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Dupont Company Fayetteville Works is a chemical manufacturing facility located in Bladen County. The facility has a Butacite manufacturing operation that includes a polyvinyl butyral sheeting, rotogravure printing operation. The printing operation is subject to MACT Subpart KK requirements and is controlled by a permanent total enclosure for the printing operation room exhaust and a multi-stage horizontal spray scrubber to control emissions of dimethylformamide (DMF). The Butacite area is subject to the Miscellaneous Organic NESHAP (MON) for methanol emissions from its wastewater stream.
The Nafion operation produces a variety of relatively uncommon monomer and polymer chemicals. Some of the monomers are shipped offsite, while others are used onsite in the production of various polymers. The polymers are shipped offsite or used onsite to produce membrane material. The two waste gas scrubbers located at Nafion are used to control the emissions of various pollutants including hydrogen fluoride and acid fluorides. The Nafion process is subject to the Miscellaneous Organic NESHAP (MON) for hydrogen fluoride emissions and to the Organic Liquids Distribution NESHAP for methyl chloride.
The ammonium perfluorooctanoate (APFO) process began operation in December of 2002. The APFO reaction process uses perfluorooctanoate (brought in by truck in its iodide/salt form) reacted with sodium hydroxide (stored in totes) to form the acid fluoride. The acid fluoride is then reacted with ammonia to produce the ammonium salt. Fuming sulfuric acid (oleum) is received by truck and used as a solvent in the process. Currently, APFO and the associated perfluorooctanoic acid (PFOA), also known as C8, are not regulated as toxic or hazardous air pollutants. However, the EPA is currently reviewing the chemical with the possibility of future designation as a regulated pollutant.
The Dupont site also includes a fluoroproducts polymer manufacturing development facility, a semi-works area, and a wastewater treatment system. There are two No. 2/No. 6 fuel oil-fired boilers (139.4 and 88.4 million Btu per hour). In addition, the permit includes a temporary boiler for cases where there are problems with the main boilers.