# OAR Box 1781 Prepped by Ollie Stewart



### Document

Number: 

# 18)11-1- 9 Docket Number: 

# A-90-3 7

Printed 10/29/2008 10:46:18 AM Sheet 18 of 142 p. 1P. 2
I -.,!» . ./A-1o-3" 7



### POLLUTIO N REDUCTIO N I N AUTOMOTIV E PAINTIN G

NS R MODIFICATIO N BASELIN E EXAMPL E Aut o assembl yplan t "X" , a majo rsourc e o f volatil e organi c compoun d (VOC ) emission s locate d i n a moderat e ozon e nonattainmen t area , paint s th e vehicle s i t make s wit h a moder n "basecoat/clearcoat " process . I n thi s process , a bas e laye r o f colo ri s applied , followe d b y a thicke rlaye ro

f protectiv e clearcoa

t before baking
. Th e colore d basecoat s an d th e clearcoat contai n multipl e hydrocarbo n solvent s - al l VOC s that ca n reac

t i n ambien t ai rt o for m ozon e o n hot , sunn ydays
. Wit h reasonabl ygoo d economi c conditions , th e plan t make s 90 0 t o 100 0 car s pe rda yo n tw o productio n shifts
. A t maximu m overtim e i t ca n buil d 120 0 vehicle s pe rda

yfo r28 0 days pe ryea r- 336,00 0 vehicle s pe ryea ra t pea k capacity
. However , wit h a wea k econom yfo rsevera l years , stron g foreig n competitio n i n it s market segmen t an d a n agin g design , custome rdeman d fo rplan t "X " product s ha s bee n declining
. I n recen t year s th e plan t has worke d n o overtime , has reduce d dail youtpu t t o 80 0 vehicle s a t most , an d has ha d occasiona l "down " week

s durin g th e yea ran d extende d mode l changeove rperiod s i n th e summer . Annua l productio n ha s range d betwee n 5 0 an d 6 0 percen t o f pea k capacity , compare d t o 7 5 t o 8 5 percen t before th e Gul f War
. Fo rth e comin g mode l year , alon g wit h a mino r"facelift " i n bod ystyling , th e plan t want s t o pain t exterio rbod ysurface s wit h waterborn e basecoats
. O n th e average , fo rth e sam e quantit yo f film-formin g solids , the ycontai n onl yhal f a s muc h VO C a s th e presen t basecoats , an d ca n b e applie d i n thinne rcoats . Th e waterborn e basecoat s includ e severa l newl ypopula rcolor s t o enhance custome r appea l an d boost marke t demand
. N o chang e i s neede d o rpropose d t o th e clearcoat
. Th e VO C emissio n reductio n fro m thi s integrated , multi-coat proces s woul d averag e on e poun d pe rvehicle , o r16. 7 percent . Th e compan yrequest s th e stat e agenc y t o revis e its ai rpermi t t o allow th e physica l change s neede d i n th e curren t topcoat syste m t o us e waterborn e basecoats
. Th e agenc

ymus t determin e whethe rth e propose d change s woul d caus e baselin e emission s t o increas e b y4 0 o rmor

e ton s pe ryea ran d thu s trigge r Ne w Source Review (NSR)
. Calculation s mad e accordin g t o existin g NS R rule s an d policie s show th e followin g baselin e an d post-chang e annua l emissions : NS R BASELINE : solventborn e basecoat ; recen t averag e actua l emission s 6.0#VOC/vehicl e x185,00 0 avg . vehicles/yea rxton/2000 # = 55 5 ton/y rVO CP. 3

POST-CHANGE : waterborn e baseqqat;. maximu m potentia l emission s 5.0#VOC/vehicl e x336,00 0 max . vehicles/yea rxton/2000 # = 84 0 ton/y rVO C Th e "actual-to-potential " calculation-indicate s a 28 5 ton/y r"increase" , du e entirel yt o th e recen t "underutilization " of th e plant
. A t an yconsisten t operatin g level , th e chang e woul d clearl yreduce VO C emissions
. Fo rinstance , a t th e depresse d operatin g leve l required , i n th e baselin e calculation , th e chang e woul d save ove r9 0 ton/yr
. I n a stronge rmarket , th e chang e woul d save mor e emissions , likel yi n th e 120-15 0 ton/y rrange , an d a t pea k capacity , 168
. However , becaus e th e "actual-to-potential " differenc e exceed s th e 4 0 ton/y rNS R "trigger " fo r increase d VO C emissions , th e projec t i s subjec

t t o Lowest Achievabl e Emissio n Rat e (LAER ) contro l technolog y an d emissio n offse t requirements
. T o meet thes e requirements , th e plan t woul d have t o retrofi t th e kin d o f VO C control s expecte d o n a totall yne w topcoat syste m an d eithe rbu yemissio n credit s (i f available ) o rreduc e emission s fro m othe rsource s t o creat e th e offsets
. T o avoi d thes e requirements , future productio n coul d b e restricte d b ypermi t conditio n s o that th e "increase " woul d neve requa l o rexcee d 4 0 ton/yr
. Thi s mean s limitin g annua l productio n t o 238,00 0 cars , les s tha n typica l outpu t before th e Gul f War , an d a sacrific e o

f 3 0 percen t o

f presen t capacity , nearl y100,00 0 vehicle s pe ryear . Plan t 'X ' coul d not respon d t o stron g market demand , an d it s competitors woul d get th e additiona l business
. Th e compan ycannot accep t this
. Alternatively , i f topcoat emission s predicte d a t pea k capacit ycoul d b e reduce d b

ya t least 24 5 ton/yr , the y woul d neve rexcee d th e NS R trigger
. However , thes e emission s ar e diffuse d i n a larg e volume s o f exhaust air
. T o duc

t enoug h of thi s ai rt o a carbo n adsorbe ro rincinerato rt o reduce 24 5 ton/y rwoul d require a multi-millio n increas e i n capita l investmen t an d ad d t o annua l operatin g costs . Thi s raise s th e tota l projec t cost t o a poin t that make s i t uneconomic ; managemen t doe s not approve it
. I t wil l no t b e considere d again , a t least unti l a majo rmode l chang e a

t plan t "X" , whic h i s no

t planne d fo rsevera l more years . Th e plan t withdraws its permi t application , continue s t o us e solventbom e basecoats , an d wait s fo ra ne w advertisin g campaig n an d pricin g strateg yt o boost marke t deman d an d production
. Emission s wil l ris e proportionall yove rrecen t annua l levels
. Th e opportunit yt o achieve substantia l day-to-dayreduction s vi a thi s projec t i s lost
. dma.10059 3 00466 5