p.1 

OAR Box 1413 

Prepped by Ollie Stewart 

Document Number: 

58) 11-1-58 

Docket Number: 

A-94-52 

Printed 7/9/2008 3:11:23 PM Sheet 58 of 114 
PJ? 

ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P 0 BOX 19506 

SPRINGFIELD, ILLINOIS 62794-9506 

FOR APPLICANTS USE 

Revision #: 

Date: 

Page 

/ / 

of 

Source Designation: 

PROCESS EMISSION UNIT 

DATA AND INFORMATION 

***** — l ^ - * *, - ^V-AH-? 

ID NUMBER: 

EMISSION POINT #: 

DATE: 

1.1- 1 

U?I;£Q 

SOURCE INFORM A TION 

1) SOURCE NAME: 

Bulk Molding Compounds, Inc. 

2) DATE FORM 

PREPARED: March 7,1996 

3) SOURCE ID NO. 

(IF KNOWN): 089813AAK 

GENERAL INFORMATION 

4) NAME OF EMISSION UNIT: 

Eight Mixing Lines and Two Resin Rooms 

5) NAME OF PROCESS: 

Bulk molding compound production 

6) DESCRIPTION OF PROCESS: 

Materials are mixed and extruded to produce bulk molding compound 

7) DESCRIPTION OF ITEM OR MATERIAL PRODUCED OR ACTIVITY ACCOMPLISHED: 

Thermoset resins A y 

8) FLOW DIAGRAM DESIGNATION OF EMISSION UNIT: 

Lines 1, 2,4-7, 9 &10; Resin Rooms 

9) MANUFACTURER OF EMISSION UNIT (IF KNOWN): 

NA 

10) MODEL NUMBER (IF KNOWN): 

NA 

11) SERIAL NUMBER (IF KNOWN): 

NA 

12) DATES OF COMMENCING CONSTRUCTION. 

OPERATION AND/OR MOST RECENT MODIFICATION 

OF THIS EMISSION UNIT (ACTUAL OR PLANNED) 

a) CONSTRUCTION (MONTH/YEAR): 

June, 1979 

b) OPERATION (MONTH/YEAR): 

July, 1979 

c) LATEST MODIFICATION (MONTH/YEAR): 

November, 1994 

13) DESCRIPTION OF MODIFICATION (IF APPLICABLE): 

Addition of hood to line 6 

THIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNDER ILLINOIS REVISED STATUTES. 1991, AS AMENDED 1992. 

CHAPTER 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 APPLICATION BEING DENIED. THIS FORM HAS BEEN 

APPROVED BY THE FORMS MANAGEMENT CENTER. 

APPLICATION PAGE 

Printed on Recycled Paper 

220-CAAPP 

FOR APPLICANTS USE 

Page 1 of 10 
P.3 

1.1-2 

14) 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 220-CAAPP MUST BE COMPLETED 

FOR EACH MODE): 

TJ YES NO 

15) PROVIDE THE NAME AND DESIGNATION OF ALL AIR POLLUTION CONTROL EQUIPMENT CONTROLLING THIS 

EMISSION UNIT, IF APPLICABLE (FORM 260-CAAPP AND THE APPROPRIATE 260-CAAPP ADDENDUM FORM 

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

Baghouse 

16) WILL EMISSIONS DURING STARTUP EXCEED EITHER THE ALLOWABLE EMISSION 

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

ESTABLISHED 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. 

rr YES NO 

17) PROVIDE ANY LIMITATIONS ON SOURCE OPERATION AFFECTING EMISSIONS OR ANY WORK PRACTICE 

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

Production of bulk molding compound 

OPERATING INFORMATION 

18) ATTACH THE CALCULATIONS, TO THE EXTENT THEY ARE AIR EMISSION RELATED, FROM WHICH THE 

FOLLOWING 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. 

19a) MAXIMUM OPERATING HOURS 

b) TYPICAL OPERATING HOURS 

20) ANNUAL THROUGHPUT 

HOURS/DAY: 

24 

HOURS/DAY: 

22 

DEC-FEB(%): 

25 

DAYSA/VEEK: 

7 

DAYS/WEEK: 

5 

MAR-MAY(%): 

25 

WEEKS/YEAR: 

52 

WEEKS/YEAR: 

52 

JUN-AUG(%): 

25 

SEP-NOV(%): 

25 

MATERIAL USAGE INFORMATION 

21a) RAW MATERIALS 

Raw bulk molding 

compounds materials 

MAXIMUM RATES 

LBS/HR 

NA 

TONS/YEAR 

NA 

TYPICAL RATES 

LBS/HR 

NA 

TONS/YEAR 

NA 

• 

APPLICATION PAGE 

Printed on Recycled Paper 

220-CAAPP Page 2 of 10 ^ 
P.4 

1.1-J 

21b) PRODUCTS 

Bulk molding compound 

21c) BY-PRODUCT MATERIALS 

Waste material 

MAXIMUM RATES 

LBS/HR TONS/YEAR 

15,123 

MAXIMUM RATES 

LBS/HR 

NA 

TONS/YEAR 

NA 

TYPICAL RATES 

LBS/HR TONS/YEAR 

9,000 

TYPICAL RATES 

LBS/HR 

NA 

TONS/YEAR 

NA 

FUEL USAGE DATA - NA 

22a) MAXIMUM FIRING RATE 

(MILLION BTU/HR): 

b) TYPICAL FIRING RATE 

(MILLION BTU/HR): 

c) DESIGN CAPACITY FIRING 

RATE (MILLION BTU/HR): 

d) FUEL TYPE: 

o NATURAL GAS o FUEL OIL: GRADE NUMBER OCOAL D OTHER 

IF MORE THAN ONE FUEL IS USED, ATTACH AN EXPLANATION AND LABEL AS EXHIBIT 220-2. 

e) TYPICAL HEAT CONTENT OF FUEL (BTU/LB, 

BtU/GALdRBtU/SCF): 

f) TYPICAL SULFUR CONTENT (WT %.. NA FOR NATURAL 

'"•QAS): 

g) TYPICAL ASH CONTENT (WT %., NA FOR NATURAL 

GAS): 

h) ANNUAL FUEL USAGE (SPECIFY UNITS, E.G., 

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

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

PROCESS UNIT EMISSIONS? 

IF NO, IDENTIFY THE EXHAUST POINT FOR COMBUSTION EMISSIONS: 

TJ YES u NO 

APPLICATION PAGE 

Printed on Recycled Paper 

220-CAAPP Page 3 of 10 3 
APPLICABLE RULES 

24) PROVIDE ANY SPECIFIC EMISSION STANDARD(S) AND LIMITATION(S) SET BY RULE(S) WHICH ARE APPLICABLE TO THIS EMISSION UNIT (E.G., VOM, IAC 218.204(j)(4). 3.5 LBS/GAL): 

REGULATED AIR POLLUTANT(S) EMISSION STANDARD(S) REQUIREMENT(S) 

VOM 

PM 

PM 

35 IAC 218.301 

35 IAC 212.321 

35 IAC 212.123 

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

REGULATED AIR POLLUTANT(S) RECORDKEEPING RULE(S) 

VOM and PM 35 IAC 201.301 

26) PROVIDE ANY SPECIFIC REPORTING RULE(S) WHICH ARE APPLICABLE TO THIS EMISSION UNIT: 

REGULATED AIR POLLUTANT(S) REPORTING RULE(S) 

27 

VOM and PM 

) PROVIDE ANY SPECIFIC MONITORING RULE(S) 

REGULATED AIR POLLUTANT(S) 

NA 

Wl35 IAC 201.302 and 35 IAC 254 

UCH ARE APPLICABLE TO THIS EMISSION UNIT: 

MONITORING RULE(S) 

VOM emissions <, 8 Ibs/hr 

Production-based PM emission limit <. 3.40 Ibs/hr 

Opacity <, 30% 

REQUIREMENTS) 

Maintain records for Annual Emissions Report 

REQUIREMENT(S) 

Annual Emissions Report 

REQUIREMENTS) 

28) PROVIDE ANY SPECIFIC TESTING RULES AND/OR PROCEDURES WHICH ARE APPLICABLE TO THIS EMISSION UNIT: 

REGULATED AIR POLLUTANT(S) TESTING RULE(S) REQUIREMENTS) 

L 

NA 

ADD I IPATin M DAnc 

x 

Printed on Recycled Paper 

220-CAAPP page 4 of 10 
P.6 

1.1-5 

29) DOES THE EMISSION UNIT QUALIFY FOR AN EXEMPTION FROM AN 

OTHERWISE APPLICABLE RULE? TJ YES NO 

IF YES. THEN LIST 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 UBEL AS EXHIBIT 220-3. OR REFER TO OTHER ATTACHMENT(S) WHICH ADDRESS 

AND JUSTIFY THIS EXEMPTION. 

COMPUANCE INFORMATION 

30) IS THE EMISSION UNIT IN COMPLIANCE WITH ALL APPLICABLE 

REQUIREMENTS? YES TJ NO 

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

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

31) EXPUNATION OF HOW INITIAL COMPLIANCE IS TO BE. OR WAS PREVIOUSLY, DEMONSTRATED: 

USEPA Method 25A stack testing data was used in correlation with production records in 

order to determine production-based emission factors. Using these factors, review of 

production histories assures past compliance. 

32) EXPUNATION OF HOW ONGOING COMPLIANCE WILL BE DEMONSTRATED: 

Production will be monitored and remain below the maximum allowable production rate of 

1,260 Ibs/hr of bulk molding compound material, thus assuring VOM emissions of <7.90 

Ibs/hr and <24.5 tons/yr. PM emissions at this maximum production rate are <0.034 Ibs/hr. 

TESTING, MONITORING, RECORDKEEPING AND REPORTING 

33a) LIST THE PARAMETERS THAT REUTE TO AIR EMISSIONS FOR WHICH RECORDS ARE BEING 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 UNIT OF MEASUREMENT METHOD OF MEASUREMENT FREQUENCY 

bulk molding 

compound production 

• 

pounds gravimetric monthly 

APPLICATION PAGE 

Printed on Recycled Paper 

220-CAAPP Page 5 of 10 5 
P.7 

1.1-6 

33b) BRIEFLY DESCRIBE THE METHOD BY 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 

METHOD OF 

RECORDKEEPING 

TITLE OF 

PERSON RESPONSIBLE 

TITLE OF 

CONTACT PERSON 

bulk molding 

compound production 

department record VICs.Prm.ldKtt.mUnut*ttmtng Vie* AWMMT I Utnufcturlng 

mnd Engln—ring 

c) IS COMPLIANCE OF THE EMISSION UNIT READILY DEMONSTRATED BY REVIEW OF 

THE RECORDS? 

IF NO, EXPLAIN: 

YES D NO 

TJ d) ARE ALL RECORDS READILY AVAILABLE FOR INSPECTION, COPYING AND 

SUBMITTAL TO THE AGENCY UPON REQUEST? 

IF NO. EXPLAIN: 

YES NO 

34a) DESCRIBE ANY MONITORS OR MONITORING ACTIVITIES USED TO DETERMINE FEES, RULE APPLICABILITY OR 

COMPLIANCE: 

Wone 

b) WHAT PARAMETER(S) IS(ARE) BEING MONITORED (E.G., VOM EMISSIONS TO ATMOSPHERE)? 

None 

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

NA 

APPLICATION PAGE 

Printed on Recycled Paper 

220-CAAPP Page 6 of 10 t 
P.8 

1.1- / 

u 34d) IS EACH MONITOR EQUIPPED WITH A RECORDING DEVICE? 

NA 

IF NO, LIST ALL MONITORS WITHOUT A RECORDING DEVICE: 

YES TJ NO 

e) IS EACH MONITOR REVIEWED FOR ACCURACY ON AT LEAST A QUARTERLY BASIS? T J YES u NO 

NA 

IF NO. EXPUIN: 

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

OPERATION? 

NA 

IF NO, EXPUIN: 

YES NO 

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

PURPOSES OF THE DETERMINATION OF FEES. RULE APPLICABILITY 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 DATE 

12flAV94-12rl6&4 

12na/94-12/2tUM 

9/30/94 

TEST METHOD 

USEPA 25A 

USEPA 25A 

TESTING COMPANY 

Air Solutions, Inc. 

Mostardi-Platt 

Associates 

OPERATING 

CONDITIONS 

typical 

typical 

SUMMARY OF RESULTS 

roof exhaust VOM • 

3.15 lbs/ton of production 

0.19 Ibs/hr VOM 

from Baghouse 

36) DESCRIBE ALL REPORTING REQUIREMENTS AND PROVIDE THE TITLE AND FREQUENCY OF REPORT 

SUBMITTALS TO THE AGENCY: 

REPORTING REQUIREMENTS 

Emissions of all regulated 

pollutants 

Compliance of source and 

emission units 

TITLE OF REPORT 

Annual Emissions Report 

Compliance Certification, 

CAAPP Form 296 

FREQUENCY 

annually 

annually 

• 

APPLICATION PAGE 

Printed on Recycled Paper 

220-CAAPP Page 7 of 10 1 
REGULATED AIR 

POLLUTANT 

CARBON 

MONOXIDE (CO) 

LEAD 

NITROGEN 

OXIDES (NOx) 

PARTICUUTE 

MATTER (PART) 

PARTICULATE 

MATTER <= 10 

MICROMETERS 

(PM10) 

SULFUR 

DIOXIDE (S02) 

VOLATILE 

ORGANIC 

MATERIAL (VOM) 

OTHER, SPECIFY: 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL: 

•

 1ACTUAL EMISSION RATE" 

B 'UNCONTROLLED EMISSION RATE 

LBS PER 

HOUR 

(LBS/HR) 

1.71 

1.51 

1.71 

1.51 

TONS PER 

YEAR 

fTONS/YR) 

7.49 

3.24 

7.49 

3.24 

24.5 

14.6 

!

 3OTHER 

TERMS 

j 

! 

t 

! 

3OTHER 

TERMS 

4DM 

2&4 

28,4 

28,4 

284 

1,2 8.4 

182 

ALLOWABLE BY RULE EMISSION RATE 

5RATE (UNITS) 

* 8 (lb/hr) 

APPLICABLE 

RULES 

See Form 260 

See Form 260 

35 IAC 218.301 

TONS PER 

YEAR 

(TONS/YR) 

EXAMPLE: 

PARTICULATE 

MATTER 

MAXIMUM: 

TYPICAL: 

5.00 

4.00 

21.9 

14.4 

0.3 

GR/DSCF 

0,24 

GRADSCF 

1 

4 

6.0 (LBS/HR) 

5.5 (LBS/HR) 

212.321 

212.321 

26.28 

••'li-M^-' 

^ m 

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

JCHECK UNCONTROLLED EMISSION RATE BOX IF CONTROL EQUIPMENT IS USED. OTHERWISE CHECK AND PROVIDE THE ACTUAL EMISSION RATE TO ATMOSPHERE. INCLUDING INDOORS. SEE INSTRUCTIONS. 

^PROVIDE THE EMISSION RATE THAT WILL BE USED AS A PERMIT SPECIAL CONDITION. THIS LIMIT WILL BE USED TO DETERMINE THE PERMIT FEE. 

'PLEASE PROVIDE ANY OTHER EMISSION RATE WHICH IS COMMONLY USED. REQUIRED BY A SPECIFIC LIMITATION OR THAT WAS MEASURED (E.G. PPM, GR/DSCF, ETC.) 

?DM • DETERMINATION METHOD: 1) STACK TEST, 2) MATERIAL BALANCE. 3) STANDARD EMISSION FACTOR (AP-42 OR AIRS). 4) ENGINEERING ESTIMATE, 5) SPECIAL EMISSION FACTOR (NOT AP-42 OR AIRS) 

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

a

 Only permitted emission rates for VOM emissions are requested herein. The requested permitted emission rates for particulate matter (PM) are 

included on CAAPP Form 260. 

APPLICATION PAGE __ 

Printed on Recycled Paper 

220-CAAPP page 8 of 10 QC 
HAP INFORMATION 

NAME OF HAP 

EMITTED 

Styrene 

2CAS 

NUMBER 

100-42-5 

(mto/ r.t\£mHI\s\jss-tw Min rfLLUin m c/r»joiiy n inry-runr. § I\.M 

•

 1 ACTUAL EMISSION RATE 

O

 1 UNCONTROLLED EMISSION RATE 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL 

POUNDS PER 

HOUR 

(LBS/HR) 

TONS PER 

YEAR 

(TONS/YR) 

24.5 

14.6 

3OTHER 

TERMS 

4DM 

1,2 8 4 

182 

ALLOWABLE BY RULE 

5RATE OR STANDARD APPLICABLE 

RULE 

EXAMPLE: 

Benzene rju&y.i 

MAXIMUM: 

TYPICAL: 

10.0 

8.0 

1.2 

0.8 

2 

2, ,-• . 

