Control of Volatile Organic Compounds Emissions from Manufacturing

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5.0 CONTROL COST ANALYSIS OF RACT ............ 5.1 BASES OF COST ANALYSES ............. 5.1.1 Thermal Incinerator Design and Cost Basis ............ 5.1.2 Flare Design and Cost Basis ....... 5.1.3 Catalytic Incinerator Design and Cost Basis ............ 5.1.4 Condenser Design and Cost Basis ..... 5.2 EMISSION CONTROL COSTS ............. 5.2.1 Polypropylene (PP) ........... 5.2.2 High-Density Polyethylene (HDPE) .... 5.2.3 Polystyrene ( PS) ............ 5.3 COST EFFECTIVENESS OF RACT ........... 5.4 REFERENCES FOR CHAPTER 5 ............ APPENDIX A .LIST OF COMMENTERS ............. APPENDIX B .COMMENTS ON MAY 1982 DRAFT CTG DOCUMENT ... APPENDIX C .MAJOR ISSUES AND RESPONSES ......... C.l THE INCLUSION OF FLARES AS RACT ........ C.2 ACCEPTABILITY OF CONDENSERS. CATALYTIC INCINERATORS. ABSORBERS. AND PROCESS HEATERS AS RACT ........... C.3 STRINGENCY OF RACT. .............. C.4 BASIS OF COST ANALYSIS ............. C.4.1 Origin of costs (GARD vs Enviroscience ............. C.4.2 Cost Effectiveness Calculations ..... C.4.3 Miscellaneous .............. C.5 SCOPE OF CTG: POLYSTYRENE CONTINUOUS PROCESS .................... C.6 SCOPE OF THE CTG: HIGH DENSITY POLYETHYLENE. LIQUID PHASE SOLUTION PROCESS AND OTHER PROCESSES NOT CURRENTLY INCLUDED ........ APPENDIX D .EMISSION SOURCE TEST DATA .......... D.l FLARE VOC EMISSION TEST DATA .......... D.l.l Control Device ............ D.1.2 Sampling and Analytical Techniques ... 0.1.3 Test Results ..............
D.2 THERMAL INCINERATOR VOC EMISSION TEST DATA. . . D.2.1 Environmental Protection Agency (EPA) Polymers Test Data . . . . . . . . . . D.2.2 Environmental Protection Agency (EPA) Air Oxidation Unit Test Data . . . . . D.2.3 Chemi cal Company Ai r Oxidation Unit Test Data . . . . . . . . . . . . D.2.4 Union Carbide Lab-Scale Test Data. . . . D.3 VAPOR RECOVERY SYSTEM VOC EMISSION TEST DATA. . D.4 DISCUSSION OF TEST RESULTS AND THE TECHNICAL BASIS OF THE POLYMERS AND RESINS VOC EMISSIONS REDUCTION REQUIREMENT . . . . . . . D.4.1 Discussion of Flare Emission Test Results. . . . . . . . . . . . . . . . D.4.2 Discussion of Thermal Incineration Test Results . . . . . , . . . . . . . D.5 REFERENCES FOR APPENDIX D . . . . . . . . . . . APPENDIX E - DETAILED DESIGN AND COST ESTIMATION PROCEDURES . . . . . . . . . . . . . . . . . E.l GENERAL............. ..... .. E.2 FLARE DESIGN AND COST ESTIMATION PROCEDURE. . . E.2.1 Flare Design Procedure . . . . . . . . . E.2.2 Flare Cost Estimation Procedure. . . . . E.3 THERMAL INCINERATOR DESIGN AND COST ESTIMATION PROCEDURE . . . . . . . . . . . . . . . . . . . E.3.1 Thermal Incinerator Design Procedure . . E.3.2 Thermal Incinerator Cost Estimation Procedure, , . . . . . . . . . .' . . . E.4 CATALYTIC INCINERATOR DESIGN AND COST ESTIMATION PROCEDURE. . . . . . . . . . . . . . E.4.1 Catalytic Incinerator Design Procedure . E.4.2 Catalytic Incinerator Cost Estimation Procedure. . . . . . , . . . . . . . . E.5 SURFACE CONDENSER DESIGN AND COST ESTIMATION PROCEDURE.... .... ........... E.5.1 Surface Condenser Design . . . . . . . . E.5.2 Surface Condenser Cost Estimation Procedure. . . . . . . . . . . . . . .
Page 1 and 2: dine Series Emission Standards and
Page 3: TABLE OF CONTENTS ................
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 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
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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
Page 166:
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
Page 204 and 205:
The total installed capital cost of
Page 206 and 207:
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
Page 215 and 216:
' organic carbon. chromatography. T
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D.3 VAPOR RECOVERY SYSTEM VOC EMISS
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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,
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APPENDIX E: DETAILED DESIGN AND COS
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characteristics: volumetric flow ra
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Footnotes for Table E-1 astandad co
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sources to the flare header were as
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Flare Tip Diameter (in.) Figure E-1
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Table E-3. CAPITAL AND ANNUAL OPERA
Page 240 and 241:
Footnotes for Table E-3 aFluidic se
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Tab1e E-4. WtORKSHEET FOR CALCULATI
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excess air for oxygen in the waste
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Table E-6. PROCEDURE TO DESIGN THER
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I I a plant had a use for it, heat
Page 252 and 253:
Footnotes for Table E-7 Wpdated usi
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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
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Tabl e -11 CAPITAL AND . IERATIONG
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$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
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I - I - 1 A nnnrrn~~nrc rn rnl PIII
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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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