2700-PM-AQ0207 Rev. 2/2002
Instructions
COMMONWEALTH OF PENNSYLVANIA
DEPARTMENT OF ENVIRONMENTAL PROTECTION
BUREAU OF AIR QUALITY
GENERAL PLAN APPROVAL & GENERAL OPERATING PERMIT
APPLICATION INSTRUCTIONS
General Permit BAQ-GPA/GP-7: Sheet-Fed Offset Lithographic Printing Press
GENERAL INFORMATION
1.
This Sheet-fed Press General Permit is designed to serve as either a Plan Approval or as an
Operating Permit for printers who exclusively use sheet-fed offset lithographic printing presses of
have one or more sheet-fed offset lithographic presses located in a facility. The specific use will
depend upon permit status and location of the facility as outlined below.
2.
Any sheet-fed offset lithographic printing press(es) proposing to operate under the general plan
approval and operating permit (BAQ-GPA/GP-7) must comply with the terms and conditions
specified therein. Failure to conform with the applicable laws, rules and regulations and terms and
conditions of this permit, for any reason, is grounds for the revocation or suspension of the
permittee’s approval to operate under this permit.
3.
BAQ-GPA/GP-7 cannot be used for a stationary 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).
BAQ-GPA/GP-7 is not intended for use by a Title V facility. A Title V facility is one that has a
potential to emit (PTE) equal to or greater than the maximum permitted facility emission levels
shown in the following table and actual emissions are not restricted to less than those levels. A
facility is eligible to operate under this Sheet-fed Press General Permit if its actual emissions will
remain below the maximum permitted facility emission levels listed below. A sheet-fed 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 listed
below:
Pollutant
CO
NOx
SOx
VOCs
PM10
HAP **
HAPs
Max Permitted Fac
Emission Levels
100 TPY
100 TPY *
100 TPY
50 TPY *
100 TPY
10 TPY
25 TPY
Fac Permit
Exemption Levels
20 TPY
10 TPY
8 TPY
8 TPY
3 TPY
1 TPY
2.5 TPY
* 25 TPY for Severe non-attainment area including Bucks, Chester, Delaware, Montgomery and
Philadelphia counties.
** See Table A for a list of hazardous air pollutants.
The installation or modification of sheet-fed offset lithographic printing press(es) that meet the
following criteria are exempt from plan approval requirements of 25 Pa. Code §127.11:
a.
Emits volatile organic compounds (VOCs) at a rate less than 2.7 tons per year (tpy), and;
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2700-PM-AQ0207 Rev. 2/2002
Instructions
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.
A cylinder width 17 inches or less.
A facility qualifying for an exemption based on the emissions criteria (a) through (c) must provide a
15-day prior written notification to the Department. The notice shall specify that the facility will limit
VOC emission increases to less that the specified levels.
4.
An applicant for BAQ-GPA/GP-7 must fulfill the requirements regarding the filing of compliance
review forms according to 25 Pa. Code Section 127.412.
5.
BAQ-GPA/GP-7 is issued for a term of five years. The application fee is described in Condition 10.
of the General Permit. An application for renewal with a renewal fee must be submitted 30 days
prior to expiration of the permit.
6.
The application and fees are to be submitted to the respective Regional Office indicated in
Attachment 3.
SPECIFIC INFORMATION
1.
Owner of Press: The name of the company that owns the sheet-fed offset lithographic press(es).
2.
Location of Press: Provide the proper mailing address for the location of the sheet-fed offset
lithographic printing press(es) including the Municipality and County in which the press is located.
3.
Contact Person: Provide the name of a contact person for questions relating to information
provided in this application.
4.
Telephone/Fax Number: Provide the telephone and fax number of the contact person identified
above.
5.
Mailing Address: Provide the complete mailing address for the sheet-fed offset lithographic
printing press(es) contact if different than given above.
6.
