p. 1 

# OAR Box 1394 Prepped by Ollie Stewart



### Document

Number: 

# 11 ) ll-B- 6 Docket Number: 

# A-94-5 2

Printed 7/3/20087:22:10AM

Sheet 11 of 57

### £ 7 IL7.1I 7 HI D 1 O PACIFI C ENVIRONMENTA L SERVICES , INC . f ~ i^ctsf T)y.a. 'jW'cx.X. r- ^°W

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## fff'B'6 Centra l Par k

Wes t 5001 Sout h Miam i Boulevar d

P O Bo x 1207 7 Researc h Triangl e Park . N C 27709-207 7 (919)941-033 3 FA

X (919 ) 941-023 4

SIT E VISI T REPORT TO :

FROM : DATE : SUBJECT : Madelein e Stru m ESD/CP B (MD-13 ) U.S . Environmenta l Protectio nAgenc y Researc hTriangl e Park , NC 2771 1 Gre g LaFla

m an dDea nCarrol l ^ ^ Pacifi c Environmenta l Services , Inc . (PES ) l l Novembe r 18 , 199 3 L:\N02 7 Sit e Visi t - - Glasti c Corporatio n Cleveland , Ohi o EP A Contrac t 68D10116 ; ES DProjec t 93/5 8 PE S Projec t N02 7 

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I . Purpos e Th e purpos e o f th e visi t wa s t o observ e pultrusio nan dclose dmoldin g composite s fabricatio nprocesse s o f th e reinforce dplasti c composite s industry . Thi s informatio ninclude dth e processes , emissions , an dcontro l measure s inus e a t th e facility , an dwil l b e use dinth e developmen t o f a Maximu m Achievabl e Contro l Technolog y (MACT ) standar dfo r th e reinforce d plasti c composite s productio nsourc e category . Thi s sit e visi t wa s par t o f a 3-day tri pt o observ e operation s a t si x composit e facilitie s b y the U.S . Environmenta l Protectio nAgenc y (EPA) , it s contractor , Pacifi c Environmenta l Services , Inc . (PES) , an drepresentative s o f tw o industry

trade associations : Th e Composite s Institut e o f th e Societ y o f th e Plastic s Industry , an dth e Composite s Fabricator s Associatio n(CFA) . II . Plac e an

dDat e Glasti c Corporatio n 432 1 Glenridg e Road Sout hEucli d(Cleveland) , Ohi o 44121-289 1 Augus t 11 , 199 3 8:0 0 a.m . - 11:4 5 a.m .P. 3 r

a 

## in . Participant s

Glasti c Mr . GlennGrant , Presiden t an dChie f Executiv e Office r Mr . Rober t Sedlatschek , Vic e Presiden t o f Engineerin g Ms . Jane t Boyer , Environmenta l Enginee r U.S . EPA Ms . Madelein e Strum , Projec t Manage r Pacifi c Environmenta l Services . Inc . fPES ) Mr . Gre g LaFlam , Environmenta l Enginee r Mr . Dea nCarroll , Environmenta l Enginee r Th e SP I Composite s Institut e Mr . JohnSchweitzer , Technica l Directo r Composite s Fabricator s Associatio n Mr . Stev e McNally , Directo r o f Governmen t Affair s IV . Discussio n Th e visi t beganinth e facility' s conferenc e room , wher e Glasti c staf f mad e a presentatio nconcernin g th e facility' s environmenta l history , processes , emissions , contro l measures , an dcurren t environmenta l program . Glasti c i s i na nonattainmen

t are a (what State/local

regulations is the facility subject

to?). A

handou t (2 3 pages ) wa s provide dt o th e participant s t o accompan

y th e presentation , an di s attache dt o thi s report . A t 10:0 0 a.m. , a tou r o f th e proces s operation s a t th e facilit y wa s taken . Th e tou r conclude da t 11:3 0 a.m . bac kinth e conferenc e room , wher e fina l question s wer e askedi na brie f session . Glasti c indicate dtha t no portion s o f th e sit e visi t woul dconsis t o f confidentia l busines s information . A . Histor y Th e company

launche da

nintensiv e environmenta l progra m afte r th e loca l communit y

became agitate dove r styren e odor s bein g create db y th e plant . (Th

e neares t residenc e i s approximatel y 45 0 fee t fro

m th e plant. ) Throug hit s effort s t o reduc e emissions , th e company improve dth e situatio nan dcreate da

n atmospher e inwhic hth e communit y i s satisfied . Volatil e organi c compound (VOC ) an dhazardou s ai r pollutan t (HAP ) reduction s wer e achieve dthroug ha combinatio no f produc t substitution , operatin g practice s designe dt o reduc e fugitiv e emissions , an dcarbo nfiltratio nunit s t o adsor bcapture demissions . Th e company' s objectiv e i s t o reduc e it s annua l VO C emission s fro m 209,10 0 pound s inlat e 199 1 t o 11,55 0 pound s pe r year . (Is this South Euclid only, or Jefferson also?) A s o f Jul y 1993 , th e compan

y hadachieve dabou t 7 7 percen tP. 4 

# s 

# p& l 

# S

o f thi s goal . Company official s estimate dtha t 4. 5 t o 5 percen t o f th e styren e use di nth e facilit y i s los t a s emissions . B . Processe s an

dProduct s Glasti c Corporatio noperate s tw o facilities , on e i nJefferson , Ohi o an d on e i nSout hEucli d(Cleveland) , Ohio . Th e Jefferso nplan t carrie s ou t injectio nmoldin g o f precision , comple xparts . Th e mai nplan t inClevelan d (27 5 employee s i nthre e shifts ) ha s fou r mai nproces s areas : 1 ) laminat e production , 2 ) compressio nmolding , 3 ) pultrusion , and4 ) manufactur e o f bul k moldin g compound(BMC) . Thes e fou r process/produc t areas , a s wel l a s some additiona l operationa l areas , ar e describe dbelow i nth e orde r i nwhic hthe y wer e observe da t th e facility . 1 . Laminat e Productio n Laminate s ar e 3 x6 foo t o r 4 x 8 foo t sheet s (0.030 n -l nthick ) produce d o nany o f nin e compressio nmoldin g presse s (250-75 0 ton) . The y ar e use da s thermal , electrical , an dcorrosio ninsulating barrier s an di na variet y

