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II.0  SUMMARYOFINITIALPHASEANDNEXTSTEPSFORMACT(#(# @%DEVELOPMENT   \  Background  n   UnderSection112(d)oftheCleanAirAct(theAct),theU.S.EnvironmentalProtectionAgency(EPA)isdevelopingnationalemissionstandardsforhazardousairpollutants(NESHAP)forthemetalcoilsurfacecoatingsourcecategory.TheEPAisrequiredtopublishfinalemissionstandardsforthemetalcoilsurfacecoatingsourcecategorybyNovember15,2000.  TheActrequiresthattheemissionstandardsfornewsourcesbenolessstringentthantheemissioncontrolachievedinpracticebythebestcontrolledsimilarsource.Forexistingsources,theemissioncontrolcanbelessstringentthantheemissioncontrolfornewsources,butitmustbenolessstringentthantheaverageemissionlimitationachievedbythebestperforming12percentofexistingsources(forwhichtheEPAhasemissionsinformation).Incategoriesorsubcategorieswithfewerthan30sources,emissioncontrolforexistingsourcesmustbenolessstringentthantheaverageemissionlimitationachievedbythebestperforming5sources.TheNESHAParecommonlyknownasmaximumachievablecontroltechnology(MACT)standards. h+&8   TheMACTstandardsdevelopmentforthemetalcoilsurfacecoatingindustrybeganwithaCoatingRegulationsWorkshopforrepresentativesofEPAandinterestedstakeholdersinApril1997andcontinuesasacoordinatedefforttopromoteconsistencyandjointresolutionofissuescommonacrossninecoatingsourcecategories. #  1      ׀ThefirstphasewasoneinwhichEPAgathers & readilyavailableinformationabouttheindustrywiththehelpofrepresentativesfromtheregulatedindustry,Stateandlocalairpollutionagencies,smallbusinessassistanceproviders,andenvironmentalgroups.Thegoalsofthefirstphaseweretoeitherfullyorpartially:2c  2cR"0    Understandthecoatingprocess2cRm݌ (#(# Ќ  2c  2c"0    Identifytypicalemissionpointsandtherelativeemissionsfromeach2c݌"r (#(# Ќ  2c  2c"0    Identifytherange(s)ofemissionreductiontechniquesandtheireffectiveness2c݌ (#(# Ќ  2c  2c"0    Makeaninitialdeterminationonthescopeofeachcategory2c݌6(#(# Ќ  2c  2cn"0    Determinetherelationshipsandoverlapsofthecategories2cn݌H(#(# Ќ  2c  2c4"0    Locateasmanyfacilitiesaspossible,particularlymajorsources2c4O݌(#(# Ќ  2c  2c"0    Identifyandinvolverepresentativesforeachindustrysegment2c݌ \(#(# Ќ  2c  2c"0    Completeinformationalsitevisits2c݌n(#(# Ќ  2c  2cy"0    Identifyissuesanddataneedsanddevelopaplanforaddressingthem2cy݌  (#(# Ќ  2c  2cJ"0    Developquestionnaire(s)foradditionaldatagatheringand2cJe݌2"(#(# Ќ  2c  2c"0    Documentresultsofthefirstphaseofregulatorydevelopmentforeachcategory.2c+݌$(#(# Ќ    TheindustrymembersthatparticipatedinthestakeholderprocessincludedmembersoftheNationalCoilCoatersAssociation(NCCA),membersoftheAluminumAssociation(AA),representativesofindividualcompaniesintheregulatedindustry,andrepresentativesofcompaniesthatsupplycoatingstotheindustry.StatesthatparticipatedintheprocessincludedFlorida,Illinois,andPennsylvania.Inaddition,datawereobtainedfromseveralotherStatesincludingGeorgia,Michigan,California,WestVirginia,Indiana,andOhio.TheU.S.EPAwas B'"2 representedbyEPARegion5,theEPAOfficeofAirQualityPlanningandStandards(EPA/OAQPS),theEPAOfficeofEnforcementandComplianceAssurance(OECA),theEPAOfficeofPollutionPreventionandToxicSubstances(OPPTS),andanEPASmallBusinessOmbudsman.  Informationpresentedinthisdocumentwascollectedfromavarietyofsources.DatacollectionbeganwithareviewofinformationcollectedbytheAgencyduringdevelopmentoftheNewSourcePerformanceStandard(NSPS).Atotaloffourmeetingswereheldinvolvingrepresentativesofallstakeholdersforthepurposeofinformationexchangeandtheidentificationofpotentialdatasources.Informationwasalsocollectedduringsitevisitstofourmetalcoilsurfacecoatingfacilitiesthatoperatecoilcoatinglineswithawiderangeofproductionrates.AteleconferencemeetingwasalsoheldwiththeregulatorysubgroupwhichismadeupofEPAandStaterepresentatives.AlistofparticipantsinthedatacollectioneffortispresentedinAppendixAofthisdocument.  TheinformationsummarizedinthisdocumentcanbeusedbyStatesthatmayhavetomakecasebycaseMACTdeterminationsunderSections112(g)or112(j)oftheAct.Theinitialphaseoftheregulatorydevelopmentfocusedprimarilyonfamiliarizingtheprojectteamwithmetalcoilsurfacecoatingoperations,identifyingplantsthatmakeuptheindustry,andinvestigatingtheemissioncontroltechnologiesinusebyplantsintheindustry.Thisdocumentrepresentstheconclusionofthatphaseofruledevelopment.  ThisdocumentincludesadescriptionoftheemissioncontroltechnologiesEPAidentifiedthatarecurrentlyusedinpracticebytheindustryandthatcouldserveasthebasisofMACT.Withintheshorttimeframeintendedforthisinitialphase,however,onlylimiteddatawerecollected.TheinformationsummarizedinthismemorandumwascollectedpriortoJuly,1998.Additionalinformationwillbecollectedandconsideredbeforethemetalcoilsurfacecoatingstandardsarepromulgated.  Duringthenextphase,EPAwillcontinuetobuildontheknowledgegainedtodateandproceedwithmorefocusedinvestigationanddataanalyses.Wewillalsocontinueoureffortstocoordinatecrosscuttingissues.Wewillcontinuetoidentifytechnicalandpolicyissuesthatneedtobeaddressedintherulemakingandenlistthehelpofthestakeholdersinresolvingthoseissues. h+&8  III.0  INDUSTRYCHARACTERIZATION (#(#  & , SummaryofExistingFederalRequirement/StateRequirements  b  FederalRegulations .FederalregulationsthatapplytometalcoilsurfacecoatingincludeaNew t ',W#SourcePerformanceStandard(NSPS)under40CFRPart60,SubpartTT,"StandardsofPerformanceforMetalCoilSurfaceCoating",whichisapplicabletoeachprimecoatoperation,eachfinishcoatoperation,andeachprimeandfinishcoatoperationcombinedwhenthefinishcoatisappliedwetonwetovertheprimecoatandbothcoatingsarecuredsimultaneously.ThecoilcoatingNSPSregulatesemissionsofvolatileorganiccompounds(VOC)andcontainsemissionlimitsinseveralforms.Ifanemissioncontroldeviceisusedonacontinuousbasis,VOCemissionsarelimitedto0.14kilogramsperliter(kg/l)ofcoatingssolidsappliedortheowneror (x  operatormustreduceemissionsby90percentforeachaffectedfacilityforeachcalendarmonth.Ifanemissioncontroldeviceisnotused,VOCemissionsarelimitedto0.28kg/lforeachaffected < facilityforeachcalendarmonth.Ifanemissioncontroldeviceisusedintermittently,VOCemissionsarelimitedtoavaluebetween0.14kg/l(ora90percentreduction)and0.28kg/l.The  NSPSwasproposedonJanuary5,1981andpromulgatedonApril26,1982.AllcoilcoatinglinesthatweremodifiedorbeganconstructionorreconstructionafterJanuary5,1981mustbeincompliancewiththeNSPS.AtleastelevenplantsaresubjecttothisNSPS.  InadditiontotheNSPS,EPAalsopublishedaControlTechniquesGuideline(CTG)documentthatcoversmetalcoilsurfacecoatingoperations.Thatdocument,entitled"ControlofVolatileOrganicEmissionsfromExistingStationarySourcesVolumeII:SurfaceCoatingofCans,Coils,Paper,Fabrics,Automobiles,andLightDutyTrucks",waspublishedinMay,1977,andwasintendedasguidanceforStatesinthedevelopmentofStateImplementationPlans(SIP).TheCTGdefinedamodelofreasonablyavailablecontroltechnology(RACT)forcoilcoatingoperations,consistingofthecoatingapplicationstation,thecuringoven,andthequenchareaas0.31kg/lofappliedcoating(minuswater).Thislimitisbasedontheuseofwaterbornecoatings %6!0 ortheuseofcoatingsthatcontain25volumepercentsolidsandanemissioncontrolsysteminwhichatleast90percentoftheemissionsarecapturedandroutedtoacontroldevice (incinerator)whichachievesatleasta90percentemissionreduction.  *\%6  StateRegulations .TheemissioncontrolrequirementsthattheStatesimposeoncoilcoating   operationsvarysubstantiallyamongthedifferentStateImplementationPlans(SIPs).TheSIPsfor24StatesincludetheCTGRACTlimitof0.31kg/lofcoatingexcludingwaterandexempt t solvents.InnineotherStates,theSIPrequiresreductionsequaltothatrequiredbytheNSPS.CaliforniahasseparateemissionlimitsforeachofitsAirQualityManagementDistricts.Mostdistrictsimposeanemissionlimitof0.20kg/lofcoatings(lesswaterandexemptsolvents).One    districtrequiresanoverallreductionof85percent.TwoStateshaveemissionlimitsof0.48kg/l  L  ofcoatingsolidsandoneotherStatehasalimitof0.20kg/lofcoatingexcludingwaterand ^  exemptsolvents.TheremainingStatesdonothaverulestargetedspecificallyforcoilcoatingoperations.Inadditiontoemissionlimitsoncoilcoatingoperations,severalStatesalsohaverestrictionsoncleanupandsurfacepreparationsolventsandthehandlingofcleanuprags.Examplesincluderestrictionsonthequantityofcleaningsolventused,limitsontheVOCcontentand/orvaporpressureofcleaningsolvents,requirementsforcleaninginenclosedareas,andstorageofcleanupragsinclosedcontainers.TableIII1presentsalistingofStaterequirementsformetalcoilsurfacecoatingoperations.@xx TableIII1.SummaryofStateRegulationsforMetalCoilSurfaceCoating      X4vXXX*w $ddd Xdd Xdd X(#(#w,wd ,d , -d ,/ dd +  ( $ ( gX X4vState/Area * H% *Numericallimit 'H& 'AlternateorAdditionalguidance 'H'  'Alabama  P( 0.31kg/l,excludingwaterand/orexemptsolvents  v +   P, # X4vX g5# gX X4v#g gd4#Alaska  !- None  !.  gg# X4vX g 7#  !/  gX X4v#g g7#Arizona  N#0 40CFR60SubpartTT gg# X4vX g7#  N#1   N#2  gX X4v#g gR8#Arkansas  $ 3 None gg# X4vX g8#  $ 4   $ 5  gX X4v#g g(9#California  N&!6 Nostatewidestandardfound gg# X4vX g9#  N&!7   N&!8  gX X4v#g g:#  '#9 BayArea  '#: 0.20kg/l,excludingwaterand/orexemptsolidsOR0.12kg/lifa90%efficientcontroldevicebeingused  *j%? Surfacepreparationandcleanupsolventalsoregulated:e.g.,solventmusthave<0.20kg/lforsurfaceprep;closedcontainersfordisposalofrags gg# X4vX g:#  @+&F  gX X4v#g g <#  ld MojaveDistrict   Shownbycoatingtype,85%reductionrequired    gg# X4vX ga<#  ld  gX X4v#g g=#    PlacerCounty     0.20kg/literORcontrolledbysystemwith85%overallefficiencyANDcleanupmaterialmustnotexceed0.200kgVOC/lor45mmHGvaporpressureorcleanupareatotallyenclosed;cleaning/surfaceprepmaterialandcleanupragsstoredinclosedcontainers    Coatingmustbeappliedwithoneofthefollowing:Electrostaticapplicationoperatedinaccordancewiththemanufacturer'srecommendations.;Flowcoat;Rollcoat;Dipcoat;Squeegeepad;High-volumelow-pressure(HVLP)spraygunoperatedinaccordancewiththemanufacturer'srecommendations. gg# X4vX gu=#   ( #X4vXX X4v&@#  LD ) gXX4vSan LD * Diego  rj , 0.20kg/literforletterpresscoatingsandothercoatingstobeachievedwithcompliantcoatingsorcontrolswith85%overallefficiency  3 Cleaningrestrictions:(i)cleaningmaterialmustcontain<0.20kgVOC/lmaterial;or(ii)materialhasaninitialboilingpointof>190oC;or(iii) 8 solventhastotalVOCvaporpressure<20mmHg;or(iv)cleaningmaterialisflushed/rinsedthroughapplicationequipmentinacontainedmannerthatwillminimizeevaporationintotheatmosphere;or(v)applicationequipment/partsarecleanedinaclosedcontainerandthecleanedequipmentorequipmentpartsaredrainedtothecontaineruntildrippingceases;or(vi)systemtotallyenclosed;or(vii)Thecombinedusageofcleaningmaterialsislessthan10gallonseachcalendarmonth gg :!2N   `"XP #g gCD#  #Q SanJoaquin  $T 0.20kg/l,tobeachievedbylowVOCtechnologyorbya90%overallcontrolORVOCemissionstoatmosphere<0.12kg/lcoatingasapplied  *'"![ Alternative:anycoatingwithatmosphericVOCemissionsequivalenttousingacoatingcontaining<0.23gVOCpergramofnonvolatilecoatingappliedinsheetbasecoatingoperation;6  #g g1T# gg0.31kg/l,excludingwaterand/orexempt >6  solvents#g gT# gg  d\    >6  #g gGU#Iowa    40CFR60SubpartTT     gg    #g gU#Kansas    None     gg    #g gV#Kentucky  ld 40CFR60SubpartTT  ld Under401KAR61:130,nodischargeintotheatmosphereofmorethan15%byweightoftheVOCsnetinputintotheaffectedfacility gg  $ #g gW#Louisiana  % 0.31kg/l,excludingwaterand/orexemptsolvents  6.(  gg  ) #g gvX#Maine  * None  +   , Maryland  - 0.31kg/l,excludingwaterand/orexemptsolvents   0   1 Massachusetts  d\2 0.48kg/lofcoatingsolids  d\3   d\4 Michigan  5 0.31kg/l,excludingwaterand/orexemptsolvents   8  gg  9 #g gsZ#Minnesota  :"2: 40CFR60SubpartTT  :"2;  gg  :"2< Missouri  #= #g g[# gg0.31kg/l,excludingwaterand/orexempt #> solvents#g g[# gg  $@   #A #g g\#Mississippi  & B None  & C  gg  & D #g g\#Montana  h'`!E None  h'`!F  gg  h'`!G #g gY]#Nebraska  ("H 40CFR60SubpartTT  ("I  gg  ("J #g g]#Nevada  *$K 40CFR60SubpartTT  *$L  gg  *$M New Hampshire   #g g^# gg0.31kg/l,excludingwaterand/orexempt ld solvents#g g3_# gg     ld NewJersey   #g g_# gg0.31kg/l,excludingwaterand/orexempt   solvents#g gL`# gg         #g g`#NewMexico  h `  None  h `  gg  h ` #g g~a#NewYork    0.31kg/l,excludingwaterand/orexemptsolvents     gg    #g g?b#NorthCarolina  >6  0.48kg/lofcoatingsolids  >6  0.31kg/lexcludingwaterandexemptcompoundsifairpollutionequipmentisinstalled gg  d\  #g gFc#NorthDakota    40CFR60SubpartTT     gg    #g gc#Ohio    0.31kg/l,excludingwaterand/orexemptsolvents  :2  0.48kg/lofcoatingsolidsifacontrolsystemisemployed gg  :2# #g gd#Oklahoma  $ Limitationsareplacedonpoundsoforganicsolventpergallonofpaint(lesswater)basedonpaintchemistry.Otherlimitationsonpoundsoforganicsolventpergallonofpaint(lesswater)arebasedonwhetherthepaintisairorforcedairdry,clearcoat,extremeperformance,powder,orother.  3  gg  4 #g gf#Oregon  5 40CFR60,SubpartTT,asadoptedunderOAR340-25-535   8  gg  9 #g geg#Pennsylvania  r!j: 0.31kg/l,excludingwaterand/orexemptsolvents  "=  gg  r!j> RhodeIsland  #? #g g*h#0.31kg/l,excludingwaterand/orexempt #@ solvents gg  %B   #C SouthCarolina  n&f D #g gh#0.31kg/l,excludingwaterand/orexempt n&f E solvents gg  '!G Specifieswaystomeetthislimit:1)lowsolventtechnology;2)incinerationwith90%destruction;3)carbonbedsolventrecovery;4)othersapprovedcasebycase.  )#N #g gi#SouthDakota  8+0%O None  8+0%P  gg  8+0%Q #g gk#Tennessee  ld 0.31kg/l,excludingwaterand/orexemptsolvents   Alternativestandard:Installationofcaptureandcontroldevicewith95%destructionORalternativecalculationmeasuresprescribedbyregulation gg     #g gql#Texas  6 .  