p. 1


# OAR Box 1394 Prepped by Ollie Stewart



### Document

Number: 

# 22 ) ll-B-1 7 Docket Number: 

# A-94-5 2

Printed 7/3/20087:22:11 AM

Sheet 22 of 57TO :

FORM : DATE : NO N CB I SIT E VISI T REPORT

Projec t Fil e Plasti c Composite s NESHA P Melani e Procto r Pacifi c Environmenta

l Services , Inc . (PES ) Jul y 10,199 8 SUBJECT : Sit e Visi t

- Glasforms , Inc. , Binningham , Alabam a EP A Contrac t

68-D6-0013 , ES D Projec t

93/5 8 

### I . PjKpQS

S N V Th e purpos e ofth e visi t

wa s t o collec t

informatio n o n th e wet

are aenclosure s tha t Glasform s constructe daroun dthei r pultrusio n lines . Th e visi t wa s als o intende dt o determin e i f industry' s propose dwe t

are aenclosure definitio n accuratel y describe s Glasforms ' we t are a enclosure , whic h may b e use di n determimng th e existin g sourc e MAC T floor fo r pultrusion .


### n . Plac e an d Dat e Glasforms , Inc . 394 3 Valle y Eas t

Industrial Driv e Birmingham , Alabam a3521 7 Januar y 15,199 8 

### in . Participant

s Glasforms . Inc . Mr . Roger Bass , Pultrusio n Genera

l Manage r Mr . Terr y McQuarrie , Vic e President Mr . Nic k Taylor , Plan t

Manage r 

### EE S Mr . Rober t Jemison , Environmenta

l Consultant Ms . Melani e Proctor , Environmenta l ConsultantP. 3

Sit e Visi t Report Glasforms , Inc . Pag e 2 IV . Pultrusio n Line s an dWe t Are aEnclosure s Th e Glasforms , Inc . facilit

y i n Birmingham , Alabama , ha s five pultrusio n line s eac h o f whic h i s equippe dvvit

h awe t are aenclosur

e aroun dth e resi n bath . Tw o pultrusio n line s hav e a larg e bath (9 8 inche s long , 4 4 inche s wid e a t th e entrance , and3 0 inche s wid e at th e exi t ofth e bath ) an daradi o frequency device . Thre e pultrusio n line s hav e asmal l bath (5 7 inche s long , 2 1 inche s wid e a t

th e entrance , and26. 5 inche s wid e a t th e exi t ofth e bath ) an dn o radi o frequency device . Th e detaile ddimension s ofth e we t are aenclosures , th e measurement s o f clearance s fo

r al l opening s i n th e enclosures , an dth e distance s ofth e enclosure s t o other component s ofth e pultrusio n line s are presente di n Attachmen t I . Th e following calculation s are als o include di n Attachment

I : (1 ) tota l surfac e are aofth e enclosures , (2 ) total are ao f opening s i n th e enclosures , an d(3 ) percen t

ope n are ai n th e surfac e are aofth e enclosures . I n additio n t o th e informatio n presente di n Attachment

I , picture s andavide o tap e ofth e pultrusio n operatio n a t th e Birmingha

mfacilit y are presente di n Attachment I I an dIII , respectively . Mr . McQuarri e indicate dtha t radi o frequency devices , whic h are locate dbetwee n th e resi n bath an dth e heate dmetal die , ar e necessar y fo r product s wit

h alarger diameter becaus e th e time product s spen di n th e heate dmeta l di e i s no t sufficien t t o cur e thes e products . Th e radi o frequency devic e start s t o pre-cure larg e diameter product s fromth e insid e b y usin g radi o waves . Mr . McQuarri e pointe dou t that th e we t are aenclosure canno t

connec t directl y t o th e radi o frequency devic e becaus e hea t i s generate dtha t

coul dmelt

th e enclosur

e o r caus e arcin g o f electricity . Th e radi o frequency devic e i s aclose duni t wit h opening s that

ar e onl y larg e enoug h t o allo w th e produc t

t o enter an dt o exit . Th e produc t

i s almos t dr y whe n i t enter s th e radi o frequency device . Mr . Bas s explaine dthat

h e calculate dth e tota l are ao f opening s i n th e enclosure aroun d th e larg e bat h pultrusio n machine s t o b e 4. 4 percent ofth e total surfac e are aofth e enclosure . Base do h Mr . Bass ' calculations , th e tota l are ao f opening s in th e enclosur

e aroun dth e smal l bat

h pultrusio n machine s i s 3. 4 percent ofth e total surfac e are aofth e enclosure . Mr . Bas s pointe d ou t tha t h e considere dth e to p ofth e resi n bath t o b e th e botto mofth e enclosure , whic h mean s tha t th e resi n bath wa s no t

include di n th e enclosure surfac e are acalculations . H e als o pointe d out tha t th e are adisplace db y th e enterin g reinforcement migh t hav e t o b e subtracte dfro

mth e entranc e ope n area . However , Mr . Bas s explaine dtha t thi s wa s no t

don e i n hi s calculation s becaus e th e amount

an dsiz e ofth e enterin g reinforcemen t change s dependin g o n th e produc t tha t i s bein g made . I f

thi s were included , th e total percen t o f open are awoul db e eve n les s than 4. 4 and3. 4 percent , respectively . A s indicate do n th e diagram s i n Attachment I , th e open area s o n th e bac k sid e ofth e enclosure s tha t

are use dt o ad dresi n ar

e covere dwit

h flexible brus h coverings . Mr . Bas s indicate dtha t

thes e area s were include di n th e tota l open are acalculation s whic h ma y o r ma y no t b e correct . Th e tw o 2. 5 b y 2. 5 inc h open area s o n th e front sid e ofth e enclosure s that

are use d 

# 7 -P. 4

Site Visi t Report Glasforms , Inc . Pag e 3 fo r resi n recirculatin g pump s i n th e larg e resi n bath s are als o covere dwit h flexibl e brus h covering s aroun deac h ofth e 1.5 inc h diamete r hoses . Mr . Bas s explaine dthat th e area s covere d b y th e flexibl e brus h were als o include di n th e tota l ope n are acalculations . Again , i f thes e area s are remove dfromth e calculation , th e total percent o f ope n are awoul db e furthe

r reduced . V . Compariso n Between Glasforms ' Wet Are aEnclosure s andIndustry' s Propose dWe t 

### Are aEnclosur e Definitio n Durin g th e sit e visi t

PE S determine di f

Glasforms ' we t

are aenclosure s wer

e accuratel y describe db y th e we t

are aenclosur

e definitio n propose dby industry . Industry' s propose dwe t are aenclosure definitio n i s presente di n Attachmen t IV . PE S determine dtha

t th e clearance s anddimension s o f Glasforms ' we t

are aenclosure s were accuratel y describe db y th e propose dwe t are aenclosure definitio n provide db y industry bu t severa l section s ofth e propose dindustr y definitio n coul db e clarifie dan dbetter define dt o accurately reflec t

th e wet are aenclosure desig n use db y Glasforms . Fo r example , th e propose d industr y definitio n state s that

"th e ope n area s o n th e enclosure end s shal l no t excee d5 percen t

o f th e total are aofth e top , bottom , sides , andend s ofth e enclosure. " Th e ope n are ao f Glasforms ' we t are aenclosure s range s from4. 4 t o 3. 4 percent ofth e tota l surfac e area . Th e propose d industr y definitio n coul ddefin

e th e allowabl e total ope n are amor e clearly t o better

reflec t Glasform s design . I n addition , th e total ope n are acalculation s fo r Glasforms ' we t

are a enclosure s ma

y hav e t o b e reexamine dwit h regardt o issue s discusse di n Sectio n IV o f thi s repor t (i.e. , flexibl e brus h covering s an dope n are adisplace db y th e enterin g reinforcement) . VI . We t

Are aEnclosur

e Emissio n Dat a Emissio n testin g a

t Glasform s a

t an ai r flow rat e o f

approximately 20 0 fee

t pe r minut e (t o ensur e capture o f

al l emissions ) an da

t alin e spee dno t

exceedin g 1 8 inche s per

minut e indicate d tha t emission s frompultrusio n line s wit h wet are aenclosure s wer

e 21. 8 pound s o f

hazardou s ai r pollutant s (HAP ) per

to n o f nea t resin . Th e resi n that

wa s use ddurin g th e emissio n tes t ha da HA P content o f 43. 7 percent . The HA

P emissio n rat e o f

21. 8 pound s pe r

to n o f resi n use d correspond s t o an emissio n facto r o f 2. 5 percent

o f availabl e HAP . Emissio n testin g at th e sam e air flow rate , lin e speed , andresi n HA P content indicate dtha

t emission s frompultrusio n line s withou t we t are aenclosure s wer

e 109. 2 pound s o f

HAP per to n o f nea t resin . Thi s emissio n rat e correspond s t o an emissio n facto r o f 12. 5 percent

o f availabl e HAP . Fo r

detail s relatin g t o th e emissio n calculation s refe

r t o Attachmen

t V . Th e tes t

repor t i s containe di n Attachment VI . 

# 3P. 5

Sit e Visi t Repor t Glasforms , Inc . Pag e 4 

### v n . Cos tInformation Mr . McQuarri e state dthat

th e tota l annua l maintenanc e cost s were $75 5 for eac h larg e enclosure an d$43 7 for

eac h smal l enclosure . Accordin g t o Mr . McQuarrie , th e tota l constructio n cost s were $76 5 fo

r eac h larg e enclosur

e and$39 7 for

eac h smal l enclosure . H e indicate dtha t a t thi s facilit y there were n o desig n cost s fo r th e enclosures , whic h ma

y no t b e th e cas e for

othe r facilities . The detaile dcost s fo r constructing th e larg e an dth e smal l enclosure s are presente di n Attachment

I . VIII . Productio n an dOperatin g Dat a Th e Binninghamfacilit

y use d647 ton s O

f resi n i n 199 6 wit

h aweighte daverag e HA P conten t o f 46. 7 percent . Th e Sa

n Jos e facilit

y use d39 9 ton s o f

styrenate dresi n i n 199 6 with a weighte daverag e HAP content o f 46. 2 percent . Th e Sa

n Jos e facilit

y als o use d19 7 ton s o f

non styrenate dresin . Th e total amount o f styrenate dan dnon-styrenate dresi n at th e Sa n Jos e facilit

y wa s 59 6 ton s i n 199 6 wit

h aweighte daverag e HAP content o f 30. 9 percent . Th e detaile dresi n usag e dat ai s show n i n Attachment I . Th e product s produce db y Glasforms , Inc . includ e roun drods , tubing , an dflatbar . Th e lin e spee drange s from12-4 8 inche s pe r minute t o 3 6 - 7 2 inche s pe r minute . A pultrusio n machin e ca

n produc e u p t o 1 0 produc t stream s a t th e same time . Th e produc t tha t wa s produce d durin g th e Januar

y 199 4 sourc e tes t

i n Sa n Jos e wa s 0.24 2 b y 0.42 1 inc h flatba r a t alin e spee d betwee n 1 2 and3 0 inche s per minute . The lin e spee ddurin g th e emissio n tes t di dno t excee d1 8 inche s per minute (se e Attachment

1) . IX . Other

Emissio n Pointe Th e Birmingha

man dth e Sa

n Jos e facilitie s are bot

h usin g acetone fo

r cleanin g purposes . Th e aceton e usag e fo

r bot h facilitie s i s presente di n Attachment 1 . Cleaner s that

contai n HAP ar e no t bein g use dat

either facility . Resi n mixin g at

th e Birmingha

mfacilit y i s conducte di n aseparat e mixin g room . Th e bul k resi n i s pumpe dfromoutsid e storag e tank s int o mixin g vessels . Specialt y resin s that

are receive di n 5 5 gallo n drum s are addedmanually int o th e mixin g vessels . An y additional ingredient s suc h a s filler, catalyst , an dpigmen t are adde dmanually . The mixin g vessel s are covere dexcept

fo r aslo t fo r th e mixing shaft . Th e slo t fo r th e mixin g shaf

t i s covere db y flexibl e brus h covering s tha

t surroun dth e shaft . Th e mixin g vesse l cove r ha s hinge s tha t

allo w th e front thir dofth e cove

r t o b e liftedu p t o ad

dingredients . Th e mixin g vesse l cover i s lifte donl y whe n ingredient s ar

e adde dt o mixin g vessel . 

