p. 1 

# OAR Box 1394 Prepped by Ollie Stewart



### Document

Number: 

# 19 ) ll-B-1 4 Docket Number: 

# A-94-5 2

Printed 7/3/2008 7:22:11 AM

Sheet 19 of 57P. 2 

### A-94-5 2 

# ll-fi-l f

FINA L NONCONFIDENTIAL SIT E VISI T REPORT PE RCOMPAN

Y REVIE W TO : Madelein e Stru m

U.S . Environmenta

l Protectio n Agenc

y FROM : Kennet

h R . Meardo n an d Melani e Procto r Pacifi c Environmenta

l Services , Inc . DATE : Apri l 22 , 199 7 SUBJECT : Sit

e Visi t t o Cyte c Industrie s I . Purpos e Th e purpos e of

thi s visi t wa s t o discus s emissio n reductio n measure s considere d an d implemente d b y Cyte c Industrie s i n suppor t of th e developmen

t o f MAC T standard s fo

r th e BMC manufacturin g subcategor y of th e Reinforced Composit

e Plastic s NESHAP . II . Locatio n and Dat

e Cyte c Industries , Inc . 12600 Ecke l Roa

d Perrysburg , Olii o 4355 2 Jul y 25 , 199 6 IH . Participant s Cyte c Industrie s Rober t Leitzman , Plant

Manager , Perrysburg , O

H Stephen V . Byrne , Regulator y Specialist , Linden , N

J Jennife r DeMarco-Handley , Environmental/Safet y Coordinato r U.S . Environmenta

l Protectio n Agenc v Madelein e Strum , Projec t

Manage r~

Ms . Madelein e Strum Apri l 22 , 199 7 pag e 2 Ohi o Environmenta l Protectio n Agencv Cha d Delbecq , Divisio n o f

Ai r Pollutio n Control *

• 0 

### Pacifi c Environmenta l Services . Inc . Kennet h R . Meardon , Senio r

Environmenta

l Scientis t Melani e Proctor , Environmenta l Scientis t * Mr . Delbec q wa s only present durin g the mornin g discussion . IV . Discussio n Mr . Leitzma

n note d tha

t h e jus t receive d th e site visi t

lette r o n Monday , Jul y 22 , 1996 , an d they di d no t

hav e time t o assembl e th e requeste d infonnation . H e suggeste d tha t w e revie w thei r

proces s and the n identif

y th e item s requeste d i n th e site visi t letter tha t w e stil l neede d additiona

l informatio n on . H e als o requeste d tha t th e EPA send hi macop y o f th e contrac t wit h PE S t o ensure tha

t PE S i s subjec t

to th e sam

e confidentia

l busines s informatio n (CBI ) procedure s and responsibilitie s a s th e EPA . Ms . Stru mindicate d tha t sh e woul d d o this . Mr . Meardo n briefly explaine d th e in-hous e procedure s tha t PE S follow s fo

r handlin g CB I an d ho w th e site visi t

repor t wil l b e prepare d an

d submitted t o Cyte c fo

r thei r review . I t

wa s als o note d tha t anon-CB I versio n woul d b e create d an d tha t th e CBI-versio n woul d b e retaine d i n th e CB I files a

t PE S o r EP A o r both . Usin g aserie s o f

overhea d slide s (se e Attachmen

t 1) , Mr . Leitzma

n bega n wit h a presentatio n overvie w o f

Cyte c Industries . Cytec was forme d i n Decembe r 1993 , whe n i t

wa s spun of f fromAmerica

n Cyanamid , an

d i s comprise d ofth e chemica l busines s formall

y owne d by America

n Cyanamid . Cytec' s hom e office i s in Wes t

Patterson , NJ . Cyte c ha s total sale s of approximately $1. 2 billio n pe r year . Ther

e ar e approximately 5,00 0 peopl e i n th e company , wit

h 3 2 location s worldwide , including sale s office s an d productio n facilities . Th e Perrysburg facilit

y i s th e onl

y Cytec plan

t tha t manufacture s bulk

moldin g compound (BMC) . The

y hav e manufacturing operations , awarehouse , and aproduc t developmen

t center a t th e facility . Cyte c ha s essentially th e sam e people , plants , and operation s a s whe

n owned by America

n Cyanamid .



# sP. 4

Ms . Madelein e Stru

m Apri l 22 , 199 7 pag e 3 Mr . Leitzma

n reviewe d th e Perrysbur g facility' s history , whic h include d th e plant start-u p i n 1960 . Mr . Leitzma

n the n presente d asummar y overview of

th e BMC productio n operations . Thre e basi c resin s are use d a t th e facilit y —vinyl-toluene-base d resins , styrene-base d resins , an d diether-base d resins . Som e vinyl-toluene-base d resi n product s als o contai n styren e i n additio n t o vinyl-toluene . Th e BMC mixer s a t Cytec , rang e i n capacit

y from25-gallon s t o 600-liter s (about

16 0 gallons) . Non e o

f th e mixer s ar

e pressurized . Approximately 30 0 different product s are produced , representin g man y combination s o

f resins , fibers, fillers, an d colors . Th e facilit

y produce s BM C i n bot

h one-ste p (i.e. , th e paste mixin g and compoundin g i s performe d i n asingl e vessel ) an d tw o step processe s (i.e. , th e paste mixin g an d compoundin g occurrin g i n different tanks) . Onc e produced , th e BM C i s either packe d in bul

k for mo r extrude d into one of

several shape s (rope , log , slug ) an d the n packed . Th e packaged BMC i s place d i n col d storag e o n sit e an d the n shippe d t

o th e customer . Col d storag e extend s th e shelf-lif e of th e BMC befor

e i t i s used . Afte

r th e brie f proces s overview , Mr . Leitzma n aske d aserie s o f

questions : 1 . Wh y i s Fibercas t

i n th e sam

e subcategor

y a s Cytec ? Mr . Leitzma

n explaine d base d o n Cytec' s informatio n Fibercas t jus t produce s centrifugally-cas t pipe . Ms . Stru mexplaine d tha

