Chapter NR 440

NR 440.72(3)(a)4. 4. 2.3 kilograms of VOCs per liter of coatings solids applied from touch-up coating of plastic parts for business machines.

NR 440.72(3)(b) (b) All VOC emissions that are caused by coating applied in each affected facility, regardless of the actual point of discharge of emissions into the atmosphere, shall be included in determining compliance with the emission limits in par. (a).

NR 440.72(4) (4) Performance tests and compliance provisions.

NR 440.72(4)(a) (a) Section NR 440.08 (4) and (5) does not apply to the performance test procedures required by this subsection.

NR 440.72(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 each nominal 1-month period for each affected facility according to the procedures in this subsection.

NR 440.72(4)(b)1. 1. The owner or operator shall determine the composition of coatings by analysis of each coating, as received, using Method 24 of Appendix A, 40 CFR part 60, incorporated by reference in s. NR 440.17 (1), from data that have been determined by the coating manufacturer using Method 24, or by other methods approved by the administrator.

NR 440.72(4)(b)2. 2. The owner or operator shall determine the volume of coating and the mass of VOC used for dilution of coatings from company records during each nominal 1-month period. If a common coating distribution system serves more than one affected facility or serves both affected and nonaffected spray booths, the owner or operator shall estimate the volume of coatings used at each facility by using procedures approved by the department.

NR 440.72(4)(b)2.a. a. The owner or operator shall calculate the volume-weighted average mass of VOCs in coatings emitted per unit volume of coating solids applied (N) at each coating operation (i.e., for each type of coating used, prime, color, texture, or touch-up) during each nominal 1-month period for each affected facility. Each 1-month calculation is considered a performance test. Except as provided in subd. 2. c., N will be determined by the following procedures:

1) Calculate the mass of VOCs used (Mo+ Md) for each coating operation during each nominal 1-month period for each affected facility by the following equation:

where n is the number of coatings of each type used during each nominal 1-month period and m is the number of different diluent VOCs used during each nominal 1-month period. (∑Ldj Ddj will be 0 if no VOCs are added to the coatings, as received.)

2) Calculate the total volume of coating solids consumed (Ls) in each nominal 1-month period for each coating operation for each affected facility by the following equation:

where n is the number of coatings of each type used during each nominal 1-month period.

3) Select the appropriate transfer efficiency (T) from Table 1 for each type of coating applications equipment used at each coating operation. If the owner or operator can demonstrate to the satisfaction of the administrator that transfer efficiencies other than those shown are appropriate, the administrator may approve their use on a case-by-case basis. Transfer efficiency values for application methods not listed below may be approved by the administrator on a case-by-case basis. An owner or operator shall submit sufficient data for the administrator to judge the validity of the transfer efficiency claims.

4) Where more than one application method is used within a single coating operation, the owner or operator shall determine the volume of each coating applied by each method through a means acceptable to the department and compute the volume-weighted average transfer efficiency by the following equation:

where n is the number of coatings of each type used and p is the number of application methods used

5) Calculate the volume-weighted average mass of VOCs emitted per unit volume of coating solids applied (N) during each nominal 1-month period for each coating operation for each affected facility by the following equation:

(Tavg = T when only one type of coating operation occurs).

NR 440.72(4)(b)2.b. b. Where the volume-weighted average mass of VOCs emitted to the atmosphere per unit volume of coating solids applied (N) is less than or equal to 1.5 kilograms per liter for prime coats, is less than or equal to 1.5 kilograms per liter for color coats, is less than or equal to 2.3 kilograms per liter for texture coats, and is less than or equal to 2.3 kilograms per liter for touch-up coats, the affected facility is in compliance.

NR 440.72(4)(b)2.c. c. If each individual coating used by an affected facility has a VOC content (kg VOC/l of solids), as received, which when divided by the lowest transfer efficiency at which the coating is applied for each coating operation results in a value equal to or less than 1.5 kilograms per liter for prime and color coats and equal to or less than 2.3 kilograms per liter for texture and touch-up coats, the affected facility is in compliance provided that no VOCs are added to the coatings during distribution or application.

NR 440.72(4)(b)2.d. d. If an affected facility uses add-on controls to control VOC emissions and if the owner or operator can demonstrate to the administrator that the volume-weighted average mass of VOCs emitted to the atmosphere during each nominal 1-month period per unit volume of coating solids applied (N) is within each of the applicable limits expressed in subd. 2. b. because of this equipment, the affected facility is in compliance. In such cases, compliance will be determined by the administrator on a case-by-case basis.

NR 440.72(5) (5) Reporting and recordkeeping requirements.

NR 440.72(5)(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 440.72(5)(a)1. 1. Except as provided for in subd. 2., the volume-weighted average mass of VOCs emitted to the atmosphere per volume of applied coating solids (N) for the initial nominal 1-month period for each coating operation from each affected facility.

NR 440.72(5)(a)2. 2. For each affected facility where compliance is determined under the provisions of sub. (4) (b) 2. c., a list of the coatings used during the initial nominal 1-month period, the VOC content of each coating calculated from data determined using Method 24, of Appendix A, 40 CFR part 60, incorporated by reference in s. NR 440.17 (1), and the lowest transfer efficiency at which each coating is applied during the initial nominal 1-month period.

NR 440.72(5)(b) (b) Following the initial report, each owner or operator shall:

NR 440.72(5)(b)1. 1. Report the volume-weighted average mass of VOCs per unit volume of coating solids applied for each coating operation for each affected facility during each nominal 1-month period in which the facility is not in compliance with the applicable emission limits specified in sub. (3). Reports of noncompliance shall be submitted on a quarterly basis, occurring every 3 months following the initial report; and

NR 440.72(5)(b)2. 2. Submit statements that each affected facility has been in compliance with the applicable emission limits specified in sub. (3) during each nominal 1-month period. Statements of compliance shall be submitted on a semiannual basis.

NR 440.72(5)(c) (c) These reports shall be postmarked not later than 10 days after the end of the periods specified in par. (b).

NR 440.72(5)(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 monthly VOC emissions from each coating operation for each affected facility as specified in s. NR 440.07 (5).

NR 440.72(5)(e) (e) Reporting and recordkeeping requirements for facilities using add-on controls will be determined by the administrator on a case-by-case basis.

NR 440.72(6) (6) Test methods and procedures.

NR 440.72(6)(a) (a) The reference methods in Appendix A, of 40 CFR part 60, incorporated by reference in s. NR 440.17, except as provided under s. NR 440.08 (2), shall be used to determine compliance with sub. (3) as follows:

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.