0.31kg/l,excludingwaterand/orexemptsolvents  \ T  gg  6 . #g g/m#Utah    None     gg    #g gm#Vermont     None      gg     Virginia  d\  #g gRn#0.31kg/l,excludingwaterand/orexempt d\  solvents gg    Requires reasonableprecautionssuchas1.Theuseofcaptureorcontroldevices;2.Theuseofnon-volatilecleaningmethods;3.Theminimizationofthequantityofvolatileorganiccompoundsusedtocleanlinesofequipment;and4.Theadjustmentofproductionschedulestominimizecoatingchanges. Controltechnologyshouldconsistofoneofthe - following:1.Useofelectrodepositedwaterbornecoatings;2.Useofotherwaterbornecoatings;3.Useofhighsolidscoatings;4.Incineration;or5.Anytechnologyofequalorgreatercontrolefficiencycomparedtotheuseofacoatingcomplyingwiththestatedemissionlimit,providedsuchtechnologyisapproved.  6&. A #g go#Washington  '!B 0.31kg/l,excludingwaterand/orexemptsolvents  ("E  gg  '!F #g gr#WestVirginia   *$G 0.31kg/l,excludingwaterand/orexemptsolvents  2+*%J  gg   *$K #g gws#Wisconsin  ld  0.31kg/l,excludingwaterand/orexemptsolvents    gg  ld #g gMt#Wyoming   40CFR60SubpartTT    gg  8 Note:Theinformationinthistablerepresentstheprimaryemissionlimitsthatapplytometalcoilsurfacecoatingoperationsandothermajorrequirementsspecifictometalcoilsurfacecoating.ItisnotintendedtoconveyallregulatoryprovisionsthatmightbeapplicabletometalcoilsurfacecoatingandsomeStatesmayallowalternativemethodsfordemonstratingcompliance.#g gt#X4vXg & & IndustryProfile  vn  GeneralProcessDescription      Themetalcoilsurfacecoatingsourcecategoryincludesanyfacilityengagedinthe'&vwsurfacecoatingofmetalcoil.Inthisprocess,acoilorrollofuncoatedsheetmetaliscoatedononeorbothsidesandrepackagedasacoilorotherwisehandled.Althoughthephysicalconfigurationoftheequipmentusedincoilcoatinglinesvariesfromoneinstallationtoanother,theindividualoperationsgenerallyfollowasetpattern.Thecoilcoatingprocessbeginswithacoil(orroll)ofbaresheetmetaland,inmostcases,terminateswithacoilofmetalwithadriedandcuredcoatingononeorbothsides.Themetalstripisunrolledfromthecoilattheentrytothecoilcoatinglineandfirstpassesthroughawetsection,wherethemetaliscleanedandmaybegivenachemicaltreatmenttoinhibitrustandpromoteadhesionofthecoatingtothemetalsurface.Insomeinstallations,thewetsectionmayalsocontainanelectrogalvanizingoperationinwhichzincisappliedthroughanelectroplatingprocesstoasteelsubstrate.Afterthemetalstripleavesthewetsection,itissqueegeedandairdriedandthenpassestoacoatingapplicatorstation.  Coatingapplicationstationsmaybeusedtoapplyavarietyofcoatings.Inadditiontoprotectiveordecorativecoatings,adhesivesandprintedpatternsusinginkmayalsobeapplied.Themostprevalentoperationincludestheapplicationofprotectiveanddecorativecoatingstooneorbothsidesofthemetalstripusingrollers.Followingthecoatingapplication,thestrippassesthroughanovenwherethetemperatureisincreasedtothedesiredcuringtemperatureofthecoating.Thestripisthencooledbyawaterspray,airspray,orcombinationofthetwo.Ifthelineisatandemline,thefirstcoatingapplicationisaprimecoatandthemetalstripnextentersanothercoatingapplicatorstationwhereatoporfinishcoatingisappliedbyrollerstooneorboth +x%8 sidesofthemetal.Thestripthenentersasecondovenfordryingandcuringofthetoporfinishcoat.Thisisfollowedbyanothercoolingorquenchstation.Thefinishedmetalstripisthennormallyrewoundintoacoilandpackagedforshipmentorfurtherprocessing.Insomecases,thecoatedmetalstripmaybecutratherthanrerolledintoacoil.Mostmetalcoilsurfacecoatinglineshaveaccumulatorsattheentryandexitthatpermitthestriptomovecontinuouslythroughthecoatingprocesswhileanewcoilismountedattheentryorafullcoilremovedattheexit.Figure1isaschematicdiagramofatypical,tandemcoilcoatingline.  L  TRP'3 Letter Landscape3' '3 Letter Landscape3'Tx?B2.p|0v/ `% #E& 0*$0* 4 *x   TRY3' LetterP'3 Letter Landscape 3' Letter '3 Letter LandscapeT  Forexistingcoilcoatinglines,processingspeedvariesconsiderably,withsomelines  havingprocessingspeedsashighas1,000feetperminute.Thewidthsofthemetalstripvaryfromafewinchesupto6feet,andthicknessmayvaryfromabout0.006inchtomorethan0.15inch.Thelowerthicknessof0.006inchhasbeenconsideredtobethelineofdistinctionbetweenmetalcoilandfoil.However,afewplantshavebeenidentifiedthatprocesscoiledmetalwithathicknessbothaboveandbelow0.006inch.Theprocessingoffoilisconsideredtobepartofthepaperandotherwebsurfacecoatingsourcecategory.Thus,thereisapotentialoverlapbetweencoilcoatingprocessesandfoilcoatingprocesses.AftertheAgencycollectsmoredata,itwillconsidertheneedandapproachesforaddressingthispotentialoverlap. IndustryMakeupandMarkets  "r    TheEPAhasidentifiedmorethan150plantsbelievedtobeoperatingabout200metalcoilsurfacecoatinglines.TheplantdatabasewasdevelopedusinginformationfromseveralsourcesbeginningwiththelistofplantsdevelopedduringtheNSPSbackgroundstudy.ThatlistwasdistributedtotheNationalCoilCoatersAssociation(NCCA)whopassedittoanumberofmembercompaniesforreview.Manyplantssubmittedverificationtotheexistingdataorprovidedupdatedinformationrelatedtoplantsontheoriginallist.Insomecases,plantswerefoundtobenolongerinoperationoroperatingunderanewname.Additionalinformation,includingthepresenceofcontroldevices,estimatesormeasurementsofannualHAPemissions,wasobtainedfromtheindustry,EPA'sToxicReleaseInventory(TRI),fromasurveyofsecondaryaluminumplants,andfromStateagencies.Plantidentificationdatahavealsobeenobtainedfromtheopenliterature.AppendixBofthisdocumentshowsthisinformation. Note X ( thattheinformationinAppendixBispreliminary,andthatmoredetailedinformationisbeingcollectedcurrently.  AlthoughTheemissionsinformation are shown ,  inAppen   c   dixB itdoesnotspecifywhichfacilitiesaremajorsourcesofHAPemissionandwhicharenot.Forexample,theestimatesareofactualemissions,ratherthanpotentialemissions.Furthermore,theTRIdataarelimitedinthatemissionsmaybereportedinrangesandmayalsobeconservativeestimates.However,despitethelimitationsoftheavailableemissionsdata,itappearsthattherewillbeanumberofcoilcoatingplantsthataremajorsourcesofHAPemissionsandothersthataresyntheticareasources. h+&8   Majormarketsforcoilcoatedmetalincludethetransportationindustry,buildingproductsindustry,largeapplianceindustry,canindustry,andpackagingindustry.Theindustryhasmaintainedapositivegrowthrateforanumberofyearsasnewendusesforprecoatedmetalhavecontinuedtoemerge.  Althoughcoilcoatedmetalisusedinawidevarietyofproducts,metalcoilsurfacecoatingistypicallynotaproductspecificoperationbutratherisadistinctprocess.TheAgencynotesherethatmanyoftheothersourcecategoriesbeingexaminedforsurfacecoatingMACTstandardsareproductspecific,suchasthemetalcanandlargeappliancessourcecategories.Forthepurposesofstandarddevelopment,theAgencyisconsideringanycoilcoatingprocess,regardlessoftheendproduct,aspartofthemetalcoilsourcecategory.Productspecificsourcecategorieswouldexaminesurfacecoatingoperationsthatarenotcoilcoatingprocesses.  