P. 1 

# OAR Box 1392 Prepped by Ollie Stewart



### Document

Number: 

# 128 ) ll-A- 3 Docket Number: 

# A-94-5 2

Printed 7/7/20089:45:58AM

Sheet 128of 136P. 2

. % A 

### A-94-5 2

•fSAA^r-r 

# •f t "iire'ii'fiXf' ^ .•\hv~- 

### Wr . OC T 19199 5 ^



### DETERMINATION OF STYREN E EMISSION S FRO

M TH E CULTURE

D MARBL E AN D SIN K MANUFACTURING INDUSTR Y FINAL REPOR

T

M r i

> . & ;«*& ^

*«& < iu4 w 1 * M

V 1P. 3

DC N No. : 92-275-026-54-1 1 Radia n No. : 275-026-5 4 EP A No. : 68-D9-005 4

DETERMINATION O F STYREN E EMISSION S FRO

M TH E CULTURE

D MARBL E AN D SIN K MANUFACTURIN

G INDUSTR

Y FINAL REPOR

T

General Marbl e Lincolnton , N

C Wor k Assignmen

t 2.5 4 EP A Contrac t

68D9005 4 Prepare d for : Rober t McCracka

n Emission Measuremen

t Branch U.S . Environmenta

l Protectio n Agenc

y Researc h Triangl e Park , Nort h Carolin a2771 1 Prepare d by : Radia n Corporatio n Researc h Triangl e Park , N.C . 2220 9
June , 199 2P. 4

TABL E O F CONTENT S Section Pag e 1. 0 PROJEC T DESCRIPTIO N 1- 1 1. 1 Introductio n 1- 1 1. 2 Tes t Objective s 1- 2 1.3 Tes t

Matrix 1- 2 2. 0 DESCRIPTIO N O F FACILIT Y AN D SAMPLIN

G LOCATIONS 2- 1 2. 1 Descriptio n o

f Facilit y 2- 2 2. 2 Samplin

g Location s - 2- 2 2.2. 1 Spra

y Boot h 2- 4 2.2. 2 Ge l Coa

t Ove n 2-4 2.2. 3 Curing Ove

n 2- 5 2.2. 4 Tan

k Va t Pip e 2- 5 2.2. 5 Baghous e Inle t

and Outle t

2- 6 3. 0 RESULT S 3- 1 3. 1 Particulate Result s 3- 1 3.1. 1 Baghous e Inlet

Result s 3- 1 3.1. 2 Baghous e Outle t

Result s 3- 3 3.1. 3 Baghous e Collectio n Efficiencie s 3-5 3. 2 Styren

e Result s 3-5 3.2. 1 Spra

y Boot h Result s 3- 9 3.2. 2 Ge l Coa

t Ove n Result s 3-9 3.2. 3 Curing Ove

n Result s 3-9 3.2. 4 Tan

k Roo mResult s 3-1 0 3.2. 5 Styrene Emission Summar y 3-1 1 4. 0 SAMPLIN

G AN D ANALYTICA

L PROCEDURE S 4- 1 4. 1 Particulate Matter/Condensabl e Particulate Matte r (PM/CPM ) Emission s Testin g 4- 1 4.1. 1 Particulate Matter/Condensabl e Particulate Matte r Samplin g Equipment

4- 2 4.1. 2 Particulate Matter/Condensabl e Particulate Matte r Samplin g Equipmen

t Preparatio n 4-4

dkd.19 6 u StyrcneJP'ii

lP. 5

Sectio n TABL E O F CONTENT S Continue d Pag e

5. 0 4.1. 3 Particulat e Matter/Condensabl e Particulate Matter Samplin g Operation s 4- 5 4.1. 4 Particulat

e Matter/Condensabl e Particulate Matter Sampl e Recover y 4- 6 4.1. 5 Particulate Matter/Condensabl e Particulate Matter Analysi s 4-7 4. 2 Styren

e 4- 9 4.2. 1 Styren

e Samplin g Equipmen

t 4- 9 4.2. 2 Styren

e Samplin g Operation s 4-1 0 4.2 3 Styren

e Analysi s 4-1 0 4. 3 EP A Metho d 1-

4 4-1 2 4.3. 1 Travers e Poin

t Locatio n b

y EP A Metho d 1 4-1 2 4.3. 2 Volumetri c Flo

w Rat e Determinatio n b

y EP A Metho d 2 4-1 2 4.3. 3 0 2 and C0 2 Concentration s b y EPA Metho d 3 4-1 3 4.3. 4 Averag e Moistur

