Fabric Printing, Coating,

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United StatesEnvironmentalProtectionAgency

Office of Air QualityPlanning and StandardsRTP, NC 27711

July 1998

Preliminary IndustryCharacterization:

Fabric Printing, Coating,and Dyeing


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Table of Contents

Sec ti o n Page

I. EXEC U TIV E SU M M A RY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1II . FA BRIC PRIN TIN G , C O A TIN G , A N D D YEIN G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-1

II .1 In tro d u c ti o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-1II .2 Su m m ary of Ex ist i n g Fed eral Req ui rem en ts/State Req ui rem en ts . . . . . . . . . . . . . . . II-2

II.2 .1 Fed eral Regu lati o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-2II.2 .1 .1 A p p l i cab i l i ty o f th e N SPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-2II.2 .1 .2 Perfo rm an ce/C on tro l Req ui rem en ts o f th e N SPS . . . . . . . . . . . . . . II-3II.2 .1 .3 A p p l i c ab i l i ty o f th e C TG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-3II.2 .1 .4 Perfo rm an ce/C o ntro l Req ui rem en ts o f th e C TG . . . . . . . . . . . . . . II-4

II.2 .2 State R egu l at i o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-4II .3 In d u stry Pro fi l e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-8

II.3 .1 Basi c Tex ti l e M an u fac tu r i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-8II.3 .1 .1 C arp ets an d Ru gs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-8

II.3 .1 .2 Po ly m eri c C o atin g o f Su b strates . . . . . . . . . . . . . . . . . . . . . . . . . II-1 2II.4 A p p l i cab i l i ty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-1 2II.5 Pro cess D escr i p t i o n s an d Cu rren t In d u stry Prac ti ces . . . . . . . . . . . . . . . . . . . . . . . II-1 5

II.5 .1 Basi c Tex ti l e M an u fac tu re . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-1 7II.5 .1 .1 D ry Pro cessi n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-1 7II.5 .1 .2 W et Pro cessi n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-3 0II.5 .1 .3 O th er O perati o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-5 8

II.6 Referen ces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-5 9

A P PEN D I X A - PA R T I C IPA N T S I N F A B R IC PR IN T I N G , C O A T I N G , A N D D Y EI N GSTA KEH O LD ER PRO CESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A -1

A PPEN D IX B - D EFIN ITIO N S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B -1


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List o f Tables

N u m b er Page

II.2 -1 Su m m ary o f State Regu lat i o n s fo r Fab r i c C o atin g . . . . . . . . . . . . . . . . . . . . . . . II-4II.3 -1 Tex ti l e Pro d u c t - En d U ses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-9II.3 -2 Su m m ary of In d u stry Secto rs C o n sti tu ti n g Tex ti l e M i l l Pro d u c ts . . . . . . . . . . . II-1 0II.3 -3 N u m b er o f Pl an ts th at A pp ly Po ly m eri c C oati ngs to Su pp ort i ng Su bstrate

b y State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-1 3II.5 -1 M ajo r D ye C l asses an d Su b strate Fi b ers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-3 5II.5 -2 C o atin g A p p l i cato r Param eters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-5 4II.5 -3 H A P Em issio n s fro m Fac i l i t i es w i th C o ati n g O p erati o n s . . . . . . . . . . . . . . . . . II-5 5


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List o f Figures

N u m b er Page

II.4 -1 Fab r i c Pr i n ti n g, C o ati n g, an d D y ei n g So u rce C atego ry . . . . . . . . . . . . . . . . . . II-1 4II.5 -1 Basic Tex ti l e Pro cessi n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-1 6II.5 -2 D ry Pro cessi n g M il l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-1 8II.5 -3 Su essen Carp et Yarn H eat-Setti n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-2 1II.5 -4 Ty p ical Sl ash in g Ran ge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-2 5II.5 -5 Ex am p le N o n w o v en M an u fac tu r i n g Pro cess Fl o w D i agram . . . . . . . . . . . . . . II-2 8II.5 -6 W ov en Fab r i c Fi n i sh in g M il l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-3 1II.5 -7 Ty p ical Fab r i c Prep arati o n Ran ge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-3 2II.5 -8 Ty p ical Fab r i c D yein g an d Fi n i sh i n g Ran ges . . . . . . . . . . . . . . . . . . . . . . . . . II-3 6II.5 -9 D y e M ach i n es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-3 8II.5 -1 0 Ex am p l e C arp et D y ein g an d Fi n i sh i n g Pro cess Fl o w D i agram . . . . . . . . . . . . . II-4 4II.5 -1 1 Ty p ical Ro tary Screen Pr in ti n g Ran ge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-4 6II.5 -1 2 Ty p ical Po ly m eri c C o atin g Ran ge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-5 2


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1 The w orkshop co vered e igh t ca tegor ies: fabr ic p r in t ing , coat ing and dy e ing; largeapp l i ances; m etal can; m etal co i l ; m etal fu rn i tu re ; m iscel laneou s m etal par ts; p last ic par ts; andw ood b u i l d in g p roduc ts. The au tom ob i l e and l i gh t du ty t r uck p ro jec t was star ted subsequen t l y .

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PRELIM IN ARY IN D U STRY CH ARACTERIZATIO N :Fabric Print i ng Coating and D yeing

I. EXECU TIVE SU M M ARY

U nd er Sect ion 1 12 (d) o f the Clean A i r Act (the Act) , the U .S. Env i ron m enta l Pro tect ion A gency(EPA) is deve lo p in g nat ion a l em ission standards fo r h azardous a i r po l lu tan ts (N ESH AP) fo r theFabr ic Pr in t ing , Coat ing , and D ye ing source ca tegory. The EPA is requ i red to pu b l i sh f ina lem ission s tand ards fo r the Fabr ic , Pr in t in g , Coat ing , and D ye ing sou rce category by N ovem ber 15,2 0 0 0 .

The A ct requ i res tha t the em ission standards fo r n ew sou rces be n o l ess st r ingent than th e em issioncon tro l ach ieved in p ract ice by the best con tro l led s im i la r sou rce. For ex is t ing sou rces, theem ission con tro l can be less st r ingent than the em ission con tro l fo r new sou rces, bu t i t m ust be noless st r ingent than the average em ission l im i ta t ion ach ieved b y best per fo rm ing 12 percent o fex is ting sources (fo r w h ich the EPA h as em ission s in form at ion) . [ In ca tegor ies or subcategor ies w i thfew er than 30 sou rces, em ission con tro l fo r ex i st ing sources m ust be no l ess st r ingent than the

average em ission l im i ta t ion ache ived by the best per fo rm ing 5 sou rces. ] The N ESH AP arecom m on ly kno w n as m ax imu m ach ievab le con t ro l techno logy (M ACT) standa rds.

The M ACT standa rds developm en t fo r the tex t i l e i ndu st r y began w i th a Coa t ing Regu la t i onsW orkshop fo r representa t ives o f EPA and in terested stakeho ld ers in A pr i l 1 99 7 and c on t inues as acoord ina ted e f fo r t to p romote consis tency and jo in t reso lu t ion o f issues common across n inecoating source categor ies. 1 The f i rst phase w as on e in w h ich EPA gathered read i ly ava i lab l ein fo rm at ion abou t the indu stry w i th the he lp o f representa t ives f rom the regu la ted ind ustry , Sta teand lo ca l a i r po l lu t io n agencies, sm al l bu siness assis tance prov iders, and env i ron m enta l g roups.The goa ls o f the f i rst phase w ere to e i ther fu l ly o r par t ia l ly :

C U nd erstand the text i le p rocesses w i th H AP emi ssion p otent ia l

C Ident i fy typ ica l em ission po in ts and th e re lat ive em ission s f rom eachC Ident i fy th e range(s) o f emi ssion reduct io n techn iqu es and the i r e f fect ivenessC M ake an i n i t i a l de term ina t i on on the scope o f each ca tego ryC D eterm ine the re la t ionsh ips and o ver laps o f the ca tegor iesC Locate as m any fac i l i t ies as po ssib l e , par t icu la r ly m ajor sourcesC Ident i fy and inv o lv e representa t ives fo r each ind ustry segm entC Com p le te i n fo rm a tiona l s i te v i si t sC Ident i fy i ssues and data needs and d eve lop p lan fo r addressing themC D eve lop qu est ionn a i re(s) fo r add i t iona l d a ta gather ing andC D ocu m ent resu l ts o f the f i rst phase o f regu la tory d eve lop m ent fo r each ca tegory.

The ind ustry m em bers tha t are par t ic ipa t ing in the s takeho ld er p rocess are m em bers o f theAm er ican Text i le M anufacturers Insti tu te (ATM I), Carpet and Rug Inst i tu te (CRI), Rubber


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M anu fac tu re rs Assoc ia t i on (RM A) , N o r the rn Tex t i l e Assoc ia t i on (N TA) , N a ti ona l Assoc ia t i on o fH os iery M anu fac tu re rs (N AH M ), IN D A (Assoc ia t i on o f the N onw oven Fab r i cs Indus tr y ), Eco log i ca land Tox i co log i ca l A ssoc ia t i on o f D yes and O rgan ic P igm en ts (ETAD ), Am er i can Ya rn Sp inne rsAssoci a t ion (AYSA) , Chem ica l M anufacturers Associa t io n (CM A) So lv ent s Cou nci l , Ind ustria lFabr ics Assoc iat io n Intern ation al (IFAI) , and Singl e Ply Ro ofi ng Inst i tute (SPRI). The States that arepar t ic ipa t ing in th e process are A l abama, F lor ida , Geo rg ia , N or th Caro l i na , Sou th Caro l in a , andVi rg in ia The U .S. EPA is represented by the EPA O ff ice o f A i r Q ua l i ty P lann in g and Standards(EPA/O A Q PS), the EPA O ff ice of Preventi on , Pestici des, and To xi c Sub stances (EPA/O PPTS), theEPA O ff ice o f Enforcem ent and Co m pl ianc e Assurance (EPA/O ECA ) and the EPA O ff ice o f Researchand D eve lopm en t (EPA/O RD ). Ap pend ix A co n ta ins a l i st o f pa rt i c i pan ts.

The in fo rm at ion sum m ar ized in th i s do cum ent can be used by Sta tes tha t may have to m ake case-by-case M AC T determin at ions un der Sect ions 112(g) o r 112 ( j ) o f the Act . The in i t ia l ph ase o f theregu la tory deve lopment focused pr imar i ly on bas ic text i le manufactur ing , carpet and rugm anufactur ing , and fabr ic coat ing . Th is do cum ent represents the conclu sion o f tha t phase o f ru led e v e l o p m e n t .

Th is document inc ludes a descr ip t ion o f the emiss ion contro l techno log ies the EPA ident i f ied tha tare cur rent ly u sed in pract ice by the industry and tha t cou ld serve as the basis o f M AC T. W i th inthe sho r t t im e -f ram e in tended fo r th i s i n i t i a l phase , how eve r, on l y l im i ted da ta w e re co l l ec ted . Thein fo rm a tion sum m ari zed i n th i s docum en t was co l l ec ted p r i o r to Ju l y 15 , 1998 . Ad d i t i ona li n fo rm a tion w i l l be co l l ec ted and co nside red be fo re the Fab r i c P r in ti ng , Coa t ing , and D ye ingM AC T standards are prom ulgated.

