<>EPA
United States
Environmental Protection
Agency
Control Technology
Center
Research Triangle Park NC 27711
EPA-450/3-87-023
October 1987
Evaluation of Emission Factors
for Formaldehyde from Certain
Wood Processing Operations
control ^technology center
-------
EPA-450/3-87-023
EVALUATION OF EMISSION FACTORS FOR
FORMALDEHYDE FROM CERTAIN WOOD PROCESSING OPERATIONS
CONTROL TECHNOLOGY CENTER
SPONSORED BY:
Emission Standards and Engineering Division
Office of Air Quality Planning and Standards
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
Air and Energy Engineering Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
Center for Environmental Research Information
•Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, OH 45268
October 1987
U.S. Environmental Protection Agency
Region V, Library
230 South Dearborn Street x*
Chicago, Illinois 60604
-------
NOTICE
This report was prepared by Radian Corporation, Research Triangle
Park, NC. It has been reviewed for technical accuracy by the Emission
Standards and Engineering Division of the Office of Air Quality Planning
and Standards, U.S. Environmental Protection Agency, and approved for
publication. Mention of trade names or commercial products is not intended
to constitute endorsement or recommendation for use.
ACKNOWLEDGEMENT
This report was prepared for the Control Technology Center by
C.E. Burklin and T.S. White of Radian Corporation. The EPA project officer
was Leslie B. Evans of the Office of Air Quality Planning and Standards.
Also serving on the EPA project team was Bruce Tichenor of the Air and
Energy Engineering Research Laboratory.
-------
TABLE OF CONTENTS
Section
List of Figures iv
List of Tables. iv
1.0 Introduction 1-1
1.1 Background !-2
1.2 Findings i'i
1.3 Conclusions !-3
1.4 Report Organization 1-3
2.0 Process Description 2-1
2.1 Furniture Manufacturing 2-1
2.2 Particleboard Manufacturing 2-3
2.3 Chemistry of U-F Resins 2-3
2.4 Formaldehyde Content Determination Techniques 2-4
3.0 Emission Characteristics .3-1
3.1 Sources of Emissions in Furniture Manufacturing. ... 3-1
3.1.1 Overview 3-1
3.1.2 Press 3-1
3.2 Press Emission Estimate 3-2
3.2.1 Particleboard Manufacturing Emissions 3-2
3.2.1.1 Excess Formaldehyde in the Adhesive. . 3-2
3.2.1.2 Press Temperature 3-4
3.2.1.3 Press Cycle Time 3-4
3.2.1.4 Amount of Adhesive Used 3-8
3.2.1.5 Use of Formaldehyde Scavengers .... 3-8
3.2.2 Furniture Manufacturing Emissions 3-8
4.0 References 4-1
Appendix A - Particleboard Emissions Data A-l
Appendix B - Telephone Conference Records B-l
-------
LIST OF FIGURES
Figure Page
3-1 Impact of Excess Formaldehyde on Emissions from
Particleboard Presses 3-5
3-2 Impact of Temperature on Emissions from Particleboard
Presses (Pilot-Scale Experiments) 3-6
3-3 Impact of Cycle Time on Emissions from Particleboard
Presses 3-7
3-4 Impact of Adhesive Usage on Emissions from Particleboard
Presses 3-9
LIST OF TABLES
Table Page
2-1 Comparison of Press Operating Conditions for Furniture and
Particleboard Manufacturing Industries 2-2
3-1 Formaldehyde Emissions from Four Particleboard Plants 3-3
A-l Formaldehyde Emissions from Particleboard Press Vents as
Measured in Four Mills A-2
A-2 Partial Summary of Results of Press Experiments by Tomas, 1964 . A-3
-------
1.0 INTRODUCTION
1.1 SCOPE
The Control Technology Center (CTC) was established by the Environmental
Protection Agency's (EPA) Office of Research and Development and the Office
of Air Quality Planning and Standards to assist State and local air
pollution control agencies in the implementation of their air toxics and
other pollution control programs. Three levels of assistance can be
accessed through the CTC. First, a CTC HOTLINE has been established to
provide telephone assistance on matters relating to air pollution control
technology. Second, more in-depth engineering assistance can be provided
when appropriate. Third, the CTC can provide technical guidance through
publication of technical guidance documents, development of personal
computer software, and presentation of workshops on control technology
matters.
This report presents the results of direct engineering assistance
provided by the CTC for the State of Virginia. The scope of the assistance
was determined by the specific needs of the State, and the findings
presented in this report may not be applicable to other facilities and
operations which were not evaluated. Also, control technology presented
in this report is not necessarily endorsed by EPA for establishment of
the basis for regulations, since the decision of whether or not to regulate
a source category and the selection of the technology on which to base
regulations are responsibilities of the individual State or local authorities,
This r-eport is, however, intended to provide technical information which
may assist in making such decisions.
The scope of this report is to present to the State of Virginia a
survey of the sources which contribute to formaldehyde emissions in the
furniture manufcturing process and to estimate formaldehyde emissions
from the most significant sources. The report discusses the impact of
process variables and modifications on these emissions. The primary sources
1-1
-------
of information for this study include library and permit data base
searches, telephone conferences, and meetings with members of the furniture
and adhesive manufacturing industries.
1.1 BACKGROUND
The Virginia State Air Pollution Control Board (VSAPCB) regulates
formaldehyde emissions from furniture plants under its Air Toxics Rules.
Manufacturers subject to the rules are required to report the estimated
formaldehyde concentration at their plant fencelines after applying an
appropriate dispersion model to plant sources.
Furniture manufacturers use urea-formaldehyde (U-F) adhesive resin
formulations which contain formaldehyde in excess of the amount required
to form the urea-formaldehyde polymer. As an alternative to fenceline
testing, VSAPCB currently allows a furniture plant to assume that 100
percent of the excess formaldehyde in its adhesive formulation is emitted
from plant vents. This number becomes an input parameter to the dispersion
model that the plant uses to estimate fenceline concentration.
