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# OAR Box 1413 Prepped by Ollie Stewart



### Document

Number: 

# 31)11-1-3 1 Docket Number: 

# A-94-5 2

Printed 7/9/2008 3:11:21 PM

Sheet 31 of 114

## IN/I D 1TA P /fa^fiy't'i P. 2

MINNESOT A TECHNICAL . ASSISTANC E PROGRA M 

# Reducin g Styren e Emission s i n

Fibe r Reinforced Plasti c Operation s PROJEC T SUMMAR Y

Projec t

Product/industr y Wast e stream/chemica l Result s Examin e styren e emission s level s o f fou rdifferen t fiberglas s resins , from conventiona l to low-styren e resins . Examine d bamer s t o incorporatin g low-styren e resin s int o existin g operations . Projec tconducted a tSunris e Fiberglass ; Wyoming , Minnesota . Fibe rreinforced plastic s Styren e emission s Styren e emission s from low-styren e resin s wer e reduce d b y 2 5 t o 4 5 percentcompared agains tth e conventiona l resi n use d a tSunris e Fiberglass . Usin g low-styren e resin s coul d sav e $1,800-4,44 0 pe ryea rb y reducin g th e nee d fo rincrease d ventilatio n t o mee tth e upcomin g OSH A workplace exposure standard fo rstyrene . Tw o o f th e low-styren e resin s examine d coul d b e substitute d directl y int o productio n operation s a tSunris e Fiberglas s withou tequipmen to rproces s changes . A thir d resi n woul d require modification s t o existin g spray equipmen ta ta cos tof

approximatel y $1,200 .
Projec tBackgroun d A numbe ro

f recen tinitiative s b y regulator s hav e pressure d th e fiber-reinforced plastic s (FRP ) industr y t o reduc e styren e emission s i n bot h th e workplace an d th e environment . Emission s can b e reduce d eithe rb y purchasin g an d installin g bette rpollutio n contro l equipment , o rb y proces s change s tha tpreven torreduc e pollutio n i n th e firstplace . Th e majorobjectiv e of tiie projec twa s t o demonstrate styren e emissio n reduction s b y usin g lo w styren e emissio n (LSE ) resin s i n a n open-mol d FRP operation . Th e projec

tevaluate d on e type of

proces s change—the substitutio n o f lo w styren e resin s i n plac e o f standar d resins—as a metho d o f reducin g styren e emissions . Low styren e resin s wer e develope d to mee tth e stric tai remission s standard s i n Californi a bu tar e no twidel y use d i n Minnesota . Thi s i s becaus e pas temissio n limit s o n th e FR P industr y i n thi s regio n hav e bee n almos tnonexistent . Th e projec tals o test s some of

th e industry' s preconception s abou tlow styren e resin s tha thav e formed a barrie ragains tthei ruse .

131 3 5t h Stree t S E Suit e E0 7 Minneapolis , Minneeot a 5B414-4B0 4 C61S ) 687-464 8 CBOO ) 647-001 5 CMinnesot a only ) FA X t612 > 687.476 9 Th e Minnesot a Offic e o f Wast e Management' s M n TA P progra m i e supporte d wit h a gran t t o th e Schoo l o f Publi c Health , Divisio n o f Environmenta l an d Occupationa l Health , a t th e Universit y o f Minneeota

.P. 3

Factor s examine d i n thi s stud y tha twoul d affectth e chang e t o a LS E resi n substitut e include : cos to f LS E resins , requirement s fo rspecialize d proces s equipment , workabilit y o f th e materia l b y th e FR

P operator , an d resultin g physica l propertie s o f th e laminate . A loca l resi n supplier , Worum Fiberglas s Suppl y Compan y o f St . Paul , Minnesota , assiste d wit h th e selectio n o f materials . Thei rassistanc e helpe d ensur e tha tth e resin s teste d would : 1 ) conside rth e above factors , 2 ) b e locall y available , an d 3 ) b e applicabl e t o th e majorit y o f open-mol d FRP companie s i n Minnesota . Thi s projec

twa s conducted a tth e facilitie s of Sunris e Fiberglas s i n Wyoming , Minnesot a wit h th e assistanc e o f

th e staf f a tSunrise . Sunris e use s th e open-mol d procedur e t o manufactur e products rangin g firom water-directiv e flumes , t o larg e cab s use d forheav y equipment . It s operation s ar e typical o f man y Minnesota FR

P open-mold facilities . Dat a firom th e 198 9 Toxi c Releas e Inventory (TRI

) showe d tha topen-mol d operation s constitut e th e larges tus e o f styren e resi n i n Minnesota i n term s o f numbe rof

facilitie s usin g th e operation , volum e o f resi n consumed , an d volum e of styren e release d t o th e environment . Regulator y Incentive s fo rChang e Incentive s t o reduce styren e emission s ar e bein g drive n b y increase d governmen tregulations . I n 1989 , th e Occupationa l Safety an d Healt h Administratio n (OSHA) establishe d rule s to reduc e styren e vaporexposure limit s b y 5 0 percen tb y th e yea r1993 . Th e regulation s wil l becom e effectiv e o n Decembe r31,1993 , an d wil l require FR P operations^ o meet*a>50 parts permillio n (ppm

