Ala. Admin. Code r. 335-3-6-.32

Current through Register Vol. 42, No. 12, September 30, 2024

Section 335-3-6-.32 - Surface Coating

(1)Can Coating.

(a) For the purpose of this paragraph, the following definitions apply:

1. "End Sealing Compound" means a synthetic rubber compound which is coated on to can ends and which functions as a gasket when the end is assembled on the can.

2. "Exterior Base Coating" means a coating applied to the exterior of a can to provide exterior protection to the metal and to provide background for the lithographic or printing operation.

3. "Interior Base Coating" means a coating applied by roller coater or spray to the interior of a can to provide a protective lining between the can metal and product.

4. "Interior Body Spray" means a coating sprayed on the interior of the can to provide a protective film between the product and the can.

5. "Overvarnish" means a coating applied directly over ink to reduce the coefficient of friction, to provide gloss, and to protect the finish against abrasion and corrosion.

6. "Three-Piece Can Side-Seam Spray" means a coating sprayed on the exterior and interior of a welded, cemented, or soldered seam to protect the exposed metal.

7. "Two-Piece Can Exterior End Coating" means a coating applied by roller coating or spraying to the exterior of a can to provide protection to the metal.

(b) This paragraph shall apply to coating applicator(s), flashoff area(s) and oven(s) of sheet, can, or end coating lines involved in sheet basecoat (exterior and interior) and overvarnish; two-piece can exterior (basecoat and overvarnish); two-piece and three-piece can interior body spray; two-piece can exterior end (spray or roll coat); three-piece can side-seam spray and end sealing compound operations.

(c) No owner or operator of a can coating line subject to this paragraph shall cause, allow, or permit the discharge into the atmosphere of any VOCs in excess of:

1. 0.34 kilograms per liter of coating (2.8 pounds per gallon), excluding water, delivered to the coating applicator from sheet basecoat (exterior and interior) and overvarnish or two-piece can exterior (basecoat and overvarnish) operations;

2. 0.51 kilograms per liter of coating (4.2 pounds per gallon), excluding water, delivered to the coating applicator from the two-piece and three-piece can interior body spray and two-piece can exterior end (spray or roll coat) operations;

3. 0.66 kilograms per liter of coating (5.5 pounds per gallon), excluding water, delivered to the coating applicator from three-piece can side seam spray operations; and

4. 0.44 kilograms per liter of coating (3.7 pounds per gallon), excluding water, delivered to the coating applicator from end sealing compound operations.

(2)Coil Coating.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Coil Coating" means the coating of any flat metal sheet or strip that comes in rolls or coils.

2. "Quench Area" means a chamber where the hot metal exiting the oven is cooled by either a spray of water or a blast of air followed by water cooling.

(b) This paragraph shall apply to the coating applicator(s), oven(s), and quench area(s) of coil coating lines involved in prime and top coat or single coat operations.

(c) No owner or operator of a coil coating line subject to this paragraph shall cause, allow, or permit the discharge into the atmosphere of VOCs in excess of 0.31 kilograms per liter of coating (2.6 pounds per gallon), excluding water, delivered to the coating applicator from prime and topcoat or single coat operations.

(3)Metal Furniture Coating.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Application Area" means the area where the coating is applied by spraying, dipping, or flowcoating techniques.

2. "Metal Furniture Coating" means the surface coating of any furniture made of metal or any metal part which will be assembled with other metal, wood, fabric, plastic, or glass parts to form a furniture piece.

(b) This paragraph shall apply to the application areas, flashoff area(s), and oven(s) of metal furniture coating lines involved in prime and topcoat or single coating operations.

(c) No owner or operator of a metal furniture coating line subject to this paragraph shall cause, allow, or permit the discharge into the atmosphere of any VOCs in excess of 0.36 kilograms per liter of coating (3.0 pounds per gallon), excluding water, delivered to the coating applicator from prime and topcoat or single coat operations.

