-------
This table briefly describes each Main Menu selection:
Select... To ...
A) Enter/View Data
Access to data about each
source.
B) List Facilities by Stream Type
Generate a report listing all
facilities that have a specified
stream type (organic or
inorganic vapors and
particulates).
C) List Facilities by Pollutant
Generate a report listing all
facilities that have a specified
pollutant (such as ammonia,
benzene, or toluene).
D) Rebuild all Indexes
Rebuild all indexes.
E) Remove Records Marked for Deletion Permanently remove all records
marked for deletion (pack) and
rebuild all indexes.
F) EXIT this System
Exit the HAP-PRO program.
-------
Data Screens
Selection A) EnterA/iew Data on the Main Menu accesses the facility data
screens.
FACILITY
Company: CCM Example
Desc.: test ccm description
Street: 2409 Drexel Street
City: Woodbridge
State: VA Zip: 22192-0000
Contact: Lee MuHeady
Telephone: (703)494-1307
Permit: 01/02/94
Reviewer: gmp
Streams: 20
EMISSION STREAMS
Stream Type
CONTROL DEVICES
Status Device
Statu
1 INORGANIC PARTICULATE
^FABRIC FILTER
ELECTROSTATIC PRECIPATATOR
HAZARDOUS AIR POLLUTANTS
Pollutant
Cone (ppmv)
Stat
ACETALDEHYDE
XAMMONIUM BROMIDE
20.0
0.0
A
A
Last Updated by: LWM Date: 11/18/94 Press F5 for Facility Not
Status may be "A" = Active or "D" = Deleted
Searches for a Facility Record
-------
HAP-PRO sorts the records in alphabetical order by facility name and organizes
them into five groups. This table describes each group.
Group Description
Facility
Name, address, and principal activity of the
facility; the reviewer's name; and the number of
emission streams.
Emission Stream
Stream type, flow rate, heat content, and so forth,
of the specified emission stream. You can assign
multiple streams to each facility.
Control Device
Control device assigned to an emission stream.
Details design and cost parameters. You can only
assign one control device to any one emission
stream.
Hazardous Air Pollutants
Pollutants or HAPs in a given emission stream,
including concentration and other parameters.
You can assign multiple pollutants to any stream.
Facility Notes
Miscellaneous notes about a facility or permit.
Press Flfor Notes.
10
-------
The data is organized with any number of Streams per Facility and any number
of Devices and HAPs per Stream. Refer to the chapter on Data Entry for
complete instructions on how to enter and edit data. The following is a general
overview of data entry showing how the data is related.
To add or edit data for a Facility:
1. or the desired Facility. (Refer to the sections on
Adding Records, Editing Records, and Facility Data in the chapter on
Data Entry for complete instructions on how to do this.)
The Stream data entered will be for this Facility.
2. Select the Stream field to open a selection list. To do this either Tab
[§j to the Stream field and press I^ERI ; or click on the Stream field
using the mouse. (Refer to the section on Stream Data.)
The data displayed in the Control Device and HAPs areas of this screen
change to show the entries for the selected Stream.
3. You may open the data entry/edit windows for these fields by double-
clicking on the item with the mouse. (Refer to the sections on Control
Device and HAP Pollutants.)
11
-------
The data that comprise the emission stream, control device, and HAPs can be
thought of as three separate tables, which consist of three to four columns. This
figure shows the STREAM PARAMETER SELECTION LIST.
r CTDFAM PARAMFTFP
EMISSION STREAM NUMBER = 1
PARAMETER
Stream Type - INORGANIC PARTICULATE
Maximum Flow Rate (scfm)
Stream Temperature (deg F)
Oxygen Content (%)
Moisture Content (%)
Stream Pressure (mmHg)
Mean Particle Diameter (Ug)
Particulate Content (gr/scf)
S03 Concentration (ESPs only, ppmv)
Drift Velocity (ESPs only, ft/s)
< Ok >
cci nrr Trtkj 1 T QT 1
APPLICANT
4
5000
100
20.0
0.0
760.0
0.000
0.000
0.000
0.000
DEFAULT VERIFIED
N
77 N
20.0 N
N
760.0 N
N
N
N
The following table lists and describes each column. The chapter on Data Entry
provides further detail.
Column Function
PARAMETER
Identifies the parameter. The unit of measure is in
parentheses.
APPLICANT
Displays the value entered. Initially defaults to the value
recorded in the third column (if any). HAP-PRO uses the
Applicant values to calculate capital and operating costs.
DEFAULT Displays the default value for the given parameter, if any.
You cannot edit this value.
VERIFIED Records confidence that the applicant value is correct. Also
used to note whether the figures have been double-checked.
12
-------
Commands
To execute a command, either:
o Enter the first letter of the command
o Highlight the desired command (use either the cursor or the mouse) and
preSS IENTERJ ; or
o Click on the command using the mouse.
If you make an incorrect selection, press ffscj to return the cursor to the
command line. The command is highlighted by default.
This table briefly describes the purpose of each command.
Select... To . . .
Search for a facility by its name. When the selection list
displays, select the desired facility.
Change data for groups: Facility, Stream, Control Device, or
HAPs. To edit/view the contents of the note field, however,
press function key 0.
