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NESHAPs for Surface Coating Metal & Plastic Parts

NESHAPs for Surface Coating Metal & Plastic Parts. Melissa Ellis Air Toxics Coordinator 471-6624. NDEQ Training December 14, 2010. Training Agenda (con’t). Training Objectives 4M (Metal coating) and 4P (Plastic coating) Applicability Subcategories Compliance options and requirements

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NESHAPs for Surface Coating Metal & Plastic Parts

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  1. NESHAPs for Surface CoatingMetal & Plastic Parts Melissa Ellis Air Toxics Coordinator 471-6624 NDEQ Training December 14, 2010

  2. Training Agenda (con’t) • Training Objectives • 4M (Metal coating) and 4P (Plastic coating) • Applicability • Subcategories • Compliance options and requirements • Practical exercises • Case Study – Becton Dickinson

  3. Training Objectives • Identify applicable sources • Understand requirements • Obtain information needed to inspect or permit properly • Emission calculations • Challenges from past permitting/compliance staff • Obtain tools & resources to help do your job effectively

  4. Rule Background Applicability Compliance Monitoring Compliance Dates Notifications Reporting Recordkeeping MMMM and PPPP

  5. MMMM: Rule Background • Proposed Rule: 8/13/02 • Final Rule: 1/2/04 (same effective date) • Amendment: 4/26/04 = clarification of rule overlap • Title 129, Chapter 28, 001.81 • Two sources subject • BD Medical – Columbus • Case New Holland – Grand Island

  6. MMMM: Applicability • Apply surface coating to misc. metal parts & products • Coating = spray guns, dip tanks, etc. • Not coating = non-refillable aerosol, touch up markers, pens, or paper or plastic film • Major source = PTE > 10 tpy single HAP or 25 tpy combined HAPs

  7. MMMM: Applicability • Use ≥ 250 gal/yr of organic HAP containing coatings • Coatings <50 gal/yr exempt provided total volume exempt < 250 gal • Not subject • Not using organic HAP products or use <250 gal/yr • R & D, maintenance, or noncommercial hobby • Military installations, munitions, or NASA • Extrusion of plastic • If subject to another NESHAP as of rule date

  8. MMMM: New vs. Existing • New Source • Construction commenced after August 13, 2002 • Completely new coating facility • Existing Source • Not new or reconstructed • ONE affected source per facility

  9. MMMM MMMM: New Source Existing :General Use :High Performance

  10. MMMM: Subcategories

  11. PPPP: Rule Background • Proposed Rule: 12/4/02 • Final Rule: 4/19/04 (same effective date) • Amendment: 4/26/04 = clarification of rule overlap • Amendment: 4/24/07 = clarification of rule overlap • Title 129, Chapter 28, 001.85 • Two sources subject • BD Medical – Columbus • A-1 Fiberglass - Hastings

  12. PPPP: Applicability • Apply surface coating to plastic parts & products • Coating = spray guns, dip tanks, etc. • Not coating = non-refillable aerosol, touch up markers, pens, or paper or plastic film • Major source = PTE > 10 tpy single HAP or 25 tpy combined HAPs

  13. PPPP: Applicability • Use ≥ 100 gal/yr of HAP containing coatings • Not subject • Not using organic HAP products or use <100 gal/yr • R & D, maintenance, or noncommercial hobby • Military installations, munitions, or NASA • Extrusion of plastic • If subject to another NESHAP as of rule date • Fiberglass boats or boat parts • In-mold or gel coating reinforced plastic parts

  14. PPPP: New vs. Existing • New Source • Construction commenced after December 4, 2002 • Completely new coating facility • New equipment in a subcategory that was not previously performed • Existing Source • Not new or reconstructed • Can have several affected sources per facility

  15. PPPP PPPP: New Source Existing New :General Use :Automotive Lamp

  16. PPPP: Subcategories

  17. 4M & 4P: Compliance Options • Subject to more than one coating NESHAP • Comply with each OR • Comply with NESHAP for predominant activity OR • Predominant activity = 90% • Not for assembled vehicles or automotive lamps • Use gallons of solids to determine • Develop Facility-Specific Emission Limit (FSEL)

