p. 1


# OAR Box 1415 Prepped by Ollie Stewart



## Document

Number: 

# 13 ) IV-E-1 3 Docket Number: 

# A-94-5 2

Printed 7/15/2008 9:38:26

AM Sheet 13 of 130P. 2 

# WJ-IZ-I3 MEMORANDU

M TO : Docke

t fo r ReinforcedPlastic Composite s NESHA P FROM : Keit

hBarnett , U.S
. Environmenta l ProtectionAgenc

y DATE : Decembe

r 17 , 200 2 SUBJECT : Minute s of

Novembe r 4 , 2002 Meeting Betwee

nEP Aan dthe America

n Composit e Manufacturers Association(ACMA , formerl y th e Composite s Manufacturers Association. ) LOCATION : Room5400 , Arie l Rio s North , WashingtonD.C
. ATTENDEES : U . S
. Environmenta

l Protectio nAgenc

y Jef f Holmstead , Willia mWehrum, Keit hMason Keit hBarnet t Anupam aRajarama

n ACM A Joh nSchweitze

r Chuc k Elkin s Joh nBarke r Perr y Bennet t Lowel l Mile s Willia mPedersen PURPOSE : Assistan t Administrato

r (AA ) fo r Ai r an dRadiation Counse l to the A A Offic e of Policy , Economics , an

dInnovation Emission s Standard s Divisio n Assistan t to the A A 

# r
ACM A Chuc k Elkin s & Associate s Strongwel l MF G Mile s Fiberglas s Sha w Pittma nL.L. P IP AAI M DCJKfc
.



## Th e purpos e ofth e meetin

g wa s fo r the America

nComposit

e Manufacturers Association (ACMA ) to presen t t o Jef f Holmstea dinformatio

nrelating t o the proposednationa l emissio n standar dfo r the Reinforce

dPlasti c Composite s sourc e category . Specifically , the y wer e concernedabou

t the proposedcaptur

e an dcontrol requirements fo

r ne w source s manufacturin

g large parts . Acop

y of thei r presentationwhic

hcover s wha

t was discusseda

t thi s meetin

g i s include das attachmen

t 1
. Th e calculation s tha

t fromthe basi s o

f som e of thei r presentationar

e include das attachmen

t 2
. Durin g the ACM

Apresentation , ther

e wa s discussiono

f on e facilit y tha t we statedha

d95P. 3



## percen t captur e an dcontrol , an

dtha t ACM Aclaime ddi dnot mee t the 9 5 percen

t contro l requirements
. Subsequen

t to thi s meeting , w e obtainedadditiona l informatio

no nthi s facilit

y (A.R.E
. i nMt Eaton , Ohio)
. Thi s informatio nhas als o bee

nplace di nthe docket
.

2
_P. 4



## Attachmen

t 1 ACM APresentation



# 3

# MMA

Sa. 

### America n Composite s Manufacturer s Associatio n p . 1



## Briefin g fo r
JeffHolmstea d Offic e o fAi ran d Radiatio n U.S
. Environmenta l Protectio n Agency

Regardin g th e Propose d MAC TRequirement s fo r Ne wComposit e Manufacturin g Operation s

Novembe r4 , 200 2 CONFIDENTIALBUSINESS INFORMATION

DELETED

# MMA America n Composite s Manufacturer s Associatio n p . 2



## Introductio n Thi s briefin g present s th e followin g issue s i n more detail , bu t i n summary :

• EPA' s propose d MAC Tfo rcomposit e manufacturin g woul d requir e al l newsource s wit h emission s o f 10 0 ton s pe ryea ro rmor e t o emplo y"total " enclosure s an d achiev e 95 % control
. • Thes e "floor " requirement s ar e base d o n thre e plant s tha t produc e larg e quantitie s o fsmal l commodit yproducts
. Smal l par t siz e make s hig h level s o fcaptur e possible , an d th e combinatio n o f smal l par t size , unifor m par

t shape , an d hig h volum e productio n make s 95 % contro l feasible
. • Plant s makin g larg e an d custo m product s hav e certai n technica l characteristic s tha t distinguis h the m fro m small-part operation s an d make hig h level s o fcaptur e practicall yimpossible
. N o suc h plan t ha s eve rdemonstrate d hig h captur e levels
. • Th e importanc e o fthes e technica l factors i s underline d b ythei reconomi cresults
. Fo rcomposit e ^ manufacturin g operations , th e cos t effectivenes s o fcaptur e an d contro l i s reasonabl e onl yfo rplant s

makin g larg e quantitie s o fsmal l unifor m products
. • Th e propose d rul e i s i n effect a constructio n ba n o n th e ne wplant s w e wil l nee d t o mak e product s fo r severa l importan t markets
.

b >MMA America n Composite s Manufacturer s Associatio n p . 3



## Backgroun d

• Th e Clea n Ai rAc t require s EP At o bas e MAC Tfo rne wsource s o n th e emissio n contro l performanc e o fth e bes t controlle d "similar " source . CA Asec . 112(d)(2)
. Th e Ac t doe s no t defin e "similar, " bu t th e onl yreadin g tha t make s sens e i s "simila ri n term s o fth e factor s tha t EP Amus t conside ri n settin g MACT. " Thes e ar e technica l achievability , cost , energy , an d non-ai rqualit yhealt h an d environmenta l impacts
. CA

Asec . 112(d)(2)
. Th e legislativ e histor ysupport s thi s reading
. • OAQP S ha s identifie d a s th e floor-settin g source s thre e highl yspecialize d plant s tha t mak e larg e quantitie s o funifor m smal l commodit yproducts
. OAQP S argue s tha t thes e plant s achiev e "total " capture 1 

## an d henc e 95 % contro l throug h oxidation
. OAQP S propose s t o requir e al l ne wsource s wit h HA P emission s abov e 10 0 tons , eve n thos e wit h ver ydifferen t technica l characteristics , t o achiev e th e sam e leve l o fcontro l a s thes e specialize d plants
. • Th e ne wplant s neede d t o mak e larg e product s o rcusto m product s wil l no t shar e th e physica l ^ > characteristic s tha t allo wth e floor-settin g small-part plant s t o practicall yenclos e thei rprocesses ,

captur e a hig h percentag e o fthei remissions , an d achiev e 95 % control
. • Accordingly , facilitie s tha t ar e specialize d t o mak e unifor m smal l part s ar e no t "similar " t o othe r facilitie s an d canno t suppor t a floo rstandar d fo rthem
. I fEP Ainsist s otherwis e an d promulgate s th e rul e a s no wdrafted , th e rul e wil l indefensibl yburde n futur e growt h ofth e industr yi n it s mos t promisin g product lines
. • W e believ e ther e ar e clea rtechnica l way s t o separat e ou t thos e source s tha t ar e simila rt o th e floor settin g facilitie s fro m thos e tha t ar e not , an d tha t thi s separatio n i s no t onl ylegall ydefensible , bu t i n fac t require d byth e Act
.

1 CFAdoe s no t believ e tha t thes e plant s actuall ysatisfyth e EPArequirement s fo rtota l capture
.

T lMMA America n Composite s Manufacturer s Associatio n p . 4



## Backgroun d (cont. )

• T o compl ywit h th e propose d rule , ne wplant s woul d have t o us e EPAMetho d 20 4 t o demonstrat e tha t the yachiev e "total " capture
. o Metho d 20 4 require s tha t proces s enclosure s maintai n continuou s negativ e pressur e durin g routin e operations
. • Smal l par

t operation s wil l hav e smal l doors an d ca n maintai n negativ e pressur e whe n door s ar e ope n t o remov e parts , brin g i n supplies , etc
. • Thi s i s not possibl e fo rlarge-par t operations , wher e th e doors woul d b e to o larg e t o maintai n negativ e pressur e whe n open . o OAQP S ha s suggeste d tha t state s ar e ofte n ver y"flexible " whe n enforcin g Metho d 204
. • However , Metho d 20 4 itsel fprovide s n o flexibility , an d loca l regulator s hav e bee n very inconsisten t i n th e degre e t o whic h the yhav e allowe d flexibl e enforcement
. Thi s uncertaintymake s investin g i n a newplan t fa rto o risky
. • I fMetho d 20 4 wer e "flexibly " enforce d fo rlarge-par t operations , th e resultin g captur e efficiencie s coul d b e s o substantiall yreduce d tha t captur e an d contro l woul d n o longe r b e th e "best " contro l approach
. Source s wil l achiev e equivalen t emissio n reduction s usin g th e pollutio n preventio n control s bein g require d fo rexistin g source s b ythi s rule
. Thes e control s have non e ofth e negativ e economi can d energ yimpact s o fcaptur e an d control
. EPAha s no t analyze d thi s issu e i n an yway . o Eve n i fthes e issue s ca n b e resolved , onl yplant s makin g larg e quantitie s o funifor m small part s wil l b e abl e t o afford captur e an d control
.

