p.1 

OAR Box 1413 

Prepped by Ollie Stewart 

Document Number: 

56) 11-1-56 

Docket Number: 

A-94-52 

Printed 7/9/2008 3:11:22 PM Sheet 56 of 114 
P.2 

\Composites Corp. 

A 945' 

II-I-^6 

December 5, 1995 

Mr. Donald Sutton 

IEPA 

Division of Air Pollution Control 

Permit Section 

2200 Churchill Rd. 

Springfield, IL 62706 

RE: Joint Construction/Operating Permit Application 

m n \m 

EPA AlH DOCKEVf 

Dear Mr. Sutton: 

Applied Composites Corporation respectfully submits the enclosed 

application for a Joint Construction/Operating Permit for the 

installation of Polyurethane Foam Injection Equipment. The 

equipment will be used to inject water-blown foam insulation into 

closed cavities of molded fiberglass reinforced plastic articles. 

The installation and use of the foam injection equipment will not 

result in a significant increase in plant VOM emissions as 

explained in Appendix A of the application. 

Please contact me at (708) 584-3130 if you have any questions or 

require further information. 

Terry Ha(w/tree 

HSEQ Coordinator. 

333 North Sixth Street • St. Charles. Illinois 60174 • 708 / 584-3 1 30 • Fax: 708 / 584-0659 
P_3_ 

" I 

M 

APPLIED COMPOSITES, CORP, 

Application For Joint 

Construction And 

Operating Permit 

Submitted By: 

Applied Composites, Corp. 

333 North Sixth St. 

St. Charles, IL 60174 

Prepared By: 

Terry Hawtree 

HSEQ Coordinator 

Applied Composites, Corp. 

December 5, 1995 

^ 
. . __ _ PA_ 

TABLE OF CONTENTS 

SECTION 

Cover Lette r 

MDI Foam Injectio n 1 

APC 200 

APC 220 MDI Foam Injection Equipment 

Exhibit B 

Appendix A 

Process Schematics 

Facility Diagram 

3 
P.5 

SECTION 1 

MDI FOAM INJECTION 

M 
P.6 

APC 200 

s 
P.7 

STATE OF ILUNOIS 

ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL 

2200 CHURCHILL ROAD 

SPRINGFIELD, ILLINOIS 62794-9276 

APPUCATION FOR PERMITW 

Q D CONSTRUCT Q 0 OPERATE 

NAME OF EQUIPMENT TO BE 

CONSTRUCTED OR OPERATED MDI Foam Injection 

.(8) 

LD. NO. 

PERMIT NO. 

OATE 

FOR AGENCY USE ONLY 

la. NAMEOFOWNER: Applie d Composites, Corp. 

lb STREET ADDRESS OF OWNER- „„ „ , , L „ 

333 North 6th Stree t 

la CITYOFOWNER: ^ charlej _ 

Id. STATE OF OWNER: 

Illinoi s 

1e. ZIP CODE: 

60174 

2a. 

2b. 

2c 

2d. 

NAME OF OPERATOR: gAM E 

STREET ADDRESS OF OPERATOR: 

CITY OF OPERATOR: 

STATE OF OPERATOR: 2e. ZIP CODE: 

la. NAME OF CORPORATE DIVISION OR PLANT: 

Applie d Composites, Corp. 

lc CITY OF EMISSION SOURCE: 

S t . Charle s 

3d. LOCATED WITHIN CITY 

UMITS: £X]YES 1 INO 

3b. STREET ADDRESS OF EMISSION SOURCE: 

333 North 6th Stree t 

3e. TOWNSHIP: 

St.-Charle s 

3(. COUNTY: 

Kane 

3g. ZIP CODE: 

60174 

. ALL CORRESPONDENCE TO: (TITLE ANO/OR NAME OF INDIVIDUAL) 

John ,T. Pnnis . V: P. . Operations 

5. TELEPHONE NUMBER FOR AGENCY TO CALL: 

(708 ) 584-3130 

. ADDRESS FOR CORRESPONDENCE: (CHECK ONLY ONE) 

I X | OWNER 1 I OPERATOR I I EMISSION SOURCE 

7. YOUR DESIGNATION FOR THIS APPUCATION*, 

MDI 

THE UNDERSIGNED HEREBY MAKES APPLICATION FOR A PERMIT ANO CER~nF~ES THAT THE STATEMENTS CONTAINED HEREIN ARE TRUE AND 

CORRECT. ANO FURTHER CERTIFIES THAT ALL PREVIOUSLY SUBMITTED MFORMATION REFERENCED IN THIS APPUCATION REMAINS TRUE. 

CORRECT AND CURRENT. BY AFFIXING HIS SIGNATURE HERETO HE FURTHER CERTFES THAT HE IS AUTHORIZED TO EXECUTE THIS APPLICATION. 

John 

OATE 

BY 

SIGNATURE OATE 

TYPED OR PRINTED NAME OF StGNEf 

V. P. Operations 

TYPED OR PRINTED NAME OF SIGNER 

TITLE OF SIGNER TITLE OF SIGNER 

J THIS FORM IS TO PROVIDE THE AGENCY WITH GENERAL INFORMATION ABOUTTHE EQUIPMENT TO BE CONSTRUCTED OR OPERATED. THIS FORM 

MAY BE USED TO REQUEST A CONSTRUCTION PERMIT. AN OPERATING PERMIT. A CONSTRUCTION OR OPERATING PERMIT. 

) ENTER THE GENERIC NAME OF THE EQUIPMENT TO BE CONSTRUCTED OR OPERATED. THIS NAME Wtti. APPEAR ON THE PERMIT WHICH MAY BE 

ISSUED PURSUANT TO THIS APPUCATION. THIS FORM MUST BE ACCOMPANIED BY OTHER APPLICABLE FORMS ANO INFORMATION. 

PROVIDE A DESIGNATION IN ITEM 7 ABOVE WHICH YOU WOULD LIKE THE AGENCY TO USE FOR IDENTIFICA-nON OF YOUR EQUIPMENT. YOUR 

DESIGNATION WOJ. BE REFERENCED IN CORRESPONDENCE FROM THIS AGENCY RELATIVE TO THIS APPUCATION. YOUR DESIGNATION MUST NOT 

EXCEED TEN (10) CHARACTERS. 

J THIS APPLICATION MUST BE SIGNED IN ACCORDANCE WITH 35 OJL. ADM. CCOE 201.1S4 OR 201.159 WHICH STATES: "ALL APPLICATIONS AND SUPPLEMENTS THERETO SHALL BE SIGNED BY THE OWNER ANO OPERATOR OF THE EMISSION SOURCE OR AIR POLLUTION CONTROL EQUIPMENT. OR T>€lf 

AUTHORIZED AGENT. ANO SHALL BE ACCOMPANIED BY EVIDENCE OF AUTHORITY TO SIGN THE APPLCATION.-

IF T>£ ONWER OR OPERATOR IS A CORPORATION. SUCH CORPORATION MUST HAVE ON FILE WrTH THE AGENCY A CERTtFtED COPY OF A RESOU* 

TON OF THE CORPORATION'S BOARD OF DIRECTORS AUTHORIZING THE PERSONS SIGNING THIS APPLICATION TO CAUSE OR-ALLOW THE CONSTRUCTION OR OPERATION OF THE EQUIPMENT TO BE COVERED BY THE PERMIT. 

.32-0238 Printraat .(P 

PAGE 1 OF 2 
P.8 

DOES THIS APPUCATION CONTAIN A PLOT PLAN/MAP: 

P H YES I I NO 

ir A PLOT PLAN/MAP HAS PREVIOUSLY BEEN SUBMITTED. SPECIFY: 

AGENCY I.D. NUMBER 08948 3 A A F APPUCATION NUMBER 9305006 6 

IS IHE APPROXIMATE SIZE OF APPUCANTS PREMISES LESS THAN 1 ACRE? 

I I YES ' [ X | MO : SPECIFY. 40 ACRES 

DOES THIS APPUCATION CONTAIN A PROCESS FLOW DIAGRAM(S) THAT ACCURATELY AND CLEARLY REPRESENTS CURRENT 

PRACTICE. 

PHYE S | | NO 

L WAS ANY EQUIPMENT. COVERED THIS APPUCATION. OWNED 

I CONTRACTED FOR. BY THE APPUCANT PRIOR TO APRIL 14.1972: 

11b. HAS ANY EQUIPMENT. COVERED BY THIS APPUCA 

TION. NOTPREVIOUSLY RECEIVED AN OPERATING 

• YES 

PERMIT: 

X NO ODYES • NO 

"F "YES" ATTACH AN ADDITIONAL SHEET. EXHIBIT A. THAT: 

(a) LISTS OR DESCRIBES THE EQUIPMENT 

(b) STATES WHETHER THE EQUIPMENT WAS tN COMPLIANCE 

WITH THE RULES AND REGULATIONS GOVERNING THE 

CONTROL OF AIR POLLUTION PRIOR TO APR! 4.1072 

F -YES". ATTACH AN ADOITIONAl. SHEET. EXHIBIT B. THAT: 

M 

0» 

(e) 

LISTS OR DESCRIBES THE EQUIPMENT 

STATES WHETHER THE EOUIPMENT 

(I) IS ORIGINAL OR ADOmONAL EQUIPMENT 

M REPLACES EXISTING EQUIPMENT. OR 

(B) MOOFES EXISTING EQUIPMENT 

PROVIDES THE ANTICIPATED OR ACTUAL OATES OF 

THE COMMENCEMENT OF CONSTRUCTION AND THE 

START-UP OF THE EOUIPMENT 

IF THIS APPUCATION INCORPORATES BY REFERENCE A PREVIOUSLY GRANTED PERMITfS). HAS FORM APC-210. "DATA AND 

INFORMATION—JNCORPORATTON BY REFERENCE* BEEN COMPLETED. NO 

13. DOES THE STARTUP OF AN EMISSION SOURCE COVERED BY THIS APPUCATION PRODUCE AIR CONTAMINANT EMISSION IN 

EXCESS OF APPUCABLE STANDARDS: 

• YES 0 0 

NO 

IF -YES.* HAS FORM APC-203. "OPERATION DURING STARTUP* BEEN COMPLETED FOR THIS SOURCE. 

I I YES C NO 

14. DOES THIS APPUCATION REQUEST PERMISSION TO OPREATE AN EMISSION SOURCE DURING MALFUNCTIONS OR 

BREAKDOWNS: 

I lYES I X I NO 

IF "YES." HAS FORM APC-204. -OPERATION DURING MALFUNCTION AND BREAKDOWN* BEEN COMPLETED FOR THIS SOURCE 

• VES (—] NO 

15. IS AN EMISSION SOURCE COVERED BY THIS APPUCATION SUBJECT TO A FUTURE COMPLIANCE OATE: 

I IV-ES I X IMP 

IF *YES.* HAS FORM APC-202. "COMPLIANCE PROGRAM & PROJECT COMPLETION SCHEDULE.* BEEN COMPLETED FOR IM S 

SOURCE: 

I I YES NO 

16. DOES THE FACIUTY COVERED BY THIS APPUCATION REQUIRE AN EPISODE ACTION PLAN (REFER TO GUIDEUNES FOR 

EPISODE ACTION PLANS): 

I I YES | X | NO 

UST AND IDENTIFY ALL FORMS. EXHIBITS. AND OTHER INFORMATION SUBMITTED AS PART OF THIS APPUCATION. INCLUDE THE 

PAGE NUMBERS OF EACH ITEM (ATTACH ADDITIONAL SHEETS IF NECESSARY): 

SEE TABLE OF CONTENTS 

TOTAL NUMBER OF PAGES 

2-0238 

inn na. n 

PAGE20F 2 
P.9 

APC 220 

fl 
P.10 

STATE Of lUINOIS 

ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIK POLLUTION CONTROL 

2200 CHURCHILL ROA0 

SPRINGFiaO, ILLINOIS 42706 

JhnAq*rKt*»>altiixUa*van*i^ltinMotmttioniiiia«mixeat 

Revised SututM.1979. Chxx->'111 1*7. Saction 1039. Ooctotwnt 

o(**MWo-m-r___n__f«iui-*_di-n-_«r*^«tS«ctio-v^ 

prevent ttw form tarn being praomad and could result in TOW 

appGcation boe-g denied ThB lorm ha* been approved by the f ormt 

Manage-nanf Center. 

•DATA ANO INFORMATION 

PROCESS EMISSION SOURCE 

THIS INFORMATION FORM IS TO BE COMPLETED FOR AN EMISSION SOURCE OTHER THAN A FUEL COMBUSTION EMISSION SOURCE Ot AN 

INCINERATOR. A FUEL COMBUSTION EMISSION SOURCE IS A FURNACE. BOILER. OR SIMILAR EQUIPMENT USEO PRIMARILY FOR PRO0UCING 

ICAT OR POWER BY INOIRECT HEAT TRANSFER. AN INCINERATOR IS AN APPARATUS IN WHICH REFUSE IS BURNED. 

1. NAME Of PLANT OWNER: 

Applied Composites, Corpt. 

3 . STREET ADDRESS Of EMISSION SOURCE: 

333 North 6th Stree t 

2. NAME OF CORPORATE DIVISION OR PLANT (IF 01FFERENT FROM 

OWNER): 

i. CITY OF EMISSION SOURU: 

St. Charles 

s. 

7. 

10. 

11. 

12. 

M . 

GENERAL INFORMATION 

NAME OF PROCESS: 

MDI Foam Injection 

EMISSION SOURCE EOUIPMENT MANUFACTURER: 

* * * 

6. NAME OF EMISSION SOURCE EQUIPMENT-. 

SAME 

B. MODEL NUMBER: 

* * * 

9. SERIAL NUMBER: 

* * * 

FLOW DIACCAM SCS'CNAflONiS} OF CMCSiON -riJUKtt: 

Building 25 

IDENTITY'S) OF ANY SIMILAR SOURCE(S) AT THE PLANT OR PREMISES NOT COWED BY THE FORM (IF THE SOURCE IS COVERED BY ANOTHER 

APPLICATION, IDENTIFY THE APPLICATION): 

AVERAGE OPERATING TIME OF EMISSION SOURCE: 

2 4 HRS/DAY 5 QAY5AHC 4 8 WKS/YR 

13. MAXIMUM OPERATING TIME OF EMISSION SOURCE: 

2 4 HRS/DAY 7 OAYS/WK 5 2 WI3/YR 

PERCENT OF ANNUAL THROUGHPUT: 

OEC-FEB 3 5 % MAC-MAY 2 5 % JUN-AUG 1 5 X SEPT-NOV 2 5 % 

INSTRUCTIONS 

4. 

5 . 

COMPLETE THE ABOVE IDENTIFICATION ANO GENERAL INFORMATION SECTION. 

COMPLETE THE RAW MATERIAL. PRODUCT, WASTE MATERIAL, ANO FUEL USAGE SECTIONS FOR THE PARTICULAR SOURCE EQUIPMENT. 

COMPOSITIONS OF MATERIALS MUST BE SUFFICIENTLY DETAJLEDTOAIXOW DETERMINATION OF THE NATURE ANO OUANTITY OF POTENTIAL 

EMISSIONS. IN PARTICULAR, THE COMPOSITION OF PAINTS, INKS, ETC.. AND ANY SOLVENTS MUST BE FUUY DCTA*LEO. 

EMISSION ANO EXHAUST POINT INFORMATION MUST BE COMPLETED, UN.ESS EMISSIONS ARE EXHAUSTED THROUGH AK POLLUTION 

CONTROL EQUIPMENT. 

OPERATING TIME ANO CERTAIN OTHER ITEMS REQUIRE BOTH AVERAGE ANO MAXIMUM VALUES. 

FOR GENERAL INFORMATION REFER TO *GENf kAL INSTRUCTIONS K * PERMIT ApftlCATIONS," APC-201. 

DEFINITIONS 

AVERAGE - THE VALUE THAT SUMMARIZES OR REPRESENTS THE GENERAL CONDITION OF THE EMISSION SOURCE, OK THE GENEfAL STATE Of 

PRODUCTION Of VHE EMlSSlON SOURCE. SPECIFICALLY: 

AVERAGE OPERATING TIME -ACTUAL TOTAL HOURS OF OPERATION fOR THE PRECEDING TWELVE MONTH PERIOD. 

AVERAGE RATE - ACTUAL TOTAL QUANTITY Of -MATERIAL- POR THE PRECEDING TWELVE MONTH PERIO0. DIVIDED BY THE AVERAGE 

OPERATING TIME. 

AVERAGE OPERATION - OPERATION TYPICAL Of THE PRECEDING TWE-.VE MONTH PERIOO, AS REPRESENTED BY AVERAGE OPERATING TIME 

AND AVERAGE RATES. 

M-.XII-HJM - THE GREATEST VALUE ATTAINABLE OR ATTAINEO FROM THE EMISSION SOURCE. OR THE PERIOO OP GREATEST OR UTMOST 

PRODUCTION Of THE EMI&ldN SOURCE. SPECIFICALLY: 

MAXIMUM OPERATING TIME - GREATEST EXPECTED TOTAL HOURS OF OPERATIONS FOR ANY TWELVE MONTH PERIOO. 

MAXIMUM RAH • GREATEST QUANTITY OF -MATERIAL" EXPECTED PER ANY ONE HOUR OF OPERATION. 

MAXIMUM OPERATION - GREATEST EXPECTED OPERATION, AS REPRESENTED BY MAXIMUM OPERATING TIME AND MAXIMUM RATES. 

II S32-02SO 

»PC 220 «•*»• i/2?/"** * Se e Exhibit B fo r Equipment 

Printed on Recycled Paper 

PAGE I OF 3 090-006 

1 
P.11 

RAW MATERIAL INFORMATION 

NAME OF RAW MATERIAL 

20o. DiphenyImethane Diisocyanate 

2,°- (MDI) 

22o. 

23a. 

Mo. 

AVERAGE RATE 

PER IDENTICAL SOURCE 

170,000 Yr 

LBjWfiX 

LB/HR 

LB/HR 

LB/HR 

LB/HR 

MAXIMUM RATE 

PER IDENTICAL SOURCE 

540,000 Yr 

LBJQK 

LB/HR 

LB/HR 

LB/HR 

LB/HR 

PRODUCT INFORMATION 

NAME OF PRODUCT 

"•* MDI Foam 

Io. 

2o. 

Jo. 

4a. 

AVERAGE RATE 

PER IDENTICAL SOURCE 

b. « 

170,000 LB£K 

b. 

LB/HR 

b . 

LB/HR 

b. 

LB/HR 

b. 

LB/HR 

MAXIMUM RATE 

PER IDENTICAL SOURCE 

540,000 LB/ME 

LB/HR 

LB/HR 

LB/HR 

LB/HR 

lo. 

<a. 

Sa. 

ia. 

o. 

Reacted 

NAME OF WASTE MATERIAL 

MDI 

WASTE MATERIAL INFORMATION 

AVERAGE RATE 

PER IDENTICAL SOURCE 

KJ- LB/HR 

b. 

LB/HR 

b. 

LB/HR 

b. 

LB/HR 

b. 

LB/HR 

MAXIMUM RATE 

PER IDENTICAL SOURCE 

«• 

«• 

<• 

«• 

-"• 

LB/HR 

LB/HR 

LB/H2 

LB/HR 

U/K8 

•FUEL USAGE INFORMATION { 

FUEL USEO 

p. NATURAL GAS D 

OTHER GAS D 

OIL • 

COAL D 

OTHER D 

TYPE 

b . 

-ERAGE FIRING RATE PER IDENTICAL SOURCE: 

BTU/HR 

HEAT CONTENT j 

c. 1000 BTU/SCF 

•TU/SC7 

BTU.'GAt • 

tTUAB 

EIU.-U • 

e. MAXIMUM FIRING RATE PER IOENTICAL SOURCE: 

:1V,'--5 

HIS SECTION IS TO BE COMPLETEO FOR AN Y FUEL USED DIRECTLY IN THE PROCESS EMISSION SOURCE. E.G. GAS IN A DRYER, OR COAL i**-

IELT FURNACE. 

C-220 10 PACf . c-
P.12 

•EMISSION INFORMATION 

5 1 . NUMBER OF IDENTICAL SOURCES (DESCRIBE AS REQUIRED): 

CONTAMINANT 

ARTICULATE 

4ATTER 

ARBON 

IONOXIDE 

IITROGEN 

OCIDES 

>RGAN1C 

ATERIAL 

JLFUR 

IOXIDE 

OTHER 

PECIFY) 

ONTAMINANT 

RTICULATE 

•.THR 

JtBON 

3NOX1DE 

TROGE'N 

CIDES 

GANIC 

.TERIAL 

_RJR 

5X1 DE 

>THER 

ECIFY) J 

AVERAGE OPERATION 

CONCENTRATION OR EMISSION RATE PER IDENTICAL 

SOURCE 

'52o. 

GR/SCF 

53o. pP M 

(VOL) 

5 4 0

 • PPM 

(VOL) 

S-5"* * * * PPM 

(VOL) 

5 6 0

 - PPM 

(VOL) 

57°- PPM 

(VOL) 

b. 

LB/HR 

b. 

LB/HR 

b. 

LB/HR 

b

- * * * 

LB/HR 

b. 

LB/HR 

b. 

LB/HR 

METHOD USEO TO DETERMINE CONCENTRATION OR 

EMISSION RATE 

c. 

c. 

c. 

e

- * * * 

c. 

c. 

MAXIMUM OPERATION 

CONCENTRATION OR EMISSION RATE PER IDENTICAL 

SOURCE 

58a. 

GR/SCF 

5 9 0

 * PPM 

(VOL) 

t0°- PPM 

(VOL) 

61a. 

* * * fP « 

(VOL) 

62o. pp M 

(VOL) 

*-*>- PPM 

(VOL) 

b. 

LB/HR 

b. 

LB/HR 

b. 

LB/HR 

b. 

* * * 

LB/HR 

b. 

LB/HR 

b. 

LB/HR 

METHOD USED TO DETERMINE CONCENTRATION OR 

EMISSION RATE 

c. 

c. 

e. 

C

' * * * 

• c . 

c. 

EMS 52 THROUGH 63 NEED NOT BE COMPLETED IF EMISSIONS ARE EXHAUSTED THROUGH AIR POLLUTION CONTROL EQUIPMENT. 

-tTHER" CONTAMINANT SHOULD BE USED FOR AN AIR CONTAMINANT NOT SPECIFICALLY NAMED ABOVE. POSSIBLE OTHER CONTAMINANTS 

« E ASBESTOS, BERYLLIUM, MERCURY, VINYL CHLORIDE, LEAD, ETC. 

•"EXHAUST POINT INFORMATION 

I. aO W DIAGRAM DESIGNATION'S) OF EXHAUST POINT: 

i. DESCRIPTION OF EXHAUST POINT (LOCATION IN RELATION TO BUtt. 

. EXIT HEIGHT ABOVE GRADE: 

. GREATEST HEIGHT OF NEARBY BUILDINGS: 

FT 

AVERAGE OPERATION 

. EXIT GAS TEMPERATURE: 

°F 

. GAS RO W RATE THROUGH EACH EXIT: 

ACFM 

67. EXIT OIAMETER: 

69. EXIT DISTANCE FROM NEAREST PLANT BOUNOARY: 

MAXIMUM OPERATION 

72. EXIT GAS TEMPERATURE: 

73. GAS RO W RATE THROUGH EACH EACH EXIT: 

FT 

°f 

AOM 

THIS SECTION SHOULD NOT BE COMPLETED IF EMISSIONS ARE EXHAUSTED THROUGH AIR POUUTION CONTROL EQUIPMENT. 

* * * See Appendix A for Emission and Exhaust Point Information. 

-220 U o*/rt 1 r*r 
P.13 

EXHIBIT B 

[T-
P.M 

EXHIBIT B 

THIS APPLICATION FOR A JOINT CONSTRUCTION AND OPERATING PERMIT IS 

FOR INSTALLATION OF EQUIPMENT ASSOCIATED WITH A POLYURETHANE FOAM 

INJECTION PROCESS. SPECIFICALLY, THE EQUIPMENT CONSISTS OF TWO 

PORTABLE, SUPPLIER-OWNED BULK STORAGE TANKS WHICH ARE FILLED WITH 

A TWO-PART POLYURETHANE SYSTEM AND DISPENSING EQUIPMENT WHICH 

CONSISTS OF A MIXING GUN UTILIZING WATER AS THE BLOWING AGENT. 

THE MATERIAL, DIPHENYLMETHANE DIISOCYANATE (MDI), IS SUPPLIED BY 

THE VENDOR IN THE REUSABLE STORAGE TANKS. THE TWO PARTS ARE PUMPED 

VIA A CLOSED-LOOP SYSTEM TO THE MIXING GUN WHERE THE PARTS ARE 

COMBINED WITH WATER AND INJECTED INTO CLOSED CAVITIES OF VARIOUS 

FIBERGLASS REINFORCED PLASTIC ARTICLES. THE COMBINED MATERIALS 

IMMEDIATELY AND COMPLETELY REACT TO FORM AN INSULATING FOAM. 

