p. 1 

# OAR Box 1384 Prepped by Charmelle Mathews



## Document

Number: 

# 172 ) ll-E-13 2 Docket Number: 

# A-94-5 2

Printed 7/2/2008 8:42:09 AM

Sheet 172 of 264• / P. 2



### MEMORANDU

M TO : Madelein e Stru m U.S . EPA/ESD/CCP G FROM : Rober

t Jemiso n Pacifi c Environmenta

l Services , Inc . (PES ) DATE : Marc h 6 , 199 8 SUBJECT : Minute s o

f Januar y 5 , 199 8 Meeting Betwee n EP A andRepresentative s o

f th e Reinforce d Plastic/Composite s Industr y LOCATION : EPA/Mutua l Building , Durham , NC , 10t h floor 12:0 0 p m- 4:0 0 p m ATTENDEES : Mr . Perr y Bennet t Ms . Alic e Boomhowe

r Ms . Lind aChappell Mr . Chuck

Elkin s Mr . Rober

t Haberlei n Ms . Lind aHerrin g Mr . Rober

t Jemiso n Mr . Bo b Lacovara Mr . Steve McNally Ms . Ja n Meye r Ms . Melani e Procto r Mr . John Schweitze

r Ms . Madeleine Stru

m MFG Justi n Tanks , Inc . (440 ) Amoco , Inc . (312 ) EPA/AQSSD/ISE G (919 ) Jelinek , Schwart

z & Connolly , Inc . (703 ) Engineerin g Environmenta l (410 ) EPA/ESD/CCP G (919 ) PE S (919 ) Composit e Fabricator s (703 ) Associatio n (CFA ) CF A (703 ) EPA/ESD/CCP G (919 ) PE S (919 ) Composite s Institut

e (CI ) o f th e (313 ) 994-520 7

856-232 6 541-286 4 312-854 0 268-736 7 541-535 8 941-033 3 525-051 1 525-051 1 541-525 4 941-033 3 668-470 3 Societ y o f th e Plastic s Industr

y (SPI ) EPA/ESD/CCP G (919 ) 541-238 3

### Madelein e Strum

Marc h 6 , 199 8 Pag e 2 PURPOS E Th e purpos e o

f th e meeting wa s fo

r representative s o

f th e reinforce dplasti c composite s industr y and EPA representative s t o discus s variou s issue s concernin g th e MAC T Standard for th e reinforce d plasti c composite s industry . Mr . Schweitze r an dMr . McNally provide d tw 6 document s describin g thei r concern s an

drecommendation s regardin g thes e issue s prio r to th e meeting . Th e documen

t provide d b y Mr . Schweitze r i s entitle d"Feasibilit

y of MAC T for

Ope n Molding - Discussio n o

f Industr y Position " andi s enclose dwit h thi s documen

t a s Attachment

1 . Th e documen

t provide d b y Mr . McNall

y i s entitle d"A

n Approac h t o th e MaximumAvailabl e (sic ) Contro l Technolog y fo r th e Polyme

r Castin g Sub-Categor

y of th e Reinforce dPlasti c Composite s NESHAP " an

d i s enclosedwit

h thi s documen

t a s Attachmen

t 2 . Th e agend afo

r th e meetin g wa s provide d b y Mr . Schweitze r andi s enclose dwit

h thi s document

a s Attachment

3 . DISCUSSION Th e firs t issu e discusse d wa s th e MAC T model fo r th e open moldin g proces s grouping . Mr . Schweitze

r inquire d if

th e EP A ha dreache dadecisio n o n which emissio n model i t wa s going to us e fo r th e ope n moldin g proces s grouping . Ms . Strumindicate dtha t th e emissio n model presente d a

t th e Decembe

r 8 , 1997 meeting betwee n EPA andindustr y representative s woul db e used . Mr . Schweitze

r inquire d i

f th e emissio n model wouldb e use di n conjunctio n wit h th e MAC T databas e to detennin e th e MACT floor s fo r th e open moldin g proces s grouping . Ms . Stru mindicate d tha

t th e MAC T floor s woul db e determine di n thi s manner . Mr . Schweitzer furthe r inquire d i f ther e wer e an y othe r use s o f th e emissio n model . Ms . Stru mindicate dtha

t th e mode l i s apoin t

valu e systemdesigne dto assig n point value s to emissio n reductio n technique s which facilitie s would us e t o determine complianc e wit h th e MACT standar

dfo r th e ope n moldin g proces s grouping . Mr . Lacovar ainquire d i

f th e poin t value s wouldb e expresse di n unit s of lb s HA P emitted/to n o

f resi n consumed o r

a n alternativ e systemo

f units . Ms . Strumindicate dtha t th e unit s woul d probably b e lb s HA P emitted/to n o

f resi n consumed . Ms . Strumaddedtha t i t shoul d b e remembere d that , in spit e o f thi s systemo

f umts , th e model i s apoint valu e systemdesigne d t o determin e complianc e an d shoul d no t

b e use dt o estimat

e facility-specifi c emissions . Mr . Lacovar ainquire d i

f AP-4 2 emissio n factor s woul db e use dt o estimat e emissions . Ms . Stru m indicate d that

emissio n factor s fro

mAP-4 2 wouldno t

b e use dto estimat

e emission s fromope n molding , bu t

ma y b e use d fo

r other processes . Ms . Strumadde dtha t som e sourc e specifi c emission s datao r

emission s information fro

mEP A Region I

V ma y b e use dt o estimat

e emissions . Ms . Stru mindicate d tha

t i t i s als o possibl e tha

t th e EP A woul dus e th e MAC T mode l fo r nationwide emissio n estimates , bu t woul dstate tha

t i t shoul dno t

b e use dfo

r estimatin g facility

P. 3



# 2 <P. 4



### Madeleine Strum Marc h 6 , 199 8 Pag e 3 specifi c emissions . Mr . Lacovarareplie dtha t th e industr

y wouldb e uncomfortabl e wit h usin g EP A Region I

V information becaus e i

t didnot thin k suc h information wouldb e representativ e of th e industry . Ms . Boomhowe

r inquired as t

o th e scop e an

dapplicabilit

y o f th e model bein g discussed . Ms . Stru mindicate d tha

t th e model wa s applicabl e to th e open moldin g subcategor y whic h consist s ofth e followin

g processes : bucke

t & too l application , mechamca l resi n applicatio n (spra

y lay-up , flo w coaters , an

d pressure-fe drollers) , filamen t windin g andgel coa

t application . Ms . Boomhowe

r inquire d a s t o how th e MACT floor s woul db e determined . Ms . Stru mreplie d that the MACT floors woul

d b e determined b

y using experimenta

l dat aan dtheor y to creat e th e MAC T model and then applying th e MACT model to th e informatio n containe di n th e MAC T databas e to ran k th e facilities . Mr . Haberlei n inquired whic h curv e i n the MACT mode l wouldb e use dwhe

n th e facilit

y used flo w coaters . Ms . Stru

mreplie d tha

t th e non-spra

y curv e generate dusin g CF A Phas e I data fo r bucke t & too l applicatio n would b e th e appropriate curve . Mr . Haberlei n replie dtha t thi s represente d achang e fromth e previou s model presente db y th e CF A whic h use dth e atomize d spra y curv e to determine th e initia l level o f emission s fo

r agiven HAP content

an dthe n applie d acontro l factor

t o accoun

t fo r th e emissio n reductio n obtaine dfromusin g aflow coater o r pressure-fe d rolle r

t o appl y th e resi n instea

dof an atomize dspra

y gun . Ms . Strumreplie d tha t thi s di d represent

such achange . Mr . Lacovar ainquire d whethe r th e MAC T floo

r fo r th e bucket

& too l applicatio n wa s lower (mor e stringent) tha

n fo r mechanica

l spra y application . Ms . Strumindicate dtha t th e MAC T floor

fo r th e bucket

& too l applicatio n i s probably lower tha n fo r mechanica

l spra y application . Ms . Strumfurthe r indicate dthi s ma

y b e du e to th e wid

e us e o f vapor suppressant s an d lowe r HA P resin s by thos e facilitie s tha t compris e th e bucke

t & too l applicatio n MAC T floor. Ms . Stru madded tha

t som e ofth e facilitie s tha

t compris e th e mechanica

l spra y applicatio n MAC T floor stil l us e atomize d mechanica l spra y applicatio n which result s i n higher emissions . Mr . Lacovaraindicate d tha

t th e CFA' s origina

l proposa l wouldencourag e facilitie s to switc h from atomized mechanica

l spra y applicatio n to non-atomize dmechanica l spra y applicatio n usin g flow coater s o r pressure-fe d rollers . Ms . Strumreplie dtha t th e previou s EP

A approac h woul d als o hav e encourage d suc

h achange . (Not

e tha t th e current

EP A approach i s the sam

e a s th e industr

y approach. ) Ms . Stru

mals o noted tha

t wit h the industr

y approach ther

e was no incentiv e t o mov e fro matomize d mechanica

l spra y applicatio n to lowe

r emittin g bucket

& too l application . Mr . Schweitze r indicate d tha

t suc h amove wouldb e a"backwar dstep " fo r afacilit y du e t o adecreas e in the facility' s maximu

mproductio n rat

e an dwouldtherefor

e not occur . Ms . Strumagree d and noted tha t thi s would b e arational e fo r considering bucke

t & too l application a s aseparat e proces s groupin g frommechamca

l no n spra y application . 

# 3P. 5



### Madelein e Stru

m Marc h 6 , 199 8 Pag e 4 Th e next

issu e discusse d involve dpossibl e alternative s tha t facilitie s coul dus e t o demonstrate complianc e wit h th e MAC T standard . Mr . Schweitze r inquire di

f a"well-run " facility , i.e.

- on

e tha t managed ai

r flows an duse dgoodhousekeeping practices , coul dus e emissio n testin g dat ato compl

y wit h th e standard . Ms . Strumindicate dtha t emissio n tes t

dat acoul d possibly b e use d o n acas e by cas e basi s bu t onl y if th e facilit y wa s usin g ane

w technolog y t o reduc e emission s and no t

fo r technique s alread

y covere dby th e MAC T model . Ms . Strumstate d he r concer n tha t if emissio n testin g wa s allowe dt o demonstrat e complianc e wit

h th e MAC T standard , the n facilitie s may , fo r example , conduc t

testin g wit

h shorter ge l time s o r

greate r laminat e thicknes s than thos e use d t o set th e MAC T standard . Ms . Stru madde dthat EP A wil l hav e t o wor

k o n developin g acase-by-cas e procedure tha t wil l ensure tha

t th e new technolog y use d b y afacilit

y doe s no t

achiev e it s emissio n reduction s b y modifying parameter s suc h a s shorter gel time s o r

increasin g laminat

e thickness . Mr . Schweitze r indicate dhi s concern abou t th e MAC T standar

d limitin g long-ter

mopportunitie s fo

r th e us e o

f ne w emissio n reductio n technologies . Ms . Boomhowe r inquire da s t o whic h parameter s coul dno t b e altere dwhe n a facilit y want s to us e emissio n testin g t o sho w tha t us e of anew technolog y result s i n complianc e wit h th e MAC T standard . Ms . Strumreplie dtha t thos e parameter s include dge l time , laminate thickness , ai r

flow, applicatio n rate , andoperato r technique . Mr . Lacovar

astated tha

t th e curve s (equations ) tha

t compris e th e MAC T Model represent averag e emissio n value s sinc e the y are base do n averag e parameter s fo r ge l time andlaminate thickness . Mr . Lacovarathen inquire di f it wa s reasonabl e fo

r afacilit y t o us e stac k

testin g t o demonstrat

e complianc e i

f ever y paramete

r (gel time , laminat

e thickness , etc ) were optimize d to reduc e emission s belo w th e averag e valu e show n b y th e curves . Ms . Stru mstate dhe r concern that eve n i f afacilit y optimize d it s parameter s t o reduc e emission s durin g th e tes t procedure , i t would b e difficul

t fo r enforcemen

t personne l to determine whethe r thes e parameter s wer e kep t at a n optimal level o n acontinuou s basis . Ms . Strumaddedtha t sinc e suc h parameter s were no t use d t o determin e th e MACT floor, they shoul dno t b e use dfo

r compliance . Mr . Lacovar a indicated tha

t th e MACT standar

d shouldcontain aprovisio n fo r emission s testin g tha

t wil l allo w afacilit y t o demonstrat

e tha t th e facilitie s emission s wer e well belo w thos e predicte db y th e model . Ms . Meye

r indicated tha

t such aprovisio n wouldhav e to specif y tha t afacilitie s emission s wer e significantly belo w th e model . Ms . Meyer continue db y statin g tha

t significantly ma

y b e define d a s emission s tha

t are 1/1 0 o r

x 

### h thos e predicte db y th e model s o ther e i s reasonabl e confidenc e tha

t actua l performanc e i s better

than th e model . Mr . Lacovar aindicate d that requirin g such alarg e differenc e betwee n th e model an dth e facilitie s emission s ma y b e makin g th e cas e b y cas e demonstratio n to o restrictive . Ms . Herrin g statedtha t sectio n 112(h

) o f th e Clea n Ai r Ac t would requir

e tha t EP A conduct a n equivalency determinatio n o n acas e b y cas e basi s fo r eac h ne w technology an

d then amen

d th e rul e in th e Federa

l Registe r unles s th e MAC T standard specified acas e b y cas e approva l procedure . Ms . Herrin g continue db y statin g tha t i t woul d b e desirabl e if

