p. 1



# OAR Box 1477 Prepped by Ollie Stewart



# Document

Number: 

# 29 ) ll-J-2 0

Docket Number: 

# A-94-5 2

Printed 7/31/2008 11:40:24

AM Sheet 29 of 36

## P. 2

. * *
. '« "



## From : KEIT H BARNET T

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

. Date : 2/23/0 0 4:31p m Subject : Additiona l Informatio n o n Reinforce d Plastic s
Dea r Joh

n an d Peter :
Attache d i s some o f th e additiona l informatio n I promised

. I don' t hav e the dat a set s use d t o develo p th e poin t valu e equations

. I a msending th e memo an d wil l sen t th e dat a set s a s soo n a s I ge t them

. Attache d are :
Th e memo describing ho wthe ope n molding poin t valu e equation s wer e develope d Th e memo furthe r describing th e cos t methodolog yan d component s An exce l fil e wit h ne wsourc e cost s Th e metho d w e discusse d t o determin e captur e (Metho d 204 ) i s i n CFR Par t 5 1 Appendi x M
. Keit h Barnet t
CC : ALDRIDGE-AMANDA , LASSITER-PENNY , RTPMAINHUB.INTERN..
.P. 3



## MEMORANDU M
TO : Mr

. KeithBarnett

U.S

. Environmental Protectio n Agenc y FROM : Melani e S

. Procto r andRobert

M

. Jemiso n Pacifi c Environmental Services , Inc

. DATE : Augus t

2 , 1999 , Revise dFebruary 23 , 200 0
SUBJECT : Cost s for

Facilitie s i

n th e Reinforce dPlasti c Composite s MAC T Databas e
Th e purpos e ofthi s memorandu mi s t o submit th e draf t tabular cost s for facilitie s i

n th e Reinforce dPlasti c Composite s MAC T databas e andt o provid e abrie f explanatio n ofth e cos t

dat a provided

. Thi s memorandu mdiscusse s cost s associate dwit hachievin g th e existin g sourc e MAC T floors andth e regulatory alternative s mor e stringen t than th e MAC T floors tha t wer e considered

. Th e draf

t tabular cost s ar e containe di

n th e Exce l file tha t

i s bein g sent

wit hthi s memorandum

. (Se e th e February 8 E-mai l for curren t cos t information. ) A mor e detaile d discussio n ofth e costin g methodologie s tha t wer e use dwill b e provide di n th e cos t chapte r ofth e Backgroun dInformatio n Documen t (BID ) tha t

i s still t o b e drafted

. ( A draf t ofthi s ha s bee n provided. )
Th e first part ofthi s memorandu mpresent s th e complianc e option s selecte dfor MAC T floor andabov e MAC T floor

costin g analyses

. Thi s part discusse s whic hcomplianc e option s wer e coste dfor

determinin g draf

t tabular cost

. Th e secon dpart

discusse s th e cos t

component s tha t

ar e provide d(i.e. , tota l capital cost , variabl e annualize dcost , an dfixedannualize dcost ) for eac hfacility

. Thi s part

als o provide s a detaile dlis t

ofwhic hindividua

l cos t element s make up th e su mofth e tota l capital cost , th e sum ofth e variabl e annualize dcost , andsumofth e fixedannualize dcost

. I n addition , th e secon dpart ofthi s memorandu mdiscusse s ho w th e tota l capital cost s wer e annualized , whic hinclude s a summar y o f equipmen t

lifetime s andth e capitalizatio n factor s employed

. Th e thir dpart

ofthi s memorandu mprovide s th e averag e incremental cost s betwee n th e MAC T floors an dabov e th e MAC T floor options

. Complianc e Option s Selecte d fo rMAC T Floo ran d Abov e MAC T Floo rCostin g Analyse s Tabl e 1 present s th e complianc e option s selecte dfor MAC T floor

an dabov e MAC T floor costin g analyses

. Al

l complianc e option s wer e assume dt o incur cost s wit hth e exceptio n ofth eP. 4



## following : coverin g o f

charges , close do r

covere ddocto r

boxes , foldin g edge s o f

shee t moldin g compoun d(SMC) , coverin g storag e containers , andusin g non-HA Pcleanin g solvents

. Dat awer e collecte dfor

switchin g t o non-HA Pcleanin g solvents , whic hshowe dn o differenc e i n pric e for aceton e ( acommonl y use dnon-HA Pcleanin g solvent ) andmethylen e chlorid e ( acommonl y use d HA Pcleanin g solvent)

. Th e ne w sourc e MAC T floors for no n corrosion-resistan t

manual resi n applicatio n and no n corrosion-resistan t

unfilledmechanical resi n applicatio n are se t b y lo w HA Presin s andth e us e o f vacuu mbagging

