p.1 

OAR Box 1384 

Prepped by Charmelle Mathews 

Document Number: 

69) ll-E-29 

Docket Number: 

A-94-52 

Printed 7/2/2008 8:42:05 AM Sheet 69 of 264 
P.2 

M W22-QS1\E 9:10 CRANE COR TEC FAX NO. 3352171 

COR TEC COMPANY 

P. 01 A-94-52 

TCLEPHONe - (81<) 33S-S400 

FAX-(81<)33Wa4a 

COR TEC 

23S1 KENSKILL WASHINGTON COURT HOUSE, OH 43160 

FACSIHILE COVER SHEET 

DATEs At**"*- J J. /9?S 

TIHE: 

# OP PAGES: JL 

TO* AfA!>e/£/rA//? OT/IUr+i 

9/9- 5TW- oejX 

ATTHs 

FROM: Joe rfc KJPJS. 

OUR FAX MUHBER IS-! 614/335-2171 

IF YOU EXPERIEHE PROBLEHS WITH THIS TRAHSHISSIOM, OR DO 

HOT RECEIVE THE COMPLETE TRAHSHISSIOH, PLEASE CALLt 

614/335-2984. 

FAX SEHT BYJ 

(INITIALS) 
P.3 

f- '0-^95 TUE 9:10 CRANE COR TEC FAX NO. 3352171 P. 02 

COR TEC 

COR TEC COMPANY 23S1 KENSKILL 

TELEPHONE - (6U) 33&S4O0 

FAX _ (814) aas-49« 

WASHINGTON COURT HOUSE, OH 43160 

To: Madeleine Strum 

U.S. Environmental Protection Agency 

Fax: 919-541-0072 

From: Joe Prior, Joe Smart, Mark Smith 

Cortec Co. 

We have reviewed the draft Contact Report from our August 8,199S conference 

telephone call and suggest the revisions noted in the attached. 

Please call if you need further information. 

z 
EA. 

FAX NO. 3352171 P. 03 '.AUG-22-95 TUE 9:11 CRANE COR TEC 

CONTACT REPORT 

From: Wanka Dunston, US Environmental Protection Agency 

Madeleine Stnim,U5 Environmental Protection Agency A 4' ) 

pale of Contact: August 8,1995 

Contacts: Joe Prior, President 

Joe Smart 

Mark Smith 

Company/Agency: Crane Cor tec Company 

Tdephone Numben (018)443 6091 (fel ^ 335-lJ f 00 

CONTACT SUMMARY 

Notes prepared by Wanita Dunston. 

• Process: Resin is pumped in a batch process into dispensing troughs. The troughs hold 

the catalyzed resin. It is poured into the laminating area. Moving carts (with holes on the 

side for dispensing resin) are used to dispense resin and to pour it onto tbe panel That 

pouring is not controlled because I) the resin is not emitting a significant amount o f 

styrene and 2) panels are on the order o f 60' x IT and tho amount o f air required to 

• —calculate tho oopturo efficiency eaa not be determined. Ahlfr J T U}0iJi*b B-fc 

( 1MJW.UCA L "fa CONTROL. A M0V/A/& ,M/*/0fcScv£C-£ . 

• With gelcoat, Cor tee can eontrol the process; but with lamination, there is a great deal o f 

movement, and there is no way to fix collection points; ie to attach hoods, etc. t o capture 

the emissions. Vacuum bag emissions are minimal. On a pound-to-pound basis, emissions 

are low. 

• In 1990, Emission test report, emissions from vacuum bagging are given. IS IT 

GENERAL ENOUGH TO USB FOR VACUUM BAGGING EMIS SION FACTORS? 

We feel that it is a good representation o f vacuum bagging processes. 

• WHEREDOESTHE30TPYFIGURECOMEFROM7 Asoflastyear,rigorousemision 

testing was done. Information given before that axe not as rigorous. So, the 30 tpy figure 

is actually obsolete. 

4 2400-2500 lbs of styrene totaUrom the vacuum bagging process is stated, and the 

Emission fector is based on the 1990 study at 1994 production levels. 

• 2325 lbs total emisicm^from the vacuum bagging process. Some leakage occurs with 

vacuum bagging and a small amount ofthe leakage caries with it styrene. It is essentially 

3 
VAUG722-95 TUE 9:11 CRANE COR TEC 

FAX NO. 3352171 ?-m 

a closed process. 

• Because ofthe 6.9 tpy figure, they arc not a major source. 

