EPA Control Technologies Hazardous Pollutants 1991

7/27/2019 EPA Control Technologies Hazardous Pollutants 1991

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EPN625/6-91/014June 1991

HandbookControl Technologies forHazardous Air Pollutants


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NoticeThe inform ation in this document has been funded wholly, or in part, by the U.S.Environmental Protection Agency (USEPA) under Contract No. 68-C8-0011,Work Assignment No . 1-31, issued to Paci fc Environmental Services, Inc. (PES),as a subcontractor to the Eastern Research Group, Inc. Mention of trade namesor com mercial products does not constitu te endorsem ent or recommendation foruse.


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AcknowledgmentThis Handbook was prepared by Michael K. Sink, Pacific Environmental Ser-vices, Inc., for the U.S. nvironmental Protection Agency's Center for Environ-mental Research information (CERI) in conjunction with the EPA Control Tech-nology Center. Carlos Nunez, Air and Energy Engineering Research Laboratory(AEERL), and Justice Manning, CERI, Office of Research and Development,served as technical project managers. Special acknowledgment is given toWilliam M. Vatavuk for guidance on sources of cost information and a detailedreview of Chapter 4. Peer review was provided by Robert H. Boywardt, AEERL,and William J. Neuffer, Office of Air Quality Planning and Standards.

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PrefaceThis document is a revision of the first (1986) edition of the Handbook. (SeeReference 1, Section 1.3).An associated project of upgrading a personal computer software package toaccompany this handbook was undertaken concurrently and funded by theControl Technology Center (CTC). The software program (HAP PRO, version 1)is a revisionof the earlier CAT (Controlling Air Toxics) program and is availablefrom the CTC by calling 919/541-0800. (The CTC has plans to install thesoftware on the CTC Bulletin Board, which is part of the OAQPS TechnologyTransfer Network, for ease of access to those with communication capabilities.Information on its availability may be obtained through the above-listed telephonenumber.) The handbook was the basis for the software design. This software wasdesigned to be user-friendly and to duplicate the manual calculations of thehandbook from user i n p t data. The purpose of the software is to provide easyaccess to the calculational techniques in the handbook for those who haveaccess to a personal computer.The CTC was established by EPA's Offices of Research and Development andAir Quality Planning and Standards to provide technical assistance to State andlocal air pollution control agencies and EPA regional staff on air pollution controlissues. Three levels of assistance can be accessed through the CTC. First, aCTC Hotline has been established to provide telephone assistance on mattersrelating to air pollution control technology. Second, more in-depth engineeringassistance can be provided when appropriate. Third, the CTC can providetechnical guidance through publication of technical guidance documents, devel-opment of personal computer software, and presentation of workshops on controltechnology matters.


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ContentsPage

Notice ............................................................................................................... iiAcknowledgment .............................................................................................. iiiPreface ............................................................................................................ ivFigures .............................................................................................................. ix Tables ................................................................................................................ xNomenclature................................................................................................. xivConversion Factors ........................................................................................ xx iChapter 1 Introduction .............................................................................. 1-1

Background and Objective ................................................ 1-1How to Use the Handbook ............................................... 1-21.3 References........................................................................ 1-5Key Phys ical Properties .......................................................... 2-12.1 Background ....................................................................... 2-1

Emission Sources ............................................................. 2-2

1.11.2Chapter 2 HAP Emissions by Source Category and

2.2 Identification of Potential HAPSand2.2.12.2.22.2.32.2.42.2.5

Solvent Usage Operations .................................... 2-3Metallurgical Industries ......................................... 2-4Industry (SOCMI) .................................................. 2-4Industry ................................................................. 2-7Chemical Products Industry .................................. 2-7

Synthetic Organic Chemical ManufacturingInorganic Chemical Manufacturing


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Contents (con t inued)Page

3.2.3 Control Techniques for Organic/Inorganic Vapor Emissions fromProcess Fugitive Sources ..................................... 3-73.2.4 Control Techniques for OrganidInorganic Vapor Emissions fromArea Fugitive Sources ......................................... 3-103.2.5 Control Device Selection for aHypothetical Facility ............................................ 3-10

Particulate EmissionsControl......................................... 3-11.33.3.1 Control Techniques for Particulate3.3.2 Control Techniques for ParticulateEmissions from Point Sources ............................ 3-11Emissions from Fugitive Sources ....................... 3-15

3.4 References ..................................................................... 3-23Chapter 4 Design and Cost of HAPControl Techniques ....................... 4-1

4.1 Background....................................................................... 4-14.2 Thermal Incineration ......................................................... 4-14.2.1 Data Required ....................................................... 4-34.2.2 Pretreatment of the Emission Stream:Dilution Air Requirements ..................................... 4-34.2.3 Design Variables, DestructionEfficiency. and Typical Operational.......................Problems ............................................................... 4-34.2.4 Determination of IncineratorOperating Variables ............................................. 4-54.2.5 Evaluation of Permit Application .......................... 4-64.2.6 Capital and Annual Costs of ThermalIncinerators ........................................................... 4-74.2.7 References.......................................................... 4-10


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Contents (con inued)Page

4.54.6

4.7

4.4.34.4.4 Evaluation of Permit Application ........................... 4-23Capital and Annual Costs of Flares ...................... 4-234.4.5 References ............................................................4-27Boiler/Process Heaters ..................................................... 4-27Carbon Adsorption ........................................................... -4-284.6.1 Data Required....................................................... 4-284.6.2 Adsorption Theory ...................................................4.6.3 Design Parameters ............................................... 4-294.6.4 Pretreatment of the Emission Stream ................... -294.6.5 Typical Operational Characteristics,Problems. and Adsorber Types ............................ 4-304.6.6 Fixed Bed Regenerative Systems......................... 4-304.6.7 Evaluationof Permit Application........................... 4-344.6.8 Capital and Annual Costs of FixedBed Regenerative Adsorbers ................................ 4-344.6.9 Carbon Canister System Design........................... 4-414.6.10 Capitaland Annual Costs of

Canister Systems .................................................. 4-424.6.1 1 References............................................................ 4-44Absorption ......................................................................... 4.44

Absorption System Design Variables.................... 4-45Design and Operating Variables ........................... 4-46Evaluation of Permit Application ........................... 4-51Capital and Annual Costs of Absorbers ................4-52

4.7.1 Data Required....................................................... 4-454.7.24.7.3 Determination of Absorber System4.7.44.7.54.7.6 References............................................................ 4-54

.

Condensers....................................................................... 4-55


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Con ents (con inued)Page

4.1 1

4.12

AppendicesA.lA.2

4.10.2 Pretreatment of the Emission Stream................... 4-814.10.3 ESP Design Variables ........................................... 4-814.10.4 Evaluation of Permit Application ........................... 4-824.10.5 Determination of ESP Operating Parameters .......4-844.10.6 Capital and Annual Costs of ESPSystems ................................................................ 4-854.10.7 References ............................................................ 4-90Venturi Scrubbers ............................................................. 4-904.1 1.1 Data Required....................................................... 4.914.1 1.2 Pretreatment of the Emission Stream ................... -914.1 1.3 Venturi Scrubber Design Variables ....................... 4-914.1 1.4 Sizing of Venturi Scrubbers .................................. 4-934.11.5 Evaluation of Permit Application ........................... 4-944.11.6 Capital and Annual Costs ofVenturi Scrubbers ................................................. 4-944.1 1.7 References ............................................................ 4-98Costs of Auxiliary Equipment ............................................ 4-984.1 2.1 Fan Purchase Cost ............................................... 4-984.1 2.2 Ductwork Purchase Cost ..................................... 4-1004.1 2.3 Stack Purchase Cost ........................................... 4-1004.1 2.4 Damper Purchase Cost ....................................... 4-1004.1 2.5 Cyclone Purchase Cost ....................................... 4-1014.12.6 References .......................................................... 4-101

Listing of Compounds Currently ConsideredHazardous........................................................................ a.1-1Toxic Air PolIutanVSource Crosswalk .............................. A.2-1


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Number1.11.22.12.23.13.23.33.43.53.63.73.83.94.2-14.3-14.4-14.6-14.7-14.7-24.7-34.7-4

FiguresPage

Steps Used When Responding o Inquires ....................................... 1-3Steps Used When Reviewing Permits............................................... 1-4Potential Emission Points for Vacuum Distillation Column................2-6HAP Emission Stream Data Form ..................................................... 2-2Approximate Percent Reduction Ranges forAdd-on Equipment ............................................................................ 3.2Effluent Characteristics for Emission Stream #1 ............................. 3-11Effluent Characteristics for Emission Stream#2 ............................. 3.12Effluent Characteristics for Emission Stream #3 ............................. 3.13Effluent Characteristics for Emission Stream #4 ............................. 3-14Effluent Characteristics for Emission Stream#5 ............................. 3-15Effluent Characteristics for Emission Stream#6 ............................. 3-17Effluent Characteristics for Emission Stream #7 ............................. 3-19Effluent Characteristics for a MunicipalIncinerator Emission Stream ............................................................ 3-20Schematic Diagram of a Thermal Incinerator.................................... 4-2Schematic Diagram of a Catalytic Incinerator System .................... 4-11Typical Steam Assisted Flare .......................................................... 4.21Adsorption System ........................................................................... 4-31Typical Countercurrent Packed Column Absorber .......................... 4.44Flooding Correlation in Randomly Packed Towers ......................... 4-46Relationship between Nw,AF. and Efficiency ................................. 4-48Costs of Absorber Towers ............................................................... 4-50

Typical Two Bed Regenerative Carbon


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TablesNumber Page2.12.22.32.42.52.62.72.82.92.102.1 12.122.132.143.13.23.3

Potential HAPs and Emission Sources forPotential HAPs and Emission Sources forEmission Sources for the SOCMI...................................................... 2-6Potential HAPs for Inorganic ChemicalPotential HAPs and Emission Sources for the

Solvent Usage Operations................................................................. 2-3Metallurgical Industries...................................................................... 2.5Manufacturing ndustry ...................................................................... 2-8 Chemical Products Industry............................................................. 2-10Potential HAPs for the Mineral Products Industry........................... 2-11Potential HAPs for the Wood Products Industry.............................. 2-12Industries (General) ......................................................................... 2-12Industries (Specific) ......................................................................... 2-13

