P.1 

OAR Box 1500 

Prepped by Ollie Stewart 

Document Number: 

2) ll-C-28 

Docket Number: 

A-94-52 

Printed 8/5/2008 1:45:55 PM Sheet 2 oj343 
P.2 

A-94-52 

^°ST< 

9 

O SE UNITED STATES ENVIRONMENTAL PROTECTION AGENCY 

RESEARCH TRIANGLE PARK. NC 27711 

••t PRO!* 

m.. 

m&sm 

**&*. EPA AIR DOCKET 

OFFICE OF 

AIR QUALITY PLANNING 

ANO STANDARDS 

February 29, 1996 

Dear Presumptive MACT Team and/or EPA Work Group Member: 

This is to confirm the teleconference for the reinforced 

plastic composites project to be held Wednesday, March 20, 1996, 

from 1pm to 3:30pm Eastern Standard Time, and to provide 

materials for the meeting. The meeting will be held at EPA in 

Room 638 of the North Carolina Mutual Building in Durham, 

North Carolina. The call-in number is (919) 541-1590. 

At this meeting we will be discussing the future of the 

P-MACT process, potential emission limits, work practice 

standards and issues. Enclosed are a briefing package and 

spreadsheets. The spreadsheets provide the details of our 

preliminary emission limit calculations. They will not be 

discussed in detail at the meeting, but may be of interest to 

those of you who wish to know the detailed data from which the 

emission limits were derived. Please note that some values on 

these spreadsheets will change as we continue to check our data 

quality. We would also welcome any efforts you make towards this 

quality assurance. 

Please have the briefing package available at the March 20th 

conference call. 

If you have any questions on the enclosed material please 

call me at (919) 541-2383. 

-/L£ 

Madeleine Strum 

Enclosures 
P.3 

Addressees 

} • vsri 

Mohan Balagopalan, South Coast Air (pual^ty 

Management District 

Bob Burmark, Washington Department ©#~Beoi< 

Jane Caldwell, OAQPS (MD-15) '„„! 

Leonardo Ceron, EPA Region IV 

Linda Chappell, OAQPS (MD-15) 

Bob Fegley, ORD 

Leslye Fraser, OGC 

Chuck French, OAQPS (MD-15) 

Linda Herring, OAQPS (MD-13) 

Norm Kaplan, ORD (MD-04) 

Karen Levy, OPAR 

Maria Malave, OECA 

Haile Mariam, OSWER 

Craig Matthiessen, OSWER 

Steve McNally, Composite Fabricators Association 

Christine McPhee, Ohio EPA 

Arnold Medbery, OSDBU 

Richard Nielson, Clark County Health District 

Carlos Nunez, ORD (MD-61) 

Nancy Pate, OAQPS (MD-12) 

Geddes Ramsey, ORD (MD-61) 

Solomon Ricks, OAQPS (MD-19) 

Ron Ryan, OAQPS (MD-14) 

Alex Santos, California Air Resources Board 

John Schweitzer, Society of Plastics 

Industry/Composities Institute 

Jordan Spooner, OPPT 

^ 
PROJECT BRIEFING 

REINFORCED PLASTIC COMPOSITES PRODUCTION 

MACT STANDARD DEVELOPMENT 

BRIEFING FOR: 

W EPA P-MACT TEAM AND EPA WORK GROUP 

Project Lead: Madeleine Strum (ESD/CCPG) 

March 20, 1996 
> 

PURPOSE 

Discuss experience with P-MACT team approach 

Present MACT floors and alternatives above the floor 

Discuss applicability of standard 

Present suggested regulatory approach and new project schedule 

Tl 

Ol 
P-MACT TEAM APPROACH 

Formed team of EPA, State/local, industry, and environmental representatives 

Lost environmental representative 

Held four teleconferences to present data and discuss issues 

\i\ 

Large and diverse industry poses problem for P-MACT 

Requests for input have been largely unsuccessful 

Lack time/funding to keep P-MACT going and get standard out in 

reasonable timeframe 

Suggestion: phase out P-MACT process and adopt the conventional 

standards development approach 

p 
G\ 

MACT ANALYSIS 

Industry Subcategorization 

Approaches for Numerical Emission Limits 

Subcategory-Specific Analyses - Numerical Emission Limits 

Work Practices 

4 

Tl 
INDUSTRY SUBCATEGORIZATION 

Separate MACT floor calculations for: 

~o 

Open Molding (hand or spray layup) 

Gel Coating 

Continuous Lamination/Continuous Casting 

Filament Winding 

Compression Molding 

Injection Molding 

Resin Transfer Molding 

Pultrusion 

Compounding - BMC 

Compounding - SMC 

Polymer Casting 

Centrifugal Casting 

Notes: Data base includes polyester and vinyl ester (styrene-containing) resins only. 

Use of "prepreg" is not part of source category. 

Tl 

00 
APPROACHES CONSIDERED FOR DETERMINING 

BEST PERFORMING FACILITIES 

1. Averaging with Resin Cure Factor 

a measure of weight loss during cure 

easy to measure in static lab test 

compatible with South Coast rule 

data for resins in use lacking 

lack of correlation with styrene content or emissions 

2. Resin HAP (Styrene) Content 

data are readily available 

• also compatible with South Coast rule 

• lower styrene content not the only means of emission reduction 

Tl 
-p 

APPROACHES CONSIDERED (continued) 

3. Percent Reduction (Add-ons) 

4. Facility "Control Status" (CS) 

units of lb HAP (monomer) per gallon of resin matrix (RM) 

• lower CS means the facility is better controlled 

• accounts for quantifiable reduction measures in use 

(low resin styrene content, filler use, suppressants, non-spray 

application, add-on controls) 

• selected as the primary ranking variable 

7 
o 

CALCULATION OF FACILITY CONTROL STATUS (CS) 

Formula: 

CS = [ Resin (lb/yr)] [HAP Wt. %] x Application x VSR x Control 

(Resin + Filler) Volume Factor Factor Factor 

Example: Resin = 5.0 MM lb/yr 

Filler = 7.0 MM lb/yr 

Styrene Wt. % = 38.0 

(no other HAP) 

Application factor = 0.55 (non-spray appl.) 

VSR factor = 0.60 (vapor suppressant) 

Control factor = 1.00 (no control device) 

Calculation: 

CS = (5xl06) x (0.38) x 0.55 x 0.60 x 1.00 = 0.69 lb HAP/gal 

(543,500 + 364,600) gal resin matrix 

8 
APPROACHES CONSIDERED (concluded) 

issues: - facilities using highly filled resin mixtures have a 

built-in advantage over unfilled applications 

- other measures are in use but not included (shorter gel 

times, resin thickness, air conditioned facility, etc.) 

- ORD developing a comprehensive model to predict open 

molding emissions; won't be available for developing 

proposal 

- approach credits same % reduction for all vapor-suppressed 

resins under all applications; industry may request 

tailored credit for each scenario (different suppressants, 

concentrations used, etc.) 
P.13 

1 

SUBCATEGORY-SPECIFIC ANALYSES 

Note: The following analyses do not include the impact 

of work practice standards; see page 37. 

10 

/2-
P.14 

OPEN MOLDING 

(21/172)* 

MACT Floors: 

Existing: median CS value (= 1.4 lb HAP/gal RM) 

New: best % reduction (= 95%) 

or 

best CS value (= 0.2 lb HAP/gal RM) 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95% reduction or CS value of less than or 

equal to 0.2 lb HAP/gal RM. 

New: None. 

indicates that "floor" facilities comprise 21 out ofthe 

total of 172 major source open molders. 

11 
EXAMPLE FOR CALCULATING MACT FLOOR -

OPEN MOLDING FACILITIES 

£* 

Rank 

i 

2 

3 

4 

5 

• 

7 

• 

9 

10 

11 

12 

11 

14 

IS 

16 

17 

11 

I t 

20 

21 

22 

23 

24 

25 

26 

27 

28 

29 

30 

31 

32 

33 

34 

35 

36 

37 

38 

39 

40 

8pnyup and Hand layup combined IM 

BaUtera 

A.R.E,toc(Ma»aaion) 

1)3. Ftborglass Products Inc 

ReeoUte 

Tompkins • Lasco Bathwara (Elltabamtown) 

Contemporary Product*. Inc. 

TompMna - Lasco Balhwara (Lancaatar) 

AiCER Plastics Company, kxMPtymoum, Pldco Or) 

8.W.C Industrias. Inc (SwirfrWay Div.) 

AKER Plastics Company. mctPtymoutti. N Oak Rd) 

TompMna - Laaco Bathwara (South Boston) 

Cadar Manufacturing, lnc(Bi«4nan Guts) 

l^iciten'e Plastics, Ir4c 

Branm Glaa, li4C 

TompMna • Laaco Bathwara (Moapa) 

TompUna • Laaco Bathwara (Cordate) 

Totnpklna • Lasco Bathwara (Anahaim) 

Tompfcina • Lasco Bathwara (HU M Rivals) 

Balhasftlnc 

Unhntsal-Rundte Corp. (Ottumwa) 

Caramlc Cooling Towar Company 

Tompkins • Lasco Bathwara (Yetm) (aka Hytsc Inc.) 

Warminster Fiberglass Company (Jackfonvflto) 

Wsrmirutet FberoJass Company (Southampton) 

CBIP4ant«7 

COR Systama Corporation (Corcoran) 

COR Systams CorporaUan (PaWka) 

Century fcUnufacturing Company 

Custom Ffcregtass (Manufacturing Co. 

National Ft w Glass Products. Inc 

American Reinforced Plastics 

Prestigious Acoassories, Inc. 

Grsat Dana Tralara Indiana. Inc (FRP Plant) 

Aema Ffeerglasa. Ire. 

Diamond Cuach Cofporauon 

Sunset Plastics Inc. 

Bristol Fibortte Industrias 

Hess County MutMes of VW. Inc. 

Fowler lytanufacturina, Inc 

Stylo Crast Products 

GW.FDarBtass.lnc 

Process Dose 

Cfida 

13*1 7 

8*1 3 

16 

16 • 

13 

12 

Resin 

l__ 

6866J 

375.0 

•0.0 

21243 

190.0 

2279.3 

164.7 

300.0 

2310.1 

2770.2 

367.0 

277.0 

11690) 

6266.6 

1976.6 

31363 

2816.4 

944.6 

2600.0 

110.0 

27633 

121.0 

139.3 

1017.0 

152.0 

125.0 

74.5 

553.0 

640.0 

288.0 

432.0 

375.0 

185.0 

138.0 

254.0 

247.0 

494.0 

439.0 

84.0 

1850.0 

% Styrene 

AsSuooSad 

4 2 0 

46.0 

24.1 

47.7 

38.0 

47.7 

36.0 

36.0 

36.0 

48.1 

36.0 

43.0 

44.0 

47.0 

47.6 

47.7 

47.7 

41.2 

46.6 

32.0 

473 

40.0 

40.0 

435 

34.0 

34.0 

48.0 

44.9 

480 

40.7 

35.0 

39.0 

43.0 

40.0 

43.0 

382 

35.0 

50.5 

24.0 

45.0 

Filar 

deyj 

M 

ao 

11.4 

33043 

ao 

3564.7 

160.6 

3003 

2378.7 

4078.1 

3593 

ao 

1658.0 

6644.6 

1002.2 

464M.6 

43664 

986.9 

3276.0 

ao 

42163 

ao 

ao 

603.0 

0.0 

0.0 

60.0 

266.0 

670.0 

121.0 

ao 

0.0 

75.0 

ao 

215.0 

0.0 

494.0 

161.0 

0.0 

395.0 

bstvrene/ 

OtUBU 

3.66 

4J2 

2.03 

2.61 

339 

2 31 

2.17 

2.17 

2J1 

239 

2.38 

4.13 

2.46 

2.46 

2.61 

2.51 

2.81 

2.52 

162 

2.64 

234 

3.67 

3.67 

3.11 

3.12 

3.12 

3.18 

3.35 

3.09 

3.11 

3.21 

3.56 

3.31 

3.67 

2.61 

3.51 

2 17 

3.98 

2 J 0 

3.75 

Application 

Easaac 

130 

1.00 

036 

1.00 

0.55 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.60 

1.00 

1.00 

130 

1.00 

1.00 

130 

1.00 

036 

1.00 

0.78 

0.78 

0.55 

0.55 

0.55 

0.55 

0 91 

1.00 

1.03 

1.00 

1.00 

1.00 

0.55 

1.00 

1.00 

1.00 

0.55 

1.00 

1.00 

VSR 

Eflflor, 

1.00 

0.60 

1.00 

O.IO 

0.60 

0.60 

0.60 

0.60 

0.60 

0.72 

0.60 

0.60 

0.60 

0.60 

0.60 

0.60 

0.60 

0.60 

0.60 

1.00 

0.64 

0.60 

0.60 

1.00 

1.00 

1.00 

1.00 

0.60 

0.60 

0.60 

0.60 

1.00 

0.60 

1.00 

0.72 

0.60 

1.00 

1.00 

1.00 

0.60 

Control 

EK&r. 

aos 

aio 

1.00 

a76 

1.00 

a n 

1.00 

1.00 

1.00 

0.78 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.55 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

Control 

Status 

(bHAEtaalfiiM) 

0.19 

0.46 

1.12 

1.14 

1.15 

1.17 

1.30 

1.30 

1.33 

1.39 

^•'£:iMj; •••••••• 

1.47 

1.48 

1.46 

1.60 

1.61 

1.51 

1.51 

1.67 

1.62 

1.62 

1.71 

1.71 

1.71 

1.72 

1.72 

1.75 

1.63 

1.65 

1.87 

1.93 

1.97 

1.98 

2.02 

2.02 

2.10 

2.17 

2.19 

Z20 

2.25 

Currant Emis. 

Oral 

31.2 

6.0 

ZO 

116.1 

ao 

128.0 

9.0 

15.9 

126.2 

180.9 

21.2 

11.3 

773 

446.8 

143.3 

227.1 

203.9 

69.1 

176.5 

4.6 

213.3 

5.7 

6.6 

61.6 

7.2 

5.9 

5.0 

34.3 

46.6 

17.8 

23.0 

20.4 

12.1 

7.7 

19.9 

14.3 

43.7 

30.6 

5.1 

126.4 

MACT Emis. 

OfiVJ 

31.2 

6.0 

2.0 

116.1 

6.0 

128.0 

9.0 

15.9 

126.2 

160.9 

21.2 

10.9 

743 

430.8 

13S.7 

216.1 

1933 

85.7 

1S9.8 

4.3 

1873 

4.6 

5.5 

51.3 

6.0 

4.9 

4.1 

26.7 

3S.9 

13.6 

17.0 

14.7 

8.7 

5.4 

14.0 

9.7 

28.7 

20.1 

3.3 

80.1 

Reduction 

Techniques 

Inrliietalur 

Cmtara.VSR 

Hand (100%) 

Incinerator, VSR 

VSR, Hand (100%) 

Incinerator, VSR 

VSR 

VSR 

VSR 

Incinerator, VSR (72%) 

VSR 

VSR, Hand (90%) A Spray (10%) 

VSR 

VSR 

VSR 

VSR 

VSR 

VSR 

VSR 

Hand (100%) 

VSR (90%) 

VSR. Hand 6 Spray 

VSR, Hand A Spray 

Hand (100%) 

Hand (100%) 

Hand (100%) 

Hand (100%) 

VSR, Hand (20%) 

VSR 

VSR 

VSR 

Vacuum bagging 

VSR 

Applies wftoOers 

VSR (70%) 

VSR 

Hand (100%) 

VSR 

12 

Y Tl 

oi 
P.16 

Issues: 

OPEN MOLDING 

(concluded) 

Highly filled applications have a built-in advantage over 

unfilled applications (lower net styrene content and hence a 

lower control status factor). 

Top performing facilities consist mainly of tub/shower makers. 

Tub/shower facilities comprise 67% ofthe 21 top performing 

facilities and 27% of all 172 known open molding facilities. 

As many as 86% of open molders spray applying unfilled 

resins could need a control device to comply (assuming none 

could switch from spray application or begin using filler). 

Industry (CFA) claims add-on controls for New Source MACT 

will kill the industry. 

Industry wants exemption for corrosion-resistant applications 

because they believe add-on controls are the only available 

compliance method. How to define a corrosion-resistant 

application; should they have a different numerical limit? 

Industry may want reduction credit for additional measures 

(spray technology, etc.). 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

13 

/<r 

172 

9,292 

Median CS 

5,832 

37% 
P.17 

PULTRUSION 

(5/17) 

MACT Floors: 

Existing: median % reduction (= 47%) 

or 

median CS value (= 1.2 lb HAP/gal RM) 

New: best % reduction (= 95%) 

or 

best CS value (= 0.2 lb HAP/gal RM) 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95% reduction or reduce CS value to less 

than or equal to 0.2 lb HAP/gal RM. 

New: None. 

14 
P.18 

PULTRUSION 

(concluded) 

Issues: 

Industry maintains that facilities using incinerators cannot be 

considered as part ofthe MACT floor for this subcategory 

because the incinerators are there due to other emission points. 

Other control measures are in use but not included. 

Median (floor) facility has an assumed 50% capture efficiency. 

Pultrusion Industry Council wants rule to include equipment 

standards that they believe produce reductions. 

"Fume collector" is in use but no data are available to assign 

reduction credit. 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

17 

167 

Median % 

Reduction 

99 

4 8% 

Median CS 

Value 

65 

6 1 % 

15 

i l 
P.19 

GEL COATING 

(18/150) 

MACT Floors: 

Existing: no numerical value* 

New: best % reduction (= 95%) 

Options Above the MACT Floor: 

Existing: 1. Use low-VOC gel coats. 

2. Use combustion or other device to achieve 

at least 95% reduction. 

New: None. 

*See work practices (page 37). 

16 
P.20 

Issues: 

GEL COATING 

(concluded) 

Inclusion of facilities using acrylic sheets in place of gel 

coating would require add-on controls for existing 

facilities. 

Lacking facility-specific gel coat density data to set a 

lb HAP/gal gel coat standard. 

