Chapter NR 440

NR 440.72(6)(a)1. 1. Method 24 for determination of VOC content of each coating as received.

NR 440.72(6)(a)2. 2. For Method 24, the sample shall be at least a 1-liter sample in a 1-liter container.

NR 440.72(6)(b) (b) Other methods may be used to determine the VOC content of each coating if approved by the administrator before testing.

NR 440.72 History History: Cr. Register, September, 1990, No. 417, eff. 10-1-90; am. (2) (a) 1. a. and 4. (5) (d), renum. (2) (a) 6. to 14. to be (2) (a) 7. to 15. and am. (2) (a) 12. and 13., cr. (2) (a) 6., Register, July, 1993, No. 451, eff. 8-1-93; CR 06-109: am. (4) (b) 1. and 2. a. 4) and (5) (a) 2. Register May 2008 No. 629, eff. 6-1-08; correction in (2) (a) 8. made under s. 13.92 (4) (b) 7., Stats., Register May 2008 No. 629.

NR 440.73 NR 440.73 Calciners and dryers in mineral industries.

NR 440.73(1) (1) Applicability and designation of affected facility.

NR 440.73(1)(a) (a) The affected facility to which this section applies is each calciner and dryer at a mineral processing plant. Feed and product conveyors are not considered part of the affected facility. For the brick and related clay products industry, only the calcining and drying of raw materials prior to firing of the brick are covered.

NR 440.73(1)(b) (b) An affected facility that is subject to s. NR 440.525, Metallic Mineral Processing Plants, is not subject to this section. Also, the following processes and process units used at mineral processing plants are not subject to this section: vertical shaft kilns in the magnesium compounds industry; the chlorination oxidation process in the titanium dioxide industry; coating kilns, mixers and aerators in the roofing granules industry; and tunnel kilns, tunnel dryers, apron dryers, and grinding equipment that also dries the process material used in any of the 17 mineral industries as defined in sub. (2) (e).

NR 440.73(1)(c) (c) The owner or operator of any facility under par. (a) that commences construction, modification or reconstruction after April 23, 1986, is subject to this section.

NR 440.73(2) (2) Definitions. All terms not defined in this section have the meanings given in s. NR 440.02. In this section:

NR 440.73(2)(a) (a) “Calciner” means the equipment used to remove combined (chemically bound) water and/or gases from mineral material through direct or indirect heating. This definition includes expansion furnaces and multiple hearth furnaces.

NR 440.73(2)(b) (b) “Control device” means the air pollution control equipment used to reduce particulate matter emissions released to the atmosphere from one or more affected facilities.

NR 440.73(2)(c) (c) “Dryer” means the equipment used to remove uncombined (free) water from mineral material through direct or indirect heating.

NR 440.73(2)(d) (d) “Installed in series” means a calciner and dryer installed such that the exhaust gases from one flow through the other and then the combined exhaust gases are discharged to the atmosphere.

NR 440.73(2)(e) (e) “Mineral processing plant” means any facility that processes or produces any of the following minerals, their concentrates or any mixture of which the majority (> 50%) is any of the following minerals or a combination of these minerals: alumina, ball clay, bentonite, diatomite, feldspar, fire clay, fuller’s earth, gypsum, industrial sand, kaolin, lightweight aggregate, magnesium compounds, perlite, roofing granules, talc, titanium dioxide, and vermiculite.

NR 440.73(3) (3) Standards for particulate matter. Each owner or operator of any affected facility that is subject to 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 180 days after the initial startup, whichever date comes first. No emissions may be discharged into the atmosphere from any affected facility that does both of the following:

NR 440.73(3)(a) (a) Contains particulate matter in excess of 0.092 gram per dry standard cubic meter (g/dscm) (0.040 grain per dry standard cubic foot (gr/dscf)) for calciners and for calciners and dryers installed in series and in excess of 0.057 g/dscm (0.025 gr/dscf) for dryers.

NR 440.73(3)(b) (b) Exhibits greater than 10% opacity, unless the emissions are discharged from an affected facility using a wet scrubbing control device.

NR 440.73(4) (4) Reconstruction. The cost of replacement of equipment subject to high temperatures and abrasion 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. Calciner and dryer equipment subject to high temperatures and abrasion are: end seals, flights and refractory lining.

NR 440.73(5) (5) Monitoring of emissions and operations.