# MMA America n Composite s Manufacturer s Associatio n p . 5



# Typica l mass-produce d smal l product s (dimension s i n feet)



# °< * • Tub/showe runits
.

• Picku p truc k

cap s • Windo wlineals...
. 2.5x5x 5 6x8x 3

. 5 x4in
. x1 1 

## /4in
. 

# Typica l larg e an d custo m product s Barg e cover s 4. 5 x2 4 x3 0 Utilit ypole s 2 dia
. x8 5 Win d turbin e blade s 9. 5 dia
. x11 2 Coolin g towe rcomponent s 1 x4 x4 8 Bridg e beam s VAx3 x6 0 Chemica l process/storag e tanks...
. 1 0 dia
. x3 0 Undergroun d gasolin e tank s 1 0 dia
. x2 0 o assemble d 1 0 x7 4 Moto rhom e sidewall s 8 x3 0 t o 9 x4 2 o roof s 8!^x4 0 o showe rstall s 2 1 

## / 4 x3 x5 o fron t an d rea rcap s 8V 2 x9/4x 4 Mode l spac e shi p 1 5 x1 4 x 4 Tank s 3 dia
. x5 t o 1 4 x3 0 Rai l ca rplatform s 101^x3 0 o doo rliner s 1 0 x1 2 Submarin e connin g towe r12x5x1 2 o batter ybo x3 x 4 x3 5 o superstructur e 1 4 x7 x7 5 Gol d dome s fo ra churc h 2 5 dia
. Yach t 10 0 o flyin g bridg e .2 0 x1 2 Facad e fo ra n athleti cstor e 5 0 x1 2 x3 And thousands

more... • Composite products ar

e mad e b yapplyin g glas s fiber

s an d liqui d resi n t o mold s that are th e shap e ofth e fina l product
. • Onc e applied , th e resi n chemicall yreact s to for m a soli d product , whic h i s the n remove d fro m th e mold
. • Composites successfull ycompet e agains t othe rmateria l system s whe n th e applicatio n call s fo rlarg e structura l shape s i n combinatio n wit h corrosio n resistance , ligh t weight , and/o rdesig n flexibility
.

# MMA America n Composite s Manufacturer s Associatio n p . 6



## Exampl e smal l mass-produce d product s

Figur e 1
. Spra yapplicatio n o fresi n t o tub/showe runi t i n spra y booth
. Workers ca n b e positione d upstrea m t o reduc e exposure .

Figur e 2
. Tub/showe rmold s o n dollies , i n fron t o fspra ybooths
. Smal l enclosure s ca n captur e hig h percentag e o femissions
. Figur e 3
. Tub/showe rmold s o n overhea d conveyor . Mold s ar e quickl ymove d throug h productio n process .

T ) o

# MMA America n Composite s Manufacturer s Associatio n 

### p. 7

O 

# Exampl e larg e an d custo m product s

• . , Figur e 4
. Moto rhom e sidewall , u p t o 4 2 fee t long
.

Figur e 5
. Moto rhom e fron t end
. Structura l requirement s deman d precis e placemen t o freinforcemen t an d carefu l assembly
. Figur e 6
. Undergroun d storag e tan k assembly
. Phot o CBI
. Assemble d product s u p t o 1 0 x7 4 feet
.
Figur e 7
. US Tsectio n an d mold
. Phot o CBI
. Overhea d cran e i s use d t o remov e 1 0 x2 0 foo t section s fro m lowe rhal fo fmold
.

# MMA America n Composite s Manufacturer s Associatio n p . 8



# Larg e an d custo m product s (cont. )
Figur e 8 . Applyin g resi n an d glas s t o barg e cove rmold . Phot o CBI . Resi n i s applie d t o glas s mat o n overhea d platform , whic h move s t o drap e th e materia l o n th e mold
. Figure 9 . Barg e cove ran d mold . Phot o CBI . Mold s ar e move d t o variou s proces s station s durin g production , an d complete d cover s are remove d fro m mold s usin g overhea d cranes . Figure 10 . Applyin g glas s an d resi n t o horizonta l tan k mold . Phot o CBI .

to

# MMA America n Composite s Manufacturer s Associatio n p . 9



## Larg e an d custo m product s (cont. )



# c ° Figur e 11
. Campe rtop
. Highl ycustomize d product mad e i n smal l

quantites
.

Figur e 12
. Architectura l dome
. Highl ycustomize d product i s typica l o fcusto m moldin g operations
. Figur e 13
. Spra yapplicatio n o fresi n an d glas s t o vertica l chemica l process/storag e tank
.



# 5

# MMA America n Composite s Manufacturer s Associatio n p . 1 0



## Larg e an d custo m product s (cont. )

V^ o Figur e 14
. Win d turbin e blades
.

Figur e 15
. Win d turbin e blade
. Amajo rne wmarke t fo r composites
. Figur e 16
. Pultrude d utilit ypoles
. Ligh t weight , eas yt o install , an d n o woo d preservative s needed
.

Figur e 17
. Pultrude d bridg e beams
. Significan t cos t an d performanc e benefit s fo rtransportatio n infrastructur e rehabilitation
.

# MMA America n Composite s Manufacturer s Associatio n p . 1 1



## Technica l characteristic s o fplant s

- G Part siz e

Numbe rofproduct s produce d pe rday Emission s Proces s logistic s Proces s are a Proces s complexit y Ai rflow s neede d t o protec t worker s Feasibilit y of"total " captur e Feasibilit y o f95 % contro l Plant s dedicate d t o th e mass-productio n of smal l unifor m product s U p t o 1 0 fee t 500 + U p t o 1,00 0 ton s pe ryea r Fas t an d ofte n automate d - mold s ar e move d o n conveyors o rdollie s Compact - ofte n no t muc h large rtha n a singl e product Lo w- simpl e laminate s requir e limite d interactio n o f worke rwit h product s Lo w- worker s ca n b e statione d upstrea m o f product s Hig h - proces s enclosure s ca n hav e continuousl y ope n smal l door s an d stil l mee t th e requirement s fo rtota l enclosur e Hig h - lowvolum e ai rflow s wit h hig h HA P concentratio n result s i n easie roxidatio n Plant s producin g larg e an d custo m product s U p t o 75 + fee t 1-2 0 U p t o 25 0 ton s pe ryea r Larg e mold s an d product s requir e slo wmovemen t usin g for k trucks , overhea d cranes , team s o fworker s Larg e - t o accommodat e productio n o fsevera l larg e product s plu s associate d equipmen t Hig h - comple xlaminate s requir e skille d worker s t o accuratel yappl yresi n an d plac e glas s reinforcemen t Hig h - neede d t o protec t worker s statione d al l aroun d an d insid e product s durin g productio n (hig h ai rflow s ar e als o neede d t o maintai n negativ e pressur e wit h larg e doors ) Lo wt o verylo w- proces s enclosure s nee d larg e door s tha t ar e frequentl yope n an d subjec t t o win d load s Lo w- hig h volum e ai rflow s wit h lo wHA P concentratio n dramaticall yincreas e th e siz e an d cos t o fai r movemen t an d contro l equipment , an d increas e th e nee d fo rsupplementa l fue l 

## Fo ral l thes e strictl yphysica l reasons , larg e an d custo m part s facilitie s ar e likel yt o hav e mor e difficult y maintainin g an d operatin g add-o n control s tha n specialize d smal l part s facilities , an d th e performanc e o f add-o n control s a t thes e facilitie s wil l b e fa rles s predictable
. Thes e factor s ar e unquestionabl yrelevan t t o determination s o f"similarity. " Se e 6 6 Fed
. Reg
. 40331
.

o i

# MMA America n Composite s Manufacturer s Associatio n p . 1 2



# Technica l characteristics : Proces s density "Proces s density " i s a measur e tha t integrate s severa l o fth e relevan t technica l characteristics , includin g par t size , proces s complexity , productio n rate , an d othe rfactor s tha t determin e th e practica l feasibility o f captur e an d control .



