P.1 

OAR Box 1392 

Prepped by Ollie Stewart 

Document Number: 

128) ll-A-3 

Docket Number: 

A-94-52 

Printed 7/7/2008 9:45:58 AM Sheet 128 of 136 
P.2 

. % A 

A-94-52 

•fSAA^r-r 

•ft "iire'ii'fiXf'^ 

.•\hv~-

Wr. OCT 191995 

^ 

DETERMINATION OF STYRENE 

EMISSIONS FROM THE CULTURED 

MARBLE AND SINK 

MANUFACTURING INDUSTRY 

FINAL REPORT 

M r 

i > . 

& ;«*& ^ *«& < iu4w 

1 * M 

V

1 
P.3 

DCN No.: 92-275-026-54-11 

Radian No.: 275-026-54 

EPA No.: 68-D9-0054 

DETERMINATION OF STYRENE 

EMISSIONS FROM THE CULTURED 

MARBLE AND SINK 

MANUFACTURING INDUSTRY 

FINAL REPORT 

General Marble 

Lincolnton, NC 

Work Assignment 2.54 

EPA Contract 68D90054 

Prepared for: 

Robert McCrackan 

Emission Measurement Branch 

U.S. Environmental Protection Agency 

Research Triangle Park, North Carolina 27711 

Prepared by: 

Radian Corporation 

Research Triangle Park, N.C. 22209 

June, 1992 
P.4 

TABLE OF CONTENTS 

Section Page 

1.0 PROJECT DESCRIPTION 1-1 

1.1 Introduction 1-1 

1.2 Test Objectives 1-2 

1.3 Test Matrix 1-2 

2.0 DESCRIPTION OF FACILITY AND SAMPLING LOCATIONS 2-1 

2.1 Description of Facility 2-2 

2.2 Sampling Locations - 2-2 

2.2.1 Spray Booth 2-4 

2.2.2 Gel Coat Oven 2-4 

2.2.3 Curing Oven 2-5 

2.2.4 Tank Vat Pipe 2-5 

2.2.5 Baghouse Inlet and Outlet 2-6 

3.0 RESULTS 3-1 

3.1 Particulate Results 3-1 

3.1.1 Baghouse Inlet Results 3-1 

3.1.2 Baghouse Outlet Results 3-3 

3.1.3 Baghouse Collection Efficiencies 3-5 

3.2 Styrene Results 3-5 

3.2.1 Spray Booth Results 3-9 

3.2.2 Gel Coat Oven Results 3-9 

3.2.3 Curing Oven Results 3-9 

3.2.4 Tank Room Results 3-10 

3.2.5 Styrene Emission Summary 3-11 

4.0 SAMPLING AND ANALYTICAL PROCEDURES 4-1 

4.1 Particulate Matter/Condensable Particulate Matter (PM/CPM) 

Emissions Testing 4-1 

4.1.1 Particulate Matter/Condensable Particulate Matter 

Sampling Equipment 4-2 

4.1.2 Particulate Matter/Condensable Particulate Matter 

Sampling Equipment Preparation 4-4 

dkd.196 u 

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Section 

TABLE OF CONTENTS 

Continued 

Page 

5.0 

4.1.3 Particulate Matter/Condensable Particulate Matter 

Sampling Operations 4-5 

4.1.4 Particulate Matter/Condensable Particulate Matter 

Sample Recovery 4-6 

4.1.5 Particulate Matter/Condensable Particulate Matter 

Analysis 4-7 

4.2 Styrene 4-9 

4.2.1 Styrene Sampling Equipment 4-9 

4.2.2 Styrene Sampling Operations 4-10 

4.23 Styrene Analysis 4-10 

4.3 EPA Method 1-4 4-12 

4.3.1 Traverse Point Location by EPA Method 1 4-12 

4.3.2 Volumetric Flow Rate Determination by EPA Method 2 4-12 

4.3.3 02 and C02 Concentrations by EPA Method 3 4-13 

4.3.4 Average Moisture Determination by EPA Method 4 4-13 

PROJECT QUALITY CONTROL 5-1 

5.1 Styrene 5-1 

5.2 Particulate 5-6 

5.3 Daily Test Preparations/Activities 5-6 

APPENDIX A 

APPENDIX B 

APPENDIX C 

APPENDIX D 

APPENDIX E 

PM10 Field Data Sheets 

Laboratory Gravimetric Data 

Calculations of Sampling Parameters (Radian) 

