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## NHDES VOC RACT APPLICATION REVIEW

SUMMARY NH Department of Environmental Services Air Resources Division P .O . Box 95, 29 Hazen Drive Concord, NH 03302-0095 Phone : 603-271-1370 Fax : 603-271-7053 Facility : Hutchinson Sealing Systems, Inc. Engineer : PRN Location : Newfields AFS #: 3301500046 Application # : 11-0156 Date : I January 27, 2012 Page 1 of 4 

### PROJECT DESCRIPTION VOC RACT order . EU09 - [Thermoplastics Extrusion Line #9] - the line is being modified to include a stainless steel pre-form unit and adhesive application ["front-end"] along with a catalytic oxidizer for control of VOC emissions fromthe added equipment . Hutchinson Sealing Systems, Inc . ["HSS" or "the Facility"] owns and operates a facility that produces sealing systems, body seals, and soft rubber glass-run channels used in automobiles and various other applications . The sealing strips are produced by several processes involving metal roll forming, rubber and plastic extruding, flocking and curing, followed by certain secondary operations including but not limited to trimming, notching, saw cutting, stretch blending, molding and assembly . On August 8, 2002, HSS was issued VOC RACT Order # ARD-01-002. At that time, the adhesive application processes were categorized as "unclassifiable", and were required to meet a 3.5 Ib VOC/gal VOC RACT limit [Env-A 1204.49(a)(3), adopted 12-21- 02] . The VOC RACT order currently allows the Facility to generate and expend credits to cover VOC emissions above the 3 .5 Ib/gal limit specified in the rule . They are able to self-generate 22 tpy of VOCcredits due to the permanent shutdown of the Body Stock Preparation Line [9/1/1999] and the Metal Parts Painting operations [5/4/1998] . This 22tpy is the difference between the baseline before the shutdown of these two processes and the Facility-wide emissions after the shut-down. The Facility is allowed to use these credits each year, but remaining unused credits do not roll-over to succeeding years . On June 1, 2011, DES adopted revisions to Env-A 1200. Among those changes was the inclusion of a new source category of Industrial Adhesives [Env-A 1220] . HSS meets the applicability requirements of this section, and the modifications to EU09 will become subject to the emission limitations upon startup . HSS has opted to comply, facility-wide with the requirements of this subpart upon issuance of their renewed permit, SP-0141 instead of waiting until January 1, of 2016. The Facility has requested to be allowed to continue to use ERCs and DERs for those adhesives that do not comply with the newRACT limit . HSS has also request they be allowed to generate credits [DERs] for the over control of VOC emissions by the catalytic oxidizer . 

### PROCESS/DEVICE DESCRIPTION During assembly of the sealing strips, as the formed metal and extruded rubber come together, an adhesive is applied, which bonds the rubber to the metal vehicle part . Some products require the application of flock to the sealing strips [flock is a polyester fiber, which has a similar consistency as powder] . An adhesive is applied to the part of the sealing strip to which the flock is being applied. As the sealing strip passes through a booth, the flock is injected through a specially designed applicator and bonded to the sealing strip. The strips are passed through an electric oven, to cure the rubber . The extrusion lines each have a Smog Hog [contains an electrostatic precipitator to control particulate matter emissions] . Device/Process Description Thermoplastic Extrusion Construction of this line commenced October 2003 with startup August 1, 2004; Line #9 [EU09] Device Model Mfi SIN I Device Model Mfa SIN Roll-Form NA KW R50 &R51 ~ Extruder 2.5 MV Davis AQ790

. _ ._. ._ .__ .... ._ ... ._ . ._...... ._._ . . ._ ._______ ._.__

.___ .. ._ . ._ ._ .... .___.___.__ . ._ . . .__ ._._ ... . .. ._ .__ ._.__. ..... ._. . . . .___

._._.__._. ._____ ... ._._._

. ._._ .._ . ._.. .__ .... .__ .. ._.__.__ ... ... .__ .. ._ .. ._ ._ ... . .__ ... ._..... . Extruder 2.5 MarkV Davis AG889 ~ Extruder MV35 IN35 Davis AQ794

