Tenn. Comp. R. & Regs. 1200-03-18-.43

Current through December 10, 2024

Section 1200-03-18-.43 - OFFSET LITHOGRAPHIC PRINTING OPERATIONS

(1) Applicability of this rule is as follows:

(a) This rule applies to offset lithographic printing operations in Davidson, Rutherford, Shelby, Sumner, Williamson, and Wilson Counties.

(b) The emission limits of this rule do not apply to offset lithographic printing operations within any facility whose potential VOC emissions from all offset lithographic printing operations within the facility are less than 100 tons of volatile organic compounds (VOC's) per year.

(2) For the purpose of this rule, the following definitions apply:

(a) "Alcohol substitute" means nonalcohol additives that contain VOC's and are used in the fountain solution. Some additives are used to reduce the surface tension of water; others (especially in the newspaper industry) are added to prevent piling (ink build up).

(b) "Batch" means a supply of fountain solution that is prepared and used without alteration until completely used or removed from the printing process.

(c) "Cleaning Solution" means liquids to remove ink and debris from the operating surfaces of the printing press and its parts.

(d) "Fountain Solution" means a mixture of water, nonvolatile printing chemicals, and an additive (liquid) that reduces the surface tension of the water so that it spreads easily across the printing plate surface. The fountain solution wets the nonimage areas so that the ink is maintained within the image area. Isopropyl alcohol, a VOC, is the most common additive used to reduce the surface tension of the fountain solution.

(e) "Heatset" means any operation where heat is required to evaporate ink oil from the printing ink. Hot air dryers are used to deliver the heat.

(f) "Lithography" means a printing process where the image and nonimage area are chemically differentiated; the image area is oil receptive and the nonimage area is water receptive. This method differs from other printing methods, where the image is a raised or recessed surface.

(g) "Non-heatset" means any operation where the printing inks are set without the use of heat.

(h) "Offset" means a printing process that transfers the ink film from the lithographic plate to an intermediary surface (blanket), which, in turn, transfer the ink film to the substrate.

(i) "Press" means a printing production assembly composed of one or many units to produce a printed sheet or web.

(j) "Sheet-fed" means a printing operation where individual sheets of substrate are fed to the press.

(k) "Unit" means the smallest complete printing component of a printing press.

(l) "Web" means a continuous roll of paper used as the printing substrate.

(3) Standard as follow apply:

(a) No owner or operator of a heatset web offset lithographic printing press subject to this rule shall apply any fountain solution unless the VOC content is equal to or less than one of the following:

1. 1.6 percent VOC by volume of the fountain solution containing alcohol, as applied;

2. 3 percent VOC by volume of the fountain solution containing alcohol, as applied, if the fountain solution is refrigerated to less than 60°F.

3. 4.6 percent VOC by volume of the fountain solution, as applied, and use no alcohol in the fountain solution .

4. 6 percent VOC by volume of the fountain solution, as applied, if the fountain solution is refrigerated to less than 60°F and use no alcohol in the fountain solution.

(b) No owner or operator of a non-heatset web offset printing press subject to this rule shall apply any fountain solution that contains alcohol, nor shall any fountain solution be applied unless the VOC content is equal to or less than 5 percent by weight of the fountain solution, as applied.

(c) Reserved.

(d) No owner or operator of a sheet-fed offset lithographic printing press subject to this rule shall apply any fountain solution unless the VOC content is equal to or less than one of the following:

1. 5 percent VOC by volume of the fountain solution, as applied;

2. 8.5 percent VOC by volume of the fountain solution, as applied, if the fountain solution is refrigerated to less than 60°F.

(e) No owner or operator of an offset lithographic printing press subject to this rule shall apply any cleaning solutions unless:

1. The VOC composite partial vapor pressure of the cleaning solutions is less than 10mm Hg at 20°C, as applied; or

2. The VOC content of the cleaning solutions are less than or equal to 30 percent by weight, as applied.

(f) Reserved.

(g) Any person who owns or operates a heatset offset lithographic printing press subject to this rule shall reduce VOC emissions from the press dryer exhaust vent by 90 percent by weight of total organic (minus methane and ethane), or maintain a maximum control device outlet concentration of 50 ppmv whichever is less stringent when the press is in operation.

