Chapter NR 440

NR 440.52 History History: Cr. Register, January, 1984, No. 337, eff. 2-1-84; am. (2) (intro.), Register, September, 1990, No. 417, eff. 10-1-90; r. and recr. (5), Register, July, 1993, No. 451, eff. 8-1-93; correction in (5) (b) 1. made under s. 13.93 (2m) (b) 7., Stats., Register, November, 1999, No. 527; CR 06-109: am. (3) (a) 1., 2., 3., 5. and 6. and (5) (c) 1. Register May 2008 No. 629, eff. 6-1-08.

NR 440.525 NR 440.525 Metallic mineral processing plants.

NR 440.525(1) (1) Applicability and designation of affected facility.

NR 440.525(1)(a) (a) The provisions of this section are applicable to the following affected facilities in metallic mineral processing plants: each crusher and screen in open-pit mines; each crusher, screen, bucket elevator, conveyor belt transfer point, thermal dryer, product packaging station, storage bin, enclosed storage area, truck loading station, truck unloading station, railcar loading station and railcar unloading station at the mill or concentrator with the following exceptions. All facilities located in underground mines are exempted from the provisions of this section. At uranium ore processing plants all facilities subsequent to and including the beneficiation of uranium ore are exempted from the provisions of this section.

NR 440.525(1)(b) (b) An affected facility under par. (a) that commences construction or modification after August 24, 1982, is subject to the requirements of this section.

NR 440.525(2) (2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02.

NR 440.525(2)(a) (a) “Bucket elevator” means a conveying device for metallic minerals consisting of a head and foot assembly that supports and drives an endless single or double strand chain or belt to which buckets are attached.

NR 440.525(2)(b) (b) “Capture system” means the equipment used to capture and transport particulate matter generated by one or more affected facilities to a control device.

NR 440.525(2)(c) (c) “Control device” means the air pollution control equipment used to reduce particulate matter emissions released to the atmosphere from one or more affected facilities at a metallic mineral processing plant.

NR 440.525(2)(d) (d) “Conveyor belt transfer point” means a point in the conveying operation where the metallic mineral or metallic mineral concentrate is transferred to or from a conveyor belt except where the metallic mineral is being transferred to a stockpile.

NR 440.525(2)(e) (e) “Crusher” means a machine used to crush any metallic mineral and includes feeders or conveyors located immediately below the crushing surfaces. Crushers include, but are not limited to, the following types: jaw, gyratory, cone and hammermill.

NR 440.525(2)(f) (f) “Enclosed storage area” means any area covered by a roof under which metallic minerals are stored prior to future processing or loading.

NR 440.525(2)(g) (g) “Metallic mineral concentrate” means a material containing metallic compounds in concentrations higher than naturally occurring in ore but requiring additional processing if pure metal is to be isolated. A metallic mineral concentrate contains at least one of the following metals in any of its oxidation states and at a concentration that contributes to the concentrate’s commercial value: aluminum, copper, gold, iron, lead, molybdenum, silver, titanium, tungsten, uranium, zinc and zirconium. This definition may not be construed as requiring that material containing metallic compounds be refined to a pure metal in order for the material to be considered a metallic mineral concentrate to be covered by the standards.

NR 440.525(2)(h) (h) “Metallic mineral processing plant” means any combination of equipment that produces metallic mineral concentrates from ore. Metallic mineral processing commences with the mining of ore and includes all operations either up to and including the loading of wet or dry concentrates or solutions of metallic minerals for transfer to facilities at nonadjacent locations that will subsequently process metallic concentrates into purified metals (or other products) or up to and including all material transfer and storage operations that precede the operations that produce refined metals (or other products) from metallic mineral concentrates at facilities adjacent to the metallic mineral processing plant. This definition may not be construed as requiring that mining of ore be conducted in order for the combination of equipment to be considered a metallic mineral processing plant. (See also the definition of “metallic mineral concentrate.” )

NR 440.525(2)(i) (i) “Process fugitive emissions” means particulate matter emissions from an affected facility that are not collected by a capture system.

NR 440.525(2)(j) (j) “Product packaging station” means the equipment used to fill containers with metallic compounds or metallic mineral concentrates.

NR 440.525(2)(k) (k) “Railroad loading station” means that portion of a metallic mineral processing plant where metallic minerals or metallic mineral concentrates are loaded by a conveying system into railcars.