EP A coul d develo

p such aprocedur

e to avoi dhaving t o amen

dth e rul e fo

r eac h ne w technolog y whil e a

t th e sam e tim e ensurin g tha

t an y procedur e developedwoul donl

y approv e new technologie s tha

t produce d real emissio n reduction s andmee t EP A criteri aregardin g rul e 

# 1P. 6



### Madeleine Stru

m Marc h 6 , 199 8 Pag e 5 enforceability . Ms . Boomhowe r indicate dhe r

concer n tha t if th e case-by-cas e procedur e for a ne w technolog y wer

e mad e plant specific , i t

wouldb e difficul

t fo r acompan

y t o develo p and market ane w emission s reductio n technology . Ms . Herrin g replie dtha t th e case-by-cas e equivalency determinatio n would no t necessarily b e plant

specific . Mr . Bennet

t inquired i f afacilit y wouldb e considere da

n existin g sourc e o r

ane w sourc e i f the facilit y tha t conduct s a

n ope n molding proces s prio r

to th e rul e promulgatio n change s t o a close d molding proces s afte r th e rul e i s promulgated . Mr . Bennet t continue db y statin g tha

t i f suc h afacilit y would b e considered ane w sourc e it

ma y b e discourage dfromchanging du e t o th e being subject

t o asignificantl

y tighter standard , even though it

ha dreduce dit s emission s b y u p to 90% . Mr . McNall

y indicate d hi s belief

tha t man y Stat e permit s woul dtreat

th e facilit y a s a n existin g source . Ms . Strumindicate dtha t th e EP A di dno t wan t t o discourag e facilitie s from changin g to close d molding . Ms . Stru mcontinue db y statin g tha t facilitie s coul dbenefit

from changin g to close d molding i n tha t thos e facilitie s coul dus e resi n system s wit h asignificantly highe r HA P content

tha n woul d b e possibl e wit

h open molding . Ms . Meyer indicate dthat

thi s ma y b e a n issu e tha t ca n b e accommodate

di n draftin

g th e rule . Ms . Herrin g indicate dtha t if th e EP A allowed facilitie s t

o chang e fromope

n molding to close dmoldin g without bein g considere d ane w sourc e i n th e fina

l rule , ther

e wouldhav e to b e aprovisio n requirin g facilitie s t o notif y th e EP A whe n such achang e occurred . Mr . Bennet t statedtha t ther e i s atren dwithi n th e reinforce d plasti c composite s industr y t o chang e to close dmolding to reduc e worker exposure to hig h ambien t level s of HAP . Mr . Bennet

t addedtha t it wouldb e undesirabl e fo

r th e rul e t o discourag e th e continuatio n o

f tha t trend . Th e nex t issue s discusse d pertaine dt o th e us e o f vapor suppresse dresi n systems . Mr . Haberlei n asked i

f th e value s obtained fromthe vapo r suppression effectivenes s tes t wouldb e use d wit h bot h th e atomized an

d non-atomizedmechamca

l spra y applications . Ms . Stru

mindicate d tha

t th e tes t would b e use d fo

r bot h atomizedan

dnon-atomizedmechamca

l spra y applications , bu t

th e value s obtaine d fromth e tes t would b e use di n differen t equation s i n th e model (base do n th e proces s th e vapor

suppressed resi n syste

mi s usedin) . Mr . Haberlein askedi f vapo r suppressant s woul d b e take n into accoun t when determinin g th e MACT floors. Ms . Strumreplie di n th e affirmative an

d stated tha

t ther e wer e anumbe r o f possibilitie s as t

o how vapo

r suppressant s coul d b e take n into accoun

t whe n determinin g th e MAC

T floor. Ms . Stru

mcontinue db y statin g th e possibl e option s wer

e t o tes t th e vapor suppresse dresi n system s o f th e companie s tha

t compris e th e MAC T floor

o r to us e amutuall

y agreedupo n suppressan t effectivenes s valu e when determining th e MAC

T floor. Mr . Lacovar

aindicatedtha

t it wouldtak e anumbe r o f month s to obtai n th e resin s fro

mth e variou s facilities . Ms . Stru mindicatedtha

t such adela

y woul d b e deleteriou s t o EPA' s schedule fo r promulgatin g th e standard . Ms . Meye r state dtha

t anothe r optio n ma y b e t o assum

e avapo r suppressan

t effectivenes s value fo

r the presen

t an dthen conduc t th e testin g a

t alate r date . Ms . Proctor

statedtha t anothe r option woul

db e to us e th e CFA Phas e U dat atha t wa s german

e to the effectivenes s o

f vapo r suppressants . Mr . Lacovaraindicate d tha t th e HAP content

ofth e vapo

r suppressedresi n systems testedduring the CF A Phas e I I testin g wa s 

# 5P. 7



### Madelein e Strum Marc h 6 , 199 8 Pag e 6 between 3 3 % an

d 48% . Mr . Lacovar

astatedhi s belief

tha t thi s rang e o

f HAP content

wa s typica

l o f th e industr

y an d a s such it

would b e reasonabl e to tak e th e averag e suppressant

effectivenes s valu e fromthi s rang e and us e thi s valu e t o help determin e th e MAC T floor. Mr . McNall y inquire d i f th e EP A assumed tha

t facilitie s tha

t reporte dusing vapor

suppressant s wer

e usin g them for al l o f thei r resi n systems . Ms . Procto r indicate dtha

t facilitie s were give n credi t fo r usin g vapo r suppressant s depending o n wha t percentag e o

f the resi n system s use dby th e facilit y actuall y containe d vapor

suppressants . Ms . Stru minquire d abou

t the preliminar

y tes t run s o f th e vapor suppresse dresi n tes t

and an y result s obtaine d i n thes e preliminar y tes t runs . Mr . Lacovar aindicate dtha t th e industr

y conducte d tw o preliminar

y tes t run s but h e di dno t

yet receiv e th e tes t

results . Mr . Lacovar a added tha t he would provide EP

A wit h the result s o

f thos e tes t run s a s soo n a s he receive dthem . Th e nex t issu e discusse d pertaine dto th e dataverificatio n effort s currentl y bein g carrie d out by th e EPA . Ms . Boomhowe r inquire da s to th e curren t

stat e o f th e dataverificatio n effort s bein g conducte d b y EPA . Ms . Stru mindicate dtha

t th e EP A i s i n th e proces s o

f updatin g th e MAC T databas e wit

h informatio n concernin g HA P conten t andflow-coater/pressure-fed rolle r usag e fo r thos e facilitie s i n th e MACT floor. Ms . Stru maddedtha

t information fo

r facilitie s ma

y als o b e update d i

f EP A obtain s informatio n from apermi t o r a n indicatio n tha

t afacilit y ma y b e usin g acontro l device . The nex t issue s discussed pertaine dto the distinctio n between corrosio n resistant and non corrosio n resistant

product s an

d resi n systems . Mr . Schweitze r inquire da s t o when th e MAC T floor fo r corrosio n resistant

application s woul db e finalized . Ms . Strumindicate dtha t EPA' s current schedule dictate d tha

t the MACT floor

fo r corrosio n resistan

t application s b e finalize d b y Jul y 8 , 1998 . Mr . Haberlei n asked ho w th e EP A decidedto separat

e facilitie s into th e corrosio n resistan t and non-corrosio n resistant subcategories . Ms . Stru mindicate dtha t th e EPA use d industry' s definitio n base d o n resi n typ e an dals o considere dwhethe r facilitie s classifie d themselve s a s corrosio n resistant o r not . Ms . Procto r

state dtha t EP A ma y als o hav e t o loo k

a t the end produc t

i n additio n to th e resi n typ e becaus e afacilit y ma y chos e aresi n systemdefined by industr y as corrosio n resistan

t fo r othe r desirabl e material s propertie s (i.e . strengt h properties) . Mr . McNall

y state d tha

t it ma y b e difficul

t to attemp t

to compil e alis t

of endproduct s and the n classif y themas corrosio n resistan t or non-corrosio n resistant . Mr . McNall y continue db y statin g tha t corrosio n resistant

resi n system s are usually mor e expensiv e an

da s such afacilit

y woul d b e unlikel y t o us e acorrosio n resi n systemunles s absolutely necessary . Ms . Procto r note d tha t a vagu e corrosion-resistant

definition tha

t onl y relie s o n resi n typ e an

dsom e ver y genera l produc t requirement s ma

y no t b e desirabl e becaus e th e corrosio n resistant definitio n woul db e use d t o determin e th e poo l o

f facilitie s tha

t determine s th e MACT floor. Ms . Procto r adde dtha

t i f th e 

# QP. 8



### Madeleine Strum Marc h 6 , 199 8 Pag e 7 facilitie s mee

t the corrosio n resistan

t definition (due to vagueness ) tha t do no t really belon g i n th e corrosio n resistant

MAC T databas e the

y coul dend u

p settin g th e MAC T floor fo r corrosio n resistant applications . Mr . Bennet

t inquired ho

w EP A woul dclassif y afacilit y tha t use dbot h corrosio n resistan t an d non-corrosio n resistan

t resi n systems . Ms . Proctor replie dtha

t th e facilit y wouldb e include d i n bot h th e corrosio n resistant

an d non-corrosio n resistan t

MAC T databas e andth e corrosio n resistant an d non-corrosio n resistant

system s use dby th e facilit y woul db e subjec t

t o differen

t standards . Mr . Bennet

t inquired i f all viny l este

r resi n system s were considere dto b e corrosio n resistant . Ms . Procto r

replie d tha

t i n genera l tha t wa s th e cas e bu t

i n certai n instance s th e combinatio n o

f resi n typ e an

d produc t fabricate dwer

e th e decidin g criteria . Ms . Boomhowe r inquired a s to whethe

r th e EP A consideredblendedresi n system s to b e corrosio n resistant o r non corrosio n resistant . Ms . Stru mindicatedtha

t th e EP A ha dconsidere dblende dresin s system s to b e non-corrosio n resistant

unles s th e facilit

y classifie ditself

a s corrosio n resistant . Ms . Boomhowe

r indicated he

r understandin g tha

t th e industr

y definitio n wa s atw o part definitio n tha

t considere d bot

h th e typ e o

f resi n systeman

dother factors . Mr . Schweitze

r indicated tha

t th e definition did contain requirement s tha t product s mee

t certai n AST

M standards . Ms . Stru mrequeste d tha

t industr y representative s attempt

t o revis e th e secondpar

t o f th e industr

y definition fo

r corrosio n resistance . Ms . Stru mindicate dtha

t on e possibl e clarifyin g step woul d b e to divide th e corrosio n resistan t subcategor

y int o tw o separat

e subcategorie s such a s corrosio n resistant subcategor

y A an d corrosio n resistant

subcategor

y B wher e subcategor

y A represent s a higher leve l o f corrosio n resistanc e tha

n subcategor

y B . Mr . Haberlei n indicate dtha t a n examinatio n o

f industr y corrosio n resistant

guide s ma

y aidi n th e developmen

t of aclea r definition . Mr . McNall

y indicate d tha

t attempting to defin

e corrosio n resistanc e base do n th e type s of environment s an

d product s aresi n syste

mca n withstan dma

y b e ineffective . Mr . McNall y continued by citing a

n example wher

e aresi n syste

mwas abl e to withstandanumber o f aggressiv e chemica

l product s but

failedwhe

n teste dwit

h distille dwater . Ms . Meye r indicate d he r concern tha

t th e definitio n shoul db e clea r enough to b e easily use db y th e applicabl e regulator y agencie s permittin g an

d enforcemen

t personnel . Mr . Lacovaraindicate dhi s concer n that th e ne w definitio n should no t

adversel y impac t (change ) th e MACT floor by includin g a numbe r o f peripheral product s largely unrelate dto th e majorit y o f product s currentl y i n th e corrosio n resistan t

subcategory . Mr . Lacovaracontinue dby statin g tha t anumbe r o f product s ma y b e constructe d o

f resi n systems tha

t ar e bot h corrosio n resistan

t an dnon-corrosio n resistant , suc h a s whe n th e produc t ha s a n oute r laye r tha t i s designe dt o b e corrosio n resistant . Mr . Lacovar afurthe

r indicate d tha

t thi s ma y mak e compiling alis t

o f corrosio n resistant

andnon corrosio n resistan t

product s difficul

t an dinappropriate . Th e nex t issue s discusse d pertaine dt o th e us e o

f ge l coats . Mr . Lacovarainquire d a s to th e siz e o f th e gel coa

t database . Ms . Proctor

indicatedtha

t the gel coa

t databas e containe d more tha n 20 0 facilities . Ms . Stru mindicate dtha

t there wer e actuall y tw o database s wit

h th e firs t 

# nP. 9



### Madelein e Stru

m Marc h 6 , 199 8 Pag e 8 databas e containing dat

afromth e origina

l 199 3 screenin g survey s (sent t o al l know n facilitie s i n th e industry ) an

d the secon

d databas e containing dat

afromthe 1997 informatio n collectio n reques t (sent t o nin e companie s who responde dt o th e origina l 199 3 screenin g survey) . Ms . Stru m continued by stating tha

t the secon d surve y wa s sen t to th e nine companie s s o tha t th e EPA coul d determin e apound HAP per gallo n o f resi n limit . Ms . Strumfurthe r state dthat , i n retrospect , EPA decide d no t

