p.1 

OAR Box 1394 

Prepped by Ollie Stewart 

Document Number: 

31) II-C-1 

Docket Number: 

A-94-52 

Printed 7/3/2008 7:52:00 AM Sheet 31 of 56 
P.2 

-*S> sr«> 

kWr! 

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY 

Office of Air Quality Planning and Standards 

Research Triangle Park, North Carolina 27711 

MAR 3-1 l" 3 

Mr. John Schweitzer 

Technical Director 

Composites Institute 

355 Lexington Avenue 

New York, New York 10017 

Dear Mr. Schweitzer: 

Thank you for coming to Durham to meet with us last week. 

At that meeting, you informed us of the Composite Institute's 

plans to survey the industry, and your willingness to share the 

raw data with the Environmental Protection Agency (EPA) . 

As discussed, I am sending a summary and three 

questionnaires that illustrate the type of data EPA requests for 

the purpose of regulatory development. These questionnaires were 

sent to the magnetic tape and wood furniture industries for the 

development of national emission standards for hazardous air 

pollutants (NESHAP's) and to the aerospace industry, for the 

development of both a NESHAP and a control techniques guideline 

for the reduction of volatile organic compounds. . I look forward 

to reviewing the draft questionnaire that you develop for the 

composites industry. In addition, please let me know the time 

frame for sending the questionnaires and receiving the data. 

If you have any questions or comments regarding this letter 

or the enclosures, feel free to call me at (919) 541-2383. 

Sincerely, 

-nhL L * 

Madeleine L. Strum 

Chemical Application Section 

Chemicals and Petroleum Branch 

Enclosures 

V ''•""»« 
P.3 

Summary of Data Needs 

GENE.RAL 

* Plant FAX number is not important 

* Latitude and longitude not important 

* All data should be requested for 1992. 

* Employee count is important 

* Information that would allow classification of the facility into 

a distinct subcategory 

PRODUCTS & PROCESS 

* Information regarding type of products manufactured and 

production rate of each product. Process information (eg: Part 

II"B" of page 8 in wood furniture questionnaire.) 

* Information regarding solvent cutting of resins or other raw 

materials (eg: Part inF" on page 7 of wood furniture questionnaire) 

* Process description for each product (eg: block diagram on page 

8 of aerospace questionnaire) Provide example. 

* Quantify HAP emissions for each operation (eg: Table 6 on page 23 

of aerospace questionnaire) in process 

* Table for usage of raw materials and HAP content of each raw 

material 

* MSDS sheets of raw materials 

* Test reports from emission testing 

* Material (HAP containing) storage procedures (drums, tanks, how 

are raw materials transfered from storage to process?) 

* Spray booth data (eg: Part II"C" on page 9 of wood furniture 

questionnaire) 

* Oven data (eg: Part II "D" on page 9 of wood furniture 

questionnaire) 

* If gluing is applicable, data on glues such as quantities used, 

HAP content 

WASTE HANDLING & CLEANUP 

* Type, quantity and disposal practices of waste material. Waste 

water characteristics. 

Z 
P.4 

* Cleaning operations and materials (chemicals) used for cleaning 

CONTROL TECHNIQUES / Pollution Prevention Measures 

* Pollution prevention measures (reformulation/material 

substitution, process changes, others) - examples provided in all 

questionnaires 

* Control device information - examples provided in all 

questionnaires 

* General information regarding Air handling (flow rates) 

* Regulations to which plant is subject 

COST AND ECONOMICS 

* Economic and cost information - examples provided in all 

questionnaires 

OTHER OPERATIONS 

* What besides composites production, results in HAP emissions 

^ 
P.5 

Enclosure 1 Not subject to the requirements of Section 3507, 

Paperwork Reduction Act of 1980. 

MAGNETIC TAPE MANUFACTURING FACILITY 

INFORMATION REQUEST FOR 

Verbatim 

Sunnyvale, California 

Please answer this information request as completely as 

possible. If you are unable to respond to an item as it is 

stated, please provide any information you believe may be 

related. Use additional sheets or the backs of the request pages 

for your responses, if necessary. In some cases you may want to 

copy blank tables to provide responses for multiple units. 