(h) As an alternative to compliance with the limits in Subparagraphs (3)(a), (d), (e), or (f) of this paragraph, an owner or operator of an offset lithographic printing press may comply with the requirements of Paragraph (4) of this rule.

(i) As an alternative to compliance with the limits in Subparagraphs (3)(g) of this paragraph, an owner or operator of an offset lithographic printing press may comply with the requirements of Paragraph (5) of this rule.

(4) Weighted average limitations as follow apply:

(a) No owner or operator of an offset lithographic printing press subject to this rule shall apply fountain solutions on the printing press unless the weighted average, by volume, VOC content of all fountain solutions, as applied, each day on the printing press is equal to or less than the limitation specified in either Part (3)(a) or (3)(d) [as determined by Subparagraph (4)(d)]; or, in the case of nonalcohol additives or alcohol substitute addition to fountain solution, (3)(c) [as determined by Subparagraph (4)(e)].

(b) Reserved.

(c) No owner or operator of an offset lithographic printing press subject to this rule shall apply cleaning solutions on the printing press unless VOC composite vapor pressure, as applied, each day on the printing press is equal to or less than the limitation specified in Subparagraph (3)(e)1 [as determined by Subparagraph (4)(f)] of this rule.

(d) The following equation shall be used to determine if the weighted average VOC content, by volume, of all fountain solutions, as applied, on the subject printing press exceeds the limitation specified in Part (3)(a) or (3)(d) of this rule:

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where:

VOC_(i)(A) = The weighted average VOC content in units of percent VOC by volume of the volatile content of all fountain solutions used each day;

i = Subscript denoting a specific fountain solution , as applied;

n = The number of different fountain solutions, as applied, each day on a printing press;

L_i = The liquid volume of each fountain solution, as applied, used that day in units of liters (L) (gallons [gal]);

V_VOCi = The volume fraction of VOC in each fountain solution, as applied; and

V_VCi = The volume fraction of volatile matter in each fountain solution, as applied.

(e) The following equation shall be used to determine if the weighted average VOC content, by weight, of all fountain solutions, as applied, on the subject printing press exceeds the limitations specified in Part (4)(a) in case of fountain solution :

Click to view Image

where:

VOC_(i)(B) = The weighted average VOC content in units of percent VOC by weight of the volatile content of all fountain solutions used each day;

i = Subscript denoting a specific fountain solution as applied;

n = The number of different fountain solutions, as applied, each day on a printing press;

L_i = The liquid volume of each fountain solution, as applied, used on the day in units of L (gal);

D_i = The density of each fountain solution, as applied, in units of mass of fountain solution per unit volume of fountain solution;

W_VOCi = The weight fraction of VOC in each fountain solution, as applied; and

W_si = The weight fraction of solids in each fountain solution, as applied.

(f) The following equation shall be used to determine if the VOC composite partial pressure of cleaning solutions, as applied, exceeds the limitation specified in Part (3)(e) of this rule:

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where:

PP_c = VOC composite partial pressure at 20°C, in mm

Hg.

VP_i = Vapor pressure of the "i"th VOC compound at 20°, in mm Hg.

W_i = Weight of the "i"th cleaning solution, in grams;

W_w = Weight of the water, in grams;

W_e = Weight of exempt compound, in grams;

MW_i = Molecular weight of the "i"th cleaning solution, in grams;

MW_w = Molecular weight of the water, in grams;

MW_e = Molecular weight of exempt compound, in grams;

i = Subscript denoting a specific cleaning solution , as applied;

n = The number of different cleaning solutions, as applied, each day on a printing press.

(5) Reserved.

(6) Test methods and procedures as follow apply:

(a) The affected facility shall be run at typical operating conditions and flow rates during any emission testing.

(b) Emission tests shall include an initial test, within 90 days of initial startup, when the control device is installed and operating that demonstrates compliance with either the 90 percent (by weight) reduction or the 50 ppmv emission limit.

(c) In conducting the tests required to comply with Paragraph (3)(a), (b), (d), or (e)(2) of this rule, the owner or operator shall use the test methods specified in rule 1200-03-18-.81 of this chapter.

