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# OAR Box 1384 Prepped by Charmelle Mathews



### Document

Number: 

# 74 ) ll-E-3 4 Docket Number: 

# A-94-5 2

Printed 7/2/2008 8:42:05 AM Sheet 74 of 264P. 2 

### A-94-5 2
CONTACT REPOR

T From : WanitaDunston , U S Environmenta l Protectio n Agency Inter

n Contact : Charli e Stanie r Company/Agency : Internationa l Pape r | ; / ftu ht'5 fQQJ Dat e o f Contact : '•(* , v*'"''-ft*. * '*?i^»*,._ *

Novembe r 21,199 5 p

_EP^AIRDOCKF T tel : (410 ) 519-209 4 fax : (410)519-211 2 Contac t Summar y (Note s prepare d b y WanitaDunston) (Retype d b y C . Stanier , strikeout indicate s deletion , itali c indicate s insertion )

• I NOTICE

D FRO M MEDELEINE' S STRUMS ' NON-CB I CONTACT REPOR T THAT A MAS S BALANCE WOUL D B E PERFORME

D T O DETERMIN

E THE QUANTITY O F HAP s ABSORBE

D B Y CARBO

N FILTERS . HA S THI S BEE N PERFORME

D YET ? A n interna l stac k tes t repor t wa s usedfo

r TRI , SAR

A 31 3 reporting . Mr . Stanie r ha s th e value s fo

r th e weigh t gain ofth e carbo n bed . See attachment A.

• WHA

T AR E TH E HA P EMISSION S (I

N TPY ) FO REACH PROCESS ? I NOTICE D THAT [THERE]APPEA

RT O B E ONL

Y THRE E PROCESS . Internationa l Paper ha s VOC s calculated , but

it i s not speciate dfo

r eac h process . M. Strum (conversation of 12/15/95) agreed

that this information was not necessary.

• HO

W MAN Y LINE S AR

E BEIN G OPERATED , AN

D HO W MAN Y AR E BEIN G CONTROLLED ? Ther

e ar e thre e processes , a s indicate di n th e survey , an dn o line s are duplicated . Proces s 1 refer s t o th e mixing plant

and continuous casting line. Materia l fo r th e continuou s laminatio n casting lin e i s produce dhere in ihe mixing plant, ft The mixing plant i s non-controlled . The continuous casting line is controlled by condensation and carbon filtration of

oven exhaust. For

proces s 2 , th e proces s i s lik e culture dmarbl e castin g (a s Madelein e referredt o it in th e contac t

report) , but

chemically , it

i s different . (Mr . Stanie

r wil l chec k on how their

shapedgood s manufacturing i s different , and get back to u s wit h tha t information) . The product s ar e shapedgoods , such a s kitchen/bathroo msinks . Proces s 3 i s th e particl e manufacturing line , andi t i s controlled . Th e products , particles , ar

e afilled polystyrene polyester. SEE ATTACHED INFORMATION

B.

• I T I S STATE

D FORCONTINUOUS LAMINATIO N CASTING

THAT TH

E EMISSION S BETWEE

N TH E DISPENSING MECHANIS M AN D THE OVE

N FO R TH E LIN E AR E "PARTIALL

Y CONTROLLED" . WHA T I S MEAN

T B Y THIS ? Continuou s laminatio n casting i s partially controlled . Th e proces s involve s putting^i/Zefl f liqui d polyme

r o n th e belt . Ther

e i s aga p t o allow filled liqui dpolyme

r into th e system .P. 3

Thi s ga p allow s fugitiv e emission s to escape , an dtherefore , th e captur

e efficiency i s no t 100 % a t th e dispensin g mechanism .
• WOUL

D YO U LIK E T O MAK

E AN Y ADDITIONA

L COMMENT S REGARDING YOU RFACILITY ? Currently , afiberglas s RACT i s bein g pu t together . Maryland looke d a t ou r processes , and i t

look s a s though RACT i s not applicable . Also , sinc e th e time of

Madeleine' s contac t

report , aspeciate dstac

k tes t ha s been don e n th e particl e manufacturin g proces s an dshapedgoods . Mr . Stanie r wil l summariz e thi s and sen

d it to EP A i n non-cb i form . H

e wil l als o dra

w asimpl e layou

t ofth e process , i n ageneralize d form , t o let u s kno w wher

e th e emission s are comin g from. ADDITIONA

L QUESTION S - See attached section C. 1 . WHA

T I S TH E VOLUMETRIC FLO

W RAT E T O THES E FILTERS ? 2 . WHA

T AR E TH E HA P EMISSION S (i n tpy ) FOREAC H EMISSION POINT ? 3 . WHO I S TH

E MANUFACTURE

R(O RDESIGNER

) O F THE FILTER S USED ? *Pleas e forwar

d all additiona

l correspondenc e to Madeleine Stru m[tel : 919.541.2383 . fax : 919.541.0072]*-Thanks . Informatio n i s accurat

e as marked. 