# HP. 6

Site Visi t Report Glasforms , Inc . Pag e 5 Th e resi n batc h i s mixe dfo r approximately tw o t o five minute s t o obtai n ahomogeneou s mixture . Th e resi n batc h i s checke dfo r viscosity , ge l time , andpea k exotherm . Afte

r th e mixin g proces s i s complete , th e covere dcontainer i s delivere dt o th e pultrusio n we t ou t tank . Th e covere dresi n batc h i s either pumpe dinto th e pultrusio n we t ou t tank o r amolasse s valv e i s inserte dthroug h th e we t

are aenclosure openin g t o accep t th e resi n batc h directl y fromth e covere dcontainer . A ne w resi n batc h i s prepare don e t o fou r time s per shif t per machin e dependin g o n th e produc t

bein g produced .



# 5P. 7

AttachmentI Informatio n Provide d Durin g th e Sit e Visi ti n Respons e t o

th e Sit e Visi tQuestionnaire



# 6P. 8

EXISTIN G SOURC E MAC T FO R TH E PULTRUSIO N PROCES S WE T ARE A ENCLOSURE S
DATE : Januar

y15,199 8 TO : Madelein e L Strum , Ph.D
. U
. S
. Environmenta l Protectio n Agenc y Offic e o f Ai rQualityPlannin g Standard s Emission s Standard s Divisio n MD-1 3 Researc h Triangl e Park , N C 2771 1 FROM : Terr

yS-McQuarrieOiY ^ Glasforms , Inc
. 27 1 Barnar d Ave
. Sa n Jose , CA 9512 5
Attache d pleas e fin d th e followin g informatio n requeste d b yLind a Herrin g i n he r correspondenc e o f Decembe r11,1997 : Sectio n 1 : We t Are a Enclosur e Measurement s Sectio n 2 : Cos t Informatio n Sectio n 3 : Productio n an d Operatin g Dat a Sectio n 4
. Othe rEmissio n Point s



# 7P. 9

Sectio n I o f

Attachment

1 Th e drawin g ofth e we t

are aenclosur

e (fo r pultrusio n line s wit

h smal l baths ) i s containe di n th e CB I files.



# iP.1 0 

# SURFACE

AREA OF

SMALL BATH COVERS OP: Width

x the length. 26.5 " x 57*- a 1,510. 5 sq-in s OTTOM: Same

as top. 26.5" x 57" = 1,510. 5 sq-irt s SIDES: Height

x Length (14"x57")x2ea.=

1,59 6 sq-in s 'JTTRANCE:

Width

x Height 26.5" X14" =37 1 sq-in s DOT: Width

x Height 26.5" X14" =37 1 sq-in s 'OTALSURFACE

AREA =5,35 9 sq-i n 

# TOTALOPEN

AREA OF

SMALLBATH

COVERS zNTRANCE

OPEN AREA BETWEEN

<c*WZ. **"*

**T Uf:OVER:

0.5" gap between he sides and top, with

a 3" x 21" gap under the c^>JW (14" + 14" + 21") x 0.5" + (3"x 21") = 87. 5 sq-in s OPEN AREA AT

ENTRANCE

OF c<T :

336 holes with a .312 diameter. (.312 x .312 x3.14x .25) x 336 = 25.6 8 sq-in s OPEN AREA ON

BACK SIDE OF COVER USED TO ADD RESIN: 1 cut out 5.5" x 10" with flexible brush coverings. 5.5" x 10" = 55 sq-ins if considered

a opening OPEN AREA ON

EXIT OF BATH COVER:

Open area 4" high x 12" wide. This

opening

fits around the dies and resin drip tray. On

a normal set up there is a 0.5" gap above the dies and a 2" x 2" open space on both sides of dies. (2"x2")X2

+ ( 10" x 0.5") =1 3 sq-in s TOTALOPE N AREA ^81.18 sq-i n 

# TOTAL%

of OPEN AREA: 181.18+

5,359 = 3.4 %


# °\P.1 1



### SECTIO N 2

COS T INFORMATIO N
Thi s Sectio n addresse

s th e followin g requested issues :
2. 1 Capita l cos

t fo r eac h we t are a enclosure . 2. 2 Operatin g an d maintenanc e cost s fo r eac h we

t are a enclosur

e



# oP.1 2

BAT H COVE R (LARGE ) MAT L & PRIC E LIS T


# C-BZE

TOTA L COS T $765.1 5 AVERAG E ANNUA L MAIN T 

# £&JZ
TOTA L COS T $75 4 8 1



# \ vP.1 3

BAT H COVE R (SMALL ) MATL. & PRIC E LIS T


# £-B31

TOTA L COS T $396.5 2 AVFRAG F ANNUA I MAIN T



## <L#J:
TOTA L COS T $436.5 5



# 1 /P. M

Sectio n II I (Productio n andOperatin g Data ) o f Attachmen

t 1 i s containe di n th e CB I File s



# \°)P.1 5



### SECTIO N 4

OTHE R EMISSIO N POINT S

Thi s Sectio n addres s th e followin g requested issues :
4. 1 .Amoun

t an d types o

f cleaner s used . 4. 2 Descriptio n of th e mixin g process .



# WP.1 6



# ANNUA L SOLVEN

T USAG E 199 6

LOCATIO N Sa n Jose Birmingha m SOLVEN T

Aceton e Aceton e QUANTITY ,

Lb s 36,05 2 34,27 2 LBS/GA L

6.4 9 6.4 9 TOTA L

GALLON S 5,55 5 5,28 1



# \1P.1 7



### DESCRIPTIO N O F TH E MIXIN G PROCES S

1 . Bul k resi n i s pumpe d (dru m resi n manuall y added ) int o a mbcin g vessel . Th e mixin g vesse l i s covere d excep t fo r a slo t fo r th e mbcin g shaft . 2 . Additiona l ingredient s ar e manuall y adde d i n th e orde r specifie d o n th e batc h sheet : i.e. , filler , catalyst , pigment , etc . Th e mixin g vesse l cove r i s lifte d onl y durin g th e additio n step . 3 . Resi n batc h i s mixe d unti l homogeneous ; i.e. , 2- 5 minutes . 4 . Resi n batc h i s checke d fo r viscosity , ge l time , an d pea k exotherm . 5 . Th e covere d containe r i s delivere d t o pultrusio n we t ou t tank . 6 . Th e covere d resi n batc h i s eithe r pumpe d into resi n holdin g tan k o r th e molasse s valv e i s inserte d throug h th e we t enclosur e openin g t o accep t th e resi n batch . 7 . Proces s i s repeate d 1- 4 time s pe r shif t pe r machin e dependin g upo n puilrude d composite bein g processed .



# ioP.1 8

Attachmen

t I I 2 6 Non-CB I Photo s (Note : A n additiona

l 5 photo s ar

e containe di n th e CB I files )

^P.1 9



# \i>P.2 0



# WP.2 1



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# IKP.2 3



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. * t

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### <lXo'••f^i.^j^:.i >••:,< - ->.^,:W-. ys>M&:sh 1 "W

K \ .* " ** •'•? • • • • • • P.2 8

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# nAP.2 9

<&P.3 0



# iAP.3 1



# ^ oP.3 2

Attachmen

t II I i s containe di n th e CB I files



# ?> \P.3 3

Attachment

IV Industry' s Propose dWe t

Are aEnclosure Definitio n



# yuP.3 4



### - ^ V z^44 ? */?/***„ /TF"



# inc 27 1 Barnar

d Avenue , Sa n Jose , Califomi a 9512 S Fa x (408)297-060 1 Phon e (408)297-930 0

Normal Delivery x Company : U.S . EP

A Attention : Dr

. Madeline L Stru

m From : Terr

y S . McQuarri

e Urgent

Delivery Confidential Fax# : (919)541-347 0 Date : Novembe r24,199 7

DearMadeline : Attache d pleas e find th e chec k Ustfo rwe tare a enclosure s to rth e MAC T forexistin g •sources for pultrusion . Thi s lia s bee n reviewed b y To m Griffith s and myself

. Afteryo u hav e reviewe d thi s Gst

, pleas e le tm e hav e a fe w propose d date s fo ryou rvisi tt o th e Glasforms faalit

y i n Birmingham

, i look forwar

d t o ou rmeetin g i

n Binningham . cc : Tom Griffiths-Omeg

a Pultrusion

s Joh n Schwertzer-SP

I Dav e Evans-Creative Pultrusion s

Page s Includin g Cover : if you do not

receive af f pages, please call

us at (408) 297-9300. 

# l?f>P-3 5

NO V ZA. "*f

ia\'lT>crvi

eu-arw o xi** , . . * • tl ~ *

WE T ARE A ENCLOSURE S INDUSTR Y PROPOSA L
Th e source shal l emplo y enclosure

s o n al l we t proces s area s whe n usin g ope n resi n baths . Enclosure s shal l b e designed an d installe d accordin g t o th e followin g criteria : ' 1 . Th e enclosur

e shal l cove r th e top , bottom , an d side s ofth e ope n bat h are a i n whic h reinforcements ar e we t ou t an d ar e movin g towar d th e dle(s) . Th e end s o f th e enclosur

e shal l b e close

d a s muc h a s prac&cat>wit h allowance fo r opening s t o enabl e th e materia l t o ente r an d exi t th e enclosure . 1.1 . Th e enclosur

e shal l exten d firo m th e fibe r cardin g index t o withi n 6 Inche s ofth e di e entranc e o r Radi o Frequenc y (RF ) prehea t uni t 1.2 . Th e ope n area s o n th e enclosur e end s shal l no t excee d 5 % ofth e tota l are a o f th e top , bottom , sides an d end s of-th e enclosure . 1.3 . Th e stoc k

exitin g th e R F pre-heat unit , an d Jus t prio r t o th e die , does - no t require a cover . 2 . Resi n dri p of

f a t th e di e entranc

e shal l b e allowed , bu t mus t b e collecte d i n a devic e tha t i s covered an d ha s n o mor e tha n 1.0 " clearanc e aroun d th e dri p off . 3 . .Acces

s panels , doors , hatches , o r flexibl e curtains ' shad b e considere d par t o f th e enclosure . 4 . Ports fb r leve l contro l devices , monitorin g devices , agitatio n shafts , fil l hoses , etc. . shal l hav

e n o mor e tha n 1.0 " dearance . 5 . N o fans , blower

s o r ai r line

s shal l b e allowed withi n th e enclosure . Th e enclosur e shal l no

t b e ventilated . 6 . Procedures -shal l b e enforce d an d record s kep

t t o sho wtha t th e enclosur

e i s I n plac e durin g operation . 

# 3 1P.3 6

Attachment

V Emissio n Calculation s

^P.3 7

Emissio n Calculation s Base d o n th e 199 4 Emissio n Tes tData from th e

Glasform s Facilit

y Locate d i n San Jose , Californi a Emissio n tes t

dat afor we t are aenclosur

e wit h tw o exhaus t

fan s fapproximatelv 20 0 feet pe r minute o f ai r flow: (A ) Pound s o f

HA P Emission s per

To n o f Resi n Use d 1 . Averag e HA P emissio n rate = 0.22 5 lbs/hr (Attachmen

t VI , pag e 4) . 2 . 3 hour s o f

emission s per

batc h o f resi n at alin e spee do f

1 8 inche s pe r

minute at 0.22 S lbs/hr = 0.67 5 Ibi

s HAP emitte dper

batch . (Base do n Attachment 1 , sectio n 3 , Tabl e MCP- 3 A , i t

too k 3 hour s t o consum

e th e resi n batch . Resin us e start s a t 9:2 5 an d continue s unti l 12:25 . A t

13:00 th e machin e pull s dr y glass. ) 3 . Compositio n o f

th e resi n batc h (Attachmen t VI , pag e 5) : Component Resi n A Resi n B Adde dStyren e Othe r Total Amoun

t (lbs ) 3 0 2 8 6 13.7 2 77.37 2 HA

P Conten t ( % b y weight) 42. 4 33. 1 10 0 0 43.73 * HAP (lbs )

12.7 2 9.2 7 6.0 0 0 27.9 9 Tota l HA P conten t ofth e nea t resi n plu s an y HA P adde d

5 . Tota l resin plu s HAP = 6 4 lbs/77.37 2 lb s = 82.72 % ofth e batc h i s resin plu s adde dHAP . Actual weight

o f batc h on e whic h wa s use di n th e 3 hour perio d= 74. 8 lb s (Attachment

VI , Appendi x D , pag e 1 ofth e computatio n notebook) . 74. 8 lb s resi n mi x x 82.72 % resi n plu s adde d.HA P = 61.8 7 lb s o f

resi n plu s adde dHAP . 0.67 5 lb s HAP emitte dper 61.8 7 lb s o f

resi n plu s adde dHA

P = 21.8 2 lb s HA P emitte d pe r to n o f resi n plu s an

y HA P added . 

