p. 1 

# OAR Box 1394 Prepped by Ollie Stewart



### Document

Number: 

# 21 ) ll-B-1 6 Docket Number: 

# A-94-5 2

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

Sheet 21 of 57P. 2

NON-CB I SIT E VISI T REPOR T TO : Project

Fil e Reinforce d Plasti c Composite s NESHAP FROM : Melani e Procto r

Pacifi c Environmenta

l Services , Inc . (PES ) DATE : Augus t

14,199 7 SUBJECT : Sit

e Visi t - LASC O Panel Products , Florence , K Y EP A Contrac t

68D10116 , ES D Projec t

93/5 8 PE S Projec t

N504 

### .A-94-5 2 1 x 

# '*-l$

I . PWEPS

e Th e purpos e o f

thi s visi t wa s t o gai n abetter

understandin g o f

LASCO' s wet

are a enclosur e (WAE) and t o discus s possibl e emissio n tes t scenario s to determin e emission s firom continuou s laminatio n operations . The visi t wa s intende d t o identif

y emissio n tes t

scenario s tha

t woul d hel p t o evaluat

e th e effectivenes s o f

WAE s o n continuou s laminatio n line s an d determin e th e effec t o f proces s variable s such a s lin e speed , produc t thickness , styren e content , us e o f methy l methacrylat

e (MMA) , and us e o f

ge l coa t i n continuou s laminatio n operations . II . Plac e e g

j P# g LASC O Panel Product s 801 5 Dixo n Driv e Florence , Kentuck

y 4104 2 Septembe r 11,199 6 III . Partjcipfflit

S Kentuck y Environmenta

l Protectio n Agenc v Mr . John Allen , phon e numbe r (606 ) 292-641 1 LASC O Pime

l Product ? Ms . Hilar y North , Manage

r of Health , Safet

y and Environmenta

l Qualit y Mr . Bruc e Westbrook , Vic e Presiden t o f Engineerin gP. 3

LASC O Sit

e Visi t Pag e 2 PE S Dr . Kennet

h Meardon , Senior

Environmenta

l Scientis t Ms . Melani e Proctor , Environmenta l Scientis t Societ y o f Plastic s Industry/Composite s Institut e Mr . Joh n Schweitzer , Technica

l Director U . S . Environmenta

l Protectio n Agenc

y (EPA) Dr . Madeleine Strum , Projec t Manage r IV . Genera

l Facilit v Infonnatio n LASC O Panel Product s and LASC O Bathwar e ar e division s o f

Tomkin s Industries , whic h i s apublicly owned , 1 4 billio n dolla r holdin g company . Tomkin s Industrie s own s alarg e variet y o f companies , includin g Smit h an d Weston Firearms , Dexte

r .Axles , Redwing Food , Gate s Rubber , Interstat

e Bakeries , and Murra

y Bicycles . The U . S . headquarter s fo r Tomkin s Industrie s ar

e locate d in Dayton , Ohio . Sinc e Tomkin s Industrie s i s publicly owned , th e compan y prepare s a

n annua l stockholde

r report , which contain s annua l sale s information . Base d o n informatio n fromMr . Westbrook , Tomkins ' annua l sale s informatio n i s als o availabl e o n th e Internet . V . Wid

e Continuou s Laminatio n Line LASC O ha s on

e wid e continuou s laminatio n line . CB I materia l deleted . Som

e section s o f th e enclosur

e ar e vented to ductwor

k connecte d to astack

whic h exhaust s to th e atmosphere . A diagra mshowing LASCO' s wide lin e wit h th e partia

l WA E (no t includin g th e gel coatin g section ) and dimension s o f

opening s in th e enclosur

e i s presente d i n Attachmen t 1 . CB I materia

l deleted . Th e resi n applicatio n are ai s enclose d b y a n (CB I materia

l deleted ) enclosure , which ha s tw o emissio n pic k up point s tha

t ar e vente d to th e atmosphere . Th e enclosur

e ha s a n opening tha

t i s 3/ 4 inche s tal l a

t th e beginnin g and 1-inc

h tal l a t th e end o f th e enclosur

e t o allo w materia

l t o ente r and exit th e enclosure . Th e resi n applicatio n enclosur e als o ha s opening s a

t bot h side s ofth e enclosur

e tha t ar e abou t 1 2 inche s tal l an

d 1 2 inche s wid e t o adjus t th e doctor

bar . Ms . Nort

h explaine d tha

t th e opening s t o adjus t

th e doctor

ba r coul d easily b e closed . CB I materia l deleted . 

