p. 1 

# OAR Box 1490 Prepped by Charmelle Mathews



### Document

Number: 

# 27 ) IV-B-2 9 Docket Number: 

# A-94-5 2

Printed 8/4/200811:51:46

AM Sheet 27 of 273P. 2

MEMORANDU

M SUBJECT : FROM : TO : DATE : Nationa

l Emissio n Standard s fo

r Hazardou s Ai

r Pollutants : Reinforce

d Plastic s Composite s Manufacturin

g - Captur e an d Contro l fo

r Larg e Part s Keit h Barnet t Projec t Lea d fo r th e Reinforce

d Plastic s Composite s NESHA P Docket fo r th e Reinforce

d Plasti c Composite s NESHAP . Februar y 10 , 200 3 I n respons e t o informatio

n presente d b

y th e America

n Composite s Manufacturin g Association (ACMA) , w e ar e subcategorizing ne

w sourc e floors b

y par t size . Therefore , i

t i s necessar y t o develo

p th e criteri afo

r par t size classification . Thi s memorandu mdocument s th e developmen

t ofth e criteria . Th e basi s fo r subcategorizing b

y par t size i s tha t facilitie s producing larg e part s ar e no t simila r t o facilitie s producing part s suc h as bathwar

e an d truck cap s becaus e larg e part s requir e large r airflow s relativ e t o emissions , an d als o requir

e larg e door s fo

r par t access . Som

e example s ar e underground storag e tanks , barg e covers , an d larg e domes . Based o

n this , EP A determine

d tha t th e par t volum e i s th e most

accurat e indicator ofth e difficult

y t o captur

e an d contro l ope

n moldin g emissions , wit

h th e larges t

squar e footag e ofany on

e sid e bein g asecondar

y indicator . I n orde r t o determin

e th e appropriat

e volum e fo r ope n moldin g parts , w e reviewe

d th e informatio n fo r tw o A.R.E . facilities . A portio n ofth e trip repor t t o thes e facilitie s i s attached (Attachmen

t 1) , along wit

h additiona

l informatio

n o n par t size s fo r A.R.E . an d Tecton (Attachment s 2 throug h 4) , an d informatio

n o n movin g part s i n an d out of permanen t tota l enclosure s (PTE ) (Attachmen t 5) . Table 1 present s th e characteristic s ofth e A.R.E . facilities . Table 1 Characteristic s o f

A.R.E . Facilitie s Locatio n Mt . Eaton , Ohi o

Massillon , Ohi o Par t

Size s Produce d Custo mMolde d parts , u p t o th e siz e o f ahears e bod y Pick-u p Truc k cap s Typ e O f

Productio n Custo mmoldin g in asingl e permanen t

tota l enclosur e (PTE ) Productio n lin e i n asingl e PT E Siz e o f PT E 85' x 75' x 25 '

165' x 68' x 27 ' Siz e o f

spra y booths/area s 18 ' x 16 ' Boot h 18' x 16'Boot h 17.5' x 15'Boot h 42.5' x 37.5 * (Larg e part s spray u p area ) 25'xl9 ' 68 ' x 28 * 

# 1P. 3

Bot h of thes e facilitie s mee

t 9 5 captur e an d contro l requirements . The larges t

singl e par t buil t a t A.R.E . i s acustomca

r body . (A.R.E . doe s not

produc e a complet e ca r body , onl y th e rea r portion) . Thi s par

t ha d dimension s of

11 4 inche s long , 6 3 inche s wide , an d 6 0 inche s high . Ifthi s par t was place d i n th e smallest

possibl e rectangula

r six-side d box , th e interior

volum e ofth e box woul

d b e 25 0 cubic feet . Th

e larges t sid e ofth e box woul

d b e 5 0 squar e feet . Therefore , w e choos e thes e dimension s as th e larges t dimension s fo

r whic h captur e an d contro l i s demonstrate d fo r ope n molding . W

e believe tha

t i t i s mos t appropriat

e t o bas e th e definition o f

larg e par t on th e actua

l size ofth e larges t

par t produced . W

e could hav

e considered basing th e definitio n on th e size ofth e larges t

par t tha t would fit int o th e existin

g PTE . However , w e believe tha

t thi s would b e speculative , becaus e ther e i s n o datat o show tha

t th e facilit y i s capable o f

producing th e large

r parts , or that , i f i t did , i t could d o s o whil e meetin g Metho d 204 . For pultrude d parts , ther

e i s one facilit

y tha t ha s 9 5 percen

t captur e an d control . Thi s i s Tecto n i n Nort h Dakota . The larges t

par t produce d a

t Tecto n i s 1 0 inche s wid

e b y 2 inche s high . Th e larges t numbe r o f reinforcements i

n an y par t a t Tecto n wa s approximatel

y 350 . Becaus e th e capabilit y ofaparticula

r pultrusio n machin

e t o accommodat

e aspecifi c par t size i s mainl

y dependen t t o th e larges t

die th e machin

e ca n accommodate , th e mos t

accurat e measur e ofth e size ofapultruded par

t i s th e outside perimeter . Therefore , w e choos e a n outside perimete

r o f 2 4 inches , an d 35 0 reinforcement s a s th e larges t part s wher

e captur e an d contro l ar

e demonstrated . A s wit h ope n molding , w e choos e t o us e th e larges t par t size actuall

y produced , no t

th e larges t size tha t th e facilit y believe s could b e produced .