## _annual quantity o f produc t throughput , raw material usage , o r emission s siz e (volume ) o f

proces s are a Figur e 1 8



## \j ^ •Plant s dedicate d to th e productio n ofsmal l unifor m products have very hig h proces s density . Thes e

plant s make larg e quantitie s o fproduct i n smal l proces s areas . •Plant s producin g larg e an d custo m product s hav e lo wproces s density . Thes e plant s make smal l quantitie s ofproduct i n ver y larg e proces s areas .

# MMA America n Composite s Manufacturer s Associatio n p . 1 3

^ 

## Technica l characteristics : Proces s densit y(cont. )

W e calculate d th e proces s densit yfo rsi xplant s tha t ar e representativ e o flikel yne wplants
. Tw o ofth e plant s ar e dedicate d t o th e mass-productio n o funifor m smal l part s (A.R.E
. i s on e o fth e floor-settin g plants) , an d fou rmak e larg e parts
.

Product s Typica l Par t Siz e fee t Proces s Densit y tpy/1,000ft 3 Mass produce d smal l part s A.R.E . picku p truc k caps
10. 4

10. 1 Plant A

bathwar e



### 7. 5

8.3 3 Larg e an d custo m part s
Monac o
moto r home sidewall s
12-4 5

0.1 8 Plant B
moto r home , truc k
14. 7

0.2 8 Proform
UST , barg e cover s
17-3 0

0.1 5 Xerxe

s


### US T



### 1 7

0.1 7 

### > .

</ > c CO Q M v t m o o Q
. 1 2 1 0 

### 8 6 4 2 ^

^



# o -^ U AR.E . 1
_

" — 

## l~ — *^~\ 1

Plant AMonac

o 1

____

_

" "

Plan t B Profor

m Xerxe

s

T J

# MMA America n Composite s Manufacturer s Associatio n p . 1 4



## Technica l characteristics : Airflo w A t th e suggestio n o fOAQPS , w e als o compare d th e si xmode l plant s b yth e rati o o fai rflo wt o amoun t o f ra wmateria l processed
. OAQP S aske d u s t o perfor m thi s compariso n becaus e thi s rati o ca n b e use d a s a n indicatio n o fcontro l feasibility
. Fo rth e plants , w e estimate d th e ai rflo wneede d bot h t o protec t worker s an d t o maximiz e capture
.



## *s /
Fo rai rflo w

neede d fo r worke r protectio n Fo rai rflo w neede d fo r worke r protectio n plu s max . captur e Ai rflo w+ materia l usag e cfm/to n Mass produce d smal l part s
L U Cai 

### <
8.7 9

8.7 9PlantA



### 5.4 2

7.2 4 Larg e an d custo m part sMonaco



### 80.0 3

97.9 6PlantB



### 35.7 8

63.2 5Proform



### 42.4 2

86.9 6Xerxes



### 31.8 5

45.5 7 CF M ai rflo wpe rto n o fm ateria l usag e fo rworke rprotectio n (blue ) an d worke rprotectio n plu s max . captur e (red )

A R E Plan t A Monac o Plan t B Profor m Xerxe s

T 3 0 0

# MMA America n Composite s Manufacturer s Associatio n p . 1 5



# Industry' s suggeste d approac h

•Th e fina l rul e shoul d limi t new-sourc e captur e an d contro l t o thos e source s tha t ar e simila rt o th e floor-settin g plants , specifically , thos e tha t mak e smal l product s i n larg e quantitie s (an d consequentl y hav e hig h proces s density) . o Th e smalles t produc t mad e b y ou rfou rmode l large-par t plant s ha s a larges t dimensio n o f1 2 feet , an d th e larges t produc t mad e b y th e floor-settin g plant s ha s a larges t dimensio n o f10. 4 feet . Therefore , w e sugges t tha t th e rul e defin e "smal l ope n molde d parts " a s thos e wit h n o dimensio n o f1 2 fee t o rmore . •Althoug h no t specificall y addresse d i n thi s briefing , w e hav e submitte d dat a an d analysi s t o EP A supportin g a definitio n o f"smal l pultrude d parts " a s thos e wit h n o mor e tha n 10 0 reinforcemen t feed s an d cros s sectiona l surfac e perimete ro fles s tha n 8 inches .

_ _o W e sugges t tha t onl y thos e operation s wit h small-par t emission s o f10 0 tp y o rmor e wil l hav e °S > sufficien t proces s densit y t o feasibl y achiev e 95 % control . Th e smalles t o fth e floor-settin g

plant s emit s 10 0 tpy , an d EP A ha s alread y agree d tha t C& C i s no t feasibl e fo rplant s wit h emission s o fles s tha n 10 0 tpy .

T J CO

# MMA America n Composite s Manufacturer s Associatio n p . 1 6



## Industry' s suggeste d approac h (cont. )

• Ou rdisagreemen t wit h OAQP S center s aroun d wher e t o "dra wth e line " separatin g ne wplant s tha t shoul d b e require d t o achiev e tota l enclosur e an d 95 % contro l fro m thos e tha t shoul d not
. o Th e OAQP S propose d rul e woul d requir e tota l captur e an d 95 % contro l fo ral l ne wplant s wit h emission s o f 10 0 ton s pe ryea ro rmore . Thi s approac h woul d clearl yinclud e man yfacilitie s tha t ar e i n n o wa y"similar " t o th e floor-settin g plants
. o Fo rne wplants , ou rapproac h require s thi s leve l o f contro l onl yfo rsmall-part operation s wit h emission s o f 10 0 tp yo rmore , o rfo r al l processe s i f tota l emission s ar e 25 0 tp yo rmore . • W e believ e tha t th e OAQP S propose d approac h woul d "capture " man yne w plant s tha t ca n no t practicall yachiev e tota l captur e an d 95 % control , an d woul d i n effect preven t thei rconstruction
. • Unde rou rapproach , large-par t operation s wil l stil l hav e t o adop t th e effectiv e pollutio n preventio n control s require d o f existin g sources , an d achiev e emissio n reduction s o f 50-65%
. • Ou rapproac h wil l allo wou rindustr yt o gro wan d provid e product s fo rimportan t ne wmarkets , whil e stil l achievin g a significan t reductio n i n emissions
. OAQP S proposa l Industry approac h Tota l capture an d 95 % contro l require d a t newplants.. .

.. . fo rsmall-part operation s wit h emission s of..
. 10 0 tp yo rmore 10 0 tp yo rmore .. . fo ral l othe roperation s i f tota l emission s are.. . 10 0 tp yo rmore 25 0 tp yo rmore

# MMA America n Composite s Manufacturer s Associatio n p.1 7



# £ Economi cCharacteristics : Contro l cos t effectivenes s

Th e importanc e o fth e technica l difference s - betwee n plant s tha t mak e larg e quantitie s o fsmal l unifor m product s an d plant s tha t mak e larg e o rcusto m product s - i s underline d b yth e economi cdifference s t o whic h the ygiv e rise
. Proces s densit yha s a ver ylarg e impac t o n th e cos t effectivenes s o fa contro l syste m (th e cos t o fcontrollin g eac h to n o fHAP)
. Plant s wit h hig h proces s densities , lik e th e floor-settin g small-part s plants , wil l hav e muc h lowe r contro l cost s tha n plant s makin g larg e parts
.

Proces s Densit y tpy/1,000ft 3 Contro l cos t effectiveness 2 $/to n o fHA P Mass produce d smal l part s A.R.E . 10. 1

75 8 Plan t A 8.3 3
78 3 Larg e an d custo m part s Monaco 0.1 8
5,42 5 Plan t B 0.2 8
4,82 9 Profor m 0.1 5
9,62 5 Xerxe s 0.1 7
5,99 4

2 Base d o n potential

emissions;

contro l cos t estimate s base d o n actual emissions

wil l b e higher
. Also , ou rcos t estimate s fo rth e fou rlarge-part plant s ar e base d o n a desig n tha t maximize s captur e whil e stil l providin g fo rth e necessar yproces s logistics
. W e d o no t believ e tha t thes e "maximu m practical " captur e system s wil l satisfyth e EPArequiremen t fo rtota l captur e o ractuall yachiev e mor e tha n 80 % capture
. "Total " captur e ha s neve rbee n demonstrate d fo rth e manufactur e o flarg e composit e products
.

T J 

### r o

# MMA America n Composite s Manufacturer s Associatio n p . 1 8



# Economi c characteristics : Capita l cos t Th e capita l cost o

fa n add-o n contro l syste m i s drive n primaril y b y th e amoun t ofplan t ai rtha t mus t b e captured,.transporte d t o th e contro l system , an d the n combusted . Becaus e large-part an d custo m plant s wil l typicall y hav e muc h highe rai rflows , an d th e capture system s wil l b e large ran d muc h mor e complex , th e capita l cost s fo rthes e plant s wil l b e muc h higher .