This information request is designed to gather information 

for the development of a national emission standard for hazardous 

air pollutants (NESHAP) for the magnetic tape manufacturing 

industry. (The list of hazardous air pollutants [HAP's] is found 

in Attachment 1.) To do so, we need to gather information on 

both HAP's and control technologies. Even information concerning 

non-HAP solvents (e.g., cyclohexanone and tetrahydrofuran) that 

are used at your facility will be useful in this effort. 

Therefore, please complete all applicable parts of this 

information request for all solvents and HAP's (liquid and 

particulate), with the exception of Part F. This request 

pertains to all processes related to magnetic tape manufacturing 

and related activities. If you provide information in units 

other than those requested, please specify those units in your 

response. 

This information request has been separated into the 

following sections: 

Page 

Part I: 

A. General Information 3 

B. Overview of Solvents and Particulate HAP's . . 3 

C. Delivery and Storage 5 

D. Mix Room 7 

E. Coating Operation 8 

F. Packaging and Labeling of Products 12 

G. Cleaning 13 

H. Fugitive Emissions 16 

I. Control Devices 16 

J. Wastewater and Solid Waste Treatment 

and Disposal 24 

K. Retrofit, Replacement, and Modification ... . 25 

L. Other 25 
P.6 

h 

Page 

Part II: 

M. Economic Information 26 

N. Cost Information 27 

Please return this information request and any additional 

information you wish to: 

Emission Standards Division (MD-13) 

United States Environmental Protection Agency 

Office of Air Quality Planning and Standards 

Research Triangle Park, North Carolina 27711 

Attention: Bruce Jordan, Acting Director 
P.7 

3 

PARTI 

A. General Information 

1. Name of legal owner of plant: 

2. Address of legal owner: 

3. Number of employees attached to the magnetic tape 

production division of the plant: 

4. Name of respondent(s): 

5. Title(s): 

6. Telephone Number: 

7. Fax Number: 

8. Latitude and longitude (or UTM coordinates): 

9. The actual operating schedule for 1990: 

hr/d; d/wk; wk/yr 

B. Overview of Solvents and Particulate HAP's 

1. Please complete Table 1. 

2. What plans, if any, do you have to further reduce HAP 

emissions (e.g., fugitive emissions reduction, switch 

to low-solvent coatings, etc.)? 

3. Please provide a diagram or blueprint that shows the 

layout of the magnetic tape production process to 

include the delivery point of the solvents and 

particulate HAP's to the plant site, storage area, mix 

room, coating room, control device, packaging area, and 

product storage area. Please also show the location of 

the major equipment in these areas. 

4. What percent of total VOC emissions from a coating line 

is from each of the following areas: (a) coater head 

; (b) drying oven ; and 

(c) coating preparation ? Please indicate if 

these values are estimates or are based on 

actual measurements . If measurements were 

taken, please provide a copy of the protocol and 

results. 

5. Have emission tests been conducted for any of the major 

emission sources at this facility (including vents, 

stacks, etc., as well as control devices)? 

If yes, please attach a copy of all complete test 

reports, including problems encountered with the tests 

and any steps taken to resolve the problems. 

(o 
TABLE 1. SOLVENT AND PARTICULATE HAP USE 

1 

Name' 

illiliiiiiPiiiBiiliili 

Emissions, 

lb/yi* 

Total amount 

purchased, 

gal/yi* 

1 

Amount used in the following": l 

Applied coatings, 

gal/yr (lb/yr) 

Purchase Recycle 

Cleaning or maintenance, 

gal/yr 

Purchase Recycle 

Packaging process, 

gal/yr 

Purchase Recycle 

aAll solvents and any particulate HAP's. 

K 

•^i 

00 
P.9 

6. If the following information is not included in your 

response to Question 5, please provide the information 

below for each solvent from each major emission source. 

Emission 

Source 

Stack concentration of 

each solvent, 

Plume 

temp., 

Exit 

velocity, 

ft/sec 

Stack 

height, 

ft 

Stack 

diameter, 

ft 

C. Delivery and Storaqe 

1. Please provide the information requested in Table 2 on 

the storage vessels used to store virgin and recovered 

solvent. 