%P. 4

*m—/ \

FINA L TRI P REPOR

T 

# IT- B 

# - NONCONFIDENTIA

L VERSIO

N BASE D ON PLAN

T COMMENT S MEMORANDU

M TO : FROM : DATE : SUBJECT : REFERENCE : Projec t fil e o f Reinforce d Plastic s Composite s Manufacturin g NESHA P Keit h Barnett , U . S . Environmenta l Protectio n Agency , Emissio n Standard s Division Decembe r 28 , 200 0 Sit e visi t t o A.R.E . Inc . Reinforce d Plastic s Composite s Manufacturing NESHAP , ES D Projec t No . 93/5 8 I . INTRODUCTIO N AN D PURPOS E Th e purpos e ofthi s visi

t wa s t o obtain information o n th e reinforce d plasti c composite s manufacturin

g operation s a

t th e tw o A.R.E . Inc . facilitie s locate d i n Ohio . Specificall

y w e wanted t o focu s on th e capture an d contro l o f

emission s fro mthes e processes . 

## n .

UI . PLACE AN

D DAT E A.R.E . Inc . 50 0 Nav e Roa

d Massillon , Ohi o 4464 8 330-830-780 0 ext . 20 1 Februar y 16 , 200 0 ATTENDEE S 

### BD M 2 6 

### 2001 - ffAAIpr.:*: * -,<E T

Mr . Ralp h Gatti , A.R.E . Inc . Mr . Chuc k Taylor , GT Environmental , Inc . (consultant t o A.R.E. ) Mr . Keit h Barnett , U . S . Environmenta l Protectio n Agenc y Ms . Melanie Proctor , Pacific Environmenta l Service s (contracto r

fo r USEPA) IV . SITE INFORMATION Thi s sit e visit covered tw o facilities , th e manufacturing facilit y i n Massillon , Ohio , an

d th e facilit y i n Moun t Eaton , Ohio . Th

e compan y ha d prepared adetaile d respons e t o alis t o f question s fo

r bot h facilitie s prio

r t o th e sit e visit . Thi s information i s included a s attachment s 1P. 5

an d 2 . Subsequent

t o th e sit e visit , A.R. E provided additiona l informatio

n i n alette r date d Februar y 23 , 2000 . Thi s include

d information o

n th e tw o stac

k tes t reports , permit

information , an d adeterminatio n fromEntrop y (th e compan y tha t performe d th e emission s test ) tha

t th e exit tunnel fromth e laminating are ai s no t anatura l draf t opening . Thi s information ma y b e foun d a s Attachmen

t 3 t o thi s trip report . A.R. E originall

y ha d on e facilit y i n Moun t Eaton . Th

e Ohio EP A ha s arul e (Rul e 21-07(G)(2) ) tha

t limits organi c compoun

d emission s froman

y one sourc e t o 4 0 pound s pe r da y an d 8 pound s pe

r hour , or require s 8 5 percen

t control . The Moun

t Eato n facilit

y could no t meet tha t requiremen

t without eithe r reducing productio n b

y 2/3 , o r retrofittin g add-o n controls . A.R.E . decided tha t using add-o n control s wa s th e bes t solution , an

d that building a new facilit y designe d t o mee

t thes e requirement s would b e easie r tha t tryin g t o retrofi t

th e Mount Eato n facilit

y wit h add-on controls . The

y als o needed t o expan

d their productio n space . Th e decisio n t o buil

d th e ne w facilit y wa s mad

e i n Januar y 1994 . A

t tha t time A.R.E . wa s asmal l busines s wit

h les s tha n 30 0 employees . The compan y i s no w alarg e busines s wit h oye r 50 0 employees . Th e emission s fromth e Mount Eato n facilit

y i n 199 3 (based i

n toxi c releas e inventor y reports ) wer

e 4 8 ton s pe

r yea r (tpy ) o f styren e an d 74 tp y o f

total HAP . I n 199 4 emission s wer e 6 3 tp y o f

styren e an d 9 1 tp y o f

total HAP . I

n 199 5 emission s wer e 5 7 tp y o f styren e an d 7 0 tp y o f

total HAP . Th e other

HA P emitte d ar

e frompainting operations . I n August , 199 5 th e Massillon facilit y starte d up . Du e t o th e siz e ofth e new Massillon facility , Ohi o EP A require d al

l majo r processe s t o mee t a9 5 percent

emission reductio n requirement . Processe s tha t d o no t meet th e 9 5 percent requiremen

t mee t th e 4 0 lb/da

y an d 8 lb/h r requiremen

t o f Rule 21-07(G)(2) . Th e origina

l pla n wa s t o curtai l operation s a t th e Moun t Eato n facilit

y t o th e point

wher e th e facilit y would mee

t Ohi o EPA rule s onc e th e Massillon facilit y starte d up . However , du e t o compan y growth , A.R.E . needed t o kee p th e Mount