NR 440.525(2)(L) (L) “Railcar unloading station” means that portion of a metallic mineral processing plant where metallic ore is unloaded from a railcar into a hopper, screen or crusher.

NR 440.525(2)(m) (m) “Screen” means a device for separating material according to size by passing undersize material through one or more mesh surfaces (screens) in series and retaining oversize material on the mesh surfaces (screens).

NR 440.525(2)(n) (n) “Stack emissions” means the particulate matter captured and released to the atmosphere through a stack, chimney or flue.

NR 440.525(2)(o) (o) “Storage bin” means a facility for storage (including surge bins and hoppers) of metallic minerals prior to further processing or loading.

NR 440.525(2)(p) (p) “Surface moisture” means water that is not chemically bound to a metallic mineral or metallic mineral concentrate.

NR 440.525(2)(q) (q) “Thermal dryer” means a unit in which the surface moisture content of a metallic mineral or a metallic mineral concentrate is reduced by direct or indirect contact with a heated gas system.

NR 440.525(2)(r) (r) “Truck loading station” means that portion of a metallic mineral processing plant where metallic minerals or metallic mineral concentrates are loaded by a conveying system into trucks.

NR 440.525(2)(s) (s) “Truck unloading station” means that portion of a metallic mineral processing plant where metallic ore is unloaded from a truck into a hopper, screen, or crusher.

NR 440.525(3) (3) Standard for particulate matter.

NR 440.525(3)(a) (a) On and after the date on which the performance test required to be conducted by s. NR 440.08 is completed no owner or operator subject to the provisions of this section may cause to be discharged into the atmosphere from an affected facility any stack emissions that:

NR 440.525(3)(a)1. 1. Contain particulate matter in excess of 0.050 grams per dry standard cubic meter (0.022 gr/dscf).

NR 440.525(3)(a)2. 2. Exhibit greater than 7% opacity unless the stack emissions are discharged from an affected facility using a wet scrubbing emission control device.

NR 440.525(3)(b) (b) On and after the sixtieth day after achieving the maximum production rate at which the affected facility will be operated, but not later than 180 days after initial startup, no owner or operator subject to the provisions of this section may cause to be discharged into the atmosphere from an affected facility any process fugitive emissions that exhibit greater than 10% opacity.

NR 440.525(4) (4) Reconstruction.

NR 440.525(4)(a) (a) The cost of replacement of ore-contact surfaces on processing equipment may not be considered in calculating either the “fixed capital cost of the new components” or the “fixed capital cost that would be required to construct a comparable new facility” under s. NR 440.15. Ore-contact surfaces are: crushing surfaces; screen meshes; bars, and plates; conveyor belts; elevator buckets; and pan feeders.

NR 440.525(4)(b) (b) Under s. NR 440.15 the “fixed capital cost of the new components” includes the fixed capital cost of all depreciable components (except components specified in par. (a) that are or will be replaced pursuant to all continuous programs of component replacement commenced within any 2-year period following August 24, 1982.

NR 440.525(5) (5) Monitoring of operations.

NR 440.525(5)(a) (a) The owner or operator subject to the provisions of this section shall install, calibrate, maintain and operate a monitoring device for the continuous measurement of the change in pressure of the gas stream through the scrubber for any affected facility using a wet scrubber emission control device. The monitoring device must be certified by the manufacturer to be accurate within ±250 pascals (±1 inch water) gauge pressure and must be calibrated on an annual basis in accordance with manufacturer’s instructions.

NR 440.525(5)(b) (b) The owner or operator subject to the provisions of this section shall install, calibrate, maintain and operate a monitoring device for the continuous measurement of the scrubbing liquid flow rate to a wet scrubber for any affected facility using any type of wet scrubbing emission control device. The monitoring device must be certified by the manufacturer to be accurate within ± 5% of design scrubbing liquid flow rate and must be calibrated on at least an annual basis in accordance with manufacturer’s instructions.

NR 440.525(6) (6) Recordkeeping and reporting requirements.

NR 440.525(6)(a) (a) The owner or operator subject to the provisions of this section shall conduct a performance test and submit to the department a written report of the results of the test as specified in s. NR 440.08 (1).

NR 440.525(6)(b) (b) During the initial performance test of a wet scrubber, and at least weekly thereafter, the owner or operator shall record the measurements of both the change in pressure of the gas stream across the scrubber and the scrubbing liquid flow rate.

