p.1 

OAR Box 1413 

Prepped by Ollie Stewart 

Document Number: 

59) 11-1-59 

Docket Number: 

A-94-52 

Printed 7/9/2008 3:11:23 PM Sheet 59 of 114 
P.2 

m£t 

A9(52r / , 

HrX-5fl 

'ccAf/u/vr PLASTICS DIVISION 

1850 RESEARCH DRIVE • TROY, MICHIGAN 48083-2167 • (810) 619-2200 • FAX (810) 619-2328 

June 20, 1996 

Mr. Chad M. Delbecq 

Division of Air Pollution Control 

Ohio EPA, Northwest District Office 

347 North Dunbridge Road 

Bowling Green, Ohio 43402 

Subject: Permit to Install Application for a Molding Press 

Dear Mr. Delbecq: 

Attached is the Permit-to-Install application for molding press #24 at our North Baltimore Plant. 

This includes the following: 

1. PTI application for compression molding press #24. 

2. Attachment to Ohio EPA application for PTI. 

3. Appendix "A" form with flow diagram. 

4. Information for Toxics Impact Analysis. 

While reviewing this application, please note that anticipated styrene emissions (Item #6 on PTI 

attachment) include styrene loss from: 

- Charging SMC to mold at 0.15% 

- Vacuum-assisted molding at 0.05% 

- Preheating SMC charges at 0.15% 

- Raw scrap SMC (varies frequently) at 0.20% 

Should you have any further questions, please contact me. Thank you for your cooperation in this 

matter. 

Sincerely, 

THE BUDD COMPANY 

Plastics Division 

t^r 9-

Vinod C. Shah, Manager 

Chemical & Environmental Affairs 

attach. vs/presspto 
P.3 

•fgriPffice Use Only 

uiecx Appropriate Box(es) 

m* 

Air Discharge 

Uater Discharge to New 

Source Treatment Works 

Solid Waste Disposal Facility 

Hazardous Waste Disposal Facility 

For Office Use Only 

PTI Application No.-_ 

Date Received ^./^ / Hk ; 

Premise No. 

OHIO ENVIRONMENTAL PROTECTION AGENCY 

Application for Permit to Install 

r - ... - w 4^ •,• V i^. -,mJ 

JUN 2 1 1996 

Applicant's iJame 

The Budd Company, Plastics Division 

Hailing Address 

1850 Research Drive 

rity :— 

OHIO E.P.A. 

N.W.D.O. 

CountyStat e 

Troy, Michigan -iOakl^nd Michigan 

Zip Code Telephone Number 

^yo*3 810-619-2294... 

Person to contact (Name and Title and Telephone Number) 

Vinod C. Shah, Manager, Chemical & Environmental Affairs . 

Location of Proposed Facility (State the location as completely and precisely as possible)* 

100 South Poe Road 

North Baltimore Wood 45872 

City Zip Code or Township County 

3089 

Standard Industrial Classification Code ' 

Directions: A Pennit to Install is required for new or modified source of pollution 

under the provisions of OAC Rule 3745-31. An application cannot be considered 

complete unless all applicable questions are answered and the required infonnation 

has been submitted. This application must be signed in accordance with OAC Rule 

3745-31-04(B) or i t cannot be accepted. 

Applicants for permits involving air emissions or wastewater treatment facilitie s 

wil l be required to pay a permit to Install fee as shown in Section 3745.11(B) and 

(C) of the Ohio Revised Code. This fee is payable fifteen days after the, date of 

final issuance of the permit. 

Name of new or modified source or facility : Compression Molding Press #24 

Product of new or modified sou rce/facility : Molded SMC Parts • 

Will the proposed source/facility involve any of the following: Check al l that apply. 

A. 

B. 

C. 

0. 

X Air Discharge 

Wastewater Treatment Works 

Solid Waste Disposal Facility 

Hazardous Waste Disposal" Facility 

*Example: "The source will be constructed on a 20 Acre plot to be located on Franklin 

Township Road No. 17, approximately 1% miles north of the intersection of 

State Route 99 and Franklin Township Road No. 17." 

