Tenn. Comp. R. & Regs. 1200-03-16-.36

Current through December 10, 2024

Section 1200-03-16-.36 - INDUSTRIAL SURFACE COATING: LARGE APPLIANCES

(1) Applicability.

(a) The provisions of this rule apply to each surface coating operation in a large appliance surface coating line.

(b) The provisions of this rule apply to each affected facility identified in subparagraph (a) of this paragraph that commences construction, modification, or reconstruction after November 6, 1988.

(2) Definitions and Symbols.

(a) Definitions

1. "Applied coating solids" means the coating solids that adhere to the surface of the large appliance part being coated.

2. "Large appliance part" means any organic surface-coated metal lid, door, casing, panel, or other interior or exterior metal part or accessory that is assembled to form a large appliance product. Parts subject to in-use temperatures in excess of 250°F are not included in this definition.

3. "Large appliance product" means any organic surface-coated metal range, oven, microwave oven, refrigerator, freezer, washer, dryer, dishwasher, water heater, or trash compactor manufactured for household, commercial, or recreational use.

4. "Large appliance surface coating line" means that portion of a large appliance assembly plant engaged in the application and curing of organic surface coatings on large appliance parts or products.

5. "Coating application station" means that portion of the large appliance surface coating operation where a prime coat or a top coat is applied to large appliance parts or products (e.g., dip tank, spray booth, or flow coating unit).

6. "Curing oven" means a device that uses heat to dry or cure the coating(s) applied to large appliance parts or products.

7. "Electrodeposition" (EDP) means a method of coating application in which the large appliance part or product is submerged in a tank filled with coating material suspended in water and an electrical potential is used to enhance deposition of the material on the part or product.

8. "Flashoff area" means the portion of a surface coating line between the coating application station and the curing oven.

9. "Organic coating" means any coating used in a surface coating operation, including dilution solvents, from which VOC emissions occur during the application or the curing process. For the purpose of this regulation, powder coatings are not included in this definition.

10. "Powder coating" means any surface coating that is applied as a dry powder and is fused into a continuous coating film through the use of heat.

11. "Spray booth" means the structure housing automatic or manual spray application equipment where a coating is applied to large appliance parts or products.

12. "Surface coating operation" means the system on a large appliance surface coating line used to apply and dry or cure an organic coating on the surface of large appliance parts or products. The surface coating operation may be a prime coat or a topcoat operation and includes the coating application station(s), flashoff area, and curing oven.

13. "Transfer efficiency" means the ratio of the amount of coating solids deposited onto the surface of a large appliance part or product to the total amount of coating solids used.

14. "VOC content" means the proportion of a coating that is volatile organic compounds (VOC's), expressed as kilograms of VOC's per liter of coating solids.

15. "VOC emissions" means the mass of volatile organic compounds (VOC's), expressed as kilograms of VOC's per liter of applied coating solids, emitted from a surface coating operation.

(b) Symbols

Ca = the concentration of VOC's in a gas stream leaving a control device and entering the atmosphere (parts per million by volume, as carbon).

Cb = the concentration of VOC's in a gas stream entering a control device (parts per million by volume, as carbon).

Cf = the concentration of VOC's in a gas stream emitted directly to the atmosphere (parts per million by volume, as carbon).

Dc = density of coating (or input stream), as received (kilograms per liter).

Dd = density of a VOC-solvent added to coatings (kilograms per liter).

Dr = density of a VOC-solvent recovered by an emission control device (kilograms per liter).

E = the VOC destruction efficiency of a control device (fraction).

F = the proportion of total VOC's emitted by an affected facility that enters a control device (fraction).

G = the volume-weighted average mass of VOC's in coatings consumed in a calendar month per unit volume of applied coating solids (kilograms per liter).

Lc = the volume of coating consumed, as received (liters).

Ld = the volume of VOC-solvent added to coatings (liters).

Lr = the volume of VOC-solvent recovered by an emission control device (liters).

Ls = the volume of coating solids consumed (liters).

Md = the mass of VOC-solvent added to coatings (kilograms).

Mo = the mass of VOC's in coatings consumed, as received (kilograms).

Mr = the mass of VOC's recovered by an emision control device (kilograms).

N = the volume-weighted average mass of VOC's emitted to the atmosphere per unit volume of applied coating solids (kilograms per liter).

