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# OAR Box 1384 Prepped by Charmelle Mathews

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# 66 ) ll-E-2 6 Docket Number: 

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Printed 7/2/20088:42:05 AM Sheet 66 of 264P. 2

CZJCZD CZJ a 

## T?~g-£6 MEMORANDUM TO : Madelein e Strum

U.S . EPA/ESD/CCP G FROM : Gre g LaFla mand Melani e Procto r Pacifi c Environmenta

l Services , Inc . (PES ) DATE : Augus t

4 , 199 5 L:\N30 8 SUBJECT : Minute s of

July 25 , 1995 , Meetin g Betwee n EP A an d Representative s o f

th e Reinforce d Plasti c Composite s Industr y LOCATION : Th e meetin g wa s hel d a t Reichhol d Chemicals , Inc . i n Researc h Triangl e Park , NC , 9:3 0 a m- 1:3 0 p m

* < [TENDEES : Mr . Mar k Bahne r Mr . Jeffre y Bes t Mr . Nic k Cra y Mr . Nelso n Dougla s Ms . Wanit aDunsto n Mr . To mGriffith s Mr . Nor mKapla n Ms . Elle n Lacke

y Mr . Gre g LaFla

m Mr . Elo y Martine z Mr . Ke n Meardo n Ms . Melani e Procto r Mr . Solomo n Rick s Mr . Joh n Schweitze

r Ms . Madelein e Strum Ms . Conni e Turlingt a RTI . OC'f ; PE S 

### /

. : Werne r Compan y C£C " Reichhol d Chemicals , Inc . ^.^r , EPA/ESD/CCP G ^-—- ^ Omeg aPultrusion s EPA/OR D Do w Chemica

l Corporatio n 

### PE S Do w Chemica

l Corporatio n 

### PE S PE S EPA/EMAD/Sourc e Characterizatio n Composite s Institut

e of th e Societ

y of th e Plastic s Industr y (SPI ) EPA/ESD/CCP G Reichhol d Chemicals , Inc . PURPOS E Th e purpos e of

th e meetin g wa s to discus s th e experimenta l desig n o f th e Pultrusio n Industr

y Counci l Phas e I I Emissio n Study . Th e stud y i s intende d to examin e method s o f

limitin g exposur

e of we t resi n t o moving ai r

stream s b y enclosin g wet

area s o f th e pultrusio n machin e o r

b y employin g differen

t type s o f resi n injection .P. 3

OEJGS J EE 3 n - . . a Madeleine Strum Augus t 4 , 199 5 Pag e 2 DISCUSSION Mr . Schweitze

r fro mSPI acte d a s th e coordinato r fo r th e industry' s presentatio n and discussion . H e introduce d th e subjec t b y firs t summarizin g result s obtaine d fro mth e Phas e I emissio n study . Thes e result s showed that , of th e operationa

l variable s studied , air flow throug h th e tes t

chambe r had , b y far , th e larges t

effect o n styren e emissions . Mr . Schweitze r describe d th e outcom

e of th e Phas e I stud

y a s positiv e sinc e ai r

flow i s a variabl e tha t

can b e change d i n th e productio n process , wherea s other variable s suc h a s th e surfac e are ao

f th e part o r bat h surfac e are awoul d b e impossibl e t o chang e without interferin g wit

h produc t specifications . Mr . Schweitze

r proceede d b y askin g fo

r comment s o n th e propose d experimenta l desig n for th e Phas e I I study . Ms . Strum(EPA ) inquire d a s t o whethe r aplan t ai r flow o f 10 0 ft/mi n use d in th e experimenta l desig n i s representativ e o f typica l pultrusio n operations . Mr . Griffith s (Omeg aPultrusions ) note d tha t ai r flow i n hi s plant

wa s highly variable . Mr . Schweitze

r agree d tha

t more informatio n need s t o b e collecte d o n thi s issu e befor e proceedin g wit

h Phas e I I an

d volunteere d t o contac t

industr y t o collec t

thi s information . Accordin g t o Mr . Schweitzer , Phas e I I i s intende d t o follo w u p o n th e firs t phas e of th e stud y an d examine reduction s of styren e emission s for

