EPA-450/3-87-016
Episodic Emissions
Data Summary
Emission Standards and Engineering Division
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Radiation
Office of Air Quality Planning and Standards
Research Triangle ParlT NC 27711
June 1987
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This report has been reviewed by the Emission Standards and Engineering Division of the
Office of Air Quality Planning and Standards, EPA, and approved for publication. Mention of
trade names or commercial products is not intended to constitute endorsement or
recommendation for use. Copies of this report are available through the Library Services
Office (MD-35), U.S. Environmental Protection Agency Research Triangle Park NC 2771 1, or
from National Technical Information Services, 5285 Port Royal Road, Springfield VA 22161
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TABLE OF CONTENTS
Chapter
Page
1.0 INTRODUCTION
1.1 OBJECTIVE 1-1
1.2 DATA COLLECTION... 1'1
1.3 DATA SUMMARIES AND ANALYSES.*.'.*.'.'.'.'.'.'.*;;;;;;; l'\
2.0 ETHYLENE DICHLORIDE PRODUCTION
2.1 DESCRIPTION OF DATA SOURCES 2~l
2.2 EPISODIC EMISSIONS SUMMARY 2'1
2.3 BACKGROUND EMISSIONS SUMMARY 2'2
2.4 REFERENCES.. 2-12
2-15
3.0 ETHYLENE OXIDE PRODUCTION
3.1 DESCRIPTION OF DATA SOURCES 3"!
3.2 EPISODIC EMISSIONS SUMMARY..'.' M
3.3 BACKGROUND EMISSIONS SUMMARY 3"3
3.4 REFERENCES 3-12
3-15
4.0 CHLORINATED HYDROCARBON PRODUCTION
4.1 DESCRIPTION OF DATA SOURCES *~l
4.2 EPISODIC EMISSIONS SUMMARY 4-1
4.3 BACKGROUND EMISSIONS SUMMARY 4'3
4.4 REFERENCES... 4-12
4-15
5-0 CHLORINATED HYDROCARBON USERS
5.1 DESCRIPTION OF DATA SOURCES 5-1
5.2 EPISODIC EMISSIONS SUMMARY..'.' l~l
54 REFERENCES EMISSIONS SUMMARY' • •''''' •'' •' •' •' •' -' •'.'.'.'.'.'.'.'!.'.'.' Ho
5-13
6.0 1,3-BUTADIENE PRODUCTION
6.1 DESCRIPTION OF DATA SOURCES 6-!
6.2 EPISODIC EMISSIONS SUMMARY 6*!
';4 REFERENCES EMISSIONS su^*:--''-'-'-'.'-'.':::::::::::::::: 66:1
6-9
7-0 POLYBUTADIENE PRODUCTION
7.1 DESCRIPTION OF DATA SOURCES 7'1
7.2 EPISODIC EMISSIONS SUMMARY 7'1
7.3 BACKGROUND EMISSIONS SUMMARY ?'3
7.4 REFERENCES.... 7-6
7-9
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TABLE OF CONTENTS (CONTINUED)
Chapter
8.0
Page
NEOPRENE/CHLOROPRENE PRODUCTION. p ,
8.1 DESCRIPTION OF DATA SOURCES... ......................... T
8.2 EPISODIC EMISSIONS SUMMARY ...... .' ...................... 2"i
8.3 BACKGROUND EMISSIONS SUMMARY. .................... o"^
8.4 REFERENCES .................... .'!."!!!."!!.".*.'.'.' ........... 89
9.0 STYRENE-BUTADIENE RUBBER PRODUCTION Q ,
9.1 DESCRIPTION OF DATA SOURCES... ........................
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LIST OF TABLES
Page
TO OBTAIN EMISSIONS
1-3
2-1 GEOGRAPHIC DATA FOR ETHYLENE DICHLORIDE PRODUCTION
FACILITIES REPORTING EPISODIC EMISSIONS DA?A
2-2
2-2 SUMMARY OF EPISODIC EMISSIONS OF ETHYLENE DICHLORIDE 2-4
2"3 FEAPCIL?nESEMISSI°NS °ATA FR°M ETHYLENE DICHLORIDE PRODUCTION
2-5
2-4 EVENTS RFPHDTrn PV FACILITIES THAT COULD NOT OCCUR
2-13
2-5 SUMMARY OF BACKGROUND EMISSIONS OF ETHYLENE DrCHinprnp
FROM PRODUCTION FACILITIES tiniLtnt UiUHLUKIDE
3'! K^CESKSS °*»™ FACILITIES^' "*
3-2 SUMMARY OF EPISODIC EMISSIONS OF ETHYLENE OXIDE....
3"3 FEAPr???{?rcEMISSIONS DATA FROM ETHANE OXIDE PRODUCTION
3-5
3-13
3-5
OXIDE FROM
3-14
4-1 PPfiPDADUTf* n/ITA r*f\n
rAOT?v£vi UArA FOR CHLORINATED HYDROCARBON PRnnnrTTnw
tAiTI TTT^o n^nAm^v.a.^. _^ f||*^«»\*\*nr\uvii ri\L/LJlJU.I liJIv
rMLlLl I IrS HPDnDT TM/^ COTCrtor/» mT«»»»<. >»www\< i i wii
AtO l\Cr Ur\ I lllU tr loUUlC EMT^^TnN^ HATfl
4-2 SUMMARY HP ppr.nnr, EMISSIONS OF CHLOROFORM, CARBON
CHLORIDE, PERCHLOROETHYLENE, AND
'•• 4-4
4-3
""" " HYDROCARBON
4-5
4-4 FVFMT* PPDnoTcn ov FACILITIES THAT CQULD NQT OCC(JR
4-13
4"5 PRU0MSScRTIO°NF FBACILmESD EMIS$I°NS °F CHLORINAT^ HYDROCARBON
4-14
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LIST OF TABLES (CONTINUED)
Table
5-1
5-2
5-3
5-4
5-5
6-1
6-2
6-3
6-4
6-5
7-1
7-2
7-3
7-4
7-5
GEOGRAPHIC DATA FOR CHLORINATED COMPOUND USERS REPORTING
EPISODIC EMISSIONS DATA
SUMMARY OF EPISODIC EMISSIONS FROM FACILITIES USING
CHLORINATED HYDROCARBONS
EPISODIC EMISSIONS DATA FROM CHLORINATED COMPOUND USERS
SIMULTANEOUS™ BY FACILITIES THAT COULD NOT OCCUR
PRODUCTION FACILITIES EMI$SI°NS FROM CHLOR™ATED HYDROCARBON
GEOGRAPHIC DATA FOR BUTADIENE PRODUCTION FACILITIES
REPORTING EPISODIC EMISSIONS DATA. ™LiLiut>
SUMMARY OF EPISODIC EMISSIONS OF BUTADIENE PRODUCTION
EPISODIC EMISSIONS DATA FROM BUTADIENE PRODUCTION
s'SAN^SY50 BY FACRITIES THAT COULD NOT OCCUR
PRODUCTION pACrGR°UND EMISSIONS 0|: BUTADIENE (BD) FROM
GEOGRAPHIC
REPORTING EPISODIC EMISSIONS DATA.™00"011™ FACILITIES
bUMMARY OF EPISODIC EMISSIONS OF BUTADIENE FROM POI YRNTAnTtr^c'
DD^^II^*TTrtkl FA/*TIY*TT^** •^^••»»**wiiw i i \wi i r w w I w w IrALJl ^ J i w
FACILITIES
FACILITIESMISSI°NS °ATA FR°M POLYBUTADIENE PRODUCTION
SEI«ll[fANREOPSsRU0 BY FACIUTIES ™AT C°ULD N°T °CCUR
f^lSffS^lS1!^^^^^
Page
5-2
5-4
5-5
5-11
5-12
6-2
6-4
6-5
6-7
6-8
7-2
7-4
7-5
7-7
7-8
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LIST OF TABLES (CONTINUED)
Table
Page
GEOGRAPHIC
8-2
8-2 SUMMARY OF FPrsnntr EMISSIONS OF BUTADIENE FROM NEOPRENE/
AM FACILITIES p.4
*ENE/CHLOROPRENE
8-5
8-4 EVENTS RFPORTPn PV earn rrrrc THAJ C()ULD ^ OCCUR
EMISSIONS OF BUTADIENE FROM NEOPRENE/
'FACILITIES gg
RUBBER PRODUCTION
DATA 9_2
triijolUNo Ur BUTADIENE FROM ^TYRPMC"
9-4
9-3 EPISODIC FMT^TnKK PIATA conu c-runi-»,i- «,,^.
RUBBER
9-5
COULD NOT OCCUR
EMISSIONS OF BUTADIENE FROM STYRENE-
"•TT~" FACILITIES g_12
1(M C^T^T^ DATA FOR MISCELLANEOUS BUTADIENE PRODUCTION <
FACILITIES REPORTING EMISSIONS DATA..? ^UUULIIUN^ .
10-2 EPISODIC EMISSIONS DATA FROM MISCELLANEOUS BUTADIENE USERS.. 10-3
10"3- F^^CTlS^ILmF?-0"5 °F MISCELLANEOUS BUTADIENE
1L111" 10-5
1M EPE?SORSPCHIEM?SSTUS°RDITPACHLOROHYDRIN PR°°UCTION REPORTING
11-2
H-2 SUMMARY OF EPISODIC EMISSIONS OF EPICHLOROHYDRIN U_4
EPICHLOROHYDRIN PRODUCTION
11-5
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LIST OF TABLES (CONCLUDED)
Table
Page
11-4 EVENTS REPORTED BY FACILITIES THAT COULD NOT OCCUR
SIMULTANEOUSLY ............................... _ .......... U_Q
11-5 SUMMARY OF BACKGROUND EMISSIONS OF EPICHLOROHYDRIN FROM
PRODUCTION FACILITIES ................................ . u.g
12-1 GEOGRAPHIC DATA FOR PESTICIDES PRODUCTION FACILITIES
REPORTING EPISODIC EMISSIONS DATA ......... ....... ........ 12.2
12-2 SUMMARY OF EPISODIC EMISSIONS FROM PESTICIDES PRODUCTION
•Llllto......... ................. 1 9 A
12-3 EPISODIC EMISSIONS DATA FROM PESTICIDES PRODUCTION
rALiLlllto..... ...... . ...... ......... 10 c
12-4 SUMMARY OF BACKGROUND EMISSIONS OF METHYLENE CHLORIDE AND
CARBON TETRACHLORIDE FROM PESTICIDES PRODUCTION FACILITIES. . 12-14
13-1 GEOGRAPHIC DATA FOR PHARMACEUTICAL PRODUCTION FACILITIES.... 13-2
13-2 SUMMARY OF EPISODIC EMISSIONS OF METHYLENE CHLORIDE FROM
PHARMACEUTICALS PRODUCTION FACILITIES. ...;.. . !...... 13.4
13"3 CAr???TtccMISSIONS DATA FROM PHARMACEUTICALS PRODUCTION
•••••••••••••••«••....... 1 "3 C
13.21
CHLOROFLUOR°WRBON
°ATA FR°M CHLOROFLUOROCARBON PRODUCTION
................................. 14-5
EMISSIONS FR°" CHLOROFLUOROCARBON
rff i* g
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1.0 INTRODUCTION
1.1 OBJECTIVE
The objective of this report is to present a complete summary of episodic
and continuous emissions data collected during the past 5 years by the
Environmental Protection Agency's (EPA) Emission Standards and Engineering
Division (ESEO) under the authority of Section 114 of the Clean Air Act
S!nce this document is intended for public distribution, only nonconfidential
information is presented.
1.2 DATA COLLECTION
In recent source category investigations, EPA has gathered episodic
emissions data from the production and use of nine potentially hazardous
organic compounds. These nine pollutants are: methylene chloride (MC)
carbon tetrachloride (CT), chloroform (CF), perchloroethylene (PCE) tri
chloroethylene (TCE), ethylene dichloride (EDC), butadiene (BO), e hylene
oxide (EO), and eoichlorohydrin (EPI). etnyiene
Emissions data have been collected through Section 114 questionnaires
or source categories emitting one or more of the pollutants list v.
