Control of Volatile Organic Compounds Emissions from Manufacturing

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elow the 0.12 kg VOC/1000 kg of product level (through the use of vacuum pumps) because of economic incentives. The 0.20 kg VOC/1000 kg of product VOC level is based on the plant that currently has the greatest known emissions. Both emi ssion levels were costed for styrene- in-steam emissions as we1 1 as for styrene-i n-ai r emi ssi ons. Both of the units examined for recovery of styrene in steam require only a minimum commercially available size condenser unit with 20 ft2 heat transfer area. Therefore, as shown in Table 5-1.2, the only difference in the costs of the two units is the amount of the recovery credit. The total installed capital cost and annualized cost of both units are $28,000 and $8,300 per year, respectively. The net annualized costs considering recovery credit are $-147,000 per year for a reduction from 3.09 kg/1000 kg and $4,130 per year for a reduction from 0.20 kg/1000 kg. For the recovery of styrene in air, a minimum commercially available size condenser unit with 20 ft2 heat transfer area is requi red when the uncontrolled emission rate is 0.2 kg VOC/Mg of product. If the uncontrolled emission rate is 3.09 kg VOC/Mg of product, then a condenser with 185 ft2heat transfer area is required to remove the styrene from the styrene-i n-ai r emi ssions. Only one additional cost analysis was undertaken for the polystyrene plant because the model plant consists of only two process lines and only one process section for which RACT is being recommended. The additional cost analysis looks at controlling emissions from a single process lfne. The results of this cost analysis are summarized in Table 5-13. 5.3 COST EFFECTIVENESS OF RACT The annualized cost effectiveness values (net annualized cost per megagram of VOC emission reduction) are given in Tables 5-14, 5-15, and 1 5-16 for the various control techniques and model plant combinations. The estimated costs of emission reduction (using the lowest cost combustion 1 control option of flares for PP and HDPE) are only $13 and $17 per I megagram of VOC reduced from uncontrolled levels, for polypropylene and high-density polyethylene, respectively. Even for a reduction from the assumed upper level of existing control for which acldi tional or replacement control might be required, the cost of the same control techniques would be about $88 and $160, per megagram. For the polystyrene model plant, the condenser analysis results in a range in the potential cost 5-28 I I I
Table 5-12. COST ANALYSIS FOR POLYSTYRENE MODEL PLANT Instal 1 ed Cost, '$ -Purchased Equipment -Instal latlon Total Instal led - Annual i zed Cost, $/yr Dl rect -Operating Labor 1,080 -Maintenance 1,400 -Natural Gas -- -El ectri ci ty 140 -Steam Subtotal Indirect &pi tal Recovery -Tax, Insurance & Administration Subtotal Styrene in Steam Styrene i n Air 0.2 kg VOC 3.09 kg VOC per Mg product per Mg product Recovery Credit 155 ,OOOef 4,170 155,000 (4,170) Total (Direct + Indirect - Recovery Credit) -146,700e 5,660 -90,800 (4,130)f a Includes only condenser and refrigeration unit costs. b Condenser only 1-2 ft in djameter so no piping, etc. beyond that in installation cost considered- necessary. L~ncl udes $29,500 for piping. d Cost is for make-up cool ant. e From uncontrolled emission rate of 3.09 kg VOC/Mg product. f Fran uncontroi'led emission rate of 0.2 kg VOC/Mg product.
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dine Series Emission Standards and
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TABLE OF CONTENTS ................