e Determinatio n b

y EP A Metho d 4 4-1 3 PROJEC T QUALIT

Y CONTRO L 5- 1 5. 1 Styren

e 5- 1 5. 2 Particulat

e 5- 6 5. 3 Dail

y Tes t Preparations/Activitie s 5- 6 APPENDI X A APPENDI X B APPENDI X C APPENDI X D APPENDI X E PM 1 0 Fiel d Dat aSheet s Laborator y Gravimetri c Dat a Calculation s o

f Samplin g Parameter s (Radian ) Calculation s o

f Samplin g Parameter s (EPA ) Styren e Fiel d Dat aSheet s

dkd.19 6 StyiencFn l U lP. 6

US T O F FIGURE S Pag e 2- 1 Genera l Marbl e Plan t Productio n Are a2- 3 4- 1 PM/CP M Sampling Trai n 4- 3

dkd.19 6 I V Styrtne.Fn lP. 7

US T O F TABLE S Pag e 1- 1 General Marbl e Tes t Matrix 1- 4 3- 1 Summar

y o f Baghous e Inle t

Particulat e Result s General Marbl e (March 1992

) 3- 2 3- 2 Summar

y o f Baghous e Outle t

Particulat e Result s Genera l Marbl e (March 1992

) .3- 4 3- 3 Summar

y o f Baghous e Remova

l Efficiencie s General Marbl e (March 1992

) 3- 6 3- 4 Styren

e Concentratio n an d Emissio n Rat e Summar

y Genera l Marbl e (March 1992

) . 3-7 5- 1 Summar

y o f Acceptanc e Criteria , Contro l Limits , and Correctiv e Actio n 5- 2 5- 2 Result s o

f Laborator y Bia s Studie s 5-5

dkd.19 6 Styrenc.Fn lP. 8

#=•• • Th e tes t progra mincluded a

n internal qualit

y contro l program . Th e goa l o f th e qualit y assurance/qualit

y contro l (QA/QC ) activitie s wer e t o ensur e tha t th e result s ar e o

f know n precisio n an

d accuracy , an d tha

t the y wer e complete , representativ e an d comparable . 1- 3 Tes t

Matri x Th e sampling and analytica l matri x that

wa s performe d i s presente d i n Tabl e 1-1 . Manua

l method s wer

e use d t o collec t

th e sample s wit

h on-sit e ga s chromatographi c (GC ) analysi s o f th e styrene . Th e particulat e sample s wer

e returne d to th e laborator

y fo r analysis . Each o

f th e propose d test s are briefl y describe d below . Total particulate matter

(PM ) was determine d wit

h asingle train . A PM

I O trai n wa s use d t o collec t P M wit h particl e size s above an

d below th e 1 0 micro n level . The PM-1 0 trai n als o consisted o f aserie s o f impinger s fille

d wit h wate r to collec t an y condensabl e PM . Th e P

M in each componen

t o f th e train s wa

s determine d gravimetricall

y i n th e laboratory . Plant exhaus t sample s fo

r styren e wer

e collected usin

g EPA Metho d 18 . Sample s were collecte d into Tedlar ® bag s an d analyzed on-sit e b y GC . Additional description s o

f th e sampling an

d analytica

l procedure s ar e provide d i n Sectio n 4.0 .

I « j dkd.19 6 1- 3 StyiencFn lTabl e 1- 1 

### Genera l Marbl e Tes tMatri x D Sampl e Locatio n 1 Spra y Boot h Exhaus t 1 Spra y Boot h Exhaus t 1 Ge l Coa

t Oven , Ven t

1 | Ge l Coa

t Oven , Vent

1 1 Ge l Coa

t Oven , Vent

2 Ge l Coa t Oven , Vent

2 Curin g Oven , Ven t

1 Carin g Oven , Ven t

1 Curin g Oven , Vent

2 Cluin g Oven , Ven t

2 Tank Roo mExhaus t Tan k Roo mExhaus t Tank Vent Pip e Ba g Hous e Inlet Ba g Hous e Inlet Ba g Hous e Outle t Ba g Hous e Outle t Numbe r o f Run s 3 3 3 3 3 3 3 5 * 3 3 3 3 2 3 3 3 3 Sampl e

Typ e Gas Velocity/Volume/Moistur e Styren e Ga s Vclocity/Volume/Moislur e Styren e Ga s Velocity/Volume/Moistur e Styren e Ga s Velocity/Volume/Moistur e Styren e Ga s Velocity/Volume/Moistur e Styren e Ga s Velocity/Volume/Moistur e Styren e Styren e Ga s Velocity/Volume/Moistur e PMI O Ga s Velocity/Volume/Moistur e PMI O EP A Metho d Metho d 1-

