National Emission Standards for Hazardous Air Pollutant Emissions >From the Production of Acrylonitrile Butadiene Styrene (ABS) Resin, Styrene Acrylonitrile (SAN) Resin, Methyl Methacrylate Acrylonitrile Butadiene Styrene (MABS) Resin, Methyl Methacrylate Butadiene Styrene (MBS) Resin, Polystyrene Resin, Poly (Ethylene Terephthalate) (PET) Resin, and Nitrile Resin (Group IV Polymers and Resins)

Note: EPA no longer updates this information, but it may be useful as a reference or resource.

[Federal Register: March 29, 1995]
[[Page 16091]]

ENVIRONMENTAL PROTECTION AGENCY
40 CFR Part 63
[AD-FRL-5175-9]
RIN 2060-AE37

National Emission Standards for Hazardous Air Pollutant Emissions
>From the Production of Acrylonitrile Butadiene Styrene (ABS) Resin,
Styrene Acrylonitrile (SAN) Resin, Methyl Methacrylate Acrylonitrile
Butadiene Styrene (MABS) Resin, Methyl Methacrylate Butadiene Styrene
(MBS) Resin, Polystyrene Resin, Poly (Ethylene Terephthalate) (PET)
Resin, and Nitrile Resin (Group IV Polymers and Resins)

AGENCY: Environmental Protection Agency (EPA).
ACTION: Proposed rule and notice of public hearing.

-----------------------------------------------------------------------

SUMMARY: The proposed rule would reduce emissions of organic hazardous
air pollutants (HAP) from existing and new facilities that manufacture
one or more of the following Group IV polymers and resins:
Acrylonitrile butadiene styrene (ABS) resin, styrene acrylonitrile
(SAN) resin, methyl methacrylate acrylonitrile butadiene styrene (MABS)
resin, methyl methacrylate butadiene styrene (MBS) resin, polystyrene
resin, poly (ethylene terephthalate) (PET) resin, and nitrile resin.
The EPA is in the process of developing standards for a wide range of
types of polymer and resin production facilities. The polymers and
resins covered by this proposed rule are thermoplastics, and with two
exceptions, use styrene as the dominant feedstock. These thermoplastics
are basically intermediate products used to produce automotive plastic
parts, appliances and appliance parts, housewares, polyester fibers,
packing and containers, soft drink bottles, and toys. In the production
of thermoplastics, a variety of organic HAP are used as monomers or are
created as by-products. The organic HAP emitted by the facilities
covered by this proposed rule include styrene, acrylonitrile,
butadiene, ethylene glycol, methanol, acetaldehyde, and dioxane. Some
of these pollutants are considered to be mutagens and carcinogens, and
all can cause reversible or irreversible toxic effects following
exposure. The proposed rule is estimated to reduce organic HAP
emissions from existing facilities by 11,750 megagrams per year (Mg/
yr). The emission reductions achieved by these standards, when combined
with the emission reductions achieved by other similar standards, will
achieve the primary goal of the Clean Air Act (Act) as amended in 1990,
which is to ``enhance the quality of the Nation's air resources so as
to promote the public health and welfare and the productive capacity of
its population''.

The proposed rule implements section 112(d) of the Act, which
requires the Administrator or Administrator's designee, hereafter
referred to as Administrator, to regulate emissions of HAP listed in
section 112(b) of the Act. The intent of this rule is to protect the
public by requiring the maximum degree of reduction in emissions of
organic HAP from new and existing major sources, taking into
consideration the cost of achieving such emission reduction, and any
non-air quality, health and environmental impacts, and energy
requirements.

Under today's action, the EPA is also proposing to revise subpart
DDD of 40 CFR part 60 by removing all references to polystyrene and PET
facilities contained therein. This proposed action is being taken
because today's proposed rule would supersede the requirements
specified in subpart DDD of 40 CFR part 60 for polystyrene and PET
facilities.

Finally, under today's action, the EPA is proposing to add nitrile
resin production to the source category list under section 112(c) of
the Act and to the source category schedule under section 112(e) of the
Act with a promulgation date no later than November 15, 2000.