N Proces s

Density tpy/1,000ft 3 

### Capita l Cos t ofC& C $1,00 0 Mass produce d smal l part s A.R.E . 

### 10. 1
1.500 3 Plan t A 

### 8.3 3
97 9 Larg e an d custo m part s
Monac o 

### 0.1 8 1,91 5 Plant B 

### 0.2 8 3,57 1 Profor m 

### 0.1 5 7,32 0 Xerxes 

### 0.1 7 3,65 8

' Estimat e base d o n th e percentag e o femission s fro m th e composit e manufacturin g operation
.

# MMA America n Composite s Manufacturer s Associatio n p . 1 9



## Economi cCharacteristics : Impac t o n capita l investmen t Large-par t an d custo m plant s typicall yhav e lo wcapita l investment s i n proces s equipment , compare d t o plant s dedicate d t o th e mass-productio n o funifor m smal l parts
. Accordingly , a requiremen t fo rcaptur e an d contro l wil l hav e a muc h large rimpac t o n th e tota l capita l investmen t neede d t o buil d a ne wplan t fo r larg e o rcusto m product s tha n i t woul d o n th e capita l cos t o fa specialize d small-part s plant
. Dat a o n capita l investmen t fo rtw o o fou rmode l plant s i s show n below
.



# rCapitalcost 

### Ne wplan t

$1,00 0 Ne wplan t wit h C& C $1,00 0
Increas e Mass-produce d

smal l part s Plan t A 7,50 0
8,47 9

13 % Larg e part s

Profor m 2,37 8
9,69 8

308 %

r o

# MMA America n Composite s Manufacturer s Associatio n p . 2 0



# Summar y

• Th e abilit yo f ou rcompanie s t o continu e developin g ne w product s fo rne wmarket s i s essentia l t o th e healt h o f ou r industry
. Man yo f thes e product s wil l b e larg e an d mad e i n smal l quantities
. • Ou ranalysi s demonstrate s tha t ther e ar e significan t technica l difference s betwee n th e floor-settin g plant s tha t mass-produc e smal l unifor m product s an d th e man yne w plant s tha t wil l mak e larg e an d custo m products
. Thes e technica l difference s hav e a profoun d impac t o n th e feasibilit yo f captur e an d control
. Smal l par t siz e make s hig h level s o f captur e possible , an d hig h proces s densit y make s 95 % contro l feasible
. • Congres s di d no t inten d th e Clea n Ai rAc t t o preven t expansio n o f businesse s o rth e inventio n o f ne w products
. W e believ e tha t ou rapproac h meet s th e statutor yrequirement s t o impos e reasonabl e ai rpollutio n control s o n ne wfacilities , bu t wil l stil l allo wou rindustr yt o produc e ne wproducts
. Recentl y commercialize d larg e product s

Figur e 19 . Unibod y campe rmol d an d campe rassembly . Improve d structura l propertie s an d lea k resistance
.

# MMA America n Composite s Manufacturer s Associatio n 

### p . 2 1



# Summary (cont. )

•W e sugges t th e followin g approac h t o MAC Tfo rnew sources : o An y ne wsourc e wit h emission s of10 0 ton s pe r yea ro rmor e fro m th e productio n o ftub/showe r units , picku p truc k

caps , windo wlineals , smal l ope n molde d part s o rsmal l pultrude d part s i s require d to reduc e thos e emission s b y 95% . •"Smal l ope n molde d parts " i s define d a s thos e wit h n o dimensio n greate rtha n 1 2 fee t (measure d a s th e distanc e betwee n th e furthes t tw o point s o n th e par t a s i t i s remove d fro m th e mold) . •"Smal l pultrude d parts " i s define d a s thos e wit h n o mor e tha n 10 0 reinforcemen t feed s an d cros s sectiona l surfac e perimete ro fn o mor e tha n 8 inches . o An y ne wsourc e wit h emission s of25 0 ton s pe r yea ro rmor e i s require d t o reduc e thos e emission s b

y 95% . o An y othe rcomposit e manufacturin g operatio n a t a ne wsourc e i s require d t o compl y wit h th e applicabl e existing-sourc e MACT . Recentl y commercialized larg e products : Figur e 20 . Win d fairin g an d artis t renderin g o finstallatio n o n th e Whiteston e Bridge . Ligh t weigth , easil yinstalled , maximize s bridg e capacity , won' t rus t o rcorrode
. Photo s CBI .

O l

# MMA America n Composite s Manufacturer s Associatio n p . 2 2



## Summar y (cont. )

• Additiona l industr

yconsiderations : o Th e floor-settin g plant s ar e specialized t o make smal l parts
. W e considere d suggestin g tha t onl yspecialize d small-part plant s shoul d b e require d t o achiev e 95 % captur e an d control
. However , thi s woul d alio wsource s t o avoi d thi s requiremen t simpl ybyno t bein g specialized
. Accordingly , w e sugges t tha t th e captur e an d contro l requirement s appl yt o th e emission s fro m productio n o fsmal l part s fro m an yne wfacilit yi fthes e small-part emission s excee d 10 0 ton s pe ryear . Thi s approac h woul d allo wcusto m molders som e abilit yt o serv e thi s segmen t o fth e marke t whil e assurin g tha t the ydi d not produc e s o man ysmal l part s a s t o undermin e th e basi c95 % contro l requirement
. o Ther e ar e n o existin g large-par t o rcusto m plant s wit h emission s o fmor e tha n 25 0 ton s pe r year . W e d o not currentl yse e ho wlarge-par t plant s large rtha n 25 0 tp ycoul d achiev e captur e an d contro l mor e readil ytha n th e existin g plants
. Althoug h i t i s no t certai n tha t suc h ^ plant s wil l b e built , w e acknowledg e tha t EP Ama yb e concerne d abou t th e emission s consequence s i fthe yare . Therefore , t o addres s thes e EP Aconcerns , w e ar e willin g t o accep t a fina l rul e tha t woul d require 95 % captur e an d contro l fo ran yne wlarge-part plan t tha t emit s more tha n 25 0 ton s pe ryear . f \P.2 7



## Attachmen t 2 Calculation s use

db y ACM Ato develo

p proces s densit

y an dcos t effectiveness
.



# II*

# iJ 

# DRAF T

Compactnes s Ratio s (smalle rvalue s indicat e processe s tha t ar e mor e compact )

proces s floo rare a pe rto n 20 4 PT E floo rare a pe rto n proces s volum e pe rto n 20 4 PT E volum e pe rto n proces s airflo wpe rto n 20 4 PT E airflo wpe rto n proces s floo rare a pe rcf m 20 4 PT E floo rare a pe rCf m proces s volum e pe rcf m 20 4 PT E volum e pe rcf m Smal l Part s Truc k Cap s A.R. E Massillo n Bathwar e

Plan t A

ft 2 /to n ft 2 /to n ft 3 /to n ft 3 /to n cfm/to n cfm/to n ft 2 /cf m ft 2 /cf m ft 3 /cf m ft 3 /cf m 1 0

2 1 9 9 57 4 9 5 9 5 0.1 1 0.2 2 1. 0 6. 0 existin g RT O existin g RT O



### 1 5 1 6 12 0 12 9 5 9 7 8 

### 0.2 6 0.2 1 2. 0 1. 6 Larg e Part s

RV/Truc k Plan t B



### 12 9 14 1 3,62 3 4,23 3 38 8 68 5 

### 0.3 3 0.2 1 9. 3 6. 2 RV/Sidewal l

Monac o Hine s

23 6 38 4 

### 5,69 7 9,79 0 86 7 1,06 1 0.2 7 0.3 6 6. 6 9. 2 US T UST/Cover s

Xerxe s Profor m Wes t Hagerstow n Memphi s

20 5 24 5 5,72 6 6,84 6 

### 65 0 93 0 0.3 1 0.2 6 8. 8 7. 4 

### 21 6

41 4 6,55 1 12,37 3 77 1 1,58 1 0.2 8 0.2 6 8. 5 7. 8
Contro l Cos t Effectivenes s Contro l cost s increas e significantl ydu e t o siz e o fpart s - mor e ND O airflo wan d large renclosure s neede d Typica l proces s a t Permitte d Emissio n Rat e $/to n Metho d 20 4 a t Permitte d Emissio n Rat e - includin g additiona l building s & $ / to n ND O flow s $75 8 $75 8 