D u r ing the nex t phase , the EPA w i l l con t i nue to bu i l d on the kn ow ledge ga ined to da te andproc eed w i th m ore focused inv est iga tion and data ana lyses. W e w i l l a lso con t inu e ou r ef fo r ts tocoo rd in a te cross-cu t t ing issues. W e w i l l con t inu e to ident i fy techn ica l and po l i cy issues tha t needto be add ressed in the ru le m aking and en l is t the he lp o f the stakeho ld ers in reso lv ing tho se issues.

Q uest i ons o r com m en ts on th i s docum en t shou l d be d i rec ted to M r . Pau l A lm odv a r (EPA/O AQ PS)a t 919 -541 -0283 o r a t a lm odov a r.pau l@epam a i l .epa .gov .


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I I . FABRIC PRIN TING , CO ATIN G, AN D D YEIN G

I I .1 IN TRO D U CTIO N

This chapter p resents a sum m ary o f ex is ting Federa l requ i remen ts/Sta te requ i rem ents, an i nd ustrypro f i l e o f the text i le indu stry ; a descr ip t ion o f the l i k e ly app l i cab i l i ty o f the N ESH AP for Fabr icPr in t ing , Coat ing , and D ye ing o pera t ions; and proc ess descr ip t io ns and ind ustry pract icesinc lud ing , w he re app l i cab le , sum m aries o f H AP emissions i n fo rma t ion and con t ro l op t i ons .Ap pend ix B con tains de fi n i t i ons o f som e o f the im po r tan t e lem en ts and op e rat i ons tha t m ake upthe Fabr ic Pr in t ing , Coat ing , and D ye ing source ca tegory fo r the purp oses o f th is docum ent .


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2 U .S. EPA, Co ntro l o f V o la t i le O rgan ic Em ission s from Exis t ing Sta tion ary Sou rces- -Vo lum e I I : Sur face Coat ing o f Cans, Co i ls , Paper , Fabr ics, Au tom ob i les and L igh t-D uty Tru cks, EPA450 /2 -77 -008 , M ay , 1977 .


I I .2 SU M M ARY O F EXISTING FED ERAL REQ U IREM EN TS/STATE REQ U IREM EN TS

II .2.1 Federal Regulatio ns

Federal vo la ti l e o rgan ic com pou nd (VO C) regu la ti ons tha t app ly to the tex t i l e i ndus tr y i nc lu de aN ew Sou rce Per form ance Standard (N SPS) under 4 0 C FR Par t 60 , Sub par t VV V, Standards o fPer form ance fo r Po ly m er ic Coat ing o f Sup po r t ing Sub stra tes Faci l i t ies . In add i t io n to the N SPS,the EPA pub l i shed a Con t ro l Techn iq ues G u ide l i ne (CTG) docum en t2 tha t covers fabr ic co at ingope ra ti ons . The fo l l ow ing sec t i ons sum m ari ze the app l i cab i l i t y and the con t ro l /pe r fo rm ancerequ i rem ents o f the N SPS and the CTG .

I I .2.1.1 Applicabil i ty of th e NSPS

The N SPS cov ers po lym er ic coat ing o f sup po r t ing sub strates. The Federal Reg ister no t ice fo r theru le (54 F.R. 37 54 0 [19 89]) no tes tha t lea ther - l i ke m ater ia ls l i ke u re thane-coated and b on dedleather fiber p ro du cts are inc lud ed in th e coverage o f the regu la t ion . Th e coat ing o f d iscre te h id es,the graph i cs ar ts, and the paper coat ing indu str ies are not in tended to b e covered. Com m enters to

the ru l e requested a separate sub category fo r text i le c oat ing o pera t ions, bu t EPA respo nd ed in steadby l o w er ing the ove ra l l r equ i red l eve l o f con t ro l to o ne they be l i eved a l l po l ym er coat i ng l i nes,i nc lud ing tex t i l es, cou ld m ee t.

The N SPS cov ers w eb coat ing app ly i ng an e lastom er or o ther po l ym er ic mater ia l on to a sup po r t ingsub stra te . Speci f ic substrates iden t i f ied in the Federa l Regis ter no t ice in c lud e kn i t , w oven , andno n-w oven text i les, f iberg lass, yarn , and c ord . The po lym er ic coat ings m ent ion ed are natura l andsyn the t i c rubbe r , u re thane , po l yv i ny l ch lo r i de , ac ry l i c , epoxy , s i l i cone , pheno l i c and n i t r oce l l u lose .(54 F.R. 375 34 [1 989 ]).

The ru le app l ies to coat ing op erat ion s tha t coat a con t inuo us w eb, de f ined as the coat ingapp l ic a tors, the part o f the opera t ion betw een coat ing app l ica tor and the dry ing ov en (f lasho f f

a reas) , and d ry ing o vens. The bou nd ar ies o f the co at ing opera t ion are ident i f ied as the sub strateunw ind s tat i on and the rew ind s tat i on . I f the re i s no rew ind s tat i on , the end o f the coa ti ngop erat ion is the last d ry i ng o ven in the pro cess (40 C.F.R. 60 .741 (a)).

The ru le a lso app l ies a lso to o ns i te coat ing m ix p reparat ion equ ip m ent used to prepare coatings fo rthe coat ing pro cess, i .e . , m ix i ng vesse ls in w h ich so lv ents and o ther m ater ia ls a re b len ded.(40 C.F.R. 6 0.74 0(a) and (40 C.F.R. 6 0.74 1(a) ).

The ru le speci f ica l ly exc l ud es w eb coat ing o pera t ions that p r in t im ag ines on sub strate sur face orany co at ing app l ied o n the sam e pr in t in g l ine tha t app l ies the im age (40 C.F.R. 60 .740 (d) (3) ).


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I I .2.1.2 Perfor mance/Control Requir ements of the N SPS

The ow ner o r ope ra to r o f an a f fec ted fac i l i ty m ay e i ther reduce VO C em issions f rom the coa ti ngop erat ion b y a t least 90% or instal l , opera te , and m ain ta in a to ta l enc losure arou nd th e coat ingop erat ion tha t vents to an add -on contro l d ev ice tha t is a t least 95% ef f ic ien t . For m ix equ i pm ent ,the standard requ i res cov ers and vent in g to a 95% ef f ic ien t add -on co ntro l dev ice w h i l e coat ingprepara t ion is tak in g p lace.

The requ i rem en ts o f Subpa r t VVV do n o t app ly to coa t i ng m ix p reparat i on equ ipm en t o r coa ti ngop erat ions dur in g those t im es they are used to prepare or app ly w aterborn e coat ing so lo ng as theVO C con ten t o f the coa ti ng do es no t exceed 9 p e rcen t o f the w e igh t o f the vo la t i l e fr ac t i on .

I I .2.1.3 Applicabil i ty of the CTG

The CTG app l i es to fab r i c coa t i ng w h ich i nc lud es a l l t ypes o f coa t i ng app l i ed to fab r i c and tov iny l coa t i ng w h ich re fe rs to any p r i n t i ng o r d eco rat i ve o r p ro tec ti ve topcoa t app l i ed ove r v iny lcoated fabr ic o r v i ny l sheets. I t does no t inc lu de the app l ica t ion o f v iny l p last iso l to the fabr ic

(em ission s f rom the app l ica t ion o f p last iso l a re near zero). The doc um ent speci f ica l ly i dent i f ies thefo l l ow ing app l i ca ti ons fo r co a ted tex t i l es:

C ind ustria l and e lect r ica l tapesC t i re cordC ut i l i ty m eter sea lsC im i tat i on l eathe rsC ta rpau l insC sho e m ater ia lC upho ls tery fabr ics

Types o f coat ings inc lu de la tex, acry l ics , PVC , po lyu re thanes, and n atural /syn th et ic rub bers.

The speci f ic sou rces o f em ission s associa ted w i th coat ing text i le substra tes are iden t i f ied as be ingpr im ar i ly the coat ing l in e (app l i ca t ion and d ry in g phases) and fug i t iv e emission s o f so lv ents.Speci f ic po in ts o f fug i t ive em ission s are :

C t ransfer f rom ra i l car / tank t ruck to s torage tanks then to proc essing ;C loss from storage tank vents;C ag i ta t ion o f mix ing tanks vented to the a tmosphere ;C so lven t evapo ra ti on f rom c lean u p o f coa t i ng app l i ca to r w hen co l o r i s changed ;C so lv ent soaked c lean ing rags;C d isposa l o f w aste ink s lud ge w i th res idua l so lvent (af te r d ist i l la t ion );C

losses f rom coat ings storage drum s as coat ing pu m ped to app l ic a tor ;C c lean ing emp ty d rum s w i th so l ven t ;C c lean ing co a ti ng l i n es w i th so l ven t ;C evapora t ion o f so lvent f rom coated fabr ic a f ter leav ing the p rocess.


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I I .2.1.4 Perfor mance/Control Requir ements of the CTG

The recomm ended V O C l im i tat i on fo r fab r i c coa ti ng i s 0 .35 kg pe r l i te r (2 .9 l bs pe r gal ) o f coa ti ng(min us w ater , inc lu d in g exem pt so lv ents) and fo r v i ny l c oat ing is 0 .45 kg per l i te r (3 .8 lb s per ga l ).The l im i ta t ions are based on th e use o f an add -on c ontro l d ev ice w h ich recovers or destroys 81pe rcen t o f the V O C in t roduced in the coa ti ng (90 pe rcen t cap tu re and 90 pe rcen t dest ruc ti on o rrecove ry ) . The CTG docu m en t al so desc ribes the fo l l ow ing con t ro l techn iqu es fo r fug i ti veemiss ions:

C cov ers fo r tanksC co l l ect ion h oo ds fo r areas w here so lv ent used fo r c lean upC c losed conta iners fo r so lv ent w ip i ng c lo thes.

II .2.2 State Regulatio ns

The emiss ion reduct ion requ i rements imposed by s ta tes and loca l governments on text i le coat ingopera t ions have been cod i f ied by many sta te leg is la tures in to laws and implemented in to

regu la t ions. M any o f these regu la t ions are based on th e CTG reduct io n requ i rem ents, bu t there isvar iab i l i ty as to the speci f ic p ercent redu ct ion s requ i red . There are no speci f ic requ i rem ents fo ro the r tex ti l e op e rat i ons, though l im i ts m ay have been p laced on emissions o f tox i c a i r po l l u tan tsf rom speci f ic fac i l i t ies th rou gh state a i r tox ics regu la t ions.

Tab le I I .2 -1 sum m ar izes sta te and loc a l requ i rem ents tha t im pact fabr ic coat ing .

