Control of Volatile Organic Compounds Emissions from Manufacturing

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FOlOTNOTES FOR TABLE E-1 (continued) gFmonp (In. H20) = 55 [V, (fps)/55012 = (1.818 x 10-~)y:, (as in footnote d.) 'From Enviroreience (Reference 1, Appendix A) ass~lcing ~ind velocity, V.,, of 60 rnph i~rom Enviroscience (Reference 1, Appendix A), assuming flamf) emissivity, o, of 0.12, flame radiation intensity, I, of 1200 Btulhr ft j~afe pipe length is the pipe length necessary to reach the horizontal distance frm the flare where the flame radiation jntensity, I, is reduced to 440 ~tulhr-ft2 including solar radiation (-300 Btulhr-ft ) , a safe working level, (Reference 7):. 7
sources to the flare header were assumed to be 70 feet in length,8 while the length of pipelines to the flare was' based on the horizontal distance required to provide a tolerable and safe radiation level for conti nuous worki ng (440 ~tulhr-ft2, incl udi ng solar radi ation) .5 Piping and ducting were selected and costed as outlined in Section E.6. E.2.2 Flare Cost Estimation Procedure. Flare purchase costs were based on costs for diameters from 2 to 24 inches and heights from 20 to 200 feet provided by National Air Oil Burner, Inc., (NAO) during November 1982 and presented in Table E-2.5 A cost was also provided for one additional case of 60 inch diameter and 40 feet height.7 These costs are October 1982 prices of self-supporting flares without ladders and platforms for heights of 40 feet and less and of guyed flares with ladders and platforms for heights of 50 feet and greater. Flare purchase costs were estimated for the various regulatory alternatives by either choosing the value provided for the required height and diameter or using two correlations developed from the NAO data for purchase cost as a function of height and diameter. (One correlation for heights of 40 feet and less, i.e., self-supporting flares and one for heights of 50 feet and greater, i.e., guyed flares.) Purchase costs of large diameter, 40-ft. high flares were approximated using a curve developed from the NAO data (see Figure E-1). Purchase costs for fluidic seals were approximated using a curve based on data provided by NAO~ (see Figure E-2). A retrofit installation factor of 2.65 (see Table 5-2) was used to estimate installed flare costs. Instal led costs were put on a June 1980 basis using the following Chemical Engineering Plant Cost Indices: the overall index for flares; the pipes, valves, and fittings index for pi ping; and the fabricated equipment index for duct ing. Annualized costs were calculated using the factors presented in Table 5-3. The flare cost estimation procedure is presented in Table E-3. E.3 THERMAL INCINERATOR DESIGN AND COST ESTIMATION PROCEDURE Thermal incinerator designs for costing purposes were based on heat and mass balances for combustion of the waste gas and any requi red
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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
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Tab1e 5-2, INSTALLATION COST FACTOR
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FOOTNOTES FOR Tab1 e 5-3 a Incl ude
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In order to prevent an explosion ha
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analysis of the Distil 1 ation NSPS
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Install ed piping and ducting costs
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estimated by the same procedure as
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.ble 5-4. POLYPROPYLENE MODEL PLANT
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Table 5-6. POLYSTYRENE MODEL PLANT
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emitters, while other dryers, e.g.,
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Table 5-8. COST ANALYSIS FOR POLYPR
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other dryers may have higher or low
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Table 5-11. COST ANALYSIS FOR HIGH
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Table 5-12. COST ANALYSIS FOR POLYS
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Polymer Table 5-15. COST EFFECTIVEN
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effectiveness of polystyrene contro
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EEA. Distil lation NSPS Pi peline C
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APPENDIX A LIST OF COMFIENJERS
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APPENDIX B COMMENTS OW MAY 1982 DRA
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Mr. J. R. Famet Page 2 EPA June 16,
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October 19, 1981 Attachment to June
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Be The mocial plant does nst incEud
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1000 BRAZOS, SUITE 200, AUSTIN, TEX
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our previous comments the TCC quest
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. . . . " . . 5. Emission Reduction
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REFERENCES Texas Chemical Council t
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' Y !. Jack R. Faner o The A~ency h
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NATION& AIR POLLUTION CONTROL Y COM
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" DEFINITION OF INCINERATION AS MCT
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-5- IN SUWRYj THE AGENCY, BY RELYIN
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STRUMS WITH RELATIVELY STABLE FLOW
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1 I CoHPlTIONS OF 10 TIMES NORMAL S
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I 1 I - gU - I I n G PROPO.SED INCI
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The use of data from the CTG for ai
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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
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: Footnotes for Table E-1 astandad co
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
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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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