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# OAR Box 1477 Prepped by Ollie Stewart



### Document

Number: 

# 32 ) ll-J-2 3 Docket Number: 

# A-94-5 2

Printed 7/31/2008 11:40:24

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# j-a a Prom : KEIT H BARNET T To : RTPMAINHUB.Internet . "Peter_D._Eglinton@omb.eop.gov . . . Date : 4/4/0 0 1:22p m Subject : Dat a fo r Reinforce d Plastic s Attache d i s th e revise d cos t chapter . Mos t o f the informatio n i n thi s chapte r ha s alread

ybee n transmitted . However , thi s revise d chapte r provide s som e additiona l explanatio n o f som e o f h e costing assumptions , an d i s mor e clearl y lai d ou t tha n th e previou s information . I believ e thi s additiona l explanatio n wil l addres s th e question s tha t wer e raise d o n costing issues . Th e appendice s hav e bee n maile d t o Jennife r Greenamoyer . Not e tha t w e stil l conside r thi s cos t chapte r a draft . I als o a

mattachin g th e draf t sourc e categor ydescriptio n chapter . Thi s documen t wa s no t o n th e lis t we agree d t o send , bu t I thin k i t wil l b e useful . Not e tha t thi s i s als o stil l i n draf t form . Keit h Barnet t CC : ALDRIDGE-AMANDA , LASSITER-PENNY , RTPMAINHUB.INTERN.. . 

### 9?m i EP AAI R norx iP. 3

TABL E O FCONTENT S Pag e 6. 0 COS T IMPACT S O FTH E PROPOSE D MAC T STANDAR D 6- 1 6. 1 INTRODUCTIO N 6- 1 6. 2 BASI C STEP S I N TH E COS T ANALYSE S 6- 2 6.2. 1 Basi c Overvie w o f Costin g Analysi s 6- 2 6.2. 2 Selectin g Contro l Technique s for Costin g Analyse s 6- 2 6.2. 3 Selectin g Typ e o f Cos t for Cos t Component s o f Contro l Technique s 6- 4 6.2. 4 Selectin g Annualizatio n Tim e Periods/Capitalizatio n Factor s .. . 6-1 0 6. 3 DEVELOPMEN T O FCOST S FO RSPECIFI C CONTRO L TECHNIQUE S 6-1 2 6.3. 1 Lo w HA P Resin s fo r Corrosio n Resistan t

Application s 6-1 2 6.3. 2 Lo w HA P Resin s fo r Non-Corrosio n Resistan t Application s ... . 6-1 6 6.3. 3 Lo w HA P Resin s fo r Mol dManufacturin g (Tooling ) 6-1 7 6.3. 4 Lo w HA P Pigmente dProductio n Ge l Coat s 6-1 8 6.3. 5 Lo w HA P Clea r

Productio n Ge l Coat s 6-2 2 6.3. 6 Lo w HA P Toolin g Ge l Coat s 6-2 5 6.3. 7 Testin g o f

Ne w Lo w HA P Resin s an dGe l Coat s 6-2 8 6.3. 8 Trainin g t o Us e Ne w Lo w HA P Resin s an dGe l Coat s 6-2 9 6.3. 9 Recertificatio n o f Product s 6-3 0 6.3.1 0 Productio n Proble mCost s Du e t o Switchin g t o Ne w Lo w

HA P Resin s an dGe l Coat s 6-3 1 6.3.1 1 Lon g Ter mIncreas e i n Labo r Cos t 6-3 1 6.3.1 2 Equipmen t

Chang e Cost s 6-3 2 6.3.1 3 Adoptio n o f

Non-Atomize dResi n Applicatio n Equipmen t 6-3 2 6.3.14 Uncoverin g onl y On e Charg e pe r Compression/Injectio n Moldin g Machin e 6-3 7 6.3.1 5 We t

Are aEnclosure s with Resi n Dri p Collectio n Syste m Fo r Pultrusio n Operation s 6-3 7 6.3.1 6 Close do r

Covere dDocto r

Boxes , Folde dEdges , an dLo w Styren e Permeabl e Fil mfor SM C Operation s 6-3 9 6.3.1 7 Non-HA P Cleanin g Material s 6-4 0 6.3.1 8 Closed/Covere dMixin g with N o Visibl e Gap s i n Mixe r Cove r . . 6-4 1 6.3.1 9 We t

Are aEnclosure s fo r

Resi n We t

Ou t Area s a t Continuou s Laminatio n an dCastin g Operation s 6-4 3 6.3.2 0 Permanen t

Tota l Enclosure s (PTEs ) 6-4 5 6.3.2 1 Captur e Device s fo r Centrifugal Castin g Operation s 6-4 96.3.2 2 Duc t Work fro mWe t

Are aEnclosure s an dPermanen t Tota l Enclosure s t o Add-O n Contro l Device s 6-5 2 6.3.2 3 Add-o n Contro l Devic e Costin g 6-5 8 6.3.2 4 Monitoring , Recordkeeping , an dReportin g 6-6 2 6. 4 RESULT S O FTH E COS T IMPACT S ANALYSI S 6-6 7 6. 5 COS T EFFECTIVENES S O FTH E MAC T FLOO RAN D TH E ABOVE-THE-FLOO RCONTRO L OPTION S 6-7 1 6. 6 REFERENCE S 6-7 6

APPENDICE S 6. 1 Summary o f

Costin g Component s for Existin g Continuou s Laminatio n an dCastin g Source s 6. 2 Summary of

Control s on Existin g Continuou s Laminatio n an dCastin g Source s t o Mee t

th e MAC T Floo r

an dRegulatory Alternative s for Existin g an dNe w Source s 6. 3 Corrosion-resistan t Resin s - Properties , Exampl e Chemica l Environment s an dMaximu mContinuou s Temperatur e Limits , an dCos t Differential s 6. 4 Spray Gu n an dFlowcoate r Syste mCost s an dComponent s 6. 5 Persona l Protectiv e Equipmen t Cos t Compariso n 6. 6 We t

Are aEnclosur e Cost s fo r Continuou s Laminatio n Source s 6. 7 Chapte r

11 , Permanen t

Tota l Enclosures , OAQP S Contro l Cos t Manual , 5t h Edition , EP A 453/B-96-001 , February 199 6 6. 8 Chapte r

10 , Hoods , Ductwork , an dStacks , OAQP S Contro l Cos t Manual , 5t h Edition , EP A 453/B-96-001 , February 199 6 6. 9 Duc t

Wor k fo r Continuou s Laminatio n an dCastin g Source s for Existin g an dNe w Sourc e MAC T Floo r an dRegulatory Alternativ e 6.1 0 Ai r

Flow s fro mWe t

Are aEnclosures , PTEs , an dOven s a t Continuou s Laminatio n an dCastin g Facilitie sP. 5

6.1 1 Duc t

Work Figure s for

Continuou s Laminatio n an dCastin g Facilitie s 6.1 2 Natura l Ga s an dElectricity Cost s 6.1 3 An Assessmen t

of Stvren e Emissio n Contro l Technologie s for th e FR P an dBoat Buildin g Industries . Mar k Bahner , Emery Kong , an dSonj i Tumer , Researc h Triangl e Institute , an dAssessmen t o f Stvren e Emissio n Control s for FRP/ C an dBoat

Buildin g Industries . Fina l Report . (Chapte r 5 , Appendi x A , 

### an dAppendi x B) . Emery J . Kong , Mark A . Bahner , an dSonj i L.Turne r Researc h Triangl e Institute . 6.1 4 Chemica l Engineerin g Cos t Indice s

i nP. 6

LIS T O FTABLE S No . Titl e Pag e 6- 1 Basi c Step s in th e Costin g Analyse s for Ne w an d Existin g Source s 6- 3 6- 2 Contro l Technique s Selecte dfor Existin g Source s 6- 5 6- 3 Contro l Technique s Selecte dfor Ne w Source s 6- 7 6- 4 Typ e o f

Cos t Associate dwit

h Contro l Technique s Cos t Component s 6- 9 6- 5 Annualizatio n Tim e Period s an dCapitalizatio n Factor s 6-1 1 6- 6 Availabl e Cos t Informatio n for

Corrosio n Resistan t

Resin s Provide d b y Reichhol d6-1 3 6- 7 Averag e Cos t

Differential for

Corrosio n Resistan t

Resin s a t Differen t Specifi c Continuou s Temperature s 6-1 5 6- 8 Availabl e Cos t Informatio n for

Toolin g Resin s fro m Resi n Manufacturer s 6-1 7 6- 9 Availabl e Cos t Informatio n for

Pigmente dProductio n Ge l Coat s fro mCoo k

Composite s an dPolymer s 6-1 9 6-1 0 Availabl e Cos t Informatio n fo r

Clear Productio n Ge l Coat s fro mGe l Coa t

Manufacturer s 6-2 3 6-1 1 Availabl e Cos t Informatio n for

Toolin g Ge l Coat s fro m Ge l Coa t Manufacturer s 6-2 7 6-1 2 Testin g ofNe w Lo w HA P Resin s 6-2 8 6-1 3 Trainin g Cost s t o Us e Ne w Lo w HA P Resin s 6-3 0 6-1 4 Impac t

o f Switchin g t o Lo w HA P Resin s o n Productio n Efficienc y 6-3 1 6-1 5 Long-ter mIncreas e i n Labo r Cos t 6-3 2

i vP. 7

LIS T O FTABLE S (continued ) No . Titl e Pag e 6-1 6 Equipmen t

Chang e Cost s 6-3 2 6-1 7 Cos t

Analysi s Element s for

Switchin g t o Flowcoater s 6-3 4 6-1 8 Availabl e Cos t Informatio n for

We t Are aEnclosure s 6-3 8 6-1 9 Cos t

Informatio n fo r

HAP

- an dno n HAP

- Containin g Cleanin g Solvent s 6-4 0 6-2 0 Availabl e Cos t Dat afo r Closed/Covere dMixin g with N o Visibl e Gap s 6-4 1 6-2 1 Pe r

Mixe r Complianc e Cos t

Assigne dt o aFacility Base do n Existin g Leve l o f

Complianc e 6-4 2 6-2 2 Dimension s an dCost s for We t Ou t Are aEnclosure s for Continuou s Laminatio n an dCastin g Operation s 6-4 6 6-2 3 Cos t

Informatio n fo r

Specifi c Equipmen t

an dStructura l Component s Use di n Constructio n o f th e Permanen t

Tota l Enclosure s 6-4 8 6-2 4 Facilit y Criteri aUse dt o Determin e th e Numbe r an dSiz e o f Permanen t

Tota l Enclosure s fo r

Operation s Othe r tha n Continuou s Laminatio n an dCastin g 6-5 0 6-2 5 Duc t

Wor k Cos t Informatio n an dDesig n Equation s 6-5 3 6-2 6 Specifi c Equation s fo r Rotary Concentrator/Therma l Oxidize r Syste mParameter s an dCost s 6-5 9 6-2 7 MR RInformatio n b y Activity 6-6 3 6-2 8 Wag e Rate s 6-6 6 6-2 9 MAC T Floo r

Cost s fo r Existin g Source s 6-6 8 6-3 0 MAC T Floo r

Cost s fo r Ne w Source s 6-6 8P. 8

LIS T O FTABLE S (concluded ) No . Titl e Pag e 6-3 1 Cost s for

th e Above-the-floo r

Contro l Optio n Withou t th e HA P Emissio n Siz e Limi t

fo r Existin g Source s 6-6 9 6-3 2 Cost s for

th e Above-the-floo r

Contro l Optio n Withou t th e HA P Emissio n Siz e Limi t

fo r Ne w Source s 6-6 9 6-3 3 Cost s fo r

th e Above-the-floo r

Contro l Optio n Wit

h th e HA P Emissio n Siz e Limi t

for Existin g Source s 6-7 0 6-3 4 Cost s fo r

th e Above-the-floo r

Contro l Optio n Wit

h th e HA P Emissio n Siz e Limi t

for Ne w Source s 6-7 0 6-3 5 Cos t

Effectivenes s o f

th e Above-the-Floo r

Contro l Optio n Withou t th e HA P Emissio n Siz e Limi t fo r Existin g Source s 6-7 2 6-3 6 Cos t

Effectivenes s o f

th e Above-the-Floo r

Contro l Optio n Wit

h th e HA P Emissio n Siz e Limi t for Existin g Source s 6-7 3 6-3 7 Cos t

Effectivenes s o f

th e Above-the-Floo r

Contro l Optio n Without th e HA P Emissio n Siz e Limi t for Ne w Source s 6-7 4 6-3 8 Cos t

Effectivenes s o f

th e Above-the-Floo r

Contro l Optio n Wit

h th e HA P Emissio n Siz e Limi t fo r Ne w Source s 6-7 5

v iP. 9



### 6. 0 COS T IMPACT S O F TH E PROPOSE D MAC T STANDAR D 6. 1 INTRODUCTIO N Thi s chapte r

present s informatio n describin g th e estimate dcos t impact s o f

potentia l MAC T standard s o n th e Reinforce dPlasti c Composite s sourc e category an dth e methodolog y use dt o estimat e thes e cos t impacts . Th e informatio n presente dinclude s cos t dat acollecte dby th e EPA , th e basi c step s an dassumption s use di n th e costin g analyses , th e detaile dprocedure s an dassumption s use dt o estimat e th e cost s for specifi c contro l techniques , th e result s of th e cos t impac t analyses , an dth e cos t

effectivenes s of

above-the-floo r

contro l options . W e calculate dcapita l an dannual cost s fo r eac h existin g an dprojcte dne w facility for tw o level s o f control. . Thes e are th e MAC T floo r level , whic h i s th e minimu mleve l o f contro l require db y law , an damor e stringen t leve l o f control . Th e mor e stringen t leve l o f contro l i s calle dth e above-the-floo r contro l level . W e als o evaluare dthre e regulatory alternatives . In Regulatory Alternativ e 1 al l ne w an d exisitn g facilitie s are require dt o mee t th e floo r leve l o f control . In Regulatory Alternativ e 2 th e abov e th e floo r

contro l leve l i s applie dt o al l facilitie s wit h combine demission s o f HA P o f 10 0 ton s pe r yea r (TPY ) o r mor e fro mth e followin g operations : ope n molding , centrifugal casting , continuou s lamination/casting , pultrusion , SM C manufacturing , an dBM C manufacturing/mixing . Al l othe r facilitie s mus t

mee t th e floo r leve l o f control . In th e thir d regulatory alternativ e al l facilitie s regardles s o f siz e ar e require dt o mee t th e above-the-floo r contro l level . Th e cos t result s presente dher e wer e als o use da s input s t o th e economi c analyse s presente d i n Chapte r

7 .

6- 1P.1 0

6. 2 BASI C STEP S I N TH E COS T ANALYSE S 6.2. 1 Basi c Overvie w o f Costin g Analyse s Th e costin g analyse s use db y th e EP A are designe dt o determin e th e total capital an d annua l cost s tha t

wil l b e incurre db y facilitie s in th e reinforce dplasti c composite s sourc e categor y du e t o th e propose drule . W e conducte dth e costin g analyse s for individua l facilitie s for both existin g an dne w source s a t th e MAC T floo r

an dth e above-the-floo r

contro l options . Th e costin g analyse s consist

o f multipl e steps , whic h ar e summarize di n Tabl e 6- 1 for ne w an d existin g facilities . Sectio n 6. 3 discusse s thes e step s i n mor e detail . 6.2. 2 Selectin g Contro l Technique s for Costin g Analyse s Th e firs t ste p i n th e costin g analyse s i s determinin g th e specifi c contro l technique s require dfo r

eac h operatio n and/o r

grou p o f operation s t o achiev e th e leve l o f contro l specifie dby th e MAC T floo r

an dth e above-the-floo r

contro l options . Fo r

certai n operation s and/o r grou p o f operations , ther e ar e multipl e contro l technique s availabl e that ar e capabl e of

providin g th e require dleve l o f

control . Fo r

example , vacuu mbagging , vapo r suppressants , lo w HA P materials , adoptio n o f

non-atomize dresi n applicatio n equipment , an dadd-o n contro l device s ar e al l contro l technique s that provid e th e require dleve l o f contro l for

th e unfille dnon-corrosio n resistan t mechanica l resi n applicatio n operation s a t th e existin g sourc e t o mee t th e MAC T floor . Fo r thos e operation s o r

grou p o f operation s wher e multipl e contro l technique s wer e available , w e selecte dth e contro l techniqu e that woul db e th e leas t

expensiv e for

th e majority o f facilitie s fo r

th e cos t analysis . Fo r

example , fo r

unfille dnon-corrosio n resistan t mechanica l resi n applicatio n operation s require dt o mee t th e existin g sourc e MAC T floor , w e selecte dnon atomize dresi n applicatio n equipmen t (followe db y replacemen t o f hig h HA P resin s wit

h lo w HA P resin s i f

necessary ) a s th e leas t

expensiv e complianc e optio n fo r th e majorit

y o f facilities . W e assume dadd-o n contro l device s ar e mor e expensiv e than non-atomize dresi n applicatio n equipmen t

an dlo w HA P resin s i n al l cases . W e di dno t selec t vacuu mbaggin g o r

vapo r suppressant s a s potential contro l technique s becaus e w e ha dn o cos t dat aan dth e ability t o appl y thes e technique s i s ver

y site specific . 6- 2p.1 1



### TABL E 6-1 . BASI

C STEPS I

N TH E COSTIN

G ANALYSES FO

R NE WAN D EXISTIN

G SOURCES Basi c Step s i

n th e Costin g Analysi s fo

r Existin g Source s Basi c Step s i n th e Costin g Analysi s fo

r Ne w Source s Fo r eac h operatio n and/o r

grou p o f operations , th e contro l technique(s ) that were use di

n th e costin g analyse s were selected . Th e cos t component(s ) associate dwit h eac h ofth e selecte dcontro l technique(s ) were determined . Th e type(s ) o f

cos t (tota l capita l cost , annua l variabl e cost , annua l fixe dcost ) t o associat e with eac h cos t componen t

were determined . Th e tim e period s an dcapitalizatio n factor s use di n annualizin g total capita l cost s were selected . Th e tota l capita l cos t

(TCC ) associate dwit

h eac h cos t

componen t

o f eac h selecte dcontro l techniqu e wa s calculated . Th e annua l variabl e cos t (ACV ) associate dwit

h eac h cos t

componen t

o f eac h selecte dcontro l techniqu e wa s calculated . Th e annua l fixedcos t

(AFC ) associate dwit

h eac h cos t

componen t

o f eac h selecte dcontro l techniqu e wa s calculated . Th e TC C for

eac h cos t

componen t

o f eac h contro l techniqu e were summe dt o obtai n th e total TCC . Th e AC V for

eac h cos t

componen t

o f eac h contro l techniqu e were summe dt o obtai n th e total ACV . Th e AF C for

eac h cos t

componen t

o f eac h contro l techniqu e were summe dt o obtai n th e total AFC . Th e tota l TCC , AV C an dAF C fro meac h contro l leve l were divide d(pro-rated) betwee n applicabl e operation s usin g uncontrolle dpre-MAC T HA P emissions . Th e tota l TCC , AV C an dAF C for eac h operatio n were determine db y summin g th e pro-rate dTCC , AV C an dAF C fromeac h applicabl e contro l technique . Th e tota l TCC , AV C an dAF C for eac h operatio n (i n term s o f dollar s pe r to n o f resi n o r dollar s pe r

to n o f ge l coat ) wa s determine dfor eac h existin g facility (servin g a s asurrogat e fo r eac h projecte dne w growth facility ) b y dividin g th e tota l TCC , AV C an dAF C fo r eac h operatio n b y th e resi n an dge l coat

usag e ofth e existin g facility . Th e averag e cos t

pe r to n o f resi n o r pe r to n o f ge l coa t for eac h operatio n a t

eac h projecte dne w growt h facility wa s determine db y averagin g th e dollar s pe r

to n o r resi n o r dollar s pe r

to n o f ge l coa t for eac h operatio n for

th e grou p o f

existin g facilitie s servin g a s surrogate s for eac h operatio n a

t th e projecte dne w growth facility . Th e tota l TCC , AVC , an dAF C for eac h operatio n for

eac h projecte d ne w growth facility wa s detennine db y multiplyin g th e averag e cos t pe r to n o r resi n o r pe r to n o f ge l coa t for eac h operatio n use db y eac h projecte dne w growth facility b y th e projecte dresi n o r ge l coa t usag e i n eac h operatio n for

th e projecte dne w growth facility . Th e tota l TCC , AV C an dAF C for eac h operatio n groupin g were determine db y summin g th e TCC , AV C an dAF C fromeac h operation . Th e tota l TCC , AV C an dAF C for eac h facility were determine db y summin g th e TCC , AV C an dAF C fromeac h grouping . Th e tota l TCC , AV C an dAF C for th e sourc e category were determine db y summin g th e TCC , AV C an dAFC .



### 6- 3P.1 2

W e use datherma l oxidize r with rotary concentrato r

for th e operation s and/o r

group s o f operation s wher e a

n add-o n contro l devic e wa s th e contro l techniqu e selecte dt o provid e th e require dleve l o f

control . Wher e w e coste dtherma l oxidizers/rotary concentrators , w e coste dth e therma l oxidizer/concentrato r base do n th e facility usin g it s curren t resin s an dgel coats (i.e. , w e di dnot cos t switchin g t o lowe r

HA P resin s and/o r

ge l coats) . Fo r facilitie s wit

h multipl e operations,'w e coste don e add-o n contro l devic e for th e entir e facility an dthe n apportione dth e cost s fo r that devic e amon g eac h operatio n base don th e relativ e contributio n o f

eac h operatio n t o th e HA P emission s upstreamof th e contro l device . Table s 6- 2 an d6- 3 summariz e b y operatio n and/o r grou p o f operation s th e contro l technique s selecte dfor existin g an dne w sources , respectively . Appendice s 6. 1 an d6. 2 provid e additiona l informatio n concernin g th e contro l technique s selecte dfor continuou s lamination/casting . 6.2. 3 Selectin g Tvp e of Cos t fo r Cos t Component s o f

Contro l Technique s Tota l capita l an dannual cos t o f acontro l techniqu e ar e mad e up o f variou s components . No t al l o f thes e component s ar e applicabl e t o eac h technique . Tabl e 6- 4 list s thes e components , an didentifie s th e component s applicabl e t o eac h individua l contro l technique . Th e tota l capita l cos t

(TCC ) represent s th e cos t o f equipmen t

purchase db y afacility t o appl y acontro l technique . Example s o f tota l capita l cost s ar e th e purchas e o f non-atomize dresi n applicatio n equipment , th e purchas e o f apermanen t

tota l enclosur e (PTE) , th e purchas e o f duc t work connectin g aPT E t o a

n add-o n contro l device , an dth e purchas e o f a n add-o n contro l device . Tota l capita l cost s ar e annualize dt o obtai n fixe dannual cost s fo r th e purpos e o f calculatin g th e tota l annua l cost s associate dwit h acontro l level . I n certai n cases , afacility wil l incu r cost s tha t

occu r durin g th e 1s t

year o f complianc e wit h th e propose drule , suc h a s produc t recertificatio n costs , ne w material s testin g costs , an d certai n monitoring , reporting , an drecordkeepin g costs . Thes e cost s ar e not tota l capita l cost s i n th e sens e tha t

thes e cost s d o no t

represen t th e purchas e pric e o f

equipment . However , thes e cost s ar e include di n TC C an dar e annualize dt o obtai n fixe dannual cost s usin g th e sam e calculatio n method s a s tota l capita l cost s for th e purpos e o f

calculatin g th e tota l annua l cost s associate dwith acontro l level .

6- 4TABL E 6-2 . CONTRO L TECHNIQUE S SELECTE D FO REXISTIN G SOURCE S

Grou p o f Operation s Ope n Moldin g

Close dMoldin g Operatio n Manua l Resi n - No n C R Manua l Resi n - C R Manua l Resi n - Toolin g Mechanica l Resi n - No n C R- Unfille d Mechanica l Resi n - No n C R- Fille d Mechanica l Resi n - C R Mechanica l Resi n - Toolin g Filamen t Windin g - No n C R Filamen t Windin g - C R Pigmente dProductio n Ge l Coa t Clear Productio n Ge l Coa t Toolin g Ge l Coa t Compression/Injectio n (C/I ) Moldin g Resi n Transfe r

Moldin g Contro l Leve l Require db y

Existin g Sourc e MAC T Floo r 7 6 lb s / to n 12 4 lbs/to n 9 7 lb s / to n 10 4 lbs/to n 14 4 lbs/to n 19 0 lbs/to n 25 6 lb s / to n 17 3 lbs/to n 16 3 lbs/to n 26 5 lb s / to n 50 4 lb s / to n 39 4 lb s / to n Uncover/Unwrap/Expos e Onl y 1 Charg e pe r

C/ I Moldin g Non e (N o MAC T Floor ) Contro l Technique s Selecte dfor Complyin g wit

h th e MAC T Floo r Lo w HA P Conten t

Resi n Lo w HA P Conten t

Resi n Lo w HA P Conten t

Resi n Non-Atomize dApplicatio n & Lo w HA P Conten t

Resi n Lo w HA P Conten t

Resi n Non-Atomize dApplicatio n & Lo w HA P Conten t

Resi n Lo w HA P Conten t

Resi n Lo w HA P Conten t

Resi n Lo w HA P Conten t

Resi n Lo w HA P Conten t

Ge l Coa t Lo w HA P Conten t

Ge l Coa t Lo w HA P Conten t

Ge l Coa t Uncover/Unwrap/Expos e Onl y 1 Charg e pe r

C/ I Moldin g Machin e Non e (N o MAC T Floor ) Contro l Leve l Require d b y th e Above-the-Floo r Contro l Optio n

Entir e Grou p o f

Operation s 95.0 % Contro l Efficienc y

Uncover/Unwrap/Expos e Onl y 1 Charg e pe r

C/ I Moldin g Non e (N o MAC T Floor ) Contro l Technique(s ) Selecte d for Complyin g with th e Above

the-Floo r Contro l Optio n

Entir e Grou p o f

Operation s Add-o n Contro l Device : Therma l Oxidize r w / Rotar y Concentrato r

Uncover/Unwrap/Expos e Onl y 1 Charg e pe r

C/ I Moldin g Machin e Non e (N o MAC T Floor )

6- 5TABL E 6-2 . CONTRO L TECHNIQUE S SELECTE D FO REXISTIN G SOURCE S (concluded )

Grou p o f Operation s Centrifuga l Castin g

Continuou s Lamination / Continuou s Castin g Pultrusio n Polyme r Castin g SM C Manufacturin g BM C Manufacturing / Mixin g Equipmen t

Cleanin g Storag e o f

HA P Containin g Material s Operatio n Centrifuga l Castin g - No n C R Centrifuga l Castin g - C R N/A
N/A N/A
N/A
N/A
N/A
N/A Contro l Leve l Require db y Existin g Sourc e MAC T Floo r 39 6 lb s / to n 53 6 lb s / to n 58.5 % Contro l Efficienc y o r 15. 7 lbs/to n 60.0 % Contro l Efficienc y Non e (N o MAC T Floor ) Closed/Covere dDocto r

Bo x / Folde dEdges/Nylo n Hi m Closed/Covere dMixin g w/ N o Visibl e Gap s i

n Cove r N o HA P Cleanin g Solvent s Close do r Covere dStorag e Container s Contro l Technique s Selecte dfor Complyin g wit

h th e MAC T Floo r Lo w HA P Conten t

Resi n Lo w HA P Conten t

Resi n Add-o n Contro l Device : Therma l Oxidize r w/ Rotary Concentrato r We t Are aEnclosure s w/ Resi n Dri p Collectio n Non e (N o MAC T Floor ) Closed/Covere dDocto r

Bo x / Folde dEdges/Nylo n Fil m Closed/Covere dMixin g w/ N o Visibl e Gap s i n Cove r Aceton e Close do r Covere dStorag e Container s Contro l Leve l Require d b y th e Above-the-Floo r Contro l Optio n Entir e Grou p o f

Operation s 95.0 % Contro l Efficienc y 95.0 % Contro l Efficienc y o r 1.4 lb s / to n 95.0 % Contro l Efficienc y Non e (N o MAC T Floor ) 95.0 % Contro l Efficienc y 95.0 % Contro l Efficienc y N o HA P Cleanin g Solvent s Close do r Covere dStorag e Container s Contro l Technique(s ) Selecte d for Complyin g with th e Above

the-Floo r Contro l Optio n Add-o n Contro l Device : Therma l Oxidize r w/ Rotar y Concentrato r Add-o n Contro l Device : Therma l Oxidize r w/ Rotar y Concentrato r Add-o n Contro l Device : Therma l Oxidize r w/ Rotary Concentrato r Non e (N o MAC T Floor ) Add-o n Contro l Device : Therma l Oxidize r w/ Rotar y Concentrato r Add-o n Contro l Device : Therma l Oxidize r w/ Rotary Concentrato r Aceton e Close do r Covere dStorag e Container s NOT E 1 : Th e above-the-floo r contro l option s considere dfor existin g source s generall y requir e contro l level s mor e stringen t than th e contro l level s require db y th e existin g sourc e MAC T floor . NOT E 2 : I

n case s wher e add-o n contro l device s wer e require dfor mor e tha n on e operatio n and/o r grou p o f operation s a

t afacility , onl y on e add-o n contro l devic e wa s coste dfor th e facility an dth e cost s associate dwith tha t add-o n contro l devic e wer e assigne dt o eac h operatio n and/o r grou p o f operation s basedo n th e magnitud e o f uncontrolle dHA P emitte db y eac h operatio n and/o r grou p o f operations . 6- 6

### TABL E 6-3 . CONTRO L TECHNIQUE S SELECTE D FO R NE W SOURCE S

Grou p o f Operation s Ope n Moldin g

Close dMoldin g

Centrifuga l Castin g Operatio n Manua l Resi n - No n C R Manua l Resi n - C R Manua l Resi n - Toolin g Mechanica l Resi n - No n C R- Unfille d Mechanica l Resi n - No n C R- Fille d Mechanica l Resi n - C R Mechanica l Resi n - Toolin g Filamen t Windin g - No n C R Filamen t Windin g - C R Pigmente dProductio n Ge l Coa t Clear Productio n Ge l Coa t Toolin g Ge l Coa t Compression/Injectio n (C/O Moldin g Resi n Transfe r

Moldin g Centrifuga l Castin g - No n C R Contro l Leve l Require db y Ne w Sourc e MAC T Floo r 5 0 lb s / to n 8 5 lb s / to n 7 2 lb s / to n 2 2 lb s / to n 1 2 lbs/to n 12 0 lbs/to n 20 5 lb s / to n 11 3 lbs/to n 144 lb s /to n 1 9 lbs/to n 42 9 lb s / to n 2 9 lb s / to n Uncover/Unwrap/Expos e Onl y 1 Charg e pe r

C/ I Moldin g Non e (N o MAC T Floor ) 39 1 lbs/to n Contro l Techniqu e Selecte d for Complyin g wit

h th e MAC T Floo r Add-O n Contro l Devic e (95.0% ) Lo w HA P Conten t

Resi n Lo w HA P Conten t

Resi n Add-O n Contro l Devic e (95.0% ) Add-O n Contro l Devic e (95.0% ) Non-Atomize dApplicatio n & Lo w HA P Conten t

Resi n Lo w HA P Conten t

Resi n Lo w HA P Conten t

Resi n Lo w HA P Conten t

Resi n Add-O n Contro l Devic e (95.0% ) Lo w HA P Conten t

Ge l Coa t Add-O n Contro l Devic e (95.0% ) Uncover/Unwrap/Expos e Onl y 1 Charg e pe r

C/ I Moldin g Machin e Non e (N o MAC T Floor ) Lo w HA P Conten t

Resi n Contro l Leve l Require d

b y th e Above-the-Floo r Contro l Optio n

Entir e Grou p o f

Operation s 95.0 % Contro l Efficienc y

Uncover/Unwrap/Expos e Onl y I Charg e per

C/ I Moldin g Non e (N o MAC T Floor ) Entir e Grou p o f

Operation s VD.U% I contro l tnicienc y Contro l Techniqu e (s)Selecte d for Complyin g with th e Above

the-Floo r Contro l Optio n

Entir e Grou p o f

Operation s Add-o n Contro l Device : Therma l Oxidize r w/ Rotary Concentrato r

Uncover/Unwrap/Expos e Onl y 1 Charg e pe r

C/ I Moldin g Machin e Non e (N o MAC T Floor ) Add-o n Contro l Device : Therma l uxiaize r w / Kotary concentrato r 

### 6- 7TABL E 6-3 . CONTRO L TECHNIQUE S SELECTE D FO RNE WSOURCE S (concluded )

Grou p o f Operation s

Continuou s Lamination / Continuou s Castin g Pultrusio n Polymer Castin g SM C Manufacturin g BM C Manufacturing / Mixin g Equipmen t

Cleanin g Storag e o f

HA P Containin g Material s Operatio n Centrifuga l Castin g - C R N/A
N/A
N/A
N/A
N/A N/A
N/A Contro l Leve l Require db y Ne w Sourc e MAC T Floo r 2 6 lb s / to n 82.6 % Contro l Efficienc y o r 5. 7 lb/to n 95.0 % Contro l Efficienc y Non e (N o MAC T Floor ) 95.0 % Contro l Efficienc y 95.0 % Contro l Efficienc y N o HA P Cleanin g Solvent s Closed/Covere dStorag e Container s Contro l Techniqu e Selecte d for Complyin g with th e MAC T

Floo r Lo w HA P Conten t

Resi n Add-o n Contro l Device : Therma l Oxidize r w/ Rotar y Concentrato r Add-o n Contro l Device : Therma l Oxidize r w/ Rotar y Concentrato r Non e (N o MAC T Floor) Add-o n Contro l Device : Therma l Oxidize r w/ Rotar y Concentrato r Add-o n Contro l Device : Therma l Oxidize r w/ Rotar y Concentrato r Aceton e Closed/Covere dStorag e Container s Contro l Leve l Require d b y th e Above-the-Floo r Contro l Optio n

95.0 % Contro l Efficienc y o r 1.4 l b / to n 95.0 % Contro l Efficienc y Non e (N o MAC T Floor ) 95.0 % Contro l Efficienc y 95.0 % Contro l Efficienc y N o HA P Cleanin g Solvent s Closed/Covere dStorag e Container s Contro l Techniqu e (s)Selecte d for Complyin g with th e Above

the-Floo r Contro l Optio n

Add-o n Contro l Device : Therma l Oxidize r w / Rotar y Concentrato r Add-o n Contro l Device : Therma l Oxidize r w/ Rotar y Concentrato r Non e (N o MAC T Floor ) Add-o n Contro l Device : Therma l Oxidize r w / Rotar y Concentrato r Add-o n Contro l Device : Therma l Oxidize r w / Rotar y Concentrato r Aceton e Closed/Covere dStorag e Container s NOT E 1 : The above-the-floo

r contro l option s considere dfo r ne w source s generall

y requir e control level s mor

e stringen t tha n require db

y the contro l level s requiredb y the ne w sourc e MACT floor . NOT E 2 : I n case s wher

e add-on control device s wer e require dfo

r mor e tha n on e operation and/or

grou p o f operation s a

t afacility , only one add-on contro l devic e was costedfo

r the facilit y an dthe cost s associatedwit

h tha t add-on control devic e wer

e assignedt

o eac h operation and/or

grou p o f operation s basedo

n the magnitud

e o f uncontrolle dHA

P emittedb

y eac h operatio n and/or

grou p o f operations .