) personal exposure limi t(PEL) an d a 10 0 ppm short-termexpo.sur e limits. ^ (STEL) . Thi s reductio n ca n b e achieve d b y institutin g change s i n wor k practice s suc h as : usin g differen tresins ; practicin g bette rhousekeeping ; usin g a closedrinold process ; o rb y * > mechanica l control s suc h a s increasin g th e ventilatin g capacit y of the * facility . UnliMh e / regulation s becom e effective , a n approve d respirato rprogra

m mus tb e uqed t o mee tth e / / requirement s of

th e ruling . ° 0 ^ > * s - / Othe rregulation s wil l com e firom th e 199 0 Clea n Ai rAc tAmendments (CAAA ) ai rquality standard s tha twil l reduce th e allowabl e styren e emission s from a FR P operation . Unde rTitl e m of th e CAAA , styren e i s liste d a s a hazardou s ai r pollutan t(HAP ) fo rwhic h boa t manufacturin g and reinforce d plasti c composit e producer

s hav e bee n liste d a s source categories . Maximum Achievabl e Contro l Technology (MACT

) standard s wil l b e writte n t o reduc e HA P emission s fo rth e source categories . Th e date s forestablishmen to f thes e standard s ar

e Novembe r15 , 1997 , forth e reinforce d plasti c composit e producers an d Novembe r15 , 2000 , forth e boa tmanufacturers . Th e standard s may closel y resembl e thos e alread y establishe d i n Californi a b y th e South CoastAi rQuality Managemen tDistrict' s (SCAQMD) Rul e 1162 , whic h are th e toughes tstandard s i n th e Unite d States . Rul e 116 2 require s tha tstyren e emissio n reduction s b e made b y usin g on e of th e followin g methods :

• Us e polyeste rresi n tha tcontain s les s tha n 3 5 percen tstyrene . • Us e polyeste rresi n tha temit s les s tha n 6 0 gm/m * durin g curing . • Us e th e closed-mold process . • Us e a n emission-control devic e tha tcapture s 9 0 percento f th e styren e vapors . SCAQMD' s Rul e 1162 als o require s th e us e o f airless , air-assiste d spra y equipmen ti n spra

y lay-u p applications . I n Minnesota , th e Minnesota Pollutio n Control Agency (MPCA ) wil l requir e FR

P facilitie s tha thav e a potentia l t o emi tmor e tha n 2 5 ton s pe ryea rof styren e t o appl y fo rai rquality permits . Thi s mean s tha tan y FR P operatio n wit h on e piec e o f spra y equipmen twil l excee d thi s limi tan d wil l require a permit . - 2 - 

# 2-P. 4

Resin s examine d Th e stud y examine d th e followin g nonfillable-typ e resins : 1 . A conventiona l genera l purpos e (GP ) orth o resi n wit h a styren e conten tof 46. 0 percen t tha ti s catalyze d wit h methy l ethy l keton e peroxid e (MEKP) . Thi s i s th e primary resi n currentl y use d a tSunrise Fiberglass . 2 . A genera l purpos e orth o resi n containin g 43. 9 percen tstyrene , catalyze d wit h benzoy l peroxid e (BPO) . 3 . A LS E genera l purpos e resi n containin g 38. 0 percen tstyrene , catalyze d wit h MEKP . 4 . A LS E genera l purpos e resi n containin g 33. 1 percen tstyrene , catalyze d wit h MEKP whic h meet s th e requirement s of SCAQMD' s Rul e 1162 . Resin s selecte d fo rth e stud y presen ttw o differen tapproache s take n b y raw materia l manufacturer s to reduc e styren e emissions . I n th e firs tapproach , th e polyeste rcomponen to f th e MEKP-catalyze d LS E resi n wa s re-engineere d t o produc e a materia l wit h propertie s tha t are comparabl e t o th e propertie s o f conventional resins , bu tcontai n substantiall y les s styren e monomer . Thi s wa s accomplishe d b y incorporatin g som e dicyclopentadien e (DCPD ) characte r int o th e polyeste rchain . A typical orth o polyeste ri s produce d b y reactin g orthophthali c aci d wit h ethylen e o

rpropylen e glycol , whic h i s the n dilute d wit h a styren e monome runti l a workabl e viscosity i s achieved . Polyester s tha tare produced wit h DCP D a s th e majoraci d componen tar

e use d t o produce resin s calle d low-profil e DCP D resin s an d ar

e easil y formulate d to yiel d lo w styren e levels . Thes e resin s giv e superio rfinish an d ar e use d i n application s wher e a hig h visua l quality i s desired . Drawback s to th e us e of thes e material s a s genera l purpos e resin s i s tha tthe y ten d t o b e lowe ri n strengt h an d mor e brittle . Fo rthes e reasons , a blen d o f