t Fibercas t ha s severa

l subcategor

y operations , includin g BM C manufacturin g an d tha t i t i s o n thi s basi s tha

t di e tw o facilitie s are include d i n th e BM

C subcategory . Ms . Strumfurthe r explaine d th e general approac h fo

r definin g existin g and ne

w sourc e MAC T floor s and pointe d ou t tha t th e leve l of

contro l considere d fo

r the BM C subcategor

y i s base d onl

y o n th e control s associate d wit h th e BM C portio n of

eac h facilit

y i n th e subcategory . Ms . Strumals o note d tha

t he r preferenc e i s to se

t aperformanc e standar

d if possibl e (I . e . pound s o

f emission s pe

r to n o f materia l produced) . 2 . I s ther

e a"baseline " yea

r o n which the standard s are bein g set ? Ms . Stru mreplie d tha

t eve n though most

o f th e informatio n was collecte d i n th e 199 3 surveys , th e EP

A i s updatin g the information in it s databas e wheneve r ne w informatio n i s foun

d about afacility . 

# 3P. 5

Ms . Madelein e Stru m Apri l 22 , 199 7 pag e 4 Wha

t i s th e definitio n o

f "affected source"? . Ms . Strumreplie d tha

t th e EP A i s stil l workin g o n th e "affected source' ' definitio n fo

r thi s sourc e category . On

e possibl e optio n i s t o defin e a n "affecte d source " tha

t i s subjec t t o th e new sourc e standar

d a s asourc e whic h ha s bee n modifie d and where reconstructio n cost s represent a t leas t 5 0 percen t

o f th e cos t for th e entire facility . Wha t i s th e timetabl e fo

r th e standard ? Ms . Strumstate d dia

t th e reinforce d plastic s NESHA P was schedule d t o b e propose d b y Novembe

r 199 6 wit h promulgatio n occurrin g November 1997 , bu t thes e date s hav e bee n postponed . Th e lates t date s are Apri l 199 7 fo

r proposa l an d Apri l 199 8 for

promulgation , bu t

Ms . Stru mnote d tha

t sh e wa s no t

sur e that thes e lates t

date s coul d b e met . Wha t i s th e timetabl e fo

r complianc e onc e the standar d i s promulgated ? Ms . Strumexplaine d tha

t th e timetabl e coul d var

y dependin g o n th e specifi c requirement s of

th e rule , bu t

tha t th e Clea n Air Ac t allow s fo r u p t o 3 year s afte r promulgatio n fo

r compliance , wimthe possibilit y o f extendin g complianc e t o afourt h year . Ho w i s profitabilit

y considere d i n determinin g th e standards ? I n reply , i t

was note d tha

t when settin g astandar

d a t th e MAC T floor , whic h i s require d by di e Clea

n Air Act , profitabilit

y impact s ar e analyzed , bu t th e standard i s stil l set

to b e a t leas t a s stringen

t a s th e MAC T floor . I s there a n emissio n tiireshold belo w whic h m e standard s do no t

apply ? Ms . Strumreplie d tha

t standard s are expected t o appl y onl y t o major source s sinc e di e reinforce d plasti c composite s industr y was liste d a s amajor

sourc e categor y (a n are asourc e categor

y findin g ha s not yet occurred) . B y definitio n a majo r sourc e ha s th e potentia

l t o emi t 1 0 ton s pe r

yea r o f asingl e HA P o r

2 5 ton s per yea r o f acombinatio n of

HAP .



# HP. 6

Ms . Madelein e Strum Apr U 22 , 199 7 pag e 5 Mr . Leitzma

n note d ma

t Cytec' s HA P emission s are limite d to styren e an d memylene chloride . H e me n note d dia t th e Stat e o f Ohi o ha s arul e tha

t limit s VO C emission s t o 8 lbs/hr o r 4 0 lbs/day , whic h i s applicabl e t o eac h o f meir mixers . Thei r

odier operation s dia

t emi t HA P includ e extrusio n and packaging , bu t me y are no t subject t o di e Ohi o rule . Mr . Leitzman als o note d dia

t base d o n emissio n modelin g result s th e facilit y i s i n compliance . I n lookin g a

t way s to comply wit

h di e Ohi o regulation , Cyte c considere d downstrea m controls . They state d dia

t me y examine d al l o

f m e add-o n controls , includin g merma l oxidation , catalyti c oxidation , an d carbo n adsorptio n (bod i nitroge n strippin g an

d stea m stripping) , bu t

foun d me mprohibitiv e fro

macos t perspective . The

y als o examine d condensatio n and biofiltration . Cyte c teste d di e us e of

condensatio n a s a

n emissio n reductio n techniqu e o n thei r mixers . A condense

r wa s installe d o n acollectio n lin e to captur e styren e a s i t

escape d di e mixer . Th e condense d styren e wa s die n fe d bac k int o di e mixer . Accordin g to Cytec , di e concentratio n o f

m e styren e exitin g di e mixer wa s s o low tha

t di e condense

r coul d no t condens e i t

an d n o styren e wa s bein g returne d t o m e mixer . Cyte c coul d no t

recal l di e operatin g temperamr

e o f th e condenser . They pointe d out dia t di e concentratio n of

me styren e leavin g th e mixer

wa s belo w saturatio n a

t th e temperamr

e of di e condenser , i n di e 50 0 pp m range , an d diu s wa s no t

nea r acondensibl e concentration . Mr . Leitzma n note d dia

t Cyte c teste d di e condenser

afte r som e o f di e ventilatio n optimizatio n technique s were pu t i n place , an d diu s di e concentration s woul d b e expecte d to b e lowe r dia n previously . Biofiltratio n wa s rule d out a s a n emissio n contro l optio n fo r BMC productio n becaus e Cyte c di d no t