to specif y apound HA P pe r

gallo n o f resi n limi t

becaus e it

coul dno t

b e incorporate d into th e averagin g approac h propose db y industry . Mr . McNally inquire d i

f th e EP A wa s plannin g to differentiat e betwee n clea

r and pigmented gel coats . Ms . Stru mindicatedtha

t ther e ma y b e differen

t MAC T floors fo

r clea r and pigmented gel coats . Ms . Struminquire di f there wa s an

y differenc e betwee n clea

r ge l coat s o r i f all clea r gel coat s wer

e essentially th e same . Mr . McNally replie dtha t no t al l clea r ge l coat s are th e sam

e du e t o the fac t tha t som e clea r gel coat s are use dfo

r sanitar y application s and thes e type s o f clea r gel coat s diffe

r fromthos e use di n the boating industry . Mr . Lacovar astate d that , i n general , clea

r gel coat s are mad

e fro miso-neopenty l glyco l type s of resin s becaus e o

f difficultie s wit

h makin g th e gel coat s clea r usin g othe

r resi n systems . Ms . Strumstate dtha t i t ma y b e difficul

t t o se t differen t floors fo r clea r an dpigmente dgel coat s sinc e facilitie s ofte n di d no t distinguis h between their

usag e o f clea r an dpigmentedgel coat s whe

n respondin g t o th e 199 3 screening survey . Mr . Jemiso n stated tha t onl y on e facilit y indicatedusin g aclea

r gel coa t i n th e response s to th e 1997 informatio n collec t request . Mr . Lacovaraindicate dtha t ther e were essentially onl

y fou r majo r gel coa t manufacturer s an

dit shouldb e relatively eas y t

o obtai n up-to dat e informatio n o n typica

l gel coa t usag e andHAP content . i 

### Ms . Stru mindicated tha

t the EP A obtainedinformation fromtw o facilitie s indicatin g non spra y applicatio n o

f gel coats . Mr . Lacovarastate d tha t gel coa t coul db e applie db y non-spra y applicatio n i n certai n cases . Mr . Jemiso n note dtha t bot h o f th e facilitie s were i n th e corrosio n resistant database . Mr . McNall

y statedtha

t the ge l coa t use din such instance s ma

y b e agel coa

t formulated "in-house " rather tha n amanufacture

r suppliedgel coat . Mr . Lacovarastate dtha t th e facilitie s ma

y b e applying aresi n syste

ma s acosmeti c finish using bucket an dtoo l applicatio n and describin g such aresi n syste mas a"ge l coat. " Ms . Strumstate dtha t th e facilitie s indicate d tha t the y were applyin g th e gel coat s usin g aflow coater . Mr . Lacovarastate dhi s belie f tha t it wa s impossibl e to appl

y agel coa

t usin g aflo

w coate r due to th e uneven stream s o f gel coa t tha t would resul t fromusin g such adevice . Mr . Jemiso n indicate dtha t h e questione dth e individual s carefull y when the

y indicated us e o

f aflo w coater to appl y agel coa

t an dthes e individual s were persistent i n their statement s concerning th e us e o f flow coater s t o appl

y gel coats . Mr . Jemiso n als o state d tha

t there ma y b e difference s i n th e term s tha t individual s us e when referrin g t o ge l coat s and flow coater s an d it ma y b e helpfu

l fo r industr y representative s t o spea

k t o th e tw o facilitie s to verif

y th e informatio n th e EP

A ha s obtained . Mr . Lacovaraindicate dtha t industr y would b e willin g to spea

k wit h the tw o facilitie s t

o ascertai n ui e accuracy o

f the information . Ms . Stru mindicate d tha

t EP A coul d provid e th e telephon e contac t report s containin g th e relevan t information . 

# < 6P.1 0



### Madelein e Stru m Marc h 6 , 199 8 Pag e 9 Mr . Lacovaraasked i f th e EP A wouldus e th e sam

e non-spra y curv e fo

r flow coater s applyin g gel coat s a s woul

d b e used fo

r flow coater s applying resi n systems . Ms . Stru mindicate d tha t it ma y b e necessar

y to us e adifferen

t curv e sinc e ge l coat s normally produc e greate r emission s tha

n resi n systems . Ms . Procto r raise dth e issu e of

wher e t o plac e facilitie s that

apply gel coa t by mean s othe

r tha n spra y gun (i.e . poure dgel coa t i n continuou s lamination) . Mr . Schweitze r indicate d tha

t th e gel coa

t i n thi s cas e shoul db e treate da s i f it wer e resi n fo r continuou s lamination . Ms . Proctor inquire da s t o wh

y gel coa t an dresi n shoul db e treate da s th e sam e whe n the y ar e used in the continuou s lamination proces s whe n gel coa t an dresi n are treate d separatel y i n th e atomized mechamca l spra y process . Mr . McNall

y state dtha

t th e emissio n potentia l of sprayed gel coa

t application i s differen

t fro mspraye dresi n applicatio n du e to , a t leas t i n part , th e layer s o

f ge l coa t being thinne

r tha n th e typica

l laminat e thicknes s o

f aresi n system . Mr . Lacovaraindicate d tha t it wa s du e t o th e greater

atomizatio n o

f th e ge l coa

t necessar y t o produc e amore attractiv e finish. Th e next issue s discusse d pertaine dto industry' s presentatio n o f apossibl e approac h t o MACT fo r th e polyme

r casting subcategory . Mr . McNall y briefl y reviewe dindustry' s proposal (Attachmen

t 2) . Ms . Stru

mindicated tha

t i t ma y b e inappropriat

e t o hav e acover

exemptio n fo

r vacuu mmixing sinc e i

t was he r understanding tha

t th e emission s woul dsimpl y b e evacuate d ou t o f the mixe r int o the atmosphere . Ms . Boomhowe r indicatedtha

t industr y representative s woul d investigat e vacuummixing furthe

r t o determin e if

tha t wa s indee dth e case . Ms . Strumindicate d tha

t sh e fel t th e propose dsiz e cutof

f of 5 5 gallon s belo w whic h covere d container s would no t b e require dwa s to o large . Ms . Stru mcontinue db y statin g that th e siz e cutof f fo r container s used in mixing , storag e an dtransfe r o f resin s tha t i s selectedshoul d tak

e into account

th e fac t tha t EP A i s plannin g t

o addres s mixing , storage , an dtransfer o f resin s a s separate subcategorie s rather tha n proposin g differen

t requirement s fo

r eac h process . Mr . McNall y indicated tha

t the size cutof

f selectedshould tak

e int o accoun t industr y diversit y an d tha t it would b e inappropriat

e t o impos e standard s o n ver

y smal l containers . Mr . McNall

y als o state d that th e languag e use d i n th e rul e shoul db e ver y specifi c s o a s no t

t o b e interprete d mor e stringentl y by enforcemen

t personne l tha

n was intende db y th e rule . Mr . Lacovaraindicated tha t h e fel t there shoul db e an exemptio n fromcovere dcontainer requirement s fo

r culture d marble mixing . Mr . Lacovaracontinue dby statin g tha t th e mixer had t o b e ope n fo

r th e operator

to pour i n pigment s use d in th e manufactur e o f th e culture dmarbl e produc t and observ e ho

w thos e pigment s ar

e distribute dthroughout

di e resi n system . Ms . Strum replie d b y statin g tha

t th e pouring o

f th e resi n systemint

o acontaine

r wa s differen

t frommixin g th e resi n systemi n acontainer . Ms . Procto r

suggested tha

t facilitie s coul db e contactedan daskedwha

t siz e container s they normall y cove r to detennin e the MAC

T floo r fo r mixing , storage , an

dtransfe r o f HAP containin g materials . Ms . Stru

mstated tha

t anothe r option wa s t

o se t acertai n siz e in th e propose drul e and 

# °\P.1 1



### Madeleine Stru

m Marc h 6 , 199 8 Pag e 1 0 me n ask fo r publi c comment . Ms . Meye r statedtha t EP A ha dto b e careful wit

h th e languag e to accoun t fo r time s when facilitie s legitimately needt o acces s th e mixer . Ms . Stru minquire d i

f asiz e cutof

f was necessar

y i f aprovisio n fo

r acces s to th e mixer

wa s included in the final rule . Mr . McNall y explaine dal l mixer s tha

t are larger tha t 5 gallon s coul d b e covere d a s long a s aprovisio n fo r acces s to th e mixe

r wa s include di n th e final rule . Mr . McNall y furthe r explained tha

t all container s including thos e tha t ar e smalle r tha n 5 gallon s coul d b e covere d whe

n the y ar e no t i n use . Ms . Struminquire di f th e acces s provisio n woul donly b e applicabl e to mixers . Mr . McNally an dMr . Lacovararesponde din th e affirmative . Mr . Lacovarastate d tha

t th e emission s fromopen container s are generally ver y low . H e adde dtha

t CF A collecte d emissio n datafroma n open five gallo n container whic h showe dver

y lo w emissions . Mr . Lacovaraoffered t o provid e thi s emission s datato th e EPA . Ms . Boomhowe

r inquire d i

f it wa s usefu l o r practica l to create arul e tha

t woul drequire enforcemen

t o n ever y five gallo n containe

r tha t was lef t uncovered . Ms . Meye

r indicate dtha

t on e possibl e optio n was to requir e amanagemen

t pla n o r standar doperatin g procedure tha

t require d cover s fo r thos e container s wit

h les s tha n five gallon s capacit

y rathe r than havin g eac h non covered bucket

represent aviolation . Ms . Meye

r continuedby stating tha

t ther e were o

f numbe r o f differen t way s acovere d containe r requirement

coul db e structure dand tha t al l meetin g participant s shoul d remembe r tha t there are severa

l possibl e approache s to thi s issue . Th e next issu e discusse d wa s th e current statu s o f EPA' s approac h t o MAC T fo r new sources . Mr . Schweitze

r inquire d i

f EP A planne dto conduc t

an y additiona

l analyse s fo

r ne w sources . Ms . Stru

mindicated tha

t no ne w analyse s wer

e planned . Ms . Procto r

indicate dtha

t th e onl y chang e tha

t coul d occu

r would b e i

n the magnitud

e o f the siz e cutof

f a s aresul t

o f analyzin g th e emission s dat

ao n continuou s lamination tha t th e EP A expectedto receiv e fromLASCO . Mr . Schweitze r indicate d tha

t th e curren t

siz e cutof f separatin g small ne

w source s fromlarg e new source s woul d requir

e acontro l devic e uia

t was mor e expensive tha

n th e entir e productio n facilit

y fo r certai n applicatio n technique s such a s open molding . Mr . McNally state dtha t ther e wa s a fundamenta

l dissimilarit

y betwee n th e open molding fabricatio n techniqu e andth e continuou s laminatio n fabricatio n techniqu e use d by th e facilit y upo n which th e siz e cutof f wa s based . Mr . Lacovar astate d tha

t continuou s laminatio n wa s a n automate dproces s usuall y requirin g a substantially larger

capita l investmen

t fo r ane w facilit y tha n ane w facilit y wit h simila r productio n capacit y which use d th e ope

n molding process . Mr . Lacovar aaddedtha

t thi s differenc e i n capita

l cos t result s i n adifferen

t level of feasibilit y fo r add-o n controls . Ms . Meye r stated tha t in th e pas t

EP A consideredthe similarit

y o f emissio n stream s rather tha n th e similarit

y o f applicatio n techniques . Ms . Stru mstate dtha

t EP A examine demissio n stream s i n th e pas t

rather tha n product s o r

material s throughput

becaus e emissio n stream s are easie r to analyze . Mr . Lacovar

astatedtha

t the emission s froma

n open moldin g facility , such a s America n Standard , wer

e dissimila r t o emission s from acontinuou s panel lin e anda s suc h i t ma y 

## (0P.1 2



### Madeleine Stru

m Marc h 6 , 199 8 Pag e 1 1 not b e reasonabl e to us e emission s from acontinuou s pane l lin e t o set th e siz e cutof

f separatin g small ne w source s fromlarg e ne

w sources . Mr . Schweitze

r indicate d tha

t industr y ha s concern s about

th e feasibilit

y o f th e MAC T standar d fo r ope n molding . Mr . Schweitze r continue db y statin g th e industry' s positio n tha t monome r conten t i s no t acontro l (particularly fo

r th e conosio n resistant

subcategory ) and tha

t facilitie s ma

y hav e problem s making product s i f th e MAC T floors are set

to o low . Actio n Item s fo

r Industr y Representatives : 1 . Provid e result s fro

mth e preliminar

y run s o f th e vapor suppressant

effectivenes s test . 2 . Provid e aclearer

definitio n o

f th e secondpar

t o f th e industr

y definitio n fo

r conosio n resistance . 3 . Investigat

e th e vacuu

mmixing proces s t

o determin e i

f emission s fro

mvacuummixin g are directl y evacuate d int

o th e atmosphere . 4 . Provid e arational e fo r th e siz e cutof

f belo w whic h mixin g container s d o no t requir e a cove r including a

n explanation o

f wh y there shoul db e an

y siz e cutof

f i f acces s to mixer s i s allowe d (i.e . t

o ad d ingredient s o r

to empt y th e mixer) . Actio n Item s fo

r EPA : 1 . Provid e industr

y representative s wit

h alis t o f product s tha

t meet th e industr

y defimtio n fo r conosio n resistanc e but

the EP A ma y no t conside r to b e conosio n resistan t

products . 2 . Provid e industr

y representative s wit

h th e tw o telephon e contac t report s documentin g conversation s wher

e reinforce dplastic/composite s facilitie s indicate dus e o f aflow coater to appl y agel coat .