Potential HAPs for Petroleum RelatedPotential HAPs for Petroleum RefiningEmission Sources for the Petroleum Related Industries................. -13Potential HAPs and Emission Sources forCombustion Sources........................................................................ 2-14Key Properties for Organic Vapor Emissions.................................. 2-15Key Properties for Inorganic Vapor Emissions................................ 2-15Key Properties for Particulate Emissions......................................... 2.15Key Emission Stream and HAP Characteristics orSelecting Control Techniques............................................................ 3-2 Control Methods for Various Inorganic Vapors.................................. 3- 7Summary of Control Effectiveness for ControllingOrganic Process Fugitive Emission Sources..................................... 3-8


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Number4.2-64.2-74.2-84.2-94.3-14.3-24.3-34.3-44.3-54.3-64.3-74.4-14.4-24.4-34.4-44.4-54.6-14.6-24.6-34.6-44.6-54.6.64.6.74.6-84.6-94.6-104.7-1

Tables (cont inued)Page

Capital Cost Factors for Thermal Incinerators ................................... 4-8Example Case Capital Costs ............................................................. 4-9Annual Cost Factors for Thermal Incinerators ................................... 4-9Typical Pressure Drops for Thermal Incinerators .............................. 4-9Catalytic Incinerator System Design Variables ................................ 4-13Comparison of Calculated Values and Vaiues Suppliedby the Permit Applicant for Catalytic Incineration........................... 4-16Equipment Costs for Fixed Bed Catalytic Incinerators .................... 4-16Example Case Capital Costs ........................................................... 4-18Annual Cost Factors for Catalytic Incinerators ................................ 4-19Typical Pressure Drops for Catalytic Incinerators ........................... 4-19Flare Gas Exit Velocities for 98 Percent DestructionEfficiency .......................................................................................... 4-22Comparison of Calculated Values and Values Suppliedby Permit Applicant for Flares ........................................................ 4-24Capital Cost Factors for Flares ........................................................ 4-24Example Case Capital Costs ........................................................... 4-25Annual Cost Factors for Flares ........................................................ 4-26Parameters for Selected Adsorption Isotherms ............................... 4-29Carbon Adsorber System Efficiency Variables ................................ 4-33Comparison of Calculated Values and Values Suppliedby Permit Applicant for Carbon Adsorption ..................................... 4-34Multiplication Cost Factors for Materials .......................................... 4-35Installation Factors for Fixed Bed Carbon Adsorbers...................... 4-35Example Case Capital Costs ........................................................... 4-36Unit Cost Factors for Carbon Adsorption Annual Costs .................. 4-37Selected Equations for Carbon Adsorption AnnualCost Estimate................................................................................... 4-38Comparison of Calculated Values and Values Suppliedby the Permit Applicant for Carbon Canister Systems .................... 4-42Equipment Costs for Canister Units ................................................ 4-42Comparison of Calculated Values and Values Supplied

Capital Cost Factors for Catalytic Incinerators ................................ 4-17


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Tables (continued)Number4.9-64.9-74.9-84.9-94.9-104.1 0-14.10-24.10-34.10-44.10-54.1 0-64.1 0-74.10-84.10-94.11-14.1 1-24.1 1-34.1 1-44.11-54.11-64.11-74.12-14.1 2-24.12-3B.1-1B.1-2

Guide to Estimate Costs of Bare FabricFilter Systems .................................................................................. 4-72Bag Prices........................................................................................ 4-76Capital Cost Factors for Fabric Filters ............................................. 4-77Example Case Capital Costs ........................................................... 4-78Annual Costs for Fabric Filters ........................................................ 4-78Plate-Wire ESP Drift Velocities ........................................................ 4-83Wet Plate-Wire ESP Drift Velocities ................................................ 4-83Flat Plate ESP Drift Velocities ......................................................... 4-83Comparison of Calculated Values and ValuesSupplied by the Permit Applicant for ESPs ..................................... 4-84Capital Cost Factors for ESPs......................................................... 4-85Equipment Cost Multipliers for ESP Optional Equipment ................ 4-85Equipment Cost Multipliers for VariousMaterials of Construction ... ..................................................... 4-86Example Case Capital Cost ..................................................... 4-89Annual Costs for ESPs ...... ..................................................... 4-89Pressure Drops for Typical Venturi ScrubberApplications ...................................................................................... 4-93Construction Materials or Typical Venturi ScrubberApplications ............4-94Comparison of Calculated Values and ValuesSupplied by the Applicant for Venturi Scrubbers ............................. 4-95Venturi Scrubber Equipment Costs ................................................. 4-95Capital Cost Factors for Venturi Scrubbers ..................................... 4-96Annual Cost Factors for Venturi Scrubbers ..................................... 4-97Example Case Capital Costs ........................................................... 4-96CE Equipment Index ........................................................................ 4-99Equation 4.1 2-3 Parameters ............................................................ 4-99Parameters for Costs of Large Stacks .......................................... 4-100Dew Point Temperature (OF) .......................................................... B.1-2Limit (LEL) Data for Selected Compounds .................................... B.1-4Heats of Combustion and Lower Explosive


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Tables (cont inued)Number PageC.7-4C.7-5 Pressure Drop Constants for Tower Packing............................... C.7-14C.8-1 Average Specific Heatsof Vapors ................................................. C.8-44.8-2 Comparison of Calculated Values and Values4.9-5 Comparison of Calculated Values and Values4.10-4 Comparisonof Calculated Values and Values4.1 1-3 Comparisonof Calculated Values and Values

Schmidt Numbers for Compounds in Water at 68F ................... C.7-13

Supplied by the Permit Applicant for Condensation ..................... .C.8-6Supplied by the Permit Applicant for Fabric Filters........................ C-9.4Supplied by the Permit Applicant for ESPs.................................. C.10-2Scrubbers ..................................................................................... C. 11-3Supplied by the Permit Applicant for Venturi


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Nomenclatureflame angle for flare, degreesadsorption cycle time, hrbed drying and cooling fan operating time, hrbed drying and cooling time, hrregeneration cycle time, hrgas viscosity, Ib/ft-secsolvent viscosity, centipoiseparticle size, aerodynamic mean diameterpacking constantair to cloth ratio, (ft3/min)/ft2bed area, ft2flooding correlation absiccacolumn area, ft2condenser surface area, ft 2cyclone inlet area, ft2ductwork parameterauxiliary equipment cost, $annual electricity cost, $fan parameter


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catalytic incinerator cost,$replacement laborcost, $/lbcooling water cost, $/1,000 alcollection efficiency, percentcanister equipmentcost, $bag replacement labor,$mean specific heat of air, Btu/lb-"Faverage specific heat of coolant, Btu/lb-OFspecific heat of HAP, BTU/lb-molO Fcost of replacement bags,$carbon replacementcost, $catalyst replacementcost, $capital recovery factor, decimal fractioncapital recovery factor for bagscapital recovery factor for carbonamount of carbon required, Ibamount of carbon required per vessel, lbsteam cost, $vessel cost, $packing constantdensity, Ib/ftcritical particle size, mdirect annualcost, $direct capitalcost, $column diameter, ftduct diameter, induct diameter, ft


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flooding fractionflare cost, $materialcost factorfan power requirement, kWh/yrdrying and cooling fan flow rate, ft3/hrpacking constantgas stream flow rate, Ib/hrgas stream flow rate based on cross-sectional area, Ib/ft2-secgas stream flow rate of flooding, IbWsecgravitational constant, ft/s&gas stream flow rate, Ib-moles/hrheat of vaporization, Btu/lb-moleflare height, ftmoles of HA P condensed, moles/minHA P emission stream concentration, ppmvmoles of HAP in inlet stream, moles/minHA P outlet concentration, ppmvmoles of HA P in outlet stream, moles/minenthalpy change of condensed vapors, Btu/minemission stream desired heat content, Btu/scfemission stream heat content, Btu/lb or Btu/scfsupplementary fuel heating value, Btu/lbflare gas heat content, Btulscfheight of gas transfer unit, ftheight of liquid transfer unit, ftcondenser heat load, Btu/hr


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solvent flow rate, Ib/hrliquid flow rate, per cross-sectional area of column, Ib/hr-ft2lower explosive limit, percentsolvent flow rate, gaVminsolvent flow rate, Ib-moleslhrvessel length, ftinlet Ib H20/lbdry airsaturated lb H20/lbdry airempirical parameter or slope of equilibrium curvemolecular weight, I /lb-moleannual maintenance cost, $/yrmoisture content, percentHAP inlet loading rate, Ib/hrmolecular weight of the emission stream, Ib/lb-molemolecular weight of the flare gas, Ib/lb-molemolecular weight of HAP, Ib/lb-molemolecular weight of solvent, Ib/lb-moleefficiency fractionnumber of bedsnumber of beds adsorbingnumber of beds desorbingnumber of gas transfer unitsemission stream oxygen content, percentannual ESP operating power, kWh/yrflooding correlation ordinatepressure drop, in. HO


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cost of FRP ductwork, $cost of fan motor and starter, $power requirement for fabric filters, kWh/yrpump power requirement, kWh/yrpartial pressure, mm Hg or psiacost of PVC ductwork, $cost of rotary air lock for cyclone, $steam price, $/1,000bcost of stack, $pressure drop, in. HOventuri scrubber pressure drop, in. H,Ovapor pressure, mm Hgflow rate of combined gas stream, scfmcoolant flow rate, Ib/hrcooling water flow rate, gaVmindilution air required, scfmemission stream flow rate, scfmactual emission stream flow rate, acfmactual emission stream flow rate per adsorbing bed, acfmactual flow rate of dry air, acfmsaturated emission stream flow rate, acfmsupplementary fuel gas flow rate, scfmflue gas flow rate, scfmactual flue gas flow rate, acfmflare gas flow rate, scfmactual flare gas flow rate, acfm


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packing constantvessel surface area, f t2specific collection plate area, ft2/1 000 acfmSchmidt number for gasSchmidt number for liquidspecific gravity of fluidsite preparation,$steam regeneration rate, Ib steam/lb carbonspace velocity through catalyst bed, hr -ltemperature, O Rlog mean temperature difference, OFtotal annual cost, $bed thickness, ft carbancombustion temperature, OFthermal incineratorcost, $total capital cost, $temperature of gas stream entering catalyst bed, OFtemperature of flue gas leaving catalyst bed, OFtemperature of condensation, OFinlet coolant temperature, OFoutlet coolant temperature, OFemission stream temperature, OFsaturation temperature, OFtemperature of flare gas, OFtemperature of emission stream exiting heat exchanger, OF


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w c = carbon bed working capacity , Ib HAP/lb carbonw e = carbon b ed equilibrium c apacity, Ib HAP/lb carbonWR = water consum ption, gal/yrY = packing constantZ = fluid h ead, ft


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Conversion Factors

QuantityMass

Length

Volume

ForcePressure

Equivalent Values1 kgI b,1 m E 100 cm = 1000 mm= l o 6pm

= 1000 g = 0.001 metric ton = 2.20462 Ib,= 16 oz = 5 lo- ton = 453.593 g = 0.453593 kg= 35.27392 OZ.

