[Federal Register Volume 61, Number 250 (Friday, December 27, 1996)]
[Proposed Rules]
[Pages 68406-68428]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 96-32237]
[[Page 68405]]
_______________________________________________________________________
Part IV
Environmental Protection Agency
_______________________________________________________________________
40 CFR Part 63
National Emission Standards for Hazardous Air Pollutants for Flexible
Polyurethane Foam Production; Proposed Rule
Federal Register / Vol. 61, No. 250 / Friday, December 27, 1996 /
Proposed Rule
[[Page 68406]]
ENVIRONMENTAL PROTECTION AGENCY
40 CFR Part 63
[AD-FRL-5664-8]
RIN 2060-AE-86
National Emission Standards for Hazardous Air Pollutants for
Flexible Polyurethane Foam Production
AGENCY: Environmental Protection Agency (EPA).
ACTION: Proposed rule and notice of public hearing.
-----------------------------------------------------------------------
SUMMARY: This proposed rule would reduce emissions of hazardous air
pollutants (HAP) from existing and new facilities that manufacture
flexible polyurethane foam. In the production of flexible polyurethane
foam a variety of HAP are used as reactants or process solvents. The
HAP emitted by the facilities covered by this proposed rule include
methylene chloride, toluene diisocyanate, methyl chloroform, methylene
diphenyl diisocyanate, propylene oxide, diethanolamine, methyl ethyl
ketone, methanol, and toluene. Methylene chloride comprises over 98
percent of the total HAP emissions from this industry. This proposed
rule is estimated to reduce emissions of these pollutants by over
12,500 Megagrams per year (Mg/yr), with over 99 percent of this total
expected to be methylene chloride emission reductions. The emission
reductions achieved by these standards, when combined with the emission
reductions achieved by other similar standards, will achieve the
primary goal of the Clean Air Act, which is to ``enhance the quality of
the Nation's air resources so as to promote the public health and
welfare and the productive capacity of its population.''
This proposed rule implements section 112(d) of the Clean Air Act
of 1990 (CAAA), which requires the Administrator to regulate emissions
of HAP listed in section 112(b) of the CAAA. The intent of this rule is
to protect the public by requiring the maximum degree of reduction in
emissions of HAP from new and existing major sources, taking into
consideration the cost of achieving such emission reduction, and any
nonair quality, health and environmental impacts, and energy
requirements.
DATES: Comments. Comments must be received on or before February 25,
1997.
Public Hearing. If anyone contacts the EPA requesting to speak at a
public hearing by January 17, 1997, a public hearing will be held on
January 27, 1997 beginning at 10 a.m. Persons interested in attending
the hearing should call Ms. Marguerite Thweatt at (919) 541-5607 to
verify that a hearing will be held.
Request to Speak at Hearing. Persons wishing to present oral
testimony must contact the EPA by January 17, 1997 by contacting Ms.
Marguerite Thweatt, Organic Chemicals Group (MD-13), U.S. Environmental
Protection Agency, Research Triangle Park, North Carolina 27711,
telephone number (919) 541-5607.
ADDRESSES: Comments. Comments should be submitted (in duplicate, if
possible) to: Air Docket Section (LE-131), Attention: Docket No. A-95-
48, U.S. Environmental Protection Agency, 401 M Street SW., Washington,
DC 20460. The EPA requests that a separate copy also be sent to the
contact person listed below. The public hearing, if required, will be
held at the EPA's Office of Administration Auditorium, Research
Triangle Park, North Carolina.
The docket is located at the above address in room M-1500,
Waterside Mall (ground floor), and may be inspected from 8:00 a.m. to
5:30 p.m., Monday through Friday; telephone number (202) 260-7548. A
reasonable fee may be charged for copying docket materials.
FOR FURTHER INFORMATION CONTACT:
For information concerning this proposed rule, contact Mr. David
Svendsgaard at (919) 541-2380, Organic Chemicals Group, Emission
Standards Division (MD-13), U.S. Environmental Protection Agency,
Research Triangle Park, North Carolina 27711.
SUPPLEMENTARY INFORMATION:
Regulated Entities
Entities regulated by this action, upon promulgation, are flexible
polyurethane foam production facilities. Regulated categories and
entities include:
------------------------------------------------------------------------
Category Examples of regulated entities
------------------------------------------------------------------------
Industry........................ Producers of slabstock, molded, and
rebond flexible polyurethane foam.
------------------------------------------------------------------------
This table is not intended to be exhaustive, but rather provides a
guide for readers regarding entities likely to be regulated by this
action. This table lists the types of entities that EPA is now aware
could potentially be regulated by this action. Other types of entities
not listed in the table could also be regulated. To determine whether
your facility is regulated by this proposed action, you should
carefully examine the applicability criteria in section 63.1290 of the
proposed rule. If you have questions regarding the applicability of
this action to a particular entity, consult the person listed in the
preceding FOR FURTHER INFORMATION CONTACT section.
In addition to its inclusion in this Federal Register notice, the
regulatory text is available in Docket No. A-95-48, or from the EPA
contact person designated in this notice. The proposed regulatory
language is also available on the Technology Transfer Network (TTN) on
the EPA's electronic bulletin boards. The TTN provides information and
technology exchange in various areas of air pollution control. The
service is free, except for the cost of a telephone call. Dial (919)
541-5742 for up to a 14,400 bps modem. For further information, contact
the TTN HELP line at (919) 541-5348, from 1:00 p.m. to 5:00 p.m. Monday
through Friday, or access the TTN web site at: http://
ttnwww.rtpnc.epa.gov.
The Basis and Purpose Document which contains the rationale for the
various components of the standard, is available in the docket and on
the TTN. This document is entitled Hazardous Air Pollutant Emissions
from the Production of Flexible Polyurethane Foam--Basis and Purpose
Document for Proposed Standards, September 1996, and has been assigned
document number EPA-453/D-96-008a.
Other materials related to this rulemaking are available for review
in the docket. Some of the technical memoranda have been compiled into
a single document, the Supplementary Information Document (SID), to
allow interested parties more convenient access to the information. The
SID is available in the docket (Docket No. A-95-48 Category III-B),
and, in limited supply, from the EPA Library by calling (919) 541-2777.
The document is entitled Hazardous Air Pollutant Emissions from the
Production of Flexible Polyurethane Foam--Supplementary Information
Document for Proposed Standards, October 1996, and has been assigned
document number EPA-453/D-96-009a.
A record has been established for this rulemaking under docket
number A-95-48 (including comments and data submitted electronically as
described below). A public version of this record, including printed,
paper versions of electronic comments, which does not include any
information included as CBI, is available for inspection from 8:00 a.m.
to 5:30 p.m. Monday-Friday, excluding legal holidays. The public record
is located in the Air & Radiation Docket & Information Center, Room
M1500, 401 M Street S.W., Washington, D.C. 20460. Electronic comments
can be
[[Page 68407]]
sent directly to EPA at: [email protected].
Electronic comments must be submitted as an ASCII file avoiding the
use of special characters and any form of encryption. Comments and data
will also be accepted on disks in WordPerfect 5.1 format or ASCII file
format. All comments and data in electronic form must be identified by
the docket number A-95-48. No Confidential Business Information (CBI)
should be submitted through e-mail. Electronic comments on this
proposed rule may be filed online at many Federal Depository Libraries.
The official record for this rulemaking, as well as the public
version, as described above, will be kept in paper form. Accordingly,
the EPA will transfer all comments received into printed, paper form as
they are received and will place the paper copies in the official
rulemaking record, which will also include all comments submitted
directly in writing. The official rulemaking record is the paper record
maintained at the address in the ADDRESSES section of this document.
The information presented in this preamble is organized as follows:
I. List of Source Categories
II. A Summary of Considerations Made in Developing This Rule.
III. Authority for National Emission Standards for Hazardous Air
Pollutants Decision Process
A. Source of Authority for NESHAP Development
B. Criteria for Development of NESHAP
IV. Summary of Proposed Standards
A. Source Categories to be Regulated
B. Pollutants to be Regulated
C. Affected Emission Points
D. Format of the Standards
E. Proposed Standards
F. Reporting and Recordkeeping Requirements
V. Request for Comment on Specific Issues
VI. Summary of Environmental, Energy, Cost, and Economic Impacts
A. Facilities Affected by These NESHAP
B. Primary Air Impacts
C. Other Environmental Impacts
D. Energy Impacts
E. Cost Impacts
F. Economic Impacts
VII. Administrative Requirements
A. Public Hearing
B. Docket
C. Executive Order 12866
D. Enhancing the Intergovernmental Partnership Under Executive
Order 12875
E. Paperwork Reduction Act
F. Regulatory Flexibility Act
G. Unfunded Mandates Reform Act
H. Miscellaneous
I. List of Source Categories
Section 112 of the CAAA requires that the EPA evaluate and control
emissions of HAP. The control of HAP is achieved through promulgation
of emission standards under sections 112(d) and 112(f) and work
practice and equipment standards under section 112(h) for categories of
sources that emit HAP. On July 16, 1992, the EPA published an initial
list of major and area source categories to be regulated, as required
under section 112(c) of the CAAA. Included on that list were major
sources emitting HAP from the production of flexible polyurethane foam.
The EPA chose to subcategorize the flexible polyurethane foam
source category into molded flexible polyurethane foam production,
slabstock flexible polyurethane foam production, and rebond foam
production. Subcategorization was necessary to reflect major variations
in production methods, and/or HAP emissions that affect the
applicability of controls. All technical analyses were conducted on a
subcategory basis to determine the appropriate level of the standard.
In addition, on June 4, 1996 the EPA added to the source category list
a separate source category for flexible polyurethane foam fabrication
(61 FR 28197). These operations are occasionally co-located with
slabstock foam production facilities, but occur other places as well. A
future standard will address flexible polyurethane foam fabrication
operations.
The EPA identified 78 facilities in the U.S. that produce slabstock
foam. It is believed that this represents the entire slabstock foam
industry. The identification of the U.S. molded foam facility
population has been more difficult to estimate. This difficulty is due
to the many small companies serving specialty markets, the production
of molded foam at facilities that also produce other molded plastic
products, and the lack of a trade association for molded foam. The EPA
identified 46 molded foam facilities in the information gathering phase
of the project, but industry estimates that there may be several
hundred molded foam facilities nationwide. The nationwide molded foam
facility population was estimated to be 228, based primarily on
information found in suppliers guides. In this notice the EPA is
requesting comments on this molded foam facility population estimate.
If commenters dispute this estimate, the EPA would request supporting
documentation for such an assertion, along with a list of molded foam
facility names and locations.
The EPA identified 21 rebond foam production facilities that are
co-located with slabstock or molded foam production facilities. It is
estimated that this represents about one-half of the total U.S. rebond
foam facility population.
This proposed rule would apply to all major sources that produce
flexible polyurethane foam. Area sources would not be subject to this
proposed rule. All of the slabstock foam facilities considered in the
analysis supporting the proposed rule are believed to be major sources
according to the CAAA criterion of having the potential to emit 10 tons
per year of any one HAP or 25 tons per year of any combination of HAP.
In this proposed rule, an affected source includes all flexible
polyurethane foam and rebond processes located at a contiguous plant
site, where a process consists of raw material storage; production
equipment and piping, ductwork, and other associated equipment; and
curing and storage areas.
II. A Summary of Considerations Made in Developing This Rule
The Clean Air Act was created in part ``to protect and enhance the
quality of the Nation's air resources so as to promote the public
health and welfare and the productive capacity of its population''
(CAAA, section 101(b)(1)). Section 112(d) of the Act establishes a
control technology-based program to reduce stationary source emissions
of HAP. The goal of the proposed rule is to apply such control
technology to reduce emissions and thereby reduce the impacts of HAP
emitted from stationary sources.
Available emission data, collected during the development of these
proposed National Emission Standards for Hazardous Air Pollutants
(NESHAP), show that the greatest volume of HAP emitted during the
production of flexible polyurethane foam is the emission of methylene
chloride. The proposed emission limits are projected to reduce
methylene chloride emissions by 70 percent. Following is a summary of
the potential health effects associated with exposure to methylene
chloride that would be reduced by the standard.
The acute (short-term) effects of methylene chloride inhalation in
humans consist mainly of nervous system symptoms such as decreased
visual and auditory functions. These effects are reversible once
exposure ceases. Short-term exposure to high concentrations of
methylene chloride also irritates the nose and throat. The effects of
chronic (long-term) exposure to methylene chloride involve the central
nervous system, and include headaches, dizziness, nausea, and memory
loss. Animal studies indicate
[[Page 68408]]
that inhalation of methylene chloride affects the liver, kidney, and
cardiovascular system. Developmental or reproductive effects of
methylene chloride have not been reported in humans, but limited animal
studies have reported lowered fetal body weights in rats exposed to
inhalation.
Human data are considered inadequate to prove cancer caused by
exposure to methylene chloride; animal studies have shown increases in
liver and lung cancer and benign mammary gland tumors following the
inhalation of methylene chloride. Methylene chloride is classified as
Group B2, probable human carcinogen of relatively low carcinogenic
potency.
As noted earlier, there are other HAP emitted by flexible
polyurethane foam production facilities. While the magnitude of
emissions of these pollutants is dwarfed by those of methylene
chloride, it is important to note that the EPA has not undertaken a
risk assessment of these facilities. Therefore, it is possible that
other HAP, such as diisocyanates, may also pose risks of concern. The
seriousness of risks remaining after imposition of the final MACT
standards will be examined at a later date, as provided for under
Section 112(f) of the Clean Air Act.
The Clean Air Act strategy avoids dependence on a detailed and
comprehensive risk assessment hampered by (but not limited to) the
following caveats, as a pre-requisite for controlling air toxics: (1)
some of the HAP emitted from stationary sources are unknown, and (2)
the EPA has incomplete data about the emissions of many of the HAP with
which to describe health hazards. In addition, this is not a
``significant'' rule as defined by Executive Order 12866, and a
specific benefits analysis is not required. Because of these issues, a
detailed and intensive risk assessment of potential effects from HAP
emitted from flexible foam plants is not included in this rulemaking.
The EPA does recognize that the degree of adverse effects to health
resulting from the most significant emissions identified can range from
mild to severe. The extent to which the effects could be experienced is
dependent upon the ambient concentrations and exposure time. The latter
is further influenced by source-specific characteristics, such as
emission rates and local meteorological conditions. Human variability
factors also influence the degree to which effects to health occur:
genetics, age, pre-existing health conditions, and lifestyle.
The alternatives considered in the development of this regulation,
including those alternatives selected as standards for new and existing
sources, are based on process and emissions data received from the
flexible polyurethane foam industry. This included information from
every existing flexible polyurethane slabstock foam facility known to
be in operation at the time of the initial data collection, and the
information gathered from the 46 molded foam facilities (which was
assumed to be representative of the entire molded foam industry). The
EPA met with industry several times to discuss this data. In addition,
facilities and State regulatory authorities had the opportunity to
comment on draft versions of the regulation and to provide addition
information. Several facilities did provide comments; of major concern
to industry were the auxiliary blowing agent (ABA) emission limitation,
and the reporting and recordkeeping requirements. The proposed
standards reflect these comments.
The proposed standards give existing facilities 3 years from the
date of promulgation to comply. This is the maximum amount of time
allowed under the Clean Air Act. New sources are required to comply
with the standard upon startup. The EPA sees no reason why new
facilities would not be able to comply with the requirements of the
standards upon startup. For existing sources, the EPA believes that the
required retrofit or other actions can be achieved in the time frame
allotted.
Included in the proposed rule are methods for determining initial
compliance as well as monitoring, recordkeeping, and reporting
requirements. All of these components are necessary to ensure that
sources will comply with the standards both initially and over time.
However, the EPA has made every effort to simplify the requirements in
the rule.
As described in the Basis and Purpose document, regulatory
alternatives were considered that included a combination of
requirements equal to, and above, the maximum achievable control
technology (MACT) ``floor.'' Cost-effectiveness was a factor considered
in evaluating options above the MACT floor; in cases where options more
stringent than the floor were selected, they were judged to have a
reasonable cost effectiveness Non-air environmental and health factors,
as well as energy impacts were also considered and deemed to be
reasonable for the proposed standards.
