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Bob Lacovara, CCM, CCT-I Convergent Composites 1.

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Presentation on theme: "Bob Lacovara, CCM, CCT-I Convergent Composites 1."— Presentation transcript:

1 Bob Lacovara, CCM, CCT-I Convergent Composites 1

2 © Convergent Composites 2011 PPE MoldingProcess EngineeringControls MaterialsSelection Styrene Exposure Reduction

3 © Convergent Composites 2011 Styrene Exposure Reduction Materials Technology Polyester Resin EPOXY RESIN

4 © Convergent Composites 2011 Styrene Exposure Reduction Materials Technology Styrene Suppressants Styrene Suppressants

5 © Convergent Composites 2011 Styrene Exposure Reduction Materials Technology Styrene Suppressants Styrene Suppressants Low Styrene Resins Low Styrene Resins LS Polyester Resin

6 © Convergent Composites 2011 Styrene Exposure Reduction Materials Technology Styrene Suppressants Styrene Suppressants Low Styrene Resins Low Styrene Resins Alternative Monomers Alternative Monomers

7 © Convergent Composites 2011 Styrene Exposure Reduction Materials Technology Styrene Suppressants Styrene Suppressants Low Styrene Resins Low Styrene Resins Alternative Monomers Alternative Monomers Epoxy Resins Epoxy Resins EPOXY RESIN

8 © Convergent Composites 2011 Styrene Exposure Reduction Materials Technology Styrene Suppressants Styrene Suppressants Low Styrene Resins Low Styrene Resins Alternative Monomers Alternative Monomers Epoxy Resins Epoxy Resins Thermoplastics Thermoplastics

9 © Convergent Composites 2011 Styrene Exposure Reduction Emissions Limiting Processes

10 © Convergent Composites 2011 Styrene Exposure Reduction Process Technology Non-Spray Application Non-Spray Application

11 © Convergent Composites 2011 Styrene Exposure Reduction Process Technology Non-Spray Application Non-Spray Application Vacuum Infusion Vacuum Infusion

12 © Convergent Composites 2011 Styrene Exposure Reduction Process Technology Non-Spray Application Non-Spray Application Vacuum Infusion Vacuum Infusion RTM Processing RTM Processing

13 © Convergent Composites 2011 Styrene Exposure Reduction Process Technology Non-Spray Application Non-Spray Application Vacuum Infusion Vacuum Infusion RTM Processing RTM Processing Pre-Preg Processing Pre-Preg Processing

14 © Convergent Composites 2011 Styrene Exposure Reduction Process Technology Non-Spray Application Non-Spray Application Vacuum Infusion Vacuum Infusion RTM Processing RTM Processing Pre-Preg Processing Pre-Preg Processing Polyester Pre-Preg Polyester Pre-Preg

15 © Convergent Composites 2011 Styrene Exposure Reduction Process Technology Non-Spray Application Non-Spray Application Vacuum Infusion Vacuum Infusion RTM Processing RTM Processing Pre-Preg Processing Pre-Preg Processing Polyester Pre-Preg Polyester Pre-Preg Robotic Application Robotic Application

16 © Convergent Composites 2011 Styrene Exposure Reduction Control Technology

17 © Convergent Composites 2011 Styrene Exposure Reduction Control Technology Best Practice Ventilation Best Practice Ventilation

18 © Convergent Composites 2011 Styrene Exposure Reduction Control Technology With general ventilation (aka, dilution ventilation) it will be difficult to produce a 20 ppm environment Enhanced ventilation will be required in most cases to technically and cost effectively address 20 ppm

19 © Convergent Composites 2011 Styrene Exposure Reduction General Ventilation Dilution ventilation moves the entire volume of air within a work space volume of air within a work space

20 © Convergent Composites 2011 Styrene Exposure Reduction Enhanced Ventilation Designed to move air specifically from breathing and emissions producing zones

21 © Convergent Composites 2011 Styrene Exposure Reduction Control Technology Enhanced Ventilation Example Filament Winding Application

22 © Convergent Composites 2011 Styrene Exposure Reduction Open Molding Application Control Technology Enhanced Ventilation Example