NR 440.525(6)(c) (c) After the initial performance test of a wet scrubber, the owner or operator shall submit semiannual reports to the department of occurrences when the measurements of the scrubber pressure loss or gain or liquid flow rate differ by more than ±30% from the average obtained during the most recent performance test.

NR 440.525(7) (7) Test methods and procedures.

NR 440.525(7)(a) (a) In conducting the performance tests required in s. NR 440.08, the owner or operator shall use as reference methods and procedures the test methods in Appendix A of 40 CFR part 60, incorporated by reference in s. NR 440.17, or other methods and procedures as specified in this subsection, except as provided in s. NR 440.08 (2).

NR 440.525(7)(b) (b) The owner or operator shall determine compliance with the particulate matter standards sub. (3) as follows:

NR 440.525(7)(b)1. 1. Method 5 or 17 shall be used to determine the particulate matter concentration. The sample volume for each run shall be at least 1.70 dscm (60 dscf). The sampling probe and filter holder of Method 5 may be operated without heaters if the gas stream being sampled is at ambient temperature. For gas streams above ambient temperature, the Method 5 sampling train shall be operated with a probe and filter temperature slightly above the effluent temperature, up to a maximum filter temperature of 121°C (250°F), in order to prevent water condensation on the filter.

NR 440.525(7)(b)2. 2. Method 9 and the procedures in s. NR 440.11 shall be used to determine opacity from stack emissions and process fugitive emissions. The observer shall read opacity only when emissions are clearly identified as emanating solely from the affected facility being observed.

NR 440.525(7)(c) (c) To comply with sub. (6) (c) the owner or operator shall use the monitoring devices in sub. (5) (a) and (b) to determine the pressure loss of the gas stream through the scrubber and scrubbing liquid flow rate at any time during each particulate matter run, and the average of the 3 determinations shall be computed.

NR 440.525 History History: Cr. Register, September, 1986, No. 369, eff. 10-1-86; renum. to be NR 440.525 and r. (6) (e), am. (2) (intro.), (g), (h), (3) (a) (intro.), 1. and (b), (4) (a), Register, September, 1990, No. 417, eff. 10-1-90; am. (6) (c), r. and recr. (7), Register, July, 1993, No. 451, eff. 8-1-93; CR 06-109: am. (2) (o), (3) (a) 1. and (6) (c) Register May 2008 No. 629, eff. 6-1-08.

NR 440.53 NR 440.53 Automobile and light-duty truck surface coating operations.

NR 440.53(1) (1) Applicability and designation of affected facility.

NR 440.53(1)(a) (a) The provisions of this section apply to the following affected facilities in an automobile or light-duty truck assembly plant: each prime coat operation, each guide coat operation and each topcoat operation.

NR 440.53(1)(b) (b) Exempt from the provisions of this section are operations used to coat plastic body components or all-plastic automobile or light-duty truck bodies on separate coating lines. The attachment of plastic body parts to a metal body before the body is coated does not cause the metal body coating operation to be exempted.

NR 440.53(1)(c) (c) Any facility under par. (a) that commences construction, reconstruction or modification after October 5, 1979 is subject to the requirements of this section.

NR 440.53(2) (2) Definitions and symbols.

NR 440.53(2)(a) (a) As used in this section, terms not defined in this paragraph have the meanings given in s. NR 440.02.

NR 440.53(2)(a)1. 1. “Applied coating solids” means the volume of dried or cured coating solids which is deposited and remains on the surface of the automobile or light-duty truck body.

NR 440.53(2)(a)2. 2. “Automobile” means a motor vehicle capable of carrying no more than 12 passengers.

NR 440.53(2)(a)3. 3. “Automobile and light-duty truck body” means the exterior surface of an automobile or light-duty truck including hoods, fenders, cargo boxes, doors and grill opening panels.

NR 440.53(2)(a)4. 4. “Bake oven” means a device that uses heat to dry or cure coatings.

NR 440.53(2)(a)5. 5. “Electrodeposition” or “EDP” means a method of applying a prime coat by which the automobile or light-duty truck body is submerged in a tank filled with coating material and an electrical field is used to effect the deposition of the coating material on the body.

NR 440.53(2)(a)6. 6. “Electrostatic spray application” means a spray application method that uses an electrical potential to increase the transfer efficiency of the coating solids. Electrostatic spray application can be used for prime coat, guide coat or topcoat operations.