1Olo angstroms (A) = 39.37 in. = 3.2808 ft= 1.0936 yards = 0.0006214 mile= 12 in. = 1/3 yd = 0.3048 m = 30.48 cmft

1 m3 = lOOOliters= 106cm3= 06ml= 35.3145 ft3= 220.83 imperial gallons= 264.17 gallons= 1056.68 quarts= 1728 in.3= 7.4805 gallons = 0.02831 7 m3= 28,317 liters= 28,317cm3

1 N = 1 kg m/s2= l o 5dynes = l o 5g-cm/s2= 0.22481 Ib,1 lbf = 32.17 Ib,-ft/s2 = 4.4482 N = 4.4482 x l o 5 dynes1 atm = 1.01325~ 05N/m (Pa), = 1.01325 bars= 1.01325 x 1O6 dynes/cm

1 ft3


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Chapter IIntroduction

1.1 Background and ObjectiveThis manual is a revision of the first (1986) edition ofthe Handbook: Control Technologies for HazardousAir Po//utants,l which incorporated information fromnumerous sources into a single, self-contained refer-ence source focusing on the design and cost of VOCand particulate control techniques. However, many ofthe references used in the 1986 version were pub-lished in the mid-to-late 19703, meaning some infor-mation in the first edition is somewhat dated. This isparticularly true for the cost data presented in Chapter5' which were based on 1977 data. Since that time, agreat deal of design and cost information on selectedcontrol techniques has been published, and EPA con-cluded that this more recent information should beincorporated into a revised manual. This revision hasbeen undertaken to incorporate more recent designandcost information where applicable, while adheringto the original focus and intent of the 1986 manual.The objective of this revised manual is described andthe reader is introduced to its overall organization inthe following paragraphs. A corresponding computerprogram (HAP PRO, Version 1 O ), which performs thenecessary calculations from user input data, is alsoavailable?

lutants. Specifically, it does not specify design re-quirements necessary to achieve compliance with stan-dards established under specific programs such asSection 112 of the Clean Air Act or standards estab-lished under the Resource Conservation and Recov-ery Act. Such requirements vary with the hazardousair pollutant emitted and with the emission source;thus, regulatory-specificdetailed specifications are be-yond the scope of this handbook.The use of this handbook is discussed in Section 1.2.Chapter 2 assists the user in identifying HAPS andtheir respective potential emission sources. Chapter 2also identifies the key emission stream characteristicsnecessary to select appropriate control techniques.Chapter 3 provides additional information to assist theuser in the control technique selection process foreach HAP emission sourcektream. Chapter 4 pre-sents simple step-by-step procedures to determinebasic design and cost parameters of the specific con-trol devices and auxiliary equipment. The capital andannual costs obtained for a given control system re-flect study-type (k30 percent) estimates in Appendi-ces A and B. Supplementary data and calculationprocedures are presented. Appendix C contains blankworksheets to be used while performing the functions


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ambient monitoring, toxicity testing, and source test-ing.The Clearinghouse provides an on-line data basecontaining all toxic-related information submitted byState and local agencies, bibliographic citations forrelevant reports by EPA and other Federal agencies,and references for ongoing EPA air toxic projects isprovided at the Clearinghouse. A quarterly newsletteris published also with articles on current air toxicsconcerns. Finally, the Clearinghouse periodically pub-lishes various special reports on topics of interest tousers. For further information regarding the "NationalAir Toxics Information Clearinghouse," contact theappropriate EPA regional office air toxics contact, orEPA/OAQPS, Pollutant Assessment Branch, MD-12,Research Triangle Park, North Carolina 2771 1 (919)541 5645 or FTS 629-5645.An additional source of information on potential toxicpollutants is the Toxic Air Pollutant/Source Crosswalk:A ScreeningTool for Locating Possible Sources Emit-ting Toxic Air Pollutants, Second Edition, EPA 45012-89-017, December 198g3. A qualitative indication ofpotential toxic pollutants for a given SIC or SCCprocess is provided in this document. Some of theinformation contained in this source has been used toupdate appropriate tables presented in Chapter 2.This reference utilizes information contained in theNational Air Toxics Information Clearinghouse(NATICH, mentioned above), the Specific Toxic Chemi-cal Listings for Title Ill, Section 313 (SARA Title Ill),the Volatile Organic Compound (VOC) Species DataManual (2nd edition), and the National Emissions DataSystems (NEDS) Source classification codes (SCC)and emission factor listings.1.2 How to Use the HandbookFigure 1.1 is a flowchart of the steps performed whenresponding to inquiries; Figure 1.2 contains the same

one of three classifications: process point sources,process fugitive sources, and area fugitive sources.(Note: See Section 2.2 for clasdification definitions.)After each emission source is determined, identify thekey HAP emission stream characteristics (e.g., HAPconcentration, temperature, flow rate, heat content,particle size) needed to select the appropria?econtroltechnique(s) (Section 3.2). Obtain the actual valuesfor these characteristics from the owner/operator orfrom available literature i f the owner/operator cannotprovide the necessary data. If two or more emissionstreams are combined prior to entry into an air pollu-tion control system, determine the characteristics ofthe combined emission stream (Appendix B. l ) .Depending upon the specific regulation and the type/characteristics of the HAP emission sourcektream,the remaining steps in the methodology will differ.Four basic "formats" for a regulation are: (1) a particu-lar "control device" may be required, (2) a "numericallimit" may be specified, (3) a "technology forcing"requirement may be imposed, and (4) a specific work ~practice or "other" related practice may be required.The regulation format will define the steps that lead tothe selection of the appropriate control technique(s).The "control device" and "other" formats specify theappropriate control technique(s). A "numerical limit"format requires the determination of the HAP removalefficiency before the appropriate control technique(s)can be identified. Lastly, the "technology forcing" for-mat has two paths: one where the cost of the controlsystem is a factor in the decision, and one where costis not a factor. If control system cost is a factor, theagency must determine the cost constraints that willbe imposed on the control technique selection pro-cess (e.9. $/ton). The steps that occur in defining theHAP control requirements will depend upon eachagency's regulatory policies.The HAP emission stream characteristics, in conjunc-


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Figun, 1.1 Steps used when responding to inquiries.

Select AppropriateControl

Manual Location toPerform SteplSedion 2.2*Section2.3'Appendix B.1'Chapter 3'Chapter 4:Design'Chapter 4: Cost

Determine RequiredControl Eff ciency5

Information Requestedon HAP Control fora Specific Facility

Agency Determinationof Cost ConstraintsSi

Plant-Specific Data

Select AppropriateControl

+efine HAPS'Define Emission SourcesI Generating HAPS'Define CharacteristicsNeeded for Each HAP

Emission StreamziCombine HAP Streams3 Inquirer Assistance

I

Define CharacteristicsOf Combined Streams'

) -ach Single/CombinedHAP Emission StreamIDefine HAP ControlRequirements6

Requiremen1Decision Factor ? Policy Decision

1NoParameters Reauested?


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Figun, 1.2 S t e p used when reviewingpermlts.

Manual Location toPerform Step1Section 2.2*Section 2.3'Appendix B .l'chapter 3'Chapter 4:Dedgn'chapter 4: cost

Control

Control Technique(s)b

Parameters for

Permit Application

Yes .k 11Obtain Additional Datafrom Applicant1

Obtain Additional Datafrom ApplicantIYes

No YesEach Single/CombinedHAP Emission Stream from Applicantt

tI Define HAP Control I II Requirements'Numerical Limit J

Determine RequiredControl Efficiency6 I I NoL I1

Is Permit Control Recommend AppropriateSystem Appropriate? Control Technique(s)Agency Determination

Control Technique(s)6


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1.3 References1. U.S. EPA. Handbook: Control Technologies forHazardous Air Pollutants, EPA/625/6-86/014 (NTISPB 91 -228809). Cincinnati, OH. September 1986.2. U.S. EPA. HAP PRO: Software Program for Con-trol Technologies for HAP, Control Technology Cen-ter, Research Triangle Park, NC. June 1991.3. U.S. EPA. Evaluation of Control Technologies forHazardous Air Pollutants, Volume 2. Appendices. EPN600/7-86/009b (NTIS PB 86-167038). Research Tri-angle Park, NC. February 1986.4. U.S. EPA. Toxic Air PollutanVSource Crosswalk:A Screening Tool for Locating Possible Sources Emit-ting Toxic Air Pollutants, Second Edition. EPA/450/2-89/017 (NTIS PB 90-170002). Research Triangle Park,NC. December 1989.