6- 8P.1 7



### TABL E 6-4 . TYP

E OFCOS T ASSOCIATE

D WIT H CONTRO

L TECHNIQU

E COS T COMPONENTS a 

### Add-On Contro l Device s w / Associate dEquipmen

t

- Tota l Capita l Cos t

- Add-O n Contro l Devic e

- Tota l Capita l Cos t

- Permanen t

Tota l Enclosur e (PTE )

- Tota l Capita l Cos t

- We t Ou t Are aEnclosur e (WAE )

- Tota l Capita l Cos t

- Captur e Devic e (CD ) fo r Centrifugal Castin g Machine s

- Tota l Capita l Cos t

- Ductwork

fromPTE , CD , o r

WA E t o Add-O n

- Direc t Operatin g Cos t

Minu s Utilitie s - Add-O n Contro l Devic e

- Electricity Cost s - Add-O n Contro l Device/Ductwork

- Fue l Cost s - Add-O n Contro l Devic e

- Overhead , Propert y Tax , Insuranc e Administratio n 

### TC C X X X X X 

### AV

C

X X X 

### AF

C X X X X X

X Resi n Bat h We t Are aEnclosur e /

Resi n Dri p Collectio n Syste m

- Tota l Capita l Cos t

- We t Are aEnclosur e /

Resi n Dri p Collectio n Syste m

- Operatin g & Maintenanc e ( 0 & M ) X X X Closed/Covere dMixin g

- Cos t o f Mixe r Cover s Replace dAnnuall y X Replacemen t

o f Spray Equipmen t

w / Flowcoate r

- Tota l Capita l Cos t

- Flowcoate r

/ Salvag e Valu e Spray Gun s

- Decreas e i n Persona l Protectiv e Equipmen t Usag e

- Decreas e in Floo r

Covering s Usag e

- Decrease dResi n Usag e Du e t o Increase dTransfe r Efficienc y X X X X X

Material s Replacemen t

- Replacemen t

o f Existin g Resi n wit

h Lo w HA P Resi n

- Replacemen t

o f Existin g Ge l Coa t

wit h Lo w HA P Ge l Coa t

- Produc t Recertificatio n (Resi n an dGe l Coat )

- Ne w Materia l Testin g X X X

X X

X Monitoring , Recor dkeeping , & Reportin g

- Subpart A Notification s (Year

1 ) - Construct/Reconstruct , Anticipate dStart

-

- Semi-Annua l Report , Period s o f Non-Complianc e Report , Maintai n HA P

- Develo p Trainin g Progra m/ Record s Syste m(Yea

r 1 )

- Conduc t Trainin g Progra m/

Kee p Trainin g Record s

- Readin g Standar d(Yea r 1 )

- Reviewin g Standar d(Annually )

- Performanc e Tests , Develo p O& M Plan , SS& M Plan (Year 1 )

- Semi-Annua l Start-up , Shut-Dow n & Malfunctio n (SS&M ) Report X X X X X X X X X X X X TC C = Tota l Capita l Cost , AV C = Annua l Variabl e Cost , AF C = Annua l Fixe dCos t 

### 6- 9P.1 8

Th e annual variabl e cost s (AVC ) o f acos t componen t

ar e cost s that

wil l var y fro myea

r t o year basedo n productio n an demissio n variation s a t afacility . A

n exampl e of

aproductio n base d annua l variabl e cos t

i s th e variatio n in th e annual cos t of usin g lo w HA P material replacement s du e t o annua l variation s in th e amoun t of ra w material s use db y afacility . A n exampl e of

a n emission s base dannual variabl e cos t i s th e variatio n in electricity an dfuel cost s o f a n add-o n contro l devic e tha t

occu r du e t o variation s i n th e flo w rat e an dHA P concentratio n of th e emissio n streambein g sen t t o th e add-o n contro l device . Th e annua l fixe dcost s (AFC ) o f acos t componen t

ar e cost s tha t

remai n fixe dfro myea

r t o year . Thes e cost s are primaril y annualize dtota l capita l cost s althoug h certai n piece s o f equipmen t

replace dannuall y an dcertai n type s o f monitoring , recordkeeping , an dreportin g cost s ar e als o annua l fixe dcosts . Fo r example , th e annual replacemen t o f mixe r cover s i s a

n annual fixe dcos t that i s no t obtaine db y annualizin g atota l capita l cost . 6.2. 4 Selectin g Annualizatio n Tim e Period s / Capitalizatio n Factor s Th e cos t component s fo r

anumbe r

o f complianc e option s includ e TC C that mus t b e annualize dint o annua l fixe dcost s (AFC) . In orde r t o annualiz e atotal capital cost , a n annualizatio n perio dan dinteres t rat e for eac h cos t componen t

mus t b e determined . Th e annualizatio n perio dan dinteres t rat e ar e use dt o generat e acapitalizatio n facto r for eac h cos t component . Th e capitalizatio n facto r i s multiplie db y the . tota l capita l cos t t o obtai n th e annua l fixe dcost . Tabl e 6- 5 summarize s th e annualizatio n period s an dcapitalizatio n factor s for eac h cos t component . Fo r

cos t component s base do n equipment , w e selecte dth e annualizatio n period s base do n th e expecte dlif e o f th e equipment . Fo r

th e cos t component s identifie da s material s replacemen t

an dmonitoring , recordkeepin g an dreporting , w e use da n annualizatio n perio do f ten years . W e use da

n annual interes t

rat e o f seve n percen t

for al l cos t components .

6-1 0P.1 9



### TABL E 6-5 . ANNUALIZATIO

N TM E PERIOD S AN

D CAPITALIZATIO

N FACTORS • Add-O n Contro l Device s w/ Associate dEquipmen t

- Add-O n Contro l Devic e

- Permanen t

Tota l Enclosur e (PTE )

- We t Ou t Are aEnclosur e (WAE )

- Captur e Devic e (CD ) fo r Centrifugal Castin g Machine s

- Ductwor k

fro mPTE , WA E o r

C D t o Add-O n Contro l Devic e Tim e Perio d (years ) 1 0 3 0 3 0 1 0 1 0 Capitalizatio n

Facto r 0.142 4 0.080 6 0.080 6 0.142 4 0.142 4 Resi n Bath We t

Ar e Enclosur e /

Resi n Dri p Collectio n Syste m

- Resi n Bath We t

Are aEnclosur e /

Resi n Dri p Collectio n Syste m 3 0 0.080 6 Replacemen t

o f Spra v Equipmen t

w/ Flowcoate r

- Flowcoate r

/ Salvag e Valu e Spray Gun s 7 0.185 6 Material s Replacemen t

- Produc t Recertificatio n

- Produc t Testin g 1 0 1 0 0.142 4

0.142 4 Monitoring , Recor dkeeping , & Reportin g

- Subpar t A Notification s (Year

1 ) - Construct/Reconstruct , Anticipate d StartUp , Actua l Startup , Notic e o f Complianc e Statu s

- Develo p Trainin g Progra m/ Record s Syste m(Year

1 )

- Readin g Standar d(Year 1 )

- Performanc e Tests , Develo p O& M Plan , SS& M Pla n (Year 1 ) 1 0 1 0 1 0 1 0 0.142 4

0.142 4 0.142 4 0.142 4

aCapitalizatio n factors fo

r eac h cost componen t ar e basedo n the annualization perio dshow n i n th e table an da n annua l interes t rat e o f 7.0% .



### 6-1 1P.2 0

6. 3 DEVELOPMEN T O FCOST S FO RSPECIFI C CONTRO L TECHNIQUE S 6.3. 1 Lo w HA P Resin s fo r Corrosio n Resistan t

Application s ' " W e determine dth e cost s for th e us e of

lo w HA P resin s for

corrosio n resistan t application s b y (1 ) estimatin g asingle averag e cos t differential betwee n hig h HA P an dlo w HA P corrosio n resistan t

resin s an d(2 ) applyin g th e averag e cos t differential t o th e quantity o f hig h HA P corrosio n resistan t

resi n currentl y use da

t th e facility , al l o f

whic h woul db e replace dwit h a lo w HA P corrosio n resistan t resin . W e applie dthi s procedur e t o ope n moldin g an dcentrifugal castin g corrosio n resistan t operations , excep t

fo r ope n moldin g corrosio n resistan t operation s wher e th e us e o f

flow-coate r

technolog y b y itsel f

allowe dth e ope n moldin g corrosio n resistan t operatio n t o mee t

th e MAC T floo r

poin t value . W e collecte dcos t

and/o r physica l propertie s informatio n for thermose t

resin s designe d specificall y fo r

corrosio n resistan t

applications fro mfiv e majo r resi n manufacturers : Alph a Owen s Cornin g (AOC) , Ashlan dChemica l Company , Do w Chemica l Company , Interplasti c Corporation , an dReichhold . Th e cos t differential associate dwit h replacin g ahig h HA P corrosio n resistan t resi n wit h a lo w HA P corrosio n resistan t resi n i s primaril y dependen t o n th e chemica l environment 1 an dth e continuou s operatin g temperatur e t o whic h th e cure dresi n i s expose dan do n th e HA P conten t o f th e lo w HA P resi n replacement . Therefore , w e examine dth e availabl e dat at o determin e whic h dat awoul dbes t

tak e int o accoun t

th e numerou s chemica l environment s an doperatin g temperature s t o whic h th e cure dcorrosio n resistan t resin s ar e expose dan dth e availabl e lo w HA P resi n replacements , whic h mus t b e capabl e o f

handlin g th e sam e chemica l environmen t a t th e sam e continuou s temperatur e a s th e hig h HA P resi n currentl y i n us e whil e no t exceedin g a certai n leve l o f

HA P content . W e determine dtha t

th e Reichhol ddat awer e th e mos t usefu l dat aprovide dt o conduc t th e cos t analysis . Th e dat asubmitte dcontaine dcost , property , an dresi n applicabilit y dat ao n hig h

1 A "chemica

l environment " i s acombination o f aspecific chemica

l a t aspecific concentration . The maximumcontinuou s temperatur e limit fo r aspecific chemica

l environmen

t i s th e maximu

m temperatur

e (basedo n testin g conducte db

y the resin supplier

) tha t aproperly constructe dplasti c composit e storag e tan

k o r typ e o f proces s equipmen

t ca n continuousl

y handl e (sustain ) without experiencin g structura

l failure . 6-1 2P.2 1

HA P isophthali c and/o r

bisphenol-A-fumarat e resin s an dlo w HA P viny l este r resins . Informatio n o n hig h an dlo w HA P resi n pair s i s neede dt o determin e th e cos t differential for switchin g t o complian t

resins . Base do n informatio n fro mcompanie s that switche dt o lowe r HA P corrosio n resistan t

resins , w e assume dth e replacemen t o f ahig h HA P isophthali c o r bisphenol-A-fumarat e resi n wit h alo w HA P viny l este r

resi n i s th e mos t

likel y resi n replacemen t scenario . Reichhol dwa s th e onl y company that supplie ddat athat

coul db e use dfor

thi s scenario . Therefore , w e use dth e dat afro mReichhol d(se e Tabl e 6-6 ) in calculatin g th e cos t differential . Tabl e A6-4 in Appendi x 6. 3 summarize s th e corrosio n resistan t propertie s of

th e Reichhol dresin s includin g th e numbe r o f resin s tha t

coul db e use di n anumbe r o f chemica l environment s a

t specifi c continuou s operatin g temperatures . TABL E 6-6 . AVAILABL E COS T INFORMATIO N FO RCORROSIO N RESISTAN T

RESIN S PROVIDE D B Y REICHHOL D

Resi n Produc t

Numbe r DIO N 910 0 DIO N 930 0 ATLA C 58 0 DIO N 948 0 DIO N 942 0 DIO N 669 4 ATLA C 38 2 ATLA C 401 0 DIO N 663 1 Resi n Typ e Bispheno l - Epox y - Viny l Este r Bispheno l - Epox y - Viny l Este r Urethan e - Viny l Este r Novala c - Epox y - Viny l Este r Viny l Este r

(Hig h Cross-link ) Bispheno l - A - Fumarat e Bispheno l - A - Fumarat e Bispheno l - A - Fumarat e Isophthali c HA P Conten t ( % b y wt. ) 43. 5 30. 0 46. 0 39. 0 34. 5 48. 0 50. 0 50. 0 48. 0 Sal e Pric e

( $ / lb ) $1,36 5 $1,43 5 $1,46 5 $2,05 0 $1,76 0 $1,46 0 $1,32 0 $1,32 0 $1,05 0

aAl l sale price s ar

e i n 199 8 dollar s basedo

n ashipmen

t siz e o f 8 0 drums an

dar e fo r non-promotedresins . Ther e ar e numerou s different chemica l environment s an dcontinuou s operatin g temperature s t o whic h cure dcorrosio n resistan t resin s ma

y b e exposed . Therefore , w e examine d al l chemica l environment s for whic h Reichhol dprovide ddata . Tabl e A6- 5 in Appendi x 6. 3 provide s example s o f

specifi c chemica l environment s an dmaximu mcontinuou s temperatur e . limit s that

wer e examine di n th e cos t analysis . 6-1 3P.2 2

Fo r th e se t o f environment s an doperatin g temperature s identifie di n th e informatio n supplie db y Reichhold , w e calculate dth e actual cos t differential associate dwit h replacin g eac h specifi c hig h HA P corrosio n resistan t resi n b y subtractin g th e pric e ofth e hig h HA P corrosio n resistan t resi n fro mth e pric e ofth e leas t expensiv e lo w HA P corrosio n resistan t resi n replacemen t

tha t i s capabl e o f

handlin g th e sam e chemica l environmen t a t th e sam e continuou s temperatur e a s th e hig h HA P resi n currentl y i n us e whil e no t exceedin g acertai n leve l o f HA P content . (Tabl e A6- 6 i n Appendi x 6. 3 provide s actual cos t differential s for

th e firs t four chemica l environment s liste di n Tabl e A6- 5 i n Appendi x 6. 3 a t eigh t differen t continuou s operatin g temperatures. ) Next , w e calculate dth e averag e cos t differential s associate dwit h replacin g hig h HA P corrosio n resistan t

resin s with lo w HA P corrosio n resistan t resin s fo r

eac h maximu mallowabl e HA P conten t

rang e an dspecifi c continuou s temperature . Tabl e 6- 7 summarize s th e result s o f thi s analysis . Th e averag e cos t differential for

amaximu mallowabl e HA P conten t rang e an d specifi c continuou s temperatur e i s th e averag e ofth e individua l cos t differential s determine dfo r eac h chemica l environmen t a t tha t maximu mallowabl e HA P conten t rang e an dspecifi c continuou s temperature . Th e majority o f

facilitie s di dno t

provid e informatio n on th e actual corrosio n resistan t resin s use db y th e facility . Therefore , w e coul dno t determin e facility-specifi c cos t differentials . Becaus e o f

this , w e selecte dasingl e averag e cos t differential fro mTabl e 6- 7 t o appl y t o al l facilities . Th e selecte daverag e cos t differential i s $0,45 5 pe r pound , whic h represent s th e highes t averag e cos t

differential fo r

th e resi n replacemen t

option s possibl e a

t aspecifi c temperatur e an dgrou p o f chemica l environments . W e calculate dth e cos t

t o eac h individua l facility b y multiplyin g th e selecte daverag e cos t differential b y th e quantity o f resi n currentl y use di n th e applicabl e ope n moldin g an dcentrifuga l castin g corrosio n resistan t operation s a

t that facility . W e assume dthat al l o f th e corrosio n resistan t resi n currentl y use di n thes e operation s a t afacilit y woul db e replace dwit

h alo w HA P corrosio n resistan t

resin . W e mad e thi s assumptio n becaus e (1 ) fo r man y products , afacility wil l

6-1 4TABL E 6-7 . AVERAG E COS T DIFFERENTIA L FO RCORROSIO N RESISTAN T RESIN S A T DIFFEREN T SPECIFI C CONTINUOU S TEMPERATURE S Pre-MAC T Resi n Cos t an dHA P Conten t Cos t ($/lb ) Leas t Expensiv e Leas t Expensiv e Leas t Expensiv e Leas t Expensiv e HA P ( % b y Wt )

N o Limi t N o Limi t N o Limi t N o Limi t Post-MAC T Resi n Cos t an dHA P Conten t Cos t ($/lb ) Leas t Expensiv e Leas t Expensiv e Leas t Expensiv e Leas t Expensiv e HA P ( % b y Wt )

< = 35 % < = 40 % < = 45 % N o Limi t Averag e Cos t Differential ($/lb ) 10 0 F 0.24 0 0.26 7 0.20 5 0.00 0 120 F

0.24 1 0.26 2 0.19 9 0.00 0 14 0 F

0.24 2 0.25 8 0.19 5 0.00 0 16 0 F

0.21 9 0.23 4 0.17 0 0.00 0 18 0 F

0.12 5 0.13 9 0.07 6 0.00 0 20 0 F

0.13 6 0.14 6 0.08 5 0.00 0 22 0 F

0.27 5 0.45 5 0.45 3 0.00 0 24 0 F

N/ A N/A N/A 0.00 0 Th e average cost

differentia l i s equa l to the average final cos t

les s the average initia

l cost . I t i s th e average ofth e individua

l cost differential s a

t aspecific continuou s temperature . Fo

r example , the average cos t

o f replacing th

e leas t expensive resi

n (wit h n o HA P limit ) tha t i s capable o

f handling achemica

l environmen

t a t 10 0 ° Fwit h th e leas t expensive resi

n (maximu mHA P = 35% ) tha

t i s capable o

f handling achemica

l environmen

t a t 10 0 ° Fi s $0.24 /

lb .

6-1 5P.2 4

wan t t o us e th e sam e HAP-leve l resi n t o ensur e produc t consistency , (2 ) usin g on e typ e of resi n wil l b e easie r

for afacility t o orde r

an dtrack , an d(3 ) operator s a t afacility ma

y findi t easie r t o appl y onl y on e typ e o f

resi n rathe r

than switchin g betwee n resins . In addition , thi s assumptio n (o f replacin g al l pre-MAC T resins ) i s conservative , becaus e som e facilitie s wit h distinc t produc t line s may elec t

t o switc h onl y th e resin s use din som e o f thei r produc t line s in orde r

t o achiev e compliance . 6.3. 2 Lo w HA P Resin s fo r Non-Corrosio n Resistan t Application s 1 2 W e determine dth e cost s for th e us e o f

lo w HA P resin s fo r

non-corrosio n resistan t application s b y (1 ) estimatin g asingl e averag e cos t differential betwee n hig h HA P an dlo w HA P non-corrosio n resistan t

resin s an d(2 ) applyin g th e averag e cos t differential t o th e quantity of hig h HA P non-corrosio n resistan t resi n currentl y use da

t th e facility , al l of

whic h woul db e replace dwith alo w HA P non-corrosio n resistan t resin . W e applie dthi s procedur e t o ope n moldin g an dcentrifugal castin g non-corrosio n resistan t operations , excep t

for ope n moldin g non corrosio n resistan t

operation s wher e th e us e o f flow-coate r

technolog y b y itsel f

allowe dth e ope n moldin g non-corrosio n resistan t operatio n t o mee t

th e MAC T floo r

poin t value . A s with corrosio n resistan t resins , ther e wa s ver

y limite dinformatio n on th e actual resin s use db y facilitie s for

non-corrosio n resistan t

operations . Therefore , w e use dth e averag e cos t differential fo r

al l facilities . W e obtaine dth e averag e cos t differential fro mth e cos t analysi s develope dfo r

th e boa t manufacturin g sourc e category . Th e averag e cos t differential w e use dwa s $0,05 5 pe r

poun dfor

facilitie s that

replace dahig h HA P polyeste r resi n (>35 % HA P b y wt. ) wit h alo w HA P polyeste r

resi n (35 % HA P b y wt.) . Th e averag e cos t differential for

th e boat manufacturin g sourc e category for non-corrosio n resistan t

resin s was $0,07 7 pe r

poun dfor facilitie s tha t

replace dahig h HA P viny l este r resi n (>35 % HA P b y wt. ) wit h alo w HA P viny l este r resi n (35 % HA P b y wt.) . Th e average cos t

differential selecte dt o represen t th e replacemen t

o f hig h HA P non corrosio n resistan t

resi n wit h lo w HA P non-corrosio n resistan t resi n was $0,05 5 pe r

pound . W e selecte dthi s averag e cos t differential becaus e facilitie s that us e non-corrosio n resistan t resin s in

6-1 6P.2 5

th e plasti c composite s sourc e category predominantl y us e polyeste r resin s rathe r

than viny l este r resins . Th e cos t

differential s use din th e boat manufacturin g sourc e category ar e base don th e assumptio n tha t

resin s wit

h 35 % HA P b y weigh t

ar e adequat e for

compliance . Th e reinforce d plastic s sourc e categor y ha s non-corrosio n resistan t operation s tha t

requir e resin s wit

h HA P content s les s than 35 % b y weigh t for compliance . However , w e assume dtha t th e selecte dcos t differential was stil l applicable . 6.3. 3 Lo w HA P Resin s for Mol dManufacturin g (Tooling ) Th e us e o f

toolin g resi n wit

h respec t t o th e us e of

productio n resi n varie s fro mfacility t o facility . Man y facilitie s di dno t indicat e toolin g resi n us e i n respondin g t o th e 199 3 Informatio n Collectio n Reques t

(ICR ) du e t o th e typicall y smal l amount s o f thi s materia l that

afacilit y use s relativ e t o it s us e o f

productio n materials . Th e toolin g resi n us e dat aprovide db y Pilling s F.R.P. , Breme n Glass , an dCusto mFiberglas s Moldin g wa s reporte dt o b e 5.1 , 0.3 , an d1. 2 percen t of th e productio n resin , respectively . Thes e dat aaverag e t o abou t 2 pound s o f

toolin g resi n for

every 10 0 pound s o f

productio n resin . W e use dthi s rati o t o calculat e toolin g resi n usage . W e collecte dcos t

an dpropertie s informatio n o n toolin g resin s fro mfiv e (5 ) majo r resi n manufacturers . Tabl e 6- 8 summarize s th e availabl e cos t informatio n submitte db y thes e resi n manufacturers . TABL E 6-8 . AVAILABL E COS T INFORMATIO N FO RTOOLIN G RESIN S

FRO M RESI N MANUFACTURER S

Resi n Manufacture r Alpha-Owen s Comin g Ashlan dChemica l Compan y Coo k Composite s & Polymer s Interplasti c Corporatio n Interplasti c Corporatio n Reichhol d Resi n Produc t Numbe r 80-610 0 AM E 500 0 Stypo l 040-423 2 MVR803 1 CORVE-Serie s Viny l Este r Hydre x 33-25 0 Resi n Typ e DCPD-Viny l Este r Viny l Este r Isophthali c Viny l Este r Viny l Este r DCPD-Viny l Este r HA P Conten t ( % b y wt. ) 3 5 3 1 4 1 44. 9 47. 5 4 5 Sal e Pric e

( $ / lb ) $0.8 5 $1.4 6 $1.0 8 $1.5 1 $1.6 6 $1.5 3 Al l sal e price s ar e i n 199 8 dollar s o n ashipmen t siz e basi s o f

drums . 6-1 7P.2 6

W e calculate dth e averag e cos t ofth e thre e "high " HA P viny l este r resin s (i.e. , thos e wit

h HA P content s equa l t o o r greate r than 44. 9 percen t

b y weight) . Th e averag e cos t for thes e thre e resin s i s approximatel y $1.5 7 pe r pound . W e the n compare dthi s cos t t o th e cost s o f

th e tw o "low " HA P viny l este r

resins . Th e averag e hig h HA P viny l este r resi n cos t

i s highe r than eithe r o f th e tw o lo w HA P viny l este r resins . Base do n this , th e us e o f lo w HA P viny l este r

toolin g resin s coul dresul t

in acos t saving s t o th e affecte dfacilities . W e coul dno t make thi s compariso n betwee n hig h HA P an dlo w HA P isophthali c toolin g resins . Therefore , w e assume dazer o cos t fo r switchin g t o lo w HA P toolin g resin s rathe r than acos t

saving s i n orde r

t o mak e th e cos t estimat e mor e conservative . 6.3. 4 Lo w HA P Pigmente dProductio n Ge l Coat s 131 4 W e calculate dth e cos t

o f convertin g t o lo w HA P pigmente dproductio n gel coat s b y (1 ) determinin g th e cost s of

lo w an dhig h HA P pigmente dproductio n gel coats , (2 ) determinin g th e amoun t an dbasi c colo r

typ e (white/off-whit e an dbright ) o f pigmente dproductio n gel coa t currentl y use da

t afacilit y (pre-MAC T floor) , (3 ) determinin g th e amoun t an dtyp e (lo w an dhig h HAP ) o f pigmente dproductio n ge l coat i n orde r t o compl y with th e MAC T floo r (after MAC T floor) , an d(4 ) applyin g th e cos t t o th e amoun t

o f lo w an dhig h HA P pigmente dproductio n ge l coa t t o determin e facility cost s pre-MAC T floo r an dafter MAC T floor . W e collecte dcos t

an dpropertie s informatio n o n pigmente dproductio n ge l coat s fro mtw o majo r ge l coa t manufacturers . In addition , w e collecte ddetaile dpigmente dgel coa t usag e dat a fro msom e facilitie s i n th e MAC T floor . O f th e MAC T floo r

facilitie s surveyed , fiv e reporte d usin g Coo k

Composit e pigmente dge l coats an don e o f th e fiv e als o reporte dusin g Nest e pigmente dge l coats . In developin g cos t

estimate s for

hig h an dlo w HA P pigmente dproductio n gel coats , it i s necessar y t o identif

y "matched " pair s o f

ge l coats ; that

is , matc h ahig h HA P pigmente dgel coa t with alo w HA P pigmente dge l coa t that woul dreplac e th e hig h HA P pigmente dge l coat . O f th e dat asupplie db y th e tw o ge l coa t manufacturers , onl y th e Coo k Composit e dat aallowe du s t o identif y matche dpairs . Sinc e mor e facilitie s us e Coo k Composit e resin s than Nest e resin s an d onl y th e Coo k

Composit e dat acoul db e use dt o develo p matche dpairs , w e use dth e Coo k 6-1 8P.2 7

Composite s dat aabov e i n developin g cos t estimate s for

lo w an dhig h HA P pigmente dproductio n ge l coats . Tabl e 6- 9 present s th e availabl e cos t dat afro mCoo k

Composite s for

thos e pigmente dgel coat line s (i.e. , Polyco r

IS O standard , sanitary lo w VOC , Armorcot e Hig h Performance , an dlo w VO C Armorcote ) identifie da s bein g use db y thes e fiv e MAC T floo r facilitie s i n th e gel coat survey . TABL E 6-9 . AVAILABL E COS T INFORMATIO N FO RPIGMENTE D PRODUCTIO N

GE L COAT S FRO M COO K COMPOSITE S AN D POLYMER S

Ge l Coa t Produc t Numbe r 944-POLYCO RIS O Standar d 95 1 -ARMORCOT E Hig h Performanc e 961-LO WVO C ARMORCOT E 962-Sanitar y LO WVO C 944-POLYCO RIS O Standar d 951-ARMORCOT E 961-LO WVO C ARMORCOT E 962-Sanitar y LO WVO C 944-POLYCO RIS O Standar d 951-ARMORCOT E 961-LO WVO C ARMORCOT E 962-Sanitar y LO WVO C Ge l Coa t Bas e Colo r Whit e Whit e Whit e Whit e Blac k Blac k Blac k Blac k Re d Re d Re d Re d HA P Content a

( % b y wt. ) 3 6 4 0 2 9 2 5 4 0 4 4 3 1 3 0 3 8 4 0 3 0 3 0 L 1

Sal e Pric e ( $ / lb ) $1.6 8 $3.0 1 $1.9 9 $1.9 9 $1.7 0 $3.0 1 $1.9 9 $1.9 9 $2.7 1 $4.8 1 $3.5 1 $3.5 1 HA P content s are show n t o th e numbe r o f decima l place s reporte db y Coo k Composites . Al l sale s price s are i n 199 8 dollar s an dare o n adru msiz e shipmen t basis . Th e firs t matche dpai r

i s th e 944-Polyco r

IS O standar dan dth e 962-Sanitar y lo w VOC . Th e result s o f

adetaile dge l coat

usag e surve y sho w that

almos t al l o f th e surveye dfacilitie s that us e Coo k Composite s & Polymer s ge l coats us e eithe r th e 944-POLYCO Rge l coa t o r 962

- Sanitary Lo w VOC . Further , thes e tw o ge l coat s ar e use di n producin g th e sam e basi c product s (bath) . Therefore , w e assume dthat th e 962-Sanitary lo w VO C gel coa t woul db e asubstitut e whereve r th e 944-Polyco r

IS O standar dge l coa t

i s bein g used . Th e secondmatche dpai r appear s 6-1 9P.2 8

t o b e th e 951-Armorcot e Hig h Performanc e an dth e 961-Lo w VO C Armorcot e gel coats . Althoug h th e lo w VO C ge l coat appear s t o b e asubstitut e for th e 95 1 ge l coat , it

i s unclear whethe r th e lo w VO C Armorcot e i s als o a"hig h performance " ge l coat . However , becaus e th e amoun t o f th e Armorcot e resi n use dappear s t o b e s o muc h lowe r relativ e t o th e Polyco r

IS O standar dresin , w e use dth e dat aof th e Polyco r

IS O Standard/Sanitary lo w VO C pai r t o develo p th e cos t estimate . In developin g th e cos t

estimate , w e als o considere dth e colo r of th e gel coats . Colo r distributio n i s importan t

becaus e differen t

colo r pigmente dproductio n ge l coat s hav e differen t price s an dphysical properties . Base do n discussion s wit h gel coat suppliers , ther e ar e thre e basi c colo r grouping s o f

pigmente dge l coats , whic h ar e white s an dof f whites , blac k

an ddar k colors , an dbrigh t

colors , suc h a s red . Th e cos t informatio n provide db y Coo k Composite s liste dprice s for : (1 ) whit e ge l coats , whic h ar e representative o f whit e an dof

f whit e gel coats , (2 ) blac k gel coats , whic h ar e representative o f blac k an ddar k colo r ge l coats , an d(3 ) re dgel coats , whic h ar e representativ e o f

re dan dothe r

brigh t colo r gel coats . Result s o f

adetaile dge l coat

usag e survey , whic h was sen t t o nin e companie s wit

h facilitie s in th e to p portio n of th e MAC T database , sho w that white/of f whit e gel coats ar e th e mos t predominan t

color s use dfollowe db y red/brigh t colore dge l coats . Th e surve y als o show s tha t th e us e o f

black/dark

colo r ge l coats i s insignifican t

fo r th e facilitie s that

responde dt o th e survey . W e di dno t

us e an y quantitativ e dat ao n colo r usag e fro mth e survey , however , becaus e th e facilitie s surveye donl y represen t abou t fiv e percen t

o f th e tota l pigmente dge l coat usag e in th e MAC T database . I

n addition , th e surveye dfacilities , whic h mainl y produc e bathwar e an d transportatio n products , may no t b e arepresentative sampl e o f al l facilitie s usin g pigmente dgel coats . Base do n qualitativ e result s o f th e pigmente dge l coa t

usag e survey , w e assume dthat th e colo r distributio n o f

pigmente dproductio n ge l coats currentl y use db y facilitie s in ope n moldin g operation s i s 80 % b y volum e white/of f whit e ge l coa t

an d20 % b y volum e red/brigh t colore d coat . W e assume dn o usag e o f black/dark

colore dge l coa t

i n th e cos t

analysi s becaus e th e amoun t reporte di n th e detaile dge l coat usag e surve y i s insignifican t compare dt o th e othe r colors . W e the n applie dthes e percentage s t o th e tota l pigmente dproductio n ge l coats estimate d 6-2 0P.2 9

fo r eac h facility t o calculat e pre-MAC T usag e o f white/of f whit e an dred/colore dpigmente dgel coats . Next , w e identifie dth e cost s fo r th e white/of

f whit e an dred/brigh t

colore dgel coa t

pairs . Th e white/of

f whit e hig h HA P ge l coa t selecte d(944-POLYCO RIS O standard) ha s acos t of $1.6 8 pe r poun dTh e white/of

f whit e lo w HA P ge l coat selecte d(96 2 - Sanitary LO WVOC ) ha s acos t o f $1.9 9 pe r

pound . Thi s yield s aswitchin g cos t of $0.2 8 pe r

pound . Th e red/brigh t colore dhig h HA P ge l coat selecte d(944-POLYCO RIS O standard) ha s acos t o f $2.7 1 pe r pound . Th e redlo w HA P ge l coa t selecte d(96 2 - Sanitary LO WVOC ) ha s acos t of $3.5 1 pe r pound . Thi s yield s aswitchin g cos t o f $0.8 0 pe r

pound . W e the n determine dth e amount s o f lo w HA P white/of

f whit e an dred/brigh t

colore d productio n ge l coat

eac h facility wil l nee dt o us e t o compl y wit h th e existin g sourc e MAC T floo r an dobtai n th e sam e surfac e are acoverage . Du e t o difference s in density an dth e amoun t o f HA P emitte ddurin g applicatio n an dcuring , th e amoun t of surfac e are athat

can b e covere db y equa l amount s o f

lo w HA P an dhig h HA P ge l coat s on aweigh t o r mas s basi s i s different . Lo w HA P ge l coats generall y hav e ahighe r density than hig h HA P gel coats . Thi s highe r density equate s t o alowe r volum e o f

ge l coat pe r poun dof ge l coat purchase . Thi s lowe r

volum e can resul t

in les s tota l ge l coa t

coverag e pe r

poun do f ge l coa t purchased . Conversely , lo w HA P ge l coat s emit les s styren e an dmethy l methacrylat e wit h th e resul t

that les s of th e applie dge l coa t

materia l evaporate s int o th e atmosphere . Thi s fac t —that les s materia l evaporate s - - can resul t i n mor e tota l coverag e pe r

poun do f ge l coa t purchased . Thes e tw o factor s ar e simultaneousl y presen t i n different

degree s an dth e combine deffec t o f both factor s determine s if th e facility mus t

increas e o r

decreas e th e amoun t

o f ge l coa t purchase di n orde r

t o obtai n th e sam e amoun t o f surfac e are acoverage . In calculatin g ho w muc h lo w HA P pigmente dproductio n ge l coat woul db e neede da

t afacility t o reac h aspecifi c contro l level , w e considere dth e actual HA P content s o f th e pigmente dproductio n ge l coats a t eac h facility , wher e tha t

informatio n was known . Otherwise , w e use da n average pigmente d productio n ge l coa t

HA P conten t

o f 3 7 percen t

for determinin g ho w muc h lo w HA P pigmente d productio n ge l coa t

i s neede dt o compl y with th e MAC T floor . Finally , becaus e o f th e cos t differential betwee n th e lo w HA P white/of f whit e an dhig h HA P white/of f whit e productio n ge l 6-2 1P.3 0

coat s i s substantiall y smalle r than th e cos t

differential betwee n th e lo w HA P red/brigh t colore d an dth e hig h HA P red/brigh t colore dproductio n gel coats , w e assume dthat facilitie s woul d replac e al l o f

th e hig h HA P white/of

f whit e pigmente dproductio n gel coat prio r t o replacin g any o f th e hig h HA P red/brigh t colore dpigmente dproductio n gel coat . Onc e w e determine dth e usage s o f white/of f whit e an dred/brigh t

colore dproductio n gel coa t usage s fo r

lo w an dhig h HA P ge l coat , w e calculate dth e annual tota l cos t incurre db y th e facility prio r

t o th e implementatio n o f th e MAC T floo r

leve l of contro l b y multiplyin g th e amoun t o f white/of f whit e an dred/brigh t

colore dproductio n ge l coat s use db y th e facility annuall y (regardles s o f

th e HA P content ) b y th e respectiv e cost s o f th e selecte dhig h HA P white/of f whit e an dred/brightl y colore dproductio n ge l coat s an dsummin g th e results . Next , w e calculate dth e annua l tota l cos t incurre db y th e facility for complyin g wit

h th e MAC T floo r

b y (1 ) multiplyin g th e amoun t

o f hig h HA P white/of

f whit e an dred/brigh t

colore dproductio n gel coats that wil l stil l b e use dafte

r implementatio n ofth e MAC T floo r leve l o f contro l b y th e respectiv e cos t o f th e selecte dhig h HA P white/of f whit e an dred/brigh t

colore dproductio n ge l coats , (2 ) multiplyin g th e amoun t

o f lo w HA P white/of

f whit e an dred/brigh t

colore dproductio n ge l coat s that wil l b e use dafter

implementatio n o f

th e MAC T floo r

leve l o f contro l b y th e respectiv e cost s o f th e selecte dlo w HA P white/of f whit e an dred/brigh t

colore dproductio n gel coats , an d(3 ) summin g th e tw o results . W e the n determine dth e cos t o f complyin g wit

h th e MAC T floo r

for eac h facility b y subtractin g th e after MAC T hig h an dlo w HA P pigmente dproductio n ge l coa t cost s fro mth e pre-MAC T pigmente dproductio n ge l coat costs . 6.3. 5 Lo w HA P Clear

Productio n Ge l Coat s 131 4 W e calculate dth e cos t

o f usin g lo w HA P clear

productio n gel coats b y (1 ) determinin g th e cost s o f

lo w an dhig h HA P clear productio n ge l coats , (2 ) determinin g th e amoun t an dtyp e (lo w an dhig h HAP ) o f

clear productio n ge l coat

currentl y use da

t afacility (pre-MAC T floor) , (3 ) determinin g th e amoun t an dtyp e (lo w an dhig h HAP ) o f clear productio n ge l coa t

in orde r t o compl y with th e MAC T floo r (after MAC T floor) , an d(4 ) applyin g th e cos t t o th e amoun t

o f lo w an dhig h HA P clear

productio n ge l coa t

t o determin e facility cost s pre-MAC T floo r an dafter

6-2 2P.3 1

MAC T floor . Complianc e with th e MAC T floo r poin t valu e fo r clear productio n ge l coat s correspond s t o aHA P conten t o f 44.0 % b y weight . W e collecte dcos t

an dpropertie s informatio n on clear productio n ge l coats fromtw o majo r ge l coat manufacturers . Tabl e 6-1 0 summarize s th e availabl e cos t informatio n submitte d b y thes e ge l coa t

manufacturers . TABL E 6-10 . AVAILABL E COS T INFORMATIO N FO RCLEA RPRODUCTIO N