Calculations of Sampling Parameters (EPA) 

Styrene Field Data Sheets 

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P.6 

UST OF FIGURES 

Page 

2-1 General Marble Plant Production Area 2-3 

4-1 PM/CPM Sampling Train 4-3 

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UST OF TABLES 

Page 

1-1 General Marble Test Matrix 1-4 

3-1 Summary of Baghouse Inlet Particulate Results General Marble 

(March 1992) 3-2 

3-2 Summary of Baghouse Outlet Particulate Results General Marble 

(March 1992) .3-4 

3-3 Summary of Baghouse Removal Efficiencies General Marble 

(March 1992) 3-6 

3-4 Styrene Concentration and Emission Rate Summary General Marble 

(March 1992) . 3-7 

5-1 Summary of Acceptance Criteria, Control Limits, and Corrective 

Action 5-2 

5-2 Results of Laboratory Bias Studies 5-5 

dkd.196 

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#=•• • 

The test program included an internal quality control program. The goal 

of the quality assurance/quality control (QA/QC) activities were to ensure that the 

results are of known precision and accuracy, and that they were complete, representative 

and comparable. 

1-3 Test Matrix 

The sampling and analytical matrix that was performed is presented in 

Table 1-1. Manual methods were used to collect the samples with on-site gas 

chromatographic (GC) analysis of the styrene. The particulate samples were returned to 

the laboratory for analysis. Each of the proposed tests are briefly described below. 

Total particulate matter (PM) was determined with a single train. A PMIO train was used to collect PM with particle sizes above and below the 10 micron level. 

The PM-10 train also consisted of a series of impingers filled with water to collect any 

condensable PM. The PM in each component of the trains was determined 

gravimetrically in the laboratory. 

Plant exhaust samples for styrene were collected using EPA Method 18. 

Samples were collected into Tedlar® bags and analyzed on-site by GC. 

Additional descriptions of the sampling and analytical procedures are 

provided in Section 4.0. 