Table II.2- 1 Sum m ary of State Regulatio ns for Fabric Coatin g

State/Locality

Operat ions

Covered

VOC Numer ica l L imi t

(min us w ater , includi ng

exempt solvent s)

Al ternate

Limi t /Compla ince O pt ion

A lab am a Prin ti n g o n V i n y lCoa ted fab r i c o rp r i n t i n g o n v i n y lsheets

0 . 4 5 kg / l (3 .8 lb /ga l )

A lab am a Fab ri c Co atin g 0 .3 5 k g/ l (2 .9 lb /ga l )

C al i fo rn i a Fab ri c Co atin g

Bay A rea Fab ri c Co atin g 0 .2 6 k g/ l (2 .2 l b /gal ) 0 .1 2 k g/ l (1 lb /ga l ) w i th aco n t r o l d e v i ce


11/85

Table II.2-1 (Continued)

State/Locality

Operat ions

Covered



exempt solvent s)

Al ternate



Bay A rea, c td . Fab ri c Co atin g Ru le p ro h i b i ts l i q u idleaks f romsto rage /mix ingcon ta ine rs & requ i resl i ds to be c losed excep tw hen m ater ia l i s be inga d d e d o r re mo v e d , wh e nthe tank o rcon ta ine r i s be ingcleaned

Cleanup so lvents andsolvent-soaked cleanuprags requi red to be k ept inc losed con taine rs

San Jo aq u i n Fab ri c Co atin g 0 .2 6 k g/ l (2 .2 l b /gal )( i nc lud ing any w ashpr im er used)

O R use a 90% e f fi c ien tco l l ec t i on system & a 95%ef fi c ien t con t ro l dev i ce

San Jo aq uin , c td . Fab ri c an d Pap erCoa t ing

Coa t ings m ust be app l i edus ing one o f thef o l l o w i n g : Fl o w Co a te r ;Ro l l Coa te r ; D ip Co a ter ;Foam Coa te r ; D ieCoa te r ; H andA p p l i cat i o n M e th o d s ;H i g h -V o l u m e L o wPressure (H V LP) Spray,fo r a i r d r i ed coa t ings

o n l y .

Evapor ative loss

minimizat ion: Conta ine rs& m i x i n g t an ks mu s t b eleak-f ree & covered ;c leanup m ate r ial has< 2 0 0 g/ l (1 .7 lb /ga l ) or< 4 5 m m ( 1.8 i n) H G v ap o rpressure or c leanup areato tal l y enc losed ;cleanin g/sur face prep

m ate r ial & c leanup ragssto red in c losed con ta ine rs

San D iego Pap er, Fi l m an dFabr i c Coa t ing

The co at ing con ta ins lessthan 0 .26 kg / l (2 .2 lb /ga l )as app l i ed O R mu st haveco m b i n e d co l l e c ti o n a n daba tem en t e f fi c i ency o fat least 90 % on a m assbasis a t a l l t im esdur in g the opera t i on .

Con ta ine rs & tanks m ust bef ree f rom l i qu id l eaks andm ust be covered .


12/85


State/Locality

Operat ions

Covered



exempt solvent s)

Al ternate



San D i ego , c td . Sal e o f th e fo l l o w in gproh i b i ted : any coa t ingo r c lean ing m ate r ia l thatw a s n e w l y f o r mu l a t edto con ta in o rre fo rm u la ted to i ncreasethe con ten t o f m e thy lenechlor ide, (CFC-11),(CFC-12 ), (CFC-11 3),(CFC-114 ) or (CFC-115 ).Content o f thesem ate r ial s m ust be show n

on labe l

C lean ing m ate r ia lrequ i remen ts :m u st c o n t ai n < 0 . 2 0 k g/ l(1 .7 l b /gal ) O Rparts to be cleaned m ustbe to tal l y enc lo sed du r in gw ash ing , r i n sing , anddra in i ng proc esses; O RClean ing so lven t m ust bet ransferred throu gha p p l i cat i o n e q u i p m e n tw i thou t exposure to a i r

i n to a v esse l w i th a t i gh tco ve r

G eo rg ia Fab ri c Co atin g 0 .3 5 k g/ l (2 .9 lb /gal ) BU T If an y co ati n gde l i ve red to the coa t ingapp l i ca to r con ta ins m orethan 0 .35 kg / l (2 .9 lb /ga l ),the so l i d s equ iv a len t l imi tsha l l be 0 .57 kg / l(4 .79 lb /ga l ) o f coa t ingso l i ds de l i ve red to thecoa t ing app l i ca to r .

I l l i n o i s Fab ri c Co atin g 0 .2 8 k g/ l (2 .3 lb /ga l )[af ter 3 /15 /96 ]

M assach u setts Fab ri c Co atin g 0 .5 8 k g/ l (4 .8 lb /ga l )

N o rth Caro l i n a Fab ri c Co atin g 0 .4 8 k g/ l (4 .0 l b /gal ) 0 .3 1 k g/ l (2 .6 lb /ga l ) i f a i rp o l l u t i o n co n t r o lequ ipm en t i s i nstal l ed

N ew Jersey Fab ri c Co atin g 0 .3 5 k g/ l (2 .9 lb /ga l )

N ew Yo rk Fab ri c Co atin g 0 .3 5 k g/ l (2 .9 lb /ga l )

So u th C aro l i n a Fab r i c o r p ap ercoa t ing

0 . 3 5 kg / l (2 .9 lb /gal ) sp ec i fi es w ay s to m eet th isl i m i t : 1 ) l o w so l ve n ttechno lo gy; 2 ) i nc ine rat i onw i t h 9 0 % d e st ru c t i o n ; 3 )ca rbon bed so lven trecovery ; 4 ) o the rsappro ved c ase by c ase.


13/85


State/Locality

Operat ions

Covered



exempt solvent s)

Al ternate



Ten n essee A p p l i es to co atin gl i n es b u t N O Tfabr i c p r in t i ngl i n e s

0 . 3 5 kg / l (2 .9 l b /gal ) al tern ati v e stan dard :Insta l la t ion of capture andco n t r o l d e v i ce w i t h 9 5 %dest ruc t i on O R a l te rna ti veca lcu la t i on m easuresp rescr ibed by regu lat i on

V i rgi n i a Pap er an d fab ri c 0 .3 5 k g/ l (2 .9 lb /ga l )


14/85


I I .3 IN D U STRY PRO FILE

The text i le industry supp l ies the la rgest non-durab le consumer product market in the country .The re a re mo re than 4 ,000 co m pan ies (m any o f w h ich a re p ri va tel y ow ned ) w i th ove r 5 ,000 p lan tsm aking prod ucts w i th m any d i f fe rent end-uses, rang ing f rom appare l to a i r bags to space su i ts . Thetex ti l e i ndus t ry has 2 .2 m i l l i on d i rec t em p loy ees (12 p e rcen t o f the U S w ork fo rce ) w i th 700 ,000 o fthese employed in the pr imary text i les segment . 1

I I .3.1 Basic Texti le M anufactur ing

The basic text i le manufactur ing industry (b road ly de f ined by product ion act iv i t ies ident i f ied in S ICm a jo r g roup 22 - Tex ti l e M i l l P roduc ts) i s a ma jo r and h igh l y d i ve rse com pon en t o f the USeconom y. The tex t i l e m i l l p rodu c ts g roup i nc lu des fac i l i t i es engaged in pe r fo rm ing any o ne o f thefo l lo w ing opera t ions: (1 ) p repara tion o f fiber and sub sequent m anufactur ing o f yarn , th reads,b ra ids, tw ine , and co rdage ; (2 ) m anu fac tu r i ng b roadw oven fab r i cs, na r row w oven fab r i cs, kn i tfabr ics, and carpets and rugs f rom yarn ; (3 ) dy e ing and f in ish ing f ib er , yarn , fabr ics, and kn i tappare l ; (4 ) coat ing , w aterproo f ing , o r o therw ise trea ting fabr ics; (5 ) the in tegra ted m anufactur ing

of kn i t appare l and o ther f in i shed ar t ic les f rom yarn ; and (6) the m anufacture o f fe l t goo ds, lacegood s, nonw ov en fabr ics, and m iscel laneou s text i les. 2 Al though there are text i le companies innear ly every Sta te, the Caro l in as and G eorg ia together accou nt fo r n ear ly ha l f the ind ustry se m p l o y m e n t . 3 The Inst i tu te o f Text i le Techn o lo gy ( ITT) 4 repor ts tha t the text i le ind ustry co nsists o f co m plexproduct mixes and tha t each fac i l i ty has un ique phys ica l /chemica l p roduct ion processes,m ach inery, raw m ater ia ls, and env i ron m enta l issues. As d isp layed in Tab le I I .3 -1 , the indu stryp roduces num erous end p rodu c ts. Tex t i l e equ ipm en t i s ve ry f l ex ib le and com pan ies o f ten have tom ake num erous and rap id ad justments to pro du ct l ines and changes to prop er t ies o f ex is tingprod ucts in respo nse to m arket cond i t ion s. Tab le I I .3 -2 d escr ibes the majo r SIC cod es tha tcon st i tu te the text i le ind ustry and descr ibes som e o f the pro duc ts and p rocesses tha t fal l u nd ereach.

Fo r the pu rpose o f background in fo rm a tion co l l ec t i on , tw o segm en ts o f the basi c tex t i l em anufactur ing ind ustry tha t have d ist inct characteris tics , use d i f fe rent term ino logy , o r p rodu ced is t inct end-produ cts, have been ident i f ied . These segm ents are carpets and rugs and po lym er iccoat ing o f sup po r t ing substrates. The fo l lo w ing sect ions prov id e mo re deta i led indu stry pro f i les o fthese segm ents.

II .3.1.1 Carpets and Rugs

A l thou gh the re was no t ve ry mu ch g row th i n the ca rpe t i ndust r y th rough the 1960 ' s, the re havesince been dram at ic increases in carpet p roduc t ion . Tota l carpet p rodu ct ion in the U S cur rent ly

reaches 1 .6 b i l l ion squ are yards annua l ly and represents a reta i l va lue o f abou t $15 b i l l ion .

7


15/85


Table II .3-1. Textile Product - End U ses

Appl icat ion Exam ple products

A p p arel C lo th in g (w o v en an d k n i ts), h o siery , b el ts

D efen se Sev eral p ro d u c ts, e.g., m ater i al fo r fl ags,

l igh tw e ight f ibers fo r a i rcra f t w ings, ten ts,parachutes, b u l l e t -p roo f v ests, h e lm ets.

Sp ace ex p lo rati o n Tex ti l e-b ased h eat sh ie ld s, sp ace su i ts

M edica l Ar t i f i c i a l a r te r ies and k id neys, band ages

Indu str ia l L iners fo r h igh w ays and reservo i rs , be l ts ,gaskets, ho ses, g lo ves

H i gh -tech u ses C o m m u n i cati o n s satel l i tes (fab r i cs i n p an el s,ci rcui t boards, receivers and senders), fabr icroofs , p r in ted c i rcu i t bo ards in co m puters and

o the r elec t ron i c equ ip m en t

A u to m ob i l es an d ai rp l an es Ti re co rd , u p h o l stery , ro o f l i n ers, h o ses

H o m e fu rn i sh in gs C arp ets, sh eets, to w el s, d rap er ies, u p h o lstery

O th ers Fi ref i gh ter u n i fo rm s, d en tal fl o ss, fo o dpackag ing, luggage, insu la t ion , and o ther uses

Source: Reference 5.


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[July 30, 199 8 D raft]I I-10

Table I I .3-2 Summ ary of Indu stry Sectors Constitu t ing Texti le M il l Product s

SIC and Ti t le D escr ip t ion Concent rat ion

2 2 1 1 -B r o a d wo ve nFabr i cs M i l l s ,

Co t ton

W e av i n g f ab r i cs m o r e t h an 1 2 i n ch e s i n w i d t h , ch i e fl y m a d ef rom co t ton (no ca rpe ts, t i re co rd , o r f i n i sh ing ) .