Industry says cannot base New Source MACT on 

A.R.E. facility (incinerator on both resin and painting 

operations). 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

150 

4,340 

No Numerical 

Value 

4,340 

0% 

17 

n 
P.21 

CONTINUOUS LAMINATION/CASTING 

(5/13) 

MACT Floors: 

Existing: median % reduction (= 49%) 

or 

median CS value (= 0.5 lb HAP/gal RM) 

New: best % reduction (= 95%) 

or 

best CS value (= 0.2 lb HAP/gal RM) 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95% reduction or reduce CS value to less 

than or equal to 0.2 lb HAP/gal RM. 

New: None. 

18 

Z<3 
P.22 

CONTINUOUS LAMINATION/CASTING 

(concluded) 

Issue: 

• Medi.an (floor) facility has an assumed 50% 

capture efficiency. 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

13 

1,123 

Median % 

Reduction 

614 

45% 

Median CS 

Value 

391 

65% 

19 
P.23 

FILAMENT WINDING 

(5/31) 

MACT Floors: 

Existing: median % HAP Content as Supplied 

(= 42.5%) 

(equivalent to median CS value of 3.9 lb 

HAP/gal RM) 

New: lowest % HAP Content as Supplied (= 33%) 

(equivalent to CS value of 3.0 lb HAP/gal RM) 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95% reduction. 

New: Require combustion or other device to achieve at 

least 95% reduction. 

20 
P.24 

Issue: 

FILAMENT WINDING 

(concluded) 

Many filament winders are using corrosion-resistant 

(CR) resins and industry claims need for an exemption. 

(South Coast rule allows 48% monomer content by 

weight vs. 35% for general purpose resins.) Some lowstyrene CR resins are entering the market. 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

31 

508 

Median % HAP 

Content 

471 

7% 

21 

£2> 
P.25 

INJECTION MOLDING 

(5/5) 

MACT Floors: 

Existing: no numerical value* 

New: no numerical value* 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95 % reduction. 

New: Require combustion or other device to achieve at 

least 95 % reduction. 

*See work practices (page 37). 

22 

-2H 
P.26 

INJECTION MOLDING 

(concluded) 

Issue: 

• Very narrow range of CS values; difficult to select a 

floor value. 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

5 

63 

No Numerical 

Value 

63 

0% 

23 

25" 
P.27 

COMPRESSION MOLDING 

(5/42) 

MACT Floors: 

Existing: no numerical value* 

New: no numerical value* 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95% reduction. 

New: Require combustion or other device to achieve at 

least 95% reduction. 

*See work practices (page 37). 

24 

2.L 
P.28 

COMPRESSION MOLDING 

(concluded) 

issi on Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

42 

354 

No Numerical 

Value 

354 

0% 

25 

21 
P.29 

RESIN TRANSFER MOLDING 

(5/9) 

MACT Floors: 

Existing: no numerical value* 

New: no numerical value* 

Options Above the MACT Floor: 

Existing: None. 

New: None. 

*See work practices (page 37). 

26 
P.30 

RESIN TRANSFER MOLDING 

(concluded) 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

9 

5.7 

No Numerical 

Value 

5.7 

0% 

27 
P.31 

COMPOUNDING - BMC 

(5/11) 

MACT Floors: 

Existing: no numerical value* 

New: best % reduction (= 49 %) 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95% reduction. 

New: Require combustion or other device to achieve at 

least 95% reduction. 

*See work practices (page 37). 

28 

SO 
P.32 

COMPOUNDING - BMC 

(concluded) 

Issue: 

There may be other non-styrene resin compounds with 

HAP that we haven't considered (no data). 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

11 

45 

No Numerical 

Value 

45 

0% 

29 

31 
P.33 

COMPOUNDING 

(5/14) 

MACT Floors: 

Existing: 

New: 

no numerical value* 

best % reduction (= 72 

- SMC 

% ) 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95% reduction. 

New: Require combustion or other device to achieve at 

least 95% reduction. 

'See work practices (page 37). 

30 

32^ 
P.34 

COMPOUNDING - SMC 

(concluded) 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

14 

268 

No Numerical 

Value 

268 

0% 

31 

3>3 
P.35 

POLYMER CASTING 

(5/19) 

MACT Floors: 

Existing: median CS value (= 1.1 lb HAP/gal RM) 

New: best CS value (= 0.5 lb HAP/gal RM) 

Options Above the MACT Floor: 

Existing: Reduce CS value to less than or equal to 0.5 

lb HAP/gal RM. 

New: None. 

32 
P.36 

POLYMER CASTING 

(concluded) 

Issue: 

• Filler equity issue - some facilities may not be able to 

increase filler usage to achieve the floor level. 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

19 

46 

Median CS 

Value 

34 

26% 

33 

35-
P.37 

CENTRIFUGAL CASTING 

(5/5) 

MACT Floors: 

Existing: median CS value (= 0.4 lb HAP/gal RM) 

New: best % reduction (= 50%) 

or 

best CS value (= 0.2 lb HAP/gal RM) 

Options Above the MACT Floor: 

Existing: Reduce CS value to less than or equal to 0.2 

lb HAP/gal RM, or require combustion or other 

device to achieve at least 95% reduction. 

New: Require combustion or other device to achieve at 

least 95% reduction. 

34 

3t> 
P.38 

CENTRIFUGAL CASTING 

(concluded) 

Issue: 

• Assumed 50% capture efficiency for Fibercast (likely to 

be a low estimate) - impacts New Source MACT. 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

5 

96 

Median CS 

Value 

91 

5% 

35 

3? 
EMISSIONS CALCULATIONS - EXISTING FACILITIES 

CA) 

Subcategory 

Open Molding 

Gel Coating 

Continuous 

Lamination/Casting 

Filament Winding 

Compression Molding 

Compounding - SMC 

Pultrusion 

Centrifugal Casting 

Injection Molding 

Compounding - BMC 

Polymer Casting 

RTM 

TOTALS 

No. of Major Source 

Facilities 

172 

150 

13 

31 

42 

14 

18 

5 

5 

9 

19 

9 

Baseline 

Emissions (tpy) 

9,292 

4,340 

1,123 

508 

354 

268 

167 

96 

63 

45 

46 

6 

16,307 

MACT Floor 

Emissions (tpy)* 

5,832 

4,340 

391 

471 

354 

268 

65 

91 

63 

45 

34 

6 

11,959 

Emission 

Reduction (tpy)* 

3,460 (37%) 

0 (0%) 

732 (65%) 

37 (7%) 

0 (0%) 

0 (0%) 

102 (61%) 

5 (5%) 

0 (0%) 

0 (0%) 

12 (26%) 

0 (0%) 

4,348 (27%) 

'Values do not include emission reductions due to P2 work practices. 

36 
~Q 

POSSIBLE WORK PRACTICE STANDARDS 

All Subcategories 

- covers on HAP-containing vessels, including mixers 

- mixers completely covered during mixing 

- clean up spills immediately 

Gel Coating and Spray Layup 

- operator training program 

^ • SMC Compounding 

- use nylon film (better vapor barrier) 

-fold edges of SMC 

Compression Molding 

- reduce number of BMC or SMC "charges" left open to evaporate 

prior to molding 

Cleaning 

- some use of methylene chloride (Mel) and other HAP solvents reported 

- used at about 20% of major sources 

- most facilities use only acetone or substitutes 

- issue: ban on MCI use could lead to a lawsuit (Wood Furniture rule) 

37 
APPLICABILITY 

Data base includes predominantly polyester and vinyl ester resins 

containing styrene monomer (and some MMA) 

• Other HAP-containing resins are in use (phenolics, epoxies, etc.) 

- low HAP contents 

- primarily phenol, epichlorohydrin, etc. 

f- - mostly advanced, high-strength applications (e.g., aerospace) 

"5" - no data on these 

• Issue: Should standard attempt to cover all thermoset resin use? 

38 

TJ 
P.42 

' 

WIDEST APPLICABILITY OF THE STANDARDS 

Subcategory 

Open Molding 

Gel Coating 

Cont. L«amination/Casting 

Filament Winding 

Compression Molding 

Compounding - SMC 

Pultrusion 

Centrifugal Casting 

Injection Molding 

Compounding - BMC 

Polymer Casting 

RTM 

Existing or 

New Plant 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Polyester and Vinyl 

Ester Plants Only 

X 

X 

X 

X 

X 

X 

X 

X 

All Thermoset 

Resin Use 

X 

X 

X 

X 

X 

X 

X 

X 

X 

' X 

X 

X 

X 

X 

X 

X 

39 
NEXT STEPS 

X 

Meeting with P-MACT Team (Industry, S/L, Work Group) 

Assessment of Impacts (additional data gathering) 

Beyond-the-Floor Analysis 

Possible Negotiations with Industry 

Review/Approval by Work Group/ESD 

Preparation of Regulatory Proposal Framework 

40 
NEAR-TERM PROJECT SCHEDULE 

Milestone 

Send MACT floors/options package to P-MACT team 

P-MACT team meeting on MACT floors/options 

First draft of framework for preamble and proposed rule 

Date 

early March 1996 

late March 1996 

June 1996 

LONG-TERM PROJECT SCHEDULE 

Milestone 

Rule proposal 

Rule promulgation 

Date 

April 1997 

April 1998 

All dates are dependent on availability of funding. 

41 
PROJECT BRIEFING 

REINFORCED PLASTIC COMPOSITES PRODUCTION 

MACT STANDARD DEVELOPMENT 

BRIEFING FOR: 

EPA P-MACT TEAM AND EPA WORK GROUP 

Project Lead: Madeleine Strum (ESD/CCPG) 

March 20, 1996 

«H 
PURPOSE 

Discuss experience with P-MACT team approach 

Present MACT floors and alternatives above the floor 

Discuss applicability of standard 

Present suggested regulatory approach and new project schedule 

/ 

4r 
P-MACT TEAM APPROACH 

Formed team of EPA, State/local, industry, and environmental representatives 

Lost environmental representative 

Held four teleconferences to present data and discuss issues 

Large and diverse industry poses problem for P-MACT 

Requests for input have been largely unsuccessful 

Lack time/funding to keep P-MACT going and get standard out in 

reasonable timeframe 

Suggestion: phase out P-MACT process and adopt the conventional 

standards development approach 

3 
MACT ANALYSIS 

Industry Subcategorization 

Approaches for Numerical Emission Limits 

Subcategory-Specific Analyses - Numerical Emission Limits 

Work Practices 

4 

^7 
INDUSTRY SUBCATEGORIZATION 

Separate MACT floor calculations for: 

Open Molding (hand or spray layup) 

Gel Coating 

Continuous Lamination/Continuous Casting 

Filament Winding 

Compression Molding 

Injection Molding 

Resin Transfer Molding 

Pultrusion 

Compounding - BMC 

Compounding - SMC 

Polymer Casting 

Centrifugal Casting 

Notes: Data base includes polyester and vinyl ester (styrene-containing) resins only. 

Use of "prepreg" is not part of source category. 

5 
APPROACHES CONSIDERED FOR DETERMINING 

BEST PERFORMING FACILITIES 

1. Averaging with Resin Cure Factor 

a measure of weight loss during cure 

easy to measure in static lab test 

compatible with South Coast rule 

data for resins in use lacking 

lack of correlation with styrene content or emissions 

2. Resin HAP (Styrene) Content 

data are readily available 

• also compatible with South Coast rule 

• lower styrene content not the only means of emission reduction 

6 
APPROACHES CONSIDERED (continued) 

3. Percent Reduction (Add-ons) 

4. Facility "Control Status" (CS) 

• units of lb HAP (monomer) per gallon of resin matrix (RM) 

• lower CS means the facility is better controlled 

• accounts for quantifiable reduction measures in use 

(low resin styrene content, filler use, suppressants, non-spray 

application, add-on controls) 

• selected as the primary ranking variable 

7 

TJ 
CALCULATION OF FACILITY CONTROL STATUS (CS) 

Formula: 

CS = [ Resin (lb/yr)] [HAP Wt. %] x Application x VSR x Control 

(Resin + Filler) Volume Factor Factor Factor 

Example: Resin = 5.0 MM lb/yr 

Filler = 7.0 MM lb/yr 

Styrene Wt. % = 38.0 

(no other HAP) 

Application factor = 0.55 (non-spray appl.) 

VSR factor = 0.60 (vapor suppressant) 

Control factor = 1.00 (no control device) 

Calculation: 

CS = (5xl06) x (0.38) x 0.55 x 0.60 x 1.00 = 0.69 lb HAP/gal 

(543,500 + 364,600) gal resin matrix 

8 

Ul 
APPROACHES CONSIDERED (concluded) 

issues: - facilities using highly filled resin mixtures have a 

built-in advantage over unfilled applications 

- other measures are in use but not included (shorter gel 

times, resin thickness, air conditioned facility, etc.) 

- ORD developing a comprehensive model to predict open 

molding emissions; won't be available for developing 

proposal 

- approach credits same % reduction for all vapor-suppressed 

resins under all applications; industry may request 

tailored credit for each scenario (different suppressants, 

concentrations used, etc.) 

Ul 

co 
P.54 

SUBCATEGORY-SPECIFIC ANALYSES 

Note: The following analyses do not include the impact 

of work practice standards; see page 37. 

10 

5^ 
P.55 

OPEN MOLDING 

(21/172)* 

MACT Floors: 

Existing: median CS value (= 1.4 lb HAP/gal RM) 

New: best % reduction (= 95%) 

or 

best CS value (= 0.2 lb HAP/gal RM) 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95% reduction or CS value of less than or 

equal to 0.2 lb HAP/gal RM. 

New: None. 

indicates that "floor" facilities comprise 21 out ofthe 

total of 172 major source open molders. 

11 

5-4 
EXAMPLE FOR CALCULATING MACT FLOOR -

OPEN MOLDING FACILITIES 

Rank 

1 

2 

3 

4 

S 

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

16 

17 

18 

19 

20 

21 

22 

23 

24 

25 

26 

27 

28 

29 

30 

31 

32 

33 

34 

"35' 

36 

~37~' 

"38 

39 

40 

Sprays art Hand layup cartmed list 

Plant Mama 

A R. E, lnc(Massfflc<i) 

US. Rbenjass Products Inc. 

Resolite 

Tompkins - Lasco Bathware (Bizabethtown) 

TorrpMns - Lasco Bathware (Lancaster) 

AKB* Plastics Company, lnc(Flymouth, Pldco Dr) 

a W C Industries, Inc. (Swirl-Way Ov.) 

AKB* Plastics Company, lnt(Plymou1h, N Oak Rd) 

Tompkins - Lasco Bathware (South Boston) 

Cedar (Manufacturing, lnc.(Breman Sas) 

Pickerfe Plasties, Inc. 

Bremen Qas, Inc 

Tompkins - Lasco Bathware (Moapa) 

Tompkins - Lasco Bathware (Ccrdele) 

Tompkins - Lasco Bathware (Anaheim) 

Tompkins - Lasco Bathware (Three Rivers) 

Bathcraft, Inc 

Untvereal-ftunde Corp. (Ottumwa) 

Ceramic Cooling Tower Company 

Tompkins - Lasco Bathware (Ydm) (aka Hytec Inc) 

Warminster Fiberglass Company (Jacksonville) 

Wfermrster Fiberglass Company (Southampton) 

CBIPlart#7 

COR Systems Corporation (Corcoran) 

COR Systems Corporation (Palatka) 

Certify Martiactuing Company 

Custom Fireglass ManUactuing Co. 

National fiber Qass Products, Inc 

American Reiifumd Plastics 

Prestigious Accessories, Ire 

Great Dane Trailers InrJana, Inc (FRP Plant) 

Acme Fiberglass, Inc 

Diamond Coach Corporation 

Sunset Plastics Ire 

Bristol fiberlite Industries 

Hess County Industries of VW, Ire 

Fowler Manufactuing, Inc. 

Style Crest Products 

GW. fiberglass. Inc 

ProcessDesc 

Code 

1 

1 

13*17 

1 

3 

1 

1 

1 

1 

1 

1 

4 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

4 

8 + 13 

16 

16 

3 

1 

1 

1 

1 

1 

4 

1 

1 

1 

13 

12 

1 

1 

Resin 

Itnrt 

58602 

375.0 

60.8 

21248 

190.0 

2279.3 

164.7 

300.0 

23101 

27702 

367.0 

277.0 

1159.0 

6258.6 

19766 

31355 

2815.4 

944.8 

2500.0 

nao 

2753.9 

121.0 

139.3 

1017.0 

1520 

125.0 

74.5 

553.0 

640.0 

288.0 

4320 

375.0 

185.0 

133.0 

254.0 

247.0 

494.0 

439.0 

B40 

1850.0 

% Styrene 

As Supplied 

42.0 

46.0 

241 

47.7 

3ao 

47.7 

36.0 

35.0 

36.0 

411 

38.0 

45.0 

44.0 

47.0 

47.8 

47.7 

47.7 

4 U 

46.5 

320 

47.8 

40.0 

40.0 

435 

34.0 

34.0 

480 

44.9 

480 

40.7 

350 

39.0 

43.0 

40.0 

43.0 

382 

35.0 

50.5 

24.0 

45.0 

Filler 

(tart 

ao 

ao 

114 

3304.6 

ao 

3564.7 

180.5 

300.0 

2378.7 

4078.6 

3594 

ao 

1558.0 

9844.6 

30922 

4890.8 

4386.6 

986.9 

32760 

ao 

4215.6 

ao 

0.0 

608.0 

0.0 

ao 

60.0 

266.0 

570.0 

121.0 

0.0 

0.0 

750 

0.0 

215.0 

0.0 

494.0 

151.0 

ao 

395.0 

lb styrene/ 

oalRM 

186 

422 

203 

251 

349 

251 

217 

217 

221 

259 

238 

413 

246 

246 

251 

251 

251 

252 

262 

294 

254 

367 

367 

an 

312 

312 

ais 

3.35 

3.09 

311 

3.21 

3.58 

331 

3.67 

281 

3.51 

217 

393 

220 

3.75 

Application 

Factor 

1.00 

1.00 

ass 

1.00 

ass 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

a«J 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

ass 

1.00 

078 

tt78 

0.55 

0.55 

0.55 

0.55 

0.91 

1.00 

1.00 

1.00 

1.00 

1.00 

0.55 

1.00 

1.00 

1.00 

0.55 

1.00 

1.00 

VSR 

Factor 

1.00 

an 

1.00 

aeo 

aeo 

O60 

aeo 

aeo 

a60 

0.72 

a60 

060 

aeo 

0.6O 

0.60 

aeo 

060 

aeo 

060 

1.00 

a64 

060 

0.60 

1.00 

1.00 

1.00 

1.00 

0.60 

060 

0.60 

0.60 

1.00 

0.60 

1.00 

0.72 

0.60 

1.00 

1.00 

1.00 

0.60 

Control 

Fi**oc 

aos 

ai9 

1.00 

076 

1.00 

078 

1.00 

1.00 

1.00 

a75 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.55 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

Control 

Status 

(IbHAP/aalRMl 

ai9 

048 

1.12 

1.14 

1.15 

1.17 

1.30 

1.30 

1.33 

1.39 

1.47 

148 

148 

1.50 

181 

151 

151 

1.57 

1.62 

1.62 

1.71 

1.71 

1.71 

1.72 

1.72 

1.75 

1.83 

1.85 

1.87 

1.93 

1.97 

1.96 

202 

202 

210 

217 

219 

220 

225 

Current Ents. 

