Document YG2ZQz47rrx6zmMnzEZOnY6mE

I 184 INTER. office mcmo tenneco CHEMICALS, INC. UW. SCIENCE To From SlJfUECT Distribution D. I. Smalley AT At Piscataway EPA-VCM Control of Dispersion Resin Manufacture Ditl March 11, 1975 COPY TO At the direction of Mr. Fath, the writer met today (3/11) with John Lawrence of SPI on the topic of anticipated EPAVCM control of dispersion resin manufacture. The recent history of this aspect of the VCM question began on 2/25 when industry members met in Durham with EPA to discuss approaches to the overall control of VCM emissions. At this session, a lack of understanding was evidenced by EPA of the differences among suspension resin, dispersion resin, and true latex manufacture. The result was that EPA appeared ready to regulate dispersion resin out of existence through the application of inappropriate suspension resin standards. To counter this threat, SPI formed a dispersion resin sub committee to prepare a document for presentation to EPA high lighting the reasons for industry's view that dispersion resin deserves separate and specific control measures. This sub committee was comprised of Firestone, Goodrich, and Union Carbide representatives. The composite effort of this group was a vinyl dispersion resin manufacturing and market analysis, a near-final draft of which is attached. This document is intended to do the following: 1. Show that the dispersion resin process is different from other vinyl processes. 2. Show that there are major markets for dispersion resin and no suitable alternate materials. 3. Reinforce the overall industry position that dispersion resin processes require a specific approach to emission control. To this latter point, earlier versions contained suggested VCM levels in spray dryer exhaust air and 1000 yards downwind. These proposals have been replaced with a statement at the end of Summary and Conclusions concerning "lowest possible level practical with available control systems". While this is actually EPA language taken from their March 1975 Standard Support-Environmental Impact Document, it leaves open industry's view on specific control measures. COLORITE 007997 Distribution March 11, 1975 Page 2 The writer will join the dispersion resin subcommittee and SPI counsel in meeting with EPA in Durham on Thursday (3/13). The purpose here will be to continue to promote the concept of the uniqueness of dispersion resin and to protect Tenneco's interest as a practitioner of atypical dispersion resin tech nology. To do this, some aspects of our proprietary process may have to be discussed but this will always be done in general terms. A report on this session will be issued promptly. /elk Distribution W. P. Anderson H. B. Carr J. Fath G. S. Flint Dr. P. A. Lobo F. X. Ritter G. I. Rozand COLORITE 007998 VINYL DISPERSION RESINS Manufacturing and Market Anlaysis SUMMARY AND CONCLUSIONS Vinyl dispersion resin are a unique variety of polyvinyl chloride plastics requiring special production techniques. Because of their unusual handling and physical properties, businesses which use them would find alternative materials scarce or non-existent. It is estimated that there are more than 70,000 employees involved in processing dispersion resin into finished products with an estimated market value in excess of $1 billion. Existing procedures for producing vinyl dispersion resins do not allow for the stripping of the resin to as low a vinyl chloride content at an early . stage of production as can be achieved with other polyvinyl chloride resins. The resin, in a water dispersion, is charged to the dryer with residual vinyl chloride contents in the range of 0.2 to 5 percent of the total dry polymer weight. Many of the unique properties of vinyl dispersion resins are the result of the drying stage of their manufacture which converts the water dispersed polymer to a finely divided powder. At the present time, there is no known technology for stripping dispersion resins to EPA's required level of 400 ppm residual vinyl chloride content nor is there demonstrated technology for reducing the vinyl chloride emissions from dispersion resin drying to the less than 10 ppm required by EPA. COLORITE 007999 If EPA's tentative plans to control vinyl chloride emissions do not distinguish between vinyl dispersion resins and other resins, it is probable that the industry's facilities producing dispersion resins will be forced to close down. Since substitutes for