OKLAHOMA DEPARTMENT OF ENVIRONMENTAL QUALITY
AIR QUALITY DIVISION
MEMORANDUM November 29, 1995
TO: W. Ray Bishop, Acting Director, Permits & Compliance Section
THROUGH: Don Whitney P.E., Acting Supervisor, Existing Source Permits Unit
THROUGH: Peer Review
FROM: Dawson Lasseter P.E., Senior Environmental Engineer
SUBJECT: Evaluation of Permit Application No. 95-426-C
Bellmar Color Press
Nowata, Nowata County, Oklahoma
Harris V-25 Heatset Offset Web Printing Press
DESCRIPTION
Bellmar Color Press has applied for a construction permit in order to add a new
web offset printing press to their existing facility. The present facility heat
press is a Harris V-15H and is subject to Operating Permit No. 90-008-O.
The new machine is a Harris V-25 heatset web lithographic printing system that
receives up to 895 ft/min of 34 inch wide paper. Eight different units within the
printing operation print different colors on the paper. Printed material then passes
to a gas-fired drier section where the ink is dried, then to a chilling section
and finally to a folding section.
Maximum anticipated hours are listed as 24 hours per day, 7 days per week, 52 weeks
per year, up to a maximum of 8,760 hours per year of printing.
AIR EMISSIONS
Anticipated air emissions from the color printing operation are primarily volatile
organic solvents in the inks and products of natural gas combustion. Air emissions
have been estimated from the volumes of inks and cleaning solvents to be used and
a 20% retention of organic solvents in the web (Control of Volatile Organic Emissions
from Existing Stationary Sources: Volume VIII, Graphic Arts - Rotogravure and
Flexography EPA-450/2-78-033).
According to Control of Volatile Organic Compound Emissions from Full-Web
Process-Color Heatset Web Offset Lithographic Printing (EPA, Draft 1981), offset
printing frequently involves the usage of large amounts of isopropanol or other
high-volatility solvents. When such solvents are used, approximately 50% are emitted
in the pressroom ventilation. The reference also states that high-volatility
solvents may be replaced by low-volatility solvents which are emitted from the drying
step.
The operation is equipped with a TEC Model Quantum 5000 catalytic afterburner which
is rated at 95% efficiency. Natural gas is supplied to the afterburners and dryer
at the rate of 3428 CFH to maintain a temperature of 650oF. Air emissions are
discharged through a stack 41 feet high, 27 inches in diameter, at a rate of 3,000
ACFM at 400oF.
Calculated Emissions *
(Basis: 8,760 Hours Per Year Operation, 3,428 SCFH Gas Consumption)
Harris V-15H Harris V-25
Heatset Press Heatset Press Pre-Press Area Total Emissions
Pollutant PPH TPY PPH TPY PPH TPY PPH TPY
NOx 0.2780 1.1120 0.2100 0.8470 0.4880 1.9590
CO 0.0750 0.3000 0.0570 0.2300 0.1320 0.5300
SO2 0.0017 0.0082 0.0013 0.0038 0.0030 0.0120
PM 0.0160 0.0641 0.0120 0.0489 0.0280 0.1130
Organic Materials
1,1,1-Trichloroethane 0.0006 0.0023 0.0003 0.0013 0.0009 0.0036