Leadin g States areN C, SC , GA , an dAL . Va lue o f

sh ipm en ts: 5 .8b i l l i o n .

2 2 2 1 , B r o ad w o ve nFabr i cs M i l l s ,M a n ma d e Fi b e rand Si lk

W e av i n g f ab r i cs m o r e th a n 1 2 i n ch e s i n w i d t h , ma i n l y m a d eof s i lk and manmade f ibers, includ ing g lass (no carpets, t i reco rd , o r f i n i sh ing ).

Leadin g States areSC, N C , GA , an dV A . V a l u e o fsh ipm en ts: $8 .8b i l l i o n .

2 2 3 1 , B r o ad w o ve nFabr i cs M i l l s ,W o o l

W e av i n g f ab r i cs m o r e th a n 1 2 i n ch e s i n w i d t h , ma i n l y m a d eo f w oo l , m oha i r , o r sim i la r an im a l fi be rs, dye ing andf in i sh ing o f al l w oven w oo l fab r i cs o r w oo l , tops, o r ya rn (nocarpets).

Leadin g States areV A , G A , M a in e ,a n d N C . V a l u e o fsh ipm en ts: $1 .6

b i l l i o n .2 2 4 1 , N a rr o wFabr i cs M i l l s

W eav ing o r b ra id ing o f n a r row fab r i cs (12 inches o r l ess) o fco t ton , w oo l , s i l k , and m anm ade fi be rs, i nc lud ing g lass.A lso fab r i c co ve red e last i c ya rn o r th read .

Leadin g States areN C, PA, RI , and SC.Va lue o f sh ipm en ts:$ 1 . 3 b i l l i o n .

2 2 5 1 - 5 2 ,Ho s i e r y *

H o si ery k n i t t i n g, d y ei n g, an d f i n i sh i n g Lead i n g State i sN C . V a l u e o fsh ipm en ts: $4 .3b i l l i o n .

2 2 5 3 - 5 9 K n i tgoods*

Kn i t t i ng , a l so dy e ing / f i n i sh ing w e f t/w arp kn i t fab r i cs andlace goods.

Leadin g States varyaccord ing to

speci f ic segment .

2261 , F in i sh ingPlants, Co t ton

F in i sh ing b roadw oven co t ton fab r i cs - i nc lu des chemica l /m echan ica l fi n i sh ing , and p r in t i ng . N o coa t ing , o r f i n i sh ingo f w o o l o r kn i t g o o d s.

Leadin g States areN C, SC , an d G A .Va lue o f sh ipm en ts:$ 2 . 6 b i l l i o n .

2262 , F in i sh ingP lan ts, M anm ade

F in i sh ing m anm ade fi be r and s i l k b roadw oven - i nc ludeschem ica l / m echan ica l f i n i sh in g , and p r in t i ng . N o coa ting ,o r f i n i sh i n g o f w o o l o r k n i t g o o d s.

Leadin g States areN C, SC, and N J.Va lue o f sh ipm en ts:$ 3 . 4 b i l l i o n .

2269 , F in i sh ingPlants, N .E.C.

D ye ing and f i n i sh ing , no t e l sew here c lassi f i ed . Exam p lesinc lu de b leach ing , dye ing , and f i n i sh ing o f raw s tock, ya rn ,

b ra ided good s, and na r row fab r i cs (no w oo l and kn i t s).

Leading State isN C . V a l u e o f

sh ipm en ts: $1 .1b i l l i o n .

2273, Carpets andRugs

M anu factu r ing w oven , tu f ted , and o the r ca rpe ts and rugsfrom text i les or o ther m ater ials such as tw isted pap er,grasses, jute, etc.

Leading State isG A . V a l u e o fsh ipm en ts: $9 .8b i l l i o n .


17/85


SIC and Ti t le D escr ip t ion Concent rat ion

[July 30, 199 8 D raft]I I-11

228 1 , YarnSp i n n i n g M i l l s

Sp inn ing ya rn made ch ie f l y f rom co t ton , manm ade fi be rs,si l k , w oo l , m oha i r , o r o the r sim i la r an im a l f i be rs. N o ya rn

dye in g o r f i n i sh ing .

Leadin g States areGA , NC , an d SC .

Va lue o f sh ipm en ts:$ 7 . 7 b i l l i o n .

2 2 8 2 , T h ro w i n ga n d W i n d i n g M i l l s

Textu r i z ing , th row ing , tw is ti ng , w in d ing , o r spoo l i ng ya rnso r m anm ade fi be r f i l amen ts - m ade ch ie f l y o f co t ton ,m anm ade fi be rs, si l k , w oo l , m oha i r , o r sim i la r an im a l fi be rs.N o d y e i n g o r f i n i sh i n g .

Leading State isN C . V a l u e o fsh ipm en ts: $2 .8b i l l i o n .

2 2 8 4 , T h re ad M i l l s M a n u fa ct u ri n g th r ead o f c o t to n , si l k , m a n m a d e fi b e rs, w o o l ,o r sim i la r an im a l f i be rs. N o f l ax , hemp , e tc .

Leading State isN C . V a l u e o fsh ipm en ts: $837m i l l i o n .

229 5 , Coa ted

Fabr i cs , N o tRubber i zed

Coa ted , im pregna ted , o r l ami na ted tex t i l es, and spec ia l

f i n i sh ing , such as va rn i sh ing o r w ax ing . N o dye ing o r( regular) f in ish in g.

Leadin g States are

M A an d O H . V a lu eo f sh ipm en ts: $1 .5b i l l i o n .

229 6 , T i re Cordand Fabr ics

M anu factu r ing co rd and fab r i cs fo r use in reen fo rc ing rubb ert i res, ind ustr ia l be l t ing, fue l ce l ls, and sim i lar uses.

Leadin g States areA L a n d GA . V a lu eo f sh ipm en ts: $981m i l l i o n .

2 2 9 7 , N o n w o v enFabr ics

M a n u f ac t u r i n g n o n w o ve n f a b r i cs b y m e ch an i ca l , th e r ma l , o rso l ven t m eans (o r com b ina t ions). N o fe l t s.

Leadin g States areN C a n d T N . V a l u eo f sh ipm en ts: $2 .9b i l l i o n .

2298 , Cordagea n d Tw i n e

Rope , cab le , co rdage , tw in e , and re la ted p rodu cts fromabaca, si sa l , henequen , hem p, co t ton , j u te , fl ax , m anm adef ibers inclu d in g g lass, and o ther f ibers.

Leadin g States areA L a n d NC . V a lu eo f sh ipm en ts:$ 6 7 2 . 7 m i l l i o n .

2299 , Text i l eG ood s, N .E.C.

Text i le good s, no t e lsew here classi f ied. Inclu des l in engoods, j u te goods, fel t goods, padd ing and uph o ls te ry f i l l i ng ,pro cessed w aste, and recovered f ibers and f lock . F iberp reparat i on ( fo r sp inn ing ) , i nc lu d ing w oo l ca rbon iz in g andscour in g - are also cov ered here.

Leadin g States areN Y , NC , a n d SC .Va lue o f sh ipm en ts:$ 1 . 8 b i l l i o n .

2 3 00 , A p p arel * A l l fac il it i es i n m a jo r gr ou p 23 are en gaged inm anu factu r ing d i f fe ren t t ypes o f app arel goo ds.

-

2 82 3 or 28 34 Fac il iti es p ri m ar i ly en gaged i n pro d uc in g an d tex tu ri zi ngm anm ade f i be r fi l amen ts and ya rns i n the same p lan t .

-

3 0 6 9 Ru b b er i z ed co atin gs ap p l i ed to fab r i cs.

* N o t t h e ac t u al t i tl eSou rce: Reference 6 .


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[July 30, 199 8 D raft]I I-12

Th is grow th came w i th the c rea ti on o f new m anmade f i be rs as w e l l as m odern techn iques fo rtu f t ing and co lo r app l ica t ion . The la rgest com panies are Shaw Indu str ies, M oh aw k Indu str ies,Beau l ieu Carpets, and Q ueen Carpets. U nt i l the 198 0 ' s, mo st carpet p rodu cers re l ied on chem ica lf iber com panies such as D uPont and M on santo or indep enden t yarn sp in ners, to ext rude the i r f iber .H ow eve r, today carpe t m i l l s p roduce ove r 80% o f the spun ya rns they need and ex t rude abou t35 % of the ind ustry s face f iber requ i rem ents. There are cur rent ly 2 55 carpet mi l ls in 23 Sta tes (9) ,bu t ov e r 74% o f a l l carpe t (177 m i l l s) i n the U S i s m anu fac tu red i n G eo rg ia, w i th the rem a inde rm anufactured in Ca l i fo rn i a and o th er Sta tes. 8 I t i s est im ated tha t 25 com panies in the ind ustryp roduce 94 % o f the na ti on s carpe ts and rugs; and the top 10 p roduce 75 % . 9

M ajor carpet m arkets inc lud e resident ia l , com m erc ia l , resident ia l con tract , transpo r t , and ou tdoo r(e,g , spo r ts a renas) . C lo se to 90 % of the m arket is con centra ted i n the res ident ia l , residen t ia lcon tract , and com m erc ia l app l ica t ion s. The types o f f ibers and techn iq ues used depend heavi ly onend -uses. Fo r examp le , l ow so i l i ng and easy c lean ing ny lon f i be rs dom ina te i n the com m erc ialm arket . The m ost im po r tan t face fibers used in the carpet ind ustry , in te rm s o f m arket share ,i nc lud e ny lon (62 .3% ), po l yp rop y lene (31 .5% ), po l yeste r (5 .8% ), and w oo l (0 .42% ). 10 Fibers suc has co t ton and acry l ic a re no t used in sign i f ic ant quant i t ies. Since p o ly prop ylene is the easiest f iber

to ext rude, i t has been the f iber o f cho ice fo r carpet com panies tha t do the i r ow n extrus ion ,a l though som e com pan ies have star ted ex t rud in g ny lo n as w e l l . 11

I I .3.1.2 Polymeric Coating of Substrates 12

Polym er ic coat ing i s a sub category o f w eb co at ing tha t encom passes coat ing o f severa l types o fsubstrates, inc lud ing n ot o n ly fabr ics, bu t a lso f lex ib le sub strates such as paper and m etal co i l ,w h ich are o ther sou rce ca tegor ies fo r w h ich M AC T standards are be ing deve lo ped. There are tw ogeneral categor ies of coated p rod uc ts. In the f i rst category , the coated sub strate takes on acom bin at ion o f p rop er t ies f rom both th e coat ing and the sub strate . Exam ples o f th is ca tegory o fcoa ted p roduc t i n c lude p o l yeste r fab r i c coa ted w i th v in y l fo r u se i n awn ings o r po l yeste r fab r i ccoated w i th synthet ic rubb er fo r use in f lex ib le hoses. The second general ca tegory co nsists o f

sub strates tha t a re coated w i th ep ox y o r ph eno l ic res ins, e .g ., f iberg lass fabr ic co ated w i thph eno l ics fo r use as m i l i ta ry fabr ic .