Allowable VOC Emission Limit: Check the appropriate box and if applicable, provide the facility’s
current total allowable VOC emissions limit for sheet-fed press(es).
7.
Allowable HAP Emission Limit: Check the appropriate box and if applicable, provide the facility’s
current total allowable HAP emissions limit for sheet-fed press(es).
8.
Press Information: Provide the manufacturer and model of press(es) located or to be installed at
the facility. If this application is for new press(es) installation, then only complete the information for
the new press(es). For both new and existing press(es), provide the internal press designation,
indicate if it is a new or existing press, date of installation or anticipated date of installation, the
number of units, and if it is equipped with a coating unit.
9.
VOC Calculations: For purposes of VOC emission determinations, use Attachment 1.
10.
HAP Calculations: For purposes of HAP emission determinations, use Attachment 2.
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2700-PM-AQ0207 Rev. 2/2002
Instructions
ATTACHMENT 1
1
Material
2
Usage
Ink-Process
Ink-PMS
Fountain Sol Concentrate
FS Additive
Cleaning Solution
Coating
Misc
Units
VOC
3
Content
lbs/yr
Units
Emission
4
Factor
VOC
5
Emissions
% by Wt
lbs/yr
% by Wt
gal/yr
lbs VOC/gal
gal/yr
lbs VOC/gal
gal/yr
lbs VOC/gal
gal/yr
lbs VOC/gal
gal/yr
lbs VOC/gal
lbs/yr
% by Wt
gal/yr
lbs VOC/gal
gal/yr
lbs VOC/gal
gal/yr
lbs VOC/gal
Total VOC Emissions
1.
Do not include any material that is used in quantities of 25 gallons or less per year.
2.
For existing press(es), indicate total pounds or gallons of material used during the year. For new
press(es), indicate total pounds or gallons of material expected to be used during the year. Amount
used is defined as the amount purchased minus the amount discarded and/or recycled.
3.
List either percent VOC content (by weight) or pounds of VOC per gallon for the product. The VOC
content information may be provided by the supplier via the Material Safety Data Sheet, USEPA
Method 24 analysis, or summing all VOCs and multiplying it by the density. Do not include exempt
VOCs such as Methylene Chloride or 1,1,1-Trichloroethane. If density is unknown, multiply specific
gravity from MSDS by 8.33 lbs/gal.
4.
For ink VOC content, the applicant can determine the VOC emissions for each ink or use the
highest VOC containing ink in each category.
5.
Use the following for the appropriate VOC emission factor:
Ink
Fountain Solution Concentrate
Fountain Solution Additive
Cleaning Solution
Coating
UV
Water-Based
Conventional
5%
100%
100%
50% *
0%
100%
5%
o
* The VOC composite vapor pressure of the cleaning solution cannot exceed 10 mm Hg at 20 C
o
(68 F). Alternatively, the VOC content of the cleaning solution cannot exceed 30% by weight.
5.
The VOC emissions are determined by multiplying the Usage, VOC Content, and Emission Factors
together. The total VOC emissions are the result of adding all of the individual VOC emission
determinations together. To convert the total pounds per year into tons per year, divide the total
pounds by 2,000 because there are 2,000 pounds in one ton.
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2700-PM-AQ0207 Rev. 2/2002
Instructions
** If individual material consumption amount by press cannot be determined, then the applicant can
estimate individual consumption by using hours of operation, impression ratio, or other suitable
means.
