Section 440.71. Magnetic tape coating facilities.

 

(1)   Applicability and designation of affected facility.

(a) The affected facilities to which the provisions of this section apply are:

1. Each coating operation; and

2. Each piece of coating mix preparation equipment.

(b) Any new coating operation that utilizes less than 38 m 3 of solvent or any modified or reconstructed coating operation that utilizes less than 370 m 3 of solvent for the manufacture of magnetic tape per calendar year is subject only to the requirements of subs. (5) (a) and (8) (b) and (c) . If the amount of solvent utilized for the manufacture of magnetic tape equals or exceeds these amounts in any calendar year, the facility is subject to sub. (3) and all other paragraphs of this section. Once a facility has become subject to sub. (3) and all other paragraphs of this section, it shall remain subject to those requirements regardless of changes in annual solvent utilization.

(c) This section applies to any affected facility for which construction, modification or reconstruction begins after January 22, 1986.

(2)   Definitions, symbols and cross reference tables.

(a) All terms used in this section that are not defined as follows have the meaning given to them in s. NR 440.02 .

1. "Base film" means the substrate that is coated to produce magnetic tape.

2. "Capture system" means any device or combination of devices that contains or collects an airborne pollutant and directs it into a duct.

3. "Coating applicator" means any apparatus used to apply a coating to a continuous base film.

4. "Coating mix preparation equipment" means all mills, mixers, holding tanks, polishing tanks and other equipment used in the preparation of the magnetic coating formulation but does not include those mills that do not emit VOC because they are closed, sealed and operated under pressure.

5. "Coating operation" means any coating applicator, flashoff area and drying oven located between a base film unwind station and a base film rewind station that coat a continuous base film to produce magnetic tape.

6. "Common emission control device" means a control device controlling emissions from the coating operation as well as from another emission source within the plant.

7. "Concurrent" means construction of a control device is commenced or completed within the period beginning 6 months prior to the date construction of affected coating mix preparation equipment commences and ending 2 years after the date construction of affected coating mix preparation equipment is completed.

8. "Control device" means any apparatus that reduces the quantity of a pollutant emitted to the air.

9. "Cover" means, with respect to coating mix preparation equipment, a device that lies over the equipment opening to prevent VOC from escaping and that meets the requirements found in sub. (3) (e) 1. to 5.

10. "Drying oven" means a chamber in which heat is used to bake, cure, polymerize or dry a surface coating.

11. "Equivalent diameter" means 4 times the area of an opening divided by its perimeter.

12. "Flashoff area" means the portion of a coating operation between the coating applicator and the drying oven where solvent begins to evaporate from the coated base film.

13. "Magnetic tape" means any flexible substrate that is covered on one or both sides with a coating containing magnetic particles and that is used for audio or video recording or information storage.

14. "Natural draft opening" means any opening in a room, building or total enclosure that remains open during operation of the facility and that is not connected to a duct in which a fan is installed. The rate and direction of the natural draft across such an opening is a consequence of the difference in pressures on either side of the wall containing the opening.

15. "Nominal 1-month period" means a calendar month or, if established prior to the performance test, a similar monthly time period, for example, 30-day month or accounting month.

16. "Temporary enclosure" means a total enclosure that is constructed for the sole purpose of measuring the fugitive emissions from an affected facility. A temporary enclosure shall be constructed and ventilated, through stacks suitable for testing, so that it has minimal impact on the performance of the permanent capture system. A temporary enclosure will be assumed to achieve total capture of fugitive VOC emissions if it conforms to the requirements found in sub. (4) (b) 5. a. and if all natural draft openings are at least 4 duct or hood equivalent diameters away from each exhaust duct or hood. Alternatively, the owner or operator may apply to the administrator for approval of a temporary enclosure on a case-by-case basis.

17. "Total enclosure" means a structure that is constructed around a source of emissions so that all VOC emissions are collected and exhausted through a stack or duct. With a total enclosure, there will be no fugitive emissions, only stack emissions. The only openings in a total enclosure are forced makeup air and exhaust ducts and any natural draft openings such as those that allow raw materials to enter and exit the enclosure for processing. All access doors or windows are closed during routine operation of the enclosed source. Brief, occasional openings of such doors or windows to accommodate process equipment adjustments are acceptable, but, if such openings are routine or if an access door remains open during the entire operation, the access door shall be considered a natural draft opening. The average inward face velocity across the natural draft openings of the enclosure shall be calculated including the area of such access doors. The drying oven itself may be part of the total enclosure. A permanent enclosure that meets the requirements found in sub. (4) (b) 5. a. is assumed to be a total enclosure. The owner or operator of a permanent enclosure that does not meet the requirements may apply to the department for approval of the enclosure as a total enclosure on a case-by-case basis. Such approval shall be granted upon a demonstration to the satisfaction of the department that all VOC emissions are contained and vented to the control device.

18. "Utilize" refers to the use of solvent that is delivered to coating mix preparation equipment for the purpose of formulating coatings to be applied on an affected coating operation and any other solvent, for example, dilution solvent, that is added at any point in the manufacturing process.

20. "Volatile organic compounds" or `VOC` means any organic compounds that participate in atmospheric photochemical reactions or that are measured by Method 18, 24, 25 or 25A or an equivalent or an alternative method as defined in s. NR 440.02 (5) .

(b) The nomenclature used in this section has the following meaning:

1. "A k " means the area of each natural draft opening (k) in a total enclosure, in square meters.

2. "C aj " means the concentration of VOC in each gas stream (j) exiting the emission control device, in parts per million by volume.

3. "C bi " means the concentration of VOC in each gas stream (i) entering the emission control device, in parts per million by volume.

4. "C di " means the concentration of VOC in each gas stream (i) entering the emission control device from the affected coating operation, in parts per million by volume.

5. "C fk " means the concentration of VOC in each uncontrolled gas stream (k) emitted directly to the atmosphere from the affected coating operation, in parts per million by volume.

