United States     Office of Air Quality      EPA-450/3-83-013
, ___ Environmental Protection Planning and Standards     June 1983
tO7\ Agency        Research Triangle Park NC 27711
   Air
   Glossary for Air
   Pollution Control
   of Industrial
   Coating Operations
   (With Graphical Aids
   for Rapid Estimation
   of Acceptable
   Compliance Alternatives)

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                  EPA-450/3-83-013
Glossary for Air Pollution
   Control of Industrial
    Coating Operations

(With Graphical Aids for Rapid
  Estimation of Acceptable
  Compliance Alternatives)

    Emission Standards and Engineering Division
                U.S. Environment?! Protection Agenc
                Region V, L" -vy
                230 South DaarLc/n S^est .--'"
                Chicago, Illinois €0604
    U.S ENVIRONMENTAL PROTECTION AGENCY
       Office of Air, Noise, and Radiation
    Office of Air Quality Planning and Standards
    Research Triangle Park, Norlti Carolina 27711
             June 1983

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 This report has been reviewed by the Emission Standards and
 Engineering Division of the Office of Air Quality Planning and
 Standards, EPA, and approved for publication Mention of trade
 names or commercial products is not intended to constitute
 endorsement or recommendation for use Copies of this report
 are available through the Library Services Office (MD 35), U S
 Environmental Protection  Agency, Research  Triangle Park,
 North Carolina 27711; or, for a fee, from the National Technical
 Information Services,  5285  Port  Royal Road,  Springfield,
 Virginia 22161.
              Publication No. EPA 450/3-83 013
US.  Environrr^ ^    •.-.,,-.
              	-•--•-tion  Agency

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                               PREFACE

      Since  1977  the U.S.  Environmental  Protection  Agency  has issued a
 series of   guidelines  and  regulations,  the  implementation  of  which
 will  result in large  reductions in air pollution emitted by  industrial
 coating operations.   The guidelines (referred to  as  Control Technique
 Guidelines, or CTG's)  are used  to apprise  the  States  of  reasonably
 available control  technology   for  major  existing  sources  of volatile
 organic compounds  (VOC's).   The Federal  regulations  are applicable to
 new or modified  sources  of pollution and are  known as New Source Per-
 formance Standards.

      This regulatory  activity  has  meant that  industries  must  become
 familiar with  regulatory terms from the  Clean Air Act,  and  State and
 local agencies  must  learn  terminology  from the  coatings  industry.
 This  glossary  is  an  attempt  to aid  both groups  by  listing  the  most
 common terms  which will  be  used   by  both   in  the application  of air
 pollution control  to  paints  and coatings.  The goal  is  for local  con-
 trol  agents and  industry representatives to be able  to  speak a  common
 language as they try to  mutually solve  the problems  of controlling air
 pollution from industrial coatings.

      Also included  as  Appendices  are  example calculations which  illus-
 trate important coating concepts.  Appendix A illustrates the effect of
 changes in  coating  solids  or  transfer efficiency on  the  amount  of VOC
which will   be  emitted from a  coating  operation.  Appendix B contains
 two charts which permit rapid manipulation of the various units  used to
 describe the solvent content of coatings.  Figure 1 allows rapid  calcu-
 lation of the  solvent  content of any of  three major  types  of coatings
when  the volume  percent  solids is  known.    Figure 2  allows a  quick
estimation of the emission reduction achieved when a coating with lower
solvent content Is  substituted for  one  which  contains more  solvent.
Appendix C  provides practical  examples  of how Figures  1  and 2 may  be
used to determine  the  possible  compliance alternatives available  to  a
coater.
er~
                                                             ytThst-ii^) „
                                                 Wi 1 1 iam Johnson
                                          Chemical  Applications  Section
                                              Emission Standards and
                                               Engineering  Division
                                 ill

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IV

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                           TABU OK CONTENTS
GLOSSARY OF TERMS  	   pa   j

APPENDIX A  -   SURFACE COATING EMISSION CALCINATIONS	  Page 25

APPENDIX B  -   RAPID CONVERSION AIDS 	  page 31

APPENDIX C  -   EXAMPLE OE DETERMINING COMPLIANCE ALTERNATIVES
                 USING GRAPHICAL AIDS 	  page 35

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                          Glossary  of Terms
 Absorption  -   The  unit operation in  which  one or  more  soluble compo-
      nents  of  a  gas mixture are dissolved in a liquid.

 Add-on control device  -  An air pollution control  device such as carbon
      adsorber  or  incinerator which reduces the pollution in an exhaust
      gas.   The control device usually does riot affect the process being
      controlled  and thus is  "add-on" technology as opposed to a scheme
      to  control  pollution through making some alteration to the basic
      process.

 Affected facility - With reference to  a  stationary  source,  any appara-
      tus to which a standard is applicable.

 Ajr dl"y -  A  coating   which  dries  or  cures   at  ambient  temperature.

 Air spray  -   Spray coating method in which the coating  is  atomized by
      mixing it with compressed air.

 Airless spray  -  Spray coating method in which the  coating  is  atomized
      byTorcing it  through a small  opening at high pressure.   The  liquid
      coating is  not  mixed   with  air  before exiting  from  the  nozzle.

 ALAPCO  -  Association of Local  Air  Pollution  Control  Officials.

 Aliphatic compounds  -  Organic  compounds composed of  open chains of car-
      bon  atoms.   These include  parafins and  olefins,  but  not aromatic
      compounds.

 Alternative  method   -   Any  method  of sampling and analyzing for an  air
      pollutant which is  not  a  reference or equivalent method but which
      has  been  demonstrated  to  the  Administrator's  satisfaction to   in
      specific cases, produce  results  adequate  for  his determination  of
      compl iance.

 Anodic electrodeposition  -  Electrodepositiori  in which  the  part being
      painted is wired  to  serve  as  the  anode  or  electron  donor.   This
     was the  first  type  of  electrodeposition  developed,   but has been
      largely replaced  by  cathodic  electrodeposition  which  gives  better
     corrosion protection.

Applied solids  -  Solids which remain on the substrate being coated  or
     painted.

Architectural coatings  - Stock  type or  shelf coatings  which  are  formu-
     lated for service under environmental conditions, and for  general

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     application on new and existing  residential,  commercial,  institu-
     tional,  and industrial  structures.  These are  distributed through
     wholesale  -  retail  channels  and purchased  by  the  general  public,
     painters, building contractors,  and others.

Aromatic solvent  - Solvents made  of compounds that contain an  unsat-
     urated ring  of  carbon  atoms,  typified  by  benzene's  structure.
     Xylene  and  toluene  are aromatic solvents often used in coatings.

Attainment area  -  An area which  is  considered  to  have air  quality  as
     good as  or better than  the  national  ambient  air quality  standards,
     as defined by Section 107 of  the Clean Air Act.   An area may  be  an
     attainment  area   for one pollutant and  a non-attainment  area for
     others.

Automatic electrostatic spray  application - Electrostatic spray applied
     by a robot or other self-acting mechanism.   Automatic electrostatic
     spray can be a very  effient  way to transfer coatings to  the  sub-
     strate thus reducing pollution  which  otherwise would result  from
     wasted paint overspray.

BACT  -  "Best available control  technology"  -  an  emission  limitation
     based  on  the maximum   degree of emission reduction which (consi-
     dering energy,  environmental,  and  economic  impacts  and  other
     costs)  is achievable through application of production processes
     and available methods,   systems, and techniques.   In no  event does
     BACT  permit emissions  in excess of those allowed under  any  appli-
     cable NSPS or NESHAP.   It   is  applicable on a case-by-case basis
     for each  major  new  (or modified)  emission source to  be located
     in areas attaining  the  National  Ambient  Air Quality  Standards.
     It applies  to  each   pollutant  regulated under the Act,   and   is
     concerned with Prevention  of Significant  Deterioration (PSD).  See
     Sections 165(a)(4) and  169  of the Clean Air  Act.

Baking temperatures -  The recommended temperatures for operation of  the
     curing oven in which  a  coated part is baked  or cured to  obtain op-
     timum properties.    The  amount of volatile  material released from
     the  coating  can  sometimes  increase  if  baking   temperature  is
     increased.

Banking  -   A  system  for  recording qualified emission reductions  for
     later use in bubble,  offset,  or netting transactions.

Base coat/Clear coat -  A two step finish coat system in which  a highly
     pigmented, often metallic,  basecoat is followed by  a thicker clear
     coat.    It  reportedly   results  in  a  finish  with  high  gloss
     characteristics.

Bell  -  An electrostatic spray  device in which the paint applicator  is
     shaped   like  a  bell.   This  bell revolves rapidly so that paint,
     metered  to the center of the bell,  is  thrown by certifugal force
     off of the edge as a fine mist.   High electrostatic voltage main-
     tained on  the  bell   also  contributes to keeping  the paint spray
     a  fine mist.   This  fine  mist  allows  electrostatic  forces   to

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      draw  the paint  to  the  part  being  coated very efficiently with
      very  little  overspray.   The  bell  is one of the most efficient
      pieces of spray  equipment  with  transfer  efficiencies  commonly
      over  90  percent.   When  high  bell speeds are used (over 30 000
      revolutions per minute)  then  high solids coatings may be sprayed
      more easily than with other types of spray equipment.

 Beverage can  -   A can used for soft drinks or beer.

