p. 1 

### OAR Box 1490 Prepped by Charmelle Mathews

Document

Number: 

### 40 ) IV-C-1 3 Docket Number: 

### A-94-5 2

Printed 8/4/200811:51:47

AM Sheet 40of 273P. 2 A-94-5 2 IV-C-1 3 

### REINFORCE

D PLASTI C COMPOSITE S MAC T STANDARD S DEVELOPMENT UPDATE

Februar y 1,200 2 -_. J
• EP A AI R DOCKE T Keit h Barnett , Projec t

Lead Office o f Air Qualit y Plannin g andStandard s Emissio n Standard s Divisio n Organi c Chemical s Grou

pP. 3



## Outlin e Wh o i s subjec t

t o thi s standard ? Whe n do I hav e t o comply ? A mI ane w o r

existin g source ? Wha t standard s mus t

I meet ? Wha t ar e som e o f my option s t o mee t standards ? Ho w do I demonstrate compliance ? Ho w do I achiev e 9 5 percen t contro l (i f required) ?P. 4 

## Wh o i s subjectt

o thi s standard ? A reinforce d plastic s composite s productio n facilit

y that i s locate da

t a major sourc e (1 0 tp y ofan y on e HA P o r 2 5 tp y ofan y combinatio n o f

HAP) : an d Use s thermose t

resin s o r ge l coat s that contai n styren e and/o r

methy l methacrylat eP. 5 

## Wha toperations ar

e covered ? Ope n Moldin g Close dMoldin g Centrifuga l Castin g Continuou s Lamination/Castin g SMC/BM C Manufacturin g Pultrusio n Mixin g Storag e Equipment

Cleanin gP. 6 

## When do I have t

o comply ? Proposal wa s Augus t

2 , 200 1 Final rul e abou t

ayea r afte r proposa l Existin g major

source s mus t

compl y withi n 3 year s fro

mfina l rul e Ne w majo r source s mus t

compl y b y effectiv e date o f

fina l rul e o r startup , whichever i s laterP. 7 

## Rul e Status an

d Planned Changes

• Th e major

chang e sinc e proposa l i s t o replac e th e poin t

valu e equation s wit

h appropriate unifie demissio n facto r (UEF ) equations .

• Thi s chang e doe s no t

chang e th e "floor " facilit y excep t fo r tw o proces s produc t grouping s

• Fo r th e tw o tha

t change , th e floor

facilit y onl y shift s b y one , s o th e chang e i s no t substantiv e

• Th e allowabl e HA P content s base do n UEF are highe r

than a t proposal whe n nonatomize dapplicatio n spra y i s use dP. 8 

## Rule Status an

d Planned Changes (Con't )

• Mos t ofth e current

effor t i s reviewin g th e contro l cost s fo

r th e abov e th e floor

optio n

• We anticipate tha

t w e wil l hav e revise d cost s b y Sprin g or

Summe r

• We inten dt o mak

e thes e revise dcost s availabl e t o th e Composite s Fabricator s Association , or

any other intereste dpartie s

• We als o wil l furthe

r investigat e th e issu e o f th e toolin g ge l coat s floors , whic h industr y claim s i s t o stringen t

• We wil l update any error s tha t are brough t t o our attentio n i n th e floor

dat abase .P. 9



## Wha ti s a ne w Source ?
Yo u commenc e constructio n afte r Augus t 2,2001 ; an d Whe n yo u commenc e construction , ther e are n o reinforce dplasti c composite s operation s a

t th e facilit y

8P.1 0 

## Wha ti s a n Existing Source ?
An y sourc e that

i s no t ne w Existin g source s are no t

considere dne w a s aresul t o f reconstructio np.1 1 

## Overvie w o f Controls t

o Meet Proposed Emission Limit

s Source s belo w aspecifie dHA P emission s threshol d

- lo w HAP resin s an d ge l coat s

- nonatomize d applicatio n technique s

- coverin g open containers , mixers , resi n bath s

- add-o n control s fo

r Continuou s laminatio n Source s abov e aspecifie dHA P emissio n threshol dmus t