I« j dkd.196 1-3 

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Table 1-1 

General Marble Test Matrix 

D Sample Location 

1 Spray Booth Exhaust 

1 Spray Booth Exhaust 

1 Gel Coat Oven, Vent 1 

| Gel Coat Oven, Vent 1 

1 Gel Coat Oven, Vent 2 

Gel Coat Oven, Vent 2 

Curing Oven, Vent 1 

Caring Oven, Vent 1 

Curing Oven, Vent 2 

Cluing Oven, Vent 2 

Tank Room Exhaust 

Tank Room Exhaust 

Tank Vent Pipe 

Bag House Inlet 

Bag House Inlet 

Bag House Outlet 

Bag House Outlet 

Number of 

Runs 

3 

3 

3 

3 

3 

3 

3 

5* 

3 

3 

3 

3 

2 

3 

3 

3 

3 

Sample 

Type 

Gas Velocity/Volume/Moisture 

Styrene 

Gas Vclocity/Volume/Moislure 

Styrene 

Gas Velocity/Volume/Moisture 

Styrene 

Gas Velocity/Volume/Moisture 

Styrene 

Gas Velocity/Volume/Moisture 

Styrene 

Gas Velocity/Volume/Moisture 

Styrene 

Styrene 

Gas Velocity/Volume/Moisture 

PMIO 

Gas Velocity/Volume/Moisture 

PMIO 

EPA Method 

Method 1-4 

Method 18 

Methods 1-4 

Method 18 

Methods 1-4 

Method 18 

Method 1-4 

Method 18 

Method 1-4 

Method 18 

Method 1-4 

Method 18 

Grab 

Method 1-4 

Method 201A 

Method 1-4 

Method 201A 

Sample 

Duration 

1 hour 

1 hour 

1 hour 

1 hour 

1 hour 

1 hour 

1 hour 

1 hour 

1 hour 

1 hour 

1 hour 

1 hour 

6 hours 

6 hours 

6 hours 

6 hours 

Analysis 

Method 

Volumetric/Gravimetric 

GC 

Volumetric/Gravimetric 

GC 

Volumetric/Gravimetric 

GC 

Volumetric/Gravimetric 

GC 

Volumetric/Gravimetric 

GC 

Volumetric/Gravimetric 

GC 

GC 

Volumetric/Gravimetric 

Gravimetric 

Volumetric/Gravimetric 

Gravimetric 

Laboratory 

Radian 

Radian 

Radian 

Radian 

Radian 

Radian 

Radian 

Radian 

Radian 

Radian 

Radian 

Radian 

Radian 

Radian 

Radian 

Radian 

Radian 

Duplicate sampling during two of the three standard runs. 
P.10 

2.0 DESCRIPTION OF FACILITY AND SAMPLING LOCATIONS 

2.1 Description of Facility 

General Marble, located in Lincolnton, N.C., manufactures products 

consisting almost entirely of bathroom sinks. This facility can be characterized as a large 

production operation in contrast to smaller custom manufacturing operations. The 

normal plant operating schedule is from 6:00 AM to 12:00 midnight, Monday through 

Friday. 

Including two 10 minute work breaks and 30 minutes for lunch, the 

operating schedules for specific tasks are as follows: .^,r..-,-

Spray Booth 6:30 AM to 11:15 PM

 5 ° - "* /«•-.• 

Casting 7:00 AM to 11:30 PM '5 • '<="'

 ; • -'"" • 

Gel Coat Oven 6:30 AM to 11:15 PM -*• ^ -' '~y 

Post Curing Oven 7:30 AM to 11:30 PM •?•'" '~ '**1 

Grinding/Sanding 7:00 AM to 3:30 PM "'•s''7 1 -"-^"-

The resin is purchased in bulk liquid form and transported to the facility 

by tanker truck. The resin is stored on site in four 4000 gallon tanks which are housed 

in a separate room attached to the main manufacturing area. The gel coat, a more 

highly refined version of the resin, is purchased in bulk liquid form in 55 gallon drums. 

The daily mixing of the resin with crushed marble filler is performed in three large open 

top mixing vats. Each vat will contain 1200 lbs. of mix of which 23% by weight is resin. 

Smaller 120 lb. "working" batches are removed from the vats as needed. Catalyst is then 

added to the "working" batch before pouring onto the molds. The casting process uses 

closed molds which have been "gel coated". (Approximately 16,000 lbs. of mix is used 

per day to produce 500 - 600 units.) 

The emission points for styrene within the building are the mixing vats, the 

gel coat spray area and the point in the process where the resin is applied to the molds. 

dkd.196 2-1 

StyrencFnl 
P.11 

The entire manufacturing operation is housed in a large single room except 

for the resin storage tanks which are in a separate room attached to the larger room. 

Individual units are produced in a clock wise flow through the facility. Molds are 

cleaned and waxed as the first step in the process. The molds then proceed to the spray 

booth where a thin layer of resin, "gel coat", is applied. The molds move down a 

conveyer passing through a gel coat drying oven. A premixed composition of resin, filler 

and catalyst are applied to the molds manually using hand held trowels. The back of the 

mold is clamped into place and the assembly is mechanically vibrated to remove bubbles 

and allow the resin to settle. The molds continue to travel along the conveyer passing 

through a curing oven and on to the sanding and grinding area. The finished products 

then go to the warehouse area for packaging and shipment. 

Exhaust fans are used to vent the work place air to the outside of the 

building. The gel coat drying oven and the curing oven, have two ducts each that extend 

through the roof. The spray booth has a single duct that also extends through the roof. 