To refine its emission assumption of 100 percent excess formaldehyde
loss, VSAPCB requested technical assistance from U. S. EPA's Control
Technology Center, an intra-agency group. In response to the VSAPCB
request, the Control Technology Center contracted Radian to research
published formaldehyde emission data and, if possible, to refine the
emission estimate.for the furniture manufacturing industry.
1.2 FINDINGS
Industry contacts provided the details of the manufacturing process
and revealed the level of technology applied by furniture manufacturing
plants to reduce emissions. They also revealed the general procedures
used in manufcturing and testing U-F adhesive resins. Discussions at the
"Formaldehyde Reporting and Control" workshop in Richmond, Virginia,
revealed the actual ranges of temperature, pressure, and resin application
rate used during furniture and particleboard press operations. The
industry also revealed many of the problems involved with process
modifications as an emission control technique.
1-2
-------
No furniture plant emission data were found. Therefore, related
industries were researched, including the particleboard manufacturing
industry.
From the standpoint of emission mechanism, the particleboard industry
was found to use similar U-F adhesive resins. Three significant sources
of process emissions data from this industry were found, including data
from the paper industry's National Council for Air and Stream Improvement,
Inc. (NCASI),1 the work of Tomas,2 and the results of a German U-F
particleboard plant survey.3
1.3 CONCLUSIONS
1. From 1.9 to 12 percent of the excess formaldehyde in the resin is
emitted to the atmosphere during particleboard manufacture, with
an average emission rate of 4.7 percent.1
2. In furniture plants a smaller percentage of the excess formaldehyde
is likely to be emitted than in particleboard plants because of less
severe press conditions and a different product configuration.
3. Comprehensive plant testing will be required to determine exactly
formaldehyde emissions from furniture plants.
4. The titration procedure which is often used to determine the excess
formaldehyde in a particular adhesive resin has not been standard-
ized by the industry. It has been found that resin temperature,
titration time and resin pH can all have a significant effect on
the results of the procedure. A standard bisulfite titration
procedure should be adopted industry-wide before excess formladehyde
content can be accurately estimated by the titration technique.
5. Process modifications have a significant impact on the formaldehyde
emission rate and promise to be a very effective way to achieve a
50-75 percent reduction. However, the implementation of process
modifications will require a significant research and development
effort, since process modifications must be accompanied by other
compensating process changes and possibly equipment changes.
1.4 REPORT ORGANIZATION
This report is organized in the following way: Section 1.0 is the
Introduction, Section 2.0 is the Process Description, Section 3.0 presents
Emission Characteristics, and Section 4.0 contains References.
1-3
-------
-------
2.0 PROCESS DESCRIPTION
The major processing steps in both particleboard and furniture
manufacturing processes which use urea-formaldehyde adhesive resins are
outlined in this chapter. Section 2.1 describes Furniture Manufacturing and
Section 2.2 describes Particleboard Manufacturing. The Chemistry of U-F
Resins is discussed in Section 2.3, and Section 2.4 presents Formaldehyde
Content Measurement Techniques.
2.1 FURNITURE MANUFACTURING
The products from this industry include furniture made from particleboard
and plywood with one or two layers of veneer glued on each side. The glue, a
urea-formaldehyde adhesive, is usually applied to the veneer and board surface
to a thickness of 0.03 inches. This adhesive is applied with a series of
rollers that convey the adhesive from a "glue pot" where the adhesive is
continuously mixed to the veneer and board surface. Immediately after
adhesive is applied, the veneer is placed on the particleboard or plywood.
The pieces are then pressed between the surfaces of a heated press, typically
ranging from 250 to 300°F. The length of time in the press depends on the
number of layers being glued, but ranges from 45 seconds for a single veneer
layer up to six minutes for five layers. Press pressures range from 100 to
175 psi. Twenty-five to 50 pounds of adhesive are used per ply per thousand
square feet (MSF) of board. The ranges of press operating conditions for the
furniture industry are summarized in Table 2-1.
Urea-formaldehyde formulations include some excess formaldehyde
(unpolymerized) to improve adhesion characteristics. Common formulations
range from less than one to over six percent excess formaldehyde by weight
of water free U-F resin. (This method of defining U:F formulations is
discussed in Section 2.4, Formaldehyde Content Determination Techniques.)
Adhesive manufacturers have been working with the furniture manufacturers to
develop adhesives that are low in excess formaldehyde. As a result, the
excess formaldehyde concentration in formulations has been dropping.
Some furniture manufacturers add a catalyst to their adhesive
formulations prior to application to lower the pH. The lower pH combined
2-1
-------
TABLE 2-1. COMPARISON OF PRESS OPERATING CONDITIONS FOR FURNITURE
AND PARTICLEBOARD MANUFACTURING INDUSTRIES
Product Cateqorv
Operating Condition Furniture Particleboard
Press Temperature (°F) 250 - 300 315 - 385
Press Pressure (psi) 100 - 175 150 - 800
Press Cycle Time (min) 0.75 - 6 4-9
LB Resin/MSF (3/4") 25 - 50* 150 - 290
Excess Formaldehyde
-------
with heat from the press causes the adhesive to cure faster. Catalysts are
slightly acidic mineral salts such as ammonium chloride.
Some plants use a hood over the press to pull formaldehyde emissions out
of the workplace and release them via a roof vent or stack. One plant in New
York reportedly burns some press fumes in its gas-fired dryer.
2.2 PARTICLEBOARD MANUFACTURING
Particleboards are board products composed of distinct particles of wood
or other ligno-cellulosic materials bonded together with an organic binder.
Particleboard often serves as a base onto which veneer layers are glued in
furniture manufacture. The thickness of each product varies, typically
ranging from 0.5 to 1.5 inches.
To manufacture particleboard, wood particles are blended with a
urea-formaldehyde adhesive resin and a small amount of wax. The wax is added
to promote binding of the resin to the wood particles. Formers spread the
mixture of wood particles and U-F resin onto platens to form mats. The mats
are pressed at 150 to 800 psi in a heated press at 315 to 385°F for a time
period appropriate for the thickness, density and grade of the product (four
to nine minutes).