_ . ._ --- . . . . . ._ ._. ._ . . . . . ._ . . . . . . . ._ . . .~_ . ._ . . . . . . . . . . . . . ._ . . . ._ . . . . ._ . . . Extruder DS125 Davis AN810 1Flash Cure Oven 6 meter Precision NA I Control

. . . . . ._.___.___ . ._ . . . .___ .__.__ ._. ._ . . .__ ._ . . . . . . . ._._._

. .__. ._ . . ._.___ ._.__ ._.___ . . ._ ._._ ._._ ._ . . . . ._ .__ . . . ._ . . .~. . . ._ . . . . .__ . .___ ._ . ._-__ . . ._ . .__ ._ . ._____ . Post cure oven 10-12x72G CC[ Thermal 0004-009 ? Flash cure and post cure ovens are LPG fired (belowpermitting threshold) 

### VOC POLLUTION CONTROL EQUIPMENT HSS is proposing to install a catalytic oxidizer to control emissions fromthe "front end" process of EU09 [specifically the adhesive coater] . The oxidizer is expected to capture 100%of the emissions fromthe adhesive coater, and to have a destruction efficiency of 99.0% for VOCs [a destruction efficiency of 95% was assumed in the permit application for emissions calculations] . The minimum operating temperature of the cat ox [PCE05] will be determined during performance testing to confirmdestruction efficiency. When the oxidizer shuts down due to malfunction or for maintenance, or when the "front-end" of EU09 is not in operations, the exhaust from- Facility :

Location : AFS #: 

### VOC RACT APPLICATION RE VIEW SUMMARY ----- - -- -------- ------ ------------- m . ---- -I - I lutchin son Sealing Systems, Inc . En ineer " PRN Newfeld Is 3301500046 ~ Application #: I 11-0156 ---------- - - I--- ~l--------- Date : January 2 7, 2012 I Page 2 of 4 the adhesive coater and pre-cure oven will be directed out the existing exhaust stack, bypassing the oxidizer stack . During these times, emission credits will be used for compliance with VOC PACT if required. 

### VOC RACT COMPLIANCE (CREDIT USE) CALCULATIONS To determine how

many [if any] credits are to be used in any month/year, the Facility must calculate the weighted average VOC emissions fromall coatings [i .e . adhesives] used, minus water and exempt VOC compounds as applied . The Facility is not required to use credits for solvent materials used as cleaners or to the ink [Image ink] used to label parts, and the VOC RACT limit does not apply to these materials . These materials will be addressed in Table 4, Item 7 of the permit (SP-0141) and are limited to 5 tons per consecutive 12-month period . These are considered minor core activities . Calculations for adhesive mixture of Chemlok 487A and Chemlok 487B to be used on EU09 after the modification : VOC Containine Adhesive Density (Ib % weight VOC % vol VOC HZ0 C/eal C) (Ib VOC/Ib C) (Qal VOC/¢al C) M wt %

wt

. A ,7, .22 ' 85 .42% 87,62 % 0% 0% Ch

. . . em

. . lok

. . . . 487

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ._ . . . . . .__ . .~_ . . . . . . ._- .-. .-__ . ._ . ._ . . . ._. . . . . . . . . . . . _ . . . . . . . ._ ._. ._ . .__. . . . . . . . ._

._ ._ .-_ .----- . . . . . . . . ._

. . . . . . . . . . . . . . . . . . . .. . . . . . . ._ , . . . . . . . . . . . . . . .. __ ._ . . . . .. Chemlok 487B I 6.71 1

_ . 98 .02% 98 .43% I 0% 1 0%

_ . . . . . . . . . . . . . . . . . . . . . . . ._

. . . . . . . . . . . . . . . . . . ._ . . . ._

. . . ._ . . ._ .__._ . ._ . . . . . .__ ._ ._ .___

._ . . ., ._.__ . . . ._ . . ._ ._. . . . . . . . ._._ . . ._ .___ . ._._ . .__ ._._i_ . . ._. ._ .__._ .--_- .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . ._ . Information is from MSDS' provided by the Facility Mixture ratio: 100 gal A to 15 gal B ; projected usage rate : 74 Ibs CM/day Solids (% v) 11 .5%