2. If a vapor balance system is used for tanker deliveries 

in which the solvent vapors in the head space of the 

tank are vented back to the tanker during delivery, 

please describe. 

3. If some type of particulate control system (e.g., 

filters) exists for delivery and storage of particulate 

HAP's, please identify. 

3 
P.10 

/ 

4. With respect to the bulk solvent storage tanks, does a 

system exist to contain (capture) emissions for 

delivery to a control device? 

If yes, please describe this system (include piping 

diameter and length, air flows, etc.). 

5. If N2 is used as part of the storage tank and/or mix 

equipment emissions control system (as opposed to other 

reasons, such as safety), please provide a description 

of the system, including: 

(a) If it is bought as liquid or gas 

(b) size of cylinders or tanks used -

(c) Flow rate, acfm, (if applicable). 

(d) Annual N2 use, ft3 

(e) Solvent concentration in N2 discharge to the 

atmosphere, ppm . 

D. Mix room 

1. Please complete the applicable statement: number of 

coating lines served by each mix room: ; or 

the percentage of mix equipment that is dedicated to a 

specific line . 

2. Please describe and attach a diagram of the emission 

capture system/ventilation system used in each coating 

mix preparation area. Indicate what systems are used 

and to where the emissions are vented. Include air 

flow rates during mix preparation and at other times, 

HAP concentration maintained in the ductwork, and, if 

tanks are closed and emissions ducted to a control 

device, how the air is supplied to the tanks. 

If any of the mix equipment is covered, please provide 

a description of the cover and the seals used (e.g., 

flat steel plate extending an inch beyond the edge of 

the mixer, no gaskets, bolted in place), how often the 

cover is opened, and how the constituents are added to 

the tank. 

Oa 
P.11 

i 

4. Are any waste coatings produced? 

If yes, how much, gal/yr 

If yes, describe how they are treated and disposed and 

provide the amount of final treated waste that is 

disposed each year. . 

5. For each mix room, please provide the data requested in 

Table 3. 

E. Coating Operation 

1. Please provide the information requested in Tables 4 

and 5 for each coating line. 

2. Please provide the following coating characteristics 

for each type of tape produced on.the magnetic tape 

manufacturing lines, even if some products are not 

magnetic. 

1 Coating parameters 

j What percent of the 

| coating is solvent 

Of the total liquid 

J solvent, what 

| volume and weight 1 percent is each 

I solvent 

1 Particulate matter 

| (PM) HAP's in 

I coating 

Of total PM in 

coating, % of each 

HAP 

volume % 

weight % 

Solvent: 

Solvent: 

Solvent: 

volume % 

weight % 

HAP: 

HAP: 

HAP: 

Density of coating, lb/gal 

1 Density of coating solids, 

| lb/gal 

Product code (see 

Attachment 2) 

10 
TABLE 3 . PHYSICAL AND OPERATING PARAMETERS FOR MIX ROOM EQUIPMENT 

' 

Number 

Capacity, gal 

Operating time, hours/day and 

hr/batch of coating 

Method of solvent and solids 

addition8 

Operated under pressure, yes or no 

How is pressure applied? 

Open or covered? 

Solvent concentration in headspace, 

specify units 

Use of breather valves/conservation 

vents; 

If yes, valve diameter, in.; 

Valve pressure setting, specify units 

Valve vacuum setting, specify units 

Mixers Mills 

" 

Polishing tanks Holding tanks Other (specify) 

* \ 

aFor example, piped, poured by hand through hatch, hopper. 

S3 
TABLE 4. COATING LINE INFORMATION 

^ 

Line 

ID Date instaUed* Width, in. 

Average line 

speed, ft/min 

Hours of 

coating, hr/yr 

Percent 

utilization of 

line 

Air drawn from Ihe coater 

head 

• LEL 

Flowrate, 

scfin 

Air drawn firom the oven 

*LE L 

Flowrate, 

scfin Temp,

 #F 

*If partial replacement occurred, please complete Section K of this infonnation request. 

