p. 1 

### OAR Box 1490 Prepped by Charmelle Mathews

Document

Number: 

### 56 ) IV-C-2

9 Docket Number: 

### A-94-5 2

Printed 8/4/200811:51:47

AM Sheet 56 of 273P. 2 A-94-5 2 IV-C-2 9 

### REINFORCE D PLASTI C COMPOSITE S MAC T STANDARD S DEVELOPMEN T UPDAT E

Ma y 7 , 200 2 Keit h Barnett , Projec t

Lea d Office o f Air Qualit y Plannin g and Standard s Emissio n Standard s Divisio n Mineral s an

dInorgani c Chemical s Grou pP. 3



## Outlin e Wh o i s subjec t

t o thi s standard ? Whe n d o I hav e t o comply ? A mI ane w o r

existin g source ? Wha t standard s mus t

I meet ? Wha t are some o f

m y option s t o mee t standards ? Ho w d o I demonstrate compliance ? Ho w d o I achiev e 9 5 percen t contro l (i f required) ?P. 4 

## Wh o i s subjec

tt o thi s standard ? A reinforce dplastic s composite s productio n facilit

y tha t i s locate da

t a majo r sourc e (1 0 tp y ofan y on e HA P o r 2 5 tp y ofan y combinatio n o f

HAP) : an d Use s thermose t

resin s o r ge l coat s tha

t contai n styren e o r

styren e an dmethy l methacrylateP. 5 

## Wha toperations ar

e covered ? Ope n Moldin g Close dMoldin g Centrifuga l Castin g Continuou s Lamination/Castin g SMC/BM C Manufacturin g Pultrusio n Mixin g Storag e Equipment

Cleanin gP. 6 

## When d o I have to comply ? Proposal wa s Augus t

2 , 200 1 Final rul e dat

e i s unde r discussio n a s par

t o f Sierr aClu

b sui t settlement Existin g majo

r source s mus t

compl y withi n 3 year s fro

mfina l rul e Ne w majo r source s mus t

compl y b y effectiv e date o f

fina l rul e or startup , whichever i s laterP. 7 

## Rule Status an

d Planned Changes

• On e major

chang e sinc e proposa l i s t o replac e th e poin t

valu e equation s wit

h appropriate unifie demissio n factor (UEF ) equations . Thi s chang e b y itsel f

di dsignificantl y affect th e floor . However , w e hav e revise dth e floor level s o f contro l base do n comment s receive do n th e propose drule . Tw o floor s wil l requir e aslightl y lowe r HA P content , thre e are slightl y highe rP. 8 

## Rule Status an

d Planne d Changes (Con't )

• W e hav e combine dth e fille dan dunfille d noncorrosio n resistan t

mechanical process/produc t

grouping s

• Th e ne w floor s ca

n stil l b e me t

wit h pollutio n prevention , bu t

i n some cases , averagin g ma

y b e require d

• We hav e revise dth e cost s fo r th e above the-floo r option . Thes e cost s wil l b e mad e availabl e sometime i n May .P. 9



## Wha ti s a new Source ?
Yo u commenc e constructio n afte r Augus t 2 , 2001 ; an d Whe n yo u commenc e construction , ther e are n o reinforce dplasti c composite s operation s a

t th e facilit y

8P.1 0 

## Wha ti s a n Existin g Source ?
An y sourc e that

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

considere dne w a s aresul t o f reconstructio np.1 1 

## Overvie w o f Controls t

o Meet Proposed Emission Limit

s Source s belo w aspecifie dHAP emission s threshol d

- lo w HAP resin s an dge l coat s

- nonatomize dapplicatio n technique s

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

- add-o n control s fo

r Continuou s Laminatio n Source s abov e aspecifie dHA P emissio n threshol dmus t