The urea-formaldehyde resin as applied is partially polymerized with
approximately 65 percent solids. The remaining compound is water. For some
products such as door core, a resin high in excess formaldehyde (high-fuming
resin) is used to reduce the press cycle time. The excess formaldehyde
content of the U-F resin used to produce commercial grade particleboard ranges
from less than one percent up to eight percent by weight of the dry resin.
The NCASI survey of particleboard press vents did not describe
ventilation specifically, but it reported formaldehyde mass emission rates
from the press and cooler vents. One of the authors indicated that emissions
are pulled away from the presses by mechanical draft roof vents.
2.3 CHEMISTRY OF U-F RESINS
Urea and formaldehyde are partially reacted by the resin supplier to form
the U-F adhesive resin. At this stage, this resin is predominately a linear
2-3
-------
polymer of alternating urea and formaldehyde monomers with some cross-linking.
Formaldehyde is added in excess of that required by stoichiometry to react
with the urea. This excess formaldehyde is required later to drive the
cross-linking reaction to completion. Final cross-linking occurs in the
adhesive as furniture pieces are joined in a heated press. This process is
called curing.
The formaldehyde and urea are initially combined by the resin supplier
under acidic conditions. After the appropriate degree of polymerization is
obtained, the reaction is arrested by raising the mixture pH. Sometimes, urea
or other chemicals are added at the end of the reaction to tie up a portion of
the excess formaldehyde present and reduce press operation emissions. The
adhesive resin is sold in this form.
A furniture manufacturer will typically lower the pH prior to use by
adding a weakly acidic reagent in water (e.g., ammonium chloride). This
mixture is spread on a ply and put in a press where the combination of acidic
conditions and heat from pressing quickly completes the cross-linking
reaction. The cross-linking reaction forms a solid space-network polymer and
causes adhesion between plies.
2.4 FORMALDEHYDE CONTENT DETERMINATION TECHNIQUES
For the purposes of the report, "excess" formaldehyde is defined as the
weight percent of formaldehyde based on total dry resin solids in excess of
the amount of formaldehyde required to react stoichiometrically with the urea
in the resin. Excess formaldehyde is often calculated from the mole ratio of
F:U supplied by the resin manufacturer. Therefore, an adhesive resin having a
F:U molar ratio of 1.03:1 (1:03 moles of formaldehyde to 1 mole of urea) will
contain one weight percent "excess" formaldehyde.1 In this paper, one weight
percent excess formaldehyde based on dry resin weight and calculated from the
formulation will be expressed as 1 weight % (dry resin; f).
The level of excess formaldehyde can also be measured using titration
techniques. A bisulfite titration method for analyzing excess formaldehyde as
a weight percent of adhesive resin solids is generally used as quality control
indicator of the final resin. The accuracy of the titration depends strongly
on temperature, titration time, and resin pH. Different resin manufacturers
2-4
-------
use slightly different titration procedures. Some of the testing techniques
that have been developed are proprietary in nature. A procedure developed by
Borden Chemical is reportedly accurate to within 0.1 percent of the excess
formaldehyde present at an excess formaldehyde level of 0.5 weight percent
(dry resin basis). Another source reports a tenfold increase in weight
percent excess formaldehyde when the procedure is run at 25°C vs. 0°C for the
same resin. Normally, the titration procedure is performed at 25°C, where
the adhesive industry generally considers the results most accurate.
The difference between test methods must be addressed and the methods
standardized before an emission estimate can be based upon titratable
formaldehyde in the adhesive resin a plant uses.
In this paper, one weight percent excess formaldehyde based on dry resin
weight and measured by titration will be expressed as 1 wt% (dry resin; t).
2-5
-------
3.0 EMISSION CHARACTERISTICS
3.1 SOURCES OF EMISSIONS IN FURNITURE MANUFACTURING
The sources of formaldehyde emissions in the manufacture of furniture are
described in this section. An overview of general plant formaldehyde sources
is given in Section 3.1.1, while the major source, the press, is discussed in
Section 3.1.2.
3.1.1 Overview
The catalyst/resin blending operation and glue pot are small contributors
to total plant formaldehyde emissions. When the adhesive is spread over large
veneer or particleboard areas, the air exposure time is typically one to two
minutes and formaldehyde emissions can be significant. These emissions are
exhausted by fans through windows and roof vents. Other process steps which
can be significant sources include the board cooling area, the finishing room,
and conveyor emissions. Here, formaldehyde diffuses through the veneer layers
themselves and is emitted from the edges of finished stock. Alkyd-urea
synthetic varnish blends used in finishing can be a formaldehyde source, as
can the wood drying process. Exhaust fans provide ventilation in these areas
through windows and roof vents.
Other minor sources include long-term board degassing during warehousing
of finished products and emissions from particleboard used as a raw material
in the process. Storage is a small contributor to total plant emissions
because air exchange rates in warehouses are typically low. During storage,
formaldehyde is exhausted to the atmosphere through warehouse doors, windows
and roof vents.
3.1.2 Press
During the press cycle, boards are compressed at temperatures of 250 to
300°F. Water vapor and formaldehyde gases are generated from the adhesive,
and are emitted through the veneer surface and board edges throughout the
pressing cycle. Emissions are typically exhausted through roof vents by large
fans when the press is opened for unloading and loading.
The press area is the largest contributor to total plant formaldehyde
emissions. In one particleboard plant, 95 percent of total plant formaldehyde
emissions came from vents over the press, unloader and associated conveyors.
3-1
-------
3.2 PRESS EMISSION ESTIMATE
No published formaldehyde emission data were available for furniture
manufacturing operations. However, emissions data from particleboard plants
have been published. Similarities and differences between the particleboard
and furniture pressing processes include 1) the adhesive surface is more
exposed in particleboard during and after pressing, 2) both industries are now
optimizing on low-emitting U-F resins, 3) particleboard presses operate at
higher temperatures and pressures, and 4) particleboard presses have longer
cycle times. In general, particleboard plant operations and conditions are
more conducive to formaldehyde evaporation than are furniture plant
operations.
Section 3.2.1 discusses formaldehyde emissions from particleboard and
Section 3.2.2 relates these formaldehyde emissions to furniture manufacture.