(tcv) 

31.2 

5.0 

20 

116.1 

60 

128.0 

ao 

15.9 

1262 

180.9 

21.2 

11.3 

774 

4465 

143.3 

227.1 

203.9 

59.1 

1765 

49 

2135 

57 

6.6 

61.6 

72 

59 

5.0 

34.3 

466 

17.8 

2ao 

204 

121 

7.7 

19.9 

14.3 

437 

30.8 

5.1 

126.4 

MACT Emis. 

(toy) 

31.2 

5.0 

20 

118.1 

6.0 

128.0 

ao 

155 

1262 

180.9 

21.2 

109 

748 

43a8 

135.7 

215.1 

193.0 

55.7 

1595 

43 

1874 

48 

55 

51.3 

ao 

4.9 

4.1 

26,7 

35.9 

ia6 

17.0 

147 

87 

5.4 

14.0 

9.7 

28.7 

201 

a3 

33.1 

Reduction 

Techniques 

Indnerator 

C filters, VSR 

Hand (100%) 

Incinerator, VSR 

VSR, Hand (100%) 

Incinerator, VSR 

VSR 

VSR 

VSR 

Incinerator, VSR (72%) 

VSR 

VSR, Hand (90%) & Spray (10%) 

VSR 

VSR 

VSR 

VSR 

VSR 

VSR 

VSR 

Hand (100%) 

VSR (90%) 

VSR. Hand& Spray 

VSR Hand & Spray 

Hand (100%) 

Hand (100%) 

Hard (100%) 

Hand (100%) 

VSR, Hand (20%) 

VSR 

VSR 

VSR 

Vacuum bagging 

VSR 

Applies WroOers 

VSR (70%) 

VSR 

Hand (100%) 

VSR 

12 

Tl 

cn 
P.57 

Issues: 

OPEN MOLDING 

(concluded) 

Highly filled applications have a built-in advantage over 

unfilled applications (lower, net styrene content and hence a 

lower control status factor). 

Top performing facilities consist mainly of tub/shower makers. 

Tub/shower facilities comprise 67% ofthe 21 top performing 

facilities and 27% of all 172 known open molding facilities. 

As many as 86% of open molders spray applying unfilled 

resins could need a control device to comply (assuming none 

could switch from spray application or begin using filler). 

Industry (CFA) claims add-on controls for New Source MACT 

will kill the industry. 

Industry wants exemption for corrosion-resistant applications 

because they believe add-on controls are the only available 

compliance method. How to define a corrosion-resistant 

application; should they have a different numerical limit? 

Industry may want reduction credit for additional measures 

(spray technology, etc.). 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

13 

S^ 

172 

9,292 

Median CS 

5,832 

37% 
wr P.58 

PULTRUSION 

(5/17) 

MACT Floors: 

Existing: median % reduction (= 47%) 

or 

median CS value (= 1.2 lb HAP/gal RM) 

New: best % reduction (= 95%) 

or 

best CS value (= 0.2 lb HAP/gal RM) 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95% reduction or reduce CS value to less 

than or equal to 0.2 lb HAP/gal RM. 

New: None. 

14 
P.59 

PULTRUSION 

(concluded) 

Issues: 

Industry maintains that facilities using incinerators cannot be 

considered as part ofthe MACT floor for this subcategory 

because the incinerators are there due to other emission points. 

Other control measures are in use but not included. 

Median (floor) facility has an assumed 50% capture efficiency. 

Pultrusion Industry Council wants rule to include equipment 

standards that they believe produce reductions. 

"Fume collector" is in use but no data are available to assign 

reduction credit. 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

17 

167 

Median % 

Reduction 

99 

4 8 % 

Median CS 

Value 

65 

61 %• 

15 

5^ 
P.60 

GEL COATING 

(18/150) 

MACT Floors: 

Existing: no numerical value* 

New: best % reduction (= 95%) 

Options Above the MACT Floor: 

Existing: 1. Use low-VOC gel coats. 

2. Use combustion or other device to achieve 

at least 95% reduction. 

New: None. 

*See work practices (page 37). 

16 
P.61 

Issues: 

GEL COATING 

(concluded) 

Inclusion of facilities using acrylic sheets in place of gel 

coating would require add-on controls for existing 

facilities. 

Lacking facility-specific gel coat density data to set a 

lb HAP/gal gel coat standard. 

Industry says cannot base New Source MACT on 

A.R.E. facility (incinerator on both resin and painting 

operations). 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

150 

4,340 

No Numerical 

Value 

4,340 

0% 

17 

4° 
P.62 

CONTINUOUS LAMINATION/CASTING 

(5/13) 

MACT Floors: 

Existing: median % reduction (= 49%) 

or 

median CS value (= 0.5 lb HAP/gal RM) 

New: best % reduction (= 95%) 

or 

best CS value (= 0.2 lb HAP/gal RM) 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95% reduction or reduce CS value to less 

than or equal to 0.2 lb HAP/gal RM. 

New: None. 

18 
P.63 

CONTINUOUS LAMINATION/CASTING 

(concluded) 

Issue: 

• Median (floor) facility has an assumed 50% 

capture efficiency. 

issi on Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

13 

1,123 

Median % 

Reduction 

614 

45% 

Median CS 

Value 

391 

65% 

19 

6*. 
P.64 

FILAMENT WINDING 

(5/31) 

MACT Floors: 

Existing: median % HAP Content as Supplied 

(=42.5%) 

(equivalent to median CS value of 3.9 lb 

HAP/gal RM) 

New: lowest % HAP Content as Supplied (= 33%) 

(equivalent to CS value of 3.0 lb HAP/gal RM) 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95% reduction. 

New: Require combustion or other device to achieve at 

least 95% reduction. 

20 
P.65 

Issue: 

FILAMENT WINDING 

(concluded) 

Many filament winders are using corrosion-resistant 

(CR) resins and industry claims need for an exemption. 

(South Coast rule allows 48% monomer content by 

weight vs. 35%) for general purpose resins.) Some lowstyrene CR resins .are entering the m.arket. 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

31 

508 

Median % HAP 

Content 

471 

7% 

21 
P.66 

INJECTION MOLDING 

(5/5) 

MACT Floors: 

Existing: no numerical value* 

New: no numerical value* 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95 % reduction. 

New: Require combustion or other device to achieve at 

least 95 % reduction. 

*See work practices (page 37). 

22 
P.67 

INJECTION MOLDING 

(concluded) 

Issue: 

• Very n«arrow range of CS values; difficult to select a 

floor value. 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

5 

63 

No Numerical 

Value 

63 

0% 

23 
P.68 

COMPRESSION MOLDING 

(5/42) 

MACT Floors: 

Existing: no numerical value* 

New: no numerical value* 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95% reduction. 

New: Require combustion or other device to achieve at 

least 95% reduction. 

*See work practices (page 37). 

24 
P.69 

COMPRESSION MOLDING 

(concluded) 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

42 

354 

No Numerical 

Value 

354 

0% 

25 
P.70 

RESIN TRANSFER MOLDING 

(5/9) 

MACT Floors: 

Existing: no numerical value* 

New: no numerical value* 

Options Above the MACT Floor: 

Existing: None. 

New: None. 

*See work practices (page 37). 

26 
P.71 

RESIN TRANSFER MOLDING 

(concluded) 

issi on Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

9 

5.7 

No Numerical 

Value 

5.7 

0% 

27 
P.72 

COMPOUNDING - BMC 

(5/11) 

MACT Floors: 

Existing: no numerical value* 

New: best % reduction (= 49 %) 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 9$i% reduction. 

New: Require combustion or other device to achieve at 

least 95% reduction. 

'See work practices (page 37). 

28 

11 
P.73 

COMPOUNDING -BMC 

(concluded) 

Issue: 

There may be other non-styrene resin compounds with 

HAP that we haven't considered (no data). 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

11 

45 

No Numerical 

Value 

45 

0% 

29 

2 
P.74 

COMPOUNDING - SMC 

(5/14) 

MACT Floors: 

Existing: no numerical value* 

New: best % reduction (= 72 %) 

Options Above the MACT Floor: 

Existing: Require combustion or other device to achieve at 

least 95% reduction. 

New: Require combustion or other device to achieve at 

least 95% reduction. 

:

See work practices (page 37). 

30 

73 
P.75 

COMPOUNDING - SMC 

(concluded) 

issi on Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

14 

268 

No Numerical 

Value 

268 

0% 

31 

Ti 
P.76 

POLYMER CASTING 

(5/19) 

MACT Floors: 

Existing: median CS value (= 1.1 lb HAP/gal RM) 

New: best CS value (= 0.5 lb HAP/gal RM) 

Options Above the MACT Floor: 

Existing: Reduce CS value to less than or equal to 0.5 

lb HAP/gal RM. 

New: None. 

32 

r* 
P.77 

POLYMER CASTING 

(concluded) 

Issue: 

• Filler equity issue - some facilities may not be able to 

increase filler usage to achieve the floor level. 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

19 

46 

Median CS 

Value 

34 

26% 

33 

7^ 
P.78 

CENTRIFUGAL CASTING 

(5/5) 

MACT Floors: 

Existing: median CS value (= 0.4 lb HAP/gal RM) 

New: best % reduction (= 50%) 

or 

best CS value (= 0.2 lb HAP/gal RM) 

Options Above the MACT Floor: 

Existing: Reduce CS value to less than or equal to 0.2 

lb HAP/gal RM, or require combustion or other 

device to achieve at least 95% reduction. 

New: Require combustion or other device to achieve at 

least 95% reduction. 

34 
P.79 

CENTRIFUGAL CASTING 

(concluded) 

Issue: 

• Assumed 50% capture efficiency for Fibercast (likely to 

be a low estimate) - impacts New Source MACT. 

Emission Impacts: 

No. of Facilities: 

Baseline Emissions (tpy): 

MACT Floor: 

Emissions (tpy): 

Percent Reduction: 

5 

96 

Median CS 

Value 

91 

5% 

35 

"7 5 
EMISSIONS CALCULATIONS - EXISTING FACILITIES 

-r 

Subcategory 

Open Molding 

Gel Coating 

Continuous 

Lamination/Casting 

Filament Winding 

Compression Molding 

Compounding - SMC 

Pultrusion 

Centrifugal Casting 

Injection Molding 

Compounding - BMC 

Polymer Casting 

RTM 

TOTALS 

No. of Major Source 

Facilities 

172 

150 

13 

31 

42 

14 

18 

5 

5 

9 

19 

9 

Baseline 

Emissions (tpy) 

9,292 

4,340 

1,123 

508 

354 

268 

167 

96 

63 

45 

46 

6 

16,307 

MACT Floor 

Emissions (tpy)* 

5,832 

4,340 

391 

471 

354 

268 

65 

91 

63 

45 

34 

6 

11,959 

Emission 

Reduction (tpy)* 

3,460 (37%) 

0 (0%) 

732 (65%) 

37 (7%) 

0 (0%) 

0 (0%) 

102(61%) 

5 (5%) 

0 (0%) 

0 (0%) 

12 (26%) 

0 (0%) 

4,348 (27%) 

* Values do not include emission reductions due to P2 work practices. 

36 
POSSIBLE WORK PRACTICE STANDARDS 

All Subcategories 

- covers on ELAP-containing vessels, including mixers 

- mixers completely covered during mixing 

- clean up spills immediately 

Gel Coating and Spray Layup 

- operator training program 

SMC Compounding 

- use nylon film (better vapor barrier) 

-fold edges of SMC 

O • Compression Molding 

- reduce number of BMC or SMC "charges" left open to evaporate 

prior to molding 

Cleaning 

- some use of methylene chloride (Mel) and other HAP solvents reported 

- used at about 20% of major sources 

- most facilities use only acetone or substitutes 

- issue: ban on MCI use could lead to a lawsuit (Wood Furniture rule) 

37 

00 
APPLICABILITY 

• Data base includes predominantly polyester and vinyl ester resins 

containing styrene monomer (and some MMA) 

• Other HAP-containing resins are in use (phenolics, epoxies, etc.) 

- low HAP contents 

- primarily phenol, epichlorohydrin, etc. 

s<\ - mostly advanced, high-strength applications (e.g., aerospace) 

~~ - no data on these 

Issue: Should standard attempt to cover all thermoset resin use? 

38 
P.83 

WIDEST APPLICABILITY OF THE STANDARDS 

Subcategory 

Open Molding 

Gel Coating 

Cont. Lamination/Casting 

V 

Filament Winding 

Compression Molding 

Compounding - SMC 

Pultrusion 

Centrifugal Casting 

! 

Injection Molding 

Compounding - BMC 

Polymer Casting 

RTM 

Existing or 

New Plant 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Existing 

New 

Polyester and Vinyl 

Ester Plants Only 

X 

X 

X 

X 

X 

X 

X 

X 

All Thermoset 

Resin Use 

X 

X 

X 

X 

X 

X 

X 

X 

X 

X 

X 

X 

X 

X 

X 

X 

39 

1^ 
NEXT STEPS 

Meeting with P-MACT Team (Industry, S/L, Work Group) 

Assessment of Impacts (additional data gathering) 

Beyond-the-Floor Analysis 

Possible Negotiations with Industry 

Review/Approval by Work Group/ESD 

Preparation of Regulatory Proposal Framework 

40 

oo 
NEAR-TERM PROJECT SCHEDULE 

Milestone 

Send MACT floors/options package to P-MACT team 

P-MACT team meeting .on MACT floors/options 

First draft of framework for preamble and proposed rule 

Date 

early March 1996 

late March 1996 

June 1996 

LONG-TERM PROJECT SCHEDULE 

-A Milestone 

Rule proposal 

Rule promulgation 

Date 

April 1997 

April 1998 

AH dates are dependent on availability of funding. 

41 
Open Molding 

?JQlS 

1 

2 

3 

4 

S 

6 

7 

S 

9 

10 

11 

12 

13 

14 

15 

16 

17 

I t 

1» 

20 

21 

22 

23 

24 

25 

26 

27 

2B 

29 

30 

31 

32 

33 

34 

35 

36 

37 

38 

39 

40 

41 

42 

43 

44 

45 

48 

47 

48 

Sprayup and Hand layup combined list 

Pkmt N»m« 

A.fi.E,lnc(Maselllon) 

U.S. Flbarglaaa Producta Inc. 

ReaoIKe 

TompMna • Laaco Bathware (Bliabethtown) 

Coftla44aM44 aPy Product^ Inc 

Tompkins • Laaco Batftwara (Lancaatar) 

AKER Plaatlca Company, lnc.(Plymouth, PIdco Dr) 

S.W.C. Induatilaa, Inc. (Swirl-Way Wv.) 

AKER Plaatlca Company, lnc.(Plymouth. N Oak Rd) 

TompMna • Laaco Bathwara (Sotith Boston) 

Cadar Manufacturing, lnc(Br»men Glas) 

Plckan'a Plaatlca, Inc. 

Bremen Glas, Inc 

TompMf4a • Laaco Bathwara (Moapa) 

TompMna • Laaco Bathwara (Cordala) 

TompMna - Laaco Bathwara (Anahtlm) 

TompMna • Laaco Bathwara (Thraa Rlvara) 

Bathcraft, Inc 

Untvental-Rundle Corp. (Ottumwa) 

Caramlc Cooling Towar Company 

TompMna • Laaco Bathwara (Yelm) (aka Hytac Inc) 

Warminster Fberglass Company (Jacksonville) 

Warminster Fberglass Company (Southampton) 

CBI Plant # 7 

CDR Systems Corporation (Corcoran) 

CDR Systems Corporation (Palatka) 

Century Manufacturing Company 

Ct4ttom Ffereglass Manufacturing Co. 

National Fber Glass Products, Inc 

American Reinforced Plastics 

Prestigious Accessories, Inc 

Great Dana Traitors Indiana. Inc (FRP Plant) 

Acme Ffcerglass, Inc. 

Diamond Coach Corporation 

Sunset Plaatlca Inc 

Bristol 4TfeorfJte Industries 

Hess County Industries of VW, Inc 

Fowler Manufacturing, Inc 

StytoCmst Products 

0. W. Ftoergtass. Inc. 

(KG Industries 

Leer East Inc. 

Gtatstae. Inc. 

PtastJc Composites Corporation 

Monarch Plastic Inc 

Universal Plastics inc 

Johnson Truck Bodies 

Process Dose. 