Representative from other interested EPA offices and programs, as
well as representative from State regulatory agencies, are included in
the regulatory development process as members of the Work Group. The
Work Group is involved in the regulatory development process, and must
review and concur with the regulation before proposal and promulgation.
Therefore, the EPA believes that the implication to other statutory
authorities and programs have been adequately considered during the
development of these standards.
In addition to this proposed standards, two of the HAP use and
emitted by the flexible polyurethane foam industry (toluene
diisocyanate and propylene oxide) are subject to the risk management
program rule requirements under section 112(r) of the CAAA. The risk
management rule was signed May 24, 1996, and the rule was published in
the Federal Register on June 20, 1996. Facilities handling a listed
subject in quantities greater than threshold amount must comply with
the risk management requirements by June 20, 1999. The list of
substances and threshold quantities were published in the Federal
Register on January 31, 1994.
III. Authority for National Emission Standards for Hazardous Air
Pollutants Decision Process
A. Source of Authority for NESHAP Development
Section 112 of the CAAA gives the EPA the authority to establish
national standards to reduce air emissions from sources that emit one
or more HAP. Section 112(b) contains a list of HAP to be regulated by
NESHAP. Section 112(c) directs the EPA to use this pollutant list to
develop and publish a list of source categories for which NESHAP will
be developed. The EPA must list source categories and subcategories of
``major sources'' (defined below) that emit one or more of the listed
HAP. A major source is defined in section 112(a) as any stationary
source or group of stationary sources located within a contiguous area
and under common control that emits or has the potential to emit in the
aggregate, considering controls, 10 tons per year or more of any one
HAP or 25 tons per year or more of any combination of HAP. This initial
list of source categories was published in the Federal Register on July
26, 1992 (57 FR 31576) and include flexible polyurethane foam.
The proposed rule, as noted in Sec. 63.1290(a), applies only to
major sources (sources which emit or have the potential to emit HAP in
excess of the major source thresholds). The rule does not affect area
sources (those that do not emit or have the potential to emit HAP
[[Page 68409]]
in excess of the major source thresholds). A definition of ``major
source'' and ``potential to emit'' is contained in Sec. 63.2 of the
general provisions to part 63. Some sources which would otherwise have
a potential to emit HAP in excess of the major source thresholds can
become area sources by accepting enforceable limitations on their
operations. A number of issues exist with respect to the requirements
for such enforceable limitations. These issues (particularly whether
such limitations must be federally enforceable) will be subject to a
separate upcoming rulemaking. In this separate rulemaking, the EPA will
be amending the definitions of ``major source'' and ``potential to
emit'' in Sec. 63.2. The EPA requests that any comments on requirements
for potential to emit limitations be directed towards this separate
rulemaking.
For those facilities that may seek enforceable limitations on their
potential to emit, the EPA believes that mechanisms are in place in
most States to provide such limitations. In addition, the owners or
operators of sources in the flexible polyurethane foam industry will
have had to address whether the title V operating permits program
affects their particular facilities well before the compliance date of
the NESHAP. Title V applications vary from State to State, but
generally will be due within the 1995-97 time frame. The compliance
date for the proposed NESHAP would be in 3 years after promulgation of
the standard, which will likely be sometime in the year 2000.
The proposed rule provides a mechanism that could be used by
sources seeking area sources status to limit their emissions. The
mechanism requires owners or operations to notify the Administrator of
their commitment to maintaining emissions below major source levels.
This notification would be included in the Precompliance Report, and
would include recordkeeping and reporting procedures. The EPA requests
comments on whether this provision, contained in Sec. 63.1290(c)(1) of
the proposed rule, is necessary. In addition, the EPA requests comments
on any amendments to the provision that would make it more useful or
understandable.
B. Criteria for Development of NESHAP
The NESHAP are to be developed to control HAP emissions from both
new and existing sources according to the statutory directives set out
in section 112(d) of the CAAA. The statute requires the standards to
reflect the maximum degree of reduction in emissions of HAP that is
achievable for new or existing sources, considering costs and other
impacts. This control level is referred to as MACT.
The MACT floor is the least stringent level allowed for MACT
standards. For new sources, the standards for a source category or
subcategory ``shall not be less stringent than the emission control
that is achieved in practice by the best controlled similar source, as
determined by the Administrator'' (section 112(d)(3)). Existing source
standards shall be no less stringent than the average emission
limitation achieved by the best performing 12 percent of the existing
sources for categories and subcategories with 30 or more sources or the
average emission limitation achieved by the best performing 5 sources
for categories or subcategories with fewer than 30 sources (section
112(d)(3)). These two minimum levels of control define the MACT floor
for new and existing sources. When the selection of MACT considers
control levels more stringent than the MACT floor (described below),
its selection must reflect consideration of the cost of achieving the
emission reduction, any non-air quality, health, and environmental
impacts, and energy requirements.
IV. Summary of Proposed Standards
This section provides a summary of the proposed regulation. The
full regulatory text is available in Docket No. A-95-48, directly from
the EPA, or from the Technology Transfer Network (TTN) on the EPA's
electronic bulletin boards. More information on how to obtain a copy of
the proposed regulation is provided at the beginning of the
SUPPLEMENTARY INFORMATION section of this document.
A. Source Categories To Be Regulated
These proposed standards would regulate HAP emissions from
facilities that produce slabstock, molded, or rebond flexible
polyurethane foam, provided that a facility is a major source or is
located at a plant site that is a major source. Flexible polyurethane
foam processes meeting one of three criteria are exempted from the
regulation: (1) A process located at a plant site, where the plant site
is limited by a federally enforceable limit to emissions less than 10
tons per year of any single HAP and less than 25 tons per year of all
HAP; (2) a process exclusively dedicated to the fabrication of flexible
polyurethane foam; and (3) a research and development process.
B. Pollutants To Be Regulated
The HAP currently emitted by the facilities covered by this
proposed rule include methylene chloride, toluene diisocyanate, methyl
chloroform, methylene diphenyl diisocyanate, propylene oxide,
diethanolamine, methyl ethyl ketone, methanol, and toluene. Emission of
any of these HAP or any other HAP that are emitted from emission points
discussed in the next section will be affected. Methylene chloride,
which comprises over 98 percent of the total HAP emissions from this
industry, will be the primary HAP affected.
C. Affected Emission Points
As noted above, three basic areas of the foam production facility
are covered by the proposed regulation: (1) raw material storage; (2)
production equipment and associated piping, ductwork, etc.; and (3)
curing and storage areas. These areas contain the following emission
points, which are covered by the proposed regulation: storage vessels,
equipment leaks, mixhead flush, mold release agents, repair adhesives,
equipment cleaning, and ABA.
D. Format of the Standards
This section discusses the selected formats for the proposed
standards. The formats and their selection are discussed in more detail
in the Basis and Purpose Document for this proposed regulation.
For mixhead flush, mold release agents, and repair adhesives at
molded foam facilities; mold release agents and equipment cleaners at
rebond foam facilities; and equipment cleaning at slabstock foam
facilities, the format of the proposed standards is the prohibition of
the use of HAP or HAP-based products.
For storage vessels at slabstock facilities, the format is an
equipment standard. For equipment leaks at slabstock facilities, the
proposed standards incorporate several formats including equipment
standards, design standards, work practices, and operational practices.
For HAP ABA at slabstock facilities, the format of the proposed
standards is an emission limitation. The proposed regulation includes
provisions for the calculation of an allowable HAP ABA emissions level,
which is compared to the actual HAP ABA emissions.
E. Proposed Standards
Existing sources subject to the proposed regulation would be
required to comply within three years of the effective date of the
regulations, and
[[Page 68410]]
new sources would be required to comply at startup. Following is a
description of the requirements of the proposed standards.
1. Standards for Molded Flexible Polyurethane Foam Production
At molded foam facilities subject to the proposed rule, emissions
from three emission sources are covered by the proposed rule: mixhead
flushing, mold release agent usage, and the use of adhesives to repair
molded foam. For each of these emission sources, the proposed rule
prohibits the use of HAP or HAP-based products at new and existing
sources. Other than the initial notification and notification of
compliance, there are no associated monitoring, reporting, or
recordkeeping requirements for molded foam producers.
2. Standards for Rebond Foam Production
This proposed regulation would prohibit the use of HAP-based
cleaners or mold release agents in the production of rebond foam at new
and existing sources. Other than the initial notification and
notification of compliance, there are no associated monitoring,
reporting, or recordkeeping requirements for rebond foam producers.
3. Standards for Slabstock Flexible Polyurethane Foam Production
At slabstock foam facilities subject to the proposed rule,
emissions from four types of emission points are covered by the
proposed rule: storage vessels, equipment leaks, HAP auxiliary blowing
agent (ABA) use, and equipment cleaning. The requirements are separated
into two basic categories corresponding to the two major uses of HAP in
the slabstock process: (1) diisocyanate used as a reactant in the foam
process, and (2) HAP ABA and equipment cleaning. The diisocyanate used
in the production of slabstock foam is almost always toluene
diisocyanate (TDI), and the HAP ABA used is almost always methylene
chloride.
a. Diisocyanate emissions
Emissions of diisocyanate from storage vessels and equipment leaks
are covered by the proposed standards. For new and existing sources,
there are two compliance options for storage vessels. The vessel can be
equipped with a vapor return line that returns vapors displaced during
storage vessel filling to the tank truck or rail car. The second option
is to equip the storage vessel with a system in which displaced vapors
are routed through a carbon adsorption system prior to being discharged
to the atmosphere. Storage vessels equipped with carbon adsorption
systems must monitor the outlet of the carbon system to detect
breakthrough.
Transfer pumps in diisocyanate service must be either sealless
pumps, or submerged pump systems that are visually monitored weekly to
detect leaks. Any transfer pump leaks detected must be repaired within
15 calendar days. Diisocyanate leaks for other components in
diisocyanate service (valves, connectors, and pressure-relief valves)
detected by visual, audible, or any other detection method must be
repaired within 15 calendar days, as well.
b. HAP ABA storage and equipment leak emissions, HAP ABA emissions from
the production line, and equipment cleaning HAP emissions
HAP ABA emissions from three types of emission points--storage
vessels, equipment leaks, and the production line--are covered by the
proposed regulation. In addition, HAP emissions from equipment cleaning
are covered.
This proposed regulation requires that owners or operators comply
with requirements for each of the four types of emission points (HAP
ABA emissions from storage vessels, equipment leaks, and the production
line, and HAP emissions from equipment cleaning). These limitations are
described below.
However, since methylene chloride is the primary HAP used as an ABA
and as an equipment cleaner, this proposed rule allows owners and
operators flexibility in complying with the HAP ABA and equipment
cleaning provisions. As an alternative to the emission point specific
limitations, the owner or operator can elect to comply with a source-
wide emission limitation. Owners or operators selecting the source-wide
emission limitation must maintain the combined emissions from all of
these sources below the required level. While this option is slightly
more stringent than the emission point specific limitations, the EPA
believes the flexibility it provides will prove to be beneficial for
sources selecting this alternative.
HAP ABA storage vessel requirements. The requirements for HAP ABA
storage vessels are identical to the diisocyanate storage vessel
requirements discussed above. Storage vessels can be equipped with
either a vapor return line to the tank truck or railcar, or a carbon
adsorption system. The requirements for new and existing sources are
identical.
HAP ABA equipment leaks. These proposed standards contain
requirements for pumps, valves, connectors, pressure-relief devices,
and open-ended valves or lines in HAP ABA service at new and existing
sources.
Pumps and valves must be monitored quarterly for leaks using Method
21, 40 CFR part 60, appendix A, where a leak is defined as an
instrument reading of 10,000 parts per million or greater. Leaks must
be repaired within 15 calendar days after their detection.
Alternatively, leakless pumps can be used. Valves that are designated
as unsafe-to-monitor must be monitored as frequently as possible, and
difficult-to-monitor valves must be monitored once per year.
Connectors must be monitored annually, unless the connector has
been opened or the seal broken. In these cases, the connector must be
monitored within 3 months after being returned to HAP ABA service. As
with the other components, a leak is defined as an instrument reading
of 10,000 parts per million or greater, and a leak must be repaired
within 15 calendar days. Connectors can also be designated as unsafe-
to-monitor, in which case they must be monitored as frequently as
possible.
Pressure-relief devices must be monitored using Method 21 if
evidence of a potential leak is found by visual, audible, olfactory, or
any other detection method. If a leak is found (10,000 parts per
million), it must be repaired within 15 calendar days.
Each open-ended valve or line in HAP ABA service must be equipped
with a cap, blind flange, plug, or a second valve.
HAP ABA Emissions from the production line. Compliance with the
proposed provisions for HAP ABA emissions from the production line is
determined by comparing actual HAP ABA emissions to an allowable
emission level for a 12-month period. Compliance must be determined
each month for the previous consecutive 12-month period.
This proposed regulation recognizes the variability in HAP ABA
emissions for different grades of foam, where a grade of foam is
determined by its density and indentation force deflection (IFD).
Therefore, the allowable emission level is dependent on the mix of foam
grades produced during the 12-month compliance period. The nucleus of
the HAP ABA emission limitation provisions is the HAP ABA formulation
limitation equation, which determines an allowable amount of HAP ABA
for each grade of foam. For existing sources, this equation is:
[[Page 68411]]
[GRAPHIC] [TIFF OMITTED] TP27DE96.001
Where,
ABAlimit = HAP ABA formulation limitation, parts HAP ABA
allowed per hundred parts polyol (pph)
IFD = Indentation force deflection (25 percent), pounds
DEN = Density, pounds per cubic foot
Therefore, for each foam grade produced during the 12-month period, the
owner or operator must determine the HAP ABA formulation limitation.
This equation was developed using actual formulation data from the best
performing foam production facilities. The development of this equation
is discussed in docket item no. II-B-6.
For new sources, the equation is used to determine the HAP ABA
formulation limitation for a limited number of grades. However, the
formulation limitation for many higher-density, higher-IFD foams is
automatically set to zero.
The allowable HPA ABA emissions for a consecutive 12-month period
are calculated as the sum of allowable monthly HAP ABA emissions for
each of the individual 12 months in the period. Allowable HAP ABA
emissions for each individual month are calculated using the following
equation.
[GRAPHIC] [TIFF OMITTED] TP27DE96.002
Where,
emisallow, month= Allowable HAP ABA emissions from the
slabstock affected source for the month, pounds
m = number of slabstock foam production lines at the affected source
n = Number of foam grades produced in the month on foam production
line j
limiti = HAP ABA formulation limit for foam grade i, parts HAP
ABA per 100 parts polyol
polyoli = Amount of polyol used in the month in the production
of foam grade i on foam production line j, pounds
The amount of polyol used is a key component of this analysis, and
it must be determined by continuously monitoring the amount of polyol
added to the slabstock foam production line at the mixhead when foam is
being poured (see section IV(E)(4)(b) below for more information).
Actual HAP ABA emissions are determined by continuously monitoring
the HAP ABA added to the slabstock foam production line at the mixhead
when foam is being poured. The allowable monitoring methods for HPA ABA
are the same as for polyol.
This proposed regulation also contains provisions to allow for the
use of HAP ABA recovery devises. If a recovery device is used, the
actual HAP emissions are the difference between the uncontrolled HAP
ABA emissions and the HAP ABA recovered. The uncontrolled HAP ABA
emissions are determined by monitoring the HAP ABA added to the
slabstock foam production line at the mixhead, as discussed above. The
amount of HAP ABA recovered is required to be monitored.
As an alternative to the rolling annual compliance approach, owners
or operators can elect to comply each month. If this approach is
selected, actual and allowable emissions are determined as discussed
above. However, compliance is determined by comparing allowable and
actual emissions for each month, rather than for the 12 previous
months. An advantage of the monthly compliance approach is that a
violation of the allowable monthly HAP limitation constitutes up to 30
days of violation for that compliance period, whereas a violation of
the allowable annual total of HAP calculated in any given month
constitutes up to 365 days of violation for that compliance period.
This alternative is allowed because it is more stringent than the
rolling annual compliance approach.
Equipment cleaning HAP emissions. Affected sources complying with
the emission point specific limitations are prohibited from using a
HAP, or a HAP-based product, as an equipment cleaner. Other than the
initial notification, there are no associated reporting, recordkeeping,
or monitoring requirements.
