Unitad States
Environmental Protection
Agency
 Office of Air Quality
 Planning and Standards
 Reeearch Triangle Park NC 27711
EPA-463/B-94-O38
May 1994
Air
HAP-PRO MODEL USER'S  MANUAL
Version 1 .2
control
technology center

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'JO
  I
                                                        HAP-PRO

                                                    USER'S MANUAL

                                                       Version 1.2
                                                           By

                                            Pacific Environmental Services, Inc.
                                               5001 South Miami Boulevard
                                            Research Triangle  Park, NC  27709

                                                EPA Contract 68-D1-0116
                                              Work Assignments 11-1 and 11-11
                                                                                        EPA 453/B-94-038
                                                   Joseph Steigerwald
                                        Office of Air Quality Planning and Standards
                                                                      Region 5, >. ic
                                                                      77 West Jackw
                                                                      (Chicago, it
                                                      Prepared for.
                                              EPA Control Technology Center
                                            Research Triangle Park, NC 27711

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                                            PREFACE
TRADEMARKS

FoxPro is trademark of Fox Software, Inc., Perrysburg, OH.
dBase III Plus and dBase IV are trademarks of Ashton-Tate, Inc., Culver City, CA.
MS-DOS is a trademark of Microsoft Corporation, Bellevue, WA.


PURPOSE

    The primary purpose of the Hazardous Air Pollutant Program (HAP-PRO) is to assist permit engineers
in reviewing applications for control of air toxics by calculating the capital and annual costs for up to six
different volatile organic  compound  (VOC) 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). A secondary purpose of HAP-
PRO is to generate reports that list all facilities containing 1) a specified pollutant in their emission stream(s)
or 2) a specified type of emission stream (e.g., organic or inorganic vapors and particulates).

       Version 1.2 includes the addition of an expert review system for the design of thermal incinerators,
catalytic incinerators, and carbon adsorber systems.  The program will review the design results generated,
make recommendations for changes, and allow for design sensitivities to be easily evaluated.


TECHNICAL NOTE

    HAP-PRO was developed using FoxPro version 2.0, a Relational Database Management System developed
by Fox Software of Perrysburg, OH. The installation program was developed using Install 2.3 from Knowledge
Dynamics  Corporation of Canyon Lake, TX.

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                                   TABLE OF CONTENTS

                                                                                       Page

PREFACE	ii

FIGURES	   iv

CHAPTER 1: INTRODUCTION
  Hardware Requirements  	  1-1
  System Files 	  1-2
  Database Files	  1-2

CHAPTER 2: SYSTEM OVERVIEW
  Logging On	  2-1
  Main Menu	  2-1
  Data Screens	  2-3
  Commands  	  2-5
  System Help 	  2-6
  System Maintenance 	  2-7
  Expert Review  System	  2-8
  Calculating Results 	2-12

CHAPTERS: DATA ENTRY TUTORIAL
  Adding Records	  3-1

CHAPTER 4: REPORTS
  Generating a Report	  4-1
              Report B - List Sources by Stream Type	  4-2
              Report C - List Sources by Pollutants	  4-5

APPENDIX A
  Data Dictionary	A-l
              Update Stamp	A-l
              Facility Data	A-l
              Thermal Incinerator 	A-2
              Catalytic Incinerator	A-4
              Flare	A-6
              Carbon Adsorber  	A-8
              Packed Column Scrubber (Stripper)  	  A-10
              Condenser   	  A-13
              Fabric Filters  	  A-15
              Venturi Scrubber  	  A-17
              ESP (Electrostatic Precipitator)  	  A-19

APPENDIX B
  Costing Methodology	 8-1

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                                         FIGURES








Figure No.            Title



       1       Welcome screen	2-2




       2      Main menu	2-2



       3      Source data screens  	2-4




       4      Plant notes	2-4



       5      Help screen  	2-6




       6      Typical Carbon Adsorber Vessel Dimensions	2-9



       7      Thermal Incinerator Operating Ranges  	2-10



       8      Catalytic Incinerator Operating Ranges	2-11
                                            iV

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                                        CHAPTER 1
                                     INTRODUCTION
       Installation of HAP-PRO is accomplished by inserting the distribution disk into the disk drive
of your computer and typing X:install, where X is the drive letter of your disk drive, for most users
this will be Drive A.  At this point, the opening screen illustrated below will appear. Press any key
to continue onto the next screen and follow the instructions.  To accept the default installation
parameters, continue to press ENTER until installation is complete.

       With the release of Version 1.2, the user has the option of either 1) installing HAP-PRO for
the first time, or 2) updating a previously installed version of HAP-PRO. Separate disks are provided
depending on the installation option  preferred.  For first time installations,  insert  disk  1, type
INSTALL, and follow the instructions displayed.  For those users who  wish  to retain previously
entered data, insert disk 2 and type INSTALL. The new version of HAP-PRO will be installed with
conversion of existing files.  Any new input parameters added by the new version will initialize at
their default values.  Consult Appendix A to review the new parameters.
                   INSTALL HAP-PRO
                    Developed for:
                    U.S. EPA
                    Control Technology Center
                    Research Triangle Park, NC 27711
                   Developed by:
                   Pacific Environmental Services, Inc.
                   P. 0. Box 12077
                   Research Triangle Park, NC 27709
      I  Press any key to continue ... I
HARDWARE REQUIREMENTS

      ~ IBM PC/XT/AT or compatible
      ~ 515K minimum free RAM
      - minimum of 3 megabytes of free hard disk storage space for installation
      - Monochrome or CGA/EGA/VGA color monitor
      - MS-DOS version 3.1 or greater
      - Hard disk required
                                            1-1

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SYSTEM FILES

      File Name            Purpose

      HAP-PRO.EXE        Compiled Program Code
      FOXPRO.ESO        FoxPro Runtime Module
      FOXPRO.ESL        FoxPro Runtime Module

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DATABASE FILES

      File Name          Purpose

      CONTROL.DBF      Data File for ALL CONTROL TYPES
      HAP.DBF          Data File for HAPS
      MEMO.DBF         Temporary Work File for PLANT NOTES
      MEMO.FPT         Temporary Work File for PLANT NOTES
      PLANT.DBF         Data File for FACILITY
      PLANT.FPT         Memo File for PLANT NOTES
      STREAM.DBF       Data File for STREAM PARAMETERS
                                      1  ^
                                      1-0

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                                       CHAPTER 2
                                   SYSTEM OVERVIEW
LOGGING ON
   The Welcome Screen is the first screen that appears to the user after the initial logon.  This
screen informs the reader as to the program's purpose and where help can be obtained if you have
difficulty in using this program (see Figure 3). Use the cursor and PgUp/PgDn keys to read the entire
screen.  Pressing ENTER will allow you to bypass or exit this menu.  Immediately following this
screen users are required to input their initials.  This information is used to stamp any records that
are modified.
MAIN MENU

   The Main Menu appears immediately after the Welcome Screen.  It provides access to the data
input screens, as well as the report and database  maintenance functions (see Figure 4).  Choose a
selection by entering either its corresponding letter (e.g. A, B,  C) or by highlighting the desired
selection with the up and down cursor movement  keys and pressing ENTER.  The message line at
the bottom of the screen briefly explains what each selection does.  For example, the corresponding
message for Selection A is Use this selection to Add, Edit, Calculate Results, etc. If a selection has
been made by mistake, press the ESC (escape) key to return to  the Main Menu.  The purpose of
each selection on the Main Menu is briefly described below:
  Selection

  ENTER/VIEWDATA

  LIST SOURCES BY
  STREAM TYPE

  LIST SOURCES BY
  POLLUTANT

  REBUILD ALL INDEXES

  REMOVE RECORDS
  MARKED FOR DELETION

  QUIT
Purpose
      Provides access to data about each permit.

      Generates a report listing all permits that have a specified
      stream type (organic or inorganic vapors andparticulates)

      Generates a report listing all permits that have a
      specified pollutant (ammonia, benzene, toluene, etc.)

      Rebuilds all indexes from scratch.

      Permanently removes all records marked for deletion.


      Quits this system.

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                   FIGURE 1. Welcome Screen

                  	WELCOME  [Read Only]	

                                HAP-PRO

                               Version 1.2
                           Joseph Steigerwald
                       Control Technology Center
                   U.S. Environmental Protection Agency

                              Developed by
                      PES Systems Development Group
                             PO Box 12077
                     Research Triangle Park, NC  27709
                            (919) 941-0333
The primary purpose of  this program is to assist permit engineers  in the
review of applications  for control of air toxics by calculating  capital
and yearly operating costs for a specified emissions control  device.
Calculations used by this program mirror those presented in the  EPA
Handbook, Control Technologies for Hazardous Air Pollutants (June  1991),
        Use T I  PgUp PgDn to Move Cursor or ENTER to Continue
                      FIGURE 2. Main Screen
                        HAP-PRO Version 1.2







::*;.'•$ '.% lift liiirvfi-feB-: (JAT&
B LIST SOURCES BY STREAM TYPE
C LIST SOURCES BY POLLUTANT
D REBUILD ALL INDEXES
E REMOVE RECORDS MARKED FOR DELETION
f QUIT






     Use T  and I  to move cursor -- Press ENTER to Make Selection
       Use  this selection to ADD, EDIT, CALCULATE results,  etc.

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DATA SCREENS

    The source data screens (see Figure 5) are accessed through selection A on the Main Menu.  The permit
records are sorted in alphabetical order by name of the facility and are organized into five groups.  Each group
is described and listed below.

        Group                 Description

       Facility                Name, address, and principal activity of the facility, as well
                               as the reviewer's name and the number of emission streams.

       Emission Stream        Stream type, flow rate, heat content, etc. of the specified emission
                               stream, e.g. stream no. 1.  A multiple number of streams can be
                               assigned to each facility.

        Control Device          Control device assigned to an emission  stream. Details design and
                               cost parameters.  Onfy one control device can be assigned to any
                               one emission stream.

       Hazardous Air          Pollutants or HAPs in a given emission stream, including concentration
       Pollutants              and other parameters.  Multiple pollutants may be assigned to any
                               stream.

       Plant Notes             Miscellaneous notes about a facility or permit (see Figure 6).

In order to view or edit the parameters associated with each group, the user must either select the appropriate
group with the Edit command or use the Calc command to view or print  the parameters from each group that
are associated with a specified emission stream, assuming that all data needed to perform the calculations have
been entered.

   The data that comprise the emission stream, control device, and HAPs can be thought of as three separate
tables, which are organized in a like manner consisting of three to four  columns.  Each column is listed and
described below.  Chapter 3 provides further detail on data entry.

       Column                Function

       Parameter Name        Identifies the parameter displayed.  Unit of measure is enclosed by
                               parentheses.

       Applicant               Displays the value input by the user.  Initially defaults to the value
                               recorded in the third column (if any). The Applicant values are used
                               to calculate capital and operating costs.

       Default                 Displays the default value for the given parameter, if any.   This value cannot
                               be  edited.

       Verified                 Records whether the user is confident that the applicant value is
                               correct.  May also be used to note whether the figures have been
                               double-checked.
                                                2-3

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                      FIGURE 3.  Source Data Screens
Last Updated by GMP  on 06/15/93
                                                           F5 * Plant  Notes
Company: ABC Chemical
Description: Chemical Mfg.
Street: Isaac Newton Ave.
City: Research Triangle Park
State: NC Zip: 27709-
Plant Contact: John Jones
Telephone: (919>999-1919
Permit Date: 10/01/90
Reviewer: Pagett
Streams: 2
 Ff
      ISSION STREAM-
|Stream Deleted? Stream Type
    1      N     ORGANIC VAPOR
    2      N     ORGANIC VAPOR
                     UNDEFINED
                     UNDEFINED
-CONTROL DEVICE	
 Deleted? Control Device
    N     THERMAL INCINERATOR
    N     CARBON ADSORBER
HA7APnrU !
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COMMANDS

   At the bottom of the data screen is the command line (See Figure 5).  Any command can be
executed by highlighting the desired command (using either the cursor or  the mouse) and pressing
ENTER or by entering the first letter of the command.  If an incorrect selection is made, press ESC
(escape) to return the cursor to the command line. The Find command is highlighted by default. The
purpose of each command briefly described below.

   Command Purpose

   Find       Searches for a facility by its name. Once the scroll box is displayed, use the arrow
              keys, PgUp, and PgDn to move to the desired record or enter the first character of
              the facility.  To move to the facility currently highlighted press ENTER or press
              ESC to abort.

