NOTICES
Availability of Final General Plan Approval and General Operating Permit for Nonheatset Web Offset Lithographic Printing Presses (BAQ-GPA/GP-10)
[29 Pa.B. 3406] The Department of Environmental Protection (Department) finalized the General Plan Approval and General Operating Permit No. BAQ-GPA/GP-10 for nonheatset web offset lithographic printing presses. Notice regarding the availability of the draft general permit was published at 29 Pa.B. 1662 (April 24, 1999).
The Nonheatset Web Press General Permit and associated documents were drafted in consultation with the Graphic Arts Association and the Graphic Arts Technical Foundation. A 45-day comment period was provided and no comments were received, therefore the general permit has been finalized as originally published
The general permit is now available for use by qualifying applicants. Copies are now available of the final general permit BAQ-GPA/GP-10 and an application form. These documents may be obtained by contacting Kimberly Maneval, Bureau of Air Quality, Rachel Carson State Office Building, P. O. Box 8468, Harrisburg, PA 17105-8468, (717) 787-4325.
The documents have also been placed on the Department's World Wide Web site on the Internet which can be accessed at http://www.dep.state.pa.us, select Bureau of Air Quality, then Division of Permits.
JAMES M. SEIF,
Secretary1. Statutory Authority and General Description--In accordance with section 6.1(f) of the Air Pollution Control Act (35 P. S. § 4006.1) and 25 Pa. Code § 127.622, the Department of Environmental Protection (Department) hereby issues this general plan approval and general operating permit for nonheatset web offset lithographic printing press(es) (hereinafter referred to as ''Nonheatset Web Press General Permit'').
2. Applicability/Source Coverage Limitations--This Nonheatset Web Press General Permit is designed to serve as either a general plan approval or as a general operating permit for printers who exclusively use nonheatset web offset lithographic printing presses or have one or more nonheatset web offset lithographic presses located in a facility. The specific use of the general permit will depend upon permit status, emission levels and location of the facility as outlined below.
Approval herein granted to operate under this Nonheatset Web Press General Permit is limited to a facility engaged in printing on nonheatset web offset lithographic printing press(es) as defined in Condition 16 of this permit. This Nonheatset Web Press General Permit has been established in accordance with the provisions described in 25 Pa. Code Subchapter H of Chapter 127. If additional types of printing or manufacturing is conducted at the facility that can not be regulated by the requirements of this general permit, an operating permit issued in accordance with 25 Pa. Code Subchapter F of Chapter 127 will be required, or, if the facility is a Title V facility, a Title V operating permit issued in accordance with Subchapters F and G will be required.
Operating Permit
This Nonheatset Web Press General Permit is not intended for use by a Title V facility as defined in 25 Pa. Code § 121.1. A ''Title V facility'' includes sources that have actual emissions or a potential to emit (PTE) equal to or greater than the maximum permitted emission levels shown in the following table for a single facility: A facility is eligible to operate under this Nonheatset Web Press General Permit if its actual emissions will remain below the maximum permitted emission levels listed below. A nonheatset web offset lithographic printing press facility is exempted from the permit requirements of § 127.402 if it is demonstrated that the facility's actual emissions are less than the permit exemption levels in this section.
Maximum Permitted Facility Permit Pollutant Emission Levels/Facility Exemption Levels CO <100 TPY <20 TPY NOx <100 TPY* <10 TPY SOx <100 TPY <8 TPY VOCs <50 TPY* <8 TPY PM10 <100 TPY <3 TPY HAP ** <10 TPY <1 TPY HAPs <25 TPY <2.5 TPY *<25 TPY for Severe nonattainment area including Bucks, Chester, Delaware, Montgomery and Philadelphia counties.
**See Table A for a list of hazardous air pollutants.
This Nonheatset Web Press General Permit can be used for any facility engaged in nonheatset web offset printing with actual emissions less than those identified above as the maximum permitted emission levels.
