), as appropriate, to select
sampling sites and velocity traverse points.
2. Method 2, 2A, 2C, 2D, 2F or 2G in 40 CFR
part 60, Appendix A, incorporated by reference in s.
NR 484.04(13), as appropriate, to
measure gas volumetric flow rate.
3. Method 3, 3A or 3B in 40 CFR part 60,
Appendix A, incorporated by reference in s.
NR 484.04(13), as appropriate, for gas
analysis to determine dry molecular weight.
4. Method 4 in 40 CFR part 60, Appendix A,
incorporated by reference in s.
NR 484.04(13), to determine stack gas
moisture.
5. Methods for
determining gas volumetric flow rate, dry molecular weight and stack gas
moisture shall be performed, as applicable, during each test run.
(b) Measure total gaseous organic
mass emissions as carbon at the inlet and outlet of the add-on control device
simultaneously, using either Method 25 or 25A in 40 CFR part 60, Appendix A,
incorporated by reference in s.
NR 484.04(13).
1. Use Method 25 if the add-on control device
is an oxidizer and you expect the total gaseous organic concentration as carbon
to be more than 50 parts per million (ppm) at the control device
outlet.
2. Use Method 25A if the
add-on control device is an oxidizer and you expect the total gaseous organic
concentration as carbon to be 50 ppm or less at the control device
outlet.
3. Use Method 25A if the
add-on control device is not an oxidizer.
(c) If 2 or more add-on control devices are
used for the same emission stream, then you shall measure emissions at the
outlet to the atmosphere of each device.
Note: For example, if one add-on control device is a
concentrator with an outlet to the atmosphere for the high-volume dilute stream
that has been treated by the concentrator, and a second add-on control device
is an oxidizer with an outlet to the atmosphere for the low-volume concentrated
stream that is treated with the oxidizer, you shall measure emissions at the
outlet of the oxidizer and the high volume dilute stream outlet of the
concentrator.
(d) For each
test run, determine the total gaseous organic emissions mass flow rates for the
inlet and the outlet of the add-on control device, using Equation 1 of this
subsection. If there is more than one inlet or outlet to the add-on control
device, you shall calculate the total gaseous organic mass flow rate using
Equation 1 for each inlet and each outlet and then total all of the inlet
emissions and total all of the outlet emissions.
Mf =
QsdCc(12)(0.0416)(10-1)
(Equation 1)
where:
Mf is the total gaseous organic
emissions mass flow rate, kg per hour (h)
Cc is the concentration of organic
compounds as carbon in the vent gas, as determined by Method 25 or Method 25A
in 40 CFR part 60, Appendix A, incorporated by reference in s.
NR 484.04(13), parts per million by
volume (ppmv), dry basis
Qsd is the volumetric flow rate of
gases entering or exiting the add-on control device, as determined by Method 2,
2A, 2C, 2D, 2F or 2G in 40 CFR part 60, Appendix A, incorporated by reference
in s.
NR 484.04(13), dry standard cubic
meters/hour (dscm/h)
0.0416 is the conversion factor for molar volume, kg-moles
per cubic meter (mol/m3) (at 293 Kelvin (K) and 760 millimeters of mercury
(mmHg))
(e) For each test
run, determine the add-on control device organic emissions destruction or
removal efficiency, using the following equation:
See
Image
where:
DRE is the organic emissions destruction or removal
efficiency of the add-on control device, percent
Mfi is the total gaseous organic
emissions mass flow rate at the inlet to the add-on control device, using
Equation 1 of this subsection, kg/h
Mfo is the total gaseous organic
emissions mass flow rate at the outlet of the add-on control device, using
Equation 1 of this subsection, kg/h
(f) Determine the emission destruction or
removal efficiency of the add-on control device as the average of the
efficiencies determined in the 3 test runs and calculated in Equation 2 of this
subsection.
(8) HOW DO I
ESTABLISH THE EMISSION CAPTURE SYSTEM AND ADD-ON CONTROL DEVICE OPERATING
LIMITS DURING THE PERFORMANCE TEST? During the performance test required by
sub. (1) and described in subs. (5), (6) and (7), you shall establish the
operating limits required by s.