Example of VOC Emission Calculation using the above approach:
Material
Annual Usage
VOC Content
Sheet-fed Ink, Process
25,200 pounds
35% by weight
Fountain Solution Concentrate
420 gallons
0.717 pounds/gallon
Fountain Solution Additive
120 gallons
6.7 pounds/gallon
Cleaning Solution - Blanket Wash
1,200 gallons
6.24 pounds/gallon
Cleaning Solution - Roller Wash
300 gallons
5.9 pounds/gallon
Coating - UV
180 gallons
8.5 pounds/gallon
Coating - Conventional
6,000 pounds
35% by weight
VOC Emissions are as follows:
Ink
25,200 lbs x 0.35 lbs x 0.05
=
441
Fountain Solution Concentrate
420 gal x 0.717 lbs/gal
=
301.14 lbs
Fountain Solution Additive
120 gal x 6.7 lbs/gal
=
804
lbs
Cleaning Solution - Blanket Wash
1,200 gal x 6.24 lbs/gal x 0.5
=
3,744
lbs
Cleaning Solution - Roller Wash
300 gal x 5.9 lbs/gal x 0.5
=
885
lbs
Coating - UV
180 gal x 8.5 lbs/gal x 0.0
=
0
lbs
Coating - Conventional
6,000 lbs x 0.35 lbs x 0.05
=
105
lbs
Total
lbs
6,280.14 lbs
3.14 tons
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2700-PM-AQ0207 Rev. 2/2002
Instructions
ATTACHMENT 2
1
Material
2
Usage
Units
Ink-Process
Ink-PMS
Fountain Sol Concentrate
lbs/yr
HAP
3
Content
Units
% by Wt
gal/yr
lbs HAP/gal
FS Additive
gal/yr
lbs HAP/gal
Cleaning Solution
gal/yr
lbs HAP/gal
gal/yr
lbs HAP/gal
gal/yr
lbs HAP/gal
lbs/yr
% by Wt
gal/yr
lbs HAP/gal
gal/yr
lbs HAP/gal
gal/yr
lbs HAP/gal
Misc
HAP
5
Emissions
% by Wt
lbs/yr
Coating
Emission
4
Factor
Total HAP Emissions
1.
Do not include any material that is used in quantities of 25 gallons or less per year.
2.
For existing press(es), indicate total pounds or gallons of material used during the year. For new
press(es), indicate total pounds or gallons of material expected to be used during the year. Amount
used is defined as the amount purchased minus the amount discarded and/or recycled.
3.
List either percent HAP content (by weight) or pounds of HAP per gallon for the product. The HAP
content information may be provided by the supplier via the Material Safety Data Sheet or USEPA
Method 311 analysis. Total HAP content may have to be estimated by summing individual HAP
concentrations and/or multiplying it by the VOC content. If the product contains any exempt VOCs
such as Methylene Chloride or 1,1,1-Trichloroethane, the amount of it will have to be added to the
total HAP content.
4.
a.
For total HAP content determination indicate total HAP content for the material.
b.
For individual HAPs content determination, indicate the individual HAP under the material
heading and its respective concentration in the HAP concentration column.
c.
For ink HAP content, use the highest HAP containing ink in each category. Note: There
should not be any HAPs in sheet-fed offset lithographic inks. Confirm with supplier.
Use the following for the appropriate HAP emission factor*:
Ink
Fountain Solution Concentrate
Fountain Solution Additive
Cleaning Solution
Coating
UV
Water-Based
Conventional
5%
100%
100%
50% **
0%
100%
5%
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2700-PM-AQ0207 Rev. 2/2002
Instructions
* Since all the HAPs used in sheet-fed offset lithography are VOCs, the same emission factors
would apply.
o
** The VOC composite vapor pressure of the cleaning solution cannot exceed 10 mm Hg at 20 C
o
(68 F). Alternatively, the VOC content of the cleaning solution cannot exceed 30% by weight.
5.
The HAP emissions are determined by multiplying the Usage, HAP Content, and Emission Factors
together. The total HAP emissions are the result of adding all of the individual HAP emission
determinations together. To convert the total pounds per year into tons per year, divide the total
pounds by 2,000 because there are 2,000 pounds in one ton.
*** If individual material consumption amount by press cannot be determined, then the applicant can
estimate individual consumption by using hours of operation, impression ratio, or other suitable
means.
The following list of HAPs can be found in materials used in sheet-fed offset printing and is provided to
assist in the identification of HAPs. A complete list of HAPs is included in this application package and the
applicant needs to compare it with materials used or expected to be used on press.