dispersion resin are scarce, if existent,' the shutting down of dispersion resin manufacturing facilities would immediately jeopardize the jobs of thousands of workers. Therefore, we request that EPA consider a special standard for polyvinyl dispersion resins. Until new technology can be developed that will provide for the stripping of the residual monomer in dispersion resins from the reactor to a significantly lower level, or the recovery or disposal of the monomer from the drying,-stage, the industry requests that EPA control emissions from dispersion resin plants to the lowest possible level practicable with available control systems. COLORITE 008000 INTRODUCTION Polyvinyl chloride plastics, the third largest plastic material in terms of volume, combines the desirable properties of toughness, elasticity, and abrasion resistance with low cost. While the mass of polyvinyl chloride resin usage is normally considered as one material in statistics, the polyvinyl chloride resin of commerce is actually made up of many materials varying in composition, molucular weight, and physical form produced for specialized areas in the plastics industry. This variety of materials makes itself known in the five processes for manufacture of the polymer itself - namely, the suspension, bulk, latex, solvent, and dispersion processes. Selection of the process to make polyvinyl chloride resin is not a matter of preference or economics on the part of a producer but it is a matter of selection of the individual resin market the producer wishes to satisfy. The producer of suspension resins is limited to the market for calendering, extrusion, injection molding, and compression molding of plastics. The producer of bulk resins limits his market to that segment of the market noted for suspension resins which uses highly porous homopolymers. The producer of latexes has a market confined to waterborne coatings and adhesives. The producer of solution polymerized resins is limited to low molecular weight copolymers for solvent-borne coatings and adhesives. The producer of dispersion resins is limited to markets utilizing plastisol or organosol techniques for resin fabrication. While there is some limited interchange of markets between processes in general, the process determines the resin market. Technology and economics COLORITE 008001 prevent the use of a resin from one process in the market for another process. Vinyl dispersion resins are relatively high molecular weight polyvinyl chloride polymers or copolymers. They are fine particle size powders with a typical diameter of 1 to 10 microns which are used in the form of a fluid dispersion in a plasticizer. On heating, this fluid dispersion is converted to a solid form or coating. The primary market utility for dispersion vinyl resins is their ease of fabrication, the low investment for fabricating equipment, and the wide variety of end-use applications. The fluid dispersions Of vinyl resins appear in two forms - plastisols are a dispersion of resin in a plasticizer; organosols are a dispersion of resin in plasticizer and solvent. While other vinyl resins are often added to these dispersions as modifiers and extenders, no other polyvinyl chloride can be substituted for dispersion vinyl resin in this application. Vinyl plastisols are stable fluid dispersions of the vinyl disperison resin in liquid plasticizer and stabilizer; depending on the end-use, pigments, colorants and other additives can be included. The plastisols are generally prepared by simple mixing of the components. Vinyl organosols are used in industry primarily for thin film, low-viscosity coating applications. Vinyl dispersion resins are readily formulated with low volatility . ..... plasticizers and other ingredients to yield formulations with no reaction by-products for application as coatings or adhesives or in the manufacture of a wide variety of molded products. Additionally, they can be formulated to yield coatings and food jar gaskets acceptable to FDA for use in contact with foods as well as for the manufacture of medical devices such as strip COLORITE 008002 bandages, surgical gloves, and prosthetic devices. Plastisols can be formulated to yield end products which are soft and flexible or which approach vitreous hardness, products which will not support combustion by themselves, or products which have outstanding impact or abrasion resistance. The total market for polyvinyl chloride dispersion resins