Cads 

13*1 7 

4~ 

8 4-13 

16 

16 

13 

12 

8*13 

Sknon-Talelact Inc | 14 

Rash 

{__ 

68862 

J78.0 

•0.6 

2124.8 

180.0 

2271.3 

184.7 

300.0 

2310.1 

27702 

3(7.0 

277.0 

1168.0 

•288.6 

1878.8 

11384 

2818.4 

944.8 

2500.0 

110.0 

2783.8 

121.0 

139.3 

1017.0 

152.0 

125.0 

74.5 

553.0 

640.0 

288.0 

432.0 

375.0 

165.0 

138.0 

254.0 

247.0 

494.0 

439.0 

S4.0 

1850.0 

127.9 

534.0 

330.0 

100.0 

87.5 

164.3 

390.0 

65.5 

% Styrvno 

Aa Sued tod 

42.0 

46.0 

24.1 

47.7 

38.0 

47.7 

36.0 

36.0 

36.0 

48.1 

38.0 

46.0 

44.0 

47.0 

47.8 

47.7 

47.7 

41.2 

46.6 

32.0 

47.8 

40.0 

40.0 

43.5 

34.0 

34.0 

48.0 

44.9 

48.0 

40.7 

35.0 

39.0 

43.0 

40.0 

43.0 

38.2 

35.0 

50.5 

24.0 

45.0 

45.0 

35.0 

3S.0 

40.0 

44.0 

35.0 

35.0 

35.4 

Filler 

(tra) 

0.0 

0.0 

11.4 

3304.8 

0.0 

3864.7 

180.6 

300.0 

2378.7 

407 M 

38* 4 

ao 

1868.0 

••44.6 

30822 

4880.8 

4388.6 

•86.6 

3276.0 

0.0 

4216.6 

0.0 

0.0 

603.0 

0.0 

0.0 

60.0 

266.0 

570.0 

121.0 

0.0 

0.0 

75.0 

0.0 

215.0 

0.0 

494.0 

151.0 

0.0 

395.0 

0.0 

437.0 

245.0 

40.0 

0.0 

0.0 

0.0 

0.0 

R) ttyrvns/ 

B8LBM 

3.88 

4 2 2 

2.03 

2.81 

Mt 

2.61 

2.17 

2.17 

2 * 1 

2 4 * 

2 48 

4.13 

146 

2 48 

161 

2.81 

2.61 

1 6 2 

2.82 

244 

2.84 

3.67 

3.67 

3.11 

3.12 

3.12 

3.18 

3.35 

3.09 

3.11 

3.21 

3.58 

3.31 

3.67 

2.61 

3.51 

2.17 

3.98 

2.20 

3.76 

4.13 

2.31 

2.37 

3.08 

4.04 

321 

321 

325 

Application 

Efc&t 

1.00 

1.00 

0.86 

1.00 

0.66 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.60 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.86 

1.00 

0.78 

0.78 

0.55 • 

0.55 

0.55 

0.55 

0.91 

1.00 

1.00 

1.00 

1.00 

1.00 

0.55 

1.00 

1.00 

1.00 

0.55 

1.00 

1.00 

0.55 

1.00 

1.00 

0.78 

0.78 

0.78 

0.78 

0.78 

VSR 

Easts* 

1.00 

0. M 

1.00 

0.80 

0.60 

0.60 

0.80 

0.80 

0.60 

0.72 

0.80 

0.80 

0.80 

0.60 

0.80 

0.80 

0.80 

0.60 

0.60 

1.00 

0.64 

0.60 

0.60 

1.00 

1.00 

1.00 

1.00 

0.60 

0.60 

0.60 

0.60 

1.00 

0.60 

1.00 

0.72 

0.60 

1.00 

1.00 

1.00 

0.60 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

Control 

Easta 

0.08 

0.11 

1.00 

0.76 

140 

0.78 

1.00 

1XN) 

1.00 

0.78 

1.00 

1.00 

1.00 

1.00 

140 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.S5 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.78 

1.00 

1.00 

1.00 

Control 

Status 

184 HAP/oal RM1 

0.18 

0.48 

1.12 

1.14 

1.16 

1.17 

1.30 

1.30 

143 

148 

147 

148 

148 

1.(0 

1.61 

141 

1.81 

147 

142 

142 

1.71 

1.71 

1.71 

1.72 

1.72 

1.75 

1.83 

1.85 

1.87 

1.93 

1.97 

1.98 

2.02 

2.02 

2.10 

2.17 

2.19 

2.20 

225 

227 

2.31 

2.37 

2.39 

2.43 

2.49 

Z49 

2.52 

Currant Emis. 

(tax) 

31.2 

6.0 

2.0 

118.1 

8.0 

128.0 

».o 

164 

1282 

1(0 4 

212 

11.3 

77.4 

4464 

143.3 

227.1 

2034 

69.1 

178.8 

4 4 

213.3 

5.7 

6.6 

61.6 

7.2 

5.9 

6.0 

34.3 

46.6 

17.6 

23.0 

20.4 

12.1 

7.7 

19.9 

14.3 

43.7 

30.8 

5.1 

126.4 

8.0 

47.3 

29.2 

7.8 

5.9 

114 

26.8 

4.5 

MACT Emis. 

(KB) 

3 1 2 

6.0 

2.0 

116.1 

6.0 

126.0 

• 4 

164 

1262 

180.9 

212 

104 

74.8 

430.8 

138.7 

216.1 

103.0 

88.7 

169.8 

4.3 

167.4 

4.6 

5.5 

51.3 

6.0 

4.9 

4.1 

26.7 

35.9 

13.6 

17.0 

14.7 

8.7 

5.4 

14.0 

9.7 

28.7 

20.1 

3.3 

. 80.1 

5.0 

2 9 2 

17.6 

4.7 

3.4 

6.5 

15.3 

2.6 

Reduction 

IvXrvfun 

Incinerator 

C Altera, VSR 

Hand (100%) 

Incinerator, VSR 

VSR, Hand (100%) 

Incinerator, VSR 

VSR 

VSR 

VSR 

Incinerator, VSR (72%) 

VSR 

VSR, Hand (80%) 6, Spray (10%) 

VSR 

VSR 

VSR 

VSR 

VSR 

VSR 

VSR 

Hand (100%) 

. VSR (80%) 

VSR, Hand 6 Spray 

VSR, Hand & Spray 

Hand (100%) 

Hand (100%) 

Hand (100%) 

Hand (100%) 

VSR, Hand (20%) 

VSR 

VSR 

VSR 

Vacuum bogging 

VSR 

AppflM wffroflm 

VSR (70%) 

VSR 

Hand (100%) 

VSR 

Hand (100%) 

Hand & Spray 

Hand (50%). Vac Bag (50%) 

Hand 8. Spray 

Hand 4 Spray 

Hand 4 Spray 

Pagel 

oo 

co 
Open Molding 

49 

50 

51 

52 

53 

54 

55 

56 

57 

58 

59 

60 

61 

62 

63 

64 

65 

66 

67 

68 

69 

70 

71 

72 

73 

74 

75 

78 

77 

78 

79 

60 

61 

82 

63 

64 

85 

88 

87 

88 

89 

90 

91 

92 

93 

94 

95 

96 

97 

98 

99 

100 

Fberglass Products, Inc 

Universal Rundle Corp. (Union Point) 

KeameyArVestem Power Products 

Blue Dolphin Fberglass Pools 

Kohler Company 

Austin Countertops, Inc 

Mr. Tubs, Inc 

Aqua Glass Corporation 

Eljer ManufacturlngfVeldosta) 

Crnrtoma Fiberglass. Inc. 

Ershigs, tne.(Bellirigham) 

Carolina Counters 

20th Century Fiberglass, Inc (Plant Four) 

M. C.Gill Corporation 

An-Cor Industrial Plastics, Inc 

Beetle Plastics. Inc 

Fberglass Industries, Inc 

Newarteslan Management Co (Artesian Plumbing Products) 

Gold Shield Fberglass tne (Decatur) 

Gold Shield Fiberglass, Inc(Fontana) 

Clark Manufacturing 

Hastings Reinforced Plastlcs-Viatec (Hastings) 

Oasis Industries Inc 

Baja Products Ltd.(SaHsoury) 

LaValley Construction Company (Biloxl) 

Arrowhead Plastic Engineering. Inc 

McCture Industries Inc 

MFG - Molded Fiber Glass Company (Adalanto) 

Kreider Manufacturing Inc. 

Accurate Glass, Inc 

Eagle Craft, Inc 

Grayson Tool Company 

Nordic Fberglass lnc(DevDs Lake) 

Armorcast Products Company 

Owens-Coming (Mount Union) 

Owens-Coming Tanks (Valparaiso) 

ACME Reinforced Plastics, Inc 

Newport Laminates 

Martey Cooling Tower Company 

VMC Fberglass Products, Inc /Tri-Glas 

Nordic Fiberglass lnc(Warran) 

Mowed Plastic Industries, Inc 

Classic Motor Carriages 

Comtech Systems, Inc 

Fbre Body Industries. Inc 

MFG Justin Tanks, Inc 

Continental Camper Company, Inc 

Great Lakes Plastics Corporation 

A-1 Fberglass, Inc. 

Electric-Glass, Inc. 

Murphy Body Co. 

Fberglass Sytems, Inc. 

14 

1 

13 

12 

12 

13 

13 

13 

13 

13 

12 

12 

1+8 

12 

13 

120.0 

1410.0 

168.0 

n ' 

550.0 

480.0 

137.0 

12000.0 

363.0 

344.0 

104.5 

159.0 

95.3 

79.0 

190.0 

115.0 

60.0 

250.0 

1989.7 

716.0 

681.0 

160.0 

145.0 

100.0 

134.0 

140.0 

140.0 

209.0 

210.0 

114.0 

60.0 

157.0 

316.2 

126.5 

n" 

n" 

133.0 

180.0 

634.0 

1156.0 

246.3 

102.0 

142.1 

166.0 

250.0 

176.4 

164.5 

306.0 

395.0 

320.0 

114.7 

235.0 

35.0 

40.0 

38.0 

50.0 

40.0 

28.0 

40.0 

43.0 

47.0 

41.0 

38.5 

35.0 

40.0 

57.4 

53.0 

41.0 

41.0 

47.0 

32.0 

32.0 

40.0 

42.0 

49.0 

47.5 

43.0 

43.0 

45.0 

35.0 

33.7 

50.0 

34.0 

34.0 

48.5 

43.0 

45.0 

45.0 

35.0 

35.0 

35.0 

35.0 

48.5 

36.0 

37.0 

37.0 

37.0 

48.7 

38.0 

50.0 

40.0 

42.0 

395 

49.0 

66.0 

1347.0 

148.0 

0.0 

520.0 

15.0 

110.0 

12000.0 

467.0 

80.0 

0.0 

53.3 

572 

0.0 

0.0 

0.0 

0.0 

260.0 

0.0 

0.0 

325.0 

0.0 

145.0 

0.0 

0.0 

0.0 

101.0 

20.0 

0.0 

114.0 

0.0 

0.0 

270.0 

62.5 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

198.5 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

200.0 

40.0 

45.0 

0.0 

117.5 

2.52 

2.52 

2.53 

4.60 

2.53 

2.53 

2.65 

2.67 

2.67 

3.39 

3.53 

2.77 

2.65 

6.27 

4.67 

3.76 

3.76 

2.92 

2.94 

2.94 

2.97 

3.88 

3.04 

4.36 

3.95 

3.65 

3.07 

3.07 

3.09 

3.11 

3.12 

3.12 

3.16 

3.20 

4.14 

4.14 

3.21 

3.21 

3.21 

3.21 

3.21 

3.30 

3.40 

3.40 

3.40 

4.47 

3.49 

3.50 

3.50 

3.61 

3.63 

3.63 

1.00 

1.00 

1.00 

0.55 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.78 

1.00 

1.00 

OSS 

0.66 

0.76 

0.76 

1.00 

1.00 

1.00 

1.00 

0.78 

1.00 

1.00 

0.76 

0.76 

1.00 ' 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.78 

0.78 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.76 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.80 

1.00 

1.00 

1.00 

1.00 

0.90 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.70 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

| 1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

| 1.00 

2.52 

2.52 

2.53 

2.53 

2.53 

2.53 

2.65 

2.67 

2.67 

2.71 

2.74 

2.77 

2.65 

2.90 

2.90 

2.92 

2.92 

2.92 

2.94 

2.94 

2.97 

2.99 

3.04 

3 0 5 

3.06 

3.06 

3.07 

3.07 

3.09 

3.11 

3.12 

3.12 

3.16 

3.20 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.30 

3.40 

3.40 

3.40 

3.46 

3.49 

3.50 

3.50 

3.61 

3.63 

3.63 

10.6 

142.7 

17.9 

n* 

55.7 

34.0 

13.9 

1305.5 

43.2 

28.5 

7.9 

14.1 

9.6 

6.3 

15.2 

9.2 

6.4 

29.7 

161.1 

58.0 

66.9 

13.2 

18.0 

8.4 

11.3 

11.8 

15.9 

18.5 

17.9 

14.4 

5.2 

13.5 

38.8 

14.0 

n' 

n* 

11.8 

15.9 

58.1 

102.4 

30.2 

9.3 

13.3 

15.5 

23.4 

16.7 

17.7 

36.7 

40.0 

34.0 

11.5 

29.1 

6.0 

80.7 

10.1 

n* 

31.4 

19.1 

7.4 

696.9 

23.0 

15.0 

4.1 

7.2 

4.8 

3.1 

7.5 

4.5 

3.1 

14.5 

78.2 

28.1 

32.1 

6.3 

6.4 

3.9 

5.3 

5.5 

7.4 

8.6 

8.3 

8.6 

2.4 

6.2 

17.5 

6.2 

n* 

n* 

5.2 

7.1 

24.9 

45.4 

13.4 

4.0 

5.6 

6.5 

9.6 

6.9 

7.2 

15.8 

16.3 

13.4 

4.5 

11.4 

Applies w/rollers 

VSR (50%) 

Hand & Spray 

Hand (100%) 

VSR (25%). Hand (75%) Spray (25%) 

Hand 4 Spray 

Hand & Spray 

Hand 8. Spray 

VSR (75%) 

Hand & Spray 

Hand 4 Spray 

Hand & Spray 

Hand & Spray 

Hand 4 Spray 

Page 2 

oo 

^i 
Ope

n Molding 

101 

102 

103 

104 

105 

106 

107 

108 

109 

110 

111 

112 

113 

114 

115 

116 

117 

118 

119 

120 

121 

122 

123 

124 

128 

126 

127 

128 

129 

130 

131 

132 

133 

134 

135 

136 

137 

138 

139 

140 

141 

142 

143 

144 

145 

146 

147 

148 

149 

150 

1S1 

152 

H 6 R Industries Inc 

Fberglass Specialties, Inc 

Florida Line of Astatula, Inc. 

Covermester, Inc. 

Fberglass Forms, Inc. 

Livingston Ine. 

Piedmont Fberglass Inc. 

Syntachnlcs 

PlasWablnc 

Holiday Rambler Corp., Plant 36 and 37 

Millennium Products, Inc 

Delta Fberglass Structures, Inc 

Krueger International Inc 

Lund Industries. Inc 

Norlhwaat Bodies Inc 

UmversaUtundle Corp. (New Castle) 

Global Glass. Inc 

Standard Glas, Inc 

Fbordomo, Inc -Plant #1 

Marrajts Corporation 

Specialty Plastics Associates, Inc 

B*MV*JT MOtOT COaMnM 

Mtlohor MflnufMSurinQ Contptny Inc. 

Prodean Corporation (Catawba Facility) 

Fbanjasss Engineering Corporation 

Owens-Corning (Auburndale) 

Owens-Coming Fberglas (Cornea) 

Red Ewald, Inc. 

KBK Industries Incorporated 

GPI Corporation 

Attbar Plastics, Inc 

Fber Pad, Inc 

Peart Baths, Inc 

Amtocti Corporation 

Plastic Development Company 

Iffira/GlaaorLakeville 

MFG - Molded Fber Glass Company (Union City) 

ARE.. IncfMountEaton) 

Aero Transportation Pioducts 

AKER Plasties Company, Ine (Martinsburg) 

Aoptacrdan Plastics, Inc 

Associated Plastics, Inc 

Betting Tank Technology (F.KA D 4 R Fabrication, Inc) 

Boakig Wichita 

C 6 K Fberglasa Plaatlca, Inc 

CBIPtort#11 

Concept Plasllca, Ine 

Diamond Fberglass Fabricators, Inc 

ED Industries tne (Sportsman Pickup Covers) 

Ersrsgs, IncfVrtson) 

FmbtrcMXl CornpaWiy 

Fsbrax Corporation 

13 13 12 12 14 14 14 14 13 J 14 14 

• 11*13*B M 12 

85.5 

77.0 

130.6 

131.0 

120.0 

612.0 

120.0 

513.0 

92.0 

700.0 

634.0 

295.0 

252.0 

493.4 

147.3 

3585.0 

276.0 

125.0 

100.0 

105.0 

641.0 

181.5 

134.0 

161.0 

75.0 n* n" 

105.0 

562.0 

129.0 

500.0 

95.0 

325.0 

46.9 

140.0 

154.0 

520.0 

987.4 

1094.0 n* 

62.0 

161.0 n* 

1155.6 

102.0 n* 

707.7 n" n" 

54.0 

67.0 n« 

48.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.3 

42.0 

40.7 

41.0 

41.0 

41.0 

41.5 

60.2 

42.0 

42.0 

43.0 

44.0 

44.0 

45.0 

45.0 

45.0 

45.0 

45.0 

45.0 

45.5 

46.0 

46.0 

48.0 

48.0 

48.7 

50.0 

50.0 

50.0 

80.0 

34.0 

n 

43.0 

n 

n n ' 

20.0 

n n* 

3Z0 n ' 

n 

n 

n 

n 

38.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

56.0 

0.0 

0.0 

0.0 

0.0 

0.0 

3256.6 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 y

k 

0.0 y

k 

0.0 n ' n" 

0.0 

0.0 n" y ' n ' n* 

0.0 2 0 n* 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.70 

3.71 

3.74 

3.76 

3.76 

3.76 

3.81 

3.85 

3.86 

3.86 

3.95 

4.04 

4.04 

4.13 

4.13 

4.13 

4.13 

4.14 

4.14 

4.16 

4.22 

4.22 

4.41 

4.41 

4.47 

4.59 

4.59 

4.59 

7.34 n ' n ' n* n ' n* n* n ' n" n ' n« n* n* n ' n* n" 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

100 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.78 n" 

0.76 

1.00 

0.78 

0.55 

1.00 

1.00 

0.55 

1.00 

0.76 

0.78 

0.55 

0.55 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.60 

1.00 

100 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

100 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

too 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.70 

3.71 

3.74 

3.76 

3.76 

3.76 

3.81 

3.85 

3.86 

3.66 

3.95 

4.04 

4.04 

4.13 

4.13 

4.13 

4.13 

4.14 

4.14 

4.16 

422 

4.22 

4.41 

4.41 

4.47 

4.59 

4.59 

4.59 

7.34 n ' n" n ' n* n ' n* n" n* n* n* n ' n" n" n* n* 

10.4 

7.8 

13.2 

13.3 

12.1 

516 

12.1 

51.9 

9.4 

74.4 

85.9 

30.6 

26.1 

51.2 

15.5 

546.0 

29.3 

13.3 

10.9 

11.7 

93.6 

20.7 

15.3 

16.3 

8.5 n* n« 

12.1 

67.7 

15.0 

60.7 

11.5 

40.0 

5.9 

17.7 

19.5 

105.2 n" n ' n* n* n ' n* n* n" n* n ' n* n ' n* n ' n* 

4.0 

3.0 

5.1 

5.1 

4.7 

20.1 

4.7 

2 0 2 

3.6 

28.6 

32.8 

11.6 

9.9 

16.4 

6.6 

202.0 

10.8 

4.9 

3.9 

4.1 

33.0 

7.1 

5.3 

6.3 

2.9 n* n' 

4.1 

22.9 

5.1 

19.6 

3.7 

12.6 

1.8 

5.5 

6.1 

20.4 n ' n" n ' n* n* n* n* n ' n* n* 

. n* n* n ' n ' n* 

-

Hand 4 Spray 

VSR 

Hand 4 Spray 

Hand 4 Spray 

Hand (100%) 

Hand (100%) 

Hand 4 Spray 

Hand 4 Spray 

Hand (100%) 

Hand (100%) 

_ 3 

Page 3 

oo oo 
-£ Open Molding 

153 

154 

155 

156 

157 

158 

159 

160 

161 

162 

163 

164 

165 

166 

167 

166 

169 

170 

171 

172 

(mages Products Corp 

Jones 6 Hunt Inc 

Lear Midwest 

Miracle Recreation Company 

Newarteslan Limited Partnership (Marble Plant) 

Owens-Coming Fberglaa (Bakersfield) 

Ranch Fbarglas, Inc 

Raven Industries, Inc (Sioux Fads) 

Rubber 6 Plastic Applicators 

S. R. Smith, Inc 

Smith Fiberglass Products Inc (Little Rock) 

CBI Plant * 10 

CBI Plant* 12 

CBI Plant #13 

CBI Plant #14 

CBI Plant #15 

CBI Plant #16 

Country Coach. Inc 

Glasgo Plastics Inc 

McClsrin Plastics Inc. 