orthophthali c an d DCP

D acid s i s use d t o produc e th e polyeste rcomponen t use d i n genera l purpos e LS E resins . Th e secon d approac

h take n b y manufacturers i s to us e a BPO-catalyze d resi n syste m t o reduc e styren e emissions . Th e resin s use d i n thes e system s diffe rslightl y fro m th e conventiona l MEKP-catalyzed resin s i n tha tth e BPO system s are promote d wit h amines , wherea s MEK P system s ar e promote d wit h cobal tsalts . The BPO-catalyze d resi n i s expecte d t o giv e lower . styren e emission s tha n a MEKP-catalyze d resi n du e t o a faste rreactio n rat e an d a lowe r temperatur e a tpea k exotherm . Experimenta l Approac h Th e experimenta l consideration s o f th e study wer e to : 1 ) us e th e open-cu p stati c emission s tes t (fro m SCAQMD' s Rul e 1162 ) a s a prescribed metho d fo rcomparin g th e styren e emission s from tes tsamples ; an d 2 ) quantif y th e styren e emission s firom th e spra y lay-u p an d cur e step s o f th e open-mol d proces s fo reac h of th e tes tsample s usin g standar d fabricatin g technique s an d equipmen ta tSunris e Fiberglass . Open-cu p stati c emission s test . Thi s tes tdetermine s th e overal l flux of styren e from

, a catalyze d resi n sampl e unde rcontrolle d conditions , an d i s a quick an d eas y wa y t o compare th e performanc

e o f tw o resins . T o perfor

m this test , 10 0 gram s o f catalyze d resi n i s weighe d int o a one-gallo n siz e pain tca n lid , allowe d to polymerize , coole d t o roo m temperature , an d then reweighed . Th e differenc e betwee n th e initia l an d final weigh ti s use d t o calculat e th e stati c emissions . Thi s simplifie d tes tsimulate s styren e losse s firom th e curin g ste p o f a n FR P process . Determinin g emissio n factors . Styren e emission s fro m th e open-mold FR P operatio n a t Sunris e Fiberglas s resul tfrom th e spra y lay-up an d th e cure step s of th e FR P process . - 3 -P. 5

Therefore , th e overal l emissio n facto rwoul d b e comprised o f contribution s firom thes e tw o steps . Trial s wer

e ru n t o quantif

y th e emission s firom thes e tw o step s i n a wa y tha tsimulate d th e actua l production environmen t(techniqu e an d equipment ) a tSunris e Fiberglass . A n importan tassumptio n i n thes e trial s i s tha tth e majo rvolatil e componen ti s styrene , an d tha t emission s fro

m th e catalys t(o

rothe rvolatil e components ) ar e negligibl e compare d t o styrene . Quantifyin g Emission s fro m Simulate d Productio n Trial s Preliminar y trial s wit h th e conventiona l orth o resi n currently use d a tSunris e Fiberglas s showe d tha tvolatil e emission s an d th e temperatur e a tpea k exother m ar e dependen to n catalys tconcentration . A s th e catalys tconcentratio n i s increased , th e hea tgenerate d firom th e polymerizatio n increased , leadin g t o a highe rtemperature a tpea k exotherm . Thi s increase d temperatur e tend s t o increas e volatil e emission s becaus e styren e ha s a fairl y lo w boilin g point . T o minimiz e th e variabilit y i n emission s du e t o catalys tconcentration , a serie s o f geltim e test s wer e performe

d a tSunris e Fiberglas s fo reach of th e resi n system s t o determin e th e catalys tconcentratio n require d t o achiev e a geltim e of 20± 2 minutes . Th e rang e ofth e catalys tconcentratio n fo rth e MEKP-catalyze d system s wa s 1.5+0. 3 percen tbase d o n th e weigh to f th e resin . Th e BPO-catalyze d syste m wa s catalyze d a t2. 0 percent , whic h i s typical fo rtha ttype o

f system . Cur e ste p emissions . Th e styren e emission s resultin g fro m th e cure ste p o f

th e FR P proces s wer e quantifie d b y a metho d equivalen tt o th e open-cu p test . Fo reac h o f

th e tes tresins , one foot-by-two-footlaminat e sample s wer e produce d usin g a glas s conten to f 4. 5 ounce s pe rsquar e foot . Th e resultin g sampl e wa s weighed , se tasid e t o cure , an d the n reweighed . Th e differenc e betwee n th e initia l an d fina l weigh twa s use d t o calculat e th e stati c emission s an d th e emissio n factorfo rth e cur e step . Spra y lay-u p emissions . A das-Craf tLPA Serie s spray-u

p syste m wa s use d t o determin e th e styren e emission s resultin g fro m th e spray step . I n this test , know n quantitie s o f resi n an d catalys twer

