EPA-450/3-80-004
Source Category Survey:
Borax and Boric Acid Industry
Emission Standards and Engineering Division
Contract No. 68-02-3064
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air, Noise, and Radiation
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
May 1980
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This report has been reviewed by the Emission Standards and Engineering
Division, Office of Air Quality Planning and Standards, Office of Air, Noise,
and Radiation, Environmental Protection Agency, and approved for publica-
tion. Mention of company or product names does not constitute endorsement
by EPA. Copies are available free of charge to Federal employees, current
contractors and grantees, and non-profit organizations - as supplies permit
from the Library Services Office, MD-35, Environmental Protection Agency,
Research Triangle Park, NC 27711; or may be obtained, for a fee, from the
National Technical Information Service, 5285 Port Royal Road, Springfield,
VA 22161:
Publication No. EPA-450/3-80-004
ii
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TABLE OF CONTENTS
Section
D
Page
1 SUMMARY ............................................ 1_1
2 INTRODUCTION ...................................... 2-l
3 CONCLUSIONS AND RECOMMENDATIONS ................... 3_1
4 INDUSTRY DESCRIPTION ....... ....................... 4-1
4.1 Source Category .............................. 4-1
4.2 Industry Background Information ....... ....... 4-2
4.3 Process Description ..... . ...... .............. 4-8
4.3.1 Ore Processing ................. . ........ 4_8
4.3.2 Brine Processing ......... '.'.'.'.'.'.'.'. .......... 4_n
4.3.3 Boric Acid Production ..... !!!!!!!!!!!!!!!!! 4-14
5 AIR EMISSIONS DEVELOPED IN SOURCE CATEGORY ...... '. . 5.-1
5.1 .Plant and Process Emissions .................. 5_1
5.1.1 Particul ate Emissions ____ ................. 5_1
5.1.2 Nitrogen Oxide Emissions ____ ........... 5-2
5.1.3 Sulfur Oxides Emissions ........... '.'.'.'.'.'.'.'.'. 5-4
5.2 Total National Particulate Emissions ......... 5-5
6 CONTROL TECHNOLOGIES ............................. 6-1
6.1 Current Control Techniques ____ . .............. 6-1
6.1.1 Fusing Furnace and Calciner Controls 6-1
6.1.2 Product Dryers and Coolers ............. ." " 6-3
6.1.3 Mixers, Reactors, and Evaporators .......... 6-4
6.2 Alternate Control Techniques . ......... . ...... 6-4
7 PARTICULATE EMISSIONS DATA ......... ....... ........ 7_!
8 STATE AND LOCAL EMISSIONS REGULATIONS ..... .. ...... 8-1
8.1 Summary of Regulations .......... ....... 8-1
8.2 Degree of Control Required by Regulations"!!.'.' 8-4
0.3 Enforcement ............................ g_4
REFERENCES ................................... R_r
APPENDIX A - PERSONS WITH EXPERTISE IN THE
BORAX/BORIC ACID INDUSTRY INDENTIFIED
DURING SOURCE CATEGORY SURVEY ...... A-l
i i i
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LIST OF ILLUSTRATIONS
Figure ^
4-1 Principal Uses of Boron Minerals and Chemical
Compounds in the United States 4-4
4-2 • Location of Borax/Boric Acid Facilities 4-9
4-3 Refining and Production of Boron Compounds 4-10
4-4 Borate Ore Refining 4~12
4-5 Colemanite Ore Processing 4"13
4-6 Boric Acid Production from Borax by Acidulation .... 4-15
4-7 Boric Acid Production from Weak Brine . . 4-16
LIST OF TABLES
Table
4-1 Summary of the Borax/Boric Acid Industry Capacity and
Production Levels • •
4-2 Borax/Boric Acid Industry Summary • 4~6
5-1 Particulate Emissions from Typical Affected
Facilities . . . . 5~6
5-2 Nationwide Particulate Emissions from Borax and
Boric Acid Production b"b
6-1 Emission Control Systems 6'2
7-1 The Data Availability on Particulate Emissions .... .7-2
7-2 Particulate Emissions 7~3
8-1 Borax and Boric Acid Plants and Governing Control ^
Agencies
8-2 Summary of State and Local Regulations (Particulate
Matter)
8-3 ' Degree of Control Required at the Two Most
Stringently Controlled Plants 8~b
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1. SUMMARY
The Clean Air Act, as amended in 1977, calls for the promulgation of
emissions standards of performance for new and modified sources (NSPS's)
that contribute significantly to air pollution. The borax/boric acid
source category has been tentatively identified as having such a potential,
The borax/boric acid source category includes those facilities used
in refining and processing either sodium or calcium borate ores or brines
to produce boric acid and other borate compounds. Facilities processing
refined borax to produce boric acid are also included, as are the
facilities processing the byproduct sodium sulfate resulting from boric
acid production. Not included, however, are associated mining, screening,
crushing, or grinding operations.
The category, as a result, consists of six plants operated by four
companies:
U.S. Borax and Chemical Corp.
Kerr-McGee Chemical Corp.
American Borate Co.
Stauffer Chemical Co.
Boron, CA
Wilmington, CA
Trona, CA
Westend, CA
Lathrop Wells, NV
San Francisco, CA
1-1
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The U.S. Borax plant at Wilmington, California is scheduled to cease
production of boric acid in 1980, when it will be replaced by a new
production unit at U.S. Borax in Boron, California.
The production of borax/boric acid expressed in terms of B203
content was 706 6g (778,000 tons) in 1978 and is expected to grow through
the 1980's at 2.3 percent per year, the historical annual growth rate of
the past 20 years. The increased production will be met through increased
utilization of existing facilities and the new boric acid unit at Boron,
rather than other new or modified facilities between 1980 and 1985.