GE L COAT S FRO M GE L COA T MANUFACTURER S

Ge l Coa t Manufacture r Nest e Polyeste r Nest e Polyeste r Nest e Polyeste r Coo k Composite s & Polymer s Ge l Coa t Produc t Numbe r CG-LE-57 0 CG-0700 9 CG-2100 9 942-XA-22 0 Ge l Coa t

Bas e Colo r Clear Clear Clear Clear Styren e

Conten t 3 4 47. 2 43. 7 MMA a

Conten t 1 0. 0 6. 1 HA P Conten t a ( % b y wt. ) 3 5 47. 2 49. 8 45. 0 Sal e Pric e

( $ / lb ) $2.10 c $1.5 3 $1.6 8 $1.9 2 Styrene , methy l methacrylate , an dtotal HA P content s are show n t o th e numbe r o f decima l place s reporte db y th e gel coat manufacturer . Al l sale s price s are i n 199 8 dollar s an dare o n adru msiz e shipmen t basis . NOTE : Blan k

space s i n th e tabl e indicat e informatio n wa s no t provide db y th e manufacturer . Base do n th e dat acollected , hig h HA P (4 5 t o 50% ) clear productio n ge l coats cos t betwee n $1.5 3 an d$1.9 2 pe r poun dwhe n delivere di n drums . W e selecte dth e Nest e Polyeste r CG-0700 9 ge l coa t

t o represen t

atypica l hig h HA P gel coa t becaus e th e Neste' s HA P conten t i s representativ e o f

th e HA P conten t

use db y th e majorit

y o f facilitie s currentl y usin g clear productio n ge l coats . Thi s ge l coat cost s $1.5 3 pe r

pound . A s see n i n Tabl e 6-10 , th e onl y clear productio n ge l coat

with alo w enoug h HA P conten t t o mee t th e MAC T floo r

(35% ) cost s $2.1 0 pe r

pound . W e use dthi s cos t t o cos t al l lo w HA P clear productio n ge l coats fo r

complianc e wit

h th e MAC T floor . Becaus e th e selecte dlo w HA P clear productio n ge l coa t

ha s asubstantiall y lowe r HA P conten t o f 35.0 % b y weigh t

tha n th e 44 % b y weigh t

neede dt o mee t

th e MAC T floor , w e assume dtha t

thi s larg e differential i n th e HA P conten t (an dth e highe r

pric e o f th e lo w HA P clear

6-2 3P.3 2

productio n ge l coat ) wil l resul t i n facilitie s usin g onl y th e amoun t o f lo w HA P clear

productio n ge l coa t necessary t o mee t

th e require dcontro l level . W e the n determine dth e amoun t o f lo w HA P clear

productio n gel coat

eac h facility wil l nee dt o us e t o compl y wit h th e existin g sourc e MAC T floo r poin t valu e limi t

an dobtai n th e sam e surfac e are acoverage . Du e t o difference s i n density an dth e amoun t o f styren e emitte ddurin g applicatio n an dcuring , th e amoun t o f surfac e are athat

can b e covere db y equal amount s o f lo w HA P an dhig h HA P gel coats o n amas s basi s i s different . Lo w HA P gel coat s generall y hav e a highe r densit y than hig h HA P ge l coats . Thi s highe r densit y equate s t o alowe r volum e of

gel coa t pe r poun do f ge l coat purchase . Thi s lowe r

volum e can resul t

i n les s total gel coat

coverage pe r poun do f gel coat purchased . Conversely , lo w HA P gel coat s emi t les s styren e an dmethy l methacrylat e wit

h th e resul t

that les s o f th e applie dge l coa t

materia l evaporate s int o th e atmosphere . Thi s fac t

- that les s materia l evaporate s - can resul t i n mor e total coverag e pe r poun do f ge l coat purchased . Thes e tw o factor s ar e simultaneousl y presen t in differen t

degree s an dth e combine deffec t o f both factor s determine s if th e facility mus t

increas e o r

decreas e th e amoun t

of gel coat purchase din orde r

t o obtai n th e sam e amoun t o f surfac e are acoverage . In calculatin g ho w muc h lo w HA P clear

productio n gel coat

woul db e neede da

t afacility t o reac h th e MAC T floo r poin t value , w e considere dth e actual HA P content s o f th e clear productio n ge l coats a

t eac h facility , wher e tha t

infoimatio n wa s known . Otherwise , w e use da n average clear

productio n ge l coa t HA P conten t

o f 47. 3 percen t

fo r determinin g ho w muc h lo w HA P clear productio n ge l coat

i s neede dt o compl y wit

h th e MAC T floor . Onc e w e determine dth e clea r productio n ge l coat

usage s for

th e pre-MAC T an dafter MAC T scenarios , w e calculate dth e annua l tota l cos t incurre db y th e facility prio r t o th e implementatio n o f

th e MAC T standar db y multiplyin g th e amoun t o f clear productio n ge l coa t use db y th e facility annuall y (regardles s o f th e HA P content ) b y th e cos t o f th e selecte dhig h HA P clea r productio n ge l coat . Next , w e calculate dth e annua l tota l cos t incurre db y th e facility fo r complyin g with th e MAC T floo r b y (1 ) multiplyin g th e amoun t o f hig h HA P clear

productio n gel coa t tha t wil l stil l b e use dafter

implementatio n o f

th e MAC T standar db y th e pric e o f th e selecte dhig h HA P clear

productio n ge l coat , (2 ) multiplyin g th e amoun t o f lo w HA P clear 6-2 4P.3 3

productio n ge l coat

that wil l b e use dafte

r implementatio n o f

th e MAC T standar db y th e pric e of th e selecte dlo w HA P clear productio n ge l coat , an d(3 ) summin g th e tw o results . W e the n determine dth e cos t

o f complyin g wit

h th e MAC T floo r

for eac h facilit

y b y subtractin g th e afte

r MAC T hig h an dlo w HA P clear productio n ge l coat

cost s fro mth e pre-MAC T clear productio n ge l coat costs . 6.3. 6 Lo w HA P Toolin g Ge l Coat s l31 5 W e determine dth e cost s fo r th e us e o f

lo w HA P toolin g ge l coats b y (1 ) estimatin g th e amoun t o f toolin g ge l coat

currentl y used , (2 ) estimatin g asingl e averag e cos t differential betwee n hig h HA P an dlo w HA P toolin g ge l coats an d(3 ) applyin g th e averag e cos t differential t o quantity o f

hig h HA P toolin g ge l coats currentl y use da t th e facility , al l of

whic h woul db e replace dwit

h alo w HA P toolin g ge l coats . A s discusse dbelow , w e calculate dthes e cost s for al l ope n moldin g operation s (excep t filamen t winding ) an dal l polyme r castin g operation s wit

h averag e toolin g gel coa t

HA P content s greate r

than th e MAC T floo r

leve l of 3 8 percent . Base don informatio n available , ope n moldin g operation s (excep t filamen t winding ) an d polyme r castin g operation s us e reinforce dplasti c composit e mold s i n thei r manufacturin g processes . Thes e molds , whic h ar e gel coated , ar e mad e fro mtoolin g resins . Whil e few facilitie s i n th e 199 3 Informatio n Collectio n Reques t (ICR ) surve y indicate dth e us e of toolin g ge l coat s (possibl y becaus e the y ar e use di n smal l amount s relativ e t o productio n materials) , w e assume d tha t al l facilitie s know n o r

assume dt o us e toolin g resi n als o us e toolin g gel coat . Whil e afew facilitie s identifie dth e amoun t o f toolin g gel coa t

used , mos t

facilitie s di d not provid e that

information . Fo r

th e latte r facilities , w e ha dt o estimat e th e amoun t o f toolin g ge l coa t bein g used . W e di dthi s b y applyin g atoolin g ge l coat t o toolin g resi n ratio o f

0.1 5 (i.e. , 1 5 lb s o f toolin g ge l coa t

mus t b e applie dfo r

every 10 0 lb s of

toolin g resin) . Thi s rati o i s base d o n a n averag e rati o o f

productio n ge l coa t

t o productio n resin . N o informatio n wa s availabl e relatin g th e us e o f

toolin g ge l coa t

t o toolin g resin . Th e ratio o f 0.1 5 i s a n averag e base do n tw o applie dge l coat

t o applie dresi n ratio s calculate dusin g actua l data . Th e firs t rati o i s th e amoun t o f pigmente dproductio n ge l coat applie dpe r

productio n resi n applie dusin g manual and/o r mechanica l resi n applicatio n (0.215) . Th e secon dratio i s th e amoun t o f clear productio n gel coa t 6-2 5P.3 4

applie dpe r

productio n resi n applie ddurin g th e polyme r castin g proces s (0.085) . Sinc e facilitie s tha t manufactur e product s usin g ope n moldin g operation s and/o r polyme r castin g operation s likel y manufactur e and/o r repai r molds , w e use dth e averag e o f thes e ratio s t o obtai n th e 0.1 5 ratio . Onc e w e determine dth e toolin g ge l coa t usag e fo r eac h facility , w e identifie dth e averag e HA P conten t

o f th e toolin g resi n a

t eac h facility i n orde r

t o determin e whic h facilitie s woul d nee dt o switc h t o alo w HA P resin . Again , onl y afew facilitie s identifie dthei r toolin g gel coa t HA P contents . Fo r

th e othe r facilities , w e estimate dth e averag e HA P conten t o f thei r toolin g gel coat s b y usin g th e averag e HA P conten t o f toolin g ge l coa t

operation s for

thos e facilitie s wher e th e actua l HA P conten t

o f th e toolin g ge l coa t

i s known . Th e calculate daverag e HA P conten t i s greate r than th e existin g MAC T floo r leve l o f 3 8 percent . Therefore , w e assume dthat facilitie s withi n unknow n toolin g gel coat HA P content s woul dswitc h t o lo w HA P toolin g gel coats i n orde r t o compl y wit

h th e MAC T floor . W e collecte dcos t

an dpropertie s informatio n o n toolin g ge l coats fromtw o majo r gel coa t manufacturers . Tabl e 6-1 1 summarize s thi s information . Fro mth e availabl e cos t information , w e selecte dNest e Polyeste r BG-550 0 a s th e toolin g ge l coat mos t likel y t o represen t

th e hig h HA P toolin g gel coats currentl y i n use . W e selecte dthi s ge l coat becaus e th e gel coat

colo r (black ) i s atypica l toolin g ge l coat colo r an dth e HA P conten t

o f th e toolin g gel coa t

(45.8 % b y wt. ) i s clos e t o th e averag e HA P conten t o f th e toolin g ge l coat

operation . Next , w e selecte dth e toolin g ge l coat(s ) mos t likel y t o represen t

th e lo w HA P toolin g ge l coat s selecte db y facilitie s t o comply . Th e existin g sourc e MAC T floo r i s se t b y agel coa t (Polydyn e 15 1 Orange ) wit h aHA P conten t

o f 38.0 % b y weight . However , n o cos t informatio n wa s availabl e fo r

thi s ge l coat . W e selecte dth e Ferr o Corporatio n G V 0176 7 ge l coat a s the.lo w HA P toolin g ge l coa t becaus e th e Ferr o G V 0176 7 ge l coa t i s alogica l matc h fo r

th e hig h HA P Nest e Polyeste r BG

5500 0 du e t o th e identica l colo r an dpresenc e o f

methy l methacrylate . I

n addition , thi s ge l coa t

i s on e o f th e mor e commonl y use dlowe r HA P toolin g ge l coat s for whic h cos t

dat awer e available . W e the n calculate dth e cos t differential betwee n th e selecte dhig h HA P an dlo w HA P toolin g ge l coats , whic h i s $0.21pe r poun d($2.7 2 - $2.93) . W e use dthi s cos t differential t o 6-2 6P.3 5



### TABL E 6-11 . AVAILABL

E COS T INFORMATIO

N FO RTOOLIN

G GE L COATS FRO

M GE L COA T MANUFACTURERS

Ge l Coa t Manufacture r Nest e Polyeste r Nest e Polyeste r Nest e Polyeste r Nest e Polyeste r Nest e Polyeste r Nest e Polyeste r Coo k Composite s & Polymer s Coo k Composite s & Polymer s Coo k Composite s & Polymer s Ferr o Corporatio n Ferr o Corporatio n Ferr o Corporatio n Ge l Coat Produc t Numbe r BG-5500 0 RG-5500 5 YG-5500 0 YG-5700 0 YG-5776 V (Viny l Ester ) CG-5116 V (Viny l Ester ) 945-B-20 1 945-GA-10 4 945-YA-05 8 G V 0389 4 58-60123 0 c GV 0176 7 Ge l Coa t Bas e Colo r Blac k Re d Orang e Orang e Orang e Clear Blac k Gree n Orang e Re d Tangerin e Blac k Styren e

Conten t ( % b y wt. ) 40. 8 45. 7 41. 3 41. 7 53. 2 54. 0

36.9 4 29.2 3 36.9 7 MMA a

Conten t ( % b y wt. ) 5. 0 0. 0 0. 0 5. 0 0. 0 0. 0

3.0 0 3.0 0 3.0 0 HAP a

Conten t ( % b y wt. ) 45. 8 45. 7 41. 3 46. 7 53. 2 54. 0 4 8 4 8 4 8 39.6 4 32.2 3 39.9 7 Sale "

Pric e ( $ / lb ) $2.7 2 $2.7 2 $3.3 6 $3.3 6 $4.1 1 $3.4 7 $3.0 6 $3.7 7 $3.7 7 $3.4 8 $4.9 9 $2.9 3 Sal e Pric e

Shipmen t Siz e Basi s 5 Gal . Pai l 5 Gal . Pai l 5 Gal . Pai l 5 Gal . Pai l 5 Gal . Pai l 5 Gal . Pai l 5 Gal . Pai l 5 Gal . Pai l 5 Gal . Pai l 5 0 lb s 5 0 lb s 5 0 lb s Styrene , methy l methacrylate , an dtotal HA P content s ar e show n t o th e numbe r o f decima l place s reporte db y th e ge l coa t manufacturer . Al l sale s price s ar e i n 199 8 dollars . Accordin g t o th e manufacture r (Ferr o Corporation) , thi s ge l coa t i s aheav y metal free pigmente dsyste mwit h avery hig h hea t distortio n temperature . Th e manufacture r als o indicate dtha t

th e ge l coat

doe s no t

hav e many customer s a t thi s tim e resultin g in th e unusuall y hig h cost . NOTE : Blan k

space s i n th e tabl e indicat e informatio n wa s not provide db y th e manufacturer .



### 6-27P.3 6

calculat e th e direc t

annua l cos t

incurre db y facilitie s i n replacin g hig h HA P toolin g gel coats wit h lo w HA P toolin g gel coats . 6.3. 7 Testin g o f

Ne w Lo w HA P Resin s an dGe l Coat s W e determine dth e cost s o f testin g ne w lo w HA P resin s an dge l coat s fo r eac h facility b y estimatin g (1 ) acos t

pe r tria l an d(2 ) th e numbe r

o f trial s eac h facility woul db e require dt o perform . W e estimate dthes e cost s for th e followin g resi n an dge l coat groupings : corrosio n resistan t resins , non-corrosio n resistan t resins , toolin g resins , pigmente dgel coats , clear gel coats , an dtoolin g ge l coats . Th e cos t informatio n discusse dher e onl y pertain s t o testin g conducte db y th e facility . Testin g conducte dfor facilitie s b y independen t testin g firm s i s discusse din Sectio n 6.3. 8 (Recertificatio n o f

Products) . W e collecte dinfoimatio n o n testin g cost s that facilitie s incurre dt o verif y that th e ne w lo w HA P resin s exhibi t

acceptabl e physical propertie s fro msi x facilities . Tabl e 6-1 2 present s thes e data . Testin g cos t

dat at o switc h fro mhig h t o lo w HA P gel coats wer e no t available . TABL E 6-12 . TESTIN G O FNE WLO WHA P RESIN S

Facility Bowi e Manufacturing , Inc . ' 1 8 Dixie-Pacifi c Manufacturin g Company , Inc .

1 9 Fibe r Pro , Inc . 2 0 LASC O Bathwar e (Yelm ) 2 1 LaValle y Constructio n Compan y 22 Shenandoa h Fiberglas s Product s Compan y Former Resi n HA P Conten t (% ) Greate r than 35. 0 39. 8 40. 0 46. 0 43. 0 45. 0 t o 50. 0 Ne w Resi n HA P Conten t (% ) 31. 0 an d32. 7 35. 0 35. 3 37. 0 an d30. 0 34. 0 35. 0 Testin g Cos t includin g Labo r an dMaterial s "Minimal "

" A fe w hundre ddollars " Non e $5,00 0 pe r

Tria l N o cos t toth e facility $ 3,00 0 pe r

Tria l A s see n i n Tabl e 6-12 , testin g cost s ma y var y fro mzer o cos t

t o $5,00 0 pe r

trial . Base don thes e data , w e selecte d$3,00 0 pe r trial a s a n averag e cos t

fo r switchin g t o lowe r

HA P resins . Testin g cost s fo r

switchin g fro mhig h t o lo w HA P ge l coat s wer e no t available . W e assume dtha t

th e testin g cost s fo r

switchin g fro mhig h t o lo w HA P ge l coat s ar e th e sam e a s fo r switchin g fro mhig h t o lo w HA P resins . 6-2 8P.3 7

Th e amoun t

o f testin g that

afacilit y doe s i s highl y variabl e an ddepend s o n th e produc t bein g manufacture dan dth e exten t of th e testin g don e b y th e resi n o r gel coa t supplier . Fo r

eac h resi n o r ge l coa t groupin g identifie dabove , w e assume dthat 3 trial s woul db e necessary . Fo r example , if

Facilit y A use s corrosio n resistan t resin s an dnon-corrosio n resistan t resins , w e assume dthat

Facilit y A conducte d3 trial s for th e corrosio n resistan t

resin s an d3 trial s for

th e non-corrosio n resistan t

resins , for

atotal of 6 trials . Facilitie s may als o us e several applicatio n technique s t o appl y th e differen t resi n groupings . Fo r

example , Facility A ma

y us e manual an dmechanica l applicatio n technique s t o appl y th e corrosio n resistan t resin s an dmanual , mechanical , an dfilamen t windin g applicatio n technique s t o appl y th e non-corrosio n resistan t resins . Fo r

facilitie s that

appl y th e resin s usin g multipl e applicatio n techniques , w e divide dth e testin g cost s equall y amon g th e applicatio n techniques . Fo r

example , Facility A woul dperform3 trial s for th e corrosio n resistan t

resin s a t a tota l cos t o f $9,000 . W e the n distribute dthi s $9,00 0 equall y ove r th e manua l corrosio n resistan t resi n applicatio n operation s an dth e mechanica l corrosio n resistan t resi n applicatio n operation s (i.e. , w e allocate d$4,50 0 t o eac h o f thes e tw o operations) . Fo r th e non-corrosio n resistan t resins , Facilit y A woul dals o incu r atota l o f $9,00 0 for

trials . With thre e applicatio n technique s bein g use dfo r non-corrosio n resistan t

resins , w e the n distribute dth e $9,00 0 cos t equall y ove r

th e manua l non-corrosio n resistan t operations , th e mechanica l non-corrosio n resistan t operations , an dth e non-corrosio n resistan t filamen t windin g operation s (i.e. , w e allocate d$3,00 0 t o eac h o f thes e thre e operations) . Fo r ge l coats , w e assume dthat th e tota l numbe r

o f trial s woul db e equal t o 3 eac h fo r clea r productio n ge l coat , pigmente dproductio n ge l coat , an dtoolin g ge l coat . W e di dno t allocat e thes e tria l cost s amon g applicatio n technique s becaus e adifferent typ e o f ge l coa t i s use d i n thes e operations . 6.3. 8 Trainin g t o Us e Ne w Lo w HA P Resin s an dGe l Coat s W e collecte dinformatio n o n trainin g cost s that facilitie s incurre dassociate dwit h switchin g t o lowe r

HA P resin s fro mfiv e facilities . Tabl e 6-1 3 present s thi s information . Trainin g cos t

dat at o switc h fro mhig h t o lo w HA P gel coat s wer e not available . 6-2 9P.3 8

TABL E 6-13 . TRAININ G COST S T O US E NEWLO WHA P RESIN S

Facility 1 8 Dixie-Pacifi c Manufacturin g Company , Inc .

1 9 Fibe r Pro , Inc . 21 ) LASC O Bathwar e (Yelm ) LaValle y Constructio n Compan y 2 2 Shenandoa h Fiberglas s Product s Compan y Forme r Resi n HA P Conten t (% ) 39. 8 40. 0 46. 0 43. 0 45. 0 t o 50. 0 Ne w Resi n HA P Conten t (% ) 35. 0 35. 3 37. 0 an d30. 0 34. 0 35. 0 Trainin g Cos t for Switchin g t o Lower HA P Resi n ($ ) Non e Non e Non e Minima l Non e A s see n i n Tabl e 6-13 , four ou t of th e fiv e facilitie s reporte dn o (zero ) trainin g cost s incurre ddu e switchin g t o lowe r HA P resin s an dth e fift

h reporte d"minimal " costs . Therefore , w e assume dther e woul db e n o trainin g cost s fo r afacility t o switc h t o lowe r HA P resin s o r

gel coats . 6.3. 9 Recertificatio n o f Product s Recertificatio n o f

product s may b e necessary whe n switchin g fro mhig h HA P t o lo w HA P resin s o r ge l coat s an di s generall y require dfo r thos e product s that

ar e mas s produced . Th e onl y mas s produce dstoc k

product s identifie dtha t

w e believ e require s independen t certificatio n appear t o b e undergroun dgasolin e storag e tanks . Custo mmad e tank s o r othe r specialty product s ar e assume dt o nee dindividua l produc t certificatio n regardles s of th e typ e an dHA P conten t o f th e resin . Thus , w e assume dtha t switchin g t o alowe r

HA P resi n doe s no t

affec t produc t certificatio n cost s fo r

custo mproducts . N o dat awer e availabl e o n produc t recertificatio n costs . W e assume datypica l produc t recertificatio n cos t

o f $50,00 0 for

eac h undergroun dgasolin e storag e tank produc t lin e wher e th e resi n i s changed . W e believ e tha t thi s numbe r

i s reasonabl e for

thi s cost . Fo r

facilitie s tha t

us e different operation s t o produc e undergroun dgasolin e storag e tanks , w e divide dth e $50,00 0 recertificatio n cos t

equall y amon g eac h operation . Fo r example , if

Facility B produce s undergroun dstorag e tank s usin g manual operation s an dmechanica l operations , th e tota l recertificatio n cos t

t o th e facility wa s $50,00 0 wit h $25,00 0 bein g allocate dt o th e manua l operation s an dth e othe r

$25,00 0 allocate dt o th e mechanica l operations .

6-3 0P.3 9

6.3.1 0 Productio n Proble mCost s Du e t o Switchin g t o Ne w Lo w HA P Resin s an dGe l Coat s Thi s i s acos t

that coul doccu r

if switchin g t o lo w HA P resin s an dge l coats resulte di n les s efficien t

production . W e collecte ddat ao n thi s potentia l cos t fro mseve n facilitie s (se e Tabl e 6-14) . TABL E 6-14 . IMPAC T O FSWITCHIN G T O LO WHA P RESIN S O N PRODUCTIO N EFFICIENC Y

Facilit y Bowi e Manufacturing , Inc . Dixie-Pacifi c Manufacturin g Company , Inc .

1 9 Fibe r Pro , Inc . 20 LASC O Bathwar e (Yelm ) LaValle y Constructio n Compan y Shakespear e Electronic s & Fiberglas s Divisio n Ll Shenandoa h Fiberglas s Product s Compan y Forme r Resi n HA P Conten t (% ) Greate r than 35. 0 39. 8 40. 0 46. 0 43. 0 42. 0 45. 0 t o 50. 0 Ne w Resi n HA P

Conten t (% ) 31. 0 an d32. 7 35. 0 35. 3 37. 0 an d30. 0 34. 0 33. 0 35. 0 Impac t o n Productio n Non e Non e Non e "Significant " "Minimal " Non e Non e A s see n i n th e dat ashow n i n Tabl e 6-14 , fiv e o f th e 7 facilitie s reporte dn o impac t on productio n associate dwit h switchin g t o lowe r

HA P resins , on e facility reporte d"minimal " costs , an don e reporte d"significant " costs . Further , informatio n wa s no t availabl e that

woul dallo w u s t o identif y whic h facilitie s woul dincu r productio n problems . Base do n thes e factors , w e assume dthat , i n general , ther e i s n o los s of productio n efficienc y du e switchin g t o lowe r HA P resins . Therefore , ther e i s n o increas e i n productio n cost s occurrin g du e t o alos s o f productio n efficiency . 6.3.1 1 Long-Ter mIncreas e i n Labo r Cos t Anothe r metho do f

identifyin g th e impact s o f switchin g t o lowe r

HA P conten t

resin s woul db e t o loo k

fo r lon g termincrease s i n labo r cost s occurrin g a

t facilitie s wher e th e switc h ha doccurred . Tabl e 6-1 5 present s th e availabl e dat afor tw o facilities . A s see n i n Tabl e 6-15 , both facilitie s reporte dn o long-termincreas e in labo r cost s du e t o switchin g t o lowe r HA P resin .

6-3 1P.4 0

TABL E 6-15 . LONG-TER M INCREAS E IN LABO RCOS T

Facility Bowi e Manufacturing , Inc . ' '1\ LaValle y Constructio n Compan y Forme r Resi n HA P Conten t (% ) Greate r than 35. 0 43. 0 Ne w Resi n HA P

Conten t (% ) 31. 0 an d32. 7 34. 0 Long-TermIncreas e i n Labo r Cos t du e t o Switchin g t o Lower

HA P Resi n ($ ) Non e Non e

6.3.1 2 Equipmen t

Chang e Cost s Anothe r potential cos t

considere dfor

switchin g t o lowe r

HA P resin s an dgel coats woul d b e purchas e o f

ne w spray equipmen t

and/o r laminatin g tool s du e t o change s in we t resi n physical properties . Tabl e 6-1 6 present s th e availabl e informatio n on thi s potentia l cos t fro mtw o facilities . TABL E 6-16 . AVAILABL E EQUIPMEN T CHANG E COST S

Facility 2 4 Bittne r Industries , Inc . Bowi e Manufacturing , Inc . Forme r Resi n HA P Conten t (% ) Greate r than 35. 0 Greate r tha n 35. 0 Ne w Resi n HA P Conten t (% ) 32. 5 31. 0 an d32. 7 Cost s for Ne w Spray Equipmen t

and/o r Laminatin g Tool s Non e Non e A s see n i n Tabl e 6-16 , th e availabl e informatio n show s that thes e tw o facilitie s di dno t incu r any equipmen t

chang e cost s du e switchin g t o lowe r HA P resins . Som e facilitie s state dthe y anticipate dcost s du e t o equipmen t changes . However , thes e ar e onl y anticipate dcosts . Therefore , w e judge di t

reasonabl e t o assum e tha t afacility woul dno t

hav e t o purchas e ne w spray equipmen t

o r laminatin g tool s i n orde r t o switc h fro mhig h HA P resi n an dge l coat s t o lo w HA P resin s an dge l coats . 6.3.1 3 Adoptio n o f

Non-Atomize dResi n Applicatio n Equipmen t W e base dth e cos t

associate dwith switchin g fro matomize dt o non-atomize dresi n applicatio n equipmen t

fo r th e reinforce dplasti c composite s sourc e category o n cos t dat a compile dfor

th e boa t manufacturin g MAC T standard. 2 5 Th e cos t analysi s for

complyin g with th e requirement s fo r

non-atomize dresi n applicatio n ha s four elements : (1 ) th e equipmen t cos t t o 6-3 2P.4 1

switc h fro matomize dresi n spray gun s t o non-atomize dresi n flowcoaters , (2 ) cos t saving s fro m th e reduce dnee dfor

persona l protectiv e equipmen t (PPE ) wit

h non-atomize dresi n applicatio n system, 26,2 ? (3 ) cos t

saving s fro mreduce dresi n consumptio n becaus e o f th e greate r

transfe r efficienc y o f

flowcoater s compare dt o spray guns , an d(4 ) th e cos t saving s fro mth e reduce dus e o f floo r covering s associate dwit h reduce dresi n overspray . W e estimate dth e cos t impac t o f switchin g t o flowcoater s a s th e total differenc e i n annualize dcapita l an dindirec t cost s for resi n spray gun s an dresi n flowcoater s ove r 1 0 year s after

th e complianc e dat e require db y th e rule . Th e predominan t

atomize dspray gun technolog y use din th e reinforce dplasti c composit e facilitie s ar e choppe r

spray guns . Non-atomize dresi n applicatio n technologie s use dinclud e resi n flowcoater s an dpressure-fe dresi n rollers . In th e cos t impac t analysis , w e assum e that reinforce d plasti c composite s manufacturer s wil l switc h fro mchoppe r spray gun s t o choppe r

flowcoaters , becaus e choppe r

flowcoater s ar e mor e similar t o choppe r

spray gun s an dcan appl y choppe d roving , wherea s resi n rollers an dresi n impregnator s cannot . In addition , som e spray gun s ca n b e converte dt o flowcoater s simpl y b y changin g th e resi n spray ti p t o aflowcoate r nozzl e an db y switchin g t o amodifie dchoppe drovin g delivery chute . Th e cos t increas e for

switchin g t o flowcoater s i s offset for man y facilitie s b y decrease d nee dfor , PPE , floo r

coverings , an dreduce dresi n los s fro mhighe r transfe r efficienc y an dreduce d resi n overspra y with flowcoaters . Th e majority o f facilitie s hav e a

n estimate dne t

cos t saving s whe n PPE , floo r

covering , an dresi n cos t

saving s ar e adde dt o th e flowcoate r cos t impacts . Thes e ne t cos t saving s wer e counte da s zer o costs , rathe r than use dt o offset

cos t impact s fo r

othe r regulate dmaterials , suc h a s ge l coats . Tabl e 6-1 7 summarize s th e cos t an dsaving s factor s use d t o estimat e th e cost s o f

switchin g t o flowcoater s for eac h o f th e four elements . Th e followin g paragraph s describ e briefl y th e derivatio n o f th e cos t factor s for

eac h o f th e four elements . Fo r mor e information , pleas e refer t o Referenc e 25 . Equipmen t

Cos t t o Switc h fro mAtomize dSpray Gun s t o Flowcoaters . Althoug h mos t manufacturer s currentl y hav e spray gun s that can b e converte dt o flowcoater s b y changin g th e nozzl e an dchute , onl y th e newe r model s o f

gun s generall y can b e converted . Therefore , w e assume dtha t

th e entir e gu n woul db e replace da t a n averag e cos t

o f $2,22 5 pe r

unit . In addition ,

6-3 3P.4 2

TABL E 6-17 . COS T ANALYSI S ELEMENT S FO RSWITCHIN G T O FLOWCOATER S Cos t Analysi s Elemen

t Equipmen t cos t due t o switc h Persona l protectiv e equipmen

t

Reducedresin consumption

Reduceddisposabl e floo

r covering s Cos t

(Savings ) $1,11 2 pe r spra y gu n switched ($595 ) pe r worke r ($0.60 ) pe r to n o f reducednoncorrosion resistan

t resin usag e ($1.05 ) pe r to n o f reducedcorrosion resistan t resin usag e ($7.78 ) pe r to n o f resin applied Commen t Thi s i s ane

t cos t fo r switching asingl e atomize dspra y gu n t o aflo w coater . Thi s i s ane

t saving s pe

r worker . The analysi s assumedone worke r pe r spra y gun . Thus , thi s facto

r ca n als o b e expressedas a saving s o f $59 5 pe r spra y gu n switched . The saving s factors ar

e applie dt o the amoun t o f non-corrosion resistant/corrosio n resistan t resin n o longe r use ddue t o th e increasedtransfe

r efficienc y o f flo w coater s versu s spra

y guns . Thi s i s calculatedas follows : (1-0.9719 ) * (resin us e prio r t o switc h t o flowcoaters ) Thi s i s ane

t saving s pe

r to n o f resi n applied currentl y appliedwit

h spra y guns .

on e manufacturer , Binks , doe s no t offe r aflowcoater . Facilitie s currentl y usin g Bink s spray gun s woul dals o nee dt o bu y ane w resi n an dcatalys t pump s a t acos t of $4,00 0 pe r

uni t for eac h Bink s spray gu n the y currentl y operate . Thes e facilitie s shoul dstil l b e abl e t o us e thei r existin g cart s an dbooms , s o the y shoul dno t hav e th e full cos t

o f replacin g th e spray gun unit . Sinc e onl y limite dinformatio n was availabl e o n th e manufacture r o f thei r spray gun s a

t reinforce dplasti c facilities , w e assume dtha t al l facilitie s woul dreplac e both th e spray gu n an dth e pum p at acos t o f $6,22 5 t o obtai n aconservativ e cos t estimate . W e estimate dth e cos t

o f switchin g t o flowcoater s fro mspray gun s a s th e ne t annua l differenc e i n cos t

betwee n afacility that

continue s t o us e spray guns , an dth e sam e facility switchin g fro mspray gun s t o flowcoater s before th e spray gun s hav e reache dth e en do f thei r usefu l economi c life . Tha t is , w e estimate dth e cost s fo r th e sam e plan t

unde r tw o scenarios : (1 ) th e plan t

operate s spray gun s i n th e absenc e o f th e rul e an d(2 ) th e sam e plan t mus t switc h t o flowcoater s whil e th e spray gun s are stil l functional . Appendi x 6. 4 provide s mor e detai l o n th e

6-3 4P.4 3

cost s o f flowcoate r

syste man dcomponents , an dprovide s a n exampl e o f

th e derivatio n of

th e ne t annua l cos t

pe r spray gun show n i n Tabl e 6-17 . Cos t Saving s fro mReduce dPersona l Protectiv e Equipment . Worker s wh o operat e flowcoater s can typicall y reduc e th e amoun t o f PP E the y wear , compare dt o spray gun operators , becaus e o f

th e reduce dpresenc e o f

resi n aerosol s an dlowe r styren e level s in th e workplace . Persona l protectiv e equipmen t typical wo mb y spray gu n operator s includ e Tyvek ® pape r suits , respirators , safet

y glasses , gloves , an dhai r an dsho e covers . Th e pape r suit s canno t

b e use dfor mor e than on e day becaus e th e worker s typicall y tap e th e ankle s an dwrist s closed . Worker s usin g non-atomize dresi n application , suc h a s flowcoaters , d o no t typicall y us e th e respirator s an dpape r suit s use db y worker s usin g resi n spray guns . Instead , th e pape r suit s are typicall y replace dwith aplasti c apro n an dn o respirato r i s usuall y needed . Th e othe r type s of PP E wor n (e.g. , safet

y glasses , gloves , hai r

an dsho e covers ) ar e th e sam e for bot h atomize dan dnon atomize dope n mol dresi n applicatio n methods . W e estimate dth e cos t

saving s for

persona l protectiv e equipmen t base do n th e cos t

of th e equipmen t

used . Th e analysi s conservativel y assume s ther e i s on e laminatio n worke r pe r resi n spray gu n o r

flowcoate r

that mus t wear PPE . However , a

t mos t facilities , ther e ar e two , three , o r four worker s for

eac h spray gun o r

flowcoate r

tha t als o wea r PPE. 26,2 7 Th e cos t

saving s fro m PP E a t thos e facilitie s woul db e highe r tha n th e saving s show n i n Tabl e 6-17 . Additiona l saving s may com e throug h reduce dnee dfo r trainin g an dmedica l monitorin g associate dwit h th e us e o f respirators , but

thes e cost s woul db e mor e difficul t t o quantif

y an dar e not

include di n thi s analysis . W e als o assum e i n th e analysi s that onl y hal f o f th e worker s that

switc h fro musin g spray gun s t o flowcoater s wil l reduc e thei r PP E usage. 26,2 7 I

n som e cases , eve n wit

h flowcoaters , a facility canno t

reduc e styren e level s belo w th e leve l requirin g arespirator . Tn othe r cases , a worke r may continu e t o wea

r arespirato r

ou t o f persona l preference . However , th e majority o f worker s a t facilitie s observe db y EP A tha t hav e switche dt o flowcoater s o r othe r type s o f non atomize dresi n equipmen t d o no t wear respirators , s o cos t

saving s woul dagai n b e highe r tha n estimate di n thi s analysis .