Eato n facilit

y operating . S o the y decide d t o retrofit add-o n control s a

t th e Mount

Eato n facility . Thi s retrofi t wa s complete d in 1999 . Massillo n Facilit

v Thi s facilit y produce s cap s fo

r pick-u p trucks . Figur

e 1 present s aproces s flow diagra m fo r thi s facility . Emission point s i n Figur e 1 identifie

d by P ar e proces s operations . Emissio n point s identified by "Z " are exempt fromOhi o permittin g requirements . Emissio n point s identified b y "K " are coatin g operations . Figur e 1 als o show s th e portion s ofth e proces s that are containe d i n apermanen

t tota l enclosur

e (PTE) . Tabl e 1 present s siz e an d airflo w information o n specific productio n areas . Mold s ar e store d nex

t t o th e lamination area . A mol d i s take n fromstorag e throug h mol d maintenance , mol

d cleaning an

d releas e application , an

d the n enter s th e lamination are athroug h

6P. 6

t)2-'12/0 3 WE D 10:3 5 FA X 202260440 0 EPA_AI R DOCKE T @)00 2 PZ302Touch-UpAreaZ309PaintRepairSandingandGrindingBoothZ319FinalAssemblyArea

V *

c vKOO > .praIntS a a .ooth II Iiers:lea

o c iS * * a. a. o ? 5 

### " 1 C O O IS J £•

- O l T - 3 n C N £ O - D T * C D <•• > * 2 N l n O

- 1P011MoldCleaningandReleaseApplicationBooth 4 -Z301MoldMaintenance >• »TABL E 1 . A.R.E. , INC , MASSILLO N FACILITY PT E AN D SPRA Y BOOT H DESIG

N INFORMATION .

*

~iS§ v PT E Descriptio n Mol d Maintenanc e Resi n Mi x Roo m Glas s Roo m Gelcoa t Boot h Gelcoa t Tunne l # 1 Laminat e Roo m Resi n Tunne l # 2 Exi t Tunne l # 3 Tota l fro m Glas s Roo m Pain t Boot h # 1 Pain t Boot h # 2 Pain t Boot h # 3 Pain t Boot h # 4 Pain t Mi x Roo m Tota l t o RTO * Lengt h (ft ) 3 0 28.6 7 164.6 7 25.3 3 78.6 7 6 8 78.6 7 8 4 5 4 5 4 5 4 5 4 38.6 7 Widt h

(ft ) 1 8 20.6 7 6 8 1 9 1 1 2 8 1 0 1 0 1 3 1 3 1 3 1 3 2 0 Heigh t (ft ) 1 1 2 2 2 7 9.2 5 8.7 5 11.2 5 8.7 5 8.7 5 1 1 1 1 1 1 1 1 13.6 7 Volum e (cuft ) 5,94 0 13,03 7 302,33 4 4,45 2 7,57 2 21,42 0 6,88 4 7,35 0 7,72 2 7,72 2 7,72 2 7,72 2 10,57 2 Exhaus t

(cfm ) 8,70 0 90 0 13,50 0 6,60 0 14,94 0 6,50 0 8,70 0 50,24 0 12,50 0 12,50 0 12,50 0 12,50 0 1,00 0 109,94 0 Ai rExchange s

(#/mln ) 1. 5 0. 1 -AB-dB3'Mj5K5liji8m3 g a ? *-*&**gM3Simi 8 3. 0 0. 9 0. 7 0. 9 1^ 2 1. 6 1. 6 1. 6 1. 6 0. 1 Opening s

Descriptio n 1 7 @ (1.5x1.5 ) Non e 4@(5x2); 1 @(10x4 ) 1 @ (16x6.67 ) 2 @ (11x4 ) 2@(10x8); 1 @(20 x 2 @ (10x4 ) 2 @ (10x4 ) Non e Non e Non e Non e Non e Are a 38.2 5 N/ A 40. 0 106. 7 88. 0 320. 0 80. 0 80. 0 N/ A N/ A N/ A N/ A N/ A Comment s Thi s uni t i s unde rconstructio n Exhaust s int o Glas s Roo m NDO s ar e 4 louvere d ai rintak e duct s i r Openin g insid e Glas s Roo m Opening s insid e Glas s Roo m Opening s insid e Glas s Roo m Opening s insid e Glas s Roo m i roo f

On e openin g insid e an d on e ND O outsid e



## HS & Eac h boot h consist s o f a separat e paintin g roo m an d curin g oven .

Include s Mol d Maintenance , Glas s Room , 4 Pain t Spra y Booth s an d Pain t Mi x Room .