98% by wt control device 

: Vea/r-ftgftftrucks 

CFR 61 

61.302(b).(d) 

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

1

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

•^CAS - CHEMICAL ABSTRACT SERVICE NUMBER. 

3PLEASE PROVIDE ANY OTHER EMISSION RATE WHICH IS COMMONLY USED, REQUIRED BY A SPECIFIC LIMITATION OR THAT WAS MEASURED (E.G.. PPM, GR/DSCF, ETC.). 

4DM - DETERMINATION METHOD: 1) STACK TEST, 2) MATERIAL BALANCE. 3) STANDARD EMISSION FACTOR (AP-42 OR AIRS. 4) ENGINEERING ESTIMATE, 5) SPECIAL EMISSION FACTOR (NOT AP-42 OR AIRS). 

•SRATE - ALLOWABLE EMISSION RATE OR STANDARD SPECIFIED BY MOST STRINGENT APPUCABLE RULE. 

_P 

APPLICATION PAGE _ 

Printed on Recycled Paper 

220-CAAPP page 9 of 10 i 

VO 
P.11 

1.1-10 

EXHAUST POINT INFORMATION3 

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

39) FLOW DIAGRAM DESIGNATION OF EXHAUST POINT: 

Roof exhaust 

40) DESCRIPTION OF EXHAUST POINT (STACK, VENT, ROOF MONITOR, INDOORS, ETC.). IF THE EXHAUST POINT 

DISCHARGES INDOORS, DO NOT COMPLETE THE REMAINING ITEMS. 

Stack 

41) DISTANCE TO NEAREST PUN T BOUNDARY FROM EXHAUST POINT DISCHARGE (FT): 

40 

42) DISCHARGE HEIGHT ABOVE GRADE (FT): 

30 

43) GOOD ENGINEERING PRACTICE (GEP) HEIGHT, IF KNOWN (FT): 

NA 

44) DIAMETER OF EXHAUST POINT (FT): NOTE: FOR A NON CIRCULAR EXHAUST POINT. THE DIAMETER IS 

1.128 TIMES THE SQUARE ROOT OF THE AREA. 

4 

45) EXIT GAS FLOW RATE a) MAXIMUM (ACFM): 

30,500 

b) TYPICAL (ACFM): 

30,000 

46) EXIT GAS TEMPERATURE a) MAXIMUM (°F): 

100 

b) TYPICAL CF): 

80 

47) DIRECTION OF EXHAUST (VERTICAL, UTERAL, DOWNWARD): 

Vertical 

48) LIST ALL EMISSION UNITS AND CONTROL DEVICES SERVED BY THIS EXHAUST POINT: 

NAME FLOW DIAGRAM DESIGNATION 

a) Mixing Unes 

b) Resin Rooms 

c) 

d) 

e) 

Unes 1, 2,4-7, 9&10 

Resin Rooms 

THE FOLLOWING INFORMATION NEED ONLY BE SUPPLIED IF READILY AVAILABLE. 

49a) UTITUDE: 

41:55:13.000 

50) UTM ZONE: 

NA 

b) LONGITUDE: 

88:20:20.00 

b) UTM VERTICAL (KM): 

NA 

c) UTM HORIZONTAL (KM): 

NA 

8

 Information only for the exhaust point for VOM emissions from the eight Mixing Lines and the 

two Resin Rooms. Information for the exhaust point for particulate matter (PM) emissions from 

these emission units is included on CAAPP Form 260, Baghouse (i.e.: PM control device). 

APPLICATION PAGE 

Printed on Recycled Paper 

220-CAAPP Page 10 of 10 \o 
P.12 

EXHIBITS 220-5 & 220-6 

1.1-11 

MIXING LINES & RESIN ROOMS 

CALCULATION SUMMARY 

Note: All VOM is assumed to be Styrene. 

Stack Test Data: 

Roof exhaust VOM = 

Baghouse VOM 

( 3.15 

\ton BA 

• ( 

lbs Styrene 

BMC production j 

0.089 lbs Styrene 

ton BMC production j 

Total VOM = 

324 lbs Styrene i 

Jon BMC production) 

Maximum production and emission rate: 

24.5 tons Styrene 

y J 

2,000 lbs Styrene 

< 1 ton Styrene > 

ton BMC production} 15,123 tons BMC production 

\ 324 lbs Styrene ) year 

Typical production and emission rate: 

Production rate: 9,000 tons BMC (1995 estimate) 

9,000 tons BMC] ( 324 lbs Styrene 

yr ton BMC production^ 

ton Styrene 

,2,000 lbs Styrene) 

14.6 tons Styrene 

year 

Test data shows that for every 1 lb Styrene exhausting through the roof exhaust, 0.032 lbs Styrene exhausts 

through the baghouse. 

5034-CA\mixexib.doc AIR SOLUTIONS, INC. 

II 
P.13 

ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD. ILLINOIS 62794-9506 

Revision #: 

Date: / 

Page of 

Source Designation: 

STORAGE TANK 

DATA AND INFORMATION 

FOR AGENCY USE OW.Y ••••. 

r ' 

ID NUMBER: 

EMISSION POINT #: 

DATE: 

NOTE: THIS INFORMATION FORM MUST BE COMPLETED FOR ANY TANK USED IN THE STORAGE OF AN ORGANIC LIQUID OR ANY 

MATERIALS CONTAINING HAZARDOUS AIR POLLUTANTS. FOR TANKS USED FOR PURPOSES OTHER THAN STORAGE. SUCH AS 

MIXING TANKS. DAY TANKS, PROCESS TANKS, ETC.. PLEASE COMPLETE FORM 220-CAAPP. 

SOURCE INFORMATION 

1) SOURCE NAME: 

Bulk Molding Compounds, Inc. 

2) DATE FORM 

PREPARED: March 7,1996 

3) SOURCE ID NO. 

(IF KNOWN): 089813AAK 

GENERAL INFORMATION 

4) TANK DESIGNATION: 

Polyester-based Resin Storage Tank 

5) FLOW DIAGRAM DESIGNATION OF TANK: 

Underground Storage Tank 1 

6) MANUFACTURER OF TANK (IF KNOWN): 

NA 

7) SERIAL NUMBER (IF KNOWN): 

NA 

8) DATES OF COMMENCING CONSTRUCTION, 

OPERATION AND/OR MOST RECENT MODIFICATION 

OF THIS TANK (ACTUAL OR PUNNED) 

9) DESCRIPTION OF MODIFICATION (IF APPLICABLE): 

NA 

10) DOES THE TANK HAVE MORE THAN ONE MODE OF OP 

(E.G., IS THERE MORE THAN ONE PRODUCT STORED I 

IF YES, EXPUIN AND IDENTIFY WHICH MODE IS COVE 

232-CAAPP MUST BE COMPLETED FOR EACH MODE): 

a) CONSTRUCTION (MONTH/YEAR): 

June, 1986 

b) OPERATION (MONTH/YEAR): 

July, 1986 

C) UTEST MODIFICATION (MONTH/YEAR): 

NA 

ERATION? D YES | NO 

>J THE TANK?)

 v—' • 

RED BY THIS APPLICATION (NOTE: A SEPARATE FORM 

THIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNDER ILLINOIS REVISED STATUTES. 1991. AS AMENDED 1992. 

CHAPTER111 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 

Printed on Recycled Paper 

232-CAAPP 

FOR APPLICANTS USE 

Page 1 of 10 

/ 2 -
P.M 

11) PROVIDE THE NAME AND DESIGNATION OF ALL AIR POLLUTION CONTROL EQUIPMENT CONTROLUNG THIS 

TANK, IF APPLICABLE (FORM 260-CAAPP AND THE APPROPRIATE 260-CAAPP ADDENDUM FORM 

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

NA 

12) PROVIDE ANY UMITATIONS ON SOURCE OPERATION AFFECTING EMISSIONS OR ANY WORK PRACTICE 

STANDARDS (E.G., PRODUCTION VARIATION, ETC.): 

None 

TANK INFORMATION 

13) TANK CAPACITY (SPECIFY BARRELS OR GALLONS): 

6,000 gallons 

14) TANK DIAMETER OR WIDTH (FT): 

8 

15) TANK HEIGHT (FT): 

NA 

16) TANK LENGTH (FT): 

16 

17) TANK SHAPE 

(CHECK ONE): 

D 

CYLINDRICAL 

OTHER; SPECIFY: 

O HORIZONTAL 

18) OUTSIDE COLOR OF 

TANK 

(CHECK ONE): L J WHITE 

S OTHER; SPECIFY: 

U SILVER 

Underground 

19) TANK CONDITION 

(CHECK ONE): GOOD o FAIR Q POOR 

20) TANK LOCATION 

(CHECK ONE): 

UNDERGROUND D ABOVEGROUND 

21) TANK TYPE 

(CHECK ONE): L J PRESSURE 

L J INTERNAL FLOATING ROOF 

V FIXED ROOF 

D EXTERNAL FLOATING 

ROOF 

L J VARIABLE VAPOR SPACE; 

SPECIFY VOLUME EXPANSION CAPACITY (bbl): 

D OTHER; SPECIFY: 

22) VENT VALVE INFORMATION: 

TYPE OF VENT 

COMBINATION 

PRESSURE 

VACUUM 

OPEN 

NUMBER 

OFVENTS 

7 

PRESSURE 

SETTING (PSIG) 

Ambient 

DISCHARGE VENTED TO (ATMOSPHERE. 

FLARE. VAPOR CONTROL. ETC.) 

Atmosphere 

THE INFORMATION IN ITEMS 23 AND 24 BELOW NEED ONLY BE PROVIDED IF READILY AVAIUBLE 

23a) UTITUDE: 

41:55:13.000 

b) LONGITUDE: 

88:20:02.0000 

24a) UTM ZONE: 

NA 

ti) UTM VERTICAL (KM): 

NA 

c) UTM HORIZONTAL (KM): 

NA 

APPLICATION PAGE 

Printed on Recycled Paper 

232-CAAPP Page 2 of 10 

i.3 
P.15 

MATERIAL STORED AND THROUGHPUT INFORMATION 

25) CHEMICAL NAME OF MATERIAL STORED: 

Polyester Resin 

26) CAS NO. (IF KNOWN): 

NA 

28) VAPOR PRESSURE AT 70 DEGREES 

FAHRENHEIT (PSIA): 

0.08 

27) DENSITY 

(LB/CU.FT.): 

(LB/GALLON): 9.16 

29) MOLECUUR WEIGHT 

(LB/LB-MOLE): 

164 

30) VAPOR PRESSURE AT MAXIMUM STORAGE TEMPERATURE (PSIA): 

0.12 

31) METHOD USED TO 

DETERMINE VAPOR 

PRESSURE PURSUANT 

TO 35 ILL. ADM. CODE 

215.108.218.109-111. 

OR 219.109-111: 

D ASTM D2879-86 D PUBLISHED LITERATURE. LIST: 

OTHER; SPECIFY: 

USEPA TANKS PROGRAM 2.0 

32) STORAGE TEMPERATURE 

MINIMUM (DEGREES 

FAHRENHEIT): 

)THROUGHPUT 

60 

GAL/DAY: 

8.90X70* 

BBLS/DAY: 

2.12 

MAXIMUM (DEGREES 

FAHRENHEIT): 105 

GAL/YR: 

3.25X10* 

BBLS/YR: 

7.74X10* 

34) MAXIMUM FILL RATE (GAUHR): 

7,000 

IT _35).IS A PERMANENT SUBMERGED LOADING PIPE USED? YES NO 

36) IS A VAPOR BAUNCE LINE USED? CD YES NO 

37) IS ANY OTHER VAPOR LOSS CONTROL DEVICE USED (OTHER THAN VAPOR 

BAUNCE)? 

IF YES, COMPLETE "AIR POLLUTION CONTROL EQUIPMENT - DATA AND 

INFORMATION," (FORM 260-CAAPP). AS PART OF THIS APPLICATION. 

CD YES NO 

38) ATTACH THE CALCUUTIONS. TO THE EXTENT THEY ARE AIR EMISSION REUTED. FROM WHICH THE 

PRECEDING INFORMATION. MATERIAL STORAGE INFORMATION AND THROUGHPUT DATA WERE 

BASED ANO UBEL AS EXHIBIT 232-1. 

APPLICATION PAGE 

Printed on Recycled Paper 

232-CAAPP Page 3 of 10 

IH 
P.16 

APPUCABLE RULES 

39) PROVIDE ANY SPECIFIC EMISSION STANDARD(S) AND LIMITATIONS(S) SET BY RULE(S) WHICH ARE APPLICABLE 

TO THIS TANK (E.G.. VOM, IAC 218.121(a). PRESSURE TANK): 

REGULATED AIR POLLUTANT(S) EMISSION STANDARD(S) REQUIREMENT(S) 

VOM 35 IAC 218.122(b) No hading ot mUtrltl unit* »qulpp*d 

wtth pvmmtnt submwg-K* loading pip* 

40) PROVIDE ANY SPECIFIC RECORDKEEPING RULE(S) WHICH ARE APPLICABLE TO THIS TANK: 

REGULATED AIR POLLUTANT(S) RECORDKEEPING RULE(S) REQUIREMENTS) 

VOM 

VOM 

35 IAC 201.301 

40 CFR 60.116b(a), (b) 

Maintain records for Annual 

Emissions Report 

Record dimensions and 

capacity of tank 

41) PROVIDE ANY SPECIFIC REPORTING RULE(S) WHICH ARE APPLICABLE TO THIS TANK: 

REGUUTEDAIRPOLLUTANT(S) REPORTING RULE(S) REQUIREMENTS) 

VOM 35 IAC 201.302 and 

35 IAC 254 

Annual Emissions Report 

42) PROVIDE ANY SPECIFIC MONITORING RULE(S) WHICH ARE APPLICABLE TO THIS TANK: 

REGUUTEDAIRPOLLUTANT(S) MONITORING RULE(S) REQUIREMENTS) 

NA 

43) PROVIDE ANY SPECIFIC TESTING RULES AND/OR PROCEDURES WHICH ARE APPLICABLE TO THIS TANK: 

REGULATED AIR POLLUTANT(S) TESTING RULE(S) REQUIREMENTS) • 

NA 

44) DOES THE TANK QUALIFY FOR AN EXEMPTION FROM AN OTHERWISE 

APPLICABLE RULE? 

Q YES NO 

IF YES, THEN LIST 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 UBEL AS EXHIBIT 232-2. OR REFER TO OTHER 

ATTACHMENTS) WHICH ADDRESS AND JUSTIFY THIS EXEMPTION 

COMPLIANCE INFORMATION 

45) IS THE TANK IN COMPLIANCE WITH ALL APPLICABLE REQUIREMENTS?: YES O

 N0 

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

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

46) EXPUNATION OF HOW INITIAL COMPLIANCE IS TO BE, OR WAS PREVIOUSLY, DEMONSTRATED: 

Material is loaded into the tank via permanent submerged loading pipe. Initial compliance 

was demonstrated by maintaining records of the quantity of material stored in the tank. 

APPLICATION PAGE 

Printed on Recycled Paper 

232-CAAPP Page 4 of 10 

\6 
P.17 

47) EXPUNATION OF HOW ONGOING COMPLIANCE WILL BE DEMONSTRATED: 

Material is loaded into the tank via permanent submerged loading pipe. Records of monthly 

material throughput quantities will be maintained. Emissions of regulated pollutants will be 

calculated using the USEPA TANKS PROGRAM 2.0. 

TESTING, MONITORING, RECORDKEEPING AND REPORTING 

48a) LIST THE PARAMETERS THAT REUTE TO AIR EMISSIONS FOR WHICH RECORDS ARE BEING 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 UNIT OF MEASUREMENT METHOO OF MEASUREMENT FREQUENCY 

Quantity ol material 

throughput 

gallons Inventory and purchase monthly 

b) BRIEFLY DESCRIBE THE METHOD BY 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 

METHOD OF 

RECORDKEEPING 

TITLE OF 

PERSON RESPONSIBLE 

TITLE OF 

CONTACT PERSON 

Quantity of material 

throughput log VIC* Pruldtn. Manufacturing 

andEngln—rtng 

Wc* Pnaidant manufacturing 

and Englnaaring 

c) IS COMPLIANCE OF THE EMISSION UNIT READILY DEMONSTRATED BY REVIEW OF 

THE RECORDS? 

IF NO. EXPUIN: 

YES Q NO 

d) ARE ALL RECORDS READILY AVAIUBLE FOR INSPECTION. COPYING AND/OR 

SUBMITTAL TO THE AGENCY UPON REQUEST? 

IF NO, EXPUIN: 

YES Q NO 

49a) DESCRIBE ANY EMISSION MONITORS USED TO DETERMINE FEES. RULE APPLICABIUTY OR COMPLIANCE: 

None 

b) WHAT PARAMETER(S) IS(ARE) BEING MONITORED (E.G.. TEMPERATURE)? 

