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# OAR Box 1490 Prepped by Charmelle Mathews



### Document

Number: 

# 8 ) IV-B- 8 Docket Number: 

# A-94-5 2

Printed 8/4/200811:51:46

AM Sheet 8of 273P. 2 

# ^V-SZ . FINA LTRI PREPOR T NONCONFIDENTIA LVERSIONBASE D O NPLAN T COMMENT S MEMORANDU M TO : FROM : DATE : SUBJECT : REFERENCE : Projec t file o f Reinforce dPlastic s Composite s Manufacturin g NESHA P KeithBarnett , U . S . Environmental Protectio nAgency , Emissio n Standard s Divisio n Marc h13 , 2002 , Revise dOctobe r 17 , 200 2 Sit e visi t t o Hydr o Systems , Inc . Reinforce dPlasti c Composite s Manufacturin g NESHAP , ES D Projec t No . 93/5 8 I . INTRODUCTIO N AN D PURPOS E

Th e purpos e ofthi s visi t

was t o obtai ninformatio no nth e reinforce dplasti c composite s manufacturin g operation s a t th e Hydr o System s facilit y i nSim i Valley , California . Specifically w e wante dt o focu s o nth e carbo nadsorptio ncontro l system . H . PLAC EAN D DAT E

Hydr o Systems , Inc . 5 0 Morelan dRoa d Sim i Valley , C A 9306 3 805-584-999 0 Februar y 14 , 200 0 III . ATTENDEE S

Mr . Larr y Burroughs , Hydr o Systems , Inc . Mr . KeithBarnett , U . S . Environmental Protectio nAgenc y Ms . Melani e Proctor , Pacifi c Environmental Service s Mr . Joh n Schweitzer , Composit e Fabricator s Associatio n IV. SIT EINFORMATIO N Thi s facilit

y starte du p in November/Decembe r 1987 . They originally operate dontheir permi t t o construc t

an dhad3 stack s 6- 8 fee t abov e th e roof

. The y pu t

i nacarbo nadsorptio n syste min198 8 becaus e the y hadanumber o f odo r complaint s fromth e surroundin g residentialP. 3

areas . Th e facilit

y ha s prepare danswer s t o specifi c question s o ncontro l syste mdesig nandcosts . Th e question s an danswer s ar e include da s attachmen t 1 . Proces s descriptio n Thi s facilit

y mainly produce s bathtubs , thoug hsom e showe r andshowe r

pan s ar e produced . The y sell t o th e wholesal e plumbin g market . All product s ar e mad e t o order . Th e facilit y ha s atota l o f

35,00 0 squar e feet

o f productio narea . Flat acryli c sheet s ar e heate dandthe nvacuu mforme dt o creat e th e surfac e ofth e tub . Th e forme dacryli c shee t

the n become s th e mold . Ther e are n o HA Pemission s fro mthi s ste p o f th e process . Th e shee t

i s the n place do nawheele ddolly androlle dt o th e choppe r booth . Th e choppe r

boot hi s ope no n thre e sides . Th e air intake i s i

nth e bac k

ofth e booth . A mixtur e o f

filler an dlaminatin g resi n i s spraye dusin g aPolycraf t airles s spray gun . Thi s ste p take s abou t

3 minutes . Th e tu b i s the nmove dout ofth e choppin g boothare at o a nare ai nfront ofth e toolin g boot han di s allowe dt o cur e for approximatel y 1 hour . Th e actua l resi ncup cur e tim e i s 5 minutes , whic hi s fairl y short for alaminatio nresin . Afte

r abou t a nhou r o f cur e time , tub s ar e move dbac k

t o th e choppe r

boot handreceiv e asecon dcoat ofresi n andchoppe dglass . Th e final produc t

i s weighted . Ever y tu b ha s t o mee t aweigh t standard Th e facilit y operate s 2 shift s (1 6 hr/day) . Th e secon dshif t doe s no t d o composite s production , the y prepar e th e for th e da y shift . Th e outdoo r

temperature s reac hth e mid-80 s i n summer an dar e above freezin g in winter . Th e styren e concentratio n o n th e choppe r androl l ou t

area s are < 2 0 ppm . Th e remainder ofth e plan t

i s in th e 1-5 pp mrange . Hydr o System s believe s th e lo w styren e concentratio ni nth e plan t ar e du e t o avapo r

