United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EPA-453/D-93-056
September 1992
Air
SEPA Guideline Series
Control of Volatile
Organic Compound
Emissions from
Industrial
Wastewater
DRAFT DOCUMENT
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DRAFT
This document has not been formally released by EPA and should not now be
construed to represent Agency policy. It is being circulated for comment on its
technical accuracy. Mention of trade names or commercial products is not
intended to constitute endorsement or recommendation for use.
Guideline Series
Control of Volatile Organic
Compound Emissions from
Industrial Wastewater
DRAFT DOCUMENT
Emission Standards Division
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Radiation
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
• September 1992
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OAQPS GUIDELINES SERIES
The guideline series of reports is issued by the Emission
Standards Division, office of Air Quality Planning and
Standards, U. S, Environmental Protection Agency, to provide
information to state and local air pollution control agencies;
for example, to provide guidance on the acquisition and
processing of air quality data and on the planning and
analysis requisite for the maintenance of air quality.
Reports published in this series will be available - as
supplies permit - from the Library Services Office (MD-35),
U. S. Environmental Protection 'Agency, Research Triangle Park,
North Carolina 27711, phone number (919) 541-2777.
11
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TABLE OF CONTENTS
Section ' ' . Page
List of Tables vii
List of Figures . ix
1.0 INTRODUCTION .................. 1-1
1.1 References . 1-5
2.0 INDUSTRY DESCRIPTIONS ............... 2-1
2.1 Organic Chemicals, Plastics, and Synthetic
Fibers Manufacturing Industry . . 2-4
2.2 Pesticides Manufacturing Industry ..... 2-8
2.3 Petroleum Refining Industry 2-10
2.4 Pharmaceuticals Manufacturing Industry . . .2-13
2.5 Hazardous Waste Treatment, Storage, and
Disposal Facilities Industry . . . . . . . . 2-15
2.6 Pulp, Paper and Paper-board and Builders'
Paper and Board Mills Industry 2-18
2.7 References . . . . . . . . . . 2-23
3 .0 VOLATILE ORGANIC COMPOUND EMISSIONS DURING
WASTEWATER COLLECTION AND TREATMENT ....... 3-1
3.1 Sources of Organic Compound-Containing
Wastewater 3-1
3.1.1 Direct Contact Wastewater . . . . . 3-2
3.1.2 Indirect Contact Wastewater .... 3-2
3.2 Sources of Air Emissions .......... 3-3
3.2.1 Drains ... . . 3-3
3.2.2 Manholes 3-5
3.2.3 Junction Boxes 3-6
3.2.4 Lift Stations . . .' -. ....... 3-7
3.2.5 Trenches .............. 3-8
3.2.6 Sumps 3-9
3.2.7 Weirs 3-9
3.2.8 Oil/Water Separators . 3-10
3.2.9 Equalization Basins . 3-11
3.2.10 Clarifiers . , 3-12
3,2.11 Aeration Basins . . , . 3-12
3.2.12 Treatment Tanks ..... 3-13
3.2.13 Surface Impoundments ... 3-14
3.3 Volatile Organic Compound Emission
Estimation . ....... . . . . . . . . ... . . 3-14
3.4 References ....... .... 3-17
ixi
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TABLE OF CONTENTS
(continued).
Section • Page
4.0 VOLATILE ORGANIC COMPOUND EMISSION CONTROL
TECHNIQUES . . . . ' . ' . . . ' •.'.".*.' 4-1
4.1 Waste Minimization 4-2
4.1.1 Gather Baseline Data 4-2
4.1.2 Identify and Rank Sources
for Reduction 4-2
4.1.3 Implementation of Reduction/
Recycling 4-3
4.2 Organic Compound Treatment Technologies . . 4-3
4.2.1- Steam Stripping . . 4-3
4.2.2 Air Stripping 4-14
4.2.3 Biological Organic Compound
Destruction Technology ....... 4-16
4.2.4 Other Organic Compound
Removal Technologies' ........ 4-19
4.3 Volatile Organic Compound Emission
Suppression from Collection and Treatment
System Components ............. 4-21
4.3.1 Collection System Controls . . . . . 4-21
4.3,2 Roofs 4-22
4.3.3 Floating Membrane Covers 4-24
4.3.4 Air-Supported Structures 4-25
4.4 Add-On Controls 4-26
4.4.1 Carbon Adsorbers 4-26
4.4.2 Thermal Vapor Incinerators . . . . . 4-28
4.4.3 Combination Adsorption—Incineration 4-29
4.4.4 Catalytic Vapor Incinerators .... 4-31
4.4.5 Flares ..... 4-32
4.4.6 Boilers and Process Heaters ..... 4-32
4.4.7 Condensers . . 4-33
4.5 References 4-34
5.0 CONTROL COST, ENVIRONMENTAL, AND ENERGY IMPACT
ANALYSES OF TREATMENT BY STEAM STRIPPING .... 5-1
5.1 Steam Stripper System Costs '. 5-1
5.1.1 Basis for Capital Costs 5-1
5.1.2 Basis for Annualized Costs ..... 5-11
5.2 Environmental and Energy Impacts
of Steam Stripping 5-17
5.2.1 Primary Air Pollution Impacts—
Volatile organic Compound Emission
Impacts ..... . 5-17
5.2.2 Secondary Air Pollution Impacts . . . 5-19
iv
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TABLE OF CONTENTS"
(continued)
Section . ' Page
5.2.3 Other Impacts \ 5-22
5.3 References . ... . . » . . . • ' • • .' • . . 5-27
6.0 SELECTION OF REASONABLY AVAILABLE CONTROL
TECHNOLOGY . . ... . . . .'.'.-.' . . 6-1
6.1 Background ... . . . . , . 6-1
6.2 Reasonably Available Control Technology
Options and Impacts ..... 6-3
6.2.1 Reasonably Available Control
Technology Options Formats . . . . . 6-4
6.2.2 Reasonably Available Control
Technology Options Impacts . . . . . 6-6
6.3 Selection of Reasonably Available Control
Technology ....... . 6-8
6.4 References ...... 6-9
7 . 0 REASONABLY AVAILABLE CONTROL TECHNOLOGY
IMPLEMENTATION ....... ...» 7-1
7.1 Introduction ...... ..... 7-1
7.2 Definitions . 7-1
7.3 Applicability ... . . . . . 7-4
7.3.1 Applicability Criteria . 7-5
7.4 Format of the Standards .......... 7-6
7.4,1 Emission Suppression from
Wastewater Collection . 7-6
7.4.2 Wastewater Treatment to Reduce
Volatile Organic Content ...... 7-7
7.4.3 Treatment of Residuals ....... 7-11
7.5 Performance Testing . 7-11
7.5.1 Wastewater Collection ....... .7-12
7.5.2 Wastewater Treatment ........ 7-12
. 7.5.3 Treatment of Residual Vapors from ,
Wastewater Collection and
Treatment Systems . ., . . . . ... . 7-12
7.6 Monitoring Requirements ..... 7-13
7.6.1 Wastewater Collection . . . . . . . . 7-13
7.6.2 Wastewater Treatment .7-13
7.6.3 Treatment of Residual Vapors from
Wastewater Collection and
Treatment Systems 7-14
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TABLE OF CONTENTS
(continued)
Section Page
7.7 Reporting/Recordkeeping Requirements .... 7-14
7.8 Relationships to Title III (Section 112)
of the Clean Air Act Amendments . 7-15
APPENDIX A: Model Rule A-l
APPENDIX B: National Impacts Analysis ..... B-l
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. . ' . . LIST,OF TABLES •
Table ' . . . Page
2-1 WASTEWATER GENERATION BY INDUSTRY . . . . . . . . 2-3
2-2 DISTRIBUTION OF AFFECTED INDUSTRIAL CATEGORIES
IN AREAS OF OZONE NONATTAINMENT . . . . . . . . . 2-5
2-3 GENERIC CHEMICAL PROCESSES . .... . . , . . . . . . 2-7
2-4 VOLATILE ORGANIC COMPOUND (VOC) LOADING IN
SOCMI WASTEWATIR STREAMS . . ... . , . . . . . 2-11
2-5 HAZARDOUS WASTE TREATMENT, STORAGE, AND
DISPOSAL FACILITIES INDUSTRY CHARACTERIZATION .. . 2-17
2-6 MILL POPULATION . . 2-20
3-1 EMISSION SOURCES IN WASTEWATER COLLECTION
AND TREATMENT SYSTEMS . 3-4
4-1 DESIGN AND OPERATING BASIS FOR THE
STEAM STRIPPING SYSTEM ............. 4-6
4-2 STEAM STRIPPER ORGANIC COMPOUND
REMOVAL PERFORMANCE 4-11
5-1 EQUIPMENT COST EQUATIONS FOR. A ... ...
STEAM STRIPPING UNIT . . . . ... . . . . . . . 5-5
5-2 ESTIMATION OF BASIC EQUIPMENT COST FOR A
STEAM STRIPPING UNIT . . . 5-7
5-3 ESTIMATION OF TOTAL CAPITAL INVESTMENT FOR A
STEAM STRIPPING UNIT 5-9
5-4 ESTIMATION OF TOTAL ANNUAL COST FOR A
STEAM STRIPPING UNIT .............. 5-12
5-5 VOLATILE ORGANIC COMPOUND EMISSION REDUCTION
FOR STEAM STRIPPING 5-20
5-6 COMBUSTION POLLUTANT EMISSION FACTORS FOR
STEAM GENERATION ....... 1 ' 5-21
5-7 SECONDARY AIR POLLUTION IMPACTS OF EXAMPLE
WASTEWATER STREAM 5-23
5-8 ANNUAL FUEL USE FOR STEAM GENERATION FOR
STEAM STRIPPER CONTROL OF EXAMPLE
WASTEWATER STREAM ..... ..... 5-26
VI i
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LIST OF TABLES
(Continued)
.Table Page
6-1 TOTAL INDUSTRY RACT NATIONAL IMPACTS ...... 6-7
7-1 VOLATILE ORGANICS STRIPPABILITY GROUPS AND
TARGET REMOVAL EFFICIENCIES ".".".*.'.' 7-9
Vlll
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LIST OF FIGURES
.Figure . . . . Page
4-1 Continuous steam stripper system ........ 4-5
4-2 Predicted steam stripper organic compound
removal efficiencies based on -log Henry's Law
constant for the compound at 25 °C . . . . . . . 4-13
4-3 Continuous air stripper system . 4-15
4-4 Combination carbon adsorption - thermal
incineration system 4-30
5-1 Summary of total capital investment versus
wastewater .feed rate for steam stripping unit . . 5-10
5-2 Total annual cost versus wastewater feed rate
for steam stripping unit 5-16
5-3 Unit operating costs versus wastewater feed rate
for steam stripping unit 5-18
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1.0 INTRODUCTION
The Clean Air Act (CAA) Amendments of 1990 require that
State implementation plans (SIP's) for certain ozone
nonattainment areas be revised to require the implementation
of reasonably available control technology (RACT) for control
of volatile organic compound (VOC) emissions from sources for
which control techniques guidelines (CTG's} have already been
published or for which a CTG document will be published
between the date of enactment of the Amendments and the date
on which an area achieves attainment status.
Section 182(b)(2). Section 172(c)(1) of the CAA requires
nonattainment area SIP's to provide, at a minimum, for
"...such reductions in emissions from existing sources in the
area as may be obtained through the adoption, at a minimum, of
reasonably available control technology,.." As a starting
point for ensuring that these SIP's provide for the required
emission reduction, the Agency, in a Federal Register notice
(44 FR 53761, September 17, 1979)l defines RACT as: "The
lowest emission limitation that a particular source is capable
of meeting by the application of control technology that is
reasonably available considering technological and economic
feasibility." Subsequent Federal Register notices elaborate
on how States and the Agency should apply the RACT
requirements (53 FR 45103, November 8, 1988}2.
The CTG's. are intended to provide State and local air
pollution authorities with an information base for proceeding
with their own analyses of RACT to meet statutory
requirements. The CTG's review current knowledge and data
concerning the technology and costs of various emissions
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control techniques. Each CTG contains a "presumptive norm"
for RACT for a specific source category, based on the Agency's
evaluation of the capabilities and problems general to that
category. Where applicable, the Agency recommends that States
adopt requirements consistent with the presumptive norm.
However, the presumptive norm is only a recommendation.
States may choose to develop their own RACT requirements on a
case-by-case basis, considering the economic and technical
circumstances of an individual source. It should be noted
that no laws or regulations preclude States from requiring
more control than recommended as the presumptive norm for
RACT. A particular State, for example, may need a more
stringent level of control in order to meet the ozone standard
or to reduce emissions of a specific toxic air pollutant.
This CTG is 1 of at least 11 that the Agency is required
to publish within 3 years of enactment of the CAA Amendments.
Section 183(a). It addresses RACT for control of VOC
emissions from the collection and treatment of industrial
wastewater from: the organic chemicals, plastics, and
synthetic fibers (OCPSF) industry? the pesticides
manufacturing industry; the Pharmaceuticals manufacturing
industry; and the hazardous waste treatment, storage, and
disposal facilities (TSDF) industry. The CTG also contains
information on two other industries: the pulp and paper, and
petroleum refining industry, but does not recommend RACT for
these industries due to other regulatory actions (i.e., MACT
standards) that will address them.
Based on information collected by the Agency, facilities
within each of these industries have the potential to generate
wastewaters containing high concentrations of volatile organic
compounds. These wastewaters typically pass through a series
of collection and primary treatment units before treatment is
applied to remove a portion of the volatile organics. Many of
these collection and treatment units are open to the
atmosphere and allow wastewaters containing volatile organics
to contact ambient air. Atmospheric exposure of these
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organic-containing wastewaters results in significant
volatilization of VOC's from the wastewater.
These emissions can be reduced by applying control at the
point of generation of the wastewater, before the stream
contacts ambient air. One effective strategy is to apply
waste minimization techniques to reduce the volatile organic
loading of the wastewaters, or to produce a more manageable
waste stream through.waste segregation or recycling. However,
even with waste minimization, some waste streams will be
generated. Emissions from these streams can be reduced by
controlling the wastewater streams from the point of
generation to a controlled treatment system.
This control approach is consistent with existing and
upcoming regulations affecting the wastewaters generated
within these industries, including the Office of Water's
Effluent Guidelines for the OCPSF, Pesticides, and
Pharmaceuticals industries; The Resource Conservation and
Recovery Act (RCRA) Air Emission Standards affecting TSDF
facilities; and other air emission control requirements
affecting these industries. Existing and future effluent
guidelines for these industries require treatment of the
wastewater to ensure that concentrations of specific priority
pollutants in the combined wastewater stream exiting the
facility do not exceed established limits. While these
concentration limits for volatile organic compounds are based
on the performance capability of steam stripping, the limits
do not require control of air emissions during the collection
and treatment of these wastewaters. Although the RCRA air
emission standards for TSOF specifically address air emissions
from wastewater, this rule is limited in scope to include
hazardous waste managed in units subject to permitting
requirements of Subtitle C of RCRA. RCRA Subtitle D surface
impoundments would not be covered by this rule.
In addition to these rules, there are existing and
upcoming air regulations which affect the wastewaters
generated within these industries. These regulations include
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the "Benzene Waste Operations National Emission Standards for
Hazardous Air Pollutants (NESHAP)" (55 FR 8292)3, promulgated
in March 1990, and the Hazardous Organic NESHAP (HON). The
Benzene NESHAP requires control of benzene-containing
wastewater streams generated by chemical manufacturing plants;
coke by-product recovery plants; petroleum refineries; and
facilities that treat, store, or dispose of wastes generated
within these industries. The HON will require the application
of maximum achievable control technology (MACT) to control
hazardous air pollutant (HAP) emissions from wastewaters
generated in the synthetic organic chemical manufacturing
industry (SOCMI), which is a subset of the OCPSF industry.
Other MACT standards will be developed to address wastewaters
generated by the remainder of the OCPSF industry, pesticides,
Pharmaceuticals, and TSDF industries. However, these
standards will only address HAP emissions and not total VOC
emissions.
The industries that are included in this CTG have
wastewater streams which contain large amounts of HAP.
Because most organic HAP are also VOC and other VOC often
would also be found in the HAP-containing streams, the MACT
standards will achieve some control of VOC emissions. For
most industries, however, many VOC-containing wastewaters do
not contain HAP and therefore, controlling only HAP-containing
streams, as would be required under a MACT standard, would not
substantially reduce VOC emissions. This would, in general,
indicate that there is a need for both MACT standards to
regulate HAP emissions and a CTG to control non-HAP VOC
emissions in nonattainment areas. For the pulp and paper and
petroleum refining industries, however, the Agency presently
believes that wastewater streams that contain non-HAP VOC also
contain a substantial amount of HAP. Therefore, the MACT
standards for these industries will substantially reduce VOC
emissions. For this reason, the recommended RACT outlined in
the CTG is not suggested for the pulp and paper and petroleum
refining industries. It should also be noted that the control
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alternatives and exclusions presented in this document will
provide for consistency in application of control strategies
to meet the various regulations.
Because the HON has not yet been proposed and is still
undergoing revision, there may be some inconsistencies between
this document and the HON; however, any revisions to the HON
will be incorporated into the final CTG. Several changes have
already been made to the HON. One of the changes is in
relation to the strippability groups A - E. The HON has
grouped compounds into 5 groups depending on the compounds'
strippability. Presently the Agency has decided to eliminate
requirements for control of group D and I compounds from the
draft proposed HON regulation which equates to groups IV and V
in this draft CTG document. The Agency has also revised the
Henry's Law constants used in the HON. The revision of the
Henry's Law constants will effect the fraction emitted (Fe) ,
fraction removed (Fr), and fraction measured (Fm) used in the
equations. Also the calculation of uncontrolled emissions is
being altered. Other changes to the HON under consideration
include changes to the wastewater collection and treatment
scenarios and adjustments to the wastewater emission estimate
models. Although certain changes have been implemented for
the HON/ the impacts shown for the draft CTG do not reflect
these changes for several reasons. Elimination of
strippability groups IV and V will not appreciably change the
emission reductions or cost effectiveness numbers, and would
not be anticipated to affect the selection of draft RACT. As
previously mentioned, the HON is still in a state of flux with
various changes being considered. Lastly, timing is a
consideration because publishing this draft CTG in the same
time period as the proposal of the HON would provide source
owners and operators the opportunity to review and comment on
the interrelationship of the two. This would also put the HON
and CTG on the same schedule to be finalized which would be
helpful to sources when developing their control strategies.
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The organization of this document is as follows. A
description of the industries covered by this document is
presented in Chapter 2.0. The sources of organic-containing
wastewater, sources of VOC air emissions, and model wastewater
streams are identified in Chapter 3.0. Available VOC emission
control strategies and control costs associated with the
recommended treatment technologies are presented in
Chapters 4.0 and 5.0, respectively. A description of RACT and
guidance to the States on implementation of RACT are presented
in Chapters 6.0 and 7.0, respectively.
A more detailed discussion of information on sources of
VOC air emissions, available VOC emission control
technologies, and calculation of emissions from example
sources can be found in a document generated by the Control
Technology Center (CTC) entitled "Industrial Wastewater
Volatile Organic Compound Emissions—Background Information
for BACT/LAER Determinations" (EPA 450/3-90-004, January
1990),* hereafter referred to as the Wastewater CTC Document.
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1.1 REFERENCES
1. Federal Register. State Implementation Plans; General
Preamble for Proposed Rulemaking on Approval of Plan
Revisions for Nonattainment Areas-Supplement (On Control
Techniques Guidelines) 44 FR 53761 to 53763.
September 17, 1979.
2. .federal'Register. Approval and Promulgation of
Implementation Plan; Illinois. 53 FR 45103 to 45111.
November 8, 1988.
3. Federal Register. National Emission Standards for
Hazardous Air Pollutants; Benzene Emissions From Chemical
Manufacturing Process Vents, Industrial Solvent Use,
Benzene Waste Operations, Benzene Transfer Operations, and
Gasoline Marketing System. 55 FR 8292 to 8361. March 7,
1990. .
4. Office of Air Quality Planning and Standards,
U. S. Environmental Protection Agency. Research Triangle
Park, North Carolina. Industrial Wastewater Volatile ,
Organic Compound Emissions—Background Information for
BACT/LAER Determinations. EPA 450/3-90-004. January
1990.
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2.0 INDUSTRY DESCRIPTIONS
This control techniques guideline (CTG) document applies
to the industrial wastewater generated in areas that are
considered nonattainment areas for ozone within the following
industries: :- • .
* The organic chemicals, plastics, and synthetic fibers
(OCPSF) industry;
•* The pesticides manufacturing industry;
' The Pharmaceuticals manufacturing industry;
•^ The hazardous waste treatment, storage, and disposal
facilities (TSDF) industry;
** The petroleum refining industry; and
' The pulp, paper, and paperboard and builders paper and
board mills industry (pulp and paper industry).
This document describes all six industries. However, only the
first four industries listed above are utilized for
determining RACT. The rationale for excluding the pulp and
paper and petroleum refining industries for determining RACT
is presented in Chapter 6.0. This chapter contains
information on wastewater streams generated by these six
industries. The industry descriptions and wastewater
characteristics presented in this chapter reflect data
collected by the Agency on volatile organic compound (VOC)
emissions from industrial wastewater and work performed by the
Agency either to develop effluent guidelines or to evaluate
the need to develop effluent guidelines.
Each of the six industries listed above generates large
quantities of wastewater containing organics. Although most
of the wastewater contains less than 1 percent (10,000 parts
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per million by weight [ppmw]) of total organics, this is a
potentially significant source of emissions because of the
large quantities of wastewater generated. These six
industries are included together in this document because the
organic content of the wastewater is similar. Additionally,
the wastewater collection and treatment systems are similar
across the six affected industries.
Table 2-1 presents estimates of the number of facilities
and the quantities of wastewater generated by each industry.
Based on information gathered by the Agency in developing
effluent guideline limitations, there were approximately
466 pharmaceutical, 119 pesticide, 1,000 OCPSF, and 1,909 TSDF
facilities in 1982. The Oil and Gas Journal Annual Refining
Survey reported that there were 190 operating refineries in
the United States in 1990.u Facilities in these five
industries produced approximately 4.2 billion liters
(1.1 billion gallons) of wastewater per day. Approximately
695 pulp and paper facilities were identified in 1982. These
facilities produce approximately 7.4 billion liters (2 billion
gallons) of wastewater per day.
In some cases, two or more industrial categories may be
located within the same facility. For example, an OCPSF
facility which produces petrochemicals may be located within a
petroleum refinery.
Based on available flow and concentration data, the
quantity of VOC in wastewater generated by each of these six
industries is considered significant. In addition, based on
the available information, similar controls are applicable for
sources within each industry. In all cases, controls should
be applied as close to the point of generation as possible in
the process, or before the wastewater stream contacts ambient
air. By applying the controls as close to the point of
generation as possible, the stream can be controlled before it
contacts the atmosphere, and emits VOC's to the atmosphere or
before the stream is diluted with other wastewater streams.
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TABLE 2-1. WASTEWATER GENERATION BY INDUSTRY-
Industry
OCPSF _' " . ;
Pesticides manufacturing
Petroleum refining
Pharmaceutical manufacturing
Hazardous waste TSDF
Pulp and paper
TOTAL
Total number
of facilities
(1982)
1,0.00
119
190b
466
1,909
603d
4,287
Daily
wastewater
generation
(Mgal/d)a
527
<100
422
82
160'
1,946
3,093
aMgal/d = Million gallons per day.
bBased on a 1990 inventory of operating refineries
(Reference 11).
cRepresents wastewater generated by the TSDF category
as landfill leachate.
1989 estimate (Ref. 6).
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Steam stripping is a control technology that is applied
throughout these industries. For example, the organic limits
for the OCPSF industry effluent limitations are based on
effluent levels that can be achieved by steam stripping.12
Additionally, new guidelines for pesticides and TSDF
facilities, revisions to existing guidelines for OCPSF and
Pharmaceuticals industries, and review of existing guidelines
for the petroleum refining industry are all expected to be
similarly based. Plans for reviewing and revising existing
effluent guidelines and promulgating new effluent guidelines
were announced January 2, 1990 in the Federal Register
(55 FR 80, January 2, 1990)."
. The following sections discuss each of the six industries
included in this document in terms of the approximate number
of facilities and the number of processes or products, and
quantities and characteristics of wastewater generated by
facilities in these industries. The distribution of each of
the six affected industrial categories in areas of ozone
nonattainment is summarized in Table 2-2.
2.1 ORGANIC CHEMICALS, PLASTICS, AND SYNTHETIC FIBERS
MANUFACTURING INDUSTRY
Approximately 1,000 facilities are included in the OCPSF
industry, defined as all facilities falling under the
following standard industrial classification (SIC) codes:
2821 Plastics Materials, Synthetic Resins, and
Nonvu1canizable Elastomers;
2823 Cellulosic Manmade Fibers;
2824 Synthetic Organic Fibers, except Cellulosic;
2865 Cyclic Crudes and Cyclic Intermediates, Dyes, and
Organic Pigments; and
2869 Industrial Organic Chemicals, Not Elsewhere
Classified.
Approximately 43 percent of the OCPSF facilities are located
in areas of nonattainment.
The OCPSF industry includes a diversity of chemical
processes producing a large number of chemical products. Some
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TABLE 2-2. DISTRIBUTION OF AFFECTED INDUSTRIAL CATEGORIES
IN AREAS OF OZONE NONATTAINMENT
\ Affected Industry Percent (%) nonattainment14
OCPSF 43
Pesticides manufacturing 36
Petroleum refining 52
Pharmaceutical manufacturing 57
Hazardous waste TSDF 43
Pulp and paper 43
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facilities within these industrial categories produce large
volumes of a single product continuously while other
facilities may produce various specialty products in short
campaigns. However, despite the diversity of this industry,
the Agency has determined that 98 percent of all products
manufactured are produced by one of 41 major generic
processes. These processes are listed in Table 2-3.
The OCPSF industry generates about 530 Mgal/d of
wastewater. Most of the wastewater collection systems at
facilities in the OCPSF industry are underground sewers. Very
few wastewater streams are transported in overhead pipes. In
addition, in some facilities, vigorous aeration of the
wastewater (which can cause high VOC emissions) prior to
biological treatment is used to improve the biological
activity. Based on Office of Air Quality Planning and
Standards (OAQPS) visits to several facilities in the OCPSF
industry, significant potential exists in this industry for
emissions of VOC's from wastewater.
Model streams representing the OCPSF industry were
developed from responses to a CAA Section 114 survey of the
synthetic organic chemical manufacturing industry (SOCMI).
These model streams are used to represent the OCPSF industry
because SOCMI is a subset of the OCPSF industry, the processes
generating wastewater in SOCMI are the same or similar to the
processes in the rest of the OCPSF industry, and the same
volatile chemicals are used.
Under authority of Section 114 of the Clean Air Act (CAA)
Amendments of 1990, facilities within nine corporations were
asked to complete questionnaires that requested information on
wastewater streams from SOCMI product processes. Facilities
provided information on the flow rate and concentration of
individual hazardous air pollutants (HAP's) and total VOC's in
each wastewater stream. These responses provided sufficient
information to allow the characterization of flow rate, VO
concentration, and emission potential and strippability of
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TABLE 2-3. GENERIC CHEMICAL PROCESSES3
1. Acid Cleavage 22.
2. Alkoxylation 23.
3. Alkylation 24.
4. Amination 25.
5. Annnonolysis 26,
6. Ammoxidatioii 27.
7. Carbonylation 28.
8. Chlorohydrlnation 29.
9. Condensation 30.
10. Cracking 31.
11. Crystallization/Distillation 32.
12. Cyanation/Hydrocyanation 33.
13. Dehydration 34.
14. Dehydrogenation 35.
15. Dehydrohalogenation 36.
16. Distillation 37.
17. Electrohydrodimerization 38.
18. Epoxidation 39.
19. Esterification 40.
20. Etherification 41 *
21. Extraction
Extractive Distillation
Fiber Production
Halogenation
Hydration
Hydroacetylation
Hydrodealkylation
Hydrogenation
Hydrohalogenation
Hydrolysis
Isomerization
Neutralization
Nitration
Oxidation
Oximation
Oxyha1ogenation
Peroxidation
Phosgenation
Polymerization
Pyrolysis
Sulfonation
aReference 1.
2-7
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individual wastewater streams from the processes. Additional
details regarding development of the OCPSF model streams may
be found in Appendix B.
Responses to a March 1990 CAA Section 114 survey of SOCMI
facilities indicate that concentrations of organic compounds
are highly variable in process wastewater generated by SOCMI
facilities. Although concentrations for different organic
compounds are highly variable, the data indicate that a small
number of wastewater streams contribute the majority of the
organic compounds in the wastewater. The organic compound
mass loading was computed for each process wastewater stream
where data were ..available from, facility responses to the CAA
Section 114 information requests, and a total organic quantity
representing all the reported streams was determined by
summing the organic quantities computed for each individual
wastewater stream. Based on these data, approximately
20 percent of the individual wastewater streams were found to
account for more than 95 percent of the organics by mass.1
Although wastewaters generated in the OCPSF industry may
contain moderate levels of oil and grease or suspended solids,
steam stripping has been demonstrated as a technically
feasible control for treating the wastewater streams generated
by OCPSF facilities.
2.2 PESTICIDES MANUFACTURING INDUSTRY
The pesticides manufacturing industry provides a wide
range of chemicals used to control crop-destroying insects and
undesirable vegetation. This document covers the segment of
the pesticide industry that manufactures the active
ingredients in pesticide chemicals. One hundred nineteen such
plants were identified in development of the 1985 effluent
standards (50 FR 40674, October 4, 1985).16 These plants
produce pesticide products covered under SIC code 2879:
Pesticides and Agricultural Chemicals, Not Elsewhere
Classified. Approximately 36 percent of the pesticides
manufacturing facilities are located in areas of ozone
nonattainment.
2-8
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The volume of wastewater discharged by facilities in this
industry ranges from less than 10,000 gallons per day to
1 Mgal/d, with over half the facilities in the industry
generating less than 10,000 gallons per day. Discharge
methods vary from plant to plant and one method or a
combination of methods may be used.
A variety of organic compounds have been detected in
pesticides industry wastewater streams. These include:
phenols, aromatics, halomethanes, chlorinated ethanes,
nitrosamines, dienes, cyanides, and pesticide compounds.
Sampling data generated during the development of effluent
guidelines on organic concentrations for the industry include
organic priority pollutant and active ingredient concentration
data. Priority pollutants are defined by a list of
126 compounds specified by the Office of Water as an outgrowth
of a 1976 consent decree. High concentrations of halomethanes
and chlorinated ethanes were detected in the pesticide plant
wastewaters. The organic compounds detected in the
wastewaters are used as solvents and raw materials or occur as
impurities or byproducts. The sources and characteristics of
wastewaters generated by pesticide manufacturing facilities
are expected to be similar to those in the OCPSF industry.
Steam stripping of wastewaters generated by facilities in
the pesticides industry has been demonstrated as a technically
feasible control. This fact is supported by detailed
information provided on 10 steam strippers in use at
pesticides industry plants in the Development Document for
Effluent Limitations Guidelines and Standards for the
Pesticide Point Source Category.3
Model streams representing the pesticides manufacturing
industry were developed from a 1989 Section 308 survey
conducted under authority of the Clean Water Act by the Office
of Water Regulations and Standards (OWRS). In the survey,
OWRS collected information on wastewater flow rates and VOC
concentrations.
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A total of 13 responses provided sufficient information
to allow the characterization of wastewater flow rate, VOC
concentration, and strippability. However, the available data
did not present flows and concentrations for individual
wastewater streams within each process unit. Instead, data
are presented for the combined process unit effluent.
Therefore, combined process unit effluent streams were
disaggregated into individual streams. The disaggregation of
combined effluent streams is based on the VOC loading
distribution determined from the Section 114 survey of SOCMI.15
Table 2-4 presents this loading distribution. Additional
details regarding development of the pesticides manufacturing
industry model streams may be found in Appendix B.
2.3 PETROLEUM REFINING INDUSTRY
In 1990, there were approximately 190 petroleum
refineries operating in the United States.11 These facilities
are defined by SIC code 2911 as primarily engaged in the
production of hydrocarbon materials by the distillation of
crude petroleum and its fractional products. These refineries
are distributed among 35 States, with approximately 40 percent
of the refineries and over half of the total U. S. crude
refining capacity located in Texas, California, and Louisiana.
Approximately 52 percent of the petroleum refining facilities
are located in areas of ozone nonattainment.
The refining process can be divided into four distinct
segments: (1) crude separation; (2) light hydrocarbon
processing; (3) middle and heavy distillate processing; and
(4) residual hydrocarbon processing. Each of the four
segments comprises a number of process modules. The crude
separation segment includes crude oil handling and
distillation processes that split the crude into three broad
factions: light hydrocarbons, middle and heavy distillates,
and residual oils. Light hydrocarbons are defined as naphtha
boiling range and lighter fractions. Middle and heavy
distillates are the fractions boiling between the naphtha
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TABLE 2-4. VOLATILE ORGANIC COMPOUND (VOC) LOADING
IN SOCMI WASTEWATER STREAMS
Percent of vastevater flow
50
40
10
Percent: VOC loading
. • 2-6
35.0
62.4
2-11
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range and the residuals. Residual oils are defined as crude
distillation bottoms or residue.
Over 150 separate processes have been identified in the
petroleum refining industry. Each refining process consists
of a series of unit operations that cause chemical and
physical changes in the feedstock or products. Each unit
operation may have different water usages. The wastewater is
generated by a variety of sources including cooling water,
steam stripping condensates, tank draw-offs, and contact
process water.
The various distillation and fractionation processes
produce the largest volumes of .wastewater, with most of the
water being discharged from three sources. The first source
is the water drawn off from overhead accumulators before
recirculation or transfer of hydrocarbons to other
fractionators. The second wastewater source is discharge from
oil sampling lines, and the third source is from oil emulsions
that form in the barometric condensers used to maintain
reduced pressures in the vacuum distillation units.
Nearly all refineries include some type of onsite
wastewater treatment system. Previous work performed by the
Agency indicates that these wastewater collection and
treatment systems are significant sources of VOC emissions.9
Model streams .representing the petroleum refining
industry were developed from wastewater generation factors
presented in Table B-10 in Appendix B and benzene
concentration data reported in the support document, "Final
National Emissions Standards for Hazardous Air Pollutants
(NESHAP) Standards for Waste Operations."10 This information
was sufficient to allow the characterization of wastewater
flow rate, VOC concentration, and strippability. However, the
available data did not present flow and concentrations for
individual wastewater streams within each process unit.
Therefore, combined process unit effluent streams were
disaggregated into individual streams, as discussed in
Section 2.2. Additional details regarding development of the
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petroleum refining industry model streams may be found in
Appendix B.
2.4 PHARMACEUTICALS MANUFACTURING INDUSTRY
The pharmaceutical manufacturing industry includes
facilities which manufacture, extract, process, purify, and
package chemical materials to be used as human and animal
medications. Four hundred and sixty-six facilities were
identified by the Agency as pharmaceutical manufacturers.
Approximately 57 percent of these facilities are located in
areas of ozone nonattainment. This industry includes
facilities in the following SIC codes;
2833 Medicinal Chemicals and Botanical Products;
2834 Pharmaceutical Preparations; and
2836 Biological Products Except Diagnostic Substances.
Other facilities covered by this document are:
** The manufacture of products considered
pharmaceutically active by the Food and Drug
Administration;
** The manufacture of nonpharmaceutlcal products made at
pharmaceutical manufacturing facilities that generate
wastewater similar to that from pharmaceutical
production;
»* The manufacture of products "which have non-
pharmaceutical uses" but that are "primarily intended
for use as a pharmaceutical"; and
»* Pharmaceutical research.
Pharmaceutical production operations may be batch,
semi-continuous, or continuous. However, batch methods are
the most common. Manufacturing in the industry can be
characterized by four processes. These are fermentation,
extraction, chemical synthesis, and formulation and packaging.
Fermentation is usually a large-scale batch process and
involves fermentation, or controlled growth of specific
microorganisms, in a reactor vessel to produce a desired
product. The desired product is then recovered from the
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fermentation broth using solvent extraction, adsorption,
precipitation and filtration, or ion exchange. Wastewater
streams generated from fermentation processes include
discharges from reactor cleanings and sterilizations, off-gas
scrubber effluents, and occasional off-specification batches.
Solvents used in extracting the product from the broth in the
recovery process may be discharged into the sewers in the
wastewater streams as well.
Extraction refers to the extraction and recovery of a
small volume of desired product from naturally occurring
sources such as plant roots and leaves, animal glands, and
parasitic fungi. Extraction operations are usually either
batch or semi-continuous. Wastewater discharges from
extraction processes include spent raw materials, solvents
used in extractions, and spills and equipment wash waters.
Chemical synthesis, either through batch or continuous
processes (usually batch), is the most common method of
preparing Pharmaceuticals. Synthesis of Pharmaceuticals
involves reaction of the appropriate raw materials and
recovery of the desired product. Effluents from synthesis
operations are highly variable as are the processes by which
they are generated. Process solutions, vessel wash waters,
filtrates, concentrates, spent solvents, and scrubber
effluents are all sources of wastewater. Pump seal water,
spills, and cleaning wash waters are additional sources. Any
of these sources may contain significant concentrations of
volatile organics.
Mixing, compounding, and formulating operations involve
preparation of the active ingredients into a dosage form for
consumer use. The primary sources of wastewater from these
processes are from equipment washings, scrubber effluents, and
spills.
Although wastewater streams from all four processes have
the potential to contain high organic loadings, fermentation
and synthesis operations usually generate larger volumes of
wastewater, and the wastewaters generated usually contain
2-14
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higher organic loadings. Based on data gathering efforts by
the Agency, the pharmaceutical manufacturing industry
discharges significant quantities of organic compounds in
their raw wastewaters.
A study by the Pharmaceutical Manufacturers' Association
that focused on 26 member companies identified a total of
46 VOC's used by the industry.17 These companies represent
53 percent of the domestic sales of prescription drugs. The
industry primarily uses organic compounds as raw materials or
solvents. An estimated 84 percent (i.e., 486,470 tons per
year) of the organic compounds are recycled and 16 percent
(i.e., 94,990 tons per year) are waste organics.
Approximately 2.7 percent (i.e., 15,850 tons per year) of the
waste organics are discharged to the sewer.
To better determine the total industry wastewater
generation, the Agency estimated the contribution from the
nonrespondents at 13 Mgal/d. The total wastewater flow,
therefore, is approximately 93 Mgal/d.
Model streams representing the pharmaceutical
manufacturing industry were developed from responses to a 1988
Section 308 survey conducted by OWRS. In the survey, OWRS
collected information on wastewater flow rates and VOC
concentrations. A total of eight responses provided
sufficient information to allow the characterization of
wastewater flow rate, VO concentration, and strippability.
However, the available data did not present flow and
concentrations for individual wastewater streams within each
process unit. Therefore, combined process unit effluent
streams were disaggregated into individual streams, as
discussed in Section 2.2. Additional details regarding
development of the pharmaceutical manufacturing industry model
streams can be found in Appendix B.
2.5 HAZARDOUS WASTE TREATMENT, STORAGE, AND DISPOSAL
FACILITIES INDUSTRY7
The EPA studied the TSDF industry in 1986 through both
the Office of Water (OW) and the Office of Solid Waste (OSW).
2-15
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The OW studied the industry in order to set effluent
guidelines. The OSW, in accordance with Section 3018(a) of
the Resource Conservation and Recovery Act (RCRA), identified
TSDF (in that study, referred to as hazardous waste treaters
[HWT]) as significant contributors of hazardous wastes to
publicly owned treatment works (POTW). The Agency has placed
very high priority on development of pretreatment standards
for treaters of aqueous waste to control toxic and hazardous
pollutants.
The Agency has divided the TSDF industry into three
categories for effluent guideline purposes:
1. Landfills with leachate collection, including
commercial (offsite) .and industrial (onsite) hazardous waste
(Subtitle C of RCRA) and municipal nonhazardous waste
(Subtitle D of RCRA) landfills.
2. Hazardous waste incinerators with wet scrubbers
(commercial and industrial); and
3. Facilities that treat aqueous hazardous waste,
including commercial, industrial, and Federal (Subtitle C of
RCRA) TSDF with and without categorical effluent regulations
(technology-based effluent standards applicable to specific
industries).
The Agency has identified 1,304 out of 1,909 facilities
that would be subject to any effluent guideline regulations
developed in the future. The industry characterization is
presented in Table 2-5. Approximately 43 percent of these
facilities are located in areas of ozone nonattainment.
