United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EPA-450/3-91-008
February 1991
Air
&EPA Best Demonstrated Control
Technology for Graphic Arts
control
technology center
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EPA-450/3-91-008
BEST DEMONSTRATED CONTROL TECHNOLOGY FOR GRAPHIC ARTS
CONTROL TECHNOLOGY CENTER
SPONSORED BY:
Emission Standards 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
February 1991
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EPA-450/3-91-003
February 1991
BEST DEMONSTRATED CONTROL TECHNOLOGY FOR GRAPHIC ARTS
Prepared by:
Beth Friedman
Chuck Vaught
Midwest Research Institute
Gary, North Carolina 27513
EPA Contract No. 68-02-4379
ESD Project No. 89/08
MRI Project No. 8952-31
Prepared for:
Karen P. Catlett
Chemicals and Petroleum Branch
Office of Air Quality Planning and Standards
Control Technology Center
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
•lil Floof
Chicago, -
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PREFACE
The CTC was established by EPA's Office of Research and Development
(ORD) and Office of Air Quality Planning and Standards (OAQPS) to provide
technical assistance to State and local air pollution control agencies.
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.
The technical guidance projects, such as this one, focus on topics of
national or regional interest that are identified through contact with
State and local agencies.
In this case, the CTC had received numerous .-requests for assistance
in determining BACT/LAER for the graphics arts industry. They had also
received reports that several graphics arts facilities were achieving VOC
control efficiencies of 90 percent or greater. This study was undertaken
to document the reported overall control efficiency for VOC's at a number
of rotogravure and flexographic printing facilities.
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NOTICE
This report was prepared by Midwest Research Institute, Gary NC.
It has been reviewed for technical accuracy by the Emission
Standards Division of the Office of Air Quality Planning and
Standards and the Air and Energy Engineering Research Laboratory
of the Office of Research and Development, 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.
ACKNOHLEOGEMEMT
This report was prepared for the Control Technology Center by
Beth Friedman, Chuck Vaught, Charles Hester, and Rebecca
Nicholson of Midwest Research Institute. The EPA project officer
was Karen Catlett. Also serving on the EPA project review team
were James Berry and Bob Blaszczak of the Office of Air Quality
Planning and Standards, and Chuck Darvin of the Office of
Research and development.
ii
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TABLE OF CONTENTS
Page
1.0 INTRODUCTION 1
2.0 CONCLUSIONS 2
3.0 DESCRIPTION OF PROCESSES USED BY THE GRAPHIC ARTS
INDUSTRY 5
3.1 FLEX06RAPHIC PRINTING 5
3.2 ROTOGRAVURE PRINTING . 7
4.0 CRITERIA FOR DETERMINING OVERALL CONTROL EFFICIENCY 9
4.1 PERMANENT TOTAL ENCLOSURE CRITERIA 9
4.2 DESTRUCTION OR REMOVAL EFFICIENCY CRITERIA 10
5.0 RESULTS 11
5.1 PACKAGE PRODUCTS 11
5.2 TARKETT, INC 16
5.3 MAXWELL GRAPHICS 19
5.4 ADVANCED PRINTING TECHNOLOGY ".... 23
5.5 MORRILL PRESS 26
5.6 AMKO PLASTICS 30
5.7 CMS GILBRETH PACKAGING SYSTEMS 32
6.0 DISCUSSION 37
6.1 . OVERALL CONTROL SUMMARY 37
6.2 WATER-BASED INKS 40
6.3 OTHER TOTAL ENCLOSURE CONSIDERATIONS 41
7.0 REFERENCES 42
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LIST OF FIGURES
Page
Figure 1. Flexographic printing process 6
Figure 2. Rotogravure printing process.... 8
LIST OF TABLES
TABLE 1. CHARACTERISTICS OF PLANTS VISITED TO ESTABLISH
CURRENT BEST DEMONSTRATED TECHNOLOGY . 3
TABLE 2. SUMMARY OF PTE CRITERIA AT PACKAGE
PRODUCTS IN CHARLOTTE, NORTH CAROLINA 15
TABLE 3. SUMMARY OF PTE CRITERIA AT TARKETT
IN WHITEHALL, PENNSYLVANIA 18
TABLE 4. SUMMARY OF PTE CRITERIA AT MAXWELL
GRAPHICS IN RICHMOND, VIRGINIA 22
TABLE 5. SUMMARY OF PTE CRITERIA AT ADVANCED PRINTING
TECHNOLOGY IN MORGANTOWN, PENNSYLVANIA 24
TABLE 6. SUMMARY OF PTE CRITERIA AT
MORRILL PRESS IN FULTON, NEW YORK 29
TABLE 7. SUMMARY OF RESULTS OF EXAMINATION FOR PTE
CRITERIA AT ALL PLANTS VISITED ,. 38
TABLES. SUMMARY OF OVERALL CONTROL EFFICIENCIES 39
1v
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1.0 INTRODUCTION
The Control Technology Center (CTC) and others within the U. S.
Environmental Protection Agency (EPA) have received reports that several
graphic arts facilities are achieving VOC control efficiencies of
90 percent or greater and that several facilities are using permanent
total enclosures. The CTC also received requests for assistance in
determining best available control technology and lowest achievable
emissions rate (BACT/LAER) for this industry. This study documents the
reported overall control efficiency for volatile organic compounds (VOC's)
at a number of rotogravure and flexographic printing facilities.
Facilities were contacted for background information to (1) identify
facilities with 90 percent control efficiency or greater and (2) document
these efficiencies. The overall objective of the effort is to provide
assistance to State and local agencies requesting information on BACT and
LAER. Documenting that several facilities achieve very high capture and
control efficiencies is a necessary approach to this effort.
The information obtained from site visits was used to document the
overall control efficiency achieved at each operation. As with any air
pollution control problem, overall control efficiency is based on the
product of two component efficiencies: capture efficiency and control
device efficiency. Previous regulatory efforts have typically focused on
the control device component; therefore, existing documentation and test
methodologies tend to be more readily available for this efficiency
determination. Therefore, the focus of this project was the collection of
information related to the efficiency of the capture system. In some
cases, limited capture efficiency test data were available; in other-
cases, information on enclosure system design criteria and operating
conditions was collected to determine capture system efficiency. An
overall control efficiency was then estimated for each facility. Because
one of the facilities had converted to water-based inks, thereby
dramatically reducing maximum potential VOC emissions, local regulations
did not require a capture system and a control device.
Midwest Research Institute contacted (by telephone) State and local
agencies, Regional EPA offices, and graphic arts facilities to obtain
information on flexographic and rotogravure graphic arts facilities that
1
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reportedly achieved VOC control efficiencies of 90 percent or greater.
Nineteen graphic arts facilities and one vinyl flooring manufacturer were
contacted. Of the 20 facilities contacted, only seven stcited that their
overal 1 VOC control efficiency was 90 percent or greater. Of these seven
facilities, six were visited by the project team. Two additional
facilities that were thought to have adopted particularly innovative
capture technologies were later identified by EPA. These facilities were
visited as well.
Table 1 is a list of facilities that were visited and a summary of
the key characteristics of the facilities. Seven of the facilities are
typical graphic arts facilities. Of these seven, six are packaging
facilities and one is a publishing facility. The eighth facility, which
is a vinyl flooring manufacturer, was visited because the VOC capture and
control system (total enclosure plus incinerator) used at this facility
promised to be applicable to graphic arts facilities also. In addition,
the eighth facility uses a rotogravure printer for its vinyl printing
operation, the basic printing process is similar to that used at more
typical graphic arts facilities, and the facility is regulated as a
graphic arts facility.
2.0 CONCLUSIONS
The following list of conclusions is based on the information
collected during the study:
1. The use of capture and control systems and the use of
water-based ink systems have been demonstrated to be effective and
reliable in achieving a greater than 90 percent overall reduction in VOC
emissions from graphic arts facilities using rotogravure and flexographic
printing presses. In addition, more recent information reported to EPA
indicates that the following graphic arts facilities using solvent-based
inks have adopted (or are in the process of adopting) capture and control
systems that achieve greater than 90 percent VOC emission reductions:
• Colonial Heights Packaging, Virginia
• Central States Diversified, Minnesota
• Maxwell Communications Corporation, Tennessee
• Princeton Packaging, Incorporated, Pennsylvania
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TABLE 1. CHARACTERISTICS OF PLANTS VISITED TO ESTABLISH CURRENT BEST DEMONSTRATED TECHNOLOGY
Company, location
Type of primary
printing system
End product
Special characteristics/
add-on control
Plants with total enclosures
Package Products,
Charlotte, NC
Tarkett, Inc.,
Whitehall, PA
Maxwell Graphics,
Richmond, VA
Advanced Printing Technology,
Morgantown, PA
Morrlll Press,
Fulton, NY
CMS Gllbreth—Bristol Plant,
Croydon, PA
CMS Gllbreth—Bensalem Plant,
Bensalem, PA
Plant which uses only
waterborne coatings
Amko Plastics,
Cincinnati, OH
Flexographlc
Rotogravure
Rotogravure
Rotogravure
Rotogravure
Rotogravure
Rotogravure and
. flexograhlc
Flexographlc
Packaging
Catalytic incinerator
Vinyl flooring Regenerative Incinerator
Publishing
Packaging
Packaging
Packaging
Packaging
Carbon adsorber
Wood grained Thermal incinerator
laminates
Catalytic incinerator
Capture systems use
recirculation,
Regenerative incinerator
Capture systems use
recirculation,
Regenerative incinerator
Water-based coatings
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Although EPA has not verified these reports, they are an indication
of the growing use of high efficiency capture and control systems in the
graphics arts industry.
