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).
NR 440.58(2)(b)19.
19. Q
b is the volumetric flow rate of each gas stream entering the control device (dry standard cubic meters per hour).
NR 440.58(2)(b)20.
20. Q
f is the volumetric flow rate of each gas stream emitted directly to the atmosphere (dry standard cubic meters per hour).
NR 440.58(2)(b)21.
21. R is the overall VOC emission reduction achieved for an affected facility (fraction).
NR 440.58(2)(b)22.
22. S is the calculated monthly allowable emission limit (kilograms of VOC per liter of coating solids applied).
NR 440.58(2)(b)23.
23. V
s is the proportion of solids in each coating as received (fraction by volume).
NR 440.58(2)(b)24.
24. W
o is the proportion of VOCs in each coating, as received (fraction by weight).
NR 440.58(3)(a)(a) On and after the date on which
s. NR 440.08 requires a performance test to be completed, each owner or operator subject to this section may not cause to be discharged into the atmosphere more than:
NR 440.58(3)(a)1.
1. 0.28 kilogram VOC per liter (kg VOC/l) of coating solids applied for each calendar month for each affected facility that does not use an emission control device; or
NR 440.58(3)(a)2.
2. 0.14 kg VOC/l of coating solids applied for each calendar month for each affected facility that continuously uses an emission control device operated at the most recently demonstrated overall efficiency; or
NR 440.58(3)(a)3.
3. 10% of the VOCs applied for each calendar month (90% emission reduction) for each affected facility that continuously uses an emission control device operated at the most recently demonstrated overall efficiency; or
NR 440.58(3)(a)4.
4. A value between 0.14 (or a 90% emission reduction) and 0.28 kg/VOC/l of coating solids applied for each calendar month for each affected facility that intermittently uses an emission control device operated at the most recently demonstrated overall efficiency.
NR 440.58(4)
(4) Performance test and compliance provisions. NR 440.58(4)(b)
(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 for each calendar month for each affected facility according to the procedures in this subsection.
NR 440.58(4)(c)
(c) The owner or operator shall use the following procedures for determining monthly volume-weighted average emissions of VOCs in kg/l of coating solids applied.
NR 440.58(4)(c)1.
1. An owner or operator shall use the following procedures for each affected facility that does not use a capture system and control device to comply with the emission limit specified under
sub. (3) (a) 1. The owner or operator shall determine the composition of the coatings by formulation data supplied by the manufacturer of the coating or by an 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 manufacturer of the coatings to determine the VOC content of coatings using Method 24 or an equivalent or alternative method. The owner or operator shall determine the volume of coating and the mass of VOC solvent added to coatings 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 coating used at each affected 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.
NR 440.58(4)(c)1.a.
a. Calculate the volume-weighted average of the total mass of VOCs consumed per unit volume of coating solids applied during each calendar month for each affected facility, except as provided under
subd. 1. d. The weighted average of the total mass of VOCs used per unit volume of coating solids applied each calendar month shall be determined by the following procedures.
1) Calculate the mass of VOCs used (M
o+ M
d) during each calendar month for each affected facility by the following equation: -
See PDF for diagram 
(S Ldj Ddj 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 calendar month
m is the number of different VOC solvents added to coatings used during the calendar month
2) Calculate the total volume of coating solids used (L
s) in each 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) Calculate the volume-weighted average mass of VOCs used per unit volume of coating solids applied (G) during the calendar month for each affected facility by the following equation: -
See PDF for diagram
NR 440.58(4)(c)1.b.
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
NR 440.58(4)(c)1.c.
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 0.28 kg/l, the affected facility is in compliance.
NR 440.58(4)(c)1.d.
d. If each individual coating used by an affected facility has a VOC content, as received, that is equal to or less than 0.28 kg/l of coating solids, the affected facility is in compliance provided no VOCs are added to the coatings during distribution or application.
NR 440.58(4)(c)2.
2. An owner or operator shall use the following procedures for each affected facility that continuously 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) 2. or
3.
NR 440.58(4)(c)2.a.
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 paragraph shall be repeated when requested 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:
l 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
The owner or operator of the affected facility shall construct the 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. (7). The owner or operator of the affected facility shall construct a temporary enclosure around the coating applicator and flashoff area during the performance test for the purpose of evaluating the capture efficiency of the system. The enclosure shall be maintained at a negative pressure to ensure that all VOC emissions are measurable. If a permanent enclosure exists in the affected facility prior to the performance test and the department is satisfied that the enclosure is adequately containing VOC emissions, no additional enclosure is required for the performance test.
3) Determine overall reduction efficiency (R) using the following equation:
R = EF
If the overall reduction efficiency (R) is equal to or greater than 0.90, the affected facility is in compliance and no further computations are necessary. If the overall reduction efficiency (R) is less than 0.90, the average total VOC emissions to the atmosphere per unit volume of coating solids applied (N) shall be computed as specified in subd. 2. b., c. and d.
NR 440.58(4)(c)2.b.
b. Calculate the volume-weighted average of the total mass of VOCs per unit volume of coating solids applied (G) during each calendar month for each affected facility using equations in
subd. 1. a. 1), 2), and 3).