The tank room has a floor level intake vent that exhausts through a louvered fan 

mounted on an outside wall. Each of the four storage tanks has a two inch static vent 

pipe that extends through an outside wall. Particulate from the grinding and sanding 

operation and from the mixing vats is controlled by a high efficiency filtration system. 

The filtered air is returned to the work place and not vented to the outside of the 

building. Five louvered exhaust fans are mounted near the ceiling on the back outside 

wall. These fans are for general building exhaust (not associated with a specific 

operation) and are operated only in the warmer months of the year. No emission 

controls are in place except for the filtration system. Figure 2-1 is a diagram of the plant 

product area. 

22 Sampling Locations 

The sampling locations are described in the following sections. Sketches of 

the locations are contained in the appendices. 

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Exhaust Fans 

Exhaust 

Fan 

Tank 

Room 

Garage Doors 

Figure 2-1. General Marble Plant Production Area 

2-3 
P.13 

3.0 RESULTS 

The results of the sampling are presented in the following sections. The 

results of the particulate sampling and a discussion ot the results are contained in 

Section 3.1. Section 3.2 contains a similar summary and discussion of the styrene 

sampling efforts. 

3.1 Particulate Results 

The results of the sampling performed at the baghouse inlet and outlet are 

presented separately in Sections 3.1.1 and 3.1.2 respectively. The collection efficiencies 

of the baghouse are presented in Section 3.1.3. 

3.1.1 Baghouse Inlet Results 

A summary of the results of the baghouse inlet samphng is contained in 

Table 3-1. Concentrations of the total, non-condensable particulate matter collected at 

the baghouse inlet ranged from 0.0200 grains per dry standard cubic foot (gr/dscf), 

collected during run 1, to 0.0408 gr/dscf collected during run 2. Test run three 

contained a measured concentration of 0.0377 gr/dscf. The average concentration of 

total particulate matter was found to be 0.0328 gr/dscf. The fraction of total particulate 

matter consisting of particles greater than 10 rnicrons averaged 86% of the total mass 

collected (85.5%, 87.0%, and 85.1% for run 1, 2, and 3 respectively). 

These measured concentrations result in emission rates of 3.36, 7.16 and 

6.77 pounds per hour (lb/hr) of total particulate matter for runs 1, 2, 3 respectively. 

Emission rates averaged 5.76 lb/hr based on an* average volumetric flow rate of 20,336 

dry standard cubic feet per minute (dscfm). The emission rate of total particulate matter 

equal to or less than 10 microns in size average 0.80 lb/hr and was approximately 14% 

of the total particulate matter emissions. 

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P.14 

Table 3-1. Summary of Baghouse Inlet Particulate Results 

General Marble (March 1992) 

T~<? -f 

Total PM-10 Concentration (gr/dscf) 

<. 10 Microns (gr/dscf) 

> 10 Microns (gr/dscf) 

Total Condensable Concentration (gr/dscf) 

Aqueous (gr/dscf) 

Organic (gr/dscf) 

Total PM-^tf Emission Rate (lb/hr) 

<4 10 Microns (lb/hr) 

> 10 Microns (lb/hr) 

Total Condensable Emission Rate (lb/hr) 

Aqueous (lb/hr) 

Organic (lb/hr) 

Run 1 

0.02000 

0.00290 

0.01710 

0.00039 

.0.00029 

0.00005 

3.3600 

0.4860 

2.8800 

0.0570 

0.0494 

0.0076 

Baghouse Inlet:: 

Run2?r 

0.04080 

0.00527 

0.03550 

0.00018 

0.00015 

0.00003 

7.1600 

0.9240 

6.2300 

0.0319 

0.0263 

0.0056 

Run 3; 

0.03770 

0.00556 

0.03210 

0.00024 

0.00020 

0.00004 

6.7700 

. 0.9980 

5.7700 

0.0434 

0.0359 

0.0076 

Average:; 

