p.1 

OAR Box 1477 

Prepped by Ollie Stewart 

Document Number: 

29) ll-J-20 

Docket Number: 

A-94-52 

Printed 7/31/2008 11:40:24 AM Sheet 29 of 36 
P.2 

.* 

* . '«" 

From: KEITH BARNETT 

To: RTPMAINHUB.Internet."Peter_D._Eglinton@omb.eop.gov... 

Date: 2/23/00 4:31pm 

Subject: Additional Information on Reinforced Plastics 

Dear John and Peter: 

Attached is some of the additional information I promised. I don't have the 

data sets used to develop the point value equations. I am sending the memo 

and will sent the data sets as soon as I get them. 

Attached are: 

The memo describing how the open molding point value equations were 

developed 

The memo further describing the cost methodology and components 

An excel file with new source costs 

The method we discussed to determine capture (Method 204) is in CFR Part 51 

Appendix M. 

Keith Barnett 

CC: ALDRIDGE-AMANDA, LASSITER-PENNY, RTPMAINHUB.INTERN... 
P.3 

MEMORANDUM 

TO: Mr. Keith Barnett 

U.S. Environmental Protection Agency 

FROM: Melanie S. Proctor and Robert M. Jemison 

Pacific Environmental Services, Inc. 

DATE: August 2, 1999, Revised February 23, 2000 

SUBJECT: Costs for Facilities in the Reinforced Plastic Composites MACT Database 

The purpose ofthis memorandum is to submit the draft tabular costs for facilities in the 

Reinforced Plastic Composites MACT database and to provide a brief explanation ofthe cost data 

provided. This memorandum discusses costs associated with achieving the existing source 

MACT floors and the regulatory alternatives more stringent than the MACT floors that were 

considered. The draft tabular costs are contained in the Excel file that is being sent with this 

memorandum. (See the February 8 E-mail for current cost information.) A more detailed 

discussion ofthe costing methodologies that were used will be provided in the cost chapter ofthe 

Background Information Document (BID) that is still to be drafted. (A draft ofthis has been 

provided.) 

The first part ofthis memorandum presents the compliance options selected for MACT 

floor and above MACT floor costing analyses. This part discusses which compliance options 

were costed for determining draft tabular cost. 

The second part discusses the cost components that are provided (i.e., total capital cost, 

variable annualized cost, and fixed annualized cost) for each facility. This part also provides a 

detailed list ofwhich individual cost elements make up the sum ofthe total capital cost, the sum 

ofthe variable annualized cost, and sum ofthe fixed annualized cost. In addition, the second part 

ofthis memorandum discusses how the total capital costs were annualized, which includes a 

summary of equipment lifetimes and the capitalization factors employed. 

The third part ofthis memorandum provides the average incremental costs between the 

MACT floors and above the MACT floor options. 

Compliance Options Selected for MACT Floor and Above MACT Floor Costing Analyses 

Table 1 presents the compliance options selected for MACT floor and above MACT floor 

costing analyses. All compliance options were assumed to incur costs with the exception ofthe 
P.4 

following: covering of charges, closed or covered doctor boxes, folding edges of sheet molding 

compound (SMC), covering storage containers, and using non-HAP cleaning solvents. Data were 

collected for switching to non-HAP cleaning solvents, which showed no difference in price for 

acetone (a commonly used non-HAP cleaning solvent) and methylene chloride (a commonly used 

HAP cleaning solvent). 

The new source MACT floors for non corrosion-resistant manual resin application and 

non corrosion-resistant unfilled mechanical resin application are set by low HAP resins and the 

use of vacuum bagging. Since no cost data were available for vacuum bagging, add-on control 

devices were costed for these two process product groupings to meet the new source MACT 

floors. 

Above MACT floor options considered for existing and new sources generally consisted 

ofthe use of add-on control devices. For closed molding, polymer casting, equipment cleaning, 

and storage of HAP-containing materials no above MACT floor options were considered for 

existing and new sources since these are already low emitting processes and no options above the 

MACT floor were available in the case of equipment cleaning. In addition, no above MACT floor 

options were considered for new sources for pultrusion, SMC manufacturing, and bulk molding 

compound (BMC) manufacturing/mixing since no options more stringent than the new source 

MACT floor were available. 

Only one above MACT floor option was costed for each subcategory, which was 95 

percent control by using a thermal oxidizer in conjunction with a rotary concentrator. 

Cost Components Provided 

The Excel cost spreadsheet provides total capital costs, variable annualized costs, and 

fixed annualized costs for each subcategory, and each facility for existing MACT floors and the 

above the floor regulatory alternative. A detailed list ofwhich individual cost elements make up 

the sum ofthe total capital cost, the sum ofthe variable annualized cost, and sum ofthe fixed 

annualized cost is presented in Table 2. 
Table 1. Compliance Options Selected for MACT Floor and Above MACT Floor Costing Analyses 

Subcategory 

Open Molding 

Closed Molding 

Centrifugal Casting 

Continuous Lamination/ 

Continuous Casting 

Pultrusion 

Polymer Casting 

SMC Manufacturing 

BMC 

Manufacturing/Mixing 

Equipment Cleaning 

Storage of HAP 

Crmtnininfj Materials 

Process/Product Grouping 

Manual Resin - Non CR 

Manual Resin - CR 

Manual Resin - Tooling 

Mechanical Resin - Non CR -Unfilled 

Mechanical Resin - Non CR - Filled 

Mechanical Resin - CR 

Mechanical Resin - Tooling 

Filament Winding - Non CR 

Filament Winding - CR 

Pigmented Production Gel Coat 

Clear Production Gel Coat 

Tooling Gel Coat 

Compression/Injection Molding 

Resin Transfer Molding 

Centrifugal Casting - Non CR 

Centrifugal Casting - CR 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

Compliance Options Selected for Cost Estimates by Subcategory and/or Process/Product Grouping 

Existing Sources 

MACT Floor 

Low HAP Content Resin 

Low HAP Content Resin 

Low HAP Content Resin 

Low HAP Content Resin & 

Non-Atomized Application 

Low HAP Content Resin 

Low HAP Content Resin & 

Non-Atomized Application 

Low HAP Content Resin 

Low HAP Content Resin 

Low HAP Content Resin 

Low HAP Content«Gel Coat 

Low HAP Content Gel Coat 

Low HAP Content Gel Coat 

Uncover 1 Charge per Machine 

None (No MACT Floor) 

Low HAP Content Resin 

Low HAP Content Resin 

Add-On Control Device 

(58.5% Control of Wet Out 

Area and Oven Emissions) 

Wet Area Enclosures w/ 

Resin Drip Collection 

None (No MACT Floor) 

Closed/Covered Doctor Box / 

Folded Edges/Nylon Film 

Closed/Covered Mixing w/ 

No Visible Gaps in Cover 

No HAP Cleaning Solvents 

Closed/Covered 

Storage Containers 

Above MACT Floor 

Entire Subcategory 

Add-On Control Device 

(95% Control Efficiency) 

None Evaluated 

None Evaluated 

Add-On Control Device 

(95% Control Efficiency) 

(1) Add-On Control Device 

(77.6% Control of Wet Out 

Area and Oven Emissions) 

(2) Add-On Control Device 

(95% Control of Wet Out 

Area and Oven Emissions) 

Add-On Control Device 

(95% Control Efficiency) 

None Evaluated 

Add-On Conlrol Device 

(95% Control Efficiency) 

Add-On Control Device 

(95% Control Efficiency) 

None Evaluated 

None Evaluated 

New Sources 

MACT Floor 

Add-On Conlrol Device (95%) 

Low HAP Content Resin 

Low HAP Content Resin 

Add-On Control Device (95%) 

Add-On Control Device (95%) 

Low HAP Content Resin & 

Non-Atomized Application 

Low HAP Content Resin 

Low HAP Content Resin 

Low HAP Content Resin 

Add-On Conlrol Device (95%) 

Low HAP Content Gel Coat 

Add-On Control Device (95%) 

Uncover 1 Charge per Machine 

None (No MACT Floor) 

Low HAP Content Resin 

Low HAP Content Resin 

Add-On Control Device 

(82.6% Control of Wet Out 

Area and Oven Emissions) 

