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# 79 ) ll-E-3 9 Docket Number: 

# A-94-5 2

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### A-94-5 2

• uaijJp<^ii*Sf;s;>2 * ; > '-ii ; •/ . 

## W D ^ 5199 7 \§S>- EP A AI R DOCKE T MEMORANDU M TO : Madelein e Stru m U.S . EPA/ESD/CCP G FROM : Gre g LaFla man d Ke n Meardo n Pacifi c Environmenta

l Services , Inc . (PES ) DATE : Marc h 29 , 199 6

P:\N40 4 SUBJECT : Minute s o f

Marc h 12 , 199 6 Meetin g Betwee n EP A an d Representative s o f th e SMC Environmenta

l Subcommitte e o

f th e SPI/Composite s Institute LOCATION : Th e meetin g wa s hel d a t th e U.S . EPA/Mutua

l Buildin g i n Durham , NC , 11t h floor conferenc e room , 9:0 0 a

m- 12:0 0 noo n ATTENDEES : Mr . Perry Bennet

t Mr . Ji mBerr

y Mr . Dal e Bertelso n Mr . Ji mBradle

y Mr . Josep h Cec h Mr . Pau l Harper Mr . Rober

t Hoffma n Mr . Gre g LaFla

m Mr . Ke n Meardo n Mr . Kevi n O'Da

y Mr . Erwi n Raphael Mr . Dav e Salma

n Mr . Joh n Schweitze

r Ms . Madelein e Strum MF G EPA/ES D Cambridg e (formerly GenCorp ) Eagle-Picher

Industrie s Menash aCorp . - MP D Eagle-Picher

Industrie s Interplasti c PE S PE S Goodyea r Navista r EPA/ES D SPI/Composite s Institut

e EPA/ES D (216 ) 994-520 7 (919 ) 541-560 5 (317 ) 392-808 1 (219 ) 627-212 7 (414 ) 262-524 0 (513 ) 629-241 8 (612 ) 481-686 3 (919 ) 941-033 3 (919 ) 941-033 3 (614 ) 286-793 4 (614 ) 870-509 0 (919 ) 541-085 9 (313 ) 668-470 3 (919 ) 541-238 3 PURPOS E Th e meetin g wa s requeste d b y th e SMC Environmenta l Subcommitte e to discus s th e preliminar y MAC T determination s fo r th e manufacturin g (compounding ) o f sheet moldin g compoun d (SMC ) and bulk molding compound (BMC ) and fo r compressio n moldin g (includin g injectio n moldin g an d RTM ) ma

t wer e develope d by EP

A an d b y th e Subcom

mittee . Th e EP

A wa s als o seekin

g to obtai n dat aand informatio n o n th e material s and processe s i n thes e industr

y subcategories .P. 3

Madelein e Stru m Marc h 29 , 199 6 Pag e 2 i DISCUSSION 1 Afte r introduction s wer e made , Mr . Schweitze r state d tw o goal s fo r

th e meeting : 1 ) t o hea r EPA' s curren t

thinkin g o n MAC T fo

r th e SMC/BM C compoundin g and compressio n moldin g processes , and 2 ) to mak e assignment s fo

r th e grou p to gathe r additiona l dat aand information . Ms . Strumbega

n b y statin g tha

t EPA' s compressio n moldin g subcategor y i s intende d to include no t

jus t compressio n molding wit

h SMC , bu t

al l other material s use d i n compressio n molding . Th e industr y grou p clarifie d tha

t th e "we t mix " proces s make s us e o f acompoun d containin g th e sam e ingredient s a s SM

C excep t fo r th e glas s fibers , whic h are use d i n th e for

mo f a"preform " to which th e we t mi x i s added in th e mold . Th e industr

y als o clarifie d th e differenc e between we t mi x moldin g and resi n transfe r moldin g (RTM) . I n we

t mi x molding , th e we

t past e i s applie d firs t

and the n th e mol d i s closed . I n RTM , th e mol d i s first close d an d the n th e wet

paste i s injected . Ms . Stru m explaine d that , i n EPA' s analysis , th e BM C compounding subcategor y include s only th e fina l compoundin g ste

p itself (i n whic h th e glas s an

d fille r ar e added) , an

d no t th e preliminar y paste mixin g proces s (i f performed) . Thi s latter

proces s i s considere d t o b e simila r t o th e resi n mixin g tha

t i s performe d withi n man

y o f th e other subcategorie s o

f thi s industry . Th e EP

A state d tha

t i t i s presentl y contemplatin g tha t resi n mixin g fromal l subcategorie s b e treate d together , an d b e subject to certai n equipmen

t standard s and wor

k practices . J MAC T Floor s Ms . Strumbega

n adiscussio n o

f EPA' s preliminar

y MAC T floor

determination s fo r resi n mixin g (whic h include s paste mixin g fo r SM C an d BM C i n additio n to other processes) , SNI