Landfill leachates contain high concentrations of toxic
organic compounds and metals, and conventional and
nonconventional pollutants. Many organic compounds are in the
range of 1 to 10 ppmw, a few at greater than 100 ppmw* Total
mass in raw wastewater discharges of nonpriority organic
compounds ranges from 1.8 to 4.7 times greater than organic
priority compounds. (A priority compound is typically
restricted to 126 pollutants as defined by the OWRS.) Of
these, 29 are VOC's as defined by the EPA Purge and Trap
2-16
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TABLE 2-5. HAZARDOUS WASTE TREATMENT, STORAGE, AND
DISPOSAL FACILITIES INDUSTRY CHARACTERIZATION
Facility type
Landfill leachate
Incinerator scrubber
Aqueous waste tr eaters
TOTAL
Direct
discharge
173
137
87
397
Indirect
discharge
355
27
515
897
Other*
383
109
123
615
* Includes offsite disposal at a commercial aqueous waste
treatment facility, deep well injection, and other methods.
2-17
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Method 624. This industry produces about 16 Mgal/d of
landfill leachate.
Incinerator wet scrubber liquors contain high
concentrations of toxic metals but very few organics at
relatively low concentrations. Approximately 15 Mgal/d of
incinerator wet scrubber liquors are produced.
Aqueous waste treatment facilities typically have high
concentrations of toxic metals and organics. Many organic
priority pollutants are found in concentrations greater than
1 ppmw, and some greater than 10 ppmw at the influent to the
wastewater treatment plant. Total mass in raw wastewaters of
nonpriority pollutant organics is approximately 7 times
greater than that of organic priority pollutants. Aqueous
waste treaters produce approximately 27 Mgal/d of wastewater.
Model streams representing TSDF's were developed from
responses to a 1986 OSW survey under authority of Section 3001
of RCRA. In the survey, OSW collected information on
wastewater flow rates and VOC concentrations. A total of
four responses provided sufficient information to allow the
characterization of wastewater flow rate, VOC concentration,
and strippability. However, the available data did not
present flow and concentrations for individual wastewater
streams within each process unit. Therefore, combined process
unit effluent streams were disaggregated into individual
streams, as discussed in Section 2.2. Additional details
regarding development of the TSDP model streams may be found
in Appendix B.
2.6 PULP, PAPER AND PAPERBOARD AND BUILDERS' PAPER AND BOARD
MILLS INDUSTRY
The OAQPS and the OWRS are currently coordinating
standards for controlling releases from the pulp and paper
industry. The OAQPS is developing a NESHAP to control air
emissions of the HAP's listed in Title III of the CAA
Amendments of 1990. The OWRS is developing effluent guideline
limitations for control of specific pollutant discharges to
receiving bodies of water.
2-18
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The most recent data indicate that there are now
603 facilities in this industry. Approximately 43 percent of
these facilities are located in areas of ozone nonattainment.
Table 2-6 shows a breakdown of the facilities by subcategory
as estimated in 1989,
To accommodate industry diversity, the Agency developed
three groupings based on the similarity in the mills, raw
materials used, products manufactured, production processes
employed, mill size, age, and treatment costs. These groups
are:
* Integrated mills,
* Nonintegrated mills, and
* Secondary fibers mills.
Integrated mills manufacture paper products or market pulp
from wood that is prepared, pulped, and bleached onsite. Some
pulp may be purchased for blending with pulp produced onsite
to achieve the desired paper properties. Nonintegrated mills
manufacture paper products by blending purchased pulps to
achieve the desired paper properties. The secondary fibers
mills get their major fiber source from purchased wastepaper.
Wastepaper is mildly cooked, bleached (if necessary) and
possibly blended with purchased pulp to achieve desired paper
properties.
The majority of the organics are formed in the pulping
and bleaching of virgin pulp. For this reason, the integrated
pulp and paper mills are most likely to generate waste streams
with high organic loadings. Secondary fibers mills and
nonintegrated mills do not generate wastewater with
concentrations of organics as high as the streams generated in
integrated mills. Approximately 2 percent of the kraft pulp
and paper facilities are located in areas of ozone
nonattainment.
During the pulping process, the lignin present in the
wood is broken down into simpler organic compounds such as
methanol and acetone. These soluble organics are washed from
the pulp and are concentrated in the spent pulping liquor.
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TABLE 2-6. MILL POPULATION
Subcategory
Market kraft
Dissolving kraft
BCT kraft
Alkaline fine
Unbleached kraft & semi-chemical
Unbleached kraft - liner
Unbleached kraft - bag
Semi-chemical
Dissolving sulfite
Papergrade sulfite
Groundwood CMN
Groundwood fine .
Groundwood TMP
Deink - fine
Deink - news
Deink - tissue
Tissue from wastepaper
Wastepaper-molded product
Paperboard from wastepaper
Builders' papers & roofing felts
NI - fine
NI - tissue
NI - lightweight
NI - electrical
NI - fine cotton
NI - filter nonwoven
NI - board
Misc . - integrated
Misc. - nonintegrated
Misc. - secondary fibers
Estimate
(1989)
14
3
8
24
8
21
5
16
6
11
5
9
7
5
4
21
19
13
132
21
35
22
10
4
6
13
12
91
38
20
TOTAL:
603
BCT = Bag carton tissue.
CMN = Chemical-mechanical pulping,
TMP = Thermal-mechanical pulping.
NI = Nori-integrated.
2-20
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In the recovery process of this pulping liquor, the organics
are evaporated and condensed. The resulting condensate
streams are rich in organics and are sometimes discharged to
the sewer without treatment. Organics are also formed as
additional lignin breaks .down in the bleaching stages. In the
presence of chlorine, chloroform and other chlorinated
organics are formed and are washed from the pulp. These
organics are readily volatilized from the bleach plant wash
waters. Digester vent condensates, evaporator condensates,
and bleach plant wash waters may contain high organic
loadings. Some of the facilities visited by Agency
representatives between 1989 and 1991 are using air strippers
and steam strippers to lower organics concentration,
biochemical oxygen demand (BOD), and/or total reduced sulfur
(TRS) from their condensate streams; however, many condensate
streams are still discharged to the sewer. In addition, no
known controls are being used to control emissions of
chlorinated compounds from the bleaching area.
Generally, the wastewaters in the pulp and paper industry
typically have higher total suspended solids concentrations
and pH values above 11 or below 3. These characteristics make
the pulp and paper wastewaters less amenable to steam
stripping with carbon steel equipment. However, as mentioned
above, stainless steel steam and air strippers have been
installed at some facilities to control TRS and BOD. One
facility has installed a steam stripper to reduce TRS odor and
BOD loading (primarily due to methanol concentrations) to
their wastewater treatment plant.18 The stripper receives
evaporator, accumulator, and digester condensates, as well as
turpentine decanter underflow for a total average flow of
approximately 1,050 gallons per minute. - The TRS and methanol
concentrations are 480 and 4,820 ppm, respectively. The
stripper achieves approximately a 90-percent reduction in
methanol and a 98-percent reduction in TRS. The feed
wastewater pH is approximately 9.5, thus the construction
material is stainless steel.
2-21
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Model streams representing condensate streams within the
Kraft pulp and paper industry were developed from responses to
a 1990 questionnaire by OWES issued under authority of the
Clean Water Act, Section 308, This information was sufficient
to allow the characterization of wastewater flow rate, VOC
concentration, and strippability. Additional details
regarding the development of the kraft pulp and paper industry
condensate streams may be found in Appendix B.
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2.7 REFERENCES
1. Office of Water Regulations and Standards.
U. S. Environmental Protection Agency. Washington, DC.
Development Document for Effluent Limitations Guidelines
and Standards for the Organic Chemicals and Plastics and
Synthetic Fibers Point Source Category. Volume I (BPT).
EPA 440/l-83/009b (NTIS PB83-205633), February 1983.
pp. 11 to 39, 94 to 96, 105 to 167, 195 to 198.
2. Office of Water Regulations and Standards.
U. S. Environmental Protection Agency. Washington, DC.
Development Document for Effluent Limitations Guidelines
and Standards for the Organic Chemicals and Plastics and
Synthetic Fibers Point Source Category Volume II (BAT).
EPA 440/l-83/009b (NTIS PB83-205641), February 1983.
pp. II-7 to 11-15, III-l to III-9, IV-10 to IV-28, V-l to
V-15, VII-1 to VII-22.
3. Office of Water Regulations and Standards.
U. S. Environmental Protection Agency. Washington, DC.
Development Document for Effluent.Limitations Guidelines
and Standards for the Pesticide Point Source Category.
EPA 440/1-85/079 (NTIS PB86-150042/REB), October 1985.
pp. III-9 to 111-16, VI-1 to VI-47.
4. Office of Water. U. S. Environmental Protection Agency.
Washington, DC. Development Document for Final Effluent
Limitations Guidelines, New Source Performance Standards
and Pretreatment Standards for the Pharmaceutical
Manufacturing Point Source Category. EPA 440/1-83/084
(NTIS PB84-180066/REB), September 1983. pp. 17 to 34, 49
to 76, 103 to 138.
5. .Office of Water Regulations and Standards.
U. S. Environmental Protection Agency. Washington, DC.
Development .Document for Effluent Limitation Guidelines
and Standards for the Pulp, Paper and Paperboard Builders
Paper and Board Mills Point Source Category.
EPA 440/1-82/025 .(NTIS PB83-163949) , October, 1982.
pp. 77 to 87, 183 to 235, 363 to 385.
6. Meeting notes. Penny E. Lassiter, Environmental
Protection Agency, Chemicals and Petroleum Branch, with
Tom O'Farrell, Office of Water Regulations and Standards,
Industrial Technology Division, March.3, 1989.
7. Office of Water Regulations and Standards.
U. S. Environmental Protection Agency. Washington, DC.
Draft Decision Document for Hazardous Waste Treatment
Industry Effluent Guidelines Development.
EPA Contract No.: 68-01-6947, August 17, 1987.
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8. Office of Water Regulations and standards.
U. S. Environmental Protection Agency. Washington, DC.
Development for Effluent Limitations Guidelines and
Standards for the Petroleum Refining Point Source
Category. EPA 440/1-82/014 (NTIS). October 1982.
9. U. S. Environmental Protection Agency. Washington, DC.
VOC Emissions From Petroleum Refinery Wastewater Systems—
Background Information for Proposed Standards.
EPA 450/3-85-OOla. February, 1985.
10. U. S. Environmental Protection Agency. Washington, DC.
Final NESHAP Standards for Waste Operations; Basis for
Impact Calculations. February 1990.
11. Annual Refining Survey, oil and Gas Journal, March 26,
1990.
12. federal Register. OCPSF Effluent Limitations Guidelines,
Final Rule. 52 FR 42522. November 5, 1987.
13- Federal Register. Effluent Guidelines Plan. 55 FR 80.
January 2, 1990.
14. Memorandum from Brailsford, J.C., Radian Corporation, to
Industrial Wastewater file. Percent Ozone Nonattainment
Calculations. January 29, 1992.
15. Memorandum from Bagley, C., Radian Corporation, to F. E.
Manning, U. S. Environmental Protection Agency.
Development of Volatile Organic Wastewater Loading
Distribution from Responses to the March 1990 Section 114
Wastewater Questionnaire. May 5, 1992.
16. Federal Register. Pesticide Chemicals Category Effluent
Limitations Guidelines, Final Rule. 50 FR 40674.
October 4, 1985.
17. Office of Air Quality Planning and Standards.
U. S. Environmental Protection Agency. Research Triangle
Park, North Carolina. Control of Volatile Organic
Emissions from Manufacture of Synthesized Pharmaceutical
Products, OAQPS Guideline Series, EPA-450/2-78-029
(NTIS PB290-58Q/0), December 1978.
18. BODs Reduction Using Condensate Stripping, Union Camp
Corporation, FranJtlin, Virginia. Submitted in a letter
from David H. Breed, Union Camp, to Susan Wyatt,
U. S. Environmental Protection Agency, November 17, 1989.
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3.0 VOLATILE ORGANIC COMPOUND EMISSIONS DURING
WASTEWATER COLLECTION AND TREATMENT
Facilities in the industries discussed in Chapter 2.0
generate wastewater streams that contain organic compounds.
These wastewaters are collected and treated in a variety of
ways. Some of these collection and treatment steps result in
the emission of volatile organic compounds (VOC's) from the
wastewater to the air. This chapter provides a discussion of
the potential VOC emissions from wastewater sources and
presents estimates of emissions for model systems.
Section 3.1 describes the sources of organic compound-
containing wastewater. Section 3.2 describes the sources of
VOC emissions from the wastewater streams and factors
affecting emissions from these sources. Procedures for
estimating VOC emissions are discussed in Section 3.3.
3.1 SOURCES OF ORGANIC COMPOUND-CONTAINING WASTEWATER
The industries discussed in Chapter 2.0 differ in
structure and manufacture a wide variety of products.
However, many of the chemical processes employed within these
industries use similar organic compounds as raw materials,
solvents, catalysts, and extractants. In addition, many of
these processes also generate similar organic products and
byproducts during reaction steps. Consequently, many of the
wastewater streams generated by the targeted industries are
similar in organic compound content. These organic compound-
containing wastewater streams result from the direct contact
of water with organic compounds and from contamination of
indirect contact wastewater through equipment leaks in
chemical processing.
3-1
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3.1,1 Direct Contact Wastewater
Water comes in direct contact with organic compounds
through many different chemical processing steps, resulting in
wastewater streams that must be discharged for treatment or
disposal. Direct contact wastewater includes:
•* Water used to wash impurities from organic compound
products or reactants;
»* Water used to cool or quench organic compound vapor
streams;
** Condensed steam from jet eductor systems pulling
vacuum on vessels containing organic compounds;
•* Water from raw material-and product storage tanks;
* Water used as a carrier for catalysts and neutralizing
agents (e.g., caustic solutions); and
** Water formed as a byproduct during reaction steps.
Two additional types of direct contact wastewater are
landfill leachate and water used in equipment washes and spill
cleanups. This wastewater is normally more variable in flow
rate and concentration than the streams previously discussed,
and it may be collected for treatment differently from the
wastewater streams discharged from process equipment such as
scrubbers, decanters, evaporators, distillation columns,
reactors, and mixing vessels.
3.1.2 Indirect Contact Wastewater
Wastewater streams that are not intended to come in
contact with organic compounds in the process equipment but
become contaminated with organic compounds through equipment
leaks are defined as "indirect contact" wastewater.
Noncontact wastewater may become contaminated as a result of
leaks from heat exchangers, condensers, and pumps. These
indirect contact wastewaters may be collected and treated
differently from direct contact wastewaters. Pump seal water
is normally collected in area drains that tie into the process
wastewater collection system. This wastewater is then
combined with direct contact wastewater and transported to the
wastewater treatment plant. Wastewater contaminated from .heat
exchanger leaks is often collected in different systems and
3-2
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may bypass some of the treatment steps used in the treatment
plant. The organic compound content in these streams can be
minimized by implementing an aggressive leak detection
program.
3.2 SOURCES OF AIR EMISSIONS
Wastewater streams are collected and treated in a variety
of ways. Generally, wastewater passes through a series of
collection and treatment units before being discharged from a
facility. Many of these collection and treatment system units
are open to the atmosphere and allow organic compound-
containing wastewaters to contact ambient air, thus creating a
potential for VOC emissions. The organic pollutants
volatilize in reaching an equilibrium with the vapor phase
above the wastewater. These organic compounds are emitted to
the ambient air surrounding the collection and treatment
units. The magnitude of VOC emissions is somewhat dependent
on factors such as the physical properties of the pollutants,
the temperature of the wastewater, and the design of the
individual collection and treatment units.
Collection and treatment schemes for wastewater are
facility specific. The flow rate and organic compound
composition of wastewater streams at a particular facility are
functions of the processes used and influence the sizes and
types of collection and treatment units that must be employed.
Table 3-1 lists the potential sources of emissions in facility
collection and treatment systems. The following sections
briefly discuss each of these emission sources. A detailed
discussion of each emission source, including diagrams,
typical design parameters, emission mechanisms, factors
affecting emissions, emission estimation models, and example
calculations for VOC emissions estimated for each source is
contained in the Wastewater CTC Document.1
3.2.1 Drains
Wastewater streams from various sources throughout a
given process are introduced into the collection system
through process drains. individual drains usually connect
3-3
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TABLE 3-1. EMISSION SOURCES IN WASTEWATER COLLECTION
AND TREATMENT SYSTEMS
Drains
Manholes
Junction boxes
Lift stations
Trenches
Sumps
Weirs
Oil/water separators
Equalization basins or neutralization
basins
Clarifiers
Aeration basins
pH adjustment tanks
Flocculation tanks
Surface impoundments
3-4
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directly to the main process sewer line, but may also drain to
trenches, sumps, or ditches. Some drains are dedicated to a
single piece of equipment, while others, known as area drains,
serve several sources. Many of these drains are open to the
atmosphere; that is, they are not equipped with a water seal
pot or p-trap to reduce emissions of organic compounds to the
atmosphere.
Emissions from drains occur by diffusive and convective
mechanisms.2 Drain emission rates are affected by a number of
factors. These factors include the composition and physical
properties of the organic compounds in wastewater entering the
drain and flowing through the sewer line below the drain, the
temperature of the wastewater, the design characteristics of
the drain, and climatic factors.2 Drain design
characteristics that affect emissions are the diameter and
length of the drain riser. Climatic factors that may have an
effect on VOC emissions from a drain include ambient air
temperature and wind speed and direction.
3.2.2 Manholes
Manholes are service entrances into process sewer lines
that permit inspection and cleaning of the sewer line. They
are placed at periodic lengths along the sewer line or where
sewers intersect or change significantly in direction, grade,
or sewer line diameter. The lower portion of a manhole is
usually cylindrical, with a typical inside diameter of
1.2 meters (m) (4 feet [ft]) to allow adequate space for
workers. The upper portion tapers to the diameter of the
opening at ground level. A typical manhole opening is about
0.6 m (2 ft) in diameter and covered with a heavy cast-iron
plate, which usually contains two to four holes _so that the
manhole cover can be grasped for removal.
As with drains, emissions from manholes occur by
diffusive and convective mechanisms. Emission rates from
manholes are affected by several factors, including the
characteristics of the wastewater passing through the sewer
line below the manhole, the manhole design characteristics,
3-5
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and climatic factors. Wastewater characteristics affecting
emission rates include wastewater composition and temperature.
Manhole design characteristics that affect emission rates
include the manhole diameter, the distance from the manhole
cover down to the sewer line, the thickness of the manhole
cover, and the number and diameter of the vent holes in the
manhole cover. Climatic factors that affect emission rates
from manholes include ambient air temperature and wind speed
and direction.
3.2.3 Junction Boxes
A junction box combines multiple wastewater streams into
one stream that .flows downstream from the junction box.
Generally, the flow rate from the junction box is controlled
by the liquid level in the junction box. Junction boxes are
either square or rectangular and are sized based on the total
flow rate of the entering streams. Junction boxes are
typically open, but for safety reasons may be closed and
vented to the atmosphere.
Emissions occur from junction boxes predominantly by
convective mass transfer. Organic compounds in the wastewater
volatilize into the ambient air just above the liquid surface
in an attempt to reach equilibrium between the liquid and
vapor phases. Since the organic compound vapors above the
liquid are in contact with the ambient air, these organic
compound vapors can be swept into the atmosphere by wind
blowing across the top of the junction box. Emission rates
from junction boxes are affected by several factors, including
the characteristics of the wastewater flowing through the
junction box, the design of the junction box, and climatic
factors
Junction box design characteristics that affect emissions
include the fetch-to-depth ratio, the water turbulence in the
junction box, and the liquid surface area. Fetch is defined
as the linear distance across the junction box in the
direction of the wind flow. Depth is represented by the
average liquid level in the junction box.
3-6
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Water turbulence enhances liquid phase mass transfer.3
In completely smooth flow through the junction boxes,
pollutants slowly diffuse to the water surface to replace the
volatilizing pollutants. In turbulent flow through the
junction box, the organic compounds are carried much more
rapidly to the surface by the turbulent water. Therefore,
more organic compounds are exposed to the surface air, and the
emission rate is increased. If the sewer lines feed water to
the junction box above the liquid surface, the exposure of
organic compounds to the surface air is also increased. The
water spills into.the junction box, causing splashing and
additional, turbulence at the liquid surface, which increases
emissions. In addition, wind entering the sewer system
through an upstream component may exit the junction box
saturated with organic compounds. These effects can be
minimized by introducing water to the junction box below the
liquid surface. Ambient wind speed is the predominant
climatic factor affecting air emissions, ,
3.2.4' Lift Stations ,
Lift stations are usually the last collection unit before
the treatment system. They accept wastewater from one or
several sewer lines. The main function of the lift station is
to collect wastewater for transport to the treatment system.
A pump provides the necessary head pressure for transport and
is generally designed to turn on and off in response to preset
high and low liquid levels. Lift stations are usually
rectangular in shape and greater in depth than length or
width. Lift stations are typically open or closed and vented
to the atmosphere.
As with junction boxes, emissions occur from lift
stations predominantly by convective mass transfer. The
factors affecting emissions from lift stations are similar to
the factors affecting emissions from junction boxes discussed
in Section 3.2.3. These factors are the concentration and
physical properties of the organic compounds present in the
3-7
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wastewater, lift station design characteristics, and climatic
factors.
The design characteristics that affect air emission rates
from lift stations include the liquid surface area, the water
turbulence in the lift station, and the fetch-to-depth ratio.
The predominant climatic factor affecting emissions from lift
stations is ambient wind speed.
3.2.5 Trenches
Trenches are used to transport wastewater from the point
of discharge from the process equipment to wastewater
collection units such as junction boxes and lift stations. In
older plants, trenches are often. the primary mode of
wastewater transportation in the collection system. Trenches
are often interconnected throughout the process area and
handle equipment pad water runoff, water from equipment wash
downs and spill cleanups, and process wastewater discharges.
Trench length is determined by the locations of the process
equipment and the downstream collection system units and
typically ranges from 15 to 150 m (50 to 500 ft). Depth and
width are dictated by the rate at which wastewater is
discharged from process equipment and must be sufficient to
accommodate emergency wastewater flows from the process
equipment. Trenches are typically open or covered with
grates.
As with junction boxes and lift stations, emissions from
trenches occur predominantly by convective mass transfer.
Factors that affect emissions from trenches are the
concentration and physical properties of the compounds in the
wastewater, .trench design characteristics, and climatic
factors.
The trench design characteristics that affect emission
rate include the depth and width of the trench and the
hydraulic retention time. As with junction boxes and lift
stations, wind speed is the predominant climatic factor
affecting emissions.
3-8
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3.2.6 Sumps
Sumps are used to collect and equalize wastewater flow
from trenches before treatment. They are usually quiescent
and open to the atmosphere. Sumps are sized based on the
total flow rate of the incoming wastewater stream. Typical
diameters and depths are approximately 1.5 m (5 ft).
Emissions occur from sumps by both diffusive and
convective mechanisms. As wastewater flows slowly through the
sump, organic compounds diffuse through the water to the
liquid surface. These organic compounds volatilize into the
ambient air above the liquid and can be swept into the air by
wind blowing across the surface of the sump.
The factors affecting emissions from a sump are similar
to the factors affecting emissions from an equalization basin.
These factors include wastewater characteristics, wind speed,
and sump design characteristics. Design characteristics that
affect air emission rates from sumps are the fetch-to-depth
ratio, the liquid surface area, and the hydraulic retention
time.
3.2.7 Weirs
Weirs act as dams in open channels. The weir face is
usually aligned perpendicular to the bed and walls of the
channel. Water from the channel normally overflows the weir
but may pass through a notch, or opening, in the weir face.
Because of this configuration, weirs provide some control of
the level and flow rate through the channel. Weirs may also
be used for wastewater flow rate measurement.
Water overflowing the weir may proceed down stair steps
that serve to aerate the wastewater. This design increases
diffusion of oxygen into the water which may benefit the
biodegradation process (often the next treatment step).
However, this increased contact with air also accelerates the
volatilization of organic compounds contained in the
wastewater.
The major factors affecting emissions from weirs include
wastewater characteristics, ambient wind speed, and weir
design characteristics. The concentration and physical
3-9
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properties of the organic compounds in the wastewater have a
significant effect on VOC emissions. The diffusivity. in water
of the specific organic compounds present in the wastewater
may be the most significant physical property.
Ambient wind speed has a significant effect on convective
mass transfer, because as the wastewater spills over the weir
and splashes down the stair steps, increased liquid surface
area is exposed.
The height of the weir is the most significant design
characteristic affecting emissions. Typical weir heights
range from 0.9 to 2.7 m (3 to* 9 ft).
3.2.8 Oil/Water Separators
Oil/water separation is often the first step in
wastewater treatment, but oil/water separators may also be
found in the process area. These units gravity separate and
remove oils, scum, and solids from the wastewater. Most of
the separation occurs as the wastewater stream passes through
a quiescent zone in the unit. Oils and scum with specific
gravities less than water float to the top of the aqueous
phase. Heavier solids sink to the bottom. Some of the
organic compounds contained in the wastewater will partition
to the oil phase and can be removed with the skimmed oil
leaving the separator.
Volatilization of organic compounds from the surface of
an oil/water separator is a complex mass transfer phenomenon.
The force behind volatilization is the drive to reach
equilibrium between the concentration of organic compounds in
the oil layer and the vapor phase just above this layer.
Organic compounds volatilizing into the vapor phase either
diffuse or are swept by wind into the ambient air surrounding
the oil/water separator.
Factors affecting emissions from oil/water separators
include characteristics of the wastewater and oil layers,
ambient wind speed, and design characteristics of the
separator.4 The concentration and physical properties of the
organic compounds contained in the wastewater significantly
3-10
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affect emissions. The thickness of the oil layer also affects
emissions since organic compounds that partition from the
wastewater into the oil phase must diffuse through the oil
layer to volatilize.
Ambient air speed above the oil surface affects
convective mass transfer into the ambient air. Design
characteristics affecting emissions include the length and
width of the oil/water separator.
3.2.9 EguaJli-Zation Basins ' • ;. .
Equalization basins are used to reduce fluctuations in
the wastewater .temperature, flow rate, and organic compound
concentrations to'the downstream treatment processes.
Equalization of wastewater flow rate results in more uniform
effluent quality from downstream units and can benefit
biological treatment performance by damping any influent
concentration and flow rate fluctuations. This damping
protects biological processes from upset or failure due to
shock loadings of toxic or treatment-inhibiting compounds.
Equalization basins normally use hydraulic retention time to
ensure equalization of the wastewater effluent leaving the
basin. However, some basins are equipped with mixers or
surface aerators to enhance the equalization, accelerate
wastewater cooling, or saturate the wastewater with oxygen
before secondary treatment.
Emissions occur from equalization basins by both
diffusive and convective mechanisms.3 Factors affecting'
emissions from equalization basins are similar to the factors
affecting emissions from other well-mixed, flow-through
impoundments. These factors are wastewater characteristics,
wind speed, and equalization basin design characteristics.
Design characteristics that affect air emission rates from
equalization basins are the fetch-to-depth ratio, the liquid
surface area, the hydraulic retention time, and the degree of
aeration.
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3,2.10 Clarifiers
The primary purpose of a clarifier is to separate solids
from the wastewater through gravitational settling. Most
clarifiers are equipped with surface skimmers to clear the
water of floating oil deposits, grease, and scum. Clarifiers
also have sludge raking arms that remove the accumulation of
organic solids collected at the bottom of the tank. The
depth and cross-sectional area of a clarifier are functions of
the settling rate of the suspended solids and the thickening
characteristics of the sludge. Clarifiers are designed to
provide sufficient retention time for the settling and
thickening of these solids.
Emissions occur from clarifiers by both diffusive and
convective mechanisms.3 The factors affecting emissions from
a clarifier are similar to the factors affecting emissions
from other well-mixed, flow-through impoundments. These
factors include wastewater characteristics, wind speed, and
clarifier design characteristics. Design characteristics that
affect emission rates from clarifiers are the liquid surface
area, the fetch-to-depth ratio, and the hydraulic retention
time.
3-2.11 |ter at lon^ gas ins
Biological waste treatment is normally.accomplished
through the use of aeration basins. Microorganisms require
oxygen to carry out the biodegradation of organic compounds,
which results in energy and biomass production. The aerobic
environment in the basin is normally achieved with diffused or
mechanical aeration. This aeration also serves to maintain
the biomass in a well-mixed regime. The performance of
aeration basins is particularly affected by: (i) mass of
organic compound per unit area of wastewater; (2) temperature
and wind patterns; (3) hydraulic retention time;
(4) dispersion and mixing characteristics; (5) sunlight
energy; and (6) amount of essential microbial nutrients
present.
3-12
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Three mechanisms affect the removal of organic compounds
in aeration basins. These mechanisms are biodegradation,
adsorption onto the sludge, and air emissions. Because these
three mechanisms compete against each other, factors affecting
the biodegradation and adsorption mechanisms will have an
effect on air emissions.
Typically, aeration basins are equipped with aerators to
introduce oxygen into the wastewater. The biomass uses this
oxygen in the process of biodegrading the organic compounds.
However, aeration of wastewater also affects air emissions.
Other factors affecting emissions from aeration basins
include wind speed and basin design characteristics.
Emissions from aeration basins are not as sensitive to wind
speed effects compared to quiescent basins. Basin design
characteristics that affect emissions include the quiescent
and turbulent surface areas, the depth of the basin, the
design of the aerators, and the hydraulic retention time of
the basin.
3.2.12 Treatment Tanks
Several different types of treatment tanks may be used in
wastewater treatment systems. Tanks designed for pH
adjustment typically precede the biological treatment step.
In these tanks, the wastewater pH is adjusted, using acidic or
alkaline additives, to prevent shocking the biological system
downstream. Flocculation tanks are typically used to treat
wastewater after biological treatment. Flocculating agents
are added to the wastewater to promote formation or
agglomeration of larger particle masses from the fine solids
formed during biological treatment. In the clarifier, which
usually follows the flocculation tanks in the system, these
larger particles precipitate more readily out of the
wastewater.
Emissions occur from treatment tanks by both diffusive
and convective mechanisms. Factors affecting emissions from a
treatment tank are similar to the factors affecting emissions
from other well-mixed, flow-through impoundments. These
3-13
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factors are the wastewater characteristics, wind speed, and
design characteristics of the treatment tank. Design
characteristics of the treatment tanks that affect emission
rates are the liquid surface area, the fetch-to-depth ratio,
and the hydraulic retention time.
3.2.13 Surface Impoundments
Surface impoundments are used for evaporation, polishing,
storage before further treatment or disposal, equalization,
leachate collection, and as emergency surge basins. They may
be quiescent or mechanically agitated.
Resource Conservation and Recovery Act (RCRA) Subtitle D
Surface Impoundments are impoundments that accept wastes as
defined under Subtitle D of RCRA.5 Subtitle D wastes are all
solid wastes regulated under the RCRA that are not subject to
hazardous waste regulations under Subtitle C. These wastes
are defined in 40 CFR Part 257. Specifically, this document
applies to process wastewater produced by generators; small
quantity generators? publicly owned treatment works (POTW);
and treatment, storage, and disposal facilities (TSDF) that is
RCRA Subtitle D waste as defined in 40 CFR 257.
Emissions occur from surface impoundments by both
diffusive and convective mechanisms. Factors affecting
emissions from a surface impoundment are similar to the
factors affecting emissions from equalization basins if the
impoundment is quiescent and similar to factors affecting
emissions from aeration basins if the impoundment is agitated.
Emission factor development for a surface impoundment will
vary depending on the impoundment's purpose and design. All
characteristics of the impoundment should be reviewed to
determine what type of collection or treatment system it best
resembles. .
3.3 VOLATILE ORGANIC COMPOUND EMISSION ESTIMATION
Emissions of VOC's from industrial wastewater depend on
both wastewater characteristics and wastewater collection and
treatment system configurations. Characteristics of
wastewater generated by facilities in the six affected
3-14
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industries are described in Chapter 2.0, Sections 2.1 .
through 2.6, with additional details and example wastewater
streams presented in Appendix B. Wastewater collection and
treatment system configurations vary across facilities, and
even for streams within a facility. Because of the many
factors that affect the general scheme used to collect and
treat facility wastewater, it is not possible to develop model
wastewater collection and treatment schematics representing
all possible scenarios. Instead, three example waste stream
collection and treatment schemes were developed in the
Wastewater CTC Document1 to evaluate potential ranges in
emissions from different facilities. The collection and
treatment system schematics were chosen to represent a range
of emission potentials.
For purposes of comparison, emissions were estimated for
an example wastewater stream with the same flow rate and
organic compound composition flowing through each example
schematic. To demonstrate a range of emission potentials,
this example wastewater stream was designed to contain
compounds that span the range of volatilities. Emissions were
estimated from the collection and treatment units in each of
the three example waste stream systems using techniques
presented in Appendix A of the Wastewater CTC Document.1 The
cumulative fraction emitted (fe) was calculated for each of
the five model compounds in each of the three schematics.6 It
was determined that the following relationship exists between
the average overall fe for the three schematics and the
Henry's Law constant for an individual compound:
fe - 1.061 + 6.546 * ID'2 * in(H-Law)
The above equation is the basis for estimating VOC emissions
from wastewater streams using the following equation:
VOC Emissions (Mg/yr) = VOC Concentration (mg/L) * Flow (£pm)*
10~9 Mg/mg * 60 min/hr * 8,760 hr/yr *
fe
3-15
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where:
VOC Concentration = total VOC concentration in the
wastewater
fe = the fraction of the total VOC
concentration emitted to the air
This relationship was used in estimating model wastewater
stream VOC emissions as described in Appendix B. In addition
to an explanation of the calculations, Tables B-13
through B-18 in Appendix B present the VOC emissions estimated
for each of the industries.
3-16
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3.4 REFERENCES
1. Office of Air Quality Planning and Standards,
U. S. Environmental Protection Agency. Research Triangle
Park, North Carolina. Industrial Wastewater Volatile
Organic Compound Emissions—Background Information for
BACT/LAER Determinations. EPA 450/3-90-004. January
1990.
2. Office of Air Quality Planning and Standards,
U. S. Environmental Protection Agency. Research
Triangle Park, North Carolina. VOC (Volatile Organic
Compound) Emissions from Petroleum Refinery Wastewater
Systems—Background Information for Proposed
Standards, Draft IIS. EPA-450/3-85-001a
(NTIS PB87-190335), February 1985.
3. Office of Ait Quality, Planning and Standards.
U. S. Environmental Protection Agency. Hazardous Waste
Treatment, Storage, and Disposal Facilities (TSDF)—Air
Emission Models, Documentation. EPA/450/3-87/026.
December, 1987.
4. Liang, S.F. Hydrocarbon Losses by Atmospheric
Evaporation from Open Separators, Technical Progress
Report, BRC-CORP 24-73-F. (Shell Models). 1973
5. Office of Solid Waste and Emergency Response.
U. S. Environmental Protection Agency. Washington, DC.
Subtitle D Study Phase I Report. EPA-530-SW-86-054,
October 1986.
6. Memorandum from Zukor, C.J., Radian Corporation, to P.E.
Lassiter, U. S. Environmental Protection Agency. Approach
for the Estimation of Uncontrolled Emissions of Hazardous
Air Pollutants from Wastewater Streams in the HON.
January 20, 1992.
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4.0 VOLATILE ORGANIC COMPOUND EMISSION CONTROL TECHNIQUES
As discussed in Chapter 3.0, volatile organic compound
(VOC) emissions during collection and treatment of industrial
wastewater can be significant, and measures to control these
emissions should be considered. This chapter describes
control measures that can be applied to reduce these VOC
emissions. Two control strategies are discussed in this
chapter. The first control strategy is waste minimization
through process modifications, modification of operating
practices, preventive maintenance, recycling, or segregation
of waste streams. The second control strategy is to reduce
the organic compound content of the wastewater through
treatment before the stream contacts ambient air. A complete
strategy for reducing the organic compound content of. the
wastewater includes: (l) suppression of emissions from
collection and treatment system components by hard piping or
enclosing the existing wastewater collection system up to the
point of treatment; (2) treatment of the wastewater to remove
organic compounds; and (3) treatment of residuals. Residuals
include oil phases, condensates, and sludges from
nondestructive treatment units. Each of these steps is
essential to the effective reduction of VOC emissions.
The purpose of this chapter is to present and discuss the
two emission control strategies. A general discussion of the
application of waste minimization to control VOC emissions
from industrial wastewaters is presented in Section 4.1.
Section 4.2 presents a discussion of organic compound
treatment technologies, including steam stripping and
biological destruction. Section 4.3 presents VOC emission
suppression technigues for collection and treatment system
4-1
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components. Add-on control devices are discussed in
Section 4.4.
4.1 WASTE MINIMIZATION
Waste minimization is a general term that includes both
source reduction and recycling. Source reduction refers to
reduction or elimination of the generation of a specific waste
at the source. This may be accomplished through process or
equipment modifications, stream segregation, or changes in
work practices. Recycling includes recovery and/or reuse of
potential waste streams. Waste minimization must be
implemented on a process-specific basis. However,
implementation of an aggressive waste minimization program can
be an effective method of reducing emissions of VOC from
industrial wastewaters.
Although many of the specific techniques that can be
applied to minimize waste generation are specific to one
application, the implementation of any waste minimization
program should follow the guidelines presented below. By
following these guidelines, the most effective steps can be
identified and implemented.
4.1.1 gatherBaseline_Data
The first step in any waste minimization program should
be to identify and characterize the individual waste streams.
This should include flow rate, composition, pH, and solids
content of the wastewater streams. Although some of these
data might need to be gathered through a sampling program,
some of them may be available from hazardous waste manifests,
Superfund Amendments and Reauthorization Act (SARA) Title III
Section 313 release reporting calculations, permits,
monitoring reports, product and raw material specifications,
and other internal records.
4.1.2 Identify andRank Sources for Reduction
Using the baseline data gathered, a cost allocation
system should be developed to assess treatment and disposal
costs of individual waste streams. Future treatment and
disposal costs should be considered in this evaluation, as
should potential liabilities associated with the waste
4-2
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handling and subsequent treatment and disposal. Once the
waste streams have been ranked and prioritized, methods for
controlling these streams can be considered.
4.1.3 Implementation of Reduction/Recycling
In selecting the appropriate method for reducing or
eliminating a wastewater stream, a variety of sources of
information can be used. The Agency's Pollution Prevention
Information Clearinghouse (PPIC), supported by the Pollution
Prevention Office, contains information on case studies and
reports on pollution prevention. The PPIC can be accessed by
telephone hotline (202-382-3000). other valuable sources of
information are State.assistance programs, vendors, and
consultants.
As waste minimization steps are implemented, it is
important that good recordkeeping be continued to document
which steps were effective and which ones failed. Good
records are especially important because future regulations
may require percentage reductions in wastes generated. To
receive credit for reductions, facilities will be required to
provide documentation regarding the quantitative impacts of
the waste reduction programs (reduction in v"OC emissions,
reduction of wastewater flow, etc.). Although some wastewater
streams will still be generated, an effective waste
minimization program may allow more cost-effective handling of
these streams.
4.2 ORGANIC COMPOUND TREATMENT TECHNOLOGIES
4.2.1 Stesp,. Stripping
Steam stripping is a proven technology that involves the
fractional distillation of wastewater to remove organic
compounds. The basic operating principle of steam stripping
is the direct contact of wastewater with steam. This contact
provides heat for vaporization of the more volatile organic
compounds. The overhead vapor, containing water and organic
compounds, is condensed and separated (usually in a decanter)
to recover the organic compounds. These recovered organics
are usually either recycled to the process or incinerated in
an onsite combustion device.
4-3
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4.2.1,1 Steam Stripper Process Description. Steam
stripper systems may be operated in a batch or continuous
mode. Batch steam strippers are generally more prevalent when
the wastewater feed is generated by batch processes, when the
characteristics of the feed are highly variable, or when small
volumes of wastewater are generated. A more detailed
discussion of the operating and design considerations of batch
steam stripper systems is contained in the Wastewater CTC
Document.
In contrast to batch steam strippers, continuous steam
strippers are generally designed to treat wastewater streams
that are continuously discharged from process equipment and
are relatively consistent in composition. However, batch
wastewater streams can also be controlled by continuous steam
strippers by incorporating a feed tank with adequate residence
time to provide a relatively consistent outlet composition.
For these reasons, the remaining discussion focuses on a
continuous steam stripping system.
Figure 4-1 presents a continuous steam stripping system
that can be designed and operated to achieve high organic
compound removal efficiencies for most wastewater streams.
The design and operating conditions for a steam stripper
system with an assumed feed rate of 300 liters per minute
(£pm) (80 gallons per minute [gal/min]) is presented in
Table 4-1. The steam stripping system includes an enclosed
wastewater collection up to a covered feed tank, the steam
stripping tower, and controls on tank and condenser vents
associated with the steam stripping system. In Figure 4-1,
the noncondensables are vented to the feed storage tank, which
is routed to a control device. Each of these steam stripper
system components are discussed briefly in the following
sections; additional discussion on these components can be
found in the Wastewater CTC Document.'