in 1974 was 470 million pounds distributed to the major "Use Categories" shown in Table 1. The 470 million pounds was formulated into plastisols to yield a volume of over one billion pounds of compound. Processing of vinyl plastisols into finished products involves hundreds of individual companies and involves an estimated 70,000 direct employees. The value of these finished goods is estimated to exceed $1 billion. Dispersion resins are produced by ten domestic resin manufacturers by somewhat similar procedures, although there are significant differences in the properties of many of the resins currently available. In most cases the processing techniques and performance of the finished products are dependent on these differences. The one common factor in producing dispersion resins is that they are all processed through drying equipment that yields a finished product in a very finely divided powder. Many of the subsequent processing techniques and properties of the finished products are dependent on the use of this powdered resin as the starting material. In the presently practiced manufacturing procedures, it is not possible to reduce the residual monomer content of dispersion resins below a range of 0.2 to 5 percent of the dry polymer weight (2,000 to 50,000 ppm). Therefore the water dispersion of resin charged to the dryer carries this residual COLORITE 008003 monomer which is subsequently stripped from the resin in the course of the drying operation. The level of monomer In the dryer exhaust runs in the range of 100 to 500 ppm. COLORITE 008004 MANUFACTURING ANALYSIS In various discussions with EPA presonnel, plastics industry representatives have pointed out that the majority of suspension resins, bulk resins, and latex products can be stripped to a residual vinyl chloride content of 400 ppm (dry basis) prior to drying or otherwise exposing such products to large volumes of air. Additionally it has been pointed out that dispersion resins cannot be stripped to this low level due to their many unique properties. The purpose of the Manufacturing Analysis section of this report is threefold: (1) To establish the unique properties of dispersion resins, as compared to latex products, in an attempt to provide EPA further insight into the problems associated with stripping dispersion resins of residual vinyl chloride; (2) To review the specific problems associated with stripping dispersion resins and controlling the vinyl chloride emissions from dispersion resin drying; (3) To review new technology that might be considered to reduce the vinyl chloride emissions that presently occur in the production of these resins. Unique Properties of Dispersion Resins Dispersion resin technology used in the processing and fabrication of products that is contingent on several critical factors: Using a vinyl resin of 1 to 10 micron size. Using a particular mix of particle size. a Having relatively non-porous particles. Having a particular molecular weight. a Producing a resin that yields a stable fluid mix of resin, stabilizer, colorants, and other additives when mixed with less than its weight of plasticizer. This resin plasticizer mix is known as a plastisol. a Upon heating the plastisol formulation in an oven it must fuse to a tough flexible film or solid object. COLORITE 008005 The properties of the plastisol are determined in the dispersion resin process by: o The specific recipe, o The shear during reactor mixing, o The thermal history during manufacturing, o Post polymerization treatment, o Spray drying, o Grinding. Critical plastisol properties are color, viscosity at both highland low shear, viscosity stability, gelation temperature, fusion temperature, thermal stability, volatiles and film strength. Each of these properties has a bearing on the ultimate utility of the resin. Each producer in the industry strives for products yielding uniform plastisol properties. A dispersion resin polymerization differs from a latex polymerization in that in a latex, the polymerization initiates from water soluble free radical catalyst sites and grows a particle less than 0.5 microns in diameter; in a dispersion resin process, the polymerization occurs within the water dispersed globules of monomer with a mean size of 2 microns which do not grow in size during polymerization. Additives, stripping, heating, spray drying, and grinding, in addition to the polymerization technique, determine the ultimate properties