0.03283 

0.00458 

0.02823 

0.00027 

0.00021 

0.00004 

5.7633 

0.8027 

4.9600 

0.0441 

0.0372 

0.0069 

3-2 
P.15 

Condensable matter concentration averaged 0.0003 gr/dscf with a range of 

0.0002 gr/dscf to 0.0004 gr/dscf (runs 2 and 1 respectively). An average of 

approximately 81% of the condensable matter was contained in the aqueous fraction 

(75%-83%). The average emission rate of condensable particulate matter was calculated 

to be 0.044 lb/hr with a range of 0.032 to 0.057 lb/hr. Emission rates of the water 

soluble fraction of condensable matter averaged 0.037 lb/hr, and solvent extractable 

condensables averaged 0.007 lb/hr. 

3.1.2 Baghouse Outlet Results 

Table 3-2 contains a summary of the particulate results for the baghouse 

outlet. 

The concentrations of total, noncondensable particulate matter were found 

to be 0.0003, 0.0004, and 0.0002 gr/dscf for runs 1, 2, 3 respectively. The average 

concentration for all three test runs was 0.0003 gr/dscf, of which an average of 52% of 

the total mass consisted of matter larger than 10 microns (46.2%, 56.4% and 52.2% for 

run, 1, 2, and 3 respectively). 

The emission rates of total, noncondensable particulate matter for runs 1 

through 3 were calculated to be 0.055, 0.068 and 0.040 lb/hr. The average emission rate 

was 0.055 lb/hr based on an average flow rate of 21,429 dscfin (21,799, 22,064, and 

20,426 dscfm for runs 1, 2, and 3, respectively). The emission rate of particulate matter 

less than or equal to 10 microns averaged 0.026 lb/hr (0.019 to 0.030 lb/hr range) and 

made up 48% of the total mass emissions. 

The concentrations of total condensable matter ranged from 0.00018 to 

0.00024 gr/dscf (runs 3 and 2, respectively), and averaged 0.00020 gr/dscf. the aqueous 

fraction contained an average concentration of 0.00017 gr/dscf^ 86% of the total. 

Emission rates of condensable matter ranged from 0.031 lb/hr to 0.045 Ib/hr 

dfcd.196 3-3 

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P.16 

Table 3-2. Summary of Baghouse Outlet Particulate Results 

General Marble (March 1992) 

Total PM-10 Concentration (gr/dscf) 

:£ 10 Microns (gr/dscf) 

> 10 Microns (gr/dscf) 

Total Condensable Concentration (gr/dscf) 

Aqueous (gr/dscf) 

Organic (gr/dscf) 

Total PM-10 Emission Rate (lb/hr) 

£ 10 Microns (lb/hr) 

> 10 Microns (lb/hr) 

Total Condensable Emission Rate (lb/hr) 

Aqueous (lb/hr) 

Organic (lb/hr) 

Run 1 

0.00030 

0.00016 

0.00014 

0.00019 

0.00016 

0.00003 

0.0553 

0.0295 

0.0258 

0.0350 

0.0295 

0.0055 

Baghouse Outlet 

r

 Run 2::: 

0.00036 

0.00016 

0.00020 

0.00024 

0.00020 

0.00004 

0.0681 

0.0297 

0.0384 

0.0454 

0.0384 

0.0070 

^••Rim-3:;;v 

1

 0.OO023 

0.00011 

1

 0.00012 

0.00018 

0.00016 

0.00002 

0.0403 

0.0193 

0.0209 

0.0306 

0.0274 

0.0032 

Averages 

0.00030 

0.00014 

0.00015 

0.00020 

0.00017 

0.00003 

0.0546 

0.0262 

0.0284 

0.0370 

0.0318 

0.0052 

3^ 
P.17 

(runs 3 and 2 respectively) and averaged 0.037 lb/hr. Mass emissions of water soluble 

condensable matter averaged 0.032 lb/hr and made up 86% of the total condensable 

emissions. 

3.13 Baghouse Collection Efficiencies 

The baghouse collection efficiencies for all sample fractions are 

summarized in Table 3-3. the efficiencies presented in this table are based on 

concentration. 