Add-On Control Device 

(95% Control Efficiency) 

None (No MACT Floor) 

Add-On Control Device 

(95% Control Efficiency) 

Add-On Control Device 

(95% Control Efficiency) 

No HAP Cleaning Solvents 

Closed/Covered 

Stora-je Containers 

Above MACT Floor 

Entire Subcategory 

Add-On Control Device 

(95% Control Efficiency) 

None Evaluated 

None Evaluated 

Add-On Control Device 

(95% Control Efficiency) 

Add-On Control Device 

(95% Control of Wet Out 

Area and Oven Emissions) 

None Evaluated 

None Evaluated 

None Evaluated 

None Evaluated 

None Evaluated 

None Evaluated 
Table 2. Total Capital Cost, Annual Fixed Cost and/or Annual Variable Cost 

P.6 

Add-On Cmm\ Mvkw wf &m&m$ KfritygMttt 

Total Capital Cost - Add-On Control Device 

Total Capital Cost - Permanent Total Enclosure (PTE) 

Total Capital Cost - Wet Area Enclosure (WAE) 

Total Capital Cost - Ductwork from PTE or WAE to Add-On 

Direct Operating Cost Minus Utilities - Add-On Control Device 

Electricity Costs - Add-On Control Device/Ductwork 

Fuel Costs - Add-On Control Device 

Overhead, Property Tax, Insurance Administration 

: W*t An JM*ttg* / ftaift 3Mp CfeHmttax Bjfsum 

Total Capital Cost -Wet Area Enclosure / Resin Drip Collection 

Operating & Maintenance (0 & M) 

&m4Kbmi& MMm 

Cost of Mixer Covers Replaced Annually 

. n«$iMCMft-tt& of §p&y Wwtiymm w/ liwwater 

Total Capital Cost - Flowcoater / Salvage Value Spray Guns 

Decrease in Personal Protective Equipment Usage 

Decrease in Floor Coverings Usage 

Decreased Resin Usage Due to Increased Transfer Efficiency 

Materials Replacement 

Replacement of Existing Resin with Low HAP Resin 

Replacement of Existing Gel Coat with Low HAP Gel Coat 

Product Recertification (Resin and Gel Coat) 

New Material Testing 

IHHHNHHHB 

Subpart A Notifications (Year 1) - Construct/Reconstruct, 

Anticipated Start-Up, Actual Startup, Notice of Compliance Status 

Semi-Annual Report, Periods of Non-Compliance Report, 

Maintain HAP Content/VSR Test Record 

Develop Training Program / Records System (Year 1) 

Conduct Training Program / Keep Training Records 

Reading Standard (Year 1) 

Reviewing Standard (Annually) 

Performance Tests, Develop O&M Plan, SS&M Plan (Year 1) 

Semi-Annual Start-up, Shut-Down &Malfunction (SS&M) Report 

TCC 

X 

X 

X 

X 

i TCC 

X 

TCC 

! TCC 

X 

1 TCC 

X 

X 

HHH 

X 

X 

X 

X 

. Acm[ 

X 

X 

X 

AC(V> 

X 

Acm 

.Acm 

X 

X 

X 

,AC(V) 

X 

X 

•Hii 

AC#) 

X 

X 

X 

X 

X 

AC$> 

X 

AC{f) 

X 

Ajcmi 

X 

. ^p^*l 

X 

X 

Iiiiii 

X 

X 

X 

X 

X 

X 

X 

X 

Abbreviations 

TCC = Total Capital Cost AC(V) = Annual Cost (Variable) AC(F) = Annual Cost (Fixed) 
P.7 

The total capital costs presented in the cost spreadsheet were annualized. A table with the 

time periods and the capitalization factors employed to annualize the total capital costs are shown 

in Table 3. All the capitalization factors are based on a seven percent interest rate. 

Table 3. Time Periods And Capitalization Factors Used To Annualize 

A-dUM&i €«»trel Devices w/Associated Equipment 

Add-On Control Device 

Permanent Total Enclosure (PTE) 

Wet Area Enclosure (WAE) 

Ductwork from PTE or WAE to Add-On 

Time Period 

10 

30 

30 

10 

factor 

0.1424 

0.0806 

0.0806 

0.1424 

. W«t Arfe Xtottami* / E«*to IMp Collection $ymm 

Wet Area Enclosure / Resin Drip Collection 30 0.0806 

Replacement of Spray Equipment w/ Fiowcdater 

Flowcoater / Salvage Value Spray Guns 7 0.1856 

•Materials Replacement 

Product Recertification 

Product Testing 

10 

10 

0.1424 

0.1424 

Monitoring, Record keeping* & Reporting 

Subpart A Notifications (Year 1) - Construct/Reconstruct, 

Anticipated Start-Up, Actual Startup, Notice of Compliance Status 

Develop Training Program / Records System (Year 1) 

Reading Standard (Year 1) 

Performance Tests, Develop O&M Plan, SS&M Plan (Year 1) 

10 

10 

10 

10 

0.1424 

0.1424 

0.1424 

0.1424 

Average Incremental Costs By Subcategory 

Refer to the Tables sent February 8 for the most recent cost data for existing sources. 

Summarized cost data for new sources is attached. 
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» Pioiociw New Grorti-. Faciioy Designated NG • 40 PC - DM - 36. Anctiuty Suxa**>>-»--*• 

ine Prowae-i New Gr.-jr-.v- Facility OesygnaaO NG - 41 (PC - 33 OM - 37. A-xai-ary SotDwieg-xieij 

•J*** projected Now Gfuwtn Faculty DaiKjrsaed NG • 42 ("FC • 34. OM *ale B» -.--. 1 

• ««ft-^ea»3NewGn>^Fa«b/DesV«cdNG- 43 (PC • is. OM - 33, Anothary SubcaleooiWisj 

• j* (or ttio Projected Ne* G* owih Faculty CXKugr-atBd MG • 44 (PC • 36. OM - 40. Anc-JKary Subcalsgo-iesi 

/ lhe Rotecuri Ne* Growth Facility Ossrgnaiod NG • 45 (PC -37.OM • 41 . Ancillary S-JtoK-Uegon-eS) 

r -j** Prciacied Now Growth Faulty De-signaied NG "6 (PC • 3ft OM - 42. Anonwy Siteattoo-ios* 

1' mais Jar tie Projected New Growth Faciisy Oes*jnai«J NG • 47 {PC - 39. OM • 43. Anartary Su****cai«gories) i the Piojecled Nuw Growth Facrlity DeaynattK) NQ - t8 (PC - 40. OM - 44 Aooillary Suixalego--.es) 

its. ProtaciiKl Now Grwih Facility Detonated NG • 40 (PC - 4i , OM - 45. AncMliary SuOcateaonesi i " aia& tor mo Projected Na-* Growth FacMRy CJ-Exignated NG • 50 (PC - 42. OM • 46. Ancillary St#c«ego**iesj • the Pr ejected Now Growth Facility DoaignatBd NG - 51 (PC - 43. OM - 47. Anciiiisry Sut5eal-I9c>rtes) 

".:*a!a tor the Projocied N»w Growth Fadlity Oes-gnau-J;." 52 (PC - 44, OM - 48. Ant-Mary Subcategories! 

-ocals lor tne Projected Ne* G'O**! Facility Designated NG - 53 (FC - 45, OM - 49, AncUSwy Subcategories! 

