Section 440.57. Industrial surface coating: large appliances.

 

(1)   Applicability and designation of affected facility.

(a) The provisions of this section apply to each surface coating operation in a large appliance surface coating line.

(b) Any facility under par. (a) that commences construction, modification or reconstruction after December 24, 1980, is subject to the requirements of this section.

(2)   Definitions and symbols.

(a) As used in this section, terms not defined in this paragraph have the meanings given in s. NR 440.02 .

1. "Applied coating solids" means the coating solids that adhere to the surface of the large appliance part being coated.

2. "Coating application station" means that portion of the large appliance surface coating operation where a prime coat or a topcoat is applied to large appliances parts or products (e.g., dip tank, spray booth or flow coating unit).

3. "Curing oven" means a device that uses heat to dry or cure the coatings applied to large appliance parts or products.

4. "Electrodeposition" or "EDP" means a method of coating application in which the large appliance part or product is submerged in a tank filled with coating material suspended in water and an electrical potential is used to enhance deposition of the material on the part or product.

5. "Flashoff area" means the portion of a surface coating line between the coating application station and the curing oven.

6. "Large appliance part" means any organic surface-coated metal lid, door, casing, panel or other interior or exterior metal part or accessory that is assembled to form a large appliance product. Parts subject to in-use temperatures in excess of 250 ° F are not included in this definition.

7. "Large appliance product" means any organic surface-coated metal range, oven, microwave oven, refrigerator, freezer, washer, dryer, dishwasher, water heater or trash compactor manufactured for household, commercial or recreational use.

8. "Large appliance surface coating line" means that portion of a large appliance assembly plant engaged in the application and curing of organic surface coatings on large appliance parts or products.

9. "Organic coating" means any coating used in a surface coating operation, including dilution solvents, from which VOC emissions occur during the application or the curing process. For the purpose of this section, powder coatings are not included in this definition.

10. "Powder coating" means any surface coating that is applied as a dry powder and is fused into a continuous coating film through the use of heat.

11. "Spray booth" means the structure housing automatic or manual spray application equipment where a coating is applied to large appliance parts or products.

12. "Surface coating operation" means the system on a large appliance surface coating line used to apply and dry or cure an organic coating on the surface of large appliance parts or products. The surface coating operation may be a prime coat or a topcoat operation and includes the coating application station or stations, flashoff area and curing oven.

13. "Transfer efficiency" means the ratio of the amount of coating solids deposited onto the surface of a large appliance part or product to the total amount of the coating solids used.

14. "VOC content" means the proportion of a coating that is volatile organic compounds (VOCs), expressed as kilograms of VOCs per liter of coating solids.

15. "VOC emissions" means the mass of volatile organic compounds (VOCs), expressed as kilograms of VOCs per liter of applied coating solids, emitted from a surface coating operation.

(b) As used in this section, symbols not defined in this paragraph have the meanings given in s. NR 440.03 .

1. C a is the concentration of VOCs in a gas stream leaving a control device and entering the atmosphere (parts per million by volume, as carbon).

2. C b is the concentration of VOCs in a gas stream entering a control device (parts per million by volume, as carbon).

3. C f is the concentration of VOCs in a gas stream emitted directly to the atmosphere (parts per million by volume, as carbon).

4. D c is the density of coating (or input stream), as received (kilograms per liter).

5. D d is the density of a VOC solvent added to coatings (kilograms per liter).

6. D r is the density of a VOC solvent recovered by an emission control device (kilograms per liter).

7. E is the VOC destruction efficiency of a control device (fraction).

8. F is the proportion of total VOCs emitted by an affected facility that enters a control device (fraction).

9. G is the volume-weighted average mass of VOCs in coatings consumed in a calendar month per unit volume of applied coating solids (kilograms per liter).

10. L c is the volume of coating consumed, as received (liters).

11. L d is the volume of VOC solvent added to coatings (liters).

12. L r is the volume of VOC solvent recovered by an emission control device (liters).

13. L s is the volume of coating solids consumed (liters).

14. M d is the mass of VOC solvent added to coatings (kilograms).

15. M o is the mass of VOCs in coatings consumed, as received (kilograms).

16. M r is the mass of VOCs recovered by an emission control device (kilograms).

17. Q a is the volumetric flow rate of a gas stream leaving a control device and entering the atmosphere (dry standard cubic meters per hour).

18. Q b is the volumetric flow rate of a gas stream entering a control device (dry standard cubic meters per hour).

19. Q f is the volumetric flow rate of a gas stream emitted directly to the atmosphere (dry standard cubic meters per hour).

