Wisconsin Administrative Code
Department of Natural Resources
NR 400-499 - Environmental Protection - Air Pollution Control
Chapter NR 466 - National emission standards for hazardous air pollutants for printing and flexible substrate surface coating processes
Subchapter III - Paper and Other Web Coating
Section NR 466.24 - General requirements for compliance with the emission standards and for monitoring and performance tests

Universal Citation: WI Admin Code § NR 466.24

Current through August 26, 2024

(1) WHAT GENERAL REQUIREMENTS MUST I MEET TO COMPLY WITH THE STANDARDS? You shall comply with the applicable general provisions of ch. NR 460 as specified in ch. NR 460 Appendix JJJJ.

(2) IF I USE A CONTROL DEVICE TO COMPLY WITH THE EMISSION STANDARDS, WHAT MONITORING MUST I DO?

(a) Summary. A summary of monitoring you shall do follows:

Monitoring Summary

If you operate a web coating line, and you have the following:	Then you shall:
1. Intermittently-controlled work stations	Record parameters related to possible exhaust flow bypass of control device and to coating use (par. (c))
2. Solvent recovery unit	Operate continuous emission monitoring system and perform quarterly audits or determine volatile matter recovered and conduct a liquid-liquid material balance (par. (d))
3. Control device	Operate continuous parameter monitoring system (par. (e))
4. Capture system	Monitor capture system operating parameter (par. (f))

(b) Capture system and control device monitoring. Following the date on which the initial performance test of a control device is completed to demonstrate continuing compliance with the standards, you shall monitor and inspect each capture system and each control device used to comply with s. NR 466.23(1). You shall install and operate the monitoring equipment as specified in pars. (c) and (f).

(c) Bypass and coating use monitoring. If you own or operate web coating lines with intermittently-controlled work stations, you shall monitor bypasses of the control device and the mass of each coating material applied at the work station during any bypass. If using a control device for complying with the requirements of this subchapter, you shall demonstrate that any coating material applied on a never-controlled work station or an intermittently-controlled work station operated in bypass mode is allowed in your compliance demonstration according to s. NR 466.25(14) and (15). The bypass monitoring shall be conducted using at least one of the procedures in subds. 1. to 4. for each work station and associated dryer.

1. `Flow control position indicator.' Install, calibrate, maintain and operate according to the manufacturer's specifications a flow control position indicator that provides a record indicating whether the exhaust stream from the dryer was directed to the control device or was diverted from the control device. The time and flow control position shall be recorded at least once per hour as well as every time the flow direction is changed. A flow control position indicator shall be installed at the entrance to any bypass line that could divert the exhaust stream away from the control device to the atmosphere.

2. `Car-seal or lock-and-key valve closures.' Secure any bypass line valve in the closed position with a car-seal or a lock-and-key type configuration. A visual inspection of the seal or closure mechanism shall be performed at least once every month to ensure that the valve or damper is maintained in the closed position, and the exhaust stream is not diverted through the bypass line.

3. `Valve closure continuous monitoring.' Ensure that any bypass line valve or damper is in the closed position through continuous monitoring of valve position when the emission source is in operation and is using a control device for compliance with the requirements of this subchapter. The monitoring system shall be inspected at least once every month to verify that the monitor will indicate valve position.

4. `Automatic shutdown system.' Use an automatic shutdown system in which the web coating line is stopped when flow is diverted away from the control device to any bypass line when the control device is in operation. The automatic system shall be inspected at least once every month to verify that it will detect diversions of flow and would shut down operations in the event of such a diversion.

(d) Solvent recovery unit. If you own or operate a solvent recovery unit to comply with s. NR 466.23(1), you shall meet the requirements in either subd. 1. or 2., depending on how control efficiency is determined.

