p. 1 

# OAR Box 1384 Prepped by Charmelle Mathews



### Document

Number: 

# 59 ) ll-E-1 9 f Docket Number: 

# A-94-5 2

Printed 7/2/2008 8:42:05 AM

Sheet 59 of 264P. 2 

### A-S4-6 2 Revise d by Charli e Stanie

r on 3/22/9 5 pe r comment s o f Nelso n O'Neill Ke n Bun k Rich Baeh r Facilit

y Manage r Fountainhea

d Manufacturing Manage

r Productio n Manager , Continuou s Lin e Th e followin g ma

y b e treate d a s ajtet^confidential document , j Th e following ha s bee

n proofed fo

r technTcahtecumo

y an d sensitiv e busines s information .

"V V 

# ", U % JULXJUii *



# III ) OC T I i 

# EF A f.-n £2£S2_ J ,P. 3

CONTAC T REPOR

T From : Madeleine Strum , U S EPA , OAQPS/ESD , Coating s an d Consume

r Product s Grou

p Dat e o f Contact : Februar

y 16 , 1995 Contact : Mr . Charli e Stanie r Company/Agency : Internationa l Paper , Decorativ e Product s Division , Odenton Facilit y (Formerl y Nevama r Corporation) , Odenton , Maryland Telephone Number : 41 0 51 9 209 4 CONTAC T SUMMARY : Th e Odenton Facilit

y o f Internationa

l Paper , Decorativ e Product s Division , wa s contacte d to clarif y th e informatio n o n th e contro l o f styrene emission s provide d by th e facilit y in th e Augus t 23,199 3 screenin g surve

y response . Mr . Stanier , a

n Environmenta

l Enginee r t o who mfurthe r question s regardin g th e surve y shoul d b e addressed , explaine d tha t th e lega l owne r an d operator ofth e facilit

y i s Internationa

l Pape r (it i s no longe r Nevama r Corporatio n whic

h wa s indicate d i n th e 199 3 survey) . Th e plant employ s betwee n 751-100 0 persons , an

d th e numbe

r o f employee s associate d wit

h th e reinforce d composit e plasti c categor

y operation s a

t th e plan t i s currentl y in th e rang e o

f 0-100 . Th e first proces s discusse d wa s th e continuou s line used t o produc e soli d surfac e plasti c sheets . Th e Stat e permi t informatio n supplie d wit

h the 199 3 surve

y ha s changed slightly . The facilit y ha s a n operatin g permi t

(02-0021 ) t

o cove r all facilit y operations , an

d a n ai r constructio n permi t (02-00216-0214 ) specificall y addressin g th e continuou s line . The fee d stock s into th e continuou s proces s include unsaturate d polyeste r resi n (containin g n o mor e tha n 35 % by weigh

t styrene) , aproprietar

y volatil e additive , styrene , catalyst , pigmen t an d variou s filler s (th e fillers ar e particulate s an

d contain n o volatil e organi c HA P materials) . Pur

e styrene i s use d to dissolv e th e catalyst . Th e mai n HAP' s emitte d i s styrene . The emission s depen d on th e exten

t o f cross-linkin g tha

t thes e monomer s underg o in th e curin g ofth e resi n mixture . Th

e facilit y no longe

r use s HA P i n cleanin g operation s (the

y switche d fro

mmethylen e chlorid e t o a n aqueou s - typ e cleanin g material) . Emissio n point s fro

mth e continuou s proces s include : 1 ) emission s fromth e vent s o f storag eP. 4

tanks , mix tank s an

d portabl e tank s (matri x storag e totes ) whic h contain HA

P materials ; 2 ) emission s betwee

n the dispensin g mechanis man d th e ove n on th e continuou s line , an d 3 ) emission s fromthe ove

n (whic h i s nitroge n blanketed) . Transfe r betwee n resi n storag e tanks , mix tank s an

d matrix storag e tote s i s don e vi aclosed piping ; however , uncontrolle d HAP s ar e emitte d fromth e vent s o f

weig h tanks , mi x tanks , an d portabl e tank s (emissio n point 1) . Emission s fromth e applicatio n ofth e mi x to th e line (i.e. , betwee n th e dispensin g mechanis m and th e ove

n - emissio n poin t

2 ) ar e partiall y controlled . Fromth e dispensin g mechanism , th e resi n mixtur

e i s distribute d and flattene d t o adesired thicknes s withi n athre e foo t wid e ban . All o f thi s are ai s enclosed an d nitroge n blanketed , an d i s vented to th e sam

e contro l syste

ma s emissio n point

3 . The contro l syste

mfo r emissio n point

3 wa s designed b y th e engineerin g staf f a t th e facility . Emission s ar

e controlle d primaril y b y condensatio n ofth e styren e vapor s release d a s th e resi n mi x i s cure d i n th e oven . Emission s resultin g fro mth e vapo

r spac e abov e th e condensat e collectio n tan

k ar e furthe r controlle d b y sendin g the

mto acarbo n filte

r bed . The facilit

y ha s around 8 filter

bed unit s rangin g from1330-1500 pound s o f carbon each . A singl e filter bed i s o n lin e fo r abou t 7 day s and pick s u p approximatel y 50 0 pound s o f