suppressio n effect

ofth e filler, andth e shor t resi nge l time . Th e fille

r als o give s th e produc t

som e fire retardancy . They us e resi nspecificatio nsheet s fo r resi nmonitoring . Les s than five percen t

ofth e productio nha s ge l coats . Thi s include s tool s an dsome tub s andshowers . A mol d(o r plu g i n th e cas e o f

too l production ) i s spraye dwit hage l coat

i nth e gel coat boothan dcure s o n th e productio nfloor. Th e ge l coat boothi s enclosed . Th e remainder o f th e proces s i s th e sam e a s tha t ofth e acryli c tubs . Th e facilit y als o ha s aboothfo r

makin g tool s (molds) . I nth e toolin g booth , toolin g resi n i s applie dt o th e ge l coate dplu g manually . Bot hth e toolin g an dge l coa t boothar e rarel y i

n service . Al l spray booth s ru n 2 4 hour s pe r day . Th e choppe r

boothha s a

nairflo w o f

24,00 0 cf m an da1 0 h

p fa n motor . Th e toolin g andge l coat booth s hav e flows o f

12,00 0 cf meac hand5 h

p motors . Resi n i s purchase din bul k (receive din20,00 0 poun dtanke r trucks ) an dstore dincovere d tanks . The y pum

p 1 day s productio n t o ahighshea r mixer wher e th e filler

i s added . Thi s mixin g ste p als o generate s alo t

o f heat . Th e mixe dresi nandfiller ar e the npumpe dt o acovere dda yP. 4

tank . Ther e i s aheate d1. 5 inchlin e fromth e da y tan k t o th e choppe r

gun . Toolin g resin s are receive din 5 5 gallo n drums . Gel coat i s receive din5 gallo npails . Carbo n adsorptio n syste m A s aresul t

o f odo r complains , Hydr o System s looke dat option s t o reduc e th e ambient impac t o f thei r styren e emissions . On e optio nconsidere dwa s talle r stack s an dmor e velocity . Th e carbo n adsorptio n systemwas next cheapest . Th e carbo nsyste mwas chose nbecaus e the y considere dit

t o b e aknow n technology . Wes t State s Carbo ndi dmos t

ofth e syste mengineering . A shee t metal fabricatio n company assiste di nth e design . Th e adsorptio n systemwas installe di n198 8 andconsist s o f

fla t panel s tha t

loo k simila r t o pleate dair

conditione r

filters excep t

the y are larger , abou t

3 " thick , an dfilledwithactivate d carbon . Th e choppe r

boot hi s se t

u p wit h3 passe s o f

carbon . Ther e ar e 39 6 panel s total . The y als o hadt o upgrad e th e fa n for th e bootht o 1 0 HP . Th e ge l coa t boothan dtoolin g boothboth hav e tw o passe s o f

carbo n panel s an d9 0 panel s each . Th e carbo n i s no t

regenerate do nsite . Th e carbo npanel s ar e regenerate db y Wes t State s Carbo n i nSant aF e Springs . Hydr o System s monitor s th e styren e concentratio ninth e stac k t o determin e whe n th e panel s nee dt o b e changed . Th e styren e concentratio ni s abou t 0. 1 pp mjus t afte r pane l chang e out . Whe n th e concentratio nreache s 2. 8 t o 2. 9 ppm , the y d o asecon d measuremen t

tha t day . Ifth e concentratio ni s still inth e 2. 8 t o 2. 9 pp mrang e the y chang e th e panel s tha t

evening . The y measure th e stac k concentratio ndaily . Th e permi t styren e concentratio n limit

i s 3 ppm . They originall y hadt o chang e th e panel s ever y tw o weeks . Thi s appeare dt o b e a excessivel y short

life , s o the y wen t

bac k t o Wes t State s Carbo nfo r

away t o lengthe npane l life . The y change dthei r

operatio n t o ru n th e fa

no nth e booth s 2 4 hour s pe r da y andpane l lif

e graduall y increase dt o 1 year . Th e pane l lif e for th e toolin g andge l coat

