Document 6N0egwJydL67q4Nzbpr1r713

Detail of Typical Aspirating Hood-Type Vent c FIGURE IV-5 TYPICAL DOUBLE BATCH COMPOUNDING OF PIPE RESIN IV-16 SPI-02308 Arthur D Little. Inc TABLE IV-6 VCM Loss During Dry Blend Compounding of Rigid PVC Formulations VCM Content (After Stripping) Input Resin (ppm) Blend from Mixer (ppm) Blend from Cooler (ppm) Z VCM Removal After Cooler Manufacturer A 218 Manufacturer B Batch 1 Batch 2 1014 413 Manufacturer C 550 Manufacturer D Batch 1 Batch 2 Batch 3 300 530 390 Werner-Pfluderer "Exorsta" Data Mixing <3 120C (237F) No Aspiration Aspiration Aspiration & Air Stripping 1000 1000 1000 190 33 - - 565 205 68 180 30 26 74 80 92 200 160 36 11 17 98 94 87 73 83 49 84 96 99 IV-17 SPl-02309 Arthur D Little Inc 3 Plastisol and Organosol Compounding Plastisols and organosols are liquid systems consisting of dispersions of PVC resins in additives. Plastisols typically contain 30 to 505! plasti cizer plus other additives such as stabilizers and fillers. Organosols differ from plastisols in that the former are thinned with solvents to control the viscosity. The VCM emissions from plastisol and organosol compounding appear to be negligible because the VCM content of the input resin is extremely low. Most organosols and plastisols are made from emulsion resins. Data from manufacturers indicate that raw emulsion resins typically have VCM content of less than 10 ppm. Thus, the total amount of VCM which could be emitted could not exceed 10 pounds of VCM per million pounds of emulsion resins used to produce plastisols or organosols, or a total of 2,000 kg (4,400 lb) per year. B. EXTRUSION Extruded products account for a large fraction of the consumption of PVC resins, and include both flexible and rigid formulations. Approximately 80% of rigid PVC is processed by extrusion; major products include pipe and conduit, panels and siding, windows and other profiles and rigid sheet. Extrusion also accounts for almost 40% of flexible PVC fabrication with major products being wire and cable sheathing, weather stripping, medical tubing, garden hose and film. (A breakdown of the type and quantity of products made by extrusion of PVC is given in Table II-3.) Extrusion takes place at temperatures ranging from 120 to 190C (Table IV-7). In general, extruders processing powder blends will operate at the upper temperatures, and those processing granulated compounds at the lower end. Unplasticized PVC is processed at a somewhat higher temperature than plasticized PVC. 1. Extrusion of Flexible PVC Extruders of flexible PVC operate in either of two modes: they may purchase compounded flexible PVC to be fed directly into their extruders, or they may purchase raw resin and do their own compounding in-house. The VCM emissions from the plants of extruders of flexible PVC is totally dependent upon which of these choices is made. As discussed under "Flexible PVC Compounding" above, almost all the residual vinyl chloride monomer in raw resin compounded into flexible formulations is lost during the hot blending portion of the compounding operation, when plasticizer is added. The amount of VCM remaining after completion of compounding is usually less than 10 ppm. Thus, the extruder of flexible PVC resin will have VCM emissions of a TnaviTmrm of only ten parts of VCM per million parts of resin processed if he starts with compound. His counterpart who purchases and compounds from raw resin will have emissions as high as 200-500 parts per million. IV-18 SPI-02310 Arthur D Little Inc TABLE IV-7 Typical Extruder Temperatures for PVC Plasticized Compounds feed end of screw front end of screw head die Unplasticized (rigid) Compounds feed end of screw front end of screw head die Temp. C 120-140 140-160 150-170 160-180 140-150 155-165 165-175 170-190 IV-19 SPI-02311 Arthur D Little Inc We estimate that approximately 70 to 75% of manufacturers of extruded flexible PVC products do their own compounding. (A breakdown of this is shown in more detail in Table III-4 of Section III.) The only major purchasers of ready-made flexible compound for extrusion are makers of film and medical tubing, who buy their compound from the resin producers; wire and cable coating extruders also buy a minor fraction of their feed as compound, from independent compounders. Wire and cable coating and film extrusion are good examples of products made by extrusion of flexible PVC. Wire and cable coating is the single largest extrusion process for flexible PVC and accounts for approximately 354 million lbs per year, or about 22% of the 1.6 billion lbs of flexible PVC consumed in the United States each year. The major resin used is a homopolymer of medium to high molecular weight, with an additive content of 40 to 60 percent based on the final compound. About 125-135 million pounds of PVC were used in 1973 for the fabrication of flexible film for packaging applications. Wire and Cable Coating The producers of PVC-insulated wire and cable generally purchase raw resin and produce granulated compound themselves. (About 70 million lbs--or 20%--is bought from independent compounders who prepare special formulations for the wire and cable industry.) The total process is shown schematically in Figure TV-6. In the extrusion process for wire coating, high rates of output are of primary importance. Figure 1V-7 is an illustration of the crosshead type die used for wire coating. The wire to be coated passes straight through a crosshead die at right angles to the length of the extruder. The polymer melt (melted granules) enters the crosshead from the extruder and is directed around the wire and merges through the die. After emerging, the wire may be preheated electrically or flamed to remove lubricants and to improve adhesion. VCM Emissions from Wire and Cable Coatings As discussed above, the primary emissions of VCM from wire and cable coating operations will occur in the compounding steps. The primary point of this emission would be in the addition of the plasticizers and additives to the raw resin during the hot mixing portion of the com pounding operation (discussed above). Emission of VCM at later points in the process is negligible. Taking as a very rough average a net emission from the entire coating operation of 300 parts of VCM per part of resin processed in 1974, the emissions from a 1,000 lb per hour extrusion line would be 0.3 lbs per hour of VCM, or 3.3 kg/day (7.2 lb/day). The total nationwide emissions from the process (assuming 354 million lbs of FVC used per year) would be approximately 48,000 kg VCM per year (106,000 lb/year). IV-20 SPI-02312 Arthur D Little Inc w i-4 0) *3 a* I 3u U I 1_| S--j[uX: V) uo u 3 3 C 2' i 4s CO u 0) *3 3 3u 0> u uX u u: to ca H 5 E 0 HU XV). <U * uc/o' o "3 3 i- A UW "03C1)' 03 t CN 00)) oe *3 c 3 O "W u X wo 4-J 0) J 3 cc to r IV 21 F ig u re IV -6 . Schem atic o f W ire and Cable C o a tin g P rocess. SPI-02313 Arthur D Little. Inc FIGURE IV- 7 CROSSHEAD DIE FOR WIRE COATING IV-22 SPI-02314 Arthur D Little Inc  Film Extrusion Most flexible PVC packaging film is made by blown film extrusion. These products are used for a variety of consumer and industrial applications. Consumer applications include meat and produce wrap; industrial applications include wrapping for small parts or loose paper type products. A particular advantage of the PVC films for these applications is their ability to be oriented and then shrunk during subsequent exposure to heat to produce a so-called shrink wrap film. It is possible to extrude film from either compounded powder or pellets. Most flexible PVC extruded film is formed from pellets (which are made using conventional powder blending techniques described earlier), followed by extrusion of a strand which is cooled and pelletized. Film is made from either purchased pellets or via in-house compounding at the fabrication plant. Flexible film is also made from powder which is compounded on-site using standard techniques. Both of these methods are indicated in the flow chart of a typical flexible film extrusion plant, shown in Figure IV-8. (Figure IV-8 also indicates the sources of VCM emission.) The major source of emission will be from the hot stage of the compounding operation. Other emission