NR 465.33(3) according to this
subsection, unless you have received approval for alternative monitoring and
operating limits under s.
NR 460.07(6) as specified in s.
NR 465.33(3).
(a)
Thermal oxidizers. If
your add-on control device is a thermal oxidizer, establish the operating
limits according to subds. 1. and 2.
1.
During the performance test, you shall monitor and record the combustion
temperature at least once every 15 minutes during each of the 3 test runs. You
shall monitor the temperature in the firebox of the thermal oxidizer or
immediately downstream of the firebox before any substantial heat exchange
occurs.
2. Use the data collected
during the performance test to calculate and record the average combustion
temperature maintained during the performance test. This average combustion
temperature shall be the minimum operating limit for your thermal
oxidizer.
(b)
Catalytic oxidizers. If your add-on control device is a
catalytic oxidizer, establish the operating limits according to either subds.
1. and 2. or subds. 3. and 4.
1. During the
performance test, you shall monitor and record the temperature just before the
catalyst bed and the temperature difference across the catalyst bed at least
once every 15 minutes during each of the 3 test runs.
2. Use the data collected during the
performance test to calculate and record the average temperature just before
the catalyst bed and the average temperature difference across the catalyst bed
maintained during the performance test. The average temperature just before the
catalyst bed and the average temperature difference across the catalyst bed
shall be the minimum operating limits for your catalytic oxidizer.
3. You shall monitor the temperature at the
inlet to the catalyst bed and implement a site-specific inspection and
maintenance plan for your catalytic oxidizer as specified in subd. 4. During
the performance test, you shall monitor and record the temperature just before
the catalyst bed at least once every 15 minutes during each of the 3 test runs.
Use the data collected during the performance test to calculate and record the
average temperature just before the catalyst bed during the performance test.
This average temperature shall be the minimum operating limit for your
catalytic oxidizer.
4. You shall
develop and implement an inspection and maintenance plan for your catalytic
oxidizers for which you elect to monitor according to subd. 3. The plan shall
address, at a minimum, the elements specified in subd. 4. a. to c.
a. Annual sampling and analysis of the
catalyst conversion efficiency following the manufacturer's or catalyst
supplier's recommended procedures. If problems are found during the catalyst
activity test, you shall replace the catalyst bed or take other corrective
action consistent with the manufacturer's recommendations.
b. Monthly external inspection of the
catalytic oxidizer system, including the burner assembly and fuel supply lines
for problems and, as necessary, adjustment of the equipment to assure proper
air-to-fuel mixtures.
c. Annual
internal inspection of the catalyst bed to check for channeling, abrasion and
settling. If problems are found during the annual internal inspection of the
catalyst, you shall replace the catalyst bed or take other corrective action
consistent with the manufacturer's recommendations. If the catalyst bed is
replaced and is not of like or better kind and quality as the old catalyst,
then you shall conduct a new performance test to determine destruction
efficiency according to sub. (7). If a catalyst bed is replaced and the
replacement catalyst is of like or better kind and quality as the old catalyst,
then a new performance test to determine destruction efficiency is not required
and you may continue to use the previously established operating limits for
that catalytic oxidizer.
(c)
Regenerative carbon
adsorbers. If your add-on control device is a regenerative carbon
adsorber, establish the operating limits according to subds. 1. and 2.
1. You shall monitor and record the total
regeneration desorbing gas mass flow for each regeneration cycle, and the
carbon bed temperature after each carbon bed regeneration and cooling cycle for
the regeneration cycle either immediately preceding or immediately following
the performance test.
2. The
operating limits for your regenerative carbon adsorber shall be the minimum
total desorbing gas mass flow recorded during the regeneration cycle and the
maximum carbon bed temperature recorded after the cooling cycle.
(d)
Condensers.
If your add-on control device is a condenser, establish the operating limits
according to subds. 1. and 2.
1. During the
performance test, you shall monitor and record the product side condenser
outlet gas temperature at least once every 15 minutes during each of the 3 test
runs.
2. Use the data collected
during the performance test to calculate and record the average condenser
outlet gas temperature maintained during the performance test. This average
condenser outlet gas temperature shall be the maximum operating limit for your
condenser.