o f structura l applications . Compositio ni s 2 0 percen t liqui dresi n(whic h1 s 2 5 percen t styren e monomer) , 2 5 percen t glas s reinforcement , an d5 5 percen t othe r material s (additive s an dfillers) . Resi ni s hando r machin e sprea dont o a nE-glas s fibe r shee t (continuou s strandmat ) whic hha s bee nplace dint o a press . (Severa l sheet s an dresi n layer s ma y

g o int o som

e laminates. ) Curing i nth e heate dpres s take s fro m 1 t o 3 0 minutes , dependin g onth e shee t thickness . Prepare dresi nmateria l i s store da t eac hpres s i nmovabl e "totes, " inwhic hcatalyze dresi nca nb e kep t fo r u pt o 2 days . Stainles s stee l cover s o nth e tote s ar e kep t close da t al l time s t o preven t styren e losses . Resi ni s dispense dint o smalle r bucket s fo r handapplicatio no f resi nan dpumpe dthroughenclose dline s fo r machin e application . Roughl y

on e dru m o f wast e resi ni s accumulate dpe r month . Laminate s accoun t fo r 4 5 percen t o f th e sale s fo r th e facility . 2 . Resi nMixin g Resi nmixe s fo r th e laminatio nan dpultrusio nprocesse s ar e prepare di n a 2-floo r mixin g an

dstorag e area . Resi ni s mixe dalternatel y i ntw o Morehous e mixer s locate do nth e secondfloo r abov e th e tot e coo l storag e area . Resi nmi xinfou r differen t colo r choice s i s pumpe dint o th e tote s throug h fou r separat e color-dedicate dpumps . A flexibl e hos e route s organi c vapor s fro m th e tote s (or

mixers?) durin g filling t o th e carbo nfilter s onth e roo f o f th e building . A

close dfille r feeder , whic hca npivo t t o eac ho f th e mixers , hadjus t bee nreworke dan dwa s du e t o b e re-installe dadjacen t t o th e mixers . Th e dus t create da s dr y fille r material s ar e adde di s route dthroug h a stac kan

dcollecte dindus t baghous e filter s onth e buildin g roof . Vapor s ar e als o collecte dfro m th e mixer s an

droute dt o th e carbo nfilte r system .P. 5

S3 3 . Bul kMoldin g Compound Bul kmoldin g compound(BMC ) i s produce di ntw o Sha r mixer s anda Littlefor d(L-600 ) mixe r locate donth e firs t floor . Fo r th e Sha r mixers , dry ingredient s ar e adde dfro m a two-par t hoppe r (glass/fillers) onth e second floor . Dus t i s collecte dfro m th e to po f th e hoppe r an dsen t t o th e filte r houses . Vapor s fro

m th e mixer s ar e route dt o th e carbo nsystem jus t befor e the door s t o th e mixer s ar e opened . Dry material s ar e adde dt o th e L-60 0 mixe r b y hand . BMC i s use di nth e facility' s compressio nmoldin g processe s an di s sol do nth e ope nmarke t (1 5 percen t o f sales) . (How is BMC handled after being mixed?) 4 . Compressio nMoldin g Compressio nmoldin g o f BMC , carrie dou t on1 1 presses , account s fo r 3 t o 4 percen t o f sales . Product s includ e primaril y houseware s components . 5 . Pultrusio n Th e facilit y

operate s 1 6 pultrusio nlines , whic hproduc e industria l electrica l fus e tube , insulate ddoo r panels , scuf f liner s fo r truc kcarg o compartments , fibe r opti c rod , an dmiscellaneou s custo

m shapes . The , majorit y

o f pultrude dproduct s ar e mad e on1 3 machines . Tw o method s wer e i nus e fo r limitin g th e escap e o f VO C vapor s fro m th e 1 3 lines . On e involve dth e us e o f resi ninjecte ddies , inwhic hresi ni s pumpe ddirectl y int o th e fron t endo f th e formin g di e (rathe r tha nwettin g ou t th e reinforcemen t inanope nresi npan) . Thi s eliminate s th e expose dresi n surface s normall y

experience dupstream

o f th e die . Th e othe r metho dinvolve d si xo r seve nline s having transparen t viny l stri pcurtain s installe daround the resi npa ninorde r t o reduc e ai r flow ove r (an

dhenc e emission s from ) th e pan . Fo r some o f th e line s wit hope nresi npans , th e siz e o f th e dri ppa nan d plat e collectin g exces s resi nhadbee nreduced . Fibe r opti c rod(FOR) , supplie dt o th e communication s industry , i s produce donthre e pultrusio nlines . A nepoxy resi ni s use dt o we t ou t th e reinforcement , andcurin g i s accomplishe db y mean s o f si xultraviole t (UV ) lamps . A

hoo dove r th e resi nimpregnatio nare a remove s vapor s fro m th e line , whic har e route dt o th e plant' s carbo nfilte r system . FO Ri s produce da t abou t 20 0 fee t pe r minute . C . Wast e Handlinqan dClean-u p Wast e resin s ar e treate dwit ha chemica l know na s Poly-Hib , whic h retard s th e curin g process . Thes e unpolymerize dmaterial s ar e marke da s hazardou s wast e an

dma y b e store da t th e facilit y fo r upt o 9 0 days . A compan y calle dChemica l Solvent s haul s th e drum s t o a facilit y wher e th e wast e resi ni s use di nfue l blending . Glasti c use s n o proces s wate r an dha s n o wastewate r issues . Tote s (40-5 0 ar e onhand ) brough t bac kfro m th e productio nfloo r ar e cleane dusin g anautomate dsystem i nwhic hmethy l methacrylat e (MMA ) i s pumpe dP. 6

jr int o the covere dtot e throug ha natomizin g wand . Base do nth e weigh t o f th e tot e versu s it s tar e weight , th e correc t amoun t o f MM A i s automaticall y delivere dthroug hth e wand . Approximatel y 8 t o 1 0 tote s ar e cleane dpe r da y ina 30-4 0 minut e cycle . MM A vapor s exi t th e tot e throug ha flexibl e hos e fo r recover y b y th e plant' s carbo nfiltratio nsystem . (How is the spent MMA handled?