If these dau are significantly different for each zone of the oven, please provide information for each zone. 

TABLE 5. COATING LINE PRODUCT INFORMATION X 

Line 

ID Product code* Product form Amount of coating applied, lb/ft Wet thickness, mils Single or double sided coating 

'Please see Attachment 2 tot product code. If more than one type is produced per line, please circle Ihe type lhat is produced in greatest amounts. 

Is the final product shipped ttom Ihe plast unalit web, pancakes, blank tape, prerecofded tape, other? 

Tl 
P.M 

3. Please write the line ID under each of the following 

types of ventilation systems used to capture emissions 

at the coater head for each coating line. 

Total 

enclosure 

Pick-u 

points Canopy hood Other 

Room H 

ventilation I 

aPick-up points are small vents, often located near the floor, 

that are not within an enclosure and provide localized 

ventilation. 

4. Please provide the following information on the air 

handling system for each coating line. 

a. 

b. 

c. 

d. 

e. 

A schematic and/or description of the air handling 

system, including recirculation 

Indicate locations of capture system pickups, 

dimensions, and volumetric flowrates. 

Makeup air requirements, acfm or scfm 

Provide a copy of the results' of any results of any 

capture system testing 

Has recirculation been considered? For which 

operations? Why was it or wasn't it installed? 

f. If there is an enclosure that completely surrounds 

the coater, provide: 

(1) Relative area of natural draft openings (NDO's) 

(2) Locations of NDO's relative to emission points 

(3) Location of NDO's relative to exhausts 

(4) Average facial velocity through and/or pressure 

drop across NDO's 

\"h 
P.15 

5. Please provide the following information for each 

coating line. 

Line ID 

Oven 

pressure3 

Coater head 

pressurea 

Coating 

room 

pressure3 

"Clean 

room" 

conditions f 

(Y/N) 

I 

aProvide actual units of pressure, if available. At a minimum, 

indicate whether area is operating at positive or negative 

pressure. 

F. Packaging and Labeling of Products 

NOTE: Complete this section only if liquid or particulate 

HAP's are used. 

1. Please provide the following information for all 

activities performed for finished magnetic tape 

products. 

Activity 

Name of 

HAP's used 

Quantity of HAP 

used or emitted/yr 

(indicate which) 

Control 

system (Y/N) 

Plastic molding 

Printing (labels 

or directly on 

boxes) 

Gluing (labels 

or boxes) 

Shrink wrapping 

Other (specify) 

|f 
P.16 

^ 

2. If HAP emissions from packaging or labeling are 

captured and controlled, please provide a detailed 

description of the process, including ventilation 

rates, concentrations, etc. 

If solvent-laden air from cleaning or treatment and 

disposal of cleaning solvents is vented to a control 

device, complete Table 8. Indicate if that control 

device is dedicated only in Section I to cleaning 

operations or also controls other emission sources 

(indicate which ones). 

G. Cleaning 

1. In Table 6, indicate all process steps in the 

production of magnetic tape that require the use of 

cleaning materials. Please identify the particular 

type of cleaning operation (e.g., wiping, dipping, 

spraying, or flushing) that is used in each process 

step. 

2. How many wash sinks are used for cleaning? How 

often are they used? What is the 

surface area of each? 

3. How many wash tanks are used for cleaning? How 

often are they used? What is the 

surface area of each? 

4. If any other equipment is used for cleaning, please 

list and describe where and how it is used. 

I * 
TABLE 6. GENERAL INFORMATION ON CLEANING OPERATIONS 

<T-. 

Cleanup description 

Mix tank (example) 

Mix equipment 

Filter housings 

Pump parts 

Coater head 

Calendaring rolls 

Blades on slitter 

Spills 

Other (please specify) 

Cleanup operation 

flushing 

Solvent used 

MEK 

Frequency of 

operation 

2/week 

Volume of 

solvent per 

operation, gal 

10 

X 

Tl 
P.18 

tf 

Using the following table, indicate how ventilation is 

provided to the areas in which the cleaning is 

performed (provide numbers, locations, airflow rates, 

concentrations, destination, etc.). 