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Chapter 2HAP Emissions by Source Category and Key Physical Properties

2.1 BackgroundThe primary goal of this chapter is to identify the follow-ing: (1) potential HAPs for a given source category andthe specific sources that may emit the potential HAPsand(2)key emission stream physicalpropertiesneededto select appropriate control strategies and size controldevices for the HAP emission sources. Specific sourcecategories are divided into nine general classifications inthis manual. [Note:The general classificationsystem isa hybrid of the classification systems used in references6 and 78.1 Every possible source category cannot belisted; however, similarities exist between many catego-ries. Thus, the user should be able to obtain someguidance for any specific facility. Common source cat-egories that are known to emit potential HAPs are pre-sented in this manual. The tables in this chapter havebeen updatedto incorporate recent informationon addi-tional potentialpollutants for the source categories. Ap-pendixA . l contains a list of compounds currentlyconsid-ered hazardous along with the corresponding CAS num-ber. While a list of hazardous compounds is provided inthis table, the user should not necessarily use it as adefinitive guide. As discussed in Chapter 1, the termHAP s broad and encompasses numerous compounds.This appendix is designed o assist in determining HAPs,rather than act as a definitive list. Other information

classification ncludes processesdependent on solvents,such as surface coating and dry cleaning operations.Individual HAPs from this category aregiven in AppendixA.3. Metallurgical Industries include processes associ-ated with the manufacture of metals, such as primaryaluminum production. Processes and operations associ-ated with the manufacture of organic and inorganicchemicals have been grouped into the Synthetic Organicand Inorganic Chemical Manufacturing classifications,respectively. Industries using chemicals in the formula-tion of products are classified as Chemical ProductsIndustries. The Mineral and Wood Products Industriesclassifications nclude operations such as asphalt batchplants and kraft pulp mills, respectively. The PetroleumRelated Industries classification s defined as oil and gasproduction, petroleum refining, and basic petrochemi-cals production. Combustion Sources are utility, indus-trial, and residential combustion sources using coal, oil,gas, wood, or waste-derived fuels.To assist the manual user in recording the pertinentinformation, a worksheet has been provided. A copy ofthis worksheet, the HAP Emission Stream Data Form,

Figum 2.1. HAP emisslonstream data form'


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Company: Glaze Chemical ComDanv Plant Contact : Mr. John LeabLocation (Street): 87Octane Drive Telephone No: (9%) 5555024(City): Somewhere Agency Contact: Mr. Elrem Johnson(State, Zip): No. of Emission Streams Under Review:_.7~AB.C.n.I=,G.H.1J.K.L.M.N.0.

F

(b) (c)(b ) (4HAP Emission Source (a)Source Classification (a) -nEmission Stream HAPs (a) (b) (c)I-WP Class and Form (a)-b) (4HAP Vapor Pressure (1,2) (a) (b) (4HAP Solubility (1,2) (a) (b) (4(b) (4(b) (4HAP Adsorptive Prop. (1,2) P. Organic Content (1)tt- 100 p ~ l vH4HAP Molecular Weight (1,2)Moisture Content (1,2,3) -2% volTemperature (1,2,3) 1'0' FFlow Rate (1,2,3)Pressure (I ,2)abnosDheric S. Particle Mean Diam. (3)HalogenIMetals (1,2) ana13 1 none T. Drift VelocitySO, (3)

Emission Stream Number/Plant Identification

(a)96QMm- -a, (b) (c )AP Content (1,2,3)"(a) PLplllZld(a)-

U. Applicable Regulation(s)V. Required Control LevelW. Selected Control MethodsThe data presented are for an emission stream (single or combined streams) prior to entry into the selected control method(s).Use extra forms if additional space is necessary (e.g., more than three HAPs) and note this need.The numbers in parentheses denote what data should be supplied depending on the data on lines C and E.* 1 = organic vapor process emission

2 = inorganic vapor process emission3 = particulate process emissionOrganic emission stream combustibles less HAP combustibles shown on lines D and F.

2.2 Identification of Potential HAPs andThe purpose of this section s o present general nforma-tion on emissions of potential HAPs by source category.Within each of the nine general classifications, informa-tion is presented on the types of potentialHAPs that may

Emission Sources broadened further, with the last five digits (instead of thelasttwo) eing unspecified.This section also presents information pertainingto thesources (e.g., processes) within each specific sourcecategory that have the potential to emit HAPs. In this

Teble2.1. Potential HAPS and Emisdo n Soums for Solvent U S U p Opt33tbtW


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Potential HAPS' Potential Emission SourcesSource Category Organic Inorganic Process Process AreaVapor Particulate Vapor Particulate Point Fugitive FugitiveSolvent DegreasingDry CleaningGraphic ArbbWaste Solvent ReclaimingSCc-Flatwood PanelingdSC-Machinery"SC-Appliances'SC-Metal FurnitureSC-AutdTrI.ICkQSC-Fabricssc-CanshSC-Paper, Tapes, LabelsMagnetic Tape CoatingSC-Electrical InsulationSC-Marine VesselsiVinyl 8 Acrylic Coating9SC-Wood FurnitureSC-Trans. VehidesLMachine Lu br i i t sRubber Tire Manufacturing

XXXXXXXXXXXXXXXXXXXX

Source KeyA - bath evaporation I -B - solvent transfer J -C - ventilation K -D - waste solvent disposal L -E - washer M-F - drying N -G - still. filtration 0 -

solvent storage Q - application areapipes, flanges, pumps R - flashoff areatransfer areas S - spray boothrollers T - sotventhating mixingink fountains U - quench areacondenser V - green tire sprayingoven W - SidewalVtread end/undertreated cementing

abcd0I0hI1

References2 , 3 , 4 , 5, 6, 7, 8,9, 10, 11 , 13,26, 7, 76.Category includes flexography, lithography. offset printing, and textile printing.SC: surface coating.Category indudes coating of other flat stock.Category indudes coating of misc. metal parts, machinery, andequipment.Category indudes all categories of appliances: Large and small.Category includes coating of automobiles and light-duty t r u k .Category indudes surface coating of coils, cans, ontainers, and closures.Category includes coating and maintenance of marine vessels.Category Includes vinyl, acrylic, and nitrocellulose coatings.

2.2.3 Synthetic Organic Chemical


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category. Appendix A.3 can be used to make a prelimi-nary determination of whether a particular solvent usageoperation may emit a specific potentialHAP or group ofpotential HAPs, as well as todetermine potentialsolventuse operations hat may emit a particular HAP.Table 2.1presents the emission sources that may emit potentialHAPs. Note that the same source may be given under aprocess point and a fugitive source, to account for differ-

Manufacturing Industry (SOCMI)The SOCMI is a large and diverse industry producingseveral thousand intermediate and end-product chemi-cals from a small number of basic chemicals. Most of thechemicals produced by this industry fall under SIC Code286. Specific SCC codes for this source category aretoonumerousto list, but most fall under SCC code 3-01 xxx-xxx. Due to the complexity of the SOCMI, a generalapproach is used in this section to describe genericemission sources and specific emission source types.This approach is identical o the approach used by EPAin its efforts to develop new source performance stan-dards for the SOCMI.A large proportion of the emissions from the SOCMIoccur as organic vapors. However, organic particulateemissions may be generated n some processes (usuallyduring the manufacture of chemicals that exist as solidsat ambient conditions). The emissions typically containraw materials (including mpurities) used n and interme-diate and final products formed during he manufacturingprocess. Many of these emission streams may containHAPs due to the great numberof compounds manufac-tured in the SOCMI.Potential emissions from this industry can be describedgenerically as follows:(a) storage and handling emissions,(b) reactor process emissions,(c) separation process emissions,(d) fugitive emissions, and(e) secondary emissions (e.g., from waste treatment).Emissions can potentially occur from raw materials andproduct storage tanks as working and brezthing lossesthrough vents. Emissions from handling result duringtransportation or transfer of the volatile organic liquids.Reactor processes and separation processes are the

Table2-2. Potential HAPS and Emiss ion Soumes for Metal lurgical Industries


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Source CategoryPotential HAPS'

Organic Inorganic Potential Emission SourcesVapor Particulate Vapor Particulate Point Fugitive FugitiveProcess Process Area

Primary Aluminum ProductionPrimary Cadmium ProductionMetallurgkal Coke 3,8,13,19,21,23, 18

Primary Copper Smelting 1826,27,28,30

12 ,3 23 12 ,3 23 A,I,J.M,N,R H,K,D N,Q,U,Z9 J,E 0 , P N,Z4,29 1,5,6,7,9,14, B C,O,X N,D,Q,U15,16,17,20,22

1,12,31 1,5,9,11,14, F,J,T G,H,K,O,P,X N,Q,U,W,Z15,17.20,24Ferroalloy Production 18

Iron and Steel Production 18

Primary Lead Smelting 18Primary Zinc Smelting 18Manganese Production 18

Nickel Production 18Secondary Aluminum OperationsSecondary Copper Operations(Brass and Bronze Production) 18

Gray Iron Foundries 2,3,13,19,21,23 18

Secondary Lead Smelting 18Steel Foundries

Secondary Zinc ProcessingLead Acid Battery ProductionCadmium-Nickel Battery Production

Q,10,11,14,16, J H,K,O,P N,Q,W17,22,2412 6,9,10,11,14, B,J,V C,H,K,O,X D,N,Q,U,W,Z16,17,22,24

H,K,O,P N,Q,U,W,Z,12 1,5, 9,11,14,15,20 J ,V1,12 1 5,9,11,14,15 E,J,T,S 0 N,Q,U,W,Z20,24

16 J H,K,M,P N,Q,Z1,12 1,9,14,17,20,24 A,I,J,M,T P N,Q,Z12 12,17 J H,KP U24 9,11,14,17,20,24 J H,KP U

1,6,7,9,10,11,14, J Y H,K,G,P U15,16,17,22,24,251,14,16,20 J H,K,P U,Q

1,7,10,11,14, J ,Y G,H,K,P U24 9,15,17,20,24 J k S H.K,L,P U14 14 0,P

9,14 V N,O

16.1 7,24,25,34

tions. Emissions rom separation processes are associ- Table2-3. EmlssionSources for #e SOCMl


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ated primarilywith absorption, scrubbing, and distillationoperations. Other separation processes that may con-tribute to emissions include drying, filtration, extraction,settling, crystallization, quenching, evaporation, on ex-change, dilution, and mixinglblending. One of the morecommonly employed separation techniques is distilla-tion. Depending on the type of distillation system used(i.e., vacuumor nonvacuum), ypical emissionpointscaninclude condensers, accumulators, hot wells, steam jetejectors, vacuum pumps, and pressure relief valves.Emission points from a vacuum distillation system areshown in Figure 2.2.Although fugitive emissions are listed as a separategroup, hey can occur from storageand handling, eactorprocesses, and separation processes. Area fugitivesources include groups of valves, pressure relief de-vices, pumps and compressors, cooling towers, open-.ended lines, and sampling systems. Process fugitivesources include hotwells, accumulators, and processdrains from reactors, product recovery devices, andseparation equipment.

