Control of Volatile Organic Compounds Emissions from Manufacturing

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Table E-15. CAPITAL AND ANNUAL OPERATING COST E1STIMATES FOR A RETROFIT 20 ft2 CONDENSER SYSTEM FOR THE STREAMS FROM THE CONTINUOUS POLYSTYRENE IYODEL PLANT - Item Value Control system Heat exchanger wi2h a maximum capacity of 20 ft heat transfer area Capital Cost: Purchase cost Instal 1 ed capital costa Annual ized cost: Operating laborb Utili t ip Water Taxes, insurancef and administration Capital recoveryg Total ann'ual ized cost without recovery credit I I I I Total amount of styrene recovered from W lb/hr (W lb/hr x 8,000 hr/yr x X heat exchanger of styrene efficiency x 90% recovery efficiency from the separator) + 2,000 1 blton = Y tonsjyear Annual styrene recovery credit at $O.3575/1 b .Total annualized cost after credit ($1,980 - $Z) Y tons x 2,000 lb/ton x $0.3575/1b = $Z Cost effectiveness of emission ($1,980 - $Z)/[W lb/hr x 8,000 hr/yr reduction ($/Mg) x X heat exchanger (VOC reduction) efficiency/2,205 1 b/Mg] ,, , a~urchase cost times retrofit installation cost factbr of 1.48 (see Table 5-2). b~peratinglabor cost = 1 hr/wk k 52 wk/yr x 1.15 (with supervision1 without supervision) x $18/hr (including overtime). '~aintenance cost = 0.05 x (installed capital cost). d~atercost = 25 gpm x 60 min/hr x 8,600 hr/yr x 0.001 make-up/total x $0.30/(1,000 gal) x (1,000 ga1)/1,000 gal. e~lectrici ty consumption (equations from Reference 40) and cost: hydraulic horsepower = 50 ft x (1.0 specific gravity) x i!5 gpm/3960 0.3157 hp brake horsepower = 0.3157 hp x 745.7 W/hp x 8,000 hr/yr , , , , , , , , x kW/1,000W + 0.65 pump efficiency = 2,900 kWh1yr Cost = 2.900 kWh/yr x $O.O49/kWh f~axes insurance, and adminjstration cost = 0.04 x (instal led capital cost). I I* I g~apital recovery factor = 0.1627, for 10 percent interest (before taxes) and 10 year 1 ife.
Table E-16. CAPITAL AND ANNUAL OPERATING COST ESTIMATION PROCEDURE FOR CONDENSERS WITH REFRIGERATION Item Ca ital Costs -+KEm Installed cost, Dec. 1979 Inst a1 1 ed cost , June 1980a Instal led retrofit cost, June 1980 Refrigeration Installed cost, Dec. 1979 Installed cost, June 1980a Total Instal led Cost, June 1980 Annual ized cosIkC Operating 1 abord Mai ntenance materi a1 s & 1 abor r . Utilities Electricity, pumping Electricity, refrigeration Coolant, make-up Capital recoveryh Taxes, administration & insurance Tot a1 annual ized cost without recovery credit Styrene recovery credit Net Annual ized Cost after recovery credit Value From Figure E-6 for A Instal led cost, Dec. 1979 x 1.O47 Installed cost, June 1980 x 1.065, from Table 5-2 From Fig. E-7 for RC & T~~ Installed cost, Dec. 1979 x 1.047 Sum of condenser and refrigeration $1,080 0.05 x total installed cost See footnote e See footnote f See footnote g 0.1627 x total installed cost 0.04 x total installed cost Operating labor & maintenance + utilities + capital recovery + taxes, admi ni st ration & insurance 2767 x Ws x (%Red'n. + 100) Total annualized cost - styrene recovery credit
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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
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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
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 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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