HAP
CAS#
Material
Cumene
98828
Blanket Conditioner
Blanket/Roller Wash
Ethyl Benzene
100414
Metering Roller Cleaner
Blanket/Roller Wash
Ethylene Glycol
107211
Fountain Solution
n-Hexane
110543
Spray Adhesive
Naphthalene
91203
Blanket/Roller Wash
Methanol
67561
Stay Open
Methyl Chloroform
(1,1,1-Trichloroethane)
71556
Blanket/Roller Wash
Methylene Chloride
(Dichloromethane)
75092
Metering Roller Cleaner
Blanket/Roller Wash
Methyl Ethyl Ketone
79345
UV Cleaning Solution
Toluene
Blanket Wash
108883
Metering Roller Cleaner
Xylene
1330207
Blanket Conditioner
Blanket/Roller Wash
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2700-PM-AQ0207 Rev. 2/2002
Instructions
Glycol Ethers
Various
Fountain
Ethylene Glycol Monobutyl Ether
- also known as Butyl Cellosolve
- also known as 2-Butoxyethanol
111762
Ethylene Glycol Monomethyl Ether
- also known as 2-Methoxyethanol
109864
Ethylene Glycol Monoethyl Ether
- also known as 2-Ethoxyethanol
110805
Ethylene Glycol Dimethyl Ether
- also known as 1, 2-Dimethoxyethane
110714
Diethylene Glycol Mono-n-Butyl Ether
- also known as Butyl Carbitol
112345
Diethylene Glycol Monomethyl Ether
- also known as 2-(Methoxyethoxy) Ethanol
111773
Diethylene Glycol Monoethyl Ether
-also known as 2-(Ethoxyethoxy) Ethanol
110900
Diethylene Glycol Dimethyl Ether
- also known as 2-Methoxyethyl Ether
111966
Diethylene Glycol Diethyl Ehter
- also known as 2-Ethoxyethyl Ether
112367
Solution
Blanket/Roller Wash
The following chemicals are not to be included in the Glycol Ethers Category:
Diethylene Glycol
111466
Propylene Glycol Methyl Ether
108656
Dipropylene Monomethyl Ether
34590948
All Other Propylene Glycol Ethers
Example of HAP Emission Calculation using the above approach:
Material
Annual Usage
Sheet-fed Ink, Process
HAP Content
25,200
lbs
0%
Fountain Solution Concentrate
(Ethylene Glycol)
420
gal
0.717
lbs/gal
Fountain Solution Additive
(2-Butoxyethanol)
(Ethylene Glycol)
120
gal
6.7
5.5
1.2
lbs/gal
lbs/gal
lbs/gal
1,200
gal
6.24
2.3
1.1
lbs/gal
lbs/gal
lbs/gal
Cleaning Solution - Roller Wash
(Naphthalene)
300
gal
5.9
1.2
lbs/gal
lbs/gal
Coating - UV
180
gal
0.0
lbs/gal
6,000
lbs
0%
by Wt
Cleaning Solution - Blanket Wash
(Naphthalene)
(2-Butoxyethanol)
Coating - Conventional
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by Wt
2700-PM-AQ0207 Rev. 2/2002
Instructions
Total HAP Emissions are as follows:
Ink
25,200 lbs x 0.0 lbs
=
Fountain Solution Concentrate
(Ethylene Glycol)
420 gal x 0.717 lbs/gal
=
301.14 lbs
Fountain Solution Additive
(2-Butoxyethanol)
(Ethylene Glycol)
120 gal x 5.5 lbs/gal
120 gal x 1.2 lbs/gal
=
=
660
144
lbs
lbs
Cleaning Solution - Blanket Wash
(Naphthalene)
(2-Butoxyethanol)
1,200 gal x 2.3 lbs/gal x 0.5
1,200 gal x 1.1 lbs/gal x 0.5
=
=
1,380
660
lbs
lbs
Cleaning Solution - Roller Wash