# 2 ^P. 4

LASC O Site Visi t Pag e 3 Followin g th e resi n applicatio n enclosur e i s a(CB I material deleted ) sectio n ofth e lin e tha t i s no t enclosed . I

n thi s uncovere d section , wove n reinforcemen

t ca n b e applie d to certai n produc t lines . During th e sit

e visit , a n approximatel

y 1 foo t wide woven materia

l wa s being applie d t o bot

h edge s ofth e product . Accordin g to Ms . North , LASC O doe s no t hav e an y plan s t o enclos e thi s sectio n ofth e line . Afte r th e wove n reinforcemen

t i s applied , anothe

r portio n ofth e enclosur

e begins , whic h enclose s th e choppe d glas s applicatio n area . Th e enclosur e fo r thi s sectio n ofth e proces s i s approximately 4 fee

t long an d doe s no t hav e duct s to ven

t emission s t o th e atmosphere . CB I material deleted . Th

e chopped glas s applicatio n enclosur e ha s a n openin g tha

t i s 1-inc h tal l a t th e beginnin g and th e en

d ofth e enclosur

e t o allo w materia

l t o enter and exi t th e enclosure . Roll s o f fiberglas s roving ar

e locate d outsid e th e enclosure . Th e fiberglas s strand s ar e fe d int o th e enclosure t o acuttin g blade tha t chop s th e reinforcemen

t into fin e pieces . N o air

i s pulle d into o r ou t ofth e enclosur

e wher e th e choppe d fiber

i s applied . CB I materia

l deleted . Th e sectio n ofth e continuou s laminatio n lin e following th e choppe d glas s applicatio n enclosure i s currently no t

enclosed , bu t

base d o n Ms . North' s informatio n a n enclosur e fo r thi s (CB I materia

l deleted ) sectio n ha s alread y been designed and i s currentl y bein g fabricated . LASC O expect s to install thi s portio n ofth e enclosur e sometim e next year . A n overhea d walkwa y crosse s th e continuou s laminatio n lin e a t th e beginnin g and a

t th e end o f thi s ope n sectio n ofth e line . Eac

h walkwa y i s approximately 3 0 inche s wide . Th e wide line ha s asecond choppe d glas s applicatio n area , afte r th e second walkwa

y crosse s th e continuou s laminatio n line . Thi s secon d chopped glas s applicatio n are ai s als o enclose d (CB I materia

l deleted) . However , th e secon d glas s choppe

r ha s asmalle

r suppl y o f glas s rovin g and i s used t

o produc e produc t

onl y abou t 5 percen t ofth e time . The firs t

glas s choppe r i s no t used whe n th e second glas s choppe

r i s used . CB I materia

l deleted . Th e blower s ar

e located towar

d th e end ofth e approximatel y 4-foot lon g enclosur

e fo r th e second choppe d glas s applicatio n area . CB I materia l deleted . Thi s sectio n ha s tw o emissio n pick u p point s clos e t o th e side s o f th e enclosur

e (CB I materia l deleted) . Th e emission s fromthi s portio n ofth e proces s ar e vente d to th e atmospher

e through th e sam

e centra l duc t a s th e othe

r enclosur e pickup points . CB I materia

l deleted . Gel coa

t i s onl y applied to asmal l portio n of product s such a s R V skin , whic h ar

e panel s used fo

r recreationa

l vehicles . CB I materia

l deleted . 