C compounding , BM C compounding , and compressio n moldin g (SMC , BMC , and we

t mix) . She stresse d tha

t MAC T floors need no t

b e i n th e for

mo f numerica l emissio n limitations . General/resi n mixin g Th e MAC T floo

r consist s o

f wor k practice s a s currentl y performe d by th e averag e o f th e to p performin g 1 2 percen t o f facilities . Container s (suc h a s buckets , totes , barrels , etc. ) wit h volatilizin g HA

P material s would need to remai n covere d excep t when material wa s bein g added t o o r

remove d fromthe container . On e grou p membe r sai d that , a

t hi s company , nylo n fil

mi s place d over

th e resi n mi

x tan k a s i t i s move d aroun d th e plant . Thi s provisio n o

f keepin g al l HAP-containin g vessel s covere d woul d b e applie d to HAP

containin g vessel s in al l proces s subcategories .

_ ~ _P. 4

Madelein e Stru m Marc h 29 , 199 6 Pag e 3 ! A secon d par

t o f th e floo r consist s o

f mixer s tha

t ar e kep t covere d durin g th e mixin g proces s and a

t al l time s when i t

i s no t necessar y to open th e mixer

t o ad d o r remov e material . Ms . Strumsuggested tha t thi s provisio n migh

t tak e th e for mo f a"no visibl e gaps " requirement . Compan y representative s sai d tha

t thes e mixer s are typicall y i n th e for mo f larg e barrel-lik

e tanks , approximately 4 to 5 fee t i n diameter . They felt

tha t mino r gap s ar e typically necessar y an d shoul d b e allowed , suc

h a s fo r th e agitato r

shaf t passin g throug h th e cover . Grou p member s referre d to sealin g approache s tha t hav e bee n tried , suc h a s addin g ateflo n or rubbe r washer/grommet

to th e shaf

t t o hel p sea l th e opening . Th e group emphasize d tha t material s need t o b e added durin g th e mixin g process ; th e agitato r

an d li d ar e typically raise d to allo w fo r th e additio n o

f filler materia l ou t o f 50-6 0 l b bags . I t

wa s pointe d out

tha t dus t i s generate d durin g th e additio n o f filler and , a s aresult , baghouse s ar e typically i n plac e to remov e dus t awa y fro mth e operator . Othe r difference s note d b

y grou p member s include d th e us e o f stationar y tank s where th e agitato r i s move d fromone tan

k to anothe r (e.g. , by overhea

d hydrauli c lift) , versu s portabl e tank s tha t

ar e moved to fixed mixers . One grou p membe r note d tha t

th e mixer

i s typicall y "of

f center " to provide vorte x mixing . On e membe

r (Navistar ) suggeste d th e possibilit

y o f aminimumheadspac e standar d for mixers , possibl y combined wit h amaximu

mpercent open are arequirement . Mr . Berr y cite d th e refrigerate d headspac e requirement i n the solven

t meta l cleanin g standar

d a s a n example . Mr . Schweitze r state d tha t cover s hav e bee n shown t o hav e littl e impac t o n reducin g emission s (a s long a s there i s sufficien t headspac e i n th e mixer) . H e sai d tha t h e woul d provid e a

n engineerin g analysi s tha

t show s this , a s well a s description s an d cost s o f th e type s o

f mixer s in use . SM C compoundin g Ms . Stru mstate d tha

t EP A agree s wit

h th e SP I o n th e MAC T floo r

for SM C compoundin g a

t existin g facilities , whic h i s reflecte d b y wor k practice s consistin g o

f nylo n fil m(rathe r than polyethylene ) an

d folding th e edge s to sea

l the sheet . Group member s offere d t o obtai n pric e datafo r th e tw o type s o

f filmmaterial . Wit h regard t o ne

w sources , Ms . Stru

mstate d that , sinc e on e sourc e (Navistar) use s a n incinerato r

to contro l it s SM

C machine emissions , th e floo r fo r new source s consist s o f tha t leve l o f contro l (currently estimate d a t 9 0 percen t overal l contro l efficien

