p.1 

OAR Box 1413 

Prepped by Ollie Stewart 

Document Number: 

13)11-1-13 

Docket Number: 

A-94-52 

Printed 7/9/2008 3:11:21 PM Sheet 13 of 114 
P.2 

A-94-52 

GGI I ,;^ ' \.:A 

I W " 
P.3 

(•• c 

SOUTHCENTRAL REGION - FIELD OPERATIONS 

Air Quality Control Program 

One Ararat Boulevard 

Harrisburg, Pennsylvania 17110 

(717) 657-4587 

November 8, 1993 

D. 

Mr. William Harclerode ~ 

Creative Pultrusions, Inc. 

Pleasantville Industrial Park 

Alum Bank, PA 15521 

Re: Department styrene Emission Tests 

Fiberglass Pultrusion Operation 

Dear Mr. Harclerode: 

Enclosed you will find one copy of the Department's styrene 

emission testing report. Based on these test results, it 

would appear that our styrene emission factor is 

approximately 1.9% (1.9 lb of styrene emitted per 100 lb of 

styrene present). Should you have any questions concerning 

the test reports, I can be reached at the above telephone 

number. 

In addition, I believe it is time to schedule another meeting 

to plan our next course of action regarding the styrene 

emissions at your facility. Please contact me so that a 

mutually agreeable time and date may be selected. 

Very truly yours, 

Richard D. Roller 

Air Pollution Control Engineer 

cc: Southcentral Region File 05-399-003A 

Altoona Office 

z 
P.4 

Commonwealth of Pennsylvania 

Environmental Resources 

October 15, 1993 

Subject: Source Test Results 

To: 

From: 

Leif Ericson 

Regional Air Pollution Control Engineer 

Region III 

L. Blaine DeHaven, Chief \f 

Division of Source Testing and Monitoring 

Bureau of Air Quality Control 

Attached are two (2) copies of a report of VOC sampling at Creative Pultrusion, Inc. in 

Alum Bank, Pennsylvania. One copy of the report is for the company's file and one copy 

is for your file. 

The following information was extracted from the test report: 

Process Tested Pultrusion Lines 

Test No. 0493C 0493D 

Pollutant Sampled Styrene Styrene 

Actual Emissions 62 ppm 64 ppm 

If you have any questions concerning the test, please do not hesitate to contact me. 

Attachments 

cc: AP File through: Jim Benson 

Reading File, Source Testing 

Data File 

LBDrdlw 

% 
P.5 

f 

COMMONWEALTH OF PENNSYLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUALITY CONTROL 

SOURCE TEST REPORT 

NAME: Creative Pultrusions, Inc. 

Alum Bank, Bedford County 

PROCESS/SOURCE TESTED: 

TEST NO. 

TEST DATE: 

POLLUTANT SAMPLED: 

STYRENE CONCENTRATION: 

STYRENE EMISSIONS: 

^TV-f-^»\ft, • y\*~\sA pVAjh 

Pultrusion Lines 

00493C 

05/19/93 

Styrene 

62 ppm 

20.7 lbs./hr. 

icn;x lbs. 

PENNSYLVANI A 

00493D 

05/19/93 

Styrene 

64 ppm 

21.5 lbs./hr. 

f/lvj , Ib i 

TEST CONDUCTED BY: T. R. Brooks, R. Szekeres 

REPORT PREPARED BY: T. R. Brooks, R. Szekeres 

REPORT APPROVED BY: L. B. DeHaven, P.E. 

4 
P.6 

r C: 

COMMONWEALTH OF PENNSYLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUAUTY CONTROL 

CREATIVE PULTRUSIONS. INC. 

ALUM BANK, BEDFORD COUNTY 

SUMMARY 

Stack Test Nos. 0393A, B, C and D and 0493A, B, C, and D 

Volumteric Flow Rate (DSCFM) Avg. 

Barometric Pressure (in.Hg.) 

Stack Temperature (Deg. F) 

Moisture (%) 

Date: 05/19/93 

20,800 

28.32 

71 

1.4 

Sampling Results 

Sampling Method: 

Stack Test No.: 

Run No.: 

PPM styrene 

EPA 18 • charcoal tubes 

0393A 

1 

N.D.* 

0393B 

2 

N.D.* 

0393C 

3 

160 + 

0393D 

4 

90 + 

Note: Glycol Ether PM Acetate was not detected in any charcoal tube samples -

detection limit for all components is 5 ppm. 

Sampling Method: 

Stack Test No.: 

Run No.: 

PPM styrene 

EPA 25A-on site FID 

0493A 

1 

87.3* + 

0493B 

2 

104.4* + 

0493C 

3 

61.7 

0493D 

4 

64.0 

•Sampling discrepancies noted for these runs 

ppm styrene 104 lbs. styrene 

Emission rate calculation: x x DSCFM x 60 min/hr = Ibs/hr. styrene 

1 x IO6 387 dscf styrene 

Stack Test No.: 

Ibs/hr styrene 

0393C 

53.7 + 

0393D 

30.2 + 

0493C 

20.7 

0493 D 

21.5 

+ For comparison of two sample methods only - these results are questionable. 
P.7 

(r 

COMMONWEALTH OF PENNSYLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUALITY CONTROL 

CREATIVE PULTRUSIONS, INC. 

ALUM BANK, BEDFORD COUNTY 

PROCESS DESCRIPTION 

Creative Pultrusions operates seventeen pultrusion lines, utilizing glass or fibrous reinforcement in a thermosetting resin matrix, for the manufacture of various pulled/extruded products. 

Reinforcement roving or matting is continuously fed into a covered bath where it is 

impregnated with resin. This saturated material is then preformed into the desired shape and 

introduced into a heated die where the resin is heat-cured at approximately 275°F. A puller 

near the end of the line draws the feedstock along, after which it is manually cut to length. 

