p. 1


# OAR Box 

# 1413 Prepped by Ollie Stewart



# Document

Number: 

# 56 ) 11-1-5 6 Docket Number: 

# A-94-5 2

Printed 7/9/2008 3:11:22 PM

Sheet 56 of 114P. 2



# \Composites Corp. A 945 ' II-I-^ 6

December 5 , 199 5

Mr . Donal d Sutton IEP A Divisio no f Ai r PollutionContro l Permi t Sectio

n 220 0 Churchil l Rd . Springfield , I L 6270 6 RE : Join t Construction/Operating Permi t Application 

# m n 

# \m
EPAAl H DOCKEV

f



## Dear Mr . Sutton : Applie d Composite s Corporationrespectfull y submit s th

e enclose

d applicatio

nfo r a Join t Construction/Operatin g Permi t fo

r th e installatio

no f Polyurethan e Foa m InjectionEquipment . Th e equipmen t wil l b

e use d t o injec t water-blow nfoa m insulatio

nint o close d cavitie s o f molde d fiberglas s reinforced plasti c articles . Th e installatio

nan d us e o f th

e foa m injectio

nequipmen t wil l no t resul t i

na significan t increas e i nplan t VO

M emission s a s explained i

nAppendi xA

o f th e application . Pleas e contac t m

e at (708 ) 584-313 0 i f yo u have an

y question s or requir e furthe r information .

Terr y Ha(w/tre e HSEQ Coordinator .

33 3 Nort h Sixt h Stree t• St . Charles . Illinoi s 6017 4 • 70 8 / 584- 3 1 3 0 • Fax : 70 8 / 584-065 9P_3
_ " I 

## M



# APPLIE D COMPOSITES , CORP , Applicatio n Fo r Join t Constructio n An d Operatin g Permi t
Submitte d By : 

## Applie d Composites , Corp . 33 3 NorthSixthSt . St . Charles , I L 6017 4

Prepare d By : Terr y Hawtre e HSEQ Coordinato r Applie d Composites , Corp .

Decembe r 5 , 199 5

^

### . . __ _

### PA_



# TABL E O F CONTENT S

SECTIO N Cove rLette r MD I Foa m Injectio n 1 

## AP C 20 0 AP C 22 0 MD I Foa

m Injectio

nEquipmen t Exhibi t B Appendi xA Proces s Schematic s Facilit y

Diagra m



# 3P. 5



# SECTIO N 1 MD I FOA M INJECTIO N



# MP. 6



# AP C 20 0



# sP. 7


### STAT E O F ILUNOI S ENVIRONMENTA L PROTECTIO N AGENCY DIVISIO N O F AI R POLLUTIO N CONTRO L 2200 CHURCHIL L ROA D SPRINGFIELD , ILLINOI S 62794-927 6 APPUCATIO N FOR PERMIT W Q D CONSTRUC TQ 0 OPERAT E NAM E O F EQUIPMEN TT O B E CONSTRUCTE D O R OPERATE D 

### MD I Foa m Injectio n .(8 ) LD . NO . PERMI TNO . OATE FO R AGENC YUS E ONL

Y

la . NAMEOFOWNER : Applie d Composites , Corp . l b STREE

TADDRES S O F OWNER - „ „ „ , , L „ 33 3 Nort h 6t h Stree t l a CITYOFOWNER : ^ charlej _ Id . STATE O F OWNER :

Illinoi s 1e . ZI P CODE : 6017 4 2a . 2b . 2 c 2d . NAM E O F OPERATOR : gAM E STREE TADDRESS O F OPERATOR : CIT YO F OPERATOR : STAT E O F OPERATOR : 2e . ZI P CODE :

la . NAM E O F CORPORAT E DIVISIO N O R PLANT :

Applie d Composites , Corp . l c CIT YO F EMISSIO N SOURCE : S t . Charle s 3d . LOCATE D WITHI N CIT Y UMITS : £X]YE S 1 IN O 3b . STREETADDRESS O F EMISSIO N SOURCE : 33 3 Nort h 6t h Stree t 3e . TOWNSHIP : St.-Charle s 3( . COUNTY : Kan e 3g . ZI P CODE :



### 6017 4

. AL L CORRESPONDENC E TO : (TITL E ANO/O R NAM E O F INDIVIDUAL ) Joh n ,T . Pnnis . V : P. . Operation s 5 . TELEPHON E NUMBE R FO R AGENC YTO CALL : (708 ) 584-313 0

. ADDRES

S FO R CORRESPONDENCE : (CHEC KONL YONE ) I X| OWNE R 1 I OPERATO R I I EMISSIO N SOURC E 7 . YOU R DESIGNATIO N FO R THI S APPUCATION* , 

### MD I

TH E UNDERSIGNE D HEREB YMAKE S APPLICATIO N FO R A PERMI TAN O CER~nF~ES THA TTH E STATEMENT S CONTAINE D HEREI N AR E TRU E AN D CORRECT . AN O FURTHE R CERTIFIE S THA TAL L PREVIOUSL YSUBMITTE D MFORMATIO N REFERENCE D I N THI S APPUCATIO N REMAIN S TRUE . CORREC TAN D CURRENT . B YAFFIXIN G HI S SIGNATUR E HERET O H E FURTHE R CERTFE S THA TH E I S AUTHORIZE D T O EXECUT E THI S APPLICATION .


### Joh n OAT E B Y SIGNATUR E OAT E TYPE D O R PRINTE D NAM E O F StGNE f 

### V . P . Operation s TYPE D O R PRINTE D NAM E O F SIGNE R TITL E O F SIGNE R TITL E O F SIGNE R J THI S FOR M I S T O PROVID E TH E AGENC YWIT H GENERA L INFORMATIO N ABOUTTH E EQUIPMEN TT O B E CONSTRUCTE D O R OPERATED . THI S FOR M MAYB E USE D T O REQUES TA CONSTRUCTIO N PERMIT . A N OPERATIN G PERMIT . A CONSTRUCTIO N O R OPERATIN G PERMIT . ) ENTE R TH E GENERI C NAM E O F TH E EQUIPMEN TT O B E CONSTRUCTE D O R OPERATED . THI S NAM E Wtti . APPEA R O N TH E PERMI TWHIC H MA YB E ISSUE D PURSUAN TT O THI S APPUCATION . THI S FOR M MUS TB E ACCOMPANIE D B YOTHE R APPLICABL E FORM S AN O INFORMATION . PROVID E A DESIGNATIO N I N ITE M 7 ABOV E WHIC H YO U WOUL D LIK E TH E AGENC YT O US E FO R IDENTIFICA-nO N O F YOU R EQUIPMENT . YOU R DESIGNATIO N WOJ . B E REFERENCE D I N CORRESPONDENC E FRO M THI S AGENC YRELATIV E T O THI S APPUCATION . YOU R DESIGNATIO N MUS TNO T EXCEE D TE N (10 ) CHARACTERS . J THI S APPLICATIO N MUS TB E SIGNE D I N ACCORDANC E WIT H 3 5 OJL . ADM . CCO E 201.1S 4 O R 201.15 9 WHIC H STATES : "AL L APPLICATION S AN D SUPPLE MENT S THERET O SHAL L B E SIGNE D B YTH E OWNE R AN O OPERATO R O F TH E EMISSIO N SOURC E O R AI R POLLUTIO N CONTRO L EQUIPMENT . O R T>€l f AUTHORIZE D AGENT . AN O SHAL L B E ACCOMPANIE D B YEVIDENC E O F AUTHORITYT O SIG N TH E APPLCATION. - I F T> £ ONWE R O R OPERATO R I S A CORPORATION . SUC H CORPORATIO N MUS THAV E O N FIL E WrT H TH E AGENC YA CERTtFtE D COP YO F A RESOU * TON O F TH E CORPORATION' S BOAR D O F DIRECTOR S AUTHORIZIN G TH E PERSON S SIGNIN G THI S APPLICATIO N T O CAUS E OR-ALLO W TH E CON STRUCTIO N O R OPERATIO N O F TH E EQUIPMEN TT O B E COVERE D B YTH E PERMIT . .32-023 8 Printraat 

### .( P PAG E 1 O F 2P. 8

DOE S THI S APPUCATIO N CONTAI N A PLO TPLAN/MAP : 

## P H YE S 

## I I N

O i r A PLO TPLAN/MA P HA S PREVIOUSL YBEE N SUBMITTED . SPECIFY : AGENC YI.D . NUMBE R 08948 3 A A F APPUCATIO N NUMBE R 

### 9305006 6 I S IH E APPROXIMAT E SIZ E O F APPUCANT S PREMISE S LES S THA N 1 ACRE ? I I YE S ' [ X| MO : SPECIFY . 

### 4 0 ACRES DOE S THI S APPUCATIO N CONTAI N A PROCES S FLO W DIAGRAM(S ) THA TACCURATELYAN D CLEARL YREPRESENT S CURREN T PRACTICE . PHYE S | | N O L WA S AN YEQUIPMENT . COVERE D THI S APPUCATION . OWNE D I CONTRACTE D FOR . B YTH E APPUCAN TPRIO R T O APRI L 14.1972 : 11b . HA S AN YEQUIPMENT . COVERE D B YTHI S APPUC A TION . NOTPREVIOUSL YRECEIVE D A N OPERATIN G 

# • YE S PERMIT : X NO 

# ODYE S • N O

" F "YES " ATTAC H A N ADDITIONA L SHEET . EXHIBITA . THAT : (a) LIST

S O R DESCRIBE S TH E EQUIPMENT (b) STATE S WHETHE R TH E EQUIPMEN TWA S t N COMPLIANC E WIT H TH E RULE S AN D REGULATION S GOVERNIN G TH E CONTRO L O F AI R POLLUTIO N PRIO R T O APR ! 4.107 2 F -YES" . ATTAC H A N ADOITIONAl . SHEET . EXHIBI TB. THAT : 

### M 0 » (e ) LIST

S O R DESCRIBE S TH E EQUIPMEN T STATES WHETHE R TH E EOUIPMEN T (I ) I S ORIGINA L O R ADOmONA L EQUIPMENT M REPLACES EXISTIN G EQUIPMENT . O R (B) MOOFE S EXISTIN G EQUIPMEN T PROVIDES TH E ANTICIPATE D O R ACTUAL OATE S O F TH E COMMENCEMEN T O F CONSTRUCTIO N AND TH E START-U P O F TH E EOUIPMEN T I F THI S APPUCATIO N INCORPORATE S B YREFERENC E A PREVIOUSL YGRANTE D PERMITfS) . HA S FOR M APC-210 . "DATA AN D INFORMATION—JNCORPORATTO N B YREFERENCE * BEE N COMPLETED . N O 13 . DOE S TH E STARTU P O F A N EMISSIO N SOURC E COVERE D B YTHI S APPUCATIO N PRODUC E AI R CONTAMINAN TEMISSIO N I N EXCES S O F APPUCABL E STANDARDS : 

# •YE S 

# 0 0 N O I F -YES. * HA S FOR M APC-203 . "OPERATIO N DURIN G STARTUP * BEE N COMPLETE D FO R THI S SOURCE . 

## I I YE S 

## C N

O 14 . DOE S THI S APPUCATIO N REQUES TPERMISSIO N T O OPREAT E A N EMISSIO N SOURC E DURIN G MALFUNCTION S O R BREAKDOWNS : 

### I lYE S I XI N O I F "YES. " HA S FOR M APC-204 . -OPERATIO N DURIN G MALFUNCTIO N AN D BREAKDOWN * BEE N COMPLETE D FO R THI S SOURC E 

## • VE S 

# (—] N

O 15 . I S A N EMISSIO N SOURC E COVERE D B YTHI S APPUCATIO N SUBJEC TT O A FUTUR E COMPLIANC E OATE : I IV-E S I XIM P I F *YES. * HA S FOR M APC-202 . "COMPLIANC E PROGRA M & PROJEC TCOMPLETIO N SCHEDULE. * BEE N COMPLETE D FO R IM S SOURCE : 

### I I YE S N

O 16 . DOE S TH E FACIUT YCOVERE D B YTHI S APPUCATIO N REQUIR E A N EPISOD E ACTIO N PLA N (REFE R T O GUIDEUNE S FO R EPISOD E ACTIO N PLANS) : 

### I I YE S | X| N O US TAN D IDENTIF YAL L FORMS . EXHIBITS . AN D OTHE R INFORMATIO N SUBMITTE D A S PAR TO F THI S APPUCATION . INCLUD E TH E PAG E NUMBER S O F EAC H ITE M (ATTAC H ADDITIONA L SHEET S I F NECESSARY) : 

### SE E TABL E O F CONTENT S

TOTA L NUMBE R O F PAGE S 2-023 8 inn na. 

# n PAGE20 F 2P. 9



# AP C 22 0



# flP.1 0

STAT E O f lUINOI S ENVIRONMENTAL PROTECTIO N AGENC Y DIVISIO N O F AI

KPOLLUTIO

N CONTROL 220 0 CHURCHIL

L ROA 0 SPRINGFiaO , ILLINOI S 4270 6 JhnAq*rKt*»>altiixUa*van*i^ltinMotmttioniiiia«mixeat

Revised SututM.1979 . Chxx->'11 1 1*7 . Sactio n 1039 . Ooctotwnt o(**MWo-m-r___n__f«iui-*_di-n-_«r*^«tS«ctio-v ^ preven t tt wfor m tarn bein g praoma d an d coul d resul t i n TO W appGcatio n boe- g denie d Th B lor m ha * bee n approved b y the f orm t Manage-nan f Center .

•DAT A AN O INFORMATIO N PROCESS EMISSIO N SOURC E

THI S INFORMATIO N FOR M I S T O B E COMPLETE

D FORA N EMISSIO N SOURC E OTHE RTHAN A FUE

L COMBUSTIO N EMISSIO N SOURC E O tA N INCINERATOR. A FUE L COMBUSTIO N EMISSIO N SOURCE IS A FURNACE. BOILER . O RSIMILA

REQUIPMENT USE O PRIMARIL Y FO RPRO0UCIN G ICA T O RPOWE RBY INOIREC

T HEA T TRANSFER . A N INCINERATORI S A N APPARATU

S I N WHIC

H REFUS E I S BURNED . 1 . NAM

E O f PLAN T OWNER : 

### Applie d Composites , Corpt . 3 . STREE

T ADDRESS O f

EMISSIO N SOURCE : 

### 33 3 Nort h 6t h Stree t 2 . NAM E O F CORPORAT

E DIVISIO N ORPLAN T (I F 01FFEREN

T FRO M OWNER) : i. CIT Y O F EMISSIO N SOURU : 

### St . Charle s

s . 7 . 10 . 11 . 12 . M . GENERAL INFORMATIO N NAM E O F PROCESS : 

### MD I Foa m Injectio n EMISSIO N SOURC E EOUIPMEN TMANUFACTURER :



### * * * 6 . NAM E O F EMISSIO N SOURC E EQUIPMENT- . SAM E B . MODE L NUMBER : 

### * * * 9 . SERIA L NUMBER : 

### * * * FLOW DIACCA M SCS'CNAflONiS } O F CMCSiO N -riJUKtt : 

### Buildin g 2 5 IDENTITY'S ) O F AN YSIMILA R SOURCE(S ) ATTH E PLAN TO R PREMISE S NOTCOWE D B YTH E FOR M (I F TH E SOURC E I S COVERE D B YANOTHE R APPLICATION , IDENTIF YTH E APPLICATION) : AVERAG E OPERATIN G TIM E O F EMISSIO N SOURCE : 2 4 HRS/DAY5 QAY5AH C 4 8 WKS/Y R 13 . MAXIMU M OPERATIN G TIM E O F EMISSIO N SOURCE : 2 4 HRS/DAY7 OAYS/W K5 2 WI3/Y R PERCEN TO F ANNUA L THROUGHPUT : OEC-FE B 3 5 % MAC-MA Y2 5 % JUN-AU G 1 5 X SEPT-NO V 2 5 %

INSTRUCTION S

4 . 5 . COMPLET

E TH E ABOV E IDENTIFICATIO N AN O GENERA L INFORMATIO

N SECTION . COMPLET

E TH E RA W MATERIAL

. PRODUCT , WAST

E MATERIAL, AN O FUE L USAG E SECTION S FO

RTH E PARTICULA

RSOURC

E EQUIPMENT . COMPOSITION S O F MATERIAL S MUS T B

E SUFFICIENTLY DETAJLEDTOAIXO W DETERMINATION O F TH E NATUR

E AN O OUANTITY O F POTENTIA L EMISSIONS . I N PARTICULAR , TH E COMPOSITIO N O F PAINTS , INKS , ETC. . AN D AN Y SOLVENT S MUS T B E FUU Y DCTA*LEO

. EMISSION AN O EXHAUST POIN T INFORMATIO N MUS T B E COMPLETED

, UN.ES S EMISSION S AR E EXHAUSTE

D THROUG

H A KPOLLUTION CONTROL EQUIPMENT . OPERATIN

G TIM E AN O CERTAI

N OTHE RITEM S REQUIR

E BOT H AVERAG

E AN O MAXIMU

M VALUES . FO RGENERA

L INFORMATIO N REFE RT O *GEN f

kA L INSTRUCTIONS K * PERMI T ApftlCATIONS, " APC-201 .

DEFINITION S AVERAG E - TH E VALU E THA T SUMMARIZES O RREPRESENT S TH E GENERA

L CONDITIO N OF TH

E EMISSIO N SOURCE , O KTH E GENEfAL STAT

E O f PRODUCTION O f

VH E EMlSSlO N SOURCE . SPECIFICALLY : AVERAG E OPERATING TIM

E -ACTUA L TOTA

L HOUR S O F OPERATIO

N fO RTH E PRECEDIN

G TWELV

E MONT H PERIOD . AVERAG E RAT E - ACTUA

L TOTA L QUANTIT Y O f

-MATERIAL - PO

RTH E PRECEDIN

G TWELV

E MONT H PERIO0 . DIVIDE D B Y TH E AVERAG

E OPERATING TIME . AVERAG E OPERATION - OPERATIO N TYPICA L O f TH E PRECEDIN

G TWE-.V E MONT H PERIOO , A S REPRESENTE D B Y AVERAG

E OPERATING TIM

E AN D AVERAGE RATES . M-.XII-HJ

M - TH E GREATES

T VALU E ATTAINABLE ORATTAINE O FRO M TH E EMISSIO

N SOURCE . O

RTH E PERIO O O PGREATES

T O RUTMOS T PRODUCTION O f

TH E EMI&ld N SOURCE . SPECIFICALLY : MAXIMU M OPERATING TIM

E - GREATEST EXPECTE D TOTA L HOUR S O F OPERATION

S FO RAN Y TWELV

E MONT H PERIOO . MAXIMU M RAH • GREATES

T QUANTIT Y O F -MATERIAL " EXPECTE D PE RANY ON E HOU

RO F OPERATION . MAXIMU M OPERATION - GREATES T EXPECTE

D OPERATION , A S REPRESENTE D B Y MAXIMU

M OPERATIN G TIM

E AN D MAXIMU

M RATES. I I S32-02S O »PC 22 0 «•*» • 

### i/2?/"** * Se e

### Exhibi tB fo rEquipmen t Printe d o

n Recycled Pape r PAG E I OF 3 090-00 6 

# 1P.1 1

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. 

### DiphenyImethan e Diisocyanate 2, 

### ° - (MDI ) 22o
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. AVERAG E RAT E PE RIDENTICA L SOURC E 

### 170,00 0 Y

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### 540,00 0 Yr LBJQ K LB/H R LB/HR LB/H R LB/H R

PRODUC T INFORMATIO N NAM E O F PRODUC T 

### "• * MD I Foa m Io . 2o . Jo . 4a . AVERAG E RAT E PE RIDENTICA L SOURC E b . « 

### 170,00 0 LB£

K b . LB/H R b . LB/H R b . LB/H R b . LB/H R MAXIMU M RAT E PE RIDENTICA L SOURC E 

### 540,00 0 LB/M

E LB/H R LB/H R LB/H R LB/H R

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### Reacte d NAM E O F WAST E MATERIA L



### MD I WAST E MATERIA L INFORMATIO N AVERAG E RAT E PE R IDENTICA L SOURC E KJ- LB/H R b
. LB/H R b
. LB/H R b
. LB/H R b
. LB/H R MAXIMU M RAT E PE R IDENTICA L SOURC E 

### «•
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«• -" • LB/H R LB/H R LB/H 2 LB/H R U/K 8

•FUE L USAG E INFORMATIO N { FUE L USE O p . NATURA L GA S D OTHE R GA S D OI L • COA L D OTHE R D TYP E b
.

-ERAG E FIRIN G RAT

E PER IDENTICA L SOURCE : BTU/H R HEATCONTEN Tj c . 100 0 BTU/SC F •TU/SC 7 BTU.'GA t • tTUA B EIU.- U • e . MAXIMU M FIRIN G RAT E PE R IOENTICA L SOURCE : :1V,'-- 5 HI S SECTIO N I S T O B E COMPLETE O FO R AN Y FUE L USE D DIRECTL YI N TH E PROCES

S EMISSIO N SOURCE
. E.G
. GA S I N A DRYER , O R COA L i** - IEL TFURNACE
.
C-22 0 

# 1 0 PAC f
. c-P.1 2

•EMISSIO N INFORMATIO N 5 1 . NUMBE R O F IDENTICA L SOURCE S (DESCRIB E AS REQUIRED) :

CONTAMINAN T ARTICULAT E 4ATTE R ARBO N IONOXID E IITROGE N OCIDE S >RGAN1 C ATERIA L JLFU R IOXID E OTHE R PECIFY)

ONTAMINAN T RTICULAT E •.TH R JtBO N 3NOX1D E TROGE' N CIDE S GANI C .TERIA L _RJ R 5X 1 DE >THER ECIFY ) J AVERAG E OPERATIO N

CONCENTRATIO N O R EMISSIO N RATE PE R IDENTICA L SOURC E '52o . GR/SC F 53o . pP M (VOL ) 5 4 0 •PP M (VOL ) S- 5 " * * * * PP M (VOL ) 5 6 0 - PP M (VOL ) 57 °- PP M (VOL ) b . LB/H R

b . LB/H R b . LB/H R b - * * * LB/H R b . LB/H R b . LB/H R METHO D USE O T O DETERMIN E CONCENTRATIO N O R EMISSIO N RATE c . c . c .
e - * * * c . c . MAXIMU M OPERATIO N CONCENTRATIO N O R EMISSIO N RATE PE R IDENTICA L SOURC E 58a . GR/SC F 5 9 0 * PP M (VOL ) t0 °- PP M (VOL ) 61a . * * * fP « (VOL ) 62o . pp M (VOL ) *-*> - PP M (VOL ) b . LB/H R

b . LB/H R b . LB/H R b . 

### * * * LB/H R b . LB/H R b . LB/H R METHO D USE D T O DETERMIN E CONCENTRATIO N O R EMISSIO N RATE c . c . e .
C ' * * *

•c . c . EM S 5 2 THROUG H 6 3 NEE D NO TB E COMPLETE D I F EMISSION S AR E EXHAUSTE D THROUG H AI R POLLUTIO N CONTRO L EQUIPMENT . -tTHER " CONTAMINAN TSHOUL D BE USE D FO R A N AI R CONTAMINAN TNO TSPECIFICALL YNAME D ABOVE . POSSIBL E OTHE R CONTAMINANT S « E ASBESTOS , BERYLLIUM , MERCURY , VINY L CHLORIDE , LEAD , ETC . •"EXHAUS TPOIN TINFORMATIO N I . aO W DIAGRA M DESIGNATION'S ) O F EXHAUSTPOINT : i . DESCRIPTIO N O F EXHAUS TPOIN T(LOCATIO N I N RELATIO N T O BUtt .

. EXI THEIGH TABOV E GRADE :

. GREATES

THEIGH TO F NEARB YBUILDINGS : F T AVERAG E OPERATIO N

. EXI TGA S TEMPERATURE : ° F

. GA S RO W RATE THROUG H EAC H EXIT : ACF M 67 . EXI TOIAMETER : 69 . EXI TDISTANC E FRO M NEARESTPLAN TBOUNOARY :
MAXIMU M OPERATIO N 72 . EXI TGA S TEMPERATURE : 73 . GA S RO W RAT E THROUG H EAC H EAC H EXIT : F T


### °f AO M THI S SECTIO N SHOUL D NO TB E COMPLETE D I F EMISSION S AR E EXHAUSTE D THROUG H AI R POUUTIO N CONTRO L EQUIPMENT . 