6. "C gv " means the concentration of VOC in the gas stream entering each individual carbon adsorber vessel (v), in parts per million by volume. For the purposes of calculating the efficiency of the individual adsorber vessel, C gv may be measured in the carbon adsorption system's common inlet duct prior to the branching of individual inlet ducts.

7. "C hv " means the concentration of VOC in the gas stream exiting each individual carbon adsorber vessel (v), in parts per million by volume.

8. "E" means the control device efficiency achieved for the duration of the emission test, expressed as a fraction.

9. "F" means the VOC emission capture efficiency of the VOC capture system achieved for the duration of the emission test, expressed as a fraction.

10. "FV" means the average inward face velocity across all natural draft openings in a total enclosure, in meters per hour.

11. "G" means the calculated weighted average mass of VOC per volume of coating solids, in kilograms per liter, applied each nominal 1-month period.

12. "H v " means the individual carbon adsorber vessel (v) efficiency achieved for the duration of the emission test, expressed as a fraction.

13. "H sys " means the carbon adsorption system efficiency calculated when each adsorber vessel has an individual exhaust stack.

14. "L si " means the volume fraction of solids in each coating (i) applied during a nominal 1-month period as determined from the facility's formulation records.

15. "M ci " means the total mass in kilograms of each coating (i) applied at an affected coating operation during a nominal 1-month period as determined from facility records. This quantity shall be determined at a time and location in the process after all ingredients, including any dilution solvent, have been added to the coating or appropriate adjustments shall be made to account for any ingredients added after the mass of the coating has been determined.

16. "M r " means the total mass in kilograms of VOC recovered for a nominal 1-month period.

17. "Q aj " means the volumetric flow rate of each gas stream (j) exiting the emission control device, in dry standard cubic meters per hour when Method 18 or 25 is used to measure VOC concentration or in standard cubic meters per hour (wet basis) when Method 25A is used to measure VOC concentration.

18. "Q bi " means the volumetric flow rate of each gas stream (i) entering the emission control device, in dry standard cubic meters per hour when Method 18 or 25 is used to measure VOC concentration or in standard cubic meters per hour (wet basis) when Method 25A is used to measure VOC concentration.

19. "Q di " means the volumetric flow rate of each gas stream (i) entering the emission control device from the affected coating operation, in dry standard cubic meters per hour when Method 18 or 25 is used to measure VOC concentration or in standard cubic meters per hour (wet basis) when Method 25A is used to measure VOC concentration.

20. "Q fk " means the volumetric flow rate of each uncontrolled gas stream (k) emitted directly to the atmosphere from the affected coating operation, in dry standard cubic meters per hour when Method 18 or 25 is used to measure VOC concentration or in standard cubic meters per hour (wet basis) when Method 25A is used to measure VOC concentration.

21. "Q gv " means the volumetric flow rate of the gas stream entering each individual carbon adsorber vessel (v), in dry standard cubic meters per hour when Method 18 or 25 is used to measure VOC concentration or in standard cubic meters per hour (wet basis) when Method 25A is used to measure VOC concentration. For purposes of calculating the efficiency of the individual adsorber vessel, the value of Q gv can be assumed to equal the value of Q hv measured for that adsorber vessel.

22. "Q hv " means the volumetric flow rate of the gas stream exiting each individual carbon adsorber vessel (v), in dry standard cubic meters per hour when Method 18 or 25 is used to measure VOC concentration or in standard cubic meters per hour (wet basis) when Method 25A is used to measure VOC concentration.

23. "Q in i " means the volumetric flow rate of each gas stream (i) entering the total enclosure through a forced makeup air duct, in standard cubic meters per hour (wet basis).

24. "Q out j " means the volumetric flow rate of each gas stream (j) exiting the total enclosure through an exhaust duct or hood, in standard cubic meters per hour (wet basis).

25. "R" means the overall VOC emission reduction achieved for the duration of the emission test, expressed as a percentage.

26. "RS i " means the total mass (kg) of VOC retained in the coated base film after oven drying for a given magnetic tape product.

27. "V ci " means the total volume in liters of each coating (i) applied during a nominal 1-month period as determined from facility records.

28. "W oi " means the weight fraction of VOC in each coating (i) applied at an affected coating operation during a nominal 1-month period as determined by Method 24. This value shall be determined at a time and location in the process after all ingredients, including any dilution solvent, have been added to the coating or appropriate adjustments shall be made to account for any ingredients added after the weight fraction of VOC in the coating has been determined.

(c) Tables 1A and 1B present a cross reference of the affected facility status and the relevant subsections of the regulation. - See PDF for table

a This table is presented for the convenience of the user and is not intended to supersede the language of the regulation. For the details of the requirements, refer to the text of the regulation.

b Refer to Part B to determine which paragraphs of subs. (5) , (6) and (8) correspond to each compliance provision ( sub. (4) ).

c As per sub. (1) (b) , any new coating operation with solvent utilization <38 m 3 /yr or any modified or reconstructed coating operation with solvent utilization <370 m 3 /yr is exempt from the VOC standards ( sub. (3) ). Such coating operations are subject only to subs. (5) (a) and (8) (b) and (c) . However, should a coating operation once exceed the applicable annual solvent utilization cutoff, that coating operation shall be subject to the VOC standards ( sub. (3) ) and all other applicable subsections. Once this has occurred, the coating operation shall remain subject to those requirements regardless of changes in annual solvent utilization.

d As applicable

e 40 CFR 60.716 permits the use of an alternative means of VOC emission limitation that achieves an equivalent or greater VOC emission reduction. - See PDF for table

a Sub. (4) (a) specifies the procedures to be used prior to modification/reconstruction to establish the applicability of the VOC standards in sub. (3) (c) for modified/reconstructed coating operations. Subsection (4) (a) 1. requires the use of the procedures of sub. (4) (b) 1. , 2. , 3. or 4. , to demonstrate prior to modification/reconstruction that 90% of the applied VOC is recovered or destroyed. Sub. (4) (a) 2. requires the use of procedures of sub. (4) (b) 5. to demonstrate prior to modification/reconstruction that the coating operation has a total enclosure vented to a control device that is at least 92% efficient. Sub. (4) (k) and (L) do not have corresponding test methods, monitoring, reporting or recordkeeping requirements.

b TI denotes thermal incinerator, CI denotes catalytic incinerator; CA denotes carbon adsorber; CO denotes condenser; PE denotes partial enclosure; TE denotes total enclosure.

c See sub. (8) (f) for additional reporting requirements when coating mix preparation equipment is constructed at a time when no coating operation is being constructed. See sub. (8) (g) for addition reporting requirements when coating mix preparation equipment is constructed at the same time as an affected coating operation.

