p. 1 

# OAR Box 1477 Prepped by Ollie Stewart



### Document

Number: 

# 20 ) II-J-1 1 Docket Number: 

# A-94-5 2

Printed 7/31/200811:18:29AM Sheet 20of 36P. 2

TANK S EP A Januar y7 , 200 0 Mai l Dro p 1 3 Researc h Triangl e Park , N C 2771 1 Attn : Mr . Keit h Barnett Subject : MACT Commentar y W e are writin g a s a follo w u p t o ou rpreviou s join t meetin g o n Decembe r14 , 1999 . W e woul d like t o commen t o n what we d o an d th e effect s we currentl yexpec t fro m th e MACT proposal . Justi n Tank

s ha s provide d FR P tank s t o a broa d industr

yfo rove r(40 ) years . Market s includ e Wate rTreatment , Wast e Wate rTreatment , Foo d Processing , Pul p & Paper , Chemical , a s wel l a s others . Eac h o f thes e markets have uniqu e requirement s an d buyin g methodologies . As a resul t o f industr

ycompetition , eac h of thes e markets ha s becom e ver ycompetitive , thu s drivin g dow n margins . Annua l sale s at ou rfacilityove rth e las t fiv e year s have average d 3. 4 millio n wit h pre-tax profit s i n th e rang e o f 2% . W e employa n averag e o f (35 ) employees , th e core ofwhic h ha s 15-2 0 years servic e wit h ou rcompany . Th e workin g lif e spa n o f ou requipment , i s directl yrelate d t o it s quality . Th e qualitylevel s we sustai n are a functio n o f th e workabilityof th e resi n systems . Th e majorit yo f th e resin s w e us e are i n th e 45-5 0 % HA P range . Th e highe rHA P resin s are used , no t onl yfo rthei r competitiv e pricing , bu t t o allow u s t o achieve th e qualityrequirement s demande d byou r custome rbase . Typicall yth e lowe rth e HAP , th e mor e difficul t i t i s t o reduc e we t ou t tim e an d achiev e ai rfre e laminates . Th e drivin g forc e behin d th e MAC T wil l forc e u s t o mov

e t o lowe rHA P resins , a 100 % conversio n o f ou rsprayequipment , rewor k al l labo rprocesse s an d provid e fo radditiona l record keeping . Eac h o f thes e ha s direc t cost impacts . Th e core o f ou rresi n system s has a HA P conten t of 45-50% . Th e averag e cos t o f thes e resins , i s i n th e rang e o f $1.20/lb . Bea ri n mind , th e purchas e pric e o f resin s i s base d o n use r volumes . Lowe rHA P resin s averag e $1.95/lb . Th e bas e cos t differentia l result s i n a 63 % increas e i n ra

w materia l cost pe rpoun d o f resi n use d fo rth e lowe rHAP . On e rationa l ma

yb e t o mov

e directl yt o th e lowe rHA P resins , unfortunatel y i n ou rmarkets , we woul d loos e 50 % o f ou rsales . Thes e customer s woul d mov

e t o mor e cos t effectiv e

JUSTI N TANKS , L.L.C . • 8 Ceda rCree k Avenu e • P.O . Bo x82 5 • Georgetown , D E 1994 7 (302 ) 856-352 1 • FA X (302 ) 856-352 7P. 3

materials . Thi s woul d require u s t o develo p ne w markets , whic h are currentl ynot define d an d ma yno t eve n b e there . Bea ri n mind , th e "En d User " typicall ydefine s th e resi n base d o n compatability fo rservice , not HA P content . T o chang e this , wil l require a majo remphasi s chang e wit h resi n suppliers , engineerin g group s an d fabricators . I t wil l b e like re-inventin g th e industry . I don' t thin k th e "En d User " wil l accep t th e transitio n wit h ope n arms . Conversio n o f equipmen t t o "flo w coaters" , othe rtha n th e expense , i s no t a bi g impact . Ther e are bac k en d benefits , whic h provid e positiv e results . Particularl ywit h worke rexposure t o emmisions . W e have alread ystarte d convertin g ou rsmal l spra yuni t ove rt o "flo w coaters" . Th e mai n proble m w e forese e i s wit h ou rVenu s Cho p Hoo p machine . Thi s i s a hig h volum e (resin ) tan k

fabricatio n machine . Venu s has ye t t o full ydevelo p an d tes t a "flo w coater " typ e spraysyste m fo rthi s machine . Conversio n cost fo rthi s equipmen t i s ye t t o b e defined . Thi s i s a $350,000.0 0 investmen t that wil l not satisf yMAC T a s i t i s currentl yoperating . Transitionin g int o a MAC T complian t environmen t wil l requir e redevelopmen t o f al l ou r process ' a s wel l a s retrainin g of al l employees . Th e estimate d cos t impac t ove rth e firs t yea r wil l b e $25,000.00-35,000.00 . Recor d keepin g fo rMAC

