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# OAR Box 1384 Prepped by Charmelle Mathews



### Document

Number: 

# 116 ) ll-E-7 6 Docket Number: 

# A-94-5 2

Printed 7/2/2008 8:42:07

AM Sheet 116 of 264P. 2 V--.-.*'f l 

### A-94-F L

MEMORANDUM TO : Madeleine Stru m

U.S . EPA/ESD/CCP G FROM : Greg LaFla

m Pacifi c Environmenta

l Services , Inc . (PES ) DATE : Octobe

r 21 , 199 6 P:\N50 4 SUBJECT : Minute s of

September

26 , 199 6 Meetin g o n Regulator y Issues

Manufacturin g of

Corrosion-Resistant

Composite s Product s LOCATION : EPA/Mutua l Building , Durham , NC , 10t h floor conferenc e room , 1:0 0 pm-3:3 0 p m ATTENDEES :

Mr . Kennet

h Kensingto n Mr . Gre g LaFla

m Mr . Steven Linnemann Mr . Richar

d Marten s Mr . Frank

Mayfiel d Mr . Ken Meardo n Mr . Fran k Pickerin g Mr . John Schweitze

r Mr . Edwar

d Shor t Ms . Madelein e Stru m Viate c PE S R L Industries , Inc . Reichhol d Chemical s Ershigs , Inc . PE S Ershigs , Inc . SPI/Composite s Institute MF G Justi n Tank s EPA/OAQP S (616 ) 948-386 0 (919 ) 941-033 3 (513 ) 874-280 0 (919 ) 990-800 7 (817 ) 865-817 1 (919 ) 941-033 3 (360 ) 733-262 0 (313 ) 668-470 3 (302 ) 856-352 1 (919 ) 541-238 3 PURPOS E Th e meetin

g wa s requeste d b y th e Societ y of th e Plastic s Industr

y (SPI ) an d severa

l companie s tha

t manufactur

e product s usin g wha

t they call "premium, " corrosion-resistan t resins . Their

purpos e wa s t o presen t

adraf t propose d definitio n for

thi s industr

y segmen t an d to explai n their

desire to b e considere d separately i n developin g MAC T standard s fo r th e reinforce d plasti c composite s industry . DISCUSSION The meeting bega

n wit h th e attendee s introducin g themselves . Mr . Schweitzer sai d tha t thos e presen

t a t th e meetin g were manufacturer s o f larg e structure s usin g corrosion

resistant (CR ) resins , primaril y b y mean s o f th e filamen

t windin g and ope n moldin g processes . He pointe d out tha t th e contro l technologie s tha t hav e bee n unde r

discussio nP. 3

Madeleine Stru

m Octobe r 10 , 199 6 Pag e 2 fo r th e industr

y (suc h a s low-monome

r conten t resins , vapo r

suppressant

additives , an d highly-fille d resins ) ma

y no t apply to th e CR resi n industr y segment an d coul d compromis e the CR propertie s of

th e products . The companie s in thi s segmen t typicall y are custo m shop s an d do no t hav e standard produc t

lines . Mr . Schweitze

r hande d out

adraf t proposa l definin g user s of

C R resin s a s a distinc t subcategor

y fo r th e purpos e o

f the MAC T standard s (Attachment) . H e explaine d tha t th e handwritte n markup s o n th e proposa l ha d bee n adde d to o recentl y to b e incorporat

e d int o th e printe d version . Unde r thi s proposal , a

t leas t tw o of th e thre e condition s liste d in th e definitio n woul d hav e to b e satisfied in order fo r afacilit y to qualif

y fo r th e C R MAC T subcategory . Ms . Stru masked whethe r i n fac t al l thre e condition s woul d nee d t o b e satisfied . Sh

e wa s concerne d tha

t someon e migh t fulfil l condition s 2 an d 3 , ye t

no t b e aC R facility , and sh

e suggeste d tha

t conditio n 1 (resi n type ) b e aprerequisit e for definin g al l CR facilitie s and the n suc h facilitie s woul d b e require d t o mee t eithe r conditio n 2 (performanc e standard ) o r