2. The facilities visited demonstrated overall control efficiencies
of 94 to over 99 percent;
3. States should be cognizant of the demonstrated control
efficiencies obtained in these and other graphic arts facilities and apply
this information in future RACT, BACT, and LAER determinations. The
previously accepted VOC reductions of 65 percent, often considered to be
RACT for this industry, may no longer be considered the maximum reduction
capability for graphic arts operations;
4. Only one of the facilities visited was a totally new facility.
The other facilities, including the facility using water-based inks, had
all been retrofitted with the technology used to reduce VOC emissions;
5. The majority of facilities reporting >90 percent overall control
used total enclosures and add-on devices to achieve that level;
6. Permanent total enclosures (PTE's) meeting EPA criteria have
been successfully installed and operated at graphic arts facilities using
rotogravure and flexographic presses;
7. At some plants, differential pressure controllers in the
enclosure were used to maintain a specified pressure drop between the
inside of the enclosure and ambient pressure. Maintaining a static
pressure drop of about 1.0 pascal (Pa) (0.004 inch [in.] water) across the
natural draft opening (NDO) results in internal face velocities of at
least 3,600 meters per hour (m/hr) (200 feet per minute [ft/min]), thus
meeting EPA Criteria 4, one of the criteria established by EPA for
defining a PTE;
8. For facilities utilizing capture and control, well-designed
localized air collection and overall air management systems not only
enhance the effectiveness of the control system but are also reported to
improve the quality of the air in the press room and, as a result, working
conditions;
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9. There was no degradation in worker safety or health conditions
in facilities utilizing permanent total enclosures. Based on comments by
management and workers, working conditions were improved in some
facilities;
10. The PTE's present no more of a fire hazard than other press
rooms. All are designed so that workers can exit quickly in case there is
a fire or explosion; and
11. The plant that used water-based inks reported other
environmental, health, and safety benefits in addition to reduced VOC
emissions. These benefits included reduced amounts of hazardous wastes
(and reduced disposal costs), elimination of the need for special storage
areas (water-based inks are noncombustible), and significantly improved
working conditions.
3.0 DESCRIPTION OF PROCESSES USED BY THE GRAPHIC ARTS INDUSTRY
3.1 FLEXOGRAPHIC PRINTING1
Flexography, shown in Figure 1, uses a flexible plate, which may be
.made of rubber or a photo sensitive polymer known as a photopolymer, and
fluid inks. Flexography is well suited for printing on almost all
flexible packaging materials since the flexographic inks dry rapidly.
Because the plastic substrates on which the ink is placed, such as
polyolefins, polystyrene, and polyesters, have nonporous surfaces (i.e.,
the ink will not penetrate the substrate), it is essential that the inks
dry quickly to avoid smearing. Flexographic inks also print well on paper
stocks, aluminum foil, paperboard, and paper used for folded cartons, cups
and containers.
Flexographic presses are rotary machines with up to eight color
stations. Ink is pumped or poured from a storage container to a press
"fountain." The ink distribution system usually consists of a fountain
roller and an anilox form roller that delivers the ink to the printing
plate, although some newer distribution systems eliminate the rubber
fountain roller and immerse the anilox form roller in the ink fountain.
A doctor blade removes excess ink from the form roller. The ink is
transferred from the form roller to the printing plate and from the
printing plate to the substrate. A drying oven then dries the printed
web.
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FLEXDGRAPHIC PRINTING
PLATE
CYLINDER
ANILDX FORM
ROLLER
FOUNTAIN
ROLLER
PAPER
IMPRESSION
CYLINDER
INK FOUNTAIN
PAPER
STOCK
Figure 1. Flexographic printing process.
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Flexographic inks consist of one or more resins dissolved in a
solvent blend. A combination of solvents may be required, particularly
when more than one resin is used. The solvent blend consists primarily of
the lower molecular weight alcohols, such as ethyl, n-propyl, and
isopropyl. These may be mixed with small amounts of glycol ethers,
aliphatic hydrocarbons, acetates, or esters to obtain optimum resin
solubility, proper drying speed, and viscosity.
Flexographic inks can also be water-based. Although they are used
primarily on porous substrates such as paper and paperboard, they can be
used successfully on any substrate if the printer is willing to invest
enough effort in devising a workable system. Water-based inks have
several advantages, including good press stability and printability,
compliance with air pollution regulations, absence of fire hazards, and
reduced insurance costs. They are also economical and convenient because
water can be used for dilution and for cleaning up. The printing industry
has reported some problems with water-based inks. On nonabsorbent
substrates such as plastic films, water-based inks do not have the gloss
of solvent-based inks and they dry more slowly. Newer types pf water-
based inks that are more suitable for printing on plastic films are being
developed and used.
3.2 ROTOGRAVURE PRINTING1
For the gravure printing process shown in Figure 2, the design to be
printed is etched or engraved into (below the surface of) the printing
cylinder. The printing image consists of thousands of recessed "cells" or
indentations per square inch. The depth and width of the cells controls
the amount of ink that is metered. The gravure process is used for
publication printing and printing folding cartons, flexible packaging, and
specialty items such as gift wraps, vinyl plastic film, and vinyl-coated
fabrics.
The gravure press consists of the gravure cylinder on which the
design to be reproduced is etched, an ink pan in which the cylinder is
immersed, a doctor blade that removes excess ink from the surface of the
cylinder, and the impression roller that brings the web of material to be
printed into contact with the gravure cylinder. A drying oven then dries
the printed web.
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GRAVURE PRINTING
oo
DDCTDR
BLADE
IMPRESSIDN
CYLINDER
ETCHED
CYLINDER
PAPER
STOCK
Figure 2. Rotogravure printing process.
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Gravure inks are composed of three ingredients: pigment, binder, and
solvent. Pigment selection is based on the color desired and any
additional properties, such as light fastness, that may be required for
the job. The binder ensures that the pigment is evenly dispersed in the
liquid ink, prevents bleeding, and helps the pigment adhere to the printed
substrate. Binders are selected based on their ability to develop maximum
adhesion to the surface to be printed and on the level of gloss and
flexibility required in the printed product. The solvent dissolves the
binder to form a fluid ink and then evaporates to leave a dried ink
film. Organic solvents used in rotogravure inks may be esters, alcohols,
ketones, acetates, aromatic hydrocarbons, or aliphatic hydrocarbons. The
solvent is selected based on a number of criteria, including complete
solubilization or dispersion of the resins, speed of drying, cost
efficiency, and compliance with OSHA and EPA standards.
Water-based inks are also being used in gravure printing for some
applications, primarily for paper and paperboard, and, to a lesser extent,
for film and foil. Research on developing ink resins that are appropriate
for water-based systems has resulted in a greater variety of resin being
available. These new water-based systems are suitable for use on more
substrates, have a wide range of end use properties, and dry more quickly.
4.0 CRITERIA FOR DETERMINING OVERALL CONTROL EFFICIENCY
As previously discussed, the purpose of this study is to verify and
document reports that some currently existing rotogravure and flexographic
printing plants routinely achieve 90 percent or greater overall control
efficiencies for VOC's. For plants using solvent-based inks, control of
VOC's is a two-part endeavor involving first the capture of the VOC's and
second the destruction or removal of the VOC's from an exhausted air
stream. Multiplying the efficiencies of these two endeavors results in
the overall VOC control efficiency.
4.1 PERMANENT TOTAL ENCLOSURE CRITERIA
Six of the eight facilities visited were using, or plan to install,
PTE's as part of their strategy to capture and control at least 90 percent
of press operation emissions. A permanent total enclosure is a structure
constructed around a source of emissions so that all VOC emissions are
collected and exhausted through a stack or duct to a control device. With
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a PTE, there are no fugitive emissions. All VOC must exit through a
ductwork so that any necessary concentration measurements can be made.
The PTE's may be built around a specific press or number of presses, or an
entire room may be sealed off and modified to function as a PTE. In
either case, EPA has developed a set of design and operational criteria
which, when incorporated into the design of an enclosure, should cause its
actual capture efficiency to be essentially total. The criteria are as
follows:
1. All VOC emissions must be captured and contained for discharge
through a control device;
2. The total area of all NDO's shall not exceed 5 percent of the
surface area of the enclosure's four walls, floor, and ceiling;
3. All access doors and windows whose areas are not included in
Criteria 2 and are not included in the calculation in Criteria 4 shall be
closed during routine operation of the process;
4. The average facial velocity (FV) of air through all NDO's shall
be at least 3,600 m/hr (200 ft/min), which equates to a pressure drop of
0.004 inches of water. The direction of air through all NDO's shall be
into the enclosure; and
5. Any NDO shall be at least 4 equivalent opening diameters from any
VOC emitting" source.
The PTE criteria were published in the new source performance
standard (NSPS) for the magnetic tape industry and the NSPS for the
coating of polymeric substrates. Additionally, a policy statement
published April 16, 1990, "Guidelines for Developing a State Protocol for
the Measurement of Capture Efficiency" contains these criteria. According
to these guidelines, if the criteria are met, EPA will presume that the
capture efficiency is 100 percent. The facilities discussed in this
report that were utilizing, or are in the process of installing, PTE's had
all based the design of the PTE's on these criteria.
4.2 DESTRUCTION OR REMOVAL EFFICIENCY CRITERIA
The determination of the destruction or removal efficiency of VOC's
exiting the enclosure is generally based on information supplied by the
plant on tests conducted to document the performance of the control
device. The EPA Reference Method 25 is one method for determining the VOC
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content into and out of a control device. The EPA has extensive
experience with the most commonly used control devices, incinerators and
carbon adsorbers, and has information to support that these control
devices should achieve efficiencies of at least 95 percent if they are
properly designed, operated, and maintained units.