of the plastisol formed from the dispersion resin. In addition, the relatively large particle size reactor product produced by dispersion resin polymerization is much less heat stable than a latex. Aqitation, heating time, pumping and other mechanical operations can result in coagulation and the inability to produce a product with the desired properties. Problems in Stripping __ Past.industry practice has been to minimize agitation, heating, and pressure - reduction in the monomer striDDina operation to avoid coagulation-or destruction \< of the product. This $ntle stripping operation generally leaves ; COLORITE 008006 approximately 10,000 ppm of vinyl chloride in the stripped, dry reactor product. To reduce the monomer contained in the particle to the levels specified by EPA (400 ppm), the reactor product would have to be heated to 180 F, and subjected to agitation and vacuum. This kind of processing cannot be done without degrading the product. The temperature stress would soften the resin particle, change its porosity and the properties of the stabilizing surfactant, causing coagulation of the mix and fouling of the vessel. During this heating period, the agitation and vacuum would further stress the relatively unstable reactor product causing foaming, further product coagulation, and the volitalization of necessary additives. In addition to the other problems noted, the prolonged heating for stripping would cause color development and thereby reduces the ultimate heat stability of the product. The resin fabricator thus would be limited in the amount of heat he could use in fabrication causing him to produce inferior products. To summarize the problems that result from intensive monomer stripping, the following are listed: 1. Change in particle porosity, thus destroying product quality. 2. Changes in characteristics of the plastisol, thus destroying product quality. 3. Extensive coagulation of the -reactor product leading to fouling of .equipment and product destruction. 4. Extensive foaming of the reactor product causing fouling of vacuum pumps, heat exchange surfaces and other monomer recovery equipment. 5. Product degradation through excessive heating thus destroying its heat stability and its usefulness to the fabricator. New Technology The various resin producers are experimenting with intensive monomer stripping by using such techniques as thin film evaporators, baffle columns, large vacuum flash tanks, anti-foams, and surfactant additions in an effort to improve vinyl chloride removal from dispersion resin slurries. Thus far, the results have COLORITE 008007 been product degradation, change in product properties, and indications of high control costs. The results, however, have tended to be encouraging, with some reduction of residual monomer content. The ultimate solution to the problem appears to require much experimental and development work to select the proper stripping equipment and to readjust the process to optimize the vinyl chloride removal and product characteristics. One company is currently installing full plant size equipment for stripping dispersion resins. This installation is based on experimental work previously conducted and still being conducted at two plants. This work indicates that vinyl chloride content, while the resin is still dispersed in water, can be reduced to something under one pound per 100 pounds of dry resin (less than 10,000 ppm) but the process is still unproven. Operating data will not be available until January 1976 since the equipment installation will not be completed until November 1975. The complexity of the monomer recovery problem indicates that available approaches must be carefully studied in the industry's research laboratories. The most viable system would then be developed either in the plant or pilot plant. Experience has shown that direct transmission of laboratory data and results to the production process is not possible. The technology development phase would require possibly two years. This development phase would then be followed by equipment design, purchase and installation and by process optimization to yield products of acceptable, salable quality. This phase would also require about two years. The rapid development of vinyl chloride stripping technology that would be applicable to a majority of producers and that would not change product characteristics is extremely unlikely. COLORITE 008008 Techniques for controlling