 JJinder -  Nonvolatile portion of the liquid portion of a coating.   When
      the paint dries,  the binder becomes part of the solid film,  bind-
      ing the pigment particles together and cementing the paint film to
      the substrate over which it is applied.

 Blushing  -  A film defect appearing as a milky opalescence which  some-
      times  appears  as the film or lacquer dries.    It is often caused
      when the  rapid solvent evaporation  cools  the   surface and causes
      Moisture   from  the  air  to  condense  on  the  wet  coating.   This
      condition is  commonly encountered in  the  wood  furniture industry.

 Bubble  -  A system under which existing sources can  propose alternative
      means   to  comply   with  a set  of  emission limitations.    Under  the
      bubble concept,   sources   can   control   more   than required at  one
      emission  point where control costs  are  relatively low  in  return
      for  a comparable   relaxation  of   controls  at a second emission
      point  where costs  are  high.  The  bubble  policy was first  announced
      in the Federal Register  December  11,   1979  (44  FR  71779),   and
      changes were  proposed  on  April  7,  1982.

 Capture  -  The containment or  recovery of  emissions front a process  for
      direction  into  a   duct which  may be  exhausted through a stack or
      sent  to a control device.  The  overall abatement of emissions from
      a  process with an add-on control device  is a function both  of the
      capture efficiency and of the control device.

 Capture device  -  A hood, enclosed  room, floor sweep or other means of
      collecting solvent or other pollutants into a duct.  The pollutant
      can then be directed to a pollution control device  such as an in-
      cinerator or carbon adsorber.   Sometimes the term is used loosely
      to include the control device.

 Capture Efficiency -  The fraction of all organic vapors generated  by a
      process that  are  directed  to   an  abatement  or  recovery  device.

Carbon Adsorber -  An add-on control device which uses activated carbon
      to absorb  volatile organic compounds from a gas  stream.  The VOC's
      are later  recovered  from  the  carbon, usually by  steam stripping.

Cast coating -   a film made by depositing a  layer of plastic  material
      in solution,  in a dispersion or in a molten state onto a (usually)
     smooth solid surface.  The plastic is  solidified and  removed  from
     the surface  as a  film having the same type of  surface as the solid
     surface on which  it  was formed.

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Catalytic incinerator -  A control  device which oxidizes  VOC  by  using  a
     catalyst to promote  the  combustion process.   The catalyst allows
     the combustion process to proceed at a lower temperature  (usually
     around  600°F  to  800°F)  than a conventional  thermal  incinerator
     would require  (1,100 to 1,400°F),   resulting  in fuel  savings  and
     lower cost incineration.

Cathodic electrodeposition  -  An  electrodeposition  paint,  application
     technique where the part being painted is the   cathode.   Cathodic
     electrodeposition gives superior corrosion resistant coatings   and
     has  largely  replaced  the  older   anodic  processes.    Cathodic
     electrodeposition is  often  used  to  apply  automobile primers.

Cellosolve  -  Proprietary  name for Union Carbide's brand of monoethyl
     ether of ethylene glycol,  CzHsOCHzCHzOH,  a commonly used  solvent
     for water borne coatings.   It  is   also  their generic  name for  a
     series  of  ethers  of  similar type such as methyl  cellosolve  and
     butyl cellosolve.

Cellulosic coating  -  A coating in which a large portion of  the solids
     are made up  of  chemically  treated  cellulose.   Cellulose lacquers
     are  widely   used   in the  wood furniture  Industry   for topcoats.

Chalking - Formation of a powder on  the  surface  of  a  paint film caused
     by disintegration of the binding due to weathering.

Clean Air Act - The Clean Air  Act,  as amended,  provides  the  foundation
     forEPA's  efforts  to improve air quality.   The Clean Air Act,
     building on  earlier  legislation,  was passed in  1970,  and  was a-
     mended in 1977.

Clear coat  -  A  transparent  coating  usually  applied  over a  colored
     opaque  coat  to  give  improved gloss and protection to the color
     coat below.   In  some  cases  a  clear  coat simply refers to  any
     transparent coating without regard  to the substrate.

Chlorinated solvent - An organic solvent  which  contains  chlorine atoms
     as part of the  molecular  structure.   For example, methylene chlo-
     ride and  1,1,1  -  trichloroethane,   the  most common,  are used   in
     aerosol spray containers and in traffic paint.   Certain  chlorinat-
     ed solvents are exempt from some air pollution  regulations  because
     of their low photochemical reactivity.

Coating -  A protective or decorative film applied in a thin  layer to  a
     surface.   This  term  often applies to paints  such  as  lacquers or
     enamels,  but  also  is  used  to refer to films applied to paper,
     plastics or foil.

Coating application station  -  The  part  of  a coating  line where  the
     coating Is  applied.   In a  spray operation  it  is the spray booth
     and is dlstinquished from the flash off area and oven.

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 Coating head  -  The  coating  applicator in a roll  coater,  rotogravure
      coater or knife coating operation.

 Coating solids  -   The  part  of  the  coating which remains after the
      coating is dried or cured.

 Coil  coating -  A very efficient metal coating operation  in  which sheet
      metal  is unwound from a coil,   roller coated and rewound.   The me-
      tal   may  then  be  formed  into products such as aluminum  siding,
      automobile parts or a variety  of  other items.

 Compliance  coating  - A coating  whose  volatile organic  compound  content
      does  not exceed that allowed by regulation.   Compliance coatings
      may  be  water  borne,   low   solvent   (higher solids)   or   powder.

 Compliance  schedule - A negotiated  agreement  between  a  pollution source
      amiif  government  agency   that  specifies dates and procedures by
      which  a  source will  reduce  emissions  and,   thereby,  comply with a
      regulation.

 Condensation   -   A  method  of   solvent recovery  in which the vaporized
      solvent  is  liquified generally by cooling.

 Control -   In the air pollution  field, this means  the abatement  of  pol-
      T¥tants  which might  be  exhausted  into  the  atmosphere.    It  often
      refers  to  the collection or destruction  efficiency of   an  add-on
      device  such  as an incinerator  or  carbon adsorber  as  opposed  to
      capture  of  the pollutants into the device.

 Control device  - Any equipment which reduces the quantity of a pollutant
      that Is  emitted to  the  air.   The device may destroy or  secure the
      pollutant   for subsequent recovery.   Examples  are  incinerators,
      carbon adsorbers  arid condensers.

 Control device efficiency  -   The ratio of the pollution released by a
      control  deviceand  the pollution introduced to the control  device
      expressed as  a  percentage.

Control Technique Guidelines (CTG) - A series  of documents  prepared by
      FPA to assistSlatesHI defining   reasonable  available  control
      technology (RACT) for major sources  of volatile  organic compounds
      (VOC).   The documents provide  information on the economic  and
      technological  feasibility of available techniques;  and,   in some
      cases,  suggest limits on VOC emissions.

Cowtall  -  Small  marks  of paint applied to wood furniture  to  give an
      antique effect.

Cratering  - A paint  film imperfection which appears as tiny  depressions
      Tn the surface.

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Criteria pollutant - A pollutant for which  a criteria  document  has  been
     issued as described by Section 108 of  the Clean Air  Act.   Criteria
     pollutants are nitrogen oxides, sulfur oxides, ozone,   particulate
     matter, and  carbon  monoxide.   A  national  Ambient  Air   Quality
     Standards (NAAQS) exists for each  criteria pollutant.

CTG  -  A Control Technique Guideline.

Cure volatlles -  Reaction products which  are emitted  during the chemi-
     caT reaction which takes place in  some coating films  at  the  cure
     temperature.   These  emissions  are   other  than  those  from the
     solvents in the coating.

Curing oven  -  A  heating  chamber  where   wet paint  solidifies either
     by drying  or  by  chemical  cross  linking  of   the  paint  film.

Designated pollutant  -   A pollutant which is not a criteria pollutant
     (as described in Section 108 of the Clean Air Act)  nor a ha/ardous
     air pollutant (as defined in Section  112 of the Clean  Air  Act)  but
     for which new source performance standards exist.   States are re-
     quired to control these pollutants under Section  Hid  of the Clean
     Air Act.  Designated pollutants are acid mist, total reduced sulfur
     (TRS), and fluorides.

Disk  -   An electrostatic spray application device which consists of  a
     rapidly spinning metal disk onto which paint Is  fed.  The  paint is
     slung off the edge of the rotating disk by centrifugal  force  and
     the paint is formed into a fine mist.    This  device applies paint
     with high transfer efficiency.

Distress  -   A mechanical deforming of the surface of a  piece  of  wood
     FuTniture during the coating process  to give an antique appearance.

Dip coating  -   Method of applying a coating in which the  substrate is
     dipped into a tank of coating and  then withdrawn.

Doctor blade - Method of applying a coating in which  a flat metal strip
     or blade Is mounted such that it scrapes off excess  coating from  a
     roll or rotogravure coater before  the coater contacts  the  paper or
     other substrate being coated.

EDP - See Electrodeposition.

Elastomer  -  A  natural  or  synthetic  polymer  which has rubber-like
     properties.

Electrocoat - See Electrodeposition.

Electrodeposition -  Dip coating method in which an electrical  field is
     used to promote  the  deposition  of  the coating material  onto the
     part.   The part being painted acts as an electrode which  is oppo-
     sitely changed  from  the  particles  of  paint  in  the dip  tank.

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  Electron beam  -   A  method  of  curing  coatings  which  uses  high  energy
       radiation  to  cross-link  polymers.