"mate tor too Projected Naw Growth Facility Dasignated NG - 54 (PC - <6, OM - 50, Anoftei^ Sufieatogones) 

NG 55 to 66 

NG 55 IO 65 

NG 55 lo 65 

NG 55 IO 65 

NG 55 lo 65 

NG 55 10 65 

NG 55 10 65 

NG 55 10 65 

NG 55 lo 65 

NG 55 10 65 

NG 55 10 65 

NG 55 lo 65 

NG 55 10 65 

NG 55 10 65 

NG 55 to 65 

OM •* : i, * 

OM 51 to 63 

OM 51 lo 63 

OM 51 10 63 

OM 51 to 63 

OM 51 to 63 

OM 51 to 63 

OM 51 to 63 

OM 51 to 63 

OM 51 to 63 

OM 51 to 63 

OM 51 to 63 

OM 51 to 63 

OM 51 10 63 

OM 51 10 63 

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PC - 47 10 58 

PC - 47 to 58 

PC - 47 lo 58 

PC • 47 10 58 

PC - 47 to 58 

PC - 47 to 58 

PC • 47 to 58 

PC - 47 to 58 

PC - 47 to 58 

PC - 47 10 58 

PC - 47 to 58 

PC - 47 lo 58 

PC • 47 to 58 

PC - 47 to 58 

A.e..O» *•« • -4 • -ts_r. •> • 

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35 

Average Annual Cod t$ •' <cr\ resin o» 5 ' ion gei coat) 

Protected Resto or Get Coat Uuge {tny*) tor NG - 4C 

oral Annuai Cos; cS.' yr) 

Avar aoe Amu*** Cost r J.' ton rasm or J I «*n .-jet cost) 

Projecaed Ream or Ge'Ccat Usag* ftpy)to( NG •* ' 

->:;, Annual Coel •:*> yfl 

Avarag« Annual Cost (S • ion resm or $ ' ton oa? coat) 

Projected Ri»n or Gel Coal Usaoe (Ipyl tor NG - <»2 

Toal Annuai Cost iS.- y, 

Average Annual Co«t (S r* ton resn or S / ton got ccat** 

Projected H3*pn or Gai Coal Usage i*a*vj tor NG • 43 

rotal Annual Cost ft - yD 

Avaiaga Annual Cos: fS. ion rssin 01S.' ion oai coan 

Projected H»Sin or Gffl Coat L-say.; (toy) tot NG - 44 

Total Annual Cosf $ "'"Vi 

Average Annual Cast (5 / icn itsin or S ' ton gal coat) 

Projected Resm or Gel Coal Usage (toy) to NG - 45 

Total Annu"a!'CoitT|7 yr)" 

Average Annual Cost ($ ' ton rosin or S •' Ion gm coat1 

Projected Resln or Gel Coax Usage (tpy) tor NG - 46 

Total Annua! Cost (S /yr) 

• torsos Ann •*) Cost •:• •* km -*--*r, at |/ton gal c "..•:>• 

Projected Besln or Gel Coat Usa-***-** (tpy} for NG - 47 

Total Annual Cost ct - yo 

Average Annual Cost (5 ' ton resin or S ' ton get coal) 

P-njected Resin or Gel Coat Usa-**** (-py) tor NG • 48 

Total Annua5 Cost & f yrl 

Average Annual Cost (i I Kmreain rx $/tcn oei coafj 

Projected Reein oi GM Coat Usaa* ppy| io NG - 4S 

Total Annual Cos!(S/yr) Av ra ag<s Annual Cosl (S/to

n ream or S / ion gei coat) 

Prc-jectod Fteein c Got Coat Usage (ij*-y) le* NG - 60 

Total Annual Coat (S.' yrt 

Average Annual Cost i's ."ton r«sm or S ' loo ow coed) 

Pn^ectod Flesin or Gal Cos* Usage (toy) lor NG - 51 

Total Annual Cosi $ / yr} 

Average Annual Cosf (S' ton resn cn S / too gas coai) 

Prj^ected Resm or Gel Coat Usage (toy) for NG - 52 

Total Annual Cosi (S1 yr) 

Average Anoual Cost {S r ton iseto or S / ton gei coart) 

Prajecwd Resi" or Gel Coat Usage (tpy) tor NG - 53 

Icial Annual Cost (S 7 yr) 

Aveiage Annua Cost (S •' ton msm or S •' ton ••joi coat) 

Projecto1 Resin ot Gel Coat Usage (ipy) tor NG - 54 

AGCO. Inc; 

Austin Counierlops, Inc 

Builders Marble. Inc 

Cameo Marble 

CDR Systems Corp. (Corcoran) 

Century Marble Co , Inc 

Ebonite International, Inc 

General Marble Co (Hornell) 

General Marble Co (Uncolntown) 

Lehigh Cultured Marble, inc 

Upper! Corp. 

Mincey Marble Manulacturing. Inc 

Rynone Manufactunng Corp (Sayre Plant) 

Sl Marys Marble. L LC. 

Superior Home Products 

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436 2 

S25.445 

N'A 

440'! 

N'A WA WA 

N/A WA WA WA WA WA WA WA WA WA WA WA 

W 3 H WA 

246 9 

i43.&!j WA 

259 1 

S45./S0 WA 

266« 

S47.120 WA 

i4fii66 WA 

C-77.9 

S48&2I WA 

285 ' 

$50,351 WA 

3C3.4 

•.-.:- 333 WA 

305 6 

S45.?7*3 WA 

3089 

«J5*3 WA 

325 5 

•JJa.Ws '. >• 

3621 

S63.467 WA 

422.3 

$73*21 WA 

432 9 

gft.&i WA 

436.2 S 7*5.202 WA 

440.7 WA WA WA WA WA WA WA WA WA WA WA WA WA 

N'A WA 

JT-

1564.46*9 WA 

.-•: i • 

$62*1988 WA 

268 5 

S544.7B3 WA 

2735 

Sfed,35*l WA 

2779 

$567,346 WA 

285 7 

$533,141 WA 

3-33 4 

sei 9 2-a WA 

S623T55 WA 

306S 

itid m WA 

3355 

$(584,676 WA 

362 1 

$738,829 WA 

4229 

im^.m 

N'A 

4329 

&&.£-i5 WA 

436? 

$890,004 WA 

440 7 WA WA 

N'A WA WA WA WA WA WA WA WA WA WA WA WA 

242.5 

i l7 |U WA 

.i44 7 

• s*i?;yo 

r.A N A 

2C? i 

$18,339 WA 

2648 

$18,888 WA 

173 5 

tiii&i WA 

2779 

S-.4 672 WA 

iio.'^ ' WA 

3C3 4 

£21.474 WA 

3056 

""»<^3 i 

N'A 

3089 

$21,666 WA 

335 5 

S23.747 WA 

362 1 

$25,628 WA 

4223 

45flidS WA 

4329 

t M W WA 

436 2 

$30,879 WA 

440.7 WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA 

1 N7 1 

S8C.3& 

&1.6 & WA 

253 1 

$65 001 *, •-. 

266.8 

$87 _it» WA 

273 5 

ied.US 

•Hi-iTi 

WA 

285 7 

$t»,ia-2 WA 

303 * 

599.303 WA 

305.6 

S'lW.rJlS 

toe a 

$101.061 WA 

335.5 

SICS.672 WA 

362 1 WA 

4228 

5l-37^lfe WA 

432 9 

S141.I36 N A 

436 2 

S142J203 WA 

440 7 

N'A WA WA WA WA WA WA WA WA WA WA WA WA WA WA 
- -m-mirn^. ; _J \T-_i f^ OfSCK >,e» /_?M- r c •:.. _^, v -_:•_-_ -yy -_ i - : - « > / - : • • -yy. yy. ijocs:= ->>"-=-*?. 