vinyl chloride in dryer emissions include incineration, solvent absorption and activated carbon adsorption. However, none of these techniques have been proven technically feasible for treating high volume air streams with low vinyl chloride concentration. Incineration of a dryer air stream has been considered as a means of reducing vinyl chloride emissions from products which may emit more than 10 ppm in the dryer discharge. In an analysis of a plant representing an annual output of 48 million pounds of resin, it was calculated that there would be a combined discharge of 60,000 SCFM air containing 125 ppm vinyl chloride. It was further assumed that this would require three 20,000 SCFM incineration units at a capital cost of $1.5 million and an annual operating cost of $0.5 million excluding amortization. Fuel oil usage was calculated at 872,000 gallons per year. Heat recovery and reuse from these units are quite unlikely because of the presence of HC1 as a breakdown product of vinyl chloride. Based on this analysis, the additional fuel consumption for the total industry amounts to 8,720,000 gallons per year. Solvent absorption technology has been used for removing vinyl chloride from low volume air streams with moderate to high concentrations of vinyl chloride. In such cases, experience has shown typical emission of vinyl chloride concentrations to be 15 ppm. To our knowledge, this technology has not been used for treating high volume low concentration air streams, particularly air streams from dispersion resin drying. Air streams from dispersion resin drying contain trace amounts of polyvinyl chloride, emulsifiers and water which would tend to interface with solvent absorption. The ~ emulsifiers would give rise to foaming problems and create a difficult solvent ; -i . Ir . r. , , -v,.-v. > ; t , ", ........ COLORITE 008009 purification problem. In order to overcome these problems and to prevent contamination of recovered vinyl chloride, it would be necessary to scrub the dryer gases, using an alcohol or glycol, prior to solvent absorption of the vinyl chloride. It would also be necessary to cool the dryer gases from H60 to 50 F. For a 60,000 SCFM solvent absorption system, * approximately 20,000 gpm of solvent would need to be circulated. A scrubbing column of approximately 30' diameter and a solvent absorption column of 50-60' diameter would be necessary. Obviously this type system would be very energy demanding, impractical in size, and might well just be trading off a vinyl chloride loss for a solvent loss. This technique is not considered to be a viable control method for dryer emissions. Removal of vinyl chloride from dilute contaminated air streams using activated carbon technology also has not been demonstrated as feasible. Certainly trace polyvinyl chloride would need to be removed from spray dryer exhaust prior to carbon adsorption. The effect of emulsifiers on carbon is yet unknown. Water is known to have a detrimental effect on carbon adsorption and thus would largely also have to be removed. A scrubbing system similar to that described above for solvent absorption would most likely be necessary prior to carbon adsorption. Specific design data for vinyl chloride removal using activated carbon does not exist. However, using available theoretical data of the Calgon Corporation, two 16' diameter carbon beds would be required for treating 60,000 SCFM dryer air. Related equipment for removing and disposal of the vinyl chloride from the carbon would also be necessary. At this time, the most logical approach would be to pass hot, inert gas through the carbon to drive off the vinyl chloride. COLORITE 008010 This hot gas stream would then have to be cooled to remove water prior to blending off a slip stream for disposal by perhaps catalytic incineration or perhaps solvent absorption. If catalytic incineration was used, the gases would also be highly energy dependent, and certainly complicated. This is not considered to be a viable alternative. COLOR!TE 008011 MARKET ANALYSIS Polyvinyl chloride dispersion resins are fine particle size resins which enable formulators to manufacture liquid dispersions called plastisols. These vinyl dispersions are a unique family of plastic formulations which giye the product manufacturer unprecedented choice of processing method , and end-use properties. Plastisols are dispersions of these particles of high molecular weight polyvinyl chloride resin in liquid