# itP.3 8

(B ) Emission s i n term s o f Percent Availabl e HA

P 1 . HA P i n th e 77.37 2 lb s resi n batc h - 27.9 9 lbs . HA P i n th e 74. 8 lb s resi n batc h = (74. 8 lb s x 27.9 9 lbs)/77.37 2 lb s = 27.0 6 lb s 2 . 27.0 6 lb s o f

.HA P ar e use dove r a3 hour period . 27.0 6 lbs/3 lir s = 9.0 2 lb s .HA P use dpe r hou r a t alin e speedo f

1 8 inche s per

minute . 3 . 0.22 5 lb s HA P emitte dpe r hour/9.0 2 lb s HA

P use dpe r hour = 2.4 9 % o f

availabl e HAP emitted . Emissio n tes t

dat awithou t

we t are aenclosure wit

h tw o exhaus t

fan s fapproximatel v 20 0 feet per 

### mimtteo f ai rflow; (A ) Pound s o f

HA P Emission s per

To n o f Resi n Used 1 . Averag e HAP emissio n rate = 1.126 lbs/h r (Attachmen

t VI , pag e 4) . 2 . 61.8 7 lb s o f

resi n plu s adde dHAP are use di n 3 hour s a t alin e spee do f

1 8 inche s per minut e durin g th e emissio n tes t wit h th e we t are aenclosur

e an da n ai r

flo w rat e o f

20 0 feet pe r minut e (se e calculatio n step (A ) 4 above) . Th e emissio n tes t

without th e we t are aenclosur

e anda n air flow rat e o f

20 0 feet pe r minut e wa s conducte da

t th e same lin e spee d(1 8 inche s per minute ) an dfor

th e sam e produc t a s fo r th e emission tes t

wit h th e wet are aenclosure . Therefore , th e hourl y resin plu s adde dHA

P usag e i s th e same i n bot

h case s an dcalculate da s follows : 61.8 7 lb s o f

resin plu s addedHAP/ 3 hour s = 20.6 2 lb s o f resi n plu s adde dHA P use dper hour . 3 . 1.12 6 lb s HA P emitte dper 20.6 2 lb s o f

resi n plu s IL\ P = 109.2 1 lb s HAP emitte dper to n o f resin plu s an

y HA P added . (B ) Emission s i n term s o f Percen t Availabl e HA

P 1 . 9.0 2 lb s HAP use dper hou r a t alin e speedo f

1 8 inche s per

minut e an dfo r th e same produc t a s fo r th e emissio n tes t

wit h th e we t are aenclosur

e (se e calculatio n ste p (B ) 2 above) . 2 . 1.12 6 lb s .HA

P emitte dpe

r hour/9.0 2 lb s HA

P usedpe r hour = 12.4 8 % o f

availabl e HA

P emitted . 

# 3 1P.3 9

Attachmen tV I Non-CB I Versio n o f

Emissio n Tes tRepor

t



# 3 *P.4 0 //-f+-Zm&r*tt«T

JU—



### INDUSTR Y PROPOSAL : EXISTIN G SOURC E MAC T FO R PULTRUSIO N PULTRUSIO N INDUSTR Y COUNCI L COMPOSITE S INSTITUT E OCTOBE R 27,199 7P.4 1

INDUSTR Y PROPOSA L EXISTIN G SOURC E MAC T FO R PULTRUSIO N
DATE : Octobe r 27,199 7 TO : Madelin e L . Stru m U.S . Environmenta l Protectio n Agenc y Offic e o f Ai r Qualit

y Plannin g Standard s Emission s Standard s Divisio n MD-1 3 Researc h Triangl e Park , N C 2771 1 FROM : Pultrusio n Industr y Counci l Composite s Institut

e Societ y ofth e Plastics Industr y
Attache d pleas e fin d th e followin g Industr y Proposa l an d supportin g documentatio n fo r a n Existin g Sourc e MAC T fo r Pultrusion : 1 . We t .Are

a Enclosures Industr

y Proposa l 2 . Supportin g Dat a 3 . Ai r Qualit

y Managemen t Distric

t Approval s 

### 4 . Enforcemen

t



### I 

# I OP.4 2

SECTIO N 1 : WE T AREA ENCLOSURE S INDUSTR Y PROPOSA L
"We t are a endosures(indudin g resi n bat h covers)shal l b e designe d t o preven t th e contact o f free-flowin g ai r wit h we t resi n i n orde r t o reduc e HA P emissions . Th e enclosur

e shal l b e designe

d to cove r th e top , bottom , an d th e side s ofth e are a i n whic h reinforcements ar e wet out , an d ar e movin g towar d th e die(s) . Th e enclosur e shai l exten d t o th e di e entranc e o r radio frequency(RF ) preheat unit ; thu s th e enclosure cover s al l side s excep t th e entrance . Th e entranc e allow s reinforcements ) to ente r th e enclosure . Acces s panels , doors , hatches , o r flexibl e curtain s shal l b e considere d part ofth e enclosure provide d tha t they ar e designed t o fit Port s for leve l contro i devices , monitorin g devices , agitatio n shafts , fill hoses , etc. , shal l hav e n o mor e tha n 1.0 " clearance . Resi n dri p of

f a t th e di e entranc

e shai l b e allowed , bu t mus t b e collecte d i n a device tha t i s covere d an d ha s n o mor e tha n 1.0 " clearanc e aroun d th e dri p off" .



# ^ vP.4 3



### SECTIO N 2 : SUPPORTIN G DAT A
Attached pleas e fin

d th e following reportcommissione d by Glasforms , Inc. an d prepared b y CH2

M Hil l fo rth e Bay .Are

a MrQualit

y Management District(BAAQMD)i

n orde rt o determin e styren e emissio n factors forTitle V applicability : Titl e V

Styren e .Emissio

n Facto rRepor

t Glasforms , Inc . 27 1 Barnar

d Avenu e Sa n Jose , Californi

a 95125 " Prepare d b y CH2MH m 111 1 Broadway , Suite 120 0 Oakland , Californi

a 94607-404 6 February , 199 4



## V(l/P.4 4



## Title V Styren e Emissio n Facto rRepor t Glasforms , Inc . 27 1 Barnar

d Avenu e Sa n Jose , California 9512 5

Prepare d b y CH2MHIL L 111 1 Broadway, Suit

e 120 0 Oakland , Califoniia 94607-404 6

Februar y 199 4

### Content s Pag e Summar y i i Introductio n 1 Tes t Mediod s andResults 2 Emission Facto r

Calculation s 4 Appendix A . Sourc e Tes t

Plan Appendix B . Sourc e Tes t

Repor t Result s Appendix C . Emission Factor Calculation s Appendix D . Fiel dNote s and.Materia l Safet y Dat aSlieet

s \. i 

### Table s Numbe r 1 Glasform s Titl e V Emission Factor s ii i 2 Summar

y o f Styrene Emission Rate s 3 3 . Averag e Emission Rate s 4 4 <£m--tzc Formul a5 5 Styren e Emission Factor s . ... . . . ..... . . . . .. . 6



# H I

## Summar y Thi s documentpresent

s the findings o f

th e styren

e emissio n factorstudy conducte d a t Glasforms , Incorporated , 27 1 Barnar d Avenue , Sa

n Jose , Califonua . Th e puipos e o f thi s study wa s t o determin e Titl e V emissio n factors ' i n accordance wit h th e requirement

s o f th e Ba y Area Ai rQualit

y Managemen

tDistric t(BAAQMD) . Emissio n factors were develope d fo rvariou s operatin g an d tes tconditio n scenarios t o simulate actua

l operatin g conditions an d conditions .specifie d by . th e testin g protocol. . Glasfonn s manufacture

s fiberglass-reinforced product s usin g th e pultrusio n process . I n thi s process , continuou

s fiberglas s strands ax

e draw n throug h a polyeste rresi n bath . Th e polyester-resin-coated strand s .ar e the n draw

n throug h a forming bushin g an

d cure d b y a n electricall y heate

d die . Styrene , a componen to f th e polyeste rresin , i s emitte d durin g thi s manufacturin

g process . T o determine th e emissio n factors , .styren e emissio n rates wer e monitore d firom a singl e pultrusio n line . Thi s monitorin g wa s accomplishe d b y constructing tTemporai y Total Enclosure (TTE) aroun d fb& pultrusion Un

e and measuring th e necessai y parameter

s fo remissio n facto rcalculations . Thes e parameter s include : TT E inletand outie tai rflo w rates , TT E inle tand outle tstyren e concentrations , an d th e polyeste r resi n bath styrene weigh tStyren e inle tan d outletconcentration

s wer e measure

d at flo w rate conditions rangin g from namra

l draf t(approximatel

y 8 0 t o 10 0 feetpe r minute ) t o force d air(approximatel y 15 0 to 20 0 fee tpe rminute) . B y monitorin g the styren

e concentrations a tgive n ai rflow rates, styren e emission s ca n b e calculate d i n pound-per-hou rrates . Emissio n rates varie d fro m a lo w o f 0.10 6 pound s pe rhourt o a hig h o f 1.15 1 pounds pe rhour . Th e lo w rat e wa s observed durin g covere d natural-draf tsampling conditions . Th e hig h rat e wa s observed durin

g uncovere d hig h forced air(i.e. , 20 0 fee tpe rminute ) conditions . Give n th e styren

e emissio n rates , an

d knowing th e weigh to f th e styrene i n th e polyeste rresin , emissio n facto n coul d b e derived i n term s o f th e styren e emissio n los s pe rtotal mas s o f

th e .styren

e i n th e resi n mixture . Thes e factors , expresse d a s th e percentage o f

styren e weigh tlos s pe rmas s o f styren e i n th e resi n mixture , ar e presente d i n expressions consisten twit h th e Environmenta l Protectio n Agency (EPA ) AP-4 2 Emissio n FactorDocument , Sectio n 4-12 , PolyesterResin Plastic Product Fabrication. Th e factor s observe d i n this^stud

y range d from 0.4 3 t o 0.85*percent weigh tlos s fo rcovered condition s .an d 1.0 5 t o 4*0 l foruncovered conditions . 

### /M s Th e result

s indicat e tha tai rflo w directl y influence s emissio n rates . Specifically , styren e emission s increase a s ai rflo w increases . The conelatio n betwee n increase d volatil e organic compoun d emission s with increase d ai rflow s i s no tuniqu e o r unexpected . Forced airwa s utilize d during portion s o f thi s smd y t o satisf y the TT E tes tprotoco l establishe

d b y th e EPA . if v*\o\ rftv\t<JJd(A
_ .
n 

# '• A 

# hA tth e EPA-specified TTE minimu m ai rflow rate o f

20 0 fee tpe rminute , th e volumetri c ai rflo w rate throug h iht TTE wa s approximatel

y 4,00 0 cubi c feetpe r minute . Thi s hig h volumetri c flo w rat e present s a conditio n tha

twoul d no tnormall

y occu ra tthi s facility , an

d i tgenerates emissio n rate s tha td o no trepresen

tdi e nonna

i operatin g conditions . Th e TT E tes tprotocol i s notsource-specific , and , i n thi s study , th e us e o f

forced ai rdoe s no tappea rt o b e a n appropriat

e parameter. Operatio n o f

th e pultrusion lin e occu n widii n an enclose d building , .an d i ti s no t expose d t o directforce d airo rexhaus tventilation impacts , whic h would increase evaporativ e los s rates an d directly increase emissio n rates . Therefore , natura l draf t concentrations provid e emissio n rates tha tcorrespon

d t o actua l operating conditions . Becaus e th e BAAQM

D Titl e V progra

m threshold

s .ar e base d o n a facility' s actua l emissions, - natura

l draf ttestin g condition s provide result s tha tax e representativ

e o f actualemissio n rates an

d consisten twith th e B.AAQM D program . Th e 0.4 3 percen t weigh tlos s factorpresent s a n emissio n factorfo ractua l operating conditions an d shoul d b e considered th e appropriat e factorfo rBAAQM

D Titl e V applicability . Th e emissio n factors an

d corresponding tes tcondition s are describe d i n Table 1 .