  18. 4M & 4P: Predominant Activity Metal Parts Coating: 8,000 gal solids Plastic Parts coating: 800 gal solids 0.91 > 0.90 \ Predominant Activity will work as an option for this facility

  19. 4M & 4P: Facility Specific Emission Limit • Calculate monthly FSEL = Facility-specific emission limit for each 12-month compliance period, lb HAP per lb solids Limiti = Applicable emission limit, lb HAP per lb solids Solidsi = Solids used in operation, lb

  20. 4M & 4P: Compliance • Compliance options • Compliant material • Emission rate with no add-on controls • Emission rate with add-on controls • Work practice standards +

  21. 4M & 4P: Compliant Materials • All coating materials have HAP content less than emission limit • All thinners, additives & cleaning materials contain no HAP • Demonstrate compliance each month • No 12-month rolling totals

  22. 4M & 4P: Compliant Materials • For each material • Determine organic HAP mass fraction (Wc) • Method 311 • Method 24 • Mfg. formulation data or test data • Other approved method • Table 3 or 4 default values

  23. 4M & 4P: Compliant Materials • For each coating • Determine volume faction of coating solids (Vc) • ASTM D2697-86 or D6093-97 • Alternate approved • Mfg. or supplier data • Calculate • Determine density (Dc) • ASTM Method D1475 • Mfg. or supplier data • Specific gravity for pure chemicals • Calculate organic HAP content & compare to emission limit

  24. 4M & 4P: Compliant Materials • Calculation for Organic HAP Content Hc = Organic HAP content, lb/gallon solids Dc = Density, lb/gallon Wc = Mass fraction of organic HAP, lb HAP/lb coating Vs = Volume fraction coating solids, gal solids/gal coating

  25. 4M & 4P: Emission Rate (No Control) • Calculated as (HAP used)/(solids used) • Rolling 12-month compliance period • Calculated monthly • No operating limits or work practice standards • Can be used for • Each subcategory or source category • Predominant activity • Facility specific emission limit

  26. 4M & 4P: Emission Rate (No Control) • For each material • Determine organic HAP mass fraction (Wc) • Method 311 • Method 24 • Mfg. formulation data or test data • Other approved method • Table 3 or 4 default values

  27. 4M & 4P: Emission Rate (No Control) • For each coating • Determine volume faction of coating solids (Vc) • ASTM D2697-86 or D6093-97 • Alternate approved • Mfg. or supplier data • Calculate • Determine density (Dc) • ASTM Method D1475 or 5965 • Mfg. or supplier data • Specific gravity for pure chemicals • Determine volume of material used (Volc,i)

  28. 4M & 4P: Emission Rate (No Control) • Calculate Mass Organic HAP • Coatings, Additives/Thinners, Cleaners, & Waste • Calculation method same for each A = Total mass organic HAP, coatings, lb Volc,i= Total volume used, gallons Dc,i= Density, lb coating/gallon coating Wc,i= Mass fraction organic HAP, lb HAP/lb coating

  29. 4M & 4P: Emission Rate (No Control) • Calculate total mass organic HAP emissions • Can subtract organic HAP in waste He = Total mass organic HAP, lb A = Total mass organic HAP, coatings B = Total mass organic HAP, additives & thinners C = Total mass organic HAP, cleaning Rw = Total mass organic HAP, waste shipped or disposed

  30. 4M & 4P: Emission Rate (No Control) • Calculate total volume solids Vst = Volume coating solids used, gallons Volc,i= Total volume used, gallons Vs,i= Volume fraction coating solids, lb solids/lb coating

  31. 4M & 4P: Emission Rate (No Control) • Calculate Emission Rate = = • Compare to emission limit • Calculate 12-month rolling totals

  32. 4M & 4P: Emission Rate + Controls • Develop & implement Startup, Shutdown, & Malfunction (SSM) Plan** • Install Capture/Control system • Conduct performance test • Previously conducted tests can be used if… • Approved • Used specific method & conditions • No process or equipment changes made • Operating parameters can be established from previous data

