p. 1


# OAR Box 1384 Prepped by Charmelle Mathews



### Document

Number: 

# 89 ) ll-E-4 9 Docket Number: 

# A-94-5 2

Printed 7/2/2008 8:42:06

AM Sheet 89 of 264P. 2 

### A-94-52 

## • l-£-l| f

MEMORANDUM TO : Madelein e Strum

U.S . EPA/ESD/CCPG FROM : Gre g LaFla m Pacifi c Environmenta

l Services , Inc . (PES ) DATE : October

2 , 199 6 P:/N50 4 :;$^^''i., : i*'$$#>'d :-V .

SUBJECT : Minute s o f

July 29 , 199 6 Meeting Betwee n EPA andRepresentative s o f th e Pultrusio n Industr

y Council LOCATION : EPA/Mutua l Building , Durham , NC , 11t h floor conferenc e room , 8:3 0 a m- 10:3 0 a

m ATTENDEES :

Mr . John Barke

r Mr . Larr y Connor s Mr . Nelso n Douglas s Mr . Ji mGauchel Mr . To mGriffith s Ms . Lind aHerrin g Mr . Gre g LaFla

m Mr . Walt McSherr y Mr . Ke n Meardo n Ms . Melani e Proctor Mr . Joh n Schweitze

r Ms . Madelein e Stru

m MMF

G Libert y POLYGLA S Reichhol dChemical s Owens-Cornin g Omeg aPultrusion s EPA/ES D PE S Omeg aPultrusion s PE S PE S SPI/Composite s Instimt

e EPA/ES D (540 ) 645-812 9 (412)466-861 1 (919 ) 990-825 6 (614 ) 321-772 4 (216 ) 562-520 1 (919 ) 541-535 8 (919 ) 941-033 3 (216 ) 562-520 1 (919 ) 941-033 3 (919 ) 941-033 3 (313 ) 668-470 3 (919 ) 541-238 3 PURPOS E Th e meetin g wa s requeste db y th e Pultrusio n Industr y Council (PIC ) t o discus s th e following thre e topi c areas : 1 ) PIC s lates t MAC T rul e proposal , 2 ) EPA' s MAC T floo r fo r ne w pultrusio n sources , an d3 ) th e additiona l PI C Phas e I I tes t

datarequeste db y EPA .

/P. 3

Madelein e Strum Octobe r 2 , 199 6 Pag e 2 DISCUSSIO N PIC s MACT Proposa

l fo r Pultrusio n T o begi n th e meeting , eac h participant introduce dhim

- or

herself , andMessrs . Connor s andGauchel identifie dthemselve s a s th e newly-electe dChairma n andCo-Chair , respectively , o f

th e PIC . Mr . Griffith s the n statedth e thre e principal aim s o f th e meetin g (a s liste dabov e unde

r Purpose) , andproceede dt o describ e th e PIC s suggeste dMACT proposa l fo r th e pultrusio n industr

y (se e Attachmen

t 1) . Th e PI C proposa

l consist s o f

fou r provisions . Mr . Griffith s reviewe dth e first thre e provision s without

any extensiv e discussion . Thes e provision s includ e conservatio n vent s fo r resi n storag e tanks , cover s fo r mixin g an

dtransfe r tank s an dreservoirs , andalimi t o f 0.01 5 lb o f

HA P solvent pe r lb o f composit e produced . Th e hear t o f th e PI C proposa

l i s containe di n th e fourt

h provision , whic h specifie s a n allowabl e maximu

mPultrusio n Emissio n Contro l Statu s (PECS ) valu e fo r existin g and fo r ne w sources . Th e PEC S represent s th e tota l level o f contro l fromth e following selecte dpollutio n preventio n measure s i n us e i n th e operation , a s applicable : (1 ) direct die injection, (2 ) preform resin injection, (3 ) wet area enclosuresfor

open baths, and (4 ) restricted

airflow (< 15

fpm) across open baths. The PEC S valu e i s determine db y weightin g th e effectivenes s o f th e individua

l measure s accordin g t o th e amoun t o f HA P monome r processe dthroug h eac h control . The PI C proposa

l consider s fou

r form s o f pollutio n preventio n measur e (a s note d above ) andassign s aContro l Factor , c f (i.e. , th e amoun

t o f emission s remainin g afte

r us e o f th e technology ) t o eac h one . Unde r thi s scheme , th e mos t

effectiv e o f

th e fou r measure s i s direc t di e injectio n (c f

= 0.01 , o r 9 9 percent

control) , followedb y prefor mresi n injectio n (c f

= 0.15) , wet

are aenclosure s (c f

= 0.41) , andair

flo w managemen

t t o 1 5 ft/min o r les s (c f = 0.53) . Th e proposa

l wouldallo w an

y combinatio n o f

thes e contro l measures , includin g area s wit h "n o control " (c f

= 1.00) , a s long a s th e overal l PEC S fo r th e operatio n meet s o r

exceed s th e require dMAC T level , whic h wa s calculate db y th e PI C t o b e 0.6 8 fo

r existin g source s and0.3 7 fo r ne w sources . Prefor mResin Injectio n Mr . Griffith s describe dprefor mresi n injection a s bein g harde r t o define tha

n direc t di e injection . H e emphasize dtiiat th e 1 percen

t resin "leakage " permitte di n th e industry' s propose ddefinitio n applie s only t o th e are aupstrea mo f th e saturatio n chambers . Resi n drip-of f fromth e wet

reinforcement

durin g an

dafte r th e saturatio n ste

p andfromth e front o f th e di e wouldb e permitted , an dwoul dnot

coun t towar dth e 1 percent

limit . The lengt

h o f expose dwet

reinforcement

i n th e directio n o f

pull woul db e limite dt o n o mor e tha n 1 5 

## 2P. 4

Madeleine Stru m Octobe r 2 , 199 6 Pag e 3 inches . A discussio n ensuedconcernin g ho w thi s proposa l correspond s t o th e condition s tha t existe di n th e PIC s 199 5 Phas e I I pultrusio n study . Mr . Douglas s note dtha t h e coul d no t recal l th e exac t

