Methods for Reducing TCE Emissionsfrom Superior Tube Co., Inc.and Accellent, Inc.Collegeville, PennsylvaniaMATSON & ASSOCIATES, INC.March 7, 2008MATSON & ASSOCIATES, INC.Based in State College, PennsylvaniaEnvironmental Engineering Consulting firmExpertise/ServicesLitigation Support and Expert WitnessingEnvironmental Engineering ConsultingBackgroundJan 2007: DEP Collegeville Area Air MonitoringReport showed excess cancer risk in Evansburg andTrappe, PA from TCESuperior Tube and Accellent: significant air emittersof TCERanked 6 and 8 nationally in 2005 (69.0 tons and 58.5 tons)Ranked 11 and 12 nationallyin 2006 (68.3 tons and 67.9tons)May 2007: EPA Final Rule for Halogenated SolventCleaning exempted narrow tube industry from TCEemissions controlsOverviewSuperior Tube’s and Accellent’sprograms are capable of achievingsignificant TCE emissions reductionsEffective operation of controltechnologies is essential to achievinggoalsPermits reflecting effective operationshould ensure successVoluntary Actions: Superior TubeRemoved from operation5 point sourcesWill remove another point source by Apr. 2008Switched from TCE to nPB3 Lubrication Spray BoothsPlan to switch remaining 4 point sources fromTCE to nPB in April 2008Source: STCI, Minor Operating PermitModification Application, 2/13/2008.Concerns: Superior TubeMaintains the option of switching back to TCE34 tons/yr TCE emissionsEPA Final Rule for other halogenated solventcleaning industries is 15.5 tons/yrNo emissions capture controls on 4 point sourcesNon-optimal operation of its Activated Carbon(AC) systemSource: STCI, Minor Operating Permit ModificationApplication, 2/13/2008;EPA Final Rule, May 2007TCE emitted (0.8%)Superior Tube’s Compliance Test, Jan 2002TCE removed byAC (99.2%)TCE to AC (100%)Activated Carbon System OperationActivated carbon(AC) bedsTCE in (100%)TCE to AC (90%)TCE emitted (19%)TCE removed byAC (90%)TCE recycledback to processSuperior Tube’s Plan Approval, Nov 2000Vapor DegreaserPermit based on 81%removal efficiencyCONCERNS:Non-optimal operation of its AC systemYearActual TCE emissions(tons/year)20036.620044.820058.0200617.7Actual TCE emissions from theAC systemControlled TCEemissions(tons/year)PrecontrolledTCE Emissionslbs/hour81%removalefficiency99.2%removalefficiency17.8 (Avg +20%)14.80.614.8 (Avg)12.30.58.0 (hourlythroughput)6.70.3Calculated TCE emissionsBased on 24/7 365 days operationSources: Plan Approval for Installation of ACsystem, 2000; DEP Inspection Reports; ComplianceTest, 2002; Best Controlled Detail Reports for emissions years: 2006, 2005, 2004, 2003Permit limit = 20.6 tons/yearRecommendations: Superior TubeConduct new Compliance Test on ACsystem and change permit levels to reflectthe resultsUse continuous monitoringInstall emission controls on uncontrolledpoint sourcesVoluntary Actions: Accellent, Inc.Installing AC system on its 2 large vapordegreasers1stunit installed Oct. 20072ndunit install by Mar. 2008~97% of TCE emissions originate from 2large vapor degreasersExpects 25 – 35% reduction in TCE emissionsplant wideSource: Best Controlled Detail Reportfor emissions year 2006; STCI toDEP, Subj: Carbon AdsorptionSystems Accellent, 4/9/2007.Concerns: Accellent, Inc.25 - 35% reduction in TCE emissions from installationof its AC systemTCE Emissions remaining = 44 – 51 tons/year TCEEPA Final Rule for other halogenated solvent industries is15.5 tons/year TCEShould be able to achieve higher reduction in TCENo AC system compliance test performedNo emissions controls on 2 smaller emittersSource: EPA Final Rule, May 2007Recommendations: Accellent, IncConduct Compliance Test on new AC systemand change permit levels to reflect the resultsSwitch to nPB and/or route emissions to ACsystem in 2 remaining point sourcesRequire continuous monitoring of TCEemissionsRecommendation:Continuous MonitoringTCE inTCE recycled backto processsensorOutletmonitorInletmonitorStack emissions = outlet monitorEmergencies: EarlyDetection and ControlPumpAC removal efficiencymonitoredBENEFITS:ConclusionsSuperior Tube and Accellent areimplementing voluntary actions to reduceTCE emissionsProper operation of control technology willreduce TCE emissions significantly belowcurrent permit levelsPermit levels based on proper operationensures compliance with voluntaryreductions