5.0 RESULTS
This section contains a brief summary of each of the eight plants
visited and an assessment of their respective VOC capture and control
efficiencies.
5.1 PACKAGE PRODUCTS2
Package Products Company operates eight flexographic printing presses
at its facility in Charlotte, North Carolina. The facility prints a
variety of flexible packaging films including plastic candy wrappers and
soft drink shrink-wrap. The presses are multicolor units with each color
applied sequentially at a different ink station. Each color of ink is
dried before the next color is applied. Drying is accomplished with a
natural-gas-fired, hot air dryer called the between-the-colors (BC)
dryer. The BC dryer blows hot air on the film after each color
application. Exhaust slots then collect the evaporated ink solvent.
After the final color is applied and dried, the printed film goes into a
natural-gas-fired overhead dryer where additional hot air is blown on the
film to remove any residual ink solvent. All the presses are located in
one large room that has been modified to serve as a PTE capable of
capturing fugitive VOC emissions from the presses. The VOC emissions from
the room are controlled by seven catalytic incinerators.
5.1.1 Capture Efficiency
Permit conditions established by the Mecklenberg County Department of
Environmental Health (MCDEH) at the Package Products facility specify
90 percent VOC removal and, for three of the presses and one laminator, a
120 tons/year combined total emissions limit. Actual combined emissions
for the three presses and one laminator were 25 tons/year. One additional
press is limited to 40 tons/year of emissions; the plant estimates that
actual emissions are less than 2 tons/year. Overall, the facility was
credited with achieving LAER for flexographic printing in a nonattainment
area for ozone.3
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The Package Products' PTE is a room of approximately 6,372 cubic
meters (m3) (225,000 cubic foot [ft3]). All entrances to the room are
- closed with the exception of a 2.7 square meter (m2) (96 square foot
[ft ]) doorway between the press room and laminating room,, which is
covered with overlapping vinyl strips. Clean air is blown toward the
vinyl strips from within the enclosed press room in order to impede the
movement of dust and dirt drawn into the press room.
Forced makeup air is supplied to the PTE at approximately
850 cubic meters per minute (m3/min) (30,000 standard cubic feet per
minute [scfm]) from the windup end of the presses. Press room air is
exhausted through ducts located at the opposite end of the presses at
approximately 935 m3/min (33,000 scfm). There are eight exhaust ducts,
one behind each press. Thus, as the air travels across the room from the
supply ducts to the exhaust ducts, it picks up fugitive VOC emissions from
the presses.
Package Products tested the capture efficiency of the PTE system
using three different techniques:
1. Room air balance on portion of air captured and incinerated;
2. Mass balance based on VOC charged to press; and
3. Chemical smoke releases.
At the time of the test program, only four of the eight fugitive pickup
ducts were connected to an incinerator because the other incinerators had
not yet been installed.
The first technique, the room air balance, showed that 670 m3/min
(23,666 ft3/min) of fresh air entered the room and 630 m3/min
(22,254 ft3/min) was captured in the fugitive pickup duct. (Note: Not
all of the fugitive pickup- ducts and incinerators were installed at this
time.) Approximately 42.5 m3/min (1,500 ft3/min) of air is collected by
. the dryers. Results of their air balance analysis led Package Products to
conclude that 97.6 percent of the VOC's are captured.
A second technique, a VOC mass balance (liquid-gas), was performed by
quantifying the amount of each color ink charged to the presses. Using
Ink solvent composition data, the quantities of solvents charged to the
presses were calculated. The VOC input was compared to the VOC loading
measured at the incinerator inlet and a capture efficiency value was
calculated.
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The capture efficiency values varied from between 42 and 130 percent.
This type of variation, although extreme, is not completely unexpected
because mass balances on presses are subject to many errors, especially
for short-term runs. First, liquid-gas material balances have been
historically difficult to close. Second, the physical layout at Package
Products has all of the presses in one large room. This configuration can
result in a mixing of fugitive emissions from the presses, such that the
amount of solvent charged to an individual press may not equal the amount
of captured solvent delivered to the control device.
As a third technique to determine qualitatively the effectiveness of
the capture system, chemical smoke tubes were used to visually demonstrate
airflow patterns in the press room. The assumption was that demonstration
of the uninterrupted movement of smoke from the press to the air"pickup
registers is an indication of optimal capture system performance and
minimal press room VOC concentrations. Package Products reports'that the
experiments showed that the airflow patterns were consistent from the air
supply registers, across the press room, to the air pickup registers.
Since these three tests were conducted, the remaining incinerators
have been installed, and four more fugitive pickup ducts were connected to
the catalytic incinerators.
During the visit, face velocity measurements were taken by the site
visit team, using a hot wire anemometer, at the vinyl-strip-covered
interior doorway and at a door leading outside that was partially
opened. Face velocities recorded at the 2.4 m x 3.7 m (8 ft X 12 ft)
doorway with vinyl strip curtains were erratic and generally less than
30.8 m/min (100 ft/min). At times, the airflow appeared to be directed
out of the enclosure as the result of a fan that continuously blew air at
the doorway from inside the enclosure. Face velocity measurements were
also taken at an outside door that was partially opened by plant personnel
for the purpose of demonstrating that even if a worker enters or exits the
enclosure, a significant inward face velocity is maintained. The
measurements showed a consistent face velocity into the enclosure of
approximately 169 m/min (550 ft/min).
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Table 2 is a summary of the PTE criteria that are satisfied at
Package Products. Criteria 1 and 3 are clearly satisfied.
Because of the vinyl strips in place at the 2.4 m x 3.7 m
(8 ft x 12 ft) doorway, it was not possible to accurately determine the
effective open area of the doorway. The enclosure exhaust system draws
85 m /min (3,000 scfm) more than the makeup air system supplies.
Theoretically for this exhaust flow rate, a well sealed enclosure with
face velocities of 61 m/min (200 ft/min) across the NDO's would have an
NDO area of 1.4 m2 (15 ft2). The total area of the doorway is 8.9 m2
(96 ft ). In order for the criteria to be satisfied, the vinyl strips
covering the doorway must cover at least 7.5 m2 (81 ft2), or 84 percent of
the area of the doorway. Observations made during the visit suggest that
over 95 percent of the doorway was effectively covered, by the vinyl
strips. This analysis indicates that the theoretical face velocity is
greater than 61 m/min (200 ft/min), thus satisfying Criteria 4, and that
because the area of the NDO must be less than 5 percent of the total
surface area of the enclosure, that Criteria 2 is satisfied.
A complicating factor .in evaluating Criteria 4 is the erratic face
velocity measurements at the 2.4 m x 3.7 m (8 ft x 12 ft) doorway leading
from the. laminating room. The vinyl strips did not hang uniformly to seal
the doorway for at least two reasons. The most obvious reason is the
85 m /min (3,000 scfm) that can enter only through the door-way. In
addition, however, the ventilation system discharged against the internal
side of the door with outside air creates turbulence at the doorway. For
this reason this facility deviates somewhat from the ideal total enclosure
and it is not possible to make absolute judgments about the probability
that fugitive emissions are not somehow aspirated through the strips. It
does however seem unlikely.
.The worst-case scenario for meeting the fifth criterion is that, in
the absence of the vinyl strips, the equivalent diameter of the natural
draft opening would be 2.9 m (9.6 ft). The distance between the opening
and the nearest emission source is approximately 12.2 m (40 ft).
Therefore, Criteria 5 would be met. In reality, the effective area of tbe
natural draft opening is much smaller because of the vinyl strips, which
greatly decrease the equivalent diameter of the opening. The fifth
criterion is thus certainly met.
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TABLE 2. SUMMARY OF PTE CRITERIA AT
PACKAGE PRODUCTS IN CHARLOTTE, NORTH CAROLINA
Criteria No.
Plant met
criteria
1. All VOC emissions must be captured and contained for
discharge through a control device
2. Total area of NDO's is not to exceed 5 percent of total
surface area
3. Access doors and windows should be closed during normal
operation
4. The average inward face velocity across all NDO's must
be at least 3,600 m/hr (200 ft/min)
Yes
Yes
Yes
Yes(
Yes
5. All sources of emissions within the enclosure should be
at least 4 equivalent diameters away from each NDO
aFace velocity measurements were erratic at the 2.4 m x 3.7 m
(8 ft x 12 ft) doorway leading from the laminating room. The vinyl
strips did not hang uniformly to seal the doorway for at least two
reasons. The most obvious reason is the 85 m /min (3,000 scfm) that can
enter only through the doorway. In addition, however, the ventilation
system discharged against the internal side of the door with outside air
creates turbulence at the doorway. For this reason this facility
deviates somewhat from the ideal total enclosure and it is not possible
to make absolute judgments about the probability that fugitive emissions
are not somehow aspirated through the strips. It does however seem very
unlikely.
.15
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Based on the Package Product capture efficiency test program, it
appears that the press room enclosure is capable of achieving a high level
of capture efficiency. Because the enclosure satisfies the PTE total
criteria, the capture efficiency can be assumed to be 100 percent.
5.1.2 Control Device Efficiency
Package Products conducted stack tests on each of the seven
incinerators in either August 1987 or February 1986. The purpose of these
tests was to determine compliance with the plant's permit conditions.
Destruction efficiencies ranged from 98.7 to 99.6 percent.