Plan Approval
This Nonheatset Web Press General Permit shall also serve as a general plan approval for nonheatset web offset lithographic printing press that meet the requirements specified in Conditions 17, 18, 19 and 20 of the general permit. The installation or modification of each nonheatset web offset lithographic printing press that meets the following criteria is exempt from plan approval requirements if the press:
a. emits volatile organic compounds (VOCs) at a rate less than 2.7 tons per year (tpy), and;
b. emits a single hazardous air pollutant (HAP) at a rate less than 1 tpy, and;
c. emits a combination of hazardous air pollutants (HAPs) rates less than 2.5 tons of all HAPs combined per year, or;
d. has a cylinder width 17 inches or less.
Facilities claiming an exemption based on the emissions-based criteria (a) through (c) must provide a 15-day prior written notification to the Department indicating that VOC/HAP emission increases will not exceed the emissions-based criteria.
The modification of a nonheatset web offset lithographic printing press includes the addition of a printing unit, coating unit, or other changes that would increase the facility's emission of VOCs or HAPs above the exemption levels specified in criteria (a) through (c).
3. Application for Use--Any person proposing to operate, install, or modify a nonheatset web offset lithographic press under this Nonheatset Web Press General Permit shall notify the Department using the Nonheatset Web Offset Lithographic Printing Press General Permit Application provided by the Department. In accordance with 25 Pa. Code § 127.621 (relating to application for use of general plan approvals and general operating permits), the applicant shall receive prior written approval from the Department prior to operating under the general permit.
4. Compliance--Any applicant authorized to operate a nonheatset web offset lithographic printing press(es) under this Nonheatset Web Press General Permit shall comply with the terms and conditions of the general permit. The nonheatset web offset lithographic printing press(es) shall be:
a. Operated in such a manner as not to cause air pollution.
b. Operated and maintained in a manner consistent with good operating and maintenance practices.
c. Operated and maintained in accordance with the manufacturer's specifications and the applicable terms and conditions of this Nonheatset Web Press General Permit.
5. Permit Modification, Suspension and Revocation--This Nonheatset Web Press General Permit may be modified, suspended or revoked if the Department determines that affected nonheatset web offset lithographic printing press(es) cannot be regulated under this general permit. Authorization to use this Nonheatset Web Press General Permit shall be suspended or revoked if the permittee fails to comply with applicable terms and conditions of the Nonheatset Web Press General Permit.
The approval herein granted to operate the nonheatset web offset lithographic printing press(es) shall be suspended, if, at any time, the permittee causes, permits or allows any modification without Departmental approval (as defined in 25 Pa. Code § 121.1) of the nonheatset web offset lithographic printing press(es) covered by this general permit. Upon suspension of the general permit, the permittee may not continue to operate or use said nonheatset web offset lithographic printing press(es). If warranted, the Department will require that the nonheatset web offset lithographic printing press(es) be permitted under the state operating permit and/or Title V operating permit program requirements in 25 Pa. Code Chapter 127, as appropriate.
6. Notice Requirements--The applications and notifications required by 25 Pa. Code § 127.621 shall be submitted to the appropriate Regional Office responsible for issuing general permits in the county in which the nonheatset web offset lithographic printing press is, or will be, located. As required under § 127.621(b), the application shall be either hand delivered or transmitted by certified mail return receipt requested.
The permittee shall notify the Department, in writing, within 24 hours of the discovery of any malfunction during a business day or by 5 p.m. on the first business day after a weekend or holiday of any malfunction of the nonheatset web offset lithographic printing press(es) which results in, or may result in, the emission of air contaminants in excess of the limitations specified in, or established under, any applicable rule or regulation contained in 25 Pa. Code, Subpart C, Article III (relating to air resources).
7. Sampling and Testing--The permittee shall, upon the request of the Department, provide input material analyses, or input material samples used in any nonheatset web offset lithographic printing press(es) authorized to operate under this general permit.
8. Monitoring, Recordkeeping and Reporting--The permittee shall comply with applicable monitoring, recordkeeping and reporting requirements set forth in 25 Pa. Code Chapter 139 (relating to sampling and testing), the Air Pollution Control Act, the Clean Air Act and the applicable regulations under the acts.
9. Term of Permit--The Nonheatset Web Press General Permit is issued for a fixed term of 5 years. The Department will notify each applicant, by letter, when approval to operate under this general permit is granted.