In 198 4 , the re w e re at l east 128 dom est i c p lan ts ow ned by 108 com pan ies tha t pe r fo rm edpo lym er ic coat ing . The d is tr ibu t ion o f p lan ts by Sta te is p resented in Tab le I I .3 -3 . Po lym er iccoa t i ng m ay be c lassi f i ed i n to tw o b road ca tego r ies, com m ission and cap t i ve (non -comm ission )coaters. The com m ission coater has m any cu stom ers and pro duc es coated sub strates accord in g toeach custom er 's speci f ica t ion s. The capt iv e coater p rodu ces coated substrate as an in term edia teproduct in a manufactur ing process.

I I .4 APPLICABILITY

The N ESH AP fo r Fab r i c P r in t i ng , Coat ing , and D ye ing ope ra ti ons w ou ld l i ke l y app ly to a l l ex i st i ng ,new , or reconstructed fac i l i t ies tha t a re a majo r sou rce o f H AP em ission s as def ined in the 1 990Clean A i r A c t Am endm en ts w i th tex t i l e p rocesses tha t emi t H AP m a te r ial . Figu re I I.4 -1 i s ad iagram o f the Fabr ic Pr in t ing , Coat ing , and D ye ing source ca tegory sho w ing text i le p ro cesses tha ta re know n to em i t HA Ps and po ten t i al l y cou ld b e cove red by the M ACT standa rd . Tex t i l eprocesses


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[July 30, 199 8 D raft]I I-13

Tab le I I.3 -3 . N um ber o f Plan ts tha t Ap p ly Po ly m er ic Coat ings to Supp or t ing Sub strate by Sta te

State N o. of Plants

A l a b a m aArkansas

Ca l i fo rn iaCo lo rado

Connec t i cu t

F lor idaGeorg ia

I l l i n o i sInd ianaKansas

M a ry l a n dM assach usetts

M i c h i g anM i n n e so t a

M ississipp iM issou r i

N e w H a m p s h i r eN ew Jersey

N e w Y o rk

N o r th C a r o l i n aO h i o

Pennsylvan iaRhod e Island

South Caro l ina

TennesseeTexas

V e r m o n tV i r g i n i a

W iscons in

T O T A L

12717

16321

11 8

21

1229

1 0

61 3278

53133

1 2 8

Sou rce: Reference 13


20/85

Basic TextileProcessing

DryProcessing

WetProcessing

Yarn and Thread

Formation

Woven orKnitted Fabric

Formation

NonwovenFabric

Formation

Carpet and Rug

Formation

Heat-Setting Slashing(Woven Fabric)

Bonding Heat-Sett ing

= Process Potentially Covered by Standard

Woven Fibers

and Woven orKnitted Fabric

Yarn and

Thread, Fabric,

Carpet andRug

Fabric, Carpet

and Rug

Cord, Thread,

Fabric, Carpetand Rug

Natural Fiber andFabric Preparation

Dyeing andFinishing

PrintingCoating and/or

Laminating

Figure II.4-1. Fabri c Prin ting, Coating, and Dy eing Sour ce Category

II-1

4


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[July 30, 199 8 D raft]I I-15

that em i t H APs bu t are sub ject to the requ i rem ents o f o ther M AC T standards; and th ere fore , w i l lno t be covered under the Fabr ic Pr in t ing , Coat ing , and Dye ing source ca tegory inc lude f lamelam inat ion , t i re cord co at ing , p rocessing o f f iberg lass text i le substra tes, and p rodu ct ion o fnon w oven fab r i cs fo r roo f i ng .

The Fabr ic Pr in t ing , Coat ing , and D ye ing source ca tegory has a potent ia l over lap w i th the Paperand O the r W eb Coa t ing sou rce ca tego ry i n the p roduc t i on o f l am i na tes consi st i ng o f fab r i c andpaper and in pr in t ing . The deve lop m ent o f these standards is be ing coo rd ina ted to ensureconsis ten t requ i rements cover ing HAP emiss ions f rom the laminat ion o f paper and fabr ic and f rompr in t i ng .

I I .5 PRO CESS D ESCRIPTION S AN D CURREN T IND U STRY PRACTICES

The characteriza t ion o f text i le m anufactur ing is com plex b ecause o f the w ide var ie ty o f sub stra tes,proc esses, com pon ents used, and f in ish ing steps un der taken. D i f fe rent types o f f ibers or yarns,method o f fabr ic construct ion , and f in ish ing opera t ions ( inc lud ing prepara t ion , p r in t ing , dye ing,chem ica l /m echan ical f i n i sh ing , and coa t i ng ), a l l i n te rre late i n p rodu c ing a f i n i shed fab r i c . W hen

on e o f these com po nents is changed, the prop er t ies o f the end pro du ct are af fected. There aresevera l p roper t ies tha t can be used to d e f ine a fabr ic and one o r m ore o f a fabr ic s inherentprop er t ies m ay be mo di f ied d ur in g processing to g ive i t the des i red end ch aracter ist ics. Som eexam ples o f fabr ic p roper t ies inc lud e w e ight , appearance, texture , st rength , luster , flex ib i l i ty , andaf fin i ty to d yestu f f . 14

F igure I I.5 -1 is a general iz ed f low d iagram d ep ic t in g the var iou s text i le p roc esses tha t a re inv o lv edin co nv er t ing raw m ater ia l to fin i shed pro du ct . A l l o f these processes do n ot necessar i ly occu r in asing le fac i l i ty , a l tho ugh there are som e in tegra ted m i l ls . There are also severa l n ich e areas andspecia l iz ed prod ucts tha t a re deve lop ed in the text i le in du stry (see Tab le I I .3 -1) w h ich m ay enta i lthe use o f specia l p rocessing s teps tha t are not show n i n F igure I I .5 -1 . In genera l , m ost d ry pro cesssteps, dep i c ted in F igure I I .5 -1 , a re not s ign i f icant sources o f H AP em ission s.

The text i le ind ustry has t rad i t io na l ly fo cused m ore on w ater -re la ted env i ronm enta l issues and a i rissues o f in te rest have pr im ar i ly been re la ted to op aci ty (con densed hyd rocarbon s) . To tha t end,m os t o f the ai r po l l u t i on co n t ro l equ ip m en t be ing used today i n the tex t i l e i ndus t ry h as beeninstal led so le ly to reduce v is ib le emi ssion s. H ow ever , the indu stry recogn izes tha t the chem ica lcom posi t ion s o f the i r d i verse raw m ater ia ls is an im po r tan t issue du e to i ts re la tion to a i r em ission sof hazardous ai r po l l u tan ts (H APs) and vo l a t i le o rgan ic com po un ds (VO Cs). The m ajor sou rces o fH AP em ission s f rom text i le p rocesses con sis t o f op erat ion s tha t inc lu de dry i ng , cur in g , o r heat-se t t ing steps. In genera l , the types o f co ntro ls repor ted to be u sed in text i le fac i l i t ies to con tro lv is ib le em ission s or V O Cs inc lu de ven tur i scrubbers, inc in erators / a f te rburn ers, fabr ic f i l te rs /dem isters, and e lect rosta tic p rec ip i ta tors. 1 6 In s takeho lder m eet ings, in du stry representa t ives have

stressed th a t they p re fer red substi tu t io ns / p roc ess mo di f ica t ion s as a w ay to con tro l a i r em ission s,as com pared w i th end-o f-p ip e add-on co ntro ls .

The fo l lo w ing sect ions descr ibe the var ious text i le p rocesses inv o lv ed in the prod uct io n o f text i lem i l l p rod ucts , inc l ud ing those tha t do no t em i t sign i f icant H APs. The process in fo rm at ion is takenf rom tex t i l e pub l i ca t i ons, w h i l e an im po r tan t sou rce o f emissions i n fo rma t ion i s the ATM I M ACTsurvey 17 tha t w as con du cted in Spr ing , 199 7. Each process descr ip t io n inc lu des in fo rm at ion on the


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[July 30, 199 8 D raft]I I-17

equ ipment and chemica ls used, sources o f HAP emiss ions, po l lu t ion prevent ion (P2) op t ions, andtypes o f contro ls cur rent ly i n use. Carpet m anufactur ing s teps are descr ibed separate ly in th esesect ions, p r im ar i ly b ecause separate segmen ts o f the text i le in du stry car ry ou t these proc esses. A l lp roc esses tha t po tent ia l ly a re H AP em ission sou rces are f lagged as such in the section head in gs.

I I .5 .1 Basi c T ex t i le Manu fac tu re

In bas ic text i le m anufacture , raw natura l o r m anufactured (manm ade) f ibers are processed tom anufacture fin i shed fabr ic . As sho w n in F igure I I.5 -1 , text i le opera t ions can be bro ad ly c lassi f iedin to d ry p ro cessing and w et p rocessing . 18 I t shou ld be no ted that d r y and w e t can bem is lead in g te rms since som e dry p rocesses l ike s lash in g are actua l ly w et and som e f in ish ing ( w et )p roc esses are actua l ly d ry . D ry processing pr im ar i ly inc l udes mech an ica l p rocesses, the m ajor i tyo f w h ich do n o t have sign i f i can t H AP emissions , w i th the excep t i ons o f slash ing and n onw ovenfabr ic p roduc t ion . D ry p rocessing inc lu des tw o m ain stages o f p rocessing ; yarn prod uct io n andfab r i c p rodu c t i on . W e t p rocessing , w h ich i nc lud es p repa ra ti on , dy e ing , and f i n i sh ing , i s acom bin at ion o f chem ica l and m echan ica l p roc esses, has var iou s po tent ia l sources o f H APem ission s. W et p rocessing inc lud es tw o m ain stages o f p rocessing ; fabr ic p reparat ion and fabr ic

f i n i sh ing .

I I .5.1.1 D ry Processing

Since m ost d ry pro cessing s teps are not s ign i f icant co ntr ibu tors to H AP em ission s, they are dea l tw i th on ly br ie f ly in th i s chapter . As has been no ted before , the on ly w et p roc esses tha t fa l l w i th inthe broad stage o f d ry processing are slash in g and n on w oven fabr ic p rod uct io n (chemi ca l bond ing) .These proc esses po tent ia l ly resu l t in H AP em ission s and are descr ibed in greater de ta i l . Thedescr ip t i on o f d ry p rocessing w i l l i n c lude m i l l s i nvo l ved i n ya rn m anu fac tu re , yarn tex tu r i ng /hea t-se t t ing , and u nf in ished fabr ic m anufacture .

F igure I I.5 -2 is a schem at ic sho w ing typ ica l p ro cess steps in a dry proc essing m i l l , a lon g w i th

in fo rm at ion on p otent ia l sou rces o f H AP em ission s. The speci f ic na ture and sequen ce o f theseop erat ions w i l l depen d upo n the sub strates be ing processed and the des i red end prod uct . Tw ogeneral ca tegor ies o f f iber used in the text i le in du stry inc l ud e natura l (e .g ., co t ton and w oo l ) andm anm ade, w h ich inc lud es ce l lu l os ic (e .g ., rayo n and acetate), and synthet ic (e.g . , po lyester andny lon ) .