Typesofmetalprocessedbythecoilcoatingindustryaremainlycoldrolledsteel,galvanizedsteel,andaluminum.Smallquantitiesofothermetalsincludingbrassarealsocoated.Coilcoatedmetalisfabricatedintoendproductsafteritiscoated,thuseliminatingtheneedforpostassemblypainting.Tollandcaptivecoatersrepresentthetwobasicindustrydivisions.Tollcoatersproducemetalthatiscoatedinaccordancewithspecificationsoftheircustomers.Captivecoatersbothcoatthemetalandfabricateitintoendproductswithinthesamecompany.Examplesarecanmanufacturerswhohavededicatedcoilcoatinglinesformetalusedinthecanmanufacturingprocess,andhousingproductsmanufacturerswhocoatthematerialfortheirproductsusingcompanyownedandoperatedcoilcoatinglines.Someplantsperformbothtollandcaptiveoperations. Coatings  ! *   Thetypesofcoatingsappliedincoilcoatingoperationsincludeawidevarietyofformulations.Amongthemoreprevalenttypesarepolyesters,acrylics,fluorocarbons,alkyds,vinyls,epoxies,plastisols,andorganosols.TableIII2liststhecoatingscommonlyusedintheindustryandgivestheapproximaterangeoforganicsolventcontentofeach.Inadditiontothesetraditionalcoatings,adhesives,bondablebackers,strippableprotectivecoatings,andothernontraditionalcoatingsarealsousedbytheindustry.Themajorityofthecoatings,estimatedatabout85percent,areorganicsolventbasedandhavesolventcontentsrangingupto80percentby h+&8 volumewithmostbeingintherangefrom30to70percent.Theremaining15percentofcoatingsaremostlyofthewaterbornetypewhichalsocontainsomeorganicsolventsrangingfromabout2to15percentbyvolume.Whilewaterbornecoatingsareinuseatanumberofcoilcoatingfacilities,theyarenotavailableinformulationsthataresuitableforallendproductapplications.Thechoiceofwaterborneversussolventbornecoatingsusuallydependsontheenduseofthecoatedmetalandthetypeofmetalused.Themostprevalentuseofwaterbornecoatingsisonaluminumusedforsidingintheconstructionindustry.  Highsolidscoatingsintheformofplastisols,organosols,andpowderarealsousedtosomeextentbythecoilcoatingindustry.Becausethesecoatingshavealowerorganicsolventcontent,potentialorganicemissionsarelowerthanfromtheother,morecommonlyusedcoatings.However,thesecoatingsalsohavelimitedapplicabilityandarenotavailablein  6 &   @  TableIII2.TypicalCoatingsUsedinMetalCoilSurfaceCoating   *$d9dwd d  -d / dd $(#(#, dd , dd +  9$ t  @@ Coatings ,9$9$ ,@0^VolatileContent@3^(Weight%) .$9$ .Acrylics 7-D  " 74045 7-D  " 7Adhesives 7-  " 77080 7-  " 7Alkyds 7-D  " 75070 7-D " 7Epoxies 7- " 74570 7- " 7Fluorocarbons 7-D " 75560 7-D " 7Organosols 7- " 71545 7- " 7Phenolics 7-D" 75075 7-D" 7Plastisols 7-" 7530 7-" 7Polyesters 7-D" 74550 7-D" 7SiliconeAcrylics&Polyesters 7-" 73560 7-" 7ТUrethanes 7-D" 76075 7-D" 7Inks 7-" 75065 7- " 7SolutionVinyls 7-D!" 77585 7-D"" 7Vinyls 7-#" 76075/%#$"   /'Vformulationssuitableforuseonallendproducts.Typicalusesforthesecoatingsareresidentialsiding,draperyhardware,andotherproducts.  LittledatahavebeenidentifiedthatrepresenttheHAPcontentofcoatingsusedinthemetalcoilsurfacecoatingindustry.InformationprovidedbyoneofthecoatingsuppliersforthreetypicalcoatingsshowedHAPcontentsrangingfromabout5to28percentbyweight.TheEPArecognizesthatthescopeofthisinformationisquitelimitedandthusmaynotberepresentativeoftheentirerangeofcoatingformulationsusedinthemetalcoilsurfacecoatingindustry.ThustheHAPcontentrangereportedhereisonlyseenasapreliminaryindicationofthepotentialrangeoverallcoatings.TheEPAisintheprocessofconductinganationwidesurveyofcoilcoatingplants.Datafromthatsurvey,whichincludesquestionsrelatedtocoatingusageandtheHAP >,'7 contentofcoatings,willprovideamorecompleteindicationoftherangeofHAPcontentincoatingsusedbythecoilcoatingindustry.& & ProcessDescriptions,CurrentIndustryPractices,andEmissionSources  t   Althoughspecificstepsinacoilcoatingoperationdifferbetweenplants,mosthavea'&tլcommonseriesofstepsthatincludestorageandhandlingofrawmaterialsandacoatinglinethatincludesawetsectionandoneormorecoatingoperationsconsistingofacoatingapplicationstation,acuringoven,andaquencharea.Mostplantsalsogeneratewastewaterandhavesometypeofwastewatertreatmentsystem.ThefollowingparagraphsprovidebriefdescriptionsofthecommonoperationsfoundoncoilcoatinglinesandprovidesgeneralinformationregardingpotentialHAPemissions. StorageandHandlingofCoatingsandOtherMaterials Manyofthecoatings,solvents,and   wetsectionchemicalsaredeliveredandstoredin55gallondrumsbutmayalsobedeliveredandstoredintotes,whicharetransportablecontainerswithacapacitygenerallyintherangeofabout200to500gallons.Someplantsalsoreceiverawmaterialsinbulkbytanktrucksorrailcarsandstorethematerialsinbulkstoragetanks.Thesetanksmaybelocatedinsideabuildingormaybeoutdoorseitherabovegroundorunderground.Forrawmaterialsdeliveredandstoredindrumsortotes,noemissionsshouldoccurduringnormalstorageprovidedthattheytypicallyarekeptsealedandgenerallydonotleak.Emissionswouldonlyoccurwhenthedrumsortotesareopened.  Wherecoatingsaredeliveredbytanktruckorrailcar,workinglossemissionsoccurwhenthecoatingsarepumpedfromthedeliveryvehicletobulkstoragetanks.Duringstorage,dailytemperaturefluctuationsgeneratebreathinglossemissions.Breathinglosseswouldbeexpectedtobelowfortanksthatareundergroundorenclosedincontrolledtemperatureenvironmentsrelativetotanksthatareoutdoors,abovegroundandexposedtodiurnaltemperaturecycles.  Beforeapplicationofthecoatingstothecoil,thecoatingsaretypicallystirred.Theymayalsobethinnedwithsolventtoadjusttheviscosity.Insomecases,coatingsaremixedtogether.Oneexampleismixingtoachieveaparticularcolor.Anotherexampleistheblendingofexcess coatingstogethertouseasabacker.  *\%6  WetSectionPretreatment Thewetsectionofametalcoilsurfacecoatinglineincludescleaning   stepsthatmayusewater,causticcleaners,brushing,oracidtreatment.Thewetsectionmayalsoincludechemicaltreatmentssuchasdriedinplace.Processesmayincludesprayapplicationsofmaterialsormayincludesubmersionofthemetalstrip.Specificprocessesincludedinthewetsectiondependonthetypeofmetalsubstrate,characteristicsofthecoatingstobeapplied,andotherparameters.ThechemicaltreatmentsusedinthewetsectionmaycontainHAP.Oneexampleischromiumcompoundssuchaschromicacid.TheEPAcurrentlyhaslittleinformationregardingthelevelsofHAPemissionsfromthewetsection.TheyareexpectedtobesmallrelativetopotentialHAPemissionsfromcoatingapplicationandcuring. CoatingApplicationStations .Atthecoatingapplicationstations,coatingsareappliedby (x  rollerstooneorbothsurfacesofthemetalstripasitpassesthroughthestation.EmissionsofHAPoccurwhenHAPcontainingsolventscontainedintheappliedcoatingsevaporate.Itisestimatedthatbetween0and15percentofthecoatingsolventevaporatesatthecoatingstationwithanaverageofabout8percent.IfHAPcontainingcleaningsolventsareused,emissionsofHAPalsooccurduringcleaningofthepaintrollersandotherpartsoftheapplicationstationbetweencoatingsessionsorwhenacolorchangeismade.Cleaningmaybecarriedoutinplaceusingsolventandrags,orportionsofthecoatersmayberemovedforcleaning.  