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D.2 THERMAL INCINERATOR VOC EMISSIO
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LIST OF TABLES End Uses of Polyprop
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Typical Inci nerator Parameters for
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LIST OF FIGURES Simplified Process
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2.1 INTRODUCTION 2.0 PROCESS AND PO
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Polypropylene resins are supplied i
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Table 2-2. POLYPROPYLENE (PP) PLANT
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Fxlrus loll l'el lciiz ltlq Methano
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Tab1e 2-3. CHARACTER1 STICS OF VENT
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in addition to C3 and process dilue
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used in maki fig shopping bags. For
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I 2 CTC E%% PCS A wrcc 2 C W P U iZ
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Table '2-6. CHARACTERISTICS OF VENT
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A1 though polymers with molecular w
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A - . STYREL +VACUUH SYSTEM (8) (9)
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Tab1e 2-8. CHARACTERISTICS OF VENT
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3.0 EMISSION CONTROL TECHNIQUES Vol
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that they require for complete comb
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PILOT AND CENTER mAlri JET ELNATION
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Ground flares are usually enclosed
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flare was operated with from 130 t
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w Table 3-1 . FLARE EMISSIONS STUDI
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has become less common during the p
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Waste Gas- Stack Section Figure 3-3
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chamber temperatures ranging from 7
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= alti-
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control can be used. Any breakdown
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and, in some cases, reused in the p
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are immiscible with the coolant. Th
Page 67 and 68: 3.2 .I .1 Condenser Control Efficie
Page 69 and 70: VOC -*, VENT TO VcntS~ AmOSPnERE Fi
Page 71 and 72: ABSORBlHG UQUlD WITH VOC OUT To Dis
Page 73 and 74: REFERENCES FOR CHAPTER 3 Lee, K.C.,
Page 75 and 76: Reference 24, p. 34. Key, J . A. Or
Page 77 and 78: 4.1 INTRODUCTION 4.0 ENVIRONME NTAL
Page 79 and 80: Table 4-1. UNCONTROLLED EMISSION RA
Page 81 and 82: C Table 4-3. UNCONTROLLED EMISSION
Page 83 and 84: the results and an analysis of cost
Page 85 and 86: Tab1e 4-4. MODEL PLANT ENVIRONMENTA
Page 87 and 88: Tab1e 4-5. ADDITIONAL ENERGY REQUIR
Page 89 and 90: -- Table 4-7. ADDITIONAL ENERGY REQ
Page 91 and 92: 5.0 CONTROL COST ANALYSIS OF RACT T
Page 93 and 94: m I W 1. Simple. continuous uanuall
Page 95 and 96: Tab1e 5-2, INSTALLATION COST FACTOR
Page 97 and 98: FOOTNOTES FOR Tab1 e 5-3 a Incl ude
Page 99 and 100: In order to prevent an explosion ha
Page 101 and 102: analysis of the Distil 1 ation NSPS
Page 103 and 104: Install ed piping and ducting costs
Page 105 and 106: estimated by the same procedure as
Page 107 and 108: .ble 5-4. POLYPROPYLENE MODEL PLANT
Page 109 and 110: Table 5-6. POLYSTYRENE MODEL PLANT
Page 111 and 112: emitters, while other dryers, e.g.,
Page 113 and 114: Table 5-8. COST ANALYSIS FOR POLYPR
Page 115 and 116: other dryers may have higher or low
Page 117: Table 5-11. COST ANALYSIS FOR HIGH
Page 122 and 123: Polymer Table 5-15. COST EFFECTIVEN
Page 124 and 125: effectiveness of polystyrene contro
Page 126 and 127: EEA. Distil lation NSPS Pi peline C
Page 129 and 130: APPENDIX A LIST OF COMFIENJERS
Page 131 and 132: APPENDIX B COMMENTS OW MAY 1982 DRA
Page 133 and 134: Mr. J. R. Famet Page 2 EPA June 16,
Page 135 and 136: October 19, 1981 Attachment to June
Page 137 and 138: Be The mocial plant does nst incEud
Page 139 and 140: 1000 BRAZOS, SUITE 200, AUSTIN, TEX
Page 141 and 142: our previous comments the TCC quest
Page 143 and 144: . . . . " . . 5. Emission Reduction
Page 145 and 146: REFERENCES Texas Chemical Council t
Page 147 and 148: ' Y !. Jack R. Faner o The A~ency h
Page 149 and 150: NATION& AIR POLLUTION CONTROL Y COM
Page 151: " DEFINITION OF INCINERATION AS MCT
Page 154 and 155: -5- IN SUWRYj THE AGENCY, BY RELYIN
Page 156 and 157: STRUMS WITH RELATIVELY STABLE FLOW
Page 158 and 159: 1 I CoHPlTIONS OF 10 TIMES NORMAL S
Page 160 and 161: I 1 I - gU - I I n G PROPO.SED INCI
Page 162: The use of data from the CTG for ai
Page 166: Mr. Jack R. Farmer, Chief July 19,
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APPENDIX C MAJOR ISSUES AND RESPONS
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generally for large volume, variabl
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control devices, such as thermal an
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modification or rep1 acement, based
