p. 1 

# OAR Box 1394 Prepped by Ollie Stewart



### Document

Number: 

# 17 ) ll-B-1 2 Docket Number: 

# A-94-5 2

Printed 7/3/2008 7:22:10AM

Sheet 17 of 57

# F P. 2 

# 46/Szr-c/e-oy

TO : Projec t

Fil e Reinforce d Plasti c Composite s NESHA P FROM : Melani e Procto r and Gre g LaFla

m Pacifi c Environmenta

l Services , Inc . (PES ) DATE : Decembe

r 17,199 6 SUBJECT : Sit

e Visit-Tecto n Products , Fargo , ND EP A Contrac t

68D10116 , ES D Projec t

93/5 8 PE S Projec t

N404 NON CB I SIT E VISI T REPORTS V ^ ^Z^SS 6 'p|j ^



### A-94-52 

## 1 1 B > | 1

I . Purpos e Th e purpos e o f

thi s visi t wa s t o determin e th e way s in which pultrusio n operation s var y fro mon e to anothe

r an d if th e ne w sourc e MACT standar

d fo r pultrusio n shoul d b e base d o n th e emissio n contro l achieve d b y Tecto n Products . Th e visi t wa s als o intended t

o provid e abette

r understandin g ofth e pultrusio n process , th e parameter s tha t affec t th e technica l feasibilit y o f applyin g ai

r emissio n controls , an

d th e potentia

l economi c impac t

o f thos e control s o n pultrusio n operations . II . Plac e an d Dat

e Tecto n Product s 440 1 15t h Avenue , N

W Pos t Offic e Box 271 2 Fargo , Nort

h Dakota5810 8 Jun e 4 and 5 , 199 6 III . Participant s Tecto n Product s Mr . Joh n Jambois , Presiden

t Mr . Bra d Kirby , Projec

t Enginee r Mr . Mitc h Irmen , Productio n Controller/Safet y Director Ms . Kath y Axtman , Purchasing Agen tP. 3

Sit e Visi t Repor t - Tecto n Product s Pag e 2 U . S . EP

A q Dr . Madelein e Strum , Projec t Manage r Nort h DakotaStat

e Departmen

t o f Healt h Mr . Gar y Helbling , Environmenta

l Engineer * Mr . Kar l Corrigan , Environmenta

l Engineer * PE S Mr . Gre g LaFlam , Environmenta l Enginee r Ms . Melani e Proctor , Environmenta l Scientis t * N D Stat e employee s participate d o n Jun e 4 only . IV . Genera

l Facilit y Informatio n Tecto n Product s bega

n constructio n o f

it s productio n facilit

y i n th e summe

r o f 1991 . Afte r constructio n wa s complete d in th e summe r o f 1992 , Tecto n obtaine d a

n operatin g penni t (permi t numbe r M93001 ) in Augus t

199 3 an d bega n production . John Jamboi s pointe d ou t tha t rumor s o f Tecton' s prio r

existenc e an d environmenta l problem s i n Minnesotaar e untrue . H e state d tha t Tecto n never

existe d in Minnesot ao r

an y othe r location . Tecto n i s aprivately hel d compan y an d doe s no t provid e annua

l report s to th e public . Th e productio n are ai s 40,00 0 ft 2 . A tota l o f 2 6 acre s o f

lan d surroundin g the operatio n ca n be use d fo r furthe r expansion . V . Descriptio n o f

Product s Tecto n currently produce s approximately 1 5 differen t style s o f windo w an

d doo r lineal s vi athe pultrusio n process . Th e window s an

d doo r lineal s ar e painte d an

d the n assemble d by Marvin Windows . Paintin g i s anecessar y ste p t o produc e amor

e weathe r resistan t product . Tecto n produce s component s for tw o distinc t

produc t lines , Marvin Window s an d Integrit y Windows . VI . Pultrusio n Operation s Tecton' s curren

t operatin g permit , which wil l expir e i n Augus t o f 1996 , allow s th e facilit y t o operat e 5 pultrusio n lines . The ne w operatin g permit

wil l reflect

th e planned expansio n an

d wil l be submitte d t

o th e Stat e thi s summer . 