conditio n 3 (application ) to qualif y for th e C R subcategory . Industr y member s agree d tha

t (1 ) meeting condition s 2 an d 3 alon e woul d no t

adequately define thi s segmen

t and (2 ) satisfying conditio n 1 in additio n t o eithe r conditio n 2 o r

3 would adequately define th e segment . Th e EP A an d PE S suggeste d tha

t th e definitio n shoul d allo w fo r potential ne

w development s i n resi n type s use d i n C R applications . The industr y agree d tha

t thi s woul d b e agoo d idea , bu t

Mr . Marten s sai d tha

t companie s ma

y no t hav e th e incentiv e t o develop ne

w resin s i f there were alo t

o f regulator y hoop s t o g o through . The group discusse d whethe r user s would b e likely t o switc h t o th e us e o f on e o f th e premium , C R resin s i n orde r t o avoi d amonome

r content limi t o r arequirement

t o us e vapor suppressant s tha

t ma y b e imposed o n non-C R fabricatio n applications . Mr . Schweit

ze r sai d i t woul d b e "stupid " fo

r amanufacture

r to chea t i n thi s way , becaus e premiu m resin s are more expensiv e tha n low-monome

r o r suppresse d resins . I n fact , th e compan y representative s agree d tha

t th e ter m"premium " i n th e industry' s proposal (conditio n 1 ) i s virtuall y equivalent

to "mor e expensive. " Mr . Schweitze r als o pointe d out

tha t odo r complaint s are commo n nea r thes e facilities , an

d thi s proble mwoul d no t

b e alleviate d b y switchin g t o th e higher

monome r content , nonsuppresse d C R resins . Mr . Marten s sai d i t woul d b e a"logistica

l nightmare " to substitut

e th e premiumresin s where they wer e no t needed . Industr y stresse d tha

t th e distinctio n between C R an d non-C R resin s i s quit

e clear , an d tha t mos t resin s d o no t

qualif y a s CR resins . Nonetheless , Mr . Marten s sai d tha t i t i s difficul t to define a"corrosion-resistant " resin . The C R resin s compete successfull y agains t metals , primaril y becaus e they are relatively maintenance-free . The y sai d tha t th e resi n (whic h i s corrosion-resistant , but brittle ) an

d glas s fiber s (whic h are non-CR , bu t strong ) wor

k together to create astrong , corrosion-resistant structure , typically , a 

# XP. 4

Madeleine Strum Octobe r 10 , 199 6 Pag e 3 resin-ric h surfac e layer

i s buil t int o the produc t

t o protec t th e reinforce d laminat

e fro m corrosio n (wear) . Mr . Mayfield noted tha t C R resin s perfor

mi n avariet

y o f environ

ments-acidic , caustic , solvents , blends-al l o f whic h pos e specia

l problem s an

d concerns . Eve n wate r ca n b e considere d acorrosiv e environmen t (thus , onl

y certai n resin s ca

n b e used i n food handlin g o r

potabl e wate

r applications) . Industr

y als o note d tha

t th e lengt h o f performanc e o

f CR resin s i s arelativ e term . I n som e applications , the

y ma y las t man y year s (e.g. , aviny l este r

tan k i n servic e fo

r 2 1 years) , bu t

i n other s they ma

y perfor m adequatel y fo r a s littl e a s 1 yea

r o r less . However , eve n i n th e shorter lif e application s th e customer s are please d becaus e C R resin s stil l provid e alonger performanc e lif

e tha n alternativ e materials . Failure o f C R resin s migh

t occu r fro msudden proces s change s o r permeabilit

y o f th e handle d liqui d int

o the structure . Failure might als o occur

a s aresul t o f simpl e mechanica

l damage . Mr . Marten s note d tha t th e resin-ric h surfac e i s i n contac t wit h th e corrosiv e environmen t an d ove r tim e ma y reac h aleve l o