# w12/31/9 7 13:2 4 ©91 9 34 1 568 9 EP A ES D CCP G P.1 3 @00 1

• - - ^



### Pleas e delive r thi s fa x to :



# Madelein e Stru m U S EP A

Tota l page s (incldg . cover) : 1 Problem s wit h thi s fax ? Cal l 313.668.470 3

Madeleine , pleas e seeth e attache d proposed agend a fo r ou r meetin g o r Jan . 5 , plu s ou r discussio n o n feasibilit y ofth e standard . Stev e McNall y wil l fax , o r brin g o n Monday , th e reference d discussio n oif i polyme r castin g an d polyme r concrete . Thanks , Joh n Schweitze r

^P. M

12/31/9 7 13:2 4 ©91 9 54 1 568 9 EP A ES D CCP G (2)00 2



### Pleas e delive r thi s fax to ; 

# Madelein e Stru m USEP A

Tota l page s (incldg . cover) : 1 9 Problem s wit h thi s fax ? Cal l 313.668.470 3

Madeleine , pleas e se e th e attache d propose d agend a fo r ou r meetin g o r Jan . 5 , plu s ou r discussio n o n feasibilit y ofth e standard . Stev e McNall y wil l fax , o r brin g o n Monday , th e reference d discussio n orj i polyme r castin g an d polyme r concrete . Thanks , Joh n Schweitze r

cc : Ja n Meyer , Stev e McNall y



# bP.1 5 : i ' ' 12/31/9 7 13:2 5 091 9 54 1 568 9 EPAES D CCP G 1000 3

Joh n Schweitze r Technica l Directo r Composite s Institut e

Regiona l Offic

e 144 1 Whit e Stree t An n Arbo r M I 4810 4 Phone 313.668.470 3 Fa

x 313.668.470 8 E-mai l jschwcft@socplas.or g 

### Decembe r

30 , 199 7 To : Madelein e Strum , EP A He : Agend aan d Material s for Januar y 5 Meetin g Madeleine , pleas e revie w th e followin g suggeste d agend afo r ou r workin g session , 12noo n l o 4pm , Monday , Januar y 5 , 1998 . W e understan d tha t

yo u hav e no t

com e t o adecisio n regardin g al l aspect s of ih e composit e MACT . However , w e woul d findi t helpfu l t o understan d you r curren t thinkin g o

n th e topic s outline d below . T n som e cases , a s noted , w e wil l presen t ou r ow n curren t

idea s o n th e topics . Pleas e le t m e 

### kno w i f yo u woul d lik e u s t

o make an y change s to thi s agenda . I . Emissio n Model s O n anumbe r

o f occasion s (a s recenll y a s Decembe r 8) , w e hav e provide d informatio n an d analysi s r.

o ESD , fo r you r us e i n establishin g a

n emissio n mode l for

MACT , an d w e appreciat e tha t

yo u hav e carefull y reviewe d thi s information . Accordin g t o th e Decembe r

1 draft , "Milestone s for Reinforce d Plastics, " ES D wil l finalize th e emissio n mode l fo r

ope n moldin g processe s i n December . O n Januar y 5 , w e woul d lik e t o lear n wha t

mode l ES D ha s chosen . We woul dals o lik e t o bette r understan d ho w th e mode l i s t o b e use d - t o se t floors? t o estimat e emissions ? l- o demonsixHip . compliance ? An d wil l th e mode l addres s th e pollutio n preventio n control s i n ou r propose d contro l matrix ? I n addition , w c woul d lik e t o discus s ho w facilitie s wil l demonstrat e comphanc e wit h th e standard . Fo r

example , wil l facilitie s us e ESD' s model , th e CF A model , stac k tes t dat a(i f available) , contro l factor s fo r ne w technologie s derive d fro mtesting , som e combination , o r

... ? II . Subcategorie s ES D i s considerin g ho w t o subcategor y th e ope n moldin g industry . W c originall y suggeste d tha t

group s b e establishe d for mechamca l an d manua l resi n applicatio n (t o encourag e an d rewar d facilitie s fo r switchin g t o flow coater s fromspray-up) , whil e ES D groupe d al l non-spra y together , includin g manua l application . O n Januar y 5 , w e woul d lik e t o revie w ESD' s curren t thinkin g o n subcategories .. P.1 6

12/31/9 7 13:2 5 ©91 9 54 1 568 9 EP A ES D CCP G @00 4



### III . Corrosio n Floo r W e woul d lik e t o discus s you r curren t plan s fo r ho w an dwhen ES D wil l se t th e floor fo r corrosio n fabrication . W e shoul dals o discus s possibl e way s to defin e th e corrosio n subcategory . IV . Ge l Coa t W e understan d tha t

ES D i s collectin g additiona l informatio n on ge l coats . W e woul d lik e to discus s th e proces s an d schedul e yo u hav e i n min dfo

r ge l coat apphcation . V . Polyme r

Concret e an dCas t

Polyme r W e woul d lik e t o presen t

ou r evaluatio n o

f th e issue s in polyme

r concret e an dcas t polyme r (summar y attached), an dwouldlike t o explore ho w consideratio n o f thes e issue s migh t

b e incorporate d int o th e MAC T fo r thi s category . VI . Ne w Source s W e hav e focuse d mos t

o f our effort s o n existin g sources , an dhav e jus t recentl y begu n consideratio n o

f you r suggeste dapproac h fo

r new sources . However , w e ar e concerne d tha t

th e 6 3 to n pe r

yea r small/larg e cui-ofTma

y no t b e appropriat e fo

r open molding . Ou r

preliminar y analysi s indicate s tha t thi s leve l may requir e newope n moldin g facilitie s t

o instal l control s tha t

ar e a s expensiv e o r

mor e expensiv e tha n th e entir e facility . W e wil l continu e ou

r analysi s an dwil l provid e informatio n t o ES D soon . What

i s you r schedul e fo

r furthe r consideratio n o

f ne w sources ? l n addition , w e woul d lik e t o explor e th e use , b y facilities , o

f ou r emissio n mode l i n determinin g i f

the y wil l b e larg e o

r smal l ne w sources . Also , we woul dlik e to discus s ho w ne w source s migh t b e abl e t o employ th e pollutio n preventio n option s i n ou r matri x t o avoi d bein g classifie da s larg e ne w sources . VII . Tes t

fo r Suppressant s W e hav e starte d developmen t ofth e suppressan t

test , pe r ou r December

8 meeting . O n Januar y 5 . w

e wil l hav e some preliminar y dat ato shar e wit

h you .

2 

# I *P.1 7

From : Joh n Schweitze rTo : Madelein e Stru m Oate : 12/31/9 7 Time : 10:03:0 4 A M Pag e 4 of 1 9



### VIII . You r

Leav e O n Januar y 5 , w e woul d Uk e t o discus s wha t

wor k ca n b e carrie dou t

durin g you r leave . I n particular , w e woul d like to kno w ho w w e can bes t continu e ou r

effort s durin g thi s period . Ar

e ther e specifi c thing s we can d o durin g you r

absence ? Ho w • can w e bes t

communicat e wit

h ES D durin g thi s period ? D C Draf

t Schedul e W c woul d lik e t

o understan d how we ca

n assis t you i n th e variou s activitie s show n o n th e December

1 draf t schedule . Fo r

example , can w

e hel p b y providin g comment s o n th e Draf

t Industr y Descriptio n Memo ? X . Feasibilit y ofth e Standar d Base d o n ou r knowledg e ofth e composite s industry , an dou r understandin g o

f ESD' s curren t approac h t o MAC

T fo r composites , w

e behev e tha t

th e ultimat e feasibilit y o f th e standar d fo

r ope n moldin g depend s on where th e floor s ar e set , an do n th e standar d providin g sufficient flexibilit y fo r u s to continu e makin g quaht y product s usin g th e material s an d processe s needed . A summar y o f our positio n on feasibility i s attached , an d w

e respectfull y as k

tha t you tak e ou r

suggestion s int o consideratio n a s yo u develo p th e standard . XI . Othe r

Issue s Doe s ES D hav e an y additiona l item s fo r discussion ? Attachment s 1 . Feasibility ofMACT

for Open Molding - Discussion of Industry Position 2 . Issues Related

to Polymer

Concrete and

Cast Polymer



# ( 6P.1 8

12/31/9 7 13:2 5 ®91 9 54 1 568 9 EP A ES D CCP G @00 5

• Th e standard , mus t

allo w u s t o tes t

an d us e ne w contro l technologie s t o mee t th e MAC T emissio n limitation . • Facihtie s mus t

hav e th e optio n o

f complyin g wit h th e standar d b y aggregatin g al l ope n moldin g operation s an d b y averagin g acros s arollin g 1 2 -mont h period. . W e believ e tha t

thes e conclusion s ar e consisten t wit h developmen t

o f 8 MAC T standar d tha t meet s th e requirement s ofth e Clea n Ai r Act , an d tha t

result s i n avei y substantia l reductio n o f emission s fro mtill s industry . 

### MAC T Floor s fo r Ope n Moldin g BPA' s databas e of

composit e industr y facilities , emissions , an d control s serve s a s th e basi s fo r settin g th e MAC T floors , o r minimu mcontro l levels , for eac h o f th e subcategories . Under

standably , EP A want s th © databas e t o contai n th e mos t up-to-dat e an d accurat e informatio n possible , an d th e Agenc y an d it s contracto r hav e worke d har d t o collec t informatio n fro mth e industry . We , too , wan t th e databas e t o accuratel y portra y th e wid e rang e of materials , processes , product* , an d facilitie s commo n i n th aindustry . However , EP A shoul d b e awar e tha t th e viabilit y o

f ou r propose d approac h depend s o n th e level s a t whic h th e floor s or e se t an d o n th e require d MAC T emissio n limitations . EP A ca n us e ou r approac h t o mee t

th e MAC T emissio n limit s w o proposed , bu t w * wil l hav e t o reevaluat e th e feasibilit y o f thi s approac h i f

th e floor s ar e significantl y reduced

Give n th e complexit y ofth e ope n moldin g an d corrosio n subcategories , th e floor s wil l b e largel y a n artifac t

o f ih e proces s use d i n settin g thes e levels , an d no t necessaril y ausefu l indicatio n ofth e leve l of contro l tha t

coul d reasonabl y o r

feasibl y b e applie d t o eve n a majorit y of

th e facilities . Fo r

example , thes e subcategorie s ar e certainl y larg e an d divers e enoug h that , Riven sufficien t tim e an d effort , EF A coul d findunusua l facilitie s wit h emis

sion s lo w enoug h tha t

di e resultin g floors woul d no t b e feasible . Also , i n settin g th e floors, EP A coul d bas e emissio n estimate s on manufacturin g variable s tha t ar e no t alway s "con

trols " (i.e. , intentionall y selecte d t o reduc e emissions) . Fo r example , monome r

conten t i n resi n i s used , a s acontro l b y man y sources . However , for othe r sources , monome r

typ e an d concentratio n pla y a n essentia l rol e i n polyme r chemistry , an d therefor e produc t perform

anna , an d monome r

i s no t reall y availabl e fo

r us e a s a"control, " I n thi s case , too . th e floor s ar e likel y no t

t o b e widel y applicable . Congres s intende d tha t

EP A us e reasonabl e judgemen t whe n settin g floors . EP A i s no t expecte d t o conduc t

9 n exhaustiv e searc h fo r faciUtie s tha t

migh t mak e unusua l product s o r us aunusua l technology , bu t rathe r t o emplo y aproces s tha t result s i n floor s tha t

ar e i n fac t fflflfiiblaan d achievabl e fo r a t leas t alarg e majorit y o

f source s withi n asubcategory . 2 

# tnP.1 9

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EP A ma y hav e suggeste d improvement s regardin g th e derivatio n of th e ME I J; , th e emis

sio n model , th e enforceabilit y an d practicalit y ofth e standard , o r othe r simila r issues , an d w e agre e tha t

thes e ar e usefu l area s fo r discussio n an d improvement . However , w c oppos e consideratio n of

limit s o n materialfi , processing , an d othe r possibl e technology-base d addi

tion s t o th e require d emissio n limitations . A s lon g a s source s ar e meetin g th e MAC T emis

sio n limits , an d doin g s o i n a n enforceabl e manner , EP A i s no t compelle d to , an d mus t not , dictat e ho w facUitie s mak e products . I n particular , th e standar d shoul d no t se t floors s o low , o r

restiic t th e us e o f

averag ing , s o tha t

facilitie s ar c unabl e to us e th e resin s o r processe s the y nee d t o mak e acceptabl e products . Unde r

ou r propose d performance-base d approach , source s wil l naturall y us e th e resin s wit h th e lowest-possibl e HA P content , an d wil l us e high-HA P resin s onl y whe n require d fo r

processin g o r

produc t performance , o r

whe n neede d t o mak e product s tha t ar e competitiv e i n th e marketplace , Nevertheless , i f th e floors ar e se t

s o lo w tha t

th e us e o f

low

HA P resin s i s necessar y t o mee t th e emissio n limits , the n th e standar d wil l severel y Umi t th e flexibiht y w e nee d t o mak e products , an d i n man y cases , wil l driv e u s ou t of markets , o r

ou t of busines s altogether , W e agre e tha t th e MACT emissio n limit s shoul d b e se t s o tha t facilitie s hav e a n incentiv e t o us e low-HA P resins , hu t w e d o not . agre e tha t

the y shoul d b e s o lo w tha t source s d o no t

hav e alternative s fo r

th e man y case s wher e th e us e o f high-HA P resin s i s required . Fo r

example , corrosio n fabricator s shoul d b e abl e t o achiev e MAC T b y usin g low-emittin g applicatio n equipment , suc h a s flo w applicators , i n combinatio n wit h isophthali c resin s containin g 45 % styrene . Ther e ar e anumbe r

o f compeUin g reason s wh y th e standar d mus t no t overl y restric t th e us e o f higher-HA P conten t

resins :