None 

APPLICATION PAGE 

Printed on Recycled Paper 

232-CAAPP Page 5 of 10 

Ik 
P.18 

49c) DESCRIBE THE LOCATION OF EACH MONITOR: 

NA 

d) IS EACH.MONITOR EQUIPPED WITH A RECORDING DEVICE? 

NA 

IF NO, LIST ALL MONITORS WITHOUT A RECORDING DEVICE: 

TJ YES u NO 

e) IS EACH MONITOR REVIEWED FOR ACCURACY ON AT LEAST A QUARTERLY 

BASIS? 

NA 

IF NO, EXPUIN: 

n YES u NO 

u u f) IS EACH MONITOR OPERATED AT ALL TIMES THE ASSOCIATED TANK IS IN 

OPERATION? 

NA 

IF NO, EXPUIN: 

YES NO 

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

PURPOSES OF THE DETERMINATION OF FEES. RULE APPLICABIUTY 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 UBEL AS EXHIBIT 232-3: 

TEST DATE TEST METHOD TESTING COMPANY 

OPERATING 

CONDITIONS SUMMARY OF RESULTS 

NA 

51) DESCRIBE ALL REPORTING REQUIREMENTS AND PROVIDE THE TITLE AND FREQUENCY OF REPORT 

SUBMITTALS TO THE AGENCY: 

REPORTING REQUIREMENTS tntE OF REPORT FREQUENCY 

Emissions of all regulated 

pollutants 

Compliance of source and 

emission units 

Annual Emissions Report 

Compliance Certification, 

CAAPP Form 296 

annually 

annually 

APPLICATION PAGE 

Printed on Recycled Paper 

232-CAAPP Page 6 of 10 

n 
•oO 

(52)EMISSION INFORMATION 

REGULATED AIR 

POLLUTANT 

CARBON 

MONOXIDE (CO) 

LEAD 

NITROGEN 

OXIDES (NOx) 

PARTICULATE 

MATTER (PART) 

PARTICULATE 

MATTER <= 10 

MICROMETERS 

(PM10) 

SULFUR' 

DIOXIDE (S02) 

VOLATILE 

ORGANIC 

MATERIAL (VOM) 

OTHER, 

SPECIFY: 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL 

MAXIMUM: 

TYPICAL 

MAXIMUM: 

TYPICAL 

MAXIMUM: 

TYPICALMAXIMUM: 

TYPICAL 

0

1

 ACTUAL EMISSION RATE 

O 'UNCONTROLLED EMISSION RATE 

LBS PER 

HOUR 

(LBS/HR) 

TONS PER 

YEAR E 

(TONS/YR) 

• 

j 

f 

<0.1 

<0.1 

'OTHER 

TERMS 

'OTHER 

TERMS 

4DM 

485 

485 

ALLOWABLE BY RULE EMISSION RATE 

5RATE (UNITS) 

NA( ) 

APPLICABLE 

RULES 

NA 

TONS PER 

YEAR 

(TONS/YR) 

PERMITTED EMISSION RATE 

RATE (UNITS) 

TONS PER 

YEAR 

(TONS/YR) 

•^BHH^^HB 

^^^^^^^^^^ i 

HI^HHHHri 

| | ~ 

HHHH^HIH ^^^^^^^^^^H 

JHHHHHml 

^^^^^^^^^ l 

HHI^HHIH 

^^^^^^^^^^ i P"""4"^4 I <0.01 (tons/month) I 0.1 I 

|HlilHillllHri [^^^^ 1 1 

ll^HI^HHHH 

EXAMPLE: 

PARTICULATE 

MATTER 

MAXIMUM: 

TYPICAL 

5.00 

4.00 

21.9 

14.4 ' 

0.3 

GR/DSCF 

0.24 

GR/DSCF 

1 

4 

6.0 (LBS/HR) 

5.5 (LBSMR) 

212.321 

212.321 

26.28 

19.80 

IMPORTANT: ATTACH CALCULATIONS, TO THE EXTENT THEY ARE AIR EMISSIONS REUTED, ON WHICH EMISSIONS WERE DETERMINED AND LABEL AS EXHIBIT 232-4. 

1

 CHECK UNCONTROLLED EMISSION RATE BOX IF CONTROLEQUIPMENT IS USED. OTHERWISE CHECK AND PROVIDE THE ACTUAL EMISSION RATE TO ATMOSPHERE. INCLUDING INDOORS. SEE INSTRUCTIONS. 

2PROVlDE THE EMISSION RATE THAT WILL BE USED AS A PERMIT SPECIAL CONDITION. THIS LIMIT WILL BE USED TO DETERMINE THE PERMIT FEE. 

'PLEASE PROVIDE ANY OTHER EMISSION RATE WHICH IS COMMONLY USED. REQUIRED BY A SPECIFIC LIMITATION OR THAT WAS MEASURED (E.G. PPM. GR/DSCF. ETC.) 

4DM - DETERMINATION METHOD: 1) STACK TEST. 2) MATERIAL BALANCE, 3) STANDARD EMISSION FACTOR (AP-42 OR AIRS). 4) ENGINEERING ESTIMATE. S) SPECIAL EMISSION FACTOR (NOT AP-42 OR AIRS) 

SRATE - ALLOWABLE EMISSION RATE SPECIFIED BY MOST STRINGENT APPLICABLE RULE. 

APPLICATION PAGE 

Printed on Recycled Paper 

232-CAAPP . page 7 oM 0 

CO 
(53) HAZARDOUS AIR POLLUTANT EMISSION INFORM A TION 

HAP INFORMATION 

NAME OF HAP 

EMITTED 

Styrene 

^CAS 

NUMBER 

100-42-5 

-Wt1 ACTUAL EMISSION RATE 

0

1

 UNCONTROLLED EMISSION RATE 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL: | 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL 

MAXIMUM: 

TYPICAL 

MAXIMUM: 

TYPICAL 

MAXIMUM: 

TYPICAL 

POUNDS PER 

HOUR 

(LBS/HR) 

TONS PER 

YEAR 

(TONS/YR) 

<0.1 

3OTHER 

TERMS 

NA 

4DM 

485 

ALLOWABLE BY RULE 

5RATE OR STANDARD 

NA 

APPLICABLE 

RULE 

NA 

EXAMPLE: 

Benzene 71432 

MAXIMUM: 

TYPICAL 

10.0 

8.0 

1.2 

0.8 

2 

2 

98% by wt control device 

Jr^jee^^Jlrucks 

CFR61 

61.302(b),(d) 

IMPORTANT: ATTACH CALCUUTIONS, TO THE EXTENT THEY ARE AIR EMISSIONS REUTED, ON WHICH EMISSIONS WERE DETERMINED AND UBE L AS EXHIBIT 232-5. 

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

2CAS - CHEMICAL ABSTRACT SERVICE NUMBER. 

'PLEASE PROVIDE ANY OTHER EMISSION RATE WHICH IS COMMONLY USED, REQUIRED BY A SPECIFIC LIMITATION OR THAT WAS MEASURED (EG.. PPM. GR/DSCF. ETC.). 

4

0M - DETERMINATION METHOD: 1) STACK TEST. 2) MATERIAL BALANCE. 3) STANDARD EMISSION FACTOR (AP-42 OR AIRS, 4) ENGINEERING ESTIMATE. S) SPECIAL EMISSION FACTOR (NOT AP-42 OR AIRS). 

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

_£> 

APPLICATION PAGE 

Printed on Recycled Paper 

232-CAAPP page 8 of 10 

ho 
P.21 

FLOATING ROOF TANK EQUIPMENT INFORMATION (IF APPUCABLE) - NA 

54) FLOATING ROOF 

TYPE (CHECK ONE): C") _ 

L J INTERNAL 

L J OTHER; SPECIFY: 

a EXTERNAL 

55) PRIMARY SEAL TYPE 

(CHECK ONE): (~~\ 

' L J METALLIC SHOE 

SEAL 

L J OTHER; SPECIFY: 

L j LIQUID MOUNTED 

RESILIENT SEAL 

L J VAPOR MOUNTED 

RESILIENT SEAL 

56) IS THE FLOATING ROOF EQUIPPED WITH A SECONDARY SEAL? 

IF YES, HOW IS THE p i f l 

SECONDARY SEAL *—J SH0 E U J RI M 

MOUNTED? (CHECK f l 

ONE): *—' OTHER; SPECIFY: 

U YES TJ NO 

u 57) IS THE FLOATING ROOF EQUIPPED WITH A WEATHER SHIELD? o YES NO 

58) WHAT IS THE AVERAGE WIND SPEED AT THE TANK SITE (MILES/HR)? 

59) WHAT IS THE 

CONDITION OF THE 

TANK SHELL 

INTERIOR? (CHECK 

ONE): 

D LIGHT RUST 

D OTHER; EXPUIN: 

o DENSE RUST o GUNITE LINED 

60) FOR COLUMN SUPPORTED TANKS. COMPLETE THE FOLLOWING: 

NUMBER OF 

COLUMNS 

DIAMETER OF EACH COLUMN 

JFT) 

61) FOR INTERNAL FLOATING ROOF TANKS. COMPLETE THE FOLLOWING: 

a BOLTING U WELDING 

DECK?

 L

-

J

 OTHER; SPECIFY: 

a) WHAT IS THE 

METHOD OF 

BONDING FOR THE f~) 

b) WHAT IS THE TOTAL LENGTH OF ALL DECK SEAMS (FT)? 

c) WHAT IS THE DIAMETER OF THE DECK (FT)? 

APPLICATION PAGE 

Printed on Recycled Paper 

232-CAAPP Page 9 of 10 

-2.0 
P.22 

62) FOR INTERNAL FLOATING ROOF TANKS. INDICATE THE NUMBER OF EACH TYPE OF FITTING: NA 

ACCESS HATCH 

BOLT COVER, 

GASKETED: 

BOLTED COVER, 

GASKETED: 

BUILT-UP COLUMN-SLIDING 

COVER. GASKETED: 

UNBOLTED COVER. 

GASKETED: 

AUTOMATIC GAUGE FLOAT WELL 

UNBOLTED COVER. 

GASKETED: 

COLUMN WELL 

BUILT-UP COLUMN-SLIDING 

COVER. UNGASKETED: 

PIPE COLUMN-SLIDING 

COVER. GASKETED: 

UNBOLTED COVER, 

UNGASKETED: 

UNBOLTED COVER, : 

UNGASKETED: 

PIPE COLUMN-FLEXIBLE 

FA8RIC SLEEVE SEAL 

PIPE COLUMN-SLIDING 

COVER. UNGASKETED: 

LADDER WELL 

SLIDING COVER. 

GASKETED: 

SLOTTED PIPE-SLIDING 

COVER, GASKETED: 

SAMPLE F »IPE 

SUDING COVER, 

UNGASKETED: 

ORWELL 

SLOTTED PIPE-SLIDING 

COVER. UNGASKETED: 

ROOF LEG 0 

ADJUSTABLE: 

VACUUf 

WEIGHTED MECHANICAL 

ACTUATION, GASKETED: 

STU 

RH> 

IA BI 

BD 

\NGERWELL 

SAMPLE WELL-SLIT FABRIC 

SEAL (10% OPEN AREA): 

FIXED: 

WEAKER 

WEIGHTED MECHANICAL 

ACTUATION, UNGASKETED: 

RAIN 

1 INCH DIAMETER: 

OTHER (EXPUIN) 

a) 

b) 

c) 

APPLICATION P 

Printed on Rec 

232-CA 

AGE 

ycled Paper 

APP Page 10 of 10 

1\ 
P.23 

EXHIBIT 232-1 

POLYESTER -BASED RESIN STORAGE TANK 

THROUGHPUT CALCULATIONS 

The throughput for Tank-1 was converted to gallons per day by dividing the aggregate throughput in 

gallons per year by 365 days: 

• ( 325 x 104 gallons *)( \yr \ _ 8.90 x 101 gallons 

y 365 days. day 

Gallons per year were converted to barrels per year: 

325x10* gallons 

y 

1 barrel } 7.74 x IO2 barrels 

42 gallons y 

The throughput was converted to barrels per day by dividing the throughput in barrels per year by 365 

days: 

7.74xlO2 barrels] 

y 

( \yr "| 2.12 barrels 

\365 days) day 

Based on facility inventory infonnation. 

5034-CA\232-1ex.doc A I R SOLUTIONS, INC. 

Z'H-
EMISSIONS REPORT - DETAIL FORMAT 

TANK IDENTIFICATION AND PHYSICAL CHARACTERISTICS 

PAGE 1 

Identification 

Identification No.: 

City: 

State: 

Company: 

Type of Tank: 

Tank-1 

St. Charles 

IL 

BMC 

Horizontal Fixed Roof 

Tank Dimensions- - -

Shell Length (ft): 

Diameter (ft): 

Volume(gallons): 

Is tank underground? (Y/N): 

Turnovers: 

Net Throughput (gal/yr): 

Paint Characteristics 

Shell Color/Shade: 

Shell Condition: 

Breather Vent Settings 

Vacuum Setting (psig): 

Pressure Setting (psig): 

16 

8 

6000 

Y 

S 

32400 

White/White 

Good 

0.00 

0.00 

Meteorological Data Used in Emission Calculations: Chicago, Illinois 

EXHIBITS 232-4 AND 232-5 

PAGE 1 of 4 

POLYESTER-BASED RESIN STORAGE TANK 

EMISSION CALCULATION SUMMARY 

5034-ca\232exh45.doc A I R SOLUTIONS, INC. 
EMISSIONS REPORT - DETAIL FORMAT 

LIQUID CONTENTS OF STORAGE TANK 

PAGE 2 

Mixture/Component 

Liquid 

Daily Liquid Surf. Bulk 

Temperatures (deg P) Temp. 

Vapor Liquid Vapor 

Vapor Pressures (psia) Mol. Mass Mass Mol. Basis for Vapor Pressure 

Month Avg. Min. Max. (deg F) Avg. Min. Max. Weight Fract. Fract. Weight Calculations 

Raw Resin Material 

Polyester Based Resin 

Styrene (Hot) 

All SO.84 45.97 55.71 49.22 0.5710 

0.9342 

0.1065 

0.5334 

0.8751 

0.0963 

0.6257 

1.0236 

0.1167 

182.975 

0.7000 0.9534 190.00 Option 1 

0.3000 0.0466 104.15 Option 1 

EXHIBITS 232-4 AND 232-5 

PAGE 2 of 4 

POLYESTER-BASED RESIN STORAGE TANK 

EMISSION CALCULATION SUMMARY 

^ 

^ S034-ca\232exh45.doc A I R SOLUTIONS, INC. 
EMISSIONS REPORT - DETAIL FORMAT 

DETAIL CALCULATIONS (AP-42) 

PAGE 3 

Annual Emission Calculations 

No Standing Losses: Underground Tank 

Withdrawal Losses (lb): 

Vapor Molecular Weight (lb/lb-mole): 

Vapor Pressure at Daily Average Liquid 

Surface Temperature (psia): 

Annual Net Throughput (gal/yr): 

Turnover Factor: 

Tank Diameter (ft) : 

Working Loss Product Factor: 

Total Losses (lb): 

80.5988 

182.974847 

0.571007 

32400 

1.0000 

8 

1. 

80 

00 

60 

EXHIBITS 232-4 AND 232-5 

PAGE 3 of 4 

N 

POLYESTER-BASED RESIN STORAGE TANK 

EMISSION CALCULATION SUMMARY 

5034-ca\232exh45.doc A I R SOLUTIONS, INC. 

TJ 
EMISSIONS REPORT - DETAIL FORMAT 

INDIVIDUAL TANK EMISSION TOTALS PAGE 4 

Annual Emissions Report 

Liquid Contents 

Losses (lbs.): 

Standing Withdrawal Total 

Raw Resin Material 

Polyester Based Resin 

Styrene (Hot) 

Total: 

0.00 

0.00 

0.00 

0.00 

80.60 

76.84 

3.75 

80.60 

80.60 

76.84 

3.75 

80.60 

EXHIBITS 232-4 AND 232-5 

PAGE 4 of 4 

5034-ca\232exh45.doc 

POLYESTER-BASED RESIN STORAGE TANK 

EMISSION CALCULATION SUMMARY 

A I R SOLUTIONS, INC. 

to 
P.28 

ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD, ILLINOIS 62794-9506 

r\Jt\ wrruuM n i a XJ a c 

Revision #: 

Date: 

Page 

/ 

of 

Source Designation: 

t 

HAZARDOUS AIR POLLUTANT (HAP) 

EMISSION SUMMARY 

ID NUMBER: 

PERMIT* 

DATE: 

fQKAQeNCYUSEONLXr:,* x :•> 

SOURCE INFORM A TION 

1) SOURCE NAME: 

Bulk Molding Compounds, Inc. 

2) DATE FORM 

PREPARED: March 7,1996 

3) SOURCE ID NO. 