Butyl cellosolve 0.0007 0.0029 0.0010 0.0039 0.0010 0.0030 0.0027 0.0098
Isopropanol 0.3214 1.2870 0.3066 1.2276 0.0013 0.0037 0.6293 2.5183
Hexane 0.0011 0.0044 0.0012 0.0047 0.0017 0.0049 0.0040 0.0140
Ethylene glycol 0.2922 1.1700 0.2922 1.1700
Nonylphenol + 9 EQ 0.1065 0.4265 0.1065 0.4265
Methylene chloride 0.0006 0.0025 0.0008 0.0032 0.0014 0.0057
Cyclohexane 0.0011 0.0044 0.0012 0.0047 0.0023 0.0091
Vinyl Acetate 0.0023 0.0092 0.0023 0.0092
Aromatic petr. dist. 0.5305 2.1241 0.5305 2.1241
Stoddard Solvent 1.4854 5.9474 1.4997 5.9889
2 methyl butane 0.0005 0.0019 0.0006 0.0026 0.0011 0.0045
Ref. petr. oils 0.0985 0.3950 0.1034 0.4134 0.2019 0.8084
Polydimethyl siloxane 0.1314 0.5261 0.1314 0.5261 0.2628 1.0522
Propane 0.0011 0.0044 0.0012 0.0047 0.0023 0.0091
Isobutane 0.0011 0.0044 0.0012 0.0047 0.0023 0.0091
Dimethyl ether 0.0011 0.0044 0.0012 0.0047 0.0023 0.0091
Dibutyl phthalate 0.0234 0.0018 0.0234 0.0018
Triethylene glycol 0.0010 0.0029 0.0010 0.0029
Diethanolamine 0.0023 0.0067 0.0023 0.0067
Hydroquinone 0.0248 0.0722 0.0248 0.0722
N-propanol 0.0099 0.0287 0.0099 0.0287
Butane 0.0049 0.0143 0.0049 0.0143
Ethanol 0.0781 0.0009 0.0781 0.0009
Cocoamphodiacetate 0.0447 0.0163 0.0447 0.0163
Linoleamide DEA 0.0447 0.0163 0.0447 0.0163
d-Limonene 0.0447 0.0163 0.0447 0.0163
Nonoxynol-9 0.0447 0.0163 0.0447 0.0163
2-Aminoethanol 0.0005 0.0015 0.0005 0.0015
Benzyl alcohol 0.0750 0.2185 0.0750 0.2185
Glycerol 0.0022 0.0064 0.0022 0.0064
Acetic Acid 0.0066 0.0193 0.0066 0.0193
TOTAL ORGANIC COMPOUNDS 0.5615 2.2489 2.9647 11.8696 0.4258 0.4915 3.9520 14.6100
* Source: AP-42 factors for external combustion of natural gas; afterburner emissions
counted in with rest of Heatset Presses. Sulfur dioxide emissions are less than
the present permit allows due to the use of the AP-42 factors and the results of
earlier stack tests. NOTE: The pre-press area and associated activities operate
intermittently; emissions on a lb/hr basis will not convert directly to TPY basis.
Facility Changes
NOx CO SO2 PM VOC
PPH TPY PPH TPY PPH TPY PPH TPY PPH TPY
Proposed 0.488 1.959 0.132 0.530 0.003 0.012 0.028 0.113 3.9520 14.6100
Present 0.278 1.112 0.075 0.300 0.016 0.064 - - 2.8974 10.3908
Change 0.210 0.847 0.057 0.230(0.013)(0.052) 0.028 0.113 1.0546 4.2192
The application listed 29 individual products used at the facility. Of these, 89%
by volume are the inks. The applicant has submitted MSDS's on the inks, toners,
cleaners, etc. used in the operation. Several materials regulated under OAC
252:100-41 (Hazardous and Toxic Air Contaminants) were listed on the MSDS's which
are non-volatile, compounds including aluminum, barium, and manganese compounds.
The organic components will evaporate in the drier and become air emissions, which
are in turn controlled by the afterburner. Emissions of non-volatile inorganic
materials (aluminum nitrate, barium compounds, copper, and manganese compounds)
will be negligible.