Episod c em,ss,ons data were provided for 13 of these source categories '
categories' aion9 wn
(1) ethylene dichloride production (EDC);
(2) ethylene oxide production (EO);
(3) chlorinated hydrocarbon production (CT, MC PCE TCE
f A \ u i • "ww» •>•»-»
W chlorinated hydrocarbon use (CT, MC, PCE, CF, EDC);
(5) butadiene production (BD);
(6) polybutadiene production (BD);
(7) neoprene/chlorpprene production (BD);
(8) styrene-butadiene rubber production (BD);
(9) miscellaneous butadiene users (BD);
(10] epichlorohydrin producers and users (EPI);
1-1
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(11) pesticides manufacture
(12) pharmaceutical manufacture (MC); and
(13) chlorofluorocarbon production (PCE, CT, CF).
Long-term emissions data were also collected for CT emissions from use in
chlorine production. However, no episodic emissions data are available for
this source category.
Emissions data were obtained with three types of Section 114
questionnaires: long-term (continuous), short-term (episodic), and long-
term/short-term. Information obtain from the short-term questionnaires best
characterizes episodic emissions. However, this type of questionnaire was
not used to obtain short-term emissions data for all 14 source categories
listed above. The types of questionnaires used to obtain emissions
information for each source category are summarized in Table 1-1.
In 1984 when ESED started obtaining emissions data for the nine
pollutants listed above, concern was focused on annual emissions so that
carcinogenic effects could be evaluated. Producers and major users of each
pollutant were identified and annual emissions data were requested with the
long-term questionnaire. Responses to the long-term questionnaires provided
sufficltnt information to estimate annual emissions, but the frequency and
duration of emissions was not specifically addressed. The long-term
questionnaires did address episodic events such as pressure-relief device
discharges, handling emissions, and equipment openings for many source
categories. However, only the annual emission quantity cr emissions per
event were requested. In some cases, companies did provide additional
information on frequency and duration of episodic emissions.
As part of source category investigations for each of the 14 source
categories, long-term or annual emissions data collected through Section 114
letters were summarized in a memorandum. A single memorandum was prepared
for each source category. The purpose of each memorandum was to provide
estimates of annual emissions for facilities within the source category
These emission estimates were used to develop estimates of cancer risks due
to emissions from each facility. These memoranda have been used in preparation
of this report as a source of summarized Section 114 data on annual emissions
1-2
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As shown in Table 1-1, emissions data were obtained with long-term
questionnaires for 12 of the 13 source categories. The types of emission
sources addressed in long-term questionnaires for each source category are
noted in Table 1-1.
Early in 1985, ESED began to address the short-term (or acute) effects
of these pollutants, in addition to the carcinogenic effects. To allow for
better evaluation of peak emission rates (due to episodic events), the
long-term questionnaire was revised. Responses to this questionnaire pro-
vided the data necessary to estimate duration, frequency, and emission rate
of peak process vent emissions, pressure-relief device discharges, storage
emissions, handling emissions, equipment openings, and spills. This
questionnaire type is referred to as the long-term/short-term questionnaire.
The long-term/short-term questionnaire was used to obtain emissions
information for two source categories - pesticides manufacture and
Pharmaceuticals manufacture.
In 1986, additional data on short-term emissions were obtained for nine
source categories. Long-term emissions data had already been obtained for
these source categories. Therefore, a questionnaire specifically addressing
episodic emissions was prepared* The short-term questionnaires included
sections for reporting peak process vent emission rates, pressure-relief
discharge events, equipment openings, accidental gas releases, and accidental
liquid releases. In some cases, emissions data for one or more of these
sources were not requested and is noted in the comments column of Table 1-1
The source categories for which short-term i-psponses were obtained are-
ethylene dichloride production, ethylene oxide production, chlorinated
hydrocarbon production, chlorinated hydrocarbon use, butadiene production
polybutadiene production, neoprene/chloroprene production, styrene-butadiene
rubber production, and epichlorohydrin production.
In addition to emission frequencies, durations, and rates, the short-term
quest10nnaires also requested information necessary for dispersion modeling
A scaled plot plan of the facility, with emission source locations and
buildings, was requested. The dimensions of all buildings within two vent
heights was requested. In addition, distances from the center of the facility
to the nearest fence line and the nearest residence were requested.
1-4
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1.3 DATA SUMMARIES
includes the nane and ,ocat1on of the facili y s w h 0
information for each episodic event: 0ll°Wln9
(1) type of event;
(2) emission source;
(3) nature of event;
(4) number of events per year;
(5) duration (largest event, if more than one per year);
(6) height of release;
(7) release diameter;
(8) discharge velocity;
(9) discharge temperature;
(10) heat capacity of released gas;
U1) Sr^)!^ 6miSSi0n (Ur9eSt ™1«"'-H' -re than one
(12) emission rate (largest release, if more than one per year)
The first four items above are used to identify the event and the p - -
each of the 12 items list*i ,h presented in this report for
— .» ~£. r,rf
response, or footnoted appropriately.
1-5
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2.0 ETHYLENE OICHLORIDE PRODUCTION
This section summarizes the available data for episodic and continuous
•msion, of ethylene dichloride (EDC, from EDO production facilities.
2.1 DESCRIPTION OF DATA SOURCES
Ethylene dichloride is a chlorinated hydrocarbon produced primary as
an ntermedme in the production of vinyl chloride monomer. By the authority
o Sect,on 114 of the Clean Air Act, EPA collected episodic (short- e '
enn«,ons data from eight companies representing twelve facilities that
pro uce EDC. Data were collected for EDC emissions only. These a ere
collected via Section 114 questionnaires sent out in January 1986
This tat1' V "",* ^ faCllU1eS WMCh SUPPll6d 6p1SOd1c «'"*""« ^ta.
t h t I0 lnC ^ 9e°9raPMC daU SUCh " latitude' longltud.. distance
the plant fence line, and distance to the nearest residence, as well as
the penod of time represented by the reported emissions data. A Se o n 114
;::':;:;:;; beypitshod1c emissions from °ne "*"** G— »>»• -
confident,.! by the company; therefore, data from their response are not
i"c uded in this report. Of the eleven nonconfidential resons s i
- in Texas, five are located in Louisiana, a, one is
units are presented separately.
1984
fac111t1
collected ,n
were combined with episodic emissions data to dete ne
em,ssion rates. Annual emissions data were obtained f om a
memorandum entitled, "Estimates of Ethylene Dichloride Emi si on f om
Products Facilities and HEM Inputs," dated April 23 198 *
2-1
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2.2 EPISODIC EMISSIONS SUMMARY
Types of episodic emissions reported from EDC production facilities
include: (I) pressure relief discharges, (2) equipment openings, (3) acci-
dental gas releases, (4) process vent discharges, and (5) accidental liquid
releases. A total of 611 episodic emission events were reported by the
eleven facilities providing nonconfidential Section 114 responses These
events represent emissions of 86,400 kg of EDC. Reported events include-
399 equipment openings, 142 process vent discharges, 44 pressure relief
discharges, 22 accidental liquid releases, and 4 accidental gas releases A
summary of average emission rate and duration, including ranges, is presented
in Table 2-2 for each of the five types of episodic emissions. The average
emission rate and duration for all 611 emission events are 8.4 kg/min and
107 mm, respectively. The highest emission rates were reported for pressure
rtlief discharges, with an average emission rate of 57.5 kg/min, and
accidental gas releases, with an average emission rate of 50.7 kg/min
A detailed summary of episodic emission events reported in Section 114
responses is presented in Table 2-3. Data presented for each episodic event
include:
(1) type of event (e.g., pressure relief discharges);
(2) emission source (e.g., reactor, incinerator);
(3) nature of event (e.g., process upset, start-up);
(4) the number of events per year;
(5) event duration;
(6) release height;
(7) release diameter;
(8) discharge velocity;
(9) temperature;
(10) heat capacity;
(11) emission rate; and
(12) emissions per event.
Parameters such as velocity, heat capacity, and emission rate were calcuUted
Sa T! " SeCt1°" "* re$POnS6S " W611 " Phys1cal P
data. Sample calculates for these three parameters are presented in
2-3
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Appendix A. Unless otherwise noted in Table 2-3 aii nth
taken directly. from Section 114 responses
*-
2-12
.1«U.n.ou,ly 1s pr., e to occur
2.3 BACKGROUND EMISSIONS SUMMARY
As discussed in Section ? i ri, + .
,«„,„:: ;;:• ;s , -• — •«
-------
TABLE 2-4. EVENTS REPORTED BY FACILITIES THAT COULD NOT OCCUR SIMULTANEOUSLY
Plant
Formosa
Formosa
B.F. Goodrich
B.F. Goodrich
Dow Chemical (I)a
Dow Chemical (II)a
Dow Chemical
Dow Chemical (I)a
Dow Chemical (II)a
Location
———————
Point Comfort, TX
Baton Rouge, LA
Calvert City,KY
La Porte, TX
Plaquemine, LA
Plaquemine, LA
Oyster Creek, TX
Freeport, TX
Freeport, TX
Dow Chemical (III)aFreeport, TX
Dow Chemical (IV)a Freeport, TX
01 in CorP. Lake Charles, LA
U.S. Industrial Port Arthur, TX
Vulcan Geismar, LA
Vista
Westlake, LA
Reported Answers to Questions Concerning
Simultaneous Event Occurrence
~ •
Equipment openings are part of routine
maintenance; others are accidental
Events can occur simultaneously but do
not have to.
Events can occur simultaneously but do
not have to.
Pressure relief discharge and process
vent would not be additive.
Events can occur simultaneously but do
not have to.
Events can occur simultaneously but do
not have to.
Events can occur simultaneously but do
not have to.
Events can occur simultaneously but do
not have to.
During pump and filter openings, pressure
reliefs do not occur. After pressure
reliefs in pumps and filters, equipment
opening occurs.
Events can occur simultaneously, but do
not have to.
Equipment opening cannot occur at same
time as pressure relief event
Events can occur simultaneously but do
not have to.
Events can occur simultaneously but do
not have to.
Process vent and pressure relief event
cannot occur simultaneously. Process
vent will occur immediately after
pressure relief.
Multiple process vents cannot occur.
2-13
-------
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2-14
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2.4 REFERENCES
1.
2.
3.
short-term EDC
LF°™S4
EDC
Corporation,
°n
, to
on
4. Letter and attachments from Kerr, L. E.,
5.
6.
7.
8.
Utter on short-ter. EOC-
short-ter. EOC
Far™eerr,a3d R^
short-tern EDC e.iss
2i986Esi;aoE
Production Facilities and HEM inputs
> to
" Chem1cal
114
"*
, to
- 0-
Emissions from
2-15
-------
-------
3.0 ETHYLENE OXIDE PRODUCTION
This section summarizes the available data for episodic and continuous
emissions of ethylene oxide (EO) from EO production facilities.
3.1 DESCRIPTION OF DATA SOURCES
Ethylene oxide is a colorless flammable toxic compound used in the
synthesis of ethylene glycol and in sterilization and fumigation. By the
authority of Section 114 of the Clean Air Act, EPA collected episodic (short-
term) emissions data from nine companies representing ten facilities that
produce EO. Data were collected for EO emissions only. These data were
collected via Section 114 questionnaires sent out in January 1986.
Table 3-1 lists the facilities which supplied episodic emissions data.
This table also includes geographic data such as latitude, longitude, dis-
tance to the plant fence line, and distance to the nearest residence, as well
as the period of time represented by the reported emissions data 01 in
Corporation's Section 114 response for their Brandenburg, Kentucky, facility
reported no EO emissions during 1986. Of the nine remaining facilities five
are located in Texas, two in Louisiana, one in Illinois, and one in Delaware
Long-terra emissions data for EO production facilities were collected in
1984. These data were also collected through Section 114 questionnaires and
are primarily concerned with annual, rather than episodic, emissions of EO
Background or constant/continuous emissions data obtained from these
questionnaires were combined with episodic emissions data to determine
maximum emission rates.
