Control of Volatile Organic Compounds Emissions from Manufacturing

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surface of a solid catalyst. The catalyst increases the rate of oxidation, allowing the reaction to occur at a lower temperature than in thermal 4 nci neration. This technique may offer advantages over thermal inci nerat ion , in auxiliary fuel savings where low VOC content makes large fuel usage necessary. Catalytic incinerators also may produce less NOx because of ' lower combustion temperatures and smaller excess air requirements. Combustion catalysts are made by depositing p1 a ti num or p1 at! num alloys, copper oxide, chromium, or cobalt on an inert substrate, which is suitably shaped to fit the mechanical design of the incinerator. The , operating temperature of the catalyst is usually from 315°C (600°F) to . 65Q°C (1,200°F). Combustion may not occur below 315°C (600°F) and temperatures higher than 650°C (1,200°F) may shorten the catalyst life or even evaporate catalyst from the support substrate.24 Accumulation of particulate matter, condensed VOC's, or polymerized hydrocarbons on the catalyst can block the active sites and reduce its effectiveness. Catalysts can also be contaminated and deactivated hy compounds containing sulphur, bi smuth, phosphorous, arsenic, antimony, mercury, lead, zi nc, tin, or halogens. If the catalyst is so "poisoned,"' VOC's will pass through unreacted or only partia 1ly oxidized. Catalytic inci nerators can operate efficiently treating offgas streams with VOC concentrations below the lower explosive limit. This is a distinct, advantage over thermal incinerators which would in this situation require auxiliary fuel . A schematic of a catalytic incinerator unit is shown in Figure 3-5. During operation, the waste gases (1) first enter the mixing chamber (also called the preheat zone) (3) where they are heated by contact with the hot combustion products of a burner (2). The m'ixing chamber temperature I may vary as a function of the composition and type of contaminants to be oxidized, but will generally operate in the range of 343°C (650°F) to 593OC (1,100~~) .25 The heated mixture then passes through the catalyst bed (4) where oxygen and VOC8s diffuse to the catalyst and are adsorbed on its surface. The oxidation reaction takes place at these "active sites," Reaction products desorb from the active sites and diffuse back Into the waste gas. As with the exhaust gases from thermal incinerators, the products of combustion leaving the bed may be used in a waste heat recovery device (5) before being exhausted to the atmosphere.
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dine Series Emission Standards and
Page 3 and 4:
TABLE OF CONTENTS ................
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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 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
Page 57: chamber temperatures ranging from 7
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
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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
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Polymer Table 5-15. COST EFFECTIVEN
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effectiveness of polystyrene contro
Page 126 and 127:
EEA. Distil lation NSPS Pi peline C
Page 129 and 130:
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,
Page 135 and 136:
October 19, 1981 Attachment to June
Page 137 and 138:
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
Page 145 and 146:
REFERENCES Texas Chemical Council t
Page 147 and 148:
' 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
Page 154 and 155:
-5- IN SUWRYj THE AGENCY, BY RELYIN
Page 156 and 157:
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,
Page 169 and 170:
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
Page 175 and 176:
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
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
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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
Page 208 and 209:
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
Page 217 and 218:
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,
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APPENDIX E: DETAILED DESIGN AND COS
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characteristics: volumetric flow ra
Page 231 and 232:
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
Page 238 and 239:
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
Page 246 and 247:
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
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~ 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
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Table F-1 . INITIAL EMISSION CHARAC
Page 293 and 294:
Table F12. SUMMARY OF ANNUAL COSTS,
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= 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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