Qa = the volumetric flow rate of a gas stream leaving a control device and entering the atmosphere (dry standard cubic meters per hour).

Qb = the volumetric flow rate of a gas stream entering a control device (dry standard cubic meters per hour).

Qf = the volumetric flow rate of a gas stream emitted directly to the atmosphere (dry standard cubic meters per hour).

R = the overall VOC emission reduction achieved for an affected facility (fraction).

T = the transfer efficiency (fraction).

Vs = the proportion of solids in a coating (or input stream), as received (fraction by volume).

Wo = the proportion of VOC's in a coating (or input stream), as received (fraction by weight).

(3) Standard for volatile organic compounds.

On or after the date on which the performance test required by 1200-3-16-.01(5) is completed, no owner or operator of an affected facility subject to the provisions of this rule shall discharge or cause the discharge of VOC emissions that exceed 0.90 kilogram of VOC's per liter of applied coating solids from any surface coating operation on a large appliance surface coating line.

(4) Performance test and compliance provisions.

(a) Subparagraphs 1200-3-16-.01(5)(d) and (f) do not apply to the performance test procedures required by this rule.

(b) The owner or operator of an affected facility shall conduct an initial performance test as required under 1200-3-16-.01(5)(a) and thereafter a performance test each calendar month for each affected facility according to the procedures in this subparagraph.

1. An owner or operator shall use the following procedures for any affected facility that does not use a capture system and control device to comply with the emissions limit specified under paragraph (3) of this rule. The owner or operator shall determine the composition of the coatings by formulation data supplied by the coating manufacturer or by analysis of each coating, as received, using Reference Method 24 as specified in rule 1200-3-16-.01(5)(g). The Technical Secretary may require the owner or operator who uses formulation data supplied by the coating manufacturer to determine the VOC content of coatings using Reference Method 24. The owner or operator shall determine the volume of coating and the mass of VOC-solvent used for thinning purposes from company records on a monthly basis. If a common coating distribution system serves more than one affected facility or serves both affected and existing facilities, the owner or operator shall estimate the volume of coatings used at each facility, by using the average dry weight of coating and the surface area coated by each affected and existing facility or by other procedures acceptable to the Technical Secretary.

(i) Except as provided in sub-part (b)1.(iv) of this paragraph, the weighted average of the total mass of VOC's consumed per unit volume of coating solids applied each calendar month will be determined as follows:

(I) Calculate the mass of VOC's consumed (Mo + Md) during the calendar month for each affected facility by the following equation:

Click to view Image

(Sum Ldj Ddj will be 0 if no VOC-solvent is added to the coatings, as received)

where

n is the number of different coatings used during the month, and

m is the the number of different VOC-solvents added to coatings during the calendar month.

(II) Calculate the total volume of coatings solids used (Ls) in the calendar month for each affected facility by the following equation:

Click to view Image

where

n is the number of different coatings used during the calendar month.

(III) Select the appropriate transfer efficiency from Table 1. If the owner or operator can demonstrate to the satisfaction of the Technical Secretary that transfer efficiencies other than those shown are appropriate, the Technical Secretary will approve their use on a case-by-case basis. Transfer efficiencies for application methods not listed shall be determined by the Technical Secretary on a case-by-case basis. An owner or operator must submit sufficient data for the Technical Secretary to judge the accuracy of the transfer efficiency claims.

TABLE 1. - TRANSFER EFFICIENCIES

Application Method	Transfer efficiency (Tk)
Air-atomized spray	040
Airless spray	0.45
Manual electrostatic spray	0.60
Flow coat	0.85
Dip coat	0.85
Nonrotational automatic electrostatic spray	0.85
Rotating head automatic electrostatic spray	0.90
Electrodeposition	0.95

Where more than one application method is used within a single surface coating operation, the owner or operator shall determine the composition and volume of each coating applied by each method through a means acceptable to the Technical Secretary and compute the weighted average transfer efficiency by the following equation:

Click to view Image

where

n is the number of coatings (or input streams) used, and

m is the number of application methods used.

(IV) Calculate the volume-weighted average mass of VOC's consumed per unit volume of coating solids applied (G) during the calendar month for each affected facility by the following equation:

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(ii) Calculate the volume-weighted average of VOC emissions to the atmosphere (N) during the calendar month for each affected facility by the following equation:

N = G Equation (5)

(iii) Where the volume-weighted average mass of VOC's discharged to the atmosphere per unit volume of coating solids applied (N) is equal to or less than 0.90 kilogram per liter, the affected facility is in compliance.