Source-wide emission limitation alternative. This alternative
allows the owner or operator to choose which of the HAP ABA emission
sources to control but is only available for sources using no more than
one HAP as an ABA and equipment cleaner in the process. In other words,
an owner or operator could choose not to control HAP ABA storage
vessels and equipment leaks, and achieve a slightly higher HAP ABA
emission reduction from the production line. Alternatively, an owner or
operator could choose to control emissions from equipment leaks and
storage to ``save'' as much HAP ABA as possible for use in the
production line. In addition, under the source-wide alternative, a
facility could utilize a HAP equipment cleaner, as long as the HAP used
as the equipment cleaner is the same chemical as the HAP ABA. However,
the equipment cleaning HAP emissions must be offset by emission
reductions from one of the HAP ABA emission sources.
An owner or operator electing to comply with the source-wide
emission limitation for HAP ABA and equipment cleaning determines
compliance by comparing actual emissions from the three HAP ABA
emission sources and from equipment cleaning with an allowable
emissions level. Compliance is determined each month for the previous
12-month period.
The allowable emissions level is determined using the same
procedures discussed above for HAP ABA emissions from the production
line. Therefore, the total HAP ABA and equipment cleaning HAP emissions
allowed under this alternative are equivalent to the allowed HAP ABA
emissions from the production line if the emission point specific
alternative is selected.
The actual HAP ABA and equipment cleaning emissions are determined
by performing a material balance at the HAP ABA storage vessel, using
the following equation:
[GRAPHIC] [TIFF OMITTED] TP27DE96.003
Where,
PWEactual = Actual source-wide HAP ABA and equipment cleaning
HAP emissions for a month, pounds/month
STi,begin = Amount of HAP ABA in storage tank i at the
beginning of the month, pounds
STi,end = Amount of HAP ABA in storage tank i at the end of the
month, pounds,
[[Page 68412]]
ADDi = Amount of HAP ABA added to storage tank i during the
month, pounds
n = Number of HAP ABA storage vessels
Weekly monitoring of the level of HAP ABA in the storage vessels is
required, thus providing the beginning and end of month amounts to be
used in the above equation. In addition, the amount of each HAP ABA
delivery must be determined. The requirements for the monitoring of HAP
ABA storage vessel levels and the amount of HAP ABA added during each
delivery is discussed later in this section. Emission reductions
achieved by recovery devices can be accounted for by monitoring the
amount of HAP ABA recovered.
As with the emission point specific limitation for HAP ABA from the
production line, the source-wide emission limitation includes a monthly
compliance alternative.
4. Monitoring Requirements
This proposed regulation contains monitoring requirements for five
situations: (1) storage vessels complying using carbon adsorption
systems, (2) polyol and HAP ABA added to the production line at the
mixhead, (3) recovered HAP ABA when a recovery device is used, (4) the
amount of HAP ABA in a storage vessel, and (5) the amount of HAP ABA
added to a storage vessel.
a. Storage Vessel Emissions Monitoring
Storage vessels equipped with carbon adsorption systems must
monitor either the concentration of HAP or the concentration of total
organic compounds (TOC) at the exit of the adsorption system.
Measurements of HAP or TOC concentration must be made using Method 18
or 25A of Appendix A of 40 CFR 60. Outlet concentration measurements
must be made monthly (or each time the vessel is filled, if filling
occurs less frequently than monthly), or the owner or operator can
install a monitoring system that continuously monitors HAP or TOC
concentrations during vessel filling.
b. Polyol and HAP ABA Monitoring at the mixhead
All slabstock facilities must continuously monitor the amount of
polyol added to the slabstock foam production line at the mixhead when
foam is being poured to allow the calculation of allowable emissions.
The regulation contains two options for continuously monitoring the
polyol added: (1) a device installed and operated to monitor and record
pump revolutions per minute, or (2) a flow rate monitoring device
installed and operated to measure the amount of polyol added at the
mixhead. Either of these devices must be calibrated at least once each
6 months, and must have an accuracy to within 2 percent.
The owner or operator can develop an alternative monitoring program to
monitor the amount of polyol added at the mixhead. The components of an
alternative monitoring plan shall include, at a minimum, (1)
description of the parameter to be monitored to measure the amount of
HAP ABA or polyol added at the mixhead; (2) a description of how the
monitoring results will be recorded, and how the results will be
converted into amount of HAP ABA or polyol delivered to the mixhead;
(3) data demonstrating that the monitoring device is accurate to within
2.0 percent; and (4) procedures to ensure that the
accuracy of the parameter monitoring results is maintained. These
procedures shall, at a minimum, consist of periodic calibration of all
monitoring devices. In addition, if an owner or operator elects to
comply with the emission point specific limitations, the amount of HAP
ABA added to the slabstock foam production line at the mixhead must be
continuously monitored when foam is being poured. The requirements for
monitoring the amount of HAP ABA added are exactly the same as
discussed above for polyol, except that the device must be calibrated
at least once per month.
c. Recovered HAP ABA Monitoring
The proposed rule also includes monitoring requirements for
slabstock facilities using a recovery device to reduce HAP ABA
emissions. The amount of HAP ABA recovered is determined by using a
device that monitors the cumulative amount of HAP ABA recovered by the
recovery device. This device must be installed, calibrated, maintained,
and operated according to the manufacturer's specifications, and must
be certified by the manufacturer to be accurate to within
2.0 percent.
d. Monitoring to Determine Amount of HAP ABA in a Storage Vessel
The amount of HAP ABA in a storage vessel must be determined by
monitoring the HAP ABA level in the storage vessel using a monitoring
device that has been certified by its manufacturer to be at least 99
percent accurate, that has either a digital or printed output, and that
is calibrated at least once a year. The level of HAP ABA in each
storage vessel must be measured and recorded at least once per week.
e. Monitoring to Determine the Amount of HAP ABA Added to a Storage
Vessel
The amount of HAP ABA added to a storage vessel during a delivery
must be determined using any one of three options. The first option
requires that the volume of HAP ABA added to the storage vessel be
determined by monitoring the flow rate using a device with an accuracy
of 98 percent or greater, and which Is calibrated at least once every
six months. The second options allows the owner or operator to
calculate the weight of HAP ABA added by determining the difference
between the full weight of the transfer vehicle prior to unloading into
the storage vessel and the empty weight of the transfer vehicle after
unloading has been completed. This weight must be determined using a
scale approved by the State or local agencies using the procedures
contained in the National Institute of Standards and Technology
Handbook 44, or a scale determined to be in compliance with the
requirements of the National Institute of Standards and Technology
Handbook 44 at least once per year by a registered scale technician.
The third option for determining the amount of HAP ABA added to a
storage vessel allows the owner or operator to develop an alternative
monitoring program. The alternative monitoring program must include, at
a minimum, a description of the parameter to be monitored to determine
the amount of the addition, a description of how the results of the
monitoring will be recorded and converted into the amount of HAP ABA
added, data demonstrating the accuracy of the monitoring measurements,
and procedures for ensuring that the accuracy of the monitoring
measurements is maintained.
5. Testing Requirements
There are two instances where the use of test methods is required.
First, for slabstock owners or operators complying with the emission
point specific requirements for HAP ABA equipment leaks, testing must
be conducted using Method 21 of 40 CFR part 60, subpart A.
Second, all slabstock affected sources must test each grade of foam
produced during a single production ``run'' to verify the IFD and
density, as these are integral inputs into the equation to determine
the HAP ABA formulation limitation. This proposed rule requires these
parameters to be determined using ASTM D3574 using a sample of foam cut
from the center of the foam bun. The maximum sample size for which the
IFD and density is determined shall not be
[[Page 68413]]
larger than 24 inches by 24 inches by 4 inches.
6. Alternative Means of Emission Limitation
This proposed regulation also contains provisions to allow an owner
or operator to request approval to use an alternative means of emission
limitation. Examples of alternative means of emission limitation could
be the reduction of HAP ABA by a combustive device, use of a storage
tank control not mentioned in the regulation, or an alternative program
to reduce HAP ABA equipment leak emissions. The request, which may be
submitted in the precompliance report for existing sources, the
application for construction or reconstruction for new sources, or at
any other time after the initial compliance, must include a complete
description of the alternative means of emission limitation and
documentation demonstrating equivalency with the requirements in the
regulation. The owner or operator can begin using the alternative means
of emission limitation upon approval of the request by the
Administrator.
7. Applicability of General Provisions
The General Provisions for Part 63; 40 CFR 63, Sub Part A; create
the technical and administrative framework for implementing national
emission standards established under section 112 of the Clean Air Act.
The General Provisions establish baseline applicable requirements for
activities such as performance testing, monitoring, notifications, and
recordkeeping and reporting, and they also implement statutory
provisions such as compliance dates for new and existing sources and
preconstruction review requirements. The General Provisions apply to
all sources that are affected by Part 63 standards, including the
proposed standard for flexible polyurethane foam production. However,
certain requirements in the General Provisions may be overridden in
individual standards. This proposed regulation contains a table
outlining the sections of the General Provisions that are applicable to
subpart III, and outlining the General Provisions' sections that are
being overridden or not incorporated.
F. Reporting and Recordkeeping Requirements
1. Reporting Requirements
This proposed regulation requires the submittal of six types of
reports: (1) initial notification, (2) application for approval of
construction or reconstruction, (3) precompliance report, (4)
notification of compliance status, (5) semi-annual compliance reports,
and (6) other reports. These reports are briefly described below.
a. Initial Notification
Each owner or operator of an affected source must submit an initial
notification to the Administrator within 120 days after promulgation of
the rule. This initial notification must contain an identification of
the facility that is subject to the regulation, the name and address of
the owner or operator of the subject facility, and a brief description
of the process.
b. Application for Approval of Construction or Reconstruction
Owners or operators constructing a new affected source, or
reconstructing an existing process, must submit an application for
approval of construction or reconstruction. This application must
contain identification information such as location, owner/operator,
and the anticipated completion and start-up dates. The application must
also contain a description of the planned process and how compliance
will be achieved. The application must be submitted as soon as
practicable before the construction or reconstruction is planned to
commence. A permit application can take the place of this report.
c. Precompliance Report
One year before the compliance date, each slabstock owner or
operator must submit a precompliance report. This report must contain
notification of whether compliance will be achieved using the emission
point specific HAP ABA and equipment cleaning emission limitation or
the source-wide emission limitation. The report must also indicate if
either of the following compliance options are going to be utilized:
If compliance will be achieved on a monthly basis for
either the emission point specific limitation for HAP ABA emissions
from the production line or the source-wide emission limitation.
If a recovery device will be used to reduce HAP ABA
emissions.
This report must also contain a description of how the amount of
polyol and HAP ABA (if required) added at the mixhead will be
monitored. If the owner or operator is developing an alternative
monitoring plan, the plan must be submitted with the precompliance
report. In addition, owners or operators of slabstock flexible
polyurethane production facilities using a recovery device to reduce
HAP ABA emission must include a description of the HAP ABA monitoring
and recordkeeping program to determine the amount of HAP ABA recovered
in the precompliance report.
Each owner or operator of a source complying with the source-wide
emission limitation must submit a description of how the amount of HAP
ABA in a storage vessel will be determined, and a description of how
the amount of HAP ABA added to a storage vessel during a delivery will
be monitored. If the owner or operator is developing an alternative
monitoring program for the determination of HAP ABA added to a storage
vessel, this program must be submitted with the precompliance report.
The owner or operator of a flexible polyurethane foam production
facility that is planning to maintain HAP emissions below major source
levels and achieve an enforceable limitation through this subpart, must
report this intention in the precompliance report.
d. Notification of Compliance Status
Each owner or operator of an affected source must submit a
notification of compliance status report 180 days after the compliance
date. For slabstock affected sources, this report must contain
notification of the compliance status of diisocyanate storage vessels
and dissocyanate transfer pumps. In addition, for slabstock affected
sources complying with the emission point specific limitations for HAP
ABA, this report must contain compliance information for HAP ABA
storage vessels and equipment in HAP ABA service. Molded and rebound
affected sources must submit a statement that compliance is being
achieved with the standards.
An owner or operator of a flexible polyurethane foam production
facility that is committing to an enforceable limit to maintain
emissions below major source levels must submit an affidavit stating
the annual HAP emissions will not exceed the major source levels in the
notification of compliance status. This affidavit must be signed by the
owner, operator, or other responsible individual.
e. Semi-annual Compliance Reports
Each slabstock owner or operator must submit semi-annual compliance
reports. For affected sources complying with the rolling annual
compliance provisions (for either the emission point specific HAP ABA
limitations or the source-wide emission limitation), the report must
contain the allowable and actual HAP ABA emissions (or allowable and
actual HAP ABA and equipment cleaning HAP emissions) for each of the
12-month periods ending on each of the six months in the reporting
[[Page 68414]]
period. For affected sources complying with the monthly compliance
alternative, the report must contain the allowable and actual HAP ABA
emissions (or allowable and actual HAP ABA and equipment cleaning HAP
emissions) for each for the six months in the reporting period.
f. Other Reports
A slapstock owner or operator must provide a report to the
Administrator indicating the intent to change the selected compliance
alternative (emission point specific limitation or source-wide emission
limitation). This report must be submitted at least 180 days prior to
the change.
Similarly, the intent to switch the compliance method (rolling
annual or monthly) must be reported. This report must be submitted at
least 12 months prior to the change.
2. Recordkeeping Requirements
Records must be recorded in a form suitable and readily available
for expeditious inspection and review, and must be kept for a period of
5 years. At a minimum, the most recent 2 years of data must be retained
on-site.
Records are required for storage vessels, equipment leaks, and HAP
ABA. If the owner of operator complies with the source-wide emission
limitation, no records are required for HAP ABA storage vessel controls
(see section ``a'' below) or controls for equipment in HAP ABA service
(see section ``b'' below).
a. Storage Vessel Records
All slabstock affected sources must maintain records listing all
diisocyanate storage vessels and the type of control utilized to comply
with the regulation. For the storage vessels complying through the use
of a carbon absorption system, the records must include the design
parameters of the system and the monitoring records.
(vi) Records of all calibrations for each device used to measure
the amount of HAP ABA in the storage vessel, conducted in accordance
with Sec. 63.1303(d)(3).
(vii) Records to verify that all scales used to measure the amount
of HAP ABA added to the storage vessel meet the requirements of
Sec. 63.1303(e)(2). For scales meeting the criteria of
Sec. 63.1303(e)(2)(i), this documentation shall be in the form of
written confirmation of the State or local approval. For scales
complying with Sec. 63.1303(e)(2)(ii), this documentation shall be in
the form of a report provided by the registered scale technician.
(d) Records for sources with enforceable emission limitations below
major source levels. Processes exempted from this subpart through a
federally enforceable emission limitation in accordance with
Sec. 63.1290(b)(1), and that have notified the Administrator of this
self-imposed limitation through Sec. 63.1306(c)(9), shall maintain
records to support the emission estimates provided in the annual
emission reports, submitted in accordance with Sec. 63.1306(f)(3).
These emission estimates may be based on inventory records, material
balance calculations, emission tests, or other engineering analyses.
b. Equipment Leak Records
All slabstock affected sources must maintain a list of components
in diisocyanate service, and a description of the control utilized for
each transfer pump. If the affected source is complying with the
emission point specific limitations, then records listing each
component in HAP ABA service must also be maintained.
When a leak, as defined in the proposed rule, is detected for any
component, the component must be marked with a readily visible
identification until the leak is repaired. For valves, the
identification must remain until 2 successive months have passed where
no leak is detected. Records must be kept specifying when the leak was
detected when it was repaired, and when the identification was removed.
c. HAP ABA Records
All slabstock affected sources must keep records integral to the
calculation of allowable emissions. These include a daily log of foam
runs, and daily records of the amount of polyol added at the mixhead
for each grade of foam, and the results of the density and IFD testing
for each grade. Monthly, a cumulative record must be maintained listing
the foam grades produced during the month, along with the total amount
of polyol used for each foam grade, and the corresponding allowable HAP
ABA (or HAP ABA and equipment cleaning) emission level. If complying on
an annual rolling basis, the allowable HAP ABA (or HAP ABA and
equipment cleaning) emission level for the previous 12 consecutive
months must also be recorded each month.
