Control of Volatile Organic Compounds Emissions from Manufacturing

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Footnotes for Table E-7 Wpdated using Chemical Engineering Plant Cost Index from December 1979' (247.6) to June 1980 (259.2). l bpipi ng updated using Chemical Engineering Plant Cost pipes, valves, and fittings index from August 1978 (273.1) to June 1980 (329.3). Ducti ng updated using Chemical Engineering Plant Cost fabricated equipment index from December 1977 (226.2) to June 1980 (291.3). CFrom F i gure E-4 for no heat recovery from Envi rosci ence (Reference 16)', which assumed 150-ft of round steel inlet ductwork with four ells, one expansion joint, and one damper with actuator;, and costed according to the GARD Manual (Reference 17). Fans were assumed for both waste gas and combustion air using the ratios developed for a "typical hydrocarbon" and various estimated pressure drops and were costed using the Richardson Rapid System (Reference 18). Stack costs were estimated by Enviroscience based on cost data received from one thermal oxidizer vendor. I I Although these Envi rosci ence estimates were developed for lower heati ng value waste gases usi ng a "typical hydrocarbon" and no di 1 ut ion to limit combustion temperature, the costs were u!jed directly because Enviroscience found variations in duct, etc., design to cause only small variations in total system cost. Also, since the duct, fan, and stack costs are based on different flow rates (waste gas, combustion air and waste gas, and flue gas, respectively) the costs can not be separated to be adjusted individually. I dupdated using Chemical Engineering Plant Cost fa ed equipment index from December 1979 (273.7) to June 1980 (29l.3). @Cost factors resented in Table 5-3. (379 scf at 60°F/lb-mole) x (1040 Btu(HHV)/scf at 60°F) x $5.98110~ 1 1 1 1 I Btu (HHV) x (106 ~tu)/106 (Btu). g~lectricit~(6 = in. H20 pressure drop) x Qfeg (scfm) x (8000 hrs/yr) x (0.7457 kW/hp) x (5.204 1b/ft2/in. H20) r [(60 seclmin) x (550 ft-lb, secfhp) x (0.6 kW blower11 kW electric) x $0.049/kwh]. h10 percent interest (before taxes) and 10 yr. life. I I
E.4.1 Catalytic Incinerator Design Procedure The basic equipment components of a catalytic incinerator include a blower, burner, mi xi ng chamber, catalyst bed, an optional heat exchanger, stack, control s, instrumentation, and control panel s. The burner is used to preheat the gas to catalyst temperature. There is essentially no fume retention requirement. The preheat temperature is determined by the VOC content of gas, the VOC destruction efficiency, and the type and amount of catalyst required. A sufficient amount of air must be available in the gas or be supplied to the preheater for VOC combustion. (All the gas streams for which catalytic incinerator control system costs were developed are dilute enough in air and therefore require no additional combustion air.) The VOC components contained in the gas streams include ethylene, n-hexane, and other easily oxidizable components. These VOC components have catalytic ignition temperatures below 315OC (600°F). The catalyst bed outlet temperature is determined by gas VOC content. Catalysts can be operated up to a temperature of 700°C (1,300°F). However, continuous use of the catalyst at this high temperature may cause accelerated thermal agi ng due to recrystal lization. The catalyst bed size required depends upon the type of catalyst used and the VOC destruction efficiency desired. About 1.5 ft3 of catalyst for 1,000 scfm is required for 90 percent control efficiency and 2.25 ft3 is required for 98 percent control efficiency.19 As di scussed earlier many factors influence the catalyst 1 ife. Typical ly the catalyst may loose its effectiveness gradual ly over a period of 2 to 10 years. In this report the catalyst is assumed to be replaced every 3 years. Heat exchanger requi rements are determi ned by gas inlet temperature and preheater temperature. A minimum practical heat exchanger efficiency is about 30 percent. Gas temperature, preheater temperature, gas dew point temperature and gas VOC content determine the maximum feasible heat exchanger efficiency. A maximum heat exchanger efficiency of 65 percent was assumed for this analysis. The procedure used to calculate fuel requi rements is presented in Table E-8. Estimated fuel ' requi rements . and costs are based on using natural gas, although either oil (No. 1 or 2) or gas can be used. Fuel requirements are drastically reduced
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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
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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
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 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
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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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