3.2.1 Particleboard Manufacturing Emissions
NCASI found average particleboard emissions of 0.51 Ibs formaldehyde per
thousand square feet (MSF) on a 3/4" basis with a range of 0.22 to 0.84.
These emissions when expressed as a percent of the excess formaldehyde in the
adhesive resin averaged 4.7 percent with a range of 1.9 to 12.0 percent.
Table 3-1 contains a summary of formaldehyde emissions from the four plants
surveyed by NCASI. In these plants, the excess formaldehyde content of the
adhesive ranged from three to eight weight percent (dry resin; f) the amount
of adhesive used averaged from five to nine percent of total board weight, and
press temperature ranged from 315° to 385°F.
A recent study of German particleboard plants found an average
formaldehyde emission rate of 0.39 Ib/MSF (3/4" basis). These findings agree
favorably with those of the above NCASI study.
The processing parameters which have been found to impact formaldehyde
emission rates are 1) excess formaldehyde in the adhesive, 2) press
temperature, 3) press cycle time, 4) the amount of adhesive used, and 5) the
use of formaldehyde scavengers. Each is discussed below.
3.2.1.1 Excess Formaldehyde in the Adhesive. Excess formaldehyde is
thought to be the primary source of emissions from adhesive curing. It
affects the amount of formaldehyde available for evaporation. In recent
years, the particleboard industry has responded to public concern about
formaldehyde emissions in indoor environments by manufacturing their boards
3-2
-------
TABLE 3-1. FORMALDEHYDE EMISSIONS FROM FOUR PARTICLEBOARD PLANTS
Parameter
Emi tted Formal dehvde
LB/MSF (3/4")
As % of Excess HCHO in the Resin
Conditions
Press Temperature (°F)
LB Resin/MSF (3/4")
Excess HCHO in Resin (wt% [resin; f])
Average*
0.51
4.7
339
216
5.9
Range
0.22 - 0.84
1.9 - 12
315 - 385
150 - 290
3.2 - 7.7
Average of all data points from the four plants tested.
3-3
-------
to conform to tighter off-gassing specifications. Particleboard presses are
operated so that more of the excess formaldehyde present in the board is
liberated during pressing and less is emitted later, in indoor environments.
In addition, adhesive resin suppliers have worked to reformulate particleboard
resins which emit at much lower rates after curing (some of the adhesives now
supplied to furniture manufacturers also emit at lower rates than the
adhesives supplied in the past).
Data from Tomas suggests that reducing excess formaldehyde from five
weight % (dry resin; t) to one weight % (dry resin; t) reduces formaldehyde
emissions from particleboard curing by 55 percent. Figure 3-1 presents data
from the NCASI Survey on formaldehyde emissions as a function of the excess
formaldehyde in the board expressed as a percent of board weight, and shows
the same general relationship. Some adhesive formulations have excess
formaldehyde levels below one weight % (dry resin; t). Catalyst additions
and/or press condition adjustments must be made to compensate if excess
formaldehyde is reduced in any given adhesive.
3.2.1.2 Press Temperature. High press temperatures cause the
volatilization of excess formaldehyde and possibly the destruction of other
organic compounds to form formaldehyde. Tomas indicates that a reduction in
the particleboard press temperature from 338°F down to 284°F reduced
formaldehyde emissions by 42 percent. This is illustrated in Figure 3-2.
Reduced press temperatures require either increased curing times or more
active catalysts. Temperatures reported by the furniture industry range from
250 to 300°F. One source reports that some adhesives can be "cold-cured" at
room temperature, but curing time is increased by two to three orders of
magnitude over hot pressing times.
3.2.1.3 Press Cycle Time. Formaldehyde emissions are thought to be
dependent on the length of time the adhesive is exposed to high press
temperatures. The NCASI survey of particleboard plants did not see this
phenomenon in formaldehyde data. However, the trend was noted in total
gaseous non-methane organics (TGNMO) data. Figure 3-3 shows that reducing the
press cycle time from 8.5 minutes to 5 minutes reduced TGNMO emissions by 73
percent.
3-4
-------
GO
U1
CO
c
g
'to
CO
E
LU
O
o
I
0.9-j
Oo
.8 •
0.7-
0.6-
.5-
.4-
0.3-
«?
1
1
• Mill A
• Mill B
o Mill C
— O
O
— O
• !
++
•
•
•
4
•
•
•
•
. •
0.25
0.30
0.35 0.40 0.45 0.50 0.55 0.60
Excess HCHO (% of Board Weight)
0.65
0.70
Figure 3-1. Impact of Excess Formaldehyde on Emissions from
Particleboard Presses
-------
4.0
CO
U_
CO
3.0
(O
C
o
"(fl
-------
o.o •
30«
CO
-Q
CO
£ 15.
"to
CO
E 2.0 .
LU
O
Z1 0 •
1 .V/
o
0.5.
* Mill A 0.35% wax
0 Mill B 0.25% wax
*
*
O
o
^
'6 7
Press Cycle Time (min.)
8
Figure 3-3. Impact of Cycle Time on Emissions from Particleboard
Presses
-------
3.2.1.4 Amount of Adhesive Used. Formaldehyde emissions are thought to
be directly proportional to the total amount of adhesive used. As shown in
Figure 3-4, NCASI observed a 22 percent reduction in formaldehyde emissions
for a 21 percent reduction in the amount of resin used in particleboard
formulations. If adhesive use is too low, however, bonding strength is
inadequate. In recent years, the use of waxes and surfactants has improved
bonding properties, thus allowing the particleboard industry to reduce
adhesive use.
3.2.1.5 Use of Formaldehyde Scavengers. These are compounds which
associate with and tie up free formaldehyde. Scavengers include urea, ammonia
compounds, and sulfite compounds. One problem with the use of scavengers is
that they can increase the press cycle time.
3.2.2 Furniture Manufacturing Emissions
In the absence of furniture plant formaldehyde emissions data, the
available range of particleboard manufacturing formaldehyde emissions data may
be used to predict a worst-case formaldehyde emissions estimate for furniture
manufacturing. This is possible because both industries use similar U:F
adhesive resins and both utilize board pressing operations at elevated
temperatures and pressures.