  Electrostatic spray - A method  of  applying  a  spray coating in which op-
       posite  electrical charges  are  applied  to   the  substrate  and  the
       coating.   The coating is  attracted  to the object  by the  electro-
       static  potential  between them.

  Elpo  - See Electrodeposition.

  Emission  reduction  -  The decrease in VOC emitted when (1) a  low solvent
      coating is used in place  of a higher  solvent  coating or  (2)  an
      add-on  control device  (such  as  carbon  adsorber  or incinerator) is
      used on  a  process.   Emission  reduction is  often expressed  as  a
      percentage.  Figure 2  in Appendex 0 allows rapid estimation of the
      percent reduction when one  coating is  substituted for  another.

 Emulsion -  A  two  phase   liquid system in  which small  droplets  of one
      liquid are uniformly dispersed throughout the second.

 Enamel^ - A coating that cures by chemical cross-linking of  its  base re-
      sin.   Enamels can be readily distinguished from  lacquers  because
      enamels are not resoluble in their original  solvent.

 End sealing compound  -   A  viscous  coating  used to form a seal or
      gasket between "the end  of a can and  the can body.

 Equivalent method  - Any method  of  sampling arid analyzing  for  an air
      pollutant which has been demonstrated to the Administrator's satis-
      faction  to  have a consistent and quantitatively known relationship
      to the reference method,  under  specific conditions.

 Exempt  solvent   -    Specified  organic compounds  that are not  subject to
      the  requirements  of a regulation.    Such  solvents  that have been
      deemed of negligible photochemical reactivity by EPA  are:   meth-
      ane,  ethane, 1,1,1-trichloroethane (methyl chloroform),  methylene
      chloride, trichlorofluoromethane (CFC-11), dichlorodifluoromethane
      (CFC-12), chlorodifluoromethane  (CFC22), trifluoromethane (FC-23)
      trichlorotrifluoroethane  (CFC-113),  dichlorotetrafluoroethane  '
      (CFC-114), and  chloropentafluoroethane  (CFC-115).

 Existing  source  -   Any stationary source of  air pollution other than a
     new  source.

 Exterior basecoat -  A coating applied to the outside  of a beverage can
     toprovide  both  corrosion  resistance  and  as  a background for
     lithography or printing.

Face velocity - The velocity  of air through a paint spray booth.   Where
     people are working,  health regulations  usually  require  this  velo-
     city to be at least 100  feet  per minute.   When electrostatic  spray-
     ing is used a  face velocity  of  60 feet per minute is permitted.

Fabric coatui^  -  A process  which applies a  uniform layer of  polymeric
     resin  on  a   supporting  fabric  substrate.   Typical coatings  are
     rubbers,  urethanes,  vinyls,  and  acrylics.

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Fabric printing  - A process which applies  a decorative,  usually  multi-
     colored pattern on a fabric  substrate.

Filler -  A thick coating applied to wood furniture to fill  large pores
    "Tn the wood.

Film former - The part of a coating that remains on the substrate after
     the cure.   Some film formers may be liquid but polymerize to form
     a  solid  when  the  coating  is  baked  to  the  requisite  curing
     temperature.

Film thickness  -   The  thickness of the dry cured coating  on  the sub-
     strate.Film thickness varies with application,   but  coatings  on
     metal generally range from 0.5 to 4 mils.

Flashoff zone -  The area within  a  plant where solvents evaporate  from a
     coating  during  the  interval between coats or before  the painted
     object enters a bake oven.

Flat screen printer  - A semi continuous process for printing on  fabric.
     fhe fabric is placed on a belt, the belt and fabric  are moved into
     position under the flat screen, and the belt is stopped.   The flat
     screen, on which print paste has been  applied is mechanically low-
     ered onto the fabric.   A squeegee moves across the  screen  forcing
     print paste through a pattern onto the fabric.   The screen  is then
     raised and the fabrics  and  belt are Indexed to the  next  position
     to receive  another  screen   and another  color  on  the  pattern.

Flexible packaging - Use of paper, aluminum foil, cellophane or plastic
     films either singly or in combination  to  produce  bags,   pouches,
     and wraps  for  consumer  and  industrial  products.   The  flexible
     package will typically  be less  than 50 micrometers  (0.002  inches)
     thick and will usually conform to the shape of the item(s)  it con-
     tains.

Flexible vinyl products  -   Those  products  composed  of  a supported
~~    or  nonsupported  vinyl  sheet  or coating and more than 50  micro-
     meters (0.002 Inches) thick.   This  term  does  not include vinyl
     resilient floor coverings.

Flexography -  A method of printing in which the image areas are  raised
     above the non-image areas.  The image carrier is made of rubber or
     other elastomeric material.

Floor sweep -  A vapor collection duct designed to capture vapors which
     are heavier than air and which collect along the floor.

Flow coat  -  Method  of  applying  coating  to  an object in which the
'     coating  is poured on the object.

Fluldized bed coating -  A powder coating technique in which the powder
     is applied by lowering  the part to be coated into a fluidized con-
     tainer of powder. The powder  is "fluidized" by blowing air through
     the powder from the bottom of the container.

                                   8

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 Fly speck   -  Small spots of paint that are sprayed onto wood furniture
      to create an antique affect.

 Freedom of  Information request  -  A   request   for  information from a
      Federal government agency  pursuant to  the   Freedom  of Information
      Act.

 Fugitive emissions - Emissions not caught by a capture system.

 General provisions - Suhpart A of part 60 -  Standard of Performance for
      New  Stationary  Sources in 40 CFR 60.    This subpart contains in-
      structions  on  monitoring  and  recordkeeping  and  definitions  of
      terms generally used in the program for development  of  new source
      performance standards.

 Glaze -  Small  amount of color coating added to  wood furniture  to high-
      light and  give character to the wood.    These  are  often manually
      wiped to remove most of the color.

 Gloss  -  A P/operty of  paints and  enamels which  can be  characterized  by
      measuring   the  specular  reflectance   of the air-dried  film using
      ASTM that  D  523-67 (1972)  Test  for  Specular Gloss.    The 60-degree
      specular  gloss   test  is   used   for  all   except  flat paints.  A
      measurement  of  65 or more  characterize the material   as  "gloss".
      Semi gloss   paints   are   those with  readings  between about 30  to
     65;   "flats" when  tested at an 85 degree angle  have  readings below
      15.

 Grain raising -    Swelling of the  fibers of  wood caused by  absorbed 11-
     qulds,  especially  water.  Grain  raising causes  the surface of wood
     to look  and  feel rough.

 Handheld electrostatic   -  A  hand  held spray gun which uses electrosta-
     ticstoimprove  efficiency.   This   application  gives  higher
     transfer efficiency than nonelectrostatic hand held spray.

 Hazardous pollutant -  An  air pollutant to which no ambient air quality
     standard is  applicable and which causes or contributes to air pol-
     lution  which  may  reasonably  be  anticipated  to  result  in an
     increase  in  serious  irreversible  or incapacitating reversible,
     illness.  This definition Is given 1n Section 112 of  the Clean Air
     Act.  Hazardous pollutants  include asbestos,  mercury,  beryllium
     benzene, arsenic, vinyl  chloride and radionuclides.

Higher-solids coatings  -  Paints containing  considerably  higher  solids
     than has been conventional  in the past.  Usually paints with  great-
     er than 60 percent solids by volume are  considered higher   solids
     coatings although the term is  often applied  to  any  coating which
     meets any of EPA's  Control  Technique Guidelines.   Formerly,  under
     California's Rule 66,   a  high  solids paint is one containing  not
     less than 80 percent solids by volume.

Hood  -   A partial enclosure  or  canopy for capturing and exhausting, by
     means of a  draft,   the organic vapors or other fumes  rising  from  a
     coating process or  other source.

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Hood capture efficiency  -   The emissions  from a  process  which  are  cap-
     tured by the hood and  directed into the control  device,  expressed
     as a percent of all  emissions.

Hot melt adhesive - Adhesive which is applied in  a  molten condition and
     cools rapidly to form  a solid.   Hot  melt adhesives  contain  little
     or no volatile organic solvents.

Hydrocarbon -  An organic compound consisting only  of carbon  and  hydro-
     gen.   Sometimes  the   term  hydrocarbon  is  used  loosely   (but
     incorrectly) to refer  to any organic  compound.

Infrared (I. R.)  -  Electromagnetic radiation of wave lengths  between
     U./8 and 1.0 micrometer (780  to 1000 nanometer)  sometimes used to
     cure coatings.

Inside spray -  Coating  applied  (sprayed) on  inside  on cans  to provide
     a protective  film between the  contents  of  the  can and  the  can
     body.

Isocyanate - A compound containing the functional group,  -N=C=0.   These
     functional groups may  be crosslinked with a  hydroxyl   containing
     material  to  form  urethane  polymers   which   are often  used  in
     coatings.

Knife coater  -  A coater used primarily for paper  or fabric  webs which
     employs an  adjustable  blade  or  "knife1  to  distribute a  liquid
     coating evenly over a  moving web surface.

LAER  -  "Lowest achievable emission rate" - Pursuant to  Section  171(1)
     of the Clean Air Act,   LAER  is  that  rate  of emissions which re-
     flects:

         (a)  the most stringent emission limitation which is contained
     in the implementation  plan of any State for  such class  or  category
     of sources,  unless   the  owner or operator  of the proposed  source
     demonstrates that such limitations are  not achievable;  or

         (b)  the  most stringent emission limitation which  is  achieved
     in practice by such  class or category of source, whichever is  more
     stringent.