• They installed the incineiator to control trough diyingoven area foHiho to Xui|, dene in 

4994: Emissions from trough diying area are nrinimaT Testing since then shows it is low 

comparatively speaking. Incinerator controls approximately 2 tpy for trough diying area. 

• The trough size is^lO in wide, 10 ft long. Resin at that point ia handled out at ambient 

temperatures. Emissions come fim heating and curing. Resin in the trough has not yet 

reached gelation. It doesn't gelate until after the vacuum bagging occurs. The troughs 

are-Mt covered. The cyde time from r^ p to tough ism the order 

&cteW Tee A 6UJ»% uouT.. 

• Emission loss from the trough is included in the table emisions "Any emission leaving the 

trough or suffice area of part before vacuum baggwg..M-refered to aa "resin to air 

contacts''. 

• THE TRADE ASSOCIATION WOULD CALL YOU CONTINOUS LAMINATION. 

We are not continuous lamination. Processes -which relate to us are gelcoatinfl, hand 

layup and etc. Probably we are most like hand layup with emission reduction through 

vacuum bagging. Our hand layup is different, it is automated. 

• Process descriptions were sent via fa^and thoychould moil omigoien test iiifumiaU'oi>i 

A 

• YOUHAVEALOWPLOWRAIETOTHEOXlDIZER;WBDlDNOTKNOWrr 

WAS THAT LOW. The cost effectiveness seems to be (S200,000/yr)/25 tons-tha 

quantity Incinerated which equals $8000Aon; which is fiirry high since it is above 5000. 

Baaed oiHPPfly ao pennit has booo-rooorded. When we eateeed 10 tpy, wc will need 

* ) 

Information is accurate: 

-?V*r 

y 
• : •• P.6 

AU(^18-95 FRI 15:38 P.01 

Fax Cover Sheet 

, -. M&. MAoasuue STRUM tu*i£i**. $7***". 

To: * Mrs. Wanita Dunston ( i , -,^-1 

USEPA (*») SV - ^S< 

Phone:(919)541-2306 

Fax: (919) 541-0072 » 

rrom: Mark Smith n A -*— . 

Crane Cor Tec Company UpflME. COR l£t / 

Phooe: (614)335-9400 

Fax: (614)335-4843 WThtT (LePNCr 

Date: August 8, 1995 

Subject: Additional Data per Phone Conference on August 8,1995 

Dear Mrs. Dunslon, 

Per your request, the addilional process emissions data you requested is as follows: 

-Vacuum bagging / oven curing process emission factor: 

E(f) = .000558 lb styrene / lb resin (based on 1990 lesl data and 1994 

TRI facility calculations) 

-Table lamination and trough application process emission factor: 

E(f) = .00268 Ib styrene / lb resin (based on 1994 test data and 1994 

TRI facility calculations) 

-1994 Total Facility Losses (per 1994 TRI calculations:) 

Fugitive Point Quantity Total 

Losses Losses Incinerated Losses 

(lb/yr) (lb/yr) (lb/yr) (lb/yr) 

Vacuum bag / ovensr 0 2.325 0 2,325 

TableilamlnaliOh and 11,162 0 0 11,162 

trough application 5 
P.7 

AUG-48-95 FRI 15:39 P. 02 

Note that the variance in the sum of total losses for all emissions sources and the 6.90 tons 

per year for the facility is due to incidental incineration of background styrene by inlet 

draft into the catalytic oxidizer. The data provided above is based on emissions testing 

and best engineering judgement regarding our manufacturing processes. If you have any 

questions or require additional information, please contact me at your convenience. 

Sincerely, 

lark Smith 

Applications Engineer 

Crane Cor Tec Company 

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/6 
P.12 

•AUG---7-95 HON 15:47 CRANE COR TEC FAX NO, 3352171 P- 01 

To: Wanita Dunston ; 

E.P.A. —. . 

Fax: 919-541-0072 (^ ^ -f££ 

From; J. Prior 

Cortec Co. 

Washington Court House, Ohio 

Date: August 7,1995 

In response to your request for information faxed to us on July 28,1995, we have 

prepared the attached responses. We will plan a conference call discussion with you 

tomorrow (August 8) as you suggested to clarify any questions you may have. As I 

mentioned to you, we would like to request a copy ofthe draft report that is prepared as. a 

result ofthe data that we are providing. 