(4)Surface Coating of Large Appliances.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Application Area" means the area where the coating is applied by spraying, dipping, or flowcoating techniques.

2. "Single Coat" means a single film of coating applied directly to the metal substrate omitting the primer application.

3. "Large Appliances" means doors, cases, lids, panels, and interior support parts of residential and commercial washers, dryers, ranges, refrigerators, freezers, water heaters, dishwashers, trash compactors, air conditioners, and other similar products.

(b) This paragraph shall apply to application area(s), flashoff area(s), and oven(s) of large appliance coating lines involved in prime, single, or topcoat coating operations.

(c) This paragraph shall not apply to the use of quick-drying lacquers for repair of scratches and nicks that occur during assembly, provided that the volume of coating does not exceed 757 liters (200 gallons) in any one year.

(d) No owner or operator of a large appliance coating line subject to this paragraph shall cause, allow, or permit the discharge into the atmosphere of any VOCs in excess of 0.34 kilograms per liter of coating (2.8 pounds per gallon), excluding water, delivered to the coating applicator from prime, single, or topcoat coating operations.

(5)Reserved.

(6)Paper Coating.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Knife Coating" means the application of a coating material to a substrate by means of drawing the substrate beneath a knife that spreads the coating evenly over the full width of the substrate.

2. "Paper Coating" means coatings put on paper and pressure sensitive tapes regardless of substrate. Related web coating processes on plastic film and decorative coatings on metal foil are included in this definition. Paper coating includes, but is not limited to, application by impregnation or saturation or by the use of roll, knife, or rotogravure coating.

3. "Roll Coating" means the application of a coating material to a substrate by means of hard rubber or steel rolls.

4. "Rotogravure Coating" means the application of a coating material to a substrate by means of a roll coating technique in which the pattern to be applied is etched on the coating roll. The coating material is picked up in these recessed areas and is transferred to the substrate.

(b) This paragraph shall apply to roll, knife, or rotogravure coater(s), flashoff areas, and drying ovens of paper coating lines. This paragraph shall also apply to other application and drying systems of paper coating lines.

(c) No owner or operator of a paper coating line subject to this paragraph shall cause, allow, or permit the discharge into the atmosphere of any VOCs in excess of 0.35 kilograms per liter of coating (2.9 pounds per gallon), excluding water, delivered to the coating applicator from a paper coating line.

(7)Fabric and Vinyl Coating.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Fabric Coating" means the coating of a textile substrate with a knife, roll, or rotogravure coater to impart properties that are not initially present, such as strength, stability, water or acid repellancy, or appearance. Fabric coating includes, but is not limited to, application by impregnation or saturation or by the use of roll, knife, or rotogravure coating.

2. "Knife Coating" means the application of a coating material to a substrate by means of drawing the substrate beneath a knife that spreads the coating evenly over the full width of the substrate.

3. "Roll Coating" means the application of a coating material to a substrate by means of hard rubber or steel rolls.

5. "Vinyl Coating" means to apply a decorative or protective or functional topcoat or printing on vinyl coated fabric or vinyl sheets. Vinyl plastisol shall not be considered a vinyl coating when it is applied to a fabric to form the substrate that is subsequently coated.

(b) This paragraph shall apply to roll, knife, or rotogravure coater(s), flashoff areas, and drying ovens of fabric and vinyl coating lines. This paragraph shall also apply to other application and drying systems of fabric and vinyl coating lines.

(c) No owner or operator of a fabric coating line or a vinyl coating line subject to this paragraph shall cause, allow, or permit discharge into the atmosphere of any VOCs in excess of:

1. 0.35 kilograms per liter of coating (2.9 pounds per gallon), excluding water, delivered to the coating applicator from a fabric coating line; and

2. 0.45 kilograms per liter of coating (3.8 pounds per gallon), excluding water, delivered to the coating applicator from a vinyl coating line.