EPA-3150 Is* 
P.4 

OHIO ENVIRONMENTAL PROTECTION AGENCY 

INSTALLATION SCHEDULE 

TO ACCOMPANY APPLICATION FOR PERMIT TO INSTALL 

IS FORM CONSTITUTES PART OF THE APPLICATION OF: 

FACILITY NAME: * The Budd Company Plastics Division 

ADDRESS: 100 S. Poe Road, P.O. Box 277, North Baltimore, Ohio 45872 

R A PERMIT TO INSTALL THE FOLLOWING AIR CONTAMINANT SOURCE: 

IDENTIFICATION: Press #24 

DESCRIPTION: 500 ton compression molding press 

DE INSTALLATION OF THE ABOVE AIR CONTAMINANT SOURCE IS PLANNED 

) FOLLOW THE TIME SCHEDULE DESCRIBED BELOW: 

1. EQUIPMENT ORDERED 

2. COMMENCE CONSTRUCTION 

3. STARTUP 

4. PERFORMANCE TESTING 

June 96 

June 96 

August 96 

August 96 

3 
P.5 

Under OAC 3745-31-04, these signatures shall constitute personal affirmation that all 

statements or assertions of fact made in the application are true and complete, comply 

fully with applicable state requirements, and shall subject the signatory to liability 

under applicable state laws forbidding false or misleading statements. 

^;^ i CL.- SI X . 6/*«l9£ 

Authorized Signature (for facility) Date 

Vinod C. Shah, Manager, Chemical & Environmental Affairs 

Title 

1850 Research Drive, Trov, Michigan 48083-2167 

Address 

For Wastewater Signature of General Contractor or Agent Date 

Treatment Plants: Performing installation, if selected. 

Company 

Address 

H 
P.6 

'-• 

ll 

2. 

3. 

4. 

5. 

6. 

7. 

8. 

9. 

10. 

ATTACHMENT TO OHIO EPA APPLICATION FOR 

PERMIT TO INSTALL 

Budd Plastics Division 

North Baltimore, Ohio 

Press #24 will be used to mold SMC material to manufacture automotive and 

other body panels. 

Name and estimated quantity of SMC material molded: 1.5 million pounds. 

This is a "new installation" for the purpose of PTI application. See attached 

installation schedule. 

No. 

Yes. 

Anticipated styrene (air) emissions*: 

Source Description Avg. Lbs. 

Press No. per Dav 

24 27.5. 

*Styrene loss from charging SMC to mold: 

Stvren \m.W % J ft ^0mm.^%mVe 4%^^ los mmWs stmf from ^km* m\.m\m\. T vacuu % • ^T ^0^ VPm* m%.% assiste H V W l W V V Wd AA1* moldin W #WUi*tg e » 

Styrene loss from preheating SMC charges: 

Styrene loss from raw SMC scrap (scrap 

varies frequently): 

Not apphcable. 

Yes. 

No. 

No. 

1 

5 

Max. Lbs. Max. Tons 

per Dav Der Year 

33.0 4.125 

0.15% by weight of SMC 

0 05% bv weieht of SMC 

0.15% by weight of SMC 

0.20% by weight of SMC 

• 
P.7 

11. None. 

12. No. 

13. Attached. 

14. Not applicable. 

15. Appendix A for Press #24 is attached. 

16-30. Not applicable. 

vs\ptiattach 
P.8 

i«se No. / / / 

ce No. / 

ication No. / 

APPENDDC A, PROCESS 

PROCESS DATA 

Name of process SMC molding 

End product of this process Molded SMC parts 

Primary process equipment 500 ton compression molding press 

Your identification Press #24 

Manufacturer Erie 

Capacity of equipment (lbs./hr): 

Method of exhaust ventilation: 

Are there multiple exhausts? 

Year Installed 1996 

Rated 

Stack |_JWindow fan 

Other, describe: 

Yes []No 

Make or model Not Known 

NK Max. 500 Ton 

X Roof Vent 

OPERATING DATA 

Normal operating schedule: __ 24 hrs./ day 6 

Percent annual production (finished units) by season 

Winter 25% Spring 25% Summer 

5000 

days/wk. 