4 Metho d 1 8 Method s 1-

4 Metho d 1 8 Method s 1-

4 Metho d 1 8 Metho d 1- 4 Metho d 1 8 Metho d 1- 4 Metho d 1 8 Metho d 1- 4 Metho d 1 8 Gra b Metho d 1- 4 Metho d 201 A Metho d 1- 4 Metho d 201 A Sampl e Duratio n 1 hou r 1 hou r 1 hou r 1 hou r 1 hou r 1 hou r 1 hou r 1 hou r 1 hou r 1 hou r 1 hou r 1 hou r

6 hour s 6 hour s 6 hour s 6 hour s Analysi s

Metho d Volumetric/Gravimetri c

G C Volumetric/Gravimetri c G C Volumetric/Gravimetri c G C Volumetric/Gravimetri c G C Volumetric/Gravimetri c G C Volumetric/Gravimetri c

G C G C Volumetric/Gravimetri c Gravimetri c Volumetric/Gravimetri c Gravimetri c Laborator y Radian Radian Radian Radian Radian Radian Radian Radian Radian Radian Radia n Radian Radian Radian Radian Radian Radian Duplicate sampling durin g tw o o f th e thre e standar d runs .P.1 0

2. 0 DESCRIPTIO N O F FACILIT

Y AN D SAMPLIN

G LOCATION

S 2. 1 Descriptio

n o f Facilit y Genera l Marble , locate d in Lincolnton , N.C. , manufacture s product s consisting almos t

entirely o f bathroo msinks . Thi s facilit y ca n b e characterize d a s alarg e productio n operatio n in contras t t o smaller

custommanufacturing operations . Th e norma l plan t operatin g schedul e i s fro

m6:0 0 A M t o 12:0 0 midnight , Monda

y throug h Friday . Includin

g two 1 0 minute wor

k break s and 3 0 minute s fo

r lunch , th e operatin g schedule s fo

r specific task s ar e a s follows : .^,r..-,

- Spra y Boot h 6:3 0 A M t o 11:1 5 P M 5 °

- " * /«•-.

• Casting 7:0 0 A M t o 11:3 0 P

M ' 5 • '<=" ' ; • -'" "

• Ge l Coa t Ove n 6:3 0 A M t o 11:1 5 P M -* • ^ -' '~ y Pos t Curing Ove

n 7:3 0 A

M to 11:3 0 P

M • ? •' " ' ~ '**1 Grinding/Sandin g 7:0 0 A M t o 3:3 0 P

M "'• s '' 7

1 -"-^"

- Th e resin i s purchase d i n bulk liqui d for mand transporte d t o th e facilit y b y tanke r truck . The resin i s store d o n site i n fou r 400 0 gallo n tank s whic

h ar e housed i n aseparat e roomattache d to th e mai n manufacturing area . Th e ge l coat , amor

e highl y refine d versio n o

f th e resin , i s purchase d in bul k liqui d for mi n 5 5 gallo n drums . Th e dail y mixin g o f th e resi n wit

h crushe d marbl e fille

r i s performe d i n thre e larg e ope n to p mixin g vats . Eac

h va t wil l contai n 120

0 lbs . o f mi x o f whic h 23 % b y weigh t i s resin . Smalle r 12 0 lb . "working " batche s ar e remove d fro mth e vat s a s needed . Catalys t i s the n adde d to th e "working " batc h befor e pourin g ont

o th e molds . Th e castin g proces s use s closed mold s whic

h have bee n "ge

l coated" . (Approximatel

y 16,00 0 lbs . o f mi x i s use d pe r da y t o produc e 50

0 - 60 0 units. ) Th e emission point s fo

r styren e within th e building ar e th e mixin g vats , th e ge l coa t spra y are aan d th e point

i n th e proces s wher

e th e resi n i s applie d t o th e molds . dkd.19 6 2- 1 StyrencFn lP.1 1

Th e entire manufacturing operatio n i s house d in alarg e singl e roo mexcept fo r th e resi n storag e tank s whic h ar e i n aseparate roo mattache d to th e large r room . Individua l unit s ar e produce d in acloc k wis e flo w throug h th e facility . Mold s ar e cleane d and waxe

d a s th e firs t

ste p i n th e process . Th e mold s the n procee d t o th e spra y boot h wher e athi n laye

r o f resin , "ge l coat" , i s applied . Th e mold s mov e dow n a conveye r passing throug h age l coa

