DEQ-CFW_00086118

9 9 0
December- Resins Monthly Emissions
Month
Date
Entered
Emission
(kg)
Emission
(kg)
Emission
(kg)
Emission
(kg)
MeOH
Emission
(kg)
TotalTotal
Emission
(kg)
Emission
(Ibs)
Total
Emission
(tons)
-month
Sum
(tons)
Jan-08
02/07/08
457
0
2276
806
26
3566
7861
3.9
33.3
03/13/08
187
1
1987
155
28
2358
5199
2.6
32.7
04/07/08
735
111
1984
71
25
2926
6450
3.2
34.3
05/08/08
41
0
2417
32
29
2520
5555
2.8
34.6
8
06/19/08
269
0
957
735
17
1977
4359
2.2
34.1
07/10/08
1121
87
1464
555
22
3249
7163
3.6
35.3
L
08/12/08
0
18
1184
53
19
1274
2809
1.4
33.8
09/13/08
265
73
1475
471
28
2312
5097
2.5
322
10/08/08
20
0
925
96
10
1051
2317
1.2
30.5
11/09/08
0
5
2195
1
26
2228
4911
2.5
30.0
12/10/08
864
0
696
16
7
1582
3488
1.7
29.4
8
01 /13/09
0
0
0
7
0
7
15
0.0
27.6

NS-H Membrane treatment (extrusion & hydrolysis) summary report.
DMSO Emissions yr Units 2008
Waste Shipped
Waste in storage tk yr end
Waste in storage tk yr end
Waste % in storage tk yr end
DMSO Waste Content
DMSO in Waste liquid
DMSO Shipped as Waste liquid
DMSO pumped to waste treatment
DMSO Inventory
inv. Begin year
inv. End year
DMSO Drums Rec
Wt/Drum
total DMSO consumed
DMSO Emissions into air
DMSO Emissions into air
Acetic Acid Emissions air
1 st Quarter
2nd Quarter
3rd Quarter
4th Quarter
Total
lb/yr C 0 data from Danny Melvin or replacement
gallons 616.8 =Waste% in Tank * Size of tank (5507 gal)
=gallons in tank* conversion of lb/gal of typical concentration
lb 6291 of KOH/DMSO/water (10.2 lb/gal)
% 10% from IP-21, Y07403LG
Per PR-70 average DMSO concentrations at highest limit,
Lab analysis as support is available. Which indicates actual
content is less then 11, Nafion® Products has decided to
wt% 11 % use the higher possible content to ensure fail safe position.
=(total lb. shipped offsite+total lb. stored
Ib/yr 692 onsite)*concentration of DMSO in tank (11%)
=(total lb. shipped offsite)*concentration of DMSO in tank
lb/yr 0 (11%)
lb/yr
drums
drums
drums
lb/drum
lb
lb/yr
tons/yr
hrs
hrs
hrs
hrs
hrs
Acetic Acid Emissions Rate Ib/hr
40 Acetic Acid HAP/TAP Emissions Ib/hr
Acetic Acid HAPITAP Emissions lb/yr
Calc. from IP21 the number of days that we pumped to
waste treatment, this rate is given at 5 gph (there is no flow
meter at this time), use tank level changes IP21 Y07403LG
to indicate tank level changes which means we are
pumping. # days * *hr/day*gal/hr* Can also try using
28885 Y30529HS, which indicates if the pump is on
20 from previous yr
8 from Shipping and Material Coordinator (Autumn Arenivas)
88 from Shipping and Material Coordinator (Autumn Arenivas)
On shipping labels (from Shipping and Material Coordinator -
507 Autumn Arenivas)
50700=wt/drum*(dmso drum rec + inv. Begin year - inv. End year)
from total DMSO consumed - DMSO shipped as waste-
21123 DMSO pumped to waste treatment
10.6 DMSO emissions into air/2000 lb. per ton
from hydr run sheets, from quarterly acetic acid emissions
99.1 report, completed by Hydrolyis ATO
from hydr run sheets, from quarterly acetic acid emissions
108.9 report, completed by Hydrolyis ATO
from hydr run sheets, from quarterly acetic acid emissions
52.38 report, completed by Hydrolyis ATO
from hydr run sheets, from quarterly acetic acid emissions
3.5 report, completed by Hydrolyis ATO
0.727 from TA-NF-01-1240 study by Lee Ann Kessler in 1999
191.7 =1b/hr * Total # of hours, brought to NS-H summary sheet
192 Acetic Acid emissions
DEQ-CFW 00086119