(e)
Concentrators. If your add-on control device includes a
concentrator, you shall establish operating limits for the concentrator
according to subds. 1. to 4.
1. During the
performance test, you shall monitor and record the desorption concentrate
stream gas temperature at least once every 15 minutes during each of the 3 runs
of the performance test.
2. Use the
data collected during the performance test to calculate and record the average
temperature. This average temperature shall be the minimum operating limit for
the desorption concentrate gas stream temperature.
3. During the performance test, you shall
monitor and record the pressure drop of the dilute stream across the
concentrator at least once every 15 minutes during each of the 3 runs of the
performance test.
4. Use the data
collected during the performance test to calculate and record the average
pressure drop. This average pressure drop shall be the minimum operating limit
for the dilute stream across the concentrator.
(f)
Emission capture
systems. For each capture device that is not part of a PTE that meets
the criteria of sub. (6) (a), establish an operating limit for either the gas
volumetric flow rate or duct static pressure, as specified in subds. 1. and 2.
The operating limit for a PTE is specified in Table 1 of this subchapter.
1. During the capture efficiency
determination required by sub. (1) and described in subs. (5) and (6), you
shall monitor and record either the gas volumetric flow rate or the duct static
pressure for each separate capture device in your emission capture system at
least once every 15 minutes during each of the 3 test runs at a point in the
duct between the capture device and the add-on control device inlet.
2. Calculate and record the average gas
volumetric flow rate or duct static pressure for the 3 test runs for each
capture device. This average gas volumetric flow rate or duct static pressure
shall be the minimum operating limit for that specific capture
device.
(9)
WHAT ARE THE REQUIREMENTS FOR CONTINUOUS PARAMETER MONITORING SYSTEM
INSTALLATION, OPERATION AND MAINTENANCE?
(a)
General. You shall install, operate and maintain each CPMS specified in pars.
(c), (e), (f) and (g) according to subds. 1. to 6. You shall install, operate
and maintain each CPMS specified in pars. (b) and (d) according to subds. 3. to
5.
1. The CPMS shall complete a minimum of
one cycle of operation for each successive 15-minute period. You shall have a
minimum of 4 equally spaced successive cycles of CPMS operation in one
hour.
2. You shall determine the
average of all recorded readings for each successive 3-hour period of the
emission capture system and add-on control device operation.
3. You shall record the results of each
inspection, calibration and validation check of the CPMS.
4. You shall maintain the CPMS at all times
and have available necessary parts for routine repairs of the monitoring
equipment.
5. You shall operate the
CPMS and collect emission capture system and add-on control device parameter
data at all times that a controlled coating operation is operating, except
during monitoring malfunctions, associated repairs and required quality
assurance or control activities, including, if applicable, calibration checks
and required zero and span adjustments.
6. You may not use emission capture system or
add-on control device parameter data recorded during monitoring malfunctions,
associated repairs, out-of-control periods or required quality assurance or
control activities when calculating data averages. You shall use all the data
collected during all other periods in calculating the data averages for
determining compliance with the emission capture system and add-on control
device operating limits.
7. A
monitoring malfunction is any sudden, infrequent, not reasonably preventable
failure of the CPMS to provide valid data. Monitoring failures that are caused
in part by poor maintenance or careless operation are not malfunctions. Any
period for which the monitoring system is out-of-control and data are not
available for required calculations is a deviation from the monitoring
requirements.
(b)
Capture system bypass line. You shall meet the requirements of
subds. 1. and 2. for each emission capture system that contains bypass lines
that could divert emissions away from the add-on control device to the
atmosphere.
1. You shall monitor or secure
the valve or closure mechanism controlling the bypass line in a non-diverting
position in such a way that the valve or closure mechanism cannot be opened
without creating a record that the valve was opened. The method used to monitor
or secure the valve or closure mechanism shall meet one of the requirements
specified in subd. 1. a. to e.
a. Install,
calibrate, maintain and operate according to the manufacturer's specifications
a flow control position indicator that takes a reading at least once every 15
minutes and provides a record indicating whether the emissions are directed to
the add-on control device or diverted from the add-on control device. The time
of occurrence and flow control position shall be recorded, as well as every
time the flow direction is changed. The flow control position indicator shall
be installed at the entrance to any bypass line that could divert the emissions
away from the add-on control device to the atmosphere.