. Sinc e n o cos t dat awer e availabl e for

vacuu mbagging , add-o n contro l device s wer e coste dfor

thes e tw o proces s produc t grouping s t o mee t

th e ne w sourc e MAC T floors.
Abov e MAC T floor option s considere dfor

existin g andne w source s generall y consiste d ofth e us e o f

add-o n contro l devices

. Fo r close dmolding , polymer casting , equipmen t

cleaning , andstorag e o f

HAP-containin g material s n o abov e MAC T floor option s wer e considere dfor existin g an dne w source s sinc e thes e ar e already lo w emittin g processe s andn o option s abov e th e MAC T floor

wer e availabl e in th e cas e o f equipment

cleaning

. In addition , n o abov e MAC T floor option s wer e considere dfor ne w source s for

pultrusion , SM C manufacturing , andbulk moldin g compoun d(BMC ) manufacturing/mixin g sinc e n o option s mor e stringen t than th e ne w sourc e MAC T floor

wer e available

. Only on e abov e MAC T floor optio n was coste dfor

eac hsubcategory , whic hwa s 9 5 percen t contro l b y usin g athermal oxidizer i n conjunctio n wit

harotary concentrator

. Cos t Component s Provide d
Th e Exce l cos t

spreadshee t

provide s tota l capital costs , variabl e annualize dcosts , and fixedannualize dcost s for eac hsubcategory , andeac hfacilit y for existin g MAC T floors andth e abov e th e floor

regulatory alternative

. A detaile dlis t ofwhic hindividua

l cos t element s make up th e sumofth e tota l capital cost , th e sumofth e variabl e annualize dcost , an dsumofth e fixed annualize dcos t

i s presente di

n Tabl e 2

.

## Tabl e 1 . Complianc e Option s Selecte d fo rMAC T Floo ran d Abov e MAC T Floo rCostin g Analyse s

Subcategor y

Ope n Moldin g

Close dMoldin g Centrifugal Castin g
Continuou s Lamination / Continuou s Castin g

Pultrusio n Polyme r Castin g SM C Manufacturin g
BM C Manufacturing/Mixin g Equipmen t

Cleanin g Storag e o f

HA P Crmtnininf j Material s Process/Produc t Groupin g

Manua l Resi n - No n C R Manua l Resi n - C R Manua l Resi n - Toolin g Mechanica l Resi n - No n C R-Unfille d
Mechanica l Resi n - No n C R- Fille d Mechanica l Resi n - C R
Mechanica l Resi n - Toolin g Filamen t Windin g - No n C R Filamen t Windin g - C R Pigmente dProductio n Ge l Coa t Clea r Productio n Ge l Coa t Toolin g Ge l Coa t Compression/Injectio n Moldin g Resi n Transfe r

Moldin g Centrifuga l Castin g - No n C R Centrifuga l Castin g - C R N/ A

N/ A
N/ A N/ A
N/ A
N/ A N/ A Complianc e Option s Selecte dfo r Cos t Estimate s b y Subcategor y and/o r Process/Produc t

Groupin g Existin g Source s MAC T Floo r Lo w HA PConten t

Resi n Lo w HA PConten t

Resi n Lo w HA PConten t

Resi n Lo w HA PConten t

Resi n & Non-Atomize dApplicatio n Lo w HA PConten t

Resi n Lo w HA PConten t

Resi n & Non-Atomize dApplicatio n Lo w HA PConten t

Resi n Lo w HA PConten t

Resi n Lo w HA PConten t

Resi n Lo w HA PContent«Ge l Coa t Lo w HA PConten t

Ge l Coa t Lo w HA PConten t

Ge l Coa t Uncove r 1 Charg e pe r

Machin e Non e (N o MAC T Floor ) Lo w HA PConten t

Resi n Lo w HA PConten t

Resi n Add-O n Contro l Devic e (58.5 % Contro l o f

We t Ou t Are aan dOve n Emissions )

We t Are aEnclosure s w / Resi n Dri p Collectio n Non e (N o MAC T Floor ) Closed/Covere dDocto r

Bo x / Folde dEdges/Nylo n Fil m Closed/Covere dMixin g w / N o Visibl e Gap s i n Cove r N o HA PCleanin g Solvent s Closed/Covere d Storag e Container s Abov e MAC T Floo r Entir e Subcategor y Add-O n Contro l Devic e (95 % Contro l Efficiency )

Non e Evaluate d Non e Evaluate d Add-O n Contro l Devic e (95 % Contro l Efficiency ) (1 ) Add-O n Contro l Devic e (77.6 % Contro l o f

We t Ou t Are aan dOve n Emissions ) (2 ) Add-O n Contro l Devic e (95 % Contro l o f

We t Ou t Are aan dOve n Emissions ) Add-O n Contro l Devic e (95 % Contro l Efficiency ) Non e Evaluate d Add-O n Conlro l Devic e (95 % Contro l Efficiency ) Add-O n Contro l Devic e (95 % Contro l Efficiency ) Non e Evaluate d Non e Evaluate d Ne w Source s MAC T Floo r Add-O n Conlro l Devic e (95% ) Lo w HA PConten t

Resi n Lo w HA PConten t

Resi n Add-O n Contro l Devic e (95% )
Add-O n Contro l Devic e (95% ) Lo w HA PConten t

Resi n & Non-Atomize dApplicatio n Lo w HA PConten t

Resi n Lo w HA PConten t

Resi n Lo w HA PConten t

Resi n Add-O n Conlro l Devic e (95% ) Lo w HA PConten t

Ge l Coa t Add-O n Contro l Devic e (95% ) Uncove r 1 Charg e pe r

Machin e Non e (N o MAC T Floor ) Lo w HA PConten t

Resi n Lo w HA PConten t

Resi n Add-O n Contro l Devic e (82.6 % Contro l o f

We t Ou t Are aan dOve n Emissions )

Add-O n Contro l Devic e (95 % Contro l Efficiency ) Non e (N o MAC T Floor ) Add-O n Contro l Devic e (95 % Contro l Efficiency ) Add-O n Contro l Devic e (95 % Contro l Efficiency ) N o HA PCleanin g Solvent s Closed/Covere d Stora-j e Container s Abov e MAC T Floo r Entir e Subcategor y Add-O n Contro l Devic e (95 % Contro l Efficiency )