(8)Magnet Wire Coating.

(a) For the purpose of this paragraph, the following definition applies:

1. "Magnet Wire Coating" means the process of applying a coating of electrically insulating varnish or enamel to aluminum or copper wire for use in electrical machinery.

(b) This paragraph shall apply to oven(s) of magnet wire coating operations.

(c) No owner or operator of a magnet wire coating oven subject to this paragraph shall cause, allow, or permit the discharge into the atmosphere of any VOCs in excess of 0.20 kilograms per liter of coating (1.7 pounds per gallon), excluding water, delivered to the coating applicator from magnet wire coating operations.

(9)Compliance Methods.

(a) The emission limits under this Rule may be achieved by:

1. the application of low solvent content coating technology; or

2. the installation and operation of a VOC capture system and a VOC control device system provided that each day the overall VOC emission reduction efficiency needed to demonstrate compliance with the applicable emission rate restriction is achieved; or

3. the application of powder coating technology; or

4. The Director may allow a coating line that has no add-on VOC control equipment to average two or more coatings under all the following conditions:

(i) The surface coating shall be for the same type of operation (source category) and shall be subject to the same regulated emission rate restriction; and

(ii) The surface coatings shall be delivered to the application system on the same coating line; and

(iii) The surface coatings shall be averaged on the basis of pounds of VOC emitted per gallon of coating solids applied to the substrate; and

(iv) The compliance demonstration time frame shall be a twenty-four (24) hour period (calendar day); and

(v) The VOC emissions shall be equal to or less than those emitted when all the surface coatings delivered to the application system comply with the applicable regulated VOC emission rate restriction.

(10)Flatwood Paneling.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Class II Hardboard Paneling Finish" means finishes which meet the specifications of Voluntary Product Standard PS-59-73 as approved by the American National Standards Institute.

2. "Hardboard" means a panel manufactured primarily from inter-felted lino-cellulosic fibers which are consolidated under heat and pressure in a hot press.

3. "Hardwood Plywood" means plywood whose surface layer is a veneer of hardwood.

4. "Natural Finish Hardwood Plywood Panels" mean panels whose original grain pattern is enhanced by essentially transparent finishes frequently supplemented by filters and toners.

5. "Thin Particle Board" is a manufactured board 1/4 inch or less in thickness made of individual wood particles which have been coated with a binder and formed into flat sheets by pressure.

6. "Printed Interior Panels" mean panels whose grain or natural surface is obscured by fillers and basecoats upon which a simulated grain or decorative pattern is printed.

7. "Tileboard" means paneling that has a colored waterproof surface coating.

8. "Coating Application System" means all operations and equipment which apply, convey, and dry a surface coating, including, but not limited to, spray booths, flow coaters, conveyors, flashoff areas, air dryers, and ovens.

(b) This paragraph shall apply to all flatwood manufacturing facilities that manufacture the following products:

1. printed interior panels made of hardwood, plywood, and thin particle board;

2. natural finish hardwood plywood panels; or

3. hardboard paneling with Class II finishes.

(c) This paragraph shall not apply to the manufacture of exterior siding, tileboard, or particleboard used as a furniture component.

(d) No owner or operator of a flatwood manufacturing facility subject to this paragraph shall emit VOCs from a coating application system in excess of:

1. 2.9 kilograms per 100 square meters of coated finished product (6.0 pounds per 1,000 square feet) from printed interior panels, regardless of the number of coats applied;

2. 5.8 kilograms per 100 square meters of coated finished product (12.0 pounds per 1,000 square feet) from natural finish hardwood plywood panels, regardless of the number of coats applied; and

3. 4.8 kilograms per 100 square meters of coated finished product (10.0 pounds per 1,000 square feet) from Class II finishes on hardboard panels, regardless of the number of coats applied.

(11)Miscellaneous Metal Parts and Products.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Air Dried Coating" means coatings which are dried by the use of air or forced warm air at temperatures up to 90° C (194° F).