• Restriction s o n monome r typ e an d conten t

ar e inappropriat e r*striction s o n th e polyme r chemistr y tha t

w e emplo y t o mak e product s i.e. : monome r i s no t a"control. "

• Adjustin g monome r typ e an d conten t

i s on e importan t

way resi n supplier s adjus t produc t properties , an d thereb y reduc e th e ris k o f faile d products . • Facihtie s wil l suffe r significan t

economi c impact s i f

prevente d fro musin g th e ful l rang e of resins . Monome r i s no

t a "control " Unsaturate d polyeste r

resin s ar ath aproduc t

o f acondensatio n reactio n betwee n difuncttona l acid s an d alcohols , crosslinke d wit h achemica l containin g aviny l unsaturation , typicall y styrene . Thes e thre e basi c buildin g block s (acid , alcohol , an d viny l monomer ) ca n b e varie d i n compositio n an d concentratio n t o obtai n amyria d o f properties . Resi n supplier s continu

-P.2 0 From : Joh n Schweitze r To : Madelein e Stru m Date : 13/31/9 7 Tims : 10:03:0 4 A M Pag e 9 of 1 8

all y adjus t

resi n component s an d concentration s t o customiz e product s fo r specifi c applica

tions . Perhap s du e t o amistake n analog y o f composite s t o coatings , som e EP A staf f ma y behev e tha t

styrene , becaus e som ao f i t evaporate s durin g th e manufactur e of products , ca n b e replace d o r

it s concentratio n ohange d withou t significantl y changin g th e propertie s o f products . I n fact , th e typ e an d amoun t o f monome r

bot h impar t

uniqu e propertie s t o th e polymer . Th e particula r monome r

use d i n aresin , an d it s concentration , ar e selecte d base d o n produc t

specifications , th e choic e o f aci d an d alcoho l use d to for mth e ester , th e proces s technology , th e cur e an d processin g propertie s required , an d th e typ e o f reinforcemen t incorporate d i n th e resi n matrix . Changin g monome r o r monome r

concentratio n alter s th e polyme r s properties ; thi s i s alway s th e case . T n certai n applications , substitutio n o f monomer s ca n b e accomplishe d t o mee t specifi c produc t

requirements . Thi s doe s no t mea n cha t

th e product s ar e identica l i n proper ties , bu t onl y tha t

th e ne w resi n formulatio n ca n mee t th e requirement s of

aspacifi e per . formanc e test. Whethe r th e ne w resi n meet s th e requirement s wil l ofte n depen d o n th e judgemen t

ofresi n suppher , fabricator , o r en d use r (se e th e discussio n startin g o n pag e $} . Wher e th e differenc e betwee n highe r an d lowe r

styren e conten t

i s no t materia l t o produc t performance , w e understan d EPA' s desir e t o encourag e us e o f th e lo w styren e resin . How

aver , EP A take s thi s positio n to o fa r i f th e standar d attempt s t o dictat e resi n compositions , Ou r abilit y t o compet e depend s o n ou r abilit y t o formulat e product s wit h aful l rang e o f properties . Effort s b y EP A t o rastrio t thi s flexibihty ar e unacceptabl e an d no t mandate d b y th e Clea n Ai r

Act . EP A ha s no t

regulotc d th e monome r conten t o f an y othe r

polyme r - o r ranke d facihtie s an d se t

floor s base d o n monome r conten t - i n an y othe r

MAC T standard . Man y o f th e monomer s use d fo r

othe r polymer s migh t

b * considere d mor e hazardou s tha n styrene , includin g butadiene , acrylonitrile , viny l chloride , an d formaldehyde . Further , CA A Sectio n 11 2 doe s no t

envisio n alterin g produc t propertie s t o achiev e aleve l of contro l equivalen t

t o th e to p 12% . A s amatte r o f consistenc y wit h th e Act , an d wit h othe r MA.C T standards , EP A shoul d reconside r

it s approac h here . Incidentally , sinc e monome r typ e an d conten t

ar e s o importan t

i n determinin g proc essin g an d produc t

properties , i t

coul d b e argue d tha t

i t i s inappropriat e to se t

floor s b y rankin g facilitie s accordin g to monome r content , or , a s we'v e propose d b y emissio n estimate s base d largel y o n monome r content . Afte r

all , monome r

i s no t acontrol . Give n th e importan t

5 

## 4 3: P.2 1 12/31/9 7 13:2 6 ®91 9 54 1 568 9 EP A ES D CCP G $00 7

rol e tha t polyme r chemistr y play s i n composite s manufacturing , monome r typ e an d conten t coul d b e bette r

use d t o establis h subcategories. 3 A awe'v e note d previously , however , th e subcategorizatio n approac h w e propose d o n Septembe r

1 3 i s muc h mor e likel y t o resul t i n areasonabl y simpl e an d workabl e standard , eve n thoug h th e subcategorie s ar e reall y highl y divers e groupings . Th e rankin g metho d employe d t o se t

th e floor s i s a convenienc e tha t allow s U Rt o satisf

y th e requirement s of

CA A Sectio n 112(d) , bu t

i s not . reall y defensibl e o n strictl y technica l grounds . A s lon g a s th e standar d allow s u s t o mee t ou r propose d MACT amissio n limit s o n a n open-moldin g aggre gate , rollin g annua l averag e basis , an d doe s not . plac e overl y stringen t restriction s o n ou r abilit y t o mak e products , w e ca n raduc e emission s t o compl y wit h th e CA A an d continu e t o mak e products . Thi s i s tru e eve n though , becaus e th e subcategorie s contai n man y highl y divers e oparations , an d monome r i 3 no t acontrol , ou r

propose d MEL s ar o actuall y no t achievabl e fo r

man y specifi c material/process/produc t combinations . Resi n supplier s mus t b e abl e t o adjust monome r conten t t o sui t application s l i i s certainl y tru e tha i an y produc t presantl y mad e wit h ahigh-HAl - * resi n ca n b aphyeiocdl y constructe d usin g alow-HA P resin , or , foi * tha t matter , usin g steel , wood , o r concrete . How

ever : Wil l th e resultin g produc t provid e acceptabl e performannft ? Wil l i t las t lon g enough ? Doe s th e resi n provid e sufficien t strengt h an d chemica l resistanc e t o giv e th e neede d margi n o f safet y i n appUcation s whar aproduct , failure s ca n resul t i n injury , death , o r

environmenta l damage'- ' Thes e ar aal l technical, a s oppose d t o economic, considerations . Unfortunately , w e seldo mhav e unambiguou s answer s t o thes e technica l questions . Fo r example , wha t

i s "acceptabl e performance? " Wha t i s "lon g enough? " Ho w ca n w e defin e astandar d "neede d margi n o f safety? " I n practice , thes e question s ar e decide d o n aproduc t -

* EP A has use d HAP-«onten t limitatio n mos t

appropriatel y where th e chemica l o f concer n i s no t par t o f th e fina l product . Thi s i s th e cas e fo r coatings , where th asolvent evaporates , an d fo

r blowing agents . A s diseuaau d i

n detai l above , th e monome r use d i n composit

e manufacturin g i s require d t o buil d th e polymer , an d th e majorit

y o f i t become s par t

o f th e fina l product . HAP-eonUm . limit s ar e als o appro priat e wher e th e emission s ca n no t b e readil y minimise d o

r controlled , i n industrie s where proces s chance s may alte r

th e rate a t

whicl i HAP s ar e emitted , bu t

no t th e amount . Thi s i s th e MB A with man y coatin g applications , wher e coating * ar e applio d i n suc h amanne r an d a t suc h location s tha t

n o contro l i s feasible . Thi s ca n als o b e tru e o f blowing agents , wher e muc h ofth e HA P i s emitte d afte r

th e produc t leave s th e productio n facility . Fo r composites , th e emissio n perio d ie alway s relativel y short , is * limite d to th e actua l productio n process , an d proces s change s ca n b e employe

d L o reduc e th e tota l amoun t o f HAP s emitted , 

## Z OP.2 2

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by-produc t

basis , b y th e end-user , fabricator , an d resi n supplier , typicall y base d o n lon g experienc e wit h specifi c resin s an d fabricatio n method s i n specifi c apphcations . Fo r example , high-HA P resins , suo h a s chlorendi c aci d polyesters , ar e recommende d b y man y resi n supplier s fo r certai n highl y aggressiv e chemica l environments ^ becaus e the y giv e ahiRh leve l o f

performance . I n thes e sam aapphcations , woul d alow-HA T viny l este r resi n b e acceptable ? Perhaps . But . again , thi s decisio n mus t b e mad e o n acase-by-cas e ba

sis , an d wil l depen d heavil y o n th e experienc e an d judgmen t ofth e user , fabricator , an d resi n suppUer . A MAC T standar d tha t reduce s th e performanc e o r safet y margin , b y requirin g th e us e of low-HA P resin s wit h eve n margina l reduction s i n properties , ma y caus e end-user at o choos e non-composit e materials . How ar e resin s selected ? Fo r corrosio n apphcations , i n particular , en d user s an d fabricator s ofte n rel y o n recommendation s mad e b y resi n suppliers . Supplier s bas e suc h recommenda

tion s o n extensiv e laborator y testin g o f Fig . 1 - O n recommendin g resins.. . "W e conside rth e followin g factor s whe n recommendin g a resin s i n literall y thousand s o f differen t chemica l environments , a s wel l a s decade s o

f successe s (o r failures ) o f

product s i n th e Held . Th e supplier s the n publis h studie s o r guide s tha t

offer resi n recommendation s fo r

specifi c chemica l services . EP A migh t

prefe r en d user s an d fabricator s to selec t resin s wit h lowe r styren e content , and , i n man y cases , thi s migh t

b afeasible . However , du at o th e significan t damage , an d healt h an d environmenta l impacts , whic h ca n resul t fro mproduc t

failures , resi n selectio n i s o f

necessit y vei y conservative . User s an d fabricator s ar e ver y unlikel y to assum e thi s liability . An d give n th e importanc e o f satisfactoi y produc t

performance , i t

i s frankl y ver y unlikel y tha t

resi n supplier s wil l eve r b e willin g t o us e monome r conten t a s asignifican t resm : What i s th e application ? Pul p an d paper , mining , pe troleum , sewage , plating , o rother ? Wha t process wil l b e use d t o fabricat e th e produc t - han d lay-up , spray , ftow-coater , filamen t winding . RTM ? Wha t i s th e structur

e - tank , pipe , plate ? Doe s i t have a lining , and , i f so , of what ? Wha t ar e th e chemical s t o whic h i t wil l b e exposed ? Ar e there likel y impuritie s no t alread y identified ? Wha t p H rang e an d specifi c gravity ? Wha t i s th e expecte d servic e life ? Wha t i s th e operatin g temperature ? What i s th e high es t upse t condition ? I s th e temperature cyclic , and , if , so , wha t i s th e cycle ? I s there pressur e o rvacuu m applied ? Wha t i s th e operatin g condition ? What i s th e highes t upse t con dition ? Doe

s th e pressur

e cycle ? I f fir e o rsmok

e resistanc e required ? I s there a requiremen t o n toxi c by-product s fro m burn ing ? I s a UV stabilize rrequired? " "Whe n we'v e answere d al l thes e question s t o ou rsatis faction , the n ou rCorrosio n Produc t Leade rwil l revie w ou r corrosio n guide , ou rhistorica l experienc e an d product testing , an d us e hi s judgemen t t o recommen d a resin. "