THIS SYSTEM IS A WATER BLOWN SYSTEM WHICH DOES NOT REQUIRE THE USE 

OF CLEAN-UP SOLVENTS OR VOMS. EMPTY STORAGE TANKS ARE RETURNED TO 

THE SUPPLIER FOR REFILLING. 

|3 
P.15 

hrWoo of PMC lo c 

PRELIMINARY DATA SHEET 

IS0FCflM®ZDH2 86A/9201-06M 

01-06M is a multipurpose water blown foam. It can be hand mixed, 

ed with. Isofroth* equipment with air nucleation or pumped with 

uipment dispensing at 1:1 by volume. This foam contains no 02one 

pleting chemicals. It contains no flammable hydrocarbons and no 

Component Code 

Specific Gravity 

Viscosity 

Ratio By Volume 

Ratio By Weight 

"A" "B" 

86A 9201-06M 

1.24 1.05 

250 cps 350 cps 

100A/100B 

100A/90B + 5% 

Cream Time 

String Gel 

Tack Free 

Density 

Compressive Strength 

Parallel 170 psi 

Perpendicular 130 psi 

K-Factor .20 

Humid Age at 158°F 100% RH 28 Days 

Dry Heat at 158°F 28 Days 

Low Temp. Aging -20°F 7 Days 

40 - 1:00 min:sec. 

1:45 - 2:15 min:sec. 

2:45 - 3:30 min:sec. 

5.5 - 6.5 lbs./Ft.3 

Less Than 3% Change 

Less Than 2% Change 

No Change 

CLER MAKES NO GUARANTEE OR WARRANTY, EXPRESS OR IMPLIED, INCLUDING 

WX OF MERCHANTABILITY OR THAT THE MERCHANDISE IS SUITABLE FOR A 

RTICULAR PURPOSE OR THAT THE MATERIAL DOES NOT CONTAIN HAZARDOUS 

BSTANCES. 

VfTEK/IPI 

tlantic Drive, Unit #5, West Chicago. IL 60185 o 708/293-9299 o FAX 708/293-9363 07/93 

4-
P.16 

APPENDIX A 

IS 
P.17 

APPENDIX A 

EMISSION ESTIMATES FOR THE PROPOSED EQUIPMENT ARE BASED ON SUPPLIER 

INFORMATION. 

AS THE POLYURETHANE COMPONENTS ARE CONTAINED IN A SUPPLIER 

MAINTAINED CLOSED-LOOP SYSTEM, WATER IS USED AS THE BLOWING AGENT, 

AND THE CHEMICAL REACTION RAPIDLY TAKES PLACE IN A CLOSED CAVITY, 

POTENTIAL VOM EMISSIONS ARE CONSIDERED NEGLIGIBLE. 

AVERAGE OPERATION 

THE EQUIPMENT WILL BE USED ON AN INTERMITTENT BASIS FOR SPECIFIC 

ARTICLES. WHILE OPERATIONAL, THE EQUIPMENT WILL RUN ON A CYCLICAL 

BASIS DEPENDENT ON THE THROUGHPUT OF THE ARTICLE BEING PRODUCED. 

THE PRODUCTION LINE RUNS AN AVERAGE OF 24 HOURS PER DAY, 5 DAYS PER 

WEEK. 

IT IS ESTIMATED THAT IN THE INITIAL YEAR OF PRODUCTION (1996-97), 

APPROXIMATELY 170,000 LBS OF POLYURETHANE MATERIAL WILL BE 

PROCESSED. 

MAXIMUM THEORETICAL EMISSIONS 

BASED ON SUPPLIER DATA (SEE ATTACHED DATA SHEET), THERE WILL BE 

NEGLIGIBLE EMISSIONS FROM THIS PROCESS. 

EXHAUST POINT INFORMATION 

BUILDING #25 WHERE THE PROPOSED PRESS WILL BE INSTALLED DOES NOT 

HAVE A FORMAL VENTILATION SYSTEM (i.e., DUCTWORK, MAKE-UP AIR, 

STACKS,ETC.). FUGITIVE EMISSIONS,IF ANY, WILLBEEXHAUSTED 

THROUGH BUILDING WINDOWS, DOORS, AND HYDRAULIC EQUIPMENT FANS 

LOCATED ABOVE THE PRESS. BUILDING #25 IS OPEN INSIDE WITH A ROOF 

HEIGHT OF 30 FEET. 

It 
P.18 

FACILITY DIAGRAM 

n 
P.19 

••^TIIIIFIPI 

IIIIIIII I m I 

IS 
P.20 

/ 

' » 

1° + + 

•Jl 

DIO 

\ 

+ + 

+ 

t 

+ + + 

I 

8 

3 

3(75 

+ + 

A 

or 

n> 

z: 

CT 

D 

nn. J] 

i l 
P.21 

PROCESS SCHEMATICS 

Z-O 
P.22 

RAH MATERIALS SMC MANUFACTURE 

SCRAP -4-

I 

SCALE 

TION 

HEAT 

I 

APPLIED COMPOSITES 

PROCESS FLOW 

I 

SCALE 

PRESS 

PRESSURE 

COHVEVOR 

SCRAP FINISH 

1 

PACK 

I 

CUSTOMER 

-*- SCRAP 

"2-1 
P.23 

APPENDIX E 

ALTERNATIVE OPERATING SCENARIOS 

-2-2-
P.24 

ALTERNATIVE OPERATING SCENARIOS 

I. Compound Preparation and Maturation Area 

Applied Composites has the capability to manufacture both sheet molding 

compound (SMC) or thick molding compound (TMC). However, Applied Composites' 

mixing operation can only support one operation at a time. The SMC machine must be 

shut down in order to use the TMC machine. The emissions are the same for either 

operation. 

n. Molding Presses 

Applied Composites' emissions in the molding press area are limited by the amount 

of SMC or TMC that Applied Composites' is capable of producing. Applied Composites 

may, however, deem it necessary to purchase SMC or TMC from another facility, thereby 

increasing the potential emissions. Applied Composites has requested that the pennit 

establish a federally-enforceable emissions cap of 99.9 tons per year. Even with the 

additional SMC or TMC purchased, Applied composites will not exceed this cap. 

m. MDI Foam Injection 

Applied Composites has applied for a pennit to construct and operate a Methyl 

Dilsocyanate (MDI) foam injection operation in which insulating foam will be injected into 

various FRP products. As set forth herein, this operation is an insignificant emissions 

activity. Applied Composites has requested a federally enforceable emissions cap for the 

facility. This operation will not cause Applied Composites to exceed this limit. 

^ 3 
P.25 

APPENDIX D 

INSIGND7ICANT SOURCE DOCUMENTATION 

27 
1994 TANK SUMMARY 

1994 TOTALS 

STYRENE ( 104.16 

(9.9 lb/gal resin @ 0.1 ps 

S-944 RESIN TANK 1 

S-944 RESIN TANK 2 

S-9S9 RESIN TANK 3 

1 

Capacity 

(gals) 

6,000 

6.000 

6,000 

S Factor 

0.6 

0.6 

0.6 

% Volatile 

32.50 

32.50 

38.00 

THRUPUT 

(gals) 

132,602.61 

131,033.54 

22,393.98 

286,030.13 

VOM LOSS 

(lbs) 

6.17 

6.10 

1.22 

13.50 

TJ 

ho 
P.27 

Table D-2. 1994 Emissions Calculations, FRP Laboratory, 

Applied Composites Corp., St. Charles, Illinois 

Input Information 

1994 Compound Processed Qb/yr) 

Average Monomer Content in Compound (%) 

Monomer Emission Factor (lb VOM emitted/100 lb available monomer)1 

13,458 

11.42 

3.04 

Calculations 

13,458 lb compound 11.421b monomer 

100 lb compound 

1.54E+03 lb available monomer 

1.54E+03 lb monomer 3.04 lb VOM 

100 lb monomer 

47 lb/yr VOM emitted 

47 lb VOM 

year 

ton 

2000 lb 

0.02 tpy VOM 

Emission fector determined through direct measurement (October 12,1992). 

Volatile organic material. 

Pounds per year. 

Percent 

Pounds. 

VOM 

fbfyt 

% 

Ib 

yr 

Tons per year. 

Year. 

Applact 12/5/95 

-zc? 
M< 

T**M . 

sup.Boior«i 

NOx 

802 CO 

VOM PM 

OfU.Bator»2 

NOx 

802 CO 

VOM PM 

V-SCM-tr*! 

NOx 

S02 CO 

VOM PM 

6ot__r«4 

NOx 

S02 CO 

VOM PM 

VHV.to^»xrmmx/.AffUtiCan^ommr.tLaxmtm.ani*» 

A c M 

Tlroughpul 

pmifffl 

I S M 

1993 

19.53 18 S3 

1993 

ActM 

Ttmudyut 

(rnml**Ar) 

1729 

17.29 

17-28 17 24 

17.29 

Acta! 

TTrouppU 

(mnxT/jf) 16 ee 

1656 

1696 

16.89 

1959 

Actual 

Tlrot-jtvul 

(m-fF/gr) 

0.00 

000 

000 

000 

0.00 

Ae»j-_ 

Houraol 

Ooaratan 

9.760 

8.760 

8.760 

8.760 

8.760 

MuM 

Hano i 

Oporalon 

6.760 

8.760 

8.760 

6.760 

6.760 

Act* 

Hano i 

Oporalon 

8.760 

6.760 

8.760 

6.760 

6.760 

Act* 

Hano i 

Oporalon 

8.760 

6.760 

6.780 

6.760 

6.760 

EF 

9oo_r 

(Mmtr) 

100 0 6 21 

6.3 12 EF 

Booor 

(Mm m 

100 

0.8 21 

6.1 12 EF 

So** 

(Mnm ITI 

100 

0.8 21 

8.1 12 EF 

Bootr 

(Mm m 

100 

0.6 21 

6.3 12 

Unoontaltd 

E-r*M_ora 

(Mr) 

1JE-01 

1.1E-03 

4.06-02 

1.06-02 

Z3E-02 

Unconkolod 

Enlutora 

(Mr. 

20E-01 

1.2E-03 

4.1E-02 

10E-02 

2.4E-02 

UnconMod : EnMo-a 

(Mr) 

1.8E-01 

11E-03 

4.0E-O2 

1.0E-02 

23E-02 

Unomrolod 

Enimora 

(Mr) 

: o.OE«oo 

O.OE400 

O.OE«00 

006*00 

: O.OE-KW 

UnconMod 

ErriMlant 

(by) 

9.3E-01 

8.06-03 

1.7E-01 

44E-02 

9.8&02 

Unoonlrolod 

EmMo-a 

(*v) 

9.96-01 

8.26-03 

1.8E-01 

4.96-02 

1.0E-01 

l_ncon*reMd 

Emuuiuia 

(by) 

83E-01 

9.0643 

1.7E-01 

4.4642 

986-02 

Uncon^otto 

Enitttons 

(by) 

O.OEfOO 

0.06*00 0 06*00 

0.0E+OO 

006*00 

M-udnui. 

Tlroi«_h-M_ 

OrmfTnil 

92.63 

6263 

82.63 

62.61 

62.63 

M-udnun) 

Ttrough-tf 

(nrrtTM 

84(3 

64.93 

94.93 

9483 

94.93 

Morir-un 

Tlrougrva 

(mrr_r.yr) 

92.74 

62.74 

62.74 

62.74 

62.74 

Motf-run 

nxou^iM 

(rmir/tf) 

48.68 

4999 

4968 

4599 

49.68 

Mucbnjn 

Hounol 

Oporalon 

9.760 

9.760 

9.760 

9.760 

6.760 

M-u-knm 

Horn * 

Oporalon 

6.760 

8.760 

9.790 

8.790 

8.760 

MwJmum 

Hounol 

Oporalon 

8.790 

9.760 

6.790 

9,760 

8.760 

Moafcrun 

Hano i 

Oporalon 

8.760 

8.760 

8.760 

6.790 

6.760 

EF 

BoTatr 

( Mm ft*) 

too 

0.6 21 

5.1 12 EF 

Bohr 

(Mrm IT) 

100 

0.8 21 

6.3 12 EF 

BoHr 

(Mmtr) 

100 

0.6 21 

8.1 12 EF 

•OOM-' 

( Mm IF) 

100 

0.9 21 

9.1 12 

Unconl-olod 

cirsolofx. 

(Mr) 

606-01 

3.9603 

I.JE-OI 

1.2E-02 

726-02 

Unoonkoitd 

E/tiukxM 

(Mr) 

9.16-01 

396-01 

1.16-01 

3.16-02 

7.6E-02 

Uhconfrotod 

EntfMtont 

(Mr) 

e.oe-oi 

3.9601 

13C-01 

12602 

726-02 

Unconl-olod 

Enta-ota 

(Mr) 

62E-01 

3.1E-03 

1.1E-01 

2.9E-02 

83E-02 

UncankoM 

ErrtMtom 

(bY) 

2.66*00 

1.0E-O2 

9.5E-01 

1.46-01 

326-01 

UnconlPolod 

6*rta**]o*a 

(by) 

2.7E*00 

196-02 

0.9E-OI 

1.66-01 

1.3E-01 

UnconMod 

Efrtuloia 

(by) 

2.96*00 

1.96-02 

9.9E-01 

1.4E-01 

3.2E-01 

UnconMod 

EMottefxi 

(t>y) 

2.3E*00 

1.4E-92 

4.3E-01 

1.2E-01 

2.7E-01 

RopjuMoiy 

Unltilon 

(Mr) NA NA NA NA NA 

Roguttory 

UntiMon 

(Mr) NA NA NA NA NA 

Rogatory 

UntftBtan 

(Mr) NA NA NA NA NA 

Ropirtory 

uitaton 

(Mr) NA NA NA NA NA 

Mvdnun 

Hano i 

ODoralon 

8.760 

8.760 

8,760 

6.760 

6.760 

Msdnwni 

Hano i 

Oporalon 

8.760 

0.790 

6.760 

8.780 

6.760 

Mvdnun 

Hano i 

Opwton 

8.760 

6,760 

9.790 

9.790 

8.760 

Mvanwn 

Hounol 

Operaton 

6.760 

8.760 

6.760 

6.7(0 

8.760 

POOMlW 

Entofltora 

(bv) 

2632 

0016 

0.993 

0.139 

0.319 

F-ottnfafl 

OIIKKU M 

(by) 

2749 

0019 

0.977 

0.149 

0.330 

Pottrttti 

Enittdoni 

(by) 

2.837 

0016 

0.894 

0.140 

0.316 

Potantal 

EmMo-a 

(by) 

*U94 

0.014 

0.460 

0.121 

0274 

EF 

6olor«B T>*o>x_rpu 

(mmffftr) 

Hano i 

OporHon (Mtm IT) 

cm JfiKL 

Tlrou-feU 

(nfrir/w) 

Hanoi 

( Mm IT) (Mr) J__ 

RoguMory 

' UnlMon 

(Mr) 

Majdnun 

Hounol Einu-ora 

(by) 

NOx 

802 CO 

VOM 

0.00 

0.00 

0.00 

000 

0.00 

6.790 

9,790 

9.790 

6.790 

9.780 

100 

0.9 21 93 12 

0.0E4O0 

ooe«oo 

00E<O0 

OJK«0 0 

0.0E«00 

O.OE400 

0.0E«00 

0.0E400 

OJ&OO 

0.06«00 

94.60 

94.90 

94.90 

94J0 

94J0 

9,790 

8.790 

9.790 

8.760 

9.760 

100 

0.6 21 

8.3 12 

81E-01 

3.8E-93 

13E-01 

HE-02 

786-02 

2.7E«O0 

1.8E-02 

6.8E-01 

1JE-01 

8.1E^>1 

N A NA 

9.780 

9.790 

8.760 

8.760 

8.760 

Z74 8 

0.018 

0.579 

0.149 

0.329 
P.29 

METHYL DI-ISOCYANATE (MDI 1 FOAM INJECTION SYSTEM 

System is considered insignificant based on the following: 

• Rapid polymerization (solidification) of MDI after injection. 

• Applied within enclosures that prevent escape of any MDI vapor. 

2 2" 
P.30 

APPENDIX C 

STATE OPERATING PERMIT 

^ < ? 
P.31 

ttZjS^l Slate of Illinois 

l ^ p ENVIRONMENTAL MmECTION AGENCY 

Mary A. Gade, Director iiii- P. O. Box J9506, Springfield, IL 62794*9306 

217/782-2113 

OPERATING! PfMS - REVISED ; 

PERMITTEE 

Applied Composites, Corp. : ! 

Attn::Mr. John Punls, Vice Pres., Operations' 

333 North Sixth Street 

St. Charles, Illinois 60174 • 

Application No.: 93050066 . I.D. No.: 089483AAF 

Applicants Designation: C0HP0UN0 -4M-8 RecelYCd'.- M&/ 19, 1*85 

gjjidaci! Compounding, Maturation, aridSiilreSsldii Molding 

Date Issued; June 14, 1995 ii^niration Date: Uune 14, 2000 

Location: 333 North Sixth Street, St. Charles 

Permit 1s hereby granted to the above-designated Permittee to OPERATE emission 

units(s) and/or air pollution control..:Equipment consisting of small lightning 

mixer, small Cowles mixer, large Cowl&s wixer, Sheet Molding Compound (SMC) 

machine, festooner, Thick Molding Conpund (TMC) machine, maturation process, 

three: resin storage tanks, twenty-oneltlosed mold hydraulic production presses 

and pigment application equipment, dust collection equipment, pigment hopper 

dust collector, Fiberglass Reinforced^Plastlc (FRP) lab, and five natural gas 

fired boilers as described 1n the above referenced application. This Permit 

is subject to standard conditions attached hereto and the following special 

condltlons(s): IP 

la. The process for making compound shall.-be performed in accordance with the 

description 1n the application with additional enclosure as required by 

Condition 7. As a result of th1S:#equlrement, the emission factor for 

production of molding compound 1s assumed to be 3.04 lb V0H/100 lb monomer 

and VOM input, based on Information provided 1ri a stack test Conducted on 

October 12, 1992. if-- '•'"-

b. For the compounding and maturation processes combined, monomer usage, 

production of molding compound, and emissions of Volatile Organic Material 

(VOM) shall not exceed the following limits: 

Pretuciion';of 

Monomer Usage Molding Compound VOM Emissions 

(lb/month) (ton/mr) Iffin/flr) HMnonth) (Tpn/yr) 

527,000 2,250 W'I.U It.QW 68.3 

These limits are based on informttiQn':provlded in ;tbeperm1t:application. 

Compliance with annual limits shall bo determined from a running total of 

twelve months of data. 

Pmi.K. IUI V.trytinl ftqxtr 

3o 
P.32 

Page 2 

2. Emissions of Volatile Organic Material (VOM) from the three resin storage 

tanks combined shall not exceed -Ue?: tons per year. This Hmit 1s based 

on Information provided in the permit application. Compliance with this 

limit shall be determined using standard calculation methods set forth 1n 

USEPA's Coi-ipnation of Emission Factors. AP-42 as Well as a running total 

df twelve months of data. 

3. Emissions of Volatile Organic Material (VOM) from the usage of isopropyl 

alcohol shall not exceed 2.0 ton per year. This Hm1t 1s based on 2.0 ton 

of alcohol used per year for Inspection and rework procedures, 

4a. Polyester resin products shall ttfeiafeitatfidiDhly byiBflsed molTdingiAs" a 

'. result of this requiretwint, theMllffmifacfcbr for fabrication is assumed 

to be 1.0 lb V0M/100 lb monomer info £ {USEPA; Compilatipn of Emission 

Eactors> AP-42). 

b. Emissions and operation of production molding equipment shall not exceed 

the following limits: 

VOM Emissions 

Item of Equipment nb/monthrrTon/vn 

5. 

0. 

7. 

21 Closed Molding 

Presses (Combined): 

6,132 26.3 

These limits are based on.processing all molding:compounding produced at 

the source, and Information provided in the permit application. 

Compliance shall be determined using monomer content of molding compound 

processed. Compliance with annual limits shall be determined from a 

running total of 12 months of data. 

Emissions of Volatile Organic Material (VOM) from each emission unit shall 

not exceed 8.0 pounds per.hour pursuant to 35 111. Adm. Code 218.301, 

Emissions of Volatile Organic Material (VOM) from the fiberglass 

Reinforced Plastic (FRP) Lab shall not exceed 0.1 ton per year. This 

limit is based on information provided 1n the permit application. 

fhe Permittee shall provide a coyer for each holding tank, mixing vessel, 

vat, or other processing equipment with a capacity greater than 7.5 liters 

(2 gall ons), 1 ncl uding any ianWiner • ifi which polyester resi ii materi als 

are delivered to the source, while polyester resin materials are being 

formulated. These covers shall: 

i. Completely cover the tank, vat, or vessel opening except for an 

opening no larger than necessary to allow for safe clearance for a 

mixer shaft; 

ill. Extend at least 1.27 cm (0.5 Inch) beyond the outer r1m of the 

opening or be attached to the rim; 

•31 
P.33 

Page 

Iii. Remain closed except when adding or removing material or when 

sampling or inspection procedures require access', and 

iv. Be maintained 1n good condition such that, When 1n place, the cover 

maintains contact with the rim of the opening for at least 90% of the 

circumference of the r1m. .' 

8a. Annual emissions of Nitrogen Oxide (NOx) and Carbon Monoxide (CO) from the 

five boilers combined shall not exceed 13.0 tons and 3,1 tons 

respectively. These limits are based on standard AP-42 emission factors 

for the firing of natural gas, 87M. hours of Qper^tion,::perry-9ar, and-? 

information provided tn the peiMfc: If plication.' \ C^pl 1 ancei with these 

limits shall be determined from I.running total: of twelve months of data. 

b. Natural gas shall be the only fuel combusted in the boilers. 

9. Emissions of particulate matter from each pigment application system with 

Nordson dust collector and the pigment hopper with Nordson dust collector, 

shall not exceed 0.55 Tb/hr and 2.41 tons per year. These limits are 

based on information provided in the permit application. 

10. The Permittee shall comply with the following operating requirements: 

I. For polyester resin materials used for products requiring corrosion 

resistant or fire retardent Materials, a monomer content of no more 

than 48% by weight as applied may be used; 

II. For polyester resin materials for products requiring a tensile 

strength of 10,000 psi or more, Including tooljlng resins, a monomer 

content of no more than 48% by weight as appl lied may be used; 

III. For clear gel coat, a monomer content of no more than 5054 by weight 

as applied may be used; 

iv. Fur other pigmented gel coats, a monomer content of no more than 45% 

by weight as applied may be used; or 

v. For all other polyester resth materials, a monomer content of no more 

than 35% by weight as applied may be used. 

11. The monomer content of polyesterTesin materials shall be determined: 

I. From supplier data and operating data; or 

II. By sampling and analysis by the methods set forth in SCAQMD 

Method 312-91. 

12a. i The Permittee shall maintain; records of the following Items to allow 

the Agency to review compliance; 

3 ^ 
Page:4 

P.34 

11. 

Formulation data for molding;..compounds, with type and amount of 

resin(s), additives, catalyst, filler, fiberglass, inhibitors, 

promoters, etc. (data for elMi.distinct formulation) 

Styrene content of resin and other materials used in molding 

compound, (data for each distinct resin and material) 

111. quantity (pounds) of each type (sheet mold or thick mold and general 

purpose, high monomer content, special purpose, or low monomer 

content) of compound producfd. (monthly) 

: iv, Quantity (pounds) of; ftion6iite|piil, :(in&tttHty) 

v. Quantity of each solvent used (dibasic ester and Isopropyl alcohol) 

and amount recovered! and sent off site for reclamation, (monthly) 

V1. VOM emissions, (calculated monthly) 

b. the Permittee shall keep written records of periodic Inspections to 

confirm implementation of the measures required by Condition 7. 

c. These records shall be retained for a period of three years and shall be 

made available for Agency inspection and upon request. Copies of records 

shall be submitted within: 10 days of Agency request. 

13. this permit is issued based uponithe sheet molding compounding process, 

thick molding compounding process, maturation process, and compound closed 

molding process not being subject to the control1 requirements of 35 111. 

Adm. Code 218, Subpart PP and PQ:for miscellaneous fabricated product 

manufacturing operations. This i's a consequence of the above conditions 

which establish limitations which xonstraln VOM emissions in the absence 

of air pollution control equipment to less than 10$ tons per year. 

It should be noted that during the review of this application, 1t was 

determined that your facility has the potential to emit more than 25 tons per 

year:of volatile organic material (VOM) and will be classified as a major 

source under the Clean A1r Act Permit Program (CAAPP). 

If you have any questions on this permit, please contact Mohamed Anane at 

'217/782,2113:" 

Oonald E. Sutton, P.E. 