(IF KNOWN): 089813AAK 

HAZARDOUS AIR POLLUTANT EMISSIONS 

4) DOES ANY EMISSION UNIT AT THE SOURCE EMIT A HAZARDOUS AIR POLLUTANT? 

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

5a) DOES THE SOURCE HAVE THE POTENTIAL TO EMIT, IN THE AGGREGATE,: 

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

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

POLLUTANTS; 

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

SOURCE AS MAJOR FOR HAZARDOUS AIR POLLUTANTS; NA 

iv) EMISSIONS OF HAZARDOUS AIR POLLUTANTS WHICH EQUAL OR EXCEED A 

POLLUTANT SPECIFIC CAAPP APPLICABILITY LEVEL AS ESTABLISHED 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 

APPLICABILITY THRESHOLDS SPECIFIED IN ITEMS (i), (ii) &(iii) ABOVE, BUT STILL 

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 

oUUKUt IS CONolUcKcD MAJOR OK KbUUlKtU TO Os IAIN A UWr p rcKMI 1: 

Styrene 

m 

m 

o 

D 

o 

YES 

YES 

YES 

YES 

YES 

o 

o 

• 

D 

m 

NO 

NO 

NO 

NO 

NO 

HAZARDOUS AIR POLLUTANT EMISSIONS TABLE 

6) COMPLETE THE FOLLOWING TABLE FOR AJJ. HAPs WHICH ARE REGULATED AIR 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. 

THIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNDER ILLINOIS REVISED STATUTES. 1991. AS AMENDED 1992. 

CHAPTER111 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 

Printed on Recycled Paper 

215-CAAPP 

FOR APPLICANTS USE 

Page 1 of 2 

-zn 
\9j nH£.Mn-jmjsmii> Mir. rKJimm-uii-\i* i cmiooiun o 

COMPLETE THE FOLLOWING TABLE FOR AiL HAPS WHICH ARE REGULATED AIR 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. 

NAME OF HAP 

EMITTED: 

Styrene 

Styrene 

Styrene 

Styrene 

1

 CAS - CHEMICAL ABSTRA 

2PROVIDE OTHER TERMS 

1

 CAS NUMBER 

100-42-5 

100-42-5 

100-42-5 

100-42-5 

CT SERVICE 

AS NECESSARY TOES 

E EMISSION UNIT 

E DESIGNATION. 

Mixing Lines and 

Resin Rooms 

Polyester-based 

Resin Storage Tank 

Molding Operations 

Portable Styrene/ 

Resin Tanks 

TABUSH APPLICABIUTY OR 

MAXIMUM 

EMISSIONS 

(TONS/YR) 

24.5 

0.10 

<0.10 

<0.10 

COMPLIANCE WIT 

TYPICAL 

EMISSIONS 

(TONS//YR) 

14.6 

<0.10 

<0.10 

<0.10 

H REQUIREMEI 

POTENTIAL 

EMISSIONS 

(TONS/YR) 

24.5 

0.10 

<0.10 

<0.10 

'JTS. 

OTHER 

TERMS2 

NA 

NA 

NA 

NA 

APPLICABLE 

RULE 

NA 

NA 

NA 

NA 

APPLICABILITY 

LEVEL (UNITS) 

NA 

NA 

NA 

NA 

APPLICATION PAGE 

Printed on Recycled Paper 

215-CAAPP page 2 of 2 

ro 

co 
P.30 

ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD, ILLINOIS 62794-9506 

FOR APPLICANTS USE 

Revision #: 

Date: 

Page 

/ / 

of 

Source Designation: 

COMPLIANCE PLAN/ 

SCHEDULE OF COMPLIANCE 

FOR CAAPP PERMIT 

MMMMMB&Mm 

ID NUMBER: 

PERMIT* 

DATE: 

H^^PM^ u'

s

^

l

^^v ^ -*U;*' 

THE CLEAN AIR ACT PERMIT PROGRAM (CAAPP) REQUIRES THAT THE APPLICANT SUBMIT A COMPLIANCE PLAN/SCHEDULE OF 

COMPLIANCE FOR ALL EMISSION UNITS AT THE CAAPP SOURCE, REGARDLESS OF THE COMPLIANCE STATUS OF EACH INDIVIDUAL 

EMISSION UNIT. THIS FORM REQUIRES THAT THE COMPLIANCE STATUS BE STATED FOR EACH EMISSION UNIT. APPLICATION FORM 

294-CAAPP, "COMPLIANCE PLAN/SCHEDULE OF COMPLIANCE - ADDENDUM FOR NON COMPLYING EMISSION UNITS." MUST BE 

SUBMITTED FOR EACH EMISSION UNIT NOT IN COMPLIANCE WITH ALL APPLICABLE REQUIREMENTS AT THE TIME OF SUBMITTAL 

SOURCE INFORM A TION 

1) SOURCE NAME: 

Bulk Molding Compounds, Inc. 

2) DATE FORM 

PREPARED: March 7, 1996 

3) SOURCE ID NO. 

(IF KNOWN): 089813A AK 

SOURCE COMPLIANCE INFORMATION 

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

IS IN COMPLIANCE WITH ALL APPLICABLE REQUIREMENTS"): 

The source is in compliance with all applicable requirements. 

5) IF IN COMPLIANCE. WILL THE SOURCE CONTINUE TO COMPLY WITH ALL APPLICABLE REQUIREMENTS? 

0 YES CD NO 

IF NO. EXPLAIN: 

6) WILL THE SOURCE MEET, ON A TIMELY BASIS, APPLICABLE REQUIREMENTS WHICH BECOME EFFECTIVE 

DURING THE PERMIT TERM? 

NA D YES D NO 

IF NO, EXPLAIN 

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

CHAPTER 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 

Printed on Recycled Paper 

293-CAAPP 

FOR APPLICANTS USE 

Page 1 of 4 

<z<? 
P.31 

EMISSION UNITS COMPUANCE INFORMATION 

7) EMISSION UNITS IN COMPLIANCE 

THE FOLLOWING EMISSION UNITS ARE IN COMPLIANCE WITH ALL APPLICABLE 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 

Mixing Unes and Resin 

Rooms 

Baghouse 

Polyester-Based Resin 

Storage Tank 

EMISSION UNIT 

Unes 1,2, 4-7, 9 A 10; Resin Rooms 

Baghouse 

Underground Storage Tank 1 

APPLICATION PAGE 

Printed on Recycled Paper 

293-CAAPP Page 2 of 4 

30 
P.32 

EMISSION UNITS COMPUANCE INFORMATION (cntd) 

DESIGNATION ID NUMBER EMISSION UNIT 

81 EMISSION UNITS SUBJECT TO FUTURE COMPLIANCE DATES 

THE FOLLOWING EMISSION UNITS, WHICH ARE CURRENTLY IN COMPLIANCE WITH ALL APPLICABLE 

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

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

AND LABEL AS EXHIBIT 293-2: 

FUTURE 

COMPLIANCE DATE 

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

NA 

APPLICATION PAGE 

Printed on Recycled Paper 

293-CAAPP Page 3 of 4 

31 
P.33 

9a) FMISSION UNITS NOT IN COMPLIANCE - COMPLIANCE TO BE ACHIEVED PRIOR TO PERMIT ISSUANCE 

THE FOLLOWING EMISSION UNITS ARE NOT IN COMPLIANCE WITH ALL APPLICABLE REQUIREMENTS AT THE 

TIME OF PERMIT APPLICATION. HOWEVER, THESE EMISSION UNITS WILL ACHIEVE COMPLIANCE WITH ALL 

APPLICABLE 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 DATE 

DESIGNATION ID NUMBER •_ EMISSION UNIT (MONTH/OAY/YEAR) 

NA 

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

FOR EACH OF THE EMISSION UNITS LISTED IN 9a) ABOVE. IF ADDITIONAL SPACE IS NEEDED, ATTACH AND 

LABEL AS EXHIBIT 293-4: 

NA 

,Q. EMISSION UNITS NOT IN COMPLIANCE - COMPLIANCE WILL NOT BE ACHIEVED PRIOR TO PERMIT ISSUANCE 

THE FOLLOWING EMISSION UNITS WILL NOT BE IN COMPLIANCE WITH ALL APPLICABLE 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 ALL APPLICABLE REQUIREMENTS AT THE TIME OF PERMIT ISSUANCE. A FORM 294-CAAPP 

IS SUBMITTED FOR THE FOLLOWING EMISSION UNITS. IF ADDITIONAL SPACE IS NEEDED, ATTACH AND LABEL 

~ "•AS" EXHIBIT 293-5: 

DESIGNATION ID NUMBER EMISSION UNIT 

NA 

DATE COMPLIANCE 

SCHEDULED TO BE 

ACHIEVED 

(MONTH/DAY/YEAR) 

APPLICATION PAGE _ 

Printed on Recycled Paper 

293-CAAPP Page 4 of 4 

31 
P.34 

ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD, ILLINOIS 62794-9506 

FOR APPLICANTS USE 

Revision*: 

Date: _ 

Page 

/ / 

of 

Source Designation: 

COMPLIANCE CERTIFICATION 

FOR AGENCY USE ONLY 

ID NUMBER: 

PERMIT* 

DATE: 

AN APPLICATION FOR A CAAPP PERMIT MUST CONTAIN A CERTIFICATION OF COMPLIANCE SIGNED BY A RESPONSIBLE OFFICIAL THIS 

FORM MUST BE SUBMITTED WITH THE ORIGINAL CAAPP PERMIT APPUCATION AND UPDATED ON AN ANNUAL BASIS. 

1) SOURCE NAME: 

Bulk Molding Compounds, Inc. 

2) DATE FORM 

PREPARED: March 7,1996 

4) CAAPP PERMIT NUMBER (IF KNOWN): 

SOURCE INFORMATION" -

5) IS THIS THE FIRST SUBMITTAL OF THIS FORM? 

IF NO, WHAT IS THE REPORTING PERIOD 

COVERED BY THIS FORM? 

MAR 111996 

3) SOURCE ID NO. 

MJfSP1^^--^' m^xtesbisAAK 

B YES 

/ / TO: / 

U

 NO 

/ 

SOURCE COMPUANCE INFORMATION 

6) DOES THE SIGNATORY OF THIS FORM HEREBY CERTIFY THAT THE SOURCE IS IN COMPLIANCE WITH ALL 

APPLICABLE REQUIREMENTS? 

0 YES O NO 

IF NO, EXPLAIN: 

7) PROVIDE THE SCHEDULE FOR SUBMISSION OF COMPLIANCE CERTIFICATION DURING THE PERMIT TERM, E.G., 

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

THAN ANNUALLY): 

Once annually in July 

8) INDICATE THE COMPLIANCE STATUS OF THE SOURCE WITH ANY APPLICABLE ENHANCED MONITORING AND 

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

REQUIRED AND IN COMPLIANCE WITH COMPLIANCE CERTIFICATION REQUIREMENTS: 

At the date of this application, Bulk Molding Compounds, Inc. does not require enhanced 

monitoring and is in compliance with compliance certification requirements. 

THIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNDER ILLINOIS REVISED STATUTES. 1991. AS AMENDED 1992. 

CHAPTER 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 

Printed on Recycled Paper 

296-CAAPP 

FOR APPLICANTS USE 

Page 1 of 5 

33 
P.35 

EMISSION UNITS COMPLIANCE INFORMATION 

9a) THE FOLLOWING EMISSION UNITS ARE IN COMPLIANCE WITH APPLICABLE REQUIREMENTS SUCH AS EMISSION 

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

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

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

EMISSION UNIT APPLICABLE RULE COMPLIANCE DETERMINATION 

METHOD 

Mixing Lines and Resin 

Rooms 

Baghouse 

Polyester-based Resin 

Storage Tank 

Molding Operations 

Portable Styrene/Resin 

Tanks 

Space Heaters 

35 IAC 218.301; 

35 IAC 212.321; 

35 IAC 212.123 

35 IAC 218.301; 

35 IAC 212.321; 

35 IAC 212.123 

35 IAC 218.122(b) 

NA 

NA 

NA 

Records of bulk molding 

compound production are 

maintained 

Records of bulk molding 

compound production are 

maintained 

Malarial la loadad Into amisaion unit via 

parmanant aubmargad hading pip*. 

Record* ot monthly notarial throughput 

quantity an maintained. 

Insignificant Activity 

Insignificant Activity 

Insignificant Activity 

APPLICATION PAGE 

Printed on Recycled Paper 

296-CAAPP Page 2 of 5 

~y 
P.36 

9b) LIST THE EMISSION UNITS THAT WERE NOT IN CONTINUOUS COMPLIANCE SINCE THE LAST REPORTING 

PERIOD, AND THE REASON(S) FOR NONCOMPLIANCE (IF ADDITIONAL SPACE IS NEEDED, ATTACH AND LABEL 

AS EXHIBIT 296-2.): 

EMISSION UNIT 

NA 

» 

* 

REASON(S) FOR NONCOMPLIANCE 

COMPUANCE INFORM A TION 

10) 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.): 

NA 

APPLICATION PAGE 

Printed on Recycled Paper 

296-CAAPP Page 3 of 5 

35 
P.37 

10b) DESCRIPTION OF MONITORING PROCEDURES USED TO DEMONSTRATE COMPLIANCE, INCLUDING ANY 

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

AS EXHIBIT 296-4.): 

NA 

c) DESCRIPTION OF RECORDKEEPING USED TO DEMONSTRATE COMPLIANCE (IF ADDITIONAL SPACE IS NEEDED, 

ATTACH AND LABEL AS EXHIBIT 296-5.): 

Mixing Lines. Resin Rooms and Baahouse: 

- Record bulk molding compound production monthly on department record. 

Polyester-based Resin Storage Tank: 

- Record quantity of material throughput monthly on log. 

APPLICATION PAGE 

Printed on Recycled Paper 

296-CAAPP Page 4 of 5 

34 
P.38 

S.3-5 

10d) DESCRIPTION OF REPORTING USED TO DEMONSTRATE COMPLIANCE (IF ADDITIONAL SPACE IS NEEDED, 

ATTACH AND LABEL AS EXHIBIT 296-6.): 

Annual report of emissions of all regulated pollutants from all emission units at the source 

and annual Compliance Certification (296-CAAPP). 

SIGNATURE BLOCK 

NOTE: THIS CERTIFICATION MUST BE SIGNED BY A RESPONSIBLE OFFICIAL APPLICATIONS WITHOUT A SIGNED CERTIFICATION 

WILL BE RETURNED AS INCOMPLETE. . 

11) I CERTIFY UNDER PENALTY OF LAW THAT, BASED ON INFORMATION AND BELIEF FORMED AFTER REASONABLE 

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

COMPLETE. 

AUTHORIZED 

BY: President 

AUTHORIZED SIGNATURE 

Larry E. Nunnery >K 

TITLE OF SIGNATORY 

96 

TYPED OR PRINTED NAME OF SIGNATORY DATE 

APPLICATION PAGE 

Printed on Recycled Paper 

296-CAAPP Page 5 of 5 37 
ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD. ILLINOIS 62794-9506 

FOR APPLICANTS USE 

Revision #: 

Date: 

Page 

/ / 

of 

Source Designation: 

FEE DETERMINATION FOR 

CAAPP PERMIT 

ID NUMBER: 

PERMIT*: 

DATE: 

FWAGEmYUSeOHLY 

. * - ^ -Tvo 

THE DATA PROVIDED ON THIS FORM WIU BE USED TO DETERMINE THE PERMIT FEE. THE EMISSION LEVELS STATED ON THIS FORM 

CAN ONLY BE USED FOR THE PURPOSE OF PERMIT FEE DETERMINATION IF THE APPUCMTOW-^JJ^TOifCEPT THESE LEVELS AS 

PERMIT SPECIAL CONDITIONS. EMISSIONS DATA PROVIDED ON THIS FORM MUST BE IDEWrtCAL TOTATAlljffHBT'ERMnTED EMISSION 

RATE" COLUMNS PROVIDED ON THE DATA AND INFORMATION FORM FOR INDIVIDUAL EMISSION UNITS OR CONTROL EQUIPMENT. IF 

ADDITIONAL SPACE IS NEEDED. ATTACH AND LABEL AS 292-1. 

MAP 1 1 -nr*? 

SOURCE INFORMATION wv v 

1) SOURCE NAME: -'^i i - Wjr O . SPWf l > 

Bulk Molding Compounds, Inc. or*!,!? 

2) DATE FORM 

PREPARED: March 7,1996 

3) SOURCE ID NO. 

(IF KNOWN): 089813AAK 

FEE DATA 

4) WILL THE SOURCE PAY THE MAXIMUM FEE OF $100,000.00 PER YEAR? f~) w _ „ M „,„ 

• 1 YES • NO 

IF YES. THE REMAINDER OF THIS FORM DOES NOT NEED TO BE COMPLETED. 