The emissions from this process are contained within the building, which serves as a total 

enclosure, until removal by collection hoods, located adjacent to each impregnation bath of 

each pultrusion line. The collection hoods are connected to a common stack from which the 

emissions are ultimately discharged to the atmosphere. Particulate matter generated by the 

pultrusion process is removed by a filtration unit, prior to being discharged. 

A process flow diagram is shown in Figure I. 

1 - PORTS 

ROOF 

or//y/s///?/s///////^^^^ 

CONTINUOUS 

ROVINGS 

IMPREGNATION 

BATH 

PULLER 

FIGURE I. PULTRUSION LINE FLOW DIAGRAM 
Test No. 00393A 

TIME POINT V.H 

in.WG 

8:43 AM B-6 0.450 

B-5 0.450 

B-4 0.070 

B-3 0.040 

B-2 0.040 

B-l 0.090 

B-l 0.090 

B-2 0.030 

B-3 0.030 

B-4 0.430 

B-5 0.450 

B-6 0.390 

B-6 0.390 

B-5 0.310 

B-4 0.420 

B-3 0.030 

B-2 0.040 

B-l 0.060 

8:47 AM A-6 0.550 

_j A-5 0.560 

A-4 0.320 

A-3 0.380 

A-2 0.520 

A-1 0.430 

Probe No.: R15 

Tsp 

deg F 

Vsp TI 

fps 

37.8 

37.8 

14.9 

11.3 

11.3 

16.9 

16.9 

9.8 

9.8 

36.9 

37.8 

35.2 

35.2 

31.3 

36.5 

9.8 

11.3 

13.8 

41.8 

42.1 

31.9 

34.7 

40.6 

36.9 

Cpp: 0.820 

kurmunMtALin ut ftrniMLVAHiA 

OEPARTHENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUALITY CONTROL 

PRELIMINARY TRAVERSE DATA 

ME POINT 

A-1 

A-2 

A-3 

A-4 

A-5 

A-6 

A-6 

A-5 

A-4 

A-3 

A-2 

A-1 

V.H 

in.WG 

0.430 

0.540 

0.390 

0.430 

0.510 

0.570 

0.570 

0.550 

0.420 

0.410 

0.550 

0.480 

Tsp 

deg F 

71 

71 

71 

71 

71 

71 

71 

71 

71 

71 

71 

71 

Vsp 

fps 

36.9 

41.4 

35.2 

36.9 

40.2 

42.5 

42.5 

41.8 

36.5 

36.1 

41.8 

39.0 

TIME POINT V.H 

in.WG 

Tsp 

deg F 

Vsp 

fps 

Averages 71 31.23 

Pbp: 28.32 in. Hg Pg: -3.10 WG 

VELOCITY 

VOLUMETRIC FLOW RATE DETERMINATION 

Vsp = 85.49 X Cpp X (JV.H.)avg X I Tsp + 

N Msp x 

VOLUMETRIC FLOW RATE 

Qsp = Vsp X A X 60 X 

STACK PRESSURE 

460 

Psp 

85.49 X 0.82 X 0.531 X 531 

28.69 X 28.09 

= 30.2 fps 

530 X Psp X (1-Bws) - 30.2 X 12.60 X 60 X 530 X 28.09 X (1-0.014) = 21,100 dscfm 

Tsp + 460 29.92 531 29.92 

Psp = Pbp + (Pg/13.6) = 28.32 + (-0.23) = 28.09 in. Hg 

00 
Test No. 00393A 

TIME 

3:09 PM 

3:12 PM 

•oO 

POINT 

B-6 

B-5 

B-4 

B-3 

B-2 

B-l 

B-l 

B-2 

B-3 

B-4 

B-5 

B-6 

B-6 

B-5 

B-4 

B-3 

B-2 

B-l 

A-6 

A-5 

A-4 

A-3 

A-2 

A-1 

Probe No.: R15 

VELOCITY 

V.H 

in.WG 

0.380 

0.4Q0 

0.410 

0.040 

0.030 

0.060 

0.060 

0.050 

0.020 

0.430 

0.300 

0.400 

0.400 

0.320 

0.460 

0.050 

0.050 

0.100 

0.470 

0.460 

0.430 

0.350 

0.430 

0.370 

Tsp 

deg F 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

DEPARTMENT OF ENVIRONMENTAL RESOUKkL* 

BUREAU OF AIR QUALITY CONTROL 

PRELIMINARY TRAVERSE DATA 

Vsp TI 

fps 

34.7 

35.6 

36.1 

11.3 

9.8 

13.8 

13.8 

12.6 

8.0 

37.0 

30.9 

35.6 

35.6 

31.9 

38.2 

12.6 

12.6 

17.8 

38.6 

38.2 

37.0 

33.3 

37.0 

34.3 

Cpp: 0.820 

C POINT 

A-1 

A-2 

A-3 

A-4 

A-5 

A-6 

A-6 

A-5 

A-4 

A-3 

A-2 

A-1 

V.H 

in.WG 

0.370 

0.470 

0.360 

0.360 

0.420 

0.450 

0.450 

0.440 

0.410 

0.350 

0.500 

0.410 

Tsp 

deg F 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

72 

Vsp 

fps 

34.3 

38.6 

33.8 

33.8 

36.5 

37.8 

37.8 

37.4 

36.1 

33.3 

39.9 

36.1 

Averages 72 30.36 

TIME POINT V.H 

in.WG 

Tsp 

deg F 

Vsp 

fps 

y \ 

Pbp: 28.32 in. Hg Pg: •2.80 WG 

Vsp - 85.49 X Cpp X (^|V.H.)avg X 1 Tsp + 460 

N Msp x Psp 

VOLUMETRIC FLOW RATE DETERMINATION 

- 85.49 X 0.82 X 0.514 X 532 

" N 28.69 X 28.11 

= 29.3 fps 

VOLUMETRIC FLOW RATE 

Qsp = Vsp X A X 60 X 

STACK PRESSURE 

530 X Psp X (1-Bws) = 29.3 X 12.60 X 60 X 530 X 28.11 X (1-0.014) = 20,400 dscfm 

Tsp + 460 29.92 532 29.92 

Psp = Pbp + (Pg/13.6) = 28.32 + (-0.21) = 28.11 in. Hg. 