NR 440.73(5)(a) (a) With the exception of the process units described in pars. (b), (c) and (d), the owner or operator of an affected facility subject to this section who uses a dry control device to comply with the mass emission standard shall install, calibrate, maintain and operate a continuous monitoring system to measure and record the opacity of emissions discharged into the atmosphere from the control device.

NR 440.73(5)(b) (b) In lieu of a continuous opacity monitoring system, the owner or operator of a ball clay vibrating grate dryer, a bentonite rotary dryer, a diatomite flash dryer, a diatomite rotary calciner, a feldspar rotary dryer, a fire clay rotary dryer, an industrial sand fluid bed dryer, a kaolin rotary calciner, a perlite rotary dryer, a roofing granules fluid bed dryer, a roofing granules rotary dryer, a talc rotary calciner, a titanium dioxide spray dryer, a titanium dioxide fluid bed dryer, a vermiculite fluid bed dryer or a vermiculite rotary dryer who uses a dry control device may have a certified visible emissions observer measure and record 3 6-minute averages of the opacity of visible emissions to the atmosphere each day of operation in accordance with Method 9 of Appendix A of 40 CFR part 60, incorporated by reference in s. NR 440.17.

NR 440.73(5)(c) (c) The owner or operator of a ball clay rotary dryer, a diatomite rotary dryer, a feldspar fluid bed dryer, a fuller’s earth rotary dryer, a gypsum rotary dryer, a gypsum flash calciner, a gypsum kettle calciner, an industrial sand rotary dryer, a kaolin rotary dryer, a kaolin multiple hearth furnace, a perlite expansion furnace, a talc flash dryer, a talc rotary dryer, a titanium dioxide direct or indirect rotary dryer or a vermiculite expansion furnace who uses a dry control device is exempt from the monitoring requirements of this subsection.

NR 440.73(5)(d) (d) The owner or operator of an affected facility subject to this section who uses a wet scrubber to comply with the mass emission standard for any affected facility shall install, calibrate, maintain and operate monitoring devices that continuously measure and record the pressure loss of the gas stream through the scrubber and the scrubbing liquid flow rate to the scrubber. The pressure loss monitoring device shall be certified by the manufacturer to be accurate within 5% of water column gauge pressure at the level of operation. The liquid flow rate monitoring device shall be certified by the manufacturer to be accurate within 5% of design scrubbing liquid flow rate.

NR 440.73(6) (6) Recordkeeping and reporting requirements.

NR 440.73(6)(a) (a) Records of the measurements required in sub. (5) shall be retained for at least 2 years.

NR 440.73(6)(b) (b) Each owner or operator who uses a wet scrubber to comply with sub. (3) shall determine and record once each day, from the recordings of the monitoring devices in sub. (5) (d), an arithmetic average over a 2-hour period of both the change in pressure of the gas stream across the scrubber and the flowrate of the scrubbing liquid.

NR 440.73(6)(c) (c) Each owner or operator shall submit written reports semiannually of exceedances of control device operating parameters required to be monitored by sub. (5). For the purpose of these reports, exceedances are defined as follows:

NR 440.73(6)(c)1. 1. All 6-minute periods during which the average opacity from dry control devices is greater than 10%; or

NR 440.73(6)(c)2. 2. Any daily 2-hour average of the wet scrubber pressure drop determined as described in par. (b) that is less than 90% of the average value recorded according to sub. (7) (c) during the most recent performance test that demonstrated compliance with the particulate matter standard; or

NR 440.73(6)(c)3. 3. Each daily wet scrubber liquid flow rate recorded as described in par. (b) that is less than 80% or greater than 120% of the average value recorded according to sub. (7) (c) during the most recent performance test that demonstrated compliance with the particulate matter standard.

NR 440.73(7) (7) Test methods and procedures.

NR 440.73(7)(a) (a) In conducting the performance tests required in s. NR 440.08, the owner or operator shall use the following test methods from 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 440.73(7)(b) (b) The owner or operator shall determine compliance with the particulate matter standards in sub. (3) as follows:

NR 440.73(7)(b)1. 1. Method 5 shall be used to determine the particulate matter concentration. The sampling time and volume for each test run shall be at least 2 hours and 1.70 dscm.

NR 440.73(7)(b)2. 2. Method 9 and the procedures in s. NR 440.11 shall be used to determine opacity from stack emissions.

NR 440.73(7)(c) (c) During the initial performance test of a wet scrubber, the owner or operator shall use the monitoring devices of sub. (5) (d) to determine the average change in pressure of the gas stream across the scrubber and the average flowrate of the scrubber liquid during each of the particulate matter runs. The arithmetic averages of the 3 runs shall be used as the baseline average values for the purposes of sub. (6) (c).