### $65 7

$78 3 $4,87 3



### $4,83 0 $4,79 1



### $5,42 5 $5,24 2

$5,99 4 $5,76 2

$9,62 6P.2 9



### A.R.E . Massillo n - truc k ca p (small-part

) productio n Productio n Activit y unit s Gelcoatin g & Laminatio n o f FR P Truc k

Cap s Automotiv e Spra yPaintin g o f

Finishe d Truc k

Cap s Emission s HA P Emissio n Rat e PT E Exhaus t Airflo w Proces s Exhaus t Airflo w ND O Exhaus t Airflo w Tota l Proces s Exhaus t Airflo w Par t Dimension s Typica l Part Dimension s "Greatest " Part Dimensio n "Most-Compact " Part Bo x

Volum e Enclosure s Proces s Enclosure s

Gelcoa t Booth : Gelcoa t Cur e Tunnel : Glassroo m Booth : Resi n Cur e Tunnel : Insid e Gelcoa t Booth : Gelcoa t Cur e /

Exi t Tunnel : Metho d 20 4 Tota l Enclosur e

Laminatio n Room : Floo rArea s Tota l Proces s Enclosur e Floo r

Are a Metho d 20 4 Enclosur e Floo r

Are a Volume s Tota l Proces s Enclosur e Volum e Metho d 204-typ e Enclosur e

Volum e Buildin g Addition s Additiona l Buildin g Area s require d t o isolat e process i n Metho d 204-typ e enclosur e

Additiona l floorare a Capita l Cos t Annua l Cos t tp y

cf m cf m cf m ft ft ft 3

ft 2 ft 2
ft 3 ft 3

ft 2 TCI $ TAC $ 52 5

50,00 0 include d abov e 50,00 0 6'W x8'L x3' H 10. 4 14 4

19'Wx25'L x9/4' H 11'Wx79'L xSV.'H 28'Wx68 ' Lx11 1 /« ' H 10'Wx79'L x8V4' H 19'Wx25'L x9'/4' H 10'Wx84'L x8'/4'H 68'Wx164'Lx27' H 5,35 3 11,15 2 52,07 4 301,10 4

NON E REQUIRE D 0 0 0 50 0 50,00 0 include d abov e 50,00 0

N A Plant-wid e Tota l 1,02 5
100,00 0 Comment s and/o rReference s

standar d truc k

ca p diagona l dimensio n

no t show n i n EP Atri p report

Natura l Draft Opening s

Fou rInle t Vents : Exi t Tunne l "exit " openin g ND O Fre e Are a ft 2 four-5'W x2' H

10'W x4' H 8 0 Add-o n Contro l Cost s

Capita l Cos t TC I $ Annua l Cos t TA C $ Cos t Effectiveness

$ I ton Compactnes s Ratio s process floorare a pe rto n ft 2 / to n 20 4 PT E floorare a pe rto n ft 2 / to n process volum e pe rto n ft 3 / to n 20 4 PT E volum e pe rto n ft 3 /to n process airflo wpe rto n cfm/to n 20 4 PT E airflo wpe rto n cfm/to n process floorare a pe rcf m ff/cf m 20 4 PT E floo rare a pe rcf m ft 2 / cf m SE E CF AC& C Report

$3,000,00 0 $988,00 0 $1,015

1 0 21 9 9 574 9 5 9 5 0. 1 0. 2 SE E EP Atri p report $2,324,80 0 $738,40 0 $75 8 assumin g 6,10 0 hr/y r assumin g 95 % o f1,02 5 tp yPT E "20 4 PTE " = Metho d 20 4 permanen t tota l enclosur e

process volum e pe rcf m 20 4 PT E volum e pe rcf m 1. 0 6. 0 

# 1$P.3 0

Plan t A - automated bathwar e (small-part) productio n Productio n Activit y
Emission s HA P Emissio n Rat e PT E Exhaus t Airflo w Proces s Exhaus t Airflo w ND O Exhaus t Airflo w Tota l Exhaus t Airflo w Part Dimension s Typica l Par

t Dimension s "Greatest " Par

t Dimensio n "Most-Compact " Typica l Par t BoxVolum e Enclosure s Proces s Enclosure s

Gelcoat Boot h Gelcoa t Cur e Tunne l Barrie rCoa t Barrie rCoa t Cur e Tunne l La m 1 Spray/Rol l Boot h La m 1 Cur e Tunne l La m 2 Spray/Rol l Boot h La m 2 Cur e Tunne l tp y

cf m cf m cf m ft ft n 3 Laminatio n o fBathwar e Tu b

& Showe rUnit s fou rmoldin g station s o n ova l conveyo rlin e 42 6 25,00 0 8,40 0 33.40 0 2.5'Wx5'Lx5' H 7. 5 6 3

18'Wx12'Lx8' H 12'Wx108'Lx8' H 18'Wx18'Lx8' H 12'Wx110'Lx8' H 1SWx3Z\.xSH 12'Wx104'Lx8' H 18'Wx25'Lx8' H 12'Wx80'Lx8' H Comment s and/o rReference s Plan t ha s +90 % contro l syste m PT E befor e RT O contro l unit , no t incl u tp yofrepair & misc
. emission s i n pla n T o RT O uni t SE E ND O sectio n belo w assum e 33,00 0 cf m appro x7 0 S F Measure d diagonall ya t greates t spa n

SE E Plan t pla n drawin g booth s ar e 18'wid e tunnel s ar e 12'wid e

Metho d 20 4 Tota l Enclosure Gelcoa t boot h entranc e tunne l

Bas e storag e room s Floo rArea s Proces s Floo rAre a Metho d 20 4 Enclosure Floo r

Are a Volume s Proces s Volum e Metho d 204-typ e Enclosur e

Volum e abov e proces s enclosure s plu s 12'Wx20'Lx8' H tw o - 6'Wx20'Lx8' H
ft 2 ft 2 ft 3 ft 3 6,39 0

6,87 0 51,12 0 54,96 0 SE E Buildin g Addition s sectio n belo w neede d t o isolat e gelcoa t boot h entranc e neede d t o isolat e bas e storag e are a insid e booth s an d tunnel s includin g additiona l tunne l & storag e area s

Buildin g Addition s Additiona l Buildin g Area s require d t o isolat e proces s i n Metho d 204-typ e enclosur e

Floo rare a ft 2 Capita l Cos t TCI $ Annua l Cos t TAC S 12'Wx20'Lx8' H 6'Wx20'Lx8' H 0 $ 0 $ 0 Newgelcoa t entranc e tunne l an d bas e

storag e area s next t o La m booths ; bas e inventor yi s restocke d betwee n workshift s (include d i n initia l constructio n cost )

Natura l Draf t Opening s ND O Doorways ND O Fre e Are a ND O Airflo wat 20 0 fp m n 3 cf m Gelcoat Boot h i n - 3 ' Wx7 ' H La m 2 Boot h ou t - 3 ' W xT H 4 2 8.40 0 Add-o n Contro l Cost s Typica l a t PT E

Capita l Cos t TC I $ Annua l Cos t TAC S Cos t Effectiveness

J/(o n w/ Buildin g Additio n & ND O

Capita l Cos t TC I $ Annua l Cos t TAC S Cos t Effectivenes s $ 7 ton Compactnes s Ratio s proces s floorare a pe rto n f e / to n 20 4 PT E floorare a pe rto n te/to n proces s volum e pe rto n ft 3 / to n 20 4 PT E volum e pe rto n fe/to n proces s airflo wpe rto n cfm/to n 20 4 PT E airflo wpe rto n cfm/to n proces s floorare a pe rcf m fe/cf m 20 4 PT E floorare a pe rcf m ffl aim proces s volum e pe rcf m fe/cf m 20 4 PT E volum e pe rcf m fe/cf m $963,10 0 $265,90 0 7165 7 S979.00 0 $316,95 0 $78 3

1 5 1 6 12 0 12 9 5 9 7 8 0. 3 0. 2 2. 0 1.6 - 100 % captur e i s currentl yachieve d wit h

doorwayfac e velocitie s tha t ar e muc h les s tha n 20 0 fp m (neede d fo rMetho d 204 )

assumin g 25,00 0 cf m & 42 6 tp y assumin g 6,66 0 hr/y roperatio n assumin g 95 % o f42 6 tp yPT E assumin g 33,00 0 cf m & 42 6 tp y assumin g 6,66 0 hr/y roperatio n assumin g 95 % o f42 6 tp yPT E



