401 KAR 59:210. New fabric, vinyl and paper surface coating operations

Link to law: http://www.lrc.ky.gov/kar/401/059/210.htm
Published: 2015

      401 KAR 59:210. New

fabric, vinyl and paper surface coating operations.

 

      RELATES TO: KRS

224.20-100, 224.20-110, 224.20-120, 40 C.F.R. 60 Appendix A (Method 24), 42

U.S.C. 7401 et seq., 7407, 7408, 7410

      STATUTORY AUTHORITY:

KRS 224.10-100

      NECESSITY, FUNCTION,

AND CONFORMITY: KRS 224.10-100 requires the Environmental and Public Protection

Cabinet to prescribe administrative regulations for the prevention, abatement,

and control of air pollution. 42 USC 7410 likewise requires the state to

implement standards for national primary and secondary ambient air quality.

This administrative regulation provides for the control of volatile organic

compound emissions from new fabric, vinyl or paper surface coating operations.

 

      Section 1.

Definitions. As used in this administrative regulation, all terms not defined

in this section shall have the meaning given to them in 401 KAR 59:001.

      (1) "Affected

facility" means a coating line for fabric, vinyl, or paper.

      (2)

"Applicator" means the mechanism or device used to apply the coating

including, but not limited to, roll, knife, or rotogravure coater.

      (3) "Flash-off

area" means the space between the applicator and the oven.

      (4) "Coating

line" means a series of equipment or operations used to apply, dry, or

cure any coatings containing volatile organic compounds (VOCs). This shall

include, but is not limited to:

      (a) Mixing

operations;

      (b) Process storage;

      (c) Applicators;

      (d) Drying

operations including, but not limited to, flash-off area evaporation, oven

drying, baking, curing, and polymerization;

      (e) Clean up

operations;

      (f) Leaks, spills,

and disposal of VOCs;

      (g) Processing and

handling of recovered VOCs;

      (h) To determine

compliance with this administrative regulation, if any equipment or operation

is considered to be a part of more than one (1) coating line, its VOC emissions

shall be assigned to each coating line of which it is a part proportionally to

the throughput of VOCs it receives from or distributes to each coating line;

      (i) If any portion

of the series of equipment or operations qualifies for an exemption according

to Section 6 of this administrative regulation, then that portion shall be

considered to be a separate coating line.

      (j) An affected

facility which is capable of performing both paper coating and paper printing

shall be considered as performing a paper printing operation subject to 401 KAR

59:212.

      (5) "Process

storage" means mixing tanks, holding tanks, and other tanks, drums, or

other containers which contain surface coatings, VOCs, or recovered VOCs, but

does not mean storage tanks of petroleum liquids which are subject to 401 KAR

59:050, 401 KAR 59:052, or 401 KAR 61:050.

      (6) "Fabric

coating" means the coating or saturation of a textile substrate to impart

properties that are not initially present, such as strength, stability, water

or acid repellency, functionality, or appearance.

      (7) "Vinyl

coating" means the coating of vinyl coated fabric or vinyl sheets, which

includes decorative, functional, or protective topcoats or printing.

      (8) "Paper

coating" means saturation or the application of a uniform layer of

material across the entire width of a web of paper, pressure sensitive tapes

regardless of substrate, related web coating processes on plastic film such as

typewriter ribbons, photographic film, magnetic tape, functional films, and

decorative coatings on metal foil such as gift wrap and packaging, but does not

include the printing of paper.

      (9) "Knife

coating" means the application of a coating material to a substrate by

means of drawing the substrate beneath a knife that spreads the coating evenly

over the full width of the substrate.

      (10) "Roll

coating" means the application of a coating material to a substrate by

means of hard rubber or steel rolls.

      (11)

"Rotogravure coating" means the application of a uniform layer of

material across a substrate by means of a roll coating technique in which the

entire coating roll is uniformly etched with recessed cells and no pattern or

design is present. The coating material is picked up in these recessed cells

and is transferred to the substrate.