20. R is the overall VOC emission reduction achieved for an affected facility (fraction).

21. T is the transfer efficiency (fraction).

22. V s is the proportion of solids in a coating (or input stream), as received (fraction by volume).

23. W o is the proportion of VOCs in a coating (or input stream), as received (fraction by weight).

(3)   Standard for volatile organic compounds. On and after the date on which the performance test required by s. NR 440.08 is completed, no owner or operator of an affected facility subject to the provisions of this section may discharge or cause the discharge of VOC emissions that exceed 0.90 kilogram of VOCs per liter of applied coating solids from any surface coating operation on a large appliance surface coating line.

(4)   Performance test and compliance provisions.

(a) Section NR 440.08 (4) and (6) does not apply to the performance test procedures required by this section.

(b) The owner or operator of an affected facility shall conduct an initial performance test as required under s. NR 440.08 (1) and thereafter a performance test each calendar month for each affected facility according to the procedures in this paragraph.

1. An owner or operator shall use the following procedures for an affected facility that does not use a capture system and control device to comply with the emissions limit specified under sub. (3) . The owner or operator shall determine the composition of the coatings by formulation data supplied by the coating manufacturer or by analysis of each coating, as received, using Method 24 of 40 CFR part 60 , Appendix A, incorporated by reference in s. NR 440.17 (1) . The department may require the owner or operator who uses formulation data supplied by the coating manufacturer to determine the VOC content of coatings using Method 24. The owner or operator shall determine the volume of coating and the mass of VOC-solvent used for thinning purposes from company records on a monthly basis. If a common coating distribution system serves more than one affected facility or serves both affected and existing facilities, the owner or operator shall estimate the volume of coatings used at each facility by using the average dry weight of coating and the surface area coated by each affected and existing facility or by other procedures acceptable to the department.

a. Except as provided in subd. 1. d. , the weighted average of the total mass of VOCs consumed per unit volume of coatings solids applied each calendar month shall be determined as follows:

1) Calculate the mass of VOCs consumed (M o + M d ) during the calendar month for each affected facility by the following equation: - See PDF for diagram

( S L dj D dj will be zero if no VOC-solvent is added to the coatings, as received.)

where:

n is the number of different coatings used during the calender month

m is the number of different VOC solvents added to coatings during the calendar month

2) Calculate the total volume of coatings solids used (L s ) in the calendar month for each affected facility by the following equation: - See PDF for diagram

where:

n is the number of different coatings used during the calendar month

3) Select the appropriate transfer efficiency from Table 1. If the owner or operator can demonstrate to the satisfaction of the department that transfer efficiencies other than those shown are appropriate, the department shall approve their use on a case-by-case basis. Transfer efficiencies for application methods not listed shall be determined by the department on a case-by-case basis. An owner or operator shall submit sufficient data for the department to judge the accuracy of the transfer efficiency claims. - See PDF for table

Where more than one application method is used within a single surface coating operation, the owner or operator shall determine the composition and volume of each coating applied by each method through a means acceptable to the department and compute the weighted average transfer efficiency by the following equation: - See PDF for diagram

where:

n is the number of coatings (or input streams) used

m is the number of application methods used

4) Calculate the volume-weighted average mass of VOCs consumed per unit volume of coating solids applied (G) during the calendar month for each affected facility by the following equation: - See PDF for diagram

b. Calculate the volume-weighted average of VOC emissions to the atmosphere (N) during the calendar month for each affected facility by the following equation:

N = G

c. Where the volume-weighted average mass of VOCs discharged to the atmosphere per unit volume of coating solids applied (N) is equal to or less than 0.90 kilogram per liter, the affected facility is in compliance.

d. If each individual coating used by an affected facility has a VOC content, as received, which when divided by the lowest transfer efficiency at which the coating is applied, results in a value equal to or less than 0.90 kilogram per liter, the affected facility is in compliance, provided no VOCs are added to the coating during distribution or application.

2. An owner or operator shall use the following procedures for any affected facility that uses a capture system and a control device that destroys VOCs (e.g., incinerator) to comply with the emission limit specified under sub. (3) .

a. Determine the overall reduction efficiency (R) for the capture system and control device. For the initial performance test the overall reduction efficiency (R) shall be determined as prescribed in this subparagraph. In subsequent months, the owner or operator may use the most recently determined overall reduction efficiency (R) for the performance test, providing control device and capture system operating conditions have not changed. The procedure in this subparagraph shall be repeated when directed by the department or when the owner or operator elects to operate the control device or capture system at conditions different from the initial performance test.

