p. 1 

# OAR Box 

# 1384 Prepped by Charmelle Mathews



### Document

Number: 

# 100 ) ll-E-6 0 Docket Number: 

# A-94-5 2

Printed 7/2/2008 8:42:06

AM Sheet 100 of 264P. 2



# INTERNATIONA L 

# ® /W4-52 . ii-E-4 0 \ —' 

# PAPE R DECORATIV E PRODUCTS DIVISIO N Certified Mail»: P199189128 833 9 TELEGRAP H ROA D ODENTON , M D 21113-139 7 PHON E 41 0 51 9 513 4 FA X 41 0 51 9 211 2 anuary 31,1997 Ms. Linda Herring Group Leader Coatings and

Consumer

Products Group United States EPA Research Triangle Park, NC 27711 Re: Review of

CBI Documents 93185-C18-11C and 93185-C18-I1D (MACT

phone conversation on 8/9/96

and 7/12/96) Dear Ms. Herring: The enclosed

documents do not

contain any confidential

business information relative to our manufacturing process. The enclosed documents have been approved for release to the public files for Reinforced

Plastic Composites National Emission Standards for Hazardous Air Pollutants. If you have any questions or concerns please contact

me at 410-519-5134. Enclosures Sincerely, / Karen Dellario Environmental

Engineer

v . A l / " hi i - M '•P. 3 

# foi&rtir-'iti

NO N CONFIDENTIA

L CONTAC T REPOR T

From : Madelein e Stru m u s EPA , OAQPS/ESD , Coating s an d Consume r Product s Grou p Dat e o f Contact : Jul y12 , 199 6 Contacts : Charli e Stanie r an d Kare n Dellari o Company : Internationa l Paper , Decorativ e Product s Division , Odento n Facility , Odenton , Marylan d Telephon e Number : 41 0 51 9 209 4 (Mr . Stanier ) 513 4 (Ms . Dellario ) Mr . Stanie r an d Ms . Dellari o wer e contacte d t o determin e whethe r th e Fountainhea d continuou s lin e migh t fi t int o th e surfac e categor yo f pape r coating , rathe r tha n th e subcategor yo f continuou s casting/continuou s laminatio n sinc e th e resi n matri x i s dispense d o n a pape r web . Da n Brown and Madelein e Stru mo f th e Coating s an d Consume r Product s Grou p initiate d th e call . Madelein e ha d jus t visite d tw o continuou s laminatio n facilitie s earlie r tha t wee k an d calle d t o investigat e th e similaritie s an d difference s betwee n th e Fountainhea d continuou s lin e t o thes e continuou s laminatio n processes . Becaus e th e continuou s laminatio n processe s use d plasti c fil m t o hol d th e resi n (an d fibers ) t o mak e th e laminat e rathe r tha n paper , Madelein e though t tha t th e proces s migh t b e covere d unde r th e paper , fil man d foi l coatin g category . Da n Brown , als o i n EPA' s Coating s an d Consume r Product s Group , i s th e projec t lea d fo r thi s effort . Mr . Stanie r describe d th e continuou s castin g process . Th e proces s entail s th e dispensin g o f a catalyze d resi n matri x o n highl ycoate d paper . Th e facilit ybuy s th e 'coate d paper , an

d th e purpos e o f usin g coate d pape r i s fo r eas ypea l off . Th e pape r i s no t par t o f th e produat . Afte r th e pape r i s peeled , bot h surface s ar e sande d t o giv e a smooth , marble-lik e finish . Th e produc t i s a counte r to p surfac e tha t feel s lik e marble . I t i s simila r t o Dupont' s Coria n surface . Th e produc t i s mad e i n thre e thicknesses : 1/ 4 inch , K inc h an d 3/ 4 inch . Th e catalyze d resi n matri x consist s o f unsaturate d polyeste r resi n (containing styren e monomer)an d alumin a trihydrat e filler . Th e mixin g proces s wa s no t discusse d durin g th e phon e call , however , i t wa s note d tha t th e matri x wa s heate d t o betwee n 9 0 an d 10 0 degree s Fahrenheit . Thi s i s necessar yt o provid e fo r th e prope r viscosit yo f th e resin . I n th e continuou s process , th e matri x i s dispense d o n th e pape r throug h a on e inc h diamete r pip e connecte d t o a dispensin g die . I n th e firs t 1 0 fee t o f th e line , gravit yflatten s ou t th e matri x t o mak e i t 3 0 inche s wid e .



