NR 440.58(5)(a)(a) Where compliance with the numerical limit specified in sub. (3) (a) 1. or 2. is achieved through the use of low VOC-content coatings without the use of emission control devices or through the use of higher VOC-content coatings in conjunction with emission control devices, the owner or operator shall compute and record the average VOC content of coatings applied during each calendar month for each affected facility according to the equations provided in sub. (4). NR 440.58(5)(b)(b) Where compliance with the limit specified in sub. (3) (a) 4. is achieved through the intermittent use of emission control devices, the owner or operator shall compute and record for each affected facility the average VOC content of coatings applied during each calendar month according to the equations provided in sub. (4). NR 440.58(5)(c)(c) If thermal incineration is used, each owner or operator subject to the provisions of this section shall install, calibrate, operate and maintain a device that continuously records the combustion temperature of any effluent gases incinerated to achieve compliance with sub. (3) (a) 2., 3. or 4. This device shall have an accuracy of ± 2.5°C or ± 0.75% of the temperature being measured expressed in degrees Celsius, whichever is greater. Each owner or operator shall also record all periods (during actual coating operations) in excess of 3 hours during which the average temperature in any thermal incinerator used to control emissions from an affected facility remains more than 28°C (50°F) below the temperature at which compliance with sub. (3) (a) 2., 3. or 4. was demonstrated during the most recent measurement of incinerator efficiency required by s. NR 440.08. The records required by s. NR 440.07 shall identify each such occurrence and its duration. If catalytic incineration is used, the owner or operator shall install, calibrate, operate and maintain a device to monitor and record continuously the gas temperature both upstream and downstream of the incinerator catalyst bed. This device shall have an accuracy of ± 2.5°C or ± 0.75% of the temperature being measured expressed in degrees Celsius, whichever is greater. During coating operations, the owner or operator shall record all periods in excess of 3 hours where the average difference between the temperature upstream and downstream of the incinerator catalyst bed remains below 80% of the temperature difference at which compliance was demonstrated during the most recent measurement of incinerator efficiency or when the inlet temperature falls more than 28°C (50°F) below the temperature at which compliance with sub. (3) (a) 2., 3. or 4. was demonstrated during the most recent measurement of incinerator efficiency required by s. NR 440.08. The records required by s. NR 440.07 shall identify each such occurrence and its duration. NR 440.58(6)(a)(a) Where compliance with the numerical limit specified in sub. (3) (a) 1., 2. or 4. is achieved through the use of low VOC-content coatings without emission control devices or through the use of higher VOC-content coatings in conjunction with emission control devices, each owner or operator subject to the provisions of this section shall include in the initial compliance report required by s. NR 440.08 the weighted average of the VOC content of coatings used during a period of one calendar month for each affected facility. Where compliance with sub. (3) (a) 4. is achieved through the intermittent use of a control device, reports shall include separate values of the weighted average VOC content of coatings used with and without the control device in operation. NR 440.58(6)(b)(b) Where compliance with sub. (3) (a) 2., 3. or 4. is achieved through the use of an emission control device that destroys VOCs, each owner or operator subject to the provisions of this section shall include the following data in the initial compliance report required by s. NR 440.08: NR 440.58(6)(b)2.2. The combustion temperature of the thermal incinerator or the gas temperature, both upstream and downstream of the incinerator catalyst bed, used to attain compliance with sub. (3) (a) 2., 3. or 4. NR 440.58(6)(c)(c) 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 local mass of VOCs 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 440.58(6)(d)(d) The owner or operator of each affected facility shall also submit reports at the frequency specified in s. NR 440.07 (3) when the incinerator temperature drops as defined under sub. (5) (c). If no periods occur, the owner or operator shall state this in the report. NR 440.58(6)(e)(e) 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 monthly VOC emissions from each affected facility and to determine the monthly emission limit where applicable. 