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

- Ope n Moldin g

- Centrifuga

l Castin g

- Continuou s Lamination/Castin g

- Pultrusio n

- SMC/BM C Manufacturin g

- Mixin g 1 0P.1 2 

## Ho w I s the HA

P Threshold Determined ? Su memission s fro

mth e al l operation s potentiall y subjec t

t o 9 5 percen t

contro l Calculate thes e emission s usin g

- unifie demissio n factor s fo r reinforce d plasti c composite s

- facilit y specifi c emissio n factor s

- Result s fro

memissio n test s

nP.1 3 

## WhatAr e th e Threshol d Levels ? Ne w source s - currentl y 10 0 tp y actual HAP emission s (thi s threshol dwil l b e reviewe dbase do n comment s an dne w data ) Existin g source s - actual emission s (Thes e number s ma

y chang e a s aresul t

o f ne w costs )

- 25 0 tp y i f

smal l busines s

- 10 0 tp y i f nonsmal l busines s Smal l busines s mean s les s than 50 0 employee s fo

r mos t SI C Code s

12P. M 

## Draf tMAC T fo r Source s belo w Threshold s (Not e thatth e thes e numbers are now base d o n UEF ) Operatio n Typ e Ope n Moldin g - Corrosio n resistan t Ope n Moldin g - Non Corrosio n Resistan t Specifi c

Operatio n Mechanica l resi n Applicatio n Filamen t Windin g Manua l Resi n Applicatio n Mechanica l resi n Applicatio n (Fille d o runfilled ) Filamen t Windin g Manua l resi n Applicatio n Floo r

UE F 11 2 17 1 12 3 8 7 18 8 8 7 Allowabl e Resi n HA P Conten t 46. 2 Non Atomize d 4 2 4 0 38. 4 Non Atomize d 4 5 33. 6

1 3P.1 5 

## Draf tMACT for Sources belo w Thresholds (Con't

) (Note thatth e thes e numbers are now base d o n UEF ) Operatio n Typ e Ope n Moldin g - Toolin g Ope n Moldin g - Product s tha t requir e Clas s 1 Fire an d Smoke Rating s Centrifuga l Castin g Specifi c

Operatio n Mechanica l Resi n Applicatio n - Toolin g Manua l Resi n Applicatio n - Toolin g Mechanica l resi n Applicatio n Filamen t Windin g Manua l Resi n Applicatio n NonC R C R Floo r

UE F 25 4 15 7 49 7 27 0 23 7 41 9 53 6 Allowabl e

HA P Conten t (Weigh t % ) 50 + Non atomize d 4 3 Atomize d 45. 9 6 0 6 0 6 0 37. 5 4 8 1 4P.1 6 

## Draf tMAC T for Sources belo w Thresholds (Con't

) (Not e thatth e thes e numbers are now base d o n UEF ) Operatio n Typ e Ope n Moldin g - Ge l Coat Specifi c

Operatio n Toolin g Ge l Coatin g Pigmente d Ge l Coatin g

- Whit e an d Of f Whit e Pigmente d Ge l Coatin g - NonWhit e Clea r Productio n Ge l Coa t Poin t Valu e

(Ib/ton ) 43 7
26 7
37 7
52 2 Allowabl e HA P Conten t (Weigh t % ) 4 0
3 0
3 7
4 4

1 5P.1 7 

## Draf tMACT for Sources belo w Thresholds (Con't

) Injection/Compressio n Moldin g - Cove r Charge s Resi n Transfe

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

1 6P.1 8 

## Draf tMACT fo

r Sources below Thresholds (Con't)

• Pultrusio n - 6 0 percen t

contro l o r

we t are a enclosure

• Sheet Moldin g Compoun d- Nylo n o r nylo n containin g film, cover resi n deliver

y t o docto r bo x

• Equipment

Cleanin g - Cleanin g material s ma y contai n n o HAP

• Resi n Mixin g an dBM C Manufacturin g - Cover th e mixer s

• Resi n Storag e - Cover

storag e container s

1 7P.1 9



## Meetin g P

2 Standard s Ope n Moldin g and Centrifugal Castin g Optio n 1 Chang e al l your

resin s an dge l coat s t o one s wit h HAP content s belo w th e standar d Thi s i s th e simples t

metho dan dresult s i n th e leas t reportin g an drecor dkeepin g

1 8P.2 0



## Meeting P

2 Standards Optio n 1 Example Prio r t o MAC T

- Atomize dapplicatio n o f 4 5 percen t HA P noncorrosio n resistan t filledresi n