believ e i t to b e awell-establishe d technique . Cyte c note d dia t m e U.S . Departmen t

of Energ y ha s abiofiltratio n uni t in operatio n an

d Ms . Stru

mnote d ma

t auni t i n Swede n i s bein g use d t o contro l styrene . Cyte c pointe d ou t dia t die y hav e abiofiltratio n uni t i n aCyte c plant

in Maine , but

ma t di e cost s o f

operatio n hav e not

bee n fiill y identified . They note d diat ma t uni t ha s to b e heate d durin g di e winte r and i s currentl y bein g plague d wid i a centipede/milliped e infestation . Base d o n Cytec' s estimates , th e cost s o f abiofiltratio n uni t woul d ru n approximately $ 1 millio n capita l wi mannua

l operatin g cos t

aroun d $300,00 0 t o $400,000 . T o estimat

e emission s fromthei r

mixers , Cyte c trie d materia l balance s and odier simila r analytica l methods , but

foun d die mt o b e al l non-repeatable . O n di e odier hand , the y conducte d carbo n mb e testin g and foun d ver y goo d repeatabilit

y i n di e results . Ms . Strum expresse d concer

n ove r dii s techniqu e an

d aske d ho w soo n di e tube s wer e analyze d afte

r di e 

# 5P. 7

Ms . Madelein e Stru m Apri l 22 , 199 7 pag e 6 sample s wer e collected . Mr . Leitzma n replie d dia

t th e sample s wer

e chille d an d die n sent

ou t overnight for analysis . Accordin g t

o Mr . Leitzman , di e repeatabilit y of me result s see mt o indicat e diat dii s metho d provide d reliabl e results . Th e Stat e o f Ohi o i s havin g Cyte c conduc t asourc e tes t

i n m e nea

r fiimr e o n on e o f di e mixers . Thi s sourc e tes t wil l b e use d t o validate di e carbo n mb e testin g Cyte c ha s conducted . Base d o n customer

requests , Cyte c replace d styren e wid i vinyl-toluene , anon-HAP , i n som e resi n formulations . The

y hav e done dii s i n anumbe r of formulations , an d believ e diey hav e gon e abou t

a s fa r a s die y can . Cyte c als o note d dia t viny l toluen e i s mor e expensiv e dia n styren e an d ha s ahigher

odo r direshol d (I . e . i s les s o f

a n odo r problem) . T o mee t th e Ohi o regulations , Cyte c wen t bac k to di e actua

l mixin g operation s t o determin e ho w emissio n reduction s coul d b e achieve d without usin g add-o n controls . One modificatio n wa s di e placemen t of cover s o n each of

di e open to p mixers . Th e mixer s ar e operate d wid i cover s dia

t fit ove r di e are ause d t o add di e ra w materials . Th e automate d line s ar e completel y close d excep t whe n emptying . Th e mixer s do ven t (namra l draf t no t diroug h force d ventilation ) durin g mixing around di e side s of di e covers , whic h are sealed , an d di e vente d emission s ar e capture d dirough ahoo d and vente d to di e atmosphere . Th e automate d line s vent directl y diroug h apip e containin g abutterfly-typ e valve , whic h i s i n di e close d positio n durin g mixing . A small amoun t of spac e remain s around di e edg e o f di e valv e allowin g vapor s t o escape . Base d on stack testing , Cyte c ha s see

n an emissio n reductio n of about a5 0 percen t

a t di e entir e plan t level afte r coverin g th e mixers . Sinc e me facilit y ha s emissio n source s othe r

dia n mixers , which wer

e no t modified by emissio n reductio n measures , Cyte c expect s di e percen t

emissio n reductio n achieve d a t eac h mixe

r t o b e muc h highe r

tha n 5 0 percent . Sinc e 199 2 o r

199 3 Cyte c maintain s anon-explosiv e environmen t withi n some o f

thei r mixer s b y usin g amtrogen-blanket . The y note d dia

t di e nitrogen-blanket

can forc e styren e out o f di e resin , s o di e amoun

t o f nitrogen use d need s to b e optimized , i n orde r to minimiz e styren e emissions . Cyte c noted dia t dieir corporate polic y i s t

o maintai n concentration s t o les s ma n 2 5 percen t

of di e lowe r explosiv e level (LEL ) of

styrene , but

in practic e di e ai mt o kee p concentration s t o les s 10 % ofth e LE L fo r styrene . Cyte c als o examine d dieir

ventilatio n system s o n di e mixers , a s t o ho w eac h i s evacuated . Originally , each o f di e ope n top mixer s were evacuated usin g asid e vent dia t pulle d ai r fromwidii n di e mixe

r durin g mixing . They note d dia t di e harder

di e ventilatio n pull s o n di e mixers , th e mor e styren e i s lost . Thus , diey attempte d t o optimiz e di e ventilatio n rate i n conjunctio n wid i di e nitrogen goin g i n fo r me nitroge n blanket . Thi s optimizatio n ha s led diemt o eliminate thi s sid e ven t completel y fromth e mixer s durin g mixing . Instead , mere i s n o activ e evacuatio n o

f di e mixe r durin g mixing . When m

e produc t i s remove d fromth e 

# 6P. 8

Ms . Madelein e Stru m Apri l 22 , 199 7 pag e 7 mixer , ther e i s asid e ven

t dia t pull s ai r acros s di e top of

di e ope n mixer

t o remov e styren e emission s fromdi e room . Ther e ar e als o vent s alon g th e botto mo f th e mixer s an d to p o f

di e mixer s t o remov e ai r

fromaroun d di e mixe

r o r to capmr e particulate s durin g filling of th e dr y material . Th e purpos e of

thes e vent s i s to reduc e worker exposure t o styren e and particulates . Accordin g t o Cytec , di e additio n of di e cover s an

d di e optimizatio n of

th e ventilatio n rate s resulte d i n mor e styren e stayin g i n di e BMC . Th e reduce d styren e losse s allowe d Cyte c to reformulate thei r