3.2 EPISODIC EMISSIONS SUMMARY
Types of episodic emissions reported from EO production facilities
include: (1) pressure relief discharges, (2) equipment openings, (3) acci-
dental gas releases, (4) process vent discharges, and (5) accidental liquid
3-1
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releases. A total of 461 episodic emission events were reported by the nine
facilities providing Section 114 responses. (This value does not include the
many" episodic events reported by Celanese Chemical Company.) These events
represent emissions of 50,839 kg of EO. Reported events include: 373 process
vent discharges (plus "many" reported by Celanese), 58 equipment openings 12
accidental liquid releases, 11 accidental gas releases, and 7 pressure relief
dTscharges. A summary of average emission rate and duration, including
ranges, is presented in Table 3-2 for each of the five types of episodic
emissions. The average emission rates and duration for all 461 emission
events are 4.26 kg/min and 284 min, respectively. Maximum emission rates
were reported for pressure relief discharges, with an average emission rate
of 15.3 kg/min.
A detailed summary of episodic emission events reported in Section 114
responses is presented in Table 3-3. Data presented for each episodic event
include:
(1) type of event (e.g., pressure relief discharge);
(2) emission source (e.g., reactor, incinerator);
(3) nature of event (e.g., process upset, start-up);
(4) the number of events per year;
(5) event duration;
(6) release height;
(7) release diameter;
(8) discharge velocity;
(9) temperature;
(10) heat capacity;
(11) emission rate; and
(12) emissions per event.
bPaasreT0terH rCh " VelOCUy> hSat CaPiCUy> ind em1SSl°n "I- -™ calculated
d ,„ da a presented in Section 114 responses as well as physical property
ata Sample calculations for these three parameters are presented i
Appendix A. Unless otherwise noted in Table 3-3, all other parameters were
taken directly from Section 114 responses
3-3
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In addition to data concerning episodic events, facilities were also
requested to indicate events that cannot occur simultaneously. A summary of
episodic events which facilities indicated would not be likely to occur
simultaneously is presented in Table 3-4.
3.3 BACKGROUND EMISSIONS SUMMARY
As discussed in Section 3.1, data on annual or long-term emissions from
£0 production facilities have also been collected. A summary of constant/
continuous annual emissions (not reported as episodic emissions) is presented
in Table 3-5. Emission sources in Table 3-5 include fugitive emissions
(equipment leaks) and air emissions from secondary sources (liquid and solid
waste systems). Fugitive and secondary emissions are assumed to be constant
over 365 days per year.
3-12
-------
TABLE 3"4' EVENTS REPORTED BY FACILITIES THAT COULD NOT OCCUR SIMULTANEOUSLY
Plant
Location
Celanese Chemical Pasadena, TX
Dow Chemical
1C I Americas
Norchem
PPG Industries
Plaquemine, LA
Pasadena, TX
Morris, IL
Beaumont, TX
Shell Oil Company Houston, TX
Sun 01 in
Union Carbide
Claymont, DE
Port Lavaca, TX
Reported Answers to Questions Concerning
Simultaneous Event Occurrence
The CO,, vent emissions will not occur
at trie same time the unit shutdown
and clearing operations are being
performed since the processing unit
will be shut down.
If the process compressor trips
rupture disks will not be blown.
No events preclude each other nor
necessitate each other.
No events preclude each other nor
necessitate each other.
No events preclude each other nor
necessitate each other.
No events preclude each other nor
necessitate each other.
No events preclude each other nor
necessitate each other.
During startup, the BDU (identified
in Table 3-3) will vent and during
the startup sequence the analyzer
will be set to the atmosphere until
a compressor is able to handle the
flow. The convenors are blown
down sometime after total unit
shutdown. No other venting should
be occurring.
3-13
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3-4 REFERENCES
I- Better and attachments from uuryE6Jorodu^ri!J?,??ctJO" ""» letter on
4.
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5.
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short-term EO emissions froEOod"." »4P>l.tter
R3^^^^^/^^ S'o ™ ^^.S. Inc., to
EO emissions £2 & JSi:tSPSci?1S1-Srt10n "* letter
8.
9.
3-15
-------
-------
4.0 CHLORINATED HYDROCARBON PRODUCTION
This section summarizes the available data for episodic and continuous
erosions of chloroform (CF), carbon tetrachloride (CT), methylene cMoride
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maximum emission rates. Annual emissions data were obtained from a memorandum
entitled, "Estimates of Carbon Tetrachloride, Methylene Chloride, Chloroform
Tnchloroethylene, and Perchloroethylene Emissions from Chlorinated Hydrocarbon
Production Facilities and Emission Reductions Achievable with Additional
Control," dated August 29, 1986.10
4.2 EPISODIC EMISSIONS SUMMARY
Types of episodic emissions reported from chlorinated hydrocarbon
production facilities include: (1) pressure relief discharges, (2) equipment
openings, (3) accidental gas releases, (4) process vent discharges,
(5) accidental liquid releases, and (6) handling operations. A total of
8,276 episodic emission events were reported by the ten facilities providing
Section 114 responses. These events represent emissions of 475,000 kg of
chlorinated hydrocarbons. Reported events include: 5,651 events due to
handling operations, 1,974 equipment openings, 441 process vent discharges
119 pressure relief discharges, 58 accidental liquid releases, and 33
accidental gas releases. A summary of average emission rate and duration
including ranges, is presented in Table 4-2 for each of the six types of '
episodic emissions. The average emission rate and duration for all 8 276
emission events are 0.802 kg/min and 166 min, respectively. The highest
emission rates were reported for pressure relief discharges, with an average
emission rate of 15.9 kg/min, and accidental gas releases, with an averag*
emission rate of 15.4 kg/min.
A detailed summary of episodic emission events reported in Section 114
responses is presented in Table 4-3. Data presented for each episodic event
me I ude:
(1) type of event (e.g., pressure relief discharge);
(2) emission source (e.g., reactor, incinerator);
(3) nature of event (e.g., process upset, start-up);
(4) the number of events per year;
(5) event duration;
(6) release height;
(7) release diameter;
4-3
-------
TABLE 4-2. SUMMARY OF EPISODIC EMISSIONS OF CHLOROFORM CARBON
METHYLENE CHLORIDE, PERCHLOROETHYLENE AND
Emissions
Event Type
Equipment Openings
Number of
Events
Reported
Duration (min)
Max. Min. Avg
Emission Rate
(kg/min)
Max. Min. Avg
1,974 2,880 0.083 25.6 1.8 0.003 1.03
Process Vent Discharges 441 10,080 5.0 628 6.4 0.002 0.19
Pressure Relief Discharges 119 30 0.083 6.30 448 0.018 15.9
Handling Operations
5,651 1,200 40
160
5.5 0.0001 0.35
Accidental Liquid Releases 58 560 5.0 87.0 8.92 0.007 2.42
Accidental Gas Releases 33 132,000 0.5 4,060 46.2 0.0018 15.4
OVERALL
8,276 132,000 0.083 166 448 0.0001 0.802
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(8) discharge velocity;
(9) temperature;
(10) heat capacity;
(11) emission rate; and
(12) emissions per event.
Parameters such as velocity, heat capacity, and emission rate were calculated
based on data presented in Section 114 responses as well as physical property
data. Sample calculations for these three parameters are presented in
Appendix A. Unless otherwise noted in Table 4-3, all other parameters were
taken directly from Section 114 responses.
In addition to data concerning episodic events, facilities were also
requested to indicate events that cannot "occur simultaneously. A summary of
episodic events which the facilities indicated would not be likely to occur
simultaneously is presented in Table 4-4.
4.3 BACKGROUND EMISSIONS SUMMARY
As discussed in Section 4.1, data on annual or long-term emissions from
chlorinated hydrocarbon production facilities have also been collected. A
summary of constant/continuous annual emissions (not reported as episodic
emissions) is presented in Table 4-5. Emission sources in Table 4-5 include
fugitive emissions (equipment leaks), storage emissions (working and
breathing losses), and air emissions from secondary sources (liquid and solid
waste systems). Fugitive and secondary emissions are assumed to be
continuous over 365 days per year. Although storage emissions may be
episodic in nature, no data are available on emission rates and durations
Therefore, emissions from these sources are also presented as constant
throughout the year.
4-12
-------
TABLE 4-4. EVENTS REPORTED BY FACILITIES THAT COULD NOT OCCUR SIMULTANEOUSLY
Plant
Dow Chemical (I)
Dow Chemical (II)
Dow Chemical (III)
Dow Chemical (I)
Dow Chemical (II)
Dow Chemical (I)
Dow Chemical (II)
DuPont
Stauffer
LCP
Vulcan (I)
Vulcan (II)
Diamond Shamrock
Location
•^——•»—•^^•^•»_
Freeport, TX
Freeport, TX
Freeport, TX
Plaquemine, LA
Plaquemine, LA
Pittsburg, CA
Pittsburg, CA
Corpus Christi, TX
Lemoyne, AL
Moundsville, WV
Geismar, LA
Geismar, LA
Belle, WV
Diamond Shamrock Deer Park, TX
PPG Lake Charles, LA
Reported Answers to Questions Concerning
Simultaneous Event Occurrence
Events can occur simultaneously but do
not have to
Events can occur simultaneously but do
not have to
Events can occur simultaneously but do
not have to
Barges and tank cars are not loaded at
the same time
Events can occur simultaneously but do
not have to
Events can occur simultaneously but do
not have to
Events can occur simultaneously but do
not have to
The equipment opening for the distillation
column cannot occur during process vent
emissions (Vent #135) and accidental
gas release (El).
Events can occur simultaneously but do
not have to
Loadings of MC, CF, and CT cannot occur at
same time. The CM-07 process vent
emissions cannot occur at the same time
as equipment openings.
Events can occur simultaneously but do
not have to
Events can occur simultaneously but do
not have to
Process vent emissions from vent 1119 and
equipment opening cannot occur at the
same time. Equipment opening from
scrubber and pressure relief discharge
cannot occur at the same time. Also'
barge and tank loading of MC cannot
occur simultaneously.
Events can occur simultaneously but do
not have to
Events can occur simultaneously but do
not have to
-------
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4.4 REFERENCES
1. Letter and
9>
from Arnold, S., Dow Chemical , to Farmer J R
hrt t : ?6Sp0nse to Section 114 ^quests for
short-term emissions data seven enclosures: #1-3 for Freeoort TX- u
for Plaquemin*, LA; #6-7 for Pittsburg, CA) ^eeport, TX, ^4-
EH: ---» -- j- •••
•
H°vath' T" D1amond Shamrock, to
. to
4-15
-------
-------
5.0 CHLORINATED HYDROCARBON USERS
This section summarizes the available data for episodic and continuous
emissions of chloroform (CF), carbon tetrachloride (CT), methylene chloride
(MC), and perchloroethylene (PCE) from facilities that use chlorinated
hydrocarbons.
5.1 DESCRIPTION OF DATA SOURCES
By the authority of Section 114 of the Clean Air Act, EPA collected
eP1sodic (short-term) emissions data from seven companies representing
fifteen facilities that use chlorinated hydrocarbons. Data were collected
for CF, CT, MC, and PCE emissions only. These data were collected via
Section 114 questionnaires sent out in March 1986.
Table 5-1 lists the facilities which supplied episodic emissions data
is tab e also includes geographic data such as latitude, longitude, distance
to the plant fence line, and distance to the nearest residence, as well as
the period of time represented by the reported emissions data. Of the
fifteen responses, four facilities are located in Texas, two are located in
California.