t dryin g oven . A premixe d composition o f resin , fille

r and catalys t

ar e applie d t o th e mold s manuall y using han d hel d trowels . Th e back o f th e mold i s clamped into plac e an d th e assembl y i s mechanically vibrate d t o remov e bubble s an d allow th e resi n to settle . Th e molds continu e t o trave l alon g th e conveye r passing through acuring ove

n an d o n t o th e sanding and grinding area . Th e finished product s the n go t o th e warehous e are afo r packagin g and shipment . Exhaus t fan s ar e used to ven

t th e wor k plac e air to th e outside o

f th e building . Th e gel coa

t dryin g ove n an d th e curing oven , hav e tw o ducts eac h that

exten d throug h th e roof . Th e spra

y boot h ha s asingle duc t

that als o extend s throug h th e roof . Th e tan k roo mha s afloo

r level intak

e ven t that exhaust s throug h alouvere d fa n mounte d on a

n outside wall . Eac h o

f th e fou r storag e tank s ha s atw

o inc h stati c ven

t pip e tha t extend s throug h an outside wall . Particulate fro mth e grindin

g an d sanding operatio n and fro

mth e mixin

g vat s i s controlle d b

y ahig h efficienc y filtratio n system . Th e filtere d ai r

i s returne d t o th e wor

k plac e and no t

vente d t o th e outside o

f th e building . Five louvere d exhaus t fans are mounte d nea

r th e ceilin g on th e back

outsid e wall . Thes e fan s ar e fo

r general building exhaus t

(no t associate d wit

h aspecific operation ) an d ar e operate d onl y i n th e warme

r month s o f th e year . N

o emissio n control s ar e in plac e except fo r th e filtratio n system . Figur e 2- 1 i s adiagra

mo f th e plant produc t area . 22 Samplin

g Location

s Th e sampling location s are describe d i n th e followin g sections . Sketche s o

f th e location s ar e containe d i n th e appendices .

dkd.19 6 2- 2 Styrcne.Fn

lP.1 2

Exhaus tFans

Exhaus t Fan

Tan k Roo m Garag e Doors 

# Figur e 2-1 . Genera l Marbl e Plan t Productio n Are a 2- 3P.1 3

3. 0 RESULT

S Th e result s o

f th e sampling are presente d i n th e followin

g sections . Th e result s o f th e particulate samplin

g an d adiscussion o t

th e result s ar e containe d i n Sectio n 3.1 . Section 3. 2 contain s asimila r summar y and discussio n o

f th e styren e sampling efforts . 3. 1 Particulat e Result s

Th e result s o

f th e samplin

g performe d at

th e baghous e inle t

and outlet

ar e presente d separately in Section s 3.1. 1 and 3.1. 2 respectively . Th e collectio n efficiencie s o f th e baghous e ar e presente d in Section 3.1.3 . 3.1. 1 Baghous e Inle t Result s A summar y o f th e result s o

f th e baghous e inlet

samphn g i s containe d in Tabl e 3-1 . Concentration s o f th e total , non-condensabl e particulat e matte r collecte d at th e baghous e inlet

range d fro

m0.020 0 grain s pe r

dr y standard cubi c foo

t (gr/dscf) , collecte d durin g ru n 1 , to 0.040 8 gr/dsc f collecte d during ru n 2 . Tes t ru n thre e containe d ameasure d concentratio n o f 0.0377 gr/dscf

. Th e averag e concentratio n o f total particulate matte r

was foun d t o b e 0.032 8 gr/dscf

. Th e fractio n o

f tota l particulat

e matte r consisting o

f particle s greater

tha n 1 0 rnicron s average d 86 % o f th e tota l mas s collecte d (85.5% , 87.0% , and 85.1 % fo r ru n 1 , 2 , and 3 respectively) . Thes e measure d concentration s result in emissio n rate s o

f 3.36 , 7.1 6 an

d 6.7 7 pound s pe r

hou r (lb/hr ) o f total particulate matte r

fo r run s 1 , 2 , 3 respectively . Emissio n rate s average d 5.7 6 lb/h r based o n an

* averag e volumetri c flo

w rat e o f 20,33 6 dr y standar d cubi c feet

pe r minut e (dscfm) . Th e emission rat e o f tota l particulat e matter equal t o o r

les s than 1 0 micron s in size averag e 0.8 0 lb/h r an d wa s approximately 14 % o f th e total particulate matte r emissions .

dkd.19 6 3- 1 Styrcne.Fn

lP.1 4



### Tabl e 3-1 . Summar

y o f Baghous e Inlet

Particulate Result s General Marbl e (March 1992)

