Document ID: EPA-HQ-OAR-2006-0537-0015
Agency: epa
Document Type: Supporting & Related Material
Title: 
Posted Date: 2006-08-04T04:00Z

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<BODY lang=EN-US style="tab-interval: .5in"><B>From:</B> Ram Singhal 
[rsinghal@flexpack.org]<BR><B>Sent:</B> Tuesday, May 23, 2006 11:49 
PM<BR><B>To:</B> Ram Singhal; Reeves, David; Schaffner, Karen S.; 
Salman.dave@epa.gov; hirtz.paula@epa.gov<BR><B>Subject:</B> Consumer & 
Commercial Products 183e: Response to your questions.<BR>
<DIV dir=ltr align=left>
<P><FONT size=2><SPAN class=218503802-24052006>Please send this email to Roy as 
well.  I do not have his email address on hand.</SPAN></FONT></P>
<P><FONT size=2><STRONG>Paula, Dave S., Dave R., Karen, and Roy 
--</STRONG> </FONT></P>
<P><FONT size=2>FPA members appreciated the opportunity to meet with you 
yesterday about the determination that EPA must make on a national rule vs. a 
CTG for flexible packaging. This is our best input at this time<SPAN 
class=218503802-24052006>.  S</SPAN>ince our entire membership has not had 
the opportunity to review it due to time constraints they may have additional 
insights and information to add during the comment period.</FONT></P>
<P><FONT size=2>As requested, here is some information about 1)capture and 
destruction efficiencies at existing presses; 2) alternative compliance limits; 
3)some notes on technical feasibility issues at certain facilities with respect 
to Permanent Total Enclosures (PTE<SPAN class=218503802-24052006>s</SPAN>) for 
capture; and 4) cost data for PTEs on new and existing presses subject to BACT 
review, subpart KK or undertaken to limit a plant's emissions to avoid 
triggering New Source Review or for NSR . We know of no RACT requirements for 
PTEs. The incremental costs of such capture systems (beyond inherent control 
achieved by design of the<SPAN class=218503802-24052006> </SPAN>press) would be 
exceedingly high in our view.</FONT></P>
<P><FONT size=2>1. <U><STRONG>Capture and Destruction Efficiency for 
Flexographic and Rotogravure Presses</STRONG></U></FONT></P>
<P><FONT size=2>A. <SPAN class=218503802-24052006> </SPAN>95% 
<U>destruction efficiency</U> is generally achievable from current design 
thermal and catalytic oxidizers and solvent recovery systems <SPAN 
class=218503802-24052006>a</SPAN>vailable<SPAN 
class=218503802-24052006> </SPAN><SPAN 
class=218503802-24052006>            
</SPAN>for <SPAN class=218503802-24052006>e</SPAN>missions<SPAN 
class=218503802-24052006> </SPAN>control<SPAN 
class=218503802-24052006> on</SPAN> flexographic and rotogravure 
presses.</FONT></P>
<P><FONT size=2>B. <SPAN class=218503802-24052006> </SPAN><U>Capture 
efficiency</U> appears to generally range from an average 65-70% for 
flexographic and rotogravure presses, but there have been no changes in design 
of these presses since the 1978 CTG was published.</FONT></P>
<P><FONT size=2>Companies may be able to purchase new presses that are capable 
of achieving higher capture efficiencies (80-85%<SPAN 
class=218503802-24052006>)</SPAN>, but these designs are not feasible to 
retrofit existing presses.</FONT></P>
<P><FONT size=2>2. <SPAN class=218503802-24052006> </SPAN>Note that 
the CTG and <SPAN class=218503802-24052006>S</SPAN>tate regulations also 
provide <U>alternate VOC compliance limits</U> for presses, including a) 25% 
VOC<SPAN class=218503802-24052006> </SPAN>by volume of the vol<SPAN 
class=218503802-24052006>a</SPAN>tile content in the co<SPAN 
class=218503802-24052006>a</SPAN>ting or ink or b) 2.9 pounds VOC/gallon ink 
less water.</FONT></P>
<P><FONT size=2>3. <SPAN class=218503802-24052006> </SPAN><U>Technical 
Feasibility Issues for PTEs</U> - Certain facilities may be space limited with 
regard to the ability to install PTEs because presses are located within close 
proximity (e.g., 15 feet). In addition, many presses are located in close 
proximity to other equipment such as slitters and finishing processes 
machines<SPAN class=218503802-24052006> </SPAN>that prohibit installation of the 
PTE. <SPAN class=218503802-24052006> </SPAN>If PTEs were installed, they 
could create material handling and operating problems as well as worker safety 
concerns. <SPAN class=218503802-24052006> </SPAN>Finally, structural 
constraints at some facilities may limit the installation of HVACs, additional 
oxidizers and other duct work.</FONT></P>
<P><FONT size=2>4. <SPAN class=218503802-24052006> </SPAN><U>Costs and 
Other PTE Considerations:</U> <SPAN class=218503802-24052006><U> 
</U></SPAN>The capital necessary for installation of a PTE generally falls into 
five categories: (a) structural (e.g., doors, walls); (b) air handling and 
ducting, dependent on number of air room turn-overs<SPAN 
class=218503802-24052006> </SPAN>(depending in part on OSHA); (c) air cooling 
equipment (depending on heat generated by enclosed ovens and OSHA concerns) and 
(d) electrical and pressure instrumentation ; (e) increased oxidizer capacity 
needed for increased air flow (natural gas is annual operating 
expense).</FONT></P>
<P><FONT size=2>Here are recent costs for PTEs:</FONT></P>
<P><FONT size=2>#1 <U>For two new flexo presses installed in an existing 