02/15/200 0

** •P. 8

atunnel . Th e tunne l entranc e has aroll u p doo r tha t i s closed unles s amol

d i s bein g move

d int o th e tunnel . A mol

d cleaning an

d releas e spra

y boot h tha t wil l b e ducte d t o th e regenerativ e therma l oxidize r (RTO ) wa s unde

r constructio n a

t th e tim e ofth e sit e visit . Thi s boot

h wil l be insid e th e PTE an

d wil l b e assume

d t o mee t 10 0 percen t capture . Som

e mino r mol d repair s ar

e performe d i n th e mol d maintenanc e are a(Z301) . Th e lamination are aconsist s o f tw o spra y booths . The first

i s th e gel coa

t boot h (POOl ) wher e th e gel coa

t i s applied t o th e mold . The secon d i s along laminat

e spra y boot h (6 8 fee t x 2 8 feet ) wher e tw o layer s o f

laminat e are applied using atomized spray-u p (chopper

guns ) a t tw o differen t station s (P00 2 an

d P003) . The resi

n contain s 3 6 percen

t styrene , an

d th e gel coa

t contain s u p t o 3 8 percent

styrene b y weight . However , th e facilit y calculate s their

potentia l t o emi t assumin g a4 2 percen

t resi n HA P conten t becaus e thei

r ai r emission s permit

allow s the

mt o us e resi n wit h u p t o 4 2 percen

t styrene . Th

e ai r exchange rate s ar

e 3 pe r minut e i n th e ge l coa t boot h an d 0. 7 pe r minut e i n th e laminat

e spra y booth . Roll-out

ofth e first

laye r o f laminat e take s plac e between spray-u

p are a# 1 an

d #2 . Roll-out

ofth e second laminat

e laye r take s plac e outside th e spra y boot h bu t within th e PTE . Afte

r roll-out th e part s exit

th e PT E throug h a8 4 foot tunnel . The resin cur

e tim e i s approximatel

y 9 0 minutes . Curing ofth e resin i s complete d i n th e exi t tunnel . The tunnel itself

i s vented t o th e RTO . For thi s reason , th e tunnel exit i s no t considered anatura

l draf t opening (NDO ) (Se e Attachmen t 3) . A t th e time ofth e visit , th e facilit y wa s makin

g improvement s t o th e seal s on th e bottom s ofth e roll-u p doors . Th e resin an

d gel coa t spra y booth s were designe

d t o mee t OSH A requirement s fo

r worke r exposure . Ther

e were n o specia l provision s mad

e i n th e design ofth e spra

y booth s becaus e they were goin g int o apermanen

t total enclosure . A

s show n i n Figur e 1 , th e facilit

y me t th e requirement s fo

r aPT E b y building awal

l aroun d th e lamination are awher

e th e spra y booth s are located . Th e wall s are cinde r bloc k wall s tha t reac h fromth e floor

t o th e buildin g roof

. The roo f i s 2 7 fee t abov e th e floor. Ther

e are . vent s tha

t rout e ai r fromth e PT E t o th e RT O i n th e roof s ofth e thre e spra

y booth s (POOl , P002 , an

d ?003) , th e gel coa

t tunnel , th e resin tunnel , an d th e exi t tunnel . The onl

y natura l draf t opening s (NDO ) ar

e 4 louvered ai

r intak e duct s hig

h i n th e wall s nea r th e roof . Thes e ND O open insid

e th e building . More specific design information i n th e booth s an d enclosure s ma

y b e foun d i n attachmen

t 1 . Th e PT E design wa s don e b y Q Sourc e i n Cincinnati , Ohio , an

d G T Environmental . Th e PT E i s no t

air conditioned . Ther

e are 4 ai r makeu p fan s tha t hav e maximu

mflow rate s o f 40,00 0 cfi n each . Th e ai

r flow i s sufiBcien

t t o maintai n a n acceptabl e interio r

temperature . Th e temperatur

e i n th e lamination are ai

n summe r i s approximatel

y th e sam e a s th e outside ambien t temperature , excep t

tha t i t lag s a n hou r o r s o behin d outside temperature changes . I n th e summe r th e temperatur

e ca n reach th e 90s . In winte

r th e makeu

p ai r i s heated . Afte r th e part s exi

t th e tunnel , railing s an

d othe r part s are adde d an

d they are painted i

n one of 4 spra y booths . The pain

t spra y booth s ar

e als o vented t o th e RT O an d als o mee t the requirement s o f

EP A Metho d 20

4 fo r aPTE . Eac

h spra y boot h has tw o zones , aspra

y zon e an d aove n zone . Part s remai

n i n th e spra y booth s fo

r approximatel

y 44 minutes , ofwhic h 2 2 minute s i s pain t application an

d 2 2 minute s i s pain

t drying . Th

e par t doe s no t exi t th e spra y boot h unti l th e pain t i s completel

y dry . Al l operation s subsequen

t t o th e lamination are awil

l no t b e covere d 

# w 

# 7P. 9

b y th e reinforce d plasti c composite s NESHAP . Th e painting operation s wil

l b e covere d b y th e plasti c part s coatin g NESHAP . Resin and ge l coa

t us e fo r th e Massillon facilit

y i n 1997 wer

e 3,539,72 8 an

d 584,86 6 pound s respectively . The RTO operate s a t al l time s the facilit

y operates . Th e RT O ha

d a n averag e destructio n efficienc y o f 98.2 7 percen

t durin g aDecembe

r 199 5 test . Th e state permi t require s a9 5 percen t

destructio n efficiency . A

t the sam e tim e th e testin g compan

y certified tha

t th e enclosur

e meet th e requirement s o f

EP A Metho d 20

4 fo r aPTE . The emission s a

t th e RTO inle

t wer e measure d a s 69.2 7 pound s pe

r hour a s carbo n i

n th e 199 5 test . Approximately 5 7 percen t ofth e mas s flow t o th e RT O i s styren e fromth e open moldin g operations . The remainde r i s variou s solvent s fromth e painting operations . The inle t concentratio n t o th e RT O wa s 43 1 ppm . The relativ e ai r flows are 50,24 0 acfi