4.2.1.1.1 Wastewatercollection and conditioning. The
controlled sewer system, or hard piping from the point of
wastewater generation to the feed tank, controls emissions
4-4
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Noncondensabtes
Vent to
Control Device
tf Necessary
Process Wastewater
vte Controlled
Sewer or Hard Piping
To Wastewater
Treatment Plant
Feed Tank/Phase Separator
Recovered Organtes
to Storage
Stripper Feed ^
Stream
ms
iger
kJL-&-&-&-
Treated
"Wastewater
Steajn
1SS8?-
-Steam
Figure
4-1. continuous
steam stripper system.
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TABLE 4-1. DESIGN AND OPERATING BASIS FOR THE STEAM STRIPPING SYSTEM
1. Wastewater stream content: water = 99,75%
total organics = 0.25% (2,500 ppm)
2. Wastewater stream organic composition:
Organic compound Henry's Waste stream
Law value organic cone. % Removal in stripper
Organic compound (atm-m3/gmol) at 25 °C (ppmw) £ra
Butadiene
Toluene
Naphthalene
Butanol
Phenol
1.42 x 10"1
6.68 X 10~3
1.18 X 10"~3
8.90 X 10~6
4.54 X 10"7
500
500
500 .
500
500 -
100
100
100
92
8.9
3. Wastewater flow: 300 t/nin
4. Stripper operating period: 24 hr/day x 300 day/yr ~ 7,200 hr/yr
•N . '
i 5. Wastewater storage: Wastewater feed collection tank with 48-hour retention time,
6. Steam stripping column:
Configuration: countercurrent flow, 9.0 m sieve tray column
Steam flow rate: 0,096 kg of steam/£ of waste feed
Wastewater feed temperature: 35 °C
Column diameter: 0.76 m
Active column height: 6.5 m
Total column height: 9.0 m
Liquid loading: 39,900 e/hr/m2
7. Condenser:
Configuration: water-cooled
Primary condenser outlet vapor temperature: 50 °C
8. Overhead control: vent to existing onsite combustion or other control device.
9. Bottoms control: feed to existing onsite wastewater treatment facility or publicly
owned treatment works.
aRemoval efficiency was estimated using ASPEN.2 Benzene was the chosen design compound.
-------
before steam stripping. Section 4.3 presents VOC emission
suppression techniques for wastewater collection and treatment
system components. The feed tank, which is covered and vented
to an onsite combustion device, collects and conditions the
wastewater fed to the steam stripper. The feed tank is sized
to provide a hydraulic retention time of 48 hours, which is
conservatively high. The desired retention time depends
primarily on the variability in wastewater flow rate,
characteristics of the inlet wastewater, and the amount of
wastewater conditioning needed (i.e., separation of aqueous
and organic phases, settling of solids). Additional surge
capacity can provide retention time for wastewater streams
with highly variable flow rates (including batch flow streams)
to maintain a relatively constant feed rate to the stripper.
4.2.1.1.2 Wastewater steam stripping. After the
wastewater is collected and conditioned, it is pumped through
the feed/bottoms heat exchanger and into the top of the steam
stripping column. Steam is sparged directly into the stripper
at the bottom of the column, and as the wastewater flows down
the column i€ contacts the steam countercurrently. Latent and
sensible heat is transferred from the steam to the organic
compounds in the wastewater, vaporizing them into the vapor
stream. These constituents flow out the top of the column
with any unqondensed steam. The wastewater effluent leaving
the bottom of the steam stripper is pumped through the
feed/bottom heat exchanger to heat the feed stream and cool
the bottoms before discharge.
The steam stripper design presented in Table 4-1 was
developed using the Advanced System for Process Engineering
(ASPEN).2 The diameter was calculated assuming a velocity of
80 percent flooding conditions. In addition, the following
engineering assumptions were made:
• ' . . -
• Operating pressure of 1 atmosphere;
• :
• Isothermal column operation;
• Constant mola1 overflow (i.e., one mole of aqueous
phase vaporized for each mole of steam condensed); and
4-7
-------
•• Linear equilibrium and operating equations (i.e.,
Henry's Law is valid for each organic compound at the
concentrations encountered in the stripping column).
The design stripper contains 10 trays. A tray efficiency
of 80 percent was assumed to estimate the actual number of
stages for the column. A tray spacing of 0.50 m (1.6 ft) was
assumed to estimate the active column height. To approximate
the total column height, a total of 2.5 m (8.2 ft) of
nonactive entrance and exit column was assumed.
4.2.1.1.3 Controlling vents and openings in the steam
stripper system. In a steam stripper system, vent lines carry
gaseous organics,, water vapor, and noncondensibles to a
control device. For the stripper in Figure 4-1, vent lines
are placed between the stripper column and primary condenser,
between the primary condenser and feed tank, and between the
feed tank and an existing onsite combustion device. A
condenser system is used to recover the organic and water
vapors in the gaseous overheads stream from the stripping
column. The condensed overheads stream is fed to an overhead
receiver, and the recovered organic compounds are either
pumped to storage and recycled to the process unit or
combusted for their fuel value in an incinerator, boiler, or
process heater. The feed tank vent line is controlled with a
combustion device or a product recovery device. A discussion
of various add-on vapor stream control devices is presented in
Section 4.4.
4.2.1.2 Steam Stripper Applicability and Performance.
Steam stripper VOC removal efficiencies are dependent on
factors affecting the degree of contact that occurs in the
steam stripping column (column dimensions—height and
diameter; contacting media—trays or packing; and operating
parameters—steam-to-feed ratio, temperature, and wastewater
pH) and wastewater characteristics such as organic compound
volatility. However, in general, steam stripping is the most
universally applicable VOC removal technology for treating
wastewater streams such as those generated within the six
industries covered by this document.
4-8
-------
Information on the design and operation of steam stripper
systems was obtained for approximately 15 steam strippers,
from facility responses to 1987 Clean Air Act Section 114
information requests. Additional information was gathered on
seven steam strippers in operation at manufacturing
facilities,*'5'6'7'8'9'10 and five steam strippers in operation
at hazardous waste transfer, storage, and disposal facilities
(TSDF).u Information about steam strippers in use at pulp
and paper facilities was also gathered by the Office of Air
Quality Planning and Standards (QAQPS).12 Although most of
the steam strippers on site at pulp and paper mills were
initially installed for total reduced sulfur (TRS) removal
from evaporator condensate streams, as discussed in
Chapter 2.0, VOC removal is also achieved. Because pulp and
paper wastewater streams generally contain a high solids
content, and high (evaporator condensate wastewater) and low
(bleach wastewater) pH, some pretreatment or design
considerations (i.e., stainless steel construction) may be
warranted for steam stripping wastewater streams at pulp and
paper facilities.
Data on steam strippers were also gathered by the Office
of Water Regulations and Standards (OWRS) for the organic
chemicals, plastics, and synthetic fibers (OCPSF); pesticide;
and pharmaceutical manufacturing industries. In response to
Clean Water Act Section 308 information requests, 64 OCPSF
facilities reported using a total of 108 steam strippers as an
in-plant control for process wastewater.13 In addition to
these information requests, data on steam strippers in
operation at three OCPSF facilities were obtained through
field testing efforts.14'15'16 .Information on steam strippers
in use at eight pharmaceutical facilities'and eight pesticide
facilities was also gathered.17'18
The organic compound removal performance of five steam
stripper systems was measured during field tests by collecting
and analyzing samples of the feed and bottoms streams. In
addition, data were gathered to evaluate the effect of design
4-9
-------
and operating parameters on the performance of each system.
These data, along with performance data provided by a facility
using a recently installed steam stripper and steam stripper
data obtained in response to a March 1990 Section 114 survey
are presented in Table 4-2. The organic compound removals
presented in Table 4-2 range from 76 percent for Site 7 to
greater than 99.9 percent for Sites C, F, 321, and 131.
4.2.1.3 Steam StripperRemoval Efficiency. The removal
efficiencies used in this document were predicted for the five
compounds in the example wastewater stream: with the steam
stripper design generated using ASPEN2 and presented in
Table 4-1. As shown, the compounds in the medium to high
volatility range were removed at efficiencies exceeding
99 percent. The results of this analysis were used to develop
a relationship between removal efficiency and the Henry's Law
constant for the compound. Prom the results of this analysis,
four equations were developed for different Henry's Law
constant (H) ranges, to best correlate removal efficiency (Fr)
to Hs
Henry's Law Constant (H)
25 °C Range (atm * m3/mol)
Fraction Removed (Fr)
H > 0.00105
H < 3.3 X ID-*7
3.3 X 10~7 < H < 8.9 X 10~6
8.9 X 10~6 < H < 1.05 X 10~3
F-r —
Fr -
Fr = 1.0
Fr = 0
4.168 + 0,6430 * log H
1.115 + 0.03865 * log H
Figure 4-2 presents these equations graphically. These
equations are used in estimating the removal efficiencies and
associated national emission reductions for the application of
reasonably available control technology (RACT) to the affected
industries. These calculations are presented in Appendix B.
4-10
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TABLE 4-2. STEAM STRIPPER ORGANIC COMPOUND REMOVAL PERFORHHNCTT
Site
1.0.
A
B
C
D
E
*.
1
H
M
.F
6
7
10
Z
151
154
163
611
921
Organic compounds
Benzene, Chlorobenzene, and other.
Chlorinated hydrocarbons
Chlorinated hydrocarbons
Benzene, Chlorobenzene,
1,2-. 1,3-,, and 1,4-DI Chlorobenzene,
Ethyl benzene, Toluene, Xylene
1 , 1-01 chl oroethane , 1 , 1-D1 chl oroethene ,
Trans-1 , 1-Di chl oroethane ,
1 , 1 ," 1 -Tr i chl oroethane ,
Trl chl oroethane, Tri chl oroethene,
1 , 1 , 2-Tr1 chl oroethane ,
1,1, 2, 2-Tetraehl oroethane,
Tetrachl oroethene
Benzene, Toluene, Ethyl benzene,
Isophorone, Naphthalene, S-Ethyl-
1,2-Methylpryride, 1,2,3,4-
Tetrahydronaphthal ene ,
Acetophenone , 2-Hethyl-
1,3-Cyelopentanedione .
Chloromethane, Methyl ene Chloride,
Chloroform, Carbon Tetrachl or Ide,
Tr 1 chl oroethyl ene ,
1 , 1 , Z-TH chl oroethane
Nitrobenzene, Hljtrotoluene
Benzene, Nitrobenzene, Phenol,
Nltrophenols
CHC, Chlorinated Ethers, Phenol,
Chlorinated Phenols
Benzene, Toluene, Chlorobenzene,
Ethyl benzene. Methyl ene Chloride
Benzene, Nitrobenzene,
2, 4-01 nitrobenzene, Aniline,
Nltrophenol, Phenol
Aniline, Nitrobenzene, Benzene
Acroleln, Vinyl Acetate, Acetaldehyde
Methyl ene Chloride, Methanol, Dimethyl
Ether
Ethyl ene 01 chloride.
Column
Height
(m)
NA
3.0b
49.0
NA
26
NA
19.2
9.8b
6.1b
12,2
11.6
11.9
7.32
8.32
13.9
design
Diameter
(*)
NA
0,2
2.5
NA
NA
1.5
0.46
o.ei
1.07
1.22
1.83
1.07
0.61 .
0.51
0.91
Column
Feed
rate
(kg/hr)
48,960
1,260
6,624
143,556
1,831
2,440
29,900
5,452
12,693
68,100
8,402°
3,885f
5,8929'"
3,?72C
16,707°
operation
Steam: feed
ratio
(kg/kg)8
0,03
oa
0.14
0.14
0.70
0.10
0.07
0.4
NA
0.20
0.625
NA
0.05
0.23
0,113
Feed cone.
(Ǥrt)
5,900
3,900
7.98
1.984
•22.9
5,860
634
1,192
453
2,073
2,317d
3,170
1.1501
55, 000 3
3241
Colunn performance
Bottoms
cone.
(«9/l) r
9.8
5.2
0.305
4.9
0.079
0.033
47.8
250
3.4
0.04
23e
31. 7e
12
5,500s
0.649
Organic
compound
etnoval (X)
>99.8
99.8
99.96
99.75
.92.2-5
>99.9
92
76
99
>99.8
99
99
99
>90
99.8
-------
TABLE 4-2. STEAM STRIPPER ORGANIC COMPOUND REMOVAL PERFORMANCE (Concluded)
l
H
to
Column design
Site
I.D.
312
321
131
716
4113
414
3310
Organic confounds
Honoester, n-Butanol, Oibutyl Phthalate
Benzene, Aniline,
Caprolaetam
n-Butanol, 4-Amlnobiphenyl, Aniline
Benzene
1 so-Butanol
n-Butanol
Ethyl morphollne,
Hethylmorphol ine,
Horpholine
Height
M
8.46
14.7
22.0
12,2
15.2
12.2
Diaweter
M
0.46
0.31
0.51
0.41
0.91
D.30 '
Colwn operation
Feed
rate
(kg/hr)
13,728k
9,945C
737°
487
1,816°
686*
Steal; feed
ratio
{kg/kg}*
0.11
0.12
0.37
0.155
0.5
0.36"1
Wtanjgerfom
Bottoms
Feed cone. cone.
(IKJ/I) («/!)
128.WO
34,300
30,000
2SO
400, 000*
28,300
2,300
31,205
21
2.8e
4,000
2,700
ance
Organic
compound
removal (X)
99.8
99.9
99.9
99
39
95
90
10
a£qual to kg of steam per I of wastewater, assuming the density of wastewater 1s 1 k§ per I.
''Height of packed section only. Total height 1s not available.
cThe feed flow rate was calculated by dividing the annual steam usage by the steam-to-feed ratio (SFR).
%eed stream volatile organic concentration is the weighted average of volatile organic concentrations In several combined process wastewater streams.
eThe bottoms volatile organic concentration is calculated from the following relationship:
Bottoms concentration « Feed concentration * (1 - stripper efficiency fraction)
^The feed flow rate was calculated from the sum of process streams Into the stripper identified In the facility process flow diagram,
^-Assumed wastewater feed temperature of 35 °C.
^Calculated the feed flow rate from known bottom flow rate using the following relationship:
Feed flow rate * (Bottoms flow rate)/[0.99 (1 + SFR)]
'The feed volatile organic concentration is calculated from the following relationship:
Feed concentration = (Bottoms concentration)/(1 - stripper efficiency fraction)
•^Assumed that the two reported wastewater feed streams were of equal flow and calculated an average volatile organic concentration.
kflatch steam stripper—Assumed median flow rate of reported range.
*The flow rate was calculated from stripper bottom flow range code. The midpoint of the flow range was used for the calculation.
"The reported steam flow rate of 250 kg/hr was divided by the calculated feed flow rate of 686 kg/hr.
NA = Not available.
-------
IU
g
u_
u.
LU
§
UJ
cc
Q
-Z
o
0.
S
O
o
g
z
cc
O
110
100
90
80 H
70
SO -
50 -
40
30
20 -|
10
0
0
234
-LOG (HENRY'S LAW CONSTANT)
~r
6
Figure 4-2. Predicted steam stripper organic compound removal efficiencies
based on -log Henry's Law constant for the compound at 25 °c.
-------
4.2.2 Air Stripping
The underlying principle for air stripping is vapor-
liquid equilibrium.19 By forcing large volumes of air through
the contaminated water, the air-water interface is increased,
resulting in an increase in the transfer rate of the organic
compounds into the vapor phase. The technology is applicable
to compounds with a wide range of volatilities; however, the
air used to remove the organic compounds from the wastewater
must be vented to a combustion or organic compound recovery
device. In many cases, this add-on control device is a carbon
adsorber. However, in some cases the air stream can be vented
to a combustion device. In practice, air stripping is
generally applicable for streams containing dilute organic
compound concentrations such as pulp and paper wastewaters or
contaminated ground water, and is most efficient in removal of
highly volatile, water insoluble compounds.
4.2.2.1 AirStripper Process Description. Air stripper
systems can be operated in a batch or continuous mode.
Because air strippers are generally used in continuous
operation applications, such as ground water or drinking water
remediation, continuous air strippers are more prevalent than
steam strippers. Removal rates of continuous, uniform
concentration wastewater streams, in general, are less
variable than for batch operation.
Figure 4-3 presents a generic continuous air stripper
system. The first component is the controlled sewer system or
hard piping from the point of wastewater generation to the
feed tank. The tank collects and conditions the wastewater
feed to the air stripper. The tank is covered and vented to a
control device. Wastewater is then pumped from the feed tank
through a preheater and into the air stripper column.
Wastewater is introduced into the top of the column while air
is blown from the bottom. The wastewater stream can be heated
from exhaust gas from an existing controlled boiler.
As the wastewater flows down through the column, it
contacts the air that is flowing countercurrently up the
column. With the increased air-water interface provided by
4-14
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Process Wastewater via
Controlled Sewer —
or Hard Piping
p
ui
Vent to Boiler .
~^
if Necessary Air Stripper
Feed Stream
Overheads
r^~n
J-
S Oartt\nn /
*- Vent to Boiler
Feed Tank
6
Feed Preheater
Exhaust Gas from
Existing Controlled Boiler
Air
Gas Blower
-»> Treated Wastewater to
Wastewater Treatment Rant
Figure 4-3. Continuous air stripper system.
-------
packing, the rate of transfer of organic compounds to air is
increased. These constituents flow out the top of the column
with the air. The overheads stream can be vented to a boiler
and used as combustion air with supplemental heating value.
The bottoms stream typically gravity flows to an existing
wastewater treatment plant.
4.2.2.2 Air Stripping Removal Performance. General
information on 177 operating air strippers in the United
States was gathered through a literature search.1 Most of the
applications were for treatment of contaminated ground water,
landfill leachate, and contaminated drinking water. Data
collected for 46 of the 177 air strippers demonstrate average
percent removal ranges for the following selected compounds:
** Benzene ** 99 to 99.9;
* Toluene = 96 to 99+;
* Kylene = 96 to 99.8;
' Trichloroethylene = 90 to 99.9;
* Methyl-tert-butyl ether = 95 to 99;
+ 2-Methyl phenol =70 (one point);
* Phenol = 74 (one point); and
« Aniline = 58 (one point).
4.2.3 Biological Organic Compound DestructionTechnology
Biological waste treatment is normally accomplished
through the use of aeration basins. Microorganisms require
oxygen to carry out the biodegradation of organic compounds
that results in energy and biomass production. The aerobic
environment in the basin is .normally achieved by the use of
diffused or mechanical aeration. This aeration also serves to
keep the biomass well mixed. The goal is to maintain the
biomass concentration at a level where the treatment is
efficiently optimized and proper growth .kinetics are induced.
The performance of aeration basins is particularly
affected by: (1) mass of organic per unit area;
(2) temperature and wind patterns; (3) hydraulic retention
time? (4) dispersion and mixing characteristics; (5) sunlight
energy; (6) characteristics of the solids in the influent; and
4-16
-------
(7) the amount of essential microbial nutrients present.
Basin efficiency, measured as the degree of stabilization of
the incoming wastewater, is dependent on both biological
process kinetics and basin hydraulic characteristics.
Three mechanisms affect the removal of organic compounds
in aeration basins. These mechanisms are biodegradation,
adsorption onto the sludge, and air emissions. Because these
three mechanisms compete against each other, factors affecting
biodegradation and adsorption mechanisms will have an effect
on air emissions. The greater the biomass concentration in
the basin, the greater the removal of organic compounds will
be by both biodegradation and adsorption mechanisms. The
biodegradability of a compound will also affect its removal by
biodegradation; as the biodegradability of the compound
increases, so does the rate of biodegradation. Also, because
the microorganisms prefer some compounds more than others, the
biodegradation process is selective and depends on the
compound matrix. Octanol-water partition coefficients are
often used to indicate the affinity of a compound for the
organic or aqueous phase. The relative magnitude of this
coefficient provides some indication of organic compound
removal by the adsorption mechanism.
Typically, aeration basins are equipped with aerators to
introduce oxygen into the wastewater. The biomass uses this
oxygen in the process of biodegrading the organic compounds.
However, aeration of wastewater also affects air emissions.
Because of the turbulence caused by the aerators, an increased
liquid surface area is exposed to ambient air; therefore, the
liquid and gas phase resistances to mass transfer are reduced.
Convective mass transfer in both phases is increased. This
transfer mechanism significantly increases air emissions
compared to quiescent, flow-through type tanks such as
clarifiers. However, many of the factors that affect
emissions from flow-through tanks also affect emissions from
aeration basins. The concentration and physical properties of
the organic compounds have a similar effect on emissions. As
the volatility and diffusivities in water and air of the
4-17
-------
organic constituents increase, air emissions also tend to
increase.
Other factors affecting emissions from aeration basins
include wind speed and basin design characteristics.
Increases in wind speed increase convective mass transfer from
the wastewater in the basin and, therefore, increase air
emissions. However, emissions from aeration basins are not as
sensitive to wind speed effects as those from quiescent
basins. Basin design characteristics that affect emissions
include: the quiescent and turbulent surface areas, the depth
of the basin, the design of the aerators, and the hydraulic
retention time of the basin. As the turbulent surface area of
the basin increases, air emissions will also tend to increase
as a result of increased convective mass transfer of the
organic compounds. The depth of the basin affects mass
transfer in the liquid phase. Convective mass transfer in the
liquid phase increases as the basin becomes more shallow, and,
therefore, air emissions also tend to increase. Because the
aerators generate the turbulence that increases the rate of
mass transfer in the liquid and gas phases, the design of
these aerators has a significant effect on emissions. The
degree of turbulence these aerators impart to the wastewater
is a function of the power output to the impellers, the
impeller speed, and the impeller diameter. Increases in these
design parameters result in additional turbulence of the
wastewater, which tends to increase air emissions. The final
design parameter affecting emissions is the volume of the
basin. As the volume increases, so does the hydraulic
retention time. Increases in the basin volume provide
additional time for removal by all three mechanisms:
biodegradation, adsorption, and air emissions. Therefore, the
magnitude of the increase in air emissions due to the
additional retention time depends on the relative removal
rates by the other two mechanisms. Biological treatment basin
emission factors can be estimated using CHEM.7.21 Site
specific biological degradation rate constants for use in
4-18
-------
developing these factors can be calculated using the biorate
protocol (under development).
4.2.4 Other Organic Compound Removal Technologies
This section presents other control technologies for
reducing VOC emissions from industrial wastewaters. These
technologies reduce VOG emissions by removing organic
compounds from the wastewater before they are emitted to the
air. Although steam stripping and air stripping are the most
widely applicable technologies for VOC emission reduction from
industrial wastewaters, there are applications where other
technologies may be more appropriate. The purpose of this
section is to present some of these technologies along with a
brief discussion of each.
In addition to steam stripping, technologies available
for removing organic compounds from wastewater include
chemical oxidation, carbon and ion exchange adsorption,
22
membrane separation, and liquid-liquid extraction. These
technologies rely on a variety of mechanisms to remove organic
compounds from wastewater. These technologies are used in
different applications by facilities in the targeted
industries and may be effective at removing certain organic
compounds. For this reason, a brief description of each
technology is provided below.
Chemical oxidation involves a chemical reaction between
the organic compounds and an oxidant such as ozone, hydrogen
peroxide, permanganate, or chlorine dioxide. The
applicability of this technology depends on the reactivity of
the individual organic compounds. For example, phenols and
aldehydes are more reactive than alcohols and alkyl-
substituted aromatics; halogenated hydrocarbons and saturated
aliphatic compounds are the least reactive.
Adsorption processes take advantage of compound
affinities for a solid sorbent medium. Activated carbon or
polymeric resins are often used as the medium. The volatile
compounds are adsorbed onto the solid sorbent medium as they
are contacted by the wastewater. Nonpolar compounds can be
adsorbed onto the surface of activated carbon. By .contrast,
I . • 4-19
-------
removal by polymeric resins involves both adsorption and ion
exchange mechanisms and is therefore more effective for polar
compounds. With carbon adsorption, the capacity of the carbon
to adsorb the organic compounds at a given influent
concentration varies widely for different compounds. In
addition, the ease of desorption (removal) of the organic
compounds and possible wastewater contaminants from the carbon
is highly variable. For these reasons, the feasibility of
using carbon adsorption must be evaluated on a case-by-case
basis. A more detailed evaluation of the applicability of
carbon adsorption to organic compound removal from industrial
wastewaters is documented in a memorandum entitled "Evaluation
of Carbon Adsorption as a Control Technology for Reducing
Volatile Organic Compounds (VOC) from Industrial
Wastewaters."24
Two types of membrane separation processes are
ultrafiltration and reverse osmosis. Ultrafiltration is
primarily a physical sieving process driven by a pressure
gradient across a membrane. This process separates
macromolecular organic compounds with molecular weights of
greater than 2,000, depending on the membrane pore size.
Reverse osmosis is the process by which a solvent is forced
across a semipermeable membrane due to an osmotic pressure
gradient. Selectivity is, therefore, based on osmotic
diffusion properties of the compound and the sizes of the
compound and the membrane pores.22
Liquid-liquid extraction, sometimes referred to as
solvent extraction, uses differences in solubility of
compounds in various solvents as a separation technique. By
contacting a solution containing the desired compound with a
solvent in which the compound has a greater solubility, the
compound may be removed from the solution. This technology is
often used for product and process solvent recovery for two
reasons. First, the solvent can usually be regenerated, and
second, the compound of. interest can often be recovered by
distillation.
4-20
-------
4.3 VOLATILE ORGANIC COMPOUND EMISSION SUPPRESSION FROM
COLLECTION AND TREATMENT SYSTEM COMPONENTS
The VOC emissions from wastewater collection and
treatment systems can be controlled either by hard piping or
by enclosing the transport and handling system from the point
of wastewater generation until the wastewater is treated to
remove or destroy the organic compounds. Suppression
techniques can be broken down into four categories:
collection system controls, roofs, floating membranes, and
air-supported structures. These devices and their associated
VOC suppression efficiencies are discussed in detail in the
Wastewater CTC Document.1 Suppression of VOC emissions merely
keeps the organic compounds in the wastewater until they reach
the next potential VOC emission source. Therefore, these
techniques are not effective unless the VOC emissions are
suppressed until the wastewater reaches a treatment device
where the organic compounds are either removed or destroyed.
4.3.1 Collection System Controls
As discussed in Chapter 3.0, collection systems comprise
components such as drains, junction boxes, sumps, trenches,
and lift stations that provide contact between wastewater arid
ambient air. These collection system components provide
escape routes for organic compounds contained in wastewater.
Suppression controls can be applied to most of these
components to reduce the potential of VOC emissions during
wastewater collection. These controls involve the use of
physical covers and water seals to minimize the contact
between ambient air and the wastewater flowing through the
component. Physical covers and water seals are only effective
if the wastewater flows downstream and to an organic compound
removal or destruction device, such as a steam stripper or
biological treatment basin. The applicable VOC suppression
controls for each of the wastewater collection system
components are presented in the following sections. A
complete description of each suppression control device can be
found in the Wastewater CTC Document.1 The collection system
4-21
-------
VOC suppression devices discussed are consistent with the
"Benzene Waste Operations National Emission Standards for
Hazardous Air Pollutants (NESHAP). 40 CFR Part 61 Subpart FF."
Two commonly used methods for controlling emissions from
drains are leg and seal pot configurations. Use of p-leg
seals and seal pots can reduce VOC emissions from drains if
the system is well maintained; however, monitoring the
performance of the control will be difficult. Control of
emissions can also be achieved by hard piping any source of
wastewater containing organic compounds to a control device.
Other collection system components that typically require
control are junction boxes, sumps, and lift stations. Since
the design of these three components are similar, the same
technique is effective for suppressing VOC emissions from all
three. For these components, a gas tight cover is typically
used.
4.3.2 Roofs
The following discussion on fixed- and floating roof tank
covers is consistent with the "New Source Performance
Standards (NSPS) for Petroleum Refinery Wastewater Systems
Final Rule," promulgated in November 1988.25
4.3.2.1 Fixed-Roof Tanks.26 Storage or treatment of
wastewater in fixed-roof tanks instead of open-top tanks
reduces VOC emissions. By covering the tank, the wastewater
surface is sheltered from the wind. This decreases the mass
transfer rate of organic compounds in the wastewater to the
atmosphere. The extent to which VOC emissions are reduced
depends on many factors including wastewater composition and
organic compound concentrations, windspeed, and the ratio of
the tank diameter to the depth of the wastewater contained in
the tank.
Although fixed-roof tanks provide large reductions in VOC
emissions compared to open-top tanks, fixed-roof tanks can
still emit significant quantities of VOC. The major sources
of VOC emissions from fixed-roof tanks are breathing losses
and working losses. Breathing losses occur from the expulsion
of vapor through the roof vents because of the expansion or
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contraction of the tank vapor space resulting from daily
changes in ambient temperature or barometric pressure. These
VOC emissions occur in the absence of any liquid level change
in the tank. Working losses occur from the displacement of
vapors resulting from filling and emptying the tank.
Breathing and working losses from fixed-roof tanks can be
reduced by installing an internal floating roof, connecting
the tank roof vents to an add-on control device, or installing
pressure-vacuum relief valves on the tank roof vents.
4.3.2.2 Floating Roof Tanks.27 Floating roofs are used
extensively in the petroleum refining, gasoline marketing, and
chemical manufacturing industries to control VOC emissions
from tanks storing organic liquids.
There are two general types of floating roof tanks:
those with external floating roofs and those with internal
floating roofs. Floating roofs are appropriate for wastewater
storage tanks and certain treatment tanks where the presence
of the floating cover would not interfere with the treatment
process. Treatment tanks equipped with surface mixing or
aeration equipment cannot use floating roofs. Also, because
floating roofs are in direct contact with the wastewater, the
materials selected to fabricate the deck and seals must be
compatible with the wastewater composition.
Floating roof tanks significantly reduce but do not
eliminate VOC emissions. Organic vapor losses called
"standing losses" occur at the deck seals and fitting
openings. Additional organic vapor losses called "withdrawal
losses" occur from evaporation of the liquid that wets the
inside tank wall as the roof descends during emptying
operations.
4.3.2.3 Oil/Water Separators. The most effective option
for controlling VOC emissions from oil/water separators is to
install either a fixed or floating roof. These roofs control
VOC emissions by reducing the oil surface exposed to the
atmosphere, reducing the effects of wind velocity, and
reducing the effects of solar radiation by insulating the oil
layer., .
. ' . '4-23 .
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Fixed roofs can be installed on most, oil/water
separators. This can be done without interfering with the
operation of the system by mounting on the sides of the
separator or by supporting with horizontal steel beams set
into the sides of the unit. Gas-tight access doors are
usually installed in the roof for maintenance and inspection.
Since the vapor space below fixed roofs may constitute an
explosion or fire hazard, the vapor space is often blanketed
with nitrogen and/or purged to a recovery or destruction
device.
For floating roofs, the effectiveness of their emission
control is primarily dependent on the effectiveness of the
seals between the roofs and walls of the separator. If these
seals are not well maintained to prevent leakage, their VOC
emission control capabilities will be reduced significantly.
One final concern in evaluating emissions from oil/water
separators is the handling of the recovered oils. Since the
oils may contain high concentrations of organic compounds,
care must be taken to minimize VOC emissions. This can be
accomplished by handling the oils and organic compounds in
closed systems equipped with emission controls.
2B
4.3.3 Floating Membrane Covers
A floating membrane cover consists of large sheets of
synthetic flexible membrane material that floats on the
surface of the wastewater. Individual sheets can be seamed or
welded together to form covers applicable to any size area.
Floating membrane covers have been used successfully for many
years to cover the surface of potable water impoundments or
reservoirs. In a "leak tight" application, floating membrane
covers have been used to cover large anaerobic digester
lagoons to collect the methane gas for energy recovery. Thus,
floating membrane covers offer good potential as a suppression
device for wastewater surface impoundments.
The effectiveness of a floating membrane cover depends on
the amount of wastewater surface that is covered and the
permeability of the membrane material to the organic compounds
contained in the wastewater. Using a membrane material with
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adequate thickness and following good installation practices
will minimize tearing or puncturing of the membrane material.
The overall cover permeability is a function of the organic
composition and concentration of the wastewater managed in the
surface impoundment as well as the cover material's
composition and thickness. The EPA has developed a laboratory
protocol to measure the permeability of volatile organics
29
(VO's) through flexible membrane covers.
4.3.4 Air-Supported Structures30 ' ' . ' .
An air-supported structure is a plastic-reinforced fabric
shell that is inflated and therefore requires no internal
rigid supports. The structure, shape, and support are
provided by maintaining a positive interior pressure (i.e.,
the interior pressure is greater than the external atmospheric
pressure), Adequate air changes are necessary to prevent the
organic vapor concentrations inside the structure from
exceeding the lower explosive limits. The vent system can
discharge directly to the atmosphere or be connected to an
add-on control device.
Because of the low leakage levels attainable, almost all
of the organic vapors contained by an air-supported structure
will be ultimately discharged through the structure's vent
system. Therefore, connecting the vent system to one of the
add-on control devices discussed in Section 4.4 will result in
an overall VOC emission control efficiency for wastewater
treatment applications using an air-supported structure that
is approximately equivalent :to the efficiency of the control
device. These add-on control devices are capable of achieving
control efficiencies in excess of 95 percent.
Large areas can be enclosed by erecting an air-supported
structure, structures are commercially available ranging in
widths from 24 to 91 m (80 to 300 ft) wide and lengths from
24 to 137 m (80 to 450 ft). For larger areas, a number of
modules can be connected together. Air-supported structures
have been used as enclosures for conveyors and coke ovens,
open-top tanks, material storage piles, biological treatment
.basins, and landfills. .
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4.4 ADD-ON CONTROLS
Add-on controls serve to reduce VOC emissions by
destroying or extracting organic compounds from gas phase vent
streams before they are discharged to the atmosphere. Add-on
controls are applicable to vents associated with collection
and treatment covers, such as drain covers, fixed roofs, and
air-supported structures, and with organic compound removal
devices, such as air strippers and steam strippers. Add-on
controls for VOC emissions are classified into four broad
categories: adsorption, combustion, condensation, and
absorption. General background information about these types
of add-on controls is available in the Wastewater CTC
Document. The type of add-on control best suited for a
particular wastewater emission source depends on the size of
the source and the characteristics of the wastewater in the
source.
Combustion destroys the organic compounds in the gas
stream by oxidation of the compounds primarily to carbon
dioxide and water. Because essentially all organic compounds
will burn, combustion add-on controls are applicable to all
emission sources for which the organic vapors can be captured.
Combustion add-on controls are thermal vapor incinerators,
catalytic vapor incinerators, flares, boilers, and process
heaters.
4.4.1 Carbon Adsorbers31
Adsorption as applied to air pollution control is the
process by which organic molecules in a gas stream are
retained on the surface of solid particles. The solid most
freguently used is carbon that has been processed or
"activated" to have a porous structure. Such carbon provides
many surfaces upon which the organic molecules can attach,
resulting in a high rate bf organic compound removal from a
gas stream as it passes through a bed of carbon.
Activated carbon has a finite adsorption capacity. When
the carbon becomes saturated (i.e., all of the carbon surface
is covered with organic material), there is no further VOC
4-26
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emission control because all of the organic vapors pass
through the carbon bed. At this point (referred to as
"breakthrough"), the organic compounds must be removed from
the carbon before VOC emission control can resume. This
process is called desorption or regeneration.
For most air pollution control applications, regeneration
of the carbon in the adsorber is performed by passing steam
through the carbon bed. The steam heats the carbon particles,
which releases the organic molecules into the steam flow. The
resulting steam and organic vapor mixture is condensed to
recover the organic compounds and separate the water for
discharge to a wastewater treatment unit. Alternative methods
for regenerating the carbon are to use hot air to desorb the
organics from the carbon or to reduce the pressure of the
atmosphere surrounding the carbon particles. Vacuum
regeneration is generally used for special carbon adsorber
applications when direct recycling of the recovered organic
compounds is desired, such as in vapor recovery at gasoline
tank truck loading terminals.
Two types of carbon adsorption systems most commonly used
for VOC emission control are fixed-bed carbon adsorbers and
carbon canisters. A fluidized-bed carbon adsorption system
has been developed but currently is not commercially
available.
Fixed-bed carbon adsorbers are used for controlling
continuous, organic gas streams with flow rates ranging from
30 to over 3,000 cubic meters per minute (m^/min) (1,000 to
over 100,000 cubic feet per minute [ft^/min]). The organic
compound concentration can be as low as several parts per
billion by volume (ppbv) or as high as 25 percent of the lower
explosive limit of the vapor stream constituents. The major
components of a fixed-bed carbon adsorber system are one or
more carbon bed units to adsorb the organic compounds, a
condenser to convert the desorbed organics and a steam mixture
to a liquid, a decanter to separate the organic and aqueous
phases, and blowers to cool and dry the carbon beds following
desorption.
4-27
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Fixed-bed carbon adsorbers may be operated in either
intermittent or continuous modes. For intermittent operation,
the adsorber removes organic compounds only during a specific
period of the day. Intermittent mode of operation allows a
single carbon bed to be used because it can be regenerated
during the off-line periods. For continuous operation, the
unit is equipped with two or more carbon beds so that at least
one bed is always available for adsorption while other beds
are being regenerated.
Carbon canisters differ from fixed-bed carbon adsorbers.
First, a carbon canister is a very simple add-on control
device consisting ofa0.21m3 (7.4 ft3) drum with inlet and
outlet pipe fittings. A typical canister unit is filled with
70 to 90 kilograms (kg) (150 to 3,200 pounds [lb]) of
activated carbon. Second, use of carbon canisters is limited
to controlling low volume gas streams with flow rates less
than 3 m3/min (100 ft3/min). Third, the carbon cannot be
regenerated directly in the canister. Once the activated
carbon in the canister becomes saturated by the organic
vapors, the carbon canister must be removed and replaced with
a fresh carbon canister. The spent carbon canister is then
recycled or discarded depending on site-specific factors.
A well designed and operated carbon adsorption system
applied to an organic compound containing vent stream is
generally capable of achieving removal efficiencies in excess
of 95 percent. Additional details regarding carbon adsorption
system design and performance are discussed in the Wastewater
CTC Document.1
32
4.4.2 Thermal Vapor Incinerators
Thermal vapor incineration is a controlled oxidation
process that occurs in an enclosed chamber. One type of
thermal vapor incinerator consists of a refractory-lined
chamber containing one or more discrete burners that premix
the organic vapor gas stream with the combustion air and any
required supplemental fuel. A second type of incinerator uses
a plate-type burner firing natural gas to produce a flame zone
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through which the organic vapor gas stream passes. Packaged
thermal vapor incinerators are commercially available in sizes
capable of handling gas stream flow rates ranging from
approximately 8 to 1,400 m3/min (300 to 47,000 ft3/min) ,32
Properly designed and operated thermal vapor incinerators are
generally capable of achieving organic compound destruction
efficiencies in excess of 98 percent. Additional information
on design and performance of thermal vapor incineration
systems is presented in the Wastewater CTC Document.1
4.4.3 Combination Adsorption—Incineration33
The technologies of carbon adsorption and thermal vapor
incineration can be combined into a single control technology.
Figure 4-4 shows a simplified diagram of such a system,
consisting of two fixed bed carbon adsorbers and an
incineration unit. Carbon bed 1 operates in the adsorption
mode, removing organic compounds from the vent stream, while
carbon bed 2 is regenerated. Regeneration is performed by
passing a portion of the hot incinerator flue gas through the
carbon bed. This regeneration gas is first cooled to
approximately -4 to 180 °C (25 to 350 °F), depending on the
physical and chemical characteristics of the organic compounds
absorbed into the carbon. The regeneration gas then passes
through the carbon bed, quickly raising its temperature and
causing the organic compounds to desorb. The resulting
concentrated vent stream is routed to the incinerator vhere
the organic compounds are thermally oxidized. The flue gas
exiting the incinerator may be routed through a scrubber for
those facilities that have chlorinated organics.
Because the organic compounds are delivered to the
incinerator in a more concentrated stream than the dilute vent
stream, auxiliary fuel requirements for the incinerator are
reduced. Additionally, there is no need for solvent recovery,
which is an advantage in those situations where recovery is
not desirable or economically feasible. This system can be
operated on a continuous or intermittent basis. On an
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intermittent basis, an auxiliary fuel such as natural gas is
used to bring the incinerator up to operating temperature.
Packaged units are available from approximately 30 to
1,400 m3/min (1,000 to 47,000 ft3/min) with organic compound
destruction efficiencies of 95 to 99 percent. Custom designed
units are available to handle requirements in excess of
1,400 m3/min (47,000 ft3/min). Organic compound
removal/destruction efficiencies are similar to those for
standard vapor phase carbon adsorption systems.
4.4.4 Catalytic Vapor Incinerators34 . • '
Catalytic vapor incineration is essentially a flameless
combustion process. Passing the organic vapor stream through
a catalyst bed promotes oxidation of the organic compounds at
temperatures in the range of 320 to 650 °C (600 to 1,200 °F).