6-3 5In estimatin g thes e cos t savings , w e assum e that

th e plan t operate s 5 0 week s pe r

yea r an d tha t eac h worke r

use s tw o apron s pe r

wee k a t acos t o f $ 2 pe r apron , o r $20 0 pe r year . I f hal f th e worker s us e th e sam e PP E a s spray gu n operator s ($l,389/year ) an dhal f us e onl y apron s ($200/year) , th e average cos t pe r worke r usin g flowcoater s i s $79 4 pe r year . Th e differenc e i

n PP E cos t betwee n atomize dan dnon-atomize dresi n worker s i s $59 5 pe r worke r pe r year . Appendi x 6. 5 provide s additiona l detai l o n th e costin g o f thi s element . Reduce dResi n Consumptio n Du e t o Greate r Flowcoate r

Transfe r Efficienc y Compare dt o Spra v Guns . Th e Researc h Triangl e Institut e (RTI ) an dEP A resi n an dgel coat stud y measure d th e transfe r

efficienc y o f

air-assiste dairles s resi n spray gun s an dflowcoaters. 2 6 Base do n th e result s o f thi s study , afacility switchin g t o flowcoater s fro mspray gun s wil l onl y nee d97.1 9 percen t o f th e resi n the y consume dwith spray gun s t o buil dth e sam e part s becaus e o f reduce d resi n los t a s overspray . T o estimat e cos t saving s fro mreduce dresi n usage , w e multiplie dth e amoun t o f resi n applie db y spray gun s b y 0.971 9 t o determin e th e amoun t o f resi n neede dwit

h flowcoaters . W e the n multiplie dth e differenc e i n resi n amount s neede dwit h spray gun s an d flowcoater s b y $0.6 0 pe r poun dfor

no n corrosio n resistan t

resin s an d$1.0 5 for

corrosio n resistan t resin s t o determin e th e resi n cos t saving s fro mreduce dresi n overspray . W e selecte dth e cost s o f $0.6 0 an d$1.0 5 pe r

poun dof resi n becaus e the y wer e th e lowes t resi n lis t price s availabl e fo r

non-corrosio n resistan t

an dcorrosio n resistan t

resins , respectively . I

f mor e expensiv e resin s ar e used , cos t saving s coul db e higher . Cos t Saving s fro mReduce dDisposabl e Floo r Coverings . Reinforce dplasti c composite s manufacturer s typicall y cove r th e floor s o f

th e laminatio n area s wit

h heav y kraf

t pape r o r cardboar dt o catc h resi n overspray . Th e floo r covering s ar e replace do n aperiodi c basi s t o preven t resi n build-u p o n th e floo r of th e laminatio n area . Becaus e ther e i s les s overspra y fro m flowcoater s tha n fro mspray guns , resi n buildu p o n th e floo r covering i s slowe r

an dth e floo r covering s d o not

nee dt o b e replace da s frequently . Base do n dat agenerate dfor th e boa t manufacturin g MACT , w e derive dauni t saving s o f

$7.7 8 pe r

to n o f resi n applied . W e estimate d th e floo r coverin g cos t

saving s for

reinforce dplasti c composite s facilitie s tha t switc h fro mspray gun s t o flowcoate r

b y multiplyin g th e $7.7 8 pe r to n cos t saving s b y th e ton s o f

resi n currentl y

6-3 6P.4 5

applie dwith spray gun s that wil l b e applie dwit

h flowcoater s after

complianc e wit

h th e MAC T standard . 6.3.1 4 Uncoverin g onl y on e Charg e pe r Compression/Injectio n Moldin g Machin e Cos t dat aon uncoverin g onl y on e charg e a s oppose dt o several charge s pe r compression/ injectio n moldin g machin e for eac h mol dcycl e wer e not available . W e believ e it i s reasonabl e t o assum e tha t

i t doe s not tak e th e operato r

o f th e compression/injectio n moldin g machin e an y longe r t o onl y uncove r

on e charg e pe r

mol dcycl e than t o uncove r several charge s pe r

mol dcycl e a t onc e for th e productio n o f

th e sam e amoun t

o f tota l product . Further , uncoverin g mor e tha n on e charg e a

t atim e pe r

moldin g cycl e may hav e anegativ e impac t on th e quality o f

th e SM C o r BM C charge , becaus e th e uncovere dcharge s los e monome r mor e quickl y than covere dcharges . Thi s monome r

los s coul dadversel y impac t th e polymerizatio n reaction. 2 8 Thus , requirin g onl y on e charg e a

t atim e t o b e uncovere dma y in fac t provid e benefits . Give n thes e considerations , w e conclude dthat

uncovering onl y on e charg e a s oppose dt o severa l charge s pe r compression/ injectio n moldin g machin e for eac h mol dcycl e i s no t

expecte dt o resul t

in any costs . 6.3.1 5 We t

Are aEnclosure s wit

h Resi n Dri p Collectio n Svste mfor Pultrusio n Operation s Th e basi c approac h w e use dt o cos t we t are aenclosure s an dresi n dri p collectio n system s fo r pultrusio n operation s wa s t o determin e th e numbe r o f pultrusio n line s a

t eac h facilit

y wit h pultrusio n operation s an dmultipl y tha t numbe r o f line s b y cos t

factor s for

capita l cost , annualize dcapita l cost , an dannual operatin g costs . I n calculatin g cost s associate dwit h we t are aenclosure s an dresi n dri p collectio n systems , w e firs t determine dth e numbe r

o f pultrusio n line s a

t eac h individua l facility . Mos t o f th e pultrusio n facilitite s (2 4 ou t of 31 ) indicate dth e numbe r o f pultrusio n line s a

t th e facilities . Fo r th e othe r seve n facilities , w e estimate dth e numbe r o f pultrusio n line s b y usin g th e reporte dresi n usag e for th e pultrusio n operation s at th e facility an dth e pultrusio n lin e t o pultrude dresi n ratio calculate dfro mfacilitie s for whic h dat aar e available . W e assume dthat

facilitie s no t

alread y determine dt o b e i n complianc e woul dinstal l on e we t are aenclosur e an don e resi n dri p collectio n syste mpe r pultrusio n lin e a

t th e facility . Thi s 6-3 7P.4 6

assumptio n wil l mak e th e cos t estimate s mor e conservativ e (i.e. , overestimat e th e cost ) becaus e facilitie s tha t

utiliz e direc t

di e injectio n withou t

resi n pre-we t

wil l no t hav e t o instal l we t

are a enclosures . On e facility provide dcos t informatio n on th e design , installation , an doperatio n o f we t are aenclosures. 2 9 Tabl e 6-1 8 summarize s thi s information . TABL E 6-18 . AVAILABL E COS T INFORMATIO N FO RWE T ARE A ENCLOSURE S a

Complianc e Conditio n Design , Installation , andOperatio n o f We t Are a Design , Installation , andOperatio n o f We t Are a Siz e o

f Wet Are aEnclosure Larg e Smal l Tota

l Capita l Cos t $765.1 5 per

yea r $396.5 2 pe

r yea r Annual Operatio n andMaintenanc e $754.8 1 per

yea r $436.5 5 per

yea r

aCos t figure s ar e i n 199 8 dollar s an

dar e fo r large an dsmal l we t are aenclosure s installedo

n pultrusion line s a

t th e Glasforms , Inc . facilit

y i n Birmingham , Alabama . Whil e thi s facility di dno t provid e any cos t

informatio n o n th e resi n dri p collectio n system s installe do n pultrusio n lines , i t di dprovid e adescriptio n o f th e resi n dri p collectio n system . Th e resi n dri p collectio n syste mpresen t a t Glasform s consist s of

aplasti c pip e (modifie dwith acut-out) , afunnel , an dacontaine r (shape dlike ableac h jug ) for collectin g resin . W e calculate dtota l capita l costs , annualize dcapita l costs , an dannual operatin g cost s fo r we t are aenclosures. 3 0 A s see n i n Tabl e 6-18 , capita l cost s ar e provide dfor "large " an d"small " we t are aenclosures . However , ther e i s insufficien t informatio n availabl e o n th e siz e o f th e pultrusio n line s presen t

at facilitie s t o determin e whethe r th e pultrusio n lin e at

th e facilitie s wil l requir e "small " o r

"large " we t

are aenclosures . W e use dth e capita l cos t for th e "large " we t

are a enclosur e (i.e. , $76 5 pe r

we t are aenclosure ) for

al l pultrusio n line s requirin g we t are aenclosures . Thi s decisio n i s likel y t o b e conservativ e i n that som e facilitie s wil l b e abl e t o instal l th e les s expensiv e "small " we t

are aenclosure s t o comply . W e calculate dth e tota l capita l cos t fo r eac h facility fo r

th e installatio n o f

we t are aenclosure s b y multiplyin g th e numbe r o f pultrusio n line s presen t a t th e facility b y $76 5 pe r

line . I n calculatin g th e annualize dcapital cos t o f th e we t are aenclosure , w e use da n interes t rat e o f 7 percen t an da n annualizatio n perio do f 3 0 years . Thi s yield s a

n annualizatio n capita l 6-3 8P.4 7

cos t facto r o f 0.0806 . Th e OAQP S cos t manua l doe s no t

specif y acapita l cos t

annualizatio n perio dfo r we t are aenclosure s installe do n pultrusio n lines . W e assume dth e annualizatio n perio dfo r PTE s i s appropriat e du e t o th e similarity i n constructio n materials . W e calculate dth e annualize dcapita l cos t

for eac h facility for

we t are aenclosure s b y multiplyin g th e numbe r o f pultrusio n line s presen t

a t th e facility b y $6 2 pe r

lin e ($76 5 x 0.0806) . Finally , consisten t

wit h th e assumptio n tha t

al l pultrusio n line s woul dinstal l th e "larger " we t are aenclosures , w e use dth e annua l operatin g cos t show n in Tabl e 6-1 8 for

th e larg e we t

are a enclosur e t o estimat e annua l operatin g cost s for al l we t are aenclosure s installe do n pultrusio n lines . Thus , w e calculate dth e annua l operatin g an dmaintenanc e cos t fo r eac h facility fo r

we t are aenclosure s b y multiplyin g th e numbe r o f pultrusio n line s presen t

a t th e facility b y th e annua l operatio n an dmaintenanc e cos t o f $75 5 pe r line . Du e t o th e relativel y simpl e material s an ddesig n ofthi s resi n dri p collectio n syste ma t Glasforms , w e assume dth e cos t associate dwit

h implementin g th e resi n dri p collectio n syste mi s minima l compare dt o th e design , installation , an doperatio n of th e we t are aenclosure . Also , resi n collecte di n th e dri p collectio n syste mmay b e recycle db y th e facility , thereb y reducin g th e facility' s ra w materia l costs . Therefore , w e assume dth e resi n dri p collectio n syste mt o hav e n o cost . 6.3.1 6 Close do r

Covere dDocto r

Boxes . Folde dEdges , an dLo w Stvren e Permeabl e Fil mfo r SM C Operation s Cos t dat ao n closin g o r

coverin g docto r

boxes , foldin g edges , an dusin g lo w styren e permeabl e fil m(e.g. , Nylon ) for SM C productio n wer e no t available . W e believ e that failur e t o clos e o r cove r docto r boxes , failur e t o fol dedges , an dfailure t o us e lo w stryren e permeabl e fil m hav e anegativ e impac t

o n th e qualit y o f

th e SMC , becaus e mor e monome r i s los t i f thes e action s ar e no t take n an dprope r

polymerizatio n reactio n ma y b e adversel y affecte db y th e los t monomer . Conversely , th e us e o f

thes e thre e technique s ma y resul t i n les s raw material s bein g use dan d improve dpolymerizatio n reactions . In th e absenc e o f bein g abl e t o quantif

y thes e relativ e cost s an dsavings , w e assume dthat th e ne t direc t annual cos t

incurre db y facilitie s du e t o closin g o r coverin g docto r

boxes , foldin g edges , an dusin g lo w styren e permeabl e fil mi s zero . 6-3 9P.4 8

6.3.1 7 Non-HA P Cleanin g Material s Base do n 199 3 industry screenin g surveys , th e mos t prevalen t HAP-containin g cleane r use din thi s industr y i s methylen e chlorid e an dacommonl y use dno n HAP-containin g cleane r i s acetone . Som e facilitie s als o us e methy l ethy l ketone , whic h i s aHAP-containin g cleaner . W e collecte dcos t

dat ao n th e mos t

commonl y use dHAP

- an dno n HAP-containin g cleanin g solvents . Tabl e 6-1 9 present s th e availabl e cos t dat afo r acetone , methylen e chloride , an dmethy l ethy l ketone .

TABL E 6-19 . AVAILABL E COS T INFORMATIO N FO RHAP

- AN D NO N HAP

- CONTAININ G CLEANIN G SOLVENT S

Solven t Supplie r Worth Chemica l Corporatio n Worth Chemica l Corporatio n Fiberglas s Coating s Inc . Cleane r Aceton e Methylen e Chlorid e Methy l Ethy l Keton e HA P Conten t (% ) b y weigh t 0 10 0 10 0 Sal e Pric e

( $ /gal ) $2.7 3 $7.2 9 $5.0 0 Sal e Pric e Shipmen t

Siz e Basi s 5 5 Gallo n Dru m 5 5 Gallo n Dru m 5 5 Gallo n Dru m

Base do n th e dat acollected , ther e ar e potential raw material s saving s o f $2.2 7 pe r

gallo n whe n switchin g fro mmethy l ethy l keton e t o aceton e an do f $4.5 6 pe r

gallo n whe n switchin g fro mmethylen e chlorid e t o acetone . Therefore , w e assume dthat al l facilitie s currentl y usin g methylen e chlorid e woul dswitc h t o acetone . Th e cos t saving s fro mswitchin g coul db e offset b y th e increas e in tim e and/o r physical effor t require db y th e us e o f

ano n HAP-containin g cleane r t o remov e th e cure do r

partiall y cure d resins . N o dat aar e availabl e t o quantif y this . Becaus e cleanin g materia l cost s decrease , w e assigne dane t

cos t o f zer o for switchin g fro mHAP

- t o no n HAP-containin g cleaners .

6.3.1 8 Closed/Covere dMixin g wit h N o Visible Gap s i n Mixe r Cove r W e calculate dth e cost s associate dwit h closin g o r

covering mixer s suc h that ther e ar e n o visibl e gaps i n th e mixe r

cove r b y determinin g (1 ) th e capita l cos t an dannual cos t

for installin g an doperatin g mixe r

cover s wit

h n o visibl e gaps , (2 ) th e degre e t o whic h mixin g bein g conducte d

6-4 0P.4 9

a t eac h facility i s alread y i n complianc e wit h th e propose drequirement , an d(3 ) th e numbe r o f mixer s a t eac h facility . Tabl e 6-2 0 summarize s th e availabl e cos t informatio n associate dwit h th e adoptio n of closed/covere dmixin g practice s wher e ther e are n o visibl e gap s i n th e mixe r cove r an dn o activ e ventilatio n o f

th e mixer. 29 ' 3 3 TABL E 6-20 . AVAILABL E COS T DAT A FO RCLOSED/COVERE D

MIXIN G WIT H N O VISIBL E GAP S Component s o f

Mixe r Cove r Cos t Material s t o Construc t

Mixe r Cove r Labo r t o Construc t

Mixe r Cove r Tota l Mixe r

Cove r Cos t Componen t Cos t $50 $4 5 $9 5 Frequenc y o f

Semiannua l Semiannua l Semiannua l Annual Cos t $10 0 $9 0 $19 0
Th e informatio n i n Tabl e 6-2 0 i s base do n mixin g operation s conducte da t th e Glasforms , Inc. , facility locate di n Birmingham , Alabama . At th e Glasform s facility , mixin g i s conducte din 5 5 gallo n drums . Th e 5 5 gallo n dru mi s covere db y aplywoo ddis k larg e enoug h t o cove r

th e entir e dru mtop . Th e front thir dof th e cove r i s hinge dt o allo w fo r

th e additio n of

variou s material s durin g o r

prio r t o th e mixin g process . Th e mixe r cove r ha s abristle-covere dopenin g tha t allow s th e cove r

t o b e place daroun dth e mixe r shaft . Th e bristle-covere dopenin g allow s for eas y replacemen t

an dremova l o f

th e mixe r

cove r durin g mixin g operation s whil e leavin g n o visibl e gap betwee n th e mixin g shaf t an dth e mixe r

cover . Th e mixe r

cover s ar e manufacture d"in-house " b y Glasforms . Th e labo r cost s an dth e ra w materia l cost s ar e approximatel y $4 5 pe r mixe r cove r an d$5 0 pe r

mixe r cover , respectively . Durin g th e mixin g operation , th e mixe r cove r come s i n contac t

wit h th e promote dresi n resultin g i n th e gradua l buildu p of

a n uneven , cure dresi n layer o n th e inside o f

th e cover . Afte

r approximatel y si x month s thi s layer increase s in siz e t o th e poin t wher e th e mixe r

cove r mus t b e replace di n orde r

fo r prope r mixin g t o occur . Base do n th e combine dlabo r an dmaterial cos t

o f $9 5 pe r mixe r cove r an dth e semi-annua l frequenc y o f replacement , w e estimate dth e annua l cos t pe r mixe r t o b e $19 0 for

a5 5 gallo n mixin g vessel .

6-4 1P.5 0

W e identifie dinformatio n o n th e wa y mixin g wa s bein g performe drelativ e t o complianc e with th e propose dstandar dfor eac h facility , becaus e th e annual cos t pe r facility i s partiall y dependen t

o n th e existin g degre e o f complianc e wit

h th e propose dstandard . Tabl e 6-2 1 summarize s th e cos t

assigne dpe r

mixe r base don afacility' s existin g leve l o f compliance . TABL E 6-21 . PE RMIXE RCOMPLIANC E COS T ASSIGNE D T O A FACILIT Y

BASE D O N EXISTIN G LEVE L O FCOMPLIANC E

Curren t Typ e o f Mixin g (Open/Closed ) Ope n Ope n Ope n Close d Close d Close d Close d Close d Close d Mixe r

Cove r Installe do n Mixe r N o N o N o Ye s Ye s Ye s Ye s Ye s Ye s Visibl e Gap s

Presen t i n Mixe r Cove r N/ A N/A N/A Ye s Ye s Ye s N o N o N o Nitroge n

Blanketin g Use dw / Mixe r N/ A N/ A N/ A N o N o N o N o N o Ye s Mixe r

Activel y Vente dt o Atmospher e N o Ye s N o N o Ye s N o N o Ye s N o Mixe r

Activel y Vente dt o Contro l Devic e N o N o Ye s N o N o Ye s N o N o Ye s Annua l Cos t

pe r Mixe r ( % o f Max ) 100 % 100 % 0 % 50 % 50 % 0 % 0 % 0 % 0 % Annua l Cos t

pe r Mixe r ($/yr ) $19 0 $19 0 $ 0 $9 5 $9 5 $ 0 $ 0 $ 0 $ 0

Th e annua l cos t

pe r facility i s als o dependan t on th e numbe r

o f mixer s presen t

at th e facility . Informatio n o f

th e numbe r

o f mixer s wa s availabl e for som e facilities . Fo r

th e remainde r

o f th e facilities , w e estimate dth e numbe r o f mixers . Th e numbe r

o f mixer s a t a facility i s dependen t

o n anumbe r

o f factors , includin g th e siz e o f th e mixin g vessel s used , th e typ e o f material s t o b e mixed , th e lengt h o f tim e require dt o completel y mi x th e material s use db y th e facility , an dth e capabilit y o f th e facility t o us e mixe dmaterial s du e t o productio n capacit y an dproduc t

demand . Becaus e mos t

o f thes e factor s wer e unknown , w e base dth e numbe r o f mixer s o n th e annua l usag e o f material s that

ar e likel y t o requir e mixin g o r agitatio n (i.e. , resins , fillers , an dge l coats) . T o estimat e th e numbe r

o f mixer s a t afacility , w e use dth e rati o o f mixer s t o th e approximat e usag e o f

thes e material s at

Glasforms ' Birmingha mfacility . Thi s rati o i s on e mixe r 6-4 2P.5 1

for every 40 0 ton s o f

materia l mixe dpe r

year . W e assume dthat

facilitie s usin g les s than 40 0 ton s pe r year o f material s hav e onl y on e mixer . W e rounde dth e numbe r o f mixer s pe r

facilit y up t o th e neares t

whol e number . Fo r

example , afacility that

use d125 0 ton s pe r

yea r o f material potentiall y requirin g mixin g o r agitatio n wa s estimate dt o hav e 4 mixer s (1250/40 0 = 3.125 ; rounde dup t o th e neares t whol e numbe r

= 4) . Onc e th e numbe r

o f mixer s wer e estimate do r identifie dan dth e degre e o f complianc e with th e propose dstandar dwa s identified , w e estimate dth e total annual cos t o f complyin g wit

h th e requirement(s ) fo r

mixin g vessel s b y multiplyin g th e estimate do r actua l numbe r

o f mixer s presen t a t th e facility b y th e applicabl e annual cos t pe r mixe r identifie di n Tabl e 6-21 . 6.3.1 9 We t

Are aEnclosure s for

Resi n We t

Ou t Area s a t Continuou s Laminatio n an dContinuou s Castin g Operation s We t ou t are aenclosure s ar e enclosure s constructe daroun dth e we t ou t are ao f a continuou s laminatio n o r castin g lin e that

captur e emission s fro mth e we t ou t area . W e base dth e costin g for

thes e enclosure s on we t

ou t are aenclosure s foun da

t th e Kemlite-Sequenti afacility i n Gran dJunction , Tennesse e (se e Appendi x 6.6 ) Cost s i n 199 2 dollar s for th e four we t are a enclosure s a

t thi s facility wer e reporte da s follows : Wid e Line : $23,00 0 Narro w Line : $ 8,30 0 Narro w Line : $12,00 0 Narro w Line : $14,00 0 W e escalate dthes e cost s t o 1998 $ usin g th e C E equipmen t cos t indice s o f

393. 7 for May 199 2 an d433. 0 fo r

Marc h 1998 . W e use dthes e cost s t o estimat e th e cost s for buildin g we t

ou t are aenclosure s at

th e othe r facilitie s b y relatin g th e estimate dvolume s o f th e we t ou t are aenclosure s at

th e Kemlite

Sequenti afacility t o th e estimate dvolum e o f th e we t ou t are aenclosure s a

t th e othe r facilities . W e estimate dth e volume s o f th e enclosure s usin g availabl e dat ao n th e lengt h an dwidt

h o f eac h continuou s laminatio n an dcastin g line . Fo r som e lines , w e ha dt o estimat e thes e dimensions . W e use da

n enclosur e heigh t

of three-fee t for eac h line . W e the n calculate dth e volum e o f eac h 6-4 3P.5 2

enclosure . A t

th e Kemlite-Sequenti afacility , w e estimate deac h enclosur e on th e narro w line s t o hav e avolum e o f

487. 5 cubi c feet

an dth e enclosur e o n th e wid e lin e t o hav e avolum e o f 1,11 6 cubi c feet . W e the n calculate dth e capita l cost s (1998$ ) o f th e we t are aenclosure s usin g th e followin g formulas : Fo r narro w lines : (volum e o f

we t ou t are aenclosure/487.5) 0 ' 6 x $11,43 3 x (433.0/393.7 ) where : $11,43 3 = th e averag e cos t o f th e thre e narro w lin e enclosure s Fo r wid e lines : (volum e of

we t ou t are aenclosure/1,116) 0 ' 6 x $23,00 0 x (433.0/393.7 ) W e estimate dannualize dcapita l cost s o f th e we t ou t are aenclosure s usin g alif e expectanc y o f

3 0 year s an da

n interes t rat e o f 7 percent . W e selecte dalif e o f 3 0 year s base do n th e lif e expectanc y o f

PTE s (se e discussio n belo w o n permanen t total enclosures) . Th e resultin g annua l capitalizatio n facto r i s 0.0806 . W e judge doperatin g cost s t o consist solel y o f maintenanc e costs . W e estimate d

• maintenanc e cost s for

eac h enclosur e a

t afacility usin g 2 hour s pe r week , 5 2 week s pe r

year , an d $45.0 4 pe r

hou r labo r rat e (se e Sectio n 6.3.24) . Tabl e 6-2 2 summarize s th e estimate dvolumes , capita l costs , operatin g costs , an d annualize dcost s for

we t ou t are aenclosures . W e di dnot cos t we t ou t are aenclosure s for Enduro , Ft . Worth an dKran e Kemlite , Jonesboro , becaus e thes e facilitie s hav e enclosure s sufficien t t o mee t both regulatory alternative s fo r existin g source s an dt o mee t th e MAC T floo r an dth e regulatory alternativ e for ne w sources . Fo r

Intemationa l Paper , Odenton , additiona l contro l o f th e shee t lin e onl y i s necessary , but aPT E i s mor e likel y t o b e constructe dthan t o furthe r enclos e th e we t

ou t are awit h awe t ou t are aenclosure . Thus , w e di dno t cos t awe t ou t are aenclosur e fo r

th e shee t lin e a t Internationa l Paper' s Odento n facility . 6.3.2 0 Permanen t

Tota l Enclosure s (PTEs ) 6-4 4P.5 3

W e coste dPTE s for

continuou s laminatio n an dcastin g operations , ope n moldin g operation s (includin g manual resi n application , mechanica l resi n application , filamen t winding , an dge l coa t

application) , pultrusio n operations , SM C manufacturin g operations , an dmixin g operations . In general , w e coste dPTE s for thes e operation s b y identifyin g th e numbe r an dsiz e o f PTE s a t eac h facility an dthe n applyin g costin g algorithm s t o eac h PTE . Th e costin g algorithm s use dar e foun di n Chapte r 1 1 o f th e OAQP S Cos t

Manua l (se e Appendi x 6.7) . Tabl e 6-2 3 summarize s th e assumption s an dcost s use di n estimatin g th e cost s o f PTEs . In costin g PTEs , w e assume dthat th e typ e o f

materia l selecte dt o construc t eac h PT E wa s identica l regardles s o f

th e proces s generatin g th e emission s capture db y th e PTE . Thes e material s ar e identifie di n Tabl e 6-23 . In addition , w e assume dtha t eac h PT E woul dhav e th e sam e type s o f

safet y equipmen t

an dinstrumentation . Th e cost s show n i n Tabl e 6-2 3 ar e i n 1997$ . W e escalate dthes e cost s t o 1998 $ usin g th e Chemica l Engineerin g equipmen t cos t indice s for

Jul y 1997 $ (434.2 ) an dth e Jul y 1998 $ (434.8) , whic h yield s a

n escalatio n facto r

o f 1.006 . W e determine dth e numbe r an dsiz e o f

PTE s a t eac h facility fo r

th e reinforce dplasti c composite s operation s identifie dabove . Th e tota l numbe r o f PTE s coste dfor

any on e facility wa s dependen t

o n th e numbe r

o f thes e operation s presen t

at th e facility . Fo r continuou s laminatio n an dcastin g facilities , w e assume deac h lin e ha s it s ow n PTE . Thus , fo r afacility with thre e continuou s laminatio n lines , thre e PTE s wer e assume dt o b e constructed . In general , w e size deac h continuou s lamination/castin g PT E usin g th e lengt h ofth e we t ou t area , addin g atota l o f

1 2 feet t o th e width o f

th e we t ou t area , an daheigh t

o f 8 feet . Fo r th e othe r operations , th e siz e an ddimension s o f eac h PT E i s dependen t

o n th e number , size , an dshap e o f th e equipmen t

that mus t b e use dwithi n th e PTE , an dth e amoun t of

6-4 5TABL E 6-22 . DIMENSION S AN D COST S FO RWE T OU T ARE A ENCLOSURE S FO RCONTINUOU S LAMINATIO N AN D CASTIN G OPERATION S
Compan y Locatio n Lin e Identifie r Widt h (ft ) Lengt

h (ft ) Heigh t

a (ft ) Estimate d Volum e (ft 3 ) May 1992 $ c

Capita l Cost s ($ ) 1998 $

Capita l Cost s ($ ) Facilitie s tha talread y hav e enclosure s sufficien tfo rcomplyin g wit h MAC T floors an d regulator y alternatives : Krane-Kemlit e Krane-Kemlit e Endur o Internationa l Pape r Internationa l Pape r Jonesbor o Jonesbor o Ft . Wort h Odento n Odento n 5 w

4 n 1 Shee t Particl e 9.3 3

5 1 7 3.3 3 2 9 0

9 0 5 2 1 0 1 0 8

8 8 3 3 6717.6 0 3600.0 0 7072.0 0 99.9 0 60.0 0 n a

n a n a n a n a n a

n a n a n a n a Facilitie s assume d t o requir e installatio n o f we tou tare aenclosure s t o compl y wit h MAC T floors o rregulator y alternatives : Glastee l Kalwal l Krane-Kemlit e Krane-Kemlit e Krane-Kemlit e Kemlite-Sequenti a Kemlite-Sequenti a Kemlite-Sequenti a Kemlite-Sequenti a Lasc o Pane l Product s Lasc o Pane l Product s Lasc o Pane l Product s Resolit e W.H . Brad y Colliervill e Bo w Joile t Joile t Joile t Gran dJunctio n Gran dJunctio n Gran dJunctio n Gran dJunctio n Florenc e Florenc e Florenc e Zelienopl e Milwauke e l n l n LP-3 n LP-6 n LP-7 n l w 2 n 3 n 4 n l w 2 n 3 n l n l n 4

5 9 9 9 9. 3 5 5 5 9. 3 4 4 6.6 7 4 6 5 19. 1 1 3 1 3 1 3 4 0 32. 5 32. 5 32. 5 4 3 3 4 3 4 2 8 4 5 3

3 3 3 3 3 3 3 3 3 3 3 3 3 780.0 0 286.2 5 351.0 0 351.0 0 351.0 0 1116.0 0 487.5 0 487.5 0 487.5 0 1199.7 0 408.0 0 408.0 0 560.0 0 540.0 0 15,15 8

8,30 7 9,38 8 9,38 8 9,38 8 23,00 0 8,30 0 12,00 0 14,00 0 24,02 0 10,27 5 10,27 5 12,42 5 12,15 7 16,67 1

9,13 6 10,32 5 10,32 5 10,32 5 25,29 6 9,12 9 13,19 8 15,39 8 26,41 8 11,30 0 11,30 0 13,66 5 13,37 0 1998$ e Annualize d Capita l Cost s ($/yr )

n a n a n a n a n a 1,344 73 6 83 2 83 2 83 2 2,03 9 73 6 1,064 1,24 1 2,12 9 91 1 91 1 1,10 1 1,07 8 1998 $ f Annua l Operatin g Cost s ($/yr )

n a n a n a n a n a 4,68 4 4,68 4 4,68 4 4,68 4 4,68 4 4,68 4 4,68 4 4,68 4 4,68 4 4,68 4 4,68 4 4,68 4 4,68 4 4,68 4 6-4 6Footnote s t o Tabl e 6-2 2

Heigh t o f enclosur e assume dt o be 3 fee t fo r al l line s unles s facility-specific datawer e provided . Th

e heigh t ofth e enclosure s fo

r Krane-Kemlite , Jonesboro , an dEndur o reflect th e heigh t o f existing permanen

t (total ) enclosures . Widt h o f line (no t product width) x lengt

h o f line (fro mresi n laydow n to ove n entry ) x heigh

t o f enclosure . Kemlite-Sequentia : Fro

mOctobe r 27 , 1998 , telephone conversation wit h Mr. Car l Novak. Lasco , l w line : Base do n lin e 1 w a t Kemlite-Sequenti aratioin g volume s t o the 0. 6 powe r time s $23,000 . Al

l othe r lines : Base

do n the averag e cos t

ofth e three othe

r Kemlite-Sequenti acost s (=$11,433 ) ratioing volume s t o the 0. 6 powe

r time s $11,433 . dEscalatedMa

y 1992$ t o 1998 $ using C

E equipmen

t cos t inde x of 393. 7 fo r Ma y 199 2 an d433. 0 fo r Marc h 1998 . Base do n 7 percen t interes t rat e an d3 0 yea r life , whic h yield s afacto

r o f 0.0806 . f Base do n 2 hour s pe

r wee k pe r line , 5 2 week

s pe r year , an dalabo r rat e o f $45.04 pe r hour .

6-4 7TABL E 6-23 . COS T INFORMATIO N FO RSPECIH C EQUIPMEN T AN D STRUCTURA L COMPONENT S USE D I N CONSTRUCTIO N O FPERMANEN T TOTA L ENCLOSURE S Equipmen t

o r Componen t

Typ e Wall s Door s Window s Ceilin g Louver s LF L Detector s Safety Equipmen t Lightin g Instrumentatio n Engineerin g Contractor s Complianc e Tes t Descriptio n o f Specifi c Equipmen t Use di n aPT E o r

Structura l Comnonen t

o f aPT E Modula r Pane l Mandoor , Hollo w Steel , 3 ' x 7 ' Window , Lexan , 4 ' x 3 ' Dro p Ceiling , Shee t

Meta l

Catalyti c Bea d Alar mBel l Alar mSigna l Fluorescent , 2'x4' , fou r

4 0 watt Differentia l Pressur e Monito r Unit s sqf t Eac h Eac h sqf t

Eac h Eac h Eac h Eac h Eac h Eac h Eac h Eac h Material s

(1997$ ) $9.7 6 $575.0 0 $85.0 0 $1.6 9

• $3,325.0 0 $70.0 0 $50.0 0 $65.0 0 $487.0 0 Installatio n

(1997$ ) $7.9 7 $415.0 0 $125.0 0 $16.5 1

$100.0 0 $60.0 0 $30.0 0 $51.0 0 $200.0 0 Costin g Assumption s an dConsideration s

Modula r pane l fo r al l PTEs ; use destimate d squar e footag e fo r

eac h PTE . 2 mandoors , hollo w stee l fo r al l PTEs ; shoul d requir e onl y personne l acces s t o th e interior . Lexa n windows , 4'x3' ; use don e windo w roughl y ever y 7. 5 fee t

o f PT E length with windows o n both sides . Dro p ceiling , shee t

meta l fo r

al l PTEs ; use d estimate dsquar e footag e fo r eac h PTE . None . Assume dtha t

natura l draf

t openin g woul dprovid e al l ai r

throug h th e enclosure . Velocitie s throug h th e NDO s rang e fro m20 0 t o 40 0 fee t

pe r minute . 2 catalyti c bea dmonitor s pe r PTE . On e alarmbel l an don e alar msigna l pe r PTE . No t required . No t required . Fluorescent , 2'x4' , fou r

4 0 watt ; on e fixtur e pe r 1 0 linear fee t o f we t ou t area . On e differentia l pressur e monitor , on e surg e dampener , an don e alar mpe r PT E $15,00 0 pe r

PTE . $2,500.0 0 pe r

PTE . Applie s onl y t o PT E certification .

6-4 8P.5 7

material s tha t

wil l b e processe dusin g thi s equipment . Tabl e 6-2 4 present s th e assumption s use d t o determin e th e numbe r

an dsiz e o f

PTE s a t eac h facility usin g thes e othe r operations . 6.3.2 1 Captur e Device s for Centrifugal Castin g Operation s W e calculate dcapita l an dannualize dcapita l cost s for captur e device s for

centrifugal castin g operation s b y (1 ) determinin g th e numbe r of centrifugal castin g machine s a t afacility , (2"

) determinin g th e cos t

of th e captur e devic e pe r

machine , an d(3 ) multiplyin g th e numbe r of centrifuga l castin g machine s b y th e cos t pe r machine . W e determine dth e tota l numbe r o f centrifugal castin g machine s a t afacilit y by usin g th e numbe r reporte di n th e industry screenin g survey . Fo r facilitie s that

di dno t report th e numbe r

of centrifuga l castin g machines , w e divide dth e resi n use di n centrifugal castin g b y th e averag e resi n usag e pe r machin e ratio of

42.6 7 t o calculat e th e numbe r o f machines . Thi s ratio of 42.6 7 wa s baseddat afro mfacilitie s i n th e screenin g survey . W e collecte dcos t

informatio n for

captur e device s fo r

centrifugal castin g machine s fro m Fibercas t Company , whic h installe dexhaus t cover s on th e en do f

eac h o f thei r 1 6 castin g machines . Th e cos t

for exhaus t cover s fo r

thei r 1 6 centrifugal castin g machine s wa s $22,71 0 i n 1992 . W e escalate dth e 1992 $ capita l cost s t o 1998 $ b y usin g th e Chemica l Engineerin g magazin e averag e C E cos t inde x o f 389. 5 for 199 8 divide db y th e averag e C E cos t inde x of 358. 2 fo r 1992 , whic h yield s a

n escalatio n facto r

o f 1.087 . Th e 1998 $ capita l cos t for th e 1 6 machine s i s thu s estimate dt o b e $24,686 . W e the n calculate dth e capita l cos t for exhaus t cover s pe r

machin e b y dividin g th e total cos t o f $24,68 6 b y th e numbe r

of castin g machine s ($24,686/1 6 = $1,543) . W e multiplie dthi s valu e b y th e numbe r

o f castin g machine s a

t afacility t o estimat e th e tota l capita l cos t for installin g captur e device s o n th e centrifugal castin g machines . Finally , w e calculate dth e annualize dcapita l cost s b y multiplyin g th e total capita l cost s b y acapita l recover y cos t

facto r o f 0.0806 , whic h i s base do n a7 percen t interes t rat e an da3 0 yea

r tim e period .