   Edit       Changes field attributes of previously entered data; the user must first specify which
              data group is to be edited (e.g. Facility, Stream, Control Device, or HAPs). Press F1 to
              obtain help on data entry or to access lookup tables. To edit/view the contents of the
              note field, however, press function key F5; hence, the Edit command is irrelevant for
              plant notes.

   Add       Creates a new record not previously entered into the system.

   Delete     Marks the currently displayed record  for deletion, including the note field.
              Records are not permanently deleted  until the database is packed, an option on  the
              Main Menu. Until then,  these records can be undeleted using the Undelete
              command.  Records marked for deletion display the flashing message "This Record
              is Marked for Deletion".

   Undelete   Undeletes the currently displayed record, including plant notes.

   Next       Skips to the next record in the database.

   Last       Skips to the previous record in the database.
   Calc       Calculates for both capital and operating costs for the selected emission
              stream. Input parameters are optionally included.

   Return     Exits to the Main Menu.
                                            2o

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SYSTEM HELP

    Help is available for many of the data fields through the use of pop-up lookup tables or text-based
notes.  For the lookup tables, simply page up or down to find the desired selection and then press
ENTER.  If no selections are desired, press ESC.  Several examples of lookup tables  are found  in
Chapter 3.  For textual help, select the field to be edited and press  F1. If help is not available for a
particular field, the system will respond that no help is available. Figure 7 below illustrates one example
of textual help.

                                      FIGURE 5.  Help Screen
             Last Updated by GMP  on 06/15/93
F5 = Plant Notes
Company: ABC Chemical
Description: Chemical Mfg.
Street: Isaac Newton Ave.
City: Research Triangle Park
State: NC Zip: 27709-
Plant Contact: John Jones
Telephone: (919)5)99-1919
Permit Date: 10/01/90
Reviewer: Pagetl:
Streams: 2
              I- STREAM Parameters                  Applicant     Verified             —
            r;	MAXIMUM FLOW RATE (SCFM) -- Press ESC to exit or T and 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.

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SYSTEM MAINTENANCE

       Selections D and E on the Main Menu are used to maintain the database by 1) rebuilding all
indexes from scratch, except for the conditional indexes associated with each report, and 2) purging
the database of all records that have been marked for deletion. A third important database maintenance
function is  not  built  into this  system at the present time -  system  backups.   It  is therefore
recommended that the DOS backup utility or some other utility be used to periodically back up all files,
or at least the data files (*.dbf, *.fpt). If the DOS backup utility is used, type in the following command
at the DOS prompt, assuming that this system is installed on drive C and  drive A  is where you wish
to backup the data.  Also be sure that the system path permits access to the backup command when
this command is issued.

To backup, use the following command.

                                  backup c:\fiap-prol *. * a:

To restore the data, use the following command.

                                  restore a: c:\hap-pro\ *. *

If HAP-PRO is  installed on  some other drive or subdirectory,  be sure to replace  c:\hap-pro as
appropriate.
                                            2-7

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EXPERT REVIEW SYSTEM

       Version 1.2 includes the addition of an expert review system to evaluate the results of carbon
adsorber designs as well as thermal and catalytic incinerators. HAP-PRO will review the design results
calculated for each of these systems and  provide recommendations for changes so that the design
results fall within reasonable boundaries. A spreadsheet-like window is made available to the user so
that different design scenarios can be evaluated interactively. An example calculation utilizing the new
expert review system for a carbon adsorber design is depicted in the CALCULATING RESULTS section
beginning on page 2-12.  The following three sub-sections describe the parameters that each control
system evaluates to confirm that a reasonably designed system has been obtained.

       Carbon Adsorber

       For carbon adsorbers, the program compares the calculated vessel dimensions with those found
in Figure 6. If the  calculated results do not fall within these boundaries, HAP-PRO recommends that
one or a combination of program inputs be changed.  If the final design is reasonable, HAP-PRO will
make no recommendations for design  changes. 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 will also now perform calculations  and
evaluate designs for both vertical and horizontal vessels.

       Thermal  Incinerator

       For thermal incinerators, Figure 7 depicts the relationship that HAP-PRO seeks to obtain for the
destruction efficiency, residence time, and combustion temperature.  If these three parameters fall
within the boundaries set by Figure 7, HAP-PRO assumes that the design is reasonable.  The family of
curves shown  are not  for  any  particular  pollutant,  but are  used  by  the program  to  place
"reasonableness" borders on the three variables (destruction efficiency, combustion temperature,  and
residence time).  Ideally, the user will have a curve such as the one in Figure  7 for the pollutant being
controlled to confirm that the design values selected are consistent with thermal incinerator laboratory
test data.

       Catalytic Incinerator

       For catalytic incinerators. Figure 8  depicts the relationship that HAP-PRO seeks to obtain for
the destruction efficiency and oxidation temperature. As with the thermal incinerator relationship, the
curve shown is not for any particular pollutant, but is used by the program to place "reasonableness"
borders on the two design variables, destruction efficiency and oxidation temperature. 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.  HAP-PRO  uses the  curve in Figure  8 as a minimum requirement in  the absence of
pollutant and catalyst-specific data.
                                             2-8

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                Height <- 30 feet
      Vertical
     Adsorber
FIGURE 6. Typical Carbon Adsorber Vessel Dimensions
                    2-9

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     100
                      lucoid
     10
f

 *

o


E

K


5
O
     20
                          INCREASING RESIDENCE TIME
      too
1000
1201         1400



      TEMPERATURE, °F
1680
1800
2000
             FIGURE 7. Thermal Incinerator Operating Ranges
                                   2-10

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in
20
                         400
     601
TEWEflATUJJE/F
100
1000
1200
          FIGURE 8. Catalytic Incinerator Operating Ranges
                                2-11

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CALCULATING RESULTS

       HAP-PRO provides the user with calculated 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 meant to be definitive, rather they are to be used as a
"ball park" reference to which the applicant's design is compared.

       Design results are calculated by executing the steps outlined in the next 9 pages.  The
example is the design of a carbon adsorber system, which is one of 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 will review the design
results generated, make recommendations for changes, and allow for design sensitivities to be
evaluated  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 design changes at the present time, plans are to create
this option for all systems that HAP-PRO is designed to evaluate.

       The following depicts the steps  required to calculate results for the three systems that utilize
HAP-PRO's expert analysis.  Control device design calculations for the six systems where HAP-PRO
does not provide expert analysis are executed by following steps 1 through  7, then steps 13
through 18. Steps 8 through 12 are applicable only for those systems that have expert review
capabilities.

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 /. Select ENTER/VIEW DA TA off of the Main Menu.
                                           HAP-PRO Version 1.2


: A mj&wm win. -
B LIST SOURCES BY STREAM TYPE
C LIST SOURCES BY POLLUTANT
D REBUILD ALL INDEXES
E REMOVE RECORDS MARKED FOR DELETION
F EXIT TO DOS


                       Use T and I to move cursor -- Press ENTER to Make Selection
2 Select the Calc command from the menu at the bottom of the screen.
              Last  Updated by GMP on 06/15/93
                      F5 = Plant Notes
                  -FACILITY-
                     Company: ABC Chemical
                 Description: Chemical Mfg.
                     Street: Isaac Newton Ave.
                       City: Research Triangle  Park
                      State: NC        Zip: 27709-
    Plant Contact: John Jones
        Telephone: (919)999-1919
      Permit  Date: 10/01/90
         Reviewer: Pagett
          Streams:   2
               	EMISSION STREAM-
                Stream Deleted? Stream Type
                   1      N     ORGANIC VAPOR
                   2      N     ORGANIC VAPOR
                               UNDEFINED
                               UNDEFINED
-CONTROL DEVICE	
 Deleted? Control Device
    N     THERMAL INCINERATOR
    N     CARBON ADSORBER
          UNDEFINED
          UNDEFINED
Stream Deleted? Pollutant
1 N TOLUENE
1 N BEN2ENE
2 N TOLUENE
2 N BENZENE
UNDEFINED
Cone (pptnv or %)
1000.0
500.0
1000.0
500.0

                           Calculates Cost  for a Specified Stream of this  Plant
                       FIND  EDIT  ADO  DELETE  UNDELETE  NEXT  LAST  CALC  RETURN
                                                  2-13

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3. Select the stream for which the calculations will be performed.


               Last Updated by GMP on 06/15/93
                                                F5 > Plant Notes
                   -FACILITY-
                     Company: ABC Chemical
                 Description: Chemical Mfg.
                      Street: Isaac Newton Ave.
                        City: Research Triangle Park
                       State: NC        Zip: 27709-
                             Plant Contact: John Jones
                                 Telephone: (919)999-1919
                               Permit Date: 10/01/90
                                  Reviewer: Pagett
                                   Streams:   2
Stream Deleted? Stream Type
1 N ORGANIC VAPOR
* * -mtttw*
Deleted? Control Device
N THERMAL INCINERATOR
'*' *ttftftgtttt«ttl*f
Stream Deleted? Pollutant
1 N TOLUENE
1
2
2

N
N
N

BENZENE
TOLUENE
BENZENE
UNDEFINED
Cone (ppmv or X)
1000.0
500.0
1000.0
500.0

                                       Select Stream for CALCULATION
                                        ESC * Exit    ENTER = Select
4. Select the pollutant for which the calculations will be performed. (If only one pollutant has been input, this
screen will not appear.)
              Last Updated by GMP on 06/15/93
                                                F5 = Plant Notes
                   -FACILITY-
                     Company: ABC Chemical
                 Description: Chemical Mfg.
                      Street: Isaac Newton Ave.
                        City: Research Triangle Park
                       State: NC        Zip: 27709-
                             Plant Contact: John Jones
                                 Telephone: (919)5*99-1919
                                            10/01/90
Permit Date:
   Reviewer:
    Streams:
                                            Pagett
                                              2
                	EMISSION STREAM-
                Stream Deleted? Stream Type
                         -CONTROL DEVICE	
                          Deleted? Control  Device
                   1
                                ORGANIC VAPOR
                                                               CARBON ADSORBER
                I	HAZAR
                Stream D
                   1
                   1
SOO'.'O'ppmv'"-"BENZENE
                       (ppmv or X)
                       0
                                BENZENE
                                UNDEFINED
                                UNDEFINED
                                UNDEFINED
                                                  500.0
                                          Select HAP for Analysis
                                        ESC = Exit    ENTER = Select
                                                    2-14

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5. As the results are being calculated, 'Calculating" will be displayed.
Last Updated by GMP on 06/15/93
    -FACILITY	
                                                                           F5 = Plant  Notes
                     Company:  ABC Chemical
                 Description:  Chemical  Mfg.
                      Street:  Isaac Newton Ave.
                        City:  Research  Triangle Park
                       State:  NC        Zip: 27709-
                                          Plant Contact:  John
                                              Telephone:  (919
               Calculating
                                            Permit Date:  10/01/90
                                               Reviewer:  Pagett
                                                Streams:    2
                	EMISSION
                Stream Deleted? Stream Type
                                      -CONTROL
                                       Deleted? Control  Device
                   1
                  ORGANIC VAPOR
CARBON ADSORBER
                	HAZARDOUS AIR POLLUTANTS-
                Stream Deleted? Pollutant
                   1      N     TOLUENE
                   1      N     BENZENE
                                UNDEFINED
                                UNDEFINED
                                UNDEFINED
                                                              Cone  (ppmv or X)
                                                              1000.0
                                                               500.0
                                       ESC = Exit    ENTER = Select
6, Once complete, the results will be displayed in the report box illustrated below.  Use the arrow keys
to scroll back and forth through the document.
              Last Updated by GMP on 06/15/93
               •	F AC ILIT Y	
               |      Company:  ABC Chemical
                                                             F5 = Plant Notes
                                          Plant Contact:  John  Jones
               C Please Review Calculated Results for Accuracy  ]	
               HAP-PRO Version  1.2
                                                   Date of Print: 06/15/93
               Note:   Parameters marked with a * are not used in calculations; all other
                      parameters must be input to perform calculations accurately.
               PLANT  DATA
                   Plant  ID: 000024
                     Company: ABC Chemical
                 Description: Chemical Mfg.
                     Street: Isaac Newton Ave.
                       City: Research Triangle Park
                      State: NC  Zip: 27709-

               STREAM TYPE -- ORGANIC VAPOR
               DEVICE TYPE -- CARBON ADSORBER
                                          Plant  Contact: John Jones
                                              Telephone: (919)999-1919
                                         Agency  Contact: John Jones
                                            Permit Date: 10/01/90
                                              Reviewer: Pagett
                                                Streams: 002
                           « Print  »   < Review >   <  Help  >   <  Exit  >
                                                  2-15

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7. The output includes intermediate and calculated results as well as the results of the expert review system.
After reviewing the output, push either *P* to PRINT the results, "R' to proceed to the REVIEW section, "ff to
get HELP, or "£" to EXIT the calculation routine. [NOTE:  For the six control systems that do not currently
allow expert review (the "R* option), proceed to Step 13.]
              Last Updated by CMP  on 06/15/93
                  -FACILITY-
                                                      F5 - Plant Notes
               r
Company:  ABC Chemical               Plant Contact:  John Jones
       •[ Please Review Calculated Results for  Accuracy ]	
               EXPERT REVIEW

                    The Length  and diameter calculated were  43.6 feet and  15.9 feet,
               respectively.  The pressure drop calculated was  13.1  inches of water.
               Typical Horizontal carbon adsorber dimensions are lengths  less than 60 feet
               and diameters between 4 and 12 feet.  Pressure drop should be no more than
               15 inches.