10. Permit and Administrative Fees--The Nonheatset Web Press General Permit establishes the following application and renewal fees payable every 5 years if no equipment changes occur:
a. Two hundred fifty dollars during the 1999 calendar year.
b. Three hundred dollars during the 2000-2004 calendar years.
c. Three hundred seventy-five dollars beginning in the 2005 calendar year.
An additional plan approval application fee as indicated above is required each time the permittee installs or modifies a nonheatset web offset lithographic printing press. The installation or modification of a nonheatset web offset lithographic printing press must be conducted according to the terms and conditions of this general permit. Two or more nonheatset web offset lithographic printing presses may be installed under a single plan approval fee.
11. Expiration and Renewal of Permit--The permittee's right to operate under this Nonheatset Web Press General Permit terminates on the date of expiration of this permit unless a timely and complete application for the renewal of the general permit is submitted to the Department at least 30 days prior to the permit expiration date.
Upon receipt of a complete and timely application for renewal, the nonheatset web offset lithographic printing press(es) may continue to operate subject to final action by the Department on the renewal application. This protection shall cease to exist if, subsequent to a completeness determination, the applicant fails to submit by the deadline specified in writing by the Department any additional information required by the Department to process the renewal application.
The Nonheatset Web Press General Permit application for renewal shall include the identity of the owner or operator, location of the nonheatset web offset lithographic printing press(es), current permit number, description of source category, the appropriate renewal fee listed in Condition 10 of this permit and any other information requested by the Department. At a minimum, the permit renewal fee shall be submitted to the Department at least 30 days prior to the expiration of the Nonheatset Web Press General Permit.
12. Applicable Laws--Nothing in this Nonheatset Web Press General Permit relieves the permittee from its obligation to comply with all applicable Federal, state and local laws and regulations.
13. Prohibited Use--Any air contamination source that is subject to the requirements of 25 Pa. Code Chapter 127, Subchapter D (relating to prevention of significant deterioration), 25 Pa. Code Chapter 127, Subchapter E (relating to new source review) 25 Pa. Code Chapter 127, Subchapter G (relating to Title V operating permits), or 25 Pa. Code § 129.91 (relating to control of major sources of NOx and VOCs), may not operate under this Nonheatset Web Press General Permit. Title V facilities may use this Nonheatset Web Press General Permit as a general plan approval when the major new source review and prevention of significant deterioration requirements are not applicable.
14. Transfer of Ownership or Operation--The permittee may not transfer the Nonheatset Web Press General Permit except as provided in 25 Pa. Code § 127.464 (relating to transfer of operating permits).
15. Plan Approval--This Nonheatset Web Press General Permit authorizes the construction and operation of nonheatset web offset lithographic printing press(es) that meet the best available technology (BAT) required under 25 Pa. Code §§ 127.1 and 127.12(a)(5). For purposes of this general permit, the emission limits specified in Conditions 17, 18, 19 and 20 of this general permit are BAT for nonheatset web offset lithographic printing press(es).
16. Definitions--For purposes of this Nonheatset Web Press General Permit, the following definitions apply:
a. Alcohol--A class of compounds containing a single hydroxyl group OH. When used as a fountain solution additive for offset lithographic printing, the term includes: ethanol, n-propanol and isopropanol.
b. Alcohol Substitutes--Nonalcohol additives that contain VOCs and are used in the fountain solution. The term includes additives used to reduce the surface tension of water or prevent piling (ink build-up).
c. Automatic Blanket Wash System--Equipment used to remotely clean lithographic blankets which may include, but is not limited to those utilizing a cloth and expandable bladder, brush, spray or impregnated cloth system.
d. Batch--A supply of fountain solution that is prepared and used without alteration until completely used or removed from the printing process. For the purposes of this general permit, this term includes solutions that are either prepared in discrete batches or solutions that are continuously blended with automix units.
e. Cleaning Solution--Liquid solvents or solutions used to remove ink and debris from the operating surfaces of the printing press and its parts.
f. Dampening System--Equipment used to deliver the fountain solution to the lithographic plate.