T~<? -f Total PM-1 0 Concentratio n (gr/dscf ) <. 1 0 Micron s (gr/dscf

) > 1 0 Micron s (gr/dscf

) Tota l Condensabl e Concentratio n (gr/dscf ) Aqueou s (gr/dscf

) Organi c (gr/dscf

) Tota l PM-^t f Emissio n Rate (lb/hr ) <4 1 0 Micron s (lb/hr ) > 1 0 Micron s (lb/hr ) Tota l Condensabl e Emissio n Rat e (lb/hr ) Aqueou s (lb/hr ) Organi c (lb/hr ) Ru n 1 0.0200 0 0.0029 0 0.0171 0 0.0003 9 .0.0002 9 0.0000 5 3.360 0 0.486 0 2.880 0 0.057 0 0.049 4 0.007 6 Baghous e Inlet: : Run2? r 0.0408 0 0.0052 7 0.0355 0 0.0001 8 0.0001 5 0.0000 3 7.160 0 0.924 0 6.230 0 0.031 9 0.026 3 0.005 6 Ru

n 3 ; 0.0377 0 0.0055 6 0.0321 0 0.0002 4 0.0002 0 0.0000 4 6.770 0

. 0.998 0 5.770 0 0.043 4 0.035 9 0.007 6 Average: ;

0.0328 3 0.0045 8 0.0282 3 0.0002 7 0.0002 1 0.0000 4 5.763 3 0.802 7 4.960 0 0.044 1 0.037 2 0.006 9

3- 2P.1 5

Condensabl e matter

concentratio n average d 0.0003 gr/dsc f wit h arang e o

f 0.000 2 gr/dsc f t o 0.000 4 gr/dsc f (run s 2 an d 1 respectively) . An averag e o f approximately 81 % o

f th e condensabl e matte r

wa s containe d in th e aqueou s fractio n (75%-83%) . Th e averag e emission rat e o f condensabl e particulat e matte r was calculate d to b e 0.04 4 lb/h r wit h arang e o

f 0.03 2 t o 0.05 7 lb/hr . Emissio n rate s o f th e wate r solubl e fraction o

f condensabl e matte r

average d 0.03 7 lb/hr , an d solven t extractabl e condensable s average d 0.00 7 lb/hr . 3.1. 2 Baghous e Outle t Result s Tabl e 3- 2 contain s asummar y o f th e particulate result s fo

r th e baghous e outlet . Th e concentration s o f total , noncondensabl e particulate matter wer e found t o b e 0.0003 , 0.0004 , an d 0.000 2 gr/dsc f fo r run s 1 , 2 , 3 respectively . Th e averag e concentratio n fo

r all thre e tes t

run s was 0.0003 gr/dscf

, o f whic h a n averag e o

f 52 % o f th e tota l mas s consiste d o

f matte r larger than 1 0 micron s (46.2% , 56.4 % an d 52.2 % for run , 1 , 2 , an d 3 respectively) .

Th e emission rate s o

f total , noncondensabl e particulate matte r fo r run s 1 throug h 3 were calculate d t o b e 0.055 , 0.06 8 an d 0.04 0 lb/hr . Th e averag e emissio n rat e was 0.05 5 lb/h r

base d o n a n averag e flow rat e o

f 21,42 9 dscfi n (21,799 , 22,064 , an d 20,42 6 dscf

mfo r run s 1 , 2 , an d 3 , respectively) . Th e emission rat e of particulate matte r les s than o r

equal t o 1 0 micron s average d 0.026 lb/h r (0.01 9 to 0.03 0 lb/h r

range ) an d mad e u p 48 % o

f th e tota l mas s emissions . Th e concentration s o

f total condensabl e matter

range d from0.0001 8 t o 0.0002 4 gr/dsc f (run s 3 an d 2 , respectively) , an d average d 0.0002 0 gr/dscf . th e aqueou s fractio n containe d a

n averag e concentratio n o

f 0.0001 7 gr/dscf

^ 86 % o f th e total . Emissio n rate s o

f condensabl e matter

range d from0.03 1 lb/h r

t o 0.045 Ib/h r

dfcd.19 6 3- 3 StyrencFn lP.1 6



### Tabl e 3-2 . Summar

y o f Baghous e Outlet

Particulate Result s Genera l Marbl e (Marc h 1992

)

