p. 1 

### OAR Box 1490 Prepped by Charmelle Mathews

Document

Number: 

### 63 ) IV-C-3 6 Docket Number: 

### A-94-5 2

Printed 8/4/200811:51:47

AM Sheet 63 of 273P. 2 A-94-5 2 IV-C-3 6 i > » 

### REINFORCE

D PLASTI C COMPOSITE S MAC T STANDARD S DEVELOPMENT UPDATE

rr^ •!,'; > nc"' u

For the Reinforced

Plastic Composites Seminar October 16 , 200 2 Keit h Barnett , Projec t

Lead Offic e o f Air Qualit y Plannin g an d Standard s Emissio n Standard s Divisio n Mineral s an dInorgani c Chemical s GroupP. 3



## Outline Wh o i s subjec t

t o thi s standard ? Wha t operation s are covered ? Wha t if l manufacture fiberglas s boat s o r boat parts ? Whe n do I hav e t o comply ? Wha t ar e th e major

change s t o rul e sinc e proposal A mI ane w o r

existin g source ? Wha t standard s mus t

I meet ? Ho w do I calculate emissio n factors ? Ho w d o I achiev e 9 5 percen t control ? Wha t are som e o f m y option s t o mee t standards ? Ho w d o I demonstrat e initial compliance ? 2P. 4 

## Wh o i s subjectt

o thi s standard ?

• Yo u are subjec t

t o thi s standar d i f you :

- Manufacture reinforce dplastic s composite s a

t afacilit y tha t i s locate da

t amajor sourc e (1 0 tp y o f

any on e HA P o r 2 5 tp y o f any combinatio n o f

HAP) : an d

- Us e thermose t

resin s o r ge l coat s that contai n styren e 

### • Yo u are no t

subjec t t o thi s standar d i f you :

- Us e les s tha

n 1. 2 tp y o f

styren e containin g resin s an dge l coats , o r

- Onl y perfor

mresearc h an d development , o r

- Onl y repai r

reinforce dplasti c composite sP. 5 

## Whatoperation s are covere d and hav e some typ e o

f contro l requirements ? Ope n Moldin g Close dMoldin g Centrifuga l Castin g Continuou s Lamination/Castin g SMC/BM C Manufacturin g Pultrusio n Mixin g Storag e Equipment

Cleanin gP. 6 

## Wha toperations ar

e covered , an d hav e n o requirements ? Applicatio n o f

mol dsealin g an dreleas e agent s Mol dstrippin g an dcleanin g Repai r unrelate dt o you r

manufacturin g operation s Material s tha

t do no t contai n resi n o

r ge l coa t Personal activitie s no t

par t o f manufacturin g operation s Prepre g material s Non-ge l coa

t surfac e coating s Researc h an ddevelopmen t operation sP. 7 

## Wha tif I Manufactur

e Fiberglas s Boat s or Boa tParts ? Yo u are subjec t

t o th e Boa

t Manufacturin g NESHA P onl v i f

yo u manufacture boat hull s or decks , o r mold s fo r boat hull s o r deck s I f yo u are no t

subjec t t o th e Boat Manufacturin g NESHAP , yo u ar e subjec t t o thi s rul e i f

yo u mee t applicability requirement s regardles s ofth e en dus e o f th e part s I f yo u are subjec t

t o th e Boa

t Manufacturin g NESHAP , bu t mak e part s tha t are no t part ofyou r boats , th e non-boat operation s ar e subjec t

t o thi s rul e Yo u ma y elec t t o plac e al l operation s unde r th e Boa t Manufacturin g NESHA P i f that result s i n equal o r

lower HA P emission sP. 8 

## Whe n d o I have to comply ? Proposal wa s Augus t

2 , 200 1 Fina l rul e publicatio n date i s par t o f 1 0 yea r MAC T settlement

negotiation s Existin g majo

r source s mus t

compl y withi n 3 year s Ne w majo r source s mus t

compl y b y effectiv e date o f

fina l rul e o r startup , whichever i s laterP. 9 

## Major Change

s t o Rule Sinc

e Proposa l Th e above-the-floo r

requirement s hav e bee n droppe dfo

r existin g ope n molding , pultrusion , SMC an dBM C manufacturing , an dmixin g operation s Th e poin t valu e equation s hav e bee n replace dwit

h th e appropriat e unifie d emissio n factor

(UEF ) equation s W e hav e revise dexistin g sourc e MAC T floor s base do n comment s receive do n th e propose drul e