from TA-NF-01-1240 study by Lee Ann Kessler in 1999 the amount of HF produced per kg of polymer processed
at various temperatures.
Use higher temp for extrusion.
kg/kg @ 200C 0.0003 5806.2 total operating schedule OS-19
kg/kg @ 200 C 0.0001 Seasonal % working schedule
kg/kg @ 275 C 0.000675
kg/kg @ 275 C 0.000075
kg/kg @ 300 C 0.00008
kg/kg @ 300 C 0.00001
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DEQ-CFW 00086120

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Emission source/Operating Scenario Data
1. Emission Source ID No.
Actual emissions per pollutant listed for source/process identified on page 1:
Criteria (NAAQS) pollutants
Pollutant
code
Emissions-
Criteria
pollutants
(tons/yr)
Emission
estimation
method
code
2008
Carbon Monoxide
CO
0
8
NOx
NOx
0
8
TSP
TSP
0
8
PM 2.5
PM-2.5
0
8
PM 10
PM-10
0
8
SO2
SO2
0
8
VOC
VOC
10.7
8
HAP/TAP pollutants
CAS #
8
Acetic Acid
64-19-7
192
8
Hydrogen Fluoride
7664-39-03
98
8
DEQ-CFW 00086121

AIR EMISSIONS INVENTORY SUPPORTING DOCUMENTATION
Emission Source ID No.: NS-1 MEMBRANE SPRAYBOOTH
Emission Source Description: Nafion® resin membrane spray booth treatment process
Process Description: OS-19 / Nafion® resin membrane spray booth treatment processes
The spray coating process supplies a thin uniform layer of coating (pigment & resin) solution to
the surface of Nafion® membrane. This is accomplished in the following process Binder solution
(Polymer and alcohol) is handled in 55 gallon drums and stored in an enclosed paint preparation
room.or temporarily on an outside pad prior to use. Pigment is received in 100 kg fiber packs and
stored in the paint preparation area again prior to use.
The coating (or paint) solution is prepared by adding measured amounts of binder solution, a
wetting agent, pigment and alcohol to an agitated premix tank. The coating solution is then tested
per specification. If acceptable, the material is put into carboys. If not acceptable, the material is
blended or processed though various equipment until tested within specifications. The acceptable
coating solution is stored in carboys in the paint preparation area until needed for spray coating
process..
In the spray coating process the resin membrane is feed continuously through the spray booth
while the coating material is "sprayed" onto the membrane. An automatic transverse machine
carries two air jet spray guns back and forth in front of the membrane and applies a thin coating.
The volatile paint alcohol is evaporated in the top section of the spray booth and in the exit
enclosure behind the top section of the spray booth, leaving a dry pigment/binder coating on the
membrane's surface.
The resin membrane spray coating and coating preparation process is contained in a enclosed
room. All emissions are contained within the room and vent through emission control stacks. Air
is supplied into the rooms and vented on a once through basis. The ventilation system is designed
for 2 to 5 minute air exchange rate.
Basis and Assumptions:
- vent to atmosphere via stack
- No fugitive emissions due to all emissions vented through stack.
- Total Suspended Particles are pigment and larger than 10 micron PM.
- Maximum coating rate is 180cc/min per spray gun design basis with air pressure at max soc's.
For these calculations the products area is using a 10% above factor to ensure emissions are not
under reported. Thus 200 cc/min is basis for rate.
- Density of coating material is 7.928 Ibs/gal average. This is soc aim. Actual lab analysis is
performed with verifies this average over annual time frame. Thus basis of calculation assumes
7.928 SOC average vs lab reported average.
- Density of coating material is 7.928 Ibs/gal average. This is soc aim. Actual lab analysis is
performed with varifies this average over annual time frame. Thus basis of calculation assumes
7.928 SOC average vs lab reported average.
DEQ-CFW 00086122