contro l th e operation s belo w b y 9 5 percen t

- OpenMoldin g

- Centrifuga

l Castin g

- Continuou s Lamination/Castin g

- Pultrusio n

y

- SMC/BM C Manufacturin g

- Mixin g 1 0P.1 2 

## Ho w I s th e HA P Threshol d Determined ? Su memission s fromth e al l operation s potentiall y subjec t

t o 9 5 percen t

contro l Calculate thes e emission s usin g

- unifie demissio n factor s fo r reinforce d plasti c composite s

- facilit y specifi c emissio n factor s

- Result s fro

memissio n test s

nP.1 3 

## Wha tAr e the Threshold Levels ? Ne w source s -10 0 tp y actual HA P emission s Existin g source s - actual emission s

- 25 0 tp y i f

smal l busines s

- 10 0 tp y i f nonsmal l busines s Smal l busines s mean s les s than 50 0 employee s fo

r mos t SI C Code s

12P.1 4 

## Proposed MAC

T for Sources belo w Thresholds (Note thatth e thes e numbers are now base d o n UEF ) Operatio n Typ e Ope n Moldin g - Corrosio n resistan t
Ope n Moldin g - Non Corrosio n Resistan t Specifi c

Operatio n Mechanica l resi n Applicatio n Filamen t Windin g Manua l Resi n Applicatio n Mechanica l resi n Applicatio n Mechanica l resi n Applicatio n Filamen t Windin g Manua l resi n Applicatio n Floo r

UE F 15 9 17 1 12 3 12 6 8 6 18 8 8 7 Allowabl e Resi n HA P Conten t 50 + Non Atomize d 36. 3 Atomize d 4 2 4 0 50 + Non Atomize d 3 4 Atomize d 37. 9 Non Atomize d 31. 2 Atomize d 4 5 33. 6 13P.1 5 

## Proposed MACT for Sources belo w Thresholds(Con't

) Operatio n Typ e Ope n Moldin g - Toolin g Ope n Moldin g - Product s tha t requir e Clas s 1 Fire an d Smok e Rating s Centrifuga l Castin g Specifi c

Operatio n Mechanica l Resi n Applicatio n - Toolin g Manua l Resi n Applicatio n - Toolin g Mechanica l resi n Applicatio n Filamen t Windin g Manua l Resi n Applicatio n No n C R C R Floo r

UE F 25 4 12 2 49 7 27 0 23 7 39 6 53 6 Allowabl e

HA P Conten t (Weigh t % ) 50 + Non atomize d 4 3 Atomize d 39. 9 6 0 6 0 6 0 35. 5 4 8
1 4P.1 6 

## Proposed MACT for Sources belo w Thresholds(Con't

) Operatio n Typ e Ope n Moldin g - Ge l Coa t Specifi c

Operatio n Toolin g Ge l Coatin g Pigmente d Ge l Coatin g

- Whit e an d Of f Whit e Pigmente d Ge l Coatin g - NonWhit e Clea r Productio n Ge l Coa t Poin t Valu e

(Ib/ton ) 39 8
26 7
37 7
52 2 Allowabl e

HA P Conten t (Weigh t % ) 3 8
31. 7
3 7
4 4

1 5P.17 . 

## Proposed MACT fo

r Sources belo w Thresholds (Con't

) Injection/Compressio n Moldin g - Cover Charge s Resi n Transfe

r Moldin g - N o Requirement s Continuou s Laminatio n an dCastin g - 58. 5 percen t contro l Polymer Castin g - N o Requirement s

1 6P.1 8 

## Propose d MAC T fo r Source s belo w Threshold s (Con't )

• Pultrusio n - 6 0 percen t

contro l o r

we t are a enclosure

• Sheet Moldin g Compoun d- Nylo n film , fol do r sea l edges , cover

docto r bo x

• Equipment

Cleanin g - Cleanin g material s ma y contai n n o HA P

• Resi n Mixin g an dBM C Manufacturin g - Cover th e mixer s

• Resi n Storag e - Cover

storag e container s

1 7P.1 9



## Meeting P

2 Standards Ope n Molding an

d Centrifuga

l Casting Option 1 Chang e al l you r

resin s an dge l coat s t o one s wit h HAP content s belo w th e standard Thi s i s th e simples t

metho dan dresult s i n th e leas t reportin g an drecor dkeepin g

1 8P.2 0



## Meeting P

2 Standards Optio n 1 Example Prio r t o MAC T

- Atomize dapplicatio n o f 4 5 percen t HA P noncorrosio n resistan t fille d resi n