### * * * Se e Appendi x A fo r Emissio n an dExhaus t Poin t Information .

-22 0 

# U o*/r t 1 r* rP.1 3



# EXHIBI TB

[T-

### P. M



## EXHIBI T B THI S APPLICATIO

N FO RA JOIN T CONSTRUCTIO

N AN D OPERATIN

GPERMI T I S FO RINSTALLATIO

N O F EQUIPMEN

T ASSOCIATED WITH A POLYURETHAN

E FOA M INJECTIO

N PROCESS . SPECIFICALLY , TH E EQUIPMEN T CONSIST S O

F TW O PORTABLE , SUPPLIER-OWNED BUL KSTORAG

E TANK S WHICH AR

E FILLE D WITH A TWO-PART POLYURETHAN E SYSTE

M AN D DISPENSIN

GEQUIPMEN

T WHICH CONSIST S OF A

MIXIN GGU N UTILIZIN

GWATE RA S TH E BLOWIN

GAGENT . TH E MATERIAL , DIPHENYLMETHAN E DIISOCYANAT E (MDI) , I S SUPPLIE D B Y THE VENDO

RI N TH E REUSABL E STORAG E TANKS . THE TW

O PART S AR

E PUMPE D VI A A CLOSED-LOO P SYSTE M T O TH E MIXIN GGU N WHER E TH

E PART S ARE COMBINED WIT H WATE RAN D INJECTE

D INT O CLOSED CAVITIE S O F VARIOU S FIBERGLAS S REINFORCE D PLASTI C ARTICLES . THE COMBINED MATERIAL S IMMEDIATEL

YAN D COMPLETELYREACT T O FOR M A N INSULATIN

GFOAM . THI S SYSTE

M I S A WATE RBLOW N SYSTE M WHICH DOE S NO T REQUIR E TH E US E O F CLEAN-UP SOLVENT S O RVOMS . EMPT

YSTORAG

E TANK S AR

E RETURNE

D TO TH E SUPPLIE

RFO RREFILLING .



# | 3P.1 5

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### PRELIMINAR Y DAT A SHEE T 

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nb e han d mixed , e d with . Isofroth * equipmen t withai r nucleationor pumpe d wit h uipmen t dispensin g a t 1: 1 b y volume . Thi s foa

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## Les s Tha

n3 % Chang e Les s Tha

n2 % Chang e N o Change
CLE RMAKE S N

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RWARRANTY , EXPRES S O RIMPLIED , INCLUDIN G WX O F MERCHANTABILIT YO RTHA T THE MERCHANDIS E I S SUITABLE FO RA RTICULA RPURPOS E O RTHA

T TH E MATERIA

L DOE S NO T CONTAI N HAZARDOU S BSTANCES . VfTEK/IP I tlanti cDrive , Uni t#5 , Wes tChicago . I L 60185 o 708/293-929 9 o FA X 708/293-936 3 

## 07/9 3 

# 4 -P.1 6



# APPENDI XA



# ISP.1 7



## APPENDI XA
EMISSIO N ESTIMATE S FO

RTHE PROPOSED EQUIPMEN T ARE BASED O

N SUPPLIE

R INFORMATION . A S TH E POLYURETHAN E COMPONENT S AR

E CONTAINED I

N A SUPPLIE

R MAINTAINED CLOSED-LOO P SYSTEM , WATE RI S USED A S TH E BLOWIN GAGENT , AN D TH E CHEMICA

L REACTIO

N RAPIDL YTAKE S PLACE I

N A CLOSED CAVITY , POTENTIA

L VO M EMISSION S ARE CONSIDERED NEGLIGIBLE . AVERAGE OPERATIO

N THE EQUIPMEN

T WIL L B

E USED O

N A N INTERMITTEN

T BASI S FO

RSPECIFI C ARTICLES . WHIL E OPERATIONAL , TH E EQUIPMEN

T WILL RU

N O N A CYCLICA

L BASI S DEPENDEN

T O N TH E THROUGHPU

T O F THE ARTICL E BEIN GPRODUCED . THE PRODUCTIO

N LIN E RUNS A

N AVERAG E O F 2 4 HOUR S PE

RDAY , 5 DAY S PE

R WEEK . I T I S ESTIMATE

D THA T I N THE INITIA

L YEA RO F PRODUCTIO

N (1996-97) , APPROXIMATEL

Y170,00 0 LB S O F POLYURETHAN

E MATERIA

L WILL B

E PROCESSED . MAXIMU M THEORETICA

L EMISSION S BASED O N SUPPLIE

RDAT A (SEE ATTACHED DAT A SHEET) , THERE WILL B E NEGLIGIBL E EMISSION S FRO M THI S PROCESS . EXHAUS T POIN

T INFORMATIO

N BUILDIN G#2 5 WHER E THE PROPOSED PRES S WILL BE INSTALLE D DOE S NO T HAV E A FORMA L VENTILATIO

N SYSTE M (i.e. , DUCTWORK , MAKE-U P AIR , STACKS,ETC.) . FUGITIV E EMISSIONS,I F ANY , WILLBEEXHAUSTE D THROUG H BUILDIN

GWINDOWS , DOORS , AN D HYDRAULI C EQUIPMEN T FAN S LOCATED ABOV

E TH E PRESS . BUILDIN G#2 5 I S OPE

N INSID E WITH A

ROO F HEIGH T O

F 3 0 FEET .



# I tP.1 8



# FACILIT YDIAGRA

M



# nP.1 9



# ••^TIIIIFIP I

IIIIIII I I m I



# ISP.2 0



## / ' » 

# 1 ° 

# + + 

# •Jl DI O \ 

# + +

+ 

# t

+ 

# + +

I 

# 8 3 3(7 5 

# + + 

# A o r n > z : CT 

# D


# nn . J ]



# i lP.2 1



# PROCES S SCHEMATIC S

Z- OP.2 2



### RA H MATERIAL S SM C MANUFACTUR

E

SCRA P-4 - 

# I

SCAL E

TIO N HEA T 

# I APPLIED COMPOSITE S PROCES S FLO

W



# I SCAL E

PRES S PRESSUR E
COHVEVO R

SCRA P FINIS H 

# 1
PACK 

# I CUSTOMER -* - SCRA P



# "2- 1P.2 3



## APPENDI

X E ALTERNATIV

E OPERATIN G SCENARIOS



# -2-2 -P.2 4



## ALTERNATIV E OPERATIN G SCENARIO S
I . Compound Preparatio n an d Maturatio n Are

a Applied Composite s has th e capabilit y t o manufactur

e both shee tmolding compoun d (SMC ) o rthickmoldin g compound (TMC) . However , Applie d Composites ' mixin g operation ca

n only supporton e operation a tatime . Th e SM C machine mustb e shu tdow n in ordert o us e th e TM C machine. The emissions are th e sam e fo reither operation .

n . Moldin g Presse s Applied Composites ' emission s i n th e molding pres s are aare limite d b y th e amoun t o f SM C o rTM C tha

tApplied Composites ' i s capable o f producing . Applie d Composite s may , however , deem itnecessar y t o purchas e SM C o rTM C from anothe rfacility , thereby increasin g th e potentia

l emissions . Applie d Composite s ha s requeste d thatth e penni t establis h afederally-enforceabl e emission s ca p o f 99. 9 ton s pe ryear . Eve n with th e additiona l SM C o rTM C purchased , Applie d composite s will notexcee d thi s cap .

m . MD I Foa

m Injectio n Applied Composite s has applied forapennitt o construc tand operate aMethyl Dilsocyanat e (MDI ) foa

m injectio n operatio n in whic h insulatin

g foam wil l b e injecte d int o variou s FR

Pproducts . A s se tfort

h herein , thi s operation i s a n insignificantemission s activity . Applied Composite s has requeste d afederall y enforceable emission s cap fo rth e facility . Thi s operatio n will no tcaus e Applied Composites t o excee d this limit.



# ^ 3P.2 5



## APPENDI

X D INSIGND7ICAN

T SOURCE DOCUMENTATION



# 2 7

### 1994 TAN KSUMMARY 1994 TOTAL S

STYREN E ( 104.1 6 (9. 9 lb/ga l resi n @ 0. 1 p s S-944 RESI N TAN K1 S-944 RESI N TAN K2 S-9S 9 RESI N TAN K3



## 1 Capacit y

(gals ) 6,00 0 6.00 0 6,00 0 S Facto r

0. 6 0. 6 0. 6 % Volatil e 32.5 0 32.5 0 38.0 0 THRUPU T

(gals ) 132,602.6 1 131,033.5 4 22,393.9 8 286,030.1 3 VO M LOS S

(lbs ) 6.1 7 6.1 0 1.22 13.5 0

T J h oP.2 7



### Tabl e D-2 . 199 4 Emission s Calculations , FR PLaboratory , Applie d Composite s Corp. , St . Charles , Illinoi s Inpu tInformatio n 199 4 Compoun d Processe d Qb/yr) Averag e Monome rConten ti n Compoun d (% ) Monome rEmissio n Facto r(l b VO M emitted/10 0 l b availabl e monomer) 1 

### 13,45 8 11.4 2 

## 3.04
Calculation s 13,45 8 l b compoun d 11.421 b monome r 10 0 l b compoun d 1.54E+0 3 l b availabl e monome r

1.54E+0 3 l b monome r 3.0 4 l b VO M 10 0 l b monome r 4 7 lb/y rVO M emitte d

4 7 l b VO M yea r 

## to n

200 0 l b 0.0 2 tp y VO M

Emission fectordetermine

d throug h direc tmeasuremen

t(Octobe r12,1992) . Volatile organicmaterial. Pound s pe ryear. Percen t Pounds. VO M fbfyt % 

### I b yr Ton s pe ryear. Year .



## Applac t 

## 12/5/9 5 

# -zc?

## M

< T**M . sup.Boior« i NO x 80 2 C O VO M P M OfU.Bator» 2 NO x 80 2 C O VO M P M V-SCM-tr* ! NOx S0 2 C O VO M P M 6ot__r« 4 NO x S0 2 C O VO M P M VHV.to^»xrmmx/.AffUtiCan^ommr.tLaxmtm.ani*»

A c M Tlroughpu l pmifffl I S M 199 3 19.5 3 1 8 S 3 199 3 Act M Ttmudyu t (rnml**Ar ) 172 9 17.2 9 17-2 8 1 7 2 4 17.2 9 Acta ! TTroupp U (mnxT/jf) 1 6 e e 165 6 169 6 16.89 195 9 Actua l Tlrot-jtvu l (m-fF/gr ) 0.0 0 00 0 00 0 00 0 0.0 0 Ae»j-

_ Hourao l Ooarata n 9.76 0 8.76 0 8.76 0 8.76 0 8.76 0 Mu M Hano i Oporalo n 6.76 0 8.76 0 8.76 0 6.76 0 6.76 0 Act * Hano i Oporalo n 8.76 0 6.76 0 8.76 0 6.76 0 6.76 0 Act * Hano i Oporalo n 8.76 0 6.76 0 6.78 0 6.76 0 6.76 0 E F

9oo_r (Mmtr ) 10 0 0 6 2 1 6. 3 1 2 E F Booo r (Mm m 10 0 0. 8 2 1 6. 1 1 2 E F So* * (Mn m IT I 10 0 0. 8 2 1 8. 1 1 2 E F Boot r (Mm m 10 0 0. 6 2 1 6. 3 1 2 Unoontalt d

E-r*M_or a (Mr ) 1JE-0 1 1.1E-0 3 4.06-0 2 1.06-0 2 Z3E-0 2 Unconkolo d Enlutor a (Mr . 20E-0 1 1.2E-0 3 4.1E-0 2 10E-0 2 2.4E-0 2 UnconMo d : EnMo- a (Mr ) 1.8E-0 1 11E-0 3 4.0E-O 2 1.0E-02 23E-0 2 Unomrolo d Enimor a (Mr ) : o.OE«o o O.OE40 0 O.OE«0 0 006*0 0 : O.OE-KW UnconMo d

ErriMlan t (by ) 9.3E-0 1 8.06-0 3 1.7E-0 1 44E-0 2 9.8&0 2 Unoonlrolod EmMo- a (*v ) 9.96-0 1 8.26-0 3 1.8E-0 1 4.96-0 2 1.0E-0 1 l_ncon*reM d Emuuiui a (by ) 83E-0 1 9.064 3 1.7E-0 1 4.464 2 986-0 2 Uncon^ott o Enittton s (by ) O.OEfO O 0.06*0 0 0 06*0 0 0.0E+OO 006*0 0 M-udnui .

Tlroi«_h-M

_ OrmfTni l 92.6 3 626 3 82.6 3 62.6 1 62.6 3 M-udnun ) Ttrough-tf (nrrtT M 84( 3 64.9 3 94.9 3 948 3 94.9 3 Morir-u n Tlrougrv a (mrr_r.yr ) 92.7 4 62.7 4 62.7 4 62.7 4 62.7 4 Motf-ru n nxou^i M (rmir/tf ) 48.6 8 499 9 496 8 459 9 49.6 8 Mucbnj n

Houno l Oporalo n 9.76 0 9.76 0 9.76 0 9.76 0 6.76 0 M-u-kn m Horn * Oporalo n 6.76 0 8.76 0 9.79 0 8.79 0 8.76 0 MwJmu m Houno l Oporalo n 8.79 0 9.76 0 6.79 0 9,76 0 8.76 0 Moafcru n Hano i Oporalo n 8.76 0 8.76 0 8.76 0 6.79 0 6.76 0 E F

BoTat r ( M m ft* ) to o 0. 6 2 1 5. 1 1 2 E F Boh r (Mr m IT ) 10 0 0. 8 2 1 6. 3 1 2 E F BoH r (Mmtr ) 10 0 0. 6 2 1 8. 1 1 2 E F •OOM- ' ( M m IF ) 10 0 0. 9 2 1 9. 1 1 2 Unconl-olod

cirsolofx . (Mr ) 606-0 1 3.960 3 I.JE-O I 1.2E-0 2 726-0 2 Unoonkoit d E/tiukxM (Mr ) 9.16-0 1 396-0 1 1.16-0 1 3.16-0 2 7.6E-0 2 Uhconfroto d EntfMton t (Mr ) e.oe-o i 3.960 1 13C-0 1 1260 2 726-0 2 Unconl-olod Enta-ot a (Mr ) 62E-0 1 3.1E-0 3 1.1E-0 1 2.9E-0 2 83E-0 2 Uncanko M

ErrtMto m (bY ) 2.66*0 0 1.0E-O 2 9.5E-0 1 1.46-0 1 326-0 1 UnconlPolo d 6*rta**]o* a (by ) 2.7E*0 0 196-0 2 0.9E-O I 1.66-0 1 1.3E-0 1 UnconMo d Efrtuloi a (by ) 2.96*0 0 1.96-0 2 9.9E-0 1 1.4E-0 1 3.2E-0 1 UnconMo d EMottefx i (t>y ) 2.3E*0 0 1.4E-9 2 4.3E-0 1 1.2E-0 1 2.7E-0 1 RopjuMoi y

Unltilo n (Mr ) N A N A N A N A N A Roguttory UntiMo n (Mr ) N A N A N A N A N A Rogator y UntftBta n (Mr ) N A N A N A N A N A Ropirtor y uitato n (Mr ) N A N A N A N A N A Mvdnu n

Hano i ODoralo n 8.76 0 8.76 0 8,76 0 6.76 0 6.76 0 Msdnwn i Hano i Oporalo n 8.76 0 0.79 0 6.76 0 8.78 0 6.76 0 Mvdnu n Hano i Opwto n 8.76 0 6,76 0 9.79 0 9.79 0 8.76 0 Mvanw n Houno l Operato n 6.76 0 8.76 0 6.76 0 6.7( 0 8.76 0 POOMl

W Entofltora (bv ) 263 2 001 6 0.99 3 0.13 9 0.31 9 F-ottnfafl OIIKKU M (by ) 274 9 001 9 0.97 7 0.14 9 0.33 0 Pottrttti Enittdon i (by ) 2.83 7 001 6 0.89 4 0.14 0 0.31 6 Potanta l EmMo- a (by ) *U9 4 0.01 4 0.46 0 0.12 1 027 4 E F 6olor« B T>*o>x_rpu

(mmffftr ) Hano i

OporHo n (Mtm IT

) 

### c m JfiK L Tlrou-fe U (nfrir/w ) Hano i ( M m IT ) (Mr ) J__ RoguMor y ' UnlMo n (Mr ) Majdnu n

Houno l Einu-ora

(by ) NO x 80 2 C O VO M 0.0 0 0.0 0 0.0 0 00 0 0.0 0 6.79 0

9,79 0 9.79 0 6.79 0 9.78 0 10 0

0. 9 2 1 9 3 1 2 0.0E4O 0 

### ooe«o o 00E<O 0 OJK«0 0 0.0E«0 0 O.OE40 0 0.0E«0 0 0.0E40 0 OJ&O O 0.06«0 0 94.6 0

94.9 0 94.9 0 94J 0 94J 0 9,79 0

8.79 0 9.79 0 8.76 0 9.76 0 10 0

0. 6 2 1 8. 3 1 2 81E-0 1

3.8E-9 3 13E-0 1 HE-0 2 786-0 2 2.7E«O 0

1.8E-0 2 6.8E-0 1 1JE-0 1 8.1E^> 1 N A N A 9.78 0

9.79 0 8.76 0 8.76 0 8.76 0 Z74 8

0.01 8 0.57 9 0.14 9 0.32 9P.2 9



## METHY L DI-ISOCYANAT E (MD I 1 FOA M INJECTIO N SYSTE M System i s considere d insignifican tbase d o n th e following :

• Rapid polymerization (solidification ) o f MD I afterinjection . • Applie d within enclosure s tha tpreventescap e o f

an y MD I vapor .



# 2 2

"P.3 0



## APPENDI

X C STAT E OPERATIN

G PERMIT



# ^ < ?P.3 1 

# ttZjS^l Slate of Illinois l ^ p ENVIRONMENTAL MmECTION

AGENCY Mar y A . Gade , Directo riiii - P . O . Box J9506 , Springfield , I L 62794*930 6 

# 217/782-211 3 OPERATING ! PfM S - REVISE

D ; PERMITTE E Applie d Composites , Corp . : ! Attn::Mr . Joh

n Punls , Vic e Pres. , Operations ' 33 3 Nort h Sixt h Stree t St . Charles , Illinoi s 60174 • Applicatio n No. : 9305006 6 . I.D . No. : 089483AA F Applicant s Designation : C0HP0UN 0 -4M- 8 RecelYCd'.- M& / 19 , 1*85 gjjidaci ! Compounding, Maturation , aridSiilreSsldi i Molding Date Issued ; June 14 , 199 5 ii^niratio n Date : Uune 14 , 2000 Location : 33 3 Nort

h Sixt h Street , St . Charle s Permi t1 s hereb y grante d t o th e above-designate d Permitte e t o OPERAT E emissio n units(s ) and/o rai rpollutio n control..:Equipmentconsistin g o f small lightnin g mixer , smal l Cowle s mixer , larg e Cowl& s wixer , Shee tMolding Compoun d (SMC ) machine , festooner , Thic kMoldin g Conpun

d (TMC ) machine , maturatio n process , three : resi n storag e tanks , twenty-oneltlose d mol d hydrauli cproductio n presse s an d pigmen tapplicatio n equipment, dus tcollectio n equipment , pigmen thoppe r dus tcollector , Fiberglas s Reinforced^Plastl c(FRP ) lab , an

d fiv e natura l ga s fire d boiler s a s describe d 1 n th e abov

e reference d application . Thi s Permi t i s subjec tt o standar d condition s attache d heret o an d th e followin g specia l condltlons(s) : I P la . Th e proces s fo rmakin

g compoun

d shall.-b e performed i n accordanc e wit h th e descriptio n 1

n th e applicatio n with additiona l enclosur e a s require d by Conditio n 7 . A

s aresul to f

th1S:#equlrement , th e emissio n facto rfo r productio n o f

moldin g compoun

d 1 s assume

d t o b e 3.0 4 l b V0H/10 0 l b monome

r an d VO M input , base d o

n Informatio n provide d 1r i astac ktes tConducte d o n Octobe r12 , 1992 . if-- '•'"- b . Forth e compoundin g an d maturatio n processe s combined , monome rusage , productio n o f

molding compound

, an d emission s o f

Volatil e OrganicMateria l (VOM ) shal l no texcee d th e followin g limits : 

## Pretuciion' ; 

## o f Monome rUsag e Moldin

g Compoun

d VO

M Emission s 

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

) 527,00 0 2,25 0 W'I.U It.QW

68. 3 Thes e limit s ar e basedo

ninformttiQn':provlde

di n;tbeperm1t : 

# application . Complianc e wit hannua l limit s shal l b o determine dfro m a runnin g tota l o f twelv e month s o f data .