5) 

EMISSION UNIT* 

Mixing Unes and Resin 

Rooms 

Baghouse 

Polyester-Based 

Resin Storage Tank 

NITROGEN 

OXIDES 

(NOy) 

(TONS/YR) 

PARTICULATE 

MATTER 

(PART) 

(TONS/YR) 

1.0 

SULFUR 

DIOXIDE 

(S02) 

(TONS/YR) 

VOLATILE 

ORGANIC 

MATERIAL (VOM) 

(TONS/YR) 

24.5 

0.1 

OTHER** 

SPECIFY 

(TONS/YR) 

"EMISSION UNIT - PROVIDE THE NAME AND FLOW DIAGRAM DESIGNATION OF THE EMISSION UNIT AS IT APPEARS ON THE DATA AND 

INFORMATION FORM. 

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

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

CHAPTER 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 

Printed on Recycled Paper 

292-CAAPP 

FOR APPLICANTS USE 

Page 1 of 2 3K 
P.40 

5) (CONTINUED) 

EMISSION UNIT* 

* 

NITROGEN 

OXIDES 

(NOx) 

(TONS/YR) 

PARTICULATE 

MATTER 

(PART) 

(TONS/YR) 

SULFUR 

DIOXIDE 

(S02) 

(TONS/YR) 

VOLATILE 

ORGANIC 

MATERIAL (VOM) 

(TONS/YR) 

OTHER'* 

SPECIFY 

(TONS/YR) 

"EMISSION UNIT - PROVIDE THE NAME AND FLOW DIAGRAM DESIGNATION OF THE EMISSION UNIT AS IT APPEARS ON THE DATA AND 

INFORMATION FORM. 

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

6 )

 SUBTOTAL 1.0 24.6 

FUGITIVE 0.09 

8) 

TOTAL 

8 

1.09 24.6 

9) GRAND TOTAL - ADD BOXES A THROUGH E (TONS/YR): 

25.7 

10) CALCULATED PERMIT FEE - IF GRAND TOTAL IN ITEM 9 ABOVE IS > 100 TONS/YR THEN 

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

11) MINIMUM PERMIT FEE IS $1,000.00 PER YEAR - MAXIMUM PERMIT FEE IS $100,000.00 PER 

YEAR. IF THE CALCULATED PERMIT FEE IN ITEM 10 ABOVE IS BETWEEN THESE TWO FEE 

AMOUNTS THEN ENTER HERE, OTHERWISE ENTER THE MINIMUM OR MAXIMUM PERMIT FEE, 

WHICHEVER IS APPLICABLE. THIS IS THE ACTUAL ANNUAL PERMIT FEE: 

$1,000.00 

APPLICATION PAGE 

Printed on Recycled Paper 

292-CAAPP Page 2 of 2 

Z°i 
P.41 

ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD. ILLINOIS 62794-9506 

FOR APPLICANTS USE 

Revision #: 

Date: 

Page 

/ / 

of 

Source Designation: 

4.1-1 

FUGITIVE EMISSIONS 

DATA AND INFORMATION 

r r ,N FWA<smw<m<MY^sry^yi 

ID NUMBER: 

EMISSION POINT #: 

DATE: 

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 TYPICAUY 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-LINE PROCESS VALVES. 

PRESSURE RELIEF DEVICES. OPEN-ENDED VALVES, SAMPLING CONNECTIONS. FLANGES. 

AGITATORS, COOLING 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: 

Bulk Molding Compounds, Inc. 

2) DATE FORM 

PREPARED: 

March 7, 1996 

SOURCE INFORM A TION 

3) SOURCE ID NO. 

(IF KNOWN): 

089813 AAK 

THIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNDER ILLINOIS REVISED STATUTES, 1991, AS AMENDED 1992. 

CHAPTER111 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 

Printed on Recycled Paper 

391-CAAPP 

FOR APPLICANTS USE 

Pagel of 11 10 
P.42 

4.1-2 

GENERAL INFORMATION 

4) PROVIDE THE FOUOWING INFORMATION FOR THE FUGITIVE EMISSION POINTS AT THE SOURCE INCLUDED IN 

THIS APPLICATION. SIMILAR POINTS MAY BE GROUPED TOGETHER. 

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

WERE BASED AND LABEL AS EXHIBIT 391 -1. IF THE ABOVE SPACE WAS NOT ADEQUATE. LIST AU OTHER FUGITIVE POINTS AND 

INCLUDE THE REQUIRED INFORMATION ON THIS ATTACHMENT. 

FOR PAVED AND UNPAVED ROADS. INCLUDE ROAD MILES (E.G., 6 MILES OF UNPAVED ROADS): FOR STORAGE PILES, INDICATE 

THE MATERIAL BEING STORED (E.G.. 20 LIMESTONE STORAGE PILES); FOR EQUIPMENT LEAK POINTS. GROUP SIMILAR POINTS 

TOGETHER (EG.. 15 ORGANIC UQUID PUMPS): FOR TRANSFER POINTS, IDENTIFY THE ORIGIN AND DESTINATION OF TRANSFER 

AND THE MATERIAL BEING TRANSFERRED (E.G.. 5 BELT TO BIN TRANSFERS OF CORN). 

UNCONTROLLED ANNUAL EMISSIONS 

(TONS/YR) 

FUGITIVE POINT(S) 

REGULATED AIR 

POLLUTANT(S) MAXIMUM TYPICAL 

3,500 square foot paved area particulate matter 0.09 0.09 

5) ATTACH A DIAGRAM OF THE SOURCE THAT INDICATES THE LOCATION OF ALL FUGITIVE 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 APPLICATION 

(E.G., PLOT PLAN/MAP). ALSO INDICATE ON THIS DIAGRAM THE LOCATION OF ANY AMBIENT AIR MONITORING 

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

SHOWN ON THIS DIAGRAM. 

All fugitive emissions at the Bulk Molding Compounds, Inc. facility are due to the paved area 

at the facility. 

APPLICATION PAGE 

Printed on Recycled Paper 

391-CAAPP Page 2 of 11 

-H 
APPLICABLE RULES 

6) PROVIDE ANY SPECIFIC EMISSION STANDARD(S) ANDiLIMITATIONS(S) WHICH ARE APPLICABLE TO FUGITIVE EMISSIONS AT THE SOURCE (E.G.. ROAD SEGMENT F. PM-10. IAC 

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

FUGITIVE POINTS(S) REGULATED AIR POLLUTANT(S) EMISSION STANDARD(S) REQUIREMENT(S) 

7) 

any process, material, handling or 

storage activity 

PROVIDE ANY SPECIFIC RECORDKEEF 

FUGITIVE POINTS(S) 

NA 

* 

>INC 

fugitive particulate matter 

i RULE(S) WHICH ARE APPLICABLE: 

REGULATED AIR POLLUTANT(S) 

IF ADDITIONAL SPACE IS NEEDED. ATTACH AND LABEL AS 391-3. 

APPLICATIO 

Printed or 

35 IAC 212.301 

EMISSION STANDARD(S) 

NPAGE 

Recycled Paper 

not visible by observer beyond property line of emission 

source 

- REQUIREMENTS) 

391-CAAPP page 3 of 11 (>> 

CO 
U3 

APPUCABLE RULES (CON'T) 

8) PROVIDE ANY SPECIFIC REPORTING RULE(S) WHICH ARE APPLICABLE: 

FUGITIVE POINTS(S) REGULATED AIR POLLUTANT(S) 

9) 

NA 

PROVIDE ANY SPECIFIC MONITORING 

FUGITIVE POINTS(S) 

NA 

• 

RUl .E(S) WHICH ARE APPLICABLE: 

REGULATED AIR POLLUTANT(S) 

EMISSION STANDARD(S) 

EMISSION STANDARD(S) 

10) PROVIDE ANY SPECIFIC TESTING RULES AND/OR PROCEDURES WHICH ARE APPLICABLE: 

FUGITIVE POINTS(S) REGULATED AIR POLLUTANT(S) EMISSION STANDARD(S) 

IF A 

NA 

• 

DDITIONAL SPACE IS NEEDED. ATTACH AND LAB EL AS 391-3.; 

APPLICAT IO hi PAGE 

REQUIREMENTS) 

REQUIREMENT(S) 

REQUIREMENT(S) 

1 

Printed on Recycled Paper 

391-CAAPP page 4 of 11 
P.45 

H.l- D 

COMPUANCE INFORM A TION 

11) IS EACH FUGITIVE POINT IN COMPLIANCE WITH ALL APPLICABLE REQUIREMENTS? YES TJ 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 APPLICATION. 

12) EXPLANATION OF HOW INITIAL COMPLIANCE IS TO BE, OR WAS PREVIOUSLY, DEMONSTRATED: 

PM from the paved area was negligible. 

13) EXPLANATION OF HOW ONGOING COMPLIANCE WILL BE DEMONSTRATED: 

Ongoing compliance for PM for the paved area will be demonstrated by cleaning, as 

necessary. 

TESTING, MONITORING, RECORDKEEPING AND REPORTING 

14a) LIST THE PARAMETERS THAT RELATE TO AIR EMISSIONS FOR WHICH RECORDS ARE BEING 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 FUGITIVE POINT METHOD OF MEASUREMENT FREQUENCY 

NA 

APPLICATION PAGE 

Printed on Recycled Paper 

391-CAAPP Page 5 of 11 

HH 
P.46 

4.1-6 

b) BRIEFLY DESCRIBE THE METHOD BY 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 

METHOD OF 

RECORDKEEPING 

TITLE OF 

PERSON RESPONSIBLE 

TITLE OF 

CONTACT PERSON 

NA 

c) IS COMPLIANCE OF THE EMISSION UNIT READILY DEMONSTRATED BY REVIEW OF 

THE RECORDS? YES TJ NO 

IF NO, EXPLAIN: 

d) ARE ALL RECORDS READILY AVAILABLE FOR INSPECTION. COPYING AND/OR 

SUBMITTAL TO THE AGENCY UPON REQUEST? YES TJ NO 

IF NO. EXPLAIN: 

15a) DESCRIBE ANY MONITORS OR MONITORING ACTIVITIES USED TO DETERMINE FEES, RULE APPLICABILITY OR 

COMPLIANCE: 

None 

b) WHAT PARAMETER(S) IS(ARE) BEING MONITORED? 

None 

c) DESCRIBE THE LOCATION OF EACH MONITOR AND/OR MONITORING PROCEDURES: 

NA 

TJ d) IS EACH MONITOR EQUIPPED WITH A RECORDING DEVICE? 

NA 

IF NO, LIST ALL MONITORS WITHOUT A RECORDING DEVICE: 

LJ YES NO 

APPLICATION PAGE 

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391-CAAPP Page 6 of 11 Hi 
P.47 

4.1-7 

TJ e) IS EACH MONITOR REVIEWED FOR ACCURACY ON AT LEAST A QUARTERLY 

BASIS? 

NA 

IF NO, EXPLAIN: 

YES TJ NO 

TJ f) IS EACH MONITOR OPERATED AT ALL TIMES THAT FUGITIVE EMISSIONS MAY 

OCCUR? 

NA 

IF NO, EXPLAIN: 

YES TJ NO 

16) PROVIDE INFORMATION ON THE MOST RECENT TESTS, IF ANY. IN WHICH THE RESULTS ARE USED FOR 

PURPOSES OF THE DETERMINATION OF FEES, RULE APPLICABIUTY 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: 

FUGITIVE POINT(S) TEST DATE 

TEST 

METHOD TESTING FIRM 

OPERATING 

CONDITIONS SUMMARY OF 

RESULTS 

NA 

17) DESCRIBE ALL REPORTING REQUIREMENTS AND PROVIDE THE TITLE AND FREQUENCY OF REPORT 

SUBMITTALS TO THE AGENCY: 

FUGITIVE 

POINT(S) 

REPORTING REQUIREMENTS TITLE OF REPORT FREQUENCY 

NA 

FUGITIVE DUST (complete if applicable) 

18a) ARE OPACITY READINGS REQUIRED TO BE TAKEN? 

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

NA 

n 

m 

Hi) 

b) SPECIFY THE FREQUENCY OF OPACITY READINGS: 

NA 

O YES 0 NO 

APPLICATION PAGE 

Printed on Recycled Paper 

391-CAAPP Page 7 of 11 4k 
4.1-8 

c) IS USEPA METHOD 9 USED TO READ ALL VISIBLE EMISSIONS? 

NA 

IF NO. EXPLAIN AND SPECIFY THE METHOD USED: 

O YES D NO 

19) IS AN OPERATING PROGRAM FOR FUGITIVE PARTICULATE MATTER AND/OR PM10 

CONTROL REQUIRED PURSUANT TO 35 ILL ADM. CODE 212.309? f—\ A 

LJ YES • NO 

IF YES, HAS SUCH A PROGRAM PREVIOUSLY BEEN SUBMITTED TO THE AGENCY? r-\ f—\ 

NA L J YES L J NO 

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

AND LABELED AS 391-5. 

20) IS THE SOURCE IN COMPLIANCE WITH 35 ILL. ADM. CODE 212.301 WHICH STATES 

THAT NO EMISSIONS SHALL BE VISIBLE BEYOND THE PROPERTY LINE OF ETHE 

SOURCE? 

IF NO. EXPLAIN: 

0 YES CD NO 

FUGITIVE VOM FROM EQUIPMENT LEAKS (complete if applicable) - NA 

21) INDICATE WHICH OF THE FOLLOWING METHODS WAS USED TO ESTIMATE FUGITIVE EMISSIONS OF VOM FROM 

EQUIPMENT LEAKS: 

o 

o 

AVERAGE 

EMISSION 

FACTOR 

OTHER; (SPECIFY): 

o LEAK/NO LEAK 

EMISSION 

FACTOR 

o STRATIFIED 

EMISSION 

FACTOR 

D LEAK RATE/SCREENING VALUE 

CORRELATION 

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) IS THERE AN ACTIVE INSPECTION AND MONITORING PROGRAM OF EQUIPMENT 

LEAKS? o YES Q NO 

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

AND LABEL AS 391-7: 

APPLICATION PAGE 

Printed on Recycled Paper 

391-CAAPP Page 8 of 11 HI 
P.49 

4.1-9 

FUGITIVE VOM FROM CLEANUP OPERATIONS (complete if applicable) • NA 

23) 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 APPLICATION: 

ANNUALUSAGE 

(GAL/YEAR) 

GENERIC NAME OF CLEANUP VOM CONTENT 

MATERIAL 

DENSITY 

(LB/GAL) (WEIGHT %) MAX TYPICAL 

24) EXPLAIN THE MEANS BY WHICH THESE MATERIALS ARE USED AND WHAT EQUIPMENT OR ITEMS ARE BEING 

CLEANED: 

TJ 25a) ARE ALL VOM USED IN CLEANUP OPERATIONS CONSIDERED TO BE EMITTED? 

IF NO, EXPLAIN: 

D YES NO 

b) IF APPLICABLE. 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 

TYP 

ii) EXPLAIN THE MEANS BY WHICH VOM IS COLLECTED FOR RECLAMATION AND/OR DISPOSAL: 

APPLICATION PAGE 

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391-CAAPP Page 9 of 11 *H 
P.50 

4.1-10 

iii) EXPLAIN THE MEANS BY WHICH THE AMOUNT OF VOM COLLECTED IS MEASURED OR DETERMINED: 

FUGITIVE CONTROL - NA 

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

CONTROL MEASURE UTILIZED: 

CONTROL MEASURES 

REGULATED AIR 

POLLUTANT 

FUGITIVE 

POINT(S) 

CONTROLLED 

REDUCTION 

EFF.(%) 

MIN TYP 

FREQUENCY 

OF 

CONTROL 

APPLICATION 

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) 

b) 

APPLICATION PAGE 

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391-CAAPP Page 10 of 11 H°\ 
P.51 

4.1-11 

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 MEASURE(S) DESCRIPTION 

NA 

-1 

e) 

9) 

APPLICATION PAGE 

Printed on Recycled Paper 

391-CAAPP Page 11 of 11 So 
P.52 

4.1-12 

EXHIBIT 391-1 

FUGITIVE EMISSIONS 

CALCULATION SUMMARY 

Paved Parking Lot 

The predictive emission factor equation from AP-42 Section 13.2.1.3 (1/9S) is used to estimate fugitive 

particulate emissions from the 3,500 square foot paved parking areas at the Bulk Moldmg Compounds, Inc. 

facility in St. Charles, Illinois. Estimated particulate matter emissions are calculated: 

where: 

fSL\06i (W\ls 

PMj-, Emissions Factor = (tf)xI —J xI —I 

E = emission factor in pounds/Vehicle Mile Traveled (VMT) 

K = Base emission factor for particle size range, 0.082 Ib/VMT 

SL = Road surface silt loading, 2.5 g/m3 

W = Average weight of vehicles traveling the parking lot, 4 tons 

substituting: 

PM^Q Emissions Factor = (0.082) x I — J x I - J 

= 0.15pounds/VMT 

Vehicle miles traveled are calculated assuming that an average of 350 vehicles travel 1,200 feet per day 

each on this parking lot throughout the yean 

VMT 

year 

50 vehicles) (365 days] , «. 