However, in furniture plants it is possible that a smaller percent of the
excess formaldehyde in the adhesive resin is emitted than in particleboard
plants. Formaldehyde emissions from furniture plants are probably lower
because: 1) presses in furniture plants operate at much lower temperatures, 2)
furniture presses have somewhat shorter cycle times than those in
particleboard plants, and 3) the physical configuration of furniture pieces is
different than that of particleboards (in a furniture piece, a veneer barrier
protects the major glue surface from direct exposure to air, while no such
continuous barrier inhibits formaldehyde evaporation during the particleboard
pressing cycle).
Only comprehensive plant testing will determine the true range of
formaldehyde emissions from furniture plants.
3-8
-------
OJ
I
u>
0.50-
0.48 •
CO 0.46 •
5
B 0.44 •
{2 0.42 •
O
w 0.40 •
w
E 0.38 •
O_ _ -. *
x 0.36 «
O
I 0.34
OOO
.0^
0.30
•
— «-^— i— — ^— •—
•
— . ^
•
^
•
+
4
•
•
*»
5.0
5.5
6.0
6.5
7.0
7.5
Adhesive in Particleboard (%)
Figure 3-4. Impact of Adhesive Useage on Emissions from Particleboard
Presses
-------
-------
4.0 REFERENCES
1 "A Survey of Formaldehyde and Total Gaseous Non-Methane Organic
Compound Emissions from Partialeboard Press Vents," NCASI Technical
Bulletin No. 493, New York, NY. June 1986.
2 Tomas, Michal, Liberation of Formaldehyde During the Hardening of
Urea-Formaldehvde Resins at High Temperatures. Holztechnol. 5, special
issue: 89-91, 1964.
3 Formaldehyde, A Joint Report of the Bundesgesundheitsamt, the
Bundesanstalt fur Arbeitsschutz and the Umweltbundesamt. Published by
Federal Ministry for Youth, Family Affairs and Health, 1985.
4. Telecon. Sandonato, Henry, Region 9, NYDEC, with Pelland, A. S.,
Radian Corporation. June 18, 1987.
5. Telecon. Huff, Dick, Borden Chemical, with White, T.S., Radian
Corporation. August 18, 1987.
6. Telecon. Barrier, Don, Southeastern Adhesives, with White, T. S., Radian
Corporation. July 22, 1987.
7. Phillips, M. W. and Wilkins, G. E., "Preliminary Source Assessment for
Formaldehyde." Final Report, EPA Contract No. 68-02-3818, WA 26.
Prepared for U. S. EPA, Research Triangle Park, NC. September 3,
1985.
8. Telecon. Groah, Bill, Hardwood-Plywood Manufacturers Association, with
White, T. S., Radian Corporation. June 11, 1987.
9. Telecon. Waters, George, Borden Chemical, with White, T. S., Radian
Corporation. June 12, 1987.
10. Telecon. Podall, Harold, EPA, with White, T. S., Radian Corporation.
June 12, 1987.
11. Telecon. Skiest, Jeane, Borden Chemical, with White, T. S., Radian
Corporation. June 12, 1987.
12. Telecon. McCredie, Bill, National Particleboard Association, with White,
T. S., Radian Corporation. June 12, 1987.
13. Telecon. Holmes, Charles, VSAPCB, with Pelland, A. S., Radian
Corporation. June 12, 1987.
14. Telecon. Emery, John, American Plywood Association, with White, T. S.,
Radian Corporation. June 15, 1987.
15. Telecon. Myer, George, Appleton Paper Institute, with White, T. S.,
Radian Corporation. June 15, 1987.
4-1
-------
16. Telecon. Jewell, Dick, Weyerhaeuser, with White, T. S., Radian
Corporation. June 15, 1987.
17. Telecon. Prosser, Dave, NYDEC, with Pelland, A. S., Radian Corporation.
June 16, 1987.
18. Telecon. Sheppard, Don, Virginia SAPCB, with Pelland, A. S., Radian
Corporation. June 16, 1987.
19. Telecon. Henderson, Tom, Virginia SAPCB, with Pelland, A. S., Radian
Corporation. June 16, 1987.
20. Telecon. Kimball, Denese, Virginia SAPCB, with Pelland, A. S., Radian
Corporation. June 16, 1987.
21. Telecon. McDonald, Dick, Singer Furniture Company, with Pelland, A.S.,
Radian Corporation. June 16, 1987.
22. Telecon. Wright, Ken, Lane Furniture Company, with Pelland, A. S.,
Radian Corporation. June 16, 1987.
23. Telecon. Thorton, Meaux, American Furniture, with Pelland, A. S., Radian
Corporation. June 16, 1987.
24. Telecon. Newton, Larry, Georgia Pacific, with White, T. S., Radian
Corporation. June 17, 1987.
25. Telecon. Parish, Jon, Lane Furniture Company, with Pell and, A. S.,
Radian Corporation. June 17, 1987.
26. Telecon. Spencer, Don, NYDEC, with Pelland, A. S., Radian Corporation.
June 17, 1987.
27. Telecon. Reid, Tim, Masonite Corporation, with White, T. S., Radian
Corporation. June 18, 1987.
28. Telecon. Groah, Bill, Hardwood-Plywood Manufacturers Association, with
White, T. S., Radian Corporation. June 18, 1987.
29. Telecon. Barrier, Don, Southeastern Adhesives, with Burklin, C. E.,
Radian Corporation. June 18, 1987.
30. Telecon. Murray, John, Formaldehyde Institute, with Burklin, C. E.,
Radian Corporation. June 18, 1987.
31. Telecon. Yatts, Lowell, Lane Furniture Company, with Pelland, A.S.,
Radian Corporation. June 18, 1987.
32. Telecon. Waters, George, Borden Chemical, with White, T. S., Radian
Corporation. June 19, 1987.
4-2
-------
33. Telecon. Waters, George, Borden Chemical, with White, T. S., Radian
Corporation. July 17, 1987.
34. Telecon. Skiest, Jeane, Borden Chemical, with White, T. S., Radian
Corporation. July 17, 1987.
35. Telecon. Gallons, Victor, NCASI, with Burklin, C. E., Radian
Corporation,. July 21, 1987.