- Tw o floor s wil l requir e aslightl y lowe r HA P content , thre e ar e slightl y highe r

- W e hav e combine dth e fille dan d unfille dnoncorrosio n resistan t mechanical resi n applicatio n operation s type s 8P.1 0



## Whati s a ne

w Source ? Yo u commence dconstructio n afte r Augus t 2 , 2001 ; an d Whe n yo u commence dconstruction , ther e were n o reinforce dplasti c composite s operation s a

t th e facilit y Note tha t th e definitio n abov e include s movin g a n existin g facilit

y (We are overridin g th e General Provision s concernin g movin g sources )P.1 1 

## Wha ti s a n Existing Source ?

An y sourc e that

i s no t ne w
Existin g source s are no t

considere dne w a s aresul t o f reconstructio n

10P.1 2



## Whati s th e 100 tp y HA P Emissio n Threshol d and Ho w I s I tDetermined ? Sumorgani c HAP emission s fromth e al l operation s potentiall y subjec t t o 9 5 percen t contro l prio r

t o any add-o n control s Fo r existin g source s thi s is :

- Centrifuga

l castin g

- Continuou s lamination/castin g Fo r ne w source s thi s is :

- Th e tw o operation s above , an d

- Open moldin g

- Pultrusio n

- SMC andBM C manufacturing ,

- Mixin g
nP.1 3



## Whati s th e 100 tp y HA P Emissio n Threshol d and Ho w I s I t

Determined ?

• Calculate thes e organi c HAP emission s usin g

- Emissio n factor

equation s i n th e rul e (whic h are base do n th e UEF )

- Other publishe demissio n factor s

- Sit e specifi c factor s i f

base do n emissio n tes t

dat a

1 2P. M 

## Draf tMACT fo

r All Sources Below th e 10

0 tpy Threshol d Operatio n Typ e Ope n Moldin g - Corrosio n Resistan t and/o rHig h Strengt h (CR/HS ) Ope n Moldin g - Non-CR/H S
Ope n Moldin g - Shrinkag e Controlle d Resin s Specifi c

Operatio n Mechanica l resi n Applicatio n Filamen t Applicatio n Manua l Resi n Applicatio n Mechanica l resi n Applicatio n (Fille d o runfilled ) Filamen t Applicatio n Manua l resi n Applicatio n Mechanica l resi n Applicatio n Filamen t Applicatio n Manua l Resi n Applicatio n Emissio n

Limi t (lb/ton ) 11 2 17 1 12 3 8 7 18 8 8 7 35 4 21 5 18 0 Allowabl e Resi n HA P Conten t 46. 2 Non Atomize d 4 2 4 0 38. 4 Non Atomize d 4 5 33. 6 5 0 Atomize d 5 0 5 0 1 3P.1 5 

## Draf tMACT for Al l Sources Below the 10

0 tp y Threshol d (Con't ) Operatio n Typ e Ope n Moldin g - Ge l Coa t Specifi c

Operatio n Toolin g Ge l Coatin g Pigmente d Ge l Coating-Whit e an d Of f Whit e Pigmente d Ge l Coatin g - NonWhit e Clea rProductio n Ge l Coatin g CR/H S o rHig h Performanc e Ge l Coatin g Fir e Retardan t Ge l Coatin g Emissio n

Limi t (lb/ton ) 43 7
26 7 37 7 52 2 60 5 85 4 Allowabl e HA P Conten t (Weigh t % ) 4 0
3 0 3 7 4 4 4 8 6 0 1 4P.1 6 

## Draf tMACT for Al l Sources Below the 10

0 tp y Threshol d (Con't ) Operatio n Typ e Ope n Moldin g - Toolin g Ope n Moldin g - Low Flam e Spread/Lo w Smok e Product s Centrifuga l Castin g Specifi c

Operatio n Mechanica l Resi n Applicatio n Manua l Resi n Applicatio n Mechanica l resi n Applicatio n Filamen t Windin g Manua l Resi n Applicatio n Non-CR/H S CR/H S Emissio n

Limi t (lb/ton ) 25 4 15 7 49 7 27 0 23 8 2 0 2 5 Allowabl e HA P

Conten t (Weigh t % ) 50 + Non atomize d 4 3 Atomize d 45. 9 6 0 6 0 6 0 37. 5 4 8
1 5P.17
_ 

## Draf tMACT for All Sources Below the 10

0 tp y Threshol d (Con't ) Injection/Compressio n Moldin g - Cove r Charge s Resi n Transfe

r Moldin g - N o Requirement s Continuou s Laminatio n an dCastin g - 58. 5 percen t contro l Polyme r Castin g - N o Requirement s