Hourly production rates (lbs.): Average 

Annual production (indicate units) 1.5 million pounds 

25% Fall 

lb/day Maximum 

50 

25% 

6000 

wks./yr. 

lb/day 

Projected percent annual increase in production 

Type of operation: xj Continuous [_J Batch 

If batch, indicate Minutes per cycle 

Materials used in process 

10% 

Minutes between cycles 

list of Raw Materials 

5MC 

Principal Use 

Molding, Deilasrung, Milling 

Amount (lbs./hr.) 

5000 lbs/day 

• 

A PROCESS FLOW DIAGRAM MUST BE INCLUDED WITH THIS APPENDIX. Show 

entry and exit points of all raw materials, intermediate products, by-products, and 

finished products. Label all materials including airborne contaminants and other 

waste materials. Label the process equipment and control equipment. 

ATTACHED 

n 
P.9 

rol Equipment Code: 

A) Settling chamber 

IB) Cyclone 

C) Multiple cyclone 

D) Electrostatic precipitator 

[E) Fabric filter 

{¥) Spray chamber 

Control Equipment Data 

CONTROL EQUIPMENT 

(G) Cyclonic scrubber 

(H) Impingement scrubber 

(I) Orifice scrubber 

(J) Venturi scrubber 

(K) Plate or tray tower 

(L) packed tower 

(M) Adsorber 

(N) Condenser 

(O) Afterburner - catalytic 

(P) Afterburner - thermal 

(Q) Other, describe Baghouse 

Item 

(a) Type (see above code) 

[b) Manufacturer 

(c) Model No. 

[d) Year installed 

(e) Your identification 

(f) Pollutant controlled 

(g) Controlled pollutant emission rate (if known) 

(h) Pressure drop 

(i) Design efficiency 

(j) Operating efficiency 

Primary Collector 

Q 

Spencer Turbine 

80X150 

1995 

North Dust Collector 

Particulate 

est. 0.025 lb/day 

0.5 inches H20

 M^ 

99.97% 

NK 

Secondary Collector 

N/A 

•i * < 

. * "'i' l 

ioxa stack identification 

STACK DATA 

North Dust Collector Stacks 

U

N

° \r e other sources vented to this stack? |x|Yes 

If yes, identify sources Various press areas 

type: Round/top inside diameter dimension 12inches 

_ Rectangular, torn inside dimensions (L) '. (W) 

height Above roof Not through roof ft, above ground 16 

Exit gas: Temp. 135 °F, Volume Max. 8000 ACFM, Velocity 

Continuous monitoring equipment |jYes QNO 

If yes, indicate: Type Manufacturer _ 

Pollutant(s) monitored 

ft 

Max. 10500 ft/min. 

Make or Model 

Emissions data: Emissions from this source have been determined and such data 

included with this appendix: |_J^e s 

If yes, check method: |_| Stack Test 

Completed by Vinod Shah 

No. 

Emission Factor |_J Material Balance 

Date 12-Jun-96 

1 
P.10 

troi Equipment Code: 

(A) Settling chamber 

(B) Cyclone 

(Q Multiple cyclone 

(D) Electrostatic precipitator 

(E) Fabric filter 

(F) Spray chamber 

Control Equipment Data 

CONTROL EQUIPMENT 

(G) Cyclonic scrubber 

(H) Impingement scrubber 

(I) Orifice scrubber 

(J) Venturi scrubber 

(K) Plate or tray tower 

(L) packed tower 

(M) Adsorber 

(N) Condenser 

(O) Afterburner - catalytic 

(P) Afterburner - thermal 

(Q) Other, describe 

Item Primary Collector Secondary Collector 

(a) Type (see above code) N/A N/A 

(b) Manufacturer 

(c) Model No. 