Totals: 

Average: 

Projected Total: 

1 

12 

1 

1 

1 

12 

1 

14* 7 

12 

1 

15 + 13 

1 

1 

1 

13 

6 + 13 

12 

1 

1 

1 

Best performing 12 % of eft open molding facilities are highlighted in bold type. 

MACT Floor « median "styrene control status" of top 12% (21) of all facilities • 

1 

Baseline emissions • Sum of actual current calculated emissions for ell facilities 

109.0 

n' 

600.0 

n' 

1000.0 

n" 

342.0 

n* 

n" 

n' 

n* 

n' 

n' 

n" 

n' 

n" 

n' 

99.0 

n* 

n' 

94152.9 

644.9 

110919.8 

1.43 

n 

n 

n 

n' 

34.0 

50.0 

35.0 

n" 

n 

• 

n" 

n* 

46.0 

46.0 

46.0 

n* 

50.0 

45.9 

n* 

n" 

6249.5 

41.1 

n" 

n

4 

500.0 

n' 

y* 

y

k 

y

k 

n' 

n" 

n* 

n' 

n* 

n' 

n" 

n* 

n" 

n ' 

n ' 

n* 

n* 

70708.2 

494.5 

85047.6 

n* 

n" 

n' 

n" 

n" 

n* 

n* 

n* 

n* 

n* 

n* 

0.50 

0.46 

0.46 

0.46 

0.46 

0.50 

0.46 

0.40 

0.50 

474.7 

3.3 

MACT emissions * Sum of currant emissions for facilities with styrene control status (SCS) values equal to or less than the median 

plus the sum of emissions equal to (resin * fiDer)vor*(median styrene control status)*(AP-42 midpoint for spray layup)*(2-3) 

for each fadlity with a SCS value greater than the median. | II I 

Therefore, MACT control wouM produce a 37.2 percent reduction in emissions cf HAP from open molding operations. 

n ' • Fadlity did not provide this infonnation. | 

y ' « Facility Indicated tha use of filler but did not quantify the amount. 

Control Status Data and AasumrjOons: 

A R. E. has an overall capture efficiency ot 100% end e destruction efficiency of 95%. 

U.S. Fberglass Products has an ovaral capture efficiency of 90% and a destruction efficiency of 90%. 

Tompkins - Laaco (Ellzabathtown) vents 50% to an Incinerator with an overall capture efficiency of 50% and a destruction efficiency of 98%. 

Tompkins - Lasco (Lancastar) vents 46% to an incinerator with an overaS capture efficiency of 50% and a destruction efficiency of 98%. 

Tompkins - Lasco (South Boston) vanta 50% to an Incinerator with an overan capture effiC4W4Cy of 50% and a destnx ^ efficiericy of 98%. 

Use of VSR for all resins received a 40% amission reduction credit | 

If all rash is applied by hand, the faoVty received a 45% emission reduction credit 

Tha use of vacuum bagging for the entire production process received a 45% emtoslon reduction credit 

Filler density was assumed to be 19.2 be par gallon. Resin density waa assumed to be 9.2 ba per gallon. 

_^ 

2/22/1996 

1.00 

0.76 

1.00 

1.00 

1.00 

1.00 

n" 

0.78 

0.55 

0.78 

0.78 

1.00 

1.00 

1.00 

1.00 

1.00 

0.78-

1.00 

1.00 

0.76 

0.60 

0.60 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

n* 

n* 

n' 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

392.8 

2.7 

n' 

n' 

n* 

n' 

n' 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

7131.2 

54.0 

9292.2 

Process Description Codes: 

1 » Get Coating and Open Molding 

2 • Gel Coating and Polymer Coating 

3 • RTM, Gal Coating, and Open Molding 

4 • Compression Molding. Gel Coating, and Open Molding 

5 • Injection Molding | | 

6 » Centrifugal Casting and Filament Winding 

7 « Centrifugal Casting 

8

 m Puflrusion 

n* 

n' 

n* 

n 

n' 

n 

n 

n 

n 

n 

n 

n' 

n' 

n' 

n 

n' 

n 

n 

n 

n 

4475.7 

33.9 

5832.0 

Hand 4 Spray 

VSR 

Hand 6 Spray 

Hand (100%) 

Hand 4 Spray 

Hand 6 Spray 

VSR 

Hand 4 Spray 

Hand 4 Spray 

9 • BMC, Compression Molding, and Puflrusion 

10 • SMC and Compression Molding 

11 • Compression Molding 

12 • Filament Winding and Open Molding 

13-Open Molding 

14 • Filament Winding. Gal Coating, and Open Molding 

15 « Compression Molding and Filament Winding 

18 "Polymer Costing end Open Molding 

17 • Continuous Lamination 

Page 4 
Gel Coating 

Bank 

i 

2 

3 

4 

S 

• 

7 

8 

9 

10 

11 

12 

13 

14 

18 

18 

17 

18 

19 

20 

21 

22 

23 

24 

25 

26 

27 

28 

29 

30 

31 

32 

33 

34 

35 

36 

37 

38 

39 

40 

41 

42 

43 

44 

I « 

Plant name 

A. R. R, Inc(Maaalllon) 

U.8. Flberglsss Producta Inc. 

Tompklna - Lasco Bathware (Ellzabathtown) 

Tompkins - Lasco Bathwara (Lancaster) 

Tompkins • Lasco Bathware (South Boston) 

Style Crest Products 

A-1 Fiberglass, Inc 

Bremen Glas, Inc. 

Cedar Manufacturing, lnc.(Bremen Glas) 

Great Dane Trailers Indiana, Inc. (FRP Plant) 

Millennium Products, Inc. 

Prodelln Corporation (Catawba Facility) 

Global Glass, Inc 

VMC Fiberglass Products, Inc/Trl-Glas 

Classic Motor Carriages 

Johnson Truck Bodies 

Prestigious Accesaortaa, Inc. 

Fiberglass Industries, Inc 

Gold Shield Fiberglass Inc (Decatur) 

UrtTa/GlasofLakeville 

A. R. E.. lnc(Mount Eaton) 

Bathcrafl Inc 

MFG - Molded Fiber Glass Company (Union City) 

Newarteslan Management Co (Artesian Plumbing Product 

Country Coach, Inc. 

Beaver Motor Coaches 

Pearl Baths, Inc 

20th Century Fiberglass, Inc. (Plant Four) 

AKER Plastics Company, Inc.(Plymouth) 

Attbar Plastics, Inc 

C 4 K Fiberglass Plastics. Inc. 

Krueger International Inc 

Pickens Plastics. Inc 

Plastic DeveJopment Company 

Aero Transportation Products 

AKER Plastics Company. Inc (Martinsburg) 

Century Manufacturing Company 

Ccvexnsntsr, Inc. 

Eagle Craft, tne 

Ershigs, lqc(BeUngham) . 

Ershigs, IncfWBson) 

Hberdome. Inc.-Plant #1 

Great Lakes Plastics Corporation 

HoMay Rambler Corp., Plant 36 and 37 

iXoNerComparty 

Process Desc 

Cede. 

14 

14 

Resin 

Any) 

1641.2 

23.6 

499.0 

328.0 

468.0 

36.0 

96.0 

369.0 

105.3 

105.0 

167.0 

38.0 

69.6 

291.0 

41.0 

66.0 

64.0 

16.0 

673.7 

41.0 

261.6 

242.1 

102.0 

75.0 

13.5 

0.5 

3.3 

15.0 

33.7 

76.0 

43.0 

61.7 

45.0 

1.0 

93.0 

124.6 

25.5 

70.0 

20.0 

3.5 

5.6 

30.0 

80.0 

150.0 

10.0 

% Styrene 

As Supplied 

40.0 

37.63 

40.0 

40.0 

40.0 

22.0 

30.0 

30.0 

30.0 

30.0 

30.0 

30.0 

30.0 

30.3 

30.6 

30.6 

31.0 

32.0 

32.0 

32.0 

34.0 

34.0 

34.0 

34.0 

34.6 

34.7 

34.9 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

Ib stryene/ 

gaIRM 

3.67 

346 

3.67 

3.67 

3.67 

2.02 

2.76 

2.75 

2.76 

2.76 

2.76 

2.76 

2.76 

2.76 

2.81 

2.61 

2.85 

2.94 

2.94 

2.94 

3.12 

3.12 

3.12 

3.12 

3.18 

3.19 

3.20 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

Control 

FBCtor 

0.06 

0.19 

0.63 

0.63 

0.63 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

Control 

Status 

(lb sty/pal RM) 

0.18 

0.66 

1.93 

1.93 

1.93 

2.02 

2.75 

2.76 

2.75 

2.76 

2.76 

2.76 

2.76 

2.78 

2.81 

2.81 

2.85 

2.94 

2.94 

2.94 

3.12 

3.12 

3.12 

3.12 

3.18 

3.19 

3.20 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

Current Emis. 

rjpyi 

21.6 

1.2 

73.6 

48.3 

68.6 

5.4 

20.0 

77.6 

22.2 

22.1 

36.1 

8.0 

14.6 

61.8 

8.8 

13.9 

13.9 

3.4 

151.2 

9.2 

62.4 

57.7 

24.3 

17.9 

3.3 

0.1 

0.8 

3.7 

8.3 

19.4 

10.8 

15.1 

11.0 

0.2 

22.8 

30.6 

6.3 

17.2 

4.9 

0.9 

1.4 

7.4 

19.6 

36.8 

2.5 

MACT Emis. 

and 

21.6 

1.2 

73.6 

48.3 

68.6 

SA 

20.0 

77.6 

22J 

22.1 

36.1 

8.0 

14.6 

61.8 

8.8 

13.9 

13.9 

3.4 

151.2 

9.2 

62.4 

57.7 

24.3 

17.9 

3.3 

0.1 

0.8 

3.7 

8.3 

19.4 

10.6 

15.1 

11.0 

0.2 

22.8 

30.6 

6.3 

17.2 

4.9 

0.9 

1.4 

7.4 

19.6 

38.8 

2.5 

Reduction 

Technique 

Incinerator 

C filter, VSGelcoat 

Incinerator 

Incinerator 

Incinerator 

VSGelcoat 

appl. w/brush, VSGelcoat 

applies with brush 

Acrylic sheets also 

*5> 

-0 

Pagel 

I 
•B Gel Coating 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 60 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 

LaValley Consbuction Company (Biioxi) 

Leer East Inc 

Leer Midwest 

McClartn Plastics Inc 

Melcher Manufacturing Company Inc. 

Molded Plastic Industries, Inc. 

Piedmont Fiberglass Inc 

Ranch Fiberglas, Inc 

Simon-Teleiect Inc 

Standard Glas, Inc. 

Universal Plastics Inc 

Universal Rundle Corp. (Union Point) 

UniversaJ-Rundle Corp. (New Castle) 

Nordic Fiberglass lnc(Devils Lake) 

Nordic Fiberglass lnc.(Warren) 

American Reinforced Plastics 

Northwest Bodies Inc 

Oasis Industries Inc 

Eljer Manufacturtng(Valdosta) 

Florida Una of Astatula, Inc 

GPI Corporation 

Kretder Manufacturing Inc 

Newport Laminates 

Sunset Plastics Inc. 

Arrowhead Plastic Engineering, Inc. 

Accurate Glass, Inc 

KBK Industries Incorporated 

Monarch Plastic Inc. 

National Fiber Glass Products, Inc. 

Fibre Body Industries, Inc. 

H & R Industries Inc 

Livingston Inc 

Plasti-Fab Inc. 

Lund Industries, Inc. 

Aqua Glass Corporation 

Charioma Fiberglass, Inc 

Gold Shield Fiberglass. Inc(Fontana) 

Applachlan Plastics, Inc 

Associated Plastics, Inc 

(^temporary Products, Inc. 

Raven Industries, lnc(Sfoux Falls) 

linages Products Corp 

Plastic C43rnposites Corporation 

Betdlnc 

CBIPU 

Tank Technology (F.ICA. D & R Fabrication, Inc.) 

int*10 

CBI Plant #13 

CBI Plant 811 

Diamond Fiberglass Fabricators, Inc. 

E-TM Enterprises, Inc 

ED Industries Inc (Sportsman Pickup Covers) 

1 I 

1 14 14 

3 

3 14 

3 

3 

6 * 1 

1 

4 14 

1 

1 

.... 14 

RTM + Gel 

1 

4.9 | 

.;;

:i24*'-'.-' 

200.0 

..;-:i24.6"yy 

14.0 

49.0 

2.3 

70.8 

24.0 

15.0 

46.6 

300.0 

607.5 

23.5 

13.5 

56.0 

22.8 

16.2 

93.0 

50.1 

15.0 

102.0 

30.0 

50.0 

28.9 

37.0 

9.0 

13.13 

167.3 

70.0 

5.0 

60.0 

20.5 

111.4 

1170.0 

86.0 

158.0 

2.0 

12.5 

42.0 

9.5 

30.0 

15.00 

124.6 

124.8 

124.6 

124.6 

124.6 

124.6 

124.6 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.0 

35.2 

35.5 

36.0 

36.0 

36.0 

36.0 

36.0 

36.0 

36.0 

36.0 

36.0 

36.6 

37.0 

37.0 

37.0 

37.0 

37.0 

37.0 

37.0 

37.4 

37.4 

37.5 

37.53 

37.53 

37.63 

37.53 

37.53 

37.53 

37.53 

37.53 

37A 

37.6 

37.6 

37.6 

37.6 

37.6 

37.6 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21' 

3.21 

3.21 

3.21 

3.23 

3.26 

3.30 

3.30 

3.30 

3.30 

3.30 

3.30 

3.30 

3.30 

3.30 

3.36 

3.40 

3.40 

3.40 

3.40 

3.40 

3.40 

3.40 

3.43 

3.44 

3.44 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45" 

3.45 

3.45 

3.45 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

i.bo 

1.00 

1.00 

1.00 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.21 

3.23 

3.26 

3.30 

3.30 

3.30 

3.30 

3.30 

3.30 

3.30 

3.30 

3.30 

3.36 

3.40 

3.40 

3.40 

3.40 

3.40 

3.40 

3.40 

3.43 

3.44 

3.44 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

3.45 

1.2 

30.6 

49.1 

30.6 

3.4 

12.0 

0.6 

17.4 

5.9 

3.7 

11.4 

73.6 

149.1 

5.8 

3.4 

14.1 

5.7 

4.1 

23.5 

12.7 

3.8 

25.8 

7.6 

12.6 

7.4 

9.6 

2.3 

3.4 

43.4 

18.2 

1.3 

15.6 

5.4 

29.2 

307.7 

22.6 

41.6 

0.5 

3.3 

11.1 

2.5 

7.9 

3.9 

32.8 

32.8 

32.8 

32.8 

32.8 

32.8 

32.8 

1.2 

30.6 

49.1 

30.6 

3.4 

12.0 

0.6 

17.4 

5.9 

3.7 

11.4 

73.6 

149.1 

5.8 

3.4 

14.1 

5.7 

4.1 

23.5 

12.7 

3.8 

25.6 

7.6 

12.6 

7.4 

9.8 

2.3 

3.4 

43.4 

16.2 

1.3 

15.6 

5.4 

29.2 

307.7 

22.6 

41.6 

0.5 

3.3 

11.1 

2.5 

7.9 

3.9 

32.8 

32.8 

32.8 

32.8' 

32.8 

32.8 

32.8 

• 

Page 2 

TJ CO 
Gel Coating 

96 97 98 99 

100 

101 

102 

103 

104 

105 

106 

107 

108 

109 

110 

111 

112 

113 

114 

115 

116 

117 

118 

119 

120 

121 

122 

123 

124 

125 

126 

127 

128 

129 

130 

131 

132 

133 

134 

135 

136 

137 

138 

139 

140 

141 

142 

143 

144 

145 

General Marble Company (Guasti) 

General Marble Company (Homed) 

General Marble Company (Uncolnton) 

GlasstJte, Inc 

Miracle Recreation Company 

6. R. Smith, Inc. 

Universal-Rundle Corp. (Ottumwa) 

Fiber Pad, Inc. 

Murphy Body Co. 

Ceramic Cooling Tower Company 

Fiberglass Sytems, Inc. 

Tompkins - Lasco Bathware (Anaheim) 

Blue Dolphin Fiberglass Pools 

Comtech Systems, Inc. 

Continental Camper Company, Inc 

Custom Fibreglass (Manufacturing Co. 