lengt h o f th e wet-out

are ai n th e stud

y (althoug h i t

wa s probabl y about 9 t o 1 2 inches) , but

tha t th e lengt h use dwa s specific fo

r th e profil e ru n durin g th e stud y (ladde r rail) . Certain profile s ma y nee dt o hav e slightl

y longe r wet-ou t areas . Ms . Proctor

askedho w asetu

p wit h adifferen

t profil e coul db e compare dt o th e result s fromth e study . Mr . Griffith s agree dtha t thi s wouldb e difficult

t o d o i n term s o f developin g aregulation . He di demphasiz e tha t th e stud y wa s acommercia

l setup , andno t jus t ates t run . Ms . Proctor

pointe dout

that th e condition s i n th e definitio n shoul d correspon dt o th e experiment , becaus e tha t wa s wher e th e reduction s wer e measured . She adde dtha t perhap s les s reductio n credi t coul db e given fo

r wette dlength s greater

tha n 1 5 inches . She als o suggestedthat w e shoul dconside

r focusin g more o n definin g or describin g specificall

y wha t wa s done durin g th e stud

y rather tha n o n quantifyin g wha

t wa s done . Ms . Strumconcurred , statin g tha t w e nee dto reexamine th e actua l tes t condition s fo r considerin g ho w t o dea

l wit h prefor mresi n injection . Sh

e emphasize dth e concer

n tha t th e definitio n doe s no t

represent th e productio n configuration tha t achieve dth e 9 1 percent emission s reduction . Mr . Barke r sai dtha t they couldobtai n more informatio n t o describ e wha t wa s don e during th e study . Mr . Gauchel explainedthat , i n th e 1 5 inche s o f wet-out area , th e produc t

goe s from afla

t for mt o th e final shape befor

e enterin g th e die . Durin g th e study , aC-channe

l shap e wa s created . Mor

e complex shape s ma

y requir e additiona

l preformers . H e explainedtha t i n som e instance s som

e ofth e preformer s ma

y b e locate di n th e saturatio n chamber , although , typically , th e preformer(s ) i s (are ) locate d3 t o 4 inche s downstrea mfromth e saturatio n chamber . Fromtha t poin t t o th e die , there i s aone-laye r form . Preformer s downstrea mo f th e saturatio n chambe

r ar e never close dan dsom

e drippag e occur s of

f the man dth e die . Mr . Gauchel notedtha t th e dri p pan i s situate dn o mor e tha n 1 2 inche s belo w th e preformers . Mr . Griffith s statedtha

t they woul dexamine whethe r they coul ddevelo p a descriptio n o f

prefor mresi n injectio n more accurately reflectin g th e setup use dfo r th e Reichhol dtest . Th

e revise ddescriptio n wil l "tighten up " th e wordin g abou t th e location s andamount s o f

resin drippage . Ms . Stru

mstate dtha

t sh e wa s concerne dabou t

th e vertica

l dri p distanc e andit s effec

t o n emissions . Mr . Douglas s state dtha t h e di dno t

think th e lengt h o f dri p i s importan

t to th e level o f

emissions . H

e sai dthi s distanc e i s typicall y about 6 inches ; facilitie s tr

y t o minimiz e thi s drop t

o preven t possibl e splashin g o f

resi n ou t o f th e dri p pan . Industr

y als o notedtha

t sufficien t space/distanc e mus t

b e provide dt o allo w worker s t o acces s th e are aabov e th e dri p pa n wit h their hand s i n cas e o f

jam-up s o r breakag e o f

th e reinforcement . The participant s discussedth e possibilit y o f limitin g th e amoun t o f wet reinforcemen

t surfac e are atha

t ma y b e exposed , bu t

du e t o varyin g par

t width s an dnumbe

r of reinforcemen

t layers , thi s approach wa s deeme dcomplicate dand 

# 3P. 5

Madeleine Strum Octobe r 2 , 199 6 Pag e 4 impractical . Ms . Strumsuggeste dtha t th e Contro l Factor

fo r prefor mresi n injectio n b e set a t th e overal l contro l statu s (PECS ) require dfo r existin g sources , an

dthe n th e standar

d woul dcontai n onl y areasonabl e descriptio n o f prefor mresi n injection , withou t

specifi c requirement s fo

r quantificatio n o f

leakage . She thought

thi s wa s wha

t wa s suggeste dat

th e previou s meetin g wit

h th e PIC , an

dtha t attendee s at

tha t meetin g wer

e amenabl e t o it . Mr . Griffith s state dtha

t th e PI C woul dg o bac k

andconside

r thi s a s agroup . A discussio n wa s hel dconcernin g th e ai r flo w aroun dth e prefor

mresi n injectio n apparatu s becaus e styren e ha s bee n show n t o evaporat

e mor e rapidly whe n th e resi n i s expose dt o higher

air flo w velocities . Mr . Gauchel state dtha t th e ai r flo w can b e controlled , andth e amount o f closur e fo r th e collecte dresi n ca

n als o b e controlled . Mr . Douglas s pointe dou t

tha t durin g th e stud

y th e resi n wa s collecte di n afunnel underneat h th e smal l dri p are awit

h ahos e a t th e botto mofth e funne

l t o recycl e th e resi n back t o th e process . H e state dthat

thi s approac h limite dexposur e o f th e drippin g resi n t o air

flow . H e als o sai dtha

t total leakag e wa s les s tha n 1 percent . Mr . Griffith s note dtha

t th e test s were designe dprimarily t o smd y ai r flow management , andthe y di dno t conside r wel l enough ho w t o defin e th e operatio n (e.g. , th e amoun t o f resi n leakage) . H e als o note dho w difficul t measuring backflo w can be , a s i t varie s wit h resi n viscosity . Ms . Strumaske dMr . Barke r about th e condition s existin g i n MMFG-Bristol' s prefor mresi n injectio n setup . He state dthat , whil e som e aspect s o f