Two companies provided separate Section 114 responses for individual
process units at each of their facilities. OuPont provided separate responses
for heir five process units in Beaumont, Texas. Dow Chemical provided a
total of sixteen responses representing process units at five facilities
Emissions from these process units are presented separately
in loiTT" TSl°nS data f°r Chl°r1nated Mrocarbon users were collected
1984. These data were also collected through Section 114 questionnaires
eh" oHnatTn'T" T'™" ^ ™M' ^ <"*" eP1'S°diC' ™^°" °f
chlorinate hydrocarbons. Background or constant/continuous emissions data
were combmed with episodic emissions data to determine maximum rates
Annual emissions data were obtained from the memorandum entitled, "Emission
Estates and Controls Memo for Chlorinated Hydrocarbon Emissions from
Chem,cal Plants - Chlorinated Compound Users," dated June 30 1986 8
5-1
-------
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5.2 EPISODIC EMISSIONS SUMMARY
Types of episodic emissions reported from facilities using Chlorinated
Hydrocarbons include: (1) pressure relief discharges, (2) equipment openings,
(3) accidental gas releases, (4) process vent discharges, (5) accidental
liquid releases, and (6) handling emissions. A total of 7,058 episodic
emission events were reported by the fifteen facilities providing Section 114
responses. These events represent emissions of 122,000 kg of chlorinated
hydrocarbons. Reported events include: 4,128 equipment openings, 1,488
pressure relief discharges, 1,240 process vent discharges, 178 events due to
handling operations, 15 accidental liquid releases and 9 accidental gas
releases. A summary of average emission rate and duration, including ranges,
is presented in Table 5-2 for each of the six types of episodic emissions.
The average emission rate and duration for all 611 emission events are
4.5 kg/min and 16 min, respectively. The highest emission rates were
reported for pressure relief discharges, with an average emission rate of
15.2 kg/min, and .accidental gas releases, with an average emission rate of
13.8 kg/min.
A detailed summary of episodic emission events reported in Section 114
responses is represented in Table 5-3. Data presented for each episodic
event include:
(1) type of event (e.g., pressure relief discharges);
(2) emission source (e.g., reactor, incinerator);
(3) nature of event (e.g., process upset, start-up);
(4) the number of events per year;
(5) event duration;
(6) release height;
(7) release diameter;
(8) discharge velocity;
(9) temperature;
(10) heat capacity;
(11) emission rate; and
(12) emissions per event.
5-3
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Parameters such as velocity, heat capacity, and emission rate were calculated
based on data presented in Section 114 response as well as physical property
data. Sample calculations for these three parameters are presented in
Appendix A. Unless otherwise noted in Table 5-3, all other parameters were
taken directly from Section 114 responses.
In addition to data concerning episodic events, facilities were also
requested to indicate events that cannot occur simultaneously. A summary of
episodic events which the facilities indicated would not be likely to occur
simultaneously is presented in Table 5-4.
5.3 BACKGROUND EMISSIONS SUMMARY
As discussed in Section 5.1, data on annual or long-term emissions from
chlorinated hydrocarbon production facilities have also been collected. A
summary of constant/continuous annual emissions (not reported as episodic
emissions) is presented in Table 5-5. Emission sources in Table 5-5 include
fugitive emissions (equipment leaks), storage emissions (working and breathing
losses), and air emissions from secondary sources (liquid and solid waste
systems). Fugitive and secondary emissions are assumed to be continuous over
365 days per year. Although storage emissions may be episodic in nature no
data are available on emission rates and durations. Therefore, emissions
from these sources are also presented as constant throughout the year
5-10
-------
TABLE 5-4. EVENTS REPORTED BY FACILITIES THAT COULD NOT OCCUR SIMULTANEOUSLY
Plant
Dupont
(I,II,III,IV,V)
Goodrich
Mobay
Borden
Diamond Shamrock
General Electric
General Electric
Location
Beaumont, TX
Cleveland, OH
Baytown, TX
Fremont, CA
Deer Park, TX
Schenectady, NY
Pittsfield, MA
Dow Chemical (I) Midland, MI
Dow Chemical (II) Midland, MI
Dow Chemical (III) Midland, MI
Dow Chemical (IV) Midland, MI
Dow Chemical (VII) Midland, MI
Dow Chemical (VIII) Midland, MI
Dow Chemical (IX) Midland, MI
Dow Chemical (X) Midland, MI
Dow Chemical (XI) Midland, MI
Dow Chemical (XIII) Pittsburg, CA
Dow Chemical (XIV) Freeport, TX
Reported Answers to Questions Concerning
Simultaneous Event Occurrence
Events can occur simultaneously, but do
not have to.
Not applicable. Only one event reported
Events can occur simultaneously, but do
not have to.
Not applicable. Only one event reported
Events can occur simultaneously, but do
not have to.
Events can occur simultaneously, but do
not have to.
Handling emissions associated with tank
loading and tank transfer cannot
occur at the same time.
Events can occur simultaneously, but do
not have to.
Handling emissions associated with tank
loading and tank transfer cannot
occur at the same time.
Tank loading and tank transfer events
could occur at the same time.
Equipment openings can only occur
during tank loading.
Pressure relief discharge cannot occur
during tank filling.
Events can occur simultaneously, but do
not have to.
Events can occur simultaneously, but do
not have to.
Pressure relief discharge, accidental
spill and equipment opening cannot
occur simultaneously.
Events can occur simultaneously, but do
not have to.
Not applicable. Only one event reported
Events can occur simultaneously, but do
not have to.
Events can occur simultaneously, but do
not have to.
5-11
-------
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5-12
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5.4 REFERENCES
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to
5-13
-------
-------
6.0 1,3-BUTAOIENE PRODUCTION
This section summarizes the available data for episodic and continuous
emissions of 1,3-butadiene (80) from butadiene production facilities.
6.1 DESCRIPTION OF DATA SOURCES
1,3-Butadiene is a high-volume intermediate organic chemical used to
produce various types of rubber, resins, and plastic. By the authority of
Section 114 of the Clean Air Act, EPA collected episodic (short-term)
emissions data from six companies representing eight facilities that produce
BD. These data were collected via Section 114 questionnaires sent out in
February 1986.
Table 6-1 Tists the facilities which supplied episodic emissions data
This table also includes geographic data such as latitude, longitude, distant
to plant fence line, and distance to nearest residence, as well as the period"
of time represented by the reported emissions data. None of the Section 114
responses for episodic emissions are considered confidential. Of the eight
reporting facilities, six facilities are located in Texas, and two are
ocated in Louisiana. Shell Oil provided separate Section 114 responses for
their two process units in Norco, Louisiana, as did Arco for their two units
in Channelview, Texas. Therefore, emissions from these process units are
presented separately.
Long-term emissions data for BO production facilities were collected in
984. These data were also collected through Section 114 questionnaires and
re primarily concerned with annual, rather than episodic, emissions of BD
Background or constant/continuous emissions data obtained from these question-
naires were combined with episodic emissions data to determine maxJ
emission rates. Annual emissions data were obtained from a memorandum
entitled. Estimates of 1,3-Butadiene Emissions from Production Facilities
and Emissions Reductions Achievable With Additional Controls," dated
March 25 1986. This memorandum summarizes annual emissions data provided
in long-term Section 114 responses.
6-1
-------
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6.2 EPISODIC EMISSIONS SUMMARY
Types of episodic emissions reported from BD production facilities
include: (1) pressure relief discharges, (2) equipment openings, (3) acci-
dental gas releases, (4) process vent discharges, and (5) accidental liquid
releases. A total of 30 episodic emission events were reported by five of
the eight facilities providing Section 114 responses. Three of the eight
facilities (including both Arco process units in Channelview, Texas) report-
no episodic events during the reporting period. The reported events represent
emissions of 50,400 kg of BO. Reported events include: 19 equipment openings
1 process vent discharge, 6 pressure relief discharges, 1 accidental liquid
release, and 3 accidental gas releases. A summary of average emission rate
and duration, including ranges, is presented in Table 6-2 for each of the
five types of episodic emissions. The average emission rate and duration for
all 30 emission events are 355 kg/min and 2,170 min, respectively. The
highest emission rates were reported for pressure relief discharges, with an
average emission rate of 1,590 kg/min, and accidental liquid releases, with
an average emission rate of 1,100 kg/min.
A detailed summary of episodic emission events reported in Section 114
responses is presented in Table 6-3. Data presented for each episodic event
include:
(1) type of event (e.g., pressure relief discharges);
(2) emission source (e.g., reactor, incinerator);
(3) nature of event (e.g., process upset, start-up);
(4) the number of events per year;
(5) event duration;
(6) release height;
(7) release diameter;
(8) discharge velocity;
(9) temperature;
(10) heat capacity;
(11) emission rate; and
(12) emissions per event.
6-3
-------
TABLE 6-2. SUMMARY OF EPISODIC EMISSIONS OF BUTADIENE PRODUCTION
Emi ssions
Event Type
Equipment Openings
of n Emission Rate
Events Duration (min) (kg/min)
Reported Max. Min. Avg. Max. Min. Avg
•
19 4,320 120 2,460 .567 .0002 .226
Process Vent Discharges 1 14,40014,400 14,400 .183 .183 .183
Pressure Relief Discharges 6 120 2
Accidental Liquid Releases 1
Accidental Gas Releases 3
120 2 26 4,540 1.323 1,590
•°8 -08 .08 1,100 1,100 1,100
3,042
5 1,260 .907 .008 .310
OVERALL
30 14,400 .08 2,170 4,540 .0002 355
-------
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-------
Parameters such as velocity, heat capacity, and emission rate were calculated
based on data presented in Section 114 responses as well as physical property
data. Sample calculations for these three parameters are presented in
Appendix A. Unless otherwise noted in Table 6-3, all other parameters were
taken directly from Section 114 responses.
In addition to data concerning episodic events, facilities were also
requested to indicate events that cannot occur simultaneously. A summary of
episodic events which the facilities indicated would not be likely to occur
simultaneously is presented in Table 6-4.
6.3 BACKGROUND EMISSIONS SUMMARY
As discussed in Section 6.1. data on annual or long-term emissions from
butadiene production facilities have also been collected. A summary of
constant/continuous annual emissions (not reported as episodic emissions) is
presented in Table 6-5. Emission sources in Table 6-5 include fugitive
emissions (equipment leaks), and air emissions from secondary sources (liquid
and solid waste systems). These emissions are assumed to be constant over
365 days per year. From information provided by the facilities, loading
emissions were considered to be negligible.
6-6
-------
TABLE 6-4. EVENTS REPORTED BY FACILITIES THAT COULD NOT OCCUR SIMULTANEOUSLY
Plant
•^—^^—^—™»—
Shell Oil
Shell Oil Ib
Shell Oil IIb
Texaco
Texas Petrochem
Exxon
Exxon
Arco Ib
Arco IIb
Corpus Christi
Location
———^—__
Deer Park, TX
Norco, LA
Norco, LA
Port Neches, TX
Houston, TX
Baytown, TX
Baton Rouge, LA
Channelview, TX
Channelview, TX
Corpus Christi, TX
Reported Answers to Questions Concerning
Simultaneous Event Occurrence
NR'
All process vents must occur at the
same time.
NR
Events can occur simultaneously but
do not have to.
Events can occur simultaneously but
do not have to.
Events can occur simultaneously but
do not have to.
Events can occur simultaneously but
do not have to.
No events.
No events.
No events.
««,,, am ,.t report..,.
„.„„ „„ 0«or ,„„,„„„„„, „„,
6-7
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6.4 REFERENCES
1. Letter and attachments from Trautner, R J shell nil rnmn,
Farmer. J. R.. FPA M^rh n IOP* 0*™™ * I I ComPany> to
1986 Response to Section .114 letter on
BD production facilities
2
*• • w %. i» i. c i a 111 j rf*ii*4rnmanTe- ^ **/>••* i_r«^A. ._. n /% *• .
» R. G., Neches
nn "" "' " ™" uiac"1 D " n-J' " , to
6-9
-------
-------
7.0 POLYBUTADIENE PRODUCTION
This section summarizes the available data for episodic and continuous
emisS1ons of 1,3-butadiene from polybutadiene (PBD) production facilities.
7.1 DESCRIPTION OF DATA SOURCES
Polybutadiene, the polymerization product of butadiene (80), is used
primarily in the production of automobile tires. By the authority of
Section 114 of the Clean Air Act, EPA collected episodic (short-term)
emissions data from seven companies representing seven facilities that
produce PBO. Data were collected for BD emissions only. These data were
collected via Section 114 questionnaires sent out in December 1985.