Manager, Permit Section 

01 vision of Air Pollution Control 

OES:MA:sad/0523Q,100-103sp 

cc: Region 1 

33 
P.35 

TABLES 

3V ... 
P.36 

Table 1. 1994 Emissions Calculations, Compound Room, 

Applied Composites Corp., St Charles, Illinois 

Input Information 

1994 Compound Processed (lb/yr) 

Average Monomer Content in Compound (%) 

Monomer Emission Factor (lb VOM/lb available monomer)1 

19,767,472 

11.47 

0.0304 

Calculations 

19,767,472 lb compound 11.47% 2.27E+06 lb available monomer 

2.27E+06 lb monomer 0.0304 lb VOM = 68,927 lb/yr VOM emitted 

lb monomer 

68,927 lb VOM 

year 

ton 34.5 tpy VOM 

20001b 

VOM 

lb/yr 

lb 

tpy 

yr 

Emission fector determined through stack testing (October 12,1992). 

Volatile organic material. 

Pounds per year. 

Percent. 

Pounds. 

Tons per year. 

Year. 

Applact 11/21/95 

3£ 
P.37 

Table 2. 1994 Emissions Calculations, Molding Presses, 

Applied Composites Corp., St. Charles, Illinois 

Input Information 

1994 Compound Molded (lb/yr)1 

Average Monomer Content in Compound (%) 

Monomer Emission Factor (lb VOM emitted/100 lb available monomer)2 

20,155,292 

10.43 

1 

Calculations 

20,155,292 lb compound 10.43% 2.10E+06 lb available monomer 

2.10E+6 lb monomer 1 lb VOM 

100 lb monomer 

21,022 lb/yr VOM emitted 

21,022 lb VOM 

year 

ton 

20001b 

10.5 tpy VOM 

I 

2 

VOM 

lb/yr 

% 

lb 

tpy 

yr 

Some SMC processed in 1993 was molded in 1994. 

Emission fector taken from AP-42 (Januaiy 1995), Chapter 4, Section 4, entided 

Polyester Resin Plastic Products Fabrication, Table 4.4-2, Closed Molding. 

Volatile organic material. 

Pounds per year. 

Percent 

Pounds. 

Tons per year. 

Year. 

Applact 12/5/95 

Si, 
Table 3. 

Product Name 

PAINTS 

Paint 

Paint 

Top Coat 

SOLVENTS 

Reducer 

Reducer 

Paint and Solvent Air Po! 

Typical 

Usage 

(galfyr) 

57 

8.5 

4 

500 

14 

Typical1 

Usage 

Ob-y) 

338.58 

96.22 

33.2 

4150 

100.8 

lutant Emis 

Typical1 

Schedule 

(hrs/yr) 

1500 

1500 

1500 

1500 

1500 

sions. Applied Composites Corporation, St Charles, Illinois 

Maximum 

Usage2 

(galtyr) 

114 

17 

8 

1000 

28 

Maximum 

Usage2 

(W-V-yr) 

677 

192 

66 

8300 

202 

Product 

Density3 

lb/gal Content3 

5.94 30% 

11.32 5% 

8.3 10% 

Total 

8.3 10% 

7.2 10% 

Total 

VHAPs: 

IPA VOM: 

Actual 

(lb/yr) 

101.574 

4.811 

3.32 

109.71 

415 

10.08 

425.08 

1728.892 

4000.000 

Toluene 

MTE4 

(ttVyr) (IPY) 

203.148 

9.622 

6.640 

219.41 

830.000 

20.160 

850.16 

3457.783 

2,000 

0.102 

0.005 

0.003 

0.11 

0.415 

0.010 

0.43 

1.729 

2.000 

PTE4 

(lh/yr) (IPY) 

203.148 

9.622 

6.640 

219.41 

830.000 

20.160 

850.16 

3457.783 

4000.000 

0.102 

0.005 

0.003 

O.U 

0.415 

0.010 

0.43 

1.729 

2.000 

TOTAL VOM: 5728.892 3459.783 3.729 7457.783 3.729 

1. 1994 data. 

2. Maximum usage was assumed to be 2.5 more than the 1994 usage data. 

3. Manufacturer's data. 

4. TPY values are based on maximum operating schedule of: 8760 hrsfyr 

EQUATIONS: 

Actual, lb/yr = (1994 Usage, gal/yr)(HAP Content %)(Prod Density, lb/gal) 

MTE, lb/hr = (Max. Usage, gal/yr)(HAP content %)(Prod. Density, lb/gal)/(Max. Sched., hrs/yr) 

MTE, TPY •= (MTE, lb/hr)(Max. Sched, hrs/jT)(ton/2000 lb) 

PTE, lb/hr = (Max. Usage, gal/yr)(HAP content %)(Prod. Density, lb/gal)/(Max. Sched., hrs/yr) 

PTE, TPY - (MTE, lb/hr)(Max. Sched., hrs/yr)(ton/2000 lb) 

Total VOM is equal to the sum of volatile HAP emission rates and fiom IPA use. 

Painthap Page 1 of 3 12/5/95 
Table 3. 

Product Name 

PAINTS 

Paint 

Paint 

Top Coat 

SOLVENTS 

Reducer 

Reducer 

Paint and Solvent Air PoUutant Emissions, Applied Composites Corporatio 

Typical' 

Usage 

(gal/yr) 

57 

8.5 

4 

500 

14 

Typical' 

Usage 

Ob^) 

338.58 

96.22 

' 33.2 

4150 

100.8 

Typical' 

Schedule 

(hrs/vr) 

1500 

1500 

1500 

1500 

1500 

Maximum 

Usage2 

(galfyr) 

114 

17 

8 

1000 

28 

Maximum 

Usage2 

Oh/yr) 

677 

192 

66 

8300 

202 

Product 

Density3 

lb/gal 

5.94 

11.32 

8.3 

8.3 

7.2 

Content3 

3% 

3% 

Total 

5% 

5% 

Total 

Actual 

(lb/yr) 

2.8866 

0.996 

3.88 

207.5 

5.04 

212.54 

Xylene 

MTE4 

0h/yr) CIPY) 

5.773 

1.992 

7.77 

415.000 

10.080 

425.08 

0.003 

0.001 

0.00 

0.208 

0.005 

0.21 

PTE4 

0h/yr) (IPY) 

5.773 

1.992 

7.77 

415.000 

10.080 

425.08 

0.003 

0.001 

0.00 

0.208 

0.005 

0.21 

U) 

1.1994 data. 

2. Maximum usage was assumed to be 2.5 more than the 1994 usage data. 

3. Manufacturer's data. 

4. TPY values are based on maximum operating schedule of: 8760 bn/yt 

EQUATIONS: 

Actual, lb/yr = (1994 Usage, gal/yr)(HAP Content %)(Prod Density, lb/gal) 

MTE, lb/hr = (Max. Usage, gal/yr)(HAP content %XProd Density, lb/gal)/(Max. Sched, hrs/yr) 

MTE, TPY - (MTE, lb/hr)(Max. Sched, hrs/yrXtom/2000 lb) 

PTE, lb/hr = (Max. Usage, gal/yr)(HAP contort, %)(Prod. Density, lb/gal)/(Max. Sched. hrs/yr) 

PTE, TPY - (MTE, lh/hr)(Max. Sched, hrs/yrj(ton/2000 lb) 

Total VOM is equal to the sum of volatile HAP emission rates and fiom IPA use. 

Painthap Page 2 of 3 12/5/95 
Table 3. 

Product Name 

PAINTS 

Paint 

Paint 

Top Coat 

SOLVENTS 

Reducer 

Reducer 

Paint and Solvent Air Pol 

Typical' 

Usage 

(galfyr) 

57 

8.5 

4 

500 

14 

Typical' 

Usage 

(lb/yr) 

338.58 

96.22 

33.2 

4150 

100.8 

lutantEmis 

Typical' 

Schedule 

(hrs/yr) 

1500 

1500 

1500 

1500 

1500 

sions, Applied Composites Cofporatio 

Maximum 

Usage 

(galfyr) 

114 

17 

8 

1000 

28 

Maximum 

Usage 

(lWyr) 

677 

192 

66 

8300 

202 

Product 

Density3 

lb/gal 

5.94 

11.32 

8.3 

8.3 

7.2 

Content3 

23% 

23% 

• • 

Actual 

(lb-yr) 

0.00 

954.50 

23.18 

977.68 

Methyl-ethyl-ketone 

MTE4 

0h/yr) (JPY) 

0.00 

1909.000 

46.368 

1955.37 

0.00 

0.955 

0.023 

0.98 

* PIE' 

(lb/yr) 

0.00 

1909.000 

46.368 

1955.37 

i 

CTPY) 

0.00 

0.955 

0.023 

0.98 

1.1994 data. 

2. Maximum usage was assumed to be 2.5 more than the 1994 usage data. 

3. Manufacturer's data. 

4. TPY values are based on maximum operating schedule of: 8760 hrs/yr 

EQUATIONS: 

Actual, lb/yr = (1994 Usage, gal/yr)(HAP Content %XProd Density, lb/gal) 

MTE, lb/hr = (Max. Usage, gal/yr)(HAP content %)(Ptod. Density, lb/gal)/(Max. Sched., hrs/yr) 

MTE, TPY = (MTE, lb/hr)(Max. Sched., hrstyrXton/2000 lb) 

PTE, lb/hr = (Max. Usage, gal/yr)(HAP content %)(Prod Density, lb/gal)/(Max. Sched., hrs/yr) 

PTE, TPY = (MTE, lh/hr)(Max. Sched, hrs/yr)(tQn/2000 lb) 

Total VOM is equal to the sum of volatile HAP emission rates and from IPA use. 

Painthap Page 3 of 3 12/5/95 
P.41 

SECTION 6 

FACILITY FORMS 

-vo: 
P.42 

ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD, ILUNOIS 62794-9506 

F9RAPPUCANT*$W 

Revision*: M"" 

Data Dacemty S. 1995 / 

Page of 

Source Designation: 

ACC 

HAZARDOUS MR POLLUTANT (HaAP) 

EMISSION SUMMARY PERMIT* 

TOTE 

SOURCE INFORMATION 

^SCURCEKIAME: Applied Composites Corp. 

3> SOURCE ID No. nonAMAAr. 

(IF KNOWN): 089483AAF 

2) DATE FORM ,_, u B Annc 

PREPARED: December 6,/1995 

HAZARDOUS MR POLLUTANT EMISSIONS 

4) D6E5 AMV EMISSiflN UNIT AT THE 56UKCE EMIT A HAZARDOUS AIR POLLUTANT? 

(IF NO, THEN THE REMAINDER OF THIS FORM NEED NOT BE COMPLETED) Q YES 

5a) DOES THE SOURCE HAVE THE POTENTIAL T6 EktlT, IKI THE AOOhEoATE,: 

i) 10 TONS PER YEAR OR MORE OF ANY INDIVIDUAL HAZARDOUS AIR POLLUTANT; 

B) 25 TONS PER YEAR OR MORE OF ANY COMBINATION OF HAZARDOUS AIR 

POUUTANTS; 

I) SUCH LESSER QUANTITY AS ESTABLISHED BY RULE WHICH CLASSIFIES THE 

SOURCE AS MAJOR FOR HAZARDOUS AIR POLLUTANTS; 

Iv) EMISSIONS OF HAZARDOUS AIR POUUTANTS WHICH EQUAL OR EXCEED A 

POLLUTANT SPECIFIC CAAPP APPUCABIUTY LEVEL AS ESTABUSHED BY USEPA 

RULE SUCH THAT THE SOURCE IS REQUIRED TO OBTAIN A CAAPP PERMIT 

SOLELY FOR THIS REASON (i.e.. HAP EMISSIONS BELOW THE CAAPP 

APPUCABILITY THRESHOLDS SPECIFIED IN ITEMS m, (II) 4(10) ABOVE. BUT STIU 

REQUIRED TO OBTAIN A CAAPP PERMIT PURSUANT TO A REGULATORY 

REQUIREMENT, e.g., NESHAP)? 

b) IF ANSWERED YES TO ANY OF THE ABOVE, IDENTIFY THE HAP(S) FOR WHICH THE 

SOURCE IS CONSIDERED MAJOR OR REQUIRED TO OBTAIN A CAAPP PERMIT: CK/rone 

• NO 

YES 

YES 

I Ives 

O 

• 

• 

NO 

NO 

NO 

NO 

HAZARDOUS AIR POLLUTANT EMISSIONS TABLE 

6, COMPLETE THE FOLLOWING TABLE Pot-fell HAP» WHICH ARE ftt&ULATEb Alft POLLUTANTS. THIS TABLE 

MUST INCLUDE EMISSIONS OF HAPS AT ACTIVITIES PROPOSED TO BE INSIGNIFICANT PURSUANT TO 35 IL 

ADM: CODE 201.211. NOTE THAT AN APPLICANT MAY PRESUME THAT AN EMISSION UNIT DOES NOT EMIT A HAP 

IF IT MEETS THE REQUIREMENTS OF 35 IL ADM. CODE 201.209. 

I~HIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNDER ILLINOIS REVISED STATUES, 1991, AS AMENDED 1992, 

:HAP 1111/2, PAR. 1039.5. DISCLOSURE OF THIS INFORMATION IS REQUIRED UNDER THAT SECTION. FAILURE TO DO SO MAY 

PREVENT THIS FORM FROM BEING PROCESSED AND COULD RESULT IN THE APPUCATION BEING DENIED. THIS FORM HAS BEEN 

APPROVED BY THE FORMS MANAGEMENT CENTER. 

APPLICATION PAGE 00 055 

215-CAAPP 

FOR APPLICANTS USE 

PAGE 1 OF 2 

HI 
INSIGNIFICANT PURSUANT TO 35 IL. ADM. CODE 201 "i'iil NOTE THAT AN APPLICANT MAY PRESUME THAT AN EMISSION UNIT DOES NOT EMIT A HAP IF IT MEETS THE REQUIREMENTS 

OF 35 IL. ADM. CODE 201.209. 

NAME OF HAP 

EMITTED: 

Stvrene 

Toluene 

Xylene 

Methyl ethyl ketone 

• 

'CAS NUMBER 

100-42-5 

108-88-3 

1330-20-7 

78-93-3 

EMISSION UNIT 

DESIGNATION. 

Compound Prep / Molding 

Paint /Solvent Usage 

Paint /Solvent Usage 

Paint /Solvent Usage 

! 

MAXIMUM 

EMISSIONS 

(TONS/YR) 

94.6 

0.535 

0.216 

0.98 

TYPICAL 

EMISSIONS 

(TONS//YR) 

41.5 

0.27 

0.11 

0.49 

POTENTIAL 

EMISSIONS 

(TONS/YR) 

94.6 

0.535 

0.216 

0.98 

OTHER 

TERMS2 APPLICABLE RULE 

N/A 

N/A 

N/A 

N/A 

APPUCABIUTY LEVEL 

(UNITS) 

N/A 

N/A 

N/A 

N/A 

^CAS - CHEMICAL ABSTRACT SERVICE 

2PROVIDE OTHER TERMS AS NECESSARY TO ESTABUSH APPUCABIUTY OR COMPLIANCE WITH REQUIREMENTS. 

APPLICATION PAGE. 

215-CAAPP 

00056 FOR APPLICANTS USE 

PAGE 2 OF 2 

CO 
P.44 

ILUNOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD, ILUNOIS 62794-9506 

FOR APPUCANTS USE 

Revision*:

 lni M 

Date: Novemtyw 15.1999 

Page of 

Source Designation: 

ACC 

. COMPUANCE PLAN/ 

SCHEDULE OF COMPUANCE 

FOR CAAPP PERMIT 

IDNUK 

PERMIT* 

TSSTET 

THE CLEAN AIR ACT PERMIT PROfiRAM (CAAPP RECUIRES THAT THE APPUCAHT SUHMIT A COMPUANCE PLAN/SCHEDULE OF 

COMPLIANCE FOR AU EMBSION UNITS AT THE CAAPP SOURCE. REGARDLESS OP THE COMPUANCE STATUS OF EACH INOMOUAL 

EMBSION UNIT. THIS FORM REQUIRES THAT THE COMPLIANCE STATUS BE STATED FOR EACH EMBSION UNfT. APPUCATION 

FORM 2B+CAAPP. -COMPUANCE PLAN/SCHEDULE OF (XMPUANCE - ADOfiNDUM FOR NON CCMPLY1NO SESSION UNITS* MUST BE 

SU8MTTED FOR EACH EMSSION UNIT NOT IN COMPUANCE WITH AU APPUCABLE REQUIREMENTS AT THE TI C OF SUBMITTAL 

\) SOURCE NAME: 

SOURCE INFORM A HON 

Applied Composites Corp. 

2) DATE FoRM 

PREPARED: December 6, 1995 

3) SOURCE ID No. 

(IF KNOWN): Q89483AA F 

SOURCE COMPUANCE INFORMATION 

4) DESCRIBE THE COMPLIANCE STATUS OF THE SOURCE WITH ALL APPLICABLE REOUIREMENTS (E.&., "SOURCE 

IS IN COMPLIANCE WITH A U APPUCABLE REQUIREMENTS*): 

Source is in compliance with all applicable requirements. 

5) IF IN COMPLIANCE, WILL THE SOURCE CONTINUE TO COMPLV WITH ALL APPUCABLE REQUIREMENTS'? 

P I YES | | NO 

IF NO, EXPLAIN: 

6) WILL THE SOURCE MEET, ON A TIMELV BASIS, APPUCABLE REOUIREMENTS WHICH BECOME EFFECTIVE 

DURING THE PERMIT TERM? 

[7] YES QN O 

IF NO, EXPLAIN 

THIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNDER ILUNOIS REVISED STATUES, 1991, AS AMENDED 1992, 

CHAP 1111/2, PAR. 1039.5. DISCLOSURE OF THIS INFORMATION IS REQUIRED UNDER THAT SECTION. FAILURE TO DO SO MAY 

PREVENT THIS FORM FROM BEING PROCESSED AND COULD RESULT IN THE APPUCATION BEING DENIED. THIS FORM HAS BEEN 

APPROVED BY THE FORMS MANAGEMENT CENTER. 

APPLICATION PAGE. 

293-CAAPP 

00057 

FOR APPLICANTS USE 

PAGE 1 OF 4 

H3 
P.45 

EMISSION UNITS COMPLIANCE INFORMATTUTT 

^m^iHiiijJii-HiiJMHWiaiajw THE FOLLOWING EMISSION UNITS ARE IN COMPUANCE WITH ALL APPUCABLE REQUIREMENTS AND WILL 

CONTINUE TO COMPLY WITH SUCH REQUIREMENTS DURING THE PERMIT TERM. IF ADDITIONAL SPACE IS 

NEEDED, ATTACH AND LABEL AS EXHIBIT 293-1: 

DESIGNATION ID NUMBER EMBSION UNIT 

Compound Preparation and Maturation 

Molding Presses 

Paint / Solvent Use 

S M Exhibit 220-A far Compound Preparation and Maturation Section 

See Exhibit 220-B for Molding Presses Section 

Paint / Solvent Use (Fugitive emissions) 

APPLICATION PAGE. 

293-CAAPP 

00058 FOR APPLICANTS USE 

PAGE 2 OF 4 H^i 
P.46 

EMISSION UNITS COMPUANCk INFORMATION Icnld) 

DESIGNATION P NUMBER EMBSION UNfT 

-4JI_*_M___l__IH*llJ:"|-<**i»Mai|ll; .*M7_ flJHJM-ltfi'M* 

THE FOLLOWING EMISSION UNITS, WHICH ARE CURRENTLY IN COMPLIANCE WITH A U APPUCABLE 

REQUIREMENTS, WILL ACHIEVE ON A TIMELY BASIS, AND MAINTAIN COMPLIANCE WITH, FUTURE COMPLIANCE 

DATES AS THEY BECOME APPUCABLE DURING THE PERMIT TERM. IF ADDITIONAL SPACE IS NEEDED, ATTACH 

AND LABEL AS EXHIBIT 293-2: 

FUTURE 

COMPUANCE DATE 

DESIGNATION ID NUMBER EMBSION UNIT (MONTH/DAY/YEAR) 

Compound Prep. & Matur. 

Molding Press Area 

Proposed USEPA Styrene MACT 

Proposed USEPA Styrene MACT 

Future compliance dates are unknown 

APPLICATION PAGE

 0Q 0 5 9 

293-CAAPP 

FOR APPLICANTS USE 

PAGE 3 OF 4 L 15 
P.47 

TV -WM.IMJliKlli.-l'M-iliT^^^ 

THE FOUOWING EMISSION UNITS ARE NOT IN COMPUANCE WITH A U APPUCABLE REQUIREMENTS AT THE 

TIME OF PERMIT APPUCATION. HOWEVER, THESE EMISSION UNITS WI U ACHIEVE COMPUANCE WITH ALL 

APPUCABLE REQUIREMENTS PRIOR TO PERMIT ISSUANCE AND WILL CONTINUE TO COMPLY WITH SUCH 

REQUIREMENTS DURING THE PERMIT TERM. IF ADDITIONAL SPACE IS NEEDED, ATTACH AND LABEL AS 

EXHIBIT 293-3: 

FUTURE 

COMPLIANCE OATE 

DESIGNATION ID NUMBER EMBSION UNIT (MONTWDAY/YEAR) 

N/A 

T 

1 t" 

b) THE FOLLOWING IS A NARRATIVE DESCRIPTION OF THE MEANS BV WHICH COMPLIANCE WILL BE ACHIEVED FOR 

EACH OF THE EMISSION UNITS USTED IN 9a) ABOVE. IF ADDITIONAL SPACE IS NEEDED, ATTACH AND LABEL AS 

EXHIBIT 293-4: 

N/A 

•)J-4.-.l_--MMJl»_IIl«JMii:re»M^ 

THE FOLLOWING EMISSION UNITS WI U NOT BE IN COMPUANCE WITH A U APPUCABLE REQUIREMENTS AT THE 

TIME OF PERMIT ISSUANCE. A FORM 294-CAAPP. 'COMPLIANCE PLAN/SCHEDULE OF COMPLIANCE • ADDENDUM 

FOR NON COMPLYING EMISSION UNITS,' MUST BE SUBMITTED FOR EMISSION UNITS NOT IN COMPLIANCE WITH _, 

A U APPUCABLE REQUIREMENTS AT THE TIME OF PERMIT ISSUANCE. A FORM 294-CAAPP IS SUBMITTED FOR THE*! 

FOUOWING EMISSION UNITS. IF ADDITIONAL SPACE IS NEEDED, ATTACH AND LABEL AS EXHIBIT 293-5: 

OATE COMPLIANCE 

SCHEDULED TO BE 

ACHIEVED 

DESIGNATION ID NUHCER EMSSIONUNtT (MONTWDAY/YEAR) 

i \-

APPUCATION PAGE°Mf> A 

293-CAAPP 

FOR APPLICANTS USE 

PAGE 4 OF 4 

HL 
P.48 

ILUNOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P O BOX 19506 

SPRINGFIELD," ILUNOIS 62794-9506 

saaaaaiBanraGHi 

Revision* »""" 

Date: Doo«*~Hwr 5,199Q* 

Page of 

Source Designation: 

ACC 

COMPUANCE CERTIFICATION 

mmmmwmmMMMMmym 

PERMIT* 

DATE: 

AN APPLICATION FOR A CAAPP PERMIT MUST CONTAIN A CERTIFICATION OF COMPLIANCE 5I5NED BV A RESPONSIBLE OfflCIAL 

THB FORM MUST BE SUBM*TTED WITH THE ORIGINAL CAAPP PERMIT APPIXATION ANO UPDATED ON AN ANNUAL BASB. 

I) SOURCE NAME: 

SOURCE INFORMATION 

Applied Composites Corp. 

5. DATE FORM 

PREPARED: December 6,1995 

4) CAAPP PERMIT NUMBER (iF kNoWN): 

J) SOURCE ID No. 

(IF KNOWN): grgVFD 

Unknown DEC 0 7 1995 

5) IS THIS THE FIRST SUBMITTAL OF THIS F0RM-> 

IF NO. WHAT IS THE REPORTING PERIOD 

COVERED BY THIS FORM? / / TO: / 

EJS^IEJ NO 

SOURCE COMPUANCE INFORMATION 

6) DOES THE SIGNATORY OF THIS FoRM HEREBY CERTIFV THAT THE SOURCE IS IN COMPLIANCE WITH ALL 

APPUCABLE REQUIREMENTS? 

& s NO 

IF NO, EXPLAIN: 

7) PROVIDE THE SCHEDULE FOR SUBMISSION OF COMPUANCE CERTIFICATION DURINO THE PERMIT TERM, E.O.. 

ONCE ANNUAUY IN JANUARY (NOTE THAT SUCH CERTIFICATION MUST BE SUBMITTED NO LESS FREQUENTLY 

THAN ANNUAUY): 

Once annually in August, following the issuance of the permit 

&) INDICATE THE COMPLIANCE STATUS OF THE SOURCE WITH ANV APPLICABLE ENHANCED MONITORING AND 

COMPLIANCE CERTIFICATION REQUIREMENTS OF THE CLEAN AIR ACT, E.G., NO ENHANCED MONITORING 

REQUIRED AND IN COMPLIANCE WITH COMPUANCE CERTIFICATION REQUIREMENTS: 

No applicable enhanced monitoring is required. The source is in compliance with 

certification requirements. 

-HIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNOER ILUNOIS REVISED STATUES, 1991, AS AMENDED 1992, 

'.HAP 1111/2, PAR. 1039.5. DISCLOSURE OF THIS INFORMATION IS REQUIRED UNDER THAT SECTION. FAILURE TO DO SO MAY 

•REVENT THIS FORM FROM BEING PROCESSED AND COULD RESULT IN THE APPLICATION BEING DENIED. THIS FORM HAS BEEN 

.PPROVED BY THE FORMS MANAGEMENT CENTER. 

APPLICATION PAGE 0006 1 

296 - CAAPP 

FOR APPLICANTS USE 

PAGE 1 OF 5 HI 
P.49 

EMISSION UNI IS COMPUANCE INFORMATION 

Sa_ THE FOLLOWING EMISSION UNITS ARE IN COMPLIANCE WITH APPUCABLE REOUIREMENTS SUCH AS EMISSION 

STANDARDS, EMISSION CONTROL REQUIREMENTS, EMISSION TESTING, COURT REQUIREMENTS, WORK 

PRACTICES, OR ENHANCED MONITORING, BASED ON THE COMPUANCE METHODS SPECIFIED BELOW (IF 

ADDITIONAL SPACE IS NEEDED, ATTACH AND LABEL AS EXHIBIT 296-1): 

EMISSION UNIT APPUCABLE RULE COMPLIANCE DETERMINATION 

METHOD 

Compound and Maturation Room 

(See Exhibit 220-A in section) 

Molding Pressae 

(See Exhibit 220-B in section) 

Paint Use 

Solvent Use 

See Appendix B,(l) 

See Appendix C 

See Appendix B,(ll) 

See Appendix C 

See Appendix C 

IAC 218.666(d) 

See Appendix B,(l) 

See Appendix C 

See Appendix B,(ll) 

See Appendix C 

See Appendix C 

recordkeeping 

APPLICATION PAGE 00062 

296 - CAAPP 

FOR APPLICANTS USE 

PAGE 2 OF 5 

Y? 
P.50 

fe) UsT THE EMISSION UNITS THAT WERE NoT IN CONTINUOUS COMPLIANCE SINCE THE LAST REPORTING PERIOfc 

AND THE REASON(S) FOR NONCOMPLIANCE (IF ADDITIONAL SPACE IS NEEDED, ATTACH AND UBEL AS EXHIBIT 

296-2.): 

EMISSION UNIT REASON(S) FOR NONCOMPLIANCE 

None 

• 

: 

COMPUANCE INFORMATION 

ifl) SUMMARY OF METHODS USED TO DETERMINE COMPLIANCE: 

a) DESCRIPTION OF TESTING METHODS USED TO DEMONSTRATE COMPLIANCE (IF ADDITIONAL SPACE IS 

NEEDED, ATTACH AND LABEL AS EXHIBIT 296-3.): 

VOM 

218.668(a)(1) Cleaning material with supplier data, sample or Method 24 

218.668(a)(3) Monomer content determined by supplier data. 

218.668(b) Upon Agency request. 

218.668(c) Upon U.S.EPA request. 

See Appendix C, State Operating Permit 

APPLICATION PAGE 0006 3 

296 - CAAPP 

FOR APPLICANTS USE 

PAGE 3 OF 5 

HI 
P.51 

lob, DESCRIPTION OF MONITORING PROCEDURES USED TO DEMONSTRATE COMPLIANCE, INCLUDING ANV 

ENHANCED MONITORING REQUIREMENTS OF THE ACT (IF ADDITIONAL SPACE IS NEEDED, ATTACH AND LABEL AS 

EXHIBIT 296-4.): 

No monitoring equipment or enhanced monitoring required. 

Compliance demonstration via recordkeeping, daily inspections(i.e. inspection of 

covers) & maintenance. 

c, DESCRIPTION OF RECoRbkEEPiNG UsED TO DEMONSTRATE COMPLIANCE (it- ADDITIONAL SPACE IS NEEDED, 

ATTACH AND LABEL AS EXHIBIT 296-5.): 

See Appendix B, (l)(B) and (I)(C) 

See Appendix C, State Operating Pennit Conditions 11 and 12 which state: 

11. The monomer content of poiye*rferii-*sJn materia shall be determined: 

I. From suppl tor data and operating data; or 

i. By s*MiK*ng art analy-w by the methoo* set forth in SC^^ 

12a. The Permittee shall maintain records of the following items to **ow the Agency to review compliance: 

I. Formulation data for molding compounds, with type and amount of re^s), additives, catalyst, 

filler, fiberglass, inhibitors, promoters, etc. (data distirx^ for each dJstinct formulation) 

H. Styrene content of resin materials used in molding compound, (data distinct for each distinct 

resin and material) 

iii. Quantity (pounds) of each type (sheet mold or thick mold and general purpose, high monomer 

content, special purpose, or low monomer content) of compound produced, (monthly) 

Iv. Quantity (pounds) of monomer used, (monthly) 

v. Quantity of each solvent used (dibasic ester and isopropyl alcohol) and amount recovered and 

sent off for site reclamation, (monthly) 

vi. VOM emissions, (calculated monthly) 

12b. The Permittee shall keep written records of periodic inspections to confirm impiementatkx. of the 

measures required by Condition 7. 

12c. These records shall be retained for a period of three years and shall be made available for Agency 

inspection upon request Copies of records shall be submitted within 10 days of Agency request 

APPLICATION PAGE 

296 - CAAPP 

00064 FOR APPLICANTS USE 

PAGE 4 OF 5 

5o 
P.52 

iod) DESCRIPTION OF REPoRTINO USED TO DEMONSTRATE COMPUANCE (IF ADWTIONAL SPACE IS NEEDED, ATTACH 

AND LABEL AS EXHIBIT 296-6.): 

Submission of Annual Emission Report under IAC 201.302. 

March 15,1995 Certification of Compliance under 218 Subpart CC. 

SIGNATURE EJZUCJC 

NCTE: -mEC«nFICA!IWMUSTBfcSlG>IEDBVARESPONSlBLE« — 

W U BE RETURNED AS -^COMPLETE. • 

..) I CERTIFY UNDER PENALTY OF LAW THAT. BASED ON INFORMATION AND BEUEF FORMED AFTER REASONABLE 

INQUIRY. THE STATEMENTS AND INFORMATION CONTAINED IN THIS APPUCATION ARE TRUE, ACCURATE AND 

COMPLETE. 

AUTHORIZED SIGNATURE: 

Vice President - Operations 

" ^ AUTH6|-aZEDSIONA'njRE 

John J. Punis 

TYPED OR PRMTED NAME OF SIGNATORY 

,/<*-

TTTVE OF SIGNATORY 

DATE 

APPUCATION PAGE. 

, 296-CAAPP 

00065 FOR APPLICANTS USE 

PAGE 5 OF 5 

5( 
P.53 

ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

•.- A DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD, ILUNOIS 62794-9506 

FOR APPLICANT'S USE 

Revision* *** " 

Date: November 15.19»5 

Page of 

Source Designation: 

ACC 

FEE DETERMINATION FOR 

CAAPP PERMIT 

THE PATA PROVIDED CN THIS FORM WILL BE U5LP TO m_n_RMINE THE PERMIT FEL THE EMISSION LEVELS STATEP ON THIS FORM 

CAN ONLY BE USEO FOR THE PURPOSE OF PERMT FEE OETERMWATION IF THE APPUC*ANT B WIUJNG TO ACCEPT THESE LEVELS 

AS PERMT SPECIAL CONDITIONS. EMBSIONS DATA PROVIDED ON THIS FORM MUST BE IDENTICAL TO OATA IN THE TERMnTED 

EMBSION RATE* COLUMNS PROVIDED ON THE OATA ANO NFORMATION FORM FOR INDIVIDUAL B«nioaUMraOR£^NTROL 

EQUIPMENT. W ADOmONAL SPACE IS NEEDED. ATTACH ANO LABEL AS 2BM. f\\?^,^jlZFW "* * •-*= 

\) SOURCE NAME: 

SOURCE INFORMATION 

Applied Composites Corp. UbC J 7 iS95 

2. DATE FORM 

PREPARED: December 6,1995 

3)

 WSSSjar0- 0BS483^V^ ' o r * ^ 

• ~ " • FEE DATA 

4) WiLL THE SOURCE PAY THE MAXIMUM FEE OF i100.ooo.oo PER YEAR* 

IFYES, THE REMAINDER OF THIS FORM DOES NOT NEED TO BE COMPLETED. 

5) 

EMBSION UNIT* 

Compounding Preparation an 

Maturation 

Molding Presses 

MTROGEN 

OXIDES 

(TONS/YR) 

I 

PARTICULATE 

MATTER 

(PART) 

(TONS/YR) 

SULFUR 

DIOXIDE 

(SOj) 

(TONS/YR) 

YES 

VOLATU 

ORGANIC 

MATERIAL (VOM) 

(TONS/YR) 

68.3 

26.3 

• NO 

OTHER" 

SPECIFY 

(TONS/YR) 

EMBSION UNIT -PROVH3E THE NAME ANO FLOW DIAGRAM DESIGNATION OF THE EMBSION UNTT AS IT APPEARS ON THE DATA AND 

MFORMATION FORM. 

"OTHER - ANY HAZARDOUS AIR POLLUTANT (HAP) NOT INCLUDED ELSEWHERE, E.G., CHLORINE. Ha, ETC. 

miS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNOER ILUNOIS REVISED STATUES, 1991. AS AMENDED 1992, 

2HAP 1111/2, PAR. 1039.5. DISCLOSURE OF THIS INFORMATION IS REQUIRED UNDER THAT SECTION. FAILURE TO DO SO MAY 

PREVENT THIS FORM FROM BEING PROCESSED AND COULD RESULT IN THE APPUCATION BEING DENIED. THIS FORM HAS BEEN 

APPROVED BY THE FORMS MANAGEMENT CENTER. 

APPLICATION PAGE 00^6 8 

292-CAAPP 

FOR APPLICANTS USE 

PAGE 1 OF 2 

S*-
P.54 

5> (CONTINUE^ 

BMBStONUNTT* 

MTROGEN 

OXDES 

(NCfc) 

(TONS/YR) 

PARTICULATE 

MATTER 

(PART) 

(TONS/YR) 

SULFUR 

DtOXDE 

(SOj) 

(TONS/YR) 

VOLATXE 

ORGAMC 

MATERIAL (VOM) 

(TONS/YR) 

OTHERTM 

SPECIFY 

(TONS/YR) 

"B«SSIONUNrr-PRO\nOe-|>IENAMeAf_On.OWDtAGIWMC)eSIGNA-^ EMBSION UNIT AS IT APPEARS ON THE DATA AND 

MFORMATION FORM. 

•OTHER - ANY HAZARDOUS AIR POLLUTANT (HAP) NOT NCLUOED ELSEWHERE, E.G.. CHLORINE. HCI. ETC. 

SUBTOTAL 94.6 

7) 

FUGITIVE 3.729 

TOTAL 

A B t ° 98.329 i 

ty GRAND TOTAL • ADD BOXES* THROUGH B (TONS/YR): 98.329 

16) CALCULATED PERMIT FEE - IF 6RAND TOTAL IN iTEM 6 ABOVE IS > ito TONSfrft THEN 

MULTIPLY GRAND TOTAL BY $13.50 AND ENTER. OTHERWISE ENTER $1,000.00: $1,000.00 

11 MINIMUM PERMIT FEE IS Jl,00o.fl0PER VEAR -MAXIMUM PERMIT FEE 15 *1M.Mu.M PER YEAR. 

THE CALCULATED PERMIT FEE IN ITEM 10 ABOVE IS BETWEEN THESE TWO FEE AMOUNTS THElt 

ENTER HERE, OTHERWISE ENTER THE MINIMUM OR MAXIMUM PERMIT FEE. WHICHEVER IS 

APPLICABLE. THIS IS THE ACTUAL ANNUAL PERMIT FEE: 

1000.00 

APPLICATION PAGE 000E7 

292-CAAPP 

FOR APPLICANTS USE 

PAGE 2 OF 2 

SJ 
P.55 

SECTION S 

PAINT/SOLVENT USE 

5H 
P.56 

ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD, ILUNOIS 62794-9506 

FOR APPLICANT'S USfc 

Revision* J"* " 

Oate: Dece-ybar 5,199ft 

Page of 

Source Designation: 

ACC 

FUGITIVE EMISSIONS 

0 

DATA AND INFORMATION 

ID NUMBEREMISSION POINT* 

TESTE: 

THIS FORM MAY BE COMPLETED FOR FUGITIVE EMISSION ACTIVITIES RATHER THAN COMPLETING AN EMISSION UNIT 

OR STAND ALONE FORM. FUGITIVE EMISSIONS ARE DEFINED AS THOSE EMISSIONS WHICH COULD NOT REASONABLY 

PASS THROUGH A STACK. CHIMNEY, VENT OR OTHER FUNCTIONALLY EQUIVALENT OPENING. NOTE THAT 

UNCAPTURED PROCESS EMISSION UNIT EMISSIONS ARE TYPICALLY NOT CONSIDERED FUGITIVE AND MUST BE 

ACCOUNTED FOR ON THE APPROPRIATE EMISSION UNIT OR STAND ALONE FORM. ANY EMISSIONS AT THE SOURCE 

NOT PREVIOUSLY ACCOUNTED FOR ON AN EMISSION UNIT OR STAND ALONE FORM MUST BE ACCOUNTED FOR ON 

THIS FORM. 

SOME EXAMPLES OF EMISSIONS WHICH ARE TYPICALLY CONSIDERED FUGITIVE ARE; 

• ROAD DUST EMISSIONS (PAVED ROADS, UNPAVED ROADS. AND LOTS) 

• STORAGE PILE EMISSIONS (WIND EROSION, VEHICLE DUMP AND LOAD) 

• LOADING/UNLOADING OPERATION EMISSION 

• EMISSIONS FROM MATERIAL BEING TRANSPORTED IN A VEHICLE 

• EMISSIONS OCCURRING FROM THE UNLOADING AND TRANSPORTING OF MATERIALS 

COLLECTED BY POLLUTION CONTROL EQUIPMENT 

• EQUIPMENT LEAKS (E.G., LEAKS FROM PUMPS, COMPRESSORS, IN-UNE PROCESS VALVES, 

PRESSURE REUEF DEVICES. OPEN-ENDED VALVES, SAMPUNG CONNECTIONS, FLANGES, 

AGITATORS. COOUNG TOWERS, ETC.) 

GENERAL CLEAN-UP VOM EMISSIONS 

NOTE THAT TOTAL EMISSIONS FROM THE SOURCE (TS) ARE EQUAL TO SOURCE-WIDE TOTAL EMISSION UNIT EMISSIONS 

(PT) PLUS TOTAL FUGITIVE EMISSIONS (FT), E.G., TS = PT = FT 

1) SOURCE NAME: 

Paint / Solvent Use 

2) DATE FORM 

PREPARED: December 6,1995 

SOURCE INFORMATION 

S) SOURCE ID NO. 

(IF KNOWN): Q89483AA F 

THIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNDER ILUNOIS REVISED STATUES, 1991, AS AMENDED 1992. 

CHAP 1111/2. PAR. 1039.5. DISCLOSURE OF THIS INFORMATION IS REQUIRED UNDER THAT SECTION. FAILURE TO DO SO MAY 

PREVENT THIS FORM FROM BEING PROCESSED AND COULD RESULT IN THE APPUCATION BEING DENIED. THIS FORM HAS BEEN 

APPROVED BY THE FORMS MANAGEMENT CENTER. 

APPLICATION PAGE 

391 - CAAPP 

00044 

FOR APPLICANTS USE 

PAGE 1 OF 11 

ss 
P.57 

GENERAL INFORMATION 

4) PROVIDE THE F0LL0MN6 INFORMATION FoR THE FUGITIVE EMISSION POINTS AT THE SOURCE INCLUDED IN THIs 

APPUCATION. SIMILAR POINTS MAY BE GROUPED TOGETHER. 

NOTE: ATTACH THE CALCULATIONS. TO THE EXTENT THEY ARE AIR EMSSIONSRBATED, FROM WHICH THE ABOVE 

EMBSIONS. WERE BASED AND LABEL AS EXHIBIT 391-1. F THE ABOVE SPACE WAS NOT ADEQUATE, UST A a OTHER 

FUGITIVE POINTS ANO INCLUDE THE REOUIRED INFORMATION ON THB ATTACHMENT. 

FOR PAVED ANO UNPAVED ROADS, INCLUDE ROAD MLES (E.G., S MLES OF UNPAVED ROADS); FOR STORAGE Pt_ES, WOICATE 

THE MATERIAL BEING STORED (E.G.. 20 UMESTONE STORAGE PILES); FOR EQUIPMENT LEAK POMTS, GROUP SMLAR POINTS 

TOGETHER (E.G., 15 ORGANIC LIQUID PUMPS); FOR TRANSFER POINTS. IDENTIFY THE ORIGIN AND DESTINATION OF TRANSFER 

ANO THE MATERIAL BEING TRANSFERRED (E.G.. S BELT TO BIN TRANSFERS OF CORN). 

FUGITIVE PONT(S) 

REGULATED AH 

POLLUTANT(S) 

UNCONTROLLED ANNUAL EMBSIONS 

(TONS/YR) 

TYPICAL 

Paint Use 

Solvent Uee 

VOM 

VOM 

0.11 

3.62 

0.06 

2.8 

5) ATTACH A BIA&RAM OF THE SOURCE THAT INDICATES THE LOCATION OF ALL FUOITIVE EMISSION POINTS: A 

SKETCH DRAWING WITH THE PROPER NOTATIONS IS SUFFICIENT. ALTERNATIVELY, THE REQUIRED INFORMATION 

MAY BE PLACED ON A COPY OF AN EXISTING PLAN OR MAP SUBMITTED WITH THIS APPUCATION (E.G., PLOT 

PLAN/MAP). ALSO INDICATE ON THIS DIAGRAM THE LOCATION OF ANY AMBIENT AIR MONITORING STATIONS. LABfl. 

THIS DIAGRAM 391-2. NOTE: EQUIPMENT LEAK FUGITIVE EMISSION POINTS NEED NOT BE SHOWN ON THIS 

DIAGRAM. 

APPLICATION PAGE. 

391 - CAAPP 

00045 

FOR APPLICANTS USE 

PAGE 2 OF 11 

% 
Ol rnuviucn n orcv.iri<_> cmiasiu n sinnunnuiainn u umnniiunaia i nniMinncnrruungL E t w ruuinri . uniuuiung m 

212.316(d), OPACITY < OR » 10% AT 4 FT): 

FUGITIVE POINTS(S) REGULATED AIR POUUTANT(S) EMBSION STANDARDS) 

~TJ 

Solvent Use 

PROVIDE ANV SPECIFIC RECORDKEEP 

FUGITIVE POINTS(S) 

N/A 

ING 

VOM 

RULE(S) WHICH ARE APPUCABLE: 

REGULATED AIR POLLUTANT'S) 

IAC 218.666(d) 

-

EMBSION STANDARD'S) 

IIII - uwyiwi . \w.«_,., nwn w W_.WIVI_.II , f , • waa-xaa, •_-,«_• 

REQLNREMENT(S) 

solvent recoverv 

* 

REQUIREMENT(S) 

IF ADOmONAL SPACE B NEEDED, ATTACH ANO LABEL AS 381-3. 

$ 

APPLICATION PAGE__£M£6 

391 - CAAPP 

ZekW;l_dia32iH!H 

PAGE 3 0F11 

01 

oo 
VA 

B) PROVIDE ANV SPECIFIC REPORTING RULE(S) WHICH ARE APPLICABLE: 

FUGITIVE POINTS(S) REGULATED AIR POU_UTANT(3) 

Paint / Solvent Use 

Solvent Use 

VOM 

VOM 

"57PROVIDE ANY SPECIFIC MONITORING RULE(S) WHICH ARE APPLICABLE: 

FUGITIVE POINTS(S) REGULATED AIR POLLUTANT(8) 

~fl! 

N/A 

) PROVIDE ANV SPECIFIC TESTING RUI 

FUGITIVE POtNTS(S) 

N/A 

.ES 

EMBSION STANDARD!?) 

IAC 201.302 

IAC 218.666(d) 

. 

EMBSION STANOARO(S) 

AND/OR PROCEDURES WHICH ARE APPUCABLE: 

REGULATED AR POLLUTANT(8) EMBSION STANDARDS) 

' ! 

REQUtRE**ENT(8) 

AER 

solvent recovery 

* 

REQUIREMENT^) 

REQUIREMENT^) 

IF ADDITIONAL SPACE B NEEDED, ATTACH AND LABEL AS-MJ1-3. 

APPLICATION PAGE "" ° 

391-CAAPP 

FOR APPLICANTS USE 

PAGE 4 OF 11 
P.60 

COMPUANCE INFORMATION 

H) IS EACH FUGITIVE POINT IN COMPUANCE WITH ALL APPUCABLE REOUIREMENTS? TZ> 40 

IF NO, THEN FORM 294-CAAPP 'COMPLIANCE PLAN/SCHEDULE OF COMPLIANCE - ADDENDUM FOR NON 

COMPLYING EMISSION UNITS" MUST BE COMPLETED AND SUBMITTED WITH THIS APPUCATION. 

IS) EXPLANATION OF HOW INITIAL COMPUANCE IS TO BE, OR WAS PREVIOUSLV, DEMONSTRATED: 

Material usage recordkeeping 

13) EXPLANATION OF HOW ONGOING COMPLIANCE WILL BE DEMONSTRATED: 

Material usage recordkeeping 

TESTING, MONITORING, RECORDKEEPING AND REPORTING 

I4i) UST THE PARAMETERS THAT RELATE TO AIR EMISSIONS FOR WHICH RECORDS ARE BEING MAINTAINED TO 

DETERMINE FEES, RULE APPUCABILITY OR COMPLIANCE. INCLUDE THE UNIT OF MEASUREMENT, THE METHOD 

OF MEASUREMENT, AND THE FREQUENCY OF SUCH RECORDS (E.G.. HOURLY. DAILY. WEEKLY): 

PARAMETER FUGITIVE POINT METHOO OF MEASUREUfCWT 

PaW /Solvent Use See Figure 3, F-2 Annual and Monthly summaries 

FREQUENCY 

monthly 

APPLICATION PAGE, 

391 - CAAPP 

00048 FOR APPLICANTS USE 

PAGE 5 OF 11 

5°\ 
P.61 

b) BRIEFLV DESCRIBE THE METHOD BV WHICH RECORDS WILL BE CREATED AND MAINTAINED. FOR EACH — 

RECORDED PARAMETER INCLUDE THE METHOO OF RECORDKEEPING, TITLE OF PERSON RESPONSIBLE FOR 

RECORDKEEPING, AND TITLE OF PERSON TO CONTACT FOR REVIEW OF RECORDS: 

PARAMETER 

PaW/Solvent Use 

METHOO OF 

RECORDKEEPtW 

WMIUM »fnonMy i 

TITLE OF 

PERSON RESPONSIBLE 

HSEQ Coordinator 

TITIE OF 

CONTACT PERSON 

HSEQ Coordinator 

c) IS COMPUANCE OF THE EMISSION UNIT READILV DEMONSTRATED BV REVIEW OF 

THE RECORDS? 

IF NO, EXPLAIN: 

YES NO 

d) ARE ALL RECORDS READILV AVAILABLE FOR INSPECTION, COPVINO ANDLOR „ 

SUBMITTAL TO THE AGENCY UPON REQUEST? * YES NO 

IF NO, EXPLAIN: 

15a) DESCRIBE ANV MONITORS OR MONITORING ACTIVITIES USED TO DETERMINE FEES, RULE APPUCABIUTV OR 

COMPLIANCE: 

N/A 

Tj WHAT PARAMETER(S) IS(ARE) BEINO MONITORED? 

N/A 

c) DESCRIBE THE LOCATION OF EACH MONITOR ANDLOR MONITORING PROCEDURES: 

N/A 

TJ IS EACH MONITOR EOUIPPED WITH A RECORDING BEVICE? 

IF NO, UST A U MONITORS WITHOUT A RECORDING DEVICE: 

N/A 

YES NO 

APPLICATION PAGE_££2iJL 

391 - CAAPP 

FOR APPLICANTS USE 

PAGE 6 OF 11 

Co 
P.62 

e) IS EACH MONITOR HEVIEWEgTOITACgORACV ON AT LEAST* QUARTERLY BSSIST" " , 

YES ' NO 

IF NO, EXPLAIN: 

N/A 

I) IS EACH MONITOR OPERATED AT ALL TIMES THAT FUGITIVE EMISSIONS MAV OCCUR? 