Atmanyplants,thecoatingapplicationstationsareenclosedinrooms.Becauseairisdrawnintotheovensfromtheserooms,itisgenerallybelievedthatalargefraction,andinsomecasesall,ofthesolventthatevaporatesinthisareaiscapturedbytheovens.Hoodsor"snouts"maybeusedtoincreasethefractionofsolventemissionscapturedbytheovens.Plantsmayalsousesmallercoatingstationenclosures,whichrequirelessventilationair,andarenotoccupiedbyworkersexceptwhentheenclosureisopenedformaintenanceorinspection.Onlinesthatdonothavecoatingroomsorsmallerenclosures,anexhausthoodisfrequentlyinstalleddirectlyovertherollcoaterstoexhaustthesolventthatevaporatesinthatarea.Inthesecases,thehoodsmaybeexhaustedtotheovens,acontroldevice,ortotheatmosphere.Someplantsdonotusehoodsorenclosuresaroundthecoatingapplicationstations;therefore,themajorityofthesolvent evaporatedatthecoatingstationwouldbeemittedtotheatmosphere. *b%6  Curingovens .Aftercoatingsareappliedtothesurfaceofthemetalstrip,thestripentersan   ovenwhereheatisappliedtoevaporatetheorganicsolventandwatercontainedintheappliedcoatings.Anestimated85to100percentoftheorganicsolventcontentofappliedcoatingsevaporateinsidethecuringovenswithanaverageestimatedatabout90percent.Mostcuringovensusedincoilcoatingoperationsaredirectfiredandusenaturalgasasfuel.Manyovensaredesignedtousepropaneasabackupfuelincaseofnaturalgascurtailments.Ovensheatedbyfueloilorelectricityareusedinsomeplants,buttoamuchlesserextentthanthoseheatedbynaturalgas.Theheatinputtotheovensmustbesufficienttoevaporatethesolventinthecoatings,tobringthemetalandcoatingsuptothedesigntemperature,usuallyintherangeof375to500F,toreplacetheheatlostfromtheovensbyradiationandconduction,andtoheatdilutionairtoovenoperatingtemperature.Ovenventilatingair(ordilutionair)isnormallythelargestsinglefactorinthetotalovenheatload.  Solventbornecoatings,ifuncontrolled,wouldresultinhigherorganicemissionsfromtheoventhaneitherwaterbornecoatingsorhighsolidscoatings.EmissionsofHAPcomparedtoorganicemissionswilldependontheproportionofHAPascomparedwithnonHAPsolventsinthecoatings. QuenchArea .Whenthemetalstripexitsthecuringoven,itiscooled,usuallybyawaterspray, &  anairspray,oracombinationofthetwobeforebeingrepackagedasacoilorpassingtoanothercoatingstation.Anestimated0to2percentoftheorganicsolventintheappliedcoatingsisreleasedinthequencharea.Thequenchareaisnormallyanenclosedareaadjacenttotheexitfromthecuringovenandalargefractionoftheemissionsreleasedinthisareaareestimatedtobecapturedbytheovenventilationsystem.However,atsomeplants,thequenchareaisventeddirectlytotheatmosphere. WastewaterHandlingandTreatment .Mostplantsgeneratewastewaterfromwetsection $. operations,quenchingoperations,orboth.BasedontheEPA'scurrentinformation,organicsolventsarenottypicallyusedinthewetsection.Therefore,theEPAdoesnotexpectmuchorganicsolventtogetintoplantwastewater;thus,organicHAPairemissionsfromwastewaterhandlingandtreatmentareexpectedtobelowornonexistent.Coilcoatingwastewatermaycontainchromiumcompoundsbutthepotentialforairemissionsofthesecompoundsisexpected z+&8 tobesmall.Wastewatermayalsobegeneratedbycleanupactivitiesatplantsthatusewaterbornecoatings. & & IV.EMISSIONREDUCTIONTECHNIQUESIDENTIFIED  t  Discussion  & '&t  Theemissionreductiontechniquesinusebythecoilcoatingindustrythathavebeenidentifiedtodateprimarilyarerelatedtocoatingapplicationandcuringovens.Therefore,thesearetheemissionpointsthatarediscussedhere.  Forcoilcoatinglinesthatusesolventbornecoatings,ovenemissionsaretypicallycontrolledbytheuseofthermalorcatalyticincineratorswhichmaybelocatedinsideoroutsidetheovens.Fromtheinformationgatheredtodate,theEPAknowsofatleast65plantsthatuseincinerationsystemstocontrolorganicemissionsfromtheovens.Noothertypesofaddoncontroldeviceshavebeenidentifiedforemissionsfromcoatingapplicationandovens.Mostplantsemploysomeformofheatrecoverytoimprovetheoverallenergyefficiencyofthecoilcoatingoperation.Incineratorexhaustgasesmaybeusedtopreheattheovenexhaustbeforeitenterstheincineratororaportionoftheheatfromtheincineratormaybeusedforovenheatingortoproducesteaminawasteheatboiler.Thesteamcanbeusedtosupplyheattowetsectionoperationsorotheroperationsinthefacility.  Littleinformationhasbeencollectedtodateontheoverallemissionreductionachievedbyexistingincinerationsystemsatexistingcoilcoatingfacilities.Ingeneral,incineratorefficienciesareintherangeof80to99percentdependingonthetypeofincinerator(i.e.,thermalorcatalytic)andtheincineratoroperatingparameters.Fiveplantsarereportedtousecatalyticincinerationsystemsand23tousethermalincineratorsystems.Thermalincineratorsarecapableofbeingdesignedandoperatedtoachieveadestructionefficiencyintherangeof98to99+percentfororganiccompoundsenteringtheincinerator.Oneregenerativethermaloxidizerwasreportedinatradejournaltoconsistentlyachieveanemissionreductionefficiencyofatleast99percentoverawiderangeofsolventloadings.Additionalevidenceisshownintheoperatingpermitforarecentlyconstructedcoilcoatingline,whichspecifiesthattheincineratorbeoperatedata destructionefficiencyof98.5percent. *V%6   Todeterminetheoverallefficiencyofanaddoncontrolsystem,itisalsoimportantto considertheefficiencywithwhichtheemissionsarecapturedtoberoutedtothecontroldevice.Asdiscussedearlierinthesectionaboutcoatingapplication,thereisavarietyofcapturesystemscurrentlyinuseintheindustrywitharangeofefficiencies.DataobtainedfromStateagenciesindicatethatatleastfourteenplantshaveinstalledpermanenttotalenclosuresaroundthecoatingapplicationstations.Theseenclosureshaveacaptureefficiencythatapproaches100percent.  TheAgencyisintheprocessofcompletinganationalsurveyofcoilcoatingplantstocollectdatadescribingcurrentoperatingpractices,airemissions,andthetypesandeffectivenessofemissioncontrols.Surveydatawillbeaprimarysourceofinformationforexistingcoilcoatingplants. &  PollutionPreventionConsiderations:      Asnotedinanearlierdiscussion,somecoatingshavelowerpotentialforproducingemissionsthanothers.Twoplantswereidentifiedsofarinthedatagatheringprocessthatuseloweremittingcoatingswithoutanaddonemissioncontroldevice.'ԀOneoftheseexclusivelyuseswaterbornecoatingsandtheotherusespowdercoatings. V.STAKEHOLDERCOMMENTS  n   Thefollowingisapresentationofcommentsreceivedfromstakeholdersonthedraftofthisdocumentthatwasdistributedforstakeholderreview.TheEPAresponsetothecommentsisalsopresented.CommentsweresubmittedbyoneindividualattorneyandtheNCCA.  ThefollowingcommentswerereceivedfromtheNCCA:Comment1󀄀Thecommentersuggeststhatthedocumentclarifythattheinformationpresentedis X ( applicableonlyforcasebycaseMACTdeterminationsfornewmajorsourcesonly.Response.TheEPAscurrentscheduleforcompletingtheMACTstandarddevelopmentprocess #l, callsforpromulgationoftheMACTstandardwellwithinthestatutorydeadline.Thus,itisunlikelythatcasebycaseMACTdeterminationswillberequiredforexistingfacilities.However,theinformationpresentedinthisdocumentisquitegeneralinnatureandincludesinformationcollectedbytheAgencytodaterelatedtoexistingfacilitiesaswellasnewones.Comment2󀄀ThecommentersuggestedthattheAgencyreviewStaterulestomorefully *V%6 representinformationintheStaterulesdescribedinTableIII1.Thecommenternotedthatsome h+&8 Statesthathavespecificemissionlimitsalsoallowalternativecomplianceoptions.Itwassuggestedthatthesealternativesbeincludedinthetable.Response.TheinformationinTableIII1wasobtaineddirectlyfromexistingStateregulations. t BecauseitisnotpracticaltotrytoincludeallprovisionsofaStateregulationinsuchatable,theinformationisintendedtorepresentonlythemajorrequirementsofeachStaterule.Inresponsetothecomment,afootnotehasbeenaddedtothetabledenotingthatfact.Comment3󀄀Thecommenterpointsoutthatapotentialoverlapbetweencoilcoatingandfoil  L  coatingisidentifiedbutnoplanispresentedtodealwiththepotentialoverlap.Response.TheAgencybelievesthatitisprematuretodeviseaplanforhandlingthisissuebefore   identifyingtheextentandfullnatureoftheoverlap.Languagewasaddedtothisdocumenttonotethatafteradditionaldatacollection,theEPAwillconsidertheneedandapproachesforaddressingthispotentialoverlap.Comment4󀄀ThecommenterstatesthatTRIdataareusuallyreportedconservativelyandmay H notbeappropriatefordeterminingmajorsourcestatus.Response.Thedocumenthasbeenrevisedtoaddressthispoint.  \ Comment5󀄀Thecommenterindicatesthatthelistingofmajormarketsforcoilcoatedmetalisan n unresolved,overlappingarea.Response.Additionallanguagewasaddedtoclarifythatthecoilcoatingsourcecategory 2" addressesthecoilcoatingprocesswithoutregardtothesubsequentuseofthecoatedmetal.Comment6󀄀Thecommentersuggestsmodificationstoreferencestorelativeorganicemissions F& fromwaterborneandsolventbornecoatings.Response.Thisparagraphpresentsadiscussionofthevarioustypesofcoatingsusedinthecoil ! * coatingindustry.Inresponsetothiscomment,theEPAhaschosentoremoveallreferencestoemissionsfromthisparagraph.Adiscussionofemissionsisalreadypresentedinanothersectionofthedocument.Comment7󀄀ThecommentersuggestsseveraladditionaltypesofcoatingsforinclusioninTable B'"2 III2. Response.Thechangesweremadeassuggested. *V%6 Comment8󀄀ThecommentersuggestsremovinginformationrelatedtotheHAPcontentof   coatingsbecauseitrepresentsasinglesourceofinformation.Response.Additionallanguagewasaddedtothisparagraphtorecognizethelimitednatureofthe t data.Comment9󀄀Thecommentersuggestedmodificationstothelistingofoperationsinthewet 8  sectionofacoilcoatingline.Response.Thechangeswereincorporated.  L  Comment10󀄀ThecommentersuggestedthatSectionIVbeidentifiedasapplyingonlytonew ^  majorsourcesandalsosuggestedaddinglanguagerelatedtovendorguaranteesforincineratorefficiency.Thecommentersuggestedthatvendorsdonottypicallyguaranteeanythingover99percentreductionandclaimthatefficienciesdeteriorateovertimeandsuggeststhat99percentisthehighestdestructionefficiencythatcouldbeusedforregulatorypurposes.Response.Inresponsetothecomment,thesectionwaseditedtoclarifythelimitedamountof H dataavailableforexistingfacilitiesandremovestatementsthatcouldhavebeeninterpretedasmeaningthehighestcontrolefficienciesarereadilyachievablebyexistingcoilcoatingfacilities.Additionaldataarecurrentlybeingcollectedfromthecoilcoatingindustrythatwillhelpidentifyemissionreductionefficienciesachievablebyexistingfacilitiesintheindustry.Comment11󀄀ThecommenterofferedcorrectionstotheTabularlistingofcoilcoatingplantsin 2" thetable.Response.Themajorityofthechangesweremade.?Thecorrectionsweremade.?@Wherethecommenternotedthat@A@the@ABafacilitBEBiBEFyFGFroFGHor F& companywasnotacoilcoater,IHtheHIJtheJKJchangeJKOLnameLOPchangewasmadeonlyiftheEPAhadadditionalinforPQPamiPQRmationfromtheindustrysurveystocon]ZiZ]^f^_^rim^_`irmthe`a`info`abcombcbembcdmededtndefnt.f]\f\]Inaddition,noteswereaddedtothetableindicatingthepreliminarynatureoftheinformationpresented.ThefollowingcommentwasreceivedfromtheMcNairLawFirm:Comment1󀄀Thecommentersuggestedthatthediscussionofmetalcoilsurfacecoatinginthis (#4 documentistoobroadbecauseitincludessourcesthat,aftercoatingthecoil,cutthecoilintosheetswithoutrecoilingthemetalintoapackageoraroll.Thecommenterinterpretedthisas h+&8 beingabroaderdefinitionthanforthenewsourceperformancestandardforcoilcoatingandbelievedthatthedifferencewouldbeconfusingtotheregulatedcommunity.Thecommenteralsonotedthattheemissionrateislinkedtothespeedoftheline.Thecommenterbelievesthat,wheretheprocessspeedislimitedbyforming,cuttingandpackingsteps,insteadofbythespeedoftherecoil,theemissionsaresubstantiallyreduced.Response:TheAgencybelievesthatitisappropriatetoexaminesuchcoatingasdescribedbythe & commenterunderthecategoryofmetalcoilcoatingbecauseofthesimilarityinthecoatingprocess.ThesurveyoftheindustrybeingcarriedoutbytheAgencyshouldprovideinformationrelatedtothevariousspeedsofcoilcoatinglinesandotheroperatingparametersfromwhichtheAgencycandetermineifthereareanyimportantvariationsthatmightwarrantsubcategorizationforpurposesofregulation.    @  %AppendixA@ParticipantsinDevelopmentofthePreliminaryIndustryCharacterization   *f$dd dd dd $(#(#f,dd ,dd +    @0 0 (  Name  d @5d Affiliation d  GlenAnderson   NationalCoilCoatersAssociation   TomAshy  d MetalPrep  d MarkBahner    ResearchTriangleInstitute    KevinBald   d  ReynoldsMetals   d  KevinBarnett     Alcoa     JimBercaw  d  TechnicalCoatings  d  SamBruntz    CommonwealthAluminum    StephenByrne  d  CytecIndustries  d  DennisCarson    PPGIndustries    RoyCarwile  d Alcoa  d DwightCohagan   TheSherwinWilliamsCompany   JimDodson  d RollCoater  d StevenDubois   Alcan   JackFarmer  d ResearchTriangleInstitute  d BobFegley   EPA/ORD    BarbaraFrancis  d! ChemicalManufacturersAssociation  d" DavidFriedland  # BeveridgeandDiamondRepresentingNCCA  $ KellyGarbin   d% NationalCoilCoatersAssociation   d& SteveGross  !' PennsylvaniaBureauofAirQuality  !( SusanHoyle  #d) PennsylvaniaBureauofAirQuality  #d* JesseHackenberg  $+ ChromographicProcessing  $, MadelynHarding  &d!- TheSherwinWilliamsCompany  &d!. GaryHayden  '"/ MSCPreFinishMetals  '"0 LindaHerring  )d$1 EPA/OAQPS  )d$2 ThomasHimmelmann  *%3 ChesapeakeFinishedMetals  *%4 WilliamJelf  d  AKZONobelCoatings  d MattJohnston   WorthingtonIndustries   JosephJunker   d ARCOChemicalCo.   d MikeKosuko    EPA/ORD    GailLacy   d  EPA/OAQPS   d  DavidLeligdon    PrecoatMetals    WilliamMadigan  d  MetropolitanMetalSales  d  BrentMarable    EPARegionV    JosephMcCloskey  d  BenjaminMoore&Co.  d  TomMcElven    AmeriMark,Inc.    ArnoldMedberry  d EPASmallBusinessOmbudsman  d HankNauer   IllinoisEnvironmentalProtectionAgency   CarolNeimi  d RepresentingCMASolvent'sCouncil  d BobNelson   NationalPaintandCoatingsAssociation   DaveOzawa  d MostardiPlattAssociates  d VenkataPanchakaria   FloridaDept.ofEnvironmentalProtection    AltonPeters  d! ResearchTriangleInstitute  d" JackPeterson   # AlleghenyCountyHealthDept.   $ AlexanderRoss  !d% RadTechInternational,NA  !d& NorbertSaatkoski  #' RollCoater  #( JasonSchnepp  $d) IllinoisEnvironmentalProtectionAgency  $d* GaryStimpson  &+ NicholsAluminum  &, RobertP.Strieter  'd!- AluminumAssociation  'd!. ScottThrowe  )"/ EPA/OECA  )"0 WilliamVallier  *d$1 GentekBuildingProducts  *d$2 BillVinzant  d  KaiserAluminum  d MiltonWright   ResearchTriangleInstitute   TomYoung   d MSCPreFinishMetals  d 5     @%AppendixB@ PlantListfortheMetalCoilSurfaceCoatingIndustry  ^   XR XXX4v    X XR@ TableB1.CoilCoatingPlantList  # XR X  w#   X XRThistablecontainsapreliminarylistofplantsthathavebeenpotentiallyidentifiedashavemetalcoilsurfacecoating d operations.Someoftheplantsmaynolongerbeinoperation.Thetabledoesnotincludeinformationcollectedaspartofanationwidesurveyofmetalcoilsurfacecoatingfacilities.Datafromthatsurveywillprovidemorespecificinformation.Abbreviations: ` ICRtonsHAPemissionsreportedinInformationCollectionRequestresponses 8   Ѐ   ` TRItonsHAPemissionsreportedin# XR X   #   X XR#g  X#  gԀEPA'sToxicReleaseInventory(1996data)  L  # XR X   #    X XRԀ    Ѐ*f:$;d6ddd dd $(#(#f,dd ,dd ,Xdd ,dd",dd ,dd"+  ( 8  (# XR X  ^ #   X XRCompany <2# "ά <PlantLocation .