......... . . __ ....... _ ._......_. ....... . .. ... 1 .5% l . Calculation of VOC-emissions fromthe coating mixture as applied minus water and exempt VOC compounds :

Chemlok 487A 7 .221bC'A' 0.8542lbVOC lC'A' x IbC'A' x100ga1C'A'=61716VOC ga Chemlok 487B 6.711bC ' B' x 0

.980216VOC x 15galC ' B'= 98 .661b VOC ga1C'l3' IbC'B' 161716 FOC+98 .661b VOCI -6.221bs VOC minus water &exempt VOC compounds 115ga1 C, gal C M VOC RACT limit = 6

.3 lb VOC/gal C as applied minus water &exempt VOC compounds 2 . Calculation of Emission Standard on a Solids Basis : If a coating used by the HSS does not meet the VOC RACT limit, HSS may use the following calculation to bubble emissions: 

### E~ . 1- E` I dA S = VOC emission standard in terms of pounds VOC per gallon of coating solids ; Ec = VOC emission limit [6.3 Ib VOC/gal coating] specified in the VOC RACT Order; dA = Actual mass density of the VOC in the applied adhesive formulation [lb VOC/gal VOC] ; average of the VOC densities of the coatings as follows :

Chemlok 487A Ethyl

.~benzenew,Y~- .-~7 .23 

### calculated based on a weighted Saeciated Densit Dd VOC ISVI Ib/ al %wt gal soeciated VOC 0 .701b Xy 7.221b C' A' 505.41b Xy / galC = - X lene 7.1 8 70% lb C' A' * gal C' A' *loo ga1C'A' 7.181bC / ga1C - ""' gal Xy

_ ...... .. . ---_._ ._ 0 .201b EB 7.221b C' A' 144.41b EB

* IOOgal C' A'= =19 .97gal EB lb C' A' gal C' 2 0% A' 7.231b / . gal Exempt VOCs

0 .01lb CF 7.221b C' A' 7.221b CF * " IOOgaI C'A'= = 0 .58ga1 CF Chloroform 12 .35 1% Ib C'A' gal C'A' 12 .351b1 gal

### VOC RACT APPLICATION REVIEW SUMMARY Facility : Hutchinson Sealing Systems, Inc . Engineer : PRN ti L Newfields on : oca 4

3301500046 Application #: 11-0156 Date : January 27, 2012 Page 3 of AFS #: Sneciated Densit D~1

VOC SV Ibl al %wt gal saeciated VOC Chemlok 1 .0lb MIB K * 6 .711b C' B' * 15ga1 C' A'- 100.616 MIBK -15 .06ga1 M/BK 487B MIBK 6.68 100% Ib C'B' gal C' B' 6.68161 gal ----------------------------------------------------------------------------------------------- ---------------------------------------------------------------------------------------------------------------- 757.6216 SV 7.1516 VOC 505.41b Xy+144.41b EB+7 .221b CF+100.616 MIBK _ d" 70.39ga1 Xy+19

.97gal EB+0.58ga1 CF+15 .06gal MIBK 106ga1 SV gal VOC 6.316 VOC

1 gal C S= - = 52 .991b VOClga1 C, solids 6.31b VOClgal C ] 1C 7.151b SV / gal C,,, 3 . Calculation of Allowable VOC Emissions - [E- ,] 

### W 

## E ., =S*VS * D m 

### Ee, = the allowable VOC emission rate of a given coating [lb/day] ; for each coating or dilution solvent used ; S = the VOC emission standard [lb VOC/gal of coating solids], as calculated in 2 above [52.99 lb VOC/gal coating 

### solids] ; Vs = the volume fraction solids content of the coating, [gal solids/gal coating] calculated as follows :

Chemlok 487A Chemlok 487B 0.115gal S

olids x 100ga1 C = 11 .Sgal solids 0 .015gal Solids x 15ga1 C = 0 .225ga1 solids gal C gal C Total solids in coating as applied (11 .5gal solids + 0 .225gal s oli ds ) x 100 = 10.2%vol 115gal C W = the weight of coating as applied on the coating line [lb coating/day] ; Dm = the density of the coating mixture as applied [lb Cm/gal C], as determined from Method 24 or 24A analysis 0 .102gal Csolids ~ 