The refinement and production of borate compounds involves
purification and crystallization processes to either isolate the borates
brom brine or remove clay and shale contaminants from crude ore. Purified
crystals are often calcined to form a powdered product and can be
dehydrated in furnaces to form anhydrous borates. Boric acid is produced
from either brine or refined borax by acidification processes.
The main pollutant of concern in this category is particulate
matter. Particulates are emitted from the furnaces, calciners, and
coolers following the product dryers. Particulate matter is also emitted
in the form of fugitive emissions from material handling. Additionally,
boric acid vapors are released from the digesters during boric acid
production.
Control of particulate matter is accomplished primarily by scrubbers
on the furnaces, calciners, and coolers. Scrubbers are also used to
control boric acid vapors. Fabric filters, although used on furnaces and
dryers, have been found to be more difficult to operate than scrubbers and
are in some cases being replaced by scrubbers. Electrostatic precipitators
that are used at only one plant, have also been found to be less effective
1-2
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than scrubbers, because of high particle resistivity associated with boron
compounds.
Present California and Nevada air pollution control regulations
typically limit particulate emissions to 0.46 g/nm3 (0.2 gr/dscf) and
20 percent opacity which requires approximately 94 percent control
efficiency. Data supplied by state and local agencies indicate that this
is being achieved. As a result, the emissions of particulate matter for
the borax and boric acid source category are estimated to be 619 Mg
(682 tons).
The impact of developing an NSPS for this source category on
nationwide particulate emissions in 1985 is estimated to be zero because
of increased utilization of existing production capability.
Therefore, it is recommended that a standard for this source
category not be developed.
1-3
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2. INTRODUCTION
The Clean Air Act (CAA), as amended in 1977, provides authority for
EPA to control discharge of pollutants into the atmosphere. The Act
contains several regulatory and enforcement options for control of
emissions from stationary sources. Options include (1) National Ambient
Air Quality Standards (NAAQS's) on the national level and .State
Implementation Plans (SIP's) on the state level, (2) NSPS's and (3)
National Emission Standards for Hazardous Air Pollutants (NESHAP's).
Section 111 of the CAA calls for promulgation of NSPS's for new and
modified sources that may contribute significantly to air pollution-
emissions that could endanger public health and welfare. The standards
must reflect the best degree of control as satisfactorily demonstrated to
EPA (taking cost, energy, and non-air environmental quality impacts into
account). This source category survey is the first step in the process of
setting an NSPS for borax and boric acid. Its primary purpose is to
verify whether or not a standard is warranted and, if so, to determine the
availability of data required to set a standard.
The necessary information for the source category survey was gathered
through the following sources:
1. Population and growth rates from literature searches, contacts
with federal agencies, data from individual states, and
discussions with industry representatives
2-1
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2. Data on emissions and applicable control devices from literature
searches, National Emissions Data System (NEDS), contracts with
federal, state, and local air pollution control agencies, records
of the agencies, contacts with industry representatives, and site
visits to four plants
3. State and local regulations from contacts with the authorities
who are responsible for air pollution control in the area
An important factor throughout the information collection, analysis,
and documentation effort has been the relationship between the borax/boric
acid source category and the nonmetallic mineral, processing source
category. For this study, the issue has been resolved by identifying
borax facilities as the dryers, furnaces, kilns, and coolers used in the
preparation of anhydrous and hydrated borax. Boric acid is defined to
include all processes in the manufacture of anhydrous or hydrated boric
acid except materials handling and grinding processes. The effect of such
a definition is that crushers, grinding mills, screening operations,
bucket elevators, conveyor transfer points, bagging operations, storage
bins, and fine product truck and rail loading stations are not addressed
in the borax/boric acid source category but are addressed in the
nonmetallic mineral processing source category.
Secondary manufacturing processes, which range from simple mixing of
borax with detergents to large, complex glass manufacturing operations,
are not included in the source category survey. To do so would
necessitate considering many unrelated sources having different emission
problems, control problems, and economic characteristics.
2-2
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3. CONCLUSIONS AND RECOMMENDATIONS
The borax/boric acid industry, which is concentrated in the desert
region of Southern California/Nevada, consists of six plants owned by four
companies. One company produces over 75 percent of the borate products
produced in the United States.
Although exact production levels of each compound are confidential,
the production of borates expressed in terms of B203 content was
706 Gg (778,000 tons) in 1978. While this represented a 6 percent annual
growth rate over the preceding 5 years, industry analysts project growth
to follow the historical rate for borate compounds of 2.3 percent per year
over the next 10 years.
The most recent industry expansions to be completed in 1979 and 1980
will increase the industry production capability from 706 Gg/yr
(778,000 tons/yr) to 848 Gg/yr (934,000 tons/yr). The effect of these
expansions is to encourage a no-growth situation in the near future since
the 1980 production capacity is sufficient to meet the anticipated
production of 804 Gg (886,000 tons) B203 in 1985.
Data supplied by state and local air pollution control agencies
indicate that the degree of control, 94 percent, required by present
regulations is being met. These regulations typically require that
particulate emissions not exceed 0.46 g/nm (0.2 gr/dscf) and 20 percent
3-1
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opacity. The particulate emissions for the source category, therefore,
are estimated to be 619 Mg (682 tons).
If an NSPS standard for borax/boric acid were developed, the
reduction in parti oil ate emissions in 1985 is estimated to be zero due to
increased utilization of existing facilities. It is recommended,
therefore, that no further action be taken at this time regarding
development and promulgation of an NSPS for borax/boric acid.