f "unacceptability " and would the n nee d to b e replaced . Mr . Linnema n als o note d tha

t performanc e lif

e i s affecte d b y th e qualit

y o f fabrication . Industr y sai d tha t th e differen

t resi n chemistrie s compet

e fo r differen t applications ; whil e eac h resi n i s typically matched to aset o f applications , ther e i s som e overla p i n selectin g resins . A s a

n exampl e o

f th e specificit

y o f resi n typ e t o application , Mr . Marten s describe d th e cas e o f achlorin e dioxide bleac h tower tha t wa s designe d for

us e i n apul p an d paper

plant , fo r which 2 8 resin s wer

e teste d and onl

y 1 o f themwa s foun

d to b e suitable . Industr

y als o stresse d tha

t th e supplier s o

f CR resin s ma

y specif y differen t resin s a s bein g "best " fo

r agiven application . Mr . Mayfiel d state d that , nevertheless , eac h resi n chemistr

y ha s it s own "best " applications . Industr y wa s aske d t

o describ e novola

c viny l ester s and bispheno l fumarates , tw o o f th e C R resin s liste d i n thei r definition . The

y sai d novola

c viny l ester s are base d o n novola c epoxy , and are especiall

y suited t o ho t solven t applications . The

y are mor e expensiv e tha

n norma l viny l ester s (which are bispheno l A-based ) and no t a s tough , bu t ar e perhap s th e mos t

corrosion-resistant

resi n i n use . Mr . Pickerin g note d tha t th e novola

c viny l ester s are use d i n th e mos t aggressiv e atmospheres . Bispheno l fumarate s are th e origina l C R resins , use d in high p H an d oxidizin g environments , and hav e excellent resistanc e properties , but

ar e bein g replace d in man

y application s b y viny l ester s becaus e th e vinyl s hav e adde d toughness , alowe r price , an d ar e "mor e friendly " i n th e fabricatio n shop . Th e group discusse d th e us e o f vapo r suppressant s i n combinatio n wit h CR resins . Industr y sai d tha t th e presenc e o

f suppressant s coul d affec

t th e chemica

l resistanc e of

th e product , whic h coul d b e amajo r liabilit y issu e fo r th e fabricator . Mr . Marten s empha

size d tha t th e lif e of aproduc t coul d b e shortene d (throug h reduce d chemica l resistanc e and/o r insufficien

t bondin g o

f components) , an

d Reichhol d woul d no t

b e comfortabl e endorsin g th e us e o f

suppressant s i n C

R applications . Mr . Kensingto n sai d th e succes s of 

# 3P. 5

Madelein e Strum Octobe r 10 , 199 6 Pag e 4 hi s busines s depend s o n th e lif e o f th e products ; i f

i t can b e demonstrate d tha

t thes e additive s d o no t

impact thi s property , h e woul d loo k into givin g thematrial . Ms . Stru m mentione d tha

t Dow ha d develope d suppressant s fo r us e i n conjunctio n wit

h viny l este r resins . Mr . Kensingto n responde d tha t h e i s on e of

th e larges t

CR produc t

manufacturers , an d Dow ha s no t

approache d hi s compan

y about thi s product . Mr . Schweitze r sai d tha t a larg e portio n o

f th e C R industr y wa s represente d a

t th e meeting , and they wer e no t usin g nor were they familia

r wit h th e successfu

l us e of suc h additive s i n C

R applications . H e repeate d tha

t th e produc t

make r bear s liabilit

y if th e produc t

fails , s o they hav e t o b e conservativ e i n making an y change s to thei r

formula s o r

methods . Mr . Schweitze

r sai d tha t low styren e content

resin s usually hav e alowe r molecula r weight , and thes e resin s ar e no t use d i n thi s segmen