1. `Continuous emission monitoring system (CEMS).' If you are demonstrating compliance with the emission standards in s. NR 466.23(1) through continuous emission monitoring of a control device, you shall install, calibrate, operate and maintain the CEMS according to subd. 1. a. to c.

a. Measure the total organic volatile matter mass flow rate at both the control device inlet and the outlet such that the reduction efficiency can be determined. Each continuous emission monitor shall comply with performance specification 6, 8 or 9, as appropriate, of 40 CFR part 60, Appendix B, incorporated by reference in s. NR 484.04(21).

b. You shall follow the quality assurance procedures in procedure 1, of 40 CFR part 60, Appendix F, incorporated by reference in s. NR 484.04(21m). In conducting the quarterly audits of the monitors as required by procedure 1, Appendix F, you shall use compounds representative of the gaseous emission stream being controlled.

c. You shall have valid data from at least 90% of the hours during which the process is operated.

2. `Liquid-liquid material balance.' If you are demonstrating compliance with the emission standards in s. NR 466.23(1) through liquid-liquid material balance, you shall install, calibrate, maintain and operate according to the manufacturer's specifications a device that indicates the cumulative amount of volatile matter recovered by the solvent recovery device on a monthly basis. The device shall be certified by the manufacturer to be accurate to within ±2.0% by mass.

(e) Continuous parameter monitoring system (CPMS). If you are using a control device to comply with the emission standards in s. NR 466.23(1), you shall install, operate and maintain each CPMS specified in subds. 9. and 10. and par. (f) according to the requirements in subds. 1. to 8. You shall install, operate and maintain each CPMS specified in par. (c) according to subds. 5. to 7.

1. Each 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 to have a valid hour of data.

2. You shall have valid data from at least 90% of the hours during which the process operated.

3. You shall determine the hourly average of all recorded readings according to subd. 3. a. and b.

a. To calculate a valid hourly value, you shall have at least 3 of 4 equally spaced data values from that hour from a continuous monitoring system (CMS) that is not out-of-control.

b. Provided all of the readings recorded in accordance with this subdivision clearly demonstrate continuous compliance with the standard that applies to you, then you are not required to determine the hourly average of all recorded readings.

4. You shall determine the rolling 3-hour average of all recorded readings for each operating period. To calculate the average for each 3-hour averaging period, you shall have at least 2 of 3 of the hourly averages for that period using only average values that are based on valid data not from out-of-control periods.

5. You shall record the results of each inspection, calibration and validation check of the CPMS.

6. At all times, you shall maintain the monitoring system in proper working order, including maintaining necessary parts for routine repairs of the monitoring equipment.

7. Except for monitoring malfunctions, associated repairs or required quality assurance or control activities, including calibration checks or required zero and span adjustments, you shall conduct all monitoring at all times that the unit is operating. Data recorded during monitoring malfunctions, associated repairs, out-of-control periods or required quality assurance or control activities may not be used for purposes of calculating the emissions concentrations and percent reductions specified in s. NR 466.25(1). You shall use all the valid data collected during all other periods in assessing compliance of the control device and associated control system. A monitoring malfunction is any sudden, infrequent, not reasonably preventable failure of the monitoring system to provide valid data. Monitoring failures that are caused in part by poor maintenance or careless operation are not malfunctions.

8. Any averaging period for which you do not have valid monitoring data, and the data are required, constitutes a deviation, and you shall notify the department in accordance with s. NR 466.26(1) (c).

9. If you are using an oxidizer to comply with the emission standards, you shall comply with subd. 9. a. to c.

a. Install, calibrate, maintain and operate temperature monitoring equipment according to the manufacturer's specifications. The calibration of the chart recorder, data logger or temperature indicator shall be verified every 3 months or the chart recorder, data logger or temperature indicator shall be replaced. You shall replace the equipment whether you choose not to perform the calibration or the equipment cannot be calibrated properly.

b. For an oxidizer other than a catalytic oxidizer, install, calibrate, operate and maintain a temperature monitoring device equipped with a continuous recorder. The device shall have an accuracy of ±1% of the temperature being monitored in degrees Celsius, or ±1° Celsius, whichever is greater. The thermocouple or temperature sensor shall be installed in the combustion chamber at a location in the combustion zone.

c. For a catalytic oxidizer, install, calibrate, operate and maintain a temperature monitoring device equipped with a continuous recorder. The device shall be capable of monitoring temperature with an accuracy of ±1% of the temperature being monitored in degrees Celsius or ±1° Celsius, whichever is greater. The thermocouple or temperature sensor shall be installed in the vent stream at the nearest feasible point to the inlet and outlet of the catalyst bed. Calculate the temperature rise across the catalyst.