facility</U> (new construction in 2006):</FONT></P>
<P><FONT size=2>Permanent Total Enclosure (For PSD avoidance in ozone attainment 
area) </FONT></P>
<P><FONT size=2>PTE to enclose two presses (walls and doors - rollup and man), 
including conditioned makeup air, interface between HVAC and oxidizer, 
differential pressure sensor, floor sweeps, increased oxidizer capacity and 
ducting</FONT></P>
<P><FONT size=2><STRONG>Total cost: $460,000</STRONG></FONT></P>
<P><FONT size=2>#2 <SPAN class=218503802-24052006> </SPAN><U>For 3 flexo 
presses of which two are existing and one is new</U> (new construction in 
2005):</FONT></P>
<P><FONT size=2>Permanent Total Enclosure - NSR permit/LAER determination and to 
generate emission offsets </FONT></P>
<P><FONT size=2>PTE to enclose two presses (walls and doors - rollup and 
man), including conditioned makeup air, interface between HVAC and oxidizer, 
differential pressure sensor, floor sweeps, ducting, positive pressure ovens and 
increased oxidizer capacity</FONT></P>
<P><FONT size=2><STRONG>Total cost: $575,000</STRONG></FONT></P>
<P><FONT size=2>##3-4 <U>Rotogravure PTE Enclosure Installations constructed in 
1999 as part of the facility's original 40 CFR 63 Subpart KK compliance 
plan.</U></FONT></P>
<P><FONT size=2>#3 <SPAN class=218503802-24052006> </SPAN>One 1960-65 
Rotogravure Vintage Press - 8 application stations enclosed;<SPAN 
class=218503802-24052006> </SPAN>1 application water based (not 
enclosed).:</FONT></P>
<P><FONT size=2>PTE Cost: <SPAN class=218503802-24052006> </SPAN>Safety 
Design, Enclosure Construction, Enclosure HVAC, Ductwork, Electrical 
(lighting/controls) </FONT></P>
<P><FONT size=2><STRONG>Total cost $170,000</STRONG> (The costs do <U>not</U> 
include additional T<SPAN class=218503802-24052006>hermal </SPAN>O<SPAN 
class=218503802-24052006>xidizer</SPAN>/C<SPAN class=218503802-24052006>atalytic 
</SPAN>O<SPAN class=218503802-24052006>xidizer</SPAN> capacity that may need to 
be added.)</FONT></P>
<P><FONT size=2>#4 Two 1990-95 Vintage Press- 10 application stations (Cost 
below is for each press) </FONT></P>
<P><FONT size=2>PTE Cost: Safety Design ,<SPAN class=218503802-24052006> 
</SPAN>Enclosure Construction, Enclosure HVAC, Ductwork Install/Modification 
,Electrical (lighting/controls).</FONT></P>
<P><FONT size=2><STRONG>Total<SPAN class=218503802-24052006> cost 
</SPAN> $219,000</STRONG> ($438,000 total<SPAN class=218503802-24052006> 
for both presses</SPAN>)<SPAN class=218503802-24052006>.  Cost </SPAN>data 
not available regarding addition <SPAN class=218503802-24052006>of 
</SPAN>oxidizer capacity.</FONT></P></DIV><BR>
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<P class=MsoNormal><!--[if supportFields]><font color=black><span 
style='color:black'><span style='mso-element:field-begin'></span><span 
style="mso-spacerun: yes"> </span>AUTOTEXTLIST \s "E-mail 
Signature" <span style='mso-element:field-separator'></span></span></font><![endif]--><SPAN 
style="COLOR: black"><B><SPAN style="FONT-WEIGHT: bold">Ram K. 
Singhal</SPAN></B></SPAN><B><SPAN 
style="FONT-WEIGHT: bold; COLOR: black; mso-color-alt: windowtext"><o:p></o:p></SPAN></B></P>
<P class=MsoNormal><FONT face="Times New Roman" size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt">Director, 
Regulatory & Government Relations</SPAN></FONT><FONT size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt; mso-color-alt: windowtext"><o:p></o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face="Times New Roman" size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt">Flexible 
Packaging Association</SPAN></FONT><FONT size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt; mso-color-alt: windowtext"><o:p></o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face="Times New Roman" size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt">971 Corporate 
Blvd., Suite 403</SPAN></FONT><FONT size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt; mso-color-alt: windowtext"><o:p></o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face="Times New Roman" size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt">Linthicum, MD 
21090-2211</SPAN></FONT><FONT size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt; mso-color-alt: windowtext"><o:p></o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face="Times New Roman" size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt">(410) 694-0823 
[phone]</SPAN></FONT><FONT size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt; mso-color-alt: windowtext"><o:p></o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face="Times New Roman" size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt">(410) 694-0900 
[fax]</SPAN></FONT><FONT size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt; mso-color-alt: windowtext"><o:p></o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face="Times New Roman" size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt">mailto: 
rsinghal@flexpack.org</SPAN></FONT><FONT size=2><SPAN 
style="FONT-SIZE: 10pt; COLOR: black; mso-bidi-font-size: 12.0pt; mso-color-alt: windowtext"><o:p></o:p></SPAN></FONT></P>
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