t of th e industry . Mr . Marten s sai d tha t CR polyester s ar

e "cooked out " to th e highes t possibl e molecula

r weight , s o mor e monome r i s require d t o mak

e themworkable . Whil e ther e are viny l ester s availabl e wit h a3 5 percen t

monome r content , thes e resin s do no t wor k i n al l applications . Mr . Schweitze

r said tha t i f aHA P monome

r content limit belo w 5 0 percen t

were impose d o n thi s industry , i t would mea

n tha t certai n resin s an

d product s woul d n o longer b e allowable . Mr . Marten s state d tha t som e product s woul d b e remove d fro mth e marke t wit h astandar

d lowe r tha n th e 4 8 percent

allowe d i n California' s Sout h Coas t district . Mr . Schweitze

r sai d industry' s MACT proposa l (no t include d in thei r

handout) consist s of acombinatio n o

f housekeeping , cover s o n containers , operato r training , and lea

k detectio n and repai r requirements . Mr . Meardo n asked abou

t test s t o distinguis h aCR resin . Mr . Schweitze r replie d tha t there i s n o such standar

d analytica

l test . Afte

r som e discussio n abou

t usin g several tes t method s t o define aCR resin , industr y generall y agree d tha

t th e us e of

tes t method s i s no t arealisti c optio n fo

r defining aC

R resin . PE S distribute d copie s o

f facilit y list s fro mth e EPA' s databas e fo

r ope n moldin g and filamen

t windin g showin

g facilitie s th e EP

A consider s to fit

th e corrosion-resistan t designation , base d primarily o n the informatio n in th e 199 3 EP A screenin g survey . Th e industr y representative s reviewe d an d commente d o n th e tables , notin g severa l instance s where they believe d facilitie s wer e incorrectl y placed . Fo r

example , Mr . Pickerin g thought tha t Owens-Cornin g use d onl

y on e resi n i n aproces s wher e choppe d glas s an d resi n are droppe d ont

o amandrel . H e di d no t

consider thi s proces s to b e filamen t winding , bu t

mor e o f acontinuou s laminatio n process . Industr y als o state d tha

t the y di d no t believ e th e resin s use d to mak e undergroun d gasolin e storag e tank s are corrosion

resistant . They als o fel

t the ligh t pole s mad

e b y th e Shakespear

e Compan y do no t qualif y a s corrosion-resistant . Ms . Stru msai d th e table s woul d b e re-evaluate d and revise d where necessary . Industr

y questione d wha

t the y fel t wer e th e "to o low " monome

r content level s show n for certai n facilities , an

d sai d tha t thes e wer e aggregat e values . Ms . Strum 

# MP. 6

Madelein e Stru

m Octobe r 10 , 199 6 Pag e 5 responde d that , i

f thes e value s (a s reporte d b y th e facilities ) wer e ameasure of

averag e monome r content , thi s indicate s tha t thes e CR facilitie s ar

e usin g resin s bot

h abov e an d belo w thes e averag e levels . Mr . Schweitze

r asked th e EP

A an d PE S wha

t the y needed industr

y t o d o t o assis t i n th e rulemakin g effor

t fo r thi s industr

y segment . Mr . Meardo n replie d that , i n orde r t o determin e MAC T floors , th e EPA neede d t o kno w wha t user s are actually doin g i n term s o f monome r conten t fo r each o f thei r application s and the amoun t o f eac h resi n tha

t they used . Thi s would allo w calculatio n o f weighte d averages . Industr y expresse d concer

n about thi s becaus e the

y us e 20 0 to 30 0 differen

t formulation s an

d questione d whether

al l of thos e dat awould b e useful . Mr . Schweitze r repeate d tha

t each environment

t o whic h C R product s ar

e exposed i s different , s o th e material s use d by on e facilit y ma y no t b e appropriate fo

r anothe r facility . The group discusse d whethe r i t woul d b e productiv e to survey facilitie s in a

n attempt to correlate monome

r conten t wit h th e correspondin g applicatio n or

chemica l environment . Industr

y sai d tha t suc h a n effor t woul d b e ver

y time-consuming . Severa

l o f th e companie s present

offere d to provid e an

y neede d dat aand to mak e thei r facilitie s availabl e fo

r asit e visit . Mr . LaFla

msai d tha

t th e EPA an d PE S woul d appreciat

e an y furthe r input tha t woul d enabl e PE S to correc t th e dat abase . ACTIO N ITEM S Mr . Schweitze

r sai d tha t industr y wil l revis e it s propose d definitio n for th e corrosion-resistant