e dispense d through th e spray equipmentan d collecte d i n a container . Th e differenc e i n weigh tbetwee n wha twa s spraye d an d wha twa s collecte d wa s use d t o calculate th e spray-relate d emissions . Materia l handlin g an d processing . Th e FRP operatin g technician , wh o mad e th e tria l sample s a tSunris e Fiberglass , evaluate d ho w eas y o rdifficulti twa s t o wor k wit h eac h materia l tested , an d ho w wel l eac h materia l wa s processed throug h th e spra y equipment . Thi s evaluatio n wa s importan ti n deterrninin g an y potentia l problem s o rbarrier s tha ta materia l substitutio n woul d presen tfo rSunris e fiberglass . Result s Th e dat a i n Table 1 sho w tha tth e reductio n i n stati c emission s firom th e LS E resin s i s 2 4 to 3 0 percen tles s tha n stati c emission s fro m th e conventional resins . Fo rth e MEK P catalyze d resin'samples , th e stati c emission s decrease d i n approximat e proportio n t o th e styren e conten t o f th e resins . Th e temperatur e a tpea k exother m als o decrease d a s th e styren e conten tof th e resi n decreased . Thi s facto rresult s i n lowe remission s becaus e th e bul k temperatur e b f th e resi n doe s no tachiev e a s hig h a temperatur e a s th e conventional resi n durin g th e cure , causin g les s styren e monome rto volatilize .

- 4 

# A-P. 6

Tabl e 1 : Open-cu p stati c emission s firompolyeste r resins

. Ambien t

conditions : temperature = 69±2°F ; relativ e humidit y <40%

. 7 Resi n '" \ Descriptio n 1 Conventiona l Ortho-G P Ortho-GP , BP O Catalyze d LS E Resi n LS E Resi n Rul e 116 2 Styren e Conten t

46. 0 43. 9 38. 0 33. 1 Temperatur e a t ,|i

Pea k Exother m(°F )
24 0 23 5 22 5 21 0 Static>Enus^ons ;



### * v 

### 'c-\gmfe^^ < 69. 6 50. 9 52. 8 48. 4 Th e styren e conten t

of th e BPO-catalyze dresi n syste mwa s roughl y equa l t o th e conventiona l orth o resin ; however , th e stati c emission s firomth e BPO-catalyze dsyste mwa s ver y low

. Thi s i s becaus e th e BPO-catalyze dsyste mproduce s ahighe r molecula r

weigh t polyme r a t afaste r rat e i n th e reactio n an dquickl y produce s atight matri x tha t

hinder s th e escap e o f

free styren e monomer . Tabl e 2 summarize s th e result s o f th e styren e emission s fro mth e cur e an dspra y lay-u p step s use di n th e FR P proces s trials

. Th e spra y lay-u p ste p wa s foun dt o b e responsibl e for ove r 7 0 percen t o f th e overal l styren e emissions

. Th e result s fo r stati c emission s liste di n Tabl e 2 ar e considerabl y highe r

tha n th e result s liste di n Tabl e 1 an dar e mos t likel y relate dt o plan t conditions , especiall y ai r movement
. Tabl e 2 : Emission s fro mcur e an dspra y lay-u p step s fro mth e simulate dproductio n trials

. Ambien t conditions : temperatur e = 68±1°F ; relativ e humidit y <40%

.
Resi n Descriptio n Styrene ^ £

Content ^ »

, Stati c Emissions; ^ i igmhhi*) \rj: ^ •<;<,>jcure ' '•v

. ^ A -f y y*

. syjwt w w* i yiv.y < Conventiona l Ortho-G P 46. 0 99. 5 0.047 0.01 7 0.06 4 0rtho-GP3P 0 Catalyze d 43. 9 65. 3 0.02 4 0.01 1 0.03 5 LS E Resi n 38. 0 79. 6 0.03 5 0.01 3 0.04 8 LS E Resi n Rul e 116 2 33. 1 57. 5 0.03 1 0.01 0 0.04 1 Fo r th e MEKP-catalyze dresi n samples , th e percen t reductio n i n th e overal l emissio n facto r o f aLS E resin , whe n compare dt o th e conventiona l resin , wa s foun dt o b e approximatel y 8 percen t highe r tha n expecte db y th e percen t reductio n o f

styren e conten t

of th e sam e materials

. Thi s ma y b e relate dt o th e highe r viscosit y o f

th e MEK P catalyze dLS E resins

. Eac h o f th e MEK P catalyze dresin s wa s processe dthroug h th e sam e piec e of equipmen t

unde r th e sam e operatin g condition s G n othe r words , th e energ y inpu t t o th e liqui dphas e for atomizatio n was th e sam e for al l o f th e resins)