(3)   Standards for volatile organic compounds.

(a) Each owner or operator of any affected facility that is subject to the requirements of this section shall comply with the emission limitations in this subsection on and after the date on which the initial performance test required by s. NR 440.08 is completed, but not later than 60 days after achieving the maximum production rate at which the affected facility will be operated or 180 days after initial startup, whichever date comes first.

(b) Each owner or operator shall control emissions from a new coating operation by recovering or destroying at least 93% of the VOC content of the coating applied at the coating applicator.

(c) Each owner or operator of a modified or reconstructed coating operation shall meet the appropriate standard in subds. 1. to 3. , 4. or par. (d) .

1. For coating operations demonstrated prior to modification or reconstruction pursuant to sub. (4) (a) 1. to have emissions controlled by the recovery or destruction of at least 90% of the VOC content of the coating applied at the coating applicator.

2. Subject to the provisions of subd. 3. , each owner or operator shall continue to control emissions from the coating operation to at least the demonstrated level or 93%, whichever is lower.

3. If the VOC control device in use during the emission reduction demonstration made pursuant to sub. (4) (a) 1. is subsequently replaced, each owner or operator shall:

a. Install a control device that is at least 95% efficient; and

b. Control emissions from the coating operation to at least the level determined pursuant to sub. (4) (a) 3. b.

4. For coating operations demonstrated prior to modification or reconstruction pursuant to sub. (4) (a) 2. to have a total enclosure installed around the coating operation and all VOC emissions ventilated to a control device that is at least 92% efficient.

a. Subject to the provisions of subd. 4. b. , each owner or operator shall continue to ventilate all VOC emissions from the total enclosure to the control device and maintain control device efficiency at or above the demonstrated level or 95%, whichever is lower.

b. If the VOC control device in use during the control device efficiency demonstration made pursuant to sub. (4) (a) 2. is subsequently replaced, each owner or operator shall install a VOC control device that is at least 95% efficient and ventilate all VOC emissions from the total enclosure to the control device.

(d) For coating operations not subject to par. (c) 1. to 4. , each owner or operator shall control emissions from the coating operation by recovering or destroying at least 93% of the VOC content of the coating applied at the coating applicator.

(e) Each owner or operator constructing new coating mix preparation equipment with concurrent construction of a new VOC control device, other than a condenser, on a magnetic tape coating operation shall control emissions from the coating mix preparation equipment by installing and using a cover on each piece of equipment and venting the equipment to a 95% efficient control device. Each cover shall meet the following specifications:

1. Cover shall be closed at all times except when adding ingredients, withdrawing samples, transferring the contents or making visual inspection when such activities cannot be carried out with cover in place. Such activities shall be carried out through ports of the minimum practical size.

2. Cover shall extend at least 2 cm beyond the outer rim of the opening or shall be attached to the rim;

3. Cover shall be of such design and construction that contact is maintained between cover and rim along the entire perimeter;

4. Any breach in the cover, such as an opening for insertion of a mixer shaft or port for addition of ingredients, shall be covered consistent with par. (c) 2. and 3. , when not actively in use. An opening sufficient to allow safe clearance for a mixer shaft is acceptable during those periods when the shaft is in place; and

5. A polyethylene or nonpermanent cover may be used provided it meets the requirements of par. (c) 2. to 4. A cover may not be reused after once being removed.

(f) Each owner or operator of affected coating mix preparation equipment not subject to par. (e) shall control emissions from the coating mix preparation equipment by either:

1. Installing and using a cover that meets the specifications in par. (c) 1. to 5. and venting VOC emissions from the equipment to a VOC control device; or

2. Installing and using a cover that meets the specifications in par. (c) 1. to 5.

(g) In lieu of complying with pars. (b) to (f) , each owner or operator may use coatings that contain a maximum of 0.20 kg of VOC per liter of coating solids as calculated on a weighted average basis for each nominal 1-month period.

(4)   Compliance provisions.

(a) The determination of the applicability of sub. (3) (c) , standards for modified or reconstructed coating operations, and determination of control level required in sub. (3) (c) 3. b. is as follows:

1. To establish applicability of sub. (3) (c) 1. to 3. , each owner or operator shall demonstrate, prior to modification or reconstruction, that at least 90% of the VOC content of the coating applied at the coating applicator is recovered or destroyed. The demonstration shall be made using the procedures of par. (b) 1. , 2. , 3. or 4. , as appropriate.

2. To establish applicability of sub. (3) (c) 4. , each owner or operator shall demonstrate, prior to modification or reconstruction, that a total enclosure is installed around the existing coating operation and that all VOC emissions are ventilated to a control device that is at least 92% efficient. The demonstration shall be made using the procedures of par. (b) 5.

3. To determine the level of control required in sub. (3) (c) 3. b. , the owner or operator shall demonstrate:

a. That the VOC control device subsequently installed is at least 95% efficient. Such demonstration shall be made using Equation (2) specified in par. (b) 2. d. or Equations (4) and (5) specified in par. (b) 3. d. and e. , as applicable and the test methods and procedures specified in sub. (6) (b) to (g) ; and

b. That the overall level of control after the VOC control device is installed is at least as high as the level demonstrated prior to modification or reconstruction pursuant to par. (a) 1. Demonstrations shall be made using the procedures of par. (b) 1. , 2. , 3. or 4. , as appropriate. The required overall level of control subsequent to this demonstration shall be the level so demonstrated or 93%, whichever is lower.