- Mik e Grotke , Alpha/Owens-Cornin g

7P.2 3

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basi s fo r recommendin g res i ns . Fo r simila r reasons , fabricator s ar e no t likel y t o ignor e th e technica l advic e ofresi n suppliers . On e o f th e difficultie s i n settin g MAC T base d n

n HAP-eonten t

- an d a reaso n wh y EP A shoul d no t eve n conside r monome r

typ e an d conten t

t o b e acontro l for

th e corrosio n subcategor y - i s tha t

differen t resi n supplier s recommen d differen t resi n types , wit h differen t

monomer s an d monome r concentrations , fo r

th e sam e apphcations . Thi s i s becaus e differen t supplier s hav e proprietar y formula s an d resins , hav e differin g experienc e i n variou s en d uses , emplo y differen t criteria , an d ma y b e more-or-les s conservativ e whe n i t

come s t o recommendin g resin s for extrem e environments . Figure s 1 an d 2 describ e th e processe s use d b y tw o resi n supplier s t o recomman d resin s fo r

corrosio n apphcations . Whil e othe r supplier s ma y emplo y differen t

processe s an d differen t criteria , al l wil l depen d o n th e abilit y t o adjus t

th e chemistr y o

f th e resin , includin g monome r typ e an d content , t o sui t

particula r

apphcations . Pig . 2 - Mor e o n recommendin g a resin.. . "Whe n a request i s place d upo n ou rla b t o rec ommen d a resi n fo rus e i n th e fabricatio n of piec e o f equipmen t that wil l b e expose d t o a corrosiv e environ ment , severa l facts nee d t o b e considered . Th e most importan t criteri a ar

e cas e histories . Positiv e o r negative , a n exampl e where a resi n ha s bee n use d fo r a give n applicatio n bring s wit h i t informatio n tha t ha s a highe rleve l o

f credibility tha n an y othe rsourc e of information . I f ther

e i s a successfu l cas e history , th e sam e resi n i s likel y t o b e recommende d onc e again , We migh t recommen d a differen t resi n i f premiu m polyeste ri s bein g used , an d laborator y testin g show

s a viny l este rt o hav

e equa l o rsuperio rperformance , becaus e i l i s easie rt o fabricat e a goo d par t ou t o f s viny l ester . "I f ther e i s a n unsuccessfu l cas e history , w e convey that t o th e requestor , an d indicat e th e mod e o f failure . We wil l the n recommen d a resi n tha t woul d b e expecte d t b give superio rperformanc e i n th e property requirin g improvement . "I f ther e i s n o cas e histor

y available , w e evaluat e th e require d service . I f th e piec e o f equip men t i s goin g t o b e expose d t o a fai ramoun t o f physica l o rtherma l stress , w e wil l tr y t o recommen d a viny l ester , a

s the y produce toughe rparts . I f n o physica l o rtherma l abus e i s anticipated , w e woul d nex t loo k a t th e chemica l environment . I f w e hav e ru n corrosio n testin g (AST M C 581 ) o n an y resin s i n th e environment , we rel y o n thi s information . I f w e hav e no t ru n an y testing , w

e loo k fo rsimila renvironments . I f we hav e severa l resin s that perfor m wel l i n th e environment , w

e wil l recommen d th e leas t expensiv e resin . "I f i t i s a n aggressive chemica l environment , li abilit y issue s deman d tha t w e select th e resi n tha t w e believe wil l perfor m bes

t i n th e give n application . A t thi s poin t ther

e i s littl e regard give n t o th e cos t o f th e resin. " •- Ti m Pepper , Ashlan d Chemica l Fo r example , Ashlan d Chemica l ha s recommende d tha t tank s fo r

a n extractio n min

in g operatio n b e mad e wit h high-HA P resins . Extractio n minin g i s afairl y commo n process , wher e aminera l i s dissolve d i n arelativel y dilut e aci d solution . typicaU y sulfuri c acid . Th e solutio n i s kep t

a s ho t a s possibl e t o faeihtat e dissolution . Th e ho t solutio n i s brough t

int o successiv e larg e vats , allowin g th e solutio n t o b e purified , an d the n transferre d t o anothe r vat . Afte r

th e appropriat e purificatio n i s carrie d out , th e desire d minera l i s oxidized , an d precipitate d ont o adiode . Th e diode s ca n b e remove d fro mth e solution , an d th e desire d minera l collected . Th e proces s allow s th e efficien t collectio n of

extremel y pur e minerals . 8P.2 4

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Asldan d foun d tha t

aformidabl e hurdl e wa s th e fac t tha t ver y fe w material s stan d u p t o ho t acidi c solutions . Th e initia l recommendatio n wa s atan k mad e out . of

alow-styren e novola c viny l este r

resin . Man y tank s wer e fabricated , an d the y starte d t o foi l withi n month s o f

installation . After

severa l attempt s t o buil d bette r tanks , o se t

o f tank s wa s mad e ou t o f aliigh-styren e creso l novola c viny l este r resin . Thi s resi n i s know n fo r impartin g a uniqu e eombi n at i n

n o f toughness, resistanc e to oxidisin g environments , an d super b thenna l performance : Eigh t

year s later , thar e ha s onl y bee n on e failure , an d i t wa s cause d b y a n eiro r i n fabricatio n tha t

resulte d i n wall s onl y hal f a s thic k a s th e specifications . Analysi s o f asectio n o

f th afaile d tan k

show s virtuall y n o los s o f propertie s du e t o corrosion . Ashlan d Chemica l ha s als o recommende d higher-HA P resins fo r ho t causti c solu

tions , on e of'th e mos t

aggreuiv e chemica l environments , common , fo r example , in th e pul p an d pape r

industry . Ashlan d ha s foun d tha t styren e impart s ahig h degre e o f chemica l resistanc e t o causti c environments . Th e tw o Aslilan d resi n system s tha t giv e acceptabl e performanc e u p t o 150° F contai n u p t o 45 % styrene , an d th e syste mtha t give s acceptabl e performanc e u p to 1S0° F contain s u p t o 50 % styrene . Table s 1 an d 2 sho w AST M C-581 results , relativ e costs , an d styren e content-fo r thes e thre e resin s an d th e othe r bes t per formin g lo w styren e system s Ashlan d ha s tested . Th e C58 1 dat ai s hste d a s th e pereen t propert y retentio n afte r 1 2 month s exposur e t o th e give n environment . Ashlan d consider s a sampl e tha t

drop s t o las s tha n 50 % ofth e origina l valu e to hav e failed . A s show n i n th e tables , Ashland' s lo w styren e viny l ester s performa d var y poorl y i n ho t caustic . Product BPA Viny l Este r Novola c Viny l Este r Creso l Novola c V E BPA/Fumarl c P E BPA Viny l Este r

Product BP A Viny l Este r Novola c Viny l Este r Creso l Novola c V E BPA/Fumari c P E BP A Viny l Este r a 1 . Ashland' s % Styren e 35 35 4 4 5 0 4 5 AST M C-58 1 Results , 10 % Causti c at 150° F

Hardnes s 0 % 0 % 51 % 83 % 17 % Stiffnes s

Coupo n failed , 29 % 81 % 78 % 54% Strengt h

soft&pliabl e 23 % 56 % 84 % 31 % l e 2 . Ashland' s AST M C-58 1 Results . 5 % Causti c a

t 180° F % Styren e 35 3 5 4 4 5 0 45 Hardness

0 % 0% 7% 100 % 54 % Stiffnes s

Coupo n failed , Coupo n failed , 42 % 84 % 70 % Strengt h

soft&pliabl e soft&pliabl e 39 % 51 % 64 % Cost

1.0 0 1.0 8 1.0 0 1.0 0 0.8 8

Cost 1.00 1.0 8 1.00 1.0 0 0.8 8 9 

## 1s>P.2 5

12/31/9 7 13:2 8 ®91 9 54 1 568 9 EP A ES D CCP G @01 1 rag t ii orI U .

Again , othe r

resi n supplier s ma y us aothe r criteria , conside r

differen t an d proprie

tar y resins , an d mak e othe r recommendation s fo r

thes e apphcations . Bu t al l woul d rel y o n a n abilit y t o adjus t

monome r

typ e an d conten t

t o sui t specifi c applications . I f th e MAC T standar d limit s ou r

abilit y t o tailo r

product s i n thi s way , o r place s a n inappropriat e empha

si s o n monome r

conten t whe n ranldn g facihtie s an d settin g floors, the n tlii s essantis d abilit y to adjus t ou r polyme r chemistr y wil l b e restricte d u r lost . Fig . 3 - Cas

e Study : Undergroun d Gasolin e Storag e Tank s EP A i s certainl y aware tha t leakin g undergroun d gaso lin e storag e tank

s (UGSTs ) pos e a significan t threa t t o th e purit y of groun d wate ri n man y communities . Fo rth e mos t part , thi s proble m has bee n alleviate d b y EPA' s UGS T program , whic h ha

s requiredth e installatio n of corrosion resistan t tanks . Composit e tanks , alon g wit h cathodicall y protecte d stee l tanks an d composite/stee l hybrids , have provide d th e corrosio n resistanc e neede d t o protect th e environment . Th e all-composit e tanks enjo y inherent corrosio n an d rust resistance ; composit e UGST s have bee n unearthe d afte r30 + year s o f continuou s service , an d hav e show n n o sig n of corrosio n o rothe rdamage . Th e tabl e below show

s th e retai l price s fo rUGST s con structe d with'th e variou s material s (sourc e o f dat a i n tabl e ca n be provide d t o EP

A a s CBI , o n request) . Retai l price s ar e use d rathertha n cost s s o tha t a compariso n ca n b e mad e amon g composite , hybrid , an d stee l tanks . Mos t o r al l o f th e difference s i n th e price s fo rth e composit e tank s ca n b e attribute d t o difference s i n resi n cost . I t ca n b e clearl y see n tha t replacin g isophthali c resin s wit h viny l este rresin s wil l make th e composit e tanks significantl y mor

e expensive tha n th e stee l tanks , an d therefor e no t competitiv e i n th e marketplace . A MACT standar d that effectivel y limit s o rprohibit s is o resin s fro m us e i n constructin g UGST s wil l simpl y an d clearl y forc e th e domesti c manufacturer

s of thes e product s ou t o f business . Retai l Pric e to r 8,00 0 Gallo n Tan k Isophthali c tan k IS O oute rtank, terephthali c inne r Viny l este rline d isophthali c tan k Is o outer , part' l is

o inner, V E line r Pur e 100 % viny l este rtan k Composit e is o wrap stee l tan k Cathodicall y protecte d stee l tank

s Economi c Impac t o f limit s o n higher HA P resin s Isophthali c resi n systems , whic h requir e relativel y liighe r level s o f styren e content , provid e ausefu l combinatio n of

moderat e cos t

an d poo d produc t performance . Viny l aste r resins , whic h ca n provid e a t leas t equivalen t

perfor mann alevels , ar e significantl y mor e expensive . Product s mad e wit h isophthali o resin s Successfull y compet e wit h product s mad e fromothe r

materials , suc h a s stainlas s steel , tha t

ar e lag s expensiv e tha n th e composit e product s woul d b e i f mad e wit h viny l este r

resi n (for example , se e th e ca3 c stud y illustrate d i n Figur e S) . l n mos t cases , th e composit e manufacture r

i s no t abl e t o pas s th e highe r viny l este r

resi n cost s alon g t o th e customer , an d th e custome r simpl y wil l no t selec t th e composit e product . Often , th e composit e manufacture r i s asmal l business , wit h asmall , specialize d produc t hne . I n thes e cases , th e inabilit y t o us e isophthali c resin s wil l simpl y mea n tha t h e goe s ou t

of business . Th e Composite s Institut e recentl y surveye d severa l of it s membe r

companie s tha t produc e corrosio n resistan t tank s an d equipment , Eac h compan y wa s aske d t o report , fo r it s 1 0 $3,80 0 

### N/ A S4.80 0 

### N/ A $5,80 0 54,00 0 $3,70 0 N/A .

$6,00 0 

### N/ A $9,00 0 $11,00 0 $7,80 0 $7,50 0



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19

most , recen t

fiscal year , it s resi n costs , tota l productio n costs , an d tota l sole s revenu e (for composite s production) , and , fo r th e sam e period , wha t

it s resi n cost s woul d hav e bee n i f i t ha d t o us e viny l este r

resin s instea d o

f isophthah o resins . A summar y th e dat aobtaine d i n thi s surve y iashow n i n Tabl e 3.* Th e "operatin g margins " i n th e tabl e represen t th e rati o of

sale s revenu e t o manufac

turin g costs . A n exces s of revenu e ove r manufacturin g cost s (operatin g margi n greate r tha n 1.0) i s require d fo r

acompan y t o pa y fo r sales , administrative , an d othe r expenses , an d retur n aprofit . I t

i s unlikel y tha t

acompan y wit h a n operatin g margi n o f les s tha n 1 . 2 i s profitable . O

f th e 1 2 companie s shown , 1 0 woul d simpl y no t

surviv e aMAC T standar d tha t prohibite d thei r

us aof isophthah o resins . Incidentally , th e variatio n i n impac t of restrictin g HA P conten t apparen t

amon g th e facihtie s i n Tabl e 3 reveal s th e variatio n i n th e product s made , an d market s served , b y th e corrosio n industry . Faciht y F , fo r example , doe s no t us e isophthah o resi n to mak e it s particula r products , whil e mos t

o f th e othe r

facihtie s us e larg e amount s o f

is o resi n t o mak e thei r products . Facility A ; B C D E F G H 1 J K L Tabl e 3

Operatin g Margi n Sale s Revenu e + Tota l Manufacturin g Cos t Actua l Fisca l Yea r 1.2 6 1.2 1 .1 2 1.3 4 1.0 1 1. 3 1.1 3 1. 3 1. 2 1.2 6 1.1 5 1.2 7 Wer

e Replaced Wit h Viny l Este r Resin s 0.8 3 0. 9 1. 1 0.9 6 0.9 5 1.3 0.8 5 i 0. 9 0.8 6 0. 9 0.9 8 0.9 7



## Ne w Tes tProtoco l Th e CF A testin g performe d a t th e Do w faciht y i n Freeport , Texa s ha s bee n instrumenta l i n quantifyin g emission s fro mcontroUe d an d uncontrolle d ope n mol d processes . Thi s tasting

ha s allowe d u s t o develo p reasonabl y accurat e an d usefu l amissio n model s fo r us e b y facih

tie s an d regulator s i n estimatin g emission s fromope n mol d processes , an d t o develo p ou r

