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: -
See PDF for diagram 
3) Select the appropriate transfer efficiency (T) from the following tables for each surface coating operation:
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:
NR 440.53 Note
Note:
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: -
See PDF for diagram
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: -
See PDF for diagram
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.
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: -
See PDF for diagram
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: -
See PDF for diagram
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 -
See PDF for diagram in the effluent gas entering the control device (in parts per million by volume) and the volumetric flow rate -
See PDF for diagram 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.d.
d. Calculate the volume weighted average mass of VOC per volume of applied coating solids emitted after the control device during a calendar month by the following equation: -
See PDF for diagram
NR 440.53(4)(c)3.e.
e. 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(5)
(5) Monitoring of emissions and operations. The owner or operator of an affected facility which uses an incinerator to comply with the emission limits specified under
sub. (3) shall install, calibrate, maintain and operate temperature measurement devices as prescribed below:
NR 440.53(5)(a)
(a) Where thermal incineration is used, a temperature measurement device shall be installed in the firebox. Where catalytic incineration is used, a temperature measurement device shall be installed in the gas stream immediately before and after the catalyst bed.
NR 440.53(5)(b)
(b) Each temperature measurement device shall be installed, calibrated and maintained according to accepted practice and the manufacturer's specifications. The device shall have an accuracy of the greater of
" 0.75% of the temperature being measured expressed in degrees Celsius or
"2.5
°C.
NR 440.53(5)(c)
(c) Each temperature measurement device shall be equipped with a recording device so that a permanent record is produced.
NR 440.53(6)(a)(a) Each owner or operator of an affected facility shall include the data outlined in
subds. 1. and
2. in the initial compliance report required by
s. NR 440.08.
NR 440.53(6)(a)1.
1. The owner or operator shall report the volume weighted average mass of VOC per volume of applied coating solids for each affected facility.
NR 440.53(6)(a)2.
2. Where compliance is achieved through the use of incineration, the owner or operator shall include the following additional data in the control device initial performance test required by
s. NR 440.08 (1) or subsequent performance tests at which destruction efficiency is determined: the combustion temperature (or the gas temperature upstream and downstream of the catalyst bed), the total mass of VOC per volume of applied coating solids before and after the incinerator, capture efficiency, the destruction efficiency of the incinerator used to attain compliance with the applicable emission limit specified in
sub. (3), and a description of the method used to establish the fraction of VOC captured and sent to the control device.
NR 440.53(6)(b)
(b) 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 total 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. Where compliance is achieved through the use of a capture system and control device, the volume-weighted average after the control device shall be reported.
NR 440.53(6)(c)
(c) Where compliance with
sub. (3) is achieved through the use of incineration, the owner or operator shall continuously record the incinerator combustion temperature during coating operations for thermal incineration or the gas temperature upstream and downstream of the incinerator catalyst bed during coating operations for catalytic incineration. The owner or operator shall submit a written report at the frequency specified in
s. NR 440.07 (3) and as defined as follows:
NR 440.53(6)(c)1.
1. For thermal incinerators, every 3-hour period shall be reported during which the average temperature measured is more than 28
°C less than the average temperature during the most recent control device performance test at which the destruction efficiency was determined as specified under
sub. (4).
NR 440.53(6)(c)2.
2. For catalytic incinerators, every 3-hour period shall be reported during which the average temperature immediately before the catalyst bed, when the coating system is operational, is more than 28
°C less than the average temperature immediately before the catalyst bed during the most recent control device performance test at which destruction efficiency was determined as specified under
sub. (4). In addition, every 3-hour period shall be reported each quarter during which the average temperature difference across the catalyst bed when the coating system is operational is less than 80% of the average temperature difference of the device during the most recent control device performance test at which destruction efficiency was determined as specified under
sub. (4).
NR 440.53(6)(c)3.
3. For thermal and catalytic incinerators, if no such periods occur, the owner or operator shall submit a negative report.
NR 440.53(7)(a)1.
1. Method 24 or an equivalent or alternative method approved by the administrator shall be used for the determination of the data used in the calculation of the VOC content of the coatings used for each affected facility. Manufacturer's formulation data is approved by the administrator as an alternative method to Method 24. In the event of dispute, Method 24 shall be the referee method.
NR 440.53(7)(a)2.
2. Method 25 or an equivalent or alternative method approved by the administrator shall be used for the determination of the VOC concentration in the effluent gas entering and leaving the emission control device for each stack equipped with an emission control device and in the effluent gas leaving each stack not equipped with a control device.
NR 440.53(7)(a)3.
3. The following methods shall be used to determine the volumetric flow rate in the effluent gas in a stack:
NR 440.53(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 for each of 3 runs shall be at least one hour. The minimum sample volume shall be 0.003 dscm except that shorter sampling times or smaller volumes, when necessitated by process variables or other factors, may be approved by the department. The department shall approve the sampling of representative stacks on a case-by-case basis if the owner or operator can demonstrate to the satisfaction of the department that the testing of representative stacks would yield results comparable to those that would be obtained by testing all stacks.
NR 440.53(8)
(8) Modifications. For purposes of this chapter, the following physical or operational changes are not, by themselves, considered modifications of existing facilities described in
sub. (1) (a):
NR 440.53(8)(a)
(a) Changes as a result of model year changeovers or switches to larger cars.
NR 440.53(8)(b)
(b) Changes in the application of the coatings to increase coating film thickness.
NR 440.53 History
History: Cr.