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 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. NR 440.58(7)(a)1.1. Method 24, or data provided by the formulator of the coating, shall be used for determining the VOC content of each coating as applied to the surface of the metal coil. In the event of a dispute, Method 24 shall be the reference method. When VOC content of waterborne coatings, determined by Method 24, is used to determine compliance of affected facilities, the results of the Method 24 analysis shall be adjusted as described in section 12.6 of Method 24. NR 440.58(7)(a)2.2. Method 25, both for measuring the VOC concentration in each gas stream entering and leaving the control device on each stack equipped with an emission control device and for measuring the VOC concentration in each gas stream emitted directly to the atmosphere. NR 440.58(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 at least a one-liter sample taken at a point where the sample will be representative of the coating as applied to the surface of the metal coil. NR 440.58(7)(c)(c) For Method 25 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17 (1), the sampling time shall be at least 60 minutes, and the minimum sample volume shall be at least 0.003 dscm (0.11 dscf); however, shorter sampling times or smaller volumes, when necessitated by process variables or other factors, may be approved by the department. NR 440.58(7)(d)(d) The department shall approve testing of representative stacks on a case-by-case basis if the owner or operator can demonstrate to the satisfaction of the department that testing of representative stacks yields results comparable to those that would be obtained by testing all stacks. NR 440.58 HistoryHistory: Cr. Register, January, 1984, No. 337, eff. 2-1-84; am. (2) (a) (intro.), (b) (intro.) and (4) (c) 2. a. 2), Register, September, 1990, No. 417, eff. 10-1-90; renum. (6) (c) to be (6) (e), cr. (6) (c) and (d), Register, June, 1993, No. 450, eff. 8-1-93; CR 06-109: am. (2) (b) 1. to 24., (4) (c) 1. (intro.) and (7) (a) 1. to 5. and (c) Register May 2008 No. 629, eff. 6-1-08. NR 440.59NR 440.59 Asphalt processing and asphalt roofing manufacture. NR 440.59(1)(1) Applicability and designation of affected facilities. NR 440.59(1)(a)(a) The affected facilities to which this section applies are each saturator and each mineral handling and storage facility at asphalt roofing plants; and each asphalt storage tank and each blowing still at asphalt processing plants, petroleum refineries and asphalt roofing plants. NR 440.59(1)(b)(b) Any saturator or mineral handling and storage facility under par. (a) that commences construction or modification after November 18, 1980 is subject to the requirements of this section. Any asphalt storage tank or blowing still that processes or stores, or both processes and stores, asphalt used for roofing only or for roofing and other purposes, and that commences construction or modification after November 18, 1980 is subject to the requirements of this section. Any asphalt storage tank or blowing still that processes or stores, or both processes and stores, only nonroofing asphalts and that commences construction or modification after May 26, 1981 is subject to the requirements of this section. NR 440.59(2)(2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02. NR 440.59(2)(a)(a) “Afterburner” or “A/B” means an exhaust gas incinerator used to control emissions of particulate matter. NR 440.59(2)(b)(b) “Asphalt processing” means the storage and blowing of asphalt. NR 440.59(2)(c)(c) “Asphalt processing plant” means a plant which blows asphalt for use in the manufacture of asphalt products. NR 440.59(2)(d)(d) “Asphalt roofing plant” means a plant which produces asphalt roofing products (shingles, roll roofing, siding or saturated felt). NR 440.59(2)(e)(e) “Asphalt storage tank” means any tank used to store asphalt at asphalt roofing plants, petroleum refineries and asphalt processing plants. Storage tanks containing cutback asphalts (asphalts diluted with solvents to reduce viscosity for low temperature applications) and emulsified asphalts (asphalts dispersed in water with an emulsifying agent) are not included. NR 440.59(2)(f)(f) “Blowing still” means the equipment in which air is blown through asphalt flux to change the softening