plasticizers, in addition to pigments, stabilizers and as many as 10 or more other ingredients. Plasticized vinyl dispersions are 100 percent solids in fluid form. They fuse to a solid quickly on application of moderate heat. With hundreds of raw material choices possible, plastisols can be tailored to a wide range of products and processes. Closely associated with plastisols are organosols. They are basically plastisols with reduced viscosity, extended with organic volatiles which are removed during fusion. Processing methods are so varied that efficient production is possible at any volume, from short runs to millions of units a year. Vinyl dispersions bring to the product designer and manufacturer, in easy-to-use form, all the physical and chemical properties of polyvinyl . chloride plastics with many others not found in other forms of polyvinyl chloride. Vinyl dispersions are used in coatings, moldings, castings, and foam products. This diversity in form and forming goes a long way toward v .explaining the increasing penetration into virtually every consumer and yindustrial market. 'X-V*. ' '' " '. % . COLORITE 008012 Applications With literally thousands of applications, sales volume of plastisols and organosols is estimated at more than a billion pounds a year. Fast growing applications such as foam backing for carpets and cushioned sheet vinyl floor covering could double industry volume by the early 1980's. It is difficult to over-estimate the versatility of vinyl dispersion resins. Coatings may be on fabric, paper, metal sheeting, or on strands or filaments of glass, nylon, metal. All coating methods--knife coating, roll coating, dipping--require about 300 million pounds of vinyl dispersion resin form ulations annually. Molding can yield open or closed hollow shapes by such processes as slush v and rotational modling, solid parts by low-pressure cavity moling or casting. Dipping and stripping a mold provides such products as gloves. These molding methods also require about 300 million pounds of vinyl dispersion resin formulations. Foamed vinyl dispersions give soft leather-like feel to a woman's coat, bounce to a shoe sole, or spongy resilience as backing for carpets and hard floor coverings. The flooring market requires an estimated 250 million pounds. A Spray coating in factory and field can put a tough corrosion-resistant skin on pipes, ducts, tanks. It would be difficult to estimate the secondary savings in dollars realized by prolonging the life of these metal products. In-place molding can put gaskets on ceramic pipe for efficient field assembly COLORITE 008013 Table 2 lists successful applications of vinyl dispersions, products that are better in quality, more economical to manufacture, or both. In every market category there are many, many more. Every year, product designers and manufacturers find new uses and open new markets for versatile vinyl dispersions. COLORITE 008014 Market Size The demand for vinyl dispersion resins is expected to nearly double by 1980 from the level of 470 million pounds produced in 1974. (See Table 3) The 10 major producers of dispersion resins listed below use several methods of manufacture to yield more than 50 resins, each having its own specific properties. B. F. Goodrich Diamond Shamrock Firestone Borden (Monsanto) Uniroyal Stauffer Union Carbide Ethyl Tenneco * Goodyear These resins are formulated into thousands of compounds for applications given in Table 2. Vinyl formulations using these dispersion resins contained approximately 425 million pounds of plasticizer, about 25 million pounds of stabilizers and substantial amounts of pigments, fillers and other additives to yield more than one billion pounds of plastisol compounds. Vinyl dispersions are used in these applications chiefly because they yield high-quality products that are economical to manufacture. Because of the generally low capital investment required for various end uses, many small companies are engaged in the manufacture of plastisols, particularly for use in the production of molded products. A reduction in, or discontinuance.