P.1 

OAR Box 1415 

Prepped by Ollie Stewart 

Document Number: 

27) IV-H-8 

Docket Number: 

A-94-52 

Printed 7/15/2008 9:38:26 AM Sheet 27 of 130 
P.2 

•

-TFE:B"'03"5

03 ^tlA M OFFICE OF ADVOCACY 

Office of Air Quality Planning and Standards 

Emission Standards Divisujn (MD-13) 

Organic Chemicals Group 

Research Triangle Park, NC 27711 

FAX COVER SHEET 

TO T^p 

Bromberg 

•OI 

U3SQM . <A Ail 

$ KEITH BARNETT / ftf)^ M j &n 

FAX* 

202-205-^925 

OFFICER 

(919)541-5605 

DATE 

January 31,2003 

FAX* 

(919) 541-3470 

* 7 ?,? 

NUMBER OF PAGES INCLUDING COVER SHEET 

4 

COMMENTS: 

Information we discussed. 

Keith

 n 

> * •• E^«^ 

'fyfyffanX^* p^-'l^y 

iff-A^I 

i 

EPA AIR DOC'vFT 

I * 

»• 

> * 

.Il l '' 

<: . • 
P.3 

T ON . "ar -swra-a 

T

H

FEB 03 '0 3 

v\m.-. K'jun 10:11AM OFFICE OF ADVOCACY 

- MS 

' °i 

'l«(v'^**QQS 

• '£•- * 

^ > -

Oi «J 

LA 

<N 

CM 

ct 

^ - > 

3P^ 

MS? 

•* CM 

XXX X 

O Lf) 

rO tf 

li CO 

co £ 

x|eb 

CM 

co 

co 

ec 

« * > 

3 

O 

£ 

^ iT 

3 

i 

°9$ 

in U9 

X X X 

CM CO <T 

X 

* 

V * 

C (A 

Cl- -= 

* 

e 

2 ra 

co 

<0 

ra o 

*• * s 5 a - a 

all-sail-^ 

? = C OT) 0)13 £ 

(D.5B tt O -C X C £ CQ 3 5U03O 3 S 

CO 

| i 8 

« c s ° to w 

"5 g^ 

^ : ^ 6 

C (B tZ. 

ro 

o 

a cn -T- vi NJ> ^~ cr IJD n^y 

cc 

w 

J £ 

§ 1 

D .« 

IO 00 £ 

''.•v/j IS 

<o 

IO •5- S 
•ararwj -^ s - *zr '•^FEB"03 '03 10:"I1AM OFFICE OF ADVOCACY M U

-

W 1 rPV3/9 

CONTACT REPORT 

T2>/L^ 

Person CaBing: 

Person Catted; 

Date of Contact: 

KedthBaniett 

U.S. Environmental Protection Agency 

OAQPS/ESD/MICG 

919-541-5605 

Mr. Larry Farber HJ ^

 e 

Noble Composites J r/^ 

574-534-0010 ; > f - C^ V H S 7 0 

Januaiy 23,2002 

: Contact Summary: 

Jjloble .Composites currently does not have emission controls. They designed their facility with 

the idea that when the MACT goes final they would already have 100 percent capture. 

They have two spray booths. The gel coat booth is 3 feet high, Gd coat is applied with 

reciprocating spay and this booth is unmanned. The second booth is the lamination booth. This 

, booth is 8 feet high and it is manned. The lamination booth is below the' 50 ppm OSHA 

rtqtoffemtjnr for styrene. 

The products are flat recreation vehide sidewall panels. The sizes are 

40 feet x 106 inches 

50 feet x 106 inches 

40 feet x 120 inches 

•'.'";.• • 'E d 

" . c* 

The spray booths were designed by Frees. 

P.4 

. 1 

- i 

i 

»* 

3 
P.5 

T L B yj3 103 1U-UMI'I UI-I-J.U1 Ul" HJJVUI-HLT P. 4/3 

CONTACT REPORT 

Person Calling: Keith Barnett 

U.S. Environmental Protection| Agency 

OAQPS/ESD/MICG 

919-541-5605 

Pearson Called; Mr. PhflMacmillun 

Frees, Inc, 

Date of Contact: October 5,2002 _LL. 

Contact Summary: 

,•',* , , i 

•'*.''' , ' • 

Frees designed the spray booths at Noble Composites] Both were designed aa permanent total 

enclosures and meet the requirements of EPA Method 204. 

The gel coat booth is automated spray. The booth size is 216 feet x 14 feet x 42 inches. Air flow 

is 245,feet per minute (fpm) through the openings at each end. ' 

'•'".• ' ! ! 

The lamination booth is 65 feet X 18 feet x 10 feet. Aif flows are 218 to'23 6 fpm through the 

openings at each end. The openings at the ends of thej booths are 12 feet x 4 feet. 

The styrene levels in the lamination booth are 20 to 30 ppm. There are $-9 employees in the 

lamination booth! 

(NQte the minimum airflow requirement through openings for EPA Method 204 is 200 fpm.) 