5.2 TARKETT, INC."
Tarkett, Inc., operates one rotogravure printing press at its
facility in Whitehall, Pennsylvania. The facility manufactures vinyl
floor covering. The press is a six station unit. The inks are thinned
with solvents, primarily methyl ethyl ketone and methyl isobutyl ketone,
to achieve the proper viscosity for printing. Each color or ink is dried
in a dryer before the next color is applied. The dryer draws air over the
web after each color application. The dryers do not require heat because
the line speed is low. The plant has been retrofitted with capture and
control devices for control of VOC emissions from the press, which is
located in a large room that is sealed off to serve as a total
enclosure. Emissions are controlled by a regenerative thermal
incinerator. Use of the PTE allows the plant to minimize the amount of
airflow to be treated by the incinerator.5
5.2.1 Capture Efficiency
A 2,095 m3/min (74,000 acfm) exhaust fan removes air from the total
enclosure and induces it through the control device. Doors leading into
the enclosure remain closed and are equipped with automatic closing
devices. Also, two slots in the enclosure walls allow passage of the web
into and out of the press room. These slots serve as the only natural
draft openings to the enclosure.
Capture efficiency tests have been conducted by Tarkett in accordance
with Pennsylvania regulations. These regulations require Tarkett to
design"and operate a capture and control system that is consistent with
good engineering practices and that provides for an overall reduction in
VOC emissions of at least 65 percent. Velocity profiles were measured at
16
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the slots where the web enters and exits the press room. Also,
differential static pressures were measured across the slots using low-
range manometers and anemometers. Based on a liquid-gas material balance,
the test contractor reported that capture efficiencies ranged between 97
and 100 percent with the printing room doors open (the test report lacks
sufficient detail to independently verify these efficiencies). Although
Tarkett intended to measure capture efficiency with the printing room
doors closed, this portion of the test was aborted when the incinerator
went down. However, it is expected that capture efficiencies will be
enhanced with the doors closed.
During our visit, face velocities were measured at the natural draft
openings using a hot wire anemometer. Face velocities through the natural
draft opening into the enclosure ranged between 45.7 and 91.4 m/min (150
and 300 ft/min) depending upon the position of the probe. The differing
face velocities are attributed to the web and web-conveying equipment that
are positioned in the natural draft opening, which possibly cause
variability in local face velocities. In reality, the effective area of
the natural draft opening is a fraction of the area of the slots because
of the area occupied by the web-conveying equipment that passes through
them.
Table 3 indicates which PTE criteria have been satisfied by Tarkett1s
enclosure of their rotogravure press. Criteria 1 and 3 are clearly
satisfied at Tarkett. The total area of the natural draft openings is
2 2
2.4 m (26 ft ). From our observations it appears that the enclosure has
approximately 818 m2 (8,800 ft2) of surface area. Therefore, the natural
draft opening is much less than 5 percent of the total surface area of the
enclosure, and so Criteria 2 is satisfied.
Theoretical face velocities through the natural draft openings into
the enclosure can be calculated by dividing the airflow exhausted from the
room (1,020 m3/min [36,000 ft3/nrin]) by the total area of the natural
draft openings (there is no forced makeup air). The theoretical face
velocity through the natural draft openings is 422 m/min (1,384 ft/min),
which satisfies Criteria 4. The equivalent diameter of the slots is
approximately 0.6 m (2 ft). There are no emission sources (ink decks)
within 2.4 m (8 ft) of the natural draft openings, so the fifth criterion
is met.
17
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TABLE 3. SUMMARY OF PTE CRITERIA AT
TARKETT IN WHITEHALL, PENNSYLVANIA
Plant met
Criteria No. criteria
1. All VOC emissions must be captured and contained for Yes
discharge through a control device
2. Total area of NDO's is not to exceed 5 percent of total Yes
surface area
3. Access doors and windows should be closed during normal Yes
operation
4. The average inward face velocity across all NDO's must Yes
be at least 3,600 m/hr (200 ft/min)
5. All sources of emissions within the enclosure should be Yes
at least 4 equivalent diameters away from each NDO
18
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Although the Tarkett capture data cannot be verified, they do
indicate a high level of capture efficiency. Because the enclosure
satisfies the PTE criteria, 100 percent capture can be assumed.
The enclosure was recently reviewed by Occupational Health and Safety
Administration (OSHA) personnel, and worker exposure was determined to be
only 40 percent of the time weighted average exposure limit. Noise levels
were well below the 55 decibel limit, and excessive temperature or
humidity conditions have not resulted from use of the enclosure. Worker
safety is not an issue either, because the presence of fire doors in the
enclosure actually contributes to fire protection.
5.2.2 Control Device Efficiency
Tests on the destruction efficiency of the RE-THERM system were done
in July 1987. The incinerator destruction efficiency averaged 98 percent
for total hydrocarbon as measured by EPA Method 25A.
5.3 MAXWELL GRAPHICS6
Maxwell Graphics operates five rotogravure printing presses and one
proof press at its facility in Richmond, Virginia. The plant prints the
National Enquirer and various advertising inserts on newsprint. The
presses are multicolor units with each color being applied sequentially at
a different ink station. Each color of ink is dried in a dryer before the
next color is applied. The dryers draw warm ajr over the web after each
color application. One new press is located in a large room that is
separate from the other presses. This press is equipped with a partial
enclosure and was designed to meet lowest achievable emission reduction
requirements (Richmond is nonattainment for ozone). Three of the other
presses have been modified to enhance local ventilation in response to
permit requirements. Captured emissions are controlled by two carbon
adsorbers.
5.3.1 Capture Efficiency
While the plant has not installed total enclosures, it has taken
steps to enhance capture of fugitive emissions from the press rooms. One
press, an Albert-Frankenthal gravure press, is located in a large room
separate from the other four older presses. Three doors lead into the
room and are equipped with automatic closing devices. Two bay doors
accommodate the loading and unloading of trucks. The larger bay door
19
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leading outdoors was open during the site visit. The Albert-Frankenthal
press is equipped with a partial enclosure above the applicators, and the
lower part of the press (near the applicators) has hoods that close to
contain vapors from the application section. The partial enclosure above
the press draws VOC-laden air through the hoods on the application section
of the press and" directs it to a carbon adsorber. The room enclosure has
no exhaust system of its own. Air in the room enclosure is induced out
through the partial enclosure mounted above the press at a rate of
1,500 m3/min (53,000 ft3/min). Approximately 1,132 m3/min
(40,000 ft3/min) of makeup air is fed into the large room. We were not
able to detect with a hot wire anemometer any significant airflow (face
velocity) into the large room containing the Albert-Frankenthal press. We
suspect this was due in part to the large bay door's being open.
Three of the remaining presses (all Goss presses) have been modified
to enhance the flow of air through the air spaces of the presses. These
modifications include the installation of rubber curtains that drop down
to cover the gap between the paint deck and the dryer. The curtains
reduce the total area of the opening and increase the velocity of air
induced through the remaining spaces. Also, these presses have air
exhaust systems designed to remove air from beneath the presses. These
presses are installed above a concrete basin. An induction fan at the
rewind end of the press induces airflow through the basin beneath the
presses, thus contributing to the capture of fugitive VOC's from the
presses. The captured emissions are sent to the carbon adsorption system.
To date, no tests have been done to determine independently the
capture efficiency of the enclosure. However, Maxwell Graphics performs a
metered and computerized daily mass balance of all the inks and solvents
used during production. This information is used to trace the use of the
solvents and to document the amount of solvent that is not recovered.
This is done by totaling the amount of solvent used and subtracting the
amount of solvent recovered in the carbon adsorbers. Daily variations
between 83 and 115 percent solvent recovery are common. According to the
plant,, the annual VOC recovery is approximately 94 to 95 percent of all
solvents used in the printing process. 'The relatively high overall
efficiency estimate indicates that capture efficiency is above 90 percent.
20
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Table 4 Indicates which PTE criteria have been satisfied by Maxwell
Graphics efforts to enclose their Albert-Frankenthal rotogravure press.
Criteria 1 and 3 are met if the bay door, which was open on the day of the
visit, is considered a natural draft opening. The bay door area accounts
for approximately 2 percent of the total surface area of the room, which
satisfies Criteria 2. Dividing the difference between the exhaust air and
makeup air rate (368 m3/min [13,000 ft3/min] by the surface area of the
natural draft opening (13.0 m2 [140 ft ]) indicates that the theoretical
face velocity is approximately 28.3 m/min (93 ft/min). Therefore,
Criteria 4 is not met. Four times the equivalent diameter of the bay door
is 14.2 m (46.7 ft). The Albert-Frankenthal press is approximately 23 m
(75 ft) away from the opened bay door; therefore, the fifth criterion is
met.
The air quality in the press room improved significantly with the
addition of the enclosure systems. The "close capture" of solvent-laden
air prevents the solvent fumes from escaping into the room. The OSHA
recently dropped the personal exposure limit for toluene to less than
100 parts per million (ppm). The plant said that this change may result
in the need for some workers to wear masks. However, without the current
enclosure system, the standard would be even more difficult to meet.7
The company has always had a training program regarding routes of
egress and procedures in the event of a fire or explosion. The addition
of the enclosures did not result in any modifications to the safety
program, i.e., the enclosures do not present an inherent safety problem.7
5.3.2 Control Device Efficiency
There are two separate carbon adsorber systems at the plant. Solvent
recovery unit No. 1 has four carbon beds, each with a capacity of
1,416 m3/min (50,000 ft3/min). This unit is used to recover solvent from
two of the Goss presses and the Motter press. These presses have a
combined exhaust rate of 2,974 m3/min (105,000 ft3/min). Solvent recovery
unit No. 2 has three carbon beds each with a capacity of 1,529 m3/min
(54,000 ft /min). This unit recovers solvent from one Goss press, the
proof press, and the Albert-Frankenthal press. These three presses have a
combined exhaust rate of 2,832 m3/min (100,000 ft3/min). Solvents (mostly
toluene and xylene) are recovered by steam injection of the beds and are
21
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TABLE 4. SUMMARY OF PTE CRITERIA
SATISFIED AT MAXWELL GRAPHICS IN RICHMOND, VIRGINIA
Plant met
Criteria No. criteria
1. All VOC emissions must be captured and contained for Yes
discharge through a control device
2. Total area of NDO's is not to exceed 5 percent of total Yes
surface area
3. Access doors and windows should be closed during normal Yes
operation
4. The average inward face velocity across all NDO's must No
be at least 3,600 m/hr (200 ft/min)
5. All sources of emissions within the enclosure should be Yes
at least 4 equivalent diameters away from each NDO
22
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sold to ink formulators. Although the efficiency of the system has never
been tested, the design efficiency of each unit is 98 percent.