cy) . Industr

y claime d tha

t Navista r woul d not

b e usin g thi s contro l i

f no t for it s paintin g operations , j Navista

r indicate d tha

t du e to Stat

e lawtf;ha d to contro l th e SM C machin e o r reduc e it s emission s fromth e proces s unit . The y considere d buyin g ane

w machin e a s tha

t woul d divid e th e emission s betwee n tw o machine s (whic

h would meet

th e Ohi o require

ment) , bu t

made th e decisio n to ven

t th e SM C emission s t

o th e existin g incinerator . Mr . Schweitze r and severa

l grou p member s expresse d disagreemen t wit h EPA' s usin g a combinatio n painting/SM C facilit y to represent

MAC T fo

r al l ne w SM C operations . 

# 3P. 5

Madelein e Stru m Marc h 29 , 199 6 Pag e 4 Ms . Stru maske d i f th e group ha s an

y emission s dat afromSM C compounding . Mr . Schweitze r sai d tha t the y coul d provide suc

h data . H e pointe d out

tha t emission s are ver

y low (about

1 0 lb/hr) , and coul d b e reduce d to aroun d 5 lb/h r i f covere d docto r

boxe s and reduce d ai r

flow ar e implemented , based o n test s o f pultrusio n operations . Group member s als o emphasize d tha t incinerator s woul d creat

e their ow n emission s o

f C O an d nitroge n oxide s (NOJ . Ms . Strumstate d tha t th e newe r incinerator s produc e ver

y niinima l NO x emissions . Mr . Schweitze r sai d tha t the flow s fro

mSM C machine s woul d b e i n th e rang e o f 10 0 t o 40 0 cfm , wit

h astyren e concentratio n o f n o more tha

n 40 0 ppm , s o us e o

f acontro l devic e ma

y no t b e practical . Ms . Stru maske d th e group wh y close d doctor

boxe s and reduce d ai r

flow s shoul d not b e par t o f MAC T fo

r existin g facilities . Mr . Schweitze r responde d b

y notin g tha

t thes e technique s are base d o n apultrusio n stud y an d ther e are n o dat afo

r SM C compound

in g specifically . Grou

p member s indicate d tha

t ever y compan y represente d a

t th e meetin g i s usin g nylo n co-extrusio n a s it s SM C film. O n th e subjec t

o f usin g condenser s instea

d o f incinerator s for

controllin g emission s fromthi s application , grou p member s sai d tha t styren e polymerize s and i s difficul t to contro l in thi s typ e o

f contro l system . Mr . Schweitze r state d tha t cryogeni c condense

r temperature s woul d b e necessary , an d thes e canno t

b e feasibl y attaine d a

t typica l SM C facilities . Also , th e collecte d styren e woul d contai n impurities , makin g reus e o f th e recovere d styren e impracticable . A s aresult , thi s approach woul d "kill " th e economy , creatin g ahazardou s wast

e strea man d offering no opportunit

y for recyclin g o r

reuse . BM C compoundin g The MAC T floo

r for existin g source s consist s o f wor k practices , suc h a s covered / enclose d container s and BM C mixer s (compounders) . Fo r new sources , th e MAC T floor reflect s th e contro l achieve d b y th e incinerator bein g use d a

t on e facilit

y (Fibercast) , estimate d a

t th e meetin g a

t 4 9 percen

t overall syste

mcontro l efficiency . (A discussio n wit h thi s facilit

y afte r th e meetin g showe

d tha t th e overal l efficienc y fo

r thi s controlle d operatio n i s 9 5 percent. ) Mr . Schweitze r asked wh y acovere d compounde

r woul d nee d to b e furthe r controlle d wit

h acontro l device . H e suggeste d tha t aclose d BM

C compounde

r ma y b e equivalent

i n th e leve l o

f contro l to acompounde

r controlle d usin g acontro l device . H e state d tha

t th e contro l syste

ma t Fibercas t i s primaril y oriente d towar d controllin g th e centrifuga

l castin g operations , which i s ahig h emittin g process , and tha t 9 0 percen t o f th e operatio n i s centrifuga l casting an

d 1 0 percen

t i s BM C compounding . Further , i t wa s fel t tha t BM C mixer s have n o vents , but tha t emission s are release d throug h th e doo r

whe n i t i s opene d to pum

p past e int o th e mixer

an d th e ai r inside i s displaced . Th e EPA and PE S sai d the y would contac t

Fibercas t t o determin e how th e compoundin g operatio n i s controlle d (mixe r exhaust , roo mexhaust , etc.) . 

