p. 1


### OAR Box 1490 Prepped by Charmelle Mathews

Document

Number: 

### 60 ) IV-C-3

3 Docket Number: 

### A-94-5 2

Printed 8/4/200811:51:47

AM Sheet 60of 273P. 2



### REINFORCE

D PLASTI C COMPOSITE S MAC T STANDARD S DEVELOPMENT UPDAT E A-94-5 2

IV-C-3 3

FP A AI R DO l W

For the Composites Fabricators Association Annual Meeting Septembe r 26 , 200 2 Keit h Barnett , Projec t

Lead Office o f Air Qualit y Plannin g andStandard s Emissio n Standard s Divisio n Mineral s an

d Inorgani c Chemical s Grou pP. 3



## Outlin e Wh o i s subjec t

t o thi s standard ? Wha t operation s are covered ? Wha t i f I manufacture fiberglass boat s o r boat parts ? Whe n d o I hav e t o comply ? Major change s t o propose drul e A mI ane w or

existin g source ? Wha t standard s mus t

I meet ? Wha t are som e o f my option s t o mee t standards ? Ho w do I calculate emissio n factors ? Ho w d o I demonstrat e initial compliance ?P. 4 

## Wh o i s subjectt

o thi s standard ?

• Yo u are subjec t

t o thi s standar di f you :

- Manufactur

e reinforce d plastic s composite s a

t afacilit y that i s locate d a

t amajor sourc e (1 0 tp y ofan y on e HA P o r 2 5 tp y ofan y combinatio n o f HAP) : an d

- Us e thermose t

resin s o r ge l coat s tha

t contai n styren e 

### • Yo u are no t

subjec t t o thi s standard i f you :

- Us e les s tha

n 1.2 tp y o f

styren e containin g resin s an d ge l coats , o r

- Onl y perfor

mresearc h an d development , o r

- Onl y repai r

reinforce d plasti c composite sP. 5 

## Wha toperations ar

e covered an

d hav e som e typ e o f control requirements ? Ope n Moldin g Close d Moldin g Centrifuga l Castin g Continuou s Lamination/Castin g SMC/BM C Manufacturin g Pultrusio n Mixin g Storag e Equipment

Cleanin gP. 6 

## Wha toperations ar

e covered , an d hav e n o requirements ? Application , o f

mol d sealin g an d releas e agent s Mol d strippin g an d cleanin g Repai r unrelate d t o you r

manufacturin g operation s Material s tha

t do no t contai n resi n o r

ge l coa t Personal activitie s no t

par t o f manufacturin g operation s Prepre g material s Non-ge l coa

t surfac e coating s Researc h an ddevelopmen t operation sP. 7 

## Wha tif I Manufactur

e Fiberglas s Boat s or Boa tParts ? Yo u are subjec t

t o th e Boa

t Manufacturin g NESHA P onl v i f

yo u manufacture boat hull s o r decks , o r mold s fo r boat hull s o r deck s I f yo u are no t

subjec t t o th e Boat Manufacturin g NESHAP , yo u ar e subjec t t o thi s rul e I f yo u are subjec t

t o th e Boat Manufacturin g NESHAP , bu t make part s that are no t par t o f you r boats , th e non-boat operation s are subjec t

t o thi s rul e Yo u ma y elec t t o plac e al l operation s unde r th e Boa t Manufacturin g NESHA P i f that result s i n equa

l o r lower HA P emission sP. 8 

## Whe n d o I have t o comply ? Proposal wa s Augus t

2 , 200 1 Final rul e publicatio n date i s part o f 1 0 yea r MAC T settlement

negotiation s Existin g majo

r source s mus t

compl y withi n 3 year s Ne w major

source s mus t

compl y b y effectiv e dat

e o f final rul e o r

startup , whichever i s laterP. 9 

## Majo r Change

s t o Proposed Rul e Th e above-the-floo r

requirement s hav e bee n droppe d fo

r existin g ope n molding , pultrusion , SMC an d BM C manufacturing , an d mixin g operation s Th e poin t valu e equation s hav e bee n replace d wit

h th e appropriat e unifie d emissio n factor

(UEF ) equation s W e hav e revise d existin g sourc e MAC T floors base d o n comment s receive d o n th e propose d rul e

- Tw o floors wil l requir e aslightl y lowe r HA P content , thre e are slightl y highe r

- We hav e combine d th e filled an d unfille d noncorrosio n resistan t mechanical resi n applicatio n operation s type sP.1 0



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

t th e facilit y Not e tha t th e definitio n abov e include s movin g a n existin g facilit

y (We are overridin g th e General Provision s concernin g movin g sources )p.1 1 