Non e Evaluate d Non e Evaluate d Add-O n Contro l Devic e (95 % Contro l Efficiency ) Add-O n Contro l Devic e (95 % Contro l o f

We t Ou t Are aan dOve n Emissions )

Non e Evaluate d
Non e Evaluate d Non e Evaluate d
Non e Evaluate d
Non e Evaluate d Non e Evaluate d

## Tabl e 2 . Tota l Capita l Cost , Annua l Fixe d Cos tand/o rAnnua l Variabl e Cos t P. 6



# Add-O n Cmm\ Mvkw wf

&m&m$KfritygMtt

t Tota l Capital Cos t

- Add-O n Contro l Devic e Total Capital Cos t

- Permanen t

Tota l Enclosur e (PTE ) Tota l Capital Cos t

- We t Are aEnclosur e (WAE ) Tota l Capital Cos t

- Ductwork

fromPT Eo r

WAEt o Add-O n Direc t Operating Cos t

Minu s Utilitie s - Add-O n Contro l Devic e Electricity Cost s - Add-O n Contro l Device/Ductwork Fue l Cost s - Add-O n Contro l Devic e Overhead , Propert y Tax , Insuranc e Administratio n 

# : W* tAn JM*ttg * /

ftaif t3M p CfeHmtta

x Bjfsum Tota l Capital Cos t

-We t Are aEnclosur e /

Resi n Dri p Collectio n Operatin g & Maintenanc e ( 0 & M ) 

# &m4Kbmi& MMm Cos t o f Mixe r Cover s Replace dAnnually



# . n«$iMCMft-tt & o f §p&y Wwtiymm w /

liwwate r Tota l Capital Cos t

- Flowcoate r

/ Salvag e Valu e Spra

y Gun s Decreas e i

n Persona l Protectiv e Equipmen t Usag e Decreas e i

n Floo r Covering s Usag e Decrease dResi n Usag e Du e t o Increase dTransfer Efficiency 

# Material s Replacemen

t Replacemen t

o f Existin g Resi n wit

hLo w HA PResi n Replacemen t

o f Existin g Gel Coat

wit hLo w HA PGel Coat Produc t Recertificatio n (Resi n andGel Coat ) Ne w Material Testin g 

# IHHHNHHH

B Subpart A Notification s (Year

1 ) - Construct/Reconstruct , Anticipate dStart-Up , Actual Startup , Notic e o f Complianc e Statu s Semi-Annua

l Report , Period s o f

Non-Complianc e Report , Maintai n HA PContent/VS RTes t Recor d Develo p Trainin g Progra m/ Record s System(Year

1 ) Conduc t Trainin g Progra m/

Kee p Trainin g Record s Readin g Standar d(Year

1 ) Reviewin g Standar d(Annually ) Performanc e Tests , Develo p O& M Plan , SS& M Pla n (Year 1 ) Semi-Annua

l Start-up , Shut-Dow n &Malfunctio n (SS&M ) Report 

# TC C X X X X



# i TC C X


# TC C
! TC C X



# 1 TC C

X X 

# HHH X

X

X

X 

# . 

# Acm [

X X X 

# AC(V >
X 

# Acm 

# .Acm

X X X 

# ,AC(V) X X 

# •Hi i AC# )

X X X X

X 

# AC$ > X 

# AC{f) X 

# Ajcmi X



# . 

# ^p^* l

X X 

# Iiiii i X
X
X X X X X X
Abbreviation

s TC C = Tota l Capita l Cos t AC(V

) = Annua l Cos t (Variable ) AC(F

) = Annua l Cos t (Fixed )P. 7



## Th e tota l capita l cost s presentedi

n the cos t spreadshee

t wer e annualized

. A tabl e wit hthe tim e period s an

dthe capitalization factors employe dt o annualize the tota

l capita l cost s ar e show n i n Tabl e 3

. Al l th e capitalization factors ar e base do n aseve n percen t interes t rate

.

Table 3 . Tim

e Periods An

d Capitalization Factor

s Use d T o Annualize A-dUM& i €«»tre l Devices w/Associate dEquipmen t
Add-O n Contro l Devic e Permanen t

Tota l Enclosur e (PTE ) We t Are aEnclosur e (WAE ) Ductwor k

fromPT E o r

WA Et o Add-O n Tim e Perio d
1 0 3 0 3 0 1 0 facto r

0.142 4 0.080 6 0.080 6 0.142 4

. W«t Arf e Xtottami * /

E«*t o IM p Collectio

n $ymm We t Are aEnclosur e /

Resi n Dri p Collectio n 3 0 0.080 6 Replacemen

t o f Spra y Equipmen

t w / Fiowcdate

r Flowcoate r

/ Salvag e Valu e Spra

y Gun s 7 0.185 6 •Material s Replacemen t Produc t Recertificatio n Produc t Testin g 1 0 1 0 0.142 4

0.142 4 Monitoring , Recor d keeping * & Reportin g Subpart A Notification s (Year

1 ) - Construct/Reconstruct , Anticipate dStart-Up , Actual Startup , Notic e o f Complianc e Statu s Develo p Trainin g Progra m/ Record s System(Year