# aP. 4

Sit e Visi t Repor t - Tecto n Product s Pag e 3 Tecton' s permi t

allow s themto emit

3 8 ton s o f

HA P pe r year , whic h woul d mak

e thema majo r source . Mr . Jamboi s di d not provide th e annua

l resi n usag e fo

r it s facility . Tecto n use s fille r i n thei r product , bu

t wa s no t willin g to shar

e filler-resi n ratio s or

an y informatio n pertainin g to thei r resi n matri x recipe . Eac h ofth e pultrusio n line s a t Tecto n i s equippe d wit

h atotal enclosur

e whic h extend s fro mth e beginnin g ofth e resi n bat h to apoint

slightl y beyond th e di e exi t (abou t 6 inches) . Th e infonnatio n about

th e emissio n contro l systemi s explaine d i n mor e detai l i n sectio n X . Durin g th e visit , i t

wa s verifie d tha

t Tecton' s proces s ca

n b e classifie d a s apultrusio n proces s containin g th e typical emission s point s o f resi n bath , drip , and die . Th e tota l lengt h ofth e pultrusio n proces s withi n eac

h enclosur e i s approximately 1 6 feet . VII . Resi n Storag e an

d Mixin g Resi n i s delivere d b y tanker truck s and pumpe d int

o storag e tanks , whic h ar

e locate d i n a roo mthat i s vente d to th e therma

l oxidizer . Th e resi n storag e roo mi s temperature controlle d an d kep t at 60 ° F . Th e mixin g roo mi s als o temperatur e controlle d and vente d t o th e therma l oxidizer . VIII . Cleaner s N o HA P cleaner s hav e eve

r bee n use d a t Tecton . Th

e facilit y use s onl y aceton e fo

r cleanup operations . IX . Paint

Boot h Th e pain t boot h operate s 2 4 hour s pe

r day , 7 day s pe

r week . Sinc e VO C concentration s ar e hig h withi n the pain

t booth , worker s wea

r respirator s whe

n painting . X . Emissio n Contro l Svste m Tecton' s therma

l oxidize r achieve s a

n overal l contro l efficiency o f a t leas t 9 5 percen t o n emission s fro

mth e pultrusio n process , storag e and mixin g tanks , and painting . Tecto n teste d th e contro l efficiency o

f it s incinerator

twice . The first

tes t resulte d i n a92.1 6 percen

t contro l efficiency , failing the State' s requiremen t o f 9 5 percent

emissio n control . Afte

r change s wer

e made , asecond tes t

indicate d adestructio n efficiency o f 96. 6 percent . No styren e odo r ca n b e detecte d o n th e roof

o f th e productio n buildin g wher e th e stac k ofth e incinerator

i s located . Tecto n installe d the incinerator becaus e th e Stat

e an d th e EP A Regiona

l offic e i n consultatio n wit

h th e Offic e o f Ai r Qualit y Plannin g and Standard s determine d tha t Tecto n i s subjec t t o the Ne w Sourc e Performanc e Standar d (NSPS ) for

polymeri c coatin g o f

supportin g 

# fP. 5

Sit e Visi t Repor t - Tecto n Product s Pag e 4 substrate s (subpar

t VW) . Mr . Jamboi s reviewe d th e NSP S an d agreed tha

t th e standard s wer

e applicabl e t o hi s operation . According t o Mr . Jambois , th e Stat

e o f Wisconsin , whic h wa s originall y considere d a s apossibl e locatio n fo r Tecton , woul d no t

hav e require d th e incinerator . Despit e th e add-o n contro l requirement , Mr . Jamboi s decide d t o locat e th e operatio n i n Nort

h Dakota . Th e therma

l oxidize r used a t Tecto n ha s abou

t a9 6 percen

t hea t recovery . Th e minimum ai r flow s fro meac h emissio n poin

t vente d t o th e incinerator

ar e liste d i n Attachmen

t 1 (CBI) . The inle t strea mi s preheate d to 16

0 t o 280 ° F and th e outlet

temperatur

e measure d i n th e stac k

i s 200 ° F . Th e locatio n ofth e cente r be d ofth e incinerato r

shifts u p an d dow n du e to change s in th e flow directio n (cycling ) ofth e inle t stream . Th e averag e temperatur e o f al l measuremen