T complianc e i s goin g t o b e extensive . Du e th e quantityof resi n system s an d process ' t o repor t on , w e expec

t th e yearl yimpac

t t o b e a minimu m o f $45,000.00 . W e have ru n number

s o n th e last seve n month s o f productio n usin g th e new UE F factor s an d takin g advantag e o f th e "flo w coaters " i n area s where the yare i n use . Thes e calculation s pu t u s at a monthl yaverag e o f 120 % of th e MAC T floor . Th e highes t mont h wa s 140. 5 % an d th e lowest wa s 100. 3 % o f th e floor . W e wil l poin t ou t th e lowest reporte d mont h wa s a tim e whe n ou rproductio n ra n th e highest volum e o f low HA P resin . Thi s evaluatio n concern s u s an d w e questio n th e validityo f th e curren t MAC T floors . I f throug h th e us e o f low HA P resin s an d "flo w Coaters" , w e are unabl e t o achiev e th e floor , th e nex t optio n i s t o g o t o ad d o n controls . Ro b Haberiei n ha s bee n t o ou rfacilit yan d I have attache d a cop yo f hi s initia l report . I n summary , h e recommend s a preconcentrator , whic h woul d hav e a maximu m capture o f 85% . Th e cos t o f th e syste m woul d b e $3,000,000.0 0 wit h a n annua l operatin g cos t o f $600,000.00 . Assumin g 5 0 tp yo f capture , whic h i s high , th e syste m woul d cos t i n exces s b f $10,000.0 0 pe rton . I f MACT proceed s i n it s curren t direction , I fee l i t i s goin g t o b e ver ydifficul t t o achiev e t o floors . W e wil l ver

ylikel yclos e th e doors . There i s n o wa yt o justifyth e additiona l expenditure s require d fo radd-o n controls , i f w e canno t meet th e floo rwithou t them . As additiona l information , I have enclose d som e photo s o f ou rsho p an d produc t w e fabricate . Yo u shoul d not e th e complexit yan d siz e of th e equipment . I f yo u can , yo u shoul d visi t ou r we b site-justintanks.com .P. 4

I woul d lik e t o than k

yo u fo rthi s opportunity . I trus t th e EP A wil l re-evaluat e thei rapproac h an d loo k fo ra bette rway , whic h allows companie s like ours t o continu e ou rlon g standin g histor yo f supplyin g equipmen t t o th e industry . Respectfull y

Presiden tP. 5

A laminatio n operation s a

t Justi n occu

r i n fou r distinct areas : Horizontal

Mandrel Stations - tw o station s locatedtogethe r i n on e area . Thes e station s produc e extremel y larg e tan k vessel s usin g manua

l application , mechanica

l application , an

d filamen t winding . Vertical Mandrel Stations (6 ) - si

x station s locate dtogether

i n on e area . Thes e station s produc e smal l t o extremel

y larg e tan k vessel s usin g manua

l application , mechanica

l application , an dfilament

winding . Part Assembly - th e larg e tan

k part s ar e assembledon th e ope

n sho p floor usin g mostl

y manua l an dsom e mechanica

l application . Small Parts Fabrication - smal

l ancillar y tan k part s are producedon numerou s smal l table s usin g manua

l application . Th e maxima l captur e syste mfo r the combinedoperation s a t Justin wouldconsis t

o f th e following enclosures : Horizontal

Mandrel Stations - one larg e horizonta l flo w boot h enclosur e wit h a n ope n door an d abou t 40,00 0 cf mo f exhaus t t o captur e th e emissions . Thi s boot

h will hav e ane

w fixed rea r wall wit h larg e filteredexhaus t

inlets . Th

e tota l project cos t fo r th e horizonta

l boot h woul dprobably b e i

n exces s o f

$120,000 . Vertical Mandrel Stations - si

x vertica l booth s (one pe

r station ) wit

h a t leas t 15,000 cf mpe r booth . Thes e booth s will have moveable sid e curtains , ceilin g suppl