1 ) Readin g Standar d(Year

1 ) Performanc e Tests , Develo p O& M Plan , SS& M Plan (Year 1 ) 1 0

1 0 1 0 1 0 0.142 4

0.142 4 0.142 4 0.142 4

Averag e Incrementa

l Cost s By Subcategor

y Refe r t o th e Table s sen

t Februar y 8 fo r th e most recen t cos t datafo r existin g sources . Summarize

dcos t datafo r ne w source s i s attached

.P. 8

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. Faciio yDesignate d N G • 4 0 P C - D M - 36

. Anctiuty Suxa **>>-»--*•

in e Prowae- i Ne wGr.-jr-.v

- Facilit yOesygnaa O N G - 4 1 (P C - 3 3 O M - 37

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. O M • 46

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## •

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' 5 5 : 3 5 Averag e Annua l Co d t $ • ' <cr\ resi n o » 5 ' io n ge i coat ) Protecte d Rest o o rGe t Coa t Uug e {tny* ) torN G - 4 C ora l Annua i Cos ; cS. ' yr ) Ava rao e Amu** * Cos t rJ. ' to n ras m o rJ I «* n .-jet cost) Projecae d Rea m o rGe'Cca t Usag * ftpy)to( N G •* ' ->:; , Annua l Coe l •:*

> yf l Avarag « Annua l Cos t (S • io n res m o r$ ' to n oa ? coat ) Projecte d Ri» n o rGe l Coa l Usao e (Ipy l torN G - <» 2 Toa l Annua i Cos t iS.

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# LP.1 7



## MEMORANDU M

TO : Projec t

Fil e Plasti c Composite s NESHA P ES D Projec t

No

. 93/5 8
FROM : Dr

. Madelein e Stru m

U.S

. Environmenta l Protectio n Agenc y
DATE : January 30 , 199 9
SUBJECT : Ope n Moldin g MAC T Mode l

Introductio n Th e ope n moldin g MAC T mode l i s a n integra l componen t

of th e MAC T standard s for th e Plastic s Composite s an dBoat Manufacturin g sourc e categories

. Th e MAC T mode l i s apoin t valu e syste mdesigne dt o accuratel y reflec t th e emissio n contro l statu s of facilitie s withi n eac hof

th e ope n moldin g process/produc t

groupings

. Durin g rul e development , thes e poin t value s wer e use dt o ran k facilitie s withi n eac hprocess/produc t groupin g for

th e purpos e of

determinin g th e ne w an dexistin g sourc e MAC T floor s for eac hprocess/produc t

grouping

. Onc e th e requirement s of th e MAC T standar dtak e effect , aweighte daverag e of thes e poin t

values wil l b e use dt o determin e afacility' s complianc e wit

hth e MAC T requirement s of th e ope n moldin g subcategory

. Informatio n Presente di n thi s Documen t Th e informatio n presente di n thi s documen t wil l describ e th e purpose , development , an d implementatio n of

th e MAC T model

. Th e EP A develope dth e MAC T mode l t o resolv e multipl e scientific , technical , an dlegal (regulatory ) issue s an dth e firs t typ e of informatio n presente di n th e documen t wil l addres s thes e issues

. Thi s informatio n include s adescriptio n of th e ope n moldin g subcategory an dth e associate demissio n reductio n techniques/contro l technologies

. Th e secon dtyp e of

informatio n presente dwil l pertai n t o th e developmen t of th e MAC T model

. Thi s informatio n include s adiscussio n o f th e ope n moldin g emission s dat aavailabl e for model development , th e selectio n o f th e emission s dat aupo n whic hth e mode l i s based , th e mathematica l an dstatistica l technique s use dt o develo p th e mode l equations , an dasummary o f th e individua l model equations

. Th e thir dtyp e of

informatio n presente dwil l addres s th e us e ofth e MAC T mode l b y facilitie s whe n complyin g withth e requirement s ofth e MAC T standard

. Thi s informatio n wil l includ e th e calculatio n of

poin t value s b y afacility for

eac hprocess/produc t

grouping , th e calculatio n of th e facility' s maximu mpoin t valu e limi t

fo r th e ope n moldin g subcategory , an dth e us e of averagin g t o determin e if

afacility i s i n complianc e wit hth e maximu mpoin t

valu e limit

.P.1 8



## I . Purpos e o f

th e MAC T Mode l

Ope n Moldin g Subcategory I n orde r t o presen t

th e multipl e reason s behin dEPA' s developmen t of th e MAC T model , backgroun dinformatio n concernin g th e subcategorizatio n ofth e plasti c composite s sourc e category mus t b e provided

. Th e EP A separate dth e plasti c composite s sourc e category int o 1 0 subcategorie s du e t o difference s in productio n processe s an dtechniques , applicatio n equipment , emissio n potential , an dth e applicability of

emissio n reductio n techniques

. Th e probability that certai n productio n processe s (an dth e associate demissio n points ) woul db e collocate dan dth e potentia l fo r emission s averagin g betwee n thos e processe s wa s als o considere db y th e EP A i n definin g subcategories

. Usin g thes e criteria , th e ope n moldin g subcategory wa s define db y th e EP A t o represen t facilitie s tha

t manufactur e product s usin g specifi c productio n processe s an dequipmen t throug hth e applicatio n of HAP-containin g material s t o a n ope n mold

