Section NR 422.143 - Lithographic printing - part 2(1) APPLICABILITY. (a) This section applies to the owner or operator of a printing facility that operates a lithographic printing press and meets all of the following criteria: 1. The facility has actual VOC emissions from all lithographic printing presses, including related lithographic cleaning activities and fountain solution use at the facility, before consideration of controls, equal to or greater than 3 tons on a 12-consecutive month rolling basis.2. The facility meets any of the following criteria:a. The facility is located in Kenosha, Milwaukee, Ozaukee, Racine, Sheboygan, Washington, or Waukesha County.b. The facility is constructed or modified on or after July 1, 2019, and is located in Kewaunee or Manitowoc county.c. The facility is located in any area designated as a moderate, serious, severe, or extreme ozone nonattainment area.d. The facility is located in any area formerly designated as a moderate, serious, severe, or extreme ozone nonattainment area that has subsequently been redesignated to attainment, except for any facility subject to s. NR 422.142.(am) When determining the VOC emissions for applicability under this subsection, the VOC emissions shall include the emissions from the use of inks, fountain solutions, and cleaning solutions, as defined in s. NR 422.02(14m).(1m) RETENTION FACTORS AND CAPTURE EFFICIENCIES. For purposes of determining VOC emissions from offset lithographic printing operations, the following retention factors and capture efficiencies may be used:(a) A 20% VOC retention factor for heatset inks printed on absorptive substrates, meaning 80% of the VOC in the ink is emitted during the printing process and is available for capture and control by an add-on pollution control device.(b) A 95% VOC retention factor for sheet-fed and non-heatset web inks printed on absorptive substrates, meaning 5% of the VOC in the ink is emitted during the printing process.(c) A 50% VOC retention factor for cleaning solution VOC in shop towels where the composite partial vapor pressure of the VOC in the cleaning solution is less than 10 mm of Hg at 20°C (68°F) and the cleaning solution and contaminated shop towels are kept in closed containers, meaning 50% of the VOC used on the shop towels is emitted during the cleaning process.(d) A 100% VOC capture efficiency for inks. All the VOC in the ink that is not retained is assumed to be volatilized in the press dryer. Capture efficiency testing for heatset dryers is not required if it is demonstrated that pressure in the dryer is negative relative to the surrounding press room and the airflow is into the dryer.(e) A 70% VOC capture efficiency for fountain solutions containing alcohol substitutes.(f) A 40% VOC capture efficiency for automatic blanket or roller wash, as defined in s. NR 422.02(7c), where the VOC composite partial vapor pressure of the automatic blanket or roller wash is less than 10 mm of Hg at 20°C (68°F).(2) EXEMPTIONS. All of the following exemptions apply to lithographic printing operations affected by this section: (a) Up to 110 gallons of cleaning solutions, on a 12-consecutive month rolling basis, that do not meet the low VOC composite partial vapor pressure or low VOC content requirements as stated in this section, are exempt from the requirements of this section.(b) The fountain solution VOC content requirements in sub. (3) (b) do not apply to sheet-fed presses with a maximum sheet size of up to 11 inches by 17 inches or to any lithographic press with a total fountain solution reservoir of less than one gallon.(c) The printing of books on a heatset lithographic press is exempt from the requirements of sub. (3) (a).(d) Heatset lithographic presses with a maximum web width of up to 22 inches are exempt from the requirements of sub. (3) (a).(3) EMISSION LIMITATIONS.(a)Dryer exhaust. 1. On and after May 1, 2010, no owner or operator of a heatset web lithographic printing press may operate, or cause, allow or permit the operation of a lithographic press that has maximum theoretical emissions of VOCs, from the dryer, equal to or greater than 25 tons per year from heatset inks, unless the owner or operator installs and operates an emission control device and meets the applicable emission limitation as follows:a. If the emission control device was first installed prior to May 1, 2010, the owner or operator shall reduce VOC emissions from the lithographic press dryer exhaust by 90% by weight as carbon, minus methane and ethane, or maintain a maximum dryer exhaust outlet VOC concentration of 20 ppmv, as carbon, minus methane and ethane.b. If the emission control device was first installed after May 1, 2010, the owner or operator shall reduce VOC emissions from the lithographic press dryer exhaust by 95% by weight as carbon, minus methane and ethane, or maintain a maximum dryer exhaust outlet VOC concentration of 20 ppmv, as carbon, minus methane and ethane. Note: With regard to use of the phrase "first installed" in this paragraph, the first installation date for a control device does not change if the device is later moved to a new location. For example, if a brand new control device first installed in 1992 is moved to a new location in 1998, the first installation date is still 1992.
