Control of Volatile Organic Compounds Emissions from Manufacturing

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is pumped to a vacuum devolatilizer where most of the monomer and by- products are separated, condensed and sent to a styrene recovery unit. Vapors from the styrene condenser are vented through a vacuum system. Molten polystyrene from the bottom of the devolatilizer is pumped through a stranding die-plate into a cold water bath. The cooled strands are pelletized and sent to product storage. In the styrene recovery unit, crude styrene rrlonomer is separated in ' a distillation column. The styrene vapor overhead frbm the tower is condensed and recycled to the feed di ssol ver tank, Noncondensi bl es are vented through a vacuum system, Heavies from the bottom of the column can be used as a fuel supplement. 2.4.2.2 VOC Sources. Table 2-8 shows the vent stream characteristics for the continuous polystyrene process. All VOC emission streams from the process are continuous. Industry's experience with continuous polystyrene plants indicate a wide range of emission rates from plant to plant. Steam present in Streams B and C reflects the use of a steam jet ejector in the vacuum system used; air reflects the use of vacuum pumps. 1. Stream A: Feed Dissolver - This vent emits mostly styrene. The VOC emission results from washing losses. Currently, the styrene is emitted to the atmosphere. 2. Stream B: Styrene Condenser Vent - Consists of unreacted styrene separated from the polystyrene in a vacuum devol ati 1 izer. The stream can be exhausted through a vacuum system ( g , steam jet ejector) to atmosphere. This is the largest VOC source. CJhen vacuum pumps are used and fol 1 owed by refrigerated bri ne condenser ,, the emi ssi ons can be lower. 3. Stream C: Styrene Recovery Unit Condenser Vent - This stream contains the noncondensible components separated in the styrene recovery I tower and is vented through a steam jet ejector or vacuum pump. 4. Stream D: Extruder Quench Vent - This stream consists of steam and a trace of styrene vapor. The stream is usually vented through l a forced-draft hood and passed through demister-pad or electrostatic I precipitator before venting to the atmosphere. 2.4.2.3 Control Systems. No routine control is applied to continuous 1 processes other than normal condensation operations. One unique system, , .3
Tab1e 2-8. CHARACTERISTICS OF VENT STREAMS FROM THE POLYSTYRENE CONTINUOUS PROCESS^ Processb Section streamC Name Nature Emission rate, kg VOC/Mg product Temperature. OC Pressure, P S ~ Cmposition, M.% Feed Dissol ver Continuous 0.009 - - 92 Styrene 7.5 Polybutadiene 1.5 Other Devolatil izer condenser vent Continuous 0.05-2.96 100 0 21.8 Styrene 78.2 Steam Styrene recovery unit condenser vent Continuous 0.05-0.13 100 0 2.1 Styrene 97.9 Steam Extruder quench vent Continuous 0.15 . 21 - 99.99 Steam Trace Styrene Total Emission Rate 0.26-3.25 a~ourceof Information: Industry correspondence. bfU!~ = raw material preparation; t1R = material recovery; PF = product finishing. 'see Figure 2-3 for stream identification.
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 and 20: Table 2-2. POLYPROPYLENE (PP) PLANT
Page 21 and 22: Fxlrus loll l'el lciiz ltlq Methano
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: A - . STYREL +VACUUH SYSTEM (8) (9)
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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