10. If you use a control device other than an oxidizer or wish to monitor an alternative parameter and comply with a different operating limit, you shall apply to the department for approval of an alternative monitoring method under s. NR 460.07(6).

(f) Capture system monitoring. If you are complying with the emission standards in s. NR 466.23(1) through the use of a capture system and control device for one or more web coating lines, you shall develop a site-specific monitoring plan containing the information specified in subds. 1. and 2. for the capture systems. You shall monitor the capture system in accordance with subd. 3. You shall make the monitoring plan available for inspection by the department upon request.

1. The monitoring plan shall do all of the following:

a. Identify the operating parameter to be monitored to ensure that the capture efficiency determined during the initial compliance test is maintained.

b. Explain why the operating parameter is appropriate for demonstrating ongoing compliance.

c. Identify the specific monitoring procedures.

2. The monitoring plan shall specify the operating parameter value or range of values that demonstrate compliance with the emission standards in s. NR 466.23(1). The specified operating parameter value or range of values shall represent the conditions present when the capture system is being properly operated and maintained.

3. You shall conduct all capture system monitoring in accordance with the plan.

4. Any deviation from the operating parameter value or range of values which are monitored according to the plan will be considered a deviation from the operating limit.

5. You shall review and update the capture system monitoring plan at least annually.

(3) WHAT PERFORMANCE TESTS SHALL I CONDUCT?

(a) Performance test methods. The performance test methods you shall use are as follows:

Performance Test Methods

If you control organic HAP on any individual web coating line or any group of web coating lines by:	You shall:
1. Limiting organic HAP or volatile matter content of coatings	Determine the organic HAP or volatile matter and coating solids content of coating materials according to procedures in pars. (c) and (d). If applicable, determine the mass of volatile matter retained in the coated web or otherwise not emitted to the atmosphere according to par. (g).
2. Using a capture and control system	Conduct a performance test for each capture and control system to determine the destruction or removal efficiency of each control device other than solvent recovery according to par. (e) and the capture efficiency of each capture system according to par. (f). If applicable, determine the mass of volatile matter retained in the coated web or otherwise not emitted to the atmosphere according to par. (g).

(b) Exceptions. If you are using a control device to comply with the emission standards in s. NR 466.23(1), you are not required to conduct a performance test to demonstrate compliance if one or more of the criteria in subds. 1. to 3. are met.

1. The control device is equipped with continuous emission monitors for determining inlet and outlet total organic volatile matter concentration and capture efficiency has been determined in accordance with the requirements of this subchapter such that an overall organic HAP control efficiency can be calculated, and the continuous emission monitors are used to demonstrate continuous compliance in accordance with sub. (2).

2. You have met the requirements of s. NR 460.06(7) for waiver of performance testing.

3. The control device is a solvent recovery system and you comply by means of a monthly liquid-liquid material balance.

(c) Organic HAP content. If you determine compliance with the emission standards in s. NR 466.23(1) by means other than determining the overall organic HAP control efficiency of a control device, you shall determine the organic HAP mass fraction of each coating material as-purchased by following one of the procedures in subds. 1. to 3., and determine the organic HAP mass fraction of each coating material as-applied by following the procedures in subd. 4. If the organic HAP content values are not determined using the procedures in subds. 1. to 3., you shall submit an alternative test method for determining their values for approval by the administrator in accordance with 40 CFR 63.7(f). The recovery efficiency of the test method shall be determined for all of the target organic HAP and a correction factor, if necessary, shall be determined and applied.