b. Secure any bypass line valve in the closed
position with a car-seal or a lock-and-key type configuration. You shall
visually inspect the seal or closure mechanism at least once every month to
ensure that the valve is maintained in the closed position, and the emissions
are not diverted away from the add-on control device to the
atmosphere.
c. Ensure that any
bypass line valve is in the closed (non-diverting) position through monitoring
of valve position at least once every 15 minutes. You shall inspect the
monitoring system at least once every month to verify that the monitor will
indicate valve position.
d. Use an
automatic shutdown system in which the coating operation is stopped when flow
is diverted by the bypass line away from the add-on control device to the
atmosphere when the coating operation is running. You shall inspect the
automatic shutdown system at least once every month to verify that it will
detect diversions of flow and shut down the coating operation.
e. Install, calibrate, maintain and operate
according to the manufacturer's specifications a flow direction indicator that
takes a reading at least once every 15 minutes and provides a record indicating
whether the emissions are directed to the add-on control device or diverted
from the add-on control device. Each time the flow direction changes, the next
reading of the time of occurrence and flow direction shall be recorded. The
flow direction indicator shall be installed in each bypass line or air makeup
supply line that could divert the emissions away from the add-on control device
to the atmosphere.
2. If
any bypass line is opened, you shall include a description of why the bypass
line was opened and the length of time it remained open in the semiannual
compliance reports required in s.
NR 465.35(2).
(c)
Thermal oxidizers and catalytic
oxidizers. If you are using a thermal oxidizer or catalytic oxidizer
as an add-on control device, including those used with concentrators or with
carbon adsorbers to treat desorbed concentrate streams, you shall comply with
the requirements in subds. 1. to 3.
1. For a
thermal oxidizer, install a gas temperature monitor in the firebox of the
thermal oxidizer or in the duct immediately downstream of the firebox before
any substantial heat exchange occurs.
2. For a catalytic oxidizer, install gas
temperature monitors upstream or downstream or both of the catalyst bed as
required in sub. (8) (b).
3. For
all thermal oxidizers and catalytic oxidizers, you shall meet the requirements
in par. (a) and the requirements in subd. 3. a. to e. for each gas temperature
monitoring device.
a. Locate the temperature
sensor in a position that provides a representative temperature.
b. Use a temperature sensor with a
measurement sensitivity of 5°F or 1.0% of the temperature value, whichever
is larger.
c. Before using the
sensor for the first time or when relocating or replacing the sensor, perform a
validation check by comparing the sensor output to a calibrated temperature
measurement device or by comparing the sensor output to a simulated
temperature.
d. Conduct an accuracy
audit every quarter and after every deviation. Accuracy audit methods include
comparisons of sensor output to redundant temperature sensors, to calibrated
temperature measurement devices, or to temperature simulation
devices.
e. Conduct a visual
inspection of each sensor every quarter if redundant temperature sensors are
not used.
(d)
Regenerative carbon adsorbers. If you are using a regenerative
carbon adsorber as an add-on control device, you shall monitor the total
regeneration desorbing gas mass flow for each regeneration cycle, the carbon
bed temperature after each regeneration and cooling cycle, and comply with par.
(a) 3. to 5. and subds. 1. to 3.
1. The
regeneration desorbing gas mass flow monitor shall be an integrating device
having a measurement sensitivity of plus or minus 10% capable of recording the
total regeneration desorbing gas mass flow for each regeneration
cycle.
2. The carbon bed
temperature monitor shall be capable of recording the temperature within 15
minutes of completing any carbon bed cooling cycle.
3. For all regenerative carbon adsorbers, you
shall meet the requirements in par. (c) 3. a. to e. for each temperature
monitoring device.
(e)
Condensers. If you are using a condenser, you shall monitor
the product side condenser outlet gas temperature and comply with par. (a) and
subds. 1. and 2.
1. The temperature monitor
shall provide a gas temperature record at least once every 15
minutes.
2. For all condensers, you
shall meet the requirements in par. (c) 3. for each temperature monitoring
device.