TOXIC AIR EMISSIONS
De Minimis
Toxicity MAAC Emissions Rates Levels
Pollutant Category ug/m3 ppm lb/hr TPY lb/hr TPY
1,1,1-Trichloroethane C 35 191000 0.0096 0.0036 5.6 6.0
Butyl cellosolve B 0.1 368 0.0027 0.0098 1.1 1.2
Isopropanol C 40 98300 0.6293 2.5183 5.6 6.0
Hexane C 5 17627 0.0040 0.0140 5.6 6.0
Ethylene glycol C 5 12695 0.2922 1.1700 5.6 6.0
Nonyphenol + 9 EQ C 0.1065 0.4265 5.6 6.0
Methylene chloride A 0.5 1736 0.0014 0.0057 0.57 0.6
Vinyl acetate C 0.4 1500 0.0023 0.0092 5.6 6.0
Stoddard solvent C 35000 1.4997 5.9889 5.6 6.0
Aromatic petr. dist. B 0.5305 2.1241 1.1 1.2
Ref. petr. oils B 0.2019 0.8084 1.1 1.2
Dimethyl ether C 0.0023 0.0091 5.6 6.0
Dibutyl phthalate C 0.04 500 0.0234 0.0018 5.6 6.0
Diethanolamine C 0.3 1500 0.0023 0.0067 5.6 6.0
Hydroquinone B 0.008 40 0.0248 0.0722 1.1 1.2
N-propanol C 40 98300 0.0099 0.0287 5.6 6.0
Ethanol B 20 38000 0.0781 0.0009 1.1 1.2
Cocoamphodiacetate * 0.0447 0.0163 0.57 0.6
Linoleamide DEA * 0.0447 0.0163 0.57 0.6
d-Limonene * 0.0447 0.0163 0.57 0.6
Nonoxynol-9 * 0.0447 0.0163 0.57 0.6
2-Aminoethanol C 3 800 0.0005 0.0015 5.6 6.0
Benzyl alcohol B 0.2 0.0750 0.2185 1.1 1.2
Acetic acid C 1 2456 0.0066 0.019 5.6 6.0
* compounds not yet evaluated for toxicity, but emissions less than de minimis for
Category A toxics.
Air emissions were calculated from the materials usages listed in the following
table. As may be seen from the table below, there is a limited number of the products
(bold type) used which are the major contributors to VOC emissions.
Product Annual Usage Solvent Content VOC Emissions
(gallons) (lb/gal) lb/yr
Heatset printing inks 88500 3.25 11,505.00
Ryco Silicone Spray 3.50 7.84 27.44
Rycoline Stay-Open 3.50 7.84 27.44
Destroyer HD Cleaner 9.75 0.97 9.50
Top Notch Fountain Solution 5200 0.45 2,340.00
AW81260A Wash 2540 6.51 16,535.40
Recon Plate Cleaner 79 0.16 12.64
Isopropanol 762 6.60 5,029.20
3M 77 Adhesive Spray 15.5 4.38 67.89
AnchorIt 3.5 0.35 1.23
Swift 42802 Adhesive 208 0.05 10.4
Hydraulic Oil 215 7.51 1,616.80
Silicone Rhodorsil 872 420 5.01 2,104.20
APPLICABLE RULES AND REGULATIONS
Oklahoma Air Pollution Control Rules
OAC 252:100-7 (Permits)
This printing operation will emit less than 100 TPY of all regulated pollutants,
and is therefore a minor source. As such, BACT for criteria pollutants and public
review are not required. BACT for organic pollutants is present in the form of the
afterburner.
OAC 252:100-19 (Particulate Matter from Fuel-Burning Equipment)
The permit will require that only pipeline quality natural gas be used as fuel for
the fuel-burning equipment. Therefore the emissions of 0.004 lb/MMBTU will comply
with the particulate matter emissions limit of 0.6 lb/MMBTU set forth in this
Subchapter.
OAC 252:100-25 (Smoke, Visible Emissions, and Particulates)
The facility will be required to comply with the opacity limit of 20% contained
in this Subchapter.
OAC 252:100-31 (Sulfur Compounds)
The permit will require that only pipeline quality natural gas be used as fuel for
the fuel-burning equipment. Therefore the emission of 0.0005 lb/MMBTU will comply
with the sulfur dioxide emission limit of 0.2 lb/MMBTU set forth in this Subchapter.
OAC 252:100-35 (Carbon Monoxide)
This Subchapter controls the emissions of CO from stationary sources. A source is
defined as a foundry cupola, a blast furnace, a basic oxygen furnace, a catalytic
cracking unit, or other petroleum natural gas process except stationary engines.
Therefore this Subchapter does not apply.
OAC 252:100-37 (Organic Materials)
This Subchapter subjects any new source of an organic material either as a solvent
or reactant to requirements of BACT and permits. Subchapter 37 has been fulfilled
by the installation of an afterburner rated at 95% efficiency.
Part 3 is the only section of Subchapter 37 applicable to this source. Standards
for coatings of parts and products affects emissions from usage of alkyd primers,
vinyls, NC lacquers, acrylics, epoxies, maintenance finishes, and custom product
finishes. Printing and publishing is not among the activities affected by Part 5
nor Part 7. Additional controls for air quality maintenance areas of Subchapter
39 are not applicable to Nowata County.