••a^ lo? the Protected f-ie-* Growth Faa*-Cy Destgratfr*} ?4G - 5£ <PC - 43 QM - 52. Ancritiary Subcategories; 

"o-tats to* &*e Projected f*e* Growth Faa&y Designated MG - 57 (PC - 49. OM - 53, Ancrf&ary Stftscategort-es) 

"•jiafc tor tfie Projected Mew Growth Faci&y Designated NG - 58 (PC - 50. OM - 54. Ancillary Subcategories) 

" estate lor the Projected New Gronrth FaciSty Designated MG - 59 (PC - 51, OM - SS. Anciikary Subcategories) 

7

 state fof the Pi-ejected New Growth Faci&ty Designated MG - 60 (PC - 52, OM - 56. AncSfeary Subcategories) 

Totals for me Projected New Growth Facility Designated NG * 61 (PC - 53, OM - 57, Ancftbaty Subcategories) 

Toiai-s ior (he Projected New Growth Facility Designated NG - 62 {PC - 54, OM - 58, AncS&ery Subcategories) 

' otate ior Ow Projected New Growth Facility Designated NG - 63 (PC - 55, OM - 58, AnctfSary Subcategories) 

Mais Jor aw Projected New Growth Facility Designated NG - 64o(PC - 56, OM - 60, AncBSaty Subcategories} 

• otab for Uw Prelected Mew Growtii Facility Designated NG - 65 <PC - 57. OM - 61 , AncSfiary Subcategories) 

''otais for the Projected Mew Growth Facility Designated NG--- 66 <PC - 53. OM - 62. Anctfiiary Subcategories) 

NG - 67 10 71 

NG - 67 to 71 

NG - 67 10 71 

NG • 67 to 71 

NG - 67 to 71 

NG • 67 to 71 

NG - 67 to 71 

OM - 63 to 68 

OM - 63 to 68 

OM - 63 to 68 

OM-63to6 8 

OM - 63 to 68 

OM-63to6 8 

OM - 63 to 68 

PC-5 9 to 64 

PC • 59 to 64 

PC • 59 to 64 

PC • 59 to 64 

PC-59to6 4 

PC - 59 to 64 

PC - 59 to 64 

"staSs lot ths Projected New Growth Facility Desaaated WSI-^riP C - 59. OU - 63, / urctiiiary Siibcateoones} 

Totals lor the Projected New Growth Facility Designated 1*3 - 68 (PC - 60. 0 M - 64. Ancaiary Subcategories) 

-"OKI's tor the Projected New Growth Facility Designated NQ - 69 (PC - 61 . OM - 65. Ancillary Subcategories) 

ToftS t r the Projected New GrowHi Facility Deslgrwled NfJ - 70 (PC - 82, (Ml - 68. Anciiliary Subcategories) 

Tola's for the Projected New Growth Faciirty Designated NG - 71 (PC - 63, OM - 67. Anciiliary Subcategories) 

To* * fcr the Projected NewtSiowth FscliUy Bsslgnsi-iKlNe - 72 (PC - 84. OW - 8a, Ancittsty Subcassgortesi 

we-w i PL-I IIII I 

Totals ta tKi Proieored New Growl* Fac-Bty Desinftatfid 1*<IG - 73 (Pi_ - l Ancillary Su*3oatQ(tcTf£»] 

'Ng-74 PL- 2 

-.rs^Ar. ^ '_y_- ; -yr-try-' y\ :./ , , -_.-j_: 

'• '.yy.iyyy'yry'. -Tes" 0-' G c ^03- Osajs '^yj': '•-•_-. fvG • 5c 

Total Ann^a; Cost (S.' >--; 

Averaoe Annua] Cost :$ •' ron resin or S -' ton ae* ccat) 

Protected Resin or Ge: Coat Usage ftpy) lor N o - 56 

Totai Annua; Cost'.% • yv, 

Average Annual Cost (5 •' ton resin or S ' ton oei coat': 

Projected Resin or Gel Coat Usage (tpy) tor NG - 57 

Totai Annua! Cost ($ •' yr} 

Averaoe Annua) Cost (5.' ton resin or $ / ton oei coat) 

Projected Resin or Gel Coat Usage (tpy) tor NG • 58 

Total Annual Cost ($ .' yr) 

Average Annual Cost (5 / ton restn or $ / ton gel coat; 

Projected Resin or Get Coat Usage 'tpy) tor NG - 59 

Total Annua! Cost (S /' yr) 

Average Annual Cost (S / ton resm or S,' ton gel coat) 

Projected Resin or Gel Coat Usage (Ipy) for NG - 60 

Total Annua) Cost ($ ; yr) 

Average Annual Cost {S /to n rssin or $ / ton gel coat) 

Projected Resin or Gel Coat Usage (tpy) "or NG - 61 

Total Annual Cost {$ / yr) 

Average Annual Cost {$ / ton resin or $ / ton gel coat) 

Projected Resin or Gel Coat Usage (tpy) for NG - 62 

Total Annual Cost ($ / yr) 

Average Annual Cost {$ /tort resin or $ / ton get coat) 

Projected Resin or Gel Coat Usage (tpy) tor NG - 83 

Totai Annua! Cost ($ / yr) 

Average Annua! Cost ($ / ton resin or $ / ton gei coat) 

Projected Resin or Get Coat Usage (Ipy) tor NG - 64 

Total Annual Cost ($ / yo 

Average Annual Cost ($ / tort resin or $ ' ton gel coat) 

Projected Resin or Gel Coat Usage (tpy) tor NG - 65 

Total Annual Cost ($ ' yr) 

Average Annual Cost ($ ' ton resin or $ / ton gel coat) 

Projected Resin or Se! Coat Usage (tpy) tor NG • 66 

Total Annual Cost ($ / yr) 

CDR Systems Corp. (Palatka) 

CR/PL Ltd. Partnership (Newartesian Ltd. Partnership) 

Dow Chemical (Russellville. AR) 

Mesa Fully Formed, Inc. 

Oasis 

Quazlte Co. 

United Technologies Motor Systems. 

Average Annua! Cost ($ / tort resin or § / ton gel coatS 

Projected Resin or Gel Coal Usage (1py) tor NG - 67 

Total Annual Cost {$ ' yt) 

Average Annual Cost ($ / ton resin or S ' ton gei coat) 

Projected Resin or Ge! Coat Usage (tpy) lor NG - 68 

Totai Annual Cost ($ / yr} 

Averaoe Annual Cost ($ ' ton restn or $ .< ton gei coat) 

Projected Resin or Ge! Coat Usage (tpy) toi NG - 69 

TfJal Afiausl Cost (S / yr) 

Averaoe Annual Cost (5 / ten rasm or S / ton oei ooa*j 

Projected ("tnain or Ggi Coat Usage (tpyi for NG - 70 

Total Annual Cosl (S / yr) 

Average Annua! Cost (5 / ton resm or S.- ton oei coal) 

Projected Resm or Gei Coat usage (tpy) for IMG - 71 

Total Annual Cost (S / yr) 

Pmmam Annual Coat {$/* ion resin or $ / ton gel coal) 

Projected Restn or Sel Coat Usage (Ipy) lor MG - 72 

Tdli'ABntW'Coet^/iiri ' ' 

Haysite Reinforced Nasties 

Average Annual Cust ($ 1 eon resin or ^ / ion qs', coaS 

Projected Re^n or Sa Oeat Uaaoj (lay) ter NG - 73 

Total Annuel Cest (S' yr) 

Marley Cooling "Power Co. 

5C7 1 

srsieees 

H/A 

5126 

$256 537 

N/A 

520.4 

$260,400 

N/A 

549.2 

S274.750 

N/A 

582.4 

S291.307 

N-'A 

607.8 

$3**kdbo 

N/A 

640.0 

$&>6,i3d*5 

N/A 

645.5 

$322,765 

N/A 

671 0 

$335,459 

N/A 

717.6 

$358,639 

N'A 

954.4 

S476746 

N'A 

961.0 

MiM . 038 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

1.0S9.*/ 

$206 676 

N/A 

1.0740 

$214,478 

N/A 

1,107.8 

S221.0S2 

WK 

1,217.9 

S243.0S1 

M/A 

I.683-4 

S8S.78S 

WA 

. MS*.} 

t*»84,»83 

WX""' " 

M/A 

3S.0 

<32<(.61« 

r WA 

mlvy ••• 

S24.056 

fi'A 

5126 

S23.661 

N'A 

5204 

$24,019 

N'A 

549 2 

$25,348 

N'A 

582.4 

$26,881 

N'A 

607.8 

42-4,646 

N'A 

840.0 

iis.Sii 

N/A 

845.5 

$29,794 

N/A 

671.0 

,t3G.36S 

N/A 

717.5 

S33.116 

N.-A 

9544 

$44,*55*> 

N'A 

9610 

$44,359 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

!,0*».7 

$34,524 

N/A 

1,074 0 

$36,009 

N/A 

1.1072 

587,1-*f 

•J/A 

1^17S 

$40,835 

N/A 

1.633.4 

$8,720 

WA 

&86E» 

fc»S8S 

"KB A'" 

W/A 

330 

$14,*!S4 

N/A 

5C7 1 

$60 736 

N-'A 

5126 

$47,862 

N-'A 

520.4 

444.565 

N/A 

549.2 

$51,179 

N/A 

5824 

$54,195 

N/A 

607.8 

$56,507 

N/A 

6400 

"$59,42> 

N/A 

6455 

$59,924 

N/A 

671 __ 

46-2.236 

N/A 

717.5 

466,446 

N'A 

954.4 

$87,970 

N'A 

961.0 

$86,573 <<<<<< < 

N'A 

1.029.7 

$38,200 

N'A 

1.074 0 

$39,787 

N'A 

1,107.2 

S40J76 

WA 

1,217.9 

S44S<*a 

N/A 

1,6534 

•M4.879 

IVA 

5.6631 

$130,840 

1 1 1

 WA " 

N'/A 

39.0 

?66.0U1 

W/A 

_*• 

•y--7 . 