Potential Emission Sources (Specific)Process Process AreaGeneric Source Category Point Fugitive Fugitiveb -Storage and Handling A B,C,DReactor Processes E,F G C,D.H,I,J,KSeparation Processes F,L G,M,N KFugitives G,M,N B.C,D,H,IJ,K,M,N,OSource KeyA - storage, transfer, and I - compressorshandling J - sampling linesB - spills K - pressure relief devicesC - valves L - separation devicesD - flanges (distillation column,E reactors absorber, crystallizer,F - product recovery devices dryer, etc.)(absober, adsorber, M- hotwellcondenser) N - accumulatorG - process drains 0 - cooling towerH - pumpsa References 12,31,32,33,34,35nd 77.Groups of small point sources (e.g., valves, compressors,pumps, etc.) at a SOCMI plant are considered as area fugitivesources in this manual.

Steam

Table 2.3 presents information on specific emissionpoints and emission source types for each of the generic xx. Chemical wood pulping involves the extraction ofcellulose from wood by dissolving he lignin hat binds he


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emission source groups. Using his information, the usercan identify the potential emission sources pertaining ohis specific situation. It is recommended that the usersupplement this information with specific source datagiven the variability of this source category.22-14 norganic Chemical ManufacturingThis industry includes the manufacture of the basicinorganic chemicals before hey are used n he manufac-ture of other chemical products. Most of the chemicalsproduced by this industry fall under SIC Code 281 andSCC codes 3-01 7 1 xx , 3-01 012-xx, 3-01-023-xx,3-01-032-xx, and 3-01 035-xx through 3-01 039-xx. Po-tential emissions from these processes may be high, butbecause of economic reasons they are usually recov-ered. In some cases, the manufacturing operation is runas a closed system, allowing little or no emissions toescape o the atmosphere. Table 2.4 contains the poten-tial HAPs and the industry-specific emission sources forthese industries.2.2.5 Chemical Products IndustryThis industry includes he manufactureof chemical prod-ucts, such as carbon black, synthetic fibers, syntheticrubber and plastics, which may be used in further manu-facture. Also included are the manufacture of finishedchemical prducts for ultimate consumption such aspharmaceutical,charcoal, soaps anddetergents;orprod-ucts to be used as materials or supplies in other indus-tries such as paints, pesticides, fertilizers and explo-sives. Most of the chemical products are covered underSIC Codes 282, 283, 284, 285, 287 and 289. SpecificSCC codes for this source category are too numerous tolist. As in other chemical indilstries, the potential emis-sions from these processes may be high, but because ofeconomic necessity they are usually recovered. Table2.5 contains the potentialHAPs and the industry-specific

industry

cellulose fibers together. The principalprocesses used nchemical pulping are the kraft, sulfite, and neutralsulfite.Plywood production nvolves the manufacturing of woodpanels composed of several thin wood veneers bondedtogether with an adhesive. The wood preserving processis one in which sawn wood products are treated byinjection of chemicals that have fungistatic and insecti-cidal properties or impart fire resistance. Table 2.7 con-tains the potential HAPs and the industry-specificemis-sion sources for this industry.2.2.8 Petroleum Related Industr iesIn this manual, the petroleum related ndustries sourcecategory includes he oil and gas production ndustry, hepetroleum refining industry, and the basic petrochemi-cals industry; these industries fall under SIC Codes 13and29.SCC codes for this source category include3-06-xxx-xx, 3-01 001 xx, 3-01 002-xx, 3-01 004-xx, and 3-01-888-XX .Theoil and gas production ndustry ncludes he followingprocesses: exploration and site preparation, drilling, crudeprocessing, natural gas processing, and secondary ortertiary recovery. The principal products of this industryare natural gas and crude oil.The petroleum refining industry involves various pro-cesses that convert crude oil into more than 2,500products, including liquefied petroleum gas, gasoline,kerosene, aviation fuel, diesel fuel, a variety of fuel oils,lubricating oils, and feedstocks for the petrochemicalsindustry. The different processes involved in the petro-leum refining industry are: crude separation, light hydro-carbon processing, middle and heavy distillate process-ing, and residual hydrocarbon processing.In the basic petrochemicals industry, hydrocarbonstreams from the oil and gas production and petroleum

Table 2-4. Potential HAPS for Inorganic Chemical Manufacturing ndustry


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Source Category Potential HAPS'InorganicVapor ParticulatePotential Emission Sources

Point Fugitive FugitveProcess Process Area

Aluminum chlorideAluminum fluorideAmmoniaAmmonium acetateAmmonium-nitrate, sulfateAmmonium phosphateAntimony oxideArsenic-disulfide, iodidepentafluoride, thioarsenatetribromide, trichloride,trifluoride, trioxideorthoarsenic addBarium-carbonate, chloridehydroxide, sulfate, sulfideBeryllium-oxide, hydroxideBoric ad d and BoraxBromineCadmium (pigment) - sulfidesulfoselenide, lithoponeCalcium-carbide, arsenatephosphateChlorineChlorosulfonic acidChromic acidChromium-acetate, borideshalides, etc.Chromium (pigment) - oxideCobalt - acetate, carbonatehalides, etc.Copper sulfateFluorineHydrazineHydrochloric acidHydrofluoric acidIodine (crude)Iron chlorideIron (pigment) - oxideLead-arsenate, halides

hydroxides, dioxide,nitrateLead chromate

thiocyanate, formate, tartrate

4,lO17111

1,1752

8.103.171019.3412

14171,3910,20171010,2040322

2

6791522511,121 11 113

2038202.21

HH,CXHXXXXXXB

B,GXXXG S

XXK J ,SXQ

K,PK.R J

XXXXX

K,RXXXP,Q

Table 2.4. Potential HAPs for Inorganic Chemical'hfanufacturi ngndustry (concluded)


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Source Category Potential Emission Sourcesotential HAPS'Inorganic Process Process AreaVapor Particulate Point Fugitive FugitiveSodium-siliconf fluoride, 17 16 X XSulfuric acid 33,34 33 A,B,C,H K, JSSulfur monochloride- 10 X XZinc chloride 36,21 21 X XZinc chromate (pigment) 35 X XZinc oxide (pigment) 37 X X

fluoride

dichloride

Pollutant Key1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -1 1 -12 -13 -14 -

ammoniaarsenicarsenic trioxidealuminum chlorideantimony trioxidebarium saltsberylliumbromineboron saltschlorinechromium saltschromic acid mistcobalt metal fumescopper sulfate

Source Ke yA -B -c -D -E -F -G -H -I -J -

converterabsorption towerconcentratordesulfurizerreformerneutralizerkilnreactorcrystallizercompressor and pump seals

15 - cadmium salts16 - chromates (chromium)17 - fluorine18 - hydrogen sulfide19 - hydrogen chloride20 - hydrochloric acid21 - lead22 - lead chromate23 - manganesesalts24 - manganese dioxide25 - mercury26 - nickel27 - nickel sulfate

K - storage tank ventsL - dryerM - leachingtanksN - filter0 - flakersP - milling/grinding/crushing0 - product handling andR - cooler (cooling tower,packagingcondenser)

28293031 -323334353637383940

nitric acid mistphosphorusphosphoric acid mistphosphorus pentasulfidephosphorus trichloridesulfuric acid mistsulfur trioxidezinc chromatezinc chloride fumeszinc oxide fumesiodinehydrazineiron oxide

S - pressure relief valvesT - raw material unloadingU - purificationV - calcinerW - hotwellX - no information

References6, 7, 19, 0. 22, 23, 4, 5.2436. 7, 8, 9, 0, 1, 2, 3, 5.76.

Table2.5. Potential HAPS and Emiss ion Sources for the Chemical Products Industry


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Source Category Potential HAPS' Potential Emission SourcesOrganic Inorganic Process Process AreaVapor Particulate Vapor Particulate Point Fugitive FugitiveCarbon black

~~

14,15,16,21, 41 1,24,49,56 1,7,10,11, 8.H GK,L I24,52,53,54,55 28,29,37Charcoal 4,23,30 41 EExplosives 9,23,42,46, 24,49,6757,59,60,61,62,64,65Fertilizers 23,26,44,67 49.67 1 D.H, RS,V K,TPaint & varnish 16,22,31,46 6,28,43,48 N,O LPharmaceuticalb 3,4,8,16,17,18,31,34,46,66,68Plasticsb

Printing Inkb

Pesticidesb

23,33,35,3942,50,51,522,8,16,27,4245,46,51,69

2,3.8,9.16,17,18,20,25,32,36,39,47,57,66,69Soap and detergents 4,82234,

38,51,69,70Synthetic fibers 3,8,13,14,19,23,24.32,38,40,42,46

41

1,10,48,56 Q1,10,63 A,H,O,X G

F

F,I

A.H,J,O.U,V,X,Z G,K I

Synthetic rubbeP 3,12.18,20,22,23, 41 A,H,O,P,X,Z Y F33,34,35,36,46,4926 - hydrogen fluoride 49 - ammonia27 - ketones 50 - vinyl chloride29 - manganese 52 - pyridinePollutant Ke y 28 - mercury 51 - toluene diisocyanate1 - arsenic 30 - methanol 53 - acetylene2 - acrolein 31 - methyl chloroform 54 - hydrogen cyanide

D -E -F -

G -

neutralizerkilncompressor and pumpseals; valves, ffanges,open ended lines,sampling linesstorage tank vents

Table2.6. Potentla1HAPS for the Mlneral ProduceS Industry


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Source Category Potential Emission Sourcesotential HAPS*Organic Inorganic Process Process AreaVapor Particulate Vapor Particulate Point Fugitive FugitiveAsbestos products 8,13,30,31, 23 3,10,11,17 D,N I,L

Asphalt batding plants 2,8,13 18 B F,J,M I32,33.34

Brick, ceramic, and relatedclay products 7,10,12, 7,?0,12 B.EC DF.N I, L21,26,35Refractories 10,12 10.12 8, E D,F,N ICement manufacture

Coal cleaning (dry)Coal cleaning (wet)