. Tabl e 1 Glasform s Titl e V Emissio n Factor s Tes tConditio n Percen tWeigh tLoss * Covered , 2 exhaustfans b \ 

# >e r 2.H Uncovered , 2 exhaustfans 6 >© T 12.4G \ Covered , 1 exhaustfanc 0.8 5 no} nt*ifm.rtJ Covered , natura

l draft 1 0.4 3 n*ln*\rt**+J Uncovered , natura

l draft ? 

### 1.0 5 »o\ sttrfiiutJ "Expresse d a s percentage o f

styrene emissio n los s pe rmas s styrene monome r b Approximatel

y 20 0 fee tpe rminut

e 'Approximately 15 0 fee tpe rminut e . ~ * d Approximatel

y 8 0 fee tpe rminut

e 'Approximately 10 0 fee tpe rminut e

i u 

# H V

## Introductio n

CH2 M HIL L wa s contracted b y Glasforms , Inc. , San Jose , Califomia , t o provid e assistance i n determining styren e emissio n factors fo rTitl e V applicability . Unde r Titl e V , styrene i s identified as a Hazardou s Ai rPoUutan

t(HAP) . Facilitie s tha

tma y emi tgreatertha

n 1 0 ton s peryearo f

a singl e HA Pax

e subjec tt o Titl e V . Th e BAAQM D interpret

s 1 0 tons o f

potentia l emission s a s equa

l t o 7 ton s o f

actua l emissions . Styrene emission s resul tfro m the operation o f

th e facility' s fiberglass pultrusio n lines . Styren e i s a componentof the polyeste rresi n tha

tfunction s as th e matrix fo rth e fiberglas s strands . Th e BAAQM D currentl

y assumes a styren

e facto ro f

5. 5 percent styrene los s pe rmas s o f

styren e monome

rmput, base d o n dat

a presented i n EP A .AP

42 . I n preparing fo rthi s report, a source tes tpla n wa s developed an d submitted t o th e BAAQMD fo rapproval . Tt e plan consiste d o f constructing a TT E i n accordance wiu i EPA guideUnes . Sampling mediods an d analyse s wer e conducte d i n accordance wit h BAAQM D methodology . The sourc e tes tresult

s were use d t o detennin e styrene emissio n factor

a expresse d i n term

s o f percentag e o f

stvrene los s pe rmas s o f styren e monome rinpu tA cop y o f the BAAQMD approve d tes tpla n i s include d i n Appendix A .



# VP.4 9 

## Tes tMethod s an d Result s Styrene emission s fro

m the pultrusio

n lin e were measure

d usin g a gas/ga s TTE . Th e TT E i s a stmctur

e tha tenclose s the pultrusion Un e an d provides fo rth e captur e o f fugitiv e styrene emissio n losses . Inle tan d outle tstyrene concentrations wer e monitored usin g direc

tflame ionization detectio n (FID ) instrument s i n accordanc

e wit h BAAQMD Method ST-7 . Th e result s o f th e .FI D provided rea

l tim e total hydrocarbo

n analyse s tha

twer e documente

d b y stri p char trecorders . - Background contamination was monitore d periodically a tth e inle tand outletsampl e streams usin g a

n on-sit e ga s chromatograph . N o backgroun d contaminant

s wer e observe d during th

e sampling . Samplin g wa s conducte

d a tsevera l differentairflo w rates tha twer e regulated throug

h th e combine d operation an d non-operatio

n o f tw o fans . .Ai

rflo w rate s wer e altere

d t o simulat e high-air-velocit

y condition

s an d natura l draf tconditions . Samplin g wa s conducte

d unde rthe tw o differen

toperatin g scenarios , a s weU . Th e firs tscenario , wit

h th e polyesterresi n bat h cove ri n place , provide d momtoring condition s consistentwit h BAAQM

D Regulatio n 8 , Rul e 50 , Sectio n 306 , Polyester Resin Operations compliance . Sectio n 30 6 require s tha tal l polyeste rresi n baths b e covere d t o reduc

e volatil e organi

c compound emissions . Th e secon d scenario , withou t th e cover , wa s intende

d t o provide dat

a fo rfutur

e evaluations o f

styrene emissio n contro l efficiencies . Al l emissio n sampling wa s conducte d o n Januai

y 12,1994 . Th e emissions , sampling wa s observe d b y representative s o f th e BAAQM

D Penni tService s and Sourc e Tes t Sections . A mor

e detailed discussio n o f

di e tes tmethods , field .sampling , an d analytica l dat a can b e foun

d i n Appendi

x B . Give n th e styrene emissio n concentration s an d airflo w rates fo rth e specifi c sampling periods , emissio n rates ca n b e calculated an d expressed i n pounds o f

styrene emission s pe rhou ro f

operation . The highes temissio n rates, 1.15 1 t o 1.10 0 pounds perhour , wer e foun d whe n th e cove rwa s ope n and th e airflo w rates were hig h (approximatel y 23 0 fee tpe rminute) . The lowes temissio n rates , 0.10 6 t o 0.13 7 pounds perhour , wer e observe d whe n th e cove rwa s dow n an d ai rflo w represented natura l draf t condition s (approximatel

y 8 0 fee tperminute) . Th e emissio n rates ar e summarize

d i n Tabl e 2 o n the foUowin

g page .



## i\<_

### Tes tConditio n Cove rClosed Cove rClosed Cove rClosed Cove rOpe n Cove rOpe n Cove rClose d Cove rClosed Cove rClosed Cove rOpe n fee tperminut

e ••pound s perhou r Table 2 Summar y o f Styren e Emissio n Rate s Sample Period (2 4 hr ) 100 0 -105 0 1100 -115 5 120 0 -125 5 141 0 -145 0 1500 -160 0 161 0 -173 0 1735 -181 5 1830-193 0 1935-201 5

- 

### AirRo w Rat e

(FPM" ) 190. 6 229. 4 225. 7 226. 8 233. 2 149. 2 80. 9 82. 5 108. 2 Emission Rat e (lb/hr* ) 0.21 5 0.26 1 0.20 0 1.15 1 1.10 0 0.23 9 0.13 7 0.10 6 0.29 3 

# 1

4< \

## Emissio n Facto rCalculation s Emissio n facto rcalculations wer e base d o n di e testresult

s an d di e styrene weigh t conten to f

th e polyeste rresi n atth e time o f tbe .sampling

. The actua

l emissio n calculation s ar

e presente d i h Appendb

c C . Glasform' s fiel d notes , MCP- 2 Batch Sheet , resi n suppUe

rcertificates o f

analysis , an

d Materia l Safet y Dat a Sheet s ar e locate d i n Appendix D . Th e foUowing step s wer e taken i n th e emission facto rcalculation :

• Determin

e th e average styren

e emission s rates

• Determine th e styrene weigh tconten to f th e polyeste rresi n

• Express th e styrene emissio n facto ri n terms o f

percentage o f styren e los s pe rmas s o f

styren e monome r Averag e Styren e Emissio n Rat e Determinatio n Give n tiie styren

e emissio n rate s ftom th e tes tresults , average hourly emissio n rate s wer e calculated ftom multipl e periods o f simila rsampUn g conditions (e.g. , ai rflo w rate, cove ropen o rclosed , etc.) . Thi s procedur e provided consistentaverag e emissio n rate s fo r.simila

rsampling conditions . Th e result s o f dii s procedur

e .ar e foun d i n Tabl e 3 . Table 3 | Averag e Emissio n Rate s
tes tCondition ~ Covered , 2 exhaus

tfan s Uncovered, 2 exhaus

tfan s Covered , 1 fa

n Covered , natura

l draf t | Uncovered, natura

l draf t Averag e Emission Rate ' (lbs/hr ) ^ 0.22 5 1.12 6 0.23 9 | 0.12 2 0.29 3 •Wher e singl e dat

a points exist , i twas assume d tha tdat a represented tiie averag e emissio n rate. 

# 6°P.5 2

Polyeste rResi n Styren e Conten tDetenninatio n Glasfonn s prepare

s polyesterresi n mixtures i n accordanc e wit h specifi c formulas . Thes e formulas include variou s combination

s o f polyeste rresins , additives , fillers , catalyst , an

d styrene . The formula

s var y to confor

m wit h specifi c end-produc

tuse s an d requirements. tC^jz: C$1 <-A-^zz wa s prepare d i n total batc

h weight s o f approximatel

y 7 7 pounds . Th e tw o polyeste rresins used, * ^&zz: containe d premixe d amount

s o f styrene . Additiona

l styren e was adde

d i n amount

s .specifie d b y th e formula . Th e tota l weigh to f th e .styren

e pe r7 7 poun

d batch was approximatel

y 2 8 pounds . Tha

tamoun t equate s t o a .styrene conten to f approximatel

y 3 6 percent

. Th e formul a i s presented i n Table 4 below . ~%>jr



# 6 d d Tabl e 4 Formul a

ttComponen t /{mC*t>j A .Amoun

t 

### 30 2 8 Unit s l b l b Amount

Obs ) 

### 3 0 2 8 Styren e

Conten t ( % b y weight ) 42. 4 33. 1

| l b | 6 10 0

Approximat

e Batc h Weight 77. 4 pound s Approximat

e Styren e Weight 28. 0 pound s Styren e

Weigh t Obs ) 12.7 2 9.2 7

6.0 0

PercentStyren

e Conten t3 6 percen

tCm cl« d'-j

fig* - UJPm*f*mt--*s) 

# 6\P.5 3

Emissio n Facto rDeterminatio n Onc e th e averag e styren e emission rate

s an d polyeste rresi

n styren e weigh tcontent wer e known , emissio n factor s wer e calculated fo reac

h specifi c tes tcondition . Consisten twith th e EP

A emissio n factorexpressio n format , th e factor s wer e calculate d i n terms o f

percentage o f

.styren e los s pe rmas s o f

styren e monomer

. Thi s calculatio n wa s complete d b y dividin g eac h styien e emissio n factorb y th e tota l styrene weigh to f th e polyeste rresin . Table 5 present s the resultan

temission factors .

Tabl e 5 Styren e Emissio n Factors Tes tConditio n Covered , 2 exhaus tfans * Uncovered , 2 exhaustfans " | Covered , 1 exhaus tfan ' J Covered , natura

l draft 1 1 Uncovered , natura

l draft 0 PercentWeigh tLoss * | Q«8 r2 . / * | £02 * 12.+V

I 0.8 5 /j#/*/«'^ V 1 

### 0.4 3 not tnftvfcf \ 1.0 5 #* / rttrltvfcf \ "Expresse d a s percentag

e o f styren e emissio n los s pe

rmas s styrene monome r "Approximatel

y 20 0 fee tpe

rminut e 'Approximately 15 0 feetpe rminut e 'Approximately 8 0 fee tperminut e 'Approximately 10 0 feetpe rminut e -

>P.5 4



### APPENDI

X A 

# P:P.5 5

Engineers Pbm&s Economists Scientists Oaobe r7 , 199 3 SF036368.A Q
Ba y Are a Ai rQualit

y Managemen

tDistric t 93 9 Elli s Street Sa n Francisco , CaUforni

a 9410 9 Attention : Mr . Gar

y Fen d \ DearGary : ' Subject : Approva

l o f Sourc e Tes tPlan , Glasforms , Inc. , Sa n Jose , C A Reference : BAAQMD Plan tNumber616 4 CH2M HIL L and ou rsubcontractor, DaRo s Associates , hav e bee n contracte d b y Glasfonns , Inc. , San Jose , California , t o assis ti n th e developmen to f a styren e emissio n factor . Thi s emissio n factorwfl l ai d i n evaluatin g the applicabilit y o f th e Tid e V Permi t requirement

s (Propose d Regulation 2 , Rul e 5) . Mr . Alex Saschi n recommende d tha t Glasform s sourc e tes ta continuous pultrusio n proces s machin e t o determin e a facilit y specifi c emissio n factor . A s a result , CH2M HEL L prqpare d a sourc e tes tpla n base d upo n Mr . Saschin' s recommendation. Attached pleas e find a cop y of th e proposed .sourc

e tes tpla n fo ryou rreview an

d approval . A s w e briefl y discusse d o n Tuesday , October5 , 1993 , th e tes tmethodologie s ar e base d upo n th e us e o f

th e total temporai

y enclosure EPA guidanc e documen

ti n conjunctio n wiu i BAAQMD Metho d ST-7 . W e .ar e confidentthatthi s pla n wfl l satisf

y you r.requirements. Shoul d ther e b e an y questions o rcomment

s pleas e fee l fre e t o contacteithermysel f at(916 ) 920-021 2 extensio n orBruce DaRo s a

t(408 ) 864-5998 . I n the even ttha tw e ar e unable t o resolv e issues - whic h ma y dela y approva

l o f th e plan , w e are more than willin g t o discus s any concern s a tou r meetin g whic h i s tentatively scheduled fo rWednesday , Octobe r13,1993 .