differen t scenario s i n whic h exposure o f

we t resi n t o movin g ai r

i s limited . Air

flow aroun d th e wet

are acan b e reduce d b y partiall y enclosin g th e wet area . However , i t

i s no t possibl e t o completely enclos e th e wet

are asinc e opening s ar e neede d t o fee d glas s o r vei l into th e resi n bath . Dependin g o n th e complexit y of feed s o f glas s o r vei l and th e frequency o f

manua l adjustment s required , th e percentag e of th e wet are atha t can b e covere d wil l vary . I n th e Phas e I I study , th e wet

are awil l b e covere d 40% , 66% , and to th e maximumpractical degre e i n differen

t tes t runs . Another wa y t o reduc e styren e emission s i s b y minimizin g contac t of wet resi n an d plan t ai r b y usin g resi n injectio n at th e prefor mstag e o r

b y direc t di e injection . I n th e prefor minjectio n proces s resi n i s pumped int o aprefor mbo x a s th e rovin g i s fe

d throug h th e box . Mr . Griffith s state d tha t prefor minjection canno t

b e use d fo

r composite s wit

h complex shape s becaus e alarg e amoun t o f spac e i s necessar

y t o for mth e fibers . Direc t di e injectio n involve s th e injection of resi n directly int

o th e heate d forming die . Mr . Cra y (Werne r Company ) pointe d ou t

tha t direc t di e injectio n generall y change s th e propertie s of th e composite t o adegre e tha t i s unacceptabl e fo

r product s fo r

th e electrical industry . There ar e als o problem s wit h inadequat

e wet-out o f th e rovin g i n th e prefor

mresi n injectio n an d direc t

di e injectio n proces s becaus e th e rovin g i s no t worke d and sheare d enoug h t o b e wetted ou t

completely . Mr . Griffith s adde d tha t hole s a s smal l a s 2 8 micron s du e t o insufficien

t wet-out wil l caus e th e composit

e t o b e rejected for

electrical applications . I n addition , lack of wet-out i s undesirabl e fo

r al l product s sinc e i t

interfere sP. 4

0QH . O Madeleine Strum August 4 , 199 5 Pag e 3 wit h the strength , corrosio n resistance , an d durabilit y o f th e product . I n respons e t o Mr . LaFlam' s (PES ) questio n about manufacturing o r

treatin g th e roving t o enhanc e wet-out , Mr . Dougla s explaine d tha t treatin g the rovin g woul d b e possibl e bu t

i t woul d b e beyon d th e scop e o f th e stud y to evaluat

e ne w technologie s that wer e no t ye t demonstrated . Mr . Meardo n (PES ) asked tha t industr y participant s tr

y to distinguis h betwee n proces s improvement s possibl e fo r ne w and existin g facilitie s whe n talkin g about implementatio n o f

processe s reducin g styren e emissions . H e als o aske d whic h product s ca n b e produce d b y usin g prefor man d di e injection . Mr . Schweitze r repeate d that

ver y larg e part s o r

part s with complex reinforcemen t woul d b e difficul

t i f no t impossibl e t o produc e b y resi n injection . Mr . Bahner

(RTI ) pointe d out

th e importanc e o f

establishin g abaselin e for styren e emission s for

th e pultrusio n industry . Accordin g t o AP-42 , styrene emission s are 4-7 % of availabl e styren e wherea s recen t emissio n measurement s fo r pultrusio n foun

d emission s t o b e 1.5 % o f

availabl e styrene . Facilitie s tha t us e AP-4 2 to calculat

e thei r styren e emission s ma y overestimat

e thei r emission s i

f AP-4 2 i s wrong . Thi s ma y caus e afacilit

y t o b e classifie d a s amajo r

sourc e even though th e facilit y emit s les s tha

n 1 0 ton s of

styren e pe r year . I n respons e t o Mr . Bahner , Mr . Schweitze r state d tha t pultrusio n facilitie s typicall y do not hav e stack s an d therefor

e sampling result s ma

y no t b e availabl e and test s ma

y b e to o difficul

t an d expensiv e to conduct . Group member s agree d tha t arevie w o

f th e AP-4 2 factor s for pultrusio n i s beyond th e scop e of thi s wor k group . Mr . Schweitze

r emphasize d tha t thi s stud y wa s no t designe d t o establis h emissio n factor s fo r th e pultrusio n process . I n respons e t o aquestio n by Ms . Strumabout th e rang e o