Hoods 

Floor sweeps 

Room air 

changes (no. 

per hour) 

other 

(specify) 

Storage 

area Mix room Coater Packaging area 

6. How are the mops/rags/sponges/brushes, etc., treated 

and disposed of? Do they enter a manifest program? 

How much dirty cleaning solvent is generated each year, 

and how it is handled and disposed? Are you required 

to manifest? 

8. If solvent-laden air from cleaning or treatment and 

disposal of cleaning solvents is vented to a control 

device, complete Table 8 in Section I. Indicate if 

that control device is dedicated only to cleaning 

operations or also controls other emission sources 

(indicate which ones). 

n 
P.19 

* 

H. Fugitive Emissions 

1. Please provide the following information on the total 

numbers of components for the equipment that transports 

HAP's and the coating during the manufacture of 

magnetic tape. 

Component 

Pump seals3 

Packed 

Mechanical 

1 Double mechanical*3 

I Compressor seals3 

1 Flanges 

Valves 

Sample connections 

1 Open-ended lines (e.g., purge, 

B vent)c 

1 

Total number 

• 

' 

3List number of seals, not number of pumps and compressors. 

bIf double mechanical seals are operated with the barrier fluid 

(B) at a pressure greater than the pump stuffing box pressure 

and/or are equipped with a sensor (S) that will detect 

failure of the seal system, the barrier system, or both,, 

indicate with a "B" and/or an "S". 

cLines closed during normal operation that would be used during 

maintenance operations. 

2. If a formal leak detection and repair program for 

reducing fugitive emissions from these sources is in 

place, please complete Table 7. 

I. Control Devices 

1. Please specify the type, manufacturer, and date of 

installation for each control device. 

« 
TABLE 7. EQUIPMENT LEAK EMISSIONS DETECTION AND REPAIR 

Equipment 

type 

Pump seals 

Compressor seals 

Flanges 

Valves 

Pressure relief 

devices 

Sample connections 

Open-ended lines 

Leak detection 

Concentration, 

ppm 

Where 

measured 

Detection 

device 

Frequency of 

leak monitoring 

Repairs 

initiated 

(days after 

detection) 

Repairs | 

completed | 

(days after [ 

initiated) 

fcv 

to 

o 
P.21 

^ 

2. Control device efficiency 

a. Please provide monthly average control efficiency 

(e.g., bed or destruction efficiency) for the 

control device. If applicable, also provide the 

average line HAP recovery efficiency (HAP 

recovered/HAP used at coaters) and total HAP 

recovery efficiency for the plant for the last 

12 months. If you do not have operating data for 

an entire year, please provide any data that are 

available. 

Month 

9 Jan. 

Feb. 

Mar. 

Apr. 

May 

Jun. 

I Jul. 

Aug. 

Sep. 

Oct. 

Nov. 

Dec. 

| Average 

9 for year 

Efficiency \ 

Control 

device 1 

Control 

device 2 

Average of 

each line 

(provide 

line ID) 

Plant 

average 

. 

| 

How were the control device efficiencies determined 

(e.g., liquid material balance, control device 

inlet/outlet ratio)? 

c. How were the average line efficiencies determined? 

Zo 
P.22 

^ 

d. How was the plant average control efficiency 

determined? 

3. Please attach a description, including a flow diagram, 

of the HAP recovery system (e.g., distillation system). 

4. What amount (indicate units) of the recovered HAP's 

are: 

a. Used in coating mix? 

b. Used in cleaning? 

c. Fired in on-site boilers? ~ 

d. Shipped off-site permanently (provide destination)? f 

e. Shipped off-site for reclamation and returned 

(provide use)? 

f. Other (specify)? . 

5. Please complete Table 8 for each control device you 

operate. If you wish to use measurement units other 

than those specified for the parameters, please 

indicate the units used. 

6. Do you continuously monitor inlet or outlet 

concentration of solvents or HAP's for any control 

device? . 

If yes, please specify each HAP monitored, the types of 

monitors, and the sampling systems used for each 

control device. 