(b) The compliance demonstrations for sub. (3) (b) , (c) 1. to 3. , 4. , (d) , (e) , (f) and (g) are made as follows:

1. To demonstrate compliance with sub. (3) (b) , (c) 1. to 3. or (d) , standards for coating operations, when emissions from only the affected coating operations are controlled by a dedicated solvent recovery device, each owner or operator of the affected coating operation shall perform a liquid- liquid VOC material balance over each and every nominal 1-month period. When demonstrating compliance by this procedure, s. NR 440.08 (6) does not apply. The amount of liquid VOC applied and recovered shall be determined as discussed in subd. 1. c. The overall VOC emission reduction (R) is calculated using the following equation:

- See PDF for diagram (Equation 1)

a. The value of RS i is zero unless the owner or operator submits the following information to the administrator for approval of a measured value of RS i , that is greater than zero:

1) Measurement techniques; and

2) Documentation that the measured value of RS i exceeds zero.

b. The measurement techniques of subd. 1. a. 1) shall be submitted to the administrator for approval.

c. Each owner or operator demonstrating compliance by the test method described in subd. 1. shall:

1) Measure the amount of coating applied at the coating applicator;

2) Determine the VOC content of all coatings applied using the test method specified in sub. (6) (a) ;

3) Install, calibrate, maintain and operate, according to the manufacturer's specifications, a device that indicates the cumulative amount of VOC recovered by the solvent recovery device over each nominal 1-month period. The device shall be certified by the manufacturer to be accurate to within " 2.0%;

4) Measure the amount of VOC recovered; and

5) Calculate the overall VOC emission reduction (R) for each and every nominal 1-month period using Equation 1.

d. For facilities subject to sub. (3) (b) or (d) , compliance is demonstrated if the value of R is equal to or greater than 93%.

e. Subject to the provisions of subd. 1. f. , for facilities subject to sub. (3) (c) 1. to 3. , compliance is demonstrated if the value of R is equal to or greater than the percent reduction demonstrated pursuant to par. (a) 1. prior to modification or reconstruction or 93%, whichever is lower.

f. For facilities subject to sub. (3) (c) 3. , compliance is demonstrated if the value of E (control device efficiency) is greater than or equal to 0.95 and if the value of R is equal to or greater than the percent reduction demonstrated pursuant to par. (a) 3. or 93%, whichever is lower.

2. To demonstrate compliance with sub. (3) (b) , (c) 1. to 3. or (d) , standards for coating operations, when the emissions from only an affected coating operation are controlled by a dedicated incinerator or when a common emission control device, other than a fixed-bed carbon adsorption system with individual exhaust stacks for each adsorber vessel, is used to control emissions from an affected coating operation as well as from other sources of VOC, each owner or operator of an affected coating operation shall perform a gaseous emission test using the following procedures:

a. Construct the overall VOC emission reduction system so that all volumetric flow rates and total VOC emissions can be accurately determined by the applicable test methods and procedures specified in sub. (6) (b) to (g) ;

b. Determine capture efficiency from the coating operation by capturing, venting and measuring all VOC emissions from the operation. During a performance test, the owner or operator of an affected coating operation located in an area with other sources of VOC shall isolate the coating operation emissions from all other sources of VOC by one of the following methods:

1) Build a temporary enclosure around the affected coating operation; or

c. Operate the emission control device with all emission sources connected and operating;

d. Determine the efficiency (E) of the control device using the following equation:

e. Determine the efficiency (F) of the VOC capture system using the following equation:

f. For each affected coating operation subject to sub. (3) (b) or (d) , compliance is demonstrated if the product of (E) (F) is equal to or greater than 0.93.

g. For each affected coating operation subject to sub. (3) (c) 2. , compliance is demonstrated if the product of (E) (F) is equal to or greater than the fractional reduction demonstrated pursuant to par. (a) 1. prior to modification or reconstruction or 0.93, whichever is lower.

h. For each affected coating operation subject to sub. (3) (c) 3. , compliance is demonstrated if the value of E is greater than or equal to 0.95 and if the product of (E) (F) is equal to or greater than the fractional reduction demonstrated pursuant to par. (a) 3. or 0.93 , whichever is lower.

3. To demonstrate compliance with sub. (3) (b) , (c) 1. to 3. or (d) , standards for coating operations, when a fixed-bed carbon adsorption system with individual exhaust stacks for each adsorber vessel is used to control emissions from an affected coating operation as well as from other sources of VOC, each owner or operator of an affected coating operation shall perform a gaseous emission test using the following procedures:

a. Construct the overall VOC emission reduction system so that each volumetric flow rate and the total VOC emissions can be accurately determined by the applicable test methods and procedures specified in sub. (6) (b) to (g) ;

b. Assure that all VOC emissions from the coating operation are segregated from other VOC sources and that the emissions can be captured for measurement, as described in subd. 2. b. 1) and 2);

c. Operate the emission control device with all emission sources connected and operating;

d. Determine the efficiency (H v ) of each individual adsorber vessel (v) using the following equation:

e. Determine the efficiency of the carbon adsorption system (H sys ) by computing the average efficiency of the adsorber vessels as weighted by the volumetric flow rate (Q hv ) of each individual adsorber vessel (v) using the following equation:

f. Determine the efficiency (F) of the VOC capture system using Equation (3).

g. For the affected coating operation subject to sub. (3) (b) or (d) , compliance is demonstrated if the product of (H sys ) (F) is equal to or greater than 0.93.

h. For the affected coating operation subject to sub. (3) (c) 2. , compliance is demonstrated if the product of (H sys )   (F) is equal to or greater than the fractional reduction demonstrated pursuant to par. (a) 1. prior to modification or reconstruction or 0.93, whichever is lower.

i. For each affected coating operation subject to sub. (3) (c) 3. , compliance is demonstrated if the value of H sys is greater than or equal to 0.95 and if the product of (H sys ) (F) is equal to or greater than the fractional reduction demonstrated pursuant to par. (a) 3. or 0.93 , whichever is lower.