Total PM-1 0 Concentratio n (gr/dscf ) : £ 1 0 Micron s (gr/dscf

) > 1 0 Micron s (gr/dscf

) Tota l Condensabl e Concentratio n (gr/dscf ) Aqueou s (gr/dscf

) Organi c (gr/dscf

) Total PM-1 0 Emissio n Rate (lb/hr ) £ 1 0 Micron s (lb/hr ) > 1 0 Micron s (lb/hr ) Total Condensabl e Emissio n Rat e (lb/hr ) Aqueou s (lb/hr ) Organi c (lb/hr ) Ru n 1 0.0003 0 0.0001 6 0.0001 4 0.0001 9 0.0001 6 0.0000 3 0.055 3 0.029 5 0.025 8 0.035 0 0.029 5 0.005 5 Baghous e Outle t

r Ru n 2:: : 0.0003 6 0.0001 6 0.0002 0 0.0002 4 0.0002 0 0.0000 4 0.068 1 0.029 7 0.038 4 0.045 4 0.038 4 0.007 0 ^••Rim-3:;; v

1 0.OO02 3 0.0001 1 1 0.0001 2 0.0001 8 0.0001 6 0.0000 2 0.040 3 0.019 3 0.020 9 0.030 6 0.027 4 0.003 2 Average s

0.0003 0 0.0001 4 0.0001 5 0.0002 0 0.0001 7 0.0000 3 0.054 6 0.026 2 0.028 4 0.037 0 0.031 8 0.005 2

3 ^P.1 7

(run s 3 and 2 respectively ) and averaged 0.03 7 lb/hr . Mas s emission s o f water solubl e condensabl e matter

average d 0.03 2 lb/h r

and mad e up 86% o

f th e tota l condensabl e emissions . 3.1 3 Baghous e Collection Efficiencie s

Th e baghous e collectio n efficiencie s fo r al l sampl e fraction s ar e summarized in Tabl e 3-3 . th e efficiencie s presente d in thi s tabl e ar e base d o n concentration .

The averag e collectio n efficienc y o f total , non-condensabl e particulate matte r wa s 99.0 % wit

h arang e o

f 98.5-99.4% . Th e collection.efficiency o f particulate matte r large r tha n 1 0 micron s average d 99.4 % wit h arang e o

f 99.2-99.6% . Th e collectio n efficienc

y wa s 96.5 % fo

r particulate matter

les s tha n or equa l t o 1 0 micron s i n size wit h arang e o

f 94.5-98.0% . Th e collectio n efficienc

y o f th e baghous e average d 14.4 % fo r tota l condensabl e particulate matter . Thi s valu e i s base d o n aver y small collecte d mas s o

f sample . An

y error s in sampl e handlin g an d weighin g are furthe

r magnifie d durin g calculations . 3. 2 Styrene Result s

Th e result s o

f th e styrene samplin

g ar e containe d i n th e followin g sections. . Thes e result s are summarize d in Tabl e 3-4 . Section 3.2. 1 present s th e result s o f th e sampling that

wa s performe d a t

th e spra y boot h exhaust . Section s 3.2. 2 an d 3.2. 3 contai n th e result s obtaine d a t

th e ge l coa t ove n an d th e curing oven , respectively . Th e result s o f sampling at

th e tank roo mar e discusse

d in Section 3.2.4 . Sectio n 3.2. 5 discusse s th e total styren e emission s and contain s astyrene emission summary .

dkd.19 6 3- 5 Styrcne.Fn

lP.1 8



### Tabl e 3-3 . Summar

y o f Baghous e Remova

l Efficiencie s Genera l Marbl e (Marc h 1992

)

Total PM-1 0 Concentratio n £ 1 0 Micron s > 1 0 Micron s Tota l Condensabl e Concentratio n Aqueou s Organi c Ru n 1 98. 5 94. 5 99. 2 51. 3 44. 8 40. 0 Baghous e Outle t Ru n 2 99. 1 97. 0 99. 4 -33. 0 -33. 0 -33. 0 Ru n 3

99. 4 98. 0 99. 6 25. 0 20. 0 50. 0 Averag e

99. 0 96. 5 99. 4 14. 4 10. 6 19. 0

3- 6P.1 9



### Tabl e 3-4 . Styren e Concentratio n an d Emissio n Rate Summar y Genera l Marbl e (Marc h 1992

)

Locatio n Tan k Roo mVen t

Curin g Ove n Inle t

Curin g Ove n Outle t

Tan k Hea d Spac e Dat e

3/04/9 2

3/05/9 2

3/05/9 2

3/06/9 2 3/10/9 2 Samplin g

Tim e 1330-143 0 1515-161 5 1650-175 0 :i} : :'AVerage;;b: : -: : 1620-172 0 1725-182 5 1830-193 0 Averag e A^AZ 1005-110 5 Duplicat e 1230-133 0 Duplicat e 1515-161 5 ifii^Averagel i 173 0 093 0 Averag e Styren e