I x | 1 x (335 feet traveled) x 

day year 

' I mile ' 

< 5,280 feet j 

1,158 VMT 

year 

Particulate emissions are calculated by multiplying the emission factor (E) by the vehicle miles traveled 

(VMT) per year: 

Particulate emissions (PMTM) = E* VMT x 

U000 pounds) 

(0.15 pwhds\ 

\ VMT ) 

1,158 KMT 

V year 

\tori 

2000 pounds J 

= 0.09 tpy 

5034-ca\391 -1 ex.doc A I R SOLUTIONS, INC. 

6\ 
ST. CHARLES, ILLINOIS 

OFFICES 

PLOT PLAN 

MOLDING 

OPERATION 

LAB 

MAINTENANCE 

SHOP WAREHOUSE 

OFFICES PRODUCT 

STORAGE 

PORTABLE 

TANK FILLING 

t 

N 

I 

NOTE: The production 

areas and resin rooms 

exhaust solely through 

the Roof Exhaust and 

Bahouse Stack 

PORTABLE 

TANK FILLING 

WAREHOUSE 

FORKLIFT 

RAMP 

PRODUCTION AREA 

ii 

PRODUCTION AREA 

o 

NOTE: Drawing not scale UNDERGROUND STORAGE TANK 1 

BAGHOUSE 

EXHAUST 

W 

5034-ca\plotplan.vsd AIR SOLUTIONS, INC. ^ 
P.54 

1.4-1 

Bulk Molding Compounds, Inc . 

Process Flow Diagram 

Polyester and Low Profile Resins 

from Underground and Indoor 

Storage Tanks 

Polyester and Low Profile 

Resins from Drums 

Pump 

^ p 

Scale 

Catalyst, Inhibitor, Pigment 

Dispersion, Anti—oxident 

Inert Fillers, Calcium Stearate, 

Zinc Stearate, High Density 

Polyethylene Powder, 

Thickener, Fiberglass 

To Product 

Storage Area 

- • 

I First Stage 

Mixing 

Resin Mix 

Tank 

Final Stage Mixing 

Belt Conveyor 

T 

Extruder 

T 

Manual 

Packaging 

53 
P.55 

1.4-2 

Bulk Molding Compounds, Inc0 

Non-Baghoose Process Area Emissions 

Resin- R©©m 

0 o ;nniDssii©ini b©ur a 

Styrene 

Limw 

5

L

I 
P.56 

1.4-3 

Molding Compounds, I 

ss Area Baghouse Emissions 

LUSt 

Resin R©©inni 

Msston S©ura 

Uoe 10 

Lime 4 

iron SIKV^VOD 

(To Atmosphere) 

t&Qr 

_^_ 

dloeattes Final Stage 

•Limn 

oduc 

^ 
1.5 

BULK MOLDING COMPOUNDS, INC. 

ST. CHARLES, ILLINOIS 

TITLE V PERMIT APPLICATION 

PROCESS DESCRIPTION 

The Bulk Molding Compound, Inc. Facility in St. Charles, Illinois is located on a four acre site. 

Production processes at this plant are made up of eight mixing lines that mix and treat various raw 

materials to create the final product, bulk molding compound. Bulk molding compound is a 

thermoset resin used for injection molding. 

Polyester and low profile resins are pumped from either a 6,000 gallon underground storage tank or 

from portable indoor storage tanks, and are mixed in weighed amounts with other resin and catalyst, 

inhibitor, pigment dispersion and/or anti-oxidants. Exact formulation varies in response to customer 

needs. This initial mixing occurs in the Resin Rooms. 

After this first stage mixing above, the raw material is pumped and sent to final stage mixing in 

weighed amounts. Final stage mixing combines the raw material with inert fillers, calcium stearate, 

zinc stearate, high density polyethylene powder, thickener and/or fiberglass. Again, the specific 

formulation is dependent on customer orders. 

The mixed product is conveyed through any of the eight existing lines, located in the production 

areas, via a belt conveyer. From here the material is either fed into a single-screw extruder or 

manually packed into boxes in bulk form. 

The exhaust system removes vapors from production areas at the mixer, conveyor and extruder. 

Additionally, there are eight (8) ducts that collect fugitive vapors from near the floor around the 

Resin Mix Tanks. All of these sources are filtered through the dust collector. 

The final product is packed into bags inside boxes, stacked on pallets and transferred to the Product 

Storage Room where it is held until shipment. The packaging ofthe final product takes place at the 

end of the Final Stage Mixing Lines. The bags that the product is packed into are co-extruded 

Polyethylene and Nylon. This combination serves as a barrier to keep styrene vapor in the product 

and excludes water vapor from the atmosphere. The plastic bag is sealed, the box is closed, labeled 

and stacked on a pallet for storage and eventual shipment. When a pallet is full, it is transferred to 

the Product Storage Area which is maintained at approximately 65°F. 

There are five small natural gas fired space heaters in the production areas and four more located in 

the lab, warehouse, maintenance and storage areas. Each space heater has a heat input capacity of 

less than 2.5 million BTU. 

There is a small pressure molding operation that recycles off-spec polystyrene bulk molding 

compound into shipping boxes. 

# 

There are trace amounts of vinyl toluene and ethylene glycol in certain product formulations, but for 

calculation purposes all VOM is assumed to be styrene. 

5034-ca\procdesc.doc AlR SOLUTIONS, INC. 

Sic 
P.58 

1.6 

BULK MOLDING COMPOUNDS, INC. 

ST. CHARLES, ILLINOIS 

TITLE V PERMIT APPLICATION 

LIST OF ITEMS FOR WHICH A PERMIT IS BEING SOUGHT 

ITEM 

Mixing Lines and Resin Rooms 

Baghouse 

Polyester-based Resin Storage Tank 

Fugitive Emissions i 

.APPUCATION FORM NUMBER 

220 

260, 260C 

232 

391 

5034-ca\itemlist.doc A I R SOLUTIONS, INC. 

si 
ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD, ILLINOIS 62794-9506 

FOR APPLICANTS USE 

Revision #: 

Date: / / 

Paae of 

Source Designation: 

A./-1 

LISTING OF INSIGNIFICANT 

ACTIVITIES 

ID NUMBER: 

PERMIT* 

DATE: 

FeRAGSficyvsEQitLr 

THIS FORM MUST BE COMPLETED FOR ALL ACTIVITIES THAT ARE "INSIGNIFICANr ACCORDING TO 35 ILL. ADM. CODE, SECTION 201.210 

AND 201.211 FOR WHICH DETAILED DATA AND INFORMATION, AS REQUESTED IN OTHER FORMS, IS NOT PROVIDED. 

SOURCE INFORMATION 

1) SOURCE NAME: 

Bulk Molding Compounds, Inc. 

2) DATE FORM 

PREPARED: March 7,1996 

3) SOURCE ID NO. 

(IF KNOWN): 089813 A AK 

INSIGNIFICANT ACTIVITIES 

YES o NO 4) ARE ANY ONE OR ALL OF THE FOLLOWING ACTIVITIES, AS IDENTIFIED IN 35 ILL. ADM. 

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

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

i) AIR CONDITIONING OR VENTILATING EQUIPMENT NOT DESIGNED TO REMOVE AIR CONTAMINANTS 

GENERATED BY OR RELEASED FROM ASSOCIATED EQUIPMENT; 

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

TO RADIANT ENERGY; 

iii) EQUIPMENT USED FOR HYDRAULIC OR HYDROSTATIC TESTING; 

iv) GENERAL VEHICLE MAINTENANCE AND SERVICING ACTIVITIES AT THE SOURCE, OTHER THAN GASOLINE FUEL 

HANDLING; 

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

FOR CONSUMPTION AT THE SOURCE; 

vi) 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 ACTIVITIES INCLUDING. BUT NOT LIMITED 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 

DETERGENTS PROVIDED THAT ANY ORGANIC SOLVENT PRESENT IN SUCH ITEMS BEFORE PROCESSING THAT 

IS RETAINED FROM CLEAN-UP OPERATIONS SHALL BE ADDRESSED AS PART OF THE VOM EMISSIONS FROM 

USE OF CLEANING MATERIALS; 

THIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNDER ILLINOIS REVISED STATUTES, 1991. AS AMENDED 1992, 

CHAPTER 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 APPLICATION BEING DENIED. THIS FORM HAS BEEN 

APPROVED BY THE FORMS MANAGEMENT CENTER. 

APPLICATION PAGE 

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297-CAAPP 

FOR APPLICANTS USE 

Page 1 of 6 51 
irm'l'L 

INSIGNIFICANT ACTIVITIES (continued) 

ix) HOUSEKEEPING ACTIVITIES FOR CLEANING PURPOSES. INCLUDING COLLECTING SPILLED AND 

ACCUMUUTED 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 USED EXCLUSIVELY FOR CHEMICAL 

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

DEVICES AND CONTROL DEVICES INSTALLED PRIMARILY TO ADDRESS POTENTIAL ACCIDENTAL RELEASES; 

xii) REST ROOM FACILITIES AND ASSOCIATED CLEANUP OPERATIONS, AND STACKS OR VENTS USED TO 

PREVENT THE ESCAPE OF SEWER GASES THROUGH PLUMBING TRAPS; 

xiii) ACTIVITIES ASSOCIATED WITH THE CONSTRUCTION, ON-SITE REPAIR, MAINTENANCE OR DISMANTLEMENT OF 

BUILDINGS, UTILITY LINES. PIPELINES, WELLS, EXCAVATIONS, EARTHWORKS AND OTHER STRUCTURES THAT 

DO NOT CONSTITUTE EMISSION UNITS; 

xiv) STORAGE TANKS OF ORGANIC LIQUIDS WITH A CAPACITY OF LESS THAN 500 GALLONS. PROVIDED THE TANK 

IS NOT USED FOR STORAGE OF ANY MATERIAL LISTED AS A HAZARDOUS AIR POLLUTANT PURSUANT TO 

SECTION 112(b) OF THE CLEAN AIR ACT; 

xv) PIPING AND STORAGE SYSTEMS FOR NATURAL GAS, PROPANE, AND LIQUEFIED PETROLEUM GAS; 

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

FEEDWATER, (B) SYSTEMS, INCLUDING COOLING 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 LISTED AS HAZARDOUS AIR POLLUTANTS PURSUANT TO SECTION 112(b) 

OF THE CLEAN AIR ACT; 

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

xviii) 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; 

xix) COLD CLEANING DEGREASERS THAT ARE NOT IN-LINE CLEANING MACHINES. WHERE THE VAPOR PRESSURE 

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

xx) MANUALLY OPERATED EQUIPMENT USED FOR BUFFING, POLISHING, CARVING, CUTTING, DRILLING, 

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

xxi) 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; 

xxii) ACTIVITIES DIRECTLY USED IN THE DIAGNOSIS AND TREATMENT OF DISEASE, INJURY OR OTHER MEDICAL 

CONDITION; 

xxiii) FIREFIGHTING ACTIVITIES AND TRAINING IN PREPARATION FOR FIGHTING FIRES CONDUCTED AT THE 

SOURCE; 

xxiv) INTERNAL COMBUSTION ENGINE OR BOILER (INCLUDING THE FUEL SYSTEM) OF MOTOR VEHICLES. 

LOCOMOTIVES, AIR CRAFT, WATERCRAFT, LIFTTRUCKS, 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 HANDLING; 

APPLICATION PAGE 

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297-CAAPP Page 2 of 6 51 
P.61 

1.7-3 

INSIGNIFICANT ACTIVITIES (continued) 

xxvii) INDIVIDUAL POINTS OF EMISSION OR ACTIVITIES AS FOLLOWS: (A) INDIVIDUAL FLANGES, VALVES. PUMP 

SEALS, PRESSURE RELIEF VALVES AND OTHER INDIVIDUAL COMPONENTS THAT HAVE THE POTENTIAL FOR 

LEAKS, (B) INDIVIDUAL SAMPLING POINTS. ANALYZERS, AND PROCESS INSTRUMENTATION, WHOSE 

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

BURNER AND SOOTBLOWERS IN A BOILER OR EACH USE OF CLEANING MATERIALS ON A COATING OR 

PRINTING LINE, (D) INDIVIDUAL EQUIPMENT THAT IS TRANSPORTABLE OR ACTIVITIES WITHIN A FACILITY 

ESTABLISHED FOR TESTING UNITS PRIOR TO SALE OR DISTRIBUTION OR FOR PURPOSES OF RESEARCH, AND 

(E) INDIVIDUAL EQUIPMENT OR ACTIVITIES WITHIN A PILOT PLANT FACILITY THAT IS USED FOR RESEARCH OR 

TRAINING; 

xxviii) ACTIVITIES AT A SOURCE ASSOCIATED WITH THE MODIFICATION ONLY OR CONSTRUCTION ONLY OF A 

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

xxix) ACTIVITIES AT A SOURCE ASSOCIATED WITH THE MAINTENANCE. REPAIR, OR DISMANTLEMENT OF AN 

EMISSION UNIT OR OTHER EQUIPMENT INSTALLED 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. 

5) ARE ANY EMISSION UNITS AT THE SOURCE CONSIDERED INSIGNIFICANT ACTIVITIES BECAUSE THEY FALL 

UNDER ONE OF THE ACTIVITIES OR EMISSION LEVELS LISTED IN 35 ILL. ADM. CODE 201.210(a)(1) THROUGH (18)7 

IF YES. IDENTIFY THE EMISSION UNITS IN THE "LIST OF INSIGNIFICANT ACTIVITIES PURSUANT TO 201.210(a)(1) 

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

LABEL AS EXHIBIT 297-1. 

ACTIVITIES 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 ILL. ADM. CODE 201.211 (SEE ITEM #6); 

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

REGULATED AIR POLLUTANT IN THE ABSENCE OF AIR POLLUTION CONTROL 

EQUIPMENT AND THAT DO NOT EMIT ANY AIR POLLUTANT LISTED AS HAZARDOUS 

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

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

REGULATED AIR POLLUTANT IN THE ABSENCE. OF AIR POLLUTION CONTROL 

EQUIPMENT AND THAT DO NOT EMIT ANY AIR POLLUTANT LISTED 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 FOLLOWS: (A) UNITS WITH 

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

NATURAL GAS, PROPANE OR LIQUEFIED 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 LIQUEFIED 

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 CHEMICALLY 

CONTAMINATED WOOD; 

YES o NO 

o 

o 

YES 

YES 

NO 

NO 

YES o NO 

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 II 

SUBSTANCES 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; 

vi) FURNACES USED FOR MELTING METALS OTHER THAN BERYLLIUM WITH A BRIM 

FULL CAPACITY OF LESS THAN 450 CUBIC INCHES BY VOLUME; 

vii) EQUIPMENT USED FOR THE MELTING OR APPLICATION OF LESS THAN 50,000 

LBS/YR OF WAX TO WHICH NO ORGANIC SOLVENT HAS BEEN ADDED; 

o YES NO 

O YES 

O YES 

NO 

NO 

APPLICATION PAGE 

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297-CAAPP Page 3 of 6 Co 
P.62 

1.7-4 

INSIGNIFICANT A CTIVITIES (continued) 

CD YES 

Q YES 

o 

o 

o 

o 

YES 

YES 

YES 

YES 

NO 

NO 

NO 

NO 

NO 

NO 

viii) EQUIPMENT USED FOR FILLING DRUMS, PAILS OR OTHER PACKAGING 

CONTAINERS, 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; 

ix) 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; 

x) STORAGE TANKS OF ORGANIC LIQUIDS WITH A CAPACITY OF LESS THAN 10,000 

GALLONS AND AN ANNUAL THROUGHPUT OF LESS THAN 100,000 GALLONS 

PROVIDED THE TANK IS NOT USED FOR THE STORAGE OF GASOLINE OR ANY 

LISTED HAZARDOUS AIR POLLUTANT PURSUANT TO SECTION 112(b) OF THE CLEAN 

AIR ACT; 

xi) STORAGE TANKS OF VIRGIN OR REREFINED DISTILLATE OIL. HYDROCARBON 

CONDENSATE FROM NATURAL GAS PIPELINE OR STORAGE SYSTEMS. 