23 © Convergent Composites 2011 Styrene Exposure Reduction Hull Molding Application Control Technology Enhanced Ventilation Example

24 © Convergent Composites 2011 Styrene Exposure Reduction Work Practice Control C 1 T 1 + C 2 T 2 + C 3 T 3 8 Hrs Exposure =

25 © Convergent Composites 2011 Styrene Exposure Reduction Work Practice Control Clean Operations Training Clean Operations Training

26 © Convergent Composites 2011 Styrene Exposure Reduction Work Practice Control Clean Operations Training Clean Operations Training Operator Positioning Operator Positioning

27 © Convergent Composites 2011 Styrene Exposure Reduction Spray Booth OperatorPositionedUpwind Air Flow Operator Positioning

28 © Convergent Composites 2011 Styrene Exposure Reduction Administrative Control Work Habit Training Work Habit Training Operator Positioning Operator Positioning Time Limited Exposure Time Limited Exposure

29 © Convergent Composites 2011 Styrene Exposure Reduction Administrative Control TWA Calculation C 1 T 1 + C 2 T 2 + C 3 T 3 8 Hrs Exposure = Exposure = Time Weighted Avg (TWA) C = Concentration (ppm) T = Time (hours)

30 © Convergent Composites 2011 Styrene Exposure Reduction TWA Calculation (50 ppm TWA) Measured Exposure: 70 ppm 70 ppm 50 ppm 50 ppm 40 ppm 40 ppm (70 x 2) + (50 x 2) + (40 x 4) 8 Hrs = = 50 ppm TWA

31 © Convergent Composites 2011 Styrene Exposure Reduction TWA Calculation (20 ppm TWA) Measured Exposure: 50 ppm 50 ppm 30 ppm 30 ppm 0 ppm 0 ppm (50 x 2) + (30 x 2) + (0 x 4) 8 Hrs = = 20 ppm TWA

32 © Convergent Composites 2011 Styrene Exposure Reduction TWA Calculation Measured Exposure: 70 ppm 70 ppm 50 ppm 50 ppm 40 ppm 40 ppm 400 ppm units/day 400 ppm units/day Current 50 ppm TWA looks like this: Measured Exposure: 50 ppm 50 ppm 30 ppm 30 ppm 0 ppm 0 ppm 160 ppm units/day 160 ppm units/day Proposed 20 ppm TWA looks like this:

33 © Convergent Composites 2011 Styrene Exposure Reduction Time Limited Exposure Scenario: Four Workers - Three Different Jobs

34 © Convergent Composites 2011 Styrene Exposure Reduction The Reality of Crew Rotation 4-Workers / 3-Jobs - Spraying - Laminating - Finishing 50 ppm - 2 hrs / 30 ppm - 2 hrs / 0 ppm - 4 hrs 2Hr. Cycle 1 2Hr. Cycle 1 Worker A - Spray Worker A - Spray Worker B - Roll Out Worker B - Roll Out Worker C - Finish Worker C - Finish Worker D - Finish Worker D - Finish 2Hr. Cycle 2 2Hr. Cycle 2 Worker B - Spray Worker B - Spray Worker A - Roll Out Worker A - Roll Out Worker C - Finish Worker C - Finish Worker D - Finish Worker D - Finish 2 Hr. Cycle 4 2 Hr. Cycle 4 Worker D - Spray Worker D - Spray Worker C - Roll Out Worker C - Roll Out Worker A - Finish Worker A - Finish Worker B - Finish Worker B - Finish 2Hr. Cycle 3 2Hr. Cycle 3 Worker C - Spray Worker C - Spray Worker D - Roll Out Worker D - Roll Out Worker A - Finish Worker A - Finish Worker B - Finish Worker B - Finish

35 © Convergent Composites 2011 Styrene Exposure Reduction An exposure limit of 20 ppm TWA will require a combination of technologies & work practices Low emissions materials Low emissions materials Emissions limiting processes Emissions limiting processes Enhanced ventilation Enhanced ventilation Enhanced work practices Enhanced work practices SUMMARY:

36 36 Contact: Bob Lacovara, CCM, CCT-I Convergent Composites


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