36. Telecon. Newton, Larry, Georgia Pacific Co., with White, T. S., Radian
Corporation. July 22, 1987.
4-3
-------
APPENDIX A
PARTICLEBOARD EMISSION DATA
A-l
-------
TABLE A-l. FORMALDEHYDE EMISSIONS FROM PARTICLEBOARO PRESS VENTS AS MEASURED IN FOUR MILLS*
i
ro
Mill & Run
Identifier
A-l
A-2
A-3
A-4
A-5
A-6
A-7
A-6
A-9
A- 10
A-ll
A-12
B-l
B-2
B-3
B-4
C-l
C-2
C-3
C-4
C-5
C-6
C-7
C-8
C-9
C-10
D-l
0-2
0-3
D-4
D-5
Emission Rate
(as % of excess
HCHO In resin)
4.0
2.5
2.7
2.5
5.4
5.3
3.3
4.0
3.4
3.0
2.6
1.9
3.2
3.5
3.6
4.8
6.0
5.0
4.0
5.0
5.0
6.0
7.0
8.0
11.0
12.0
5 .4
5.1
4.4
4.9
4.2
Emission Rate Press Time
(1b HCHO/MSF (Span, mln)
% 3/4 In)
0.53 4.8 - 8.7
0.41
0.45
0.41
0.61
0.57
0.35
0.38
0.36
0.39
0.31
0.25
0.59 6.1 - 8.6
0.76
0.62
0.84
0.33 4.3 - 4.9
0.32
0.22
0.31
0.35
0.35
0.45
0.49
0.79
0.81
0.50
0.46
0.51
0.44
Press Temp
( F)
320
320
320
320
320
320
320
320
320
320
320
320
360
360
360
360
320
320
320
320
320
320
320
320
320
320
315
J LJ
315
385
385
385
Excess HCHO
(wtX [resin; f])
6.7
6.7
6.7
6.7
6.7
6.7
6.7
6.7
6.7
6.7
6.7
6.7
7.7
7.7
7.7
7.7
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
5.9**
5.9
5.9
5.9
5.9
X Resin
(lb/100 Ib board)
7.3
7.1
7.1
7.1
6.1
5.9
5.7
5.7
5.2
6.2
5.7
6.1
8.8
8.6
8.0
8.0
8.6
8.6
8.6
9.1
9.1
9.1
9.9
9.9
10.0
10.0
6.9
6.9
6.9
6.9
6.9
*In Mill .B. approximately 95* of the HCHO was found In the vents over the press, unloader and conveyors.
The remaining 5X was found over the board cooler vents.
**As no data was given, this number was an average of Mills A, B, 4 C.
#Board densltleb used to calculate these values were extrapolated from Mill A & B values.
-------
I
00
TABLE A-2. PARTIAL SUMMARY OF RESULTS OF PRESS EXPERIMENTS BY TOMAS, 1964
Emission Rate Emission Rate* Excess HCHO
Run (as % of excess (Ib HCHO/MSF Press Temp (weight * * Dry ResIn
Identifier HCHO in resin) @ 3/4 in) (°F) Cdry resin; t]> (lb/100 Ib BD)
C-1A
C-2A
C-3A
C-4A
C-5A
C-6A
C-7A
C-8A
C-1B
C-2B
C-3B
C-4B
C-5B
C-6B
C-7B
C-7B
21
14
8
7
6
4.4
3.8
3.4
23
21
22
17
8
8.2
6.8
6.5
2.1
1.8
1.2
1.1
2.2
3.2
4.0
4.9
2.4
2.8
3.4
2.6
3.1
5.9
7.1
9.5
284
284
284
284
284
284
284
284
338
338
338
338
338
338
338
338
0.4
0.5
0.6
0.6
1.4
2.8
4.0
5.7
0.4
0.5
0.6
0.6
1.4
2.8
4.0
5.7
30
30
31
31
31
31
32
31
30
30
31
31
31
31
32
31
~;Tn7average7article board density as calculated fron data Presented in NCASI Technical
Bulletin No 493, "A Survey of Formaldehyde and Total Gaseous Non-Methane Organic Corn-
pod missions ro^ articleboard Pres/Vents," June 1986. was used In this calculation.
-------
APPENDIX B
TELEPHONE CONFERENCE RECORDS
B-l
-------
RADIAN
TELEPHONE CALL RECORD
Qlnco-lng Call
QouC(olnf Call
Person Calli
Person Called
I \v.T\n u ., Sp nrv
1 G*n«nl Subjct
TOPICS DISCUSSED AND ACTION TAKEN
Cn V^Cv\
-------
RADIAN
TELEPHONE CALL RECORD
d Incoming Call
/Soutgolng Call
Person Calling
ISO 5- l^>4<~e
Person Called _ ,
Project Nane
\/fl . ffCf/o
Date
(O / c2 Ci? ~7
C? ~ 1 ^_> ~ S3 '
Tlaa
Activity
/^g.&'^f^r ^f^/f^ £ *+ «5/V? ' S T^H |iO^"«j.
Activity
^. O*^''^'^ L ' |N-
General Subject ~\ t-T 1 / IAS * / \ — * — — a. r -~^\
TiTA»T'o/o , MPO : ^Sol} 746-3461 ^Jcir co/^<:-^)
TOPICS DISCUSSED AND ACTION TAKEN
0.3
of-
T?c
J 1
-------
D
S
C
-Z-5
-------
RADIAN
'lojecc No.
Project Kane
TELEPHONE CALL RECORD
Qlncomtng Call
Qoucgolnj Call
Distribution
TOPICS DISCUSSED AND ACTION TAKEN
»iJ HO^-) 81 O-'P
.5
1.3 -
A
0 F
-/c?
n
e 2
Uci-to
-------
is
-------
RADIAN
I'caject No
DvslliSuC.