Table 7-1 lists the facilities which supplied episodic emissions data
Thls table also includes geographic data such as latitude, longitude dis-
tance to the plant fence line, and distance to the nearest residence,' as well
as the period of time represented by the reported emissions data. None of
the Section 114 response for episodic emissions are considered confidential
Of the seven reporting facilities, five facilities are located in Texas, one
is located in Illinois, and one is located in Kentucky.
Long-term emissions data for PBD production facilities were collected in
1984. These data were also collected through Section 114 questionnaires and
are primarily concerned with annual, rather than episodic, emissions of BD
Background or constant/continuous emissions data obtained from these question-
naires were combined with episodic emission data to determine maximum emission
rates. Annual emissions data were obtained from a memorandum entitled
"Estates of 1,3-Butadiene Emissions from Production Facilities and Emissions
Reduct10nS Achievable with Additional Controls," dated March 27, 1986 8 This
memorandum provides a summary of long-term emissions data collected via
Section 114.
7-1
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7.2 EPISODIC EMISSIONS SUMMARY
Types of episodic emissions of BD reported from PBD production facilities
include: (1) pressure relief discharges, (2) equipment openings, (3) acci-
dental gas releases, (4) process vent discharges, and (5) accidental liquid
releases. A total of 456 episodic emission events were reported by five of
the seven facilities providing Section 114 responses. Two facilities reports
no episodic events during the reporting period. The reported events repr»sen'
emissions of 6,580 kg of BD. Reported events include: 450 equipment
openings, one process vent discharge, one pressure relief discharge, one
accidental liquid release, and three accidental gas releases. A summary of
average emission rate and duration, including ranges, is presented in
Table 7-2 for each of the five types of episodic emissions. The average
emission rate and duration for all 456 emission events are 24.0 kg/min and
7.54 min, respectively. The highest emission rates were reported for acci-
dental liquid releases, with an average emission rate of 81.4 kg/min, and
equipment openings, with an average emission rate of 24.0 kg/min.
A detailed summary of episodic emission events reported in Section 114
responses is presented in Table 7-3. Data presented for each episodic event
include:
(1) type of event (e.g., pressure relief discharge);
(2) emission source (e.g., reactor, incinerator);
(3) nature of event (e.g., process upset, start-up);
(4) the number of events per year;
(5) event duration;
(6) release height;
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(10) heat capacity;
(11) emission rate; and
(12) emissions per event.
7-3
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and
. Sample calcula o
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taken directly from Section 114 responses
« -" « Physical pr0pirtv
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Parameters were
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7.3 BACKGROUND EMISSIONS SUMMARY
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7-6
-------
TABLE 7-4. EVENTS REPORTED BY FACILITIES THAT COULD NOT OCCUR SIMULTANEOUSLY
Plant
Location
American
Arco Chemical
Borg-Warner
Firestone
Goodyear
Phillips
Polysar
Louisville, KY
Channelview, TX
Ottawa, IL
Orange, TX
Beaumont, TX
Borger, TX
Orange, TX
Reported Answers to Questions Concerning
Simultaneous Event Occurrence
"
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accidental liquid release. Any
events can occur simultaneously.
Events can occur simultaneously but
do not have to.
Events can occur simultaneously but
do not have to.
No episodic events reported.
Events can occur simultaneously but
do not have to.
Not applicable: only one event
reported.
No episodic events reported.
7-7
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7.4 REFERENCES
1.
2.
f^miils?"0™"16™ DUtadlene «"'«1ons from polybutadiene'production
Chemicals, Inc.
-
""'
7. Letter and attachments from Harris, I. W. F
' to
7-9
-------
-------
8.0 NEOPRENE/CHLOROPRENE PRODUCTION
This section summarizes the available data for episodic and continuous
emissions of 1,3-butadiene (BO) from neoprene/chloroprene (NP/CP) production
facilities.
8.1 DESCRIPTION OF DATA SOURCES
Neoprene (NP), also called polychloroprene, is a polymer product of
chloroprene (2-chlorol,3-butadiene). Chloroprene (CP) is produced through
the chlorination of BD. Neoprene rubber is used primarily in the automobile
industry for such applications as belts, cables, hoses, and wires. By the
authority of Section 114 of the Clean Air Act, EPA collected episodic (short-
term) emissions data from two companies representing two facilities that
produce NP/CP. Data were collected for BD emissions only. These data were
collected via Section 114 questionnaires sent out in December 1985.
Table 8-1 lists the facilities which supplied episodic emissions data.
This table also includes geographic data such as latitude, longitude,
distance to the plant fence line, and distance to the nearest residence, as
well as the period of time represented by the reported emissions data
Neither of the Section 114 responses for episodic emissions is considered
confidential. One of the facilities is located in Texas, and the other in
Louisiana.
Long-term emissions data for NP/CP production facilities were collected
in 1984. These data were also collected through Section 114 questionnaires
and are primarily concerned with annual, rather than episodic, emissions of
BD. Background or constant/continuous emissions obtained from these question-
naires were combined with episodic emission data to determine maximum emission
rates. Annual emissions data were obtained from a memorandum entitled
"Estimates of 1,3-Butadiene Emissions from Neoprene Facilities and Emissions
Reductions Achievable With Additional Controls," dated December 23 1985 3
Th,s memorandum provides a summary of long-term emissions data collected
8-1
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8.2 EPISODIC EMISSIONS SUMMARY
Types of episodic emissions of BO reported from NP/CP production
facilities include pressure relief discharges and process vent discharges A
total of 75 episodic emission events were reported by the two facilities
providing Section 114 responses. These events represent emissions of 1 310 kc
of 80. Reported events include: 74 process vent discharges and one pressur/
relief discharge. A summary of average emission rate and duration, includin-
ranges, is presented in Table 8-2 for both of the types of episodic e^isslon,-
reported. The average emission rate and duration for all 75 emission events
are 2.93 kg/min and 38.8 min, respectively. The highest emission rate was
reported for a pressure relief discharge, with an emission rate of 181 kg/min
A detailed summary of episodic emission events reported in Section 114
responses is presented in Table 8-3. Data presented for each episodic event
include:
(1) type of event (e.g., pressure relief discharge);
(2) emission source (e.g., reactor, incinerator);
(3) nature of event (e.g., process upset, start-up);
(4) the number of events per year;
(5) event duration;
(6) release height;
(7) release diameter;
(8) discharge velocity;
(9) temperature;
(10) heat capacity;
(11) emission rate; and
(12) emissions per event.
Parameters such as velocity, heat capacity, and emission rate were calculated
d on da a presented in Section 114 responses as well as physical property
ata Sample calculations for these three parameters are presented in
ppendix A. Unless otherwise noted in Table 8-3, all other parameters were
taken directly from Section 114 responses
8-3
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In addition to data concerning episodic events, facilities were also
requested to indicate events that cannot occur simultaneously. A summary of
episodic events which the facilities indicated would not be likely to occur
simultaneously is presented in Table 8-4.
8.3 BACKGROUND EMISSIONS SUMMARY
As discussed in Section 8.1. data on annual or long-term emissions from
NP/CP production facilities have also been collected. A summary of constant
continuous annual emissions (not reported as episodic emissions) is presented
m Table 8-5. Emission sources in Table 8-5 include fugitive emissions
(equipment leaks) only. These emissions are assumed to be constant over
365 days per year.
8-6
-------
TABLE 8-4. EVENTS REPORTED BY FACILITIES THAT COULD NOT OCCUR SIMULTANEOUSLY
Plant
-^"^—••^••^•B
Oenka
DuPont
Location
—•'
Houston, TX
LaPlace, LA
Reported Answers to Questions Concerning
Simultaneous Event Occurrence
— .
Equipment opening and first process vent
are the same event.
Events can occur simultaneously but do
not have to.
Event is only counted once.
1-7
-------
TABLE 8-5. SUMMARY OF BACKGROUND EMISSIONS OF BUTADIENE FROM NEOPRENE/
CHLOROPRENE PRODUCTION FACILITIES NtUHKtNE/
Plant
Denka
Location
Houston, TX
Fugitive Emissions
(kg/yr) (kg/min)
10,000
0.019
Total Emissions
(kg/yr) (kg/min)
•
10,000 0.019
DuPont LaPlace, LA
32,200 0.0612 32,200 0.0612
8-8
-------
8.4 REFERENCES
"jo"^"'*" °e"k* Chemical Corporation, to
^^
2. Letter and attachments from Surge, G E E r n,,D« <• ^ .,
Company, to Farmer, J. R cpa jan,,;^-;7 ,I;c°uPont de Nemours and
Section 114 letter on short-term bKJ ' ^ Response to
-er
neoprene/chloroprene pSductn
L. 8.,
Emissions reductions AcievabewUhitio
8-9
-------
-------
9.0 STYRENE-BUTADIENE RUBBER PRODUCTION
This section summarizes the available data for episodic and continuous
Missions of 1,3-butadiene (BO) from styrene-butadiene rubber (SBR) production
facilities.
9.1 DESCRIPTION OF DATA SOURCES
Styrene-butadiene copolymers are composed of the monomer units butachene
and styrene. Depending on the feed composition and extent of drying in the
process, styrene-butadiene copolymers can be solid (elastomer) or elastomer
emulsion (latex). By the authority of Section 114 of the Clean Air Act EPA
collected episodic (short-term) emissions data from ten companies representing
seventeen facilities that produce SBR. Data were collected for 80 emissions
only. These data were collected via Section 114 questionnaires sent out in
February 1986.
Table 9-1 lists the facilities which supplied episodic emissions data
This table also includes geographic data such as latitude, longitude, distance
to the plant fence line, and distance to the nearest residence, as well as
the period of time represented by the reported emissions data. None of the
Sect,on 114 responses for episodic emissions are considered confidential Of
the seventeen reporting facilities, five facilities are located in Texas, two
are located in Louisiana, two are located in Ohio, two are located in Georgia
and one each in Kentucky, West Virginia, Tennessee, Connecticut, and
Cal,forma. Dow Chemical provided separate Section 114 responses for their
two process units in Midland, Michigan, as did Polysar for their two process
units in Chattanooga, Tennessee. Therefore, emissions from these process
units are presented separately.
Long-tern, emissions data for SBR production facilities were collected in
1984. These data were also collected through Section 114 questionnaires and
are primarily concerned with annual, rather than episodic, emissions of BD
Background or constant/continuous emissions data obtained from these
questionnaires were combined with episodic emission data to determine maximum
em,ssion rates. Annual emissions data were obtained from a memorandum
9-1
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9-2
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entitled, "Estimates of 1,3-Butadiene Emissions from Styrene-Butadiene
Copolyroer Facilities and Emissions Reductions Achievable With Additional
Controls," dated April 8, 1986.12 This memorandum provides a summary of
long-term emissions data collected.
9.2 EPISODIC EMISSIONS SUMMARY
Types of episodic emissions of BO reported from SBR production facili*ie<
include: (1) pressure relief discharges, (2) equipment openings, (3) acci-
dental gas releases, (4) process vent discharges, and (5) accidental liquid
releases. A total of 1,534 episodic emission events were reported by seven-
teen facilities providing Section 114 responses. These events represent
emissions of 156,000 kg of BD. Reported events include: 226 equipment
openings, 391 process vent discharges, 872 pressure relief discharges 15
accidental liquid releases, and 30 accidental gas releases. A summary of
average emission rate and duration, including ranges, is presented in
Table 9-2 for each of the five types of episodic emissions. The average
emission rate and duration for all 1,534 emission events are 3.92 kg/min and
49.6 mm, respectively. The highest emission rates were reported for acci-
dental gas releases, with an average emission rate of 9.91 kg/min and
accidental liquid releases, with an average emission rate of 9.18 kg/min
A detailed summary of episodic emission events reported in Section 114
responses is presented in Table 9-3. Data presented for each episodic event
include:
(1) type of event (e.g., pressure relief discharge);
(2) emission source (e.g., reactor, incinerator);
(3) nature of event (e.g., process upset, start-up);
(4) the number of events per year;
(5) event duration;
(6) release height;
(7) release diameter;
(8) discharge velocity;
(9) temperature;
9-3
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(10) heat capacity;
(11) emission rate; and
(12) emissions per event.