2. If a combined dryer and control device is a part of the press design, a 100% capture at the control inlet may be assumed for purposes of meeting the emission reduction limits in subd. 1.(b)Fountain solutions.1. `Heatset web presses.' On and after May 1, 2010, any person who owns or operates a heatset web lithographic printing press shall use a fountain solution which has a VOC content, as applied, of no more than one of the following: a. 1.6% by weight if the fountain solution contains any restricted alcohol and is not refrigerated to 60°F or less.b. 3.0% by weight if the fountain solution contains any restricted alcohol and is refrigerated to 60°F or less.c. 5.0% by weight if the fountain solution contains no restricted alcohol.2. `Non-heatset web presses.' On and after May 1, 2010, any person who owns or operates a non-heatset web lithographic printing press shall use a fountain solution which contains no restricted alcohol and which has a VOC content, as applied, of no more than 5.0% by weight.3. `Sheet-fed presses.' On and after May 1, 2010, any person who owns or operates a sheet-fed lithographic printing press shall, use a fountain solution which has a VOC content, as applied, of no more than one of the following: b. 8.5% by weight if the fountain solution is refrigerated to 60°F or less.(c)Cleaning solutions. Except as provided in sub. (2) (a), no owner or operator of a lithographic printing press may cause, allow, or permit the use of a cleaning solution unless the cleaning solution has a VOC content less than 70% by weight or has a composite partial vapor pressure of less than or equal to 10 mm of Hg at 68°F.(4) WORK PRACTICES. (a) On and after November 1, 2009, the owner or operator of a lithographic press subject to this subsection shall store all solvents, solvent solutions and any applicator moistened with solvents or solvent solutions that are used in cleaning operations related to lithographic printing in covered non-absorbent, non-leaking containers, except when filling or emptying the container.(5) MONITORING REQUIREMENTS. (a) The owner or operator of any lithographic printing press shall monitor, at least once each 8-hour shift, the temperature of each fountain solution reservoir for any fountain solution subject to sub. (3) (b) 1. b. or 3. b.(b) The owner or operator of any lithographic printing press subject to the VOC control device requirements of sub. (3) (a) shall comply with all of the following monitoring requirements:1. Install and operate continuous temperature monitoring and recording equipment that measures and records any of the following temperature of the control device at least once every 15 minutes:a. The combustion chamber or minimum operating temperature for thermal oxidizers.b. The catalytic bed inlet temperature for catalytic oxidizers.2. Meet the instrument requirements in s. NR 439.055(3) (a) and (4) for the temperature monitoring devices.3. Maintain the 3-hour average temperature at or above any of the following levels when the associated printing press is in operation: a. 50°F below the minimum operating temperature specified by the manufacturer for regenerative thermal oxidizers.b. 50°F below the average temperature measured during the most recent emission test that demonstrated compliance for all other type of oxidizers.4. For catalytic oxidizers, inspect the catalyst bed material annually for general catalyst condition and any signs of potential catalyst depletion. The owner or operator shall also collect a representative sample of the catalyst from the catalytic oxidizer, in accordance with manufacturer's recommendations, and have it tested to evaluate the catalyst's capability to continue to function at or above the required control efficiency. An evaluation of the catalyst bed material shall be conducted whenever the results of the inspection indicate signs of potential catalyst depletion or poor catalyst condition based on manufacturer's recommendations, but not less than once per year.5. Perform maintenance for the control devices in accordance with manufacturer's recommendations.(6) RECORDKEEPING REQUIREMENTS. In addition to the applicable recordkeeping requirements in s. NR 439.04, the owner or operator of any lithographic printing press shall collect and record the applicable information specified in this subsection. The information shall be maintained at the facility for a minimum of 5 years and shall be made available to an authorized department representative at any time during normal working hours. The information required is all of the following: (a) For a heatset web lithographic printing press using a control device, all of the following: 1. Temperature monitoring data for the control device in accordance with sub. (5) (b) 1. for each day of operation.2. A log or record of any time when the control device or control device monitoring equipment is offline while the associated printing line is in operation.3. A maintenance log for the control device and control device monitoring equipment detailing all maintenance performed and including the dates and duration of any outages.4. Annual inspection results for catalytic oxidizers.(b) For fountain solutions monitored under sub. (5), the fountain solution reservoir temperature for each 8-hour shift of operation.(c) For each fountain solution used, the percent by weight VOC content as applied, and the CAS number and chemical name of each restricted alcohol.(d) For each cleaning solution prepared, the percent by weight VOC content or the VOC composite partial vapor pressure for the cleaning solution prepared.(e) For each month of operation, the volume of all cleaning solutions used that do not meet either of the emission limitations in sub. (3) (c).