# 1 _P. 4

and th e selecte d thickness . Afte r movin g throug h thes e 1 0 fee t o f th e line , th e matri x i s pulle d throug h th e oven . Madelein e aske d whethe r a top fil mwa s place d ove r th e matri x befor e i t passe d throug h th e oven . Sh e explaine d tha t thi s i s commo n practic e i n a continuou s laminatio n process . Charli e Stanie r note d tha t ther e i s n o to p fil mplace d ove r th e matri x i n thi s castin g process . I t wa s determine d ove r th e phon e tha t th e proces s woul d no t b e i n th e pape r coatin g subcategor ybecaus e th e pape r i s peele d of f t o mak e th e fina l product . Th e proces s ma ystil l b e considere d unde r th e reinforce d plasti c composite s categor ydu e t o th e similaritie s i n material s use d an d similarit yi n emissio n points . I t i s stil l no t clea r whethe r th e facilit ywoul d b e covere d i n th e continuou s laminatio n subcategor yunde r th e reinforce d plastic s sourc e category . Mai n difference s betwee n thi s proces s an d th e continuou s laminatio n proces s includ e th e lac k o f fiber s o r ma t adde d t o th e laminat e and th e lac k o f plasti c fil mt o cove r th e resi n matri x a s i t enter s th e oven .



# 3P. 5

Docke t No . A-94-5 2 Categor y II- E The followin

g information i s locate din th e confidentia l files o f th e Director , Emissio n Standard s Division , Offic

e of Ai r Qualit y Plannin g an

dStandards , U . S . Environmenta l Protectio n Agency , Research Triangl e Park , Nort h Carolin a27711 . Thi s informatio n i s confidentia

l pending final determinatio n by th e Administrator an di s not availabl e fo

r publi c inspection . Telecon , M . Strum , EPA:OAQPS:CCPG , K . Meardon an dM . Proctor , PES , Inc . wit h C . Stanie r and K . Dellario , Internationa l Paper , (formerl

y Nevama r Corp.) , dated , July 12 , 1996 . Thi s contact

repor t wa s fo r th e purpos e to determine whethe r th e Fountainhea

d continuou s line migh

t fi t int o th e surfac e categor

y of pape r coating , rathe

r tha n th e subcategor

y of continuou s casting/continuou s laminatio n sinc e th e resin matrix i s dispense do n apape r web . The confidentia

l information i s comprise do f a2-pag e report . CN-504-1/93185-C18-11 C



# u*P. 6 

# " • (}3/l&/Mfi)-

NONCONFIDENTIA L CONTAC T REPOR T From : Madeleine Strum , U S EPA , OAQPS/ESD , Coating s an dConsumer ' Product s Group Kennet h Meardo n an

dMelani e Proctor , Pacifi

c Environmenta

l Services , Inc . (PES ) Date : Augus t 9 , 199 6 Contact : Charli e Stanie r andKaren Dellari o Company : Internationa l Paper , Decorativ e Product s Division , Odento n Facilit y (Formerl y Nevama r Corporation) , Odenton , Marylan d Telephone Number : (410 ) 519-513 4 (Ms . Dellario )

(410 ) 519-209 4 (Mr . Stanier ) CONTACT SUMMARY : Th e Odento n Facilit

y o f Internationa

l Paper , Decorativ e Product s Division , wa s contacte d t o clarif y th e followin

