401 KAR 61:122.
Existing graphic arts facilities using rotogravure and flexography.
RELATES TO: KRS
224.20-100, 224.20-110, 224.20-120, 40 C.F.R. 60 Appendix A (Method 24A), 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
existing graphic arts facilities which use rotogravure and flexography.
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 61:001.
(1) "Affected
facility" means a printing line for packaging rotogravure, publication
rotogravure, specialty rotogravure, and flexographic printing.
(2)
"Applicator" means the mechanism or device used to apply the ink.
(3) "Flash-off
area" means the space between the applicator and the oven.
(4) "Printing
line" means a series of equipment or operations used to apply, dry, or
cure any inks containing 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) For the purposes
of determining compliance with this administrative regulation, if any equipment
or operation is considered to be a part of more than one (1) printing line, its
VOC emissions shall be assigned to each printing line of which it is a part
proportionally to the throughput of VOCs it receives from or distributes to
each printing 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 printing line;
(j) All units in a
machine which has both coating and printing units shall be considered as
performing a printing operation.
(5) "Process
storage" means mixing tanks, holding tanks, and other tanks, drums, or
other containers which contain inks, 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)
"Printing" means the formation of words, designs, and pictures,
usually by a series of application rolls each with only partial coverage. It
applies to flexographic and rotogravure processes as applied to publication,
specialty, and packaging printing.
(7)
"Coating" means the application of a uniform layer of material across
the entire width of a web.
(8)
"Classification date" means February 4, 1981.
(9) "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 emissions shall apply.
(10) "Packaging
rotogravure printing" means rotogravure printing upon paper, paper board,
metal foil, plastic film, and other substrates, which are, in subsequent
operations, formed into packaging products and labels for articles to be sold.
(11)
"Publication rotogravure printing" means rotogravure printing upon
paper which is subsequently formed into books, magazines, catalogs, brochures,
directories, newspaper supplements, and other types of printed materials.
(12)
"Flexographic printing" means the application of words, designs and
pictures to a substrate by means of a roll printing technique in which the
pattern to be applied is raised above the printing roll and the image carrier
is made of rubber or other elastomeric materials.
(13) "Rotogravure
printing" means the application of words, designs, and pictures to a
substrate by means of a roll printing technique which involves intaglio or
recessed image areas in the form of cells.
(14) "Roll
printing" means the application of words, designs and pictures to a
substrate usually by means of a series of hard rubber or steel rolls each with
only partial coverage.
(15) "Specialty
rotogravure printing" means all rotogravure printing except packaging
rotogravure and publication rotogravure printing. It includes, but is not
limited to, rotogravure printing on paper cups and plates, patterned gift wrap,
wallpaper and floor coverings.
Section 2.
Applicability. This administrative regulation shall apply to each affected
facility commenced before the classification date defined in Section 1 of this
administrative regulation which is located in a county or portion of a county
which is designated ozone nonattainment, for any nonattainment classification
except marginal, under 401 KAR 51:010.
Section 3. Standard
for VOCs. (1) No person shall cause, allow, or permit an affected facility for
publication rotogravure printing to discharge into the atmosphere more than
twenty-five (25) percent by weight of the VOCs net input into the affected
facility.
(2) No person shall
cause, allow, or permit an affected facility for packaging rotogravure printing
or specialty rotogravure printing to discharge into the atmosphere more than
thirty-five (35) percent by weight of the VOCs net input into the affected
facility.
(3) No person shall
cause, allow, or permit an affected facility for flexographic printing to
discharge into the atmosphere more than forty (40) 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.
(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 inks used at
an affected facility to verify that the inks meet the requirements in Section 6
of this administrative regulation. Appendix A to 40 CFR 60, Method 24A, which
has been incorporated by reference in 401 KAR 50:015, shall be used as
applicable 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) The amount of
exempt solvents shall be subtracted from the amount of inks, just like water,
with the ultimate value of interest being the mass of VOC per unit volume of
ink less exempt solvent or water or both.
(6) 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 graphic arts material or solvent used at each point of application,
including exempt compounds;
(d) The VOC content
as applied in each graphic arts material or solvent;
(e) The date for
each application for graphic arts material 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 February 4, 1981, shall have achieved
final compliance by December 31, 1982.
(2) The owner or
operator of an affected facility 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 inks 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 inks 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 inks 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. Any affected facility shall be exempt from Section 3 of this
administrative regulation if the printing systems:
(1) Utilize a
waterborne ink whose volatile portion consists of seventy-five (75) volume
percent water and twenty-five (25) volume percent organic solvent (or a lower
VOC content) in all printing units;
(2) Achieve a
seventy (70) volume percent overall reduction of solvent usage (compared to all
solvent-borne ink usage);
(3) Utilize inks
which, excluding water, contain sixty (60) percent or more by volume nonvolatile
material as applied to the substrate; or
(4) Utilize inks
with an emission limit of five-tenths (0.5) VOC/lb solids as delivered to the
applicator. (7 Ky.R. 375; Am. 548; eff. 2-4-81; 8 Ky.R. 915; 9 Ky.R. 373; eff.
9-22-82; 18 Ky.R. 2661; 2955; 3369; eff. 6-24-92; TAm eff. 8-9-2007.)