(f)
Concentrators. If you are using a concentrator, such as a
zeolite wheel or rotary carbon bed concentrator, you shall comply with the
requirements in subds. 1. and 2.
1. You shall
install a temperature monitor in the desorption gas stream. The temperature
monitor shall meet the requirements in pars. (a) and (c) 3.
2. You shall install a device to monitor
pressure drop across the zeolite wheel or rotary carbon bed. The pressure
monitoring device shall meet the requirements in pars. (a) and (g) 2.
(g)
Emission
capture systems. The capture system monitoring system shall comply
with the applicable requirements in subds. 1. and 2.
1. For each flow measurement device, you
shall meet the requirements in par. (a) and subd. 1. a. to g.
a. Locate a flow sensor in a position that
provides a representative flow measurement in the duct from each capture device
in the emission capture system to the add-on control device.
b. Use a flow sensor with an accuracy of at
least 10% of the flow.
c. Perform
an initial sensor calibration in accordance with the manufacturer's
requirements.
d. Perform a
validation check before initial use or upon relocation or replacement of a
sensor. Validation checks include comparison of sensor values with electronic
signal simulations or via relative accuracy testing.
e. Conduct an accuracy audit every quarter
and after every deviation. Accuracy audit methods include comparisons of sensor
values with electronic signal simulations or via relative accuracy
testing.
f. Perform leak checks
monthly.
g. Perform visual
inspections of the sensor system quarterly if there is no redundant
sensor.
2. For each
pressure drop measurement device, you shall comply with the requirements in
par. (a) and subd. 2. a. to g.
a. Locate the
pressure sensor in or close to a position that provides a representative
measurement of the pressure drop across each opening you are
monitoring.
b. Use a pressure
sensor with an accuracy of at least 0.5 inches of water column or 5% of the
measured value, whichever is larger.
c. Perform an initial calibration of the
sensor according to the manufacturer's requirements.
d. Conduct a validation check before initial
operation or upon relocation or replacement of a sensor. Validation checks
include comparison of sensor values to calibrated pressure measurement devices
or to pressure simulation using calibrated pressure sources.
e. Conduct accuracy audits every quarter and
after every deviation. Accuracy audits include comparison of sensor values to
calibrated pressure measurement devices or to pressure simulation using
calibrated pressure sources.
f.
Perform monthly leak checks on pressure connections. A pressure of at least 1.0
inches of water column to the connection shall yield a stable sensor result for
at least 15 seconds.
g. Perform a
visual inspection of the sensor at least monthly if there is no redundant
sensor.
Table 1
Operating Limits if Using the Emission Rate With
Add-On Controls Option in s.
NR 465.33(2) (c)
If you are required to comply with operating limits by s.
NR 465.33(3) (b), you shall comply with
the applicable operating limits in the following table. -
For the following device:
|
You shall meet the following operating
limit:
|
And you shall demonstrate continuous
compliance with the operating limit by:
|
(1) Thermal oxidizer
|
(a) The average combustion temperature in any
3-hour period may not fall below the combustion temperature limit established
according to s. NR 465.38(8) (a).
|
1. Collecting the combustion temperature data
according to s. NR 465.38(9) (c);
2. Reducing the data to 3-hour block averages;
and
3. Maintaining the 3-hour average combustion
temperature at or above the temperature limit.
|
(2) Catalytic oxidizer
|
(a) The average temperature measured just before
the catalyst bed in any 3-hour period may not fall below the limit established
according to s. NR 465.38(8) (b); and either par. (b) or (c).
|
1. Collecting the temperature data according to
s. NR 465.38(9) (c);
2. Reducing the data to 3-hour block averages;
and
3. Maintaining the 3-hour average temperature
before the catalyst bed at or above the temperature limit.
|
(b) Ensure that the average temperature
difference across the catalyst bed in any 3-hour period does not fall below the
temperature difference limit established according to s. NR 465.38(8) (b)
2.
|
1. Collecting the temperature data according to
s. NR 465.38(9) (c);
2. Reducing the data to 3-hour block averages;
and
3. Maintaining the 3-hour average temperature
difference at or above the temperature difference limit.
|
(c) Develop and implement an inspection and
maintenance plan according to s. NR 465.38(8) (b) 4.
