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# OAR Box 1384 Prepped by Charmelle Mathews



### Document

Number: 

# 67 ) ll-E-2 7 Docket Number: 

# A-94-5 2

Printed 7/2/2008 8:42:05 AM Sheet 67 of 264P. 2 V 

## jr-^-2 7 ODD O a MEMORANDU M TO : Madelein e Strum , EPA/ES D FROM : Gre g LaFlam , PE S DATE : Augus t

25 , 199 5 L:/N30 8 SUBJECT : Pre-MAC T Tea mTeleconferenc e o n Pollutio n Preventio n I . Purpos e Th e purpos e o f

thi s meetin g wa s t o shar e informatio n o n arecen t pollutio n preventio n tes t

progra man dt o discus s tw o additiona l fabricatio n processe s tha t offe r a potentia l fo r

lo w styren e emissions . II . Locatio n of

Meetin g an dParticipant s Place : U.S . Environmenta l Protectio n Agenc y

N.C . Mutua l Lif

e Building , Roo m101 9 Durham , N C Date : Jul y 31 , 199 5 Participants : Bija n Ataian , SCAQM D (909 ) 396-245 4 Mark Bahner , RT I (919 ) 541-601 6 Jeffrey Best , PE S (919 ) 941-033 3 Da n Boyd , industr

y consultan t

(410 ) 827-6244 Mark Callicut , Reichhol dChemical s (919 ) 990-801 3 Ami r Dejbakhsh , SCAQM D (909 ) 396-261 8 Chuc k French , EPA/OAQP S (919 ) 541-046 7 Eri c Goehl , Radia n (919 ) 461-136 7 TomHedger , Magnu mIndustrie s (813 ) 573-295 5 Mar k Hollenbech , Coo k

Composite s (816 ) 391-6044 Kenneth Jacobs , Liqui dContro l Corp . (216 ) 494-131 3 Nor mKaplan , EPA/OR D (919 ) 541-255 6 Bo b Lacovara , CF A (703 ) 524-333 2 Gre g LaFlam , PE S (919 ) 941-033 3 To mMaves , Ohi o EP A (216 ) 963-120 5 Stev e McNally , CF A (703 ) 524-333 2 Arnol dMedbery , EPA/OSDB U (703 ) 305-517 1P. 3

Madelein e Stru m Augus t 18 , 199 5 Pag e 2 Richar dNielson , Clark County , N V (702 ) 383-127 6 Carlo s Nunez , EPA/OR D (919 ) 541-115 6 Bria n Palmer , Radia n (919 ) 461-121 8 Nanc y Pate , EPA/OAQP S (919 ) 541-534 7 Everet t Pearson , TP I Inc . (401 ) 245-120 0 Solomo n Ricks , EPA/OAQP S (919 ) 541-524 2 Ton y Sasson , Ohi o EP A (216 ) 963-120 5 Joh n Schweitzer , Composite s Institut e (313 ) 668-470 3 Jorda n Spooner , EPA/OPP T (202 ) 260-441 8 Madelein e Strum , EPA/OAQP S (919 ) 541-238 3 Georg e Tuni s III , Hardcor e Composite s (302 ) 427-925 0 III . Discussio n Ms . Stru mopene dth e meetin g b y askin g th e attendee s presen t i n th e meetin g roo mt o introduc e themselves . Sh e sai dtha t thi s meetin g woul db e simila r t o th e previou s pre-MAC T tea mteleconferenc e (vendo r presentation s o n severa l add-o n contro l options) , bu t

wit h th e them e o

f pollutio n preventio n (P2) . Mr . Spooner , wit h EPA' s pollutio n preventio n division , state dtha t hi s rol e wa s t o b e apollutio n preven tio n advocate , an dt o presen t t o th e grou p th e availabl e polic y options . Th e remainde r

of th e meetin g consiste do f presentation s give n b y participant s i n arecen t EP A progra mt o asses s option s for preventin g pollutan t

emission s from sprayu p an dge l coatin g operations , an db y industr y representative s of

tw o fabricatio n processe s wit

h reduce dstyren e emissions . (Descriptiv e materia l relate dt o thes e presentation s wa s distribute dt o th e tea ma s a n enclosur e t o th e meetin g notic e date d Jul y 21 , 1995. ) EPA/OR D Pollutio n Preventio n Progra m Mr . Bahner , acontracto r t o EPA/ORD , presente dpreliminary result s o f arecen t tes t program . H e describe dth e tes t objective s as : 1 ) comparin g amas s balanc e approac h fo r determinin g emission s t o EP A Metho d25 A (tota l hydrocarbo n analyzer ) emissio n measurements ; 2 ) establishin g baselin e emissio n result s (fro m"uncontrolled " material s an dpractices ) t o compar e wit h result s frompollutio n preventio n techniques ; an d 3 ) determinin g emissio n reduction s for avariet y o f approache s tha t

include dchange s t o operationa l parameter s an dwor k practices , resi n an dge l coa t formulations , an d appUcatio n equipment .P. 4

