Control of Volatile Organic Compounds Emissions from Manufacturing

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I 1 ov&state both the missions and the cost effectiveness of RACT con- & L-O1 . for thege sources. ~-1 6 . Formerly ~antrfaiturin~ Chen~sts ~ssocihion-sarving t h Chemical ~ Industry Since 1872, 4 . 2%; M Street. NW Washin=!on. DC 20037 Tele2hone 2021118711260 Telex 69617 (CMA \FISH) , o The cold plant description and enissions factors for polystyrene , nenuf+cture are not representative of current industry practice and
' Y !. Jack R. Faner o The A~ency hzs relied on obsolete irifomation in developing incinerator costs which overstatos the cost effectiveness of RkCT. Designation of PACT The.Draft CTG states t3at a 98%weight reduction of VOC emissions from continuo-zs vents is re~resatativeof ?.XCT for Polymers and Resins Wmufactare. This level of err.issions~reduction is more t~icalof LPZR for process emissions sources. For ex=ple, the &aft CTG is more stringent tha the preliminary draft NS?S for SOmI Distillation Units. It is also more stringent thzn the 97% reduction in benzene emissions specified in the Agency's proposed EESE'F3 for Benzene from Maleic Mhydride Mzmfacture. R?CT retrofit recyirmeats for existing sources shoul6 be less strinr~en than the NSPS regiremerits fsr the sane source category. The RACT requirements : should also be less stringent thin BACT, LAZR, and NESH.;LP requirements for sirnilzr types of emissions. The level of control specified by this CTG should be consistent with the levels sgecified in other CTG?~that are under develop- ment for the control or' VOC emissions. c!!A recornends that RACP be' set at a lower percentage level of VOC extissiors reZuctions that will allow iceividual states to select t3e level of emissions reductions for existing sources. Th'is permits the ogtimal selection of 3ACT used by the stztes to bring individual ozone non-attainment areas into compliance with GIe NAAQS. Flares as Egivalent RACT At the UwE.3C pu5lic hearing on the Pzeliminary Draft CTG for Polymers az~d Resins Manufacture, CFA camented extensively on this issue. OU; concerns have not been addressed 5y the Agency in the latest draft of the CTG. CIM-9 maintains that the availaSle data on flare destruction efficiency demonstrate that these devices quzlify as RACT for VOC erdssions control. The Draft CTG should be changed to 2eL?nit the use of flares as RACT for pblyolefins plants. CMA and ETA are currently funding a study of flare efficiency at the John Zink Com?any Test Center. This study is designed to determine the VOC comSustion a d destruction efficiencies achieve6 by flares controlling zmall continucus streams typical of those found in polymers and resins and other chem'ical 'mmufactuzing _processes. Since EPA is intinately involved in this study, (23% t&es the position that any CTG provision that would preclude the use of flares is ina_o_oropriate and strongly recommends that the language in the final CTG not discourage their use. Furthermora, since flares are specified as an acceptable control techniqe for meeting the NSPS for SOGYI Distillation Units, CYA sees no reason why flares should not be acceptable as RACT for the CTG for Polymers and Resins Mnufacture. ,
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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
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3.2 .I .1 Condenser Control Efficie
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VOC -*, VENT TO VcntS~ AmOSPnERE Fi
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ABSORBlHG UQUlD WITH VOC OUT To Dis
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REFERENCES FOR CHAPTER 3 Lee, K.C.,
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Reference 24, p. 34. Key, J . A. Or
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4.1 INTRODUCTION 4.0 ENVIRONME NTAL
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Table 4-1. UNCONTROLLED EMISSION RA
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C Table 4-3. UNCONTROLLED EMISSION
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the results and an analysis of cost
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Tab1e 4-4. MODEL PLANT ENVIRONMENTA
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Tab1e 4-5. ADDITIONAL ENERGY REQUIR
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-- Table 4-7. ADDITIONAL ENERGY REQ
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5.0 CONTROL COST ANALYSIS OF RACT T
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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 and 118: Table 5-11. COST ANALYSIS FOR HIGH
Page 119 and 120: Table 5-12. COST ANALYSIS FOR POLYS
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: REFERENCES Texas Chemical Council t
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,
Page 169 and 170: APPENDIX C MAJOR ISSUES AND RESPONS
Page 171 and 172: generally for large volume, variabl
Page 173 and 174: control devices, such as thermal an
Page 175 and 176: modification or rep1 acement, based
Page 177 and 178: epresent excellent agreement for su
Page 179 and 180: Response: The following responses a
Page 181: processes (e.g ., polypropylene and
Page 184 and 185: I I I I The purpose of this appendi
Page 187 and 188: Data collection continued for each
Page 189 and 190: Test . Number ~104Velocity (scfm) (
Page 191 and 192: found for tests of incinerators at
Page 194 and 195: 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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