6-4 9TABL E 6-24 . FACILIT Y CRITERI A USE D T O DETERMIN E TH E NUMBE RAN D SIZ E O FPERMANEN T TOTA L ENCLOSURE S FO ROPERATION S OTHE RTHA N CONTINUOU S LAMINATIO N AN D CASTIN G Operatio n Ope n Moldin g Manua l Resi n Applicatio n

-C R -No n C R -Toolin g

Mechanica l Resi n Applicatio n b -C R -No n C R(Unfilled ) -No n C R(Filled ) -Toolin g Filamen t Windin g (FW ) b -C R -Non-C R Ge l Coa t Applicatio n D c -Pigmente dProductio n -Clear Productio n -Toolin g Numbe r ofPTE' s 1

1

1 1 Dimensio n Selectio n Criteri aa Resi n Usag e = 0 to < 3 tp y Resi n Usag e = 3 to < 5 tp y Resi n Usag e = 5 to <1 0 tp y Resi n Usag e = 1 0 t o <5 0 tp y Resi n Usag e = 5 0 t o <20 0 tp y Resi n Usag e = 200 t o <100 0 tp y Resi n Usag e > 100 0 tp y Resi n Usag e = 0 to <8 5 tp y Resi n Usag e = 8 5 t o <30 0 tp y Resi n Usag e = 30 0 t o <100 0 tp y Resi n Usag e = 100 0 t o <500 0 tp y Resi n Usag e > 500 0 tp y Note : PT E Dimension s Base dOnl y o n Numbe r o f Filamen t Windin g Machines . Ge l Coa t Usag e = 0 t o <5 0 tp y Ge l Coa t Usag e = 5 0 t o < 10 0 tp y Ge l Coat Usag e = 10 0 t o <30 0 tp y Ge l Coa t Usag e = 300 t o <70 0 tp y Ge l Coa t Usag e = 70 0 t o <150 0 tp y Ge l Coa t Usag e > 150 0 tp y Length (ft) 1 0 1 6 2 4 4 0 5 0 6 0 7 5 2 4 5 6 8 3 8 6 13 0 PT E Are a /5 0 f t 2 0 3 6 4 6 6 8 4 6 6 8 Widt h

(ft ) 1 0 1 6 2 4 3 0 3 6 4 5 5 0 1 9 2 4 4 4 5 6 8 6 5 0 2 0 1 9 2 4 2 4 4 6 4 6 Heigh t

(ft ) 1 0 1 0 1 0 1 2 1 2 1 2 1 2 1 0 1 0 1 0 1 2 1 2 1 0 1 0 1 0 1 0 1 0 1 0 1 2 Surfac e Are a

(sqft ) 60 0 1,15 2 2,112 4,08 0 5,66 4 7,92 0 10,50 0 1,77 2 4,28 8 10,35 2 13,04 0 27,54 4 #ofF W Machine s x 75 0 + 25 0 1,600 2,46 8 3,60 8 5,10 4 6,07 2 8,99 6

6-5 0TABL E 6-24 . FACILIT Y CRITERIA USE D T O DETERMIN E TH E NUMBE RAN D SIZ E O FPERMANEN T TOTA L ENCLOSURE S FO ROPERATION S OTHE RTHA N CONTINUOU S LAMINATIO N AN D CASTIN G (concluded ) Operatio n Pultrusio n

SM C Manufacturin g Mixin g No t

Applicabl e

No t Applicabl e No t Applicabl e Numbe r o f PTE' s 1

#o f SM C Machine s 1 Dimensio n Selectio n Criteri aa #o f Pultrusio n Machine s = 1 t o 1 0 #o f Pultrusio n Machine s = 1 1 #o f Pultrusio n Machine s > 1 1 Note : Dimension s Constant . Numbe r o f PTE' s = Numbe r

SM C Machine s Dimension s Constant . Length (ft ) 4 0 8 2 26 7 5 5 3 0 Widt h

(ft) 2 2 + 1 2 x ( #- 1 ) 10 0 10 7 2 4 2 4 Heigh t

(ft) 8 8 8 1 2 1 4 Surfac e Are a

(sqft ) Depend s on # 19,31 2 63,12 2 4,53 6 2,60 0 On e PT E wa s assume dt o b e use dpe r operatio n rathe r

than multipl e PTE' s bein g use dfor differen t operations . Resi n o r ge l coa t usag e i s th e annua l usag e for thi s grou p o f

operations . Facilitie s applyin g ge l coat (o f any type ) in conjunctio n wit h polyme r

castin g were assume dt o us e aPT E wit h dimension s 14' x 18 ' x 10 ' = (1,14 4 sqft) .

6-5 1P.6 0

6.3.2 2 Duc t

Work fro mWe t

Are aEnclosure s an dPermanen t Tota l Enclosure s t o Add-O n Contro l Device s Duc t wor k i s necessary t o ven t

th e capture demission s fromPTEs , fro mcentrifugal castin g captur e devices , fro menclosure s o n continuou s laminatio n an dcastin g we t out areas , an d fro mth e continuou s laminatio n an dcastin g oven s t o th e contro l device . W e use dth e cos t algorithm s base do n Chapte r 10 , Hoods , Ductwork , an dStacks , OAQP S Contro l Cos t Manual , 5t h Editio n (Cos t

Manual) . Tabl e 6-2 5 summarize s basi c assumption s an dequation s use di n estimatin g duc t

wor k costs . Thi s tabl e show s th e duc t wor k cos t component s an dth e desig n equation s fo r

th e duc t work , th e electricity costs , an dth e direc t an dindirec t

cos t factors . W e escalate dth e equipmen t

cost s reporte di n th e Cos t Manual , whic h ar e in 199 3 dollars , t o 199 8 dollar s b y usin g th e annua l averag e C E cos t indexes . Appendi x 6. 8 contain s pertinen t page s fro mChapte r

1 0 o f th e Cos t Manual . Th e cos t o f duc t wor k i s base don : (1 ) th e flo w rat e of th e ga s streambein g vente dt o th e contro l device , (2 ) th e length o f duc t wor k required , includin g th e numbe r o f elbows , tees , an d dampers , an d(3 ) th e typ e o f materia l use dt o construc t th e duc t work . Appendi x 6 present s a summary o f

th e flo w rates , costs , duc t diameter s an dlengths , an dnumbe r o f elbows , tees , an d damper s use dt o estimat e th e duc t cost s for existin g continuou s laminatio n an dcastin g source s an dne w continuou s laminatio n an dcastin g sources . Ai r Flo w Rate s I n general , ai r

flo w rate s ar e base do n th e mas s o f emission s captured , th e operatin g hour s pe r year o f th e source , an dth e concentratio n o f th e emissions . W e calculate dth e flo w rat e o f th e ga s streamout

o f awe t are aenclosure , acentrifugal castin g captur e device , o r aPT E t o th e contro l devic e usin g on e o f severa l method s a s describe dbelow . W e firs t calculate dth e ai r

flo w rate s fo r

eac h operation , excep t

fo r oven s a t continuou s laminatio n an dcastin g operations , usin g th e followin g equation : Q = I * (45400 0 mg/lb ) * 1/ H * ( 1 hr/60 min ) * ( 1 m 3 /4.32 6 mg ) * (35. 3 ft 3 /m 3 ) * 1/ C where : Q = ai r

flo w rate , cubi c feet

pe r minut e I = emission s captur e an dvente dt o th e contro l device , pound s pe r yea r H = operatin g hour s pe r

yea r C = concentratio n o f

emissions , part s pe r

millio n b y volum e 6-5 2TABL E 6-25 . DUC T WOR K COS T INFORMATIO N AN D DESIG N EQUATION S Equatio n Numbe r 1 2

3

4 5 6
7

8 9 Paramete r

Calculate d Duc t Diamete r (feet ) Straigh t Ductwor k

($/foot ) Damper s ($/damper )

Elbow s ($/elbow ) Equipmen t

Cos t (199 8 $) Purchase d Equipmen t

Cos t (199 8 $ ) Tota l Capita l Investmen t (199 8 $) Straigh t Duc t Frictio n Los s pe r 10 0 fee t o f Duc t Lengt h Curve dElbo w Frictio n Los s Variabl e D d S D

D

E
E C PE C TC I

F d F c Equatio n

= 1.12 8 x[Q s /(V x 60)]° 5

= 1.55x(DJ 093 6

_4 5 ^ g 0.059

7 x (Dili )

_5 3 4 e 0.0633(Diii )

= (S D + D + E ) * E F

= EC * 1. 1

= PEC * 1.6 1

= 0.13 6 x (1/D d )" 8 x (V/1000) 1 8

= k f l x((Vx60)/4016) 2 Additiona l Informatio n Q s = Flo w Rat e o f

Ga s Strea m(scfm ) V = Velocit y o f

Ga s Strea m(fee t

pe r second ) Dj, , = Duc t

Diameter , inche s Galvanize dCircular , Spiral-Woun dDuc t wit h 1-Inch Insulatio n D i n= Duc t

Diameter , inche s Double-wal l "opposed-blade " butterfl y dampene r with 1

- inc h fiberglas s insulation. ; galvanize dcarbo n steel . Dj, , = Duc t

Diameter , inche s Double-walle d"gored " 90 ° elbows , galvanize dcarbo n stee l wit h one-inc h insulatio n E F= Escalatio n Facto r

= 199 8 C E Cos t

Inde x (389.5 ) / 199 3 C E Cos t

Inde x (359.2 ) E C = Equipmen t

Cos t (199 8 $ ) PE C = Purchase dEquipmen t Cos t (199 8 $ )

D d= Duc t

Diameter , Fee t V = Velocit y o f

Ga s Strea m(fee t

pe r second ) 1 ^ = Frictio n Los s Facto r V = Velocit y o f

Ga s Strea m(fee t

pe r second )
6-5 3TABL E 6-25 . DUC T WOR K COS T INFORMATIO N AN D DESIG N EQUATION S (concluded ) Equatio n Numbe r

1 0

1 1
1 2 1 3 1 4 1 5 Paramete r

Calculate d

Electricit y Cos t (199 8 $/yr ) Propert y Tax , Insurance , & Administratio n (199 8 $/yr ) Capita l Recover y Cos t Facto r Annualize d Capita l Cost s (199 8 $/yr ) Tota l Variabl e Annua l Cos t (199 8 $/yr ) Tota l Fixe d Annua l Cos t (199 8 $/vr ) Variabl e

E C

PTI A CR C AC C AC(V ) AC(F ) Equatio n

= (1.17 5 x IO"4

) x P c x Q „ x (F d+ F c )xO f / E

= TC I * 0.0 4

= (0.07*(1.07) 10 )/((1.07) 10 -1 )

= TC I * CR C

= E C

= PTI A + AC C Additiona l Informatio n P c = Pric e o f

Electricit y ($/kWh ) = 0.044 8 $/kWh Q a= Flo w Rat e o f

Ga s Strea m(AFCm) . Note : assum e Q a= Q s F d= Straigh t

Duc t Frictio n Los s F c = Curve dElbo w Frictio n Los s O f = Operatin g Facto r

(hr/yr ) = 600 0 hr/y r E = Combine dFan Moto r Efficienc y = 0. 6 TC I = Tota l Capita l Investmen t (199 8 $) Assum e 1 0 Yea r

Perio dan d7 % Interes t

Rat e TC I = Tota l Capita l Investmen t (199 8 $) CR C = Capita l Recover y Cos t Facto r E C = Electricit y Cos t

(199 8 $) PTI A = Propert y Tax , Insurance , & Administratio n (199 8 $/yr) AC C = Annualize dCapita l Cost s (199 8 $/yr )

6-5 4P.6 3

Emissions . W e calculate dwe t ou t are aan dove n emission s o n apoun dpe r hou r basi s fro mcontinuou s laminatio n an dcastin g operation s usin g th e estimate dannual we t ou t are aan d ove n emission s an doperatin g hour s pe r yea r for that line . W e base doperatin g hour s for continuou s laminatio n an dcastin g operation s on actual o r estimate doperatin g hour s fo r 199 7 for eac h line . Th e percen t

of th e emission s fro mth e we t ou t are acapture dvarie dbetwee n th e MAC T floo r

an dth e regulatory alternatives . W e assume dove n emission s t o b e capture d10 0 percen t a s th e oven s ar e operate dunde r negativ e pressure . Operatin g Hours . Westimate demission s o n apoun dpe r hou r basi s fro mcentrifugal castin g machine s an dothe r reinforce dplasti c operation s usin g annual emissio n estimate s an d 6,00 0 operatin g hour s pe r year . W e assume demission s fro mcentrifugal castin g machine s ar e capture d10 0 percen t

b y thei r captur e devices . In addition , w e assume demission s fro mal l operation s locate dinsid e PTE s ar e capture d10 0 percen t base do n th e enclosur e meetin g EPA' s fiv e poin t criteri afo r

atota l enclosure . Concentrations . Fo r

continuou s laminatio n an dcastin g operations , w e use datarge t concentratio n t o th e add-o n contro l device , base do n test s conducte da t Lasc o Pane l Product s an d tes t dat afro mKrane-Kemlite' s Jonesbor o facility , o f 50 0 ppm v in estimatin g ai r flow s fro mwe t out are aenclosure s and , basedo n Endur o dat aan dKrane-Kemlite' s Jonesbor o tes t data , 20 0 ppm v fo r PTEs . Fo r

continuou s casting , w e use datarge t concentration , base do n Fibercas t data , o f 3,50 0 pppv. . Actua l concentration s use di n th e costin g for PTE s var

y for som e continuou s laminatio n an dcastin g facilitie s becaus e highe r flo w rate s wer e use dt o ensur e a t leas t 1 5 ai r change s pe r

hou r i n th e PT E (se e discussio n below) . Fo r al l othe r operation s w e use daconcentratio n o f 10 0 ppm v a

t th e inle t t o th e contro l device . Actua l dat afro moperatin g facilitie s sho w that stac k HA P concentration s rang e fro m6 1 t o 24 9 ppm v wit

h amean o f

12 0 ppmv . W e choos e 10 0 ppm v a s aconservativ e estimate . Th e actua l numbe r

come s fo r

th e curren t

OSH A exposru e limit s fo r styrene . Thoug h th e industr y ha s agree dt o avoluntar y standar do f 5 0 ppmv , th e availabl e dat ad o no t support usin g 5 0 ppm v a s th e concentratio n leve l expecte da t th e inle t t o acontro l device . Next , w e calculate dai r

flo w rate s fo r

PTE s usin g th e siz e o f

th e natura l draf

t opening s (NDOs ) i n th e PT E an davelocity o f 20 0 feet pe r minute , whic h i s th e minimu mvelocity 6-5 5P.6 4

require dspecifie di n EPA' s five-poin t criteri ause dt o determin e i f a n enclosur e qualifie da s a tota l enclosure . Th e followin g equatio n wa s used :

Q = ND O * 200/fee t

pe r minut e where : Q = ai r

flo w rate , cubi c feet

pe r minut e ND O = natura l draf

t openings , squar e feet W e calculate dth e siz e of th e NDOs i n aPT E usin g apercentag e o f th e surfac e are ao f

th e PTE . Althoug h th e EPA' s five-poin t criteri afor

tota l enclosure s allow s fo r NDOs o f u p t o 5 percen t o f th e tota l surfac e are ao f

th e PTE , w e foun dthat

reinforce dplasti c composit e facilitie s with PTE s hav e muc h lowe r percentages . Fo r

PTE s on operation s othe r than continuou s laminatio n an dcasting , th e EP A use dafacto r o f 0. 2 percen t

t o calculat e th e NDOs . Fo r continuou s laminatio n an dcastin g operations , w e foun don e facility wit h aPT E t o hav e NDO s representin g approximatel y 1 percen t o f th e tota l surfac e are ao f

th e PTE . Becaus e othe r facilitie s may no t

b e abl e t o achiev e thi s lo w percentag e (du e t o th e wid e variatio n i n configuratio n o f

continuou s laminatio n an dcastin g lines) , w e use d2 percen t t o calculat e th e NDO s for PTE s installe do n th e othe r continuou s laminatio n an dcastin g operations . Onc e w e estimate dthes e tw o ai r flo w rates , w e selecte dth e large r o f th e tw o for

costin g purposes . Appendi x 6.1 0 contain s table s summarizin g th e ai r flo w volume s calculate dfo r th e continuou s laminatio n an dcastin g facilities . Fo r continuou s laminatio n an dcastin g PTEs , w e als o considere dth e numbe r o f ai r change s pe r

hou r t o ensur e prope r

engineerin g design . Accordin g t o Chapte r 1 1 o f th e OAQP S Cos t Manua l (se e Appendi x 6.7) , 1 0 t o 1 5 ai r change s pe r

hou r ar e generall y considere d necessar y t o provid e adequat e worke r comfort withi n a n enclosure . Base do n thi s guidance , w e use dai r flow s i n th e costin g that

wer e a t leas t equivalen t

t o 1 5 ai r change s pe r

hour . If eithe r o f th e calculate dai r

flow s equate dt o ai r

flow s les s than 1 5 ai r

change s pe r

hour , w e use dth e ai r flo w necessary t o achiev e 1 5 ai r change s pe r

hou r in th e costing . Fo r continuou s laminatio n an dcastin g ovens , w e estimate dai r flow s for eac h ove n usin g ove n ai r flo w dat aobtaine ddurin g th e Lasc o Pane l Product s sourc e test . Th e dat aobtaine d showe da n ai r flo w rat e o f

approximatel y 3,75 4 dr

y standar dcubi c feet

pe r minute . W e estimate dth e volum e o f

th e ove n t o b e approximatel y 3,34 8 cubi c feet . Thes e values yiel da facto r o f 1.121 3 cubi c feet

o f dry ai r flo w pe r minut e pe r

cubi c foo t

o f ove n volume . W e 6-5 6P.6 5

estimate dth e ove n volume s associate dwit h th e othe r

continuou s laminatio n an dcastin g line s (se e Tabl e A6-1 1 i n Appendi x 6.10 ) an duse dth e 1.121 3 facto r t o estimat e ai r

flo w ou t o f th e ove n t o th e contro l device . W e calculate dth e concentratio n o f th e ai r flo w fromth e ove n usin g thi s estimate dai r

flo w an dth e estimate dove n emissio n rate , wit h th e assumptio n that

th e onl y HA P i n th e ai r

streami s styrene . Th e resultin g estimate dHA P concentration s range dfro m2 6 t o 33 1 ppm . Length o f Duc t an dNumbe r

o f Elbows , Tees , an dDamper s Figure s 1 throug h 7 i n Appendi x 6.1 1 illustrat e th e lengt h o f duc t wor k an dth e numbe r

o f dampers , elbows , an dtees estimate dfor eac h continuou s laminatio n an dcastin g facility . I n general , w e use donl y majo r difference s betwee n configuration s t o develo p facility

- o r line

specifi c duc t

wor k assumptions . Thes e ar e show n i n th e figures . Fo r operation s othe r

than continuou s laminatio n an dcasting , w e use dth e sam e se t o f parameter s for

eac h PT E locate da

t th e facility . In general , w e use dduc t wor k component s consistin g o f

thre e separat e section s o f straigh t duc t work , thre e 90 ° elbows , an don e dampener . Th e straigh t

duc t wor k i s comprise do f

tw o 1 5 foo t

lon g section s o f

ductin g an don e 7 5 foo t

lon g sectio n o f duc t work . Electricit v Cost s Electricit y cost s ar e incurre dt o mov e th e ai r t o throug h th e duc t

wor k an dt o th e contro l device . Th e cos t

o f th e electricity depend s o n th e volum e o f ai r moved , frictio n loss , operatin g hours , an dcos t

o f electricity . W e calculate dth e volum e ai r move da s describe dabove . W e calculate dstraigh t

duc t an dcurve delbo w frictio n losse s usin g Equation s 8 an d9 in Tabl e 6-25 . (Thes e equation s ar e take n fro mChapte r 1 0 o f th e Cos t Manual , se e Appendi x 6.8. ) In calculatin g thes e frictio n losses , w e use dvelocity dat aobtaine dfro mth e sourc e tes t a t Lasc o Pane l Products . Fo r al l operations , excep t

th e oven s a

t continuou s laminatio n an dcastin g operations , w e use d3 8 feet pe r secon da s th e velocity o f th e ga s streamfro mth e PT E o r we t out are aenclosur e throug h th e ductwork t o th e contro l device . Fo r continuou s laminatio n an d castin g ovens , w e use davelocity o f 3 3 feet pe r second . W e als o use dth e operatin g hour s use dt o calculat e th e ai r flows , a s discusse dabove , i n estimatin g electricity costs . 6-5 7P.6 6

W e calculate dth e electricity cos t usin g cost s reporte db y th e Departmen t o f Energy . Th e industria l seven-month cos t averag e (January throug h Jul y 1998 ) wa s reporte dt o b e $0.044 8 pe r kWh (se e Appendi x 6.12) . 6.3.2 3 Add-O n Contro l Devic e Costin g W e selecte dspecifi c costin g informatio n an dequation s associate dwit h th e installatio n an doperatio n o f

add-o n contro l device s fro mchapte r 3 o f th e OAQP S Contro l Cos t Manual an d a n EP A documen t

title d"Assessmen t

o f Styren e Emissio n Control s fo r FRP/ C an dBoa t

Buildin g Industries. " Tabl e 6-2 6 summarize s th e equation s use dt o calculat e add-o n contro l devic e parameter s an dcosts . Appendi x 6.1 3 present s tw o paper s presentin g additiona l informatio n on th e derivatio n o f

thes e costin g algorithms . Whil e ther e are avariety o f differen t type s o f add-o n contro l device s available , w e assume dthat al l facilitie s woul dus e acombine drotary concentrato r an dtherma l oxidatio n system . Eve n thoug h thi s particular typ e of add-o n contro l devic e ma y no t b e th e mos t

cos t effectiv e devic e for

al l facilities , w e mad e thi s assumptio n t o simplif y th e costin g analyses . Th e capita l cos t

o f th e contro l devic e i s primaril y base do n th e flo w an dconcentratio n t o th e contro l device . W e summe dth e flow s fro meac h PT E an deac h captur e devic e t o determin e th e tota l flo w t o th e contro l device . W e estimate dth e HA P concentratio n i n pp mvente dt o th e contro l devic e usin g th e su mo f th e emission s fro meac h PTE/captur e devic e in tpy , th e facility operatin g hour s pe r

year , an dth e su mo f

th e flow s fro meac h PTE/captur e devic e in cfm . W e calculate dth e contro l devic e equipmen t cost s usin g Equatio n 5 o f Tabl e 6-26 . W e escalate dth e equipmen t

costs , whic h ar e basedo n dat acollecte dfro mDurr in 199 6 dollars , t o 199 8 dollar s b y usin g th e Vatavu k Ai r Pollutio n Contro l Indexe s (se e Appendi x 6.14) . W e calculate dth e purchase dequipmen t cos t (PEC ) i n 199 8 dollar s usin g Equatio n 6 o f Tabl e 6-26 . Th e PE C includ e cost s for contro l devic e instrumentation , sale s tax , an dfreight . W e assume dtha t

instrumentatio n cost s ar e 1 0 percen t o f th e contro l devic e equipmen t costs , sale s tax ar e 5 percen t

o f th e contro l devic e equipmen t costs , an dfreight

cost s ar e 5 percen t

o f th e contro l devic e equipmen t

costs .

6-5 8TABL E 6-26 . SPECIFI C EQUATION S FO RROTAR Y CONCENTRATOR/THERMA L OXIDIZE RSYSTE M PARAMETER S AN D COST S Equatio n Numbe r 1 2 3 4

5

6 7

8

9 Paramete r

Calculate d Flo w Rat e (cfm ) Concentratio n (ppm ) Electrica l Powe r

(kW ) Fue l Usag e (BTU/hr ) Rotar y Concentrato r an dTherma l Oxidize r Equipmen t

Cos t (199 8 $ ) Purchase dEquipmen t Cos t (199 8 $) Tota l Capita l Investmen t

(1998$ ) Direc t Operatin g Costs , Excludin g Fue l an dElectricit y Cost s (199 8 $/yr ) Fue l Cost s (199 8 $/yr ) Variabl e Q 

## c E P F U

E C

PE C TC I

DO C

F C Equatio n

= I * (200 0 lb/ton ) * (45400 0 mg/lb ) * 1/ H * ( 1 hr/6 0 min) * ( 1 m 3 /4.32 6 mg ) * (35. 3 ft 3 /m 3 ) * 1/ C

= I * (200 0 lb/ton ) * (45400 0 mg/lb ) * 1/ H * ( 1 hr/6 0 min) * (35. 3 ftVm

3 ) * 1/ Q * ( 1 m 3 /4.32 6 mg )

= 3.01 9 + 0.0007 1 * Q If Q < 75000 : = (0.00150 7 + 5.4E-0 5 * Q ) * 1.0E+0 6 I f Q * > 75000 : = 108000 0 - 1833 0 * C

= 9711 3 + 8.3409 8 * Q + 1.38246E-0 5 * Q 2

-4.866E-11*Q 3 *EF ,

= EC * 1. 2

= PE C * 1.6 1 + (500 0 + (2. 3 * Q) )

= ( 4 hr/wk ) * (5 2 wk/yr ) * (45.0 4 $/l.OE+0 4 hr-cfm ) * 1.1 5 * Q + (484 0 $/yr

+ 419 0 $/y r

+ (0.2 5 $/yr-cfm ) * Q ) * EF 2

= (F U BTU/hr ) * (3.2 4 S/1.0E+0 6 BTU ) * H Comment s I = Contro l Devic e Inpu t Mas s (tpy ) H = 600 0 operatin g hour s pe r year fo r operation s othe r tha n continuou s laminatio n an dcasting . H = facility specifi c informatio n fo r continuou s laminatio n an dcastin g operation s

EF , = Escalatio n Facto r EF , = 199 8 Vatavu k

Ai r Pollutio n Contro l Inde x for Therma l Incinerator s (110.5)/199 6 Vatavu k Ai r pollutio n Contro l Inde x fo r Therma l Incinerator s (108.2 )

EF 2 = Escalatio n Facto r EF 2 = 199 8 Vatavu k

Ai r Pollutio n Contro l Inde x fo r Therma l Incinerator s (110.5)/199 5 Vatavu k Ai r pollutio n Contro l Inde x fo r Therma l Incinerator s (105.9 ) H = 600 0 operatin g hour s pe r year fo r operation s othe r tha n continuou s laminatio n an dcasting . H = facility specifi c informatio n fo r continuou s laminatio n an dcastin g operation s

6-5 9TABL E 6-26 . SPECIFI C EQUATION S FO RROTAR Y CONCENTRATOR/THERMA L OXIDIZE RSYSTE M PARAMETER S AN D COST S

(concluded ) Equatio n Numbe r 1 0

1 1

1 2 1 3 1 4 1 5 Paramete r

Calculate d Electri c Cos t

(199 8 $/yr ) Overhead , Propert y Tax , Insurance , an d Administratio n (199 8 $/yr ) Capita l Recover y Cos t Facto r Annualize dCapita l Cost s (199 8 $/yr ) Tota l Variabl e Annua l Cos t (199 8 $/yr ) Tota l Fixe dAnnua l Cos t (199 8 $/vr ) Variabl e

EL C

OPTI A
CR C AC C AC(V ) AC(F ) Equatio n

= H * E P * 0.044 8 $/kWh

= (DO C * 0.6 ) + (TCI * 0.04 )

= (0.07 * (1.07)'°)/((1.07) 10 -1 )

= TC I * CR C

= DO C + (Fue l Cost s $/yr) + (Electri c Cos t $/yr )

= OPTI A + AC C Comment s H = 600 0 operatin g hour s pe r yea r fo r operation s othe r tha n continuou s laminatio n an dcasting . H = facility specifi c informatio n fo r continuou s laminatio n an dcastin g operation s Rate s ar e fro mChapte r

3 , Therma l an dCatalyti c Incinerators , OAQP S Contro l Cos t Manual , 5 t h Edition , EP A 453/B-96-001 . Februar y 1996 . Pag e 3-52 . 7 percen t fo r 1 0 years .

6-6 0P.6 9

W e calculate dth e tota l capita l investmen t for th e contro l devic e usin g th e OAQP S Cos t Manua l a s show n i n Equatio n 7 o f Tabl e 6-26 . Thi s equatio n calculate s th e tota l direc t cost s basedo n PEC , site preparatio n costs , an dcos t of building s t o hous e th e contro l device . W e assume dtha t

th e sit e preparatio n cos t

are $5,00 0 plu s $2. 3 pe r

cf mo f flo w an dthat

th e cos t o f building s t o hous e contro l device s are zer o becaus e al l contro l device s wer e assume dt o b e outdoors . W e calculate dth e direc t

operatin g cost s excludin g fue l an delectricity cost s usin g Equatio n 8 o f

Tabl e 6-26 . Thi s equatio n estimate s th e maintenanc e cost s associate dwit h th e operatio n o f

th e contro l device . W e base dmaintenanc e cost s o n 4 hour s pe r week , 5 2 week s pe r year , a t alabo r rat e o f $45.0 4 pe r

hou r for eac h 10,00 0 cf

mo f th e contro l system . W e adde da n additional 1 5 percen t

fo r supervisory cost . W e assume da n annual maintenanc e contrac t o f $4,84 0 fo r

eac h contro l device . W e als o include dadditiona l costs , suc h a s cost s for medi a replacement , i n th e direc t operatin g cos t

calculation . Th e labo r rat e use dt o calculat e th e direc t operatin g cos t

i s already in 199 8 dollars . W e escalate dth e non-labo r

relate ddirec t

operatin g costs , whic h ar e base do n Jul y 199 5 data , t o 199 8 dollar s usin g th e Vatavu k Ai r Pollutio n Contro l Indexes . W e calculate dth e fuel cost s for th e contro l devic e usin g Equatio n 9 of Tabl e 6-26 . Th e fuel cos t i s th e produc t

o f th e fuel usag e (se e Equatio n 4) , th e annual operatin g hours , an dth e fuel cost . W e basedth e fuel cos t o n natura l ga s cost s reporte db y th e Departmen t o f Energ y (se e Appendi x 6.12) . Th e industrial six-month cos t averag e (January throug h Jun e 1998 ) fo r natura l ga s wa s reporte dt o b e $3.2 4 pe r 1,000 standar dcubi c feet (scfm) . Thi s i s equivalen t t o approximatel y $3.2 4 pe r

millio n BTU . W e calculate dth e electricit y cost s for th e contro l devic e usin g Equatio n 1 0 in Tabl e 6-26 . Th e electricit y cos t

i s th e produc t

o f th e electrica l powe r

consume d(se e Equatio n 5) , th e annua l operatin g hours , an dth e electricit y cost . W e base dth e electricity cos t on cost s reporte db y th e Departmen t

ofEnerg y (se e Appendi x 6.12) . Th e industria l seven-month cos t averag e (January throug h Jul y 1998 ) was reporte dt o b e $0.044 8 pe r kWh . W e calculate doverhead , property tax , insurance , an dadministratio n cos t usin g Equatio n 1 1 o f Tabl e 6-26 . W e calculate dth e overhea dcos t base do n 6 0 percen t

o f th e direc t

operatin g 6-6 1P.7 0

cos t an dth e propert y tax , insurance , an dadministratio n cos t base do n 4 percen t

o f th e total capita l investment . W e derive dthes e percentage s fro mth e OAQP S Contro l Cos t Manual . W e calculate dth e capita l recovery cos t facto r usin g a7 percen t

interes t rat e an da1 0 yea

r tim e period . W e the n calculate dth e annualize dcapita l cos t b y multiplyin g th e total capita l investmen t

b y th e capita l recovery cos t factor . Next , w e calculate dth e tota l variabl e annua l cos t b y summin g th e direc t

operatin g costs , th e fuel cost , an dth e electri c cost . Finally , w e calculate d th e tota l fixe dannua l cos t b y summin g th e overhead , property tax , insurance , an dadministratio n cost , an dth e annualize dcapita l costs . 6.3.2 4 Monitoring , Recordkeeping , an dReportin g Tabl e 6-2 7 summarize s th e monitoring , recordkeeping , an dreportin g (MRR ) requirement s associate dwith complyin g wit h th e propose drule . W e use dth e estimate dhour s an dcost s for

MR Rtask s base do n dat adevelope dfo r othe r standard s an dfro mth e Emissio n Standard s Division (ESD ) Procedure s Manual. 3 4 Fo r thos e MRRtask s fo r

whic h n o hou r estimate s wer e available , w e mad e assumption s t o estimat e th e MR Rhours . A s see n i n Tabl e 6-27 , w e identifie dsi x MR Rcategories : (1 ) reading rule , (2 ) performanc e test s an dothe r requirement s for

facilitie s complyin g b y usin g a n add-o n contro l device , (3 ) employe e training , (4 ) subpart A notifications , (5 ) percen t HA P monome r

record s fo r ope n moldin g an dcentrifugal castin g operation s an drecord s for othe r pollutio n preventio n technique s use di n ope n molding , an d(6 ) developin g arecor dsystem . W e develope d informatio n for

eac h o f thes e si x categorie s for : (1 ) applicability (e.g. , existin g facilities , ne w facilities , facilitie s with contro l devices , etc.) , (2 ) firs t yea r hours , (3 ) annua l hours , an d(4 ) assumptions . W e determine dth e tota l firs t year MR Rhour s an dth e tota l annua l MR Rhour s o n a facility basi s (base do n applicability ) fo r al l activitie s liste di n Tabl e 6-27 . Th e EP A the n determine dth e firs t

year MR Rhour s an dth e annual MR Rhour s for eac h proces s withi n agrou p o f operation s (base do n applicability ) fo r eac h activity . Onc e w e estimate dth e numbe r o f hours , w e calculate dth e cos t b y applyin g th e wag e rate s develope dfo r

th e Architectura l Coating s Informatio n Collectio n Reques t (ICR ) (se e Tabl e 6-28) . 6-6 2TABL E 6-27 . MR RINFORMATIO N B Y ACTIVIT Y

MR RCategor y Rea drul e

Performanc e test s an dothe r requirement s fo r facilitie s wit

h add

o n control s Activity

Rea dpromulgate drul e an dSubpar t

A , Genera l Provision s Initia l performanc e tes t

- Contro l devic e efficienc y Initia l performanc e tes t

- Captur e efficienc y Notificatio n o f

initia l performanc e tes t Repor t o f initia l performanc e tes t Developmen t

o f operatio n an dmaintenanc e pla n Developmen t

o f startup , shutdown , an d malfunctio n (SSM ) plan Record s an dreport s o f SS M an dcorrectiv e measure s take n Applicabilit y Al l existin g an dne w facilitie s Facilitie s complyin g b y usin g contro l device s that hav e no t don e testin g Facilitie s complyin g b y usin g contro l device s that hav e no t don e testin g Facilitie s complyin g b y usin g contro l device s Facilitie s complyin g b y usin g contro l device s Facilitie s complyin g b y usin g contro l device s Facilitie s complyin g b y usin g contro l device s Facilitie s complyin g b y usin g contro l device s Firs t Year Hour s 8 hour s per

facility plus 1 additiona l hou r

pe r eac h grou p o f operation s a

t th e facility 28 0 hour s pe r

facility

4 0 hour s pe r

facility

2 hour s per

facility

Include di

n performanc e tes t hour s 4 0 hour s pe r

facility 2 0 hour s per

facility 2 hour s per

facility Annua l Hour s

1 hou r pe r facilit y

Non e

Non e

Non e

Non e

Non e Non e 2 hour s pe r

facility Assumption s

Readin g rul e an dSubpar t A wil l b e necessar y fo r

complianc e Facilitie s that

alread y conducte d destructio n efficienc y testin g accordin g t o EP A requirement s d o no t hav e t o retes t Facilitie s tha t

alread y conducte d captur e efficienc y testin g accordin g t o EP A requirement s d o no t hav e t o retes t Doe s no t appl y t o facilitie s tha t alread y demonstrate d destructio n an dcaptur e efficienc y Doe s no t appl y t o facilitie s that alread y demonstrate d destructio n an dcaptur e efficienc y Non e Non e SS M repor t

hour s ar e covere d unde r report s o f

accedence s an d period s o f

noncomplianc e

6-6 3TABL E 6-27 . MR RINFORMATIO N B Y ACTIVIT Y (continued ) MRRCategor y Employe e trainin g Employe e Trainin g (continued )

Subpart A notification s

Subpart A notification s (concluded ) Activity

Developmen t

o f operato r trainin g cours e Tim e t o trai n personne l

Record s o f

operator s completin g operato r trainin g cours e Notificatio n o f constructio n an d reconstructio n Notificatio n o f

anticipate d startu p Notificatio n o f

actua l startu p Notificatio n o f

complianc e statu s Semiannua l repor t

- Complianc e certificatio n Applicabilit y Facilitie s wit

h wor k practic e requirement s Al l facilitie s

Al l facilitie s Ne w facilitie s Ne w facilitie s Ne w facilitie s Al l facilitie s Al l facilitie s Firs t Year Hour s 8 hour s fo

r wor k practice s an d2 4 hour s fo r

spray trainin g Smal l Facilities : 2 hour s fo

r wor k practice s an d4 fo r spray trainin g Mediu mFacilities : 4 hour s fo

r Wor k practice s an d8 fo r spray trainin g Larg e Facilities : 8 hour s for

Wor k practice s an d1 6 fo r

spray trainin g 2 hour s pe r

facility 2 hour s per

facility Re t

3 7
2 hour s pe r

facility Ke t

3 7 2 hour s pe r

facility Re t

3 7 4 hour s pe r

facility Re t

3 7 8 hour s pe r

facility Ref3 7 Annua l Hour s

Non e

Non e

2 hour s Non e Non e Non e Non e 1 6 hour s pe r

facility ( 8 hour s X 2) 1 4 Assumption s

Trainin g hour s ar e incrementa l hour s betwee n curren t

leve l trainin g an dMAC T leve l trainin g Trainin g ne w employee s base d o n requirement s in th e standar d doe s no t tak e mor e tim e tha n trainin g ne w employee s withou t MAC T standar din plac e Smal l - s 10 0 Employee s Mediu m> 100- s 25 0 Employee s Larg e > 25 0 Employee s Non e N o reconstructio n wil l occu r a t existin g facilitie s N o reconstructio n wil l occu r a t existin g facilitie s N o reconstructio n wil l occu r a t existin g facilitie s Non e Onl y on e semiannua l repor t i s submitte di n th e firs t

yea r plu s th e Notificatio n o f

complianc e statu s 6-6 4TABL E 6-27 . MR RINFORMATIO N B Y ACTIVIT Y (continued ) MR RCategor y

Percen t HA P monome r an d pollutio n preventio n record s Develo p recor d syste m Activity

Semiannua l repor t

- Period s o f

noncomplianc e an dmethod s use dt o attai n complianc e Record s o f

HA P percen t an dweighte daverag e HA P concentratio n calculation s an drecord s o f othe r pollutio n preventio n technique s Develo p recor dsyste m Applicabilit y Al l facilitie s wit

h period s o f noncomplianc e Ope n Moldin g an d Centrifuga l Castin g facilitie s

Al l facilitie s Firs t Year Hour s 1 6 hour s pe r

facility

1 2 hour s pe r

facility

Wor k practices : 1 hou r HA P conten t

an dothe r pollutio n preventio n measures : 5 hour s Contro l devices : 2 hour s Annua l Hour s 3 2 hour s pe r

facility (1 6 hour s X 2) 1 4
1 2 hour s pe r

facility

Non e Assumption s

2 0 Percen t

o f facilitie s wil l hav e som e period s o f

noncomplianc e an d8 0 percen t

wil l no t hav e an > period s o f

noncomplianc e Non e

Non e

6-6 5P.7 4

TABL E 6-28 . WAG E RATE S 3 8
Labo r Clas s Clerical Technica l Managemen t Bas e Labo r Rate from Burea u of Labo r Statistic s (BLS ) ($/hr ) 11.9 5 18.8 6 28.5 4 Fring e Benefit Loadin g Rate fro mBL S 1.4 1 1.43 1.4 0 Overheadan dProfi t

Rate 1.6 7 1.6 7 1.6 7 "Loaded " Wag e Rate

($/hr ) 28.1 4 45.0 4 66.7 3 I n calculatin g th e MR Rcosts , w e assume dthat al l o f th e MR Rwork

i s performe db y manageria l staf

f wit h on e hou r

of clerica l support

for every eigh t

hour s o f manageria l work . Fo r example , if

28 0 hour s ar e estimate dfo r agive n activity , w e assume dthat 28 0 hour s ar e spen t

a s manageria l hour s an d3 5 hour s (280/ 8 = 35 ) ar e spen t a s clerica l hours . Thi s assumptio n probabl y over-estimate s th e cos t impac t o f th e rule' s MR Rrequirement s fo r som e facilitie s becaus e a t som e facilitie s som e ofth e wor k wil l b e performe db y technica l rathe r than manageria l staff

. Fo r eac h operation s grou p a

t afacility , w e determine dth e firs t yea r MR Rcost s b y multiplyin g th e firs t

yea r managemen t

an dclerica l hour s b y th e associate dlabo r rat e fo r tha t MR Rcategory , $66.7 3 an d$ 28.1 4 pe r hour , respectively . Then , w e determine dth e annua l MR Rcost s fo r

eac h operation s grou p b y multiplyin g th e annua l managemen t an dclerica l hour s b y th e associate dlabo r

rat e fo r that MR Rcategory , $66.7 3 an d$ 28.1 4 pe r hour , respectively . W e annualize dth e firs t

yea r MR Rcost s for

eac h operation s grou p a

t afacility ove r

ate n year perio dusin g aseve n percen t interes t rate . W e the n summe dth e annualize dfirs t year MR R cost s an dannua l MR Rcost s for eac h operation s grou p a

t afacility t o obtai n th e tota l annua l MR Rcost s fo r

th e facility . Fo r

eac h operation s grou p with multipl e individua l operation s a t a facility (e.g. , ope n moldin g with manua l corrosio n resistan t resins , mechanica l corrosio n resistan t resins , filamen t

winding) , w e divide dth e annual MR Rcos t fo r tha t operation s grou p equall y amon g th e eac h ofindividua l operation s withi n tha t operation s grou p conducte da t th e facility .