Pmi.K . IU I V.trytinl

ftqxtr 

# 3oP.3 2



### Page 2
2 . Emission s o f Volatil e Organi c Materia l (VOM ) fro m th e thre e resi n storag e tank s combine

d shal l no t excee d -Ue? : ton s pe r year . Thi s Hmi t 1 s based o n Informatio n provide d i n th e permi t application . Compliance wit h thi s limi t shal l b

e determine d usin g standar d calculatio n methods se t fort h 1 n USEPA's Coi-ipnatio n o f Emissio n Factors . AP-42 a s Wel l a

s a runnin g tota l d f twelv e months o f data . 3 . Emission s o f Volatil e Organi c Materia l (VOM ) fro m th e usag e o f isopropy l alcoho l shal l not exceed 2. 0 to n pe r year . Thi s Hm1 t 1 s based on 2. 0 to n o f alcoho l use

d pe r yea r fo r Inspectio n an d rewor k procedures , 4a . Polyeste r resi n product s shal l ttfeiafeitatfidiDhly byiBflse d molTdingiAs " a '. resul t o f thi s requiretwint , theMllff m ifacfcb r fo r fabricatio n i s assume d t o be 1. 0 l b V0M/10

0 l b monome

r inf o £ {USEPA ; Compilatip n o f Emissio n 

## Eactors > AP-42) . b . Emission s and operatio n o f productio n moldin g equipment shal l no t excee d th e followin g limits : VO M Emission s 

## Ite m o f Equipment nb/monthrrTon/v n



# 5 . 0 . 7 . 2 1 Close dMoldin g

Presse s (Combined) : 6,13 2 26. 3 Thes e limit s ar e base don.processin g al l molding:compoundin g produce da t th e source , an

d Informatio nprovide di nth e permi t application . Complianc e shal l b e determine dusin g monome r conten t o f moldin g compoun d processed . Complianc e wit hannua l limit s shal l b e determine dfrom

a runnin g tota l o f 1 2 month s o f data . Emission s o f Volatil e Organi c Materia l (VOM ) fro m eac hemissio nuni t shal l no t excee d8. 0 pound s per.hou r pursuan t t o 3 5 111 . Adm . Cod e 218.301 , Emission s o f Volatil e Organi c Materia l (VOM ) fro m th e fiberglas s Reinforce dPlasti c (FRP ) La bshal l no t excee d0. 1 tonpe r year . Thi s limi t i s base do

ninformatio nprovide d1nth e permi t application . fh e Permitte e shal l provid e a coye r fo r eac hholding tank , mixin g vessel , vat , o r othe r processing equipmen t wit ha capacit y greate r than7. 5 liter s ( 2 gal l ons) , 1 nc l uding an y ianWine r • if

i whic hpolyeste r res i i i mater i al s ar e delivere dt o th e source , whil e polyeste r resi nmaterial s ar e bein g formulated . Thes e cover s shall : i . Completel y

cove r th e tank , vat , o r vesse l opening excep t fo r an openin g n

o large r tha nnecessar y t o allo w fo r saf e clearanc e fo r a mixe r shaft ; ill . Extendat leas t 1.2 7 c m (0. 5 Inch ) beyondth e oute r r1 m o f th e openin g o r be attache dt o th e rim ;


# •3 1P.3 3



## Pag e Iii . Remai nclose dexcep t whe nadding o r removin g materia l o r whe n

samplin g o r inspectio nprocedure s requir e access' , an d iv . B e maintaine d1ngoo dconditio nsuc hthat , Whe n1 nplace , th e cove r maintain s contac t wit hth e rim o f th e openin g fo r a t leas t 90 % o f th e circumferenc e o f th e r1m . . ' 8a . Annua l emission s o f Nitroge nOxid e (NOx ) an dCarbo nMonoxid e (CO ) fro m th e fiv e boiler s combine dshal l no t excee d13. 0 ton s an d3, 1 ton s respectively . Thes e limit s ar e basedonstandar dAP-4 2 emissio nfactor s fo r th e firin g o f natura l gas , 87M . hour s o f Qper^tion, :: 

## perry-9ar , and- ? informatio nprovide dtnth e peiMfc : 

## I f plication. ' \ C^p l 1 ancei wit hthes e limit s shal l b e determine dfrom I.running total : o f twelv e month s o f data . b . Natura l ga s shal l be th e onl y fue l combuste di nth e boilers . 9 . Emission s o f particulat e matte r fro m eac hpigmen t applicatio nsystem wit h Nordso ndus t collecto r an dth e pigmen t hoppe r wit hNordso ndus t collector , shal l no t excee d0.5 5 Tb/h r an d2.4 1 ton s pe r year . Thes e limit s ar e base doninformatio nprovide dinthe permi t application . 10 . Th e Permitte e shal l compl y wit hthe followin g operatin g requirements : I . Fo r polyeste r resi nmaterial s usedfo r product s requirin g corrosio n resistan t o r fir e retarden t Materials , a monome r conten t o f n o mor e tha n48 % b

y weigh t a s applie dmay be used ; II . Fo r polyeste r resi nmaterial s fo r product s requirin g a tensil e strengt ho f 10,00 0 ps i o r more , Includin g tooljln g resins , a monome r conten t o f n o mor e tha n48 % b y weigh t a s app l lie

dma y b e used ; III . Fo r clea r ge l coat , a monome r conten t o f n o mor e tha n505 4 b

y weigh t a s applie dmay

b e used ; iv . Fu r othe r pigmente dge l coats , a monome r conten t o f n o mor e tha n45 % b y weigh t a s applie dma y b e used ; o r v . Fo r al l othe r polyeste r rest hmaterials , a monome r conten t o f n o mor e tha n35 % b

y weigh t a s applie dmay be used . 11 . Th e monome r conten t o f polyesterTesi nmaterial s shal l b e determined : I . Fro m supplie r dat a an

doperatin g data ; o r II . B y samplin g an

danalysi s b

y th e method s se t fort hi nSCAQM D Metho d312-91 . 12a . i Th e Permitte e shal l maintain ; record s o f the followin g Item s t o allow

th e Agenc y

t o revie w

compliance ;


# 3 ^

## Page: 4 P.3 4



# 11 . Formulatio ndat a fo r molding;..compounds , wit htyp e an damoun t o f resin(s) , additives , catalyst , filler , fiberglass , inhibitors , promoters , etc . (dat a fo r elMi.distinc t formulation ) Styren e conten t o f resi nan dothe r material s use di nmoldin g compound , (dat a fo r eac hdistinc t resi nan dmaterial ) 111 . quantit y

(pounds) o f eac htyp e (shee t mol do r thic kmol dan dgenera l purpose , hig hmonome r content , specia l purpose , o r lo w monome r content ) o f compoundproducfd . (monthly ) : iv , Quantit y

(pounds ) of ; ftion6iite|piil, :(in&tttHty ) v . Quantit y

o f eac hsolven t used(dibasi c este r an dIsopropy l alcohol ) an damoun t recovered ! an dsent of f sit e fo r reclamation , (monthly ) V1 . VOM emissions , (calculate dmonthly ) b . th e Permitte e shal l kee pwritte nrecord s o f periodi c Inspection s t o confir m implementatio no f th e measure s require db y Conditio n7 . c . Thes e record s shal l b e retaine dfo r a perio do f thre e year s an dshal l b e mad e availabl e fo r Agenc y inspectionandupo nrequest . Copie s o f record s shal l b e submitte dwithin : 1 0 day s o f Agenc y request . 13 . thi s permi t i s issue dbase duponith e shee t moldin g compoundin g process , thic kmoldin g compoundin g process , maturatio nprocess , andcompoundclose d moldin g proces s no t being subjec t t o th e control 1 

## requirement s o f 3 5 111 . Adm . Cod e 218 , Subpar t P P an dPQ:fo r miscellaneou s fabricate dproduc t manufacturin g operations . Thi s i' s a consequenc e o f th e abov e condition s whic hestablis hlimitation s whic hxonstral nVOM emission s i nth e absenc e o f ai r pollutio ncontro l equipmen t t o les s tha n10 $ ton s pe r year . I t shoul dbe note dtha t durin g th e revie w o f thi s application , 1 t wa s determine dtha t you r facilit y ha s th e potentia l t o emi t mor e tha n2 5 ton s pe r year:o f volatil e organi c materia l (VOM ) an dwil l b e classifie da s a majo r sourc e unde r th e Clea nA1 r Ac t Permi t Program (CAAPP) . I f yo uhave an

y question s o

nthi s permit , pleas e contac t Mohame dAnan e a t '217/782,2113: "

Oonal dE . Sutton , P.E . Manager , Permi t Sectio n 0 1 visio no f Ai r Pollutio nContro l OES:MA:sad/0523Q,100-103s p cc : Regio n1 

# 33P.3 5



## TABLE S



# 3

V 

# .. .P.3 6



### Tabl e 1 . 199 4 Emission s Calculations , Compoun d Room , Applie d Composite s Corp. , S tCharles , Illinoi s Inpu tInformatio n 199 4 Compoun d Processe d (lb/yr ) Averag e Monome rConten ti n Compoun d (% ) Monome rEmissio n Facto r(l b VOM/l b availabl e monomer) 1 

### 19,767,47 2 11.4 7 

## 0.0304
Calculation s 19,767,47 2 l b compoun d 11.47 % 2.27E+0 6 l b availabl e monome r

2.27E+0 6 l b monome r 0.030 4 l b VO M = 68,92 7 lb/y rVO M emitte d l b monome r 68,92 7 l b VO M yea r 

## to n 34. 5 tp y VO M

20001 b

VO M lb/y r l b tp y yr Emissio n fectordetermine

d throug h stac ktestin g (Octobe r12,1992) . Volatile organicmaterial. Pound s peryear . Percent . Pounds. Tons pe ryear . Year .

Applac t 11/21/9 5 

# 3£P.3 7



## Tabl e 2 . 199 4 Emission s Calculations , Moldin g Presses , Applied Composite s Corp. , St . Charles , Illinoi s Inpu tInformatio

n 199 4 Compound Molde d (lb/yr) 1 

## Averag e MonomerContentin Compound (% ) Monome rEmissio n Facto r(lb VO M emitted/10 0 l b available monomer) 2 

## 20,155,29 2 10.4 3 1
Calculations 20,155,29 2 l

b compound 10.43 % 2.10E+0 6 lb available monome r

2.10E+ 6 l b monomer 1 l

b VO M 10 0 lb monome r 21,02 2 lb/yrVOM emitted
21,02 2 lb VO M year 

## ton

20001 b 10. 5 tpy VOM

I 2 

### VO M lb/y r % l b tp y y r Som e SM C processe d i n 199 3 wa s molde d i n 1994 . Emissio n fectortake n from AP-4 2 (Januai y 1995) , Chapte r4 , Sectio n 4 , entide d Polyeste rResi n Plasti cProduct s Fabrication , Tabl e 4.4-2 , Close d Molding . Volatil e organi cmaterial . Pound s pe ryear . Percen t Pounds . Ton s pe ryear . Year .



## Applact 12/5/9 5 

# Si,

### Tabl e 3 .

Produc t Nam e PAINT S Pain t Pain t To p Coa t
SOLVENT S Reducer Reducer Pain t an dSolven

t Ai r Po ! Typica l Usag e (galfyr )
5 7 8. 5 4

50 0 1 4 Typical 1 

### Usag e Ob-y )
338.5 8 96.2 2 33. 2

415 0 100. 8 lutant

Emi s Typical 1 

### Schedul e (hrs/yr)
150 0 150 0 150 0

150 0 150 0 sions . Applie dComposite s Corporation , S t Charles , Illinoi s Maximu m Usage 2 

### (galtyr)
11 4 1 7 8

1000 2 8 Maximu m Usage 2 

### (W-V-yr )
67 7 19 2 6 6

830 0 20 2 Produc t Density 3 

### lb/ga l Content 3


### 5.9 4 30 % 11.3 2 5 % 8. 3 10 %

Total 8. 3 10 % 7. 2 10 %

Total VHAPs : IPA VOM : Actua l

(lb/yr )
101.57 4 4.81 1 3.3 2 109.7 1 41 5 10.0 8 425.0 8 1728.89 2 4000.00 0 Toluen e

MTE4 

### (ttVyr ) (IPY )
203.14 8 9.62 2 6.64 0 219.4 1 830.00 0 20.16 0 850.1 6 3457.78 3 2,00 0 0.10 2

0.00 5 0.00 3 0.1 1 0.41 5 0.01 0 0.4 3 1.729 2.00 0 PTE 4



### (lh/yr ) (IPY )
203.14 8 9.62 2 6.64 0 219.4 1 830.00 0 20.16 0 850.1 6 3457.78 3 4000.00 0 0.10 2

0.00 5 0.00 3 O. U 0.41 5 0.01 0 0.4 3 1.72 9 2.00 0 TOTA L VOM : 5728.89 2 3459.78 3 3.72 9 7457.78 3 3.72 9 1 . 1994 data . 2 . Maximu musag e wa s assume dt o b e 2. 5 more tha n th e 1994 usag e data . 3 . Manufacturer' s data . 4 . TPY value s ar e base do n maximu moperatin g schedul e of : 876 0 hrsfy r EQUATIONS : Actual , lb/yr

= (199 4 Usage , gal/yr)(HA PConten t %)(Pro dDensity , lb/gal ) MTE , lb/hr

= (Max . Usage , gal/yr)(HA Pconten t %)(Prod . Density , lb/gal)/(Max . Sched. , hrs/yr) MTE , TPY •

= (MTE , lb/hr)(Max . Sched , hrs/jT)(ton/200 0 lb ) PTE , lb/hr = (Max . Usage , gal/yr)(HA Pconten t %)(Prod . Density , lb/gal)/(Max . Sched. , hrs/yr ) PTE , TPY - (MTE , lb/hr)(Max . Sched. , hrs/yr)(ton/200 0 lb ) Total VO M i s equal t o th e su mo f volatil e HAPemissio n rates an dfiomIPA use .

Paintha p Pag e 1 o f 3 12/5/9 5

### Tabl e 3 .

Produc t Nam e PAINT S Pain t Pain t To p Coat
SOLVENT S Reducer Reducer Pain t an dSolvent

Ai r PoUutan t Emissions , Applie dComposite s Corporati o Typical ' Usag e (gal/yr)
5 7 8. 5 4

50 0 1 4 Typical ' Usag e Ob^ )
338.5 8 96.2 2 ' 33. 2

415 0 100. 8 Typical ' Schedul e (hrs/vr)
150 0 150 0 150 0

1500 1500 Maximu m

Usage 2 

### (galfyr )
11 4 1 7 8

1000 2 8 Maximu m Usage 2 

### Oh/yr)
67 7 19 2 6 6

830 0 20 2 Produc t Density 3 

### lb/gal
5.9 4 11.3 2 8. 3

8. 3 7. 2 Content 3



### 3 % 3 % Total 5 % 5 % Total Actual

(lb/yr)

2.886 6 0.99 6 3.8 8 207. 5 5.04 212.5 4 Xylen e

MTE4 

### 0h/yr ) CIPY )

5.77 3 1.992 7.7 7 415.00 0 10.08 0 425.0 8 0.00 3

0.00 1 0.0 0 0.20 8 0.00 5 0.2 1 PTE 4



### 0h/yr ) (IPY )

5.77 3 1.99 2 7.7 7 415.00 0 10.08 0 425.0 8 0.00 3

0.00 1 0.0 0 0.20 8 0.00 5 0.2 1



# U ) 1.199 4 data .

2 . Maximu musag e wa s assume dt o b e 2. 5 mor e than th e 1994 usag e data . 3 . Manufacturer' s data . 4 . TPY value s ar e base do n maximu moperatin g schedul e of : 876 0 bn/yt EQUATIONS : Actual , lb/yr

= (199 4 Usage , gal/yr)(HAPConten t %)(Pro dDensity , lb/gal ) MTE, lb/hr= (Max . Usage , gal/yr)(HAPconten t%XPro d Density , lb/gal)/(Max . Sched , hrs/yr ) MTE, TP Y - (MTE , lb/hr)(Max. Sched , hrs/yrXtom/200 0 lb ) PTE, lb/hr= (Max . Usage , gal/yr)(HAPcontort , %)(Prod. Density , lb/gal)/(Max . Sched . hrs/yr ) PTE, TP Y - (MTE , lh/hr)(Max. Sched , hrs/yrj(ton/2000 lb ) Tota l VOM i s equa

l to th e su m o f volatil e HA

Pemissio n rates an

d fiom IP A use .

Paintha p Pag e 2 o f 3 12/5/9 5

### Table 3 .

Produc tNam e PAINT S Pain t Pain t To p Coa t
SOLVENT S Reduce r Reduce r Pain

tan d Solven tAi rPo l Typical ' Usag e (galfyr )
5 7 8. 5 4

50 0 14 Typical ' Usag e (lb/yr )
338.5 8 96.2 2 33. 2

415 0 100. 8 lutantEmi s

Typical ' Schedul e (hrs/yr ) 150 0 150 0 150 0

150 0 150 0 sions , Applie d Composites Cofporati o Maximu m Usag e (galfyr )
11 4 1 7 8

1000 2 8 Maximu

m Usag e (lWyr )
67 7 192 6 6

830 0 20 2 Produc

t Density3 

### lb/ga l
5.9 4 11.3 2 8. 3

8. 3 7. 2 Content 3



### 23 % 23 %

• • 

### Actua

l (lb-yr )

0.0 0 954.5 0 23.1 8 977.6 8 Methyl-ethyl-ketone

MTE 4 

### 0h/yr) (JPY )

0.0 0 1909.00 0 46.36 8 1955.3 7 0.0 0

0.95 5 0.02 3 0.9 8 * PIE '

(lb/yr)

0.0 0 1909.00 0 46.36 8 1955.3 7 i 

### CTPY

)

0.0 0 0.95 5 0.02 3 0.9 8

1.199 4 data . 2 . Maximu musag e wa s assume dt o b e 2. 5 more tha n th e 199 4 usag e data . 3 . Manufacturer' s data . 4 . TP Y value s ar e base do n maximumoperatin g schedul e of : 876 0 hrs/y r EQUATIONS : Actual , lb/yr

= (199 4 Usage , gal/yr)(HAPConten t %XPro dDensity , lb/gal ) MTE , lb/hr

= (Max . Usage , gal/yr)(HAPconten t %)(Ptod . Density , lb/gal)/(Max . Sched. , hrs/yr) MTE , TP Y = (MTE , lb/hr)(Max . Sched. , hrstyrXton/200 0 lb ) PTE , lb/hr

= (Max . Usage , gal/yr)(HAPconten t %)(Pro dDensity , lb/gal)/(Max . Sched. , hrs/yr) PTE , TP Y = (MTE , lh/hr)(Max . Sched , hrs/yr)(tQn/200 0 lb ) Total VO M i s equa l t o th e su mo f volatil e HA Pemissio n rates an dfromIP A use .

Paintha p Pag e 3 o f 3 12/5/9 5P.4 1



## SECTION 6 FACILIT Y FORM S



# -vo :P.4 2
ILLINOI S ENVIRONMENTA L PROTECTIO N AGENC Y DIVISIO N O F AI R POLLUTIO N CONTRO L - PERMI TSECTIO N P.O . BO X1950 6 SPRINGFIELD , ILUNOI S 62794-950 6 F9RAPPUCANT*$ W Revision* : M" " Dat a Dacemty S

. 199 5 / Pag e o

f Source Designation : AC C


## HAZARDOUS

MR POLLUTANT

(HaAP) EMISSION

SUMMARY PERMIT* TOTE SOURCE

INFORMATION ^SCURCEKIAME : 

## Applie d Composite s Corp . 3 > SOURC

E I D 

## No . nonAMAAr



## . (I F KNOWN) : 

## 089483AA F 2) DAT E FOR M ,_ , u B

Annc PREPARED : Decembe r6,/199 5 HAZARDOUS

MR POLLUTANT

EMISSIONS 4) D6E 5 AM

V EMISSifl N UNIT A

TTH E 56UKC E EMI

T AHAZARDOU

S AI R POLLUTANT

? (I F NO , THE N TH E REMAINDE R O F THI S FOR M NEE D NO TB E COMPLETED

) 

# Q YE S 5a ) DOE S TH E SOURC

E HAV E TH E POTENTIA

L T 6 EktlT , IK

I TH E AOOhEoATE, : i ) 1 0 TON S PE R YEA

R O R MOR E O F AN

YINDIVIDUA L HAZARDOU S AI R POLLUTANT ; B ) 25 TON S PE R YEA

R O R MOR E O F AN

YCOMBINATIO N O F HAZARDOU S AI R POUUTANTS ; I ) SUC H LESSE R QUANTIT YA S ESTABLISHE D B

YRULE WHIC H CLASSIFIES TH E SOURC E A

S MAJO R FO R HAZARDOU S AI R POLLUTANTS ; Iv ) EMISSION S O F HAZARDOU S AI R POUUTANT S WHIC H EQUA L OR EXCEE D A POLLUTANTSPECIFI C CAAP P APPUCABIUT YLEVEL A

S ESTABUSHE D B

YUSEP A RUL E SUC H THA

TTH E SOURC E I S REQUIRE D T O OBTAI N A CAAP P PERMI T SOLEL YFO R THI S REASO N (i.e. . HAP EMISSION S BELO W TH E CAAPP APPUCABILIT

YTHRESHOLDS SPECIFIE D I N ITEM S m, (II ) 4(10 ) ABOVE . BUTSTI U REQUIRE D TO OBTAI N A CAAP P PERMITPURSUAN TT O A REGULATOR

Y REQUIREMENT , e.g. , NESHAP) ? b ) I F ANSWERE D YE S T O AN YO F TH E ABOVE , IDENTIF YTH E HAP(S

) FO R WHIC H TH E SOURC E I S CONSIDERE D MAJOR O R REQUIRE D T O OBTAI N A CAAPP PERMIT : CK/ron e 

# • N O
YES YES 

# I Ive s 

# O 

# • • N O N O N O N O

HAZARDOUS

AIR POLLUTANT

EMISSIONS

TABLE 6 , COMPLET

E TH E FOLLOWING TABL E Pot-fel l HAP » WHIC H AR E ftt&ULATEb Alf t POLLUTANTS
. THI S TABL E MUS TINCLUD E EMISSION S O F HAP S A TACTIVITIE S PROPOSE D T O B E INSIGNIFICAN TPURSUANTTO 3 5 I L ADM : COD E 201.211 . NOT E THA TA N APPLICANTMA

YPRESUM E THA

TA N EMISSIO N UNI TDOES NO TEMI TA HAP I F I TMEET

S TH E REQUIREMENT

S O F 3 5 I L ADM . COD E 201.209 .

I~HI S AGENC YI S AUTHORIZE D TO REQUIR E THI S INFORMATIO N UNDE R ILLINOI S REVISE D STATUES , 1991 , A S AMENDE D 1992 , :HA P 1111/2 , PAR . 1039.5 . DISCLOSUR E O F THI S INFORMATIO N I S REQUIRE D UNDE R THA TSECTION . FAILUR E T O D O S O MA Y PREVEN TTHI S FOR M FRO M BEIN G PROCESSE D AN D COUL D RESUL TI N TH E APPUCATIO N BEIN G DENIED . THI S FOR M HA S BEE N APPROVED B

YTH E FORM S MANAGEMENTCENTER . 

## APPLICATIO N PAG E 0 0 05 5

215-CAAP P FO R APPLICANT S US E
PAG E 1 O F 2 

# HIINSIGNIFICAN TPURSUAN TT O 3 5 IL . ADM . COD E 20 1 "i'ii l NOT E THA TA N APPLICAN TMAYPRESUM E THA TA N EMISSIO N UNI TDOE S NO TEMI TA HA P I F I TMEET S TH E REQUIREMENT S

O F 3 5 IL . ADM . COD E 201.209 . NAM E O F HA P EMITTED : 

### Stvren e Toluen e Xylen e Methy l ethy l keton e

• 'CA S NUMBE R



### 100-42- 5 108-88- 3 1330-20- 7 78-93- 3 EMISSIO N UNI T DESIGNATION . Compoun d Pre p /

Moldin g 

### Paint /Solven t Usage Pain t /Solven t Usage Pain t /Solven t Usag

e

! MAXIMU M EMISSION S (TONS/YR ) 

### 94. 6 0.53 5 0.21 6 0.9 8 TYPICA L

EMISSION S (TONS//YR ) 

### 41. 5 0.2 7 0.1 1 0.4 9 POTENTIA L

EMISSION S (TONS/YR ) 

### 94. 6 0.53 5 0.21 6 0.9 8 OTHE R

TERMS 2 APPLICABL E RUL E



### N/ A N/ A N/ A N/ A APPUCABIUT YLEVE L (UNITS ) 

### N/ A N/ A N/ A N/ A

^CA S - CHEMICA L ABSTRAC TSERVIC E 2PROVID E OTHE R TERM S A S NECESSAR YT O ESTABUS H APPUCABIUT YO R COMPLIANC E WIT H REQUIREMENTS .



## APPLICATIO N PAGE .

215-CAAP P 

# 0005 6 FO R APPLICANTS US E
PAG E 2 O F 2

C OP.4 4

ILUNOI S ENVIRONMENTA L PROTECTIO N AGENC Y DIVISIO N O F AI R POLLUTIO N CONTRO L - PERMI T SECTIO N P.O . BO X 1950 6 SPRINGFIELD , ILUNOI S 62794-950 6 FO R APPUCANT S US E Revision* : lni M Date : Novemty

w15.199 9 Pag e o f Sourc e Designation : AC C



## . COMPUANCE

PLAN/ SCHEDULE

OF COMPUANCE FOR CAAPP PERMIT IDNU K PERMIT* 

### TSSTE T TH E CLEA N AI R AC

TPERMI TPROfiRA M (CAAP P RECUIRE S THA TTH E APPUCAH

TSUHMI TA COMPUANC E PLAN/SCHEDUL E OF COMPLIANC E FO R A U EMBSIO N UNIT S A TTH E CAAP P SOURCE . REGARDLES S O P TH E COMPUANC E STATU S O F EAC H INOMOUA L EMBSIO N UNIT . THI S FOR M REQUIRE S THA TTH E COMPLIANC E STATU S B E STATE D FO R EACH EMBSIO N UNfT . APPUCATIO N FOR M 2B+CAAPP . -COMPUANC E PLAN/SCHEDULE O F (XMPUANC E - ADOfiNDU M FO R NO N CCMPLY1NO SESSIO N UNITS * MUS TB E SU8MTTE D FO R EAC H EMSSIO N UNITNO TI N COMPUANC E WIT H A U APPUCABL E REQUIREMENT

S A TTH E TI C O F SUBMITTA L \) SOURCE NAME : SOURCE INFORM

A HON 

## Applie d Composite s Corp
. 2 ) DAT E FoR M PREPARED : Decembe r 6 , 199 5 3 ) SOURC E I D No . (I F KNOWN) : Q89483AA F SOURCE

COMPUANCE

INFORMATION 4) DESCRIB E TH E COMPLIANC E STATU

S O F TH E SOURC

E WITH AL

L APPLICABL

E REOUIREMENT

S (E.&. , "SOURC E I S I N COMPLIANC E WIT H A U APPUCABL E REQUIREMENTS*) : 

## Sourc e i s i n complianc e wit h al l applicabl e requirements
.

5) I F I N COMPLIANCE , WILL TH E SOURC E CONTINU E T

O COMPL

V WIT H AL L APPUCABL

E REQUIREMENTS'

? 