For affected sources complying with the emission point specific
limitation for HAP ABA emissions from the production line, records must
be kept regarding the amount of HAP ABA added at the mixhead each day.
In addition, there must also be a cumulative HAP ABA usage record for
each month, and a cumulative record for the previous 12 consecutive
months (if complying on an annual rolling basis).
For affected sources complying with the source-wide emission
limitation, monthly records must be kept regarding the actual HAP ABA
and equipment cleaning emissions, as measured at the storage vessel.
Also required are daily records of the HAP ABA storage vessel levels
and records of the amount of HAP ABA added to the storage vessel during
each delivery. If complying on an annual rolling basis, monthly records
must be kept of the actual cumulative HAP ABA and equipment cleaning
emissions for the previous 12 months.
If an affected source uses a recovery device to reduce HAP ABA
emissions, records must be kept regarding the amount of HAP ABA
recovered. In addition, records of all required calibrations must be
maintained.
d. Records for Sources With Enforceable Emission Limitations Below
Major Source Levels
The owner or operator of a flexible polyurethane foam production
facility that is committing to an enforceable limit to maintain
emissions below major source levels must keep records documenting HAP
emissions. These records can consist of basic inventory records and
engineering calculations.
V. Request for Comment on Specific Issues
The Administrator welcomes comments from interested persons on any
aspect of this proposed standards, and on any statement in the preamble
or the referenced supporting documents. These proposed standards were
developed on the basis of information available. The Administrator is
specifically requesting factual information that may support either the
approach taken in these proposed standards or an alternate approach. To
receive proper consideration, documentation or data should be provided.
Specifically, the EPA is requesting comment and data on the following
issue.
The proposed standards for slabstock foam production contain
provisions to control emissions of TDI from storage vessels and
equipment leaks. However, the standards do not contain provisions to
control TDI emissions from the foam production line. At baseline, no
facilities in the industry reported control for these TDI emissions;
therefore, the MACT floor was determined to be ``no control.'' Further,
no control options more stringent than the MACT floor were
investigated, since
[[Page 68415]]
no demonstrated technology were identified. However, some State and
local agencies have requirements affecting sources emitting TDI in
their air toxics regulations. One State with such a regulation has
expressed concern to the EPA that this proposed regulation will not
reduce TDI emissions from foam production. Therefore, the EPA is
requesting comments on the need for additional controls for TDI from
this industry. The EPA would like to be made aware of any control
technologies that are being used, or could be used, to reduce TDI
emissions from slabstock foam production lines. Comments should be
detailed and include costs, control effectiveness, operation and
monitoring requirements, and any other relevant factors to be
considered.
For the proposed requirements for HAP ABA emissions from the
production line, and source-wide HAP ABA and equipment cleaning HAP
emissions, the EPA considered two averaging time formats: (1)
Compliance determined monthly for the previous 12 months (i.e., a
rolling annual compliance determination), and (2) compliance determined
for each individual month. The Agency determined that the rolling
annual compliance format was most appropriate for this industry, but
the industry was particularly concerned about enforcement implications
of this format. Therefore, the proposed rule allows each slabstock
facility to choose the individual monthly averaging time as an
alternative, because it is more stringent. The EPA is specifically
requesting comments from State and local agencies, as well as the
industry, on the burdens caused by the inclusion of this choice in the
proposed regulation.
The point of compliance for the proposed source-wide HAP ABA and
equipment cleaning ABA emission limitation would be the HAP ABA storage
vessel, where a monthly material balance would be performed to
determine the amount of HAP ABA and HAP equipment cleaner used/emitted.
This proposed rule requires sources complying with the source-wide
emission limitation to monitor the amount of HAP ABA in each storage
vessel at least once per week. These monitoring results are used to
determine monthly source-wide HAP ABA emissions. The device used to
determine this amount must meet three criteria: (1) It must be
certified by its manufacturer to be accurate to within +/-1 percent,
(2) it must have either a digital or printed output, and (3) it must be
calibrated at least once per year. As proposed, the rule would not
allow the use of gauge glasses and simple float systems (i.e., float
and tape), which are common practices in the industry. The concerns
that led the Agency to propose requirements that exclude the use of
these devices were the uncertainty of the accuracy of these devices,
and the potential errors associated with the visual reading of the
level of liquid in the tank. Since the use of these technologies is
wide-spread in the slabstock foam industry, the EPA would prefer that
the use of these technologies be allowed. However, questions regarding
the concerns mentioned above remain unanswered. Therefore, the EPA is
requesting comment on the proposed monitoring requirements to determine
the amount of HAP ABA in storage vessels. The EPA is also specifically
requesting comment on whether the use of gauge glasses, float and tape
systems, and other visually-read systems should be allowed under this
rule. Commenters that believe that it is appropriate to allow the use
of these systems should provide rationale and supporting documentation
regarding the accuracy of these systems, measures to ensure the
accuracy of visual readings, and calibration procedures.
The EPA estimated that there are 228 molded foam facilities in the
U.S. The EPA is requesting comments on this estimate, and any
information related to the molded foam production facility population.
This proposed regulation prohibits the use of HAP-based adhesives
for molded foam repair. The EPA is requesting comments on the technical
feasibility of these requirements.
VI. Summary of Environmental, Energy, Cost, and Economic Impacts
This section presents the air, non-air environmental (waste and
solid waste), energy, cost, and economic impacts resulting from the
control of HAP emissions under this rule.
A. Facilities Affected by These NESHAP
It is estimated that 176 sources will be subject to the proposed
regulation. This consists of 57 slabstock foam facilities, 21
facilities with slabstock and rebond processes, and 98 molded foam
facilities. It is assumed that 130 molded foam facilities are area
sources, and will not be subject to today's proposed rule. It is also
assumed that all rebond facilities not co-located with a slabstock foam
process are area sources.
B. Primary Air Impacts
These proposed standards are estimated to reduce HAP emissions from
all existing sources of flexible polyurethane foam manufacturing by
over 12,500 Mg/yr. This represents a 70 percent reduction from
baseline. This includes over 10,400 Mg/yr from slabstock foam
production (69 percent reduction from baseline) and over 2,100 Mg/yr
from molded foam production (73 percent reduction from baseline). No
reduction is expected from rebond foam production, since it is believed
that the entire industry has already stopped using HAP cleaners and
mold release agents.
C. Other Environmental Impacts
The Agency estimates that there will be minimal secondary
environmental impacts from this proposed regulation. There could be a
slight increase in volatile organic compound (VOC) air emissions if
facilities switch from a HAP-based product to a non-HAP VOC based
product for equipment cleaning, mold release agents, mixhead flushes,
and repair adhesives. Wastewater could contain minor amounts of HAP if
carbon adsorption systems are used to comply with the HAP ABA
limitations, but the Agency believes the use of such systems will be
rare. The only potential hazardous waste impact would be due to the
disposal of spent carbon adsorption canisters used to control storage
vessels.
D. Energy Impacts
Due to the use of several control technologies in both slabstock
and molded foam there will be some increase in the amount of energy
used by this source category. The impact will vary depending on which
control technology is chosen by each facility, but is not expected to
be significant.
E. Cost Impacts
Cost impacts include the capital costs of new equipment that
reduces HAP emissions, the cost of energy required to operate the
equipment, operation and maintenance costs, as well as cost savings.
Also, cost impacts include the costs of monitoring, recordkeeping, and
reporting associated with the proposed standards. Average cost
effectiveness ($/Mg of pollutant removed) is also presented as part of
cost impacts and is determined by dividing the annual cost by the
annual emission reduction.
For the molded subcategory, the estimated total capital investment
in $6.1 million, and the total estimated annual cost is almost $760,000
per year. The total annual HAP emission reduction is 2,100 Mg/year,
resulting in a cost effectiveness of $360/Mg per year.
For the rebond subcategory, it is anticipated that there will be no
cost or environmental impacts, since it is believed that every facility
already
[[Page 68416]]
complies with these provisions. The regulation will prohibit the future
use of HAP-based cleaners and mold release agents in this industry.
For the slabstock subcategory, the total estimated capital
investment is around $68 million, and the total estimated annual cost
is $7.3 million per year. The total annual HAP emission reduction is
over 10,400 Mg/yr, resulting in a cost-effectiveness of around $700/Mg
per year.
Therefore, the total capital investment for this proposed
regulation is estimated at $74 million. The total estimated annual cost
is $8.1 million per year. The total emission reduction is over 12,560
Mg/yr, resulting in an overall cost effectiveness of around $650/Mg per
year.
F. Economic Impacts
An economic impact analysis of these proposed standards was
prepared to evaluate primary and secondary impacts on (1) the slabstock
and molded foam sectors of the flexible polyurethane foam industry, (2)
consumers, and (3) society.
For the slabstock foam sector of the industry, the total annualized
social cost (in 1994 dollars) of this proposed regulation is $7.18
million. Market price is estimated to increase by 2.20 percent, and the
corresponding decrease in market output is estimated to be 1.08
percent. Employment loss is estimated to be 1.09 percent (i.e., 96
jobs).
For the molded foam sector, impacts on price and output are
estimated to be smaller than those predicted for the slabstock market.
The total annualized social cost (in 1994 dollars) of the proposed
standards for the molded foam subcategory is $0.71 million. Price is
estimated to increase by 1.14 percent, and the corresponding decrease
in market output is estimated to be 0.56 percent. Employment loss in
the molded sector is estimated to be 0.67 percent (37 jobs).
However, given the predicted changes in market price and output,
the industry will experience increases in the value of shipments (i.e.,
industry profits), because estimated price increases more than offset
the lower production volumes. Since no significant export or import
markets exist for the industry (due to prohibitive transportation
costs), no impacts on foreign trade are expected.
The analysis also predicts the number of plant closures that may
result from the imposition of compliance costs on a facility. For the
analysis, worst-case assumption is adopted that the facilities with the
highest emission control costs are the least efficient producers in the
market. Actual plant closures will be less than that predicted if
plants with the highest emission control costs are not the least
efficient producers in the industry. In addition, the outcome of
predicted closures is sensitive to the wide variety of emission control
technologies assigned to the model plants. If the control technology
assigned to the representative model plant is different than that which
would be chosen by an actual facility, the analysis could overestimate
the number of predicted plant closures. Therefore, a sensitivity
analysis was performed to test the outcome of closures based on the
assignment of control technology to model plants. For the slabstock
sector, plant closures are estimated to range from 1 to 3 facilities
for this proposed standard. For the molded foam sector, closures are
estimated to be zero for this proposed standard (a sensitivity analysis
was not performed for the molded foam production subcategory). Given
the significant amount of restructuring currently occurring in the
industry (mergers, buy-outs, and shut-downs), the number of facility
closures that will result from the proposed regulation is likely to be
minimal.
VII. Administrative Requirements
A. Public Hearing
A public hearing will be held, if requested, to discuss the
proposed standard in accordance with section 307(d)(5) of the Clean Air
Act. Persons wishing to make oral presentation on the proposed
standards for flexible polyurethane foam production should contact the
EPA at the address given in the ADDRESSES section of this preamble.
Oral presentations will be limited to 15 minutes each. Any member of
the public may file a written statement before, during, or within 30
days after the hearing. Written statements should be addressed to the
Air Docket Section address given in the ADDRESSES section of this
preamble and should refer to Docket No. A-95-48.
A verbatim transcript of the hearing and written statements will be
available for public inspection and copying during normal working hours
at the EPA's Air Docket Section in Washington, DC (see ADDRESSES
section of this preamble).
B. Docket
The docket is an organized and complete file of all the information
submitted to or otherwise considered by the EPA in the development of
this proposed rulemaking. The principal purposes of the docket are:
(1) To allow interested parties to readily identify and locate
documents so that they can intelligently and effectively participate in
the rulemaking process; and
(2) To serve as the record in case of judicial review (except for
interagency review materials [section 307(d)(7)(A)]).
C. Executive Order 12866
Under Executive Order 12866, (58 FR 51,735 (October 4, 1993)) the
Agency must determine whether the regulatory action is ``significant''
and therefore subject to Office of Management and Budget (OMB) review
and the requirements of the Executive Order. The Order defines
``significant regulatory action'' as one that is likely to result in a
rule that may:
(1) have an annual effect on the economy of $100 million or more or
adversely affect in a material way the economy, a sector of the
economy, productivity, competition, jobs, the environment, public
health or safety, or State, local, or tribal governments or
communities;
(2) create a serious inconsistency or otherwise interfere with an
action taken or planned by another agency;
(3) materially alter the budgetary impact of entitlements, grants,
user fees, or loan programs or the rights and obligations of recipients
thereof; or
(4) raise novel legal or policy issues arising out of legal
mandates, the President's priorities, or the principles set forth in
the Executive Order.
It has been determined that this rule is not a ``significant
regulatory action'' under the terms of Executive Order 12866 and is
therefore not subject to OMB review.
D. Enhancing the Intergovernmental Partnership Under Executive Order
12875
In compliance with Executive Order 12875 the EPA has involved State
and local Governments in the development of this rule. These
governments are not directly impacted by the rule; i.e., they are not
required to purchase control systems to meet the requirements of the
rule. However, they will be required to implement the rule; e.g.,
incorporate the rule into permits and enforce the rule. They will
collect permit fees that will be used to offset the resource burden of
implementing the rule. Three representatives of the State and local
governments have been members of the EPA Work Group developing the
rule. The Work Group has met numerous times, and comments have been
solicited from the Work Group members, including the State
representatives; and their comments
[[Page 68417]]
have been carefully considered in the rule development. In addition,
all States are encouraged to comment on this proposed rule during the
public comment period, and the EPA intends to fully consider these
comments in the final rulemaking.
E. Paperwork Reduction Act
The information collection requirements in this proposed rule have
been submitted for approval to the OMB under the Paperwork Reduction
Act, 44 U.S.C. 3501 et seq. An Information Collection Request (ICR)
document has been prepared by the EPA (ICR) No. 1783.01) and a copy may
be obtained from Sandy Farmer, OPPE Regulatory Information Division;
U.S. EPA (2137); 401 M St., S.W.; Washington, DC 20460 or by calling
(202) 260-2740.
The information collection is needed as part of the overall
compliance and enforcement program required by section 112 of the CAAA.
The prescribed records and reports are necessary to enable the EPA to
identify sources subject to the emission standards and to ensure that
the standards are being achieved. All information submitted to the EPA
for which a claim of confidentiality is made will be safeguarded
according to the Agency policies set forth in 40 CFR part 2, subpart
B--Confidentiality of Information.
The public reporting burden for this collection of information is
estimated to average 101 hours per respondent per year. The average
burden for the 78 affected slabstock foam producers is somewhat higher
than this estimate, due to their monthly recordkeeping and semiannual
reporting requirements, while the average burden for the 98 affected
molded foam manufacturers is less than 101 hours, since they are only
required to submit an initial one-time notification of compliance. No
cost burden associated with the purchase of new equipment or technology
is estimated to result from this collection of information.
``Burden'' means the total time, effort, or financial resources
expended by persons to generate, maintain, retain, or disclose or
provide information to or for a Federal agency. This includes the time
needed to review instructions; develop, acquire, install, and utilize
technology and systems for the purposes of collecting validating, and
verifying information, processing and maintaining information, and
disclosing and providing information; adjust the existing ways to
comply with any previously applicable instructions and requirements;
train personnel to be able to respond to a collection of information;
search data sources; complete and review the collection of information.
An Agency may not conduct or sponsor, and a person is not required
to respond to a collection of information, unless it displays a
currently valid OMB control number. The OMB control numbers for the
EPA's regulations are listed in 40 CFR Part 9 and 48 CFR Chapter 15.
Comments are requested on the Agency's need for this information,
the accuracy of the provided burden estimates, and any suggested
methods for minimizing respondent burden, including the use of
automated collection techniques. Send comments on the ICR to the
Director, OPPE Regulatory Information Division; U.S. Environmental
Protection Agency (2137); 401 M St., S.W.; Washington, DC 20460; and to
the Office of Information and Regulatory Affairs, Office of Management
and Budget, 725 17th St., N.W., Washington, DC 20503, marked
``Attention: Desk Officer for EPA.'' Include the ICR number in any
correspondence. Since OMB is required to make a decision concerning the
ICR between 30 and 60 days after December 27, 1996 a comment to the OMB
is best assured of having its full effect if the OMB receives it by
January 27, 1997. The final rule will respond to any OMB or public
comments on the information collection requirements contained in this
proposal.