# i tP.3 1

Plan t B - misc
. R V & truc k (large-part ) productio n Productio n Activit y
Emission s HA P Emissio n Rat e PT E Exhaus t Airflo w Proces s Exhaus t Airflo w ND O Exhaus t Airflo w Tota l Exhaus t Airflo w Part Dimension s Typica l Par

t Dimension s "Greatest " Par

t Dimensio n "Most-Compact " Typica l Par t BoxVolum e tp y Gelcoatin g an d Laminatio n of Misc
. RV & Truc k

Part s thre e cross-connecte d productio n line s 12 9 cf m cf m cf m f t f t 50,00 0

38,40 0 88,40 0 custo m part s maxsiz e 9'Wx10'Lx6' H 14. 7 Comment s and/o rReference s

Maximu m HA P emission s booth s onl y- cur e area s no t capture d SE E ND O sectio n belo w us e 90,00 0 cf m syste m Measure d diagonall ya t greates t spa n 54 0 Enclosure s Proces s Enclosure s

Gelcoa t Booth s Gelcoa t Cur e are a Laminatio n Booth s Laminatio n Roll/Cur e are a tw o - 16'Wx30'Lx16' H 40'Wx130'Lx30' H thre e - 16'Wx30'L x16' H 70'Wx130'Lx30' H downdraft supply , sidewal l exhaus t approx . roo m dimension s a t boot h heigh t downdraft supply , sidewal l exhaus t approx . roo m dimension s a t boot h heigh t Metho d 20 4 Tota l Enclosure 130'Wx140'Lx30' H SE E Buildin g Addition s sectio n belo w Floo rArea s Proces s Floo rAre a Metho d 20 4 Enclosur e Floo r

Are a Volume s Proces s Volum e Metho d 204-typ e Enclosure

Volum e ft 2 ft 2 ft 3 ft 3 16,70 0

18,20 0 467,40 0 546,00 0 Buildin g Addition s Additiona l Buildin g Area s require d t o isolat e proces s i n Metho d 204-typ e enclosur e

Floo rare a Capita l Cos t Annua l Cos t Natura l Draft Opening s ND O Doorway s ND O Fre e Are a ND O Airflo wa t 20 0 fp m ft 2 TCI $ TAC $

ft 2 cf m NON E REQUIRE D

0 $ 0 $ 0
16'Wx12' H 19 2 38,40 0 SE E Metho d 20 4 pla n vie w- newcurin g room s t o enclosur e entir e proces s (par t o f initia l buildin g cost )

Add-o n Contro l Cost s Typica l a t PT E

Capita l Cos t TC I $ $1,090,70 0 Annua l Cos t TAC $ $314,30 0 Cost Effectiveness

$/ton $4,873 w fBuildin g Additio n & ND O

Capita l Cos t TC I $ $1,915,40 0 Annua l Cos t TA C $ $591,90 0 Cost Effectiveness

$/ton $4,830 Compactnes s Ratio s assumin g 50,00 0 cf m & 12 9 tp y assumin g 6,00 0 hr/y roperatio n assumin g 50 % o f12 9 tp yPT E assumin g 90,00 0 cf m & 12 9 tp y assumin g 6,00 0 hr/y roperatio n assumin g 95 % o f12 9 tp yPT E

proces s floorare a pe rto n 20 4 PT E floo rare a pe rto n proces s volum e pe rto n 20 4 PT E volum e pe rto n proces s airflo wpe rto n 20 4 PT E airflo wpe rto n proces s floo rare a pe rcf m 20 4 PT E floorare a pe rcf m proces s volum e pe rcf m 20 4 PT E volum e pe rcf m ft 2 /to n ft 2 /to n ft 3 /to n ft 3 /to n cfm/to n cfm/to n ft 2 /cf m ft 2 /cf m ft 3 /cf m ft 3 / cf m 12 9

14 1 3.62 3 4,23 3 38 8 68 5 0. 3 0. 2 9. 3 6. 2 

# 3oMonac o Hine s - tw o type s o fR V parts ; sidewall s an d misc . fiberglas s part s P.3 2

Productio n Activity

two separat e operation s Emission s HA P Emissio n Rat e PT E Exhaus t Airflo w Proces s Exhaus t Airflow ND O Exhaus t Airflow Total Exhaus t Airflow Par t Dimension s Typica l Part Dimension s "Greatest " Part Dimensio n "Most-Compact " Part Box

Volum e Enclosure s Proces s Enclosure s Gelcoatin g & Laminatio n o f unit s Sidewal l Panel s

Pane l Lin e on e automate d ova l productio n lin e tp y 5 3 Gelcoatin g an d Laminatio n o f Misc . Fiberglas s Part s Fiberglas s te n fixe d moldin g station s

12 0 Plant-Wid e Total s

17 3 cf m cf m cf m
f t f t ft 3 50,00 0

4,80 0 54,80 0 sidewal l pane l 8'Wx45'Lx0.5 , H 45. 7 18 0

Pane l Lin e Roo m - 67'Wx322'Lx26' H 100,00 0 28,80 0 128,80 0 roo f roof-10'Wx45 , Lx1' H endca p - 8'Wx9'Lx4' H roo f46. 1 endca p 12. 7 roo f45 0 endca p 28 8
Fiberglas s Roo m - te n - 24'Wx80'Lx16' H 150,00 0 33,60 0 183,60 0 Comment s and/o rReference s

SE E plant' s PT E spreadshee t 10,00 0 cf m wal l fa n pe rfixe d statio n SE E ND O sectio n belo w Additiona l exhaus t flowneede d t o balanc e ND O airflowint o th e rooms , assum e 184,00 0 cf m

Metho d 20 4 Tota l Enclosur e 67'Wx322'Lx26' H 160"Wx320'Lx26 ' H Floo rArea s Proces s Floo rAre a Metho d 20 4 Enclosur e Floo r

Are a Volume s Proces s Volum e Metho d 204-typ e Enclosur e

Volum e ft 2 ft 2 ft 3 ft 3 21,57 4

21,57 4 618,41 0 618,41 0 19,20 0 44,80 0 367,20 0 1,075,20 0 40,77 4 66,37 4 985,61 0 1,693,61 0 Buildin g Addition s Additiona l Buildin g Area s require d t o isolat e proces s i n Metho d 204-typ e roo m enclosure s w/

o exterio rdoor s Floo rare a tt 2 Capita l Cos t TC I $ Annua l Cos t TA C $ Natura l Draf

t Opening s NON E REQUIRE D O $ 0 $ 0 NON E REQUIRE D 0 $ 0 $ 0 0 $ 0 $ 0 SE E Plan t pla n vie w- insid e room s wil l

enclosur e bot h operation s (cost o froo m i s par t ofInitia l buildin g cost)

ND O Doorway s ND O Fre e Are a ND O Airflo wa t 20 0 fp m Add-o n Contro l Cost s ft 2 cf m Typica l a t PT E

Capita l Cos t TC I $ Annua l Cos t TAC S Cost Effectiveness

$/ton w / Buildin g Additio n 8
. ND O

Capita l Cos t TC I $ Annua l Cos t TA C $ Cos t Effectivenes s $ / to n Compactnes s Ratio s proces s floorare a pe rto n 20 4 PT E floo rare a pe rto n proces s volum e pe rto n 20 4 PT E volum e pe rto n proces s airflo wpe rto n 20 4 PT E airflo wpe rto n proces s floorare a pe rcf m 20 4 PT E floorare a pe rcf m proces s volum e pe rcf m 20 4 PT E volum e pe rcf m ft 2 /to n ft 2 /to n ft 3 /to n ft 3 /to n cfm/to n cfm/to n fr/cf m fr/cf m ft 3 /cf m ft 3 /cf m one-12'Wx2' F 2 4 4.80 0

Pane l Lin e 40 7 40 7 11.66 8 11,66 8 94 3 1,03 4 0. 4 0. 4 12. 4 11. 3 one-12'Wx12' H 14 4 28,80 0 16 8 33,60 0

Fiberglas s Roo m 16 0 37 3 3,06 0 8,96 0 83 3 1,07 3 0. 2 0.3 3. 7 8. 3 $2,998,80 0 $745,90 0 54,79 * $3,571,10 0 $891,60 0 $5,42 5 Plant-Wid e 23 6 38 4 5,69 7 9.79 0 86 7 1.06 1 0. 3 0. 4 6. 6 9. 2 Slo t an d doo rremains ope n continuousl y

assumin g 150,00 0 cf m & 17 3 tpy assumin g 4,00 0 hr/y r(two-shift) operatio n assumin g 90 % o f17 3 tpy PT E assumin g 184,00 0 cf m & 17 3 tp y assumin g 4,00 0 hr/y r(two-shift) operatio n assumin g 95 % o f17 3 tpy PT E