## P I YE S | | N

O I F NO , EXPLAIN :

6 ) WIL L TH E SOURC E MEET

, O N A TIMEL

V BASIS , APPUCABL E REOUIREMENT

S WHIC H BECOM E EFFECTIV E DURIN G TH E PERMI TTERM ? 

# [7 ] YE S QN O I F NO , EXPLAI N

THI S AGENC Y I S AUTHORIZE D T O REQUIR E THI S INFORMATIO N UNDE R ILUNOI S REVISE D STATUES , 1991 , A S AMENDE D 1992 , CHA P 1111/2 , PAR . 1039.5 . DISCLOSUR E O F THI S INFORMATIO N I S REQUIRE D UNDE R THA TSECTION . FAILUR E T O D O S O MA Y PREVEN TTHI S FOR M FRO M BEIN G PROCESSE D AN D COUL D RESUL TI N TH E APPUCATIO N BEIN G DENIED . THI S FOR M HA S BEE N APPROVE D B Y TH E FORM S MANAGEMEN TCENTER .



## APPLICATIO N PAGE .

293-CAAP P 

# 0005 7 FO R APPLICANT S US E
PAG E 1 O F 4 

# H3P.4 5 

### EMISSION

UNITS COMPLIANCE

INFORMATTUTT 

## ^m^iHiiijJii-HiiJMHWiaiaj w TH E FOLLOWIN G EMISSIO N UNIT S AR E I N COMPUANC E WIT H AL L APPUCABL E REQUIREMENT S AN D WIL L CONTINU E T O COMPL YWIT H SUC H REQUIREMENT S DURIN G THE PERMI TTERM . I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S EXHIBI T293-1 : DESIGNATIO N I D NUMBE R EMBSIO N UNI T Compoun d Preparatio n an d Maturatio n 

## Moldin g Presse s Pain t / Solven t Us e S M Exhibit 220-A far Compoun d Preparatio n an d Maturatio n Sectio n 

## Se e Exhibi t 220- B fo r Moldin g Presse s Sectio n Pain t / Solven t Us e (Fugitive emissions )

APPLICATIO N PAGE . 293-CAAP P 

# 0005 8 FO R APPLICANT

S US E
PAG E 2 O F 4 

# H^iP.4 6 

## EMISSION

UNITS COMPUANCk

INFORMATION

Icnld) DESIGNATIO N P NUMBE R EMBSIO N UNf T

-4JI_*_M___l__IH*llJ:"|-<**i»Mai|ll ; .*M7

_flJHJM-ltfi'M* TH E FOLLOWIN G EMISSIO N UNITS , WHIC H AR E CURRENTL YI N COMPLIANC E WIT H A U APPUCABL E REQUIREMENTS , WIL L ACHIEV E O N ATIMEL YBASIS , AN D MAINTAI N COMPLIANC E WITH , FUTUR E COMPLIANC E DATE S AS THE YBECOM E APPUCABL E DURIN G TH E PERMI TTERM
. I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S EXHIBI T293-2 : FUTUR E COMPUANC E DAT E DESIGNATIO N I D NUMBE R EMBSIO N UNI T(MONTH/DAY/YEAR ) Compoun d Prep
. & Matur. 

## Moldin g Pres

s Area Propose d USEP AStyren e MAC T

Propose d USEP AStyren e MAC T Futur e complianc

e dates ar e unknow n

APPLICATIO N PAG E 0Q 

## 0 5 9 293-CAAP P FO R APPLICANT S US E PAG E 3 O F 4 

## L 

# 15P.4 7



# TV -WM.IMJliKlli.-l'M-iliT^^ ^ TH E FOUOWIN G EMISSIO N UNIT S AR E NO TI N COMPUANC E WIT H A U APPUCABL E REQUIREMENT S A TTH E TIM E O F PERMI TAPPUCATION . HOWEVER , THES E EMISSIO N UNIT S WI U ACHIEV E COMPUANC E WIT H AL L APPUCABL E REQUIREMENT S PRIO R T O PERMI TISSUANC E AN D WIL L CONTINU E T O COMPL YWIT H SUC H REQUIREMENT S DURIN G THE PERMI TTERM . I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S EXHIBI T293-3 : FUTUR E COMPLIANC E OAT E DESIGNATIO N I D NUMBER EMBSIO N UNI T(MONTWDAY/YEAR ) 

# N/ A T 

# 1 t"

b ) TH E FOLLOWIN G I S A NARRATIV E DESCRIPTIO N O F TH E MEAN S BV WHIC H COMPLIANC E WIL L B E ACHIEVE D FO R EAC H O F TH E EMISSIO N UNIT S USTE D I N 9a ) ABOVE . I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S EXHIBI T293-4 : 

# N/ A

•)J-4.-.l_--MMJl»_IIl«JMii:re»M ^ TH E FOLLOWIN G EMISSIO N UNIT S WI U NO TB E I N COMPUANC E WIT H A U APPUCABL E REQUIREMENT S A TTH E TIM E O F PERMI TISSUANCE . A FOR M 294-CAAPP . 'COMPLIANC E PLAN/SCHEDUL E O F COMPLIANC E •ADDENDU M FO R NO N COMPLYIN G EMISSIO N UNITS, ' MUS TB E SUBMITTE D FO R EMISSIO N UNIT S NO TI N COMPLIANC E WIT H
_ , A U APPUCABL E REQUIREMENT S A TTH E TIM E O F PERMI TISSUANCE . A FOR M 294-CAAP P I S SUBMITTE D FO R THE* ! FOUOWIN G EMISSIO N UNITS . I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S EXHIBI T293-5 : OAT E COMPLIANC E SCHEDULE D T O B E ACHIEVE D (MONTWDAY/YEAR

) DESIGNATIO N I D NUHCE R EMSSIONUNtT


# i \-

APPUCATIO N PAGE°Mf > A 293-CAAP P FO R APPLICANT S US E
PAG E 4 O F 4 

# HLP.4 8
ILUNOI S ENVIRONMENTA L PROTECTIO N AGENC Y DIVISIO N O F AI R POLLUTIO N CONTRO L - PERMI TSECTIO N P O BO X1950 6 SPRINGFIELD, " ILUNOI S 62794-950 6 

# saaaaaiBanraGH i Revision * »"" " Date : Doo«*~Hw

r5,199Q * Pag e o f Sourc e Designation : AC C 

## COMPUANCE

CERTIFICATION 

# mmmmwmmMMMMmym PERMIT * DATE : 

### AN APPLICATION FO

R A CAAP P PERMI TMUS TCONTAI N A CERTIFICATION OF COMPLIANC E 5I5NE D B

V A RESPONSIBL

E OfflCIA L TH B FOR M MUS

TB E SUBM*TTE D WIT H TH E ORIGINA L CAAP P PERMITAPPIXATIO N AN O UPDATE D O N A N ANNUAL BASB . 

### I ) SOURC E NAME : 

### SOURCE INFORMATION 

## Applie d Composite s Corp
. 5 . DAT E FOR

M PREPARED : 

### Decembe r 6,199 5 4) CAAP P PERMI TNUMBE R (i F kNoWN) : J) SOURC E I D No . (I F KNOWN) : 

# grgVF D Unknow n 

# DE C 

# 0 7 1995 5 ) I S THI S TH E FIRSTSUBMITTA L O F THI S F0RM- > I F NO . WHA TI S TH E REPORTIN G PERIO D COVERE D BYTHI S FORM ? 

### / / TO : / 

# EJS^IE J N

O
SOURCE COMPUANCE

INFORMATION 6 ) DOE S TH E SIGNATORYO F THI S FoR M HEREB YCERTIFV THATTH E SOURC E I S I N COMPLIANC E WIT H AL L APPUCABL E REQUIREMENTS ? 

## & s N O I F NO , EXPLAIN : 

### 7) PROVID E TH E SCHEDUL E FO R SUBMISSIO N O F COMPUANC E CERTIFICATIO N DURIN O TH E PERMI TTERM , E.O. . ONC E ANNUAU YI N JANUAR Y(NOT E THA TSUC H CERTIFICATIO N MUS TB E SUBMITTE D N O LES S FREQUENTL Y THA N ANNUAUY) : 

## Onc e annuall yi n August , followin g th e issuanc e of th e permi t &) INDICAT E TH E COMPLIANC E STATU S O F TH E SOURC E WIT H AN VAPPLICABL E ENHANCE D MONITORIN G AN D COMPLIANC E CERTIFICATIO N REQUIREMENT S O F TH E CLEA N AI R ACT , E.G. , N O ENHANCE D MONITORIN G REQUIRE D AN D I N COMPLIANC E WIT H COMPUANC E CERTIFICATIO N REQUIREMENTS : 

## N o applicabl e enhance d monitorin g i s required
. Th e source i s i n complianc e wit h certificatio n requirements
.

-HI S AGENC YI S AUTHORIZE D T O REQUIR E THI S INFORMATIO N UNOE R ILUNOI S REVISE D STATUES , 1991 , A S AMENDE D 1992 , '.HA P 1111/2 , PAR . 1039.5 . DISCLOSUR E O F THI S INFORMATIO N I S REQUIRE D UNDE R THA TSECTION . FAILUR E T O D O S O MA Y •REVEN TTHI S FOR M FRO M BEIN G PROCESSE D AN D COUL D RESUL TI N TH E APPLICATIO N BEIN G DENIED . THI S FOR M HA S BEE N .PPROVE D B YTH E FORM S MANAGEMEN TCENTER . 

## APPLICATIO N PAG E 0006 1 29 6 - CAAP P FO R APPLICANT S US E
PAG E 1 O F 5 

# HIP.4 9 

### EMISSION

UNI IS COMPUANCE

INFORMATION Sa

_TH E FOLLOWIN G EMISSIO N UNIT S AR E I N COMPLIANC E WIT H APPUCABL E REOUIREMENT S SUC H A S EMISSIO N STANDARDS , EMISSIO N CONTRO L REQUIREMENTS , EMISSIO N TESTING , COUR TREQUIREMENTS , WOR K PRACTICES , O R ENHANCE D MONITORING , BASE D O N TH E COMPUANC E METHOD S SPECIFIE D BELO W (I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S EXHIBI T296-1) :

EMISSIO N UNI T APPUCABL E RUL E COMPLIANC E DETERMINATIO N METHO D Compoun d an d Maturatio n Roo m (Se e Exhibit 220- A i n section ) Moldin g Pressae (Se e Exhibit 220- B i n section ) 

### Pain t Us e Solven t Us e Se e Appendi x B,(l ) Se e Appendi x C Se e Appendi x B,(ll ) Se e Appendi x C 

### Se e Appendi xC IA C 218.666(d ) Se e Appendi x B,(l ) Se e Appendi x C Se e Appendi x B,(ll ) Se e Appendi x C 

### Se e Appendi xC recordkeepin g

APPLICATIO N PAG E 0006 2 29 6 - CAAP P FO R APPLICANT S US E PAG E 2 O F 5 

# Y ?P.5 0



### fe) Us TTH E EMISSIO N UNIT S THA TWER E No TI N CONTINUOU S COMPLIANC E SINC E TH E LAS TREPORTIN G PERIOf c AN D TH E REASON(S ) FO R NONCOMPLIANC E (I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D UBE L A S EXHIBI T 296-2.) : EMISSIO N UNI TREASON(S ) FO R NONCOMPLIANC E 

## Non e

•

: COMPUANCE INFORMATION ifl ) SUMMAR YO F METHOD S USE D T O DETERMIN E COMPLIANCE : a ) DESCRIPTIO N O F TESTIN G METHODS USE D T O DEMONSTRAT E COMPLIANC E (I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S EXHIBI T296-3.) : 

## VO M 218.668(a)(1 ) Cleanin g materia l wit h supplie rdata , sampl e o rMetho d 2 4 218.668(a)(3 ) Monome rconten t determine d b ysupplie rdata
. 218.668(b ) Upo n Agenc yrequest . 218.668(c ) Upo n U.S.EP Arequest . Se e Appendi xC , Stat e Operatin g Permi t

APPLICATIO N PAG E 0006 3 29 6 - CAAP P FO R APPLICANT S US E PAG E 3 O

F 5 

# HIP.5 1



### lob , DESCRIPTIO

N O F MONITORIN

G PROCEDURE

S USE D T O DEMONSTRAT

E COMPLIANCE

, INCLUDIN

G AN V ENHANCE D MONITORIN G REQUIREMENT S O F TH E AC T(I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S EXHIBI T296-4.) : 

## N o monitorin g equipmen t o renhance d monitorin g required
. Complianc e demonstratio n vi a recordkeeping , dail yinspections(i.e
. inspectio n o f covers ) & maintenance
.

c , DESCRIPTION O

F RECoRbkEEPiNG UsED T O DEMONSTRAT

E COMPLIANC

E (it - ADDITIONA

L SPAC E I S NEEDED

, ATTAC H AN D LABE L A S EXHIBI T296-5.) : Se e Appendi x B , (l)(B ) an d (I)(C ) Se e Appendi x C , State Operatin g Penni t Condition s 1 1 an d 1 2 whic h state : 11 . Th e monome r conten t o f poiye*rferii-*sJ n materi a shal l b e determined : I . Fro m supp l tor dat a an d operatin g data ; o r i . By s*MiK*n g ar t analy- wb y th e methoo * set forth i n SC^ ^ 12a . Th e Permittee shal l maintai n record s o f th e followin g item s t o **o wth e Agency to revie wcompliance : I . Formulatio n data fo r moldin g compounds , wit h type an d amoun t of re^s), additives , catalyst , filler, fiberglass, inhibitors , promoters , etc . (data distirx ^ fo r eac h dJstinc t formulation ) H. Styren e conten t of resi n material s use d i n moldin g compound , (dat a distinct fo r eac h distinc t resi n an d material ) iii . Quantit

y (pounds) o f eac h type (sheet mol d o r thic k mol d an d genera l purpose , hig h monome r content , specia l purpose , or lo wmonome r content

) o f compoun d produced , (monthly ) Iv . Quantit

y (pounds) o

f monome r used , (monthly ) v . Quantit

y o f eac h solven t used (dibasi c este r an d isopropyl alcohol ) an d amoun t recovere d an d sen t of f fo r site reclamation , (monthly ) vi . VO M emissions , (calculate d monthly ) 12b . Th e Permittee shal l kee p writte n record s o f periodi c inspection s t o confir m impiementatkx . o f th e measure s required b

y Conditio n 7 . 12c . Thes e record s shal l b e retaine d fo r a period o f thre e year

s an d shal l b e mad e availabl e fo r Agenc y inspectio n upo n request Copies o f record s shal l b e submitted withi n 1 0 days o f Agenc y request



## APPLICATIO N PAG E 296 - CAAP P 

# 0006 4 FO R APPLICANT S US E PAG E 4 O F 5 

# 5oP.5 2

iod ) DESCRIPTIO

N OF REPoRTINO USE D T O DEMONSTRAT

E COMPUANC E (I F ADWTIONA L SPAC E I S NEEDED

, ATTAC

H AN D LABE L A S EXHIBI T296-6.) : 

## Submissio n o f Annua l Emissio n Repor t unde rIAC 201.302
. Marc h 15,199 5 Certificatio n o f Compliance unde r21 8 Subpar t CC
.

SIGNATURE

EJZUCJC NCTE : -mEC«nFICA!IWMUSTBfcSlG>IEDBVARESPONSlBLE « — W U B E RETURNE D AS -^COMPLETE . •

.. ) I CERTIF

Y UNDE

R PENALT

Y O F LA W THAT

. BASE D O N INFORMATIO

N AN D BEUE

F FORME

D AFTE R REASONABL

E INQUIRY . TH E STATEMENT S AN D INFORMATIO N CONTAINE D I N THI S APPUCATIO N AR E TRUE , ACCURAT E AN D COMPLETE . AUTHORIZE D SIGNATURE : 

## Vic e Presiden t - Operation s

" ^ AUTH6|-aZEDSIONA'njR E 

## Joh n J
. Puni s TYPE D O R PRMTE D NAM E O F SIGNATOR Y 

### ,/<*- TTTV E O F SIGNATOR

Y DAT E



## APPUCATIO N PAGE .
, 296-CAAP P 

# 0006 5 FO R APPLICANT S US E
PAG E 5 O F 5 

# 5(P.5 3
ILLINOI S ENVIRONMENTA L PROTECTIO N AGENC Y •.- A DIVISIO N O F AI R POLLUTIO N CONTRO L - PERMI T SECTIO N P.O . BO X 1950 6 SPRINGFIELD , ILUNOI S 62794-950 6 FO R APPLICANT' S US E Revision * *** " Date : Novembe

r 15.19» 5 Pag e o f Sourc e Designation : ACC 

## FEE DETERMINATION

FOR CAAPP PERMIT

THE PAT A PROVIDE

D C N THI S FOR M WIL L B E U5L P T

O m_n_RMIN

E THE PERMI

T FE L TH

E EMISSIO

N LEVEL S STATE P O N THI S FOR M CA N ONL

YB E USE

O FO R TH E PURPOS E O F PERM TFE E OETERMWATION I F TH E APPUC*AN TB WIUJN G T O ACCEP TTHES E LEVEL

S A S PERM TSPECIA

L CONDITIONS . EMBSION S DAT A PROVIDE D O N THI S FOR M MUS TB E IDENTICA L T O OAT A I N TH E TERMnTE D EMBSIO N RATE

* COLUMNS PROVIDE D O N TH E OAT A ANO NFORMATIO N FOR M FO R INDIVIDUA L B«nioaUMraOR£^NTRO L EQUIPMENT. W

ADOmONA L SPAC E I S NEEDED . ATTAC H ANO LABE L A S 2BM . f\\?^,^jlZFW "* * •-* = 

### \) SOURC E NAME : SOURCE INFORMATION Applie d Composite s Corp . 

# Ub C J 7 iS9 5 2 . DATE FOR M PREPARED : 

### Decembe r 6,199 5 

### 3 ) 

# WSSSjar 0


# - 0BS483^V ^

' o r

# * ^

• ~ " •FEE DATA 

### 4 ) WiL L TH E SOURC E 

### PA

YTH E MAXIMU

M FEE O F i100.ooo.o

o PE R YEAR * IFYES , TH E REMAINDE R O F THI S FOR M DOE S NO TNEE D T O B E COMPLETED . 5 ) EMBSIO N UNIT * Compoundin g Preparatio n a n Maturatio n 

### Moldin g Presse s MTROGE N OXIDES (TONS/YR) I PARTICULAT E MATTE R (PART ) (TONS/YR

) SULFU R

DIOXID E (SOj ) (TONS/YR) YE S

VOLAT U ORGANI C MATERIAL (VOM ) (TONS/YR) 

## 68. 3 26. 3 

# • N O OTHER " SPECIF Y (TONS/YR

)

EMBSIO N UNI T-PROVH3 E TH E NAM E AN O FLO W DIAGRA

M DESIGNATIO N O F TH E EMBSIO N UNT TA S I TAPPEAR

S O N TH E DAT

A AN D MFORMATIO N FORM . "OTHE R - AN

YHAZARDOU S AI R POLLUTANT(HAP) NOTINCLUDED ELSEWHERE , E.G. , CHLORINE . Ha , ETC .
mi S AGENC YI S AUTHORIZE D T O REQUIR E THI S INFORMATIO N UNOE R ILUNOI S REVISE D STATUES , 1991 . A S AMENDE D 1992 , 2HA P 1111/2 , PAR . 1039.5 . DISCLOSUR E O F THI S INFORMATIO N I S REQUIRE D UNDE R THA TSECTION . FAILUR E T O D O S O MA Y PREVEN TTHI S FOR M FRO M BEIN G PROCESSE D AN D COUL D RESUL TI N TH E APPUCATIO N BEIN G DENIED . THI S FOR M HA S BEE N APPROVE D B YTH E FORM S MANAGEMEN TCENTER . 

## APPLICATIO N PAG E 00^6 8 292-CAAP P FO R APPLICANT S US E PAG E 1 O F 2 

# S*-P.5 4

5 > (CONTINUE ^ BMBStONUNTT * MTROGE N OXDE S (NCfc ) (TONS/YR ) PARTICULAT E MATTE R (PART ) (TONS/YR ) SULFU R DtOXD E (SOj ) (TONS/YR ) VOLATX E ORGAM C MATERIA L (VOM ) (TONS/YR ) OTHER TM SPECIF Y (TONS/YR )

"B«SSIONUNrr-PRO\nOe-|>IENAMeAf_On.OWDtAGIWMC)eSIGNA- ^ EMBSIO N UNI TA S I TAPPEAR

S O N TH E DAT

A AN D MFORMATIO N FORM . •OTHE R - AN

YHAZARDOU S AI R POLLUTAN T(HAP ) NO TNCLUOE D ELSEWHERE , E.G. . CHLORINE . HCI . ETC . SUBTOTA L 

## 94. 6 7 ) FUGITIV E 

## 3.72 9
TOTA L 

## A B 

## t 

## ° 98.32 9 i ty GRAN DTOTAL • AD DBOXES * THROUG H B (TONS/YR) : 

# 98.32 9 16) CALCULATE D PERMI TFE E - I F 6RAN D TOTA L I N iTE M 6 ABOV E I S > ito TONSfrf t THE N MULTIPL YGRAN D TOTA L B Y$13.5 0 AN D ENTER . OTHERWIS E ENTE R $1,000.00 : 

# $1,000.00 1 1 MINIMU M PERMI TFE E I S Jl,00o.fl0PE R VEA R -MAXIMU M PERMI TFE E 1 5 *1M.Mu. M PE R YEAR . TH E CALCULATE D PERMI TFE E I N ITE M 1 0 ABOV E I S BETWEE N THES E TW O FE E AMOUNT S THEl t ENTE R HERE , OTHERWIS E ENTE R THE MINIMU M O R MAXIMU M PERMI TFEE . WHICHEVE R I S APPLICABLE . THI S I S TH E ACTUA L ANNUA L PERMI TFEE : 

# 1000.00

APPLICATIO N PAG E 000E 7 292-CAAP P FO R APPLICANT S US E
PAG E 2 O F 2 

# SJP.5 5



## SECTION S PAINT/SOLVEN T US E



# 5HP.5 6 ILLINOI S ENVIRONMENTA L PROTECTIO N AGENC Y DIVISIO N O F AI R POLLUTIO N CONTRO L - PERMI TSECTIO N P.O . BO X1950 6 SPRINGFIELD , ILUNOI S 62794-950 6 FO R APPLICANT' S USf c Revision * J"* " Oate : Dece-yba

r 5,199f t Pag e of Sourc e Designation : ACC 

## FUGITIVE

EMISSIONS 0 

## DATA AND

INFORMATION I D NUMBEREMISSIO N POINT * TESTE : THI S FOR M MA

YB E COMPLETE D FOR FUGITIV E EMISSIO N ACTIVITIE S RATHE R THAN COMPLETIN G AN EMISSIO N UNI T O R STAN D ALON E FORM . FUGITIV E EMISSION S AR E DEFINE D A S THOS E EMISSION S WHIC H COUL D NOTREASONABL Y PASS THROUG H A STACK . CHIMNEY

, VEN TOR OTHE R FUNCTIONALL YEQUIVALEN

TOPENING . NOT E THA T UNCAPTURE D PROCESS EMISSIO N UNITEMISSION S AR E TYPICALL YNO TCONSIDERE D FUGITIV E AN D MUS TB E ACCOUNTE D FO R O N TH E APPROPRIATE EMISSIO N UNI TO R STAN D ALON E FORM . ANYEMISSION S A TTH E SOURC E NOTPREVIOUSL

YACCOUNTE D FOR O N AN EMISSIO N UNI TO R STAN D ALON E FOR M MUS TB E ACCOUNTE D FO R O N THI S FORM . SOM E EXAMPLE S O F EMISSION S WHIC H AR E TYPICALL YCONSIDERE D FUGITIV E ARE ;
•ROA D DUS TEMISSION S (PAVE D ROADS , UNPAVE D ROADS . AN D LOTS )
•STORAG E PIL E EMISSION S (WIN D EROSION , VEHICL E DUM P AN D LOAD )
•LOADING/UNLOADIN G OPERATIO N EMISSIO N
•EMISSION S FRO M MATERIA L BEIN G TRANSPORTE D I N A VEHICL E
•EMISSION S OCCURRIN G FRO M TH E UNLOADIN G AN D TRANSPORTIN G O F MATERIAL S COLLECTE D BYPOLLUTIO N CONTRO L EQUIPMEN T
•EQUIPMEN TLEAKS (E.G. , LEAKS FRO M PUMPS , COMPRESSORS , IN-UN E PROCES S VALVES , PRESSUR E REUE F DEVICES . OPEN-ENDE D VALVES , SAMPUN G CONNECTIONS , FLANGES , AGITATORS . COOUN G TOWERS , ETC. )

GENERA L CLEAN-U P VO M EMISSION S
NOT E THA

TTOTA L EMISSION S FRO M TH E SOURC E (TS ) AR E EQUAL TO SOURCE-WID E TOTA L EMISSIO N UNI TEMISSION S 

## (PT ) PLU S TOTA L FUGITIV E EMISSION S (FT) , E.G. , T S = P T= F T 1 ) SOURC

E NAME: Pain t / Solven t Us e 2 ) DAT E FOR M PREPARED : 

### Decembe r6,199 5 SOURCE INFORMATION S ) SOURC E I D NO
. (I F KNOWN) : Q89483AA F

THI S AGENC

YI S AUTHORIZE D T

O REQUIR E THI S INFORMATIO N UNDE R ILUNOI S REVISE D STATUES , 1991 , A S AMENDE D 1992 . CHA P 1111/2 . PAR . 1039.5 . DISCLOSUR E O F THI S INFORMATIO N I S REQUIRE D UNDE R THA TSECTION . FAILUR E T O D O S O MA Y PREVENTTHI S FOR M FRO M BEIN G PROCESSE D AN D COUL D RESUL TI N TH E APPUCATIO N BEIN G DENIED . THI S FOR M HA S BEEN APPROVE D B

YTH E FORM S MANAGEMEN TCENTER . 