Parameters such as velocity, heat capacity, and emission rate were calculated
based on data presented in Section 114 responses as well as physical property
data. Sample calculations for these three parameters are presented in
Appendix A. Unless otherwise noted in Table 9-3, all other parameters were
taken directly from Section 114 responses.
In addition to data concerning episodic events, facilities were also
requested to indicate events that cannot occur simultaneously. A summary of
episodic events which the facilities indicated would not be likely to occur
simultaneously is presented in Table 9-4.
9.3 BACKGROUND EMISSIONS SUMMARY
As discussed in Section 9.1, data on annual or long-term emissions from
SBR production facilities have also been collected. A summary of constant/
continuous annual emissions (not reported as episodic emissions) is presented
in Table 9-5. Emission sources in Table 9-5 include fugitive emissions
(equipment leaks) and air emissions from secondary sources (liquid and solid
waste systems). Fugitive and secondary emissions are assumed to be constant
over 365 days per year. From information provided by the facilities, loading
emissions were considered to be negligible.
9-10
-------
TABLE 9-4. EVENTS REPORTED BY FACILITIES THAT COULD NOT OCCUR SIMULTANEOUSLY
Plant
^^^^•W^^H^
Copolymer
Goodyear
Goodyear
Goodyear
Gencorp
Gencorp
W.R. Grace
Uniroyal
Borg-Warner.
Polysar (I)1
Dow
Dow
Dow
Dow
Dow (I)b
Dow (II)b
B.F. Goodrich
Firestone
——————__
Assume events
Location
^—^"—"^—«»-^—»,
Baton Rouge, LA
Akron, OH
Calhoun, GA
Houston, TX
Odessa, IX
Mogadore, OH
Owensboro, KY
Port Neches, TX
Washington, WV
Chattanooga, TN
Polysar (II)b Chattanooga, TN
Freeport, TX
Dal ton, GA
Gales Ferry, CT
Pittsburg, CA
Midland, MI
Midland, MI
Port Neches, TX
Lake Charles, LA
Reported Answers to Questions Concerning
Simultaneous Event Occurrence
_
Process vents and accidental gas releases
do not occur simultaneously. Pressure
relief discharges do not occur
simultaneously.
Accidental gas releases did not occur
simultaneously.
Events can occur simultaneously but do
not have to.
Events can occur simultaneously but do
not have to.
Events can occur simultaneously but do
not have to.
Events can occur simultaneously but do
not have to.
Process vents cannot occur at the same
time as equipment openings.
Events can occur simultaneously but do
not have to.
Not reported
Decanter must empty before the water
decanter.
Equipment opening occurs before accidental
liquid release. No other event occurs
during equipment opening.
Events can occur simultaneously but do
not have to.
Events can occur simultaneously but do
not have to.
Events can occur simultaneously but do
not have to.
Events can occur simultaneously but do
not have to.
None of the events occurred at the same
time or in series.
Events can occur simultaneously but do
not have to.
Events can occur simultaneously but do
not have to.
Events can occur simultaneously but do
not have to.
can occur simultaneously but do not have to
£
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9.4 REFERENCES
1.
2. Letter and attachments from Lockemer, R. r Goodyear Tire and
L» omo 3 n v frt P 3 V*HIO v* i D cr}/\ LJ i_ ^ /\ y^-s*i iitCQiivj
product?onSfaciini"esbUtadiene 6missions from styrene-butadiene rubber
3* F^r^r ^ attachments from Frase, R. W., DiversiTech General, Inc., to
production facilities. iene rubber
8. Letter and attachments from Harris, I. W E Polvsar MmitoH f
-a-^'
9-13
-------
• R., i ircaiune ivnrnar-ir DnKk^w. __j
Section 114 letter on snor^term butidEET* "' 19f6' R«P°n« to
butadiene production faciliti« butadlen> emiss'°"s from styrene-
12. Mefnorandum from Kuhn i^ n -»«/^ n i «
«... 11 win INUIIII, i\. \j. t and WA^COI D A n--u__ *.
to
s,.cncrii- '" »n»r.t1on, to
l,3-8utadiene Emissionsion Styrlne Bull*'^? 8,' 1986' Esti™tes o
Emissions Reductions Achiev'b^Hh6 S^SJo^l"111*1" and
9-14
-------
10.0 MISCELLANEOUS BUTADIENE PRODUCTION
This section summarizes the available data for episodic and continuous
emissions of butadiene (80) from miscellaneous 80 use facilities.
10.1 DESCRIPTION OF DATA SOURCES
In 1984, EPA obtained emissions data from ten companies representing
thirteen facilities that use 1,3-butadiene as a raw material. Although only
the long-term type questionnaire was used to obtain data for this source
category, episodic events were reported for five facilities. Only episodic
process vent emissions were reported for four of these facilities The
frequency and duration of these reported intermittent process vents were
provided for only three facilities. Equipment opening emissions were reports-
for one facility. However, the frequency and duration of equipment openings
was not provided.
The thirteen facilities that provided emissions information are listed
in Table 10-1. This table also includes geographic data such as latitude and
long,tude, as well as the calendar year represented by the reported data.
Long-term emissions data provided in the Section 114 responses are
summarized in a memorandum entitled, "Estimates of 1,3-Butadiene Emissions
from M,scellaneous Sources and Emissions Reductions Achievable with Candidate
NESHAP Controls," dated December 12, 1986.
10.2 EPISODIC EMISSIONS SUMMARY
A detailed summary of episodic emission events reported in Section 114
responses is presented in Table 10-2. Data presented for each episodic even'
include:
(1) type of event (e.g., process vent discharge);
(2) emission source (e.g., reactor, incinerator);
(3) nature of event (e.g., process upset, start-up);
10-1
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(4) the number of events per year;
(5) event duration;
(6) release height;
(7) release diameter;
(8) discharge velocity;
(9) temperature;
(10) heat capacity;
(11) emission rate; and
(12) emissions per event.
Parameters such as velocity, heat capacity, and emission rate were calculated
based on data presented in Section 114 responses as well as physical property
data. Sample calculations for these three parameters are presented in
Appendix A. Unless otherwise noted in Table 10-2, all other parameters were
taken directly from Section 114 responses.
As shown in Table 10-2, frequency (events/year) and duration were
provided for only six reported events. All six of these are intermittent
process vents. The lack of episodic emissions data for this source category
is primarily the result of the information requested. Only the long-term
type questionnaire was used to obtain emissions data for this source category
This questionnaire was focused toward obtaining annual emissions data and did'
not specifically address episodic emissions. It is likely that episodic
events reported for other facilities in this report also occur at misceHa-
neous BD use facilities. However, data on these events have not been obtained
10.3 BACKGROUND EMISSIONS SUMMARY
As discussed in Section 10.1, data on annual emissions from miscellaneous
BD production facilities have been collected. A summary of constant/
continuous annual emissions (not reported as episodic emissions) is presented
n Table 10-3. Emission sources in Table 10-3 include fugitive emissions
(equipment leaks), storage emissions (working and breathing losses), and air
emissions from secondary sources (liquid and solid waste systems). Fugitive
and secondary emissions are assumed to be constant over 365 days per year
10-4
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Although storage and loading emissions may be episodic in nature, no data are
available on emission rates and durations. Therefore, emissions from these
sources are also presented as constant throughout the year.
10-6
-------
10.4 REFERENCES
from Bor9-Wai-ner Chemicals, Inc., to
letter on
" °Snka Chemical Corporation,
on ---
" 0uPont "emical Camoan
on -
4. Letter and attachments from Holbrook, W. C., B F Goodrich tn
f™
M°sant°
letter on long-ter. BO
BD ion 80
.o o , Inc.,
on long-tern, BO eions^o BDro10" 1U letter
C.rt1d. Corporation,
long-ter.
11. Letter and attachments from Uni royal, to Farmer 1 R
tOcSection114 letter on long-ter^ BD e^S'fro/BD
'
10-7
-------
-------
11.0 EPICHLOROHYDRIN PRODUCTION AND USE
This section summarizes the available data for episodic and continuous
emissions of epichlorohydrin (EPI) from facilities that produce or use EPI.
11.1 DESCRIPTION OF DATA SOURCES
Epichlorohydrin is used primarily in the production of glycerin, esoxv
and polyamide resins, elastomers, and surfactants. By the authority of"
Section 114 of the Clean Air Act, EPA collected episodic (short-term)
emissions data from nine companies representing fifteen facilities that
produce or use EPI. Data were collected for EPI emissions only. These data
were collected via Section 114 questionnaires sent out in February 1986.
Table 11-1 lists the facilities which supplied episodic emissions data.
This table also includes geographic data such as latitude, longitude, dis-
tance to the plant fence line, and distance to the nearest residence,' as well
as the period of time represented by the reported emissions data. None of
the Section 114 responses for episodic emissions are considered confidential
Of the fifteen reporting facilities, two facilities each are located in New
Jersey, Ohio, and Wisconsin; and one facility is located in each of nine
other states: Alabama, Kentucky, Massachusetts, Oregon, Georgia, Kansas
Louisiana, Texas, and Mississippi.
Dow Chemical provided separate Section 114 responses for their eight
process units in Freeport, Texas, as did Hercules, Inc., for their two
process units, in Hattiesburg, Mississippi. Therefore, emissions from these
process units are presented separately.
Long-term emissions data for EPI facilities were collected in 1983
These data were also collected through Section 114 questionnaires and are
primarily concerned with annual, rather than episodic, emissions of EPI
Background or constant/continuous emissions data obtained from these
questionnaires were combined with episodic emissions data to determine
maximum emission rates. Annual emissions data were obtained from a memoranda
entitled Epichlorohydrin Emissions Summary," dated February 16, 1984.18
11-1
-------
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11-2
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This memorandum presents a summary of long-term emissions data. In addition
some data were taken from the actual responses to the long-term Section 114
questionnaires.
11.2 EPISODIC EMISSIONS SUMMARY
Types of episodic emissions reported from facilities that produc° or :JS =
EPI include: (1) pressure relief discharges; (2) equipment openings
(3) accidental gas releases, (4) process vent discharges, and (5) accidental
liquid releases. A total of 379 episodic emission events were reported by
thirteen of the fifteen facilities providing Section 114 responses. Two
facilities reported no episodic events during the reporting period. Also
one of the two Hercules process units in Hattiesburg, Mississippi, and three
of the eight Dow Chemical process units in Freeport, Texas, had no reported
episodic events. The events reported represent emissions of 1,050 kg of EPI
Reported events include: 359 equipment openings, 1 process vent discharge
4 pressure relief discharges, 13 accidental liquid releases, and 2 accidental
gas releases. A summary of average emission rate and duration, including
ranges, is presented in Table 11-2 for each of the five types of episodic
emissions. The average emission rates and duration for all 379 emission
events are 0.418 kg/nin and 24.0 min, respectively. The highest emission
rates were reported for accidental gas releases, with an average emission
1! i, k9/min> ^ equ1pment ^nings, with an average emission rate of
.405 kg/min.
A detailed summary of episodic emission events reported in Section 114
responses is presented in Table 11-3. Data presented for each episodic event
i nc I tide:
(1) type of event (e.g., pressure relief discharge);
(2) emission source (e.g., reactor, incinerator);
(3) nature of event (e.g., process upset, start-up);
(4) the number of events per year;
(5) event duration;
11-3
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(6) release height;
(7) release diameter;
(8) discharge velocity;
(9) temperature;
(10) heat capacity;
(11) emission rate; and
(12) emissions per event.
Parameters such as velocity, heat capacity, and emission rate were caicuiac-
based on data presented in Section 114 responses as well as physical prop^v
data. Sample calculations for these three parameters are presented in
Appendix A. Unless other-wise noted in Table 11-3, all other parameters were
taken directly from Section 114 responses.
In addition to data concerning episodic events, facilities were also
requested to indicate events that cannot occur simultaneously. A summary of
episodic events which the facilities indicated would not be likely to occur
simultaneously is presented in Table 11-4.