                    HAP-PRO recommends that one of the following parameters be changed and
               the design  rerun to generate more reasonable results:
               Input Parameter
                     Current   Recommen-
                      Value    dation
Acceptable Range
               No. of Adsorbing  Beds              6       5            1-10
               Bed Velocity (ft/min)       60.00000       44            < 150  ft/s
               Carbon-to-Vessel  Ratio      .4000000      0.4       0.25 - 0.4  ft3/ft3
                            « Print  »   < Review >
                                   Help
   Exit
8. If'R" is selected, the REVIEW screen appears.  This spreadsheet-like screen allows the user to perform
unlimited sensitivities to develop the most effective carbon adsorber design.  Any of the four input parameters at
the top of the screen may be changed and the design recalculated. The design type can be changed by pressing
the space bar.
Las»l 	
— 1 UPI IT DAD AMPTFPQ
r™" 1 NrU 1 r An/\nc 1 CKd
1 Design Type
— No. of Adsorbing Beds
EX Bed Velocity (ft/min)
Carbon-to-Vessel Ratio
re CALCULATED RESULTS
Ty HAP Density (Ib/ft3)
an Inlet HAP Loading (Ib/hr)
15 Adsorptive Capacity
Carbon Requirement (Ibs)
Vessel Diameter (ft)
th Vessel Length (ft)
Vessel Surface Area (ft2)
Steam Requirement (Ibs/min)
In Pressure Drop (in of water)
System Fan Power (hp)
No Bed Gas Flow Rate (scfm)
Be Total Capital Costs ($)
Ca Direct Annual Costs ($)
Total Annual Costs ($}
Pi IPPWl^ Df*O\/ 1 DPOW 9
l«UI icill r 1 CV 1 r 1 CV £
HORI2TL
6
60.000
0.400

0.235
3,525.000
0.067
732,715.9
15.9
43.5
2,579.4
1,794.4
13.0
880.4
697,824.6
4,496,900
4,889,600
5,547,500
« Recalc » < Save > < Cancel > < Help >
e»





















                                                   2-16

-------
9, Recalculations are performed by editing the input field (or fields) desired and pressing *R" for RECALC, or
by pressing « RECALC » with the mouse or pressing CNTL-ENTER.  The new results are instantly
displayed.  HAP-PRO saves up to two iterations.
LBSl
r- INPUT PARAMETERS
1 Design Type
— No. of Adsorbing Beds
Bed Velocity (ft/min)
Carbon- to- Vessel Ratio
EX CALCULATED RESULTS
HAP Density (Ib/ft3)
Inlet HAP Loading (Ib/hr)
re Absorptive Capacity
Ty Carbon Requirement (Ibs)
an Vessel Diameter (ft)
15 Vessel Length (ft)
Vessel Surface Area (ft2)
Steam Requirement (Ibs/min)
th Pressure Drop (in of water)
System Fan Power (hp)
Bed Gas Flow Rate (scfm)
In Total Capital Costs ($)
Direct Annual Costs ($)
No Total Annual Costs ($)
Current Prev 1 Prev 2
HORIZTL
5
60.000
0.400

0.235
3,525.000
0.067
732.715.9
15.9
43.5
2,579.4
1,794.4
13.0
880.4
697,824.6
4,496,900
4,889,600
5,547,500
« Recalc » < Save > < Cancel > < Help >
C»

	


















10. Once the sensitivities are complete, push < SAVE > or press "S".  The program will then prompt the user
for the input data set to save.
              Las

               r


               HA

               No

               PL
INPUT PARAMETERS
  Design Type
  No. of Adsorbing Beds
  Bed Velocity (ft/min)
  Carbon-to-Vessel Ratio

CALCULATED  RESULTS
  HAP Density (Ib/ft3)
  Inlet HAP Loading (Ib/hr)
  Adsorptive Capacity
  Carbon Requirement (Ib
  Vessel Diameter (ft)
  Vessel Length (ft)
  Vessel Surface Area (f
  Steam Requirement (Ibs
  Current
  HORIZTL
        6
   50.000
    0.400
    0.235
3,525.000
    0.067
                                            Previous Set  1
                                            Previous Set  2
                     Pressure Drop (in of water)         8.8
                     System Fan Power (hp)             616.0
                     Bed Gas Flow Rate (scfm)      697,824.6
                     Total  Capital Costs ($)       4,651,900
                     Direct Annual Costs ($)       4,742,000
                     Total  Annual Costs ($)        5,431,200
   Prev 1
  HORIZTL
        5
   50.000
    0.400
    0.235
3,525.000
    0.067
628,042.2
     11.0
     90.3
  3,332.3
  1.495.3
      7.3
    523.7
697,824.6
4,167,800
3,960,300
4,589,200
   Prev 2
  HORIZTL
        5
   60.000
    0.400
    0.235
3,525.000
    0.067
628,042.2
     13.2
     62.7
  2,893.6
  1,495.3
     10.9
    744.0
697,824.6
3,987,500
4,083,200
4,675,600
                              « Recalc »   *'•;' Save'-;'*   <  Cancel >   <  Help  >
                                                                     es
                                                  2-17

-------
11. As the new input is saved, "Saving Data" will be displayed.
LOS
r




HA


No


PL







ST
ST

I UP! IT PARAMETERS Current Prm/ 1
i Hru 1 r nimnc i cno bui i cin r i w I
Design Type HORIZTL HORIZTL
kin of Arbtnrhina Rarla A 4
HO • VI nv!9 VI U 1 [Iff DC\J9 O 7
Bed Velocity (ft/min) 50.000 50.000
Carbon-to-Vessel Ratio 0.400 0.400

CALCULATED RESULTS
HAP Density (Ib/ft3) 0.235 0.235
Inlet HAP Loading (Ib/hr) 3,525.000 3,525.000
Adsorptive Capacity 0.067 0.067
Carbon Requirement (Ibs) 732,715.9 628,042.2
Vessel Diameter (ft) 13.2 11.0
Vessel Length (ft) 62.7 90.3
Vessel Surface Area (ft2) 2,893.6 3,332.3
Steam Requirement (Ibs/min) 1,794.4 1,495.3
Pressure Drop (in of water) 8.8 7.3
System Fan Power (hp) 616.0 523.7
Bed Gas Flow Rate (scfm) 697,824.6 697,824.6
Total Capital Costs ($) 4,651,900 4,167,800
Direct Annual Costs ($) 4,742,000 3,960,300
Total Annual Costs ($) 5,431,200 4,589,200
« Recalc » £$$iinii?sf < Cancel > < Help

Saving Data


60.000
0.400


0.235
3,525.000
0.067
628,042.2
13.2
62.7
2,893.6
1,495.3
10.9
744.0
697,824.6
3,987,500
4,083,200
4,675,600
i >
es






















12. After saving, the final output is displayed as in Step 6.  Additional sensitivities may be run at this point or
the output may simply be sent to the printer.
              Last Updated by GMP on 06/15/93
                  -FACILITY-
                                                       F5 = Plant Notes
               r
 Company: ABC Chemical               Plant Contact:  John Jones
	[ Please Review Calculated Results for Accuracy :i	
               HAP-PRO Version 1.2
                                             Date of Print:  06/15/93
               Note:  Parameters marked with a *  are not  used  in calculations; all other
                      parameters must be input to perform calculations accurately.
               PLANT DATA
                    Plant ID: 000024
                     Company: ABC Chemical
                 Description: Chemical Mfg.
                      Street: Isaac Newton Ave.
                        City: Research Triangle  Park
                       State: NC  Zip: 27709-

               STREAM TYPE -- ORGANIC VAPOR
               STREAM RELATED PARAMETERS
                                    Plant Contact:  John Jones
                                        Telephone:  (919)999-1919
                                   Agency Contact:  John Jones
                                      Permit Date:  10/01/90
                                         Reviewer:  Pagett
                                          Streams:  002
                            « Print  »   < Review >
                                    Help
Exit
                                                   2-18

-------
13. Files may be printed from either the review screen or the initial results screen.  For printing options, select
« PRINT » or *P*.
              Last Updated by GHP on 06/15/93
                  -FACI LITY-
                F5 * Plant Notes
                     Company: ABC Chemical               Plant Contact: John Jones
                             -[ Please Review Calculated  Results for Accuracy ]	
               INTERMEDIATE RESULTS
                          Dilution Air Requirements  (scfm):
                   Temp of Stream after Heat Exchange CF):
                              Natural Gas Flow Rate  (scfm):
                           Combustion Chamber Volume (ft3):
                                 Flue Gas Flow Rate  (scfm):
                          Electricity Requirement  (Kwh/yr);
       0
478.1000
76.99343
.0000000
15076.99
.0000000
                                       Fuel  Usage (ft3/yr): 27717634
               CAPITAL COSTS
                           Site Preparation:            0
                                   Building:            0
                        Purchased Equipment:      255,400
                        Direct Installation:       76,600
                         Total Direct Costs:      332,000
                       Total Indirect Costs:       79,200
                            « Print  »   < Review >   <  Help  >   <  Exit  >
14, If printing is selected, a menu pops up to prompt the user for the type of output desired (Le., ASCII file or hard
copy).
Last Updated by GMP on 06/15/93
. 	 runt ?TV

F5 = Plant Notes

| Company: ABC Chemical Plant Contact: John Jones


-[ Please Review Calculated Res
HAP-PRO Version 1.2


Date of Print: 06/15/93
INTERMEDIATE RESULTS
Dilution Air Requirements (scfm):
Temp of Stream after Heat Exchange (*F):

Natural Gas Flow Rate (scfm):
Combustion Chamber Volume (ft3):

Flue Gas Flow Rate (scfm):
Electricity Requirement (Kwh/yr):

CAPITAL COSTS
Fuel Usage (ft3/yr):

0
478.1000
76.99343
.0000000
15076.99
.0000000
27717634

Site Preparation: 0

Pure
Dire

9n
u
: 'StS'Clg -WlV; t: 255,400
Printer n: 76,600




«? j»F£rif '. '•'% < Review > < Help > < Exit >
                                                   2-19

-------
15. For an ASCII file output, another menu requests the receiving drive name and the file name.
              Last Updated by GHP on 06/15/93
                   FACILITY	
                                                            F5  =  Plant  Notes
r
                     Company: ABC Chemical               Plant Contact: John Jones
                             C Please Review Calculated Results for Accuracy ]-
               HAP-PRO Version 1.2
               INTERMEDIATE RESULTS
                          Dilution Ai
                   Temp of Stream aft
                              Natural
                           Combustion
                                 Flue
                          Electricity
               CAPITAL COSTS
                           Site Prepa
                                               Date of Print:  06/15/93





A
B
C
D




Filename: FILEOUT.DOC
                                   Building:            0
                        Purchased Equipment:      255,400
                        Direct Installation:       76,600
                                         <  Review >   <  Help  >   <  Exit  >
16. Once the ASCII file is input, push ENTER to execute.  "Creating File..." will appear.
              Last Updated by GMP on 06/15/93
                   FACILITY	
                                                            F5 = Plant Notes
r
                     Company:  ABC Chemical
PI
                            -C Please Review Calculated Res
Creating File C:\FILEOUT.DOC
               HAP-PRO Version 1.2
               INTERMEDIATE RESULTS
                          Dilution Air  Requirements (scfm):
                   Temp of Stream after Heat Exchange (*F):
                              Natural Gas  Flow Rate (scfm):
                           Combustion Chamber Volume (ft3):
                                 Flue Gas  Flow Rate (scfm):
                          Electricity Requirement (Kwh/yr):
                                       Fuel Usage (ft3/yr):

