MDI Emissions Reporting Guidelines for the ... - Polyurethanes

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14. Belts and Tire Cord MDI Emissions Reporting Guidelines for the Polyurethanes Industry A MDI/PMDI mixture is used in belt manufacturing as a hardener. In the manufacture of belts, part of the process is to run synthetic cords through a vat solution containing a MDI/PMDI and toluene mixture and then passed it through an oven to activate the bonding process between the synthetic cord and isocyanate and dry the cord coating. The off-gases from the oven are passed through an incinerator or combustion device for destruction. Depending upon the process, the synthetic cord then goes through a number of various mixture dips and oven treatments. Once the cords have been treated, they are wound on spools for use in the belt building process. The controlling parameters that influence the emission rate are the temperature, flow rate, concentration of the exit gas stream, reaction rate, and the unreacted fraction of MDI. The worst-case scenario is that the exit gas stream is saturated with all the MDI that is available. The MDI emissions can be calculated using the following formula: L = (V air /359) * (273.15/T sp ) * 60 * (C mdi /1000000) * M W * k MDI * C f * R MDI Where: L = the emissions in lb/hr Vair = the exhaust airflow rate in ft3 /min Tsp = the exhaust temperature in K Cmdi = the MDI concentration, in ppmv, in the exhaust air MW = the molecular weight of MDI (250.26) KMDI = the adjustment factor to the vapor pressure that is a function of MDI concentration in the feedstock and the temperature Cf = per cent MDI/PMDI in solution 359 = the molar volume of an ideal gas in ft3 /lb-mole @ 0 o C and 1-atmosphere Cmdi = (VPMDI /760) x 10 6 VP MDI = MDI vapor pressure at exhaust temperature R MDI = Unreacted fraction of MDI Where: R MDI = e^(-k * t R ) Where: R MDI = the unreacted fraction of MDI k = the first order reaction rate constant in min -1 t R = the reaction time in minute D-13
MDI Emissions Reporting Guidelines for the Polyurethanes Industry Appendix E – Glossary AP‐42 The EPA document, Compilation of Air Pollutant Emission Factors, which contains information on over 200 stationary source categories. This information includes brief descriptions of processes used, potential sources of air emissions from the processes, and in many cases, common methods used to control these air emissions. Covered Facility A facility defined in 40 CFR Section 372.3 that has 10 or more full-time employees, is in a covered NAICS code and meets the activity threshold for manufacturing, processing, or otherwise using a listed toxic chemical (40 CFR Section 372.22). Covered NAICS Code You can determine whether a NAICS code is covered by TRI (EPCRA Section 313) by going to http://www.epa.gov/tri/lawsandregs/naic/ncodes.htm. Disposal Any underground injection, placement in landfills/surface impoundments, land treatment, or other intentional land disposal (40 CFR Section 372.3). Environment Includes water, air, and land and the interrelationship that exists among and between water, air, and land and all living things (EPCRA Section 329(2)). Facility All buildings, equipment, structures and other stationary items which are located on a single site or contiguous or adjacent sites and which are owned or operated by the same person (or by any person which controls, is controlled by or under common control with such person) (40 CFR Section 372.3). Full‐time Employee A person who works 2,000 hours per year of full time equivalent employment. A facility would calculate the number of full-time employees by totaling the hours worked during the calendar year by all employees, including contract employees, and dividing the total by 2,000 hours (40 CFR Section 372.3) Manufacture To produce, prepare, import, or compound a toxic chemical. Manufacture also applies to a toxic chemical that is produced coincidentally during the manufacture, processing, use, or disposal of another chemical or mixture of chemicals, including a toxic chemical that is separated from that other chemical or mixture of chemicals as a byproduct, and a toxic chemical that remains in that other chemical or mixture of chemicals as an impurity (40 CFR Section 372.3). E-1
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