(7) COMPLIANCE TESTING. (a) The owner or operator of a heatset web lithographic printing press shall demonstrate compliance with the appropriate destruction efficiency or emission rate in sub. (3) (a) by performing compliance emission tests on each control device. The initial emission tests shall be performed by the compliance deadline in sub. (8) (am). Each emission test shall follow the methods and procedures listed in s. NR 439.07. Method 18, 25 or 25A in 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04(16), (19) and (20), shall be used to determine the VOC concentration at the sampling points. When determining the VOC concentration, the probe shall be heated during testing to at least the exhaust gas stream temperature.(b) The owner or operator of a heatset web lithographic printing press shall perform the compliance emission tests required under par. (a) according to one of the following applicable test schedules:1. Any facility with allowable VOC emissions from lithographic printing presses of 100 tons or more per year shall perform an emission test that demonstrates compliance with sub. (3) (a) every 24 months. Each biennial test shall be performed within 90 days of the anniversary date of the initial emission test or an alternate date approved by the department. The testing exceptions listed in s. NR 439.075(4) may apply to this test schedule.2. Any facility with allowable VOC emissions from lithographic printing presses of less than 100 tons per year shall perform an initial emission test that demonstrates compliance with sub. (3) (a).(c) The VOC content of the as-applied fountain solutions and cleaning solutions shall be determined by any of the following methods: 1. The method referred to in s. NR 439.06(3) (j).2. If diluted prior to use, a calculation shall be performed for VOC content that combines the method referred in s. NR 439.06(3) (j) for the concentrated materials used to prepare the as-applied fountain solution or cleaning solution, and the proportions in which they are mixed to make the as-applied fountain solution or cleaning solution.(d) The VOC composite partial vapor pressure of each cleaning solution shall be determined by any of the following methods: 1. If diluted prior to use, calculate the VOC composite vapor pressure of the as-applied solvent by using the formula for "VOC composite vapor pressure" as follows: a. Determine the identity and quantity of each compound in a blended organic solvent.b. Determine the vapor pressure of each pure VOC component.c. Calculate the VOC composite partial pressure of the solvent by using the formula for "VOC composite partial pressure." For the purpose of this calculation, the blended solvent shall be assumed to be an ideal solution where "Raoult's Law" applies. The partial vapor pressures of each compound at 68°F shall be used in the formula. The VOC composite partial pressure shall be calculated as follows: See PDF for diagram
where:
Wi is the weight of the "i"th VOC compound, in grams.
Ww is the weight of water, in grams.
We is the weight of exempt compound, in grams.
MWi is the molecular weight of the "i"th VOC compound, in grams per gram-mole.
MWw is the molecular weight of water, in grams per gram-mole.
MWe is the molecular weight of the "e"th exempt compound, in grams per gram-mole.
PPc is the VOC composite vapor pressure at 68°F, in mm Hg.
VPi is the vapor pressure of the "i"th VOC compound at 68°F, in mm Hg.
2. If not diluted prior to use, the owner or operator shall use formulation information provided by the supplier, such as a safety data sheet (SDS) or equivalent information from the supplier, as long as it is based on results determined in accordance with the procedure in subd. 1.(8) COMPLIANCE SCHEDULE AND CERTIFICATION REQUIREMENTS. (am) The owner or operator of a heatset web lithographic printing press that is installed after July 1, 2019, shall perform a compliance emission test within 180 days after installation of the press and shall submit to the department no later than 60 days after the test written certification that the press is in compliance with the applicable requirements of sub. (3) and a demonstration of compliance in accordance with subs. (6), (7), and (8).(bm) The owner or operator of any lithographic printing press, other than a heatset web press, that is installed after July 1, 2019, shall submit to the department, no later than 180 days after installation of the press, written certification that the press is in compliance with the applicable requirements of sub. (3) and a demonstration of compliance in accordance with subs. (6), (7), and (8). (c) Facilities subject to this section and located in an area described under sub. (1) (a) 2. c., shall comply with the applicable requirements of this section by the following deadlines: 1. Facilities that were initially constructed in an area described in sub. (1) (a) 2. c., prior to the effective date of its designation as moderate, serious, severe, or extreme ozone nonattainment, shall comply with applicable requirements within 180 days of the effective date of designation.2. Facilities that were initially constructed in an area described in sub. (1) (a) 2. c., after the area has been designated as moderate, serious, severe, or extreme ozone nonattainment, shall comply with applicable requirements upon startup.Wis. Admin. Code Department of Natural Resources NR 422.143
CR 08-102: cr. Register July 2009 No. 643, eff. 8-1-09; CR 11-005: renum. (3) (c) to be (3) (c) (intro.) and am., cr. (3) (c) 1., 2., am. (6) (d) Register January 2012 No. 673, eff. 2-1-12.Amended by, CR 18-067: am. (1) (a), cr. (1) (a) 1., 2., (am), am. (1m) (f), (2) (intro.), (a), (3) (c) (intro.) and 2. cons. and renum. to (3) (c) and am., (5) (a) renum. to (5), am. (5) (title), cr. (5) (b), am. (6) (intro.), (a), cr. (6) (a) 4., am. (6) (d), (e), (7) (a), (b) 1., 2., (7) (c) (renum.) to (7) (c) (intro.) and am., cr. (7) (c) 1., 2., (d), (8) (b) 1. renum. to (8) (am) and am., (8) (b) 2. renum. to (8) (bm) and am., cr. (8) (c) Register June 2019 No. 762, eff. 7-1-19; correction in numbering of (1) (a) made under s. 13.92(4) (b) 1, and corrections in (1) (a) (intro.), 1., (am), (7) (d) 1. c., 2. made under s. 35.17, Stats., Register June 2019 No. 762; correction in (1) (am) made under s. 13.92(4) (b) 7, Stats., Register June 2019 No. 762, eff. 7/1/2019