4 Th e ra w dat aan d identity o f th e participatin g companie s in Tabl e 3 can b « provide d to EP A a s CBI , o n ioquest . 1 1P.2 7 i 12/31/9 7 13:2 8 ©91 9 541568 9 EP A ES D CCP G .®9H . . . " .

propose d matri x o f

contro l option s fo r

facilitie s t o us e i n meetin g th e MAC T emission s limitations . Whil e th e testin g ha s characterize d emission s fro mawid e rang e of materials , apph

catio n techniques , e t

cetera , w awil l alway s hav e anaa d fo r emissio n dat afromne w tech

nologies . Suc h dat aca n h ause d t o establis h contro l factor s fo r ne w technologies , s o tha t th e CF A emissio n mode l ca n b e use d t o estimat e emission s fro msource s usin g th e technologies , an d s o tha t

source s ca n us e th e technologie s t o compl y wit h th e MAC T emissio n limits . T o facilitat e suc h ongoin g testing , CF A ha s develope d ales t procedur e fo r

character

izin g emiesion s fro mope n moldin g operations . EP A ha s previousl y bee n give n a n earl y draf t of thi s procedure . We ar e no w revisin g th e procedur e t o addres s validit y an d reliabilit y n f th e testing , an d t o specif y ho w emissio n dat afro mane w technolog y ca n b e converte d int o a contro l facto r

fo r us * wit h th e CF

A emissio n model . Th e revise d protoco l wil l b e provide d t o EP A b y mid-February . Th e procedur e require s ates t sit e t o replicat e th e instrumentation , quaht y control , airflow , molds , an d othe r importan t

factor s fromth e CF A tes t program , Th e procedur e als o require s tha t

ates t sit e b e certifie d a s complyin g wit h TSO 9000 , an d tha t th e appropriatel y traine d an d qualifie d personne l ar e availabl e t o operat e an d maintai n th atestin g an d analytica l equipment . Eac h sit e i s required , o n aregula r basis , t o mol d apar t

usin g aee t

o f standar d oper atin g condition s (mold , resi n an d formula , apphcatio n davic e an d rate , ge l time , e t cetera) , an d sho w tha t

th aresultin g emissio n rat e i s withi n som e reasonabl e rang e o f astandar d emissio n rata . Thi s standardizatio n prooadur e wil l insur e tha t an y significan t

variatio n i n dat ai « du e t o th e variabl e bein g studied , an d no t du e t o variatio n i n instrumentation , operato r technique , o r

othe r source s o

f error . W e sugges t

tha t th e MAC T standar d shoul d allo w u s to : 1 ) tes t ne w technologie s us in g th o CF A procedure ; 2 ) us e th e tes t dat ato develo p contro l factor s fo r th e ne w technolo * gies ; S) us e th e contro l factor s wit h th * CF A emissio n mode l t o estimat e emission s from sourea s usin g th e ne w technologies ; 4 ) us e emissio n reduction s resultin g fromth e ne w technologies , an d estimate d b y us e of th e contro l facto r

an d model , t o mee t

th e MAC T emissio n limitation ; an d 5 ) als o us e thes e emissio n reduction s i n ou r averagin g approac h t o offse t above-the-floo r

emission s elsewher e i n sources . Th e standar d coul d us e th e metho d promulgate d a s par t o f th e HO N fo r

approvin g ne w technologie s demonstrate d b y th e emissio n testing metho d [§63.150(1)] . Unde r tlii s approach , industr y coul d tes t ane w technolog y an d quantif y it s emissions , usin g ou r pro pose d protocol . Th e contro l factor s fo r thi s ne w technolog y woul d b e submitte d t o th e Agenc y 1 2 

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. . . ........... . f-*!,| C I/O I «y< r i / o i i s

fo r revie w withi n areasonabl e tim aperiod . Base d o n ho w broadl y th e technolog y i s apphca

bl e t o the . composite s industry , EP A coul d publis h th * result s i n th e Federa l Register . Finally , ther e shoul d b e n o restriction s o n ou r abilit y t o us e tlii s procedur e t o estab

lis h contro l factor s fo r

ne w technologies . Shoul d th e standar d allo w u s t o us e th e procedur e onl y fo r technologie s tha t

promis e ver y larg e omissio n reductions , tlii s wil l stifl e innovatio n an d discourag e developmen t of technologie s tha t

achiev e smaller , bu t

stil l important , amissio n reductions .



### Emissio n Averagin g W e understan d tha t

EP A agree s tha t

th e ope n moldin g MAC T shoul d provid e a n optio n fo r emissio n averaging . W e appreciat e tha t EP A ha s apparentl y take n thi s position . T o mak e sur e tha t EP A an d w e ar e i n agreemen t abou t wha t averagin g is , we' d lik e t o reiterat e ou r suggeste d approach . I n short : W e propos e tha t

eae h majo r

sourc e mee t

aMACT emission limitation that is essentially the weighted

average ofthe MACT

floors for

each ofthe open mold processes ai the source. Th e majorit y o f majo r source s i n th e composite s in

dustr y ca n chang e thei r operation s t o limi t

emission s t o level s tha t ar e a s stringen t thes e suggeste d MACT emissio n limit3 . However , t o accoun t foi * th e extrem e diversit y ofth e Rntijcce s withi n eac h proces s group , our facilities must be allowed

to achieve theee limits on a rolling-annuahaverage basis, aggregating all

open mold

operations. Th e example s provide d t o EP A o n Septembe r 1 8 demonstrat e bot h th e nee d for , an d practi

calit y o £ ou r

averagin g approach . Consistency wit h th e HO N Durin g ou r

Septembei-1 8 meetin g wit h EPA , th e Agenc y suggeste d tha t th o emissio n tradin g provision s i n th e HO N migh t serv e a s ausefu l mode l fo r th e averagin g provision s w e nee d i n th e composit e MAC T standard . W e hav e carefull y reviewe d th aHO N emissio n averagin g provision s an d concu r

tha t thi s regulatio n serve s a s a n excellen t mode l fo r

th e composit e MACT . • W e not e tha t

th e HO N averagin g provision s rel y heavil y o n emissio n factor afo r esti

matin g emission s fromstorag e vessels , wastewater , an dloadin g racks . W e se e aclea r paralle l t o th e emissio n averagin g w e propose d o n Septembe r 18 . 1 3 

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G _-JJ^Jfi s

• W e ar e als o enoour3g« d b y EPA' s 3tron g suppor t fo r pollutio n preventio n i n th e HON . W e advocat e th e us e of

pollutio n preventio n whereve r feasible , an d strongl y encourag e th aAgenc y t o adop t

th e pollutio n preventio n approac h i n th e HON . • Th e HO N averagin g provision s exclud e source s fo r whic h ther e i s n o fixed performanc e leve l an d fo r

whic h determinin g th e magnitud e of allowabl e emission s i s no t possibl e (e.g. , equipmen t

leaks) . W e agre e tha t

wher e performanc e level s er anot . estabUshed , emission s shoul d b e exclude d fro maveraging , an d ther e ar e n o sue h source s covere d un de r ou r propose d averagin g approach . • Th e HO N allow s state s t o disallo w averaging . Whil e state s ar e alway s fre e t o sa t mor e stringen t requirements , w e propos e tha t th e standar d formall y recognis e tha t averagin g i s Critica l t o th e implementatio n an d feasibilit y o f MACT fo r

ope n molding , s o tha t

state s ar e discourage d fro mdisallowin g it , • Th e HO N apphe s adiscoun t facto r o f 10% , excep t

fo r pollutio n prevention . Th e majorit y ofth e contro l option s i n ou r matri x ar e pollutio n preventio n techniques , an d w e d o no t suppor t a n across-the-boar d discoun t facto r i n th e composit e MAC T standard . • Finally , th e HO N allow s annua l averaging , wit h quarterl y check s t o show n tha t emis

sion s d o no t

excee d th e MAC T emissio n limitatio n b y mor e tha n 00% , W e believ e tha t thi s woul d b e aworkabl e approoc h fo r th e composit e MAC T standard . Consistenc y wit h othe r MAC T standard s EF A ha s include d emissio n averagin g i n asubstantia l numbe r o f MAC T standard s regulat

in g adivers e grou p o

f industries . Fo r

example :

• Th e petroleu mrefinin g MAC T utilize s a n averagin g approac h ver y simila r t o tha t include d i n th e HON . I n orde r t o allo w additiona l averagin g opportunities , EP A altere d th e definitio n o

f th « petroleu mrefinin g sourc e oategor y t o incorporat e marin e tan k vesse l loadin g operation s an d gasolin e loadin g racke , covere d b y othe r MAC T standards , whe n locate d a t

refineries . Thi s revisio n "increase d flexibilit y t o reduc e emission s i n th e mos t cost-effectiv e manner. "

• Th e pharmaceutical s MAC T an d polymer s an d resin s MACT s mirro r th e HO N require

ments , adjuste d fo r

industry-specifi c needs . • I n th e primar y aluminu mMACT , EP A provide d a n emissio n averagin g approac h specifi c t o th e industry , an d disallow s averagin g fo r tw o HAP s (tota l fluorides an d POM) . Th e inter-pollutan t

tradin g issue s or e no t

german e t o th e composit e MACT , t I n th e propose d polyurethan e foa mMACT , EP A appear s t o tak e tw o approache s t o standar d development . Th e first regulate s individua l emissio n point s (equipmen t leaks , productio n hne , an d equipmen t cleaning) , an d th e secon d establishe s asource-wid e emis

1 4P.3 0

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sio n limitation . Th asource-wid e approac h i s quit e simila r t o averaging , althoug h i t i s no t designate d a s such . 

### Conclusio n A s EP A develop s th e NESHA P fo r composites , w e respectfull y sugges t tha t th e Agenc y conside r th e followin g element s o f industry' s suggeste d MAC T approach ; • MAC T stand s fo r

"maximu machievable eontro l technology. " EP A shoul d adop t th e MAC T floors an d emissio n limit s w e propose d o n Septembe r 18 . Alternatively , befor e proposin g floors an d MAC T emissio n hmitations , o r othe r requ i ra mAnt s base d o n th e floors, EP A shoul d carefull y evaluat e th e "acMevablility' ' ofth e floors. Industr y ca n hel p tes t th e feasibilit y o

f possibl e MAC T requirement s throughou t th ahighl y divers e ope n moldin g an d corrosio n subcategories . • Especiall y for

th e corrosio n subcategoi-y , monome r i s no t a"control. " However , s o tha t a n effectiv e an d workabl e standar d ca n b e readil y develope d an d promulgated , w e agre e tha t monome r

content s ca n b e use d t o estimat e emission aan d se t floors, a s lon g a s th e resultin g floors ar e i n fac t achievabl e b y th e man y divers e facihtie s i n th e industry . Th e MAC T emissio n limit s mus t no t b e sa t s o lo w tha t

facihtie s hav * n o choic e bu t t o us e low

HA P resins . Fo r

example , corrosio n fabricator s shoul d b e abl e t o satisf y th e standar d b y usin g low-emittin g processes , suc h a e flow coaters , i n conjunctio n wit h high-HA P resins . • Th e standar d shoul d provid e aworkabl e procedure , base d o n th e CF A tes t protocol , fo r estabUshin g contro l factor s for ne w technologies , an d fo r usin g thes e technologie s an d associate d eontro l factor s t o mee t th e MACT emissio n limits . • Facihtie s shoul d b e abl e t o compl y wit h th e MAC T emissio n limit s b y aggregatin g al l ope n moldin g operations , an d o n arolling-annual-averag e basis .



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## , . 