F. Regulatory Flexibility Act
Pursuant to section 605(b) of the Regulatory Flexibility Act, 5
U.S.C. 605(b), as amended, Pub. L. 104-121, 110 Stat. 847, the EPA
certifies that this rule will not have a significant economic impact on
a substantial number of small entities and therefore no initial
regulatory flexibility analysis under section 604(a) of the Act is
required.
Due to insufficient data on the ownership of the plants in the
flexible polyurethane foam industry, an analysis of each parent company
in the industry was not feasible. Consequently, the EPA used data
collected in the section 114 survey to evaluate the impact on small
businesses based on model facilities. That analysis indicates that
there is a total of approximately 121 businesses (31 slabstock, 90
molded) that are affected by the proposed regulation, of which
approximately 71 are small businesses (18 slabstock, 53 molded).
The calculation of average compliance costs as a percent of
revenues is less than one percent for nearly all model facilities in
the analysis. The analysis also indicates a potential for business
courses ranging from 0 to 3 of the total number of estimated entities.
However, because there is insufficient data to determine the exact size
of the plants that may close, the analysis cannot determine if these
impacts will occur at small businesses. Given the results of the
analysis and the use of worst-case assumptions in the closure analysis,
the EPA believes that the affect of the proposed regulation on small
businesses will be minimal.
G. Unfunded Mandates Reform Act
Title II of the Unfunded Mandates Reform Act of 1995 (UMRA), P.L.
104-4, establishes requirements for Federal agencies to assess the
effects of their regulatory actions on State, local, and tribal
governments and the private sector. Under section 202 of the UMRA, the
EPA generally must prepare a written statement, including a cost-
benefit analysis, for proposed and final rules with ``Federal
mandates'' that may result in expenditures to State, local, and tribal
governments in the aggregate, or to the private sector, of $100 million
or more in any one year. Before promulgating an EPA rule for which a
written statement is needed, section 205 of the UMRA generally requires
the EPA to identify and consider a reasonable number of regulatory
alternatives and adopt the least costly, most cost-effective or least
burdensome alternative that achieves the objectives of the rule. The
provisions of section 205 do not apply when they are inconsistent with
applicable law. Moreover, section 205 allows the EPA to adopt an
alternative other than the least costly, most cost-effective, or least
burdensome alternative if the Administrator publishes with the final
rule an explanation why that alternative was not adopted. Before the
EPA establishes any regulatory requirements that may significantly or
uniquely affect small governments, including tribal governments, it
must have developed under section 203 of the UMRA a small government
agency plan. The plan must provide for notifying potentially affected
small governments, enabling officials of affected small governments to
have meaningful and timely input in the development of EPA regulatory
proposals with significant Federal intergovernmental mandates, and
informing, educating, and advising small governments on compliance with
the regulatory requirements.
The EPA has determined that this rule does not contain a Federal
mandate that may result in expenditures of $100 million or more for
State, local, and tribal governments, in aggregate, or the private
sector in any one year, because
[[Page 68418]]
they contain no requirements that apply to such governments or impose
obligations upon them.
H. Miscellaneous
In accordance with section 117 of the Act, publication of this
proposal was preceded by consultation with appropriate advisory
committees, independent experts, and Federal departments and agencies.
The Administrator will welcome comments on all aspects of this proposed
regulation, including health, economic and technical issues, and on the
proposed test methods.
This regulation will be reviewed 8 years from the date of
promulgation. This review will include an assessment of such factors as
evaluation of the residual health and environmental risks, any overlap
with other programs, the existence of alternative methods,
enforceability, improvements in emission control technology and health
data, and the recordkeeping and reporting requirements.
List of Subjects in 40 CFR Part 63
Environmental protection, Air pollution control, Hazardous
substances, Reporting and recordkeeping requirements.
Dated: December 9, 1996.
Carol M. Browner,
Administrator.
For the reasons set out in the preamble, part 63 of title 40,
chapter I of the Code of Federal Regulations is proposed to be amended
as follows:
PART 63--NATIONAL EMISSION STANDARDS FOR HAZARDOUS AIR POLLUTANTS
FOR AFFECTED SOURCE CATEGORIES
1. The authority citation for part 63 continues to read as follows:
Authority: 42 U.S.C. 7401, et seq.
2. It is proposed that part 63 be amended by adding subpart III,
consisting of Secs. 63.1290 through 63.1307, to read as follows:
Subpart III--National Emission Standards for Hazardous Air Pollutant
Emissions from Flexible Polyurethane Foam Production
Sec.
63.1290 Applicability.
63.1291 Compliance schedule.
63.1292 Definitions.
63.1293 Standards for slabstock flexible polyurethane foam
production.
63.1294 Standards for slabstock flexible polyurethane foam
production--diisocyanate emissions.
63.1295 Standards for slabstock flexible polyurethane foam
production--HAP ABA storage vessels.
63.1296 Standards for slabstock flexible polyurethane foam
production--HAP ABA equipment leaks.
63.1297 Standards for slabstock flexible polyurethane foam
production--HAP ABA emissions from the production line.
63.1298 Standards for slabstock flexible polyurethane foam
production--HAP emissions from equipment cleaning.
63.1299 Standards for slabstock flexible polyurethane foam
production--source-wide emission limitation.
63.1300 Standards for molded flexible polyurethane foam production.
63.1301 Standards for rebond foam production.
63.1302 Applicability of subpart A requirements.
63.1303 Monitoring requirements.
63.1304 Testing requirements.
63.1305 Alternative means of emission limitation.
63.1306 Reporting requirements.
63.1307 Recordkeeping Requirements.
Subpart III--National Emission Standards for Hazardous Air
Pollutant Emissions from Flexible Polyurethane Foam Production
Sec. 63.1290 Applicability.
(a) The provisions of this subpart apply to each new and existing
flexible polyurethane foam or rebond foam process that meets the
criteria listed in paragraphs (a) (1) through (3) of this section:
(1) Produces flexible polyurethane or rebond foam;
(2) Uses a HAP, except as provided in paragraph (c)(2) of this
section; and
(3) Is located at a major source plant site.
(b) For the purpose of this subpart, an affected source includes
all processes meeting the criteria in paragraphs (a)(1) through (a)(3)
of this section that are located at a contiguous plant site.
(c) A process meeting one of criteria listed in paragraphs (c) (1)
through (3) of this section shall not be subject to the provisions of
this subpart, but shall maintain supporting documentation of the
applicable criteria.
(1) A process located at a plant site for which the plant site does
not have a potential to emit more than 10 tons per year of any single
HAP, or more than 25 tons per year of all HAP. A limitation on
potential to emit may be obtained by notifying the Administrator of a
commitment to maintain emissions below the major source levels noted in
the Precompliance Report, as specified in Sec. 63.1306(c)(9), and
following the applicable reporting and recordkeeping procedures.
(2) A process exclusively dedicated to the fabrication of flexible
polyurethane foam; or
(3) A research and development process.
Sec. 63.1291 Compliance schedule.
(a) Existing affected sources shall be in compliance with all
provisions of this subpart no later than [3 years from effective date
of final rule].
(b) New or reconstructed affected sources shall be in compliance
with all provisions of this subpart upon startup.
Sec. 63.1292 Definitions.
All terms used in this subpart shall have the meaning given them in
the Act, in subpart A of this part, and in this section. If a term is
defined in subpart A and in this section, it shall have the meaning
given in this section for purposes of this subpart.
Auxiliary blowing agent, or ABA, means a low-boiling point liquid
added to assist foaming by generating gas beyond that resulting from
the isocyanate-water reaction.
Breakthrough means that point in the adsorption step when the mass
transfer zone (i.e., the section of the carbon bed where the adsorbate
is removed from the carrier gas stream) first reaches the carbon bed
outlet as the mass transfer zone moves down the bed in the direction of
flow. The breakthrough point is characterized by the beginning of a
sharp increase in the outlet adsorbate concentration.
Calibrate means to verify the accuracy of a measurement device
against a known standard. For the purpose of this subpart, there are
two levels of calibration. The initial calibration includes the
verification of the accuracy of the device over the entire operating
range of the device. Subsequent calibrations can be conducted for a
point or several points in a limited range of operation that represents
the most common operation of the device.
Canned motor pump means a pump with interconnected cavity housings,
motor rotors, and pump casing. In a canned motor pump, the motor
bearings run in the process liquid and all seals are eliminated.
Carbon adsorption system means a system consisting of a tank or
container that contains a specific quantity of activated carbon. For
the purposes of this subpart, a carbon adsorption system is used as a
control device for storage vessels. Typically, the spent carbon bed
does not undergo regeneration, but is replaced.
Connector means flanged, screwed, or other joined fittings used to
connect two pipe lines or a pipe line and a piece of equipment. A
common connector is a flange. Joined fittings welded completely around
the circumference of the interface are not considered to be connectors
for the purposes of this subpart.
[[Page 68419]]
Cured foam means flexible polyurethane foam with fully developed
physical properties. A period of 12 to 24 hours from pour is typically
required to completely cure foam, although mechanical or other devices
are sometimes used to accelerate the curing process.
Curing area means the area in a slabstock foam production facility
where foam buns are allowed to fully develop physical properties.
Diaphragm pump means a pump where the driving member is a flexible
diaphragm made of metal, rubber, or plastic. In a diaphragm pump, there
are no packing or seals that are exposed to the process liquid.
Diisocyanate means a compound containing two isocyanate groups per
molecule. The most common diisocyanate compounds used in the flexible
polyurethane foam industry are toluene diisocyanate (TDI) and methylene
diphenyl diisocyanate (MDI).
Flexible polyurethane foam means a flexible cellular polymer
containing urea and carbamate linkages in the chain backbone produced
by reacting a diisocyanate, polyol, and water.
Flexible polyurethane foam process means the equipment used to
produce a flexible polyurethane foam product. For the purpose of this
subpart, the flexible polyurethane foam process includes raw material
storage; production equipment and associated piping, ductwork, etc.;
and curing and storage areas.
Grade of foam means foam with a distinct combination of indentation
force deflection (IFD) and density values.
HAP ABA means methylene chloride, or any other Hap compound used as
an auxiliary blowing agent.
High-pressure mixhead means a mixhead where mixing is achieved by
impingement of the high pressure streams within the mixhead.
Identation Force Deflection (IFD) means a measure of the load
bearing capacity of flexible polyurethane foam. IFD is generally
measured as the force (in pounds) required to compress a 50 square inch
circular indentor foot into a four inch thick sample, typically 15
inches square or larger, to 25 percent of the sample's initial height.
In diisocyanate service means a piece of equipment that contains or
contacts a diisocyanate.
In HAP ABA service means a piece of equipment that contains or
contacts a HAP ABA.
Isocyanate means a reactive chemical grouping composed of a
nitrogen atom bonded to a carbon atom bonded to an oxygen atom; or a
chemical compound, usually organic, containing one or more isocyanate
groups.
Magnetic drive pump means a pump where an externally-mounted magnet
coupled to the pump motor drives the impeller in the pump casing. In a
magnetic drive pump, no seals contact the process fluid.
Metering pump means a pump used to deliver reactants, ABA, or
additives to the mixhead.
Mixhead means a device that mixes two or more component streams
before dispensing foam producing mixture to the desired container.
Mold release agent means any material which, when applied to the
mold surface, serves to prevent sticking of the foam part to the mold.
Molded flexible polyurethane foam means a flexible polyurethane
foam that is produced by shooting the foam mixture into a mold of the
desired shape and size.
Plant site means all contiguous or adjoining property that is under
common control, including properties that are separated only by a road
or other public right-of-way. Common control includes properties that
are owned, leased, or otherwise operated by the same entity, parent
entity, subsidiary, or any combination thereof.
Rebond foam means the foam resulting from a process of adhering
small particles of foam together to make a usable cushioning product.
Various adhesives and bonding processes are used. A typical application
for rebond foam is for carpet underlay.
Rebond foam process means the equipment used to produce a rebond
foam product. For the purpose of this subpart, the rebond foam process
includes raw material storage; production equipment and associated
piping, ductwork, etc.; and curing and storage areas.
Reconstructed source means an affected source undergoing
reconstruction, as defined in subpart A. For the purposes of this
subpart, process modifications made to reduce HAP ABA emissions to meet
the existing source requirements of this subpart shall not be counted
in determining whether or not a change or replacement meets the
definition of reconstruction.
Recovery device means an individual unit of equipment capable of
and used for the purpose of recovering chemicals for use, reuse, or
sale. Recovery devices include, but are not limited to, carbon
absorbers, absorbers, and condensers.
Research and development process means a laboratory or pilot plant
operation whose primary purpose is to conduct research and development
into new processes and products, where the operations are under the
close supervision of technically trained personnel, and which is not
engaged in the manufacture of products for commercial sale.
Run of foam means a continuous production of foam, which may
consist of several grades of foam.
Sealless pump means a canned-motor pump, diaphragm pump, or
magnetic drive pump, as defined in this section.
Slabstock flexible polyurethane foam means flexible polyurethane
foam that is produced in large continuous buns that are then cut into
the desired size and shape.
Slabstock flexible polyurethane foam production line includes all
portions of the flexible polyurethane foam process from the mixhead to
the point in the process where the foam is completely cured.
Storage vessel means a tank or other vessel that is used to store
diisocyanate or HAP ABA for use in the production of flexible
polyurethane foam. Storage vessels do not include vessels with
capacities smaller than 38 cubic meters (or 10,000 gallons).
Transfer pump means all pumps used to transport diisocyanate or HAP
ABA that are not metering pumps.
Transfer vehicle means a railcar, tank truck, or other vehicle used
to transport HAP ABA to the flexible polyurethane foam facility.
Sec. 63.1293 Standards for slabstock flexible polyurethane foam
production.
Each owner or operator of a new or existing slabstock affected
source shall comply with Sec. 63.1294 and either paragraph (a) or (b)
of this section:
(a) The emission point specific limitations in Secs. 63.1295
through 63.1298, or
(b) For sources that use only one HAP as an ABA and equipment
cleaner, the source-wide emission limitation in Sec. 63.1299.
Sec. 63.1294 Standards for slabstock flexible polyurethane foam
production--diisocyanate emissions.
Each new and existing slabstock affected source shall comply with
the provisions of this section.
(a) Diisocyanate storage vessels. Diisocyanate storage vessels
shall be equipped with either a system meeting the requirements in
paragraph (a)(1) of this section, or a carbon adsorption system meeting
the requirements of paragraph (a)(2) of this section.
(1) The storage vessel shall be equipped with a vapor return line
from the storage vessel to the tank truck or rail car that is connected
during unloading, and contains no leaks, where
[[Page 68420]]
a leak is detected by visual, audible, or any other detection method.
(2) The storage vessel shall be equipped with a carbon adsorption
system, meeting the monitoring requirements of Sec. 63.1303(a), that
routes displaced vapors through activated carbon before being
discharged to the atmosphere.
(b) Transfer pumps in diisocyanate service. Each transfer pump in
diisocyanate service shall meet the requirements of paragraph (b)(1) or
(b)(2) of this section.
(1) The pump shall be a sealless pump; or
(2) The pump shall be a submerged pump system meeting the
requirements in paragraphs (b)(2)(i) through (iii) of this section.
(i) The pump is completely immersed in bis(2-ethylhexyl)phthalate
(DEHP, CAS #118-81-7), 2(methyloctyl)phthalate (DINP, CAS #68515-48-0),
or another neutral oil.
(ii) The pump shall be visually monitored weekly to detect leaks,
(iii) When a leak is detected, it shall be repaired in accordance
with the procedures in paragraphs (b)(2)(iii)(A) and (b) of this
section.
(A) The leak shall be repaired as soon as practicable, but not
later than 15 calendar days after it is detected.
(B) A first attempt at repair shall be made no later than 5
calendar days after the leak is detected. First attempts at repair
include, but are not limited to, the following practices where
practicable:
(1) Tightening of packing gland nuts.
(2) Ensuring that the seal flush is operating at design pressure
and temperature.
(c) Other components in diisocyanate service. If evidence of a leak
is found by visual, audible, or any other detection method, it shall be
repaired as soon as practicable, but not later than 15 calendar days
after it is detected, except as provided in Sec. 63.1296(f). The first
attempt at repair shall be made no later than 5 calendar days after
each leak is detected.
