Achieving Compliance with New MACT Standards

In assisting one of the first facilities in the country to comply with the new MACT standards, Battelle managed the design, procurement and installation of an air emission capture and control system for an existing composite panel production facility. The objective was to upgrade the facility by applying maximum achievable control technology (MACT) on its fiberglass reinforced plastic panel manufacturing operations according to an aggressive 12-month schedule beginning in June 2002. Battelle shepherded the facility through planning and implementing a prospective MACT compliance project, including the challenges of problem assessment, identification of unknowns, data acquisition, technology selection, production interference, risk tolerance, vendor selection and contractual requirements.

The project goals were to capture and destroy fugitive styrene emissions from several production lines and a mixing room with a minimum 95% efficiency in conformance with MACT requirements. This was to be accomplished while also ensuring less than 25 parts per million by volume (ppmv) of worker exposure (8-hour Time Weighted Average) to styrene, and by minimizing interference and encumbrances to routine production operations.

Preliminary capture design was based on the results of initial baseline mapping of fugitive styrene emissions from wet end production areas. The design solution included the strategic placement of high-velocity hoods to capture emissions close to their sources while minimizing the uptake of fiberglass strands and other particulates. Exhaust and natural draft opening volumes were balanced through the introduction of clean, tempered make-up air at key positions within permanent total enclosures established in the production areas, while also fully compensating for winter heat losses from the production building.

Review of available control technologies resulted in the selection of a regenerative thermal oxidizer (RTO) system that was optimally sized to minimize operating costs yet achieve a sufficient number of air changes per hour to control worker exposure to less than 25 ppmv styrene. RTO reserve capacities were also determined and specified to enable future selective curing oven stack inclusion, based on studies of each oven’s styrene emission contribution under various production conditions. This will be implemented following a recommended modernization program currently under way to improve oven energy efficiency and conservation.

Battelle was responsible for initial project evaluation and planning, technology selection, preparation of technical specifications, vendor screening and solicitation, bid review and recommendation, design review, installation monitoring, system performance evaluation, testing and approval. The project achieved all of the design objectives and was completed on budget within the 12-month schedule.

For additional information, please contact Mr. Alan Tilstone at (781) 895-4877, tilstonea@battelle.org.