1 NESHAPs for Surface Coating Metal & Plastic Parts Melissa Ellis Air Toxics Coordinator 471-6624 NDEQ Training December 14, 2010
Jan 12, 2016
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NESHAPs for Surface CoatingMetal & Plastic Parts
Melissa Ellis
Air Toxics Coordinator471-6624
NDEQ Training December 14, 2010
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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
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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
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MMMM and PPPP
Rule BackgroundApplicabilityComplianceMonitoring
Compliance DatesNotificationsReportingRecordkeeping
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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
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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
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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
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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
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MMMM: New Source
MMMM
Existing
:General Use :High Performance
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MMMM: Subcategories
Coating Type
Emission Limit
(lb organic HAP/gal coating solids)
Existing New/Reconstructed
General Use 2.6 1.9
High Performance 27.5 27.5
Magnet Wire 1.0 0.44
Rubber to Metal 37.7 6.8
Extreme Performance Fluoropolymer
12.4 12.4
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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
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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
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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
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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
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PPPP: New Source
PPPP
Existing New
:General Use :Automotive Lamp
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PPPP: Subcategories
Coating Type
Emission Limit
(lb organic HAP/lb coating solids)
Existing New/Reconstructed
General Use 0.16 0.16
Automotive Lamp 0.45 0.26
Thermoplastic Olefin 0.26 0.22
Assembled On-road Vehicle
1.34 1.34
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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)
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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
91.0gal 800gal 000,8
gal 000,8
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4M & 4P: Facility Specific Emission Limit
Calculate monthly
n
i
i
n
i
ii
Solids
SolidsLimitFSEL
1
1
)(
))((
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
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4M & 4P: Compliance
Compliance options– Compliant material– Emission rate with no add-on
controls– Emission rate with add-on controls
Work practice standards +
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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
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4M & 4P: Compliant Materials
For each material– Determine organic HAP mass fraction (Wc)
Method 311Method 24Mfg. formulation data or test dataOther approved methodTable 3 or 4 default values
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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
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4M & 4P: Compliant Materials
Calculation for Organic HAP Content
s
ccc
V
WDH
))((
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
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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
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4M & 4P: Emission Rate (No Control)
For each material– Determine organic HAP mass fraction (Wc)
Method 311Method 24Mfg. formulation data or test dataOther approved methodTable 3 or 4 default values
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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)
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4M & 4P: Emission Rate (No Control)
Calculate Mass Organic HAP– Coatings, Additives/Thinners, Cleaners, & Waste– Calculation method same for each
))()(( ,,
1
, icic
m
i
ic WDVolA
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
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4M & 4P: Emission Rate (No Control)
Calculate total mass organic HAP emissions– Can subtract organic HAP in waste
we RCBAH 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
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4M & 4P: Emission Rate (No Control)
Calculate total volume solids
))(( ,
1
, is
m
i
icst VVolV
Vst = Volume coating solids used, gallons
Volc,i= Total volume used, gallons
Vs,i= Volume fraction coating solids, lb solids/lb coating
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4M & 4P: Emission Rate (No Control)
Calculate Emission Rate =
Solids TotalHAP Total
n
y
st
n
y
e
yr
V
H
H
1
1=
Compare to emission limit
Calculate 12-month rolling totals
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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
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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
4M & 4P: Emission Rate + Controls
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4M & 4P: Emission Rate + Controls
Calculated as (HAP used)/(solids used) Include capture and control efficiency Rolling 12-month compliance period Calculated monthly
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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
)100100
)((DREx
CEHRCBAH uncwcccc
Hunc=Mass of organic HAP during deviations
CE= Capture efficiency
DRE = Destruction or removal efficiency
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4M & 4P: Emission Rate + Controls
Calculate mass of organic HAP emissions
)()(1 1
,,
q
i
r
j
jCSRiceHAP HHHH
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
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4M & 4P: Emission Rate + Controls
Calculate Emission Rate =
Solids TotalHAP Total
n
y
st
n
y
HAP
yr
V
H
H
1
1=
Compare to emission limit
Calculate 12-month rolling totals
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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
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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
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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
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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
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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
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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
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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
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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
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Differences: Units
MMMM
lbs HAP/gal solids
PPPP
lbs HAP/lb solids
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Differences: Applicability
MMMM
≥ 250 gal/yr HAP Coating
PPPP
≥ 100 gal/yr HAP Coating
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Differences: Exemptions
MMMM
Individual coatings
< 50 gal/year
(total 250 gal max)
PPPP
No Specific Exemptions
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Differences: New Source
MMMM
Completely new facility
PPPP
New coating equipment at new subcategory
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Differences: New Source
MMMM PPPP
Existing Existing New
:General Use :Automotive Lamp :High Performance
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Differences: FSEL Conversion
MMMM
Conversion Factor of 10.5 lbs solids/gal solids
solids galsolids lbs
10.5solids lbHAP lbs
solids HAP lbs
gal
PPPP
Conversion Factor of 12.5 lbs solids/gal solids
solids lbsolids gal
12.51
solids galHAP lbs
solids HAP lbs
lb
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Example #1: Is Facility A Subject?