Concentratio n (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 a8. 8 a8. 8 a8. 4 a7. 9 11. 8 11. 7 ;iS;i§|%|:^|s||:g:Hi;5 :

661 2 622 0 318 6 323 1 Ru n Averag e

Styren e Concentratio n (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: #

641 6 320 9 481 2 Averag e

SUc k Flo w Rat e (dscfm ) 157 9 157 9 157 9 ^•: : ;:.:v-:vl579: : 248 4 248 4 248 4 WA'' :AZm342 3 342 3 342 3 342 3 342 3 ^^3423 ; N/ A N/ A Emissio n Rat e (lb/hr ) 0.57 3 0.54 0 0.17 8 ^.•••-Of430 ? 0.53 7 0.40 3 0.58 1 rA- 6:507 : 0.28 3 0.28 3 0.47 9 0.44 6 0.64 2 ZAZ\ti4m

c

c 5 -

J 3 .

aCalculate d Styren e concentratio n usin g pea k heights . b Lo w sampl e volume . c Sampl e wa s agrab sample , n o emissio n rat e calculated . Se e Sectio n 3.2.5 . N/ A —No t

applicabl e 3- 7P.2 0



### Tabl e 3-4 . Continue d

Locatio n Ge l Coa t Ove n Inle t

Ge l Coa t Ove n Outle t

Spra y Boot h Dat e 3/09/9 2

3/09/9 2

3/09/9 2 Samplin g

Tim e 0950-105 0 1054-115 4 1156-125 6 :pi:Averag e 1630-173 0 1732-183 2 1840-194 0 Averag e 1305-140 5 1414-151 5 1517-161 7 Averag e Styren o

Concentratio n (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 Ru n Averag e

Styren e Concentratio n (ppm ) i r <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 : Averag e

Stac k Flo w Rat e (dscfm) 239 3 239 3 239 3 239 3 375 2 375 2 375 2 ii|: : :^;^3752

- 1225 1 1225 1 1225 1 AZA-Z^V22SX: Emissio n

Rat e (lb/hr ) 1.6 7 1.5 5 1.0 1 1.4 1 5.2 6 4.9 7 3.7 7 %---zM#W> 5.2 0 5.0 9 4.5 0

•• : :-;-:4:93 : aCalculate d Styren e concentratio n usin g pea k heights . b Lo w sampl e volume . c Sampl e wa s agra b sample , n o emissio n rat e calculated . Se e Sectio n 3.2.5 . N/ A — No t applicabl e



### 3- 8P.2 1

3.2. 1 Spra

y Boot h Result s Analyse s o

f thre e sample s collecte d at th e spra y boot h gav e a n averag e concentratio n o

f 25. 3 pp mstyrene . Th e rang e o

f measure d concentration s wa s 23.1-26. 7 ppm . Th e emission rat e o f styren e was calculate d t o b e 4.9 3 lb/h r base d thi s averag e concentratio n an

d avolumetri c flow rat e o

f 12,25 1 dscfm . 322 Ge

l Coa tOve n Result s Th e averag e emission s o

f styren e wer

e calculate d t o b e 1.4 1 lb/h r a t th e gel coat oven inle t

stack based o n a n averag e concentratio n of 37. 1 pp mstyren e an d a volumetri c flow o

f 239 3 dscfm . Th e rang e o

f concentration s tha

t was measure d at

th e inlet stack wa s 26.6-43. 9 pp

mstyrene . Concentration s o

f styren e measure d a t

th e gel coa

t oven outle t

stac k average d 78. 2 pp mstyren e wit h th e concentration s ranging from63.1-83. 2 ppm . Base d o n avolumetri c flow rat e o f 375 2 dscf mth e averag e emission rat e at th e oven outle t stack was calculate d to b e 4.6

7 lb/hr . Th e tota l emission rat e o

f styren e a t th e gel coa

t oven wa s 6.0 8 Ib/hr . 3.2. 3 Curin

g Ove n Result s Th e averag e concentratio n o f styrene at th e curing ove

n inle t stac k wa s 12. 8 pp mwit

h arang e o

f 10.2-14. 7 ppm . Th e volumetri c ga s flo w wa s determine d t o b e 2484. 0 dscf

man d th e emission rat e t o b e 0.5 1 lb/hr .

dkd.19 6 . 3- 9 StyreocFn lp.2 ; •n i

The averag e concentratio n o f styren e at th e curing ove

n outle t stac k was 7. 8 ppm . Th e rang e o

f concentration s measured at thi s stack wa s 5.2-11. 8 ppmstyrene . Base d o n avolumetri c flow o

f 342 3 dscf mth e averag e emissio n rat e o f styren e wa s 0.43 lb/hr . Th e tota l emissio n rat e o f styrene a t th e curingioven was 0.9