2. "Clear Coat" means a coating which lacks color and opacity or is transparent and uses the undercoat as a reflective base or undertone color and any coating used as an interior protective lining on any cylindrical metal shipping container of greater than one gallon capacity.

3. "Coating Application System" means all operations and equipment which applies, conveys, and dries a surface coating, including, but not limited to, spray booths, flow coaters, flashoff areas, air dryers and ovens.

4. "Extreme Environmental Conditions" means exposure to any one of the following; the weather all of the time, temperatures consistently above 95° C (203° F), detergents, abrasive and scouring agents, solvents, corrosive atmospheres, or similar environmental conditions.

5. "Extreme Performance Coatings" means coatings designed for harsh exposure or extreme environmental conditions.

6. "Heat Sensitive Material" means materials which cannot consistently be exposed to temperatures greater than 95° C (203° F).

7. "Low Solvent Coating" means coatings which contain less organic solvent than the conventional coatings used by the industry. Low solvent coatings include water-borne, higher solids, electrodeposition and powder coatings.

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

9. "Single Coat" means one film of coating applied to a metal surface.

(b) This paragraph shall apply to coating of miscellaneous metal parts and products in the following industries:

1. large farm machinery (harvesting, fertilizing and planting machines, tractors, combines, etc.);

2. small farm machinery (lawn and garden tractors, lawn mowers, rototillers, etc.);

3. small appliances (fans, mixers, blenders, crock pots, dehumidifiers, vacuum cleaners, etc.);

4. commercial machinery (office equipment, computers and auxiliary equipment, typewriters, calculators, vending machines, etc.);

5. industrial machinery (pumps, compressors, conveyor components, fans, blowers, transformers, etc.);

6. fabricated metal products (metal covered doors, frames, etc.); and

7. any other industrial category which coats metal parts or products under the Standard Industrial Classification Code of Major Group 33 (primary metal industries), Major Group 34 (fabricated metal products), Major Group 35 (nonelectric machinery), Major Group 36 (electrical machinery), Major Group 37 (transportation equipment), Major Group 38 (miscellaneous instruments), Major Group 39 (miscellaneous manufacturing industries), Major Group 40 (railroad transportation), and Major Group 41 (transit passenger transportation).

(c) This paragraph shall not apply to the surface coating of the following metal parts and products:

1. automobiles and light-duty trucks;

2. metal cans;

3. flat metal sheets and strips in the form of rolls or coils;

4. magnet wire for use in electrical machinery;

5. metal furniture;

6. large appliances;

7. exterior of airplanes;

8. automobile refinishing;

9. customized coating of automobiles and trucks, if production is less than 35 vehicles per day and if the VOC emission rate from the customized coating operation does not exceed 60 tons per year based on an annual rolling average calculated at the end of each calendar month; and

10. exterior of marine vessels.

11. fabricated metal parts and products under the major Standard Industrial Classification Code of Group No. 34 if the VOC emissions rate is less than a potential ten tons per calendar year (10 TPY) before an add-on VOC control device.

(d) This paragraph shall apply to the application area(s), flashoff area(s), air and forced air dryer(s) and oven(s) used in the surface coating of the metal parts and products in subparagraph (b) of this paragraph. This paragraph also applies to prime coat, top coat, and single coat operations.

(e) No owner or operator of a facility engaged in the surface coating of miscellaneous metal parts and products shall operate a coating application system subject to this paragraph that emits VOCs in excess of:

1. 0.52 kilograms per liter (4.3 pounds per gallon) of coating, excluding water, delivered to a coating applicator that applies clear coatings;

2. 0.42 kilograms per liter (3.5 pounds per gallon) of coating, excluding water, delivered to a coating applicator in a coating application system that is air dried or forced warm air dried at temperatures up to 90° C (194° F);

3. 0.42 kilograms per liter (3.5 pounds per gallon) of coating, excluding water, delivered to a coating applicator that applies extreme performance coatings;

4. 0.36 kilograms per liter (3.0 pounds per gallon) of coating, excluding water, delivered to a coating applicator for all other coatings and coating application systems, excluding powder coating systems; and

5. 0.05 kilograms per liter (0.4 pounds per gallon) of coating, excluding water, delivered to a coating applicator for all powder coating systems.