## Wha t i s an Existin g Source ?

Any sourc e tha

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

considere d ne w a s aresul t o f reconstructio n

1 0P.1 2 

## Overvie w o f Controls t

o Mee t Emission Limit

s Mos t existin g source s mus t

onl y mee t th e existin g sourc e floor

- lo w HA P resin s an dge l coat s

- nonatomize dapplicatio n technique s

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

- add-o n control s for

continuou s lamination/casting 

### Existin g source s wit

h centrifugal castin g an d continuou s lamination/castin g operation s that emi t over 100 tp y o f

HA P mus t

- Us e add-o n control s for bot h centrifuga l castin g an dcontinuou s lamination/castin g (9 5 percen t control )

- Mee t th e sam e requirement s a s othe r existin g source s for

thei r othe r operation s

nP.1 3 

## Overview o

f Controls t

o Meet Emission Limit

s (Con't)
Ne w source s wit

h HA P emission s belo w th e 10 0 tp y threshol d mee t

th e sam e limit s a s existin g source s Ne w source s a

t o r abov e th e 100 tp y threshol d mus t

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

- OpenMoldin g

- Centrifuga

l Castin g

- Continuou s Lamination/Castin g

- Pultrusio n

- SMC/BM C Manufacturin g

- Mixin g

12P.1 4 

## Whati s th e 100 tp y HA P Emissio n Threshol d an

d Ho w I s I tDetermined ?
Sumemission s fromth e al l operation s potentiall y subjec t

t o 9 5 percen t

contro l prio r t o any add-o n control s Calculate thes e emission s usin g

- Unifie d emissio n factor s

- Other publishe d emissio n factor s

- Sit e specifi c factor s i f

base d o n emissio n tes t

dat a

1 3
/A/PP.1 5 

## Draf tMACT for A

U Sources Below Thresholds Operatio n Typ e Ope n Moldin g - Corrosio n Resistan t and/o rHig h Strengt h (CR/HS ) Ope n Moldin g - Non-CR/H S
Ope n Moldin g - Shrinkag e Controlle d Resin s Specifi c

Operatio n Mechanica l resi n Applicatio n Filamen t Applicatio n Manua l Resi n Applicatio n Mechanica l resi n Applicatio n (Fille d o runfilled ) Filamen t Applicatio n Manua l resi n Applicatio n Mechanica l resi n Applicatio n Filamen t Applicatio n Manua l Resi n Applicatio n Emissio n

Limi t (Ib/ton ) 11 2 17 1 12 3 8 7 18 8 8 7 35 4 21 5 18 0 Allowabl e Resi n HA P Conten t 46. 2 Non Atomize d 4 2 4 0 38. 4 Non Atomize d 4 5 33. 6 5 0 Atomize d 5 0 5 0
1 4P.1 6 

## Draf tMACT for Al l Sources Below Thresholds (Con't)
Operatio n Typ e Ope n Moldin g - Toolin g Ope n Moldin g - Low Flam e Spread/Lo w Smok e Product s Centrifuga l Castin g Specifi c

Operatio n Mechanica l Resi n Applicatio n Manua l Resi n Applicatio n Mechanica l resi n Applicatio n Filamen t Windin g Manua l Resi n Applicatio n Non-CR/H S CR/H S Emissio n

Limi t (Ib/ton ) 25 4 15 7 49 7 27 0 23 8 2 0 2 5 Allowabl e HA P

Conten t (Weigh t % ) 50 + Non atomize d 4 3 Atomize d 45. 9 6 0 6 0 6 0 37. 5 4 8

15P.1 7 

# Draf tMAC T for Al l Source s Below Threshold s (Con't) Operatio n Typ e Ope n Moldin g - Ge l Coat Specifi c

Operatio n
Toolin g Ge l Coatin g Pigmente d Ge l Coatin g - Whit e an d Of f Whit e Pigmente d Ge l Coatin g - NonWhit e Clea rProductio n Ge l Coatin g CR/H S o rHig h Performanc e Ge l Coatin g Fir e Retardan t Ge l Coatin g Emissio n

Limi t (Ib/ton ) 43 7 26 7
37 7
52 2 60 5 85 4 Allowabl e HA P Conten t (Weigh t % ) 4 0 3 0
3 7
4 4 4 8 6 0 1 6P.1 8 

## Draf tMAC T fo r All Sources Belo w Thresholds (Con't) Injection/Compressio n Moldin g - Cover Charge s Resi n Transfe