# 3 |P.3 3

Xerxe s Hagerstow n - US T(large-part ) productio n onl y Productio n Activit y Laminatio n & Assembl yo f
. Undergroun d Storag e Tanks

UST twelv e USTmoldin g station s Emission s HA P Emissio n Rat e PT E Exhaus t Airflo w Proces s Exhaus t Airflo w ND O Exhaus t Airflo w Tota l Exhaus t Airflo w Par t Dimension s Typica l Par

t Dimension s "Greatest " Par

t Dimensio n "Most-Compact " Typica l Par t Bo xVolum e Smalles t Large-Part "Greatest " Par

t Dimensio n o f Smalles t Large-Part Enclosure s Proces s Enclosure s

Laminatio n - Assembl y- Mis cParts/Testing/Repai r- tp y cf m cf m cf m f t f t ft 3 f t 20 0

130,00 0 56,00 0 186,00 0 1 0 Di a x20 ' La s molde d 1 0 Di a x40 ' L a s assemble d

22. 4 2,00 0 6 ' Dia x16 ' La s molde d

17. 1

55'Wx328'Lx28' H 45'Wx328'Lx28' H 60'Wx135'Lx28' H Comment s and/o rReference s

SE E Xerxe s MAC Tcomment s (styren e only ) SE E ND O sectio n belo w

Measure d diagonall ya t greates t spa n

Measure d diagonall ya t greates t spa n

Buildin g Enclosur e 100'Wx328'Lx28' H 60'Wx135'Lx28' H Metho d 20 4 Total Enclosur e 100'Wx378'Lx28' H 60Wx185'Lx28' H SE E Buildin g Addition s sectio n belo w Floo rArea s Proces s Floo rAre a Buildin g Enclosur e Floo rAre a Metho d 20 4 Enclosur e Floo r

Are a Volume s Proces s Volum e Buildin g Enclosur e Volum e Metho d 204-typ e Enclosur e

Volum e ft 2

t e t e t e t e 40,90 0

40,90 0 48.90 0 1,145,20 0 1.145,20 0 Th e proces s i s curren t enclose d insid e a buildin g

Th e proces s i s cunen t enclose d insid e a buildin g 1.369,200 Buildin g Addition s Additiona l Buildin g Area s required t o isolat e proces s i n Metho d 204-typ e roo m enclosure s wit h n o exterio r

door s Floo rare a 50 ' x6 0 airloc k t o Nort h sid e 50'Wx60'Lx28' H 50 ' extensio n t o Eas t sid e 50 ' W x100'Lx28' H 8,00 0 Capita l Cos t TC I $ Annua l Cos t TAC S Natura l Draf t Opening s ND O Doorway s $240,000 $26,544

on e - 20 ' Wx14 ' H ope n one-20Wx14'Hclose d ND O Fre e Are a ND O Airflo wa t 20 0 fp m Add-o n Contro l Cost s Typica l a t PT E

Capita l Cos t Annua l Cos t Cos t Effectiveness w/ Buildin g Additio n & ND O

Capita l Cos t Annua l Cos t Cost Effectiveness Compactnes s Ratio s proces s floorare a pe rto n 20 4 PT E floorare a pe rto n proces s volum e pe rto n 20 4 PT E volum e pe rto n proces s airflo wpe rto n 20 4 PT E airflo wpe rto n proces s floo rare a pe rcf m 20 4 PT E floo rare a pe rcf m proces s volum e pe rcf m 20 4 PT E volum e pe rcf m t e cf m

TCI S TAC S S/ton TCI S TAC S S/ton

ffl ton ffl ton ffl ton ffl ton cfm/to n cfm/to n n/cf m fe/cf m fe/cf m ffl cf m 28 0

56,00 0
$2,699,10 0 $838,70 0 $5,24 2 $3,658,20 0 $1,138,90 0 $5,994

20 5 24 5 5,72 6 6,84 6 65 0 93 0 0. 3 0. 3 8. 8 7. 4 SE E FR P Buildin g Cost s

assumin g 11.06 % o fTC I
Tw o "NDO " door s mayb e ope n simultaneously , bu t assum e onl yon e doo r wil l b e ope n a t a tim e

assumin g 130,00 0 cf m & 20 0 tp y assumin g 24-h roperatio n assumin g 80 % of20 0 tp yPT E assumin g 186,00 0 cf m & 20 0 tp y assumin g 24-h roperatio n plu s buildin g cost s assumin g 95 % o f20 0 tp yPT E



# 3 ^Profor m Wes t Memphi s - thre e large-parts ; barg e cover , UST , AG Tproductio n P.3 4

Productio n Activit y thre e separat e operation s Emission s HAP Emission Rat

e PT E Exhaust Airflow Proces s Exhaus t Airflo w NDO Exhaus

t Airflo w Tota l Exhaus

t Airflo w Par t Dimension s Typica l Par

t Dimensions "Greatest " Par

t Dimensio n "Most-Compact " Par

t Bo x Volume Smalles t Large-Par

t "Greatest " Par

t Dimension tp

y cf m cf m cf m
f t ft 5 Gelcoatin g & Laminatio n o f RiverBarge Cover

s Barg e Covers one production line

88,00 0 89.60 0 177,60 0 24'Wx30'Lx4'/i' H 38. 7 3.24 0 Laminatio n & Assembl y o f Undergroun d Storag e Tank s UST fou rUS Tmoldin g station s

52.00 0 56,00 0 108,00 0 10 ' Di a x20 ' L a s molde

d 10 ' Di a x40 ' L a s assemble d 22. 4 2,00 0 6 ' Di a x16 ' L as molde

d 17. 1 Laminatio n & Fil . Wind o f Abovegroun d Storag e Tank s AG T- a.k.a . Vertica l Tank s fou rAG Tmolding stations

52,00 0 56,00 0 108,00 0 10 * Di a x30 ' L a

s molde d 31. 6 3,00 0 Plant-Wid e Total s

192.00 0 201.60 0 393,60 0 Comment s and/o rReference

s

SE E ND O sectio n belo

w

Measured diagonally at greates t spa n

Enclosure s Proces s Enclosures

Buildin g Enclosur

e
Method 20 4 Tota l Enclosur e Floo rArea s Proces s FloorAre

a Building Enclosur

e FloorArea Metho d 20 4 Enclosur

e Floo r Are a Volumes Proces s Volum e Building Enclosur

e Volum e Metho d 204-typ e Enclosur

e Volum e t f

ff
ff ff Gelcoa t-

50'Wx165'Lx24' H Resi n - 50'Wx165'Lx24' H 10,000 ft

3 o fthe gelcoa

t and resi n are a ha s a 40 * H ceilin g Smal l Part

s - 40'Wx100'Lx24' H Barge Cove rBuilding - 140'Wx266'Lx24' H 10.00 0 ft 3 o fthi s enclosur e ha s a 40 7 H cellin g 140'Wx366'Lx24' H 20,50 0 37,24 0

Buildin g Addition s Additional Buildin g Areas require d t o isolat e proces s i n Metho d 204-type roo

m enclosure s wit h n o exterio r door s Floorare a f e Capita l Cos

t TC I $ Annua l Cos

t TAC $ Natura l Draf t Opening s NDO Doorway

s ND O Free Are

a NDO Airflo

wa t 20 0 fpm Laminatio n - 85'Wx55'Lx24' H Assembl y - 85Wx125'Lx24' H

US TBuildin g - 85Wx180'Lx24' H 85'Wx2B0'Lx24' H

652,00 0 1,053,76 0

10 0 extensio n t

o North en d 140'Wx100'Lx24' H Laminatio n - 100'Wx100'Lx40' H Assembl y - 100'Wx80'Lx40' H