Temperatures below this range slow down or stop the oxidation
reactions, which results in low destruction efficiencies.
Temperatures above this range shorten catalyst life or may
even cause catalyst failure. Oxidation of vapor streams with
a high organic compound content can produce temperatures well
above 650 °C (1,200 °F). Consequently, vapor streams with
high organic compound concentrations may not be suitable for
catalytic incineration. In a typical" catalytic incinerator,
the gas stream vented from the emission source is heated in a
combustion chamber to the desired reaction temperature by
mixing the organic vapors with hot combustion gas from natural
gas-fired burners. The heated gas mixture then contacts the
catalyst bed and is oxidized. The catalyst is composed of a
porous inert substrate material that is plated with a metal
alloy containing platinum, palladium, copper, chromium, or
cobalt. A well designed and operated catalytic vapor
incinerator generally destroys 97 to 98 percent of the
organics and hazardous air pollutants (HAP's).34 Other design
and performance of catalytic vapor incinerators are discussed
in the Wastewater CTC Document. A heat exchanger is
typically installed to preheat the inlet vapor stream by
indirect heat transfer from the hot flue gasses, thus reducing
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the amount of fuel that must be burned to maintain the
operating temperature.
4.4.5 Flares35
Unlike vapor incinerators, a flare is an open combustion
process. The ambient air surrounding the flare provides the
oxygen needed for combustion. Consequently, a flare does not
require blowers to provide combustion air. To achieve
smokeless flare operation, turbulent mixing of the organic
vapor stream with the ambient air at the flame zone boundary
can be "assisted" by injecting steam or air at the flare tip
or by releasing the gas stream through a high-velocity nozzle
(i.e., a nozzle with a high pressure drop). Flares are used
extensively to burn purge and waste gases from many industrial
processes such as petroleum refinery process units, blast
furnaces, and coke ovens. A study by the EPA concluded that
98 percent combustion efficiency can be achieved by steam-
assisted and air-assisted flares burning gases with heat
contents greater than 11 megajoules (MJ) per m3 (300 British
thermal units [Btu] per ft3),35 Design and performance of
flares are discussed in detail in the Wastewater CTC
Document.1
4.4.6 Boilers and Process Heaters36
A boiler or process heater can be used for organic vapor
destruction. The organic vapor stream is either:
(1) premixed with a gaseous fuel and fired using the existing
burner configuration, or (2) fired separately through a
retrofit special burner or burners to the combustion unit.
Industrial boilers and process heaters are currently being
used to burn vent gases from chemical manufacturing, petroleum
refining, and pulp and paper manufacturing process units. A
study investigating the destruction efficiency of five process
heaters firing a benzene vapor and natural gas mixture showed
98 to 99 percent overall destruction efficiencies for C^ to Cg
hydrocarbons. Design and performance of boilers and process
heaters are discussed in the Wastewater CTC Document.1
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4.4.7 Condensers
Condensation is the process by which a gas or vapor is
converted to a liquid form by lowering the temperature or
increasing the pressure. This process occurs when the partial
pressure for a specific organic compound in the vapor stream
equals its partial pressure as a pure substance at operating
conditions. For air pollutant control applications, cooling
the gas stream is the more cost-effective method of achieving
organic compound condensation.
There are two major types of condensers: surface
condensers and contact condensers. In a surface condenser the
coolant does not contact the vapors or the condensate. In a
contact condenser the coolant and vapor stream are physically
mixed together inside the vessel and exit the condenser as a
single stream.
A field evaluation of a condenser used to recover
organics from a steam stripping process used to treat
wastewater at a plant manufacturing ethylene dichloride and
vinyl chloride monomer was conducted. The measured condenser
removal efficiencies for specific organic constituents ranged
from a high value of 99.5 percent for 1,2-dichloroethane to a
low value of 6 percent for vinyl chloride. Additional design
and performance of condensers are discussed in the Wastewater
CTC Document
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4.5 REFERENCES
1. Office of Air Quality Planning and standards,
U. S. Environmental Protection Agency. Research Triangle
Park, North Carolina. Industrial Wastewater Volatile
Organic Compound Emissions—Background Information for
BACT/LAER Determinations. EPA-450/3-90-004. January
1990.
2. U. S. Environmental Protection Agency. ASPEN Expert
System for Steam Stripping Calculations.
EPA-450/3-90-003. July 1990.
3. Letter and attachments from Radian Corporation to P.E.
Lassiter, EPA/OAQPS, July 27, 1987, on the summary of data
provided in confidential Section 114 questionnaire
responses.
4. Trip Report. Howie, R. H., and M. A. Vancil, Radian
Corporation, to file. 7 p. Report of May 12, 1987, visit
to Allied Fibers.
5. Trip Report. Herndon, D. J., and S. K. Buchanan, Radian
Corporation, to file. 10 p. Report of May 22, 1987,
visit to Rhone-Poulenc Agricultural (RP Ag) Company.
6. Trip Report. Herndon, D. J., Radian Corporation, to file.
5 p. Report of May 6, 1987, visit to PPG Industries.
7. Trip Report. Herndon, D. J., and S. K. Buchanan, Radian
Corporation, to file. 7 p. Report of May 21, 1987, visit
to Mobay Chemical Company.
8. Trip Report. Herndon, D. J., Radian Corporation, to file.
11 p. Report of May 4, 1987, visit to Borden Chemical
Company.
9. Trip Report. Herndon, D. J., Radian Corporation, to file.
4 p. Report of May 5, 1987, visit to Union Carbide
Corporation.
10. Trip Report. Herndon, D. J., Radian Corporation, to
file. 13 p. Report of May 8, 1987, visit to Dow
Chemical Company.
11. U. S. Environmental Protection Agency. Hazardous Waste
Treatment, Storage, and Disposal Facilities (TSDF)—
Background Information for Proposed RCRA Air Emission
Standards. Volume 2. Appendices D-F.
EPA/450/3-89/023B. June 1991. pp. F-148 to F-163.
12. Trip Report. Elliott, J. A., and S. L. Watkins, Radian
Corporation, to file. 8 p. Report of September 25,
1989, visit to Union Camp Corporation.
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13. Memorandum from Herndon, D. J., Radian Corporation, to
Industrial Wastewater file. Summary of Facilities
Reporting Use of Steam Stripping. May 20, 1988.
14. Environmental Science & Engineering, Inc., and SAIC.
Plant No. 4—Organic Chemicals Best Available Technology
Long-Term Field Sampling. Prepared for U. S.
Environmental Protection Agency, Office of Water
Regulations and Standards. July 1985.
15. Reference 13, Plant No. 7.
16. Reference 13, Plant No. 15.
17. U. S. Environmental Protection Agency. Development
Document for Effluent Limitations Guidelines for the
Pesticide Point Source Category. EPA-440/1-85/079.
October 1985. pp. VI-60 to VI-62.
18. U. S. Environmental Protection Agency. Development
Document for Final Effluent Limitations Guidelines, New
Source Performance Standards and Pretreatment Standards
for the Pharmaceutical Manufacturing Point Source
Category. EPA-440/1-83-084. September 1983.
19. U. S, Environmental Protection Agency, Office of Air
Quality Planning and Standards. Air Stripping of
.Contaminated Water Sources—Air Emissions and Control.
EPA-450/3-87-017 (NTIS PB88-106166). Research Triangle
Park, North Carolina. August 1987.
20. U. S. Environmental Protection Agency. Office of Air
Quality Planning and Standards. Hazardous Waste
Treatment, Storage, and Disposal Facilities (TSDF)—Air
Emission Models. Draft Report. EPA-450/3-87-026.
November 1989.
21. U. S. Environmental Protection Agency. Chemical and
Petroleum Branch, Office of Air Quality Planning arid
Standards. User's Guide for CHEMDATA Compound Property
Processor (CHEM7). Research Triangle Park, NC. December
1989.
22. Weber, Walter J. and Edward H. Smith. Removing Dissolved
Organic Contaminants from Water. Environmental Science
Technology. Vol. 20, No. 10. October 1986. pp. 970
to 979.
23. Cheremisinoff, Paul N. Haz Waste Treatment and Recovery
Systems. Pollution Engineering. Vol. XX, No. 2, pp. 52
to 61. February 1988.
24. Memorandum from Elliott, J. A., Radian Corporation, to
Industrial Wastewater file. Evaluation of Carbon
Adsorption as a Control Technology for Reducing Volatile
; - . 4-35 • • '
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Organic Compounds (VOC) from Industrial Wastewaters.
November 30, 1988.
25. Federal Register, Volume 53, No. 226. pp. 47616
to 47629. 40 CFR, Part 60, November 23, 1988.
26. U. S. Environmental Protection Agency. Hazardous Waste
Treatment, Storage, and Disposal Facilities (TSDF)—
Background Information for Proposed RCRA Air Emission
Standards. Volume -1. Chapters 1-8 and Appendices A-C.
EPA-450/3-89-023a. June 1991. pp. 4-5 to 4-9.
27. Reference 26, pp. 4-9 to 4-11.
28. Reference 26, pp. 4-12 to 4-15.
29. U. S. Environmental Protection Agency. Method
Development for Flexible Membrane Permeability Testing
for Hazardous Waste Treatment, Storage, and Disposal
Facilities. Filial Report. September 1990. Contract
NO. 68-D9-0055.
30. Reference 26, pp. 4-15 to 4-19.
31. Reference 26, pp. 4-22 to 4-27.
32. Reference 26, pp. 4-28 to 4-30.
33. Letter and attachments from Calgon Corporation to R. H.
Howie, Radian Corporation, January 29, 1990, on CADRE™.
34. Reference 26, pp. 4-30 to 4-33.
35. Reference 26, pp. 4-33 to 4-36.
36. Reference 26, p. 4-36.
37. Reference 26, pp. 4-36 to 4-39.
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5.0 CONTROL COST, ENVIRONMENTAL, AND ENERGY IMPACT
ANALYSES OF TREATMENT BY STEAM STRIPPING
This chapter presents the control cost, environmental,
and energy impacts of the treatment of wastewater by steam
stripping. Steam strippers were discussed in Chapter 4.0 as
an effective emission control strategy for removal of organic
compounds from industrial wastewater. In Section 5.1, steam
stripper capital costs and annualized costs are presented for
an example wastewater stream. Section 5.2 presents
environmental and energy impacts for the same example
wastewater stream. The impacts presented are for the steam
stripper system design presented in Chapter 4.O (see
Figure 4-1).
5.1 STEAM STRIPPER SYSTEM COSTS
5.1.1 Basis For Capital Costs : - •
The total capital investment (TCI) for a steam stripper
system includes the purchased equipment costs (PEC), direct
installation costs, and indirect installation costs. The PEC
comprises the basic equipment cost (EEC), auxiliary piping and
equipment costs, instrumentation costs, freight charges, and
sales tax. The BEC is estimated using published engineering
cost estimation techniques. The TCI required for a new steam
stripper system is calculated as a direct function of the BEC.
These estimation procedures are described more specifically in
the following section.
5.1.1.1 Basic Equipment Costs. To determine the BEC,
the base equipment must be identified and sized. The design
of the base equipment that makes up the steam stripper system
presented in Chapter 4.0, Figure 4-1 was based on a
combination of information gathered previously1'2 and design
5-1
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evaluations performed using the Advanced System for Process
Engineering (ASP1N), a computer software for designing
distillation columns.
Wastewater stream organic compound concentrations and
total wastewater throughputs vary widely within the target
industries. For the purpose of sizing the base equipment
composing the steam stripper system, a wastewater stream with
an organic compound concentration of 2,500 parts per million
by weight (ppmw) (0.25 percent) at various wastewater
throughputs was chosen. A sensitivity analysis, measuring the
effect of organic compound concentration upon the removal
efficiency while the remaining parameters were held constant,
was performed using ASPEN.4 The organic compound
concentration was varied from 300 to 30,000 ppmw and the
removal efficiency of the steam stripper was monitored. The
results of the sensitivity analysis showed that the removal
efficiency was not significantly affected by differences in
organic compound concentration at set design and operating
parameters. Additionally, five organic compounds were chosen,
based on ranges of Henry's Law constants, to represent the
range of organic compound strippability with the target
industries. Table 4-2 in Chapter 4.0 presents the example
wastewater stream characteristics and steam stripper design
and operating parameters.
The wastewater storage tank was sized conservatively to
provide a retention time of 48 hours for the stripper feed
stream. It was also assumed that five batch and/or continuous
streams would be combined for treatment by the same steam
stripper, and each process wastewater stream would require
approximately 300 m (980 ft) of connective piping. This
design is based on conservative estimates. That is, the
average storage tank may require less retention time; fewer
than five streams may be combined for treatment; and less
connective piping than the 300 m (980 ft) assumed for this
costing exercise may be needed for each stream.
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All equipment in the steam stripper unit was designed
using ASPEN. The steam stripper column is designed as a sieve
tray unit with countercurrent flow. The column is operated at
a typical steam-to-wastewater feed ratio of 0.096 kilograms
(kg) (0.212 pounds [lb]) of steam per liter of wastewater.
The liquid loading of the column is 39,900 liters per hour per
square meter (4/hr/m2) (980 gallons per hour per square foot
[gal/hr/ft2]). Based on ASPEN results, an average removal of
80 percent is predicted for the five compounds.
A sensitivity analysis, similar to the one described
above, was performed to determine the effect of the column
height on the total annualized cost. The ASPEN simulations
were conducted at column heights varying from 11.6 to 30.5 m
(38.1 to 100 ft) with all other parameters remaining constant.
The resulting difference in the ASPEN-generated total
annualized cost between the shortest and tallest columns was
approximately 1.5 percent. Because of the relatively;small
difference in annual costs, emphasis was placed on generating
a design that would be most cost effective, be within
practical design parameters, and would remove virtually
100 percent of the highly volatile compounds. The controlling
compound used for design purposes was benzene. A column
height of 9 m (30 ft) with a total of 10 sieve trays is used
for the steam stripper unit.
The overheads from the steam stripper are recovered with
a condenser unit consisting of a water cooled shell-and-tube
heat exchanger. The condenser is designed for an outlet vapor
temperature of 50 °C (120 °F) with an overall heat-transfer
coefficient (U) of 1,000 joules per square meter per second
per degree kelvin (J/m2/s/K) (5,680 Btu per square foot per
hour per degree rankine [Btu/ft2/hr/R]). The organic phase of
the overhead stream is recovered from the overheads decanter.
The overhead vapor from the primary condenser is assumed to be
vented to the feed storage tank and then routed to an existing
on-site combustion or other control device.
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The bottoms from the steam stripper are pumped to the
existing wastewater treatment facility. Before being
discharged from the stripper system, the bottoms pass through
a feed preheater to enhance the efficiency of the steam
stripper. The overall heat transfer coefficient used by ASPEN
for the feed preheater is 1,000 J/m2/s/K (5,680 Btu/ft2/hr/R).
Pumps are installed to transfer the wastewater from the
feed tank to the stripper, from the stripper to the
feed/bottoms heat exchanger, from the decanter to the
collection pot, and from the collection pot to storage.
Noncondensible gases are vented through the .feed storage
tank and decanter, which is vented to a flare. A flare
arrestor is installed in this vent line to the flare to
prevent flame' propagation back into the steam stripper feed
tank.
Steam stripper costs are estimated using the equipment
sizes generated by ASPEN.3 The cost of each piece of process
equipment is determined from published engineering cost
estimation techniques. Table 5-1 presents equations for the
costs of the various components of the steam stripper system.5
All costs are for carbon steel construction except for sieve
trays and pumps. It was assumed that these components would
be constructed of stainless steel since they take the greatest
wear and are exposed to the harshest conditions. Table 5-2
summarizes the estimated equipment costs calculated for each
component, the estimated size or capacity, the construction
material, and the reference or information source used to
obtain the cost estimate for a 300 liters per minute (£pm)
(80 gallons per minute [gal/min]) capacity treatment system.
Initial estimates were based on equipment costs for the year
in which the textbook or journal article was published. These
costs were then adjusted to July 1989 dollars using the
Chemical Engineering fabricated equipment index for the
appropriate month and year. The adjusted cost for each
individual component was summed to yield the EEC for the
design steam stripper.
5-4
-------
TABLE 5-1. EQUIPMENT COST EQUATIONS FOR A STEAM STRIPPING UNIT
ui
I
U)
Equipment component
Feed Tanks
Feed Preheater
Costing equation3 *^
exp[2. 331+1. 3673*ln(v)-0.063088*ln(V)2]
exp[ll. 362-0. 6104*ln(v)+0.045355*ln(v)2]
exp[8. 551-0. 30863*ln(A)+0.06811*»n(A)2]
Cost
indexb
230. 9
230.9
1,300 gal
21,000 gal
150 ft2 <
Qualifier0
< V < 21.000 gal
< V < 11,000.000 gal
A < 12,000 ft2
Cost reference
7
7
7
Steam Stripper
1A. Column Shell,
Skirts, Nozzles and
Manholes
IB. Platforms and
Ladders
1C. Sieve Trays-
Stainless Steel
2A. Column Shell
2B. Manholes
2C. Nozzles
20. Sieve Trays-
Stainless Steel
Primary Condenser
Overhead Collection
Decanter
(expt-1. 1156+0. 0906*ln(A)])
(1A + IB + 1C + 2A + 2B + 2C + 2D)/2
exp[6. 823+0. 14178*ln(Ws)+0.02468*tn(Ws)2]
0.85*(1. 189+0. 0577*0)*
(No. of Trays)*278.38*exp[0.1739*D]
83.69*WS<°-6124)
(Ho. of Manholes)*18*(53.83+40.71*TS)
each nozzle length
£ (No. of nozzles)*(length of
i=l nozzles, inch)* [24. 57+35. 94*TS]
(no. of Trays)*214.54*exp[0.2075*Di]
2228. 8*exp[0. 0041 1*A]
5328. 8*exp [0.0008762* A]
74.55*(V)°-5662
230.9 9020 Ib < Us < 2,470,000 lb
230,9 3 ft < D, < 24 ft; 57.5 ft < Lt < 170 ft
230.9 2 ft < D < 16 ft
225.9 1.000 lb < Ws < 70,000 lb
225.9 0.375 in. < Ts < 2 in.
225.9 0.375 in. < Ts < 2 in.
225.9 2 ft < D1 < 12.5 ft
343 37.5 ft2 < A < 240 ft2
343 240 ft2 < A < 1500 ft2
225.9 100 gal < V < 100,000 gal
8
8
9
9
9
10
10
11
-------
TABLE 5-1. EQUIPMENT COSTS EQUATIONS FOR A STEAM STRIPPING UNIT (Concluded)
CTv
Equipment component
Flame
Pumps
Arrestor
- Stainless Steel
Costing
equation3 •'
$100/arrestor
8740.7*w(°-42°7); W in
13783. 4*W(°
,28§0).
U in
hp
hp
Cost
index"
319
347.
347.
8
8
NA
10 gpm < Q <
30 gpra < Q <
Qualifier0
ISO
900
gp»
9pm
Cost reference
12
10
10
aAll cost equations are based on components constructed of carbon steel except the equations for sieve trays and pumps. Cost equations for these two
components are based on construction with stainless steel.
"The July 1989 Chemical Engineering fabricated equipment cost index is 358.0. To calculate costs in July 1989 dollars, multiply the equations in the
table by the ratio of 356.0 to the cost index given in the table.
c A = Surface Area
D = Steam stripper outside column diameter '
Oj = Steam stripper inside column diameter
L-J. = Steam stripper tangent-to-tangont length
Q « Flow rate through component
TS = Steam stripper column wall thickness
V * Volume of component
tf = work
Wj = Steam stripper column weight.
-------
TABLE 5-2. , ESTIMATION OF BASIC EQUIPMENT COST FOR A STEAM STRIPPING UNIT
VI
i
Equipment component
Feed Tanks
Feed Preheater
(Shell and Tube)
Steam Stripping
Column & Trays
Primary Condenser
(Water Cooled,
Shell & Tube)
Equipment sizea
960 m3
240 m2
0.76 m diameter
9 m height
22 m2
Construction
material
Carbon Steel
Carbon Steel
Carbon Steel
Trays-Stainless
Carbon Steel
Equipment
$75,000
$32,000
$52,000
$6,000
Cost
reference
7
7
8,9
10
Overhead Collection
Decanter
Pumps (4)
3.9 m3
6,300 total Watt
Carbon Steel $6,000
Stainless Steel $44,000
11
10
TOTAL BASE EQUIPMENT COST (EEC)
$215,000
a Based on 300 ipm wastewater flow.
b July 1989 dollars.
NA = Not Applicable.
-------
5.1.1.2 Total Capital Investment, As previously
discussed, the TCI required to install a new steam stripper
unit can be calculated as a direct function of the EEC value.
The TCI for the steam stripper unit and the values of each
component of the TCI are presented in Table 5-3. The PIC is
calculated by multiplying the BIG by an appropriate percentage
value. This percentage value and the other multipliers
discussed below are selected from ranges recommended in cost
estimation reference documents. Piping costs are implicitly
included in the direct installation costs; however, auxiliary
piping (i.e., additional piping for the combination of
wastewater streams and vapor vent- lines for storage tanks) and
flame arrestors are accounted for separately in the PEC.
Instrumentation, sales tax, and freight are also components of
the PEC.
The PEC is used to estimate the steam stripper system
direct installation costs and indirect installation costs.
Each of these costs is calculated by multiplying the PEC by an
appropriate percentage value.. The direct installation costs
include items such as electrical wiring, insulation, equipment
support and erection, and painting of equipment. The indirect
installation costs include engineering, construction and field
expense, construction fee, start-up and testing, and
contingency. The total of PEC, direct installation costs, and
indirect installation costs yields the TCI. The TCI can also
include costs for buildings, offsite facilities, land, working
capital, and yard improvements; however, these costs are not
typically included in the PEC for a steam stripper system.
5.1.1.3 Total Capital Investment Versus Wastewater
Throughput. The TCI for installing a new steam stripper
system is presented in Figure 5-1 as a function of wastewater
feed rate. The TCI costs for this graph were calculated using
the cost equations in Table 5-3 and are based on steam
stripper designs sized for five different wastewater flow
rates chosen arbitrarily: 40, 150, 300, 455, and 760 £pm (10,
40, 80, 120, and 200 gal/min). Figure 5-1 presents TCI costs
5-8
-------
TABLE 5-3.
ESTIMATION OF TOTAL CAPITAL INVESTMENT
FOR A STEAM STRIPPING UNITa/b
Cost component
Cost factor
Total
Component capital Cost
cost3 investment reference
Direct Equipment Costs
Base Equipment Costs (BEC)
Piping"5
Flame Arrestor
Instrumentation
Sales Tax and Freight
Purchased Equipment Cost (PEC)
Direct Installation Costs
TABLE 5-2 $215,000
$8.48/m $14.500
$100/Arrestor $100
0.1 * [BEC + Pipe + Arrestor] $23,000
,0.08 * [BEC + Pipe + Arrestor] $18,400
$270,900
TOTAL DIRECT INSTALLATION COST
$149,000
13
12
14
14
Foundations and Supports
Electrical
Erection and Handling
Painting
Insulation
12% of PEC
1% of PEC
40% of PEC
1% of PEC
1% of PEC
$32,500
$2,700
$108,400
$2,700
$2,700
14
14
14
14
14
Indirect Installation Costs
Engineering and Supervision
Construction & Field Expense
Construction Fee
Start-Up and Testing
Contingency
TOTAL INDIRECT INSTALLATION COST
TOTAL CAPITAL INVESTMENT (TCI)
10% of PEC
10% of PEC
10% of PEC
1% of PEC
3% of PEC
$27.100
$27,100
$27,100
$2,700
$8,100
$92,100
$512,000
14
14
14
14
14
a July 1989 Dollars.
D Based on 300 Ipm wastewater flow.
c Additional piping for combination of five wastewater streams is assumed to total
approximately 1500 m. Vapor vent lines on the storage tank, condenser, and decanter route
noncondensible VOC's back to the storage tank, or to a vapor recovery or control device. Each vent
line is assumed to be 61 m in length and constructed of 5.1 cm diameter schedule 40 steel pipe.
5-9
-------
2
1.9 -
1.8 -
1.7 -
1.6 -
1.5 -
1.4 -
1-1 -"
I
«s 0.8 -
II 0.7 -
O
0.5 -
0.4
0.3 -
0.2 -
0.1 -
0
• Stainless Steel
* Carbon Steel
O TCI Algorithm
TCI (carbon steel) = 239,645 + 837.9 (£pm)
I
200
I
400
600
800
Wastewater Feed Rate (Ipm)
Figure 5-1. Summary of total capital investment versus
wastewater feed rate for steam stripping unit.
tr
-------
for both carbon steel and stainless steel construction.
Stainless steel construction costs are included for comparison
of streams with corrosive wastewater (i.e., very high or low
pH). Equipment costs for stainless steel were developed from
the same information sources used for carbon steel equipment
costs. Generally, a factor for material of construction was
used for conversion of carbon steel to 304 stainless steel.
The TCI for a steam stripper system constructed of stainless
steel is approximately 2.0 times more costly than a system
constructed of carbon steel.
Based on the TCI costs for the five different wastewater
flow rates, a linear expression was developed to estimate the
TCI for steam stripper systems as a function of the wastewater
feed rate. The TCI for carbon steel construction can be
estimated from the following equation:
TCI = 239,645 + 837.9 * (Wastewater
(Carbon Steel, $) Feed Rate, £pm)
This cost algorithm is also presented in Figure 5-1. Use of
this equation in estimating the national impacts of applying
PACT to the affected industries is presented in Appendix B.
5.1.2 Basis for Annualized Costs
Total annualized costs (TAG) are the costs incurred to
operate the steam stripper process unit throughout the year.
The annual operating costs are composed of direct and indirect
charges. The TAG and each of its components are presented in
Table 5-4, and are discussed in detail in the following
sections.
5.1.2.1 Total Annualized Cost. Direct annual costs are
composed of the expenses that are incurred during normal
operation of the steam stripper process. These costs include
utilities, labor, and maintenance activities. Three types of
utilities are required to operate the steam stripper process
unit: electricity, steam, and cooling water. Electricity is
required to operate pumps and other electrical components
included in the system. The electricity required for the
pumps is calculated assuming a developed head of approximately
5-11
-------
TABLE 5-4.
ESTIMATION OF TOTAL ANNUAL COST
FOR A STEAM STRIPPING UNITa*b
Cost component
Direct Annual Costs
Utilities
Electricity
Steam
Cooling Water
Labor
Operating Labor
Supervision & Admin
Maintenance
Labor
Hater ials
TOTAL DIRECT ANNUAL COST (TDAC)
I nsJicecJL Annual Costs
Overhead
Property Taxes
Insurance
Administrative Charges
Capital Recovery (CR)
TOTAL INDIRECT ANNUAL COST (TIAC)
RECOVERY CREDIT (RC)
TOTAL AHNUAL COST (TAG)
ANNUAL WASTE THROUGHPUT (AWT)
COST PER UNIT WASTEWATER ($/MG)
COST PER LITER WASTEWATER FEED ($/l)
Cost factor Annual consumption
$0,0509/kWhr 45,300 kWhrc
$7,68/Mg ' 17,200 Mgd
$0.0528/1.000 liter 470,000,000 liters8
$!3.20/hr 450 hrs
15% of Op. Labor
$14.5Q/hr 450 hrs
100% of Maint. Labor
60% of All Labor and
Materials
1% of TCI •
1% of TCI
2% of TCI
10% @ 15 yrs
TOAC + TIAC - RC
12i,400 Mg/yr
TAC/AWT
TAC/FLOW 180,000,000 l/yr
Annual
cost
$2,300
$132,200
$24,800
$5,900
$900
$6,500
$6,500
$179.100
$11,900
$5,100
$5,100
$10,200
$67,400
$99,700
$10,900f
$267,900
$2.07/Mg
$0.00167/1
Cost
reference
16
16
17
14
14
14
14
14
14
14
14
18
a July 1989 dollars.
" Based on 300 Ipm wastewater flow.
c 150 kWhr/day, 300 days/yr.
° 57,300 kg/day, 300 days/yr.
• 1,570,000 I/day, 300 days/yr,
' Recovery credit based on approximately 28,000 KJ/Kg heating value (see Ref. 18).
5-12
-------
37 m (120 ft) of water and a pump efficiency of 64 percent,
and using design flow rates to each pump. The steam costs are
estimated using the design steam loading: 0.096 kg steam per
liter (0.80 Ib/gal) of wastewater feed. Streams containing
highly volatile compounds may be effectively treated using
lower steam loadings, resulting in reductions in annual
operating cost. Appendix B discusses how lower steam
requirements for streams containing highly volatile compounds
are accounted for in estimating national impacts. The cooling
water cost is calculated using water requirements necessary
for the overhead primary condenser. Other direct costs
include labor and maintenance. Labor cost is calculated by
multiplying the estimated number of hours required to operate
a steam stripper process unit (0.5 hour per shift) by a $13.20
per hour labor rate. The supervisory and administrative costs
are estimated as 15 percent of operating labor. The
maintenance costs are composed of labor and materials.
Maintenance labor cost is estimated assuming 0.5 hours per
shift operation and a $14.50 per hour labor rate. Maintenance
materials cost is 100 percent of maintenance labor cost.
The indirect operating expenses are incurred regardless
of the operating status of the steam stripper system. The
cost of overhead is estimated to be 60 percent of all labor
and maintenance costs. The remaining components of the
indirect annual costs are a percentage of the TCI. Property
taxes and insurance are both estimated to be l percent of the
TCI while administrative charges are estimated to be 2 percent
of the TCI. The capital recovery for the steam stripper
system is calculated based on a 15-year equipment life at an
interest rate of 10 percent.
Another aspect of the TAG included in this estimate is
the recovery credit. This factor accounts for any cost
credits that would result from the organic compounds being
recovered from the overheads stream. There are several
alternatives for handling the recovered organic compounds. If
steam is produced onsite, the recovered organic compounds can
5-13
-------
be used as fuel for the existing boiler. The money saved by
not having to purchase conventional fuels (i.e., fuel oil or
natural gas) is the recovery credit. In this situation, the
value of the recovered compounds is equal to the fuel value
only. Another option is to reuse the recovered organic
compounds in the manufacturing process. In some cases the
organic compounds can be recycled directly to the process; in
other cases the organic compounds must be separated by
distillation before reuse. The savings from reducing the
purchase of raw materials is the recovery credit and is valued
at the cost of the recovered organic compounds; however, this
cost savings may be offset by the cost of distillation for the
recovered organic compounds. Another option for the recovered
organic compounds is to sell them to a chemical manufacturer
who will recover the individual components in the waste
organic stream. However, in cases where a cost-effective use
for the recovered organic compounds does not exist, the plant
would have to pay for disposal of the collected organic
compounds. There will be no cost savings in this case; in
fact, an additional cost for disposal may be incurred.
For this cost estimate it is assumed that the organic
compounds can be used as fuel for an existing boiler. A
heating value of approximately 28,000 kJ/kg (12,000 Btu/lb)
was calculated based on the range of VOC concentrations
reported in responses to a Section 114 survey of the organic
chemicals, plastics, and synthetic fibers (OCPSF) industry.18
The organic compounds used to calculate the heating value
were chosen based on the highest concentration values of
compounds reported in the Section 114 questionnaire responses:
acrylonitrile, carbon tetrachloride, ethanol, formaldehyde,
styrene, toluene, and triethylamine. The cost of generating
steam is reported to be two to three times more than the fuel
cost in Perry's Chemical Engineers' Handbook.19 Therefore, to
assess a cost savings for burning organic compounds in place
of a typical fuel used (i.e., coal, distillate/residual oil,
5-14
-------
etc.)/ the typical fuel cost was assumed to be the steam cost
divided by 2.5. The resulting fuel cost is $1.3 x 10~6/KJ
($1.4 x 10~6/Btu). The recovery credit is calculated by
multiplying the organic compound removal per year by the
calculated organic compound heating value and the estimated
fuel cost. This calculation is presented in a memorandum
entitled "Development of Recovery Credit for Volatile Organic
Compounds Removed from Wastewater Streams by Steam
Stripping."18
5.1.2.2 Total Annualized Costs Versus Wastewater
Throughput. The TAG for operating a steam stripper system is
presented in Figure 5-2 as a function of wastewater feed rate.
The development of this linear expression is presented in a
memorandum.15 The TAC's for this graph were calculated using
the cost factors in Table 5-4 and are based on the same
wastewater flow rates as the TCI costs in Figure 5-1: 40,
150, 300, 455 and 760 £pm (10, 40, 80, 120, and 200 gal/min).
Figure 5-2 presents TAG for both carbon steel and stainless
steel construction. The TAG for a steam stripper system
constructed of stainless steel is approximately 3 times more
costly than a system constructed of carbon steel.
Based on the TAG for the five different wastewater flow
rates (shown in Figure 5-2), a linear expression was developed
to estimate the TAG for steam stripper systems as a function
of the wastewater feed rate.15 The TAG for carbon steel
construction can be estimated from the following equation:
TAG = 72,812 + 639.1 * (Wastewater
(Carbon Steel, $/yr) Feed Rate, £pm)
The annualized unit operating cost ($ per liter) for the
steam stripper system is calculated by dividing the total
annualized operating cost ($ per year) for the steam stripper
system operating cost by 300 £pm (80 gal/min). The resulting
annualized unit operating cost is approximately $0.0017 per
liter ($0.0064 per gallon). Annualized unit operating costs
were also estimated for the other four wastewater flow rates.
5-15
-------
J\
I
0\
0.8
0.7 -
0.6 -
(0
o
O 0.4
CO
I-
I
0.2 -
0.1 -
• Stainless Steel
* Carbon Steel
O TAC Algorithm
TAG (carbon steel) $/yr = 72,812 + 639.1 (Ipm)
200
I
400
I
600
800
Wastewater Feed Rate (Ipm)
Figure 5-2. Total annual cost versus wastewater feed rate for
steam stripping unit.
-------
The results of these cost estimates are presented in
Figure 5-3 as an indirect function of the wastewater feed rate
to the steam stripper system. This figure shows that the unit
operating cost is nearly constant at flow rates of 300 £pm
(80 gal/min) and greater. At flow rates less than 300 £pm
(80 gal/min) there is a significant increase in the unit
operating costs. These facts illustrate that it is most
economical to treat larger flow rates of wastewater up to
about 300 £pm (80 gal/min). There is no significant reduction
in TAG at flow rates greater than 300 £pm (80 gal/min).
The TAG equation presented above was used in estimating
the cost impacts and calculating the cost effectiveness of
applying RACT to the affected industries. These impact
calculations are presented in Appendix B.
5.2 ENVIRONMENTAL AND ENERGY IMPACTS OF STEAM STRIPPING
The purpose of this section is to evaluate the
environmental and energy impacts associated with steam
stripping. Steam stripping effectively reduces potential air
emissions of volatile organic compounds (VOC's) during
downstream wastewater collection and treatment and also
improves water quality. Analysis of the environmental impacts
of this control technique included an evaluation of the air
and water pollution impacts, impacts on waste disposal,
pollution prevention, and energy use. Section 5.2.1 presents
an assessment of primary air pollution impacts (VOC
emissions); Section 5.2.2 presents secondary air pollution
impacts resulting from fuel combustion for production of
steam; and Section 5.2.3 discusses water pollution, solid
waste, pollution prevention, and energy impacts.
5.2.1 Primary AirPollution Impacts—Volatile Organic
Compound Emission Impacts
The reduction in VOG emissions that can be achieved by
steam stripping a wastewater stream is dependent on the
stripper design and the characteristics of the wastewater
streams (i.e., flow rate, composition, and concentration).
5-17
-------
0.007
0.006 -
'0.005 -
ta
O
O
'0.004 -
<5
a.
O
as
0.003 -
0.002 -
0.001
I
200
400
Wastewater Feed Rate (jtprri)
• Stainless Steel
.* Carbon Steel
I
600
800
Figure 5-3,
Unit operating costs versus wastewater feed rate
for steam stripping unit.
I
-------
Table 5-5 presents VOC emission reductions achievable through
steam stripping for the example model wastewater stream. Also
presented in Table 5-5 are baseline VOC emissions. National
estimates of VOC emission reductions resulting from the
application of reasonably available control technology (RACT)
to the affected industries have been calculated using the
procedure summarized in Table 5-5 and are presented in
Appendix B.
5.2.2 ' Secondary Air PollutionImpacts . -
Secondary air impacts occur from combustion of fossil
fuels for steam and electricity generation. Combustion
pollutants formed include particulate matter (PM), sulfur
dioxide (S02)', nitrogen oxides (NOX), carbon monoxide (CO),
and VOC's. Although pollutants can be formed during steam and
electricity generation, only steam generation was assumed to
occur onsite? therefore, impacts from offsite electricity
generation are not discussed here. The secondary emissions
presented in this section were estimated using the EPA
emission factors presented in Table 5-6.2l Assumptions
concerning the fuel composition and boiler efficiency are
based on information compiled by the Agency and the Energy
52 ?3
Information Administration. ' These values were adjusted to
accommodate emission reductions by existing control devices.
Typical controls and control efficiencies presented in these
sources were assumed.
The industrial boiler used for steam generation was
assumed to have a capacity of less than 158 million kJ/hr
(150 million Btu/hr). A thermal efficiency of 80 percent was
assigned to the industrial boiler as an average expected
value. It is assumed to be controlled for SO2, PM, and NO^
emissions using desulfurization (90 percent SO2 removal
efficiency), an electrostatic precipitator (99 percent PM
removal efficiency), and flue gas recirculation (assuming the
mid-range of 40 percent NOX removal efficiency) .2*'2S Fuel
composition was based on national fuel use for industrial
boilers: natural gas at 45 percent, residual oil at
5-19
-------
TABLE 5-5. VOLATILE ORGANIC COMPOUND EMISSION REDUCTION FOR STEAM STRIPPING
01
I
to
o
Waste stream organic Fraction
compound concentration emitted
Compound (ppmw) (fe)
1,3 -Butadiene
Toluene
Naphthalene
1-Butanol
Phenol
500
500
500
500
500
0.933
0.733
0.62
0.30
0.10
Fraction Volatile organic Fraction
measured concentration removed
Fma (ppmw) b Frc
1.00
1.00
1.00
0.68
0.057
500
500
500
385
30
1.00
1.00
1.00
0.92
0.089
a Surrogate fraction measured by draft EPA Reference Method 25D.20
k VO Concentration (ppmw) - Waste stream organic compound concentration (ppmw) * fm
c Fraction removed by the steam stripper is based on ASPEN results for the design
steam stripper.3
1. Baseline VOC emissions (Mg/yr) = 0.683 * SVO Cone (mg/£). * Flow (£pm) *
10 (Mg/mg) * 525,600 (min/yr)
where: 0.683 = a proportionality constant representing the fraction of total
organic compounds in a wastewater stream that would be emitted
to the air (fe) divided by the fraction of total organic
compounds in a wastewater stream measured by Draft Reference
Method 25D (fm) (see Appendix B) .
Flow = 300 £pm
S VO Cone = 1915 ppmw
Baseline VOC emissions (Mg/yr) =206 Mg/yr
2. VOC Emission Reduction (Mg/yr) = Baseline VOC Emissions * fr avg
where:
fr avg « 2 (VOCi * fei * frjj /E (VOCi * fei) = 1343/1285 = 0.96
VOC Emission Reduction (Mg/yr) = 198 Mg/yr
-------
TABLE 5-6. COMBUSTION POLLUTANT EMISSION FACTORS FOR STEAM GENERATION
U1
1
to
H
Natural Gas
(kg/105m3)
(lb/106ft3)
(KJ/m3)
(Btu/ft3)
Residual oil
(kg/m3)»
(Ib/gal)
(KJ/m3)
(Btu/gal)
Distillate oil
(kg/m3)3
(Ib/gal)
(KJ/m3)
(Btu/gal)
Pulverized Coal
(g/kg)
(Ib/lb)
(KJ/kg)
(Btu/lb)
PM
4.8
3.0
1.6
0.013
0.24
0.002
60. Ob
0.06
SO?
1.0
0.62
19.0
0.16
17.0
0.14
29. Oc
0.029
NOX
440
275
6.6
0.055
2.4
0.020
11.0
0.011
CO VOC
64 2.2
40 1.4
0.60 0.034
0»0050 0.00028
0.60 0.024
0.0050 0.00020
0.30 0.035
0.00030 0.000035
Heating
Value
3.8 x 103
1.0 x 103
4.2 X 107
1.5 x 105
3.8 x 107
1.4 X 105
2.8 X 104
1.2 X 104
aAssumes 1.0 percent sulfur content in the fuel oil.
^Factor derived from the EPA emission factor given as 10A, where A = % ash in coal, which
was assumed to be a typical value of 12 percent.
GFactor derived from the EPA emission factor given as 39S, where S
which was assumed to be the mid-range at 1.5 percent.
