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Pollution Reduction Strategies in the Fiberglass Boatbuilding and Open

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Pollution Reduction Strategies in the Fiberglass Boatbuilding and Open . I POLLUTIONREDUCTION STRATEGIES in the FIBERGLASSBOATBUILDING and OPEN MOLD PLASTICS INDUSTRIES Prepared by: Darryl Davis, Chainnan Department of Manufacturing East Carolina University Assisted by: Y. J. Lao, Chairman Department of Environmental Health East Carolina University Copyright 0 1987 Reprint with permission This project was supported by the Pollution Prevention Pays Program through a grant from the North Carolina Board of Science and Technology Acknowledgementsand Notice Sincereappreciation is expressedto the following individuals who have provided support in the development of this manual: Lori Rosinus, Lab Technician forthe East Carolina University Department of EnvironmentalHealth; Nathan Wolfe, Graduate Student, East Carolina University Department of Manufacturing; PhillipHagan, Graduate Student, East Carolina University Department of Environmental Health; Debbie Hathaway, Project Coordinator for the East Carolina UniversityCenter for Applied Technology; Sarah McPherson, proofreader, Greenville, NC.; Dr.William Grossnickle, Industrial Psychologist, East Carolina University; Tim Ross, President of Rimcraft Technologies, Inc.; Roger Schecter and Gary Hunt of the Pollution Prevention Pays Program; Terry Gray, Technical Writer, Flanders Filters, Inc.; W. C. Jones, Student, East Carolina University Department of Manufacturing; Hope Kemp,Secretary, East Carolina University Department of Manufacturing; and the North Carolina Board of Science and Technology. Everyeffort has been made to insure that informationprovided in this manual is accurate. However, neither the Authors or East Carolina University takes . responsibilityfor the information contained in this manual. No endorsements are provided or implied for the services or products provided by any companies or individualsmentioned in this publication. Comments which can improve the accuracy or usefulness of this manual are welcomed by the Senior Author and by the Pollution Prevention Program. Darryl Davis,Chairman Department of Manufacturing EastCarolina University Greenville,NC 27858 (91 9)-757-6705 Roger N. Schecter, Director PollutionPrevention Pays Program Dept. of Natural Resources and Community Development P. 0. Box 27687 Raleigh, NC 27607 (91 9)-733-7015 I I TABLE OF CONTENTS Introductory Materials Acknowledgments and PublishedNotices 1 Introduction V Chapters I. An Overview of the Industry 1 A. Products 1 B. FabricationProcessesFacilities 2and C. EstablishingPollution Reduction Strategies 3 II. Are PollutionReduction Changes Necessary? 5 A. Economic Factors 5 1. Economics 5 2. IncentivesGovernmental 5 Regulatory FactorsB. Regulatory 7 1. ~ Regulated Materials 7 2. Environmental Impact 8 3. WorkEnvironment and Worker Protection 8 C. Liabilities 10 Legal Concerns 1. Legal 10 Limiting Legal Liability2. Legal Limiting 10 Legal Disincentives3. Legal 11 Psychological FactorsC. Psychological 11 1. The Inevitabilityof Change 11 2. Managing theChange Process and Overcoming Resistance 12 3. Barriers to Change 12 4. Overcoming Resistance to Change 14 111. Production-BasedPollution Reduction Strategies 16 A. Air-AssistedAirless Spray Guns 16 1. ConventionalSpray Systems 16 2. Air Assisted Airless Designs 16 Pressure Reduction3. Pressure 17 Potential Benefits4. Potential 17 5. Economic Factors 18 Units in 6. Units Use 18 Resin ImpregnatorsB. Resin 19 1. ConventionalMaterials Application Systems 19 . 2.Reinforcing FiberPrepreg 20 3. ImpregnationIn-HouseResin 21 Potential Benefits 22 Benefits4. Potential 5. Economic Factors 22 Units in 6. Units Use 23 Resin Roller Dispensers 24Dispensers RollerC. Resin 1. SpraylessApplication Systems 24 2. Roller DispenserDesigns 24 3. Resin Delivery 24 4. Potential Benefits 25 5. Economic Factors 26~- D. Vacuum Bag Molding 26 1. Improving Open Mold Systems 26 2. Vacuum Bag Molding Processes27 3. Potential Benefits 28 4. Economic Factors 29 5. Vacuum Bagging Applications29 E. Resin Transfer Molding 31 Closed Mold1. Closed Systems 31 2. Resin Transfer Molding Processes 31 3. Potential Benefits 33 4. Economic Factors 34 5. Units in Use 34 F. Rotational Molding 36 1. Examining ThermoplasticOptions 36 2. Rotational Moldina of SmallTanks 36 G. Low-Emission Resins 38 H. Resin Storage 39 1. Purchasing and Storing Resins39 2. Mini-Bulk Resin Storage 39 IV. ContaminatedManaging43Solvents U se 43 A. Solvent Use B. In-Plant Solvent Recovery 43 1. Small Batch Solveni DistillationEquipment 43 2. ContinuousFeed Distillation Equipment 48 Ongoing Developments3. Ongoing 49 C. Out-Of-Plant Solvent Recovery 50 1. Recycling Agreements 50 2. Features of Out-of-Plant Recycling 50 D. Incineration of ContaminatedSolvents 52 - V. Facility Based Pollution