Chapter NR 466

NR 466.22(25) (25) “Pressure sensitive tape” means a flexible backing material with a pressure-sensitive adhesive coating on one or both sides of the backing.

NR 466.22(26) (26) “Research or laboratory equipment” means any equipment for which the primary purpose is to conduct research and development into new processes and products where the equipment is operated under the close supervision of technically trained personnel and is not engaged in the manufacture of products for commercial sale in commerce except in a de minimis manner.

NR 466.22(27) (27) “Rewind or cutting station” means a unit from which substrate is collected at the outlet of a web coating line.

NR 466.22(28) (28) “Uncontrolled coating line” means a coating line consisting of only never-controlled work stations.

NR 466.22(29) (29) “Unwind or feed station” means a unit from which substrate is fed to a web coating line.

NR 466.22(30) (30) “Web” means a continuous substrate, such as paper, film or foil, which is flexible enough to be wound or unwound as rolls.

NR 466.22(31) (31) “Web coating line” means any number of work stations, of which one or more applies a continuous layer of coating material across the entire width or any portion of the width of a web substrate, and any associated curing or drying equipment between an unwind or feed station and a rewind or cutting station.

NR 466.22(32) (32) “Work station” means a unit on a web coating line where coating material is deposited onto a web substrate.

NR 466.22(33) (33) “You” means the owner or operator of a new or existing facility that is a major source of HAP at which web coating lines are operated.

NR 466.22(34) (34) “Your” means of or relating to the owner or operator of a new or existing facility that is a major source of HAP at which web coating line are operated.

NR 466.22 History History: CR 07-045: cr. Register April 2008 No. 628, eff. 5-1-08.

NR 466.23 NR 466.23 Emission standards and compliance dates.

NR 466.23(1) (1) What emission standards must I meet?

NR 466.23(1)(a) (a) If you own or operate any affected source that is subject to the requirements of this subchapter, you shall comply with the requirements in this section on and after the compliance dates specified in sub. (3).

NR 466.23(1)(b) (b) You shall limit organic HAP emissions to the level specified in one of the following:

NR 466.23(1)(b)1. 1. No more than 5% of the organic HAP applied for each month (95% reduction) at existing affected sources and no more than 2% of the organic HAP applied for each month (98% reduction) at new affected sources.

NR 466.23(1)(b)2. 2. No more than 4% of the mass of coating materials applied for each month at existing affected sources and no more than 1.6% of the mass of coating materials applied for each month at new affected sources.

NR 466.23(1)(b)3. 3. No more than 20% of the mass of coating solids applied for each month at existing affected sources and no more than 8% of the coating solids applied for each month at new affected sources.

NR 466.23(1)(b)4. 4. If you use an oxidizer to control organic HAP emissions, operate the oxidizer such that an outlet organic HAP concentration of no greater than 20 parts per million by volume (ppmv) by compound on a dry basis is achieved and the efficiency of the capture system is 100%.

NR 466.23(1)(c) (c) You shall demonstrate compliance with this subchapter by following the procedures in s. NR 466.25.

NR 466.23(2) (2) What operating limits must I meet?

NR 466.23(2)(a) (a) For any web coating line or group of web coating lines for which you use add-on control devices, unless you use a solvent recovery system and conduct a liquid-liquid material balance, you shall meet the operating limits specified in Table 1 of this subchapter or the requirements in par. (b). The operating limits apply to emission capture systems and control devices, and you shall establish the operating limits during the performance test according to the requirements in s. NR 466.24 (3) (e) 3. You shall meet the operating limits at all times after you establish them.

NR 466.23(2)(b) (b) If you use an add-on control device other than those listed in Table 1 of this subchapter or wish to monitor an alternative parameter and comply with a different operating limit, you shall apply to the administrator for approval of alternative monitoring under s. NR 460.07 (6).

NR 466.23(3) (3) When must I comply?

NR 466.23(3)(a) (a) If you own or operate an existing affected source subject to the provisions of this subchapter, you shall comply by the compliance date. The compliance date for existing affected sources is December 5, 2005. You shall complete any performance test required in s. NR 466.24 (3) within the time limits specified in s. NR 460.06 (1) (b).

NR 466.23(3)(b) (b) If you own or operate a new affected source subject to the provisions of this subchapter, your compliance date is immediately upon start-up of the new affected source or by December 4, 2002, whichever is later. You shall complete any performance test required in s. NR 466.24 (3) within the time limits specified in s. NR 460.06 (1) (b).