n fromth e open molding operation s an

d 51,00 0 acf

mfromth e painting operations . Not e tha t al l pain t spra y booth s canno t

operat e i n th e spra y mod e a t th e sam e tim e i f al l other unit s are operating . Thi s facilit y wa s reteste d o

n Jun e 12 , 2000 . Th

e RTO agai

n me t th e 9 5 percent destructio n requirement

an d th e PT E wa s agai

n certifie d a s meeting th e requirement s o f EP A Metho d 204 . There ar e tw o resin storag e tank s locate d insid e th e building tha

t ven t t o th e RTO . There are thre e tank s i

n th e closed resin mi

x room . The tank s ven

t int o th e room , and th e roo mvents , into th e laminatio n are aPTE . Th e add-o n control s allo w th e facilit y t o have flexibility i

n their operations . They ca

n us e highe r solven t paint s an d highe r HA P resin s tha

n woul d b e allowed i

f they did no t

hav e th e add

o n controls . Worker

exposur e t o styrene i

n th e laminatio

n area s wa s recently measured a s 11 6 ppmfo r th e chopper

gu n operato r

whe n spraying i s actuall

y takin g place . Tha

t i s abou t 2 0 percent ofth e time . Concentration s fo r other worker s i n th e spra y booth s wer e 4 3 ppm . Thi s facilit y meet s th e voluntar

y OSH A standar d o f 5 0 pp mfo r a n 8-hou r average . Th e spra

y gu n operator s wea

r respirator s wit

h charcoa l filters a s aprecautionar

y measure . An

y other worker s wit h an y exposure t o 5 0 pp

mo r mor e of styrene ar e als o required b y compan

y rule s t o wea

r respirators . Thi s facilit y doe s no t us e an y flow coater s o r

fluid impingemen

t technolog y t o appl

y resin . Th e state d reaso n wa s they believe tha t flow coater s do no t

wor k wel l whe n you hav e vertica

l surfaces . Startup fromth e weeken

d shutdown begin s o

n Sunda y a t 8:00 p man d take s about

2 hours . Th e RT O typicall

y operate s a

t 1500 ° F , but

i s allowe d t o g o a s lo w a s 1450 ° F . The y d o no t have continuou s emissio

n monitor s on th e RTO , they must continuously monito r

th e RT O temperature . Th e origina

l capita l cos t an d operatin g cost s ofth e syste mare show n i

n attachment

1 . The cos t impact ofth e contro l devic e di

d increas e th e price s fo

r th e truc k caps .P.1 0

Th e bigges t

technica l challeng e fo

r th e contro l syste

mi s properl

y balancing th e ai

r flow . Yo u mus t kee p th e enclosur

e unde r negative pressure . However , to o muc h negativ e pressur

e i n th e enclosur

e make s th e equipmen

t wor k harde r the n necessar y t o maintai

n th e airflow out

ofth e enclosure . Th e damper s fo r th e ai r handlin g syste mare controlled fromth e RT O contro l room . Mount Eato n Facilit

v Th e Mount

Eato n facilit

y doe s custommoldin

g an d produce s th e tool s fo

r bot h Mount Eato n an d Massillon . Thi s facilit

y i s abou t 1/ 3 the siz e of

Massillo n o n asquar e footag e basis . Th e type s o f

part s produce d a

t Moun t Eato n includ

e roofto p carriers , tannea

u covers , an

d equipmen t covers . A

t one tim e the y als o produced customca

r bodies . Th

e larges t par t siz e i s approximatel

y 12 ' x 4 ' x 4' . Though thi s facilit y i s 1/ 3 th e size o f

Massillon i

n asquar e footag e basis , i t use s les s tha

n 1/ 3 ofth e amoun

t ofresi n used a

t Massillon . I

n 199 7 (prio r

t o th e installatio n ofth e RTO) , thi s facilit y use d 174,622 lb . ofresi n an

d 16,55 5 lb . o f

ge l coat , whic

h were les s tha

n 5 percen t o f total material s used b

y A.R.E . Thi s facilit y wa s th e origina

l facilit y fo r A.R.E . tha

t evolve d from aon e roo marea . Based on th e succes s ofth e contro l syste ma t th e Massillon faciht

y an d th e need t o accommodat

e growth , A.R.E . decided t o retrofit Moun t Eato n wit h controls . The

y do no t conside r retrofit t o b e technicall

y challenging i

f sufficien t floor spac e i s available . The

y built PT E i n th e existing building an

d the n move d existing spra

y booth s insid

e th e PTE . Th

e contro l devic e a

t Mount Eato n wa s starte d u

p i n March o f

1999 . Figur e 2 present s th e current

facilit y layou t an d Table 2 present s desig n information o n individua l spra y booths . More detailed design an d cos t informatio n are presente d i

n Attachmen

t 2 . Ther e are thre e spra

y booth s an

d alarg e componen

t spray-u p are ai n th e PTE . One spra

y boot h i s fo r gel coat , an

d th e other

tw o ar e fo r resin application . Mold s enter th e PTE , an

d part s exit , throug h larg e roll-u

p doors . The door s ar

e kep t closed durin

g norma l operation . Becaus e thi s i s amuc

h lowe r volum e operation , tunnel s t o allo w curing t o b e complete d are no t necessary . The Mount