## APPLICATIO N PAG E 39 1 - CAAP P 

# 0004 4 FO R APPLICANT S US E
PAG E 1 O F 1 1 

# ssP.5 7 

### GENERALINFORMATION 4) PROVID E TH E F0LL0MN 6 INFORMATIO N Fo R TH E FUGITIV E EMISSIO N POINT S A TTH E SOURC E INCLUDE D I N THI s APPUCATION . SIMILA R POINT S MA YB E GROUPE D TOGETHER . NOTE : ATTAC H TH E CALCULATIONS . T O TH E EXTEN TTHE YAR E AI R EMSSIONSRBATED , FRO M WHIC H TH E ABOVE EMBSIONS . WER E BASED AN D LABEL A S EXHIBI T391-1 . F TH E ABOV E SPAC E WA

S NO TADEQUATE , USTA a OTHE R FUGITIV E POINT

S AN O INCLUD E TH E REOUIRE D INFORMATIO N O N TH B ATTACHMENT. FO R PAVE D ANO UNPAVE D ROADS , INCLUD E ROA D MLE S (E.G. , S MLE S O F UNPAVE D ROADS) ; FO R STORAG E Pt_ES , WOICATE TH E MATERIA

L BEING STORE D (E.G. . 2 0 UMESTON E STORAG E PILES) ; FO R EQUIPMEN TLEA KPOMTS , GROU P SMLA R POINT S TOGETHE R (E.G. , 1 5 ORGANI C LIQUI D PUMPS) ; FO R TRANSFE R POINTS . IDENTIF YTH E ORIGI N AN D DESTINATIO N O F TRANSFE R AN O TH E MATERIA

L BEING TRANSFERRE D (E.G. . S BEL TTO BI N TRANSFER

S O F CORN) .
FUGITIVE PONT(S ) REGULATE D A H POLLUTANT(S

) UNCONTROLLE D ANNUA L EMBSION S (TONS/YR) TYPICA L Pain t Us e Solven t Ue e 

## VO M VO M 0.1 1

3.6 2 0.0 6

2. 8

5 ) ATTAC H ABIA&RA M O F TH E SOURC E THA TINDICATE S TH E LOCATIO N O F AL L FUOITIV E EMISSIO N POINTS : A SKETC H DRAWIN G WIT H TH E PROPE R NOTATION S I S SUFFICIENT . ALTERNATIVELY , TH E REQUIRE D INFORMATIO N MA YB E PLACE D O N A COP YO F A N EXISTIN G PLA N O R MA P SUBMITTE D WIT H THI S APPUCATIO N (E.G. , PLO T PLAN/MAP) . ALS O INDICAT E O N THI S DIAGRA M TH E LOCATIO N O F AN YAMBIEN TAI R MONITORIN G STATIONS . LABfl . THI S DIAGRA M 391-2 . NOTE : EQUIPMEN TLEA KFUGITIV E EMISSIO N POINT S NEE D NO TB E SHOW N O N THI S DIAGRAM . 

## APPLICATIO N PAGE . 39 1 - CAAP P 

# 0004 5 FO R APPLICANT S US E PAG E 2 O F 1 1

%O l rnuviucn n orcv.iri<_ > cmiasiu n sinnunnuiainn u umnniiunaia i nniMinncnrruungL E t wruuinri . uniuuiung m

212.316(d) , OPACIT Y< O R » 10 % A T4 FT) :

FUGITIV E POINTS(S

) REGULATE D AI R POUUTANT(S ) EMBSIO N STANDARDS)



## ~TJ Solven t Us e

PROVID E AN V SPECIFI C RECORDKEE P

FUGITIV E POINTS(S

) 

## N/ A IN G VO M

RULE(S ) WHIC H AR E APPUCABLE : REGULATE D AI R POLLUTANT'S ) 

## IA C 218.666(d )

-

EMBSIO N STANDARD'S ) IIII - uwyiwi . \w.«_,. , nwn wW_.WIVI_.II , f , •waa-xaa, •_-,«_ • REQLNREMENT(S

) 

## solven t recover

v *

REQUIREMENT(S

)

I F ADOmONA L SPAC E B NEEDED , ATTAC H ANO LABEL A S 381-3 .



## $ 

# APPLICATIO N PAGE__£M£ 6 

### 39 1 - CAAP P 

## ZekW;l_dia32iH! H PAG E 3 0F1 1

0 1 o o

# V A B

) PROVID E ANV SPECIFI C REPORTIN G RULE(S) WHIC H AR E APPLICABLE :

FUGITIV E POINTS(S ) REGULATE D AI R POU_UTANT(3 ) 

## Pain t / Solven t Us e Solven t Us e VO M VO M

"57PROVID E ANYSPECIFI C MONITORIN G RULE(S ) WHIC H AR E APPLICABLE : FUGITIV E POINTS(S ) REGULATE D AI R POLLUTANT(8 )



### ~fl ! 

## N/ A

) PROVID E ANV SPECIFI C TESTIN G RU I

FUGITIV E POtNTS(S ) 

## N/ A .E S EMBSIO N STANDARD!? ) 

## IAC 201.30 2 IAC 218.666(d )

. EMBSIO N STANOARO(S )



### AND/O R PROCEDURE S WHIC H AR E APPUCABLE : REGULATE D A R POLLUTANT(8 ) EMBSIO N STANDARDS )



### ' ! REQUtRE**ENT(8 ) 

## AE R solven t recover

y *

REQUIREMENT^ )

REQUIREMENT^ )

I F ADDITIONA L SPAC E B NEEDED , ATTAC H AN D LABE L AS-MJ1-3 . 

## APPLICATIO N PAG E "" ° 391-CAAP P FO R APPLICANT S US E
PAG E 4 O F 1 1P.6 0 

### COMPUANCE

INFORMATION H ) I S EAC

H FUGITIVE POIN

TI N COMPUANC

E WITH ALL APPUCABL

E REOUIREMENTS

? 

# TZ > 4 0 I F NO , THE N FOR M 294-CAAP P 'COMPLIANC E PLAN/SCHEDUL E O F COMPLIANC E - ADDENDU M FO R NO N COMPLYIN G EMISSIO N UNITS " MUS TB E COMPLETE D AN D SUBMITTE D WIT H THI S APPUCATION .



### IS ) EXPLANATIO

N OF HO W INITIA L COMPUANC

E I S T O BE , O R WA S PREVIOUSLV

, DEMONSTRATED: Materia l usag e recordkeepin g

13 ) EXPLANATIO

N OF HO W ONGOIN

G COMPLIANC

E WILL BE DEMONSTRATED : Materia l usag e recordkeepin g

TESTING, MONITORING, RECORDKEEPING AND REPORTING I4i ) US TTH E PARAMETER

S THA TRELAT E T O AI R EMISSIONS FO

R WHIC H RECORD

S AR E BEING MAINTAINE D T O DETERMIN E FEES , RUL E APPUCABILITYO R COMPLIANCE . INCLUD E TH E UNI TO F MEASUREMENT , TH E METHO D O F MEASUREMENT , AN D THE FREQUENC YO F SUC H RECORD S (E.G. . HOURLY . DAILY . WEEKLY) : PARAMETE R FUGITIV E POIN T METHO O O F MEASUREUfCW T Pa W /Solven t Us e 

### Se e Figur e 3 , F- 2 Annua l an d Monthly summarie s FREQUENC Y 

### monthl y



## APPLICATIO N PAGE ,

39 1 - CAAP P 

# 0004 8 FO R APPLICANT S US E PAG E 5 O F 1 1 

# 5°\P.6 1



### b ) BRIEFL

VDESCRIB E TH E METHO D BVWHIC H RECORD S WIL L B E CREATE D AN D MAINTAINED . FO R EACH — RECORDE D PARAMETE R INCLUD E TH E METHO O O F RECORDKEEPING , TITL E O F PERSO N RESPONSIBL E FO R RECORDKEEPING , AN D TITL E O F PERSO N T O CONTAC TFO R REVIE W O F RECORDS : PARAMETER PaW/Solven t Us e METHO O O F RECORDKEEPt

W WMIU M »fnonM y i TITL E O F PERSO N RESPONSIBLE 

## HSEQ Coordinato r TITI E O F CONTAC TPERSO N 

### HSE Q Coordinato r

c ) I S COMPUANC E O F TH E EMISSIO N UNI TREADILVDEMONSTRATE D B VREVIE WO F TH E RECORDS ? I F NO , EXPLAIN : YE S N O



### d ) AR E AL L RECORD S READIL VAVAILABL E FO R INSPECTION , COPVIN O ANDLO R „ SUBMITTA L T O TH E AGENC YUPO N REQUEST ? * YE S N O I F NO , EXPLAIN :


### 15a ) DESCRIB E AN VMONITOR S O R MONITORIN G ACTIVITIE S USE D T O DETERMIN E FEES , RUL E APPUCABIUT VO R COMPLIANCE : 

## N/ A T j WHA TPARAMETER(S ) IS(ARE ) BEIN O MONITORED ? 

## N/ A

c ) DESCRIB E TH E LOCATIO N O F EAC H MONITO R ANDLO R MONITORIN G PROCEDURES : 

## N/ A T J I S EAC H MONITO R EOUIPPE D WIT H A RECORDIN G BEVICE ? I F NO , US TA U MONITOR S WITHOU TA RECORDIN G DEVICE : 

## N/ A YE S N O



# APPLICATIO N PAGE_££2iJ L 39 1 - CAAP P FO R APPLICANT S US E
PAG E 6 O F 1 1 

# CoP.6 2



### e ) I S EAC H MONITO R HEVIEWEgTOITACgORAC V O N A TLEAST * QUARTERL YBSSIST " " , YE S ' N O I F NO , EXPLAIN : 

## N/ A I) I S EAC H MONITO R OPERATE D A TAL L TIME S THATFUGITIV E EMISSION S MA V OCCUR ? YE S N O * I F NO , EXPLAIN : 

## N/ A IS ) PROVID E INFORMATIO N O N TH E MOS TRECEN TTESTS , I F ANV , I N WHIC H TH E RESULT S AR E USE D FO R PURPOSE S O F TH E DETERMINATIO N O F FEES , RUL E APPUCABILITYO R COMPLIANCE . INCLUD E TH E TES TDATE , TES TMETHO D USED , TESTIN G COMPANY . OPERATIN G CONDITION S EXISTIN G DURIN G TH E TES TAN D A SUMMAR YO F RESULTS . I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S EXHIBI T391-4 : TES TOPERATM G FUGITIV E POINT(S

) TES TDATE METHOO TESTIN G FIR M CONDmON S SUMMARYO F RESULT S



## T J N/ A i

•

• *) DESCRIB E AL L REPORTIN G REOUIREMENT S AN D PROVID E TH E TITL E AN D FREQUENC YO F REPOR T SUBMITTAL S T O TH E AGENCY : FUGITIV E REPORTIN G REQURBriENTS TITL E O F REPORTFREQUENC Y POtNT<S ) 

## F- 2 

## IAC 201.30 2 AE R Annua l

ru&iivb

DUST 

### (complete

it applicable) ifia ) AR E OPACIT

YREADING S REOUIRE D T O B E TAKEN ? YE S N/ A N O I F YES , SPECIF YTH E RELEVAN TFUGITIV E POINT(S) :



### b) SPECIFYTH E FREOUENC YO F OPACITYREADINGS : N/ A



## APPLICATIO N PAG E

39 1 - CAAP P 

# 0005 0 FO R APPLICANT S US E PAG E 7 O F 1 1 

# 6 1

### c)IBU5EPA"METH0 D 3 U5ED7 0 REA D AL L VISIBL E EMISSIONS ? I F NO , EXPLAI N AN D SPECIF YTH E METHO O USED : 

## N/ A YE S N O



### Ifl ) I S A N OPERATIN G PROORA M FO R FUGITIV E PARTICULAT E MATTE R AND/O R PMI 6 , , CONTRO L REQUIRE D PURSUAN TT O 3 6 IL L ADM . COD E 212.300 ? 1 1 \w^ I F YES , HA S SUC H A PROGRA M PREVIOUSL YBEE N SUBMITTE D T O TH E AGENCY ? 1 1 1 1 

### 1 |YE S | 1 N O I F SUC H A PROGRA M HA S NO TBEE N SUBMITTED , I TSHOUL D B E ATTACHE D T O THI S FOR M UPO N SUBMITTA L AN D LABELE D A S 391-5 . 

### 20 ) 1 5 TH E SOURC E I N COMPLIANC E WIT H 3 5 IL L ADM . COD E 212.30 1 WHIC H 5TATE 5 THA T N O EMISSION S SHAL L B E VISIBL E BEYON D TH E PROPERT YUN E O F TH E SOURCE ? I I I F NO , EXPLAIN : 

## N/ A 

# •

# N O

FUGITIVE VOM FROM EQUIPMENT

LEAKS (complete

d applicable) H ) INDICAT E WHIC H O F TH E FOLLOWIN G METHOD S WA S USE D T O ESTIMAT E FUGITIV E EMISSION S O F VO M 

### FRO M EQUIPMEN TLEAKS* . 

### fJAV I 1 EM I lAVERAG E IISSIO N FACTO R LEAK/N O LEA K EMISSIO N FACTO R STRATIFIE D EMISSIO N FACTO R 

# • LEA KRATE/SCREENIN G VALU E CORRELATIO N 

# • OTHER ; (SPECIFY) : ATTAC H A COP YO F TH E FINA L REPOR TFO R AN YO F TH E ABOV E TEST S THA THAV E BEE N PERFORMED . THI S REPOR TSHOUL D SUMMARIZ E TH E TES TPROCEDURE S AN D RESULTS . LABE L A S 391-6 . 

### 22 ) 1 5 THER E A N ACTIV E INSPECTIO N AN D MONITORIN G PROGRA M O F EQUIPMEN T LEAKS ? 

# • « * D N O I F YES , PROVID E A DESCRIPTIO N O F SUC H PROGRA M O R ATTAC H TH E INSPECTIO N PROGRA M T O THI S FOR M AN D LABE L A S 381-7 : 

# N/ A

APPLICATIO N PAG E 0005 1

39 1 - CAAP P FO R APPLICANT S US E PAGE 8 O F 1

1 

# ClP.6 4


### FUGITIVE

VOM FROM CLEANUP

OPERATIONS

(compleia

it appUcable) » ) COMPLET E TH E FOLLOWIN G FO R EAC H Vo M CONTAININ G MATERIA L USE D FO R CLEANU P FO R WHIC H TH E EMISSION S AR E FUGITIV E AN D HAV E NO TBEE N ACCOUNTE D FO R ELSEWHER E I N THI S APPUCATION : ANNUA L USAG E (GAUYEAR

) GENERI C NAM E O F CLEANU P

MATERIAL DENSIT Y (LB/GAL ) VO M CONTEN T

(WEIGH T%

) MA

X TYPICA L

• ) b )
e ) 

## se e Tabl e 3

24 ) EXPLAI N TH E MEAN S 

### B V WHIC H THES E MATERIAL S AR E USE D AN D WHATEOUIPMEN TO R ITEM S AR E BEIN G CLEANED : 

## Solvent s ar e primaril yuse d fo rlin e flushing , pain t thinnin g an d cleanup
.

25a ) AR E AL L Vo M UsE D I N CLEANU P OPERATION S CONSIDERE D T O B E EMITTED ? YE S N O I F NO , EXPLAIN : 

## * Wast e solvent s are shippe d offsit e fo renerg yrecovery . Cleanu p solvent s use d i n th e Compoun d Preparatio n an d Maturatio n Are a ar e include d i n th e tota l emission s fro m Compoun d Preparatio n an d Maturatio n Are a (se e Sectio n 3)
. b ) I F APPUCABLE , COMPLET E ITEM S I , II , AN D ii i BELOW : I ) PROVID E TH E MAXIMU M AN D TYPICA L AMOUN TO F VO M RECLAIME D AND/O R SHIPPE D OFF-SIT E AN D HENCE , NO TEMITTED : (GALSYR ) (TONS/YR) MA X 

## N/ A N/ A N/ A N/ A ii ) EXPLAI N TH E MEAN S BV WHIC H VO M I S COLLECTE D FO R RECLAMATIO N ANDfl R DISPOSA L 

## Wast e dibasi ceste ri s store d i n 5 5 gallo n drum s prio rt o offsit e energ yrecovery .

APPLICATIO N PAG E 0005 2 39 1 - CAAP P FO R APPLICANT S US E PAG E 9 OF 1 0 

# C3P.6 5


### IS) EXPLAI N TH E MEAN S BV WHIC H TH E AMOUN TO F VO M COLLECTE D 1 5 MEASURE D O R DETERMINED : 

## Wast e solvents ar e shippe d offsite fo r energ y recovery .

FUGITIVE

CONTROL 26 ) COMPLET E TH E FOLLOWING , INCLUDIN G TH E MINIMU M AN D TYPICA L REDUCTIO N EFFICIENC YFO R EAC H CONTRO L MEASUR E UTILIZED :



### • ) b )
c ) 

### < 0

• ) CONTRO L MEASURE S 

# N/ A REGULATE D A R POLLUTAN T FUGITIV E POINT'S ) CONTROLLE D REDUCTIO N MIN EFF(% -TV P FREQUENC Y O F CONTRO L APPUCATIO N

NOTE : I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S 391-8 . 

### 27 ) PROVID E ADESCRIPTIO N O F EAC H O F TH E CONTRO L MEASURE S INDICATE D I N ITE M 32
. I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S 391-9 .

CONTRO L MEASURE(S

) DESCRIPTIO N a ) 

## N/ A

b ) 

## N/ A

APPLICATIO N PAGE

_ 39 1 - CAAP P 

# 0005 3 FO R APPLICANT S US E PAG E 1 0 O F 1 1 

# 6 HP.6 6



### 27 ) {CONTINUED) PROVID E A DESCRIPTIO N O F EAC H O F TH E CONTRO L MEASURE S INDICATE D I N ITE M 26 . I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S 391-9 .
« ) CONTRO L MEASUREIS ) 

# N/ A DESCRf-HO N



# N/ A

N/ A

N/ A

N/ A

•• ) 

## N/ A



# APPLICATIO N PAG E 0005 4

39 1 - CAAP P PAG E 1 1 O F 1 1 

# L$P.6 7



## SECTIO N 4 MOLDIN G PRESSE S



# G GP.6 8
ILLINOI S ENVIRONMENTA L PROTECTIO N AGENC Y DIVISIO N O F AI R POLLUTIO N CONTRO L - PERMI TSECTIO N P.O
. BO X 1950 6 SPRINGFIELD , ILUNOI S 62794-950 6 FO R APPLICANT S US E Revisio n # : WB ' 1 Date : Dace-jnberS
. 199S Pag e o f Sourc e Designation : AC C 

## PROCESS

EMISSION UNIT DATA AND

INFORMATION EMISSIO N 

### POIN T4 •BATE .


### I ) SOURC E NAME : 

## Applie d Composite s Corp
. SOURCE INFORMATION 2 ) DAT E FoR M PREPARED : 

### Decembe r6,199 5 3) SOURC E I b NO . nonjlMAAP 

### . (I F KNOWN) : 089483AA F 

### GENERALINFORMATION 4 ) NAM E O F EMISSIO N UNIT : : M o 

## ' d 

## ' n 

## g Presse s 

## (se e Appendi xA , Exhibi t C fo rlis t of moldin g presses ) 5 ) NAM E O F PROCESS : 

## Moldin g Presse s 6 ) DESCRIPTIO N O F PROCESS : 

## Se e Introductio n 7) DESCRIPTIO N o F IYE M O R MATERIA L PRODUCE D O R ACTIVIT YACCOMPUSHED : 

## Molde d Fiberglas s Reinforce d PlasticJFRP ) 6 ) FLO W DIAGRA

M DESIGNATIO

N O F EMISSIO

N UNIT : " " Moldin g Presse s (se e Figur e 3 ) 5 ) MANUFACTURE

R O F EMISSIO N UNI T(I F kNOWN) : S e e Appendi x A , Exhibi t C 10 ) MODE L NUMBE R (I F KNOWN): S e e Appendi x A , Exhibi t C 12 ) DATE S OF COMMENCIN

G CONSTRUCTION . r 

### " OPERATIO N AND/O R MOS TRECEN TMODIFICATIO N O F THI S EMISSIO N UNI T(ACTUA L O R PLANNED )



### 13 ) DESCRIPTIO N OF MODIFICATIO N (I F APPUCABLE) : 

## N/ A 11 ) SERIA L NUMBE R (I F KNOWN) : Se e Appendi x A , Exhibi t C a ) CONSTRUCTIO N (MONTH/VEAR) : 

## Se e Appendi xA, Exhibi t C b ) OPERATIO N (MONTH/YEAR) : 

## Se e Appendi xA , Exhibi t C e ) LATES TMODIFICATIO N (MoNYHA'EAR) : 

## N/ A

THI S AGENC YI S AUTHORIZE D T O REQUIR E THI S INFORMATIO N UNDE R ILUNOI S REVISE D STATUES , 1991 , A S AMENDE D 1992
. CHA P 1111/2 , PAR
. 1039.5
. DISCLOSUR E O F THI S INFORMATIO N I S REQUIRE D UNDE R THA TSECTION
. FAILUR E T O O O S O MA Y PREVEN TTHI S FOR M FRO M BEIN G PROCESSE D AN O COUL D RESUL TI N TH E APPUCATIO N BEIN G DENIED
. THI S FOR M HA S BEE N APPROVE D B YTH E FORM S MANAGEMEN TCENTER
.



## APPLICATIO N PAG E 0003 1 220-CAAP P 

### FO R APPLICANT S US E PAG E 1 O F 1 0 

# GlP.6 9



### U ) DOE S TH E EMISSIO N UNI THAV E MOR E THA N ON E MOD E O F OPERATION ? I F YES , EXPLAI N AN D IDENTIF YWHIC H MOD E I S COVERE D B YTHI S FOR M (NOTE : A SEPARAT E PROCES S EMISSIO N UNI TFOR M 220CAAP P MUS TB E COMPLETE D FO R EAC H MODE) : 

## res 1 0



### I f l PROVID E TH E NAM E AN D DESIONATIO N O F AL L AI R POLLUTIO N CONTRO L EOUIPMEN TCONTROLLIN O THI S EMISSIO N UNIT , I F APPUCABL E (FOR M 260-CAAP P AN D TH E APPROPRIAT E 260-CAAP P AODENDU M FOR M MUS TB E COMPLETE D FO R EAC H ITE M O F AI R POUUTIO N CONTRO L EQUIPMENT) : 

## N A - Tori t dust collector s an d E P dus t collector s al l ven t indoors 16 ) WIL L EMISSION S DURIN O STARTU P EXCEE D EITHE R TH E ALLOWABL E EMISSIO N T RAT E PURSUAN TT O A SPECIFI C RULE . O R TH E AUOWABL E EMISSIO N UMI TA S YE S ESTABUSHE D B YA N EXISTIN G O R PROPOSE D PERMI TCONDITION ? I F YES , COMPLET E AN D ATTAC H FOR M 203-CAAPP , •REQUES TT O OPERAT E WIT H EXCES S EMISSION S DURIN G STARTU P O F EQUIPMENT . 