The average collection efficiency of total, non-condensable particulate 

matter was 99.0% with a range of 98.5-99.4%. The collection.efficiency of particulate 

matter larger than 10 microns averaged 99.4% with a range of 99.2-99.6%. The 

collection efficiency was 96.5% for particulate matter less than or equal to 10 microns in 

size with a range of 94.5-98.0%. 

The collection efficiency of the baghouse averaged 14.4% for total 

condensable particulate matter. This value is based on a very small collected mass of 

sample. Any errors in sample handling and weighing are further magnified during 

calculations. 

3.2 Styrene Results 

The results of the styrene sampling are contained in the following sections.. 

These results are summarized in Table 3-4. Section 3.2.1 presents the results of the 

sampling that was performed at the spray booth exhaust. Sections 3.2.2 and 3.2.3 contain 

the results obtained at the gel coat oven and the curing oven, respectively. The results 

of sampling at the tank room are discussed in Section 3.2.4. Section 3.2.5 discusses the 

total styrene emissions and contains a styrene emission summary. 

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P.18 

Table 3-3. Summary of Baghouse Removal Efficiencies 

General Marble (March 1992) 

Total PM-10 Concentration 

£ 10 Microns 

> 10 Microns 

Total Condensable Concentration 

Aqueous 

Organic 

Run 1 

98.5 

94.5 

99.2 

51.3 

44.8 

40.0 

Baghouse Outlet 

Run 2 

99.1 

97.0 

99.4 

-33.0 

-33.0 

-33.0 

Run 3 

99.4 

98.0 

99.6 

25.0 

20.0 

50.0 

Average 

99.0 

96.5 

99.4 

14.4 

10.6 

19.0 

3-6 
P.19 

Table 3-4. Styrene Concentration and Emission Rate Summary 

General Marble (March 1992) 

Location 

Tank Room Vent 

Curing Oven Inlet 

Curing Oven Outlet 

Tank Head Space 

Date 

3/04/92 

3/05/92 

3/05/92 

3/06/92 

3/10/92 

Sampling 

Time 

1330-1430 

1515-1615 

1650-1750 

:i}::'AVerage;;b::-:: 

1620-1720 

1725-1825 

1830-1930 

Average A^AZ 

1005-1105 

Duplicate 

1230-1330 

Duplicate 

1515-1615 

ifii^Averageli 

1730 

0930 

Average 

Styrene 

Concentration 

(ppm) 

22.7 

22.8 

21.6 

21.3 

7.5 

6.7 

A^Zk^A^gZ 

13.6 

13.6 

10.2 

b 

14.4 

14.9 

ZmZ^ZmM&B 

5.4 

4.9 

5.3 

5.1 

a 8.8 

a 8.8 

a 8.4 

a 7.9 

11.8 

11.7 

;iS;i§|%|:^|s||:g:Hi;5: 

6612 

6220 

3186 

3231 

Run Average 

Styrene 

Concentration 

(ppm) 

22.8 

21.5 

7.1 

mmgrnim 

13;6 

10.2 

14.7 

li§!illi£# 

5.2 

5.2 

8.8 

8.2 

11.8 

t|§;;iii:7:# 

6416 

3209 

4812 

Average 

SUck 

Flow Rate 

(dscfm) 

1579 

1579 

1579 

^•::;:.:v-:vl579:: 

2484 

2484 

2484 

WA'':AZm3423 

3423 

3423 

3423 

3423 

^^3423 ; 

N/A 

N/A 

Emission 

Rate 

(lb/hr) 

0.573 

0.540 

0.178 

^.•••-Of430? 

0.537 

0.403 

0.581 

rA- 6:507: 

0.283 

0.283 

0.479 

0.446 

0.642 

ZAZ\ti4m 

c 

c 

5 -J 

3 . 

a Calculated Styrene concentration using peak heights. 

b Low sample volume. 

c Sample was a grab sample, no emission rate calculated. See Section 3.2.5. 