The f i rs t p rocess op erat ion is to prepare (manm ade f ibers) o r m anufacture (na tura l f ib ers) the f iber ,a f te r w h ich th e yarn m ay be spu n. The next few steps depend o n the requ i rem ents o f the endprod uct . I f the fabr ic is to be w ov en, a pro tect iv e coat ing cal led a size is f i rst app l ied to w arp yarnsin a pro cess te rmed as slash in g. I t sho u ld be no ted tha t yarn or th read m ay a lso b e dyed b eforebe ing w oven o r kn i t ted i n to fab r i c . Som e fab r i cs a re a l so m anu fac tu red us ing nonw oven

proc esses, w h ich co u ld h ave associa ted H AP emission s. O ther anc i l la ry opera tion s inc lud e thosesuch as fab r i c i nspec ti on and spo t c lean ing , w h ich m ay a l so be do ne fo l l ow ing f i n i sh ing . Theseop erat ion s are descr ibed in Sect ion I I .5 .1 .3 fo l lo w ing a l l the pro cess descrip t io ns sinc e they arel ik e ly to be s imi la r regard less o f the stage in w h ich they are per fo rm ed.


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RawCotton

Opening andPicking

Carding andSpinning

CottonYarn

Slashing(Sizing)

Weaving

PureCottonWoven

Fabrics

Size MixKitchen

KnittingKnit

Fabric

PolyesterStock

BlendCarding and

SpinningBlended

YarnSlashing(Sizing)

Weaving

Cotton-PolyesterWoven

Fabrics

LW

H

AP

H

AP

LW

H

AP

LW

H

AP

LW

To WovenFabric Finishing

To Yarn Dyeing

and Finishing

To Knit FabricFinishing

To WovenFabric Finishing

To Yarn Dyeing

and Finishing

= Potentially Containing HAP

= Potential HAP

Source: Reference 19

Figure II.5-2. D ry Processing Mil l

II-1

8


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[July 30, 199 8 D raft]I I-19

I I .5.1.1.1 N atural Fiber Preparation.

N atural f ibers requ i re severa l steps to op en and c lean the f ibers to prepare them for yarnm anufactur ing . The f i rst step , term ed as open ing and b l end in g, is typ ic a l ly to take the natura lf ibers f rom com pressed ba les and sor t and c lean them to rem ove d i r t and im pu r i t ies. The nextsevera l steps are aim ed a t teasing o ut the f ibers, lengthen i ng them , and a l ign in g them in to th inpara l le l sheets, w i th each successive s tep resu l t in g in a f iner p ro du ct . These steps are card ing ,com b ing , d raw ing , and d raf t i ng ; a l l o f w h ich p repare the f i be r fo r sp inn ing . D i f feren t types o ff i be rs m ay be b lended ( comb ined ) du r ing d raw ing o r fo l l ow ing d ra ft i ng . A f te r d raf t i ng , the ya rn i sw ound on to ro ta t i ng sp ind les, w h ich a re m oun ted o n to sp inn ing f rames, w he re they a re se t fo rsp inn ing . 20 These steps w i l l v ary accord in g to the f iber be ing p rocessed and the d esi red end -p roduc t .

In w oo len and w orsted system s, the fiber lengths range from 2 .5 to 9 i nch es (as opp osed to under2 .5 in ches in sho r t stap le spun yarn) and the yarns have a fuz z ier appearance. In proc essing w oo l ,som e type o f ac id t r eatmen t o r scou r ing may be requ i red to remov e im pu r i t i es. Such ch emi ca lt reatm ents cou ld be sou rces o f H AP emission s. O ther w orsted system s m ay requ i re chem ica l

c lean ing as we l l , w h ich w ou ld typ i ca l l y en ta i l use o f a soap o r a l ka l i , w h ich i s fu r the r neu t ra l i zedw i th an ac id b e fo re fi na l r i ns ing. 21

I I .5.1.1.2 M anmade Fiber and Yarn M anufacture.

M anm ade f ibers do n ot need to go th rou gh the same c lean in g and f iber p reparat ion s teps tha tnatura l fibers und ergo. The m anm ade fibers can be m anufactured by th ree d i f ferent metho ds, eacho f w h ich i n vo l ves fo rc ing a l i qu id th rough a sm a l l open ing , w he re the l i qu id so l i d i f i es to fo rm acon t i nuo us fi l amen t . These m e thod s a re m e l t sp inn ing , d ry sp inn ing , and w e t sp inn ing , and eachis used to produ ce d i f fe rent types o f m anm ade f ibers. M el t sp in n in g requ i res no ch em ica l react ionsand no so lv ent recovery system and is typ i ca l ly used to m anufacture ny lo n , po lyester , o le f in , andg lass. D ry sp in n in g is used to produ ce acry l ic , aceta te, t r iace tate , spand ex, and aram id . I t uses a

so lv ent tha t evapora tes, bu t is general ly reco vered fo r reuse. W et sp in n in g a lso m akes use o f aso l ven t and i s used to p roduce rayon , ac ry l i c , and m odacry l i c . 2 2 W et sp inn ing requ i res w ash ing torem ove im pu r i t ies and so lvent and ch em ica ls are recovered a f ter use. 23

M anm ade f ibers m ay a lso be b l ended w i th na tura l f ibers (as descr ibed in the abov e sect ion) o r m aybe produced in lengths tha t make i t su i tab le fo r p rocess ing on woo l o r co t ton-system mach inery. 2 4 A l thou gh m anmade f i be r p roduc t i on cou ld resu l t i n H AP emissions , these w ou ld b e cove red un de rseparate sourc e categor i es.

II .5.1.1.3 Texturi ng and H eat-Setti ng (Potenti al HA P emission s).

Af te r sp inn ing , the manm ade f i be rs are d raw n to a l i gn and o r i en t the po l ym er mo lecu les andst reng then the fi l amen t . Th i s m ay be fo l l ow ed by tex tu r i ng . 25 Textur ing is a process o f cr im p in g,im po r t i ng random loop s, o r o the rw ise mod i fy ing con t i nuo us fi l amen t ya rn to i nc rease cove r ,resi l ienc e, abrasion resis tance, w armth , in su la t ion , o r m ois ture absorp t ion , o r to pro v id e a d i f fe rentsurface texture. 26 Textur ing bas ica l ly invo lves deforming the f i laments (such as by impar t ing atw ist ) w i th a mech an ica l p rocess to g ive m anm ade f ibers spu n- l ike prop er t ies, af te r w h ic h thedeform at ion i s se t , usua l ly by a heat-se t t ing proc ess (the deform at ion i s no t a lw ays heat-se t). H eat-


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[July 30, 199 8 D raft]I I-20

set t ing is typ ica l ly done on ly fo r syn thet ics , does not invo lve app l ica t ion o f any chemica ls , and canbe don e on a sem i-contact oven or ten ter f ram e. In false-tw is t textur ing , the deform at ion is fu r therr e m o v e d . 2 7

H eat-se t t ing invo lves app ly in g h igh tem pera tures (350 - 400EF) to co nfer d im ensiona l stab i l i ty tothe syn thet ic fabr ics, o r b lend s (e .g ., po ly-co t ton ) con ta in ing therm op last ic f ibers. O ne funct io n o fheat-sett ing is to preven t creasin g du r in g pro cessin g. 28 N o chem ica l s a re app l i ed ; ho w eve r, theh igh tem pera ture requ i red fo r heat-se t t ing w i l l vo la t i l i ze sp in f in ishes tha t may have been app l i edto the fibers, som e o f w h ich m ay conta in H APs. F iber is heated in a sem i-contact oven o r ten terf ram e und er tens ion abo ve i ts g lass t rans i t ion tem pera ture and he ld fo r a per iod o f t im e. 29 I t i styp ic a l ly used on po lyester , ny lon , and t r iace ta te , and n ot on rayo n, co t ton , and acry l i cs . 3 0

H eat-se t t ing is also used fo r s tab i l i za t ion o f carpet yarns by exp osure to heat , p r io r to th e tu f t ingp rocess, o r p r i o r to b ind e r o r resin app l i ca t i on i n n onw oven ca rpe t m anu fac tu re. N o t a l l ya rn i sheat se t (just cu t p i le ) . The pr in c ipa l b enef i ts o f heat-se t t ing are tw is t re ten t ion i n p l ied y arns in c u tp i l e carpet and general stab i l i za t ion o f yarn con f igura t ion . There are 3 heat-se t t ing metho ds fo rcarpets, classi f ied by type of equipment used; Superba, autoclave, and Suessen (see Figure II .5-3).

Sup erba and Suessen systems are cont in uou s opera tion s and the autoc lave m ethod is a ba tchproc ess tha t is no lo nger com m on . In ba tch process heat-se t t ing in conv ent ion a l au toc l aves, yarnsare f i rst t rea ted in a tum bler con ta in ing c i rcu la ted l i ve s team at a round 14 0EF for a round 5 minutes.Ske ins can w e igh from 7 to 10 pou nds w i th a c i r cumfe rence o f app rox im a te l y 96 i nches. Theske ins are then loaded onto a m etal b asket and ro l led in to an autoc lave, a la rge pressure vesse lautom at ical ly p rogram m ed for a desi red heat and tw is t se t t ing cyc le ( tem pera tures rang ing f rom240 - 300EF). 31 ,32

In b o th Suessen and Sup erba system s, yarn to yarn s t rands are tw is ted in to o ne s t rand p r io r to theope ra ti on . Supe rba m ach ines cons i st o f tw o u n i ts, each o f w h ich can p rocess 6 to 24 co n t i nuou syarn ends. Yarn feed rates are abou t 1230 fee t per m inu te . Tw isted yarn is loo se ly co i l ed in to a

per fora ted p last ic o r s tain l ess stee l conv eyor b e l t w h ich passes th rou gh an enc l osed low pressuresteam bath , a prebu l ker , w h ich bu lks the yarn pr io r to i ts passage th rou gh the Superba.Tem pera tures in th e centra l zone o f the Superba are abo ut 26 0-280EF w i th p ressures o fapp rox im a te l y 55 ps i . D w e l l t ime ranges f rom on e to tw o m inu tes, and no steam i s i n t roduced inthe core cham ber (d ry heat). A f te r be ing heat-se t the yarn is coo led and w ou nd . 3 3

Suessen system s con sist of six heat-set tunn els each o f w hi ch av erages a yarn feed rate of 21 00 to280 0 fee t pe r m inu te . A i r op e rated i n jec to rs gu ide ya rn ends f rom tw iste r bob b ins to on e o f si xrope con veyo rs. The yarn is w oun d around the con veyor rop es w h ich p ass th rou gh the heat-se tchamb er , wh e re i t can co n tac t d ry heat (383 EF), saturated steam (212 EF), o r superh eated steam(356EF), depend i ng on p reset chamb er cond i t ion s. Ac tua l heat-se t t ing cond i t ion s are usua l ly

be tw een 284 - 384E

F, w i th the ya rn dw e l l tim e rang ing f rom on e to tw o m inu tes. A f te r hea t-se t t ing , yarn is w ou nd o nto co nes, packaged, and sent to the carpet m i l l . 3 4

Fiber prod uct io n and yarn p rocessing steps add severa l chem ica ls to f ibers (t in ts and f in ishes) tom ake the f ibers easier to pro cess. H eat-sett ing in Superb a or Suessen system s co ul d cause thesechem ica ls to be re leased in the fo rm o f H APs or v is ib le em ission s. Sp in f in ishes are typ ic a l ly o i l sor em uls ions app l ied to f ibers to g ive them coh esion and lu br ic i ty ch aracter ist ics. These cou ld


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Carpet

YarnCoiler

Heat Expansion

or Heat-SetChamber

Heat-Set

CarpetYarn

HAP = Potential HAP Air Emission

HAP

Figure II.5-3. Suessen Carpet Yarn H eat-Sett ing

II-2

1


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[July 30, 199 8 D raft]I I-22

con ta in hazardous ingred ients, al tho ugh co nst i tuents are o f ten prop r ie tary . For exam ple , EzSpinm anu fac tu red by W aco Chem ica l con ta ins t race quan t i t i es o f ethy lene ox id e . T in ts a re fug i t i ve(i .e . , no t perm anent), b io degradab le , co lo red chem ica ls m ixed w i th f in ishes and app l ied to f iber toa id in f iber iden t i f i ca t ion . O ther sou rces tha t cou ld have hazardous ingred ients inc l ude var ioustypes o f equ ip m ent and oven c leaners ( residu a ls m ay be emi t ted) . C lean in g opera t ions can beda i l y , w eek ly , o r qua r te r l y . The p r im ary con st i tuen ts o f the f i be rs themse lves cou ld be H APsou rces. Fo r examp le , ny lon 6 i s fo rmed by p o l ym er i z ing cap ro lac tam (no l on ge r a HA P), w h ich i sem i t ted dur in g Suessen heat-se t t ing o f ny lo n 6 y arns. Po lyester fibers can con ta in d im ethy lte rephtha la te (no t a H AP) and e thy lene g lyco l (a H AP) . 35

H AP emissions: H eat-se t t ing opera t ions have the potent ia l to resu l t in o r contr ib u te to majo r H APemiss ions. 36 H eat-se t t ing emi ssion s inc lud e m ethano l , fo rm aldehyd e, and g ly co l e thers (g reaterthan 1 TPY) and sm al le r quant i t ies o f o ther em ission s.