f lin e speed s an d th e effec t o f th e lin e spee d o n ai r

flow , Mr . Griffith s explaine d tha t m e lin e speed i n a productio n environmen t

ma y rang e fro

m4 inche s t o 8 fee

t per minute . Mr . Dougla s (Reichhol d Chemicals ) adde d tha t emission s are no t

correlate d wit

h lin e speed . Eve n though increase d lin e spee d increase s th e ai r flow and thereb y styrene emissions , i t als o increase s th e productio n rate . Increasin g th e productio n rate mean s tha t th e equipment doe s no t hav e t o operate a s long t o reac h th e sam e output , thu s reducin g styren e emissions . Mr . Kapla

n (EPA ) asked i

f coolin g th e wet

are aenclosur

e coul d b e use d a s a mean s o f reducin g styren e emissions . Mr . Schweitze r explaine d tha

t ai r conditionin g th e we t are aenclosure woul d increas e air flow over th e wet area , which wa s exactly wha t the y wer e tryin g t o avoid . Othe

r coolin g option s lik

e coolin g coil s would caus e water t o condens e o n th e coil s an d dri p into th e resi n bath , whic h i s undesirable . I n adiscussio n of

th e propose d experimenta l runs , Ms . Stru

msuggeste d th eP. 5

CJEJEg J (S 3 Madelein e Strum Augus t 4 , 199 5 Pag e 4 additio n of

anothe r ru n withou t

resi n cove

r to serv e a s acontrol . Mr . Schweitze r agree d t o add th e additiona

l ru n to th e study . Mr . Kapla n propose d t o ad d aru n wit h th e total temporar y enclosur e (TTE ) fa

n shu t of f while runnin g only th e we t are aenclosur

e (WAE ) fa n t o determin e how muc h styren e woul d b e present i n th e tota l temporar

y enclose d are a i n th e wors t

cas e scenario . Mr . Schweitze r responde d tha

t th e ru n woul d no t

provid e an

y additiona l information . H e explaine d tha t the WA E fa n wil l no t remov e 100 % o f

th e styren e emission s becaus e th e wet are ai s no t

completely covere d an d therefor e styren e woul d continu e to evaporat e fromth e resi n bat

h into th e tota

l enclose d are aunti l an equilibriu mi s reached . Eventually , th e styrene vapor s i n th e total temporar y enclose d are a woul d reac h dangerou s level s and caus e unacceptabl e workin g condition s fo r employees . Mr . Kapla n recommende d tha

t th e air fro mth e resi n bat

h b e sen t t o th e WAE exhaus t i n th e we t are aenclosure experiments . Perhap s th e ai r fromth e resi n bat

h coul d b e directe d throug h th e WA E enclosur

e wit h asimpl e L-shape d duct . Mr . Schweitze r replie d tha

t venting ai r

fromth e resi n bat

h a s opposed t o jus t

coverin g it

woul d increas e styren e evaporation . Bu

t h e promise d t o furthe

r investigat e thi s issue . Th e grou p the n went

t o th e laborator

y pultrusio n lin e t o vie w th e intende d experimenta

l setu p an d desig n (th e tes t

setu p wa s only partiall y constructed) . Mr . Dougla s explaine d ho w th e equipment woul d b e operate d durin g th e testin g an d answere d question s about th e tes t program , includin g ho w much of th e wet are aca n b e covere d dependin g o n th e complexit

y o f th e product . Th e trial s for

th e Phas e U emissio n stud y are tentativel y schedule d t o begi n o n Septembe r 6 , 199 5 an d are expecte d t o las t 8- 9 workin g days . ACTIO N ITEM S 0 Mr . Schweitze

r agree d t o ad d anothe

r ru n t o th e tes t

schedule , acontro l ru n wit h th e wet are acompletely uncovered . 0 Mr . Schweitze

r wil l investigat

e plan t air flow informatio n relativ e to pultrusio n operations . ° Mr . Schweitze

r wil l discus s wit

h the Pultrusio n Industr

y Counci l member s th e usefulnes s of

sendin g th e ai r

above the resi n bat

h t o th e WAE exhaus t

i n th e wet are aenclosur

e experiments .