Eato n facilit

y als o ha s aresi

n transfe r moldin g operation . Thi s include s agel coa t spra y booth . Neithe

r o f thes e operation s i s vente d t o th e RTO . Th e resin mi x roo man d mol d fabrication area s als o d o no t ven t t o th e RTO . Mold s fo

r bot h th e Massillo n an

d Moun t Eato n facilit

y are fabricated a

t Mount Eaton . Ther e ar e 4 pain t spra y booth s a t th e Moun t Eato n facility . Thes e booth s were presen t prio r t o th e retrofit

ofth e RTO . Each boot

h i s aseparat

e PTE . Thes e booth s d

o no t haveFigur e 2 . A.R.E. , Inc . Mount Eato n Facilit

y Genera l Proces s Flo w Diagrama s o f Februar y 11,2000 . Resi n Mi x Roo m

Catalys t

Gelcoa t (drums ) Catalys t 

# o Catalys t -Tota l Enclosure R01 3 Fiberglas s Spray-U p # 1 R01 4 Fiberglas s Spray-U p #2

R01 2 Gelcoa t Boot h

Z12 9 Mol d Maintenanc e R01 6 Larg e Componen t Fiberglas s Spray-U p Are a Regenerativ e Therma l Oxidize r (RTO )

j** * Pain t Mi x Roo m 2112-211 5 Pain t Gu n Cleaner s 1- 4 Plan t # 2 Mol d Fabricatio n Z12 8 Sandin g an d Grindin g R008 - Gelcoa t an d Prime r Booth# 1 R009-Gelcoa t an d Prime r Boot h # 2 R010-Cerami c Spray-U p Are a R011-Spray-U p Are a

R00 4 Pain t Spra y Boot h # 1 R00 5

Pain t Spra y Boot h # 2 R00 6 Pain t Spra y Boot h # 3 R00 7 Pain t Spra y Boot h # 4

Waxe d Par t Mol d

Z12 0 Weldin g Are a Fiberglas s Par t Z12 3 Fossline r Boot h

Z12 1 WoodSho p P00 3 Tri m Boot h P00 1 RT M Equipmen t

i i R00 3 Gelcoa t Boot h •4

4 212 2 RT M

Tan k

Z12 7 Foa m Sandin g

P00 4 Sanding / Grindin g Boot h Eac h Boot h i s a n Enclosur e Painte d Par t Z116-Z11 7 Pain t Gu n Cleaner s Locate d throughou t th e facilit y

R01 5 Prime r Boot h

P00 2 Pre p Are a 212 6 CN C Cuttin g Roo mV TABL E 2 . A.R.E. , INC , MOUN

T EATON FACILIT

Y PT E AN D SPRAY BOOT

H DESIG N INFORMATION . PT E Descriptio n Lengt h (ft ) Widt h (« ) Heigh t (ft ) Volum e (cuft ) Exhaus t

(cfm ) Ai rExchange s

(#/mtn l Opening s

Descriptio n Are a Comment s Glassroo m 8 5 7 5 1 @ ( 8 x 6.33) ; 1 @ ( 8 x 8 ) 114. 6 NDO s fo rpart s egres s an d mol d ingress/egres s Gelcoa t Boot h 17. 5 1 5 3,15 0 5,89 0 Non e N/ A Openin g insid e Glas s Roo m Gelcoa t Flash-Of

f Are a 4 0 1 6 5,12 0 4,93 0 1. 0 Non e N/ A Ope n are a withi n Glas s Roo m Spray-U p # 1 1 8 1 6 1 2 3,45 6 7,58 0 2. 2 Non e N/ A Openin g insid e Glas s Roo m Spray-U p # 2 Rollou t Flash-Of

f Ar e i 7,S- N-*- » Tota l fro m Glas s Roc m ^V^.'- : ^-.r-l i>.frf.^5gg? P 3 1 , C N' A Openin g insid e Glas s Roo m t'm'S »3 £ Ope n are a withi n Glas s Roo m I****-*" * "ti l • — " Pain t Boot h # 1 Pain t Boot h # 2 Pain t Boot h # 3 Pain t Boot h # 4 2 7 2 7 2 7 2 7 1 4

1 4 1 4 1 4 3,40 2

3,40 2 3,40 2 3,40 2 6,30 0

6,20 0 3,84 0 3,86 0 1. 9

1. 8 1. 1 1. 1 Non e

Non e Non e Non e N/ A N/ A N/ A N/ A Al l fou rpain t spra y booth s hav e tw o mode s (spra y an d bake) . Th e flowrat e i n th e bak e mod e i s les s tha n th e spra y mode . Eithe rboot h # 1 o r# 2 i s i n th e bak e mod e whe n al l unit s ar e i n operation . Pain t Mi x Roo m 28. 5 8 1 0 2,28 0 1,00 0 0. 4 Non e N/ A Tota l t o RTO * 50,00 0 * Include s Glas s Room , 4 Pain t Spra y Booth s an d Pain t Mi x Room . Not e tha t al l fou rPain t Spray Booth s canno t b e i n th e "spray " mod e whe n al l othe runit s ar e operating .