     In no event,  however, shall the application of this term  permit a
     proposed new or modified source to emit any  pollutant in excess of
     the  amount  allowable  under  applicable  new source standards of
     performance.  Areas  of the country that have not attained  national
     ambient air quality standards may require LAER on  new  sources of
     pollution.

Lacquer  -  A coating which dries primarily  by solvent evaporation, and
     hence is resoluble in  its original solvent.
                                  10

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 Lamination -  The process of adhering two web surfaces together to form
      a single composite material.  Paper, fabric, foil and plastic film
      may be laminated to each other.

 Latex  -  A dispersion of rubber,  synthetic resin or  polymers used  in
      paints, adhesives, or coatings.

 LEL - See lower explosive limit.

 LEL Meter  -  A device used to measure the concentration  of combustible
      vapors in an air sample.

 Less water -  A term used by the  Environmental  Protection Agency  in its
      series of  Guidelines  to the States on development  of regulations
      for the coating industry   and  subsequently  adopted  by many  States
      in their regulations.   The  term usually appears  in  the expression
      "pounds of volatile organic  compound per gallon   of  coating   (less
      water)".

 Letter  press - A method of printing in which the  image areas are  raised
      above the background area.    The  mechanism  which   transfers  the
      image is  made  of metal  or  other relatively hard material.

 Lithography -  See off-set lithography.

 Lower Explosive  Limit -  (LED  -   The concentration of a compound  in air
      below which  a  flame will  not propagate  if the mixture  1s ignited.

 Low-solvent  coating   -   A  coating  which  contains a  lower amount  of
      volatile  organic  compound  (VOC) than conventional  organic solvent
      borne  coatings.   Low  solvent coatings usually fall   into the three
      major  groups  of  higher  solids,  waterborne  or  powder coatings.

 Magnet wire  - Wire used  In equipment such as electrical motors, genera-
      tors  and   transformers.   Magnet  wire  is coated with an elec-
      trically  insulating  varnish  or enamel.

 Maintenance coatings  -  Coatings used for bridges, chemical plants and
      other heavy duty  industrial  type applications.

 Major modification   (with respect to Prevention  of Significant  Deterio-
      ration and New Source Review)  -  This  term is defined as in Section
      111 of the Clean Air Act with two changes:    (1)  includes  only
     modifications to  major  stationary   sources   and   (2)   provides
      significant pollutant increase levels below which a modification is
      not considered major.   (See Section 111 (a)  of the Clean  Air Act
     40 CFR  51.24(b)(2),  (23);  52.2Kb)  (2), (23); and51.18(j)  (vi)
     (viii)).

Major stationary source  -  This term is  used to determine the  applica-
     bility of prevention of significant  deterioration  (PSD) and nonat-
     tainment new source review regulations.   In  a  nonattainnient  area,
     any stationary  source that has the potential  to emit  more  than 100
     tons per year is considered a  major  stationary   source.   In PSD


                                  11

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     areas, the cut-off  level  maybe cither  100  or 250  tons per year
     depending on  the type of  source.   (See Subsection 169  and  302{j)
     of the Clean  Air Act and 40 CFR Section 51.24(b)(lJ, 52.21  (b)0),
     and 51.18(j)(l)(i)-(vi)).

Make-up air -  Fresh air drawn in from  outside  the  plant  to  replace  the
     dlrty  solvent  laden  air from a  coating  operation  or  drying oven
     that is exhausted from the building.    This  make-up  air   must be
     heated in the winter to room temperature or even  to oven tempera-
     ture, thus accounting for a large  energy usage.

Make-up solvent  -  Portion  of  solvent required to compensate  for  the
     amount  Tost,  normally   via  evaporation,   during a manufacturing
     process.

Manufacturer's formulation -   A list of substances or component parts of
     coatings as described by the maker of  the  coatings.   This   may be
     used, in  many  cases,  to  calculate the volatile   organic compound
     content of a  coating.

Marine paint - A coating used on ships  or boats.

Material balance  -  A calculation based on conservation  of  mass,  i.e.,
     the amount of material going into  a process  is equal to the amount
     which leaves  the process.    This  relationship is  often   used to
     estimate solvent losses  from coating operations.

Metallic paint -  Paint containing tiny flecks  of aluminum or other  me-
     tal often used  for painting  automobiles because  of  the attractive
     appearance of the paint.

Method 18 - An EPA test  method which uses gas chromatographic techniques
     to measure the concentration of individual  volatile  organic
     compounds in a gas stream.

Method 24 - An EPA reference method to  determine  density, water  content
     amTtotal  volatile  content (water and  VOC) of  coatings.   (40  CFR
     Part 60 Appendix A)

Method 25 - An  EPA  reference method to determine the  VOC concentration
     of a gas stream. (40 CFR Part 60 Appendix  A)

Metric ton - A unit of weight equivalent to 2,204.6 pounds or one mega-
     gram (10^ grams).

Mini-bell  -  An electrostatic spray application  device using a  rapidly
     rotating bell to atomize paint. The bell is  of small diameter giv-
     ing  rise to  the name mini-bell.

Mil - A unit of length equal  to one thousandth  of an  inch.

Miscellaneous metal parts  -   As  used in  the  Environmental Protection
     Agency'sControlTechnique Guidelines, any metal parts excluding
                                   12

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      those produced in can, coil coating,  magnet wire,  metal  furniture,
      and large appliance plants, and also  excluding  automobile,   ship,
      and airplane bodies.

 Model plant - A description of a typical  but theoretical  plant used  for
      developing economic, environmental  impact,  and energy  impact
      analyses  as  support  for  regulations  or  regulatory  guidelines.
      It  is  an   imaginary  plant the parameters  of  which are  typical
      of  existing  or future plants.  The parameters  are used  to  esti-
      mate the cost  of  incorporating air  pollution  control  technology
      as the first step in  exploring the economic  impact  of a  potential
      NSPS.   Such   analyses   are   a   fundamental  part  of the development
      of a  standard,   as   recorded  in    the   Background Information
      Document.

 Modified source   -   An existing facility  in which  a  physical change in
      the facilfty, or a change   in   method   of operation, increases the
      amount of  any air pollutant  (to which a standard applies) emitted
      into the atmosphere  by  that facility or which  results  in the emis-
      sion of any  air pollutant   (to  which a  standard  applies)  into the
      atomosphere  not previously  emitted.

 Monomer - The starting compound  for  a polymerization  reaction.

 NAAQS   -   National  Ambient Air Quality Standards  are developed by EPA
      pursuant to  Section  109 of  the  Clean Air Act.   They are standards
      which,   in   the  judgement   of  the  Administrator of EPA, must be
      attained  and  maintained   in   order to protect the public health,
      with allowance  for an adequate  margin of safety.  "Secondary" NAAQS
      similiarly specify a level necessary to  protect the public welfare.

 NAPCTAC   -   "The National  Air Pollution Control Techniques Advisory Com-
 ~mTttee", a group constituted pursuant to §  117 of the CAA consist-
      ing  of representatives from  industry, universities, local  air pol-
      lution  control  agencies,  and environmental  groups.   The  committee
      meets at the  request of the Agencv  to assist in the development  of
      NSPS and NESHAP's.

 Naphtha - Any of  several  hydrocarbon solvents, or their mixtures, which
      are  derived  from petroleum products or coal  tar.  These  may be  com-
      posed of aliphatic or aromatic compounds.

 NESHAP -  National Emission Standards for Hazardous Air Pollutants,  re-
      gulations as defined in Section 112 of the Clean  Air  Act  which re-
      gulate asbestos, mercury,  beryllium,  benzene,  arsenic,  vinyl chlo-
      ride,  radionuclides   and  any other substance  for which no ambient
      air quality standard  is applicable  and which  in   the judgement of
      the EPA Administrator may  cause an  increase   in  mortality,  or an
      increase in serious  irreversible or incapacitating  reversible  ill-
     ness. (40 CFR Part 61)

New source -  Any  stationary source  the  construction or modification of
     which commences after the  publication  of regulations   or proposed
                                   13

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     regulations which prescribe a  standard  of  performance  which  is
     intended to apply to that  type  of air pollution emission  source.

New source performance standards -  see NSPS.

NCR stain -  Non-grain raising stain used on  wood furniture.   These  are
     usually organic borne because  of the tendency   of   water  to cause
     the grain of wood to swell.

Nonattainment area - An area,  as defined under Section  107  of the Clean
     Air Act,which is in violation of one or  more of  the  national
     ambient air quality standards.

NSPS - New  source  performance  standards, i.e.   standards  for emission
     of air  pollutants  from  new,    modified    or   reconstructed  sta-
     tionary emission sources  which   reflects  the  degree   of   emis-
     sion limitation  achievable through the  application of   the   best
     system of emission reduction which  (taking  into  account the cost
     of achieving  such  reduction)  the   administrator   determines   has
     been adequately demonstrated.   The Clean Air Act usually refers  to
     these as  standards   of  performance  for  new  stationary  sources.

OAQPS - The Office of Air Quality Planning and Standards,  a part  of  the
   ^~U.S. Environmental  Protection  Agency.