NR 440.53(2)(a)6e. 6e. “Flashoff area” means the structure on automobile and light-duty truck assembly lines between the coating application system (dip tank or spray booth) and the bake oven.

NR 440.53(2)(a)6g. 6g. “Guide coat operation” means the guide coat spray booth, flashoff area and bake ovens which are used to apply and dry or cure a surface coating between the prime coat and topcoat operation on the components of automobile and light-duty truck bodies.

NR 440.53(2)(a)6k. 6k. “Light-duty truck” means any motor vehicle rated at 3,850 kilograms gross vehicle weight or less, designed mainly to transport property.

NR 440.53(2)(a)6p. 6p. “Plastic body” means an automobile or light-duty truck body constructed of synthetic organic material.

NR 440.53(2)(a)7. 7. “Plastic body component” means any component of an automobile or light-duty truck exterior surface constructed of synthetic organic material.

NR 440.53(2)(a)8. 8. “Prime coat operation” means the prime coat spray booth or dip tank, flashoff area and bake oven or ovens which are used to apply and dry or cure the initial coating on components of automobile or light-duty truck bodies.

NR 440.53(2)(a)9. 9. “Purge” or “line purge” means the coating material expelled from the spray system when clearing it.

NR 440.53(2)(a)10. 10. “Solventborne” means a coating which contains 5% or less water by weight in its volatile fraction.

NR 440.53(2)(a)11. 11. “Spray application” means a method of applying coatings by atomizing the coating material and directing the atomized material toward the part to be coated. Spray applications can be used for prime coat, guide coat and topcoat operations.

NR 440.53(2)(a)12. 12. “Spray booth” means a structure housing automatic or manual spray application equipment where prime coat, guide coat or topcoat is applied to components of automobile or light-duty truck bodies.

NR 440.53(2)(a)13. 13. “Surface coating operation” means any prime coat, guide coat or topcoat operation on an automobile or light-duty truck surface coating line.

NR 440.53(2)(a)14. 14. “Topcoat operation” means the topcoat spray booth, flashoff area and bake oven or ovens which are used to apply and dry or cure the final coating or coatings on components of automobile and light-duty truck bodies.

NR 440.53(2)(a)15. 15. “Transfer efficiency” means the ratio of the amount of coating solids transferred onto the surface of a part or product to the total amount of coating solids used.

NR 440.53(2)(a)16. 16. “VOC content” means all volatile organic compounds that are in a coating expressed as kilograms of VOC per liter of coating solids.

NR 440.53(2)(a)17. 17. “Waterborne” or “water reducible” means a coating which contains more than 5 weight percent water in its volatile fraction.

NR 440.53(2)(b) (b) As used in this section, symbols not defined in this paragraph have the meanings given in s. NR 440.03.

NR 440.53(2)(b)1. 1. Caj is the concentration of VOC (as carbon) in the effluent gas flowing through stack (j) leaving the control device (parts per million by volume).

NR 440.53(2)(b)2. 2. Cbi is the concentration of VOC (as carbon) in the effluent gas flowing through stack (i) entering the control device (parts per million by volume).

NR 440.53(2)(b)3. 3. Cfk is the concentration of VOC (as carbon) in the effluent gas flowing through exhaust stack (k) not entering the control device (parts per million by volume).

NR 440.53(2)(b)4. 4. Dci is the density of each coating (i) as received (kilograms per liter).

NR 440.53(2)(b)5. 5. Ddj is the density of each type VOC dilution solvent (j) added to the coatings, as received (kilograms per liter).

NR 440.53(2)(b)6. 6. Dr is the density of VOC recovered from an affected facility (kilograms per liter).

NR 440.53(2)(b)7. 7. E is the VOC destruction or removal efficiency of the control device.

NR 440.53(2)(b)8. 8. F is the fraction of total VOC which is emitted by an affected facility that enters the control device.

NR 440.53(2)(b)9. 9. G is the volume weighted average mass of VOC per volume of applied solids (kilograms per liter).

NR 440.53(2)(b)10. 10. Lci is the volume of each coating (i) consumed, as received (liters).

NR 440.53(2)(b)11. 11. Lcil is the volume of each coating (i) consumed by each application method (l), as received (liters).

NR 440.53(2)(b)12. 12. Ldj is the volume of each type VOC dilution solvent (j) added to the coatings, as received (liters).

NR 440.53(2)(b)13. 13. Lr is the volume of VOC recovered from an affected facility (liters).