NR 466.23(3)(c) (c) If you own or operate a reconstructed affected source subject to the provisions of this subchapter, your compliance date is immediately upon startup of the affected source or by December 4, 2002, whichever is later. Existing affected sources which have undergone reconstruction as defined in s. NR 460.02 are subject to the requirements for new affected sources. The costs associated with the purchase and installation of air pollution control equipment are not considered in determining whether the existing affected source has been reconstructed. Additionally, the costs of retrofitting and replacing equipment that is installed specifically to comply with this subchapter are not considered reconstruction costs. You shall complete any performance test required in s. NR 466.24 (3) within the time limits specified in s. NR 460.06 (1) (b).

NR 466.23 History History: CR 07-045: cr. Register April 2008 No. 628, eff. 5-1-08.

NR 466.24 NR 466.24 General requirements for compliance with the emission standards and for monitoring and performance tests.

NR 466.24(1) (1) What general requirements must I meet to comply with the standards? You shall comply with the applicable general provisions of ch. NR 460 as specified in ch. NR 460 Appendix JJJJ.

NR 466.24(2) (2) If I use a control device to comply with the emission standards, what monitoring must I do?

NR 466.24(2)(a) (a) Summary. A summary of monitoring you shall do follows:

NR 466.24(2)(b) (b) Capture system and control device monitoring. Following the date on which the initial performance test of a control device is completed to demonstrate continuing compliance with the standards, you shall monitor and inspect each capture system and each control device used to comply with s. NR 466.23 (1). You shall install and operate the monitoring equipment as specified in pars. (c) and (f).

NR 466.24(2)(c) (c) Bypass and coating use monitoring. If you own or operate web coating lines with intermittently-controlled work stations, you shall monitor bypasses of the control device and the mass of each coating material applied at the work station during any bypass. If using a control device for complying with the requirements of this subchapter, you shall demonstrate that any coating material applied on a never-controlled work station or an intermittently-controlled work station operated in bypass mode is allowed in your compliance demonstration according to s. NR 466.25 (14) and (15). The bypass monitoring shall be conducted using at least one of the procedures in subds. 1. to 4. for each work station and associated dryer.

NR 466.24(2)(c)1. 1. ‘Flow control position indicator.’ Install, calibrate, maintain and operate according to the manufacturer’s specifications a flow control position indicator that provides a record indicating whether the exhaust stream from the dryer was directed to the control device or was diverted from the control device. The time and flow control position shall be recorded at least once per hour as well as every time the flow direction is changed. A flow control position indicator shall be installed at the entrance to any bypass line that could divert the exhaust stream away from the control device to the atmosphere.

NR 466.24(2)(c)2. 2. ‘Car-seal or lock-and-key valve closures.’ Secure any bypass line valve in the closed position with a car-seal or a lock-and-key type configuration. A visual inspection of the seal or closure mechanism shall be performed at least once every month to ensure that the valve or damper is maintained in the closed position, and the exhaust stream is not diverted through the bypass line.

NR 466.24(2)(c)3. 3. ‘Valve closure continuous monitoring.’ Ensure that any bypass line valve or damper is in the closed position through continuous monitoring of valve position when the emission source is in operation and is using a control device for compliance with the requirements of this subchapter. The monitoring system shall be inspected at least once every month to verify that the monitor will indicate valve position.

NR 466.24(2)(c)4. 4. ‘Automatic shutdown system.’ Use an automatic shutdown system in which the web coating line is stopped when flow is diverted away from the control device to any bypass line when the control device is in operation. The automatic system shall be inspected at least once every month to verify that it will detect diversions of flow and would shut down operations in the event of such a diversion.

NR 466.24(2)(d) (d) Solvent recovery unit. If you own or operate a solvent recovery unit to comply with s. NR 466.23 (1), you shall meet the requirements in either subd. 1. or 2., depending on how control efficiency is determined.

NR 466.24(2)(d)1. 1. ‘Continuous emission monitoring system (CEMS).’ If you are demonstrating compliance with the emission standards in s. NR 466.23 (1) through continuous emission monitoring of a control device, you shall install, calibrate, operate and maintain the CEMS according to subd. 1. a. to c.

NR 466.24(2)(d)1.a. a. Measure the total organic volatile matter mass flow rate at both the control device inlet and the outlet such that the reduction efficiency can be determined. Each continuous emission monitor shall comply with performance specification 6, 8 or 9, as appropriate, of 40 CFR part 60, Appendix B, incorporated by reference in s. NR 484.04 (21).