booth s i s 2 years . Apparently , b y runnin g air over th e carbo ndurin g nonproductio nperiods , styren e i s desorbed . Thi s i s acceptabl e t o th e permittin g authority a s lon g a s th e 3 pp mstac k concentratio ni s no t exceeded . Therefore , th e actual emission s reductio nofthi s syste mi s unknown . At th e tim e ofth e site visit , the y reverse dth e ai r flow inth e toolin g an dge l coa t booth s afte r th e secon dshif

t ( 8 hour s pe r

day) . They discontinue dthi s practic e sinc e th e site visi t becaus e i t wa s drawin g styren e lade n ai r bac k int o th e building , whic hresulte dinsom e styren e escap e t o ambient

air andodo r complains . The y chang e out carbo ndurin g secon dshift , whe n ther e i s n o production . The y can prolon g carbo nlif e Vishif t o r s o especiall y o naho t

da y by usin g kraf t pape r t o cove r botto mrun s o f

filters. Whe n the y chang e panel s in th e choppin g both , the y remov e th e 1 s t pass , mov e th e 2 n dand 3 r dpas s panel s int o th e first pass , andthe nplac e fres hpanel s i nth e 2 n dand3 r dpasses . I nth e toolin g andge l coa t

booth s the y replac e all th e panels . The y kee p 18 0 extr apanel s o nsite . Th e portabl e stac k

monito r i s aHUP I 10 1 tha t

cos t $5000.0 0 in1998 . The y calibrat e th e monito r with1 0 pp misobutylene .P. 5



### ATTACHMEN

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RESPONS E T O EP A QUESTIONS , FEBRUAR Y200 0 - A . ADD-O N CONTRO L DEVIC E TECHNICA L DATA - 1 . Hazardou s ai rpollutan t (HAP ) concentratio n a t th e picku p point s t o eac h carbo n pane l (rang e an d averag e HA P ppm) . Choppe rboot h - Estimate d rang e i s 1 - 100ppm . Gelcoa t Boot h - Estimate d rang e i s 1 t o 10 0 ppm . Toolin g Boot h - Estimate d rang e i s 1 - 2 0 ppm . Grindin g Boot h - Estimate d rang e i s 1 - 5 pp m 2 . HA P concentratio n i n th e facilit y(rang e an d averag e HA P ppm) . Rang e = 1 t o 2 0 ppm . Averag e fo rfacilit y= estimate d 3 t o 4 ppm . 1 3 . HA P concentration s a t eac h singl e emissio n poin t a t th e outle t o f eac h carbo n pane l (rang e an d averag e HA P ppm) . Rang e = les s tha n 1 pp m t o 3 ppm . Averag e = estimate d 1. 5 ppm . 4 . A t whic h time s o f th e da yi s monitorin g dat a collected ? Variou s times , usuall ybetwee n 8 A M an d Noon . 5 . Flo wrat e t o eac h carbo n pane l (averag e an d range ) Gelcoa t Boot h i s 12,00 0 CFM. , an d contain s 9 0 panel s i n th e firs t pass . 12,00 0 * 9 0 = 133.3 3 CF M pe rpane l (? ) Choppe rBoot h i s 24,00 0 CF M an d ha s 18 0 panel s i n th e firs t pass . 24,00 0 * 18 0 = 133.3 3 CF M pe rpane l (?) . Th e Toolin g Boot h i s 12,00 0 CF M an d contain s 9 0 panels . 12,00 0 * 9 0 = 133.3 3 CF M pe rpane l (?) . 6 . Weigh t o f eac h carbo n pane l befor e remova l fo rregeneratio n o r replacement . 41. 5 lbs . 7 . Facilit yoperatin g hour s (dail yan d annual ) Firs t shif t = 6:0 0 A M t o 2:3 0 PM . Secon d shif t = 3:3 0 P M t o Midnight , Monda ythroug h Friday , ever yda yexcep t Ne wYear' s Day , Memoria l Day , Jul y4 th , Labo rDay , Thanksgivin g an d th e da yafte rThanksgiving , an d Christmas . 8 . Destructio n efficienc ytes t result s o restimate s o f th e carbo n pane l system . W e hav e n o data. . 9 . Metho d o f demonstratin g continuou s complianc e wit h permi t condition s fo r activate d carbo n panels . Primar ymetho d i s th e absenc e o f odo r complaint s fro m ou rneighbors . W e ar e als o require d t o kee p a recor d o f dail ystac k