Please describe

the process.) Th e facilit y

i s pursuin g a program t o reduc e VO C an

dHA P emission s fro

m it s us e o f solvent s fo r cleanin g operations . Th e primar y cleanin g solven t use di s a blendreferre dt o a s Solven t 65 , supplie db y Chemica l Solvents . (For what cleaning

operations

is this solvent

used?) Anothe r cleane

r bein g evaluate d(an

dinus e a t th e Jefferso nfacility ) i s calle dEnvirosol v 2000 , b y Envirosolv , Inc . Neithe r o f thes e ha s an y HA P content . Th e compan y ha s eliminate dth e us e o f Solven t 85 , a blendcontainin g toluene ; 1,1,1-trichloro ethane ; an

dmethylen e chloride . OTHER QUESTIONS: 1. How much waste resin is collected

from each operation

(pultrusion, lamination, closed

molding, BMC

production)? 2. How often is the waste resin collected

from each operation? 3. Please

describe

the cleanup

operation

for each of the above operations. 4. Is styrene

monomer

ever used as a cleaning

material? D . VOC/HA P Contro l Measure s A s a resul t o f it s experience s wit hth e community , Glasti c ha s initiate d a nenvironmenta l polic y an dobjective s fo r th e Clevelan dfacility . On e goa l i s t o reduc e th e 199 1 annua l VO C emissio nrat e fro m 209,10 0 l b(10 5 tons ) t o 11,55 0 l b(5. 8 tons) , o r b y 9 4 percent . Accordin g t o th e company' s estimates , emission s inJul y

199 3 wer e abou t 57,20 0 l b(2 9 tons) . Thi s represent s an emissio nreductio no f 7 3 percent , whic hi s 7 7 percen t o f it s target . Th e company' s emissio nreductio ngoal s wer e me t throug hth e followin g contro l measures : Cleanin g solven t replacement . Th e switc hfro m Solven t 8 5 t o Solven t 6 5 an dEnvirosol v

200 0 ha s reduce dVO C emission s b y abou t 93,10 0 lb/y r (4 6 TPY) . Th e HAP s toluene ; 1,1,1-trichloroethane ; an dmethylen e chlorid e hav e bee n eliminate di nth e solvent s used . Th e ne w Solven t 6 5 ha s some disadvantages , suc ha s slowe r evaporation , highe r cos t (3 6 percent) , an dobjectionabl e odo r (the compan

y adde da pine-scente dcleaner) . Envirosol v 2000 , inus e a t th e Jefferso nfacility , i s unde r evaluatio nfo r us e a t Cleveland . Thi s cleane r ca nb e re-use dupt o 4 0 times , accordin g t o th e manufacturer . (Please send copies of the NSDS for Solvent

65 and Envirosolv

2000.) Reductio no f fugitiv e emissions . Th e facilit y ha s introduce dsevera l change s int o it s mixin g an dtot e storag e area s tha t reduc e th e amoun t o fP. 7

/ 

# s-

•g cleanin g operation s necessar y an dcreat e a close dsystem fo r th e emittin g materials . Th e fou r color s o f resin s (red , black , white , an dtan ) ar e pumpe d b y individual , color-dedicate dpump s fro m the mixer s t o th e resi ntotes . Thi s ha s eliminate dth e cleanin g previousl y neede dwhe nth e singl e pum pprovidin g al l fou r color s wa s undergoin g a colo r change . Al l resi ntransfer s ar e mad e ina close dsystem

int o container s wit htight-fittin g lids . (Please describe these containers in greaterdetail.) Quick-disconnec t fitting

s ar e use dfo r th e line s use dt o fil l an dven t th e system . Ventin g fro m th e close dvessel s occur s a t specifi c time s inth e mixin g an dtot e cleanin g cycle s i norde r t o captur e th e maximu

m concentration s generated , an demission s ar e route dt o th e carbo nfilte r system . Carbo nfilte r system . Th e company ha s designe dit s ow

ncontro l system consistin g o f 2 0 passiv e filte r housing s mounte donth e roo f o f th e productio n building . Fiv e o f th e housing s (i nplac e sinc e Februar y 1993 ) eac hcontai n (48 ) 1 f t x2 ft , 6-inchdee pfilte r panels , containin g 3 0 lb s o f activate d carbo neach . Th e filter s ar e weighe dweekl y and , upo n7 l bweigh t gain , ar e sen t ou t fo r regeneration . (Mho does this regeneration and how is it

done?) Th e res t o f th e housings , whic hhav e bee ninplac e fo r a longe r time , ar e situate ddirectl y

above th e several ^ 20,00 0 cfm plan t exhaus t fans , an deac h contain s (48 ) 2-inc h(som e contai n4-inch ) dee pfilte r panels . Thes e panel s ar e dispose do f afte r use , an dcos t abou t $5 0 pe r poundo f VO C controlled . Th e company

emphasize dtha t th e system i s stil l unde r development , an dtha t the y woul dno t configur e th e system i nthi s wa y