DATES: Comments. Comments must be received on or before May 30, 1995.
Public Hearing. If anyone contacts the EPA requesting to speak at a
public hearing by April 19, 1995, a public hearing will be held on
April 28, 1995 beginning at 10 a.m. Persons interested in attending the
hearing should call Ms. Marguerite Thweatt at (919) 541-5607 to verify
that a hearing will be held.

Request to Speak at Hearing. Persons wishing to present oral
testimony must contact the EPA by April 19, 1995 by contacting Ms.
Marguerite Thweatt; Organic Chemicals Group, (MD-13), U. S.
Environmental Protection Agency, Research Triangle Park, North Carolina
27711, telephone number (919) 541-5607.

ADDRESSES: Comments. Comments should be submitted (in duplicate, if
possible) to: Air Docket Section (LE-131), Attention: Docket No. A-92-
45, U.S. Environmental Protection Agency, 401 M Street SW., Washington,
DC 20460. The EPA requests that a separate copy also be sent to the
contact person listed below. The public hearing, if required, will be
held at the EPA's Office of Administration Auditorium, Research
Triangle Park, North Carolina.

The docket is located at the above address in room M-1500,
Waterside Mall (ground floor), and may be inspected from 8 a.m. to 4
p.m., Monday through Friday; telephone number (202) 382-7548. A
reasonable fee may be charged for copying docket materials.

FOR FURTHER INFORMATION CONTACT: For information concerning the
proposed rule, contact Mr. Leslie Evans at (919) 541-5410, Organic
Chemicals Group, Emission Standards Division (MD-13), U.S.
Environmental Protection Agency, Research Triangle Park, North Carolina
27711.

SUPPLEMENTARY INFORMATION: The proposed regulatory text is not included
in this Federal Register document, but is available in Docket No. A-92-
45, on the Technology Transfer Network (TTN), or from the EPA contact
person designated in this notice. The TTN, EPA's electronic bulletin
board, provides information and technology exchange in various areas of
air pollution control. The service is free, except for the cost of a
telephone call. Dial (919) 541-5742 for up to a 14,400 bps modem. If
more information on the TTN is needed, call the HELP line at (919) 541-
5384.

In addition to the proposed regulatory text, the Basis and Purpose
Document, which contains the rationale for the various components of
the standard, is available in the docket (Docket No. A-92-45, Category
II-A), and on the TTN. This document is entitled Hazardous Air
Pollutant Emissions From Process Units in the Thermoplastics
Manufacturing Industry--Basis and Purpose Document for Proposed
Standards, March 1995, and has been assigned document number EPA-453/R-
95-004a.

Other materials related to this rulemaking, including technical
memoranda, are available for review in the docket. Some of these
memoranda have been compiled into a single document, the Supplementary
Information Document (SID), to allow interested parties more convenient
access to the information. The SID is available in the docket (Docket
No. A-92-45, Category II-A) and from the EPA Library by calling (919)
541-2777. The document is entitled Hazardous Air Pollutant Emissions
>From Process Units in the Thermoplastics Manufacturing Industry--
Supplementary Information Document for Proposed Standards, March 1995,
and has been assigned document number EPA-453/R-95-003a.
The information presented in this preamble is organized as follows:

I. List of Affected Source Categories

II. Background

A. Summary of Considerations Made in Developing This Rule
B. Regulatory Background

III. Authority for National Emission Standards for Hazardous Air
Pollutants (NESHAP) Decision Process

A. Source of Authority for NESHAP Development
B. Criteria for Development of NESHAP
IV. Summary of Proposed Standards

A. Source Categories To Be Regulated
B. Relationship to Other Rules

C. Pollutants To Be Regulated

D. Affected Emission Points

E. Format of the Standards

F. Proposed Standards

G. Compliance and Performance Test Provisions and Monitoring
Requirements

H. Recordkeeping and Reporting Requirements
V. Solicitation of Comments

VI. Summary of Environmental, Energy, Cost, and Economic Impacts
A. Facilities Affected by These NESHAP
B. Primary Air Impacts