CO 
«.vifiitiv/i«« » kjr-ki. t • • w t r -^-.Mim-* - *-,<**----.-msi** 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUAUTY CONTROL 

SAMPLING TRAVERSE FIELD DATA 

Company Creative Pultrusions. Inc. 

Sample location In Stack 4 Feet Upstream from Bend 

at center of Exhaust Duct 

Run #f: 

Comments: 

Cartridge I.D. No. 

Charcoal 

Tube A-Sample 

TubeB-Backup 

Tubes sampled backwards -

arrows pointing wrong way 

Source 

Run# 

Pultrusion Lines 

1 

Barometric Pressure (Pb) 29.32 in. Hq. 

Probe No. 2-Teflon 

Module No. VOST1 

Leak Check 

Pre Test 

Post Test 

13 in. Hq.-ok 

20in. Hq.-ok 

Type of Test M 18-Styrene Date 5/19/93 

Module Operated By 

Meter Y-Factor 

Test Personnel 

Brooks 

0.995 

Brooks, Szekeres 

Port 

A 

Time 

9:52 a.m. 

+ 5 

+ 10 

+ 15 

+ 20 

+ 25 

+ 30 

+ 35 

+ 40 

+ 45 

+ 50 

+ 55 

+ 60 

Rotameter 

Setting 

80 

80 

80 

80 

80 

85 

88 

90 

89 

88 

90 

88 

88 

Sample Volume 

(Liter) 

0.0 

2.5 

4.5 

6.9 

9.0 

11.0 

13.5 

17.1 

19.6 

21.9 

24.8 

27.5 

30.01 

Probe 

Temp. 

CO 

First 

Condenser 

Outlet 

Temp. 

(°C) 

• 

Press. 

(In. H20) 

Dry Gas Meter 

Inlet 

Temp. 

(°C) 

14 

14 

14 

14 

14 

14 

14 

14 

14 

15 

15 

16 

16 

Outlet 

Temp. 

CO 

Pump Vacuum, 

(tn. Hg) 

'•" " ; ^ 

1 

o 
COMMONWEALTH OF PENNSYLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUAUTY CONTROL 

SAMPUNG TRAVERSE FIELD DATA 

Company Creative Pultrusions. Inc. 

Sample location In Stack 4 Feet Upstream from Bend 

at center of Exhaust Duct 

Cartridge I.D. No. 

Charcoal 

Run 42: Tube B - Sample 

Tube A-Backup 

Comments: Tubes A and B Reversed 

Source 

Run# 

Pultrusion Lines 

Barometric Pressure (Pb) 29.32 in. Hq. 

Probe No. 2-Teflon 

Module No. VOST1 . 

Leak Check 

Pre Test 

Post Test 

20 in. Hq. - ok 

20 in. Hq. - ok 

Type of Test M18-Styrene 

Module Operated By 

Meter Y-Factor 

Test Personnel 

Brooks 

0.995 

Date 5/19/93 

Brooks. Szekeres 

') 

Port 

A 

Time 

11:11a.m. 

+ 5 

+ 10 

+ 15 

+ 20 

+ 25 

+ 30 

+ 35 

+ 40 

+ 45 

+ 50 

+ 55 

+ 60 

Rotameter 

Setting 

90 

90 

90 

90 

90 

90 

90 

88 

88 

88 

85 

85 

85 

Sample Volume 

(Liter) 

0.0 

2.6 

5.25 

7.8 

10.45 

13.1 

15.5 

18.4 

20.8 

23.45 

26.0 

28.5 

31.02 

Probe 

Temp. 

CO 

First 

Condenser 

Outlet 

Temp. 

CC) 

Press. 

(In. H20) 

Dry Gas Meter 

Inlet 

Temp. 

CC) 

16 

16 

16 

16 

16 

16 

16 

16 

16 

17 

17 

18 

18 

Outlet 

Temp. 

CC) 

Pump Vacuum, 

(In. Hg) 

1 ^ 
COMMONWEALTH OF PENNSYLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUAUTY CONTROL 

SAMPLING TRAVERSE FIELD DATA 

Company Creative Pultrusions, Inc. 

Sample location In Stack 4 Feet Upstream from Bend 

at center of Exhaust Duct 

Cartridge I.D. No. 

Charcoal 

Run #3 Tube A-Sample 

Tube B- Backup 

Source 

Run# 

Pultrusion Lines 

Barometric Pressure (Pb) 29.32 

Probe No. 2-Teflon 

Module No. VOST1 

Leak Check 

Pre Test 

Post Test 

19 in. Hq. -ok 

19 in.Hg.-ok 

Type of Test M18-Styrene 

Module Operated By 

Meter Y-Factor 

Test Personnel 

Brooks 

0.995 

Date 5/19/93 

Brooks. Szekeres 

O*, 

Port 

A 

Time 

12:28 p.m. 

+ 5 

+ 10 

+ 15 

+ 20 

+ 25 

+ 30 

+ 35 

+ 40 

+ 45 

+ 50 

+ 55 

+ 60 

Rotameter 

Setting 

85 

86 

88 

88 

88 

88 

88 

88 

88 

88 

88 

88 

88 

Sample Volume 

(Liter) 

0.2 

2.6 

5.2 

7.8 

10.4 

13.1 

15.3 

17.9 

20.5 

23.1 

25.6 

28.2 

30.68 

Probe 

Temp. 

CQ 

First 

Condenser 

Outlet 

Temp. 

CO 

Press. 