LUBRICATING OIL, OR RESIDUAL FUEL OILS; 

xii) DIE CASTING MACHINES WHERE A METAL OR PLASTIC IS FORMED UNDER 

PRESSURE IN A DIE; 

xiii) COATING OPERATIONS (EXCLUDING POWDER, ARCHITECTURAL AND INDUSTRIAL 

MAINTENANCE COATING) WITH AGGREGATE VOM USAGE THAT NEVER EXCEEDS 

15 LBS/DAY FROM ALL COATING LINES AT THE SOURCE, INCLUDING VOM FROM 

COATING. DILUTENTS, AND CLEANING MATERIALS; 

xiv) PRINTING OPERATIONS WITH AGGREGATE ORGANIC SOLVENT USAGE THAT 

NEVER EXCEEDS 750 GALLONS PER YEAR FROM ALL PRINTING LINES AT THE 

SOURCE, INCLUDING ORGANIC SOLVENT FROM INKS, DILUTENTS, FOUNTAIN 

SOLUTIONS, AND CLEANING MATERIALS; 

xv) GAS TURBINES AND STATIONARY RECIPROCATING INTERNAL COMBUSTION 

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

xvi) GAS TURBINES AND STATIONARY RECIPROCATING INTERNAL COMBUSTION 

ENGINES OF BETWEEN 112 KWAND 1,1118 KW (150 AND 1.500 HORSEPOWER) 

POWER OUTPUT THAT ARE EMERGENCY OR STANDBY UNITS; 

xvii) 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; 

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

WATERCRAFT THAT HANDLE ONLY THE FOLLOWING LIQUID MATERIALS PROVIDED 

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

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

OILS; GREASES, ANIMAL FATS, SWEETENERr 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 LISTED IN 35 ILL. ADM. CODE 

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

WHICH STATUS AS AN INSIGNIFICANT ACTIVITIES IS PROPOSED PURSUANT TO • YES 

201.211(a)" AND PROVIDE THE REQUESTED INFORMATION. IF ADDITIONAL SPACE IS 

NEEDED, ATTACH AND LABEL AS EXHIBIT 297-2. 

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 POLLUTANT NOT 

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

POLLUTION CONTROL EQUIPMENT; 

ii) THE EMISSION UNIT WOULD NOT EMIT MORE THAN 0.1 LB/HR OF ANY REGULATED AIR POLLUTANT LISTE'D AS 

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

CONTROL EQUIPMENT; AND 

iii) THE EMISSION UNIT IS NOT A PROCESS UNIT. 

CD YES 

CD YES 

CD YES 

0 NO 

0 NO 

0 NO 

o YES NO 

o YES NO 

o NO 

APPLICATION PAGE 

Printed on Recycled Paper 

297-CAAPP Page 4 of 6 ic 
EMISSION UNIT 

AND DESIGNATION 

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

#OF 

UNITS DESCRIPTION OF UNIT INCLUDING ANY CONTROL 

BASIS FOR INSIGNIFICANCE 

SECTION 201.210(a) 

'BASIS FOR DETERMINATION 

OF EMISSIONS 

i 

Space Heaters 9 assorted sizes, all < 2.5 BTU/hr, natural gas fired 

combustion units 

(5lv) designed and used for comfort heating, rated 

heat Input < 2.3 MM BTU/hr, natural gas fired 

NA 

i 

!-

! 

! 

: 

! 

. 

*IF CONSIDERED INSIGNIFICANT BASED ON EMISSION LEVEL. THE DETERMINATION METHOD OF EMISSION MUST BE PROVIDED (E.G., 1) STACK TEST. 2) MATERIAL BALANCE. 3) STANDARD EMISSION 

FACTOR (AP-42 OR AIRS). 4) ENGINEERING ESTIMATE. 5) SPECIAl EMISSION FACTOR (NOT AP-42 OR AIRS)). 

APPLICATION PAGE _ 

Printed on Recycled Paper 

297-CAAPP Page 5 of 6 i 
LIST OF ACTIVITIES FOR WHICH STATUS AS AN INSIGNIFICANT ACTIVITIES IS PROPOSED PURSUANT TO 201.211 (a) 

EMISSION UNIT 

AND DESIGNATION 

1|U DESCRIPTION OF UNIT 

INCLUDING ANY CONTROL 

OPERATING HOURS 

HRS PER 

OAY 

DAY PER 

WEEK 

WEEK PER 

YEAR 

2DISCUSSION: 

EMISSIONS 

POLLUTANT 

LB PER 

HOUR 

TON PER 

YEAR 

DETERMINATION METHOD: 

OTHER 

SUPPORTING 

INFORMATION 

Molding Operations 1 Off-spec polystyrene bulk molding 

compound is pressure molded 

to recycle the material into storage 

boxes 

22 | 5 | 52 Styrene <0.10 

2 • material balance 

4 - engineering estimate 

<0.10 NA 

Portable Styrene Resin 

Tanks 

See 

a 

250 gallon portable 

styrene/resin tanks 

24 | 7 I « Styrene <0.10 

4 - engineering estimate 

seeb 

<0.10 portable tanks; 

contain HAPs 

1

IU - TOTAL NUMBER OF UNITS (EMISSION RATES SHOULD BE PROVIDED ON A PER UNIT BASIS). 

2DISCUSSION - PROVIDE AN EXPLANATION OF OPERATING HOURS (E.G.. THE UNIT IS ON EMERGENCY STANDBY - THEREFORE IT ONLY OPERATES ONE DAY PER MONTH.) 

'DETERMINATION METHOD: 1) STACK TEST. 2) MATERIAL BALANCE. 3) STANDARD EMISSION FACTOR (AP-42 OR AIRS), 4) ENGINEERING ESTIMATE, 5) SPECIAL EMISSION FACTOR (NOT AP-42 OR AIRS). 

* Numerous 250 gallon containers on-site; calculations based on total throughput Into one container with appropriate number of turnovers to include all conatlners. 

b

 Based on the pool emissions calculations found in the USEPA's Handbook of Chemical Hazard Analysis Procedures. 

6N 

Ui 

APPLICATION PAGE 

Printed on Recycled Paper 

297-CAAPP Page 6 of 6 i 
P.65 

ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD, ILLINOIS 62794-9506 

FOR APPLICANTS USE 

Revision #: 

Date: / / 

Paae of 

Source Designation: 

2.1-1 

AIR POLLUTION CONTROL 

EQUIPMENT 

DATA AND INFORMATION 

FMAGMCYUSEOHLY ! V",' 

ID NUMBER: 

CONTROLEQUIPMENT* 

DATE: 

THIS FORM MUST BE COMPLETED FOR EACH AIR POUUTION CONTROL EQUIPMENT. COMPLETE AND PROVIDE THIS FORM IN ADDITION 

TO THE APPUCABLE ADDENDUM FORM 260-A THROUGH 260-K. A SEPARATE FORM MUST BE COMPLETED FOR EACH MODE OF 

OPERATION OF AIR POLLUTION CONTROL EQUIPMENT FOR WHICH A PERMIT IS BEING SOUGHT. 

SOURCE INFORMATION 

1) SOURCE NAME: 

Bulk Molding Compounds, Inc. 

2) DATE FORM 

PREPARED: March 7,1996 

3) SOURCE ID NO. 

(IF KNOWN): 089813AAK 

GENERAL INFORMATION 

4) NAME OF AIR POLLUTION CONTROL EQUIPMENT AND/OR CONTROL SYSTEM: 

Baghouse 

5) FLOW DIAGRAM DESIGNATION OF CONTROL EQUIPMENT AND/OR CONTROL SYSTEM: 

Baghouse 

6) MANUFACTURER OF CONTROL EQUIPMENT (IF KNOWN): 

Dracco Corporation 

7) MODEL NUMBER (IF KNOWN): 

Dust Collector MB-20S 

8) SERIAL NUMBER (IF KNOWN): 

NA 

9) DATES OF COMMENCING CONSTRUCTION. 

OPERATION AND/OR MOST RECENT MODIFICATION 

OF THIS EQUIPMENT (ACTUAL OR PLANNED) 

a) CONSTRUCTION (MONTH/YEAR): 

June, 1985 

b) OPERATION (MONTH/YEAR): 

July, 1985 

c) LATEST MODIFICATION (MONTH/YEAR): 

NA 

10) BRIEFLY DESCRIBE MODIFICATION (IF APPLICABLE): 

NA 

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

CHAPTER 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 

FOR APPLICANTS USE 

Printed on Recycled Paper 

260-CAAPP Pagel of 10 ^ 
P.66 

11) LIST ALL EMISSION UNITS AND OTHER CONTROL EQUIPMENT DUCTING EMISSIONS TO THIS CONTROL 

EQUIPMENT: 

NAME DESIGNATION OR CODE NUMBER 

Mixing Lines 

Resin Rooms 

Unes 1, 2,4-7, 9 8.10 

Resin Rooms 

12) DOES THE CONTROL EQUIPMENT HAVE MORE THAN ONE MODE OF OPERATION? 

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

A SEPARATE AIR POLLUTION CONTROL EQUIPMENT FORM 260-CAAPP MUST BE 

COMPLETED FOR EACH MODE): 

o YES NO 

13) IDENTIFY ALL ATTACHMENTS TO THIS FORM RELATED TO THIS AIR POLLUTION CONTROL EQUIPMENT(E.G., 

TECHNICAL DRAWINGS): 

- See Form 260C (Filter/Baghouse) 

- See Process Flow Diagram for equipment arrangement 

OPERATING SCHEDULE 

14) IDENTIFY ANY PERIOD WHEN THE CONTROL EQUIPMENT WILL NOT BE OPERATING DUE TO SCHEDULED 

MAINTENANCE AND/OR REPAIRS WHEN THE FEEDING EMISSION UNIT(S) TO THIS CONTROL EQUIPMENT IS/ARE 

IN OPERATION: 

None 

15a) IDENTIFY ANY PERIODS DURING OPERATION OF THE FEEDING EMISSION UNIT(S) WHEN THE CONTROL 

EQUIPMENT IS/ARE NOT USED: 

None 

b) IS THIS CONTROL EQUIPMENT IN OPERATION AT ALL OTHER TIMES THAT THE 

FEEDING EMISSION UNIT(S) IS/ARE IN OPERATION? 

IF NO. EXPLAIN AND PROVIDE THE DURATION OF THE CONTROL EQUIPMENT 

DOWNTIME: 

YES NO 

APPLICATION PAGE 

Printed on Recycled Paper 

260-CAAPP Page 2 of 10 

icS 
AHrLHm.AB-.m-- KUlmt-TZm 

16) PROVIDE ANY SPECIFIC EMISSION STANDARD(S) AND UMITATION(S) SET BY RULE(S) WHICH ARE APPLICABLE TO THIS EMISSION UNIT (E.G.. VOM. IAC 218.207(b)(1). 81% 

OVERALL & 90% CONTROL DEVICE EFF.): 

REGULATED AIR POLLUTANT(S) EMISSION STANDARDS) REQUIREMENTS) 

VOM 

PM 

PM 

35 IAC 218.301 

35 IAC 212.321 

35 IAC 212.123 

VOM Emissions <8 Ibs/hr 

Production-based PM Emissions limit £3.40 Ibs/hr 

Opacity £30% 

17) PROVIDE ANY SPECIFIC RECORDKEEPING RULE(S) WHICH ARE APPLICABLE TO THIS EMISSION UNIT: 

REGULATED AIR POLLUTANT(S) 

VOM and PM 

RECORDKEEPING RULE(S) REQUIREMENTS) 

35 IAC 201.301 Maintain records forAnuual Emissions Reports 

18) PROVIDE ANY SPECIFIC REPORTING RULE(S) WHICH ARE APPLICABLE TO THIS EMISSION UNIT: 

REGULATED AIR POLLUTANT(S) 

VOM and PM 

REPORTING RULE(S) REQUIREMENT(S) 

35 IAC 201.302 and 35 IAC 254 Annual Emissions Report 

19) PROVIDE ANY SPECIFIC MONITORING RULE(S) WHICH 

REGULATED AIR POLLUTANT(S) 

ARE APPLICABLE TO THIS EMISSION UNIT: 

MONITORING RULE(S) REQUIREMENT(S) 

NA 

20) PROVIDE ANY SPECIFIC TESTING RULES AND/OR PROCEDURES WHICH ARE APPLICABLE TO THIS EMISSION UNIT: 

REGULATED AIR POUUTANT(S) 

NA 

TESTING RULE(S) REQUIREMENT(S) 

APPLICATION PAGE _ 

Printed on Recycled Paper 

260-CAAPP page 3 of 10 

^1 
P.68 

COMPUANCE INFORMATION 

21) IS THE CONTROL SYSTEM IN COMPLIANCE WITH ALL APPLICABLE 

REQUIREMENTS? YES o 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 APPLICATION. 

22) EXPLANATION OF HOW INITIAL COMPLIANCE IS TO BE. OR WAS PREVIOUSLY, DEMONSTRATED: 

USEPA Method 25A stack testing data was used in correlation with production records in 

order io determine production-based emission factors. Using these factors, reviews of 

production histories assures past compliance. 

23) EXPLANATION OF HOW ONGOING COMPLIANCE WILL BE DEMONSTRATED: 

Production will be monitored and remain below the maximum allowable rate of 1,260 

tons/month of bulk molding compound material, thus assuring VOM emissions of 

<7.90 Ibs/hr and <24.5 tons/yr. PM emissions at this maximum production rate are 

<0.034 Ibs/hr. 

TESTING, MONITORING, RECORDKEEPING AND REPORTING 

24a) LIST THE PARAMETERS THAT RELATE TO AIR EMISSIONS FOR WHICH RECORDS ARE BEING 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 

bulk molding 

compound production 

UNIT-OF-MEASUREMENT- -

pounds 

METHOD OF MEASUREMENT .. 

gravimetric 

FREQUENCY 

monthly 

APPLICATION PAGE 

Printed on Recycled Paper 

260-CAAPP Page 4 of 10 

£T 
P.69 

24b) BRIEFLY DESCRIBE THE METHOD BY 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 

METHOD OF 

RECORDKEEPING 

TTTLEOF 

PERSON RESPONSIBLE 

bulk molding 

compound production 

department record Vie* Pmktmii, ManuActuiftig and 

TTTLEOF 

CONTACT PERSON 

M M PmJdant tmnu-ftcturing 

MB Eft00VMnfl0 

U c) IS COMPLIANCE OF THE CONTROL EQUIPMENT READILY DEMONSTRATED BY 

REVIEW OF THE RECORDS? YES NO 

IF NO, EXPLAIN: 

d) ARE ALL RECORDS READILY AVAILABLE FOR INSPECTION, COPYING AND/OR 

SUBMITTAL TO THE AGENCY UPON REQUEST? YES o NO 

IF NO, EXPLAIN: 

25a) DESCRIBE ANY MONITORS OR MONITORING ACTIVITIES USED TO DETERMINE FEES. RULE APPLICABILITY OR 

COMPLIANCE: 

None 

b) WHAT OPERATING PARAMETER(S) IS(ARE) BEING MONITORED (E.G.. COMBUSTION CHAMBER TEMPERATURE)? 

None 

c) DESCRIBE THE LOCATION OF EACH MONITOR (E.G., EXIT OF COMBUSTION CHAMBER): 

NA 

APPLICATION PAGE 

Printed on Recycled Paper 

260-CAAPP Page 5 of 10 y 
P.70 

TJ u 25d) IS EACH MONITOR EQUIPPED WITH A RECORDING DEVICE? 

NA 

IF NO, LIST ALL MONITORS WITHOUT A RECORDING DEVICE: 

YES NO 

U e) IS EACH MONITOR REVIEWED FOR ACCURACY ON AT LEAST A QUARTERLY BASIS? 

NA ' 

IF NO, EXPLAIN: 

YES TJ NO 

0 IS EACH MONITOR OPERATED AT ALL TIMES THE CONTROL EQUIPMENT IS IN 

OPERATION? 

NA 

IF NO, EXPLAIN: 

a YES TT NO 

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

PURPOSES OF THE DETERMINATION OF FEES, RULE APPLICABIUTY 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 260-1: 

TEST DATE TEST METHOD TESTING COMPANY 

12/94 

9/94 

USEPA 25A 

USEPA 2SA 

OPERATING 

CONDITIONS 

Air Solutions, 

Inc. 

Mostardi-Platt 

Associates 

typical 

typical 

SUMMARY OF RESULTS 

Roof Exhaust VOM a 3.1 S 

lbs/ton of production 

0.19 Ibsfor VOM 

from Baghouse 

27) DESCRIBE ALL REPORTING REQUIREMENTS AND PROVIDE THE TITLE AND FREQUENCY OF REPORT 

SUBMITTALS TO THE AGENCY: 

REPORTING REQUIREMENTS TITLE OF REPORT FREQUENCY 

Emissions of all regulated 

pollutants 

Compliance of source and 

emission units 

Annual Emissions 

Report 

Compliance Certification, 

CAAPP Form 296 

annually 

annually 

CAPTURE AND CONTROL 

28) DESCRIBE THE CAPTURE SYSTEM USED TO CONTAIN, COLLECT AND TRANSPORT EMISSIONS TO THE CONTROL 

EQUIPMENT. INCLUDE ALL HOODS, DUCTS, FANS, ETC. ALSO INCLUDE THE METHOD OF CAPTURE USED AT 

EACH EMISSION POINT. (IF ADDITIONAL SPACE IS NEEDED, ATTACH AND LABEL AS EXHIBIT 260-2): 

A dust collection duct from each mixing line and from the Resin Rooms feeds into a main 

duct to the baghouse. 