6-6 6P.7 5

6. 4 RESULT S O FTH E COS T IMPACT S ANALYSI S A s previousl y discussed , tw o contro l level s wer e coste dfor eac h ne w an dexistin g facility . Thes e ar e th e floo r leve l o f control , an dh e abov e th e floo r option . Base do n thes e contro l level s w e develope dthre e regulatory alternatives . Thes e ar e a s follows .

• Regulatory Alternativ e 1 - Al l ne w an dexistin g facilitie s are require dt o mee t th e applicabl e floo r leve l o f control .

• Regulatory Alternativ e 2 - Al l ne w an dexistin g facilitie s wit h combine demission s o f HA P o f 10 0 ton s pe r

year (TPY ) o r mor e fro mth e followin g operations : ope n molding , centrifugal casting , continuou s lamination/casting , pultrusion , SM C manufacturing , an dBM C manufacturing/mixin g ar e require dt o mee t th e above-the-floo r

contro l level . Al l othe r facilitie s mus t

mee t th e floo r leve l o f control .

• Regulatory Optio n 3 - Al l ne w an dexistin g facilitie s mus t mee t th e above-the-floo r

contro l level . Table s 6-2 9 an d6-3 0 summariz e th e tota l capital an dannual cost s for existin g an dne w source s fo r

Regulatory Alternativ e 1 . A s see n i n thes e tables , th e annual cost s for thi s alternativ e fo r existin g an dne w source s i s approximatel y 2 4 millio n dollar s pe r yea r an dapproximatel y 3 6 millio n dollar s pe r

year , respectively . Th e total annual cos t woul db e approximatel y 6 0 millio n dollar s pe r

year . Table s 6-3 1 an d6-3 2 summariz e th e total capita l an dannual cost s for existin g an dne w source s for

Regulatory Alternativ e 2 . A s see n i n thes e tables , th e annual cost s associate dwit h thi s alternativ e for

existin g an dne w source s i s approximatel y 3 5 millio n dollar s pe r year an d approximatel y 3 7 millio n dollar s pe r year , respectively . Th e tota l annua l cos t woul db e approximatel y 7 2 millio n dollar s pe r year . Table s 6-3 3 an d6-3 4 summariz e th e tota l capita l an dannual cost s for existin g an dne w source s Fo r

Regulatory Alternativ e 3 . A s see n i n thes e tables , th e annual cost s associate dwith 6-6 7P.7 6



### thi s alternativ e ar

e approximately 6

7 million dollar s pe

r yea r an dapproximatel

y 6 6 million dollar s pe r year, respectively . The tota l annua l cos t wouldb e approximatel

y 13 3 million dollar s pe r year . 6. 5 COS T EFFECTIVENES S OFREGULATOR Y ALTERNATIVES The incrementa

l cos t effectivenes s o

f Regulator y Alternative s 2 an

d3 ar e determinedb

y dividin g the difference i

n their annua l cost s comparedt

o Regulator

y Alternativ e 1 b

y the differenc e i

n the emission reduction . W e calculate dthe cos t

effectivenes s fo

r bot h above-the floo r Regulator y Alternative s fo

r eac h applicabl e grou

p o f operation s an

dthe sourc e category . Table s 6-3 5 an

d6-3 6 summarize the cos t

effectivenes s o

f Regulator y Alternativ e 2 fo

r ne w an d existin g sources , respectively . Table s 6-3 7 an d6-3 8 summarize the cos t

effectivenes s fo

r Regulator y Alternativ e 3 .

6-6 8P.7 7



### TABL E 6-29 . REGULATOR

Y ALTERNATIV

E 1 COST S FO

REXISTIN

G SOURCE S

Grou p o f Operation s Ope n Moldin g Close dMoldin g Centrifuga l Castin g Continuou s Laminatio n / Castin g Polyme r Castin g Pultrusio n SM C Manufacturin g Equipmen t

Cleanin g BM C Manufacturin g /

Mixin g Storag e o f

HA P Containin g Mat'l s Total s fo r th e Sourc e Categor y TC C (1998$ ) $8,514,38 2 $24,58 1 $34,97 5 $2,186,84 8 $18,25 8 $166,63 0 $5,46 5 $265,78 2 $186,82 4 $231,50 2 $11,635,24 8 AV C

(1998$/yr ) $19,506,29 9

$ 0 $306,62 9 $171,97 2 $ 0 $156,28 5 $ 0 $ 0 $ 0 $ 0 $20,141,18 5 AF C

(1998$/yr ) $1,743,17 2 $66,44 6 $13,26 0 $428,78 9 $44,78 8 $33,96 2 $13,64 8 $367,59 9 $531,73 0 $326,13 3 $3,569,52 7 AV C + AF C

(1998$/yr ) $21,249,47 1 $66,44 6 $319,88 9 $600,76 1 $44,78 8 $190,24 7 $13,64 8 $367,59 9 $531,73 0 $326,13 3 $23,710,71 2 TCC , AVC , AF C ar e th e abbreviation s fo r Tota l Capita l Cost , Annua l Variabl e Cost , an dAnnua l Fixe dCost , respectively .


### TABL E 6-30 . REGULATOR Y ALTERNATIV E 1 COST S FO R NE W SOURCE S a

Grou p o f Operation s Ope n Moldin g Close dMoldin g Centrifuga l Castin g Continuou s Laminatio n / Castin g Polyme r Castin g Pultrusio n SM C Manufacturin g Equipmen t

Cleanin g BM C Manufacturin g /

Mixin g Storag e o f

HA P Containin g Mat'l s Total s fo r th e Sourc e Categor y TC C (1998$ ) $39,369,28 3 $1,36 1 $73,13 6 $606,71 5 $55,68 8 $50,377,16 0 $417,02 4 $43,12 8 $65,246,24 5 $42,75 9 $156,232,49 9 AV C

(1998$/yr ) $2,630,30 2 $ 0 $212,46 5 $62,46 2 $ 0 $2,296,48 4 $18,10 0 $ 0 $2,491,68 8 $ 0 $7,740,65 1 AF C

(1998$/yr ) $8,488,08 1 $3,39 3 $15,32 9 $116,13 3 $136,37 1 $8,136,49 6 $67,69 9 $59,59 6 $10,988,37 7 $59,09 9 $28,070,54 3 AV C + AF C

(1998$/yr ) $11,118,38 3 $3,39 3 $227,79 4 $178,59 4 $136,37 1 $10,462,12 9 $85,76 9 $59,59 6 $13,480,06 6 $59,09 9 $35,811,19 4
TCC , AVC , AF C ar e th e abbreviation s for Tota l Capita l Cost , Annua l Variabl e Cost , an dAnnua l Fixe dCost , respectively .



### 6-6 9P.7 8



### TABL E 6-31 . REGULATOR

Y ALTERNATIV

E 2 COST S FO

REXISTING SOURCES

Grou p o f Operation s Ope n Moldin g Close dMoldin g Centrifuga l Castin g Continuou s Laminatio n / Castin g Polyme r Castin g Pultrusio n SM C Manufacturin g Equipmen t

Cleanin g BM C Manufacturin g /

Mixin g Storag e o f

HA P Containin g Mat'l s Total s fo r th e Sourc e Categor y TC C (1998$ ) $85,967,92 1 $24,58 1 $996,06 1 $3,954,24 2 $18,25 8 $3,744,69 5 $5,46 5 $265,78 2 $4,639,28 1 $231,50 2 $99,842,78 9 AV C

(1998$/yr ) $14,728,09 6

$ 0 $97,67 6 $406,25 9 $ 0 $271,34 1 $ 0 $ 0 $78,82 9 $ 0 $15,582,19 9 AF C

(1998$/yr ) $16,475,38 5 $66,44 6 $205,44 7 $755,57 0 $44,78 8 $542,78 8 $13,64 8 $368,19 6 $986,49 9 $326,73 0 $19,785,49 8 AV C + AF C

(1998$/yr ) $31,203,48 1 $66,44 6 $303,12 3 $1,161,82 9 $44,78 8 $814,12 9 $13,64 8 $368,19 6 $1,065,32 7 $326,73 0 $35,367,69 7
TCC , AVC , AF C ar e th e abbreviation s for Tota l Capita l Cost , Annua l Variabl e Cost , an dAnnua l Fixe dCost , respectively . 

### TABL E 6-32 . REGULATOR Y ALTERNATIV E 2 COST S FO R NE W SOURCE S

Grou p o f Operation s Ope n Moldin g Close dMoldin g Centrifuga l Castin g Continuou s Laminatio n / Castin g Polyme r Castin g Pultrusio n SM C Manufacturin g Equipmen t

Cleanin g BM C Manufacturin g /

Mixin g Storag e o f

HA P Containin g Mat'l s Total s fo r th e Sourc e Categor y TC C (1998$ ) $49,894,05 4 $1,36 1 $782,78 1 $904,50 3 $55,68 8 $50,377,16 0 $417,02 4 $43,12 8 $64,447,33 4 $42,75 9 $166,965,79 3 AV C

(1998$/yr ) $2,757,38 9 $ 0 $91,58 9 $95,70 0 $ 0 $2,235,63 3 $18,10 0 $ 0 $2,440,84 7 $ 0 $7,729,25 8 AF C

(1998$/yr ) $10,113,86 4 $3,39 3 $159,04 8 $150,83 4 $136,37 1 $8,136,49 6 $67,66 9 $59,64 1 $10,818,30 7 $59,14 4 $29,704,76 6 AV C + AF C

(1998$/yr ) $12,871,25 2 $3,39 3 $250,63 7 $246,53 5 $136,37 1 $10,462,12 9 $85,76 9 $59,64 1 $13,259,15 3 $59,14 4 $37,434,02 4 TCC , AVC , AF C ar e th e abbreviation s for Tota l Capita l Cost , Annua l Variabl e Cost , an dAnnua l Fixe dCost , respectively .



### 6-7 0P.7 9



### TABL E 6-33 . REGULATOR

Y ALTERNATIV

E 3 COST S FO

REXISTIN

G SOURCE S

Grou p o f Operation s Ope n Moldin g Close dMoldin g Centrifuga l Castin g Continuou s Laminatio n / Castin g Polyme r Castin g Pultrusio n SM C Manufacturin g Equipmen t

Cleanin g BM C Manufacturin g /

Mixin g Storag e o f

HA P Containin g Mat'l s Total s fo r th e Sourc e Category TC C (1998$ ) $237,457,54 0 $24,58 1 $1,931,74 3 $5,565,69 4 $18,25 8 $17,470,18 5 $7,722,53 0 $265,78 2 $36,842,57 4 $231,50 2 $307,530,38 9 AV C

(1998$/yr ) $12,777,22 8

$ 0 $125,60 7 $561,28 6 $ 0 $870,04 3 $424,89 8 $ 0 $569,46 7 $ 0 $15,328,53 0 AF C

(1998$/yr ) $40,582,71 9 $66,44 6 $398,40 7 $1,063,82 3 $44,78 8 $2,774,75 1 $1,372,41 7 $372,29 4 $4,658,32 8 $330,82 8 $51,664,80 1 AV C + AF C

(1998$/yr ) $53,359,94 7 $66,44 6 $524,01 5 $1,625,10 9 $44,78 8 $3,644,79 4 $1,797,31 5 $372,29 4 $5,227,79 5 $330,82 8 $66,993,33 1 TCC , AVC , AF

C ar e th e abbreviation s fo

r Tota l Capita l Cost, Annua

l Variable Cost, an

dAnnua l Fixe dCost, respectively . 

### TABL E 6-34 . REGULATOR Y ALTERNATIV E 3 COST S FO R NE W SOURCE S
Grou p o f Operation s Ope n Moldin g Close dMoldin g Centrifuga l Castin g Continuou s Laminatio n / Castin g Polyme r Castin g Pultrusio n SM C Manufacturin g Equipmen t

Cleanin g BM C Manufacturin g /

Mixin g Storag e o f

HA P Containin g Mat'l s Total s fo r th e Sourc e Category TC C (1998$ ) $245,598,47 7 $1,36 1 $1,270,51 2 $965,09 0 $55,68 8 $49,649,83 4 $421,29 0 $43,12 8 $34,800,78 6 $42,75 9 $332,848,34 9 AV C

(1998$/yr ) $9,866,45 1 $ 0 $75,14 3 $106,95 8 $ 0 $2,247,73 7 $18,82 6 $ 0 $608,31 9 $ 0 $12,923,43 5 AF C

(1998$/vr ) $40,089,65 1 $3,39 3 $260,95 4 $170,70 8 $136,37 1 $7,976,54 7 $68,65 0 $60,22 5 $4,513,96 4 $59,72 8 $53,340,19 2 AV C + AF C

(1998$/yr ) $49,956,10 3 $3,39 3 $336,09 8 $277,66 6 $136,37 1 $10,224,28 4 $87,47 7 $60,22 5 $5,122,28 3 $59,72 8 $66,263,62 7 TCC , AVC , AF

C ar e th e abbreviation s fo

r Tota l Capita l Cost , Annua

l Variable Cost, an

dAnnua l Fixe dCost, respectively .



### 6-7 1

### TABL E 6-35 . COS T EFFECTIVENES S OFREGULATOR Y ALTERNATIV

E 2 FO REXISTIN G SOURCE S a , b

Grou p o f Operation s Ope n Moldin g Close dMoldin g Centrifuga l Castin g Continuou s Laminatio n / Castin g Polyme r Castin g Pultrusio n SM C Manufacturin g Equipmen t

Cleanin g BM C Manufacturin g /

Mixin g Storag e o f

HA P Containin g Mat'l s Total s fo r

th e Sourc e Categor y Regulator y Alternativ e 1 (MAC T Floor ) Tota l Cos t ($/vr ) $21,249,47 1 $66,44 6 $319,88 9 $600,76 1 $44,78 8 $190,24 7 $13,64 8 $367,59 9 $531,73 0 $326,13 3 $23,710,71 2 Emissio n

Reductio n (tons/yr ) 7056. 4 0. 0 44. 0 360. 6 0. 0 228. 1 0. 0 807. 1 153. 3 0. 0 8649. 5 Regulatory Alternativ e 2

Total Cos t ($/yr ) $31,203,48 1 $66,44 6 $303,12 3 $1,161,82 9 $44,78 8 $814,12 9 $13,64 8 $368,19 6 $1,065,32 7 $326,73 0 $35,367,69 7 Emissio n

Reductio n (tons/yr ) 13625. 2 0. 0 859. 6 580. 8 0. 0 348.2 0. 0 807. 1 292. 3 0. 0 16513. 2 Incrementa l

Tota l Cos t ($/vr ) $9,954,01 0 $ 0 ($16,767 ) $561,06 8 $ 0 $623,88 2 $ 0 $59 7 $533,59 7 $59 7 $11,656,98 5 Emissio n

Reductio n (tons/yr ) 6568. 7 0. 0 815. 5 220. 2 0. 0 120. 1 0. 0 0. 0 139. 0 0. 0 7863. 5 Averag e Cos t

Effectivenes s ($/ton ) $1,51 5 N/ A ($21 ) $2,54 8 N/ A $5,91 6 N/ A N/ A $3,48 2 N/ A $1,48 2

aThi s tabl e present s cos t effectivenes s value s fo

r group s o f operation s an

dth e sourc e categor

y i f the proposedrul e require s al l existin g facilitie s wit

h uncontrolle dHAP emission s greate r tha n o r equa l t o 10 0 tp y t o implemen

t th e above-the-floo

r contro l option o

f 95 % contro l fo

r th e following group s o

f operations : ope

n molding , centrifuga

l casting , continuou s lamination/casting , pultrusion , SMC manufacturing , an dBMC manufacturing/mixing . The averag e cos t

effectivenes s o

f th e regulator

y option fo

r eac h grou p o f operation s an

dthe sourc e categor

y is determine dusin g th e following formula :

Cost Effectiveness (S/ton) = Annual Cost of Regulatory Option (S ) - Annual Cost of MACT Floor (S ) Emission Reduction of

Regulatory Option (tons) - Emission Reduction of MACT Floor (tons)



### 6-12

### TABL E 6-36 . COS T EFFECTIVENES S OFREGULATOR Y ALTERNATIV

E 2 FO RNE WSOURCE S a

a, b

Grou p o f Operation s Ope n Moldin g Close dMoldin g Centrifuga l Castin g Continuou s Laminatio n / Castin g Polyme r Castin g Pultrusio n SM C Manufacturin g Equipmen t

Cleanin g BM C Manufacturin g /

Mixin g Storag e o f

HA P Containin g Mat'l s Total s fo r

th e Sourc e Categor y Regulator y Alternativ e 1 (MAC T Floor ) Tota l Cos t ($/vr ) $11,118,38 3 $3,39 3 $227,79 4 $178,59 4 $136,37 1 $10,462,12 9 $85,76 9 $59,59 6 $13,480,06 6 $59,09 9 $35,811,19 4 Emissio n

Reductio n (tons/vr ) 277. 2 0. 0 101. 6 215. 7 0. 0 760. 0 7. 3 0. 0 133. 6 0. 0 1495. 4 Regulator y Alterntiv e 2

Tota l Cos t ($/vr ) $12,871,25 2 $3,39 3 $250,63 7 $246,53 5 $136,37 1 $10,462,12 9 $85,76 9 $59,64 1 $13,259,15 3 $59,14 4 $37,434,02 4 Emissio n

Reductio n (tons/yr ) 497. 4 0. 0 655. 0 243. 6 0. 0 760. 0 7. 3 0. 0 133. 6 0. 0 2297. 0 Incrementa l

Total Cos t ($/vr ) $1,752,86 9 $ 0 $22,84 3 $67,94 0 $ 0 $ 0 $ 0 $4 5 ($220,913 ) $4 5 $1,622,83 0 Emissio n

Reductio n (tons/yr ) 220. 2 0. 0 553. 5 27. 9 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 801. 6 Averag e Cos t Effectivenes s ($/ton ) $7,96 0 N/ A $4 1 $2,43 5 N/ A N/ A N/ A N/ A N/ A N/ A $2,02 4

aThi s tabl e present s cos t effectivenes s value s fo

r group s o f operation s an

dthe sourc e categor

y i f th e proposedrule require s al l existin g facilitie s wit

h uncontrolledHA

P emission s greate

r tha n o r equa l t o 10 0 tp y t o implemen

t th e above-the-floor

contro l option o

f 95 % contro l fo

r th e following group s o

f operations : ope

n molding , centrifuga

l casting , continuou s lamination/casting , pultrusion , SMC manufacturing , an dBMC manufacturing/mixing . The averag e cos t

effectivenes s o

f the regulator

y option fo

r eac h grou p o f operation s an

dth e sourc e categor

y is determine dusing th e following formula :
Cost Effectiveness (S/ton) = Annual Cost of Regulatory Option (S) - Annual Cost of MACT Floor ($ ) Emission Reduction of

Regulatory Option (tons) - Emission Reduction of MACT Floor (tons)



### 6-7 3

### TABL E 6-37 . COS T EFFECTIVENES S OFREGULATOR Y ALTERNATIV

E 3 FO REXISTIN G SOURCE S a, b

Grou p o f Operation s Ope n Moldin g Close dMoldin g Centrifuga l Castin g Continuou s Laminatio n / Castin g Polyme r Castin g Pultrusio n SM C Manufacturin g Equipmen t

Cleanin g BM C Manufacturin g /

Mixin g Storag e o f

HA P Containin g Mat'l s Total s fo r th e Sourc e Categor y Regulator y Alternativ e 1 (MAC T Floor ) Tota l Cos t ($/vr ) $21,249,47 1 $66,44 6 $319,88 9 $600,76 1 $44,78 8 $190,24 7 $13,64 8 $367,59 9 $531,73 0 $326,13 3 $23,710,71 2 Emissio n

Reductio n (tons/yr ) 7056. 4 0. 0 44. 0 360. 6 0. 0 228. 1 0. 0 807. 1 153. 3 0. 0 8649. 5 Regulatory Alternatvi e 3

Total Cos t ($/vr ) $53,359,94 7 $66,44 6 $524,01 5 $1,625,10 9 $44,78 8 $3,644,79 4 $1,797,31 5 $372,29 4 $5,227,79 5 $330,82 8 $66,993,33 1 Emissio n

Reductio n (tons/yr ) 16898. 3 0. 0 1001. 1 683. 5 0. 0 466. 3 338. 6 807. 1 421. 7 0. 0 20616. 6 Incrementa l

Tota l Cos t ($/vr ) $32,110,47 7

$ 0 $204,12 5 $1,024,34 8 $ 0 $3,454,54 7 $1,783,66 7 $4,69 5 $4,696,06 5 $4,69 5 $43,282,61 9 Emissio n

Reductio n (tons/yr ) 9481. 8 0. 0 957. 0 317. 6 0. 0 238. 2 338. 6 0. 0 268. 4 0. 0 11967. 1 Averag e Cos t

Effectivenes s ($/ton ) $3,26 3 N/ A $21 3 $3,22 6 N/ A $14,50 5 $5,26 8 N/ A $17,49 5 N/ A $3,61 7

aThi s tabl e present s cos t effectivenes s values fo r

group s o f

operation s assumin g tha t th e propose drul e require s al l existin g facilitie s t o implemen t th e above-the-floo r

contro l optio n o f

95 % contro l fo r

th e followin g group s o f

operations : ope n molding , centrifuga l casting , continuou s lamination/casting , pultrusion , SM C manufacturing , an dBM C manufacturing/mixing . Th e averag e cos t

effectivenes s o f

th e regulator y optio n for eac h grou p o f

operation s an dth e sourc e categor y i s determine dusin g th e followin g formula :
Cost Effectiveness (S/ton) Annual Cost of Regulatory Option ($ ) - Annual Cost of MACT Floor ($ ) Emission Reduction of

Regulatory Option (tons) - Emission Reduction of MACT Floor (tons)



### 6-7 4TABL E 6-38 . COS T EFFECTIVENES S O FREGULATOR Y ALTERNATIV E 3 FO RNE WSOURCE S a b

Grou p o f Operation s Ope n Moldin g Close dMoldin g Centrifuga l Castin g Continuou s Laminatio n / Castin g Polyme r Castin g Pultrusio n SM C Manufacturin g Equipmen t

Cleanin g BM C Manufacturin g /

Mixin g Storag e o f

HA P Containin g Mat'l s Total s fo r th e Sourc e Categor y Regulatory Alternativ e 1 (MAC T Floor ) Tota l Cos t ($/vr ) $11,118,38 3 $3,39 3 $227,79 4 $178,59 4 $136,37 1 $10,462,12 9 $85,76 9 $59,59 6 $13,480,06 6 $59,09 9 $35,811,19 4 Emissio n

Reductio n (tons/vr ) 277. 2 0. 0 101. 6 215. 7 0. 0 760. 0 7. 3 0. 0 133. 6 0. 0 1495. 4 Regulator y Alternativ e 3

Tota l Cos t ($/vr ) $49,956,10 3 $3,39 3 $336,09 8 $277,66 6 $136,37 1 $10,224,28 4 $87,47 7 $60,25 5 $5,122,28 3 $59,72 8 $66,263,62 7 Emissio n

Reductio n (tons/yr ) 759. 0 0. 0 733. 8 248. 1 0. 0 760. 0 7. 3 0. 0 133. 6 0. 0 2641. 9 Incrementa l

Tota l Cos t ($/vr ) $38,837,71 9

$ 0 $108,30 4 $99,07 2 $ 0 ($237,845 ) $1,70 7 $62 9 ($8,357,783 ) $62 9 $30,452,43 3 Emissio n

Reductio n (tons/yr ) 481. 9 0. 0 632. 2 32. 4 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 1146. 5 Averag e Cos t Effectivenes s ($/ton ) $80,59 9 N/ A $17 1 $3,05 8 N/ A N/ A N/ A N/ A N/ A N/ A $26,56 1

aThi s tabl e present s cos t effectivenes s value s fo r

group s o f

operation s assumin g that th e propose drul e require s al l existin g facilitie s t o implemen t th e above-the

floo r contro l optio n o f

95 % contro l fo r

th e followin g group s o f

operations : ope n molding , centrifuga l casting , continuou s lamination/casting , pultrusion , SM C manufacturing , an dBM C manufacturing/mixing . b Th e averag e cos t

effectivenes s o f

th e regulator y optio n for eac h grou p o f

operation s an dth e sourc e categor y i s determine dusin g th e followin g formula :
Cost Effectiveness (S/ton) = Annual Cost of Regulatory Option ($ ) - Annual Cost of MACT Floor ($ ) Emission Reduction of

Regulatory Option (tons) - Emission Reduction of MACT Floor (tons)

6-7 5

o oP.8 4

6. 6 REFERENCE S 1 Lette r fro mGrotke , M. , Alph aOwen s Cornin g (AOC ) t o Strum , M. , EPA/ESD . May 1 , 1998 . lp . 2 Lette r fro mBrody , B.G. , Ashlan dChemica l Company , t o Strum , M. , EPA/ESD . May 7 , 1998 . Respons e t o reques t for cos t informatio n for

corrosio n resistan t

resin s produce db y Ashlan dChemica l Company . 2 pp . 3 Ashlan dChemica l Company . HETRON ® an dAROPOL TM Resi n Selectio n Guid e for Corrosio n Resistan t

FR P Applications . 1997 . 4 7 pp . 4 Lette r fro mCraigie , L.J. , Do w Chemica l Company , t o Strum , M. , EPA/ESD . Apri l 27 , 1998 . 1 p . Respons e t o reques t

for cos t informatio n for

corrosio n resistan t

resin s produce dby Do w Chemica l Company . 5 Do w Chemica l Company . DERAKAN E Epox y Viny l Este r Resins : Chemica l Resistanc e an d Engineerin g Guide . Octobe r 1995 . 4 0 pp . 6 Do w Chemica l Company . DERAKAN E Epox y Viny l Este r Resins : Technica l Produc t Information . Marc h 1996 . 1 6 pp . 7 Lette r fro mHerzog , D.J. , Interplasti c Corporation , t o Jemison , R.M. , Pacifi c Environmenta l Services , Inc . Augus t

17 , 1998 . 1 p . Respons e t o reques t for cos t informatio n for

corrosio n resistan t resin s produce db y Interplasti c Corporation . Docke t No . U-D-81 3 8 Interplasti c Corporation . CoREZYN ® Viny l Este r Resins . 1996 . 3 3 pp . 9 Interplasti c Corporation . CoREZYN ® Isophthali c Corrosio n Resistan t Resins . 1998 . 1 0 pp . 1 0 Facsimil e fro mHelpler , A. , Reichhold , t o Strum , M. , EPA/ESD . Jun e 1 , 1998 . 1 1 pp . Respons e t o reques t

for cos t an dHA P conten t

informatio n for

corrosio n resistan t

resin s produce db y Reichhold . 1 1 Reichhold . Atlac ® an dDion® : Corrosio n Resi n Selectio n an dDesig n Guide . 1996 . 4 4 pp . 1 2 ERG . Daf

t Cos t Procedure s Documentatio n Memorandu mfo r Boa t MAC T Standard . Apri l 16,1999 . p p 3 -7 . 1 3 Lette r fro mHollenbeck , M. , Coo k Composite s & Polymers , t o Proctor , M.S. , Pacifi c Environmenta l Services , Inc . Augus t 26,1998 . Respons e t o reques t for cos t an dpropertie s informatio n fo r

pigmente dproduction , clear production , an dtoolin g gel coats produce db y Coo k

Composite s & Polymers . 2 pp .