th e operatio n are considere dproprietary , h e woul dprovid e t o EP A videotap e of

th e productio n operatio n at MMFG . Mr . Barke

r als o agree dt o provid e aquantitativ e descriptio n (surfac e are aand amount) o f

th e leakag e (expose dt o air ) fromth e devic e usedi n th e tests . We t Are aEnclosure s Mr . Griffith s clarifie dtha

t th e radi o frequency (RF ) prehea t uni t referre dt o i n th e descriptio n o f

wet are aenclosure s i s use dt o star t th e cure proces s fo

r certai n thic k

parts , an di s wel l seale dt o minimiz e radiatio n leakage . A s aresult , resi n woul dno t b e expecte d to lea k fromsuch aunit . Ms . Strumaske dwhethe

r th e opening s durin g th e tes t ha da3/8-inc h clearance . Mr . Douglas s state dtha

t fo r al l incomin g materials , hoses , etc . there wa s a3/8-inc h clearance . Mr . Griffith s pointe dout tha t th e siz e o f

th e slot s aroundth e rovin g wil l var y wit h th e weight

o f th e rovin g (e.g. , 1/

2 ounc e versu s a2 ounc e roving) . H e sai di t i s possibl e t o describ e wha

t i s coming into th e enclosur e andt o se

t specifi c clearances , bu t tha t th e propose d3/8-inc h specificatio n wa s a n attemp t t o simplify . H e als o note dtha t industr y doe s no t

want t o conduc t

operation s poorly , s o clearance s wil l b e wha t the y nee d t o b e t o provid e asmoot

h productio n operation . SP I note dtha

t clearance s nee dt o b e larg e 

# HP. 6

Madeleine Strum Octobe r 2 , 199 6 Pag e 5 enough t o accommodat

e splice s wher

e tha t practic e occurs . Mr . Griffith s fel t that th e 3/8

- inc h clearanc e wa s sufficien t t o accommodat

e mos t reinforcements . Ms . Procto r aske d about th e possibilit

y o f specifying th e siz e of

th e clearanc e a s apercentag e o f th e rovin g o r reinforcemen

t size . Mr . Griffith s pointedout tha t industr y ha s informatio n tha

t relate s th e openin g siz e t o specifi c reinforcements , an dcoul dprovid e th e informatio n t o EP A fo r review . Air Flo w Managemen

t . In th e discussio n o n air

flo w management , i t

wa s state dtha

t th e propose d1 5 feet per minut e or les s air flow requiremen

t wouldb e considere dt o apply a t 3 inche s abov e th e we t surface . The utilit y an dpracticalit

y o f th e "puf f o f smoke " techniqu e fo

r measurin g ai r

flo w wa s discussed , andsome thought tha t thi s metho dma

y no t b e accurat

e o r reliabl e enoug h fo r measurin g th e variabl e flow s a t man y plants . Also , th e smok

e ma y dissipate to o quickly t o allo w adeterminatio n t o b e made . Mr . Schweitze r agree dt o researc h th e applicabilit

y o f smok e pencil s fo

r thi s purpose . The anemomete r made by Soloma

t wa s describe da s havin g th e abilit y t o integrat e variation s i n flo w velocit y andprovid e astabl e readin g a t lo w flows . Mr . Schweitze r provide dMs . Strumwit

h acop y o f

sale s literatur e o n th e Soloma

t anemometer , but

pric e information wa s no t availabl e (se e Attachment 2) . Contro l Factor

Issue s Wit h regar dt o th e propose dbackflow limi t fo r direc t di e injection o f

5 l b o f resi n perhr , Ms . Strumstate dtha t th e actua l backflo w she observe di n th e PIC s Phas e I I study appeare dt o b e much less , perhap s 5 ounce s per hour . Mr . Connor s note dtha t th e Owens

Cornin g facilitie s i n Europ e operat e wit h essentially n o backflow , whil e their facilitie s i n th e Unite dState s hav e acertai n percentag e loss . Ms . Strumaske dMr . Connor s i f the y coul dprovid e awrite-up o n wha t their compan y i s doing . Mr . Griffith s state dthat th e systemMr . Connor s referre dto i s preliminary . He als o state dtha t he thought

tha t th e amoun t o f backflo w coul db e expresseda s apercentag e o f th e amoun

t o f resi n passin g throug h th e die . Mr . Connor s note dtha t i f you "drop " som

e glass , you get

alocalize dlo w pressur e spo t tha t result s i n atemporar

y highe r backflo w o f

resin . Mr . Griffith s state dthat h e woul dg o back

andlook at th e percentag e backflo w fromth e testing . H e fel t th e inten t wa s to get peopl e to us e direc t

di e injection , but

stil l believe s prefor

mresi n injectio n i s preferabl e t o usin g th e standar duncontrolle dope

n bat h configuration . Mr . Gauche l expresse dconcer

n tha t abackflo w limit

wouldno t

b e me t durin g startup andshutdow n o f th e operation . Mr . Schweitze r agreedto obtai n actua

l backflo w rate s fo

r direc t di e injectio n semp s engage di n ladde r rai l production . Ms . Strumaske dabou t th e feasibilit

y o f allowin g unrestricte dbackflow , but requirin g collectio n o f

all o f th e resi n i n aclose d system . Mr . Gauchel replie dthat , fo r existin g systems , spac e ma y no t b e available , bu t 