TELEPHONE CALL RECORD
Qlncoaini Call
Oouegoinf Call
TOPICS DISCUSSED AND ACTION TAKEN
-------
*
/O . T \J
Air /JUTE'S
f^ : o
I.T :
i. 8 •
/vj
OP
-------
RADIAN
TELEPHONE CALL RECORD
ncMtni C*ll
TOPICS OISCUSSEO AND ACTION TAKEN
EyiQl T A So U T
-------
RADIAN
TELEPHONE CALL RECORD
Qlneo«in» Call
TOPICS DISCUSSED AND ACTION TAKEN
,o/\Ji.j/v\ Soi^T^oA S^A^
o tfrM
-------
' j. i
-------
RADIAN
i'roj«ct No
Dts t r i bu c i _
TELEPHONE CALL RECORD
Qln«o«tnt C»U
Qoue«oi"« CJll
TOPICS DISCUSSED AND ACTION TAKEN
-------
A/f)
HO
p
Z.' I
-------
RADIAN
TELEPHONE CALL RECORD
TOPICS DISCUSSED AND ACTION TAKEN
-To 3/y5g
-------
J-
Lfr
-------
RADIAN
TELEPHONE CALL RECORD
Qlncoming C*ll
Doutgoing Call
TOPICS DISCUSSED AND ACTION TAKEN
kk'TxiCJL, M"fvQ.x5- C^
r».Uv-.(
-------
p
14
• wrow
CDT>(C?V-V'T)
] c^r '
%0r/
-------
r,
f
"
~"c-C" /^
A t
7-?
\. <&
i . V*
^
I
r
x
C'
c
£
r,
?'
c~
c
-------
RADIAN
C. ;?o/£^<-4
iA.iktM/^
TELEPHONE CALL RECORD
Qlneo«ln« Call
Qouc«oin| Call
(n^ B/M gVZ-M
TOPICS DISCUSSED AND ACTION TAKEN
-------
RADfAN
rtoject No
OlS cribuC. i
TELEPHONE CALL RECORD
Ooucjoing C*U
«^^^-^—
P.Iion CtLltnf
Pro)«cc N*««
tec*
TIM
TOPICS DISCUSSED AND ACTION TAKEN
-------
RADIAN
i'toj*et No
TELEPHONC CALL RECORD
TOPICS DISCUSSED AND ACTION TAKEN
-------
RADIAN
'reject iwmet
\fg . N^cWTYV/g*
TELEPHONE CALL RECORD
Qlncoming CjU
Doutgoing Cjll
TOPICS DISCUSSED AND ACTION TAKEN
J>YV>d AflAAjQj
^MzL_l^u^- ftrwwajQAAJ im (Wfvw\^-^
\t)
x
^JflJL-. K
"Yrvx Prx frAOfrO mx/^L.iluM ^ ^ntQj\ ou
'—'~A^ .1 . \J A ,
V 1 y \_ i ; yjgs^^^^*^ >-/ '^.A-^^^' '^ V-i >*" . ~ — r-r
fj^JiLn ^^AAioCU no^'in^ : i^aAyc^v^
a JAJLG J Lrv/U^AkL^
^%/^\^i _ i i i-^ rv\. i\J^-
| i .
-------
-------
RADIAN
TELEPHONE CALL RECORD
TOPICS DISCUSSED AND ACTION TAKEN
^OQJ I (vjQAvKfi
- ~.
-------
RADIAN
TELEPHONE CALL RECORD
Qlncoming Cjll
Qoucgoing Call .
Person Calling
Person Called
Ck5T(\
'rojeci. No.
"
Ttl|
Activity
sjEjTA&JUflVVfl JAO*V- Q
I '
TOPICS DISCUSSED AND ACTION TAKEN
o
\aor-.ruioi^ KJE.
- /w > : -^-: n ,
_^orl r^rtv^x^-
c/Vyxv^\v>
}-v_ 1^-
-------
-------
RADIAN
I'roject. No
TELEPHONE CALL RECORD
Project N«(M
roec .
\ / A R)£JV\AL-Oe f-H
TOPICS DISCUSSED AND ACTION TAKEN
Qyvy^l ChTU
i ..i
j^jw^fio11 nn'JbL ft^f^jzJv^r
GAt.rMJLQ uyr\/cyjMi/U.
^
|o^ jLuAm^juruJ pJO-^tn
TO Ji / i/:/l, /i ri n^^J
_
fJcJL ^^P^^-M^
-------
asjc-J^cZJfs
^
J
Wm 'W
0
-------
RADIAN
TELEPHONE CALL RECORD
Qlncoaing C»ll
Ooucgotng C»U
Person CjlUni .... j)
flUu-S^k^
nvr ^.IWM (T>O ^,
DisctibuC; ,n
Project Hilt* J
Va
(olfrlV
Tin.
d^AAryv>Cv)aii\jL up,
0
TOPICS DISCUSSED AND ACTION TAKEN
^Yr\^_AVr ^(TTNtW U)OQ (&1±_&2*A
-------
RADIAN
TELEPHONE CALL RECORD
TOPICS DISCUSSED AND ACTION TAKEN
-------
-------
RADIAN
I'roject No
2L
3
Project Njrae
TELEPHONE CALL RECORD
Pis tribut inn
TOPICS DISCUSSED AND ACTION TAKEN
J)
\f/i
A
?6 -f. QOfw^x 3o^i<}*9 Voiy ^ _f i U
&t KA^T 4T^aDr V(VYVX-CU^LAJ Cjuu-gcv. .fL-/Xjpccx-L^T7
-------
& vjt ^ ^ ' TWlxt^ ^i o~m^-'7Vlc&/) by/UL -}-tULs ,rr^_,yjt
^—^ I /- -^ 1 ^ s\ ^/ /? J /^
r . ^ ^*" I *^
J
(^ vitLL .m\cO^u^Q3 41amjr .f
(3?OT) '
^
&
_
x3GuJ
60 <
lvx>o 4 OTJDM_ IC^rW
-------
RADIAN
rtojeet No
TELEPHONE CALL RECORD
TOPICS DISCUSSED AND ACTION TAKEN
-------
-------
RADIAN
TELEPHONE CALL RECORD
Q Incoming Call
Qoutgoing Call
Person Calling
Person C*L
['toject Nc
Project Na
(o-n-%7
Activity
,-TOm
u>
Pis cribu c ion
General Subjact
A UA/XU t*\i
tr
TOPICS DISCUSSED AND ACTION TAKEN
iy
0
f rd
oib tjj- AV/WMOA
"
CA
o
Ae
0\)
Li (Vwg.