Delta Fiberglass Structures, Inc 

Diamond Coach Corporation 

Fiberglass Forms, Inc 

Fiberglass Products, Inc. 

Fiberglass Specialties, inc 

G. W. Fiberglass. Inc. 

Glasgo Plastics Inc 

Grayson Tool Company 

Mailey Cooling Tower Company 

MFG - Molded Fiber Glass Company (Adelanto) 

Newarteslan Limited Partnership (Marble Plant) 

Red Ewald, Inc 

Syntechnics 

Tompkins - Lasco Bathware (Cordele) 

Tompkins - Lasco Bathware (Moapa) 

Tompkins - Lasco Bathware (Three Rivers) 

Tompkins • Lasco Bathware (Yelm) (aka Hytec Inc) 

United Panel Inc 

VVarminster Fiberglass Company (Jacksonville) 

VVairninstar Fiberglass Company (Southampton) 

Acme Frbergtass, Inc 

ACME Relnforoed Plastics. Inc 

KeatTiey/VVeslem Power Products 

Bristol Fibertte Industries 

MarbeHts Corporation 

Austin Countartops, Inc 

Fiberglass Engineering Corporation 

S.VV.C. Industries, Inc (Swirl-Way Div.) 

Carolina Counters 

Upper! Corporation 

SchrrWrrlarblef'roducts 

Nova Enterprises, Inc 

Superior Home Products 

a\*mttt*\%%\s*t\Ats sf* m .*m m mma\ m *%\ 

•jiwcn corporation 

2 

2 

2 

1 * 8 14 

- •• — 17 +Gel 

1 

4 

4 

4 

1 

1 

2 

1 

1 

1 

1 

2 + RTM 

2 

2 

2 

1 

1246 

124 6 

124 6 

124.6 

124.8 

124.6 

593 0 

20.0 

17.21 

17.6 

77.0 

616.0 

124.6 

27.0 

72.5 

124.0 

23.0 

24.0 

6.0 

30.0 

20.0 

113.7 

.::::;j124>8:sy; 

45.0 

110.0 

46.0 

135.0 

11.0 

140.0 

405.0 

1596.0 

580.0 

525.0 

22.0 

30.0 

37.3 

37.5 

21.0 

42.0 

15.8 

20.0 

26.0 

13.5 

0.3 

10.5 

60.0 

50.0 

13.0 

39.0 

17.3 

37.6 37 6 37 6 

37.6 

37.6 

37.6 

38.0 

38.8 

39.1 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

40.0 

41.4 

43.0 

45.0 

45.0 

45.0 

45.0 

45.0 

45.0 

47.0 

48.0 

50.0 

3 45 

345 

3.45 

3.45 

3.45 

3.45 

3.49 

3.56 

3.59 

3.67 

3.67 

3.67 

3.67 

3.87 

3.87 

3.87 

3.87 

3.87 

3.87 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.87 

3.67 

3.67 

3.67 

3.67 

3.67 

3.87 

3.67 

3.80 

3.95 

4.13 

4.13 

4.13 

4.13 

4.13 

4.13 

4.31 

4.41 

4.59 

1 00 

100 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

3 45 

345 

3.45 

3.45 

3.45 

3.45 

3.49 

3.56 

3.59 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.87 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.67 

3.80 

3.95 

4.13 

4.13 

4.13 

4.13 

4.13 

4.13 

4.31 

4.41 

4.59 

32 8 

32.8 

32.8 

32.8 

32.8 

32.8 

158.0 

5.4 

4.7 

4.9 

21.6 

172.8 

35.0 

7.8 

20.3 

34.8 

6.5 

6.7 

2.2 

8.4 

5.8 

31.9 

35.0 

12.6 

30.9 

12.9 

37.9 

3.1 

39.3 

113.6 

447.7 

162.7 

147.3 

6.2 

8.4 

10.5 

10.5 

5.9 

11.8 

4.5 

6.0 

8.2 

4.3 

0.1 

3.3 

18.9 

15.8 

4.3 

13.1 

6.1 

32 8 

32.8 

32.8 

32.8 

32.8 

32.8 

158.0 

5.4 

4.7 

4.9 

21.6 

172.8 

35.0 

7.6 

20.3 

34.8 

6.5 

6.7 

2.2 

8.4 

5.6 

31.9 

35.0 

12.6 

30.9 

12.9 

37.9 

3.1 

39.3 

113.6 

447.7 

162.7 

147.3 

6.2 

8.4 

10.5 

10.5 

5.9 

11.8 

4.5 

6.0 

8.2 

4.3 

0.1 

3.3 

18.6 

15.8 

4.3 

13.1 

6.1 

Applies with rollers 

Applies with rollers 

VSGelcoat 

_o Pag

e 3 

eo ro 
f Gel Coating 

146 

147 

148 

149 

150 

International Marble Inc. 2 

Marbtocast Products Inc 

Parthenon Marble Products Inc. 

Rynone Manufacturing Corporation-Sayre Plant 

Cameo Marble 

Total 

Average 

Projected Total for 150 facilities 

2 

2 

2 

2 

100 

124 6 

35.6 

50.0 

j47.2 

16323.4 

124.6 

18690.9 

Best performing 12 % of ail compounding facilities are highlighted in bold type. 

MACT Floor• median "styrene control statusl" of top 12% (18) of all facilities « 

I I 

Baseline emissions = Sum of actual current calculated emissions for all facilities 

50.0 

50.0 

50.0 

50.0 

55.0 

5146.4 

37.6 

no control 

4.59 1.00 4 59 

4.59 

4.59 

4.59 

5.05 

450.9 

3.4 

516.3 

1.00 

1.00 

1.00 

1.00 

4.59 

4.59 

4.59 

5.05 

505.8 

3.9 

(MACT emissions « Sum of current emissions for facilities with styrene control status (SCS) values equal to or less than the median 

SCS value plus the sum of emissions equal to (resin)vol*(lb sty/gal RM)*(median styrene control status value)*(0.7013) 

for each facility "with a SCS value greater than the median. 

Therefore, implementing MACT would produce a 0 percent reduction In emissions of HAP from compounding operations. 

Control Status Data and AtsumptJoni; 

A. R. E. has an overall capture efficiency of 100% and a destruction efficiency of 95%. 

U.S. Fiberglass Products has an overall capture efficiency of 90% and a destruction efficiency of 90%. 

Tompkins - Lasco (Elizabethtown) vents 50% to an incinerator with an overall capture efficiency of 50% and a destruction efficiency of 98%. 

Tompkins - Lasco (Lancaster) vents 46% to an incinerator with an overall capture efficiency of 50% and a destruction efficiency of 98%. 

Tompkins • Lasco (South Boston) vents 50% to an incinerator with an overall capture efficiency of 50% and a destruction efficiency of 98%. 

;iG4iw^l**>wur444^;^ues- —y • • I I I 

Filler density was assumed to be 19.2 lbs per gallon. Resin density was assumed to be 9.2 lbs per gallon. 

1 » Gel Coating and Open Molding 

2 = Gel Coating and Polymer Casting 

3 = RTM, Gel Coating, and Open Molding 

4 • Compression Molding, Gel Coating, and Open Molding 

5 • Injection Molding 

6 « Centrifugal Casting and Filament Winding 

7 • Centrifugal Casting 

8 "Pultrusion 

2/22/96 

| 

Process Description Codes; 

9 • BMC, Compression Molding, and Pultrusion 

10 = SMC and Compression Molding 

11 = Compression Molding | 

12 = Filament Winding and Open Molding 

13 = Open Molding | j 

14 = Filament Winding, Gel Coating, and Open Molding 

15 = Compression Molding and Filament Winding 

16 = Polymer Casting and Open Molding 

17 = Continuous Lamination 

I I 

35 , 

43.7 

12.5 

17.5 

18.2 

4339.6 

33.1 

3.5 

43.7 

12.5 

17.5 

18.2' 

4339.6 

33.1 

• - -

Page 4 

TJ 

CO 

CO 
Polymer Casting 

Bank 

1 

2 

3 

4 

6 

6 

7 

8 

8 

10 

11 

12 

13 

14 

15 

18 

17 

18 

16 

_ 

Plant Name 

Uppert Corporation 

Cameo UrUrtole 

Schmltt Marble Products 

International Marble Inc. 

Nova Enterprises, Inc. 

Marbeiite Corporation 

CDR Systems Corporation (Paiatka) 

Superior Home Products 

Cor Tec Company 

Parthenon Marble Products Inc. 

CDR Systems Corporation (Corcoran) 

General Marble Company (Guasti) 

General Marble Company (Homed) 

General Marble Company (Lincolnton) 

Marblecast Products Inc. 

CBI Plant 8 4 

Fsball Enterprises of Utah, Inc. (see Atec) 

Rynone Manufacturing Corporation-Sayre Plant 

Structural North America 

Total 

Average 

Projected Total 

Process Desc. 

Coda 

2 +RTM 

2 

2 

2 

2 

2 

16 

2 

17 + Pol. Cast 

2 

16 

2 

Resin 

asui 

666.9 

433.8 

34.6 

145.0 

111.0 

228.0 

457.0 

448.0 

2100.0 

303.0 

351.0 

% Styrene 

As SuDplied 

27.2 

29.0 

35.0 

33.0 

33.0 

30.0 

32.7 

32.6 

33.0 

35.0 

32.7 

Filler 

am 

6059.0 

1353.5 

138.4 

600.0 

330.0 

561.0 

1147.0 

1076.0 

776.0 

789.0 

726.0 

Ib stryene/ 

gaIRM 

0.53 

1.07 

1.10 

1.14 

1.26 

1.27 

1.36 

1.39 

2.57 

1.43 

1.51 

423.7 34.0 909.0 1.54 

2 423.7 34.0 909.0 1.54 

VSR 

Eacjgx 

1.0 

0.6 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

2 423.7 34.0 909.0 1.54 1.0 

2 423.7 34.0 909.0 1.54 1.0 

Pol. Cast. 423.7 34.0 cbi 

5 • Pol. Cast 

2 

Pol. Cast. 

— • • - -

• - • 

Top 5 performing facilities are highlighted in bold type. 

(MACT Floor • median "styrene control status" of top 5 facilities = 

1 

238.1 

409.2 

16.5 

5932.1 

423.7 

8050.7 

Baseline emissions = Sum of actual current calculated emissions for all facilities 

39.5 

40.0 

43.2 

475.9 

33.99 

MACT emissions = Sum of current emissions for facilities with styrene control status (SCS) values equ 

the sum of emissions equal to (resin * filler)vol*(lb st 

Therefore, implementing MACT would produce a 26. 

Emission Reduction Data and Assumptions; 

y/gal RM)*(median S( 

2 percent reduction in 

-

:S value)*(> 

emissions 

A 40 % emission reduction credit was given (or the use of vapor suppressed resin. 

Facilities using Vacuum bagging received a 45% em 

Grey cells = assumed values 

Finer density was assumed to be 19.2 lbs per gallon. 

1 = Gel Coating and Open Molding 

2 = Gel Coating and Polymer Casting 

3 = RTM. Gel Coaling, and Open Molding 

4 = Compression Molding, Gel Coating, and Open M 

5 = Injection Molding 

6 = Centrifugal Casting and Filament Winding 

7 = Centrifugal Casting 

8 • Pultrusion 

02/13/1996 

ssion reduction credit 

Resin density was a 

164.1 

105.0 

0.9 

12725.9 

" 909.0 

17270.9 

180 

2.73 "'"" 

3.27 

3.66 

32.5 

' 2 2 

i 

i7io 

l 

1.0 

"1.0 " 

1.0 

1.0 

— .... 

...- . _ 

al to or less than the median SCS value 

\P-42 midpoint) for each facility with a SCS value greater 

of HAP from polymer casting operations. j 

_ I i 

ssumed to be 9.2 lbs per gal 

Process Descriotion Codes: 

olding 

• - •• -

• -

: :•. ';•.[• . ' 

on. 

: : 

9 = BMC, Comp 

10 = SMC and C 

ression Molding, and Pultrusion 

ompression Molding 

11= Compression Molding 

12 = Filament Winding and Open Molding 

13 = Open Mold 

14 = Filament W 

15 = Compress ii 

16 = Polymer C< 

ing 

tnding. Gel Coating, and Open Molding 

in Molding and Filament Winding 

isling and Open Molding 

17 * Continuous Lamination 

"Control 

Factor 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

0.55 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

Too" 

1 do 

1.00 

1.00 

plus 

than the rr 

-

Control 

Status 

(Ibstv/oalRM) 

0.53 

0.64 

li^Tiio'Slis? 

1.14 

1.25 

1.27 

1.36 

1.39 

1.42 

1.43 

1.51 

1.54 

1.54 

1.54 

V54 

Teo 

2.73 ' " 

3.27 

3.86 

30.87 

1.62 

-

ledian 

Current Emis. 

am 3.67 

1.51 

0.24 

0.96 

0.73 

1.37 

2.99 

2.92 

7.62 

2.12 

2.30 

MB:?-:-:-

2.88 

2.88 

2.88 

2.88 

1.88 

3.27 

0.14 

46.03 

2.4 

. 

MACT Emis. 

fltryj 

3.57 

1.51 

0.24 

0.92 

0.65 

1.19 

2.42 

2.31 

5.94 

1.63 

1.68 

2.06 

2.06 

2.06 

2.06 

1.77 ' 

0.76 

1.10 

0.04 

33.99 

1.9 

• 

Reduction 

Techniques 

VSR (100%) 

Vac. Bag 

••• -

-

.: 

-

- • 

Page 1 

TJ 

CO 
Pultrusion 

Bank 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

18 

17 

18 

i 

; 

P|antjiame 

Enduro Fiberglass (formerly W. R. Grace) 

Tscton (Fargo) 

CBI Plant # 6 

Clastic Corp.(8outh Euclid) 

Industrial Dielectrics 

Hayslte Reinforced Plastics 

CBI Plant # 7 

Creative Pultruslons, Inc (Alum Bank) 

Carsonite International Corporation 

Dom-Fab (DFI Puttruded Composites) 

Shakespeare Company 

Omega Pultruslons Incorporated 

Enduro Fiberglass Systems, Inc 

R. 0. Werner Company, Inc 

Martey Cooling Tower Company 

IKG Industries 

Glasforms, Inc 

Flberftex, Inc 

Total 

Average 

Projected Total 

Process Desc. 

Cfidfl 

17 + 8 

8 

9 

9 +SMC 

9 • SMC • 17 

8 + 13 

8 

8 + 11 

8 

8 • Rl. Wind. 

8 

RTM+11 + 8 

8 

1+8 

8 + 13 

8 

8 

Top 5 performing facilities are highlighted in bold type. 

MACT Floor = median "control status factor" of top 5 facilities = 

1 

Resin 

am 62 

472.0 

472.0 

472.0 

49.0 

42.5 

55.5 

1560.0 

554.0 

144.0 

200.0 

1269.0 

390.0 

1744.0 

117.0 

207.2 

256.0 

440.0 

7080.2 

472.0 

8024.2 

Baseline emissions • Sum of actual current calculated emissions for all facilities. 

% Styrene 

As Suoolied 

41.21 

45.00 

41.3 

414 

40.7 

41.0 

43.5 

35.0 

40.0 

41.3 

42.0 

42.6 

44.0 

40.0 

40.0 

41.6 

41.5 

45.0 

619.3 

41.3 

Filler 

(toy) 

6 

168.6 

n 

165.5 

70.0 

54.0 

33.1 

62.0 

190.0 

45.0 

70.1 

408.0 

117.0 

76.0 

0.0 

0.0 

0.0 

60.5 

1121.6 

80.1 

1442.1 

1.16 

lb styrene/ 

galBM 

3.6852841 

3.54 

2.20 

3.25 

2.22 

2.34 

3.11 

3.1 S 

3.15 

3.30 

3.30 

3.39 

3.53 

3.60 

3.67 

3.81 

3.81 

3.88 

58.8 

Control 

EaEtox 

0.05 

0.05 

0.53 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

15.2 

MACT emissions * Sum of current emissions for facilities with control status (CS) values equal to or less than the median plus 

Control 

Status 

(Ibstv/oalRM) 

0.179264204 

0.18 

1.16 

1.79 

2,22 

2.34 

3.11 

3.15 

3.15 

3.30 

3.30 

3.39 

3.53 

3.60 

3.67 

3.81 

3.81 

3.88 

Current Emis. 

am 0.08 

0.58 

5.63 

5.90 

1.10 

0.96 

1.33 

30.03 

12.19 

3.27 

4.62 

29.73 

9.44 

38.37 

2.57 

4.73 

5.84 

10.89 

167.2 

9.3 

the sum of emissions equal to (resin • filler)vol*(1b sty/gal RM)*(median CS value)*(AP-42 midpoint) for each facility with a CS value greater than the median. 

1 lll l 

Therefore, implementing MACT would produce a 61.0 percent reduction in emissions of HAP from pultrusion operations. 

Emission Reduction Data and Assumptions; 

Enduro Fiberglass vents 100% to Incinerator, which has 100% capture and 85% destruction efficiency. 

Die resin injection received no emission reduction credit | 

CBI Plant # 5 has an ovaral capture of 50% and a 95% destruction efficiency. 

Glastic Corp. vtrtts 100% to carbon filter, which has 90% capture and 90% destruction efficiency. 

R. P. Werner's fume oolBClor received no emission reduction credit | J 

Facilities with a temperature controlled environment received no emission reduction credit 

Cover«oV4»nclc«edrsslnsreas received r» ensssion reduction credit | | 

FBer density was assumed to be 19.2 lbs per gallon. Resin density was assumed to be 9.2 lbs per gallon. 

.' 

MACT Emis. 

am 0.0589303 

0.68 

S.63 

6.90 

0.57 

0.47 

0.49 

11.00 

4.46 

1.15 

1.62 

10.13 

3.09 

12.32 

0.81 

1.43 

1.77 

3.24 

64.7 

3.6 

Reduction 

Techniques 

Incinerator, die is resin injected 

Incinerator 

Incinerator 

C Alter, covered/enclosed resin bath 

Temperature controlled env. 

Temperature controlled env. 

Covered/enclosed resin bath 

Fume collector, Temp, controlled env. 

covered/enclosed resin bath 

Temperature controlled env. 