Madelein e Stru m Augus t 18 , 199 5 Pag e 3 Th e testin g utilize d"controlled " sprayin g ( aP 2 technique) , amor e refine d applicatio n techniqu e designe dt o resul t i n les s overspra

y tha n typical spraying . Thi s chang e i n operato r

spra y techniqu e wa s foun dt o hav e a n effec t i n reducin g emissions . Othe r change s foun dt o affec t

emissio n level s wer e low-styren e an dstyrene-suppresse d ge l coat s an dresins , an dswitchin g fromspra y gun s t o flo w coater s an dpressure-fe d resi n rollers . N o significan t differenc e wa s foun dbetwee n air-assiste dairless , HVLP/ externa l mix , an dHVLP/interna l mix spray guns . Also , ove r th e velocit

y rang e tested , ai r velocity wa s no t

foun dt o hav e asignificant effect . Finally , us e of

abenzoy l peroxid e (BPO ) catalys t

di dno t significantl y reduc e emission s compare dt o amethy l ethy l keton e peroxid e (MEKP ) catalyst . Th e result s of

th e testin g tende dt o confir man earlie r

findin g tha t

emissio n factor s wer e approximatel y 2. 3 time s highe r than th e midpoin t

of th e AP-4 2 facto r rang e fo r thes e operations . Individual reductio n measure s wer e foun dt o lowe r styren e emission s b y u p t o approximatel y 4 0 percent . Question s an ddiscussio n followe dMr . Banner' s presentation . Spooner : Wha t d o yo u conside r

a"significant " emission s difference ? Nunez : Greate r tha n abou t

1 0 percent . Nunez: Ho w d o "normal " an d"controlled " sprayin g compare ? Hedger , Lacovara : Controlle dsprayin g ha s bette r transfe r efficiency , les s waste dresin . Mor e styren e i s los t

fromth e thi n fil

mo f overspray , which cure s mor e slowl y tha n th e thicker laye r o n th e mold . Nielson : I s EP A Metho d25 A specifi c fo r measurin g styrene ; ar e emission s measure da s highe r o r lowe r usin g thi s method ? Bahner : Styren e wa s th e only VO C presen t

i n th e materials , s o th e measurements i n thi s cas e represente d styren e emissions . Lacovara : I n th e CFA-sponsore dtestin g a t Do w Chemical , measurement s usin g Metho d25 A an dareal-tim e ga s chromatograp h showe dgoo d agreement . Strum : Wer e airles s spra y gun s tested ? Banner , Lacovara : No , thes e gun s ar e bein g phase dou t i n thi s industry an dthei r us e i s no t

common . However , sinc e the y ar e stil l i n us e at som e facilities , the y ma

y b e adde dt o th e CF A Phas e I I testin g program . Mr . Hollenbech , Coo k

Composite s an dPolymers , discusse dth e ge l coat supplie db y hi s compan y fo r th e testing . Thi s ge l coat , whic h ha s alo w styren e conten t (abou t 2 5 percent ) an davapo r suppressant , i s stil l undergoin g fiel dtestin g an di s no t ye t commerciall y available . H e state dtha t th e propertie s of

thi s produc t

ar e compara bl e t o th e bette r

ge l coat s tha t

ar e availabl e (bu t

no t th e to p o f

th e lin e products) . I t i s presentl y bein g produce donly i n whit e an doff-white . Intende dapplication s ar e i n th e marine , sanitary (tubs , etc.) , an dtransportatio n markets . Mr . Hollenbec h conclud

e db y cautionin g tha t

establishin g standard s o n th e basi s o f thi s produc t

woul db e premature .P. 5

Madelein e Stru m Augus t 18 , 199 5 Pag e 4 Durin g question s an ddiscussion , Mr . Hollenbec h relate dtha t thi s ge l coat

ha s ver y goo dproperties , bu t

som e tackiness , an dlower shrinkag e tha n normal . Whil e th e actua l formul acontain s bot h styren e an dmethy l methacrylate , th e produc t teste d containe donly styrene . McNally : I s th e curren t restrictio n o n color s alimitatio n o f th e produc t