18 10,12,17,23 7.9.10.14, E F,G.N,S 1.L

22 M,N,R I,L1,5,6,7,9,10,11,14, B,C M,N I,L

15,17,24,25

16,17,2O,21,24Coal conversion 8,19,27,28 18 4,23 1,5,7,9,14,16, B,H F,G,M,N I,L17,2029Glass fiber manufacturing 13,19 19 6,20,22 c , o D,F,G,N,P IFrit manufacturing 12 12 B,C S I,LGlass manufacturing 1,4,12,14,26 1,5,6,12,14, C D,F,M,N I20,21time manufacturing 15 15 E T G.RS 1sMercury ore processingMineral wool manufacturing 12.13.19,31,36,37Perlite manufacturing 12 12 B,C G,M,N,S I,LPhosphate rock processing 6,20,21 6,2O,21 A,B,Q F.M,N,R I,LTaconite ore processing 3 C,Q F, M,N,R I,L

Table2.7. Potential HAPS fo r the WoodProducts Industry


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Source Category Potential HAPS Potential Emission Sourcesorganic Inorganic Process Process AreaVapor Particulate Vapor Particulate Point Fugitive FugitiveChemicalwood pulpingKraft pulp mill i e k a,b.c.d A,B,C,DSulfite pulp mill h e f,k a,b.c,d A.B.CNeutral sulfite pulp mill e k a,c,d A,C,E

hardboardPlywood, particleboard.and h,l,o.p G FWood preservative j.g,m,n F~Pollutant K ey Source K ey

a - arsenic i - methylmetcaptan A - recoveryfurnaceb - asbestos j - dioxin B - digesterd - mercury I - phenol D - lime kilne - polycydic organic m - pentachlorophenol E - fluidized bed reactorf - chlorine o - abiiticaad G - dryerg - chlorobenzene p - pineneh - formaldehyde

c - chromium k - hydrogen sulfide C - blowtankmatter (POM) n - cresols F - resin and/or adhesive application

References 4, 18, 19, 28, 49, 50, 76, 77.Table 2.8. Potential HAPs for Petroleum Related Indu st tfW(General L lsting fo r Entire Source Category)

Potential HAPsInorganic OrganicVapor Particulate Vapor Particulate

Paraffins (Cl-C,,) Coke fines Sulfides Catalyst fines(e.g., hydrogenCydoparafflns (C8-C,) sulfide, carbondisulfide, carbonylsulfide)Aromatics (e.g., benzene, AmmoniaPhenolstoluene, xylene)

stream generated by a process source are identified nthis section, be it either a process point source or aprocess fugitive source. Design and costing techniquesfor area fugitive emission control methodologies areoutside he scopeof this manual due tobudget consider-ations; however, control echniques for vapor emissionsand particulate emissions from area fugitive sources arediscussed in Sections 3.1.4 and 3.2.2, respectively.The actuaVestimated values for the process emissionstream properties should be obtained from the owner/operator or from available iterature f theowner/operatorcannot supply the necessary data. The values obtainedare used in conjunction with the guidelines given inChapter 3 to perform the control technique selection

Table 2.9. Potential HAPs for Petroleum Refinlng Indu st rl ese(Specific Usting for Petroleum Refining Segment)


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Process Potential HAPsOrganic InorganicVapor Partialare vapor Partialate

Pollutant K eya - maleicanhydriide I -cresols y - cyanides N - nickel carbonylb - benzoicacid m - inorganic z - chromates 0 - tetraethyl leadc - chlorides sulfides P - cobalt carbonyl

- d - ketones n -mercaptans A - acetic acid Q - catalyst finese - aldehydes o -polynuclear B - formic acid R - coke finesf - heterocydic compounds (benzo- C - methylethylamine S - formaldehydecompounds (e.g., pyrene, anthracene, D - diethylamine T - aromaticaminespyridines) etc.) E - thiosulfide U - copperg - benzene p -vanadium F - methyl mercaptani - xylene r -lead H - molybdenumj - phenols s - sulfuric aa d I - zinck - organic compounds t -hydrogen sulfide J - cresylic acid

containing sulfur u -ammonia K - xylenols(sulfonates, v - carbon disulfide L - thiophenessulfones) x -carbonyl sulfide M - thiophenol

h - toluene q -nickel G - cobalt

a Source: Reference21.Reference 76 contains additionalHAPinformation or this industry.Table 2.10. Emisslon Sources for the Petroleum Related Industries

Potential HAP Emission SourcesProcess Process AreaSource Category Point Fugitive FugitiveOil and Gas ProductionExploration, site preparation and drilling A

Table2.11. Potential HAPS and Emiss ion Sources for CombustionSourcesPotential HAPS' Potential Emission Sources


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Source Category Organic Inorganic Process Process AreaVapor Particulate Vapor Particulate Point Fugitive FugitiveCoal combustion 3,14,19, 1921,25,28

Oil combustion 14 19Natural gas combustion 14 19Gasoline combustion 12,14 12,19Diesel combustion 12 12,19Wood combustion 3,4,12.14,25 12,19Waste oil combustion 7,12.21,23,26 12,19Muniapal refuse incineration 12 12.19

Sewage sludge incineration 12 12.19PCB incineration 12,21 12,19

1,2,8,9,13, 1,2,5,6,8,9, A,B I H17,27,31 10,11,15,16,18,20,22,2413,17,27 1,2,5,6,8,9, A,B,E10.1 1,15,16,29

A.B,EF17 15 G

6,18 G27 16,20 A B C

6,8,9,15.18 A,B,D17,27 6.8.9,11, D15.16,18

17 1,6,8.9,15,16,18 D30 D,B

Pollutant Key Source Key1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -

arsenicantimonyacetaldehydeacetic acidbariumberylliumbenzenecadmiumchromiumcobaltcopperdioxinfluoridesformaldehydelead

16 - manganese17 - mercury18 - nickel19 - polycyclic organic matter (POM)21 - polychlorinatedbiphenyls (PCB)22 - radionuclides23 - trichloroethylene24 - zinc25 - phenols26 - ethyl benzene27 - chlorine28 - pyridine29 -vanadium30 - dibenzofuran

20 - PhOsphofUS

A -B -C -D -E -F -G -H -I -

furnaceboilerwoodstove/fireplaceincineratorgas turbinereciprocating engineindustrial engine and/or equipmentcoal storage pileash handlingsystem

a References 6, 16, 17, 18. 19, 20, 1, 22, 23, 24, 25, 28, 29, 30, 1,46,65, 72. 74, 75, 76.

Table 2.12. Key Properties for Organic Vapor EmissionsEmission Stream Propert ies HAP Propert ies

Table 2.13. Key Properties for Inorganlc Vapor EmissionsEmission Stream Propert ies HAP Propert ies


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(Preferred units of measu re)HAP content (ppm by vd um e) Molecular weightOrganic cont ent (ppm by volum e) Vapor pressu reHeat content (Btu/sco Solubil i ty (graph)Oxygen content (% by volum e) Adsorptive prop erties( isotherm plot)Moisture content (4 by volume)Halog edm etal content (yes or no)Flow rate (scfm)Temperature (F)Pressure (mm Hg)These properties pertain to the specific HAP or mixture of HAPs in the

9.

10.

11.

emission stream.Primary p r o p that affect control technique selection.Organic mn tentisdefined as organic emission stream combustibles less HAP emissionstream CMnbUstiMes.Heat content is determined from HAP/Organlc Content (see Appendix 6.1for calculational procedures).

face Coating of Miscellaneous Metal Parts andProducts. EPA-450/2-78-015 NTIS PB286157).June 1978.US. EPA. Control of Volatile Organic Emissionsfrom Existing Stationary Sources - Volume I I :Surface Coating of Cans, Coils, Paper, Fabrics,Automobiles, and Light Duty Trucks. EPA-450/2-77-008 (NTIS PB272445). May 1977.U.S. EPA. Control of Volatile Organic CompoundEmissions from Large Petroleum Dry Cleaners.EPA-450/3-82-009 NTIS PB83-124875). Sep-tember 1982.U.S. EPA. Pressure Sensitive Tape and LabelSurface Coating Industry - Background Informa-tion for Proposed Standards. EPA-450/3-80-003a (NTIS PB81-10594270). September 1980.

(preferred units of measure)HAP content (ppm by vdu me) Molecular weightMoisture content (Aby volume) Vapor pressureHalogenlmetal content (yes or no) Solubi l i ty (graph)Flow rate (scfm) Adsorptive prop erties(isotherm plot)Tem m ra tu re (OF1Pr es su re (m m. ~ g )a These prm rti es pertain to the specific HAP or mixture of HAPS n theemission stream.Primaty properties that affect control technique seledon.

Table 2.14. Key Prvpertles for Particulate Emiss ionsEmission Stream Propert ies HAP Propert ies (preferred units of measure)

~~ ~

HAP content (% by mass)Part iculate content (gr/dscf)Moisture content (96 y volume)SO, content (ppm by vo lume)Flow rate (acfm)Temperature ( F)Particle mean diameter E (pm)Partide size distribution cf iDrift velocity (Wsec)Particle resistivity cd (ohm-cm)a These propertiespertaln to the specific HAP or mixtureof HAPs In t heemission stream.Data indud e total particulate loading and principle particulate constituent.These pro perties are necessary only for speclfic contml techniques.Some sources may not have this Inform ation.

(None)

16. U.S. EPA. A Method for Characterization andQuantificationof Fugitive Lead Emissions fromSecondary Lead Smelters, Ferroalloy Plants, andGray Iron Foundries. EPA-450/3-78-003 (NTISPB289885). January 1978.