Reduction and Management 55 Strategies A. Localizing andIsolating Problem Operations 55 Pollution Sources1. Pollution 55 2. Isolating Problems Areas 56 3. Confining Gel Coat Application 56 4. Approaches to Gel Coat Isolation 58 5. Approaches to Isolating OtherOperations 60 6. Air Filtration and Recirculation Systems63 1. Filtering ContaminatedAir 63 2. Dry FiltrationRecirculation and 64 3. Wet Filtration Systems 67 C. Fume Incineration 70 iii 1.Using Heat to Reduce Styrene Emissions 70 2. Incineration Unit Application 71 D. Controlling Air-Flow and Exhaust 73 1. Introduction 73 2. Exhaust Ventilation 73 3. Maintaining PressurePositive 73 General Guidelines4. General 74 5. Local Exhaust 75 Appendices A Materials SafetyMaterials A Information 76 1. Material Safety Data Sheets Overview76 M SD S-Acetone 80 2. MSDS-Acetone M SD S-MEK P 83 3. MSDS-MEKP 4. MSDS-Styrene 86 5. Recommendations for a Styrene Standard89 B Pollution PreventionProaram Pavs 103 ~~~ ~ C. SuppliersEquipmentProcessing 104 D. Suppliers of Distillation Equipment 106 E. Hazardous Waste Services 108 F. Regulatory Information Resources 113 Case Studies 1. Air assisted airless spray application of gel 18 coat, Grady White Boats, Greenville, NC 2. Resin impregnator, Synthnics, Inc., 23 Paducah, KY 3. Vacuum bag molding, Fountain Powerboats, 30 Chocowinity, NC 4. Resin transfer molding, Hatteras Yachts, 35 New Bern, NC 5. Mini-bulk resin storage system, Privateer 41 Manufacturing, Chocowinity, NC 6. In-plant solvent distillation, Steamex, 46 Raleigh, NC 7. In-plant solvent distillation, Fountain 47 Powerboats, Washington, NC 8. Out-of-plant solvent recovery, Hatteras 51 Yachts, New Bern, NC 9. Plant air recirculation system, S2 Yachts, 67 Holland, MI 10 Fume incineration, Lasco Bath Fixtures, 72 South Boston, VA iv INTRODUCTION Funding for this project, "Development of Cost-Effective Pollution Reduction Technologies for Open Mold Plastics Processing Industries in North Carolina," has been provided by the North Carolina Board of Science and Technology through theDepartment of NaturalResources and Community Development, Pollution Prevention Pays Program. Mr. Roger N. Schecter of the Pollution Prevention Pays Program felt that efforts should be undertaken to reduce the generation of waste and other pollutants in North Carolina industries. Mr. Schecter and the Board of Scienceand Technology agreed that open mold plastics processing industries should be given attention in the development of pollution reduction strategies for thestate. Concentration on this industry was considered important since the industry operations require use of large quantities of liquid resins and produce considerable quantities of contaminated solvents. Openmold fabricators utilize a number of materialsand processing strategies which make knowledge of environmental regulations and appropriate waste management strategies essential to the survival of their companies. The materialsused include styrene based polyester resins, methyl ethyl ketone . peroxides,acetone, as well as other solvents and specialty chemicals. Since resins are often applied through an atomization process, air quality in and outside the facility is a major concern. Special attention must also be focused on proper inventoryand controlling of materialswhich are purchased, stored, used, and disposed of by the firm. Informationpresented in this manual is based on a number of sources. Federaland state regulations were reviewed. Interviews with regulatory compliance inspectors were also conducted. Much of the content was developed asresult of numerousin-plant visits and observations, as well as telephone interviews with a number of fiberglass fabricators. Firms engaged in production andmarketing of processingequipment and supplies for the industry provided valuable information and many useful leads. V CHAPTER I AN OVERVIEW OF THE INDUSTRY A. Products Open molding of thermosetting plastics is carried out in a variety of North Carolina firms. Some of these companies operate facilities which are dedicated almost exclusively to the production and marketing of molded components such as boat hulls, cultured marble bath fixtures, bathtubs, large storage tanks, and vehicle body components. Other firms may accommodate open molding only to the extent of producingaccessories or parts for the more complex products which are assembled in their facility. Open molding firms are an important element of North Carolina's economy. Several thousand residents are employed in jobs that are directly related to the production of open molded plastic products. Facilities may range in size from local one or twoman operations to nationally and internationally recognized organizations which employ more than 1,000 people. Most of these firms employ farfewer than 100 peoplein daily plantoperations. Plants are located in all geographic regions of
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