United States Office of Air Quality EPA-450/2-78-033
Environmental Protection Planning and Standards OAQPS No. 1.2-109
Agency Research Triangle Park NC 27711 December 1978
_—
?,EPA OAQPS Guideline
Series
Control of Volatile
Organic Emissions
from Existing
Stationary Sources
Volume VIII: Graphic
Arts - Rotogravure
and Flexography
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EPA-450/2-78-033
OAQPS No. 1.2-109
Control of Volatile
Organic Emissions
from
Existing Stationary Sources -
Volume VIII: Graphic Arts -
Rotogravure and Flexography
Second Printing
(First printing errata corrected)
Emission Standards and Engineering Division
Chemical and Petroleum Branch
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
U.S. Environmental Protection Agency
December 1978 ?^J" ^J^ (PL-12J)
// West Jackson Boulevard, 12th Fkw
Chicago. It 60604-3590
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OAQPS GUIDELINE SERIES
The guideline series of reports is being issued by the Office of Air Quality Planning and Standards (OAQPS) to
provide information to state and local air pollution control agencies; for example, to provide guidance on the
acquisition and processing of air quality data and on the planning and analysis requisite for the maintenance of air
quality. Reports published in this series will be available - as supplies permit - from the Library Services Office
(MD-35), U.S. Environmental Protection Agency, Research Triangle Park, North Carolina 27711, or, for a nominal
fee, from the National Technical Information Service, 5285 Port Royal Road, Springfield, Virginia 22161.
Publication No. EPA-450/2-78-033
(OAQPS No. 1.2-109)
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CONVERSION FACTORS FOR METRIC UNITS
Equivalent
Metric Unit Metric Name English Unit
Kg kilogram (103grams) 2.2046 lb
liter liter 0.0353 ft3
m meter 3.28 ft
_ 3
m cubic meter 35.31 ft
Mg megagram (10 grams) 2,204.6 lb
metric ton metric ton (10 grams) 2,204.6 lb
In keeping with U.S. Environmental Protection Agency policy, metric
units are used in this report. These units may be converted to common
English units by using the above conversion factors.
Temperature in degrees Celsius (C°) can be converted to temperature
in degrees Farenheit (°F) by the following formula:
t°f = 1.8 (t°c) + 32
t°f = temperature in degrees Farenheit
t° = temperature in degrees Celsius or degrees Centigrade
m
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TABLE OF CONTENTS
CONVERSION FACTORS FOR METRIC UNITS iii
1.0 INTRODUCTION AND SUMMARY 1-1
1.1 General Discussion 1-1
1.2 Achievable Control Levels l-i
1.2.1 Available Add-On Control Devices 1-2
1.2.2 Water Borne and High-Solids Inks 1-3
1.2.3 Alternative Control Methods 1-3
1.2.A Differentiation of Coating and Printing I-/1
1.3 Cost Effectiveness 1-5
2.0 SOURCES AND TYPES OF EMISSIONS 2-1
2.1 General Discussion 2-1
2.2 Printing Processes 2-1
2.2.1 Flexography 2-2
2.2.2 Gravure 2-2
2.2.2.1 Uses for Flexographic and Rotogravure Printing
and Coating 2-A
2.2.2.2 Nature of the Flexographic and Gravure Printing
Industries 2-5
2.3 Stock Feeding Methods 2-5
2.4 Printing Inks 2-5
2.5 Emmission Points 2-5
2.5.1 Dryer Types 2-7
2.6 National Emmissions 2-7
2.7 References 2-Q
iv
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3.0 APPLICABLE SYSTEMS OF EMMISSION REDUCTION 3-1
3.1 Introduction 3-1
3.2 Add-On Equipment 3-1
3.2.1 Carbon Adsorption 3-1
3.2.2 Incineration 3-3
3.2.2.1 Heat Recovery 3-A
3.3 Use of Low Solvent Inks for Packaging Gravure
and Flexographic Printing 3-6
3.3.1 Water-Borne Inks 3-9
3.4 Summary of Applicability of Control Methods 3-°
3.A.I Rotogravure 3-9
3.4.2 Flexography 3-10
3.5 References 3-11
4.n COST ANALYSIS 4-1
4.1 Introduction 4-1
4.1.1 Purpose 4-1
4.1.2 Scope 4-1
4.1.3 Use of Model Plants 4-1
4.1.^ Bases for Capital Costs 4-"
4.1.5 Bases for Annualized Costs 4-^
4.2 VOC Control in the Printing Industry 4-6
A.2.1 Model Plant Parometers 4-fi
4.2.2 Control Costs 4-6
4.2.3 Cost-effectiveness 4-21
4.2.4 References 4-2fi
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5.0 ADVERSE AND BENEFICIAL EFFECTS OF APPLYING CONTROL
METHODS 5_1
5.1 Incineration 5_1
5.2 Carbon Adsorption 5_T
6.0 MONITORING TECHNIQUES AND ENFORCEMENT ASPECTS 6-1
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1.0 INTRODUCTION AND SUMMARY
1.1 GENERAL DISCUSSION
This report is one of a continuing series designed to assist State
and local jurisdictions in the development of air pollution control
regulations for volatile organic compounds. (VOC) which contribute to the
formation of photochemical oxidants. The report deals with VOC
emissions from the graphic arts operations which utilize inks containing
volatile organic solvents.
The graphic arts industry encompasses printing operations which fall
into four principal categories, namely: letterpress, offset lithography,
rotogravure and flexography. This guideline is applicable to both the
flexographic and rotogravure processes as applied to both publication
and packaging printing. It does not apply to offset lithography or
letterpress printing.
1.2 ACHIEVABLE CONTROL LEVELS
Rotogravure and flexography utilizes inks which contain large
fractions (50 to 80 percent or higher) of volatile organic solvents.
Certain applications are as high as 96 percent solvent.
Below are provided emission limitations that represent the presumptive
norm that can be achieved through the application of reasonably available
control technology (RACT). Reasonably available control technology is
defined as the lowest emission limit that a particular source is
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capable of meeting by the application of control technology that is
reasonably available considering technological and economic feasibility.
It may require technology that has been applied to similar, but not
necessarily identical source categories. It must be cautioned that the
limits reported in this section are based on capabilities and problems
which are general to the industry, but may not be applicable to every
plant.
1.2.1 Available Add-On Control Devices
The vast majority of rotogravure and flexographic printing units use
organic solvent-borne inks. Emission reduction can be achieved by use
of carbon adsorption or incineration sytems. A reduction efficiency of
90 percent of the VOC delivered to these devices can and should be achieve.;.