points of less importance are from: unloading, venting to the atmosphere from raw powder and pellet storage silos, the vacuum port of the pelletizing extruder, and the fume collector which surrounds the film bubble. We have obtained data on residual VCM content of extrusion-blown film from two major manufacturers. In one case the manufacturer reported that during a six month period VCM concentrations in film leaving the plant never exceeded 0.02 ppm. The second manufacturer indicated that with rare exception the concentrations were below the levels detectable by gas chromato graphic methods. Thus, emissions from this portion of the industry can be estimated by assuming all of the VCM entering as raw resin leaves the film operation. One major manufacturer's sampling of incoming (uncompounded) resin between June and November of 1974 measured VCM concentrations ranging from 2 to 325 ppm, with typical readings of 65 ppm. Assuming this figure is typical and that 130 MM lbs of flexible PVC packaging film are processed annually, the emissions from this sector of the industry are 65 x 130 " 8450 lbs/yr (3840 kg/year). It should be noted that approxi mately 902 of this arises from the compounding portion of the operation, and less than 102 arises from the actual extrusion process. IV-23 SPI-02315 Arthur L) Little Inc IV-24 ' Direct Vent Vent to Atmosphere to Atmosphere IGURE I V - 8 FLEXIBLE PVC FILM EXTRUSION WITH IN-PLANT COMPOUNDING SPI-02316 Arthur D Uttle Inc 2. Extrusion of Rigid PVC Resins a. General As in the case of processors of flexible PVC resins by extruders, manufac turers of rigid PVC resins by extrusion may purchase ready-made compound from the resin producers, or may compound their resins themselves. (The independent compounder of rigid PVC resins for extrusion is virtually non existent.) Manufacturers of pipe and conduit--which account for 78% of the total consumption of rigid PVC for extrusion--compound about 99% of their resin themselves. Most other manufacturers of extruded rigid PVC products purchase all of their compound from the resin producers. (An exception to this rule are the producers of foam molding, many of whom formulate their own compounds.) b. Major Examples of Extruded Rigid PVC Products (1) PiPe Production of PVC pipe represents about 55% of the total extrusion of PVC in this country (or about 78% of extrusion of rigid PVC). Most PVC pipe manufacturers compound raw material at the same site, and the majority of the VCM loss is from the hot mixing step of the compounding operation. A typical PVC pipe manufacturing facility produces 20-25 million pounds of extruded pipe per year using 4805 extruders. A schematic of a typical plant's operations is shown in Figure IV-9. (Note that in Figure IV-9 compounding via both simple and double batching is indicated.) The economics of PVC pipe extrusion dictate that individual processors purchase raw PVC resin powder and add stabilizers, lubricants, and process ing aids and pigments in a central compounding operation at the plant. The powder blend to feed the extruders is typically prepared in 400-1,000 lb (180-455 kg) batches. The capacity of the extruders is typically 600-700 lbs/hr (270-320 kg/hr) although some plants, particularly those manufacturing larger diameter pipe, use extruders with capacities as high as 1,300 lbs/hr (590 kg/hr). Simple twin-screw machines typically consist of two twinscrew machines operating in series. In this mode of operation, the first extruder's function is to melt and mix the powder and extrude it into the hopper of the second extruder via an intermediate evacuated pelletizing stage (in which the molten strands of resin are cut into pellets using a hot face cutter.) Evacuation occurs from this Intermediate "pelletizing" stage. After emerging from the second extruder, the melt passes through the annular orifice of the die, and then is cooled in a water bath, cut into lengths and stored. Some types of pipe require a secondary finishing or shaping operation prior to storage. IV-25 SPI-02317 Arthur D Little Inc IV-2 6 SPI-02318 Arthur D Little Inc FIGURE IV - 9 TYPICAL PVC PIPE EXTRUSION OPERATION c. Sources of VCM Loss in Pipe Extrusion In practice, resin is transferred from the storage silo to the hot mixer via an intermediate weighing station in which additives are mixed. The batch is processed using either the single or double-batch method which have been described previously. From the processor's viewpoint, double batching is efficient in that energy savings are possible and the heat exposure of the resin is minimized. Single batching, however, removes a considerably larger quantity of VCM. In estimating the quantity of VCM discharged by a particular plant, it is therefore essential to determine which practice is used. Sources of VCM losses from pipe extrusion facilities are from vents in the following four areas: 1. Resin Handling Hopper car, transfer devices, and raw resin storage silos In-plant conveying systems Weighing station Extruder hopper Hot mixer 2. Compounding Cold mixer Compound storage 3. Extrusion Extruder vent pump Extruder die 4. Pipe Handling/Storage Pipe cutting station Pipe storage facility The major locations of VCM removal and discharge to the atmosphere are (in decreasing order of importance): hot mixer, cold mixer, extruder vent, resin unloading and transfer. IV-27 SPI-02319 Arthur D Little Inc Hot mixer. As discussed previously, considerable quantities of VCM can be removed during the hot blending stage. Modern installations remove VCM directly from the bowl of the hot mixer through the use of an air sweep or a vacuum. Although there are still a considerable number of installa tions which do not follow this practice, it appears that the pressures of OSHA regulations and the hazards of exceeding the lower explosive limit for VCM will result in provision for VCM removal from the bowl of the intensive mixer. Cold mixer. After hot mixing the powder compound is transferred to the cooling stage. Removal of VCM at this stage is comparable to that achieved in the hot mixer. Extruder vent. Elimination of volatiles from the molten pipe extrudate is crucial to the production of quality pipe. This removal occurs from an evacuated port at a stage in the extruder at which the resin is molten. Typically, the molten resin is exposed to a vacuum of 12-14" Hg., although vacuums as high as 23" Hg. have been observed during our field visits. In the case of pipe production using a single extruder (either single screw or twin screw), the volatiles are removed from a vacuum port located along the barrel. Ventilation. In modern pipe production plants the ventilation systems from the storage/transfer and compounding stages are collected at a central location - often this is a rooftop collector containing a bag for filtering powder particles. This is known as the bag house and is important for economical operation since considerable quantities of FVC powder can be recovered. The bag house is also the major concentrated location of VCM in a typical pipe processing plant. Robintech, Inc., has the capability of blending additives in the polymeri zation kettle. These resins are referred to as in-house compounded (IHC) resins and they do not require compounding at the pipe extrusion facility. The VCM discharge from such plants should be considerably less since the compounding steps are eliminated. VCM Loss in Pipe Extrusion. Although data on VCM levels in pipe from extruders are not available, an estimate of the amount of VCM lost may be made from the measured VCM levels in the air exiting from the extrusion process. Typical concentrations of VCM between 23.5 and 430 ppm (in air) were reported at a flow rate of 3.5 SCPM of air, corresponding to a total loss of 4.2 x 10"4 - 77.4 x 10"4 lbs/hr (1.9 x 10-4 - 35 x 10"4 kg/hr) of VCM at an extrusion rate of 1,000 lbs/hr (454 kg/hr) of pipe. This cor responds to a VCM loss of 0.4 - 7 lbs VCM per million lbs of PVC pipe extruded--a negligible quantity. The total nationwide emissions of VCM from PVC pipe extrusion (accounting for 1.26 billion lbs/year of PVC resin) are estimated to be: IV-28 SPI-02320 Arthur D Little Inc VCM loss from compounding: (250-450 ppm lost) VCM