N/A — Not applicable 

3-7 
P.20 

Table 3-4. Continued 

Location 

Gel Coat Oven Inlet 

Gel Coat Oven Outlet 

Spray Booth 

Date 

3/09/92 

3/09/92 

3/09/92 

Sampling 

Time 

0950-1050 

1054-1154 

1156-1256 

:pi:Average 

1630-1730 

1732-1832 

1840-1940 

Average 

1305-1405 

1414-1515 

1517-1617 

Average 

Styreno 

Concentration 

(ppm) 

44.2 

43.5 

41.1 

40.2 

27.2 

25.9 

* 

88.9 

87.4 

79.1 

87.3 

63.4 

62.7 

26.7 

b 

27.6 

24.6 

23.4 

22.8 

Run Average 

Styrene 

Concentration 

(ppm) 

ir 

<13.9 

40.7 

26.6 

37.1 

88.2 

83.2 

63.1 

iii«;^8;2:-

26.7 

26.1 

23.1 

g^;,,:,;25:3: 

Average 

Stack 

Flow Rate 

(dscfm) 

2393 

2393 

2393 

2393 

3752 

3752 

3752 

ii|:::^;^3752-

12251 

12251 

12251 

AZA-Z^V22SX: 

Emission 

Rate 

(lb/hr) 

1.67 

1.55 

1.01 

1.41 

5.26 

4.97 

3.77 

%---zM#W> 

5.20 

5.09 

4.50 

••::-;-:4:93: 

a Calculated Styrene concentration using peak heights. 

b Low sample volume. 

c Sample was a grab sample, no emission rate calculated. See Section 3.2.5. 

N/A — Not applicable 

3-8 
P.21 

3.2.1 Spray Booth Results 

Analyses of three samples collected at the spray booth gave an average 

concentration of 25.3 ppm styrene. The range of measured concentrations was 

23.1-26.7 ppm. The emission rate of styrene was calculated to be 4.93 lb/hr based this 

average concentration and a volumetric flow rate of 12,251 dscfm. 

322 Gel Coat Oven Results 

The average emissions of styrene were calculated to be 1.41 lb/hr at the 

gel coat oven inlet stack based on an average concentration of 37.1 ppm styrene and a 

volumetric flow of 2393 dscfm. The range of concentrations that was measured at the 

inlet stack was 26.6-43.9 ppm styrene. 

Concentrations of styrene measured at the gel coat oven outlet stack 

averaged 78.2 ppm styrene with the concentrations ranging from 63.1-83.2 ppm. Based 

on a volumetric flow rate of 3752 dscfm the average emission rate at the oven outlet 

stack was calculated to be 4.67 lb/hr. 

The total emission rate of styrene at the gel coat oven was 6.08 Ib/hr. 

3.2.3 Curing Oven Results 

The average concentration of styrene at the curing oven inlet stack was 

12.8 ppm with a range of 10.2-14.7 ppm. The volumetric gas flow was determined to be 

2484.0 dscfm and the emission rate to be 0.51 lb/hr. 

dkd.196 . 3-9 

StyreocFnl 
p.2; 

•ni 

The average concentration of styrene at the curing oven outlet stack was 

7.8 ppm. The range of concentrations measured at this stack was 5.2-11.8 ppm styrene. 

Based on a volumetric flow of 3423 dscfm the average emission rate of styrene was 

0.43 lb/hr. 

The total emission rate of styrene at the curingioven was 0.94 lb/hr. 

3.2.4 Tank Room Results 

The three samples collected at the tank room exhaust duct measured 21.5, 

22.8, and 7.1 ppm styrene, averaging 17.1 ppm. The low result was from a sample that 

had been collected after an outside door to the tank room had been left open by plant 

personnel. Based on the average of the three runs and a volumetric flow of 1,579 dscfm 

the emission rate of styrene was calculated to be 0.43 lb/hr. Based on the average of the 

first two samples collected (222 ppm) the emission rate would be 0.56 lb/hr. 