# 5P. 7

Madeleine Strum Octobe r 2 , 199 6 Pag e 6 woul dno t b e aproble mfo

r new systems . He state dtha t any di e injection systemwil l hav e some resi n backflow , bu t

that the amoun

t coul dcertainl y b e minimized . PEC S Value s I n reviewin g th e industry' s PEC S calculations , PI C note dtha t thei r existin g sourc e PEC S valu e i s 0.6 8 o n th e basi s o f th e five facilitie s tha

t the y kno w t o b e majo

r sources . They note dthat

Creativ e Pultrusion s i s usin g ai r flo w management ; tha

t Omega' s Contro l Factor valu e i s 1.0 an dno t

really 0.68 , becaus e wha

t the y are currently doin g doe s no t meet th e propose ddefimtio n tha t woul dgiv e the mth e credi t identifiedi n th e propose d averagin g scheme ; an dthat MMF G i s a t 0.9 8 becaus e only asmall par t o f wha t the y are doin g woul dreceiv e an y credit . Mr . Connor s state dthat th e real state-of-the-ar

t i n th e industr y i s closer t o a1.0 Contro l Factor

than anythin g else . Mr . Gauchel pointe dou t that th e 1.0 valu e i s base do n th e definition s containe di n th e documen t andthat alo t o f what peopl e are doin g ca

n b e improve dver

y quickly . Mr . Griffith s sai dthat , fo r example , the y woul db e abl e t o reduc e th e lengt h o f th e wet are ai n aprefor

mresi n injectio n setup t o meet th e industry' s propose ddefinition (1 5 inche s maximum) . Ms . Proctor note dthat , i f th e Tecto n Product s facilit y wa s addedt o th e lis t

o f majo r facilities , th e existin g MAC T floo r woul db e 0.3 8 a s presente di n thi s document . Ne w Sourc e MAC T Mr . Schweitze

r aske dfo r mor e informatio n o n th e pultrusio n operatio n a t Tecto n Product s i n Fargo , North Dakota(whic h th e EP A visite di n June 1996) . Ms . Strumnote d tha t Tecto n i s apultruder , i s pennitte dfo r five lines , andha s emissio n point s typical o f other pultruder s (bath , drip , anddie) , andthu s belong s i n thi s subcategory . Mr . Griffith s state dtha t i t wa s hi s understandin g tha t Tecto n control s bot

h pultrusio n andpaintin g operation s usin g a n oxidizer . Ms . Stru mnote dtha

t thi s wa s no t

th e origina

l setup , that

th e oxidize r operate da t

leas t 7 month s without

th e paintin g operations , andtha t Tecto n wa s i n th e proces s o f

askin g th e Stat

e i f they coul ddisconnec t

th e paintin g operation s fromth e oxidizer . She note dthat

th e Stat e ha s given their

oka y fo r thi s to occur . Thi s facilit y use s total enclosure s (per

EPA' s criteria) andatherma l oxidizer t o contro l styren e emissions , andpresumably coul dserv e a s th e basi s fo r EPA' s ne w sourc e MAC

T floo r determination . Mr . Schweitze

r indicate dtha

t industr y i s largely unfamilia

r wit h Tecton' s operation , bu t

h e believe dthat

Tecto n installe dthe incinerator t o contro l emission s frombot h it s pultrusio n an dit s paintin g operations . Ms . Stru mstate dtha

t th e control s ar

e in plac e principall y for th e pultrusio n emissions , an demphasizedtha t th e compan

y i s plannin g t o remov e th e control s fromth e paintin g operatio n wit h th e State' s approval . Mr . Schweitze

r aske dabou

t th e styren e concentration s tha t exis t withi n Tecton' s enclosures , an dwhether

the y mee t th e OSH A worke r exposur e limits . H e als o aske d whethe r worker s coul denter

th e enclosure s andwhethe r th e enclosure s encompas s th e
^P. 8

Madelein e Stru m Octobe r 2 , 199 6 Pag e 7 rovin g an dma

t creels . Ms . Stru

mstresse dtha

t much o f th e detail s o f

th e operatio n are considere dconfidentia

l busines s informatio n (CBI ) b y Tecton , but tha t th e Nort h Dakot a permi t an dth e tes t

repor t fo r th e incinerator

coul db e supplie dt o provid e informatio n abou t th e system . Mr . Schweitze r asserte dtha

t EP A shoul dno t

rel y o n CB I dat ai n settin g MAC T floors , sinc e thi s wil l limi t industry' s abilit

y t o full y evaluate th e contro l technology . H e felt

tha t thi s contro l technolog y ma y no t b e availabl e t o other

pultrusio n operations , andtha

t th e industr

y neede dmor

e informatio n s o tha

t i t coul devaluate th e feasibilit y o f thi s for mo f control . H e als o fel

t tha t certai n line s ma

y b e abl e t o us e enclosures , whil e other s ma y not . Pultrusio n coul dtherefor e b e shut ou t o f some market s i f a n enclosure/contro l devic e standar dwer e enacted . Mr . Griffith s agree dtha t h e coul d no t evaluate th e feasibilit

y o f enclosure s base do n wha

t h e knew . Mr . Schweitze

r requeste dblueprint s an

dengineerin g specification s o n Tecton' s system . Ms . Strumagree d t o provid e non-CB I fromth e permit andtes t report , includin g styren e concentratio n level s bot h i n th e enclosur

e an di n th e inlet

andexhaus t

o f th e incinerator . Sh e state dtha t EP A consider s th e non-confidentia l informatio n availabl e fo

r Tecto n sufficien

t t o suppor

t ane w sourc e floor

o f 9 5 percent

control . Dat afromPIC s Phas e I I Stud y A brie f discussio n wa s hel dconcernin g EPA' s reques t t o PI C fo r

additional Phas e I I stud y tes t dat atha t wa s no t include di n th e stud

y report . Th e PI C supplie dth e informatio n (se e Attachmen t 3 ) wit h th e cautio n tha

t i t no t b e use dt o calculate emissio n factor s for pultrusion , notin g tha

