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
NR 440.57(4)(b)2.b.
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).
NR 440.57(4)(b)2.c.
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)
NR 440.57(4)(b)2.d.
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.
NR 440.57(4)(b)3.
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).
NR 440.57(4)(b)3.a.
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).
NR 440.57(4)(b)3.c.
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
NR 440.57(4)(b)3.d.
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.
NR 440.57(4)(b)3.e.
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.
NR 440.57(5)(a)(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:
NR 440.57(5)(a)1.
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.
NR 440.57(5)(a)2.
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.
NR 440.57(5)(a)3.
3. Each temperature measurement device shall be equipped with a recording device so that a permanent continuous record is produced.
NR 440.57(6)(a)(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):
NR 440.57(6)(a)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.
NR 440.57(6)(a)2.
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.
NR 440.57(6)(a)3.
3. For each affected facility where compliance is achieved through use of an incineration system, the following additional information shall be reported:
NR 440.57(6)(a)3.a.
a. The proportion of total VOCs emitted that enters the control device (F).
NR 440.57(6)(a)3.c.
c. The average combustion temperature (or the average temperature upstream and downstream of the catalyst bed), and
NR 440.57(6)(a)3.d.
d. A description of the method used to establish the amount of VOCs captured and sent to the incinerator.
NR 440.57(6)(a)4.
4. For each affected facility where compliance is achieved through use of a solvent recovery system, the following additional information shall be reported:
NR 440.57(6)(b)
(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.
NR 440.57(6)(c)
(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:
NR 440.57(6)(c)1.
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).
NR 440.57(6)(c)2.
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.
NR 440.57(6)(c)3.
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.
NR 440.57(6)(d)
(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.
NR 440.57(7)(a)1.
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.
NR 440.57 Note
Note:
Procedures to determine VOC emissions are provided in sub. (4).
NR 440.57(7)(a)2.
2. Method 25 for the measurement of the VOC concentration in the gas stream vent.
NR 440.57(7)(b)
(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.
NR 440.57(7)(c)
(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.
NR 440.57(7)(d)
(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.
NR 440.57 History
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.
NR 440.58
NR 440.58 Metal coil surface coating. NR 440.58(1)
(1)
Applicability and designation of affected facility. NR 440.58(1)(a)(a) The provisions of this section apply to the following affected facilities in a metal coil surface coating operation: each prime coat operation, each finish coat operation, and each prime and finish coat operation combined when the finish coat is applied wet on wet over the prime coat and both coatings are cured simultaneously.
NR 440.58(1)(b)
(b) Any facility under
par. (a) that commences construction, modification or reconstruction after January 5, 1981, is subject to the requirements of this section.
NR 440.58(2)(a)(a) As used in this section, terms not defined in this paragraph have the meanings given in
s. NR 440.02.
NR 440.58(2)(a)1.
1. “Coating" means any organic material that is applied to the surface of metal coil.
NR 440.58(2)(a)2.
2. “Coating application station" means that portion of the metal coil surface coating operation where the coating is applied to the surface of the metal coil. Included as part of the coating application stations is the flashoff area between the coating application station and the curing oven.
NR 440.58(2)(a)3.
3. “Curing oven" means the device that uses heat or radiation to dry or cure the coating applied to the metal coil.
NR 440.58(2)(a)4.
4. “Finish coat operation" means the coating application station, curing oven and quench station used to apply and dry or cure the final coating or coatings on the surface of the metal coil. Where only a single coating is applied to the metal coil, that coating is considered a finish coat.
NR 440.58(2)(a)5.
5. “Metal coil surface coating operation" means the application system used to apply an organic coating to the surface of any continuous metal strip with thickness of 0.15 millimeter (mm) (0.006 in) or more that is packaged in a roll or coil.
NR 440.58(2)(a)6.
6. “Prime coat operation" means the coating application station, curing oven and quench station used to apply and dry or cure the initial coating or coatings on the surface of the metal coil.
NR 440.58(2)(a)7.
7. “Quench station" means that portion of the metal coil surface coating operation where the coated metal coil is cooled, usually by a water spray, after baking or curing.
NR 440.58(2)(a)8.
8. “VOC content" means the quantity, in kilograms per liter of coating solids, of volatile organic compounds (VOCs) in a coating.
NR 440.58(2)(b)
(b) As used in this section, symbols not defined in this paragraph have the meanings given in
s. NR 440.03.
NR 440.58(2)(b)1.
1. C
a is the VOC concentration in each gas stream leaving the control device and entering the atmosphere (parts per million by volume, as carbon).
NR 440.58(2)(b)2.
2. C
b is the VOC concentration on each gas stream entering the control device (parts per million by volume, as carbon).
NR 440.58(2)(b)3.
3. C
f is the VOC concentration in each gas stream emitted directly to the atmosphere (parts per million by volume, as carbon).
NR 440.58(2)(b)4.
4. D
c is the density of each coating, as received (kilograms per liter).
NR 440.58(2)(b)5.
5. D
d is the density of each VOC solvent added to coatings (kilograms per liter).
NR 440.58(2)(b)6.
6. D
r is the density of VOC solvent recovered by an emission control device (kilograms per liter).
NR 440.58(2)(b)7.
7. E is the VOC destruction efficiency of the control device (fraction).
NR 440.58(2)(b)8.
8. F is the proportion of total VOCs emitted by an affected facility that enters the control device (fraction).
NR 440.58(2)(b)9.
9. G is the volume-weighted average mass of VOCs in coatings consumed in a calendar month per unit volume of coating solids applied (kilograms per liter).
NR 440.58(2)(b)12.
12. L
r is the volume of VOC solvent recovered by an emission control device (liters).
NR 440.58(2)(b)15.
15. M
o is the mass of VOCs in coatings consumed, as received (kilograms).
NR 440.58(2)(b)16.
16. M
r is the mass of VOCs recovered by an emission control device (kilograms).
NR 440.58(2)(b)17.
17. N is the volume-weighted average mass of VOC emissions to the atmosphere per unit volume of coating solids applied (kilograms per liter).
NR 440.58(2)(b)18.
18. Q
a is the volumetric flow rate of each gas stream leaving the control device and entering the atmosphere (dry standard cubic meters per hour).