loss from extrusion: 142,000-257,000 kg/yr (315,000-567,000 lbs/year) 218-3,800 kg/year (negligible) (480-8,400 lbs/year) (2) Profiles and Siding Profiles and siding account for almost 100 million lbs of rigid PVC extrusion per year. Manufacturers typically buy pelletized compounds from the resin manufacturers who supply custom formulations to the large fabricators. Compound arrives to the fabricator in trucks and is stored in vented silos. The residence time of the compound in the silo can vary from three days to two months. From the silos, the resin is conveyed into vented surge hoppers where it is warmed slightly [to 380C (100F)], and then into the extruder. From the extruder, the profile is conveyed through a cooling system--either water or air-cooled--and thence to a cutter. Scrap from the cutting opera tion (averaging about 15% of the product) is sent to the grinding room for recycling. (Figure IV-10 shows a schematic of the operation.) Essentially no data are available on the VCM emission from these operations. One manufacturer quoted an input compound level of 100 ppm VCM as received from the resin manufacturer. The amount of further loss during the extrusion step is not known. One source of loss to the atmosphere is from the storage silo. This loss may be relatively small since the resin is in pellet form rather than in powder form. Some loss probably occurs over the heated extrusion section. However, this appears to be quite small, since the measured levels of VCM in the air exhaust over the extrusion is very small --less than 0.1 ppm (volume of VCM vapor per volume of air). C. CALENDERING Calendering is used for the production of both plasticized and rigid PVC sheet as well as coated fabrics and unsupported flexible films. It is capable of producing high quality material at very high rates of output. The resin formulations typically contain 20-30% plasticizer. Its major application is in the production of flexible PVC sheet and film, and accounts for the consumption of approximately 867 million pounds per year of flexible resin--or about 54% of the total U.S. consumption of flexible compound. Essentially all calendering compound is produced by the fabricator rather than the resin producer. Typically, the raw (suspension or bulk process) resin and additives are fed to a hot blender, thence to a Banbury mixer where it is melted; it is then milled and discharged directly into the calender. Often a screening extruder is used before the calender. After the calender, the sheet is cooled and finished. IV-2 9 SPI-02321 Arthur D Little Inc IV-30 Recycle of Scrap FIGURE IV -1 0 RIGID PROFILE EXTRUSION Arthur D Little Inc Calendering can also be used for coating fabric and paper with plasticized ?VC sheet; the substrate is fed into the calender nip of the last roll to carry out the lamination. In calendering, the PVC is subjected to fairly high temperature because of the high shear; molecular weight polymers can therefore be used. In rigid sheet production, extreme pressures and high roll temperatures--approaching 200C for homopolymers--must be used. Figure IV-11 shows a schematic of a typical calendering operation which could be used for manufacturing flexible unsupported films or coated fabrics These products are used for shower curtains, baby pants, wall coverings, swimming pool lining, tape, surgical drapeB and book covers. As in all processing of flexible PVC resins, the majority of the residual vinyl chloride monomer loss in PVC calendering plants occurs during the compounding portion of the operation. In the past, raw resin arrived with a residual VCM level typically between 100 and 500 ppm. Even at these input levels it is possible to reduce VCM in outgoing film to below 1 ppm. Table IV-8 shows data obtained from a manufacturer of unsupported film which shows the reduction in VCM at different stages in the process. This data was obtained on a process which has two mills following the Banbury. Unfortunately data were not obtained directly after the Banbury. The data does indicate however that the major portion of VCM is removed either by the Banbury alone or in combination with the first run. The fact that very little reduction in VCM content is measured between the first and second mill supports the conclusion that the major portion of the VCM is eliminated by the Banbury. This loss is not surprising, since the polymer during this operation is hot, molten, plasticized, and has a high surface-to-volume ratio--all optimum conditions for the release of monomer. Based on these data, the nationwide emissions from calendering of flexible PVC can be estimated to be: Compounding portion: (100-500 ppm) 39,000-195,000 kg/year (86,700-430,000 lbs/year) Calendering portion: (10-20 ppm) 3,900-7,900 kg/year (8,670-17,340 lbs/year) D. BLOW MOLDING Rigid PVC bottles are produced by the blow molding process. All blow molded PVC bottles are made from compounded pellets purchased by the blow molder from the resin supplier. These pellets are stored after delivery and then vacuum-conveyed to a hopper which feeds a single-screw extruder. The compound is melted in the extruder, reaching a temperature of 380F. From the extruder, the molten compound passes through a die to a mold where it is blown and cooled. After cooling the flashings are cut from the bottle and recycled into a grinder and thence to the extruder hopper. About 30Z of the feed is recycled as ground flashings. IV-31 SPI-02323 Arthur D Little Inc s 8 U Ja g I OfO_5 *3Oo ui 3 to. FIGURE IV -1 1 TYPICAL CALENDERING OPERATION IV-32 SPI-02324 Arthur D Little Inc TABLE IV-8 VCM Losses from Flexible PVC Calendering PVC resin to Banbury PVC compound from Banbury PVC compound from first mill PVC compound from second mill Film from calender VCM Concentration (PPm)________ 400 - (No value was measured) 32 26 ND (<1 ppm) IV-3 3 SPI-02325 Arthur D Little Inc Resin manufacturers typically control the VCM levels in compound for bottles to extremely low values. Ethyl Corporation, who is a major supplier of blow molding resins for example, currently produces to a specification of less than 1 ppm VCM for their food grade bottles and to a specification of less than 10 ppm in its general purpose bottle compound. They estimate and we agree, that less than 15% of the VCM in the compounded pellets is removed during blow molding. These figures indicate that the total loss of VCM from blow molding is very small (probably less than 1 lb VCM loss per million lbs of PVC processed by this route). The major source of this loss may be at the point at which the bottles are blown. Prior to this, the process is essentially totally enclosed. Little, if any, VCM can escape from the extruder, and the residence time at the die (where the molten compound is first exposed to the atmosphere) is too low--typically about 4 seconds--to allow much escape of VCM. E. INJECTION MOLDING Injection molding is an intermittent, cyclic process in which particles of compound are heated until they become molten. The melt is then forced into a closed mold where it cools, solidifies and is ejected as a finished or semi-finished part. Both flexible and rigid PVC compounds are injection molded. Both homo polymers and copolymer resins are used, with homopolymers predominating. Although it is possible to mold powder blends, most injection molders use compounded pellets. Shoe components account for the majority of the injection molding of flexible compound and pipe fittings account for the majority of rigid compound which is injection molded. VCM Loss. VCM loss during the injection molding of flexible PVC pellets is slight or negligible. Little monomer remains in the compound granules which are put into the injection molding process since most has been removed during compounding. In addition, the Injection molding process is essen tially close to the atmosphere allowing little or no monomer to escape. We have no data on the VCM losses during injection molding of rigid PVC compound. In contrast to flexible compound, the VCM content of rigid compound is sometimes substantial (possibly ranging as high as 100 ppm in late 1974 compound). However, the opportunity for VCM loss 1b relatively slight. We would estimate that the