               CAPITAL COSTS
                           Site Preparation:            0
                                   Building:            0
                        Purchased Equipment:      255,400
                        Direct Installation:       76,600
                                                Date of  Print: 06/15/93
                                                   0
                                            478.1000
                                            76.99343
                                            .0000000
                                            15076.99
                                            .0000000
                                            27717634
                                         < Review >   <  Help  >   <  Exit  >
                                                   2-20

-------
 17. For a hardcopy report, select "Printer*.
               Last Updated by GMP  on 06/15/93
                    FACILITY	
                                                       F5  = Plant Notes
                      Company:  ABC  Chemical               Plant Contact: John Jones
                     	C Please  Review Calculated Results for Accuracy ]	
                HAP-PRO Version 1.2
                                          Date  of Print: 06/15/93
                Note:   Parameters marked with a * are not used in calculations; all other
                       other parameters must be input to perform calculations accurately.
                PLANT DATA
                     Plant ID:  00024
                      Company:  ABC Chemical
                  Description:  Chemical Mfg.
                       Street:  Isaac  Newton Ave.
                         City:  Research Triangle Park
                        State

                STREAM TYPE  -
                STREAM RELATE
                                          09-
                                    Plant  Contact:  John Jones
                                        Telephone:  (919)999-1919
                                      Permit Date:  10/01/90
                                        Reviewer:  Pagett
                                          Streams:  002
                                         * Review >   <  Help  >   <  Exit  >
 18. After pushing ENTER, a box will appear with the text "Printing.'
               Last  Updated by GMP on 06/15/93
                   -FACILITY-
                                                      F5 = Plant Notes
                r
Company: ABC Chemical
                Plant Contact:  John Jo
                             -[ Please Review Calculated Results for Accuracy ]-
Printing
                HAP-PRO Version 1.2
                                         Date of Print: 06/15/93
                Note:  Parameters marked with a * are not used in calculations;  all  other
                      other parameters must be input to perform calculations accurately.
               PLANT DATA
                    Plant  ID: 00024
                     Company: ABC Chemical
                 Description: Chemical Mfg.
                      Street: Isaac Newton Ave.
                        City: Research Triangle Park
                       State: NC  Zip: 27709-

               STREAM TYPE -- ORGANIC VAPOR
               STREAM RELATED PARAMETERS
                                   Plant Contact: John Jones
                                       Telephone: (919)999-1919
                                     Permit Date: 10/01/90
                                        Reviewer: Pagett
                                         Streams: 002
< Review >
                                   Help
                                                                      Exit
After printing the output, press Esc or "E" to exit from this screen.  You will then be able to select another
stream for calculation or return to the Main Menu.

-------
                                            CHAPTERS
                                      DATA ENTRY TUTORIAL

        This chapter consists of step-by-step  instructions on how to enter a new record  into the
system. In general, the same procedures can be used when editing a previously existing record.

ADDING RECORDS

7. Select ENTER/VIEWDATA from the Main Menu by pressing ENTER or by clicking on the horizontal
bar for users with a mouse.
                                         HAP-PRO Version 1.2





- ^^i^MftMf^^^ DATA
:•:•:•: :•:• W- ••:-.-*lt \M\f. .¥ t*iW W\fft
B LIST SOURCES BY STREAM TYPE
C LIST SOURCES BY POLLUTANT
0 REBUILD ALL INDEXES
E REMOVE RECORDS MARKED FOR DELETION
F QUIT





                      Use t and I to move cursor --  Press ENTER  to Make Selection
                        Use this selection to ADD, EDIT, CALCULATE results,  etc.
Z Select ADD from the command line at the bottom of the screen.
             Last Updated by GMP on 02/12/94
                -FACILIT Y	
                     F5 = Plant Notes
                   Company:  Glaze Chemical Co.
                Description:  Chemical Mfg.
                    Street:  87 Octane Drive
                      City:  Durham
                     State:  NC        Zip: 27707-
    Plant Contact: John Doe
       Telephone: (999)555-5024
     Permit Date: 10/01/90
        Reviewer: Moore
         Streams:  2
                  EMISSION STREAM-
               Stream Deleted? Stream Type
                  1      N    ORGANIC VAPOR
-CONTROL DEVICE	
 Deleted? Control Device
    N     THERMAL INCINERATOR
              ,	HAZARDOUS AIR POLLUTANTS-
               Stream Deleted? Pollutant
                 1      N    TOLUENE
                             UNDEFINED
                             UNDEFINED
                             UNDEFINED
                             UNDEFINED
                      Cone (ppmv or X)
                        73.0
                                     Creates a new Plant Record
                      FIND  EDIT  AOB DELETE  UNDELETE  NEXT  LAST  CALC  RETURN
                                                2-1

-------
3. Select FACILITY if you wish to enter data about a new facility; otherwise select the group to which you wish
to add data.
              Last Updated by GMP on 02/12/94
                       F5 = Plant Notes
Company: Glaze Chemical
Description: Chemical Mfg.
Street: 87 Octane Drive
City: Durham
State: NC Zip:
EMISSION STREAM
Stream Deleted? Stream
1 N ORGANIC 'i^S
2 N ORGANIC 	
3 N ORGANIC
4 N ORGANIC

Stream Deleted? Pollutant
1 N TOLUENE
UNDEFINED
UNDEFINED
UNDEFINED
UNDEFINED
Co. Plant Contact: John Doe
Telephone: (999)555-5024
Permit Date: 10/01/90
Reviewer: Moore
27707- Streams: 4

'"' "EMI ssi ON " STREAM
CONTROL DEVICE
HAP POLLUTANTS


Device
INCINERATOR
1C INCINERATOR
ADSORBER

Cone (ppmv or %)
73.0
                                  Use this selection to ADD a new facility
4. At this point the cursor will be reposition itself to the first field in the Facility Group. Enter in the appropriate
data and press ENTER or the down cursor 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.  You will also notice that the data
for the other groups have now been blanked out.
              Last Updated by GMP  on  02/12/94
                      F5 = Plant Notes
Company: ^ " '• •"•. •- ':
Description: = . : : • .. i
Street: . .. .. •: ...- :
City: ' . . ";" : .
State: : . Zip:
:•'.' • Plant Contact: : 	 . ,.;
'•••; Telephone: (. . i> ~..r
Permit Date: /'./'•
Reviewer:
Streams: Q
                   EMISSION STREAM-
                Stream Deleted?  Stream  Type
-CONTROL  DEVICE	
 Deleted? Control Device
                	HAZARDOUS AIR POLLUTANTS-
                Stream Deleted? Pollutant
                       Cone (ppmv or %)
                                         ESC = ABORT   F10 = EXIT
                                          Enter Name of Facility
                                                    3-2

-------
5.   To access the State pop-up displayed below, press Fl.  Then press the first letter of the state you are seeking
and use the cursor keys to highlight the desired state.  Press ENTER to accept a selection or press ESC to abort.
Users with a mouse may alternatively scroll through the states by clicking and holding down the mouse button on
the arrow indicators of the scroll box f*  *).  Selections are accepted with a double click.  These procedures will
hold true for all scroll boxes.
              Last Updated by GMP on 02/12/94
                                                              =  Plant  Notes
    Company: ABC Chemical, Inc.
Description: CN«fltf«at flfg>
     Street: Isaac ReHtOR AVe>
       City: ftes«rrch Tn'frgte
      State: ;..:         Zip:
                                                         Plant Contact:
                                                             Telephone:
                                                           Permit  Date:
                                                              Reviewer:
                                                               Streams:
                   EMISSION STREAM-
                Stream Deleted? Stream
                	HAZARDOUS AIR POLLUT
                Stream Deleted? Polluta
                       MONTANA
                       NEBRASKA
                       NEVADA
                       NEW HAMPSHIRE
                       NEW JERSEY
                       NEW MEXICO
                       NEW YORK
                                        NORTH DAKOTA
                                        OHIO
                                        OKLAHOMA
Device
                                                            Cone  (ppmv  or  %)
                                          ESC
                               ABORT   F10 = EXIT
                               Select  State
6. Once ENTER has been pressed, the popup will disappear and the state code will be automatically written into
the field.
              Last Updated by GMP on 02/12/94                               F5  = Plant Notes
                  -FACILIT Y	
    Company: ABC. Cljjjsijtfcal,  Inc.'
Description: ChemtcdlXfj:     '     :
     Street: Isaac;Newton Ave,  ..  : .
       city: Research Triangle  Park
      State: feC        Zip:  : .    *
                                                         Plant  Contact:   .   .
                                                             Telephone:  t';'..•')•'..-
                                                           Permit Date:  •.'.;/  /
                                                             Reviewer:
                                                               Streams:  .D
                  -EMISSION STREAM-
                Stream Deleted? Stream Type
                                    -CONTROL  DEVICE	
                                     Deleted? Control Device
               I	HAZARDOUS AIR POLLUTANTS-
                Stream Deleted? Pollutant
                                                                            Cone (ppmv or
                                          ESC  =  ABORT    F10 = EXIT
                                           Enter Name  of  Facility
                                                    o-o

-------
 7. If you need to enter notes about this facility, you may do so at any time by pressing F5.  The size of the note
field is limited onfy by the amount of free disk space.
              Last Updated by GMP on 02/12/94
                                                             F5 = Plant  Notes
Company: ABC Chemical, Inc.
Description: Chemical Mfg.
Street: Isaac Newton Ave.
City: Research Triangle Park
State: NC Zip: 27709-
Plant Contact: John Jones
Telephone: (919)999-1919
Permit Date: 10/01/90
Reviewer: Moore
Streams: 2
                           -PLANT NOTES --  Press  Ctrl-W to Save or ESC to Abort-
                Plant to cease CFC production in  1991.
8.  Once data has been entered into each field, press F10 to exit.  Accept the highlighted selection by pressing
ENTER.
Last Updated by GMP  on 02/12/94
    -FACILITY	
                                                                           F!i = Plant Notes
       Company:
   Description:
        Street:  Usetd Hewtoft
          City:  Research Triangle Park
         State:  m       Zip: 2T7G9-
                                                        Plant Contact: John Joftes
                                                            Telephone:
                                                          Permit Date:
                                                             Reviewer: Moore
                                                              Streams:  2
                   EMISSION STREAM-
                                      -CONTROL DEVICE-
                Stream Deleted? Stream Type          Deleted? Control Device
                                    	Select Disposition	
                i	HAZARDOUS AIR P
                Stream Deleted? Po
                                         ABORT DATA ENTRY AND EXIT
                                         RETURN  FOR FURTHER EDITING
                                                              Cone  (ppmv or %)
                                          ESC  = ABORT   F10 = EXIT
                                           Enter Name of Facility
                                                    3-4

-------
9. You must now specify the stream for which you are entering data.  The default value is 1. If you enter a stream
number greater than the number specified in the streams field, you will be given an error message and will not be
allowed to proceed.
              Last Updated by GMP on 02/12/94
                  -FACILITY-
                                   F5 = Plant Notes
                     Company: ABC Chemical,  Inc.
                 Description: Chemical  Mfg.
                      Street: Isaac Newton Ave.
                        City: Research  Triangle Park
                       State:  NC
Zip: 27709-
Plant Contact:  John Jones
    Telephone:  (919)999-1919
  Permit Date:  10/01/90
     Reviewer:  Moore
      Streams:   2
                   EMISSION STREAM-
                Stream Deleted? Stream Type
             -CONTROL DEVICE	
              Deleted?  Control Device
                	HAZARDOUS AIR POLLUTANTS-
                Stream Deleted? Pollutant
                                    Cone (ppmv or %)
                                            Enter Stream No.:  t
10. Now specify one of the four types of emission streams.  The type of stream you specify now will determine which
of the control types you have access to later.  However, the control type can be changed if it is incorrectly specified
(see step 13).
              Last Updated by GMP on 02/12/94
                  -FACILITY	
                                   F5 = Plant Notes
                     Company:  ABC Chemical,  Inc.
                 Description:  Chemical  Mfg.
                      Street:  Isaac  Newton Ave.
                        City:  Research  Triangle Park
                       State:  NC       Zip: 27709-
                 Plant Contact: John Jones
                    Telephone: (919)999-1919
                  Permit Date: 10/01/90
                     Reviewer: Moore
                      Streams:  2
                   EMISSION STREAM-
                Stream Deleted?  Stream Type
                                                    -CONTROL DEVICE-
                	HAZARDOUS  AIR  P
                Stream Deleted? Po
             Deleted? Control Device
    -Select  STREAM Type	
'ORGANIC VAPOR;  	
 INORGANIC VAPOR
 ORGANIC PARTICULATE
 INORGANIC PARTICULATE
                                                                            Cone (ppmv  or
                                        Use  r and 1 to move cursor
                                       ESC = Abort   ENTER = Select
                                                   3-5