6-7 6P.8 5

1 4 Facsimil e fro mNissila , P. , Nest e Polyeste r America , t o Proctor , M.S. , Pacifi c Environmenta l Services , Inc . Novembe r 6 , 1998 . Respons e t o reques t for cos t an d propertie s informatio n for pigmente dproduction , clear production , an dtoolin g gel coat s produce db y Nest e Polyeste r America. 4 pp . 1 5 Facsimil e fro mKigweba , K. , Ferr o Corporation , t o Proctor , M.S. , Pacifi c Environmenta l Services , Inc . Novembe r 3 , 1998 . Respons e t o reques t for cos t an dpropertie s informatio n fo r

toolin g ge l coats produce db y Ferr o Corporation . 1 6 Telecon . Hester , C , Pacifi c Environmenta l Services , Inc . wit h Bowi e Manufacturing , Inc . Jun e 24,1998 . Cos t

dat aon indirec t

cost s associate dwit

h switchin g t o lo w HA P resins . 1 7 Telecon . Jemison , R. , Pacifi c Environmenta l Services , Inc . wit h Bowi e Manufacturing , Inc . Apri l 3 , 1998 . Resi n an dgel coat HA P conten t

information . 1 8 Telecon . Proctor , M . an dMcKee , S. , Pacifi c Environmenta l Services , Inc . wit h Dixie-Pacifi c Manufacturin g Company , Inc . Jul y 29 , 1998 . Indirec t cos t dat aassociate dwit

h th e switc h t o lo w HA P resin/ge l coat . 1 9 Telecon . Hester , C , Pacifi c Environmenta l Services , Inc . wit h Fibe r Pro , Inc . Jun e 18 , 1998 . Indirec t cos t dat aassociate dwit

h th e switc h t o lo w HA P resin/ge l coat . 2 0 Telecon . McKee , S. , Pacifi c Environmenta l Services , Inc . wit h LASC O Bathware-Yel m Plant . Septembe r

2 , 1998 . Indirec t

cos t dat aassociate dwit

h th e switc h t o lo w HA P resin/ge l coat . 2 1 Telecon . McKee , S. , Pacifi c Environmenta l Services , Inc . wit h GL& V LaValle y Industries , Inc . Augus t

27,1998 . Indirec t

cos t dat aassociate dwith th e switc h t o lo w HA P resin/ge l coat . 2 2 Telecon . McKee , S. , Pacifi c Environmenta l Services , Inc . wit h Shenandoah Fiberglas s Product s Company . Jul y 30 , 1998 . Indirec t cos t dat aassociate dwit

h th e switc h t o lo w HA P resin/ge l coat . 2 3 Telecon . Jemison , R. , Pacifi c Environmenta l Services , Inc . wit h Shakespear e Electronic s & Fiberglas s Division . Marc h 25,1998 . Cos t dat aassociate dwith th e switc h t o lo w HA P resin/ge l coat . 2 4 Telecon . McKee , S. , Pacifi c Environmenta l Services , Inc . wit h Bittne r Industries , Inc . Augus t 4,1998 . Cos t

dat aassociate dwit

h th e switc h t o lo w HA P resin/ge l coat . 2 5 ERG . Daf

t Cos t Procedure s Documentatio n Memorandu mfor Boat MAC T Standard . Apri l 16,1999 . p p 8 -19 . 6-7 7P.8 6

2 6 Evaluatio n o f

Pollutio n Preventio n Technique s t o Reduc e Styren e Emission s fro mOpe n Contac t Moldin g Processes . Volum e I , Fina l Report . Prepare dB y Emery J . Kong , Mark A . Bahner , Robert

S . Wright , an dC . Andre w Clayton , Researc h Triangl e Institute . Prepare d fo r Gedde s Ramsey , Ai r

Pollutio n Preventio n an dContro l Division , Nationa l Ris k Managemen t

Researc h Laboratory , Offic e o f Researc h an dDevelopment , U.S . EPA . Researc h Triangl e Park , NC . EP A Publicatio n No . EPA-600/R-97-018a . 2 7 Telecon . Larson , P. , Larson/Glastro n Boats , with Palmer , B. , Eastern Researc h Group , Inc . Decembe r

7 an d8,1998 . Carpe t

an dfabri c adhesive s an dcost s associate dwit h switchin g t o non-atomize dresi n application . 2 8 Interoffic e Correspondenc e fro mAnderson , R . D. , Th e Bud dCompan y Plastic s Division , t o Shah , V . C , Th e Bud dCompan y Plastic s Division . Septembe r 28 , 1995 . 2 9 Tri p Report . Proctor , M.S . (Pacifi c Environmenta l Services , Inc.) . Report o f Plan t Visi t t o Glasforms , Inc. , Birmingham , Alabama , o n Januar y 15 , 1998 . Prepare dfo r U.S . Environmenta l Protectio n Agency . Jul y 10 , 1998 . 12 8 pp . 3 0 Surve y Respons e an dattachment s fro mBass , K.E. , Glasforms , Inc . t o Jordon , B.C. , EPA/ESD . Augus t

20,1993 . Respons e t o Sectio n 11 4 screenin g informatio n reques t for th e Sa n Hose , C A facility . Docke t No . H-D-28 3 3 1 Telecon . Proctor , M. , Pacifi c Environmenta l Services , Inc . wit h Wort h Chemica l Corporation . Augus t

17 , 1999 . Cos t

dat ao n aceton e an dmethylen e chloride . 3 2 Fiberglas s Coatings , Inc . Suppl y Catalog . 1998 . Pag e 34 . 3 3 Telecon . McKee , S. , Pacifi c Environmenta l Services , Inc. , with McQuarrie , T. , Glasforms , Inc . Octobe r

16 , 1998 . Telephon e contac t repor t collectin g informatio n concernin g cost s o f mixe r cover s fo r

th e facility i n Birmingham , Alabama . 3 4 U.S . Environmenta l Protectio n Agency , Emissio n Standard s Division . Regulatory Procedure s Manual . Par t

3 , Volum e X , Sectio n 2.2 . Octobe r 1990 . 3 5 Wag e rate s for

th e Architectura l Coating s Informatio n Collectio n Reques t (ICR )

6-7 8P.8 7

MEMORANDU M TO : Projec t

Fil e Plasti c Composite s NESHA P ES D Projec t

No . 93/5 8 FROM : Madelein e Stru m

EPA/OAQPS/CCP G DATE : Marc h 16,199 8 SUBJECT : Sectio n 1 - Sourc e Category Descriptio n Thi s memorandu mcontain s th e fina l versio n ofth e sourc e category descriptio n memorandu mfo r

th e Plasti c Composite s NESHAP . Thi s mem o i s include da s Sectio n 1 of th e Supplementary Informatio n Documen t (docke t ite mno . ) .TABL E O FCONTENT S P.8 8

LIS T O FFIGURE S Pag e iv LIS T O FTABLE S i v 1. 1 INTRODUCTIO N 1- 1 1.1. 1 Genera l Introductio n 1.1. 2 HA P Emission s 1.1. 3 Processe s 1.1. 4 Product s 1- 1 1- 1 1- 1 1- 2 1. 2 GENERA L DESCRIPTIO N 1- 2 1.2. 1 Type s o f

Industria l Group s Include d 1.2. 2 Distributio n o f

Source s b y SI C Cod e 1.2. 3 Distributio n of

Source s b y Geographi c Locatio n 1.2. 4 Numbe r

o f Employee s 1.2. 5 Distributio n b y Proces s 1.2. 6 Resi n Usag e b y Process 1.2. 7 Majo r

Market s an dProduct s 1. 3 PROCES S DESCRIPTION S AN D EMISSIO N POINT S 1- 2 1- 3 1-3 1- 8 1- 8 1-1 0 1-1 0 1-1 3 1.3. 1 Bul k

Moldin g Compoun d(BMC ) Manufacturin g 1.3. 2 Centrifugal Castin g 1.3. 3 Compressio n Moldin g 1.3. 4 Continuou s Lamination/Continuou s Castin g 1.3. 5 Filamen t

Windin g 1.3. 6 Ge l Coatin g 1.3. 7 Han dLay-up/Bucke t an dToo l Applicatio n 1.3. 8 Injectio n Moldin g 1.3. 9 Polyme r

Castin g 1.3.1 0 Pressure-Fe dRoller/Flo w Coate r Applicatio n 1.3.1 1 Pultrusio n 1.3.1 2 Resi n Transfe r

Moldin g (RTM ) 1.3.1 3 Shee t

Moldin g Compoun d(SMC ) Manufacturin g 1.3.1 4 Spray Lay-u p 1-1 5 1-1 3 1-1 4 1-1 4 1-1 6 1-1 7 1-1 8 1-1 9 1-1 9 1-2 0 1-2 1 1-22 1-23 1-2 4

DRAF T 3/16/9 8P.8 9

TABL E O FCONTENT S (concluded ) Pag e 1.4 ANCILLAR Y PROCESSE S 1-2 5 1.4. 1 Cleanin g 1-2 5 1.4. 2 Resi n Mixin g 1-26 1.4. 3 Hazardou s Ai r

Pollutan t (HAP ) Containin g Materia l Storag e 1-26 1. 5 REFERENCE S 1-2 8

ii i DRAF T 3/16/9 8P.9 0

LIS T O F FIGURE S Pag e HGUR E 1- 1 NUMBE RO FEMPLOYEE S REPORTE D B Y MAJO RSOURCE S

I N TH E 199 3 INDUSTR Y SURVE Y 1 - 9

LIS T O F TABLE S TABL E 1- 1 DISTRIBUTIO N O FSI C CODE S FO RSOURCE S I N TH E MAC T DATABAS E

1- 4 TABL E 1-

2 DISTRIBUTIO N O FMAJO RSOURCE S B Y STAT E 1-6 TABL E 1-3 DISTRIBUTIO N O FMAJO RSOURCE S B Y PROCES S 1-1 1 TABL E 1-

4 199 2 US E O FTHERMOSE T PLASTI C RESIN S B Y PROCES S 1-1 2

i v DRAF T 3/16/9 8P.9 1

1. 0 DESCRIPTIO N O FTH E SOURC E CATEGOR Y 1. 1 INTRODUCTION 1 1.1. 1 Genera l Introductio n Th e plasti c composite s sourc e category involve s th e productio n o f plasti c product s from cros s linkin g resins , usuall y in combinatio n wit h reinforcin g material s an dinorgani c fillers . Th e productio n o f

product s whic h d o no t

contai n reinforcin g material s (i.e. , non-reinforce dplastics ) i s als o include di n thi s category a s wel l a s th e productio n o f intermediat e compound s whic h ar e late r use dt o mak e th e final plasti c products . Thi s sourc e category wil l b e limite dt o thos e resin s whic h contai n styrene , eithe r b y itsel f o r wit h acombinatio n o f

othe r monomer s o r

solvents . Plastic s ar e divide dint o tw o majo r group s know n a s thermose t an dthermoplastic . Onc e cure dint o asoli dform , thermose t material s remai n ahar dsolid . Thermoplastics , o n th e othe r hand , can b e melte dthroug h th e applicatio n of heat . Th e plasti c composite s sourc e category include s onl y thermose t

resi n materials . Thermose t resin s ar e usuall y liquid s o r lo w meltin g poin t solid s i n thei r

initia l form . I

n th e productio n o f

finishe dgoods , thermosettin g resin s ar e cure dint o asoli db y us e o f a n initiator , heat , o r

acombinatio n of

both . 1.1. 2 Hazardou s Ai r

Pollutan t (HAP ) Emission s Th e HA P emission s fro mth e plasti c composite s sourc e category ar e du e primaril y fro m th e evaporatio n o f

styren e an dothe r

HA P organi c liquid s containe din th e resi n durin g th e applicatio n and/o r

curin g (cross-linking ) o f th e resin . Sinc e th e styren e containe din th e resi n participate s i n th e cros s linkin g reaction , no t al l o f i t i s emitted . Severa l differen t emissio n reductio n technique s ar e applie dt o reduc e emission s fro mth e productio n o f plasti c composites . Th e differen t

emissio n reductio n technique s ar e discusse di n detai l i n th e Emissio n Reductio n Technique s Memorandum. 2 1.1. 3 Processe s Ther e i s awid e variety o f processe s that

utiliz e styrene-containin g cross-linkin g resin s t o mak e plastics . Suc h processe s includ e centrifugal casting , compressio n molding , continuou s lamination/continuou s casting , filamen t winding , ge l coatin g (whic h i s typicall y don e in combinatio n with on e ofth e othe r processes) , han dlay-up/bucke t an dtoo l application , injectio n 1- 1 DRAF T 3/16/9 8P.9 2

molding , polyme r

casting , pressure-fe drolle r o r flo w coate r

application , pultrusion , resi n transfe r moldin g (RTM) , an datomize dspray lay-up . Tw o processe s whic h ar e use dt o manufactur e intermediat e product s ar e th e manufactur e of shee t moldin g compoun d(SMC ) an dmanufactur e o f bul k moldin g compoun d(BMC) . Man y facilities , includin g thos e that d o no t perfor mge l coating , us e multipl e processe s t o mak e thei r products . Fo r

example , afacilit

y that perform s th e filamen t windin g proces s usuall y conduct s han dlay-u p and/o r spray lay-u p operation s a t th e sam e facility . However , ther e ar e facilitie s that ma y conduc t onl y on e process ; for

example , a facility makin g product s usin g th e pultrusio n proces s may no t hav e any othe r

plastic s composit e manufacturin g processe s o n site . Differen t processe s hav e differen t

emission s characteristic s an ddifferent applicabl e emissio n reductio n techniques . Fo r example , ge l coating , spray lay-up , han dlay-up , an d filamen t windin g (whic h ar e characterize dunde r a n umbrell aterm"ope n molding" ) ar e relativel y hig h emittin g processe s a s compare dt o RTM , compressio n molding , an dinjectio n moldin g (whic h ar e characterize dunde r th e ter m"close dmolding") . Th e emissio n reductio n techniqu e of lowerin g th e HA P conten t o f th e resi n i s effectiv e for

reducin g emission s fro mope n moldin g processes , bu t

no t necessaril y fo r

th e othe r type s o f processes . 1.1. 4 Product s Th e sourc e category produce s awid e variety o f product s traversing suc h broa dmarke t segment s a s transportation , construction , electronics , consume r products , marine , an daerospace . Thi s divers e sourc e category encompasse s a t leas t 4 3 Standar dIndustria l Classificatio n (SIC ) codes. 3 ' 4 However , boat

manufacturin g ha s bee n specificall y exclude dfro mthi s rul e developmen t

effor t an dwil l b e addresse dunde r separat e action . W e hav e estimate dtha t ther e ar e approximatel y 44 0 majo r source s i n th e Unite dStates . Informatio n abou t th e vas t majority o f thes e source s was provide di n th e 199 3 industry screenin g surveys . Additiona l dat awer e collecte ddurin g sit e visits , contac t reports , an dfro mfacility operatin g permits . 1. 2 GENERA L DESCRIPTIO N 1.2. 1 Type s o f

Industria l Group s Included 3 Th e SI C code s include di n th e plasti c composite s sourc e category wer e determine db y searchin g th e toxi c releas e inventor y syste m(TRIS ) databas e for facilitie s emittin g styrene , a 1- 2 DRAF T 3/16/9 8P.9 3

majo r HA P emitte db y thi s sourc e category . Th e TRI S databas e identifie datota l set o f 23 2 SI C code s unde r

th e pollutan t

styrene . Th e majorit

y o f thes e code s wer e delete dfor categorie s that clearl y di dnot

belon g i n th e plasti c composite s sourc e category . Th e 4 3 remainin g SI C code s contai n facilitie s involve di n th e productio n of plasti c composites . However , i t i s cautione dthat not al l facilitie s tha t

may fal l unde r

thes e 4 3 SI C code s ar e in th e composite s industry . In addition , ther e coul db e facilitie s no t encompasse db y thes e 4 3 SI C code s that may us e thermose t resin s i n thei r

operations . Wit

h thes e caveat s i n mind , Tabl e 1- 1 present s th e 4 3 SI C code s potentiall y covere dunde r th e plasti c composite s NESHAP . 1.2. 2 Distributio n o f

Source s b v SI C Code 3 4 Th e distributio n o f

majo r source s i n th e plasti c composite s sourc e category b y SI C cod e i s show n i n Tabl e 1-1 . Th e majorit y of th e source s (7 3 percent ) ar e classifie dunde r SI C code s 30 7 an d308 , whic h classifie s miscellaneou s plastic s products . SI C cod e 30 7 i s a n ol dcod e use din th e 197 2 editio n o f

th e Standar dIndustria l Classificatio n Manual 5 , but TRI S stil l include s several facilitie s with thi s code . Approximatel y 6 percen t o f th e source s include din th e composite s industr y ar e classifie dunde r SI C cod e 371 , whic h applie s t o moto r vehicle s an dmoto r

vehicl e equipment . Fo r

approximatel y 5 percen t o f th e majo r

source s th e SI C code s wer e no t reported . Th e remainin g 1 6 percen t ofth e source s are distribute dove r 2 5 different

three-digi t

SI C codes . Tabl e 1- 1 show s th e SI C cod e distributio n an dth e descriptio n for eac h SI C code . 1.2. 3 Distributio n o f

Source s b v Geographi c Location 6 Th e geographi c location s o f majo r source s involve din th e plasti c composite s industry ar e show n i n Tabl e 1-2 . Th e geographi c informatio n was obtaine dfro msit e specifi c informatio n collecte dfo r

thi s standar d(e.g. , th e 199 3 industry screenin g surveys , tri p reports , an dtelephon e contac t reports) . Fo r

thi s analysis , amajo r

sourc e i s define da s asourc e wit h potential emission s o f 1 0 ton s pe r

year o r mor e o f asingl e hazardou s ai r

pollutan t (HAP ) o r

2 5 tp y o r mor e o f any combinatio n o f

HAP . A detaile ddiscussio n o f ho w facility emission s wer e determine do n a proces s basi s i s provide di n th e Emissio n Factor/Baselin e Emissio n memorandu m(SI D chapte r 3) . Tabl e 1-

2 show s tha t

th e larges t

concentratio n o f

facilitie s i s i n Ohi o (42) , followe db y Indian a(38) , an dCalifomi a(34) .

1- 3 DRAF T 3/16/9 8P.9 4



### TABL E 1- 1 DISTRIBUTION OFSI

C CODES FORSOURCES I N TH E MAC T DATABASE3 4 

### ' 6 SI C Cnrl p 243 4 251 9 252 2 254 1 259 9 282 1 307 9 308 2 308 3 308 4 308 7 308 8 308 9 328 1 329 6 329 9 343 1 349 9 353 1 353 3 354 6 356 1 356 4 358 9 361 2 361 3 Three-Digi t

ST C POH P 24 3 25 1 25 2 25 4 25 9 28 2 30 7

30 8

32 8 32 9 34 3 34 9 35 3 35 4 35 6 35 8 36 1 Fou r H i ai t ST P CnH p Titlf

Woo dKitche n Cabinet s Househol dFurniture , NE C Meta l Offic e Furnitur e Woo dPartitions , Shelving , Lockers , etc . Furnitur e an dFixtures , NE C Plasti c Materials , Syntheti c Resins , & Nonvulcanizabl e

Elastomer s Plastic s Products , NE C Unsupporte dPlasti c Profil e Shape s Laminate dPlastic s Plastic s Pip e Custo mCompoun dResin s Plastic s Plumbin g Fixture s Plastic s Products , NE C Cu t Ston e an dSton e Product s Minera l Woo l Nonmetalli c Minera l Products , NE C Enamele dIro n an dMeta l Sanitary Ware Fabricate dMeta l Products , NE C Constructio n Machiner y an dEquipmen t Oil/Ga s Fiel dMachinery/Equip . Power-Drive n Han dTool s Pumps an dPumpin g Equipmen t Blower s an dFan s Servic e Industr y Machines , NE C Powe r Transformer s Switchgear

an dSwitchboar dApparatu s Majo r Snnrcp.s*

- 1 1 1 1 1 2 3 8 2 2 0 6 8 7 4 17 0 5 2 3

2

3 Percen t

o f TntnlCWA 1

- 0. 2 0. 2 0. 2 0. 2 0. 2 0. 5 8. 7 0. 5 4. 6 1.4 1. 8 16. 9 38. 9 1. 1 0. 5 0. 7 0. 2 0. 2 0. 2 0. 2 0. 2 0. 5 0. 2 0. 2 0. 2 0. 7 

### 1- 4 DRAF T 3/16/9 8P.9 5



### TABL E 1- 1 (CONCLUDED ) SI C Cnrl p 362 1 364 7 366 3 367 9 371 1 371 3 371 4 371 5 371 6 372 8 374 3 379 2 379 9 382 1 394 9 399 3 399 9 N A Three-Digi t

ST C TnH p 36 2 36 4 36 6 36 7

37 1

37 2 37 4 37 9 38 2 39 4 39 9 N A FniirniaitSTrPnHpTitl P Motor s an dGenerator s Vehicular Lightin g Equipmen t Radio/Televisio n Broadcasting/Communicatio n Equipmen t

Electroni c Components , NE C Moto r Vehicles/Passenge r

Car Bodie s Truc k an dBu s Bodie s Moto r Vehicle s Parts/Accessorie s Truc k Trailer s Moto r Home s Aircraf t Parts/Equipment , NE C Railroa dEquipmen t Trave l Trailers/Camper s Transportatio n Equipment , NE C Laboratory Equipmen t

an dSupplie s Sporting/Athleti c Goods , NE C Signs/Advertisin g Specialtie s Manufacturin g Industries , NE C N o SI C Cod e reporte d TOTA L Majo r Snnrcp.s " 1 2 1 1 2 9 9 1 5 1 1 1 3 1 2 4 2 1 3 2 1 43 7 Percen t

o f Tnt.n l (<?„-_* 0. 2 0. 5 0. 2 0. 2 0. 5 2. 1 2. 1 0. 2 1. 1 0. 2 0. 2 3. 0 0. 2 0. 5 0. 9 0. 5 3. 0 4. 8 10 0 Majo r source s i n thi s tabl e are source s that hav e th e potentia l t o emi t 1 0 ton s pe r

yea r o r more ofan y singl e hazardou s ai r pollutan t o r 2 5 ton s pe r

yea r o r more o f any combinatio n o f

hazardou s ai r

pollutants . Value s show n i n th e tabl e ma y no t ad du p t o 10 0 percen t

du e t o rounding .



### 1- 5 DRAF T 3/16/9 8P.9 6



### TABL E 1- 2 DISTRIBUTIO

N O FMAJORSOURCES B Y STATE 6

Stat e Alabam a Arkansa s Arizon a Californi a Colorad o Connecticu t Delawar e Florid a Georgi a Hawai i Idah o Illinoi s Indian a Iow a Kansa s Kentucky Louisian a Main e Marylan d Massachusett s Michiga n Minnesot a Mississipp i Missour i Nebrask a Nevad a Ne w Hampshir e Numbe r o f Majo r Source s 9 4 3 3 4 1 1 3 1 8 9 1 3 1 5 3 8 1 1 1 1 6 3 2 2 3 1 7 1 3 4 1 0 5 2 2 Percen t o f Total 2. 1 0. 9 0. 7 7. 8 0. 2 0. 2 0. 7 4. 1 2. 1 0. 2 0. 7 3. 4 8. 7 2. 5 2. 5 1.4 0. 7 0. 5 0. 5 0. 7 3. 9 3. 0 0. 9 2. 3 1. 1 0. 5 0. 5 

### 1- 6 DRAF T 3/16/9 8P.9 7

TABL E 1-

2 (Concluded )

Stat e Ne w Jerse y Ne w Mexic o Ne w York Nort h Carolin a Nort h Dakot a Ohi o Oklahom a Orego n Pennsylvani a South Carolin a South Dakot a Tennesse e Texa s Uta h Virgini a Washingto n Wes t Virgini a Wisconsi n TOTAL S Numbe r o f Majo r Source s 4 1 9 2 0 3 4 2 5 1 1 2 5 9 2 1 1 2 5 3 9 1 1 2 1 6 43 7 Percen t o f Tota l 

## (%r 0. 9 0. 2 2. 1 4. 6 0. 7 9. 6 1. 1 2. 5 5. 7 2. 1 0. 5 2. 5 5. 7 0. 7 2. 1 2. 5 0. 5 3. 7 100. 0 Value s show n i n th e tabl e ma y no t ad du p t o 10 0 percen t

du e t o rounding .

1- 7 DRAF T 3/16/9 8P.9 8

1.2. 4 Numbe r

o f Employees 6 Th e numbe r

o f employee s reporte db y majo r source s i s show n in Figur e 1-1 . Employmen t dat awer e obtaine dfro msit e specifi c informatio n collecte dfor thi s standar d(mainl y th e 199 3 industr y screenin g surveys) . I n th e screenin g survey , facilitie s wer e aske dt o report th e numbe r o f employee s attache dt o th e plasti c composite s operatio n an dth e numbe r o f employee s o f

th e busines s enterpris e that

own s th e facility . Th e facilitie s wer e aske dt o provid e th e employmen t informatio n i n range s (0-100 ; 101-250 ; 251-500 ; 501-750 ; 751-1,000 ; 1,001-1,500 ; an d>1,500) . Fro mth e tota l 43 7 majo r facilities , informatio n o n th e numbe r of employee s attache dt o plasti c composite s operation s was availabl e for 40 0 facilitie s an dinformatio n o n paren t compan y employmen t

was availabl e fo r

40 6 facilities . Th e employmen t informatio n for

employee s directl y attache dt o plasti c composite s operation s show s that approximatel y 8 0 percen t o f th e majo r facilitie s emplo y 10 0 employee s o r less , 1 2 percen t

emplo y betwee n 10 1 an d25 0 employees , 5 percen t

emplo y betwee n 25 1 an d50 0 employees , 2 percen t emplo y betwee n 50 1 an d1,00 0 employees , an dles s than 1 percen t emplo y mor e than 1,000 employees . Th e informatio n o n th e numbe r o f employee s of

th e busines s enterpris e o r paren t compan y tha t

own s individua l facilitie s indicates tha t 5 4 percen t

of thes e companie s emplo y 10 0 employee s o r less , 1 6 percen t

emplo y betwee n 10 1 an d25 0 employees , 6 percen t emplo y betwee n 25 1 an d50 0 employees , 7 percen t

emplo y betwee n 50 1 an d1,000 employees , an d1 7 percen t emplo y mor e tha n 1,00 0 employees . 1.2. 5 Distributio n b y Process 6 Ther e ar e anumbe r

o f differen t processe s that

ca n b e use dt o produc e plasti c composites . A ful l descriptio n ofth e majo r processe s i s provide di n Sectio n numbe r 1. 3 ofthi s memorandum . However , ther e may b e additiona l processe s o r variation s o f

th e majo r

processe s tha t

ar e not describe di n Sectio n 1.3 . Th e followin g fabricatio n processe s ar e described : BM C manufacturing , centrifugal casting , compressio n molding , continuou s lamination/continuou s casting , filamen t

winding , ge l coating , han dlay-up/bucke t an dtoo l application , injectio n molding , polyme r

casting , pressure-fe droller/flo w coate r application , pultrusion , RTM , SM C manufacturing , an datomize dspray lay-up . Ther e ar e anumbe r o f facilitie s that

carry out mor e tha n on e proces s a

t thei r facility . Fo r

example , anumbe r

o f 1- 8 DRAF T 3/16/9 8

### FIGUR E 1- 1 Numbe r o

f Employee s Reporte d by Majo r Source s i n th e 199 3 Industry Surve y 35 0

100 o rles s 101-25 0 251-50 0 501-75 0 Numbe r o

f Employee s i r

751-100 0 1001-150 0 >150 0

1- 9 DRAF T 3/16/9 8p. 1

facilitie s combin e filamen t windin g wit

h spray lay-up , han dlay-up , and/o r pressure-fe d roller/flo w coate r

applicatio n processe s i n orde r t o produc e pipin g an dtanks . Several facilitie s tha t manufactur e moldin g compound s subsequentl y us e thi s material in thei r ow n injectio n o r compressio n moldin g operations . Tabl e 1- 3 show s th e distributio n ofth e 43 7 majo r source s b y productio n process . Facilitie s that us e several different

processe s wer e counte dunde r eac h proces s reporte dfo r

thei r facility . Tabl e 1- 3 show s tha t th e mos t frequentl y use dprocesse s ar e ge l coatin g whic h i s use db y approximatel y 6 0 percen t ofth e facilitie s an datomize dspray lay-up whic h i s use db y abou t

5 1 percen t

ofth e facilities . Han dlay-u p application , whic h i s reporte db y approximatel y 2 1 percen t of th e facilities , i s th e thir dmos t commo n process , followe db y polyme r castin g wit

h 1 8 percent . 1.2. 6 Resi n Us e b v Process 6 Accordin g t o sit e specifi c informatio n collecte dfor thi s standard , atotal o f

abou t 284,60 0 ton s o f thermose t

resi n i s use dpe r

year . Tabl e 1-

4 provide s informatio n abou t th e resi n usag e b y process . Th e resi n use dt o produc e intermediary product s suc h a s SM C an dBM C i s eventuall y use di n othe r

processe s suc h a s compressio n o r injectio n moldin g t o produc e th e fina l products . Intermediar y an dfina

l product s hav e bee n separate di n Tabl e 1- 4 t o avoi ddoubl e countin g o f th e resin . Th e majority o f

th e product s ar e produce di n th e spray lay-u p proces s wher e approximatel y 3 3 percen t ofth e tota l resi n i s used . Th e combinatio n o f compressio n moldin g an dinjectio n moldin g account s fo r abou t 2 2 percen t

o f th e resi n use di n composite s productio n processes . Th e nex t

mos t commo n productio n proces s i s continuou s lamination/continuou s castin g wher e approximatel y 1 8 percen t o f th e tota l resi n i s used . 1.2. 7 Maio r

Market s an dProducts 4 ' 7 Th e majo r

marke t categorie s include di n th e plasti c composite s sourc e category are : transportation , packaging , buildin g an dconstruction , electrical/electronics , an d consumer/institutiona l products . Th e transportatio n marke t category include s moto r

vehicle s an d parts , railroa dequipment , trave l trailers , campers , aircraft , an drecreationa l vehicles . Th e SI C code s include dunde r

thi s marke t

category ar e 371 , 372 , 374 , an d379 . Th e packagin g marke t category include s variou s shippin g container s lik e drums , boxes , an dcrates . Th e SI C cod e 308 , Miscellaneou s Plastic s Products , cover s thi s marke t category . Th e buildin g an dconstructio n 1-1 0 DRAF T 3/16/9 8P. 2

TABL E 1- 3 DISTRIBUTIO N O FMAJO RSOURCE S B Y PROCESS 6 (Total Numbe r

O f Majo r Source s = 437 ) Proces s BM C Manufacturin g Centrifugal Castin g Compression/Injectio n Moldin g Continuou s Lamination/Continuou s

Castin g Filamen t Windin g Ge l Coatin g Han dLay-up/Bucke t

& Too l Applicatio n Polyme r Castin g Pressure-Fe dRoller/Flo w Coate r

Pultrusio n RT M SM C Manufacturin g Spray Lay-u p Numbe r o f Facilitie s 1 5 8 6 2 1 3 4 4 26 1 9 3 7 9 1 4 3 2 2 0 2 1 22 3 Percentag e of Facilitie s Reportin g Process 1 1 (% )

3. 4 1. 8 14. 2 3. 0 10. 1 59. 7 21. 3 18. 1 3. 2 7. 3 4. 6 4. 8 51. 0 Value s show

n i n the table d

o no t ad du p t o 10 0 percen t sinc e facilitie s ofte

n perfor mmultiple processes .

1-1 1 DRAF T 3/16/9 8P. 3

TABL E 1-

4 1992 aUS E O FTHERMOSE T PLASTI C RESIN S B Y PROCESS 6 (Ton s pe r Year ) Proces s Groupin g Resi n Quantit y Percen t of Total b (% ) Processe s fo r

Intermediat e Product s BM C Manufacturin g SM C Manufacturin g 20,00 0 28,70 0 No t

Applicabl e No t Applicabl e Processe s fo r

Fina l Product s Centrifugal Castin g Compression/Injectio n Moldin g Continuou s Lamination/Continuou s Castin g

Filamen t Windin g Ge l Coatin g Han dLay-up/Bucke t

& Too l Applicatio n Polyme r Castin g Pressure-Fe dRoller/Flo w Coate r

Pultrusio n RT M Spray Lay-u p TOTAL S 1,700 61,400 c 51,50 0 4,30 0 22,80 0 9,60 0 18,70 0 3,70 0 14,70 0 1,300 94,80 0 284,600 d 0. 6 21. 6 18. 1 1. 5 8. 0 3. 4 6. 6 1. 3 5. 2 0. 5 33. 3 100. 0

aMos t

o f th e dat ai s fro m1992 , whic h ha s bee n collecte di n th e 199 3 industry screenin g surveys . However , th e dat afo r som e facilitie s ha s bee n update dbasedo n tri p an dcontac t report s that

occurre da s recen t

a s 1998 . b Value s show n i n th e tabl e ma y no t ad du p t o 10 0 percen t

du e t o rounding . c Feedstock s ar e usuall y SM C o r BM C whic h generall y contai n 3 0 percen t resin . Th e resi n containe din th e 209,58 5 to n o f

feedstoc k

i s 62,87 6 basedo n th e assumptio n tha t th e feedstoc k

contain s 3 0 percen t

resi n b y weight . dTota l resi n quantity doe s no t includ e resi n use dt o produc e intermediat e product s t o avoi ddoubl e counting .

1-1 2 DRAF T 3/16/9 8P. 4

marke t categor y include s item s lik e pipe , conduit , plumbin g fixtures , showers , bathtubs , siding , flooring , skylights , an drailings . Th e SI C code s mos t closel y relate dt o thi s category ar e 35 3 an d 308 , whic h cove r

construction , material s handlin g an dequipment , an dmiscellaneou s plasti c products . Th e electronic s marke t category include s hom e an dindustria l appliances , resistors , an d cabl e coverings . Th e SI C code s for thi s marke t

category are 349 , 361 , 362 , 364 , 366 , an d367 . Consume r

an dindustrial product s ar e covere db y SI C code s 308 , 394 , an d39 9 an dcove r awid e variety o f good s rangin g fro mtoys , sportin g goods , buttons , an dladder s t o barbe r sho p equipment . 1. 3 PROCES S DESCRIPTION S AN D EMISSIO N POINT S 1.3. 1 BM C Manufacturin g Proces s description. 8 9 BM C manufacturin g consist s of preparin g a

n easil y handle dputty lik e moldin g compoun dwhic h contain s resins , catalysts , fillers , an dreinforcement s in a"ready

to-mold " form . BM C can b e use di n compressio n moldin g an dinjectio n moldin g t o manufactur e product s with comple x shapes . In th e productio n of BMC , approximatel y 3 0 percen t resin , 5 0 percen t fille r an dadditives , an d2 0 percen t reinforcemen t

ar e combine ddurin g energ y intensiv e mixing . Th e mixtur e i s extruded , allowe dt o thicke n an dcu t int o appropriat e size s an dshapes . Th e primar y reinforcemen t use di n BM C compound s i s choppe dglas s fiber . Th e choic e o f th e resi n (polyeste r

o r viny l ester) determine s th e physical characteristic s o f th e product . BM C i s use dprimaril y a s areplacemen t for cas t metals . Exampl e product s includ e ai r conditione r components , pum p housings , compute r an dbusines s equipmen t

components , an dpowe r

tools . HA P emissio n points. 8, 9 In th e productio n o f BMC , HA P ar e release dfro mth e mixin g tank , particularl y if

th e tan k i s uncovered , partiall y covered , o r activel y vented . HA P can als o b e release dfro mcovere dtank s throug h leakin g seal s an dcovers . Durin g th e intensiv e agitatio n o f th e resi n mixture , th e HA P containe di n th e resi n i s exposedt o th e ope n ai r an dcan evaporate . HA P emission s may als o b e release ddurin g th e produc t formatio n an dthickenin g processes .

1-1 3 DRAF T 3/16/9 8P. 5

1.3. 2 Centrifuga l Castin g Proces s description. 9 In centrifugal casting , resi n an dfiber reinforcement s (if

needed ) ar e deposite dagains t

th e inside surfac e o f

arotatin g mold . A resi n applicato r whic h i s often locate d i n th e cente r

o f th e rotatin g mol dsupplie s th e resi n t o th e inside of th e cast . Centrifugal forc e hold s th e materia l i n plac e whil e th e part i s cured . Th e outside surfac e o f th e part , whic h i s cure d agains t th e insid e surfac e o f

th e mold , represent s th e finishe dsurface . Th e interio r surfac e o f

th e centrifugall y cas t

part can b e improve db y addin g a n additiona l coat

o f pur e resin . Centrifuga l castin g i s use dt o commerciall y produc e product s suc h a s larg e an dsmal l diamete r pip e an d tanks . Th e tw o mai n limitation s i n centrifugal castin g operation s ar e th e inability t o spi n mold s o f larg e siz e an dth e relativel y lo w productivity pe r tool . HA P emissio n points. 91 0 Durin g th e centrifugal castin g proces s ai r may b e move dthroug h th e insid e o f

th e rotatin g mol dt o facilitat e th e resi n distributio n an dcuring . Th e rotatin g cas t i s generall y vente dan dHA P ar e emitte ddurin g th e actual castin g process . In additio n t o th e emission s fro mth e inside o f th e mold , asmal l amoun t of HA P ca n b e emitte dwhe n th e resi n i s transferre dt o th e interio r o f th e mol dan dwhe n th e produc t i s removed . 1.3. 3 Compressio n Moldin g Proces s description. 9 " Compressio n moldin g operation s involv e compressin g th e composit e materia l unde r hydrauli c pressur e (a

t 25 0 t o 3,00 0 psi ) in matche dmeta l die s an d holdin g th e configured , condense dmateria l i n th e desire dshap e unti l th e resi n syste mha s cured . Th e composit e material s use di n th e compressio n moldin g proces s includ e SM C an dBMC . Th e productio n outpu t

in compressio n moldin g i s relativel y hig h becaus e th e moldin g compound s cur e rapidl y i n th e heate dmold . Th e material s generall y yiel dagoo dfinis h withou t applicatio n o f ge l coat . Both surface s o f th e molde dproduc t

wil l b e a s smoot

h a s th e mol dsurface . Compressio n moldin g can reduc e hig h uni t productio n costs , bu t

onl y ifth e productio n volum e i s at leas t 15 0 part s pe r

mol dpe r shif t t o sufficientl y sprea dou t th e hig h cos t

o f th e require d matche dmeta l dies . Compressio n moldin g processe s hav e bee n successfull y use di n th e automotiv e industr y fo r

mor e tha n 3 0 years . Th e automotiv e part s that ar e produce dinclud e car bodies , truc k

hoods , fenders , an davariety o f smalle r vehicl e parts . Othe r

type s o f product s produce db y compressio n moldin g includ e appliance s an dbusines s equipmen t components . A t 1-1 4 DRAF T 3/16/9 8P. 6

leas t on e facility use s compressio n moldin g t o produc e bathtubs , showe r stalls , an dlavatory bowls. 1 2 HA P emissio n points." 1 3 Sinc e compressio n moldin g i s aclose dproces s an dn o we t resi n surface s ar e exposeddurin g molding , emission s ar e generall y ver y low . Som e HA P emission s can occu r

whe n BM C o r

SM C ar e prepare dfo r

moldin g (i.e. , cu t

an dstrippe do f

film , etc. ) an dplace di n th e mold . Othe r HA P emission s ar e release dwhe n th e mol di s opene dt o remov e th e product , bu t

thes e emission s ar e presume dt o b e extremel y lo w becaus e curin g occur s insid e th e close dmold . 1.3. 4 Continuou s Lamination/Continuou s Castin g Proces s description. 91 4 Continuou s lamination/continuou s castin g i s asubstantiall y automate dproces s fo r

producin g fla

t o r corrugate dlaminate s o n a n in-lin e conveyor . Continuou s castin g involve s puttin g fille dliqui dpolyme r o n abel t t o produc e cas t

sheets . In continuou s lamination , resi n an dchoppe dglas s are sandwiche dbetwee n tw o carrie r film s an dpasse d throug h acurin g oven . I

n thi s process , th e resi n mi x i s metere dont o abotto mcarrie r film , usin g ablad e t o contro l th e thickness . Th e film , mad e o f polyester , cellophane , o r nylon , form s th e panel's oute r

surface . I

f extr aweathe r

resistanc e i s required , apolyviny l fluorid e film , tha t permanentl y bond s t o th e resin , i s added . In addition , methy l methacrylat e can b e use da s th e cross-linkin g agen t

t o increas e strength , weathe r resistance , an dprotectio n fro multr aviolet radiation . Reinforcemen t can b e used , bu t

doe s no t hav e t o b e part

of th e process . On e way t o incorporat e reinforcemen t int o th e produc t

i s t o cho p an devenl y distribut e continuou s stran d fiberglas s roving s int o th e resi n mi x wher e the y ar e allowe dt o we t out . A secon dplasti c fil mi s typicall y applie dove r

th e reinforcemen t

an dth e materia l i s fe dthroug h compactio n roller s whic h allo w mixin g an dexclusio n o f ai r that i s usuall y trappe dbetwee n th e tw o films . Th e glass/resi n composit e i s sandwiche dbetwee n th e carrie r film s an dthe n passe dthroug h acurin g oven . Corrugate dproduct s ar e pulle dthroug h aserie s o f formin g guide s t o create dth e corrugate dshap e o f th e produc t

befor e the y ente r

th e curin g oven . Cure dpanels ar e automaticall y trimme dt o width an dcu t

t o length . Th e larges t

us e o f continuou s laminatio n i s for th e productio n o f skylights , panels , fences , garag e doors , awnings , an dcoolin g towe r louvers . HA P emissio n points. 1 3 An importan t sourc e o f

organi c vapo r

emission s in continuou s 1-1 5 DRAF T 3/16/9 8lamination/continuou s castin g operation s i s th e we t ou t table , wher e athi n layer

o f resi n i s expose dfor

up t o afew minute s t o th e ambien t air . In som e instance s th e tabl e i s heated , whic h increase s th e potentia l t o emit organi c vapors . Anothe r HA P emissio n poin t

i s th e ove n in whic h th e product s ar e cured . Th e heat applie din th e ove n cause s volatil e monome r i n th e uncure d resi n t o evaporate . 1.3. 5 Filamen t

Windin g Proces s description. 9131 5 Filamen t windin g i s acomposit e productio n proces s for manufacturin g product s that ar e surface s o f

revolution . In thi s process , fiber s ar e impregnate d with resi n i n aresi n bat

h an dwrappe daroun darotatin g mol dsurfac e o r mandre l followin g a machin e controlle dgeometri c pattern . Th e applicatio n o f resi n b y brus h o r

tool , spray gun , o r pressure-fe droller/flo w coate r i s no t considere dpart

o f th e filamen t

windin g process . Th e produc t i s the n cure di n a

n ove n o r a t roo mtemperature . Al l type s o f reinforcin g fiber s can b e utilize din filamen t

winding , bu t

continuou s glas s fiber

i s mos t commonl y use ddu e t o it s hig h specifi c strengt

h an drelativel y lo w cost . Th e filamen t windin g proces s use s thre e commo n patterns : circumferential , helical , an dpolar winding . Th e different

windin g pattern s can b e applie dalon e o r

in combinatio n t o achiev e th e desire dstrength an dshap e characteristics . Ther e ar e variou s technique s an dmaterial s t o produc e th e mandrel . Reusabl e stee l mandrel s ar e use d fo r hig h volum e repetitiv e products , disposabl e mandrel s ar e use dfor short productio n run s o r prototypes , an dfor

som e product s th e mandre l become s a n integra l line r

o r cor e in th e fina

l part . Exampl e product s ar e storag e tanks , ai r an dga s pressur e bottles , fuselages , win dturbin e an d helicopte r

blades , an dtubin g an dpipe . HA P emissio n points. 1 5 Th e HA P emission s i n filamen t windin g operation s ar e release d fro mth e resi n bat

h an dth e surfac e o f

th e mandre l whic h i s covere dwit h resin-ric h fiber . Th e surfac e o f th e mandre l emit s durin g th e windin g proces s an ddurin g curing . A stud y conducte d b y Th e Do w Chemica l Compan y foun dthat 8 0 percen t

o f th e emission s occu r

durin g th e windin g proces s fro mth e mandre l surfac e an dth e bat h an dth e remainin g 2 0 percen t ar e release ddurin g curing .