## ^i 

## * 

# Composites

Miriam • 

# Association The Sottm torG"*.":pcwi«>* EJiKXtsost 

### FROM : Stev e McNall y Director o f Governmen

t Affair s PHONE : 703-610-022 0 FAX : 703-619-975 6 PLEAS E DELIVE RTHI S FA X TO : Dr . Madelin e Stru

m 7fc * OsB> f wit * ii.du.ij } 5Cforr.iAl!;? 7



### Pages : P.3 1 l$!00 1



### +1(919)541-568 9 Subject : Polyme

r Castin g MAC T Note : Madeline : Attache d i s acop y ofou

r presentation on a

n approac h t o th e portio n ofth e MAC T whic h will dea l wit h polyme r castin g operations . W e loo k forwar d t o ou r meeting wit

h yo u on Monda

y th e 5lh . Sincerely , Stev e McNall y



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Januar y 5,199 8 

### Al l Approac h t o th e Maximu m Availabl e Contro l Technolog y fo r th e Polyme r Castin g Sub-Categor y ofth e Reinforce d Plasti c Composite s NESHA P Polyme r castin g i s aproces s whic

h involve s th

e us e o f resi n material s containing Hazardou s Ai r Pollutan t (HAP ) components . Th

e proces s normall

y involve s th

e blendin g o f aliqui d resin wit

h afille r material , th e additio n o f achemica l initiator , o

r catalyst, an

d the n pouring the resultin g "matrix' ' into amold . Upo n th e completio n ofth e cur

e ofth e resi

n matrix , the resultin g plasti c materia l i s remove

d fromth e mold a s asoli d material . Ther

e ma y b e certai n application s wher

e o casting resin i s poured into amold , wit h n o fil le r material s added . Polyme r casting generall

y ca n be divide d int o the A following majo

r categories : 1 . Polyme

r Concret e 2. Soli d Surfac

e Manufactur

e 5 . Cultured Marble Manufactur e 4 . Decorative Casting Polvme r Concrete : Polyme r concret e i s atemwhic

h describe s products whic

h resembl e concret e in anumbe

r o f important respects . Th

e polyme r concret e material s utiliz e man

y iner t fille r material s whic

h ar e coul d b e foun

d in ordinar y concrete , These

, matenal s woul

d be variou s minera

l sands , grave

l an d smal l rocks . Th

e primar y differenc e betwee

n polyme r concret e an d ordinar y concret e i s tha t ther e i s no lim e o r wate r use d i n th e preparatio n ofth e concret

e aggregate . Th

e reactio n o f th e lim e an d th e wate r i s unnecessary , a s th e polyme r resi n i s the agen

t whic h bind s al l ofthe filler

material s together . Polyme r concret e i s apremiu

mgrad e materia l whic h i s utilized in situation s wher e enhanced physica

l propertiei s ar

e desired , wher

e enhance d wate r resistanc e i s desired , o

r wher e ther e i s a n overwhelming nee d fo r th e concret

e materia l to b e placed int

o immediat e service . Polyme r concret e i s used i n th e manufactur

e o f manhol e covers , utilit

y vaults , outdoo

r furniture , construction , roa

d surfacing , chemica

l impoundment

, civi l engineerin

g applications , an

d i t i s bein g evaluate d a s abroa

d replacemen

t fo r cast iro n i n man y applications . Polyme r concret e i s sometime s mixe

d i n th e fiel d fo r man y fiel d applications . I

n thes e applications , th e material s ma

y b e pre-mixe

d a t ih e factory , an

d placed in drums fo

r deliver y to ihe construction site , wher e th e catalys t

materia l wil l b e blended int

o th e resin matrix . I n mos t situation s wher

e polyme r concret e products ar

e manufacture

d a t the manufacturer' s facility , th e filler material s ar

e blended togethe

r wit h th e catalyst an d resin malarge mixer . Th e aggregat e i s the n poure d int o mold s o

r forms . Give n th e larg e particl e siz e o

f th e sand , an d grave l material s in polyme

r concrete , i t i s importan

t tha t th e resi n material s have aparticula r viscosity . Som e polyme r concret e application s ar

e i n conosiv e applications . I

n thes e applications , acorrosio n resistant resi n i s most

ofte n employed, Th

e corrosio n resistan t resin s whic

h ar e currentl y availabl e fo

r th e polyme r concret e industr y ar e hig h molecula r weigh t isopthali c acid base

d resins , an

d vinyleste r resins . Soli d Surface Manufacture : 

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Soli d Surface i s a tc m whic h describe s a panel materia l product , which resemble s polyme r concret e i n a number o f

importan trespects , Th

e soli d surfac

e materials utiliz e finel y ground iner tfille r materials , suc h as alumina tri-hydratc . Th e polyme r resi n i s th e agen twhic h bind s al l o f

th e filler material s together . Soli d surface i s a premiu

m grad e materia l which i s utilize d i

n situation s wher

e enhance d physica l propertie s ar

e desired . T

L i s use d i n th e fabrication o f

counterto p products , plasti c plumbin g fixtures, wal l panel s and man

y decorative applications . In mos tfacilitie s Wher

e soli d surfac

e product s ar e manufactured, th e filler material s ar e blende d togethe r wil h th e catalys tan

d resi n i n a larg

e mixer. Th

e aggregat

e i s then poure

d into mold s o r forms . Th e desirabl e properties o f

soli d surfac

e materials ar

e enhance d as th e fille r contento f

th e matri x i s increase d In order l o increas e th e filler content, an d enhanc e th e "wet-out " ofth e filler particles , th e mixing i s mos t ofte n conducte d i n a close d mixin g machine , an d unde r vacuum. In som e facilities , th e uniformit y ofth e resi n an d filler materials , an d hig h volume s o f

production , ha

s permitte d th e us e o f

automated mixin g an

d dispensin g equipmem . Give n hig h filler loadin g ofth e soli d surfac e matrbc , an d th e larg e amoun to f surfac e are a o f th e fine particl e material s i n soli d surface , iti s importan ttha i ihe resin materials hav e a particula r viscosity . Culture d Marbl e Manufacture : Culture d Maibl e i s a ter

n which describe s a polymer produc twhic h resemble s polyme r concrete i n a number o f

importan trespects . Th

e culture d maibl e materials utiliz e finely groun d iner tfiller materials , suc h as cakiu m carbonate , Th e polyme r resi n i s th e agen twhic h bind s al l ofth e fille r material s together . Culture d marbl

e i s primaril

y use d i n th

e fabricatio

n o f plasti c plumbin

g fixtures, wal

l panel s an

d i n man y decorativ e applications . I tha s als o been use d i n counterto p applications . I n mos tfacilitie s wher

e culture d marbl e pioducts ar

e manufactured, th e filler material s ar e blende d togethe r with th e catalys tan

d resi n i n a larg

e mixer . Th

e aggregat

e i s the n poured into mold s o r forms . Th e desirabl e properties o f

culture d marbl e material s ar

e somewha

tenhance d as th e filler conten to f

ih e matri x i s increased . Th e mixing i s mos toften conducted i n a n open mixin g machine . I n som e facilities , th e uniformit y o f th e resi n and filler materials , an d hig h volume s o f

production , ha s permitte

d th e us e o f

automate d mixin g an

d dispensin g equipment. I ti s importan

ttha tth e resi n materials have a particula r viscosity . Th

e viscosit y ofth e resi n i s controlle d mainl y through th e additio n o f styrene a s a "reactiv

e diluent" , althoug

h som e manufacturer

s hav e reported a limite d abilit

y t o elevate th e temperatur e ofth e resindurin g mixing . Thi s reportedly result s i n a lowerin g ofth e resi n viscosity . Thi s has enabled som e manufacturer s l o utiliz e lowe r monome r conten tresi n systems , Decorativ e Casting : Decorotiv e Castin g i s a tc m whic h describe s polymer product s wliich have been crafte

d l o fulfil l a numbe r o f marke tniches . Th

e polyme r resin s ar

c typicall y blended wit

h a wid e variet

y o f material s l o mimi c variou s materials . Th e fillers includ e meta l powders , minera

l fillers, woo d flour an

d a numbe r o f

othe r natura l and man-mad

e materials . The final product

s ca n b e mad

e t o mimi c cas tbronze , anima l ivory , marble , an

d a number o f

othe r materials . The marke

tniche s fo

r thes e product

s extend from smal

l decorative figurines t o expensiv e museu m replicas , and work s o f art . I n mos tfacilitie s wher

e decorativ e castin g product s ar e manufactured, th e fille r material s ar c blende d togethe r with th e catalys tan d resi n i n a larg

e mixer. Th

e aggregat

e i s the n poured int o mold s o r forms . 

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Th e desirabl e propertie s o r decorative castin g material s ca n b e enhanced a

s th e filler conten to f

th e matri x i s manipulated eithe r up o r down . Th e mixin g i s mos toften conducted i n a n ope n mixing machine . I

n som e facilities , th e uniformit y o f th e resi n an d filler materials , an

d hig h volume s o f

production , ha

s permitte d th e us e o f

automated mixin g an

d dispensin g equipment

. I ti s importan

ttha tth e resi n materials have a particula r viscosity . Th

e viscosity ofth e resi n i s controlle d mainl y throug

h th e addition o f

styren e as a "reactiv

e diluent" , althoug

h i tma y b e possibl e t o elevate the temperatur

e o f th e resi n durin

g mixing . Thi s reportedl

y result s i n a lowerin g ofth e resi n viscosity i n culture d marbl e manufacture . This ma

y enable d som e manufacturer

s t o utiliz e lowe r monome r conten t resin systems . Ther e ar e als o instance s wher

e th e resi n material

s wil l b e utilize d withoutan

y filler materia

l havin g bee n blende d into th e matrix. Generally thi s proces s develop s a decorative castin g produc twhic h relic s o n ih e resin t o produce a clear, finishe d plastic . This application ca n often b e see n i n th e productio n o f poured clear finishe s o n tabl e tops , dea r cas tencapsulation o f materials , an

d in th e productio n o f

decorativ e o

r artwor k piece s whic h mimi c glass . Characteristic s o f

Emission s Fro m Polyme r Casting : Durin g th e testin g whic h wa s performe d a tthe Do w Chemica

l facilit y i n Freepor

tTexas , ther

e wa s a n evaluatio n don e o n th e emission s from th e production o f culture d marbl e sinks . Thi s testin g involve d a smal l open to p mixer , an d a sin k mold . Th e produc

twa s manufactured i n a manner consisten twith industr

y practice , an

d th e resultin g emission s wer e measured . L l genera l i l wa s foun

d tha tth e emission s from th

e mixing an

d castin g ofth e produc

tresulte d i n emission s o f les s tha n on e percen

tofth e availabl e HA

P in th e resi

n (emission s wer

e measure d a t0.9%) , Ii was note d tha

tapproximatel

y 5n % ofth e emission s fro m the proces s wer

e develope d durin g th e mixin g portio n o f

th e process . Emission s Reductio n Technique s fo r Polyme r Casting : Followin g i s a lis to f

possibl e melhod s o f

reducing emission s from polyme r casting , an d a discussio n ofth e feasibility o f

adoptin g thes e limitations as a portion ofth e regulation . Covere d Mixin g Equipment : Th e testin g performe

d hy th e industr

y o n polyme r castin g indicate d thatroughly 50 % o f ih e emission s from polymer castin g wer e develope d durin g th e mixin g process . The industr

y als o feel s tha

i ihes e characteristi

c emission s ar

e presen ti n al l o f th e mixin g processe s whic h occu r throughou tth e broade

r Reinforce

d Plasti c Composite s Industry . A requirementwilhi n th e regulatio n whic h woul d addres s covers o n mixin g processe s woul d b e a n appropriat

e way l o addres s emission s from ih c mixin g process , bu twit h som e limitations . Certain portion s ofth e industr y mi x th e resin material

s unde r vacuum. Th

e industr y feel s lha tthes e "vacuu m mixing' * processe s shoul d b e exempted fro m an y requirement

s fo r th e us e o f

"covers " o n th e mixin g operations , sinc e th e vacuu m mixin g proces s presume s tha tth e syste m i s entirel y sealed . Also , th e industr

y often mixe s an

d blend s material

s i n smal l batches whic

h ar e intende d fo r immediate usage . Technicall y i twoul d b e unworkabl e t o place to o stringen

to f a limitatio n o

n th e mixin g and blendin g o f

resin s i n small quantities . 

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difficul t t o accomplis h unde

r close d mixin

g restrictions . Therefore , w

e woul d hop e lha t

smalle r batc h mixin g woul d no t

b e require d t o b e accomplishe d unde r closed mixing conditions . W e woul d Tecommen

d tha t al l mixing whic

h i s performe

d i n container s o

f 5 5 gaUon s volume , an d larger , shoul d b e accomplishe d wit h tight fitting lida , W e woul d als o recommen

d tha t mixin g whic h i s performe

d unde r vacuu mshoul d b e exempte d fromth e "tight fitting lid " requirements , a s th e proces s i s alread y accomplished i n aclose d system . W e woul d recommend tha

t al l materia

l b e stored i n covere

d containers , an d only thos e resi n containers : Whic h ar c les s tha t 5 5 gallon s i n volume , and engage d i n murin g activities , Which ar e les s tha n 5 5 gallon s an

d being use d t o transpor

t resi n material ,

- Whic h ar

e les s tha n 5 5 gallon s and bein

g activel y i n us e i n th e dispensing o r applicatio n o f resi n material , shal l b e permitte d t o b e uncovered . W e woul d als o recommen

d tha t th e regulatio n requir

e tha t polyme r castin g facilitie s shal l develo p writte n emission s managemen

t procedures . Thi s approac

h would b e modeled afte

r asimila r approach whic h wa s use d b y ih c BP A i n th e maintenanc e wastewate r requirements at

4 0 CFR63 . \ 05 . Thes e writte n procedure s shoul d include :

A n inventor

y o f al l HA P containin

g material s use d i n th e Polyme r Castin g Process . A step b y step descriptio n of th e handling o

f th e HA P containin g material s use d i n th e polyme r castin g process . A n evaluation an

d determination regardin

g the mos t effectiv e metho d t o eliminat

e O T reduc e th e expose d surface areao

f th e we t resin . An evaluatio n an d determination regarding th e reductio n or eliminatio n ol" th e us e of

HA P containin g material s i n mold preparation an d maintenance . A n evaluatio n and determination regardin g th e reductio n or

elimination o

f th e us e of HA P containin g material s i n clean-u p operations . A n evaluation an d determination regardin g th e effectivenes s an d technica l feasibilit y o f th e us e of styrene suppressant s i n th e manufacturin g process . Conclusion : Th e Industr

y feel s tiiat

thi s approac

h will lea d t o th t mos t effectiv e reductio n o

f emission s i n thi s industr

y segment , whil e allowin g th e industr y t o continue t o manufactur

e product s utilizin g thi s characteristically low emittin g process .



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