5.4 ADVANCED PRINTING TECHNOLOGY8
Advanced Printing Technology operates two rotogravure printing
presses at its facility in Morgantown, Pennsylvania.
The presses are multicolor units that print wood-grained laminates
used for interior decor. Each color or design is applied sequentially at
a different ink station. Each color or application of ink is dried before
the next color is applied. The inks are dried with hot gases recovered
from the regenerative thermal incinerator. The plant, built in 1987, was
designed to incorporate state-of-the-art techniques to capture and control
.fugitive VOC's. Both presses are located in one large room, which is
designed to serve as a PTE. Air is exhausted from this room and sent to a
Smith Environmental Corporation thermal incinerator.
5.4.1 Capture Efficiency Criteria
All doors leading into the enclosure remain closed and are equipped
with automatic closing devices. The fork!ift door and product conveyor
door are equipped with overlapping vinyl strips that seal off the
enclosure and allow personnel and equipment to move in and out of the
press room.
Tests were performed in July 1989 to determine the average inward
face velocity at the natural draft openings. This determination was made
to demonstrate compliance of the enclosure with EPA's proposed PTE
criteria. During the test, anemometer readings were taken at the product
conveyor and forklift doors. The anemometer readings at the product
conveyor door ranged between 102 and 132 m/min (334 and 439 ft/min) and
averaged 113 m/min (370 ft/min) into the press room. Likewise,
measurements were taken at the forklift door that ranged between 107 and
130 m/min (352 and 426 ft/min) with an average of 119 m/min (389 ft/min)
into the press room. During our visit, MRI took anemometer readings that
registered over 183 m/min (600 ft/min) at an opening located next to the
fork lift door.
Table 5 indicates whether the PTE criteria have been satisfied at the
Advanced Printing facility. Advanced Printing is a new facility that was
designed and built to meet or exceed these enclosure criteria. Criteria 1
and 3 are clearly met.
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TABLE 5. SUMMARY OF PTE CRITERIA AT
ADVANCED PRINTING TECHNOLOGY IN MORGANTOWN, PENNSYLVANIA
Plant met
Criteria No. criteria
*
1. All VOC emissions must be captured and contained for Yes
discharge through a control device
2. Total area of NDO's is not to exceed 5 percent of total Yes
surface area
3. Access doors and windows should be closed during normal Yes
operation
4. The average inward face velocity across all NDO's must Yes
be at least 3,600 m/hr (200 ft/min)
5. All sources of emissions within the enclosure should be Yes
at least 4 equivalent diameters away from each NDO
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The facility is equipped with a pressure sensor to monitor the
differential pressure between the enclosure and its surroundings. Because
the makeup airflow rate is automatically contralled based upon input from
the differential pressure sensor, the airflow rate is subject to
variations when disturbances such as door openings or exhaust gas flow
rate changes occur. As a result, plant personnel are generally not aware
of what the changing makeup airflow rate is at any given time. However,
the differential pressure controller has an adjustable control set point
that enables maintaining a desired and relatively constant pressure drop
between the enclosure and its surroundings. The control set point of
Advanced Printing's differential pressure controller is 0.02 inches of
water column. Studies performed on industrial ventilation indicate that a
static pressure drop of 0.004 inches of water column is sufficient to
induce face velocities of 61 m/min (200 ft/min) through natural draft
openings. The differential pressure controller used by Advanced Printing
is set to maintain a much greater differential pressure. Consequently,
face velocities through their two natural draft openings will exceed
61 m/min (200 ft/min), thus satisfying Criteria 4.
The total surface area of the room is approximately 6,568 m2
(70,700 ft2). While it is not possible to exactly determine the area of
the natural draft openings, the total area must be less than 15 m2
(161 ft2) (total area of NDO's without vinyl strips) because the
overlapping vinyl strips block the majority of the opening. The area is
certainly less than the 5 percent requirement, which would be 94 m2
(1,010 ft2) in this case. Therefore, Criteria 2 is met. The natural
draft openings are approximately 30.5 m (100 ft) away from any emission
source at the presses. The forklift door and product conveyor door have .
an equivalent diameter of 12 and 3.7, respectively (not considering the
placement of the vinyl strips over the door openings). These doors are
not within four equivalent diameters of any VOC emission source, so
Criteria 5 is met.
In addition to satisfying the EPA criteria for a PTE, the enclosure
also easily satisfies OSHA requirements. Plant management indicated that
the concentration of VOC's in the enclosure is approximately 30 percent of
that allowed by OSHA. Also, the large enclosure allows the workers to
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have easy access to the two presses with no significant restrictions to
workers in the event it becomes necessary to quickly evacuate the
enclosure.
5.4.2 Control Device Efficiency
Also in July 1989, Advanced Printing Technology tested the
destruction efficiency of the incinerator. The tests showed an average
destruction efficiency of 99.3 percent for VOC's entering the incinerator
as measured by EPA Method 25A.
5.5 MORRILL PRESS9
Merrill Press operates four rotogravure printing presses in Fulton,
New York. The plant prints paper and plastic packaging materials for the
food processing and other industries. Two of the four presses are new,
and the two new presses are subject to prevention of significant
deterioration (PSD) regulations. The best available control technology at
the time of permitting was 75 percent.3 In addition to the Federal PSD
regulations, these new sources must meet the applicable New York State
regulations that require an overall control efficiency of 90 percent for
each press.
These presses are located in a large room that serves as an enclosure
to capture and collect fugitive VOC emissions from the presses. The VOC
emissions from the two presses are reduced individually by two catalytic
incinerators.
5.5.1 Capture Efficiency
The plant has made extensive use of local capture devices in addition
to the enclosure as a whole. For example, each printing station is
equipped with a hood to capture solvent evaporating from the web.
Airflows through the hoods are controlled by automatic positioning dampers
that are controlled by static pressure in the hoods. This ensures a
constant fugitive pickup (capture) by the hoods. In addition, both
presses have flexible duct floor sweeps located at each printing station
to capture fugitive VOC emissions from beneath the ink decks. Because the
floor sweeps are flexible, they can be placed where they will be most
effective. To reduce fugitive VOC losses, the inks are mixed as needed
and held in 12-gallon kits, which remain covered during printing.
26
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There are two makeup air duct outlets that supply fresh air to the
enclosure. One makeup air duct outlet is located inside, the enclosure;
the maximum airflow rate through this duct is 283 m3/min (10,000 scfm).
This duct is generally not turned on except in the winter months, when
additional heat is needed for worker comfort. The other duct is located
outside of the enclosure outlet in the cylinder storage room, because it
created airflow problems when it was placed in the press room. While this
duct is always on, it is not operated at its maximum airflow rate of
1,416 m3/min (50,000 scfm). Plant personnel said that the fan usually
remains on a low speed, but they could not provide any information on the
exact volume of air delivered. The air from the cylinder storage room
-duct outlet is delivered through the adjacent staging room and from there
through the only natural draft opening in the enclosure, which is a 7.4 m2
(80 ft.) open doorway between the press room and the staging room.
Airflow measurements taken at the inlet of each catalytic incinerator
indicate that the exhaust rate from the two presses are approximately 402
and 463 m3/min (14,200 and 16,350 scfm), respectively.
Y Compliance testing was performed simultaneously on these two presses
on May 18, 1989, to determine the VOC capture efficiency (liquid/gas
balance) and incinerator VOC destruction efficiency (discussed below) on
each line. Total solvent use was measured over a 3-hour period while VOC
measurements were made at the inlet and outlet of the two catalytic
incinerators. During the test, all outside doors and the doors leading to
the dock and cylinder storage areas were closed. The makeup air duct in
the cylinder storage room was delivering approximately 1,416 m3/min
(50,000 scfm) (maximum rated capacity), while the makeup air duct in the
enclosure remained idle. The doorway between the staging room and the
enclosure was open. Face velocity through the natural draft opening was
determined by hot wire anemometer to be about 160 m/min (525 ft/min).
For the one press, the VOC capture efficiency averaged 112 percent
and the VOC destruction efficiency averaged 97.0 percent. The overall VOC
control efficiency was reported as 108.6 percent, which is the product of
the capture efficiency and destruction efficiency. The other press had an
average VOC capture efficiency of 99.7 percent and a VOC destruction
efficiency of 99.6 percent. The overall VOC control efficiency was
27
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reported as 99.3 percent. The test team said that the fact that the VOC
capture efficiency on each press approached or exceeded 100 percent was
apparently due to the collection of fugitive VOC emissions from the other
two presses not located within the enclosure. Fugitive emissions from
these presses could be entering the enclosure via the NDO or other leaks.
