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# OAR Box 1384 Prepped by Charmelle Mathews



### Document

Number: 

# 63 ) ll-E-2 3 Docket Number: 

# A-94-5 2

Printed 7/2/2008 8:42:05 AM Sheet 63 of 264P. 2

CONTAC T REPOR

T From : Wanit aDunston , U S Environmenta l Protectio n Agenc

y Madelein e Strum , U S Environmenta

l Protectio n Agenc

y Dat e of Contact : Augus t

1 , 1995 ^ , . ~ " f Contact : Richar d Wells , Laborator

y Manage r Company/Agency : Spauldin g Composite s Compan

y Telephone Number : (815)758-818 1 '"**""*""" * "- ~ CONTAC T SUMMAR

Y Note s prepare d b

y Wanit aDunston
.

• WHA

T I S VOLUMETRI

C FLO W RAT E THROUG

H TH E INCINERATOR
. The volumetri c flow rate i s 1400 0 cfm
. WHA

T I S THE INLE

T CONCENTRATION O

F STYREN E T O TH E OXIDIZER ? Ther

e i s no styren e a

t th e inlet
.

• TEL

L M E A LITTL

E ABOU T YOU RSATURATIO

N PROCESS
. W

e manufactur

e phenoli c plastics , primarily
. Spauldin g manufacture s som

e phenolic resins , som

e are supplied frommanufactures
. Th e resin i s put

int o th e machine , pape

r o r clot h i s put int o th e di p pa n an d the n goe s through squeez e rolls , then int o th e ove n b y aconveye

r belt
. Th e hea t i n th e ove n partiall y drive s of f th e solvents , an

d thes e solven

t vapor s travel throug h th e manifol

d hoo d int o th e incinerator
. (Th e genera l proces s i s stea

mpowered)
. Materia l fromout ofth e en d ofth e horizonta

l curing oven s i s eithe

r cut int o sheet s or rolle d onto rollers ; thi s i s calle d prepre g (B-stage)
.

• Thi s materia

l i s sen t t o store room s until needed b y th e othe r processes . Prepre g sheet s g o t o th e pres s room . The prepre g shee t i s placed betwee

n stee l plate s unde

r pressur e an d heat ; thi s complete s th e cros s linin g ofth e plastics
. The stee

l plate s are remove d leavin

g th e finished sheets , whic

h ar e sen t t o th e fabrication proces s fo r cuttin g an d machinin

g int o th e desire d shape
. The rolled B-stag e goe s t o th e tub e rollin g machine
. We

b goe s acros s stea mheate d rollers
. The hea

t melt s of f th e resin , an

d the n i t i s wrapped aroun d th e mandre l until th e desired wal

l thicknes s i s obtained
. The final cur e ofth e tub e take s plac e i n th e oven . The mandre

l wit h th e tub e o n it

i s place d int

o th e oven . Whe

n curin g i s complete , th e tub e pulle

r remove s th e tube , an

d i t i s machine

d t o sel l t o th e customer .

• AR

E THER E AN Y PLANT S WIT

H SIMILA

RPROCESSES ? Yes , Westinghous e (i n Nort h o r Sout h Carolina , he wasn' t

sur e which) , Norplex (nea

r Wisconsin , Iowa)-the y have a n incinerato

r an d Allie d Signa l i s their paren t company .P. 3

WHA T AR E TH E CAPTUR

E AN D DESTRUCTIO

N EFFICIENCIES ? Captur e i s 95 % an d the destructio n i s 99.3%
.
ADDITIONA

L QUESTION S 1
. WHA

T TYP E O F OXIDIZE

RI S USE D (catalyti c o r

thermal) ? WH

O I S TH E MANUFACTURE

RO F THI S OXIDIZER ? 2
. WHA

T AR E TH E CAPITAL/ANNUALIZE D OPERATING COST S FO RTH E OXIDIZER ? 3
. WHA

T I S THE INLET CONCENTRATIO N (T O THE INCINERATOR ) O F HA P CONSTITUENTS ? (phenol , formaldehyde , methanol , etc. ) 4
. I N TH E SURVEY , I T I S STATE D THA T YOU RPLAN T CONTAINS : 2 REACTORS , 4 COATERS , 9 LAMINAT E PRESSES , AN

D 7 MOLDING PRESSES
. HO W MAN Y O F THE ABOV

E COMPONENT S AR

E CONTROLLED ? 5
. I T I S FURTHE

RSTATE D THA T SOLVEN

T FUMES (CONSISTING O F LES S THA N 0. 1 TP Y O F HA P EMISSIONS ) AR

E VENTE D TO TH E INCINERATO

RDURING THE SATURATIO

N PROCESS
. AR

E THES E TH

E SAM E ONES YO

U WER E REFERRING T O I N TH E SATURATIO

N PROCES S DESCRIPTION ABOVE ? 6
. WH

Y AR E THER E N O EMISSION S FRO

M CURING DURIN

G TH E LAMINATION

/ TUB E ROLLIN

G PROCESS , BU

T THER E AR E EMISSION S FRO

M TH E SATURATIO

N PROCESS ? 7
. CF A (COMPOSITE S FABRICATIO N ASSOCIATION) WOUL D TER M YOU R PROCES S A

S CONTINUOU S LAMINATION
. CONTINUOU S LAMINATIO N I S DEFINE

D A S THE FOLLOWING : reinforcemen t an d resi n are combine

d o n aplasti c filmtha

t i s pulled throug h th e process . A second plasti c filmi s applied ove r th e reinforcemen