APPLICATION PAGE 

Printed on Recycled Paper 

260-CAAPP Page 6 of 10 (,"l 
P.71 

29) ARE FEATURES OF THE CAPTURE SYSTEM ACCURATELY DEPICTED IN THE FLOW 

DIAGRAM CONTAINED IN THIS APPLICATION? 

IF NO. A SKETCH SHOWING THE FEATURES OF THE CAPTURE SYSTEM SHOULD BE 

ATTACHED AND LABELED AS EXHIBIT 260-3: 

YES o NO 

30) PROVIDE THE ACTUAL (MINIMUM AND TYPICAL) CAPTURE SYSTEM EFFICIENCY. CONTROL EQUIPMENT 

DESTRUCTION/REMOVAL EFFICIENCY. AND THE OVERALL REDUCTION EFFICIENCY PROVIDED BY THE 

COMBINATION OF THE CAPTURE SYSTEM AND CONTROL EQUIPMENT FOR EACH REGULATED AIR POLLUTANT 

TO BE CONTROLLED. ATTACH THE CALCULATIONS, TO THE EXTENT THEY ARE AIR EMISSIONS RELATED, ON 

WHICH THESE EFFICIENCIES WERE BASED AND LABEL AS EXHIBIT 260-4: 

al CONTROL PERFORMANCE: 

REGULATED 

AIR 

POUUTANT 

CAPTURE SYSTEM 

EFFICIENCY (%) 

CONTROL EQUIPMENT 

EFFICIENCY (%) 

OVERAU REDUCTION 

EFFICIENCY (%) 

(MIN) (TYP) (MIN) (TYP) (MIN) (TYP) 

PM 100 100 98 98 98 98 

bi. EXPLAIN ANY OTHER REQUIRED LIMITS ON CONTROL EQUIPMENT PERFORMANCE SUCH AS OUTLET CONCENTRATION. 

COOLANT TEMPERATURE. ETC.: 

b) METHOD USED TO DETERMINE EACH OF THE ABOVE EFFICIENCIES (E.G.. STACK TEST. MATERIAL BALANCE, 

MANUFACTURER'S GUARANTEE, ETC.) AND THE DATE LAST TESTED, IF APPLICABLE: 

EFFICIENCY DETERMINATION METHOD 

DATE LAST 

TESTED 

CAPTURE: 

Engineering Estimate 

CONTROL: 

Manufacturer's Guarantee 

OVERALL: 

NA 

NA 

c) REQUIRED PERFORMANCE: 

REGULATED AIR 

POUUTANT 

CAPTURE 

SYSTEM 

EFFICIENCY (%) 

CONTROL 

EQUIPMENT 

EFFICIENCY (%) 

OVERALL 

REDUCTION 

EFFICIENCY APPLICABLE RULE 

PM 35 IAC 212.321 

EXPLAIN ANY OTHER REQUIRED LIMITS ON CONTROL EQUIPMENT PERFORMANCE SUCH AS OUTLET CONCENTRATION, 

COOLANT TEMPERATURE. ETC.: 

APPLICATION PAGE 

Printed on Recycled Paper 

260-CAAPP Page 7 of 10 no 
REGULATED AIR 

POLLUTANT 

CARBON 

MONOXIDE (CO) 

LEAD 

NITROGEN 

OXIDES (NOx) 

PARTICULATE 

MATTER (PART) 

PARTICULATE 

MATTER <» 10 

MICROMETERS 

(PM10) 

SULFUR 

DIOXIDE (S02) 

VOLATILE 

ORGANIC 

MATERIAL (VOM) 

OTHER, SPECIFY: 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL 

MAXIMUM: 

TYPICAL: 

MAXIMUM: 

TYPICAL 

MAXIMUM: 

TYPICAL 

LBS PER 

HOUR 

(LBS/HR) 

• 

0.034 

0.030 

0.034 

0.030 

See Form 

220 

See Form 

220 

1ACTUAL EMISSION RATE8 

TONS PER 

YEAR : 

fTONS/YR^ 

) 

0.15 

0.06 

0.15 

0.06 

SeeFomt 

220 ' 

See Form 

220 

3OTHER 

TERMS 

3OTHER 

TERMS 

4DM 

2&4 

2&4 

2&4 

2&4 

EXAMPLE: 

PARTICULATE 

MATTER 

MAXIMUM; 

TYPICAL 

5.00 

4,00 

21.9 • 

u.4 : 

0.3 

GR/DSCF 

0.24 

GR/DSCF 

1 

4 

ALLOWABLE BY RULE EMISSION RATE 

5RATE (UNITS) 

( ) 

( ) 

( ) 

< ) 

( ) 

( ) 

£3.40 (Ibs/hr) 

( ) 

£3.40 (Ibs/hr) 

( ) 

< ) 

( ) 

( ) 

( ) 

( ) 

' ( ) 

APPLICABLE 

RULES 

35/AC 2f 2.321 

35/AC 212.321 

TONS PER 

YEAR 

(TONS/YR) 

6.0 (LBSMR) 

5.5 (LBSfliR) 

212.321 

212.321 

26.28 

19.80 

5.5 LBSMR 

Wt^^^M. 

22 

WMMimk 

IMPORTANT: ATTACH CALCULATIONS, TO THE EXTENT THEY ARE AIR EMISSIONS RELATED, ON WHICH EMISSIONS WERE DETERMINED AND LABEL AS EXHIBIT 2«X. 

}PROVIDE CONTROUED EMISSIONS (E.G.. THE EMISSIONS THAT WOULD RESULT AFTER AU CONTROL AND CAPTURE EFFICIENCIES ARE ACCOUNTED FOR). 

2PROVIDE THE EMISSION RATE THAT WIU BE USED AS A PERMIT SPECIAL CONDITION. THIS LIMIT WIU BE USED TO DETERMINE THE PERMIT FEE. 

3PLEASE PROVIDE ANY OTHER EMISSION RATE WHICH IS CC-MMONLY USED. REQUIRED BY A SPECIFIC UMITATION OR THAT WAS MEASURED (E.G. PPM. GR/DSCF. ETC.) 

JOM - DETERMINATION METHOD: 1) STACK TEST. 2) MATERIAL BALANCE, 3) STANDARD EMISSION FACTOR (AP-42 OR AIRS). 4) ENGINEERING ESTIMATE. S) SPECIAL EMISSION FACTOR (NOT AP-42 OR AIRS) 

5RATE • AUOWABLE EMISSION RATE SPECIFIED BY MOST STFUNGENT APPUCABLE RULE. 

* Only permitted emission rates for particulate matter (PM) emissions -are requested herein. The requested permitted emission rates fbr VOM emissions are Included on CAAPP Form 220. 

-3 APPLICATION PAGE _ 

Printed on Recycled Paper 

260-CAAPP page 8 of 10 

ro 
HAP INFORMATION 

NAME OF HAP 

EMITTED 

None 

2CAS 

NUMBER 

•\A.t.j n/iMnuuu o Mir\ rvLLum m cimoou/iv ii.r\jr.m*. i i\jn 

1

 ACTUAL EMISSION RATE 

MAXIMUM:; 

TYPICAL 

MAXIMUM:; 

TYPICAL: 

MAXIMUM:; 

TYPICAL ' 

MAXIMUM:! 

TYPICAL ! 

MAXIMUM:; 

TYPICAL: : 

MAXIMUM:! 

TYPICAL : 

MAXIMUM:; 

TYPICAL 

MAXIMUM:: 

TYPICAL ; 

POUNDS PER 

HOUR 

(LBS/HR) 

TONS PER 

YEAR 

(TONS/YR) 

3OTHER 

TERMS 

• 

4DM 

ALLOWABLE BY RULE 

SRATE OR STANDARD APPLICABLE 

RULE 

EXAMPLE: 

Benzene 71432 

MAXIMUM.; 

TYPICAL j 

10.0 

8.0 

r:2 -: ,-,-;W: 

0.8 

- • 2 •::.••• • 

' z..r 

98%bywt control device 

leak-tight trucks 

CFR 61 

61.302(b).(d) 

IMPORTANT: ATTACH CALCULATIONS, TO THE EXTENT THEY ARE AIR EMISSIONS RELATED, ON WHICH EMISSIONS WERE DETERMINED AND LABEL AS EXHIBIT 260-6. 

1

 PROVIDE CONTROLLED EMISSIONS (E.G., THE EMISSIONS THAT WOULD RESULT AFTER AU CONTROL AND CAPTURE EFFICIENCIES ARE ACCOUNTED FOR). 

^AS-CHEMICAL ABSTRACT SERVICE NUMBER. 

3PLEASE PROVIDE ANY OTHER EMISSION RATE WHICH IS COMMONLY USED. REQUIRED BY A SPECIFIC UMITATION OR THAT WAS MEASURED (E.G., PPM, GR/DSCF, ETC.). 

4DM - DETERMINATION METHOD: 1) STACK TEST, 2) MATERIAL BALANCE. 3) STANDARD EMISSION FACTOR (AP-42 OR AIRS. 4) ENGINEERING ESTIMATE, 5) SPECIAL EMISSION FACTOR (NOT AP-42 OR AIRS). 

5RATE • AUOWABLE EMISSION RATE OR STANDARD SPECIFIED BY MOST STRINGENT APPUCABLE RULE. 

_J3 

APPLICATION PAGE _ 

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260-CAAPP page 9 of 10 
P.74 

-•.*•• • f » 1 -sf * 

EXHAUST POINT INFORMATION' 

33) DESCRIPTION OF EXHAUST POINT (STACK. VENT. ROOF MONITOR. INDOORS. ETC.). IF THE EXHAUST POINT 

DISCHARGES INDOORS, DO NOT COMPLETE THE REMAINING ITEMS. 

Baghouse 

34) DISTANCE TO NEAREST PLANT BOUNDARY FROM EXHAUST POINT DISCHARGE (FT): 

40 

35) DISCHARGE HEIGHT ABOVE GRADE (FT): 

25 . 

36) GOOD ENGINEERING PRACTICE (GEP) HEIGHT, IF KNOWN (FT): 

10 

37) DIAMETER OF EXHAUST POINT (FT): NOTE: FOR A NON CIRCULAR EXHAUST POINT. THE DIAMETER IS 

1.128 TIMES THE SQUARE ROOT OF THE AREA. 

2.0 

38) EXIT GAS FLOW RATE 

39) EXIT GAS TEMPERATURE 

a) MAXIMUM (ACFM): 

5,750 

a) MAXIMUM (aF): 

100 

b) TYPICAL (ACFM): 

5,250 

b) TYPICAL (#F): 

80 

40) DIRECTION OF EXHAUST (VERTICAL. LATERAL. DOWNWARD): 

Vertical 

41) LIST ALL EMISSION UNITS AND CONTROL DEVICES SERVED BY THIS EXHAUST POINT: 

NAME FLOW DIAGRAM DESIGNATION 

a) Mixing Lines 

b) Resin Rooms 

o) 

d) 

e) 

0 

9) 

Lines 1, 2, 4-7, 9 8.10 

Resin Rooms 

42) WHAT PERCENTAGE OF THE CONTROL EQUIPMENT EMISSIONS ARE BEING DUCTED TO THIS 

EXHAUST POINT (%)? 

100 

43) IF THE PERCENTAGE OF THE CONTROL EQUIPMENT EMISSIONS BEING DU 

100%, THEN EXPLAIN WHERE THE REMAINING EMISSIONS ARE BEING EXH 

NA 

CTED TO THE EXHAUST POINT IS NOT 

AUSTFD TOTHE FOLLOWING INFORMATION NEED ONLY BE SUPPUED IF READILY AVAILABLE. 

44a) LATITUDE: 

41:55:13.0000 

45) UTM ZONE: 

NA 

b) LONGITUDE: 

88:20:02.0000 

b) UTM VERTICAL (KM): 

NA 

* Information only for the exhaust point for p« 

Mixing Lines and two Resin Rooms. Inform, 

from these emission units is included on CAAI 

APPLICATION 

Printed on Re 

260-C 

c) UTM HORIZONTAL (KM): 

NA 

irticulate matter (PM) emissions from the eight 

ition for the exhaust point for VOM emissions 

»P Form 220. 

PAGE 

jcycled Paper 

AAPP Page 10 of 10 

!

 — 

q3 
P.75 

BAGHOUSE 

EXHIBITS 260-5 & 260-6 CALCULATION SUMMARY 

Maximum input rate of PM to Baghouse : 1.71 lbs/hr 

Baghouse control efficiency: 98% (manufacturer's guarantee) 

Maximum PM emissions = (1.71 lbs/hr) x (0.02) = 0.034 lbs/hr 

Typical input rate of PM to Baghouse: 1.51 lbs/hr 

Baghouse control efficiency: 98% (manufacturer's guarantee) 

Typical PM emissions = (1.51 lbs/hr) x (0.02) = 0.030 lbs/fir 

S034-CA\bagexib.doc AI R SOLUTIONS, INC. 
P.76 

ILLINOIS ENVIRONMENTAL PROTECTION AGENCY 

DIVISION OF AIR POLLUTION CONTROL - PERMIT SECTION 

P.O. BOX 19506 

SPRINGFIELD. ILLINOIS 62794-9506 

FOR APPLICANTS USE 

Revision #: 

Date: 

Page 

/ / 

of 

Source Designation: 

SUPPLEMENTAL FORM 

AIR POLLUTION CONTROL 

EQUIPMENT 

FILTER (260C) 

- * FWAGENCYVSEOmX^r •& V* I & 

ID NUMBER: 

CONTROL EQUIPMENT #: 

DATE: 

DATA AND INFORMATION 

1) FLOW DIAGRAM DESIGNATION OF FILTER: 

Baghouse 

2) FILTER CONFIGURATION 

L J OPEN PRESSURE L J CLOSED PRESSURE W CLOSED SUCTION 

L J OTHER. SPECIFY: 

3) DESCRIBE FILTER MATERIAL: 

Cotton Socks 

4) FILTERING AREA 

(SQUARE FEET): 

420 

5) AIR TO CLOTH RATIO 

(FEET/MIN): 

13.7:1 

6) CLEANING METHOD 

W SHAKER L J REVERSE AIR 

L J OTHER. SPECIFY: 

7) NORMAL RANGE OF 

PRESSURE DROP: 2 TO 5 

8a) INLET EMISSION STREAM PARAMETERS: 

MOISTURE CONTENT (% BY VOLUME): 

PARTICULATE INLET LOADING (GRAINS/SCF): 

b) MEAN PARTICLE DIAMETER (MICRONS): 

>10 

L J PULSE AIR L J PULSE JET 

(INCH H20) 

MAX 

4 

0.035 

TYPICAL 

2 

0.034 

THIS AGENCY IS AUTHORIZED TO REQUIRE THIS INFORMATION UNDER ILLINOIS REVISED STATUTES, 1991. AS AMENDED 1992. 

CHAPTER 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 APPLICATION BEING DENIED. THIS FORM HAS BEEN 

APPROVED BY THE FORMS MANAGEMENT CENTER. 

APPLICATION PAGE 

FOR APPLICANTS USE 

Printed on Recycled Paper 

260C-CAAPP Page 1 of 2 15 
P.77 

9) FILTER OPERATING PARAMETERS: 

INLET FLOW RATE (SCFM): 

INLET GAS TEMPERATURE (DEGREES 

FAHRENHEIT): 

# 

EFFICIENCY (PM REDUCTION): 

EFFICIENCY (PM10 REDUCTION): 

DURING MAXIMUM 

OPERATION OF 

FEEDING UNIT(S) 

5,750 

100 

98 

98 

(%) 

(%) 

DURING TYPICAL 

OPERATION OF 

FEEDING UNIT(S) 

5,250 

80 

98 

98 

(%) 

(%) 

10) HOW IS FILTER MONITORED 

FOR INDICATIONS OF 

DETERIORATION 

(E.G., BROKEN BAGS)? 

LJ CONTINUOUS LJ 

OPACITY 

PRESSURE 

DROP 

D ALARMS-AUDIBLE 

TO PROCESS 

OPERATOR 

VISUAL OPACITY READINGS. FREQUENCY: 

o OTHER, SPECIFY: 

* Non-compliance will be immediately visible and recorded, and corrective action will be 

appropriately taken. 

11) DESCRIBE ANY RECORDING DEVICE AND FREQUENCY OF LOG ENTRIES: 

NA 

12) DESCRIBE ANY FILTER SEEDING BEING PERFORMED: 

NA 

APPLICATION PAGE 

Printed on Recycled Paper 

260C-CAAPP Page 2 of 2 

%