g. Fountain Solution--A mixture of water, nonvolatile printing chemicals and an additive (liquid) that reduces the surface tension of the water so that it spreads easily across the printing plate surface. The fountain solution wets the nonimage area so that the ink is maintained within the image areas. Nonvolatile additives include mineral salts and hydrophilic gums. For the purpose of this general permit, the additives may include a VOC content of 5.0% or less. Alcohol and alcohol substitutes, including isopropyl alcohol, glycol ethers and ethylene glycol, are the most common VOC additives used to reduce the surface tension of the fountain solution.
h. Fountain Solution Recirculating Reservoir--The collection tank which accepts fountain solution recirculated from printing unit(s). The tanks typically contains a coarse filter to remove contaminants from the fountain solution and in some cases, are equipped with cooling coils for refrigeration of the fountain solution.
i. Inking System--A series of rollers used to meter the ink onto the lithographic plate. The system can include agitators, pumps, and totes and other types of ink containers.
j. Lithography--A planographic printing process where the image and nonimage areas are chemically differentiated; the image area is oil receptive and the nonimage area is water receptive. This method differs from other printing methods, where the image is typically printed from a raised or recessed surface.
k. Nonheatset--A lithographic printing process where the printing inks are set without the use of heat. Traditional nonheatset inks set and dry by absorption and/or oxidation of the ink oils. For the purposes of this general permit, ultraviolet-cured and electron beam-cured inks are considered nonheatset, although radiant energy is required to cure these inks.
l. Offset--A printing process that transfers the ink film from the lithographic plate to an intermediary surface (blanket), which, in turn, transfers the ink film to the substrate.
m. Press--For purposes of this general permit, a printing production assembly composed of one or more units used to produce a printed substrate or a web. The term includes any associated coating, spray powder application or infra-red heating units.
n. Unit--The smallest complete printing component, composed of inking and dampening systems, of a printing press.
o. VOC Composite Partial Vapor Pressure--The sum of the partial pressure of the compounds defined as VOCs. VOC composite partial pressure is calculated as follows:
Where:
Wi = Weight of the ''i''th VOC compound, in grams
Ww = Weight of water, in grams
Wc = Weight of exempt compound, in grams
MWi = Molecular weight of the ''i''th VOC compound, in g/g-mole
MWw = Molecular weight of water, in g/g-mole
MWc = Molecular weight of exempt compound, in g/g-mole
PPc = VOC composite partial pressure at 20°C, in mm Hg
VPi = Vapor pressure of the ''i''th VOC compound at 20°C, in mm Hg p. Web--A continuous roll of paper used as the printing substrate in a printing process.
17. Equipment Standards for Fountain Solutions--Any nonheatset web offset lithographic printing press(es) subject to this Nonheatset Web Press General Permit shall meet one of the following requirements for the fountain solution used on that press:
a. Maintain the as applied VOC content of the fountain solution at or below 5.0% by weight, and;
b. The fountain solution shall contain no alcohol.
18. Equipment Standards for Blanket and Roller Cleaning Solutions--Any blanket and roller cleaning solution used on a nonheatset web offset lithographic printing press subject to the terms and conditions this Nonheatset Web Press General Permit shall meet one of the following requirements:
a. VOC content, as applied, is less than or equal to 30 percent by weight, or;
b. VOC composite partial vapor pressure, as used, is less than or equal to 10 mm Hg at 20°C (68°F).
c. The use of cleaning solutions not meeting Conditions 18 a. or b. is permitted provided that the quantity used does not exceed 55 gallons over any twelve consecutive months.
19. Equipment Standards for Solvent Containers--Any owner/operator of a nonheatset web offset lithographic printing press(es) subject to this Nonheatset Web Press General Permit shall keep all solvent containers closed at all times unless filling, draining or performing cleanup operations.
20. Equipment Standards for Solvent Laden Shop Towels--Any owner/operator of a nonheatset web offset lithographic printing press(es) subject to this Nonheatset Web Press General Permit shall keep all solvent laden shop towels in a closed container when not being used.