(d) In conducting the tests required to comply with Subparagraph (3)(g) of this rule, the owner or operator shall use the test methods specified in rule 1200-03-18-.84 of this chapter.

(e) To be in compliance with the fountain solution refrigeration requirements of this rule, the affected facility shall use a thermometer or other temperature detection device capable of reading to 0.5°F to ensure that a refrigerated fountain solution containing alcohol is below 60°F at all times.

(f) To be in compliance with the Subparagraph (3)(e)1 of this rule, if applicable, each owner or operator of an offset lithographic printing press subject to this rule shall determine VOC composite partial pressure as given in Subparagraph (4)(f).

(7) Monitoring requirement apply as follow:

(a) To be in compliance with the emission control requirements of this rule, the affected facility shall monitor any add-on dryer exhaust control device as follow:

1. The owner or operator of a subject heatset offset lithographic printing press shall install, calibrate, maintain, and operate a temperature monitoring device, according to the manufacturer's instructions, at the inlet or outlet of the control device. The monitoring temperature shall be set during testing required to demonstrate compliance with the emission standard. Monitoring shall be required only when the unit is operational.

2. The temperature monitoring device shall be equipped with a continuous recorder and shall have an accuracy of 0.5°F.

3. The dryer pressure shall be maintained lower than the press room air pressure such that air flows into the dryer at all times when the press is operating. A 100 percent emissions capture efficiency for the dryer shall be established using an air flow direction indicator, such as a smoke stick or aluminum ribbons.

(b) To be in compliance with the Subparagraph (3)(a), (b), or (d) of this rule, each owner or operator of an offset lithographic printing facility subject to this rule shall monitor the fountain solution as follow:

1. The purpose of monitoring the VOC concentration in the fountain solution is to provide data that can be correlated to the amount of material used when the fountain solution contains alcohol and complies with the limits listed in Subparagraph (3)(a) or (d). The following methods may be used to determine the concentration of alcohol in the fountain solution frequently. Alternatively, calculation of the alcohol concentration using the protocol of Subparagraph (7)(c) or (d) may be used to demonstrate compliance with Subparagraph (3)(a) or (d). The monitoring requirements of Subparagraph (7)(b) shall only be required if noncompliance is suspected.

(i) The owner or operator of any subject offset lithographic printing press shall monitor the alcohol concentration of the fountain solution with a refractometer, that is corrected for temperature, at least once per 8-hour shift or once per batch, whichever is longer. The refractometer shall have a visual, analog, or digital readout with an accuracy of 0.5 percent. A standard solution shall be used to calibrated the refractometer for the type of alcohol used in the fountain. Alternatively, the refractometer shall be standardized against measurements or calculations performed to determine compliance, according to the procedures described in Subparagraph 7(c) or (d).

(ii) Alternatively, the owner or operator of any subject offset lithographic printing press shall monitor the alcohol concentration of the fountain solution with a hydrometer, that is corrected for temperature, at least once per 8-hour shift or once per batch, whichever is longer. The hydrometer shall have a visual, analog, or digital readout with an accuracy of 0.5 percent. A standard solution shall be used to calibrate the refractometer for the type of alcohol used in the fountain. Alternatively, the refractometer shall be standardized against measurements or calculations performed to determine compliance, according to the procedures described in Subparagraph 7(c) or (d).

(iii) The VOC content of the fountain solution may be monitored with a conductivity meter if it is determined that a refractometer or hydrometer cannot be used for monitoring the type of VOC's in the fountain solution. The conductivity meter reading for the fountain solution shall be referenced to the conductivity of the incoming water. A standard solution shall be used to calibrate the conductivity meter for the type of alcohol used in the fountain. Alternatively, the conductivity shall be standardized against measurements or calculations performed to determine compliance, according to the procedures described in Subparagraph (7)(c) or (d).

2. If, through recordkeeping for a period of 6 months or more, the printing process is shown to consistently meet the requirements in (3)(a) or (d), the monitoring requirement may be waived or extended by the Technical Secretary to a longer period of time.

3. The owner or operator of any subject offset lithographic printing press using refrigeration equipment on the fountain to comply with the requirements of Subparagraph (3)(a)2. Or (d)2., shall maintain, and operate a temperature monitor of the fountain solution reservoir.