YES NO 

* 

IF NO, EXPLAIN: 

N/A 

IS) PROVIDE INFORMATION ON THE MOST RECENT TESTS, IF ANV, IN WHICH THE RESULTS ARE USED FOR 

PURPOSES OF THE DETERMINATION OF FEES, RULE APPUCABILITY OR COMPLIANCE. INCLUDE THE TEST DATE, 

TEST METHOD USED, TESTING COMPANY. OPERATING CONDITIONS EXISTING DURING THE TEST AND A 

SUMMARY OF RESULTS. IF ADDITIONAL SPACE IS NEEDED, ATTACH AND LABEL AS EXHIBIT 391-4: 

TEST OPERATMG 

FUGITIVE POINT(S) TEST DATE METHOO TESTING FIRM CONDmONS SUMMARYOF 

RESULTS 

TJ 

N/A 

i 

• 

• 

*) DESCRIBE ALL REPORTING REOUIREMENTS AND PROVIDE THE TITLE AND FREQUENCY OF REPORT 

SUBMITTALS TO THE AGENCY: 

FUGITIVE REPORTING REQURBriENTS TITLE OF REPORT FREQUENCY 

POtNT<S) 

F-2 IAC 201.302 AER Annual 

ru&iivb DUST (complete it applicable) 

ifia) ARE OPACITY READINGS REOUIRED TO BE TAKEN? 

YES N/ A NO 

IF YES, SPECIFY THE RELEVANT FUGITIVE POINT(S): 

b) SPECIFY THE FREOUENCY OF OPACITY READINGS: 

N/A 

APPLICATION PAGE 

391 - CAAPP 

00050 FOR APPLICANTS USE 

PAGE 7 OF 11 

61 
c)IBU5EPA"METH0D 3 U5ED70 READ ALL VISIBLE EMISSIONS? 

IF NO, EXPLAIN AND SPECIFY THE METHOO USED: 

N/A 

YES NO 

Ifl) IS AN OPERATING PROORAM FOR FUGITIVE PARTICULATE MATTER AND/OR PMI6 , , 

CONTROL REQUIRED PURSUANT TO 36 ILL ADM. CODE 212.300? 1 1 \w^ 

IF YES, HAS SUCH A PROGRAM PREVIOUSLY BEEN SUBMITTED TO THE AGENCY? 1 1 1 1 

1 |YES | 1 NO 

IF SUCH A PROGRAM HAS NOT BEEN SUBMITTED, IT SHOULD BE ATTACHED TO THIS FORM UPON SUBMITTAL AND 

LABELED AS 391-5. 

20) 15 THE SOURCE IN COMPLIANCE WITH 35 ILL ADM. CODE 212.301 WHICH 5TATE5 THAT 

NO EMISSIONS SHALL BE VISIBLE BEYOND THE PROPERTY UNE OF THE SOURCE? I I 

IF NO, EXPLAIN: 

N/A 

• NO 

FUGITIVE VOM FROM EQUIPMENT LEAKS (complete d applicable) 

H) INDICATE WHICH OF THE FOLLOWING METHODS WAS USED TO ESTIMATE FUGITIVE EMISSIONS OF VO M FROM 

EQUIPMENT LEAKS*. 

f JAVI 1

 EMI 

lAVERAGE 

IISSION 

FACTOR 

LEAK/NO LEAK 

EMISSION 

FACTOR 

STRATIFIED 

EMISSION 

FACTOR 

• LEAK RATE/SCREENING VALUE 

CORRELATION 

• OTHER; (SPECIFY): 

ATTACH A COPY OF THE FINAL REPORT FOR ANY OF THE ABOVE TESTS THAT HAVE BEEN PERFORMED. THIS 

REPORT SHOULD SUMMARIZE THE TEST PROCEDURES AND RESULTS. LABEL AS 391-6. 

22) 15 THERE AN ACTIVE INSPECTION AND MONITORING PROGRAM OF EQUIPMENT 

LEAKS? • «* D NO 

IF YES, PROVIDE A DESCRIPTION OF SUCH PROGRAM OR ATTACH THE INSPECTION PROGRAM TO THIS FORM 

AND LABEL AS 381-7: 

N/A 

APPLICATION PAGE 0005 1 

391 - CAAPP 

FOR APPLICANTS USE 

PAGE 8 OF 11 

Cl 
P.64 

FUGITIVE VOM FROM CLEANUP OPERATIONS (compleia it appUcable) 

» ) COMPLETE THE FOLLOWING FOR EACH VoM CONTAINING MATERIAL USED FOR CLEANUP FOR WHICH THE 

EMISSIONS ARE FUGITIVE AND HAVE NOT BEEN ACCOUNTED FOR ELSEWHERE IN THIS APPUCATION: 

ANNUAL USAGE 

(GAUYEAR) 

GENERIC NAME OF CLEANUP 

MATERIAL 

DENSITY 

(LB/GAL) 

VOM CONTENT 

(WEIGHT %) MAX TYPICAL 

•) 

b) 

e) 

see Table 3 

24) EXPLAIN THE MEAN S BV WHICH THESE MATERIALS ARE USED AND WHAT EOUIPMENT OR ITEMS ARE BEING 

CLEANED: 

Solvents are primarily used for line flushing, paint thinning and cleanup. 

25a) ARE ALL VoM UsED IN CLEANUP OPERATIONS CONSIDERED TO BE EMITTED? 

YES NO 

IF NO, EXPLAIN: 

* Waste solvents are shipped offsite for energy recovery. Cleanup solvents used 

in the Compound Preparation and Maturation Area are included in the total 

emissions from Compound Preparation and Maturation Area (see Section 3). 

b) IF APPUCABLE, COMPLETE ITEMS I, II, AND iii BELOW: 

I) PROVIDE THE MAXIMUM AND TYPICAL AMOUNT OF VOM RECLAIMED AND/OR SHIPPED OFF-SITE AND 

HENCE, NOT EMITTED: 

(GALSYR) (TONS/YR) 

MAX 

N/A 

N/A 

N/A 

N/A 

ii) EXPLAIN THE MEANS BV WHICH VOM IS COLLECTED FOR RECLAMATION ANDflR DISPOSAL 

Waste dibasic ester is stored in 55 gallon drums prior to offsite energy recovery. 

APPLICATION PAGE 0005 2 

391 - CAAPP 

FOR APPLICANTS USE 

PAGE 9 OF 10 

C3 
P.65 

IS) EXPLAIN THE MEANS BV WHICH THE AMOUNT OF VOM COLLECTED 15 MEASURED OR DETERMINED: 

Waste solvents are shipped offsite for energy recovery. 

FUGITIVE CONTROL 

26) COMPLETE THE FOLLOWING, INCLUDING THE MINIMUM AND TYPICAL REDUCTION EFFICIENCY FOR EACH 

CONTROL MEASURE UTILIZED: 

•) 

b) 

c) 

<0 

•) 

CONTROL MEASURES 

N/A 

REGULATED AR 

POLLUTANT 

FUGITIVE 

POINT'S) 

CONTROLLED 

REDUCTION 

MINEFF(%-TVP 

FREQUENCY 

OF 

CONTROL 

APPUCATION 

NOTE: IF ADDITIONAL SPACE IS NEEDED, ATTACH AND LABEL AS 391-8. 

27) PROVIDE A DESCRIPTION OF EACH OF THE CONTROL MEASURES INDICATED IN ITEM 32. IF ADDITIONAL SPACE IS 

NEEDED, ATTACH AND LABEL AS 391-9. 

CONTROL MEASURE(S) DESCRIPTION 

a) N/A 

b) 

N/A 

APPLICATION PAGE_ 

391 - CAAPP 

00053 FOR APPLICANTS USE 

PAGE 10 OF 11 

6H 
P.66 

27) {CONTINUED) PROVIDE A DESCRIPTION OF EACH OF THE CONTROL MEASURES INDICATED IN ITEM 26. IF 

ADDITIONAL SPACE IS NEEDED, ATTACH AND LABEL AS 391-9. 

«) 

CONTROL MEASUREIS) 

N/A 

DESCRf-HON 

N/A 

N/A 

N/A 

N/A 

••) 

N/A 

APPLICATION PAGE 00054 

391 - CAAPP PAGE 11 OF 11 

L$ 
P.67 

SECTION 4 

MOLDING PRESSES 

GG 
P.68 

ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD, ILUNOIS 62794-9506 

FOR APPLICANTS USE 

Revision #:

 WB '1 

Date: Dace-jnberS. 199S 

Page of 

Source Designation: 

ACC 

PROCESS EMISSION UNIT 

DATA AND INFORMATION EMISSION POINT 4 

•BATE. 

I) SOURCE NAME: 

Applied Composites Corp. 

SOURCE INFORMATION 

2) DATE FoRM 

PREPARED: December 6,1995 

3) SOURCE Ib NO. nonjlMAAP. 

(IF KNOWN): 089483AA F 

GENERAL INFORMATION 

4) NAME OF EMISSION UNIT: : 

M o 'd

'

n

g

 Presse s

 (see Appendix A, Exhibit C for list of molding presses) 

5) NAME OF PROCESS: 

Molding Presses 

6) DESCRIPTION OF PROCESS: 

See Introduction 

7) DESCRIPTION oF IYEM OR MATERIAL PRODUCED OR ACTIVITY ACCOMPUSHED: 

Molded Fiberglass Reinforced PlasticJFRP) 

6) FLOW DIAGRAM DESIGNATION OF EMISSION UNIT: " " 

Molding Presses (see Figure 3) 

5) MANUFACTURER OF EMISSION UNIT (IF kNOWN): 

S ee Appendix A, Exhibit C 

10) MODEL NUMBER (IF KNOWN): 

S ee Appendix A, Exhibit C 

12) DATES OF COMMENCING CONSTRUCTION.

 r " 

OPERATION AND/OR MOST RECENT MODIFICATION 

OF THIS EMISSION UNIT (ACTUAL OR PLANNED) 

13) DESCRIPTION OF MODIFICATION (IF APPUCABLE): 

N/A 

11) SERIAL NUMBER (IF KNOWN): 

See Appendix A, Exhibit C 

a) CONSTRUCTION (MONTH/VEAR): 

See Appendix A, Exhibit C 

b) OPERATION (MONTH/YEAR): 

See Appendix A, Exhibit C 

e) LATEST MODIFICATION (MoNYHA'EAR): 

N/A 

THIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNDER ILUNOIS REVISED STATUES, 1991, AS AMENDED 1992. 

CHAP 1111/2, PAR. 1039.5. DISCLOSURE OF THIS INFORMATION IS REQUIRED UNDER THAT SECTION. FAILURE TO OO SO MAY 

PREVENT THIS FORM FROM BEING PROCESSED ANO COULD RESULT IN THE APPUCATION BEING DENIED. THIS FORM HAS BEEN 

APPROVED BY THE FORMS MANAGEMENT CENTER. 

APPLICATION PAGE 0003 1 

220-CAAPP 

FOR APPLICANTS USE 

PAGE 1 OF 10 

Gl 
P.69 

U) DOES THE EMISSION UNIT HAVE MORE THAN ONE MODE OF OPERATION? 

IF YES, EXPLAIN AND IDENTIFY WHICH MODE IS COVERED BY THIS FORM (NOTE: 

A SEPARATE PROCESS EMISSION UNIT FORM 220CAAPP MUST BE COMPLETED 

FOR EACH MODE): 

res 10 

I fl PROVIDE THE NAME AND DESIONATION OF ALL AIR POLLUTION CONTROL EOUIPMENT CONTROLLINO THIS 

EMISSION UNIT, IF APPUCABLE (FORM 260-CAAPP AND THE APPROPRIATE 260-CAAPP AODENDUM FORM 

MUST BE COMPLETED FOR EACH ITEM OF AIR POUUTION CONTROL EQUIPMENT): 

NA - Torit dust collectors and EP dust collectors all vent indoors 

16) WILL EMISSIONS DURINO STARTUP EXCEED EITHER THE ALLOWABLE EMISSION T 

RATE PURSUANT TO A SPECIFIC RULE. OR THE AUOWABLE EMISSION UMIT AS YES 

ESTABUSHED BY AN EXISTING OR PROPOSED PERMIT CONDITION? 

IF YES, COMPLETE AND ATTACH FORM 203-CAAPP, •REQUEST TO OPERATE WITH 

EXCESS EMISSIONS DURING STARTUP OF EQUIPMENT. 

17) PROVIDE ANV LIMITATIONS ON SOURCE OPERATION AFFECTINO EMISSIONS OR ANV WORK PRACTICE 

STANDARDS (E.G., ONLY ONE UNIT IS OPERATED AT A TIME): 

FRP fabricated only by closed molding presses. 

MO 

OPERATING INFORMATION 

IS) ATTACH THE CALCULATIONS, TO THE EXTENT THEV ARE AiR EMISSION RELATED, FROM WHICH THE 

FOUOWING OPERATING INFORMATION. MATERIAL USAGE INFORMATION AND FUEL USAGE DATA WERE 

BASED AND LABEL AS EXHIBIT 220-1. REFER TO SPECIAL NOTES OF FORM 202-CAAPP. 

I b ) MAXIMUM OPERATINO HOURS 

8760 hrs/yr . 

b) TYPICAL OPERATING HOURS 

5760 hrs/yr* 

2fl) ANNUALTHROUGHPUT 

8816 TPY* 

H0UR5JDAV: 

24 

H0UR5/OAV: 

24 

DEC-FEBfi): 

35 

DAYSWEEK: 

7 

DAVSAWEEK: 

WEEKS/YEAR: 

52 

WEEKSflEAR: 

48 

MAR-MAV(^): 

25 

JUN-AUOM; 

15 

SEP-N0V(4t): 

25 

MATERIAL USAGE INFORMATION 

21a) RAW MATERIALS 

Molding Compound 

MAXIMUM RATES 

LBS/HR 

6000 

TCN5/VEAR 

18,771 

TVPICAL RATES 

TBS7RR" 

3,061* 8,816* 

TONSftEAR 

APPLICATION PAGE 

220-CAAPP 

000 Qf FOR APPLICANTS USE 

* 1994 data 

PAGE2 OF 10 

&S 
P.70 

21b) PRODUCTS 

FRP Parts 

21c) BY-PRODUCT MATERIALS 

Scrap SMC 

MAXIMUM RATES 

LBSVHR 

6000 

TONS/YEAR 

18,771 

MAXIMUM RATES 

LBS/HR 

16.2 

TONS/YEAR 

70.9 

TYPICAL RATES 

LBS/HR 

3,061* 

TONS/YEAR 

8,816* 

TYPICAL RATES 

LBS/HR 

11. 6 

TONS/YEAR 

33.4 

FUEL USAGE DATA 

22a) MAXIMUM FIRIN5 RATE 

(MIUION BTU/HR): 

N /A 

«T FUEL TYPE: 

b) TVPICAL FIRINO RATE 

(MIUION BTU/HR): 

c)DE5l&N CAPACITY FIRINO 

RATE (MILUON BTU/HR): 

[ [ NATURAL GAS | [FUEL OIL GRADE NUMBER | |COAL | |OTHER_ 

IF MORE THAN ONE FUEL IS USED, ATTACH AN EXPLANATION AND LABEL AS EXHIBIT 220-Z 

"a) TYPICAL HEAT CONTENT OF FUEL (BTU/LB. 

BTU/GAL OR BTU/SCF): 

8) TVPICAL ASH CONTENT (WT tt., NA FOR NATURAL 

GAS): 

T) TYPICAL SULFUR CONTENT (WT -*.. NA FOR 

NATURAL 

GAS): 

h) ANNUAL FUEL USAGE (SPECIFY UNITS; EA , 

SCF/YEAR. GAL/YEAR, TON/YEAR): 

23) ARE C0MBU5TI0N EMISSIONS DUCTED TO THE SAME STACK OR CONTROL AS 

PROCESS UNIT EMISSIONS? 

IF NO, IDENTIFY THE EXHAUST POINT FOR COMBUSTION EMISSIONS: 

N/A 

•~ • NO 

APPLICATION PAGE. 

220-CAAPP 

00031; FOR APPLICANTS USE 

M994 data 

PAGE 3 OF 10 

&°i 
\ 

•.-> 

REGULATED AIR POLLUTANT(S) 

Styrene 

VOM 

—# • 

EMISSION STANDARDS) 

See Appendices B and C. 

See Appendices B and C. 

25) PROVIDE ANY SPECIFIC RECORDKEEPING RULE(S) WHICH ARE APPUCABLE TO THIS EMISSION UNIT: 

REGULATED AIR POLLUTANT(S) RECORDKEEPINO RULE(S) 

VOM See Appendices B and C. 

"55) PROVIDE ANV SPECIFIC REPORTING RULE(S) WHICH ARE APPLICABLE TO THIS EMISSION UNIT: 

REGULATED AIR POUUTANT(S) REPORTING RULE(S) 

T7 

VOM 

) PROVIDE ANV SPECIFIC MONITORINO RULE(S) 

REGULATED AIR POUUTANT(S) 

N/A 

WH 

See Appendices B and C. 

ICH ARE APPUCABLE TO THIS EMISSION UNIT: 

MONITORING RULE'S) 

N/A 

REQUIREMENT(S) 

See Appendices B and C. 

See Appendices B and C. 

REQUIREMENTS) 

See Appendices B and C. 

REQUIREMENT^) 

See Appendices B and C. 

REQUIREMENT^) 

N/A 

"18) PROVIDE ANY SPECIFIC TESTING RULES AND/OR PROCEDURES WHICH ARE APPUCABLE TO THIS EMISSION UNIT: 

REGULATED AIR POLLUTANT(S) TESTING RULE(S) REQUIREMENT^) 

VOM 

Stvrene 

See Appendices B and C. 

See Appendices B and C. 

•^ nnn?r 

O APPLICATION PAGE 

. 

See Appendices B and C. 

See Appendices B and C. 

__________!___• __"•] r#_,"|__l _j I WA? l fcllfc* **rt 

. 

220-CAAPP 

PAGE 4 OF 10 
P.72 

2fl) DOES THE EMISSION UNIT OUAUFY FOR AN EXEMPTION FROM AN 

OTHERWISE APPUCABLE RULE? u YES NO 

IF YES, THEN UST BOTH THE RULE FROM WHICH IT IS EXEMPT AND THE RULE WHICH AUOWS THE EXEMPTION. 

PROVIDE A DETAILED EXPLANATION JUSTIFYING THE EXEMPTION. INCLUDE DETAILED SUPPORTING DATA AND 

CALCULATIONS. ATTACH AND LABEL AS EXHIBIT 2203, OR REFER TO OTHER ATTACHMENT(S) WHICH ADDRESS 

AND JUSTIFY THIS EXEMPTION. 

COMPUANCE INFORMATION 

36) IS THE EMISSION UNiT IN COMPLIANCE WITH ALL APPUCABLE 

REQUIREMENTS? 13 YES NO 

IF NO, THEN FORM 294-CAAPP 'COMPLIANCE PLAN/SCHEDULE OF COMPUANCE - ADDENDUM FOR NON 

COMPLYING EMISSION UNITS* MUST BE COMPLETED ANO SUBMITTED WITH THIS APPUCATION. 

31) EXPLANATION OF HOW INITIAL COMPLIANCE 15 TO BE, OR WAS PREVIOUSLY, DEMONSTRATED: 

Applied Composites Corp. retained Geraghty & Miller to assist in documenting 

process equipment and emission units in the facility, completing a facility-wide 

emissions inventory, and preparing the Title V permit application. Applied 

Composites certified compliance on March 15,1995 with Subpart CC rules. 

32) EXPLANATION OF HOW ONOOINO COMPUANCE WILL BE DEMONSTRATED: 

See Appendix C, Slate Operating Pennit Conditions U and 12 : 

12a. The Pennittee ihali maintain feoordfi ofthe following itam to alio** the Agency to review oompltancc: 

L Fctrawl_*_oncUU for avoiding cwi_poui_dg;...(^^ 

iL Styrene content ofresin mUn-iali med in molding compound, (data distinct for each distinct resin and material) 

iv. Quantity (pounds) of monomer used, (monthly) 

v. Quantity of each solvent used -.(monthly) 

vi VOM emissions, (calculated monthly) 

12>. *fht ftm___Mih-_^iiiv--iil»iiiuw-ateofp->_fc)d_r i»_Hmb^ reqMire-lbyOiodiboo?. 

12c. Thunr«CTifci_aJbci«__c_rffa»pa_odofthi«yc»»*^--^ 

rn&m 10 d_yi of Atency request. 

TESTING, MONITORING, RECORDKEEPING AND REPORTING 

33a) UST THE PARAMETERS THAT RELATE TO AIR EMISSIONS FOR WHiCH RECORDS ARE BEINO MAINTAINED TO 

DETERMINE FEES. RULE APPLICABILITY OR COMPLIANCE. INCLUDE THE UNIT OF MEASUREMENT. THE METHOD 

OF MEASUREMENT. AND THE FREQUENCY OF SUCH RECORDS (E.G.. HOURLY, DAILY, WEEKLY): 

PARAMETER 

FRP Produced 

formulation date 

VOM emissions 

UNIT OF MEASUREMENT 

pounds 

% by weight 

type & amount 

pounds 

METHOD OF MEASUREMENT 

recordkeeping 

•UU*-* dm* SCAQMD 312-81 

recordkeeping 

recordkeeping 

FREQUENCY 

Monthly 

Monthly 

Monthly 

Monthly 

APPLICATION PAGE 00U»:* 

220-CAAPP 

FOR APPLICANTS USE 

PAGE 5 OF 10 

7( 
P.73 

•33BJ BRIEFLV DESCRIBE THE METHOD BV WHICH RECORDS WILL BE CREATED AND MAINTAINED. FOR EACH 

RECORDED PARAMETER INCLUDE THE METHOO OF RECORDKEEPING, TITLE OF PERSON RESPONSIBLE FOR 

RECORDKEEPING, AND TITLE OF PERSON TO CONTACT FOR REVIEW OF RECORDS: 

PARAMETER 

METHOO OF 

RECORDKEEPING 

See 33A parameters 

TITLE OF 

PERSON RESPONSIBLE 

TIRE OF 

CONTACT PERSON 

•must k\ monthly surwraras HSEQ Coordinator HSEQ Coordinator 

c) IS COMPLIANCE OF THE EMISSION UNIT READILV DEMONSTRATED BV REVIEW OF 

THE RECORDS? 

IF NO, EXPLAIN: 

YES NO 

d) ARE ALL RECORDS READILV AVAILABLE FOR INSPECTION, COPVINO AND 

SUBMITTAL TO THE AGENCY UPON REQUEST? 

IF NO, EXPLAIN: 

YES NO 

34a) DE5CRIBE ANV MONITORS OR MONITORINO ACTIVITIES U5ED TO DETERMINE FEES. RULE APPUCABIUTV OR 

COMPLIANCE: a . . . 

N/A 

TJ WHAT PARAMETER® I5(ARE) BEINO MONITORED (EA, VOM EMISSIONS TO ATMOSPHERE)* 

N/A 

c) DESCRIBE THE LOCATION OF EAcH MONITOR (E.O., IN STACK MONITOR 3 FEET FROM EXIT): 

N/A 

APPLICATION PAGE OOP*9' 

220-CAAPP 

FOR APPLICANTS USE 

PAGE 6 OF 10 

7*2-
P.74 

34d) IS EACH MONITOR EOUIPPED WITH A RECORDINO DEVICE-? 

IF NO, UST A U MONITORS WITHOUT A RECORDING DEVICE: 

N/A 

YES NO 

e) 15 EACH MONITOR REVIEWED FOR ACCURACY ON AT LEAST A OUARTERLV BASIS'? 

IF NO, EXPLAIN: 

N/A 

YES NO 

TJ 15 EACH MONITOR OPERATED AT ALL TIMES THE ASSOCIATED EMISSION UNIT 

IS IN OPERATION? 

IF NO. EXPLAIN: 

N/A 

YES • NO 

35) PROVIDE INFORMATION ON THE MOST RECENT TESTS, IF ANV, IN WHICH THE RESULTS ARE USED FOR 

PURPOSES OF THE DETERMINATION OF FEES, RULE APPUCABILITY OR COMPLIANCE. INCLUDE THE TEST DATE. 

TEST METHOD USED, TESTING COMPANY, OPERATING CONDITIONS EXISTING DURING THE TEST AND A 

SUMMARY OF RESULTS. IF ADDITIONAL SPACE IS NEEDED, ATTACH AND LABEL AS EXHIBIT 220-4: 

TEST OATE TEST METHOO 

N/A 

TESTING COMPANY 

OPERATMG 

CONDITIONS SUMMARY OF RESULTS 

35) DESCRIBE A U REPORTINO REOUIREMENTS AND PROVIDE THE TITLE AND FREOUENCV OF REPORT 

SUBMITTALS TO THE AGENCY: 

REPORTING REQUIREMENTS 

IAC 201.302 

Part 128 Subpart CC 

TITLE OF REPORT FREQUENCY 

AER 

Certificate of compliance 

Annual 

Onetime, 3/15/95 

APPLICATION PAGE. 