i f the y wer e t o begi nagai n (plan s ar e t o chang e ou t th e throwawa y filter s an

dcollec t fro

m specifi c poin t sourc e operations) . Testin g onth e carbo nfilte r s o fa r indicate s tha t inle t VO C concentration s shoul db e inth e 2 0 t o 30 0 pp

m rang e fo r goo dcontro l efficiency . Eac hfilte r system (4 8 cartridges ) i s designe dt o handl e 50 0 t o 1,00 0 cfm . Estimate dcost s ar e $ 9 pe r poundo f VO C controlle d(no t includin g capita l an

dlabo r costs) . Glasti c estimate s tha t annua l filte r cost s coul db e o nth e orde r o f $250,000 . E . Actio nItem s Ms . Boye r o f Glasti c agree dt o sen dcopie s o f severa l MSDS s t o PES , an d t o mak e availabl e th e consultan t report s tha t provide dth e basi s fo r Glastic' s environmenta l program . Ms . Stru m o f EPA agree dt o sendinformatio nonth e Polya dadsorptio nsyste m t o Glastic . Attache dt o thi s repor t ar e th e sheet s Glasti c provide ddurin g th e visit . Content s ar e a s follows : Subjec t Pag e 1 . Compan

y fact s 1 2 . Clevelan d plan tlayou t2 3 . Environmenta

l polic y 3 4 . Consultan treport s 4- 5 5 . Progra

m objective s 6P. 8

. % 

# s / / 6 . Reductio nstrategie s 7

7 . Solven t replacemen t 8- 9 8 . Reductio no f fugitive s 10-1 5 9 . Carbo nfiltratio n16-2 3 Glasti c als o provide da repor t (attached ) summarizing styren e measurement s take na t a

ninjectio nmolding pres s a t th e Jefferso nfacilit y inMarc h1993 . Thi s tes t involve dus e o f a temporary tota l enclosur e t o captur e emissions . Th e tes t showe da styren e emissio nrat e o f 1. 1 percen t o f th e availabl e styren e enterin g th e molding process .P. 9 

### GLASTI C CORPORATIO N OWNERSHI P Kob e Stee l US

A85 % ItochuCo
. 15 % FACILITIE S Sout h Euclid , Ohi o Headquarter s an d Mai n Plant - 128,00 0 sq . f t Jefferson , Ohi o Injectio n Molding - 90,00 0 sq . f t ANNUA L SALE S Sout h Eucli d $35,000,00 0 Jefferso n $15,000,00 0 PRODUCT S AN D PROCESSE S Laminates - 3'x6' , 4'x8 ' Sheets for :

Electrica l Insulatio n Therma l Insulatio n Corrosio n Resistance Structura l Application s Compressio n an d Injectio n Molde d Part s Electrica l Insulators , Circui t Breaker s Moto rComponent s Houseware s Components - Disposers , Sewin g Machines , Vacs , Fuse s et < Printe rFrame s Pultrude d Shape s

Electrica l Insulation , Fuse Tube s Custo m Shape s fo rTrucks , Sportin g Good s etc . Fibe rOpti cRo d Bul d Moldin g Compound s RA WMATERIAL S Fiberglass , Minera l Fillers , Polyeste rResins , Epox yResins , Phenolic , Monomer s (Styrene , Viny l Toluene , an d Methylmethacylate. )



## 'tMOREHOU S BMC CAR T TOT E TAN KAN O SHA

R T-M O OXANIN C BM C RE9 N »M C MONOMER OIANE R MIXER S MIXER ARE

A EXTRUOER

S .TAW S , STOHAOI ! .TANK S

*P.1 1

A SUBSIDIAR

YO f K06 € STE R 

# ENVIRONMENTA L POLIC Y A s a resul t o fit s plannin g an d developmen t activities , Glasti c Corporatio n expect s t o gro wan d prospe r withi n th e communit y o fSout h Euclid . Th e managemen t an d owner s o fGlasti c full y recogniz e tha t thi s growt h require s th e Compan y t o be , an d t o be viewe d as , a goo d communit y citizen . Th e healt h an d wel l bein g o fou r neighbor s an d worker s ar e amon g ou r highes t priorities . Glastic' s Polic y i s to :

•Conduc t operation s i n compliance wit h al l local , state , an d federa l environmenta l regulation s

•B e particularl y awar e o fit s locatio n i n a residentia l community , an d t o wor k t o develo p an d maintai n a n ope n dialogu e wit h th e communit y resident s an d thei r electe d official s

•Reduc e plan t emission s t o mee t th e 199 7 requirement s o fth e CLEAN AI R AC TAMENDMENTS b y th e en d o f1993 .
•Eliminat e nuisanc e odor s

•Develo p an d maintai n th e bes t availabl e contro l technolog y fo r al l it s processe s

•Continu e nois e abatemen t program s

•Compl y wit h local , state , an d federa l stor m an d wast e wate r regulation s Glasti c wil l commi t th e financia l an d huma n resource s necessar y t o successfull y implemen t thi s polic y an d expect s t o b e viewe d i n th e futur e a s a n integra l an d responsibl e par t o fth e Sout h Euclid/Eucli d Communit y

p . i loP.1 2

GLASTI C COR P CONSULTAN TREPORT S COMPOSIT E SERVICE S CORPORATIO N

1 . HEALT H RIS KASSESSMEN T- CLEVELAN D 2 . SOLVEN T8 5 3 . MIXIN G ARE AREPOR T 4 . FIBE R OPTIC S LIN E STUD Y 5 . HEALT H RIS KASSESSMEN T- JEFFERSO N

\\ 

# VP.1 3

CONSULTAN TREPOR TSUMMARIE S 199 1 ESTIMATE D EMISSIONS :

MONOMER S STYREN E VINY L TOLUEN E MMA SOLVEN T(SS~) 1,1,1-TRICLOROETHAN E METHYLEN E CHLORID E TOLUEN E TOTA L CLEVELAN D 5900 0 1200 0 4200 0