1. `Method 311.' You may test the coating material in accordance with Method 311 of 40 CFR part 63, Appendix A, incorporated by reference in s. NR 484.04(25). The Method 311 determination may be performed by the manufacturer of the coating material and the results provided to the owner or operator. The organic HAP content shall be calculated according to the criteria and procedures in subd. 1. a. to c.

a. Include each organic HAP determined to be present at greater than or equal to 0.1% by mass for the United States occupational safety and health administration-defined (OSHA-defined) carcinogens as specified in 29 CFR 1910.1200(d) (4) and greater than or equal to 1.0% by mass for other organic HAP compounds.

b. Express the mass fraction of each organic HAP you include according to subd. 1. a. as a value truncated to 4 places after the decimal point, e.g., 0.3791.

c. Calculate the total mass fraction of organic HAP in the tested material by summing the counted individual organic HAP mass fractions and truncating the result to 3 places after the decimal point, e.g., 0.763.

2. `Method 24.' For coatings, determine the volatile organic content as mass fraction of non-aqueous volatile matter and use it as a substitute for organic HAP using Method 24 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04(13). The Method 24 determination may be performed by the manufacturer of the coating and the results provided to you.

3. `Formulation data.' You may use formulation data to determine the organic HAP mass fraction of a coating material. Formulation data may be provided to you by the manufacturer of the material. In the event of an inconsistency between Method 311 of 40 CFR part 63, Appendix A, incorporated by reference in s. NR 484.04(25), test data and a facility's formulation data, and the Method 311 test value is higher, the Method 311 data will govern. Formulation data may be used provided that the information represents all organic HAP present at a level equal to or greater than 0.1 % for OSHA-defined carcinogens as specified in 29 CFR 1910.1200(d) (4) and equal to or greater than 1.0 % for other organic HAP compounds in any raw material used.

4. `As-applied organic HAP mass fraction.' If the as-purchased coating material is applied to the web without any solvent or other material added, the as-applied organic HAP mass fraction is equal to the as-purchased organic HAP mass fraction. Otherwise, the as-applied organic HAP mass fraction shall be calculated using Equation 1a of s. NR 466.25.

(d) Volatile organic and coating solids content. If you determine compliance with the emission standards in s. NR 466.23(1) by means other than determining the overall organic HAP control efficiency of a control device and you choose to use the volatile organic content as a surrogate for the organic HAP content of coatings, you shall determine the as-purchased volatile organic content and coating solids content of each coating material applied by following the procedures in subd. 1. or 2. and the as-applied volatile organic content and coating solids content of each coating material by following the procedures in subd. 3.

1. `Method 24.' You may determine the volatile organic and coating solids mass fraction of each coating applied using Method 24 in 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04(13). The Method 24 determination may be performed by the manufacturer of the material and the results provided to you. If these values cannot be determined using Method 24, you shall submit an alternative technique for determining their values for approval by the administrator.

2. `Formulation data.' You may determine the volatile organic content and coating solids content of a coating material based on formulation data and may rely on volatile organic content data provided by the manufacturer of the material. In the event of any inconsistency between the formulation data and the results of Method 24 in 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04(13), and the Method 24 results are higher, the results of Method 24 will govern.

3. `As-applied volatile organic content and coating solids content.' If the as-purchased coating material is applied to the web without any solvent or other material added, the as-applied volatile organic content is equal to the as-purchased volatile content and the as-applied coating solids content is equal to the as-purchased coating solids content. Otherwise, the as-applied volatile organic content shall be calculated using Equation 1b of s. NR 466.25 and the as-applied coating solids content shall be calculated using Equation 2 of s. NR 466.25.