220-CAAPP 

000 FOR APPLICANTS USE 

PAGE 7 OF 10 

73 
M)EMIr,SI6NINF6M/rAri6N 

REGULATED AIR 

POLLUTANT 

CARBON 

MONOXIDE (CO) 

LEAD 

NITROGEN 

OXIDES (NOx) 

PARTICULATE 

MATTER (PART) 

PARTICULATE 

MATTER <-1 0 

MICROMETERS 

(PMIO) 

SULFUR 

DIOXIDE (S02) 

—VTOCTICE — 

ORGANIC 

MATERIAL (VOM) 

OTHER, SPECIFY: 

TYPICAL; 

TYPICAL. 

i**iKj_m_ 

LBS PER 

HOUR 

(LBS/HR) 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

'UNCONTROLLED EMI*WQN RATE 

TOWS BER" 

YEAR 

(TONS/VR) 

26.3* 

10.5* 

TERMS 

MOTHER 

TERMS 

eiJ2tWmorth 

*m 

•wEmmm 

: PAfTpCLHAIZ 

MATTER 

MAXMUU; 

TYPICAL; 

tot> 

•XO0 

M 

14.4 

. 0.9 

QtoDSCF 

i 024 . 

GWDSCF 

' 1 

4 

ALLOWABLE BY RULE EMISSION RATE 

"RATE (UNITS) 

JL 

6123lbAponth 

N/A JL 

( 

APPLICABLE 

RULES 

Parol* 93060068 

TONS PER' 

YEAR 

(TONS/YR) 

26.3 

N/A 

00(l6&Hlt) 

MfLBUmi 

2lt.Si1 

312.H1 MM 

PERMITTED EMISSION RATE 

RATE (UMTS) 

6123 lb/month 

N/A 

TONS rai 

YEAR 

(TONS/YR) 

26.3 

N/A 

n*wm "ti 

IMPORTANT: ATTACH CALCULATIONS. TO THE EXTENT THEY ARE AIR EMISSIONS RELATEO. ON WHICH EMISSIONS WERE DETERMINED ANO LABEL AS EXHIBIT 2204. 

!cHECKUNCONTRC-Ha33EWSSK>l RATE BOX IF CONTROL EKWP^ SEE INSTRUCTIONS. 

2PROVtDe THE EMISSION RATE THATWU. BE USED AS A PBtMIT SPECIAL CONDITION. THSI_OOTWI_LBEUSfSTODETT_3U<]NETHE'-£RI_tfTFEE 

-VlEASE PROVIDE ANY OTl-©»-aUSS»NRATCWHCHGCOMMC^ 

*tM - DETERMINATION METHOD: 1) STACK TEST. 2) MATBtlAL 6AIANCE, 3)'STANDARD EM*_S»N FACTOR (AP-42 OR Al* ^ 4 *_NGME 

5RATE - AUOWABLE EMISSION RATE SPECIFIED BY MOST STRINGENT APPUCABLE RULE. 

APPLICATION PAGE 

000 

220-CAAPP PAGE 6 OF 10 
13B) HAZARDOUS AIR POLLUTANT EMISSION INFORMATION 

HAP INFORMATION 

NAME OF HAP 

EMITTED 

Styrene 

2gAS 

NUMBER 

100-42-5 

Fj1 ACTUAL EMISSION RATE 

\J UNCONTROLLED EMISSION RATE 

iir»_j-i_ 

MAAIMUIW: 

ITHLAU— 

POUNDS PER 

HOUR 

(LBS/HR) 

N/A 

N/A 

TONS PER 

YEAR 

(TONS/YR) 

26.3* 

10.5* 

^THER 

TERMS 

6132 lb/month 

• 

-*DM 

3 

3 

ALLOWABLE BY RULE 

SRATE OR STANDARD 

N/A 

APPUCABLE 

RULE 

N/A 

EXAMPLE: 

ftito 

-wwaaosr* 

"ffWIW"' 

) ;m •" 

' [ " ..** 

' !•«

 s

 .. 

- -, 4M ' ' 

+* * s •"_ • _• g

1 

- * ' 

IMPORTANT: ATTACH CALCULATIONS, TO THE EXTENT THEY ARE AIR EMISSIONS RELATED, ON WHICH EMISSIONS WERE DETERMINED AND LABEL AS EXHIBIT 2204. 

'PROVIDE UNCONTROLLED EMISSIONS W CONTROL EQUIPMENT IS USED. OTHERWISE. PROVIDE ACTUAL EMISSIONS TO THE ATMOSPHERE, INCLUDING INDOORS. CHECK BOX TO SPECIFY. 

X AS - CHEMICAL ABSTRACT SERVICE NUMBER. 

7LEASE PROVIDE ANY OTHER EMBSION RATE WHICH IS COMMONLY USED, REOUIRED BY A SPECIFIC LMTATION OR THAT WAS MEASURED (E.G., PPM. GR/DSCF. ETC.). 

T~*M - OETERM-NATION METHOO: 1) STACK TEST, 2) MATERIAL BALANCE. 3) STANDARD EMBSION FACTOR (AP-42 OR AIRS. 4) ENGINEERING ESTMATE. 5) SPECIAL EMBSION FACTOR (NOT AP-42 OR AIRS). 

-"RATE • AUOWABLE EMBSION RATE OR STANDARD SPECIFIED BY MOST STRINGENT APPLICABLE RULE. 

u APPLICATION PAGE. 

220-CAAPP 

ooo 3»i;*n;raimzia! • Ha pratttt 0HM fc Ap*. As W*. Q. 

PAGE 9 OF 10 
P.77 

EXHAUST POINT INFORMATION —~" ~ 

TW5s*C-rWsmiLBN0TKttMK_ETO 

SS, FL6W BIA6RAM BEsiGNATIoN 6P EXHAUST P6INT: 

Molding Press. See Figure F-1 

BEScRIPYioN 6P EXftAUsf P6IMT (STAcK. • 

DISCHARGES INDOORS, DO NOT COMPLETE THE REMAINING ITEMS. 

40, BEScRIPYioN 6P EXHAUsf tolMT (STAcK. VENT. R66F M6NIT6R, INb6oRS, ETC.). IP THE EXHAUST P6INT 

Fugitive Indoors 

41, BISTANcE T6 NEAREST PLANT 66UNBARV FR6M EXHAUST P6INT BI5<1HAR6E (FT): 

N/A 

42) BISCHARGE HEIGHT AB6VE 6RABE (PT): 

M/A 

43) £666 ENGINEERING PRACTICE (GEP) HEIGHT, IF KNo-A-N (PT): 

NA 

44) BIAMETEROP EXHAUST P6INTJFTV N6TE: F6RAN6N 

1.128 TIMES THE SQUARE ROOT OF THE AREA.ki/A 

CIRCULAR EXHAUST P6INT. THE BIAMETER IS 

N/A 

45) EXIT GAS FL6W RATE 

N/A 

4fi) EXIT GAS TEMPERATURE 

N/A 

a) MAXIMUM (ACFM): 

a) MAXIMUM ('P): 

b) TVPICAL (ACFM): 

b) TVPICAL (»P): 

775 BIRECTI6N CP EXHAUST (VERTICAL. LATERAL B6\A/N\A/ARfi): 

N/A 

46) UST ALL EMISSION UNITS ANB C6NTR6L BEVICES SERVEB 6V THIS EXHAUST P6INT: 

NAME FLOW DIAGRAM DESIGNATION 

Sf Molding Presses 

W 

See Figure 3, F-1 

THE FOLLOWINC INFORMATION NEED ONLV Bt_ SUPPLIED IP READILV AVAILABLE: 

46a) LATITUDE: 

5o)UTM26NE: 

b)LoNGlTUBE: 

b) UTM VERTICAL (kM): c)UTMHoRlZ6NTAL(kM): 

APPLICATION PAGE. 

220-CAAPP 

000 FOR APPLICANTS USE 

PAGE 10 OF 10 

7t 
P.78 

SECTION 3 

COMPOUND PREPARATION AND MATURATION AREA 

-11 
P.79 

ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD, ILUNOIS 62794-9506 

FOR APPLICANTS USE 

Revision*

 WI M 

Date: DeoeyibwS, 19?S 

Page of 

Source Designation: 

AC 

PROCESS EMISSION UNIT 

DATA AND INFORMATION 

ID NUMBER: 

EMISSION POINTS 

TOTET 

TTSSDRCnCOyiE 

Composites Corp. 

SOURCE INFORMATION 

Applied 

22)) DAT BATEE EO EORF M 

PREPARED: December 6, 1995 

i) SouhCE IB No. ft0rt_10„AAr. 

(IF KNOWN): 089483AAF 

GENERAL INFORMATION 

4) NAME GF EMISSION UNIT: 

Compound Preparation and Maturation (see Appendix A Exhibit A for list of equipment) 

5)NAME6FPR6CESS: 

Compound Preparation and Maturation 

6) BESCRIPTIoN 6F frftoCESS: 

See Introduction 

7) BESCftlPTIoN oF ITEM 6ft MATERIAL PR6BUCEB CR ACTIVlTV ACCOMPLISHES: 

Sheet Molding Compound 

b) FL6W biAGRAM DESIGNAYION CF EMISSION UNIT: 

Compound Preparation and Maturation Area 

a) MANUFACTURER CF EMISSION UNIT (IF KN6WN): 

See Appendix A, Exhibit A 

10) MABEL NUMBER (IP KNOWN): 

See Appendix A, (Exhibit A 

ii) BATES CP CCMMENCING CONSTRUCTION, 

OPERATION AND/OR MOST RECENT MODIFICATION 

OF THIS EMISSION UNIT (ACTUAL OR PLANNED) 

IS) BESCWPTI6N oF Mbbll-lcATlCN (IF APMJCA&LE): 

N /A 

11) SERIAL NUMBER (IF KNOWN): 

See Appendi APE x A, Exhibit A 

a) CONSTRUCTIO •15TRI N (MONTH/VEAR): 

SeeAppendxA, Exhibit A 

b) OPERATION (MONTH/YEAR): 

SeeAppendxA, Exhibit A 

c) LATEST MoBIFICATIoN (MONTI-WEAR): 

N/A 

THIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNDER ILUNOIS REVISED STATUES, 1991, AS AMENDED 1992, 

CHAP 111 1/2, PAR. 1039.5. DISCLOSURE OF THIS INFORMATION IS REQUIRED UNDER THAT SECTION. FAILURE TO DO SO MAY 

PREVENT THIS FORM FROM BEING PROCESSED AND COULD RESULT IN THE APPLICATION BEING DENIED. THIS FORM HAS BEEN 

APPROVED BY THE FORMS MANAGEMENT CENTER. 

APPLICATION PAGE. 

220-CAAPP 

0 'I U ? 4 

FOR APPLICANTS USE 

PAGE 1 OF 10 

7* 
P.80 

U) BOES THE EMISSION UNIT HAVE MoRE THAN ONE MOBE OP OPERATION*) 

IF YES, EXPLAIN AND IDENTIFY WHICH MODE IS COVERED BY THIS FORM (NOTE: 

A SEPARATE PROCESS EMISSION UNIT FORM 220-CAAPP MUST BE COMPLETED 

FOR EACH MOOE): 

fES MO 

15) PROVtSE THE NAME ANB BESI6NATI0N OF ALL AIR POLLUTION CONTROL EQUIPMENT CONTROLUNS THIS 

EMISSION UNIT, IF APPUCABLE (FORM 2SJ-CAAPP AND THE APPROPRIATE 260-CAAPP ADDENDUM FORM 

MUST BE COMPLETED FOR EACH ITEM OF AIR POLLUTION CONTROL EQUIPMENT): 

N / A 

IS) WILL EMISSIONS BURING STARTUP EXCEEB EITHER THE ALLOWABLE EMISSION 

RATE PURSUANT TO A SPECIFIC RULE, OR THE ALLOWABLE EMISSION UMIT AS 

ESTABUSHED BY AN EXISTING OR PROPOSED PERMIT CONDITION? 

IF YES, COMPLETE AND ATTACH FORM 203-CAAPP, "REQUEST TO OPERATE WITH 

EXCESS EMISSIONS DURING STARTUP OF EQUIPMENT*. 

YES NO 

17) PROVibE ANV UMITATIONS O N SOURCE OPERATION AFFECTING AMISSIONS OR ANV WORK! PRACTICE 

STANDARDS (E.G., ONLY ONE UNIT IS OPERATED AT A TIME): 

The operation ofthe SMC and TMC machines is mutually exclusive. 

The maturation room can only hold 80 crates of material at one time, thus limiting compound 

production to a maximum of 40 hours in any 48 hour period. 

For a detailed description of the limitations, see Introduction (Section 1). 

. THE TOLLOWIKG ARE PROVIDED FOR COMPOUNDING OPERATIONS 

-Ida) MAXIMUM OPERATINS HOURS | HOURS/BAV: | BAVS/WEEK: 

OPERATING INFORMATION 

tS ATTACH THE CALCULATIONS, TO THE EXTENT THEV ARE AIR EMISSION RELATEB. PROM WHICH THE 

FOUOWING OPERATING INFORMATION. MATERIAL USAGE INFORMATION AND FUEL USAGE DATA WERE 

BASED AND LABEL AS EXHIBIT 220-1. REFER TO SPECIAL NOTES OF FORM 202-CAAPP. 

riMlfr HfP_Mi_-i.*-> 

mtnaf. -T-Btnfr 

pMP q 

b) TVPICAL OPERATING HOURS 

4000 hrs/yr* 

» ) ANNUAL THROUGHPUT 

8816 TPY* 

20 

HOURS/DAY: 

1 6 

BEC-FEB(tt): 

35 

BAV5AA/EEK: 

5 

MARIMAV(-A): 

25 

WEEKS/VEAR: 

50 

JUN-AUG(%): 

1 5 

WEEKS/YEAR: 

50 

SEP-NOVM: 

25 

MA TEK1AL USAGE INFORMATION 

21a) RAW MATERIALS 

Resins. 

Catalysts 

Fillers 

Fiberglass 

MAXIMUM RATES 

LBS/HR 

1617.5 

24.1 

2675.9 

1263.8 

TONS/VEAR 

4658.4 

69.4 

7706.6 

3639.7 

TVPICAL RATES 

LBS/HR 

825.2* 

12.3* 

1365.2* 

644.7* 

24.6* 

TONJWEAR 

1650* 

2730.4* 

1289.4* 

oou>-

APPLICATION PAGE. 

220-CAAPP 

-In 

FOR APPLICANTS USE 

994 data 

PAGE 2 OF 10 

1°, 
P.81 

21b) PRODUCTS 

Molding Compound 

21c) BY-PRODUCT MATERIALS 

N/A 

MAXIMUM RATES 

LBS/HR 

6000 

TONS/VEAR 

18,771 

• 

MAXIMUM RAYES 

LBS/HR TONS/YEAR 

TVPICAL RATES 

LBS/HR 

3061 * 

TONS/YEAR 

8816* 

TVPICAL RAYES 

LBS/HR 

-

TONS/YEAR 

FUEL USAGE DATA 

2S») MAXIMUM FIRING RATE 

(MILUON BTU/HR): 

N/A 

~w FUEL TVPE: 

b) TVPICAL FIRINO RATE 

(MILUON BTU/HR): 

C)BE5I5 N CAPACITY FIRIM5 

RATE (MILUON BTU/HR): 

| [NATURAL GAS | [FUEL OIL GRADE NUMBER | [COAL | |0THER_ 

IF MORE THAN ONE FUEL IS USED, ATTACH AN EXPUNATION AND LABEL AS EXHIBIT 220-Z 

Si TVPICAL HEAT CONTENT OF FUEL (BTU/LB, 

BTU/GAL OR BTU/SCF): 

a) TVPICAL ASH CONTENT (WT-A..NA FOR NATURAL 

GAS): 

TJ TVPICAL SULFUR CONTENT (WT *., NA FOR 

NATURAL 

GAS): 

h) ANNUAL FUEL USAGE (5PECIFV UNITS, E.O., 

SCF/YEAR. GAL/TEAR, TON/YEAR): 

a ) ARE COMbUSTION EMISSIONS BUCTEb TO THE SAME STAcK OR CoNTRoL AS 

PROCESS UNIT EMISSIONS? 

IF NO, IDENTIFY THE EXHAUST POINT FOR COMBUSTION EMISSIONS: 

N/A 

o • NO 

APPLICATION PAGE. 

220^AAPP 

FOR APPLICANTS USE 

•1994 data 

PAGE 3 OF 10 

?o 
REGULATED AIR POLLUTANT(S) 

Styrene 

VOM 

EMISSION STANDARDS) 

See Appendices B and C. 

See Appendices B and C. 

' 

~5S) PROVIDE ANV SPECIFIC RECORDKEEPING RULE(S) WHICH ARE APPLICABLE TO THIS EMISSION UNIT: 

REQUIRED MR POLLUTANT(S) RECORDKEEPING RULE(S) 

VOM See Appendices B and C. 

• 

~2S) PROVIDE ANV SPECIFIC REPORTING RULE(S) WHICHjARE APPLICABLE TO THIS EMISSION UNIT: 

REGULATED AIR POLLUTANT(S) REPORTING RULE(S) 

"57 

"5S 

VOM 

) PROVIBE ANV SPECIFIC MONITORINO RULE(S) 

REGULATED AIR PCXLUTANT(S) 

N/A 

) PROVIBE ANV SPECIFIC TESTINO RULES ANbA 

REGULATED AIR POLLUTANT(S) 

Stvrene 

VOM 

WH 

JRI 

See Appendices B and C. 

ICH ARE APPLICABLE TO THIS EMISSION UNIT: 

MONITORING RULE(S) 

N/A 

REQUIR-_MENT(S) 

See Appendices B and C. 

See Appendices B and C. 

REQUIREMENT(S) 

See Appendix B and C. 

REQUIREMENT^) 

See Appendices B and C. 

REQUIREMENTS) 

N/A 

PROCEBURES WHICH ARE APPLICABLE TO THIS EMISSION UNIT: 

TESTING RULE(S) REQUIREMENT^) 

See Appendices B and C. 

See Appendices B and C. 

See Appendices B and C. 

See Appendices B and C. 

. • wwu/f-u/v*/ , %•».-»# t_.E_t-»J/V_~V~t-_./. 

• 

^ 

APPLICATION PAGE. 

220-CAAPP 

0002 rt rI 

PAGE 4 OF 10 
P.83 

28) BOES THE EMISSION UNiT OUAUFV FOR AN EXEMPTION FROM AN 

OTHERWISE APPUCABLE RULE? YES NO 

IF YES, THEN UST BOTH THE RULE FROM WHICH IT IS EXEMPT AND THE RULE WHICH ALLOWS THE EXEMPTION. 

PROVIDE A DETAILED EXPLANATION JUSTIFYING THE EXEMPTION. INCLUDE DETAILED SUPPORTING DATA AND 

CALCUUTIONS. ATTACH AND LABEL AS EXHIBIT 220-3, OR REFER TO OTHER ATTACHMENTS) WHICH ADDRESS 

AND JUSTIFY THIS EXEMPTION. 

COMPUANCE INFORMATION 

36) IS THE EMISSION UNIT IN COMPLIANCE WITH ALL APPUCABLE 

REQUIREMENTS? YES NO 

IF NO, THEN FORM 294-CAAPP "COMPLIANCE PLAN/SCHEDULE OF COMPLIANCE - ADDENDUM FOR NON 

COMPLYING EMISSION UNITS' MUST BE COMPLETED AND SUBMITTED WITH THIS APPUCATION. 

31) EXPLANATION OF HOW INITIAL COMPLIANCE IS TO BE, OR WAS PREVIOUSLY, BEM0N5TRATEB: 

Applied Composites Corp. retained Geraghty & Miller to assist in documenting 

process equipment and emission units in the facility, completing a facility-wide 

emissions inventory, and preparing the Title V permit application. Applied 

Composites certified compliance on March 15,1995 with Subpart CC rules . 

32) EXPUNATION OF HOW 0N60IN0 COMPLIANCE WILL BE BEMONSTRATEb: 

See Appendix C State Operating Pennit Cooditiooi 11 and 12: 

12a. Tbe Permittee shall maintain records ofthe following hemi to allow the Agency to review compliance: 

i. Formulation data for molding compounds, ...(daU dktinct for each otaina formulation) 

iL Styrene content of rain maliriali used in molding compound, (data distinct for each distinct resin and material) 

iii. Quantity (pounds) of each type... of compound produced, (monthly) 

iv. Quantity (pounds) of monomer used, (monthly) 

v. Quantity of each solvent uaed ...(monthly) 

vl VOM emissions, (calculated monthly) 

lib. The PmiM-mj -hid top written recent-, rf periodic -wpiminw lo cnafim _n*n» i_j__on cf ttn mturmi nqi_ndbyCand__tt_7. 

12c ThiMiu>i-_iih-_lb«ieteinedlbf «pgiodrftt_t--.y-_»««__i.^ 

within 10 dqrt rfAfcncy request 

TESTING, MONITORING, RECORDKEEPING AND REPORTING 

33a) UST THE PARAMETERS THAT REUTE TO AiR EMiSSIoNS FOR WHICH RECORbS ARE BEINO MAINTAINEB TO 

DETERMINE FEES, RULE APPUCABILITY OR COMPLIANCE. INCLUDE THE UNIT OF MEASUREMENT, THE METHOD 

OF MEASUREMENT, AND THE FREQUENCY OF SUCH RECORDS (E.G., HOURLY, DAILY, WEEKLY): 

PARAMETER 

SMC Production dots 

M M inonofnof content 

formulation data 

VOM emissions 

special purpose resm 

UNIT OF MEASUREMENT 

pounds 

% by weight 

fypeT£ amount 

pounds 

type & amount 

METHOD OF MEASUREMENT 

recordkeeping 

supplier data, SCAQMD 31241 

recordkeeping 

recordkeeping 

recordkeeping 

FREQUENCY 

monthly 

monthly 

monthly 

monthly 

as used 

APPLICATION PAGE. 

220-CAAPP 

ooo?s 

FOR APPLICANTS USE 

PAGE 5 OF 10 

72-
P.84 

"SR BRIEFLV DESCRIBE THE METHOD BV WHICH RECORDS WILL BE CREATED AND MAINTAINED. FOR EACH 

RECORDED PARAMETER INCLUDE THE METHOD OF RECORDKEEPING, TITLE OF PERSON RESPONSIBLE FOR 

RECORDKEEPING, AND TITLE OF PERSON TO CONTACT FOR REVIEW OF RECORDS: 

PARAMETER 

METHOO OF 

RECORDKEEPINO 

TmEOF 

PERSON RESPONSIBLE 

TmEOF 

CONTACT PERSON 

See 33a parameter* manaity * annual sumtniies HSEQ Coordinator HSEQ Coordinator 

c) IS COMPUANCE OF THE EMISSION UNIT READILV DEMONSTRATED BV REVIEW OF 

THE RECORDS? 

IF NO, EXPLAIN: 

YES NO 

d) ARE ALL RECORDS READILV AVAILABLE FOR INSPECTION, COPVINO AND 

SUBMITTAL TO THE AGENCY UPON REQUEST? 

IF NO, EXPLAIN: 

YES NO 

34a) DE5CRI6E ANV MONITORS OR MONITORINO ACTIVITIES USED TO DETERMINE FEES, RULE APPUCABIUTV OR 

COMPLIANCE: ... . 

N/A 

"BJ WHAT PARAMETER'S) IS<ARE) BEINO MONITORED (EA , VOM EMISSIONS TO ATMOSPHERE)? 

N/A 

c) DESCRIBE THE LOCATION OF EAcH MONITOR (E.O., IN STACK MONITOR S FEET FROM EXIT): 

N/A 

APPLICATION PAGE. 

220-CAAPP 

000°: 

FOR APPLICANTS USE 

PAGE 6 OF 10 

£3 
P.85 

34d) IS EACH MONITOR EOUIPPEB WITH A RECORbINO DEVICE? 

IF NO, UST A U MONITORS WITHOUT A RECORDING DEVICE: 

N/A 

YES NO 

e) IS EACH MONITOR REVIEWED FoR ACCURACV ON AT LEAST A OUARTERLV BASIS? 

IF NO, (EXPLAIN: 

N/A 

YES NO 

TJ IS EACH MONITOR OPERATED AT ALL TIMES THE ASSOCIATED EMISSION UNIT 

IS IN OPERATION? 