In addition, it is implicit the RACT requires installation of the best
practicable capture system to assure that the VOC is directed to the control
device. A number of carbon adsorption systems at publication and roto-
gravure plants have been reported to achieve overall recovery efficiencies
of 75 percent or more, based on material balances. Assuming adsorber
efficiencies of 90 to 95 percent, capture efficiencies of 75 to 85 percent
were being realized. There is no available method of measuring capture
efficiency directly.
Large packaging rotogravure presses could be expected to have capture
efficiencies somewhat less than publication plants because of shorter
runs and other factors. A capture efficiency of 75 percent would appear
to be reasonable, with an overall VOC recovery/control efficiency of about
65 percent for either adsorption on incineration systems.
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The capture problem for flexographic presses is more difficult than
for rotogravure presses because of the manner of construction of
flexographic presses. The printing units and dryers are mounted on a
vertical circular axis such that effective hooding and ducting are
difficult to construct. A capture efficiency of 70 percent appears
to be reasonable for these presses for an overall VOC control efficiency
of 60 percent.
1.2.2 Water-Borne and High Solids Inks
Water-borne inks are available which will meet some printing
requirements of both rotogravure and flexography. Ink manufacturers
are working to develop water-borne inks which will meet additional
requirements. EPA desires to encourage such developments because of
the material and energy saving potentials. It is recommended that
printing systems in which all printing units utilize a water-borne
ink whose volatile portion consists of 75 volume percent water and 25
volume percent organic solvent (or a lower VOC content) be considered
equivalent to the exhaust treatment systems described in Section 1.2.1.
Some printing systems may be able to utilize water-borne inks for
heaviest coverage, but still require some solvent-borne inks for light
coverage.* For such systems, if a 70 volume percent overall reduction
of solvent usage is achieved (compared to all solvent-borne ink usage),
the complete operation can be considered equivalent to the exhaust treat-
ment systems described in Section 1.2.1.
There are no high solids inks now in use in rotogravure or
flexographic printing operations. However, ink manufacturers have stated
that they will continue development work in this area. It is recommended
that inks which contain 60 percent or more non-volatile material be exempt
from emission limitations in order to encourage development of high
solids inks.
*Heavy coverage means large areas of a given color. A thin strip of a
given color is an example of light coverage.
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1.2.3 Alternative Control Methods
Publication rotogravure uses inks with solvent mixtures of water-
immiscible solvents. The vapor can be recovered with carbon adsorption
systems and reused by ink manufacturers and printers. Some systems
yield a net profit after amortization and operating expenses.
Printing of "packaging materials by rotogravure and flexography
requires inks with more complex solvent mixtures. Many of the solvents
are water-soluble. Conventional carbon adsorption systems using steam
for regeneration may not be a viable control method because the
recovered solvents cannot be reused. Reformulation of the inks may, in
some cases, make carbon adsorption a viable control technique. A new
fluidized bed carbon adsorption system uses nitrogen for desorption and
may provide a viable method for recovering solvents from packaging inks;
as well as publication inks. Incineration systems with heat recovery
may be a more practical solution for some packaging operations.
Incineration has been shown to provide 90 percent and greater removal
of VOC in many similar applications.
]-2-4 Differentiation of Coating and Printing Operations
The production of packaging materials involves two principal
operations which emit volatile organic compounds: 1) coating and
laminating of paper, film, and foil; 2) printing of words, designs, and
pictures upon webs of paper, film, and foil. For the purposes of this
document, coating is defined as the application of a uniform layer of
material across the entire width of a web. Printing is the formation
of words, designs and pictures, usually by a series of application rolls
each with only partial coverage.
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The recommended emission limits for coating and laminating operations
in the production of packaging materials are given in Volume II of this
series.* The emission limits in this document apply to printing
operations in the production of packaging materials and to publication
rotogravure printing operations. However, all units in a machine which
has both coating and printing units will be considered as performing
a printing operation. A typical operation is as follows: The first unit
applies a uniform background color; subsequent units print addtiional
colors; the final unit applies a varnish overcoat. Such a machine would
be subject to the guideline for graphic arts.
1.3 COST EFFECTIVENESS
The cost effectiveness of carbon adsorption is influenced strongly
by VOC concentration and tonnage and by the value of recovered solvent.
Where VOC concentration is 1200 ppm, cost effectiveness range from
$51 to $38/Mg ($46 to $34/ton) of VOC recovered over the range of
2000 Mg (2200 tons) to 4000 Mg (4400 tons) of VOC input per year. At a
VOC concentration of 2400 ppm and 2000 Mg/yr input the recovery system
pays for itself, and at 4000 Mg/yr input yields a $15/Mg profit.
These values are typical of a large operation where the solvent can be
reused in the process or sold to an ink manufacturer. No data are"
available for smaller carbon systems.
The cost effectiveness of incineration systems are strongly influenced
by annual tonnage of the VOC controlled and by the VOC concentration and
degree of heat recovery. For a VOC input rate of about 90 Mg/yr
(100 tons/yr) the cost of effectiveness ranges from $600/Mg ($600/ton)
of VOC controlled at a concentration of 1500 ppm and 85 percent heat
*Control of Volatile Organic Emissions from Existing Stationary Sources -
Volume II: Surface Coating of Cans, Coils, Paper, Fabrics, Automobiles,
and Light-Duty Trucks. EPA-450/2-77-008, May 1977.
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recovery to $2000/Mg ($1800/ton) at a VOC concentration of 500 ppm and
no heat recovery. For a VOC input rate of about 1500 Mg/yr (1650 ton/yr)
the cost effectiveness ranges from $120 per ton of VOC at concentrations
of 1500 ppm and 85 percent heat recovery to $1500/Mg ($1650/ton) for
concentrations of 500 ppm and no heat recovery.
The greatest VOC control costs are associated with small flexo-
graphic printing operations having relatively low VOC levels and often
operated intermittedly. In many cases, it may be possible to improve
capture systems resulting in higher VOC levels and lower ventilation rates,
Even with improved capture systems, it may not be reasonable to require
exhaust gas treatment at many small printing installations.
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2.0 SOURCES AND TYPES OF EMISSIONS
2.1 GENERAL DISCUSSION
Originally the term graphic arts meant only such fine arts as painting
and drawing. In time the meaning expanded and shifted to various picture
reproduction methods, such as engraving, etching, and lithographing.
Finally, the graphic arts industry has become simply a different name for
the printing industry.
This diverse industry is characterized by a large number of small
plants and a small number of large plants. Approximately 80 percent of
2
commercial printing establishments employ fewer than 20 people. The
largest publication gravure plants employ hundreds of people and have
a daily potential VOC emission rate of 20 Mg (22 tons).