Facility is described below:
Total HAP: 22 ton/yr
Largest HAP: xylene: 11 ton/yr
Metal coating operations occur
30,000 gallons of coating applied yearly
Coatings contain HAPs
This facility is subject to MMMM
Major Source
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Example #1
Coating Type
Use (gal/yr)
Coating Density (lb/gal)
HAP Content
(% by wt)
Solids Content (gal/gal)
Emission Limit
(lb/gal)
General Use
20,000 11.0 12.0 0.55 2.6
High Performance
10,000 9.5 60 0.20 27.5
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Example #1: Compliant Materials
General Use:
Limit:
55.0
12.0gallbs
0.11 In Compliancegallbs
.42
gallbs
.62
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Example #1: Compliant Materials
High Performance:
Limit
20.0
60.0gallbs
5.9 NOT In Compliancegallbs
.528
gallbs
.527
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Example #1: Facility Specific EL
Emission Limit:
yrgal
,yrgal
,
yrgal
,gallbs
.yrgal
,gallbs
.
000200011
00025270001162
solids galHAP lbs
.436
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Example #1: Facility Specific EL
Emission Rate:
yrgal
,yrgal
,
.gallbs
.yrgal
,.gallbs
yrgal
,
000200011
6059000101201100020
solids galHAP lbs
.426
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Example 1: Conclusion
Emission Rate < Emission Limit
6.42 < 6.43
Facility will demonstrate compliance using the facility specific emission limit
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Not Compliant
(2.6 lbs/gal emission limit)
(0.16 lbs/lb emission limit)
Example #2
Major Source of HAPs Metal coating occurs Plastics coating occurs
Use (yearly)
HAP Emissions
(yearly)
Emission Rate
Metal Coating
2,452 gal solids
7,076 lbs 2.89 lbs/gal
Plastic Coating
8,338 lbs solids
808 lbs 0.097 lbs/lb
Compliant
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Example #2: Predominant Activity
Metal Parts coating: 2,452 gal solids
Plastic Parts coating: 8,338 lbs solids
Must convert Plastic Parts coating to gallons
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Example #2: Plastics Coatings
Material Gallons Used Solids (%) Gal solids
Type A 399 30 119.7
Type B 351 100 351.0
Type C 500 100 500.0
Type D 1100 0 0.0
Type E 30 100 30.0
Type F 20 10 2.0
Total 1,002.7
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Example #2: Predominant Activity
Metal Parts Coating: 2,452 gal solids
Plastic Parts coating: 1,002.7 gal solids
0.71 < 0.90
Predominant Activity will not work as an option for this facility
71.07.002,1452,2
452,2 gal gal
gal
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Example #2: Facility Specific EL
Emission Limit:
yrgal
.,yrgal
452,
yrgal
.,gallbs
.lblbs
.yrgal
,gallbs
.
700212
70021510160452262
solids galHAP lbs
.332
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Example #2: Facility Specific EL
Emission Rate
Emission Limit:
yrgal
.,yrgal
452,
yrHAP lbs
yrHAP lbs
,
700212
8080767
Compliant
solids galHAP lbs
.282
solids galHAP lbs
.332
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Case Study: BD Medical
Major source of HAP Existing source Coat needles, syringes, & cannula
– Metal & plastic
Subject to 4M & 4P
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Case Study: BD Medical
Compliance choice– Comply with 4M through FSEL
Meets 4P
– Emission rate with add-on controlRegenerative Thermal OxidizerFull enclosure
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Case Study: BD Medical
Compliance history– 2007 - exceeding Low Emitter, failure to obtain
CP, failure to OP, failure to submit notification for 4M
– 2008 – inspection violations – not keeping records to demonstrate 4M compliance – NOV issued
– 2009 – Enforcement settlement
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Case Study: BD Medical
Compliance history– 2010 – Class I OP issued– 2010 – inspection violations – FSEL 12-month
totals not calculated, capture system monitoring, auditing, no CPMS, RTO audits, work practice plan records, enclosure monitoring – NOV issued
– 2010 – Enforcement referral
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Case Study: BD Medical
Issues– No experienced consultant or full time environmental
staff– Overwhelmed with requirements
Permitting– Source requested all info from NESHAP be detailed in
permit to help them– Organized logically– LOTS of work for Anne!!! You go girl!
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Compliance– OP helped source comply, but not fully!– Collection system installed & monitored per OSHA
requirements prior to 4M
Take aways…. – Compliance, permitting, planning staff working
together– How complicated the rules are– No matter how much we help – sources still may not
understand requirements
Case Study: BD Medical
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Resources & Tools
BD Medial OP Previous inspections Air Toxics Notebook
– 4M - EPA Flow Chart Summarizes all requirements
– Brochures, University of Tennessee link, compliance timelines, EPA training
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Special thanks to Dave G. for all the awesome calcs & effects!!!!
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Questions or Comments???
Look for the electronic survey in your email
soon!!!