Table 6 is a summary of the PTE criteria that are satisfied at
Morrill Press. Criteria 1 is clearly met. Even if one assumed that all
seven doors leading into the enclosure remained open during operation,
they would comprise approximately 1 percent of the total surface area of
the enclosure. Therefore, Criteria 2 is met. Because the presses were
not operating at the time of our visit, we were not able to- observe the
normal operation of the capture and control system. Plant personnel did
indicate that all doorways remained closed in the press room except one
doorway leading into the staging room, which would satisfy Criteria 3 (the
staging room door is considered a natural draft opening). Recent test
data have documented that inward face velocities have approached 160 m/min
.(525 ft/min) at the natural draft opening. Also, the difference between
the amount of air exhausted to the two incinerators and the maximum amount
of air returning through the makeup air duct 1n the enclosure is
708 m3/min (25,000 scfm). Dividing 708 m3/min (25,000 scfm) by the area
of the natural draft opening (7.4 m2 [80 ft2]) yields an inward face
velocity of 95 m/min (312 ft/min), thus satisfying Criteria 4. .The
doorway that serves as a natural draft opening is approximately 24.4 m
(80 feet) away from the nearest ink station along the presses. The
natural draft opening is 7.4 m2 (80 ft2), with an equivalent diameter of
2.7 m (8.9 ft). Therefore, Criteria 5 is satisfied.
Although the test program data probably represent an overestimation
of capture efficiency, a high level of capture efficiency is indicated.
Because the enclosure satisfies the PTE criteria, 100 percent capture
efficiency can be assumed. In addition to satisfying EPA criteria plant
personnel indicated that VOC exposure levels are less than 50 percent of
the level that would trigger worker protection requirements by OSHA.
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TABLE 6. SUMMARY OF PTE CRITERIA AT
MORRILL PRESS IN FULTON, NEW YORK
Plant met
Criteria No. criteria
1. All VOC emissions must be captured and contained for Yes
discharge through a control device
2. Total area of NDO's is not to exceed 5 percent of total Yes
surface area
3. Access doors and windows, should be closed during normal Yes
operation
4. The average inward face velocity across all NDO's must Yesa
be at least 3,600 m/hr (200 ft/min)
5. All sources of emissions within the enclosure should be Yes
at least 4 equivalent diameters away from each NDO
aNo measurements were made during our visit because the plant was not
operating. An emissions test dated May 18, 1989, contains measurements
taken at an open doorway in the northwest corner of the storage area.
The face velocity through this openings was determined using a hot wire
anemometer to be approximately 160 m/min (525 ft/min). Theoretical
calculations suggest that the minimum face velocity through the NDO to be
95 m/min (312 ft/min).
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5.5.2 Control Device Efficiency
The two TEC System HXC catalytic incinerators were installed in
1988. The incinerators are 3-chamber catalytic units designed to treat
142 to 566 m3/ntin (5,000 to 20,000 scfm) of air each. Typically these
systems will destroy 95 percent of the inlet VOC and are guaranteed to
achieve 90 percent destruction. The system is sized to handle the maximum
exhaust gas from each press with all stations in service, or 566 m3/min
(20,000 scfm). If the exhaust rate from the press drops below 142 m3/min
(5,000 scfm), incinerator exhaust is recirculated to the inlet to maintain
the required minimum airflow and bed temperatures. The TEC Systems HXC
unit is equipped with a variety of automatic controls permitting a self-
sustaining catalytic oxidation (no auxiliary fuel) if sufficient VOC is
present in the inlet gas.
As stated above, control device efficiency on the two incinerators
was determined to. be 97.0 percent and 99.6 percent, respectively.
'5.6 AMKO PLASTICS10
Amko Plastics extrudes polyethylene film, prints it, and converts the
printed film into finished bags and wraps. The facility employs
11 flexographic presses. Until 1984, Amko Plastics printed using solvent-
based (alcohol-based) inks. In 1984 the facility applied for permits to
install three new printing presses. The State EPA Office informed Amko it
would have to comply with BACT guidelines. Amko then decided to convert
to water-based inks. The early days of this conversion resulted in some
equipment-related problems. Amko made several modifications to their
presses and added new systems that have eliminated most of the early
problems. They redesigned air blowers, plenums, and dryer hoods on all of
their presses to enhance the drying characteristics of the water-based
.inks. Changes also had to be made to the anilox and fountain rollers and
to the printing plate (refer to Appendix A and to the Amko trip report for
details). Amko's newest press, installed in December 1987, was
specifically designed to run water-based inks exclusively at press speeds
of up to 297 m/min (975 ft/min).
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The use of water-based inks has eliminated the need for total
enclosures around the presses and emission control equipment to destroy or
collect the fugitive VOC's emitted from solvent-based inks. The most
notable contrast between Amko's water-based printing operation and other
solvent-based printing operations is the lack of any noticeable solvent
odors in the press room. Even when standing in the direct vicinity of an
operating press, no solvent odors were noticeable.
Although MRI was not able to determine the exact emission reduction
achieved by Amko's conversion to water-based inks, estimates indicate that
the reduction is significant. In 1983, before the conversion occurred,
VOC emissions were estimated to exceed 81.7 Mg/yr (90 tons/yr). In 1989,
with more production volume, emissions were estimated at approximately
27.2 Mg/yr (30 tons/yr).
A paper presented at an Air Pollution Control Association (APCA)
meeting by Mr. Makrauer, President/CEO of Amko, Inc. (Appendix A),
describes in detail the efforts, difficulties, and successes of Amko
Plastics, Inc., in converting their flexographic printing operations from
solvent-based inks to water-based inks for printing on low density
polyethylene film. In Mr. Makrauer1s presentation to APCA, and during the
site visit, he discussed the following benefits that are associated with
the use of water-based inks:
1. Water-based inks are not classified as a combustible material, so
containers of water-based inks are not required to be stored in expensive,
explosion-protected storage rooms. As a result, water-based inks may be
stored conveniently close to the printing presses themselves.
2. The Resource Conservation and Recovery Act requires special
conditions to be maintained for outdoor solvent storage tanks, installed
either above ground or underground. Special liability coverage is
required to protect against environmental contamination damage resulting
from tank leakage. Insurance premiums for one underground solvent storage
tank were $15,000 per year. Since Amko purchases only small amounts of
solvent, it has chosen to do so in 55 gallon drums. By emptying and
sealing their underground tank, Amko saves $15,000 each year on this
insurance premium.
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3. Water evaporates more slowly than solvent; therefore, viscosity
changes due to evaporation take place more slowly in water-based inks than
1n solvent-based inks. With smaller viscosity fluctuations, it is easier
to hold consistent color throughout a press run of water-based ink.
4. Water-based inks have greater coverage yield than solvent-based
inks. Although the cost per pound of some water-based inks is higher than
solvent-based inks, the cost margin is generally less than the increased
yield and a net ink cost advantage exists; and
5. A most notable benefit Amko experienced was the improvement of
working conditions in the press room. The drastic reduction in the
solvent content of inks has significantly reduced solvent vapors,
resulting in a noticeable improvement in the quality of ambient press room
air.
Even though Amko has succeeded in converting to water-based inks,
some difficulties still exist. Some customers refuse to accept bags
printed with water-based inks because they may not have the same gloss
level as bags printed with solvent-based inks. Amko can generally achieve
the same levels of gloss with water-based inks, but some colors
occasionally have lower gloss when using standard pigments. In those
circumstances, to improve the gloss, Amko uses chip dispersion pigment
systems. These pigments cost more than standard pigments.
The plant's biggest waste problem is associated with the wastewater
and sludge generated during the cleanup of the presses. Amko spends
approximately $60,000 per year to dispose of this material. However, Amko
has ordered a dewatering device costing about $40,000 that will dewater
the sludge and treat the effluent water to standards acceptable for
discharge into the city sewer system. The payback on this equipment is
estimated to be 1.5 years.
5.7 CMS GILBRETH PACKAGING SYSTEMS11
CMS Gilbreth Packaging Systems operates two plants, one in Croydon,
Pennsylvania, and one in Bensalem, Pennsylvania. The plants are known as
the Bristol and Bensalem plants, respectively. Both plants print flexible
packaging on heat-shrinkable polyvinylchlorfde (PVC) film, e.g., battery
covers and candy wrappers. The Bristol plant operates one eight-station
rotogravure press. The Bensalem plant operates 4 rotogravure presses and
one flexographic press.
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The Bristol plant is currently operating at its permitted VOC
emission limit. The plant's owners are not allowed to increase press
speed, add shifts, or install additional presses without first reducing
the VOC emission rate. On the advice of a consultant, Richmond Tech-Air
Corp., the plant instituted a program to install the necessary capture and
control system to reduce VOC emissions. A similar system was aVso
designed for the Bensalem plant, which is also subject to LAER
requirements.12 Neither system was fully operational at the time of the
site visit.
5.7.1 Capture Efficiency—Bristol Plant
The capture system at the Bristol plant was designed to meet EPA's
PTE criteria. Because the capture system was not operational at the time
of the visit, it is not possible to document whether the enclosure meets
the PTE criteria. Therefore, the discussion in this report will focus on
efforts taken by the plant to incorporate air management techniques to
minimize the size of airflow to be controlled. Limiting airflow reduces
the requisite size of the control device and its operating costs.
However, the desire to limit airflow must be balanced against the need to
maintain reasonable working conditions within the enclosure. Humidity
levels, temperature, solvent fumes, and the effects of machinery on
airflow patterns must all be considered.12
One technique to reduce the size of airflows is to maintain a
quiescent environment in the press room particularly around the printing
stations. This condition allows the heavier than air solvent vapors to be
readily picked up by the ink tray exhausts and floor sweeps without being
scattered by air currents in the room. The ink tray pickup device, which
is a rectangular box mounted slightly below the ink fountain, was designed
with this condition in mind. Air is drawn through two slots in the pickup
device in an attempt to ensure that airflow velocities across the length
of the exhaust are uniform. However, measurements made by plant personnel
show that the air velocity across the face of the device differs by
approximately 366 m/min (1,200 ft/min) from one end to the other. Plant
personnel are currently considering ways to equalize the air velocity
across the pickup devices.