Printing establishments are scattered throughout the country but the
vast bulk of the printing has historically been done in the large
metropolitan areas. Most periodicals are published in New York, Chicago,
Philadelphia and Los Angeles.2 However, in the last few years several
new large plants have been built in non-urban areas. This appears to be a
new trend.
2.2 PRINTING PROCESSES
Printing operations of any sizeable volume utilize presses in which
the image carrier is curved and mounted on a cylinder which rotates,
(rotary presses) or the image is engraved or etched directly on a cylinder.
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In direct printing the image is transferred directly from the image to
the print surface. In indirect printing the image is transferred to an
intermediate roll (called a blanket) and thence to the print surface.
2.2.1 Flexography
In flexographic printing, the image areas are raised above the non-
image surface. The distinguishing feature is that the image carrier is
made of rubber and other elastomeric materials. A feed cylinder rotates
in a trough of ink (called an ink fountain), and delivers ink to the
plate (image), cylinder, through a distribution roll, as shown in Figure 2.1.
Flexographic presses are usually of rotary web design, i.e., roll-fed.
Presses printing upon corrugated paperboard are a major exception.
Flexography uses very fluid inks, (low viscosity) typically about
75 volume percent organic solvent. The inks dry by solvent absorption into
the web and evaporation, usually in high velocity air dryers at temperatures
below 120 C. Solvents compatible with rubber or other plate materials
must be used. Typical solvents are alcohols, glycols, esters, hydrocarbons
and ethers.
2.2.2 Gravure
In the gravure method printing, image areas are recessed relative to
non-image area. The image carrier is a copper-plated steel cylinder
usually also chrome plated to enhance wear resistance. The image is in
the form of cells or cups mechanically or chemically etched in the surface.
Typically, a gravure cell is 35 y (.0014 inches) deep by 125 y (.005 inches)
square, with 22,500 cells to the square inch. The gravure cylinder rotates
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in an ink trough or fountain. Excess ink is removed by a steel doctor
blade. The ink in the cells is then transferred to the web when it is
pressed against the cylinder by a rubber-covered impression roll, as
shown in Figure 2-2. Rotary gravure presses are called rotogravure presses.
Rotogravure also requires very fluid inks. Solvent content ranges
from 50 to 85 percent or higher. Typical solvents, include alcohols,
aliphatic napthas, aromatic hydrocarbons, esters, glycol ethers, ketones,
nitroparaffins and water. Solvent is evaporated in low temperature driers,
38° to 93°C (100° to 200°F). The hot air infringement dryers usually are
indirectly heated by steam or hot air. Steam drum dryers are also used.
2.2.2.1 Uses for Flexographic and Rotogravure Printing and Coating
Flexographic and gravure printing and coating applications fall into
three major cateogries: publication, packaging and specialties. In the
publications field, magazines, mail order catalogues, brochures, newspaper
supplements, comics and other commercial printing are printed by the
gravure process. Packaging products predominantly printed by gravure,
include cigarette cartons and labels, can labels, detergent cartons, and
many other folding cartons. Flexography is typically used for bread bags,
multi-wall bags, milk cartons, corrugated paper board, paper cups and plates,
labels, tags, tapes and envelopes. Both printing processes are used for
flexible film and foil to be used for overwraps or laminates, composite
cans, carrier cartons, frozen food wraps, and gift wraps.
In the specialty field, both flexography and gravure are used for wall
covering and decorating household paper products such as towels and tissue.
Gravure is used for floor covering, cigarette filter tips, vinyl upholstery,
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woodgrains, and a variety of other products. Gravure is also used for
applying accurately metered quantities of coatings to paper and other
kinds of webs in various manufacturing operations where its fast-drying
inks and the ability to print well on a wide variety of surfaces are
advantageous. Recommended emissions limitations from the coating uses
of gravure are covered in other volumes of this guideline series, such
as Volume II: Surface Coating of Cans, Coils, Paper, Fabric, Automobiles,
and Light-Duty Trucks, and Volume VII: Factory Surface Coating of Flat Wood
Paneling. The recommended emission limitations given in this volume do not
apply to these operations.
2.2.2.2 Nature of the Flexographic and Gravure Printing Industries -
Publication printing is done in large printing plants, numbering less than
3
50 in total. Package and specialty printing by flexography and gravure is
done by a considerably larger number of companies, ranging from large
integrated packaging companies with many press units of small captive
operations with only one or two press units. It is estimated that there
/i
are from 13 to 14 thousand gravure printing units'* and 30,000 flexographic
printing units.
2.3 STOCK FEEDING METHODS
Presses are divided into two classes by feeding methods:
sheet-fed and roll-fed. Stock fed from a roll is referred to as a web.
High volume roll presses are significant sources of VOC.
2.4 PRINTING INKS
Printing inks are composed of the same type of ingredients as surface
coatings: pigments, vehicles and solvents. Of course, they are tailored
to have different properties than coatings. In addition to regulatory
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limitations required by EPA, OSHA, FDA, and USDA, the specifications
for an ink are governed by a number of considerations such as: (1)
printing processes and methods; (2) kind of press; (3) paper or other
substrate; (4) drying process; (5) desired finish, matte, gloss, etc.,
(6) end use of the printed product; (7) color; (8) fabrication method to
which the printed stock will be subjected; (9) sequence of ink application,
in multicolor printing.
The solvent content of inks varies widely. Flexograph and gravure ink
contain 50 to 85 percent solvent and dry by solvent evaporation. Water-
borne inks are used for special applications; they contain 5 to 30 percent
VOC solvent.
The following solvents are representative of those used in printing
inks, usually in combinations:
Toluene Ethanol
Xylene Butanol
Heptane Glycols
Isooctane Glycol ether esters
Mineral Spirits Glycol esters
Naphtha Acetone
Hexane Methyl ethyl ketone
Propanol Isopropyl acetate
Isopropanol Normal propyl acetate
Methanol Ethyl acetate
2.5 EMISSION POINTS
Roll-fed printing presses require dryers to evaporate solvent in
order to produce a product with immediate handleability. Solvent vapors
are emitted from printing units and dryers. Some printing operations
which utilize air pollution control equipment have the printing units
hooded and vented to the control device.
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2.5.1 Dryer Types
A variety of dryer types are used including steam-heated and other
indirectly heated designs. Direct-fired dryers are mainly high velocity/
hot air dryers. Steam-heated dryers are the principal type of indirectly
heated dryers.