1 6P.1 8 

## Draf tMACT for All Sources Below the 10

0 tpy Threshol d (Con't ) Pultrusio n - 6 0 percen t

contro l o r

we t are a enclosure (excep t

fo r larg e parts ) Sheet Moldin g Compoun d- Nylon
containin g film , cover

resi n deliver

y t o docto r bo x Equipmen t

Cleanin g - Cleanin g material s ma y contai n n o HAP (excep t fo r close d systems ) Resi n Mixin g an dBM C Manufacturin g - Cover th e mixer s Resi n Storag e - Cover

storag e container s
1 7P.1 9 

## Draf tMACT for Existin g Sources a tor abov e the 10 0 tp y Threshol d
Fo r existin g source s tha

t emi t 100 tp y o r more o f HA P combine dfrom

- Centrifuga

l Castin g

- Continuou s Lamination/Castin g Th e requirement s are 9 5 percen t contro l o f th e operation s liste dabov e Th e requirement s fo

r al l othe r operation s are th e same a s facilitie s belo w th e threshol d

1 8P.2 0 

## Draf tMAC T for New Source s a t o r above th e 100 tp y Threshol d

• Fo r ne w source s that

emi t 100 tp y o r

more o f HAP combine dfro

m

- Open Moldin g

- Centrifuga

l castin g

- Continuou s lamination/castin g

- Pultrusio n

- SMC/BM C Manufacturin g

- Mixin g Th e ne w sourc e MAC T i s 9 5 percen t contro l ofth e operation s liste dabov e Operation s no t

liste dabov e mus t

mee t th e sam e requirement s a s existin g source s

1 9P.2 1 

## Ho w d o I Calculat

e Emissio n Factors ? Equation s are presente di n th e rule , an dar e identical t o current

unifie demissio n factor s publishe db y th e CFA . Resi n us e ma

y b e base do n purchas e record s i f yo u ca n reasonabl y estimat e ho w th e resi n i s applie d Resi n HAP content

may b e base do n MSD S o r resi n specificatio n sheet s Emission s are base do n organi c HA P content W e hav e adde dprovision s fo r norma l manufacturin g tolerance s

2 0P.2 2 

## Exampl e Emissio n Facto r Calculatio n

• Ope n moldin g - mechanical resi n applicatio n - nonatomize d- noncorrosion
resistan t

- Resi n HAP conten t

(fromMSDS ) i s 3 6 percen t

- Emissio n Facto r

(EF ) equatio n i s • EF = ((0.157)(%styrene)-.0165) x 200 0
• EF = ((0.157)(0.36)-.0165 ) x 200 0

• EF = 8 0

- Draf t final MAC T i s 8 7

- Thi s meet s MAC T
• D o no t consider catalyst s o r

promoter s • D o consider

any additional monome r additio n 2 1
/ / /P.2 3 

# Ho w do I achiev e 9 5 percen t contro l (i f

required) ?

• Enclos e operation s requirin g 9 5 percen t contro l wit

h apermanen t

total enclosur e

• Desig n an doperate enclosure i n accordanc e wit

h EPA Metho d20 4

• Instal l an doperate a9 5 percen t efficien t contro l devic e

- Concentrator/oxidizer

- Therma

l oxidizer

- Catalyti c oxidizer

• I f yo u d o no t

us e apermanen t

tota l enclosure , yo u mus t

tes t fo r capture efficiency , an doveral l capture an dcontro l mus t b e 9 5 percen t

o r mor e 2 2P.2 4 

## Option s t o Mee tStandards Ope n Moldin g an d Centrifuga

l Casting Yo u ma y averag e ope n moldin g operations , an dseparatel y averag e centrifuga l castin g operation s (12-mont h rollin g average ) Al l operation s o f

aspecifi c resi n typ e (CR , Non-CR , an dTooling ) ma y us e th e sam

e HAP content

resi n Operation s subjec t

t o 9 5 percen t

contro l hav e alternativ e poin t

valu e limit s Yo u ma y chang e complianc e option s
23

. * . * r* / . ' **' "P.2 5



## Meeting P

2 Standard s Ope n Molding an

d Centrifuga

l Casting Option 1 Chang e al l your

resin s an dge l coat s t o one s wit h HAP content s belo w th e standard Thi s i s th e simples t

metho dan dresult s i n th e leas t reportin g an drecor dkeepin g

24P.2 6



## Meeting P 2 Standards Optio n 1 Exampl e
Prio r t o MAC T

- Atomize dapplicatio n o f 4 5 percen t HAP noncorrosion-resistan t resi n

- Atomize dapplicatio n o f a3 5 percen t HAP white ge l coa

t Afte r MAC T

- Nonatomize dapplicatio n o f 3 8 percen t HA P noncorrosion-resistan t resi n

- Atomize dapplicatio n o f 3 0 percen t HA P white ge l coa

t

- I f nonatomize dge l coa

t applicatio n i s possible , allowabl e HA P conten t wil l b e highe r
2 5P.2 7



