OAQ Process Information Application PI-16 Reinforced Plastics And Composites {52557}

Indiana Department of Environmental Management Office of Air Quality Air Permit Application Page 1 of 7 PI-16 Instructions 5/2006 PROCESS INFORMATION: Reinforced Plastic & Composites ­ INSTRUCTIONS Microsoft Word version of PI-16 Adobe PDF version of PI-16 The purpose of PI-16 (state form 52557) is to obtain detailed information about the reinforced plastic and composites operations. Complete one form for each process unit (or group of identical process units). PI-16 is a required form for all air permit applications submitted to IDEM, OAQ. For the purposes of this form, the term "source" refers to the plant as a whole and NOT to the individual emissions units. If you do not provide the enough information to adequately describe the process, the application process may be stopped. If you have any questions, contact the Air Permit Reviewer of the Day (PROD) at (317) 233-0178 or 1-800-451-6027 extension 3-0178 (toll free call within Indiana). 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: Provide the identification number for the unit. The identification numbers listed on this form should correspond to the emissions unit identified on the Plant Layout and Process Flow diagrams. 2. Installation Date: Provide the date on which the process unit was installed. If the exact date is not known, provide the month and year of the installation. If the unit has not yet been installed, provide the anticipated installation date. If the unit has been modified since the original installation, include the most recent modification date. 3. How many identical units are identified in this form? Indicate whether this form identifies one process unit, or a number of identical process units. Identical units must be of the same type, capacity, and installation date. If more than one identical unit, specify the number of units in the space provided. 4. Type of Unit Specify the type of unit from the list of possibilities or use the "Other" option to specify an alternate type of emission unit. 5. Products Produced: Specify the all final and intermediate products produced by this process. 6. Product Type: For resin and/or gel coat products, specify the type of product produced from the list of possibilities or use the "Other" option to specify an alternate type of product. 7. Maximum Production Rate: Provide the maximum production rate for the unit in parts per hour (parts/hr). 8. Mixer Capacity: Provide the maximum mixer capacity for the unit in pounds per hour (lb/hr). Part B: Open Molding Application Part B specifies details pertaining to the open molding atomized mechanical application method. 9. Resin Application: Specify the application method from the list of possibilities or use the "Other" option to specify an alternate method of application. American LegalNet, Inc. www.FormsWorkflow.com Indiana Department of Environmental Management Office of Air Quality Air Permit Application Page 2 of 7 PI-16 Instructions 5/2006 10. Gel Coat Application: Specify the application method from the list of possibilities or use the "Other" option to specify an alternate method of application. 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. 11. Surface Coating: If surface coating (e.g., painting) operations are present at this source, complete form PI-19 for each process. 12. Solvent Cleaning: If solvent cleaning (e.g., degreasing) activities are present at this source, complete form PI-09 for each process. 13. Combustion: If combustion (e.g., boilers / process heaters) activities are present at this source, complete forms PI-02A, PI-02B, PI02F, PI-02G, and/or PI-02H for each process, as applicable. 14. Other Process: If one or more other processes are present at this source, complete the appropriate PI forms for each process. Part D: Resin and Gelcoat Data Part D identifies the components associated with the resins and gel coats that will be used to calculate potential to emit. Provide a Material Safety Data Sheet (MSDS) for each material 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: Provide the name of the resin or gel coat as listed on the material safety data sheet (MSDS). 16. Emission Factors: For each resin or gelcoat listed, provide the relevant emission factor for volatile organic compounds (VOC), styrene, and methyl methacrylate. Be sure to include appropriate units of measure (e.g., lb/units, lbs/ton, lbs/gal, lbs/cf, etc.) as well as the source of the emission factors. Common sources include AP-42, stack test data, engineering analysis. The United States Environmental Protection Agency (U.S. EPA) has developed a Clearinghouse for Inventories & Emission Factors containing AP-42 and other emission factors. Appendix A of AP-42 lists several common conversion factors that may be needed to calculate potential to emit. For the reinforced plastic and composites industry, the Unified Emission Factors for Open Molding of Composites may be more representative than AP-42. 17. Weight Percent Monomer: Provide the percent by weight of monomer (%). 18. Density: Provide the material density in pounds per gallon (lb/gal). 19. Usage: Quantify the maximum material usage in gallons per part (gal/part). 20. Transfer Efficiency: Specify the transfer efficiency for each material (%). 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. American LegalNet, Inc. www.FormsWorkflow.com Indiana Department of Environmental Management Office of Air Quality Air Permit Application Page 3 of 7 PI-16 Instructions 5/2006 21. Material Identificat