Sec. 63.1295 Standards for slabstock flexible polyurethane foam
production--HAP ABA storage vessels.
Each owner or operator of a new or existing slabstock affected
source complying with the emission point specific limitation option
provided in Sec. 63.1293(a) shall control HAP ABA storage vessels in
accordance with the provisions of this section.
(a) Each HAP ABA storage vessel shall be equipped with either a
vapor balance system meeting the requirements in paragraph (b) of this
section, or a carbon adsorption system meeting the requirements of
paragraph (c) of this section.
(b) The storage vessel shall be equipped with a vapor balance
system. The owner or operator must ensure that the vapor return line
from the storage vessel to the tank truck or rail car is connected
during unloading, and that there are no significant leaks in the
system.
(c) The storage vessel shall be equipped with a carbon adsorption
system, meeting the monitoring requirements of Sec. 63.1303(a), that
routes displaced vapors through activated carbon before discharging to
the atmosphere.
Sec. 63.1296 Standards for slabstock flexible polyurethane foam
production--HAP ABA equipment leaks.
Each owner or operator of a new or existing slabstock affected
source complying with the emission point specific limitation option
provided in Sec. 63.1293(a) shall control HAP ABA emissions from leaks
from transfer pumps, valves, connectors, pressure-relief valves, and
open-ended lines in accordance with the provisions in this section.
(a) Pumps. Each pump in HAP ABA service shall be controlled in
accordance with either paragraph (a)(1) or (a)(2) of this section.
(1) The pump shall be a sealless pump, or
(2) Each pump shall be monitored for leaks in accordance with
paragraphs (a)(2) (i) and (ii) of this section. Leaks shall be repaired
in accordance with paragraph (a)(2)(iii) of this section.
(i) Each pump shall be monitored quarterly to detect leaks by the
method specified in Sec. 63.1304(a). If an instrument reading of 10,000
parts per million (ppm) or greater is measured, a leak is detected.
(ii) Each pump shall be checked by visual inspection each calendar
week for indications of liquids dripping from the pump seal. If there
are indications of liquids dripping from the pump seal, a leak is
detected.
(iii) When a leak is detected, it shall be repaired in accordance
with the procedures in paragraphs (a)(2)(iii) (A) and (B) of this
section, except as provided in paragraph (f) of this section.
(A) The leak shall be repaired as soon as practicable, but not
later than 15 calendar days after it is detected.
(B) A first attempt at repair shall be made no later than 5
calendar days after the leak is detected. First attempts at repair
include, but are not limited to, the following practices, where
applicable:
(1) Tightening of packing gland nuts.
(2) Ensuring that the seal flush is operating at design pressure
and temperature.
(b) Valves. Each valve in HAP ABA service shall be monitored for
leaks in accordance with paragraph (b)(1) of this section, except as
provided in paragraphs (b) (3) and (4) of this section. Leaks shall be
repaired in accordance with paragraph (b)(2) of this section.
(1) Each valve shall be monitored quarterly to detect leaks by the
method specified in Sec. 63.1304(a). If an instrument reading of 10,000
parts per million or greater is measured, a leak is detected.
(2) When a leak is detected, the owner or operator shall repair the
leak in accordance with the procedures in paragraphs (b)(2) (i) and
(ii) of this section, except as provided in paragraph (f) of this
section.
(i) The leak shall be repaired as soon as practicable, but not
later than 15 calendar days after it is detected.
(ii) A first attempt at repair shall be made no later than 5
calendar days after the leak is detected. First attempts at repair
include, but are not limited to, the following practices where
practicable:
(A) Tightening of bonnet bolts;
(B) Replacement of bonnet bolts;
(C) Tightening of packing gland nuts; and
(D) Injection of lubricant into lubricated packing.
(3) Any valve that is designated as an unsafe-to-monitor valve is
exempt from the requirements of paragraphs (b) (1) and (2) of this
section if:
(i) The owner or operator of the valve determines that the valve is
unsafe to monitor because monitoring personnel would be exposed to an
immediate danger as a consequence of complying with paragraphs (b) (1)
and (2) of this section; and
(ii) The owner or operator of the valve has a written plan that
requires monitoring of the valve as frequently as practicable during
safe-to-monitor times, but not more frequently than monthly.
(4) Any valve that is designated as a difficult-to-monitor valve is
exempt from the requirements of paragraphs (b) (1) and (2) of this
section if:
(i) The owner or operator of the valve determines that the valve
cannot be monitored without elevating the monitoring personnel more
than 2 meters above a support surface or it is not accessible at any
time in a safe manner;
(ii) The process within which the valve is located is an existing
source, or the owner or operator designates less
[[Page 68421]]
than 3 percent of the total number of valves in a new source as
difficult-to-monitor; and
(iii) The owner or operator of the valve follows a written plan
that requires monitoring of the valve at least once per calendar year.
(c) Connectors. Each connector in HAP ABA service shall be
monitored for leaks in accordance with paragraph (c)(1) of this
section, except as provided in paragraphs (c) (3) and (4) of this
section. Leaks shall be repaired in accordance with (c)(2) of this
section.
(1) Connectors shall be monitored at the times specified in
paragraphs (c)(1) (i) through (iii) of this section to detect leaks by
the method specified in Sec. 63.1304(a). If an instrument reading of
10,000 ppm or greater is measured, a leak is detected.
(i) Each connector shall be monitored annually, and
(ii) Each connector that has been opened or has otherwise had the
seal broken shall be monitored for leaks within the first 3 months
after being returned to HAP ABA service.
(iii) If a leak is detected, the connector shall be monitored for
leaks in accordance with paragraph (c)(1) of this section within the
first 3 months after its repair.
(2) When a leak is detected, it shall be repaired in accordance
with the procedures in paragraphs (c)(2) (i) and (ii) of this section,
except as provided in paragraph (c)(4) and paragraph (f) of this
section.
(i) The leak shall be repaired as soon as practicable, but no later
than 15 calendar days after the leak is detected.
(ii) A first attempt at repair shall be made no later than 5
calendar days after the leak is detected.
(3) Any connector that is designated as an unsafe-to-monitor
connector is exempt from the requirements of paragraph (c)(1) of this
section if:
(i) The owner or operator determines that the connector is unsafe
to monitor because personnel would be exposed to an immediate danger as
a result of complying with paragraph (c)(1) of this section; and
(ii) The owner or operator has a written plan that requires
monitoring of the connector as frequently as practicable during safe to
monitor periods, but not more frequently than annually.
(4) Any connector that is designated as an unsafe-to-repair
connector is exempt from the requirements of paragraphs (c)(1) and
(c)(2) of this section if:
(i) The owner or operator determines that repair personnel would be
exposed to an immediate danger as a consequence of complying with
paragraph (c)(2) of this section; and
(ii) The connector will be repaired as soon as practicable, but not
later than 6 months after the leak was detected.
(d) Pressure-relief devices. Each pressure-relief device in HAP ABA
service shall be monitored for leaks in accordance with paragraph
(d)(1) of this section. Leaks shall be repaired in accordance with
paragraph (d)(2) of this section.
(1) Each pressure-relief device in HAP ABA service shall be
monitored within 5 calendar days by the method specified in
Sec. 63.1304(a) if evidence of a potential leak is found by visual,
audible, olfactory, or any other detection method. If an instrument
reading of 10,000 ppm or greater is measured, a leak is detected.
(2) When a leak is detected, the leak shall be repaired as soon as
practicable, but not later than 15 calendar days after it is detected,
except as provided in paragraph (f) of this section. The owner or
operator shall make a first attempt at repair no later than 5 calendar
days after the leak is detected.
(e) Open-ended valves or lines.
(1) Each open-ended valve or line in HAP ABA service shall be
equipped with a cap, blind flange, plug, or a second valve, except as
provided in paragraph (e)(5) of this section.
(2) The cap, blind flange, plug, or second valve shall seal the
open end at all times except during operations requiring process fluid
flow through the open-ended valve or line, or during maintenance or
repair.
(3) Each open-ended valve or line equipped with a second valve
shall be operated in a manner such that the valve on the process fluid
end is closed before the second valve is closed.
(4) When a double block and bleed system is being used, the bleed
valve or line may remain open during operations that require venting
the line between the block valves but shall comply with paragraph (a)
of this section at all other times.
(5) Open-ended valves or lines in an emergency shutdown system
which are designed to open automatically in the event of a process
upset are exempt from the requirements of paragraphs (e) (1), (2), (3),
and (4) of this section.
(f) Delay of repair.
(1) Delay of repair of equipment for which leaks have been detected
is allowed for equipment that is isolated from the process and that
does not remain in diisocyanate or HAP ABA service.
(2) Delay of repair for valves and connectors is also allowed if:
(i) The owner or operator determines that emissions of purged
material resulting from immediate repair are greater than the fugitive
emissions likely to result from delay of repair, and
(ii) The purged material is collected and destroyed or recovered in
a control device when repair procedures are effected.
(3) Delay of repair for pumps is also allowed if repair requires
replacing the existing seal design with a sealless pump, and repair is
completed as soon as practicable, but not later than 6 months after the
leak was detected.
Sec. 63.1297 Standards for slabstock flexible polyurethane foam
production--HAP ABA emissions from the production line.
(a) Each owner or operator of a new or existing slabstock affected
source complying with the emission point specific limitation option
provided in Sec. 63.1293(a)(1) shall control HAP ABA emissions from the
slabstock polyurethane foam production line in accordance with the
provisions in this section. Compliance shall be determined on a rolling
annual basis as described in paragraph (a)(1) of this section. As an
alternative, the owner or operator can determine compliance on a
monthly basis, as described in paragraphs (a)(2) and (a)(3) of this
section.
(1) Rolling annual compliance. In determining compliance on a
rolling annual basis, actual HAP ABA emissions shall be compared to
allowable HAP ABA emissions for each consecutive 12-month period. The
allowable HAP ABA emission level shall be calculated based on the
production for the 12-month period, resulting in a potentially
different allowable level for each 12-month period. Compliance shall be
determined each month for the previous 12-month period. The compliance
requirements are provided in paragraph (b) of this section.
(2) Monthly compliance alternative. As an alternative to
determining compliance on a rolling annual basis, an owner or operator
can determine compliance by comparing actual HAP ABA emissions to
allowable HAP ABA emissions for each month. The allowable HAP ABA
emission level shall be calculated based on the production for the
month, resulting in a potentially different allowable level each month.
The requirements for this monthly compliance alternative are provided
in paragraph (c) of this section.
(3) Each owner or operator complying with the monthly compliance
alternative described under paragraph
[[Page 68422]]
(a)(2) of this section shall include notification of the intent to use
this option in the precompliance report.
(4) Each owner or operator electing to change between the
compliance methods described under paragraphs (a)(1) and (a)(2) of this
section shall notify the Administrator no later than 180 days prior to
the change.
(b) Rolling Annual Compliance. At each slabstock foam production
source complying with the rolling annual compliance provisions
described in Sec. 63.1297(a)(1), actual HAP ABA emissions shall not
exceed the allowable HAP ABA emission level for a consecutive 12-month
period. The actual HAP ABA emission level for a consecutive 12-month
period shall be determined using the procedures in paragraph (b)(1) of
this section, and the allowable HAP ABA emission level for the
corresponding 12-month period shall be calculated in accordance with
paragraph (b)(2) of this section.
(1) The actual HAP ABA emissions for a 12-month period shall be
calculated as the sum of actual monthly HAP ABA emissions for each of
the individual 12 months in the period. Actual monthly HAP ABA
emissions shall be based on the amount of HAP ABA added to the
slabstock foam production line at the mixhead, determined in accordance
with Sec. 63.1303(b). Slabstock foam production sources using recovery
devices to reduce HAP ABA emissions shall determine actual monthly HAP
ABA emissions using the procedures in paragraph (e) of this section.
(2) The allowable HAP ABA emissions for a consecutive 12-month
period shall be calculated as the sum of allowable monthly HAP ABA
emissions for each of the individual 12 month shall be calculated using
Equation 1.
[GRAPHIC] [TIFF OMITTED] TP27DE96.004
Where:
emissallow, month = Allowable HAP ABA emissions from the
slabstock foam production source for the month, pounds.
m = Number of slabstock foam production lines.
polyoli = Amount of polyol used in the month in the production
of foam grade i on foam production line j, determined in accordance
with paragraph (b)(3) of this section, pounds.
n = Number of foam grades produced in the month on foam production
line j.
limiti = HAP ABA formulation limit for foam grade i, parts HAP
ABA per 100 parts polyol. The HAP ABA formulation limits are
determined in accordance with paragraph (d) of this section.
(3) The amount of polyol used for specific foam grades shall be
based on the amount of polyol added to the slabstock foam production
line at the mixhead, determined in accordance with the provisions of
Sec. 63.1303(b).
(c) Monthly Compliance Alternative. At each slabstock foam
production source complying with the monthly compliance alternative
described in paragraph (a)(2) of this section, actual HAP ABA emissions
shall not exceed the corresponding allowable HAP ABA emission level for
the same month. The actual monthly HAP ABA emission level shall be
determined using the procedures in paragraph (c)(1) of this section,
and the allowable monthly HAP ABA emission level shall be calculated in
accordance with paragraph (c)(2) of this section.
(1) The actual monthly HAP ABA emission shall be based on the
amount of HAP ABA added to the slabstock foam production line at the
mixhead, determined in accordance with Sec. 63.1303(b). Slabstock foam
production sources using recovery devices to reduce HAP ABA emissions
shall determine actual monthly HAP ABA emissions using the procedures
in paragraph (e) of this section.
(2) The allowable HAP ABA emissions for the month shall be
determined in accordance with Equation 1.
(d) HAP ABA Formulation Limitations. The HAP ABA formulation
limitations shall be determined in accordance with paragraphs (d)(1)
through (d)(3) of this section.
(1) For existing sources, the HAP ABA formulation limitation for
each grade of slabstock foam produced shall be determined using
Equation 2.
[GRAPHIC] [TIFF OMITTED] TP27DE96.005
Where:
ABAlimit = HAP ABA formulation limitation, parts HAP ABA
allowed per hundred parts polyol (pph).
IFD = Indentation force deflection, pounds.
DEAN = Density, pounds per cubic foot.
(2) For new sources, the HAP ABA formulation limitation for each
grade of slabstock foam produced shall be determined as described in
paragraphs (d)(2)(i) through (d)(2)(iv) of this section.
(i) For each foam grade with a density of 0.95 pounds per cubic
foot or less, the HAP ABA formulation limitation shall be determined
using Equation 2.
(ii) For each foam grade with a density of 1.4 pounds per cubic
foot or less, and an IFD of 15 pounds or less, the HAP ABA formulation
limitation shall be determined using Equation 2.
(iii) For each foam grade with a density greater than 0.95 pounds
per cubic foot and an IDF greater than 15 pounds, the HAP ABA
formulation limitation shall be zero.
(iv) For each foam grade with a density greater than 1.40 pounds
per cubic foot, the HAP ABA formulation limitation shall be zero.
(3) The IFD and density for each foam grade shall be determined in
accordance with Sec. 63.1304(b).
(e) Compliance using recovery devices. If a recovery device is used
to comply with paragraphs (b) through (c) of this section, the owner or
operator shall determine the allowable HAP ABA emissions for each month
using Equation 1 in paragraph (b)(2) of this section, and the actual
monthly HAP ABA emissions in accordance with paragraph (e)(1) of this
section. The owner or operator shall also comply with the provisions of
paragraph (e)(2) of this section.
(1) The actual monthly HAP ABA emissions shall be determined using
Equation 3.
[[Page 68423]]
[GRAPHIC] [TIFF OMITTED] TP27DE96.006
Where:
Eactual = Actual HAP ABA emissions after control, pounds/month.
Eunc = Uncontrolled HAP ABA emissions, pounds/month, determined
in accordance with paragraph (b)(2) of this section.
HAPABArecovered = HAP ABA recovered, pounds/month, determined
in accordance with paragraph (e)(2) of this section.
(2) The amount of HAP ABA recovered shall be determined in
accordance with Sec. 63.1303(c).
Sec. 63.1298 Standards for slabstock flexible polyurethane foam
production--HAP emissions from equipment cleaning.