(Naphthalene)
300 gal x 1.2 lbs/gal x 0.5
=
180
lbs
Coating - UV
180 gal x 0.0 lbs/gal
=
0
lbs
Coating - Conventional
6,000 lbs x 0.0 lbs
=
0
lbs
Total
0
lbs
3,325.14 lbs
1.66 tons
Individual HAPs
2-Butoxyethanol
1,320
lbs
Ethylene Glycol
445.14
lbs
1,560
lbs
Naphthalene
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2700-PM-AQ0207 Rev. 2/2002
Instructions
TABLE A: Hazardous Air Pollutants (112(b))
CAS#
Pollutant
75070
60355
75058
98862
53963
107028
79061
79107
107131
107051
92671
62533
90040
1332214
71432
92875
98077
100447
92524
117817
542881
75252
106990
156627
133062
63252
75150
56235
463581
120809
133904
57749
7782505
79118
532274
108907
510156
67663
107302
126998
1319773
95487
108394
106445
98828
94757
72559
334883
132649
Acetaldehyde
Acetamide
Acetonitrile
Acetophenone
2-Acetylaminofluorene
Acrolein
Acrylamide
Acrylic acid
Acrylonitrile
Allyl chloride
4-Aminobiphenyl
Aniline
o-Anisidine
Asbestos
Benzene (including Benzene from gasoline)
Benzidine
Benzotrichloride
Benzyl chloride
Biphenyl
Bis(2-ethylhexyl)phthalate (DEHP)
Bis(chloromethyl)ether
Bromoform
1,3-Butadiene
Calcium cyanamide
Captan
Carbaryl
Carbon disulfide
Carbon tetrachloride
Carbonyl sulfide
Catechol
Chloramben
Chlordane
Chlorine
Chloroacetic acid
2-Chloroacetophenone
Chlorobenzene
Chlorobenzilate
Chloroform
Chloromethyl methyl ether
Chloroprene (2-chloro-1,3-butadiene)
Cresols/Cresylic acid (isomers and mixture)
o-Cresol
m-Cresol
p-Cresol
Cumene (Isopropylbenzene)
2,4-D, salts,esters (Dichlorophenoxyacetic acid)
DDE (p,p-Dichlorodiphenyldichloroethylene)
Diazomethane
Dibenzofurans
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2700-PM-AQ0207 Rev. 2/2002
Instructions
CAS#
Pollutant
96128
84742
106467
91941
111444
542756
62737
111422
121697
64675
119904
60117
119937
79447
68122
57147
131113
77781
534521
51285
121142
123911
122667
106898
106887
140885
100414
51796
75003
106934
107062
107211
151564
75218
96457
75343
50000
76448
118741
87683
77474
67721
822060
680319
110543
302012
7647010
7664393
123319
78591
58899
108316
67561
72435
1,2-Dibromo-3-chloropropane
Dibutylphthalate
1,4-Dichlorobenzene
3,3-Dichlorobenzidine
Dichloroethyl ether (Bis(2 chloroethyl)ether)
1,3-Dichloropropene (mixture)
Dichlorvos
Diethanolamine
N,N-Dimethylaniline
Diethyl sulfate
3,3-Dimethoxybenzidine
Dimethyl aminoazobenzene
3,3-Dimethyl benzidine
Dimethyl carbamoyl chloride
Dimethyl formamide
1,1-Dimethyl hydrazine
Dimethyl phthalate
Dimethyl sulfate
4,6-Dinitro-o-cresol, and salts
2,4-Dinitrophenol
2,4-Dinitrotoluene
1,4-Dioxane (1,4-Diethyleneoxide)
1,2-Diphenylhydrazine
Epichlorohydrin (1-chloro-2,3-epoxypropane)
1,2-Epoxybutane (1,2-Butylene oxide)
Ethyl acrylate
Ethyl benzene
Ethyl carbamate (Urethane)
Ethyl chloride (Chloroethane)