Socramento

Offic e 3840

Jtas h Court. Suite

110 L M 9169200300 Sacramento. CA9S834-1644 )

\ Fa*

No. 916 9204463 

# 5 HP.5 6

Ba y Area Ai rQualit

y ManagementDistric

t Pag e 2 Octobe r7,199 3 SF036368.A Q
Than k yo u foryou rassistanc e an d cooperation. W e loo k forwar d t o you rapprova l o f di e propose d tes tplan . Sincerely , CH2MHIL L

# yaSigjA.SLilrDavi d A . Omot

o Ai rQualit

y Specialis t DAO/dao / cc : AlexSaschin/BAAQM D Terr y McQuarrie/Glasforms Brac e DaRos/DaRo s .Associate s Joe l Refeman/CH2

M .HILLP.5 7



### SOURC E TES T PLA

N T O DETERMIN

E STYREN

E EMISSION FACTO

RFO RA CONTINUOUS PULTRUSIO N PROCESSE S LOCATE D A T GLASFORMS , INC , SA N JOSE , CALIFORNI

A PURPOS E Th e purpos e o f

th e testing i s t o detennin e a n emission factorforstyren e from continuous pultrusion processes . Th e pultrusio n proces s equipmen

ti s operated by Glasfonns , bi c (Glasfonns) , an d i s locate d at27 1 Barnar d Avenue , Sa

n Jose , California. PROCES S DESCRIPTION Pultrusion i s a fabricatin

g process , whic

h can b e thoughto f

a s extrusio

n b y pulling , tha ti s use d t o produce continuou s cross-sectiona

l lineal s simila

rt o thos e made b y extrudin g metal s suc

h a s aluminum : Som e examples o f pultrude d product s are : electrica

l insulation materials , ladders , walkwa y gratings , an

d structura

l materials . I n panicuiar , th e Glasfonns proces s use s continuous fiberreinforcemen t(fiberglass ) draw n throug h a polyesterresin bat

h t o coa teach fiberwit h a specially formulate

d thermosetting resin mixture. Th e coate d fiberi s .assemble d b y a forming guid e and then draw n throug h a n electricall

y heate d die . Cure o f

th e thermosetting resin i s initiated by hea ti n th e di e and a n organic peroxide catalysti n th e .resin mix. Tn e rate o f reaction i s controlled b y heatin g th e die . Th e .resultin g pultruded produc

ti s cu tt o lengt

h an d read y fo rus e a s i tleave s th e machine . Th e Glasforms proces s use s a resin consisting primaril y o f basi c polyeste rresin , styrene, filler, and catalyst. Dependin g upon th e formulatio n needed , styren e concentratio n ca

n var y betwee n 28. 6 percentt o 5 0 percen tb y weigh tCopie s o f Materia l Safet y Data Sheet

s (MSDS ) "representative " o f th e constituen

tmaterials typicaU

y use d by Glasform

s ar e attached . yiETHOD S Th e foUowing tes tpla

n methods are proposed : Fugitive and poin

tsource emissions o f

styrene from th e pultrusion proces s equipmentwfl

l b e measure

d using a Total Temporaiy Enclosur e (TTE ) a s described i n th e document, The Measurement Solution: Using a Temporary Total Enclosure forCapture Efficiency Testing EPA-450/4-91-020 , i n conjunction wit h * Ba y Are a Ai rQuaUt

y Managemen

tDistrict(BAAQMD ) Metho d ST-7 , described i n th e BAAQMD Manual of Procedures, whic

h use s direc

tFlame Ionizatio n Detector s (FED) . - 1 . A TT E structur

e wfl l b e constructe

d thatencloses : (1 ) a portion o f th e area afterth e entr y o f th e fiberglass (priort o th e resi n coating reservoir) , (2 ) th e resi n reservoir, an d (3 ) th e formin

g guide . Th e TT E structur e wil l b e fabricate

d from 4 mil flame
.SAQSFO3«368/001.WP S 10/9 3 

# y,P^8
_



### CH2 M HDLL/GLASFORM

S - OCTOBE

R4,199 3 RE : SOURC

E TEST PLA

N T O DETERMIN

E A STYREN

E EMISSIO N FACTO

R FO RA PULTRUSIO

N PROCESS LOCATE

D A T GLASFORMS , INC , SA N JOSE , CALIFORNI

A retara'an tpolyethylen

e plasti c film supporte

d o n existing structure

s an d additiona

l framing as required. One side o f th e TT E wil

l utiliz e an existin

g concret e wal l adjacentthe process equipment . Seams an

d attachmen

to f th e plasti c film to support s wfl l b e made usin

g duc ttap e Th e TT E wil

l b e rectangula

ri n shap e wit

h on e Natura

l Draf tOpening (NDO ) an

d on e exhaust

. Ambien tai rwfl l b e moved throug

h th e TT E using appropriatel

y size d blower s o rfan s t o achieve a fac e velodty o f notles s tha

n .20 0 fee tperminute Averag e fac

e velocit y test s forth e TT E wil

l b e mad e using a Davis Instrument s mechanica

l vane anemomete

ran d checked wit

h a Kurz, Model 440 , hot-wir e ai rfiow mete rpe rth e metho

d protocol . .Ai

rfiow measurement

s tha tar e require d a tan y other duct s o rsource point

s wil l b e made usin

g BAAQMD Method s 1 7 an d 18 . 2 . Tb e TT E inletan

d outletVolatil e Organi

c Carbo n (VOC) concentration

s wil l b e measured simultaneousl

y usin g tw o (2 ) Bechman , Mode l 400 , Tota

l Hydrocarbo

n (THC ) .Analyzer

s employin

g direc tFIDs . Both - .analyzer

s wfl l b e operate

d usin g 10 0 percenthydroge

n fue L Sampl e gase s wil

l b e coUecte

d a tth e TT E inle

tand . outle t using a .stainless steel o rTeflon rake d probe . Th e rake

d probe s wfl

l b e configure

d onsit e and wil

l a ta minimu

m consisto f

four. (4 ) .sampl

e points arrange

d t o collec ta n equa l portion o f

sample gases from eac

h locatio n an

d combin e the

m int o on e composite sample strea

m foi \ analysis . Th e composit

e sample gase s wfl

l b e transporte

d t o each analyze

rvia unheate

d Teflon sampling line s wit h n o furthe

rsampl e conditioning . Analyzer

s wfl l b e placed as clos e t o th e proces s a s feasible t o minimiz e th e lengt h o f th e sampl e lin e needed . 3 . Calibratio

n ofth e THC analyzer

s wil l b e accomplishe

d wit h field-prepared standard

s o f styrene i n zero ai

rcontaine d i n new Tedla

rbags . 4 . Each tes tn

m wil l b e fou r(4 ) hour s lon g an d wil l b e performed .a

s follows : 4a . Th e samplin

g syste m wfl l b e lea k checked priort o start-u p and a tth e completio

n of th e tes tday. Additiona

l lea k checks wfl

l b e performe

d o n an "a

s needed " basi

s foUowin g an y disruptio

n o rupse tt o th e samplin

g system . 4b . Th e TH C analyzer

s wil l b e wanned up , zeroed , and calibrate d wit h styren e i n ai r standards (typicall

y 5-5 0 part s pe rmilUo

n b y volume) . 4 c Th e tes twfl

l begi n b y collectin g VO C dat

a continuousl

y o n standar

d fiatbe d strip-char

t recorders . Calibration

s wfl l b e repeate d a

ttw o (2 ) hourintervals .

SAC/5FO3W8/00LWP 5 10/9 3 

# $ 1P.5 9



### CH2 M HILL/GLASFOHM

S - OCTOBE

R4,199 3 RE : SOURC

E TES T PLA

N T O DETERMIN

E A STYREN

E EMISSIO

N FACTO R FO RA PULTRUSIO

N PROCES S LOCATE

D A T GLASFORMS , INC , SA N JOSE , CALIFORNI

A 4d . A tleas tonc e durin

g th e testing , caUbratio

n ga s wil l b e introduce

d int o th e inleto f

th e sampling Une

. Thi s procedur

e wil l b e compare

d t o th e usua

l caUbratio

n t o determine Un e losses . 4e . TT E volumetric flow rate wfl l b e measure

d eac h hour . Thi s wil

l b e accomplishe

d by measurin g th e linearvelocit

y o f th e ai ratth e inlet

s an d exhaus tlocations . Th e exac

t measuremen

tlocations wfl

l determine

d usin g th e method protocol . Th e averag e linear velocit y wfl l b e multipUe

d b y th e cross sectiona

l are a t o give th e volumetric flow rat e i n cubi c fee tpe rminute . Hourl y value s wfl l b e used fo rfinal dat

a reduction . 4f . Data reductio

n wil l b e as foUows : VO C dat a from th e strip-chart

s wfl l b e integrate

d a n average

d forfive (5 ) minut

e intervals . Thes e reading

s wil l b e average

d int o on e (1 ) hourvalues . Mass stvrene emissions wfl

l b e calculated a s th e su

m of af l measure d emission poin

tconcentration

s conecte d forbackgroun

d VOC s base

d o n the volumetric flowrate determine d durin g th e sam e period . 5 . Th e amoun

to f resin durin

g th e tes tperio

d wfl l b e detennine d gravimetrically. Specifically , Glasfonns wfl l us e a OS E W

S 900-I S Industria

l Part s Countin g Mete rwfl

l b e use d t o formulat

e resin mixtures. Accordin g t o th e manufacturer

, this balance i s capabl e o f

0. 1 pound resolution an

d was recentl

y calibrate

d o n Augus

t14,1993 . Prior t o initiation o f

the . emission monitorin

g tests , th e pultrusio

n machin e t o b e teste d wfl

l b e cleaned an

d prepared fo ra ne

w batc h o f resin . Th e resin reservoirwfl l b e tared prio rt o th e addition o f

th e ne w resin mixture

. Th e resin mixtur

e wil l b e delivered t o th e reservoi

ri n covered five (5) gallo n pail s tha thav e bee n als o bee n tare d t o obtain an initia l weigh tTh e resi n mixtur e an d pail s wfl l b e reweighe

d t o detennin e resin "hang-up " afterchargin

g th e reservoir

. Upo n completio n o f

th e tes tperiod , th e reservoirwfl

l b e weighed t o detennine th e weigh to f an y unuse d resi n mixture. Th e ne tusage o f

resin durin

g th e tes tperio

d wil l the n b e calculated by determinin g th e amoun to f resi n delivered t o th e reservoi rles s th e weighto f

th e unuse

d resin i n th e reservoir . Ne tusag e fora four(4 ) hou rtestis estimated t o b e approximatel y fifty (50 ) pounds . 6 . A n emissio

n facto rforstyrene wfl

l b e calculate

d o n a weightpercentbasis forstyrene emitted pe

rpound o f

styrene i n the resi n mixture . 7 . FoUowin

g th e completio n o f

th e field tests , a final repor twil l b e completed . Th e repor twil l include a ful

l descriptio

n o f al l testmethods , equipmen

tuse d (includin

g a U appropriat

e calibratio

n data) ; summar

y o f results ; pertinen

tdrawings, figures, an

d photograph

s (i f available) ; process parameters ; an d copie s o f

all ra w dat a and field notes . SAQSP036368/M1.WP S 10/9 3 ^ 

# 5*P.6 0

\



### APPENDI X B 

# 5T. .P.6 1 

## DaRo s Associate s CONSULTANTS I N ENVIRONMENTA L SCIENC E AN O R1SKASSESSM.EN T 701 3 Real m Ott o •Suit e F pSanJoM.Cafifbmi a 9S11 9