### 17) PROVID E AN V LIMITATION S O N SOURC E OPERATIO N AFFECTIN O EMISSION S O R AN V WOR KPRACTIC E STANDARD S (E.G. , ONL YON E UNI TI S OPERATE D A TA TIME) : 

## FR P fabricate d onl yb yclose d moldin g presses . M O



### OPERATING

INFORMATION IS ) ATTAC H TH E CALCULATIONS , T O TH E EXTEN TTHE V AR E Ai R EMISSIO N RELATED , FRO M WHIC H TH E FOUOWIN G OPERATIN G INFORMATION . MATERIA L USAG E INFORMATIO N AN D FUE L USAG E DAT A WER E BASE D AN D LABE L A S EXHIBI T220-1 . REFE R T O SPECIA L NOTE S O F FOR M 202-CAAPP . 

### I b ) MAXIMU M OPERATIN O HOUR S 

### 876 0 hrs/y r. b ) TYPICA L OPERATIN G HOUR S 

## 576 0 hrs/yr* 2fl ) ANNUALTHROUGHPU T 

## 881 6 TPY * H0UR5JDAV : 

## 2 4 H0UR5/OAV : 

## 2 4 DEC-FEBfi) : 

## 3 5 DAYSWEEK :



## 7 DAVSAWEEK: WEEKS/YEAR :



## 5 2 WEEKSflEAR : 

## 4 8 MAR-MAV(^) : 

## 2 5 JUN-AUOM ;

1 5 SEP-N0V(4t) :



# 2 5 MATERIALUSAGE

INFORMATION

21a ) RA W MATERIAL S 

## Moldin g Compoun d MAXIMU M RATE S LBS/H R 

## 600 0 TCN5/VEA R



## 18,77 1 TVPICA L RATE S

TBS7RR " 

# 3,061 * 8,816 *

TONSftEA R



## APPLICATIO N PAG E 220-CAAP P 

# 00 0 Q f FO R APPLICANT S US E 

## * 199 4 dat a

PAGE 2 O F 1 0 

# & SP.7 0

21b ) PRODUCT S 

## FR P Part s

21c ) BY-PRODUC TMATERIAL S 

## Scrap SM C MAXIMU M RATE S LBSVH R 

### 600 0 TONS/YEA R



## 18,77 1

MAXIMU M RATE S LBS/H R 

### 16. 2 TONS/YEA R



### 70. 9 TYPICA L RATE S LBS/H R 

## 3,061 * TONS/YEA R



### 8,816 *

TYPICA L RATE S LBS/H R 11. 6 TONS/YEA R



### 33. 4

FUELUSAGE

DATA 22a) MAXIMU M FIRIN 5 RAT E (MIUIO N BTU/HR) : 

### N / A 

### « T FUE L TYPE : b ) TVPICA L FIRIN O RAT E (MIUIO N BTU/HR) : 

### c)DE5l& N CAPACIT Y FIRINO RAT E (MILUON BTU/HR) :

[ [ NATURA L GA S | [FUE L OI L GRAD E NUMBE R | |COA L | |OTHER
_ I F MOR E THA N ON E FUE L I S USED , ATTAC H A N EXPLANATIO N AN D LABE L A S EXHIBI T220- Z 

### "a ) TYPICA L HEATCONTEN TO F FUE L (BTU/LB
. BTU/GA L O R BTU/SCF) : 

### 8 ) TVPICA L AS H CONTEN T(W Ttt., N AFO R NATURA L GAS) : 

### T) TYPICA L SULFU R CONTEN T(WT-*.
. N AFO R NATURA L GAS) : h ) ANNUA L FUE L USAG E (SPECIF YUNITS ; EA , SCF/YEAR . GAL/YEAR , TON/YEAR) : 

### 23 ) AR E C0MBU5TI0 N EMISSION S DUCTE D T O TH E SAM E STAC KO R CONTRO L A S PROCES S UNI TEMISSIONS ? I F NO , IDENTIF YTH E EXHAUS TPOIN TFO R COMBUSTIO N EMISSIONS : 

## N/ A 

# • ~ • N O



## APPLICATIO N PAGE .

220-CAAP P 

# 00031 ; FO R APPLICANT S US E 

# M99 4 dat a

PAG E 3 O F 1 0 

# &°i\ •.-

> REGULATE D AI R POLLUTANT(S ) 

## Styren e VO M — #• EMISSIO N STANDARDS) 

## See Appendice

s B an d C . Se e Appendice

s B an d C .
25 ) PROVID E ANYSPECIFI C RECORDKEEPIN G RULE(S ) WHIC H AR E APPUCABL E T O THI S EMISSIO N UNIT : REGULATE D AI R POLLUTANT(S ) RECORDKEEPIN O RULE(S ) 

## VO M See Appendice s B an d C .

"55 ) PROVID E ANV SPECIFI C REPORTIN G RULE(S ) WHIC H AR E APPLICABL E T O THI S EMISSIO N UNIT : REGULATE D AI R POUUTANT(S ) REPORTIN G RULE(S )



### T 7 

## VO M

) PROVID E AN V SPECIFI C MONITORIN O RULE(S )

REGULATE D AI R POUUTANT(S ) 

### N/ A 

### W H 

## See Appendice

s B an d C .

IC H AR E APPUCABL E T O THI S EMISSIO N UNIT :

MONITORIN G RULE'S) 

## N/ A REQUIREMENT(S ) 

## See Appendice

s B an d C . See Appendice

s B an d C .

REQUIREMENTS) 

## See Appendice

s B an d C .

REQUIREMENT^ ) 

## See Appendice

s B an d C .

REQUIREMENT^ ) 

## N/ A

"18 ) PROVID E ANYSPECIFI C TESTIN G RULE S AND/O R PROCEDURE S WHIC H AR E APPUCABL E T O THI S EMISSIO N UNIT : REGULATE D AI R POLLUTANT(S ) TESTIN G RULE(S ) REQUIREMENT^ ) 

### VO M 

## Stvren e See Appendice s B an d C . Se e Appendice

s B an d C .



# • ^ nnn? r 

# O APPLICATIO N PAG E

. 

## Se e Appendice

s B an d C . See Appendice

s B an d C .

__________!___

•__"• ] r#_,"|__ l
_ j I WA? l fcllfc * **r t .

220-CAAP P PAG E 4 O F 1 0P.7 2



### 2fl ) DOE S TH E EMISSIO

N UNI TOUAUF YFO R AN EXEMPTIO

N FRO M A N OTHERWIS E APPUCABL E RULE ? 

# u YE S N O I F YES , THE N US TBOT H TH E RUL E FRO M WHIC H I TI S EXEMP TAN D TH E RUL E WHIC H AUOW S TH E EXEMPTION . PROVID E A DETAILE D EXPLANATIO N JUSTIFYIN G TH E EXEMPTION . INCLUD E DETAILE D SUPPORTIN G DAT A AN D CALCULATIONS . ATTAC H AN D LABE L A S EXHIBI T2203 , O R REFE R T O OTHE R ATTACHMENT(S ) WHIC H ADDRES S AN D JUSTIF YTHI S EXEMPTION . 

### COMPUANCE INFORMATION 36 ) I S TH E EMISSIO

N UNi TI N COMPLIANC

E WIT H AL L APPUCABL

E REQUIREMENTS ? 

# 1 3 YE S 

### N

O I F NO , THE N FOR M 294-CAAP P 'COMPLIANC E PLAN/SCHEDUL E O F COMPUANC E - ADDENDU M FO R NO N COMPLYIN G EMISSIO N UNITS * MUS TB E COMPLETE D AN O SUBMITTE D WIT H THI S APPUCATION . 

### 31 ) EXPLANATIO

N O F HO W INITIA L COMPLIANCE 1 5 T

O BE , O R WA S PREVIOUSLY

, DEMONSTRATED : 

## Applie d Composite s Corp
. retaine d Geraght y& Mille rt o assis t i n documentin g proces s equipmen t an d emissio n unit s i n th e facility , completin g a facility-wid e emission s inventory , an d preparin g th e Titl e V permi t application
. Applie d Composite s certifie d complianc e o n Marc h 15,199 5 wit h Subpar t C C rules
.

32 ) EXPLANATIO

N O F HO W ONOOIN

O COMPUANCE WILL B

E DEMONSTRATED

: Se e Appendix C , Slat

e Operatin g Pennit Conditions U an d 1 2 : 12a . Th e Pennitte

e ihal i maintai n feoordf

i ofth e followin g ita m to alio** the Agenc y to revie woompltancc : L Fctrawl_*_oncU U fo r avoidin g cwi_poui_dg;...(^ ^ i L Styren e conten t ofresi n mUn-ial i med i n moldin g compound , (dat a distinc t fo r eac h distinc t resi n an d material ) iv . Quantit

y (pounds

) o f monome

r used , (monthly

) v . Quantit

y o f eac h solven t use d -.(monthly

) v i VO M emissions

, (calculate

d monthly

) 12> . *fh t ftm___Mih-_^iiiv--iil»iiiuw-ateofp->_fc)d_r i»_Hmb ^ reqMire-lbyOiodiboo?. 12c . Thunr«CTifci_aJbci«__c_rffa»pa_odofthi«yc»»*^-- ^ rn&m 1 0 d_y i o f Atenc y request.


### TESTING, MONITORING, RECORDKEEPING AND REPORTING 33a ) US TTH E PARAMETER

S THA TRELAT E T O AI R EMISSION

S FO R WHiCH RECORD

S AR E BEINO MAINTAINE D T O DETERMIN E FEES . RUL E APPLICABILITYO R COMPLIANCE . INCLUD E TH E UNI TO F MEASUREMENT . TH E METHO D O F MEASUREMENT . AN D TH E FREQUENC YO F SUC H RECORD S (E.G. . HOURLY , DAILY , WEEKLY) : PARAMETE R FR P Produce d
formulatio n dat e 

### VO M emission s UNI TO F MEASUREMEN T 

## pound s %b yweigh t typ e & amoun t pound s METHO D O F MEASUREMEN T



## recordkeepin g •UU*- * dm * SCAQM D 312-8 1 

## recordkeepin g recordkeepin g FREQUENC Y



## Monthl y Monthl y Monthl y Monthl y

APPLICATIO N PAG E 00U»: *

220-CAAP P 

### FO R APPLICANT S US E
PAG E 5 O F 1 0 

# 7 (P.7 3



### •33B J BRIEFLV DESCRIB E TH E METHO D BV WHIC H RECORD S WIL L B E CREATE D AN D MAINTAINED . FO R EAC H RECORDE D PARAMETE R INCLUD E TH E METHO O O F RECORDKEEPING , TITL E O F PERSO N RESPONSIBL E FO R RECORDKEEPING , AN D TITL E O F PERSO N T O CONTAC TFO R REVIE W O F RECORDS : PARAMETER METHO O O F RECORDKEEPIN G Se e 33 A parameter

s TITL E O F PERSO N RESPONSIBL E TIR E O F CONTAC TPERSO N •mus t k\

monthl y surwrara s HSE Q Coordinato r HSE Q Coordinato r



### c ) I S COMPLIANC E O F TH E EMISSIO N UNI TREADIL V DEMONSTRATE D B V REVIE WO F TH E RECORDS ? I F NO , EXPLAIN : YE S 

### N O

d ) AR E AL L RECORD S READIL V AVAILABL E FO R INSPECTION , COPVIN O AN D SUBMITTA L T O TH E AGENC YUPO N REQUEST ? I F NO , EXPLAIN : YE S N O



### 34a ) DE5CRIB E AN V MONITOR S O R MONITORIN O ACTIVITIE S U5E D T O DETERMIN E FEES . RUL E APPUCABIUT V O R COMPLIANCE : a . . .



## N/ A

T J WHA TPARAMETER ® I5(ARE ) BEIN O MONITORE D (EA , VO M EMISSION S T O ATMOSPHERE) * 

## N/ A

c ) DESCRIB E TH E LOCATIO N O F EAc H MONITO R (E.O. , I N STAC KMONITO R 3 FEE TFRO M EXIT) :



## N/ A

APPLICATIO N PAG E OOP* 9 

## '

220-CAAP P 

### FO R APPLICANT S US E PAG E 6 O F 1 0 

# 7*2 -P.7 4



### 34d ) I S EAC H MONITO R EOUIPPE D WIT H A RECORDIN O DEVICE-? I F NO , US TA U MONITOR S WITHOU TA RECORDIN G DEVICE : 

## N/ A YES N O



### e ) 1 5 EAC H MONITO R REVIEWE D FO R ACCURAC YO N ATLEASTA OUARTERL V BASIS' ? I F NO , EXPLAIN : 

## N/ A YES N O



### T J 1 5 EAC H MONITO R OPERATE D ATAL L TIME S TH E ASSOCIATE D EMISSIO N UNI T I S I N OPERATION ? I F NO . EXPLAIN : 

## N/ A YES 

# • N O



### 35 ) PROVID E INFORMATIO N O N TH E MOS TRECEN TTESTS , I F ANV , I N WHIC H TH E RESULT S AR E USE D FO R PURPOSE S O F TH E DETERMINATIO N O F FEES , RUL E APPUCABILITYO R COMPLIANCE . INCLUD E TH E TES TDATE . TES TMETHO D USED , TESTIN G COMPANY , OPERATIN G CONDITION S EXISTIN G DURIN G TH E TES TAN D A SUMMAR YO F RESULTS . I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S EXHIBI T220-4 : TES T OAT E TESTMETHO O 

## N/ A TESTIN G COMPAN Y OPERATM G

CONDITION S SUMMAR YO F RESULT

S



### 35 ) DESCRIB E A U REPORTIN O REOUIREMENT S AN D PROVID E TH E TITL E AN D FREOUENC V O F REPOR T SUBMITTAL S T O THE AGENCY : REPORTIN G REQUIREMENT S 

## IAC 201.30 2 Par t 12 8 Subpar

t C C TITL E O F REPOR T FREQUENC Y 

### AE R Certificat e o f complianc

e Annua l 

## Onetime , 3/15/9 5

APPLICATIO N PAGE .

220-CAAP P 

# 00 0 FO R APPLICANTS US E PAG E 7 O F 1 0 

# 7 3M)EMIr,SI6NINF6M/rAri6N

REGULATE D AI R POLLUTAN T
CARBO N MONOXID E (CO )
LEA D

NITROGE N OXIDE S (NOx )
PARTICULAT E MATTE R (PART ) PARTICULAT E MATTE R<-1 0 MICROMETER S (PMIO ) SULFU R DIOXID E (S02 ) —VTOCTICE — ORGANI C MATERIA L (VOM ) OTHER , SPECIFY : TYPICAL ;

TYPICAL .

i**iKj_m
_ LB S PE R

HOU R (LBS/HR ) 

## N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A 'UNCONTROLLE D EMI*WQ N RAT E

TOWS BER " YEA R (TONS/VR )



## 26.3 * 10.5 * TERM S MOTHE R

TERM S

eiJ2tWmort h 

### *m



# •wEmmm : PAfTpCLHAIZ MATTE R MAXMUU ;

TYPICAL ; tot>

•XO0 M

14.4 . 0. 9

QtoDSCF i 024 . GWDSCF '1 4 ALLOWABL E B YRUL E EMISSIO N RAT E

"RAT E (UNITS )



## J L 6123lbApont h 

## N/ A J L ( APPLICABL E

RULE S

Parol * 9306006

8 TONS PER '

YEA R (TONS/YR )



## 26. 3 N/ A

00(l6&Hlt) MfLBUmi 2lt.Si1

312.H1 MM PERMITTE D EMISSIO N RAT E
RAT E (UMTS )



## 612 3 lb/month N/ A TON S rai YEA R (TONS/YR )



## 26. 3 N/ A 

# n*wm "ti

IMPORTANT : ATTAC H CALCULATIONS . T O TH E EXTEN TTHE YAR E AI R EMISSION S RELATEO . O N WHIC H EMISSION S WER E DETERMINE D AN O LABE L A S EXHIBI T2204 . !cHECKUNCONTRC-Ha33EWSSK> l RAT E BO X I F CONTRO L EKWP ^ SE E INSTRUCTIONS . 2 PROVtD e TH E EMISSIO N RAT E THATWU . B E USE D A S A PBtMI TSPECIA L CONDITION . THSI_OOTWI_LBEUSfSTODETT_3U<]NETHE'-£RI_tfTFE E -VlEAS E PROVID E AN Y OTl-©»-aUSS»NRATCWHCHGCOMMC ^ *tM - DETERMINATIO N METHOD : 1 ) STAC KTEST . 2 ) MATBtlA L 6AIANCE , 3)'STANDAR D EM*_S» N FACTO R (AP-4 2 O R Al* ^ 4 *_NGM E 5RAT E - AUOWABL E EMISSIO N RAT E SPECIFIE D B Y MOS TSTRINGEN TAPPUCABL E RULE . 

## APPLICATIO N PAG E 

# 00 0
220-CAAP P PAG E 6 O F 1 0

### 13B) HAZARDOUS

AIR POLLUTANT

EMISSION

INFORMATION HA P INFORMATIO N
NAM E O F HA P EMITTE D 

## Styren e 2gA S NUMBE R 

## 100-42- 5 Fj 1 

### ACTUA L EMISSIO N RAT E \J UNCONTROLLE D EMISSIO N RAT E

iir»_j-i
_ MAAIMUIW :

ITHLAU — 

### POUND

S PE R HOU R (LBS/HR ) 

### N/ A N/ A TON S PER YEA R (TONS/YR ) 

## 26.3 * 10.5 * ^THE R TERM S 613 2 lb/mont h



### • -*D M 

## 3 3 ALLOWABL E B YRUL E

SRAT E O R STANDAR D 

## N/ A APPUCABL E RUL E 

## N/ A

EXAMPLE: 

## ftito -wwaaosr* "ffWIW" ' 

### )

;m • " 

# ' [ " 

# ..* * ' !• « s
. .



### - - , 4M ' ' +* *

s •"_ • _ • 

### g 1



### - * ' IMPORTANT : ATTAC H CALCULATIONS , T O TH E EXTEN TTHE YAR E AI R EMISSION S RELATED , O N WHIC H EMISSION S WER E DETERMINE D AN D LABE L A S EXHIBI T2204 . 'PROVID E UNCONTROLLE D EMISSION S W CONTRO L EQUIPMEN TI S USED . OTHERWISE . PROVID E ACTUAL EMISSION S T O TH E ATMOSPHERE , INCLUDIN G INDOORS . CHEC KBO X T O SPECIFY . X A S - CHEMICA L ABSTRAC TSERVIC E NUMBER . 7LEAS E PROVID E AN YOTHE R EMBSIO N RAT E WHIC H I S COMMONL YUSED , REOUIRE D B Y A SPECIFI C LMTATIO N O R THA TWA S MEASURE D (E.G. , PPM . GR/DSCF . ETC.) . T~* M - OETERM-NATIO N METHOO : 1 ) STAC KTEST , 2 ) MATERIA L BALANCE . 3 ) STANDAR D EMBSIO N FACTO R (AP-4 2 O R AIRS . 4 ) ENGINEERIN G ESTMATE . 5 ) SPECIA L EMBSIO N FACTO R (NO TAP-4 2 O R AIRS) . -"RAT E •AUOWABL E EMBSIO N RAT E O R STANDAR D SPECIFIE D B Y MOS TSTRINGEN TAPPLICABL E RULE . 

# u APPLICATIO N PAGE . 220-CAAP P 

# oo o 3»i;*n;raimzia! s •H a prattt

t 0H M fc Ap*

. A W* . Q . 

### PAG E 9 O F 1 0P.7 7



### EXHAUST

POINT INFORMATION

—~" ~ TW5s*C-rWsmiLBN0TKttMK_ET O SS , FL6 WBIA6RA M BEsiGNATIo N 6 P EXHAUS TP6INT : 

## Moldin g Press . Se e Figur e F- 1 BEScRIPYio N 6 P EXftAUs fP6IM T(STAcK
. • DISCHARGE S INDOORS , D O NO TCOMPLET E TH E REMAININ G ITEMS . 

### 40 , BEScRIPYio N 6 P EXHAUs ftolMT(STAcK
. VENT
. R66 F M6NIT6R , INb6oRS , ETC.)
. I P TH E EXHAUS TP6IN T 

## Fugitiv e Indoors 41 , BISTANc E T 6 NEARES TPLAN T66UNBAR V FR6 M EXHAUS TP6IN TBI5<1HAR6 E (FT) : 

## N/ A 42 ) BISCHARG E 

### HEIGH TAB6V E 6RAB E (PT) : M/ A 

### 43) £666 ENGINEERIN G PRACTIC E (GEP ) HEIGHT , I F KNo-A- N (PT) : N A 44 ) BIAMETERO P 

### EXHAUS TP6INTJFT V N6TE : F6RAN6 N 1.12 8 TIME S TH E SQUAR E ROO TO F TH E AREA.ki/ A 

### CIRCULA R EXHAUS TP6INT
. TH E BIAMETE R I S 

## N/ A 45 ) EXI TGA

S FL6 WRAT E 

## N/ A 4fi ) EXI TGA

S TEMPERATUR E 

## N/ A a ) MAXIMU M (ACFM) : 

### a ) MAXIMU M ('P) : b ) TVPICA L (ACFM) : b ) TVPICA L (»P) : 77 5 BIRECTI6 N C P EXHAUS T(VERTICAL
. LATERA L B6\A/N\A/ARfi) : 

## N/ A 46 ) US TAL L EMISSIO N UNIT S AN B C6NTR6 L BEVICE S SERVE B 6 V THI S EXHAUS TP6INT : NAM E FLO W DIAGRA M DESIGNATIO N 

### Sf 

## Moldin g Presse s 

# W Se e Figur e 3 , F- 1

TH E FOLLOWIN C INFORMATIO N NEE D ONL V Bt

_SUPPLIE D I P READIL

V AVAILABLE : 

### 46a) LATITUDE : 5o)UTM26NE : b)LoNGlTUBE : b ) UT M VERTICA L (kM) : c)UTMHoRlZ6NTAL(kM) :



## APPLICATIO N PAGE . 220-CAAP P 

# 00 0 FO R APPLICANT S US E PAG E 1 0 O F 1 0 

# 7 tP.7 8



## SECTION 3 COMPOUN

D PREPARATIO

N AND MATURATIO N ARE A



# -11P.7 9


### ILLINOI S ENVIRONMENTA L PROTECTIO N AGENC Y DIVISIO N O F AI R POLLUTIO N CONTRO L - PERMI TSECTIO N

P.O . BO X1950 6 SPRINGFIELD , ILUNOI S 62794-950 6 FO R APPLICANT S US E Revision * WI M 

### Date : DeoeyibwS , 19?

S Pag e of Sourc e Designation : A C
PROCESS

EMISSION

UNIT DATA AND

INFORMATION I D NUMBER : 

### EMISSIO N POINT S TOTET TTSSDRCnCOyi E

Composite s Corp
. SOURCE INFORMATION Applie d 2 ) BAT E EO

F 2 ) DAT E EOR M PREPARED : 

### Decembe r6 , 199 5 i ) SouhC E I B No . ft0rt



### _ 10 

### „ AAr 

### . (I F KNOWN) : 

### 089483AA F GENERALINFORMATION 4 ) NAM E G F EMISSIO N UNIT : Compoun d Preparatio n an d Maturatio n (se e Appendi xAExhibi t Aforlis t o f equipment ) 5)NAME6FPR6CESS : Compoun d Preparatio n an d Maturatio n 6 ) BESCRIPTIo N 6 F frftoCESS: Se e Introductio n 7 ) BESCftlPTIo N o F ITE M 6f t MATERIA L PR6BUCE B C R ACTIVlT V ACCOMPLISHES : Shee t Moldin g Compoun d b) FL6 WbiAGRAM DESIGNAYIO N 

### C F EMISSIO N UNIT : Compoun d Preparatio n an d Maturatio n Are a a ) MANUFACTURE R C F EMISSIO N UNI T(I F KN6WN) : Se e Appendi xA , Exhibi t A 10 ) MABE L NUMBER (I P KNOWN) : Se e Appendi xA , (Exhibi t A ii) BATE S C P CCMMENCIN G CONSTRUCTION , OPERATIO N AND/O R MOS TRECEN TMODIFICATIO N O F THI S EMISSIO N UNI T(ACTUA L O R PLANNED )



### IS ) BESCWPTI6 N o F Mbbll-lcATlC N (I F APMJCA&LE) : N / A 11 ) SERIA L NUMBE R (I F KNOWN) : 

### Se e Appendi xA , Exhibi t A AP E •15TR I a ) CONSTRUCTIO N (MONTH/VEAR) : SeeAppendxA , Exhibit A b ) OPERATIO N (MONTH/YEAR) : SeeAppendxA , Exhibit A c ) LATES TMoBIFICATIo N (MONTI-WEAR) : N/A

THI S AGENC YI S AUTHORIZE D T O REQUIR E THI S INFORMATIO N UNDE R ILUNOI S REVISE D STATUES , 1991 , A S AMENDE D 1992 , CHA P 11 1 1/2 , PAR . 1039.5 . DISCLOSUR E O F THI S INFORMATIO N I S REQUIRE D UNDE R THA TSECTION . FAILUR E T O D O S O MA Y PREVEN TTHI S FOR M FRO M BEIN G PROCESSE D AN D COUL D RESULTI N TH E APPLICATIO N BEIN G DENIED . THI S FOR M HA S BEE N APPROVE D B YTH E FORM S MANAGEMEN TCENTER .



