Control of Volatile Organic Compounds Emissions from Manufacturing

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2.2.2.1 Process Description. The continuous slurry processes, conventional and hi gh-yiel d, are represented in Figure 2-1. Reactor feed materials consist mainly of monomer propylene, comonomer ethylene, monomer impurities propane and ethane, hexane, and a stereospeci fic catalyst. Hexane is used as a process diluent and acts as a heat transfhr agent and polymer suspending medium. The catalyst is usual ly manufactured on site to consistently maintain the required catalyst activity. It is mixed with necessary solvents and metered accurately into the polymerizati reactor along with other reactants. Process di luent is also used in catalyst preparation and spent diluent is sent to the diluent recovery section for reuse. The reactor is a continuously stirred jacketed vessel or a loop reactor. During reaction, a portion of the polymer/monomer/diluent mixture is continuously drawn from the reactor to a flash tank in which the unreacted propylene and propane are separated, and recovered by condensation. Slurry from the flash tank is then fed to the deactivationldecanting section for washing with an alcohol-water solution to remove most of the catalyst residues. The diluentlcrude product slurry is lighter than the alcohol-water solution and the two phases are separated by decantation. The a1 cohol-water phase is distil led to recover a1 cohol ; whereas, the diluent/crude product phase which is in the form of a slurry is stripped1 to remove part of the diluent. The product slurry is then sent to a slurry vacuy fi1,ter system in which isotactic polyrr~er product solids are separated from the di luent. The atacti c polymer rerrrai ns di ssol ved in the diluent. The isotactic product goes through a product dryer, then is extruded, pelletized, and sent to product storage. In the methanol recovery section, the crude methanol streams are refined and recycled, and the bottom streams, contai ni ng catalysts metals are sent to the plant waste-water treatment f'acil ity. The atactic-diluent solution is fed to the by-plroduct (atactic) and diluent separation unit in which the diluent is purified and dried for recycle, and the atactic solids are recovered or burned in incinerators. In the high-yield slurry process, the catalyst is left in the product so deacti vati onldecanti ng and a1 cohol recovery sections are unnecessary. Along with this, one of the major emission streams is also I I
Fxlrus loll l'el lciiz ltlq Methanol- Water Solution I'rotLtc t Storage hthanol to Process Note: Process Steps 6 and 7 arc unnecessary in the high yield catalyst process. Fi yure 2-1 . Simp1 if i ed Process Block Diagram for the Polypropylene Continuous , Liquid Phase Slurry Process
Page 1 and 2: dine Series Emission Standards and
Page 3 and 4: TABLE OF CONTENTS ................
Page 5 and 6: D.2 THERMAL INCINERATOR VOC EMISSIO
Page 7 and 8: LIST OF TABLES End Uses of Polyprop
Page 9 and 10: Typical Inci nerator Parameters for
Page 11: LIST OF FIGURES Simplified Process
Page 15 and 16: 2.1 INTRODUCTION 2.0 PROCESS AND PO
Page 17 and 18: Polypropylene resins are supplied i
Page 19: Table 2-2. POLYPROPYLENE (PP) PLANT
Page 23 and 24: Tab1e 2-3. CHARACTER1 STICS OF VENT
Page 25 and 26: in addition to C3 and process dilue
Page 27 and 28: used in maki fig shopping bags. For
Page 29 and 30: I 2 CTC E%% PCS A wrcc 2 C W P U iZ
Page 31 and 32: Table '2-6. CHARACTERISTICS OF VENT
Page 33 and 34: A1 though polymers with molecular w
Page 35 and 36: A - . STYREL +VACUUH SYSTEM (8) (9)
Page 37 and 38: Tab1e 2-8. CHARACTERISTICS OF VENT
