NR 440.525 HistoryHistory: 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 440.53NR 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)(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). NR 440.53(2)(b)17.17. Mr is the total mass of VOC recovered from an affected facility (kilograms). NR 440.53(2)(b)18.18. N is the volume weighted average mass of VOC per volume of applied coating solids after the control device, NR 440.53(2)(b)19.19. Qaj is the volumetric flow rate of the effluent gas flowing through stack (j) leaving the control device (dry standard cubic meters per hour). NR 440.53(2)(b)20.20. Qbi is the volumetric flow rate of the effluent gas flowing through stack (i) entering the control device (dry standard cubic meters per hour). NR 440.53(2)(b)21.21. Qfk is the volumetric flow rate of the effluent gas flowing through exhaust stack (k) not entering the control device (dry standard cubic meters per hour). NR 440.53(2)(b)24.24. Vsi is the proportion of solids by volume in each coating (i) as received, NR 440.53(2)(b)25.25. Woi is the proportion of VOC by weight in each coating (i), as received, NR 440.53(3)(3) Standards for volatile organic compounds. On and after the date on which the initial performance test required by s. NR 440.08 is completed, no owner or operator subject to the provisions of this section may discharge or cause the discharge into the atmosphere from any affected facility VOC emissions in excess of: NR 440.53(3)(a)(a) 0.16 kilograms of VOC per liter of applied coating solids from each prime coat operation. NR 440.53(3)(b)(b) 1.40 kilograms of VOC per liter of applied coating solids from each guide coat operation. NR 440.53(3)(c)(c) 1.47 kilograms of VOC per liter of applied coating solids from each topcoat operation. NR 440.53(4)(b)(b) The owner or operator of an affected facility shall conduct an initial performance test in accordance with s. NR 440.08 (1), and thereafter for each calendar month for each affected facility according to the procedures in this subsection. NR 440.53(4)(c)(c) The owner or operator shall use the following procedures for determining the monthly volume weighted average mass of VOC emitted per volume of applied coating solids. NR 440.53(4)(c)1.1. The owner or operator shall use the following procedures for each affected facility which does not use a capture system and a control device to comply with the applicable emission limit specified under sub. (3). NR 440.53(4)(c)1.a.a. Calculate the volume weighted average mass of VOC per volume of applied coating solids for each calendar month for each affected facility. The owner or operator shall determine the composition of the coatings by formulation data supplied by the manufacturer of the coating or from data determined by an analysis of each coating, as received, by 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 coating to determine data used in the calculation of the VOC content of coatings by Method 24 or an equivalent or alternative method. The owner or operator shall determine from company records on a monthly basis the volume of coating consumed, as received, and the mass of solvent used for thinning purposes. The volume weighted average of the total mass of VOC per volume of coating solids used each calendar month shall be determined by the following procedures: 1) Calculate the mass of VOC used in each calendar month for each affected facility by the following equation where “n” is the total number of coatings used and “m” is the total number of VOC solvents used: (∑ Ldj Ddj will be zero if no VOC solvent is added to the coatings, as received.)
2) Calculate the total volume of coating solids used in each calendar month for each affected facility by the following equation where“n” is the total number of coatings used: 3) Select the appropriate transfer efficiency (T) from the following tables for each surface coating operation:
Table 1 - Transfer Efficiencies
The values in the table above represent an overall system efficiency which includes a total capture of purge. If a spray system uses line purging after each vehicle and does not collect any of the purge material, the following table shall be used:
Table 2 - Transfer Efficiencies
NR 440.53 NoteNote: Under 40 CFR 60.393 (c) (1) (i) (C), if the owner or operator can justify to the administrator’s satisfaction that other values for transfer efficiencies are appropriate, the administrator will approve their use on a case-by-case basis. j) When more than one application method (l) is used on an individual surface coating operation, the owner or operator shall perform an analysis to determine an average transfer efficiency by the following equation where “n” is the total number of coatings used and “p” is the total number of application methods:
4) Calculate the volume weighted average mass of VOC per volume of applied coating solids (G) during each calendar month for each affected facility by the following equation: NR 440.53(4)(c)1.b.b. If the volume weighted average mass of VOC per volume of applied coating solids (G), calculated on a calendar month basis, is less than or equal to the applicable emission limit specified in sub. (3), the affected facility is in compliance. Each monthly calculation is a performance test for the purpose of this section. NR 440.53(4)(c)2.2. The owner or operator shall use the following procedures for each affected facility which uses a capture system and a control device that destroys VOC (e.g., incinerator) to comply with the applicable emission limit specified under sub. (3). NR 440.53(4)(c)2.a.a. Calculate the volume weighted average mass of VOC per volume of applied coating solids (G) during each calendar month for each affected facility as described under subd. 1. a. NR 440.53(4)(c)2.b.b. Calculate the volume weighted average mass of VOC per volume of applied solids emitted after the control device, by the following equation: 1) Determine the fraction of total VOC which is emitted by an affected facility that enters the control device by using the following equation where “n” is the total number of stacks entering the control device and “p” is the total number of stacks not connected to the control device: If the owner can justify to the department’s satisfaction that another method will give comparable results, the department shall approve its use on a case-by-case basis.
a) In subsequent months, the owner or operator shall use the most recently determined capture fraction for the performance test.
2) Determine the destruction efficiency of the control device using values of the volumetric flow rate 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 where “n” is the total number of stacks entering the control device and “m” is the total number of stacks leaving the control device: a) In subsequent months, the owner or operator shall use the most recently determined VOC destruction efficiency for the performance test.
3) If an emission control device controls the emissions from more than one affected facility, the owner or operator shall measure the VOC concentration in the effluent gas entering the control device (in parts per million by volume) and the volumetric flow rate of the effluent gas (in dry standard cubic meters per hour) entering the device through each stack. The destruction or removal efficiency determined using these data shall be applied to each affected facility served by the control device. NR 440.53(4)(c)2.c.c. If the volume weighted average mass of VOC per volume of applied solids emitted after the control device (N) calculated on a calendar month basis is less than or equal to the applicable emission limit specified in sub. (3), the affected facility is in compliance. Each monthly calculation is a performance test for the purposes of this section. NR 440.53(4)(c)3.3. The owner or operator shall use the following procedures for each affected facility which uses a capture system and a control device that recovers the VOC (e.g., carbon adsorber) to comply with the applicable emission limit specified under sub. (3). NR 440.53(4)(c)3.a.a. Calculate the mass of VOC used during each calendar month for each affected facility as described under subd. 1. a.