### APPLICATIO N PAGE . 220-CAAP P 

### 0 'I U ? 4 FO R APPLICANT S US E PAG E 1 O F 1 0 

# 7 *P.8 0



### U ) BOE S TH E EMISSIO N UNI THAV E MoR E THA N ON E MOB E O P OPERATION*) I F YES , EXPLAI N AN D IDENTIF YWHIC H MOD E I S COVERE D B YTHI S FOR M (NOTE : A SEPARAT E PROCES S EMISSIO N UNI TFOR M 220-CAAP P MUS TB E COMPLETE D FO R EAC H MOOE) : fE S M O



### 15) PROVtS E TH E NAM E AN B BESI6NATI0 N O F ALL AI R POLLUTIO N CONTRO L EQUIPMEN TCONTROLUN S THI S EMISSIO N UNIT , I F APPUCABL E (FOR M 2SJ-CAAP P AN D TH E APPROPRIAT E 260-CAAP P ADDENDU M FOR M MUS TB E COMPLETE D FO R EAC H ITE M O F AI R POLLUTIO N CONTRO L EQUIPMENT) : 

### N / A IS ) WIL L EMISSION S BURIN G 

### STARTU P EXCEE B EITHE R TH E ALLOWABL E EMISSIO N RAT E PURSUAN TT O A SPECIFI C RULE , O R TH E ALLOWABL E EMISSIO N UMI TA S ESTABUSHE D B YA N EXISTIN G O R PROPOSE D PERMI TCONDITION ? I F YES , COMPLET E AN D ATTAC H FOR M 203-CAAPP , "REQUES TT O OPERAT E WIT H EXCES S EMISSION S DURIN G STARTU P O F EQUIPMENT* . YES N O



### 17 ) PROVib E AN V UMITATION S O N 

### SOURC E OPERATIO N AFFECTIN G AMISSION S O R 

### AN V WORK ! 

### PRACTIC E STANDARD S (E.G. , ONL YON E UNI TI S OPERATE D A TA TIME) : 

## Th e operation ofth e SM

C an d TM C machine s i s mutuall yexclusive
. Th e maturatio

n roo m ca n onl yhold 8 0 crate s o f materia l a t on e time , thu s limitin g compoun

d productio n t o a maximu

m o f 4 0 hour s i n an y4 8 hou rperiod
. Fo ra detaile d descriptio n o fth e limitations , se e Introductio n (Sectio n 1) .

. TH E TOLLOWIKG ARE PROVIDE D FO RCOMPOUNDIN G OPERATION S 

### -Ida ) MAXIMU M OPERATIN S HOUR S | HOURS/BAV : 

### | BAVS/WEEK : 

### OPERATING

INFORMATION t S ATTAC H TH E CALCULATIONS , T O TH E EXTEN TTHEV AR E AI R EMISSIO N 

### RELATEB . PRO M WHIC H TH E FOUOWIN G OPERATIN G INFORMATION . MATERIA L USAG E INFORMATIO N AN D FUE L USAG E DAT A WER E BASE D AN D LABE L A S EXHIBI T220-1 . REFE R T O SPECIA L NOTE S O F FOR M 202-CAAPP . riMlfr HfP_Mi_-i.*- > mtnaf. -T-Btnf r pMP q 

### b ) TVPICA L OPERATIN G HOUR S 

## 400 0 hrs/yr

* » ) ANNUA L THROUGHPU T 881 6 TPY * 2 0 HOURS/DAY : 

### 1 6 BEC-FEB(tt) : 

## 3 5 BAV5AA/EEK :



## 5 MARIMAV(-A) : 

### 2 5 WEEKS/VEAR : 5 0 JUN-AUG(%) : 1 5 WEEKS/YEAR :



### 5 0 SEP-NOVM : 

## 2 5 MA TEK1ALUSAGE

INFORMATION

21a ) RA W MATERIAL S 

## Resins
. Catalyst s Fillers Fiberglas s MAXIMU M RATE S LBS/H R 

### 1617. 5 24. 1 

## 2675. 9 1263. 8 TONS/VEA R



### 4658. 4 

## 69. 4 7706. 6 

## 3639. 7 TVPICA L RATE S LBS/H R 825.2 * 12.3 * 1365.2 * 644.7 * 24.6 *

TONJWEA R 1650 * 2730.4 * 1289.4 *



# oou>- APPLICATIO N PAGE . 220-CAAP P 

# -I n FO R APPLICANT S US E 

## 99 4 dat a

PAG E 2 O F 1 0 

# 1°,P.8 1

21b ) PRODUCT S 

## Moldin g Compoun d

21c ) BY-PRODUC TMATERIAL S 

# N/ A MAXIMU M RATE S LBS/H R 

## 600 0 TONS/VEA R



## 18,77 1 •



### MAXIMU M RAYE

S LBS/H R TONS/YEA R 

### TVPICA L RATE S LBS/H R 3061 * TONS/YEA R



## 8816 *

TVPICA L RAYE

S LBS/H R

- TONS/YEA R



### FUELUSAGE

DATA 2S» ) MAXIMU M FIRIN G RAT E (MILUO N BTU/HR) : 

## N/ A 

# ~w FUE L TVPE : b ) TVPICA L FIRIN O RAT E (MILUO N BTU/HR) : C)BE5I5 N 

### CAPACIT YFIRIM 5 RAT E (MILUO N BTU/HR) :

| [NATURA L GA S | [FUE L OI L GRAD E NUMBE R | [COA L | |0THER
_ I F MOR E THA N ON E FUE L I S USED , ATTAC H A N EXPUNATIO N AN D LABE L A S EXHIBI T220- Z 

### Si TVPICA L HEATCONTEN TO F FUE L (BTU/LB , BTU/GA L O R BTU/SCF) :


### a ) TVPICA L AS H CONTEN T(WT-A..N AFO R NATURA L GAS) : 

### T J TVPICA L SULFU R CONTEN T(W T*. , N AFO R NATURA L GAS) : 

### h ) ANNUA L FUE L USAG E (5PECIFV UNITS , E.O. , SCF/YEAR . GAL/TEAR , TON/YEAR) : 

### a ) AR E COMbUSTIO N EMISSION S BUCTE b T O TH E SAM E STAc KO R CoNTRo L A S PROCES S UNI TEMISSIONS ? I F NO , IDENTIF YTH E EXHAUS TPOIN TFO R COMBUSTIO N EMISSIONS : 

## N/ A 

# o • N O



## APPLICATIO N PAGE .

220^AAP P 

### FO R APPLICANT S US E 

## •199 4 dat

a PAG E 3 O F 1 0 

# ? oREGULATE D AI R POLLUTANT(S )



## Styren e VO M EMISSIO N STANDARDS ) 

## Se e Appendice s B an d C . Se e Appendice s B an d C . ' ~5S ) PROVID E AN V SPECIFI C RECORDKEEPIN G RULE(S ) WHIC H AR E APPLICABL E T O THI S EMISSIO N UNIT :

REQUIRE D M R POLLUTANT(S ) RECORDKEEPIN G RULE(S ) 

## VO M Se e Appendice s B an d C .

•


### ~2S ) PROVID E AN V SPECIFI C REPORTIN G RULE(S ) WHICHjAR E APPLICABL E T O THI S EMISSIO N UNIT :

REGULATE D AI R POLLUTANT(S ) REPORTIN G RULE(S )



### "5 7

"5 S 

## VO M
) PROVIB E AN V SPECIFI C MONITORIN O RULE(S )

REGULATE D AI R PCXLUTANT(S ) 

## N/ A
) PROVIB E AN V SPECIFI C TESTIN O RULE S ANb A

REGULATE D AI R POLLUTANT(S ) 

## Stvren e VO M W H

JR I 

## Se e Appendice s B an d C .

IC H AR E APPLICABL E T O THI S EMISSIO N UNIT :

MONITORIN G RULE(S ) 

## N/ A REQUIR-_MENT(S ) 

## Se e Appendice s B an d C . Se e Appendice s B an d C .

REQUIREMENT(S ) 

## Se e Appendi x B an d C .

REQUIREMENT^ ) 

## Se e Appendice s B an d C .

REQUIREMENTS ) 

## N/ A

PROCEBURE S WHIC H AR E APPLICABL E T O THI S EMISSIO N UNIT :

TESTIN G RULE(S ) REQUIREMENT^ ) 

## Se e Appendice s B an d C . Se e Appendice s B an d C . Se e Appendice s B an d C . Se e Appendice s B an d C . . •wwu/f-u/v*/ , %•».-» # t_.E_t-»J/V_~V~t-_./

.



### •

^ 

## APPLICATIO N PAGE . 220-CAAP P 

# 000 2 rt r I 

### PAG E 4 O F 1 0P.8 3



### 28 ) BOE S TH E EMISSIO

N UNi TOUAUF V FO

R A N EXEMPTIO

N FRO M A N OTHERWIS E APPUCABL E RULE ? YE S NO I F YES , THE N US TBOT H TH E RUL E FRO M WHIC H I TI S EXEMP TAN D TH E RUL E WHIC H ALLOW S TH E EXEMPTION . PROVID E A DETAILE D EXPLANATIO N JUSTIFYIN G TH E EXEMPTION . INCLUD E DETAILE D SUPPORTIN G DATA AN D CALCUUTIONS . ATTAC H AN D LABE L A S EXHIBI T220-3 , O R REFE R T O OTHE R ATTACHMENTS ) WHIC H ADDRES S AN D JUSTIF YTHI S EXEMPTION . 

### COMPUANCE INFORMATION 36 ) IS TH E EMISSIO

N UNI TI N COMPLIANC

E WIT H AL L APPUCABL

E REQUIREMENTS ? YE S N O I F NO , THE N FOR M 294-CAAP P "COMPLIANC E PLAN/SCHEDUL E O F COMPLIANC E - ADDENDU M FO R NO N COMPLYIN G EMISSIO N UNITS ' MUS TB E COMPLETE D AN D SUBMITTE D WIT H THI S APPUCATION . 

### 31 ) EXPLANATIO

N O F HO W INITIA L COMPLIANC

E IS T O BE , O R WA S PREVIOUSLY

, BEM0N5TRATEB : 

## Applie d Composite s Corp
. retaine d Geraght y& Mille rt o assis t i n documentin g proces s equipmen t an d emissio n unit s i n th e facility , completin g a facility-wid e emission s inventory , an d preparin g th e Titl e V permi t application
. Applie d Composite s certifie d complianc e o n Marc h 15,199 5 wit h Subpar t C C rule s .

32 ) EXPUNATIO N O

F HO W 0N60IN 0 COMPLIANC E WIL L B E BEMONSTRATEb

: Se e Appendi

x C Stat e Operating PennitCooditioo i 1 1 and 12 : 12a . Tb e Permitte

e shall maintain records ofth e followin g hem i to allo w the Agency t o review compliance : i . Formulatio

n dat afo rmoldin g compounds , ...(da U dktinctforeac h otain aformulation) i L Styren e conten to f rain malirial i use d i n moldin g compound, (dat adistinctforeach distinc

tresi n and material ) iii . Quantit

y (pounds ) o f

each type.. . o f

compound produced , (monthly) iv . Quantit

y (pounds ) o f

monomerused , (monthly ) v . Quantit

y o f each solven tuae

d ...(monthly ) v l VO M emissions , (calculate d monthly ) lib . Th e PmiM-m j -hi d top writte

n recent-, rf

periodi c-wpiminw l o cnafim _n*n » i_j__o n c f ttn mturm i nqi_ndbyCand__tt_7 . 12 cThiMiu>i-_iih-_lb«ieteinedlb f «pgiodrftt_t--.y-_»««__i. ^ withi n 1 0 dqr trfAfcncy request 

### TESTING, MONITORING, RECORDKEEPING AND REPORTING 33a ) US TTH E PARAMETER

S THA TREUT E T

O Ai R EMiSSIoN

S FO R WHIC H 

### RECORb

S AR E BEIN O MAINTAINE

B T O DETERMIN E FEES , RUL E APPUCABILIT YO R COMPLIANCE . INCLUD E TH E UNI TO F MEASUREMENT , TH E METHO D O F MEASUREMENT , AN D TH E FREQUENC YO F SUC H RECORD S (E.G. , HOURLY , DAILY , WEEKLY) : PARAMETE R SM C Productio n dot s M M inonofno f conten t formulatio n dat a 

### VO M emission s specia l purpos

e res m UNI TO F MEASUREMEN T 

## pound s % byweigh t fypeT£ amoun t pound s typ e & amoun t METHO D O F MEASUREMEN T



## recordkeepin g supplie r data , SCAQM D 3124 1 

## recordkeepin g recordkeepin g recordkeepin g FREQUENC Y



## monthl y monthl y monthl y monthl y a s use d

APPLICATIO N PAGE .

220-CAAP P 

# ooo? s FO R APPLICANT S US E
PAG E 5 O F 1 0 

# 72 -P.8 4



### "S R BRIEFL

V DESCRIB E TH E METHO D B VWHIC H RECORD

S WIL L B E CREATE D AN D MAINTAINED . FOR EAC H RECORDE D PARAMETE R INCLUD E TH E METHO D O F RECORDKEEPING , TITL E O F PERSO N RESPONSIBL E FO R RECORDKEEPING , AN D TITL E O F PERSO N T O CONTAC TFO R REVIE W O F RECORDS : PARAMETER METHOO O F RECORDKEEPIN O TmEO F PERSO N RESPONSIBL E TmEO F CONTAC TPERSO N Se e 33 a parameter* manait y * annua l sumtniie s 

### HSE Q Coordinato r HSE Q Coordinato r



### c ) I S COMPUANC E O F TH E EMISSIO N UNI TREADIL VDEMONSTRATE D B VREVIE WO F TH E RECORDS ? I F NO , EXPLAIN : YE S N O



### d ) AR E AL L RECORD S READIL VAVAILABL E FO R INSPECTION , COPVIN O AN D SUBMITTA L T O TH E AGENC YUPO N REQUEST ? I F NO , EXPLAIN : YE S N O



### 34a ) DE5CRI6 E AN VMONITOR S O R MONITORIN O ACTIVITIE S USE D T O DETERMIN E FEES , RUL E APPUCABIUT VO R COMPLIANCE : ... .



## N/ A

"B J WHA TPARAMETER'S ) IS<ARE ) BEIN O MONITORE D (EA , VO M EMISSION S T O ATMOSPHERE) ?



## N/ A

c ) DESCRIB E TH E LOCATIO N O F EAc H MONITO R (E.O. , I N STAC KMONITO R S FEE TFRO M EXIT) :



## N/ A

APPLICATIO N PAGE .

220-CAAP P 

# 000° : FO R APPLICANT S US E PAG E 6 O F 1 0 

# £3P.8 5



### 34d ) I S EAC H MONITO R EOUIPPE B WIT H A RECORbIN O DEVICE ? I F NO , US TA U MONITOR S WITHOU TA RECORDIN G DEVICE : 

### N/ A YE S N O



### e) I S EAC H MONITO R REVIEWE D Fo R ACCURAC V

### O N A TLEAS TA OUARTERL V BASIS ? I F NO , (EXPLAIN : 

## N/ A YE S N O



### TJ I S EAC H MONITO R OPERATE D A TAL L TIME S TH E ASSOCIATE D EMISSIO N UNIT I S I N OPERATION ? I F NO , EXPLAIN : 

## N/ A YE S N O



### 35 ) PROVID E INFORMATIO N O N TH E MOS TRECENTTESTS , I F ANV , I N WHIC H TH E RESULT S AR E USE D FO R PURPOSE S O F TH E DETERMINATIO N O F FEES , RUL E APPUCABILIT YO R COMPLIANCE . INCLUD E TH E TES TDATE , TES TMETHO D USED , TESTIN G COMPANY , OPERATIN G CONOITION S EXISTIN G DURIN G TH E TES TAN D A SUMMAR YO F RESULTS . I F ADDITIONA L SPAC E I S NEEDED , ATTAC H AN D LABE L A S EXHIBI T220-4 : TESTDAT E 

### 10/12/9 2 TES T METHO O TESTIN G COMPAN Y USEP A MM . M2S

* OPERATIN G CONDITION S 

### Mostard i Piat t SUMMAR YO F RESULT

S 

### Ful l Loa d 0.03041 3 VCMk n



### 36) DESCRIB E AL L REPoRTIN O REQUIREMENT S AN b PRovib E TH E TITL E AN D FREQUENC V O F REPORT SUBMITTAL S T O TH E AGENCY : REPORTINGREQUIREMENT S 

### IA C 201.30 2 Par t 12 8 Subpar t C C TITL E Q F REPOR T 

### Annua l Emission s Repor t FREQUENC Y 

### Certificat e o f complianc e 

## Annua l One time , 3/15/9 5

APPLICATIO N PAG E 00 0 ? ^

220-CAAP P 

### FO R APPLICANT S US E PAG E 7 O F 1 0 

# WREGULATE D AI R

POLLUTAN T CARBO N MONOXID E (CO ) LEA D

NITROGE N OXIDE S (NOx ) PARTICULAT E MATTE R (PART ) MATTE R < > 1 0 MICROMETER S (PM10 ) SULFU R DIOXID E (S02 ) VOLATIL E ORGANI C MATERIA L (VOM ) OTHER . SPECIFY :

EXAMPLE: PARTlCUrATg MATTE R MfOCMM :

TYPICALMrtX__H_t " TVPICAL : MrtJtmjM : TYPICAL : iMVMM : TYPICAL : i_-*tyiiii ~ TYPICAL : MAXML M TYPICAL : MAXMU M TYPICAL : MAXMJM : TVPICAL :
MAXMJ A TYPICAL : 

### MEMISSIOK

—'ACTUA L EMISSIO N RATE 'UNCONTROLLE D EMISSIO N RATE I B S PER " HOU R (LBS/HR ) 

### N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A 6.00 4.00 TONS PE R

YEAR (TONS/VR

)



### 68.3 * 34.5 *
H$ 14.4 -MOTHER

TERM S



### ! ftj QR/DSCF 0.24 GIVDiCf •\jTHE R

TERM S

18,000 ib/m o -t*
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### _ll_UNOI S ENVIRONMENTA L PROTECTIO N AGENC Y A A DIVISIO N O F AI R POLLUTIO N CONTRO L - PERMI TSECTIO N P.O . BO X1950 8 SPRINGFIELD , ILUNOI S 62794-950 6 

# •siHaa»iasaiHPH Revisio n # : Oate : Nwamfrar 15,199f

t Pag e of Sourc e Designation : J___ 

## USTING OF INSIGNIFICANT ACTIVITIES IbNUM&ER : PERMIT* : 

## "BATE : TKSFORMMUgTBec^CilPLkiyil-WAaAclMTlES-n^TAftEl-^ ^ 3 S IL L ABM . C6BE . SECTIO N 201.21 0 AN O 201.21 1 FO R WHIC H DETA_LE D DAT A AN O INFORMATION , A S REQUESTE D M OTHE R FORMS , I S NOTPROVOEO . 

## SOURCE

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### 5 ) BAT E F6R M PREPARED : 

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IN 3 5 ILLADM. CODE

201.210(b): YE S N O
I ) AI R CONDITIONIN G O R VENTILATIN G EQUIPMEN TNO TDESIGNE D T O REMOV E AI R CONTAMINANT S GENERATE D B YO R RELEASE D FRO M ASSOCIATE D EQUIPMENT ; I ) PHOTOGRAPHI C PROCES S EQUIPMEN TB YWHIC H A N IMAG E I S REPRODUCE D UPO N MATERIA L SENSITIZE D T O RADIAN TENERGY ; M) EQUIPMEN TUSE D FO R HYDRAUU C O R HYDROSTATI C TESTING ; iv) GENERA L VEHICL E MAINTENANC E AN D SERVICIN G ACTTVITIE S A TTH E SOURCE , OTHE R THA N GASOUN E FUE L HANDUNG ; v ) CAFETERIAS . KITCHEN S AN D OTHE R FACILITIE S USE D FO R PREPARIN G FOO D O R BEVERAGE S PRIMARIL YFO R CONSUMPTIO N A TTH E SOURCE ; Vf ) EQUIPMEN TUSIN G A WATER , WATE R AN D SOA P O R DETERGENT , O R A SUSPENSIO N O F ABRASIVE S I N WATE R FO R PURPOSE S O F CLEANIN G O R FINISHIN G PROVIDE D N O ORGANI C SOLVEN THA S BEE N ADDE D T O TH E WATER ; vii ) ADMINISTRATIV E ACTTVITIE S INCLUDING , BU TNO TUMITE D TO , PAPE R SHREDDING , COPYING , PHOTOGRAPHI C ACTIVITIES . AN D BLUEPRINTIN G MACHINES . THI S DOE S NO TINCLUD E INCINERATORS ; viii ) LAUNDRYDRYERS , EXTRACTORS . AN D TUMBLER S PROCESSIN G CLOTHING , BEDDING , AN D OTHE R FABRI C ITEM S USE D A TTH E SOURC E THA THAV E BEE N CLEANE D WIT H WATE R SOLUTION S O F BLEAC H O R DETERGEN Ti PROVIDE D THA TAN YORGANI C SOLVEN TPRESEN TI N SUC H ITEMS_BEFOR E PROCESSIN G THATJS_RETAINE D FRO M CLEAN-U P OPERATION S SHA U B E ADDRESSE D A S PAR TO F TH E VO M EMISSION S FRO M US E O F CLEANIN C MATERIALS ;

HI S AGENC YI S AUTHORIZE D T O REQUIR E THI S INFORMATIO N UNOE R ILUNOI S REVISE D STATUES , 1991 , A S AMENDE D 1992 . HA P 1111/2 . PAR . 1039.5 . DISCLOSUR E O F THI S INFORMATIO N I S REQUIRE D UNDE R THA TSECTION . FAILUR E T O D O S O MA Y REVEN TTHI S FOR M FRO M BEIN G PROCESSE D AN D COUL D RESUL TI N TH E APPUCATIO N BEIN G DENIED . THI S FOR M HA S BEE N PPROVE D B YTH E FORM S MANAGEMEN TCENTER .