Offset 1ithography  -   A method of printing  in which the  image  area  of
     the printing roll is essentially at the  same level  as  the nonimage
     area.   The ink wets the  image area only and  the  nonimage  area  is
     wetted by water.  Ink is  transferred from the  printing roll  to  the
     rubber surface on a roll  called the blanket cylinder  which   trans-
     fers the ink to the paper.  When a web or continuous  roll of paper
     is used, the process is called "web offset."

Olefins -  A class of unstructured  aliphatic  hydrocarbons  having  one  or
     more double bonds.   The  double  bond makes these  compounds  highly
     chemically reactive and useful  as starting materials  for the manu-
     facture of other compounds.  Examples are  ethylene and propylene.

Orange peel -  A paint surface appearance, characterized by small  pits,
     resembling the surface texture of an orange. Depending on the pro-
     duct,  this  may  be desirable  (appliances) or highly undesirable
     (automobiles).

Organic aerosol - Fine organic  particles  or  droplets which remain dis-
     persed In the atmosphere.

Organisol  -  A thick coating consisting of resin and plastiicizers  and
"some  organic  solvent  which   is often  used to coat  flexible sub-
     strates such as paper or fabrics.   It is similar   to  a plastisol
     except that an organisol  contains more organic solvent.

Oven - Enclosed  area  in  which a coating  is heated  and  baked or  cured.
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 Overall control - The product of the capture efficiency and the control
      device efficiency gives an overall  control efficiency for the pro-
      cess.

 Overspray - That solids portion  of  a  coating sprayed from a  spray  ap-
      plicator which fails  to adhere to the part being sprayed.  (Applied
      solids plus overspray  solids equal  total  coating  solids  delivered
      by the spray application system.)

 Overvarnish  -  Coating applied over the ink on the outside of  beverage
      cans to provide gloss and protect the can  from corrosion and  abra-
      sion.

 Oxygenated solvent   -   An organic  solvent containing oxygen as  part  of
      the molecular  structure.   Alcohols  and ketones are  oxygenated com-
      pounds often used as  paint solvents.

 Ozone  -   An oxygen molecule  composed of three oxygen atoms.    It is a
      component of photochemical  smog and its concentration  in  the air
      is regulated by pollution control laws.    It   is a  pollutant  which
      meets the criteria  of Section  110 of the Clean Air  Act.

 Paper coating  -    As used in  Environmental  Protection Agency's  control
      technique guidelines,  is  the coating of paper,  plastic film or me-
      tallic  foil  usually  with a roll,  knife,   or  rotogravure   coater.

 Percent capture  -   The  ratio  of  solvent  vapors  collected into the cap-
      ture system  to  the  amount of solvent vapors released by a  process
      expressed as a  percentage.

 Photochemical  oxidant -    Ozone  and smaller  amount  of other irritating
      chemicals  such  as peroxyacetyl nitrate which are products of atmos-
      pheric  reactions  of volatile organic compounds,  NOX and sunlight.
      Photochemical oxidants  are a major portion of   the  air  pollution
      commonly  known  as "smog".

 Photochemical  reactivity - Measure of  the rate at which an organic com-
      pound reacts in  the presence of ultraviolet radiation to form pho-
      tochemical oxidants.

 Pigment   -   A  finely ground insoluble  powder dispersed  in a coating to
      give a characteristic color.

 Pinhole  - An imperfection in a paint film which resembles a hole caused
      B7 penetration with a pin.

 Plasticizer - A  substance  added to  a polymer composition to soften and
~add flexibility to the product.

 Plastisol  -  A coating made of a mixture of finely  divided resin and  a
      pTaTticizer.   It is applied as a  thick gel which solidifies  when
      heated.
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Precursor - In photochemical  terminology,  a compound such  as  a  volatile
     organic compound which  "precedes" oxidant.   Precursors react  in
     sunlight to form ozone or other photochemical  oxidants.

Pressure sensitive adhesive - An adhesive  which,  when placed  on  a  back-
     1ng material, "adheres  to another  surface   on  contact   without
     wetting, heating or adding a curing agent.

Primary heat recovery  -   A  method of conserving  energy  by  using heat
     from incinerator exhaust gases  to preheat the  inlet   gases  to the
     Incinerator.

Primer - First layer of coating applied to a surface.

Primer surfacer -  A coating, usually applied over  a thin  primer,  which
     gives  "body"  to the surface,   fills in irregularities  and unlike
     the primer,  is intentionally thick enough  to  permit  sanding  with-
     out cutting through to bare metal.   A  topcoat  Is applied over a
     primer surfacer.

Pot 11fe  -  The amount of time a paint may be stored before  it  hardens
     and can no longer be used.   This  usually   refers  to catalyzed or
     "two component"  coatings which may have a pot  life  of  only  a few
     hours after the two components  are combined.

Powder coating - A coating applied as a dry powder  which,  when  baked at
     sufficiently high temperature,  flows  out  to form a continuous  film.

Print paste - A pigmented coating used to  render designs on fabric, us-
     ually applied by the roller, rotary screen  or  flat  screen  printing
     processes.  Mineral  spirits  are  the  solvent in  print  pastes.

Promulgation - The publication of a  final  rule in the Federal Register.
     Promulgation  is   preceeded  by  a  formal  proposal publfshed in the
     Federal Register and an intervening public  comment  period.

Proposal -  The publication of a rule In a preliminary (not final) form
     in the  Federal Register.   Usually  comments  are invited  from the
     affectedpublic,  andthe  final  rule is promulgated  only  after
     these comments are considered.