^ of the availability of vinyl dispersion resins would result in a severe hardship for these companies, necessitating substantial investment to .. {.. change over to alternative materials. In many cases, suitable material , I* i alternatives are not currently available; in others, expenditure of-required V ' , -iV ' 1 , ,. *'V ' . !i,-s "... l:KJ. f t COLORITE 008015 investment capital could not be justified based on the volume of sales. Abandonment of the business would be necessary. Each of the applications for vinyl dispersions involves the manufacture of a large number of individual units. This industry consists of ten dispersion resin producers selling to * hundreds of formulators who in turn supply thousands of small, meduim and large consumer product manufacturers. In most cases, processing of vinyl dispersions constitutes the entire business. Table 4 lists possible replacement materials for the polyvinyl chloride dispersion resins use categories as listed in Table 1. Table 4 also shows the impact on vinyl dispersion producers and fabricators as a result of switching to replacement materials. COLORITE 008016 TABLE 1 Polyvinyl chloride Dispersion Resin Markets* 19 7-1 (Thousands of Pounds) Use Category Flooring - via coating Textile and Paper Coating Slush, dip and rotational molding Food gasketing Adhesives Protective coatings Film cas ting All other plastisol Applicationa TOTAL Dispersion Resin Use (1000 pounds) 132.000 125.000 05.000 25.000 20.000 15.000 5,000 63.000 ' 470,000 Source: SPI Statistical Report - Ernst & Ernst * For domestically produced material COLORITE 008017 TABLE 2 Appliances coated dishwosher tubs and racks commercial refrigerator and freezer coatings office machine finishes coated refrigerator shelves air conditioner insulation refrigerator foam insulation foamed gaskets Automotive foamed crash pods and sun visors air filter gaskets oil filter end caps garnish molding onti-rattle body clips . pump diaphragms spark plug covers ' coated battery boxes weather stripping 'coated seat springs ' station wagon floors and tailgates Building 6c Construction precoated roiled steel sheet and strip, galvanized black plate s' and tin plote coated aluminum screen door frames and metal doors coated wire fences coated metal lockers and shelves coated metal balustrades, railings, gratings, grilles coated metal awnings, shutters, roofs, window casings and frames -coated metal and fiber glass screening coated metal siding foamed weatherstripping and glazing splines seals for ceramic tile ladder and stair treads folding doors Electrical , foamed cable insulation ' electrical conduit sleeves encapsulated electric and - electronic components motor coil coating housings and conduits flashlight cases insulating ond corrosion-resistant coating for underground power distribution systems Furniture & Horae Furnishings upholstery coating carpet underlay ond backing cushioned floor covering top coating for printed floor covering metal furniture coating wallpaper coating and flocking table cloths and place mats i patterned fabrics foam furniture pods coated metal Venetian blinds choir seats Household Products coated clothes, hangers coated clothes lines coated tool handles toilet tank valve boll coated decorative tape sink and disposal stoppers Military foamed crash pods in tanks and gun tufrefs foamed hatch liners on surface ships and submarines extruded sponge jacketing for missile cables coating for missile parts Packaging 6t Display foamed packaging for fragile instruments, parts gaskets for bottle caps, jar lids envelope for glass aerosol containers and bottles threaded caps 1 drum linings con top coatings protective covering for storage and 1 shipment of appearance parts advertising display plaques promotion novelties , manikins Sports & Toys Industrial foam floats and buoys foam life jackets : * coated metal for corrosion bicycle seats, handlebar grips resistance coating for anchors, chains - coated wire baskets and boxes for parts handling coated ducting coated filter press coated steel impellers interior tooted battery sinks coated conveyors and tote boxes coated valves foamed gaskets cellular cover for volatile liquids decoys uniform padding golf club and fishing rod grips fishing lures and lines cooted sails dolls' heads and bodies piggy banks . toy blocks and tires balls and squeeze toys ' ! i 1 ; i | in storage in-plant gasketed sewer pipes flexible joints tank and tank car lining pipe sleeves ond seals Wearing Apparel & Accessories foam jacket lining foam footwear lining boots ' Medical shoe soles raincoats < coolings for medical filters squeeze bulbs strip bandages, finger cols surgical gloves and masks prosthetic devices cooted textiles for outerwear foamed slipper soles work gloves safety clothing coated luggage I