# A^z_ Charli e Stanie

r



# 2 _P. 4

A . A mas s balanc e to evaluat e HA P adsorption i n th e [CFHP ] carbo n beds has notbee

n performed . Currently availabl e informatio n show s condensatio n o f 4.0X10" 4 l b condensat

e pe r l b matri x applie d t o th e castin g machine , an daweigh t gain i n th e carbo n bed s o f

6.8x10" 4 l b pe r l b matri x applie d t o th e castmg machine . B . Descriptio n of

installations : "Proces s 1 " - Fountainhea

d Sheet Manufactur

e A . Mixin g o f

resi n wit h filler : no t

controlle d B. | Continuou s castin g (CFH P - Continuou s Fountainhea dProcess) : controlle d wit h condense

r andcarbo n be d- captur

e efficiency no t

determine d Thi s operatio n produce s 3 ' wide cure dsheet s in 1/4" , 1/2 " an d3/4 " thicknesses . Materia l i s continuously cas t

an dthe n cut

into 8,10 , and1 2 foot

sections . "Proces s 2 " - Castin g o f

polyeste r shape dgoods : no t

controlle d Th e produc t

fromthi s are ai s kitche n an dbathroo msinks . Thes e are produce d by pourin g catalyzed , fille dpolyester resi n into close dmolds . Th e differenc e betwee n thi s operatio n and culture dmarbl e i s a s follows : In culture dmarble , th e mal e portio n ofth e mol d i s spraye dwit h age l coa t wit h ahigh styren e content . Thi s i s the n backfille d wit

h afille dpolyester , giving alayere dproduct . Ou r shape d good s product s are homogenous , made b y castin g fille dpolyeste r i n aclose dmold . "Proces s 3 " - Productio n o f polyeste r particle s Thi s operatio n produce s polyeste r particle s (sorte dby size ) fo r additio n t o "Proces s T'iand "Proces s 2" . Th e particle s are produce di n 2 steps : A. i Castin g athi n (<l/4" ) ribbon o f Fountainhea

dmaterial (20 " wide ) o n a continuou s castin g machin e (moving bel t andcurin g oven ) - th e oven and mix tank s are controlle db y acarbo n bed . B . Siz e reductio n (grinding/crushing ) followedb y sortin g by siz e - n o VOCs . C . Styren e PP

M (volume) of

exhaus tgase s (t

o atmosphere) fro

m each process . High cone , stream s Low cone , stream s Continuou s Sheet

Castin g Proces s mixin g only 400 0 - 8000 castin g only * Particl e Castin g ; * Shape d Good s Plant

400 0 - 800 0 *Hig h concentratio n stream s i n thi s are aare controlled . Additiona l questions : 1 . Volumetri c flow t o th e CFH P carbo n be di s approximatel y 7 5 scfm . 

# 3. 2
-

0
- 1 4 4 5 0.4- 2 1
- 1 7P. 5

Volumetri c flo w t o th e particl e plant carbo n be di s 21 6 scfin . 2 . Agree dtha

t thi s infonnatio n wa s no t

neede d(Strum/

Stanie r 12/15/95) . 3 . Th e VO C contro l syste mwa s designe dcooperatively between i n hous e personne l an d HYDROSYSTEMS , INC . Attachment

s Summarized result

s fro m 1995 styren e stack tests performe d in particl e castin g plan tand shape d goods plan t i See attache dsummary . Th e tes t result s wer

e combine dwit

h th e productio n dat adurin g th e tes t t o create l b VO C / l b produc t emissio n factor s use dt o comput e emission s fo

r reportin g andTitl e V planning . Th e development ofth e in-hous e factor s involve s detaile dproductio n informatio n an di s considere dconfidentia

l busines s information . 

### PLEAS E MOT E - TH E TES T 5UMM/\R V CALCULATES DAIL Y 

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# m ,,,. ' ENVIRONMENTALINC. Ma y11 , 199 5 Mr . Charli e Stanie r Environmenta l Enginee r Internationa l Pape r Corporatio n NEVAMA R Divisio n 833 9 Telegrap h Roa d Odenton , Marylan d 2111 3 Subject : Fugitiv e Emissio n Estimate s Associate d wit h Shape d Good s

Plan t (SGP ) an

d Particl e Plan t (PP ) EM S Projec t No. : 621 4 ' Dea r Charlie : Enclose d i s a summar yrepor t tha t present s estimate s o f MM Aan d Styren e Fugitiv e Emission s tha t wer e generate d b yth e SG P an

d P P operation s durin g th e da yshift s o f Apri l 1 9 an d Apri l 20 , 1995 . ASente x Scentograp h Plu s I I fiel d portabl e ga s chromatograp h wa s use d t o sampl e pp mconcentration s o f MM Aan d Styrene . Als o include d i n th e repor t i s a n estimat e o f VO C emission s fo r Stac k 5 i n th e Shape d Good s Plan t a s wel l a s a n estimat e o f mas s loadin g fo r th e Particl e Plan t carbo n unit . Du e t o hig h sourc e concentration s and/o r th e presenc e o f interferents , thes e source s coul d no t b e sample d wit h th e ga s chromatograp h an d wer e measure d usin g a JUM VE- 7 Flam e Ionizatio n Analyzer . Jo e Slaughte r o f EMS , yourself , an