resi n mixture wimles s amount s of styren e input

dia n befor e di e emissio n reductio n technique s were applied . V . Plan t

Tou r Th e first mixer observe d had a

n openin g i n di e to p of

di e mixer ma t i s opene d t o add di e resi n an d fillers. Th e resi n i s adde d vi aata p o n aresi n barre l dia

t i s suspende d from a hoist . When addin g resin , di e barre l i s moved vi adi e hois t t o di e mixe

r an d di e ta

p i s opened . Th e amoun

t of resi n adde d i s monitore d usin g ascal e dia t weigh s di e suspende d barrel . Onc e di e initial ingredient s ar e added , di e opening in m e top of th e mixe r i s covered , and mixin g begins . Fiberglas s i s place d i n achute over di e mixer . Th e openin g i n di e to p o f di e mixer i s the n opene d agai n t o allo w th e fiberglas s to enter di e mixer . Thi s i s don e diroug h vibratio n o f di e chute and extende d "fingers " help distribute di e fiberglas s mor e evenly into th e mixer . Afte r di e fiberglass reinforcement i s added , di e opening i n th e to p o f di e mixer i s covere d an d mixin g resumes . Onc e th e cycl e i s completed , di e tan k i s opene d an

d tippe d forward , an d di e BMC i s remove d manually . Durin g mixing , th e to p o

f di e mixer , whic

h ha s a n openin g to ad

d ra w materials , i s covere d widi asomewha

t tight fitting cover . A differenc e i n di e fit of di e cover s wa s observe d between th e differen

t mixers . Accordin g to Cytec , adding di e cover cut dow n noticeabl y o n di e styren e odo r

and emissions . Vent s a

t di e bac k of di e to p o f di e mixer , which pul l ai r perpendicula

r t o di e covere d openin g i n th e top o f di e mixer , are use d t o capmre emission s durin g di e filling o f

di e mixer and emission s tha

t lea k aroun d di e side s of

di e cover s durin g mixing . Ther e appeare d t o b e aver y stron g pull , especially fro mone ofth e vents . Ther e i s n o activ e evacuatio n o f

th e hea d spac e of di e mixe r onc e i t i s i n operation . Th e capmre d emission s fromth e ven

t a t di e bac k of di e top of di e mixe r ar e vente d diroug h abaghous e to di e atmosphere . No t

al l mixer s a

t Cyte c hav e nitrogen blanketing . Another mixer observe d durin g di e plant

tour i s ajackete d mixe

r fo r coolin g and heating . Al l o f

di e additiv e materials , includin g di e fiberglass and filler , ar e adde d t o ahopper dia t i s hydraulicall y lifted t

b di e top o

f di e mixe r an d di e materia

l i s droppe d in diroug h a

n opening i n di e to p of

di e mixer . A ven

t a t di e top of mixe r evacuate s and capture s di e particulate emission s dia

t occur durin g di e additio n o f

dies e material s an d vent s die mt o a 

# 1P. 9

Ms . Madelein e Stru m Apri l 22 , 199 7 pag e 8 baghouse . Whe n asked , Cyte c noted dia t diey hav e never

see n an y styren e polymerizatio n i n thei r baghouses . Th e resi n i s adde d vi aaretractabl e pip e lin e ove r di e to p o f di e mixer . If required , additional styren e i s hard-pipe d directl y into di e mixer . Nitroge n i s als o hard-pipe d int o th e mixe r

t o provid e di e nitrogen-blanket . A cove r i s place d ove r

di e opemn

g diroug h whic h di e ra

w material s ar e added . Th e cove r i s fairl y tigh t

fitting, but

stil l allow s roo mfo

r emission s t o escap e fromth e mixe r durin g operation . Thes e emission s are capture d by di e sam e vent use d to captur

e particulat e emission s durin g filling of ra w materials . Ther

e i s n o activ e evacuatio n of ai r widii n di e mixin g vesse l durin g operation . Onc e di e mixin g cycl e i s completed , di e mixe r i s opene d an

d tippe d ove r

t o allo w acces s t o remov e di e BMC , which i s don e manually . There i s aside-ven t dia t pull s ai r acros s di e to p o f di e mixe r when i t i s opened . I n addition , mere i s abotto mven t t o pul l awa

y emission s fromth e botto mwhe n die mixe r i s tippe d ove r

t o remov e th e material . Thes e tw o vent s an d di e to p vent

ar e alway s "on " an

d continually pul l ai r

awa y fromdi e mixer . Whe n di e mixer i s closed , di e botto man

d the side-ven

t pul l ai r fromth e productio n room . Th e total flo w fromdi e evacuatio n vent s aroun d dii s mixe

r i s estimate d t o b e approximatel y 1,30 0 cftn . Resi n i s fe

d directl y (har

d piped) int

o anodie r mixer , which i s enclosed , frombarrel s store d o n di e secon d level . Th e dr y material s are weighte d o r measure d an d die n place d manuall y into on e o f

tw o hopper s o n top of

di e mixer . Thes e hopper s are opene d i n acertai n sequenc e t o dro p di e material int o di e mixer . Fo r

on e hopper , arotatin g se t o f vane s (simila

r to arevolvin g door ) move s th e materia l int o th e mixer . Pre-choppe d fiberglas s i s als o fe d into di e mixer vi aaconveyo r

belt . Th e orde

r i n which dies e materia

l are adde d varie s dependin g o n di e specifi c BM C product . Th e mixer ha s a n induced draf

t pulle d o n i t

b y di e baghous e fan . Durin g filling, displacement

ai r i s vente d diroug h apip e to di e baghouse . Th e butterfly-typ e valv e i n di e lin e i s open a t thi s tim e to allo w displacemen

t o f air . Sinc e ai r

displacemen

t doe s no t occu r durin g mixing , me valv e i s close d to reduc e the dra w o n di e mixer . A smal

l amoun t o f spac e remain s around di e edg e of

di e valv e t

o allow vapor s to escape . Flo w fromth e mixer i s estimate d t o b e 15 0 cft n witi i aconcentratio n o

f 600 ppm . At di e conclusio n o

f di e mixin g cycle , the botto mof

th e mixe r open s u p an d drop s di e finished BM C onto aconveyor belt . The conveyor

belt s move s di e BM

C t o di e extrude r

belt , wher e i t i s fe d diroug h a

n extruder an d extrude d a s "slugs. " Th e slug s are the n place d into a cart , an d a s diey ar e stacke d die

y ar e covere d wid

i plasti c a t differen t points . 