## APPLICATIO N PAGE . 297-CAAP P 

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G ACTIVITIE S F6 R CLEANING PURPOSES , INCLUDIN G COLLEC

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# • YE S
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# • YE S GA S TURBINE S AN D STATIONAR YRECIPROCATIN G INTERNA L COMBUSTIO N ENGINE S O F LES S THA N 11 2 K W (15 0 HORSEPOWER ) POWE R OUTPUT ; GA S TURBINE S AN D STATIONAR YRECIPROCATIN G INTERNA L COMBUSTIO N ENGINE S I 1 O F BETWEE N 11 2 K W AN01.111 8 K W (15 0 AN D 1,50 0 HORSEPOWER ) POWE R OUTPU TYE S THA TAR E EMERGENC YO R STANDB YUNITS ; ' ' xvl ) STORAG E TANK S O F AN YSIZ E CONTAININ G EXCLUSIVEL YSOAPS , DETERGENTS , SURFACTANTS , GLYCERIN , WAXES , VEGETABL E OILS , GREASES , ANIMA L FATS , SWEETENERS , COR N SYRUP , AQUEOU S SAL TSOLUTIONS . O R AQUEOU S CAUSTI C SOLUTION S PROVIDE D A N ORGANI C SOLVEN THA S NO TBEE N MIXE D WIT H SUC H MATERIALS ; xvil ) LOADIN G AN D UNLOADIN G SYSTEM S FO R RAILCARS , TAN KTRUCKS , O R WATERCRAF TTHA THANDL E ONLYTH E FOUOWIN G UQUI D MATERIAL S PROVIDE D A N ORGANI C SOLVEN THA S NO TBEE N MIXE D WIT H SUC H MATERIALS : SOAPS , DETERGENTS , SURFACTANTS , LUBRICATIN G OILS , WAXES , GLYCERIN , VEGETABL E OILS , GREASES , ANIMA L FATS , SWEETENER , COR N SYRUP , AQUEOU S SAL T SOLUTIONS . O R AQUEOU S CAUSTI C SOLUTIONS . 6 ) AR E AN YEMISSIO N UNIT S A TTH E SOURC E PROPOSE D T O B E CONSIDERE D INSIGNIFICAN TACTIVITIE S THA TMEE TTH E CRITERI A USTE D I N 3 5 I U ADM . COD E 201.211(a) ? I F YES , US TTH E EMISSIO N UNIT S I N TH E "US TO F ACTIVITIE S FO R WHIC H STATU S A S A N INSIGNIFICAN TACTIVITIE S I S PROPOSE D PURSUAN TT O 201.211(a) " AN D PROVID E TH E REQUESTE D INFORMATION . AN D LABE L A S EXHIBI T297-2 . I F ADDITIONA L SPAC E I S NEEDED . ATTAC H 

# 0 ] 

# Q 

# 0 0 N O


### N O
N O N O N O 

### N O
N O 

# 0~ °

•« s 0]N O


# • « 

# _2 QYE S • N

O

N O CRITERIA IN

3 5 ILLADM. CODE

201.211(a) I ) TH E EMISSIO N UNI TWOUL D NO TEMI TMOR E THA N 1. 0 LBS/H R O F AN YREGULATE D AI R POUUTAN TNO TUSTE D A S HAZARDOU S PURSUAN TT O SECTIO N 112(b ) O F TH E CLEA N AI R AC TI N TH E ABSENC E O F AI R POUUTIO N CONTRO L EQUIPMENT ; I ) TH E EMISSIO N UNI TWOUL D NO TEMI TMOR E THA N 0. 1 LB/H R O F AN YREGULATE D AI R POUUTAN TUSTE D A S HAZARDOU S PURSUAN TT O SECTIO N 11 2 (b ) O F TH E CLEA N AI R AC TI N TH E ABSENC E O F AI R POUUTIO N CONTRO L EQUIPMENT ; AN D m) TH E EMISSIO N UNI TI S NO TA PROCES S UNIT .



## APPLICATIO N PAGE . 297-CAAP P 

# C0U 2 FO R APPLICANTS US E PAG E 4 O

F 6 

# 9 Z

## LIS TO F INSIGNIFICAN TACTIVITIE S PURSUAN TT O 201.21 0 (a)(1 ) THROUG H (18 )

EMISSION UNI

T AN D DESIGNATIO N 

## MD I Foa m Injectio n #0 F UNIT S 

# 1



# i



# I DESCRIPTIO N O F UNI T INCLUDIN G ANY CONTRO L

Methy l Dilsocyanat e Foa m Injectio n

i BASI S FO R INSIGNIFICANC

E SECTIO N 201 .210(a

) 

## IAC201.210(a)i i


# I i


# I * 1 BASI S FO R DETERMINATIO N O F EMISSION S 

## 4 , See Appendix D 

# 1

I i 

# I i i 

# I I I V CONSIDERE D MSIQN-FICAN TBASE D O N EMBSIO N LEVE L TH E DETERMNATIO N METHOO O F BtiSSIO N MUS TB e PROVIDE D (E.G.
. 1 ) STAC KTEST
. 2 ) MATERIA L BALANCE
. 3 ) STANDAR D EMBSIO N FACTO R (AP-4

2 O R AIRS)
. 4 ) ENQINEERIN O ESTMATE
. 6 ) SKOA L EMBSIO N FACTO R (NOTAP-4 2 O R ARS)) .


## APPLICATIO N PAG E 297-CAAP P 

# coo: - Sl£KH31HaJIiai H PAG E 5 O F 6

# Y

V

• - > ( 

## LIS TO F ACTIVITIE S FO R WHIC H STATU S A S A N INSIGNIFICAN TACTIVITIE S I S PROPOSE D PURSUAN TT O 201.21 1 (a )

EMISSIO N UNI T AN D DESIGNATIO N 

## Resi n Storag e Tank s FR P Laborator

y Dus t Collector

s
Natura l Gas Boiler s Compoun d Storag e 1| U



## 3
1 1 7
5
1 DESCRIPTIO N O F UNI T

INCLUDIN G AN

YCONTRO L 

## Storag e o

f resi n R& D Laborator

y
Internall y ventin g particulat e emissio n contro l devices o n presses & 1 fiberglass choppe r Natura l ga s fire d boiler s fo r proces s energ y an d comfor t heatin g Storag e o f ra wmaterial s use d I n compoun d preparatio n OPERATIN G HOUR S 

# " F | "LWP



# | " W DISCUSSION : •>A Yt

I a? Loadin g ioeeee only , se e Appendi x D 8 1 7 1 5 2 291 2 hour

e pe r yea r 2 4 1 7 1 5 2 Vent s Indoors
2 4 1 7 1 5 2 Use d continuously , se e Appendi x D 2 4 1 7 1 5 2 Use d continuously , ee e Appendi x D 

## 1 1 EMISSION S POUUTAN T| HOU R VEA R DETERMINATIO N METHOD : Syren . (VOM ) 0.0007 0.000 3

Styren * (VOM ) 0.0006 0.02

0. 0 2 6

SbrmlYQM

) 0001 5 0.0066 OTHE R SUPPORTIN G INFORMATIO N 

## 3 , See Appendi x D , Tabl e D-1 . 2 , See Appendix D , Tabl e D-2 . 4 , See Appendix D , Tabl e D-3 . 2 , See Appendi x D , Tabl e D-4 . 5 , See Appendix D

1| U - TOTA L NUMBE R O F W#T S (EMBSIO N RATE S SHOUL D B E PROVDE D O N A PE R UNI TBASB) . JXSCUSSIO N - PROMD E A N EXPLANATIO N O F OPERAT** ) HOURS (E.Q , TH E UN^BCI N EMERGENC YSTANDBY-THEREFOR E H" ONL YOPERATES ON E DA

YPE R MONTH ) -VETEf-MNATIO N METHOO* . 1)8TAC KTEST . 2 ) MATERIAL BALANCE . 3 ) STANDAR D BylSSW N FACTO R (AP-42 O R ARS) , 4) ENCUNEERMOESTIMTE.Q8PECM L EMBSIO N FACTO R (NO TAP-4 2 O R ARS) .

-J* ; 

## APPUCATIO N PAGE . 297-CAAP P 

# coo?: <

PAG E 6 O F 6Moldin g

Compoun d 

### A Insignifican t VO M A 

### F- 1 (VOM ) ' P M vented indoor * 

### Materia l Flow Emission Poin

t Compoun d Storag e Roo

m Molding Presse s Ooae d Moldin g (Heat , Prcoure ) 

### ST-l f (representative itac k ic e Appendix A . ExhibitC for individual stackpuvnetai ) 

### VO M P M Verte d Indoor

s 

### Scra p SM C _ + Finished Products . (Molde d FRP )
Rewor k Product s tF- 2

VO M Produc t Packaging , Storage and Shippin g

Maturatio n Roo m SM

C Machin e TM

C Machin e Mixe r

NOTE : TM

C an d SM C Machine

s d o no toperat e a tthe sam e time . Scra p SMC Touch-U p Pain t an d Solvent s Ra w Materials Resins Catalyst s ' Fillets Fiberglass insignifican t VO M

Resi n Storag e Tank s Compoun d Preparation an

d Maturation Are a 

# 4WW GERAGHT Y & MILLER . INC . Environmental

Services A Heldemi J Compan y 

# FIGUR E 3 Facilit y Proces s Flo

wDiagra m Applie d Composites Corp. St . Charles , Illinoi

s FILE : FIGURE3AD0 C DW O OATE : 5-D«c-fl 5 PRJCTNO:WI0466.00 1 APPROVED : GJ T DRAFTER : GJ T 

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

# COO 1 0P.9 7



## SECTIO N 1 INTRODUCTIO N PERMI T SHIEL D REQUES T LIS T O F PROCESSE S T O B E PERMITTE D

%P.9 8



## TITL E V PERMI T APPUCATIO N APPLIE D COMPOSITE S CORP . ST . CHARLES , ILLINOI S
INTRODUCTIO N Applie d Composite s Corp . operates amolde d fiberan d fiberglass reinforced plasti c (FRP ) productio n facilit y i n S tCharles , Illinois . Figur e 1 present s asite ma

p indicatin g th e locatio n o f

th e facility . Kan

e Count y i s designate d a s asever e ozon e non-attainmentarea . Figure s 2 and 3 presentalayou tpla n an d proces s fiow diagra

m forthe facility . Applie d Composite s i s submitting aTitl e V penni tapplicatio n becaus e th e facility' s potentia l emission s o f volatil e organi cmaterials (VOM ) exceed s th e 2 5 ton s peryear(tpy ) majo rsourc e threshol d fo rsource s locate d in severe ozon e non-attainmen tarea . In addition , th e facilit y emit s styrene , afederal hazardou s airpollutant , a tlevel s abov e th e 1 0 tp y majo rsource threshold . Table s 1 through 3 presen tadetailed emission inventor y fo rth e significantemitting processe s locate d at th e facility . Th e facilit

y consists o f

three distinctsignificantemissio n processes ; compoun d preparation and maturation , moldin g pres s operation s an

d paint/solventusage . A tota l o f 2 1 moldin g presses , with vacuum-assisted capabilit y an d six 1 

## presse s incorporatin g electrostati c pigmen tcoatin g technology , ar e used forFR

Pproduction . The structur e o f th e permit applicatio n ha s bee n simplifie d by consolidatin g al

l o f th e presse s int

o the Moldin g Presse s emissio n unit , whic h i s consistentwit h th e facility' s curren

tstate operating permit

. Appendb cB contain s th e applicabl e rules an d requirement

s fo reac h emissio n unit, an d Appendb

cC presents th e facility' s stat e operating permit . Othe roperation s a

tth e facilit

y which resul ti n insignifican temissions , includ e five natura l gas-fire d boilers , a

n FR Plaboratory, polyeste rresi n storag e tank s which stor e resin s use d in th e compoun d preparatio n process , acompoun d storag e room , an d amethyl di isocyanate (MDI ) foa

m injection syste

m which wil l b e installed in the nea rfuture . Thes e 1 

## Tw o ar e currentl y installed , th e othe rfou rwil l b e installe d pursuan tt o th e construction/operatin

g permi t application s #9405003

9 an d 94080129

. 

# nP.9 9



### $ 

## emission unit s were classifie da s insignifican

t emissio n unit s pursuan

t t o th e criterio n contained i n th e Illinoi s Administrative Code (IAC ) $ 201.210(a)i i an dIAC § 201.211(a) . Appendix D provide s documentation for th e insignifican

t emittin g operations . PERMI T SHIEL

D REQUES T Applie dComposite s Corp . request s apermi t application shieldfo

r it s entir e facilit y wit hrespect t o al l applicable regulation s an dregulation s fromwhichAppliedComposite s i s exempt as identifie

di n thi s application . OPERATIONA LFLEXIBILIT Y REQUES T Applie dComposite s reques t

a n emissions ca

p fo r th e entire facilit

y base don th e record s se t fort hi n thi s application . LIS T O F PROCESSE S T O B E PERMITTE D COMPOUN

D PREPARATION AN D MATURATIO N ARE A Applie dComposite s operate s acompoun dpreparation roo mt o manufactur e shee t molding compoun

d(SMC ) andthic k

moldin g compoun

d(TMC) . Sectio n 3 o f

thi s application contain s the 220-CAAP

Pfo r thi s emission unit . Equipmen t associatedwit

hth e SMC proces s i s liste di n Exhibi t A o f Appendix A . I n the SMC process , polyester resin s (fabricate

doff-sit e andstore di

n underground storag e tanks ) ar

e transferre dtojh e mbdn

g operation s vi aaclosedloo p piping system . The resi n i s mixe

dt o adesire dA-side past e leve l usin g th e foUowin

g equipment : 

# " X 1 . smal l lightning mbdn

g (1 5 gallon) ; 2 . 1 larg e cowle s mixe

r wit h3 vessel s (35 0 gallon s each) ; and 3 . spar e cowle s mixer . 

# 0001 2p. 1



## Onc e th e mixture achieve s acertain temperature , i ti s combine d wit h B-sid e thickened past e which i s mixe d in th e smal l cowle s mixer(5 5 gallon) . Thi s mixerdetermines th e maximu m fee d rat

e t o th e SM C machine . Th e resulting compoun d i s injected into "docto r boxes " o n th e 4 8 inch SM C machine vi aaclose d mixing pump . Th e compoun d i s metere d onto abotto m carrie rfilm, usin g ablade t o control thickness , an

d conveyorized . Continuou s fiberglass roving , cutt o on e inc h orlonge rlength s b y ahoode d choppe r(ducte d t o adus tcollecto ran d vente d indoors) , are the n dropped t o th e resin mix . Anothe rlaye ro f resi n mb e i s applie d ove rth e roving . Th e materia l i s then covere d wit h ato p carrie

rfilm. Th e encapsulate d compoun d i s ru n throug h acompactio n bel tinsuring tha tth e rovin g i s impregnated with thickened paste . Th e pliable compoun d i s the n "festooned " (folded ) into crates . Th e crate s ar e stored foraminimu

m o f 4 8 hour

s i n a n adjacen

t temperatur

e controlle d maturation room t o achiev e th e desired moldin g viscosity . After maturation, th e crate s ar

e store d fo rashor

tperiod o f

tim e in th e compoun d storag e room unti l they are use d in th e moldin g process . Th e TM C machine differ s from th e SM C b y usin g afiberglass choppe rtha thas smaller diameterblad e an

d th e rovin g i s blow n down wit h th e us e o f

a n oscillatin g ai

rspra y int o tw o fee d rollers . Th e paste nuxture i s injected above th e fee d rollers alon g with the roving , thereby drawing th e combined materials dow n t o th e rollers where iti s lai d ont o th e botto m carrie r film. Th e encapsulated TM C i s no tfestooned , butchoppe d into 4 8 inch block s an d placed i

n crates . Th e SM C an

d th e TM C machines cannotru n simultaneously becaus e th e mbdn g operation i s capabl e o f

onl y supportin g on e machin e a tan y give n time . Becaus e o f

th e inherentnatur

e o f th e B-Sid e mbdn

g proces s (S S gallo n drum) , th e SM C machine can only ru n atamaximu

m rat e o f 5,75 0 lb/hr. Thi s i s du e t o alimited fee d rat e ofth e B-Sid e thickene d paste . Anothe rlimitatio n exist s in th e maturatio n ofth e formulated SM C a s the materia

l must b e placed in atemperatur e controlle d room (maturation room ) fo raminimu m o f 4 8 hours t o achiev e th e propermoldin g viscosit y according t o specifications . Th e maturatio n room ca

n 

# 0001 3P. 2



## onl y hol d 8 0 crate s o f

materia l a tan y on e time , thu s limiting compound productio n t o a maximu m o f 4 0 hour s i

n a4 8 hourperiod . Therefore , th e compounding proces s can theoreticall y ru

n onl y 6,25 7 hour

s peryear . Thi s correspond s t o maximu m theoretical * 

## emission s fo rth e compounding an d maturation processe s according t o th e followin g calculation s an

d a s se tfort

h i n Table 1 : 1 6 crate s * 300 0 lb s SMC * 1 shif t* 876 0 hrs * £ = 37,542,85 6 lb s SMC/y r shif tcrat

e 8 hours y r7 37.542.85 6 lb s SM C * 20. 9 lb s VO M = 136,69 8 lb s VOM/y r 5,74 0 lb s SMC/h rh r

= 68. 3 ton s VOM/y r r* 

## Applie d Composite s use s som e SM C formulations wit h amonomerconten to f

greate r tha n 35 % fo rproducts tha thave specia

l flexibility, strength , corrosio n resistance , an d fire retardan trequirement

s (i.e . boa thulls) . Ai remission s from th e compound roo m are exhausted from fourexhaus tpomts , including th e Tori tdus tcollecto rventwhich vents indoors . The emissio n points represen tal l emission s from th e compounding proces s including al l equipment

, maturatio

n room , solven t use , an d fugitives . Exhibi tB o f

Appendb cA presents th e exhaustpointinfonnation . Sinc e th e maturation roo m i s undernegative pressur e whe n compared t o it s surrounding buildin g enclosure , an

d th e compound roo

m i s undernegativ e pressure relative t o th e maturation roo m an d adjacen tareas , airi s being pulled in from al l interio ropening s an

d i s ultimately exhauste d through th e above-mentione d emissio n points . Compoun d roo m ai remission s are quantified through recordkeepin g (i.e . materia l usag e data) an

d a n emissio n facto r(0.030 4 lb VO M pe rl b o f monome rused ) whic h wa s determine d b y sourc e testin g conducted o n Octobe r12 , 1992 .
MOLDIN G PRESSE S Applie d Composite s utilize s acompressio n moldin g proces s where hea tan d pressure ar e applied t o th e initiated SMC i n aclose d mold . Th e compression molding proces s use s 

# 0001 4P. 3



## matche d stee l mold s t o compres s aweighe d "charge " o f moldin g compoun d into ane w an d specifi cshape . The tw o halves o f th e mold , which ar

e mounted in ahydraulicmoldin g press , ar e close d aroun

d the "charge" . Sectio n 4 o f thi s application provide s th e 220-CAAP Pfor m fo rthi s emissio n unit

. A lis tofth e moldin g presses , including mode l number s an d installatio n dates , are presented i

n Exhibi tC o f AppendbcA an

d i s reproduce

d below .
Equipment Pres s #34 * Pres s #25 * Pres s #33 * Pres s #3 7 Pres s #2 6 Pres s #4 4 Pres s #35 * Pres s #3 0 Pres s #3 1 Pres s #3 6 Pres s #38 * Pres s #2 9 Pres s #0 1 Pres s #39 * Pres s #3 2 Pres s #2 8 Pres s #2 1 Pres s #0 5 Pres s #2 7 Pres s #0 6 La b Press . Manufacture r Verso n 4000 T Erie 2500 T Wms/Whit

e 2000 T Wms/Whit

e 1500 T Erie 1500 T Wms/Whit

e 1000 T Clearin g 1000 T Wms/Whit

e 1000 T Wms/Whit

e 1000 T Wms/Whit

e 800 T Erie 750 T Wms/Whit

e 750 T Erie 650 T Dake 600 T Wms/Whit

e 600 T Erie400 T Hannifi n 350 T Erie300 T Dake 150 T Hannifi n 100 T PH I 25 T Seria l Number 2335 3 21-786 7 C422 6 C401 6 21-832 3 C420 1 11-518 6 C426 7 C394 8 C401 8 21-600 6 C426 3 R-405 8 15588 2 C4062 A SOR405 7 T-425 1 R-3215- A 1698 6 T-1083- 2 Installatio n

Dat e Pos t197 2 Pos t197 2 Pos t197 2 Pr e 197 2 Pos t197 2 Pos t197 2 Pos t197 2 Pos t197 2 Pos t197 2 Pr e 197 2 Pos t197 2 Pos t197 2 Pre 197 2 Pos t197 2 Pos t197 2 Pos t197 2 Pr e 197 2 Pos t197 2 Pos t197 2 Pr e 197 2 Pre 197 2 Wit h electrostati cpigmen

tcoatin g capability . Crate s o f prepare d SM C ar

e positione d a

tth e fronto f

each moldin g press . Th e festoone d SM C i s threade d into a h airactuate d film stripperwhic h remove s th e film from th e SM C materia

l an d places i to n acuttin g table . Th e pres s operatorthen quickly cut s th e SM C into apredetermine

d patter n an d place s th e materia

l int o aplasti cenclosur e (clam shell ) fastene d o n to p o f

a n electroni cscale . Next , th e charge patter n i s transferre

d t o anotherplasti c 

# 0001 5 

# l°lP. 4



## enclosur e o n a"waiting table " whil e th e operato rcut s an d weigh s anothe rpattern . The press i s loade d wit

h th e materia

l o n th e weighin g table , then th e operato ractivate s th e pres s cycl e whic h close s th e mold . The combinatio n o f hea tan d pressur e activat e across-linkin g reaction

_ > 

## (polymerization ) betwee n th e resi n component' s unsaturate d polyme ran

d th e unsaturate

d monome r(styrene) , convertin g th e SM C materia l int o athre e dimensiona

l thermosetplastic part. The cutting/weighing procedur e i s repeated , rotating SM C materia l from th e scale , t o th e waitin g table , an

d t o th e press . Pres s cycl e time s range from 1.3 t o 6. 5 minute s according t o th e siz e an

d characteristics ofth e par tbein g molded . Molde d part s whic h are removed from th e pres s ar

e deflashed , sande

d and/o rdrilled , inspected , an d packaged fo rshipping . A variet y o f products , including basketball backboards , bathroo m fixtures an

d marine recreationa

l equipmentar

e manufacture

d t o custome rspecifications . VOM emission s from th e moldin g presse s ar e exhausted through buildin g windows , doors , an

d hydrauli

cequipmen

tfens locate d above hydraulicpump s o n to p o f th e longer presses . The buildings ar e ope n area s insid e wit

h a3 0 foo troo f

height . Pres s areaemissions wer e estimated usin g a

n USEP A AP-4 2 emissio n faao r(5t h edition , Seaio n 4.4 ) o f 1 l b VOM pe r10 0 lb monomerfo rclose d moldin g presses .

The maximu

m theoretical emission s were estimated usin g th e the n highes tSM C monome rcontentin us e an d th e maximu

m quantit y o f such SM C thatcan b e produced a t Applie d Composite s according t o th e followin g calculation an d a s se tfort

h in Tabl e 2 :
37.542.85 6 lb s SM C * 01 4 lb s monome r* 1 l b monomer= 52,56 0 lb s VOM/yr y rlb s SM C 10 0 lb s monomer 26. 3 ton s VOM/yr


# 0001* 6 

# I 0 2 

# -P. 5



## There are sb

cmolding presse s tha

tar e permitted t o apply electrostati cpigmen t coatings . Particulat

e matter(PM ) generated b y th e coating s ar e controlle d b y eitherTorito r Nordso n dus tcollector s tha texhaus tinside th e facility . PM emission s from th e moldin g presse s ar

e considere d negligible . PAINT/SOLVEN T US E Relativel y modes tquantities o f paint s an d solvents ar

e use d fo rmiscellaneou s touch-up painting , thinning an

d cleanup operations . Emissions from pain tan d solven tus e ar

e fugitive . VO M emission s are determined b y recordkeeping (i.e . materia l usag e data) an

d mas s balance calculations . Sectio n 5 o f thi s application contains for m 391-CAAP Pfo rthi s emissio n unit.



# 0001 7 

# 10J