(d) Year installed 

(e) Your identification 

(f) Pollutant controlled 

(g) Controlled pollutant emission rate (if known) 

(h) Pressure drop 

(i) Design efficiency 

(j) Operating efficiency 

STACK DATA 

Your stack identification Vacuum unit stack 

• No 

3:75 inches 

Are other sources vented to this stack? I X| Yes 

If yes, identify sources Other press areas 

Type: X Round, top inside diameter dimension 

Rectangular, torn inside dimensions (L) 

Height Above roof 4 ft, above ground 

Exit gas: Temp. _ 

(W) 

23 

80 °F, Volume 

Continuous monitoring equipment |_ Yes 

If yes, indicate: Type 

230 ACFM, Velocity 

0No 

Manufacturer 

3000 

jft 

ft/min. 

Make or Model Pollutant(s) monitored 

Emissions data: Emissions from this source have been determined and such data 

included with this appendix: | [Yes 

If yes, check method: |_| Stack Test 

Completed by Vinod Shah 

No 

Emission Factor |_J Material Balance 

Date 12-Jun-96 

1 
Vacuum Molding 

Styrene Emissions2 

3.00 lb/day 

Charging J^_ 

Styrenej Emissions1 

9.00 lb/day Vacuum 

Pumps 

Particulate 

Emissions3 

0.025 lb/day 

• 

Preheater 

Styrene Emissions1 

9.00 lb/day 

A. 

o 

Scrap and 

Rejected SMC, 

Press 24 

500 ton 

Particulate 

Emissions1 

0.624 lb/day 

A 

Dust 

Collector 

Molded Parts 

H 

Deflash and 

Secondary 

Milling Operations 

- ^ Molded Parts 

Styrene Emissions1 

12 lb/day 

• 

Total Styrene Emissions: 33 lb/day Total ParticulateEmissions: 0.649 lb/day 

4.13 tons/yr 0.08 tons/yr 

1

 Emissions inside plant - exit through general plant ventilation 

2

 Emissions both inside plant and through stack 

3

 Emissions through stack of dust collectors 
P.12 

Information for Toxics 

Impact Analvsis 

1. Air toxics being emitted and ACGIH TWA: 

Styrene 50 ppm 

2. Total maximum hourly emissions (lb/hr): 

Styrene 38.475 lb/hr 

3. Most emissions will be vented through general exhaust ventilation fans, 

although some may pass through doors and windows and some passes 

through the vacuum system. 

4. Exhaust point size (diameter), air velocity (ft/s) and temperature (F): 

See attached page 

5. There is no easy way to differentiate emissions rates at the various 

exhaust vents. In a theoretical "worst case", we could assume that the 

plant was being exhausted at a rate of 60,000 cfm through two exhaust 

vents - for example fans #6 and #13. Under these conditions, the entire 

38.475 pounds of styrene generated in one hour would exit through the 2 

working exhaust vents. 

6. Only the doors and windows will be non-vertical. 

7. All roof vents will have basically vertical air flow leaving the vents. Some 

vents have weather caps or similar devices which may deviate the flow 

shghtiy. 

8. Building dimensions and other building w/in 100 ft see attached 

drawing. 

9. Emissions exit points: see attached drawing 

10. Distance to nearest property line: 132 ft. 
P.13 

General Plant Exhaust Vent Information 

Vent# 

1 

2 

3 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

IA 

2A 

3A 

Diameter 

inches 

48 

48 

48 

54 

48 

54 

54 

54 

48 

54 

48 

42 

42 

42 

36 

36 

36 

Design 

CFM 

36,000 

36,000 

36,000 

50,000 

36,000 

36,000 

36,000 

24,000 

24,000 

24,000 

36,000 

24,000 

24,000 

24,000 

14,100 

14,100 

14,100 

Calculated 

velocity (ft/s) 

47.7 

47.7 

47.7 

52.4 

47.7 

37.7 

37.7 

25.2 

31.8 

25.2 

47.7 

41.6 

41.6 

41.6 

33.2 

33.2 

33.2 

Approx. 

Temp (F) 

90 

90 

90 

90 

90 

90 

90 

90 

90 

90 

90 

90 

90 

90 

90 

90 

90 

Prepared by The Budd Company - Plastics Division 7/12/95 
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