t th e stud y wa s no t designe dto establis h emissio n factors . Mr . Griffith s state dtha

t certai n datawer

e subject t o error andwer e no t measured , suc h a s th e rate o f

styren e processe dthroug h th e system . However , th e calculatio n wa s estimate d t o b e 8. 5 l b o f

styren e processedper

hour , wit h aminimu

mexpecte derro r

o f ±1 0 percent . H e pointe dou t

tha t lin e speeddoe s no t

affect th e tim e rat e o f

styren e emitted , bu t

doe s affect emission s expresse da s apercentag e o f th e tota l styren e enterin g th e process . Mr . Griffith s sai dth e tes t

speedwa s 2 ft/min and , fo r a4 ft/min speed , th e emissio n factor woul dlikel y b e afacto

r o f 2 lower . ACTIO N ITEM S Follow-u p activitie s agree dt o b y meetin g participants : Part y Actio n Agreedto 1 . U.S . EPA (M . Strum) Provide non-CB I informatio n o n Tecton' s syste mt o J . Schweitze

r 

# 7P. 9

Madelein e Strum Octobe r 2 , 199 6 Pag e 8 2 . PI C (J . Barker)

3 . PI C (J . Schweitzer

)

4 . PI C (T . Griffiths )

Attachment s Provide photo s o f th e PI C tes t

setu p andquantitativ e descriptio n to M . Stru m Provide videotap e o f

MMFG' s prefor

mresin injectio n setu p t o M . Stru m Research th e applicabilit

y o f smok e pencil s fo

r measuring lo w air

flow s i n pultrusio n operation s Obtai n information o n resi n backflo w rate s i n direc t di e injectedladde

r rai l productio n andprovid e t o M . Stru m Revis e PIC s definitio n o f

"prefor mresi n injection " base do n th e meetin g discussio n G o back andlook a t th e condition s ofth e Phas e I I tes t andre-examine th e assignment o f a0.1 5 contro l factor fo r prefor mresi n injectio n Provide information o n openin g size s specifie dfo r variou s type s o f

reinforcemen

t t o M . Stru

m



# 7. P.1 0

From : Joh n Schweitze r To : Madeleine Stru m Date : 7/22/96 Time : 12:32:0 8 rag e to n



### Attachment

1 Pultrusio n Industr

y Counci l MAC T Standard s fo r Pultrusio n

Proposa l Resi n storag e Bul k resi n storag e tank

s shal l hav

e conservatio n vents . Mixin g an d transfe r tanks , an d reservoir s Mixin g an d transfe r tanks , an d reservoirs a t pultrusio n machines , shal l remai n covere d unles s material s ar c bein g added . Clearanc e o f 3/ 8 inc h pe r sid e shal l b e allowe d fo r mixin g shafts , fill-pipes , etc . Cleanin g operation s HA P solven t purchase

s (oilie r llia n reactiv e diluent s o r monomers ) shal l b e n o mor e tha n 0.01 5 pound s pe r poun d o f composit e produced . Pultrusio n operation s A Pultrusio n Emissio n Contro l Statu s (PECS) shal l b e calculate d monthly , fo r al l pultrusio n productio n fo r th e previou s 1 2 months . Fo r existin g sources , th e 12-month-moving-averag e PEC S shal l no t excee d 0.68. 1 Fo r ne wsources , th e 12-month-moving-averag e PEC S shal l no t excee d 0. 3 7. 2

1 A PEC S o f 0.6 8 i s th e averag e PEC S achieve d i n practic e b y th e Werne r Co.(p.38) , Bedfor d Reinforce d Plastics(1.0) , Creativ e Pultrusion(0.37) , Omega(0.65) , an d MMFC(0.98 ) facilitie s (located , respectively , i n Frankli n Park, III. , Bedford , Pa. , Bedford , Pa. , Aurora , Ohio , an d Bristol , Va.) . Thes e fiv e facilitie s ar e th e onl y pultrusio n majo r source s know n t o th e Pultrusio n Industr y Council . 2 A PECS o f 0.3 7 i s th e contro l achieve d i n practic e b y th e besNoontrolle d o f thes e fadlitie s (Creativ e Pultrusions , Bedford , PA) . 1 pictmact003/)ul y 22,199 0



# 7. P.1 1

From : Joh n Schweitze rTo : Madelein e Stru m Date : 7/22/9 6 Time : 12:32:3 5 Pag e 3 o f 9

4.1 . I h e PhC S i s th e weighte d averag e o f th e Contro l l-actors fo r eac h o f th e contro l technologie s employe d durin g th e reportin g period . Th e Contro l Factor s ar e weighte d b y di e amoun t o f styren e (o r othe r HAI * monomer ) processe d wit h eac h o f th e contro l technologies . Th e formul a fo r calculatin g PrC S i s a s shown :

Wher e PECS = Pultrusio n Emissio n Contro l Facto r

sp t = amoun t o f styren e o r othe r HA P monome r processed , fo r eac h contro l technolog y

. cf t = contro l facto r fo r eac h contro l technolog y 4.2 . Contro l Technologie s Fo r pultrusion , MAL I i s an y combinatio n o f direc t di e injection , prefor m resi n injection , we t are a enclosures , ai r flowmanagement , an d "n o control,' ' a s lon g a s th e PEC