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epresent excellent agreement for su
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Response: The following responses a
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processes (e.g ., polypropylene and
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I I I I The purpose of this appendi
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Data collection continued for each
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Test . Number ~104Velocity (scfm) (
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found for tests of incinerators at
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7' Tab1e 0-4. TYPICAL INCINERATOR P
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I I I I I l l I averages for the mo
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Table D-5. ARC0 POLYMERS INCINERATO
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Thempies Spaced Evenly Across the T
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probe for the temperature while a w
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The total installed capital cost of
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3. Test Results - VOC destruction e
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Figure D-4. Petro-Tex 0x0 unit inci
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air to reduce the air flow through
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HEAT EXCHANGE1 NOTE: From Exchanger
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' organic carbon. chromatography. T
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D.3 VAPOR RECOVERY SYSTEM VOC EMISS
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However, the calculations assume pe
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The 20 pprn level was judged to be
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REFERENCES FOR APPENDIX D McDaniel,
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APPENDIX E: DETAILED DESIGN AND COS
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characteristics: volumetric flow ra
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Footnotes for Table E-1 astandad co
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sources to the flare header were as
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Flare Tip Diameter (in.) Figure E-1
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Table E-3. CAPITAL AND ANNUAL OPERA
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Footnotes for Table E-3 aFluidic se
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Tab1e E-4. WtORKSHEET FOR CALCULATI
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excess air for oxygen in the waste
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Table E-6. PROCEDURE TO DESIGN THER
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I I a plant had a use for it, heat
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Footnotes for Table E-7 Wpdated usi
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Table E-8. OPERATING PARAMETERS AND
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TABLE E-9. GAS PARAMETERS USED FOR
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~ 1 1 I I l 1 I I represent June 19
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Tabl e -11 CAPITAL AND . IERATIONG
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$0.335/scfm for units with no heat
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Table E-12. PROCEDURE TO CALCULATE
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Footnotes for Table E-12 (Concluded
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i m- Table E-13. PROCEDURE TO CALCU
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I - I - 1 A nnnrrn~~nrc rn rnl PIII
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Table E-15. CAPITAL AND ANNUAL OPER
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aUpdated using Chemical ~ I nneiri
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Condenser ~y2 ! ;tern Area (ftL) Fi
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ased on an equation in the Chemical
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m Equi p ent Type Check Valves Gate
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- 1/8 - - Table E-20. INSTALLED DUC
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Reference 12, p. 6-3 and 6-4. Refer
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APPENDIX F CALCULATION OF UNCONTROL
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Table F-1 . INITIAL EMISSION CHARAC
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Table F12. SUMMARY OF ANNUAL COSTS,
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= the difference between the operat
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I 8 - a F.Z. 1 Sty rene-i n-Steam m
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(9 CE = AC - (0.9 ~ CDnA ~ x eRC) d
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Substituting the values from Table
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Table 7. EXPONENTS USED FOR CONDENS
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Within Line Table F-8. STYRENE'-IN-
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Control of Volatile Organic Compounds Emissions from Manufacturing

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