CTA Report, Draft 1, ISP Review - US Chemical Safety and Hazard ...
CTA Report, Draft 1, ISP Review - US Chemical Safety and Hazard ...
CTA Report, Draft 1, ISP Review - US Chemical Safety and Hazard ...
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actuated water sprinkler was positioned over this area to extinguish fires. The binder-feeder deposited<br />
phenolic resin powder onto the fiberglass web, 5 which then entered the mat-former on a forming chain. 6<br />
<strong>CTA</strong> purchased <strong>and</strong> used two types of phenolic resin powder. The powders—referred to as “natural” <strong>and</strong><br />
“black”—have similar chemical compositions <strong>and</strong> properties (Section 8.1). The natural resin, Borden<br />
<strong>Chemical</strong> Durite SD-110A, was used on lines 401 <strong>and</strong> 402 to make duct liner; while the black resin,<br />
Borden <strong>Chemical</strong> Durite SD-52SS, was used on lines 403 <strong>and</strong> 405 to make automotive acoustic insulation<br />
products. The black resin contained approximately 2 percent carbon black to produce the desired color.<br />
Substantial quantities of phenolic resins, often several hundred thous<strong>and</strong> pounds per month, were used.<br />
The quantity of black resin greatly exceeded the quantity of natural resin used in the plant’s production<br />
lines.<br />
Building roof<br />
Blend room roof<br />
Blend line<br />
feeders<br />
Picker<br />
Residue<br />
feeder<br />
Air lock<br />
Baghouse<br />
Mat-former<br />
Chute<br />
Box (on floor)<br />
Resin<br />
feeder<br />
Figure 3. Line 405 process flow.<br />
Oven air<br />
intake<br />
Transition<br />
Facing<br />
Incinerator<br />
Curing oven<br />
Natural<br />
gas<br />
burner<br />
5<br />
Phenolic resin powder arrived at the <strong>CTA</strong> facility in 2,000-pound super sacks. A screw conveyor attached to the<br />
bottom of the feed hopper transported the powder to the binder-feeder.<br />
6<br />
The forming chain was basically an open mesh conveyor line.<br />
24