4. To demonstrate compliance with sub. (3) (b) , (c) 1. to 3. or (d) , standards for coating operations, when the VOC emissions from more than one affected coating operation are collected by a common capture system and are vented through a common duct to a control device that is also controlling emissions from nonaffected sources and the emissions from the nonaffected sources are vented separately from the affected coating operations, the owner or operator may:

a. Consider the combined affected coating operations as single emission source; and

b. Conduct a compliance test on this single source by the methods described in subd. 2. or 3. , as applicable.

5. An alternative method of demonstrating compliance with sub. (3) (b) or (d) , standards for coating operations, and the sole method of demonstrating compliance with sub. (3) (c) 4. , standards for modified or reconstructed coating operations, is the installation of a total enclosure around the coating operation and the ventilation of all VOC emissions from the total enclosure to a control device with the efficiency specified in par. (b) 5. c. 1) or 2), as applicable. If this method is selected, the compliance test methods described in par. (b) 1. to 4. are not required. Instead, each owner or operator of an affected coating operation shall:

a. Demonstrate that a total enclosure is installed. An enclosure that meets the requirements in subd. 5. a. 1) to 4) shall be assumed to be a total enclosure. The owner or operator of an enclosed coating operation that does not meet the requirements may apply to the administrator for approval of the enclosure as a total enclosure on a case-by-case basis. The enclosure shall be considered a total enclosure if it is demonstrated to the satisfaction of the administrator that all VOC emissions from the affected coating operation are contained and vented to the control device. The requirements for automatic approval are as follows:

b. Determine the control device efficiency using Equation (2) or Equations (4) and (5), as applicable and the test methods and procedures specified in sub. (6) (b) to (g) .

c. Compliance is demonstrated if the installation of a total enclosure is demonstrated and the value of E determined from Equation (2), or the value of H sys determined from Equations (4) and (5), as applicable, is equal to or greater than the required efficiency as follows:

6. To demonstrate compliance with sub. (3) (e) (standard for new mix equipment with concurrent construction of a control device), each owner or operator of affected coating mix preparation equipment shall demonstrate upon inspection that:

a. Covers satisfying the requirements of sub. (3) (e) 1. to 5. have been installed and are being used properly;

b. Procedures detailing the proper use of covers, as specified in sub. (3) (c) 1. , have been posted in all areas where affected coating mix preparation equipment is used;

c. The coating mix preparation equipment is vented to a control device; and

d. The control device efficiency (E or H sys , as applicable) determined using Equation (2) or Equations (4) and (5), respectively and the test methods and procedures specified in sub. (6) (b) to (g) is equal to or greater than 0.95.

7. To demonstrate compliance with sub. (3) (f) 1. , standard for mix equipment, each owner or operator of affected coating mix preparation equipment shall demonstrate upon inspection that:

a. Covers satisfying the requirements of sub. (3) (e) 1. to 5. have been installed and are being used properly;

b. Procedures detailing the proper use of covers, as specified in sub. (3) (c) 1. , have been posted in all areas where affected coating mix preparation equipment is used; and

c. The coating mix preparation equipment is vented to a control device.

8. To demonstrate compliance with sub. (3) (f) 2. , standard for mix equipment, each owner or operator of affected coating mix preparation equipment shall demonstrate upon inspection that both:

a. Covers satisfying the requirements of sub. (3) (e) 1. to 5. have been installed and are being used properly; and

b. Procedures detailing the proper use of covers, as specified in sub. (3) (c) 1. , have been posted in all areas where affected coating mix preparation equipment is used.

9. To determine compliance with sub. (3) (g) , high-solids coatings alternative standard, each owner or operator of an affected facility shall determine the weighted average mass of VOC contained in the coating per volume of coating solids applied for each and every nominal 1-month period according to the following procedures:

a. Determine the weight fraction of VOC in each coating applied using Method 24 as specified in sub. (6) (a) ;

b. Determine the volume of coating solids in each coating applied from the facility records; and

c. Compute the weighted average by the following equation:

d. For each affected facility where the value of G is less than or equal to 0.20 kilogram of VOC per liter of coating solids applied, the facility is in compliance.

(c) Startups and shutdowns are normal operation for this source category. Emissions from these operations are to be included when determining if the standards for coating operations specified in sub. (3) (b) to (d) are being attained.

(d) If a control device other than a carbon adsorber, condenser or incinerator is used to control emissions from an affected facility, the necessary operating specifications for that device shall be obtained from the administrator. An example of such a device is a flare.

(5)   Installation of monitoring devices and recordkeeping. All monitoring devices required under the provisions of this subsection shall be installed and calibrated, according to the manufacturer's specifications, prior to the initial performance tests in locations such that representative values of the monitored parameters will be obtained. The parameters to be monitored shall be continuously measured and recorded during all performance tests.

(a) Each owner or operator of an affected coating operation that utilizes less solvent annually than the applicable cutoff provided in sub. (1) (b) and that is not subject to sub. (3) , standards for coating operations, shall maintain records of actual solvent use.

(b) Each owner or operator of an affected coating operation demonstrating compliance by the test method described in sub. (4) (b) 1. , liquid material balance, shall maintain records of all the following for each and every nominal 1-month period:

1. Amount of coating applied at the applicator;

2. Results of the reference test method specified in sub. (6) (a) for determining the VOC content of all coatings applied;

3. Amount VOC recovered; and

4. Calculation of the percent VOC recovered.

(c) Each owner or operator of an affected coating operation or affected coating mix preparation equipment controlled by a carbon adsorption system and demonstrating compliance by the procedures described in sub. (4) (b) 2. , 3. , 4. , 5. or 6. , which include control device efficiency determinations, shall carry out the monitoring and recordkeeping provisions of subd. 1. or 2. , as appropriate.