major source of loss in the injection molding process would be at the point at which the pellets are melted. IV-34 SPI-02326 Arthur D Little Inc F. COMPRESSION MOLDING Fhonograph records are the major PVC product fabricated by compression molding. In the record molding process either compounded resin or dry blend is fed to a small extruder where it is melted. A measured amount of material is then extruded between the labels that go onto the record. The operator picks this up from the extruder and places the sandwich in a press. The press closes and the finished record is removed some 15 to 30 seconds later. VCM Loss. Records are made from a polyvinyl chloride/polyvinyl acetate copolymer which in early 1974 had a relatively high monomer content (greater than 500 ppm). However, manufacturers of records tell us that in late 1974 the monomer content in raw resin was reduced to 50 to 100 ppm. Compounding of semi-rigid compound for records may take place either at the resin producers or at the record manufacturing site. It appears that approximately half of the input resin monomer content is lost in the compounding process. (This is a very rough estimate, based on a minimal amount of data.) We cannot estimate the additional VCM loss during the compression molding process since no data are available. G. SOLVENT CAST FILM The solvent casting process is used to produce packaging films of higher quality than those made by blown film extrusion. The solvent cast product has better gauge control and improved clarity. The solvent cast processing consists of dissolving powdered resin and casting the solution onto a belt. The casting belt is totally enclosed thereby permitting complete recovery of solvent. The wet film is then passed to a drying oven. A high percentage of solvent recovery is essential to the economics of the process. The details of the solvent recovery system are considered proprietary by the film manufacturers. A generalized flow chart for solvent cast film production showing potential emission points for VCM is shown in Figure IV-12. The sources of VCM loss are primarily from the solvent recovery operation with minor quantities during resin transfer and storage. We have not been able to obtain quantitative data on VCM concentrations in streams leaving the processes. One manufacturer reported the results of several months monitoring of incoming resin at solvent casting operations, indicating an average VCM concentration of 20 ppm. Typically they found no detectable concentration of VCM in film leaving the process, but they have not been able to isolate the specific source of VCM loss from the process. We estimate that 50 million lbs of solvent cast PVC film are manufactured in the U.S. Assuming that an average concentration of 20 ppm enters the process in the raw PVC powder, and that it is completely lost in the IV-35 SPI-02327 IV-36 Vent FIGURE IV--12 SOLVENT CAST PVC FILM PRODUCTION SPI-02328 Arthur D Little. Inc production process, the loss of VCM from this segment of the industry is estimated to be: 20 lbs million lbs 50 million lbs 1,000 lbs/year (450 kg/year) IV-37 SPI-02329 Arthur D Little Inc V. TOTAL U.S. EMISSIONS OF VINYL CHLORIDE MONOMER FROM POLYVINYL CHLORIDE COMPOUNDING AND FABRICATING Table V-l lists estimates of the total U.S. emission rate of VCM from FVC compounding and fabricating processes. These totals are based on 1974 production rates of PVC products and on representative VCM levels in the various types of resins in late 1974. Bases for the various estimates are discussed in some detail in Section IV above. Table V-2 shows the estimated annual VCM emissions from all stages of FVC product manufacture! starting with the monomer production and proceeding to PVC polymerization and thence to fabrication. As shown in this table PVC fabrication processes, Including compounding, account for less than one-half of one percent of the total VCM emissions in the U.S. Fabrication excluding compounding amounts to about one one-hundredth of one percent of total U.S. emissions. SPI-02330 V-l Arthur D Little Inc TABLE V-l ' TOTAL U.S. EMISSION RATE OF VCM FROM POLYVINYL CHLORIDE PROCESSING Process Estimated VCM Emission Rate* kg/year A. Flexible PVC 1. Compounding 2. Extrusion 3. Calendering 4. Molding 220,000 <3,000 <4,000 <400 B. Rigid PVC 1. Compounding 2. Extrusion 3. Molding 300,000 <4,000 <1,000 C. Plastisols, Organosols, Solution and Latex Fabrication 2,000 (lbs/vr) (480,000) (<6,000) (<1,000) (<800) (660,000) (<10,000) (<2,000) (4,500) * Based on 1974 production rates and late 1974 VCM contents of resins. SPI-02331 Arthur D Little Inc S' oc :i q o o OC .. cn ?! '2 O' CN 00 o CN cn as o CO m CN as <N pH CN O <--> CN T03) *o3o o Li a 00 CN OO 00 c w u 3 T3 0 u, GiC, F; 0 c 0 * <n a> m CN cn tfl ww ) c> J3 u o 'X c o 0 Jm o U o o Cm Cm c U1 u C/3 c c CU 03 N00 u n U a.1 H Cfl c F"l cUnt c o fM 0 iM Cl. r CJ QJ 4m> Cu a. 3 t/3 to f--1 p-i C3 03 a. to CO fc; V-3 Cm U 0 Cu c 0 4-1 CJ u H jn o SPI-02332 A: thin' I >! ii ill- Inc. VI. CURRENT STATUS OF CONTROLS TO LIMIT VCM EMISSIONS FROM THE PVC FABRICATION INDUSTRIES A. CURRENT CONTROL TECHNIQUES In 1974, the major emphasis on limitation of VCM emissions was, perforce, concentrated on reduction of VCM content in plant air, in order to mini mize risk to the plant workers. These control measures took two forms: 1. Massive ventilation and hooding at the points of the process where large amounts of VCM could be expected to be emitted; and 2. Reduction of the residual VCM levels in input resins so that the total amount of monomer available to be released would be minimized. In none of the 25 to 30 facilities we visited or interviewed by telephone and letter was there any control equipment used to limit the VCM emission from the fabricating plants into the surrounding atmosphere (aside from the usual stacks).* Manufacturers believed that the most practical way to limit emissions both inside and outside the plant was to reduce the monomer content in the incoming resin. Both resin manufacturers and users of the resins were confident that, by the end of 1975, the residual mono mer in resin coming into compounding and fabricating facilities would be sufficiently low that additional control measures to limit external emis sions would not be required. (Thus, the OSHA regulations to limit internal plant emissions were expected to result in solving of the "external" emis sion problem also.) Compounders and fabricators did not believe that, at present, there were any economically practical ways to control emissions from compounding and fabricating externally without seriously hindering their ability to control internal plant emissions. Not even the more sophisticated and advanced facilities (notably those compounding operations operated by the more research-minded resin-producing firms) had any method for removing VCM from vented air from the plant. The reason for the lack of control methods available appears to be in the very low level of VCM in the vented air (typically less than 1.0 and *It should be noted that VCM emissions from oven-dried PVC coatings (such as coatings on Bheet metal and fused plastisol resins on cast sheet and coated fabrics) are inadvertently controlled. The air in the drying ovens is recirculated through the gas burners; both the solvent and the VCM are thereby consumed. The VCM released in coatings, however, is negligible--totalling less than a few thousand lbs/year nationwide. VI-1 SPI-02333 Arthur D Little Inc almost always less than 10 ppm even in the air vented directly from the dry blenders and Banbury machines in the compounding facilities) and in the large volumes of air to be processed. These factors made scrubbers, after-burners and adsorbers (such as carbon columns) largely impractical. We should note at this point that activated carbon adsorption of VCM has been suggested as a practical method for removing and recovering VCM from stack gas. Although this method offers some promise for the reduction of VCM emissions from PVC polymerization facilities, its utility appears to be limited to recovery of VCM from low volume, high concentration streams. In the Tenneco pilot plant in which it is currently under investigation, the