C. Non-Air Impacts [[Page 16092]]

D. Energy Impacts

E. Cost Impacts

F. Economic Impacts

VII. Administrative Requirements

A. Public Hearing

B. Docket

C. Executive Order 12866

D. Enhancing the Intergovernmental Partnership Under Executive
Order 12875

E. Paperwork Reduction Act

F. Regulatory Flexibility Act

G. Miscellaneous

I. List of Affected Source Categories

Section 112 of the Act requires that the EPA evaluate and control
emissions of HAP. The control of HAP is achieved through promulgation
of emission standards under sections 112(d) and 112(f) of the Act and
work practice and equipment standards under section 112(h) of the Act
for categories of sources that emit HAP. On July 16, 1992, the EPA
published an initial list of major and area source categories to be
regulated, as required under section 112(c) of the Act. Included on
that list were major sources emitting HAP from ABS, SAN, MABS, MBS,
polystyrene, and PET. Nitrile resin production is being added to the
source category list under section 112(c) of the Act because, based on
information obtained during the gathering of HAP emission data for this
proposed rule, the one facility identified as producing nitrile resins
was determined to be a major source. Further, the EPA decided to
include nitrile resin production under today's proposed rule because of
similarities in process operations, emission characteristics, and
control device applicability and costs with the various styrene-based
resin source categories. For the purpose of this notice, these seven
polymer and resin source categories are collectively referred to as the
Group IV polymers and resins or the Group IV thermoplastics.
The EPA identified a total of 66 facilities producing one or more
of the Group IV thermoplastics. Twenty facilities were identified that
produced thermoplastics using multiple processes and, thus, fall within
multiple subcategories. For example, six of the PET facilities use both
the continuous terephthalic acid (TPA) process and the continuous
dimethyl terephthalate (DMT) process.

All of the facilities considered in the analysis supporting today's
proposed rule are believed to be major sources according to the 1990
Amendments criterion of emitting or of having the potential to emit 10
tons per year (tons/yr) of any one HAP or 25 tons/yr of combined HAP.
(A year, for the purposes of compliance with this rule, is any
consecutive twelve month period or 365 rolling days). The proposed rule
would apply to all major sources that produce any of the seven
thermoplastics identified in this notice. Area sources would not be
subject to this proposed rule.

In developing the background information to support the proposed
rule, the EPA chose to subcategorize four of the seven source
categories for purposes of analyzing the maximum achievable control
technology (MACT) floors and developing regulatory alternatives. A
source category was subcategorized to account for major differences in
production methods, raw material usage, or both. Table 1 summarizes the
subcategories developed.

Table 1.--Subcategorization of Group IV Polymers and Resinsa

Number of
subcategoryb
Continuous emulsion.......... 2
Batch emulsion............... 4
Batch suspension............. 2
Batch latex.................. 1
Batch........................ 2
ASA/AMSAN.................... 1
Batch........................ 11
EPS.......................... 7
TPA, batch................... 1
DMT, continuous.............. 10
DMT, batch................... 10
shown in this table.
facilities within a source category.
ASA=acrylonitrile styrene acrylate.
AMSAN=alpha methyl styrene acrylonitrile.
EPS=expandable polystyrene.
TPA=terephthalic acid.
DMT=dimethyl terephthalate.
Table 2.--Summary of NSPS Pet Standards
Affected Number of end Type of vacuum
Recovery. product OR limit
temperature to +37
deg.F from each
final condenser in
the material
recovery section.
High............ Single.......... ................ (same as above).
Multiple........ ................ (same as above).
Reaction. product.
Steam jets...... 0.02 kg TOC/Mg of
product AND 0.35
percent ethylene
glycol by weight in
the effluent exiting
the vacuum system.
High............ Single.......... Not steam jets.. 0.02 kg TOC/Mg of
product.
Steam jets...... 0.02 kg TOC/Mg of
product AND 0.35
percent ethylene
glycol by weight in
the effluent exiting
the vacuum system.
Multiple........ Not steam jets.. 0.02 kg TOC/Mg of
product.
Steam jets...... 0.02 kg TOC/Mg of
product AND 6.0
percent ethylene
glycol by weight in
the cooling water in
the cooling tower.
Preparation. product.
High............ Single.......... ................ (same as above).
[[Page 16095]]