V * 

v» 

Lf 
P.6 

•Fi)^'FEBr 03 '.ga i0.:l_2AM_QFFI.CE.O_F ADVOCACY S7453389T0 T-3B1 P. 001 P.5/9S0 * | 

NOBLE 

COMPOSITES , INC . 

2424 E. Kercher Road • Goshen, Indiana 46526 

Facsimile Cover Sheet 

Office: (574) 534-0010 

Fax: (574) 533-8970 

'••TQ;'/ 

FAX: 

•<•.• 

Kevin Brombeng 

220-205-6928 DATE:1/31/03 

NUMBER QF. PAGES INCLUDING COVER SHEET 

E > F l Urgent • Please Reply |§3 No Reply Necessary Gl Original sent by mail 

., .Comments: 

' pLEASE SEE ATTACHED DOCUMENTS REF. YOUR PHONE CALL OF THIS AFTERNOON. 

, TWANKYOU 

.'.'• JOESPEICHER 

>• 

.-.. *'::r . 

i / 

>

#

l 

" • ••!•• •.' ' 

S i 
1

 F*^FEB_03 /_03, ' 10:12AM„OFFI(£.P_F ADVOCACY 5745339970 T-381 P.002/DQP.6/95D 

•rsi 

*.. 

(St NOBLE 

^^^^ . COMPOSITES , INC . 

Jan. 31,2003 

. Mr. Kevin Bromberg 

Small Business Administration 

In response to your telephone call this afternoon to Mr. Larry Farver, President Noble 

Composites. Inc.. of which I was made a part of via speaker phone. I will make the following 

1

 ,'..*. comments: 

To your question, "Is our facility designed for, or capable of, 100% capture of air toxics per 

proposed EPA standards?" My/our answer is "NO". 

",.'•' You stated that you are working with Mr. Keith Barnett, USEPA. attempting to reach an 

- agreement regarding the [size] difference between [small] and [large] parts produced in the 

. Reinforced Plastics Industry. You faxed us two [Contact Reports]: 

, , Report No. 1: Mr. Barnett contacts Mr. Parver on Jan. 23.2002 via telephone. Mr. Farver noted 

. several discrepancies in me [Contact Summary]. 

A. Mr. Farver does not recall talking to Mr. Barnett on that date. 

B: If the conversation did take place. Mr. Farver may have said, * W e already have 

100% capture." Not understanding what this physically meant 

C. The Gel ReciProcators are NOT ENCLOSED tN THE GELCOAT BOOTHfS). 

D. The Gel Reciprocators are manned. 

The remaining comments of report #1 are correct. 

You then asked if our facility could be 100% capture compliant Again we said, "No. not without 

spending a huge amount of money to enclose the whole building.* I am enclosing documentation 

or one company's cost to do a 100% capture of our facility at $6.6 million plus. This Is out of the 

question. , 

100% capture ofthe gel reciprocator(s) and booth(s) could be done without breaking the bank. 

166% capture of the lamination booth could also be done. It is when the mold/part(s) leave the 

lamination booth that 100% capture becomes impossible considering the overhead cranes 

system used in the vacuum bagging operation, and that the moid must clear the booth before it 

cah be bagged. 

Please keep in mind that Frees, Ina is in business to sell "Capture and Control" equipment They 

dent want a line drawn between small and large pans. 

Please call me if I can be of further assistance. 

Joe Speicher. 

Environmental Mgr. 

vCk^N^*^**-**-^——-

b 

i 

V * 

P.7 

I' 

I 

Report No. 2: Mr. Barnett contacts Mr. Phil Macmillian. Frees, Inc.. on Oct 5.2002. This report 

.appears to be correct :-! 

s 

2424 E. Kercher Road • Goshen, IN 46526 

.Tool Free: 866.946.6253 

Tel: 574.534.0010 • Fax: 574.533.8970 
P.8 

p^HB.FEg_03/.0 3 10;.12AM.OFFICE OF ADVOCACY 574533BS70 T-3B1 P.003/OOP.7/9SO 

Attachment 4 

Noble Composites. Inc. 

Summary of Economic, Ernrironrnerilal, and Energy Evaluations 

»* 

VENDOR ALLIANCE 

CORP 

CAPITAL COSTS 

1 Purchased Equipment 

a. Basic Equipment & Auxiliaries (A) 

b. Instrumentation & Controls (0.1 A) 

C Tarns (0.06 A) 

d. Freight (0.05 A) 

Total Purchased Baulnmont Cost fB) 

Regenerative 

Thermal 

Oxidation 

S 3.500,000.00 

•JSZA '•-•''• • 

"$ 2ia"ooo!do' 

S 175.000.00 

S 3.BBS.000.0Q 

2 Direct InstaUation Coete 

a. Foundations & Supports (O.OB B) 

c. Erection & Handling (0.14 B) 

c £locWcal.(0^4 B ) 

4. Piping (0.02 B) 

e. Insulation (0.01 B) 

f. Painting (o.oi B) 

g. Site Preparation (Ae Required) 

h. BuUdng/Piroeess 

Sack Hampering < Ftn Protection 

Ducting Not Induded In Proposal 

Capture Enclosure Not Included kt Proposal 

Total Direct Installation Caste 

Total Direct Carta ma n fPurchasad * Installation! 