VCM concentration in the stream is between 10 and 30X (100,000 to 300,000) ppm. The maximum concentrations of VCM in fabricating plant vents is usually 50,000 to 100,000 times lower than this. In addition, much of the emissions from compounding and fabricating plants will also contain larger amounts of volatile plasticizers and other additives--frequently in much larger concentrations than the VCM--which would be expected to compete with VCM for the carbon adsorption sites, and significantly limit the utility of the carbon. At present, therefore, it does not appear practical to suggest carbon adsorption for limiting emissions from fabricating and compounding facil ities, unless significant and unanticipated breakthroughs in VCM concen trating and adsorption techniques occur. Similar difficulties arise in attempting to apply other emission control techniques such as condensation, compression and scrubbing which have been suggested for application to PVC polymerization facilities. The levels of VCM are simply too low to be practical. B. FUTURE CONTROL TECHNIQUES 1. Reduction of VCM in Input Resins The major control technique for the future appears to be reduction of residual VCM content in incoming resins. Since polyvinyl chloride does not generate VCM (decomposition of PVC generally produces HC1 instead), the only VCM vhlch can be emitted from compounding and fabricating facil ities will be that in the incoming resins. We are told by resin manu facturers that they anticipate reducing residual VCM levels in resins to less than 50 ppm. Should this be achieved, the total nationwide emissions from all PVC compounding and fabricating facilities will be less than 110,000 kg/year (230,000 lbs/year) nationwide. A few resin producers have predicted that a 10 ppm residual monomer content can be achieved by 1976 to 1977. Should this be achieved, the total nation wide emissions should be less than 23,000 kg/year (50,000 lbs/year) by 1977--a negligible quantity. These estimates are summarized in Table VI-1. VI-2 SPI-02334 Arthur D Little Inc Table VI-1 ANTICIPATED FUTURE VCM LOSS RATES FROM COMPOUNDING AND FABRICATION PVC Production Rates Avg. VCM Content Year (millions of kg) of Raw Resin (ppm) Total Annual U.S. VCM Release from Compounding and Fabricating (kg) 1974 2000 300 600,000 1975 2100* 50 105,000 1980 2400 (est.) 20 48,000 *Assumes 7% growth rate. VI-3 SPI-02335 Arthur D Little Inc Finally, it appears that reduction of VCM emissions at later stages of fabricating (after compounding) is best accomplished by reducing the VCM levels either in the input raw resin or in the final compound. Tech niques exist for both reductions, and it would appear wasteful to attempt to design and build equipment for removing VCM further downstream if it could be removed before it even entered the fabricating operations. The major difficulty in achieving these low VCM levels appears to be the quality of resin produced. Current techniques for reducing monomer con tent--many of them proprietary at this time--appear to result in dimin ished adsorbability of the raw resin for plasticizer and in reduced insulation properties and altered color. The additional cost of producing resins of lower VCM levels cannot be estimated at this time since techniques are still in the developmental stage and information is proprietary. However, it appears that the pres sures from OSHA to reduce in-plant emissions (and the high cost of pro viding respirators and other controls if emissions cannot be reduced), will place a very high premium on reducing the VCM content in resins. The industry is quite competitive, and it appears that fabricators will favor those manufacturers' resins which have the lowest VCM levels, thus increasing the incentives for the resin manufacturers to reduce these levels. 2. Auxiliary "External" Control Techniques For completeness one should consider other techniques which might be appli cable for controlling VCM emitted from compounding and fabricating opera tions. It should be stressed, however, that these techniques are purely speculative at this time, and have not been considered by any manufacturers we interviewed. The most promising control techniques which we can envision are those which might operate at points of high VCM emissions--notably at the dry blending points of compounding operations. As we have noted, up to 90% of the residual VCM in resins used in flexible formulations is emitted at the dryblending stage. A sizable fraction of the VCM in rigid com pounds is also emitted at this stage. At least in theory, it should be possible to totally enclose the dryblending equipment,. and vent it with only small volumes of air, which could then be used as feed air to gas burners or incinerators. The purpose of the small volume of venting air would be to increase the VCM levels in the air and to reduce the volume of air to be processed to amounts which could be usefully employed in the burners. VCM is highly combustible and decomposes readily at normal burner temperatures. VI-4 SPI-02336 Arthur I) Little Inc There are several disadvantages to this technique which must he considered. At present, it runs totally counter to current "Improvements" in process ing equipment designed to sweep away any VCM emissions which might go into the workspace. Thus, equipment would have to be totally redesigned for low flows. Secondly, the dryblend powder would probably need a longer residence time in order to ensure that enough VCM is stripped out under the low-air-flow conditions. Finally, of course, the burners would have to be built of materials that would withstand the HC1 emitted when vinyl chloride monomer is burned. It is not possible at this stage to estimate the cost of equipment rede sign tor VCM burning since such a system is simply at the speculation stage. VI-5 SPI-02337 Arthur!) I ittlu Inc APPENDIX TABLE A-I Major U.S. Producers of Raw PVC Resin Annual Capacity (million lbs) by December 1975 Goodrich Borden Tenneco Robintech Continental Oil Firestone Tire & Rubber Diamond Shamrock Union Carbide Goodyear Georgia Pacific* Others (Air Products, American Chemical, Certain-teed, Ethyl, General Tire, Olin, Pantasote, Shintech, Occidental Petroleum, Stauffer Chemical, Uniroyal, Keysor) 950 545 480 470 430 400 360 350 200 220 1,895 TOTAL 6,400 *Not currently a producer; plant opening in late 1975. SPI-02338 A-l Arthur D Little, Inc APPENDIX TABLE A-II MAJOR MERCHANT PVC RESIN CONSUMERS COMPANY Wire and Cable Anaconda Wire & Cable American Enka Belden Manufacturing Essex Wire & Cable General Cable General Electric Hatfield (Div. Continental Cooper & Steel) Kaiser Aluminum & Chemical Okonite (LTV) Packard Electric (General Motors) Phelps Dodge Simplex Wire & Cable Triangle Conduit & Cable Western Electric Flooring American Biltrite Rubber Armstrong Cork Congoleum Flintkote Johns-Manville Kentile Robbins Floor Products Ruberoid (GAF) Uvalde Rock Asphalt Vinyl Plastics (U.I.P.) Film, Sheet and Coated Fabrics Athol Mfg. Bemis Burlington Industries Chrysler Dart Industries (Fabrovin) Dayco (L.E. Carpenter) MAJOR PLANT LOCATION Hastings, New York Willimantic, Connecticut Chicago, Illinois Marion, Indiana Bayonne, New Jersey Bridgeport, Connecticut Hillside, New Jersey Bristol, Rhode Island Passaic, New Jersey Warren, Ohio Yonkers, New York Cambridge, Massachusetts New Brunswick, New Jersey Baltimore, Maryland Trenton, New Jersey Lancaster, Pennsylvania Kearny, New Jersey Chicago, Illinois Manville, New Jersey New York, New York Tuscumbia, Alabama Newburgh, New York Houston, Texas Sheboygan, Wisconsin Butner, North Carolina Stratford and Plainfield, Connecticut Reading, Massachusetts Sandusky, Ohio Paterson, New Jersey Wharton, New Jersey A-2 SPI-02339 Arthur I) I ink Inc. APPENDIX TABLE A-II (continued) MAJOR MERCHANT PVC RESIN CONSUMERS COMPANY MAJOR PLANT LOCATION Film, Sheet and Coated Fabrics (Continued) Fields Plastics and Chemicals Ford Motor W.R. Grace (Southbridge, Elm Coated Fabric, Ellay Rubber) Haart2-Mason Interchemical Lyntex 3M O'Sullivan Rubber Plastic Calendering Plymouth Rubber Weymouth Art Leather Whittaker (Am. Finishing) Lodi, New Jersey Mt. Clemens, Michigan Clifton, New Jersey; Brooklyn, New York; Corinth, Mississippi