- Atomize dapplicatio n o f a3 5 percen t HAP whit e ge l coa

t Afte r MAC T

- Nonatomize dapplicatio n o f 4 5 percen t HA P noncorrosio n resistan t fille dresi n

- Atomize dapplicatio n o f 3 1 percen t HA P whit e ge l coa

t

19P.2 1



## Meeting P

2 Standards Ope n Moldin g an d Centrifuga

l Casting Option 2 Chang e you r

resin s an dge l coat s s o th e weighte daverag e meet s MAC T Require s purchas e record s b y resi n type , an dmonthl y averag e calculatio n Averag e i s base do n las t

1 2 month s o f operatio n

2 0

/ • /

/ -P.2 2



## Meetin g P

2 Standard s Optio n 2 Exampl e Prio r t o MAC T

- Currentl y us e tw o noncorrosio n resistan t unfille dresins , on e 3 7 percen t HA P an don e 4 2 percen t

HA P

- nonatomize dmechanica l applicatio n

- ratio ofresi n us e i s 60/4 0 after MAC T (Floo r

= 86 )

- convert 4 2 percen t

HA P resi n t o les s tha n 39.2 5 percen t

HA P

- maintai n sam e 60/4 0 spli t

2 1P.2 3



## Meetin g P

2 Standard s Open Moldin g an

d Centrifugal Castin g Optio n Determin e th e highes t

resi n HA P conten t allowabl e fo

r eac h operatio n Us e thi s resi n fo

r al l operation s Ca n no t includ e ge l coat s o r

mi x corrosio n an dnoncorrosio n resistan t operation s

2 2P.2 4



## Meeting P 2 Standards Option 3 Example Prio r t

o MACT makin g corrosio n resistan t tank s usin g atomize d mechanica l (en dcaps) , filamen t windin g (body) , an dmanua l applicatio n (joinin g parts ) usin g 5 0 percen t

HA P resi n

23P.2 5



## Meetin g P

2 Standard s Optio n 3 Exampl e Afte r MAC T Determin e MAC T fo

r eac h operatio n

- Mechanical i s 50 + percen t HA P resi n nonatomize dapplicatio n

- Filamen t

windin g i s 4 2 percen t

HA P resi n

- Manua l i s 4 0 percen t

HAP resi n Selec t highes t allowabl e HA P leve l (50 + percent ) Us e thi s resi n i n al l application s

2 4P.2 6 

## Option s fo r Meetin g Standard s

Pultrusio n
Wet are aenclosure s t o mee t

th e 6 0 percen t reductio n requiremen t Direc t di e injectio n t o meet

th e 6 0 an d9 5 percen t reductio n requirement s Add-o n control s We are strongl y considerin g allowin g averagin g o f

pultrusio n line s

2 5

LS ^P.2 7 

## Option s for Meetin g Standard s Continuou s Lamination/Castin g Ca n averag e line s Existin g source s ca

n elec t t o contro l onl y we t ou t are aemission s b y 9 5 percen t Ca n mee t a n alternativ e emissio n limi t o f 14. 7 lb/to n (58. 5 percen t

contro l level ) o r 1.4 7 lb/to n (9 5 percen t

contro l level )

2 6P.2 8 

## Ho w d o I Calculat

e UE F Th e equivalent

UEF equatio n wil l replac e th e correspondin g poin t

valu e equatio n i n th e fina l rul e Resi n us e ma

y b e base do n purchas e record s Resi n HAP content

ma y b e base do n MSD S o r resi n specificatio n sheet s I f averaging , yo u mus t

determin e th e amount s o f

resi n use dfo

r eac h specifi c operatio n

2 7P.2 9 

## Example UE

F Calculatio n Ope n moldin g - mechanical resi n applicatio n - no n atomize d- fille d- noncorrosio n resistan t