% sulfur in coal,
-------
28 percent, distillate oil at 7 percent, and coal at
20 percent.22 Average heating values are presented in
Table 5-6.
Estimated emissions, based on these assumptions, were
calculated as follows;
Uncontrolled = Annual Fuel Use * Emission Factor
Emissions (m3/yr) (Kg/105m3)
(Mg/yr) (see Table 5-6)
and
Controlled = Uncontrolled * (1 - Control Efficiency)
Emissions Emissions (see Table 5-6)
(Mg/yr) (Mg/hr)
The resulting secondary emission estimates for the example
wastewater stream are presented in Table 5-7. National
secondary impact estimates were calculated for the application
of RACT to the affected industries using the emission factors
presented in Table 5-6. These impacts are presented in
Appendix B.
Handling the recovered organics for disposal may also
contribute to secondary air impacts. For example,
incineration of recovered organic compounds produces
combustion pollutants as a secondary impact. However, the
recovered organic compounds could be used as an alternate
energy source, i.e., to generate some of the steam required by
the steam stripper. Although combustion of the organic
compounds will produce combustion pollutants, the emissions of
SC>2 and PM will typically be less than those generated by
fossil fuel combustion. This is due primarily to two factors:
(1) most organic compounds do not contain sulfur, which reacts
to form SOa when burned, and (2) organic compounds do not
contain high concentrations of inorganics, which are emitted
as particulates when burned. If recovered organic compounds
are recycled (i.e., not combusted), then they do not
contribute to the secondary air impacts.
5.2.3 Ot:her Impacts
5.2.3.1 Water Pollution Impacts. Steam strippers remove
organic compounds from the wastewater, thereby improving the
5-22
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Ol
N)
LJ
TABLE 5-7. SECONDARY AIR POLLUTION IMPACTS OF EXAMPLE WASTEWATER STREAM3
Emission Pollutant emissions
Wastewater reduction with C¥?SUX£l
stream flow rate steam stripping "~ "" K "K~"K
(Mg/yr) ™b S02b N0xb co ¥OC
300 200 0.18 1.5 4.5 0.6 0.03
aFuel composition for steam generation is based on 45, 28, 7, and 20 percent natural gas,
residual oil, distillate oil, and coal, respectively.
24 25
., NOX, and PM controls reduce emissions by 90, 40, and 99 percent, respectively. '
-------
quality of wastewater being discharged to wastewater treatment
plants or to publicly owned treatment works (POTW). The EPA
has established effluent guideline standards for 51 industrial
categories, for both conventional (i.e., biochemical oxygen
demand [BOD])f and for a list of 126 specific chemicals, or
priority pollutants. Some facilities have installed steam
strippers to meet the effluent guideline standards for organic
priority pollutants. Steam strippers also remove other
organic compounds, not listed as priority pollutants, which
may be present in the wastewater. Therefore, steam strippers
reduce the total organic loading of wastewater, and also
positively impact conventional wastewater pollutants, chiefly
BOD.
5.2.3.2 Solid and HazardousWaste Impacts. Solid and
hazardous waste can be generated from three possible sources?
organic compounds recovered in the steam stripper overheads
condenser, solids removed during feed pretreatment, and wastes
generated in the control of system vent emissions. System
vent emissions, if not sent to a combustion control device,
may be collected on a sorbent medium that requires either
disposal or regeneration. If the sorbent is disposed of, it
creates additional solid waste.
Although waste generation can increase for any
nonrecyclable organics that cannot be used as supplemental
fuel, these organic wastes most likely would have been removed
otherwise from the wastewater via the air (volatile organics
only) or via an oil/water separator. Similarly, solids
removed from the wastewater in cases where pretreatment is
necessary would have likely been removed in a clarifier or
activated sludge unit.
5.2.3.3 Pollution Prevention. As described in
Chapter 4.0, the condenser unit in a steam stripping system is
used to recover the organic and water vapors in the overheads
stream. The organics recovered are usually either pumped to
storage and then recycled to the process or burned as fuel in
a combustion device such as the steam-generating boiler.
5-24
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If the organics are used as fuel, this represents a
pollution prevention credit by reducing the usage of
conventional fuels. For organic compounds recovered for use
in the manufacturing process, the pollution prevention credit
is the reduction in the amount of raw materials that must be
used in the process. Another option for recovered organic
compounds is to sell them to a chemical manufacturer who will
recover the separate components of the waste organic compound
stream. .
5.2.3.4 Energy Impacts. The additional fuel demand to
generate steam for the steam stripper system reduces available
nonrenewable resources: coal, oil, and natural gas. This can
be partially offset if the recovered organics are used as
supplementary fuel or if they are recycled. (Recycling
reduces the facility demand for petroleum-derived feedstocks.)
Table 5-8 summarizes the annual fuel usages for steam
generation for the example wastewater stream. These values
are based on the steam stripper design presented in
Chapter 4.0 and the boiler capacity and efficiencies discussed
previously. The fuel composition assumed for steam generation
is as follows: 45 percent natural gas, 28 percent residual
oil, 7 percent distillate oil, and 20 percent coal. These
percentages were based on national fuel-use data for
industrial boilers.22
5-25
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TABLE 5-8.
ANNUAL FUEL USE FOR STEAM GENERATION
FOR STEAM STRIPPER CONTROL OF
EXAMPLE WAST1WATER STREAM3
Wastewater
stream
flow rate
Fuel
Percent
compos itionb
Annual use
300
Natural gas
Residual oil
Distillate oil
Coal
45
28
20
4.79 * 105m3
(1.69 * Io7ft3)
279 m3
(7.36 * 104 gal)
74.6 m3
(1.97 * 104 gal)
2.92 * 105 kg
(6.43 * 10s Ib)
aBased on steam stripper design in Chapter 4.0.
bBased on national fuel use for industrial and electrical
generating boilers.
5-26
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5.3 REFERENCES
1. Letter from Plant B to J. Farmer, U. s. Environmental
Protection Agency, Office of Air Quality Planning and
Standards (Confidential Section 114 response.)
November 1986.
2. OWRS Data, June 12, 1985. JRB/SAIC. Costing
Documentation and National New Information. EPA Contract
No. 68-01-6947.
3. U. S. Environmental Protection Agency. ASPEN Expert
System for steam stripping Calculations.
EPA 450/3-90-003. July 1990.
4. Memorandum from C. Zukor, Radian Corporation to Project
File. Sensitivity Analysis on Design Variables for the
Steam Stripping Unit in the Hazardous Organic NESHAP
(HON). February 3, 1992.
5. Memorandum from C. Zukor, Radian Corporation to P. E.
Lassiter, Office of Air Quality Planning and Standards,
U. S. Environmental Protection Agency, Research Triangle
Park, N.C. Development of Equipment Cost Equations for a
Steam stripping Unit. January 24, 1992.
6. U. S. Environmental Protection Agency. EAB Control Cost
Manual. Chapter 2: Cost Estimating Methodology. 4th
Edition, Office of Air Quality Planning and Standards.
EPA 450/3-90-006. Research Triangle Park, North Carolina.
January 1990. pp. 2-5 to 2-8.
7. Corripio, A. B., K. S. Chrien, and L. B. Evans. Estimate
Costs of Heat Exchangers and Storage Tanks via
Correlations. Chemical Engineering. January 25, 1982.
pp. 144 to 146.
8. Corripio, A. B., A. Mulet, and L. B. Evans. Estimate
Costs of Distillation and Absorption Towers via
Correlations. Chemical Engineering. December 28, 1981.
p. 180.
9. Peters, M. S., and K. D. Timmerhaus. Plant Design and
Economics for Chemical Engineers. 3rd ed. New York:
McGraw-Hill Book Company. 1980. pp. 768 to 773.
10. Hall, R. S., W. M. Vatavuk, J.. Matley. Estimating
Process Equipment Costs. Chemical Engineering.
November 21, 1988. pp. 66 to 75.
11. Reference 9, p. 572, Figure 13-58.
5-27
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12. Teleconference. A. Gitelman, Research Triangle
Institute, with Hoyt Corporation. Cost of Flame
Arresters, September 9, 1986.
13. Richardson Engineering Services, Inc. Richardson Process
Plant Construction Estimation Standards: Mechanical and
Electrical. Volume 3, Mesa, Arizona. 1988.
Section 15-40, pp. i to 9.
14. Vatavuk, W. M., and R, B. Neveril. Part II: Factors foi
Estimating Capital and Operating Costs. Chemical
Engineering. November 3, 1980. pp. 157 to 182.
15. Memorandum from C. Zukor, Radian Corporation to
P. E. Lassiter, Office of Air Quality Planning and
Standards, U. S. Environmental Protection Agency,
Research Triangle Park, N.C. Development of Total
Capital Investment (TCI) and Total Annual Cost (TAG)
Equations for the Steam Stripping Unit in the Hazardous
Organic NESHAP (HON). February 3, 1992.
16. Memorandum from P. Peterson, Research Triangle Institute,
to S. Thorneloe, Office of Air Quality Planning and
Standards, U. S. Environmental Protection Agency. Basis
for Steam Stripping Organic Removal Efficiency and Cost
Estimates Used for the Source Assessment Model (SAM)
Analysis. January 18, 1988.
17. Reference 6, p. 4-27.
18. Memorandum from C. Zukor, Radian Corporation to
P. E. Lassiter, Office of Air Quality Planning and
Standards, U. S. Environmental Protection Agency,
Research Triangle Park, N.C. Development of Recovery
Credit for Volatile Organic Compounds Removed from
Wastewater Streams by Steam Stripping. January 20, 1992,
19. Perry, R. H., and C. H. Chilton. Chemical Engineers'
Handbook. 5th ed. New York: McGraw-Hill Book Company.
1973. pp. 25 to 29.
20. Memorandum from Brailsford, J., Radian Corporation, to
Elaine Manning, U.S. Environmental Protection Agency.
Regarding Calculation of fm. December 3, 1991.
21. Compilation of Air Pollutant Emission Factors. Volume Is
Stationary Point and Area Sources. U. S. Environmental
Protection Agency. Office of Air Quality Planning and
Standards. Research Triangle Park, NC. Publication
No. AP-42, September 1985, and Supplement A, October
1986. pp. 1.1-2, 1.3-2, 1.4-2.
5-28
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22. Fossil Fuel Fired Industrial Boilers - Background
Information. U. S. Environmental Protection Agency.
Office of Air Quality Planning and Standards. Research
Triangle Park,. NC. Volume I: Chapters 1-9. Draft EIS.
Publication No. EPA-450/3-82-oo6a. March 1982. pp. 3-12
to 18.
23. Electric Power Quarterly, April to June 1984. Energy
Information Administration. U. S. Department of Energy.
Washington, D. C. Publication No. DQE/EIA-0397C84/2Q.
October 1984. pp. 19, 20.
24. Reference 21, pp. 1.3-9, 1.3-4.
25. Reference 21, pp. 1.1-5, 1.1-6.
5-29
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6.0 SELECTION OF REASONABLY AVAILABLE CONTROL TECHNOLOGY
This chapter provides State and local regulatory
authorities with guidance on the selection of reasonably
available control technology (RACT) for volatile organic
.compound (VOC) emissions from industrial wastewaters generated
in six targeted industries: organic chemicals, plastics, and
synthetic fibers (OCPSF); Pharmaceuticals; pesticides
manufacturing; petroleum refining; pulp, paper, and
paperboard, builder's paper, and board mills (pulp and paper);
and hazardous waste treatment, storage, and disposal
facilities (TSDF). Background on the regulatory authority and
goals for establishment of RACT is discussed in Section 6.1.
Options and impacts of RACT on the selected subgroup of
industries studied in this control techniques guideline (CTG)
are presented in Section 6.2. Section 6.3 describes the
selection of RACT.
6.1 BACKGROUND
The Clean Air Act (CAA) Amendments of 1990 mandate that
State implementation plans (SIP's) for ozone nonattainment
areas be revised to require the installation of RACT to limit
VOC emissions from sources for which a CTG document has
already been published or for which a CTG document will be
published between the date the Amendments are enacted and the
date an area achieves attainment status. Section 182(b)(2).
The Agency defines RACT as "...the lowest emission limitation
that a particular source is capable of meeting by the
application of control technology that is reasonably
available, considering technological and economic feasibility.
The RACT for a particular industry is determined on a case-by-
6-1
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case basis, considering the technological and economic
circumstances of the individual source category."
The CTG documents are intended to provide State and local
air pollution authorities with an information base for
proceeding with their own analysis of RACT to meet statutory
requirements. These documents review existing information and
data concerning the technical capability and cost of various
control techniques to reduce emissions. Each CTG document
contains a recommended "presumptive norm*1 for RACT for a
particular source category, based on the Agency's current
evaluation of capabilities and problems general to the source
category. However, the presumptive norm is only a
recommendation. Where applicable, the Agency recommends that
regulatory authorities adopt requirements consistent with the
presumptive norm. However, authorities may choose to develop
their own RACT requirements on a case-by-case basis,
considering the economic and technical circumstances of the
individual source category within an area. To achieve
attainment of the ozone standard, regulatory authorities may
need to require a higher degree of control than recommended.
The EPA is developing national emission standards for
hazardous air pollutants (NISHAP) for the six industries
addressed in this CTG. These future NESHAP will define
maximum achievable control technology (MACT) standards for
organic hazardous air pollutant (HAP) emissions from
wastewater. The control approach to reduce HAP emissions is
the same as the approach outlined in the CTG; identify certain
streams for control and treat them to reduce air emissions.
Because most organic HAP are also VOC and other VOC often
would also be found in the HAP-containing streams, the MACT
standards will get some control of VOC emissions. For most
industries, however, many VOC-containing wastewater streams do
not contain HAP and therefore, controlling only HAP-containing
streams, as would be required under a MACT standard, would not
substantially reduce VOC emissions. This would, in general,
indicate that there is a need for both MACT standards to
6-2
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regulate HAP emissions and a, CTG to control non-HAP VOC
emissions in nonattainment areas. For the pulp and paper and
petroleum refining industries, however, the Agency presently
believes that wastewater streams that contain non-HAP VOC also
contain a substantial amount of HAP. Therefore, the MACT
standards for these industries will substantially reduce VOC
emissions. For this reason, the recommended RACT outlined in
the CTG is not suggested for the pulp and paper and petroleum
refining industries, '
Three of the pharmaceutical subcategories were excluded
from the RACT option analysis because the wastewater flow
characteristics from these pharmaceutical subcategories are
believed to represent a small VO loading relative to the other
industries included in the analysis. More specifically,
although wastewater flow from fermentation processes is
relatively high, the VOC concentration is low; both the
wastewater flow rate and VOC concentration is low from
formulation processes; and extraction processes are
characterized by low flow rates.
6.2 REASONABLY AVAILABLE CONTROL TECHNOLOGY OPTIONS AND
IMPACTS
Reasonably available control technology for VOC emissions
from industrial wastewater is the application of a controlled
collection and treatment system to individual wastewater
streams that fail the cutoff criteria. A controlled
collection and treatment system is defined as hard-piping or a
controlled collection system from the point of wastewater
generation to a controlled removal or destruction device that
has all associated vents and openings controlled. Example
requirements for a controlled collection and treatment system
can be found in the "National Emission Standards for Hazardous
Air Pollutants (NESHAP) for Benzene Waste Operations"
(40 CFR 61 Subpart FF).2 Residuals (condensed and decanted
organics) removed from a controlled collection and treatment
system should be contained in a controlled storage vessel and
recycled within the process or disposed of properly.
6-3
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The technology underlying RACT for removal of VOC from
wastewater is steam stripping. Steam stripping is a proven
wastewater treatment technology for wastewaters generated
within each of the targeted industries. It is generally
applicable to wastewater streams with the potential to emit
VOC and, in general, achieves the highest VOC emission
reduction among demonstrated VOC control technologies. A
controlled steam stripper can achieve greater than 98 percent
VOC reduction (see control efficiencies of operating steam
strippers in Table 4-2 in Chapter 4.0). Details on the
recommended steam stripper system are presented in
Chapter 4.0. The cost basis for the control costs presented
in this chapter is the design steam stripper system as
presented in Chapter 5.0. Although the performance and cost
of applying RACT to the affected industries is based on the
application of a controlled collection and treatment system,
with steam stripping as the VOC removal technology, there are
other technologies that can be considered for removal of VOC
from wastewater. These technologies (air stripping,
biodegradation, carbon and ion exchange adsorption, chemical
oxidation, membrane separation, and liquid-liquid extraction)
should, however, achieve at least the recommended control
level (as defined by the capabilities of the design steam
stripper).
6.2.1 Reasonably Available Control Technology options Formats
In defining RACT for control of VOC emissions from
wastewater, the presumptive norm specifies which streams to
control and how to control them. One approach to determine
which wastewater streams to control is to make the decision
based only on the volatile organic (VO) concentration of the
wastewater stream, as detected by proposed reference
Method 25D (56 Fg 33544, July 22, 1991)3. All wastewater
streams exceeding the VO concentration cutoff would require
control regardless of the flow rate. This approach has the
advantage of requiring measurement of only one parameter, that
is, VO concentration. This approach also ensures that all
6-4
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streams highly concentrated with VO are controlled. A
concentration-only approach could potentially achieve a high
degree of emission reduction; however, it would likely do so
by requiring control of wastewater streams with low flow rates
that have relatively low VO loadings and are less cost
effective to control. In this approach, there could also be
some high-flow-rate wastewater streams with relatively high VO
loadings that would be reasonable to control but would escape
control because Method 25D results indicate a low VO
concentration.
Another approach to determine which wastewater streams to
control is to make the decision to control based only on the
flow rate of each wastewater stream. All individual streams
exceeding the flow rate cutoff would require control. This
approach has the advantage of requiring measurement of only
one parameter, that is, flow rate. A flow-rate-only approach
could potentially achieve a high degree of emission reduction;
however, it would likely do so by controlling wastewater
streams with low voc emissions that are less cost effective to
control. In this approach, there could also be some
wastewater streams with high VOC emissions that would be cost
effective to control but would escape control because they
have a low flow rate.
A third approach to'determine which wastewater streams to
control is to establish a combination of a minimum VO
concentration (as determined by Method 25D) and minimum
flow rate. The VO concentration and flow rate would be
determined for each individual wastewater stream. Any
wastewater stream exceeding both the VO concentration and
flow rate would be required to be controlled. This approach
would reduce the number of low-flow-rate (and, therefore, low-
emission-rate) streams that would require control under the
concentration-only approach. It would also reduce the number
of wastewater streams with low VO concentrations (and,
therefore, low-emission-rates) that would have required
control under the flow-rate-only approach.
6-5
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The third approach described above can be combined with a
maximum VO concentration, above which a wastewater stream is
controlled, regardless of flow. This provides for control of
those wastewater streams which fall below the minimum flow
rate, but have a sufficiently high VO concentration such that
they are cost effective to control.
Options for the recommended presumptive norm for RACT
have been identified based on the combination of a minimum VO
concentration and minimum flow rate with a maximum VO
concentration of 10,000 parts per million by weight (ppmw)
above which a wastewater stream is controlled, independent of
flow rate.' Thus, the impacts analysis assumes that any
wastewater stream having both a flow rate and VO concentration
above the selected cutoff values or a VO concentration greater
than 10,000 ppmw (independent of flow rate) will be controlled
to a level achievable by the steam stripper system design
presented in Chapter 4.0.
6.2.2 Reasonably Available Control Technology ppfrjlpus._ Impacts.
Table 6-1 summarizes the estimated national impacts of
various control options for the recommended presumptive norm
for RACT. These impacts were estimated for wastewater streams
from the following industrial categories?
' Pharmaceutical industry
— Chemical Synthesis Subcategory
' Pesticides Manufacturing Industry
* OCFSF Industry
— Organic Chemical Industry
— Plastics Industry
— Synthetic Fibers Industry
' Hazardous Waste TSDF Industry
The above list of industrial categories considered in the
R&CT option analysis does not include all the industries
presented previously in this document. The pulp and paper and
the petroleum refining industries were excluded from RACT
based on the reasoning presented in Section 6.1. Additionally
three of the pharmaceutical subcategories were excluded from
6-6
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TABLE 6-1. TOTAL INDUSTRY RACT NATIONAL IMPACTS
cr>
I
RACT option cteserij
VO
concentration
cutoff
(ppw)
1,000
500
200
100
TIC
flow
rate
cutoff
(lj»5
10
1
1
1
at Ion
Maximum VO
concentration
(ppw)
10,000
10,000
10.000
10,000
voc
emission
reduction
(Mg/yr)
232,000
244,000
251,000
252,000
255,000
Percent
VOC
emission
reduction
83X
68X
90%
91%
QVt
Total
national
capital
cost
($NN)
190
240
300
330
600
Total
national
annual
cost
($MN/yr)
100
120
150
170
380
National cost
effectiveness
($/Hg)
430
480
610
690
1,500
Incremental
cost
effectiveness
($/Mg)
1,400
5,700
13,800
65,900
*A11 options include a maximum VO concentration cutoff of 10,000 ppmw.
Baseline VQC Emissions » 27S.OOO Mg/yr
Total Wastewater Volume * 563,000 Ipn
Total Number Vastewater Streams » 8,100
TIC » Total Industry Control
-------
the RACT option analysis which is also discussed in
Section 6.1.
The impacts presented include VOC emission reduction
(Mg per year), percent emission reduction, total national
capital and annual costs (million dollars and million dollars
per year), and national and incremental cost effectiveness
($ per Kg).'
A detailed description of the technical approach for the
impacts analysis are summarized in Appendix B. Reasonably
available control technology impact summaries for each of the
individual industrial categories described in this document
are also presented in Appendix B.
6.3 SELECTION OF REASONABLY AVAILABLE CONTROL TECHNOLOGY
Table 6-1 summarizes the impacts of various options for
the recommended presumptive norm for RACT. After review of
the impacts in Table 6-1, the Agency has selected a VO
concentration cutoff of 500 ppmw and a flow rate cutoff of
1 4pm as the recommended presumptive norm for RACT in this
draft CTG. This cutoff level would reduce an estimated 88
percent of the available VOC emissions at an estimated cost of
120 million dollars per year. For discussion on the approach
for estimating the national impacts presented in Table 6-1,
see Appendix B.
The Agency has also selected a facility-wide loading
cutoff based on the annual total VO loading of the affected
streams in a facility. The facility-wide loading cutoff
selected is 10 Mg/yr. This cutoff will serve to exempt small
facilities with a low annual total VO loading, or allow larger
facilities to exempt certain streams from their control
requirements. The facility-wide loading cutoff is based on
streams that must be controlled as determined by the 500 ppmw
concentration and 1 1pm flow rate cutoff. Further explanation
of the facility-wide loading cutoff is in section 7.3.1.
6-8
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6.4 REFERENCES
1. Federal Register. State Implementation Plans; General
Preamble for Proposed Rulemaking on Approval of Plan
Revisions for Nonattainment Areas-Supplement (On Control
Techniques Guidelines) 44 FR 53761 to 53763.
September 17, 1979.
2. Federal Register. National Emission Standards for
Hazardous Air Pollutants; Benzene Emissions From Chemical
Manufacturing Process Vents, Industrial Solvent Use,
Benzene Waste Operations, Benzene Transfer Operations, and
Gasoline Marketing System. 55 FR 8292 to 8361. March 7,
1990.
3. Federal Register. Hazardous Waste Treatment, Storage, and
Disposal Facilities; Organic Air Emission Standards for
Tanks, Surface Impoundments, and Containers; Proposed
Rule. 56 FR 33544 to 33555. July 22, 1991.
6-9
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7.0 R1ASONABLY AVAILABLE CONTROL TECHNOLOGY IMPLEMENTATION
7.1 INTRODUCTION
This chapter presents guidance on factors State air
quality management agencies should consider in developing an
enforceable rule limiting volatile organic compound (VOC)
emissions from the collection and treatment of industrial
wastewater from the four affected industries: the organic
chemicals, plastics, and synthetic fibers (OCPSF) industry;
the pesticides industry; the pharmaceutical industry; and the
hazardous waste treatment, storage, and disposal facilities
(TSDF) industry. Guidance is provided on definitions of
pertinent terms, applicability, emission limit format,
performance testing requirements, monitoring requirements, and
reporting/recordkeeping requirements.
For each aspect of implementation, this chapter
identifies multiple options, presented for informational
purposes only. Additionally, Appendix A contains an example
rule incorporating the options provided in this document; the
example rule is also for informational purposes only.
Specific numerical limitations are given as guidance only, and
should not be considered regulatory standards. The air
quality management agency should consider all information
presented in this chapter along with additional information
made available to it from affected sources in adopting an
actual rule.
7.2 DEFINITIONS
Air quality management agencies should accurately
describe the types of emission sources affected by reasonably
available control technology (RACT) and clearly define the
four industries listed above and the applicable control
7-1
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methods. This section offers guidance to agencies in
selecting terms that may need to be clarified when used in a
regulatory context. Example definitions of these terms are
provided or sources are cited where definitions may be found
and to which the agency may refer when drafting a RACT
regulation for the affected source categories.
A description of each of the four affected industrial
categories is found in Chapter 2.0 of this document. Useful
terms defining volatile organic chemical (VOC) emission
sources within the affected industrial categories include
wastewater treatment and collection system components such as:
"drains," "junction boxes," "lift stations," "manholes,"
"trenches," "sumps," "weirs," "oil/water separators,"
"equalization basins," "clarifiers," "aeration basins," "pH
adjustment tanks," "flocculation tanks," and "surface
impoundments." A discussion of these terms is given in
Chapter 3.0 of this document.
Process modification techniques such as "waste
minimization" and "source reduction" should be included as
allowable options for the facility to use in complying with
the rule. These terms are discussed in Section 4.1.
Additionally, it may be helpful to explain emission control
techniques such as "steam stripping," "air stripping,"
"chemical oxidation," "adsorption," "membrane separation," and
"extraction." A discussion of the different emission control
techniques is found in Section 4.2. Volatile organic chemical
emission suppression components from collection and treatment
units that may be defined include: "p-leg seals," "seal
pots," "gas tight covers," "roof covers," "floating membrane
cover," and "air-supported structures." Section 4.3 explains
these different suppression components. Finally, add-on
devices for the control of VOC emissions from wastewater
treatment devices that may be defined include: "carbon
adsorbers," "thermal vapor incinerators," "combination
adsorption," "catalytic vapor incinerators," "flares,"
7-2
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"boilers and process heaters," and "condensers." Section 4.3
also explains these add-on controls in detail.
A term that is important to the implementation of RACT is
"point of generation." Point of generation means the location
where the wastewater stream exits the process unit component
or product or feed storage tank before handling or treatment
in a piece of equipment that is not an integral part of the
process unit, A piece of equipment is an integral part of the
process unit if it is essential to the operation of the unit,
i.e., removal of the equipment would result in the process
unit being shut down. For example, a steam stripper column is
part of the process unit if it produces the principal product
stream and a wastewater that is discharged to the sewer.
However, an identical stripper that treats a wastewater stream
and recovers residual product would not be considered an
integral part of the process unit. The point of generation
for measurement or sampling is defined as the point where the
wastewater stream exits the process unit before it is treated
or mixed with other streams, and prior to exposure to the
atmosphere. The point of generation for landfill leachate is
at the pump well from which the leachate is pumped out of the
landfill.
Another terra that may require art explanation is
"residuals." Residual means any material containing volatile
organics (vO'sj that is removed from a wastewater stream by a
waste management unit that does not destroy organics
(nondestructive unit). Examples of residuals from
nondestructive waste-management units are the organic layer
and bottom residue removed by a decanter or organic-water
separator and the overhead condensate stream from a steam
stripper or air stripper. Residuals do not include the
effluent wastewater stream that complies with the treatment
standards and that results from management or treatment of the
influent wastewater stream to the waste management unit.
Examples of materials that are not residuals are the effluent
wastewater stream exiting a decanter or organic-water
7-3
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separator after the organic layer has been removed; and the
bottoms from a steam stripper or air stripper. Examples of
destructive devices are biological treatment units and
incinerators; sludges, ash, or other materials removed from
the wastewater being treated by these devices are not
considered residuals under this subpart.
Other terms that are important to the implementation of
RACT are "VO concentration," "strippability," "VOC," and
"loading." The term "VO concentration" refers to those
organic compounds in a wastewater stream measured by proposed
reference Method 25D (56JES 33544, July 22, 1991).*
"Strippability" refers to the degree to which organic
compounds are removed from wastewater by steam stripping, and
is expressed as the fraction removed (Fr). Highly volatile
compounds exhibit a high Fr while compounds of lower
volatility have a lower Fr. "Volatile organic, compound" means
any organic compound that participates in atmospheric
photochemical reactions. An owner or operator may exclude the
following organic compounds, designated as having negligible
photochemical reactivity: methane, ethane, methyl chloroform
(1,1,1-trichloroethane), CFC-113 (trichlorotrifluoroethane),
methylene chloride, CFC-11 (trichlorofluoromethane), CFC-12
(dichlorodifluoromethane), CFC-22 (chlorodifluoromethane),
FC-23 (trifluoromethane), CFC-114 (dichlorotetrafluoroethane),
CFC-115 (chloropentafluoroethane), HCFC-123
(dichlorotrifluoroethane), HFC-l34a (tetrafluoroethane),
HCFC-141b (dichlorofluoroethane), and HCFC-142b
(chlorodifluoroethane). "Loading" is a measure of the mass
air emission potential of a wastewater stream, determined by
multiplying the VO concentration in the wastewater by the
annual quantity of the wastewater stream.
7.3 APPLICABILITY
The facilities that will be considered affected
facilities are those processes and/or pieces of equipment that
generate any organic-containing wastewater stream and that are
within the affected source category. The three criteria that
7-4
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define the affected source category are: (1) the facility is
one of the four industries described in Section 7.1; (2) the
facility is located in an area of nonattainment for ozone; and
(3) the facility generates wastewater streams containing
organic compounds. A detailed description of different
sources of wastewater streams is presented in Chapter 3.0.
A series of figures has been prepared to illustrate
applicability criteria for determining the level of control
required for wastewater generated by affected facilities,
treatment standards for wastewater streams requiring control,
and levels of treatment needed for residuals. These figures
are presented in the model rule included as Appendix A. These
figures are used in the following discussion to define
applicability and level of control required.
7.3.1 Applicability Criteria
To determine the applicability to a wastewater stream,
the flow and total VO concentration of that wastewater stream
should be determined at the point of generation. If the
stream has a total VO concentration equal to or greater than a
maximum VO concentration 10,000 parts per million by weight
(ppmw), or if the stream has a total flow greater than or
equal to 1 £pm and a VO concentration greater than 500 ppmw,
then the stream is defined as an affected stream.
After the affected streams have been determined, the
facility-wide loading cutoff may be applied. The facility-
wide loading cutoff is based on the annual VO loading of the
affected streams in the facility. This loading cutoff will
serve to exempt small facilities with a low annual total VO
loading, or allow larger facilities to exempt certain streams
from their control requirements. The Agency has selected
10 Mg/yr as the facility-wide loading cutoff. To utilize this
option the facility would calculate the annual VO loading of
individual streams exceeding the flow and concentration
cutoffs at the point of generation. An individual stream
equal to or less than the 10 Mg/yr cutoff or a combination of
several streams totalling or less than the 10 Mg/yr cutoff
7-5
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could be eliminated from control. If the facility-wide annual
VO loading is equal to or below 10 Mg/yr the facility would be
exempt from control.
Facilities that exceed the facility loading cutoff have
the option of making process changes that will reduce the VO
concentration and/or the quantity of wastewater at the point
of generation for individual streams. Once process changes
are made, the individual streams are reevaluated using the
total VO concentration and flow rate criteria.
Facilities that do not use process changes to reduce
their total VO loading below the cutoff may recycle affected
streams back to the process or reduce the VO loading by using
waste management units that are properly controlled for air
emissions.
If it is possible to recycle or treat affected streams
under either one or a combination of these options, then the
annual total VO loading is reevaluated, based on the following
summation: (Annual total VO loading at point of generation
for untreated, affected streams) + (Annual total VO loading at
the treatment process outlet for affected streams not treated
to treatment standards [Section 7.4]). The loadings of
affected streams recycled back to the process or fully treated
to the treatment standards would not be included in the annual
total VO loading reevaluation. Facilities that cannot use
these options to reduce the VO concentration below the RACT
concentration and flow rate cutoffs should be required to meet
the treatment standards described in Section 7.4.
7.4 FORMAT OF THE STANDARDS
The control of VOC emissions from wastewater comprises
three different components: emission suppression and control
of vapors from wastewater collection and treatment, wastewater
treatment to reduce VO content in the wastewater, and
treatment of residuals. Wastewater collection refers to
transporting wastewater from the point of generation to a
treatment unit. Wastewater treatment pertains to different
techniques employed to reduce the mass of organic compounds in
7-6
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the wastewater stream. Finally, the treatment of residuals
refers to vapors from transport, handling, and treatment, as
well as oil phases, condensates, and sludges removed from
controlled wastewater streams. These residuals must be
collected in a closed-vent system, then recycled or destroyed.
Each of these three components are discussed separately below.
7.4.1 Emission Suppression from Wastewater Collection
The recommended method for suppression of emissions from
wastewater collection systems includes a combination of
equipment standards and work practices. Equipment used to
suppress emissions from wastewater collection and treatment
systems includes covers, lids, roofs, and enclosures.
Typically, the design of this equipment includes gasketing
around all openings, doors, hatches, and sampling ports.
Proper work practices are needed to ensure that the equipment
will suppress emissions. Examples of work practices include:
(1) annual monitoring for leaks; (2) visual inspection for
cracks and gaps in the equipment, and (3) repair of
deficiencies as soon as practical but no later than 5 calendar
days after identification.
7.4.2 Wastewater Treatment to Reduce Volatile Organic Content
Two formats are presented for the reduction of wastewater
VO content. These are a numerical format and an equipment
design and operation format. Since emission potential is a
function of VO concentrations and wastewater flow rate, which
can be measured directly, VO concentration and wastewater
flow rate are used as the bases for the numerical format.
A total of four numerical emission limit formats are
presented to provide facilities with a maximum degree of
operational flexibility in demonstrating compliance: (1) an
overall percent reduction of total VO in the wastewater
stream; (2) percent reductions for individually speciated VO;
(3) an effluent concentration limit for total VO; and (4) a
required mass removal for VO. These four numerical formats
and the equipment design format are discussed below.
7-7
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7.4.2.1 Percent Reduction. The percent reduction format
is based on the VO removal efficiency of a steam stripper, and
should be considered as an alternative standard to an
exclusive effluent concentration limit because of the wide
variations in influent wastewater characteristics. Data
available from steam strippers treating wastewater streams
containing VO indicate that removal efficiencies of greater
than 99 percent are achievable with a properly designed and
operated system for treating compounds that are volatile.
However, any treatment process that can achieve the proposed
efficiency can be used to comply with the standard.
Therefore, one form of a percent reduction standard that might
be considered would be a required overall VO removal
applicable both to streams that are treated individually and
to those that are combined prior to treatment.
A second alternative percent reduction standard is based
on the percent reduction for individually speciated VO. Some
VOC's are highly soluble or have low volatilities and cannot
be removed as easily by steam stripping as other compounds.
Wastewater streams composed mostly of compounds with low
volatility may not be able to achieve the total VO percent
reduction. Therefore, the organic compounds have been grouped
by Henry's Law constants into five strippability groups.
Strippability refers to the predicted removal efficiency of a
compound using the design steam stripper discussed in
Section 4.2.1. These groups are shown in Table 7-1. The
groups are ordered by decreasing strippability. Target
percentage removals for VO in each group have been developed
based on the range of Henry's Law constants for the compounds
in that group. Facilities may choose to use this alternative
standard in cases where individual or combined streams contain
VO with low volatility, such as a stream containing phenol.
This approach will result in adequate control of VOC air
emissions within the full range of volatilities.
7.4.2.2 Effluent Concentration. The effluent
concentration limits are also based on the performance of a
7-8
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TABLE 7-1. VOLATILE ORGANICS STRIPPABILITY GROUPS
AND TARGET REMOVAL EFFICIENCIES
Target
Strippability Henry's Law Constant Range removal
Group (25°C) efficiency
I H > 1.333 X 10-3 99%
II 1.3333 X ID"3 >H > 7.499 X 10~5 95%
III 7.499 X 10~5 > H > 2.208 X 10~6 70%
IV 2.208 X 10"6 > H > 4.217 X 10~7 25%
V 4.217 X 10~7 > H 0%
7-9
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steam stripper. Again, any treatment process that can achieve
the proposed effluent concentration limits can be used to
comply with the standard. Effluent concentration limits are
provided as alternatives to the percent reduction standard to
allow compliance flexibility for facilities required to treat
individual streams having low VO concentrations.
Additionally, a percent reduction standard for these streams
may require additional treatment with little reduction in
emissions, since at very low concentrations it is more
difficult and costly to achieve the same level of percent
reduction.
7.4.2.3 Mass Removal. Required mass removal is an
alternative for combined streams where streams requiring
control might be mixed with other streams not requiring
control. It is based on the removal performance of a steam
stripper for the different volatility groups of compounds.
The mass removal alternative was provided in lieu of
concentration limits because concentration limits could be
achieved by dilution of affected streams through combination
with less concentrated affected streams or unaffected streams.
A series of treatment processes may be used to comply
with this requirement. However, wastewater collection and
treatment processes located between treatment processes being
used to achieve the required mass removal should follow
suppression or treatment formats. For example, if a
combination of two steam strippers is used to achieve the
required mass removal, and a tank is located between the two
steam strippers, then the tank should be controlled to
suppress emissions, even if not all streams entering the tank
are defined as affected streams.
7.4.2.4 Equipment Design and Operation. Another
regulatory format considered for wastewater treatment is an
equipment design and operation format. The equipment standard
consists of the installation of a steam stripper designed and
operated at specified parametric levels, as discussed in
Chapter 4.0. The specifications for the steam stripper were
7-10
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developed to provide a standard piece of equipment (with
associated operating conditions) that can achieve high removal
of VOC's for most streams, and greater than 99 percent for
streams containing primarily high-volatility compounds.
This equipment format was included to provide an
alternative standard with which all facilities would be able
to comply, while achieving the desired emission reduction.
Steam strippers are universally applicable treatment devices
that provide a consistently high level of VO removal. This
treatment format is applicable for individual or combined
streams.
In summary, five alternative standards are proposed for
wastewater treatment. Four alternatives are based on a
numerical format, and one is an equipment/operational format.
This combination of alternatives using different formats
provides a wide range of flexibility in complying with the
standard and takes into consideration the variabilities in
waste streams produced in the affected industry.
7.4.2.5 Alternative Treatment Standards. Alternative
treatment standards are recommended when the wastewater
streams within a process unit can be combined for treatment.
To demonstrate compliance with these alternative treatment
standards, a facility should be required to demonstrate that
the total VO concentration of all streams (individual or
combined) leaving the process unit is less than or equal to
10 ppmw. The VO concentration may be determined after
combination with other streams and after treatment, but before
exposure to the atmosphere.
7.4.3 Treatment of Residuals
Residuals, defined in Section 7.2, must be controlled.
It is suggested that facilities be given the following options
for handling residuals: (1) return the residual to the
process; (2) return the residual to a treatment device; or
(3) destroy the total VO loading of the residual by at least
99 percent. Residual treatment and destruction devices are
discussed in Chapter 4.0.
7-11
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7.5 PERFORMANCE TESTING
Performance testing is required to demonstrate that the
control devices chosen to comply with RACT requirements are
capable of achieving the recommended performance standards or
equipment design requirements. Testing is typically requested
by the regulating agency at the time the regulatory standard
is initially triggered at a facility and at any time
thereafter that it is deemed necessary (usually on a continual
or continuous basis). The initial test, or performance test,
usually requires testing of influent and effluent
concentrations and associated operating parameters, whereas a
monitoring test may require the operator to record only those
operating parameters met during the initial performance test.
When the owner or operator of an affected facility conducts a
performance test, the treatment process should be operating at
the most demanding conditions the control device is expected
to encounter. This section addresses performance testing.
Monitoring requirements are addressed in Section 7.6.
7.5.1 Wastewater Collection
The purpose of performance testing for wastewater
collection systems is to demonstrate that both the recommended
equipment performance levels and work practices discussed in
Section 7.4.1 are being met. The air quality management
agency may require testing and/or inspection of emission
reduction equipment to ascertain that this equipment is
installed and maintained according to manufacturer's
specification. The agency may also provide guidelines for
operators to follow with respect to work practices (i.e.,
equipment leak monitoring).
7.5.2 Wastewater Treatment
The purpose of performance testing for wastewater
treatment systems is to demonstrate that the recommended
equipment performance levels and design requirements discussed
in Section 7.4.2 are being met. The air quality management
agency may require testing to determine that the facility is
operating its equipment at design specifications to meet RACT
7-12
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standards. For wastewater streams being controlled under a
performance standard, testing to demonstrate that the required
percent reduction or required mass removal is being achieved
should be required. At a minimum, the air quality management
agency should require the measurement of the influent and
effluent VO concentrations.