# 3P. 5

LASC O Sit

e Visit Pag e 4 Th e gel coating sectio n i s (CB I materia l deleted ) enclose d at

th e to p an d th e sides . Fou

r emissio n pic k

u p point s (tw o a

t eac h end ofth e enclosure ) vent emission s fromth e ge

l coatin g enclosure t o th e atmospher

e throug h th e sam

e centra l duc t a s th e othe

r enclosur e picku p points . CB I materia

l deleted . Afte

r th e ge l coate d top fil

mleave s th e (CB I materia l deleted ) enclosure , i t

move s down throug h a

n ope n vertica l sectio n (CB I materia

l deleted) . Th e wid e lin e wa s adde d i n 1994 and i s locate d i n anewl y constructe d sectio n ofth e facility . Tli e we

t are aand th e oven ofth e wide lin e ar e i n tw o separat

e room s tha

t connec t throug h a n approximatel

y 3-foo t tal l and 10-foo

t wid e opening . Bot

h room s ar e als o connecte d wit h eac h other , an

d to th e res t

ofth e facility , by fire doors , whic h ar e kept ope n fo r better acces s an d t o mov e material s bac k and forth . According t o Ms . North , th e fire door s ca n b e close d an d th e openin g betwee

n th e roo mfo

r th e wet are aan d roomfo r th e oven ca

n b e mad e smalle r fo r emission s testin g t o tur

n th e wid e lin e wet

are aroo minto atemporar

y total enclosure . Th e we t are aroo mofth e wid

e lin e ha s it s own ventilatio n syste mcontainin g tw o duct s fo

r make-u p air , on e duc t fo r outlet air , and emissio n pic k

u p point s i n part s ofth e enclosure . A s indicate d previously , th e air fromth e emissio n pic k

u p point s i n th e enclosur

e i s vente d t o one centra

l duc t wit h a(CB I materia

l deleted ) fan . Ms . Nort

h contacte d th e vendor

o f th e ventilatio n syste

mt o determin e th e air

flow a t eac h emissio n pic k

u p point . Th e vendo r

wa s unabl e t o provid

e tha t informatio n (CB I materia l deleted) . Th e product s produce d a

t th e wide lin e (CB I materia l deleted ) includ

e product s suc h a s liner board , truck

traile r liner , doo r

skins , and R

V skins . CB I materia

l deleted . CB I materia

l deleted . VI . Nanow Continuou s Laminatio n Line s LASC O ha s tw o narro w continuou s laminatio n line s tha t allo w th e productio n of apane l (CB I materia

l deleted) . Thes e tw o nano w line s wer e installe d i n 1967 . CB I materia l deleted . However , Ms . Nort

h explaine d tha

t th e to p an d bottomgel coatin g sectio n ar e neve r ru n at th e sam e time . Th

e laminatio n tabl e o f

bot h narro w line s i s subdivide d into (CB I materia l deleted ) heatin g zone s (CB I materia l deleted) . On

e ofth e nano w line s i s used to ru n bot h corrugate d an d flat products , while th e other

narro w line onl

y produce s flat

products . Bot

h nano w line s us e compactio n rollers . CB I materia l deleted . The narrow fla

t lin e i s locate d in aseparat

e roo mconnecte d t o th e res t

ofth e facilit

y b y fire doors , whic

h ar e kept open fo r materia l transfer . Simila

r t o th e wide lin e describe d earlier , th e narro w fla

t lin e ha s (CB I material deleted ) place s wher e choppe d reinforcemen

t ca n b e applied . CB I materia

l deleted . 

# iP. 6

LASC O Sit

e Visi t Pag e 5 CB I materia

l deleted . Durin g th e site visit , th e narro w corrugate d lin e wa s producin g a panel wit h ato p gel coa

t layer . The gel coa

t laye r applie d t o th e filmi s ver

y thi n and du e to th e hea t applie d i n th e gel coating section , alarg e portio n ofth e monome r in th e ge l coa

t i s assume d to evaporate . CB I materia l deleted . VII . Oven s fo

r th e Continuou s Laminatio n Line s LASCO' s oven s fo

r th e continuou s laminatio n line s ar e heated b y (CB I materia

l deleted ) direc t

ga s fired burners . Th e temperatur e ofth e oven s i s variabl e and range s (CB I materia l deleted ) depending o n th e lin e and th e produc t tha t i s bein g produced . CB I materia l deleted . VIII . Resi n Mix Are a Ms . Nort h pointe d ou

t tha t resi n mi x area , which i s currently in th e same roo ma s th e narro w corrugate d line , i s being redesigne d (CB I materia l deleted) . Th e ne w mixer s wil l b e locate d i n aseparat

e mix room . Presently , th e resi n tha t i s stored i n undergroun d storag e tank s i s pumpe d throug h line s int