|
1. Maintaining an up-to-date inspection and
maintenance plan, records of annual catalyst activity checks, records of
monthly inspections of the oxidizer system, and records of the annual internal
inspections of the catalyst bed. If a problem is discovered during a monthly or
annual inspection required by s. NR 465.38(8) (b) 4., you shall take corrective
action as soon as practicable consistent with the manufacturer's
recommendations.
|
(3) Regenerative carbon adsorber
|
(a) The total regeneration desorbing gas mass
flow for each carbon bed regeneration cycle may not fall below the total
regeneration desorbing gas mass flow limit established according to s. NR 465.38(8) (c).
|
1. Measuring the total regeneration desorbing gas
mass flow for each regeneration cycle according to s. NR 465.38(9) (d);
and
2. Maintaining the total regeneration desorbing
gas mass flow at or above the mass flow limit.
|
(b) The temperature of the carbon bed, after
completing each regeneration and any cooling cycle, may not exceed the carbon
bed temperature limit established according to s. NR 465.38(8) (c).
|
1.Measuring the temperature of the carbon bed
after completing each regeneration and any cooling cycle according to s. NR 465.38(9) (d); and
2. Operating the carbon beds so that each carbon
bed is not returned to service after completing each regeneration and any
cooling cycle until the recorded temperature of the carbon bed is at or below
the temperature limit.
|
(4) Condenser
|
(a) The average condenser outlet gas temperature
in any 3-hour period may not exceed the temperature limit established according
to s. NR 465.38(8) (d).
|
1. Collecting the condenser outlet gas
temperature according to s. NR 465.38(9) (e);
2. Reducing the data to 3- hour block averages;
and
3. Maintaining the 3-hour average gas temperature
at the outlet at or below the temperature limit.
|
(5) Concentrators, including zeolite wheels and
rotary carbon adsorbers
|
(a) The average gas temperature of the desorption
concentrate stream in any 3- hour period may not fall below the limit
established according to s. NR 465.38(8) (e).
|
1. Collecting the temperature data according to
s. NR 465.38(9) (f);
2. Reducing the data to 3-hour block averages;
and
3. Maintaining the 3-hour average temperature at
or above the temperature limit.
|
(b) The average pressure drop of the dilute
stream across the concentrator in any 3- hour period may not fall below the
limit established according to s. NR 465.38(8) (e).
|
1. Collecting the pressure drop data according to
s. NR 465.38(9) (f);
2. Reducing the pressure drop data to 3-hour
block averages; and
3. Maintaining the 3-hour average pressure drop
at or above the pressure drop limit.
|
(6) Emission capture system that is a PTE
according to s. NR 465.38(6) (a)
|
(a) The direction of the air flow at all times
shall be into the enclosure; and either (b) or (c) shall be satisfied.
|
1. Collecting the direction of air flow, and
either the facial velocity of air through all natural draft openings according
to s. NR 465.38(9) (g) 1. or the pressure drop across the enclosure according
to s. NR 465.38(9) (g) 2.; and
2. Maintaining the facial velocity of air flow
through all natural draft openings or the pressure drop at or above the facial
velocity limit or pressure drop limit, and maintaining the direction of air
flow into the enclosure at all times.
|
(b) The average facial velocity of air through
all natural draft openings in the enclosure shall be at least 200 feet per
minute.
|
1. See items (6) (a)1. and 2.
|
(c) The pressure drop across the enclosure shall
be at least 0.007 inch H2O, as established in Method 204
in 40 CFR part 51, Appendix M, incorporated by reference in s.