PSD  -   Prevention of Significant Deterioration  refers  to regulations
~~~  requiring preconstruction review of major new sources  and major mo-
     difications  locating in attainment or  unclassified  areas   (clean
     air areas).  The requirements are outlined in  40 CFR  52.21, 40 CFR
     51.24, and Part D  of  the  Clean  Air Act.  The  objective  of the PSD
     program is to assure that areas of the country  that are  relatively
     free from air pollution remain that way.

RACT -  "Reasonably available control technology" -    the  lowest emission
     limit  that a particular source is capable of meeting  by  the appli-
     cation of control  technology that is   reasonably  available  consi-
     dering technological  and economic feasibility.  RACT  is  usually
     applied to  existing  sources  in  nonattainment areas and  in most
     cases  is  less  stringent  than  new source  performance  standards.
                                  16

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 Radiation cure  -    Method of curing or drying coatings by exposure to
      electromagnetic waves or particles such as infrared,  ultra-violet,
      or electron beam.

 Reactive compound - A volatile  organic compound which  is  a  precursor,
      i.e., reacts  in  the  atmosphere   to  form photochemical   oxidants!
      Almost all  organic  compounds  are  photoreactive,   but a  few  have
      such low reactively that they are  usually considered  nonreactive.
      Solvents that have  been  deemed  of negligible photochemical  reac-
      tivity by EPA  are:    methane,  ethane,  1,1,1-trichloroethane
      (methyl  chloroform),  methylene   chloride,   trichlorofluoromethane
      (CFC-11), dichlorodifluoromethane (CFC-12),   chlorodifluoromethane
      (CFC22), trifluoromethane  (FC-23),  trichlorotrifluoroethane
      (CFC-113),  dichlorotetrafluoroethane  (CFC-114),   and   chloropenta-
      fluoroethane (CFC-115),

 Reconstructed source  -    An  existing  facility  in  which  components  are
      replaced to such an extent that  the fixed capital cost of the  new
      components  exceed 50 percent  of  the fixed capital cost that would
      be  required to construct a comparable entirely new facility.    New
      source performance  standards  may be applied to sources,  which  are
      reconstructed after  the  proposal  of the standard  if it is techno-
      logically and economically  feasible to  meet the standard.

 Recovered solvent   -  Solvent which  is extracted from a process or ex-
      haust stream  usually  by  adsorbtion  or condensation.

 Reducing solvent -  A  solvent  added to dilute a coating usually for  the
      purpose  of  lowering  the  coating's  viscosity.

 Reference method -  Any  method of sampling  and  analyzing  for an  air
      pollutant which  is published in Appendix A of 40 CFR 60.

 Regulatory  alternative -   Any  of several air pollution control  strate-
      gtes  or  options  that  are considered  during the  development  of a
      regulation.  Each such alternative is evaluated  in terms  of  cost
      of  control  and economic  impact on  the industry.

 Release  coating  -  A coating  applied to a substrate   (usually a flexi-
      ble  one)which  limits the  adherence  of  a  pressure  sensitive
      coating.   This  is  used as a covering sheet for pressure  sensitive
      labels   so  that  the  labels can he pulled off and used.   The  back
      side of adhesive tapes  are  coated  with release  coating to allow
      the  tape  to be unrolled.

Reverse roll coater  -  A roll type coater for  paper,   film,   foil  and
     metal coil  which applies  coating  to the web  by a  roll  which turns
      in a reverse direction to the direction   of  travel   of  the   web.
     This procedure  is   said   to reduce  striations  in  the   coating.
Roll
coating (Roller coating)  -  Method of  applying  coating  to  a  flat
sheet or strip in which the  coating is  transferred  by  a  roller  or
series of rollers.
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Rotary screen printer  -   A  widely   used fabric  printing  technique  In
     which a moving fabric  web passes  in contact with  a  series  of  rota-
     ting drums.   The cylindrical drums  have holes  in the  drum surface
     in the shape of a pattern.    Liquid print  paste is  forced  through
     the holes in the drum  surface onto the fabric,   leaving  a pattern
     on the fabric surface.

Rotational electrostatic spray -  A  spray paint device which  uses  a ro-
     tatlng bell  or disk to shear the paint into a  fine mist and  which
     efficiently  draws the  paint onto  the part  being  painted  by  elec-
     trostatic forces.

Rotogravure  -   A  method   of printing in which the image  areas of the
     printing roll are recessed relative to the background.   The  image
     Is In the form of cells or cups mechanically  or chemically etched
     in the surface.   Typically,  a gravure cell  Is 35  microns deep  by
     125 microns  square, with 22,500 cells in the  square inch.

Rule 66  -   An  air pollution regulation passed by  the  Los Angeles Air
     Pollution Control District in 1966.    This regulation  was  aimed  at
     controlling  hydrocarbons and defined certain  types  of  compounds  as
     unreactlng and exempt  from control.   This  was one of the first VOC
     regulations,  was  very influential  and was widely  copied  by  other
     jurisidictlons.

Salt spray test - A test to determine  corrosion resistance  of paints  by
     exposing a standardized steel panel  to a  salt  (sodium chloride)
     solution.   The  length  of  time until the panel corrodes gives a
     measure of corrosion resistance of the paint.

Sealer  -   A coating used  to seal  the pores of a  surface,  especially a
     wood surface, before additional coats of paint  or varnish  are add-
     ed.

Secondary heat recovery   -   Use of heat from an incinerator exhaust for
     uses within  a plant such as heating an oven or  a  room.   This is
     distinguished from primary heat  recovery  which   is   the  use   of
     the hot  incinerator exhaust gases  to heat the  inlet  gases to the
     incinerator.

Section 111 - A section of  the Clean Air Act which requires development
     of standards of performance for new stationary  sources (new source
     performance  standards).

Section Illd  -  A part of   Section 111 of  the  Clean Air Act  that  regu-
     lates emissions  of noncriteria  and  nonhazardous  air  pollutants
     (which are  the  so  called  "designated pollutants").    After EPA
     issues an NSPS  for a new source  category, state  air agencies must
     submit to EPA a plan to control emissions  of  designated  pollutants
     from existing sources  in that category.

Section 112 - A section of  the Clean Air Act which requires development
     of national   emission   standards   for  hazardous  air  pollutants.
                                   18

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Section 114  -  A section of the Clean Air Act giving the Environmental
~~   Protection Agency authority for information gathering, inspections,
     and  monitoring  and  provides  for  EPA  personnel to have access
     into plants with air pollution emissions.

Shade  -   A color coat used on wood furniture which gives character to
     the finish.   It  is  often  applied   by  hand  wiping with  a  rag.

SIC code -  Standard Industrial Classification, a numerical  Identifica-
     tion system developed by the U. S. Government for statistical  pur-
     purposes and widely used by business firms.   Industries are group-
     ed into siniiliar categories and each category is  given  a   number
     representing the category.

Side seam sealer -  A  compound  for  protecting the  side seam of  three
     piece cans.

S^  -   State Implementation Plans  are required by Section 110 of the
     Clean Air Act, as amended.   Each State is to submit a  plan to the
     EPA Administrator which provides for implementation,  maintenance,
     and enforcement  of  the national  ambient air  quality  standards.

Smog - A common name for the visible haze which results from air pollu-
     tion containing photochemical  oxidants.

Speciality printing  -   Printing  on  such  items as food packages and
     other than printing of publications.

Spray booth - An  enclosed,  ventilated  area  used  for  spray  painting.

Solvent  -  A liquid used in a  paint or coating to dissolve  or disperse
     film-forming constituents   and to adjust viscosity.  It evaporates
     during drying  and  does  not  become a  part  of  the  dried film.

Solvent density  -   The weight per unit  volume of a solvent or  solvent
~mixture.This  number is often used in calculating the VOC emis-
     sions from coatings.  Densities of  common   organic solvents range
     from 6.6 Ib/gal to 9.5 Ib/gal.    The Environmental   Protection  A-
     gency has chosen  7.36 Ib/gal   as  an average density of a  coating
     solvent mixture to  use in  some calculations.

Solvent borne coating -   Coatings which contains  only organic solvents.
     If water is present,  it is only in trace quantities.

Stain  -  A  wood  coating which is used  to  give  color to wood.  Stains
     usually have low  solids  and   high  solvent   content,  i.e., often
     greater than 95* solvent by volume.

Standards of performance - A standards  for  emission of  air  pollutants
     from new,   modi f ied  or  reconstructed  stationary emission  sources
     which  reflects  the  degree   of  emission  limitation   achievable
     through the application of  the  best system of emission reduction
     which  (taking   into  account the cost of achieving such  reduction)
                                   19

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      the  administrator   determines   has  been adequately demonstrated.
      These are also commonly  known  as  new source performance standards
      (NSPS).

STAPPA  -  State and Territorial  Air Pollution  Program Administrators.

Substrate - The surface to which a coating is applied.

Surface coating operation -  The application of a film which covers the
      surface of some object. Painting and varnishing are common surface
      coating  operations  as  are  coatings  applied  to fabric, paper,
      plastic film and metallic foil.

Surfacer - A coating applied over a primer to provide a uniform surface
      ffiTck  enough  to  permit  some  sanding before  application  of a
    .  topcoat.  Surfacer is also known as primer surfacer.

Textile printing  -   The decorative enhancement of cloth by applying a
      pattern or colored design with inks,   dyes,  or print pastes.   The
      design is usually applied by roller,   flat screen or rotary screen
      techniques.

Theoretical  VOC content  -   The quantity  of VOC which will  be released
      during application,  flashoff  and cure per unit volume of coating
      (or coating solids).

Thermal incinerator  -   A  device  for  oxidizing  waste  material  via
      flame and heat.   This contrasts with  a catalytic incinerator which
      incorporates a catalyst to aid the combustion.

Thinner -  A liquid used to reduce the viscosity of a coating and which
     will evaporate before or during the cure of a film.

TIV -  Threshold Limit Values (TLV)  represent the air concentrations  of
     chemical  substances   to  which It is believed that  workers may  be
     daily exposed without adverse effect.

Topcoat - The last coat applied in a coating system.

Total enclosure - An  enclosure around the  coating head of a  web coating
     lineor other coating application device so that all  volatile or-
     ganic compounds   (VOC)   from  the coating application  and flashoff
     operations  are   collected  and ducted through  a stack  or into the
     oven.    With  a  total enclosure on a  coating line there will be  no
     fugitive emissions,  only stack emissions.   Some air pollution re-
     gulations may require a total  enclosure so  that  all  VOC emitted  by