(In. H20) 

1.0 

1.0 

1.0 

1.0 

1.1 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

Dry Gas Meter 

Inlet 

Temp. 

CC) 

16 

17 

17 

16 

17 

17 

17 

17 

17 

17 

17 

17 

17 

Outlet 

Temp. 

CC) 

Pump Vacuum, 

(In. Hg) 

1 "' 
COMMONWEALTH OF PENNSYLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUAUTY CONTROL 

SAMPLING TRAVERSE FIELD DATA 

Company Creative Pultrusion'i, Inc. 

Sample location In Stack 4 Feet Upstream from Bend 

at center of Exhaust Duct 

Cartridge I.D. No. 

Charcoal 

Run #4 Tube A - Sample 

Tube B- Backup 

Source 

Run# 

Pultrusion Lines 

Barometric Pressure (Pb) 29.32 in. Hq. 

Probe No. 2-Teflon 

Module No. VOST1 

Leak Check 

Pre Test 19 in. Hq. -ok 

Post Test 19 in. Hq.-ok 

Type of Test M18-Stvrene 

Module Operated By 

Meter Y-Factor 

Test Personnel 

Brooks 

0.995 

Date 5/19/93 

Brooks. Szekeres 

:T 

Port 

A 

Time 

1:45 p.m. 

+ 5 

+ 10 

+ 15 

+ 20 

+ 25 

+ 30 

+ 35 

+ 40 

+ 45 

+ 50 

• 55 

+ 60 

Rotameter 

Setting 

90 

90 

90 

90 

90 

90 

90 

90 

90 

90 

90 

90 

90 

Sample Volume 

(Liter) 

• 

Probe 

Temp. 

CQ 

First 

Condenser 

Outlet 

Temp. 

(°C) 

Press. 

(In. H20) 

1.0 

1.0 

1.0 

1.0 

1.0 

1.1 

1.1 

1.1 

1.1 

1.1 

1.1 

1.1 

1.1 

Dry Gas Meter 

Inlet 

Temp. 

CC) 

16 

16 

16 

16 

16 

17 

17 

17 

17 

18 

17 

17 

17 

• 

Outlet 

Temp. 

CC) 

Pump Vacuum, 

(In. Hg) 

' 

EEE» 
P.M 

COMMONWEALTH OF PENNSYLVA.U.r f 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUALITY CONTROL 

M25A FIELD DATA 

Run No. 1 Test No. 00493A 

Company Creative Pultrusions Source Pultrusion Lines Date 5/19/93 

Sampling Location Center of Exhaust Duct - Port B Flue Configuration 48 in. I.D. 

No. of Ports & Arrangement 2 at 90° Data Recorded by R. Szekeres Module No. FIA#1 

Calibration Gas: 

101 PPM styrene in N? 

Zero Ai r 

TIME 

9:52 am 

+ 1 

+ 2 

+ 3 

+ 4 

+ 5 

+ 6 

+ 7 

+ 8 

+ 9 

+ 10 

• 11 

+ 12 

+ 13 

+ 14 

+ 15 

+ 16 

+ 17 

+ 18 

+ 19 

+ 20 

Concentration (PPM) as 

Styrene 

80 

81 

83 

84 

88 

85 

84 

82 

82 

87 

83 

79 

79 

79 

82 

77 

80 

^

7 8 

82 

80 

82 

TIME 

+ 21 

+ 22 

+ 23 

+ 24 

• 25 

• 26 

+ 27 

• 28 

+ 29 

+ 30 

• 31 

• 32 

+ 33 

+ 34 

+ 35 

• 36 

+ 37 

+ 38 

+ 39 

+ 40 

Concentration (PPM) as 

Styrene 

78 

83 

81 

84 

84 

88 

90 

82 

95 

92 

87 

91 

87 

86 

84 

90 

89 

87 

90 

86 

* 

TIME 

+ 41 

+ 42 

+ 43 

+ 44 

+ 45 

• 46 

+ 47 

+ 48 

+ 49 

+ 50 

+ 51 

+ 52 

+ 53 

+ 54 

+ 55 

+ 56 

+ 57 

+ 58 

+ 59 

+ 60 

* 

Avg. 

Concentration (PPM) as 

Styrene 

87 

94 

93 

96 

89 

93 

97 

89 

94 

95 

90 

93 

92 

91 

91 

96 

102 

97 

100 

96 

87.3 

Comments: Ambient Temp. = 69°F Calibration done at 4.00 LPM - Dilution Possible 

* Post test Cal Check - Zero = -1,101 PPM = 103 PPM 

\

r

h 
P.15 

r e 

COMMONWEALTH OF PENNSYLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUALITY CONTROL 

M25A FIELD DATA 

Run No. 2 Test No. 00493B 

Company Creative Pultrusions Source Pultrusion Lines Date 5/19/93 

Sampling Location Center of Exhaust Duct - Port B Flue Configuration 48in. I.D. 

4 

No. of Ports & Arrangement 2 at 90° Data Recorded by R. Szekeres Module No. FIA#1 

Calibration Gas: 

101 PPM styrene in N? 

Zero Air 

TIME 

11:11am 

+ 1 

+ 2 

+ 3 

+ 4 

+ 5 

• 6 

• 7 

• 8 

• 9 

+ 10 

+ 11 

• 12 

+ 13 

+ 14 

+ 15 

+ 16 

+ 17 

+ 18 

+ 19 

+ 20 

Concentration (PPM) as 

Styrene 

^ 

4 

100 

100 

99 

94 

98 

100 

97 

102 

100 

98 

101 

106 

99 

101 

97 

100 

98 

- 106 

104 

106 

101 

TIME 

+ 21 

+ 22 

+ 23 

+ 24 

+ 25 

+ 26 

+ 27 

• 28 

+ 29 

• 30 

+ 31 

+ 32 

+ 33 

+ 34 

+ 35 

+ 36 

+ 37 

+ 38 

+ 39 

+ 40 

Concentration (PPM) as 

Styrene 

104 

105 

107 

110 

104 

104 

106 

100 

102 

103 

102 

106 

108 

108 

108 

104 

107 

104 

109 

104 

TIME 

+ 41 

+ 42 

+ 43 

+ 44 

• 45 

• 46 

+ 47 

• 48 

• 49 

• 50 

+ 51 

+ 52 

+ 53 

+ 54 

+ 55 

+ 56 

+ 57 

+ 58 

+ 59 

+ 60 

• 

Avg. 