$ " .No.   ЀofLines <2#$t " pp <Control   Device <2#` "  <Total   AnnualHAPEmissions(tons)#g   #  g F<($t " pp  F !   !City ' \ " 'State +! \ " + %   %    #g  #  g     AlcanAluminumLtd.#g  #  g  | Cleveland#g  n#  g  | OH#g  #  g 4* |  ?1?41 4*(|  ?1 ? 4thermalincineratorforcoatcuringovens#g  '#  g  @ unknownfromincinerator,74(ICRestimateforuncontrolledorganicHAPemissionsfrompaintingprocess)#g  #  g  ( ALCOA#g  #  g  D) Newburgh  D* IN 4* D+  @3@43 4*(D,  @3 @ 4  D- #g  #  g# XR X  #   X XR  D. ALCOA  L/ Lebanon  L0 PA 4* L1  @6@46 4*(L2  @6 @ 4  L3 #g   #  g  L4 ALCOABldg.Prod.  5 Sidney  6 OH 4* 7  @2@42 4*(8  @2 @ 4  9 #g  [##X4vXgN#gXX4v  g  : ТAlumaxMillProducts#g  #  g  L; Lancaster  L< PA  L=   L> incineratorforovenexhaust  @ 10.5(perplant)#g  "#  g  B ТAlumaxMillProducts#g  #  g  !hC Texarkana  !hD TX  !hE   !hF Incineratorforovenexhaust  !,H 2.5(perplant)#g  q#  g# XR X  #   X XR  !,J ТALUMET(formerlyGentek)Bldg.Products#g  R#  g  #HL Mesquite  4#M TX  4#N   4#O   4#P   4#Q ТAlusuisseComposites  P% R Benton  P% S KY 4* P% T  ?1?41 4*(P% U  ?1 ? 4regenerativethermalincinerationofoven/coaterexhaust  &("X #g  #  g  P% Y AmericanMetalsCorporation  0(#Z ТWestlake  0(#[ OH 4* 0(#\  ?1?41 4*(0(#]  ?1 ? 4  0(#^   0(#_ AmericanNickeloid  )$` Peru  )$a IL 4* )$b  ?1?41 4*()$c  ?1 ? 4  )$d   )$e AmericanNickeloid#g  #  g  *0&f ТWalnutport  *0&g PA 4* *0&h  ?1?41 4*(*0&i  ?1 ? 4  *0&j #g  #  g  *0&k ТAmeriMark,Inc.  d ТRoxboro  d NC 4* d  @2@42 4*(d  @2 @ 4catalyticincinerators forcoatingroom&ovenemissions  |  34.4(TRI#g  #  g)  (  ТAmeriMark,Inc.     LincolnPark   D  MI 4*  D   @3@43 4*( D  @3 @ 4regenerativethermaloxidizerforcoatingroom&oven  \  58.4(TRI)#g  n!#  g    ТAmeriMark#g  "#  g,Inc.   $ ТAshville   $ OH 4*  $  ?1?41 4*( $  ?1 ? 4thermalincineratorforϢcoaterroom&ovenemissions  < 40.58(TRI)#g  /##  g  x ТAppolloMetals#g  l$#  g    Bethlehem    PA 4*    @2@42 4*(   @2 @ 4   ! #g  $#  g   " ArmcoAdvancedMaterialCorporation   $ Zanesville  \ % OH  \ &   \ '   \ (   \ ) ArrowGroup  x * Haskell  x + NJ 4* x ,  @2@42 4*(x -  @2 @ 4thermalincinerationofϢcoaterroomandcuringovenexhaust  0 1.1(plantestimate)#g  %#  g  < 2 ТBerridge  X3 SanAntonio  X4 TX  X5   X6   X7   X8 BHPCoatedSteelCorp.#g  '#  g  @9 RanchoϢCucamonga#g  (#  g  t; CA  @<   @=   @> 1(TRI)#g  E)#  g  t@ BHPCoatedSteelCorp.#g  )#  g  \A ТKalama  \B WA  \C   \D   \E #g  Q*#  g  \F ТCentria#g  +#  g  $G Cambridge  $H OH 4* $I  ?1?41 4*($J  ?1 ? 4  $K   $L ChampionPartsWesternDivision  @N Fresno   |O CA   |P    |Q    |R 40.6(CalEPA)  @T ChesapeakeFinishedMetals  (U Baltimore  (V MD 4* (W  ?1?41 4*((X  ?1 ? 4regenerativethermaloxidizerforovenexhaust#g  f+#  g   [ 10.4(TRI)#g   .#  g  \] ChicagoFinishedMetals#g  l.#  g  "x^ ТBridgeview#g  .#  g  "x_ IL 4* "x`  @2@42 4*("xa  @2 @ 4onelinehasaregenerativethermaloxidizerforoven&coatingroomexhaust;otherlinehasarecuperativethermaloxidizerforoven&coatingareaexhaust  d'i 13(TRI)#g  =/#  g  "<k ТChromagraphicProcessingCo.  )!m Williamsport  (,!n PA 4* (,!o  @6@46 4*((,!p  @6 @ 4catalyticoxidizers  (,!q 3.8(TRI)#g  0#  g  )!s CoilCoatersofAmerica  *H#t ТMableton  *H#u GA 4* *H#v  ?1?41 4*(*H#w  ?1 ? 4thermalincinerator  *H#x 5.3(TRI)#g  2#  g  + $z ТCoilplusAlabama  d Athens  d AL  d   d   d   d ТCoilplusIllinois  L  Plainfield  L  IL  L     L     L     L   ТCoilplusOhio     Springfield    OH                ColMetInc,   l Tampa   l FL   l    l    l #g  @3#  g   l CommonwealthAluminumCorp.#g  5#  g   Torrance  T  CA 4* T   ?1?41 4*(T   ?1 ? 4thermaloxidizer  T  0.10(ICR1996data)#g  T6#  g    CommonwealthAluminumCorp.  4" ТLewisport  p# KY 4* p$  ?1?41 4*(p%  ?1 ? 4thermalincinerationofoven&coaterhouseemissions  h ( 14.71(ICR1997data)#g  l7#  g  4* CommonwealthAluminumCorp.#g  8#  g   , Bedford  P - OH  P .   P / thermalincinerationofovenandcoaterhouseemissions  H 2 13.53(ICR1997data)#g  O9#  g   4 ConsolidatedMetalProducts(formerlySoutheasternCoatedProd.)  (7 Columbia  0 8 SC 4* 0 9  ?1?41 4*(0 :  ?1 ? 4  0 ;   0 < CooperCoilCoatingInc.  = Clearwater  > FL 4* ?  @2@42 4*(@  @2 @ 4Incinerator 8. A ?5^I ?0.282?5^I ?80.282#g  Q:#  g# XR X  #   X XR 8.,B ?5^I ?0.282 ?5^I ? 8CrownCork&Seal#g  <#  g# XR X  <#   X XR  hC FortLupton# XR X  =#   X XR#g  {=#  g  hD CO 4* hE  ?1?41 4*(hF  ?1 ? 4Incinerator  hG   hH CrownCork&Seal# XR X   >#   X XR#g  b>#  g  0I Toledo  0J OH  0K   0L   0M   0N CustomMetals  O Chicago  P IL 4* Q  ?1?41 4*(R  ?1 ? 4  S   T DecaturAluminumCorporation  4V Decatur  pW AL 4* pX  ?1?41 4*(pY  ?1 ? 4None  pZ 119(ADEM)#g  ?#  g# XR X  j?#   X XR  4\ ТDoublecote  ] Jackson  ^ MS 4* _  ?1?41 4*(`  ?1 ? 4afterburnerforovenexhaust 6, P b @o@250@o@6250#g  $B##X4vXgfB#gXX4v  g 6,*c @o@250 @o@ 6EaglePicher  !d Lisbon  !e FL 4* !f  ?1?41 4*(!g  ?1 ? 4Incinerator  !h 62(VOC)  l"j ТEdcoProducts  #4k Hopkins  #4l MN 4* #4m  @2@42 4*(#4n  @2 @ 4  #4o #g  C#  g  #4p ТEnglertInc.  %q PerthAmboy  %r NJ  %s   %t   %u 4.3(TRI)#g  F#  g  %Pw EpicMetalsCorp.#g  G#  g  8'x Braddock  8'y PA 4* 8'z  ?1?41 4*(8'{  ?1 ? 4  8'| #g  hG#  g  8'} FinishedMetalsInc.  (!~ Chicago  (! IL 4* (!  ?1?41 4*((!  ?1 ? 4  (! #g  \H#  g  (! ТGentekBldg.Products  )X" ТWoodbridge  )X" NJ 4* )X"  ?1?41 4*()X"  ?1 ? 4catalyticafterburneronovenemissions  *# #g  xI#  g28 )X" (TRI)#g  J#  g6  *#   ,t$ У  ,t$ 62101263  ,t$ 363 4* ,t$  ?1?4136  ,t$ 64incinerator45  ,t$ 565  ,t$ 567  *# GoldenAluminum7#g  !K#7  g  ,t$ Golden  ,t$ CO  ,t$   ,t$   ,t$ #g  L#7  g  *# HannaSteelCorporation  ,t$ Fairfield  ,t$ AL  ,t$   ,t$   ,t$   ,t$ ТHexcelCorporation  d CasaGrande  d AZ 4* d  ?1?41 4*(d  ?1 ? 4  d   d ТHexcelCorporation#g  M#  g  L  Graham  L  TX 4* L    ?1?41 4*(L    ?1 ? 4  L     L   ТHomeshieldFabricatedProducts  h  Chatsworth    IL 4*    ?1?41 4*(   ?1 ? 4ovenemissionstoanafterburner  h  1.5(TRI)#g  zO#  g  h  HunterDouglas#g  ~Q#  g   0 Tupelo   0 MS 4*  0  ?1?41 4*( 0  ?1 ? 4   0 #g  Q#  g   0 JupiterCoilCoatingDivision   Fairfield   TN 4*   ?1?41 4*(  ?1 ? 4    #g  R#  g  ! ТK.B.P.CoilCoatersInc.  p" Denver  p# CO 4* p$  ?1?41 4*(p%  ?1 ? 4thermaloxidizer  4' 1.3(perplant)per1997CoilWorld,plantconductedstacktesting."stateofartplant"#g  S#  g  < / KaiserAluminum  $0 Spokane  $1 WA 4* $2  ?1?41 4*($3  ?1 ? 4coatinglineafterburner  X5 0.8#g  U#  g $6 (measuredatafterburneroutlet̀perICR)#g  V#  g8  p9 ТKenMex  8: Louisville  8; KY  8<   8=   8> 8  p9 KirschCompany  8: Sturgis  8; MI 4* 8<  ?1?41 4*(8=  ?1 ? 4  8> #g  :W#  g9  8? ТLevolorLorentzen,Inc.   @ GardenGrove   A CA 4*  B  ?1?41 4*( C  ?1 ? 4   D 9#g  X#  g  8? LoganAluminumInc.   @ ТRussellville   A KY 4*  B  ?1?41 4*( C  ?1 ? 4incinerationofovenemissions  TE    F LSITElectrogalvanizing  <G Columbus  <H OH  <I   <J   <K   <L LusterCote,Inc.  M Montclair  N CA  O   P   Q   R ТMarwaisSteelownedbyϢMSCPreFinish(PP)   T Richmond  \U CA 4* \V  ?1?41 4*(\W  ?1 ? 4Recuperativethermaloxidizer   Y   \Z ТMcCordPayer,Inc.#g  Z#  g  "x[ Athens  "x\ AL 4* "x]  @2@42 4*("x^  @2 @ 4IncineratorandRecuperativeThermaloxidizer  #a 8.63(VOC)#g  ]#  g# XR X  C#   X XR  "<c MetalCoatersofCalifornia  $Xd RanchoϢCucamonga  %f CA 4* $Xg  ?1?41 4*($Xh  ?1 ? 4Regenerativeoxidizerforovensandcoatingrooms  p&k 6.75(CalEPA)#g  ^#  g# XR X  A_#   X XR  %m MetalCoatersofGeorgiaInc.  '8 n Marietta  '8 o GA 4* '8 p  ?1?41 4*('8 q  ?1 ? 4Smithdirectfiredthermalincinerator  ( s 29(TRI)#g  `##X4vXg`#gXX4v  g  ( u MetalPrep  )T"v Memphis  )T"w TN 4* )T"x  ?1?41 4*()T"y  ?1 ? 4Directfiredthermalincinerator  *#{ 16(TRI)#g  b##X4vXggb# XR XXX4v   X XR  *#} MetalPrep#g  c#  g  d Houston  d TX  d   d DirectFiredThermal Incinerator#g  md#  g# XR X  d#   X XR  ( 23(TRI)#g  6e#  g# XR X  xe#   X XR  ( MidwestMetalCoatings     GraniteCity     IL     onlineend1998    oxidizer/ovencombination   D 35(Constructionpermitapplication)#g  e#  g    MitsubishiChemicalAmerica,Inc.   $ Chesapeake   ` VA   `    `    ` #g  Ig#  g   ` ТNAPCOInc.   | Valencia   | PA 4*  |  ?1?41 4*( |  ?1 ? 4ThermalIncinerator   | 54.2(TRI)#g  6h#  g  @! NappSystems(USA),Inc.  ( " SanMarcos  ( # CA 4* ( $  ?1?41 4*(( %  ?1 ? 4  ( & 54.9ROG(CalEPA):  \ ( NatiowideCoilCoatingCo.Inc.  x * Toledo  D + OH  D ,   D -   D . :#g  hi#  g  \ ( ТNicholsAluminumDavenport  x * Davenport  D + IA 4* D ,  ?1?41 4*(D -  ?1 ? 4ovenemissionstoanafterburner  x / 12.2(perplant)#g  Mk#  g  x 1 #g  l#  gԢNorandalUSAInc.  ` 2 ТScottsboro  ` 3 AL 4* ` 4  ?1?41 4*(` 5  ?1 ? 4Afterburnerforovenandcoatingstations  $7 6to8#g  l#  g# XR X  f#   X XR  ` 8 ТNorandex  |9 Bedford  |: OH 4* |;  ?1?41 4*(|<  ?1 ? 4  |=   |> ТORMETAluminumMillProductsCorp.  @ Jackson  DA TN  DB   DC   DD #g  5n#  g  DE PacesetterSteelServiceIL#g  4p#  g  `F ТSaukVillage  `G IL  `H   `I   `J #g  p#  g# XR X  wn#   X XR  `K PacesetterSteelServiceTX#g  cq#  g  HL Houston  HM TX  HN   HO   HP #g  r#  g# XR X  q#   X XR  HQ ТPittsburgCanfield  R ТCanfield  S OH 4* T  ?1?41 4*(U  ?1 ? 4  V 5.9(TRI)#g  r#  g  dX PolychromeCorp.  ,Y Columbus  ,Z GA 4* ,[  @3@43 4*(,\  @3 @ 4hoods&scrubbersonpretreatmentdiptanks;coatinglinesventedtotwothermalincinerators(line1ventedtooneincinerator&lines2&3ventedtotheother)  %Le #g  9t#  g  ,f PolymerCoilCoaters  4'g Fairfield  4'h AL 4* 4'i  ?1?41 4*(4'j  ?1 ? 4twothermalincinerators  'h l 35(ICR1996)#g  u#  g  'h n PreFinishMetals,Inc.  d ElkGroveVillage  ( IL 4* d  ?1?41 4*(d  ?1 ? 4thermaloxidizersforprime&finishexhaust  ( 16*(TRI.majorforϢMEK)#g  7w#  g *TBDperplant#g  x#  g   t  PreFinishMetals,Inc.#g  y#  g \   Plant7(new)    ElkGroveVillage    IL 4* \   ?1?41 4*(\   ?1 ? 4thermaloxidizersforprime&finishexhaust#g  |y#  g    30*(TRI)*TBDperplant#g  z#  g   PreFinishMetals,Inc.#g  ${#  g  p Middletown  p OH 4* p  ?1?41 4*(p  ?1 ? 4recuperativethermaloxidizer  4  113*(TRI)*TBDperplant#g  {#  g  L " PreFinishMetals,Inc.#g  |#   # ТMorrisville   $ PA 4*  %  ?1?41 4*( &  ?1 ? 4recuperativethermaloxidizer  h ( 59(StateofPA1996data)  g  , + ТPrecoatMetals  , #g  ~#  gChicago#g  ~#  g  - IL 4* .  ?1?41 4*(/  ?1 ? 4Recuperativethermaloxidizerforprime&finish#g  ~#  g   |2 69(TRI)#g  #  g  H4 ТPrecoatMetals#g  3#  g  d5 GraniteCity#g  #  g  d6 IL 4* d7  ?1?41 4*(d8  ?1 ? 4Thermaloxidizerforprime&finish#g  #  g  (: 44(TRI)#g  #  g  (< ТPrecoatMetals  = Portage  > IN 4* ?  ?1?41 4*(@  ?1 ? 4Recuperativeforprime,regenerativeforfinish#g  A#  g  xC 59(TRI)#g  s#  g  DE ТPrecoatMetals#g  ҃#  g  `F St.Louis#g  9#  g  `G MO 4* `H  @2@42 4*(`I  @2 @ 4Thermaloxidizerforbothlines#g  #  g  $K 84(TRI)#g  z#  g  $M ТPrecoatMetals#g  م#  g  | N Jackson#g  @#  gԀ  | O MS 4* | P  ?1?41 4*(| Q  ?1 ? 4Onethermaloxidizerforbothovens#g  #  g 6, @!S ffffff"@9.2ffffff"@69.2#g  #  g 6,*@!U ffffff"@9.2 ffffff"@ 6#g  #  gԢPrecoatMetals#g  y#  g  "V ТMcKeesport  "W PA 4* "X  @2@42 4*("Y  @2 @ 4Thermaloxidizersforbothlines  \#[ 52(TRI)#g  ˈ#  g  \#] ТPrecoatMetals#g  #  g  $$^ Houston#g  R#  g  $$_ TX 4* $$`  ?1?41 4*($$a  ?1 ? 4Recuperativeoxidizerforprime&finish#g  #  g 5+ x%c  L@56L@5#g  #  g56 $$d #g  #  g 5+)x%e  L@56 L@ 5PriorCoatedMetals,Inc.#g  j#  g  &@f Allentown  &@g PA 4* &@h  ?1?41 4*(&@i  ?1 ? 4HirtThermalincineratorforoven  ' k 20(TRI)#g  #  g  ' m ProTecCoatingCo.  (\!n Leipsic  (\!o OH  (\!p   (\!q   (\!r #g  #  g  (\!s ReynoldsMetals#g  #  g  d Sheffield#g  f#  g  d AL 4* d  @2@42 4*(d  @2 @ 4twocuringovensexhaust(or1ovenand1coaterheadexhaust) tothermalincinerator#g  Ə#  g  @  547(TRI)#g  #  g  (  ReynoldsMetalsCo.AlloysPlant     MuscleShoals    AL 4*    ?1?41 4*(   ?1 ? 4oven/coater/paintmixroomexhaust#g  I#  gԀtwo \  thermalincineration#g  #  g    #g  #  g    ReynoldsMetals  x Harrison  x OH  x   x   x   x ReynoldsMetals  @ Richmond  @ VA  @   @   @   @  RollCoater  ( ! Greenfield  ( " IN 4* ( #  @2@42 4*(( $  @2 @ 4thermaloxidizers 8. \ & ̬Z@106.7̬Z@8106.7#g  M#  g 8.,\ ( ̬Z@106.7 ̬Z@ 8RollCoater#g  ͕#  g  D ) ТKingsbury  D * IN 4* D +  ?1?41#g  T#  g 4*(D ,  ?1 ? 4thermaloxidizers#g  #  g  x . 114#g  #  g D / (TRI)#g  #  g  x 0 RollCoater#g  ?#  g  ` 1 ТWeirton  ` 2 WV 4* ` 3  ?1?41 4*(` 4  ?1 ? 4thermaloxidizer#g  #  g  $6 230VOC(StateEstimate)#g  #  g  $8 RollexCorporation  |9 Ixonia  |: WI 4* |;  @2@42 4*(|<  @2 @ 4RegenerativeThermalOxidizer  @> #g  #  g  |? SignodeEasternOperations  @ SparrowsPoint  \B MD 4* C  @2@42 4*(D  @2 @ 4Thermalincinerator  E   F SmithSteelite  $G Cambridge  $H OH  $I   $J   $K #g  8#  g  $L SouthwesternOhioSteel   |M Hamilton   |N OH   |O    |P    |Q    |R SpringsWindowFashions  dS Montgomery  dT PA 4* dU  "@9"@49 4*(dV  "@9 "@ 4  dW #g   #  g  dX SpringsWindowFashions  ,Y Middleton  ,Z WI 4* ,[  ?1?41 4*(,\  ?1 ? 4  ,]   ,^ StanleyWorks  !_ NewBritain  !` CT 4* !a  @6@46 4*(!b  @6 @ 4  !c ;  !d ТStolleCorp.  l"e Sidney  l"f OH 4* l"g  ?1?41 4*(l"h  ?1 ? 4  l"i ;  !d ТTeleldyneRodneyMetals  l"e NewBedford  l"f MA 4* l"g  @2@42 4*(l"h  @2 @ 4  l"i   l"j UnitedCoaters  #4k ТAmbridge  #4l PA 4* #4m  ?1?41 4*(#4n  ?1 ? 4Ovenincineration  #4o 10.78(TRI)#g  ̞#  g  $q ТVulcraft  %Pr FortPayne  %Ps AL 4* %Pt  ?1?41 4*(%Pu  ?1 ? 4  %Pv 36.3VOC(ADEM)#g  x#  g# XR X  s#   X XR  &x ТWalbridgeCoatings  'l y ТWalbridge  'l z OH  'l {   'l | Ovenincineration  'l } 6.5(TRI)#g  #  g  (0! WesternMetalDecorating  *" RanchoϢCucamonga  *L# CA  *"   *"   *" #g  ݥ#  g  *" ТWismarqCorp.  4,$ ТOconomowoc  4,$ WI  4,$   4,$   4,$ #g  ɦ#  g  4,$ ТWorldsourceCoilCoatingInc.  ( ТHawesville  d KY  d   d   d 0.7(TRI)#g  #  g  ( ТWorthingtonSteel     Malvern     PA 4*     ?1?41 4*(    ?1 ? 4     27.9(TRI)#g  #  g# XR X  #  D q #X4vX X XR#*X` XX*