OAC 252:100-41 (Control of Emissions of Hazardous and Toxic Air Contaminants)
This Subchapter governs emissions of substances that have been categorized as
hazardous or toxic. All toxics and hazardous air pollutants are below de minimis
levels except for aromatic petroleum distillates. New sources of Category A toxics
are required to implement BACT; new sources of all air toxics are required to meet
MAAC standards. Modeling was conducted using the ISCST2 software to determine maximum
downwind impacts. Stoddard solvent is very near the de minimis and was also modeled
to be well below the MAAC. Based on experience and the low maximum ambient
concentration for the aromatic petroleum distillates, a hazardous concentration
will not exist.
Compound MAAC ug/m3 Modeled Results ug/m3
Aromatic petroleum dist. Not Established 2.21
Stoddard solvent 35,000 6.25
Federal Regulations
PSD (Prevention of Significant Deterioration)
The source is not subject to PSD because all emissions are less than 250 TPY, the
level of significance.
NESHAP (National Emission Standards for Hazardous Air Pollutants) 40 CFR 61
The source is not subject to NESHAPS. There will be no emissions of any of the
pollutants subject to regulation under 40 CFR 61: Radon-222, beryllium, mercury,
vinyl chloride, radionuclides, benzene, asbestos, and inorganic arsenic.
NSPS (New Source Performance Standards) 40 CFR 60
The facility is not subject to NSPS. The following NSPS subparts apply to surface
coating operations:
Subpart EE: metal furniture
Subpart MM: automobiles and light-duty trucks
Subpart QQ: graphic arts (rotogravure)
Subpart RR: pressure-sensitive tape and labels
Subpart SS: large appliances
Subpart TT: metal coil
Subpart WW: beverage cans
Subpart FFF: flexible vinyl and urethane
Subpart QQ affects rotogravure printing operations that commenced construction or
modification after October 28, 1980. However, the web offset printing operation
is not a rotogravure printing operation. Rotogravure printing involves use of inks
which average 70-75% solvent, whereas the inks in the Bellmar operation are 35%
solvent. Subpart QQ is therefore not applicable.
TESTING
Stack tests were conducted at the facility on May 4, 1995. 95% efficiency of the
catalytic oxidizer was confirmed. Emissions from the new press will be routed through
this same catalytic oxidizer.
FEES PAID: $250 Construction Permit fee.
SUMMARY: The facility has demonstrated the ability to achieve compliance with the
requirements of the several air pollution control rules and regulations. Ambient
air quality standards are not threatened at the site. Approval is recommended.
PERMIT TO CONSTRUCT
AIR POLLUTION CONTROL FACILITY
SPECIFIC CONDITIONS
Bellmar Color Press
Harris V-25 Heatset Offset Web Printing Press Permit No. 95-426-C
The permittee is authorized to construct in conformity with the specifications
submitted to Air Quality on September 27, 1995, and analyzed in AQD's Evaluation
of Permit Application No. 95-426-C dated November 29, 1995. Continuing construction
or operations under this permit constitutes acceptance of, and consent to, the
conditions contained herein:
1. This is a permit to construct in accordance with and under the authority of the
Oklahoma Clean Air Act and the rules promulgated thereunder. It does not relieve
the holder of the obligation to comply with other applicable federal, state, or
local statutes, regulations, rules, or ordinances.