g thre e mai

n issues : 1 ) determin e if

th e continuou s lin

e proces s use dt o produc e soli

dsurfac e plasti c sheet s i s i

n th e continuou s laminatio

n subcategory ; 2 ) quantif

y th e emissio n reductio n achieved i

n th e continuou s lin

e process , an

d3 ) determine i f

ther e are an

y planne d change s t o th e continuou s lin e proces s within th e nex

t tw o years . Internationa

l Paper' s continuou s lin

e proces s doe s no t

us e fiberglass reinforcement s an d i s controlle d wit

h acondense

r an d carbo n filters. Ms . Struminquire dif Internationa

l Paper ha s experienced an

y problem s wit

h particle s clogging th e condense r an di f thi s typ e o f

contro l syste

m could b e used i

f fiberglass reinforcemen

t wa s use di

n th e process . Mr . Stanie

r explainedtha

t al l particulat e matte r withi n th e matri

x i s completel

y wette dwit

h resi n befor e emission s ar

e vente d t o th e condenser . According t o Mr . Stanie r th e condense

r onl y collect s water

vapors , styrene , [confidentia

l material ] an

d traces ' o f

xylen e (les s tha n 1/1 0 of apercent) . Mr . Stanie

r note dtha t the y di d not anticipat e water i n th e vapor

strea mwhen th e syste

mwa s initiall

y designe dan

d thu s the y decided t o operate acondense r a s th e mai n contro l devic e a

t atemperature o f

100° K (-279 ° F) , an d acarbon filters t o "polish " of f th e emissio

n strea mfromth e condenser . However , ic e formatio n o n th e condense

r force d Internationa

l Pape r t o increas e th e condense

r temperatur

e an d to rel y on th e carbon filters t o mee t environmenta

l requirements . Th

e condense

r i s primaril y use d a s a"precooler" . Mr . Stanie r explainedtha

t Internationa

l Pape r has som e problem s wit

h polystyren e "gum " build u

p i n thei r valve s an di n th e condenser . However , th e buildu p ca n b e cleane d u p easil y an d doe s no t pos e abig proble

mbasedo n Mr . Stanier' s opinion . According to Mr . Stanier , th e emissio

n contro l syste

muse da t th e Odento n facilit

y coul dprobably no t

b e applie d i f reinforced fibers wer

e presen t i n th e proces s ga s stream . Som e additiona

l pre condense r filtration syste

mwoul d likel y b e necessary . 

# 5P. 7

Whe n Mr . Staine

r wa s asked ho w he woul dclassif y th e processe s a

t th e Odento n facility , h e explaine d tha t th e facilit y cast s polymer s i

n eithe r bow l o r sin k shape s an di n thin or thick sheets . Th e thi n an d thic k sheet s ar e produce di

n acontinuou s lin

e process . Th e Odenton facilit y stil l has apermi

t t o cas t sheet s i n aluminu mmolds , bu t

thi s proces s i s no t

i n us e anymore . Mr . Meardon asked whethe r polyme r castin g o f sinks an dbowl s couldb e controlle d by th e sam e typ e o f emissio n contro l syste

mtha t i s use dfo r th e continuou s lin

e process . Mr . Stanie

r explaine d tha t carbo n filters are onl

y feasible when th e flo

w o f th e emissio

n strea mi s lo w an

d th e VO C conten t i s hig h a s i n th e cas e o f

th e partially enclose dcontinuou s lin e process . According t o Mr . Stanier, othe

r VO C source s tha

t woul db e feasible t o ven

t to th e emissio

n contro l syste

m includ e ove n exhaust , mixin

g exhaust , an dth e exhaus t

fromth e dispensin

g are awher

e th e mol d i s filled.' Mr . Stanie

r explaine d tha t th e sin k andbow l castin g proces s a t th e Odento n facilit

y canno t b e enclose d due t o spac e limitation s a t th e facihty . I f

th e entir e roomwouldb e ventedt o th e contro l system, th e ai

r flow would hav e t o b e increase dconsiderably , which woul dinterfer e wit h th e prope r functionin g o f th e carbon filters. Mr . Stanie r though t tha t i t migh t b e difficul t but possible to enclos e polyme

r casting a t anewl y constructe dfacilit

y an dven t emission s t o acontro l device . Bu

t according t o Mr . Stanier , continuou s processe s ar e muc h easil y andmor e effectivel y controlled b

y add-on contro l device s than batc h processes . Mr . Stanie r added tha t from acos t

perspective , it

di dnot mak e sens e t o contro l an

y o f thei r processe s wit

h th e typ e o

f contro l systemi

n plac e a t th e Odenton facility . The cos t t o contro l on e to n o f HA P wit h th e condense