. Ra w Material s Th e HA Pcontainin g material s presen t i n th e ope n moldin g subcategory are cross-linkin g thermose t resin s an dge l coat s that

contai n styren e and/o r

methy l methacrylate

. In additio n t o thes e HA Pcontainin g materials , reinforcemen t (especiall y glas s fiber s an dmatting ) an dfille r material s (suc ha s aluminu mtrihydrate , hydrou s aluminu msilicate , an dcalciumcarbonate ) ar e frequentl y adde dt o thermose t

resin s t o enhanc e th e physica l propertie s of th e en dproduc t

and/o r decreas e produc t cost

. Productio n Processe s Th e facilitie s include dwithi n th e ope n moldin g subcategory us e anumbe r o f different productio n processe s t o manufactur e ahighl y divers e grou p of products

. Thes e productio n processe s includ e han dlay-up , spray-up , helica l filamen t winding , chop-hoo p filamen t winding , centrifugal casting , an dge l coating

. Eac hproductio n proces s ha s on e o r mor e type s of

applicatio n equipmen t

associate d withit

. Thes e type s of

applicatio n equipmen t

includ e bucke t

& brus h(o r

tool) , pressure-fe drollers , flo w coaters , flo w choppers , resi n bath s & rotatin g mandrels , centrifugal castin g machine s & rotatin g molds , an dspray gun s (conventiona l air , airless , air-assisted-airless , & HVLP)

. Tabl e 1 summarize s th e productio n processe s an dapplicatio n equipmen t use db y facilitie s i n th e ope n moldin g subcategory

. Tabl e 1 . Ope

n Molding Production Processes & Associated Application Equipmen t 

# ti$&%$faffr

.:;;-*.

. -:;U-& Han dLay-U p Spray-U p (Atomized

) Spray-U p (Non-Atomized

) Chop-Hoo p Filamen t Windin g Helica l Filamen t Windin g Centrifuga l Casting Ge l Coating (Atomized

) Ge l Coating (Non-Atomized

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

. '•. *

. , ..,- . . . ,

Bucke t & Brush , Bucke

t & Tool , Pressure-Fe

dRoller, Conventiona

l Ai r Spra y Gun , HVL

PSpra y Gun , Airles s Spra

y Gun , Airless-Air-AssistedSpra y Gu n Flow-Coaters , Row Chopper s Conventiona

l Ai r Spra y Gun , HVL

PSpra y Gun , Airles s Spra

y Gun , Airless-Air-AssistedSpra y Gu n Resi n Bat h& Rotatin

g Mandre l Centrifuga l Castin g Machin e w / Rotatin g Mol d Conventiona

l Ai r Spra y Gun , HVL

PSpra y Gun , Airles s Spra

y Gun , Airless-Air-Assiste

dSpra y Gu n Bucke t & Brush , Bucke

t & Too lP.1 9



## Emissio n Reductio n & Contro l Technique s Th e emissio n reductio n an dcontro l technique s presen t in th e ope n moldin g subcategory are monome r conten t contro l (lo w HA Presin s an dgel coats) , non-atomizin g resi n applicatio n equipmen t (pressure-fe drollers , flow-coaters , flow-choppers) , vapo r suppressants , vacuu mbagging , an dadd-o n contro l devices

. Th e emissio n reductio n an dcontro l technique s presen t in th e ope n moldin g subcategor y are no t

alway s technicall y possibl e for all processe s an dproducts

. Ther e are several example s of

thi s technica l infeasibleness

. Th e us e of

fille dresi n system s i s problemati c for bot hnon-atomize dresi n applicatio n equipmen t

an dvapo r

suppressants

. Emissio n studie s hav e indicate dthat th e us e of

hig hfiller loading s (50 % b y weight ) interfere s wit hth e successfu l functionin g of vapo r suppressants

. Flow

coate r an dflow-choppe r

technolog y are often incompatibl e wit hth e us e of

hig hfiller

loadings

. Th e us e o f monome r

conten t a s acontro l i s limite dbecaus e th e HA Pconten t o f aresi n o r

ge l coat can onl y b e reduce donl y t o acertai n leve l before th e physical propertie s of th e en dproduc t

are negativel y effected

. Finally , vacuu mbaggin g ma y no t b e suitabl e for

part s wit huneve n surface s o r comple x geometries

. Ope n Moldin g Proces s Grouping s Th e larg e numbe r

of productio n process/applicatio n equipmen t combination s wer e organize d int o fou r basi c groupings : manua l resi n application , mechanica l resi n application , rotationa l application , an dgel coat

application

. Thes e specifi c productio n processe s an dapplicatio n equipmen t withi n eac hof

thes e four

grouping s i s summarize di n Tabl e 2

. Table 2 . Ope

n Molding Proces s Groupings 1 ,a, b

Proces s Groupin g Manua l Resi n Applicatio n Mechanica l Resi n Applicatio n

Rotationa l Applicatio n

Ge l Coa t Applicatio n Productio n Proces s Han dLay-U p Spray-U p (Atomized ) Spray-U p (Non-Atomized ) Filamen t Windin g Centrifugal Castin g Gel Coatin g (Atomized ) Applicatio n Equipmen t Bucke t & Brush , Bucke t

& Too l Conventiona l Air , Airless , Airless-Air-Assisted , & HVL PSpray Gun s Flow-Coaters , Flo w Choppers , Pressure-Fe dRoller s Resi n Bat h& Rotatin g Mandre l Centrifugal Castin g Machin e & Rotatin g Mol d Conventiona l Air , Airless , Airless-Air-Assisted , & HVL PSpray Gun s

"Th e applicatio n o f

ge l coa t usin g han dlay-u p i s extremel y rar e i n th e ope n moldin g subcategory