MACT subcategor

y base d o n th e handwritten markup s an d o n th e discussion s a

t th e meeting . The revisio n wil l include the specifi c emissio n reductio n measure s industr

y i s proposin g fo

r manufacturer s usin g C

R resins . Industr

y wil l als o provid e to th e EP

A an y additiona

l correction s o

f th e dat abase . Tw o o

f th e companie s (Ershig s an

d Viatec ) agree d to provid e th e HA P conten t fo r thei r formulations . Th e EP A will revis e th e databas e table s i n order to plac e facilitie s i n th e correc t subcategories , based o n inpu t fro mth e industry .

$1 Draf t proposa l Attachmen t > P. 7

MAC T subcategor y fo r th e manufactur e o f corrosion-resistan t composit e product s Introductio n Whil e composite s i n genera l wil l no t rus t o r degrad e unde r norma l conditions , man

y composit e product s ar e specificall y formulate d and produce d fo r application s requirin g highe r level s o f chemica l purit y and/o r resistanc e t o corrosion . Suc h application s includ e wast e wate r treatment , pollutio n control , meta l plating , foo d and dru g processing , pul p an d pape r production , chemica l processing , an d man y others . Thes e "corrosio n resistant " application s ofte n requir e specia l resin s and/o r manufacturin g technologie s t o ensur e tha t th e resultin g produc t i s sufficientl y chemicall y resistan t o r inert . Th e us e o f thes e specia l resin s an d technologie s ar e ofte n incompatibl e wit h emissio n reductio n method s commonl y use d elsewher e i n th e composite s industry . Fo r example , corrosio n resistan t composit e product s ofte n canno t b e economicall y manufacture d usin g low-VOC , emission-suppressed , o r highly-fille d resins . Subcategor y definitio n

Acomposit e produc t shal l b e considere d "corrosio n resistant, " an d th e manufactur e o f th e produc t shal l b e include d i n th e corrosion



# 6P. 8



### resistan t MAC T subcategory , i f an ytw o o f th e followin g thre e condition s ar e satisfied . •> 1 . Th e produc t i s *a€t e wit h n premiu mresi n o r i s post-cure d a t temperature s abov e 10 0 deg . C . Premiu m• resin s includ e isophthali c polyester, , viny l ester , .fumarat e polyester , chlorendi c aci d polyester , an d novola c viny l ester . . 2 . Th e produc t i s manufacture d t o a n accepte d standar d fo r corrosion-resistan t o r foo d contac t applications . Suc h standard s includ e ASM E RTP-1 ; AST M D5364 , -C502- , D3299 , D4097 , D2996 , D2997 , D3262 , D3517 , D37$4 , D3840 , D4024 , D4160 , D4161 , :>£?$Z. , D4162 , D4163 , D4184 ; ANSI/AWW AC950 ; d** ^ Ssc+-X . •* ' I 3 . Th e produc t i s manufacture d specificall yfo r a n applicatio n tha t require s increase d chemica l inertnes s o r resistanc e t o chemica l attack . Suc h application s includ e product s intende d fo r us e i n chemica l processing ^ pul p an d paper , sewe r an d wast e wate r treatment , potabl e water , foo d an d dru g processing

- v pollutio n o r odo r control , metal s plating , semiconducto r manufacturing , petroleu mproductio n an d refining , an d others .

v^n7"< f tex&le, ffe* * Hftlear, ^**u«M- / d:cmcmac 

### ti.do c



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