# 1P. 6

Madelein e Stru m Marc h 29 , 199 6 Pag e 5 Compression/injectio n molding/RT M Fo r compressio n molding , th e MAC T floor s wer e no t se t o n th e basi s o

f BMC / SMC/we t mi x styren e conten

t becaus e styren e wa s not

considere d t o b e th e drivin g forc e i n emission s fromth e moldin g process . Bot h existin g an

d ne w sourc e MAC T floor s consis t o f wor k practices , primaril y maintainin g cover s on al l HAP-containin g vessel s excep t whe n remova

l o f th e cove r i s necessar

y to ad d or remov e material . Anothe r potentia l measur e involve s th e numbe

r o f SM C o r BM C charge s tha

t ar e "pre-cut " o r

remove d fro

mth e seale d sourc e o

f bul k materia l prio r t o th e actua

l moldin g step , an d th e coverin g o

f suc h charge s unti l the

y ar e actuall y used . Th e EP A fel

t tha t som e limi t o n pre-cuttin g (an

d pre-strippin g o

f SMC ) ma y b e a n effectiv e measure . Grou p member s wer e i n agreemen t o n th e coverin g o

f charges , sayin g tha

t th e industr

y alread y cover s pre-cu t

charge s (usin g plasti c fil

mwit h th e edge s tucke d under ) a s aqualit y contro l step t o preven t

degradatio n o f

th e material . However , th e industr y wa s concerne d about limitin g th e numbe

r o f "pre-cuts, " statin g tha

t the y ofte n prefe r t o cu t acertai n numbe

r o f charge s ahead , s o tha

t productio n i s no t

interrupte d whe

n th e operato r

i s calle d t o perfor

m other tasks . Also , multipl e mol d cavitie s ma y b e use d fo

r simultaneou s molding , whic h necessitate s tha

t th e correc t

numbe r o f charge s b e prepare d in advanc e o f molding . Th e conclusio n reache d wa s tha t only thos e charge s "i n use " shoul d b e pre-cu t (whic h ma

y translate int o one molding cycle) . However , th e mos t reasonabl e statement

o f thi s requiremen t

stil l remain s to b e worke d out . Th e MAC T floor s fo

r injectio n moldin g processe s usin g thermoset s consis t o f th e sam e wor k practice s tha

t are applicabl e to compressio n molding . One compan y (Good

year ) perform s injectio n moldin g b y slittin g SM C int o certai n widths , whic h are rolle d int o bundle s tha t

are me n covere d wit

h nylon . Th e bundl e i s place d into ahopper , pushe d int o astuffer , an d the n int

o abarre l fro

mwhic h i t

i s hydraulically injecte d into amold . The charg e i s abou t

2 0 lb s an d 1 squar e foot , an d 5 inche s deep . Th e hopper i s alittl e bigger tha n th e charge . Anothe

r compan y (MFG) state d tha

t their proces s i s ver

y similar . A

t Goodyear , styren e (approximately 1 cupful ) i s manuall y poure d into th e hopper

to allo w th e tack y material to b e fe

d i n smoothly . Thi s compan y claime d tha

t styren e i s th e onl

y materia l tha t wil l wor k in dii s application . MF G di d not kno w i f styren e wa s use d fo

r thi s operatio n a t

it s facility . Cleaner s Th e group member s were aske d abou t th e cleaner s use d i n thei r

operations . Mos t o f th e participknt s have eliminate d th e us e o f methylene chlorid e (MCI) . One compan y (MFG ) state d that , du e t

o frequen t change s o

f it s pigmente d resin s use d to mak e smal l batches , th e line s hav

e to b e tor

n dow n frequentl

y s o tha t the y ca n b e cleane d thoroughly . Th e company state d tha

t th e onl y effective cleane

r fo r thi s jo b i s MCI . Therefore , whil e

^P. 7

Madelein e Stni m Marc h 29 , 199 6 Pag e 6 the y hav e dramaticall y reduce d their MC I use , the y hav e no t

bee n abl e to totall y eliminate it . Thi s membe

r pointe d ou t

tha t us e o f pigmente d resi n mixe s eliminate s th e nee d to paint th e parts , whic h save s agreat quantit y o f VOC/HAP emissions . Anothe r compan y (Eagle