................ Multiple........ ................ (same as above).
Reaction. product.
Steam jets...... 0.02 kg TOC/Mg of
product AND 0.35
percent ethylene
glycol by weight in
the effluent exiting
the vacuum system.
High............ Single.......... Not steam jets.. 0.02 kg TOC/Mg of
product.
Steam jets...... 0.02 kg TOC/Mg of
product AND 0.35
percent ethylene
glycol by weight in
the effluent exiting
the vacuum system.
Multiple........ Not steam jets.. 0.02 kg TOC/Mg of
product.
Steam jets...... 0.02 kg TOC/Mg of
product AND 6.0
percent ethylene
glycol by weight in
the cooling water in
the cooling tower.
Key:
DMT = dimethyl terephthalate.
TPA = terephthalic acid.
Uncontrolled
emission rate,
producta
terephthalate process.
terephthalic acid process.
Polymerization Reaction... 3.92c,f,h
resale.
bEmission rate applies to continuous emissions only.
dIncludes emissions from the cooling water tower.
terephthalate).
terephthalate).
gSee footnote h.
esterifiers).
63 and Subpart DDD of 40 CFR Part 60
Type of emission point
Subcategory Heat exchange
Storage vessels Process vents Equipment leaks Wastewater systems
emulsion. exchange
systems.
mass. Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
compliant flare.
emulsion. Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
compliant flare.
suspension. Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
compliant flare.
Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
compliant flare.
Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
compliant flare.
Vents: MACT Floor exchange
Batch Process Vents: systems.
90 percent reduction
or compliant flare.
Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
compliant flare.
Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
compliant flare.
exchange
systems.
continuous. Vents from material exchange
recovery: same as systems.
subpart DDD Other
Continuous Process
vents: HON Batch
Process Vents: 90
percent reduction or
compliant flare.
batch. Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
compliant flare.
polystyrene. Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
compliant flare.
continuous. Vents from raw wastewater water allowed
material preparation (including all in vacuum
and polymerization vacuum system system contact
reaction sections: generated condensers. HON
same as subpart DDD wastewater).a. for heat
Other Continuous exchange
Process vents: HON systems.
Batch Process Vents:
90 percent reduction
or compliant flare.
DMT, batch. Vents: HON Batch wastewater water allowed
Process Vents: 90 (including all in vacuum
percent reduction or vacuum system system contact
compliant flare. generated condensers. HON
wastewater).. for heat
exchange
systems.
continuous. Vents from material wastewater water allowed
recovery and (including all in vacuum
polymerization vacuum system system contact
reaction sections: generated condensers. HON
same as subpart DDD wastewater).a. for heat
Other Continuous exchange
Process vents: HON systems.
Batch Process Vents:
90 percent reduction
or compliant flare.
[[Page 16099]]

Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
compliant flare.
provisions (subpart G) shall be considered Group 1 and are required to be controlled.
Subpart DDD of 40 CFR Part 60
Type of emission point
Subcategory Heat exchange
Storage vessels Process vents Equipment leaks Wastewater systems
emulsion. Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
a compliant flare.
mass. Alternative 2a. Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
a compliant flare.
emulsion. Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
a compliant flare.
suspension. Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
a compliant flare.
Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
a compliant flare.
Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
a compliant flare.
Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
a compliant flare.
Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
a compliant flare.
exchange
systems.
exchange
systems.
continuous. Vents from material exchange
recovery: Same as systems.
subpart DDD Other
Continuous Process
Vents: HON Batch
Process Vents: 90
percent reduction or
a compliant flare.
batch. Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
a compliant flare.
polystyrene. Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
a compliant flare.
continuous. Vents from raw wastewater water allowed
material preparation (including all in vacuum
and polymerization vacuum system system contact
reaction sections: generated condensers. HON
same as subpart DDD wastewater).b. for heat
Other Continuous exchange
Process Vents: HON systems.
Batch Process Vents:
90 percent reduction
or a compliant flare.
[[Page 16100]]