IF NO, EXPLAIN: 

N/A 

YES NO 

35) PROVIDE INFORMATION ON THE MOST RECENT TESTS, IF ANV, IN WHICH THE RESULTS ARE USED FOR 

PURPOSES OF THE DETERMINATION OF FEES, RULE APPUCABILITY OR COMPLIANCE. INCLUDE THE TEST DATE, 

TEST METHOD USED, TESTING COMPANY, OPERATING CONOITIONS EXISTING DURING THE TEST AND A 

SUMMARY OF RESULTS. IF ADDITIONAL SPACE IS NEEDED, ATTACH AND LABEL AS EXHIBIT 220-4: 

TEST DATE 

10/12/92 

TEST METHOO TESTING COMPANY 

USEPA MM. M2S* 

OPERATING 

CONDITIONS 

Mostardi Piatt 

SUMMARY OF RESULTS 

Full Load 0.030413 VCMkn 

36) DESCRIBE ALL REPoRTINO REQUIREMENTS ANb PRovibE THE TITLE AND FREQUENCV OF REPORT 

SUBMITTALS TO THE AGENCY: 

REPORTINGREQUIREMENTS 

IAC 201.302 

Part 128 Subpart CC 

TITLE QF REPORT 

Annual Emissions Report 

FREQUENCY 

Certificate of compliance 

Annual 

One time, 3/15/95 

APPLICATION PAGE 000 ?^ 

220-CAAPP 

FOR APPLICANTS USE 

PAGE 7 OF 10 

W 
REGULATED AIR 

POLLUTANT 

CARBON 

MONOXIDE (CO) 

LEAD 

NITROGEN 

OXIDES (NOx) 

PARTICULATE 

MATTER (PART) 

MATTER <> 10 

MICROMETERS 

(PM10) 

SULFUR 

DIOXIDE (S02 ) 

VOLATILE 

ORGANIC 

MATERIAL (VOM) 

OTHER. SPECIFY: 

EXAMPLE: 

PARTlCUrATg 

MATTER 

MfOCMM: 

TYPICALMrtX__H_t" 

TVPICAL: 

MrtJtmjM: 

TYPICAL: 

iMVMM: 

TYPICAL: 

i_-*tyiiii~ 

TYPICAL: 

MAXMLM 

TYPICAL: 

MAXMUM 

TYPICAL: 

MAXMJM: 

TVPICAL: 

MAXMJA 

TYPICAL: 

MEMISSIOK 

— 'ACTUAL EMISSION RATE 

'UNCONTROLLED EMISSION RATE 

I B S PER " 

HOUR 

(LBS/HR) 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

6.00 

4.00 

TONS PER 

YEAR 

(TONS/VR) 

68.3* 

34.5* 

H$ 

14.4 

-MOTHER 

TERMS 

! 

ftj 

QR/DSCF 

0.24 

GIVDiCf 

•\jTHER 

TERMS 

18,000 ib/mo 

-t*_ 

5** 

5** 

i 

4 

IMPORTANT: ATTACH CALCULATIONS. TO THE EXTENT THEY ARE AIR EMISSIONS RELATED, ON WHICH EMISSION! 

fcHECKUNCOWTROU^EWSSIONRATEBOXtFro^ 

?PROVH5€THE EMISSION RATE THAT W U BE USED AS A PERMIT SPECIAL CONDnKDN. THIS UMIT WILL BE USEO Tl 

•VLEASE PROVlOE ANY OTHER EMISSION RATE WHICH IS COMMONLY USEOJ REQUIRED BY A SPECIFIC UMITATKIN 

**OM - DETERMINATION METHOD: 1) STACK TEST. 2) MATERIAL BALANCE. J) STANDARD EMISSION FACTOR (AP-42 Of 

laATe.itt±cMAmseuissicMnA,i^spB^mD»fuos^sn»tNaBaAPfiucASLBmAP 

IN 

IWI 

ET> 

30* 

OR 

IAS 

APPLICATION PAI 

220-CA APP 

FO/MMHdN 

ALLOWABLE BY RULE EMISSION RATE 

5RATE (UNITS) 

16.000 INITIO . 

N/A ( , 

*.6/l66feRj 

5.5<lfl&HRJ 

APPLICABLE 

RULES 

Parmit #93050068 

N/A 

TONS PER 

YEAR 

(TONS/YR) 

68.3 

N/A 

tnrsit 

Z1i.SH 

_RE DETERMINED ANO LABEL AS EXHIBIT 

CE ACTUAL EMISSION RATE TO ATMOSPHE 

ETERMINE THE PERMIT FEE. 

THAT WAS MEASURED (EO. PPM. OR/DSC 

IS). 4) ENQINEERINO ESTIMATE. S) SPECIA 

0003 

3E 

\ 

&** 

19.M 

220-8. 

HE, INCLUDING tNDOC 

F.ETC.) 

L EMISSION FACTOR) 

MS 

NOT 

'PERMITTED EMISSION RATE 

RATE (UNITS) 

16.000 blmo 

N/A 

YEAR 

(TONS/YR) 

68.3 

N/A 

smtBsm 

SEE INSTRUCTIONS. 

AP-42 OR AIRS) 

FOR APPLICANTS USE 

*CcncAMcn dl HMrioi k m a**MpwV M M to Ajp. _K EJ^M A\ 

"GwnMb-MnMHMnWgr 

PAGE 8 OF 10 

*a 
(38) HAZARDOUS MR POLLUTANT EMISSION INFORMATIO V 

HAP INFORMATION 

NAME OF HAP 

EMITTED 

Styrene 

^CAS 

NUMBER 

100-42-5 

0

 1 ACTUAL EMISSION RATE 

[j UNCONTROLLED EMISSION RATE 

MAXIMUM: 

ITPHJUJ 

MAXIMUM! 

ITHILAU 

MAAINIUM: 

ITHLAU— 

MAXIMUM! 

ITHUXU— 

MAXIMUM! 

*~TTPICXC— 

MAXIMUM! 

ITHLAL'— 

MAXIMUM! 

1TW130_!— 

POUNDS PER 

HOUR 

(LBS/HR)-

N/A 

N/A 

TONS PER 

YEAR 

(TONS/YR) 

68.3* 

34.5* 

3OTHER 

TERMS 

18.000 lb/mo 

"DM 

5** 

5** 

ALLOWABLE BY RULE 

•^T E OR STANDARD 

N/A 

APPLICABLE 

RULE 

N/A 

EXAMPLE: " 

tUs\2 

-nmmamr 

"nwMi 

'- ] m '•-

. M 

'a iJt " 

M 

1 

i ixatH^mtm . 

WRM 

IMPORTANT: ATTACH CALCULATIONS, TO THE EXTENT THEY ARE AIR EMISSIONS RELATED, ON WHICH EMISSIONS WERE DETERMINED ANO LABEL AS EXHIBIT 220-6. 

'PROVIDE UNCONTROLLED EMISSIONS IF CONTROL EQUIPMENT IS USED. OTHERWISE. PROVIDE ACTUAL EMBSIONS TO THE ATMOSPHERE. INCLUDINO INDOORS. CHECK BOX TO SPECIFY. 

X A S - CHEMICAL ABSTRACT SERVICE NUMBER. 

JtEASE PROVIDE ANY OTHER EMBSION RATE WHICH IS COMMONLY USED, REQUIRED BY A SPECIFIC LMTTATION OR THAT WAS MEASURED (E.G., PPM. OR/DSCF, ETC.). 

T.M - DETERMINATION METHOD: 1) STACK TEST. 2) MATERIAL BALANCE. 3) STANDARD EMBSION FACTOR (AP-42 OR AIRS. 4) ENQINEERINO ESTMATE. 5) SPECIAL EMISSION FACTOR (NOT AP-42 OR AIRS). 

-RATE - ALLOWABLE EMBSION RATE OR STANDARD SPECIFIED BY MOST STRINGENT APPLICABLE RULE. 

APPLICATION PAGE. 

220-CAAPP 

0003: 

< • » 

PAGE 9 OF 10 

oo 
P.88 

EXHAUSI POINT IN FORM AI ION ' 

•raBSEc-lVWSI^mWTBEraMPlETED^ 

») FL6W BIA&RAM BESI5NATI6N 6F EXHAUST P6INT: 

see Figure 3, ST-1 (Representative stack, individual stack parameters listed in Appendix A Exh&it B.) 

4b) BEScRIPTIoN 6F EXHAUST PoiNT (STAck. VENT, R66F M6NIT0R. IN006RS, ETC.). IP THE EXHAUST POINT 

DISCHARGES INDOORS, DO NOT COMPLETE THE REMAINING ITEMS. 

4 stacks: one vents indoors 

4i) BISYANCE T6 NEAREST PLANT BOUNDARV PR6M EXHAUST PAINT BlscHAR6E (FT): 

2 8 0 

4Z) BISCHARGE HEldHT A&6VE GRADE (PT): : 

43) $$b^clW?MW&l (<5EP) HEI&HT, IF KN6WN (FT): 

44) BIAM^PRO ^ EXHAUST P6INT (FT): N6TE: F6R A N6N CIRCULAR EXHAUST P6INT. THE BIAMETER IS 

4S) EXI 1.12T8 GA TIMES PLbv S THVE RAT SQUAR E E ROOT OP THE AREA. ^ Appendix A, Exhibit B. 

see Appendix A, Exhibit B. 

a) MAXIMUM (ACPM): b) TYPICAL (ACFM): 

{Appj 

46) EXIT'GAS GAS TEMPERATUR I E a) MAXIMUM ('F): b) TYPICAL ('F): 

see Appendix A, Exhibit B. 

^75 BIRECTIoN OF EXHAUST (VEKYICAL, LATERAL BoWNWARb): 

vertical 

46) LIST ALL EMISSION UNITS ANB C6NTR6L BEVICES SERVEB 6V THIS EXHAUST P6INT: 

NAME FLOW DIAGRAM DESIGNATION 

a*» Appendix A Exhb* a 

b> 

cT 

«T 

^T 

see Figure 3, ST-1 

Wk t-OLLOWINS INFORMATION NEED ONLV BE SUPPLIED IF RHABILV AVAILABLE. 

a)LATITUBE: b) LoNGlTUBE: 

SO) UTM ZONE: b) UTM VERTICAL (kM): c) UTM HORIZONTAL (kM): 

APPLICATION PAGE. 

220-CAAPP 

00033 FOR APPLICANTS USE 

PAGE 10 OF 10 

tl 
P.89 

SECTION 2 

LISTING OF INSIGNIFICANT SOURCES 

<fi 
P.90 

_ ll_UNOIS ENVIRONMENTAL PROTECTION AGENCY 

A A DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19508 

SPRINGFIELD, ILUNOIS 62794-9506 

•siHaa»iasaiHPH 

Revision #: 

Oate: Nwamfrar 15,199ft 

Page of 

Source Designation: 

J___ 

USTING OF INSIGNIFICANT 

ACTIVITIES 

IbNUM&ER: 

PERMIT*: 

"BATE: 

TKSFORMMUgTBec^CilPLkiyil-WAaAclMTlES-n^TAftEl-^^ 3S ILL ABM. C6BE. SECTION 

201.210 ANO 201.211 FOR WHICH DETA_LED DATA ANO INFORMATION, AS REQUESTED M OTHER FORMS, IS NOT PROVOEO. 

SOURCE INFORMATION 

i) SOURCE NAME: 

ilied Composites Corp. 

3) SOURCE IB N6. 

(IF KNOWN): 0894g3AA F 

5) BATE F6RM 

PREPARED :

 December 6,199 5 

INSIGNIFICANT ACTIVITIES 

U ARE ANV 6NE oR ALL 6F THE F6LL6WIN 6 ACTIVITIES, AS IBENTIFIEB IN 35 ILL 

ADM. CODE 201.210(b). PRESENT AT THE SOURCE? CHECK THE APPROPRIATE BOX 

ACTTVITIES IN 35 ILL ADM. CODE 201.210(b): 

YES NO 

I) AIR CONDITIONING OR VENTILATING EQUIPMENT NOT DESIGNED TO REMOVE AIR CONTAMINANTS GENERATED 

BY OR RELEASED FROM ASSOCIATED EQUIPMENT; 

I) PHOTOGRAPHIC PROCESS EQUIPMENT BY WHICH AN IMAGE IS REPRODUCED UPON MATERIAL SENSITIZED TO 

RADIANT ENERGY; 

M) EQUIPMENT USED FOR HYDRAUUC OR HYDROSTATIC TESTING; 

iv) GENERAL VEHICLE MAINTENANCE AND SERVICING ACTTVITIES AT THE SOURCE, OTHER THAN GASOUNE FUEL 

HANDUNG; 

v) CAFETERIAS. KITCHENS AND OTHER FACILITIES USED FOR PREPARING FOOD OR BEVERAGES PRIMARILY FOR 

CONSUMPTION AT THE SOURCE; 

Vf) EQUIPMENT USING A WATER, WATER AND SOAP OR DETERGENT, OR A SUSPENSION OF ABRASIVES IN WATER 

FOR PURPOSES OF CLEANING OR FINISHING PROVIDED NO ORGANIC SOLVENT HAS BEEN ADDED TO THE 

WATER; 

vii) ADMINISTRATIVE ACTTVITIES INCLUDING, BUT NOT UMITED TO, PAPER SHREDDING, COPYING, PHOTOGRAPHIC 

ACTIVITIES. AND BLUEPRINTING MACHINES. THIS DOES NOT INCLUDE INCINERATORS; 

viii) LAUNDRY DRYERS, EXTRACTORS. AND TUMBLERS PROCESSING CLOTHING, BEDDING, AND OTHER FABRIC 

ITEMS USED AT THE SOURCE THAT HAVE BEEN CLEANED WITH WATER SOLUTIONS OF BLEACH OR DETERGENT i 

PROVIDED THAT ANY ORGANIC SOLVENT PRESENT IN SUCH ITEMS_BEFORE PROCESSING THATJS_RETAINED 

FROM CLEAN-UP OPERATIONS SHAU BE ADDRESSED AS PART OF THE VOM EMISSIONS FROM USE OF CLEANINC 

MATERIALS; 

HIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNOER ILUNOIS REVISED STATUES, 1991, AS AMENDED 1992. 

HAP 1111/2. PAR. 1039.5. DISCLOSURE OF THIS INFORMATION IS REQUIRED UNDER THAT SECTION. FAILURE TO DO SO MAY 

REVENT THIS FORM FROM BEING PROCESSED AND COULD RESULT IN THE APPUCATION BEING DENIED. THIS FORM HAS BEEN 

PPROVED BY THE FORMS MANAGEMENT CENTER. 

APPLICATION PAGE. 

297-CAAPP 

ooou FOR APPLICANTS USE 

PAGE 1 OF 6 ?1 
P.91 

INSIGNIFICANT ACTIVITIES /continue (continuedT 

ftNGCCLLECm be) HOUSEKEEPING ACTIVITIES F6R CLEANING PURPOSES, INCLUDING COLLECT INS SPILLED ANP ACCUMULATED 

MATERIALS AT THE SOURCE, INCLUDING OPERATION OF FIXED VACUUM CLEANING SYSTEMS SPECIFICALLY FOR 

SUCH PURPOSES, BUT NOT INCLUDING USE OF CLEANING MATERIALS THAT CONTAIN ORGANIC SOLVENT; 

x) REFRIGERATION SYSTEMS, INCLUDING STORAGE TANKS USED IN REFRIGERATION SYSTEMS, BUT EXCLUDING 

ANY COMBUSTION EQUIPMENT ASSOCIATED WITH SUCH SYSTEMS; 

xi) BENCH SCALE LABORATORY EQUIPMENT AND LABORATORY EQUIPMENT USEO EXCLUSIVELY FOR CHEMICAL 

AND PHYSICAL ANALYSIS, INCLUDING ASSOCIATED LABORATORY FUME HOODS, VACUUM PRODUCING OEVICES 

AND CONTROL DEVICES INSTALLED PRIMARILY TO ADDRESS POTENTIAL ACCIDENTAL RELEASES; 

xB) REST ROOM FACIUTIES AND ASSOCIATED CLEANUP OPERATIONS, AND STACKS OR VENTS USED TO PREVENT 

THE ESCAPE OF SEWER GASES THROUGH PLUMBING TRAPS; 

Xfli) ACTTVITIES ASSOCIATED WITH THE CONSTRUCTION, ONSITE REPAIR, MAINTENANCE OR DISMANTLEMENT OF 

BUILDINGS, UTIUTY UNES, PIPEUNES. WELLS, EXCAVATIONS, EARTHWORKS AND OTHER STRUCTURES THAT DC 

NOT CONSTITUTE EMISSION UNITS; 

xiv) STORAGE TANKS OF ORGANIC UQUIDS WITH A CAPACITY OF LESS THAN 500 GALLONS, PROVIDED THE TANK IS 

NOT USED FOR STORAGE OF ANY MATERIAL USTED AS A HAZARDOUS AIR POUUTANT PURSUANT TO SECTION 

112(b) OF THE CLEAN AIR ACT; 

xv) PIPING ANO STORAGE SYSTEMS FOR NATURAL GAS, PROPANE. AND UQUEFIED PETROLEUM GAS; 

xvi) WATER TREATMENT OR STORAGE SYSTEMS AS FOUOWS: (A) SYSTEMS FOR POTABLE WATER OR BOILER 

FEEDWATER. (B) SYSTEMS. INCLUDING COOUNG TOWERS, FOR PROCESS WATER PROVIDED THAT SUCH 

WATER HAS NOT BEEN IN DIRECT OR INDIRECT CONTACT WITH PROCESS STREAMS THAT CONTAIN VOLATILE 

ORGANIC MATERIAL OR MATERIALS USTED AS HAZARDOUS AIR POUUTANTS PURSUANT TO SECTION 112(b) OF 

THE CLEAN AIR ACT; 

xvii) LAWN CARE, LANDSCAPE MAINTENANCE, AND GROUNDSKEEPING ACTIVITIES; 

xvfl) CONTAINERS, RESERVOIRS. OR TANKS USED EXCLUSIVELY IN DIPPING OPERATIONS TO COAT OBJECTS WITH 

OILS, WAXES. OR GREASES, PROVIDED NO ORGANIC SOLVENT HAS BEEN MIXED WITH SUCH MATERIALS; 

xtx) COLD CLEANING DEGREASERS THAT ARE NOT INUNE CLEANING MACHINES, WHERE THE VAPOR PRESSURE OF 

THE SOLVENTS USED NEVER EXCEED 2kPa MEASURED AT 38C OR 0.7kPa AT 20C; 

xx) MANUAUY OPERATED EQUIPMENT USED FOR BUFFING, POUSHING, CARVING, CUTTING, DRILLING, MACHINING, 

ROUTING, SANDING, SAWING, SCARFING, SURFACE GRINDING, OR TURNING; 

mi) USE OF CONSUMER PRODUCTS, INCLUDING HAZARDOUS SUBSTANCES AS THAT TERM IS DEFINED IN THE 

FEDERAL HAZARDOUS SUBSTANCES ACT. WHERE THE PRODUCT IS USED AT A SOURCE IN THE SAME MANNER 

AS NORMAL CONSUMER USE; 

xxfl) ACTIVITIES OIRECTLY USED IN THE DIAGNOSIS AND TREATMENT OF DISEASE, INJURY OR OTHER MEDICAL 

CONDITION; 

xxfl) FIREFIGHT1NG ACTIVITIES ANO TRAINING IN PREPARATION FOR FIGHTING FIRES CONDUCTED AT THE SOURCE; 

xxtv) INTERNAL COMBUSTION ENGINE OR BOILER (INCLUDING THE FUEL SYSTEM) OF MOTOR VEHICLES, 

LOCOMOTIVES, AIR CRAFT, WATERCRAFT, UFTTRUCKS, AND OTHER VEHICLES POWERED BY NONROAD 

ENGINES; 

xxv) ACTIVITIES ASSOCIATED WITH THE CONSTRUCTION, REPAIR OR MAINTENANCE OF ROADS OR OTHER PAVED OR 

OPEN AREAS, INCLUDING OPERATION OF STREET SWEEPERS, VACUUM TRUCKS, SPRAY TRUCKS, AND OTHER 

VEHICLES RELATED TO THE CONTROL OF FUGITIVE EMISSIONS OF SUCH ROADS OR OTHER AREAS; 

xxvi) STORAGE AND HANDLING OF DRUMS OR OTHER TRANSPORTABLE CONTAINERS WHERE THE CONTAINERS ARE 

SEALED DURING STORAGE AND HANDUNG; 

APPLICATION PAGE 0^ '

 9 

297-CAAPP 

3M»a;iaife&MI*?lP13 

PAGE2 OF 6 

% 
P.92 

INSIGNIFICANT ACTIVITIES* (coniinu {continuedT 

:MIN6IVIBUAll 

NTS THAT HAVE 

xxvil) INDIVIDUAL POINTS OF EMISSION OR ACTIVITIES AS FOLLOWS: \k) INBIVIBUAl FLANGES, VALVES, PUMP SEALS. 

PRESSURE REUEF VALVES AND OTHER INDIVIDUAL COMPONENTS THAT HAVE THE POTENTIAL FOR LEAKS, (B) 

INDIVIDUAL SAMPUNG POINTS, ANALYZERS, AND PROCESS INSTRUMENTATION, WHOSE OPERATION MAY 

RESULT IN EMISSIONS, (C) INDIVIDUAL FEATURES OF AN EMISSION UNIT SUCH AS EACH BURNER ANO 

SOOTBLOWERS IN A BOILER OR EACH USE OF CLEANING MATERIALS ON A COATING OR PRINTING UNE, (D) 

INDIVIDUAL EQUIPMENT THAT IS TRANSPORTABLE OR ACTIVITIES WITHIN A FACILITY ESTABUSHED FOR TESTINI i 

UNITS PRIOR TO SALE OR DISTRIBUTION OR FOR PURPOSES OF RESEARCH, AND (E) INDIVIDUAL EQUIPMENT OR 

ACTIVITIES WITHIN A PILOT PLANT FACIUTY THAT IS USED FOR RESEARCH OR TRAINING; 

XXVH) ACTTVITIES AT A SOURCE ASSOCIATED WITH THE MODIFICATION ONLY OR CONSTRUCTION ONLY OF A 

FACILITY, AN EMISSION UNIT OR OTHER EQUIPMENT AT THE SOURCE; 

xxfc) ACTTVITIES AT A SOURCE ASSOCIATED WITH THE MAINTENANCE, REPAIR, OR DISMANTLEMENT OF AN 

EMISSION UNIT OR OTHER EQUIPMENT INSTAUED AT THE SOURCE, NOT INCLUDING THE SHUTDOWN OF THE 

UNIT OR EQUIPMENT, INCLUDING PREPARATION FOR MAINTENANCE. REPAIR OR DISMANTLEMENT, AND 

PREPARATION FOR SUBSEQUENT STARTUP, INCLUDING PREPARATION OF A SHUTDOWN VESSEL FOR ENTRY, 

REPLACEMENT OF INSULATION, WELDING AND CUTTING, AND STEAM PURGING OF A VESSEL PRIOR TO 

STARTUP. 

Si ARE ANV EMISSION UNITS AT THE SOURCE CONSIBEREB INSIGNIFICANT ACTIVITIES BECAUSE THEV FALL 

UNDER ONE OF THE ACTTVITIES OR EMISSION LEVELS USTED IN 35 I U ADM. CODE 201 -210(a)(1) THROUGH (18)7 IF 

YES, IDENTIFY THE EMISSION UNITS IN THE *UST OF INSIGNIFICANT ACTIVITIES PURSUANTTO 201510(a)(1) 

THROUGH (18)* AND PROVIDE THE REQUESTED INFORMATION. IF ADDITIONAL SPACE IS NEEDED. ATTACH AND 

LABEL AS EXHIBIT 297-1. 

ACTTVITIES AND EMISSION LEVELS IN 35 ILL ADM. CODE 201.210(a) 

I) ANY EMISSION UNIT DETERMINED TO BE AN INSIGNIFICANT ACTIVITY BY THE 

AGENCY PURSUANT TO 35 I U ADM. CODE 201.211 (SEE ITEM #8); 

I) EMISSION UNITS WITH EMISSIONS THAT NEVER EXCEED 0.1 LBS/HR OF ANY 

REGULATED AIR POUUTANT IN THE ABSENCE OF AIR POUUTION CONTROL 

EQUIPMENT AND THAT DO NOT EMIT ANY AIR POUUTANT USTED AS HAZARDOUS 

PURSUANT TO SECTION 112(b) OF THE CLEAN AIR ACT; 

•) EMISSION UNITS WITH EMISSIONS THAT NEVER EXCEED 0.44 TONS/YR OF ANY 

REGULATED AIR POUUTANT IN THE ABSENCE OF AIR POUUTION CONTROL 

EQUIPMENT AND THAT DO NOT EMIT ANY AIR POUUTANT USTED AS HAZARDOUS 

PURSUANT TO SECTION 112(b) OF THE CLEAN AIR ACT; 

Iv) DIRECT COMBUSTION UNITS DESIGNED AND USED FOR COMFORT HEATING 

PURPOSES AND FUEL COMBUSTION EMISSION UNITS AS FOUOWS: (A) UNITS WITH A 

RATED HEAT INPUT CAPACITY OF LESS THAN 2.5 MMBTU/HR THAT FIRE ONLY 

NATURAL GAS, PROPANE OR UQUEFIED PETROLEUM GAS, (B) UNITS WITH A RATED 

HEAT INPUT CAPACITY OF LESS THAN 1.0 MMBTU/HR THAT FIRE ONLY OIL OR OIL IN 

COMBINATION WITH NATURAL GAS. PROPANE OR UQUEFIED PETROLEUM GAS, AND 

(C) UNITS WITH A RATED HEAT INPUT CAPACITY OF LESS THAN 200.000 BTU/HR 

WHICH NEVER BURN REFUSE. OR TREATED OR CHEMICAUY CONTAMINATED 

WOOD; 

V) EXTRUDERS USED FOR THE EXTRUSION OF METALS, MINERALS, PLASTICS, RUBBER, 

OR WOOD, EXCLUDING EXTRUDERS USED IN THE MANUFACTURE OF POLYMERS. 