- Atomize dapplicatio n o f a3 5 percen t HA P white ge l coa

t Afte r MAC T

- Nonatomize dapplicatio n o f 3 8 percen t HA P noncorrosio n resistan t filledresi n

- Atomize dapplicatio n o f 3 0 percen t HA P whit e ge l coa

t

- I f nonatomize dge l coa

t applicatio n i s possible , allowabl e HA P conten t wil l b e highe r 1 9

'**? :P.2 1



## Meeting P

2 Standards Ope n Molding an

d Centrifuga

l Casting Optio

n 2 Chang e you r

resin s an dge l coat s s o th e weighte daverag e meet s MAC T Require s purchas e record s b y resi n type , an dmonthl y averag e calculatio n Averag e i s base do n las t

1 2 month s o f operatio n

2 0P.2 2



## Meetin g P

2 Standard s Optio n 2 Exampl e Prio r t o MAC T

- Currentl y us e tw o noncorrosio n resistan t unfille dresins , on e 3 7 percen t HAP andon e 4 2 percen t

HA P

- nonatomize dmechanical applicatio n

- rati o o f resi n us e i s 60/4 0 afte r MAC T (Floo r

= 87 )

- conver t th e 4 2 percen t

HA P resi n t o resi n wit h 4 0 percen t

HA P o r les s

- maintai n sam

e 60/4 0 spli t

2 1P.2 3



## Meeting P

2 Standards Ope n Molding an

d Centrifuga

l Casting Option Determin e th e highes t

resi n HA P conten t allowabl e fo

r eac h operatio n Us e thi s resi n fo

r al l operation s Ca n no t includ e ge l coat s o r

mi x corrosio n an dnoncorrosio n resistan t operation s

2 2P.2 4



## Meetin g P

2 Standard s Optio n 3 Exampl e Prio r to MAC T makin g corrosio n resistan t tank s usin g atomize dmechanical (en dcaps) , filament windin g (body) , an dmanual applicatio n (joinin g parts ) usin g 5 0 percen t

HA P resi n

23P.2 5



## Meeting P

2 Standards Option 3 Example After MAC T Determin e MAC T fo

r eac h operatio n

- Mechanical i s averag e o f 46. 2 percen t HAP resi n wit

h nonatomize d applicatio n

- Filamen t

windin g i s 4 2 percen t

HA P resi n

- Manual i s 4 0 percen t

HA P resi n Selec t highes t allowabl e averag e HA P leve l (46. 2 percent ) Maintai n thi s averag e resi n HA P conten t fo r al l application s 2 4 oP.2 6 

## Option s for Meetin g Standard s

Pultrusio n 1 Wet are aenclosure s t o mee t

th e 6 0 percen t reductio n requiremen t 1 Direc t di e injectio n (o r

potentiall y pre forme dinjection ) t o mee t

th e 6 0 an d9 5 percen t reductio n requirement s 1 Add-o n control s

• We are strongl y considerin g allowin g averagin g o f

pultrusio n line s

• N o final decisio n i n ho w t o handl e larg e pultrude dpart s
2 5P.2 7 

## Option s for Meetin g Standard s Continuou s Lamination/Castin g Ca n averag e line s Existin g source s ca

n elec t t o contro l onl y we t out are aemission s b y 9 5 percen t Ca n meet a n alternativ e emissio n limi t o f 14. 7 lb/to n (58. 5 percen t

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

contro l level )