Steam-heated dryers are of two types: drum and forced circulation
dryers. Drum dryers are cylinders to which steam is applied. The printed
web is brought around the drum with the printed surface on the outside.
The web is heated by conduction. In forced circulation dryers, air is
heated by passing over steam coils or tubes and is circulated through the
drying chamber by a fan(s).
2.6 NATIONAL EMISSIONS
Data for a direct determination of the total national emissions from
2
the printing industry are not available. However, a report by Gadomski
contained data on the ink and solvent usage for 1968 from plants estimated
to have 32 percent of the national total. Total ink usage for these
plants was 141 million pounds. Additional solvent for ink dilution
and clean-up totaled 21 million gallons. Total solvent usage was 95,000
tons (87,000 Mg). From this the study suggested a 1968 national total
usage of 300,000 tons (270,000 Mg). Assuming a three percent annual growth
rate, the 1976 solvent usage rate would be 380,000 tons (340,000 Mg). The
average degree of control is estimated to be 30 percent leaving uncontrolled
emissions of 270,000 tons per year (240,000 Mg/yr).
The above report separated the ink consumption into a percentage for
each printing process by the survey results and by a survey conducted by
the National Association of Printing Ink Manufacturers. The additional
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solvent figures were also separated by printing process type. The three
sets of figures were averaged to give the following breakdown:
Percent of Emissions
Process Emissions Mg/yr
Gravure 41 100,000
Lithography 28 67,000
Letterpress 18 43,000
Flexography 13 30,000
240,000
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2.7 REFERENCES
1. Strauss, Victor, The Printing Industry. Printing Industries of
America, Inc., Washington, D.C. 1967.
2. Gadomski, R. R., et. al. Evaluations of Emissions and Control
Technologies in the Graphic Arts Industries, Phase I, Graphic Arts
Technical Institute. August 1970.
3. George, H. F., Gravure Industry's Environmental Program. In
conference on Environmental Aspects of Chemical Use in Printing
Operations. EPA-5601/1-005. Office of Toxic Substances,
Environmental Protection Agency, January 1976. pp 204-216
4. Long, R. P., and W. R. Daum, "Gravure Survey," Package Printing
Diecutting, January 1975, pp 12-14. Cited in Reference 3.
5. Comment letter from the Flexographic Technical Association,
November 27, 1978. :
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3.0 APPLICABLE SYSTEMS OF EMISSION REDUCTION
3.1 INTRODUCTION
Emissions of volatile organic compounds (VOC) can be reduced by
add-on control devices and by the use of water-borne and low solvent
inks. In this chapter the applicability of these methods to the
various printing processes will be reviewed.
3.2 ADD-ON EQUIPMENT
Fume incinerators and carbon adsorbers are the only devices which
have proven to have a high efficiency in controlling vapors from rotogravure
and flexographic printing operations.
3.2.1 Carbon Adsorption
Recovery of solvents by use of carbon adsorption systems has been
successful at a number of large publication rotogravure plants. The presses
in question used a single, water immiscible solvent (toluene) or a mixture
which is recovered in approximately the proportions used in the ink. Three
such plants were reported to have systems which recover 6,000 to 7,000
gallons (20 to 23 Mg) per day of solvent each.1'2'3 These recovery systems
were installed for economic and regulatory reasons. Solvent is evaporated
from the web in indirect steam heated dryers which precludes any solvent
decomposition. Regeneration is accomplished by use of steam, followed by
condensation and a simple decantation. Because the solvents are water-
immiscible a relatively simple system for separating condensed water and
solvent is possible.
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Some rotogravure operations, such as printing and coating of packaging
materials, utilize inks and coatings containing complex solvent mixtures.
Many of the solvents are water soluble. The solvents required for a folding
carton operation, for example, consists of toluene, heptane, ethyl acetate,
methyl ethyl ketone, and isopropyl alcohol. The last three are soluble
in water. If a carbon recovery system with steam regeneration were used, a
distillation system would be required to recover and separate the water-
soluble solvents. Since azeotropes (constant boiling mixtures) are formed,
adequate separation would be very difficult. In addition, frequent product
changes result in varying solvent combinations, making solvent recovery
for reuse difficult and costly.
However, reformulation of inks offers a possible method of avoiding
the above difficulties. Many of the present solvent mixtures were developed
to comply with Rule 66 of Los Angeles County and similar legislation. Because
of EPA's 1977 policy statement on reactivity, it is now possible to revert
to the simpler solvent mixtures used in the past. Many printers will be
able to revert to a mixture of immiscible hydrocarbons and a single ester
or MEK, which could be reused as a mixture after dewatering. It will be
practical for many packaging type printers to solve a large percentage of
their emission control requirements by the use of carbon adsorption and
4
relatively simple dewatering techniques.
A new type of carbon adsorption system offers another method of
avoiding trouble with water soluble solvents. A fluidized bed carbon
system, developed in Japan, is being marketed in the United States. The
carbon is in the form of highly abrasion resistant carbon beads. In the
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adsorbing section the beads cascade in the fluidized state down a tray
tower. Solvent laden air enters the bottom of the tower and leaves at the
top. The beads then flow through the desorbing section in a dense bed where
they are heated indirectly in the presence of nitrogen which acts as a
desorbing gas. The nitrogen is then cooled in indirect heat exchangers to
condense the solvent. The nitrogen is then recycled to the desorber.
The following advantages are claimed for the fluidized bed system,
relative to fix bed systems:
. Better thermal efficiency
Lower blower power consumption
. No mixing with water at desorption
. No valves or cycling equipment
. less space required
. Less susceptible to blinding
Can be regenerated at higher temperatures to remove high boiling
materials
A disadvantage of this system is that relatively constant air volume
must be maintained. Also the capital cost may be higher.
Additional information on theory, design and practices concerning
carbon adsorption systems is given in Volume I (EPA-450/2-76-028) of this
5
guideline series.
3.2.2 Incineration
Incineration destroys organic emissions by oxidizing them to carbon
dioxide and water vapor. Incineration is a technically feasible method of
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controlling emissions from all printing operations. Both direct flame
(thermal) and catalytic incinerators are potential methods of controlling
emissions from flexography and packaging gravure printing.
3.2.2.1 Heat Recovery
The cost of operating an incineration system can be substantially
reduced by the use of heat recovery equipment. Primary heat recovery uses
the hot incinerator exhaust gases to preheat the dryer exhaust gases prior
to incineration. A secondary heat exchanger can sometimes supply the heated
air required to operate the dryer. Cost data is given in Chapter 4 for
incineration systems with and without heat recovery. Incineration and
heat recovery systems are described in Volume I (EPA-450/2-76-028) of this
series.