NR 484.04(9).
|
1. See items (6) (a)1. and 2.
|
(7) Emission capture system that is not a PTE
according to s. NR 465.38(6) (a)
|
(a) The average gas volumetric flow rate or duct
static pressure in each duct between a capture device and add-on control device
inlet in any 3-hour period may not fall below the average volumetric flow rate
or duct static pressure limit established for that capture device according to
s. NR 465.38(8) (f).
|
1. Collecting the gas volumetric flow rate or
duct static pressure for each capture device according to s. NR 465.38(9)
(g);
2. Reducing the data to 3- hour block averages;
and
3. Maintaining the 3-hour average gas volumetric
flow rate or duct static pressure for each capture device at or above the gas
volumetric flow rate or duct static pressure limit.
|
Table 2
Default Organic HAP Mass Fraction for Solvents and
Solvent Blends
You may use the mass fraction values in the following table
for solvent blends for which you do not have test data or manufacturer's
formulation data and which match either the solvent blend name or the chemical
abstract series (CAS) number. If a solvent blend matches both the name and CAS
number for an entry, that entry's organic HAP mass fraction shall be used for
that solvent blend. Otherwise, use the organic HAP mass fraction for the entry
matching either the solvent blend name or CAS number, or use the organic HAP
mass fraction from Table 3 of this subchapter if neither the name or CAS number
match.
Solvent or Solvent Blend
|
CAS No.
|
Average Organic HAP Mass
Fraction
|
Typical Organic HAP, percent by
mass
|
(1) Toluene
|
108-88-3
|
1.0
|
toluene
|
(2) Xylenes
|
1330-20-7
|
1.0
|
xylenes, ethylbenzene
|
(3) Hexane
|
110-54-3
|
0.5
|
n-hexane
|
(4) n-Hexane
|
110-54-3
|
1.0
|
n-hexane
|
(5) Ethylbenzene
|
100-41-4
|
1.0
|
ethylbenzene
|
(6) Aliphatic 140
|
0
|
none
|
(7) Aromatic 100
|
0.02
|
1% xylene, 1% cumene
|
(8) Aromatic 150
|
0.09
|
naphthalene
|
(9) Aromatic naphtha
|
64742-95-6
|
0.02
|
1% xylene, 1% cumene
|
(10) Aromatic solvent
|
64742-94-5
|
0.1
|
naphthalene
|
(11) Exempt mineral spirits
|
8032-32-4
|
0
|
none
|
(12) Ligroines (VM & P)
|
8032-32-4
|
0
|
none
|
(13) Lactol spirits
|
64742-89-6
|
0.15
|
toluene
|
(14) Low aromatic white spirit
|
64742-82-1
|
0
|
none
|
(15) Mineral spirits
|
64742-88-7
|
0.01
|
xylenes
|
(16) Hydrotreated naphta
|
64742-48-9
|
0
|
none
|
(17) Hydrotreated light distillate
|
64742-82-1
|
0
|
none
|
(18) Stoddard solvent
|
8052-41-3
|
0.01
|
xylenes
|
(19) Super high-flash naphta
|
64742-95-6
|
0.05
|
xylenes
|
(20) Varsol[] solvent
|
8052-49-3
|
0.01
|
0.5% xylenes, 0.5% ethylbenzene
|
(21) VM & P naphtha
|
64742-89-8
|
0.06
|
3% toluene, 3% xylene
|
(22) Petroleum distillate mixture
|
68477-31-6
|
0.08
|
4% naphthalene, 4% biphenyl
|
Table 3
Default Organic HAP Mass Fraction for Petroleum
Solvent Groupsa
You may use the mass fraction values in the following table
for solvent blends for which you do not have test data or manufacturer's
formulation data.
Solvent Type
|
Average Organic HAP Mass
Fraction
|
Typical Organic HAP, percent by
mass
|
Aliphatic b
|
0.03
|
1% Xylene, 1% Toluene and 1% Ethylbenzene.
|
Aromatic c
|
0.06
|
4% Xylene, 1% Toluene and 1% Ethylbenzene.
|
a Use this table only if the solvent blend does not match
any of the solvent blends in Table 2 by either solvent blend name or CAS number
and you only know whether the blend is aliphatic or aromatic.
b Mineral Spirits 135, Mineral Spirits 150 EC, Naphtha,
Mixed Hydrocarbon, Aliphatic Hydrocarbon, Aliphatic Naphtha, Naphthol Spirits,
Petroleum Spirits, Petroleum Oil, Petroleum Naphtha, Solvent Naphtha, Solvent
Blend.
c Medium-flash Naphtha, High-flash Naphtha, Aromatic
Naphtha, Light Aromatic Naphtha, Light Aromatic Hydrocarbons, Aromatic
Hydrocarbons, Light Aromatic Solvent.