y an din-ground floo r exhaust . Thes e booth s will requir e extensiv e reconstructio n t o install . The tota l project cos t fo r th e vertica

l booth s wouldprobabl

y b e i n exces s o f

$300,000 . Part Assembly - due t o th e larg e siz e ofth e part s an dscattere dlocation s acros s th e plan t floor , th e onl y practica l approach wouldb e t o mak e th e buildin g int

o aBuildin g Enclosure . Unfortunately , th e existing buildin g i s ver y leaky , an

dth e exterior

door s cannot

b e close d durin g production . Th

e door s ar e openedt o allow fo

r ingres s an degres s o f

parts , tools , ra w materials , an

dwaste , an

dt o cool th e employee s i

n th e summe

r months . Fo r

thes e reasons , par

t assembl y cannot b e practically enclosed . Th e emission s fromthi s are ama y b e a s muc h a s 5 % ofth e tota

l emissions . Small Parts Fabrication - smal

l enclosure s must

b e customdesignedt o match each typ e o f smal l part . Thi s i s to o complicatedt o asses s a t thi s time an

dwoul drequir

e extensiv e desig n an dexperimentation . For

thes e reasons , Smal

l Part s Fabricatio n canno t

b e practically encloseda

t thi s time . Th

e emission s fromthi s are ama y a s muc h a s 5 % ofth e tota l emissions . Du e t o th e sporadi c emission s pattern , hig h exhaus t flo w rate , an dlow exhaus t

concentration , th e onl y feasibl e contro l technolog y optio n wouldb e apreconcentrator oxidize r syste msimila r t o th e Dur r syste ma t Ake r Plastic s i n Wes t Virginia . Thi s syste

mwouldb e sizeda

t 130,000 cf

mt oP. 6

include th e tota

l exhaus t flow s fromth e horizonta

l an dvertica l booths . The approximat

e installe dcos t

fo r th e Dur r syste man dth e ne w enclosure s wouldb e i

n exces s o f

$ 3 million . The annualize dcontro l cos t

woul db e i n exces s of

$600,00 0 pe

r yea r (basedon th e reporte dcost s fo r th e Ake r system) . Assuming about

5 0 tp y o f capture demission s pe

r year , th e contro l cos t

effectivenes s fo

r th e maxima l captur e an dcontro l syste

mwouldb e i

n exces s o f

$10,00 0 pe

r ton . Note tha

t les s tha n 85 % ofth e tota

l plan t emission s wouldb e capture dby thi s system .

Ro b Haberiei n Januar y 6 , 200 0P. 7

Dat e Compan y Plan t Perio d 12/22/9 9

Justi n Tanks , LL C 

### Plan t Summary o f MAC T Poin t Value s an d Styren e Emission s

MONT H May-9 9 Jun-9 9 Jul-9 9 Aug-9 9 Sep-9 9 Oct-9 9 Nov-9 9 Dec-9 9 Jan-0 0 Feb-0 0 Mar-0 0 Apr-0 0 Tota l

Monthl y Materia l Usag e se e not e 1 (lb/mo ) 43,95 1 22,09 9 27,78 1 29,03 0 27,48 0 32,60 1 28,15 9 0 0 0 0 0 Monthl y

Weighte d Averag e MAC T Poin t Valu e se e not e 2 (Ib/ton ) 250. 3 218. 3 192. 2 201. 1 183. 0 203. 5 174. 3 0. 0 0. 0 0. 0 0. 0 0. 0 Monthl y

Weighte d Averag e MAC T Floo r se e not e 3 (Ib/ton ) 178. 1 169. 9 170. 2 163. 3 168. 8 174. 1 173. 9 0. 0 0. 0 0. 0 0. 0 0. 0 Monthl y

Weighte d Percen t o f MAC T Floo r se e note 4 ( % o f floor ) 140.5 % 128.5 % 112.9 % 123.2 % 108.4 % 116.9 % 100.3 % 0.0 % 0.0 % 0.0 % 0.0 % 0.0 % Rollin g

12-Mont h Weighte d Averag e Percen t o f MAC T Floo r se e not e 5 ( % o f floor) N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A N/ A Tota l