Ethylene dibromide (1,2-Dibromoethane)
Ethylene dichloride (1,2-Dichloroethane)
Ethylene glycol
Ethylene imine (Aziridine)
Ethylene oxide
Ethylene thiourea
Ethylidene dichloride (1,1-Dichloroethane)
Formaldehyde
Heptachlor
Hexachlorobenzene
Hexachlorobutadiene
Hexachlorocyclopentadiene
Hexachloroethane
Hexamethylene 1,6-diisocyanate
Hexamethylphosphoramide
Hexane
Hydrazine
Hydrochloric acid
Hydrogen fluoride (Hydrofluoric acid)
Hydroquinone
Isophorone
Lindane (gamma hexachlorocyclohexane) (all isomers)
Maleic anhydride
Methanol
Methoxychlor
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2700-PM-AQ0207 Rev. 2/2002
Instructions
CAS#
Pollutant
74839
74873
71556
78933
60344
74884
108101
624839
80626
1634044
101144
75092
101688
101779
91203
98953
92933
100027
79469
684935
62759
59892
56382
82688
87865
108952
106503
75445
7803512
7723140
85449
1336363
1120714
57578
123386
114261
78875
75569
75558
91225
106514
100425
96093
1746016
79345
127184
7550450
108883
95807
584849
95534
8001352
120821
79005
Methyl bromide (Bromomethane)
Methyl chloride (Chloromethane)
Methyl chloroform (1,1,1-Trichloroethane)
Methyl ethyl ketone (2-Butanone)
Methyl hydrazine
Methyl iodide (Iodomethane)
Methyl isobutyl ketone (4-methyl-2-pentanone) (Hexone)
Methyl isocyanate
Methyl methacrylate
Methyl tert butyl ether
4,4-Methylene-bis(2-chloroaniline)
Methylene chloride (Dichloromethane)
Methylene diphenyl diisocyanate (MDI)
4,4-Methylenedianiline
Naphthalene
Nitrobenzene
4-Nitrobiphenyl
4-Nitrophenol
2-Nitropropane
N-Nitroso-N-methylurea
N-Nitrosodimethylamine
N-Nitrosomorpholine
Parathion
Pentachloronitrobenzene (Quintobenzene)
Pentachlorophenol
Phenol
p-Phenylenediamine
Phosgene
Phosphine
Phosphorus
Phthalic anhydride
Polychlorinated biphenyls (PCB's) (Aroclors)
1,3-Propane sultone
beta Propiolactone
Propionaldehyde
Propoxur (Baygon)
Propylene dichloride (1,2-Dichloropropane)
Propylene oxide
1,2-Propylenimine (2-Methyl aziridine)
Quinoline
Quinone (1,4-benzoquinone)
Styrene
Styrene oxide
2,3,7,8-Tetrachlorodibenzo p dioxin
1,1,2,2-Tetrachloroethane
Tetrachloroethylene (Perchloroethylene)
Titanium tetrachloride
Toluene
2,4-Toluene diamine
2,4-Toluene diisocyanate
o-Toluidine
Toxaphene (chlorinated camphene)
1,2,4-Trichlorobenzene
1,1,2-Trichloroethane
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2700-PM-AQ0207 Rev. 2/2002
Instructions
CAS#
Pollutant
79016
95954
88062
121448
1582098
540841
108054
593602
75014
75354
1330207
95476
108383
106423
Trichloroethylene
2,4,5-Trichlorophenol
2,4,6-Trichlorophenol
Triethylamine
Trifluralin
2,2,4-Trimethylpentane
Vinyl acetate
Vinyl bromide (bromoethene)
Vinyl chloride
Vinylidene chloride (1,1-Dichloroethylene)
Xylenes (isomers and mixture)
o-Xylenes
m-Xylenes
p-Xylenes
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