Los Angeles, California Watertown, Massachusetts Toledo, Ohio Conshohocken, Pennsylvania Hastings, Michigan Winchester, West Virginia Farmingdale, New York Canton, Massachusetts Braintree, Massachusetts Memphis, Tennessee Phonograph Records Capital CBS Decca MGM RCA Scranton, Pennsylvania Pitman, New Jersey Gloversville, New Jersey Bloomfield, New Jersey Indianapolis, Indiana Slush Molding (Dolls, Toys) Doughbough Industries DubIon Ideal Toy Kaysam Mattel Richmond, Virginia Newark, New Jersey Hollis, New York Paterson, New Jersey .Hawthorne, California Miscellaneous Extrusions Abbott Labs American Biltrite Rubber American Vinyl Backstay Welt (Division of Essex International) Ashland, Ohio Trenton, New Jersey Hialeah, Florida Union City, Indiana SPI-02340 A-3 Arthur I) Little Iik APPENDIX TABLE A-II (continued) MAJOR MERCHANT PVC RESIN CONSUMERS COMPANY Miscellaneous Extrusions (Continued) Dart Industries (Colorite) Geauga Industries Globe Hoover Johnson Plastics Kraco 3M Norton Premoid Rubbermaid Swan Rubber (Div. Amerace) Whittaker (Suval) Industrial Tape Anchor Continental Tape Arno Adhesives Behr-Manning (Norton) 3M Permacel Tape (Johnson & Johnson) Technical Tape Packaging Film Clopay Filmco (R.J. Reynolds) FMC (American Viscose) W.R. Grace (Cryovac) Reynolds Metal Rigid Products (Pipe,Sliding,Other) Alpha Plastics Amos Molded Plastics (National Lead) Andersen Bird & Son Borg-Warner Cabot Certain-teed Products A-4 MAJOR PLANT LOCATION Paterson, New Jersey Middlefleld, Ohio Philadelphia, Pennsylvania Canton, Ohio Chagrin Falls, Ohio Los Angeles, California St. Paul, Minnesota Akron, Ohio Holyoke, Massachusetts Wooster, Ohio Bucyrus, Ohio New York Columbia, South Carolina Michigan City, Indiana Troy, New York Minneapolis, Minnesota New Brunswick, New Jersey New Rochelle, New York Cincinnati, Ohio Aurora, Ohio Marcus Hook, Pennsylvania Cedar Rapids, Iowa Grottoes, Virginia Livingston, New Jersey Edinburg, Indiana Bayport, Minnesota Bardstown, Kentucky Los Angeles, California Louisville, Kentucky McPherson, Kansas SPI-02341 Arthur I) I title Inc APPENDIX TABLE A-II (continued) MAJOR MERCHANT PVC RESIN CONSUMERS COMPANY MAJOR PLANT LOCATION Rigid Products(Pipe,Sliding.Other) (Continued) Colonial Plastics Mfg.(Van Dorn) Consolidated Pipe Crane Plastics Flintkote Glamorgan Pipe h Foundry Harsco Johns-Manville Kraloy (Div. of Dart Industries) Mastic Asphalt Skyline Plastics (Phillips Petroleum) Sloane Mfg. (Susquehanna) Standard Oil (Ohio) Whittaker (Thermoplastics) Yardley (Div. of Celanese) Cleveland, Ohio Stow, Ohio Columbus, Ohio Whippany, New Jersey Lynchburg, Virginia Mineral Wells, Texas Manville, New Jersey Santa Ana, California South Bend, Indiana Titusville, Pennsylvania Sun Valley, California Columbus, Ohio Charlotte, North Carolina Columbus, Ohio Containers American Can Creative Packaging (Div. of Eli Lilly) Owens-Illinois Chicago, Illinois Roanoke, Virginia Toledo, Ohio Footwear American Biltrite Rubber Avon Sole Bata Shoe Brown Shoe Genesco International Shoe New Jersey Rubber O'Sullivan Rubber USM Chelsea, Massachusetts Avon, Massachusetts Belcamp, Maryland St. Louis, Missouri Nashville, Tennessee St. Louis, Missouri Taunton, Massachusetts Winchester, Virginia Kenton, Tennessee Coatings American Cyanamid Baldwin Montrose Bradley & Vrooman (Whittaker) Buchanan, New York St. Louis, Missouri Chicago, Illinois SPI-02342 A-5 Arthur 1)1 ink' Ini APPENDIX TABLE A-II (continued) MAJOR MERCHANT PVC RESIN CONSUMERS COMPANY Coatings (Continued) Chemical Products Continental Can Dennis Chemical DeSoto Dewey and Almy (Div. W.R. Grace) General Electric Glidden (Div. SCM) Interchemical Michigan Chrome & Chemical 3M Permalastic Stoner-Mudge (Div. Mobil Oil) Compounding Bamberger Reichhold Chemicals A. Shulman Vinyl Industrial Products Machlin Premier Chemical Products MAJOR PLANT LOCATION East Providence, Rhode Island New York, New York St. Louis, Missouri Chicago, Illinois Cambridge, Massachusetts Louisville, Kentucky Cleveland, Ohio Newark, New Jersey Detroit, Michigan St. Paul, Minnesota Detroit, Michigan Cleveland, Ohio Carlstadt, New Jersey Mansfield, Massachusetts Akron, Ohio Grand Rapids, Michigan SPI-02343 A-6 Arthur I) I .title liu APPENDIX TABLE A-III LIST OF SUPPLIERS OF PVC COMPOUND TYPE OF COMPOUND AAAA AAA AA A B-D Over Over Over Over < $1,000,OOO/Year in Sales 500,000/Year in Sales 300,000/Year in Sales 100,000/Year in Sales 50,000/Year in Sales SPI-02344 A-7 Arthur I) I ittlu hx APPENDIX TABLE A-III (continued) LIST OF SUPPLIERS OF PVC COMPOUND TYPE OF COMPOUND ------------------------------------------- 1 Basic Resins M olding o r E x tru s io n Compounds O rganosols & P la s tis o ls S olutions.E m ulsions or D ispersions CORPORATION____________ Atlas Coatings Corp. Long Island, N.Y. Axel Plastics Research Labs, Inc. Long Island City, N.Y. Ball Chemical Co. Glenshaw, Pa. Blane Chemical Division Reichhold Chemo, Inc. Mansfield, Mass. Borden Chemical Div. of Borden, Inc. Columbus, Ohio X Bostik Chemical Group USM Corp. Middleton, Mass. AAAA AAA AA A B-D Over Over Over Over < X X X SALES CATEGORY (Of Parent Corporation XX A XX A X AAAA AA XX AAAA X AAAA $1,000,000/Year in Sales 500,000/Year in Sales 300,000/Year in Sales 100,000/Year in Sales 50,000/Year in Sales SPI-02345 A-8 Arthur I) I it tic lix. APPENDIX TABLE A-III (continued) LIST OF SUPPLIERS OF PVC COMPOUND **Cc4O CVO CL *uH nCO CO CORPORATION Cary Page Chems.,Inc. Edison, N.J. *Chemetron Corp. Pigments Division Holland, Michigan Chemical Coating & Engineering Co., Inc. Media, Pa. Chemical & Engineering Assoc., Inc. Elkton, Md. Chemical Industries Pasadena, California Chemical Prod. Co. E. Providence, R.I. TYPE OF COMPOUND -CaO UO oCHc c3 Oe0a0 v s0: -hm0p 3 uU tXil CO CO 00 COO CO G CO CO ac co OU CL X oCCO CO WE3 OCCO * CO CCoO u00a1) 4J *H 3Q 0 C/5 JO- SALES CATEGORY (Of Parent Corporation) X AAAA XX A XX X X AAAA AAAA AAA AA A B-D *Chemetron Corp., Over Over Over Over < 111 E. Wacker Drive, $1,000,000/Year in Sales 500,000/Year in Sales 300,000/Year in Sales 100,000/Year in Sales 50,000/Year in Sales Chicago, 111. 60601 SPt-02346 A-9 Arthur!) I utk Int APPENDIX TABLE A-III (Continued) LIST OF SUPPLIERS OF PVC COMPOUND TYPE OF COMPOUND AAAA AAA AA A B-D Over Over Over Over < A-10 $1,000,000/Year in Sales 500,000/Year in Sales 300,000/Year in Sales 100,000/Year in Sales 50,000/Year in Sales SPI-02347 Arthur 1)1 ink Ihl APPENDIX TABLE A-III (continued) LIST OF SUPPLIERS OF PVC COMPOUND TYPE OF COMPOUND B asic Resins M olding or E x tru s io n Compounds O rganosols & P la stiso ls S o lu tio n s , Em ulsions or D ispersions CORPORATION Eronel Industries Hawthorne, California *Ethyl Corp. Polymer Division Baton Rouge, La. *Ferro Corp. Composite Div. Norwalk, Conn. X Firestone Plastics Co. Div. Firestone Tire & Rubber Co. Pottstown, Pa. X Flexcraft Industries Newark, N.J. George, P.D. Co. St. Louis, Mo. X X X X X SALES CATEGORY (Of Parent Corporation) XB AAAA (All plants and division) AAAA (All divisions of Ferro) AAAA X X AAAA AAAA AAA AA A B-D Over Over Over Over < $1,000,000/Year in Sales 500,000/Year in Sales 300,000/Year in Sales 100,000/Year in Sales 50,000/Year in Sales * Ethyl Corp., 330 S. 4th St., Richmond, Va. 23219 Ferro Corp., 1 Erie View Plaza, Cleveland, Ohio 44144 A-ll SPI-02348 Arthur!) I iuIu Ini. APPENDIX TABLE A-III (continued) LIST OF SUPPLIERS OF PVC COMPOUND TYPE OF COMPOUND AAAA AAA AA A B-D Over Over Over Over < A-12 $1,000,000/Year in Sales 500,000/Year in Sales 300,000/Year in Sales 100,000/Year in Sales 50,000/Year in Sales SPI-02349 An I hi r I) I ink- Ini APPENDIX TABLE A-III (continued) LIST OF SUPPLIERS OF PVC COMPOUND TYPE OF COMPOUND B asic R esins M olding or E x tru s io n Compounds O rganosols & P la s tis o ls S o lu tio n s , Em ulsions or D ispersions CORPORATION Howell Industries Paterson, N.J. Jedco Chemical Corp. Mt. Vernon, N.Y. Key Polymer Corp. Lawrence, Mass. Leon Chem.