7.5.3 Treatment of Residual Vapors from Wastewater Collection
and Treatment Systems
It is recommended that the air quality management agency
require initial performance testing of residual vapor
destruction devices. A destruction efficiency should be
required for flares and combustion devices, whereas a weight
percent reduction format is recommended for such product
recovery devices as carbon adsorbers, condensers, and
absorbers.
7.6 MONITORING REQUIREMENTS
In implementing RACT, specific monitoring requirements
should be required. One purpose of monitoring is to ensure
that wastewater streams which are initially determined not" to
exceed the RACT cutoff criteria, continue to remain below the
RACT cutoff level. A second purpose of monitoring is to
demonstrate proper operation of a treatment device in place to
control a stream exceeding the RACT cutoff criteria. The
following is guidance on specifying requirements for
monitoring.
7.6.1 Wastewater Collection
The air quality management agency should require
evaluation of all collection systems that use a closed vent
system to reduce emissions. It is suggested that this
evaluation be conducted initially and at some periodic time
interval to determine if any leaks are present. This
evaluation can be conducted by visually inspecting seals,
access doors, and openings for cracks, gaps, and improperly
fitted gaskets, and/or using an approved test method
(Reference Method 21). Suggested monitoring parameters and
7-13
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frequencies for wastewater collection equipment are summarized
in the model rule in Appendix A.
7.6.2 gfasj;evyat.er Treatment
In order to ensure that the facility is maintaining the
control equipment selected to comply with the standards (i.e.,
steam stripper), the air quality management agency may require
continuous monitoring of those parameters that indicate proper
system operation. For a steam stripper, these parameters may
include steam flow rate, liquid loading, wastewater feed
temperature, and condenser vapor outlet temperature. If an
alternative treatment is used to comply with the performance
standard, the agency may consider requiring monitoring of
influent and/or effluent streams for VO concentration, percent
VO removal, or required mass removal on a regular basis, or
monitoring specific operating parameters that provide an
indication of the treatment device performance. Suggested
monitoring parameters and frequencies for the different
treatment formats are summarized in the model rule in
Appendix A. A distinction between the different monitoring
requirements for treatment of individual versus combined
wastewater streams is also made in the model rule.
7.6.3 Tr.eatment pf. Residual Vapors from Wastewater Collection
and Treatment Systems
The treatment of the vapors from residuals lends itself
to a performance based standard, because there are numerous
appropriate alternatives. The air quality management agency
may want to require monitoring to ensure that these devices
are operating properly. For incinerators, boilers, and
condensers, the equipment's temperature may be the appropriate
parameter to monitor on a continuous basis. An organic
compound monitoring device may be recommended for carbon
adsorbers and condensers. Suggested monitoring parameters and
frequencies for different control devices used to comply with
the standards are summarized in the model rule in Appendix A.
7-14
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7.7 REPORTING/RECORDKEEPING REQUIREMENTS
For each facility subject to the RACT requirements, the
air quality management agency should require reporting and
recordkeeping of certain key parameters to indicate
compliance. First, affected facilities should identify the
control method selected to meet the RACT requirements. Next,
the results of any performance test results should be
recorded. It is also recommended that the facility record all
parameters monitored on a routine basis to indicate continued
compliance with the RACT emission limit. These parameters
differ depending on the means by which the RACT requirements
are met. Any exceedances of the monitored parameters listed
should be recorded along with any corrective actions taken to
correct the exceedance. The agency should specify which of
the recorded data should be reported and what the reporting
frequency should be. Guidance for recordkeeping and reporting
requirements are provided in the model rule in Appendix A.
7.8 RELATIONSHIPS TO TITLE III (SECTION 112) OF THE CLEAN AIR
ACT AMENDMENTS
Section 112 of the Clean Air Act, as amended November
1990, requires EPA to develop national standards for source
categories that emit one or more of 189 hazardous air
pollutants listed in Section 112(b). EPA is currently
planning to promulgate a standard by November 1992 that will
address hazardous air pollutants from the SOCMI industry.
This standard is referred to as the HON. It will cover
process vents, equipment leaks, storage, transfer, and
wastewater operations. Meanwhile, EPA is developing several
CTG's which address some of these same types of emission
points in the SOCMI industry; these include reactor and
distillation process vents, storage, and wastewater. EPA has
already published CTG's for SOCMI air oxidation process vents
and equipment leaks.
The same basic control technology requirements are
included both in the proposed HON and the CTG's (e.g., steam
stripping). The only real difference between the draft CTG's
7-15
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and the proposed HON is the applicability. There may be
process vents, storage vessels, or wastewater streams in
plants covered by the proposed HON that would not be subject
to the Section 112 standards because they contain no HAP's or
because they contain less HAP's than the specified
applicability criterion. These same emission points, however,
may contain enough VOC to meet the applicability criteria
recommended in the CTG's (e.g., 1 £pm and 500 ppmw). The
reverse could be true. An emission point could fall below a
CTG-recommended cutoff and be above a HAP cutoff. The net
effect is that a plant owner or operator may need to control
more total emission points than, he would under either
requirement alone. Thus, even though the control technology
would be the same under both sets of rules, the owner or
operator may need a larger control device, for example, to
control all the emission points addressed by the CT6 and HON
together. Being aware of the need for owners and operators to
have a knowledge of both sets of requirements as they develop
their control strategies, EPA's intent is to publish the CTG's
on the same schedule as the promulgated Section 112 rule, if
possible, so owners and operators are at least informed of the
CTG recommendations (even though the actual State rules for
the VOC sources may be different).
In the current draft version of the HON, compliance can
be achieved using emissions averaging, which means that some
emission points may remain uncontrolled as long as the
requisite emission reductions are achieved at other emission
points. However, these "averaged-out" emission points may
still be subject to the requirements of RACT because of their
VOC emissions. To minimize the constraints to flexibility
with meeting the HON, such as described above, while at the
same time not jeopardizing the VOC emission reductions that
would be achieved by the installation of controls at CTG-
affected points, EPA is planning to publish in the Federal
Register for public comment a presumptive alternative RACT for
those emission points that are affected by the HON and CTG's.
7-16
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7.9 REFERENCES
1. Federal Register. Hazardous Waste Treatment, Storage, and
Disposal Facilities; Organic Air Emission Standards for
Tanks, Surface Impoundments, and Containers; Proposed
Rule. 56 FR 33544 to 33555. July 22, 1991.
7-17
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APPENDIX A
MODEL RULE
The model rule for the IWW CTG is being based on the
HON. The HON is addressing hazardous air pollutant
emissions from wastewaters generated in SOCMI, which is a
subset of the OCPSF industry. The HON is presently
undergoing revisions which will alter the model rule.
Therefore the Agency has elected to not include a model rule
in the draft version of the IWW CTG. The final document
will include a complete model rule which will reflect any
revisions to the HON.
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APPENDIX B
NATIONAL IMPACTS ANALYSIS
-------
-------
APPENDIX B. NATIONAL IMPACTS ANALYSIS
This appendix presents the approach for estimating the
national impacts of implementing reasonably available control
technology (RACT) for wastewater streams generated by
facilities within the six industrial categories discussed in
Chapter 2.0.
Section B.I details the development of model wastewater
streams for the six industries, including the methodology for
calculating total volatile organic (VO) concentration and
average strippability (fravg) factors used (along with flow
rate) to define the model wastewater stream, from individual
compound information. Because in some cases these initial
model wastewater streams represent the combined streams leaving
the process unit, and not the individual wastewater streams at
their point of generation, a methodology for disaggregating the
combined streams into individual streams was developed.
Section B.2 details this approach for disaggregating combined
streams into individual wastewater streams. Sections B.3
and B.4 present the methodology (including sample calculations)
for estimating uncontrolled volatile organic compound (VOC)
emissions and emission reductions with control, and cost and
secondary impacts of control. Finally, Section B.5 presents
the national impacts of applying RACT to each of the individual
industries. . ' ' •
B.I MO01L WASTIWATIR STREAMS
As discussed in Chapter 2.0, model wastewater streams were
developed from a variety of sources to represent the six
industries included in this document. The information provided
by the sources typically consisted of flow and speciated VOC
concentration data. From these data, along with Henry's Law
- ' •' B-l
-------
constants for the individual VOC's, model wastewater streams
were developed, with the following parameters: flow rate,
total VO concentration, and strippability [fraction removed by
steam stripping (fr)]. VO concentrations were calculated from
VOC concentrations using the following formula:
VO = E (VOCi * fmi)
where :
VO = volatile organic concentration as measured
by EPA Method 25D;
= total concentration of volatile organic
compound i; and
= the fraction of the total volatile organic
compound i measured by EPA Method 25D,
predicted for compounds of interest using a
theoretical analysis.1
In estimating the potential VOC removal efficiency
for individual compounds in the wastewater stream, the
predicted efficiency of the design steam stripper was used.
The efficiency was first predicted on an individual compound
basis (as discussed in Section 4.2), and then the average
fractional reduction in emission potential (fraVg) due to steam
stripping was calculated for each model wastewater stream using
the following equation:
_ i ( voci * f ei * fri)
rravg ~ —
E i voci * f ei
where:
fravg = tne average fraction of the total VO
removed from the wastewater due to steam
stripping, or the fractional reduction in
emission potential;
(mg/£) = the VOC concentration of compound i;
= the fraction of compound i emitted into the
atmosphere; and
B-2
-------
fr^ = the fraction of compound i removed by steam
stripping from a wastewater stream.
Table B-l presents an example calculation of the total VO
concentration and the average fr for a model wastewater stream.
The development of model wastewater streams for the six
industries discussed in this document is presented in the
following sections.
B.I.I Organic Chemicals. Plastics, and synthetic Fibers
Industry
Table B-2 presents a summary of the Organic Chemicals,
Plastics, and Synthetic Fibers (OCPSF) model wastewater
streams. The basis for the development of these model
wastewater streams is the wastewater stream data reported by
facilities in the synthetic organic chemical manufacturing
industry (SOCMI) in response to a 1990 Section 114 Survey. The
data reported were for individual streams at the point of
generation and included individual organic compound
concentration data and wastewater flow rates. The fraction
removed (fr) was calculated for the entire SOCMI 114 data base
using the VO loading weighted average fr as described in
Section B.I. The resulting fr was 0.93. This number describes
the steam strippers effectiveness to remove the organic
compounds present in the 114 data base. Additional description
of the basis is presented in Section 2.1. The wastewater
stream total VO concentrations and average fr's were calculated
as detailed in the example in Table B-l.
B.1.2 Pesticides Manufacturing Industry
Table B-3 summarizes the pesticides manufacturing industry
model wastewater streams. The basis for the development of
these model wastewater streams is the wastewater stream data
reported by facilities in response to a 1989 Section 308 survey
by the Office of Water Regulations and Standards (OWRS). Data
reported in the survey responses included flow rates and
individual organic compound concentrations. Additional
description of the basis is presented in Section 2.2. The data
were reported for combined process unit effluent streams and
B-3
-------
TABLE B-l. EXAMPLE WASTEWATER STREAM DEVELOPMENT
Plant Stream Flow
ID ID (tpm)
A 1 10
Compound
Chloroform
Isopropanol
Methanol
Acetone
Wastewater stream total/composite
VOC
cone.
(mg/£)
13
1,170
170
1,340
2,693
VO
conc.k
fma . (mg/£)
1.
0.
0.
0.
0
793
321
829 1
2
13 0
930 0
55 0
, 110 0
,108
fe
.69
.48
.22
.37
frc,d
1
0.
0.
0.
0.
.0
89
97
94
92
a fm^ = the fraction of the total volatile organic compound i measured by EPA
Method 25D, predicted for compounds of interest using a theoretical analysis.1
w b Volatile organic concentration = VOC
i
concentration * fm
c Individual compound, fri = the fraction of compound i removed from the
wastewater due to steam stripping.
^ Fravg = the average fraction of the total VO removed from the wastewater due to
steam stripping, or the fractional reduction in emission potential.
Ei (VOC^ * fe^ * fr^ ) _ 1,011
avg ^ TI~~ * fei 1,104
-------
TABLE B-2. MODEL STREAMS;V ORGANIC CHEMICALS, PLASTICS, AND
SYNTHETIC FIBERS MANUFACTURING INDUSTRY
Stream
ID
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
; i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
121
122
131
132
133
141
142
161
162
163
164
165
112 1
112 2
112 3
112 4
112 5
311
312
313
314
315
316
317
318
319
3 110
3 111
3 112
321
322
323
324
325
326
411
412
413
414
415
421
422
423
424
425
426
Flow
(ipm)
11.36
0.05
0.34
0.59
98.41
158.97
0.05
2.08
0.22
:25,21
66.24
0.05
6.13
6.13
8.63
8.63
7.91
5.37
2.16
0.22
66.24
2 . 08
11.36
11.36
11.36
11.36
2.16
28.39
141.94
0.54
66.24
283.88
2.08
2.16
0.22
66.24
0.54
3.86
12.53
40.73
2.16
0.54
5.79
0.22
0.05
25.93
Total VO Fraction removed
concentration by steam stripper
(ppmw) (fr)
521
38,500
3,198
777
213
213
821,800
242,781
556
160
6,021
63
8,227
871
7,629
6,973
893
0
0
0
5
-5 .
5
49
5
1,225
5
0
12
0
24,700
500
3,300
1,050
200
0
0
931
949
41
9
9
42
23,511
32,596
18
0.956
0.160
0.878
0.649
0.303
0.303
0.944
0.951
0.770
0.820
0.818
0.815
0.617
0.930
0.921
0.922
0.915
0.000
0.580
0.000
0.588
0.000
0.000
1.000
0.000
0.580
0.000
0.000
0.580
1.000
1.000
0.966
1.000
1.000
0.958
0.090
0.090
0.940
0.958
0.971
0.941
0.941
0.976
0.956
0.928
0.655
B-5
-------
TABLE B-2. MODEL STREAMS: ORGANIC CHEMICALS, PLASTICS, AND
SYNTHETIC FIBERS MANUFACTURING INDUSTRY (Continued)
Stream
ID
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
427
428
429
431
432
433
434
435
436
437
438
439
441
442
443
444
451
452
461
462
463
465
466
467
468
469
4 610
481
482
411 1 .
411 2
411 3
411 4
411 5
411 6
411 7
411 8
411 9
41110
41111
41112
41113
41114
41115
41116
412 1
412 2
Flow
(£pm)
12.94
12.94
0.54
67.94
36.71
0.22
0.54
5.45
2.16
,18.13
" 2.16
2.16
66.24
66.24
66.24
0.05
66.24
66.24
889.48
28.39
1,135.50
141.94
208.18
28.39
0.22
2.16
2.16
11.36
11.36
193.04
378.50
66.24
2,668.43
66.24
66.24
2.16
11.36
141.94
2.16
0.22
141.94
141.94
28.39
28.39
2.08
0.05
0.22
Total VO Fraction removed
concentration by steam stripper
(ppmw) • (fr)
9
9
48,022
193
32
850
26,163
10
10
45
• 7,516
803
26
66
66
81
12
20
2,363
1,215
740
2,136
1,567
4,813
500
500
4,000
1,000
1,000
115
230
296
72
8
5
26,545
5
64
100
100
825
2,498
420
47
100
55
54
0.144
0.144
0.374
0.997
0.839
0.697
0.953
0.947
0.947
0.978
0.996
1.000
0.813
0.926
0.926
0.737
0.700
0.700
0.988
0.980
1.000
0.978
0.986
0.984
1.000
1.000
0.998
1.000
1.000
0.991
0.980
0.980
0.980
0.980
0.980
0.980
0.980
0.980
1.000
1.000
0.981
0.946
0.981
0.986
1.000
0.949
0.965
B-6
-------
TABLE B-2. MODEL STREAMS: ORGANIC CHEMICALS, PLASTICS, AND
SYNTHETIC FIBERS MANUFACTURING INDUSTRY (Continued)
Stream
ID
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
412
412
412
412
412
412
412
413
413
413
413
413
413
413
413
413
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
41312
41313
41314
417
417
417
417
417
417
417
418
418
418
418
418
418
418
418
418
1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
9
41810
419
419
419
419
419
419
419
420
420
420
420
1
2
3
4
5
6
7
1
2
3
4
Flow
0
0
0
0
0
0
2
283
28
141
0
0
2
2
0
66
141
0
0
0
2
2
0
0
14
0
0
99
50
33
50
2
26
7
89
3
0
36
36
3
0
17
0
0
95
38
2
.05
.54
.01
.22
.03
.22
.16
.88
.39
.94
.22
.54
.16
.16
.54
.24
.94
.22
.22
.04
.16
.16
.22
.05
.19
.00
.54
.85
.57
.69
.57
.16
.76
.42
.25
.71
.05
.07
.07
.60
.05
.52
.54
.22
.91
.38
.16
Total VO Fraction removed
concentration by steam stripper
(ppmw) (fr)
55
54
55
54
55
54
55
1,126
196
678
1,128
0
1,129
1,129
1,129
1,092
1,780
1,129
1,129
4,070
9
9
9
42,123
9
4,070
5,386
6
4
4
4
18,788
8
8
10
8,069
8,202
8
11
11
89,181
8
8,202
23,805
30
6
4
0.
0.
0.
0.
0.
0.
0.
0.
0,
0.
0.
0.
0,
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0 .
0.
0.
0.
0.
0.
949
965
949
965
949
965
949
940
580
000
940
000
000
000
000
580
000
000
000
930
951
951
951
931
951
930
925
968
980
980
980
950
901
901
864
929
930
943
747
747
931
953
930
996
904
986
980
B-7
-------
TABLE B-2. MODEL STREAMS: ORGANIC CHEMICALS, PLASTICS, AND
SYNTHETIC FIBERS MANUFACTURING INDUSTRY (Continued)
Stream
ID
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
420
420
420
5 1
5 1
5 1
5 1
5 1
5 2
5 3
5 3
5 3
5 4
5 4
5 4
5 4
6 1
6 2
6 2
6 2
6 3
6 3
6 3
6 3
6 3
6 3
6 3
6 3
7 1
7 1
2 4
2 4
2 4
2 5
2 5
2 5
210
210
210
210
210
210
210
210
212
212
213
5
6
7
3
4
5
6
7
1
1
2
3
3
4
5
7
1
1
2
3
1
2
3
4
5
6
7
8
1
2
1
2
3
1
2
3
1
2
3
4
5
6
7
8
1
2
1
Flow
(£pm)
0
53
2
177
94
94
291
3
473
548
416
70
132
37
3
18
2
106
5
101
113
52
719
1
0
0
0
0
0
0
264
18
18
11
11
28
66
66
66
2
2
2
2
2
66
11
5
.05
.63
.16
.90
.63
.63
.45
.79
.13
.83
.35
.02
.48
.85
.79
.93
.08
.74
.30
.44
.55
.99
.15
.66
.35
.09
.20
.92
.32
.58
.95
.93
.93
.36
.36
.39
.24
.24
.24
.08
.08
.08
.08
.08
.24
.36
.37
Total VO Fraction removed
concentration by steam stripper
(ppmw) (fr)
48,
12,
1,
2,
4,
1,
1,
1,
1,
7,
5,
22,
23,
9,
31,
8,
6,
976
13
064
76
96
96
80
093
32
278
173
109
101
828
828
094
370
0
0
9
631
793
131
612
762
652
24
0
8
095
22
34
34
441
810
441
1
1
40
20
20
20
20
20
800
398
0
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
1.
1.
1.
1.
1.
1.
0.
0.
0.
999
960
998
931
915
915
928
930
590
685
972
800
927
789
789
930
800
000
000
984
968
591
590
864
871
952
590
000
940
883
894
980
980
950
950
950
800
800
000
000
000
000
000
000
905
985
000
B-8
-------
TABLE B-2. MODEL STREAMS: ORGANIC CHEMICALS, PLASTICS, AND
SYNTHETIC FIBERS MANUFACTURING INDUSTRY (Continued)
Stream
ID
2
2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
214
214
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
3
3
1
1
1
2
2
2
3
3
3
4
4
4
5
5
5
1
1
1
1
1
1
1
1
i
1
2
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
4
5
6
7
8
9
110
2
1
1
1
3
3
4
4
4
7
7
8
8
310
310
310
311
311
311
1
1
2
3
1
2
1
2
3
1
2
1
2
1
2
3
1
2
3
Flow
2.
28.
11.
66.
66.
0.
0.
0.
2 .
2 .
' . 2 .
66.
66.
66.
66.
66.
66.
378.
141.
141.
28.
208.
66.
244.
66.
28.
3.
11.
1.
2.
306.
5.
2.
1.
2.
306.
11.
11.
28.
11.
11.
' 11.
11.
264.
28.
66.
08
39
36
24
24
54
54
54
16
16
16
24
24 ..
24
24
24
24
50
94 -.
94
39
18
24
89
24
39
60
36
26
90
59
37
08
26
90
59
36
36
39
36
36
36
36
95
39
24
Total VO Fraction removed
concentration by steam stripper
(ppmw) (fr)
3,
1,
3,
28,
1,
2,
5,
1,
23,
17,
10,
10,
2,
9,
2,
1,
4,
695
4
4
4
17
158
190
307
589
462
425
678
900
,317
550
950
097
382
28
428
186
522
26
43
19
511
030
575
6
8
19
0
642
6
8
19
0
2
660
0
050
246
162
287
000
800
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
1.
0.
0.
0.
0.
0.
0.
1.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
1.
1.
0.
0.
0.
0.
0.
0.
1.
1.
800
800
980
980
980
000
980
920
980
950
980
000
980
950
980
980
980
000
710
983
996
982
980
980
000
840
840
985
541
553
503
000
590
541
553
503
000
000
950
000
950
952
959
849
000
000
B-9
-------
TABLE B-2. MODEL STREAMS: ORGANIC CHEMICALS, PLASTICS, AND
SYNTHETIC FIBERS MANUFACTURING INDUSTRY (Continued)
Stream
ID
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
1 3
1 3
1 4
1 4
1 5
1 5
1 5
113
114
115
116
116
116
116
116
116
2 1
2 1
2 1
2 1
2 1
2 1
2 1
2 1
2 1
3
4
1
2
1
2
3
1
0
1
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
2 110
2 111
2 112
2 113
2 2
2 2
2 2
2 3
2 4
2 5
2 5
2 5
2 5
2 6
2 6
2 6
2 6
2 7
2 7
2 7
2 8
2 8
1
2
3
1
1
1
2
3
4
1
2
3
4
1
2
3
1
2
Flow
(£pm)
11.
719.
66.
11.
141.
66.
66.
7.
5.
11.
66.
283.
141.
0.
11.
28.
66.
66.
227.
11.
2.
11.
11.
11.
11.
11.
2.
28.
7.
20.
454.
37.
141.
28.
19.
0.
3.
0.
46.
0.
3.
46.
0.
11.
66.
66.
11.
36
15
24
36
94
24
24
57
37
36
24
88
94
22
36
39
24
24
10
36
08
36
36
36
36
36
08
39
95
82
20
85
94
39
45
23
07
32
82
11
13
82
54
36
24
24
36
Total VO
concentration
(ppmw)
7
3
14
7
1
12
1
1
3
671
2
3
1
1
1
14
25
7
4
1
6
2
7
0
,217
,232
251
35
11
,741
0
,655
,275
62
62
,460
,246
158
,700
682
120
,400
,700
0
0
,550
663
,754
17
572
25
,328
229
,516
,284
,310
414
486
,415
,900
0
206
,743
0
,497
,035
364
,170
434
Fraction removed
by steam stripper
(fr)
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
.980
.000
.781
.947
.991
.963
.987
.966
.000
.512
.960
.940
.940
.940
.940
.976
.980
.979
.964
.980
.941
.000
.000
.980
.940
.949
.980
.950
.960
.570
.583
.960
.590
.950
.905
.343
.980
.000
.000
.520
.529
.000
.395
.980
.458
.000
.000
B-10
-------
TABLE B-2. MODEL STREAMS: ORGANIC CHEMICALS, PLASTICS, AND
SYNTHETIC FIBERS MANUFACTURING INDUSTRY (Continued)
Stream
ID
4
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
.5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
3
4
4
4
4
4
4
4
4
4
4
4
4
4
5
5
5
5
6
6
6
6
8 3
21
2 2
4 1
42
4 3
4 5
46
4 7
4 8
410
411
412
413
414
415
416
1 1
1 2
1 3
1 5
2 1
2 2
2 3
2 4
1 1
1 1
1 2
1 3
1 4
1 5
1 6
2 1
4 1
4 2
4 3
4 4
4 5
4 6
3 1
3 2
4 1
4 2
1 1
1 2
1 3
1 4
Flow
(4pm)
2.
28.
283.
8.
66.
283.
19.
66.
141.
' 141.
11*
28.
141.
283.
283.
66.
11.
18.
34.
2.
0.
8.
0.
0.
0.
227.
2.
5.
0.
11.
0.
0.
11.
0.
141.
2.
66.
5.
5.
283.
283.
141.
283.
141.
28.
60.
189.
08
39
88
71
24
88
45
24
94
94
3.6
39
94
88
88
24
36
13
56
88
36
71
11
19
05
10
08
37
00
36
22
05
36
05
94
08
24
37
37
88
88
94
88
94
39
56
25
Total VO Fraction removed
concentration by steam stripper
(ppmw) (fr)
4,340
300
0
108
359
348
82
184
28
75
7,093
323
48
0
0
50
2
895
109
533
8,540
43,335
31,137
27,092
160,500
8,212
0
0
0
0
0
0
33
300
803
241
241
24
241
8,491
8,475
10,186 .
3,970
80
100
1,750
1,000
1.
1.
0.
0.
0.
0.
0.
0.
0.
0.
1.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
0.
0.
0.
0.
1.
0.
0.
1.
000
000
000
992
982
970 -
976
962
975
977
000
998
994
980
000
993
981
933
933
950
815
590
590
590
590
913
000
000
000
000
000
000
000
000
000
000
000
000
000
979
980
980
977
000
995
995
000
B-ll
-------
TABLE B-2. MODEL STREAMS: ORGANIC CHEMICALS, PLASTICS, AND
SYNTHETIC FIBERS MANUFACTURING INDUSTRY (Continued)
Stream
ID
5
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 1
1 1
1 2
1 3
1 4
1 5
1 6
1 7
2 1
2 2
2 3
2 4
2 5
2 6
2 7
2 8
4 1
4 2
4 3
4 4
4 5
4 6
1 1
1 2
1 3
1 4
1 5
1 6
1 7
1 8
1 9
110
111
112
113
114
115
2 1
2 2
2 3
2 4
2 5
2 6
2 7
2 8
2 9
212
Total VO Fraction removed
Flow concentration by steam stripper
(£pm) (ppmw) (fr)
408
0
66
0
2
0
0
0
1
•• 2
" 0
2
2
0
0
2
141
2
2
2
0
5
9
11
11
2
0
11
0
530
28
141
28
66
0
28
0
62
62
12
7
2
105
7
4
0
2
.78
.22
.24
.54
.08
.54
.22
.05
.04
.16
,22
.16
.08
.22
.22
.16
.94
.16
.16
.16
.54
.76
.16
.36
.36
.16
.22
.36
.54
.01
.39
.94
.39
.24
.05
.39
.54
.45
.45
.49
.95
.46
.98
.95
.43
.95
.08
0
2,460
521
4,045
1,350
285
110
100
100
105
• 3,000
23
2,485
70
24
310
161
332
7,870
5,683
446
83
28
16
85
13,406
21
85
28
54
85
85
85
85
17,030
0
3
11,514
0
0
0
0
0
0
6
0
13
1
1
0
1
1
1
1
1
1
1
1
0
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
.000
.000
.747
.000
.000
.000
.000
.000
.000
.000
.000
.981
.000
.000
.000
.000
.882
.618
.605
.717
.699
.637
.984
.993
.980
.985
.982
.980
.988
.986
.980
.980
.980
.980
.980
.000
.000
.000
.000
.000
.000
.000
.000
.000
.000
.000
.000
B-12
-------
TABLE B-2. MODEL STREAMS: ORGANIC CHEMICALS, PLASTICS, AND
SYNTHETIC FIBERS MANUFACTURING INDUSTRY (Continued)
Stream
ID
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
8
8
8
8
8
8
8
8
8
8
8,
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
.1
1
1
1
1
1
1'
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
3
3
3
3
3
3
214
215
3 4
3 6
3 7
3 8
310
311
312
313
315
316
4 1
4 2
4 3
4 4
4 5
4 6
4 7
4 8
4 9
414
415
6 1
6 2
6 3
64
6 5
6 6
6 7'
6 8
6 9
610
611
612
1 1
1 2
2 1
2 2
1 1
1 2
13
1 4
4 1
4 2
5 1
5 2
Flow
62.
180.
10.
140.
10.
5.
Q.
0.
0.
5.
238.
141.
79.
79.
15.
9.
3.
132.
9.
5.
1.
79.
225.
3.
2.
5.
0.
2.
7.
2.
23.
6.
8.
2.
2.
0.
0.
28.
28.
141.
66.
5.
205.
28.
11.
66.
283.
45
17
22
05
22
87
19
19
19
44
08
94
49
49
90
84
14
48
84
53
21
49
21
97
16
26
22
16
34
16
81
81
06
16
16
54
54
39
39
94
24
37
90
39
36
24
88
Total VO Fraction removed
concentration by steam stripper
(ppmw) (fr)
85
0
0
0
0
6
1,865
36
56
604
^ 0
85"
11,514
0
0
0
0
0
0
6
0
85
0
27
0
14
0
2
147
680,003
88
1
1
1
0
0
0
0
15
4
0
4
1
30
137
0
0
0.
0.
1.
1.
1.
1.
1.
1.
1.
1.
0.
0.
1.
1.
1.
1.
1.
1.
1.
1.
1.
0.
0.
0.
0.
0.
1.
0.
0.
0.
0.
0.
0.
0.
0.
1.
1.
1.
1.
0.
1.
0.
0.
0.
0.
0.
0.
998
000
000
000
000
000
000
000
000
000
000
998
000
000
000
000
000
000
000
000
000
998
000
980
995
984
000
989
980
980
981
991
998
980
980
000
000
000
000
990
000
990
983
004
967
000
000
B-13
-------
TABLE B-2. MODEL STREAMS: ORGANIC CHEMICALS, PLASTICS, AND
SYNTHETIC FIBERS MANUFACTURING INDUSTRY (Concluded)
Stream
ID
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
5
5
5
8
8
8
8
8
8
8
8
8
3
4
5
1
2
3
4
5
6
7
8
9
810
811
9
9
9
310
312
312
312
312
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
1
2
3
1
1
2
3
4
1
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
310
1
1
Flow
(£pm)
283
2
283
283
3
141
5
37
9
3
'll
66
28
3
75
757
113
2
66
28
0
0
0
0
2
0
0
283
0
10
0
66
7
264
2
2
11
11
0
279
.88
.16
.88
.88
.71
.94
.45
.32
.31
.71
.24
.24
.39
.71
.70
.00
.55
.16
.24
.39
.22
.22
.22
.22
.16
.22
.22
.88
.22
.98
.22
.24
.57
.95
.16
.16
.36
.36
.22
.26
Total VO Fraction removed
concentration by steam stripper
(ppmw) (fr)
0
0
0
927
810
453
451
2,667
451
451
451
104
2,100
96
8
3
32
1
0
145
0
0
0
20
16,610
20
20
16,610
16,610
0
17
0
1
1
0
0
0
0
0
1
0.
0.
0.
0.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
0.
1.
0.
0.
0.
0.
0.
0.
1.
1.
0.
1.
1.
0.
0.
0.
0.
1.
0.
1.
1.
1.
1.
1.
1.
1.
000
000
000
999
000
000
000
000
000
000
000
000
000
000
590
000
590
090
000
960
000
000
000
000
940
000
000
940
940
998
992
000
993
000
000
000
000
000
000
000
B-14
-------
TABLE B-3. MODEL STREAMS: PESTICIDES MANUFACTURING INDUSTRY
Plant
ID
A
A
A
B
C
C
C
C
C
D
D
D
D
D
D
D
D
D
E
E
E
E
E
E
E
E
F
F
F
F
F
F
F
F
F
F
F
F
G
G
G
G
G
G
Process
ID
1
1
1
1
1
1
1
1
1
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
2
2
1
1
1
2
2
2
3
3
3
4
4
4
1
1
1
2
2
2
Stream
ID .
1
2
3
1
1
2
3
4
5
.1
2 .
3
4
5
6
7
8
9
1
2
3
4
5
6
1
2
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
Flow
(£pm)
18.3
14.6
3.65
2.90
0.825
7.23
5.78
1.45
4.21
11.3
9.04
2.26
11.4
9.08
2.27
24.64
19.7
4.93
5.40
4.32
1.08
78.6
62.9
15.7
1.13
4.00
28.4
22.7
5.68
8.62
6.89
1.72
12.4
9.92
2.48
10.3
8.24
2.06
67.6
54.1
13.5
89.5
71.6
17.9
Total VO
concentration
(ppmw)
50.1
843
6,010
13.0
1,180
0.99
16.7
119
203
10.1
170
1,210
1,060
17,800
127,200
0.078
1.31
9.36
135
2,270
16,200
8.53
143
1,020
0.250
4.00
278
4,670
33,300
356
6,000
42,800
21.7
1,020
2,600
60.4
1,020
7,240
19.9
334
2,380
60.1
1,010
7,210
Fraction
removed by
steam stripper
(fr)
1.00
1.00
1.00
0.89
1.00
1.00
1.00
1.00
0.97
0.42
0.42
0.42
0.95
0.95
0.95
0.97
0.97
0.97
1.00
1.00
1.00
0.71,
0.71
0.71
0.94
0.94
0.97
0.97
0.97
0.40
0.40
0.40
0.98
0.98
0.98
0.31
0.31
0.31
0.90
0.90
0.90
0.95
0.95
0.95
B-15
-------
TABLE B-3. MODEL STREAMS:
PESTICIDES MANUFACTURING INDUSTRY
(Concluded)
Plant
ID
H
H
H
H
H
H
I
I
I
I
I
I
K
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
Process
ID
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Stream
ID
1
2
3
4
5
6
1
2
• 3
4
5
6
1
1
2
3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Flow
(£pm)
32.4
25.9 :
6.48
10.6
8.49
2.12
301
241
60.3
47.3
37.9
9.46
0.329
97.4
77.9
19.5
2.63
2.10
0.526
2.63
2.10
0.526
2.63
2.10
0.526
35.9
28.7
7.17
5.68
4.54
1.14
Total VO
concentration
(ppmw)
2.70
45.5
324
1.66
28.0
200
15.1
254
1,810
4.68
78.7
562
12.0
67.4
1,130
8,090
12.7
214
1,530
7.49
126
899
1.51
25.4
181
184
3,090
22,000
355
5,980
42,600
Fraction
removed by
steam stripper
(fr)
0.99
0.99
0.99
0.07
0.07
0.07
1.00
1.00
1.00
1.00
1.00
1.00
0.96
0.39
0.39
0.39
0.48
0.48
0.48
0.96
0.96
0.96
0.97
0.97
0.97
1.00
1.00
1.00
1.00
1.00
1.00
B-16
-------
were disaggregated to produce individual wastewater stream data
using the procedure discussed in Section B.2. The wastewater
stream total VO concentrations and average fr's were calculated
as detailed in the example in Table B-l.
B.I.3 Treatment, Storage, and Disposal Facilities Industry
Table B-4 summarizes the Treatment, Storage, and Disposal
Facilities Industry (TSDF) model wastewater streams. The basis
for the development of these model wastewater streams is the
wastewater stream data reported by facilities in response to
the 1986 Office of Solid Waste (OSW) Generator Survey under
authority of Section 3007 of the Resource Conservation and
Recovery Act (RCRA). Data reported in the survey responses
included flow rates and individual organic compound
concentrations. Additional description of the basis is
presented in Section 2.5. The data were reported for combined
process unit effluent streams and were disaggregated to produce
individual wastewater stream data using the procedure discussed
in Section B.2. The wastewater stream total VO concentrations
and average fr's were calculated as detailed in the example in
Table B-l.
B.1.4 Pharmaceutical Manufacturing Industry
Table B-5 summarizes the pharmaceutical manufacturing
industry model wastewater streams. The basis for the
development of these model wastewater streams is the wastewater
stream data reported by facilities in response to a 1988
Section 308 survey by OWRS. Data reported in the survey
responses included flow rates and individual organic compound
concentrations. Additional description of the basis is
presented in Section 2.4. The data were reported for combined
process unit effluent streams and were disaggregated to produce
individual wastewater stream data using the procedure discussed
in Section B.2. The wastewater stream total VO concentrations
and average fr's were calculated as detailed in the example in
Table B-l.
B.I.5 Petroleum Refining Industry
The model streams representing the petroleum refining
industry are based on the following:
B-17
-------
TABLE B-4. MODEL STREAMS: TREATMENT, STORAGE,
AND DISPOSAL FACILITIES
Model
Stream No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Flow
(£pm)
1,080
861
215
861
688
172
'430
86.1
688
172
688
551
138
344
430
344
86.1
13.9
11.1
2.77
0.170
0.790
1,200
963
241
963
771
193
482
Total VO
concentration
(ppmw)
0.0484
0.814
5.80
0.814
13.7
97.7
112
0.814
13.70
97.70
13.70
230
1,640
1,880
112
1,880
13,400
8.35
140
1,000
500
500
0.0573
0.96
6.9
0.96
16
116
132
Fraction removed
by steam stripper
(fr)
0.65
0.65
0.65
0.65
0.65
0.65
0.65
0.65
0.65
0.65
0.65
0.65
0.65
0.65
0.65
0.65
6.65
0.59
0.59
0.59
1.00
1.00
0.94
0/94
0.94
0.94
0.94
0.94
0.94
B-18
-------
TABLE B-4. MODEL STREAMS: TREATMENT, STORAGE,
AND DISPOSAL FACILITIES (Concluded)
Model
Stream No.
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Flow
(4pm)
963
771
193
771
617
. 154
385
482
385
96.3
18.1
14.5
3.62
106
84.6
21.2
1.40
241
192
48.1
Total VO
concentration
(ppmw)
0.963
16
116
16
273
1,950
2,220
132
2,220
15,900
5.21
88
625
438
7,360
52,500
100
1.48
24.9
178
Fraction removed
by steam stripper
(fr)
0.94
0.94
0.94
0.94
0.94
0.94
0.94
0.94
0.94
0.94
0.99
0.99
0.99
0.82
0.82
0.82
1.00
0.09
0.09
0.09
B-19
-------
TABLE B-5. MODEL STREAMS: PHARMACEUTICAL MANUFACTURING INDUSTRY
Manufacturing
subcategory
A (Fermentation)
C (Chemical
Synthesis)
Stream
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3 ,
4
5
6
7
8
9
10
11
12
Flow
(4pm)
187
149
37.3
456
365
91.1
47.3
37.9
9.46
255
204
51
129
103
25.8
248
198
49.6
31.5
25.2
6.31
1,240
996
249
26.3
21
5.26
Total VO
concentration
(ppmw)
1.51
25.4
181
46.4
781
5,570
35.6
599
4,270
21.8
367
2,620
40.7
685
4,890
75
1,260
9,000
3.64
61.2
437
15.3
258
1,840
75.3
1,270
9,040
Fraction
removed
by steam
stripper
(fr)
0.59
0.59
0.59
0.84
0.84
0.84
0.92
0.92
0.92
0.93
0.93
0.93
0.79
0.79
0.79
0.91
0.91
0.91
0.80
0.80
0.80
0.82
0.82
0.82
0.63
0.63
0.63
B-20
-------
TABLE B-5. MODEL STREAMS:
PHARMACEUTICAL MANUFACTURING INDUSTRY
(Concluded)
Manufacturing
subcategory Stream
C (continued) 13
14
15
D (Formulation 1
and Packaging)
• . • . ' : • - 2
3
4
5
6
7
8
9
10
11
12
13
14
15
Flow
(ipm)
52.6
42.1
10.5
26.3
21
5.26
2.1
1.68
0.421
4.86
3.89
0.973
1.08
0.862
0.216
13.1
10.5
2.63
Total VO
concentration
(ppmw)
984
16,600
118,000
10.4
175
1,250
0.104
1.75
12.5
110
1,850
13,200
0.00936
0.157
1.12
7.38
124
886
Fraction
removed
by steam
stripper
(fr)
0.82
0 . 82
0.82
0.93
0.93
0.93
0.00
0.00
0.00
0.93
0.93
0.93
0.92
0.92
0.92
0.87
0.87
0.87
B-21
-------
• Throughput capacities for process units identified in
the petroleum refining industry, for the
190 refineries included in the 1990 Oil and Gas
Journal Survey (Table B-6);2
• Wastewater generation factors for combined effluent
wastewater streams from each process unit
(Table B-7), taken from the "New Source Performance
Standards (NSPS) Background Information Document
(BID) for Petroleum Refining Wastewater Systems,"3
and multiplied by process unit capacities to
calculate process unit wastewater flow rates for each
refinery; and
• Volatile organic concentrations for the combined
effluent wastewater streams from each process unit,
based on benzene concentration data presented in the
NSPS BID for Petroleum Refining Wastewater Systems3
and Benzene National Emissions Standards for
Hazardous Air Pollutants (NESHAP) Impacts Document.4
Table B-8 summarizes the development and assignment of VO
concentrations to each process unit. The catalytic
hydrorefining and catalytic hydrocracking process units are
assigned concentrations based on the solubilities of compounds
expected to be present. Each of the other process units is
assigned a benzene, toluene, xylene, and non-BTX (benzene,
toluene, xylene) concentration.