. I n case s wher e th e ge l coat i s applie di n ihi s fashion , th e ge l coa t

i s usuall y applie dt o th e finishe dpart rathe r than th e ope n mold

. Whe n ge l coa t i s applie di n thi s fashion , it i s include di

n th e manua l resi n applicatio n proces s grouping

.
rher e ar e tw o basi c type s o f filament winding : "helical " filamen t windin g an d"cho p hoop " filamen t winding

. Helical filamen t windin g involve s th e wettin g o f

reinforcemen t

b y drawin g th e continuou s glas s reinforcemen t throug haresi n bat

hprior t o th e reinforcemen t

bein g woun don arotatin g mandrel

. I

n chop-hoo p filament

winding , dr

y continuou s glas s reinforcemen t i s helicall y woun don amandre l (perpendicular t o th e axis ) i n athi n "we t bed " ofresi n an dchoppe dreinforcement

. Th e "we t bed " o f reinforcemen t

i s applie dt o th e mandre l usin g aspray gu n (choppe r gun ) tha t feed s 1 o r 2 strand s o f

continuou s glas s reinforcemen t thoroug hth e spray gu n choppe r mechanis mdurin g th e resi n application

. Sinc e cho p hoo p filament windin g i s conducte dusin g th e sam e typ e o f spra y equipmen t

a s atomize dspray-up , i t i s include di n th e mechanica l resi n applicatio n grouping

. Helica l filament

windin g i s th e typ e o f

filamen t windin g include di n th e rotationa l applicatio n proces s grouping

.



## Ope n Moldin g Produc t

Grouping sP.2 0



## Th e product s i n th e ope n moldin g subcategory wer e organize dtw o basi c groupings : non corrosio n resistan t

an dcorrosio n resistant

. Thes e produc t grouping s are differentiate dfromon e anothe r o n th e basi s ofth e require dpropertie s ofth e material s use dt o mak e th e produc t an dth e en d produc t specifications

. Th e primary differenc e betwee n th e tw o grouping s in thi s cas e i s corrosion

resistan t product s generall y requir e th e us e of premiu mresin s wit

hahighe r HA Pcontent s t o provid e chemica l resistanc e i n corrosiv e environments

. In additio n t o th e abov e produc t groupings , ge l coat s wer e organize dint o thre e basi c groupings : pigmente dproduction , clear production , an dmol dmanufacturin g (tooling)

. Th e primary differenc e betwee n pigmente dproductio n an dclear productio n gel coat s i s pigmente dproductio n ge l coat s hav e highe r

densitie s than clear

productio n gel coats du e t o th e presenc e o f colorin g pigments

. Thi s highe r

density allow s pigmente dgel coat s t o hav e lowe r HA Pcontent s on apercen t weigh t basi s than clear

ge l coats

. Toolin g ge l coat s wer e separate dfromclear an dpigmente d productio n ge l coat s becaus e different requirement s fo r

surfac e an dstructura l propertie s deman d highe r HA Pcontent s fo r

toolin g application s a s oppose dt o normal productio n applications

. Ope n Moldin g Process/Produc t Grouping s Th e proces s an dproduc t

grouping s wer e combine dt o creat e a n ope n moldin g subcategory wit h1 0 process/produc t

groupings

. Thes e grouping s are designe dt o reflec t different productio n techniques , raw materials , end-produc t requirements , an dapplicability o f emissio n reduction/contro l technique s presen t i n th e ope n moldin g subcategory

. Th e process/produc t grouping s an dassociate demissio n reduction/contro l technique s are summarize din Tabl e 3

. Table 3

. Ope

n Moldin g Process/Product

Grouping s

KESS S 0OMtoff

l ©Mpig 3 

### &fflSi55lKebuBu53li(S6ntrsiii(SSi*fii'iSiSBS i 

# L^tet e Manua l Resi n Applicatio n Manua l Resi n Applicatio n Mechanica l Resi n Applicatio n (Unfilled ) Mechanica l Resi n Applicatio n (Filled ) Mechanica l Resi n Applicatio n Rotationa l Applicatio n Rotationa l Applicatio n Ge l Coa t Applicatio n Ge l Coa t Applicatio n Ge l Coa t Applicatio n 

## xmsmmmn^m Non-Corrosio n Resistan t Corrosio n Resistan t Non-Corrosio n Resistan t Non-Corrosio n Resistan t Corrosio n Resistan t Non-Corrosio n Resistan t Corrosio n Resistan t Pigmente dProductio n Clear Productio n Mol dManufacturin g (Tooling ) 

### SteauS ?
* X X X 

## x * 

## x X X X /SflHiTftHf

l



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# Z.M"" X X X 

### * *

• ~ w*y

Igtaggji m1 X X X X

x 

### Rasmu s

X X

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X X

X X

X

"Th e proces s grouping s an dproduc t grouping s combin e t o for mprocess/produc t

groupings

. For

example , th e proces s groupin g manua l resi n applicatio n combine s withth e corrosio n resistan t produc t groupin g t o for

mth e corrosio n resistan t

manua l resi n applicatio n process / produc t grouping

. "Th e emissio n reduction/contro l technique s use db y facilitie s withi n eac hofth e process/produc t groupings , individua l facilitie s withi n th e sam e process/produc t

groupin g frequentl y us e different combination s o f

emissio n reduction/contro l techniques

. Specifi c emissio n reduction/contro l technique s ma

y no t b e suitabl e for

o r exhibi t th e sam e degre e o f

effectivenes s i n al l process/produc t grouping s (e.g

. vapo r

suppressants)

.
"Th e fac t tha t aemissio n reductio n o r

contro l techniqu e i s no t

currentl y use dfor

on e ofth e 1 0 process/produc t grouping s doe s no t

impl y tha t

i t i s unsuitabl e for

tha t process/produc t

grouping

. For

example , add-o n contro l device s can contro l HA Pemission s fro mmanua l resi n applicatio n an d ge l coa t applicatio n wit

hclear productio n ge l coats

. Vacuu mbaggin g ca n b e use dwithnon-corrosio n resistan t manua l resi n application

. 