Concentration (PPM) as 

Styrene 

-

105 

108 

103 

103 

103 

105 

110 

108 

113 

107 

107 

108 

107 

111 

112 

111 

104 

107 

109 

113 

104.4 

Comments: • Ambient Temp. = 67°F. Calibration Done at 4.00 LPM-Source of dilution found at completion of this run. 

* Post Test Cal Check - Zero = -1,101 PPM = 101 PPM 

It 
P.16 

(J ( 

COMMONWEALTH OF PENNSYLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUALITY CONTROL 

M25A FIELD DATA 

Run No. 3 Test No. 00493C 

Company Creative Pultrusions Source Pultrusion Lines Date 5/19/93 

Sampling Location Center of Exhaust Duct - Port B Flue Configuration 48 In. ID 

No. of Ports & Arrangement 2 at 90" Data Recorded by R. Szekeres Module No. FIA# 1 

Calibration Gas: 

101 PPM styrene in N-j 

Zero Air 

TIME 

12:28 pm 

• 1 

+ 2 

+ 3 

+ 4 

+ 5 

• 6 

• 7 

+ 8 

• 9 

+ 10 

• 11 

• 12 

+ 13 

+ 14 

+ 15 

+ 16 

+ 17 

+ 18 

+ 19 

+ 20 

Concentration (PPM) as 

Styrene 

57 

56 

58 

60 

60 

62 

63 

59 

62 

63 

59 

58 

59 

59 

58 

62 

60 

- 61 

62 

65 

64 

. 

TIME 

+ 21 

+ 22 

+ 23 

+ 24 

+ 25 

+ 26 

• 27 

• 28 

+ 29 

• 30 

+ 31 

• 32 

+ 33 

+ 34 

• 35 

+ 36 

+ 37 

+ 38 

+ 39 

+ 40 

Concentration (PPM) as 

Styrene 

64 

62 

63 

62 

63 

61 

60 

63 

64 

66 

65 

62 

63 

59 

62 

62 

58 

61 

59 

60 

TIME 

+ 41 

+ 42 

+ 43 

+ 44 

• 45 

• 46 

• 47 

• 48 

• 49 

+ 50 

• 51 

+ 52 

+ 53 

+ 54 

+ 55 

+ 56 

+ 57 

+ 58 

+ 59 

+ 60 

* 

Avg. 

Concentration (PPM) as 

Styrene 

• 

60 

63 

64 

63 

62 

63 

62 

62 

61 

62 

63 

62 

60 

65 

66 

63 

64 

63 

66 

64 

61.7 

Comments: Ambient Temp. 61°F. Calibration at 4.00 LPM. 

* Post Test Cal Check - Zero - 0, 101 PPM =101 PPM. 50 PPM = 49 PPM 

\ 5> 
P.17 

(r f~ 

COMMONWEALTH OF PENNSYLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUALITY CONTROL 

M25A FIELD DATA 

Run No. 4_ Test No. 00493D 

Company Creative Pultrusions Source Pultrusion Lines Date 5/19/93 

Sampling Location Center of Exhaust Duct - Port B Flue Configuration 48 in. I.D. 

No. of Ports & Arrangement 2 at 90° Data Recorded by R. Szekeres Module No. FIA#1 

Calibration Gas: 

101 PPM styrene in N? 

Zero Air 

TIME 

1:43 pm 

+ 1 

+ 2 

+ 3 

+ 4 

• 5 

+ 6 

+ 7 

+ 8 

+ 9 

• 10 

• 11 

+ 12 

+ 13 

+ 14 

+ 15 

+ 16 

+ 17 

+ 18 

+ 19 

+ 20 

Concentration (PPM) as 

Styrene 

65 

63 

65 

65 

65 

64 

63 

64 

61 

60 

66 

65 

62 

63 

61 

63 

62 

- 6 3 

63 

63 

62 

TIME 

+ 21 

+ 22 

+ 23 

+ 24 

+ 25 

+ 26 

• 27 

• 28 

+ 29 

+ 30 

+ 31 

• 32 

+ 33 

+ 34 

+ 35 

+ 36 

+ 37 

+ 38 

+ 39 

+ 40 

Concentration (PPM) as 

Styrene 

65 

68 

62 

62 

63 

62 

63 

63 

64 

64 

63 

65 

63 

63 

62 

62 

65 

63 

60 

65 

TIME 

+ 41 

+ 42 

+ 43 

+ 44 

+ 45 

+ 46 

• 47 

• 48 

• 49 

+ 50 

+ 51 

+ 523 

+ 53 

+ 54 

+ 55 

+ 56 

+ 57 

+ 58 

+ 59 

+ 60 

• 

Avg. 

Concentration (PPM) as 

Styrene 

65 

65 

63 

65 

64 

64 

65 

65 

67 

65 

64 

66 

66 

68 

65 

66 

66 

67 

69 

61 

64.0 

Comments: Calibration Done at 4.00 LPM 

* Post Test Cal Check - Zero = 0,101 PPM = 102 PPM, 50 PPM = 48 PPM 

it 
P.18 

r e 

COMMONWEALTH OF PENNSYLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUALITY CONTROL 

CREATIVE PULTRUSIONS 

ALUM BANK. BEDFORD COUNTY 

PROCESS INFORMATION 

Test Nos. 00393A and 00493A Test Date: 5/19/93 

Line No. 