In addition to direct-flame and catalytic incinerators, a third
type is available. Pebble bed incinerators combine the functions of a
heat exchanger and a combustion device. A diagram of such a system
is shown in Figure 3-3. The solvent laden exhaust from the dryers and
floor sweeps enter one of the pebble beds which has been heated by the
combustion chamber exhaust in the previous cycle. Oxidation of the
vapors starts in the preheat bed and is completed in the combustion
chamber. The exhaust gases exit through a second pebble bed transferring
heat to the pebbles. The dampers are reversed periodically, thereby
alternating the functions of the two pebble beds.
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An incinerator having three or more pebble beds will allow one
pebble bed to be removed from the process while the other two pebble beds
are acting as both the energy recovery after incineration and as air
preheat prior to incineration. The use of the third pebble bed will further
allow the residual fumes in that chamber to be flushed to the combustion
zone prior to flow reversal, thus providing the highest level of combustion
efficiencies. Such flushing is not possible if there are only two pebble
beds. A diagram of a five bed system is shown in Figure 3-4.
Pebble bed systems have been designed to achieve a heat recovery
efficiency of 85 percent. When the vapor concentration is about 10 percent
of the LEL, the burner throttles to a pilot light condition, the VOC fumes
furnishing virtually all of the fuel requirement during periods of continuous
operation.
Recovery of heat from incineration exhaust gases can also be
accomplished by the use of liquid media heat exchangers. A system using
hot oil to transfer heat from the incinerator exhaust to the dryers has
been installed on a number of rotogravure presses at paperboard and bag
printing plants. This system utilizes an organic vapor sensing device to
control dampers in dryer exhaust so as to maintain a preset percentage of
the Lower Explosive Limit (L.E.L.). Thus the exhaust rate is minimized, and
the VOC furnishes the greater part of the heat to operate the incinerator.
Also the incinerator furnishes the heat to operate the dryers. A sketch of
such a system is shown in Figure 3-5.
3.3 USE OF LOW SOLVENT INKS FOR PACKAGING GRAVURE AND FLEXOGRAPHIC PRINTING
Low solvent inks are of three types: water-borne, high-solids and
radiation curable inks. Only water-borne inks are widely used at the present
time and are discussed in the following section.
3-6
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3.3.1 Water-Borne Inks
These inks are not completely solvent-free, as the volatile portion
contains up to 35 percent water soluble organic compounds. Water-borne inks
are used extensively in printing of corrugated paperboard for containers,
or multi-wall bags and other packaging materials made of paper and paper
products. There is a limit upon the amount of water-borne ink that can be
printed upon thin stock before paper will be seriously weakened. Thus,
the expanded use of water-borne inks faces this severe limitation.
3.4 SUMMARY OF APPLICABILITY OF CONTROL METHODS
The available control methods for each of the printing methods are
summarized in the following sections.
3.4.1 Rotogravure
Publication rotogravure operations can be controlled by carbon
adsorption systems with a capture efficiency of 75-85 percent of the VOC
emitted from the printing units and the dryers. The carbon recovery system
can be operated with a recovery efficiency of 90 percent of the VOC entering
the carbon beds. An overall emission reduction efficiency of 75 percent
can thus be achieved.
Packaging rotogravure printing operations can be controlled by
incineration systems with an expected capture efficiency of 70-80 percent
and a combustion efficiency of 90 percent. An overall emission reduction
efficiency of 65 percent can thus be achieved.
Some rotogravure packaging printing operations with less demanding
quality requirements can use water-borne inks. Most water-borne inks
contain some VOC as a co-solvent. Emission limits comparable to carbon
adsorption and incineration can be achieved if the solvent portion of the
ink consists of 75 volume percent water and 25 volume percent organic solvent.
3-9
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3.4.2 Flexography
Flexographic printing operations can be controlled by incineration
systems with an expected capture efficiency of 65-70 percent and a combustion
efficiency of 90 percent. Thus an overall emission reduction efficiency of
60 percent can be achieved.
Some flexographic packaging printing operations can utilize water-
borne inks. Emission limits comparable to incineration can be achieved
when the solvent portion of the ink consists of 75 volume percent water
and 25 volume percent organic solvent.
3-10
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3.5 REFERENCES
1. George H. F., Gravure Industry's Environmental Program. In con-
ference on Environmental Aspects of Chemical Use in Printing Operations
EPA-5601/I-75-005. Office of Toxic Substances, Environmental
Protection Agency, January 1976. pp 204-216
2. Watkins, B.G., and P. Marnell, Solvent Recovery in a Modern
Rotogravure Printing Plant. In conference on Environmental Aspects
of Chemical Use in printing Operations, EPA 5601/1-75-005. Office
of Toxic Substances, Environmental Protection Agency. January 1976.
pp. 344-355.
3. Marvin, R. L., Recovery and Reuse of Organic Ink Solvents. In
conference on Environmental Aspects of Chemical Use in Printing
Operations. EPA 5601/1-75-005 Office of Toxic Substances,
Environmental Protection Agency, pp 367-387. January 1976.
4. Comment letter from Michael J. Worral, American Ceca Corporation.
November 30, 1978.
5. Control of Volatile Organic Emissions from Existing Stationary
Sources - Volume I: Control Methods for Surface Coating Operations.
U.S. Environmental Protection Agency. Research Triangle Park, N.C.
27711. November 1976.
6. Study of Systems for Heat Recovery from Afterburners. Prepared
for U.S. Environmental Protection Agency by Industrial Gas Cleaning
Institute, Inc. Stamford, Connecticut. April 1978.
3-11
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4.0 COST ANALYSIS
4.1 INTRODUCTION
4.1.1 Purpose
This section presents estimated installed capital and annualized costs
for control of volatile organic compounds (VOC) from that portion of the
graphic arts industry involved in flexographic and rotogravure packaging
printing and rotogravure publication printing. The section also includes
an analysis of the cost-effectiveness of the control methods.
4.1.2 Scope
The analysis includes all the printing operations involved, i.e., the
application and drying or curing of inks. Cost estimates have been developed
on the basis of retrofitting VOC controls on existing plants. Two groups of
printing processes are analyzed. The first uses flexographic and rotogravure
processes on packaging. The second uses the rotogravure processes to print
publications. Light hydrocarbon emissions are generated by both groups.
Various typical plant sizes (based on annual ink use) are analyzed for both
packaging and publication printing. Tables 4-1 and 4-2 present the process
parameters of the model sizes selected for the packaging and publications
groups, respectively. These parameters include exhaust gas volumetric
flow rates and temperatures, control devices, and control efficiencies
for each model plant. (Flow diagrams showing the plant configurations
are presented in Chapter 2.)