22. U.S. EPA. Review of National Emission Stan-dadsfor Mercury. EPA450/384-014(NllSpB85 35. U.S. EPA. Organic Chemical Manufacturing Vol-ume 6: Selected Processes. EPA-450/3-80-028a


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153906).DeCemberl984.23. U.S. EPA. Status Assessment of Toxic Chemi-cals: Lead. EPA-60012-79-21Oh (NTIS PB80-146376).December 1979.24. U.S. EPA. Status Assessment of Toxic Chemi-cals: Mercury. EPA-600/2-79-21 i (NTIS PB80-146384). December 1979.25. U.S. EPA. Sources of Copper Air Emissions.EPA-600/2-85-046 NTIS PB85-191138). April1985.26. U.S. EPA. The Use and Fateof Lubricants,Oils, Greases and Hydraulic Fluids in The Ironand Steel Industry. EPA-600/2-78-101 (NTISPB284973). May 1978.27. U.S. EPA. Rubber Tire Manufacturing Industry -Background Information for Proposed Standards.EPA-450/3-81-008a NTIS PB83-163543). July1981.28. U.S. EPA. Human Exposure to AtmosphericConcentrationsof Selected Chemicals Vols. 1 &2. EPA Contract No. 68-02-3066 (NTIS PB81-193252 and 193260). February 1982.29. U.S. EPA. Survey of Cadmium Emission Sources.EPA-450/3-81-013 NTIS PB82-142050). Sep-tember 1981.30. U.S. EPA. Source Category Survey: SecondaryZinc Smelting and Refinery Industry. EPA-450/3-

80-012 (NTIS PB80-191604). May 1980.31. U.S. EPA. Air Oxidation Processes in Synthetic

(NTIS PE381-220550). December 1980.36. U.S. EPA. Source Category: Ammonia Manu-facturing Industry. EPA-450/3-80-014 (NTIS37. U.S. EPA. Source Assessment: Ammonium Ni-trate Production. EPA-600/2-77-107i (NTISPB271984). September 1977.38. US. EPA. Ammonium Sulfate Manufacture -Background Information for Proposed Standards.EPA-450/3-79-034a (NTIS PB80-140163). De-cember 1979.

PB81-113912). August 1980.

39. US. EPA. Preliminary Study of Sources of Inor-ganic Arsenic. EPA-450/5-82-005 (NTIS Pf383-153528). August 1982.

40. US. EPA. Source Assessment: Major BariumChemicals. EPA-600/2-78-004b NTISPE3280756). March 1978.41. US. EPA. Emission Factors for Trace Sub-stances. EPA-450/2-73-001 (NTIS PB230894).

December 1973.42. US. EPA. Review of New Source PerformanceStandards for Nitric Acid Plants. EPA-450B-84-01 (NTIS PB84-185206). April 1984.43. U.S. EPA. Sodium Carbonate Industry - Back-ground Information for Proposed Standards. EPA-450/3-80-029a (NTIS PB80-219678).August 1980.44. U.S. EPA. Industrial Process Profiles for Envi-ronmental Use: Sulfur, Sulfur Oxides and Sulfuric

49. U.S. EPA. Locating and Estimating Air Emissionsfrom Sources of Carbon Tetrachloride. EPA-450/4-84-007b (NTIS PB84-200625). March 1984.63. U.S. EPA. Final Standards Support and Envi-ronmental Impact Statement Volume 11: Promul-gated Standards of Performance or Lime Manu-


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50.

51.

52.

53.

54.

55.

56.

57.

58.

U.S. EPA. Locating and Estimating Air Emissionsfrom Sources of Chlorobenzenes.EPA-450/4-84-007 (NTIS PB87-189841).September 1986.U.S. EPA. Plastics and Resins Industry - Indus-trial Process Profiles for EnvironmentalUse,Chap.10. EPA-600/2-77-023j NTIS PB291640). Feb-ruary 1977.U.S. EPA. Locating and EstimatingAir Emissionsfrom Sources of Phosgene. EPA-450/4-84-007i(NTIS PB86-117595). September 1985.U.S. EPA. Locating and Estimating Air Emissionsfrom Sources of Acrylonitrile. EPA-450/4-84-007a(NTIS PB84-200609). March 1984.U.S. EPA. Locating and Estimating Air Emissionsfrom Sources of Ethylene Dichloride. EPA-45014-84-007d (NTIS PB84-239193). March 1984.U.S. EPA. AsphaR Roofing Manufacturing ndus-try - Background Information or Proposed Stan-dards. EPA-450/3-80-021 (NTlS PB80-21 21 11). June 1980.U.S. EPA. Trace Pollutant Emissions from theProcessing of Nonmetallic Ores. EPA-650/2-74-122 (NTlS PB240117). November 1974.U.S. EPA. Source Category Survey: RefractoryIndustry. EPA-450/3-80-006 NTIS PB81-111445). March 1980.U.S. EPA. A Review of Standards of Performancefor New Stationary Sources - Portland Cement

64.

65.

66.

67.

68.

69.

70.

71.

facturing Plants. EPA-450/2-77-007b NTISPB80-194491). October 1977.U.S. EPA. Source Category Survey: MineralWool Manufacturing ndustry. EPA-450/3-80-01 6 (NTIS PB80-202781). March 1980.U.S. PA. Source Category Survey: Perlite In-May 1980.dustry. EPA-450/3-80-005 NTIS PB80-194822).U S . EPA. Radionuclides - Background Infor-mation Document for Final Rules. Volume I.October 1984.EPA-520/1-84-022-1 NTIS PB85-165751).U.S. EPA. Kraft Pulping - Controlof TRS Emis-sions from Existing Mills. EPA-450/2-78-003b.(NTIS PB296135). March 1979.U.S. EPA. Industrial Process Profiles for Envi-ronmental Use: Chapter 2. Oil and Gas Produc-tion Industry. EPA-600/2-77-023b NTISPB291639). February 1977.U.S. EPA. Industrial Process Profiles for Envi-ronmental Use: Chapter 3. Petroleum RefiningIndustry. EPA-600/2-77-023~NTlS PB273649).January 1977.U.S. EPA. Industrial Process Profiles or Envi-ronmental Use: Chapter 5. Basic Petrochemi-cals Industry. EPA-600/2-77-023e NTISPB266224). January 1977.U.S. EPA. VOC Fugitive Emissions in PetroleumRefining ndustry-Background Information or

76. U.S. EPA. Toxic Air PollutanVSource Cross-walk. A Screening Tool for Locating PossibleSources Emitting Toxic Air Pollutants, Second


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Edition. EPA-450/2-89-017 NTIS PB90-170002).December 1989.77. U.S. EPA. Handbook: Control Technologies forHazardousAir Pollutants. EPA 6236-86-014 (NTISPB91-228809). Cincinnati, OH. September 1986.

U S . EPA. BACT/LAER Clearinghouse- ACompiationof Control Technology Determin-ations. EPA/450/3-90-015a-d. Research TrianglePark, NC, July 1990.78.


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Chapter 3Control Device Selection

3.1 BackgroundGuidelines hat will enable the user to select the controltechnique@) that can be used to control HAPS arepresented in this chapter. The control techniques thatcan be appliedto control HAP emissions rom a specificemission source will depend on the emission sourcecharacteristics and HAP characteristics.Therefore, Sec-tion 3.2, Vapor Emissions Control, and Section 3.3,Particulate Emissions Control each pertain to specificHAP groups. The discussion of control technique selec-tion within each section is according to type of HAP(organic or inorganic) and emission source (point, pro-cess fugitive, or area fugitive).In he followingsections, guidelines or selectingcontrolsfor point sources are discussed in detail. Point sourcesare typically controlled by add-on control devices. Foreach control technique, ranges of applicability with re-spect to emission stream characteristics, HAP charac-teristics, performance levels (e.g., removal efficiency),and other considerations that are important in controldevice selection are described in detail.Work practices, includingequipment modifications,playa key role in reducing emissions from process fugitiveand area fugitive sources. These sources can also be

3.2 Vapor Emissions Control3.2.1 Control Techniques for Or ganic VaporThe most frequent approach o point source control stheapplication of add-oncontrol devices. Thesedevices canbe of two types: combustion and recovery. The combus-tion devices discussed in this manual include thermalincinerators, catalytic incinerators, flares, and boilers/process heaters. Applicable recovery devices includecondensers, adsorbers, and absorbers. The combustiondevices are the more commonly applied control devices,since they are capableofhigh removal (Le., destruction)efficiencies for almost any type of organic vapor HAPalthough carbon adsorbers are also quite popular. Com-bustion devices serve as an ultimate control technique;that is, they destroy rather than collect pollutants. Withcarbon adsorbers and condensers, the VOC HAP mustbe dealt with after collection. The removal efficiencies ofthe recovery echniques generally depend on the physi-cal and chemical characteristics of the HAP under con-sideration as well as the emissionstreamcharacteristics.

Emissions f rom Point Sources

Applicability of the control techniques depends more onthe individualemission stream under consideration hanon the particular source category (e.g., degreasing vs.

Table 3.1. Key Emission Stream and HAP Characteristics for Selecting Control Techniques or Organlc Vapors From Polnt Sources


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Emission Stream Ckracter istics HAP Characteristics

MOlecUlarHAPlOrganics Heat Moisture Weight Vapor AdsorptiveContensb Content Content Flow Rate Temp. (IbAb- Solubility Pressure PropertiesControl Device (PPmv) (BtU/Scf) Yo (scfm) ("F) mole) " g)Thermal >20;incinerator (m 5,000-10,000 10 (atroom tem perature)Refers to the characteristics of the individual HAP if a single HAP is present and to that of the HAP mixture f a mixture of HAPS s present.Determined from HAPhydrocarbon content.For emission streams that are mixtures of air and VOC; insome cases,he LELcan be increased o 40 to 50percentwith proper moni-toring andcontrol (seeSection 4.2 for definition of LEL).* For pa&ged units; multiple-package or custom-made units can handle larger flows.Basedon EPA's guidelines for 98 percent destruction efficiency.Units: Ibmr. Source: Reference 12.e Applicable if such a unit is already available on site.Total heat amtentRelative humidity. Applicable for HAP concentration ess than about 1,000 ppmv.

applicable control devices oachieve he required perfor-mance evels. The expected emission reduction rom theapplication of each control techniqueon the basisof the3.2.1.2 Catalyf ic IncineratorsCatalytic incinerators are similar to thermal incineratorsin design and operation except that they employ a cata-lyst to enhance the reaction rate. Since the catalyst