1. 

2. 

3. 

4. 

5. 

6. 

7. 

8. 

9. 

10. 

11. 

12. 

13. 

14. 

15. 

16. 

17. 

TOTAL 

Part Name 

H x 100 Rd. Tube 

2Hx.080Rd.Tube 

Ladder Rail 

Type I Front Rail 

Ladder Channel 

H Side Post 

3x1x3/16 Channel 

2x 1/4 Angle 

Panel Filter 

1 3/4x1/8 q Tube 

.2* x 24 Panel 

Brady Sign Cover 

2 i x 8 Channel 

Part 

Length 

(ft) 

447 

430 

480 

568 

496 

105 

250 

125 

72 

192 

53 

235 

236 

3.689 

Resin 

Usage 

(lbs) 

326 

338 

328 

403 

399 

61 

146 

82 

49 

131 

36 

Styrene * 

in Resin 

(lbs) 

117 

122 

118 

145 

120 

21 

48 

27 

16 

43 

12 

Styrene * 

in Additive 

(lbs) 

13 

10 

18 

22 

19 

8 

10 

7 

3 

9 

3 

167 

164 

2,630 

58 

58 

905 

8 

10 

140 

Total styrene equals styrene in resin plus styrene in additive. 

n 
P.19 

c c

: 

COMMONWEALTH OF PENNSLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUALITY CONTROL 

CREATIVE PULTRUSIONS 

ALUM BANK, BEDFORD COUNTY 

PROCESS INFORMATION 

TEST NOS. 003938 AND 00493B TEST DATE: 5/19/93 

.ine No. 

1. 

2. 

3. 

4. 

5. 

6. 

7. 

8. 

9. 

10. 

11. 

12. 

13. 

14. 

15. 

16. 

17. 

Total 

Part Name 

H x 100 Rd. Tube 

Ux.080 Rd. Tube 

Ladder Rail 

Type 1 Front Rail 

Ladder Channel 

H Side Post 

3x1x3/16 Channel 

2x1/4 Angle 

Panel Filter 

1 3/4 x 1/8 q. Tube 

2^x24 Panel 

Brady Sign Cover 

•$• x 8 Channel 

•irt 

th(ft) 

453 

448 

480 

588 

465 

105 

250 

200 

72 

173 

53 

Resin 

Usage 

(lbs) 

331 

352 

328 

417 

318 

61 

146 

131 

49 

118 

36 

Styrene* 

in Resin 

(lbs) 

119 

127 

118 

150. 

112 

21 

48 

35 

16 

39 

12 

Styrene* 

in Additive 

(lbs) 

13 

11 

18 

23 

18 

8 

10 

10 

3 

8 

3 

276 

192 

196 

133 

69 

47 

9 

8 

3,755 2,616 913 142 

'Total styrene equals styrene in resin plus styrene in additive. 

J-
P.20 

COMMONWEALTH OF PENNSYLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUALITY CONTROL 

CREATIVE PULTRUSIONS 

ALUM BANK, BEDFORD COUNTY 

PROCESS INFORMATION 

Test Nos. 00393C and 00493C Test Date: 5/19/93 

Line No. 

1. 

2. 

3. 

4. 

5. 

6. 

7. 

8. 

9. 

10. 

11. 

12 

13. 

14. 

15. 

16. 

17. 

TOTAL 

Part Name 

H i 100 Rd. Tube 

H x . 080 Rd. Tube 

Ladder Rail 

Type I Front Rail 

Ladder Channel 

H Side Post 

3x1x3/16 Channel 

2x 1/4 Angle 

Panel Filter 

1 3/4 x 1/8 q. Tube 

2± x 24 Panel 

Brady Sign Cover 

2} x 8 Channel 

Part 

Length 

(ft) 

453 

448 

408 

681 

505 

105 

181 

200 

72 

192 

53 

276 

222 

3,796 

Resin 

Usage 

(lbs) 

331 

352 

279 

483 

345 

61 

105 

131 

49 

131 

36 

Styrene * 

in Resin 

(lbs) 

119 

127 

100 

174 

122 

21 

35 

35 

16 

43 

12 

Styrene * 

in Additive 

(lbs) 

13 

11 

16 

27 

19 

8 

7 

10 

3 

9 

3 

196 

154 

2,653 

69 

55 

928 

9 

9 

144 

* Total styrene equals styrene in resin plus styrene in additive. 

•/>• 

H 
P.21 

COMMONWEALTH OF PENNSLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUALITY CONTROL 

CREATIVE PULTRUSIONS 

ALUM BANK, BEDFORD COUNTY 

PROCESS INFORMATION 

TEST NOS. 00393D AND 00493D TEST DATE: 5/19/93 

.ine No. 

1. 

2. 

3. 

4. 

5. 

6. 

7. 

8. 

9. 

10. 

11. 

12. 

13. 

14. 

15. 

16. 

17. 

Total 

Part Name 

HxlOORd.Tube 

U x.080 Rd. Tube 

Ladder Rail 

Type 1 Front Rail 

Ladder Channel 

H Side Post 

3x1x3/16 Channel 

2x1/4 Angle 

Panel Filter 

1 3/4 x 1/8 q. Tube 

24- x 24 Panel 

Brady Sign Cover 

ixB Channel 

irt 

th(ft) 

453 

448 

432 

720 

489 

105 

282 

227 

72 

192 

64 

Resin 

Usage 

(lbs) 

331 

352 

295 

510 

334 

61 

164 

149 

49 

131 

43 

Styrene* 

in Resin 

(lbs) 

119 

127 

106 

184 

119 

21 

S4 

49 

16 

43 

14 

Styrene* 

in Additive 

(lbs) 

13 

11 

17 

28 

19 

8 

12 

12 

3 

9 

4 

276 

206 

196 

143 

69 

51 

9 

9 

3,966 2,758 972 154 

•Total styrene equals styrene in resin plus styrene in additive. 