4.1.3 Use of Model Plants
Cost estimates developed for this analysis are based solely on model
plant configurations. Yearly ink usage of the model plant sizes selected for
packaging printing are 7 Mg (7.7 tons), 40 Mg (44 tons), 150 Mg (165 tons),
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400 Mg (440 tons), and 2500 Mg (2750 tons). For publication printing,
the yearly ink usages are 3500 Mg (3860 tons) and 7000 Mg (7720
tons). Because factors such as width and operating speed of the printing
machinery influence control costs at actual facilities, actual costs for
specific plant sizes will vary. Nevertheless, cost estimates based on model
plants are useful for comparing control alternatives.
4.1.4 Bases for Capital Costs
Installed capital costs represent the total investment required for
installing retrofit emission control systems on existing presses; they
include the cost of equipment, material, labor for equipment erection, and
other associated costs. These estimated costs reflect mid-1978 dollars and
are based on equipment costs obtained from equipment vendors. ' The
control equipment is assumed to be mounted on structural steel above grade
or roof; the ducting requirement is based on equipment that is installed
within 100 meters (350 ft) of the press. The installation costs have
been estimated on installed material requirements. No attempt has
been made to include either production losses during installation and
startup, or research and development costs. Table 4-3 presents the
bases and assumptions used in estimating capital costs.
4.1.5 Bases for Annualized Costs
Annualized costs represent the cost of operating and maintaining control
systems and the cost of recovering the capital investment required for these
systems. They include direct costs such as utilities, materials, labor, and
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TABLE 4-3. BASES FOR CAPITAL COST ESTIMATES
All costs are expressed in mid-1978 dollars.
The afterburners have a 0.5-second residence time and a 746°C (1375°F)
incineration temperature.
Afterburners and carbon adsorption systems have a VOC emission
reduction efficiency of 90 percent.
The initial carbon for bedding is included in capital costs.
Capital investment includes:
Basic control equipment
Auxiliary equipment (e.g., hoods, ducts)
Fuel oil storage for 10 days operation
Installation of basic and auxiliary equipment
Removal of existing equipment, as required
Contingencies
Contractor's fee, taxes, and other indirect costs
4-5
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maintenance; indirect costs such as taxes, insurance, depreciation, interest
rate, administration, and permits; and adjustments such as credits for re-
covered solvents. Table 4-4 presents bases and assumptions used to estimate
annualized costs.
4.2 VOC CONTROL IN THE PRINTING INDUSTRY
4.2.1 Model Plant Parameters
Costs were developed for thermal incinerators with and without 40
percent primary heat recovery on flexographic and rotogravure packaging,
and for carbon adsorption control on rotogravure publication printing
processes. In addition, the costs for thermal incinerators with heat
recovery were compared to costs for identically sized pebble bed incinera-
tors.
4.2.2 Control Costs
The capital and annualized costs and cost-effectiveness ratios of
thermal incinerators for VOC control on flexographic and rotogravure
packaging model plants are presented in Tables 4-5 through 4-9; costs of carbon
adsorption systems on rotogravure publication model plants are presented in
Table 4-10. The respective cost data are plotted against model plant ink usage
in Figures 4-1, 4-2, and 4-3. Finally, Table 4-11 displays these data for
pebble bed incinerators.
In packaging printing, the incinerator with a primary heat recovery
system requires a larger capital investment than one without primary heat
recovery. Because primary heat recovery reduces fuel costs, the savings
therefrom increase proportionately with volumetric flow rate and VOC concentration,
In packaging printing, incineration for each model plant size has been eval-
uated at two gas flow rates, the smaller rate being one third of the larger.
These lower rates are considered attainable with minor modifications to press
4-6
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TABLE 4-4. BASES FOR ANNUALIZED COST ESTIMATES
Description
Unit cost
Basis for costs and other comments
Annualized costs
Installation type
Press operating time
Utilities
No. 2 fuel oil3
Electricity
Steam
Operating labor
Maintenance
Labor
Material
Misc. maint., parts
and material
Capital recovery
factor
Taxes and insurance
Administration and
permits
Adjustment
creditc
0.105/liter
($0.396/gal)
0.0266/kWh
$9.02/Mg
($4.10/103 lb)
$8.66/h
$9.53/h
$9.53
16.275% of
capital cost
2% of capital
cost
2% of capital
cost
$0.105/liter
($0.396/gal)
One year period commencing mid-1978
Retrofit
1000 h/yr or 250 days/yr at 4 h/day;
2000 h/yr or 250 days/yr at 8 h/day;
3000 h/yr or 250 days/yr at 12 h/day;
4000 h/yr or 250 days/yr at 16 h/day
$0.105/liter ($0.396/gal); based upon
transport lots of 27,250 liters (7200
gal) delivered from Midwest terminal
EPA-230/3-77-015b report cost for
iron and steel industry
Based on 80% efficiency; includes 16C
for facilities, maintenance, depreciation,
and others b
Includes 20% for fringes
Hourly rate at 10" premium over operating
labor $9.53/h
Average (over life of equipment) material
costs equal to labor costs
Carbon beds: annual allowance for 5-year
life, 10% of the equipment capital cost
10% interest rate and 10 years equip-
ment life
Reclaimed solvent for use of diesel or
fuel oil
a Assumed to be the only fuel used by all systems.
b In other words: 1000 lb steam x 1000 Btu/lb x $0.396/gal * (140,000 Btu/gal x 0.8 eff.)
= $354/103 lb steam plus 16% = $4.10/103 lb steam.
c Where applicable.
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enclosures. Significant modifications to enclosures or the addition of high-
velocity air jets could reduce ventilation rates to one-sixth that of the
unimproved, and could increase VOC concentration proportionately. This reduction
in flow rates significantly reduces the control system capital cost for all
plants. The capital cost reductions for the model plant sizes of 7 Mg/yr
(7.7 tons/yr), 40 Mg/yr (44 tons/yr), 150 Mg/yr (165 tons/yr), 400 Mg/yr (440
tons/yr), and 2500 Mg/yr (2750 tons/yr) are, respectively: 10%, 10%, 41%, 36%, and
67% for incinerators without heat recovery; and 6%, 13%, 23%, 31%, and 67% for
incinerators with 40% primary heat recovery.