Enter data for groups not previously in the system.
Mark the currently selected record for deletion. Records aren't
permanently deleted until the database is packed, using option
E) Remove Records Marked for Deletion on the Main
Menu. Until then, these records can be undeleted using the
Undelete command.
Undelete the currently selected record.
Skip to the next facility in the database.
Skip to the previous facility in the database.
Calculate capital and operating costs for the selected emission
stream.
Exit to the Main Menu.
13
-------
Help
Help is available through pop-up lookup tables or text-based notes.
Both types of help are accessed through the edit windows for the stream, control
device, and HAP groups. While in the Applicant value field, press 0 for a
lookup table or 0for the text-based notes. This is described in further detail in
the section on Data Entry.
-Press ESC to Exit or 1 I to Scroll Text-
Maximum Flow Rate (scfm)
The value to be input is the maximum value of the emission stream flowrate
in standard cubic feet per minute (scfm). If the emission stream happens
to be in actual cubic feet per minute (acfm), the following formula can be
used to convert acfm to scfm:
Qe = Qe,a [537/Te + 460]
Where: Qe = Maximum emission stream flowrate, scfm.
Qe,a = Maximum emission stream flowrate, acfm.
Te = Temperature of emission stream, »F.
Example: Qe,a = 20,000 acfm.
Te = 120 of
14
-------
Maintenance
The following Main Menu selections provide database maintenance.
Select. . . To . . .
D) Rebuild all Indexes Rebuild all indexes.
E) Remove Records Marked for Deletion Purge (pack) the database of all
records marked for deletion and
rebuild all indexes.
Backup
A third important database maintenance function not currently built into this
system is system backup. You should use the DOS backup utility or another
utility to periodically back up all files, or at least the data files (*.DBF, *.FPT).
To use the DOS backup utility:
1. Ensure that the system path permits access to the backup command.
2. Enter the following command at the DOS prompt:
BACKUP C:\HAP-PRO\** A:
To restore the data, enter the following command:
1. Ensure that the system path permits access to the backup command.
2. Enter the following command at the DOS prompt:
RESTORE A: C:\HAP-PRO\**
Note: This example assumes that HAP-PRO is installed on drive C and drive A
is where you wish to backup the data. If HAP-PRO is on another drive or
subdirectory, replace C:\HAP-PRO as appropriate. If you wish to backup the
data to a different drive, replace A: as appropriate.
15
-------
Calculating Results
HAP-PRO calculates values of important engineering parameters for each
evaluated control system. The calculated values presented for each control
device correspond to those values calculated in the revised HAP manual which
are considered necessary to perform a permit review. The calculated values are
not definitive, they are a "ball park" reference to which the applicant's design is
compared.
HAP-PRO calculates design results by executing the steps outlined in the next
section. The example is the design of a carbon adsorber system, which is one
of the three air pollution control systems for which HAP-PRO provides "expert"
comments on the design. Expert review is also available for thermal and
catalytic incinerator designs. The expert system reviews the design results
generated, makes recommendations for changes, and allows for design
sensitivity analysis in a spreadsheet-like environment. Although the remaining
six control system design routines (flare, packed column scrubber, condenser,
fabric filters, venturi scrubber, and ESP) do not provide expert review or allow
for interactive analysis changes currently, future plans are to create this option
for all systems that HAP-PRO evaluates.
16
-------
Follow these steps to calculate results for the three systems that utilize
HAP-PRO's expert analysis.
1. Select Enter/View Data from the Main Menu. The Data Screen
appears.
FACILITY
Company: CCM Example
Desc.: test ccm description
Street: 2409 Drexel Street
City: Uoodbridge
State: VA Zip: 22192-0000
Contact: Lee Mulleady
Telephone: (703)494-1307
Permit: 01/02/94
Reviewer: gmp
Streams: 20
EMISSION STREAMS
Stream Type
CONTROL DEVICES
Status Device
Stat
1 INORGANIC PARTICULATE
>-FABRIC FILTER
ELECTROSTATIC PRECIPATATOR
HAZARDOUS AIR POLLUTANTS
Pollutant
Cone (ppmv)
Stat
>-ACETALDEHYDE
AMMONIUM BROMIDE
20.0
0.0
A
A
Last Updated by: LWM Date: 11/18/94 Press F5 for Facility Not
Status may be "A" = Active or "D" = Deleted
Searches for a Facility Record
2. Select . The SELECT DESIRED FACILITY window opens.
, 1 SELECT DESIRED FACILITY ] ,
CCM Example
Company Test 1
17
-------
3. Select the desired facility from the selection list. HAP-PRO updates the
Data Screen.
FACILITY
Company: Company Test 1
Desc.: desc
Street: street x
City: city x
State: VA Zip: 22192-0000
Contact: Alan Thomas
Telephone: (919)777-2222
Permit: 01/05/95
Reviewer: Reviewer x
Streams: 5
EMISSION STREAMS
Stream Type
CONTROL DEVICES
Status Device
1 ORGANIC VAPOR
>-THERMAL INCINERATOR
HAZARDOUS AIR POLLUTANTS
Pollutant
Cone (ppmv)
XACENAPHTHENE
0.0
Last Updated by: SKH Date: 11/29/94 Press F5 for Facility Note:
Status may be "A" = Active or "D" = Deleted
Searches for a Facility Record
Select the stream for which the calculations will be performed, by
highlighting the stream and pressing |(ENTEB| or double-clicking on it with
the mouse.