- Solution make up alcohol concentrations are soc specification averages. COA's verify actual
concentrations are at soc averages. Thus basis of calculation assumes soc average for solution
concentrations.
- Coating solution solid concentrations are soc specification averages. Lab analysis is performed
and verifies this average over annual time frame. Thus the basis of calculation assumes 18%
solids in coating batch.
- Paint applications emissions arrestor efficiency is 95% based on equipment design specification.
5% of total solids are lost as air emissions.
Information Inputs and Source of Inputs:
Information
Source
Paint batches made
Spray coating run sheets & lab numbering system for each batch made.
Gallons/batch
PR-81 process SOC
Paint batches remade
Spray coating run sheets & lab numbering system for each batch made.
Note that the lab numbering system will indicate R for remade batches.
Gallons added/remade batch
PR-81 process SOC
Coating Density
PR-81 process SOC
Binder solution make up
PR-81 process SOC
% Ethanol
PR-81 process SOC
% Methanol
PR-81 process SOC
% 1-Propanol
PR-81 process SOC
Coating % solid pigment
PR-81 process SOC
Paint Arrestor efficiency
PR-81 process SOC
CA membrane Coated
Master Production Scheduler via SAP BW Reporting
Total hours of operation
Master Production Scheduler via SAP BW Reporting
% Hours operation per quarter
Master Production Scheduler via SAP BW Reporting
DEQ-CFW 00086123

NS-1 Membrane Spraybooth summary.
Coating Process yr
2008
Max Spray Coat Rate
cc/min (2 guns)
400
Max Process Rate
gal/hr
6.3
from spraycoating
paint & binder lab
Paint Batches
batch
248
results
Gallons/batch
gals
25 or 50
Gallons from Original batches
gals
7900
from spraycoating
paint & binder lab
results NG first
Remade batches
batchs
0
samples.
Gallons added/batch
gals
5
Gallons added to remake batchs
gals
0
Annual Process Throughput
gals/yr
7900
Coating Density
lb/gal
7.928
Coating Consumed
Ibs/yr
62631
VOC Emissions
69%
Ethanol
wt %
Methanol
wt %
1 %
1-Propanol
wt %
8%
Annual VOC Emissions
Ibs/yr
48852
tons/yr
24.4
TSP Emissions
Coating Solids
wt %
18%
Paint Arrestor Effic
%
95%
Solids Produced
Ib/yr
11274
Annual TSP Emissions Ibs/yr 563.7
total suspended particles tons/yr 0.28
•
DEQ-CFW 00086124

Actual emissions per pollutant listed for source/process identified on page 1:
Criteria (NAAQS) pollutants
Pollutant
code
Emissions -Criteria
pollutants tons/yr
Carbon Monoxide
CO
0
NOx
NOx
0
TSP
TSP
0.28
PM 2.5
PM-2.5
0.28
PM 10
PM-10
0.28
SO2
SO2
0
VOC
VOC
24.4
�1
DEQ-CFW 00086125

Ll
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2008 AIR EMISSIONS INVENTORY SUPPORTING DOCUMENTATION
Emission Source ID No.:
Emission Source Description:
Process and Emission Description:
NS-K
Nafion E-Fluids Production Process
The E2 process is a batch manufacturing process. All emissions from this process
vent to the atmosphere, some via a vertical stack. The control of emissions of
certain compounds will be addressed in the attached spreadsheet.
Basis and Assumptions:
Engineering calculations using compositions, volumes and paritial pressures are used
to determine amounts vented. See attached information for assumptions made for
each vessel. A typical batch is — 220 kgs of E fluids with the following composition
(86% E2, 10% E1 and 4% E3).
Information Inputs and Source of Info.:
Information Input
Source of Inputs
E2 production quantity
E2 Production Facilitator
Speciated emission rates
Attached calculations
Point Source Emissions Determination:
Point source emissions for individual components are given in the attached
spreadsheet
Equipment Emissions and Fugitive Emissions Determination:
Emissions from equipment leaks which vent as stack (point source) emissions and
true fugitive (non -point source) emissions have been determined using equipment
component emission factors established by DuPont. The determination of those
emissions are shown in a separate section of this supporting documentation.
DEQ-CFW 00086126