470 0 3040 0 6100 0 20910 0 JEFFERSO N 4494 0 1640 0

327 0 338 0 169 0 6968 0
199 1 HEALT H RIS KASSESSMEN TBASE D O N ABOV E (ISCST 2 PROGRAM) : POSSIBL E CARCINOGENS - Methlyen e Chlorid e i s five time s less tha n OEPA' s cance rris k threshol d leve l of 1 pe r100,000 . Avg . annua l exposure i s 86 0 time s les s thanth e amoun t t o caus e on e additiona l cance rcase . NONCANCE R HEALT H EFFECTS - Severa l order s of magnitud e belowOEP Athreshol d limits .

consum s 

### \oOVERAL L SUMMAR Y- EMISSIO N REDUCTIO N PROGRA M OBJECTIVE S LATE'9 1 SOL

V 85 CLOSE D FILTER S TARGE T RATE SYSTEM S JLBS/YR ) PLAN : STORAG E TANKS MIXIN G ARE A LAMINATE/C&

T PULTRUSIO N FO R TOT E ROO M EPA/DRU M AREAS 192 0 9702 0 2579 0 5285 0 138 0 2023 0 991 0 20910 0 0

-4505 0 -1922 0 -1922 0 0 0 -961 0 -9310 0 0

-4602 0 -200 0 -1500 0 -50 0 -1223 0 -20 0 -7595 0 0

-400 0 -300 0 -1500 0 -50 0 -600 0 0 -2850 0 192 0

195 0 157 0 363 0

. 38 0 200 0 10 0 1155 0 ACTUAL : EMISSIO N REDUCTIO N PROGRA M STATU S - JUL Y199 3

STORAG E TANKS MIXIN G ARE A LAMINATE/C&

T PULTRUSIO N FO R TOT E ROO M EPA/DRU M AREA

S LATE'9 1 RATE 192 0 9702 0 2579 0 5285 0 1380 2023 0 991 0 20910 0 SOL

V 8 5 0 -4505 0 -1922 0 -1922 0 0 0 -961 0 -9310 0 CLOSE D

SYSTEM S 0 -3236 0 0 -150 0 -50 0 -1223 0 -20 0 -4679 0 FILTERS

0 -400 0 -30 0 -1.50 0 -20 0 -600 0 0 -1200 0 NEEDE D

TARGE T 0 1366 0 470 0 2700 0 30 0 0 0 4566 0


# nP.1 5

REDUCTIO N STRATEGIE S 1 ) REPLAC E SOLVENT8 5 (-93,00 0 lb s annually )

- Solven t 6 5

- Envirosol v200 0 2 ) REDUC E FUGITIVE S (-76,00 0 lb s annually )

- Reduc e Cleanin g Operation s

' - Clos e U p Resin/Monome rTransfer s

- Reduc e Resin/Monome rEvaporatio n 3 ) CARBO N FILTRATIO N (-29,00 0 lb s annually )

- Roo f To p Filte rHouses/Refillabl e Filter s

- Attentio n T b Detail s I s Importan t 4 ) TEMP . TOTAL ENCLOSUR E TESTING - JEFFERSO N INJECTIO N PRESS
.

- 1.1 % Proces s Los s of Availabl e Styren e

14 -P.1 6



### SOLVEN TREPLACEMEN T



## 15P.1 7

SOLVEN TCOMPARISON S ITE M EVAPORATIO N RAT E EFFECTIVENES S COST ODO R HA P COMPONENT S
MF G COMMENTS SOLVEN T8 5 VER YHIG H EXCELLEN T $6.67/GALLO N O K TOLUEN E 1.1. 1 TRICLOR . METHLEN E CHLORID E CHEMICA L SOLVT S CLEVELAN D PHASE D OU T SOLVEN T6 5 LO W O K S9.07/GALLO N PROBLE M NON E
CHEMICA L SOLVENTS CLEVELAN D USE D A TCLEVELAN D ENVIROSOL V 200 0 LO W GOO D $24/GALLO N O K NON E
ENVIROSOL

V JACKSONV1LL USE D A TJE F U P T O 4 0 REUSE S CLAIME D B YMANUFACTURE R

solvent s 

### If,P.1 8



### REDUCTIO N O F FUGITIVE S -CONTAINMENT 1- 7P.1 9



### OLASTIC EVAPORATION TES T WEIGH T LOSS VBRSU S TIM

B EFFECT O

F AIRFLO

W CONDITIO

N STYREN B RBSI N LIQUI D 2 5


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## ttfcgC 1 3
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I %P.2 0



### 4 5 40 3 5 3 0 2 5 20 15 1 0 5 0 GLASTIC EVAPORATIO N TES T

WEIGH T LOS S VERSU S TEM

B BFFBCT OF TEMPERATUR E STYRENE BUL KMOLDIN G COMPOUND ^20'degC - - 3 5 de g C •50 de g C Hoo d Airflo w

TIME

(min )

14P.2 1



### BEFOR E

(2;-.N£S-« * i- p I' O



### MIXIN G ARE A"VOC " ANALYSI S

(«;-L:NE S • NE WSYSTE

M CLOSE D rEEO

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S T O REOUCE CUANIN C -UOREXLfS t CAR T O.0S C CIEAMN G -COMPUTE * CONTROLLE D VENT.NG . '5)->»>CE S -CYUCC = CONTROLLE D OVE R CART S
UPOATE : 12/I0/9 J C FORMAT ' WEXA ?

•7, oP.2 2



# SHA R MIXE R ENVIRONMENTA L CONTRO L SYSTE M FILTE R HOUS E 10'xlO * 4 8 FILTER S 9 6 FT 2 FILTE R ARE A 144 0 LBS . CARBO N 

# <Q ? BLOWE R
VAPO R EXHAUS TDUCT < & - ^



# V BLOWE R

35 0 CFM , 1 1/2"S.P .

