Section NR 419.08 - Core and mold manufacturing for iron or steel foundries(1) APPLICABILITY. (a) This section applies to the manufacture of cores or molds for use at iron or steel foundries at any facility which is located in the county of Kenosha, Kewaunee, Manitowoc, Milwaukee, Ozaukee, Racine, Sheboygan, Washington or Waukesha.(b) The emission limits of sub. (2) do not apply to:1. Iron or steel foundries or core manufacturing facilities which are located in the county of Kenosha, Milwaukee, Ozaukee, Racine, Washington or Waukesha which have maximum theoretical emissions of VOC from core and mold manufacturing of less than 25 tons per year.2. Iron or steel foundries or core manufacturing facilities which are located in the county of Kewaunee, Manitowoc or Sheboygan which have maximum theoretical emissions of VOC from core and mold manufacturing of less than 100 tons per year.(c) Any owner or operator of an iron or steel foundry or core manufacturing facility having annual emissions less than the applicability thresholds in par. (b) shall comply with the recordkeeping requirements of sub. (6) for that facility.(2) EMISSION AND OPERATIONAL LIMITATIONS. No owner or operator of a core or mold manufacturing system which produces cores or molds for use at iron or steel foundries may cause, allow or permit the operation of the system unless all of the following requirements are met: (a) The as applied VOC content of each core or mold coating, when measured using the methods contained in s. NR 439.06(3) (b), does not exceed any of the following limits: 1. 30%, by weight, including water, for core or mold coatings which have an as purchased density of 15.0 pounds per gallon or greater.2. 70%, by weight, including water, for core or mold coatings which have an as purchased density of less than 15.0 pounds per gallon.(b) All core and mold coating storage vessels and containers remain covered whenever product is not being moved into or out of the vessel or container.(c) Emissions of the organic gases used in the catalysis step in the formation of urethane cold box binders are controlled with an overall efficiency of at least 90%.(3) COMPLIANCE AND CERTIFICATION DEADLINES. (a) Final compliance with the requirements of sub. (2) shall be achieved by May 31, 1995 or upon startup, whichever is later.(b) The owner or operator shall submit certification to the department, by July 1, 1995 or within 90 days after startup, whichever is later, that the facility is in compliance with the requirements of sub. (2), as demonstrated by the applicable testing methods of s. NR 439.06(3).(4) EMISSION TESTING. The owner or operator of a facility which employs a urethane cold box binder shall demonstrate compliance with the emission rate in sub. (2) (c) using one of the test methods in s. NR 439.06(3) (a) prior to the final compliance date in sub. (3) (a), and at least every 2 years thereafter within 60 days of the anniversary of the initial compliance test.(5) EMISSION CONTROL SYSTEM MONITORING. The owner or operator of any facility which uses a wet scrubber to control organic gas emissions from the catalysis of urethane cold box binders shall continuously measure and record the pH of the scrubber liquid in addition to meeting the monitoring requirements of s. NR 439.055(1) (e).(6) RECORDKEEPING. Owners or operators of a facility subject to this section, including those exempt from the requirements of sub. (2) under sub. (1) (b), shall maintain the following records in accordance with s. NR 439.04(1) to (3): (a) The quantity, in pounds, of each type of core binder used on an annual basis.(b) Records of operation variables which are required to be measured under sub. (5) and s. NR 439.055(1) (e).(c) The total quantity, in pounds, of organic gas used to catalyze the formation of urethane cold box binders on an annual basis.(d) The as purchased density and percent VOC, by weight, of each core or mold coating used at the facility.(e) The total quantity, in pounds or gallons, of each core or mold coating used on a monthly basis.(f) The total quantity of solvent, in pounds, added to each core or mold coating on a monthly basis.Wis. Admin. Code Department of Natural Resources NR 419.08
Cr. Register, June, 1994, No. 462, eff. 7-1-94; am. (1) (c), (2) (intro.), (b), (c), (3), (5) and (6) (intro.) and r. (7), Register, October, 1999, No. 526, eff. 11-1-99.