& Plastics, Inc. Div. of U.S.Industries, Inc. Grand Rapids, Mich. Loes Enterprises X X X M.R. Plastics & Coating, Inc. Maryland Heights,Mo. X X AAAA AAA AA A B-D Over Over Over Over < SALES CATEGORY (Of Parent Corporation XX B X XX AAA XX XX A AAAA $1,000,000/Year in Sales 500,000/Year in Sales 300,000/Year in Sales 100,000/Year in Sales 50,000/Year in Sales SPI-02350 Arthur I ) I ittk' Ini APPENDIX TABLE A-III (continued) LIST OF SUPPLIERS OF PVC COMPOUND CORPORATION__________ M-R-S Chemo, Inc. Hazelwood, Mo. *M & T Chems., Inc. Subs.American Can Co. Rahway, N.J. Machlin Co. Industry, California Michigan Chrome & Chemical Co. Detroit, Michigan Monsanto Co. St. Louis, Mo. TYPE OF COMPOUND (0 e C0 (0 0) C 0) U T3 CO CO 0 0C r-H ^ 3 o o CO u oo o CO CO f*4 c c. 0 3 CO 05 h E -o 0 CO 1o-t CJ Cu <0 CO 00 CO W- f-t ec W0 H * CO X. C 0 O a- CO u CV H 0 & 0) H CO 3 W H w 3Q X 0 vw C/3 O X X X X X X XX X SALES CATEGORY (Of Parent Corporation) AAAA AAAA AAAA AAAA AAAA AAAA AAA AA A B-D Over Over Over Over < $1,000,000/Year in Sales 500,000/Year in Sales 300,000/Year in Sales 100,000/Year in Sales 50,000/Year in Sales *M & T Chem.,Inc., Subs. American Can Co., American Lane, Greenwich, Conn. 06830 SPI-02351 A-14 Arthur I) I ittlc Iik APPENDIX TABLE A-III (continued) LIST OF SUPPLIERS OF PVC COMPOUND CORPORATION Moore Chemical Corp. Div. Moore Plastics Ind.,Inc. Burlingame, Calif. TYPE OF COMPOUND cn CerOt CO DuC Oac3o u eo 5 CO CO uH a C<Q0 ou OO c CH 0H C3O 0U wX CoO oCO oC&UCOC *4-CCHJOQ O CU CO c0H CO 3 CO UE CO uCC0HO coW aaCO 3O t/05 u0 XX H. Muchlstein & Co. Greenwich, Conn. XX Nat'l Adhesives Div. Nat'l Starch & Chemical Corp. New York, N.Y. X P.F.D., Penn. Color,Inc. Subs. Bonn Ind.,Inc. Doylestown, Pa. X Parcloid Chemical Co. Ridgewood, N.J. XX SALES CATEGORY(Of Parent Corporation) AAAA AAAA AAAA AAAA AAA AA A B-D Over Over Over Over < A-15 $1,000,000/Year in Sales 500,000/Year in Sales 300,000/Year in Sales 100,000/Year in Sales 50,000/Year in Sales SPI-02352 Arthur I) I ittli- APPENDIX TABLE A-III (continued) LIST OF SUPPLIERS OF PVC COMPOUND TYPE OF COMPOUND AAAA AAA AA A B-D Over Over Over Over < A-17 $1,000,000/Year in Sales 500,000/Year in Sales 300,000/Year in Sales 100,000/Year in Sales 50,000/Year in Sales SPI-02353 Artlui!' I) I mlc-1iv APPENDIX TABLE A-III (continued) LIST OF SUPPLIERS OF PVC COMPOUND TYPE OF COMPOUND B asic Resins M olding or E x tru s io n Compounds O rganosols & P la stiso ls S o lu tio n s , Em ulsions or D ispersions CORPORATION Solar Compounds Corp. Linden, N.J. Special Products Div. Sun Steel Co. Chicago Hghts.,111. Stanchem, Inc. E. Berlin, Conn. Stauffer Chemical Co. Plastics Div. Westport, Conn. X Tamite Industries Div. Watsco, Inc. Hialeah, Fla. Tenneco Chemicals, Inc. Tenneco Intermediate Div Piscataway, N.J. X AAAA AAA AA A B-D Over Over Over Over < X X SALES CATEGORY(Of Parent Corporation) X AAA X AAAA X AAAA AAAA XX AAAA (Watsco, Inc.) XX AAAA $1,000,000/Year in Sales 500,000/Year in Sales 300,000/Year in Sales 100,000/Year in Sales 50,000/Year in Sales A-18 SPt-0235* Arthur I) Little Inc APPENDIX TABLE A--III (continued) LIST OF SUPPLIERS OF PVC COMPOUND TYPE OF COMPOUND B asic Resins M olding or E x tru s io n Compounds O rganosols A P la stiso ls S o lu tio n s , Em ulsions o r D ispersions CORPORATION Union Carbide Corp. Chemicals & Plastics New York, N.Y. XX SALES CATEGORY (Of Parent Corporation) AAAA *Uniroyal, Inc. Adhesives & Coatings Dept. Mishawaka, Ind. X AAAA The Vorac Co. Carlstadt, N.J. X AAA Watson Standard Co. Harwick, Pa. XX AAAA George Woloch Co.,Inc. Allentown, Pa. Youngstown Vinyl Comp., Inc. ___ Youngstown, Pa._________ X X AAAA AAAA AAA AA A B-D Over Over Over Over < $1,000,000/Year in Sales 500,000/Year in Sales 300,000/Year in Sales 100,000/Year in Sales 50,000/Year in Sales *Uniroyal, Inc., Uniroyal Products Information Center 1230 Avenue of the Americas, New York, N.Y. 10020 A-19 SPI-02355 Arthur I) I ittlc Inc APPENDIX TABLE A-IV PRODUCERS OF PVC PIPE AND FITTINGS CORPORATION Adams Brothers Co., Inc. Eads, Tennessee Amoco Chemicals Corp. Industrial Products Division Stow, Ohio ASC Industries, Inc. Plastics Division Spokane, Washington Can-Tex Industries A Division of Harsco Corp. PIPE X X X X Celanese Piping Systems Hilliard, Ohio Certain-Teed Products Corp. McPherson, Kansas Charlotte Pipe & Foundry Co. Plastic Division Monroe, North Carolina Clin Plastics X X X X Continental Plastics Industries, Inc. Denver, Colorado Creslina Plastic Pipe Co., Inc. Evansville, Indiana Cupples Coiled Pipe, Inc. Austin, Texas Dixie Plastics Mfg. Co. New Orleans, Louisiana X X X X A-20 FITTINGS X X X X X X X X X X X SPI-02356 Arthur I) I iuIu liu APPENDIX TABLE A-IV (continued) PRODUCERS OF PVC PIPE AND FITTINGS CORPORATION Graspo, Inc. Honolulu, Hawaii Harvel Plastics, Inc. Easton, Pennsylvania Jet Stream Plastics (Ralph Jones Co.) Div. of Winrock Enterprises Siloam Springs, Arkansas Mid-American Industries, Inc. Memphis, Tennessee Plastiline, Inc. Pompano Beach, Florida Portco Corp. Vancouver, Washington Shamrock Industries, Inc. Minneapolis, Minnesota Simpson Extruded Plastics Co. Eugene, Oregon R & G Sloane Mfg. Co., Inc. Sun Valley, California U-Brand Corp. Plastic Division Ashland, Ohio Western Plastics Corp. Hastings, Nebraska Western Plastics Corp. Tacoma, Washington PIPE X X X X X X X X X FITTINGS X X X X X X SPI-02357 A-21 Arthur I) I title liu APPENDIX TABLE A-V SUPPLIERS OF RESIN OR COMPOUND TO PVC PIPE FABRICATORS Allied Chemical Corp., Plastics Division Morristown, New Jersey American Chemical Corp. Long Beach, California Argus Chemical Corp., Subsidiary of Witco Chemical Corp. Brooklyn, New York Borden Chemical, Division of Borden, Inc. Leominster, Massachusetts Celanese Piping Systems Newark, New Jersey Cincinnati Milacron Chemicals, Inc. Reading, Ohio Conoco Chemicals Saddle Brook, New Jersey Diamond Shamrock Chemical Co. Cleveland, Ohio E.I. duPont de Nemours & Co., Inc. Pencader Plant, Pipe Division Wilmington, Delaware Eastman Chemical Products, Inc. Kingsport, Tennessee Ethyl Corp., Polymer Division Baton Rouge, Louisiana General Electric Co., Plastics Dept. Pittsfield, Massachusetts B.F. Goodrich Chemical Co. Cleveland, Ohio A-22 SPI-02358 Arthur 1) I it tie Iiil APPENDIX TABLE A--V (continued) SUPPLIERS OF RESIN OR COMPOUND TO PVC PIPE FABRICATORS Goodyear Tire & Rubber Co., Chemical Division Niagara Falls, New York Gulf Oil Co., Houston, Texas Hooker Chemical Corp., Ruco Division Burlington, New Jersey M & T Chemicals, Inc. Rahway, New Jersey Mallinckrodt Chemical Works St. Louis, Missouri Marbon Division, Borg-Warner Corp. Washington, West Virginia Mobil Chemical Co. New York, New York Monsanto Polymers & Petrochemicals Co. St. Louis, Missouri Permatex Co., Inc. West Palm Beach, Florida Rohm & Haas Philadelphia, Pennsylvania A. Schulman, Inc. Akron, Ohio Sinclair-Koppers Co. Pittsburgh, Pennsylvania Synthetic Products Co. Cleveland, Ohio Tenneco Chemicals, Inc., Tenneco Intermediates Division Piscataway, New Jersey A-23 SPI-02359 Arthui l )l inlc Ini APPENDIX TABLE A-V (continued) SUPPLIERS OF RESIN OR COMPOUND TO PVC PIPE FABRICATORS Union Carbide Corp., Plastics Products Division New York, New York Uniroyal Chemical Division, Uniroyal, Inc. Naugatuck, Connecticut Witco Chemical Corp. New York, New York A-24 SPI-02360 Ai thm I ) I m APPENDIX TABLE A-VI FILM AND SHEETING CALENDERS IN OPERATION IN THE U.S.A. *** (Includes coating but not flooring calenders) COMPANY LOCATION Associated Rubber Bronx, New York Bemis Bag Stratford, Connecticut ** Borden Co. Columbus, Ohio (4) San Francisco, Calif.(1) ** Burlington Industries Reading, Massachusetts ** Chrysler Corp. Sandusky, Ohio Continental Plastics Avenel, New Jersey C.S. Fields Lodi, New Jersey Diamond Shamrock (Harte & Co.) Brooklyn, New York (5) Mountaintop, Pa.