o th e resi n mi x are ainto (CB I materia l deleted ) containers . Th e pigmen t i s dissolve d in resi n an

d receive d i n 5 5 gallo n drums . Th e drum s are move d into th e mi x are ab y for

k lift s an d th e dissolve d pigmen

t i s adde d t o th e resi n mi x container . Th e filler i s als o adde d t o th e resi n matrix in th e mix area . CB I materia l deleted . Durin g degassing , air i s remove d fromth e resi n mix b y agitatin g th e resi n mi x and by creatin g avacuumi n th e resi n tank . CB I materia

l deleted . IX . Possibl e Emission s Tes t Scenario s a

t LASCO' s Wid

e Lin e Th e mai n objective s o f

emission s testin g a

t LASC O ar

e t o determin e emissio n reduction s achieve d b y WA

E an d to determine th e effec

t o f proces s variable s such a s lin e speed , produc t thickness , styren e content , MM A content , and th e us e o f

gel coa t in continuou s laminatio n operations . Durin g th e sit

e visit , variou s emissio n tes t scenario s wer

e discussed . In orde r to determine th e effectivenes s ofatota l WAE , the section s o f

LASCO' s wet

are a tha t ar e currently no t

enclosed would hav e t o b e enclose d fo r testin g purpose s and th e emissio n pick up point s tha

t ar e cunentl y vente d t o th e atmospher e would hav e to b e close d off . Ms . Nort h though t tha t th e plan t could desig n ari

d construc t

suc h atemporar

y WA E fo r testin g purposes . Mr . Schweitze

r wondered i f

th e current

ventilatio n syste

mma y increas e emission s an

d suggeste d tha

t th e tes t fo r th e baselin e cas e shoul d b e conducted without operatin g th e current ventilatio n system . Ms . Stru madded that , i n th e pultrusio n study , th e WAE-exhaus t scenari o showed adecreas e in emission s ove r th e baselin e and thi s ma

y b e th e cas e here a s well . Ms . Stru magree d tha

t th e tes t progra mshoul d investigate thi s scenario . Thus , an emissio n tes t woul d als o hav e t o b e conducte d wit h a s much ofth e WA

E removed o

r opened a s possible . I

n orde r t o evaluat e th e possibl e rang e o

f emissio n reduction s achieve d by th e WAE , bot h ofth e abov e 

# SP. 7

LASC O Site Visi t Pag e 6 describe d scenarios , wit

h an d without enclosure , woul d have to b e teste d fo r aproduc t wit h th e highes t expecte d emission s (highes t styren e content , lowes t

lin e speed , and thinnes t

product) an

d th e lowes t expecte d emission s (lowes t styrene content , highes t

lin e speed , an

d thickes t product) . The effect s o f

proces s variable s o n emission s firomcontinuou s laminatio n operation s ca n b e examine d b y testin g LASCO' s current partiall y enclose d proces s (fo r eas e o f testing ) and var

y on e proces s variabl e a

t atime . Th e following tes t run s t o determine th e effec

t o f proces s variable s were discussed :

Gel coa t versu s no gel coa

t MM A versu s no MM

A Thic k pane l versu s thi n panel Slo w lin e speed versu s fast

lin e spee d Lo w HA P versu s hig h HA

P resi n Ms . Nort h promise d to discus s thes e propose d tes t scenario s wit

h he r managemen

t to determin e i f

and t o wha

t exten t testin g ca n b e done a

t LASC O to minimiz e th e effects o n production . Ms . Nort

h als o promise d to provide th e EP A wit h acomplet

e lis t o f LASCO' s product s produce d a

t th e wid e lin e containin g informatio n o n th e relativ e amoun

t o f eac h produc t produced , styren e content , MM A content , lin e speed , product thickness , an

d gel coa t usage . Thi s lis t o f product s an d proces s infonnatio n fo r eac h produc t

will hel p th e EP A t o determin e whic h produc t run s shoul d b e selected fo

r testing . X . Actio n Item s LASC O promise d to provide th e EP A wit h th e followin

g information : 1 ) Annua

l resi n and ge

l coa t usag e fo r th e entir e facilit y fo r 1995 . Pleas e refe

r t o th e lette

r maile d t o yo u o n Septembe r 20,199 6 fo

r abetter description of

th e informatio n requested . (Received ) 2 ) The weigh

t percent HA P conten t o f eac h resi n an d ge l coa t matri x used , includin g HA P added a t LASCO . Th

e weigh t percen t o f HA P (e.g. , styrene , MMA

) o f eac h resin/ge l coa t matri x i s define

d a s th e total amoun

t (lbs ) o f HA P (styrene , MMA) in th e resin/ge l coa t a s supplie d plu s the amoun t of HA P (styrene , MMA