4 lb/hr . 3.2. 4 Tan

k Roo mResult s Th e thre e sample s collecte d at th e tan k roo mexhaus t

duc t measured 21.5 , 22.8 , an d 7. 1 pp

mstyrene , averagin g 17. 1 ppm . Th e lo w resul t wa s from asample tha

t ha d bee n collected afte

r a n outsid e doo r

t o th e tan k roo mha d bee n lef

t open b y plant personnel . Base

d o n th e averag e o

f th e thre e run s and avolumetri c flow o f 1,57 9 dscf m th e emission rat e o

f styren e wa s calculate d to b e 0.43 lb/hr . Base d o n th e averag e o f th e first two sample s collecte d (22 2 ppm ) th e emissio n rat e would b e 0.5 6 lb/hr . Sample s take n t o quantif

y emission s o

f styren e fro

mth e tan k vents wer e collecte d fromtan

k headspac e o n two differen t days . Th e first

o f th e sample s wa

s take n in th e evenin

g o f 3/6/92 , th e second i n th e mornin g o f 3/10/92 . Analyse s o

f th e first headspac e sample take n fro mon e o f th e 4 tank s in th e tan k roo myielded a

n averag e concentratio n o

f 6,41 6 ppmstyrene . Thi s concentratio n wa

s roughl y equivalent

t o th e concentratio n o

f styren e at saturatio n and would resul t

in emission s o

f 0.9 3 pound s o

f styren e eac h time a

n empt y tan k i s filled , or , 0.00023 pound s o

f styren e vente d pe r

gallon resin adde d t o atank . Analyse s o

f th e secon d headspac e sample fromth e sam e tan k gav e result s o f 3,41 4 ppmstyrene . Thi s concentratio n o f styrene would resul t

i n emission s o

f 0.0001 2 pound s o f styrene vente d pe r

gallo n o f resi n adde d to th e tank .

dkd.19 6 3-1 0 Styrene.Fn

tP.2 3

3.2. 5 Styren

e Emissio n Summar y Monthl y inventor y dat arelativ e t o th e consumptio n o f resin , gel coa

t an d fille r was availabl e fromGenera l Marble . Th e inventor y dat afo r th e mont h o f February , 199

2 show s tha

t 114,80 5 lbs . o f resin , 628 9 lbs . o

f ge l coa t an d 499,000 lbs . o

f filler wa s used i n th e manufacturing process . Fo r thi s time period , th e number o f productio n day s wa s 19 . Th e averag e dail y us e oi" resin , gel coa

t an d filler i s calculate d t o b e 604 2 lbs. , 33 1 lbs . an d 26,26 3 lbs . respectively . Th e averag e dail y consumptio n o

f resi n wa s calculate d t o b e 6,37 3 lbs . (resi n plu s ge l coat ) whic h was use d t o produc e a dail y averag e o

f 60 8 units . Thi s show s that o n th e averag e fo

r ever y poun d o f resin^ten unit s ca n b e produced . Thi s agree s ver y closel y wit h th e dail y productio n logs . Fro mth e dat agive n in Tabl e 3-3 , th e styren e emission rate s fromth e spra y booth , gel coa

t oven inle t an d outle t

th e curing oven inle t

an d outle t

an d th e tan

k roo mexhaus t

ca n b e summed t o giv

e a n averag e plant

wid e emissio n rat e o

f 12.4 lbs./hour . Fo r

a1 6 hour productio n day , th e dail

y styren e emission rat e woul d b e 19 8 lbs/day . Therefore th e daily emission rat e o

f styren e woul

d b e 19 8 lbs . pe r

6,37 3 lb s o

f resi n used .



### - „ . , " --•-. ' v . 7, 4^- v /

dkd.19 6 3-1 1 StyrencFn l•STATE : N C TES T DATE : FACILITY : G^i^^.J

H^f c ^ ADDRESS : LZuCoj^jo^ t y y OBJECTIV E CATEGORIES : Inclusio n o f production / operatio n rat e Documentatio n o f Method s 1- 4 I 2-3 H *"">• " L-. AI

^ RATE D ITEMS : [1-3 , 3 bein g highest ] Proces s Descriptio n Documentatio n o f contro l equipmen t an d efficienc y Documentatio n o f Q/ A 

# 3

Z * y PROCESS(ES ) TESTE D (SCC) :



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