     the process can  be measured.

Total organic compound (TOC) - Those compounds measured according to the
     procedures in an  applicable test method.

Touch-up coating - Often,  after a  metal  part such as  an automobile body
     or large appliance goes through a  coating line,  small pdint Imper-
     fections will be  present which  are corrected later In   a  separate


                                  20

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     spray booth.  This process is called "touch-up".   Volatile organic
     compounds from this repair process may be treated differently than
     emissions from the main coating line in regulations.

Trade Association - An organization formed by members  of an industry to
     promote""the  business  of the industry as a whole or to encourage
     scientific and technical advances which will benefit the industry.
     Government air pollution  regulators  often talk  to trade associa-
     tions  who  have  an interest in volatile organic compound regula-
     tions.  Prominent among these are:

          American Petroleum Institute
          American Society for Testing Materials
          Can Manufacturers  Institute
          Chemical Manufacturers Association
          Flexible Packaging Association
          Graphic Arts Technical Foundation
          International Gas Cleaning Institute
          Motor Vehicle Manufacturers Association
          National Coil Coaters Association
          National Paint and Coatings Association
          National Spray Equipment Manufacturers Association
          Powder Coating Institute
          Rubber Manufacturers Association

Trade journal  -  A magazine devoted to the interests  of a specific 1n-
     duitry.

Trade sales  -  Paint sold as shelf goods through retail outlets to the
     general  public and used mainly for coating of architectural struc-
     tures.

Traffic gaint  -  Any coating used for traffic control such as to paint
     'center-lines on highways and also  for  parking lot and curb markings.

Transfer efficiency  -   The ratio of the amount of coating solids depo-
     "sTted  onto" the  surface of the coated part to the  total amount of
     coating  solids used.

Three-piece can - A  can  made of three different pieces, a body, a top,
     an(J a bottom.

Two component paint  -  A  coating  which is manufactured in two compo-
     nents~wfiich~ must  be maintained  separate  until  shortly before use.
     When  mixed,  the  two  liquids rapidly  crosslink  to form  a solid
     composi tion.

Two-piece' can -  A can which consists of a body and bottom manufactured
     from li Single piece of  steel or aluminum  and a separate top which
     is attached  to  the body.

Units  -  In  air pollution regulatory usage,  units are  the dimentlonal
     quantities such as length,  weight,  or volume  in  which an air pol-
     lution regulation or a  guideline is expressed.   In  the series of


                                   21

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     reports known as Control  Techniques Guidelines,  suggested RACT le-
     vels are given in units of "Ibs of VOC per gallon of coating (less
     water)".   The  metric euivalent of this can also be used:   "Kg of
     VOC per liter of coating  (less water)".   For  new source perfor-
     mance standard regulations,   units  of  "Kg  of   VOC  per liter cf
     coating solids" have  been used.   These  latter units permit  easier
     consideration of transfer efficiency  in any  calculations  that are
     required.   Figure 1,  in  Appendix  B,  allows  rapid  calculation  of
     the solvent  content,   in  pounds  of  VOC/gallon   of coating  (less
     water) of  three Important types  of coatings when  the volume  per-
     cent solids is known.

Urethane coating - A one  or two part coating which contains polyisocya-
     nate monomer and a hydroxyl-containing material  which react  during
     to form polyurethane.   The basis reaction  Is:
               RlNCO + R20H —>RiNHCOOR2-

Ultraviolet (UV)  -  Electromagnetic radiation  of wavelength  between 10
     and 400 nanometer.   Sources of UV are used to cure coatings which
     are specially designed for this purpose.

Vapor capture system -  Any combination of hoods and  ventilation  system
     that captures or contains organic vapors in order that they  may be
     directed to an abatement or  recovery  device.

Varsol  -  The  brand name of Exxon produced mineral spirits.   Varsol  is
     often used  as  the  solvent   in  print paste  for  fabric  painting.

Vinyl plastlsol -  An  emulsion  of  polyvlnyl   chloride  (PVC)   resin,
     plasticizers, emulslfiers and stabilizers.    It  might contain a
     small  amount  of  diluent,   1-5  percent,  for viscosity  control.

Vinyl printing  Ink  -  Any  mixture  or  solution containing a polymeric
     resinand dye or pigment which  is applied in decorative  patterns
     to  vinyl   sheets  or  coated   webs   using a  rotogravure  printing
     process.

Vinyl printing  and top-coating  -  The application of a decorative pat-
     tern to a  vinyl  sheet  or coated web with a  rotogravure type  print-
     ing press.   Frequently a thin,  protective top  coat is  applied by
     the last print head  of the press.

Viscosity - A measure of  a  coating's resistance  to flow.

VOC - See volatile organic  compound.

Volatile Organic Compound (VOC)   -  Any organic  compound which  particl-
     pates in atmospheric photochemical  reactions;  that is, any  organic
     compound other than  those which the  Administrator  designates  as
     having negligible photochemical reactivity.   VOC  may be  measured
     by a reference method, an equivalent  method,  an  alternative  method
     or by procedures specified under any  subpart.  A reference  method,
                                   22

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     an equivalent method,  or  an alternative method, however, may also
     measure nonreactive organic compounds.  In such cases, an owner or
     operator may exclude the nonreactive organic compounds when deter-
     mining compliance with a standard.   The  Administrator has desig-
     nated  the  following  organic  compounds  as negligibly reactive:
     methane, ethane, 1,1,1-trichloroethane (methyl chloroform), methy-
     lene chloride,  trichlorofluoromethane  (CFC-11), dichlorodlfluoro-
     methane (CFC-12), chlorodifluoromethane  (CFC22),  trifluoromethane
     (FC-23), trichlorotrifluoroethane  (CFC-113),  dlchlorotetrafluoro-
     ethane (CFC-114), and chloropentafluoroethane (CFC-115).

Volume percent sol Ids -  The portion of a coating whiqh remains as part
     of the cured film expressed as percent by volume.    This contrasts
     to another convention of expressing solids content  by weight per-
     cent.  Often a percentage is given without specifying whether vol-
     ume or weight.   This  is confusing and leads to errors in coating
     calculations.   Figure  1 in  Appendix  B allows quick  estimation  of
     the solvent content, in pounds of VOC per  gallon  of coating (less
     water), when the volume percent solids is known.

Washcoat  -  A  wood  furniture coating which is applied after the body
     stain.  It seals the wood surface and stiffens the wood fibers for
     subsequent sanding.

Waterborne coating  -  A  coating  which contains more  than five weight
  ~percent water in its volatile fraction.

Waterwash spray booth  -  A  spray  booth  in which water is used to col-
~~lect overspray.    Ventillation  air  is drawn through  the  sheet and
     paint overspray  is   captured  in  the water from  which it  can  be
     recovered  as  sludge.    The  waterwash may help the booth to be
     kept free of  overspray  buildup   and may  reduce  the  necessity  of
     frequent cleanings.

Weather resistance  -  The  ability  to  undergo exposures  to  weather
     without failure, which is  an important paint characteristic.  Many
     new paints are  tested  by  exposure  to weather for several years
     before the paint is judged acceptable for specific use.

Heb coating -  Coating  of   fabric,  paper,  plastic  film,  metalic  foil,
     metal coil  or other  products which  are  flexible  enough  to  be
     unrolled from a  large  roll,   coated by  blade,  roll  coating  or
     rotogravure as  a  continuous  sheet   and,  after  cure,  rerolled.

Weight percent solids -  The portion of a coating which remains as part
     of the cured film expressed as percent by weight.    This contrasts
     to another  convention  of  expressing content  by   volume  percent.
                                  23

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24

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                     APPENDIX A
          SURFACE COATING EMISSION CALCULATIONS
                  How to Determine

The volume of coating needed to do a  particular  job

The  difference  (expressed   as  a  percentage)  in  emissions
between two coatings

The emission reduction (expressed as  a percentage)  needed to
meet an emission limit

The effect of improvements in transfer efficiency
                        25

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     HOW MUCH COATING IS  NEEDED TO DO A PARTICULAR JOB?

     The same volume of coating solids must  be  deposited on an object
to coat  it  to a desired  film thickness regardless  of the  type  of
coating or volatile  organic  compound content  of  the  coating used.
Solids make the film.  Volatiles  (VOC, water, and non-photochemically
reactive solvents)  evaporate.

     Four gallons of a 25 volume  percent  (v/o)  solids coating must be
used to get one gallon of coating solids.
But, only two gallons of a 50 v/o solids coating must be used to get
one gallon of coating solids.
                                26

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     This means that twice as much work can be done with a gallon  of
50 v/6 solids coating than with a "gallon of J?5 v/o solids coating.
Twice as many  gallons  of 25  percent  solids coating are  needed than
gallons of 50 percent solids coating to do the same job.
     HOW DO EMISSIONS FROM DIFFERENT COATINGS COMPARE?

     Comparisons of the percent  difference  in emissions  between  two
coatings, or between a coating and an emission limit,  must be done on
a solids basis.
VOC.
     Each gallon of the 25 v/o  solids  coating  contains  5.5  pounds  of
     So, for  each  gallon of  coating  solids, 22.0 pounds  of  VOC are
emitted.
     5.5 pounds VOC
     gallon coating
4 gallons coating
 gallon solids
     Each gallon  of the  50 v/o  solids  coating contains  3.7  pounds
of VOC.
                                 27

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 emitted.
      So, for each  gallon  of  coating  solids,  7.4  pounds  of VOC  are
           3.7 pounds VOC     X    2 gallons  coating
           gallon coating           gallon solids
      Thus,  emissions from the 50  v/o  solids coatings are 66  percent
 less than  from  the 25  v/o  solids  coating when  providing  an  equal
 amount of solids to the  process.

                   22.0-7.4   =    0.66
                     277U
 °   VHAT  EMISSION  REDUCTION  IS NEEDED TO MEET AN EMISSION LIMIT?

      This  calculation, which must also be done on a solids basis
 is  the   same   as  that  used  aoove  to   compare  emissions — FFonT two
 different  coatings.

      A coater  who uses a  25 v/o solids  coating containing 5.5 pounds
 of  VOC per gallon,  less  water,  must  reduce emissions  by  66 percent
 to  meet  an emission limit of 3.7 pounds of VOC per gallon
 less  water.
°  HOW MUCH DO IMPROVEMENTS IN TRANSFER EFFICIENCY HELP A SOURCE TO
   COMPLY?                                           ~	
     The coater may want to use a coating that does not comply with a
regulation and compensate  by  improvements  in the transfer efficiency
with which  the  coating  is applied  to  meet  an equivalent  emission