(iv) If each individual coating used by an effected facility has a VOC content, as received, which when divided by the lowest transfer efficiency at which the coating is applied, results in a value equal to or less than 0.90 kilogram per liter, the affected facility is in compliance, provided no VOC's are added to the coating during distribution or application.

2. An owner or operator shall use the following procedures for any affected facility that uses a capture system and a control device that destroys VOC's (e.g., incinerator) to comply with the emission limit specified under paragraph (3) of this rule.

(i) Determine the overall reduction efficiency (R) for the capture system and control device. For the initial performance test the overall reduction efficiency (R) shall be determined as prescribed in (I), (II), and (III) below. In subsequent months, the owner or operator may use the most recently determined overall reduction efficiency (R) for the performance test, providing control device and capture system operating conditions have not changed. The procedures in (I), (II), and (III) below, shall be repeated when directed by the Technical Secretary or when the owner or operator elects to operate the control device or capture system at conditions different from the initial performance test.

(I) Determine the fraction (F) of total VOC's emitted by an affected facility that enters the control device using the following equation:

Click to view Image

where

n is the number of gas streams entering the control device

p is the number of gas streams emitted directly to the atmosphere.

(II) Determine the destruction efficiency of the control device (E) using values of the volumetric flow rate of each 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:

Click to view Image

where

n is the number of gas streams entering the control device, and

m is the number of gas streams leaving the control device and entering the atmosphere.

(III) Determine overall reduction efficiency (R) using the following equation:

R = EF. Equation (8)

(ii) Calculate the volume-weighted average fo the total mass of VOC's per unit volume of applied coating solids (G) during each calendar month for each affected facility using equations (1), (2), (3) if applicable, and (4).

(iii) Calculate the volume-weighted average of VOC emissions to the atmosphere (N) during each calendar month by the following equation:

N = G (1-R) Equation (9)

(iv) If the volume-weighted average mass of VOC's emitted to the atmosphere for each calendar month (N) is equal to or less than 0.90 kilogram per liter of applied coating solids, the affected facility is in compliance.

3. An owner or operator shall use the following procedure for any affected facility that uses a control device for VOC recovery (e.g., carbon adsorber) to comply with the applicable emission limit specified under paragraph (3) of this rule.

(i) Calculate the total mass of VOC's consumed (Mo + Md) and the volume-weighted average of the total mass of VOC's per unit volume of applied coating solids (G) during each calendar month for each affected facility using equations (1), (2), (3) if applicable, and (4).

(ii) Calculate the total mass of VOC's recovered (Mr) during each calendar month using the following equation:

Mr = LrDr Equation (10)

(iii) Calculate overall reduction efficiency of the control device (R) for each calendar month for each affected facility using the following equation:

Click to view Image

(iv) Calculate the volume-weighted average mass of VOC's emitted to the atmosphere (N) for each calendar month for each affected facility using equation (9).

(v) If the volume-weighted average mass of VOC's emitted to the atmosphere for each calendar month (N) is equal to or less than 0.90 kilogram per liter of applied coating solids, the affected facility is in compliance. Each monthly calculation is considered a performance test.

(5) Monitoring of emissions and operations.

(a) The owner or operator of an affected facility that uses a capture system and an incinerator to comply with the emission limits specified under paragraph (3) of this rule shall install, calibrate, maintain, and operate temperature measurement devices as prescribed below:

1. 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.

2. Each temperature measurement device shall be installed, calibrated, and maintained according to the manufacturer's specifications. The device shall have an accuracy of the greater of 0.75 percent of the temperature being measured expressed in degrees Celsius or ± 2.5°C.

3. Each temperature measurement device shall be equipped with a recording device so that a permanent continuous record is produced.

(6) Reporting and recordkeeping requirements.

(a) The reporting requirements of 1200-3-16-.01(5)(a) apply only to the initial performance test. Each owner or operator subject to the provisions of this rule shall include the following data in the report of the initial performance test required under 1200-3-16-.01(5)(a):

1. Except as provided in part (a)2 of this paragraph, the volume-weighted average mass of VOC's emitted to the atmosphere per volume of applied coating solids (N) for a period of 1 calendar month from each affected facility.