3-2
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4. INDUSTRY DESCRIPTION
4.1 SOURCE CATEGORY
Borax and boric acid belong to a group of chemical compounds known as
borates, all of which contain the component B^O.,. Borax, a sodium
borate, is the most common naturally occurring compound. It occurs both
as the mineral tincal and in lake brines. The chemical formulas of the
naturally occurring borates with commercial value are as follows:
Tincal
Tincalconite
Kernite
Colemanite (borocalcite)
Ulexite (boronatrocalcite)
Probertite
Priceite
Pandermite
Boracite (stassfurite)
Sassolite (natural boric acid)
Szaibelyite (ascharite)
' 10H20
' 5H20
Ca2B6°ll
NaCaB5Og
5H2°
NaCaBgOg * 5H20
Ca5B12°23 * 7-1/2H2°
Ca4B10°19 ' 7H2°
MgoB-yO.,0 ' C1
MgB02(OH)
The borax/boric acid source category includes those facilities which
are used in the refining and processing of either sodium or calcium borate
ores or brines to produce boric acid and other borate compounds. The
4-1
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facilities processing the byproduct sodium sulfate resulting from boric
acid production are also included. Not included, however, are any
associated mining, screening, crushing, or grinding operations used on
either crude ore or borax products. The standard under development for
nonmetallic mineral processing will apply to these processes. Secondary
or end-use processes of borax and boric acid are also not included, due to
differences in emissions, controls, and economic characteristics. The
exceptions to this are the facilities processing refired borax to produce
boric acid.
4.2 INDUSTRY BACKGROUND INFORMATION
The United States is the leading world producer of borate compounds.
Production in 1977 expressed in terms of borate (B203) content was 667
Gg (735,000 tons), which constituted 53 percent of the world production
I n
for that year. ' U.S. production of borate compounds in 1978 was 706
Gg (778,000 tons) B203. Although this represents a 6 percent per year
increase in production over the past 5 years, industry analysts project
growth in the future to be much slower. Based on the historical growth in
production over the past 20 years of 2.3 percent per year, production in
2
the year 1985 is estimated to be 804 Gg (886,000 tons) of B203.
The increase in production rate will be met through increasing utilization
of the new capacity level as of 1980. Recent industry expansions, to be
completed in 1979 and 1980, will increase production capacity from 706 Gg
(778,000 tons) to 848 Gg (934,000 tons). No other expansions are
anticipated in the next five years. Table 4-1 summarizes these changes in
capacity and production levels. Borate compounds are used in a wide
variety of manufacturing applications, including the manufacture of glass,
4,-2
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laundry products, and flame proof cellulosic insulation. A more complete
list of borate mineral and compound uses is presented in Figure 4-1.
Table 4-1. SUMMARY OF THE BORAX/BORIC ACID INDUSTRY
CAPACITY AND PRODUCTION LEVELS
(Gg (thousand tons))
Year
1978
1980
1985
Capacity
706 (778)
848 (934)
848 (934)
6203 content
production
706 (778)
739 (814)
804 (886)
Borate compound processing is done by three companies at facilities
located in the vicinity of Death Valley, California. The nature of the
recovery and refining processes dictate that almost all of these processes
be done at or near the deposit sites. Since bori.c acid and anhydrous
borax both may be produced from calcined borax, it is feasible to process
these compounds offsite, as is currently done at U.S. Borax's Wilmington
plant and the Stauffer Chemical Company boric acid processing plant in San
Francisco. No other offsite processing plants exist.
Table 4-2 summarizes the products produced at each of the borate
compound processing sites operated by these companies. U.S. Borax
Chemical Corp., a subsidiary of Rio-Tinto Zinc Corp., is the largest
producer of borate compounds; more than 75 percent of the borate compounds
produced in the United States are produced by U.S. Borax.1 At their
facilities in Boron, California, tinea! ore is processed to produce
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refined boraxes, anhydrous borax, boric acid, and several specialty
products. Kernite ore is presently used in the production of crude sodium
pentaborate (Rasorite ), and will be used in boric acid production when
new facilities at Boron begin operation. Boric acid and anhydrous boric
acid are currently manufactured at the U.S. Borax plant in Wilmington,
California. These facilities will be shut down, however, when a new boric
acid processing plant in Boron begins production. The new 182 Gg (200,000
tons/year) of boric acid/year plant will have more than twice the capacity
1 3
of the Wilmington plant. '
Kerr-McGee Chemical Corporation operates two brine extraction plants
located on adjacent sites near Searles Lake in California. Both the Trona
and the Westend facilities extract borax and boric acid from lake brines,
in addition to several nonborate compounds, including sodium sulfate. The
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Trona plant processes approximately 38 m (10,000 gallons) of brine per
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minute, the Westend plant processes about 15 m (4,000 gallons) per
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Calcium borate (colemanite) and sodium/calcium borate (ulexite and
probertite) ores are processed at the American Borate Co. plant located in
Lathrop Wells, near Las Vegas, Nevada. The Lathrop Wells plant has just
been expanded to include facilities for processing calcium borate by a new
flotation process. These facilities, which have replaced part of the old
washing facilities, have a capacity of 91 Gg of colemanite (100,000 tons)
1 4
per year. ' Ulexite and probertite are very similar compounds which
are typically sold as one compound.
The boric acid facilities in San Francisco are operated by Stauffer
Chemical Company. These facilities use refined borax obtained from U.S.
Borax to supply approximately 5 percent of the market for boric acid.5
4-7
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The location of each of these processing sites in indicated on the
map in Figure 4-2.