Each owner or operator of a new or existing slabstock affected
source complying with the emission point specific limitation option
provided in Sec. 63.1293(a)(1) shall not use a HAP, or a HAP-containing
product, as an equipment cleaner.
Sec. 63.1299 Standards for slabstock flexible polyurethane foam
production--source-wide emission limitation.
Each owner or operator of a new or existing slabstock affected
source complying with the source-wide emission limitation option
provided in Sec. 63.1293(a)(2) shall control HAP ABA storage and
equipment leak emissions, HAP ABA emissions from the production line,
and equipment cleaning HAP emissions in accordance with the provisions
in this section. Compliance shall be determined on a rolling annual
basis in accordance with paragraph (a) of this section. As an
alternative, the owner or operator can determine compliance monthly, as
described in paragraph (b) of this section.
(a) Rolling annual compliance. Under the rolling annual compliance
provisions, actual source-wide HAP ABA storage and equipment leak
emissions, HAP ABA emissions from the production line, and equipment
cleaning HAP emissions are compared to allowable source-wide emissions
for each consecutive 12-month period. The allowable source-wide HAP
emission level is calculated based on the production for the 12-month
period, resulting in a potentially different allowable level for each
12-month period. While compliance is on an annual basis, compliance
shall be determined monthly for the preceding 12-month period. The
actual source-wide HAP emission level for a consecutive 12-month period
shall be determined using the procedures in paragraph (c) of this
section, and the allowable HAP emission level for a consecutive 12-
month period shall be determined using the procedures in paragraph (d)
of this section.
(b) Monthly compliance alternative. As an alternative to
determining compliance on a rolling annual basis, an owner or operator
can determine compliance by comparing actual HAP emissions to allowable
HAP emissions for each month. The allowable source-wide emission level
is calculated based on the production for the month, resulting in a
potentially different allowable level each month. The actual monthly
emission level shall be determined using the procedures in paragraph
(c) of this section, and the allowable monthly HAP ABA emission level
shall be determined using the procedures in paragraph (e) of this
section.
(c) Procedures for determining actual source-wide HAP emissions.
The actual source-wide HAP ABA storage and equipment leak emissions,
HAP ABA emissions from the production line, and equipment cleaning HAP
emissions shall be determined using the procedures in this section.
Actual source-wide HAP emissions for each consecutive 12-month period
shall be calculated as the sum of actual monthly source-wide HAP
emissions for each of the individual 12 months in this period. Actual
source-wide HAP emissions for each individual month shall be determined
using the procedures specified in paragraphs (c) (1) through (3) of
this section.
(1) The actual source-wide HAP emissions for a month shall be
determined using Equation 4 and the information determined in
accordance with paragraphs (c) (2) and (3) of this section.
[GRAPHIC] [TIFF OMITTED] TP27DE96.007
Where:
PWEactual = Actual source-wide HAP ABA and equipment cleaning
HAP emissions for a month, pounds/month.
n = Number of HAP ABA storage vessels.
STi, begin = Amount of HAP ABA in storage vessel i at the
beginning of the month, pounds, determined in accordance with the
procedures listed in paragraph (c)(2) of this section.
STi, end = Amount of HAP ABA in storage vessel i at the end of
the month, pounds, determined in accordance with the procedures
listed in paragraph (c)(2) of this section.
ADDi = Amount of HAP ABA in storage vessel i at the end of the
month, pounds, determined in accordance with the procedures listed
in paragraph (c)(1)(3) of this section.
(2) The amount of HAP ABA in a storage vessel shall be determined
by monitoring the HAP ABA level in the storage vessel in accordance
with Sec. 63.1303(d).
(3) The amount of HAP ABA added to a storage vessel for a given
month shall be the sum of the amounts of all individual HAP ABA
deliveries that occur during the month. The amount of each individual
HAP ABA delivery shall be determined in accordance with
Sec. 63.1303(e).
(4) At each slabstock foam production source complying with the
monthly compliance alternative described in paragraph (b) of this
section, the actual source-wide HAP emissions for each month shall be
calculated in accordance with paragraphs (c) (1) through (3) of this
section.
(d) The allowable HAP emissions for a consecutive 12-month period
shall be calculated as the sum of allowable monthly HAP ABA emissions
for each of the individual 12 months in the period. Allowable HAP ABA
emissions for each individual month shall be calculated using Equation
5.
[[Page 68424]]
[GRAPHIC] [TIFF OMITTED] TP27DE96.008
Where:
emissallow,month = Allowable HAP ABA storage and equipment leak
emissions HAP ABA emissions from the production line, and equipment
cleaning HAP emissions from the slabstock foam production source for
the month, pounds.
m = Number of slabstock foam production lines.
polyoli = Amount of polyol used in the month in the production
of foam grade i on foam production line j, determined in accordance
with Sec. 63.1303(b), pounds.
n = Number of foam grades produced in the month on foam production
line j.
limiti = HAP ABA formulation limit for foam grade i, parts HAP
ABA per 100 parts polyol. The HAP ABA formulation limits are
determined in accordance with Sec. 63.1297(d).
Sec. 63.1300 Standards for molded flexible polyurethane foam
production.
Each owner or operator of a new or existing molded affected source
shall comply with the provisions in paragraphs (a), (b), and (c) of
this section.
(a) A HAP solvent shall not be used as an equipment cleaner to
flush the mixhead, nor shall it be used elsewhere at a molded flexible
polyurethane foam source.
(b) A HAP-based mold release agent shall not be used in a molded
flexible foam source.
(c) A HAP-based adhesive shall not be used to repair foam products
in a molded flexible polyurethane foam source.
Sec. 63.1301 Standards for rebond foam production.
Each owner or operator of a new or existing rebond foam affected
source shall comply with the provisions in paragraphs (a) and (b) of
this section.
(a) A HAP solvent shall not be used as an equipment cleaner at a
rebond foam source.
(b) A HAP-based mold release agent shall not be used in a rebond
foam source.
Sec. 63.1302 Applicability of subpart A requirements.
Table 1 provides cross references to 40 CFR part 63, subpart A,
indicating the applicability of the general provisions requirements to
subpart III.
Sec. 63.1303 Monitoring requirements.
Owners and operators of affected sources shall comply with each
applicable monitoring provision in this section.
(a) Monitoring requirements for storage vessel carbon adsorption
systems. Each owner or operator using a carbon adsorption system to
meet the requirements of Sec. 63.1294(a) or Sec. 63.1295 shall monitor
the concentration level of the HAP or the organic compounds in the
exhaust vent stream (or outlet stream exhaust) from the carbon
adsorption system monthly and replace the existing carbon with fresh
carbon immediately upon indication of carbon breakthrough.
(1) As an alternative to monthly monitoring, the owner or operator
can set the monitoring frequency at an interval no greater than 20
percent of the carbon replacement interval, which is established using
a design analysis described in paragraphs (a)(1)(i) through (iii) of
this section.
(i) The design analysis shall consider the vent stream composition,
constituent concentration, flow rate, relative humidity, and
temperature.
(ii) The design analysis shall establish the outlet organic
concentration level, the capacity of the carbon bed, and the working
capacity of activated carbon used for the carbon bed, and
(iii) The design analysis shall establish the carbon replacement
interval based on the total carbon working capacity of the carbon
adsorption system and the schedule for filling the storage vessel.
(2) Measurement of HAP concentration shall be made using 40 CFR
part 60, appendix A, Method 18. The measurement shall be conducted over
at least one 5-minute interval during which the storage vessel is being
filled.
(b) Monitoring for HAP ABA and polyol added to the foam production
line at the mixhead.
(1) The owner or operator of each slabstock affected source shall
comply with the provisions in paragraph (b)(1)(i) of this section, and
the provisions of paragraph (b)(1)(ii) of this section, if applicable.
(i) All slabstock affected sources shall continuously monitor the
amount of polyol added at the mixhead when foam is being poured, in
accordance with paragraphs (b)(2) and (4) of this section.
(ii) For sources using the emission point specific limitation
option provided in Sec. 63.1293(a)(1), the amount of HAP ABA added at
the mixhead shall be continuously monitored when foam is being poured
in accordance with paragraphs (b)(2)(ii), (3), and (4) of this section.
(2) The owner or operator shall monitor either:
(i) Pump revolutions; or
(ii) Flow rate.
(3) The device used to monitor the parameter from paragraph (b)(2)
shall have an accuracy to within 2.0 percent of the HAP
ABA being measured, and shall be calibrated initially, and
periodically, in accordance with paragraph (b)(3) (i) or (ii) of this
section.
(i) For polyol pumps, the device shall be calibrated at least once
each 6 months.
(ii) For HAP ABA pumps, the device shall be calibrated at least
once each month.
(4) Measurements must be recorded at the beginning and end of the
production of each grade of foam within a run of foam.
(5) As an alternative to the monitoring described in paragraphs (b)
(2) through (4) of this section, the owner or operator may develop an
alternative monitoring program. The components of an alternative
monitoring plan shall include, at a minimum, the items listed in
paragraphs (b)(5) (i) through (iv) of this section.
(i) A description of the parameter to be continuously monitored
when foam is being poured to measure the amount of HAP ABA or polyol
added at the mixhead.
(ii) A description of how the monitoring results will be recorded,
and how the results will be converted into amount of HAP ABA or polyol
delivered to the mixhead.
(iii) Data demonstrating that the monitoring device is accurate to
within 2.0 percent.
(iv) Procedures to ensure that the accuracy of the parameter
monitoring results is maintained. These procedures shall, at a minimum,
consist of periodic calibration of all monitoring devices.
(c) Recovered HAP ABA monitoring. The owner or operator of each
slabstock affected source using a recovery device to reduce HAP ABA
emissions shall develop a recovered HAP ABA monitoring and
recordkeeping program. The components of these plans shall include, at
a minimum, the items listed in paragraphs (c) (1) through (5) of this
section.
(1) A device, installed, calibrated, maintained, and operated
according to the manufacturer's specifications, that
[[Page 68425]]
indicates the cumulative amount of HAP ABA recovered by the solvent
recovery device over each 1-month period. The device shall be certified
by the manufacturer to be accurate to within 2.0 percent.
(2) The location where the monitoring will occur. The location
shall ensure that the measurements are taken after HAP ABA has been
fully recovered (i.e., after separation from water introduced into the
HAP ABA during regeneration).
(3) A description of the parameter to be monitored, and the times
the parameter will be monitored.
(4) Data demonstrating that the monitoring device is accurate to
within 2.0 percent.
(5) Procedures to ensure that the accuracy of the parameter
monitoring results is maintained. These procedures shall, at a minimum,
consist of periodic calibration of all monitoring devices.
(d) Monitoring of HAP ABA in a Storage Vessel. The amount of HAP
ABA in a storage vessel shall be determined weekly by monitoring the
HAP ABA level in the storage vessel using a device that meets the
criteria described in paragraphs (d)(1) through (d)(3) of this section.
(1) A device certified by the manufacturer to be no less than 99
percent accurate,
(2) The device must have either a digital or printed output,
(3) The device must be calibrated initially and at least once per
year thereafter.
(e) Monitoring of HAP ABA added to a Storage Vessel. The amount of
HAP ABA added to a storage vessel during a delivery shall be determined
in accordance with either paragraphs (e) (1), (2), or (3) of this
section.
(1) The volume of HAP ABA added to the storage vessel shall be
determined by monitoring the flow rate using a device with an accuracy
of 2.0 percent, and calibrated initially and at least once
each six months thereafter.
(2) The weight of HAP ABA added to the storage vessel shall be
calculated as the difference of the full weight of the transfer vehicle
prior to unloading into the storage vessel and the empty weight of the
transfer vehicle after unloading into the storage vessel. The weight
shall be determined using a scale meeting the requirements of either
paragraph (e)(2) (i) or (ii) of this section.
(i) A scale approved by the State or local agencies using the
procedures contained in the National Institute of Standards and
Technology Handbook 44.
(ii) A scale determined to be in compliance with the requirements
of the National Institute of Standards and Technology Handbook 44 at
least once per year by a registered scale technician.
(3) As an alternative to the monitoring options described in
paragraphs (e)(1) and (e)(2) of this section, the owner or operator may
develop an alternative monitoring program shall include, at a minimum,
the items listed in paragraphs (e)(3) (i) through (iv) of this section.
(i) A description of the parameter to be monitored to determine the
amount of HAP ABA added to the storage vessel during a delivery,
(ii) A description of how the results will be recorded, and how the
results will be converted into the amount of HAP ABA added to the
storage vessel during a delivery,
(iii) Data demonstrating that the monitoring device is accurate to
within 2.0 percent, and
(iv) Procedures to ensure that the accuracy of the monitoring
measurements is maintained. These procedures shall, at a minimum,
consist of periodic calibration of all monitoring devices.
Sec. 63.1304 Testing Requirements.
Owners and operators of affected sources shall use the test methods
listed in this section, as applicable, to demonstrate compliance with
this subpart.
(a) Test Method and Procedures to Determine Equipment Leaks.
Monitoring, as required under Secs. 63.1294(c) and 63.1296, shall
comply with the following requirements:
(1) Monitoring shall comply with Method 21 of 40 CFR part 60,
appendix A.
(2) The detection instrument shall meet the performance criteria of
Method 21 of 40 CFR part 60, appendix A, except that the instrument
response factor criteria in section 3.1.2(a) of Method 21 shall be for
the average composition of the source fluid, rather than for each
individual VOC in the stream. For source streams that contain nitrogen,
air, or other inerts which are not HAP or VOC, the average stream
response factor shall be calculated on an inert-free basis. The
response factor may be determined at any concentration for which
monitoring for leaks will be conducted.
(3) The instrument shall be calibrated before use on each days of
its use by the procedures specified in Method 21 of 40 CFR part 60,
appendix A.
(4) Calibration gases shall be:
(i) Zero air (less than 10 ppm of hydrocarbon in air); and
(ii) A mixture of methane and air at a concentration of
approximately, 1,000 ppm for all transfer pumps; and 500 ppm for all
other equipment, except as provided in paragraph (f)(4)(iii) of this
section.
(iii) The instrument may be calibrated at a higher methane
concentration (up to 2,000 ppm) than the leak definition concentration
for a specific piece of equipment for monitoring that piece of
equipment. If the monitoring instrument's design allows for multiple
calibration gas concentrations, then the lower concentration
calibration gas shall be no higher than 2,000 ppm methane and the
higher concentration calibration gas shall be no higher than 10,000 ppm
methane.
(5) Monitoring shall be performed when the equipment is in HAP ABA
service, in use with an acceptable surrogate volatile organic compound
which is not a HAP ABA, or is in use with any other detectable gas or
vapor.
(6) If no instrument is available onsite that will meet the
performance criteria specified in section 3.1.2(a) of Method 21 of 40
CFR Part 60, appendix A, the readings from an available instrument may
be adjusted by multiplying by the average response factor for the
stream.
(b) Test Method to Determine Foam Properties. The IFD and density
shall be determined using ASTM D3574, using a sample of foam cut from
the center of the foam bun. The maximum sample size for which the IFD
and density is determined shall not be larger than 24 inches by 24
inches by 4 inches.
Sec. 63.1305 Alternative Means of Emission Limitation.
An owner or operator of an affected source may request approval to
use an alternative means of emission limitation, following procedures
in this section.
(a) The owner or operator can request approval to use an
alternative means of emission, limitation in the precompliance report
for existing sources, the application for construction or
reconstruction for new sources, or at any time.
(b) This request shall include a complete description of the
alternative means of emission limitation.
(c) Each owner or operator applying for permission to use an
alternative means of emission limitation under Sec. 63.6(g) shall be
responsible for collecting and verifying data to demonstrate the
emission reduction achieved by the alternative means of emission
limitation.
(d) Use of the alternative means of emission limitation shall not
begin until approval is granted by the Administrator in accordance with
Sec. 63.6(g).
[[Page 68426]]
Sec. 63.1306 Reporting requirements.
Owners and operators of affected sources shall comply with each
applicable reporting provision in this section.
(a) Initial Notification. Each affected source shall submit an
initial notification in accordance with Sec. 63.9(b).
(b) Application for Approval of Construction or Reconstruction.
Each owner or operator shall submit an application for approval of
construction or reconstruction in accordance with the provisions of
Sec. 63.5(d).