point and penetration rate. NR 440.59(2)(g)(g) “Catalyst” means a substance which, when added to asphalt flux in a blowing still, alters the penetrating-softening point relationship or increases the rate of oxidation of the flux. NR 440.59(2)(h)(h) “Coating blow” means the process in which air is blown through hot asphalt flux to produce coating asphalt. The coating blow starts when the air is turned on and stops when the air is turned off. NR 440.59(2)(i)(i) “Electrostatic precipitator” or “ESP” means an air pollution control device in which solid or liquid particulates in a gas stream are charged as they pass through an electric field and precipitated on a collection surface. NR 440.59(2)(j)(j) “High velocity air filter” or “HVAF” means an air pollution control filtration device for the removal of sticky, oily or liquid aerosol particulate matter from exhaust gas streams. NR 440.59(2)(k)(k) “Mineral handling and storage facility” means the areas in asphalt roofing plants in which minerals are unloaded from a carrier, the conveyor transfer points between the carrier and the storage silos and the storage silos. NR 440.59(2)(L)(L) “Saturator” means the equipment in which asphalt is applied to felt to make asphalt roofing products. The term saturator includes the saturator, wet looper and coater. NR 440.59(3)(a)(a) On and after the date on which s. NR 440.08 (2) requires a performance test to be completed, no owner or operator subject to the provisions of this section may cause to be discharged into the atmosphere from any saturator: NR 440.59(3)(a)1.a.a. 0.040 kg/Mg (0.080 lb/ton) of asphalt shingle or mineral-surfaced roll roofing produced. NR 440.59(3)(a)1.b.b. 0.040 kg/Mg (0.080 lb/ton) of saturated felt or smooth-surfaced roll roofing produced. NR 440.59(3)(a)3.3. Any visible emissions from a saturator capture system for more than 20% of any period of consecutive valid observations totaling 60 minutes. Saturators that were constructed before November 18, 1980 and that have not been reconstructed since that date and that become subject to this section through modification are exempt from the visible emissions standard. Saturators that have been newly constructed or reconstructed since November 18, 1980 are subject to the visible emissions standard. NR 440.59(3)(b)(b) On and after the date on which s. NR 440.08 (2) requires a performance test to be completed, no owner or operator subject to the provisions of this section may cause to be discharged into the atmosphere from any blowing still any of the following: NR 440.59(3)(b)1.1. Particulate matter in excess of 0.67 kg/Mg (1.3 lb/ton) of asphalt charged to the still when a catalyst is added to the still. NR 440.59(3)(b)2.2. Particulate matter in excess of 0.71 kg/Mg (1.4 lb/ton) of asphalt charged to the still when a catalyst is added to the still and when No. 6 fuel oil is fired in the afterburner. NR 440.59(3)(b)3.3. Particulate matter in excess of 0.60 kg/Mg (1.2 lb/ton) of asphalt charged to the still during blowing without a catalyst. NR 440.59(3)(b)4.4. Particulate matter in excess of 0.64 kg/Mg (1.3 lb/ton) of asphalt charged to the still during blowing without a catalyst and when No. 6 fuel oil is fired in the afterburner. NR 440.59(3)(b)5.5. Exhaust gases with an opacity greater than zero percent unless an opacity limit for the blowing still when fuel oil is used to fire the afterburner has been established by the administrator in accordance with the procedures in 40 CFR 60.474 (g). NR 440.59(3)(c)(c) Within 60 days after achieving the maximum production rate at which the affected facility will be operated, but not later than 180 days after initial startup of such facility, no owner or operator subject to the provisions of this section may cause to be discharged into the atmosphere from any asphalt storage tank exhaust gases with opacity greater than zero percent, except for one consecutive 15-minute period in any 24-hour period when the transfer lines are being blown for cleaning. The control device may not be bypassed during this 15-minute period. If, however, the emissions from any asphalt storage tank or tanks are ducted to a control device for a saturator, the combined emissions shall meet the emission limit contained in par. (a) during the time the saturator control device is operating. At any other time the asphalt storage tank or tanks shall meet the opacity limit specified in this paragraph for storage tanks. NR 440.59(3)(d)(d) Within 60 days after achieving the maximum production rate at which the affected facility