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OAQ PROCESS INFORMATION APPLICATION PI-16: Reinforced Plastics & Composites
State Form 52557 (R / 1-07)

INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENT

IDEM ­ Office of Air Quality ­ Permits Branch 100 N. Senate Ave., MC 61-53 Indianapolis, IN 46204-2251 Telephone: (317) 233-0178, or Toll Free: 1-800-451-6027 x30178 (within Indiana) Facsimile Number: (317) 232-6749 www.idem.IN.gov/permits/air/index.html

NOTES:

· · ·

The purpose of this form is to obtain detailed information about the process. Complete one form for each process unit (or group of identical process units). This is a required form. Detailed instructions for this form are available online at

www.idem.IN.gov/permits/air/apps/instructions/pi16instructions.doc .
All information submitted to IDEM will be made available to the public unless it is submitted under a claim of confidentiality. Claims of confidentiality must be made at the time the information is submitted to IDEM, and must follow the requirements set out in 326 IAC 17.1-4-1. Failure to follow these requirements exactly will result in your information becoming a public record, available for anyone to inspect and photocopy.

PART A: Process Information Part A identifies the process. If there are multiple process units that are identical in nature, capacity, and use, you may use one form to summarize the data for the identical process units. 1. Unit ID: 3. How many (identical) process units are identified in this form? 4. Type of Unit Open Molding: Resin Gel Coat Complete Part B of this form. Resin Injection Molding (RIM) 2. Installation Date:
(actual or anticipated)

One

More than one (specify number):

Resin Transfer Molding (RTM) Closed Molding:

Sheet Molding Compound (SMC) Manufacturing Bulk Molding Compound (BMC) Manufacturing Compression Molding Other (specify): Polymer Concrete Other (specify):

Polymer Casting: Centrifugal Casting:

Cultured Marble

Vented molds, but air vented through the molds are not heated Heated air blown through molds Other (specify):

Filament Winding with resin bath Continuous Lamination / Casting Pultrusion Mixing Other (specify): 5. Products Produced: 6. Product Type: Filled Unfilled Corrosion-Resistant and/or High Strength (CR/HS) Low-Flame Spread/Low-Smoke Tooling Clear Production Gel Coat: High Performance Fire Retardant 7. Maximum Production Rate: 8. Mixer Capacity: parts per hour pounds per hour (lb/hr)
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Non CR/HS

Resin:

Shrinkage Controlled

Other (specify): White/Off White Pigmented All Other Pigmented

Corrosion-Resistant and/or High Strength Tooling Other (specify):

Indiana Department Of Environmental Management Office Of Air Quality State Form 52557 (R / 1-07)

Process Information ­ Reinforced Plastics & Composites FORM PI-16 Page 2 of 6

PART B: Open Molding Application Part B specifies details pertaining to the open molding atomized mechanical application method. 9. Resin Application: Manual: Hand Brush Roller Other (specify): Air-assisted airless LVLP Airless

Air-atomization Atomized Mechanical: Nonatomized * HVLP Other (specify): Flow Coater

Robotic or Automated Spray

Pressure Fed Roller Fluid Impingement Technology (FIT)

Robotic or Automated Spray Other (specify):

Other (specify): 10. Gel Coat Application: Manual: Hand Brush Roller Other (specify): Air-assisted airless LVLP Airless

Air-atomization Atomized Mechanical: Nonatomized * HVLP Other (specify): Flow Coater

Robotic or Automated Spray

Pressure Fed Roller Fluid Impingement Technology (FIT)

Robotic or Automated Spray Other (specify):