February 8 , 199 4 ' CH2MHXU

. 384 0 Rosi n Cour t Suit e U O Sacramento , Californi a 95834-164 4 ATXEHTXOM : Davi d A . Omot o

Ai r Quality

specialis t SUBJECT : FINA

L REPOR T - Styren

e Emission s fro

m a Continuou s Fibe r Pulttuaio n Proces s Dea r Mr . Oroto : Thi s repor t present s tb e .result s o f emissions .monitorin g a-easureoent s t o determin

e styren

e (Vinyl benzene ) emissions fro a a continuou s fi.be r .pultrusio

n proces s .locate

d a t Glasforms , Inc. # (Glasforms) , 27 1 Barnar d Avenue , San Jose , California . Th

a followin

g .sections * provid

e a n overvie

w o f th e tes t progran , a brie f rilnraif-mlono f th e -samplin g an d analysi s methods , an d results . Presente

d i n the appendi xax e al l ra w field-{lata , a -descriptio n o f tbe qualit

y control/qualit

y assuranc e progra

m applicabl e t o thi s task , an d saapl e calculation s whic hsho w ho w tbe result s wer e derive d fro m the data . Tes t Progra

m Overvie

w Fugitiv e emission s o f styrene , a Volatil e Organi c Compoun d (VOC) , fro

m a pultrusio

n proces s equipmen t lin e wer e measure

d usin g a gas/ga s Tota l Temporar y Enclosure (TIB ) a s describe d i n th e document , Th e Measurement Solution : Psin q A Temporar

y Tota l Enclosur e fo r Captur e Efficienc y Testing , EPA-450/4-91-020 . Th e purpos e o f th e TX S wa s t e completel y encapsulat e th e pultrusio n equipmen t an

d capture an

y VOC' s t o allo

w fo r accurat e measuremen t o f the proces s VO C H— < w w rate . Ventilatio

n o f th e TT E wa s attaine d usin g tw o explosio

n proof , ai r powered , sixtee n (16 ) inc

hdiamete r variabl e spee d fans . Styren

e concentration s wer e continuousl

y measure

d a t th e inle t an

d outle t o f the TI E using Ba y Are a Air . Qualit y Managemen t Distric t (BAAQKD) , Metho d ST-7 , describe

d i n th e BAAQM

D Manua l o f Procedures . Thi s metho d utilise * direc t flam e ionizatio

n detection instrument s calibrate

d wit hknow

n concentration s o f a VO C in air . Additionally , t o determine potentia l backgroun

d contaminatio

n fro m acetone , whic

hi s use d a t th e faciUt y a s a'permitte

d clean-u

p solven

t fo r epox y resi n lines , th e inle t an d outle t sanpl e stream

s wer e periodically

analyze

d usin g a n on-sit e ga s chromatograp hto speciat e aceton

e an d styrene . Pag e 1 o f 1 0 

### (oQ

### DaRo

s Assoc^tes/CH2

M H.IL L - Januar

y 31 , 199 4 RB : Styren e Emission s fro m a Continuou

s Fibe rPultrusio n Proces s PAOE : 2 o f 1 0

Al l testing wa s conducte d o n Januar y 12 , 199 4 durin g operatio n o f th e pultrusio n equipmen t b y Glasform s personnel . Mr . Terr y S . McQuarri e and Mr . Ke n E . Bass , Glasforms , provide d proces s dat a an d coordinatio n o f testing activities . Testin g wa s performe d by Mr . Bruc e C . DaRos , DaRo s Associate s an d Mr . Mar k Chips . Testin g wa s observe d a t variou s stage s b y Mr . Gar y

Fen d an d Mr . Ale xSaschin , BAAQMD . Mr . Davi d A . Omot o an d Ms . Tany a Can p o f CH2 M

HIL L wer e als o presen t t o observ e tb e testing . Tota l Temporar y

Enclosur e A TI E consistin g o f tw o Natura l Draf t Opening s (NDO) , designate d th e inle t an d outlet , wa s constructe d on.th e da y prio r t o testing . Th e inle t ND O incorporate d a n existin g ma n doo r leading t o th e outsid e o f th e building tha t wa s locate d i n clos e proximit y t o th e proces s equipment . Th e outle t ND O openin g wa s constructe d a s par t o f th e TI E and incorporated a transitio n sectio n t o enhanc e fac e velocit y

ai r flo

w measurements . Th e geometri c configuratio n and openin g area s o f inle t and outle t NDO' s wer e identical . Figur e 1 present s a floorpla n diagra a o f th e TI E constructe d fo r thes e tests . Specifically , th e TT E structur e wa s fabricate d usin g heav y wal l PV C tubing/fitting s a s framin g an d covere d wit h4 mi l flam e retardan t polyethylen e sheeting , lh e structur e wa s frame d i n suc ha manne r t o b e sel f supporting , and al l seam s an d abutment s wer e seale d usin g duc t tape . Pe r Metho d 204 , Criteri a fo r an d Verificatio n o f a Permanen t o f Temporar y Tota l Enclosur e (contained l n th e TT E metho d guideline s previousl y referenced) , specifi c minimu m criteri a fo r constructio n an

d operatio n o f a TI E wer e implemente d t o ensur e a n adequat e enclosur e fo r thes e tests . Tabl e 1 present s a lis t o f thes e criteri a vs . th e actua l TT E configuratio n an d -test findings . Supportin g calculation s ar e presente d i n th e appendi xt o thi s report . Sampling/Measuremen t Location s Emissio n sampling an d ai r flo w measurement s wer e conducte d a t th e inle t an d outle t NDO' s o f th e TTE . Al l measurement s wer e mad e a t a sample/travers e poin t locate d a t th e centroi d o f fou r equa l area s o f th e ND O cross-sectio n pe r Unite d State s Environmenta l Protectio n Agenc y Metho d 1 (4 0 CFR , Par t 60) . Fac e Velocity/Volumetri c Flowrat e Fac e velocitie s (FV ) a t th e TI E opening s wer e measure d usin g a Davi s Instrument s Manufacturin g Compan y van e anemomete r and/o r a n Alnor , Mode l 8565 , Conpuflo w

TberaoAnemometer . Thes e measurement s wer e conducte d t o verif y tha t th e inle t an d outle t ND O FV' s wer e consisten t wit hth e TT E operatin g criteri a durin g th e tes t period . Xntercomparriso n o f measurement s collecte d durin g operatio n o f th e TT E from

bot hinstrument s showe d clos e agreement . Th e directio n o f flo w wa s verifie d usin g th e van e anemomete r and wit hth e us e o f smok e trace r tube s a t variou s time s durin g th e tests . F V measurement s wer e mad e b y takin g fou r minut e flo w reading s a t th e previousl y describe d ND O travers e points . A digita l stopwatc hwa s use d t o time th e flo w measurements . 

# 0( 

# sfP.6 3 

# sryssss : e ; saw s .M
- «

— PAGE : 3 o f

1 0



# Gp £

* ^ Inc. , San Jose , Californi a 

# ?,P-6 4 ,



### .DaRo s Assoclates/CH2

M HI.L L - Januar

y 31 , 1995 RE : Styren e Emission s fro

m a Continuou

s Fibe rPultrusio n Proces s PAGE : 4 o f 1 0
Tabl e 1 : Temporar y

Tota l Enclosur e Constructio n Criteri a vs . Actua l Tes t Condition s Conditio n 1 : An y

ND O shal l b e a t leas t 4 equivalen t diameter s fro m eac hVO C emittin g point . Actua l Tes t Condition : Base d o n a n equivalen t ND O duc t diamete r o f 5. 1 feet , th e VO C sourc e is"approximatel y 3. 5 an d 3. 7 equivalen t duc t diameter s respectivel y fro m th e inle t and outle t ND O openings . Thes e distance s d o no t mee t th e criteria . lhe y wer e th e maximu

m achievabl e distance s wit hregar d t o constraint s pose d withi n th e facilit y fo r constructio n o f th e TTE . Base d o n th e tes t dat a an d observations , thoroug h mixin g o f fugitiv

e VOC' s wa s achieve d an d ther e i s no t inpac t t o th e tes t data . Conditio n 2 : An y

exhaus t poin t fro

m th e enclosur e shal l b e a t leas t 4 equivalen t duc t o r hoo d diameter s fro m eac hNDO . Actua l Tes t Condition : No t appUcabl e t o thi s enclosur e becaus e ther e ar e n o activ e exhaus t points . Conditio n 3 : Th e tota l are a o f a UNDO' s shal l no t excee d 5 % o f th e surfac e are a

o f th e enclosure' s walls , floor , an d ceiling . Actua l Tes t Condition : Base d o n a tota l ND O are a o f 40. 6 ft 2(1) , an d a . tota l enclosur e surfac e are a o f 160 0 ft 2 , th e ND O i s approximatel y

2.5 % o f tb e surfac e are a and therefor e meet s th e criteria . Conditio n 4 : Th e averag e Fac e Velocit y (FV ) o f ai r throughal l NDO' s shal l b e a t leas t 20 0 ft/mlh (n . Th e Directio n o f ai r throug ha UNDO' s shal l b e int o th e enclosure . Actua l Tes t Condition : Tes t measurement s wer e conducte d a t differen t operatin g FV' s throughth e TTE , som e o f whic hwer e intentionall y below th e prescriEe d FV

criteria . Two tes t scenario s wer e conducte d a t th e prescribe d F V (referenc e Tabl e 2) . Ai r velocit y

measurement s mad e durin g th e test s indicate d th e directio n t o b e inwar d a t al l time s durin g operatio n o f on e o r mor e ventilatio n fans . I n addition , smok e trace r tube s wer e use d t o visuall y verif y flow direction . Som e backflo w wa s note d hoveve r durin g th e natura l draf t test s whe n bot hfan s wer e shutdown .
1 ft 2 = squar e fee t 2 ft/mi n = fee t pe r minut e 

# £ 3 Ct>P.6 5



### PAGE : 5 o f 1 0

« . 1 <=o«tin,*d> . T-^« T « * •--« • Constructio n Criteri

a v, . **u * * w N 

### Tes t Condition s

^ A Endow s whos e area s ar e no t include da s NDO' s routin e operationo f th e process . Actua l Tes t Condition : No t applicabl e t o thi s enclosure .



# < W°P.6 6

DaRo s Associates/CH2 M HIL

L - Januar

y 31 , 1994 RE : Styren e Emission s from a Continuou s Fibe rPultrusio n Proces s PAGE : 6 o f 1 0
Ambien t temperatur e an d relativ e humidit y condition s i n th e TT E wer e monitored/determine d fro m dry an d we t bul bthermomete r reading s usin g a Bendix , "Psychron, " Electri c Psychrometer . Dr y bul btemperature s wer e als o monitore d usin g a typ e Kthermocoupl e an d Omega , Serie s 872 , Digita l Thermomete r a s a cros s reference . Measurement s wer e mad e nea r th e outle t NDO . Generally , reading s wer e recorde d every

hal f hou r durin g th e tes t period . Thea e measurement s wer e no t use d a s par t o f th e dat a reductio n fo r thi s report ; however , the y ar e presente d t o documen t TT E operatin g conditions . Volumetri c flowrat e calculation s ar e base d o n th e averag e one-hou r F V measurement s durin g th e tes t period and d o no t includ e any correction s fo r moisture . Barometri c pressur e wa s obtaine d fro m th e Sa n Jos e Internationa l Airport . Tabl e 2 present s a summar y o f th e ambien t conditions , FV measurements , an d volumetri c flowrates . Copie s o f th e fiel d data sheet s an d associate d calculation s ar e presente d i n th e appendi xt o thi s report . Emissio n Monitorin g A Uemissio n sanpling an d analysi s wa s don e l n accordanc e wit hprocedure s an d methodology

describe d I n BAAQM D Metho d ST-7 . Continuou s sample s wer e coUecte d a t tb e Inle t an d outle t NDO' s o f th e TT E usin g rake d teflo n probe s consistin g o f fou r inlet s eac hwhic hcombined th e sample s int o on e composit e stream . Bac ho f th e rake d probe s wa s locate d a s describe d i n . th e Sampling/Measuremen t Location s sectio n o f thi s report . Eac ho f th e composite d ga s sample s wa s transporte d t o th e respective analyze r vi a non-heate d teflo n tubin g an d discrete , teflo n coated , diaphrag m vacuu m pumps . Tb e VC C concentratio n o f th e sample d gase s wer e measure d simultaneousl y usin g tw o Beckman , Mode l 400 , Tota l Hydrocarbo n (THC ) analyzer s employin g direc t Flam e Ionizatio n Detector s (FID) . Bot hanalyzer s wer e operate d usin g 100 % hydroge n fuel . Tb e analyzer s wer e zeroe d using ultrapur e air , and calibrate d usin g a •/ - 1 % Nationa l Institut e o f Standard s an d Technology (NIST ) traceabl e ga s mixtur e o f styren e i n ultrapur e air . Th e analyzer s wer e zeroe d an d calibrate d b y admittin g th e appropriat e standard int o th e samplin g syste m vi a th e rake d probe s usin g ne w

4 0 Ute r (L ) tedla r bag s containin g th e appropriat e spa n gas . Thi s metho d o f calibratio n take s int o accoun t an y losse s tha t ma y

b e attributabl e t o th e sampling system . A description o f th e TH C analyze r specification s i s presente d i n th e appendi xt o thi s report . Rea l tim e TH C analyze r outpu t wa s recorde d o n standar d fla t be d strip-char t recorders . .Copie s o f th e analyze r stri p charts , char t dat a reduction , an d calibratio n ga s certificat e ar e presente d i n th e appendi xt o thi s report . 