For all model plants, these lower capital costs effect proportional
reductions in annualized capital charges. This 66% reduction in the
volumetric flow rate (with an accompanying trebling of VOC concentration)
causes reductions in the direct annual operating costs (fuel, electricity,
etc.) for the respective model plant sizes of: 50%, 65%, 70%, 72%, and
74% for incinerators without heat recovery; and 37%, 60%, 78%, 75%, and
78% for incinerators with 40% primary heat recovery. In other words,
for a given model plant size, smaller incinerators are less expensive
than larger ones to buy and operate.
The addition of primary heat recovery equipment to incinerators increases
the capital cost, but reduces annual fuel consumption proportionately with
the operating hours. Neither the 7 Mg/yr (7.7 tons/yr) plant nor the 40 Mg/yr
(44 tons/yr) plant operates enough hours per year to realize an annual ized cost
savings from heat recovery, relative to the corresponding thermal incinerator
without heat recovery. For the larger plants operating more hours per year,
however, the incinerators with heat recovery have lower annual ized
costs than those without heat recovery.
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The effect of heat recovery on total annualized cost is also illustrated
by Figures 4-1 and 4-2. As these figures show, the annualized costs are
less than 25% of the capital costs of incinerators with or without heat
recovery for the smallest model plant. As the plant size increases to
the largest model plant size, however, the annualized costs exceed
capital costs for those without heat recovery, but the addition of heat
recovery reduces the annualized costs to less than the corresponding
capital costs.
Table 4-10 lists capital and annualized costs for carbon adsorption
systems. Although the capital cost increases with plant size, smaller
volumetric flow rates may effect reductions in both capital and operating
costs for a given model plant size. For example, a 50 percent reduction in
volumetric flow rate for the 3500 Mg/yr (3860 tons/yr) plant reduces the
capital cost from $701,000 to $435,000, and reduces the annualized
capital charges from $142,100 to $88,200. The solvent recovery credits
are $170,100 for both volumetric flow rates, since the VOC emissions
from the presses are based on the same hourly emission rate and the same
annual operating hours. The direct operating costs are reduced from
$100,800 and $82,900 solely because less electric power is required for
the lower volumetric flow rate. It is important to note that neither
the steam requirements for desorbing nor the cooling water required for
condensing the steam and desorbed VOC is reduced, because both are
related to the VOC collected and not the volumetric flow rate. In all,
the total annualized cost is reduced from $72,800 to $1000 for a 3500 Mg/yr (3860
4-17
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be emphasized that the pebble bed incinerator vendor claims a very high
primary heat recovery (85 to 90%), versus 40% for the thermal incinerator.
Thus, the pebble bed's fuel cost constitutes an even lower percentage of
its total annualized cost. Indeed, in some cases, the fuel requirements--
and costs—are negligible.
Shown in Table 4-11, the annualized cost ranges from $26,600 to $478,000
per year for the smallest and largest plant sizes. These costs are signifi-
cantly lower than those for the thermal incinerator with primary heat
recovery. The incinerator costs range from $33,700 to $1,117,000 per year.
Now, the costs in Table 4-11 correspond to an 85% heat recovery, a fairly
typical value. If the recovery were boosted to 90%, the annualized costs
would decrease modestly in most cases. However, in some instances the
annualized costs would increase, because the higher heat recovery units would
require larger pebble beds which would, in turn, drive up their installed
costs.
4.2.3 Cost-effectiveness
The cost-effectiveness ratio (in this report) is defined as the total
annualized cost per annual unit of pollutant controlled. The annual amount
of pollutant controlled depends on control device efficiency and total
operating hours. By definition, the lower the ratio, the better the cost-
effectiveness.
The cost-effectiveness ratios and efficiencies of the control systems
and the quantities of pollutant controlled are shown in Tables 4-5 through
4-10 for thermal incinerators and carbon adsorbers, and in Table 4-11 for
pebble bed incinerators. Figures 4-4, 4-5, and 4-6 present cost-effectiveness
curves for thermal incinerators on packaging printing processes and carbon
adsorbers on publication printing processes.
4-21
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Data show that the cost-effectiveness of control systems improves with
plant size. Because thermal incinerator costs are based on the same
efficiency for all plant sizes, their cost-effectiveness is enhanced by
increased plant operation and control utilization. As shown in Figure
4-5 and discussed in Section 4.2.2, the incinerator with heat recovery
is less cost-effective than a system without heat recovery for the two
smaller packaging printing plants analyzed, and is more cost-effective
for the three larger plants. The cost-effectiveness ratio for thermal
incinerators with heat recovery decreases from $12,500/Mg ($ll,370/ton)
at the smallest plant to $280/Mg ($250/ton) at the largest plant, based
on the 90% control device efficiency.
The cost-effectiveness of controlling the publication printing process
also improves as the plant size increases. Specifically, the cost-
effectiveness ratio decreases from $51/Mg ($46/ton) at the smallest plant
to a negative $15/Mg ($13/ton) at the largest plant, based on this same
90% control device efficiency.
Lastly, because its annualized costs are consistently lower than
those for identically-sized thermal incinerators with heat recovery, the
cost-effectiveness of pebble bed incinerators is also better. Its cost-
effectiveness ratio decreases from $9,260/Mg ($8,400/ton) to $130/Mg
($120/ton) as the plant size goes from smallest to largest.
4-25
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REFERENCES FOR CHAPTER 4
1. Industrial Gas Cleaning Institute, Stamford, Connecticut. Study of
Systems for Heat Recovery from Afterburners. Prepared for Chemical and
Petroleum Branch, U.S. Environmental Protection Agency, Research Triangle
Park, North Carolina, under Contract No. 68-02-1473, Task No. 23.
October 1977.
2. C-E Air Preheater, Combustion Engineering, Wellsville, New York. Report
of Fuel Requirements, Capital Cost, and Operating Expense for Catalytic
and Thermal Afterburners. Prepared for Environmental Protection Agency
under Contract No. 68-02-1473, Task No. 13. December 1973.
3. Personal communication from Derek Oaks, Hoyt Manufacturing Corporation,
Westport, Massachusetts, to Art Knox, PEDCo Environmental,
Inc., Cincinnati, Ohio. August 1978.
4. Personal communication from K. Allen Napier, Oxy-Catalyst, Inc., Research-
Cottrell, Inc., West Chester, Pennsylvania, to Art Knox, PEDCo Environmental,
Inc., Cincinnati, Ohio. February 23, 1978.
5. Personal communication from Dennis Snyder of Smith Environmental, South
Elmonte, California, to Art Knox, PEDCo Environmental, Inc.,
Cincinnati, Ohio. August 23, 1978.
6. Personal communication from Carol Paulette of C-E Preheater Division,
Wellsville, New York, to Art Knox, PEDCo Environmental, Inc., Cincinnati,
Ohio. August 30, 1978.