$316665 

ri'A 

5126 

S2S6.53-

N-A 

520 4 

$260,400 

N-'A 

549 2 

$274,750 

N'A 

5824 

$291,307 

N'A 

807.8 

$304,000 

N'A 

840.0 

4420.666 

N'A 

6455 

$322,765 

N'A 

671.0 

$SS5.459 

N/A 

717.5 

$358,639 

N'A 

954 4 

$476,746 

N'A 

961 0 

$480,058 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

l*A 

1,029.7 

$240,333 

N/A 

1,074 0 

$250,627 

N-'A 

1,1072 

$256,*ta 

N/A 

1.817 9 

$284,083 

WA 

1.6S3.4 

$259,177 

N/A 

S.888.1 

" W6;b^'" 

'IOT""""1 

f*A 

39 0 

S3**4,618 

f WK 

5C7 1 

$24 056 

N'A 

512 6 

$23 661 

N-'A 

5204 

$24,019 

N A 

54S.2 

$25,348 

N'A 

582.4 

$26,681 

N/A 

607.8 

426.056 

N/A 

6400 

$H,iS&" 

N-'A 

645 5 

$29,794 

N/A 

671.0 

4S6.669 

M/A 

717.5 

$33,116 

N/A 

954.4 

$44,052 

N-A 

981.0 

$44,353 <<<<<< < 

2 22 2*2 22 

N/A 

1.029.7 

$30,257 

N'A 

1.074.0 

$$1,566 

N'A 

1,1075 

mw "M 

1,2178 

44i.7a*? 

PI/A 

1,6534 

ss,eo3 

WA 

5,6681 

mM 

'" ""TO"" 

M/A 

^ . 0 

S14.2S4 

N/A 

' . A 

*?:-71 

$60 7*"£ 

N-'A 

5126 

547.862 

N-'A 

5204 

$48,565 

N'A 

549 2 

$51,179 

N-'A 

5624 

$54,195 

N-'A 

607.8 

456,561 

N'A 

640.0 

456.422 

N'A 

645.5 

$59,924 

N-A 

671.0 

$62,236 

tt'A 

717.5 

$66,458 

N/A 

954 4 

$87,970 

N/A 

961 0 

$SE,573 <<<<<< < 

2 2 2 2 2 22 N/A 

1,026.7 

444,589 

M-A 

1,074 0 

$46,450 

N/A 

1,1072 

'-Mtm 

WA 

1.2179 

$sa4 * 

N'A 

1.883.4 

$45^42 

N/A 

S.6SM 

*S1tH.«B' 

rox 

L W/A 

380 

$56,081 

'rox 

'. i 

OT -: 

$S35 875 

N'A 

512 6 

5508 802 

N'A 

5204 

$516,479 

N-A 

5492 

$544,995 

N'A 

582.4 

$577,897 

N'A 

607.8 

4603,123 

N'A 

640.0 

4634.S26 

N-'A 

645 5 

$640,412 

N/A 

671.0 

$665,637 

N/A 

717.5 

$711,701 

N'A 

954.4 

$946,406 

N'A 

9610 

$952587 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N'A 

1.029 7 

$504489 

N'A 

1.0740 

$526,144 

N'A 

1.107,2 

K4M6 6 

N/A 

1,217.9 

$598,523 

M/A 

1,6534 

8370,168 

WA 

5,668! 

$1,S»,a37 

MM' ' 

N/A 

3S.0 

'iS24.61S 

T

 N/A" ' ' ] 

•_fx 

S'O? 1 

$34,415 

N-A 

5126 

S19.002 

N/A 

520 4 

J1-S.28-S 

o N/A 

549 2 

$20,357 

N'A 

5824 

$21,566 

N'A 

607.8 

422.642 

N/A 

640.0 

'*" 424.122 

N/A 

645.5 

'•; 425.927 

N/A 

671.0 

$24,871 

N/A 

717.5 

S26,MS 

N/A 

954 4 

$35,378 

N'A 

= 9610 

$35,624 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

N/A 

i-j-- N,,A 

1,029 7 

$22,941 

N-'A 

i,074 0 

•&$,&. 

N'A 

1,107 2 

**B4,e97 

N'A 

1.217 9 

$27,134 

N'A 

1.65a4 

**S«36 

N'A 

3.668.1 

sai .721 

n ^ , „ 

M/A 

33 0 

$14,234 

roA 

* . A 

507 1 

$152,360 

N/A 

5126 

S82416 

N'A 

520.4 

444,642 

N'A 

549.2 

$88,194 

N'A 

582.4 

$33,447 

N/A 

6078 

$97,475 

N/A 

640 0 

4162,643 

N/A 

645 5 

4na,426 

N/A 

671.0 

$107,456 

N/A 

717.5 

4"4*il6 

N/A 

954.4 

4152.282 

N'A 

961.0 

$153,332 <<<<<< < 

2 22 22 22 N/A 

1.029.7 

$84,446 

N'A 

1.074.0 

$88,022 

N'A 

1,107.2 

$90,703 

(W 

1,21 ?.S 

539 539 

N/A 

t,6S3-4 

SS4.t368 

f*A 

5^861 

(fiH '" 

"" Kl/A 

N'A 

3S.0 

*66.061 

N/A 
P.M 

f 8 

I- Ia 

k 

a 

8 8 

?-

i» *? 

?-

g_ 

! •5 

g. 

I I 

S

5 

•8 i 

11 

Si S 

£ j* 

O 1 

?j 

3 

i i ?! 

sj 

8 •• 

i i 

?« 

l l sSii 

'3* 

|i 

I* 

l f i 

i i 

.sg; 

%_. 

uz ss 

*te : ??! 

1 6 

8 c 

??S 

I. 

1?; 

> St 

818 

ill U\ 

I 

i 

i**>i , 

s : 

S r 

g* 

83: 

> a < 
CL 

. •.. 

v^ j,'-JZ__''. l-v^n^^^^u^•^lI^•I'M^lJ^ iiv, • 

win F*c*ty Oas-gnaiad NG - 92 (PL - 2a. AnoSary SuUi-Kegorawj lAvai t... Ann I 

TM Illll l 

i * ate Pto&c&i »«*,» Gfowm ?actfir, c^vy^.-- *ary SutcatfryotHut 

' » u {• Pti*jicl*; Now Olowin Facility Designaiei; K"i l-caiagories; 

— ^ 

K Coat Usage (Ipy) lorNG - 02 

<S / ton rwin or s ' w i gei wa t 

Pro/ac**) Resm ty Gel Coat Uss:: 

T o w Annual boo; ($ / yr] 

Average Annua! Cost ($ •' Wn re«n cw S ' ten ort coat 

Pn '-.ie d fit*- cn G d Coal Usage -. ,* far N G - M 

TOBTAWK 

I*513 

* ' die Projeciuc) New G'owiti Factiuy Dssignawa K G • 65 (PL - 23, Ancnuaiy Sutx-asfl-xieici Averag* Annas! Cost (S / ten resm cx S / ion gal cow 

Proiacted Resm oi G d Coal Usage ppy * lor NG - 95 

Total Annual Co* 

TM@B 

.' lhe ProjocMM NewGiotWi Facdiiy Deognalad NG - 96 (Pt -£*, Ancillary Sutc8tegor>esi ... Bra-pa Annual Cosi :5 an refin n i Bn •>:*< coal 

PraiecW) Rftain or Gel Coat Ua soc fury) Jar NG - 96 

rom AnraaJ ....-•'.•<• ••• • 

TM H 

•or Hi* PiojertfcO New Growm Faculty Dwignawd NG • 97 -pi. - 25. Ancfiiiafy Subc"*j»iof«si Aawaga Annual Coat (& i lon resin oii-tan get coal) 

M ti e Pro-jaded New t -tfiiary SuLcateg.'.* . 

