AC Molding Compounds - Executive Summary

| Accident History | Chemicals | Emergency Response | Registration | Source | Executive Summary |

Since the time of the first RMP submission for this facility, there was a change in ownership from Borden Chemical  to AC Molding Compounds. This new RMP is being submitted because of this change in ownership. 
 
(a)  ACCIDENTAL RESEASE PREVENTION AND EMERGENCY RESPONSE POLICIES     
 
AC Molding Compounds is committed to continuous improvement  in it's safety, health and environmental programs.  Our commitment for protecting our employees and the community that is home to our operations is an integral part of our way of doing business.  We have recently formed a CAP (Citizen's Advisory Panel) as a means for assurring issues faced by our facility which may have community impact our reviewed with representatives from the community. 
 
(b)  THE STATIONARY SOURCE AND THE REGULATED SUBSTANCES HANDLES 
 
AC Molding Compounds  makes melamine-formaldehyde resins and urea-formaldehyde resins that are used as raw materials to make wall plates, buttons and dinnerware. The RMP substances involved with th 
is operation are  50% formaldehyde solution and anhydrous ammonia.  
 
(c)  WORST-CASE RELEASE SCENARIOS AND ALTERNATIVE RELEASE SCENARIOS 
 
The worst case release scenario is the failure of a storage tank and the release of 50,000 pounds of anhydrous ammonia.  The effects of the release from the evaporating anhydrous ammonia could reach offsite endpoints and nearby public receptors. 
 
The alternative release scenario for anhydrous ammonia is the failure of a joint in exterior ammonia piping and the release of 1,000 pounds of material. The effects of the release from the evaporating anhydrous ammonia could reach offsite endpoints and nearby public receptors. 
 
The alternative release scenario for 50% formaldehyde solution is the failure of an unloading hose and the release of 1,950 pounds of material. The mitigating effects of a dike, berm, drain and sump were included in the evaluation of the possible consequences. The effects of the release from the evaporating formaldehyde could reach of 
fsite endpoints and nearby public receptors. 
 
 
(d)  THE GENERAL ACCIDENTAL RESEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION STEPS 
 
AC Molding Compound's general accidental release prevention program includes: 
 
- EPA 40 CFR 68 - Risk Management Plans 
- OSHA 29 CFR 1910.119 - Process Safety Management of Highly Hazardous Chemicals 
- OSHA 29 CFR 1910.120 - Hazardous Waste Operations & Emergency Response 
- Other EPA, OSHA, DOT and State regulations 
- Generally recognized & accepted engineering codes and standards 
 
The following engineering and administrative controls help prevent a release of ammonia and formaldehyde: 
 
- Operating procedures and constant attendance during transfer operations by trained personnel 
- High level controls with automatic shutoffs 
- Computer control system with safety and environmental interlocks 
- Multiple level indicators in storage tanks and production vessels. 
 
 
(e)  5-YEAR ACCIDENT HISTORY 
 
There has been no incident at the AC Molding Compounds Da 
llas facility that meets the criteria for reporting in the five-year accident history. 
 
 
(f) EMERGENCY RESPONSE PROGRAM 
 
The facility Emergency Response Plan specifies procedures for potential hazardous material releases, including coordination with the Dallas Fire Department. This plan is written in the "One Plan" format to satisfy regulatory requirements of several agencies.  An emergency response drill is conducted annually to test the Emergency Response Plan. 
 
 
(g)  PLANNED CHANGES TO IMPROVE SAFETY 
AC Molding Compounds is constantly striving to upgrade its processes, control technology, employee training, inspection, repair and maintenance of process equipment in order to improve safety.
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