DMT, batch. Vents: HON Batch wastewater water allowed
Process Vents: 90 (including all in vacuum
percent reduction or vacuum system system contact
a compliant flare. generated condensers. HON
wastewater).b. for heat
exchange
systems.
continuous. Vents from material wastewater water allowed
recovery and (including all in vacuum
polymerization vacuum system system contact
reaction sections: generated condensers. HON
same as subpart DDD wastewater).b. for heat
Other Continuous exchange
Process Vents: HON systems.
Batch Process Vents:
90 percent reduction
or a compliant flare.
Vents: HON Batch exchange
Process Vents: 90 systems.
percent reduction or
a compliant flare.
provisions (subpart G) shall be considered Group 1 and are required to be controlled.
eq>1.9 psia and 2. external floating
capacity <gr-thn- roof; or
eq>20,000 gallonsc. 3. an external
floating roof
converted to an
internal floating
roof; or
4. a closed vent
system and control
device.
If vapor pressure <gr-
thn-eq>11.1 psia: a
closed vent system
and control deviced
thn-eq>10,200 gallons.
Styrene/acrylonitrile 98 percent reduction.
for capacities <gr-thn-
eq>1,000 gallons.
Acrylonitrile for 98 percent reduction.
capacities <gr-thn-
eq>20,000 gallons.
Any other chemical:.... If vapor pressure is
Vapor pressure <gr- <11.1 psia:
thn-eq>0.75 psia and 1. fixed roof and
capacity <gr-thn- internal floating
eq>40,000 gallonsc. roof; or
Vapor pressure <gr- 2. external floating
thn-eq>1.9 psia and roof; or
capacity <gr-thn- 3. an external
eq>20,000 gallonsc. floating roof
converted to an
internal floating
roof; or
4. a closed vent
system and control
device.
If vapor pressure <gr-
thn-eq>11.1 psia: a
closed vent system
and control device0d
acrylonitrile storage of control).
vessels <gr-thn-
eq>3,500 gallons.
psia and capacity <gr- of control)
thn-eq>20,000 gallons.
Vapor pressure <gr-thn-
eq>2.08 psia and
capacity <gr-thn-
eq>10,000 but less
than 20,000 gallons.
bRequired for Group 1 storage vessels only.
the HON.
dThe level of control is the same as the HON.
KEY: AMST = alpha methyl styrene.