In an a i r em ission assessm ent study con du cted a t a text i le f in ish ing p l an t , 37 no em issions w e reest im a ted by m ass ba lance , g i ven that no chem ica l s w e re added a t the tex ti l e p lan t . H ow eve r ,stack m easurem ents f rom the po l y /co t ton heat-se t range inc l ud ed em ission s o f V O Cs,

fo rma ldehyd e , and g l yco l e the rs and g l yco l s. O n ly the V O Cs were m easu red a t g rea te r than 1TPY. Sou rce test ing w as per fo rm ed on the m ain s tack o f 6 Suessen heat-se t tunne ls and on on eautoc lave a t a carpet fiber p rocessing fac i l i ty in G eorg ia . 3 8 The m easured autoc lave em ission s(inc lud ing fo rm a ldehyde and ace ta ldehyde ) w e re on the o rde r o f m agn i tude o f p ound s pe r yea r.The Suessen em ission s w ere est im ated as 34.7 ton s per year o f V O C u sing the h ighest con versionfac to r o f targeted com poun ds to con ve r t fr om pou nds o f carbon m easu red to pou nds o f VO C.Prev io us stud ies o f VO C em ission s f rom heat-se t t ing carpet f iber have sho w n the V O C em ission s tobe app rox im a te l y 50 pe rcen t cap ro lac tam . Spec ia ti on o f the emissions i den t i f i ed fo rm a ldehydeand acetaldeh yde; the em ission s o f these H APs w ere not quant i f ied .

Ac cord ing to an in i t ia l assessm ent o f em ission s from heat-se t t ing carpet yarn , 39 unde r no rma lop erat ing con d i t io ns, tem pera ture o f heat-se t t ing m ach ines is no t sign i f icant eno ugh to cause f iber

degradation . The prop r ie tary na ture o f m any o f the chem ica ls app l ied to f ibers a lso m akespred ic t ing potent ia l H AP em ission s d i f f i cu l t . Sup erba op erat ing cond i t ion s are no t l i k e ly to besubstant ia l eno ugh to cause f in ish m ater ia ls to vo la t i l i ze , o r fo r yarn f ib ers to degrade. Em ission sgenerated f rom Superb a opera tion s are be l ieved to be s team f rom prebu lk o pera t ions. 4 0 O n th eother h and, Suessen co nd i t ion s are sub stant ia l ly d i f fe rent , w i th tem pera tures be ing s ign i f icant lyh igh er , possib l y app roach in g g lass transi t ion temp eratures, thus creating th e po tent ia l fo r f iberdegradat ion .

Cont ro l O pt ions: A p r im ary con t ro l op t i on i s the use o f sp in f i n i shes tha t do no t con tain H APs.M ost fac i l i t ies are no t us ing any add-on co ntro ls fo r heat-se t t ing , al thou gh a sm al l num ber o ffaci l i t ies use incinerators/afterburners. 4 1 Emissions from heat-sett ing carpet yarn are general ly

un con tro l led . There is som e use o f cond ensers or absorbers to contro l PM and V O C contr ibu t ingto v is ib le em ission s. 4 2

II .5.1.1.4 Yarn and Thread Spinn ing.

Yarns are classi f ied ei th er as spu n yarn s or f i l am ent yarn s. Spu n yarn s use staple ( f in i te) lengthnatura l o r manm ade fibers com bin ed to produ ce a yarn w i th h igh s t rength and st ructura l in tegr i ty


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[July 30, 199 8 D raft]I I-24

then w oun d on to a l arge cy l i nde r ca l l ed a w a rp beam. W arp ya rns (i n add i t i on to o the rprepara tion requ i rem ents) need to sustain the i r e lon gation and f lex ib i l i ty du r ing the w eavingproc ess. Kn i t t in g yarns or f i l l ing yarns used in w eaving, do not have th is requ i rem ent . Th isrequ i rem ent necessi ta tes a process ca l led s lash in g or siz i ng , w h ich is the app l ica t ion o f a chem ica lsiz i ng so lu t ion to w arp yarns pr io r to w eaving to pro tect them against snagg ing or abrasion tha tcou ld occ ur dur in g w eaving. F igure I I .5 -4 is a schem at ic o f a typ i ca l slash in g range, ind ica t ingpo tent ia l sou rces o f H AP em ission s. Slash in g is necessary as lon g as the w arp is in tens ion ; toe l im inate the need fo r s lash in g, there have been som e e f fo r ts to deve lo p w eaving proc esses w i thless tension , 49 a l though these processes are l i ke ly to b e m uch slow er .

The o b ject iv es o f s lash in g are to st rengthen, sm oo th the o uter sur face, and lub r ica te the yarn . 50 The chem ica l na ture o f the size app l i ed is depen dent on the yarn sub strate and th e type o f w eavingbe in g used. The th ree m ain types o f size cu r rent ly used are natura l p rodu cts (sta rch) , fu l lysynth et ic p ro du cts (e .g ., PVA ), and sem isynthet ic b lend s (e .g ., m od i f ied s tarches andcarbox ym ethy l ce l lu l ose or CM C). In add i t ion to these, aux i l i a ry chem ica ls (lub r icants, adhesives,add i t iv es, e tc . ) and w ater o r a so lv ent are o f ten added. PVA can b e app l ied in p ure fo rm (w i thadd i t iv es) o r b lended w i th n a tural substances, such as starch . 5 1

The s iz ing o pera t ion is don e on a la rge range cal led a s lasher us ing pad/dry techn iq ues. 52 Th eslasher con ta ins d i f fe rent sect ions tha t take up yarn f rom the w arp beam and p ass i t th rou gh a sizebo x tha t conta ins the aqueou s siz in g so lu t ion . Squ eeze ro l ls remo ve excess so lu t ion and the yarnthen passes th rou gh a d ry in g un i t tha t usua l ly con sis ts o f steam -heated cans (dry i ng cy l in ders) o r anoven . A f te r be ing d r i ed , the wa rp th reads are sepa ra ted and w rapped on a l oom beam to fo rm asheet to f i t the w id th o f the loo m . At on e fac i l i ty , the size m ixture is coo ked in a separate roomand pipes transfer size solut ion to size boxes in slashers. 53 N ew s i z ing techno log ies i nc lud e h igh -pressure squ eezing, ho t m el t siz in g , and fo am s iz in g . 5 4

H AP emissions: The pr im ary sou rce o f a i r tox i cs f rom slash in g is m ethano l f rom PVA s ize ,typ i ca l ly app l ied to synthet ics (a l thou gh i t adheres to na tura l f ibers as w e l l ) . Tox ic add i t iv es are

l ike ly to be m ino r contr ibu tors to H AP emission s. The m ethano l em ission s can ar ise e i ther fromthe size co oki ng op erat ion and/or f rom the slash in g or siz in g process - the d is t ribu t ion i s un c lear ,a l though i t w i l l depend upo n the tempera tu re at w h ich the s i ze i s cook ed , the cook ing t im e , andho w o f ten conta iners (coo kers) a re open ed. O ne fac i l i ty do ing siz in g contends tha t m ost o f themethano l emiss ions are l i ke ly to be emi t ted dur ing the s ize cooking s tep . 55 There a re no H APem ission s f rom desiz i ng opera t ions or w hen recyc led PV A is used, since a t tha t po in t the m ethano lhas al ready b een f lashed o f f .

Contro l opt ions: A c c o r d i n g to t h e A T M I M A C T su r v e y , 5 6 no add-on a i r emi ssion con tro ls a rebe in g used fo r PVA and PVA m ix slash in g opera tion s. A very smal l nu m ber o f fac i l i t ies repor teduse o f fabr ic f i l te rs fo r o ther (non PVA) slash in g opera t ions. The feasib i l i ty o f o ther con tro l

techno log ies has not ye t been determined.

There are severa l factors tha t af fect the requ i red s ize add -on (and w et p ick up ) and these inc lud echaracter ist ics o f the yarn , nu m ber o f ends and tension o f w arp , squ eeze ro l l con tro l andcond i t i ons , residence t im e o f ya rn i n the si ze bo x , and v i scosi t y o f the m ix . 57 H o w e v er , t h e m a inP2 op t i on fo r reduc ing H AP emissions i s to reduce m e thano l con ten t i n the PVA . ATM I mem bersrepo r t that PVA w i th gua ran teed m e thano l con ten ts l ess than 1% i s now avai l ab le f r om la rge PVA


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Warp

YarnSize Box Drying Cylinders

Sized

Warp Yarn

HAP

LW

= Potential HAP Air Emission

= Liquid Waste Potentially Containing HAP

Size Mix Kitchen

HAP

HAP

HAP

LW

LW

Figure II.5-4. Typical Slashing Range

II-2

5


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[July 30, 199 8 D raft]I I-26

vendo rs w i thou t any p remium app l i ed to the p r i ce . M os t o f the PVA supp l i ed by these vendo rscon ta ins less than 0 .5% m ethano l . Buy ers can request cert i f i ca tes ver i fy in g methano l con tentsf rom a t l east one vendo r . O the r qua l i ty con t ro l m e thods tha t can be a imed a t reduc in g quan t i t i eso f size used inc lu de prepar ing co r rect qu ant i t ies o f size , p rop er se lect ion o f size m ix, sched u l in gruns, e l im inat ing un necessary add i t ives, and avo id i ng leaks and sp i l l s .