t point s in the incinerato r

i s currently abou

t 1,590 ° F . I

n orde r t o maintain aminimu

mtemperatur

e o f 1,680° F a t th e oute r corner s ofth e cente

r be d a s require d by the State , th e temperatur e i n th e middl e ofth e cente

r bed reache s 1,890° F . The oxidize r remain s operatin g wit

h minima l amount s o f

natura l ga s even whe

n no proces s emission s ar

e vente d to th e incinerator . I f th e incinerator ha s t o b e shu

t dow n fo r an y reason , i t

take s 3 to 4 day s to get

i t bac k o n line . Th e Stat e ha s to b e contacte d when the oxidizer i s off-lin e an d record s hav e t o b e kep t

to sho w tha

t th e 5 percent

noncomplianc e hour s allowe d by th e Stat e ar e not exceeded . Eve n thoug h Tecto n currentl y vent s emission s fromit s paintin g operatio n t o th e contro l device , th e thermal oxidize r was no t originally designe d no

r intende d t o contro l paint

spra y boot h emissions . Tecto n di d no t

originally conduc t

paintin g operation s a

t thei r facility , bu t

decide d t o paint thei r ow n produc t

t o improv e produc t

quality . Th e oxidize

r operate d fo

r 8 month s befor

e the spra y boot h existed . Tecto n i s plannin g t o remov e the pain

t spra y boot h exhaus t fro mth e oxidize r t o provid e mor

e capacit y fo r th e planne d expansio n ofth e pultrusio n operatio n and ha s discusse d thi s issu e wit

h th e State . The Stat

e doe s no t requir e add-on control s fo

r paintin g operation s an d doe s no t

objec t t o th e planne d removal . Tecton' s pultrusio n emission s ar e capture d i

n permanen

t tota l enclosures , which ar

e vente d t o the incinerator . The enclosure s a t Tecto n mee

t th e EP A criteri afor

10 0 percen t capture . Each pultrusio n machin e ha s aseparat

e enclosur e constructe d ou

t o f meta l wit h window s fo

r continuou s viewin g o

f th e process . Th

e ai r flo w i n the enclosure s i s monitore d an d se t t o achiev e aface velocit

y 1 0 percen

t abov e th e minimu

mrequiremen

t o f 20 0 fee t pe r minut e along an y natura l draf t openin g t o maintai n negativ e pressur e i n the enclosures . Th e enclosure s wer

e constructe d t

o provide abette

r workin g environment . Durin g th e visit , onl y aver y sligh t styrene odo

r coul d b e detecte d outsid

e th e enclosure s wher

e employee s ar e working . Occasionally , a n employe e need s t

o ente r th e enclosur e t o mak e correction s to the process . Mr . Kirb y explaine d tha t th e HA P emission s in the enclosur e ar e stratifie d wit

h highe r concentration s a

t the pick u p points . He di d not

thin k tha t the HA P concentratio n i

n th e breathin g zon e ofth e enclosur e exceede d 5 0 ppm . Tecto n doe s no t conside r the enclosure s detrimenta l t o it s operation . 

### IP. 6 -ii.' -_ » Sit e Visi t Repor t - Tecto n Product s Pag e 5 XI . Cos t

Informatio n Base d on informatio n provide d b y Mr . Jambois , contro l cost s ar e amino r par t o f Tecton' s expense s and Tecto n i s aprofitabl e operatio n eve n wit h the add-o n contro l systemin place . Th e participant s discusse d PES' s independen t estimatio n o f

Tecton' s capita

l cost , annua

l costs , and th e cos t

per to n o f HA P controlle d s o tha

t EP A coul d validat

e the contro l cos t spreadsheet s develope d to estimat e cos t impact s o n othe

r facilitie s tha

t migh t hav e to us e add-on s in th e future . PE S calculate d acontro l cos t o f $5,00 0 pe r to n o f styren e remove d base d o n permi t information , whic h assume s five pultrusio n machine s an d doe s not include paintin g operations . Cost s provide d b

y Tecto n and calculate d by PE S wer e withi n 2 0 percen

t o f each other . XII . Fina

l Question s an

d Actio n Item s fo

r Tecton :

• Provide MSD S fo

r resin s

• Provide asampl e cop y ofacomplianc e reportin g shee t

• Provide maximu

mmonthl y resi n usag e (al l machine s operating )



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