-------
11. Once ENTER has been pressed, the table below appears, consisting of the parameters associated with the
stream type specified, in this case, Organic Vapor.  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 of the applicant parameters.
              Last  Updated by GMP on 02/12/94
F5 = Plant Notes
Company: ABC Chemical, Inc.
Description: Chemical Mfg.
Street: Issac Newton Ave.
City: Research Triangle Park
State: NC Zip: 27709-
r- STREAM Parameters
«•
Emission Stream No.
Stream Type - ORGANIC VAPOR
Maximum Flow Rate (scfm)
Stream Temperature (deg F)
•- Moisture Content (%)
S Stream Pressure (mmHg)
Mean Particle Diameter (Ug)
Particulate Content (gr/scf)
S03 Concentration (ESPs only, ppmv)
Drift Velocity (ESPs only, ft/s)
Plant Contact: John Jones
Telephone: (919)999-1919
Permit Date: 10/01/90
Reviewer: Moore
Streams: 2
Applicant Default Verified
1
1
0 N
77 77 N
20.0 20 N
0.0 N
760.0 760 N
0.000 N
0.000 N
0.000 N
0.000 ' N



%)
                          ESC = Abort    ENTER = Edit Parameter    F10 = Continue
        Unavailable Selections  Not Appropriate for Selected Stream Type
12. Every parameter except for the Emission Stream number, specified in step 9, can be edited by highlighting the
appropriate line and pressing ENTER. If you attempt to edit the first line, however, you will be given the error
message  illustrated below.
              Last Updated by GMP on 02/12/94
F5 = Plant  Notes
Company:
Description:
Street:
City:
State:
ABC Chemical, Inc. PI
Chemical Mfg.
Issac Newton Ave.
Research Triangle Park
NC Zip: 27709-

Th is
Press
Line
Any
Cannot
Key to
be Edited
Continue


r- STREAM Parameters
c-
Emission Stream No.
Stream Type - ORGANIC VAPOR
Maximum Flow Rate (scfm)
Stream Temperature (deg F)
— Oxygen Content (%)
r— Moisture Content (%)
S Stream Pressure (ntnHg)
Mean Particle Diameter (Ug)
Particulate Content (gr/scf)
S03 Concentration (ESPs only, ppmv)
Drift Velocity (ESPs only, ft/s)
Appl icant
1
1
0
77
20.0
0.0
760.0
0.000
0.000
0.000
0.000
Default



77
20

760




Verified 	 •


N
N
N
N
N
N
M






	
X)


U
H •

                     Unavailable Selections Not Appropriate  for Selected Stream Type

                                                  3-6

-------
13. If you have incorrectly specified the stream type, it may be changed by highlighting the second line and pressing
ENTER, which displays the edit box illustrated below.  To change the emission stream, press the spacebar to cycle
through the four different stream types and press PgDn or ENTER to accept the new stream type. If no change
is desired, press ESC.
              Last Updated  by GMP on 02/12/94
                                                        F5 = Plant Notes
Company: ABC chemical, Inc.
Description: Chemical Mfg.
Street: Jssac Newton Ave.
City: Research Triangle Park
State: NC Zip: 27709-
Plant Contact: John Jones
Telephone: (919)999-1919
Permit Date: 10/01/90
Reviewer: Moore
Streams: 2
               i- STREAM  Parameters
                                    Applicant  Default  Verified       	,
Emission Stream No.
Stream Type
  Maximum F
  Stream Te
  Oxygen Co
                                                             1
                                             -Enter Parameter-
                              Stream Type - ORGANIC  VAPOR
S
Stream Pr
Mean Part
Particula
S03 Conce
Drift VeU
(Press spacebar for selections)
ESC = Abort F1 = Help PgDn = Exit

scity (ESPs only, ft/s) 0.000 N


                      Unavailable Selections Not  Appropriate for Selected Stream Type
14. To edit parameters other than the stream type, highlight the desired parameter and press ENTER, as you did
in step 13.  This time, however, simply type in 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.
              Last  Updated by GMP on 02/12/94
                                                        F5 = Plant  Notes
Company: ABC Chemical, Inc.
Description: Chemical Mfg.
Street: Issac Newton Ave.
City: Research Triangle Park
State: NC Zip: 27709-
Plant Contact: John Jones
Telephone: (919)999-1919
Permit Date: 10/01/90
Reviewer: Moore
Streams: 2
S
s
STREAM Parameters Applicant Default Verified
Emission St
Stream Type
Maximum F
Stream Te
Oxygen Co
Moisture
Stream Pr
Mean Part
Particula
S03 Conce
Drift VeU
•earn No. 1
Maximum Flow Rate (scfm)
'Applicant Value: ;Q - •
Default:
Verified? (Y/N): N
ESC = Abort F1 = Help PgDn = Exit

)city (ESPs only, ft/s) 0.000 N

%)
                     Unavailable Selections  Not Appropriate for Selected  Stream Type
                                                   3-7

-------
75. If you are not sure what value to input, press Fl for help.  The textual information will generally define the
parameter, state the formula used to derive it (if any),  and give a  citation to the revised edition of the EPA
Handbook, Control Technologies for Hazardous Air Pollutants. To scroll through a lengthy help note use the
cursor and PgUp/PgDn keys. To exit from the help file, press ESC.
              Last Updated by  GMP on 02/12/94
F5 = Plant Notes
	 rnci LI i i 	
Company: ABC Chemical, Inc.
Description: Chemical Mfg.
Street: Isaac Newton Ave.
City: Research Triangle Park
State: NC Zip: 27709-
Plant Contact: John Jones
Telephone: (919)999-1919
Permit Date: 10/01/90
Reviewer: Moore
Streams: 2
                                                                                        —
                      XIMUM  FLOW RATE"(S'CFM)'":-""Press"ESC'to exit or T 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.
16.  Qnce the data has been entered in the edit box, press PgDn or ENTER to return to the stream parameter table.
You will note that the Applicant and Verified columns now reflect the newly input values.  Continue this process
until all of the data is input.
              Last  Updated by GMP on 02/12/94
F5 = Plant  Notes
Company: ABC Chemical, Inc.
Description: Chemical Mfg.
Street: Issac Newton Ave.
City: Research Triangle Park
State: NC Zip: 27709-
r-. STREAM parameters . .••.
S'
Emission Stream No.
Stream Type - ORGANIC VAPOR
Maximum Flow Rate (scfra) . '
Stream Temperature (deg F)
— Oxygen Content (%)
S Stream Pressure (mmHg)
Mean Particle Diameter (Ug)
Particuiate Content (gr/scf)
S03 Concentration (ESPs only, ppm>
Drift Velocity CESPs only, ft/s)
i
Plant Contact:
Telephone:
Permit Date:
Reviewer:
Streams:
Applfc'aht D'e'flay
1
1
D :'
77 ' '
20.0
0 0
760.0 7
0.000
0.000
/) 0.000
0.000
John Jones
(919)999-1919
10/01/90
Moore
2
It ;VeHfVed ; 	 1
r 'ft ' ':
77 ' N '
60 N %)
M
N
N
                          ESC = Abort   ENTER = Edit  Parameter   F10 = Continue
           Unavailable Selections  Not  Aopropriate for Selected Stream  Type
                                                   3-3

-------
17. To exit from the stream parameter table, press F10.  You are now given an opportunity to save the data, abort
data entry, or return for further editing.  If you choose to save the data, the system will automatically take you to
the next step, which is to input data about the control device.
              Last Updated by GMP on 02/12/94
                                                                          F5 = Plant Notes
	 rm. inii 	
Company: ABC Chemical, Inc.
Description: Chemical Mfg.
Street: Issac Newton Ave.
City: Research Triangle Park
State: NC Zip: 27709-
Plant Contact: John Jones
Telephone: (919)999-1919
Permit Date: 10/01/90
Reviewer: Moore
Streams: 2
S
S
siKtAH parameters Applicant ueraun vennea
Emission Stream
Stream Type - OR
Maximum Flow R
Stream Tempera
Oxygen Content
Moisture Conte
Stream Pressur
Mean Particle C
Particutate Cor
S03 Concent rat
Drift Velocity

T?" " SAVE SfiREA^iCiATA'AH&i'EXiT " •" '".""
ABORT DATA ENTRY AND EXIT 	
RETURN FOR FURTHER EDITING
iameter (Ug) 0.000
itent (gr/scf) 0.000
on (ESPs only, ppmv) 0.000
(ESPs only, ft/s) 0.000
N
N
N
N
N
N
N
N
N



%)
                      Unavailable Selections Not Appropriate for Selected Stream Type
]8.  You are now prompted to specify the control device.  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. If you do not wish to input the control device data at this time, press ESC to return
to (he command line at the bottom  of the screen.
              Last  Updated by GMP on 02/12/94
F5 = Plant  Notes
Company: ABC Chemical, Inc. Plant Contact: John Jones
Description: Chemical Mfg. Telephone: (919)999-1919
Street: Issac Newton Ave. Permit Date: 10/01/90
City: Research Triangle Park Reviewer: Moore
State: NC Zip: 27709- Streams: 2
| 	 EMISSION STREAM 	
Stream Deleted? Stream
1 N ORGAN I
	 HAZARDOUS AIR POLLU
Stream Deleted? Pollut
UNDEFI
UNDEF!
IJNDFFI
THERMAL JKCtNERATQB •
CATALYTIC INCINERATOR
FLARE
CARBON ADSORBER
PACKED COLUMN SCRUBBER
CONDENSER
FABRIC FILTERS
VENTURI SCRUBBERS
ESP

I Device
NED

Cone (ppmv or %)
                               UNDEFINED
                               UNDEFINED
                 Unavailable selections  are not are applicable for specified Stream Type

-------
19.  The parameters for the control device are entered using the same methods as described for data entry into the
emission stream table (see steps 12-17).  The data is  organized into four columns under two different groups-
Design Related Parameters and Cost Related Parameters. Default values are provided for many of the parameters.
              Last Updated by CMP on 02/12/94
FS = Plant  Notes
Company: ABC Chemical, Inc. Plant Contact: John Jones
Description: Chemical Mfg. Telephone: (919)999-1919
Street: Isaac Newton Ave. Permit Date: 10/01/90
City: Research Triangle Park Reviewer: Moore
State: NC Zip: 27709- Streams: 2
frsi rameiwr? " for' -If W%Htf ' 1 SCi HiES'ATDH

bfeWCfi-J'tfpE"'-* ft«ERW::::iftCftiERATOR
bESIGN RELATED PARAMETERS
Destruction Efficiency (%)
Combustion Temp (°F)
Residence Time (sec)
Heat Exchanger Efficiency (%)
Reference Temp (°F)
Heat Cap. of Air at Comb. Temp (Btu/scf°F)
COST RELATED PARAMETERS

Applicant I
98.0
.0000000
.0000000
70.0
77.00000
.2650000

JefauU Verified — ,
98
70
77
0.265

N
N
N
N
N
N

*
                                    ESC = Abort   ENTER  = Edit Parameter   F10  =  Exit
20.  To edit a parameter, select the appropriate line with the scroll bar and press ENTER.  The Device Type cannot
be edited at the present time.  If an attempt is made to edit a line that cannot be edited, a warning will be given
to the user. In general, data should be entered to the greatest degree of accuracy known.  Most design parameters
will permit the decimal point to float from -1  to -7; exceptions are percentages and those which require whole
numbers.  Be sure to express all values in the units indicated.
              Last Updated by GMP on 02/12/94
F5 = Plant Notes
Company: ABC Chemical, Inc.
Description: Chemical Mfg.
Street: Isaac Newton Ave.
City: Research Triangle Park
State: NC Zip: 27709-