MIXE R PL C CONTROLLE D

PNEUMATI C GAT E VAPO R EXHAUS TDUC T

/ PL C CONTROLLE D BLASTGAT E 55 0 GALLO N KETTL E PL C CONTROLLE D PNEUMATI C BAL L VALV E

QUIC K DISCONNECT S SEALE D LIDLIQUI D LEVE L PROB E T

O PL C 30 0 GALLO N TOT E 

# L T 

# D 

# . A PL C CONTRO L PANE L

•7.1P.2 3



### BEFOR E

RBERGLASS ROVIN G 5285 0 

# 1 ax o 

# ,1- , I OUST COLLECTO R

1922 0 

# ft

CU TOF F SA W SOLVEN T 

# LJ
PULTRUSIO N 300 0


### AFTE R 

# l
RLTE R SYSTE M 

# rL , I OUST COLLECTO R
RBERGLASS ROVIN G

RESI N

ORU M 1500 0

DRI P IPLATE J ENCLOSE D W / PLEXIGLASS , & CURTAIN S 

# ft CU TOF F SA W VEN T

•7. ?.P.2 4

CARBO N FILTRATIO N PREDICTION S FRO M ADSORPTIO N ISOTHERMS :

- O n th e orde ro

f 25 % adsorptio n capacity(lb s VOC/lb s C ) i s indicated .

- Highe rconcentration s favo rhighe rcapacity .

- Lowe rtemperature s favo rhighe rcapacity . DESIG N ISSUE S AN D APPROAC H

- Us e coconu t shel l charcoal .

- Maintai n hig h residence tim e ( > 1/ 8 second)
.

- Kee p VO C concentration s i n th e 2 0 t o 30 0 pp m range .

- Avoi d wetness .

- Charcoa l regeneratio n i s essentia l fo rcos t effectiveness
.

- Filte rhouse s containin g 48,1'x2'x6 " filters , 30lb s carbo n each . PLCs an d poin t source contro l assure s hig h VO C concentration . Blower s engineere d t o handl e Tf pressure dro p at correct CFM
. RESULT S S O FAR :

- Lab testin g showe d anticipate d adsorptio n an d adsorptio n capacity .

- Subjective testin g o n 6 " roof to p unit s indicat e odors t o b e significantl yreduced .

- Evaluatio n of recentl yinstalle d filte rhouse s show s weigh t gains . Chemica l analysi s o

f medi a shows bot h VO C an d Wate rVapor .

- Lif e cycl e adsorptio n costs estimate d t o b e o n th e orde rof $ 9 pe rI b VOC
. (assumin g 7 lb s VO

C pe rfilte ran d 3 regeneratio n cycles ) GOIN G FORWARD :

- Measurements o

f mi xarea systems ' exhaus t VO C inpu t t o filte rhouse s an d accurat e comparisio n t o filte rhous e weigh t gains .

- Evaluate humidit

yaffects
.

- Confir m abilityt o regenerate carbon .

- Dee p be d system s vs filte rhouse s ma yb e considered .

- Internationa l Filter

s In cin-sit u carbo n regeneratio n syste m wil l b e studied . Use s microwave s t o remov e VO C fro m carbon . VO C mayb e reusable .

- O n goin g testin g of al l systems .

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E T O FUTUR E INSTALLATIO N O F CURB S O N LATE R UNITS . 2)-R00 F O F HOUSIN G TO P T O B E APPROXIMATEL YU'-O " X13'-0 " 1 8 GALVANIZE D MANDINi ; MA M 1101.11 . l> ll ) MD l MOUMNi ; OV

t KlAI * 'O R WA U KDIVERSION S T O B F 18'* O N I AC H SIDE . ROO F T O HAV E A J " PITC H I N 10 " 1 0 ALLO W FO R DRAINAG E 3)-FiLTE R RACK

S T O HAV E 4 8 LOCATION S T O RECEIV E V

X2 " FILTER S WIT H PROVISION S TO R 1 6 ADDITIONA L LOCATION S WITHOU TMAJO R MODIFICATIONS . UPRIGH TCHANNELS T O B E 1 8 GAUG E WIT H 2 4 GAUG E BLAN KOFFSET S tc IM.'J O HORIZONTA L flLIE R HOLDER S POPRIVETE U TOGETHER . TW O FRAM E UNIT S T

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f (Ii4 ) lllllK' i 1*

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•2X 4 WOO D FRAM E
ROO F UN F



### Corporatio n p » MtMTt M HMMtftl U I'LAN I IILU M HACKHOUOIN U

PLAN TROO F 02 6

r o o oP.2 9



# Sande rFilte rWeigh t Gai n

1 1 1

4 2 3 TME(DAYS ) 3 6 4 3

-7 . aP.3 0



# Morehouse/Sha rFilte rWeigh t Gai n

8 11 1

7 TIME(DAYS) 3 0 37



### -Z< ?P.3 1

WHA TWE'V E GOT : 

### SUMMAR Y
GREATL YREDUCE D FENC E LIN E ODOR S ASOUN D BASI S FO R ATTAININ G "NO N MAJO R SOURCE " STATU S AGOO D RELATIONSHI P WIT H TH E CITYAN D LOCA L CITIZENS
. WHA TWE'V E PAID : PROJ
. #
585 6

586 5
588 4

588 7 591 0 PROJEC T

AI R TESTIN G MIXE R REPORT FO R & SOL V 8 5 RPT S HEALT H RISKS (2 ) PURCHASE S (000's ) 15 0

1 8 FILTE R SYSTEM S 15 6 PULTRUSIO N SHIELD S WEATHE R STATIO N MIX/TOT E ROOM S INC L 6 " FILTER S PL C CONTRO L FILLE R FEEDE R CLEANIN G RED' N STOR M WATE R BM P ST
. WATE R IMPT S 235