4. The temperature monitor shall be read and noted at least once per operation day to verify that the refrigeration system is operating properly.

(c) The VOC content of fountain solution shall be determined by using the test methods specified in rule 1200-03-18-.81.

(d) Alternatively, a sample of the fountain solution (as used) may be taken from the fountain tray or reservoir of fountain solution during use and measured with a hydrometer or refractometer that has been standardized with tests or calculations performed in accordance with Subparagraph (7)(b). The unit shall be considered in compliance with Section 6(c) if the refractometer or hydrometer measurement is less than of equal to the value determined according to section 7(c), plus ten percent.

(8) Compliance Certification, recordkeeping and reporting requirements as follow apply:

(a) By November 15, 1996, any owner or operator of an offset lithographic printing press that is exempt from the requirements of this rule because of the criteria in Subparagraph (1)(b) of this rule shall comply with the following:

1. The owner or operator of a facility in Davidson, Rutherford, Sumner, Wilson and Williamson County shall certify to the Technical Secretary that the facility is exempt under the provisions of Subparagraph (1)(b) of this rule. Such certification shall include:

(i) The name and location of the facility;

(ii) The address and telephone number of the person responsible for the facility;

(iii) A declaration that the facility is exempt from emission limitations of this chapter because total VOC emissions from the facility are below 25 tons per year; and

(iv) Calculations demonstrating the combined VOC emissions from the facility are below 25 tons per year before the application of capture systems and control devices. The following equations shall be used to calculate the VOC emissions:

A. Ink VOC Content and Emissions:

Ink VOC Content:

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where,

C₁ = VOC content in Ink

M₁ = Weight of ink used: (amount purchased -amount discarded or recycled).

W₁ = %VOC (by weight) in ink from either supplier (MSDS) or method specified in Subparagraph (2)(a) of rule 1200-03-18-.81.

G₁ = Volume (gallons) used; (volume purchased -volume discarded or recycled)

R = % VOC (by weight) retained by paper: Non-heatset - 95% as per Nov. 1993 draft Control Techniques Guideline for Offset Lithography.

Heatset - 20% as per Nov. 1993 draft Control Techniques Guideline for Offset Lithography. UV - Amount from method specified in subparagraph (2)(a) of rule 1200-03-18-.81 after curing (assume 100%).

T₁ = Total VOC emissions from all inks, 1 + 2 + .. + n.

B. Fountain solution VOC Content and emissions:

Fountain solution VOC content:

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Fountain solution VOC emissions:

E_f= C_f - D_f

Total fountain solution VOC emissions:

T_F= E_F1+E_F2+...+E_FN

where,

C_f = VOC content of fountain solution

D_f = VOC content of press-ready fountain solution discarded or recycled.

M_c = Fountain solution concntrate weight.

W_c = % VOC (by weight) in fountain solution from supplier (MSDS) or method specified in subparagraph (2)(a) in rule 1200-03-18-.81.

M_a = Isopropanol weight.

W_a = % Isopropanol (by weight) from supplier (MSDS) .

M_s = Weight of alcohol substitute.

W_s = % VOC (by weight) in alcohol substitute from supplier (MSDS) or method specified in Subparagraph (2)(a) in rule 1200-03-18-.81.

T_f = Total emissions from all fountain solutions, 1 + 2 + ... + n.

weight of material:

M = V x D

M = Weight of material

V = Volume (gallon) of material used: ( volume purchased - volume discarded or recycled).

D = Density in lb/gal from MSDS or ( specific gravity x 8.33 lbs/gal).

C. Cleaning solution VOC content and emissions:

Cleaning solution VOC content:

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C_l = L_lx G_l

Cleaning solution VOC emissions from Automatic Blanket Wash System:

E_l = C_l

Cleaning solution VOC emissions from hand washing:

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Total cleaning solution VOC emissions:

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Key:

C_L = VOC content in cleaning solution

M_L = Weight of cleaning solution (see above for calculation).

w_L = % VOC (by weight) in cleaners from supplier (MSDS) or method specified in Subparagraph (2)(a) in rule 1200-03-18-.81.

L_L = Pounds VOC per gallon from supplier (MSDS) or method specified in Subparagraph(2)(a) in rule 1200-03-18-.81. G_L = volume (gallon) used: (volume purchased -volume discarded or recycled).