r an dth e carbo n bed s i s betwee n $20,00 0 an

d$30,000 . I f th e facilit y could redesig n th e emission contro l system , Mr . Stanie r thought the y wouldcove

r th e sheets produce d i

n th e continuou s line proces s wit h aga s impermeabl

e filmt o mor

e effectivel y contro l emissions . I n orde r t o determin

e i n which subcategor

y aspecific proces s belongs , th e EP A i s developin g definition s tha

t would distinguis h th e differen t subcategorie s basedo n proces s characteristics . Ms . Procto r rea d tl^followin g preliminar

y definition s fo

r continuou s lamination/continuou s casting an d polyme r castin g an

daskedMr . Stanie

r t o commen

t on thes e definition s wit

h regar d t o th e processe s a

t th e Odento n facility : Continuou s lamination/continuou s castin g i s asubstantiall y automate dproces s fo

r producin g laminate s o

n a h in-line conveyer . Th e proces s involve s applyin g resin or gel coa t ont o aflat, movin

g surface , andthen curin g th e material , typicall y i n a n ove n throug h whic h th e laminat

e i s automatically moved . Polyme r casting involve s th e productio n o f anon-reinforcedcomposit

e tha t combine s polymers , fillers, an

d additive s b y pourin g o r

dispensing thes e material s int o ope n o r partiall y ope n mold s an

d then curin g the

ma t elevate d o

r ambien t temperature . Mr . Stanie r pointe d out

tha t th e proces s o f

castin g sink

s an dbowl s definitel

y belonged i

n the polyme r casting subcategor

y an d tha t th e continuou s lin

e proces s fo

r casting thi

n an dthick

iP. 8

sheet s appeared to belon

g i n th e continuou s lamination/continuou s casting subcategor y based on th e definition s provided . However , Mr . Stanie r explainedtha

t th e product s produce di

n th e continuou s lin

e process , ar

e non-reinforce dan

dtraditionally produce db

y polyme r casting . Mr . Stanie r inquired i f th e continuou s lamination/continuou s casting definitio n woul dinclud

e reinforced an

d non-reinforce

d products . Ms . Stru mindicate d tha t n o final decision s hav e bee n mad e concerning th e subcategor y definitions . Accordin

g t o Ms . Strum , ther e i s som e flexibilit y i n ho w th e facilitie s ar

e subcategorized , bu

t du e t o th e variet

y o f product s i n th e reinforcedplastic s industry , subcategorizatio n i s likel

y determine d base do n proces s rathe r tha n product . Ms . Stru

mfurthe r explaine d tha t i f Internationa

l Paper' s continuou s lin

e proces s doe s no t

fit i n an y o f the existing subcategories , thi s proces s coul d b e place di n it s own subcategory . Th e nex t majo r issue o f th e discussio n wa s th e descriptior r o f th e continuou s lin

e proces s wit h it s enclosur

e an d th e emissio

n reductio n achievedi

n thi s process . Mr . Stanie

r explaine d that th e continuou s lin

e consist s o f

a10 0 foo t lon g an d4 0 inch wid

e belt tha t move s i n acircle . Filled resi n i s dispense

d ont o th e movin

g belt andreache s a

n ove n 1 0 fee t afte r th e poin t wher e th e resin has bee n dispensed . Approximatel

y on e foo t afte r th e resin ha s been dispensedonto the belt , a n enclosure , whic

h cover s th e are aabov e andbelo w th e belt , enclose s th e belt an dth e oven . Wher

e th e dispensed resi

n enter s th e enclosure , there i s a4 t o 6 inc h ga p i n th e enclosur

e t o allo w th e resi n mixtur e t o ente r th e enclosure . The ove n has boxe s wit

h lid s o n eithe

r side o f th e ove n t o acces s th e sheet s tha

t are bein g produced . I

n area s wher

e frequent

acces s i s neededth e lid s ar

e automated , whil e scre

w dow n cover s ar e placed i n area s o f lo w maintenance . The ove n i s nitrogen blankete dan

dkep t under positiv e pressur

e t o avoi d an y oxygen fromenterin g th e ove n which coul dpotentially caus e a n explosion . Th