2. For each affected facility where compliance is determined under the provisions of sub-part (4)(b)1.(iv) of this rule, a list of the coatings used during a period of 1 calendar month, the VOC content of each coating calculated from data determined using Reference Method 24 (as specified in 1200-3-16-.01(5)(g)), or supplied by the coating manufacturer, and the minimum transfer efficiency of any coating application equipment used during the month.

3. For each affected facility where compliance is achieved through use of an incineration system, the following additional information will be reported:

(i) The proportion of total VOC's emitted that enters the control device (F),

(ii) The VOC reduction efficiency of the control device (E),

(iii) The average combustion temperature (or the average temperature upstream and downstream of the catalyst bed), and

(iv) A description of the method used to establish the amount of VOC's captured and sent to the incinerator.

4. For each affected facility where compliance is achieved through use of a solvent recovery system, the following additional information will be reported:

(i) The volume of VOC-solvent recovered (Lr), and

(ii) The overall VOC emission reduction achieved (R).

(b) Following the initial performance test, the owner or operator of an affected facility shall identify and record:

1. Each instance in which the volume-weighted average of the total mass of VOC's emitted to the atmosphere per volume of applied coating solids (N) is greater than the limit specified under paragraph (3) of this rule.

2. Where compliance with paragraph (3) of this rule is achieved through use of thermal incineration, each 3-hour period of coating operation during which the average temperature of the device was more than 28°C below the average temperature of the device during the most recent performance test at which destruction efficiency was determined as specified under paragraph (4) of this rule.

3. Where compliance with paragraph (3) of this rule is achieved through use of catalytic incineration, each 3-hour period of coating operation during which the average temperature recorded immediately before the catalyst bed is more than 280C below the average temperature at the same location during the most recent performance test at which destruction efficiency was determined as specified under paragraph (4) of this rule. Additionally, all 3-hour periods of coating operations during which the average temperature difference across the catalyst bed is less than 80 percent of the average temperature difference across the catalyst bed during the most recent performance test at which destruction efficiency was determined as specified under paragraph (4) of this rule will be recorded.

(c) Each owner or operator subject to the provisions of this rule shall maintain at the source, for a period of at least 2 years, records of all data and calculations used to determine VOC emissions from each affected facility. Where compliance is achieved through the use of thermal incineration, each owner or operator shall maintain at the source daily records of the incinerator combustion chamber temperature. If catalytic incineration is used, the owner or operator shall maintain at the source daily records of the gas temperature, both upstream and downstream of the incinerator catalyst bed. Where compliance is achieved through the use of a solvent recovery system, the owner or operator shall maintain at the source daily records of the amount of solvent recovered by the system for each affected facility.

(7) Test methods and procedures.

(a) The reference methods in 1200-3-16-.01(5)(g), except as provided under 1200-3-16 - .01(5)(b), shall be used to determine compliance with paragraph (3) of this rule as follows:

1. Method 24 or formulation data supplied by the coating manufacturer to determine the VOC content of a coating. In the event of dispute, Reference Method 24 shall be the reference method. For determining compliance only, results of Method 24 analyses of waterborne coatings shall be adjusted as described in Subsection 4. 4 of Method 24. Procedures to determine VOC emissions are provided in paragraph (4) of this rule.

2. Method 25 for the measurement of the VOC concentration in the gas stream vent.

3. Method 1 for sample and velocity traverses.

4. Method 2 for velocity and volumetric flow rate.

5. Method 3 for gas analysis.

6. Method 4 for stack gas moisture.

(b) For Method 24, the coating sample must be a 1-liter sample taken into a 1-liter container at a point where the sample will be representative of the coating material.

(c) For Method 25, the sample time for each of three runs is to be at least 60 minutes and the minimum sample volume is to be at least 0.003 dscm except that shorter sampling times or smaller volumes, when necessitated by process variables or other factors, may be approved by the Technical Secretary.

(d) The Technical Secretary will approve sampling of representative stacks on a case-by-case basis if the owner or operator can demonstrate to the satisfaction of the Technical Secretary that the testing of representative stacks would yield results comparable to those that would be obtained by testing all stacks.

Tenn. Comp. R. & Regs. 1200-03-16-.36

Original rule filed September 21, 1988; effective November 6, 1988.

Authority: T.C.A. §§ 68-25-105 and 4-5-202.