S meet s o r exceed s th e require d level . Othe r contro l method s ma y b e employed , a s lon g a s th e sourc e ca n demonstrate , t o di e satisfactio n o f its permittin g authority , tha t suc h othe r method s achiev e a leve l o f emissio n reductio n at . least , as stringent , a s th e MACT . Direc t di e injectio n i s a pultrusio n syste m i n whic h th e reinforcement , enter s th e applicatio n syste m dry . We t reinforcemen t i s no t expose d t o ai r prio r t o bein g cure d i n di e die . Prefor m resi n injectio n i s compose d o f reinforcemen t saturatio n (we t out ) chambers . Th e we t ou t occur s withi n th e enclose d chamber s b y pressurize d resi n mixe s transferre d t o th e chambe r withou t ai r exposure . Afte r exitin g th e saturatio n chambers , th e we t reinforcemen t ma y b e expose d t o th e air , bu t a maximu m exposur e o f 1 5 inche s o f we t reinforcemen t alon g th e directio n o f pul l i s permitted . Leakag e o r drip-of f o f exces s resi n i s permitte d a t th e saturatio n chambers , alon g th e we t reinforcement , an d a t th e die . However , leakag e fro m th e saturatio n chambe r shal l b e n o mor e tha n 1 % o f di e resi n processed . (Example : i f a pultrusio n lin e processe s 10 0 pound s o f resi n pe r hour , the n n o mor e tha n on e poun d pe r hou r ma y lea k fro m th e saturatio n chamber. ) Shrouds , covers , and/o r odie r device s ma y b e provide d aroun d th e saturatio n chamber s t o preven t contac t o f we t resi n wit h air , an d t o collec t leake d resi n an d retur n i t t o th e reservoir . Onl y resi n expose d t o freel y movin g plan t ai r shal l b e considere d a s leakage . We t are a enclosure s ar e designe d t o preven t di e contac t o f free-flowin g ai r wit h we t resin . Th e enclosur e wil l b e designe d t o cove r th e top , bottom , sides , an d end s o f th e are a i n whic h reinforcement s ar e we t out , an d di e are a i n whic h we t reinforcement s ar e movin g towar d th e die . Th e enclosur e wil l b e fit t o th e di e entranc e o r radi o frequenc y (RF) prehea t unit . A covere d resi n bat h ma y functio n a s par t o f th e endosure . Acces s panels , doors , hatches , o r flexible curtain s shal l b e considere d par t o f ih e enclosur e provide d the y ar e designe d t o fit . Ther e wil l b e n o ope n flo wo f resi n int o o r ou t o f th e endosure . Opening s t o allo wdry reinforcemen t t o ente r th e endosur e may b e n o large r tiia n th e dimension s o f thos e reinforcement s plu s 3/ 8 inch . Ports fo r leve l contro l devices , monitorin g 2 pictmact003/)ul y 22,199 C 

# / oP.1 2

From : Joh n Schweitze r To : Madelein e Stru m Date : 7/22/9 6 Time : 12:33:1 8 rage4oi » . .

devices , agitatio n shafts , fil l hoses , etc. , shal l have h o mor e dia n 3/ 8 inc h pe r sid e dearance . Appropriat e measure s shal l b e take n t o protec t personne l fro m exposur e t o hazardou s atmospheres . Ai r flowmanagement , i s comprise d o f an y combinatio n o f shield s o r covers , ai r curtains , o r genera l ventilatio n design , whic h maintain s a n ai r velodt y o f 1 5 fee t pe r minut e o r les s a t thre e inche s abov e th e wet . reinforcemen t Ai r flo wi s measure d b y on e o f tw o methods : 1 . A puf f o f smok e i s release d fro m a smok e pend l 3 inche s abov e th e exi t fro m th e resi n bath , an d th e distanc e travelle d b y di e puf f i n 4 second s i s measured . Repea t thi s measuremen t a t 3 inche s abov e th e entranc e t o th e die , an d a t 3 indie s abov e th e midpoin t betwee n th e bat h an d th e die . Th e averag e distanc e (ravelle d b y di e dire e smoke puffs i n 4 second s shal l no t excee d 1 foo t ( 1 foo t i n 4 second s i s 1 5 fee t pe r minute. ) 2 . I h e prob e o f a hot-wir e anemomete r i s hel d thre e inche s abov e th e exi t ofth e resi n bath , an d slowl y rotate d fo r on e minute . Th e instrumen t take s reading s ever y second , an d th e averag e fo r th e one-minut e perio d i s recorded 1 . I h e measuremen t i s repeate d a t th e cente r ofth e we t area , an d a t di e entranc e t o th e die . Th e averag e o f thes e thre e reading s shal l not . excee d 1 5 feet , pe r minute .

\Solomat . Mode l MP M 500 E Anemomete r (o r equivalent ) wil l perfor m th e one-secon d samplin g an d one-minute-averaging . (Soloma t telephone : 800-765-6628. ) 3 pictmact003fluly22,199 6


# ll— — —, P.1 3

From : Joh n Schweitzer To : Madelein e Stru m Date : 7/22/9 6 Time : 12:33:46 Page 5 o f 9

4.3 . Contro l Factors Fo r eac h contro l technology , th e Contro l Facto r represent s th e amoun t o f emission s remainin g afte r us e o f th e technology , compare d t o uncontrolle d operations. 4 I n general , th e Contro l Facto r fo r a give n technolog y i s calculate d b y di e formula :

. _Emissions wtth control

technology ' Emissions without

control
Fo r example , i f th e emissio n rat e fro m a n uncontrolle d operatio n wa s 0.9 2 pound s styren e pe r hour , an d i f th e emissio n rat e fro m productio n o f th e sam e par t usin g a We t Are a Endosur e wa s 0.3 8 pound s styren e pe r hour , dien : cf = P- H - 0.4 1 Jw 0.9 2

Fo r Direc t Di e Injectio n wit h les s tha n 5 poun d pe r hou r backflow , th e Contro l Facto r shal l b e 0.01 . To r Direct . Di e Injectio n wit h backtio wo f 5 poun d pe r hou r o r more , di e Contro l Tacto r shal l b e calculate d wid i th e formula :

* B Ibsjhourbacfifiow ***** * * Ibslhourtotal

resin processed
Th e Contro l Facto r fo r Prefor m Resi n Injectio n i s 0.15 . Th e Contro l Facto r fo r We t Are a Endosure s i s 0.41 . Th e Contro l Facto r fo r Ai r FlowManagemen t t o 1 5 ft/rnir i o r les s i s 0.53 . I h e Contro l l-acto r fo r "n o control " i s 1.0 .