2 6j j ^



## How do I Calculate UE F Th e equivalent

UE F equatio n wil l replac e th e correspondin g poin t

valu e equatio n i n th e final rul e Resi n us e ma

y b e base do n purchas e record s Resi n HAP content

may b e base do n MSD S or resi n specificatio n sheet s I f averaging , yo u mus t

determin e th e amount s o f

resi n use dfo

r eac h specifi c operatio n

2 7P.2 9 

## Example UE

F Calculatio n Ope n moldin g - mechanical resi n applicatio n - nonatomize d- filled - noncorrosio n resistan t

- Resi n HA P content

(fromMSDS ) i s 3 6 percen t

- UEF equatio n i s • UEF = ((0.157)(%styrene)-.0165 ) x 200 0 • UE F = ((0.157)(0.36)-.0165 ) x 200 0

• UE F = 8 0

- Propose dMAC T Floo r

i s 8 7

- Thi s meet s MAC T D o no t conside r catalyst s o r

promoter s D o conside r

any additional monome r additio n 2 8P.3 0 

## Ho w d o I demonstrat

e Initia l Complianc

e Fo r emissio n limit s - perfor

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

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

standard s - submi t

a certifie dstatement

tha t th e equipmen t

i s i n plac e an dmee t

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

2 9P.3 1 

## Ho w do I achiev e 9 5 percen tcontro l

(if required )
Enclos e operation s requirin g 9 5 percen t contro l wit

h apermanen t

tota l enclosur e Desig n an doperate enclosure i n accordanc e wit

h EPA Metho d20 4 Instal l an doperate a9 5 percen t efficien t contro l devic e

- Concentrator/oxidizer

- Thermal oxidizer

- Catalyti c oxidizer

3 0P.3 2 

## Whatar e th e Metho d 20 4 PT E Requirement

s

• Al l natural draf

t opening s (NDO ) a

t leas t fou r diameter s fromth e neares t HA P emittin g poin t

• Al l exhaus t

point s a t leas t fou r diameter s fromth e neares t

ND O Al l ND O no t

t o excee d5 percen t

o f th e enclosure' s surfac e are a Th e averag e ND O facia

l velocity i s a

t leas t 20 0 fp m

3 1P.3 3 

## Whatare th e Metho d 20 4 PT E Requirements (Con't ) Th e directio n o f

airflo w i n al l ND O shal l b e inward Al l PT E exhaust s mus t

discharg e throug h a contro l devic e ND O are ama

y b e reduce db y plasti c strip s or ai r curtain s

3 2P.3 4 

## Ho w d o I Demonstrat

e Initial Complianc

e Fo r Add-on Control s

• Perfor macomplianc e tes t

prio r t o th e complianc e date

• Performanc e test s method s are EP A Metho d18,25 , 25 A ' 5 **") Th e PTE mus t

b e certifie dusin g EPA Metho d20 4 Ifth e PT E doe s no t

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

33P.3 5 

## Ho w Do I Demonstrat

e Initial Complianc

e fo r a PTE Determin e th e equivalen t

diameter s o f

al l ND O an dexhaust s Determin e th e equivalen t

diameter s o f

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

mND O (mus t

b e a t leas t four) Measure PTE surfac e are a(A T ) an dND O surfac e are a(A N ) . Th e rati o o f AT/A N mus t 0.0 5 o r less .

34P.3 6 

## Ho w Do I Demonstrat

e Initial Complianc

e fo r a PT E (Con't )

- Measure al l exhaus t

flow s (Q 0 ) an dal l force dmakeup ai r

flows (Qj ) usin g EPA Metho d 2 .

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

- FV mus t

b e 20 0 fp mo r more ; o r

- measure pressur e differentia l acros s enclosure

- differentia

l mus t b e 0.00 7 inche s o f wate r or more 3 5

' /••. -P.3 7 

## Ho w D o I Demonstrat

e Initial Complianc

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

flow i s inwar dfo

r al l ND O usin g streamers , smoke tubes , o r trace r gase s I f FV i s 50 0 o r

more , inwardflow verificatio n i s no t

require d #

3 6