testing . B . ADD-O N CONTRO L DEVIC E COS TDATA - 1 . Carbo n pane l syste m capita l cos t an d yea rofth e cos t dat a W e installe d th e carbo n syste m i n th e Sprin g o f 1988 . W e n o longe rhav e an y record s o f th e cost s involved , bu t t o th e bes t o f ou rmemor yw e spen t approx . $400,00 0 o n th e system . 2 . Freigh t cos t an d sale s ta xTh e carbo n cam e fro m Lo s Angeles , al l th e fabricatio n an d shee t meta l wa s don e locally . Th e freigh t an d sale s ta xwoul d b e include d i n th e figur e above . 3 . Electrica l powe rconsumptio n an d cos t associate d wit h carbo n pane l operation . W e upgrade d th e motor s o n al l booths . Estimate d increas e i s $14,10 0 pe ryear .P. 7

Carbo n pane l maintenanc e costs , medi a regeneration/replacemen t costs , an d frequenc yo f medi a regeneration/replacement . W e currentl ypa y $45.0 0 pe rpane l fo rregeneration . W e chang e 18 0 panel s eac h tim e o n th e Gelcoa t Boot h @ $4 5 e a = $810 0 + abou t $30 0 i n labo r= $8400 . W e chang e 18 0 panel s o n th e Choppe rBoot h eac h time , too . Cos t pe rchang e ou t = $8400 . W e chang e 9 0 panel s eac h tim e o n th e Toolin g Boot h @ $4 5 e a = $405 0 + $15 0 i n labo r= $4200 . W e probabl ychang e th e Choppe rBoot h onc e a yea ran d th e othe rtw o mayb e ever yothe ryear . Annua l cos t probabl yaverage s abou t $14,700 . Overhead , propert ytax , insurance , an d administratio n cos t associate d wit h th e carbo n pane l system . « Carbo n Regeneratio n (5 > $14,700/yr . ( # 4 above ) • » Increase d Electrica l Us e @ $14,100/yr . ( # 3 above ) © Annua l Moto rReplacemen t @ $900/y r(base d o n avg . moto r lif e o f 3 years ) « W e replac e th e pre-filter s mor e frequentl y- abou t once/mo . a t a cos t o f abou t $400/mo . fo rfilter s + labo r= $4800/yr . * Cos t t o transpor t filter s fo rregeneratio n - abou t $22 5 roun d trip . <• > Propert yta xi s 1 % o f origina l cost . = approx . $4000/yr . o Insuranc e - annua l premiu m t o cove rth e syste m i s approx . $2000 . • Administratio n Cos t - $5400/yr . ( # 6 below ) Recor d keepin g an d reportin g tim e an d cost s associate d wit h th e carbo n pane l system , lis t o f record s an d report s currentl yrequired , an d tim e an d cost s t o prepar e thes e reports . Tim e t o chec k stack s an d recor d result s = appro xV

z hr/day . X 24 0 day s =12 0 hrs/yr . Tim e spen t eac h mont h t o updat e othe rreport s = approx . 5 hrs/mo . (includin g Accountin g dept ) X 1 2 = 6 0 hrs/yr . Tota l tim e = 18 0 hrs/yr . @ avg . 30/h r= $5400/yr . Fo ra lis t o f report s required , pleas e se e Permi t t o Operate , Conditio n 15 . 

### CAPTUR E SYSTE M TECHNICA L DAT A. ^ 1 . Lis t o f retrofittin g don e t o th e buildin g t o captur e emissions . Ther e wer e n o modification s mad e t o th e buildin g othe rtha n th e installatio n o f th e carbo n adsorptio n system . (W e conside ral l electrica l an d plumbin g relatin g t o th e carbo n syste m t o b e par t o f th e system , no t par t o f th e building) . 2 . Lis t o f emissio n point s capture d an d vente d t o th e carbo n pane l system . Th e primar yemissio n point s ar e th e choppe rgun , whic h i s installe d i n fron t o f th e Choppe rBooth , an d part s whic h hav e bee n choppe d bu t hav e no t ye t cure d Thes e part s ar e locate d i n fron t o f th e Choppe rBoot h an d i n fron t ofth e Toolin g Booth . Th e othe rsourc e o f emission s i s th e gelcoa t gun , whic h i s locate d insid e th e Gelcoa t Boot hP. 8