02/15/200 0

t- 0P.1 3

separate spra

y an d oven zones . Bot

h operation s take plac e i

n th e sam e zone . Part s are kep t

i n th e PT E unti l dry . Th e pain t spra y booth s an

d pain t mi x roo mven

t t o th e RTO . Contro l Equipment

Maintenanc e an

d Cost s A.R.E . ha s amaintenanc e contrac t wit h Durr , th e compan

y wh o manufacture d th e RTO . Dur r no w ha s th e responsibilit

y fo r al l maintenanc e ofth e RT O an d receive s afixed fe

e ever y month . Thi s give s Dur

r a n incentiv e t o kee

p th e RT O operatin g a s efficientl y a s possibl e t o reduc e maintenanc e costs . The y als o upgrade a s necessar

y t o balanc e resourc e us e an d equipmen

t longevity . There i s aDur

r employee o n sit

e who cover s bot

h facilities . Dur

r ca n als o troubleshoo t

RT O problem s remotel

y throug h amodem . Prio r t o thi s contract , A.R. E performed maintenanc e themselves . A.R.E . personnel state d tha t the y believ e cos t

estimate s fo

r RT O rarel

y take int o accoun t repair cost s fo r fans , an d burne r parts . A.R. E ha s fixed th e lif e cycle cost s ove

r te n year s a s aresul

t ofth e contract s wit

h Durr . A.R.E . said that

th e cos t o f natura l gas , an d th e tota l syste mpressur e dro p ha d increase d ove

r time . A.R.E . choos e t o us e a n RTO rather

tha n ahybri d concentrator/oxidizer

syste mbecaus e o f concern s relate d t o th e technica l feasibilit y o f concentrator s wit

h styren e an

d multipl e other VO C constituents . The

y als o ha d concern s that , becaus e ofth e variet y o f solvent s i n th e painting operations , th e performanc e of ahybrid syste mmigh t b e mor e variabl e that

aRT O alone . Whe

n A.R.E . retrofitte d add-o n control s a t Moun t Eaton , they sa

w no reaso n t o chang e th e typ e o f add

o n contro l becaus e th e Massillo n contro l syste mwa s workin g well , an

d th e Moun t

Eato n facilit

y als o ha d styren e emission s an

d painting operations .



## P 

# I VP.1 4 Avfcp^rx/-*^ ^ A Ralp h Gatt i To : Keit h Barnett/RTP/USEPA/US@EPA <RGATTI@4are.com > cc : Subiect : Hears e Bod

y Dimension s 02/21/200 3 02:1 3 P M Keith , Not a s larg e a s I thought . 114 " lon g 63 " wid e 60 " hig h Hop e thi s help s yo u ge t thi s dow n th e road . Ralp h *************************** * Ralp h Gatt i Presiden t A.R.E . Inc . (330 ) 830-7800 , ex t 20 1 www.4are.co m *************************** *



# 1 3P.1 5 

### A*W&C/1,NS<^ T 3 Ralp h Gatt i <RGATTI@4are.com > 02/21/200 3 02:5 9 P M To : Keit h Barnett/RTP/USEPA/US@EP A cc : Subject : Th e larges t part Keith , Th e larges t par t tha t coul d currentl ymak e withou t modificatio n t o th e PT O woul d b e 18 ' long x 9 ' wid e x 6 ' deep . I f th e hears e wasn' t bi g enough t o ge t yo u dow n th e road mayb e thi s wil l be . Ralp h *************************** * Ralp h Gatt i Presiden t A.R.E . Inc . (330 ) 830-7800 , ex t 20 1 www.4are.co m *************************** *



# 1 402/25/0 3 TU E 17:2 3 FA I 70 1 27 7 021 9 TECTO NPRODUCT S FEB.24.200 3 8:51fl

M 

# hbhii r^ + H NO.57 0 P. 2 P.1 6

@00 2

CONTAC T REPOR

T Perso n Calling :

Perso n Called : Dat e o f Contact : Keit

h Barnet t U. S Environmenta

l Protectio n Agency OAQPS/ESD/MIC G 919-S41-S60 5 John Jamboi

s President Tecto n Product

s Februar y 21,2003 , an

d Februar y 24,200 3 ContactSummary : I calle d Mr . Jamboi s t o obtai n informatio n o n par tsize s an d thd r curren

tcontrols . Tecto n products has 9 5 percen tcaptur e an d control o n al

l thei r pultrusion machines . Th e 9 5 captur e an d contro l ha s bee n confirme d throug h emissio n tests . Th e larges tpart

s the y ca n produc e woul d h e 1 6 inche s wid e by 6 inche s i n height . Th e possibl e length i s unlimited . Th e larges tpart

s the y hav e actually produced wer e approximatel y 10 " wid e an

d 1.5* ' t o 2 " high . Th e longes tpar

tlength wa s 4 0 feet . Th e maximu

m number o f

reinforcement

s i n an y c f th e part s they hav e produced I

s 348 . * * \

Confirmation : I confir

m tha tth e infonnatio n abov e i s A . correc tcorrec

t-wit h th e changes note d above . Signature : >,'



