# OAR Box 1500 Prepped by Ollie Stewart



### Document

Number: 

# 3 ) ll-C-2 9 Docket Number: 

# A-94-5 2

Printed 8/5/20081:45:55PM Sheet 3 of 343 P. 1P. 2

s*° sr., , 

### A-94-52 

### 1-C - 

### 2" )

UNITE D STATE S ENVIRONMENTA L PROTECTIO N AGENCY

RESEARC H TRIANGL E PARK. N C 2771 1

OFFIC E O F AI R QUALIT

YPLANNIN G AN D STANDARD S


### MA R7 199 6
Mr . Mar k Smit h Co r Te c Compan

y 235 1 Kenskil l Washingto nCour t House , Ohi o 4316 0 Vi a Facsimil e a t (614 ) 335-484 3 Dea r Mr . Smith : Thi s i s t o provid e background informatio nfo r ou r conferenc e cal l o n Monday , Marc h11 , 199 6 a t 1:30pm . Th e purpos e o f thi s cal l i s t o bette r understand Co r Tec' s operation s wit hrespec t t o th e process-base d approache s w e ar e considering fo r developin g emissio n standard s fo r th e reinforce d plasti c composite s industry
. A s yo u know , ther e i s a larg e numbe r o f differen t processe s i n thi s industry
. W e hav e define d ou r processe s from mor e o f a n emission/emissio n reductio nviewpoin t tha na produc t viewpoint , an

d fo r thi s reason , th e manufactur e o f a singl e produc t o r wha t mayb e considere d t o b e a singl e proces s bya manufacture r ma yentai l tw o differen t processe s (an d henc e tw o separat e emissio nstandards ) froma n emissio n viewpoint
. Ou r goa l i n th e cal l i s t o agre e upo n th e processe s w e hav e identifie d fo r Co r Tec . Th e following contain s a descriptio n o f thos e processe s fo r whic hw e ar e developing separat e emissio nlimit s tha t yo u may conside r t o b e relevan t t o Co r Tec' s operations
. Ge l coating group s togethe r facilitie s i n whic hge l coa t i s applie d bya noperato r (typicall yusin g a spraygu n bu t ma yb e applie d usin g a brus ho r othe r applicatio nmethod ) t o th e surfac e o f a mold . Th e ge l coa t i s applie d t o th e surfac e whic h wil l b e th e outermos t visibl e par t o f the product . Th e ge l coa t i s the n cure d a t elevate d o r ambien t temperature .P. 3

Hand/spraylav-up group s togethe r facilitie s whic hpour , brush , spray , us e a flo wcoate r o r impregnato r t o appl yresi no r resi n and reinforcemen t t o th e surfac e o f a mol d o r t o reinforcemen t tha t ha s bee nplace d ont o th e mold . Th e resi ni s the n typicall yrolle d ou t and cure d a t ambien t o r elevate d temperature , bu t ma yals o b e cure d vi a a vacuu mba g process . Th e proces s ma yb e repeate d t o buil d up severa l layer s o f resin
. Continuou s lamination/continuou s rasHn a i s a substantiall yr automate d proces s fo r producin g laminate s o n a nin-lin e conveyer . Th e proces s involve s applying resi n o r ge l coa t ont o a flat , / " ; -,- movin g surface , and the n curing the material , typicall yi n a n ove n throughwhic hth e laminat e i s automaticall ymoved . Polyme r casting involve s th e productio no f a non-reinforce d composit e tha t combine s polymers , fillers , and additive s by•* — pourin g o r dispensin g thes e material s int o ope n o r partiall yope n mold s and the n curin g thema t elevate d o r ambien t temperature . W e ar e considerin g tha t th e proces s tha t Co r Te c characterize s a s ge l coatin g bes t fit s int o th e Environmenta l Protectio n Agency' s (EPA ) continuou s laminatio n/continuou s castin g description
. Th e majo r characteristic s ar e tha t th e proces s i s a fla t process , ha s a movin g conveye r belt , and involve s a machin e whic hi s fixe d i nspace . Th e presen t contro l optio n fo r thi s particula r categoryi s t o remov e abou t 5 0 percen t o f th e hazardou s ai r pollutant s (HAP ) emitte d fromthi s process . Thi s valu e wa s derive d base d o ndat a th e EP Aha s o nth e leve l o f performanc e achieve d byth e media n o f th e bes t performin g fiv e source s tha t conduc t thi s process . Wit hregar d t o thi s level , Co r Te c wa s on e o f th e bes t performing source s byachieving a n overal l remova l efficienc yo f 9 1 percent . Th e proces s associate d wit hthe second par t o f Co r Tec' s operatio n involving th e laminating tabl e and vacuumbaggin g i s mor e difficul t t o determine
. W e ar e considering thi s t o fi t int o th e hand/spraylay-up process . W e considere d polyme r casting , bu t vacuu mba g moldin g doe s no t seemt o b e a cur e metho d fo r polyme r casting , and polyme r castin g typicall yinvolve s a concave mold . W e als o considere d 

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continuou s laminatio n fo r thi s operation , bu t i t seem s no t t o involv e a movin g bel t and i s mor e o f a noperator-drive nproces s rathe r tha n machin e driven
. Fo r you r information , th e limi t w e ar e considering fo r hand/spraylay-u

p i s a w contro l status " o f around 1. 5 pound s (lbs ) HAP pe r gallo n o f resi n matrix , wher e th e matri xinclude s bot hresi n and filler
. Afacility' s contro l statu s i s no t onl y base d o n th e quantit yo f HA P containe d i nth e matrix , bu t als o pollutio n preventio nand contro l technique s tha t reduc e emissions
. Th e us e o f vacuu mba g moldin g and non-spray applicatio n processes , fo r example , ar e tw o suc htechnique s tha t woul d achiev e a "credit " whic hi s incorporate d i n th e calculatio n o f a facility' s contro l status . I nparticular , th e lb s HA P pe r gallo n o f th e resi n matri xi s multiplie d by0.5 5 fo r vacuu mba g moldin g and 0.5 5 fo r th e us e o f a non-sprayapplicatio nprocess . Th e contro l statu s o f 1. 5 lb s HAP pe r gallo n wa s derive d by computing th e media n contro l statu s o f th e bes t performin g 1 2 percen t o f th e facilitie s usin g hand/spraylay-up , considerin g th e credit s achieve d byvariou s pollutio n preventio nand emissio n contro l techniques
. Wit hthi s approach , usin g you r styren e and fille r content s reporte d i n the 199 3 surve yresponse , w e determine d fo r thi s proces s tha t Co r Te c ha s a contro l statu s o f 0. 8 lb s HA P pe r gallo n o f resi n matrix
. I hop e thi s provide s yo u wit hsufficien t background informatio n fo r ou r call . Pleas e b e awar e tha t th e emissio n standar d fo r thi s industryi s stil l ver ymuc hunde r developmen t and althoughth e deadlin e i s fas t approaching , w e hav e muc ht o d o befor e w e eve n propose . W e loo k forwar d t o you r assistanc e i n determining th e mos t appropriat e placemen t o f Co r Tec' s operation s wit hrespec t t o ou r proces s definitions
. I f yo u hav e anyquestion s befor e Monday' s call , d o no t hesitat e t o cal l m e a t (919 ) 54 1 2383 . Sincerely ,

Madele'ine Stru

m Coating s and Consume r Product s Group


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