Benzene concentrations were assigned from the linear
average of the ranges of benzene concentrations reported in the
Benzene NESHAP Impacts Document.4 Toluene and xylene
concentrations were assigned, based on the benzene
concentrations, using scaling factors developed from liquid and
gas phase concentration data for samples taken at air flotation
devices in petroleum refineries.5 These scaling factors are:
fBenzene = 143 ppmw;
fToluene = 168 ppmw; and
= 83
B-22
-------
TABLE B-6.
PETROLEUM REFINERY PROCESS UNIT CAPACITY DATA BASE
(barreIs/day)
Crude3
^Facility storage
1
2
3
4
5
6
7
8
9
10
f ll
* 12
13
14
15
16
17
18
19
20
21
22
23
24
25
14,250
45,000
80,000
12,000
16,000
22,000
102,000
7,000
72,000
5,710
8,000
3,800
6,770
48,000
10,000
220,000
14,200
286,000
270,000
9,500
41,600
128,000
26,500
10,348
40,600
Crude3
desalting
14,250
45,000
80,000
12,000
16,000
22.000
102,000
7,000
72,000
5,710
8,000
3,800
6.770
48,000
10, '000
220,000
14,200
286,000
270,000
9,500
41,600
128,000
26,500
10,348
40,600
Atmospheric3
distillation
14,250
45,000
80,000
12,000
16,000
22,000
102,000
7,000
72.000
5,710
8,000
3,800
6,770
48,000
10,000
220,000
14,200
286.000
270.000
9,500
41,600
128,000
26,500
10,348
40,600
Vacuum
distil-
lation
14,000
15,000
20,000
0
0
0
6,000
0
0
2,000
6,000
1,500
4,000
25,000
7,000
112,000
0
114,000
175,000
7,800
21,165
67,000
17,000
10,230
25,000
Vis-
breaking
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
13,800
Coking
0
12,000
0
0
0
0
0
0
0
0
0
0
0
0
0
56,000
0
54,000
0
0
0
27,500
0
0
0
Catalytic
cracki ng
0
0
0
0
0
0
0
0
0
0
0
0
0
19,275
0
82,000
0
62.000
63,000
0
0
75,000
12,000
0
13,500
Catalytic
ref ormi ng
0
6,000
20,000
0
0
0
0
0
12.000
0
0
. 0
0
9,000
0
48.000
0
51,000
50,000
0
0
32,000
5,000
0
19,000
Distillate
upgrading
0
0
0
'" 0
0
0
0
0
0
0
0
0
0
0
0
22,000
0
45,000
45,000
0
0
32.000
0
0
11,000
Catalytic
hydro-
refining
0
14,800
15.000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
98,000
125,000
0
0
37,000
12,000
0
0
Naphtha
Hydrodesul -
furization
0
7,500
20.000
0
0
0
0
0
12,000
0
0
0
0
15,500
0
76,000
0
70,000
66,000
0
0
74,000
5,000
0
12,000
Asphalt
10,000
9,500
0
0
0
6,000
2,000
0
0
1,000
0
1,000
2,200
6,500
7,000
0
0
0
11,000
6,800
15,554
0
0
4,000
4,000
Catalytic
hydro-
cracking
0
0
0
0
0
0
0
0
9,000
0
0
0
0
0
0
0
0
0
60,500
0
0
0
0
0
0
-------
TABLE B-6.
PETROLEUM REFINERY PROCESS UNIT CAPACITY DATA BASE
(barrels/day) (Continued)
Crude3
Facility storage
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
. 48
49
50
8.400
5,500
20,000
7,000
123,000
52,250
42.700
46,550
18,000
140,100
139,000
15.000
4.000
48,000
75,000
131,900
68.000
108,000
113,100
28,000
48,000
15,200
140,000
28,000
7.500
Crude3
desalting
8,400
5,500
20,000
7,000
123,000
52,250
42,700
46,550
18.000
140,100
139,000
15.000
4,000
48,000
75.000
131.900
68,000
108,000
113.100
28.000
48,000
15,200
140,000
28,000
7,500
Atmospherl ca
distillation
8,400
5,500
20,000
7,000
123,000
52,250
42,700
46,550
18,000
140,100
139,000
15.000
4,000
48,000
75,000
131,900
68,000
108,000
113,100
28.000
48,000
15.200
140.000
28,000
7,500
Vacuum
distil-
lation
7,500
5,000
0
7,500
95,000
17.000
29,000
26,000
14,000
98,000
75.000
0
0
23,000
42,000
118,000
42,000
83,000
74,100
10,000
23.000
8,100
95.000
0
0
VI s-
breakl ng
0
0
0
0
0
12,000
0
0
10,000
0
0
0
0
0
0
0
0
20,000
0
0
0
0
0
0
0
Coking
0
0
0
0
48,000
0
0
10,400
0
22,000
53,000
0
0
13,000
48,000
46,000
24,000
0
46,900
0
0
4,200
46,000
0
0
Catalytic
cracking
0
0
0
0
63,000
0
0
12,500
0
68,000
42,000
0
0
0
28,000
62,000
38,000
47.000
0
8.500
18,000
0
70,000
0
0
Catalytic
reforming
0
0
3,000
0
36,000
15,000
10,500
9,000
0
28,000
24,000
1,500
0
22,000
38,000
43,000
14,500
52,000
34,000
9,000
10,000
3,400
56,000
0
0
Distillate
upgrading
0
0
0
o
21,700
3,500
0
8,000
0
27,000
0
0
0
14,300
20,000
27,000
0
0
32.500
0
0
5,000
0
0
0
Catalytic
hydro-
refining
0
0
0
0
68,000
0
11,000
19,500
0
50,000
11.000
0
0
15,000
0
50,000
42,000
0
0
0
0
0
0
0
0
Naphtha
Hydrodesul -
furization
0
0
4,500
0
65,000
15,000
18,000
15,500
0
56,000
93,700
1,500
0
14,000
30,000
34,000
15,000
90,000
35,000
9,000
21,800
3.400
110,000
0
0
Asphalt
4,500
3,500
0
0
0
0
15,000
0
5,000
11,000
0
0
2,000
0
0
0
0
0
0
0
5,000
0
0
22,500
4,000
Catalytic
hydro-
cracking
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
22,000 .
0
0
0
0
19,000
0
0
-------
TABLE B-6.
PETROLEUM REFINERY PROCESS UNIT CAPACITY DATA BASE
(barrels/day) (Continued)
Crude3
Facility storage
51
52 .
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
52,800
77.000
64.600
60,000
195.000
180,000
274,000
147,000
350,000
20,600
8,300
48.000
0
30,400
29,925
56,500
26,400
70,900
78.000
56,000
213,400
5.500
46,200
12,000
4,500
Crude*
desalting
52,800
77,000
64,600
60,000
195,000
180,000
274,000
147,000
350,000
20,600
8,300
48,000
0
30,400
29.925
56,500
26,400
70,900
78,000
56,000
213.400
5,500
46.200
12.000
4.500
Atmospheri ca
distillation
52,800
77,000
64.600
60,000
195,000
180,000
274,000
147,000
350,000
20,600
8,300
48.000
0
30.400
29,925
56,500
26,400
70.900
. 78,000
56,000
213,400
5,500
46,200
12,000
4,500
Vacuum
distil-
lation
31,250
40,000
27,000
18,000
62,000
88,000
108.000
58.000
203,000
7.200
6,000
17,000
. 0
12,000
10,000
19,500
10,000
27,000
32,000
16,150
92,000
0
24,300
0
4,500
Vis-
breaki ng
0
13.000
0
0
4,000
0
18,000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Coki ng
0
0
0
14,500
22,000
38,000
0
27.900
27.500
0
0
0
0
0
5,500
12,000
0
22,000
12,500
0
. 0
0
0
0
0
Catalytic
cracking
20,000
0
26,000
27,000
42,000
98,000
94,000
68,000
144.000
7,000
0
19.500
0
14,500
19,000
24,500
0
21,000
34,000
.19.500
100,000
0
0
0
0
Catalytic
reforming
0
12,000
30,500
12,000
79,000
46,000
93,000
29,800
85,000
4,000
0
10.500
10,000
4,500
6,500
16,000
5,300
15,000
18,500
18,000
52,000
1,000 .
10,000
0
0
Distillate
upgradi ng
0
16.000
9,500
0
23,000
. 0
33,500
0
0
• 0
0
0
0
0
0
0
0
0
0
0
0
400
0
0
0
Catalytic
hydro-
refining
0
0
0
0
6,000
o
29,000
0
80,000
0
0
0
0
0
0
o
0
0
44.000
0
40,000
0
0
0
0
Naphtha
Hydrodesul -
furization
3,500
11,000
20,500
28,000
65.000
156,000
143,500
97,400
153,000
6,000
0
13,500
14,500
4,000
7,000
26.500
7,500
37,500
49,000
18,000
112,000
1,700
10,000
0
0
Asphalt
1,300
1,100
4,500
0
0
0
28,500
3,600
40,000
0
. 3,500
2,500
0
2,500
0
0
2,000
0
0
0
30,000
0
600
0
900
Catalytic
hydro-
cracking
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0 "
0
0
3,190
0
0
0
0
0
-------
TABLE B-6.
PETROLEUM REFINERY PROCESS UNIT CAPACITY DATA BASE
(barrels/day) (Continued)
Crude3
Facility storage
76
77
78
79
80
81
82
83
84
85
f 86
J
* 87
88
89
90
91
92
93
94
95
96
97
98
99
100
9,865
320,000
159,500
421,000
62.300
40,000
7,800
255,000
160,000
92.500
47,000
215,000
194,750
225,000
4,000
5,600
68,500
45,600
67,100
218,500
30,000
295,000
16,800
5,800
11,000
Crude3
desalting
9,865
320,000
159,500
421,000
62,300
40,000
7,800
255,000
160,000
92,500
47,000
215,000
194.750
225,000
4,000
5,600
68,500
45,600
67,100
218,500
30,000
295,000
16,800
5.800
11,000
Atmospheric3
distillation
9,865
320,000
159,500
421,000
62,300
40,000
7,800
255,000
160,000
92,500
47,000
215,000
194,750
225,000
4,000
5,600
68,500
45,600
67,100
218,500
30,000
295.000
. 16.800
5,800
11.000
Vacuum
distil-
lation
0
83,000
63,000
183,000
24.000
20,000
0
125,000
92,500
40,000
18,000
78,000
73.000
75,000
0
0
30,000
0
32,000
160,000
20,000
243,000
15,600
0
0
Vis-
breaking
0
0
0
0
0
0
0
0
0
0
0
0
0
12,000
0
0
0
0
0
0
0
0
0
0
0
Coking
0
63,000
60,000
90,000
0
0
0
0
33,000
0
0
21,000
21,000
0
0
0
0
0
0
58,000
8,000
62,000
0
0
0
Catalytic
cracking
0
150,000
42,500
188,000
30,000
0
0
90,000
55,000
37.500
20.500
0
91.300
90,000
0
0
28,300
19,500
23,000
56,000
16,000
58,000
0
0
0
Catalytic
ref ormi ng
1,900
91,000
28,000
90,000
12.500
0
0
48,000
47,000
23,000
10,000
56.000
37,500
40,000
0
1,000
18,500
14.000
23,500
32.000
5,800
90,000
0
0
0
Distillate
upgradi ng
0
37,000
0
24,000
0
0
0
0
18,000
0
0
35,000
0
0
0
0
0
0
0
0
0
68,000
0
0
0
Catalytic
hydro-
refining
0
40,000
0
0
0
0
0
109,000
43,000
15,000
0
70.000
0
0
0
0
16.000
5,800
23,000
63,500
0
189,000
5,000
0
0
Naphtha
Hydrodesul -
furization
0
105,000
141,000
152,500
12,500
0
0
48,000
69,000
29,000
10,000
57,000
88,000
142,000
0
0
21,000
23,000
31,700
87,000
11,800 .
48,000
0
0
0
Asphalt
0
0
0
28,900
0
0
0
25,000
0
0
0,
0
0
0
0
0
10,000
0
14.000
35.000
0
20.000
12.000
3,500
5,100
Catalytic
hydro-
cracking
0
0
0
0
0
0
0
0
0
0
0
0
0
35,000
0
0
0
0
0
0
0
0
0
0
0
-------
TABLE B-6.
PETROLEUM REFINERY PROCESS UNIT CAPACITY DATA BASE
(barrels/day) (Continued)
Crude3
Facility storage
101
102
103
104 .
105
106
107
108
109
110
tfl
1 111
w
-1 112
113
114
115
116
117
118
119
120,
121'
122
123
124
125
40,400
49.500
42,000
7,000
4,500
0
80,000
109,250
130,000
100,000
75,000
16,800
19,000
38,000
6,500
42,500
58,000
66,000
171,000
120,650
125.000
13,000
140,000
43,000
50,000
Crude3
desalting
40,400
49,500
42,000
7,000
4,500
0
80,000
109,250
130,000
100,000
75.000
16.800
19.000
38,000
6,500
42.500
58,000
66,000
171,000
120,650
125,000
13,000
140,000
43,000
50,000
Atmospheric3
distillation
40,400
49,500
42,000
7.000
4,500
0
80,000
109,250
130,000
100,000
75.000
16.800
19,000
.38,000
6,500
42.500
58,000
66,000
171,000
120,650
125,000
13,000
140,000
43,000
50,000
Vacuum
distil-
lation
14.000
20,000
18,000
2,800
2,500
0
46,000
45,000
66.000
62,400
30.000
0
7,900
6,000
0
27.000
0
33,000
51,000
49,000
30,000
0
45,000
13,000
26,500
Vis-
breaki ng
0
0
0
0
0
0
0
10,000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Coking
0
0
7,700
0
0
0
0
0
0
21.500
0
0.
0
0
0
0
0
0
16,200
13,700
0
0
20,500
0
0
Catalytic
cracking
15,000
19,500
24,500
2,600
0
50,000
0
50,000
145,000
36,000
0
6,500
10,800
17,000
0
0
31.200
25,000
43.800
55,000
61,000
0
53,000
20,000
23,000
Catalytic
reforming
12,000
14,700
10,000
1,000
0
0
0
27,000
28,000
23,500
0
4,000
6,800
7,800
2,500
0
12,100
20,000
53,000
42,000
45,600
0
36,000
8,500
12,000
Distillate
upgrading
0
0
4,900
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
28.200
0
0
5,000
0
Catalytic
hydro-
refining
14,000
0
0
0
0
0
0
0
50,000
15,000
0
0
0
0
0
0
0
23.000
0
0
0
0
0
0
0
Naphtha .
Hydrodesul -
furization
15,000
42,500
35,500
2,500
0
0
0
56,000
113,000
65.500
0
4,000
6,800
19,500
0
0
16.600
27,000
59,000'
37,000
40,000
0
66,000
9,000
17,000
Asphalt
6,000
6,500
11,000
1,200
0
0
35,000
0
38,000
0
0
0
700
3,400
0
0
0
12,000
0
7,000
0
0
0
0
2,500
Catalytic
hydro-
cracking
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1,000
0
0
0
23,000
35,000
0
0
0
0
0
-------
TABLE B-6.
PETROLEUM REFINERY PROCESS UNIT CAPACITY DATA BASE
(barrels/day) (Continued)
Crude3
Facility storage
126
127
128
129
130
131
132
133
134
135
136
D 137
138
139
140
141
142
143
144
145
146
147
148
149
150
85,000
60,500
15,000
175,000
8,200
15,700
6,500
171,000
165,000
125,000
64,600
60,000
415,000
135,000
66,000
329,000
90,250
100,000
110,000
50,000
26,000
426,000
55,000
110,000
66,000
Crude3
desalting
85,000
60,500
15,000
175,000
8,200
15,700
6,500
171,000
165,000
125,000
64,600
60,000
415,000
135,000
66,000
329.000
90,250
100,000
110,000
50,000
26,000
426,000
55,000
110,000
66,000
Atmospheric3
distillation
85,000
60,500
15,000
175,000
8,200
15,700
6,500
171,000
165,000
125.000
64,600
60,000
415,000
135,000
66,000
329.000
90,250
100,000
110,000
50,000
26.000
426,000
55,000
110,000
66,000
Vacuum
distil-
lation
29,000
32,000
16,000
80,000
0
6,500
2,680
75,000
46,000
83,000
27,000
12,000
195,000
80,000
54,000
163,200
53.000
40,000
47,000
20,000
0
219,000
24,000
50,000
28,000
Vis-
breaking
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
11,000
0
0
0
0
0
0
0
0
Coking
0
0
0
0
0
0
0
0
0
0
0
0
37,000
32,000
0
34,000,
12,000
12,500
0
0
4,400
28,000
0
0
0
Catalytic
cracking
30,840
23,500
0
58,300
0
0
0
51,600
87,000
29,000
20,200
30,000
238,000
70,000
22,000
116,000
18,500
56,000
45.000
20,000
10,800
185,000
22,000
36,000
50,000
Catalytic
ref ormi ng
24,000
14,000
0
34,000
3,300
5,820
2.100
48.000
39,600
50,000
16,000
10.000
160,000
52.000
25,000
67,100
28,500
36,000
29,000
11,000
6,700
123,000
20,000
34,000
13,500
Distillate
upgrading
0
0
0
0
0
0
0
0
0
0
0
0
60,000
0
0
0
10,000
0
0
0
0
19,000
0
0
0
Catalytic
hydro-
refining
0
21,000
0
0
0
0
0
50,000
0
0
0
0
85,000
95,000
19,000
0
0
10,000
0
0
0
110,000
6,000
31,000
0
Naphtha
Hydrodesul -
furization
24,000
20.000
0
64,000
0
6,500
2,900
108,000
81,700
104,000
26,000
31,000
210,000
54,000
25,000
205,100
50,000
26,000
33,000
11.000
6.700
350,500
43,000
68,000
37,000
Asphal t
4,600
6,000
11,500
0
0
0
0
0
0
35,000
8,000
3,500
0
0
5,500
0
0
0
5,000
0
0
7,000
7,000
2,000
5,000
Catalytic
hydro-
cracki ng
0
0
0
0
0
0
0
21,000
0
30,000
0
0
60,000
0
0
0
0
0
20,000
0
0
0
0
0
0
-------
TABLE B-6.
PETROLEUM REFINERY PROCESS UNIT CAPACITY DATA BASE
(barrels/day) (Continued)
Crude3
Faci 1 1 ty storage
151
152
153
154
155
156
157
- 158
159
160
d 161
j 162
ifi
163
164
165
166
167
168
169
170
171
172
173
174
175
123,000
2,900
125.000
49,500
10,000
265,000
69,500
275,000
105,000
175,000
44,100
215,900
28,600
104,000
250,000
27,000
120,000
25,000
40,000
24,000
45,000
12,500
8,000
25,000
53,000
Crude3
desalting
123,000
2.900
125,000
49,500
10,000
265,000
69,500
275,000
105,000
175.000
44.100
215,900
28.600
104,000
250.000
27,000
120,000
25.000
40,000
24,000
45,000
12,500
8,000
25,000
53,000
Atmospheri ca
distillation
123.000
2,900
125,000
49,500
10,000
265,000
69,500
275,000
105,000
175,000
44,100
215,900
28,600
104,000
250,000
27,000
120,000
25,000
40,000
24,000
45,000
12,500
8,000
25,000
53,000
Vacuum
distil-
lation
64,000
0
42,000
16,000
0
129,000
27,000
86,000
0
83,000
12,000
88,000
10,000
36,000
143.100
15,000
43,000
24,000
0
3.800
35,500
4,000
0
4.800
29.000
Vis-
breaking
21,000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
10,000
0
0
0
0
0
0
0
0
0
Coki ng
0
0
12,000
6,000
0
40,000
0
29.500
0
0
0
0
0
0
0
0
0
0
0
0
8.500
0
0
0
13,500
Catalytic
cracking
50,000
0
40,800
17,850
0
90,000
39,000
102,000
70,400
99,000
0
70,000
10,500
50,000
141,500
0
43,000
67,700
22,000
6,000
19,000
0
6.500
11.000
29,500
Catalytic
reforming
23,000
1,200
48,500
16.200
0
110,000
10,000
103,000
26,000
36,000
0
63,000
10,000
30,000
42,000
0
32,000
0
7,600
5,000
7,500
3,000
2,000
6,000
10,200
Distillate
upgrading
0
0
0
. 0
0
0
0
32,000
0
0
0
65,000
0
0
15,000
0
0
0
0
0
0
0
0
0
0
Catalytic
hydro-
refining
0
°
0
0
0
129,000
0
0
90,000
125,000
0
45.000
0
18,000
0
0
0
61,000
0
0
5,500
0
0
1,600
0
Naphtha
Hydrodesul-
furization
52,000
0
57,500
20,800
0
163,000
0
208.000
26,500
53,000
0
172,500
11,000
67,000
122,000
0
53,600
0
7,600
6,000
7,500
0
2,000
11,000
26,000
Asphalt
0
0
0
0
0
0
0
0
0
0
0
7,400
"0
0
14,000.
0
2,500
0
0
0
0
0
0
1,700
0
Catalytic
hydro-
cracking
0
0
0
0
0
0
0
0
0
0
0
o
0
0
0
0
0
0
0
0
0
0
0
0
0
-------
TABLE B-6.
PETROLEUM REFINERY PROCESS UNIT CAPACITY DATA BASE
(barrels/day) (Concluded)
Crude3
Facility storage
176
177
178
179
180
181
182
183
184
M 185
-) 186
187
188
189
190
164,000
5,000
85,000
77,000
11,900
117,000
32,775
19,180
10,500
32,000
40,000
36,100
22,000
54,000
12,500
Crude3 Atmospheric3
desalting distillation
164,000
5,000
85,000
77,000
11,900
117,000
32,775
19.180
10.500
32,000
40,000
36,100
22,000
54.000
12,500
164,000
5,000
85,000
77.000
11,900
117,000
32,775
19.180
10.500
32,000
40,000
36,100
22,000
54.000
12.500
Vacuum
distil- Vis-
1 at ion breaking
95,000
6,000
36,000
28,000
6,000
50,000
19,500
2,000
8,850
20.500
17,000
19,500
8,600
30,000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Coking
50,000
0
0
0
0
22.000
0
0
0
0
0
8,400
0
0
0
Catalytic
cracking
0
0
48,000
27,500
0
49,000
0
0
0
12,000
16,200
12,500
17,000
22,000
7,000
Catalytic Naphtha
Catalytic Distillate hydro- Hydrodesul-
reforming upgrading refining furization
56,000
0
25.000
11.800
0
21.000
6,000
1,500
3,400
8,000
7,000
7,000
6,000
14,500
2,750
52,000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
18,000
0
7,500
0
0
0
0
0
0
5,800
0
8,000
0
21,000
0
38,000
0
52,500
28,500
0
50,000
11,000
0
3,900
9,000
7,100
7,200
13,750
26,500
0
Catalytic
hydro-
Asphalt cracking
0
5,000
0
0
3,600
0
8,000
0
0
13,500
0
7,000
1.000
5,000
0
0
0
0
0
0
0
0
0
4,500
0
0
0
0
0
0
a Annual Refining Survey. Oil and Gas Journal, March 26, 1990.
-------
TABLE B-7. SUMMARY OF PETROLEUM REFINING INDUSTRY PROCESS UNIT
WASTEWATER GENERATION FACTORS
Process unit
Direct to
drain
wastewater
generation
factor
(gal/barrel)
Comments
Crude Storage
Crude Desalting
Atmospheric
Distillation
Vacuum Distillation
Visbreaking
Coking
Catalytic Cracking
Catalytic Reforming
Distillate Upgrading
Catalytic Hydrorefining
Naphtha Desulfurization
Catalytic Hydrocracking
Asphalt Production
2.0
0.002
0.3
0.8
0.3
3.1
1.1
0.22
0.64
0.104
0.06
0.64
0.3
Assumed equal to
atmospheric distillation
Assumed equal to catalytic
hydrocracking.
Assumed equal to the
average of the direct to
sewer wastewater
generation factor reported
for Hydrodesulfurization
in Ref. 3. .
Assumed equal to
atmospheric distillation.
B-31
-------
TABLE B-8.
SUMMARY OF PETROLEUM REFINING INDUSTRY
COMBINED STREAM VOLATILE ORGANIC
CONCENTRATIONS
Process Unit
Crude Storage
Crude Desalting
Atmospheric
Distillation
Vacuum Distillation
Visbreaking
Coking
Catalytic Cracking
Compound3
Benzene
Toluene
Xylene
Non-BTX
Benzene
Toluene ••
Xylene
Non-BTX
Benzene
Toluene
Xylene
Non-BTX
Benzene
Toluene
Xylene
Non-BTX
Benzene
Toluene
Xylene
Non-BTX
Benzene
Toluene
Xylene
Non-BTX
Benzene
Toluene
Xylene
Non-BTX
Total compound
concentration
(ppmw)
26
31
15
99b
26
31
15
99b
167
196
97
635b
167
196
97
635b
167
196
97
635b
167
196
97 '
635b
167
196
97
635b
Total organic Total VO
concentration concentration
(ppmw) (ppmw)c Comments
171 136
171 136
1,095 868
1 ,095 868 Benzene concentration
assumed equal to that
reported for atmospheric
distillation in Ref. 4.
1,095 868
1,095 868
1,095 868
B-32
-------
TABLE B-8.
SUMMARY OF PETROLEUM REFINING INDUSTRY
COMBINED STREAM VOLATILE ORGANIC
CONCENTRATIONS (Concluded)
Process Unit
Catalytic Reforming
Distillate Upgrading
Catalytic
Hydrorefining
Naphtha
Desulfurization
Catalytic
Hydrocracking
Asphalt Production
Total compound
concentration
Compound3 (ppmw)
Benzene
Toluene
Xylene
Non-BTX
Benzene
Toluene
Xylene
Non-BTX
Naphthalene
1-Methylnaphthalene
2-Methylnaphthalene
Biphenyl
Acenaphthene
Benzene
Toluene
Xylene
Non-BTX
Naphthalene
1 -Methylnaphthalene
2-Methylnaphthalene
Biphenyl
Acenaphthene
Benzene
Toluene
Xylene
Non-BTX
565
664
328
2,150b
167
196
97
635b
32
28
26
7
A
167
196
97
635b,
32
28
26
7
4
167
196
97
635b
Total organic Total VO
concentration concentration
(ppmw) (ppmw)0 Comments
3,707 2,940
1,095 868 Benzene concentration
assumed equal to that
reported for atmospheric
v . distillation in Ref. 4.
97 77 Concentrations based on
solubilities of compounds
expected to be present.
1 ,095 868 Benzene concentration
assumed equal to that
reported for naphtha
sweetening in Ref. 4.
97 77 Concentrations based on
solubilities of compounds
expected to be present.
1 ,095 868 Benzene concentration
assumed equal to that
reported for coking in Ref. 4.
aBenzene concentration calculated as the average of the range reported
bEqual to 58% of the sum of the total organic concentration.
°Total VO Concentration ,(mg/L) = Total organic concentration (mg/L) *
from the SOCMI Section 114 data base).
in Ref. 4.
0.793 (the average ratio of VO concentration to VOC concentration
B-33
-------
Individual compound concentration data for refinery
products were used to estimate the concentration of non-BTX
compounds in refinery wastewater streams. These data indicate
that approximately 42 percent of the VQ's present in petroleum
refinery wastewater is expected to consist of BTX. Therefore,
the total concentration of non-BTX VOC's is the BTX
concentration multiplied by 1.38 (0.58/0.42). Table B-9
details an example of the use of these scaling factors to
calculate the total organic concentration from the assigned
benzene concentration.
For all but the catalytic hydrorefining and catalytic
hydrocracking process units, the fraction removed (fr) was
assumed equal to the VO loading weighted average fr calculated
from the SOCMI 114 data base (fr « 0.93). The fr for the
catalytic hydrorefining and catalytic hydrocracking process
units was calculated to be 0.99, based on the fr of individual
compounds expected to be present in the wastewater from these
process units.
The individual model streams for petroleum refineries were
developed by disaggregating the combined stream data, as
described in Section B.2. Table B-10 summarizes these
petroleum refining industry model streams.
B.I.6 Pulpand Paper Industry
The basis for development of the model streams
representing the kraft pulp and paper industry is described in
Section 2.6. Condensate streams generated in the kraft pulp
and paper industry, generally have lower flows and higher VO
concentrations than other wastewater streams such as bleach
plant effluents. Therefore, the model wastewater streams were
developed to represent condensate streams. Condensate stream
flow rate factors were developed from condensate flow rates and
the facility production rate reported in a steam stripper
design report.6
Typical condensate stream organic concentrations were
obtained from an Agency environmental pollution control
document.7 However, this document did not report concentration
B-34
-------
TABLE B-9. EXAMPLE OF TOTAL ORGANIC CONCENTRATION
. : ESTIMATION USING SCALING FACTORS .
Assigned benzene
. concentrationa Scaling
Compound (ppmw) factor ratiob
Benzene
Toluene
Xylene
26 .. : '•'
— 168/143
83/143
Total BTX Concentration
Total Non-BTX Concentration
Assigned
concentration0
(ppmw)
26
31
15
(ppmw) =72 ppmw
(ppmw} =99 ptamw^
Total Organic Concentration (ppmw) = 171 ppmw
aCalculated from the linear average of range reported in
Reference 4.
^Scaling Factor Ratio: Toluene = ftoluene/fbenzene
Xylene = fxylene/fbenzene
°Assigned concentration (ppmw) = Assigned Benzene Concentration
(ppmw) * Scaling Factor Ratio
Toluene = 26 * (168/143) = 31 ppmw
Xylene - 26 * (83/143) - 15 ppmw
<%otal Non-BTX Cone, (ppmw) = Total BTX Cone, (ppmw) *
(0.58/0.42)
=72 (0.58/0.42)
= 99
B-35
-------
TABLE B-10. MODEL STREAMS: PETROLEUM REFINING INDUSTRY
Process unit
Crude Storage
Crude Desalting
Atmospheric
Distillation
Vacuum
Distillation
Visbreaking
Coking
Catalytic
Cracking
Catalytic
Reforming
Distillate
Upgrading
Catalytic
Hydrorefining
Naphtha
Desulfurization
Catalytic
Hydrocracking
Asphalt
Production
Model
stream
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
Wastewater
generation
factor
(gal/barrel)
1.0
0.8
0.2
0.001
0.0008
0.0002
0.15
0.12
0.03
0.4
0.32
0.08
0.15
0.12
0.03
1.6
1.2
0.31
0.55
0.44
0.11
0.11
0.088
0.022
0.32
0.26
0.06
0.052
0.042
0.010
0.03
0.024
0.006
0.32
0.26
0.06
0.15
0.12
0.03
VO
concentration
(ppmw)
7
119
849
7
119
849
45
760
5,416
45
760
5,416
45
760
5,416
45
760
5,416
45
760
5,416
153
2,575
18,346
45
760
5,416
4
67
480
45
760
5,416
4
67
480
45
760
5,416
fr
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.99
0.99
0.99
0.93
0.93
0.93
0.99
0.99
0.99
0.93
0.93
0.93
B-36
-------
data for the hot water accumulator stream, so the organic
concentrations for the hot water accumulator stream were
calculated as the average of the organic concentrations
reported for the other four model streams. This assumption was
made because the BODs loading of this wastewater stream, as
reported in the steam stripper design report, indicated that
the pollutant loading of this stream was approximately equal to
the average BODs loading of the other condensate streams. The
model stream flow rate generation factors and the development
of the total VO concentrations are summarized in Table B-ll.
Because only 13 kraft pulp and paper mills are located in
areas of ozone ndnattainment, the reported production
• R
capacities of these mills were used in combination with the
flow rate factors to develop the model wastewater streams
presented in Table B-12.
B.2 DISAGGREGATION
Because the available wastewater data for the pesticides
manufacturing industry, pharmaceutical manufacturing industry,
TSDF, and petroleum refining industry presented flows for
combined process unit effluents, rather than for individual
wastewater streams, a procedure was developed to disaggregate ,
these combined streams into individual streams. The combined
streams were disaggregated into individual streams using a VO
loading distribution determined from the 114 survey of SOCMI
conducted by the Office of Air Quality Planning and Standards
(OAQPS) in 1990.9 This distribution was determined to be:
• 50 percent of the wastewater flow contains
2.6 percent of the VO loading;
• 40 percent of the wastewater flow contains
35.0 percent of the VO loading; and
• 10 percent of the wastewater flow contains
62.4 percent of the VO loading.
Using the above distribution, the following flow and VO
loading factors were defined:
B-37
-------
TABLE B-ll.
SUMMARY OF KRAFT PULP AND PAPER CONDENSATE
WASTEWATER STREAM CHARACTERISTICS
Stream No.
Stream description
Flow (gal /ton)3
Compound fm
Dimethyl sulfide 0.508
Dimethyl di sulfide 0.508
Methyl mercaptan 0.330
Hethanol 0.321
Ethanol 0.623
Acetone 0.829
Total VO cone.
(ppmw)
Turpentine decanter
30
Total
organic
cone. VO
(ppmw)b (ppmw)
400 203
130 66
250 83
6,500 2,086
1,600 997
160 133
3,568
Digester blow
42
Total
organic
cone. VO
(ppmw)b (ppmw)
70 36
50 25
80 26
4.300 1,380
500 312
40 33
1,812
Evaporator effects
212
Total
organic
cone. .VO
(ppmw)b (ppmw)
5 3
5 ' 3
10 3
10,000 3,210
60 37
6 5
3,261
Evaporator hotwell
212
Total
organic
cone. VO
(ppmw)b (ppmw)
7 4
15 8
40 13
1,000 321
40 25
10 8
379
Hot water accumulator
condensate
152
Total
organic
cone. VO
(ppmw)c (ppmw)
120 61
50 25
95 31
5,450 1,749
550 343
54 45
2,254
I
to
oo
Developed from flows reported in Reference 6 divided by production capacity of facility (1,900 tons/day) reported 1n Reference 10.
bReference 7.
cAverage of total organic concentrations reported in Reference 9 for other four condensate streams.
-------
TABLE B-12. MODEL STREAMS: KRAFT PULP AND PAPER MILL CONDENSATE
Production
capacity
Mill Stream (tons/day)
1 1 530
2
3
••'-••' 4
5
2 1 200
2
3
4
5
3 1 1,350
2
3
; • . 4
5
4 1 250
2
3
4
5
5 1 575
2
3
' . ' 4
5
6 1 1,650
2
3
4
5
7 1 700
2
3
4
5
Flow
42
59
295
295
212
16
22
111 •
111
80
106
149
752
752
539
20
28
139
139
100
45
63
320
320
230
130
182
920
920
659
55
77
390
390
280
VO
concentration
(ppmw)
3,568
1,812
3,271
398
2,263
3,568
1,812
3,271
398
2,263
3,568
1,812
3,271
398
2,263
3,568
1,812
3,271
398
2,263
3,568
1,812
3,271
398
2,263
3,568
1,812
3,271
398
2,263
3,568
1,812
3,271
398
2,263
fr
0.92
0.93
0.96
0.95
0.94
0.92
0.93
0.96
0.95
0.94
0.92
0.93
0.96
0.95
0.94
0.92
0.93
0.96
0.95
0.94
0.92
0.93
0.96
0.95
0.94
0.92
0.93
0.96
0.95
0.94
0^92
0.93
0.96
0.95
0.94
B-39
-------
TABLE B-12. MODEL STREAMS:
KRAFT PULP AND PAPER MILL CONDENSATE
(Concluded)
Mill Stream
8 1
2
3
4
5
9 1
2 ••
3
4
5
10 1
2
3
4
5
11 1
2
3
4
5
12 1
2
3
4
5
13 1
2
3
4
5
Production
capacity Flow
(tons/day) (£pm)
1,850 146
204
1,031
1,031
739
300 24
33
167
167
120
250 20
28
139
139
100
560 44
62
312
312
224
1,150 91
127
641
641
460
725 57
80
404
404
290
VO
concentration
(ppmw)
3,568
1,812
3,271
398
2,263
3,568
1,812
3,271
398
2,263
3,568
1,812
3,271
398
2,263
3,568
1,812
3,271
398
2,263
3,568
1,812
3,271
398
2,263
3,568
1,812
3,271
398
2,263
fr
0.92
0.93
0.96
0.95
0.94
0.92
0.93
0.96
0.95
0.94
0.92
0.93
0.96
0.95
0.94
0.92
0.93
0.96
0.95
0.94
0.92
0.93
0.96
0.95
0.94
0.92
0.93
0.96
0.95
0.94
B-40
-------
Flow Factors
fl = 0.5
f2 = 0.4
f3 = 0.1
VO Loading Factors
£1 = 0.026
£2 = 0.35
£3 = 0.624
The use of these factors to develop three individual wastewater
streams is demonstrated in the following example:
Example Disacrcrrecration
Stream
Total VO
Flow Concentration
(£pm) (ppmw)
71.7
3,530
Using the flow and VO loading factors defined above, and the
combined wastewater stream flow (71.7 £pm) and total VO
concentration (3,530 ppmw>, three disaggregated streams can be
defined:
Total VO Concentration
Stream
l-l
1-2
1-3
Flow (£pm)
Flow * fl =
71.7 * 0.5 =
35.8
Flow * f2 =
71.7 * 0.4 =
28.7
Flow * f3 =
71.7 * 0.1 =
7.2
3,530
3,530 *
3,530
3,530 *
3,530
3,530 *
(ppmw)
* (£l/fl) =
(0.026/0.5) =
184
* (£2/f2) =
(0.35/0.4) =
3,090
* (£3/f3) =
(0.624/0.1) =
22,000
Note: streams with flows less than 5 £pm were not
disaggregated.
B.3 ESTIMATION OF UNCONTROLLED EMISSIONS AND EMISSION
REDUCTIONS (EXAMPLE CALCULATION)
Uncontrolled VOC emissions from wastewater streams were
estimated using the following equation:
Uncontrolled VOC = VO concentration (ppmw) * Flow (£pm)
Emissions (Mg/yr) * 10~9 Mg/mg * 60 min/hr * 8,760 hr/yr
* 0.683
B-41
-------
The potential emission reduqtion achievable for each affected
stream was calculated using the following equation:
VOC Emission = fravg * Uncontrolled
Reduction VOC Emissions
(Mg/yr) (Mg/yr)
where:
fravg = the fractional reduction in emission
potential achieved by steam stripping
Draft Reference Method 25D measures the VO concentration
in a wastewater stream, or provides a relative measure of the
emission potential. The fraction of the compound measured (fm)
is equal to the ratio of the VO concentration to the VOC
concentration:
fm = VO/VOC
Table B-13 presents the fm's used for all six industries.
To estimate VOC emissions as a function of VO
concentration, a relationship for estimating wastewater VOC
emissions as a function of VO concentration was derived:
VOC Emissions = (fe/fm) * VO (ppmw) * Flow (£pm) *
(Mg/yr) 10~9 Mg/mg * 60 min/hr * 8,760 hr/yr
where:
fe = the fraction of total organic compounds in a
wastewater stream that would be emitted to the air;
and
fm = the fraction of total organic compounds in a
wastewater stream measured by Draft Reference
Method 25D.
For an individual stream containing multiple compounds, a
stream average ratio of fe to fm can be calculated:
_ D-j [(fe/fm)-; * VO Loadings 3
avg 2 VO
B-42
-------
TABLE B-13. FRACTION MEASURED (fro) FROM METHOD 25D
Compound Name
fm
Acetal .
Acetaldehyde
Acetaldehyde Polymer
Acetaldol
Acetamide
Acetic Acid
Acetic Anhydride
Acetone
Acetonitrile
Acetophenone
Acifluorfen .
Acrolein .
Acrylamide
Acrylic acid
Acrylonitrile
Adiponitrile
Alcohol,acetal,ester
Aldicarb
Alkyl benzene
Allyl alcohol
Allyl chloride
Amertryn
Aminobiphenyl, 4-
Ammonia
Aniline
Anisidine, o-
Aziridiene Ethyleneimine
Benzaldehyde
Benzene (including benzene from gasoline)
Benzidiene
Benzoic acid
Benzotrichloride
Benzyl alcohol
Benzyl chloride
Bidimethylaminomethane
Biphenyl
Bis(2-ethylhexyl)phthalate (DEHP)
Bis (Chloromethyl) Ether
Bisphenol A
Bromacil .