4.3 PROCESS DESCRIPTION
Borate compounds are produced from calcium or sodium borate ores, or
brine. The preparation of purified borax from sodium borate ore (tincal
and kernite) principally involves separating the clay and shale impurities
from the crushed ore. Borax is then used in dehydration, fusion, and
acidification processes to produce boric acid and anhydrous derivatives of
borax and boric acid. Figure 4-3 summarizes the refining and processing
operations used in the production of borate compounds. Each of these
processes is described in the following paragraphs.
4.3.1 Ore Processing
Borax products, such as borax decahydrate, borax pentahydrate, and
anhydrous borax are refined from the sodium borate ore, tincal
(Na2B407 * 10H20). The crude ore is a mixture of clay, shale,
and borax, containing approximately 40 percent borax by weight. During
the refining process, about 85 percent of the borax is recovered from the
clay and shale.3 The ore is dissolved in a hot, weak borax solution,
then passed through vibrating screens to remove large insoluble particles
from the solution. The solution is then pumped to thickening tanks where
the insoluble clay fines settle out. The clarified borax liquor is
filtered and pumped to vacuum crystal!izers. A centrifuge removes the
borax crystals from the liquor. These crystals are then dried in gas-
fired dryers to form either borax pentahydrate or borax decahydrate.
Anhydrous borax is produced by first heating the borax in calciners to
decrepitate the crystals into a powder, then melting the calcined borax in
fusing furnaces at 1255 to 1366K (1800° to 2000°F) to form an
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amorphous glass-like product. The anhydrous borax glass is crushed and
screened prior to storage or shipment.
The refinement processes used on colemanite, a calcium borate ore,
remove shale and clay contaminants by means of the flotation process (the
details of which are confidential). The colemanite is then dried in a
gas-fired rotary kiln dryer, and either calcined or sold as uncalcined
4
product.
Particulates are emitted from the fusing furnaces, dryers, calciners,
and coolers (which are located after the dryers). Process flow diagrams
for ore refining are given in Figures 4-4 and 4-5.
4.3.2 Brine Processing
Boraxes (both penta and decahydrate forms) are extracted from lake
brines along with several other inorganic compounds. Two processes,
carbonation and evaporation, produce borax as an endprbduct. During the
carbonation process, carbon dioxide is bubbled through the brine to
precipitate soda ash. By neutralizing and cooling the remaining brine in
vacuum crystal!izers, borax crystals are formed. These crystals are
dewatered and dried to form borax pentahydrate and borax decahydrate.
Sodium sulfate is crystallized when the brine in the vacuum crystallizers
is further cooled. During the evaporation process, rapid, controlled
cooling is used to selectively precipitate halite (NaCl), sodium carbonate
(Na2CCL) and potassium chloride (KC1). Borax crystals are formed when
the remaining liquor is fed into crystallizer tanks containing borax seed
crystals. These crystals are separated from the liquor in cyclones, then
filtered, washed, redissolved, and recrystallized. The recrystallized
product from the vacuum crystal!izers is then separated in cyclones and
4-11
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dried to form borax. A portion of the borax is used as feed to calciners
and fusing furnaces to produce anhydrous borax.
4.3.3 Boric Acid Production
Boric acid can be produced by either acidulation of borax, or by acid
extraction from Searles Lake brines. Flow diagrams of these two processes
are presented in Figures 4-6 and 4-7. In the borax acidulation process,
which is used by both U.S. Borax and Stauffer, a hot saturated borax
solution or finely granulated borax is reacted with sulfuric acid in an
acidifier or digester. When the solution is cooled in vacuum
crystallizers to the appropriate temperature, crystalline boric acid
precipitates. Sodium sulfate is also recovered from the solution by
crystallization at a slightly lower temperature. The filtered crystals
may then be refined by recrystallization from water to produce pure boric
acid.
Boric acid is recovered from weak Searles Lake brines by feeding
recycled liquors from other processes along with the weak brines to an
extraction system. The borates contained in the brine are extracted with
a kerosene solution of a chelating agent, such as 2 ethyl-1,3 hexanediol.
The chelated borates are contained in the organic phase, which is sent to
a stripping mixer. In the stripping mixer, dilute sulfuric acid strips
the borates from the chelate. The stripped organic phase, containing
kerosene and chelating agent, is recycled to the extractor for reuse. The
aqueous phase contains boric acid and sulfate compounds. Any organics
contaminating the boric acid solution are removed by treatment with
activated carbon; the boric acid is then crystallized out of the solution
in an evaporator/crystallizer. A second crystallizer is used to recover
4-14
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4-17
-------
-------
5. AIR EMISSIONS DEVELOPED IN SOURCE CATEGORY
Air pollutants are released into the atmosphere during borate
compound production. The production processes that release air
contaminants have been discussed in Section 4.3. This chapter discusses
the characteristics and quantities of the air pollutants and their impact
on nationwide criteria pollutant emissions.
5.1 PLANT AND PROCESS EMISSIONS '
Air pollutants are emitted by the fusing.furnaces, calciners, dryers,
and coolers. These emissions consist primarily of particulate matter;
however, sulfur dioxide and nitrogen oxides, which are generated as a
result of fuel combustion, are also emitted. Additionally, boric acid
vapors are released from the digesters during boric acid production.
It is assumed that complete combustion is achieved in all the
combustion sources and hence that hydrocarbon and carbon monoxide
emissions are negligible; however, no test data on these pollutants are
available to substantiate this.