t an d resi n t o allow mixin g an d exclusio n o f air tha t i s usuall y accomplishe

d b y compaction rollers
. Th e curing i s don e i n a n oven . I n thi s process , sheet s are continuall y produced , lik

e SMC , the

n hea t i s applied t o cure them ; th e application ha s abath
. I t i s als o simila

r t o pultrusion
. 8
. WH

Y D O YOU

REPOX Y RESIN S HAV

E HA P EMISSIONS ? (I

N SATURATIO

N PROCESS , TH

E 2 0 TP Y O F EPOXY RESI

N LISTE D I N TH E FEEDSTOCK

S I S STATE

D T O CONTAI

N TOLUEN

E AN D MEK. ) W

E WER E TOL D (AN D HAV E FOUN D FRO M VARIOU S SOURCES ) THA T EPOXY RESIN S HAV

E N O HA P EMISSIONS
.P. 4

9
. WH

Y ISN' T TH

E SATURATIO

N PROCES S REFERRE

D TO A S PREPRE G MANUFACTURING ?

Information i s accurate : Richar d Well sPi
_ 08/08^9 5 1582 ? S 8X 5 ?5 8 156 1 SPOULDING-SP D 0 1

Date : Augus t8,199 5 To : Wanit

a Dunston , USEPA From : Richard Well s Spauldin g Composite s Co . Inc . 101 5 Sout h Sevent h Street DcKaJb,I l 6011 5 Subj : ContactSummaiy , Augus t1,1995 , Additional Question s 1 . A thenna l oxidize r i s used . Itwa s manufactured b y Combusio n Engineerin g Associates . 2 . Th e capital cost s ofth e incinerato r i n 1972 wer e approximately S2S0K and th e annualize d cost s ofth e incinerato r are approximately SlOO k a tpresen t 3 . Th e inle tconcentratio n t o th e incinerato r o f HA P constituent

s i s i n th e area o f

2-3 % methano l an d under 1 % for th e phenol , cresol , an d formaldehyd e levels . 4 . Th e plantcontains : 2 reactors , 3 coaters , 9 laminatin g presses , an d 7 moldin g presses . Th e 2 reactors ar

e controlle d b y condenser s and 3 coater s are controlle d b y th e incinerator . 5 . I assum e tintemission s from th e incinerato r wa s whatI ha d m min d for les s tha

n 0. 1 TP Y HA P emissions . O f

course , man

y ton s o f methanol ar

e red t o m e incinerato r eac h yea r bu tare destroye d i n i tThes e fume s ar e tb e one s I wa s referring t o i n th e proces s description . 6 . Th e saturatio n proces s evaporate s th e solvent s from th e we b ofB-Stag e whic h arc the n bume d i n th e incinerator . I tals o partially cros s link s th e molecule s i n th e resin. Th e heatin g i n th e laminatin g o r tub e rolling processe s i s tor th e purpos e o f

Uquifyin g th e resin s o i tflows evenl y throughou

tth e material and the n completin g th e cros s linldn g ofth e molecule s forming a thermose tplastic . Th e vehicl e solvent s ar e removed i n th e saturatio n proces s an d no longe r presenta tth e tub e rollin process . 7 . Our proces s use s n o plasti c film i n any for m a tall . Th e resin i s absorbe d into th e substrat

e o f clot h o r paper an d coat s it s surface . Th e hea to f th e ove n i s the

n use d t o driv e of

f solvent s an d paitaill y cros s lin k th e resin. Exposure t o ai r rathe r tiian exclusio n from air i s a ke y elemen ti n ou r process . 8 . Our epox y resin s hav e HA P emission s becaus e solvent s mus tb e use d a s a vehicl e t o facilitat e th e absorptio n ofth e resi n int o th e substrat e (usuall y glas s cloth) . Ih e treate r oven s then volatiliz e tiie solvent s whic h ar e conveye d t o th e incinerato r an d oxidize d Phenoli c resin s fo r tha tmatte r hav e n o solvent s i n the m either , i f

no tneede d a s a processin g aid .P. 6 08'08'9 5 15:2 8 X 81 5 75 8 156 1 SPfiULDING-SP D 8 2

9 . Tiie saturatio

n proces s a

tthi s compan

y predate s th e tenn Pr

e descriptio n o f wha tw e do . Th

e tenn Prepre

g i s a n inclusive tenn whic

h coul d describ e severa l processe s notuse d a tthi s locatio

n suc h a s rovings spraye

d wit h resin, tumblin

g substrat e wit h resin , powde

r application , etc . Infonnatio n i s accurat

e to th e bes

to f m y knowledge : /

( [ \ C/L^yjPjSd- ) Richar d Well s