NESHAPs for Surface Coating Metal & Plastic Parts

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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!!!