Select . The calculations are performed based on all the HAPS
for the stream. If the Carbon Adsorber is the Control Device selected
for the stream, you will be prompted to select the HAP for the
calculations. Otherwise, the system uses an average of all the HAPS.
As the system calculates the results, Calculating displays.
Calculating
Important Note:
does not include records marked for deletion.
18
-------
When complete, the results will be displayed in the report window. Use
the Q and [Tj keys to scroll back and forth through the document.
-[ Please Review Calculated Results for Accuracy ]-
HAP-PRO Version 2.0
A
Date of Print: 11/29/94 0
Note: Parameters marked with a * are not used in calculations; all other
parameters must be input to perform calculations accurately.
PLANT DATA
Plant ID: 000001
Company: CCM Example
Description: test ccm description
Street: 2409 Drexel Street
City: Woodbridge
State: VA Zip: 22192-0000
STREAM TYPE -- INORGANIC PARTICULATE
STREAM RELATED PARAMETERS
Plant Contact: Lee Mulleady
Telephone: (703)494-1307
Permit Date: 01/02/94
Reviewer: gmp
Streams: 020
Applicant Default Verified
< Print >
< Help >
< Exit >
Press <1> and to scroll through calculation report - Press to leave
The output includes intermediate and calculated results, and the results
of the expert review system. After reviewing the output, select either:
to PRINT the results,
to proceed to the ANALYSIS section,
to get HELP, or
to EXIT the calculation routine.
19
-------
Expert Review System
The review system evaluates the results of carbon adsorber designs, and thermal
and catalytic incinerator designs. HAP-PRO reviews the design results
calculated for each of these systems and provides recommendations for changes
so that the design results fall within reasonable boundaries. A spreadsheet-like
window is available to interactively evaluate different design scenarios.
The Calculating Results section depicts an example calculation using the expert
review system for a carbon adsorber design. The following three subsections
describe the parameters that each control system evaluates to confirm a
reasonably designed system.
20
-------
Carbon Adsorber
For carbon adsorbers, the program compares the calculated vessel dimensions
with those found in the next figure.
Length <=
Typical Carbon Adsorber Vessel Dimensions
If the calculated results do not fall within these boundaries, HAP-PRO
recommends changing to one or a combination of program entries. HAP-PRO
makes no recommendations for design changes whenever the final design is
reasonable.
The recommendations for changes to the design revolve around three key
parameters: The number of adsorbing beds, the bed velocity, and the carbon-to-
vessel ratio. The effects of changes to these three parameters can be evaluated
interactively on the review screen to quickly develop the best design.
HAP-PRO performs calculations and evaluates designs for both vertical and
horizontal vessels.
21
-------
Thermal Incinerator
For thermal incinerators, this figure depicts the relationship that HAP-PRO
seeks to obtain for the destruction efficiency, residence time, and combustion
temperature for a given level of turbulence in the flow.
INCREASING RESIDENCE TIME
1000
1200 1400
TEMPERATURE, "f
1(00
1100
ZOOO
Thermal Incinerator Operating Ranges
If these three parameters fall within the boundaries set, HAP-PRO assumes that
the design is reasonable. The family of curves shown is not for any particular
pollutant. The program uses this curve to place "reasonableness" borders on the
three variables (destruction efficiency, combustion temperature, and residence
time). These variables are defined for a level of turbulence typically found in
real units. Ideally, laboratory test data for the pollutant being controlled should
be used to confirm that the design values selected are appropriate.
22
-------
Catalytic Incinerator
For catalytic incinerators, this figure depicts the relationship that HAP-PRO
seeks to obtain for the destruction efficiency and oxidation temperature.
i
u
20
COO
TEMPERATURE, "f
no
moo
1200
Catalytic Incinerator Operating Ranges
As with the thermal incinerator relationship, the curve shown is not for any
particular pollutant. The program uses this curve to place "reasonableness"
borders on the two design variables, destruction efficiency and oxidation
temperature. Again this is for turbulence levels usually found.
Since there are many catalysts that might be effective in destroying a particular
pollutant or combination of pollutants, an accurate design should evaluate
several catalysts. Catalyst-specific lab data is therefore needed to determine the
destruction efficiency and oxidation temperature requirements for each catalyst-
pollutant combination. In the absence of pollutant and catalyst-specific data,
HAP-PRO uses the curve in this figure as a minimum requirement.
-------
Using Analysis
1.
If is selected on the Calculated Results screen, the
REVIEW screen opens.