5.1.1 Particulate Emissions
The exhaust gases from dryers, coolers, calciners, and fusing
furnaces typically are laden with borate compound particulate matter. The
contribution to parttculate emissions due to fuel combustion is negligible
since natural gas and distillate oil are the fuels commonly used.6
5-1
-------
In general, the quantity of parti oil ate emissions released depends on
the product desired. The production of anhydrous borax or boric acid
generates more particulate emissions than that of hydrated borates since
the former requires processing the mineral through the calciner and fusing
furnace in addition to the dryer. Based on data from one plant,
96 percent of the particulates emitted by the dryers are retained on'325
mesh sieve, which corresponds to 44 ym (0.0017 in.) particle diameter. It
is estimated that approximately 20 to 30 percent of the particles emitted
from the calciner are in the submicron size range. These particles are
lightweight (density of approximately 15 kg/m3 (0.94 lb/ft3)) and
white.
Particulates are emitted from the fusing furnace during the descent
of the feed material (calcined borates) and as the borates are melted.
These emissions, therefore, contain calcined borate particles and
anhydrous borates. Particles exiting the furnace have a mass median
diameter of 14 urn according to one source.
Typical SIP regulations for this source category require that
particulate emissions not exceed 0.23 g/nm3 (0.1 gr/scf) from new or
modified facilities and 0.46 g/nm3 (0.2 gr/scf) from existing
facilities.8 Controlled emission rates from typical new dryers,
calciners, and fusing furnaces in compliance with these regulations are
shown in Table 5-1, along with uncontrolled emissions. Uncontrolled
particulate emissions are calculated using emission factors generated in
Reference 9.
5.1.2 Nitrogen Oxide Emissions
During combustion processes, NOX emissions are formed both due to
oxidation of the nitrogen in the fuel and due to fixation of nitrogen and
5-2
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oxygen in the combustion air (thermal NOX). Oxidation of fuel nitrogen
is insignificant in borate compound processing since the fuels burned
(natural gas and distillate oil) contain little or no nitrogen. The NOX
emissions from calciners depend on the amount of dehydration which, in
turn, depends upon the heat release rate from the burner, if the calciner
is equipped with its own burner. In many cases, however, the material in
the calciner is heated using the hot off-gases from the fusing furnace.
In these cases, calciners do not generate oxides of nitrogen.
The fusing furnaces, where temperatures as high as 1366K (2000 F)
exist, are expected to generate NOX emissions.7'10 No data, however,
are available on the amount of NOX emitted from fusing furnaces. No
control measures for nitrogen oxide emissions have been implemented on any
of the borax and boric acid plants.
5.1.3 Sulfur Oxides Emissions
Emissions of sulfur oxides are generated by the combustion of sulfur
in the fuel. Although distillate oil is used in production processes, the
sulfur content in the distillate oil is limited by two factors. First,
regulations in California, where approximately 90 percent of borax and
boric acid is produced (see Chapter 4), limit sulfur content in the fuel
to 0.2 percent.8 And secondly, the sulfur oxides from combustion can
potentially react with the sodium borates and thus form undesirable sodium
sulfates. Due to these limitations, S02 emissions from borax and boric
acid production can be expected to be low. No data are available,
however, on S02 emissions measurements from borax and boric acid
production.
5-4
-------
5.2 TOTAL NATIONAL PARTICULATE EMISSIONS
Controlled particulate emissions from borax and boric acid plants are
shown in Table 5-2. These emissions were estimated by the state and local
air pollution control agencies for the year 1978.
Total controlled particulate emissions generated during borate
compound processing amount to 619 Mg (682 tons) per year.11
Table 5-2. NATIONWIDE PARTICULATE EMISSIONS FROM BORAX AND
BORIC ACID PRODUCTION
Plant
A
B
C
D
E
F
Total
Controlled particulate
emissions (1978)
Mg/yr
530
34
11
8
33
<3
619
tons/yr
584
38
12
9
36
<3
682
5-5
-------
-------
6. CONTROL TECHNOLOGIES ,
6.1 CURRENT CONTROL TECHNIQUES
Participate emission control equipment has been in use on borate
compound processing facilities for the past decade. The main particulate
emission sources have been the fusing furnaces; however, the dryers,
coolers, and calciners also emit particulates. Boric acid vapor emissions
from digesters are typically controlled in order to recover the valuable
acid. No controls have been used to reduce either NO or SO
A A
emissions. Table 6-1 summarizes the controls used for each of the
emission sources.
6.1.1 Fusing Furnace and Calciner Controls
Wet scrubbers are the most common particulate control devices used in
reducing emissions from both anhydrous boric acid (boric oxide) and
anhydrous borax (pyrobor) fusing furnaces; however, an electrostatic
precipitator has been used in one instance. Typically the same control
device also controls emissions from the calciner. Scrubbers with pressure
drops ranging from 4.4 kPa to 10 kPa (17.5 to 44 in. WC) have been used to
reduce fusing furnace emissions to compliance levels.7'10
A venturi scrubber controlling fusing furnace emissions at one plant
has reported an efficiency of 97.5 percent in removing particles having a
mass median diameter of 14 vim.10
6-1
-------
Table 6-1. EMISSION CONTROL SYSTEMS
Facility
Borax dryer
Colemanite dryer
Boric acid dryer
Fusing furnace and
cal ci nes
Boric acid digester
Control
Venturi scrubber
Fabric filter
Fabric filter
Multivane scrubber
Fixed throat venturi
scrubber
Orifice scrubber
Adjustable throat
venturi scrubber
High energy wet
scrubber
Electrostatic
precipitator
Wet scrubber
Operating
parameter
A/C = 6:1
A P = 7 kPa
(28 in. WC)
A p = 4.4-4.7 kPa
(17.5-19 in. WC)
A P = 8.7-10 kPa
(35-40 in. WC)
22 KVA
6-2
-------
Fusing furnace exhaust gas temperatures at this source range from
1255 to 1366K (1800° to 2000°F). These gases are cooled by quenching
with scrubber liquor to about 340K (153°F) before entering the venturi
scrubber. The pressure drop across the venturi is maintained at about
10.7 kPa (43 in. WC) by varying the throat diameter between 0.64 cm to
25.4 cm (0.25 to 10 in.). The scrubber operates at a liquid to gas ratio
of 1.65 1/m3 (0.01 gal/ft3). About 33 1/s (520 gal/min) of scrubbing
liquor are used to treat 20 m3/s (43,000 acfm) of furnace exhaust gas.