E_L = Clenaing solution VOC emissions.

R = % VOC (by weight) retained by wipes: 50%

per June 1994 ACT for Offset lithography and cleaning solutions with VOC partial vapor pressure of 10mm Hg or less at 20 degree C.

T_L = Total VOC emissions from all cleaners, 1 + 2 + .. +n

2. On or after November 15, 1996, the owner or operator shall collect and record all of the following information and maintain the information at the facility for a period of 3 years:

(i) The name and identification of each ink, fountain solution and cleaning solvent;

(ii) The weight of VOC per unit weight of ink and the weight of ink used;

(iii) The weight of VOC per unit weight of cleaning solvent and fountain solution and the weight of cleaning solvent and fountain solution used; and

(iv) The average VOC emissions as calculated using the equation in Subparagraph (8)(a)1(iv) of this paragraph.

3. Any record showing that total emissions of VOC from all offset lithographic printing operations exceeded 25 tons in any calendar year, before the application of capture systems and control devices, shall be reported by sending a copy to the Technical Secretary within 30 calendar days after the exceedences occurs.

(b) Any owner or operator of a printing press subject to this rule and complying by means of use of complying inks, fountain solution, and cleaning solution, shall comply with the following:

1. By November 15, 1996, or upon initial startup of a new printing press

(i) The name and identification number of each ink, fountain solution, and cleaning solution as applied; and

(ii) The VOC content of all inks, fountain solutions and cleaning solutions, as applied, expressed in units of the applicable standard.

(c) Any owner or operator of a printing press subject to this rule and complying by means of weighted averaging shall comply with the following:

1. By November 15, 1996, or upon initial startup of a new printing press, or change method of compliance, the owner or operator of a subject printing press shall certify to the Technical Secretary that the printing press is in compliance with Paragraph (4) of this rule. Such certification shall include:

(i) The name and location of the facility;

(ii) The address and telephone number of the person responsible for the facility;

(iii) The name and identification of each printing press which will comply by means of Paragraph (4) of this rule;

(iv) The name and identification of each ink, fountain solution, or cleaning solution as applied;

(v) The VOC content of all inks, fountain solutions or cleaning solutions, as applied, expressed in units of the applicable standard;

(vi) The instrument or method by which the owner or operator will accurately measure or calculate the volume of each solution, as applied, each day on each printing press;

(vii) The methods by which the owner or operator will create and maintain records each day as required in Part 2 of this subparagraph; and

(viii) An example of the format in which the records required in Part 2 of this Subparagraph will be kept.

2. On or after November 15, 1996, or on and after the initial startup date, or change method of compliance, the owner or operator of a printing press subject to the limitations of this rule and complying by means of weighted averaging shall collect and record all of the following information each day for each printing press and maintain the information for a period of 3 years:

(i) The name and identification number of each coating, fountain solution, or cleaning solution, as applied;

(ii) The VOC content and the volume of each solution, as applied, expressed in units necessary to determine compliance; and

(iii) The weighted average VOC content of all solutions, as applied.

3. On or after November 15, 1996, the owner or operator of a printing press subject to the limitations of this rule shall notify the Technical Secretary of any instance of noncompliance with Paragraph (4) be sending a copy of the calculation showing such noncompliance to the Technical Secretary within 30 calendar days following the occurrence.

(d) Any owner or operator of a printing press subject to this rule and complying by means of control devices shall comply with rule 1200-03-18-.03(5) of this chapter, except that the applicable date for certification, recordkeeping and reporting shall be November 15, 1996 rather than April 22, 1994.

(9) With respect to petitioning for a source-specific compliance schedule according to and as provided for in rule 1200-03-18-.07 of this chapter, the owner or operator shall insure the petition is received by the Technical Secretary no later than October 1, 1995 rather than October 22 1993.

Tenn. Comp. R. & Regs. 1200-03-18-.43

Original rule filed August 11, 1995; effective October 26, 1995. Amendment filed March 13, 1997; effective May 27, 1997. Amendment filed January 15, 2009; effective March 31, 2009.

Authority: T.C.A. §§ 4-5-201 et. seq. and 68-201-105.