2. Point of emissions and emissions limitations:
Harris V-15H Harris V-25
Heatset Press Heatset Press Pre-Press Area
Pollutant lb/hr TPY lb/hr TPY lb/hr TPY
NOx 0.2780 1.1120 0.2100 0.8470
CO 0.0750 0.3000 0.0570 0.2300
SO2 0.0017 0.0082 0.0013 0.0038
PM 0.0160 0.0641 0.0120 0.0489
Organic Materials
1,1,1-Trichloroethane 0.0006 0.0023 0.0003 0.0013
Butyl cellosolve 0.0007 0.0029 0.0010 0.0039 0.0010 0.0030
Isopropanol 0.3214 1.2870 0.3066 1.2276 0.0013 0.0037
Hexane 0.0011 0.0044 0.0012 0.0047 0.0017 0.0049
Ethylene glycol 0.2922 1.1700
Nonyphenol + 9 EQ 0.1065 0.4265
Methylene chloride 0.0006 0.0025 0.0008 0.0032
Cyclohexane 0.0011 0.0044 0.0012 0.0047
Vinyl Acetate 0.0023 0.0092
Stoddard Solvent 1.4854 5.9474 0.0143 0.0415
Aromatic petr. dist. 0.5305 2.1241
Ref. petr. oils 0.0985 0.3950 0.1034 0.4134
2 Methyl butane 0.0005 0.0019 0.0006 0.0026
Propane 0.0011 0.0044 0.0012 0.0047
Polydimethyl siloxane 0.1314 0.5261 0.1314 0.5261
Isobutane 0.0011 0.0044 0.0012 0.0047
Dimethyl ether 0.0011 0.0044 0.0012 0.0047
Dibutyl phthalate 0.0234 0.0018
Triethylene glycol 0.0010 0.0029
Diethanolamine 0.0023 0.0067
Hydroquinone 0.0248 0.0722
N propanol 0.0099 0.0287
Butane 0.0049 0.0143
Ethanol 0.0781 0.0009
2. Cont.
Pre-Press Area
lb/hr TPY
Cocoamphodiacetate 0.0447 0.0163
Linoleamide DEA 0.0447 0.0163
d Limonene 0.0447 0.0163
Nonoxynol 9 0.0447 0.0163
2 Aminoethanol 0.0005 0.0015
Benzyl alcohol 0.0750 0.2185
Glycerol 0.0022 0.0064
Acetic Acid 0.0066 0.0193
3. Materials usages shall not exceed the following levels:
Annual Usage
Product (gallons)
Heatset printing inks 88500
Top Notch Fountain Solution 5200
AW81260A Wash 2540
Isopropanol 762
Silicone Rhodorsil 872 420
Hydraulic oil 215
4. The afterburner shall be operated at a temperature of at least 650oF when the
unit is processing solvent vapors. A minimum destruction efficiency of volatile
organic materials of 95% shall be achieved. A temperature-monitoring device shall
be maintained on the device.
5. The fuel-burning equipment shall be fired with commercial grade pipeline natural
gas only.
6. Upon issuance of an operating permit, the permittee shall be permitted to operate
the facility 24 hours per day, 52 weeks per year, 8,760 hours per year.
7. The permittee shall not allow any discharge into the atmosphere of any smoke,
fumes, aerosol, mist, gas, vapor, or particulate matter, or any combination thereof,
of a shade or density greater than 20% equivalent opacity.
8. Wastes from the facility shall be disposed of in accordance with the requirements
of the Oklahoma Solid Waste Management Act, the Oklahoma Controlled Industrial Waste
Act, and the federal Resource Conservation and Recovery Act and rules and regulations
promulgated thereunder.
9. The permittee shall notify Air Quality of any change in the quantity (gallons)
and type(s) of products used at the facility. This notification shall be made in
writing within 10 days of the change and may, at the discretion of the Air Quality
Division, require permit modification.
10. At least once every six months, the permittee shall conduct tests of catalyst
effectiveness on the air pollution controls sufficient to verify that the catalyst
is active.
11. When afterburner temperatures or catalyst activity are insufficient, the owner
or operator shall comply with the provisions of OAC 252:100-9 for excess emissions
during start-up, shut-down, and malfunction of air pollution control equipment.
Requirements of OAC 252:100-9 include prompt notification to AQD and prompt
commencement of repairs to correct the condition of excess emissions.
12. The following records shall be maintained on site. All such records shall be
made available to regulatory personnel upon request. These records shall be
maintained for a period of at least two years after the time they are made.
a. Usage, by volume, of the materials listed in Specific Condition No.
3 (monthly).
b. A material data sheet which documents the volatile organic solvent
content expressed in pounds of VOC per gallon of ink less water and
exempt solvents, percentage of water by weight, solids percent by
weight, solvent density, and percentage of exempt solvents by weight
(if any), of each ink and fountain solution.
c. Catalyst effectiveness verification (every 6 months).
d. Afterburner temperature (daily when operating).