7. R.S. Means Company. Building Construction Cost Data - 1978; and Mechanical
and Electrical Cost Data - 1978. Duxburn, Massachusetts.
8. Personal communication from R.L. Pennington, REECo, Inc., Morris Plains,
New Jersey, to E.J. Vincent, U.S. Environmental Protection Agency,
Office of Air Quality Planning and Standards, Research Triangle Park,
N.C., October 27, 1978.
9. Personal communication from W.M. Vatavuk, U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle
Park, N.C., to R.L. Pennington, REECo, Inc., Morris Plains, New Jersey.
November 13, 1978.
10. Ibid. November 20, 1978.
11. Personal communication from W.M. Vatavuk, U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle
Park, N.C., to Art Knox, PEDCo Environmental, Inc., Cincinnati, Ohio.
November 22, 1978.
4-26
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5.0 ADVERSE AND BENEFICIAL EFFECTS OF APPLYING
CONTROL TECHNOLOGY
5.1 INCINERATION
Incineration is applicable to packaging gravure and flexographic
printing operations which use conventional solvent-borne inks. The principal
disadvantage is the use of scarce and increasingly expensive fuel. Fuel
consumption can be minimized by the inclusion of heat recovery equipment in
the design. Primary heat exchangers can reduce fuel usage to some extent.
Hypothetically, the use of pebble bed incinerators with their inherently
effective heat recovery systems can reduce fuel usage substantially. At
current fuel prices the annualized cost of the heat recovery system will be
greater than the fuel saving and there will be a net increase in operating
cost.
5.2 CARBON ADSORPTION
Carbon adsorption systems can recover solvent for reuse in ink manufacture.
Thus, a valuable and increasingly scarce material can be conserved. Steam
stripping is the usual method for removing adsorbed solvent from the carbon
beds. If water soluble solvents are used in the inks, the condensed steam
will contain orgam'cs which will require the additional expense of pretreatment
facilities. This disadvantage is not present in the recently developed
fluidized bed carbon adsorption system in which desorption is achieved by
indirect heat and nitrogen gas.
5-1
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6.0 MONITORING TECHNIQUES AND ENFORCEMENT ASPECTS
In the majority of cases the suggested emission limits will probably
be met by incineration and carbon adsorption systems. The basic problem of
the control official is determining that the control device is operating
correctly. A measurement of efficiency across the device could be required
when the unit is installed. (One test may be adequate when several identical
units are installed).
A thermal incinerator which initially shows a high combustion efficiency
will probably continue to perform well if operated at the same or greater
temperature. All incinerators should be equipped with temperature indicators;
recorders should be required for larger installations. The range instrument
of 1200° to 1800°F will cover thermal incinerators; catalytic units seldom
operate at less than 600° or more than 1200°F. The sensing elements should
be shielded from direct flame radiation. Other incinerator parameters are
fixed by the design, e.g., there is no need to monitor residence time or
mixing velocity.
For catalytic incinerators, the temperature rise across the catalyst
bed should be measured during the initial test for combustion efficiency.
This temperature rise reflects the activity of the catalyst (but may also
vary with process variables and material input changes in the process).
Temperature sensors should be installed on both the inlet and outlet of the
catalyst bed to provide a continuous indication of catalyst activity.
6-1
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To assure satisfactory operation of carbon adsorbers, it is necessary
to regenerate the carbon beds at intervals sufficient to prevent "breakthrough"
Breakthrough is the point at which VOC starts to appear in the exit gases
in significant concentrations. The regeneration cycle is controlled by
three methods: 1) a sequence timer, 2) a vapor detector, 3) both a
sequence timer and a vapor detector.
A sequence timer is the simplest control method. The length of the
adsorption period is determined by trial at the highest VOC concentrations
likely to occur. This method can be wasteful of steam, as regeneration will
often be performed before the bed is fully loaded. On the other hand, if
the cycle is made too long , breakthrough will often occur.
A vapor detector sensitive to 50 to 100 ppm is sufficient for most
applications. The detector may actuate an audible or visible alarm only, with
the regeneration operations being performed manually. Or the detector
may actuate an automatic control mechanism for performing the regeneration
operation. This method is the more economical of steam, as regeneration is
done only when the bed is loaded to the maximum allowable level. However,
if the detector malfunctions extended breakthroughs could occur.
The combination system is always fully automatic. The sequence timer
is set for a period of average VOC concentration. During periods of higher
than average VOC concentration the vapor detector will initiate the
regeneration. The timer will act as a back-up device in case of a mal-
function of the vapor detector. Most system at publication rotogravure plants
are of this type.
6-2
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TECHNICAL REPORT DATA
(Please read Instructions on the rei'trse before completing)
1. REPORT NO.
EPA-450/2-78-033
TITLE AND SUBTITLE
Control of Volatile Organic Emissions from Existing
Stationary Sources - Volume VIII: Graphic Arts -
Rotogravure and Flexography
7. AUTHOR(S)
Edwin J.
William f
Vincent
I. Vatavuk
8. PERFORMING ORGANIZATION REPORT NO
OAQPS No. 1.2-109
3. RECIPIENT'S ACCESSION NO.
5. REPORT DATE
December 1978
6. PERFORMING ORGANIZATION CODE
9 PERFORMING ORGANIZATION NAME AND ADDRESS
U. S. Environmental Protection Agency
Office of Air, Noise and Radiation
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
12. SPONSORING AGENCY NAME AND ADDRESS
13. TYPE OF REPORT AND PERIOD COVERED
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
This document provides guidance for development of regulations to limit
emissions of volatile organic compounds from rotogravure and flexographic printing
operations. This guidance includes recommended control requirements for carbon
adsorption and incineration systems which represent Reasonably Available Control
Technology for these operations. Provisions for the potential compliance by use
of water-borne and high-solids inks are recommended. The industry is described,
methods for reducing organic emissions are reviewed, and monitoring and enforcement
aspects are discussed.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
Air Pollution
Publication Rotogravure Printing
Packaging Printing Industry
Volatile Organic Compound Emissions
Limits
Regulatory Guidance
b.IDENTIFIERS/OPEN ENDED TERMS
Air Pollution Control
Stationary Sources
Organic Vapors
c. COSATl Field/Group
18. DISTRIBUTION STATEMENT
19. SECURITY CLASS (This Report)
Unclassified
Unlimited
21. NO. OF PAGES
52
20 SECURITY CLASS (This page}
Unclassified
22. PRICE
EPA Form 2220-1 (Rev. 4-77) PREVIOUS EDITION is OBSCH ETE
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