21. Testing of Fountain Solutions--Any owner/operator of a nonheatset web offset lithographic printing press(es) subject to this Nonheatset Web Press General Permit shall determine the VOC content of fountain solution by one of the following procedures:
a. Analysis by USEPA Method 24 of a fountain solution sample,
b. Calculation which combines USEPA Method 24 analytical VOC content data for the concentrated materials used to prepare the press ready fountain solution and records of the proportions in which they are mixed. The calculation shall only be performed once for each press ready fountain solution and kept in the form of a batch log. See the Fountain Solution Batch VOC Content Form and Fountain Solution VOC Addition Form attached to this general permit. The analysis of the concentrated fountain solution may be performed by the supplier(s) of those materials.
22. Testing of Blanket and Roller Cleaning Solutions--Any owner/operator of a nonheatset web offset lithographic printing press(es) subject to this Nonheatset Web Press General Permit shall determine the VOC content or VOC composite partial vapor pressure of cleaning solutions by one of the following procedures:
a. Analysis by USEPA Method 24 of a cleaning solution sample for VOC content or by an appropriate method for composite partial vapor pressure,
b. Calculation which combines USEPA Method 24 analytical VOC content data for the concentrated materials used to prepare the press ready cleaning solution and records of the proportions in which they are mixed. The calculation shall only be performed once for each press ready cleaning solution and kept in the form of a batch log. See the Cleaning Solution Batch VOC Content Form attached to this general permit. The analysis of the concentrated cleaning solution may be performed by the supplier(s) of those materials,
c. Calculation for VOC composite partial vapor pressure which combines analytical VOC vapor pressure data for the concentrated materials used to prepare the press ready cleaning solution and records of the proportions in which they are mixed. The analysis and vapor pressure determinations of the concentrated material(s) may be performed by the suppliers(s) of the material(s).
23. Monitoring Requirements for Automatic Blanket Wash Systems--Any owner/operator of a nonheatset web offset lithographic printing press(es) subject to this Nonheatset Web Press General Permit using an automatic blanket wash system that mixes cleaning solution at the point of application must demonstrate compliance with the VOC limitation in Condition 18 a. or b. shall document that flow meters or fixed volume spray systems result in the VOC content of the mixed solution complies with Condition 18 a. or b. of the general permit.
24. Recordkeeping Requirements--Any owner/operator of a nonheatset web offset lithographic printing press(es) subject to this Nonheatset Web Press General Permit shall collect and record the applicable information specified in this Condition. The information shall be maintained at the facility for a minimum of 5 years. The Department or an authorized representative of the Department shall, at reasonable times, have access to and require the production of books, papers or records, as the Department may reasonably prescribe relevant to compliance with the terms and conditions in this general permit. The information required includes the following:
a. For each nonheatset web offset lithographic ink or conventional varnish used: the monthly consumption in pounds or gallons; the percent by weight VOC and HAP content, as applied; and, an estimate of VOC and HAP emissions. Alternately, the ink with the highest VOC and HAP content may be used to represent all inks used by all nonheatset web offset lithographic printing presses.
b. For each fountain solution and additive: the monthly consumption in pounds or gallons; the percent by weight or weight to volume ratio (lbs/gal) VOC and HAP content and an estimate of VOC and HAP emissions.
c. For each blanket and roller cleaning solution used: the monthly consumption in pounds or gallons; the percent by weight or weight to volume ratio (lbs/gal) VOC and HAP content and an estimate of VOC and HAP emissions.
d. For each month of operation, the volume of all cleaning solution used which does not meet Condition 18 a. or b.
e. For each month of operation, an estimate of VOC and HAP emissions during the latest 12 months.
Fountain Solution Batch VOC Content Form Fountain Solution Concentrate
Name: __________
Formula Number: __________
Density(lbs/gal)*: __________
VOC Content (lbs/gal)**: __________
Fountain Solution Additive
Name: __________
Formula Number: __________
Density(lbs/gal)*: __________
VOC Content (lbs/gal)**: __________
* Density may be obtained from data on the Material Safety Data Sheet or determined by multiplying the specific gravity from the MSDS by 8.33 pounds per gallon.