1. For carbon adsorption systems with a common exhaust stack for all the individual adsorber vessels, install, calibrate, maintain and operate, according to the manufacturer's specifications, a monitoring device that continuously indicates and records the concentration level of organic compounds in either the control device outlet gas stream or in both the control device inlet and outlet gas streams. The outlet gas stream would be monitored if the percent increase in the concentration level of organic compounds is used as the basis for reporting, as described in sub. (8) (d) 3. The inlet and outlet gas streams would be monitored if the percent control device efficiency is used as the basis for reporting, as described in sub. (8) (d) 4.

2. For carbon adsorption systems with individual exhaust stacks for each adsorber vessel, install, calibrate, maintain and operate, according to the manufacturer's specifications, a monitoring device that continuously indicates and records the concentration level of organic compounds in the outlet gas stream for a minimum of one complete adsorption cycle per day for each adsorber vessel. The owner or operator may also monitor and record the concentration level of organic compounds in the common carbon adsorption system inlet gas stream or in each individual carbon adsorber vessel inlet stream. The outlet gas streams alone would be monitored if the percent increase in the concentration level of organic compounds is used as the basis for reporting, as described in sub. (8) (d) 3. In this case, the owner or operator shall compute daily a 3-day rolling average concentration level of organics in the outlet gas stream from each individual adsorber vessel. The inlet and outlet gas streams would be monitored if the percent control device efficiency is used as the basis for reporting, as described in sub. (8) (d) 4. In this case, the owner or operator shall compute daily a 3-day rolling average efficiency for each individual adsorber vessel.

(d) Each owner or operator of an affected coating operation controlled by condensation system and demonstrating compliance by the procedures described in sub. (4) (b) 2. , 4. or 5. , which include control device efficiency determinations, shall install, calibrate, maintain and operate, according to the manufacturer's specifications, a monitoring device that continuously indicates and records the temperature of the condenser exhaust stream.

(e) Each owner or operator of an affected coating operation or affected coating mix preparation equipment controlled by a thermal incinerator and demonstrating compliance by the procedures described in sub. (4) (b) 2. , 4. , 5. or 6. , which include control device efficiency determinations, shall install, calibrate, maintain and operate, according to the manufacturer's specifications, a monitoring device that continuously indicates and records the combustion temperature of the incinerator. The monitoring device shall have an accuracy within " 1% of the temperature being measured in Celsius degrees.

(f) Each owner or operator of an affected coating operation or affected coating mix preparation equipment controlled by a catalytic incinerator and demonstrating compliance by the procedures described in sub. (4) (b) 2. , 4. , 5. or 6. , which include control device efficiency determinations, shall install, calibrate, maintain and operate, according to the manufacturer's specifications, a monitoring device that continuously indicates and records the gas temperature both upstream and downstream of the catalyst bed. The monitoring device shall have an accuracy with " 1% of the temperature being measured in Celsius degrees.

(g) Each owner or operator of an affected coating operation demonstrating compliance pursuant to sub. (4) (b) 2. , 3. or 4. , which include VOC capture system efficiency determinations, shall submit a monitoring plan for the VOC capture system to the department for approval. This plan shall identify the parameter to be monitored as an indicator of VOC capture system performance, for example the amperage to the exhaust fans or duct flow rates, and the method for monitoring the chosen parameter. The owner or operator shall install, calibrate, maintain and operate, according to the manufacturer's specifications, a monitoring device that continuously indicates and records the value of the chosen parameter.

(h) Each owner or operator of an affected coating operation who uses the equipment alternative described in sub. (4) (b) 5. to demonstrate compliance shall follow the procedures described in par. (g) to establish a monitoring plan for the total enclosure.

(i) Each owner or operator of an affected coating operation shall record time periods of coating operations when an emission control device is not in use.

(j) Each owner or operator of an affected coating operation or affected coating mix preparation equipment complying with sub. (3) (g) shall maintain records of the monthly weighted average mass of VOC contained in the coating per volume of coating solids applied for each coating as described in sub. (4) (b) 9. a. to d.

(k) Records of the measurements and calculations required in sub. (4) and this subsection shall be retained for at least 2 years following the date of the measurements and calculations.

(6)   Test methods and procedures. Methods in Appendix A of 40 CFR part 60 , incorporated by reference in s. NR 440.17 , except as provided under s. NR 440.08 (2) , shall be used to determine compliance as follows:

(a) Method 24 is used to determine the VOC content in coatings. If it is demonstrated to the satisfaction of the administrator that plant coating formulation data are equivalent to Method 24 results, formulation data may be used. In the event of any inconsistency between a Method 24 test and a facility's formulation data, the Method 24 test will govern. For Method 24, the coating sample shall be a 1-liter sample taken into a 1-liter container at a location and time such that the sample will be representative of the coating applied to the base film, that is, the sample shall include any dilution solvent or other VOC added during the manufacturing process. The container shall be tightly sealed immediately after the sample is taken. Any solvent or other VOC added after the sample is taken shall be measured and accounted for in the calculations that use Method 24 results.

(b) Method 18, 25 or 25A, as appropriate to the conditions at the site, is used to determine VOC concentration. The owner or operator shall submit notice of the intended test method to the administrator for approval along with the notification of the performance test required under s. NR 440.08 (2) . Method selection shall be based on consideration of the diversity of organic species present and their total concentration and on consideration of the potential presence of interfering gases. Except as indicated in par. (b) 1. and 2. , the test shall consist of 3 separate runs, each lasting a minimum of 30 minutes.

1. When the method is to be used in the determination of the efficiency of a fixed-bed carbon adsorption system with a common exhaust stack for all the individual adsorber vessels pursuant to sub. (4) (b) 2. , 4. , 5. or 6. , the test vessel shall consist of 3 separate runs, each coinciding with one or more complete sequences through the adsorption cycles of all the individual adsorber vessels.