Bromodichloromethane
Bromoform (Tribromomethahe)
Bromomethane
Bromoxynil
Butadiene, 1,3-
Butane
Butanol
Butanol, n-
0,
0,
0.813
0.724
0.850
0.025
0.426
.115
.361
0.829
0.739
0.807
0.8886
0.850
0.003
0.454
0.875
0.009
0.813
0.024
1.000
0.630
1.000
0.0229
0.097
0.000
0.245
0.030
0.582
0.108
1.000
0.000
0.010
1.000
0.288
1.000
0.850
1.000
0.968
0.889
0.235
0.5822
0.047
0.4805
0.539
0.0185
1.000
1.000
0.768
0.768
B-43
-------
TABLE B-13.
FRACTION MEASURED (fm) FROM METHOD 25D
(Continued)
Compound Name
fm
Butene
Butyl acetate
Butyl acrylate
Butyl alcohol
Butylamine
Butylene glycol
Butylenes
Butylisobutyrate, n-
Butyraldehyde, n-
C-10 Aromatics
Caprolactam
Captan
Carbaryl (Sevin™)
Carbendazim
Carbon disulfide
Carbon sulfide
Carbon tetrachloride
Carbonyl sulfide
Catecho1
Chlordane
Chloroacetic acid
Chloroacetophenone
Chloroaniline, 2-
Chloroaniline, m-
Chloroaniline, o-
Chloroaniline, p-
Chlorobenzene
Chlorobenzilate™
Chlorobenzotrifluoride, p-
Chlorobutadiene
Chlorobutene
Chloroethane
Chloroform
Chlorohydrin
Chloromethyl methyl ether
Chloronitrobenzene, o-
Chloronitrobenzene, p-
Chlorophenol, o-
Chlorophenol, p-
Chloroprene (2-Chloro-l,3-Butadiene)
Cresols/Cresylic acid (isomers & mixtures)
Cumene hydroperoxide
Cumene (isopropyl benzene)
Cyclohexane
Cyclohexanol
Cyclohexanone
Cyclohexylamine
1.000
Q.812
0.858
0.768
0.857
0.011
1.000
0.873
0.867
1.000
0.010
0.093
0.277
0.4067
1.000
0.547
1.000
0.547
0.000
1.000
0.026
0.841
0.463
,223
,223
0,
0,
0.463
1.000
0.989
1.
1.
1.
1.
1.
000
000
000
000
000
0.009
0.839
0.803
0.803
0.441
0.064
1.000
0.108
000
000
000
692
0.940
0.933
B-44
-------
TABLE B-13. FRACTION MEASURED (fm) FROM METHOD 25D
(Continued)
Compound Name
Dazomet
Di-isopropylamine
Diallyl ether
Diazinon
Diazomethane
Dibenzofurans
Dibromochloromethane
Dibromoethane, 1,2-
Dibromo-3-chloropropane, 1,2-
Dibromo— 4 -hydroxybenz onitr ile
D ibuty Iphtha 1 a t e
Dichloroaniline, 2,3-
Dichloroaniline, 2,3-
Dichloroaniline, 2,5-
Dichloroaniline, 3,4-
Dichlorobenzene, 1,4-
Dichlorobutene
Dichloroethane, 1,1-
Dichloroethyl ether
Dichlorophenol, 2,4-
Dichlorophenol, 2,5-
Dichlorophenol , 2,6-
Dichlorophenol , 3,4-
Dichloropropane, 1,2-
Dichloropropene, 1,3-
Dichlorvos
DIDP (Diisodecyl phthalate)
Diethanolamine
Diethyl sulfate
Diethylaniline, N,N-
Diethylthiophosphatebenzomethane
Diisobutylene
Diisopropylamine
Diisopropyl ether
Diisopropylbenzene
Dimethoxy- (3,3') -benz idine
Dimethyl carbamoyl chloride
Dimethyl disulfide
Dimethyl ether
Dimethyl formamide
Dimethyl hydrazine, 1,1-
Dimethylphenol, 2,4-
Dimethyl phthalate
Dimethyl sulfate
Dimethyl sulf ide
Dimethylacetamide
Dimethylamine
fm .
0.3905
0.939
0.973
0.0459
0.550
1.000
0.063
1.000
1.000
0.1964
0.316
0.132
1.000
0.132
0.132
1.000
1.000
1.000
0.939
0.369
0.476
0.476
0.369
1.000
1.000
0.012
0.981
0.000
0.014
1.000
0.023
1.000
0.939
0.939
1.000
0.005
0.247
0.5899
0.698
0.009
0.486
0.057
0.098
, 0.077
0.508
0.708
0.709
B-45
-------
TABLE B-13.
FRACTION MEASURED (fro) FROM METHOD 25D
(Continued)
Compound Name
fm
Dimethylsulfone
Dimethylsulfoxide
Di-n-butyl phthalate
Dinitrobenzenes
Dinitro-o-cresol, 4,6- and salts
Dinitrophenol, 2,4-
Dinitrotoluene, 2,4-
Dioctyl phthalate
Dioxane, 1,4- (1,4-Diethyleneoxide)
Diphenyl ether
Diphenylhydirazine, 1,2-
DIPK
Dipropyl Butyral
Dipropylene glycol
DOE, p,p-
EGMBE acetate
Epichlorohydrin
Epoxybutane, 1,2-
Ethane
Ethanol
Ethlene dibromide
Ethyl acetate
Ethyl acrylate
Ethyl alcohol
Ethyl benzene
Ethyl carbamate
Ethyl chloride (Chloroethane)
Ethyl ether
Ethyl morpholine
Ethyl vinyl ether
Ethylene
Ethylene dichloride (1,2-Dichloroethane)
Ethylene glycol
Ethylene oxide
Ethylene thiourea
Ethylenediamine
EthyIhexano1
Ethylhexanol, 2-
Ethylidene dichloride (1,2-Dichloroethane)
Formaldehyde
Formic Acid
Freon 11 and 12
Fumaron itr i1e
Glycerol
Glycol ethers
Glyoxal
Glyphosate
0.008
0.0747
0.762
0.564
0.044
0.014
0.004
0.965
681
000
,000
0,
1,
1,
1,
0,
1,
0.973
1.000
0.029
1.000
0.033
0.859
0.879
,000
,623
,000
0.724
0.788
0.623
1.000
0.011
1.000
0.856
0.159
0.890
,000
,000
0.004
0.712
0.001
0.034
0.941
0.941
1.000
0.533
0.064
1.000
0.850
0.000
0.850
0.535
0.0034
1.
1.
B-46
-------
TABLE B-13.
FRACTION MEASURED (fin) FROM METHOD 25D
(Continued)
Compound Name
fm
Guthion
Heptachlor
Heptane
Hexachlorobenzene
Hexachlorobutadiene
Hexachlorocyclopentadiene .
Hexachloroethane
Hexafluoroacetone
Hexamethylene-1,6-diisocyanate
Hexamethylphosphoramide
Hexane
Hexanone, 2-
Hydrazine
Hydrogen cyanide
Hydroguinone
Hydroxyacetic acid
Isobutyl isobutyrate
Isobutanol
Isobutryaldehyde
Isobutylene
Isobutyric acid
Isodecanol
Isophorone
Isopropyl acetate
Isopropyl alcohol
Isopropyl ether
Isopropylamine
Lindane
Maleic Acid
Maleic anhydride
Merpol 6169 (PEG 32)
Merpol 6344 (PEG 180)
Methacrylic acid
Methanol
Methomyl
Methoxychloride
Methyl Acetate
Methyl benzyl alcohol
Methyl bromide (Bromoethane)
Methyl chloride (Chloromethane)
Methylene chloride (Dichloromethane)
Methylenedianiline, 4,4-
Methylene diphenyl diisocyanate (MDI)
Methyl ethyl ketone (2-Butanone)
Methyl hydrazine
Methyl iodide
Methyl isobutyl ketone (Hexone)
0.0094
000
000
000
000
000
000
0.968
0.088
0.000
1.000
0.940
0.573
0.000
0.000
0.001
0.873
0.852
0.886
1.000
0.750
0.923
0.997
0.786
0.793
0.939
811
000
0.001
0.510
0.000
0.000
154
321
0426
000
0.627
0.284
0.539
000
000
0.007
0.473
0.881
0.052
0.354
0.954
0.
1,
0.
0.
0.
1.
1.
1.
B-47
-------
TABLE B-13. FRACTION MEASURED (fin) FROM METHOD 25D
(Continued)
Compound Name fm
Methyl isocyanate 0.271
Methyl methacrylate 0.802
Methyl xnorpholine 0.668
Methylnaphthalene, 1- 1.000
Methylnaphthalene, 2- 1.000
Methyl-tertiary-butyl ether 0.911
Methyl isopropyl ketone (MIPK) 0.931
Misc. HAPs 0.850
Misc. organics 0.850
Misc. Organics 0.850
Misc. paraffins • 0.850
Misc. paraffins and olefins 0.850
Mixed xylidenes 0.388
Monoadducts 0.850
Monoester 0.850
Monoethanolamine 0.006
Monomethylformamide 0.002
Monopropylene glycol 0.000
Morpholine 0.251
Nabam 0.000
Naphthalene 1.000
Naphthol, alpha- 1.000
Naphthol, beta- 0.012
Naphthol (0-naphthol), 2- 0.012
Naphthoquinone, 1,4- 0.250
Nitroaniline, p- 0.000
Nitrobenzene 0.575
Nitrophenol, 4- 0.001
Nitropropane, 2- 0.537
Nitrosodimethylamine, N- 0.118
Nitrosomorpholine 0.061
Nitroso-n-methylurea, N- 0.380
Nitrotoluene 0.800
Nitrotoluene isomers 0.800
Nitrotoluene, m- 0.786
Nitrotoluene, o- 0.800
Nitrotoluene, p- 0.712
Nitroxylene 0.844
Nonanol, n- 0.844
Octane 1.000
Oil 0.850
Oils 0.850
Olefins and 2AB 0.850
Other Chlorophenols 0.441
Other nitrocresols 0.800
Palatinol, N- 0.850
Paraffins and alkylates 0.850
B-48
-------
TABLE B-13.
FRACTION MEASURED (fm) FROM METHOD 25D
(Continued)
Compound Name
fm
Parathion
PEG 15EO
PEG 3350
PEG 3EO
PEG 520EO
PEG 60EO
PEG 77EO
PEG 7EO
Pentachlorobenzene
Pentachlorophenol
Pentaerythritol
Perchloroethane
Phenol
Phenolic salts
Phenylenediamine, m-
Phenylenediamine, o-
Phenylenediamine> p-
Phosgene
Phosphine
Phthalic anhydride
Piperazine
PNCB
Polyvinyl alcohol
Propane Sultone,. 1,3-
Propanol
Propanone, 2-
Propene
Propiolacetone, beta
Propionaldehyde
Proporur (Baygon)
Propylene
Propylene chlorohydride
Propylene dichloride
Propylene glycol
Propylene oxide
Propylene imine (2-Methylaziridine)
Pyridine
Quinoline
Quinone
Resorcinol
Sodium Acetate
Sodium Chloroacetate
Sodium Formate
Soluble organic lead
Styrene
Styrene oxide
Succinonitrile
1,
0,
0.007
0.000
0.000
0.000
0.000
0.000
0.000
0.000
1.000
0.430
0.002
,000
,057
0.000
0.580
0.580
0.001
0.868
0.213
0.101
0.0013
0.803
1.000
0.005
0.399
0.829
1.000
0.243
0.813
0.099
1.000
0.549
1,
1
,000
.000
0.841
0.811
0.721
0.018
0.868
0.000
0.000
0.000
0.000
,000
,000
,000
1,
1,
1,
0.850
B-49
-------
TABLE B-13. FRACTION MEASURED (fin) FROM METHOD 25D
(Continued)
Compound Name fm
Tertiary butyl alcohol 0.768
Tamaron (Methamidiphos) 0.5289
Tars • 1.000
Terephthalic acid 0.004
Terpineol, alpha- 1.000
Tetrachlorodibenzo-p-Dioxin, 2,3,4,8- 1.000
Tetrachlbroethane, 1,1,2,2- 1.000
Tetrachloroethene 1.000
Tetrachloroethylene (Perchloroethylene) 1.000
Tetrachlorophenol 1.000
Tetrachlorophenol, 2,3,4,6- 1.000
Tetrachlorophenol, 2,3,5,6- 1.000
Tetraethylene pentamine 0.000
Tetraethyllead 1.000
Tetrafluoromethane 1.000
Total organic carbon 0.850
Toluene 1.000
Toluene diamine, 2,4- 0.001
Toluene diisocyanate, 2,4- 0.002
Toluenesulfonyl chloride 0.338
Toluidiene 0.267
Toluidine, m- 0.267
Toluidine, o- 0.267
Toluidine, p- 0.545
Total Organics 0.850
Toxaphene 0.968
Trans-l,2-Dichloroethene 1.000
Tributyl phosphorotrithioate, S,S,S- 0.0034
Tributyl tin acetate 0,9484
Trichlorobenzene, 1,2,4- 1.000
Trichloroethane 1,1,1- (Methyl chloroform) 1.000
Trichloroethane, 1,1,2- 0.966
Trichloroethylene 1.000
Trichlorophenol, 2,3,4- 0.396
Trichlorophenol, 2,4,5- 0.286
Trichlorophenol, 2,4,6- 0.396
Trichlorophenol, 3,4,5- 0.396
Trichloropropane 1.000
Triethylamine 0.930
Trifluralin 0.736
Triisobutylene 1.000
Trimethylpentane, 2,2,4- 1.000
Triisopropylamine 1.000
Trimethyl benzenes 1.000
Tripropylene glycol 0.112
B-50
-------
TABLE B-13. FRACTION MEASURED (fro) FROM METHOD 25D
(Concluded)
Compound Name fm
Vinyl acetate 0.748
Vinyl acetylene 1.000
Vinyl chloride 1.000
Vinylidene chloride 1,000
Xylenes (isomers and mixture) 1.000
Xylidine 0.388
B-51
-------
Substituting the definition for fe/fm, and expressing the VO
loading as the VO concentration multiplied by the wastewater
flow yields:
(fe/fm)avg =
* VO Concentration^(mg/l) * Flow(1pm)
.[vo Concentrationi(mg/l) * Flow (1pm)]
Using this equation, a weighted average value of 0.683 was
calculated from the 461 wastewater streams reported in response
to the 1990 SOCMI Section 114 survey. The resulting emission
estimation equation was used to calculate the uncontrolled VOC
emissions from the example wastewater streams for each of the
affected industries in Appendix B:
VOC Emissions = VO concentration (mg/£) * Flow (4pm) *
(Mg/yr) 10~9 Mg/mg * 60 min/hr * 8,760 hr/yr *
0.683
The use of these equations is shown in the following example:
Example Calculation l
OCPSF Manufacturing Plant
Stream 1121
VO Concentration =521 ppmw (from Table B-2)
Flow = 11.36 £pm
fr = 0.93
Uncontrolled VOC Emissions (Mg/yr) =
521 ppmw
11.36 £
min
10~9 Mg
mg
60 min
hr
8,760 hr
yr
* 0.683
=2.12 Mg/yr
B-52
-------
VOC Emission Reduction = fr * Uncontrolled.VOC
(Mg/yr) Emissions (Mg/yr)
= 0.93 * 2.12 Mg/yr
=1.97 Mg/yr
Similar calculations are performed for all other affected
streams. ' ..'"•'
B.4 COST AND SECONDARY ENVIRONMENTAL IMPACTS OF CONTROL
The equations for estimating total capital investment
(TCI) and total annualized costs (TAG) of a carbon steel steam
stripper are derived in Chapter 5.0. With a steam-to-feed
ratio (SFR) of 0.8 Ib/gal, the equations are:
TCI ($} = 239,645 + 837.9 * (Wastewater Feed Rate, £pm)
TAG ($/yr) = 72,812 + 639.0 * (Wastewater Feed Rate, 4pm)
For the example calculation begun in Section JB.3, the
facility's flow from all its model wastewater streams requiring
treatment under the specified RACT option is 401.0 £pm.
Therefore:
TCI = 239,645 + 837.9 * (401) = $575,600
TAG - 72,812 + 639.0 * (401) =* $329,000/yr
This assumes the installation of a single steam stripper.
Similar calculations are performed for each individual SOCMI
facility.
To account for lower steam requirements for streams with
more volatile compounds, new cost equations were derived for
lower SFR's. Next, those streams which can achieve 99 percent
removal with a lower SFR were identified in the OCPSF data
base. The costs were calculated for the more volatile streams
at the appropriate SFR while the costs of the remaining streams
were calculated using the cost equation presented above. For
the majority? of these more volatile streams, the optimal SFR
was 0.1 and the applicable TCI and TAG equations were:
TCI ($) = 235,664 + 771.0 * (flow)
TAG ($/yr) =72,239 + 240.9 * (flow)
B-53
-------
It was assumed that only one steam stripper was installed per
facility and that those facilities requiring different SFR's
will adjust the SFR accordingly.
The costs were totaled and scaled up to obtain national
impacts (see Section B.5.1). For each RACT option, the
national costing impacts (e.g., TAG) for lowering the SFR was
compared to the cost of treating all the streams at an SFR of
0.8. Scaling factors for lower costs at each RACT option were
calculated. These option-specific scaling factors were applied
to reduce the TAG to the remaining five industries.
The secondary impacts of RACT implementation are a product
of the electricity required to generate the steam. The
equation used to calculate these secondary pollution emissions
utilizes the fuel composition, heat values of said fuels and
steam, and air pollution control efficiencies presented in
Section 5.2.2. The following pollution emissions, after
the appropriate controls, are estimated for steam
generation using these equations:11
PM (Mg/yr) = WW flow * [(0.0006 Mg PM * min)/(£ * yr) ]
SO2 (Mg/yr) = WW flow * [(0.005 Mg SO2 * min)/(£ * yr) ]
NOX (Mg/yr) = WW flow * [(0.015 Mg NOX * min)/(£ * yr) ]
CO (Mg/yr) = WW flow * [(0.002 Mg CO * min)/(£ * yr) ]
VOC (Mg/yr) = WW flow * [(O.oooi Mg vpc * min)/(£ * yr) ]
where :
WW flow = Wastewater flow (£pm)
The secondary impacts are presented in Section B.5.7.
B.5 NATIONAL IMPACTS ESTIMATES
As discussed in Section B.4, the representative model
streams are used to calculate the following RACT impacts:
uncontrolled VOC emissions, emission reductions total capital
investment, total annual cost, cost effectiveness, and
incremental cost effectiveness. After these RACT impacts
(excluding incremental cost effectiveness) are calculated on a
model stream basis, the total impacts for all the model streams
must be appropriately scaled to estimate the impacts of
applying RACT on a national basis. The development and actual
B-54
-------
national impacts for the six industries discussed in this
document are presented in the following sections.
B.5.1 Organic Chemicals, Plastics, and Synthetic Fibers
Table B-14 presents OCPSF RACT national impacts. The
impacts of applying RACT to the model wastewater streams
discussed in Section 8.1.1 were scaled up to a national level
using a flow-based scaling factor. This flow scaling factor
accounts for that portion of the industry that will be
controlled by the hazardous organic national emission standards
for hazardous air pollutants (HON) and will not require
additional control (235,000 £pm) . The flow factor also
accounts for the 43 percent of the facilities located in areas
of nonattainment for ozone. The total OCPSF industry flow is
1,374,800 £pm. The resulting flow scaling factor equation is:
OCPSF Scaling Factor —
(OCPSF Flow* - HON Flow*) * w '..Tj*^1?11 °£ , .
— * - ,-. . — - — — - — - - T - *— Facilities Located in
(Model Stream Flow) Nonattainment Areas
= (1,374,800 - 235,000) * 0.43
(30,739)
= 15.94
aFlow given from the EPA 308 survey which is the direct contact
process water use for OCPSF.
bThe amount of wastewater flow controlled by the HON at a
maximum achievable control technology (MACT) standard of
500 ppmw volatile hazardous air pollutant (VHAP) and 1 £pm.
B.5.2 Pesticides Manufacturing Industry •
Table B-15 presents pesticide RACT national impacts. The
impacts of applying RACT to the model streams discussed in
Section B.I. 2 were scaled up to a national level using a flow
based scaling factor. This flow factor accounts for the
36 percent of the facilities located in areas of nonattainment
B-55
-------
TABLE B-14.
ORGANIC CHEMICALS, PLASTICS, AND SYNTHETIC FIBERS
RACT OPTIONS NATIONAL IMPACTS
03
I
ui
a\
Option
description*
VO
concentration Flow rate
cutoff cutoff
(ppmw) (tprn)
- 1,000
500
200
100
TIC
10
1
1
1
VOC
emission
reduction
(Mg/yr)
213.000
225,000
230,000
231.000
234,000
Percent
VOC
emission
reduction
85%
89%
91%
92%
93%
Percent
wastewater
flow
controlled
21%
29%
39%.
46%
100%
Percent
wastewater
stream
control 1 ed
20%
30%
37%
41%
100%
Total
capita! cost
(MH$)
160
200
240
270
500
Total
annual cost
(MH$/yr)
85
100
130
150
320
Average cost
effectiveness
($/Mg)
400
460
550
630
1,400
*A11 options include a maximum VO concentration cutoff of 10,000 ppmw.
Baseline VOC Emissions = 250,000 Mg/yr
Total Wastewater Volume = 490,000 Ipm
Total Number Uastewater Streams =7,300
TIC = Total Industry Control
-------
TABLE B-15. PESTICIDES RACT OPTIONS NATIONAL IMPACTS
W
I
01
vj
Option
description*
VO
concentration Flow rate
cutoff cutoff
(ppmw) (Ipm)
1,000
500
200
100
TIC
10
1
1
1
we
emission
reduction
(Mg/yr)
1,400
1,500
1,600
1,600
1,600
Percent
\IOC
emission
reduction
73%
79%
83%
84%
85%
Percent
wastewater
flow
control 1 ed
20%
24%
43%
49%
100%
Percent
wastewater
stream
controlled
23%
37%
48%
57%
100%
Total-
capital cost
.(HM$)
4.4 •
5.2
7.1
7.4
11
Total
annual cost
(MM$/yr)
1.5
1.8
2.5
2.7
4.7
Average cost
effectiveness
($/Mg)
1,200
1,200
1,600
1.700
2,900
*A11 options include a maximum VO concentration cutoff of 10,000 ppmw.
Baseline VOC Emissions = 1,900 Mg/yr
Total Wastewater Volume = 4,700 Ipm
Total Number Wastewater Streams = 190
TIC = Total Industry Control
-------
for ozone. The total pesticide industry wastewater flow is
12,934 £pm. The resulting scale-up equation is:
Pesticide Scaling Factor =
Industry Total Wastewater Flow * Fraction of
Facilities Located in
Model Stream Total Flow Nonattainment Areas
= (12,934 £pm) * (0.36)
(1,838 £pm)
= 2.533
B.5.3 Treatment, Storage, and Disposal Facilities
Table B-16 presents TSDF RACT impacts on a national basis.
The impacts of applying RACT to the model streams discussed in
Section B.I.3 were scaled to national impacts using a flow
based scaling factor. This flow factor accounts for the
43 percent of the facilities located in areas of nonattainment
for ozone. The flow factor also accounts for the wastewater
flow already regulated by the Benzene NESHAP (approximately
14.7 percent), and the assumption that the flow of the model
streams represents 45 percent of the total industry flow. The
resulting scaling equation is:
TSDF Scaling Factor =
(Industry Total (Fraction of (1 - Fraction of
Wastewater * Facilities Located in * Flow Regulated by
Flow) Nonattainment Areas) Benzene NESHAP)
= 42,060 * (0.43) * (1 - 0.147)
18,999
= 0.81
B.5.4 Pharmaceutical Manufacturing Industry
Table B-17 presents pharmaceutical RACT impacts on a
national basis. The impacts of applying RACT to the model
streams discussed in Section B.I.4 were averaged on a facility
basis. This facility average RACT impact was multiplied by the
number of facilities in each pharmaceutical subcategory. The
impacts of each combination of subcategories (e.g., A, AC, ACD,
B-58
-------
TABLE B-16. TREATMENT, STORAGE, AND DISPOSAL FACILITIES RACT OPTIONS NATIONAL IMPACTS
03
I
01
Option
description*
VO
concentration Flow rate
cutoff cutoff
(ppmw) (tpm)
1,000
500
200
100
TIC
10
1
1
1
VOC
emission
reduction
(Mg/yr)
1,900
1,900
2,000
2.000
2,100
Percent
VOC
emission
reducti on
61%
61%
63%
65%
65%
Percent
wastewater
flow
controlled
9%
9%
14%
24%
100%
Percent
wastewater
stream
controlled
18%
20%
24%
39%
100%
Total'
capital cost
,(MH$)
3.5
3.7
5.2
8.3
22
Total
annual cost
(MM$/yr)
1.7
1.8
2.6
4.3
13
Average cost
effectiveness
($/Hg)
910
940
1,300
2,100
6,200
*A11 options include a maximum VO concentration cutoff of 10,000 ppmw.
Baseline VOC Emissions = 3,100 Hg/yr
Total Wastewater Volume = 15,000 Ipm
Total Number Wastewater Streams = 40
TIC = Total Industry Control
-------
TABLE B-17. PHARMACEUTICALS RACT OPTIONS NATIONAL IMPACTS
W
I
Option
description*
VO
concentration Flow rate
cutoff cutoff
(ppmw) (Ipm)
1,000
500
200
100
TIC
10
1
1
1
voc
emission
reduction
(Mg/yr)
18,000
20,000
21,000
21,100
21,400
Percent
VOC
emission
reduction
70%
76%
82%
83%
84%
Percent
wastewater
flow
controlled
14%
22%
46%
49%
100%
Percent
wastewater
stream
controlled
21%
46%
52%
65%
100%
Total •-
capital cost
(HH$)
43
"71
87
90
144
Total
annual cost
(HH$/yr)
17
25
35
36
68
Average cost
effectiveness
($/Hg)
940
1,300
1,600
1,700
3.200
*A11 options include a maximum VO concentration cutoff of 10,000 ppmw.
Baseline VOC Emissions = 25,000 Mg/yr
Total Wastewater Volume = 76,000 fpm
Total Number Wastewater Streams = 3,000
TIC = Total Industry Control
-------
AD, C, CD, D) are added together. This total is then
multiplied by the percent of facilities in nonattainment
(57 percent). The resulting scaling equation is:
Pharmaceutical Scaling Factor =
^ (impact * No. of Facilities Fraction of
in Each * Facilities Located in
Subcategory) >, Nonattainment Areas
where:
Fraction of Facilities located
in nonattainment areas = 0.57
No. of facilities in each subcategory:
A only
AC
ACD
AD
C only
CD
D only
15
9
20
26
50
67
403
Table B-18 presents RACT impacts on a national basis for
Subcategory C (Chemical Synthesis) only.
B.5.5 Petroleum Refining
Table B-19 presents petroleum refining RACT impacts on a
national basis. The impacts of applying RACT to the model
streams discussed in Section B.I.5 were scaled to national
impacts based on the percent of facilities in nonattainment
(52 percent) and the wastewater flow already regulated by the
Benzene NESHAP (67 percent). The resulting scaling factor is:
Petroleum Refining Scaling Factor
(Fraction of (1 - Fraction of
= Facilities Located in * Flow Regulated by
Nonattainment Areas) Benzene NESHAP)
- (0.52) * (1 - 0.67)
= 0.17
B-61
-------
TABLE B-18. PHARMACEUTICALS (SUBCATEGORY C ONLY) RACT OPTIONS NATIONAL IMPACTS
00
I
o\
to
Option
description*
VO
concentration Flow rate
cutoff cutoff
(ppnw) (tpm)
1,000
500
200
100
TIC
10
1
1
1
VOC
emission
reduction
(Mg/yr)
15,600
16,000
17.000
17,000
17,500
Percent
VOC
emi ssi on
reduction
74%
76%
82%
82%
83%
"Percent
wastewater
flow
controlled
18%
20%
51%
51%
100%
Percent
wastewater
stream
controlled
35%
47%
62%
62%
100%
Total
capital cost
(MM$)
27
27
43
43
65
Total
annual cost
(MM$/yr)
11
11
20
20
38
Average cost
effectiveness
($/Hg)
720
680
1.200
1,200
2,100
*A11 options include a maximum VO concentration cutoff of 10,000 ppmw.
Baseline VOC Emissions = 21,000 Mg/yr
Total Wastewater Volume = 53,000 fpm
Total Number Wastewater Streams = 500
TIC = Total Industry Control
-------
TABLE B-19. PETROLEUM REFINING RACT OPTIONS NATIONAL IMPACTS
I
a\
to
Option
description*
VO
concentration Flow rate
cutoff cutoff
(ppmw) (fpm)
1,000
500
200
100
TIC
10
1
1
1
voc
emission
reduction
(Mg/yr)
1,700
3,700
3,700
3.900
4,000
Percent
VOC
emission
reduction
41%
91%
91%
97%
100%
Percent
wastewater
f 1 ow
controlled
3%
27%
27%
507.
100%
Percent
wastewater
stream
controlled
10%
43%
44%
51%
100%
Total '
capital cost
(MH$)
7.9
21
21
31
44
Total
annual cost
(HM$/yr)
2.6
7.9
7.7
12
21
Average cost
effectiveness
($/Mg)
1,600
2,100
2,100
3,200
5,300
*A11 options include a maximum VO concentration cutoff of 10,000 ppmw.
Baseline VOC Emissions = 4,000 Mg/yr
Total Wastewater Volume = 25,000 Ipm
Total Number Wastewater Streams = 720
TIC = Total Industry Control
-------
B.5.6 Pulp and Paper Industry
Table B-20 presents the pulp and paper national RACT
impacts. There are only 13 integrated pulp and paper mills
located in areas of ozone nonattainment. The data from these
13 mills were used to calculate the model streams and the
resulting RACT impacts. Because these are the only facilities
affected by this CTG, the model stream RACT impacts are
equivalent to the national RACT impacts.
B.5.7 Secondary Impacts
Table B-21 presents the VOC emission reductions and
secondary impacts from each of the industries at the RACT
option of 500 ppm and 1 £pm flow.
B-64
-------
TABLE B-20. PULP AND PAPER RACT OPTIONS NATIONAL IMPACTS
W
I
o\
tn
Option
VO
description*
concentration Flow rate
cutoff cutoff
(ppnrw) (tpm)
1,000
500
200
100
TIC
10
1
1
1
voc
emission
reduction
(Wg/yr)
11,000
11,000
12.000
12,000
12,000
Percent
VOC
emission
reduction
89%
89%
95%
95%
95%
Percent
wastewater
flow
controlled
67%
67%
100%
100%
100%
Percent
wastewater
stream
controlled
80%
80%
100%
100%
100%
Total "•
capital cost
. (MH$) .
13
13
18
18
18
Total
annual cost
(MM$/yr)
8.0
8.0
10
10
11
Average cost
effectiveness
($/Mg)
720
720
1,000
1,000
1,000
*A11 options include a maximum VO concentration cutoff of 10,000 ppmw.
Baseline VOC Emissions = 12,000 Mg/yr
Total Wastewater Volume = 17,000 Ipm
Total Number Wastewater Streams = 65
TIC = Total Industry Control
-------
TABLE B-21. VOLATILE ORGANIC COMPOUND EMISSION REDUCTIONS
AND SECONDARY IMPACTS
RACT Option: 500 ppinw
1 Ipm
Secondary impacts (Mg/yr)
VOC emission
Industry reduction (Hg/yr) PH S02 NOX CO VOC
OCPSF
Pesticides
TSOF
Pharmaceuticals
TOTAL
225,000
1.500
1.'900
20.000
248.400
86
1.0
1.0
10
98
720
5.5
8.3
' 83
820
2.100
17
25
250
2.400
290
2.2
3.3
33
330
14
0.1
0.2
1.7
16
B-66
-------
B.6 REFERENCES . _ ' • .
1. Memorandum from Brailsford, J., Radian Corporation, to
F. E. Manning, U.S. Environmental Protection Agency.
Regarding Calculation of f^.'' December 3, 1991.
2. Annual Refining Survey. Oil and Gas Journal. March 26,
1990.
3. U. S. Environmental Protection Agency. VOC Emissions from
Petroleum Refinery Wastewater Systems—Background
Information Document for Proposed Standards. EPA-450/3-
85-OOla. February 1985.
4. U. S. Environmental Protection Agency. Final NESHAP
Standards for Waste Operations: Basis for Impacts
Calculations,. .. February 16, 1990.
5. Memorandum .from Bagley C., Radian Corporation to Project
File. Assignment of Total Organic Concentrations to
Petroleum Refinery Model Wastewater Streams. March 31,
1992.
6. Letter from Breed, D. H., Union Camp, to S. R. Wyatt,
U. S. Environmental Protection Agency. BODg Reduction
Using Condensate Stripping, Union Camp Corporation,
Franklin, Virginia, November 17, 1989.
7. U. S. Environmental Protection Agency. Environmental
Pollution Control, Pulp and Paper Industry, Part I-Air.
EPA-625/7-76-001. October 1976.
8. 1991 Lqckwood-Post's Directory of the Pulp, Paper, and
Allied Trades. Miller Freeman Publications. 1990.
pp. 42, 67 to 68, 72 to 73, 82 to 85, 105, 111, 124 to
126, 130 to 134.
9. Memorandum from Bagley, C., Radian Corporation, to
F. E. Manning, U. S. Environmental Protection Agency.
Development of Volatile Organic Wastewater Loading
Distribution from Responses to the March 1990 Section 114
Wastewater Questionnaire. May 5, 1992.
10. Trip Report. Elliott, J. A., and S. L. Watkins, Radian
Corporation, to file. 8 p. Report of September 25,: 1989,
visit to Union Camp Corporation.
11. Memorandum from Zukor, C., Radian Corporation, to
F. E. Manning, U. S. Environmental Protection Agency.
Development of Environmental Impact Factors for Steam
Stripping Wastewater Streams in the Industrial Wastewater
Control Techniques Guideline (IWW CTG) Document.
January 31, 1992.
B-67
-------
October 1993
Add end tun -bo September 1992
Draft Industrial Wastewater
Control Techniques Guideline Document
The tables in this Addendum are the same as the
tables presented in Chapter 6 and Appendix B
with the.addition of two options and a
correction to the Pesticides RACT Options Table.
The two additional options included are
1', 000 ppmw at 1 £pm and 500 ppmw at 10 £pm. The
correction to the Pesticides RACT Options Table
is concerning the total annual cost value for
the 1,000 ppmw 10 £pxn option which should be
1.6 MM$/yr instead of the 1.5 MM$/yr value in
table on page B-57.
-------
TOTAL INDUSTRY RACT OPTIONS NATIONAL IMPACTS
to
<*
oo
Option description
vo
concentration Flow rate Maximum VO
cutoff cutoff concentration
(ppmw) (Ipm) {ppmw)
1.000
1,000
500
500
200
100
TIC
10
1
10
1
1
1
10,000
10,000
10,000
10,000
10,000
10,000 ;
voc
emission
reduction
(Hg/yr)
232,000
234,000
242,000
244,000
251.000
252,000
255,000
Percent
VOC
emission
reduction
83%
84%
87%
88%
90%
91%
92%
Total
national
capital cost
(MN$)
190
210
240
240
300
330
600
Total
national
annual cost
(MM$/yr)
100
100
120
120
150
170
380
National cost
effectiveness
($/Mg)
430
440
470
480
610
690
1,500
Incremental
cost
effectiveness
($/Mg)
230
2,500
(1,200)
5,700
13,800
65,900
Baseline VOC emissions = 278,000'Mg/yr
Total wastewater volume = 563.000 Ipm
Total number wastewater streams = 8,100
TIC = Total Industry Control
-------
ORGANIC CHEMICALS, PLASTICS, AND SYNTHETIC FIBERS
RACT OPTIONS NATIONAL IMPACTS
Option description
vo
concentration Flow rate Maximum VO
cutoff cutoff concentration
(ppmw) (Ipm) (ppmw)
W
1
a\
VO
1,000
1.000
500
500
200
100
TIC
10
1
10
1
1
1
10.000
10,000
10,000
10,000
10,000
10,000
voc
emission
reduction
(Hg/yr)
213,000
214.000
223.000
225,000
230,000
231,000
234,000
Percent
VOC
emission
reduction
85%
85%
89%
89%
91%
92%
93%
Percent
wastewater
flow
control 1 ed
21%
21%
29%
29%
39%
46%
100%
Percent
wastewater
stream
control 1 ed
20%
24%
24%
30%
37%
41%
100%
Total
capital cost
(HNS)-
160
170
200
200
240
270
500
Total
annual cost
(HH$/yr)
85
88
100
100
130
150
320
Average cost
effectiveness
($/Mg)
400
410
460
460
550
630
1,400
Baseline VOC emissions = 252,000 Hg/yr
Total wastewater volume = 490,000 Ipm .
Total number wastewater streams = 7,300
TIC = Total Industry Control
-------
PESTICIDES RACT OPTIONS NATIONAL IMPACTS
Option description
vo
concentration Flow rate VO maximum
cutoff cutoff concentration
(ppmw) (fpm) . (pptnw)
W
1
vl
O
1,000
500
1,000
500
200
100
TIC
10
10
1.
1
1
1
10,000
10,000
10.000
10,000
10,000
10,000
voc
emission
reduction
(Hg/yr)
1,400
1,400
1,500
1.500
1,600
1.600
1,600
Percent
VOC
emission
reduction
73%
74%
78%
79%
83%
84% .
85%
Percent
wastewater
flow
controlled
20%
21%
22%
24%
43%
49%
100%
Percent
wastewater
stream
controlled
23%
24%
35%
37%
48%
57%
100%
Total
capital cost
(HH$)
4.4
5.1
5.1
5.2
7.1
7.4
11
Total
annual cost
(MMj/yr)
1.6
1.8
1.9
1.8
2.5
2.7
4.7
Average cost
effectiveness
($/Mg)
1,200
1,300
1,300
1,200
1.600
••(':
1,700
2,900
Baseline VOC emissions = 1,900 Mg/yr
Total wastewater volume = 4,700 fpm
Total number wastewater streams = 190
TIC = Total Industry Control
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TREATMENT, STORAGE, AND DISPOSAL FACILITIES RACT OPTIONS NATIONAL IMPACTS
Option description
vo
concentration Flow rate Maximum VO
cutoff cutoff Concentration
(pptnw) (Ipm) (ppmw)
CO
-j
H
1,000
500
l.OOO3
500
200
100
TIC
10
10
1
1
1
1
10.000
10,000
10,000
10.000
10,000
10,000
voc
emission
reduction
(Mg/yr)
1.900
1,900
1,900
1,900
2,000
2,000
2,100
Percent
VOC
emission
reduction
61%
61X
61%
61%
63%
65%
66%
Percent
wastewater
flow
controlled
9%
9%
9%
9%
14%
24%
100%
Percent
wastewater
stream
controlled
18%
18%
19%
20%
24%
39%
100%
Total
capital cost
(MS)
3.3
3.3
3.5
3.7
5.2
8.3
22
Total
annual cost
(HM$/yr)
1-7
1.7
1.7
1.8
2.6
4.3
13
Average cost
effectiveness
($/Mg)
870
870
910
940
1,300
2,100
6.200
Baseline VOC emissions = 3,100 Mg/yr
Total wastewater volume * 15,000 Ipm
Total number wastewater streams * 40
TIC = Total Industry Control
Previously reported as the 1,000 ppmw/10 Ipm option In the CTG document on page B-59.
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PHARMACEUTICALS SUBCATEGORY C (CHEMICAL SYNTHESIS)
RACT OPTIONS NATIONAL IMPACTS
Option
description
VO
concentration Flow- rate Maximum VO
cutoff cutoff concentration
(ppmw) (Ipm) (ppmw)
1,000
1,000
500
500
200
f 100
to TIC
10
1
10
1
1
1
10,000
10,000
10,000
10,000
10,000
10,000
VOC
emission
reduction
(Mg/yr)
15,600
15,800
15.900
16,000
17.000
17,000
17,500
Percent
VOC
emission
reduction
74%
75%
76%
76%
82%
82%
83%
Percent
wastewater
flow
controlled
18%
18%
19%
20%
51%
51%
100%
Percent
wastewater
stream
controlled
35%
40%
42%
47%
62%
62%
100%
Total
capital cost
(HM$)
27
27
27
27
43
43
65
Total
annual cost
(MH$/yr)
11
11
11
11
20
20
38
Average cost
effectiveness
($/Mg)
720
730
680
680
1.200- *...-«•*,>
1,200
2.100
Baseline VOC emissions = 21,000 Hg/yr
Total wastewater volume = 53,000 fpm
Total number wastewater streams = 500
TIC = Total Industry Control
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