nipples baby pants COLORITE 008018 TABLE Estimated U.S.A. PVC Dispersion Resin Production, Millions of Pounds - Annual* Millions of Pounds 1071 1972 1973 1974 1975 1976 1977 1978 1979 1380 350 4 30 470 470 450 e s t, 550 est. 600 e s t. 660 cs t 720 est. 800 os t . `Based on Tariff Commission, SPI fi Industry Information COLORITE 008019 TABLE 4 APPLICATIONS FOR PVC, DISPERSION RESINS POSSIBLE REPLACEMENT MATERIALS, DISLOCATION OF JOBS AND ESTIMATED TOOLING TIKE Use category* FLOORING (COATING) TEXTILE S PARER COATINGS Impact of using Replacement Material Typical applica tions RESILIENT FLOOR COVERINGj Kitchens, Family rooms, commercial & institutional bldgs, Pos sible replacement ma t erial Existing vinyl dispersion Relative fabricator cost of plant replacement obsolete? Vinyl dispersion workers displaced? Commercial carpet Outdoor carpet Solid vinyl tile Higher Higher Lower Yes Yes Yes Yes Yes Yes Retooling, existing plants (column 3) years NF** AUTO UPHOLSTERY INTERIOR SOTT TRIM. (DOT 302) Flame-retarded textile fabric Higher Yes lo 1-2 INDUSTRIAL BELTING (Coal mining, grain handling, food pro-) cessing, Post Office) FIame-retarde d Synthetic rubber or polyurethane Higher Yes Yes NF HEALTH CARE ITEMS (Disposable hospital gowns, disposable diapers, ladies sanitary napkins) Vinyl or Acrylic 1 a tex Higher No No 0-1 FOOTWEAR. E APPAREL (Shoe uppers, ladies fashion boots, hand bags, and outer-wear coats) Leather Polyurethane Acrylics Higher Higher Higher Yes Yes Yes Yes No ' No *NF 1-2 1-2 TRANSPORTATION (Truck tarpauline) Polyurethane Synthetic rubber Higher Higher Yes Yes No Yes 1-2 NF COLORITE 008020 TABLE 4 Impact of using Replacement Material USE CATEGORY* Typical applications TEXTILE S PAPER COATINGS CONSTRUCTION (Wall cowering, awnings, furniture upholstery) Possible replacement material Polyurethane Vinyl or acrylic latex Relative cost of replacement Existing vinyl dispersion fabricator plant obsolete? Higher Higher Tes Mo Vinyl dispersion wo rkers displaced? Re tooling existing plants [column . vsars '.Jo 1-2 No 0-1 PROTECTIVE COATING ADHESIVES 6 OTHER COATIHGS MISCELLANEOUS {Air supported ware houses, tents, mine safety curtains) Polyurethane Synthetic rubber Mass Transit Seats Dishwasher lining Dishwasher baskets Refrigerator trays Outdoor Furniture Urethane Epoxy Solvent or Pwdr. Vinyl Solvent or Pwdr. Vinyl Solvent or Pwdr. Vinyl Adhesive Bandages (2and-Aid, Curads, etc.) Solvent or Cal endered Vinyl Higher Higher Higher Higher Higher Higher Higher Higher Yes Yes Yes Yes Yes Yes Yes Yes no Yes NO NO NO No NO No 1-2 NF 1-2 1-2 1-2 1-2 1-2 2-3 Auto Sealants Insect Screening Silicons Synthetic rubber cement Aluminum Higher Higher Aluminum House Siding Solvent vinyl Acrylics Higher Higher Yes Yes No No NO Yes NO NO % 1-2 NF 0 0 COLORITE 008021 f TABLE 4 Impact of using Replacement Material Use Category* PbASTISOL ALL OTHER PASTE Typical applications Auto Gaskets Auto Interior, Safety Trim {DOT 302 J Electrician lineman tools Traffic safety cones Industrial safety mats Childrensf soft toys and balls Foamed back carpeting Foamed back football fields numerous medical applications fstethoscope, cathetar blood transfusion equipment, surgeons gloves, etc.) Food jar closures fall food & beverage in glass) Pos sible replacement material Relative cost of rcplac emen t Synthetic rubber Higher Soft Synthetic polymers Polyurethane Higher Higher Natural Rubber latex Highe r Synthetic rubber Higher Synthetic rubber Higher Synthetic rubber Higher Synthetic rubber Synthetic rubber Equal Higher Natural rubber latex Higher Synthetic rubber Higher Existing vinyl dispersion fabricator plant obsolete? Yes Yes Ifes Yes Ves yes Ve s Ho Yes Ho Yes Vinyl dispersion workers displaced? Retooling, existing plants (column 3! Ho 1-2 Ho 1-2 NO 1-2 Ho 1-2 Yes MF Yes NF Yes HP No Yes 0 HF Ho 0 > Yes 3 COLORITE 008022 VV`.*JW Use Category* ALL OTHER PASTE (continued) TABLE 4 Impact of using Replacement Material Typical ______ applications Childrens' foul weather boots Building insulation tape Highway bridge surface repair Possible replacement material Relative cost of replacement Natural rubber latex Polyurethane Higher Higher' No known substitute - Existing vinyl dispersion fabricator plant obsolete? Yes Yes Yes Vinyl dispersion workers displaced? Retooling, existing plants (column 3) years No 1-2 Ho 1-2 Yes HF From Society for the Plastics Industry (SPI) statistical report* NF - Hot feasible to retool existing plants.