# 1P.1 0

Ms . Madelein e Stru m Apri l 22 , 199 7 pag e 9 Anotiie

r enclose d mixer

use s chute s an d hopper s to add dr y material s diroug h a hydrauli c door . Onc e mixin g i s begun i n dii s vessel , i t i s closed , bu t

som e emission s are stil l allowe d t o emerg e ou t

o f di e vents . Emissio n Reductions . When asked about di e measurement s die

y hav e take n s o fa

r o n di e mixer s an d tiieir

effectiveness , Cyte c estimate d dia t emission s afte

r modification s for

on e o f dieir mixer s showe d an emissio n reductio n of about 6 7 percent . Mr . Leitzman explaine d dia t storag e tank s are vente d to di e atmospher e an d di e vent s are equippe d witi i flam

e arresters . Mr . Leitzman note d dia

t on e of Cytec' s mixer s wit

h alon g batc h cycl e time wa s found t o emit more dian anotiier

mixer wit h ashor t batc h cycl e time . Cyte c note d dia t mixin g time i s a n indicato r

of di e efficiency of

di e mixer , bu t

dia t no t al l formulation s coul d b e mixe d a t di e sam e rate . Th e ke y i n producin g BM C i s t o provid e enoug h tim e to ensure everythin g i s properl y mixed , witiiou t

agitatin g di e materia

l excessively . Finally , Cyte c note d diat some formulation s simply can no t b e "rushed " an

d dia t di e namr e o f di e formulatio n wil l requir e a longe r mix time . VI . Revie w o f

Sit e Visi t Questionnair

e Afte r di e plan t tour , di e site visi t

questionnair

e wa s reviewe d t o ensur

e al l o f di e point s wer e covere d an d t o identif

y specificall

y di e additiona

l informatio n Cyte c would provid e a t a later date . Witi i regard t o productio n information , Cyte c sai d die y coul d provide it , bu t

tiiat i t would b e CBI . They agai n note d dia t die y hav e about

30 0 differen

t formulations , bu t

ma t about 75 % o f wha t the y produc e ca

n b e classifie d into 6 o r

7 products . Som

e of thei r majo r markets/product s includ e headligh t housings , valv e covers , circui t breakers , an

d toaste r ove n end pieces . They note d tiiat headligh t housing s neede d certai n hea t resistant an d assembly properties , ma

t valve s cover s needed certai n hea t and flam e resistant properties , and tiiat circui t breaker s neede d certai n hea t an d electri c charg e resistan t

properties . Cyte c note d tiiat th e toaster ove n en d piece s are no t

painte d afterwards , bu t

ar e produce d witi i variou s colore d BM C products . Th e hig h glos s achieved i s afunction o f di e BM C itself , additives , an d di e mold s use d t o produc e di e piec e (chrome-plated , highly polished) . Cyte c state d dia t diey coul d provide di e total annua

l productio n o

f BMC , bu t

no t by product . The

y als o state d dia

t diey coul d supply apric e list . (Th e abov e mentioned infonnation , which was provide d b y Cyte c o n October 21,1996 , i s shown i n Attachmen t1) . 

# 1P.1 1

Ms . Madelein e Strum Apri l 22 , 199 7 pag e 1 0 Wit h regar d to proces s description , Cyte c note d agai n tiiat they plan mak

e som e proces s change s to on e o

f their mixers . In doin g tiiis, they wil l stil l us e th e curren t holdin g tank s for di e mixer . Thes e will serv e th e sam e functio n a s th e drum s use d t o fe d di e resin s t o th e otiier mixer s in tiie facility . Cyte c noted dia t diey hav e n o expansio n plan s a t dii s time . Mos t o f di e growd i i n th e busines s i s likely t o com e fromin-road s they can mak e i n th e metal s market . Ms . Strumaske d abou

t growt h i n di e thermoset

resin s versu s th e thermoplasti c resins . Cyte c note d dia

t tiiere i s greate

r interes t in usin g thermoplastic s b y som e of thei r market s becaus e thermoplastic s are les s expensiv e and di e higher propertie s (e.g. , hea

t resistance ) o f thermose t resin s ma y no t really b e needed in som

e applications . Mr . Leitzma

n wa s asked t

o provide informatio n frommateria l safet y datasheet s (MSDS ) fo r

di e differen

t resin s use d at

Cytec . Ms . Stru mpointe d ou t dia t th e onl y informatio n fromth e MSD S neede d i s di e styren e content of di e differen

t resin s used . Mr . Leitzma n promise d t o provid e asummar y tabl e o f tiie styren e content

i n eac h of

Cytec' s resins . (Thi s information , whic h was provided by Cyte c o n Octobe r 21,1996 , i s show n i n Attachmen t1) . When aske d about

di e us e o f cleaners , Cyte c note d tiiat they us e methylen e chlorid e primaril y becaus e they hav e frequent colo r change s i n thei r

products . Colo r

change s ar e don e i n di e smaller

mixers . If

Cyte c i s no t

doin g an y colo r changes , the

y us e other

non-HAP cleaners . Cyte c als o attempt s t o produc e lighte

r colore d product s earlie r

i n di e sequenc e and switc h t o darke r

color s towar

d di e en d of

di e sequenc e t o avoi d cleanin g i n betwee n colo r changes . Fo r

example , switchin g color s fromgrey to blac k require s n o equipmen

t cleaning , wherea s acolo r

chang e fromblack

t o gre y doe s require cleaning . When aske d ho w frequentiy die y mak e colo r changes , Cyte c state d dia