[[Page 16101]]
eq>1.9 psia and 2. external floating
capacity <gr-thn- roof; or
eq>10,000 gallonsc. 3. an external
floating roof
converted to an
internal floating
roof; or
4. a closed vent
system and control
device.
If vapor pressure <gr-
thn-eq>11.1 psia: a
closed vent system
and control deviced.
and capacity <gr-thn- of control).
eq>10,000 gallons and
<12,000 gallons.
Styrene for capacities
<gr-thn-eq>12,000
gallons.
VP <gr-thn-eq> 0.0782
psia and <gr-thn-
eq>12,000 gallons.
to <0.1 psia and
capacity <gr-thn-
eq>600,000 gallons.
VP <gr-thn-eq> 0.1 to (same as the HON level
<1.45 psia and <gr-thn- of control).
eq>40,000 gallons.
VP <gr-thn-eq> 1.45 to 98 percent reduction.
<14.7 psia and
capacity <gr-thn-
eq>8,000 to <40,000
gallons.
thn-eq>10,200 gallons.
Styrene/acrylonitrile 98 percent reduction.
for capacities <gr-thn-
eq>1,000 gallons.
Acrylonitrile for 98 percent reduction.
capacities <gr-thn-
eq>20,000 gallons.
Any other chemical:.... (same as the HON level
Vapor pressure <gr-thn- of control).
eq>0.1 psia and
capacity <gr-thn-
eq>40,000 gallonsc.
Vapor pressure <gr-thn-
eq>1.9 psia and
capacity <gr-thn-
eq>10,000 gallonsc.
acrylonitrile storage of control).
vessels <gr-thn-eq>
3,500 gallons.
eq> 0.78 psia and of control).
capacity <gr-thn-eq>
29,000 gallons.
Vapor pressure <gr-thn-
eq> 0.09 psia and
capacity <gr-thn-eq>
12,000 gallons but
less than 29,000
gallons.
Vapor pressure <gr-thn-
eq> 1.1 psia and
capacity <gr-thn-eq>
5,170 gallons but less
than 12,000 gallons.
bRequired for Group 1 storage vessels only.
those in the HON.
d The level of control is the same as in the HON.
KEY: CM = continuous mass; VP = vapor pressure.
Table 8.--Summary of Proposed Process Vent Applicability Criteria for Existing Facilities
Process vents Subcategory Applicability criteria
Continuous Unit Operations........ All (except as specified below)..................... TREa <ls-thn-eq> 1.
MBS................................................. TREa <ls-thn-eq> 3.7.
ASA/AMSAN.................................... None. All vents are required to be controlled.
Polystyrene, continuous: material recovery.......... None. Must meet standard.
PET/DMT, continuous: material recovery.............. 0.12 kg TOC per Mg productb.
PET/DMT, continuous: polymerization reaction........ None. Must meet standard.
PET/TPA, continuous: raw material preparation and None. Must meet standard.
polymerization reaction.
equationc
----------------------------------------------------
Low......... (0.00437) AE--51.6d.
Moderate.... (0.00187) AE--14.0d.
High........ (0.00081) AE--8.5d.
TRE coefficients for existing and new process vents.
bIf emissions from the described process vents are greater than the applicability criteria, control is required.
required to be controlled.
dAE = annual emissions in kilograms per year.
Table 9.--Summary of Proposed Process Vent Applicability Criteria for New Facilities
Process vents Subcategory Applicability criteria
Continuous Unit Operations............ All (except as specified below)......................... TREa <ls-thn-eq> 1
SAN, batch.............................................. None. Must meet standard.
ASA/AMSAN....................................... None. All vents are required to be controlled.
Polystyrene, continuous: material recovery.............. None. Must meet standard.
PET/DMT, continuous: material recovery and None. Must meet standard.
polymerization reaction.
PET/TPA, continuous: Raw material preparation and None. Must meet standard.
polymerization reaction.
equationb
------------------------------------------------------
Low......... (0.00437) AE--51.6c.
Moderate.... (0.00187) AE--14.0c.
High........ (0.00081) AE--8.5c.
SAN, batch................................. None................... Must meet standard.
TRE coefficients for existing and new process vents.
required to be controlled.
cAE=annual emissions in kilograms per year.
10,000 ppmw. and
or for a subset of organic
wastewater streams and control is required.
c VOHAP=volatile organic HAP.

[[Page 16108]]
Table 11.--Organic HAP Emissions and Emission Reductions
Existing sources New sources
-------------------------------------------------------------------------
Subcategory Emission Emission
Baseline, reduction, Percent Baseline, Reduction, Percent
Mg/yr Mg/yr reduction Mg/yr Mg/yr reduction
ABS, continuous mass.............. 240 190 80 %
ABS, batch emulsion............... 500 56 11 %
ABS, batch suspension............. 15 5 33 %
SAN, continuous................... 110 65 60 %
SAN, batch........................ 35 13 37 %
MBS............................... 190 130 68 %
Polystyrene, continuous........... 1,440 1,060 74 %
--No new growth projected, therefore no impacts expected.

[[Page 16109]]
Table 12.--Summary of Cost Impacts
Existing sources New sources
---------------------------------------------------------------------------------
Total Total
costs, effectiveness capital costs, Effectiveness
cost, $1000 $1000/yr ($/Mg) cost, $1000 $1000/yr ($/Mg)
--No new growth projected, therefore no impacts expected.

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