(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:
Click
to view Image
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;
Li = The liquid volume of each
fountain solution, as applied, used that day in units of liters (L) (gallons
[gal]);
VVOCi = The volume fraction of VOC in
each fountain solution, as applied; and
VVCi = 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;
Li = The liquid volume of each
fountain solution, as applied, used on the day in units of L (gal);
Di = The density of each fountain
solution, as applied, in units of mass of fountain solution per unit volume of
fountain solution;
WVOCi = The weight fraction of VOC in
each fountain solution, as applied; and
Wsi = 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:
Click
to view Image
where:
PPc = VOC composite partial pressure
at 20°C, in mm
Hg.
VPi = Vapor pressure of the "i"th VOC
compound at 20°, in mm Hg.
Wi = Weight of the "i"th cleaning
solution, in grams;
Ww = Weight of the water, in
grams;
We = Weight of exempt compound, in
grams;
MWi = Molecular weight of the "i"th
cleaning solution, in grams;
MWw = Molecular weight of the water,
in grams;
MWe = 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:
Click
to view Image
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:
Click
to view Image
Fountain solution VOC emissions:
Ef= Cf
- Df
Total fountain solution VOC emissions:
TF=
EF1+EF2+...+EFN
where,
Cf = VOC content of
fountain solution
Df = VOC content of
press-ready fountain solution discarded or recycled.
Mc = Fountain
solution concntrate weight.
Wc = % VOC (by
weight) in fountain solution from supplier (MSDS) or method specified in
subparagraph (2)(a) in rule 1200-03-18-.81.
Ma = Isopropanol
weight.
Wa = % Isopropanol
(by weight) from supplier (MSDS) .
Ms = Weight of
alcohol substitute.
Ws = % VOC (by
weight) in alcohol substitute from supplier (MSDS) or method specified in
Subparagraph (2)(a) in rule 1200-03-18-.81.
Tf = 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:
Click
to view Image
or
Cl =
Llx Gl
Cleaning solution VOC emissions from Automatic Blanket Wash
System:
El =
Cl
Cleaning solution VOC emissions from hand washing:
Click
to view Image
Total cleaning solution VOC emissions:
Click
to view Image
Key:
CL = VOC content in
cleaning solution
ML = Weight of
cleaning solution (see above for calculation).
wL = % VOC (by
weight) in cleaners from supplier (MSDS) or method specified in Subparagraph
(2)(a) in rule 1200-03-18-.81.
LL = Pounds VOC per
gallon from supplier (MSDS) or method specified in Subparagraph(2)(a) in rule
1200-03-18-.81. GL = volume (gallon)
used: (volume purchased -volume discarded or recycled).
EL = 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.
TL = 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.