1) Determine the fraction (F) of total VOCs emitted by an affected facility that enters the control device using the following equation: - See PDF for diagram

where:

n is the number of gas streams entering the control device

p is the number of gas streams emitted directly to the atmosphere

2) Determine the destruction efficiency of the control device (E) using values of the volumetric flow rate of each of the gas streams and the VOC content (as carbon) of each of the gas streams in and out of the device by the following equation: - See PDF for diagram

where:

n is the number of gas streams entering the control device

m is the number of gas streams leaving the control device and entering the atmosphere

3) Determine overall reduction efficiency (R) using the following equation:

R = EF

b. Calculate the volume-weighted average of the total mass of VOCs per unit volume of applied coating solids (G) during each calendar month for each affected facility using the equations in subd. 1. a. 1), 2), 3) if applicable, and 4).

c. Calculate the volume-weighted average of VOC emissions to the atmosphere (N) during each calendar month by the following equation:

N = G (1- R)

d. If the volume-weighted average mass of VOCs emitted to the atmosphere for each calendar month (N) is equal to or less than 0.90 kilogram per liter of applied coating solids, the affected facility is in compliance.

3. An owner or operator shall use the following procedure for any affected facility that uses a control device for VOC recovery (e.g., carbon adsorber) to comply with the applicable emission limits specified under sub. (3) .

a. Calculate the total mass of VOCs consumed - See PDF for diagram and the volume-weighted average of the total mass of VOCs per unit volume of applied coating solids (G) during each calendar month for each affected facility using the equations in subd. 1. a. 1), 2), 3) if applicable, and 4).

b. Calculate the total mass of VOCs recovered - See PDF for diagram during each calendar month using the following equation: - See PDF for diagram

c. Calculate overall reduction efficiency of the control device (R) for each calendar month for each affected facility using the following equation: - See PDF for diagram

d. Calculate the volume-weighted average mass of VOCs emitted to the atmosphere (N) for each calendar month for each affected facility using equation in subd. 2. c.

e. If the volume-weighted average mass of VOCs emitted to the atmosphere for each calendar month (N) is equal to or less than 0.90 kilogram per liter of applied coatings solids, the affected facility is in compliance. Each monthly calculation is considered a performance test.

(5)   Monitoring of emissions and operations.

(a) The owner or operator of an affected facility that uses a capture system and an incinerator to comply with the emission limits specified under sub. (3) shall install, calibrate, maintain and operate temperature measurement devices as prescribed below:

1. Where thermal incineration is used, a temperature measurement device shall be installed in the firebox. Where catalytic incineration is used, a temperature measurement device shall be installed in the gas stream immediately before and after the catalyst bed.

2. Each temperature measurement device shall be installed, calibrated and maintained according to the manufacturer's specifications. The device shall have an accuracy of the greater of " 0.75% of the temperature being measured expressed in degrees Celsius or " 2.5 ° C.

3. Each temperature measurement device shall be equipped with a recording device so that a permanent continuous record is produced.

(6)   Reporting and recordkeeping requirements.

(a) The reporting requirements of s. NR 440.08 (1) apply only to the initial performance test. Each owner or operator subject to the provisions of this section shall include the following data in the report of the initial performance test required under s. NR 440.08 (1) :

1. Except as provided in subd. 2. , the volume-weighted average mass of VOCs emitted to the atmosphere per volume of applied coating solids (N) for a period of one calendar month from each affected facility.

2. For each affected facility where compliance is determined under the provisions of sub. (4) (b) 1. d. , a list of the coatings used during a period of one calendar month, the VOC content of each coating calculated from data determined using Reference Method 24 of 40 CFR part 60 , Appendix A, incorporated by reference in s. NR 440.17 , or supplied by the coating manufacturer, and the minimum transfer efficiency of any coating application equipment used during the month.

3. For each affected facility where compliance is achieved through use of an incineration system, the following additional information shall be reported:

a. The proportion of total VOCs emitted that enters the control device (F).

b. The VOC reduction efficiency of the control device (E).

c. The average combustion temperature (or the average temperature upstream and downstream of the catalyst bed), and

d. A description of the method used to establish the amount of VOCs captured and sent to the incinerator.

4. For each affected facility where compliance is achieved through use of a solvent recovery system, the following additional information shall be reported:

a. The volume of VOC solvent recovered (L r ), and

b. The overall VOC emission reduction achieved (R).