** VOC content may be determined by either using the Material Safety Data Sheet, conducting USEPA Method 24, or by summing the percent composition of each individual VOC and multiplying it by the density. Do not include exempt VOCs, especially Methylene Chloride and 1,1,1-Trichloroethane.
____ Ounces of Fountain Concentrate Added Per Gallon of Water.
____ Ounces of Fountain Additive Added Per Gallon of Water.
Press Ready VOC Concentration:
Fountain Solution VOC Addition Form Indicate When Any VOC Is Added To Press Ready Fountain Solution
Press or Fountain Amount Added In Final VOC Content In Date Recirculator Material Added Ounces Weight Percent Final Press Ready VOC Concentration:
Cleaning Solution Batch VOC Content Form Cleaning Solution Concentrate
Name: __________
Formula Number: __________
Density(lbs/gal)*: __________
VOC Content (lbs/gal)**: __________
Cleaning Solution Additive
Name: __________
Formula Number: __________
Density(lbs/gal)*: __________
VOC Content (lbs/gal)**: __________
* Density may be obtained from the Material Safety Data Sheet or by multiplying the specific gravity from the MSDS by 8.33 pounds per gallon.
** VOC content may either be obtained from the Material Safety Data Sheet, conducting USEPA Method 24, or determined by summing the percent composition of each individual VOC and multiplying it by the density. Do not include exempt VOCs, especially Methylene Chloride and 1,1,1-Trichloroethane.
____ Ounces of Cleaning Solution Concentrate Added Per Gallon of Water.
____ Ounces of Cleaning Solution Additive Added Per Gallon of Water.
Press Ready VOC Concentration:
NONHEATSET WEB PRESS GENERAL PERMIT RECORDKEEPING FORMAT
Month: ______
Inks:
Vendor Color Formula # VOC Content1 HAP HAP Content2 Usage3 VOC7 Emissions HAP7 Emissions ABC Inks Black P-45701 15% N/A N/A 10,000 lbs. Fountain Solution Concentrate: Vendor Formula # VOC Content4 VOC Content As Applied1 HAP HAP Content5 Usage3 VOC7 Emissions HAP7 Emissions Wet All I WA-001 2.3 4.5% 2-Butoxy-
ethanol2.3 200 gal Fountain Solution Additive: Vendor Formula # VOC Content4 VOC Content As Applied4 HAP HAP Content5 Usage3 VOC7 Emissions HAP7 Emissions Wet All II WA-002 6.0 4.5% 2-Butoxy-
ethanol6.0 200 gal Cleaning Solutions: Vendor Formula # VOC Content4 VOC Content As Applied4 Vapor Pressue6 HAP HAP Content5 Usage3 VOC7 Emissions HAP7 Emissions Clean All CA-010 7.5 100% 5 mmHg Xylene, cumene 2-Butoxy-
ethanol2.0 850 gal Coatings:
Vendor Formula # VOC Content1,4 VOC Content As Applied1,4 HAP HAP Content2,5 Usage3 VOC7 Emissions HAP7 Emissions Coatings, Inc. P-46400 42.6% 42.6% N/A N/A 2,000 lbs 1VOC content in weight percent
2HAP content in weight percent
3Usage in pounds or gallons
4VOC Content in pounds/gallon
5HAP Content in pounds/gallon
6Vapor pressure in millimeters of mercury (mm Hg)
7Use appropriate emission/retention factors as identified in permit application
12-Month Totals The U.S. Environmental Protection Agency requires the Department to track emissions on a 12-month total basis rather than on a calendar basis. This means that emission estimates should be recalculated each month totaling emissions that occurred during the last 12 months. For example, at the end of March, 1998 you would total the emissions which occurred from April, 1997 through March, 1998; at the end of April, 1998 you would total the emissions which occurred from May, 1997 through April, 1998, etc.
Sample Form
12-Month Totals for Calendar Year - - - -
Month VOCs HAPs 12-Mon. Tot. VOCs 12-Mon. Tot. HAPs January February March April May June July August September October November December
[Pa.B. Doc. No. 99-1054. Filed for public inspection July 2, 1999, 9:00 a.m.]
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