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total VOC concentration n the emission stream is iden-tified in Figure 3.1. Very little data regarding controldevice removal efficiency for specific HAPs are avail-able. Therefore, without actual source test data for aspecific emission stream and contrd system, HAP re-moval efficiency is assumed to equal total volatile or-ganic compound (VOC) removal efficiency.3.2.7.1 Thermal incineratorsThermal ncineratorsare used o controla wide varietyofcontinuous emission streams containing VOCs. Com-pared to the other techniques, thermal incineration isbroadly applicable; that is, it is much less dependent onHAP characteristics and emission stream characteris-tics. Destruction efficiencies up to 99 + percent areachievable with thermal incineration. Although they ac-commodate minor fluctuations in flow, thermal incinera-tors are not well suited to streams with highly variableflow because the reduced residence time and poormixing during increased flow conditions decreases thecompletenessof combustion. This causes the combus-tion chamber temperature to fall, thus decreasing thedestruction efficiency.Two types of thermal incinerators are commonly used.The thermal recuperative ype uses a conventionalheatexchanger to heat the incoming emission stream. Thethermal regenerative ype uses ceramic beds o heat theincoming stream. The discussion in Chapter 4 focuseson hermal recuperative ncinerators.Thermal regenera-tion (and thermal recuperative incinerators) are dis-cussed in Reference21.Thermal incineration is typically applied to emissionstreams that are dilute mixtures of VQC and air. in suchcases,duetosafety considerations, concentrationof heVOCs is generally limited by insurance companies o 25percentof the LEL (lower explosive limit) for the VOC in

a!lows the reaction o take place at lower temperatures,significant fuel savings may be possible with catalyticincineration.Catah,+:: incineration is not as broadly applicable asthern-ial:rx-neiation sirice performanceof catalytic nr;irierators is more sensitive to pollutant characteristicsan?process conditions than is thermal incinerator perk+rnance. Materials such as phosphorus, bismuth, lead.arsenic, antimony, mercury, iron oxide, tin, zinc, sulfur,and halogens in the emission stream can poison thecatalyst and severely affect ts performance. (Note: Somecatalysts can handle emission streams containing halo-genated compounds.) Liquid or solid particles that de-posit on the catalyst and form a coating also reduce hecatalysts activity by preventing contact between theVOCs and the catalyst surface. Catalyst life s limitedbythermal aging and by loss of active sites by erosion,attrition, and vaporization. With proper operating tern--peratures and adequate temperature control, these pro-cesses are normally slow, and satisfactory performanceca n be maintained or 2 to 5 years before replacementofthe catalyst is necessary.Goth fixed bed and fluid bed catalytic incinerators areencountered. The discussion in Chapter 4 focuses onfixed bed catalytic incinerators. For more information oftfluid bed catalytic incineration, consult Reference 19.Catalytic ncinerationcan be ess expensive han hermalincineration n treating emission streams with lo w VOCconcentrationsdue to lower auxiliary fuel requirements.Emission streams with high VOC concentrations shouldnot be treated by catalytic incineration without dilutionsince such streams may cause the catalyst bedto over-heat and iose its activity. Also, fluctuations in the VOCcontent of the emission stream should be kept io a


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L0r e

Dehumidificationmay be necessary tthe emission streamconcentration s less than 1,000 ppmv arid the emissionstream has a high humidity (relative himiiditv > 50 perextremely low for it to be suitable for reuse. Also, i f theVOCs in the effluent from the absorber have appreciablevapor pressure (e.g., > 0.1 mm Wg), the possibility of


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cent).18Cooling may be required f the emisslCG streamtemperature exceeds 120" - 130" FTo prevent excessive bed temperatures resliitiisg fromthe exothermic adsorption process and oxidation reac-tions in he bed, concenfraticnshigher?l:an10,300 ppmvmust frequently be reduced This is usilnlly done bycondensationor dilutionof the emission stream aheadofthe adsorption step. Exothermic reactions may alsooccur if incompatible solvents are mixed in the bed,leading o polymerization. f flammable vapors are present,the VOC concentrations may be limited by insurancecompanies to less than 25 percentof the LEL. If propercontrols and monitors are used,LEL evels up to 40 to 50percent may be allowed. To ensure breakthrough doesnot occur, continuous moriitoringof the outlet bed con-centration is recommended.3.2.1.6 AbsonSers (Scrubbers)Absorption is widely used as a raw material and/or aproduct recovery echnique r!separation and purificationof gaseous streams containing high concentrations ofVOCs.As an emission control echnique, t ismuch morecommonly employed for inorganic vapors (e.g., hydro-gen sulfide, chlorides, etc.) than for organic vapors.Using absorption as the primary control technique fororganic vapor HAPS s subject to several [imitationsandproblems as discussed below.The suitabilityof absorption for controlling organic vaporemissions s determined by several actors; mostof thesefactors will depend on the specific HAP inquestion. Forexample, he most important factor is the availability of asuitable solvent. The pollutant in question should bereadily soluble in the solvent for effective absorptionrates and the spent solvent should be easily regeneratedordisposedof inan environntentally acceptable manner.

VO C emissions to the atmosphere should be consid-ered.in organic vapor HAP contrd applications, low outletconcentrations will typically be required Trying to meetsuch requirements with absorpiiori alorre will lead toimpractically tall absorption towers, long contact times,and high liquid-gas ratios that mey not be cost effective.Therefore, absorbers will generatiy be effective whenthey are used in combination with other control devicessuch as incinerators or carbon adsorbers.Removal efficiencies in excess of 99 percent can beachieved with absorption.3.2.7.7 CondensersCondensers are widely used as raw material and/orproduct recoverydevices.Theyare frequently applied aspreliminary air pollution control devices for removingVOC contaminants from emission streams prior to othercontrol devices such as incinerators, adsorbers, or ab-sorbers.Condensers are also used by themselves for controlringemission streams containing high VOC concentrations(usually>5,000 ppmv). In hese cases, removal efficien-cies obtained by condensers can range from 50 to 90percent although removal efficiencies atthe higher endofthis scale usiialiy require HAPconcentrations of around10,000 ppmv or greater. The removal efficiency of acondenser is highly dependent on the emission streamcharacteristics including he nature of the HAP in ques-tion (vapor pressure-temperature elationship) andHA Pconcentration, and the type of coolant used. Note that acondenser cannot lower the inlet VOC concentration olevels below he saturation concentration (or vapor pres-sure) at the coolant temperature. When water, ?he most

spent coolant. Therefore, using contact condensers hatgenerate such effluents or controlling HAP emissions isnot recommended.emissionswill be discussed.3.2.2.1 Abso&ers (Scrubbers)


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Flow rates up to about 2,000 scfm can be considered asrepresentativeof the typical range for condensers usedas emission control devices. Condensers for emissionstreams with flow rates above2,OOO scfm and containinghigh concentrations of noncondensibleswill require pro-hibitively large heat transfer areas.The temperature of the outlet steam is a fundamentalindicator of performance or a condenser system. There-fore, continuous monitoring of this parameter is recom-mended for control of HAPs.3.2.2 Contro l Techniqu es for Inorganic VaporInorganicvapors make up only a small portionof the totalHAPs emitted to the atmosphere. Potential sources ofthevarious norganicvaporsfound n heatmospherearediscussed n Chapter 2. Inorganic HAP vapors typicallyinclude gases such as ammonia, hydrogen sulfide, car-bonyl sulfide, carbon disulfide, metals with hydride andcarbonylcomplexes, chloride, oxychloride,and cyanide.

Emissions From Point Sources

In manycases, although he inorganic HAPs are emittedas vapors at the emission source, they may condensewhen passing through various ducts and form particu-lates. Prior to discharge to the atmosphere, these par-ticulates are typically controlled by methods that will bediscussed n Section 3.3. In this section, the discussionwill be based on control techniques for HAPs that areemitted as vapors to the atmosphere.Only a limited number of control methods are applicableto inorganicvapor emissions rom point sources. The twomost commonly used control methods are absorption(scrubbing)and adsorption. Absorption s the most widelyused and accepted method for inorganic vapor control.

Absorption is the most widely used recovery techniquefor separation and purificationof inorganic vapor emis-sions. The removal efficiency achievable with absorberscan be greater than 99 percent. It will typically be deter-mined by the actual concentrationsof he specific HAP ngas and liquid streams and the corresponding equilib-rium concentrations.Table 3.2 summarizes he reportedefficiencies for various inorganic vapors employing ab-sorption as the control method.As discussed in Section 3.2.1.6 for organic vapors, thesuitabilityof absorption or controlling norganicvapors ngaseous emission streams is dependent on severalfactors. The most important factor is the solubility of thepollutant vapor in the solvent. The ideal solvent shouldbe nonvolatile, noncorrosive, nonflammable, nontoxic,chemically stable, readily available, and inexpensive.Typical solvents used by industry for inorganic vaporcontrol nclude water, sodium hydroxide solutions, amylalcohol, ethanolamine, weak acid solutions, and hypo-chlorite solutions. Other factors which may affect inor-ganic vapor absorption are similar to those for organicvapor absorption (see Section 3.2.1.6).Water is the ideal solvent for inorganic vapor control byabsorption. It offers distinct advantages over other sol-vents, the main one being ts low cost. It is typically usedon aonce-throughbasis and then discharged o a waste-water treatment system. The effluent may require pHadjustment to precipitate metals and other HAPs ashydroxidesorsalts; hese are typically ess oxic and canbe more easily disposed of.3.2.2.2 AdsorbersWhen the removal of inorganic vapors is especiallydifficult using absorption methods, adsorptionmay proveto be more effective. Adsorbents such as activated

due to adsorption, ease of regeneration, and the usefullife of the adso&ent. Most o! the reported removalefficiencies for inorganicvapors are fo ractivatedc a r b nFugitive emissions of organic vapors occur in plantsprocessingorganic liquids and gases, such as petroleumrefineries,chemical plants, and plants producingchemi-


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and impregnatedaciivarad carbon, and rariga from90 tcr100percent.Table 3.2sumimarizes removalefficienciesreported for various iiwrganic vapors controlled by ad-sorption.Activated carbons are t h n most wideiy used adsorbentsfor inorganic v a p r control. in several cases. they mustbe treated (Le., impregnat& with ct-iemicalj or effectiveapplication. Since activated carbonsare relatively sensi-tive to emission stream conditions pretreatment c th

EPA Control Technologies Hazardous Pollutants 1991

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Transcript of EPA Control Technologies Hazardous Pollutants 1991