(b) Following the initial performance test, the owner or operator of an affected facility shall identify, record and submit a written report to the department every calendar quarter of each instance in which the volume-weighted average of the total mass of VOC's emitted to the atmosphere per volume of applied coating solids (N) is greater than the limit specified under sub. (3) . If no instances have occurred during a particular quarter, a report stating this shall be submitted to the department semiannually.

(c) Following the initial performance test, the owner or operator of an affected facility shall identify, record and submit at the frequency specified in s. NR 440.07 (3) the following:

1. Where compliance with sub. (3) is achieved through use of thermal incineration, each 3-hour period of coating operation during which the average temperature of the device was more than 28 ° C (50 ° F) below the average temperature of the device during the most recent performance test at which destruction efficiency was determined as specified under sub. (4) .

2. Where compliance with sub. (3) is achieved through the use of catalytic incineration, each 3-hour period of coating operation during which the average temperature recorded immediately before the catalyst bed is more than 28 ° C (50 ° F) below the average temperature at the same location during the most recent performance test at which destruction efficiency was determined as specified under sub. (4) . Additionally, all 3-hour periods of coating operation during which the average temperature difference across the catalyst bed is less than 80% of the average temperature difference across the catalyst bed during the most recent performance test at which destruction efficiency was determined as specified under sub. (4) shall be recorded.

3. For thermal and catalytic incinerators, if no periods as described in subd. 1. and 2. occur, the owner or operator shall state this in the report.

(d) Each owner or operator subject to the provisions of this section shall maintain at the source for a period of at least 2 years, records of all data and calculations used to determine VOC emissions from each affected facility. Where compliance is achieved through the use of thermal incineration, each owner or operator shall maintain at the source daily records of the incinerator combustion chamber temperature. If catalytic incineration is used, the owner or operator shall maintain at the source daily records of the gas temperature, both upstream and downstream of the incinerator catalyst bed. Where compliance is achieved through the use of a solvent recovery system, the owner or operator shall maintain at the source daily records of the amount of solvent recovered by the system for each affected facility.

(7)   Test methods and procedures.

(a) The reference methods in 40 CFR part 60 , Appendix A, incorporated by reference in s. NR 440.17 , except as provided under s. NR 440.08 (2) , shall be used to determine compliance with sub. (3) as follows:

1. Method 24 or formulation data supplied by the coating manufacturer to determine the VOC content of a coating. In the event of dispute, Method 24 shall be the reference method. For determining compliance only, results of Method 24 analyses of waterborne coatings shall be adjusted as described in section 12.6 of Method 24.

2. Method 25 for the measurement of the VOC concentration in the gas stream vent.

3. Method 1 for sample and velocity traverses.

4. Method 2 for velocity and volumetric flow rate.

5. Method 3 for gas analysis.

6. Method 4 for stack gas moisture.

(b) For Method 24 of 40 CFR part 60 , Appendix A, incorporated by reference in s. NR 440.17 , the coating sample shall be a one-liter sample taken into a one-liter container at a point where the sample will be representative of the coating material.

(c) For Method 25 of 40 CFR part 60 , Appendix A, incorporated by reference in s. NR 440.17 (1) , the sample time for each of 3 runs shall be at least 60 minutes and the minimum sample volume shall be at least 0.003 dscm (0.1 dscf) except that shorter sampling times or smaller volumes, when necessitated by process variables or other factors, may be approved by the department.

(d) The department shall approve sampling of representative stacks on a case-by-case basis if the owner or operator can demonstrate to the satisfaction of the department that the testing of representative stacks would yield results comparable to those that would be obtained by testing all stacks.

History: Cr. Register, January, 1984, No. 337 , eff. 2-1-84; am. (2) (a) (intro.) and (b) (intro.), Register, September, 1990, No. 417 , eff. 10-1-90; am. (2) (a) (intro.), r. and recr. (6) (b) renum. (6) (c) to be (6) (d), cr. (6) (c), Register, June, No. 450 , eff. 8-1-93; CR 06-109 : am. (2) (b) 1. to 23., (4) (b) 1. (intro.) and 3. a., (6) (c) 1. and 2. and (7) (a) 1. and 2. to 5. and (c) Register May 2008 No. 629 , eff. 6-1-08.

Note

Procedures to determine VOC emissions are provided in sub. (4). Microsoft Windows NT 6.1.7601 Service Pack 1