PROVIDED THAT VOLATILE ORGANIC MATERIALS OR CLASS I OR B SUBSTANCES i—i 

SUBJECT TO THE REQUIREMENTS OF TITLE VI OF THE CLEAN AIR ACT ARE NOT USED 

AS FOAMING AGENTS OR RELEASE AGENTS OR WERE NOT USED AS FOAMING *—' 

AGENTS IN THE CASE OF EXTRUDERS PROCESSING SCRAP MATERIAL; 

VQ FURNACES USED FOR MELTING METALS OTHER THAN BERYLUUM WITH A BRIM FUU 

CAPACITY OF LESS THAN 450 CUBIC INCHES BY VOLUME; 

vl) EQUIPMENT USED FOR THE MELTING OR APPUCATION OF LESS THAN 50,000 LBS/YR 

OF WAX TO WHICH NO ORGANIC SOLVENT HAS BEEN ADDED; 

0* 

0YES 

• VES 

• 

• 

0 

NO 

NO 

NO 

|_J YES [7 ] NO 

YES 0 NO 

D 

• 

YES 

YES 

0 

0 

NO 

NO 

APPLICATION PAGE. 

297-CAAPP 

QOV'cU 

FOR APPLICANTS USE 

PAGE 3 OF 6 

It 
P.93 

INSIGNIFICANT ACTIVITIES> (continued) fconbnu 

EQUIPMENT USED FOR FILLING BRUMS, PAILS OR OTHER PACKAGIN KAGINOCONTAI O CONT/ I UERST 

EXCLUDING AEROSOL CANS, WITH SOAPS, DETERGENTS. SURFACTANTS. 

LUBRICATING OILS, WAXES, VEGETABLE OILS, GREASES. ANIMAL FATS. GLYCERIN. 

SWEETENERS. CORN SYRUP, AQUEOUS SALT SOLUTIONS, OR AQUEOUS CAUSTIC 

SOLUTIONS; 

EQUIPMENT USED FOR THE MIXING AND BLENDING OF MATERIALS AT AMBIENT 

TEMPERATURE TO MAKE WATER BASED ADHESIVES PROVIDED EACH MATERIAL 

CONTAINS LESS THAN 5% ORGANIC SOLVENT BY WEIGHT; 

STORAGE TANKS OF ORGANIC UQUIDS WITH A CAPACITY OF LESS THAN 10,000 

GALLONS AND AN ANNUAL THROUGHPUT OF LESS THAN 100.000 GAUONS PROVIDED I 1 

THE TANK IS NOT USED FOR THE STORAGE OF GASOUNE OR ANY USTED YES 

HAZARDOUS AIR POUUTANT PURSUANT TO SECTION 112(b) OF THE CLEAN AIR ACT; ' ' 

STORAGE TANKS OF VIRGIN OR REREFINED DISTILLATE OIL HYDROCARBON 

CONDENSATE FROM NATURAL GAS PIPEUNE OR STORAGE SYSTEMS, LUBRICATING 

OIL OR RESIDUAL FUEL OILS; 

DIE CASTING MACHINES WHERE A METAL OR PLASTIC IS FORMED UNDER PRESSURE I I 

IN A DIE; | | YES 

COATING OPERATIONS (EXCLUDING POWDER, ARCHITECTURAL AND INDUSTRIAL 

MAINTENANCE COATING) WITH AGGREGATE VOM USAGE THAT NEVER EXCEEDS 15 

LBS/DAY FROM A U COATING UNES AT THE SOURCE, INCLUDING VOM FROM 

COATING, DILUTENTS, AND CLEANING MATERIALS; 

PRINTING OPERATIONS WITH AGGREGATE ORGANIC SOLVENT USAGE THAT NEVER 

EXCEEDS 750 GAUONS PER YEAR FROM A U PRINTING UNES AT THE SOURCE, | 1 

INCLUDING ORGANIC SOLVENT FROM INKS, DILUTENTS, FOUNTAIN SOLUTIONS, AND 

CLEANING MATERIALS; ' ' 

"vaj" 

*) 

x) 

xi) 

Xi) 

xi) 

mv) 

XV) 

xvl) 

• 

• 

YES 

YES 

• YES 

• YES 

YES 

• YES 

GAS TURBINES AND STATIONARY RECIPROCATING INTERNAL COMBUSTION ENGINES 

OF LESS THAN 112 KW (150 HORSEPOWER) POWER OUTPUT; 

GAS TURBINES AND STATIONARY RECIPROCATING INTERNAL COMBUSTION ENGINES I 1 

OF BETWEEN 112 KW AN01.1118 KW (150 AND 1,500 HORSEPOWER) POWER OUTPUT YES 

THAT ARE EMERGENCY OR STANDBY UNITS; ' ' 

xvl) STORAGE TANKS OF ANY SIZE CONTAINING EXCLUSIVELY SOAPS, DETERGENTS, 

SURFACTANTS, GLYCERIN, WAXES, VEGETABLE OILS, GREASES, ANIMAL FATS, 

SWEETENERS, CORN SYRUP, AQUEOUS SALT SOLUTIONS. OR AQUEOUS CAUSTIC 

SOLUTIONS PROVIDED AN ORGANIC SOLVENT HAS NOT BEEN MIXED WITH SUCH 

MATERIALS; 

xvil) LOADING AND UNLOADING SYSTEMS FOR RAILCARS, TANK TRUCKS, OR 

WATERCRAFT THAT HANDLE ONLY THE FOUOWING UQUID MATERIALS PROVIDED 

AN ORGANIC SOLVENT HAS NOT BEEN MIXED WITH SUCH MATERIALS: SOAPS, 

DETERGENTS, SURFACTANTS, LUBRICATING OILS, WAXES, GLYCERIN, VEGETABLE 

OILS, GREASES, ANIMAL FATS, SWEETENER, CORN SYRUP, AQUEOUS SALT 

SOLUTIONS. OR AQUEOUS CAUSTIC SOLUTIONS. 

6) ARE ANY EMISSION UNITS AT THE SOURCE PROPOSED TO BE CONSIDERED 

INSIGNIFICANT ACTIVITIES THAT MEET THE CRITERIA USTED IN 35 I U ADM. CODE 

201.211(a)? IF YES, UST THE EMISSION UNITS IN THE "UST OF ACTIVITIES FOR WHICH 

STATUS AS AN INSIGNIFICANT ACTIVITIES IS PROPOSED PURSUANT TO 201.211(a)" AND 

PROVIDE THE REQUESTED INFORMATION. 

AND LABEL AS EXHIBIT 297-2. 

IF ADDITIONAL SPACE IS NEEDED. ATTACH 

0] 

Q 

0 

0 

NO 

NO 

NO 

NO 

NO 

NO 

NO 

0~° 

• «s 0]NO 

• « _2 

QYES • 

NO 

NO 

CRITERIA IN 35 ILL ADM. CODE 201.211(a) 

I) THE EMISSION UNIT WOULD NOT EMIT MORE THAN 1.0 LBS/HR OF ANY REGULATED AIR POUUTANT NOT USTED 

AS HAZARDOUS PURSUANT TO SECTION 112(b) OF THE CLEAN AIR ACT IN THE ABSENCE OF AIR POUUTION 

CONTROL EQUIPMENT; 

I) THE EMISSION UNIT WOULD NOT EMIT MORE THAN 0.1 LB/HR OF ANY REGULATED AIR POUUTANT USTED AS 

HAZARDOUS PURSUANT TO SECTION 112 (b) OF THE CLEAN AIR ACT IN THE ABSENCE OF AIR POUUTION 

CONTROL EQUIPMENT; AND 

m) THE EMISSION UNIT IS NOT A PROCESS UNIT. 

APPLICATION PAGE. 

297-CAAPP 

C0U2 

FOR APPLICANTS USE 

PAGE 4 OF 6 

9Z 
LIST OF INSIGNIFICANT ACTIVITIES PURSUANT TO 201.210 (a)(1) THROUGH (18) 

EMISSION UNIT 

AND DESIGNATION 

MDI Foam Injection 

#0F 

UNITS 

1 

i 

I 

DESCRIPTION OF UNIT INCLUDING ANY CONTROL 

Methyl Dilsocyanate Foam Injection 

i 

BASIS FOR INSIGNIFICANCE 

SECTION 201.210(a) 

IAC201.210(a)ii 

I 

i 

I 

* 

1

 BASIS FOR DETERMINATION 

OF EMISSIONS 

4, See Appendix D 

1 

I 

i 

I i i 

I I I 

V CONSIDERED MSIQN-FICANT BASED ON EMBSION LEVEL THE DETERMNATION METHOO OF BtiSSION MUST Be PROVIDED (E.G.. 1) STACK TEST. 2) MATERIAL BALANCE. 3) STANDARD EMBSION 

FACTOR (AP-42 OR AIRS). 4) ENQINEERINO ESTMATE. 6) SKOAL EMBSION FACTOR (NOT AP-42 OR ARS)). 

APPLICATION PAGE 

297-CAAPP 

coo:- Sl£KH31HaJIiaiH 

PAGE 5 OF 6 
Y 

V 

• - > 

( 

LIST OF ACTIVITIES FOR WHICH STATUS AS AN INSIGNIFICANT ACTIVITIES IS PROPOSED PURSUANT TO 201.211 (a) 

EMISSION UNIT 

AND DESIGNATION 

Resin Storage 

Tanks 

FRP Laboratory 

Dust Collectors 

Natural Gas 

Boilers 

Compound 

Storage 

1|U 

3 

1 

17 

5 

1 

DESCRIPTION OF UNIT 

INCLUDING ANY CONTROL 

Storage of resin 

R&D Laboratory 

Internally venting particulate emission 

control devices on presses & 1 

fiberglass chopper 

Natural gas fired boilers for 

process energy and comfort 

heating 

Storage of raw materials used In 

compound preparation 

OPERATING HOURS 

" F | "LWP |" W 

DISCUSSION: 

•>A Yt I a? 

Loading ioeeee only, see 

Appendix D 

8 17 1 52 

2912 houre per year 

24 1 7 1 52 

Vents Indoors 

24 17 1 52 

Used continuously, see 

Appendix D 

24 17 1 52 

Used continuously, eee 

Appendix D 

1 1 

EMISSIONS 

POUUTANT | HOUR VEAR 

DETERMINATION METHOD: 

Syren. (VOM) 0.0007 0.0003 

Styren* (VOM) 0.0006 0.02 

0.0 26 

SbrmlYQM) 00015 0.0066 

OTHER 

SUPPORTING 

INFORMATION 

3, See Appendix 

D, Table D-1. 

2, See Appendix 

D, Table D-2. 

4, See Appendix 

D, Table D-3. 

2, See Appendix 

D, Table D-4. 

5, See Appendix 

D 

1|U - TOTAL NUMBER OF W#TS (EMBSION RATES SHOULD BE PROVDED ON A PER UNIT BASB). 

JXSCUSSION - PROMDE AN EXPLANATION OF OPERAT**) HOURS (E.Q, THE UN^BCIN EMERGENCY STANDBY-THEREFORE H" ONLY OPERATES ONE DAY PER MONTH) 

-VETEf-MNATION METHOO*. 1)8TACK TEST. 2) MATERIAL BALANCE. 3) STANDARD BylSSWN FACTOR (AP-42 OR ARS), 4) ENCUNEERMOESTIMTE.Q8PECML EMBSION FACTOR (NOT AP-42 OR ARS). 

-J*; APPUCATION PAGE. 

297-CAAPP 

coo?:< 

PAGE 6 OF 6 
Molding 

Compound 

A Insignificant 

VOM 

A F-1 (VOM) 

' PM vented indoor* 

Material Flow 

Emission Point 

Compound 

Storage Room 

Molding Presses 

Ooaed Molding 

(Heat, Prcoure) 

ST-l f 

(representative itack 

ice Appendix A. Exhibit C for 

individual stack puvnetai) 

VOM 

PM Verted Indoors 

Scrap 

SMC 

_+ Finished Products. 

(Molded FRP) 

Rework 

Products 

tF- 2 

VOM 

Product 

Packaging, 

Storage and 

Shipping 

Maturation 

Room 

SMC 

Machine 

TMC 

Machine 

Mixer 

NOTE: TMC and SMC Machines do not operate at the same time. 

Scrap SMC 

Touch-Up Paint 

and Solvents 

Raw Materials 

Resins 

Catalysts ' 

Fillets 

Fiberglass 

insignificant 

VOM 

Resin Storage Tanks 

Compound Preparation and Maturation Area 

4WW GERAGHTY 

& MILLER. INC. 

Environmental Services 

A HeldemiJ Company 

FIGURE 3 

Facility Process Flow Diagram 

Applied Composites Corp. 

St. Charles, Illinois 

FILE: FIGURE3AD0C 

DWO OATE: 5-D«c-fl5 

PRJCTNO:WI0466.001 

APPROVED: GJT 

DRAFTER: GJT 

\J\ V_4Jrojec(\appldconip\w(}468\applicat\working^gure3.doc 

COO 10 
P.97 

SECTION 1 

INTRODUCTION 

PERMIT SHIELD REQUEST 

LIST OF PROCESSES TO BE PERMITTED 

% 
P.98 

TITLE V PERMIT APPUCATION 

APPLIED COMPOSITES CORP. 

ST. CHARLES, ILLINOIS 

INTRODUCTION 

Applied Composites Corp. operates a molded fiber and fiberglass reinforced plastic 

(FRP) production facility in St Charles, Illinois. Figure 1 presents a site map indicating the 

location of the facility. Kane County is designated as a severe ozone non-attainment area. 

Figures 2 and 3 present a layout plan and process fiow diagram for the facility. Applied 

Composites is submitting a Title V pennit application because the facility's potential emissions 

of volatile organic materials (VOM) exceeds the 25 tons per year (tpy) major source threshold 

for sources located in severe ozone non-attainment area. In addition, the facility emits styrene, 

a federal hazardous air pollutant, at levels above the 10 tpy major source threshold. Tables 1 

through 3 present a detailed emission inventory for the significant emitting processes located at 

the facility. 

The facility consists of three distinct significant emission processes; compound 

preparation and maturation, molding press operations and paint/solvent usage. A total of 21 

molding presses, with vacuum-assisted capability and six1 presses incorporating electrostatic 

pigment coating technology, are used for FRP production. The structure of the permit 

application has been simplified by consolidating all of the presses into the Molding Presses 

emission unit, which is consistent with the facility's current state operating permit. Appendbc B 

contains the applicable rules and requirements for each emission unit, and Appendbc C presents 

the facility's state operating permit. 

Other operations at the facility which result in insignificant emissions, include five 

natural gas-fired boilers, an FRP laboratory, polyester resin storage tanks which store resins 

used in the compound preparation process, a compound storage room, and a methyl diisocyanate (MDI) foam injection system which will be installed in the near future. These 

1

 Two are currently installed, the other four will be installed pursuant to the construction/operating permit 

applications #94050039 and 94080129. 

n 
P.99 

$ 

emission units were classified as insignificant emission units pursuant to the criterion contained 

in the Illinois Administrative Code (IAC) $ 201.210(a)ii and IAC § 201.211(a). Appendix D 

provides documentation for the insignificant emitting operations. 

PERMIT SHIELD REQUEST 

Applied Composites Corp. requests a permit application shield for its entire facility 

with respect to all applicable regulations and regulations from which Applied Composites is 

exempt as identified in this application. 

OPERATIONAL FLEXIBILITY REQUEST 

Applied Composites request an emissions cap for the entire facility based on the 

records set forth in this application. 

LIST OF PROCESSES TO BE PERMITTED 

COMPOUND PREPARATION AND MATURATION AREA 

Applied Composites operates a compound preparation room to manufacture sheet 

molding compound (SMC) and thick molding compound (TMC). Section 3 of this application 

contains the 220-CAAPP for this emission unit. Equipment associated with the SMC process is 

listed in Exhibit A of Appendix A. 

In the SMC process, polyester resins (fabricated off-site and stored in underground 

storage tanks) are transferred tojhe mbdng operations via a closed loop piping system. The 

resin is mixed to a desired A-side paste level using the foUowing equipment: 

" X 

1. small lightning mbdng (15 gallon); 

2. 1 large cowles mixer with 3 vessels (350 gallons each); and 

3. spare cowles mixer. 

00012 
p.1 

Once the mixture achieves a certain temperature, it is combined with B-side thickened 

paste which is mixed in the small cowles mixer (55 gallon). This mixer determines the 

maximum feed rate to the SMC machine. The resulting compound is injected into "doctor 

boxes" on the 48 inch SMC machine via a closed mixing pump. 

The compound is metered onto a bottom carrier film, using a blade to control 

thickness, and conveyorized. Continuous fiberglass roving, cut to one inch or longer lengths 

by a hooded chopper (ducted to a dust collector and vented indoors), are then dropped to the 

resin mix. Another layer of resin mbe is applied over the roving. The material is then covered 

with a top carrier film. The encapsulated compound is run through a compaction belt insuring 

that the roving is impregnated with thickened paste. The pliable compound is then "festooned" 

(folded) into crates. The crates are stored for a minimum of 48 hours in an adjacent 

temperature controlled maturation room to achieve the desired molding viscosity. After 

maturation, the crates are stored for a short period of time in the compound storage room until 

they are used in the molding process. 

The TMC machine differs from the SMC by using a fiberglass chopper that has smaller 

diameter blade and the roving is blown down with the use of an oscillating air spray into two 

feed rollers. The paste nuxture is injected above the feed rollers along with the roving, thereby 

drawing the combined materials down to the rollers where it is laid onto the bottom carrier 

film. The encapsulated TMC is not festooned, but chopped into 48 inch blocks and placed in 

crates. The SMC and the TMC machines cannot run simultaneously because the mbdng 

operation is capable of only supporting one machine at any given time. 

Because of the inherent nature of the B-Side mbdng process (SS gallon drum), the 

SMC machine can only run at a maximum rate of 5,750 lb/hr. This is due to a limited feed rate 

ofthe B-Side thickened paste. 

Another limitation exists in the maturation ofthe formulated SMC as the material must 

be placed in a temperature controlled room (maturation room) for a minimum of 48 hours to 

achieve the proper molding viscosity according to specifications. The maturation room can 

00013 
P.2 

only hold 80 crates of material at any one time, thus limiting compound production to a 

maximum of 40 hours in a 48 hour period. Therefore, the compounding process can 

theoretically run only 6,257 hours per year. This corresponds to maximum theoretical 

* 

emissions for the compounding and maturation processes according to the following 

calculations and as set forth in Table 1: 

16 crates * 3000 lbs SMC * 1 shift * 8760 hrs * £ = 37,542,856 lbs SMC/yr 

shift crate 8 hours yr 7 

37.542.856 lbs SMC * 20.9 lbs VOM = 136,698 lbs VOM/yr 

5,740 lbs SMC/hr hr 

= 68.3 tons VOM/yr 

r* 

Applied Composites uses some SMC formulations with a monomer content of greater 

than 35% for products that have special flexibility, strength, corrosion resistance, and fire 

retardant requirements (i.e. boat hulls). 

Air emissions from the compound room are exhausted from four exhaust pomts, 

including the Torit dust collector vent which vents indoors. The emission points represent all 

emissions from the compounding process including all equipment, maturation room, solvent 

use, and fugitives. Exhibit B of Appendbc A presents the exhaust point infonnation. Since the 

maturation room is under negative pressure when compared to its surrounding building 

enclosure, and the compound room is under negative pressure relative to the maturation room 

and adjacent areas, air is being pulled in from all interior openings and is ultimately exhausted 

through the above-mentioned emission points. Compound room air emissions are quantified 

through recordkeeping (i.e. material usage data) and an emission factor (0.0304 lb VOM per lb 

of monomer used) which was determined by source testing conducted on October 12, 1992. 

MOLDING PRESSES 

Applied Composites utilizes a compression molding process where heat and pressure 

are applied to the initiated SMC in a closed mold. The compression molding process uses 

00014 
P.3 

matched steel molds to compress a weighed "charge" of molding compound into a new and 

specific shape. The two halves of the mold, which are mounted in a hydraulic molding press, 

are closed around the "charge". Section 4 of this application provides the 220-CAAPP form 

for this emission unit. A list ofthe molding presses, including model numbers and installation 

dates, are presented in Exhibit C of Appendbc A and is reproduced below. 

Equipment 

Press #34* 

Press #25* 

Press #33* 

Press #37 

Press #26 

Press #44 

Press #35* 

Press #30 

Press #31 

Press #36 

Press #38* 

Press #29 

Press #01 

Press #39* 

Press #32 

Press #28 

Press #21 

Press #05 

Press #27 

Press #06 

Lab Press. 

Manufacturer 

Verson 4000T 

Erie 2500T 

Wms/White 2000T 

Wms/White 1500T 

Erie 1500T 

Wms/White 1000T 

Clearing 1000T 

Wms/White 1000T 

Wms/White 1000T 

Wms/White 800T 

Erie 750T 

Wms/White 750T 

Erie 650T 

Dake 600T 

Wms/White 600T 

Erie400T 

Hannifin 350T 

Erie300T 

Dake 150T 

Hannifin 100T 

PHI 25T 

Serial Number 

23353 

21-7867 

C4226 

C4016 

21-8323 

C4201 

11-5186 

C4267 

C3948 

C4018 

21-6006 

C4263 

R-4058 

155882 

C4062A 

SOR4057 

T-4251 

R-3215-A 

16986 

T-1083-2 

Installation 

Date 

Post 1972 

Post 1972 

Post 1972 

Pre 1972 

Post 1972 

Post 1972 

Post 1972 

Post 1972 

Post 1972 

Pre 1972 

Post 1972 

Post 1972 

Pre 1972 

Post 1972 

Post 1972 

Post 1972 

Pre 1972 

Post 1972 

Post 1972 

Pre 1972 

Pre 1972 

With electrostatic pigment coating capability. 

Crates of prepared SMC are positioned at the front of each molding press. The 

festooned SMC is threaded into ah air actuated film stripper which removes the film from the 

SMC material and places it on a cutting table. The press operator then quickly cuts the SMC 

into a predetermined pattern and places the material into a plastic enclosure (clam shell) 

fastened on top of an electronic scale. Next, the charge pattern is transferred to another plastic 

00015 

l°l 
P.4 

enclosure on a "waiting table" while the operator cuts and weighs another pattern. The press 

is loaded with the material on the weighing table, then the operator activates the press cycle 

which closes the mold. The combination of heat and pressure activate a cross-linking reaction 

_> 

(polymerization) between the resin component's unsaturated polymer and the unsaturated 

monomer (styrene), converting the SMC material into a three dimensional thermoset plastic 

part. 

The cutting/weighing procedure is repeated, rotating SMC material from the scale, to 

the waiting table, and to the press. Press cycle times range from 1.3 to 6.5 minutes according 

to the size and characteristics ofthe part being molded. Molded parts which are removed from 

the press are deflashed, sanded and/or drilled, inspected, and packaged for shipping. A variety 

of products, including basketball backboards, bathroom fixtures and marine recreational 

equipment are manufactured to customer specifications. 

VOM emissions from the molding presses are exhausted through building windows, 

doors, and hydraulic equipment fens located above hydraulic pumps on top of the longer 

presses. The buildings are open areas inside with a 30 foot roof height. Press area emissions 

were estimated using an USEPA AP-42 emission faaor (5th edition, Seaion 4.4) of 1 lb VOM 

per 100 lb monomer for closed molding presses. 

The maximum theoretical emissions were estimated using the then highest SMC 

monomer content in use and the maximum quantity of such SMC that can be produced at 

Applied Composites according to the following calculation and as set forth in Table 2: 

37.542.856 lbs SMC * 014 lbs monomer * 1 lb monomer = 52,560 lbs VOM/yr 

yr lbs SMC 100 lbs monomer 

26.3 tons VOM/yr 

0001*6 

I 02-
P.5 

There are sbc molding presses that are permitted to apply electrostatic pigment 

coatings. Particulate matter (PM) generated by the coatings are controlled by either Torit or 

Nordson dust collectors that exhaust inside the facility. PM emissions from the molding 

presses are considered negligible. 

PAINT/SOLVENT USE 

Relatively modest quantities of paints and solvents are used for miscellaneous touch-up 

painting, thinning and cleanup operations. Emissions from paint and solvent use are fugitive. 

VOM emissions are determined by recordkeeping (i.e. material usage data) and mass balance 

calculations. Section 5 of this application contains form 391-CAAPP for this emission unit. 

00017 

10J