Although the scrubbing liquor is recycled, approximately 28 1/s of fresh .
water needs to be added to maintain the borax concentration between 10 and
15 percent. A 746 kW (1000 hp) blower moves the gas through the scrubbing
system. This blower is capable of handling 44 m3/s (93,500 acfm) of gas
at 357K (184°F) and 11.2 kPa (45 in. WC) pressure drop. A cyclone
entrainment separator separates the scrubbing liquor from the gas in the
scrubber effluent stream.
Two other high energy scrubbing systems applied to borax fusing
furnaces at another plant are designed to handle incoming gas streams of
3 3
33 m /s (70,000 acfm) and 47 m /s (100,000 acfm) at temperatures
between 450 and 533K (350° to 500°F). These scrubbers operate at
pressure drops of 8.7 kPa (35 in. WC) and 10 kPa (40 in. WC) and reduce
emissions to meet a 0.23 g/Nm3 (0.1 gr/scf) emission standard. The fans
required to push the gas through these scrubbers use between 746 and
1119 kW total power (1000 and 1500 horsepower).7
6.1.2 Product Dryers and Coolers
Emissions from product dryers frequently are ducted to coolers, and
therefore control equipment is typically located downstream of the
coolers, where the emissions are released to the atmosphere. Both wet
6-3
-------
scrubbers and fabric filters have been used to control particulate
emissions. Fabric filters, however, have in some applications been
replaced with scrubbers because of difficulties in maintaining bag
temperatures above the dew point.3 Efficiencies up to 99 percent on wet
scrubbers have been reported.12 Data on scrubber pressure drops used in
this application are not available.
6.1.3 Mixers, Reactors, and Evaporators
Boric acid vapors are typically emitted by the evaporators during
boric acid production. These emissions are typically controlled by wet
scrubbers; boric acid is recovered from the scrubber effluent. No data on
scrubber operating parameters are available.
6.2 ALTERNATE CONTROL TECHNIQUES
Fabric filters and electrostatic precipitators (ESP's) have both been
used to a limited extent on borate compound processing equipment. ESP's,
which have been used on pyrobar fusing furnaces and calciners, cannot
continuously achieve regulatory limits. Plant operators have attributed
the poor performance of the ESP's to excessive particle resistivity.
Fabric filters have been used on borate compound dryers and calciners
to recover the product from the dryer or calciner exhaust gas, as well as
for emission control. A fabric filter operating on a colemanite dryer
uses a cyclone precleaner and operates at an air to cloth ratio of
6:I.4 Nomex bags are used to handle the 422K (300°F) gas. Frequently
the same filter also controls emissions from screening and conveying
operations. However, due to the hygroscopic characteristics of the
particulate matter, the particles tend to form a cake which blinds the
bags when temperatures drop below the dewpoint with resulting moisture
condensation. In some cases where operators have had difficulty
6-4
-------
maintaining the temperature above the dewpoint, filters are being replaced
by wet scrubbers. Glass fiber filter bags have been successful in
reducing fusing furnace emissions in pilot scale tests, but have not been
used on full size furnaces to date.
6-5
-------
-------
7. PARTICULATE EMISSIONS DATA
Participate emissions measurements have been made at many of the
borax and boric acid production plants. The measurements were made to
evaluate whether emissions were in compliance with the applicable air
pollution control regulations of the respective states or air pollution
control districts. Table 7-1 summarizes the relative amount of data
available on air emissions from all six borax and boric acid production
plants at the state or local air pollution control agency offices.
Large borax and boric acid plants such as those operated by U.S.
Borax and Kerr-McGee have their own testing crews which make emissions
measurements for internal company use. These emissions data, obtained
from the company during recent plant visits, are shown in Table 7-2 along
with typical emission data available from the control agency. The test
methods used for internal company measurements do not necessarily adhere
to acceptable EPA practice. In many cases, the company's crew only makes
one or two runs to complete the test. Sampling and analysis of the
particulate emissions by local and state agencies are reported to be
performed according to EPA Method 5, however, this has not been confirmed.
7-1
-------
Table 7-1. THE DATA AVAILABILITY ON PARTICULATE EMISSIONS
Plant/location
U.S. Borax and Chemical
Corporation, Boron, CA
U.S. Borax and Chemical
Corporation, Wilmington,
California
Kerr-McGee Chemical
Corporation, Trona, CA
Kerr-McGee Chemical
Corporation,
Westend, California
American Borate Co.,
Lathrop Wells, Nevada
Stauffer's Chemical Co.
San Francisco, CA
Air pollution
control agency
Kern County Air
Pollution Control
District
Southcoast Air Quality
Management District
Southcoast Air Quality
Management District
Southcoast Air Quality
Management District
Nevada Department of
Conservation
Bay Area Air Pollution
Control District
Availability of
of useful data
Substantial data available. Many of the
processes tested.