2. When the method is to be used in the determination of the efficiency of a fixed-bed carbon adsorption system with individual exhaust stacks for each adsorber vessel pursuant to sub. (4) (b) 3. , 4. , 5. or 6. , each adsorber vessel shall be tested individually. The test for each adsorber vessel shall consist of 3 separate runs. Each run shall coincide with one or more complete adsorption cycles.

(c) Method 1 or 1A is used for sample and velocity traverses.

(d) Method 2, 2A, 2C or 2D is used for velocity and volumetric flow rates.

(e) Method 3 is used for gas analysis.

(f) Method 4 is used for stack gas moisture.

(g) Methods 2, 2A, 2C, 2D, 3 and 4 shall be performed, as applicable, at least twice during each test period.

(8)   Reporting and monitoring requirements.

(a) For all affected coating operations subject to sub. (3) (b) , (c) 1. to 3. , 4. or (d) and all affected coating mix preparation equipment subject to sub. (3) (e) , the performance test data and results shall be submitted to the department as specified in s. NR 440.08 (1) . In addition, the average values of the monitored parameters measured at least every 15 minutes and averaged over the period of the performance test shall be submitted with the results of all performance tests.

(b) Each owner or operator of an affected coating operation claiming to utilize less than the applicable volume of solvent specified in sub. (1) (b) in the first calendar year of operation shall submit to the department, with the notification of projected startup, a material flow chart indicating projected solvent use. The owner or operator shall also submit actual solvent use records at the end of the initial calendar year.

(c) Each owner or operator of an affected coating operation initially utilizing less than the applicable volume of solvent specified in sub. (1) (b) per calendar year shall report the first calendar year in which actual annual solvent use exceeds the applicable volume.

(d) Each owner or operator of an affected coating operation or affected coating mix preparation equipment subject to sub. (3) (e) , shall submit semiannual reports to the department documenting the following:

1. The 1-month amount of VOC contained in the coating, the VOC recovered and the percent emission reduction for months of noncompliance for any affected coating operation demonstrating compliance by the performance test method described in sub. (3) (g) , liquid material balance;

2. The VOC contained in the coatings for the manufacture of magnetic tape for any 1-month period during which the weighted average solvent content (G) of the coatings exceeded 0.20 kilogram per liter of coating solids for those affected facilities complying with sub. (3) (g) , high-solids coatings alternative standard;

3. For those affected facilities monitoring only the carbon adsorption system outlet concentration levels of organic compounds, the periods, during actual coating operations specified in subd. 3. a. or b. , as applicable.

a. For carbon adsorption systems with a common exhaust stack for all the individual adsorber vessels, all periods of 3 consecutive adsorption cycles of all the individual adsorber vessels during which the average value of the concentration level of organic compounds in the common outlet gas stream is more than 20% greater than the average value measured during the most recent performance test that demonstrated compliance.

b. For carbon adsorption systems with individual exhaust stacks for each adsorber vessel, all 3-day rolling averages for each adsorber vessel when the concentration level of organic compounds in the individual outlet gas stream is more than 20% greater than the average value for that adsorber vessel measured during the most recent performance test that demonstrated compliance.

4. For those affected facilities monitoring both the carbon adsorption system inlet and outlet concentration levels of organic compounds, the periods, during actual coating operations, specified in par. (d) 4. a. or b. , as applicable.

a. For carbon adsorption systems with a common exhaust stack for all the individual adsorber vessels, all periods of 3 consecutive adsorption cycles of all the individual adsorber vessels during which the average carbon adsorption system efficiency falls below the applicable level as follows:

b. For carbon adsorption systems with individual exhaust stacks for each adsorber vessel, all 3-day rolling averages for each adsorber vessel when the efficiency falls below the applicable level as follows:

5. All 3-hour periods, during actual coating operations, during which the average exhaust temperature is 5 or more Celsius degrees above the average temperature measured during the most recent performance test that demonstrated compliance for those affected facilities monitoring condenser exhaust gas temperature;

6. All 3-hour periods, during actual coating operations, during which the average combustion temperature is more than 28 Celsius degrees below the average combustion temperature during the most recent performance test that demonstrated compliance for those affected facilities monitoring thermal incinerator combustion gas temperature;

7. All 3-hour periods, during actual coating operations, during which the average gas temperature immediately before the catalyst bed is more than 28 Celsius degrees below the average gas temperature during the most recent performance test that demonstrated compliance and all 3-hour periods, during actual coating operations, during which the average gas temperature difference across the catalyst bed is less than 80% of the average gas temperature difference during the most recent performance test that demonstrated compliance for those affected facilities monitoring catalytic incinerator catalyst bed temperature; and

8. All 3-hour periods, during actual coating operations, during which the average total enclosure or VOC capture system monitoring device readings vary by 5% or more from the average value measured during the most recent performance test that demonstrated compliance for those affected facilities monitoring a total enclosure pursuant to sub. (5) (h) for VOC capture system pursuant to sub. (5) (g) .

(e) Each owner or operator of an affected coating operation or affected coating mix preparation equipment subject to sub. (3) (e) , not required to submit reports under par. (d) because no reportable periods have occurred shall submit semiannual reports so affirming.

(f) Each owner or operator of affected coating mix preparation equipment that is constructed at a time when no affected coating operation is being constructed shall:

1. Be exempt from the reporting requirements specified in s. NR 440.07 (1) (a) and (d) ; and

2. Submit the notification of actual startup specified in s. NR 440.07 (1) (c) .

(g) The owner or operator of affected coating mix preparation equipment that is constructed at the same time as an affected coating operation shall include the affected coating mix preparation equipment in all the reporting requirements for the affected coating operation specified in s. NR 440.07 (1) (a) to (d) .

(h) The reports required under pars. (b) to (e) shall be postmarked within 30 days of the end of the reporting period.