Pagel 

CO 

cn 
- & . Pultrusion 

1 • Gel Coating and Open Molding 

2 » Gel Coating and Polymer Casting 

3 » RTM, Gel Coating, and Open Molding 

Process Descriotion Codes: 

4 « Compression Molding, Gel Coating, and Open Molding 

5 «= Injection Molding 

6 • Centrifugal Casting and Filament Winding 

7 • Centrifugal Casting 

8 • Pultrusion 

2/22/96 

II I 9 = BMC, Compression Molding, and Pultrusion 

10 = SMC and Compression Molding 

11 = Compression Molding 

12» Filament Winding and Open Molding 

13 - Open Molding | | 

14 * Filament Winding, Gel Coating, and Open Molding 

15 • Compression (Molding and Filament Winding 

1 6" Polymer Casting and Open Molding | 

17» Continuous Lamination 

1 1 1 

Page 2 
Continuous Lamination, Casting 

Bank 

1 

2 

3 

4 

6 

i 6 

7 

8 

• 9 

10 

11 

12 

13 

< 

Plant name 

Enduro Fiberglass (formally W. R. Grace) 

Cor Tec Company 

CBI Plant # 4 

Crane Kemllte (formerly BP Chemicals) 

Resettle 

Haysite Reinforced Plastics 

Keml'rte Co., Inc 

United Panel Inc. 

Tompkins - Lasco Panel Products (KY) 

Kalwafl Corporation 

SequentJa. Inc.(Grandview) 

Sequentla, lnc(Grand Junction) 

Brady USA (W. H. Brady Co.- Milwaukee) 

Total 

Average 

Projected Total 

Process Desc. 

fiOJjfi 

8 + 17 

17 + Pol. Cast 

17 

17 

17 + 13 

9 + SMC + 17 

17 

17 • Gel 

17 

17 

17 

17 

17 

Top 5 performing facilities are highlighted in bold type. 

MACT Floor - median "styrene control status" of top 5 facilities = 

| 

Resin 

jam 

1287.0 

350.0 

cbl 

7592.8 

1182.0 

927.0 

12218.0 

199.0 

9890.0 

1881.0 

4188.0 

11106.0 

376.0 

51194.50 

4266.21 

55460.71 

Baseline emissions » Sum of actual current calculated emissions for sll facilities. 

% Styrene 

/\8 Supplied. 

41.40 

31.00 

Cbl 

42.0 

25.8 

41.0 

41.3 

58.1 

40.0 

41.0 

42.7 

41.40 

50.0 

495.40 

41.28 

0.91 

Filler 

iBa) 

8.0 

0.0 

cbl 

0.0 

50.0 

1170.0 

6497.0 

264.0 

2380.0 

477.0 

1258.8 

2459.0 

0.0 

14583.80 

1215.32 

15799.12 

lbs Styrene/ 

aaLBM 

3.79 

2.85 

uw 

3.86 

2-29 

2.35 

3.02 

3.17 

3.29 

3.38 

3.43 

3.44 

4.59 

41.23 

3.44 

Control 

Eastoi 

0.06 

0.09 

0.51 

0.63 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

10.17 

0.78 

Styrene Control 

Status 

(lb Sty/gal RM) 

0.19 

0.25 

aw2.02 « 

2.29 

2.35 

3.02 

3.17 

3.29 

3.36 

3.43 

3.44 

4.69 

MACT emissions * Sum of current emissions for facilities with styrene control status (SCS) values equal to or less than the median SCS value plus 

Current Emis. 

am 1.47 

0.53 

Cbl 

92.08 

16.68 

20.90 

277.49 

6.36 

217.58 

42.42 

98.36 

252.88 

10.34 

1036.98 

88.41 

1123.39 

the sum of emissions equal to (resin + flller)voT(lb sty/gal RM)*(median SCS value)*(AP-42 midpoint) for each facility with a SCS value greater than the median. 

Therefore, irrtplementlng MACT would produce a 65.2 percent reduction in emissions of HAP from continuous lamination operations. 

Control factor Data and Assjflrjffllgns; 

Enduro Fiberglass has an overall capture efficiency of 100% and a destruction efficiency of 95%. 

Crane Kemlite has an overall capture efficiency of 50% and a destruction efficiency of 95%. 

Cor Tec has an overall capture efficiency of 94% and a destruction efficiency of 96.9%. | 

CBI Plant #4 has a condenser with an overall capture efficiency of 50% and a destruction efficiency of 99%. 

Covered/enclosed resin areas received no control factor aedit 

Covered mixers received no control factor credit | 

Partially covered mixers received no control factor credit 

Covered holding tanks received no control factor credit 

Rlter density was assumed to be 19.2 lbs per gallon. Resin density was assumed to be 9.2 lbs per gallon. 

1 • Gel Coating and Open Molding 

2 • Gel Coating and F"olymer Casting 

3 « RIM, Gel Coating; and Open Molding 

I 

Process Description Codes: 

4 = Compression Molding, Gel Coating, and Open Molding 

5-lnJrjctionMoldiiig 

6 •= Centrifugal Casting and Fllamerrl Winding 

7 • Centrifugal Casting 

8 » Pulbusion 

02/13/90 

9 > BMC, Compression Molding, and Pultrusion 

10 = SMC and Compression Molding 

11 » Compression iMolding | 

12 a Filament Winding and Open Molding 

13 = Open Molding | | 

14 = Filament Winding. Gel Coating, and Open Molding 

15 a Compression Molding and Filament Winding 

18 = Polymer Casting and Open Molding 

17'a Continuous Lamination 1 

MACT Emis. 

atari 

1.47 

0.53 

cbl 

92.08 

6.67 

8.10 

83.45 

1.82 

80.06 

11.49 

26.09 

66.89 

2.05 

360.57 

30.05 

390.62 

Reduction 

Techniaues 

Incinerator 

Incinerator 

Condenser/C filter 

Incinerator 

Covered mixers 

Partially covered mixers 

Covered mixers 

Covered/enclosed resin area 

Covered/enclosed resin area 

Covered holding tanks 

-

6^ Pagel 

TJ 

CO 

^ l 
Centrifugal Casting 

Rank 

1 

2 

3 

4 

5 

- • • 

Plant, name 

Emsig Manufacturing Corporation 

Fibercast Company 

Raven Industries, lnc.(Sioux Falls) 

CBI Plant #15 

CBI Plant # 2 

Total 

Average 

Projected Total 

Process Description 

Code 

7 

6 + 11 + 13 +BMC 

6 + 1 

6+1 3 

7 

tMACT Floor = median styrene control status of top 5 Facilities = 

| 

Resin 

Mil 

487.3 

318.0 

117.0 

iWMismm. 

192.6 

1114.3 

278.6 

1392.9 

Baseline emissions = Sum of actual current calculated emissions for all facilities. 

% Styrene 

As SuoDlied 

35.1 

42.6 

42.50 

46.0 

50.0 

216.2 

43.2 

Control 

Factor 

0.6 

0.515 

1.0 

1.0 

1.0 

0.425 

Control 

Status 

(Ibsty/qaIRM) 

0.211 

0 219 

'^y^jfrifpr-'-

0.460 

0.500 

1.81 

0.36 

1.81 

Current Emis. 

am 17.70 

12.03 

8.58 

MACT Emis. 

(toy) 

17.70 

12.03 

8.58 

22.10 20.42 

16.56 

77.0 

19.2 

96.2 

MACT emissions = Sum of current emissions for facilities with styrene control status (SCS) values equal to or less than the median SCS value plus 

the sum of emissions equal to (resin)'(median styrene control status)*(EF of 0.075)*2.3 for each facility with a SCS value greater than the median. 

Therefore, implementing MACT would produce a 4.5 percent reduction in emissions of HAP from centrifugal casting operations. 

Emission Reduction Assumptions: 

Fibercast's incinerator has an overall capture efficiency of 50% and a destruction efficiency of 97%. 

A 40 % emission reduction credit was given for the use of vapor suppressed resin. 

Grey cells = assumed values: 

1 = Gel Coating and Open Molding 

2 = Gel Coating and Polymer Casting 

Process Descriotion Code 

--

3 = RTM, Gel Coating, and Open Molding 

4 = Compression Molding. Gel Coating, and Open Molding 

5 = injection Molding | 

6 = Centrifugal Casting and Filament Winding 

J7 = Centrifugal Casting 

!8 = PuUrusion 

2/22/96 

.. .. 

51 

.. 

. . _ ._ H 

9 = BMC, Compression Molding 

10 = SMC and Compression Mo 

11= Compress 

12 ="Filament W 

13 = Open Mold 

14 a Filament VI 

on Molding 

/inding and Oper 

ing 

and Pultrusion 

ding 

i Molding 

/inding. Gel Coating, and Open Molding 

15 = Compression Molding and 

16 = Polymer Casting and Open 

17 = Continuous Lamination 

:

ilament Winding 

Molding 

--• - -

14.08 

72.8 

18.2 

91.0 

-— 

Reduction 

Techniaues 

VSR (100%) 

Incinerator 

- - — • • 

Page 1 

CO 

oo 
Compounding - SMC 

Bank 

i 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

SftrlC 

Plant name 

Navistar International Transportation(Columbus) 

E^le-Pidw Industries Inc(Grabill) 

Industrial Dielectrics 

Budd Company(Van Wert) 

GenCorp Automotive, Inc. (Marion) 

Applied Composites, Corp 

Mertasha Corporation (Watertown) 

Columbia Specialties, Inc. 

Haysite Reinforced Plastics 

Bailey Transportation Products, Inc 

Goodyear Tire & Rubber Co. 

Rockwell International 

MFG • Molded Fiber Glass Companies (Unesville) 

CBI Plant 8 6 

MACT Floor = median "styrene control status" of top 5 facilities » 

Process Description 

Cflflfi 

10 

10 

9 +SMC 

10 

10 

10 

10 

10 

9 + SMC • 17 

10 

10 

10 

10 + BMC 

10 +BMC 

, 

no numerical limit 

Baseline emissions a Sum of actual current calculated emissions for all facilities 

Compound 

SMC 

SMC 

SMC/BMC 

SMC 

SMC 

SMC 

SMC 

SMC 

SMC/BMC 

SMC 

SMC/XMC 

O M w 

SMC 

SMC/BMC/TMC 

Total: 

Average: 

. . .. 

Resin 

am 

2817.0 

3190.0 

1574.0 

5192.0 

4910.0 

2469.0 

2540.1 

1208.0 

112.4 

970.0 

2498.3 

2498.3 

2498.3 

2498.3 

24982.5 

2498.25 

. . 

... . 

% Styrene 

As Supplied 

44.7 

25.9 

41.6 

43.6 

41.7 

40.5 

41.3 

45.0 

40.6 

47.9 

41.3 

41.3 

41.3 

41:3 

412.8 

41.28 

-

Filler 

(tpy) 

8224.0 

7810.0 

4773.0 

15410.0 

12894.0 

6103.0 

5371.4 

2974 

213.0 

1980.0 

6575.2 

6575.2 

6575.2 

6575.2 

65752.4 

6575.24 

Ib styrene/ 

gaLBM 

1.71 

1.10 

1.56 

1.65 

1.70 

1.70 

1.89 

1.90 

1.96 

2.23 

1.68 

1.68 

1.68 

1.68 

MACT emissions a Sum of cunent emissions for facilities with styrene control status (SCS) values equal to or less than the median SCS value plus the sum of 

emissions equal to (resin + filler)voi*(median styrene control status)*(AP-42 midpoint) for each fadliity with a SCS value greater than Ihe median. 

Therefore, implementing MACT would produce a 0 percent reduction in emissions of HAP from compounding operations. 

Control Status Data and Assumptions: 

Navistar's s incinerator has an overall capture efficiency of 80% a 

Filler density was assumed to be 19.2 lbs per gallon. Resin dens 

1 = Gel Coating and Open Molding 

2 a Gel Coating and Polymer Casting 

3 » RTM, Gel Coating, and Open Molding 

4 a Compression Molding, Gel Coating, and Open Molding 

5 = Injection Molding 

6 = Centrifugal Casting and Filament Winding 

7 a Centrifugal Casting 

8 a Pultrusion 

2/14/96 

-

nd a destruction efficiency of 90%. 

ty was assumed to be 9.2 lbs per gallon. 

4

5

fo^sll)"escriDtion"Codes: 

.. . 

9 = BMC, Compress 

10 = SMC and Comr. 

11 = Compression'M 

on Molding, and Pultrusion 

iression Molding 

Olding I 

12 = Filament Winding and Open Molding 

13 = Open Molding

 ; f 

. 

-

14 = Filament Winding, Gel Coating, and Open Molding 

15 = Compression rV 

16 = Polymer Castiru 

Control 

Factor 

0.28 

otding and Filament Winding 

3 and Open Molding 

Control 

Status 

(lb sty/gal RM) 

0.48 

1.10 

1.56 

1.65 

1.70 

1.70 

1.89 

1.90 

1.96 

2.23 

1.68 

1.88 

1.68 

1.68 

- ' 

'JJE: 

17 = Continuous Lamination' ~T ! • 

r 

Current Emis. 

am 7.05 

16.52 

13.10 

45.27 

40.95 

20.00 

20.98 

10.87 

0.91 

9.29 

20.63 

20.63 

20.63 

20.63 

267.45 

19.1 

- --

— • -•- • 

MACT Emis. 

am 7.05 

16.52 

13.10 

45.27 

40.65 

20.00 

20.98 

10.87 

0.91 

9.29 

20.63 

20.63 

20.63 

20;63^ 

267.45 

19.1 

-

Reduction 

Techniques 

Incinerator 

Page 1 
Compounding - BMC 

Rank 

1 

2 

3 

4 

5 

6 

7 

8 

9 

BMC 

Plant name 

Fibercast Company 

CBI Plant # 9 

MFG • Plant 1 • Ashtabula 

Industrial Dielectrics 

Haysite Reinforced Plastics 

MFG - Molded Fiber Glass Company (Linesville) 

Allied Moulded Products, Inc. 

CBI Plant # 6 

Glastic Corp.(South Euclid) 

Process Description 

Code 

6 + 11 +BMC+ 13 

BMC 

11+Wet Mix 

9 +SMC 

9 + SMC + 17 

10 +Wet Mix 

11 +BMC 

10 + BMC/TMC 

9 

Total: 

Average: 

Projected Total: 

Top 5 performing facilities are highlighted in bold type. 

MACT Floor = median "styrene control status" of top 5 facilities = no numerical limit 

| 

Baseline emissions = Sum of actual current calculated emissions for all facilities 

Resin 

am 

127.0 

1009.0 

2012.0 

1574.0 

112.4 

425.0 

1254.4 

cbi 

n 

6513.8 

930.5 

% Styrene 

As SuDDlied 

14.1 

28.7 

16.2 

41.6 

40.6 

15.25 

28.9 

* 

n 

185.4 

26.5 

Filler 

(toy) 

302.0 

8347.0 

810.0 

4773.0 

213.0 

2689.0 

2889.0 

• 

n 

14445.0 

2889.0 

lb styrene/ 

oalRM 

0.61 

0.53 

1.25 

1.56 

1.96 

0.33 

1.26 

8.26 

0.98 

Control 

Factor 

0.515 

0.19 

MACT emissions = Sum of current emissions tor facilities with control status (CS) values equal to or less than the median CS value plus the sum of 

emissions equal to (resin + filler)vol*(median control status)*(AP-42 midpoint) for each fadliity with a CS value greater than the median. 

Therefore, implementing MACT would produce a 0 percent reduction in emissions of HAP from compounding operations. 

Control Status Data and Assumptions: 

Fibercast1 s incinerator has an overall capture efficiency of 50% and a destruction efficiency of 97%. 

Glastjc's carbon filter has an overall capture efficiency of 90% and a destruction efficiency of 90%. 

Filler density was assumed to be 19.2 lbs per gallon. 

Grey cells = assumed values 

1 = Gel Coating and Open Molding 

2 = Gel Coating and Polymer Casting 

3 = RTM, Gel Coating, and Open Molding 

Resin density was assumed to be 9.2 lbs 

Process Descrirjtion Codes: 

4 = Compression Molding, Gel Coating, and Open Molding 

5 a injection Molding 

6 a Centrifugal Casting and Filament Winding 

7 a Centrifugal Casting 

8 = Pultrusion 

2/22/96 

per gallon. 

9 = BMC, Compression Molding, and Pultrusion 

10 = SMC and Compression Molding 

11 a Compression Molding 

12 a Filament Winding and Open Molding 

13 = Open Molding | ( 

14 = Filament Winding, Gel Coating, and Open Molding 

15 a Compression Molding and Filament Winding 

16 a Polymer Casting and Open Molding 

17 a Continuous Lamination 

I I 

Control 

Status 

(lb stv/aal RM) 

0.31 

0.53 

1.25 

1.56 

1.96 

n 

n 

n 

n 

Current Emis. 

(toy) 

0.18 

5.78 

6.52 

13.10 

0.91 

1.30 

7.30 

n 

n 

35.10 

5.0 

45.1 

MACT Emis. 

am 0.18 

5.79 

6.52 

13.10 

0.91 

1.30 

7.30 

n 

n 

35.10 

5.0 

45.1 

Reduction 

Techniques 

Incinerator 

Carbon Filter 

Page 1 
RTM 

Ban* 

1 

2 

3 

4 

5 

6 

7 

6 

9 

R I M 

Plant name 

Livingston Inc. 

Plasti-Fab Inc. 

(Millennium Products, Inc 

Associated Plastics, Inc 

Contemporary Products, Inc 

E-T-M Enterprises, Inc 

Lippert Corporation 

Enduro Fiberglass Systems, Inc. 

Century Manufacturing Company 

MACT Floor = median "styrene conti 

Process Desc 

Coda 

3 

3 

3 

3 

3 

RTM • Gel 

2 +RTM 

RTM+11 +8 

3 

Total: 

Average: 

rol status" of top 5 

Resin 

ito*) 

170.0 

29.0 

30.0 

140.0 

% Styrene 

As Supplied 

40.8 

40.S 

Filler 

om 

75.0 

0.0 

43.6 0.0 

43.6 0 0 

73.8 43.8 0.0 

73.8 43.8 0.0 

73.8 43.8 0.0 

63.4 

10.5 

442.9 

73.8 

43.79 

50.0 

175.1 

43.8 

facilities a no numerical limit 

1 1 1 

Baseline emissions = Sum of actual current calculated emissions for all facilities 

Assumptions; 

Grey oeiis

 = assumed values 

Filler density was assumed to be 19 

1 a Gel Coating and Open Molding 

2 a Gel Coating and Polymer Castin 

3 a RTM, Gel Coating, and Open M< 

4 a Compression Molding. Gel Coat 

5 a Injection Molding 

6 a Centrifugal Casting and Filamen 

7 = Centrifugal Casting 

8 a Pultrusion 

2/13/96 

• •• — 

0 

0 

lb styrene/ 

oilfiM 

3.09 

3.72 

4.02 

4.02 

4.02 

4.02 

4.02 

4.02 

4.59 

2 lbs per gallon. Resin density was assumed to be 8.2 lbs per gallon. 