"Th e Contro l Facto r i s no t usefu l i n estimatin g tota l emissions , sinc e mos t o f th e styren e processe d polymerize s an d remain s i n th e part . Rather , th e Contro l Tacto r i s onl y a n estimat e o f th e rati o o f controlle d t o uncontrolle d emissions . 4 pictmact003/July22,199 0



# llP. M

From : Joh n Schweitze r To : Madeleine Stru m Cite : 7/22/9 6 Time : 12:34:1 2 rag e o O T a

4.4 . Exampl e PfcC

S Calculatio n Assum e tha tfo

r th e mos trecen t1 2 mont h period , a pultrusio n fadlit y ha s ru n th e followin g product s wid i th e Control Technologie s shown : Product
. A B C D E Total s Contro l

Technolog y Di e injectio n Prefor m injecto r We t Are a Endosur

e Non e Ai rFlo w Managemen t Contro l Facto r 0.0 2 0.1 5 0.4 1 1. 0 0.5 3 Lbs.Styren e

Processe d 1,75 0 5,00 0 3,00 0 1,50 0 2,00 0 13,25 0 cf x s n

35 0 75 0 1,23 0 1,50 0 1,06 0 4,89 0 The n di e PECS

5 fo r liti s 12-motil h perio d woul d b e a s shown :

PECS 4,89 0 13,25 0 0.3 7

5 Thi s i s no ta n emission s estimate ; se e Footnote 4 . pictmacL003/Jul y 22,199 GP.1 5 JOH N SCHWEITZE R "51 1 66 8 470 9 p.e i 

## WERNE R CO . To Office Subject N.K . Cra

y Asst . Genera

l Mngmnt. Soloma tHotwir e Anemometer- Ai rFlo w Measurin g Instrumen t 

## Inter-Offic e Correspondenc e Attachmen t2 0 aie June 14,199 6 

### Jrorn G



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e Jin d wet-ou ttank . 3 ) Ove rwet-out . tank

* Th e hotwir e prob e i s slowl y rotated aboutcente rt o pic k up varying airdraft s o rcurrents . Mete r ha s automati c averagin g feature an d th e measurement

s w c mad e ove ron e minute . Averagin g features includ e on e sampl e pe rsecond .

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*

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# Anemomerer

n vues Precis-e n »in>petx) measurement s ar e vttft i fo r thos e mv.tfve d I n heatin g an d ventilation , ai r conditioning . f>l*n t mainf-oar-c o an d laboratories . Th e ho t wir e prob e menitor t th e coolin g o f a ho t wir e o « thermisto r t o measur e airspeed , whil e tn e van e prob e electronicall y monitor s ih e rotationa l tyeed n f a smal l propollat* . Th e smal l prob a az9

an d fas t respons e o f th o ho t wir o r-^hc \t idea l fo r monitorin g slo wai r flows , e.g . dr«f l detectio n if , clea n room s an d smal l ducts . Tw o hotwir e probe s ar e available ; you r choic e i s betwee n th e standar d 12 7 o r th e mor e versatil e 129 ; selec t eithe r th e telescopi c 129M3 X or Ui e flexibl e lZSOm fo r measurin g airflo wi n difficul t o r inaccessibl e placw . I h e traditiona l van a orob e Incorporate s a njggw J ronstr*)rtinn wit h specia l lo wfrictio n bearings . Choos e eithe r th e 28SMS X wit h telescopi c latiUl e uf Us e 2S8QN X wil h flexibl e sha* ! fo r measurin g overhea d duct s an d difficul t to reac h spots .

* i4W-76Si6lr t

\ 127MS X HOTWIRE : Fac t raeponca , compac t prob e decig n ari d lo wspee d sensitivit

y *Ho weas y checkin g o

f drafts , fur - •> hood s an d huma n comfor

t conditions . 1WM0 X . •a^-w-. o

~ - '

r ' 3*>iAtDll»B« d 2Wr.«ittended i -I* * 129GN X .••e k »i» A •j^a^^^^axa ^ 1*%*
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y (e,g . ductin g ta high-ris e buildings) . Thi s anemomete r ca n withstan d shoc k an o abuse . Th « 228MS X tdaseopi c handi * wllapse s t o a com t*t i step i fo r eas

y transpor t Th e flexibl e 229GN X allow s acces s t o overhea d grill e work . Th e detachabl e 04 1 i s a I mate r oxtontfo n f c bnt h th e 129GN X an d 228GNX . Rivin g •ye n greate r reac h wha n yo u nee d It . Sa « aeeessnrie s P*g *

Senso r RjnjeUlr»P»»iJ)tfw'

l fc/Wa- 'wl- (T*mperehw

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. :i_. P.1 8

From : Joh n Schweitze r To : Madelein e Stru m Date : 7/22/9 6 Time : 12:34:3 1 rag e / o i 9 