• / • % 0 
P.22 

o 

COMMONWEALTH OF PENNSYLVANIA 

DEPARTMENT OF ENVIRONMENTAL RESOURCES 

BUREAU OF AIR QUALITY CONTROL 

CREATIVE PULTRUSIONS, INC. 

ALUM BANK, BEDFORD COUNTY 

DISCUSSION 

Volatile organic compound testing was conducted in the outlet stack servicing the hood pickup 

system for the pultrusion lines at Creative Pultrusion, Inc.'s facility at the above location. EPA 

Method 25Aand EPA Method 18 were conducted simultaneously at the test location to determine 

the styrene concentration. 

Four one hour test runs were conducted with each method. A 12 point velocity traverse was 

conducted before and after the series of test runs and the results were averaged to determine the 

volumetric flow rate. 

Source test Nos. 0393A, B, C and D were conducted at a single point in the center area of the stack 

utilizing EPA Method 18 with charcoal tubes. The tubes were then desorbed with carbon disulfide 

and analyzed for styrene with a GOmass spec. Each sample consisted of two, 2 section tubes in series 

with each tube containing an 800 milligram sample section and a 200 milligram backup section. 

During test No. 0393A. the tubes were sampled backwards with the sample collected in the backup 

section. While this should not have affected the results, it is possible that the backup tube was 

analyzed in place of the sample tube, resulting in no styrene detected. In test No. 0393B, the sample 

tubes were correctly oriented while sampling but the "A" and "B" tubes were reversed. Again, it 

appears possible that the wrong tube was analyzed and the results indicated no styrene detected. 

The results of test Nos. 0393C and D were 160 ppm and 90 ppm styrene, respectively. The sample 

tubes and the tubes collected for calibration purposes were stored for approximately one month 

prior to analysis. While the maximum storage times are not specified in the method, analysis is 

encouraged as soon as possible, especially for unstable compounds such as styrene. For this reason 

results ofthe Method 18 sampling are considered questionable and should only be used as an 

indicator of the general range of the styrene concentrations. 

Source test Nos. 0493A, B, C and D were conducted at a single sampling point in the center area of the 

stack utilizing EPA Method 25A. A flame ionization detector calibrated with styrene in nitrogen was 

used for testing. Test Nos. 0493A and B are biased high because a dilution fitting on the calibration 

line was open during sampling. The fitting was closed and the FID was recalibrated for subsequent 

runs. The results of Run No. 0493C and D were 62 ppm and 64 ppm styrene, respectively. Test 

No. 0493C and D were conducted in accordance with EPA and DER procedures and are representative 

ofthe styrene concentrations in the test stack at the operating conditions present during testing. 

z\ 
P.23 

COMMONWEALTH OF PENNSYLVANIA 

Department of Environmental Resources 

October 5, 1994 

SUBJECT: Source Test Review 

TO: Data File 

Creative Pultrusions, Inc. 

West St. Clair Township, Bedford County 

o *0,/\S« JlV^ot- l^,JFROM: Timothy R. Brooks 

Air Quality Program Specialist 

Division of Source Testing and Monitoring 

Bureau of Air Quality Control 

THROUGH: L. Blaine DeHaven 

Chief 

Division of Source Testing and Monitoring 

Bureau of Air Quality Control 

Creative Pultrusions, Inc. operates 19 pultrusion lines utilizing fiberglass reinforcement 

in a heat set resin matrix for the manufacture of various pulled/extruded products at 

their Bedford County location. 

The process consists of continuously feeding reinforcement roving and/or matting into a 

covered bath where it is impregnated with resin. This saturated material is then 

preformed into the desired shape and introduced into a heated dye where the resin is 

heat-cured at approximately 275° F. A puller near the end of the line draws feed stock 

along until proper length is achieved and the product is manually cut to length. 

Emissions from this process are contained within the building which serves as a total 

enclosure. Collection hoods located adjacent to each impregnation bath duct VOC 

emissions from the process to a collection duct which discharges to a common stack. 

Clean Air Engineering conducted EPA Method 18 tests for styrene utilizing charcoal 

tubes, and EPA Method 25A, total hydrocarbon sampling, utilizing a flame ionization 

detector. These tests were conducted in accordance with pre-approved procedures and 

are acceptable to the Department. 

IX 
Pultrusions, Inc. 

t. Clair Township, Bedford County 

The following information was extracted from the stack test report: 

Date: May 19, 1994 

cc: File No.05-399-003 

<4BBHflnlAHB9lK Southcentral Regional Office 

A&C 

EPA/RSL 

Reading File - Stack Test 

TRB:dlr 

October 5, 1994 

Run No. 

Volumetric Flow Rate (dscfm) 

Styrene Usage (lbs/hr) 

M18 - Styrene 

Concentration (PPM Styrene) 

Emission Rate (lbs/hr Styrene) 

M25A - Total VOC 

Concentration (PPM Styrene) 

Emission Rate (lbs/hr Styrene) 

Styrene Release (%) 

1 

21,360 

805 

52 

18.0 

42.1 

14.6 

1.81 

2 

20,790 

660 

. 41 

13.9 

43.0 

14.5 

2.20 

3 

20,690 

839 

37 

12.3 

42.9 

14.4 

1.72 

> ^ 

» y 

•c —\ 

^3 

O 

O 

> 

CD 

CO 

%b 
P.25 

Environmental Resources 

July 27, 1994 

SUBJECT: Source Test Review 

Creative Pultrusions, Inc. 