7. Additional questions regarding fabric filters: 

a. Describe the bag cleaning cycle. Indicate how the 

cleaning frequency is controlled and estimate the 

typical frequency. 

b. If there have any particular problems with bag 

failure, please describe. 

tl 
TABLE 8 . CONTROL 

Type device/parameter 

Operations served by this control device 

DEVICE SPECIFICATIONS 

Control device No. 1 

Design Actual 

Control device No. 2 

Design Actual 

CARBON ADSORBER 

Section 1. This section applies to both fixed and fluidized bed units. 

* SLA* flow rate, nominal, acfm 

maximum, acfm 

• SLA inlet temperature, °F 

• SLA inlet percent RH 

• SLA inlet concentration, ppmv or ppmC: 

* SLA outlet concentration, ppmv or ppmC: 

Typical 

Maximum 

• Carbon lifetime, mo 

• Total carbon charge, lb 

. 

• 

Section 2. The following section applies only to fixed beds. 

• No. of beds 

• No. of beds used at one time 

• Steam rate, lb/hr 

lb/lb charcoal 

lb/ (specify) 

Control device No. 3 I 

Design Actual 

-

X 
TABLE 8 . 

Type device/parameter 

Section 3. This section applies only to fluidized beds. 

• No. of trays 

• Carbon flow rate, lb/hr 

• Pressure drop per tray, in. water 

• Regeneration agent—N2 or steam? 

• Regeneration temperature, °F 

• N2 or steam rate, lb/hr or ft^/hr 

CONDENSATION SYSTEM 

• SLA flow rate, nominal, acfm 

maximum, acfm 

• SLA inlet temperature, °F 

• SLA inlet gas composition, percent LEL 

• N2 consumption rate, ft3/yr 

(continued ) 

Control device No. 1 

Design Actual 

Control device No. 2 

Design Actual 

Control device No. 3 

Design Actual 

\ 
^ 

- ^ 

TABLE 8 . 

Type device/parameter 

INCINERATOR 

• Catalytic (Q or thermal (T) 

• SLA flow rate, nominal, acfm 

minimum, acfm 

maximum, acfm 

• SLA inlet temperature, °F 

• Incinerator temperature, °F 

• Destruction efficiency, percent 

• Residence time, sec 

• Fuel consumption: 

Type fuel 

Annual amount 

• Heat recovery: 

With primary heat exchange? Yes or No 

With secondary heat exchange? Yes or No 

FABRIC FILTER (give both average and typical range values) 

• Gas temperature, °F 

• Gas flow rate, acfm 

• Moisture content, percent 

(continued) 

Control device No. 1 

Design Actual 

• 

Control device No. 2 

Design Actual 

Control device No. 3 

Design Actual 

\ 
TABLE 8 . 

Type device/parameter 

• Inlet particulate loading, gr/dscf 

• Cleaning mechanism (e.g., shaker, reverse air, pulse jet) 

• Gas to cloth ratio, acfm/ft2 

• Bag length, ft 

• No. of bags 

* No. of compartments 

• Outlet particulate loading, gr/dscf 

• Pressure drop across baghouse, in. w.c. 

• Bag life, mo 

(contin ued) 

Control device No. 1 

Design Actual 

Control device No. 2 

Design Actual 

Control device No. 3 

Design Actual 

FLARE 

• Maximum heat content of vent stream, BTU/scfm 

• Exit velocity, ft/s 

• Average HAP content of vent stream, percent 

X 

a

SLA is solvent laden air. 
P.27 

p 

Please provide data on baghouse dust 

characteristics. 

d. Describe the baghouse dust collection system and 

dust disposal practices. 

e. Do you pretreat the air stream or are reagents 

injected to enhance performance? 

If yes, please describe the process. 

8. Additional flare question: Is the flare steam-assisted 

, air-assisted, or nonassisted ? 

J. Wastewater and Solid Waste Treatment and Disposal 

Please provide the following information on any solid 

wastes or wastewater generated by (1) the HAP control devices, 

(2) the HAP recovery systems (e.g., distillation), and (3) other 

(specify). If magnetic tape waste is combined with the total 

plant waste, please estimate quantities that result from magnetic 

tape production and control. 

