DEQ-CFW_00086680

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AIR EMISSIONS INVENTORY SUPPORTING DOCUMENTATION
Emission Source ID No.: NS-I 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.
- 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 u
% Ethanol
% Methanol
% 1-Pro anol
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
°I° Hours operation per qrt
Master Production Scheduler via SAP BW Reporting

NS-I Membrane Spraybooth summary.
Max Spray Coat Rate
cc/min
2guns)
400
From PR-81 in process specification spray gun maximum capability
Max Process Rate
gal/hr
6.3
=cc/min * 2.64E-4 gal/cc * 60 min/hr, conversion for cc/min to gal/hr
Paint Batches
batch
314
from spraycoating
From spraycoating run sheets on how many batches were made
paint & binder lab
during the year. Note that lab sample analysis numbering system
results
provides last 3 numbers which equals number of batches made and
tested during the year ie 3FWC169 means that 169 batches were
made in 2003.
Gallons/batch
Gallons from Original batches
gals
I gals
L 25
I 7-85-0—F
From PR-81 process specifications for batch size.
calculation from batch size * number of batches
Remade batches
batchs
0
from spraycoating
In 2003 we stopped tracking remade batchs as a separate process
paint & binder lab
and combined this with the paint batch number.From spraycoating
results NG first
run sheets on how many batches were remade during the year. Note
samples.
that the lab numbering system will indicate R for remade batches.
From PR-81 process specifications for remake batch size.
Gallons added/batch
Gallons added to remake batchs
gals
5
0
gals
calculation from gallons added * number of remade batches
addition of original batches + remade batch gals producted. This
Annual Process Throughput
gals/yr
7850
number is brou ht to NS-I summary sheet
Coati ig Density
[Coating Consumed
lb/gal
Ibis/
7.928
From PR-81 process specifications for coating batches
r 1
62235
1
1 calculation of coating densitgals per year
VOC Emissions
Ethanol
Methanol
wt %
69%
From PR-81 process specification for binder solution make u
1-Pro anol
wt %
%
1 %
From PR-81 process specification for binder solution make u
wt
8%
From PR-81 process specification for binder solution make up

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Annual VOC Emissions
Ibs/ r
48543
calculation of voc components % * coating consumed
tons/yr
24.3
conversion to tons Ibs/2000lbs per ton. This number is brought to
NS-I summary sheet
TSP Emissions
Coating Solids
wt %
18%
From PR-81 process s ecifictions for coatings batch.
Paint Arrestor Effie
%
95%
From PR-81 equipment specifictions for coatings paint arrestor
efficiency.
Solids Produced
Ib/ r
11202
calculation of % coatings solids * coating consumed
Annual TSP Emissions
Ibs/yr
560.1
=Ibs/yr of coating consumed * wt% coating solids * (I-efficiencyof
arrestors) , calculation of emissions due to paint arrestor efficiency
not 100%
total suspended particles
tons/yr
0.28
calculation from Ibs per year to tons per year. This number is brought
to NS-I summary sheet

Emission Source ID No.
Criteria (NAAQS) pollutants
Pollutant
code
Emissions
(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
24.3
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DEQ-CFW 00086685