Register, January, 1984, No. 337, eff. 2-1-84; am. (2) (a) (intro.), (b) (intro.), (4) (c) 1. a. 3), (7) (a) 1. and 2., cr. (2) (a) 6 e., 6 g., 6 k and 6 p.,
Register, September, 1990, No. 417, eff. 10-1-90; r. and recr. (6) (b), am. (6) (c) (intro.),
Register, May, 1993, No. 450, eff. 7-1-93; am. (2) (a) 10., (4) (c) 1. a., (3) (intro.), (6) (c) (intro.),
Register, December, 1995, No. 480, eff. 1-1-96;
CR 06-109: am. (2) (b) 1. to 25, (4) (c) 1. a. (intro.) and 3), (6) (d) and (7) (a) 1. and 2. and (b) and (c) Register May 2008 No. 629, eff. 6-1-08. NR 440.54(1)
(1)
Applicability and designation of affected facility. NR 440.54(1)(a)(a) The provisions of this section are applicable to the following affected facilities used in phosphate rock plants which have a maximum plant production capacity greater than 3.6 megagrams per hour (4 tons/hr): dryers, calciners, grinders, and ground rock handling and storage facilities, except those facilities producing or preparing phosphate rock solely for consumption in elemental phosphorus production.
NR 440.54(1)(b)
(b) Any facility under
par. (a) which commences construction, modification or reconstruction after September 21, 1979, is subject to the requirements of this section.
NR 440.54(2)
(2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in
s. NR 440.02.
NR 440.54(2)(a)
(a) “Beneficiation" means the process of washing the rock to remove impurities or to separate size fractions.
NR 440.54(2)(b)
(b) “Calciner" means a unit in which the moisture and organic matter of phosphate rock is reduced within a combustion chamber.
NR 440.54(2)(c)
(c) “Dryer" means a unit in which the moisture content of phosphate rock is reduced by contact with a heated gas stream.
NR 440.54(2)(d)
(d) “Grinder" means a unit which is used to pulverize dry phosphate rock to the final product size used in the manufacture of phosphate fertilizer and does not include crushing devices used in mining.
NR 440.54(2)(e)
(e) “Ground phosphate rock handling and storage system" means a system which is used for the conveyance and storage of ground phosphate rock from grinders at phosphate rock plants.
NR 440.54(2)(f)
(f) “Phosphate rock feed" means all material entering the process unit including moisture and extraneous material as well as the following ore minerals: fluorapatite, hydroxylapatite, chlorapatite and carbonateapatite.
NR 440.54(2)(g)
(g) “Phosphate rock plant" means any plant which produces or prepares phosphate rock product by any or all of the following processes: mining, beneficiation, crushing, screening, cleaning, drying, calcining and grinding.
NR 440.54(3)(a)(a) On and after the date on which the performance test required to be conducted by
s. NR 440.08 is completed, no owner or operator subject to the provisions of this section may cause to be discharged into the atmosphere:
NR 440.54(3)(a)1.a.
a. Contain particulate matter in excess of 0.030 kilogram per megagram of phosphate rock feed (0.060 lb/ton), or
NR 440.54(3)(a)2.
2. From any phosphate rock calciner processing unbeneficiated rock or blends of beneficiated and unbeneficiated rock, any gases which:
NR 440.54(3)(a)2.a.
a. Contain particulate matter in excess of 0.12 kilogram per megagram of phosphate rock feed (0.23 lb/ton), or
NR 440.54(3)(a)3.
3. From any phosphate rock calciner processing beneficiated rock any gases which:
NR 440.54(3)(a)3.a.
a. Contain particulate matter in excess of 0.055 kilogram per megagram of phosphate rock feed (0.11 lb/ton), or
NR 440.54(3)(a)4.a.
a. Contain particulate matter in excess of 0.006 kilogram per megagram of phosphate rock feed (0.012 lb/ton), or
NR 440.54(3)(a)5.
5. From any ground phosphate rock handling and storage system any gases which exhibit greater than zero percent opacity.
NR 440.54(4)(a)(a) Any owner or operator subject to the provisions of this section shall install, calibrate, maintain and operate a continuous monitoring system, except as provided in
pars. (b) and
(c), to monitor and record the opacity of the gases discharged into the atmosphere from any phosphate rock dryer, calciner or grinder. The span of this system shall be set at 40% opacity.
NR 440.54(4)(b)
(b) For ground phosphate rock storage and handling systems, continuous monitoring systems for measuring opacity are not required.
NR 440.54(4)(c)
(c) The owner or operator of any affected phosphate rock facility using a wet scrubbing emission control device will not be subject to the requirements in
par. (a), but shall install, calibrate, maintain and operate the following continuous monitoring devices:
NR 440.54(4)(c)1.
1. A monitoring device for the continuous measurement of the pressure loss of the gas stream through the scrubber. The monitoring device shall be certified by the manufacturer to be accurate within
"250 pascals (
"one inch water) gauge pressure.
NR 440.54(4)(c)2.
2. A monitoring device for the continuous measurement of the scrubbing liquid supply pressure to the control device. The monitoring device shall be accurate within
" 5% of design scrubbing liquid supply pressure.
NR 440.54(4)(d)
(d) For the purpose of conducting a performance test under
s. NR 440.08, the owner or operator of any phosphate rock plant subject to the provisions of this section shall install, calibrate, maintain and operate a device for measuring the phosphate rock feed to any affected dryer, calciner or grinder. The measuring device used shall be accurate to within
" 5% of the mass rate over its operating range.
NR 440.54(4)(e)
(e) For the purpose of reports required under
s. NR 440.07 (3), periods of excess emissions that shall be reported are defined as all 6-minute periods during which the average opacity of the plume from any phosphate rock dryer, calciner or grinder subject to
par. (a) exceeds the applicable opacity limit.