Picher) , whic h ha s les s nee d fo r frequen t colo r changes , offered to shar

e it s non-MC l cleanin g method s wit

h th e other

companie s (possibl

y throug h avisi t

t o it s facility) . On e o

f th e company' s method s fo r cleanin g involve s ho t

wate r jets . Grou

p member s were generall y no t

willin g t o concede tha

t al l methylen e chlorid e coul d b e eliminate d a t al l facilities . Mr . Schweitzer offere d to surve y severa l companie s in thes e subcategorie s o n thei r us e o f cleaner s and repor

t back t o EP A by Marc h 31 , 1996 . Additiona l HA P cleaner s in us e include axylen e solutio n (mol d cleaning ) and th e styren e monome

r itself . Th e styren e use d fo

r cleanin g i s ofte

n reuse d in th e proces s by addin g i t t o th e resi n matrix . The discussio n the n focuse d o n the possibilit y o f allowin g th e us e o f th e monome

r fo r cleaning , s o long a s i t

wa s reuse d i n the process . However , Mr . Schweitze

r pointe d out

tha t overal l emission s ma

y no t b e reduce d by reusin g th e styren e cleaner . H e sai d that , afe w year s ago , aproposa

l to reduc e HAP cleane

r us e b y custo mmolder s wa s prepared , an d h e woul d tr y to locate and suppl

y thi s proposa

l t o EPA . Scra p Ms . Stru maske d whethe r th e industr

y keep s record s o

f scra p a s ametho d fo

r evaluatin g th e efficienc y o f th e process . Grou

p member s indicate d the

y trac k fou r categorie s o

f scrap : 1 ) raw materia

l (resin , paste , etc. ) neve

r formed into finishe d compound , 2 ) tri mscra

p (excess/edge s o

f charg e material) , 3 ) productio n rejects , an d 4 ) Q C (test) scra

p frommachin e setup , etc . Companie s attemp t t o minimiz e waste , and us e record s o f scra p t o correc t

operato r or productio n problems , bu t thes e record s are no t

use d to evaluat e proces s efficiency . Th

e companie s collec t

dail y records , an

d prepare monthl y summaries . Genera l The industr

y member s asked abou

t EPA' s curren t

schedule . Ms . Strumcite d Apri l 199 7 fo r proposal , an d Apri l 199 8 fo r promulgatio n o

f thi s NESHAP . A framewor k for the proposa

l i s iexpecte

d i n June 1996 . Ms . Stru mmentione d tha

t EP A i s considerin g performin g testin g a t either a pultrusio n or

a n SM C productio n process . Sinc e the SM C machine a t Navista r ha s a n existin g tota

l enclosure , thi s locatio n wa s under consideration . Th e Navista r compan y representativ e wa s no t

abl e to mak

e an y commitment , bu t

offere d to investigat

e th e feasibilit y o f suc h ates t takin g plac e a

t their facility .



## • £P. 8

Madelein e Strum Marc h 29 , 199 6 Pag e 7 Actio n Item s Mr . Schweitze

r (representin g th e group' s combine d efforts ) agree d to researc h an d obtai n information , an

d suppl y EP A wit h datato assis t

i n th e development

o f th e regulato

r y proposal . Thes e actio n item s are : 1 . Develo p asurve

y o f cleane r us e (especiall

y HA P cleaners ) by custo mmolders , send t o severa

l companie s o n Marc h 14 , and repor t th e result s t o EPA by Marc h 31 , 1996 . 2 . Locat

e and provide to EP

A th e previou s industr

y proposa l t o reduc e th e us e o f HAP-containin g cleaner s b y custo mmolders . 3 . Researc h an

d provid e to EPA description s o f resi n mixers . 4 . Provid e t o EP

A dat aindicatin g th e relativ e emission s fo r ope n an d covere d mixers . 5 . Obtai n pricin g informatio n for th e tw o type s (nylo n and polyethylene ) o f SM C film material . 6 . Provid e to EP

A dat ao n emissio n level s fromthe SM C compoundin g process . 7 . Provid e t o EP

A definition s o

f th e processe s discusse d a

t th e meetin g s o a s t o include al l o

f th e variations . I n addition , the representativ e fromNavista r offere d t o loo k into th e possibilit

y o f makin g th e company' s enclosed/controlle d SM C machin e availabl e fo

r emissio n testin g b

y EPA . Th e EP

A an d PE S sai d tha

t the y woul d investigat

e th e contro l syste mi n us e fo r th e BM C compoundin g operatio n a t th e Fibercas t

facilit y i n San d Spring s (Tulsa) , Oklahoma .



# 7