Page 41 and 42: 3.0 EMISSION CONTROL TECHNIQUES Vol
Page 43 and 44: that they require for complete comb
Page 45 and 46: PILOT AND CENTER mAlri JET ELNATION
Page 47 and 48: Ground flares are usually enclosed
Page 49 and 50: flare was operated with from 130 t
Page 51 and 52: w Table 3-1 . FLARE EMISSIONS STUDI
Page 53 and 54: has become less common during the p
Page 55 and 56: Waste Gas- Stack Section Figure 3-3
Page 57 and 58: chamber temperatures ranging from 7
Page 59 and 60: = alti-
Page 61 and 62: control can be used. Any breakdown
Page 63 and 64: and, in some cases, reused in the p
Page 65 and 66: 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 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 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,
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
Page 196 and 197:
I I I I I l l I averages for the mo
Page 198 and 199:
Table D-5. ARC0 POLYMERS INCINERATO
Page 200 and 201:
Thempies Spaced Evenly Across the T
Page 202 and 203:
probe for the temperature while a w
Page 204 and 205:
The total installed capital cost of
Page 206 and 207:
3. Test Results - VOC destruction e
Page 208 and 209:
Figure D-4. Petro-Tex 0x0 unit inci
Page 210 and 211:
air to reduce the air flow through
Page 213 and 214:
HEAT EXCHANGE1 NOTE: From Exchanger
Page 215 and 216:
' organic carbon. chromatography. T
Page 217 and 218:
D.3 VAPOR RECOVERY SYSTEM VOC EMISS
Page 219:
However, the calculations assume pe
Page 222 and 223:
The 20 pprn level was judged to be
Page 224 and 225:
REFERENCES FOR APPENDIX D McDaniel,
Page 227 and 228:
APPENDIX E: DETAILED DESIGN AND COS
Page 229 and 230:
characteristics: volumetric flow ra
Page 231 and 232:
Footnotes for Table E-1 astandad co
Page 233 and 234:
sources to the flare header were as
Page 235:
Flare Tip Diameter (in.) Figure E-1
Page 238 and 239:
Table E-3. CAPITAL AND ANNUAL OPERA
Page 240 and 241:
Footnotes for Table E-3 aFluidic se
Page 242 and 243:
Tab1e E-4. WtORKSHEET FOR CALCULATI
Page 244 and 245:
excess air for oxygen in the waste
Page 246 and 247:
Table E-6. PROCEDURE TO DESIGN THER
Page 248:
I I a plant had a use for it, heat
Page 252 and 253:
Footnotes for Table E-7 Wpdated usi
Page 255 and 256:
Table E-8. OPERATING PARAMETERS AND
Page 257:
TABLE E-9. GAS PARAMETERS USED FOR
Page 260 and 261:
~ 1 1 I I l 1 I I represent June 19
Page 262 and 263:
Tabl e -11 CAPITAL AND . IERATIONG
Page 264 and 265:
$0.335/scfm for units with no heat
Page 266 and 267:
Table E-12. PROCEDURE TO CALCULATE
Page 268 and 269:
Footnotes for Table E-12 (Concluded
Page 270 and 271:
i m- Table E-13. PROCEDURE TO CALCU
Page 272 and 273:
I - I - 1 A nnnrrn~~nrc rn rnl PIII
Page 274 and 275:
Table E-15. CAPITAL AND ANNUAL OPER
Page 276 and 277:
aUpdated using Chemical ~ I nneiri
Page 278 and 279:
Condenser ~y2 ! ;tern Area (ftL) Fi
Page 280 and 281:
ased on an equation in the Chemical
Page 282 and 283:
m Equi p ent Type Check Valves Gate
Page 284 and 285:
- 1/8 - - Table E-20. INSTALLED DUC
Page 286 and 287:
Reference 12, p. 6-3 and 6-4. Refer
Page 289 and 290:
APPENDIX F CALCULATION OF UNCONTROL
Page 291 and 292:
Table F-1 . INITIAL EMISSION CHARAC
Page 293 and 294:
Table F12. SUMMARY OF ANNUAL COSTS,
Page 295:
= the difference between the operat
Page 298 and 299:
I 8 - a F.Z. 1 Sty rene-i n-Steam m
Page 300 and 301:
(9 CE = AC - (0.9 ~ CDnA ~ x eRC) d
Page 302 and 303:
Substituting the values from Table
Page 304 and 305:
Table 7. EXPONENTS USED FOR CONDENS
Page 306 and 307:
Within Line Table F-8. STYRENE'-IN-
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Control of Volatile Organic Compounds Emissions from Manufacturing

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