. Th e increas e i n viscosity lead s to large r

- 5 - 

## 5P. 7

drople tsize , whic h reduce s th e overal l numbe ro f droplet s an d expose

d surfac e are a o f

th e spray , thereb y decreasin g th e releas e o f styrene . Tabl e 2 als o show s tha tth e BPO-catalyze d resi n dramaticall y out-performe d th e abilit y o f

th e MEKP-catalyzed resin s to reduce emissions . Emission s reductio n with th e BPO-catalyze d resi n durin g th e cure-ste p i s relate d t o a faste rpost-ge l reactio n rate , bu tth e caus e o f emission s reductio n fro m th e spra y ste p i s les s understood . On e reaso n fo rgreate rreductio n may b e tha twhe n th e catalys tan d resi n stream s ar e impingin g o n eac h othe rt o facilitat e mixin g durin g spray-up , th e wate ri n th e catalys t(3 8 percen tby weight ) doe s no treadil y mi x wit h th e resi n an d instea d migrate s to th e drople tsurface , where i tforms a barrie rtha t inhibit s styren e release . Processin g Characteristic s o f Resin s Th e viscosit y o f

th e MEKP-catalyze d LS E resin s tende d to b e 200-30 0 centipois e highe rtha n conventiona l resins . Thi s cause d concern tha tth e mixin g of th e resi n an d catalys tstream s durin g spray-u

p an d th e wettin g o f

th e glas s reinforcin g materia l with th e resi n woul d b e problematic . Th e LS E resin s wer e processe d throug h air-assiste d airles s spra y equipmen t usin g typical fabricatin g techniques . Mixin g considerations . Mixin g of th e catalys tan d resi n stream s durin g spray-up wa s found t o b e adequate foral l th e material s i n th e study . Ther e wa s no evidenc e of sof to rtack y spots , o rarea s o

f obviou s discoloratio n withi n th e cure d laminat e sample . Glas s wet-ou tcharacteristics . Al l th e LS E resi n sample s exhibite d glas s wetou t characteristic s comparabl e to th e conventiona l resin . A commo n misconceptio n b y industr y i s tha tth e highe rviscosit y of th e LS E resin s wil l increas e th e amoun to f manual labo rrequire d to rol l ou ttrappe d ai rbubble s an d to distribut e th e resin . I n al l cases , th e time require d b y th e operato rto prepar e th e laminat e sample s wa s similar , an d eac h of th e cure d sample s exhibite d th e translucenc y characteristi c of completel y saturate d glas s fibers. We tweigh to f

laminat e samples . Th e we tweigh tof th e laminate sample s produced firom LS E resin s tende d b e highe rtha n th e sampl e produce d fro m th e conventional resin . Th e increas e tende d to paralle l th e viscosity increas e o f th e LS E resin . A tth e upperextreme , laminat e sample s produce d fro m th e "Rule 1162 " LS E resi n (has a viscosity 30 0 centipois e highe rtha n conventiona l resin ) resulte d i n sample s wit h a we tweigh ttha twa s 8 percen t highe rtha n th e conventiona l resi n samples . Th e weigh to f th e glas s i n eac h sampl e wa s th e same ; therefore , th e weigh tincreas e of th e laminat e sample s wa s du e t o a n increas e i n th e amoun to f resi n used . Thi s situatio n i s though tt o b e relate d more to operato rtechniqu e and lac k of experienc e with LS E resins , tha n to a nee d to us e mor e LS E resi n i n th e process . A n operato rwith , extensiv e experienc e wit h a particula rresi n get s a fee l fo rth e amounto f liqui d require d t o saturat e a piec e ; o f glass reinforcin g material . Sinc e conventiona l G P resin s ar

e les s viscou s tha n LS E resin&san d hav e a slightl y greate rtendency to flow , a n operatorinexperience d wit h LS E resin s ma y spray to o lon g a s a resul to f a sligh tdifferenc e i n wet-ou trates . Economi c Consideration s Substitutin g a LS E resi n int o th e existin g FR P operatio n a tSunris e Fiberglas s i s contingen t upo n th e followin g economi c factors :

6 - 

## (bP. 8

• Raw materia l costs . • Capita l cost s forequipmen tto proces s th e ra w materials . • Cost s to achiev e complianc e wit h futur e regulation s (i.e. , modifie d o rne w ventilatio n systems) , especiall y th e OSH A 5 0 ppm PEL fo rstyrene . Tabl e 3 summarize s th e cost s associate d wit h thes e factors fo rSunrise Fiberglass . Tabl e 3 : Economi c analysi s of LS E substitutes. *

Variable s Conventiona l
, Ortho-Resi

n (46 % styrene ) ^ E ,\'<38*

#styreneX : l ISEResxnV^ - , X33.i % stg£ene);< v Catalys tleve l (%

) 1.

5 1.6 1.7 2. 0 Catalys tcost" ' ($/yr

) 2,85 0 3,04 0 3,23 0 4,80 0 Resi n cost ' ($/yr

) 70,00 0 70,00 0 70,00 0 70,00 0 Annual catalys t+ resi n cos t($/yr

) 72,85 0 73,04 0 73,23 0 74,80 0 Adde d cos to f ra w materia l substitutio n ($/yr) 190 38 0 1,95 0 Ven tcosts to mee t 5 0 pp m PEL

* ($/yr ) 9,00 0 7,00 0 5,94 0 2,70 0 Reductio n i n ven t cos tt o mee t5 0 pp m PE L ($/yr) 2,00 0 3,60 0 6,30 0 Annua l saving s a s a resul to f

LS E substitutio n ($/yr) 1.81 0 4_5 g "Analysis is based

on the following information related to Sunrise Fiberglass: annual resin consumption is 100,000 pounds; present ventilation airrequirement to meet 100 ppm PEL is 10,000 cfm; and production fadiity specifications are 60 ft by 104 ft by 10.7

ft (67,000 /r*

J
b Catalyst

cost is $1.90/lb. forMEKP; and $2.40/lb. fbrBPO.