(l) ** Firestone Tire & Rubber Pottstown, Pennsylvania Co. ** Ford Motor Co. Mt. Clemens, Michigan ** General Tire & Rubber Co. Columbus, Mississippi (4) Jeanette, Pa. (3) Lawrence, Mass. (6) Newcomerstown, Ohio (2) Toledo, Ohio (3) ** B.F. Goodrich A Co. Marietta, Ohio Goodyear Tire & Rubber Co. Akron, Ohio *S0URCE: Monsanto Company **MAJOR PRODUCT: Coated Fabrics A-25 TOTAL NO. OF CALENDERS 2 4 5 4 4 2 4 6 3 3 18 2 5 SPl-02361 Arthur 1) l ittle Inc APPENDIX TABLE A-VT (continued) FILM AND SHEETING CALENDERS IN OPERATION IN THE U.S.A. * (Includes coating but not flooring calenders) COMPANY LOCATION W.R. Grace Los Angeles, Calif. (2) Brooklyn, N.H. (7) Corinth, Miss. (3) ** Hooker Chemical Corp. Carteret, New Jersey Imperial Chemical (Atlantic Tubing) Cranston, R.I. ** Inmont Toledo, Ohio Lamcal Hickory, North Carolina Lynn Vinyl Plastics Co. Lynn, Massachusetts Lyntex Corp. Conshohocken, Pennsylvania Macklin Co. Los Angeles, Calif. Middletown Rubber Co. Middletown, Connecticut MMM St. Paul, Minnesota Monsanto Co. Springfield, Massachusetts ** O'Sullivan Rubber Corp. Winchester, Virginia Pantasote Co. Passaic, New Jersey Parker, Streams & Co. Brooklyn, New York Phillips Petroleum Auburn, Pennsylvania TOTAL NO. OF CALENDERS 12 3 5 1 2 1 2 1 1 2 2 3 5 1 2 A-26 SPI-02362 Arthur I) I ittle Inc APPENDIX TABLE A-VII MANUFACTURERS ' FLEXIBLE (PLASTICIZED) PVC SHEET CORPORATION NUMBER OF EMPLOYEES Ace-Tex Vinyls, Inc. New York, New York 1-9 American Renolit Corp. Whippany, New Jersey Ameron Corrosion Control Division Brea, California Bakellte Xylonite Ltd London, England Cadillac Plastic & Chemical Co. Detroit, Michigan 800 Commercial Plastics & Supply Corp. Cornwells Heights, Pennsylvania Dynamit Nobel of America, Inc. Northvale, New Jersey Ellay Rubber Division W.R. Grace Co. Los Angeles, California 100 - 499 Ethyl Corp. Baton Rouge, Louisiana 13,743 Firestone Plastics Co. Div. of Firestone Tire & Rubber Pottstown, Pennsylvania i. 675 Ford Motor Co. Mount Clenens, Michigan 442,607 CALENDERED EXTRUDED X X X XX XX XX XX X X X XX SPI-02363 A-28 Arthur!)Little Inc APPENDIX TABLE A-VII (continued) MANUFACTURERS OF FLEXIBLE (PLASTICIZED) PVC SHEET CORPORATION NUMBER OF EMPLOYEES Franklin Fibre-Lamstex Wilmington, Delaware 50-99 Gelman, Herman A. Co. Brooklyn, New York General Tire A Rubber Co. Akron, Ohio 37,000 Goodyear Tire & Rubber Co. Akron, Ohio 145,000 Goss Plastic Corp. Los Angeles, California Harte & Co. New York, New York 100 - 499 Hydrawlik Co. Roselle, New York Industrial Vinyls, Inc. Miami, Florida 60 Jodee Plastics, Inc. Brooklyn, New York 20 - 49 Kessler Products Co. Youngstown, Ohio 200 Lavorazlone Materse Plastlche, S.P.D. Torino, Italy Leathertone, Inc. Chelsea, Massachusetts 20 - 49 Maclin Co. Industry, California 50 - 99 A-29 CALENDERED X EXTRUDED X XX XX X X X X XX X X X X SPI-02364 Arthur D Little Inc APPENDIX TABLE A-VII (continued) MANUFACTURERS OF FLEXIBLE (PLASTICIZED) PVC SHEET CORPORATION Masland Duraleather Co. Philadelphia, Pennsylvania Monsanto Co. St. Louis, Missouri New England Plastic Corp. Woburn, Massachusetts Norton Co. Akron, Ohio O'Sullivan Corp. Winchester, Virginia Pervel Industries, Inc. Plainfield, Connecticut Plastic Mfg., Inc. Philadelphia, Pennsylvania Polyval Corp. New York, New York Rowland Products, Inc. Kensington, Connecticut Ross & Roberts, Inc. Stratford, Connecticut Rotuba Extruders, Inc. Linden, New Jersey Ruco Division, Hooker Chemical Corp. Burlington, New Jersey NUMBER OF EMPLOYEES 450 CALENDERED EXTRUDED X 57,833 20 - 49 100 - 499 700 1,300 200 250 100 - 499 700 A-30 SPI-02365 Arthur I) I it tic Inc APPENDIX TABLE A-VH (continued) MANUFACTURERS OF FLEXIBLE (PLASTICIZED) PVC SHEET CORPORATION S G*L Haddonfield, New Jersey Scranton Plastic Laminating, Inc. Scranton, Pennsylvania Stauffer Chemical Co. Westport, Connecticut Strauss, H.B. Corp. Bronx, New York Tenneco Chemical Co. New York, New York Union Carbide Corp. New York, New York Uniroyal, Inc. Chicago, Illinois Vanguard Extruders, Inc. Farmingdale, New York Vernon Plastics Corp. Haverhill, Massachusetts NUMBER OF EMPLOYEES 940 75 10,000 20 - 49 67,942 100 - 499 50 - 99 40 CALENDERED EXTRUDED X X X X XX XX XX X X A-31 SPI-02366 Arthur 1)1 ittlcliK APPENDIX TABLE A-VIII MANUFACTURERS OF RIGID PVC SHEET CORPORATION NO. OF EMPLOYEES Ain Plastics Co. Mt. Vernon, New York Ameron Corrosion Control Div. Brea, Calif. 650 Atlas Plastics Corp. Cape Guardeaw, Mo. 300 Bakelite Xylonite Ltd. London, England Brlmal Fair Lawn, N.J. Canadian Industries Ltd. Montreal, Que, Canada 9,000 Ellay Rubber Division U.R. Grace & Co. Los Angeles, Calif. 100-499 Ethyl Corp. Baton Rouge, Louisiana 13,743 Extrudyne, Inc. Amityville, New York 20-49 Hydrawlik Co. Roselle, New York Industrial Vinyls, Inc. Miami, Florida 60 Keller Products, Inc. Manchester, N.H. 110 Kessler Products Co. Youngstown, Ohio 200 CALENDERED X EXTRUDED X X X X X X XX X X X X X ' SPI-02367 A-32 Arthur I ^ Little Inc APPENDIX TABLE A- VIII (Continued) MANUFACTURERS OF RIGID PVC SHEET CORPORATION NO. OF EMPLOYEES Lavorazione Materse Plastiche, S.P.D. Torino, Italy Leathertone, Inc. Chelsea, Mass. 20-49 Lustro Corp. of California Valencia, California 100 Masland Duraleather Co. Philadelphia, Pa. 450 Monsanto Co. St. Louis, Missouri 57,833 New England Plastic Corp. Woburn, Mass. 20-49 Polyval Corp. New York, New York Rohm & Haas Co. Philadelphia, Pa. 16,026 Rotuba Extruders, Inc. Linden, New Jersey 100-499 Scranton Plastic Laminating, Inc. Scranton, Pennsylvania 75 S.G.L. Industries, Inc. Haddonfield, New Jersey 940 Sheffield Plastics, Inc. Sheffield, Mass. 100-499 Technical Plastic Extruders, Inc. 50-99 Kearny, New Jersey A-33 CALENDERED EXTRUDED X X XX X XX X X X X X XX X XX SP1-02368 Arthur I) 1 .ittic Inc APPENDIX TABLE A-VIII (Continued) MANUFACTURERS OF RIGID PVC SHEET CORPORATION Union Carbide Corp. New York, New York Uniroyal, Inc. Chicago, 111. Vanguard Extruders, Inc. Farmingdale, New York NO. OF EMPLOYEES 67,942 100-499 50-99 CALENDERED X EXTRUDED X XX XX A-34 SPI-02369 Arthur! )l.ittlc Inc APPENDIX TABLE A-IX U.S. PRODUCERS OF PVC FILM (Calendered and Extruded) CORPORATION Ace-Tex Vinyls, Inc. New York, New York Allied Chemical Corp. Morristown, New Jersey Alusuisse Metals, Inc. Fort Lee, New Jersey American Hoechst Corp. Delaware City, Delaware American Renolit Corp. Whippany, New Jersey American Soplaril Co. Atlanta, Georgia Columbus Coated Fabrics Columbus, Ohio Continental Plastic Co. Chicago, Illinois Dynamit Nobel of America, Inc. Northvale, New Jersey Fabric Leather Corp. Glen Cove, New York Firestone Plastics Co., Division of Firestone Fire & Rubber Co. Pottstown, Pennsylvania Flex-O-Glass, Inc. Chicago, Illinois Ford Motor Co. Mount Clenens, Michigan NUMBER OF EMPLOYEES 1-9 33,000 2,500 500 - 999 50 - 99 250 675 325 442,607 A-35 SPI-02370 Arthur I) Little. Inc APPENDIX TABLE A-IX (continued) U.S. PRODUCERS OF PVC FILM (Calendered and Extruded) CORPORATION Franklin Fibre-Lamstex Corp. Wilmington, Delaware General Binding Corp. Northbrook, 111. General Plastics Corp. Marion, Indiana General Tire & Rubber Co. Akron, Ohio Gelman, Herman A. Co. Brooklyn, New York Goodrich, B.F. Chemical Co. Cleveland, Ohio Goodyear Tire & Rubber Co. Akron, Ohio Goss Plastic Corp. Los Angeles, California Grace, W.R & Co. New York, New York Harte & Co. New York, New York Jodee Plastics, Inc. Brooklyn, New York Maclln Co. Industry, California Norton Co. Akron, Ohio NUMBER OF EMPLOYEES 50 - 99 1,800 50 37,000 145,000 66,400 100 - 499 20 - 49 50 - 99 100 - 499 A-36 SPI-02371 Arthur D Little Inc APPENDIX TABLE A-IX (continued) U.S. PRODUCERS OF PVC FIIM (Calendered and Extruded) CORPORATION O'Sullivan Corp. Winchester, Virginia Pervel Industries, Inc. Plainfield, Connecticut Reynolds Metals Co. Richmond, Virginia Ross & Roberts, Inc. Stratford, Connecticut Rowland Products, Inc. Kensington, Connecticut Ruco Division, Hooker Chemical Corp. Burlington, New Jersey Stauffer Chemical Co. Westport, Connecticut Strauss, H.B. Corp. Bronx, New York Vernon Plastics Corp. Haverhill, Massachusetts NUMBER OF EMPLOYEES 700 1,300 35,200 250 200 700 10,000 20 - 49 40 A-37 SPI-02372 Arthur L) Little Inc APPENDIX TABLE A-X U.S. PRODUCERS OF CAST PVC FILM AND SHEET Borden Chemical Division, Borden, Inc. Columbus, Ohio Cadillac Plastic & Chemical Co. Detroit, Michigan Clopay Corp., Plastic Film Division Cincinnati, Ohio Commercial Plastics & Supply Corp. Cornwells Heights, Pennsylvania Crystal-X Corp. Darby, Pennsylvania Dura Plastics of New York, Inc. Westport, Connecticut Fassler, M.J. & Co. Bayshore, New York King Plastic Corp. Venice, Florida Newage Industries, Inc. Jenklntown, Pennsylvania Plastic Mfg., Inc. Philadelphia, Pennsylvania Reynolds Metals Co. Richmond, Virginia Rhodia, Inc. New York, New York Tenneco Chemical, Foam & Plastic Division New York, New York A-38 SPI-02373 Arthur I )l title Inc A CAMBRIDGE, MASSACHUSETTS SAN FRANCISCO WASHINGTON ATHENS BRUSSELS CARACAS LONDON PARIS RIO DE JANEIRO TORONTO WIESBADEN SPI-02374