Data exists, however, available only with
prior permission from the plant
management
Data exists, however, available only with
prior permission from the plant
management
Data exists, however, available only with
prior permission from the plant
management
No data exists since no tests performed
after the completion of expansion/
renovation of the plant
Limited data available
7-2
-------
Table 7-2. PARTICULATE EMISSIONS
Plant
A
B
C
Affected process
Rotary dryer No. 1 for
production of sodium
borate decahydrate
Rotary dryer No. 4 for
production of sodium
borate decahydrate
Rotary dryer No. 5 for
production of sodium
borate decahydrate
Rotary dryer for
production of sodium
borate pentahydrate
Calcining and cooling
(combined)
Fluid bed dryer
Anhydrous borax
furnace No. 1
Anhydrous borax
furnace No. 2
Anhydrous borax
furnace No. 3
Boric acid dryer
No. 2 and No. 3
pyrobor furnace
Dryer No. 2
Dryer
Source of data
Kern County Air
Pollution
Control District
Company
Company
Company
Southcoast Air
Quality
Management
District
Particulate
emissions rate,
g/ninS
(gr/dscf)
0.034 (0.015)
0.085 (0.037)
0.096 (0.042)
0.172 (0.075)
0.052 (0.023)
0.019 (0.0083)
0.088 (0.0384)
0.098 (0.0429)
0.269 (0.1173)
0.085 (0.0373)
0.107 (0.0467)
0.062 (0.0279)
0.062 (0.0272)
0.0095 (0.0414)
0.0852 (0.0372)
0.057 (0.0250)
0.627 (0.2740)
0.150 (0.0697)
0.038 (0.0165)
Date of
testing
Apr. 1976
Apr. 1976
Apr. 1976
Apr. 1976
Apr. 1976
Nov. 1978
Jun. 1972
Jun. 1972
Jul. 1972
Jun. 1972
Jun. 1972
Jun. 1972
Jun. 1972
Jun. 1972
Jun. 1972
Oct. 1976
Oct. 1976
Oct. 1976
Oct. 1976
Reported
test
method
EPA
Method 5
EPA
Method 5
EPA
Method 5
EPA
Method 5
EPA
Method 5
EPA
Method 5
Not known
Not known
Not known
Not known
Not known
Not known
Not known
Not known
Not known
EPA
Method 5
EPA
Method 5
EPA
Method 5
EPA
Method 5
7-3
_
-------
-------
8. STATE AND LOCAL EMISSIONS REGULATIONS
Regulations do exist governing air emissions from borax and boric
acid production as a part of the SIP to attain or maintain national
ambient air quality standards. This chapter presents relevant state and
local regulations, the degrees of controls required due to them and
enforcement of these regulations.
8.1 SUMMARY OF REGULATIONS
Air pollution regulations affecting borax and boric acid production
exist in the states of California and Nevada. Although several other
states have regulations that could be applicable to borax and boric acid
production, no production facilities for borax and boric acid as defined
in this source category are known to exist in those states. Table 8-1
shows the respective plants and the air pollution control agencies having
jurisdiction.
Air pollution control regulations for new or modified borax and boric
acid production facilities are presented in Table 8-2 for the states of
California and Nevada. The regulations have been presented for
particulate matter only since it is considered the only major pollutant
emitted from this source category (see Chapter 5).
8-1
-------
Table 8-1. BORAX AND BORIC ACID PLANTS AND GOVERNING CONTROL AGENCIES
PI ant/ location
U.S. Borax
Boron, CA
U.S. Borax
Wilmington, CA
Kerr-McGee
Trona, CA
Kerr-McGee
Westend, CA
American Borate
Lathrop Wells, NV
Stauffer
San Francisco, CA
Control agency
Kern County Air Pollution Control
District, State of California
Southcoast Air Quality Management
District, State of California
Southcoast Air Quality Management
District, State of California
Southcoast Air Quality Management
District, State of California
State of Nevada, Department of
Conservation
Bay Area Air Pollution Control
District, State of California
8-2
-------
Table 8-2. SUMMARY OF STATE AND LOCAL REGULATIONS
(PARTICULATE MATTER)
Control agency
state/county
California/Kern
County Air Pollution
Control District
Calif ornia/Southcoast
Air Quality Management
District
Nevada
California/Bay Area
Air Pollution
Control District
Affected
facility
Dryer
Calciner
Fusing furnace
Dryer
Calciner
Fusing furnace
Dryer
and calciner
combined
Dryer
Fusing furnace
New or modified source regulation
0.23 g/nm3 (0.1 gr/dscf), or
E = 1.73 pO.62 (E = 3.59 p0.62)
if p< 27.2 (30)
E = 7.98 pO-16 (E = 17.31 P0.16)
if p< 27.2 (30)
whichever is stringent,
where, E = emission rate, kg/h (Ib/hr)
p = process weight,
Mg/h (tons/hr)
Opacity limited to 20 percent
0.23 g/nm3 (0.1 gr/dscf) corrected to
12 percent COg
Opacity limited to 20 percent
0.31 kg/Mg (0.62 lb/tons)a
Opacity limited to 20 percent
0.34 g/nnp (0.15 gr/dscf) and,
E = 1.99 pO.67 (E = 4.10 pO.67)
where, E = emissions rate, in kg/h
(Ib/hr) not to exceed
18.2 kg/h (40 Ib/hr)
and p = process weight rate Mg/h
(tons/hr)
Opacity limited to 20 percent
aThis rule applicable to American Borate Co., Lathrop Wells, Nevada only.
8-3
-------
The State of California regulations differ from other states'
regulations in that local air pollution control districts comprising of
one or more counties promulgate regulations affecting facilities under
their jurisdiction. These regulations, however, are promulgated only
after state approval under the State Implementation Plan. The enforcement
activities concerning these regulations are also delegated to individual
air pollution control districts.