^T^^^ ^ 1 1 1 1 1 

NG - 100 ••'•• - 1 1 1 | 

njaciad NowGrow* F»dHty Oeegnateti NG • io o *PL • 28 AraBiazy Subcategories) 

rr-rrrr-TrrrT^rr 

UiilV-,-li',IJ-J^ 

'fT'-KjfflRJflFf.'l 

Bedtord Reinlorced F 

"TLSiTill'J-n 

^^^^^ TM III I 

"«al»torttieFtcjeciedN»wGrowth Facilily Owig-WtKi vJ - IO I (PL-29, AncmuwySutcategortoel 

Illll l 

rmsls for tfie Projected Now Growth Facility De<»gnaled NG • 102 (PL - 30 AnoWary SuDcategonesj 

'ih»Ptoi«ntKJN»wGrciwiti FatSiiy OesignaKKiNG-103(PL -31 . AnciBiary SuOeaiBaoUss* 

N G- 104 PL - 32 

Totals 1a Ute Projected Now GiowUi F ac-ftty Oesgnaiofj UG- l (M •; 

, _ _ 

'L - 32. Ancktary Su£**catoaot,»»* 

•••• i. v ; '•• : ; :•• 

Coat Usage (ipy) brro . 

yr) 

($•' ton resin or J / ton gal coat 

j] Coal Us=oc lU,vi ler NG - 98 

y ) 

: >y) lor NG - 89 

yo 

(S l ton resin or S ' tun gei CoaE 

I Coal Usage (tov) tor NG-1 M 

y . 

Avwage Annual Coat {$ / ton rssn oc S.- lon gel co-af* 

Projected Resm or Gel Coal Usags (tpy) for NG -101 

Total Annual Cos! <*$ /y?) 

Average Annual Cosl (5 •" ton resm or S t M I o«l coal] 

Projected Resin or Gal Coai Usage (toy) lor NG - t02 

Total Annual Co« (S / yr) 

Average Annual Cosi {$.' ion resm or S.' uxt gel r.-oat) 

Projecltsd Resm or Gel Cosl Usage (toy) tor NG -103 

Total Annual Cow <S / yr3 

:

iberllex. Inc 

Carsoniie International Corp 

Snakespeaie Co 

Glaslorms. Inc (Birmingham) 

Glastlc Corp (Soulh Euclid) 

C 'native Pultrusions. Inc (Alum Bank) 

Omega Pultrusions. Inc 

Liberty Poiyglas. Inc 

Bedford Retnlorced Plasties, Inc 

Avenge Mnual Cosi (S i m reski -,*.-. : n Kd coal 

Projeaed Resin or Gel Coat Usage (Ipyj lor NG 104 

Total Annual Cost ! 

$'.'-. 

N'A 

SIB0 

•K«ic « 

H.K 

5 M O 

" ii>654fi ' 

H-A 

63S.0 

i-&6A.W 

N/A 

<././•/ , 

S487.480 

WA 

7-10.0 

"•USi-Wfl " 

N/A 

B33 0 

SWi.9M 

N/A 

3SE.0 

S«6<3i09 

S1.503.559 

N/A 

1.755 0 

•51,488,918 

WA 

4.42S0 

$1*53.592 

WA 

B^B9.0 

SI.828.607 

WA 

8.680 0 

Cag7 2 

WA 

WA 

WA 

WA 

WA 

WA 

WA 

WA 

H t. 

N'A 

1.0210 

SI.C23.539 

4S4C 

$58877 S220.96I 

WA 

L • B " 

-. yy [ • '.-

WA 

554 0 

' " llxiHi 

WA 

S3S 0 

S«l.474 

WA 

",:- 0 

i 16.44 7 

WA 

7400 

HA.JM 

WA 

8330 

$30 039 

WA 

9650 

S34.»l 

SS5.878 

WA 

1.756 0 

$65,148 

WA 

4.429.0 

SI 01,450 

WA 

5i8 9 0 

m ••:-• 

N'A 

8.680.0 

WA 

N/A 

WA 

WA 

WA 

WA 

WA 

WA 

' . . •: 

WA 

1.021.0 

$46,607 

WA 

siao 

SM QM 

WA 

5540 

•5-M.14? 

WA 

638.0 

-UA&-SM" ' 

WA 

647 0 

UiSot 

WA 

740.0 

mins 

WA 

a*?.; o 

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Pomlana - LASCO Panel Products (KY*) 

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Projected Resm or Ge Coat Usage (tpy) lor NG -104 

$52,704,170 S&-9M 160 S2JW7398 $78233.738 $2,963,029 

L 
P.17 

MEMORANDUM 

TO: Project File 

Plastic Composites NESHAP 

ESD Project No. 93/58 

FROM: Dr. Madeleine Strum 

U.S. Environmental Protection Agency 

DATE: January 30, 1999 

SUBJECT: Open Molding MACT Model 

Introduction 

The open molding MACT model is an integral component of the MACT standards for the 

Plastics Composites and Boat Manufacturing source categories. The MACT model is a point value 

system designed to accurately reflect the emission control status of facilities within each of the open 

molding process/product groupings. During rule development, these point values were used to rank 

facilities within each process/product grouping for the purpose of determining the new and existing 

source MACT floors for each process/product grouping. Once the requirements of the MACT 

standard take effect, a weighted average of these point values will be used to determine a facility's 

compliance with the MACT requirements of the open molding subcategory. 

Information Presented in this Document 

The information presented in this document will describe the purpose, development, and 

implementation of the MACT model. The EPA developed the MACT model to resolve multiple 

scientific, technical, and legal (regulatory) issues and the first type of information presented in the 

document will address these issues. This information includes a description of the open molding 

subcategory and the associated emission reduction techniques/control technologies. 

The second type of information presented will pertain to the development of the MACT 

model. This information includes a discussion of the open molding emissions data available for 

model development, the selection of the emissions data upon which the model is based, the 

mathematical and statistical techniques used to develop the model equations, and a summary of the 

individual model equations. 

The third type of information presented will address the use ofthe MACT model by facilities 

when complying with the requirements ofthe MACT standard. This information will include the 

calculation of point values by a facility for each process/product grouping, the calculation of the 

facility's maximum point value limit for the open molding subcategory, and the use of averaging to 

determine if a facility is in compliance with the maximum point value limit. 
P.18 

I. Purpose of the MACT Model 

Open Molding Subcategory 

In order to present the multiple reasons behind EPA's development of the MACT model, 

background information concerning the subcategorization ofthe plastic composites source category 

must be provided. The EPA separated the plastic composites source category into 10 subcategories 

due to differences in production processes and techniques, application equipment, emission potential, 

and the applicability of emission reduction techniques. The probability that certain production 

processes (and the associated emission points) would be collocated and the potential for emissions 

averaging between those processes was also considered by the EPA in defining subcategories. Using 

these criteria, the open molding subcategory was defined by the EPA to represent facilities that 

manufacture products using specific production processes and equipment through the application of 

HAP-containing materials to an open mold. 

Raw Materials 

The HAP containing materials present in the open molding subcategory are cross-linking 

thermoset resins and gel coats that contain styrene and/or methyl methacrylate. In addition to these 

HAP containing materials, reinforcement (especially glass fibers and matting) and filler materials 

(such as aluminum trihydrate, hydrous aluminum silicate, and calcium carbonate) are frequently 

added to thermoset resins to enhance the physical properties of the end product and/or decrease 

product cost. 

Production Processes 

The facilities included within the open molding subcategory use a number of different production 

processes to manufacture a highly diverse group of products. These production processes include 

hand lay-up, spray-up, helical filament winding, chop-hoop filament winding, centrifugal casting, 

and gel coating. Each production process has one or more types of application equipment associated 

with it. These types of application equipment include bucket & brush (or tool), pressure-fed rollers, 

flow coaters, flow choppers, resin baths & rotating mandrels, centrifugal casting machines & rotating 

molds, and spray guns (conventional air, airless, air-assisted-airless, & HVLP). Table 1 summarizes 

the production processes and application equipment used by facilities in the open molding 

subcategory. 