• All resin costs are $0.70/lb.
•••"TW * Assumes that

ventilation airrequirements are doubled to meet 50 ppm PEL. Operating costs associated

with heating the makeup airand operating the system were taken from a 1988 SIRC report, "Cost

of Compliance and

Economic Impact

upon Selected

Reinforced

Plastics and

Composites Industries of

a Proposed

OSHA Standard

of 50 ppm fbrStyrene."
Ra w materia l costs . Th e added expens e resultin g fro m substitutin g th e LS E alternative s int o th e presen tproduction situatio n (shown i n Tabl e 3 ) i s relate d to th e catalys trequirements only . Th e cos tof

th e BP O catalys ti s 2 5 percen thighe rtha n tha to f th e MEK

P catalys tan d i s processe d a ta highe rconcentration . Th e adde d materia l expens e associate d wit h th e MEKP - - 7 -

^P. 9

catalyze d LS E system s resulte d firom th e nee d to increas e th e catalys tleve l t o achiev e th e desire d geltime s use d i n th e study . ' Capita l cost s relate d t o proces s equipment . Currently , Sunris e Fiberglas s use s th e das Craf tLP A serie s spra y equipmen tfo rspra y lay-up . T

o proces s th e MEKP-catalyze d LS E resins , n o change s t o existin g equipmen twoul d b e require d an d th e material coul d b e directl y substituted . However , equipmen tchange s woul d b e require d to process th e BPO-catalyze d LS E resi n becaus e th e BP O catalys ti s supplie d a s a n aqueou s suspensio n wit h a viscosit y tha t i s highe rtha n MEK P catalysts . Th e presen tequipmen ta tSunris e Fiberglas s coul d b e upgraded to accommodate th e BP O catalys tb y installin g a mixe rtha twoul d kee p th e catalys t suspende d durin g production , an d b y installin g large rpipin g fordeliverin g th e catalys tt o tiie spra y gun . Fo rth e Glas-Craf tLP A serie s spra

y unit , th e conversio n cos twoul d b e approximately $1,200 . Th e cos tof a ne w spra

y syste m fo reithe rcatalys twoul d b e approximately $7,000 . Compliance-relate d costs . Th e economi c impactof th e OSH A rul e tha trequire s reducin g th e PE L o

f styren e fro m 10 0 ppm to 5 0 pp m b y Decembe r31,1993 , i s an issu e o f concer n t o Sunris e Fiberglas s an d man y othe rFR P operations . Th e presen tstatu s o f th e rul e require s tha tth e 5 0 ppm exposur e limi tb e me tb y mechanical mean s orwor k practice change s tha t eliminat e th e nee d fo rrespirator s b y th e workers . The mechanica

l option s availabl e to achiev e th e OSH A requirements are : 1 . Increas e th e make-u p ai rthroughpu to f th e existin g ventilatio n system , provide d th e syste m ha s som e flexibilit y to handl e th e increas e (wil l resul ti n increase d operatin g costs) . 2 . Upgrad

e th e existin g ventilatio n syste m wit h a make-u p ai runi tand exhaus tfan s t o increas e capacit y (wil l require a larg e capita l expense) . Th e existin g ventilatio n syste m a tSunris e Fiberglas s wa s designe d to handl e increase d air flow capacit

y an d coul d b e increase d sufficientl y t o mee tth e ne w OSH A requirement s (a s liste d i n option 1 above) . Th e modification s woul d involv e exchangin g th e existin g fa n pulley s wit h large rdiamete rpulley s t o increas e fa n spee d Th e makeu p ai rheate runi tha s th e flexibility t

o hea tthi s large rvolum e o f air . Added operatin g cost s woul d b e relate d t o th e highe rpowe

rrequirement s to operat e th e fan s an d th e highe rhea trequirements t o hea tth e makeu p air . Tabl e 3 show s th e approximat e saving s o n ventilatio n cost s foreac h ofth e LS E substitutes . I f optio n 1 (liste d above ) wa s no tavailabl e t o Sunris e Fiberglas s and a switc h t o a LS E resi n coul d no tensur e compliance , th e capital expens e require d to desig n an d upgrad e th e existin g ventilatio n syste m woul d b e substantial . ForSunrise , th e capital expens e to upgrad e th e makeup ai runi tan d th e exhaus tfan s woul d excee d $35,000 , accordin g t o a repor tb y th e Styren e Infonnatio n an d Researc h Council (SIRC) . Whe n th e ra w material cost s ar e take n int o account