Monthl y Styren e Emission s base d o n UE F Factor

s se e note 6 (lb/mo ) 5,29 8 2,30 1 2,50 0 2,68 1 2,23 6 2,73 7 1,92 9 0 0 0 0 0 Tota l Annua l Styren e Emission s (lb/yr ) 19,68 2P. 8

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TANK S 

# AMERICA S FOREMOS T PROVIDE RO F CUSTOM ENGINEERE D FIBERGLAS S TANKS . Fo r mor e tha n 4 0 years , Justi n ha s provide dcos t effectiv e Fiberglas s Reinforce dPlasti c (FRP ) tank s an dancillar y product s fo r awid e rang e o f applications . Ou r

expertis e ha s earne du s th e reputatio n amon g ou r satisfie d Fortun e 10 0 customer s tha t "Justi n tank s neve r

fail" . Justi n wit h it s pioneerin g technolog y build s th e world' s fines t tank s wit h awid e variet y o f

configurations . Ou r

FR P tank s an dvessel s provid e outstandin g corrosio n resistance , standin g u p t o awid e rang e o f temperature s , acids , alkalies , an dothe r corrosiv e chemicals . FR P tank s cost s less , provid e agreate r strengt h t o weigh t rati o tha n stee l o r

alloys , hav e a n excellen t therma l valu e an dperfor mbette r tha n othe r material s i n avariet y o f applications . Th e Justi n plan t

locate di n Susse x Count y Airpar k i n Georgetown , Delaware , i s on e o f th e fe w i n th e industr y specificall y designe dan dbuil t t o fabricat e FRI 3 tank s an d equipment . Throug h th e us e o f multi-statio n vertica l an dhorizonta l winders , Justi n provide s tank s wit h diameter s rangin g fro m3 throug h 1 4 foot . Tank s ar e fabricate dutilizin g bot h filamen t woun dan dcontac t

molde dprocesses . No n standar ddiameter s an dconfiguration s ar e als o availabl e

t o mee t custome r

needs . Justin' s highl y skille dtea mprovide s complet e solution s j an dstan db y suppor t

fro mdesig n throug h installation . W e suppor t

ou r produc t durin g al l phase s o f

th e project . <



### Fabricatio n 

## Fiel dServic e

.P.2 0



# 4 0 Year s o f

Manufacturin g Integrit y Yo u Ca n Rel y O n 

# i K B

, _P.2 1 

# Justi n manufacture s accessor y item s t o mee t you r proces s requirement s .. . exactly !



# We Say What

We Build, Build What We Say! Servic e Fo r JUSTI N TANK S L.L. C P.O . Bo x82 5 • 8 Ceda rCree k Ave . Georgetown , D E 1994 7 (302 ) 856-352 1 • FA

X (302 ) 856-352 7 www.justintanks.co mP.2 2



# JUSTI N TANK S IS COMMITTE

D T O PROVIDING HIGH QUALIT Y LIQUI D STORAG

E TANK S THROUG

H A PARTNERSHI

P O F SERVICE, THROUGHOU T THE LIFECYCL

E O FOU RPRODUCT . Justi n Provide s

• Mos t Economicall y Viabl e Solution s wit h Uncompromisin g Qualit y • Engineerin g an dSpecification s fo r aVariet y o f Custome r

Specifi c Application s • Acces s t o Qualit y Inspectio n Record s ^ ^Al l Resi n System s an dApplication s ^ ^ » Compute r

Aide dDesign s • Fiel dModification s an dRepai r • Mixe r System s Ful l Complimen t o f Accessorie s Including ; • Agitatio n • Factor y Insulate dTank s • Temperatur e Maintenanc e System s • Platform s & Walkway s • Ladder s & Cage s • Handrai l System s • Flange dNozzle s & Acces s Manway s 

# Justi n Capabilitie s Filamen t Woun dan dContac t

Molde dTank s Buil t t o Industi y o r

Custome r

Specifi c Standard s Siz e i s Determine db y Shippin g an dHandlin g Limitation s - Usuall y U p t o 14 ' ft . Diamete r Vertical , Horizonta l an dRectangula r Configuration s Dished , Cone do r

Fla t Bottom s 

# Industrie s Serve d Chemica l Foo dProcessin g Pul p an dPape r Wate r Treatmen t Wast e Wate r

Treatmen t Brewin g & Distillatio n Ph.irm.ieeutie.i l Biologica l Enera v 

### Pain t & Dy e Aqu.ieiiltiu e

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