NR 466.24(2)(d)1.b. b. You shall follow the quality assurance procedures in procedure 1, of 40 CFR part 60, Appendix F, incorporated by reference in s. NR 484.04 (21m). In conducting the quarterly audits of the monitors as required by procedure 1, Appendix F, you shall use compounds representative of the gaseous emission stream being controlled.

NR 466.24(2)(d)1.c. c. You shall have valid data from at least 90% of the hours during which the process is operated.

NR 466.24(2)(d)2. 2. ‘Liquid-liquid material balance.’ If you are demonstrating compliance with the emission standards in s. NR 466.23 (1) through liquid-liquid material balance, you shall install, calibrate, maintain and operate according to the manufacturer’s specifications a device that indicates the cumulative amount of volatile matter recovered by the solvent recovery device on a monthly basis. The device shall be certified by the manufacturer to be accurate to within ±2.0% by mass.

NR 466.24(2)(e) (e) Continuous parameter monitoring system (CPMS). If you are using a control device to comply with the emission standards in s. NR 466.23 (1), you shall install, operate and maintain each CPMS specified in subds. 9. and 10. and par. (f) according to the requirements in subds. 1. to 8. You shall install, operate and maintain each CPMS specified in par. (c) according to subds. 5. to 7.

NR 466.24(2)(e)1. 1. Each CPMS shall complete a minimum of one cycle of operation for each successive 15-minute period. You shall have a minimum of 4 equally spaced successive cycles of CPMS operation to have a valid hour of data.

NR 466.24(2)(e)2. 2. You shall have valid data from at least 90% of the hours during which the process operated.

NR 466.24(2)(e)3. 3. You shall determine the hourly average of all recorded readings according to subd. 3. a. and b.

NR 466.24(2)(e)3.a. a. To calculate a valid hourly value, you shall have at least 3 of 4 equally spaced data values from that hour from a continuous monitoring system (CMS) that is not out-of-control.

NR 466.24(2)(e)3.b. b. Provided all of the readings recorded in accordance with this subdivision clearly demonstrate continuous compliance with the standard that applies to you, then you are not required to determine the hourly average of all recorded readings.

NR 466.24(2)(e)4. 4. You shall determine the rolling 3-hour average of all recorded readings for each operating period. To calculate the average for each 3-hour averaging period, you shall have at least 2 of 3 of the hourly averages for that period using only average values that are based on valid data not from out-of-control periods.

NR 466.24(2)(e)5. 5. You shall record the results of each inspection, calibration and validation check of the CPMS.

NR 466.24(2)(e)6. 6. At all times, you shall maintain the monitoring system in proper working order, including maintaining necessary parts for routine repairs of the monitoring equipment.

NR 466.24(2)(e)7. 7. Except for monitoring malfunctions, associated repairs or required quality assurance or control activities, including calibration checks or required zero and span adjustments, you shall conduct all monitoring at all times that the unit is operating. Data recorded during monitoring malfunctions, associated repairs, out-of-control periods or required quality assurance or control activities may not be used for purposes of calculating the emissions concentrations and percent reductions specified in s. NR 466.25 (1). You shall use all the valid data collected during all other periods in assessing compliance of the control device and associated control system. A monitoring malfunction is any sudden, infrequent, not reasonably preventable failure of the monitoring system to provide valid data. Monitoring failures that are caused in part by poor maintenance or careless operation are not malfunctions.

NR 466.24(2)(e)8. 8. Any averaging period for which you do not have valid monitoring data, and the data are required, constitutes a deviation, and you shall notify the department in accordance with s. NR 466.26 (1) (c).

NR 466.24(2)(e)9. 9. If you are using an oxidizer to comply with the emission standards, you shall comply with subd. 9. a. to c.

NR 466.24(2)(e)9.a. a. Install, calibrate, maintain and operate temperature monitoring equipment according to the manufacturer’s specifications. The calibration of the chart recorder, data logger or temperature indicator shall be verified every 3 months or the chart recorder, data logger or temperature indicator shall be replaced. You shall replace the equipment whether you choose not to perform the calibration or the equipment cannot be calibrated properly.

NR 466.24(2)(e)9.b. b. For an oxidizer other than a catalytic oxidizer, install, calibrate, operate and maintain a temperature monitoring device equipped with a continuous recorder. The device shall have an accuracy of ±1% of the temperature being monitored in degrees Celsius, or ±1° Celsius, whichever is greater. The thermocouple or temperature sensor shall be installed in the combustion chamber at a location in the combustion zone.