  33. 4M & 4P: Emission Rate + Controls • Establish operating limits • Unless using recovery system & using liquid-liquid mass balance • Continuous Parameter Monitoring System (CPMS) • Develop & implement work practice plan • Minimize emissions from storing, spilling, handling, mixing, & cleaning

  34. 4M & 4P: Emission Rate + Controls • Calculated as (HAP used)/(solids used) • Include capture and control efficiency • Rolling 12-month compliance period • Calculated monthly

  35. 4M & 4P: Emission Rate + Controls • Similar to Emission Rate with no add-on controls • Calculate mass organic HAP before add-on controls • Calculate mass organic HAP emission reduction Hunc=Mass of organic HAP during deviations CE= Capture efficiency DRE = Destruction or removal efficiency

  36. 4M & 4P: Emission Rate + Controls • Calculate mass of organic HAP emissions HHAP= Total mass of organic HAP He = Total mass of organic HAP before add-on controls Hc,i = Total mass of organic HAP emission reduction, not using liquid-liquid HCSR,j = Total mass of organic HAP emission reduction, using liquid-liquid

  37. 4M & 4P: Emission Rate + Controls • Calculate Emission Rate = = • Compare to emission limit • Calculate 12-month rolling totals

  38. 4M & 4P: Continuous Compliance • Perform monthly compliance calculations for 12 month compliance period • Submit semiannual compliance reports • Keep records • Monitor operating limits for add-on controls • Apply work practice standards for add-on controls

  39. 4M & 4P: Monitoring • Continuous Parameter Monitoring System • One reading every 15 minutes • 4 equally spaced readings per hour • Average all recorded readings for each successive 3-hour period • Inspection, calibration, validation check results • Maintain CPMS, spare parts available • Operate CPMS when coating operation in operation

  40. 4M & 4P: Compliance Dates • MMMM • Existing source = 1/2/07 • New source (after 8/13/02) = 1/2/04 or startup • PPPP • Existing source = 4/19/07 • New source (after 12/4/02) = 4/19/04 or startup • Area increases to major • Existing source = 1 year after becoming major or 3 years after 1/2/04 (4M) or 4/19/04 (4P), whichever is later • New source = Initial startup

  41. 4M & 4P: Notifications • Initial Notification • MMMM • Existing source = 1/2/05 • New source = 5/1/04 or 120 days after startup • PPPP • Existing source = 4/19/05 • New source = 4/19/04 or 120 days after startup

  42. 4M & 4P: Notifications • Notification to Conduct Performance Test • 60 days prior to test • Compliance Status Notification • 30 days after initial compliance period • Initial compliance period ends on last day of the 12th full month after compliance date

  43. 4M & 4P: Reports • Performance Test Report • 60 days after test • SSM Report • Immediate if not consistent with plan • Semiannual if consistent • Semiannual Compliance Report • Covers 1/1-6/30 or 7/1-12/31 • Due January 31 and July 31

  44. 4M & 4P: Records I • Notifications/reports & documentation • Mfg. & supplier data • Test reports • Data/documentation supporting capture efficiency • Compliance options for each operation • Compliance calculations and documentation

  45. 4M & 4P: Records II • Waste disposal records, calculations, & documentation • SSM plan & records • Monitoring data • Work practice plan documentation • Deviations info • Keep records for 5 years • Last 2 years on-site

  46. MMMM lbs HAP/gal solids PPPP lbs HAP/lb solids Differences: Units

  47. MMMM ≥ 250 gal/yr HAP Coating PPPP ≥ 100 gal/yr HAP Coating Differences: Applicability

  48. MMMM Individual coatings < 50 gal/year (total 250 gal max) PPPP No Specific Exemptions Differences: Exemptions

  49. MMMM Completely new facility PPPP New coating equipment at new subcategory Differences: New Source

  50. MMMM PPPP Differences: New Source Existing Existing New :General Use :High Performance :Automotive Lamp

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