Vertica l Tan k

8uildin g • 100'Wx180'Lx40' H 100'Wx280'Lx40' H

14,00 0 $420,00 0 $46,45 2

one - 28 ' Wx16 ' H ope n one-28'Wx16' H close d two-20'Wx12' H close d ff 44 8 cf m 89,60 0 15.30 0 15,30 0
367,20 0 367,20 0 571,20 0
5 0 extensio n t

o West side 50'Wx85'Lx24' H 50 ' extensio n t

o Eas t side 50'Wx85'Lx24' H 8,50 0 $255,00 0 $28,20 3

one - 20 ' W x14 ' H ope n on e - 20'W x14' H close d 28 0 56,00 0 18,00 0 18,00 0 28,00 0 612,00 0 612,00 0 1,120,00 0
5 0 extensio n t

o Wes t side 50'Wx100'Lx24' H 5 0 extensio n t

o Wes t side 50'Wx100'Lx24' H 10,00 0 $300,00 0 $33,18 0

on e - 20 ' Wx14' H ope n one - 2 0 W x14' H close d 28 0 56.00 0 53.80 0 70.54 0 103.04 0 1,631,20 0 2,032.96 0 3,080,96 0

32,50 0 $975,00 0 $107,83 5

1.008 201,60 0 SE E Buildin g Addition s sectio n belo w

SE E FR P Buildin g Cost

s 11.06 % o fTC I Tw o door s pe rarea ma

y b o ope n simultaneously, but assum e onl y on e doo rpe rarea wil l be ope n
Add-o n Contro l Cost s Typica l at PT E

Capita l Cos

t Annua l Cos

t Cost Effectiveness w / Buildin g Additio n & ND O

Capita l Cos

t Annua l Cos

t Cos t Effectivenes

s Compactnes s Ratio s proces s floo rarea perto n 20 4 PT E floorarea pe rto n proces s volume pe rton 204 PT E volume perto n proces s airflo wpe rto n 20 4 PT E airflo

wperto n proces s floorarea pe rcf

m 204 PT E floo rarea percfm proces s volume percf

m 20 4 PT E volum

e pe rcf m TCI S TAC S $/ton TCI S TAC $ $/to n

ffl ton fflton ff /to n ft 3/to n cfm/to n cfm/to n tf/dlrn fe/cf m ft 3/cf m fe/cf m Barg e Covers

35 3 88 3 11.24 1 23.96 1 1,51 7 3,06 2 0. 2 0. 3 7. 4 7. 8 14 3 22 2 3,43 2 5.33 8 1,009 0. 3 0. 2 7. 1 5. 3 a . Vertica l Tank s 21 4 33 3 7,28 6 13,33 3 61 9 1.286 0. 3 0. 3 11. 8 10. 4 $3,656,80 0

$1,147,80 0 $5,76 2 $7,320,00 0 $2,277,00 0 $9,62 6 Plant-Wid e 21 6 41 4 6.55 1 12,37 3 77 1 1,58 1 0. 3 0. 3 8. 5 7. 8 assumin g 190,00 0 cf m 4 24 9 tp

y assumin g 24-h roperatio n assumin g 60 % o

f24 9 tp y PT E assumin g 390,00 0 cfm & 24 9 tp y plus buildin g & ND O cost s assumin g 95 % o

f24 9 tp y PT E



# 3 3P.3 5


## Large-par t plant buildin g cost

s Profor m Wes t Memphi s cost Sit e wor k $ 472,00 0 First-phas e buildin g cos t $ 1,044,000 Chang e order

s $ 91,00 0 Second-phas e additio n $ 371,00 0 Third-phas e additio n (projected ) $ 400,00 0

Tota l plan t buildin g cost $ 2,378,00 0 Tota l plan t floo rare a 70,54 0 ft 2 

### Buildin g cos t pe rft 2 

### 33.7 1 $ pe rft 2



### Assum e TC I of$3 0 pe rft 2 

### Additiona l buildin g annua l operatin g costs include s taxes , insurance , maintenance i s assume d t o be 3% ofTC I Annualize d capita l cos t i s assume d a t 7% interest fo r3 0 years CRF(7% , 30 yr) = 0.080 6 o r8.06 %



## TrjAdditiona l Airflo w

neede d t o protec t worker s agains t styren e exposur e

VA ) Smal l Part s Truc k Cap s A.R. E Massillo n existin g RT O Informatio n o n styren e exposur e a t A.R.E
. i s no t publicall yavailabl e an d ha s no t bee n provide d t o industryo rCF A representatives
. Respirato rusag e ha s bee n rumore d a t A.R.E. , bu t suc h usag e canno t b e confirmed
. Therefore , th e nee d fo r additiona l ventilatio n airflo wcanno t b e assessed
. unknow n Bathwar e Plan t A existin g RT O Larg e Part s RV/Truc k Plan t B

Al l o fth e lin e worker s wea rpressurized-ai r respirato rhood s o rhalf fac e persona l respirators
. Almos t al l o fth e lin e Thus , ventilatio n airflo wi s worker s wea rhalf-fac e no t neede d t o protec t th e persona l respirators , workers
. Th e loca l OSH AThus , ventilatio n airflo w offic e grante d th e i s no t neede d t o protect compan ya specia l waive rth e workers , tha t permit s respirato r usag e an d verylo w ventilatio n airflows
. RV/Sidewal l Monac o Hine s

0 cf m 0 cf m Almos t al l o fth e productio n worker s wea r half-fac e persona l respirators
. Thus , ventilatio n airflo wi s no t neede d t o protec t th e workers , (doublecheck this with Kurt Anderson)

0 cf m US T

Xerxe s Hagerstow n
Du e t o th e unique , idea l configuratio n ofth e US T wor k area , additiona l ventilatio n airflo wi s no t neede d t o protec t th e productio n worker s insid e th e US Tmolds
. Curren t worke r exposure s wer e measure d a t significantl y les s tha n th e PE L (5 0 ppm)
. Respirator s ar e no t required
.

0 cf m UST/Cover s

Profor m Wes t Memphi s Th e US Toperatio n a t Profor m i s identica l t o th e Xerxe s operatio n (SE E previou s column ) Also , th e curren t ventilatio n airflo wi n th e Barg e Cove rare a i s jus t abl e t o achiev e th e PE L withou t respirators
. Th e airflo wneede d fo rth e planne d Vertica l Tan k are a i s unknow n (assume d t o b e 52,00 0 cfm)
. 0 cf m Additiona l Airflo w neede d t o mee t Metho d 20 4 criteri a throug h th e NDO s non e 8,40 0 cf m 38,40 0 cf m 33,60 0 cf m 56,00 0 cf m 201,60 0 cf mActua l resi n & gelcoa t usages canno

t b e directl ydetermined i n advanc e fo ra NE W plant
. However, typica l normalized resin/gelcoa t usage-to-emissio n ratio s ca n b e assumed , an d thes e assumption s ca n the n b e used t o conver

t a NE W plant' s permitted PT E (i n tpy ) int o a n equivalent annua l usag e o f resin/gelcoa

t (tota l lb/yr)
. % Tota l "Wet " Laminat e Weigh t 30 % 70 % 100 % 100 % Normalize d Resin/Gelcoa t Usag e Assumption s

Materia l Typ e Gelcoa t Resi n Tota l (both ) Corrosio n Resi n Styren e Conten t 40 % b ywt 35%byw t 42%byw t UE F facto r materia l wt ) atomize d - 21.9 % non-ato m - 3.8 %
non-ato m - 4.9 % (

% Styren e Emission s (I b styrene/l b material ) 0.065 7 0.026 6 0.092 3 0.049 0



## 6 " PT E (tpy )

Maximu m Materia l Usag e (tpy ) Gelcoa t Resi n Tota l Proces s airflo w(cfm ) 204 PT E airflo w(cfm ) Proces s airflo wpe rto n materia l 20 4 PT E airflo wpe rto n materia l Smal l Part s Truc k Cap s A.R. E Massillo n existin g RT O 52 5 1,70 6 3,98 2 5,68 8 50,00 0 50,00 0 8.7 9 8.7 9 Bathwar e Plan t A existin g RT O 42 6 1,38 5 3,23 1 4,61 5 25,00 0 33,40 0 5.4 2 7.2 4 Larg e Part s RV/Truc k Plan t B
12 9
41 9 97 8 1,39 8 50,00 0 88,40 0 35.7 8 63.2 5 RV/Sidewal l

Monac o Hine s
17 3
56 2 1,31 2 1,87 4 150,00 0 183,60 0 80.0 3 97.9 6 US T

Xerxe s Hagerstow n corrosio n resi n

200
0 4,08 2 4,08 2 130,00 0 186,00 0 31.8 5 45.5 7 onl y UST/Cover s Profor m Wes t Memphi s 24 9 (19 1 i s corros.resi n only )

18 9 4,33 8 4,52 6 192,00 0 393,60 0 42.4 2 86.9 6

c o ^ i