(f) If add-on control equipment is used, continuous monitors of the following parameters shall be installed, periodically calibrated, and operated at all times that the associated control equipment is operating:

1. exhaust gas temperature of all incinerators;

2. temperature rise across a catalytic incinerator bed;

3. breakthrough of VOC on a carbon adsorption unit; and

4. any other continuous monitoring or recording device required by the Director.

(12)Recordkeeping.

(a) The owner or operator of a coating line subject to the requirements in this Rule shall maintain as a minimum the following daily records to demonstrate compliance in the time frame required by any regulation under this Rule or Air Permit condition:

1. the quantity in gallons of all surface coatings delivered to the application system; and

2. the quantity in gallons of all organic liquid diluents (coating thinners and additives) added to the surface coatings; and

3. the quantity in gallons of all organic liquid solvents used for wash or cleanup; and

4. the quantity in gallons of all organic liquid waste properly contained and shipped out for proper disposal and a certification of the waste density and percent VOC content by weight; and

5. the date of each application of surface coatings and diluents and usage of wash and cleanup solvents; and

6. the regulation(s) applicable to the coating line for which the records are being maintained; and

7. the daily records shall be kept in the units necessary to verify compliance with the applicable regulations (i.e., pounds of VOC per gallon of coating delivered to the application system, excluding water and exempt VOC); and

8. the application method and the substrate material type; and

9. where applicable, the surface coating curing and/or drying oven temperature(s) in degrees Fahrenheit; and

10. where applicable, the continuous combustion temperature in degrees Fahrenheit of a thermal incinerator control system; and

11. where applicable, the temperature rise across the catalyst bed and exhaust temperature in degrees Fahrenheit of a catalytic incinerator control system; and

12. where applicable, the inlet and outlet temperature in degrees Fahrenheit of the cooling medium of a condenser control system; and

13. the following information on all surface coatings, and organic liquid solvents (diluents, additives, wash and cleanup):

(i) manufacturer (supplier); and

(ii) product name and manufacturer's code number; and

(iii) density (pounds per gallon); and

(iv) VOC content in percent weight and volume; and

(v) solids content in percent weight and volume; and

(vi) water content in percent weight and volume; and

(vii) exempt VOC content in percent weight and volume; and

(viii) pounds of VOC per gallon of coating delivered to the application system, excluding water and exempt VOC.

(b) The compliance demonstration time frame for an individual coating line that applies coatings that are subject to the same regulated VOC emission rate under this Rule shall be a twenty-four (24) hour period (calendar day).

(c) The daily records required under subparagraph (a) of this paragraph shall be retained by the owner or operator at the location of the regulated source for a minimum of two years after the date of record and shall be available to representatives of the Director upon request.

(d) The recordkeeping provisions of subparagraph (a) of this paragraph shall not apply if the Director determines that alternative records would be sufficient to provide assurance that the source is operating in compliance on a twenty-four (24) hour basis and these alternative requirements are incorporated as permit conditions for the source. In no case can recordkeeping requirements be waived or the stringency of the emissions limit be relaxed.

Author:

Ala. Admin. Code r. 335-3-6-.32

Effective Date: June 9, 1987. Amended: Effective Date: September 21, 1989, July 31, 1991, October 24, 1991. Amended: Filed October 17, 1996; effective November 21, 1996.

Statutory Authority:Code of Ala. 1975, §§ 22-28-14, 22-22A-5, 22-22A-6, 22-22A-8.