/ / 
AUG-.7-95 MON 15:47 CRANE COR TEC FAX NO. 3352171 

P.13 

P. 02 

August 1, 1995 

Cor Tec manufactures fiberglass/resin reinforced, plywood cored structural 

panels, primarily for the transportation industry. Thermosetting polyester 

resin, fiberglass, plywood, and either a polyester gel coat or Tedlar film are 

bonded together utilizing a vacuum bagging process. Gel coat finishes are 

prepared in a seperate spraying operation, and transported to the vacuum 

tables after they are cured for incorporation into the laminate. The manufacturing 

process is a batch-type process. After the panels are cured, they are cut to 

size using computer-controlled saws. (See attached process diagram). 

Emission points currently vented to the oxidizer include the gel coater, resin 

trough filling stations, and resin trough diying cabinet. The emissions from 

1994 tor these sources, as calculated for the facility's 1994 TRI form R 

submissions, are as follows: 

Gel Coater 

Trough filling 

Trough diying 

Fugitive 

Losses 

(lb/yr) 

3,011 

0 

0 

Point 

Losses 

(lb/yr) 

1,573 

4 

118 

Quantity 

Incinerated 

(lb/yr) 

49,180 

133 

3,673 

Total 

Losses 

Gb/yr) 

4,780 

4 

118 

Average inlet flow rate to the oxidizer is 4596 dscfm (dry standard cubic ft / min), 

and the average outlet flow rate is 4778 dscfm. 

Average inlet concentration of styrene to the oxidizer is 276.6 ppm and the 

average outlet concentration of styrene is 14.3 ppm (per testing conducted 

February, 1994). 

Capture efficiencies: gel coater 94.4% 

trough filling not established (insignificant) 

trough drying 100% (total enclosure) 

Destruction efficiency of catalytic oxidizer: 96.9% 

(above data from Februaiy 1994 testing) 

Capital investment: $ 700,000.00 

Annualized operating costs: $ 89,000.00 

I'he laminating process and vacuum process are not vented directly to the 

oxidizer due to the prohibitive volume of air which would be required to 

effectively collect emissions from these sources. 

Lo 
P.M 

3-.7-9 5 KM 15*48 CRANE CCR TEC FAX NO. 3352171 P.03 

8. The Permit Engineer most familiar with our operation is Chris Bulinski, Ohio 

Environmental Protection Agency. 

9. The referenced paper in the questions does pertain to our facility. 

10. Total HAP (styrene) emissions for 1994, as calculated for the 1994 filing of 

Toxic Release Inventoiy (TRI) Form R submissions for the facility, were 

6.90 tons during 1994. 

13 
P.15 

f• AUGT-7-9 5 HON 15:48 CRANE COR TEC FAX NO. 3352171 

.,-tiit: COR TEC 

« urnvaum or OMMI ee. 

P. 04 

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PllOCeSS F*Q*t T>t4<rtA+1 
• P.16 

« --AUG;- 9-95 WED 15:03 P. 01 

Fax Cover Sheet 

To: Mrs. Wanita Dunston 

USEPA 

Phone: (919) 541-2306 

Fax: (919) 541-0072 

From: Mark Smith 

Crane Cor Tec Company 

Phone: (614)335-9400 

Fax: (614)335-4843 

Date: August 8, 1995 

Subject: Additional Data per Phone Conference on August 8, 1995 

Dear Mrs. Dunston, 

Per your request, the additional process emissions data you requested is as follows: 

-Vacuum bagging / oven curing process emission factor: 

E(f) - .000558 lb slyrenc / lb resin (based on 1990 lest dala and 1994 

TRI facility calculations) 

-Table lamination and trough application process emission factor: 

E(f) = .00268 lb styrene / Ib resin (based on 1994 test data and 1994 

TRI facility calculations) 

-1994 Total Facility Losses (per 1994 TRI calculations:) 

Vacuum bag / ovens 

Table lamination and 

trough application 

Fugitive 

Losses 

Ob/yr) 

0 

11,162 

Point 

Losses 

(lb/yr) 

2,325 

0 

Quantity 

Incinerated 

(lb/yr) 

0 

0 

Total 

Losses 

(lb/yr) 

2,325 

11,162 

Js 
P.17 

•AtBr*9-95 MED 15:04 P. 02 

Note that the variance in the sum of total losses for all emissions sources and the 6.90 tons 

per year for the facility is due to incidental incineration of background styrene by inlet 

draft into the catalytic oxidizer. The data provided above is based on emissions testing 

and best engineering judgement regarding our manufacturing processes. If you have any 

questions or require additional information, please contact me at your convenience. 

Sincerely, 

Mark Smith ^- ^ 

Applications Engineer 

Crane Cor Tec Company 

U