Description and source 

of waste 

EXAMPLE 

Still bottoms 

from solvent 

recovery 

Amount, gal/yr; lb/yr 1,000 gal/yr 

On-site treatment 

methods, if any 

none 

Disposal methods Reclaimer 

HAP concentration in 

waste from each source, 

PPm 

1,000 ppm 

Rate of discharge from 

plant, gal/yr; lb/yr 

N/A 

lb 
P.28 

S 

K. Retrofit. Replacement, and Modification 

1. Please list any modifications or replacements of the 

coating line(s) and the associated costs. 

j Year 

Line 

ID 

Description of 

modification 

Reason for 

modification Cost, $ 

2. Are there plans to replace existing equipment? 

If yes, why, and what equipment is to be replaced? 

3. If emissions from the storage tanks, mix equipment, or 

coater are not already controlled, please discuss the 

feasibility of retrofitting control. Please be 

specific (e.g., distances, access, configuration, 

etc.). 

L. Other 

1. Is the facility subject to any State or local agency 

air pollution control requirements? 

If yes, please provide a copy of the permit. 

2. Are there any other regulatory requirements (e.g., 

OSHA, RCRA) that would affect your ability to comply 

with additional air pollution control requirements? 

If yes, please discuss: 

27 
P.29 

PARTE 

M. Economic Information 

1. Please provide the following estimates of your 

expansion plans for the next 5 years. 

No. of new lines added to existing plant 

No. of new plants built 

2. 

No. of lines at the new plant 

If installation of new lines is anticipated, please 

provide the following information about each probable 

line. 

Line 

Line width, 

in. 

Line speed, 

ft/min Coating method Product code 

3. Please provide the following information for your 

products. 

9 Product 

1 code 

Annual production 

or annual sales 

(indicate which)a 

Average 

price per 

unitb 

Production 

cost, 

$/ft2 c 

Average fl 

percent I 

pretax H 

profit fl 

1 

1 1 

aNumber of cassettes, disks, ft2 of coated product, etc. 

^Provide the average price for each unit of output for each major 

category of product. Give price, lot size, and to whom sold 

(e.g., wholesale, distributor) or attach price list. 

^otal production cost, including line operation, control device, 

etc. 

4. Are your products sold in regional, national, and/or 

international markets? 

5. The Small Business Administration definition of a small 

business for SIC Codes 3573 and 3679 is a firm that 

employs 500 persons or fewer. Can your firm and parent 

company be considered a small business by this 

definition? 

If yes, please provide the total number of employees in 

your firm (parent company) (i.e., not just the magnetic 

tape production facility or your individual plant 

site). '. :— 

1% 
P.30 

rf 

N. Cost Information 

Please provide total capital and current annual 

operating costs for the magnetic tape production 

operations (from delivery of raw materials to shipment 

of final product). 

Total capital cost 

Total annual operating cost 

(year .) 

Capital and annual costs should be provided for process 

equipment. Annual operating costs should include, for 

example, labor (production, maintenance, and supervisory) , supplies, energy, and waste disposal costs. 

Please document all assumptions, including cost 

reference year and discount factors. Provide work 

sheets/tables showing how these costs were calculated. 

If it is simpler to provide capital and annual 

operating costs for the combination of production and 

control equipment rather than just for the process 

equipment, please do so. 

What is the cost of each HAP used? 

I

 HAP 

1 1 1 

$/unit (specify) HAP $/unit (specify) 

Please provide the capital cost information in Table 9 

for the ventilation systems for the various emission 

sources indicated, if the ventilation is part of the 

emissions control system. If any of the equipment was 

retrofitted, please indicate on the table with an 

asterisk. 

If there are any annual operating costs for these 

ventilation systems other than the energy costs, please 

describe and quantify here. (Be sure that the airflow 

rate information has been supplied where requested in 

Questions C.4, D.2, E.4, F.2, and G.5.) 