# 4 ^ 

# sP.6 7

DaRo s Assoolates/CH2 M HIL L - Januar y

31 , 199 4 RE : Styren e Emission s fro m a Continuou s Fibe r Pultrusio n Proces s PAGE : 7 o f 1 0

Tabl e 2 . Tota l Temporary Enclosur e Operating Parameter s TIM E DBT 1 WBT 3 RH * Inle t FV* Outle t F V Avg . Volumetri c (2 4 Hr. ) ("T 2 ) (°P

> (%? ) (FPM 7 ) (FPM ) Flowrate 1 (CFtf ) 080 0 NOTE : Fan s Nos . 1 an d 2 operationa l

4 7 4 2 6 6 - 083 0 4 9 4 3 6 1 - 090 0 4 9 4 4 6 7 - O92 0 NOTE : Pour firs t batc ho f resi n mixtur e int o proces s eguipmen t 093 0 5 1 4 5 6 2 100 0 NOTE : Proces s stabl e wit hcove r dow n 5 5 4 8 5 9 100 5 - . - 197. 5 101 0 - 102 5 103 0 5 4 4 7 5 9 103 5 NOTE : F

V measure d ove r resi n bat hi s 11 7 FP M 104 5 - 16 5 105 0 - 21 0 21 3 (Avg . HV

« 190.6 ) 167. 5 3,86 8 110 0 111 5 112 0 113 0 115 0 115 5 120 0 123 0 125 0 125 5 1300 * 

### 5 7

-

- 

### 5 9

-

- 

### 5 9 6 0

- m» 

### 6 0 4 9

• ^
• ^ 

### 4 9 ^

- 

### 4 9 5 0

-

• •• • - 

### 5 0 5 5

-

- \ 4 7

— 

### 4 7 4 8

-

. . . mm . 

### 4 8 23 0

225 . 233. 8 (Avg . E V - 229.4 ) 228. 8 4,65 6

221. 3 23 0 (Avg . £t / » 225.7 ) 4,58 1 133 0 6 3 50. 5 3 7 - - • J.40 0 NOTE : Pou r secon d batc ho f resi n mixtur e int o proces s equipmen t 6 3 50. 5 3 7 - (Est . F V « 226 ) 140 5 NOTE : F

V measure d ove r uncovere d resi n bat hcove r i s 12 0 FPM 4,58 7

a DB T top s 

### HJB T *R H ' « % « *F V i 7 FP M Dr y

Bul bTemperatur e degree s Fahrenhei t Ve t bulb - Temperatur e Relativ e Humidit y Percen t Fac e Velocit y Fee tpe rMinute flowrat e base d o n averag e o f inle tan

d outle tF

V measurement s fo rtes tperiod , typicaU y 1-hou r 'CF M a Cubi c Fee tpe rMinute 

# U c vDaRo s Assoclates/CH2M HIL L - Januar

y 31 , 199 4 RE : Styren

e Emission s fro

m a Continuous Fibe r Pultrusio n Proces s PAGE : 8 o f 1 0
Tabl e 2 (continued) . Tota l Temporar y Enclosur

e Operatin

g Parameter s TIM E DBT 1 WBT 3 RH 4 Inle t FV 6 (2 4 Hr. ) («T 2 ) (*F ) (%* ) (PPM 7 ) Outle t F

V Avg . Volumetri c (FPM ) Flowrate 1 (CFM 9 ) 141 0 NOTE : Proces s stabl e wit hcover ope

n 24 0 141 5 143 0 144 5 145 0 6 3 50. 5 3 7 22 4 23 0 21 3 (Avg . F

V * 226.8 ) 4,60 3 150 0 153 0 155 0 155 5 160 0 6 4

6 4 6 4 5 2

5 2 5 2 4 2

4 2 4 2 236. 3

23 0 (Avg . F V « 233.2 ) 4,73 3 161 0 NOTE : Cover dow n 162 0 NOTE : Fa

n No . 1 operational , Fa n No . 2 shut-dow

n 162 5 - 143. 8 163 0 6 4 5 2 4 2 163 5 - 14 0 164 0 NOTE : F

V measure

d ove r resin bat

hcove r i s 9 9 FP

M 172 5 - 163. 8 (Avg . F V - 149.2 ) 173 0 6 2 - x - - - 3,02 8 173 5 NOTE : Al l fan s shut-dow n [natura l draf t ventilatio n only ]

- 7 7 180 0 5 8 5 0 5 6 - 180 5 NOTE : Pou

r thir d batcho f resin int o proces s equipment

- - - - 103. 8 181 0 - 62. 8 (Avg . F V « 80.9 ) 181 5 NOTE : F

V measure

d ove r resi n bat

hcove r i s 5-2 0 FP

M 1,64 2 183 0 185 0 185 5 190 0 193 0 5 9 .

-

- 6 0 5 7 5 0

-

- 5 1 4 9 5 2

-

- 5 3 5 5 87. 5

77. 5 (Avg . F V • 82.5 ) 1,67 4 193 5 NOTE : Proces s stabl e wit hcover ope n

- - - 10 0 10 9 194 0 - - - 12 3 194 5 - 10 0 200 0 5 6 4 8 5 5 - 200 5 9 6 201 0 - 12 1 (Avg . F V « 108.2 ) 201 5 NOTE : F

V measure

d ove r resi n bat

hcover i s 5-2 0 FP

M 2,19 6 

# £ 7 aP.6 9 

# TUZ£%S K 

# " . saw * — —*~" s PAGE : 9 o f 1 0 Tabl e 3 . Summar

y o f Styren e Emission s Time Perio d (2 4 hour ) Volumetri c

Flowrate , (CFM 1 ) INLE

T conc. 2 , Rate * (PPMv 3 ) (lbs/Hr* ) OUTLE T conc. , Rate , •?••*£ . (PPMv ) (lbs/Hr ) Rate , (lbs , Cove rDown

, TIE 5 FV» * 190. 6 FEM 7 "iOO O - 105 0 3,86 8 0.6 6 Cove rDown

, TI E FV « 229. 4 FK

4 110 0 - U5 5 4,65 6 0-4 9 Cove rDown

, TI E F V - 225. 7 IS

M 1200-125 5 4,58 1 0.5 1 0.04 4 0.0 4 0.04 1 3.8 5

3.7 4 3.0 2 

# • - -**2-*n5S ' """ef

tm 

# Si * TM « 130 0 - 140 5 4,58 7 «•»• * Cove rOpen, TT

E FV-^226. 8 FP

M 141 0 - 145 0 4,60 3 0-8- 5 Cove rOpen, TI

E F V « 233. 2 FB I 15O 0 ^160 0 4,73 3 0.6 4 Cove rDown

, TI B F V - 149. 2 FP

M 161 0 - 173 0 3,02 8 *-0 1 Cove rDown

, TI E F V - 80. 9 FP

M 173 5 - 181 5 1,64 2 1-8 2 Cove rDown

, TI E FV « 82. 5 FP

M 1830-193 0 1,67 4 1.3 2 Cove rOpen

, TT E F V - 108. 2 FP

M 193 5 - 201 5 2,19 6 0. 6 0.06 8 0.053. . 0.05 3 0.05 2 0.03 8 0.02 3 15.2 2

14. 0 5.5 4 6.6 3 4.9 4 8.2 7 0.25 9 0.30 1 0.24 1 0.68 6 1.21 9 1.15 3 0.29 2 0.18 9 0.14 4 0.31 6 0.21 5

0.26 1 0. 2 0.61 9 1.15 1 1. 1 0.23 9 0.13 7 0.10 6 0.29 3

*CF M « 2 conc . s 'PPM V a 4 lbs/H r » 5 TT E a Sp y « 7 FP M a Cubi c Fee t pe r Minut e concentratio

n Part s pe r MilUon , volum e pound s pe r hou r Tota l Temporar

y Enclosur

e Fac e Velocit y Fee t pe r Minut e 

# c? Ci~P.7 0

DaRo s Associates/CH2 M BILL - Januar y

31 , 199 4 RE : Styren e Emission s fro m a Continuou s Fibe r Pultrusio n Proces s PAGE : 1 0 o f 1 0

T o determin e th e presenc e o f aceton e vapor s i n th e inle t an d outle t sample d ga s streams , gra bsample s wer e coUecte d and analyze d usin g a Hewlett-Packar d (HP) , Mode l 5890 , Ga s Chromatograph(GC) . Fiv e cubi c centimete r aliquot s o f eac h o f th e composite d sampl e stream s wer e injecte d ont o th e G C an d separate d usin g a si xfoo t b y

1/ 8 .inc

hglas s colum

n packed wit h1 % SP-100 0 o n Carbopak , 80/10 0 mesh . Th e chromatogra m wa s obtaine d usin

g a n isotherma l progra m a t 22 5 degree s Centigrad e a t 3 0 cc/minut e nitroge n carrie r ga s throug hth e colum n wit hcomponen t detectio n b

y FI D wit hhydroge n fuel-Th e G C wa s calibrate d usin g standard s o f aceton e and styren e prepare d on-sit e l n ne w 4 0 L tedla r bag s f lUe d wit ha know n volume o f ultrapur e ai r a s wel l a s th e NIS T traceabl e styren e l n ai r ga s mixture . Chromatographi c dat a wa s recorde d using a H P 3393 A Reportin g Integrator . Copie s o f th e ra w

dat a ar e presente d I n th e appendi xt o thi s report . Tes t Result s Tabl e 3 present s a summar y .o f th e styren e emissio n tes t results . Th e styren e emissio n rat e wa s calculate d b y subtractin g th e inle t mas s rate , o r background VOC , fro

m th e outle t mas s rat e t o arriv e a t a correcte d hourl y rate . Ga s chromatograph

y result s o f sample s coUecte d t o determin e backgroun d concentration s o f potentia l aceton e interferenc e indicate d insignifican t level s an d wer e no t use d t o correc t any o f th e data . Copie s o f th e date , dat a reduction , a sanpl e calculatio n showin g ho w th e result s wer e derived , an d proce s dat a suppUe d b

y Glasform s ar e presente d i n th e appendi xt o thi s report . I f yo u hav e any

question s o r requir e additiona l information , pleas e d o no t hesitat e t o contac t m e a t (408 ) 864-5998 . Sincerely , 

# ^v— 1 2 Bruc e C . DaRo s Principa l
Enclosure s

FIL E D16::40130CH2.WP 

### <o°> Of-P.7 1

DaRo s ^aUmtmiam HIL L - ^SL^^S^ m Proces s RE : Styren e Emission s fro m a Continw u PAGE : Append ^

APPENDI X



# 7 0P.7 2

DaRo s .Assoc.Lates/CB2

M BIL L - Januar y

31 , 199 4 RE : Stvren e Emission s fro a a Continuou s PultrusionProces s PAK : Appendi x QUALIT Y ASSURANCE/ptJAL

m CONTRO

L Qualit y Assurance/Qualit y Contro l wa s maintaine d a s follow s durin g th e conduc to f

emissio n testin g an d dat a reduction : 1 . Al l portion s o f

th e samplin g syste m whic h contac tth e sample , zero , o rspa n gase s ar e TeflonTM , TedlarTM , PyrexTM , stainles s steel , quartz , o rplatinum . 