Other (specify): * If you are using UEF emission factors, include documentation provided by manufacturer or user that the design of the application tool has been organic HAP emissions tested, and the test results showed that use of this application tool results in organic HAP emissions that are no greater than the organic HAP emissions predicted by the applicable nonatomized application equation(s) in the UEF Table. Part C ­ Other Processes Part C identifies any forms that may need to be submitted for other parts of the source. If the source has the listed process, submit the necessary form for the process. Process 11. Surface Coating 12. Solvent Cleaning 13. Combustion Use the form listed for the specified processes. Check all that apply. Check N/A if your sources does not include the listed process. This form is included for surface coating (painting) operations: This form is included for solvent cleaning (degreasing) activities: These forms are included for combustion (process heating) activities: PI-19 PI-09 PI-02A PI-02B PI-02F PI-02G PI-02H N/A N/A N/A N/A N/A N/A N/A N/A

14. Other (specify):

This form is included for other process:

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Indiana Department Of Environmental Management Office Of Air Quality State Form 52557 (R / 1-07)

Process Information ­ Reinforced Plastics & Composites FORM PI-16 Page 3 of 6

PART D: Resin and Gel Coat Data Part D identifies data on the Resins and Gel Coats necessary to calculate emissions. Provide an MSDS for each materials used in the process. Use additional forms as necessary. For UEF emission factors on open molding processes, include documentation provided by manufacturer or user that the design of the application tool has been organic HAP emissions tested, and the test results showed that use of this application tool results in organic HAP emissions that are no greater than the organic HAP emissions predicted by the applicable nonatomized application equation(s) in the UEF Table. 15. Material Name RESINS 16. Emission Factors (specify value and units of measure) VOC Styrene Methyl Methacrylate 17. Weight % Monomer 18. Density
(lb/gal)

19. Usage
(gal/part)

20. Transfer Efficiency (%)

AP42

Other

AP42

UEF

Other

AP42

UEF

Other

AP42

Other

AP42

UEF

Other

AP42

UEF

Other

AP42

Other

AP42

UEF

Other

AP42

UEF

Other

AP42

Other

AP42

UEF

Other

AP42

UEF

Other

AP42

Other

AP42

UEF

Other

AP42

UEF

Other

GELCOATS
AP42 Other AP42 UEF AP42 UEF

Other

Other

AP42

Other

AP42

UEF

Other

AP42

UEF

Other

AP42

Other

AP42

UEF

Other

AP42

UEF

Other

AP42

Other

AP42

UEF

Other

AP42

UEF

Other

AP42

Other

AP42

UEF

Other

AP42

UEF

Other

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Indiana Department Of Environmental Management Office Of Air Quality State Form 52557 (R / 1-07)

Process Information ­ Reinforced Plastics & Composites FORM PI-16 Page 4 of 6

PART E: Solvent Data Part E provides data about the release agents, clean up solvents, and degreasers used in this process. Provide a Material Safety Data Sheet (MSDS) for each material used in the process. Space has been provided for up to six (6) solvents; use additional sheets as necessary. 21. Material Identification: 22. Batch Identification: 23. Manufacturer: 24. Usage (gal/part) 25. Material Density (lbs/gal) (DC)

26. Weight % Total Volatiles (water and organics) (WV) 27. Weight % Water 28. Weight % Solids 29. Weight % VOC (WW) (WN) (WO)

30. Volume % Total Volatiles (water and organics) (VV) 31. Volume % Water (VW)

32. Volume % Solids (VN) 33. Volume % VOC (VO)

34. VOC Content, less water (lbs/gal) (VOC) 35. VOC Emission Factor
AP-42 Other AP-42 Other AP-42 Other AP-42 Other AP-42 Other AP-42 Other

36. Single HAP Emission Factor (specify):
AP-42 Other AP-42 Other AP-42 Other AP-42 Other AP-42 Other AP-42 Other

37. Other Pollutant Emission Factor (specify):
AP-42 Other AP-42 Other AP-42 Other AP-42 Other AP-42 Other AP-42 Other

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Indiana Department Of Environmental Management Office Of Air Quality State Form 52557 (R / 1-07)