Z<? 
P.31 

s 

T.ABLE 9. INSTALLED COSTS FOR VENTILATION EQUIPMENT 

j • ' 

9 Emission 

| source 

1 Delivery 

and storage 

Mix room 

Qeaning 

Packaging/ 

labeling 

Fugitive 

emissions 

Equipment included in the 

cost estimate 

Coater heads for each line 

Line ID: 

Line ID: 

Line ED: 

Line ID: 

Purchase 

cost, $ 

Installation 

cost1, $ 

• 

Reference 

year 

Depreciable 

life, yr 

aIncluding start-up, engineering, contingency fees, etc. 

3>o 
P.32 

X 

5. The following questions ask for cost data on the 

control device(s); complete one column for each control 

device. If data are not available, please estimate 

replacement costs in 1991 dollars. Please provide 

annual operating costs in 1990 dollars. If absolute 

amounts are not available, please respond with data 

that best fit that specific block of the table. If any 

of the costs are for retrofitted equipment, please 

indicate with an asterisk. 

a. Installed Capital Costs of Control Device(s) 

Type of control system: 

Material of construction 

(e.g., stainless 

steel): 

Purchased cost, $: 

Reference year: 

Depreciable life, yr: 

Initial carbon charge 

Total charge, lb: 

Carbon cost, $/lb: 

Initial N2 charge 

(for condensation systems) 

Amount, ft3: 

N2 cost, $/ft3: _ 

Other installation 

costs (specify): 

TOTAL installed cost, $: 

b. Please list the major equipment included in the 

above capital cost estimate(s). 

c. Annual Operating Costs for Control Device(s) 

Type of control device 

Direct labor 

Labor hours: 

Cost, $/hr.: 

Supervisory labor 

Labor hours: 

Cost, $/hr.: 

3/ 
P.33 

Repairs and maintenance 

Parts and supplies, 

$/yr.: 

Labor hours: 

Labor cost, $/hr.: 

Electricity (fans, etc.) 

Use, kWh: 

Cost, $/kWh: 

Activated carbon replacement 

Cost, $: 

$/lb: __ 

Carbon regeneration 

Rate, lb: 

Cost, $/lb: 

Steam/N

2 fo

r carbon adsorber 

Units: 

$/unit: 

Fuel for steam generation 

Type: 

Use, units: 

Cost, $/unit: ~ 

Water (bed quenching, etc.) 

Use, 1,000 gal: 

Cost, $/l,000 gal: ~ 

N

2 consumptio

n for 

condensation system 

Use, ft

3: 

Cost, $/ft

3: 

Incinerator/flare fuel 

Cost, $: 

type: 

$/unit: 

$/yr.: 

Other annual 

operating costs 

(please specify) 

TOTAL annual operating 

costs, 1990 $: 

!>l 
P.34 

7* 

6. Please provide the following cost information for the 

distillation, solid waste, wastewater, and other 

(e.g., waste coating) treatment systems at your 

facility. 

a. Installed Capital Costs 

Distil- Solid Wastelation waste water Other 

Purchased 

cost, $: 

Material of 

contruction: 

Reference yr: 

Depreciable 

life, yr: 

Other installation costs 

(specify): 

TOTAL installed 

cost, $: 

b. Please list the major equipment included in the 

above capital cost estimate(s). 

Annual Operating Costs 

Electricity 

Use, kWh: 

Cost, $/kWh: 

Steam generation 

Use, lb: 

Cost, $/lb: 

Fuel for steam 

generation 

Type: 

Use, No. 

units: 

Cost, $/unit: 

TOTAL annual 

operating 

cost, $/yr: 

b5304-l/DIS 

"3 3 
P.35 

Attachment 2 

Please use the following product codes in response to the 

questions. 

Product code 

A-C 

A-OR 

A-P 

V-VHS 

V-P 

C-OR 

C-D 

I 

D-M 

M-I 

L 

Type of tape produced 

audio cassette (consumer) 

audio open reel 

audio - professional 

video VHS 

video - professional 

computer open reel 

computer floppy disks 

instrumentation tape 

computer magnetic card media 

magnetic inks not applied at this facility 

leader tape (nonmagnetic) 

Please specify others 

^ f