) tha t i s added to th e supplie d resin/ge l coa

t b y th e facilit

y divide d b y th e weigh

t ofth e resin/gel coa

t matrix . Th e resin/ge l coa

t matri x onl

y include s th e resin/ge l coa t itself , th e HA P (styrene , MMA) tha

t i s in th e supplie d resin/gel coat , and HA P (styrene , MMA

) tha t i s added to th e supplie d resin/ge l coa

t b y th e facility . Filler , catalyst , promoters , reinforcement , and other additive s are no t

included in th e resin/ge l coa t matri x definition . Th

e following equation s sho w th e calculation s fo

r determinin g th e weigh

t percen t of styrene an d MM A i n a resin/ge l coa

t matrix . 

# LP. 8

LASC O Sit

e Visi t Pag e 7

. . .. Total Amount of Styrene ,--. , % Styrene in Resin/gel

coat Matrix = —X 100 % (Total Amount of Resin) * (Total

Amount of Styrene and

MMA)

m. ..... . -. • i i w _. , Total Amount of MMA „ ..... % MMA in Resinlgelcoat Matrix = - X 100 % (Total Amount of Resin) * (Total

Amount of Styrene and

MMA) Thi s information has been received and furthe r information was collecte d durin g a visi tto LASC O o n Octobe r 29,1996 . 3 ) Whic h HA

P is/ar e i n th e gel coa

t used at LASCO ? Pleas e verif

y tha t LASC O Pane l Product s use s only one ge l coat . (Information received . CB I materia l deleted) . 4 ) Complet

e lis t o f LASCO' s product s produce d includin g al l product s containin g informatio n o n th e amoun

t o f eac h produc t produced , styrene content , MM A content , lin e speed , produc t

thickness , an

d resin , ge l coat , filler, pigment , an

d reinforcemen

t usage . Pleas e refe r t o th e letter

maile d t o you o n Septembe r 20,199 6 fo

r adetaile d Tabl e ofth e informatio n requested . (Collecte d durin g a visi tt o LASC O o

n Octobe r 29,1996) .



# 7P. 9

ATTACHMEN

T 1 I S CB I WID E LIN

E AN D PARTIA

L WE T ARE A ENCLOSUR

E DIAGRA

M



# 7

### RECEIVE D EPA . OAQP S CBI O RTP . N C 2771 1 97AU G I I PM2--2- 4

O l dP.1 1

Docke t No . A-94-5 2 Categor y II- B Th e followin g information i s located in th e confidentia l files ofth e Director , Emissio n Standard s Division , Office of Air Qualit y Planning an

d Standards , U.S . Environmenta l Protectio n Agency , Researc h Triangl e Park , Nort h Carolin a27711 . Thi s infonnatio n i s confidentia

l pendin g final detenninatio n b y th e Administrator

an d i s not availabl e fo

r publi c inspection . Changed t o CN-N801- 2 Sit e Visit inf o fo r Lasc o Panel , Florence , K

Y

CN-N504- 3 

## | 0P.1 2

Docke t No . A-94-5 2 Categor y II- B Th e following informatio n i s locate d i n th e confidentia l files ofth e Director , Emissio n Standard s Division , Offic

e of Ai r Qualit y Planning an

d Standards , U.S . Environmenta l Protectio n Agency , Research Triangl e Park , Nort h Carolin a27711 . Thi s information i s confidentia

l pendin g final detenninatio n by the Administrato r an d i s no t availabl e fo

r publi c inspection . Lasc o Panel Products , florence , K Y - (Thi s i s th e Sit

e Visit Materia l file: changed fro

mCN

N504- 3 t o CN-N801-2 ) 1 Sit e Visi t repor t date d 12/6/96 ; 1 0 page s

CN-N801- 2 ES D 93/5 8 

# K