      (12)

"Classification date" means June 29, 1979.

      (13) "VOCs net

input" means the total amount of VOCs input to the affected facility minus

the amount of VOCs that are not emitted into the atmosphere. VOCs that are

prevented from being emitted to the atmosphere by the use of control devices

shall not be subtracted from the total for the purposes of determining VOCs net

input. If the nature of any operation or design of equipment permits more than

one (1) interpretation of this definition, the interpretation that results in

the minimum value for allowable emission shall apply.

      (14)

"Printing" means the formation of words, designs, and pictures, usually

by a series of application rolls, each with only partial coverage. It shall

apply to flexographic and rotogravure processes as applied to publication,

specialty, and packaging printing as defined in 401 KAR 59:212.

 

      Section 2.

Applicability. (1) This administrative regulation shall apply to:

      (a) Each affected

facility commenced on or after the classification date defined in Section 1 of

this administrative regulation and located in a county or portion of a county

designated as nonattainment for ozone in 401 KAR 51:010, for any classification

except marginal; and

      (b) Each affected

facility commenced on or after the effective date of this administrative

regulation which is a part of a major source located in a county or portion of

a county designated attainment or marginal nonattainment for ozone in 401 KAR 51:010.

      (2) Each affected

facility commenced on or after the classification date defined in Section 1 of

this administrative regulation but prior to the effective date of this

administrative regulation which is a part of a major source located in a county

or portion of a county designated attainment or marginally nonattainment for

ozone in 401 KAR 51:010 shall be exempt from this administrative regulation

except that control devices and procedures required at the time it commenced

shall continue to be operated and maintained.

 

      Section 3. Standard

for VOCs. No person shall cause, allow, or permit an affected facility to

discharge into the atmosphere more than fifteen (15) percent by weight of the

VOCs net input into the affected facility.

 

      Section 4. Compliance.

(1) In all cases the design of any control system shall be subject to approval

by the cabinet.

      (2) Compliance with

the standard in Section 3 of this administrative regulation shall be

demonstrated by a material balance unless the cabinet determines that a

material balance is not possible. If a material balance is not possible,

compliance shall be determined based upon an engineering analysis by the

cabinet of the control system design, control device efficiency, control system

capture efficiency, and any other factors that may influence the performance of

the system. If requested by the cabinet, performance tests specified by the

cabinet shall be conducted to determine the efficiency of the control device.

Capture efficiency shall be determined by procedures specified in 401 KAR

50:047 in all ozone nonattainment areas except marginal.

      (3) With the prior

approval of the cabinet, the owner or operator may elect to effect all changes

necessary to qualify for an exemption under Section 6 of this administrative

regulation.

      (4) If deemed

necessary by the cabinet, the cabinet shall obtain samples of the coatings used

at an affected facility to verify that the coatings meet the requirements in

Section 6 of this administrative regulation. Appendix A to 40 CFR 60, Method

24, which has been incorporated by reference in 401 KAR 50:015, shall be used

as applicable to determine compliance of the coatings unless the cabinet

determines that other methods would be more appropriate. Case-by-case

alternatives approved by the cabinet, but not previously authorized by the U.S.

EPA, shall be submitted to the U.S. EPA as a SIP revision.

      (5) Compliance on

one (1) coating line with VOC emission limits shall be based on an averaging

period not to exceed twenty-four (24) hours. If it is not economically or

technically feasible to determine emission on a daily basis, alternatives

expressing emission limits for longer averaging times may be accepted if

approved by the cabinet. Case-by-case alternatives approved by the cabinet, but

not previously authorized by the U.S. EPA, shall be submitted to the U.S. EPA

as a SIP revision.

      (6) The amount of

exempt solvents shall be subtracted from the amount of coatings, just like

water, with the ultimate value of interest being the mass of VOC per unit

volume of coating less exempt solvent or water or both.