level.  In order to calculate  credit for VOC reductions  which result
from improvements in transfer efficiency, calculations should be done
using units of:                              ~	

                             1b VOC
                      gal Ion solids deposited

     These units are determined  by  dividing lb VOC/gallon  solids  by
the transfer efficiency expressed as a decimal  fraction.   For
example, if the  starting transfer efficiency is 60  percent,  the units
would be:
                                                  1.0  gal  solids
  ,   ]b V°C            =      lb VOC         x     in coating used
gal  solids deposited       gal  solidsU.bU gal  solids
(with the  old system)       in  coating used          deposited
                                28

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     If the  same  paint  were  now  to  be   sprayed  with  90  percent
transfer efficiency, the new value w.ould be:

                                              1.0 gal  solids
     Ib VOC         =   Ib VOC            x   in coating used
gal Ion solids           gal Ion solids         O.'JO gal  solids
  deposited             in coating used          deposited
(with new system)

     If both  the solvent content of  the   coating  and  the  transfer
efficiency are changed, the  situation becomes:

                                                   1.0  gal   solids  in
     Ib VOC               =        Ib VOC       x   new  coating used
gal solids depositedgal  solids in          y  gal  solids
(with new paint and           new coating              deposited
new transfer efficiency)       used

where T  =  the  new  transfer  efficiency   expressed  as  a  decimal

     Expressed in  these  units,  the  emissions  from the  old and  new
systems can be directly compared to determine the reduction achieved.

NOTE:   For  metal  furniture  and  appliance  coating,   the  EPA  has
recommended* that credit  for  transfer efficiency be given from a base-
line of  60 percent  transfer  efficiency  (TE).   For  example,  if  a
company goes from  35 percent TE to 85 percent TE, credit  should only
be given  for  going  from 60  percent TE to 85 percent  TE to  avoid
rewarding a source that has  historically had poor transfer efficiency
- hence a high emission rate.

     The rationale  for  this  is that 60 percent  TE  is  a  reasonable
transfer efficiency  to  achieve   for these  industries,  and  credit
should only be given for exceeding 60 percent TE.

     For the automobile industry,  the CTG recommendation for baseline
transfer efficiency  is  30 percent  TE for  both  primer  surfacer  and
topcoat.  This is  the  efficiency  at  which waterborne  coatings were
applied at two existing assembly plants.
* Memo from  G.  T.  Helms,  Chief, Control Programs Operations  Branch,
EPA, to  Chief,  Air Programs  Branch,  EPA  Regions  I-X,  "Appropriate
Transfer Efficiencies for  Metal  Furniture and Large Appliance
Coating."
                                 29

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30

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                             APPENDIX B
                        RAPID CONVERSION AIDS*
* The  graphs  in  this  appendix are  based  on  graphs  on  Page  1-4 and
on Page D-4  in  "Control   of  Volatile Organic  Emissions  from Existing
Stationary Sources  -  Volume   II:   Surface  Coating  of   Cans,  Coils,
Paper, Fabrics,  Automobile,  and light-duty  Trucks,  F.PA-450/2-77-008,
Hay, 1977
                                  31

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  cc
o in
O jjj
Z O
o u
u  c
I- JO

1}
                            CURVES FOR WATER BORNE
                            COATINGS ARE FOR WATER/SOLVENT
                            RATIOS OF 70/30 AND 80/20
                              SOLVENT DENSITY = 7.36 Ib/gal
              10    20    30    40    50    60   70   80   90   100
                        SOLIDS IN COATING. Vol %
Figure 1.   Approximate weight of organic solvent per gallon of
coating  (less  water)  for  three coatings as a function of solids
content.  (A  40 volume percent  solids coating could contain as
little as 1.7 pounds of VOC per gallon of coating (less water) if it
is of the 80/20 water borne type, or as much as 4.4 pounds for an
organic borne coating).
                              32

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                                          SOLVENT CONTENT
                                          OF ORIGINAL
                                          COATING,
                                          Ib VOC/gal COATING
                                          (LESS WATER)
                12345
                  SOLVENT CONTENT OF REPLACEMENT
               COATING. Ib VOC/gallon COATING (LESS WATER)

Figure 2.   Approximate reduction in emissions which occurs by
replacing  a  higher  solvent coating with  one of  lower solvent
content.  (In  the  example  above, a  74 percent reduction  in
emissions  can be  obtained  by replacing a coating with a solvent
content of 5.1 pounds of VOC  per  gallon, less water, with a
coating which contains 2.8  pounds of VOC per gallon,  less water)
                            33

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34

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                  APPENDIX  C
EXAMPLES OF DETERMINING  COMPLIANCE ALTERNATIVES
             USING GRAPHICAL  AIDS
                      35

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                  EXAMPLES OF COMPLIANCE SITUATIONS


                                CASE 1

 SITUATION:
     A company using an organic-borne coating with a VOC content of 5.1
 Ibs. of VOC per gallon of coating (less water) must comply with a State
 regulation that  limits  it to  2.8 Ibs.  of VOC  per  gallon  of coating
 (less water).   What are the company's options for compliance?

                  RAPID DETERMINATION OF ALTERNATIVES

 STEP 1 -  Figure  1 in Appendix  B indicates  three coatings that meet the
 2.8 1b VOC/gallon of coating (less water)  regulation:   An 80/20 water-
 borne coating with 24 volume percent solids,  a  70/30 waterborne coating
 with 33  volume  percent  solids, and an  organic-borne  coating  with  62
 volume percent solids.  Conversion  of  the process  to  use any of these
 would comply with the regulation.

 STEP 2 -  If compliance with an add-on control device such as incinerator
 or carbon adsorber  is  desired (instead of changing the  coating)  use
 Figure 2 In Appendix B to determine that a change  from  a  coating  with
 5.1 Ib VOC per  gallon  of  coating (less water) to one with  2.8 Ib VOC
 per gallon (less  water)  represents  about a  74 percent  reduction  In
 emissions.  Any combination of capture  device  and  control  system  that
 will achieve  an  overall  74 percent  reduction  would be  an  equivalent
 compliance scheme.

CAUTION - Avoid the erroneous tendency to calculate the required reduc-
 tion In Step 3 by this  method:

     5.1-2.8   x   100%  =  45%
        571

     Such a calculation does not  truly compare  the  relative  amounts  of
VOC needed to apply  the  same  volume  of coating solids.
                                CASE 2

SITUATION:

     A company using an organic-borne coating with  a  solvent  content  of
30 volume percent  solids  must  comply  with  a  State  regulation  that
limits It to 2.8 Ibs  of  VOC per gallon of coating (less water).   What
are the company's option's  for compliance?
                                  36

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                 RAI'H) 1)1 ItRMINAIIOM OF  AMKKNAIIVES
STEP 1 -  Use Figure  1,  Appendix  B,  to  find  that an  organic-borne
 coating with 30 volume  percent  solids  contains 5.1 Ibs. of  VOC  per
 gallon of  coating  less  water.    (Obviously,  the  company  is  not
 currently in compliance with the regulation.)

     From this point, the example  is  identical  with the  situation in
CASE I.  Go  to  Step 1  in CASE  1  and proceed  through that  example.
                                CASE 3
SIFUATION:
     A coating plant  with several  coating  lines  is currently  using
100 gallons/day  of a  5.1 Ib  VOC/gallon  (less  water)  conventional
solvent-borne coating to  coat a  given output of  products, but  the
company must  now  comply with  a  State regulation  that limits  it  to
2.0 Ibs of VOC per gallon of  coating (less water).

     Ihe company  want  to calculate  the  daily  maximum VOC  emissions
from the plant that will  be permitted  by  the  new  regulation at their
current production rate.  The  plant is located in a State  that will
permit the emissions  from all  lines to be considered  as  a  "bubble."
The company wants to vary the amounts of solvent  used on  each coating
line, but  in  such  a  way  that   the  total  daily  maximum  allowable
emissions for the whole plant are never exceeded.

     Calculate the  daily  allowable  emissions under  this  "bubble."

STEP 1-  Remember  that essentially  all equivalency  calculations must
be based  on  the  volume  of  coating sol ids not  volumes   of  coating.

SftP 2- Figure 1  in Appendix D shows that the existing 5.1 Ib VOC/gal
coating contains  approximately 30  volume  percent  solids.   Therefore,
the amount of coating solids  sprayed each day  is  equal  to:

100 gal coating/day   x   0.30 gal solids = 30 gal  solids/day
                            gal coating
                                  37

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S1EP 3  -  Figure 1  in Appendix B  shows that a  solvent-home  coating
 complying with the 2.f) 1t> VOC/gal of coating (less water)  limitation
 contains 62 volume percent solids.

STtP 4  - The amount of  solids  required at  a  constant  production  rate
 will be the  same  (JO gallons solids/day) regardless  of whether  the
 original or the complying coating is used.

     For the complying  coating,  the  usage  rate  in  gallons  of  coating
required i s:

gal coating   -   30  ga]_o£ sol i ds_a£pljed  x  1  gal  complying  coating
 required                  ^lay"                0.6? gal soTHTs	

     gal coating  =  40.4 gal  complying coating needed/day
      requi red

STEP 5  - Calculate the allowable emissions.

     Allowable  =  2.8 Ib VOC	  x  18.4 gal  complying coatuig
      emissions   gal  compTyTng                  day
                    coating

                    = 135 Ib VOC/day

CAUTION - Avoid the error  of  calculating allowable emissions  in  the
 following way:

     100 gal/day x  2.8 Ib VOC  = 280 Ib VOC/day
                        ^gal

     This is incorrect  and  allows  a  high emission rate which  is  not
in compliance with  the regulation.
                                 38

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TECHNICAL REPORT DATA
(fltatf ttod Innrvcttont on Ihf tevrnt bffote co/n/r/rlfng^
EPA 450/3-H3-On
Glossary Ft
Industrial Coating Operations
llapid Estimation of Aiceptabl

! REPORT DAT!
r Air Pollution Control of *hwe 1983
e Compliance Alternatives)
1 AU.HORtS) i PERFORMING ORGANIZATION REPORT NO
Office of Air Quality Planning and Standatds Ti~cCNTRiECT/SKAfimo 	
J.S. Environmental Protection Agency
Research Triangle Park, NC 27711



14 SPONSORING AGENCV CODE
FPA/ZOO/04

Common terms used in the air pollution control of emissions from industrial
coating operations are defined. The definitions cover both coatings
terminology and terms related to the Clean Air Act Appendices give
sample calculations to illustrate emission reductions achieved by changing
coatings. Graphical aids which simplify calculations are shown.
17
» DESCRIPTORS
Air Pol lut i on
Coatings
Pollution Control
Volatile Organic Compounds


1) IDENTIFIERS/OPEN ENDED TERMS c COS ATI 1 Kld/CfOUp
Air Pollution Control 13 0
Unclassified 35
20 SECURITY CLASS fJlnif>aft) 22 PRICE
Unclassified
39

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U.S. Environn—'iM  'Vtsction Agency
Region V, i   ' .-,•/
230 South Dearborn  Street
Chicago,  Illinois  60604

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