Table 1. Open Molding Production Processes & Associated Application Equipment 

ti$&%$faffr .:;;-*.. -:;U-& 

Hand Lay-Up 

Spray-Up (Atomized) 

Spray-Up (Non-Atomized) 

Chop-Hoop Filament Winding 

Helical Filament Winding 

Centrifugal Casting 

Gel Coating (Atomized) 

Gel Coating (Non-Atomized) 

^P^on^ugrilnt^j , ', „ , \, ; ,;, >~)&*-$$.jS*:*-^ . '•.* . , ..,-. .. , 

Bucket & Brush, Bucket & Tool, Pressure-Fed Roller, 

Conventional Air Spray Gun, HVLP Spray Gun, Airless Spray Gun, Airless-Air-Assisted Spray Gun 

Flow-Coaters, Row Choppers 

Conventional Air Spray Gun, HVLP Spray Gun, Airless Spray Gun, Airless-Air-Assisted Spray Gun 

Resin Bath & Rotating Mandrel 

Centrifugal Casting Machine w/ Rotating Mold 

Conventional Air Spray Gun, HVLP Spray Gun, Airless Spray Gun, Airless-Air-Assisted Spray Gun 

Bucket & Brush, Bucket & Tool 
P.19 

Emission Reduction & Control Techniques 

The emission reduction and control techniques present in the open molding subcategory are 

monomer content control (low HAP resins and gel coats), non-atomizing resin application equipment 

(pressure-fed rollers, flow-coaters, flow-choppers), vapor suppressants, vacuum bagging, and add-on 

control devices. The emission reduction and control techniques present in the open molding 

subcategory are not always technically possible for all processes and products. There are several 

examples of this technical infeasibleness. 

The use of filled resin systems is problematic for both non-atomized resin application 

equipment and vapor suppressants. Emission studies have indicated that the use of high filler 

loadings (50% by weight) interferes with the successful functioning of vapor suppressants. Flowcoater and flow-chopper technology are often incompatible with the use of high filler loadings. The 

use of monomer content as a control is limited because the HAP content of a resin or gel coat can 

only be reduced only to a certain level before the physical properties of the end product are 

negatively effected. Finally, vacuum bagging may not be suitable for parts with uneven surfaces or 

complex geometries. 

Open Molding Process Groupings 

The large number of production process/application equipment combinations were organized 

into four basic groupings: manual resin application, mechanical resin application, rotational 

application, and gel coat application. These specific production processes and application equipment 

within each of these four groupings is summarized in Table 2. 

Table 2. Open Molding Process Groupings1 ,a,b 

Process Grouping 

Manual Resin Application 

Mechanical Resin Application 

Rotational Application 

Gel Coat Application 

Production Process 

Hand Lay-Up 

Spray-Up (Atomized) 

Spray-Up (Non-Atomized) 

Filament Winding 

Centrifugal Casting 

Gel Coating (Atomized) 

Application Equipment 

Bucket & Brush, Bucket & Tool 

Conventional Air, Airless, Airless-Air-Assisted, & HVLP Spray Guns 

Flow-Coaters, Flow Choppers, Pressure-Fed Rollers 

Resin Bath & Rotating Mandrel 

Centrifugal Casting Machine & Rotating Mold 

Conventional Air, Airless, Airless-Air-Assisted, & HVLP Spray Guns 

"The application of gel coat using hand lay-up is extremely rare in the open molding subcategory. In cases where the gel coat is applied in ihis 

fashion, the gel coat is usually applied to the finished part rather than the open mold. When gel coat is applied in this fashion, it is included in the 

manual resin application process grouping. 

rhere are two basic types of filament winding: "helical" filament winding and "chop hoop" filament winding. Helical filament winding involves 

the wetting of reinforcement by drawing the continuous glass reinforcement through a resin bath prior to the reinforcement being wound on a rotating 

mandrel. In chop-hoop filament winding, dry continuous glass reinforcement is helically wound on a mandrel (perpendicular to the axis) in a thin 

"wet bed" ofresin and chopped reinforcement. The "wet bed" of reinforcement is applied to the mandrel using a spray gun (chopper gun) that feeds 

1 or 2 strands of continuous glass reinforcement thorough the spray gun chopper mechanism during the resin application. Since chop hoop filament 

winding is conducted using the same type of spray equipment as atomized spray-up, it is included in the mechanical resin application grouping. 

Helical filament winding is the type of filament winding included in the rotational application process grouping. 

Open Molding Product Groupings 
P.20 

The products in the open molding subcategory were organized two basic groupings: noncorrosion resistant and corrosion resistant. These product groupings are differentiated from one 

another on the basis ofthe required properties ofthe materials used to make the product and the end 

product specifications. The primary difference between the two groupings in this case is corrosionresistant products generally require the use of premium resins with a higher HAP contents to provide 

chemical resistance in corrosive environments. 

In addition to the above product groupings, gel coats were organized into three basic 

groupings: pigmented production, clear production, and mold manufacturing (tooling). The primary 

difference between pigmented production and clear production gel coats is pigmented production 

gel coats have higher densities than clear production gel coats due to the presence of coloring 

pigments. This higher density allows pigmented gel coats to have lower HAP contents on a percent 

weight basis than clear gel coats. Tooling gel coats were separated from clear and pigmented 

production gel coats because different requirements for surface and structural properties demand 

higher HAP contents for tooling applications as opposed to normal production applications. 

Open Molding Process/Product Groupings 

The process and product groupings were combined to create an open molding subcategory with 10 

process/product groupings. These groupings are designed to reflect different production techniques, 

raw materials, end-product requirements, and applicability of emission reduction/control techniques 

present in the open molding subcategory. The process/product groupings and associated emission 

reduction/control techniques are summarized in Table 3. 

Table 3. Open Molding Process/Product Groupings 

KESSS 0 OMtoffl ©Mpig3 &fflSi55lKebuBu53li(S6ntrsiii(SSi*fii'iSiSBSi 

L^tete 

Manual Resin Application 

Manual Resin Application 

Mechanical Resin Application (Unfilled) 

Mechanical Resin Application (Filled) 

Mechanical Resin Application 

Rotational Application 

Rotational Application 

Gel Coat Application 

Gel Coat Application 

Gel Coat Application 

xmsmmmn^m 

Non-Corrosion Resistant 

Corrosion Resistant 

Non-Corrosion Resistant 

Non-Corrosion Resistant 

Corrosion Resistant 

Non-Corrosion Resistant 

Corrosion Resistant 

Pigmented Production 

Clear Production 

Mold Manufacturing (Tooling) 

SteauS? 

* 

X 

X 

X 

x 

* 

x 

X 

X 

X 

/SflHiTftHfl 

,,,, , 

Z.M"" 

X 

X 

X 

* * 

• ~ w* y 

Igtaggjim 1 

X 

X 

X 

X 

x 

Rasmus 

X 

X 

r

'~";v-&' 

MMM 

©msHm \ 

X 

X 

X 

X 

X 

"The process groupings and product groupings combine to form process/product groupings. For example, the process grouping manual resin 

application combines with the corrosion resistant product grouping to form the corrosion resistant manual resin application process/ product grouping. 

"The emission reduction/control techniques used by facilities within each ofthe process/product groupings, individual facilities within the same 

process/product grouping frequently use different combinations of emission reduction/control techniques. Specific emission reduction/control 

techniques may not be suitable for or exhibit the same degree of effectiveness in all process/product groupings (e.g. vapor suppressants). 

"The fact that a emission reduction or control technique is not currently used for one ofthe 10 process/product groupings does not imply that it is 

unsuitable for that process/product grouping. For example, add-on control devices can control HAP emissions from manual resin application and 

gel coat application with clear production gel coats. Vacuum bagging can be used with non-corrosion resistant manual resin application. 