CRITICAL INPUT PARAMETERS
>• Bed Type
Desired Destruction Efficiency (%)
Heat Exchanger Efficiency (%)
Catalytic Oxidation Temp (»F)
CALCULATED RESULTS
>• Heat Content (Btu/scf)
Dilution Air Requirements (scfm)
Temp of Stream after Heat Exchange
Natural Gas Flow Rate (scfm)
Flue Gas Flow Rate (scfm)
Actual Flow Rate (scfm)
Catalyst Bed Requirement (ft3)
Fuel Usage (ft3/yr)
Total Capital Costs ($)
< Edit > <
INCINERATOR* PARAMETER REVIEW ] 1
Current Previous 1 Previous 2
Fixed |
95
50
600
Current Previous 1 Previous 2
2.2 /\
0.0 0
(oF) 339 I
2.1 1
502.1 I
991.2 1
1.5 1
772481.7 |
73900 V
•
Save > < Help >
1
1
Perform Review Process
This screen allows you to evaluate unlimited sensitivities to develop the
most effective carbon adsorber design. Any of the four critical input
parameters can be changed and the design recalculated.
To perform recalculations, edit the field (or fields) desired. To do this,
select the desired field and press |i*H or double-click with the mouse.
An edit window opens.
[ EDIT CONTROL DEVICE PARAMETER ]••
PARAMETER: Desired Destruction Efficiency (%)
Applicant Value: 75.0
Default Value: 95.00
Verified:
< Ok >
Enter the desired changes and then select .
24
-------
Select . The new results display. HAP-PRO saves up to
two previous iterations.
When the sensitivities are complete, select . The program
prompts for the data set to save.
Current
Previous
Previous
Set
Set
Set
1
2
Select the set that you want to save. When the new data is saved,
Saving Data is displayed.
Saving Data
After saving, the final output is displayed. Additional sensitivities can
be run at this point or the output can be sent to the printer.
25
-------
Printing Review Results
1. Files may be printed from either the review screen or the initial results
screen. For printing options, select . HAP-PRO prompts for
the type of output desired (ASCII file or hard copy).
2.
ASCII File
Printer
If you select ASCII File, another window requests the receiving drive
and filename.
Receiving Drive:
A
B
C
D
Filename: FILEOUT.DOC
Enter the drive and filename for the ASCII file and press
execute. The following message displays.
to
Creating File C:\FILEOUT.DOC
3. If you select Printer, you will get a hardcopy report. A window appears
with the text Printing. . .
Printing Report...Please Stand By
When the printing is complete, the following window appears.
Printing Complete...Press any key to continue
26
-------
4. When finished printing the output, press II ESC| to exit from this screen.
You can then select another stream for calculation or return to the Main
Menu.
27
-------
Data Entry
This chapter consists of step-by-step instructions on how to enter a new record
or edit an existing record in HAP-PRO.
Adding Records
1. Select Enter/View Data from the Main Menu.
FACILITY
Company: CCM Example
Desc.: test ccm description
Street: 2409 Drexel Street
City: Woodbridge
State: VA Zip: 22192-0000
Contact: Lee MuHeady
Telephone: (703)494-1307
Permit: 01/02/94
Reviewer: gmp
Streams: 20
EMISSION STREAMS
Stream Type
CONTROL DEVICES
Status Device
1 INORGANIC PARTICULATEA| [^FABRIC FILTER
ELECTROSTATIC PRECIPATATOR
HAZARDOUS AIR POLLUTANTS
Pollutant
Cone (ppmv)
>-ACETALDEHYDE
AMMONIUM BROMIDE
20.0
0.0
A
A
Last Updated by: LWM Date: 11/18/94 Press F5 for Facility Note
Status may be "A" = Active or "D" = Deleted
Searches for a Facility Record
2.
If you want to add data to an existing facility, select from the
command line and select the Facility.
Select from the command line. The SELECT GROUP window
opens.
-[ SELECT GROUP ]-
FACILITY
EMISSION STREAM
CONTROL DEVICE
HAP POLLUTANTS
3. Select the GROUP to add and refer to the section that corresponds to
28
-------
your desired selection, to continue.
Editing Records
1. Select EnterA/iew Data from the Main Menu.
FACILITY
Company: CCM Example
Desc.: test ccm description
Street: 2409 Drexel Street
City: Uoodbridge
State: VA Zip: 22192-0000
Contact: Lee MuHeady
Telephone: (703)494-1307
Permit: 01/02/94
Reviewer: gmp
Streams: 20
EMISSION STREAMS
Stream Type
CONTROL DEVICES
Status Device
J INORGANIC PARTICULATE A| |>-FABRIC FILTER
ELECTROSTATIC PRECIPATATOR
HAZARDOUS AIR POLLUTANTS —
Pollutant
Cone (ppmv)
VACETALDEHYDE
>
AMMONIUM BROMIDE
,
20.0 A
0.0 A
Statu
Last Updated by: LWM Date: 11/18/94 Press F5 for Facility Note:
Status may be "A" = Active or "D" = Deleted
Searches for a Facility Record
2.
Select from the command line. The SELECT DESIRED
FACILITY window opens.
