MDI Emissions Reporting Guidelines for the ... - Polyurethanes

Process Details:
MDI Emissions Reporting Guidelines for the Polyurethanes Industry
10,000,000 lbs. of MDI/PMDI a year are received by rail car. The product is offloaded
into a 40,000-gallon storage tank located outdoors. Average annual air
temperature is 68 o
F with an average daily temperature range of 18 o
F.
The total manufacturing area measures 200 feet by 300 feet by 30 feet (1.8 million
cu.ft.). The air exchange rate is 5 air changes per hour. The operation manufactures
24 hours per day 365 days per year. The outside operation consists of a closed system
that has 1000 connectors, 8 pumps (with 2 seals per pump), 25 light liquid valves, 4
agitators, and 4 safety relief valves. The annual average air temperature was
reported to be 78 o
F.
The facility makes sun visors for the automotive industry. The average size sun visor
is 2feet long by 6 inches wide and 2 inches thick (0.17 cu.ft.). The company produces
1.5 million parts using a closed mold two-component system of MDI/PMDI and polyol
resin (1/1 ratio). The process is carried out at a temperature of 85 o
F. 2,000,000
pounds of MDI/PMDI are used to produce seat cushions. The polyol and isocyanate are
mixed through a special head at 85 o
F at a ratio of 1/1. The foam density of the
cushion is 2.0 pounds/cubic feet.
Laminated boardstock 8 feet long by 4 feet wide and 2 inches thick is produced at a
rate of 17 feet/minuet. The temperature of the exit air is 85 o
F. The wind velocity
across the surface of the board was measured at 3 ft/sec. Tack-free time is one
minute. The line operates 24 hours per day 7 days per week.
MDI/PMDI is repackaged at 75 o
F into 55 gallon drums each one weighing 500 pounds
net. Total pounds re-packaged 1,000,000 pounds.
Shipping cartons are assembled using an adhesive mixture containing 2% MDI. The
adhesive is applied using a special roller applicator that covers 20,000 sq.ft./day.
The plant operates 5 days/week (250 days/year). The material is applied at 275 o
F
and the exposed area is subject to an airflow velocity of 5 meters/second. Tack-free
time is 10 seconds.
A spray coating operation, carried out in the Specialty Products Section, spray coats
automotive parts in a spray booth. The exhaust temperature is 90 o
F and the blower
air exhaust rate is 10,000 cfm. The percentage of MDI in the spray mix is 33%. The
total annual spray time was 1,000 hours.
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