VOC s an d water . Spen

t unit s ar e sen t offsit e fo r regeneration . Th

e condensate , which consist s o f mainly o f styrene an d water , i s sen

t offsit e a s hazardou s wast

e fo r us e i n fue l blending . Measurement s don e on the inle t an d outlet t o the carbo n filters hav e indicate d anearl y 100 % efficienc

y on th e carbon filters . Th e captur e efficienc y ofth e system , i.e. , th e quantit y o f HA P emitte d tha

t i s eithe r condense d or absorbe d b y th e carbon , ha s no t been measured . Th

e facilit y plan s t o us e amas s balanc e to determin e thi s quantit

y fo r th e purpos e o f

it s Titl e V permit

application . Mr . Stanie r indicate d tha

t he ha d dat aon th e cos t

ofth e carbon filter

syste m(bot h capita l an d operatin g costs ) an

d woul d b e abl e to forwar

d the information t

o us . The second proces s discusse d wa s tha t associate d wit

h the shaped good s plant . Thi s proces s i s a cas t polyme r (culture d marble ) i n whic h aresi n mixtur e i s pumpe d into apartiall y close d mold , i s cure d and the n i s remove d fro mth e mold . Th

e fee d stock s tha

t g o int o th e resi n mi

x include unsaturate d polyeste

r resi n (containin g n o mor

e tha n 35 % by weigh

t styrene) , aproprietar

y volatil e additive , catalyst , pigmen t an d variou s fillers (th e fillers ar e particulate s an

d contain no volatil e organi c HA

P materials) . Th e emissio n point s associate d wit h thi s proces s ar

e (1 ) vent s fromstorag e drum s containin g HA P materials , (2 ) mixin g ofth e resin , (3 ) fillin g ofth e mold an d (4 ) initia l curin g i n th e curing oven . Pos t

curin g in th e secon d oven ha s negligibl e emission s sinc e th e materia l i s mostl y cure d befor e enterin g th e second oven . Mr . Stanie r estimate d tha

t th e larges t

emissio n point s in thi s proces s ar e th e mixin g an

d mold filling operations . Mixing i s done in vente d close d vessels , an d th e filling ofth e mold i s don eP. 5

..« '

manually b

y a n operator tha t direct s th e "faucet " containin g th e resi n mi x int o asmal l openin g o f th e mold . I

n 1993 , th e facilit

y estimate d emission s fro

mth e mixin g proces s t

o b e 0. 2 ton s pe

r year , an d emission s fromth e fillin g proces s t o b e 0. 6 ton s pe

r year . Thes e estimate s ar

e based , respectively , on astac

k tes t fromth e exhaus t

ofth e mixin g vessels , an d a n industria l hygiene tes t in th e filling area . (Industria l hygien e test s i

n thi s are aar

e a n 8-hou r samplin g procedur

e usin g eithe r activ e o r passiv e samplin g techniques. ) Mr . Stanie r explaine d tha

t becaus e the mold s ar

e nearly completel

y seale d (excep t

fo r asmal l opening wher

e they ar e filled), curin g emission s ar e expecte d t o b e negligible . Th

e second curing ove

n woul d hav e negligibl e emission s becaus e th e polyme r ha s almos t

completely cure d i

n th e first oven . Th e primar y mol d releas e use d i n thi s proces s i s water-base d wit

h silicone-derive d additives . The thir d proces s discusse d i s acastin g proces s use d to mak e polyeste r particles . Th

e particle s ar e use d a s a n inpu t (par t ofth e filler) t

o th e previou s tw o processes . The fee d stock s tha

t g o int o th e resi n mi x include unsaturate d polyeste r resin (containin g no mor

e tha n 35 % b y weigh t styrene) , aproprietar

y volatil e additive , catalyst , pigmen t an d variou s filler s (th e filler s ar e particulate s an

d contai n n o volatil e organi c HA P materials) . The emissio n point s fromthi s proces s involv e the vent s fromth e storag e tanks , pre-mix tanks , mixe r an d th e oven . Emission s vente d fromth e pre-mix tank s an

d mixe r ar e controlle d b

y th e sam e typ e o f carbon filter

bed s use d to contro l the emission s fromth e condensat e tan k fromth e first proces s (th e continuou s line) . The ove n emission s fromthi s castin g proces s ar e als o controlle d by thes e filter

beds . Not e tha t ove n emission s ar

e coole d dow n (fro

mabou t 12 0 F t o 8 0 F ) befor

e the y ente r th e filte r bed . The fourt h proces s liste d o n th e surve y i s no longe

r operate d (it

wa s replace d wit

h th e continuou s line) .

/CT YP. 6 

## fc DocketMo. A 

### „ §4



### _ 5 2 

### Categor y ^T - i f Th e followin g infonnatio n i s locate d 1 n th e confidentia l file s o f th e Director , Emissio

n Standard

s Division , Offic e o f

Ai r Quality Plannin

g an d Standards , U

. S . Environmenta

l Protectio n Agency

, Researc h Triangl e Park

, Nort h Carolin a 27711 . Thi s informatio n i s confidentia l pending fina l determinatio n b

y th e Administrato r an

d 1 s no tavailabl e fo r publi c inspection .

Jn/f-vrxf/Sona/

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