I C SELECT DESIRED FACILITY ] ,
CCM Example
Company Test 1
3. Select the desired facility from the list.
29
-------
Contact: Alan Thomas
Telephone: (919)777-2222
Permit: 01/05/95
Reviewer: Reviewer x
Streams: 5
Company: Company Test 1
Desc.: desc
Street: street x
City: city x
State: VA Zip: 22192-0000
CONTROL DEV CES
EMISSION STREAMS
Stream Type
^THERMAL INCINERATOR
ORGANIC VAPOR
HAZARDOUS AIR POLLUTANTS
>ACENAPHTHENE
Last Updated by: SKH Date: 11/29/94 Press F5 for Facility Notes
Status may be "A" = Active or "D" = Deleted
Searches for a Facility Record
Note: You can press Ifcriqj and jx]together from this screen to get a calculator.
4. The first Stream, Control Device, and Hazardous Air Pollutant
(HAP) listed are selected by default. If you want to edit another Stream,
Control Device, or HAP, select the desired items by highlighting them.
5.
Select from the command line. The SELECT GROUP
window opens.
-[ SELECT GROUP ]-
FACILITY
EMISSION STREAM
CONTROL DEVICE
HAP POLLUTANTS
6.
Select the GROUP to edit and refer to the section that corresponds to
your desired selection, to continue.
30
-------
Facility Data
Select FACILITY, from the SELECT GROUP window, to enter or edit
data about a facility. The FACILITY DATA window opens.
Company:
Desc.:
Street:
City:
State:
r FAfTI 1TY DATA 1
Contact:
Telephone: ( ) -
Permit: / /
Reviewer:
Zip: - Streams: 0
< Ok >
Enter or edit the appropriate data and press |[i^l Or the fTj key to
advance to the next field. Up to 99 streams can be assigned to a facility,
although this number is more likely to be no more than two or three.
To access the State selection list displayed below, position the cursor in
the State field and press fjj].
ALABAMA
ALASKA
AMERICAN SAMOA
ARIZONA
ARKANSAS
CALIFORNIA
COLORADO
CONNECTICUT
DELAWARE
DISTRICT OF COLUMBIA
FLORIDA
Press the first letter of the state you are seeking and use the [fj or 0
keys to highlight the desired state; or scroll through the states by clicking
and holding down the mouse button on the arrow indicators of the scroll
window (* »). Press ||E"H to accept a selection or press Ifisci to abort.
These procedures work for all scroll windows.
When a selection is made, the state code is automatically entered
(written) into the field.
When all data is entered or edited, select .
31
-------
6. To enter notes about this facility, press 0. The size of the note field is
limited only by the amount of free disk space.
-FACILITY NOTES -- Press Ctrl-W to Save or ESC to Abort-
These are temporary facility notes.
32
-------
Stream Data
To add records start here:
1. Select EMISSION STREAM from the SELECT GROUP window. The
following window opens if you are editing a new stream.
Enter Stream Number: 1
If you are adding data, you need to specify the stream. The default
value is the next available stream that currently does not exist.
If you enter a stream number greater than the number specified in the
streams field of the facility data, you are given an error message and not
allowed to proceed.
Stream Number exceeds defined maximum...Press any key to continue
If you enter a valid stream number, the following window opens.
-[ Select STREAM Type ]-
ORGANIC VAPOR
INORGANIC VAPOR
ORGANIC PARTICULATE
INORGANIC PARTICULATE
Now specify the type of emission stream. The type of stream you
specify now determines which of the control types you have access to
later.
33
-------
To edit records start here:
The following window opens, consisting of the parameters associated
with the stream type specified, here, ORGANIC VAPOR.
r CTDCAU DADAUCTCD
EMISSION STREAM NUMBER = 1
PARAMETER
Stream Type - ORGANIC VAPOR
Maximum Flow Rate (scfm)
Stream Temperature (deg F)
Oxygen Content (%)
Moisture Content (%)
Stream Pressure (mmHg)
Mean Particle Diameter (Ug)
Particulate Content (gr/scf)
S03 Concentration (ESPs only, ppmv)
Drift Velocity (ESPs only, ft/s)
< Ok >
APPLICANT
1
0
77
20.0
0.0
760.0
0.000
0.000
0.000
0.000
DEFAULT VERIFIED
N
77 N
20.0 N
N
760.0 N
N
N
N
N
Note: You can press
calculator.
and fx] together from this screen to get a
Users with color monitors will notice that this table differs in color from
rest of the screen. The data itself is arranged into three columns. The
first column lists the parameter name, the second column lists the
applicant value, and the last column notes whether the value indicated by
the applicant column has been verified or checked. Default values are
supplied for many applicant parameters.
34
-------
Every parameter except the EMISSION STREAM NUMBER can be
edited. To edit parameters other than the stream type, highlight the
desired parameter and press |["HI, or double-click on the parameter
using the mouse. The EDIT STREAM PARAMETER window opens.
-[ EDIT STREAM PARAMETER ]-
PARAMETER: Maximum Flow Rate (scfm)
Applicant Value:
Default Value:
Verified: N
< Ok >
- Press for Help-
Enter the value of the parameter to the greatest known degree of
accuracy or to the greatest level of accuracy the field permits. Be sure
to express all values in the units specified. Use the Verified field to
record whether you are confident that applicant value is correct.
If you are not sure what value to enter, press 0 for help. The textual
information defines the parameter, states the formula used to derive it (if
any). This help is not available for every parameter.