t fo r on e o f tiieir mixer s they ma

y g o ada y o r tw o wit h n o colo r changes , but

o n som e day s i t ma y b e a s man

y a s 1 5 o r 1 6 colo r change s pe r mixer . Suc h alarg e numbe r o f colo r change s woul

d b e ver y unusua l and doe s no t

imply tha t mere woul d b e 1 5 o r

1 6 cleaning s becaus e the

y tr y t o g o fro mligh t t o dar k colors . Cyte c note d tha

t dieir metiiylene chlorid e usag e ha s droppe d significantly from 3 year s ago . The y us e Thermoclea n fo r som e applications , but

hav e no t bee n abl e t o us e i

t fo r colo r changes . Thermoclea

n i s asodiu

mmedasilicate , which need s to b e heate d t o aroun d 150°F . The y canno t us e i t fo r colo r change s becaus e the

y nee d aquic k

turnaroun d time on th e mixer . (Base d o n informatio n provided by Mr . Leitzman , Cyte c wil l discontinu e th e us e o f al l HAP containin g cleaners i n early 1997) .P.1 2

Ms . Madelein e Strum Apri l 22 , 199 7 pag e 1 1 Whe n aske d about

di e cos t o f di e modification s t o th e mixers , Cyte c estimate d tiiat they probabl y spent

somewher

e betwee n $35,00 0 and $50,00 0 tota l fo r al l o f di e mixers . Cyte c agree d t o provid e mor

e specifi c informatio n o n th e costs . I t wa s suggeste d tha

t thi s informatio n coul d b e provide d i n th e for mof material s and labo r

require d and dia

t EP A woul d the n estimate th e costs . (Thi s information , whic h was provide d b y Cyte c o n October 21 , 1996 , i s show n i n Attachment1) . VII . Actio n Item s (Al

l th e informatio n requested belo w wa s provide d by Cyte c o n Octobe r 21 , 1996 . Th

e informatio n i s show

n i n Attachmen

t1) . Cvte c 1 . Provide a s muc h detaile d informatio n o n th e sourc e test s a s possibl e fo r eac h mixer , especiall y proces s informatio n lik e th e amoun

t o f HA P goin g i n an

d coming out

of di e process . 2 . Performanc e dat at o calculat e th e pound s of

HAP emitte d pe r

poun d of produc t produce d fo

r eac h individua

l mix systembefor

e an d afte r th e emissio n reductio n techniqu e wa s pu t

in plac e t o calculat

e th e overal l perfonnanc e o f your operation . 3 . .Amoun

t o f HA P cleaner

usag e pe r to n of product . 4 . HAP conten

t of resin s (o r MSD S —"ingredients " pag e only ) plu s di e amoun t of HAP added . 5 . Cos t

dat ao r material s an d labo r

requirement s fo

r modification s to di e mixers . 6 . Copie s of

overhead slides . 7 . Provide informatio n abou t dietiier-base d resi n product s an d explai n i f thes e product s als o contai n styren e o r othe r HAP .



## MP.1 3 

### /tHtthto,*!

3 

# CVTE C

CYTE C INDUSTRIE S INC . P.O . Bo x 14 8 Perrysburg , O H 4355 2 Tel : (419 ) 874-794 1 

# PUBLI C DOMAIN Oaobe r 21,199 6 Dr . Madelein e L . Stru

m Unite d State s EP A Offic e o f Ai r Qualit

y Planning an

d Standard s Emission s Standard s Divisio n ' '•'•' MD-1 3 Research Triangl e Park , N C 2771 1 RE : Manufacturing an

d Emission s Dat a fo r BM C MAC T Dea r Dr . Strum : Pursuan tt o you r reques tfb r additiona l informatio n t o assis ti n m e MAC T detenninatio n fo r di e Bul k Moldin g Compound s mdustry , w e ar e enclosin g di e infonnatio n requeste d a s discusse d a tou r Juf y 25 , 199 6 meeting . Du e t o di e nature ofth e infonnatio n requested , w e inquire d abou texistin g confidentialit

y agreement

s betwee n di e agenc y an

d it' s contractors . Dr . Meardo n provide d u s with a cop y ofth e confidentialit y agreementan

d associate d infonnatio n firom di e EPA contractor , PES . Discusse d durin g th e meeting , a portio n o f

u e infonnatio n bein g submitte d i s confidentia l busines s information - W e reques ttha tal l informatio n stampe d 'Trad e Secret " b e kep tconfidential A n identica l versio n o f

dii s packet , marke

d "Publi c Domain" , i s als o attached , with all confidentia l information blacke d ou t The attache d informatio n i s a compilatio n o f m e document

s reviewe d and/o r requeste d durin g di e 7/25/9 6 meetm g an

d addresse s di e followin g topics : Copie s o f th e overhead slide s show n durin g di e meetin g

Dichloromethan e usag e Lis to f hig h volum e proces s raw materials & component s Pr e & pos tmodificatio n emission s number s A brief descriptio n o f

eac h attachmen

tprecede s ti e attachment s an d wil l assis ti n di e understmdm g ti e information . 