Indirect Costs 

3 Engineering & Supervision (0.05 B) 

4 Lo3s of Production Cost (1 Week) 

5 Construction & Field Expenses (0.10 B) 

6 Confiracter Fees (aio B) 

7 Start Up Costs (0.02 6) 

8 Performance Test (Oin B) 

9 Contingency (0.03 B) 

Total lndlr»ct Coste 

& 310.aaa.oo 

$ 543.900.00 

$ 155.400.00 

S 77.700.00 

S 33.B50.00 

i$:>\L.:-A?:..'i.y 

s 

$ 200.000.00 

* 50,000.00 

S 7S.OO0.OO 

$ 75.000.00 

$1.326.650.00 

$5.211,850.00 

S 194.250.00 

S 230.769.23 

S 338.500.00 

$ 3S8.SO0.O0 

77.700.00 

38.B5040 

$ 

s 

S 116.S50.00 

$ 1.435.119.83 

s , * 

To^llnttertlgdCaottelCnst S y,^a,76ft.2? 

7 

V * 
Feferj^iFEB 0 3 ^03 

1

, ' '. ' " 

10:12AM OFFICE OF ADVOCACY E7AS33B970 T-3B1 

Attachment 4 

Noble composites, inc. 

Summary of Economic, Environmental, and Energy Evaluations 

ANNUALIZE? COSTS 

Direct Operating Costs 

1 operating Laber S 124.BOO.00 

a. Number of Employees 1 

b. sGost/Employoe/Hourw/BenetHs $ 20.00 

P.D04/O0p.8>§50 

\ 

i 

.J 

P.9 

* 

1 

•' U ,: 

• ; \ :, . i 

c Operating Hoars/Year 

2 Supervisory Labor (0.151) 

3 Maintenance Labor & Materials (5% of TOC) 

4 Replacement Parts (SK of Basic Capital Costs) 

5 Urflttles 

a. Natural Gas 

UMBTWHR Input 

Operating Houn/Year 

CosvMMBTl/ - Providod by Facility 

MMBTLVYR 

b. Electridty 

HP Requirements 

KWRequlrementa/Hr 

KWWYR 

CosVKWH • Providod by facility 

c. Water 

d. Air 

e. Catalyst Replacement 

(20% Basic Capital Cost/5 Years) 

Total Direct Operating Coats 

Indirect Operating Costs 

6 Overhead (60% of Oper. Labor & Maintenance) 

7 Property Tax (0.01 Capital Cost) 

B Insurance (0.01 Capital Cost) 

9 Administrative Costs (0.02 Capital Cost) 

SHMfl*" -'"«•""»•=* Operating Costa 

10 Capital Cost Recovery Factor (5% INT. 10 Years) 

= 0.2638 

Total Indirect Operating Coste 

Heat Recovery Credit 

B. Heat Input • Annually - HMBTWYr 

b. Unit Heat Efficiency- Hon Output of 

Control Device 

c. Heat Available for Recovery 

d. HealExchangerEfficiencyforHeatRecovery 

e. Percent Heat Recovery/Year (S-Months) 

f. Heat Value Recovered-MUBTWYr 

g. CoefHWPTU. Provided by Facility 

Total Annualized Costs 

uncontrolled VOC Emissions (PTE - Requested Limit) 

Control Efficiency 

TPY VOC Removed at Control Effletaney 

Cost Effectiveness. $fTon VOC Removed 

Included in Capital Proposal 

6JM.00 

16,720.00 

S 260.58230 

S 194,250.00 

3 

S 1,075,651.20 

30.00 

6,240 

S 5.7490 

187,200 

% 96,514.00 

250.00 

f87.50 

1.170.000 

0.0842 

S 1.772,517.70 

3 323.282.00 

S 66,467.68 

S 66.467.69. 

$ 132.935.38 

$ 539.1 Sft-IZ 

51,7*53.417.72 

*3,?4,?.g7P,43 

S Q32.107.31) 

187,200-00 

9SX 

177,040.00 

6S'A 

50% 

S7.7aa.oo 

$ 5.7460 

S 3.782.980.88 

24S.0 

95% 

232.8 

2 1S-2S3 

v * 

\ : • 

^ 
P.10 

•c-ilns^EB 0 3 '0 3 10:13AM OFFICE OF ADVOCACY 5745338970 T-3B1 P.Q05/00P. 9/950 

Attachment 4 

Noble Composlus, Inc. 

Summary of Economic Environmental, and Energy Evaluations 

Environmental Impacts 

1 Additional Emissions - Tons par Year (TPY) 

Estimated Fuel Consumption • MMCF Burned 

Eetlmated CO Emissions - TPY 

Estimated NOX Emissions - TPY 

Estimate PT/PM10- TPY 

Uncontrolled Emissions 

Emissions Before Controls 

2 Enamv Requirements 

Natural Gas-MMCFAYR 

Elecmdty- KWH/YR 

187.20 

1.87 

9.36 

0-29 

12.2S 

245,00 

187.20 

1,170,000 

. > • ••' * *r 

•»»