o r merel y aproces s issue ? Hollenbech : A ful l rang e of color s fo r

th e produc t i s technicall y possibl e an dth e compan y plan s t o offe r severa l colo r

choice s i n th e future . Also , th e produc t ha s ahighe r

cos t tha n norma l ge l coats , bu t du e t o th e highe r solid s filmles s ma

y b e neede dt o buil dth e surfac e layer . Th e produc t ha s bee n availabl e fo r

approximatel y 1 yea

r an di s presentl y bein g use db y som e facilities . Mr . Callicut , Reichhol dChemicals , briefl y describe dth e low-styren e an d styrene-suppresse dresin s supplie db y hi s compan y fo r th e tes t program . Thes e resin s containe dingredient s t o promot e goo dsecondary bondin g despit e th e presenc e of th e suppressant , an dwettin g agent s t o compensat e fo r th e lowere dstyren e content . A resi n syste mcontainin g filler s wa s no t tested . I n respons e t o aquestion , Mr . Callicu t sai dtha t th e suppressedresi n containin g extr awa x (t o furthe r

suppres s emissions ) coul db e use di n an y applicatio n a s lon g a s goo dsurfac e preparatio n wa s carrie dout . LaFlam : Wha t i s th e potentia l effec t

o n emission s whe n usin g BP O versu s MEK P catalysts ? Callicut , Banner : Th e selectio n o f catalys t woul dprobabl y no t

b e alarg e factor . Emission s measure dfromth e tw o resin/catalys t

formulation s i n th e recen t tes t progra mshowe dn o significant difference . Mr . Hedger , Magnu mIndustries , describe dth e thre e type s o f spray gun s supplie db y hi s company for th e tes t program . H e sai dthat , sinc e atru e HVL P syste m (a s use dfo r

painting ) coul dno t

b e use dfor

resi n products , th e HVL P use dher e wa s actuall y amodifie dair-assiste dairles s syste man ds o bot h gu n type s showe dsimila r emissio n levels . Spooner : What i s th e prevalenc e of

flow coater s an dpressure-fe d roller s versu s spray gu n technology ? Hedger : Flo w coater s ar e use dapproximatel y 5: 1 ove r roller s (roller s hav e limitation s whe n makin g larg e o r comple x shape dparts) , an d th e tw o type s of

equipmen t

accoun t for abou t 3 0 percen t

o f sale s i n th e ope n moldin g sector . Ge l coat s mus t

stil l b e applie dusin g spray equipment . Alternativ e Low-Emissio n Fabricatio n Processe s Georg e Tuni s III , Hardcor e Composites , discusse davacuu minfusio n fabrica

tio n proces s terme dth e Seema n composit e resi n infusio n moldin g proces s (SCRIMP) . Thi s proces s i s jointl y controlle dby Bil l Seeman , Hardcore , an dTP I Incorporate d (Everet t Pearson) . Othe r

companie s wishin g t o utiliz e th e proces s ar e assesse da n 

### initial fe e (whic h include s training ) an d the n a royalt y ( 5 percen to f

laminate) .^ 6 _

Madelein e Stru m Augus t 18 , 199 5 Pag e 5 Mr . Tuni s state dtha t SCRIM P i s simila

r t o traditiona l vacuu mbaggin g an d resi n transfe r

molding , bu t

ha s severa l advantage s an dproduce s superio r qualit y parts . Th e proces s i s bes t

suite dfo r

large r part s wit h lo w productio n quantities . Part s produce dinclud e oi l rigs , railcar s an dferr y bumpers , bridg e sections , Nav y vesse l components , an dairfram e parts . SCRIM P produce s composite s o f u p t o 70-7 5 percen t fiber conten t b y volume , an di s effectiv e wit h 50-10 0 oz . clot

h reinforcement s (u p t o 20 0 oz . cloth s ar e anticipate di n th e future) . Laminate s u p .t o 6 inche s thic k

wit h severa l layer s o

f cor e material s can b e produced . Al l reinforcements , trusses , an d cor e material s ar e place di n th e mol dan dseale db y abaggin g system . Th e bag s can b e compose do f

asilicon e material , whic h ma y b e use dman y times , o r of aone-time us e materia l whic h provide s asmoothe r finis h o n th e insid e surface . Th e baggin g syste mi s seale dt o th e material s usin g asimpl e "zi p lock " syste man db y appUcatio n o f vacuum . Resi n i s distribute dunde r th e baggin g syste mb y wa y o f a n "arter y an dcapiUary " distributio n network . Sinc e resi n i s infuse dafter avacuu mi s apphe d t o th e bagge d system , ther e i s n o direc t exposur e of