Ranking Facilities 
P.21 

Once the EPA had developed the 10 process/product groupings, the next step in the MACT 

standard development process was to rank the facilities contained within each process/product 

grouping for the purpose of obtaining the new source and existing source MACT floors. The use 

of different and multiple emission reduction techniques by individual facilities within each of the 

10 process/product groupings resulted in the need for EPA to develop a method of evaluating a 

facility's overall emission control status within each process/product grouping. 
P.22 

II. Development of the MACT Model 

Data Selection Criteria 

The first step in the development of the MACT model was to select the data that will form 

the basis for the model equations. There were several open molding emission studies available to 

the EPA for the development ofthe MACT model. These emission studies were conducted by the 

Composite Fabricators Association (CFA), the National Marine Manufacturers Association 

(NMMA), and the EPA's Office of Research and Development (EPA/ORD) in conjunction with the 

Research Triangle Institute (RTI). 

1.) -Tested Process Parameters that Affect Emissions w/ Example (CFA Phase I Hand Lay-Up) 

2.) -Tested Process Parameters are Representative of Industry (CFA Phase I Hand Lay-Up) 

-Representative HAP Contents, Thicknesses, Gel Times, Air Flows, Application Rates 

3.) -Balanced Data Sets w/Example (CFA Phase I: Hand Lay-Up) 

Open Molding Emission Studies 

-EPA ORD Unfilled Resin Study 

-EPA ORD Filled Resin Study 

-NMMA Emission Study 

-CFA Phase I Emission Study 

-CFA Phase U Emission Study 

-DOW Chemical Filament Winding Study 

Data Selection Criteria 

-Balanced Data Sets w/ Example (CFA Phase I: Hand Lay-Up) 

-Tested Process Parameters that Affect Emissions w/ Example (CFA Phase I Hand Lay-Up) 

-Tested Process Parameters are Representative of Industry (CFA Phase I Hand Lay-Up) 

-Representative HAP Contents, Thicknesses, Gel Times, Air Flows, Application Rates 
P.23 

IV.) Equation Development Criteria 

Statistically Best-Fit Equations w/ Following Conditions 

-Boundary Conditions: 

-Lower: 0.0 lb/ton @0.0%HAP 

-Upper: <2000.0 lb/ton @ 100.0% HAP 

-Increasing HAP Emissions w/ Increasing HAP Content 

-Reflect Non-Linearity of Test Results 

-Non-Atomized Application < Atomized Application 

-Accurate Control Factors 

-Emission Profile Factors for VSR 

-VSR Test Method 

-Emission Profile Factors for VB/CM Curing 

-Different Factors for VB w/ and w/o Roll-out 

V.) Equation Development - Manual/Non-Atomized Mechanical 

-Statistical Analysis for Base Equation 

-Balanced Data Set (Table) 

-Base Equation Result in Summary Table 

-Emission Profile Analysis for Control Factor Equations 

-Emission Profile Analysis (Table) 

-VSR Profile Factor (Summary Table) 

-VB/CM Curing Profile Factors (Summary Table) 

VU.) Equation Development - Atomized Mechanical 

-Statistical Analysis for Base Equation 

-Balanced Data Set (Table) 

-Base Equation Result in Summary Table 

-Emission Profile Analysis for Control Factor Equations 

-Emission Profile Analysis (Table) 

-VSR Profile Factor (Summary Table) 

-VB/CM Curing Profile Factors (Summary Table) 

VUl.) Equation Development - Filament Winding 

-Statistical Analysis for Base Equation 

-Balanced Data Set (Table) 

-Base Equation Result in Summary Table 

-Emission Profile Analysis for Control Factor Equations 

-Emission Profile Analysis (Table) 

-VSR Profile Factor (Summary Table) 

DC.) Equation Development - Gel Coat Application 

-Statistical Analysis for Base Equation 

-Balanced Data Set (Table) 

-Base Equation Result in Summary Table 
P.24 

Summary Table 

Table : Summary of the MACT Model Equations 

1'roi.css 

Manual Resin Application 

Mechanical Resin Application: Atomized 

Mechanical Resin Application: Non-Atomized 

Filament Winding Operations 

Gel Coat Application: Atomized 

"VI.7 IF-* i*-f5W"|. l^''l^^Sffis»',i * 

Non-Vapor Suppressed 

Vapor Suppressed 

Vacuum Bagging/ 

Closed Mold Curing 

w/ prior Roll-out 

Vacuum Bagging/ 

Closed Mold Curing 

w/o prior Roll-out 

Non-Vapor Suppressed 

Vapor Suppressed 

Vacuum Bagging/ 

Closed Mold Curing 

w/ prior Roll-out 

Vacuum Bagging/ 

Closed Mold Curing 

w/o prior Roll-out 

Non-Vapor Suppressed 

Vapor Suppressed 

Vacuum Bagging/ 

Closed Mold Curing 

w/ prior Roll-out 

Vacuum Bagging/ 

Closed Mold Curing 

w/o prior Roll-out 

Non-Vapor Suppressed 

Vapor Suppressed 

Non-Vapor Suppressed 

Brass**.

 w « a . v -Taw*,?•<*•<£ _ **» \ .. A . . v ,ai , » .!_ it i 

0.028 x (Resin HAP%)2*

275 

0.028 x (Resin HAP%)2*

275

 x (1.000 - (0.5419 x VSR Test Value)) 

0.028 x (Resin HAP%)2275 x (1.000 - 0.2133) 

0.028 x (Resin HAP%)2*

275

 x (1.000 - 0.4554) 

0.028x (Resin HAP%)2*

425 

0.028 x (Resin HAP%)2425 x (1.000 - (0.4559 x VSR Test Value)) 

0.028 x (Resin HAP%)2'

425

 x (1.000 - 0.1535) 

0.028 x (Resin HAP%)2425 x (1.000 - 0.3261) 

0.028 x (Resin HAP%)2*

275 

0.028 x (Resin HAP%)2*

275

 x (1.000 - (0.5419 x VSR Test Value)) 

0.028 x (Resin HAP%)2275 x (1.000 - 0.2133) 

0.028 x (Resin HAP%)2275 x (1.000 - 0.4554) 

1.675 x (Resin HAP%)1225 

1.675 x (Resin HAP%)'*225 x (1.000 - (0.4693 x VSR Test Value)) 

0.890 x (Resin HAP%)'*675 

aThe equation for vacuum bagging with roll-out would be applicable when a facility rolls out the applied resin prior to applying the vacuum bagging 

materials. The equation shown for this type of application assumes that the facility starts the vacuum bagging/closed mold curing process two 

minutes after the end of the roll-out stage. 

The equation for vacuum bagging without roll-out would be applicable when a facility applies the vacuum bagging materials immediately after resin 

application without rolling out the resin. The equation shown for this type of application assumes that the facility starts the vacuum bagging/closed 

mold curing process two minutes after the end of the application (or roll-out) stage. 
P.25 

X.) Using the MACT Model for Averaging Purposes 

-Averaging Across Process/Product Groupings 

-Averaging Across 12-Month Rolling Period 

-Maximum Allowable Facility Point Value Per Rolling Period 

-Actual Facility Point Value Per Rolling Period 

-Compliance Determination 

-Averaging Example 
P.26 

Attachments 

Data Sets for Open Molding Emission Studies 

Attachment 1 - CFA Phase I Emission Study Data Sets 

Attachment 2 - CFA Phase II Emission Study Data Sets 

Attachment 3 - DOW Chemical Filament Winding Study Data Sets 

Attachment 4 - EPA/ORD Unfilled Resin Study Data Sets 

Attachment 5 - EPA/ORD Filled Resin Study Data Sets 

Attachment 6 - NMMA Emission Study Data Sets 
P.27 

Attachment 1 

CFA Phase I Emission Study Data Sets 
P.28 

I • 

I 

Attachment 2 

CFA Phase II Emission Study Data Sets 
P.29 

l 

i * < '" 

Attachment 3 

DOW Chemical Filament Winding Study Data Sets 
P.30 

( * 

Attachment 4 

EPA/ORD Unfilled Resin Study Data Sets 
P.31 

i* • 

Attachment 5 

EPA/ORD Filled Resin Study Data Sets 
P.32 

4 ^ •" ' * 

Attachment 6 

NMMA Emission Study Data Sets