d th e undersigne d participate d i n th e fiel d sampling/analysi s activities . I n th e continuou s operatio n Particl e Plant , th e result s o f th e fiel d samplin g activitie s indicat e tha t th e mas s emission s o f MM A ar e estimate d t o b e 2,4 7 lbs/day , an d Styren e t o b e 3.1 8 lbs/day . Th e VO C loadin g t o th e P P carbo n uni t i s estimate d t o b e 65.5 5 lbs/da y a s carbon . I n th e batc h operatio n Shape d Good s Plant , mas s emission s o f MM

Aar e estimate d t o b e 0.2 6 lbs/hr , an d styren e t o b e 0.4 9 lbs/hr . SG P Stac k 5 VO C emission s ar e estimate d t o b e 0.1 4 lbs/h r a s carbon . Furthe r analysis , i.e . a weighte d averag e o f th e Stac k 5 emission s obtaine d b ymultiplyin g flo w time s concentratio n fo r eac h o f th e 9 9 dat a points , yield s a n "actual " VO C emissio n o f 0.2 3 lb s (a s carbon ) fo r th e perio d o f sampling . Thi s work s ou t t o b e 0.1 4 lbs/hr , coincidentaUy , th e same a s th e figur e reporte d abov e wher e estimate d emission s wer e base d o n a n averag e concentratio n an

d a n averag e velocit yfo r th e entir e run .

4580- G Mac k

Ave. , Frederick , Marylan d 2170 1 (301 ) 695-582 8 Fa x (301 ) 695-334 8P. 7

ENVIRONMENTALM l Mr . Charli e Stanie r Pag e 2 Ma y11 , 199 5
Th e summar y ; tabl e a t th e beginnin g o f Sectio n l present s th e concentration s an d mas s emissio n rate s o f MM Aan d Styrene , respectively , a s wel l a s concentration s an d mas s emissio n rates/loadin g o f VOCs . A s a back-u p t o thi s mas s emissio n data , additiona l table s i n Sectio n 1 presen t ai r flow s and measure d concentration s fo r eac h source . Pleas e not e tha t a n additiona l pag e fo r SG P Stac k 5 reflect s calculatio n o f th e previousl yreporte d "actual " VO C emissions . Stri p char t integration s fo r VOC s an d specifi c ga s chromatographi c dat a fo r MM Aan d Styren e emitte d fro m eac h sourc e ar e include d i n Sectio n 2 . Fiel d note s ar e include d i n Section 3 . Pleas e fee l fre e t o contac t m e i f yo u hav e an yquestion s abou t th e finding s presente d i n thi s report . EM S appreciate s th e opportunit y t o b e o f continuin g servic e t o Nevama r an d thank s yo u fo r you r suppor t durin g samplin g events . Ver ytrul yyours , EM S Environmental , Inc . Vincen t V . Dobb s Grou p Leade r Ai r Qualit yManagemen t
cc : Jo e Slaughte r

^V J Are a
SGP :

PP :

Are a
PP : Sourc e

Stac k 5 Ven t 2 3 Stac k 3 Ven t 1 3 Stac k 2 Subtotal s Stac k 2 Ven t 2 Ven t 1 Stac k 3 Stac k 1 Subtotal s Total s

Sourc e
Carbo n uni t Cone , av g

pp m 13.1 9 3.7 6 0.2 5 19.4 6

0.7 8 1.4 2 1.3 7 0.0 4 0.5 3 Fugitiv e Emissio n

Summar v MM A Mas s lbs/h r 0.0 5 0.1 1 1.96E-0 3 0.1 0 0.2 6 0.0 1 0.0 3 0.0 5 1.0 1 E-0 4 1.5 7 E-0 3 0.0 9 0.3 5 Emission s

lbs/da y

0.3 3 0.8 0 1.3 0 2.42E-0 3 0.0 4 2.4 7

Mas s Loadin g Summar y MM A Cone.av g pp m 16.7 2 9.8 6 7.1 9 8.9 2
1.5 6 1.8 1 1.3 1 0.4 9 1.3 1 STYREN E

Mas s Ibs/h r 0.0 7 0.3 1 0.0 6 0.0 5 0.4 9 0.0 3 0.0 4 0.0 5 1.28E-0 3 4.07E-0 3 0.1 3 0.6 2

STYREN E Emission s

lbs/da y

0.6 9 1.0 6 1.3 0 0.0 3 0.1 0 3.1 8 Cone.av g

pp m 17,04 9

Cone , av g pp m 3.01 3 VOC s (a s carbon )

Mas s Emission s Ibs/h r 0.1 4

0.1 4

0.1 4 lbs/da y

1 VOC s (a s carbon ) Mas s lbs/h r 2.7 3 Loadin g

lbs/da y 65.6 6

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