, th e annua l saving s forSunris e coul d rang e from $2,00 0 fo rth e LS E resi n containin g 3 3 percen tstyrene , to $4,40 0 fo rth e BPO-catalyze d LSE resin . Fo rth e BPO catalyze d LSE resin , th e paybac k perio d woul d b e les s tha n fourmonth s i f th e cos tt o upgrad e th e spra y equipmen tt o handl e th e BP O catalys ti s include d i n th e economic analysis . Conclusion s Th e result s o

f th e stud y sho w tha tstyren e emission s fro m th e open-mol

d FR P proces s a t Sunris e Fiberglas s coul d b e reduced substantiall y b y usin g LS E resin s (BPO - o rMEKP -

- 8P.1 0

catalyzed) . Th e MEKP-catalyzed LS E resi n system s wer e found to hav e th e followin g characteristics :

• Reduc e styren e emission s b y 25-3 6 percent . • Easil y incorporate d int o th e existin g process . • Require d n o spra

y equipmen tchanges . • Hav e th e lowes tadde d ra w materia l costs . Althoug h th e viscosity o f thes e material s i s somewha thighe r(200-30 0 centipoise ) tha n th e conventiona l resins , th e processin g characteristic s o f th e materials , wit h respec tto wetout , wa s comparabl e to conventiona l materials . Ther e wa s a tendency t o overappl y th e IS E material s durin g spray-u p bu tthi s wa s speculate d to b e relate d t o th e operators lac k o f experienc e wit h thes e mor e viscou s material s an d could b e overcom e wit h time. Th e BPO-catalyze d LS E resi n syste m wa s foun d to hav e th e followin g characteristics :

• Reduce d styren e emission s b y 4 6 percent . • Easil y incorporate d int o th e existin g process . • Require d a $1,20 0 expens e to upgrad e existin g spra y equipmen tt o handl e BP O catalyst . • Increase d ra w material expens e becaus e of BPO catalyst . • Offere d greates tsaving s i n ventilatio n cost s require d fo rcomplianc e wit h OSH

A 5 0 ppm PE L fo rstyrene . • Comparabl e processin g characteristic s to th e conventional resin . A present-worth analysi s comparin g th e LS E resin s showe d tha tth e conversio n t o a BPO catalyze d resi n woul d yiel d th e mos teconomi c benefits . Assumin g a five-yea rlif e fo rth e equipmen tan d an interes trat e o f 7 percent , th e presentwort h o f saving s an d costs are $7,400 , $11,00 0 an d $16,70 0 fo

rth e MEKP-catalyze d LS E resin s an d th e BPO-catalyze d resin , respectively . Option s fo rAchievin g Compliance . Minnesota FR P shop s can achiev e th e futur e OSH A complianc e requirements b y implementin g on e o f th e tw o followin g options , dependin g o n thei rcurren tstyren e emissio n levels : 1 ) instal l mechanica l change s t o increas e ventilatio n capacity , an d 2 ) substitute a LS E resi n int o th e currentprocess . Befor e eithe rof

thes e option s are implemented , however , currentemission s level s mus tb e determined . OSH

A require s tha tstyren e exposure level s b e determine d b y worke rexposure monitoring . One metho d of exposure monitorin g requires tha ta worke rwea ra compact^ ^ styrene-sensitiv e monito ro n hi s o rhe rshir tcolla rfo rth e duratio n o f

a wor k perio d Th e I exposur e monito ri s the n sen tfo ranalysi s to determin e styren e exposur e levels . [Note : I ti s ' " likel y tha tmos tFR

P shop s hav e alread y don e som e exposur e monitoring , an d know wha t thei rbaselin e workerexposure level s ar e forth e resi n syste m the y ar e using. ] I f th e result s of

workerexposure monitorin g indicat e tha tth e 8-hou rtime-weighted averag e CTWA ) fo rHyren e i s abov

e th e OSH

A 5 0 ppm PE L bu tbelo w 7 0 ppm , i tma y b e possibl e t o reduc e th e TW

A t o th e require d complianc e leve l by substitutin g a LS E resi n int o th e presen t process . Two method s exis tfo rdeterminin g whethe ra LS E resi n ca n reduc e styren e emission s to require d compliance levels : 1 ) substitut e a LS E resi n int o th e presen tproces s for a testin g perio d o

f a da y o rmore an d perfor

m workerexposur

e monitorin g to detennin e exposur e levels ; o

r2 ) us e th e open-cup tes tto scree n LSE resin s fo rthei rpotentia l t o reduce exposure .