The State of Nevada regulation affecting new or modified sources was
recently promulgated through the revision of its State Implementation
Plan. The rule was revised to restrict particulate emissions from one
borax production plant which planned expansion and renovation of its
facility. The State of Nevada estimates that due to this new regulation,
the overall controlled particulate emissions from the plant were reduced
from 106 Mg (118 tons) in 1977 to 41 Mg (46 tons) in 1978 after
13
expansion.
8.2 DEGREE OF CONTROL REQUIRED BY REGULATIONS
The particulate emissions control requirements in the State of Nevada
are the-most stringent of all the regulations affecting borax production.
The degree of control required, as indicated in Table 8-3, is 0.31 kg/Mg
(0.62 Ib/ton).
Table 8-3 also presents the degree of control required under the Kern
County Air Pollution Control District regulations. Over 75 percent of the
borax/boric acid produced would be governed by these regulations.
8.3 EXTENT OF ENFORCEMENT
In the State of Nevada and California, compliance with particulate
regulations is presently verified through plant inspections, opacity
observations, and performacne tests. Plant inspections include inspection
8-4
-------
Table 8-3. DEGREE OF CONTROL REQUIRED AT THE TWO MOST STRINGENTLY
CONTROLLED PLANTS
State/local
agency
Nevada
Kern County
Affected
facility
Dryer and
calciner
combined
Dryer b
Calciner0
Fusingd
furnace
Uncontrolleda
emission rate
kg/Mg
11.6
11.6
11.6
11.6
lb/ ton
23.2
23.2
23.2
23.2
SIP (new source)
emissions rate
kg/Mg
0.31
0.46
0.75
0.82
Ib/ton
0.62
0.92
1.50
1.62
^Uncontrolled emission rate based on Reference 1.
"Assuming process weight rate of 11 Mg/h (12 tons/hr) throuqh
the dryer.
Assuming process weight rate of 9 Mg/h (10 tons/hr) through
the calciner.
dAssuming process weight rate of 7 Mg/h (8 tons/hr) through
the fusing furnace.
8-5
-------
of the equipment and equipment maintenance records. The opacity
observations are made periodically by duly certified opacity observers.
Opacity observations and equipment operation and maintenance records are
used as guides in determining whether performance tests should be made.
The permit to operate is then renewed only after source test results
verify compliance.
8-6
-------
REFERENCES
1. Absolom, S. T. Boron in 1978. Mineral Industry Surveys, Annual
Advance Summary. U.S. Department of the Interior, Bureau of Mines.
June 25, 1979.
2. Absolom, S. T. Mineral Commodity Profiles. May 1979: Boron. U.S.
Department of the Interior, Bureau of Mines. May 1979.
3. Modetz, H. Trip Report of October 31, 1979 visit to U.S. Borax and
Chemical Corporation, Boron, California. November 1, 1979.
4. Telecon. Franklin, C., Acurex Corporation with Richard Walters,
American Borate. November 16, 1979.
5. Telecon. Franklin, C., Acurex Corporation with Jack S. Edwards,
Stauffer Chemical Company. November 8, 1979.
6. Kern County of California. Permit to Operate. Issued to Borax
Production Facility.
7. Lemon, E. D. Wet Scrubbing Experience with Fine Borax Dust. Journal
of the Air Pollution Control Association. 27. November 1977.
8. Kern County Air Pollution Control Regulations. Regulation IV:
Prohibitions.
9. Source Assessment: Overview Matrix for National Criteria Pollutant
Emissions. Environmental Protection Agency. Research Triangle Park,
N.C. Publication No. EPA-600/2-77-107C. April 1978.
10. Calvert, S., et al. American Air Filter Kinpacter 10 x 56 Venturi
Scrubber Evaluation. Publication No. EPA-600/2-77-209b. November
1977.
11. Kern County Air Pollution Control District: Air Emissions
Inventory. 1978.
12. National Emissions Data System Point Source Emissions.
Industry.
Borax
13. Telecon. Raisoni, R., Acurex Corporation with Hugh Ricci, Nevada
Environmental Protection Division. September 27, 1979.
R-l
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APPENDIX A
PERSONS WITH EXPERTISE IN THE
BORAX/BORIC ACID INDUSTRY
IDENTIFIED DURING SOURCE CATEGORY SURVEY
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing}
1. REPORT NO.
EPA-450/3-80-004
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
5. REPORT DATE
Source Category Survey; Borax and Boric Acid Industry
Mav.1980
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO,
9. PERFORMING ORGANIZATION NAME AND ADDRESS
10. PROGRAM ELEMENT NO.
Acurex Corporation
Route 1, Box 423
Morrisville, NC 27560
11. CONTRACT/GRANT NO.
68-02-3064
12. SPONSORING AGENCY NAME AND ADDRESS
DAA for Air Quality Planning and Standards
Office of Air, Noise, and Radiation
U.S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
EPA/200/04
15. SUPPLEMENTARY NOTES
16. ABSTRACT :•
Background information is presented on the borax and boric acid industry
for the purpose of determining the need for a new source performance standard
(NSPS). The industry is surveyed and categorized by plant, process, and other
factors. Information is presented on the processes, emissions, and air pollution
control equipment. State and local regulations are summarized. The impact of
a potential NSPS on particulate emissions is discussed.
17.
KEY WORDS AND DOCUMENT ANALYSIS
a.
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Air pollution
Pollution control
Standards of performance
Borax plants
Boric acid plants
Particulate matter
Air Pollution Control
13 B
18. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (ThisReport}
Unclassified
21. NO. OF PAGES
52
2O. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220—1 (Rev. 4—77) PREVIOUS COITION is OBSOLETE
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