## Meeting P

2 Standard s Ope n Molding an

d Centrifuga

l Casting Option 2 Chang e you r

resin s an dge l coat s s o th e weighte daverag e meet s MAC T Require s purchas e record s b y resi n type , an dmonthl y averag e calculatio n Averag e i s base do n las t

1 2 month s o f operatio n Averag e i s weighte dbase do n resi n us e over that perio d

2 6P.2 8



## Meetin g P2 Standard s Optio n 2 Exampl e
Prio r t o MAC T

- Currentl y us e tw o noncorrosio n resistan t resins , on e 3 7 percen t

HA P an don e 4 2 percen t

HA P

- nonatomize dmechanical applicatio n

- rati o o f resi n us e i s 60/4 0 afte r MAC T (Emissio n limi t

= 87 )

- conver t th e 4 2 percen t

HA P resi n t o resi n wit h 4 0 percen t

HA P o r les s

- maintai n same 60/4 0 spli t

2 7P.2 9



## Meeting P

2 Standard s Ope n Molding an

d Centrifuga

l Casting Option 3 Determin e th e highes t

resi n HA P conten t allowabl e fo

r eac h operatio n Us e thi s resi n fo

r al l operation s Ca n no t includ e ge l coat s o r

mi x corrosio n an dnoncorrosio n resistan t operation s

2 8P.3 0



## Meetin g P

2 Standard s Optio n 3 Exampl e Prio r to MAC T makin g corrosion-resistan t tank s usin g atomize d mechanical (en dcaps) , filament windin g (body) , an dmanual applicatio n (joinin g parts ) usin g 5 0 percen t

HA P resi n

29P.3 1



## Meeting P

2 Standard s Optio n 3 Example After MAC T
Determin e MAC T fo

r eac h operatio n

- Mechanical i s averag e o f 46. 2 percen t HA P resi n wit

h nonatomize d applicatio n

- Filamen t

windin g i s 4 2 percen t

HA P resi n

- Manual i s 4 0 percen t

HA P resi n Selec t highes t allowabl e averag e HA P leve l (46. 2 percent ) Maintai n thi s averag e resi n HA P conten t fo r al l corrosion-resistan t

operation s
3 0P.3 2 

## Options fo r Meetin g Standard s

Pultrusio n

Wet are aenclosures , prefor

minjection , o r direc t di e injectio n t o mee t

th e 6 0 percen t reductio n requiremen t Yo u ma y averag e acros s differen

t machine s fo

r bot h percen t reductio n an d time s that cover s o r door s are ope n Fo r averagin g purposes , direc t di e injectio n an dprefor minjectio n are assume dt o achiev e a9 0 percen t

HA P emissio n reductio n

3 1P.3 3 

## Option s for Meeting Standard s Continuou

s Lamination/Castin g Ca n averag e line s Existin g source s ca

n elec t t o contro l onl y we t out are aemission s b y 9 5 percen t Ca n meet a n alternativ e emissio n limi t o f 14. 7 lb/to n (58. 5 percen t

contro l level ) o r 1.4 7 lb/to n (9 5 percen t

contro l level )

32P.3 4 

## How D o I Demonstrate Initia l Compliance fo r a PTE ? Determin e th e equivalen t

diameter s o f

al l ND O an dexhaust s Determin e th e equivalen t

diameter s o f

al l ND O fromHAP emissio n point s an d exhaust s fro

mND O (mus t

b e a t leas t four ) Measure PTE surfac e are a(A T ) an dND O surfac e are a(A N ) . Th e rati o o f AT/A N mus t 0.0 5 o r less .

3 5P.3 5 

## Ho w D o I Demonstrat

e Initia l Complianc

e for a PTE (Con't) ?

• Verif y directio n o f

flo w i s inwar dfo

r al l ND O usin g streamers , smok e tubes , o r trace r gase s

• I f F V i s 50 0 o r

more , inwardflo w verificatio n i s no t

require d

3 7