# \ZP. M



# PUBLI C DOMAI N Du e t o th e variabilit

y o f processe s include d i n th e BM C Sourc e category , w e suppor tEPA' s interes ti n a >erformance-base

d standar d (e.g . I b HAP/to n produc tproduced) . Thi s approac h i s advantageou s fo r di e followin g reasons :

• i tencourage s pollutio n preventio n • i tprovide s flexibility t o regulate d facilitie s • i ti s les s prescriptive , whic h i s consisten twith initiative s t o streamlin e environmental regulatio n • add-o n control s ar e no tamenabl e t o som e ofth e proces s equipmen tuse d i n BM C facilities . Du e t o di e relativ e vintag e ofth e processes , an d th e succes s w e hav e achieve d o n emission s reductions , ;v e recommend tha

ttile performanc e o f

flHHHHHHHMHH^e considere d Ne w Sourc e m d Existin g Sourc e MACT , respectively . .•\kematively , th e wor k practic e standards develope d b y Cyte c whic h achieve d significantemission s reduction s coul d b e specifie d a s MAC T (e.g . fJ///_____J/K-Wt minimiz e oo&ce

r ventilation , kee p produc tcovered) . Ou r discussio n o n MAC T wa s a learnin g experienc e for u s a s I a m sur e i twa s fb r you . Th e Perrysburg Plan ti s ver y intereste d in th e developmen tofth e MAC T detenninatio n fbr ou r industr y and I am sure you wil l find di e attache d infonnatio n useful . I f yo u hav e question s regarding thi s information , o r nee d additiona l information , pleas e do no thesitat e t o cal l m e a t(419)874-7941 , ex t41 1 o r Jennifer DeMarco Handle y a text . 432 . Sincerely , CYTE C INDUSTRIE S INC .

Rober tA Leitzma

n Plan tManager jd h ittachment

s ZOPY : Dr . Kennet

h Meardo n Ms . Melani e Procto r Pacifi c Environmenta

l Services , Inc . Centra l Par k Wes t 500 1 S . Miam

i Boulevar d .P O Bo x 1207 7 Researc h Triangl e Park , N C 27709-207 7 TLE : MACTCOVE.WPD/JD H Mr . Cha d Delbec q Ohi o EPA , NWD O Div . o f Ai r Pollutio n Contro l 34 7 N . Dunbridge Roa d P.O . Bo x 46 6 Bowlin g Green , Ohi

o 43402-046 6 

# 1 3 Pag e 2P.1 5



# PUBLI C DOMAI N DESCRIPTIO N O

F ATTACHMENT S A brie f descriptio n o f eac h attachment

, a s follows , wil

l assis ti n th e understandin

g the informatio

n attached . Overhea d Slide s - Attachmen

tI Copie s o f di e overhea d slide s show n durin g th e meetin g o n 7/25/9 6 includ

e a summai

y o f dj e physica

l locatio n ofth e Cyte

c Perrysbur

g Plant , WK__\^t___\ a genera l process flow diagra

m an d a n overvie w o f som e ofth e employe

e program s i n whic h man y ofth e employee

s participate

.

Lbs . Stvren e Emission/To

n Styrenate

d Produc tManufacture

d - Attachmen

tIT I Attachmen

tm include

s di e emission

s divide d b y the ton s o f styrenate d BM C manufacture

d for th e give n year . Modification

s J^^BHHHHHflflHH B wer e -itiate d i n th e 4t h quarte r o f 1995 , therefore , th e post-modificatio

n emissions data(se

e Attachmen

tVI ) wa s onl y used i n a portion ofth e emission s calculate d fo r 1995 .

Hig h Volum e Resi n Price s - A^c}\rj}mt

TT T Tw o type s o f resi n containin

g VOCs ar

e used a tth e Perrysbur

g Plant , includin g styrenate

d resin s an d viny l toluen e base d resins. Ih e highestvolum e resin s an d th e lis tpric e pe r poun d o f thes e resin

s ar e included . Dichloromethan

e Usag e - Attar^-me-n

tTT T Methylen e Chlorid e i s use d fo r cleanin g th e mixers, extruder

s an d part s betwee n colo r changes . Liste

d in thi s attachmen

ti s th e tota l amoun to f Methylen e Chlorid e emitte d pe r ton o f al l productio

n i n 1995 , includin g th e non-VO C containin

g BMC . 

# I' iP.1 6



# PUBLI C DOMAI N DESCRIPTIO N O F ATTACHMENT S (CONT. ) isto f Hig h Volume Proces s Ra w Material s & Components - Attachmen tT V i.ttachnien tI V i s a lis tofth e high volum e ra w materials an

d th e percentag

e o f component s o f

thes e ra w latenal s utilized a

tth e Perrysburg Plant

. Include d i n th e Us tar e th e styrenate

d an d viny l toluen e base d isins .

•T e & PostModificatio n Emission s Rates - AttachmentV I .Ti e emissions dat

a measure d through in-hous e testin g befor e an d afle r modifications wer e made^ H

Thi s attachment ichide s th e highes tdat

a poin tmeasure d afte

r di e initia

l moomcanon s wer

e completed , a s weU a s th e verag e ofth e dat

a fo r eac h product , bot

h pr e an d pos tmodification .

HE : MA.CTCOVR.WPD/JD H 

# \5P.1 7 ATEaCWEN

T I 

# POLYESTE R MOLDIN G COMPOUND S PERRYSBUR G PLAN T FACILITIE S o Locatio n

- Perrysbur g Townshi p Woo d County , Ohi o o Plan t Propert y

• i



## - 6 5 Acre s tota l



# o Buildings

Manufacturing/Warehousin g

t • —••• • m . / 

# lieP.1 8 

# i

G L 

# o | cs i 

# s o < 

# E 

# G < 

# i 

# O l

r 

# [f t C O L U 

# o o a . ATTACHMENT I (CONT. ) 

# PUBLI C DOMAI N

•TM »



### o 3 

# B 

# J nP.1 9 ATTACHMEN T II I 

# PUBLI C DOMAI N CYTE C INDUSTRIE S INC . MAC T INFORMATIO N

•4NUA L EMISSION S (LBS) ' ^;.:il.jli;^i;j^:ip;^SI^R£lj i 199 5 45,92 0 1994 ; 48,38 0