NR 440.73 History History: Cr., Register, December, 1995, No. 480, eff. 1-1-96; CR 06-109: am. (3) (intro.) and (a) Register May 2008 No. 629, eff. 6-1-08.

NR 440.74 NR 440.74 Polymeric coating of supporting substrates facilities.

NR 440.74(1) (1) Applicability and designation of affected facility.

NR 440.74(1)(a) (a) The affected facility to which the provisions of this section apply is each coating operation and any onsite coating mix preparation equipment used to prepare coatings for the polymeric coating of supporting substrates.

NR 440.74(1)(b) (b) Any affected facility for which the amount of VOC used is less than 95 Mg per 12-month period is subject only to the requirements of subs. (5) (b), (8) (b) and (c). If the amount of VOC used is 95 Mg or greater per 12-month period, the facility is subject to all the requirements of this section. Once a facility has become subject to the requirements of this section it will remain subject to those requirements regardless of changes in annual VOC use.

NR 440.74(1)(c) (c) This section applies to any affected facility for which construction, modification or reconstruction begins after April 30, 1987, except for the facilities specified in par. (d).

NR 440.74(1)(d) (d) This section does not apply to the following:

NR 440.74(1)(d)1. 1. Coating mix preparation equipment used to manufacture coatings at one plant for shipment to another plant for use in an affected facility or for sale to another company for use in an affected facility;

NR 440.74(1)(d)2. 2. Coating mix preparation equipment or coating operations during those times they are used to prepare or apply waterborne coatings so long as the VOC content of the coating does not exceed 9% by weight of the volatile fraction;

NR 440.74(1)(d)3. 3. Web coating operations that print an image on the surface of the substrate or any coating applied on the same printing line that applies the image.

NR 440.74(2) (2) Definitions, symbols and cross-reference tables.

NR 440.74(2)(a) (a) All terms used in this section not defined as follows have the meaning given to them in s. NR 440.02.

NR 440.74(2)(a)1. 1. “Coating applicator” means any apparatus used to apply a coating to a continuous substrate.

NR 440.74(2)(a)2. 2. “Coating mix preparation equipment” means all mixing vessels in which solvent and mixing vessels in which solvent and other materials are blended to prepare polymeric coatings.

NR 440.74(2)(a)3. 3. “Coating operation” means any coating applicators, flashoff areas and drying ovens located between a substrate unwind station and a rewind station that coats a continuous web to produce a substrate with a polymeric coating. If the coating process does not employ a rewind station, the end of the coating operation is after the last drying oven in the process.

NR 440.74(2)(a)4. 4. “Common emission control device” means a device controlling emissions from an affected coating operation as well as from any other emission source.

NR 440.74(2)(a)5. 5. “Concurrent” means the period of time in which construction of an emission control device serving an affected facility is commenced or completed, beginning 6 months prior to the date that construction of the affected facility commences and ending 2 years after the date that construction of the affected facility is completed.

NR 440.74(2)(a)6. 6. “Control device” means any apparatus that reduces the quantity of a pollutant emitted to the air.

NR 440.74(2)(a)7. 7. “Cover” means, with respect to coating mix preparation equipment, a device that fits over the equipment opening to prevent emission of volatile organic compounds from escaping.

NR 440.74(2)(a)8. 8. “Drying oven” means a chamber within which heat is used to dry a surface coating; drying may be the only process or one of multiple processes performed in the chamber.

NR 440.74(2)(a)9. 9. “Equivalent diameter” means 4 times the area of an opening divided by its perimeter.

NR 440.74(2)(a)10. 10. “Flashoff area” means the portion of a coating operation between the coating applicator and the drying oven where VOC begins to evaporate from the coated substrate.

NR 440.74(2)(a)11. 11. “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 pressure on either side of the wall or barrier containing the opening.

NR 440.74(2)(a)12. 12. “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.

NR 440.74(2)(a)13. 13. “Onsite coating mix preparation equipment” means those pieces of coating mix preparation equipment located at the same plant as the coating operation they serve.

NR 440.74(2)(a)14. 14. “Polymeric coating of supporting substrates” means a web coating process that applies elastomers, polymers or prepolymers to a supporting web other than paper, plastic film, metallic foil or metal coil.

NR 440.74(2)(a)15. 15. “Substrate” means the surface to which a coating is applied.