JJL
/o
£
JUJ
l\«A V
AxUUK£4/\J. V J^r
-------
-------
RADIAN
Dxs Cribu c ion
TELEPHONE CALL RECORD
TOPICS DISCUSSED AND ACTION TAKEN
xvt'Av T ecu -^ &^>v
-------
RAMAN
TELEPHONE CALL RECORD
£-18-37
t-. 40 AM
Qtneo«ln« Cill
QoutfOlm Call
TOPICS DISCUSSED AND ACTION TAKEN
HCH n Rif -rAi^t*L
-------
"
^ *
* I
2- 0
r\
r
5
O
41
0
C
11*
T^
.^
vfi
-v.
>
<>
^
«
-
HI
^
t)
c
~T
r
^
V
fl)
fT\
X
n
X
D
> X
o X
c^ a
A
0
^ r
^ -c
J ?
m
/^ C
Ti
^
^
-^
^
1
1>
00
>
b
w
-------
TELEPHONE CALL RECORD
Qtneo«ii
-------
4
10
- 8
-/ 0^5
-------
7*4.
/•
Date
RADIAN
CORPORATION
CONTACT REPORT
Originator
CONTACT BY: TELEPHONE :_ MEETING
NAME, TITLE & ORGANIZATION
Other
ADDRESS & TELEPHONE NUMBER
PURPOSE OR SUBJECT (Give project number if appropriate)
S
. 7/u
ACTION
Distribution:
CD
ID
-------
RADIAN
CORPORATION
CALCULATION SHEET
SIGNATURE
PROJECT
-------
-------
RADIAN
CONTACT REPORT
Date
CONTACT BY: TELEPHONE -^"MEETING
Originator
Other
NAME, TITLE & ORGANIZATION
ADDRESS & TELEPHONE NUMBER
L/
PURPOSE OR SUBJECT (Give project number if appropriate)
SUMMARY
E?
(s
&**
ACTION
to
if)
00
05
Distribution:
-------
RADIAN
Pis tribuc ion
TELEPHONE CALL RECORD
Qlncoaing Cjll
Ooutgolng Call
TOPICS DISCUSSED AND ACTION TAKEN
(j£ L^L-gL^O^
I
J
^L ^JZXZXGf^ &*—J * fc-^
-------
RADIAN
TELEPHONE CAUL RECORD
TOPICS DISCUSSED AND ACTION TAKEN
I. /V I I l^ /-* «•- f . 1 «-T . I
^,^^^^^^^^.^-2-^^^^^
>^//€XA<
(^•T(o_^J±^±
^A7£s.__j2_t:
-------
/oo/
-------
RADIAN
TELEPHONE CALL RECORD
Qlncoaing C*U
^Outgoing C*ll
Pel son Oiling
Person CjLLcd
i'tojecc No
Project N«B*
\/A .
7- 17 - 37
Acclvlty
Activity
Timt
Dts cti but i.
C- ^
General Subject
74-6 -
TOPICS DISCUSSED AND ACTION TAKEN
F/ttt Hct-tO
/v\ IC i-f-7
\c€
Co*\
"Trr/^/l
-------
RADIAN
Discri button.
TELEPHONE CALL RECORD
Qlncoatnt Call
Qoutjotng Call
TOPICS DISCUSSED AND ACTION TAKEN
0 /*v>J£ /ti
ou TH£
7>T> AoT
-------
RADIAN
'roject No.
Project
TELEPHONE CALL RECORD
Dj. s C r t bu c i o n_
TOPICS DISCUSSED AND ACTION TAKEN
^^f-fte r^^euS
T'T/2Aft
-------
TELEPHONE CALL RECORD
Q Incoming Oil
Doutgoing CiU
Person Calling
Person tilled
i'roject No.
Project
T> B
0* It
7-22'
timt
f: io
Activity
S
tc Lo.
Distnbuc iori
General Subject
9g f - J 2
TOPICS DISCUSSED AND ACTION TAKEN
~fi-\G-
O- F
A L
T/V
/"7 S S ' o
A/J EFFECT.
BU AH)tA/2.
li
UJfl S /Jor
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing]
1. REPORT NO.
EPA-450/3-87/023
3. RECiPIENI
4. TITLE AND SUBTITLE
Evaluation of Emission Factors for Formaldehyde from
Certain Wood Processing Operations
5. REPORT DATE
October 1987
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
8. PER
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Office of Air Quality Planning and Standards
U.S. Environmental Protection Agency (EPA)
Research Triangle Park, North Carolina 27711
10. PROGRAM ELE^
11 CONTRACT/GRANT NO.
12. SPONSORING AGENCY NAME AND ADDRESS
DAA for Air Quality Planning and Standards
Office of Air and Radiation
U.S. Environmental Protection Agency
Research Triangle Park. North Carolina 27711
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
FPA/2QO/04
15. SUPPLEMENTARY NOTES
16. ABSTRACT
A State pollution control agency requested assistance from EPA's Control
Technology Center (CTC) in estimating formaldehyde emissions from furniture manu-
facturing processes. These plants use urea-formaldehyde adhesive resin formulations
which emit formaldehyde during application, curing, and storage.
The primary sources of information for this study include library and permit
data base searches, telephone conferences and meetings with members of the furniture
and adhesive manufacturing industries.
The report estimates emission factors for the most significant sources and
discusses the impact of process variables and modifications on these emissions.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b. IDENTIFIERS/OPEN ENDED TERMS
Air Pollution
Pollution Control
Volatile Organic Compounds
Air Toxics
Formaldehyde
Wood Processing
Furniture Manufacture
Air Pollution Control
Stationary Sources
13B
18. DISTRIBUTION STATEMENT
Unlimited
19 SECURITY CLASS {This Report/
UNCLASSIFIED
21. NO. Of PAGES
75
20. SECURITY CLASS (This page/
UNCLASSIFIED
22. PRICE
EPA Form 2220-1 (R«». 4-77) PREVIOUS EDITION is OBSOLETE
------- |