Process Information ­ Reinforced Plastics & Composites FORM PI-16 Page 5 of 6

PART F: Control Technology Part F identifies the methods used to control emissions from this process. 38. Add-On Control Technology: Identify all control technologies used for this unit, and attach completed CE-01 (unless "none"). None Baghouse / Fabric Filter ­ Attach CE-02. Electrostatic Precipitator ­ Attach CE-04. Oxidizer / Incinerator ­ Attach CE-06. Condenser ­ Attach CE-08. Dry Filters ­ Attach CE-10. Other (specify): Cyclone ­ Attach CE-03. Absorption / Wet Collector / Scrubber ­ Attach CE-05. Adsorber ­ Attach CE-07. NOX Reduction ­ Attach CE-09. Waterwash­ Attach CE-10. ­ Attach CE-10.

39. Control Techniques: Identify all control techniques used for this process. None Vapor Suppressed Resin Specify the Vapor Suppressant Effectiveness Factor (as determined using the test method from Appendix A of 40 CFR 63 Subpart WWWW): *Attach a copy of the test results to this form. Covered & Cured Before Rollout Covered & Cured After Rollout

Vacuum Bagging (specify): Other (specify):

40. Process Limitations / Additional Information: Identify any acceptable process limitations. Attach additional information if necessary.

PART G: Federal Rule Applicability Part G identifies any federal rules that apply to the process. 41. Is a New Source Performance Standard (NSPS) applicable to this source?
Attach a completed FED-01 for each rule that applies.

Yes

No

40 CFR Part 60, Subpart

(Specify):

42. Is a National Emission Standard for Hazardous Air Pollutants (NESHAP) applicable to this source? Attach a completed FED-01 for each rule that applies. 40 CFR Part 63, Subpart VVVV 40 CFR Part 63, Subpart WWWW 40 CFR Part 63, Subpart Boat Manufacturing Reinforced Plastic Composites Production
(Specify):

Yes

No

43. Non-Applicability Determination: Provide an explanation if the process unit appears subject to a rule (based on the rule title or the source category), but the rule will not apply.

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Indiana Department Of Environmental Management Office Of Air Quality State Form 52557 (R / 1-07)

Process Information ­ Reinforced Plastics & Composites FORM PI-16 Page 6 of 6

PART H: State Rule Applicability Part H clarifies applicability of the state rule regarding styrene emissions (326 IAC 20-25). 44. Is your source (as a whole, not just the unit listed on list form) a major source of HAPs?
(If no, your source is not subject to 326 IAC 20-25.)

Yes Yes Yes

No No No

45. Does your source manufacture reinforced plastic parts, products, or watercraft?
(If no, your source is not subject to 326 IAC 20-25.)

46. Does your source have an emission unit where resins and/or gel coats that contain styrene are applied and cured using the open molding process?
(If no, your source is not subject to 326 IAC 20-25.)

47. Is this emission unit subject to 326 IAC 20-48 (NESHAP 40 CFR Part 63, Subpart VVVV) concerning HAP emission standards for boat manufacturing?
(If Yes, this source is exempt from 326 IAC 20-25.)

Yes

No

48. 326 IAC 20-56 Applicability (NESHAP 40 CFR Part 63, Subpart WWWW): a. Is your source subject to 326 IAC 20-56 (NESHAP WWWW) concerning HAP emission standards for reinforced plastic composites production? b. Was your source existing on or before August 2, 2001, as a major source of HAPs?
(If you answered Yes to both questions, your source is exempt from 326 IAC 20-25.

Yes Yes Yes Not an Existing Source Yes

No No No

49. Existing Source: Does your source have actual emissions of styrene equal to or greater than three (3) tons per year.
(If Yes, your source may be subject to 326 IAC 20-25.) (If No, attach the last two years of styrene emissions data including a summary, the calculation method, and the raw data used.)

50. New Source or Modification: Do you project your source have actual emissions of styrene equal to or greater than three (3) tons per year.
(If Yes, your source may be subject to 326 IAC 20-25.) (If No, attach the projected styrene emissions data including a summary, the calculation method, and the raw data used.)

No

Not a New or Modified Source

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