NR 466.24(2)(e)9.c. c. For a catalytic oxidizer, install, calibrate, operate and maintain a temperature monitoring device equipped with a continuous recorder. The device shall be capable of monitoring temperature with an accuracy of ±1% of the temperature being monitored in degrees Celsius or ±1° Celsius, whichever is greater. The thermocouple or temperature sensor shall be installed in the vent stream at the nearest feasible point to the inlet and outlet of the catalyst bed. Calculate the temperature rise across the catalyst.

NR 466.24(2)(e)10. 10. If you use a control device other than an oxidizer or wish to monitor an alternative parameter and comply with a different operating limit, you shall apply to the department for approval of an alternative monitoring method under s. NR 460.07 (6).

NR 466.24(2)(f) (f) Capture system monitoring. If you are complying with the emission standards in s. NR 466.23 (1) through the use of a capture system and control device for one or more web coating lines, you shall develop a site-specific monitoring plan containing the information specified in subds. 1. and 2. for the capture systems. You shall monitor the capture system in accordance with subd. 3. You shall make the monitoring plan available for inspection by the department upon request.

NR 466.24(2)(f)1. 1. The monitoring plan shall do all of the following:

NR 466.24(2)(f)1.a. a. Identify the operating parameter to be monitored to ensure that the capture efficiency determined during the initial compliance test is maintained.

NR 466.24(2)(f)1.b. b. Explain why the operating parameter is appropriate for demonstrating ongoing compliance.

NR 466.24(2)(f)1.c. c. Identify the specific monitoring procedures.

NR 466.24(2)(f)2. 2. The monitoring plan shall specify the operating parameter value or range of values that demonstrate compliance with the emission standards in s. NR 466.23 (1). The specified operating parameter value or range of values shall represent the conditions present when the capture system is being properly operated and maintained.

NR 466.24(2)(f)3. 3. You shall conduct all capture system monitoring in accordance with the plan.

NR 466.24(2)(f)4. 4. Any deviation from the operating parameter value or range of values which are monitored according to the plan will be considered a deviation from the operating limit.

NR 466.24(2)(f)5. 5. You shall review and update the capture system monitoring plan at least annually.

NR 466.24(3) (3) What performance tests shall I conduct?

NR 466.24(3)(a) (a) Performance test methods. The performance test methods you shall use are as follows:

NR 466.24(3)(b) (b) Exceptions. If you are using a control device to comply with the emission standards in s. NR 466.23 (1), you are not required to conduct a performance test to demonstrate compliance if one or more of the criteria in subds. 1. to 3. are met.

NR 466.24(3)(b)1. 1. The control device is equipped with continuous emission monitors for determining inlet and outlet total organic volatile matter concentration and capture efficiency has been determined in accordance with the requirements of this subchapter such that an overall organic HAP control efficiency can be calculated, and the continuous emission monitors are used to demonstrate continuous compliance in accordance with sub. (2).

NR 466.24(3)(b)2. 2. You have met the requirements of s. NR 460.06 (7) for waiver of performance testing.

NR 466.24(3)(b)3. 3. The control device is a solvent recovery system and you comply by means of a monthly liquid-liquid material balance.

NR 466.24(3)(c) (c) Organic HAP content. If you determine compliance with the emission standards in s. NR 466.23 (1) by means other than determining the overall organic HAP control efficiency of a control device, you shall determine the organic HAP mass fraction of each coating material as-purchased by following one of the procedures in subds. 1. to 3., and determine the organic HAP mass fraction of each coating material as-applied by following the procedures in subd. 4. If the organic HAP content values are not determined using the procedures in subds. 1. to 3., you shall submit an alternative test method for determining their values for approval by the administrator in accordance with 40 CFR 63.7 (f). The recovery efficiency of the test method shall be determined for all of the target organic HAP and a correction factor, if necessary, shall be determined and applied.

NR 466.24(3)(c)1. 1. ‘Method 311.’ You may test the coating material in accordance with Method 311 of 40 CFR part 63, Appendix A, incorporated by reference in s. NR 484.04 (25). The Method 311 determination may be performed by the manufacturer of the coating material and the results provided to the owner or operator. The organic HAP content shall be calculated according to the criteria and procedures in subd. 1. a. to c.