Plant Contact: John Jones
Telephone: (919)999-1919
Permit Date: 10/01/90
Reviewer: Moore
Streams: 2

                parameters for THERMAL  INCINERATOR :'      .   ...Applicant default  Verified  —,
HFV/I PF TYPF c— 4--_ n. --.««.«. ~-
DESIGN RELATE
Destruction
Combustion
Residence T
Heat Exchan
Reference T
Heat Cap. o
Destruction Efficiency (%)

Applicant Value: 95.0
Default Value: 98
Verified? (Y/N): V

ESC = Abort F1 = Help PgDn = Exit

' N
N
N
N
N
N
COST RELATED PARAMETERS
                                                 3-10

-------
21. Press PgDn or ENTER to exit from the edit box and return to the device table.  You will now notice that the
columns reflect your newfy entered values.  Continue this process until data has been input for all of the Design
Related parameters.
              Last Updated by GMP on 02/12/94
                                   F5 = Plant Notes
                  -FACILITY-
                     Company: ABC Chemical, Inc.
                 Description: Chemical Mfg.
                      Street: Isaac Newton Ave.
                        City: Research Triangle Park
                       State: NC        Zip: 27709-
                 Plant Contact: John Jones
                     Telephone: (919)999-1919
                   Permit Date: 10/01/90
                     Reviewer: Moore
                      Streams:  2
rar?fflet?r¥ T
-------
23. Once all of the data has been input, press F10 to exit and save the control device table to the disk.
              Last Updated by CMP on 02/12/94
                       F5 = Plant Notes
im»iLi i i
Company: ABC Chemical, Inc. Plant Contact: John Jones
Description: Chemical Hfg. Telephone: (919)999-1919
Street: Issac Newton Ave. Permit Date: 10/01/90
City: Research Triangle Park Reviewer: Moore
State: NC Zip: 27709- Streams: 2
Device Input Parameters
COST RELATED PARAN
Site Preparation
Building Cost ($
Damper Cost ($)
Duct Cost ($/lin
Length of Duct (
Total Pressure D
Average Equipment
Fan/Motor Efficic
Interest Rate (X]
frlrrt
Applicant

Default

SAVE BEVICE £>*TA XN0 EXIT
ABORT DATA ENTRY AND EXIT
RETURN FOR FURTHER EDITING
Life (yr)
•ncy (%)
10
60
10

10
60
10
Verified — ,
N
N
N
N
N
N
N
N
N

X)
UNDEFINED
24. You are now prompted to input the stream number to which the HAPs will be linked. This value defaults at
1.
              Last Updated by GMP on 02/12/94
                       F5  =  Plant  Notes
                  -FACILITY-
                     Company:  ABC Chemical,  Inc.
                 Description:  Chemical  Mfg.
                      Street:  Isaac Newton Ave.
                        City:  Research  Triangle Park
                       State:  NC        Zip: 27709-
    Plant Contact:  John Jones
        Telephone:  (919)999-1919
      Permit Date:  10/01/90
         Reviewer:  Moore
          Streams:   2
                	EMISSION STREAM-
                Stream Deleted? Stream Type
-CONTROL DEVICE	
 Deleted? Control  Device
                	HAZARDOUS AIR POLLUTANTS-
                Stream Deleted? Pollutant
                        Cone  (ppmv or X)
                                           Enter Stream No.: |.;

-------
 25a. You are now ready to specify the method which will be used to input the pollutants in the designated stream,
 Le. stream number 1.  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.
              Last Updated by GMP  on  02/12/94
                  F5 = Plant Notes
                  -FACILITY-
                     Company:  ABC  Chemical, Inc.
                 Description:  Chemical Mfg.
                      Street:  Isaac  Newton Ave.
                        City:  Research Triangle Park
                       State:  NC        Zip: 27709-
Plant Contact:  John Jones
    Telephone:  (919)999-1919
  Permit  Date:  10/01/90
     Reviewer:  Moore
      Streams:  2
                   EMISSION STREAM-
                                                    -CONTROL  DEVICE-
                Stream Deleted?  Stream Type           Deleted?  Control Device
                                       efine Method of HAPS Selection
                  -HAZARDOUS AIR  P
                                              SiC"CAtEGORY
                Stream Deleted?  Pollutant
                   Cone (ppmv or
                                       ESC = Exit   Enter  =  Select
26a. Now select the pollutant(s) potentially present in this emission stream by pressing ENTER.  The first letter
of each pollutant is hot-keyed, meaning that typing this letter will position the scroll bar on the first pollutant listed
for that letter.  For example, typing "TO" will move the scroll bar to TOLUENE. You will notice that only the
organic pollutants are listed since the emission stream was defined as an organic vapor stream.
              Last Updated by GMP on 02/12/94
                  F5 = Plant Notes
Company: ABC Chemical, Inc.
Description: Chemical Mfg.
Street: Issac Newton Ave.
City: Research Triangle Park
State: NC Zip: 27709-
Plant Contact: John Jones
Telephone: (919)999-1919
Permit Date: 10/01/90
Reviewer: Moore
Streams: 2
Stream Deleted? St
1 N OR
UN
UN
UN
	 HAZARDOUS AIR P
Stream Deleted? Po
UN
UN
UN
UN
TETRAHYDROPTHALIMIDE
THJOPHENE
THIOPHOSGENE
THIOUREA
THIRAM
TQUfgws ?-..-• •••;•-• :' ••'.••' ' •,;••••••;•'- :
TOLUENE DIISOCYANATE '
TOLUENE , 24 , D 1 1 SOCYAMATE
TOLUIDINE.O-
TRIBUTYL PHOSPHATE
TRICHLOROBENZENE, 1,2,3-
ce
NERATOR

Cone (ppmv or %)
                               UNDEFINED
                                       ESC = Exit    Enter = Select
                                 Select Potential  HAPS Present (Organic)
                                                     ! O

-------
27a.  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 will already be known, except for the concentration.
              Last Updated by GMP on 02/12/94
F5 = Plant Notes
Company: ABC Chemical, Inc.
Description: Chemical Mfg.
Street: Issac Newton Ave.
City: Research Triangle Park
State: NC Zip: 27709-
r- HAP Parameters
«•
ftftttutdftti TOlUEffi -,,-,
Inlet HAP Concentration (ppmv or X)
Molecular Weight (Ib/lb mole)
Specific Heat Equation Constant A
- Specific Heat Equation Constant B
- Specific Heat Equation Constant C
S Specific Gravity
Boiling Point (deg R)
Refractive Index
Heat Vaporization (BTU/lb mole)
Heat of Combustion (BTU/lb mole)
Plant Contact: John Jones
Telephone: (919)999-1919
Permit Date: 10/01/90
Reviewer: Moore
Streams: 2
Applicant Default Verified
0.0 N
92.2 92.2 N
0.57600 0.57600 N
93.49300 93.49300 N
-31.2200 -31.2200 N
0.86600 0.86600 N
695.08 695.08 N
1.49610 1.49610 N
16863.3 16863.3 N
1683043 1683043 N

X)
                              ESC = Abort   Enter = Select   F10 = Continue
28a.  The HAP parameters are edited in same manner as described for the stream and control device tables, by
selecting the desired line with the scroll bar and pressing ENTER to access the edit box below. For most pollutants,
you will onfy need to input the concentration of the pollutant in the emission stream.
              Last Updated by GMP on 02/12/94
F!) = Plant Notes
Company: ABC Chemical, Inc. Plant Contact: John Jones
Description: Chemical Mfg. Telephone: (919)999-1919
Street: Issac Newton Ave. Permit Date: 10/01/90
City: Research Triangle Park Reviewer: Moore
State: NC Zip: 27709- Streams: 2
S
S
HAP Parameters Applicant Default Verified
Pollutant:
Inlet HAP
Molecular
Specific H
Specific H
Specific H
Specific G
Boiling Po
Refractive
Heat Vapon
Heat of Con

Inlet HAP Concentration (ppmv or X)
AppU**S# Values *2°0 ,0
Default Value:
Verified? (Y/N): N
ESC = Abort F1 = Help PgDn = Exit
ration (BTU/lb mole) 16863.3 16863.3
[fcustion (BTU/lb mole) 1683043 1683043
N
N
N
N
N
N
N
N
N
N

X)
                                                 3-14

-------
29a.  Save the parameters to the disk by pressing PgDn and selecting the default option.
              Last Updated by GMP on 02/12/94
                                   F5  =  Plant  Notes
                  -FACILITY-
                     Company: ABC Chemical, Inc.         Plant  Contact:  John  Jones
                 Description: Chemical Mfg.               -   Telephone:  (919)999-1919
                      Street: Issac Newton Ave.            Permit Date:  10/01/90
                        City: Research Triangle  Park         Reviewer:  Moore
                       State: NC        Zip: 27709-             Streams:   2
                r— HAP Parameters
             Applicant    Default    Verified     	1
                  Pollutant: TOLUE
                   Inlet HAP Conce
                   Molecular Weigh
                   Specific Heat E
                   Specific Heat E
   -Select Disposition-
ABORT DATA ENTRY AND EX it  '
RETURN FOR FURTHER EDITING
s
specific neat t
Specific Gravit
Boiling Point (c
Refractive Inde>
Heat Vapor izatic
Heat of Combust

leg R) 695.08 695.08
c 1.49610 1.49610
>n (BTU/lb mole) 16863.3 16863.3
on (BTU/lb mole) 1683043 1683043
N
N
N
N
N
N

%)
256. An alternative method of inputing HAPs is to select the SIC category which best describes the processes at
this facility.
              Last Updated by GMP on 02/12/94
                                   F5 = Plant Notes
Company: ABC Chemical, Inc.
Description: Chemical Mfg.
Street: Issac Newton Ave.
City: Research Triangle Park
State: NC
, 	 CMTQCTrtij ^TBPAM
Zip: 27709-

Stream Deleted? Stream Type
1 N OR
.UN
UN
UN

i 	 Define Method

Plant Contact:
Telephone:
Permit Date:
Reviewer:
Streams:
	 rnuTPni nrurrP
Deleted? Control
of HAPS Selection-

John Jones
(919)999-1919
10/01/90
Moore
2

Device
	 .NERATOR

POLLUTANT LIST
:...;. '... ' ;' sic CAitGtiR*' '..'l;; _'"•' : ;


Stream Deleted? Pollutant
1 N TOLUENE

Cone (ppmv or %)
1290.0
UNDEFINED
UNDEFINED
UNDEFINED
UNDEFINED
                                        ESC  = Exit   Enter = Select

-------
26b. Now select the appropriate category. The first character of each category is hot-keyed to enable you to move
quickfy through the categories.
              Last Updated by GMP on 02/12/94
                   F5  = Plant  Notes
                   FACILITY-
                     Company: ABC Chemical,  Inc.
                 Description: Chemical Mfg.
                      Street: Issac Newton Ave.
                        City: Research Triangle Park
                       State: NC        Zip:  27709-
Plant Contact:  John Jones
    Telephone:  (919)999-1919
  Permit Date:  10/01/90
     Reviewer:  Moore
      Streams:    2
Stream Deleted? St
1 N OR
UN
UN
UN
I 	 HAZARDOUS AIR P
Stream Deleted? Po
1 N TO
UN
UN
UN
UNC
A'CCO^ll'Tt¥G7'AubTfilJ'G7w^''''B'd^'iSE'EPTN6''
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
EFINED
ce
NERATOR

Cone (ppmv or %)
1290.0
                                        ESC = Exit    Enter = Select
                                           Select Appropriate SIC
27b. For ABC Chemical, Inc., the SIC category highlighted below best describes the activities which occur at this
plant.
              Last Updated by GMP on 02/12/94
                   F5  =  Plant  Notes
Company: ABC Chemical, Inc. Plant Contact: John Jones
Description: Chemical Mfg. Telephone: (919)999-1919
Street: Issac Newton Ave. Permit Date: 10/01/90
City: Research Triangle Park Reviewer: Moore
State: NC Zip: 27709- Streams: 2
I 	 EMISSION STREAM
Stream Deleted? St
1 N OR
UN
UN
UN
| 	 HAZARDOUS AIR P
Stream Deleted? Po
1 N TO
UN
UN
UN
UNC
AA
CARBURETORS, PISTONS, RINGS, VALVES
CARPENTERING
CARPET AND UPHOLSTERY CLEANING
CEMENT, HYDRAULIC
CERAMIC WALL AND FLOOR TILE
CHEESE, NATURAL AND PROCESSED
CHEMICAL PREPARATIONS, NEC
CHlKtCALS :AND 'ALltffl PRODUCTS' : . ' " •• ;
CHEMICALS AND ALLIED PRODUCTS
CHILDREN'S DRESSES AND BLOUSES
CHILDREN'S OUTERWEAR, NEC
A
JEFINED
ce
NERATOR