-Press ESC to Exit or I J to Scroll Text-
Maximum Flow Rate (scfm)
The value to be input is the maximum value of the emission stream flowrate
in standard cubic feet per minute (scfm). If the emission stream happens
to be in actual cubic feet per minute (acfm), the following formula can be
used to convert acfm to scfm:
Qe = Qe,a [537/Te + 460]
Where: Qe = Maximum emission stream flowrate, scfm.
Qe,a = Maximum emission stream flowrate, acfm.
Te = Temperature of emission stream, of.
Example: Qe,a = 20,000 acfm.
Te = 120 op
35
-------
7. To scroll through a lengthy help note use the cursor and IIpawl or ||>SDNJ
keys. To exit from the help file, press If ESC I.
A pop-up selection list may also be available for the applicant value. To
view this list, move the cursor to the APPLICANT value field and press
8. When the data has been entered, select from the EDIT STREAM
PARAMETER window to return to the STREAM PARAMETER
SELECTION LIST window. You will note that the APPLICANT and
VERIFIED columns now reflect the newly entered values. Continue this
process until all data is entered or edited.
9. To exit from the stream parameter table, select .
36
-------
Control Device
To add records start here:
1. Select CONTROL DEVICE from the SELECT GROUP window. You
are prompted to specify the control device.
— [ Select Control Device ]—|
THERMAL INCINERATOR
CATALYTIC INCINERATOR
FLARE
CARBON ADSORBER
PACKED COLUMN SCRUBBER
CONDENSER
FABRIC FILTERS
VENTURI SCRUBBERS
ESP
The list of control types from which you may choose is determined by
the emission stream type specified earlier, as not every control
technology is appropriate for use with each emission stream type.
To edit records start here:
2. The DEVICE TYPE cannot be edited. If you attempt to edit a line that
cannot be edited, a warning is given. The parameters for the control
device are entered using the same methods as described for data entry
into the emission stream table.
37
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The data is organized into four columns under two different groups:
DESIGN RELATED PARAMETERS and COST RELATED
PARAMETERS. DEFAULT values are provided for many parameters
when you initially add the device.
DEVICE TYPE = THERMAL INCINERATOR
LIST
PARAMETER APPLICANT
DESIGN RELATED PARAMETERS
Desired Destruction Efficiency (%)
Combustion Temp (deg F)
Residence Time (sec)
Heat Exchanger Efficiency (%)
Reference Temp (deg F)
Heat cap. of Air at Comb Temp (Btu/lb F)
COST RELATED PARAMETERS
Site Preparation Cost ($)
Bui Iding Cost ($)
98
1400
0.75
70
77
0.254
DEFAULT
98
1400
0.75
70
77
0.254
VERIFIED
A
N 0
N
N
N
N
N
N
N V
< Ok >
Note: You can press ICTRLJ and fx) together from this screen to get a
calculator.
To edit a DESIGN RELATED PARAMETER, highlight the desired
parameter and press l™™\, or double-click on the parameter using the
mouse. The EDIT CONTROL DEVICE PARAMETER window opens.
r Fh T T rnwTpni HFVTPF PAPAMFTFR i
PARAMETER: Desired Destruction Efficiency (%)
Applicant Value: 98.0
Default Value: 98.00
Verified: N
< Ok >
Enter data to the greatest degree of accuracy known. Most design
parameters permit the decimal point to float from -1 to -7; exceptions are
percentages and those that require whole numbers. Be sure to express all
values in the units indicated.
38
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5. Select to exit from the edit window and return to the CONTROL
DEVICE PARAMETER SELECTION LIST window. Notice that the
columns reflect the newly entered values. Continue this process until
data is entered for all of the DESIGN RELATED PARAMETERS and
COST RELATED PARAMETERS.
6. When all of the data has been entered or edited, select on this
window and again on the CONTROL DEVICE PARAMETER
SELECTION LIST window to exit and save the control device data.
39
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HAP Pollutants
To add records start here:
1. Select HAP POLLUTANTS from the SELECT GROUP window. The
SELECT HAP SELECTION METHOD window opens.
Pollutant List
i—[ SELECT HAP SELECTION METHOD ]—,
POLLUTANT LIST
SIC CATEGORY
Specify the method to use to enter the pollutants in the designated
stream. Refer to the appropriate section, to continue.
If you choose POLLUTANT LIST, the first option, the pollutants from
which you will choose are presented by one of two alphabetical lists, one
for organic pollutants and another for inorganic pollutants.
-t ORGANIC HAPS ]-
ACENAPHTHENE
ACENAPHTHYLENE
ACETALDEHYOE
ACETALDEHYDE
ACETIC ACID
ACETIC ANHYDRIDE
ACETONE
ACETONITRILE
ACETYLENE
ACETYLSALICYLIC ACID
ACROLEIN
Select the pollutant(s) that are potentially present in this emission stream.
The first letter of each pollutant is hot-keyed, press the letter to position
the scroll bar on the first pollutant listed for that letter. For example,
pressing T and 0 will move the scroll bar to TOLUENE. Notice that
only the organic pollutants are listed in this example, since the emission
stream was defined as an organic vapor stream.