5 6 LABO R

(OOO'S ) 5

3
7 0

0 0 589 8 

## s "• a P C & SOFTWAR E 4 0 TOTAL S 55 6 7 8 634 ESTIMATE D ONGOIN G FILTE R COST S AR E O N TH E ORDE R O F $250,00 0 ANNUALLY . OU R THOUGHTS : CONTAINMEN TI S TH E KE YT O ASUCCESSFU L ENVIRONMENTA L PROGRAM. INVESTMENT S I N COVERS
. LIDS
. HOSES
. PUMPS
. VALVES
. CURTAINS
. REDUCE D WE T AREA . PROCEDURES
. TRAINING
. DISCIPLIN E AN D TH E UK E HAV E TH E BES TPAYOFFS
. CARBO N FILTRATION , WHER E UNAVOIDABL E FUGITIVE S OCCUR , SEEM S VIABL E FO R PLANT S SUC H A S GLASTIC
. POIN TSOURC E COLLECTION
. CONCENTRATION S O F 1 0 T O 30 0 PPM . AN D EXHAUS TRATE S O F LES S THA N 100 0 CF M PROMOT E EFFICIENC Y OPERATIN G COST S AR E CURRENTLYESTIMATE D A T$9/L B VOC
. 

## ZoP.3 2

MOLDIN GPRES S EMISSION S TESTIN G GLASTI C CORPORATIO

N JEFFERSO

N PLAN T

B y Jane t Boye r Environmenta l Enginee r Apri l 23 , 199 3



# 3 /P.3 3

O n Marc h 19 , 1993 , styren e emission s wer e measure d fro mPres s #2 9 a t th e Glasti c Corporation' s Jefferso n facility . Th e purpos e o f th e testin g wa s t o obtai n concret e dat a fo r emission s fro mth e injectio n moldin g operatio n rathe r tha n assumin g tha t 1.5-2.0 % o f th e availabl e styren e i s emitted , pe r emissio n factor s foun d i n Compilatio n o f Ai r Pollutan t Emissio n Factors . U S EPA , AP-42 . Accurat e emissio n rate s ar e necessaryfo r permi t applications , calculatin g carbo n filte r requirements , an d othe r reporting requirements . Th e testin g wa s don e followin g th e protoco l outline d i n EPA-450/4
- 91-02 0 Th e Measuremen t Solution : Using a Temporar yTota l Enclosur e fo r Captur e Efficienc yTesting . Atemporarytota l enclosur e (TTE ) i s a n enclosur e installe d specificall yfo r emission s testing . I t completel ysurround s th e affecte d facilit ysuc h tha t al l VO C emission s ar e capture d an d discharge d through a duc t tha t allow s fo r th e accurat e measuremen t o f VO C rates . I n othe r words , a TT E i s a temporaril yinstalle d enclosur e tha t ensure s tha t n o VO C escape s withou t bein g measured . Minimumcriteri a hav e bee n develope d fo r a n enclosur e t o b e considere d a TT E fo r testin g purposes . Thes e criteri a ar e intende d t o ensur e tha t al l VOC' s ar e capture d fo r measuremen t an d t o minimiz e disruptio n o f th e norma l condition s i n th e absenc e o f th e enclosure . ATT E wa s constructe d t o mee t th e followin g minimu m criteria : 1 . AnyNatura l Draf t Openin g (NDO ) shal l b e a t leas t 4 equivalen t diameter s fromeac h VOC-emittin g point . Tha t is , ou r inle t wa s a n adequat e distanc e fromth e press . 2 . An yexhaus t poin t fromth e enclosur e shal l b e a t leas t 4 equivalen t duc t o r hoo d diameter s fro meac h NDO . 3 . Th e tota l are a o f al l NDO' s shal l no t excee d 5 percen t o f th e enclosure' s walls , floor , an d ceiling . 4 . The . averag e fac e velocit y(FV ) o f ai r throug h al l NDO' s shal l b e a t leas t 20 0 ft/min . Th e directio n o f ai r through al l NDO' s shal l b e int o th e enclosure . 5 . Al l acces s door s an d window s whos e area s ar e no t include d a s NDO' s an

d ar e no t include d i n th e calculatio n o f FV shal l b e close d durin g routin e operatio n o f th e process . ATT E wa s constructe d aroun d pres s #2 9 . On e o f th e reason s tha t thi s pres s wa s chose n wa s becaus e ther e wer e alread ytw o existin g walls . Tw o additiona l wall s wer e buil t fro mclea r plasti c fil mo n a woo d frame . A n existin g doo r wa s use d a s a Natura l Draf t Openin g (NDO ) t o allo wplent yo f ai r fo r th e worker s insid e th e enclosure . Th e doo r wa s partiall yblocke d t o achiev e a minimu m fac e velocit y o f 20 0 ft/min . A n exhaus t fa n wa s installe d i n a n existin g openin g