Process Descript 

9 

siding 

ng, and Open Mo 

t Winding 

__ 

on Codes: 

ding 

' " -

• •• i — 

! 

Control 

Fjctor 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1 

i 

9 a BMC. Compression Molding, and Pultrusion 

10 a SMC and Compression Molding 

11 = Compression Molding | 

12 = Filament Winding and Open Molding 

13 = Open Molding | 

14 = Filament Winding, Gel Coating, and Open Molding 

15 a Compression Molding and Filament Winding 

16 = Polymer Casting and Of 

17 a Continuous Lamination 

>en Molding 

... _ 

Styrene Control 

Status 

(lostWaalRM) 

3.09 

3.72 

4.02 

4.02 

4.02 

4.02 

4.02 

4.02 

4.59 

-

— 

Current Emis. 

OCtf) 

1.39 

0.23 

0.26 

1.23 

0.85 

0.65 

0.65 

0.56 

0.11 

5.71 

. 

iMACT Emis. 

am 

1.39 

0.23 

0.26 

1.23 

0.65 

0.65 

0.65 

0.56 

0.09 

5.70 

Reduction 

Techniques 

— 

o 

Page 1 

TJ 

ro 
1 s 

Back 

i 

2 

3 

4 

S 

6 

7 

8 

9 

10 

11 

12 

13 

14 

16 

16 

17 

18 

19 

20 

21 

22 

23 

24 

25 

26 

27 

28 

29 

30 

31 

32 

33 

34 

35 

38 

37 

38 

39 

40 

41 

42 

Compression Molding 

PtanLname 

Fibercast Company 

Budd C4jmpany(North Baltimore) 

Budd Company(Carey) 

Budd CompanyfVan Wart) 

Eagle-Picher Industries, Inc.(Huntlngton) 

Eagle-Picher Plastics Dtv.(Ashley) 

MFG • Molded Rber Glass Company (Plant 2 • Ashtabula) 

Applied C4jmposites, Corp 

GenCorp Automotive, Inc (Marion) 

Navistar International Transportation(Columbus) 

Picken's Plastics, Inc 

Menasha Corporation (Watertown) 

Columbia Specialties. Inc 

MFG - (Molded Fiber Glass Company (F»1ant 1 - Astitabuta) 

Nordic Rberglass lnc(Devils Lake) 

Prodetin terporatton (Catawba Facility) 

Men Industries 

Eagle-Picher Industries Inc(GrebiH) 

Warminster Fiberglass Company (Southampton) a 

Haysite Reinforced Plastics 

Allied Moulded Products, Inc. 

ACME Reinforced Plastics, Inc. 

Krueger International Inc 

Industrial Dielectrics 

Bailey Transportation Products, Inc 

Molded Plastic Industries, Inc 

Carsontte International Corporation 

Enduro Fiberglass Systems. Inc. 

MFG • Molded Fiber Glass Company (Union City) 

Allied Signal Laminate Systems 

Ameron Inc. (Burkburnett) 

Bering Wichita 

CBIPtant«6 

Gencorp Automotive, Reinforced Plastic Div. (Ionia) 

Ghntic Corp.(South Euclid) 

Goodyaar Tire & Rubber Co. 

MFO • Molded Fiber Glass Company (Llnesville) 

Plastk} CpmfjXMltes Corporation 

Oft_*_r____\ _f*j__tt_-1ljtJ\a\\\ 

Smith (tfcargtass Products lnc(Uttje Rock) 

Spautdtng C4xnposites Co. (Specialty Plastics Div.) 

Sterling Plumbing Group, Inc. 

Process Description 

Coda 

6 + 11+BMC + 8 

11 

11 

10 

11 

11 

11 

10 

10 

10 

4 

10 

10 

11 + B4MC 

4 

4 

11 + 5 

10 

4 

9 + SMC + 17 

11+BMC 

4 

4 

9 +SMC 

10 

4 

11 + 8 

11 +RTM+ 8 

4 

11 

15 

11 + 13 

10 + BMC 

11 

9 

10 

10 +BMC 

4 

10 

15+13 

15 

11 

Total: 

Average: 

Projected Total: 

Compression Molding 

Resin 

.(toy) 

178.0 

7060.0 

7860.0 

660.0 

6000 

5000 

2577.0 

8700.0 

17800.0 

2760.0 

13.0 

8000.0 

3672 

2012.0 

75.0 

860.0 

193.0 

11000.0 

97.0 

289 

1207.0 

63.0 

65.0 

157.0 

934.0 

143.2 

11 

71.5 

42.0 

n 

n 

n 

cbl 

n 

n 

n 

1112.0 

n 

n 

n 

n 

n 

% Styrene 

As Supplied 

10.1 

11.0 

114) 

11.0 

11.11 

11.11 

12.8 

11.5 

11.5 

21.50 

12.0 

13.1 

13.2 

16.2 

14.5 

15.0 

21.5 

20.0 

20.0 

41 

30.0 

30.0 

30.0 

41.6 

51.0 

33.5 

40 

43.1 

54.9 

n 

n 

n 

cbl 

n 

n 

n 

21.50 

n 

n 

n 

n 

50.0 

Pagel 

•Titer -

(tpy) 

222.0 

0.0 

0.0 

0.0 

0 

0 

799.0 

0.0 

0.0 

4912.0 

0.0 

0.0 

0 

810.0 

0.0 

0.0 

132 

0.0 

0.0 

370 

34.0 

0.0 

0.0 

125.0 

1150.0 

0.0 

3 

0.0 

0.0 

n 

n 

n 

cbl 

n 

n 

n 

y 

n 

n 

n 

n 

y 

ib styrene/ 

galRM 

0.58 

1.01 

1.01 

1.01 

1.02 

1.02 

1.03 

1.06 

1.06 

1.07 

1.10 

1.20 

1.21 

1.25 

1.33 

1.38 

1.49 

1.84 

1.84 

2.33 

2.72 

2.75 

2.75 

2.77 

2.95 

3.08 

3.25 

3.96 

5.04 

n 

n 

n 

cbl 

n 

n 

n 

n 

n 

n 

n 

n 

n 

Control 

Eaflox 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

1.0 

Control 

Status 

fib sty/gal RM) 

0.58 

1.01 

1.01 

S1.02 » 

1.02 

1.03 

1.08 

1.06 

1.07 

1.10 

1.20 

1.21 

1.25 

1.33 

1.38 

1.49 

1.84 

1.84 

2.33 

2.72 

2.75 

2.75 

2.77 

2.85 

3.08 

3.25 

3.98 

5.04 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

Current Emis. 

ftov) 

0.36 

15.53 

17.29 

1.23 

11.11 

11.11 

6.61 

20.01 

40.94 

11.87 

0.03 

20.99 

9.69 

6.52 

0.22 

2.58 

0.83 

44.00 

0.39 

2.37 

7.24 

0.32 

0.39 

1.31 

9.53 

0.96 

0.09 

0.62 

0.46 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

244.60 

8.43 

354.24 

MACT Emis. 

am 0.36 

15.53 

17.29 

1.23 

11.11 

11.11 

. 6.61 

20.01 

40.94 

11.67 

0.03 

20.99 

9.69 

6.52 

0.22 

2.58 

0.83 

44.00 

0.39 

2.37 

7.24 

0.32 

0.39 

1.31 

9.53 

0.96 

0.09 

0.82 

0.46 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

n 

244.60 

8.43 

354.24 
9 Compression Molding 

Assumption; | | | 

Filler density was assumed to be 19.2 lbs per gallon. Resin density was assumed to be 9.2 lbs per gallon. 

1 > Gel Coating and Open Molding 

2 a Gel Coating and Polymer Casting 

3 > RTM, Gel Coating, and Open Molding 

4 a Compression Molding, Gel Coating, and Open Molding 

5 > Injection Molding 

6 » Centrifugal Casting and Filament Winding 

7 a Centrifugal Casting 

8 a Pultrusion 

02/13/96 

1 Process Description Codes; 

9 a BMC, Compression Molding, and Pultrusion 

10 > SMC and C4xnpresslon Molding 

11 • C«Tipression (Molding 

12 > Filament Winding and Open Molding 

13-Open Molding | | 

14 a Filament Winding, Gel Coating, and Open Molding 

15 a Compression Molding and Filament Winding 

16 a Polymer Casting and Open Molding 

17 a Continuous Lamination | 

1 1 1 

Page 2 

TJ 
Injection Molding 

Rank 

1 

2 

. 3 

4 

5 

I 

Plant_namn 

tten Industries 

GMC (Inland Fisher Guide Div.) 

Square D Company (Lincoln) 

Glastic Corp.(Jefferson) 

Faball Enterprises of Utah, Inc (se e Ate 

Process Description 

Coda 

5 + 11 

5 

5 

5 

5 + Polymer Casting 

Total: 

Resin 

itov) 

193 

4850 

4750.0 

% Styrene 

As Supplied 

21.5 

17 

15.25 

4800.0 16.1 

4800.0 16.1 

9793.0 

MACT Floor a median "styrene control status" of top 5 facilities = no numerical limit 

I I 

BasePne emissions a Sum of actual cunent calculated emissions for all facilities 

Assumptions: 

Greyt^'asMWiedvSruM 

Rller density was assumed to be 19.2 lbs 

1 a Gel Coating and Open Molding 

2 a Gel Coating and Polymer Casting 

3

 B RTM, Gel Coating, and Open MokJinj 

Filler 

(1BVJ 

132 

0 

100 

0.0 

0.0 

per gallon. Resin density was assumed to be 9.2 lbs per gallon. 

I 

process Descriptiqn Codes; 

4 a Compression Molding, Gel Coating, and Open Molding 

5 a injection Molding | 

8

 a Centrifugal Casting and Filament Winding 

7 a Centrifugal Casting 

8 = Pultrusion 

2/13/96 

9 a BMC, Compression Molding, and Pultrusion 

10 a SMC and Compression Molding 

11 a compression Molding | 

12a Filament Winding and Open Molding 

13 a Open Molding [ 

Ib styrene/ 

gaLBM 

1.49 

1.56 

1.39 

1.46 

1.48 

14 a Filament Winding, Gel Coating, and Open Molding 

15 a Compression Molding and Filament Winding 

16 a Polymer Casting and Open Molding 

17 a Continuous Lamination 

Control 

Factor 

1 

1 

1.0 

1.0 

1.0 

Styrene Control 

Status 

(ibstv/galRMl 

1.49 

1.56 

1.39 

1.48 

1.48 

Current Emis. 

am 0.83 

16.49 

14.49 

15.48 

15.48 

62.78 

MACT Emis. 

am 0.83 

16.49 

14.49 

15.46 

15.48 

62.78 

Reduction 

Techniaues 

o. 

Pagel 

TJ 

CJI 
Filament Winding 

Bank 

i 

2 

3 

4 

5 

8 

7 

8 

9 

10 

"ii" 

"12 

13 

14 

15 

16 

17 

16 

19 

20 

21 

22 

23 

24 

25 

26 

27 

2B 

29 

30 

31 

Plant Name 

Shakespeare Company 

Balding Tank Technology (F.K.A. D & R Fabri 

BaaMa Plastics, Inc. 

Raven Industries, lnc.(Sloux Falls) 

Owens-Coming (Aubumdale) 

Owens-Corning (Mount Union) 

Owens-Coming Fiberglas (Conroe) 

Owens-Coming Tanks (Valparaiso) 

Red Ewald. Inc. 

Rubber & Plastic Applicators 

Ameron Inc. (Burkbumett) 

Fowler Manufacturing, Inc. 

GPI Corporation 

CBI Plant* 15 

Hastings Group, Inc-Viatec (Belding) 

Ershigs, Inc(Bellingham) 

Ecowater Systems 

MFG Justin Tanks, Inc. 

Diamond Fiberglass Fabricators. Inc. 

Owens-Coming Fiberglas (Bakersfield) 

Spaulding Composites Co. (Specialty Plastics Di 

Applachian Plastics, Inc. 

Fibercast Company 

Ershigs. Inc.fWUson) 

Slmon-Telelect Inc. 

An-Cor Industrial Plastics, Inc. 

Fibrex Corporation 

Jones 4 Hunt, Inc. 

Smith Fiberglass Products lnc.(Little Rock) 

Smith Fiberglass Products lnc.(Wichila) 

CBI Plant * 16 

Totals 

Process besc. 

Coda 

8 + FU. Wind. 

14 

12 

6 + 1 

12 

12 

12 

12 

14 

12 

15 

12 

14 

6+1 3 

Fil. Wind. 

14 

Fil. Wind. 

12 

14 

12 

15 

14 

6+1 1 • BMC + 13 

14 

14 

12 

12 

12 

12 + 11 

Fil. Wind. 

12 

Average; 

Projected Total i 

Top 6 performing facilties are highlighted in bold type. 

MACT Floor a median styrene content as supplied of (op 

Baselii 

MACT 

(resin) 

L .. . 

5 facilities = 

ie emissions a actual current projected emissions for all facilities 

Resin 

jim 

739.4 

n 

177.3 

21.2 

n 

n 

n 

n 

294.7 

146.0 " 

_2.5 

n 

131.5 

n 

400.0 

226.1 

122.0 

153.3 

254.0 

n 

• 

100.0 

83.0 

87.0 

65.0 

n 

n 

n 

n 

n 

n 

3003.0 

187.7 

5818.3 

"42.2 

% Styrene 

As supplied 

33.0 

40.0 

42.2 

42.7 

L_ 45.0 

45.0 

45.0 

45.0 

45.0 

45.0 

"45.0 

45.0 

46.0 

46.0 

46.3 

47.6 

48.0 

49.0 

49.0 

50.0 

• 

7 

7 

? 

? -

n 

n 

n 

n 

ti 

n 

899.8 

45.0 

Filter 

(tttt) 

y 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

9-?. 

n 

0.0 

n 

0.0 

0.0 

0.0 

0.0 

0.0 

y 

* 

20.0 

1.0 

" 0.0 

ao 

n 

n 

n 

"oo 

As aoolied% 

7 

40.0 

42J 

42.7 

4ifi 

45.0 

45.0 

45.0 

45.0 

45.0 

45.0 

46.0 

7 

46.3 

47.6 

48.0 

49.0 

49.0 

7 

? 

7 

43.0 

43.8 "'" 

43.6 " 

7 

7 

7 

? 

n i 7 

n j 7 

21.0 ' 855.9TM"" 

1.0 ! 42.8" 

31.0 ! 

- 3.87 lb styrene/gal RM 

i 

i • 

emissions * Sum of current emissions from all facilities using less than 42.2% styrene resins as supplied plus the sum 

•(3.87 lb styrene/gal RM)*(0.075)'(2.3) for all facilities using resins with more than 42.2% styrene as supplied. 

i " :::..r .

 ; ~: : 

MACT produces a 7 2 percent reduction in emissions of HAPs from filament winding operations. 

! ' • - | : • • 

JAsajmotign, j i 

iFitler density was assumed to be 19.2 lbs per gan on. Resin density « rasassum sd to be 9.2 ite iper gallon 

Ib stryene/ 

gaIRM 

3.03 

3.67 

3.87 

3.92 

4.13 

4.13 

4.13 

4.13 

4.13 

4.13 

4.13 " 

4.13 

4.22 

4.22 

4.25 

4.37 

4.41 

4.50 

4.50 

4.59 

• 

? 

? 

'"? 

? 

n 

n 

n 

n 

n 

n 

82.6 

...... 

"128. 0 

of emissions 

• 

Control 

Factor 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

i.oo 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

1.00 

iM ' 

1.00 

equal to 

Control _. 

Status 

(lb sty/gal RM) 

3.03 

3.67 

3.87 

3.92 

4.13 

4.13 

4.13 

4.13 

4.13 

4.13 

4.13 

4.13"" 

4.22 

4.22 

4.25 

4.37 

4.41 

4.50 

4.50 

4.59 

• 

7 

7 

7 

7 

n 

n 

n 

n 

n 

n 

- - -•• 

Current Emis. 

am 

42.1 

n 

12.9 

1.6 

n 

n 

n 

n 

22.9 

11.3 

6.2 __'_ 

n 

10.4 

n 

31.9 

18.6 

10.1 

13.0 

21.5 

n 

• 

7 

7 

7 

7 

n 

n 

n 

n 

n 

n 

196.4 

16.4 

507.5 

. 

MACT Emis. 

am 

42.1 

n 

12.9 

1.5 

n 

n 

n 

n 

21.4 

10.6 

"n 

6.6 

n 

29.1 

16.4 

8.9 

11.1 

18.5 

n 

* 

? 

7 

? 

7 

n 

n 

n 

n 

n 

n 

182.3 

15.2 

471.0 

.. . . ._ 

Reduction 

Techniques 

• — 

some enclosed mixers 

.... . 

Page 1 

TJ 
C7 

en 

Filament Winding 

n a Facility did not provide this information. 

y a Facility indicated the use of filler but did not quantify the amount. 

1 a Gel Coating and Open Molding 

2 a Gel Coating and Polymer Casting 

3 a RTM, Gel Coating, and Open Molding 

Process Description Codes; 

4 a Compression Molding, Gel Coating, and Open Molding 

5 a injection Molding 

6 a Centrifugal Casting and Filament Winding 

7 a Centrifugal Casting 

8 = Pultrusion 

2/22/96 

•• - ---

9 a BMC, Compression Molding, and Pultrusion 

10 a SM C and Compression Molding 

11a Compression Molding 

12 a Filament Winding and Open Molding 

13 a open Molding | | 

14 a Filament Winding, Gel Coating, and Open Molding 

15 a Compression Molding and Filament Winding 

16 a Polymer Casting and Open Molding 

17 a Continuous Lamination 

I I 

• 

__ 

i 

- — 

i 

Page 2 

XI