# 1 6 02/24/0 3 MO N07 : 5 & [TX/RX N O 8535 ] ©00 2P.1 7 

## A c-tftc/ l r<\en

+ ^ Ho w do facilitie s mov e part s an d equipmen ti n an d ou to f a Permanen tTota l Enclosur e (PTE ) an d stil l compl y wit h EPA Metho d 204 ? EP A Metho d 20 4 consist s o f 4 desig n criteri aan d 2 operationa l criteria . Th e desig n criteri aar e straightforwar d an d simpl e t o verify . Th e operationa l criterial ar e als o ver y simple , excep t

whe n considerin g door s use d t o mov e equipment , molds , an d part s in an d out ofth e enclosure . Th e operationa l criteri area d a s follows : Th e averag e facia

l velocity throug h al l natura l draf t opening s (NDO's ) shal l b e a t leas t 20 0 feet pe r minute . Th e directio n o f ai r flow throug h al

l NDO' s shal l b e inwar d All acces s door s an d window s tha t ar e no t treate d a s NDO' s shal l b e close d durin g routin e operatio n ofth e proces s I t i s thi s las t

criteri atha t

ha s bee n mos t

confusin g t o th e reinforce d plastic s industry . Why i s thi s important ? Fabricator s mus t

mov e part s an d equipmen t i n an d ou t

o f PTE . I f the y ar e require d t o trea t acces s door s a s NDO's , th e airflo w require d t o ventilat e th e PTE , an d th e cos t o f control , ar e increased . Fo r

smal l part s thi s increas e ma y b e negligible , bu t

for larg e part s thi s coul d doubl e th e airflo w requirin g control . Wha t doe s th e criteri areall y mean ? Th e requiremen t

tha t acces s door s an d window s b e close d i s not intende d t o requir e tha t

thes e door s b e close d at

all times . I t

mean s tha t

door s mus t

b e close d any tim e tha t

yo u ar e no t

actuall y movin g part s o r

equipmen t

throug h them . Why don' t

w e jus t sa y that ? Obviously , in som e situation s a n acces s doo r

shoul d b e treade d a s a

n NDO . Fo r

example , ifth e acces s doo r

i s use d s o ofte n tha t

i t i s almos t alway s open , the n i t

shoul d probabl y b e considere d a n NDO . W e coul d establis h atim e limit , bu t ever y facilit y i s goin g t o b e different , an d aspecifi c tim e limi t woul d reduc e th e flexibility ofth e method . W e allo w th e permittin g authorit y t o make thei r ow n determination s concernin g whe n adoo r shoul d b e considere d a

n NDO . Factor s the y typicall y conside r

are : Siz e ofth e doo r Location , i.e . i s i t

clos e t o th e actua l emissio n points , o r fa r away • What

percentag e o f

tim e i s th e doo r

ope n • Doe s th e doo r

hav e hangin g plasti c strip s o r a n ai r curtai n t o reduc e th e effectiv e area ? Ho w can afacilit

y determin e if

adoo r will b e treate d a s a

n NDO ? A facilit y woul d nee d t o submi t

t o th e permittin g authority th e desig n ofth e PT E showin g emissio n points , ai r

flows, doo r

locations, , an d estimate d tim e th e door s will b e open . I t woul d b e 

# | tP.1 8

u p t o th e permitting authorit

y t o approv e or

disapprov e th e design . Ifth e desig n i s approved , the n i t i s th e responsibilit

y ofth e facilit

y t o buil d an d operat e th e PT E i n accordanc e wit

h th e submitte d design . W

e d o not se e thi s a s atremendou s burde n sinc e ane

w facilit y wil l hav e t o d o thi s i n an y case . Doe s thi s mea

n tha t a t som e times , th e PT

E wil l not have 20 0 fee

t pe r minut e throug h al

l openings ? Yes . W e recogniz e tha

t allowin g acces s door s t o b e opene

d t o mov e materia l through the

mca n potentiall y result i n HA P escaping th e PTE . W

e have neve

r state d tha t meetin g th e requirement s of EP A Metho d 20

4 wil l mea n 10 0 captur e of emissions , 10

0 percen t ofth e time . Th

e method wa s intended t o get

a s clos e a s w e ca

n t o 10 0 percen t capture , bu

t stil l allow facilitie s t o ru

n thei r productio n processe s i

n a n efficien t manner . However , as long as th e approved Metho d 20 4 desig n an d operatin g criteri aar

e met, w e credit

th e facilit y wit h 10 0 percen t capture . I t shoul d b e noted tha

t 20 0 fee t pe r minut e i s aver y conservativ e figure based o n th e NIOS H industria l ventilatio n guidelines . S o eve n whe n door s ar e ope n an d afacilit y doe s no t hav e 200 fp mthroug h al

l openings , captur

e efficienc y wil l stil l b e 10 0 percen t i f al l airflo w i s inward .



# 17