9 5 METHYLEN E CHLORID E USAG E pCiPaiSi^Biii i 23,32 0 39,82 0 53,48 0

mission s number s ar e fro m annua l Ai rFe e Emission s Report

. 199 4 & mosto

f 189 6 emission s ase d o n gravimetri

c emission s numbers . Th e mos tcurren temissions dat

a i s base d o

n a l emission s testing MACTINF0.WK4/JD H 

# nP.2 0 ATTAOSEN r I(GGNT. ) 

# Employee Partidpatiio n Qualit y Improvemen t Team s Cos t Improvemen t Custome r Liaiso n Ra w Material s Capita l Improvemen t Housekeepin g

•Qwtnjn i 

# nP.2 1 

# PUBLI C DOMAI N ATTACHMEN

T I V CYTE C INDUSTRIE S INC . PROCES S RA W MATERIALS/COMPONENT S RA W MATERIA L RESIN S - HIGHES T VOLUM E STYRENE

BASED RESI N # 1 RESI N # 2 WWY L TOLUENE

BASED RESI N # 1 MONOME R FILLER S - HIGHES T VOLUM E

FILLE R # 1 FILLE R # 2 FILLE R # 3 REINFORCEMEN T RBER S FIBE R # 1 RBE R # 2 ALYSTS/INHIBITOR S - HIGHES T VOLUM E

SOU D CATALYS

T SOU D INHIBITO R UQUI D CATALYS

T # 1

UQUI D CATALYS

T # 2 

### COMPONENT S

STYREN E ' CALCIU M CARBONAT E ALUMIN A TRIHYDRAT E KAOU N CLA

Y CHOPPE D STRAN D RBERGLAS S

SIZIN G NYLO N FLOC K BENZOY L PEROXID E WATE R BUTYLATE D HYDROX

Y TOLUEN E D i - (2-ethylhexyl)phthalat e Butyl benzy l phthalat

e t-BUTY L PERBENZOAT E 

### EEBQEN I

VINY L ESTE R RESI N STYREN E POLYESTE R RESI N STYREN E POLYESTE R RESI N VINY L TOLUEN E 60-7 0 • .30-4 0 68-7 0 30-3 2 68-7 2 29-3 3 10 0 10 0 10 0 9-5-10 0 97-9 9 <1- 3 10 0 7 5 2 5

2 5 1 0 . 99-10 0



# 10P.2 2 

# PUBLI C DOM/II N ATTACHMEN T IV (CONT. ) 

### CYTE C INDUSTRIE S INC . PROCES S RA W MATERIALS/COMPONENT S PIGMENT S • HIGHES T VOLUM E SOU D PIGMEN T # 1 SOU D PIGMEN T # 2 PAST E PIGMEN T # 1 PAST E PIGMEN T # 2 DDIIWE S - HIGHES T VOLUM E TRAC E ADDITIV E # 1 TRAC E ADDITIV E # 2 TRAC E ADDITIV E # 3 CARBO N BLAC K ZIN C SULFID E 2 , B/BO N RE D ORGANI C PIGMEN T UNSATURATE D POLYESTE R RESI N

CARBO N BLAC K IRO N OXID E UNSATURATE D POLYESTE R RESI N CALCIU M STEARAT E (TECHNICALL Y PURE ) HYDRATE D AMORPHOU S SIUC A POLYETHYLEN E POWDE R 10 0 9 8 2 7 7 3 1 2 2 3 6 5 100 87(MIN ) 100 TRAC E ADDITIV E # 4 TRAC E ADDITIV E # 5 TRAC E ADDITIV E # 6

L E RAWMAT%.WKS/JD H



# L\P.2 3

ATTACHMEN T V I 

# PUBLI C DOMAI N EMISSION S REDUCTION S THROUG H PROCES S MOOIRCATION S

PERRYSBUR G FACILIT Y ' • Highes t & Averag e Emission s Measured , Lb s VO C Emitted/Lb s VO C Use d

Prod . Group Prod . 1 Pro d 2 Prod . 3 Prod . 4 Highest

Emission Pre-Modificatlon 0.019 5 N A 0.013 4 0.019 2 Averag e Emission

Pre-Modificatlon 0.013 1 NA 0.012 8 0.016 0 Highest Emission Post Modification 0.002 8 0.003 8 0.007 4 0.005 5 Averag e Emission

Post Modification -0.002 2 " 0.002 4 0.004 3 0.004 4

Prod . Group Prod. 1 Prod . 2 Prod . 5 * Prod . 6 Highest

Emission Pre-Modiffcatfo n N A 0.039 9 N A N A Average Emission Pre-Modification NA 0.034 0 N A NA Highest Emission Post Modification 0.005 8 0.012 5 0.027 0 0.014 0 Averag e Emission

Post Modification 0.004 3 0.011 0 0.020 9 0.009 9 "Currentl y no t manufactured ^ Th e measurement s show n represen t th e highes t an d averag e ofth e emission s recorde d fo r eac h produc t grou p throug h in-hous e testbig . N A indicate s thi s produc t wa s no t manufacture d and , consequently , no t measure d unt o afte r th e modification s wer e made . I n mos t cases , th e highes t emission s dat a poin t wa s measure d afte r th e initia l modification s wer e complete . Modification s t o th e mixer s hav e continue d throughou t ou r ongoin g emission s reductio n projec t

FIL E PREiPOST.WK^O H • 9/23/9 6

^ ^P.2 4

Docke t No . A-94-5 2 Categor y II- B Th e following informatio n i s located in th e confidentia l file s ofth e Director , Emissio n Standard s Division , Office of Air Qualit y Plannin g and Standards , U.S . Environmenta l Protectio n Agency , Researc h Triangl e Park , Nort h Carolin a27711 . Thi s information i s confidentia

l pendin g final determinatio n b y th e Administrator

and i s not availabl e fo

r publi c inspection . Cop y 1 - Sit e Visi t repor t date d 3/5/97 , 3 0 page s

CN-N404-1 1 96185-C18-0 8



## Z^>