Control of Volatile Organic Compounds Emissions from Manufacturing

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FOOTNOTES FOR Tab1 e 5-3 (Concl uded) j Average equipment lives given by Neverill in reference cited in g., p* 3-16. 1 k Fugitive Emission Sources of Organic Compounds -- rlddi tional Informati on on Emissions, Emission Reductions, and Costs. U .S. Envi ronmental Protection Agency. Research Triangl e Park, N.C. 45013-82-010. April 1982. p. 5-16. 1 Per reference cited in footnote k: Pub1ication No. EPA- 9 percent of total install ed capital costs for maintenance and miscell aneous charges - 4 percent of total instal 1 ed capital costs for taxes, insurance and administration (equivalent to mi sce11 aneous) .
In order to prevent an explosion hazard and satisfy insurance requirements, dilution ai r was added to any individual or combined waste stream with both a lower heating value between 13 and 50 Btu/scf at O°C (32°F) (about 25 and 100 percent of the lower explosive limit) and an oxygen concentration of 12 percent or greater by volume. Dilution air was added to reduce the lower heating value of the stream to below 13 Btu/scf. (Adding dilution air is a more conservative assumption than the alternative of adding natural gas and Is probably more realistic as other streams often have enough heat content to sustain the combustion of the combined stream.) The combustion products were then calculated assuming 18 percent excess air for required combustion air, but 0 percent excess air for oxygen in the waste gas, i.e., oxygen thoroughly mixed with VOC in waste gas. The procedure includes a cal cu1 ation of auxi 1 iary fuel requirements for streams (usually with heating values less than 60 Btu/scf) unable to achieve stable combustion at 870°C (1600°F) or greater. Natural gas was assumed as the auxi 1i ary fuel as it was noted by vendors as the primary fuel now being used by industry. Natural gas requirements were calculated using a heat and mass balance assuming a 10 percent heat loss in the incinerator. Minimum auxi 1 iary fuel requirements for 1 ow heati ng value streams were set at 5 Btu/scf to ensure flame stability.4 For streams able to maintain combustion at 870°C (1600°F), fuel was added for flame stability in amounts that provided as much as 13 percent of the lower heating value of the waste gas for streams with heating values of 650 Btu/scf or less. For streams containing more than 650 Btu/scf, flame stability fuel requirements were assumed to be zero since coke oven gas, which sustains a stable flame, contains only about 590 Btu/scf. In order to prevent damage to incinerator construction materials, quench air was added to reduce the combustion temperature to below the incinerator design temperature of 980°C (1800°F) for the cost curve given by IT Envi rosci en~e.~ The total flue gas was then calculated by summing the products of combustion of the waste gas and natural gas along with the dilution air. The required combustion chamber volume was then calculated for a residence time of 0.75 sec, conservatively oversizing by 5 percent according to standard industry pract ice.6 The design procedure assumed a minimum
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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
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: FOOTNOTES FOR Tab1 e 5-3 a Incl ude
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
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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
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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
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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
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Footnotes for Table E-7 Wpdated usi
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Table E-8. OPERATING PARAMETERS AND
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TABLE E-9. GAS PARAMETERS USED FOR
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~ 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
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Table E-12. PROCEDURE TO CALCULATE
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Footnotes for Table E-12 (Concluded
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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
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aUpdated using Chemical ~ I nneiri
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Condenser ~y2 ! ;tern Area (ftL) Fi
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ased on an equation in the Chemical
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m Equi p ent Type Check Valves Gate
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- 1/8 - - Table E-20. INSTALLED DUC
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Reference 12, p. 6-3 and 6-4. Refer
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APPENDIX F CALCULATION OF UNCONTROL
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Table F-1 . INITIAL EMISSION CHARAC
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Table F12. SUMMARY OF ANNUAL COSTS,
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= the difference between the operat
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I 8 - a F.Z. 1 Sty rene-i n-Steam m
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(9 CE = AC - (0.9 ~ CDnA ~ x eRC) d
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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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