## Rankin g Facilitie sP.2 1



# Once th e EP A ha ddevelopedthe 1 0 process/product groupings , the nex

t ste p i n the MAC

T standar ddevelopmen

t proces s was t

o ran k the facilitie s containedwithi n eac hprocess/product grouping fo

r the purpos e o

f obtainin g the ne

w sourc e an

dexisting sourc e MAC

T floors

. The us e o f differen t an dmultiple emission reduction technique s b y individua

l facilitie s within eac

ho f the 1 0 process/product

grouping s resulte di

n the needfo

r EP A t o develop amethodo

f evaluating a facility' s overal

l emission control statu s within eac hprocess/product

grouping

.P.2 2



## II . Developmen to f

th e MAC T Mode l
Dat aSelectio n Criteri a Th e firs t ste p in th e developmen t

of th e MAC T mode l wa s t o selec t th e dat athat

wil l for m th e basi s for

th e mode l equations

. Ther e wer e several ope n moldin g emissio n studie s availabl e t o th e EP A for

th e developmen t

ofth e MAC T model

. Thes e emissio n studie s were conducte db y th e Composit e Fabricator s Associatio n (CFA) , th e Nationa l Marin e Manufacturer s Associatio n (NMMA) , an dth e EPA' s Offic e of Researc han dDevelopmen t (EPA/ORD ) in conjunctio n wit hth e Researc hTriangl e Institut e (RTI)

.

1. ) -Teste dProces s Parameter s that Affec t Emission s w/

Exampl e (CFA Phas e I Han dLay-Up )
2. ) -Teste dProces s Parameter s are Representativ e of Industry (CFA Phas e I Han dLay-Up ) -Representativ e HA PContents , Thicknesses , Ge l Times , Ai r Flows , Applicatio n Rate s 3. ) -Balance dDat aSet s w/Exampl e (CF A Phas e I : Han dLay-Up ) Ope n Moldin g Emissio n Studie s -EP A OR D Unfille dResi n Study -EP A OR D Fille dResi n Study -NMM A Emissio n Stud y -CF A Phas e I Emissio n Study -CF A Phas e U Emissio n Study -DO WChemica l Filamen t Windin g Study
Dat aSelectio n Criteri a -Balance dDat aSet s w/

Exampl e (CFA Phas e I : Han dLay-Up ) -Teste dProces s Parameter s that Affec t Emission s w /

Exampl e (CFA Phas e I Han dLay-Up ) -Teste dProces s Parameter s are Representativ e of Industry (CFA Phas e I Han dLay-Up ) -Representativ e HA PContents , Thicknesses , Ge l Times , Ai r Flows , Applicatio n Rate sP.2 3



## IV. ) Equatio n Developmen t Criteri a Statisticall y Best-Fi t

Equation s w/

Followin g Condition s -Boundary Conditions : -Lower : 0. 0 lb/to n @0.0%HA P -Upper : <2000. 0 lb/to n @ 100.0 % HA P -Increasin g HA PEmission s w/ Increasin g HA PConten t -Reflec t Non-Linearity of

Tes t Result s -Non-Atomize dApplicatio n < Atomize dApplicatio n -Accurat e Contro l Factor s -Emissio n Profil e Factor s for VS R -VS RTes t

Metho d -Emissio n Profil e Factor s for VB/C M Curin g -Differen t Factor s fo r

V B w/ an dw/o Roll-ou t
V. ) Equatio n Developmen t - Manual/Non-Atomize dMechanica l -Statistica l Analysi s fo r

Bas e Equatio n -Balance dDat aSe t

(Table) -Bas e Equatio n Resul t

i n Summary Table -Emissio n Profil e Analysi s for Contro l Facto r

Equation s -Emissio n Profil e Analysi s (Table) -VS RProfil e Facto r

(Summary Table) -VB/C M Curin g Profil e Factor s (Summary Table)
VU. ) Equatio n Developmen t - Atomize dMechanica l -Statistica l Analysi s for

Bas e Equatio n -Balance dDat aSe t

(Table) -Bas e Equatio n Resul t

i n Summary Table -Emissio n Profil e Analysi s for Contro l Facto r

Equation s -Emissio n Profil e Analysi s (Table) -VS RProfil e Facto r

(Summary Table) -VB/C M Curin g Profil e Factor s (Summary Table)
VUl. ) Equatio n Developmen t - Filamen t