Pleasantville Industrial Park 

West St. Clair Township, Bedford County 

File: 05-399-003A 

TO: L. Blaine DeHaven, Chief 

Division of Source Testing and Monitoring 

FROM: Richard D. Roller 

Air Pollution Control Engineer 

Southcentral Regional Office 

Please review the attached source test conducted by Clean Air 

Engineering on the fiberglass pultrusion operation exhaust 

stack at the above location. The Manufacturing facility and 

its exhaust system were designed to act as a total enclosure. 

Therefore, all liberated styrene should be vented through the 

exhaust stack. Your files should contain a previously 

forwarded process description. 

The pretest protocol was reviewed and accepted by Tin Brooks. 

I was present during such of the testing program. A copy of 

ny inspection report is attached. 

The purpose of the testing was to verify the styrene emission 

factor (1.9 lb styrene liberated per 100 lb styrene input 

with the remainder being tied up in a chemical reaction) 

presently being used by the Department in estimating the 

facility's emissions. This emission factor is based on the 

results of Departmental testing conducted in May 1993. 

The facility is subject to a VOC yearly emission limit of 

50 tons and an ambient styrene odor threshold of 0.2021 mg/m3 

(hourly basis). The odor threshold limit has been addressed 

in a separate modeling report which will be reviewed by Bob 

Simonson for accuracy. 

14 
P.26 

Creative Pultrusions 

Source Test Review 

-2- July 27, 1994 

File: 05-399-003A 

The VOC emissions at this facility are a combination of 

acetate and styrene. All acetate emissions arise from the 

use of cleanup solvent and can thus be calculated through 

material balance. Although the company attempted to quantify 

the amount of cleanup solvents used during the testing 

program, I prefer that we disregard that portion of the 

review and concentrate on the results of the Method 18 and 

25A testing. It was assumed for purposes of the Method 25A 

testing that all hydrocarbon emissions were styrene. Comparing 

the results of the Method 18 and 25A testing would seem to 

confirm this assumption. 

I would appreciate a copy of your source test review. Should 

you have any questions or comments, please contact me 

at 657-4587. 

cc: Southcentral Region 05-399-003A / 

i 

%5 

t^>i^^a,'>*\gLji«*?4i(*u*ityiitAiii jiyurr-jry-ifiFyj,^ VA 

••.*>.« *rfr*;r tf'-j 
' JUN-20-1994 13:17 FROM CLEAN AIR ENGINEERING 

*4U t ( »-*-» 

!^:i,4:

.r.'r.ii^*:-.22^ 

TO 

• •,; | .:.^ . *y_i;.'*-. t ^..^^.v . 

REPORTS P.02 

TEST 1 

Line No. Part Name Part Length Resin Usage Styrene in Styrene iti AMttve 

(fi.) (lbs.) Resin (lbs.) (U>*) 

1 LaoUwRail 690 467 165 26 

2 11/4 Rd. Tube 680 49? 177 20 

3 lx.080Rd.Tobe 560 410 145 - 17 

4 LaddttRail 492 333 118 20 

5 

6 3 x 1 x 3/16 Channel Setup 

7 l-Beam 24 16 6 1 

8 

9 2TralIfflobile$idePost 129 74 26 9 

10 

11 ll/8xl5Todco 80 SS 20 1 

12 lxl/ 8 Angle 26 17 6 1 

13 24x11/4 Panel 52 35 12 3 

14 

15 2x6 Rectangular Tube 39 26 9 2 

16 15/8 Stmt 60 ' 39 14 2 

17 Beam (Tie Tac Toe) 28 11 4 1 

*»o' 

I.-. 

v. 

TOTAL 2860 1984 702 103 

t^ 
P.28 

, JUN-20-1994 13:18 FROM CLEAN AIR ENGINEERING 

JUN £!0 "3H wi-ijr-n -c 

TO REPORTS P.03 

TEST 2 

Line No. Part Name Part Length Resin Usage Styrene in Styrene in Addit 

(ft.) ' (lbs.) Resin (lbs.) (lbs 

1 Ladder Rail 

2 11/4 Rd. Tube 

3 Ix.OSORd.'nibe 

4 Ladder Rail 

5 

6 3x1x3/16 Chanae! 

7 I-Beam 

8 

9 2 Teailmobile Side Post 

10 

tl H/SxlSTodco 

12 lxl/8 Anek 

13 24x11/4 Panel 

14 ~ 

15 2x6 Rectangular Tube 

16 15/8 Strut 

17 Beam (Tic Tec Toe) 

60 

676 

640 

540 

Setup 

Pigment Change 

40 

495 

469 

366 

132 

73 

48 

76 

53 

32 

14 

175 

166 

130 

27 

19 

11 

2 

20 

19 

20 

30 

120 

28 

20 

77 

11 

7 

27 

4 

I 

4 

1 

TOTAL 2347 1639 580 80 

^l 
P.29 

JUN-20-1994 13:13 FROM LLtHN HIK tNbiHtcrwi-iu 

JIXI aa '»» wi*ijrn c 

i u rci-fl.n'. i . 

TEST 3 

Line No. Pari Name Part Length Resin Usage 

(ft) Obs.) 

1 Udder Rafl 532 360 

2 11/4 RA Tube 692 507 

3 lx.080Rd.Tobe 645 473 

4 Ladder RAH 504 341 

5 

6 3x 1x3/16 Omuttl 105 60 

7 1-Beam 12 8 

8 

9 2Traflxn6bileSidePost 139 80 

10 -

11 ll/8xl5Todoo 73 S3 

12 I x 1/8 Anglo 

13 24x11/4 Panel 44 30 

14 

15 2x 6 Rectangular TUbe 59 39 

16 15/8 Strut 160 102 

17 Beam (Tio Tac Toe) 28 11 

TOTAL 2993 2064 

Styrene in Styrene in Additive 

Resin (lbs.) (lbs.) 

128 

180. 

167 

121 

21 

3 

20 

21 

19 

20 

4 

1 

29 

19 

10 

14 

36 

4 

732 

10 

2 

5 

I 

107 

1%