D ur in g desiz in g opera t ions, PVA can som et im es be recovered fo r reuse (such as by u singm em brane f i l t ra tion ), a l though th is is easiest in in tegra ted m i l ls w here both s iz in g and d esiz i ngop erat ion s take p lace (so tha t the recovered PVA do es no t need to be sh ipp ed to anoth er fac i l i ty )and is no t feasib l e w hen s ize b len ds are used. H ow ever , the PVA recovery pro cedure is a lsoexpensive and no t econo m ica l ly feasib le fo r sm al l vo lum e op erat ion s. There is no t eno ughin fo rm at ion o n o ther po ssib l e sub st i tu t ion s (since s ize m ixes ach iev e speci f ic resu l ts), a l thoughnatura l p rod ucts such as starch cann ot be app l ied to synthet ic yarns. In fact syn thet ic sizes arerecomm ended fo r use because na tu ral m a te r i al s cause w a te r po l l u t i on (BO D /CO D ) p rob lems. 58

I I .5.1.1.7 W eaving.

W eav ing i s a d ry ope rat i on , bu t i s no rm a l l y done i n bu i l d ings ma in tained a t h igh hu m id i t y toinc rease f l ex ib i l i t y o f the y a rn and m in im ize b reakage . 5 9 W eav ing i s pe r fo rm ed on d i f feren t typesof loo m s, w h ich vary in speed and m ethod s used to t ranspor t f i l l yarns. The w arp yarns arear ranged so tha t they run lengthw ise and the f i l l y arns run crossw ise (a t r igh t ang les to w arpthreads) , so tha t these tw o yarns can be in ter laced to im par t a w eave to the fabr ic . The w arp yarnsare w ou nd on to la rge meta l cy l in ders ca l led beam s and these are the yarns tha t norm al ly passthrou gh a siz in g so lu t ion (see Sect ion I I .5 .1 .1 .6 on slash in g). The f i l l y arn is t ranspor ted e i ther by ashu t t le o r by shu t t le less metho ds, such as us ing h i gh-speed j e ts o f w ater , a i r , o r p ro ject i les. 6 0

Both natura l and m anm ade f ibers (o r b len ds) can be w oven . A l so re levant in w oven fabr ic designare con sidera t ions l i ke the type o f y arn , fabr ic co nstruct ion and d esign requ i red . 6 1 Carpets are alsow oven (1 .7% of m arket share) us ing the sam e basic pr in c ip l es as in fabr ic w eaving, a l though th ere

are var ia t ions in m ethod s (such as to m anufacture ve lve t carpets) and equ i pm ent used. W ovenca rpe t o f ten h as a backcoa ti ng o f l a tex o r a resinous com poun d to im p rove tu f t b ind and hand .See Sect ion I I .5 .1 .2 .8 fo r more in format ion on backcoat ing .

I I .5.1.1.8 Knit t ing.

In kn i t t ing , fabr ic is fo rmed by in ter lock ing or in te rmesh ing loops o f one or more se ts o f yarns.Kn i t t in g is per fo rm ed us ing one o f tw o pro cesses - w ef t and w arp kn i t t in g , each is do ne on severald i f fe rent types o f m ach in es. In w ef t (o r f i l l in g) kn i t t ing , loop s are fo rm ed by need l es kn i t t ing theyarn across the w id th o f the fabr ic . In w arp kn i t t ing , loo ps are fo rm ed by need l es kn i t t ing a ser iesof w arp yarns fed paral le l to the d i rect ion o f fabr ic fo rm at ion . 62 Kni t t ing is used fo r p roducing

sw eaters, hos iery , and o ther types o f fabr ic . Kn i t t in g can use any typ e o f fiber o r yarn . Carpetcons truc t i ons l i ke kn i t ted , need lepun ch , b ra ided , e tc . accoun t fo r 6 .7% o f the U .S. m arke t . 6 3Kn i t ted ca rpe ts a re ve ry uncom m on and M ohaw k Indu st r i es i s bel i eved to be the on l y kn i t tedcarpet manu facturer in the U .S.


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[July 30, 199 8 D raft]I I-27

I I .5.1.1.9 Tuft ing.

Tuf t ing inv o lv es inser ting add i t io na l yarns in to the fabr ic to create p i l e fabr ic . In m od ern tu f t ingm ach ines, ho l low need les car ry and inser t the yarn th rough a sub strate c lo th , w h ich can range f roma th in back in g to heavier mater ia l . Tu f t ing is used fo r appare l fabr ics, upho lstery , and b lankets,a l thou gh m ost tu f t ing m ach ines are used fo r carpets. In the U S, 91 .6 p ercent o f al l carpet isp roduced using tu f t i ng . 6 4 The p r im ary b ack ing i n to w h ich the tu f ts o f ya rn a re i nse r ted i s a w ovenor non -w oven fabr ic . Pat te rn a t tachm ents can be added to bas ic tu f t ing m ach ines. 6 5

I I .5.1.1.10 N onw oven manufactur ing (Potential H AP Source).

In add i t io n to the fabr ic fo rm at ion m ethods descr ibed abo ve, m anm ade f ibers can be processedin to fab r i c using nonw oven techn iques. N onw ovens a re typ i ca l l y used i n i nd ust r i al app l i ca ti onsand are a grow th segmen t in the text i le indu stry . N on w ov ens are essent ia l ly sheet o r w ebstructures m ade by bo nd ing and/o r in te r lock i ng f ibers, yarns, o r f i lamen ts us ing m echan ica l ,therm al , chem ica l , o r so lv ent means. F igure I I .5 -5 is a schem at ic o f a typ i ca l nonw ov enm anufactur ing opera tion . N onw ov ens have severa l per fo rm ance advantages such as m old ab i l i ty ,

and are typ ica l ly eng ineered fo r speci f ic u ses, such as geotext i les, b l ankets, d i apers, e lect r ica li nsu lat i on , and f i l t e rs. N onw ovens can b e hom ogenous fi be r -w eb o r ne t l i ke st ruc tu res o r can belamin a tes/com pos i tes. Typ i ca l f i be rs used i n m ak ing nonw ovens i nc lude po l yeste r, po l yp ropy lene ,r ay o n , an d w o o d p u l p . 66

Raw m ater ia ls in m aking no nw oven fabr ics are sup p l i ed e i ther as syn thet ic po l ym er ch ips or asf ibers. I f a po l ym er ch ip is used, i t needs to be m el ted and extruded, w hereas f ibers need to beop ened, separated, and c l eaned (us ing the sam e metho ds as in spun yarns). N onw ov ens can bem anufactured us ing d i f fe rent p rocesses: d ry lay; w et lay; spun bo nd ; and m el t spun . Each one o fthese processes inv o lv es w eb fo rm at ion and sheet /w eb entang lem ent (bo nd i ng) . The w ebform at ion typ i ca l ly in vo l ves a ser ies o f m echan ica l p ro cesses to feed in the f iber , open/b lend, andto com b and stra igh ten i t to fo rm a com po si te w eb, tha t var ies in s ize and th i ckn ess. In the w et lay

proc ess ho w ever , the f ibers are f i rst suspended i n a so lv ent , w h ic h can b e w ater o r a chem ica lso l ven t . Th i s i s fo l l ow ed by w eb fo rma t ion , dew a te r ing , and d ry ing . In m e l t -b low n p rocesses, thefeed consists o f po lym er tha t has been m ol ten u sing a st ream of ho t a i r . 67 ,68

Af te r web fo rm a tion , the shee t i s bond ed us ing chem ica l bond in g , the rma l bon d ing , o r m echan icalen tang lemen t . Examp les o f m echan ical techn iques i nc lude us ing need le punch in g to en tang lef ibers, us ing w ater je ts to en tang le f ibers (spu n laced) , o r s t i tch in g sect ion s o f the w eb (st i tchbonded ) .

Latex resin bon d ing (chem ica l bond ing ) i s a comm on techn ique . A w eb , supp o r ted on a mo v ingbe l t o r screen, has an adhesive resin ca l led a la tex b ind er app l ied to i t by d ip p in g the w eb in to th e

la tex and rem ov ing the excess, o r by spray in g , foam ing, o r p r in t in g the la tex onto the w eb.

69

Var iou s types o f l iqu id b in ders can a lso be used, w h ich inc l ud e aqu eous so lu t ion s (e .g ., PVA andacry l ic la tex) , o rgan ic so lvent b i nd ers (e .g ., N . Rubber and b enzene) , and w ater -based em uls ions(e.g . , u rea-fo rm aldehy de, phen o l - fo rm aldehyd e, PVC , and natura l R. latex). 70 ,71 In add i t i on , thew ebs can be co lo red by add ing p igm en t to the l a tex so lu t i on s. H ow eve r the l atex resin bo nd in gprocess requ i res la rge amo un ts o f heat to remo ve w ater and thereby d ry and se t the b in der in to th e


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Fiber

Stock

Fiber

PreparationWeb Formation Web Bonding

Nonwoven

Fabric

LW

= Potential HAP Air Emission

= Liquid Waste Potentially Containing HAP

Extruded

Polymer

HAP

LW

HAP

Figure I I .5-5. Example No nw oven M anufacturing Process Flow D iagram

II-2

8


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[July 30, 199 8 D raft]I I-29

fab r i c . M ore heat i s needed fo r b ind e r app l i ed by d ipp ing o r p r i n t i ng com pared to b ind e r app l i edby sp ray ing o r foam ing . 72

The la rgest end u ses fo r la tex resin b on ded stap le n onw ov ens are cover s tock, w ipers, fabr icso f tener substrate , and in ter l in ings. Th is c lass o f non w oven s has lost share in these m arkets overthe last decade as thermal bonded, spunbonded, and spun laced nonwovens rep laced res in bondedvers ions in numerous app l ica t ions. 73

In therm al bon d in g, f iber sur faces are fused to each o th er e i ther by so f ten ing the f ib er sur face, i f i tm e l ts a t l ow tempera tu res, o r by m e l t i ng fusib le add i t i ves i n the fo rm o f pow ders o r f i be rs. Thef i be rs and po w ders a re m ade f rom fusib le p o l ym ers such as po l ye thy lene , po l y p ropy lene , andpo ly este r. Bond ing f i be rs and pow ders can be b lended in w i th the w eb f i be rs be fo re the w eb i sfo rm ed or they can be sprayed on and in to the w eb w i th a spray gun. Throu gh-ai r heating andca lende r ing a re two com m on b ond i ng m e thods. The th rough -a i r m e thod uses ho t a i r to fuse f i be rsw i th in the w eb and on the su r face o f the w eb to m ake h igh l o f t , l ow densi ty fab r i cs. 74 A t o n efac i l i ty , the no nw oven m anufactur ing l ine inc lud es proc esses fo r chop p in g gre ige w aste m ater ia lsto be used, shredd i ng, b lend i ng, and n eed l ing . Som e o f these fibers are bo nd ed by m el t ing

po lyester (heaters drop do w n ov er the w eb) at 300E

F .75

In ca lender po in t bond ing, the w eb is d raw n betw een h igh-pressure , heated cy l i nders tha t have anem bo ssed pat te rn so tha t on ly par t o f the w eb is expo sed to ext rem e heat and pressure . Th is typeof ca lender ing prod uces st rong, low lo f t fabr ics. U l t rasou nd can a lso be used to cause loc a l izedfus ion and bond ing o f f ibers. 7 6

O ver 80 p e rcen t o f the U .S. consump t ion o f the rm a l bonded ca rded fab r i cs i s i n cove r stock .Therm al bond ed carded fabr ics have a lso ga ined share at the exp ense o f resin bo nd ed non w oven sin the i n te rl i n i n g m arke t . 77

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