40
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SIC Category
An alternate method of entering HAPs is to select SIC CATEGORY.
The following list appears.
-C SIC CATEGORIES ]-
ABRASIVE PRODUCTS *
ACCOUNTING, AUDITING, & BOOKKEEPING •
ADHESIVES AND SEALANTS
ADVERTISING, NEC
AGRICULTURAL CHEMICALS
AGRICULTURAL CHEMICALS
AGRICULTURAL CHEMICALS, NEC
AIR AND GAS COMPRESSORS
AIR, WATER & SOLID WASTE MANAGEMENT
AIRCRAFT
AIRCRAFT AND PARTS
Select the appropriate category. The first character of each category is
hot-keyed to enable you to move quickly through the categories.
A list of pollutants is supplied for the selected SIC category. Select the
pollutants present in your stream.
-[SIC ASSOCIATED ORGANIC HAPS ]-
ACETONE
BUTYL ALCOHOL
CRESOL.O-
CURENE
METHOXYETHANOL.2-
NAPHTHALENE
TOLUENE
TOLUENE,24,D11SOCYANATE
TRICHLOROETHANE,1,1,1 -
The pollutant data is arranged as shown in the next figure.
41
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To edit records start here:
8.
9.
T HAP PAPAHFTFP
POLLUTANT = ACETALDEHYDE
PARAMETER
Inlet HAP Concentration (ppmv)
Molecular Weight (Ib/lb mole)
Specific Gravity
Boiling Point (deg R)
Refractive Index
Heat Vaporization (BTU/lb mole)
Heat of Combustion (BTU/lb mole)
Heat of Condensation (BTU/lb mole)
< Ok >
SELECTION LIST ]
APPLICANT
20.0
23.0
0.00000
0.00
0.00000
0.0
502643.0
0.0
DEFAULT
44.1
0.00000
0.00
0.00000
0.0
502643.0
0.00000
VERIFIED
N
N
N
N
N
N
N
Note: You can press [[CTRL] and [xj together from this screen to get a
calculator.
The pollutant data is arranged into four columns, in the same manner as
the control device table. For most of the common pollutants, the
APPLICANT values are already known, except the concentration.
The HAP parameters are edited in same manner as described for the
stream and control device tables, highlight the desired parameter and
press |[ENTEB| , or double-click on the parameter using the mouse, to access
the edit window.
-C EDIT HAP PARAMETER ]-
PARAMETER: Inlet HAP Concentration (ppmv or %)
Applicant Value:
Default Value:
Verified: N
0.0
< Ok >
- Press for Help—
For most pollutants, you only need to enter the Concentration of the
pollutant in the emission stream.
42
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10. Enter or edit the HAP parameters as desired. Continue the process until
all have been entered for this stream. Virtually an unlimited number of
pollutants can be assigned to a stream.
Note: For the Carbon Adsorbers, HAP-PRO calculates a pollutant-
specific adsorptive capacity using the boiling point and the index of
refraction of a specific compound. Consequently, combinations of
pollutants can no longer be analyzed. The user should therefore base the
analysis on the dominant pollutant, or the pollutant with the lowest
adsorptive capacity. Minimum adsorptive capacity can be determined by
running HAP-PRO for each pollutant.
11. Save the parameters by selecting . HAP-PRO updates the screen
to reflect the newly added HAPs. Additional streams may be entered by
using the command and selecting STREAM.
43
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Reports
Generating a Report
HAP-PRO generates the following two reports. Both reports are options on the
Main Menu.
Select. . . To . . .
B) List Facilities by Stream Type Generate a report listing all facilities that
have a specified stream type (organic or
inorganic vapors and participates)
C) List Facilities by Pollutant Generate a report listing all facilities that
have a specified pollutant.
The length of time it takes to generate a report will .vary with the speed of the
computer itself and the number of records in the system.
The following sections provide step-by-step instructions on how to generate
each report.
44
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List Facilities by Stream Type
1.
5.
Select B) List Facilities by Stream Type from the Main Menu. The
following window opens.
-[ Select STREAM Type ]-
ORGANIC VAPOR
INORGANIC VAPOR
ORGANIC PARTICULATE
INORGANIC PARTICULATE
2. Select the desired STREAM TYPE. The following window opens.
-[ Select Destination ]-
SCREEN
PRINTER
ASCII FILE
3. Choose a destination for your report.
4. If a report is sent to an ASCII File, HAP-PRO prompts you to enter the
filename.
Receiving Drive:
A
B
C
D
Filename: FILEOUT.DOC
Enter the drive and filename and press |ENTER| to continue. The file is
automatically written into the current (default) subdirectory (for
example, \HAP-PRO).
If the report is sent to the screen, a report appears. The system returns
to the Main Menu when the «Done» option is selected.
6. For a hardcopy report, select Printer.
45
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List Facilities by Pollutant
1. Choose selection C) List Facilities by Pollutant from the Main Menu.
The following window opens.
— Select Pollutant Type —|
ORGANIC
INORGANIC
Select the type of pollutant. The pollutant selection list opens.