NR 466.24(3)(c)1.a. a. Include each organic HAP determined to be present at greater than or equal to 0.1% by mass for the United States occupational safety and health administration-defined (OSHA-defined) carcinogens as specified in 29 CFR 1910.1200 (d) (4) and greater than or equal to 1.0% by mass for other organic HAP compounds.

NR 466.24(3)(c)1.b. b. Express the mass fraction of each organic HAP you include according to subd. 1. a. as a value truncated to 4 places after the decimal point, e.g., 0.3791.

NR 466.24(3)(c)1.c. c. Calculate the total mass fraction of organic HAP in the tested material by summing the counted individual organic HAP mass fractions and truncating the result to 3 places after the decimal point, e.g., 0.763.

NR 466.24(3)(c)2. 2. ‘Method 24.’ For coatings, determine the volatile organic content as mass fraction of non-aqueous volatile matter and use it as a substitute for organic HAP using Method 24 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04 (13). The Method 24 determination may be performed by the manufacturer of the coating and the results provided to you.

NR 466.24(3)(c)3. 3. ‘Formulation data.’ You may use formulation data to determine the organic HAP mass fraction of a coating material. Formulation data may be provided to you by the manufacturer of the material. In the event of an inconsistency between Method 311 of 40 CFR part 63, Appendix A, incorporated by reference in s. NR 484.04 (25), test data and a facility’s formulation data, and the Method 311 test value is higher, the Method 311 data will govern. Formulation data may be used provided that the information represents all organic HAP present at a level equal to or greater than 0.1% for OSHA-defined carcinogens as specified in 29 CFR 1910.1200 (d) (4) and equal to or greater than 1.0% for other organic HAP compounds in any raw material used.

NR 466.24(3)(c)4. 4. ‘As-applied organic HAP mass fraction.’ If the as-purchased coating material is applied to the web without any solvent or other material added, the as-applied organic HAP mass fraction is equal to the as-purchased organic HAP mass fraction. Otherwise, the as-applied organic HAP mass fraction shall be calculated using Equation 1a of s. NR 466.25.

NR 466.24(3)(d) (d) Volatile organic and coating solids content. If you determine compliance with the emission standards in s. NR 466.23 (1) by means other than determining the overall organic HAP control efficiency of a control device and you choose to use the volatile organic content as a surrogate for the organic HAP content of coatings, you shall determine the as-purchased volatile organic content and coating solids content of each coating material applied by following the procedures in subd. 1. or 2. and the as-applied volatile organic content and coating solids content of each coating material by following the procedures in subd. 3.

NR 466.24(3)(d)1. 1. ‘Method 24.’ You may determine the volatile organic and coating solids mass fraction of each coating applied using Method 24 in 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04 (13). The Method 24 determination may be performed by the manufacturer of the material and the results provided to you. If these values cannot be determined using Method 24, you shall submit an alternative technique for determining their values for approval by the administrator.

NR 466.24(3)(d)2. 2. ‘Formulation data.’ You may determine the volatile organic content and coating solids content of a coating material based on formulation data and may rely on volatile organic content data provided by the manufacturer of the material. In the event of any inconsistency between the formulation data and the results of Method 24 in 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04 (13), and the Method 24 results are higher, the results of Method 24 will govern.

NR 466.24(3)(d)3. 3. ‘As-applied volatile organic content and coating solids content.’ If the as-purchased coating material is applied to the web without any solvent or other material added, the as-applied volatile organic content is equal to the as-purchased volatile content and the as-applied coating solids content is equal to the as-purchased coating solids content. Otherwise, the as-applied volatile organic content shall be calculated using Equation 1b of s. NR 466.25 and the as-applied coating solids content shall be calculated using Equation 2 of s. NR 466.25.

NR 466.24(3)(e) (e) Control device efficiency. If you are using an add-on control device other than solvent recovery, such as an oxidizer, to comply with the emission standards in s. NR 466.23 (1), you shall conduct a performance test to establish the destruction or removal efficiency of the control device according to the methods and procedures in subds. 1. and 2. During the performance test, you shall establish the operating limits required by s. NR 466.23 (2) according to subd. 3.

NR 466.24(3)(e)1. 1. An initial performance test to establish the destruction or removal efficiency of the control device shall be conducted such that control device inlet and outlet testing is conducted simultaneously and the data are reduced in accordance with the test methods and procedures in subd. 1. a. to i. You shall conduct 3 test runs as specified in s. NR 460.06 (4) (c), and each test run shall last at least one hour.