NR 440.74(2)(a)16. 16. ‘Temporary enclosure‘ means a total enclosure that is constructed for the sole purpose of measuring the fugitive VOC emissions from an affected facility.

NR 440.74(2)(a)17. 17. “Total enclosure” means a structure that is constructed around a source of emissions and operated so that all VOC emissions are collected and exhausted through a stack or duct. With a total enclosure, there will be no fugitive emission, only stack emissions. The drying oven itself may be part of the total enclosure.

NR 440.74(2)(a)18. 18. “Vapor capture system” means any device or combination of devices designed to contain, collect and route solvent vapors released from the coating mix preparation equipment or coating operation.

NR 440.74(2)(a)19. 19. “VOC in the applied coating” means the product of Method 24 VOC analyses or formulation data, if those data are demonstrated to be equivalent to Method 24 results, and the total volume of coating fed to the coating applicator.

NR 440.74(2)(a)20. 20. “VOC used” means the amount of VOC delivered to the coating mix preparation equipment of the affected facility, including any contained in premixed coatings or other coating ingredients prepared off the plant site, for the formulation of polymeric coatings to be applied to supporting substrates at the coating operation, plus any solvent added after initial formulation is complete, for example, dilution solvents added at the coating operation. If premixed coatings that require no mixing at the plant site are used, “VOC used” means the amount of VOC delivered to the coating applicators of the affected facility.

NR 440.74(2)(a)21. 21. “Volatile organic compounds” or “VOC” means any organic compounds that participate in atmospheric photochemical reactions; or that are measured by a reference method, an equivalent method, an alternative method or that are determined by procedures specified under any section.

NR 440.74(2)(a)22. 22. “Waterborne coating” means a coating which contains more than 5 weight percent water in its volatile fraction.

NR 440.74(2)(a)23. 23. “Web coating” means the coating of products, such as fabric, paper, plastic film, metallic foil, metal coil, cord and yarn, that are flexible enough to be unrolled from a large roll; and coated as a continuous substrate by methods including, but not limited to, knife coating, roll coating, dip coating, impregnation, rotogravure and extrusion.

NR 440.74(2)(b) (b) The nomenclature used in this section has the following meanings:

NR 440.74(2)(b)1. 1. “Ak” means the area of each natural draft opening (k) in a total enclosure, in square meters.

NR 440.74(2)(b)2. 2. “Caj” means the concentration of VOC in each gas stream (j) exiting the emission control device, in parts per million by volume.

NR 440.74(2)(b)3. 3. “Cbi” means the concentration of VOC in each gas stream (i) entering the emission control device, in parts per million by volume.

NR 440.74(2)(b)4. 4. “Cdi” 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.

NR 440.74(2)(b)5. 5. “Cfk” 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.

NR 440.74(2)(b)6. 6. “Cgv” means the concentration of VOC in the gas stream entering each individual carbon absorber vessel (v), in parts per million by volume. For purposes of calculating the efficiency of the individual absorber vessel, Cgv may be measured in the carbon adsorption system’s common inlet duct prior to the branching of individual inlet ducts.

NR 440.74(2)(b)7. 7. “Chv” means the concentration of VOC in the gas stream exiting each individual carbon absorber vessel (v), in parts per million by volume.

NR 440.74(2)(b)8. 8. “E” means the control device efficiency achieved for the duration of the emission test, expressed as a fraction.

NR 440.74(2)(b)9. 9. “F” means the VOC emission capture efficiency of the vapor capture system achieved for the duration of the emission test, expressed as a fraction.

NR 440.74(2)(b)10. 10. “FV” means the average inward face velocity across all natural draft openings in a total enclosure, in meters per hour.

NR 440.74(2)(b)11. 11. “Hv” means the individual carbon absorber vessel (v) efficiency achieved for the duration of the emission test, expressed as a fraction.

NR 440.74(2)(b)12. 12. “Hsys” means the carbon adsorption system efficiency calculated when each absorber vessel has an individual exhaust stack.

NR 440.74(2)(b)13. 13. “Mci” means the total mass (kg) of each coating (i) applied to the substrate at an affected coating operation during a nominal 1-month period as determined from facility records.

NR 440.74(2)(b)14. 14. “Mr” means the total mass (kg) of VOC recovered for a nominal 1-month period.

NR 440.74(2)(b)15. 15. “Qaj” means the volumetric flow rate of each gas stream (i) 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.

NR 440.74(2)(b)16. 16. “Qbi” 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.