11.3 BACKGROUND EMISSIONS SUMMARY
As discussed in Section 11.1, data on annual or long-term emissions of
EPI have also been collected. A summary of constant/continuous annual
emissions (not reported as episodic emissions) is presented in Table 11-5
Emission sources in Table 11-5 include fugitive emissions (equipment leaks)
storage emissions (working and breathing losses), and air emissions from '
secondary sources (liquid and solid waste systems). Fugitive and secondary
emissions are assumed to be constant over 365 days per year. Although
storage emissions may be episodic in nature, no data are available on
em,ssion rates and duration. Therefore, emissions from these sources are
also presented as constant throughout the year.
11-7
-------
TABLE 11-4. EVENTS THAT FACILITIES REPORTED COULD NOT OCCUR SIMULTANEOUSLY
Plant
B.F. Goodrich
Borden
Borden
Celanese
Ciba-Geigy
Hercules
Hercules
Hercules
Hercules
Hercules
Hercules
(I)
(ID
Procter and Gamble
Procter and Gamble
Shell Oil
Dow Chemical (I)
Dow Chemical (II)
Dow Chemical (III)
Dow Chemical (IV)
Dow Chemical (V)
Dow Chemical (VI)
Dow Chemical (VII)
Dow Chemical (VIII)
Union Carbide
Location
—
Avon Lake, OH
Sheboygan, WI
Demopolis, AL
Louisville, KY
Toms River, NJ
Chicopee, MA
Portland, OR
Milwaukee, WI
Hattiesburg, MS
Hattiesburg, MS
Savannah, GA
Kansas City, KS
Cincinnati, OH
Norco, LA
Freeport, TX
Freeport, TX
Freeport, TX
Freeport, TX
Freeport, TX
Freeport, TX
Freeport, TX
Freeport, TX
Piscataway, NJ
Reported Answers to Questions Concerning
Simultaneous Event Occurrence
Events can occur simultaneously but
do not have to.
Events can occur simultaneously but
do not have to.
Events can occur simultaneously but
do not have to.
Not applicable.
Events can occur simultaneously but
do not have to.
Not reported.
No episodic events reported.
Not applicable.
None of the reported events could
occur simultaneously.
No episodic events reported.
Events can occur simultaneously but
do not have to.
Not applicable.
Not applicable.
Not applicable.
No episodic events reported.
No episodic events reported.
No episodic events reported
Not applicable.
Events can occur simultaneously but
do not have to.
Events can occur simultaneously but
do not have to.
Events can occur simultaneously but
do not have to.
Events can occur simultaneously but
do not have to.
No episodic events reported.
-------
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11.4 REFERENCES
Farmer ^ R^FpT^r^3^',*- °" B'F- G°°dr1Ch Coi»P«y. t°
«h^? Jni. cif •' ?arcnr13' 1986- Response to Section 114 letter on
short-term EPI emissions from EPI production facilities.
Letter and attachments from Springer, C. R., Borden, Inc to
Apr11 8' 1986' Response to Sect on 114 letter on
short-term EPI emissions from EPI production facilities.
mer pp», P- J" PrOCtor & Gamble ComPany. to
. I A ^ > 4 ^U«J •
letter on long-term EPI emissions from EPI
and
.. to
11-10
-------
13. Data from Flegenheimer, H. H., Celanese Specialty Resins, to EPA
fS'gi rnet0S14 1§ttir °" ^^ EPI ^
14. Letter and attachments from Bobsein, W. P., Ciba-Geigy Corp., to
JTSnn t* R'^PAVDecember 9, 1983. Response to slction'l 4 letter
on long-term EPI emissions from EPI production facilities.
tfpfrmp^ f^rS^ Mr°m ;>chwart2m*n> H., Proctor & Gamble Company
to Farmer J. R., EPA, November 4, 1983. Response to Section 114
letter on long-term EPI emissions from EPI production facilities.
16' Farmfr ^ SUa«!Jen«S/rom C^hm^> W« L- Shell Oil Company, to
Farmer, J. R., EPA, October 13, 1983. Response to Section 114 letter
on long-term EPI emissions from EPI production facilities.
17' tf£!r *"d 1U§Chmf™S ^°m Burstein, R., Union Carbide Corporation,
to Farmer J. R., EPA, October 12, 1983. Response to Section 114
letter on long-term EPI emissions from EPI production faci ities
18.
"" "• n-» n*i» to oecic, u. A., EPA, February 16
lissions Summary.
11-11
-------
-------
12.0 PESTICIDE MANUFACTURING
This section summarizes the available data for episodic and continuous
emissions of carbon tetrachloride (CT) and methylene chloride (MC) from
pesticide manufacturing facilities.
12.1 DESCRIPTION OF DATA SOURCES
Under the authority of Section 114 of the Clean Air Act, EPA collected
emissions data from eight companies representing thirteen facilities that
manufacture pesticides. The long-term/short-term questionnaire was used to
obtain emissions data for the pesticide source category. Data were collected
for both CT and MC emissions. These data were collected via Section 114
questionnaires sent out in November 1985. From responses to these
questionnaires, episodic emissions data were extracted.
Table 12-1 lists the facilities which supplied annual emissions data
This table also includes geographic data such as latitude, longitude, and the
period of time represented by the reported emissions data. Portions of the
Section 114 responses from five facilities were claimed confidential by the
companies; therefore, data from these portions are not included in this
report. One facility, Mobay Corporation's Kansas City, Missouri, plant
reported that no CT nor MC is emitted. Of the thirteen remaining responses
three facilities each are located in both Texas and Maryland, while one
facility is located in Tennessee, California, Missouri, West Virginia,
Georgia, Delaware, and Alabama, respectively.
Background or constant/continuous emissions data obtained from the
Sect,on 114 questionnaires were combined with episodic emission data to
determine maximum emission rates. Annual emissions data were obtained from a
memorandum entitled, "Estimates of Hazardous Compound Emissions from Pestiad*
Facilities and Emissions Reductions Achievable with Additional Controls "
dated July 24, 1986.
12-1
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12.2 EPISODIC EMISSIONS SUMMARY
Types of episodic emissions reported from pesticide manufacturers
include: (1) pressure relief discharges, (2) equipment openings, (3) acci-
dental gas releases, (4) process vent discharges, and (5) accidental liquid
releases. Since data were collected for both CT and MC emissions, the
summaries are presented independently. A total of 6,801 episodic CT and
24,133 episodic MC emission events were reported by the thirteen facilities
providing Section 114 responses. These events represent emissions of
976,841 kg of CT and 1,126,142 kg of MC. For CT, reported events include:
4,390 process vent discharges, 1,763 accidental liquid releases, 594
equipment openings, 34 accidental gas releases, and 20 pressure relief
discharges. For MC, reported events include: 23,038 equipment openings, 883
process vent discharges, 188 accidental liquid releases, 1 pressure relief
discharge, and 23 handling emissions. Summaries of average emission rates
and durations for CT and MC, including ranges, are presented in Table 12-2
for each of the five types of episodic emissions. The average emission rate
and duration for all 6,801 CT emission events are 76.4 kg/min and 18.8 mln,
respectively. The highest emission rates of CT were reported for process
vent discharges, with an average emission rate of 117 kg/min. For MC, the
average emission rate and duration for all 24,133 events are 0.152 kg/min and
307 min, respectively. The highest maximum emission rates were reported for
pressure relief discharges, with an average emission rate of 13.6 kg/min.
A detailed summary of episodic emission events reported in Section 114
responses is presented in Table 12-3. Data presented for each episodic event
include:
(1) type of event (e.g., pressure relief discharge);
(2) emission source (e.g., reactor, incinerator);
(3) nature of event (e.g., process upset, start-up);
(4) pollutant;
(5) the number of events per year;
(6) event duration;
(7) release height;
12-3
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(8) release diameter;
(9) discharge velocity;
(10) temperature;
(11) heat capacity;
(12) emission rate; and
(13) emissions per year.
Parameters such as velocity, heat capacity, and emission rate were calculates
based on data presented in Section 114 responses as well as physical property
data. Sample calculations for these three parameters are presented In
Appendix A. Unless otherwise noted in Table 12-3, all other parameters were
taken directly from Section 114 responses.
12.3 BACKGROUND EMISSIONS SUMMARY
A summary of continuous annual emissions (not reported as episodic
emissions) is presented in Table 12-4. Emission sources in Table 12-4
include fugitive emissions (equipment leaks), storage emissions (working and
breathing losses), and handling emissions (shipping and loading). Fugitive
and secondary emissions are assumed to be constant over 365 days per year.
Although storage and loading emissions may be episodic in nature, no data are
available on emission rate and duration. Therefore, emissions from these
sources are also presented as constant throughout the year.
12-13
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-------
12.4 REFERENCES
'• sMS^^jSHjrsssH-S
7.
10.
i But]f'lnP- C" Buckman Laboratories, Inc.,
, January 17, 1986. Response to Section 1
- CT and MC "'"ions
5. Letter and attachment, from Srh^dt, J. E., FMC Corporation to
5, 1986. "
""C"!
'
8. Letter and attachments from Fiesinaer F r, M™*^ A r-u
TntoymnH.i,+««. fnmnanu fl c rie:>iriyer» t. u., Monsanto and Fibers
Company,^to Farmer, J. R., EPA, January 30, 1986.
-T and
9.
Achievable with Additional ContrSli^IMlies ana tmission Reductions
12-15
-------
-------
13.0 PHARMACEUTICAL PRODUCTION
This section summarizes the available data for episodic and continuous
emissions of methylene chloride (MC) from pharmaceutical production
facilities.
13.1 DESCRIPTION OF DATA SOURCES
Methylene chloride is a low-boiling solvent used in the production of
Pharmaceuticals. By the authority of Section 114 of the Clean Air Act, EPA
collected emissions data from seven companies representing twenty facilities
that produce Pharmaceuticals. The long-term/short-term type questionnaire
was used to obtain data for all twenty facilities. The pollutant of concern
for this category is MC. These data were collected via Section 114 question
naires sent out in October 1985, and summarized in a memorandum entitled,
"Estimates of Potentially Hazardous Compound Emissions from Pharmaceutical
Facilities and Emission Reductions Achievable with Additional Controls,"
dated September 17, 1986.15
Table 13-1 lists the facilities which supplied emissions data. This
table also includes geographic data such as latitude and longitude, and the
period of time represented by the reported emissions data. The distance to
the plant fenceline and distance to the nearest residence was not requested
in the long-term/short-term type questionnaire. None of the Section 114
responses for episodic emissions are considered confidential.
Of the twenty reporting facilities, five facilities are located in
Puerto Rico, four facilities are located in Indiana, three are located in
Illinois, two are located in New Jersey, and one facility is located in each
of six other states: North Carolina, New York, Pennsylvania, Georgia,
Connecticut, and Michigan.
13-1
-------
TABLE 13-1.
GEOGRAPHIC DATA FOR PHARMACEUTICAL PRODUCTION FACILITIES
Plant
Abbott
Abbott
Abbott
Abbott
Abbott
Burroughs Wellcome
Ciba-Geigy
Eli Lilly
Eli Lilly
Eli Lilly
Eli Lilly
Merck and
Merck and
Merck and
Merck and
Pfizer
Pfizer
Pfizer
Pfizer
Pfizer
Inc.
Inc
Inc,
Inc.
Inc.
P
II'
Co.
Co.
Co.
Co.
r
ir
Upjohn Co.
Upjohn Co.
Location
Barceloneta, PR
Chicago, IL
Barceloneta, PR
North Chicago, IL
North Chicago, IL
Greenville, NC
Summit, NJ
Indianapolis, IN
Indianapolis, IN
Lafayette, IN
Clinton, IN
Albany, GA
Rahway, NJ
Barceloneta, PR
Danville, PA
Groton, CT
Groton, CT
Terre Haute, IN
Barceloneta, PR
Brooklyn, NY
Kalamazoo, MI
Barceloneta, PR
. *•* _, Report
Latitude Longitude Period
(deg-min-sec) (deg-min-sec) (year) Reference
18 25 55
42 18 03
18 25 55
42 20 00
42 20 00
35 39 39
40 43 30
39 44 30
39 46 10
40 23 26
39 44 00
31 29 54
40 37 00
18 25 30
40 57 40
41 19 57
41 19 59
39 27 07
18 26 19
40 48 30
42 12 42
18 25 43
66 33 30
87 53 14
66 33 30
87 50 12
87 50 12
77 21 33
74 22 50
86 11 04
86 09 20
86 56 05
87 23 30
84 07 55
74 16 00
66 32 30
76 38 30
72 04 44
72 04 46
87 08 25
66 34 05
73 57 42
85 33 25
66 35 06
1984
1984
1984
1984
1984
1984
1985
1985
1984
1985
1985
1984
1985 ,
6/83-6/84°
1984
1984
1984
1984
1985
1984
1984
1984
5
3
4
2
6
7
3
8
9
9
10
12
11
10
13
13
13
13
13
14
14
— p- —• - ' -^ j * • i ^d
Groton, Connecticut.