## 3 ZP.3 4

i n th e wal l behind th e press . Acardboar d duc t wa s mad e fo r th e ai r exiting th e enclosure . Th e flo wvelocit ymeasurement s an d th e exi t sample s wer e take n i n th e duct . Duplicat e sample s wer e take n a t thre e differen t location s durin g tw o separat e samplin g periods . Sample s take n a t th e ND O "inlet " provid e a background concentration . Th e sample s take n a t th e exhaus t duc t "outlet " represen t th e concentratio n o f styren e from pres s #2 9 plu s background . Sample s wer e als o take n a t th e dus t collecto r t o verif yestimate d emissions . Tw o o f th e sample s o n th e report , Inlet-2(A ) an d Outlet-2(A) , appea r t o possibl yb e swapped . Fo r thi s reason , thes e number s wer e omitte d fro mth e calculatio n o f averages . Eve n i f th e result s wer e correct , droppin g thes e number s wil l onl ymak e ou r calculation s mor e conservative . Th e averag e inlet , o r background , concentratio n wa s 3.5 2 ppm . Th e averag e concentratio n a t th e outlet , o r exhaust , wa s 5.1 6 ppm . Thi s indicate s tha t ther e i s a ne t gai n o f 1.6 4 pp mstyren e from th e emission s fro

mpres s #29 . Th e 1.6 4 pp mconcentratio n o f styren e convert s t o .1 3 lb/hr usin g th e know n exhaus t rat e o f 70 6 ft/min . Th e BM C wa s use d a t a rat e o f 17 6 pound s pe r hou r durin g th e test . Th e availabl e styren e wa s 6.85 % o f th e BM C assumin g tha t th e resi n wa s 10 % styrene . Thi s mean s tha t 1.1 % (0.01 1 lb/lb ) o f th e availabl e styren e wa s i n th e emissions , an d tha t 0.08 % (0.000 8 lb/lb ) o f th e BMC result s i n styren e emissions . Se e attache d calculations . Th e result s o f thi s tes t sho wtha t fo r th e injectio n moldin g operation s a t th e Jefferso n facilit yo f Glasti c hav e a n emissio n rat e o f abou t 1.1 % o f availabl e styren e whic h i s significantl y lowe r tha n th e 1.5-2.0 % assume d b yU S EPAAP-42 .



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# 3 5P.3 7

.ANALYTICAL RESULT S

FO R Glasti c Corporatio n 432 1 Glenridg e Roa d Cleveland , O H 4412 1
Nam e o f Collector : Kath yRoyl e
ASSIGNE D ASA P I D # 930319-23- A 930319-23- B 930319-23- C 930319-23- D 930319-23- E 930319-23- F 930319-23- G 930319-23- H 930319-23- 1 930319-23- J 930319-23- K 930319-23- L CUSTOME R I D Inlet-l(A ) Inlet-l(B ) Outlet-l(A ) Outlet-l(B ) Dus t Collector
1(A ) Dus t Collector
1(B ) Inlet-2(A ) Inlet-2(B ) Outlet-2(A ) Outlet02(B ) Dus t Collector
2(A ) Dus t Collector
2(B ) Ai r

Ai r Ai r Ai r Ai r Ai r Ai r Ai r Ai r Ai r Ai r Ai r SAMPL E MATRI X Sorben t Sorben t Sorben t Sorben t Sorben t Sorben t Sorben t Sorben t Sorben t Sorben t Sorben t Sorben t Tub e

Tub e Tub e Tub e Tub e Tub e Tub e Tub e Tub e Tub e Tub e Tub e SITE , DAT E 6 TIM E O F COLLECTIO N Pres s #2 9 Jefferso n Plan t 3/19/9 3 9:4 5 a m

- 1:1 0 p m

Laborator

y Information : Sample s wer e refrigerate d upo n receip t

an d analyze d a s received .
Released by : Husei n Sitabkha n PhD . La b Directo r Pag e 1 o f 2 ASA P TECHNICA L SERVICES , IN C 1970 1 SOUT H MILE S ROAD
. WARRENSVILL E HEIGHTS
. OHI O 4412 8

TEL : (216) 663-080 8 • (800 ) 969-080 8

FAX : (216) 663-065 6 

## 3 #P.3 8

Dat e : 4/6/9 3 Analysi s Fo r :Glasti c Corporatio n Parameter : Styren e Dat e Receive d :3/19/93 Dat e Analyze d :3/31/93

ASA P #/CUSTOME R I D D L 930319-23- A 930319-23- B 930319-23- C 930319-23- D 930319-23- E 930319-23- F 930319-23- G 930319-23- H 930319-23- 1 930319-23- J 930319-23- K 930319-23- L Inlet-l(A )

Inlet-l(B ) Outlet-l(A ) Outlet-l(B ) Dus t Collector
Dus t Collecto r - Inlet-2(A ) Inlet-2(B ) Outlet-2(A ) Outlet02(B ) Dus t Collector
Dus t Collecto r -

-1(A ) -1(B )
-2(A ) -2(B ) 0.0 2

0.0 2 0.0 2 0.0 2 0.0 2 0.0 2 0.0 2 0.0 2 0.0 2 0.0 2 0.0 2 0.0 2 

### pp m pp m pp m pp m pp m pp m pp m pp m pp m pp m pp m pp m RESULT S 3 7 6 9 0 9 0 5 4 4 1 8 27
- ,5 1 81 - 5.3 5 5.3 4 4.2 8

Metho dBlan k 0.0 2 /x g BD L

D L = Detectio n Limi t BD L = Belo wDetectio n Limi t
Metho d : NIOS H 150 1
Pag e 2 o f 2



### ASA P TECHNICA L SERVICES , IN C 1970 1 SOUT H MILE S ROAD . WARRENSVILL E HEIGHTS . OHI O 4412 8

TEL : (216 ) 663-080 8 • (800 ) 969-080 8 FAX : (216)663-065 6



### ^ 7. - J CHAIN-OF-CUSTOD Y

ASA P TECHNICA L SERVICES , INC . 1970 1 SOUT H MILE S ROAD , WARRENSVILL E HEIGHTS , OHI O 44128-425 7 TEL : (216 ) 663-0808 , (800 ) 969-080 8 FAX : (216 ) 663-065 6



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CIT Y PARAMETER-SE E R

72-h r On e Wee k Regula r TCL P
SIT E LOCATION : DAT E LOGGED : 

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L RESULT S DUE. T'< * -^ J SALESPERSON : WH. ASAP # CUSTOME R SAMPL E IDENTIFICATIO N No . o f ' DAT E TIM E SAMPL E CON COLLECTE D COLLECTE D MATRI XTAINER S 

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