Cone (ppmv or %)
1290.0
                                        ESC = Exit    Enter = Select
                                           Select Appropriate SIC

-------
28b. Listed below are the pollutants associated with the SIC category CHEMICALS AND ALLIED PRODUCTS.
Pick the pollutants present in your stream by pressing ENTER
              Last Updated by GHP  on 02/12/94
                                                         F5 = Plant Notes
                  FACIL1TY-
    Company: ABC Chemical,  Inc.
Description: Chemical Mfg.
     Street: Issac Newton Ave.
       City: Research Triangle Park
      State: NC        Zip: 27709-
                                                      Plant
                                                          T
                                              Selecting Associated HAPs
                                                        Permit Date:  10/01/90
                                                           Reviewer:  Moore
                                                            Streams:   2
	 cmaaiun aincwi
Stream Deleted? St
1 N OR
UN
UN
UN
I 	 HAZARDOUS AIR P
Stream Deleted? Po
1 N TO
UN
UN
UN
UNC
CARBURETO
CARPENTER
CARPET AN
CEMENT, H
CERAMIC U
CHEESE, N
CHEMICAL
E«EHieAtS
CHEMICALS
CHILDREN'
CHILDREN'
i
ACEt«»E
BUTYL :" ALCOHOL"
CRESOL.O-
CURENE
METHOXYETHANOL.2-
NAPHTHALENE
SILICA
TOLUENE
TOLUENE , 24 , D 1 1 SOCYANATE
TRICHLOROETHANE.1,1,1-
EFINED


v or X)
Use AX and
                                      ESC = Exit   Enter = Select
                          AY to Move Cursor --  Press ENTER to Make  Selection or ESC to Exit
29b. Once this point has been reached, input and edit the HAP parameters as described in steps 28a and 29a.
             Last Updated by GMP on 02/12/94
                                                         F5  = Plant Notes
Company: ABC Chemical, Inc. Plant Contact: John Jones
Description: Chemical Mfg. Telephone: (919)999-1919
Street: Issac Newton Ave. Permit Date: 10/01/90
City: Research Triangle Park Reviewer: Moore
State: NC Zip: 27709- Streams: 2
r-HAP'ParsmetKrs. '
S ' " '
PfriiutjBftti ACETQ8E
In i let HAP '"'Concent rat ibn""(ppmv" or
Molecular Weight (Ib/lb mole)
Specific Heat Equation Constant A
- Specific Heat Equation Constant B
- Specific Heat Equation Constant C
S Specific Gravity
Boiling Point (deg R)
Refractive Index
Heat Vaporization (BTU/lb mole)
Heat of Combustion (BTU/lb mole)
'*sppt»<5*it 'itefadT* Verified
*>' 	 6.0 	 	 N
58.1 58.1 N
1.50500 1.50500 N
62.24000 62.24000 N
-29.2900 -29.2900 N
0.79200 0.79200 N
593.16 593.16 N
1.35880 1.35880 N
13754.7 13754.7 N
768917.0 768917.0 N

X)
                             ESC = Abort   Enter = Select   F10 = Continue
                                                3-1'

-------
                                       CHAPTER 4
                                        REPORTS
GENERATING A REPORT

   HAP-PRO is designed to generate the following two reports, in addition to its primary function of
calculating capital and yearly costs for a specified control device. Both reports are options on the Main
Menu.

  Report   •                Purpose

  LIST SOURCES BY        Generates a report listing all permits that have a specified
  STREAM TYPE            stream type (organic or inorganic vapors and particulates)

  LIST SOURCES BY        Generates a report listing all permits that have a
  POLLUTANT        specified pollutant (ammonia, benzene, toluene, etc.)

   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.

   What follows is a step-by-step guide on how to generate each report.

-------
REPORT B - LIST SOURCES BY STREAM TYPE

/. Select the desired report with the scroll bar, in this case Selection B.
                                        HAP-PRO Version 1.2


A ENTER/VIEW DATA
:B LIST; SOURCES BY STREAM TYPE
C LIST SOURCES BY POLLUTANT
D REBUILD ALL INDEXES
E REMOVE RECORDS MARKED FOR DELETION
f EXIT TO DOS


                      Use T and i  to move cursor --  Press ENTER  to Make Selection
                           List all Facilities with a specified STREAM TYPE
   Specify the desired STREAM TYPE.







HAP-PRO Version 1.2


A ENTER/VIEW DATA
B LIST SOURCES BY STREAM TYPE
: ORGANIC VAPOR ;
INORGANIC VAPOR
ORGANIC PARTICULATE
INORGANIC PARTICULATE















!
                                     Use T and i to move cursor
                                    E£C = Abort   ENTER = Select
                                               4-2

-------
3. Choose a destination for your report.
                                            HAP-PRO Version 1.2











A ENTER/VIEW DATA
. & LIST SOURCES BY STREAM TYPE
-- '• ' screen; : :
Printer
ASCII File












                                         Use T and i  to move  cursor
                                            Sends  Report to CRT
4a.  The following display will appear.
 Printed 06/08/93
 at 11:19:09
FACILITIES WITH THE  FOLLOWING  STREAM TYPE
               ORGANIC  VAPOR
Page
Facility
ABC Chemical

Aerospace NESHAP




Bob's Example Problem
Carbon Adsorber Test Case
GLASS PAINTING - 1
GLASS PAINTING - 2
GM Adsorber Case
HAP Manual Case
Plant # 1
Texti le Plant A
« Done » < More > Column:
No. Pollutant(s) in Stream
001 TOLUENE
001 BENZENE
001 STYRENE
001 TOLUENE
001 ZINC
001 TOLUIDINE,0-
002 TOLUENE
001 TOLUENE
001 ACETIC ACID
001 Not Recorded
001 Not Recorded
001 TOLUENE
000 Not Recorded
001 Not Recorded
001 Not Recorded
0
Cone.
1000.
500.
0.
1000.
1.
0.
1000.
1000.
1000.
0.
0.
300.
0.
0.
0.

                                                   4-3

-------
4b. If a report is sent to an ASCII file, you will be prompted to enter the filename.  Type in the name and press
ENTER to continue.  The file will automatically be written into the current (default) subdirectory (e.g. \HAP-PRO).
                                          HAP-PRO Version 1.2
                                   A) Enter/View Data
Receiving Drive:







B
C
D





Filename: ! FILEOUT.DOC






                                       Use T and i to move cursor
                                      ESC = Abort   ENTER = Select
5. Once the Quit command has been issued (if the report is sent to the screen), the system returns control to HAP-
PRO 's Main Menu.
                                          HAP-PRO Version 1.2








A ENTER/VIEW DATA
B LIST SOURCES BY STREAM TYPE :
C LIST SOURCES BY POLLUTANT
D REBUILD ALL INDEXES
E REMOVE RECORDS MARKED FOR DELETION
F EXIT TO DOS








i
                       Use T and l  to move cursor --  Press ENTER to Make Selection
                             List all Facilities with a specified STREAM TYPE
                                                  4-4

-------
REPORT C - LIST SOURCES BY POLLUTANT

1.  Instead of Selection B on the Main Menu, choose selection C.
                                          HAP-PRO Version 1.2


A ENTER/VIEW DATA
B LIST SOURCES BY STREAM TYPE
C L I ST SOURCES BV POLWTANT
D REBUILD ALL INDEXES
E REMOVE RECORDS MARKED FOR DELETION
F EXIT TO DOS


                       Use T and i to move cursor -- Press ENTER to Make Selection
                            List all Facilities with a specified STREAM TYPE
2. Now select the type of pollutant by choosing Organic.
                                          HAP-PRO Version 1.2
A  ENTER/VIEW DATA

B  LIST  SOURCES BY STREAM TYPE

C  LIST  SOURCES BY POLLUTANT

D  |	Select Pollutant Type—

E           Organic             ION

F  !
                                              Inorganic
                       Use  r and I to move cursor --  Press ENTER to Make  Selection

-------
3. Once ENTER is pressed, the pollutant pop-up displayed below should appear.  Use the cursor, PgDn, and PgUp
to move the cursor or press the first character of the pollutant you are seeking.
                                           HAP-PRO Version  1.2



A ENTER/VIEW DATA
B LIST SOURCES BY STREAM TYPE
C LIST SOURCES BY POLLUTANT
ACENAPHTHEME :
ACENAPHTHYLENE
ACETALDEHYDE
ACETALDEHYDE
ACETIC ACID
ACETIC ANHYDRIDE
ACETONE



                       Use  i and T to move cursor --  Press ENTER to Make Selection
4. Once the desired pollutant is highlighted, in this case ACETONE, press ENTER to select it.
                                           HAP-PRO Version  1.2
                                   A  ENTER/VIEW DATA

                                   B  LIST SOURCES BY  STREAM TYPE

                                   C  LIST SOURCES BY  POLLUTANT
                                  ACENAPHTHENE
                                  ACENAPHTHYLENE
                                  ACETALDEHYDE
                                  ACETALDEHYDE
                                  ACETIC ACID
                                  ACETIC ANHYDRIDE
                                  ACETONE
                        Use  r and  i to move cursor --  Press ENTER to Make Selection

-------
5. At this point, the screen shown below is generated, assuming these records were found for the pollutant specified.
 Printed 06/08/93
 at 11:19:22

 Facility
 ABC Chemical
 NC Petroleum
FACILITIES  WITH  THE FOLLOWING POLLUTANT
                ACETONE

           No.    Cone.
Page
           001      1000.0
           001      1000.1
           002      1000.0
  « Done »  < More >   Column:
6. Once the Done command has been issued (if the report is sent to the screen), the system returns control to HAP-
PRO's Main Menu.
                                           HAP-PRO Version  1.2


A ENTER/VIEW DATA
B LIST SOURCES BY STREAM TYPE
C LIST SOURCES BY POLLUTANT
D REBUILD ALL INDEXES
E REMOVE RECORDS MARKED FOR DELETION
F EXIT TO DOS


                       Use T and i to move cursor  --  Press ENTER to Make Selection
                              List  all  Facilities with a specified  POLLUTANT

-------
                                              APPENDIX A
                                          DATA DICTIONARY
Parameters marked with a  * are not  used  in calculations;  all other parameters must  be input to perform
calculations accurately.