'Reported for "half of 1983 and half of 1984."
the1r two
for their two Process units
in
13-2
-------
13.2 EPISODIC EMISSIONS SUMMARY
The questionnaires collected for this source category are primarily
concerned with both annual (continuous) and episodic emissions of MC from
pharmaceutical production facilities. Reported types of episodic emissions
include: (1) pressure relief discharges, (2) equipment openings, (3) process
vent discharges, (4) accidental liquid releases, and (5) handling emissions
A total of 80,402 episodic emission events were reported by the twenty
facilities providing Section 114 responses. These events represent emiss10ns
of ,840,000 kg of MC. Reported events include: 17,084 equipment oPenlngs
62,230 process vent discharges, 1 pressure relief discharge, 11 accidental '
liquid releases, and 1,076 handling emission events. A summary of average
emission rate and duration, including ranges, is presented in Table 13-2 for
each of the five types of episodic emissions. The average emission rate and
duratlon for all 80,402 emission events are 1.54 kg/min and 163 mln
respect,vely. Maximum emission rates were reported for accidental liquid
releases, w,th an average emission rate of 21.3 kg/min, and pressure relief
dTscharges, with an average emission rate of 4.99 kg/min.
A detailed summary of episodic emission events reported in Section 114
responses is presented in Table 13-3. Data presented for each episodic event
(1) type of event (e.g., pressure relief discharges);
(2) emission source (e.g., reactor, incinerator);
(3) nature of event (e.g., process upset, start-up);
(4) the number of events per year;
(5) event duration;
(6) release height;
(7) release diameter;
(8) discharge velocity;
(9) temperature;
(10) heat capacity;
(11) emission rate; and
(12) emissions per event.
13-3
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Parameters such as velocity, heat capacity, and emission rate were calculated
based on data presented in Section 114 responses as well as physical property
data. Sample calculations for these three parameters are presented in
Appendix A. Unless otherwise noted in Table 13-3, all other parameters were
taken directly from Section 114 responses.
13.3 BACKGROUND EMISSIONS SUMMARY
Events which could not be considered episodic in nature are considered
constant/continuous and are used to supplement the episodic events by pro-
viding background emission rates. Background emissions can then be combined
with episodic emissions to determine maximum emission rates. A summary of
constant/continuous annual emissions (not reported as episodic emissions) is
presented in Table 13-4. Emission sources in Table 13-4 include fugitive
emissions (equipment leaks), storage emissions (working and breathing losses)
air emissions from secondary sources (liquid and solid waste systems), and
one process vent which was constant and continuous. Although storage'
emissions may be episodic in nature, no data are available on emission rates
and durations. Therefore, emissions from this source are presented as
constant throughout the year.
13-20
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13-21
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13.4 REFERENCES
1. Letter and attachments from Robertson, W. M., Abbott Laboratories to
Farmer, J R., EPA, April 7, 1986. Response to Section 114 lettlr on
|ong-tenn/short-term MC emissions from pharmaceutical production
2. Letter and attachments from Robertson, W. M., Abbott Laboratories *o
farmer- J- «•• EPA, April 29, 1986. Response to Section III let l*ron
faciiiUes term MC em1ss10ns frora Pharmaceutical production
3' Farmer *jd R""'™?"^ fJOB,22!!8irtSon' W' M" Abbott Laboratories, to
farmer, J R., EPA, May 5, 1986. Response to Section 114 letter nn
facil'K ~term "C em1ss1ons fr™ Pharmaceutical production
Letter and attachments from Roberts, W. M., Abbott Laboratories tn
1Farmer- J; "•• EPA, May 9, 1986. Response to Section 114 letter on
fa "" "C em1ss1ons frora Pharmaceutical production
4.
5' Farmlr ^ R"^"^ fS°m,o«er^°n' W" M" Abbott Laboratories, to
farmer, J R., EPA, May 9, 1986. Response to Section 114 letter nn
raci tenB MC era1SSi°nS fr°" P^ace'tica? iroduction
6. Letter and attachments from McGovern, J. 6., Burroughs Wellcome
--^^'
8. Better and attachments from Gelhausen, D. L., Eli Lilly and
I™*0*',EuA\May 23' 1986' Response to Section 114 letter on
long-term/short-term MC emissions from pharmaceutical product?^
9' Rf^8rnandr^ta^ents f™m ?!!hausen, D. L., Eli Lilly anc
10. Letter
13-22
-------
11. Letter and attachments from Bowers, D. P., Merck and Company, to
Farmer, J. R., EPA, February 7, 1986. Response to Section 114 letter
on long-term/short-term MC emissions from pharmaceutical production
facilities.
12. Letter and attachments from Bowers, D. P., Merck and Company, to
Farmer, J. R EPA, February 12, 1986. Response to Section 114 letter
on long-term/short-term MC emissions from pharmaceutical production
facilities.
13. Letter and attachments from Davidson, J. R., Pfizer Inc to
Beck D. EPA February 13, 1986. Response to Section 114 letter on
long-term/short-term MC emissions from pharmaceutical production
I a d I I ll-lPV
14. Letter and attachments from Knox, S. J., The Upjohn Company, to
Farmer, J. R EPA January 31, 1986. Response to Section 114 letter
on long-term/short-term MC emissions from pharmaceutical production
15. Memorandum from Pandullo, R., Nash, R., and P. Murphy, Radian
Corporation, to Methylene Chloride File, September 17, 1986. Estimates
of Potentially Hazardous Compound Emissions from Pharmaceutical
Facilities and Emission Reductions Achievable with Additional Controls.
13-23
-------
-------
14.0 CHLOROFLUOROCARBON PRODUCTION
This section summarizes the available data for episodic and continuous
emissions of carbon tetrachloride (CT), chloroform (CF), and perchloroethylene
(PCE) from chlorofluorocarbon (CFC) production facilities.
14.1 DESCRIPTION OF DATA SOURCES
Carbon tetrachloride, CF, and PCE are feedstocks for the production of
CFC's. By the authority of Section 114 of the Clean Air Act, EPA collected
emissions data from five companies representing eleven facilities that
produce CFC. The three pollutants of concern for this source category are
CT, CF, and PCE. Chlorofluorocarbon emissions data were obtained with
long-term/short-term questionnaires, sent out in October 1985, while CT and
PCE emissions data were obtained with the long-term type questionnaires sent
out in November 1984. These data were summarized in a memorandum entitled,
"Estimates of Carbon Tetrachloride, Chloroform, and Perchloroethylene
Emissions from Chlorofluorocarbon Production Facilities and Emissions
Reduction Achievable with Additional Control."
Table 14-1 lists the facilities which supplied emissions data. This
table also includes geographic data such as latitude and longitude, as well
as the period of time represented by the reported emissions data. Section }M
responses from two facilities, Essex and Penwalt, were reported as being
confidential. Of the nine nonconfidential responses, two facilities are
located in California, two are located in Louisiana, two are located in
New Jersey and the remaining three facilities are located in Illinois,
Kentucky, and Michigan.
14.2 EPISODIC EMISSIONS SUMMARY
The questionnaires collected for this source category are primarily
concerned with annual (continuous) emissions of CT, CF, and PCE. However
certain types of events included in the questionnaires are considered
episodic emissions. These types of emissions include: (1) equipment
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openings, (2) process vent discharges, and (3) handling emissions. A total
of 225 episodic emission events were reported by the nine facilities
providing nonconfidential Section 114 responses. These events represent
emissions of 32.7 kg of PCE, 2,320 kg of CT, and 4,260 kg of CF. Reported
events include: 132 equipment openings, 1 process vent discharge, and 92
handling emissions. A summary of average emission rate and duration,
including ranges, is presented in Table 14-2 for each of the three types of
episodic emissions. The average emission rates and duration for all 225
emission events are 0.532 kg/min and 277 min, respectively. Maximum emission
rates were reported for equipment openings, with an average emission rate of
0.696 kg/min.
A detailed summary of episodic emission events reported in Section 114
responses is presented in Table 14-3. Data presented for each episodic event
include:
(1) type of event (e.g., pressure relief discharge);
(2) emission source (e.g., reactor, incinerator);
(3) nature of event (e.g., process upset, start-up);
(4) the number of events per year;
(5) event duration;
(6) release height;
(7) release diameter;
(8) discharge velocity;
(9) temperature;
(10) heat capacity;
(11) emission rate; and
(12) emissions per event.
Parameters such as velocity, heat capacity, and emission rate were calculated
based on data presented in Section 114 responses as well as physical property
data. Sample calculations for these three parameters are presented in
Appendix A. Unless otherwise noted in Table 14-3, all other parameters were
taken directly from Section 114 responses.
14-3
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14.3 BACKGROUND EMISSIONS SUMMARY
Events which are not episodic in nature are considered background
emissions. Background emissions were combined with episodic emissions to
determine peak emission rates. A summary of these constant/continuous
emissions not reported as episodic emissions is presented in Table 14-4
Emission sources in Table 14-4 include fugitive emissions (equipment leaks)
storage emissions (working and breathing losses), air emissions from
secondary sources (liquid and solid waste systems), and handling emissions
These emissions are assumed to be constant over 365 days per year. Although
storage and handling emissions may be episodic in nature, no data are
available on emission rates and durations. Therefore, emissions from these
sources are also presented as constant throughout the year.
14-7
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14.4 REFERENCES
2.
3.
''
on long-term Cl
Letter and attachments from
short-tern, CF eissions
on
long-tern, CT
E" A111ed
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114
f«l«.
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SAMPLE CALCULATION
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A. 5 ACCIDENTAL LIQUID RELEAS
gas release of ethylene dichloride from the Formosa Plastics Corporation
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-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA 45Q/3-87-Q16
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
EPISODIC EMISSIONS DATA SUMMARY
5. REPORT DATE
June 1987
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
R. H. Howie, R. A.
Radian Corporation
Nash
8. PERFORMING ORGANIZATION REPORT NO.
87-231-020-17-30
9. PERFORMING ORGANIZATION NAME AND ADDRESS
10. PROGRAM ELEMENT NO.
Radian Corporation
Post Office Box 13,000
Research Trianale Park, NC
27709
11. CONTRACT/GRANT NO.
EPA Contract 68-02-5816
12, SPONSORING AGENCY NAME AND ADDRESS
U.S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Emission Standards and Engineering Division
Chemicals and Petroleum Branch - RTP, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
March 1987- June 1987
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
This report presents a complete summary of episodic emissions data collected by
the Environmental Protection Agency (EPA) under the authority of Section 114 of the
Clean Air Act (CAA). Episodic emissions data were collected for the production and
use of nine potentially hazardous organic compounds: methylene chloride (MC), carbon
tetrachloride (CT), chloroform (CF), perchloroethylene (PCE), trichloroethylene (TCE)
ethylene dichloride (EDC), butadiene (BD), ethylene oxide (EO), and epichlorohydrin
(EPI). These chemicals and data are reported in 13 source categories that best
describe the scope of use of these chemicals.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATi Meld/Group
Butadiene
Carbon Tetrachloride
Chloroform
Ethylene Dichloride
Epichlorohydrin
Episodic Emissions
Ethylene Oxide
Methylene Chloride
Perchloroethylene
Short-term
Emissions
Trichloroethylene
Air Pollution
Hazardous Organic
Compounds
Episodic Emissions
8. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 (R.v. 4-77)
PREVIOUS EDITION IS OBSOLETE
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