      (7) Calculations to

determine equivalency on one (1) coating line shall be based on mass of VOC per

volume of solids. Vinyl plastisols and organisols shall not be included in VOC

equivalency calculations that are required to be included in applications for

VOC bubbles.

      (8) Daily records

shall be maintained by the source for the most recent two (2) year period.

These records shall be made available to the cabinet or the U.S. EPA upon

request. The records shall include, but not be limited to, the following:

      (a) Applicable

administrative regulation number;

      (b) Application

method and substrate type;

      (c) Amount and type

of adhesive, coating (including catalyst and reducer for multicomponent coatings),

or solvent used at each point of application, including exempt compounds;

      (d) The VOC content

as applied in each adhesive, coating, or solvent;

      (e) The date for

each application for adhesive, coating, or solvent;

      (f) The amount of

surface preparation, cleanup, or washup solvent (including exempt compounds)

used and the VOC content of each; and

      (g) Oven

temperature, if applicable.

 

      Section 5.

Compliance Timetable. (1) Affected facilities which were subject to this

administrative regulation as in effect on June 29, 1979, shall have achieved

final compliance upon start-up.

      (2) The owner or

operator of an affected facility that, on or after the effective date of this

administrative regulation, becomes subject to this administrative regulation

for any reason other than construction, modification, or reconstruction shall

be required to complete the following:

      (a) A final control

plan for achieving compliance with this administrative regulation shall be

submitted no later than nine (9) months after the date the affected facility

becomes subject to this administrative regulation.

      (b) The control

system contract or the exempt coatings and any accompanying process change

contracts shall be awarded no later than eleven (11) months after the date the

affected facility becomes subject to this administrative regulation.

      (c) On-site

construction or installation of emission control equipment or process changes

for exempt coatings shall be initiated no later than thirteen (13) months after

the date the affected facility becomes subject to this administrative

regulation.

      (d) On-site

construction or installation of emission control equipment or process changes

for exempt coatings shall be completed no later than seventeen (17) months

after the date the affected facility becomes subject to this administrative

regulation.

      (e) Final compliance

shall be achieved no later than eighteen (18) months after the date the

affected facility becomes subject to this administrative regulation.

      (f) If an affected

facility becomes subject to this administrative regulation because it is

located in a county previously designated nonurban nonattainment or

redesignated in 401 KAR 51:010 after November 15, 1990, final compliance may be

extended to May 31, 1995, and the schedule in paragraphs (a) through (d) of

this subsection adjusted by the cabinet.

 

      Section 6.

Exemptions. (1) Any affected facility coating fabric or paper shall be exempt

from Section 3 of this administrative regulation if the VOC content of the

coating is less than 0.35 kg/l of coating (two and nine-tenths (2.9) lb/gal),

excluding water or exempt solvent or both, delivered to the applicators

associated with the coating line.

      (2) Any affected

facility coating vinyl shall be exempt from Section 3 of this administrative

regulation if the VOC content of the coating is less than 0.45 kg/l of coating

(three and eight-tenths (3.8) lb/gal) excluding water or exempt solvent or

both, delivered to the applicators associated with the coating line.

      (3) An affected

facility shall be exempt from this administrative regulation if the total VOC

emissions from all affected facilities subject to this administrative

regulation are less than or equal to:

      (a) Three (3) lb/hr

actual emissions before add-on control;

      (b) Fifteen (15)

lb/day actual emissions before add-on control; or

      (c) Ten (10) tons

per year theoretical potential emissions based on design capacity for maximum

production) and 8760 hr/yr before add-on control.

      (4) Low-use coatings

shall be exempt from Section 3 of this administrative regulation if the

plantwide consumption of these coatings in the aggregate is less than or equal

to fifty-five (55) gallons during the previous twelve (12) months. (5 Ky.R.

462; Am. 6 Ky.R. 23; eff. 6-29-79; 8 Ky.R. 910; eff. 9-22-82; 18 Ky.R. 2622;

2939; 3344; eff. 6-24-92; TAm eff. 8-9-2007.)
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