Samples taken to quantify emissions of styrene from the tank vents were 

collected from tank headspace on two different days. The first of the samples was taken 

in the evening of 3/6/92, the second in the morning of 3/10/92. 

Analyses of the first headspace sample taken from one of the 4 tanks in 

the tank room yielded an average concentration of 6,416 ppm styrene. This 

concentration was roughly equivalent to the concentration of styrene at saturation and 

would result in emissions of 0.93 pounds of styrene each time an empty tank is filled, or, 

0.00023 pounds of styrene vented per gallon resin added to a tank. 

Analyses of the second headspace sample from the same tank gave results 

of 3,414 ppm styrene. This concentration of styrene would result in emissions of 0.00012 

pounds of styrene vented per gallon of resin added to the tank. 

dkd.196 3-1 0 

Styrene.Fnt 
P.23 

3.2.5 Styrene Emission Summary 

Monthly inventory data relative to the consumption of resin, gel coat and 

filler was available from General Marble. The inventory data for the month of 

February, 1992 shows that 114,805 lbs. of resin, 6289 lbs. of gel coat and 499,000 lbs. of 

filler was used in the manufacturing process. For this time period, the number of 

production days was 19. The average daily use oi" resin, gel coat and filler is calculated 

to be 6042 lbs., 331 lbs. and 26,263 lbs. respectively. The average daily consumption of 

resin was calculated to be 6,373 lbs. (resin plus gel coat) which was used to produce a 

daily average of 608 units. This shows that on the average for every pound of resin^ten 

units can be produced. This agrees very closely with the daily production logs. From the 

data given in Table 3-3, the styrene emission rates from the spray booth, gel coat oven 

inlet and outlet the curing oven inlet and outlet and the tank room exhaust can be 

summed to give an average plant wide emission rate of 12.4 lbs./hour. For a 16 hour 

production day, the daily styrene emission rate would be 198 lbs/day. Therefore the 

daily emission rate of styrene would be 198 lbs. per 6,373 lbs of resin used. 

- „. , " --•-.' v. 7, 4^- v / 

dkd.196 3-11 

StyrencFnl 
•STATE: N C TEST DATE: 

FACILITY: G^i^^.J H^f c ^ 

ADDRESS: 

LZuCoj^jo^ t y y 

OBJECTIVE CATEGORIES: 

Inclusion of production/ 

operation rate 

Documentation of Methods 

1-4 I 2-3H 

*"">•" L-.A I 

^ 

RATED ITEMS: [1-3, 3 being highest] 

Process Description 

Documentation of 

control equipment and 

efficiency 

Documentation of Q/A 

3 

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PROCESS(ES) TESTED (SCC): 

7V- or-'- °.-- > -7< 

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3-i-i/^^/i 

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stack/process tested 

Documentation of test/ 

estimation method 

Equipment prep 

documentation 

Thorough field data on 

standard forms for at 

least 3 runs 

Consistency of results 

r^L^ 

hr«t._T* :• 3 ^fs. 

~A> 
P.25 

Source Test Information Form 

AP-42 

Date: ?~ % ~

:

7 Z-. 

Section: -v H , fg J ^ > <TTA^ - R^ : 

Firm/Companyo^S e^e,*-*] & & '&' <sTesting Group: ]>^ 0 /,^, , C 

Test Date: 

P. T"P 

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c, ?.. 7* ^ n ^ 

Special Processes/Condiuons/Other Comments: 

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£_- J,-.-. 

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Control Processes: 

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Calibration Data: 

Sampling Method: 

Production Rate: 

Yes No 

Given Calculated 

Te-y*-, 

\U,ooo (Is f p.A '•':*•*!)/J.n,, j 

Production Rate Source: 

Results: 

Run# 

1 

2 

3 

Average 

Production Rate 

Mton/dav Mton/vear 

Test Rating: 

5 , £ 

' I. \AS. So-,- 1 !.,...,!. - V .*' st* ?*•</.£ 

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£>-?V ,< 

Emission Factor 

ke/Mton lbs/Mton 

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