- Resi n HAP conten t

(fromMSDS ) i s 3 6 percen t

- UEF equatio n i s • UEF = ((0.157)(%styrene)-.0165 ) x 200 0 • UEF = ((0.157)(0.36)-.0165 ) x 200 0

• UEF = 8 0

- Propose dMAC T Floo r

i s 12 6

- Thi s meet s MAC T D o no t consider catalyst s o r

promoter s D o consider

any additional monome r additio n 2 8P.3 0 

## Ho w d o I demonstrat

e Initia l Complianc

e Fo r UEF emissio n limit s - perfor mUE F calculation s a s specifie di n th e rul e Fo r wor k practic e standard s - submi t a certifie dstatement

tha t th e wor k practic e i s bein g performe d Fo r equipment

standard s - submi t

a certifie dstatement

tha t th e equipmen t

i s i n plac e an dmee t

th e requirement s specifie d i n th e rul e

2 9 9 i)P.3 1 

## Ho w do I achiev e 9 5 percen tcontro l

(i f required )

• Enclos e operation s requirin g 9 5 percen t contro l wit

h apermanen t

tota l enclosur e

• Desig n an doperate enclosure i n accordanc e wit

h EPA Metho d20 4

• Instal l an doperate a9 5 percen t efficien t contro l devic e

- Concentrator/oxidizer

- Therma

l oxidizer

- Catalyti c oxidizer

3 0P.3 2 

## Whatar e th e Metho d 20 4 PT E Requirement

s Al l natural draf

t opening s (NDO ) a

t leas t fou r diameter s fromth e neares t HA P emittin g poin t > Al l exhaus t

point s a t leas t fou r diameter s fromth e neares t

ND O Al l ND O no t

t o excee d5 percen t

ofth e enclosure' s surfac e are a Th e averag e ND O facia

l velocity i s a

t leas t 20 0 fp m

3 1P.3 3 

## Whatar e th e Metho d 204 PT E Requirement

s (Con't) Th e directio n o f

airflo w i n al l ND O shal l b e inward Al l PTE exhaust s mus t

discharg e throug h a contro l devic e ND O are ama

y b e reduce db y plasti c strip s o r ai r curtain s

3 2P.3 4 

## How d o I Demonstrat

e Initia l Compliance Fo r Add-o n Control s Perfor macomplianc e tes t

prio r t o th e complianc e dat

e Performanc e test s method s are EP A Metho d 18 , 25 , 25 A Th e PTE mus t

b e certifie dusin g EPA Metho d20 4 Ifth e PTE doe s no t

mee t 20 4 criteria , yo u mus t tes t fo r capture usin g EP A Method s 204B-204 E

3 3P.3 5 

## Ho w Do I Demonstrat

e Initial Complianc

e fo r a PTE Determin e th e equivalent

diameter s o f

al l ND O an dexhaust s Determin e th e equivalent

diameter s o f

al l ND O fro mHA P emissio n point s an d exhaust s fro

mND O (mus t

b e a t leas t four ) Measure PTE surfac e are a(A T ) an dND O surfac e are a(A N ) . Th e rati o o f AT/A N mus t 0.0 5 o r less .

3 4P.3 6 

## Ho w D o I Demonstrat

e Initia l Compliance fo r a PTE (Con't )

- Measure al l exhaus t

flow s (Q 0 ) an dal l force dmakeup air

flow s (Qj ) usin g EPA Metho d2 .

- Calculate th e averag e ND O facia l velocit y a s FV = (Q 0 - Q^/A N

- FV mus t

b e 20 0 fp mo r more ; o r

- measure pressur e differentia l acros s enclosure

- differentia

l mus t b e 0.00 7 inche s o f water o r mor e 3 5P.3 7 

## Ho w D o I Demonstrat

e Initial Complianc

e for a PT E (Con't) Verif y directio n o f

flo w i s inwar dfo

r al l ND O usin g streamers , smoke tubes , o r trace r gase s I f FV i s 50 0 o r

more , inwardflo w verificatio n i s no t

require d

3 6