History: Cr. Register, July, 1993, No. 451 , eff. 8-1-9 3 ; am. (4) (b) 1. (intro.), 2. d., e., 3. d., e., 5. a. 3) b), 9. c., Register, December, 1995, No. 480 , eff. 1-1-96; CR 06-109 : renum. (5) (a) (intro.) and (8) (c) (intro.) to be (5) (a) and (8) (c) and am., r. (5) (a) 1. and 2. and (8) (c) 1. and 2., am. (8) (d) (intro.) Register May 2008 No. 629 , eff. 6-1-08; corrections in (2) (a) 15., (4) (b) 1. b., (5) (g) and (8) (f) 1. made under s. 13.92 (4) (b) 7. , Stats., Register May 2008 No. 629 .

Note

See sub. (2) (a) 16. Microsoft Windows NT 6.1.7601 Service Pack 1 2) Shut down all other sources of VOC and continue to exhaust fugitive emissions from the affected coating operation through any building ventilation system and other room exhausts such as drying ovens. All ventilation air shall be vented through stacks suitable for testing; Microsoft Windows NT 6.1.7601 Service Pack 1 - See PDF for diagram (Equation 2) Microsoft Windows NT 6.1.7601 Service Pack 1 - See PDF for diagram (Equation 3) Microsoft Windows NT 6.1.7601 Service Pack 1 - See PDF for diagram (Equation 4) Microsoft Windows NT 6.1.7601 Service Pack 1 - See PDF for diagram (Equation 5) Microsoft Windows NT 6.1.7601 Service Pack 1 1) Total area of all natural draft openings may not exceed 5% of the total surface area of the total enclosure's walls, floor and ceiling; Microsoft Windows NT 6.1.7601 Service Pack 1 2) All sources of emissions within the enclosure shall be a minimum of 4 equivalent diameters away from each natural draft opening; Microsoft Windows NT 6.1.7601 Service Pack 1 3) Average inward face velocity across all natural draft openings (FV) shall be a minimum of 3,600 meters per hour as determined by the following procedures: Microsoft Windows NT 6.1.7601 Service Pack 1 a) Construct all forced makeup air ducts and all exhaust ducts so that the volumetric flow rate in each can be accurately determined by the test methods and procedures specified in sub. (6) (c) and (d) . Volumetric flow rates shall be calculated without the adjustment normally made for moisture content; and Microsoft Windows NT 6.1.7601 Service Pack 1 b) Determine FV by the following equation: Microsoft Windows NT 6.1.7601 Service Pack 1 - See PDF for diagram (Equation 6) Microsoft Windows NT 6.1.7601 Service Pack 1 4) The air passing through all natural draft openings shall flow into the enclosure continuously. If FV is less than or equal to 9,000 meters per hour, the continuous inward flow of air shall be verified by continuous observation using smoke tubes, streamers, tracer gases or other means approved by the administrator over the period that the volumetric flow tests required to determine FV are carried out. If FV is greater than 9,000 meters per hour, the direction of airflow through the natural draft openings shall be presumed to be inward at all times without verification. Microsoft Windows NT 6.1.7601 Service Pack 1 1) For coating operations subject to the standards of sub. (3) (b) , (c) 4. b. and (d) , 0.95 (95%); or Microsoft Windows NT 6.1.7601 Service Pack 1 2) For coating operations subject to the standards of sub. (3) (c) 4. a. , the value of E determined from Equation (2), or the value of H sys determined from Equations (4) and (5), as applicable, pursuant to par. (a) 2. prior to modification or reconstruction or 0.95 (95%), whichever is lower. Microsoft Windows NT 6.1.7601 Service Pack 1 - See PDF for diagram (Equation 7) Microsoft Windows NT 6.1.7601 Service Pack 1 Under 40 CFR 60.716 , if, in the administrator's judgment, an alternative means of emission limitation will achieve a reduction in emissions of VOC from any emission point subject to sub. (3) (e) or (f) (standards for mix equipment) at least equivalent to that required by sub. (3) (e) or (f), respectively, the administrator will publish in the Federal Register a notice permitting the use of the alternative means. The notice may condition permission on requirements related to the operation and maintenance of the alternative means. Any such notice shall be published only after public notice and an opportunity for a public hearing. Any person seeking permission under 40 CFR 60.716 shall submit either results from an emission test that documents the collection and measurement of all VOC emissions from a given control device or an engineering evaluation that documents the determination of such emissions. Microsoft Windows NT 6.1.7601 Service Pack 1 1) For those affected facilities demonstrating compliance by the performance test method described in sub. (4) (b) 2. or 4. , the value of E determined using Equation (2) during the most recent performance test that demonstrated compliance. Microsoft Windows NT 6.1.7601 Service Pack 1 2) For those affected facilities demonstrating compliance pursuant to sub. (4) (b) 5. c. 1) or 6., 0.95 (95%). Microsoft Windows NT 6.1.7601 Service Pack 1 3) For those affected facilities demonstrating compliance pursuant to sub. (4) (b) 5. c. 2), the required value of E determined using Equation (2) pursuant to sub. (4) (a) 2. prior to modification or reconstruction or 0.95 (95%), whichever is lower. Microsoft Windows NT 6.1.7601 Service Pack 1 1) For those affected facilities demonstrating compliance by the performance test method described in sub. (4) (b) 3. or 4. , the value of H v determined using Equation (4) during the most recent performance test that demonstrated compliance. Microsoft Windows NT 6.1.7601 Service Pack 1 2) For those affected facilities demonstrating compliance pursuant to sub. (4) (b) 5. c. 1) or 6., 0.95 (95%). Microsoft Windows NT 6.1.7601 Service Pack 1 3) For those affected facilities demonstrating compliance pursuant to sub. (4) (b) 5. c. 2), the value of H v determined using Equation (4) pursuant to sub. (4) (a) 2. prior to modification or reconstruction. Microsoft Windows NT 6.1.7601 Service Pack 1