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The press room also contains electrical boxes that are pressurized
with purge air that is drawn from inside the press room. EJecause the
electrical boxes are not airtight, leaking air can be swept up under the
press and create air currents across the print stations. These air
currents then sweep solvent vapors from around the print stations and
contribute to an increase in ambient press room VOC levels and a decrease
in the VOC capture efficiency of the system. To solve this problem, the
plant has installed a lightweight panel wall between the print stations
and the pressurized electrical boxes to shield the print stations from the
purge air.
The plant also plans to recirculate 425 m3/min (15,000 ft3/min) of
dryer exhaust in the press room rather than sending the full 623 m3/min
(22,000 ft3/min) directly to the control device. However, when the
recirculation system was placed in service for testing, the result was a
significant increase in the VOC concentration of the press room air. This
increase proved to be due to the many leaks that existed in the ductwork
that carried the recirculating exhaust under positive pressure. Since
then, the "cracks" have been caulked to prevent VOC's from leaking into
the press room from the ductwork. Unfortunately, at the time of the site
visit, the recirculation system was not being operated.
The capture system design also incorporates the idea of close capture
in the placement of fugitive pickups. The system consists of an ink tray
pickup device that is suspended slightly below the ink tray and a floor
sweep positioned at each of the eight print stations for close capture of
fugitive VOC's emitted from the press. At each print station, 2.8 m3/min
(100 ft3/min) of air is drawn through the ink tray pickup device and
26 m3/min (900 ft3/min) of air is drawn through the floor sweep. The
total fugitive exhaust pickup is therefore 227 m3/min (8,000 ft3/min) of
air.
The makeup air system is controlled by a.differential pressure
controller that is set to deliver 57 m3/min (2,000 ft3/min) less air to
the enclosure than what is taken out through the exhaust. The controller
is designed to be used in the differential pressure range of 0.01 to
0.2 inches of water column. Because EPA accepts a differential pressure
of 0.004 inches of water column as sufficient to induce a 61 m/min
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(200 ft/min) velocity across a natural draft opening, the CMS Gilbreth
system should satisfy EPA's PTE Criteria 4.
The fugitive VOC capture system has had a major effect on ambient VOC
levels in the press room. Before the system was installed, ambient VOC
levels in the press room averaged around 300 ppm as hexane. After
installation of the capture system, ambient VOC levels dropped to about
30 ppm. Subsequent installation of the dryer exhaust recirculation system
has probably resulted in a further decrease in press room ambient VOC
concentrations. In a recent conversation, Mr. Nash said that the facility
can now operate the enclosure with the doors closed, run the air
conditioner or heating system (as required), and still meet the OSHA
standard.1
5.7.2 Control Device Efficiency—Bristol Plant
At the time of the site visit, the plant was completing construction
on the regenerative thermal oxidizer that will control solvent vapors sent
from the capture system. The thermal oxidizer has three beds packed with
ceramic beryl saddles. Combustion is a cyclical operation that uses
valves to alter the airflow to regenerate the heat stored in the beryl
saddles. Once online, the thermal oxidizer, which is rated for 482 m3/min
(17,000 ft /min), will receive exhaust gases from both the press room and
the ink room.
5.7.3 Capture Efficiency—Bensalem Plant
The five presses at the Bensalem plant are contained in two rooms,
which are connected by a 2.4 m by 3.7 m (8 ft x 12 ft) overhead door that
remains open. The flow of exhaust air and forced makeup air was designed
so that the two print rooms connected by the door serve as a single
enclosure. The enclosure is designed to remove approximately 567 m3/min
(20,000 ft3/min) of room air and to return 510 m3/min (18,000 ft3/min) of
makeup air. A differential pressure controller identical to the one used
at the Bristol plant is used to control the makeup air rate. This
differential pressure controller also has a range of 0.01 to 0.2 inches of
water column.
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One of the presses, the TECMO press, employs the same fugitive VOC
control equipment as that used at the Bristol plant. However, during the
site visit, the ink tray exhaust hoods were disconnected from the ink
trays and were lying on the floor. Apparently, Bensalem plant personnel
believe that the wet printed substrate is the source of evaporative losses
rather than the ink trays. Mr. Nash, the plant engineer, said that
another problem is that the press operators have become so insensitive to
the solvent odor that even major changes in the VOC concentration in the
room are not detectable by them during the normal work week. Mr. Nash
said that unless and until the workplace is essentially odor free for a
matter of weeks, the employees may not develop the incentive to improve
operating practices. In contrast, at the Bristol facility, where the
capture system (particularly the ink tray pickup devices) is utilized, the
press operators quickly notice increases in solvent concentrations because
they have become accustomed to the lower odor levels.
The plant is working to resolve air management problems related to
their relatively complicated exhaust system, and the system is not
considered fully operational. Therefore, it was not possible to evaluate
whether the system can be judged to meet the total enclosure criteria.
Certainly, there was a very strong solvent odor in the room. Recent
liquid-gas mass balance capture tests performed by the State concluded
that only 48 percent of the solvent'vapors were being captured by the
enclosure. Plant personnel indicated a lack of confidence in the test
methodology, and the system is to be retested.
When it is operational, the enclosure should be capable of meeting
EPA's PTE criteria. If the enclosure operates as designed, with all doors
closed, there should be no natural draft openings except for unsealed
cracks around doorways. Although the set point of the differential
pressure controller is not known, the range in which it operates (0.01 to
0.2 inches of water column) exceeds the differential pressure of
0.004 inches of water necessary to maintain inward face velocities of
61 m/min (200 ft/min).
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5.7.4 Control Device Efficiency—Bensalem Plant
Approximately 553 m3/nrin (19,500 ft3/nrin) Of air is sent to the
thermal oxidizer, which has a capacity to handle 623 m3/niin
(22,000 ft /min). The thermal oxidizer has three beds packed with ceramic
beryl saddles and is operated using regenerative heat recovery. When
operational, all air exhausted from the enclosure and from the ink room is
to be sent to the thermal oxidizer. No control efficiency test data are
available.
6.0 DISCUSSION
6.1 OVERALL CONTROL SUMMARY
A summary of MRI's evaluation of the PTE criteria for the eight
plants visited is presented in Table.7. One of the plants elected to
reduce VOC emissions by converting to water-based coatings. Therefore,
the PTE criteria are not applicable.
Four of the plants have enclosures that clearly satisfy each of the
five criteria and may be deemed as "PTE's." One plant failed to meet
Criteria 4 (i.e., maintaining at least a 3,600 m/hr [200 ft/min] face
velocity across all NDO's) and, therefore, cannot be considered a PTE.
Two of the plants have not completed installation of their enclosure
systems, and their status as PTE's cannot be determined. However, based
on the design and operating data presented during the site visit, it
appears that once the enclosures are fully operational that they will meet
the PTE criteria.
Table 8 presents a summary of EPA's evaluation of capture efficiency
at each of the plants visited. The four plants that have PTE's have been
assumed by EPA to have a capture efficiency of 100 percent. Although one
plant met four of five PTE criteria, it is not possible to predict the
capture efficiency of this enclosure in the absence of capture efficiency
test data. As can be seen in Table 8, capture efficiencies are
unavailable at this time for the remaining plants as well.
To control the exhaust gases coming from the enclosures, four of the
plants use (or plan to use) thermal oxidizers, two of the plants use
catalytic incinerators, and one plant uses a carbon adsorber (see
Table 1). The control efficiencies of each of these devices as they are
operated in the plants visited can be found in Table 8. The EPA has
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TABLE 7. SUMMARY OF RESULTS OF EXAMINATION FOR
PTE CRITERIA AT ALL PLANTS VISITED
Plant
Satisfied enclosure criteria
Package Products
Charlotte, NC
Tarkett
Whitehall, PA
Maxwell Graphics
Richmond, VA
Advanced Printing Technology
Morgantown, PA
Morrill Press
Fulton, NY
CMS Gilbreth-Bristol,
Croydon, PAr
CMS Gilbreth-Bensalem,
Bensalem, PAf
Amko Plastics
Cincinnati,
Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes
Yes Yes Yes
No
Yes Yes Yes Yes
Yes
Yes
Yes Yes Yes Yes Yes
aAll VOC emissions must be captured and contained for discharge through a
.control device.
DTotal area of NDO's is not to exceed 5 percent of total surface area.
^Access doors and windows should be closed during normal operation.
dThe average inward face velocity across all NDO's must be at least
3,600 m/hr (200 ft/min).
eAll sources of emissions within the enclosure should be at least
4 equivalent diameters away from each NDO.
'These plants' exhaust systems were designed around the PTE concept, but
one was not yet complete and the other shut down before the
examination could be completed during our visits.
Amko plant uses waterborne inks so these criteria are not applicable.
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TABLE 8. SUMMARY OF OVERALL CONTROL EFFICIENCIES
Plant
Package Products
Charlotte, NC
Tarkett
Whitehall, PA
Maxwell Graphics
Richmond, VA
Advanced Printing Technology
Morgantown, PA
Merrill Press
Fulton, NY
Amko Plastics
Capture
efficiency
PTE (100)
PTE (100)
-
PTE (100)
PTE (100)
Destruction/
removal
efficiency
99.5
98.0
-
99.3
97.0
Overall
control
efficiency
for compli-
ance purposes
99.5
98.0
94a
99.3
97.0
66. 7b
Cincinnati, OH
CMS Gilbreth-Bristol
Croydon, PAC
CMS Gilbreth-Bensalem
Bensalem, PAC
aOverall control efficiency obtained from material balances performed from
records kept on solvent used and solvent recovered in carbon adsorption
.system.