e enclosur e upstrea mfromth e ove

n i s kep t a t neutra l pressur e allowin g som e o f th e ai r fromthe ove

n t o be draw

n awa y fromth e ove

n int o th e enclosur

e an descap e (through th e entranc e an

d an y othe r opening s i n th e enclosure ) t o th e atmosphere . According t o Mr . Stanier , th e hazardou s ai

r pollutan t (HAP ) concentratio n escaping out o f th e enclosur

e through th e ga

p nea r th e resi n dispensin g are aca n b e a s hig

h a s 40 0 t o 60 0 ppm . Mr . Stanie r explaine dtha t th e HA P concentration withi

n th e facilit

y i s clos e t o th e threshol dlimit'valu e (TLV) , bu t tha t th e TL V i s no t exceeded . Mr . Stanie

r furthe r explaine dtha

t it i s impossible t o create anegativ e pressure environmen

t i n th e ove n o r i n the*enclosur

e i n genera l becaus e th e risk

of explosion i s to o high . Th e emission s fromth e enclosure aroun dth e continuou s lin e including emission s from tote s an d pump s ar

e vente d t o th e emission contro l system . Mr . Stanie r estimate dtha

t th e captur e fromth e entir

e continuou s lin

e proces s fifty percen

t o r less . Th e contro l efficienc

y o f th e condense r an d the carbo

n filters, which are changedonc e aweek , i s 9 9 t o 10 0 percent . Th e compound s collected b

y th e condense

r are sen t of f a s hazardou s waste . Th e Odento n facilit y als o operate s aparticl e lin e tha t produce s 20 inc

h wid e ribbons . Th

e productio n o f

polyeste r particle s i s acontinuou s proces s tha t i s controlle db

y acarbon bed . Mr . 

# nP. 9

Stanie r pointed ou t

that th e oven i n tha t lin e ca n operat e a

t negativ e pressur

e without th e risk o f explosions . According t o Mr . Stanie r th e emissio

n captur e efficienc

y of tha t lin e i s 9 2 percent . Th e las t purpos e o f

th e discussion wa s t o determin e i f Internationa

l Pape r i s plannin g an y change s t o the continuou s lin e proces s withi

n th e nex t tw o years . Mr . Stanie

r note dtha t th e continuou s lin

e i s producin g 3 differen

t sheet s varyin g in widt

h an dth e entranc e ga

p int o th e enclosur e i s cu t t o accommodat

e th e wides t

shee t produced . According t o Mr . Stanier , th e onl y planne d chang e t o th e continuou s lin e proces s i s t o cove r

up part o f th e entranc e ga

p whe n narrowe r sheets are produced . Thi s wouldincreas e th e capture efficienc y fo r th e narrowe

r sheets . Mr . Stanie r added tha t Maryland' s fiberglass RACT requirement causedthe

mt o look a t retrofitting th e enclosure , bu t Internationa

l Paper foun dthat

th e cost s wer

e no t justifiable .

%P.1 0

Docke t No . A-94-5 2 Categor y II- E The following information i s locate din th e confidentia l files of th e Director , Emissio n Standard s Division , Offic

e of Ai r Qualit y Planning andStandards , U . S . Environmenta l Protectio n Agency , Research Triangl e Park , Nort h Carolin a27711 . Thi s information i s confidentia

l pendin g final determinatio n b y the Administrator

an di s no t availabl e fo

r publi c inspection . Telecon , M . Strum , EPA:OAQPS:CCPG , K . Meardon an dM . Proctor , PES , Inc . wit h C . Stanie r an d K . Dellario , Internationa

l Paper , (formerl

y Nevama r Corp.) , dated , Augus t

9,1996 . Thi s contac t

repor t wa s fo r th e purpos e t

o clarif y thre e main issue s 1.

) determine if

th e continuou s lin e proces s use d t o produc e soli dsurfac e plasti c sheet s i s in th e continuou s laminatio n subcategory ; 2. ) quantif y th e emissio n reductio n achieve di n th e continuou s lin e process , and 3. ) determine i f ther e ar e an y planne dchange s to th e continuou s lin e proces s withi n th e nex t tw o years . Th

e confidentia

l information i s comprisedof a4-pag e report . CN-504-1/93185-C18-11 D