uncure dresi n t o th e air . Cross-linkin g i s enhance d du e t o lo w styren e los s an dvoid s ar e essentiaU y eliminated , resultin g in laminat e comparabl e i n quality t o aerospac e epoxy composites . T o ge t a n ide aof

emission s fromth e SCRIM P process , activate dcarbo n filters wer e installe di n th e lin e t o th e vacuu mpump . Measurement s indicate dtha t only 0.006 1 percen t

o f th e styren e pu t

int o th e moldin g proces s appear s i n th e vacuu m pum p exhaus t

stream . Strum : Hav e weight s bee n recorded ? Pearson : Mea

surement s sho w les s tha n a0. 1 percen t weight los s betwee n th e resi n infuse dan d tha t endin g u p o n th e part . Mr . Tuni s compare dstyren e emission s fromth e moldin g of 3 0 millio n l b o f

resi n a s 20-9 0 ton s usin g conventiona l ope n moldin g versu s only 20-9 0 pound s usin g th e SCRIM P process . Mr . Pearso n emphasize dth e cleanlines s of th e SCRIM P wor

k environmen t

an d th e fac t tha t worke r moral e ha s bee n improve dt o afantasti c degre e i n th e 2 year s hi s compan y ha s bee n usin g SCRIMP . Saving s ar e realize ddu e t o reduce dlabo r an d cleanu p materials , an di n lowe r plan t ventilatio n rate s (th e TP I plan t use s n o exhaus t fans) . McNally : Ar e an y part s no t abl e t o b e SCRIMPed ? Pearson : SCRIM P i s no t competitiv e fo r

man y part s (suc h a s tubs/showers ) produce db y sprayup , bu t furthe r developments i n preform s (reinforcement s premolde d int o th e fina l shap e usin g a binde r system ) wil

l likely chang e this . Mr . Jacobs , Liqui dContro l Corporation , discusse dth e resin-transfe r moldin g (RTM ) process . Th e proces s use s metering , mixing , an ddispensin g equipmen t t o injec t catalyze dresi n a t

4 0 t o 5 0 ps i pressur e int o aclose dmol dcontainin g glas s reinforcement . Th e proces s i s mos t suitabl e for

smalle r parts , suc h a s bathtubs , produce da t

moderat e productio n rates . Th e ge l coa t i s spraye dont o th e mol dhalve s prio r t o par t moldin g usin g conventiona l sprayin g techniques . Th e RT M proces sP. 7



### Madelein e Stru

m Augus t 18 , 199 5 Pag e 6 differ s fromth e SCRIM

P proces s i

n tha t part s wit h two finishe

dside s ar e produced . Also , RTM use s hard , two-par t mold s tha t ca n withstandconsiderabl e moldin g pressure . In RTM , resin move s along fibe r bundle s paraUe

l t o th e fiber

direction , while i n th e SCRIM

P proces s resin move s ove

r th e fiber layer s an ddow

n through th e fibe r bundles . I

n respons e t o aquestion , Mr . Jacob s indicate dtha t ther e i s n o licensing fee fo

r th e us e o f th e RT M process . Ms . Stru

mnote dthat , pe r

th e 1982 articl e o n RTM distribute dt o th e tea mbefor e th e meeting , MF G selecte dRTM fo r making bathtubs , bu t

it wa s no t know n whethe r th e compan

y wa s still engagedi

n thi s effort . Representative s o

f CF A saidtha t acompendiu

mo f article s o n RT

M woul d b e pubUshe di n 6 0 to 9 0 days . Nex t Step s Ms . Stru mencouragedth e team/Wor k Group member s t o provide an y comment s they hav e o n an

y aspec t o f th e pre-MAC T decision t o hersel f o r t o Gre g LaFla ma t PES . Wit

h regar dt o th e nex

t meeting o f th e team , sh e propose dth e issue o f subcategorizatio n o

f th e industr

y fo r regulator y purpose s a s th e mai n topi c fo r th e meeting . Mr . Bahne

r saidtha t RT I i s preparin g arepor

t on emission s fromth e variou s processe s an dth e implication s fo r th e MAC T floo r determination . Thi s repor t should b e read y in August . Ms . Stru

mfel t that thi s repor t coul db e distribute dt o th e tea

m an dthe n discusse

da t th e nex t meeting .