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

1 7P.1 9 

## Draf tMACT for All Sources Below Thresholds (Con't) Pultrusio n - 6 0 percen t

contro l o r

we t are a enclosure (excep t

fo r larg e parts ) Sheet Moldin g Compoun d - Nylon
containin g film, cover

resi n delivery t o docto r bo x Equipmen t

Cleanin g - Cleanin g material s ma y contai n n o HAP (excep t fo r close d systems ) Resi n Mixin g an d BM C Manufacturin g - Cover th e mixer s Resi n Storag e - Cover

storag e container s
1 8P.2 0 

## Draf tMAC T fo r Existin g Source s a to r above th e 100 tp y Threshol d

Fo r existin g source s that

emi t 100 tp y o r more o f HAP combine d fro

m

- Centrifuga

l Castin g

- Continuou s Lamination/Castin g Th e requirement s are 9 5 percen t contro l o f th e operation s liste d abov e Th e requirement s fo

r al l other operation s are th e sam

e a s facilitie s belo w th e threshol d

1 9 / cnP.2 1 

## Draf tMAC T fo r New Source s at o r above th e 10 0 tp y Threshol d

• Fo r ne w source s that

emi t 100 tp y o r

mor e o f HA P fro m

- OpenMoldin g

- Centrifuga

l castin g

- Continuou s lamination/castin g

- Pultrusio n

- SMC/BM C Manufacturin g

- Mixin g Th e ne w sourc e MAC T i s 9 5 percen t contro l ofth e operation s liste d abov e Operation s no t

liste d abov e mus t

mee t th e same requirement s a s existin g source s

2 0P.2 2 

## Option s t o Mee tStandard s Ope n Moldin g and Centrifugal Castin g
Yo u ma y averag e ope n moldin g operations , an d separatel y averag e centrifuga l castin g operation s (12-mont h rollin g average ) Al l operation s o f

aspecifi c resi n typ e (CR , Non-CR , an d Tooling ) ma y us e th e same HA P content

resi n Operation s subjec t

t o 9 5 percen t

contro l hav e alternativ e poin t

valu e limit s Yo u ma y chang e complianc e option s
2 1P.2 3 

## Options for Meeting Standard s

Pultrusion

Wet are aenclosures , prefor

minjection , o r direc t di e injectio n t o mee t

th e 6 0 percen t reductio n requiremen t Yo u ma y averag e acros s differen

t machine s fo

r bot h percen t reductio n an d time s that cover s o r door s are ope n Fo r averagin g purposes , direc t di e injectio n an d prefor minjectio n are assume d t o achiev e a9 0 percen t

HA P emissio n reductio n

2 2P.2 4 

## Option s fo r Meeting Standards Continuou

s Lamination/Casting Ca n averag e line s Existin g source s ca n elec t t o contro l onl y we t ou t are aemission s b y 9 5 percen t Can mee t an alternativ e emissio n limi t o f 14. 7 lb/to n (58. 5 percen t

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

contro l level )

2 3P.2 5 

## Ho w do I Calculat

e Emissio n Factors ? Equation s are presente d i n th e rule , an d ar e identical t o curren t

unifie d emissio n factor s publishe d b y th e CFA . Resi n us e may b e base d o n purchas e record s i f yo u ca n reasonabl y estimat e ho w th e resi n i s applie d Resi n HAP conten t

ma y b e base d o n MSD S o r resi n specificatio n sheet s Emission s ar e base d o n organi c HA P content W e hav e adde d provision s fo r norma l manufacturin g tolerance s

2 4P.2 6



## How do I demonstrat

e Initia l Compliance ? I f yo u are usin g add-o n controls , yo u mus t perfor macomplianc e tes t

prio r t o th e complianc e date Performanc e test s method s are EP A Metho d 18 , 25 , 25 A Th e PTE mus t

b e certifie d usin g EP A Metho d 20 4 I f th e PTE doe s no t

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

25P.2 7 

## Ho w d o I demonstrat

e Initia l Complianc

e (Con't) ? Fo r emissio n limit s - perfor

memissio n factor calculation s a s specifie d i n th e rul e Fo r wor k practic e standard s - submi t a certifie d statement

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

standard s - submi t

a certifie d statement

that th e equipmen t

i s i n plac e an d mee t

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

2 6P.2 8 

## Ho w D o I Demonstrat

e Initia l Compliance for a PTE ? Determin e th e equivalent

diameter s o f

al l ND O an d exhaust s Determin e th e equivalen t

diameter s o f

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

mND O (mus t

b e a t leas t four) Measure PT

E surfac e are a(A T ) an d ND O surfac e are a(A N ) . Th e rati o o f AT/A N mus t 0.0 5 or less .

2 7P.2 9 

## Ho w D o I Demonstrat

e Initial Complianc

e for a PT E (Con't) ?

- Measure al l exhaus t

flow s (Q 0 ) an d al l force d makeup ai r

flow s (Qj ) usin g EPA Metho d 2 .

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

- F V mus t b e 20 0 fp mo r more ; o r

- measure pressur e differentia l acros s enclosure

- differentia

l mus t b e 0.00 7 inche s o f wate r o r more

2 8P.3 0 

## Ho w D o I Demonstrat

e Initial Complianc

e fo r a PT E (Con't) ?
Verif y directio n o f

flo w i s inwar dfor al l ND O usin g streamers , smok e tubes , o r trace r gase s I f F V i s 50 0 o r

more , inwar dflo w verificatio n i s not

require d

2 9