Based on emission reductions reported by Amko from 1983 to 1989. The
calculated reduction does not include a correction for the increased
production that occurred over the 6-year period. If this could be done,
Amko's emission reduction would be larger than presented on the table.
These plants' exhaust systems were designed around the PTE concept, but
one was not yet complete and the other shut down before the examination
could be completed during our visits.
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extensive data that confirm that these control devices are capable of
achieving very high efficiencies. These control devices are capable of
routinely achieving efficiencies of 95 percent or greater. In fact, the -
control efficiencies documented from our visits ranged from 97 to
99.5 percent. Overall control efficiencies ranged from 94 to 99.5 percent
for those facilities using add-on controls.
The information gathered in the course of this study leads to the
conclusion that capture and control systems have been demonstrated to be
effective and reliable in controlling greater than 90 percent of the VOC
emissions from graphic arts facilities. This level of control is not
limited to new facilities. Only one of the facilities visited during this
study was a totally new facility. The other facilities, including the
facility using water-based inks had all been retrofitted with the
technology to reduce VOC emissions. In addition, recent information
reported to EPA indicates that other facilities have adopted capture and
control systems that achieve greater than 90 percent VOC emission
reductions.
The information contained in this report serves to demonstrate that
VOC control efficiencies of 90 percent and greater are obtainable and
previously accepted VOC emission reductions of 65 percent may no longer
serve as a practical upper bound for control of these sources. States
should.be cognizant of the demonstrated control efficiencies obtained in
these and other graphic arts facilities and apply this information in
future BACT/LAER and RACT determinations.
6.2 WATER-BASED INKS
The use of water-based inks as an alternative to reducing VOC
emissions in flexible packaging printing operations has been demonstrated
by Amko Plastics in Cincinnati, Ohio. Some of the advantages to water-
based inks include:
1. Water-based inks are noncombustible and are not subject to
special storage requirements;
2. Water evaporates more slowly than solvent, resulting in less
fluctuation of the ink viscosity during printing that affects product
quality; and
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3. Ambient press room air is virtually free of solvent vapors.
The conversion from solvent-based inks to water-based inks requires that
presses be altered and dryers redesigned to accommodate the greater drying
capacity needed to dry water-based inks. Appropriate pigment systems have
to be developed, which requires close coordination between pigment and
coating manufacturers as well as buyer awareness programs. In addition,
the polyethylene film must be custom blended for use with water-based
inks. The EPA should consider whether further VOC reductions are possible
if consumers'can be educated about the environmental and worker health and
safety benefits of conversion to water-based coatings.
6.3 OTHER TOTAL ENCLOSURE CONSIDERATIONS
6.3.1 Differential Pressure Controllers
Some plants are equipped with differential pressure sensors/
controllers that activate a variable speed forced makeup air fan to adjust
the amount of forced makeup air that is being sent to the enclosure.
Usually, the differential pressure controllers are set to maintain a
specified pressure drop between the inside of the enclosure and the
ambient air outside of it. Door openings and disturbances within the
enclosure affect the pressure in the enclosure, which may result in a
change in the forced makeup air rate. Since the design of the
automatically controlled system means that knowledge of actual average
airflow rates is unnecessary and is difficult to determine, plant
personnel are generally not able to provide information on the average
airflow rate of the makeup air fan. The alternative, using maximum design
values for the makeup air fan, can overestimate actual face velocities
through NDO's. Consequently, it is difficult to calculate whether the
enclosure satisfies the average face velocity requirement of Criteria 4.
An alternate means of complying with Criteria 4 is to establish a
minimum static pressure drop across the NDO of about 1.0 Pa (0.004 in.
water). This pressure drop results in inward face velocities of least
3,600 m/hr (200 ft/min). Therefore, maintaining a minimum acceptable
differential pressure across the NDO's will ensure reasonable compliance
with the 3,600 m/hr (200 ft/min) face velocity requirements regardless of
the changing NDO areas caused by the opening of doors and other
disturbances.
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The EPA personnel involved in inspecting or permitting facilities
that use differential pressure controllers should confirm two pieces of
Information, however. First, if the controller controls supply air only,
it is possible that a low exhaust flow rate could result in the controller
switching off the supply fan. In this case, there is no assurance that an
adequate pressure drop will be maintained. It should also be noted that
the differential pressure readings must be taken across the NDO's and not
necessarily with respect to atmospheric pressure (unless the NDO leads
directly to the outside). Enclosures with exhaust fans may effectively
reduce the pressure of an entire facility relative to atmospheric
pressure, making it necessary to measure static pressure differences
across NDO's that open to other areas of a plant.
6.3.2 Worker Exposure and Safety Considerations
Attaining a high level of capture efficiency is only one of the
design criteria that facilities consider when they design or retrofit
total enclosures. Issues of worker exposure to concentrated solvent
vapors and the ability of workers to .quickly exit from the enclosure in
the event of a sudden hazard must be addressed, just as they were in the
design of the initial plant. Personnel at several facilities which have
total enclosures confirmed that worker exposure is'not a problem at their
facilities; they report that solvent levels in their enclosures are
approximately 30 to 50 percent of those allowed by OSHA and at least one
plant is reported to have altogether eliminated the characteristic solvent
odor so ubiquitous to printing facilities. Worker exit requirements were
also specifically addressed in our discussion with plant personnel. None
of the facilities believed that the enclosures had increased safety
problems in any respect.
7.0 REFERENCES
1. The Printing Ink Handbook, National Association of Printing Ink
Manufacturers, Inc., Harrison 1988. pp. 39-47.
2. Memorandum. Vaught, C., MRI, to Catlett, K., EPA:CPB. Trip Report:
Package Products Company in Charlotte, North Carolina, on November 30,
- 1989.
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3. Telecon. Shine, B., MRI, with Warlick, T., Engraph. June 26, 1989.
Discussion about control levels and technologies at Engraph
facilities.
4. Memorandum. Vaught, C., MRI, to Catlett, K., EPArCPB. Trip Report:
Tarkett, Inc. in Whitehall, Pennsylvania, on December 6, 1989.
5. Telecon. Friedman, B., MRI, with Switzer, W., Tarkett, Inc.
December 18, 1990. Discussion about total enclosure.
6. Memorandum. Vaught, C., MRI, to Catlett, K., EPA:CPB. Trip Report:
Maxwell Graphics in Richmond, Virginia, on January 16, 1990.
7. Telecon. Friedman, B., MRI, with Kontny, D., Maxwell Graphics.
December 17, 1990. Discussion about enclosures.
8. Memorandum. Vaught, C., MRI, to Catlett, K., EPA:CPB. Trip Report:
Advanced Printing Technology in Morgantown, Pennsylvania, on
December 5, 1989.
9. Memorandum. Vaught, C., MRI, to Catlett, K., EPA:CPB. Trip Report:
Merrill Press in Fulton, New York, on April 6, 1990.
10. Memorandum. Vaught, C., MRI, to Catlett, K., EPA:CPB. Trip Report:
Amko Plastics, Inc., in Cincinnati, Ohio, on January 18, 1990.
11. Memorandum. Vaught, C., MRI, to Catlett, K., EPA:CPB. Trip Report:
CMS Gilbreth Packaging Systems in Croydon and Bensalem, Pennsylvania,
on July 19, 1990.
12. Telecon. Friedman, B., MRI, with Nash, J., CMS Gilbreth Packaging
Systems. December 17, 1990. Discussion about enclosures.
b3101-l/ESD
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TECHNICAL REPORT DATA
(Please read instructions on the reverse before completing)
1. REPORT NO.
EPA, 450/3-91-008
*•
4. TITLE AND SUBTITLE
Best Demonstrated Control
Technology for Graphic Arts
7. AUTHOR(S)
Friedman, Vaught
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Midwest Research Institute
401 Harrison Oaks Boulevard, Suite 350
Gary, North Carolina 27513
12. SPONSORING AGENCY NAME AND ADO
U.S. Environmental Protecti
Emission Standards Division
Office -of Air Quality Planr
Research Triangle Park, NC
RESS
.on Agency (MD-13)
L
ling and Standards
27711
3. RECIPIENT'S ACCESSION NO.
5. REPORT DATE
Fehrnarv 1991
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO.
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-02-4379
13. TYPE OF REPORT AND PERIOD COVERED
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES ~
ESD Work Assignment Manager: Karen Catlett (MD-13) (919) 541-0835
The Graphic Arts Industry is a source of volatile organic compound (VOC)
emissions. This study was conducted to document the reported overall control
efficiency for VOC at a number of rotogravure and flexographic printing facilities.
The primary conclusions form this study are: (1) the use of capture and control
systems and the use of water-based ink systems have been demonstrated to be effective
and reliable in achieving greater than 90 percent overall VOC reduction rotogravure
and flexogrpahic printing facilities; (2) facilities can be retrofitted to achieve
90 percent VOC reductions; and (3) permanent total enclosures meeting EPA criteria
have been successfully installed and operated at rotogravure and flexographic
printing facilities. ' . -
17- KEY WORDS AND DOCUMENT ANALYSIS
»• DESCRIPTORS
Graphic Arts
Rotogravure Priniting
Flexographic Printing
Volatile Organic Compounds Emissions
VOCs ...
Permanent Total Enclousres
18. DISTRIBUTION STATEMENT
Release Unlimited
b.lDENTIFIERS/OPEN ENDED TERMS
19. SECURITY CLASS (This Report 1
20. SECURITY CLASS (This page)
c. COSATI Field/Group
21. NO. OF PAGES
22. PRICE
PREVIOUS EDITION IS OBSOLETE
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