# C 7416 CM /day ay 52 .99lbVOC 861b VOCl d » 55 - _ .

*

# C EQ~ - ( gal Csolids ) gal C, 7.1616 C, / gal CM 4 . _ Example Calculation of Actual VOC Emissions per Adhesive - E, 

### W E Q` = W,, * ( D ,, Wv = weight fraction of VOC in the coating as applied [lb VOC/gal CM] ; 6.221b VOC 7416 C, l day 64.316 VOC E°` gal C, *(7.161b C,y l gal C, ) day 5. Calculation of Credit Use 

## E = Eal - Eac 55 .861b V

O C 64.31b VOC E= - - - = -8.441b VOC l day

day dayFacility :

Location : AFS #: VO C R ACT APPLICATION REVIEW SUMM ARY ------------ - -- ---- ------- - ---------- ------------ -- Hutchinson Scaling Systems, Inc. ~ Engineer " Ncwfields 330-1500046-- --_---I_ .Ap plicati on # : 11-0156 Date: PRN January 27, 2012 Page 4 of 4 Since the result of the subtraction is a negative number, it means that actual emissions are greater than allowable emission rates, and emission credits must be used . 

### 6. Bubble and Use of DERs The Facility will be allowed to bubble the emissions from multiple coatings (as applied minus water and exempt VOC compounds) on a daily basis if an adhesive is used that does not meet the 6 .3 lb VOC/gallon of coating as applied minus water and exempt VOC compounds, and use ERC's/DERs to offset the excess emissions.

a. Compliant Coatings : Each operating day, when all coatings applied on all lines meet the emission limit of 6 .3 Ib/gal of coating as applied minus water and exempt VOC compounds is in use, emission credits do not need to be used . b . Non-Compliant Coatings : Excess emissions shall be calculated for each coating by subtracting the actual emissions (as applied, minus water and exempt VOC compounds) fromthe allowable emissions (Ee, - E j . The excess emissions fromall the coatings (as applied minus water and exempt VOC compounds) shall be added together (bubbling), and based on the results, one of the following shall be required : i . ii . If the result of the bubble calculation is a positive number, then the source is in compliance with the emission limits and no further action is required ; and If the result of the bubble calculation is a negative number, then actual emissions exceed the allowable emission rates and need to be offset with the use of credits ; The actual ERC's/DERs required shall be calculated by taking the absolute value of the total excess emissions and dividing by an environmental benefit factor of 0 .9. 

### VOC RACT CREDIT GENERATION CALCULATIONS In accordance with Env-A 3103 .02, the general rule for computation of DERs is as follows : "The amount of DERs shall be the difference between : (a) The amount of vOC or NOx emissions that would have been emitted from the source during the generation period calculated by multiplying the actual activity levels during that period by the lower of (1) The lowest applicable allowable emissions rate ; or (b) The amount of actual emissions during the generation period based on actual activity levels during that period" (2) The actual emissions rate that would have been emitted based on normal source operation ; and In this case, the "lowest applicable allowable emissions rate" for credit generation is the lower of: The alternative limit (an overall control efficiency of at least 85%) to the VOC emission limit (6.3 lb/gal) for motor vehicle weatherstrip adhesive listed in Table 1220-1, in accordance with Env-A 1220.02(e) . This is equivalent to a facility-wide emissions rate equal to 15%

of uncontrolled emissions ; a. The emission rate of 3.5 Ib/gal included in conditions D .2 . and D

.3 . of RACT Order ARD-O1-002 dated August 8,2002; or b. An emissions rate of 23 tons/year, in order to preserve the previously agreed upon protocol for calculating the 22 ERCs that HSS receives each year . In other words, if HSS exceeds any of the above emissions rates, then no DER credits would be generated. Calculation of the uncontrolled facility-wide emissions shall be in accordance with Table 5, Item 4 of the permit (SP-0141) . Actual calendar year emissions shall be reported in accordance with Table 7, Item 1 of the permit (SP-0141) . The daily allowable emissions rate for credit generation shall be calculated by substituting 3.5 Ib/gal for the VOC RACT limit of 6 .3 Ib/gal in the above VOC RACT compliance calculations .