will be operated, but not later than 180 days after initial startup of such facility, no owner or operator subject to the provisions of this section may cause to be discharged into the atmosphere from any mineral handling and storage facility emissions with opacity greater than one percent. NR 440.59(4)(a)(a) The owner or operator subject to the provisions of this section, and using either an electrostatic precipitator or a high velocity air filter to meet either the emission limit in sub. (3) (a) 1. or (b) 1., or both, shall continuously monitor and record the temperature of the gas at the inlet of the control device. The temperature monitoring instrument shall have an accuracy of ± 15°C (± 25°F) over its range. NR 440.59(4)(b)(b) The owner or operator subject to the provisions of this section and using an afterburner to meet either the emission limit in sub. (3) (a) 1. or (b) 1., or both, shall continuously monitor and record the temperature in the combustion zone of the afterburner. The monitoring instrument shall have an accuracy of ± 10°C (± 18°F) over its range. NR 440.59(4)(c)(c) An owner or operator subject to the provisions of this section and using a control device not mentioned in par. (a) or (b) shall provide to the department information describing the operation of the control device and the process parameter or parameters which would indicate proper operation and maintenance of the device. The department may require continuous monitoring and determine the process parameters to be monitored. NR 440.59(4)(d)(d) The industry is exempted from the quarterly reports required under s. NR 440.07 (3). The owner or operator is required to record and report the operating temperature of the control device during the performance test and, as required by s. NR 440.07 (5), maintain a file of the temperature monitoring results for at least 2 years. NR 440.59(5)(a)(a) For saturators, the owner or operator shall conduct performance tests required in s. NR 440.08 as follows: NR 440.59(5)(a)1.1. If the final product is shingle or mineral-surfaced roll roofing, the tests shall be conducted while 106.6-kg (235-lb) shingle is being produced. NR 440.59(5)(a)2.2. If the final product is saturated felt or smooth-surfaced roll roofing, the tests shall be conducted while 6.8-kg (15-lb) felt is being produced. NR 440.59(5)(a)3.3. If the final product is fiberglass shingle, the test shall be conducted while a nominal 100-kg (220-lb) shingle is being produced. NR 440.59(5)(b)(b) 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 440.59(5)(c)(c) The owner or operator shall determine compliance with the particulate matter standards in sub. (3) as follows: NR 440.59(5)(c)1.1. The emission rate (E) of particulate matter shall be computed for each run using the following equation: where:
E is the emission rate of particulate matter, kg/Mg (lb/ton)
cs is the concentration of particulate matter, g/dscm (gr/dscf)
Qsd is the volumetric flow rate of effluent gas, dscm/hr (dscf/hr)
P is the asphalt roofing production rate or asphalt charging rate, Mg/hr (ton/hr)
K is the conversion factor, 1000 g/kg (7000 gr/lb)
NR 440.59(5)(c)2.2. Method 5A shall be used to determine the particulate matter concentration (cs) and volumetric flow rate (Qsd) of the effluent gas. For a saturator, the sampling time and sample volume for each run shall be at least 120 minutes and 3.00 dscm (106 dscf), and for the blowing still, at least 90 minutes or the duration of the coating blow or non-coating blow, whichever is greater, and 2.25 dscm (79.4 dscf). NR 440.59(5)(c)3.3. For the saturator, the asphalt roofing production rate (P) for each run shall be determined as follows: The amount of asphalt roofing produced on the shingle or saturated felt process lines shall be obtained by direct measurement. The asphalt roofing production rate is the amount produced divided by the time taken for the run. NR 440.59(5)(c)4.4. For the blowing still, the asphalt charging rate (P) shall be computed for each run using the following equation: where:
P is the asphalt charging rate to blowing still, Mg/hr (ton/hr)
V is the volume of asphalt charged, m3 (ft3)
d is the density of asphalt, kg/m3 (lb/ft3)
K’ is the conversion factor, 1000 kg/Mg (2000 lb/ton)
θ here is the duration of test run, hr
NR 440.59(5)(c)4.a.a. The volume (V) of asphalt charged shall be measured by any means accurate to within 10%. NR 440.59(5)(c)4.b.b. The density (d) of the asphalt shall be computed using the following equation: where:
d is the density of the asphalt, kg/m3 (lb/ft3)