Windin g -Statistica l Analysi s fo r

Bas e Equatio n -Balance dDat aSe t

(Table) -Bas e Equatio n Resul t

i n Summary Table -Emissio n Profil e Analysi s for Contro l Facto r

Equation s -Emissio n Profil e Analysi s (Table) -VS RProfil e Facto r

(Summary Table)
DC. ) Equatio n Developmen t - Ge l Coat

Applicatio n -Statistica l Analysi s fo r

Bas e Equatio n -Balance dDat aSe t

(Table) -Bas e Equatio n Resul t

i n Summary TableP.2 4



# Summary Table Tabl e : Summar

y o f the MACT Mode

l Equations

1'roi.cs s Manua l Resi n Applicatio n

Mechanica l Resi n Application : Atomize d

Mechanica l Resi n Application : Non-Atomize d

Filamen t Windin g Operation s

Ge l Coa t Application : Atomize d "VI. 7 IF - * i*-f5W"|

. l^'' l ^^Sffis»', i * Non-Vapo r

Suppresse d Vapo r Suppresse d Vacuu mBagging / Close dMol dCurin g w/ prior Roll-ou t Vacuu mBagging / Close dMol dCurin g w/ o prior Roll-ou t Non-Vapo r

Suppresse d Vapo r Suppresse d Vacuu mBagging / Close dMol dCurin g w / prio r Roll-ou t Vacuu mBagging / Close dMol dCurin g w/ o prior Roll-ou t Non-Vapo r

Suppresse d Vapo r Suppresse d Vacuu mBagging / Close dMol dCurin g w/ prior Roll-ou t Vacuu mBagging / Close dMol dCurin g w/ o prio r Roll-ou t Non-Vapo r

Suppresse d Vapo r Suppresse d Non-Vapo r

Suppresse d Brass**

. w « a . v -Taw*,?•<*•< £

_** » \

. . A

. . v ,ai , » .!_i t i 0.02 8 x (Resi n HAP%) 2 * 27 5 0.02 8 x (Resi n HAP%) 2 * 27 5 x (1.00 0 - (0.541 9 x VS RTes t Value) ) 0.02 8 x (Resi n HAP%) 227 5 x (1.00 0 - 0.2133 )

0.02 8 x (Resi n HAP%) 2 * 27 5 x (1.00 0 - 0.4554 )

0.028 x (Resi n HAP%) 2 * 42 5 0.02 8 x (Resi n HAP%) 242 5 x (1.00 0 - (0.455 9 x VS RTes t Value) ) 0.02 8 x (Resi n HAP%) 2 ' 42 5 x (1.00 0 - 0.1535 )

0.02 8 x (Resi n HAP%) 242 5 x (1.00 0 - 0.3261 )

0.02 8 x (Resi n HAP%) 2 * 27 5 0.02 8 x (Resi n HAP%) 2 * 27 5 x (1.00 0 - (0.541 9 x VS RTes t Value) ) 0.02 8 x (Resi n HAP%) 227 5 x (1.00 0 - 0.2133 )

0.02 8 x (Resi n HAP%) 227 5 x (1.00 0 - 0.4554 )

1.67 5 x (Resi n HAP%) 122 5 1.67 5 x (Resi n HAP%)'* 22 5 x (1.00 0 - (0.469 3 x VS RTes t Value) ) 0.89 0 x (Resi n HAP%)'* 67 5

a Th e equatio n for

vacuu mbaggin g withroll-ou t woul db e applicabl e whe n afacilit y roll s ou t th e applie dresi n prio r

t o applyin g th e vacuu mbaggin g materials

. Th e equatio n show n for this typ e o f

applicatio n assume s tha t th e facilit

y start s th e vacuu mbagging/close dmol dcurin g proces s tw o minute s after

th e en do f

th e roll-ou t

stage

. Th e equatio n for

vacuu mbaggin g withou t roll-ou t woul db e applicabl e whe n afacilit y applie s th e vacuu mbaggin g material s immediatel y after resi n applicatio n withou t

rollin g ou t

th e resin

. Th e equatio n show n fo r thi s typ e o f

applicatio n assume s tha t

th e facility start s th e vacuu mbagging/close d mol dcurin g proces s tw o minute s after th e en do f

th e applicatio n (o r

roll-out ) stage

.P.2 5



# X. ) Using the MAC

T Mode l fo r Averaging Purpose s -Averaging Acros s Process/Product Grouping s -Averaging Acros s 12-Mont hRolling Perio d -Maximu mAllowable Facilit

y Poin t Value Pe r Rolling Perio d -Actua l Facilit y Poin t Value Pe r Rollin g Perio d -Complianc e Determination -Averaging ExampleP.2 6



# Attachment s Dat aSet s fo r

Ope n Moldin g Emissio n Studie s

Attachmen

t 1 - CF A Phas e I Emission Stud

y DataSet s

Attachmen

t 2 - CF A Phas e I I Emission Stud

y DataSet s

Attachmen

t 3 - DO WChemica

l Filamen t Winding Stud

y DataSets

Attachmen t 4 - EPA/OR

D UnfilledResi

n Stud y DataSet s

Attachmen

t 5 - EPA/OR

D Fille dResi

n Stud y DataSet s

Attachmen

t 6 - NMM A Emission Stud

y DataSet sP.2 7



# Attachmen t

1 CF A Phase I Emissio n Stud y Dat aSet sP.2 8

I • I 

# Attachmen t 2
CFA Phas e I I Emissio n Stud y Dat aSet sP.2 9 l

i * < ' "



# Attachmen t 3 DO WChemica l Filamen t Windin g Stud y Dat aSet sP.3 0


## ( *



# Attachmen t 4
EPA/OR D Unfille dResi n Stud y Dat aSet sP.3 1



## i* •



# Attachmen t 5
EPA/ORD Fille dResi n Stud y Dat aSet sP.3 2



### 4 ^ • " ' *



# Attachmen t 6
NMMA Emissio n Stud y Dat aSet s