(e) Control device efficiency. If you are using an add-on control device other than solvent recovery, such as an oxidizer, to comply with the emission standards in s. NR 466.23(1), you shall conduct a performance test to establish the destruction or removal efficiency of the control device according to the methods and procedures in subds. 1. and 2. During the performance test, you shall establish the operating limits required by s. NR 466.23(2) according to subd. 3.

1. An initial performance test to establish the destruction or removal efficiency of the control device shall be conducted such that control device inlet and outlet testing is conducted simultaneously and the data are reduced in accordance with the test methods and procedures in subd. 1. a. to i. 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. Method 1 or 1A of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04(13), shall be used for sample and velocity traverses to determine sampling locations.

b. Method 2, 2A, 2C, 2D, 2F or 2G of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04(13), shall be used to determine gas volumetric flow rate.

c. Method 3, 3A or 3B of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04(13), shall be used for gas analysis to determine dry molecular weight. You may also use as an alternative to Method 3B the manual method for measuring the oxygen, carbon dioxide and carbon monoxide content of exhaust gas in ANSI/ASME PTC 19.10-1981, "Flue and Exhaust Gas Analyses, Part 10, Instruments and Apparatus", incorporated by reference in s. NR 484.11(6) (b).

d. Method 4 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04(13), shall be used to determine stack gas moisture.

e. The gas volumetric flow rate, dry molecular weight and stack gas moisture shall be determined during each test run specified in subd. 1. g.

f. Method 25 or 25A of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04(13), shall be used to determine total gaseous non-methane organic matter concentration. Use the same test method for both the inlet and outlet measurements which shall be conducted simultaneously. You shall submit notice of the intended test method to the department for approval along with notification of the performance test required under s. NR 460.06(2). You shall use Method 25A if any of the following 4 conditions apply to the control device:

1) The control device is not an oxidizer.

2) The control device is an oxidizer but an exhaust gas volatile organic matter concentration of 50 ppmv or less is required to comply with the emission standards in s. NR 466.23(1).

3) The control device is an oxidizer but the volatile organic matter concentration at the inlet to the control system and the required level of control are such that they result in exhaust gas volatile organic matter concentrations of 50 ppmv or less.

4) The control device is an oxidizer but, because of the high efficiency of the control device, the anticipated volatile organic matter concentration at the control device exhaust is 50 ppmv or less, regardless of inlet concentration.

g. Except as provided in s. NR 460.06(4) (c), each performance test shall consist of 3 separate runs with each run conducted for at least one hour under the conditions that exist when the affected source is operating under normal operating conditions. For the purpose of determining volatile organic compound concentrations and mass flow rates, the average of the results of all the runs shall apply.

h. Volatile organic matter mass flow rates shall be determined for each run specified in subd. 1. g. using Equation 1:

See Image

where:

Mf is the total organic volatile matter mass flow rate in kilograms (kg)/hour (h)

Qsd is the volumetric flow rate of gases entering or exiting the control device, as determined according to par. (e) 1. b., dry standard cubic meters (dscm)/h

Cc is the concentration of organic compounds as carbon, ppmv

12.0 is the molecular weight of carbon

0.0416 is a conversion factor for molar volume, kg-moles per cubic meter (mol/m3) at 293 Kelvin (K) and 760 millimeters of mercury (mmHg)

i. For each run, emission control device destruction or removal efficiency shall be determined using Equation 2:

See Image

where:

E is the organic volatile matter control efficiency of the control device, percent

Mfi is the organic volatile matter mass flow rate at the inlet to the control device, kg/h

Mfo is the organic volatile matter mass flow rate at the outlet of the control device, kg/h

j. The control device destruction or removal efficiency is determined as the average of the efficiencies determined in the test runs and calculated in Equation 2 of this section.

2. You shall record process information as may be necessary to determine the conditions in existence at the time of the performance test. Operations during periods of startup, shutdown and malfunction will not constitute representative conditions for the purpose of a performance test.