### Attachment

3
Jul y 29,199 6 To : Madelein e Strum , U S EP A Fr : Joh n Schweitze r Re : Pultrusio n Industr y Counci l Phas e I I Emissio n Stud y I n respons e t o you rreques t th e Pultrusio n Industr y Counci l i s please d t o provid e th e informatio n show n below
. A s yo u know , thi s informatio n wa s no t include d i n th e repor t o f th e Phas e I I study , an d it s omissio n wa s no t a n oversight
. Rather , th e PI C wa s concerne d tha t th e dat a woul d b e misused
. Th e Phas e I I stud y wa s designe d t o determin e th e relative effectivenes s o f variou s sourc e reductio n technologies , an d t o determin e wha t concentratio n an d quantit y o f styren e migh t b e collecte d i n a clos e captur e device
. Th e Phas e I I dat a i s no t suitabl e fo rus e i n calculatin g emissio n factor s fo rpultrusion
. T o generat e dat a fo rcalculatio n o f emissio n factors , th e stud y woul d hav e include d consideratio n o f ai rflo w condition s typica l o f a commercia l pultrusio n operation , change s i n lin e speed , par t geometry , configuratio n ofth e we t reinforcemen t an d th e dri p pa n o f expose d resin
. Th e processin g experienc e o f ou rmembe rcompanie s als o indicate s tha t styren e evaporate s fro m th e syste m o n a regressivel y slidin g scal e an d a n extensio n o f th e tim e perio d woul d definitel y b e required
. W e kno w fro m thi s stud y an d agai n fro m th e experienc e o f ou rmember s tha t thes e factor s coul d hav e a significan t impac t o n th e tota l tim e weighte d emission s o f a facilit y an d th e emissio n factor s derive d fro m same . Th e reportin g perio d bein g discusse d fo rth e MAC T standar d regardin g th e Pultrusio n Emissio n Contro l Statu s i s monthly
. Thi s timefram e ma y result , i n lowe remissio n factor s tha n wer e experience d durin g thi s controlle d experimen t W e als o kno w fro m thi s stud y tha t thes e contro l factor s hav e ver y significan t impact s o n emission s an d emissio n facto rcalculations
. N o singl e stud y ca n replicat e th e wid e variabilit y o f commercia l pultrusio n operations
. Th e Phas e I I stud y nevertheles s doe s giv e u s som e usefu l informatio n about , th e relativ e effect s o f severa l sourc e reductio n technologies
. I n realit y ther e i s n o "typical " pultrusio n line , becaus e o f wid e variabilit y i n th e speed , ai rflow , par t geometry , wet-glas s configuration , etc . Becaus e o f thi s fac t emissio n factor s mus t b e determine d o n a pe rsit e basis
. I h e PI C i s providin g thi s dat a i n th e spiri t o f cooperatio n wit h yo u i n th e preparatio n o f a MAC T standard
. W e respectfull y reques t tha t yo u d o no t distribut e thi s dat a beyon d thos e a t EP A wh o ar c directl y involve d i n th e MAC T developmen t proces s fo rpultrusion
. Th e PI C hope s tha t yo u understan d thei rconcer n tha t thi s dat a canno t accuratel y b e use d t o determin e a n emissio n facto rfo rth e purpos e o f ascertainin g whethe ro rno t a pultrusio n facilit y i s subjec t t o I itl e V permitting
.

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# nFrom : Joh n Schweitze r To : Madeleine Stru m Date : 7/22/9 6 Time : 12:35:1 4 P.1 9 Pag e 8 of 9

ro m th e repor t ofth e Phas e I I study :

*dhn. PI C Phas

e I I Ru n A,AA(avg. ) U,U U (avg. ) | -,. « , , ; G H 1 J Styrene

emille d — Ibs/h r 0.9 1 0.7 2
* 0.3 0 0.6 6 0.0 9 0.0 1 0.4 9



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From : Joh n Schweitze r To : Madelein e Stru m Date : 7/22/9 6 Time : 12:35:3 1 Pag e 9 o f 9

PI C Phas e I I Lmissio n Stud y —Styren e Calculatio n MMF G - Ladde rrai l profil e Measure d weight/ft. : 0.644 7 lbs Calculatio n o f fibe rconten t by weight : 10 0 (11 3 yiel d roving ) x 0.0029 5 lbs
. (wt
. o f 1-11 3 yiel d rovin g - 1 foo t long ) = 0.29 5 lbs/ft .^ ^ Continuou s stran d mats : 5.7 5 in
. + 5.2 5 in
. + 5.2 5 in
. width s = 16.2 5 tota l widt h 16.2 5 in
. x 0.005 2 lb s (wt
. 1 o z cs m 1 i n x 12ihf^O.d04 5 lbs/ft Tota l fibe rweight/foo t . 0.379 5 lb s > ? s ^ ^ ?tt * * * Calculatio n o f resi n mi x conten t b y weight : *'«*«- £ I \. 0.644 7 (profil e wl/fool ) - 0.379 5 = 0.265 2 lbs
. :» • M t Calculatio n o f styren e content , b y weight : -KtK- '!*"<» % Tota l weigh t o f resi n mi x = 124. 5 lbs
. •-. m ^m «*-
. Bas e resi n = 9 9 lb s @ 32.6 % styren e + I I b additiona l styren e (t o dissolv e Percadox16 ) 9 9 lb s / 124. 5 lbs
. = 79.52 % (resi n i n mix ) 79.52 % x 0.265 2 (resi n wt ) - 0.21 1 lb s (po!yester*tesi n pe rfoot ) 0.21 1 lb s x 32.6 % (styren e i n bas e resin ) = 0.0687136 ' lbs/ft 1 lb / 124. 5 lb s = 0.8%styren e •"••«• * ;* ' 0.8 % x 0.265 2 (resi n wl. ) = 0.0021 2 lbs
. addilionahslyren e (l o dissolv e P-16 ) 0.06878 6 lbs/ft + 0.0021 2 lbs/f t = 0.07090 6 lbs/ft ..(tota l styren e pe r1 ft lengt h o f profile ) ...,.., . j^
. 0.07090 6 lbs/f t x 2 ft/minute pul l rat e = 0.141 8 Jbs^ni n 0.141 8 Ibs/mi n x 6 0 minutes/h r= 8.5 1 lb s (styren e processe d pe rhour ) Bas e o n th e abov e calculations , th e estimate d styren e processe d pe rhou ri s 8. 5 pounds
. Thi s calculatio n is b y n o mean s exact , an d ma y b e subject , t o erro ro f ±10 % o rmore . • • • : -.^aemt

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