(c) Precompliance Report. Each slabstock affected source shall
submit a precompliance report no later than (12 months before the
compliance date). This report shall contain the information listed in
paragraphs (c)(1) through (6) of this section, as applicable. Processes
requesting a federally enforceable emission limitation in accordance
with Sec. 63.1290(b)(1) shall submit a precompliance report in
accordance with paragraph (c)(9) of this section.
(1) Whether the source will comply with the emission point specific
limitations described in Sec. 63.1293(a), or with the source-wide
emission limitation described in Sec. 63.1293(b).
(2) For a source complying with the emission point specific
limitations, whether the source will comply on a rolling annual basis
in accordance with Sec. 63.1297(b), or will comply with the monthly
alternative for compliance contained in Sec. 63.1297(c).
(3) For a source complying with the source-wide emission
limitation, whether the source will comply on a rolling annual basis in
accordance with Sec. 63.1299(a), or will comply with the monthly
alternative for compliance contained in Sec. 63.1299(b).
(4) A description of how HAP ABA and/or polyol added at the mixhead
will be monitored, and whether or not the owner or operator is
developing an alternative monitoring program, as described in
Sec. 63.1303(b)(5).
(5) Notification of the intent to use a recovery device to comply
with the provisions of Sec. 63.1297 or Sec. 63.1299.
(6) For slabstock affected sources complying with Sec. 63.1297 or
Sec. 63.1299 using of a recovery device, the continuous recovered HAP
ABA monitoring and recordkeeping program, developed in accordance with
Sec. 63.1303(c).
(7) For sources complying with the source-wide emission limitation,
a description of how the amount of HAP ABA in a storage vessel shall be
determined.
(8) For sources complying with the source-wide emission limitation,
a description of how the amount of HAP ABA added to a storage vessel
during a delivery will be monitored, and whether or not the owner or
operator is developing an alternative monitoring program, as described
in Sec. 63.1303(e)(3).
(9) Processes requesting a federally enforceable emission
limitation in accordance with Sec. 63.1290(b)(1) shall submit a
precompliance report. This report shall notify the Agency of the
intention to limit emissions to less than 10 tons per year of any
single HAP, and less than 25 tons per year of all HAP from the plant
site. Notification of this status relieves the owner or operator from
the provisions of this subpart, other than the requirements to annually
report HAP emissions in accordance with (f)(3) of this section, and to
maintain records documenting the reported emission estimates.
(d) Notification of Compliance Status. Each affected source shall
submit a notification of compliance status report no later than (180
days after the compliance date). For slabstock affected sources, this
report shall contain the information listed in paragraphs (d)(1)
through (3) of this section, as applicable. This report shall contain
information listed in paragraph (d)(4) of this section for molded foam
processes and in paragraph (d)(5) for rebond foam processes.
(1) A list of diisocyanate storage vessels, along with a record of
the type of control utilized for each storage vessel.
(2) For transfer pumps in diisocyanate service, a record of the
type of control utilized for each transfer pump.
(3) If the source is complying with the emission point specific
limitations of Sec. Sec. 63.1294 through 63.1298, the information
listed in paragraphs (b)(3)(i) through (iii) of this section.
(i) A list of HAP ABA storage vessels, along with a record of the
type of control utilized for each storage vessel.
(ii) A list of pumps, valves, connectors, pressure-relief devices,
and open-ended valves or lines in HAP ABA service.
(iii) A list of any modifications to equipment in HAP ABA service
made to comply with the provisions of Sec. 63.1296.
(4) A statement that the molded foam affected source is in
compliance with Sec. 63.1300, or a statement that molded foam processes
at an affected source are in compliance with Sec. 63.1300.
(5) A statement that the rebond foam affected source is in
compliance with Sec. 63.1301, or that rebond processes at an affected
source are in compliance with Sec. 63.1301.
(e) Semi-Annual Compliance Reports. Each slabstock affected source
shall submit a compliance report containing the information specified
in paragraphs (e)(1) through (3) of this section semiannually no later
than 60 days after the end of each 180 day period. The first report
shall be submitted no later than 240 days after the date that the
Notification of Compliance Status is due and shall cover the 6-month
period beginning on the date that the Notification of Compliance Status
Report is due.
(1) For slabstock affected sources complying with the rolling
annual compliance provisions of either Sec. 63.1297 or Sec. 63.1299,
the allowable and actual HAP ABA emissions (or allowable and actual
source-wide HAP emissions) for each of the 12-month periods ending on
each of the six months in the reporting period. This information is not
required to be included in the initial semi-annual compliance report.
(2) For sources complying with the monthly compliance alternative
of either Sec. 63.1297 or Sec. 63.1299, the allowable and actual HAP
ABA emissions (or allowable and actual source-wide HAP emissions) for
each of the six months in the reporting period.
(3) For sources complying with the storage vessel provisions of
Sec. 63.1294(a) or Sec. 63.1295 using a carbon adsorption system,
instances where the carbon in the system is replaced, along with the
date of the replacement.
(4) Any equipment leaks that were not repaired in accordance with
Sec. 63.1294(b) or Sec. 63.1296.
(f) Other Reports.
(1) Change in selected emission limitation. An owner or operator
electing to change their slabstock flexible polyurethane foam emission
limitation (from emission point specific limitations to a source-wide
emission limitation, or vice versa), selected in accordance with
Sec. 63.1293, shall notify the Administrator no later than 180 days
prior to the change.
(2) Change in selected compliance method. An owner or operator
changing the period of compliance for either Sec. 63.1297 or
Sec. 63.1299 (between rolling annual and monthly) shall notify the
Administrator no later than 180 days prior to the change.
(3) Annual emission reports for area sources. Processes exempted
from this subpart through a federally enforceable emission limitation
in accordance with Sec. 63.1290(b)(1), and that have notified the
Administrator of this self-imposed limitation through
Sec. 63.1306(c)(9), shall
[[Page 68427]]
submit an annual emission report. This report shall be submitted once
per year and shall report the total HAP emissions for the plant site
for the previous 12-month period.
Sec. 63.1307 Recordkeeping requirements.
The applicable records designated in paragraphs (a) through (c) of
this section shall be maintained by owners and operators of processes
exempted from this subpart through a federally enforceable emission
limitation in accordance with Sec. 63.1290(b)(1) shall maintain records
in accordance with paragraph (d) of this section.
(a) Storage Vessel Records.
(1) A list of diisocyanate storage vessels, along with a record of
the type of control utilized for each storage vessel.
(2) For each slabstock affected source complying with the emission
point specific limitations of Secs. 63.1294 through 63.1298, a list of
HAP ABA storage vessels, along with a record of the type of control
utilized for each storage vessel.
(3) For storage vessels complying through the use of a carbon
adsorption system, paragraph (a)(3) (i) or (ii), and paragraph
(a)(3)(iii) of this section.
(i) Records of dates and times when the carbon absorption system is
monitored for carbon breakthrough and the monitoring device reading,
when the device is monitored monthly in accordance with
Sec. 63.1303(a); or
(ii) For affected sources monitoring at an interval no greater than
20 percent of the carbon replacement interval, in accordance with
Sec. 63.1303(a)(1), the records listed in paragraphs (a)(3)(ii) (A) and
(B) of this section.
(A) Records of the design analysis, including all the information
listed in Sec. 63.1303(a)(1) (i) through (iii), and
(B) Records of dates times when the carbon adsorption system is
monitored for carbon breakthrough and the monitoring device reading.
(iii) Date when the existing carbon in the carbon adsorption system
is replaced with fresh carbon.
(b) Equipment Leak Records.
(1) A list of components as specified in paragraphs (b)(1) (i) and
(ii) of this section.
(i) For all affected sources, a list of components in diisocyanate
service,
(ii) For affected sources complying with the emission point
specific limitations of Secs. 63.1294 through 63.1298, a list of
components in HAP ABA service.
(2) For transfer pumps in diisocyanate service, a record of the
type of control utilized for each transfer pump and the date of
installation.
(3) When a leak is detected as specified in Sec. 63.1294(b)(2)(ii),
Sec. 63.1294(c), Sec. 63.1296(a)(2), (b)(1), (c)(1), and (d)(1), the
requirements listed in paragraphs (b)(3) (i) and (ii) of this section
apply:
(i) Leaking equipment shall be identified in accordance with the
requirements in paragraphs (b)(3)(i) (A) and through (C) of this
section.
(A) A readily visible identification, marked with the equipment
identification number, shall be attached to the leaking equipment.
(B) The identification on a valve may be removed after it has been
monitored for 2-successive months as specified in Sec. 63.1296(b)(1)
and no leak has been detected during those 2 months.
(C) The identification on equipment, other than a valve, may be
removed after it has been repaired.
(ii) The information in paragraphs (b)(2)(ii) (A) through (G) shall
be recorded for leaking components.
(A) The instrument and operator identification numbers and the
equipment identification number.
(B) The date the leak was detected and the dates of each attempt to
repair the leak.
(C) Repair methods applied in each attempt to repair the leak.
(D) The words ``above leak definition'' if the maximum instrument
reading measured by the methods specified in Sec. 63.1296(f) after each
repair attempt is equal or greater than the leak definitions for the
specified equipment.
(E) The words ``repair delayed'' and the reason for the delay if a
leak is not repaired within 15 calendar days after discovery of the
leak.
(F) The expected date of the successful repair of the leak if a
leak is not repaired within 15 days.
(G) The date of successful repair of the leak.
(H) The date the identification is removed.
(c) HAP ABA Records.
(1) Emission Point Specific Limitations--Rolling Annual Compliance
and Monthly Compliance Alternative Records. Each slabstock affected
source complying with the emission point specific limitations of
Secs. 63.1294 through 63.1298, and the rolling annual compliance
provisions of Sec. 63.1297(a)(1), shall maintain the records listed in
paragraphs (c)(1) (i), (ii), (iii), and (iv) of this section. Each
flexible polyurethane foam slabstock source complying with the emission
point specific limitations of Secs. 63.1294 through 63.1298, and the
monthly compliance alternative of Sec. 63.1297(a)(2), shall maintain
the records listed in paragraphs (c)(1) (i), (ii), and (iv) of this
section.
(i) Daily records of the information listed below in paragraphs
(c)(1)(i) (A) through (C) of this section.
(A) A log of foam runs each day, identified by the amount of each
grade produced during the run.
(B) Results of the density and IFD testing for each run of foam,
conducted in accordance with the procedures in Sec. 63.1304(b).
(C) The amount of polyol added to the slabstock foam production
line at the mixhead for each run of foam, determined in accordance with
Sec. 63.1303(b).
(ii) Monthly records of the information listed in paragraphs
(c)(1)(ii) (A) through (E) of this section.
(A) A listing of all foam grades produced during the month,
(B) For each foam grade produced, the residual HAP formulation
limitation, calculated in accordance with Sec. 63.1297(d).
(C) For each foam grade produced, the total amount of polyol used
in the month.
(D) The total allowable HAP ABA emissions for the month, determined
in accordance with Sec. 63.1297(b)(2).
(E) The total amount of HAP ABA added to the slabstock foam
production line at the mixhead during the month, determined in
accordance with Sec. 63.1303(b).
(iii) Each source complying with the rolling annual compliance
provisions of Sec. 63.1297(b) shall maintain the records listed in
paragraphs (c)(1)(iii) (A) and (B) of this section.
(A) The sum of the total allowable HAP ABA emissions for the month
and the previous 11 months.
(B) The sum of the total actual HAP ABA emissions for the month and
the previous 11 months.
(iv) Records of all calibrations for each device used to measure
polyol and HAP ABA added at the mixhead, conducted in accordance with
Sec. 63.1303(b)(3).
(2) Source-Wide Limitations--Rolling Annual Compliance and Monthly
Compliance Alternative Records. Each slabstock affected source
complying with the source-wide limitations of Sec. 63.1299, and the
rolling annual compliance provisions in Sec. 63.1299(a), shall maintain
the records listed in paragraphs (c)(2)(i) through (c)(2)(vii) of this
section. Each flexible polyurethane foam slabstock source complying
with the source-wide limitations of Sec. 63.1299, and the monthly
compliance alternative of Sec. 63.1299(b), shall maintain the records
listed in paragraphs (c)(2)(i) through (c)(2)(iii) and paragraphs
[[Page 68428]]
(c)(2)(v) through (c)(2)(vii) of this section.
(i) Daily records of the information listed in paragraphs (c)(2)(i)
(A) through (C) of this section.
(A) A log of foam runs each day, identified by the grade.
(B) Results of the density and IFD testing for each run of foam,
conducted in accordance with the procedures in Sec. 63.1304(b).
(C) The amount of polyol added to the slabstock foam production
line at the mixhead for each run of foam, determined in accordance with
Sec. 63.1303(b).
(ii) For sources complying with the source-wide emission
limitation, weekly records of the storage tank level, determined in
accordance with Sec. 63.1303(d).
(iii) Monthly records of the information listed in paragraphs
(c)(2)(iii) (A) through (E) of this section.
(A) A listing of all foam grades produced during the month,
(B) For each foam grade produced, the residual HAP formulation
limitation, calculated in accordance with Sec. 63.1297(d).
(C) For each foam grade produced, the total amount of polyol used
in the month.
(D) The total allowable HAP ABA and equipment cleaning emissions
for the month, determined in accordance with Sec. 63.1297(b)(2).
(E) The total actual source-wide HAP ABA emissions for the month,
determination in accordance with Sec. 63.1299(c)(1), along with the
information listed in paragraphs (c)(2)(iii)(E) (1) and (2) of this
section.
(1) The amounts of HAP ABA in the storage vessel at the beginning
and end of the month, determined in accordance with Sec. 63.1299(c)(2);
and
(2) The amount of each delivery of HAP ABA to the storage vessel,
determined in accordance with Sec. 63.1299(c)(3).
(iv) Each source complying with the rolling annual compliance
provisions of Sec. 63.1299(a) shall maintain the records listed in
paragraphs (c)(2)(iv) (A) and (B) of this section.
(A) The sum of the total allowable HAP ABA and equipment cleaning
HAP emissions for the month and the previous 11 months.
(B) The sum of the total actual HAP ABA and equipment cleaning HAP
emissions for the month and the previous 11 months.
(v) Records of all calibrations for each device used to measure
polyol added at the mixhead, conducted in accordance with
Sec. 63.1303(b)(3).
Table 1 to Subpart III.--Applicability of General Provisions (40 CFR
Part 63, Subpart A) to Subpart III
------------------------------------------------------------------------
Applies to subpart
Subpart A reference III Comment
------------------------------------------------------------------------
Sec. 63.1.............. Yes.................. Except that Sec.
63.1(c)(2) is not
applicable since area
sources are not
subject to subpart
III.
Sec. 63.2.............. Yes..................
Sec. 63.3.............. Yes..................
Sec. 63.4.............. Yes..................
Sec. 63.5.............. Yes..................
Sec. 63.6.............. Yes.................. Except that Sec.
63.6(h) is not
applicable since
subpart III does not
require opacity and
visible emission
standards.
Sec. 63.7.............. No................... Performance tests not
required by subpart
III.
Sec. 63.8.............. No................... Continuous monitoring,
as defined in subpart
A, is not required by
subpart III.
Sec. 63.9(a)-(d)....... Yes..................
Sec. 63.9(e)-(g)....... No...................
Sec. 63.9(h)........... No................... Subpart III specifies
Notification of
Compliance Status
requirements.
Sec. 63.9(i)-(j)....... Yes..................
Sec. 63.10(a)-(b)...... Yes.................. Except that the records
specified in Sec.
63.10(b)(2) (vi)
through (xiv) are not
required.
Sec. 63.10(c).......... No...................
Sec. 63.10(d)(1)....... Yes..................
Sec. 63.10(d) (2)-(3).. No...................
Sec. 63.10(d) (4)-(5).. Yes..................
Sec. 63.10(e).......... No...................
Sec. 63.10(f).......... Yes..................
Sec. 63.11............. Yes..................
Sec. 63.12............. Yes..................
Sec. 63.13............. Yes..................
Sec. 63.14............. Yes..................
Sec. 63.15............. Yes..................
------------------------------------------------------------------------
[FR Doc. 96-32237 Filed 12-26-96; 8:45 am]
BILLING CODE 6560-50-M