3 . Numbe ran d siz e o f permanentl yope n door s o ran yothe ropening s i n th e buildin g enclosure . Th e sho p ha s thre e truc k door s - tw o o n th e Sout h wal l (22 ' X 13 ' an d 20 ' X 16' ) an d on e o n th e Wes t wal l (10 ' X 14' ) Ther e ar e als o fou rman-door s (approx . 3 ' X 7' ) Tw o othe rman-door s lea d t o th e offic e are a o f th e building . N o door s ar e permanentl yopen , bu t whe n w e ar e operatin g w e kee p on e o f th e truc k

door s ope n (se e Conditio n 10 . o f ou rPermi t t o Operate). . 4 . Ca n th e buildin g b e considere d a permanen t tota l enclosur e base d o n Metho d 204 ? W e hav e n o idea . 5 . Captur e efficienc ytes t result s o n buildin g enclosur e o rfacilit yestimat e o f captur e efficienc yi f n o tes t result s ar e available . W e hav e n o idea . 6 . Method s o f demonstratin g continuou s complianc e wit h airflo wbalanc e requirement s i n th e permit . Absenc e o f odo rcomplaint s fro m ou r neighbors . 

### D . CAPTUR E SYSTE M COS T DAT A- 1 . Capita l cos t t o retrofi t th e buildin g t o captur e emission s an d yea ro f th e cos t data . Ther e wa s n o retrofittin g t o th e building , onl yth e installatio n o f th e carbo n adsorptio n system . 2 . Incrementa l operatin g an d maintenanc e cost s o f th e buildin g associate d wit h capturin g emissions . Ther e ar e n o incrementa l cos t increase s othe rtha n thos e associate d wit h th e carbo n syste m itself . E . DUCTWOR KTECHNICA L DAT A 1 . Basi cductin g material s befor e an d afte rcarbo n pane l syste m installatio n (steel/aluminum/plastic , circular/straight , insulated/non-insulated ) Steel , befor e an d after . 2 . Basi cductin g configuratio n befor e an d afte rcarbo n pane l syste m installatio n (genera l configuration , length , diameter , locatio n o f tees , dampeners , elbows , an d fans . Al l ductin g change s fo rth e carbo n syste m wer e mad e withi n th e building . Gelcoa t Boot h - w e adde d 2 e a 34 " dia . 90°swee p elbows , approx . 10 ' o f 34,^. . dia . duct , an d tie d int o th e existin g exhaus t stac k o n th e roof . ' Choppe rBoot h - w e adde d 2 e a 24 " X 72 " X 36 " squar e transition s t o th e to p o f th e carbon , 2 e a 24 " X 60 " X 72 " lon g squar e ducts , on e 54 " X 72 " X 48 " squar e transition , approx . 16 ' o f 42' " roun d duct , an d tw o 42 " dia . 45 ° elbows , an d tie d int o th e existin g exhaus t stac k o n th e roof . Th e Toolin g Boot h onl yrequire d th e additio n o f 2 e a 34 " dia . 45 ° elbow s t o ti e int o th e existin g exhaus t stac k o n th e roof . 3 . Measured/estimated/assume d velocit yo f ga s strea m i n ductwork . N o dat a available . 

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### DUCTWOR KCOS TDAT A 1 . Capita l cost t o retrofi t ductwor k t o ven t emission s t o th e carbo n pane l syste m an d yea rof th e cost data . W e installe d th e ductwor k i n 198 8 an d it s cos t i s include d a s part o f th e entir e carbo n syste m cost . 2 . Freigh t cost an d sale s taxfo rductwor k retrofitting . Include d i n syste m cost . 3 . Incrementa l electrica l powe rconsumptio n an d cost associate d wit h duc t fa n operatio n du e t o installatio n o f carbo n pane l system . Approx . $14,100/yr . ( B.3 . above) . 4 . Incrementa l ductwor k maintenance costs du e t o installatio n of carbo n pane l system . N o increas e i n ductwor k maintenanc e costs . 5 . Incrementa l ductwor k overhead , propert

ytax , insurance , an d administratio n cost s du e t o installatio n of carbo n pane l system . Include d i n B.5 . above .



# t