-[ ORGANIC HAPS ]-
ACENAPHTHENE
ACENAPHTHYLENE
ACETALDEHYDE
ACETALDEHYDE
ACETIC ACID
ACETIC ANHYDRIDE
ACCTONE
Use the 0, Q, FSDNJ, or FOUR] keys to move the cursor or press the
keys corresponding to the first characters of the pollutant you are
seeking. When the desired pollutant is highlighted, here ACETONE,
press [[ENTER] to select it. The window shown is opened.
-[ Select Destination ]-
SCREEN
PRINTER
ASCII FILE
Choose a destination for your report.
46
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5. For an ASCII File output, another window requests the receiving drive
and filename.
Receiving Drive:
A
B
C
D
Filename: FILEOUT.DOC
Enter the drive and filename for the ASCII file and press iN^I to
execute. The file is automatically written into the current (default)
subdirectory (for example, \HAP-PRO).
Creating File C:\FILEOUT.DOC
6. If the report is sent to the screen, a report like this one appears.
Printed 10/31/94
at 14:39:02
Facility
CCM Example
FACILITIES WITH THE FOLLOWING POLLUTANT
ACETONE
No. Cone.
Page
004
011
375000.0
20000.0
« Done » < More > Column: 0
The system returns to the Main Menu when the «Done» command is
selected.
7. For a hardcopy report, select Printer.
47
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Appendix A - Costing Methodology
The following is a discussion of the methodology used to develop costs for
controlling emissions of hazardous air pollutants or HAPs. The approach and
cost data are those used in the EPA Manual, OAQPS Control Cost Manual,
EPA 450/3-90-006,a,b,c (four volumes). The possible control devices include
thermal incinerators, catalytic incinerators, flares, carbon adsorbers, packed
column scrubbers, condensers, fabric filters, venturi scrubbers, and ESPs. All
of the default costs in HAP-PRO are based on 1988 dollars.
Total Capital Investment
The total capital investment can be broken down into the direct and indirect
costs shown below:
Direct Capital Costs:
Control Device
Auxiliary Equipment
Instrumentation and Controls
Taxes
Freight Charges
Direct Installation Costs:
Site Preparation
Foundation and Supports
Erection and Handling
Electrical
Piping
Insulation
Painting
Indirect Capital Costs:
Engineering and Supervision
Construction and Field Expenses
Construction Fee
Start-up
Performance Test
Model Study
48
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Annual Operating Costs
The annual operating costs are also broken down into direct and indirect costs:
Direct Operating Costs:
Utilities
Natural Gas
Electricity
Steam
Water
Operating Labor and Maintenance
Operating Labor
Supervisory Labor
Maintenance Labor
Maintenance Materials
Replacement Parts
Replacement Labor
Indirect Operating Costs:
Overhead
Property Tax
Insurance
Administrative
Capital Recovery
Summing the direct and indirect operating costs yields the total annualized
operating cost. The net annualized cost is determined by subtracting the solvent
recovery credit, where it applies.
49
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TECHNICAL REPORT DATA
(Please read Instructions on reverse before completing)
1 REPORT NO
EPA-456/B-94-002
2.
4. TITLE AND SUBTITLE
HAP-PRO User's Manual Version 2.0
7. AUTHOR(S)
Joseph E. Steigerwald
9 PERFORMING ORGANIZATION NAME AND ADDRESS
U.S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Information and Program Integration Division
Information Transfer Group, MD-12
Research Triangle Park, NC 27711
12. SPONSORING AGENCY NAME AND ADDRESS
Information Transfer Group, MD-12
Information and Program Integration Division
Office of Air Quality Planning and Standards
Office of Air and Radiation
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
3. RECIPIENT'S ACCESSION NO
5. REPORT DATE
December, 1994
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO
10 PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO
68-D1-0116
13 TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY
EPA/200/04
CODE
15 SUPPLEMENTARY NOTES
16 ABSTRACT
The primary purpose of the Hazardous Air Pollutant Program (HAP-PRO) is to assist permit engineers
in reviewing applications for control of air toxics. HAP-PRO calculates the capital and annual costs for
up to six different volatile organic compounds (VOCs) and three particulate control devices, including
selected engineering parameters. Calculations used by the program mirror those presented in the EPA
Handbook, Control Technologies for Hazardous Air Toxics (June 1991)(EPA-625/6-91/014) and the
EPA's Control Cost Manual (March 1990)(EPA-450/3-90/006).
This document replaces the document HAP-PRO User's Manual Version 1.2 (EPA-453/B-94-038).
17
KEY WORDS AND DOCUMENT ANALYSIS
a DESCRIPTORS
Hazardous Air Pollutants
Control Technology Center
Air Pollution Control Equipment Design
18. DISTRIBUTION STATEMENT
Release Unlimited. Available
5285 Port Royal Road,
Springfield, Virginia 22161
from NTIS,
b. IDENTIFIERS/OPEN ENDED TERMS
Air Pollution control
19. SECURITY CLASS (Report)
Unclassified
20. SECURITY CLASS (Page)
Unclassified
c. COSATI Field/Group
21. NO. OF PAGES
22 PRICE
EPA Form 2220-1 (Rev. 4-77) PREVIOUS EDITION IS OBSOLETE
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