1-1 6 DRAF T 3/16/9 8P. 8

1.3. 6 GelCoatin g Proces s description. " Gel coat i s aclear o r pigmente dnon-reinforce dfinishin g layer applie dt o th e surfac e o f

th e mol do r

th e actual produc t

i n man y productio n processe s in orde r t o improv e th e appearanc e an dsurfac e propertie s o f aproduct . Th e averag e thicknes s o f age l coa t laye r i s betwee n 1 5 an d2 0 millimeters . Th e ge l coat i s sometime s applie din multipl e passe s whic h means tha t

th e part i s completel y covere db y several thi n layer s t o reac h th e fina l thicknes s ofth e part . Ge l coatin g i s usuall y don e i n conjunctio n wit h spray lay-up , han dlay-up , polyme r casting , o r

resi n transfe r

molding . I

n som e case s ge l coat

i s als o use di n conjunctio n wit h continuou s laminatio n an dcompressio n molding . Whe n th e gel coat i s use din conjunctio n wit h spray lay-up , han dlay-up , polyme r casting , o r

resi n transfe r

moldin g i t

i s usuall y applie db y us e o f aspray gu n but

i t can als o b e applie dwit

h non-atomize dspray equipment . Ge l coa t that i s applie di n conjunctio n with continuou s laminatio n i s poure do r metere dont o acarrie r

fil mwhic h form s th e oute r

laye r o f th e laminate . Whe n th e ge l coat i s applie din conjunctio n wit h compressio n molding , i t

i s typicall y injecte dint o aclose dmold . Ge l coa t spray system s consist

o f separat e source s o f

gel coat an dacatalyst , wit

h ahand

hel dspray gun tha t

mixe s bot

h component s togethe r

int o a n atomize dresin/catalys t

stream . Fou r mai n type s o f

spray gun s ar e availabl e for th e applicatio n o f

gel coat : conventiona l ai r spray guns , airless spray guns , air-assiste dairles s guns , an dhig h volum e lo w pressur e (HVLP ) spray guns . Conventiona l ai r

spray gun s us e compresse dair , hig h flui dpressures , o r acombinatio n o f

flui d pressur e an dcompresse dai r t o atomiz e th e ge l coa t

o r resin . Airles s spray gun s atomiz e th e ge l coa t b y pumpin g i t

a t extremel y hig h flui dpressur e (1,00 0 t o 3,00 0 psi ) throug h a n atomizin g nozzle . Ai r

assiste dairles s gun s als o us e flui dpressur e t o atomiz e ge l coat s throug h aspray nozzle . However , th e flui dpressur e i s considerabl y lowe r (40 0 t o 1,000 psi ) than fo r airles s gun s an dmus t therefor e b e augmente db y introducin g pressurize dai r int o th e ge l coat

spray patter n a s i t exit s th e pressur e nozzle . HVL P spray gun s us e ahig h volum e o f ai r (1 0 t o 2 0 cfm ) delivere d a t apressur e o f

approximatel y 1 0 ps i t o atomiz e th e ge l coat . Th e hydrauli c pressur e comin g t o th e gun i s a s lo w a s 20 0 t o 2,00 0 psi . Whe n th e ge l coat leave s th e orifice , th e lo w pressur e ai r complete s

1-1 7 DRAF T 3/16/9 8P. 9

th e atomizatio n an dencapsulate s th e ge l coat fa n o n it s way t o th e mol dsurface , creatin g asoft , lo w velocit y spray . Onc e th e ge l coat

i s applie di t

i s commonl y cure dunde r ambien t conditions . However , in som e case s heat

i s applie dt o accelerat e th e curin g process . Specialize dbooth s o r

bay s for ge l coat applicatio n ar e use db y anumbe r o f facilitie s t o bette r manag e pollutio n an dworke r safety . Th e us e o f

spray booth s fo r

ge l coatin g i s mos t commo n with producer s o f relativel y smal l item s o r hig h volum e producer s wh o hav e incorporate dmovin g assembl y line s int o thei r operation . HA P emissio n points. " HA P emission s fro mge l coa t that i s spraye do r

poure doccu r durin g th e applicatio n o f

th e gel coa t

an ddurin g curin g i n ope n mol dprocesses . Whe n th e gel coa t i s injecte dint o close dmolds , n o we t ge l coat surface s ar e exposeddurin g applicatio n an d curin g an demission s are generall y ver y low . Som e HA P emission s ar e release dfro mclose d mol dge l coatin g whe n th e mol di s opene dt o remov e th e product , bu t thes e emission s ar e presume dt o b e extremel y lo w becaus e curin g occur s inside th e close dmold . 1.3. 7 Han dLay-up/Bucke t an dToo l Applicatio n Proces s description. 9131 6 Han dlay-up/bucke t an dtoo l applicatio n involve s placin g reinforcemen t

ont o th e mol dan dsaturatin g th e reinforcemen t wit h liqui dresin . Th e reinforcemen t

i s manuall y fitte dagains t th e surfac e o f

amol dan di s the n wette dwit h catalyze d resi n mix , after

whic h i t i s saturate dwith mor e resi n an drolle dou t t o remov e ai r

bubbles . Mos t han dlay-up/bucke t

an dtoo l operation s us e glas s fiber choppe dstran dmat s in weigh t percentage s o f 3 0 t o 4 5 percen t

o f th e composit e laminate . Wove n rovin g i s use dwhe n highe r reinforcemen t loading s ar e desired . Th e wove n rovin g a s aweigh t percen t o f laminat e ma

y b e a s hig h a s 6 5 percent . Th e desire dlaminat e thicknes s i s achieve db y addin g layer s o f reinforcemen t

an dresin . Th e individua l layer s ar e smoothe dan dcompacte dwith squeegees , brushes , an drollers . HA P emissio n points. 1 3 Durin g han dlay-up/bucke t an dtoo l applications , arelativel y larg e surfac e o f

we t resi n and/o r

impregnate dfiber

i s expose dt o th e atmospher e fo r mos t o f th e productio n cycle . Hazardou s ai r pollutant s evaporate fro mth e liqui dresi n whic h i s in contac t with th e ai r

a s i t i s applie dan dfro mth e produc t surface . Durin g rollin g an dcuring , HA P als o evaporat e fro mth e squeegees , brushes , an drollers use di n th e resi n application. Compactin g an d 1-1 8 DRAF T 3/16/9 8P.1 0

smoothin g th e resi n surfac e allow s further volatilizatio n of

HA P unti l th e resi n reache s th e gel poin t an dthe n final cure . Severa l layer s o f resi n are applie din han dlay-up/bucke t an dtoo l operation s unti l th e desire dthicknes s i s achieved . Eac h layer applie dincrease s th e amoun t o f volatil e HA P emitte dt o th e atmosphere . 1.3. 8 Injectio n Moldin g Proces s description. 9 Injectio n moldin g i s aclose dproces s that involve s feedin g liqui d resin , reinforcin g fiber , an dothe r additive s int o on e en dof acoole dmetalli c cylinder . Insid e th e cylinde r i s ascre w o r

plunge r tha t rotate s an dreciprocate s bac k an dfort h alon g th e axi s o f

th e cylinder . Thi s actio n meter s th e resi n for th e mel t volum e require dt o fill th e mol dan dtransfer s th e metere dresi n charg e int o th e mold . An additiona l functio n of th e injectio n moldin g machin e i s t o retai n th e mold , clampin g i t close dunde r

pressur e durin g injectio n an dejectio n o f th e finishe dpart

after heat curin g takes place . Th e mol dcavity represent s th e exac t shap e o f th e part t o b e produced . Dependin g o n th e part siz e an dmoldin g machin e capacity , th e mold s can contai n on e o r

mor e cavities . Choppe dglas s fiber s rangin g i n lengt h fro m5 t o 4 0 m

mar e th e mai n reinforcemen t

use di n injectio n moldin g operations . Fibe r loading s var

y fro m5 t o 4 0 percen t b y weight . Th e injectio n moldin g proces s i s wel l suite dfor producin g ahig h volum e of comple x product s wit

h excellen t

dimensiona l accuracy . HA P emissio n points. 9 Injectio n moldin g i s aclose dproces s wher e n o we t resi n surface s ar e exposed . Som e HA P emission s may occu r whe n th e finishe dpart

i s ejecte dfro mth e mold , bu t thos e emission s ar e considere dver y lo w becaus e curin g take s plac e inside th e close dmold . I n addition , som e fugitiv e emission s can occu r whe n liqui dresi n i s fe dint o th e metalli c cylinder . 1.3. 9 Polyme r

Castin g Proces s description. 9141 7 In th e polyme r castin g process , polymers , fillers , an dadditive s ar e combine db y pourin g o r dispensin g thes e material s int o ope n o r partiall y ope n mold s an dthe n curin g them . Fiberglas s reinforcemen t i s not use di n cas t

polyme r products . In th e polyme r castin g process , th e resi n matri x i s catalyze dan dcas t ont o th e mol dwhic h i s usuall y vibrate dt o allo w ai r bubble s t o escape . Followin g vibration , th e produc t enter s a n exothermi c stag e in whic h th e matrix' s chemica l reactio n generate s hea t that cause s th e produc t

t o cure . I

n som e case s aheate dove n i s use dt o accelerat e cure . Product s produce db y th e polyme r castin g proces s 1-1 9 DRAF T 3/16/9 8P.1 1

includ e polyme r

concret e (utility structure s an dbridges) , culture dmarbl e product s (sinks , tubs , showe r panels , an dcountertops) , an dbowlin g balls . HA P emissio n points. 1 4 Source s of emission s i n polyme r

castin g includ e emission s fro m th e semi-ope n polyme r

castin g machin e an demission s fro mcuring . Curin g emission s can b e release dfro mth e ove n o r durin g curin g a

t ambien t temperature . 1.3.1 0 Pressure-Fe dRolle r o r Flo w Coate r

Applicatio n Proces s description. 1 8 Pressure-fe drollers o r flo w coater s ar e mechanica l resi n applicatio n equipmen t

use dt o appl y resi n t o a

n ope n mol dwithou t

atomizin g th e resi n o r sprayin g it . Th e proces s i s similar t o th e spray applicatio n proces s whic h i s describe din Sectio n 1.3.1 4 excep t

that th e resi n i s no t

broke n up int o distinc t

droplet s before arrivin g a t th e mold . Ther e i s othe r

mechanica l resi n applicatio n equipmen t tha t ca n b e use dt o appl y resi n withou t atomizin g (o r

spraying ) it ; however , onl y pressure-fe droller s an dflo w coater s wil l b e discusse d here . Pressure-fe drollers are use dt o appl y resi n t o pre-cu t piece s o f reinforcemen t

whic h ar e hand-lai dint o th e mol d(eithe r before o r afte r the y ar e saturate dwit

h th e resin) . Sinc e th e resi n i s "rolled " ont o th e reinforcement , th e rolle r als o aid s in distributin g an drollin g th e resi n evenly ont o th e reinforcement . However , th e detaile drol l ou t ste p use di n flo w coatin g an dspray la y u p i s stil l necessary . A pressure-fe drolle r consist s o f

afabri c rolle r

whic h i s fedb y acontinuou s suppl y o f catalyze dresin . A flui dpump draw s resi n fro madru mo r bul k distributio n line . Th e resi n pump i s mechanicall y linke dt o aseparat e catalys t pump . Thes e tw o pump s suppl y th e resi n an dcatalys t

i n aprese t

rati o t o amixe r

i n th e handl e o f

th e roller . Th e mixe r

the n feed s th e catalyze dresi n t o th e rolle r hea dthroug h th e handl e o f th e roller . A valv e controlle db y th e operato r regulate s th e amoun t

o f resi n flowin g t o th e rolle r hea dan dt o th e part

bein g fabricated . Th e rolle r hea di s covere dwit

h adispensabl e fabri c cove r similar t o astandar dpain t

roller . Resi n roller s ar e intende dt o b e operate dalmos t continuousl y durin g ashif t t o preven t

th e resi n fro mhardening betwee n th e mixe r an dth e rolle r

cover . A t

th e en d

1-20 DRAF T 3/16/9 8P.1 2

o f th e shift , th e rolle r

cove r i s discarde dan dth e mixin g unit , handle , an drolle r manifol dar e flushe dwith solvent . Flo w coater s ar e use dt o appl y th e resi n t o th e mol di n aflo w pattern consistin g of distinc t streams o f

resi n a s oppose dt o aspray pattern consistin g o f resi n droplets . Wherea s aspray gun ha s asingle smal l orifice , th e ti p o f aflo w coate r

ha s adoze n o r

s o precisel y drille dhole s that produc e stead y stream s o f resin , similar

t o asmal l showerhead . Th e catalys t i s mixe dwit

h th e resi n befor e th e resi n exit s th e flo w coater . At leas t tw o manufacturer s produc e internal-mi x resi n spray gun s that

can b e converte dt o flo w coater s simpl y b y switchin g th e nozzl e from single-orific e tip s t o flo w coate r nozzles . Unlik e pressure-fe drollers , flo w coater s can als o b e use dt o simultaneousl y appl y resi n an dchoppe dfiberglas s reinforcement s b y fittin g th e flo w coate r with achoppe r

hea dtha t shoot s th e choppe dglas s int o th e flo w pattem . Th e curren t pressure-fe droller/flo w coate r equipmen t

i s bein g use di n plac e o f conventiona l spray lay-u p equipmen t

i n numerou s product s excep t fo r thos e that

requir e hig h amount s o f

filler . HA P emissio n points. 1 4 Th e emissio n point s associate dwit h pressure-fe drollers/flo w coater s ar e applicatio n ofth e resi n an dth e post-applicatio n step s o f rollin g an dcuring . Hazardou s ai r

pollutant s are emitte dfro mwe t produc t surface s durin g rollin g an dcurin g an d fro mbrushe s o r

rollers use dt o remov e entrappe dai r fro mth e applie dresin . 1.3.1 1 Pultrusio n Proces s description. 9131 9 Pultrusio n i s acontinuou s manufacturin g proces s that produce s part s with constan t

cross-sectiona l shapes . Th e ter m"pultrusion " come s fro mth e fac t that th e composit e i s pulle dthroug h a n extrusion-typ e di e b y agripper/pulle r system . In th e standar d pultrusio n process , reinforcin g fiber s ar e pulle dthroug h aresi n bath wher e al l material s ar e thoroughl y impregnate dwit h liqui dresin . Th e we t

fibrou s laminat e i s forme dt o th e desire d geometri c shap e i n apreformin g sectio n an dpulle dint o th e heate dstee l die . A s a n alternativ e t o usin g aresi n bath , resi n can b e injecte dint o th e pre-formin g sectio n (resi n injection ) o r directl y int o th e formin g di e (di e injection) . In th e die , th e resi n cur e i s initiate db y controllin g precis e elevate dtemperatures . Th e laminat e solidifie s i n th e exac t shap e o f th e di e cavity a s i t

i s bein g continuousl y pulle db y th e pultrusio n machine . Th e cure dproduc t can

1-2 1 DRAF T 3/16/9 8P.1 3

the n b e cu t

t o desire dlengths . Exampl e product s includ e electrica l insulatio n materials , ladde r rails , walkwa y gratings , structura l supports , rods , antennas , an dwindo w an ddoo r frame lineals . HA P emissio n points. 1 3 Th e majo r emissio n point s in pultrusio n operation s ar e th e resi n impregnatio n bath , th e dri p pan , an dth e we t reinforcement . Hazardou s ai r pollutant s evaporat e fro mth e surfac e o r

expose darea s o f

th e resi n bath , th e dri p pan , an dth e wet , drippin g reinforcemen t

int o th e ambien t

air . Hazardou s ai r

pollutant s ar e release ddirectl y fro mth e we t reinforcemen t

a s i t passe s throug h th e formin g guide s after leavin g th e resi n bath . Also , whe n th e we t reinforcemen t

passe s throug h th e formin g guides , exces s resi n drip s int o th e dri p pan , creatin g alarg e surfac e are afro mwhic h styren e can evaporate . Emission s durin g th e curin g phas e ar e presume dt o b e insignifican t i n pultrusio n operations , sinc e curin g take s plac e in close d meta l dies . 1.3.1 2 Resi n Transfe r

Moldin g (RTM ) Proces s description. 9,11 ' 1 3 RT M i s aclose dmol dproces s in whic h matchin g mal e an d femal e molds , containin g continuou s o r choppe dglas s fiber

strands , ar e clampe dtogether . Usuall y ge l coa t

i s applie dt o on e o r

both side s o f

th e mol dprio r

t o th e RT M process . After th e ge l coa t applicatio n proces s reinforcin g fiber i s place dint o th e botto mhal f of th e mold , th e mol d i s close dan dresi n i s pumpe dint o th e mol dthroug h injectio n port s designe dt o contai n th e resi n unde r pressure . A perimete r

gaske t seal s th e edge s o f

th e mol dan dai r

vent s locate dat

th e gaske t lin e evacuat e ai r

an drestric t

los s o f resin . Sinc e moldin g pressure s ar e typicall y betwee n 3 0 an d 7 5 psi , th e mold s can b e mad e o f plasti c base dcomposite s rathe r than metal . RT M can thu s b e se t u p t o replac e man y conventiona l ope n moldin g processes . Th e mold s ca n b e produce dfro m th e sam e material s usin g th e sam e technique s a s for conventiona l mol dproduction , an dresi n an d fille r material s differ

littl e fro mthos e use din ope n molding . RT M i s bes t suite dfor

intermediat e volum e productio n (50 0 t o 10,00 0 part s pe r year ) o f smal l t o mid-size dproduct s suc h a s restauran t seats , automotiv e parts , plumbin g components , an delectrica l covers . However , part s a s larg e a s persona l watercraf t hull s an ddeck s ar e als o bein g mad e with RTM .

1-2 2 DRAF T 3/16/9 8P.1 4

HA P emissio n points." 1 3 Sinc e RT M i s aclose dprocess , ai r exchang e betwee n we t

resi n surface s an dth e atmospher e i s greatl y limited , resultin g i n lo w HA P emissions . Som e HA P emission s can stil l b e release dfro mth e exces s resi n pumpe dint o th e injectio n port that exit s th e mol dthroug h distributio n ports . I n addition , som e HA P emission s ar e release dwhe n th e mol di s opene dt o remov e th e product . However , emission s durin g produc t releas e fro mth e mol dar e relativel y lo w becaus e curin g occur s insid e th e close dmold . 1.3.1 3 SM C Manufacturin g Proces s description. 9,2 0 SM C i s a n integrate dcomposit e materia l whic h contain s al l reinforcement , resin , fillers , chemica l thickeners , catalysts , mol dreleas e agents , an dothe r ingredient s i n a

n easil y handle dsheet . SM C ca n b e store dfor

aperio do f

tim e prio r

t o moldin g i t int o comple x shape s in compressio n o r injectio n moldin g operations . In th e SM C productio n th e resi n paste , aliqui dpast e wit h aviscosity betwee n 40,00 0 an d100,00 0 centipoise , i s pumpe d int o th e docto r

bo x o f th e SM C machine . At

th e SM C machine , th e past e i s metere dthroug h docto r blade s ont o nylon , polyethylen e o r similar carrie r films . Glas s fiber s ar e choppe dt o a specifi c lengt

h an duniforml y distribute dove r th e lowe r

past e bed . After

th e uppe r

an dlowe r past e bed s ar e brough t

together , th e forme dsandwic h progresse s throug h acompactio n bel t wher e i t i s consolidated . Th e compacte dSM C shee t i s rolle dint o th e desire dlength , package di n anylo n sleev e t o reduc e evaporatio n o f volatil e compounds , an dstore di n atemperatur e controlle darea . Thickenin g o f th e resi n i s influence db y ingredient s suc h a s magnesiu moxid e o r magnesiu mhydroxid e an dcan tak e anywher e fro mseveral hour s t o severa l days . Onc e th e SM C reache s th e desire dmoldin g viscosity o f 6,000,00 0 t o 75,000,00 0 centipoise , i t i s cu t int o desire d size s an dshapes . Finally , th e SM C ca n the n b e utilize da s araw materia l in compressio n o r injectio n moldin g operations . Ther e ar e different type s o f SM C availabl e dependin g o n th e pattern o f reinforcemen t

used , whic h include s rando mfiber reinforcement , unidirectiona l continuou s fiber , unidirectiona l continuou s fiber wit h rando mfiber

reinforcement , an d directiona l discontinuou s reinforcing . SM C i s ahig h throughput , hig h volum e proces s an di s widel y use di n economicall y demandin g market s suc h a s th e automotive , appliance , an d electrica l industries .

1-23 DRAF T 3/16/9 8P.1 5

HA P emissio n points. 9 ' 2 0 In th e productio n o f SMC , HA P emission s ar e release dfrom th e docto r

bo x an dth e part

o f th e SM C machin e wher e th e resi n i s metere dont o carrie r film s an d expose dt o th e ope n air . Furthe r HA P emission s ar e release da t th e compactio n belt , wher e th e uppe r an dlowe r

past e bed s ar e brough t

together . Durin g th e maturatio n process , mor e HA P ar e release dunti l th e produc t reache s it s desire dmoldin g viscosity . 1.3.1 4 Spra y Lay-u p Proces s description. 9131 4 Spray lay-u p i s a n ope n mol dproces s tha t use s mechanica l sprayin g equipmen t

tha t atomize s th e resin . In th e spray lay-u p process , glas s fibe r reinforcemen t an dcatalyze dresi n ar e typicall y spraye don amol dwit h aspecialize d"chopper " spray gun . A choppe r spray gu n simultaneousl y chop s continuou s fiber reinforcemen t

int o suitabl e length s an d applies i t with th e catalyze dresi n spray . Th e spraye dresi n precoat s th e cho p an dbot h ar e deposite da

t th e sam e tim e t o th e desire dlayer thicknes s o n th e mol dsurfac e o r on th e ge l coa t tha t wa s applie dt o th e mold . Wove n rovin g o r mat s ca n als o b e use dinstea do f

choppe dfiber , i

n whic h cas e aspray gu n woul db e use dinstea do f th e choppe r

gun . Basically , ther e ar e catalys t injectio n system s whic h ar e externa l mi x spra y gun s an dtwo-po t

system s whic h ar e interna l mi x spray guns . Catalyst

injectio n gun s ad dcatalys t t o th e alread y promote dresi n throug h aspecia l catalys t injector . Thi s injecto r

pre-measure s th e amoun t o f catalys t added , whic h i s usuall y 0. 5 t o 2 percen t b y weight . In th e cas e o f atwo-po t

spray gun,th e resi n syste mitsel f i s divide dint o tw o parts . On e sid e i s catalyzed , wherea s th e othe r sid e i s promoted . Whe n th e tw o part s ar e spraye d together , acurin g reactio n i s initiated. Airless , ai r assisted , HVLP , an dconventiona l air

atomize dspray gun s ar e use din spray lay-u p operations , althoug h conventiona l ai r spray equipmen t

ha s bee n virtuall y replace db y th e othe r technologies . Airles s system s dispens e th e resi n with hydrauli c pressur e throug h special nozzle s tha t break up th e resi n strea mint o smal l droplet s whic h saturat e th e reinforcement . Ai r atomize dspray gun s us e pressurize dai r in th e gun t o spray th e resin . Onc e th e materia l ha s bee n applie dt o th e mold , brushe s o r rollers ar e use dt o remov e any entrappe dai r

an dt o assur e tha t

th e laminat e i s thoroughl y "we t out. " Layer s o f

choppe d

1-2 4 DRAF T 3/16/9 8P.1 6

materia l o r

specialize dreinforcement s ca n b e adde dt o th e laminat e dependin g upo n th e requirement s o f

th e application . Part s produce di n spray lay-u p operation s includ e aut o an dtruc k bod y parts , swimmin g pools , tub s an dshowers , electrica l an dequipmen t housings , tanks , an dfurniture . Th e productio n rat e i s greate r

fo r spray lay-u p than han dlay-up/bucke t an dtoo l application , bu t generall y mor e resi n i s use di n producin g similar part s b y spray lay-u p becaus e o f overspray durin g application . HA P emissio n points. 1 4 Th e emission s associate dwit h spray lay-u p ar e release ddurin g applicatio n o f

th e resi n an dth e post-applicatio n step s o f rollin g an dcuring . Hazardou s ai r pollutant s ar e emitte dfro mwe t produc t surface s durin g rollin g an dcurin g an dfro mbrushe s o r roller s use dt o remov e entrappe dai r fro mth e applie dresin . I t i s commo n practic e t o appl y severa l coat s o f

resi n t o achiev e th e desire dproduc t thickness . Th e surfac e are ao f eac h layer represent s asourc e o f

hazardou s ai r

pollutan t emissions . 1.4 ANCILLAR Y PROCESSE S 1.4. 1 Cleaning 6 I n cleanu p operations , avariety o f cleaner s an dsolvent s that d o no t contai n HA P ar e use d includin g acetone , dibasi c ester , diaceton e alcohol , an dwater-base dresi n emulsifier s o r detergen t cleaners . Eve n thoug h aceton e i s treate da s ahazardou s chemica l unde r RCR A an dth e Clean Wate r Regulations , aceton e i s not aHAP . Aceton e an dothe r similar solvent s lik e dibasi c este r an ddiaceton e alcoho l ar e widel y use dt o remov e uncure dresin s fro mspray equipment , rollers , brushes , tools , finishe dsurfaces , an dth e hand s o f employees . A s areplacemen t fo r th e traditiona l cleane r

acetone , som e facilitie s hav e switche dt o water-base dresi n emulsifier s o r detergen t cleaners . Was h tank s containin g th e water-base dcleaner s ar e use dfo r soakin g an d scrubbin g tools . Onc e th e tool s ar e clean , the y ar e drie db y dippin g th e too l o r brus h int o asmal l bucke t o f aceton e o r

a n aceton e substitute . Sinc e th e primary cleanin g i s usuall y don e b y a water-base dcleaner , th e smal l amoun t of aceton e use dfor

dryin g i s exchange dinfrequently . Whe n th e was h tank s wit h th e water-base dcleane r ar e emptied , th e liqui dcan b e discharge dint o asanitary sewer . Th e solid s i n th e botto mo f th e tan k ar e trappe dan ddispose do f separately . Som e facilitie s stil l us e HA P containin g cleaner s suc h a s methylen e chlorid e a s avapo r degrease r an dfor liqui dcleanin g o f

part s an dequipment . Othe r HA P component s i n cleaner s 1-25 DRAF T 3/16/9 8P.1 7

may includ e methy l ethy l ketone , xylene , toluene , an d2-butoxyethanol . 1.4. 2 Resi n Mixing 6, " In large r operations , th e mixin g proces s i s usuall y carrie dou t i n larg e mixin g vat s int o whic h resin , filler , pigments , an dothe r ingredient s ar e pumpe di n a n automate dprocess . Smalle r operation s may manuall y ad dth e different ingredient s t o mixin g drums . A s th e ingredient s are adde ddurin g th e mixin g operation , th e container s ar e generall y uncovered , allowin g HA P t o b e emitte dfro mth e resin . Durin g th e actual mixin g process , vessel s ma y b e completel y o r

partiall y covered . I n th e 199 3 screenin g survey , abou t hal f o f th e facilitie s reporte dcovere do r partiall y covere dmixers . 1.4. 3 HA P Containin g Materia l Storage 6,1 3 Th e HA P containin g material s that are store daplasti c composite s productio n facilitie s includ e resins , ge l coats , catalysts , mol dreleas e agents , an dcleanin g solvents . Thes e HA P containin g material s can b e store din permanentl y mounte dstorag e tank s o r in temporary storag e containers , suc h a s buckets an dda y tanks . Mos t

smal l productio n facilitie s purchas e an dstor e thei r resin s i n 5 5 gallo n drums , whil e large r firm s purchas e practicall y al l of thei r resin s in bul k an dstor e the mi n larg e storag e tanks . Th e size s o f storag e vessel s var

y greatl y an drang e fro m5 gallo n bucket s t o storag e tank s a s larg e a s 60,00 0 gallons . Th e majority o f th e facilitie s that

use d storag e tank s reporte dsize s rangin g fro m1,000 t o 15,00 0 gallon s i n th e 199 3 screenin g survey. 6 Material s suc h a s ge l coats , toolin g resin , fire retardan t resins , cleanin g solvents , an dothe r HA P containin g additive s ar e almos t alway s purchase dan dstore di n 5 5 gallo n drums . Bul k system s ar e bette r suite dfo r

deliverin g larg e quantitie s o f resi n t o vat s for

mixin g wit

h filler s o r

othe r additives . Th e purchas e o f drums , however , allow s smalle r facilitie s th e flexibility t o mee t seasona l demand s i n term s o f quantitie s purchased . Thi s practic e enable s smalle r operation s t o maintai n fres h stoc k

a t al l times . In addition , drum s d o no t requir e installatio n o f

expensiv e storag e tanks , resi n delivery pump s an dpiping , an dperiodi c storag e tan k cleanup . Drum s are , however , difficul t

t o dispos e of

an dmay b e considere dhazardou s materia l whe n the y contai n liqui dresidue . The y als o requir e agitatio n t o preven t stratificatio n an dt o maintai n uniform properties . HA P emission s fro mstorag e tank s ar e eithe r workin g losse s that

occu r whil e fillin g th e tank , o r

breathin g losse s du e t o expansio n fro mtemperatur e changes . HA P emission s fro m 1-2 6 DRAF T 3/16/9 8P.1 8

drum s occu r

durin g resi n agitation , resi n withdrawal , an devaporatio n of residue s lef

t in th e drums . Emission s fro mHA P containin g storag e container s als o occu r whe n thes e container s are lef t uncovered .

1-2 7 DRAFT . 3/16/9 8P.1 9

1. 5 REFERENCE S 1 . SP I Composite s Institute , Introductio n t o Composite s Referenc e Handbook . 1992 . Docke t No . H-I-8 . 2 . Strum , M. , U.S . Environmenta l Protectio n Agenc y t o Plasti c Composite s Projec t File . Dat e . Memorandum . Emissio n Reductio n Technique s for th e Plasti c Composite s Production . Docke t

No . A-94-52 . Documen t No . II-B

- . 3 . 199 2 Toxi c Releas e Inventory System . 4 . Standar dIndustria l Classificatio n Manual , Nationa l Technica l Informatio n Service . 1987 . 5 . Standar dIndustria l Classificatio n Manual , Nationa l Technica l Informatio n Service . 1972 . 6 . Response s fro msectio n 11 4 screenin g surve y sent t o th e plasti c composite s industry . 1993 . 7 . Th e Society o f

th e Plastic s Industry , Inc. , Fact s & Figure s o f th e U.S . Plastic s Industry . Septembe r

1994 . Docke t

No . IH-18 . 8 . Tri p repor t

o f plan t visi t t o Glasti c Corporation , Sout h Euclid , OH . Augus t

11 , 1993 . Docke t No . H-B-6 . 9 . SP I Composite s Institute . Introductio n t o Composite s Referenc e Handbook . 1994 . 10 . Telecon . W . Dunston , EPA:OAQPS , wit h B . Kinman , Fibercast . Discussio n o f centrifugal castin g proces s an dit s controls . Augus t 4 , 1995 . Docke t

No . II-E-24 . 11 . Hillis , R . an dD . Davis . Wast e Reductio n Strategie s for Fiberglas s Fabricators . Officeo f Wast e Reduction , North Carolin aDepaitmen t o f Environment , Health , an dNatura l Resources . 1995 . Docke t No . H-I-20 . 12 . Sectio n 11 4 screenin g surve y respons e fro mSterlin g Plumbin g Group , Inc. , Huntsville , Alabama . 1993 . Docke t No . H-D-593 . 13 . Rogozen , M. , Scienc e Applications , Inc . Contro l Technique s for Organi c Gas Emission s fro mFiberglas s Impregnatio n an dFabricatio n Processes . Prepare dfor Californi aAi r Resource s Board , Sacramento , CA . Jun e 1982 . Docke t No . U-I-3 .

1-2 8 DRAF T 3/16/9 8P.2 0

14 . Compilatio n of

Ai r Pollutan t Emissio n Factors . AP-42 . U . S . EPA , Researc h Triangl e Park,NC . pp . 4.12. 1 - 4.12.10 . Docke t No . II-A-l . 15 . Kelley , L. , et

al. , Th e Do w Chemica l Company . Reductio n of Styren e Emission s for Filamen t Windin g Operations . Docke t No . H-I-19 . 16 . Elsherif

, M . Staf f Report , Propose dRul e 116 2 - Polyeste r Resi n Operations , Sout

h Coas t Ai r Quality Managemen t

District . Rul e Developmen t Division , El Monte , CA . NTI S documen t numbe r PB82-251109 . January 23,1987 . Docke t No . H-I-4 . 17 . Dawson , D.K . Cas t Polymer s Captur e Sophisticate dMarkets . Composite s Technology . September/Octobe r

1995 . Docke t

No . H-I-35 . 18 . Lacovara , B . Th e Yea r of th e Non-Spra y Application . Composite s Fabrication . Marc h 1997 . Docke t

No . H-I-42 . 19 . Dillner , R . Creativ e Pultrusions , Inc . Application s for Pultrude dProducts . Undated . Docke t No . II-I-2 . 20 . Tri p repoi t

of plan t visi t t o Premix , Inc. , Nort

h Kingsville , OH . Augus t 11,1993 . Docke t No . II-B-5 .

1-2 9 DRAF T 3/16/9 8