9 -P.1 1

Th e us e of

th e open-cu p tes tassume s tha tstyren e concentratio n i n th e workplace i s proportiona

l t o stati c emissions of

th e resin . T o us e th e open-cup tes tmetho d t o compare on e ormor e LS E resin s t o a curren tresin , determin e th e following : 1 . An 8-hou

rTW A fo rth e presen tplan tconditions . 2 . Open-cu

p stati c emission s forth e resi n presentl y i n use . 3 . Open-cu

p stati c emission s forth e LS E resi n substitute . Th e expecte d TW

A fo rth e LS E substitut e ca n b e found b y multiplyin g th e presen tTW A (# 1 above ) by th e rati o o f

th e stati c emission s result s (divid e #3 b y #2) . Onc e thi s procedure identifie s resin s tha treduc e emission s sufficiently , th e bes tresi n ca n the n b e selecte d fo r a plan ttria l durin g whic h exposur e ca n b e measure d fo rverification . NOTE : Th e OSH

A 5 0 pp m PE L rul e ha s bee n challenge d an d overturne d i n othe rarea s o f th e Unite d States , an d th e futur e statu s o f th e rul e i n Minnesota i s somewhatuncertain . Becaus e of thi s uncertainty , Sunrise Fiberglas s (and othe rFRP operations ) are hesitan tto implemen t change s i n thei rprocesses , includin g th e us e o f LS E resins . Th e possibility tha tfutur e regulation s may no trequir e th e proposed styren e emissio n reductions , alon g wit h familiarit y wit h conventional resins , add s t o th e resistanc e t o change . However , i f th e OSH A rul e becomes law , th e LS E resin s woul d b e a viabl e optio n formeetin g workerexposur e limits . I n addition , LS E resin s wil l hel p FR P operation s mee tfutur e CAA A regulations . Fo rMor e Informatio n If yo u hav e question s abou tthi s stud y and woul d lik e more informatio n aboutreducin g styren e emissions , contac tRandy Coo k a tMnTA

P a t612/627464 6 or800/247-0015 . Reference s

• Costof Complianc e an d Economi c Impac tupo n Selecte d Reinforced Plastic s an d Composite s Industrie s o f

a Propose d OSH

A Standard o

f 5 0 ppm forStyrene . Repor tt o th e Styren e Industr y Researc h Council (SIRC) . Augus t3,1988 . Arthu rD . Little , Inc . Referenc e No . 61936 .

• Rule s an d Regulations , Volume s 1 and 2 . Januar y 1992 . Sout h CoastAi rQualit y ManagementDistrict . Diamon d Bar , CA .

• 198 9 Toxic Releas e Inventory (TRI ) Report . Minnesota Emergency Respons e Commission . This styrene emissions reduction demonstration project was made possible by a grant from the U.S. Environmental

Protection Agency (EPA) Pollution Prevention Incentives to States (PPIS) Program. (3/93 )

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APPENDI X 1 Lis to f Acronym s
BP O benzoy l peroxid e CAA A Clea n Ai rAc tAmendments of 199 0 DCP D dicyclopentadien e EP A Environmenta l Protectio n Agenc y FR P fibe rreinforced plastic s G P genera l purpos e HA P hazardou s ai rpollutan t LS E lo w styren e emissio n MAC T maximu m achievabl e contro l technolog y MEK P methy l ethy l keton e peroxid e MPC A Minnesot a Pollutio n Control Agenc y OSH A Occupational Safet y an d Healt h Administratio n PE L permissibl e exposure limi t PP M part s pe rmillio n SCAQM D Sout h Coas tAi rQuality Managemen tDistric t SIRC Styren e Informatio n an d Researc h Counci l STE L shor tter m exposur e limi t TR I Toxi c Releas e Inventory TW A time weighte d averag e VO C volatil e organi c compoun d

1 1

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### "7 f ;• " tf ,
APPENDI X 2 Glossar y o f

Term s

1

. Airless , air-assisted

. A spra y technolog y tha t deliver s lo w pressur e ai r to th e resin/gelcoa t

an dcatalys t

immediatel y afte r

th e tw o material s hav e bee n mixed

. Th e air

assiste dcontainmen t

form s abarrie r

aroun dth e materials , whic h develop s ashiel dtha t prevent s polyeste r

o r catalys t particle s fro mbecomin g airborn e emissions

. Airless implie s tha t ai r i s no t use dt o atomiz e th e polyeste r o r catalys t stream s prio r

t o mixin g 2

. Emissio n factor

. A numbe r tha t quantifie s th e emission s fro maproces s base do n th e input s int o th e process . Dimension s o n emissio n factor s ar e mas s emission s pe r mas s materia l inpu t

to process . 3

. Exotherm

. Internally-develope dhea t tha t accompanie s achemica l reaction

. 4

. Geltime

. Th e lengt h of tim e tha t

acatalyze dpolyeste r

remain s workabl e befor e i t start s to solidify

. 5

. Make-u p air

. Replace s ai r tha t i s exhauste dfro maplan t to mee t ventilatio n requirements

. 6
. Stati c emissions

. Refers to th e VO C emission s pe r uni t surfac e are aof

expose dcurin g material

. Result s o f

th e open-cu p test

ar e reporte da s stati c emissions

. 7
. Wet-out . A measuremen t rat e tha t measure s ho w lon g i t

take s areinforcin g materia l to b e completel y saturate dwit h resin

. Rat e i s usuall y determine dvisuall y an dmeasure di n elapse dtime.

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