3. If you are using one or more add-on control devices other than a solvent recovery system for which you conduct a liquid-liquid material balance to comply with the emission standards in s. NR 466.23(1), you shall establish the applicable operating limits required by s. NR 466.23(2). The operating limits apply to each add-on emission control device, and you shall establish the operating limits during the performance test required by this paragraph according to the requirements in subd. 3. a. or b.

a. If your add-on control device is a thermal oxidizer, establish the operating limits according to the following 2 requirements:

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 is the minimum operating limit for your thermal oxidizer.

b. If your add-on control device is a catalytic oxidizer, establish the operating limits according to subd. 3. b. 1) and 2) or 3. b. 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. These are the minimum operating limits for your catalytic oxidizer.

3) As an alternative to monitoring the temperature difference across the catalyst bed, you may 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. 3. b. 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 is the minimum operating limit for your catalytic oxidizer.

4) You shall develop and implement an inspection and maintenance plan for the catalytic oxidizers which you elect to monitor according to subd. 3. b. 3). The plan shall address, at a minimum, all of the following elements:

a) Annual sampling and analysis of the catalyst activity, i.e., conversion efficiency, following the manufacturer's or catalyst supplier's recommended procedures.

b) Monthly inspection of the oxidizer system including the burner assembly and fuel supply lines for problems.

c) Annual internal and monthly external visual inspection of the catalyst bed to check for channeling, abrasion and settling. If problems are found, you shall take corrective action consistent with the manufacturer's recommendations and conduct a new performance test to determine destruction efficiency in accordance with this section.

(f) Capture efficiency. If you demonstrate compliance by meeting the requirements of s. NR 466.25(5), (6), (7), (11), (14) (b) or (c) or (16), you shall determine capture efficiency using the procedures in subd. 1., 2. or 3., as applicable.

1. You may assume your capture efficiency equals 100% if your capture system is a permanent total enclosure (PTE). You shall confirm that your capture system is a PTE by demonstrating that it meets the requirements of section 6 of Method 204 of 40 CFR part 51, Appendix M, incorporated by reference in s. NR 484.04(9), and that all exhaust gases from the enclosure are delivered to a control device.

2. You may determine capture efficiency according to the protocols for testing with temporary total enclosures that are specified in Methods 204 and 204A through F of 40 CFR part 51, Appendix M, incorporated by reference in s. NR 484.04(9). You may exclude never-controlled work stations from such capture efficiency determinations.

3. You may use any capture efficiency protocol and test methods that satisfy the criteria of either the data quality objective or the lower confidence limit approach as described in 40 CFR part 63, Subpart KK, Appendix A, incorporated by reference in s. NR 484.04(24). You may exclude never-controlled work stations from capture efficiency determinations made under this subdivision.

(g) Volatile matter retained in the coated web or otherwise not emitted to the atmosphere. You may choose to take into account the mass of volatile matter retained in the coated web after curing or drying or otherwise not emitted to the atmosphere when determining compliance with the emission standards in s. NR 466.23(1). If you choose this option, you shall develop a testing protocol to determine the mass of volatile matter retained in the coated web or otherwise not emitted to the atmosphere and submit this protocol to the department for approval. You shall submit this protocol with your site-specific test plan under s. NR 460.06(5). If you intend to take into account the mass of volatile matter retained in the coated web after curing or drying or otherwise not emitted to the atmosphere and demonstrate compliance according to s. NR 466.25(3) (c), (d), (e) or (4), the test protocol you submit shall determine the mass of organic HAP retained in the coated web or otherwise not emitted to the atmosphere. Otherwise, compliance shall be shown using the volatile organic matter content as a surrogate for the HAP content of the coatings.

(h) Control devices in series. If you use multiple control devices in series to comply with the emission standards in s. NR 466.23(1), the performance test shall include, at a minimum, the inlet to the first control device in the series, the outlet of the last control device in the series, and all intermediate streams, such as gaseous exhaust to the atmosphere or a liquid stream from a recovery device, that are not subsequently treated by any of the control devices in the series.

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