### 2 . A U samplin g equipmen ti s properl y maintained an d calibrate d an

d wa s cleane d prio rt o testing . 3 . Th e samp i in g equipmen twa s lea k checke d prio rt o th e initiatio n o f testin g and a tth e completio n o f

th e tests . Additiona l lea k test s wer e performe d o n a n 'a s needed ' basi s followin g any disruptio n o rupse tt o th e samplin g system . 4 . Th e samplin g syste m was zeroe d an d spanne d befor e and afte reac h tes tru n t o determin e instrumen tdrift . 5 . An y drif tdetecte d afte rtb e initia l calibratio n wa s recorde d and use d t o correc tth e data . 6 . -Wher e possible , stratificatio n check s wer e performe d to-determin e i f stratificatio n o f

th e stac k gase s exists . Generally , thoroug h mixin g wa s eviden ta ta U samplin g locations . 7 . Onl y th e highes tpurit y reagent s an d know n standard s wer e used .



# K ^P.7 3

DaRo s A8SOclates/CH2 M HIL L - Januar y 31 , 199 4 RE : Styren e Emission s fro m a Continuou s Pultrusio n Proces s PAOE : Appendi x
SPECIFICATION S O

F CONTINUOU

S EMISSIONS MONITORIN G ANALYZER

S FO REMISSION S ANALYSI S ANALYTE: ANALYZE RMANUFACTURER

: MODEL : .PRINCIPL

E O F DETECTION : RANGE S O F DETECTION : •SENSITIVITY : NOISE LEVEL : PRECISION : RESPONS E TIM E ( O - 90V) : PRECISION : OPEMTINO'TEMPERATUR E RANGE : AMBIENT HUMIDIT YLIMITS : ZER O DRIFT : SPA N DRIFT : LINEARITY : MEE T O REXCEE D O S EP A REQUIREMENTS : MEE T O REXCEE D CAR B REQUIREMENTS : MEE T OR EXCEE D BAAQM D REQUIREMENTS : Hydrocarbon s Beckma n 40 0 Flam e Ionization XI , XlO , X100 , XI,00 0 0 - 1 pp m t o 0 - 2 % ful l scal e a s methan e Unknow n +/ - 1 % fu Uscal e 0. 6 second s ( 3 lpr

a bypass ) 3 2 - 11 0 degree s F 95 % R H +/ - 1 % fu Uscale/2 4 hour s +/ - I t fu Uscale/2 4 hour s Unknow n YE S YE S YE S

FU E 0A12::CEWIST.W P 

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# WP.9 6 MATERIA L SAFET

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SECTIO N I I COMPONENT S tmponent s ar e liste d b t thi s sectio n I f the y .presen t a yslca l o r healt h hazar d an d ar e presen t a t o r abov e ; i n th e mixture . I f a componen t i a identifie d a s a J-tCINOGB-

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SECTIO N I V FIR S -AN O EXPLOSIO N OAT A H POINT : Metho d Identified . OSlO N LIMITS : Fo r produc t i f known . Th e lowse t o f th e component s fcs liste d fo r mixtures . ROOU S DECOMPOSITIO N PRO0UCTS : Know n o r ,te d hatardou s product s resultin g fro m heating . if l o r othe r reactions . g^CHO M I V front.) EXTINGUISHIN G MEDIA* Followin g Protectio n Associatio n criteri a Nationa l Fir * FIREFIGKTIN O PROCEDURES : Minimu m equipmen t t o protec t firefighter s fro m toxi c product s o f vaporisation , combustio n o r decompositio n i n fir e situations . Othe r firefightin g hazard s ma y als o b e Indicete.d . SPECIA L FIR E AN O EXPLOSIO N HAZARDS : State s " hazard s not covere d by othe r sections . NFPA CODES : Hazard rating s assigne d b y th e Nationa l Fire Protectio n Association .



### ffgenowY HEALT H HAZAR D OATA ^ PERMISSIBL E EXPOSUR E LIMIT : Fo r produc L THRESHOL D LIMI T VALUE : Fo r produc t EFFECT S O F ACUT E OVEREXPOSURE : Potentia l loca l an d systemi c effect s due t o singl e o r shor t ter m overexposure t o th e eye s an d ski n o r throug h inhalatio n o r ingestion . EFFECT S O F CHRONI C OVEREXPOSUR E Potentia l loca l an d systemi c effect s du e t o repeate d e r lon g ter m overexposure t o th e eye s an d ski n e r throug h inhalatio n e r ingestion . FIRS T AlOt Procedure s t o b e followe d whe n dealin g wit h accidenta l overexposure . PRIMAR Y ROUT E O F ENTRY : Base d o n propertie s an d expecte d use . SECTIO N V I

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T PAI A * HAZARDOU S POLYMERI.ZATION : Condition s t e evoi d t o preven t hazardou s polymerisatio n resultin g i n a larg e 'releas e o f energy . •STABILITY : Condition s t o avoi d t o preven t hazardou s o r violen t decomposition , INCOMPATIBILITY : Material s an d condition s t o avoi d t o preven t hazardou s reactions .

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A TYP E AR/H T 8.1 9 1188 1 P P 8.16 6 8.3 5 1285 4 P V 8.89 3 8.4 4 18189 8 V B 8.89 5 2.7 1 4293 6 B P 8.82 7 15*56*2 6 • .
AREA * 4.45 2 4.87 9 73.29 2 17.37 7 

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TOTA L AREA

s 24788 8 MU L FACTOR

S 1.8888E-t-8 8 

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### R T 8.9 3 8.3 2 8.7 2 7.5 4 ARFA

TYP E 93 6 B B 4S48 6 BV P746 8 V B 1316 3 B

V AR'H T 8.96 7 8.26 7 8.36 5 8.37 4 AREA *

1.87 6 52.28 7 31.58 2 15.13 5 TOTAL AREA s 8697 3 HU L FACTOR * 1.8888E+8 0 

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B UORKFILE NAHE * AREA* R T 8.1 9 8.3 3 8.4 3 8.7 2 7.5 3 58.6 8 ARE

A TYP E 362 4 B

V 2563 1 V

V 2669 6 W 2496 8 V

B 5589 5 B B 66 2 D P B AR/H

T 0.16 9 8.14 2 8.19 4 8.38 5 8.37 8 8.81 5 16*57'8 4

AREA * 2.65 2 18.75 4 19.53 3 18.26 3 48.31 3 8.48 4 •l.-»|-1C-*'4 V * •

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TOTAL AREA

s 13667 8 NU L FACTORS !.9988E-t8 8 te « VGo-Kdr \$fi? 

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A TYP E AR/H

T 817 9 P

V 8.14 6 6532 7 V

V 8.29 5 5551 2 V

B 8.45 6 651 5 B B 8.35 7 19'23'8 2

AREA * 6.83 5 48.28 8 48.95 8 4.88 7 TOTAL AREA

s 13553 8 HU L FACTOR

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A TYP E 818 7 B

V 6812 3 V

V 4636 6 V

B 7942 8 8 8 194A2 8 1 aaaac+aa AR/H

T 8.15 4 8 26 7 8.41 3 8.37 2 tc « 19-49*1 3

AREA * 4.17 9 38.98 9 23.89 8 48.93 5 

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A TYP E AR/H T 0.1 9 985 5 B V 8.15 5 0.3 2 6448 6 W 8.27 3 0.7 1 ' 4884 7 V B 0.48 2 7.3 9 18387 8 B B 8.37 5 28*81'2 2

AREA * 4.34 2 28.37 6 21.52 1 45.76 1 ..... r .

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A TYP E AR/H T 334 8 B V 8.15 3 7784 1 VB 8.63 3 23776 8 B B 8.37 9 AREA * 1.85 9 24.48 5 74.54 5 TOTAL AREA = 31895 8 HUL FACTOR S 1.8988E+8 B e.*f*i f 

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TYP E AR/H T AREA * --81 6 B P 8.85 6 8.23 9 5493 2 P B 8.44 6 16.18 2 28548 8 V B 8.38 8 83.65 8 TOTA L AREA s 34114 0 NUL FACTORS . 1.0888E+8 8 ic e 

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N t 5 JAN/12/9 4 UORKFIL E ID ' B UORKFIL E NAHE ' AREA * R T 8.8 2 8.3 3 7.4 5 TOTA L AREA * ARE A

TYP E AR/H T 244 8 B V 8.18 8 3835 8 V V 8.31 8 18612 8 B B 8.38 8 < \ Z-CQ < 

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TYP E AR/H T 346 9 B V

9.12 6 3828 6 W

8.32 8 18961 8 B B 8.38 8 TOTA L AREA = 15136 8 NU L FACTOR S 1.8889E48 A AREA * 2.29 2 25.29 4 72.41 4 tu o 

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TYP E 188 1 P V 4329 1 W 2145 9 V B 4568 8 P B AR/H T

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v «P.3 1

SECTIO N 3 : AI R QUAUT Y MANAGEMEN T DISTRIC T APPROVAL S
Th e followin g .Ai r Quafit y Managemen t District

s hav e accepte d thi s repor t an d approve d th e styren e emissio n facto r o f 0.81% : 1 . Ba y Are a Ai r Qualit

y Managemen t Distric

t 93 9 Elli s Stree

t Sa n Francisco . Californi a 9410 9 (415)771-600 0 (415 ) 928-856 0 FAX 2 . Departmen t of Healt h Jefferso n County , Alabam a 140 0 Sixt h Avenu e Sout h P.O . Bo x 264 8 Birmingham , Alabam a 3520 2 (205)933-911 0 3 . Ai r Pollutio n Contro l Distric t Count y o f Sa n Dieg o 915 0 Chesapeak

e Drive Sa n Diego , Californi a 92123-109 6 (619)694-330 7

n JP.3 2

SECTIO N 4 : ENFORCEMEN T
Enforcemen t a t bot h th e Ba y Are a Ai r Qualit y .Managemen t Distric

t an d th e Jefferso n Count

y Departmen t of Healt h consist s of reportin g th e amoun t o f styren e purchased a s monome r an d i n resin s containin g styren e o n a yearl y basis . Thi s dat a reporte d i s th e sam e a s tha t submitted t o th e EP A unde r SAR A 31 3 Forn i R . Th e respectiv e district s the n use th e amoun t o f styren e purchased pe r year , i n eithe r pound s o r gallons , time s th e emissio n facto r i n orde r t o determin e th e styren e emission s for th e facilit y involved . EXAMPLE: 1 BAAQM D EMISSIO N CALCULATION S FO R PULTRUSIO N MACHINES : Emissions ^ (resi n throughput)(%styrene)(styren e densHy)(emlsslo n factor) * Fo r S- 1 Pultrusio n machin e o.oZ4f 73f r Zfiz Emissions=(897 1 gal/yr)(0.435)(7. 6 lb/gal)(O£081)=24 O lb/yr/36 5 days/yr=D£t f Ib/da y styren e
* Th e Distric

t assumes a styren e densit y o f 7. 6 lb/ga l an d a wors

t cas e maximu m styren e conten t of 43.5 % styrene=0.43 5
1 : FAX fro m .Ale

x Saschin , Ai r Qualit

y Enginee r II , Permi t Services Division , BAAQMD , Apri l 19,1996 .Docket No . A-94-5 2 Categor y II- B Th e following information i s locate din the confidentia l file s ofth e Director , Emissio n Standard s Division , Offic

e of Ai r Qualit y Plannin g an

dStandards , U.S . Environmenta l Protectio n Agency , Research Triangl e Park , Nort h Carolin a27711 . Thi s information i s confidentia

l pendin g fina

l determinatio n b y the Administrato r an di s no t availabl e fo

r publi c inspection . 1 set o f photo s = 31 ; 1 vide o tape ; 1 cassett e tape ; 1 diskett

e 1 copy CB I Sit

e visit Repor t (Plan t Comments - 4/22/98,12 4 pp . Confidentia l Busines s Informatio n locate di

n CN-N801-12/ES D 98185-C18-02 .



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