Key to DATA TYPE

   C - Character
   N - Numeric
   F - Floating Decimal
   M * Memo


UPDATE STAMP
INPUT PARAMETERS
      Last Updated by
      on

FACILITY DATA
INPUT PARAMETERS
Data
Type

  C
  D
                                                         Len    Fieldname    Range Values (default)
 3
 8
updated_by
updt_date
      Company
      Description
      Street
      City
      State
      Zip
      Plant Contact
      Telephone
      Permit Date
      Reviewer
      Streams
      Plant Notes
  C
  C
  C
  C
  C
  C
  C
  C
  D
  C
  N
  M
25
25
25
25
 2
10
20
13
 8
20
 3
10
plant_name
scen_desc
address
city
state
zip
contact
telephone
appl_date
reviewer
no_streams
notes
USPS Code
0 - 999
                                                  A-i

-------
THERMAL INCINERATOR
INPUT PARAMETERS

   ORGANIC VAPOR ONLY

   Emission Stream Input Parameters:

      Maximum Flow Rate (scfm)
      Stream Temperature (deg F)
      Oxygen Content (X)
   *  Moisture Content (X)
   *  Stream Pressure (mmhg)
 HAP   Data
Manual Type
Len   Fieldname    Range Values (default)
Qe
Te
02


N
N
N
N
N
8
8
5.1
5.1
8.1
flow_rate
temp
o2
moisture
pres

(77)
0 - 100
0 - 100

   Design Related Input Parameters:

      Desired Destruction Efficiency (X)
      Combustion Temp (°F)
      Residence Time (sec)
      Heat Exchanger Efficiency (X)
      Reference Temp (°F)
      Heat Cap. of Air at Comb. Temp (Btu/lb°F)

   Cost Related Input Parameters:

      Duct Cost ($/linear ft)
      Length of Duct (ft)
      Total Pressure Drop (in H20)
      Average Equipment Life (yr)
      Operator Labor Requirements (hrs/shift)
      Maintenance Labor Requirements (hrs/shift)
      Operator Labor Wage ($/hr)
      Maintenance Labor Wage ($/hr)
      Operating Hours (hrs/yr)
      Site Preparation Cost ($)
      Building Cost ($)
      Interest Rate (X)
      Price of Natural Gas (J/1000 cu ft)
      Damper Cost ($)

MESSAGES TO USER

   NONE

INTERMEDIATE CALCULATED RESULTS

    calc_de = calculated destruction efficiency
      Od    = dilution air requirements
      The   = temp of emission stream after heat  exchange
      Of    * natural gas flow rate
      Qfg   = calc flue gas flow rate
      Vc    = calc combustion chamber volume
      Fp    = electricity requirement
      fuel  = fuel usage
      he    « heat content
DE
Tc
tr
HR
Tr
Cpair


P
n
olr
mlr
olwr
mlwr
HRS
spc
bldg
i
ngc
Pdamp
N
F
F
N
F
F
N
N
N

N
N
N
N
N
N
N
N
N
N
5.1
8.7
8.7
5.1
8.7
8.7
8.2
8.1
8.1
8.1
8.1
8.1
8.2
8.2
8
8
8
8.2
8.2
8
dest.eff
comb_.temp
res_time
heat exch
t_re?
heat_air1
duct cost
lenJSuct
pres_drop
eqpt_life
olabor_req
mlabor_req
olaborwage
mlaborwage
op_hrs_yr
site_cost
bldg_cost
int_rate
gas_cost
dampers
0 - 100 (98)


0,35,50,(70)
(77)
(0.265)



(10)
(0.5)
(0.5)
(12.96)
(U.26)
(6000)


(10)
(3.30)

CAPITAL COSTS

      spc   = site preparation cost
      bldg  - building
      PEC   = purchased equipment cost
   +  DC    = direct installation costs

      Tdc   = total direct costs
   +  Tic   = total indirect costs

      Tec   = total capital costs
                                                    A-2

-------
OPERATING COSTS

      Fc    « fuel cost
      AEC   « electricity cost
      Olc   » labor
      Svd   » supervisory cost
      Mlc   » maintenance labor cost
   +  Ntc   » maintenance materials cost

      Tdac  = total direct annual  costs (operating costs)

      OH .   * overhead
      adm   * administrative cost
      Pt    = property taxes
      In    = insurance
   +  CRC   = capital recovery cost

      Tiac  = total indirect annual costs

      * total annual costs
      Tac   = Tdac + Tiac
                                                   A-3

-------
CATALYTIC INCINERATOR
INPUT PARAMETERS
   ORGANIC VAPOR ONLY

   Emission Stream Input Parameters:

      Maximum Flow Rate (scfm)
      Stream Temperature (deg F)
      Oxygen Content (X)
   *  Moisture Content (X)
   *  Stream Pressure (romhg)
   Design Related Input Parameters:

      Desired Destruction Efficiency (X)
      Heat Exchanger Efficiency (X)
      Heat Cap. of Air at Comb. Temp (Btu/lb'F)
      Space Velocity (per hr)
      Reference Temp (*F)
      Catalytic Oxidation Temperature (°F)

   Cost Related Input Parameters:

      Duct Cost ($/linear ft)
      Length of Duct (ft)
      Total Pressure Drop (in H20)
      Average Equipment Life (yr)
      Operator Labor Requirements (hrs/shift)
      Maintenance Labor Requirements (hrs/shift)
      Operator Labor Wage ($/hr)
      Maintenance Labor Wage ($/hr)
      Operating Hours (hrs/yr)
      Site Preparation Cost ($)
      Building Cost ($)
      Interest Rate (X)
      Price of Natural Gas ($71000 cu ft)
      Catalyst Replacement Cost ($)
      Damper Cost ($)
HAP
Manual
Qe
Te
02


DE
HR
Cp1
sv
Tr
Tci


p
n
olr
mlr
olwr
mlwr
HRS
spc
bldg
i
ngc
Ccat
Pdamp
Data
Type
N
N
N
N
N
N
N
F
F
F
F
N
N
N
8
N
N
N
N
N
N
N
M
N
N
N

Len
8
8
5.1
5.1
8.1
5.1
5.1
8.7
8.7
8.7
8.7
8.2
8.1
8.1
.1
8.1
8.1
8.2
8.2
8.2
8
8
8.2
8.2
8
8

Fieldname
flow rate
temp"
o2
moisture
pres
dest..eff
heat._exch
heat~air1-
space vel
t_re1r
t~co
duct_.cost
len_eiuct
pres_drop
eqpt_life
olabor_req
mlabor_req
o labor wage
mlaborwage
op_hrs_yr
site_cost
bldg_cost
int_rate
gas_cost
cat~cost
dampers

Range Values

(77)
0 - 100
0 - 100

0 - 100 (95)
0.35, (50), 70
(.0254)

(77)
(600)



(10)
(0.5)
(0.5)
(12.96)
(14.26)
(6000)


(10)
(3.30)


INTERMEDIATE CALCULATED RESULTS

      catc_de = calculated destruction efficiency
      he      = heat content
      Qd      = dilution air requirements
      The     = temp of emission stream after  heat  exchange
      Qf      = natural gas flow rate
      Qcom    » flue gas flow rate
      Qcoma_a = actual flow rate
      Vbed    = catalyst bed requirement
      Fp      = electricity requirement
      fuel    = fuel usage
MESSAGES TO USER

   NONE
                                                    A-4

-------
CAPITAL COSTS
      spc   a site preparation cost
      bldg  = building
      PEC   = purchased equipment cost
      Oc    • direct installation costs

      Tdc   * total direct costs
      Tic   = total indirect costs

      Tec   = total capital costs
OPERATING COSTS
Fc
AEC
CRCT
Olc
SVC
Mlc
+ Mtc
s
s
s
a
s:
s
fuel cost
electricity cost
catalyst replacement cost
labor
supervisory cost
maintenance labor cost
maintenance materials cost
      Tdac  = total direct annual  costs (operating costs)

      OH    » overhead
      adm   = administrative cost
      Pt    « property taxes •
      In    = insurance
      CRC   = capital  recovery cost

      Tiac  = total indirect annual costs

      * total annual costs
      Tac   = Tdac + Tiac
                                                   A-5

-------
FLARE
INPUT PARAMETERS

   ORGANIC VAPOR ONLY

   Emission Stream Input Parameters:
      Naxinun Flow Rate (scfm)
      Stream Temperature (deg F)
      Oxygen Content (X)
      Moisture Content (X)
      Stream Pressure (mmhg)
   Design Related Input Parameters:

      Flare Tip Diameter (in)
      Temp of Flare Gas CF)
      Flare Gas Heat Content (BTU/scf)
      Supplementary Fuel Heat Content (BTU/scf)
      Mean Molecular Weight of Stream (Ib/lb-mole)

   Cost Related Input Parameters:

      Duct Cost ($/linear ft)
      Length of Duct (ft)
      Stack Cost ($)
      Total Pressure Drop (in H20)
      Average Equipment Life (yr)
      Operator Labor Requirements (hrs/shift)
      Maintenance Labor Requirements (hrs/shift)
      Operator Labor Wage (S/hr)
      Maintenance Labor Wage ($/hr)
      Operating Hours (hrs/yr)
      Site Preparation Cost ($)
      Building Cost ($)
      Interest Rate (X)
      Price of Natural Gas (S/1000 cu ft)
      Cost of Fans and Motors ($)
      Damper Cost ($)
HAP
Manual
Qe
Te
02


Dtip
Tflg
hflg
hf
> MUe


Pstack
P
n
olr
mlr
olwr
mlwr
HRS
spc
bldg
i
ngc
Pfan
Pdamp
Data
Type
N
N
N
N
N
F
F
F
F
F
N
N
N
N
8
N
N
N
N
M
N
N
N
N
N
N

Len
8
8
5.1
5.1
8.1
8.7
8.7
8.7
8.7
8.7
8.2
8.1
8
8.1
.1
8.1
8.1
8.2
8.2
8
8
8
8.2
8.2
8
8

Fieldname
flow_rate
temp
o2
moisture
pres
diameter
t_gas
heat._cont
suppjieat
avgjiM
duct cost
lenjiuct
stack:_cost
pres_drop
eqptjlfe
olabor_req
mlabor_req
olaborwage
mlaborwage
op_hrs_yr
site_cost
bldg_cost
int_rate
gas~cost
fan_cost
dampers

Range Vi

(77)
0 - 100
0 - 100



(300)
(882)
(29)




(10)
(0.5)
(0.5)
(12.96)
(U.26)
(6000)


(10)
(3.3)


MESSAGES TO USER

   Condition

   hflg < 300
   hflg > 1000
Variable

DEflag
Deflag
Message

Based on hflg.
Based on hflg.
DE
DE
98
98
INTERMEDIATE CALCULATED RESULTS

      Of      = supplemental fuel requirements
      Uflg    = flare gas exit velocity
      DE      = efficiency level
      Qs      = steam requirement
      Theta_b = flame angle
      H       = flare height
      fuel    = fuel usage
      Fp      = electricity requirement
                                                    A-6

-------
CAPITAL COSTS

      Spc   * site preparation
      Btdg  * building cost
      PEC   a purchased equipment cost
   +  DC    = direct installation costs

      Tdc   = total direct costs
   +  Tic   = total indirect costs

      Tec   a total capital costs
OPERATING COSTS

      Fc    = fuel cost
      AEC   = electricity cost
      Olc   s labor
      Svc   = supervisory cost
      Mlc   = maintenance labor cost
      Mtc   a maintenance materials cost
   +  SC    = steam cost

      Tdac  = total direct annual costs (operating costs)

      OH    = overhead
      adm   = administrative cost
      Pt    = property taxes
      In    = insurance
   +  CRC   = capital recovery cost

      Tiac  = total indirect annual costs

      * total annual costs
      Tac   = Tdac + Tiac
                                                   A-7

-------
CARBON ADSORBER
INPUT PARAMETERS
   ORGANIC VAPOR ONLY

   Emission Stream Input Parameters:
      Maximum Flow Rate (scfm)
      Stream Temperature (deg F)
      Oxygen Content (X)
      Moisture Content (%}
      Stream Pressure (mmhg)
   HAP Input Parameters:
      Inlet HAP Concentration (ppmv or X)
      Molecular Weight (Ib/lb mole)
      Specific Heat Equation Constant A
      Specific Heat Equation Constant B
      Specific Heat Equation Constant C
      Specific Gravity
      Boiling Point
      Refractive Index
      Heat Vaporization (BTU/lb mole)
   Design Related Input Parameters:

      Design Type
      Carbon-to-Vessel  Ratio
      Removal Efficiency (X)
      Number of Adsorbing Beds
      Number of Deadsorbing Beds
      Stream Velocity Through Bed (ft/roin)
      Operational Mode
      Cycle Time for Adsorption (hr)
      Cycle Time for Regeneration (hr)
      Cycle Time for Drying and Cooling  (hr)
      Steam Ratio (Ib steam/Ib carbon)

   Cost Related Input Parameters:

      Duct Cost ($/linear ft)
      Length of Duct (ft)
      Stack Cost ($)
      Average Equipment Life (yr)
      Operator Labor Requirements (hrs/shift)
      Maintenance Labor Requirements  (hrs/shift)
      Operator Labor Wage (S/hr)
      Maintenance Labor Wage ($/hr)
      Operating Hours (hrs/yr)
      Site Preparation  Cost ($)
      Building Cost ($)
      Interest Rate (X)
      Equipment Factor
      Carbon Cost ($/lb)
      Steam Cost ($/lb)
      Cooling Water Cost (S/1000 gals)
      Value of Recovered Product ($/lb)
      Damper Cost ($)
HAP
Manual
Qe
Te



HAPe









CVR
RE
NA
NO
Ue

Theta_a
Theta_reg
Theta dc
St


Pstack
n
olr
) mlr
olwr
mlwr
HRS
spc
bldg
i
Fm
Cc
PS
Pew
VRPC
Pdamp
Data
Type
N
N
N
N
N









C
F
N
N
N
F
C
F
F
F
F
N
N
N
8
N
N
N
N
N
N
N
N
N
N
N
N
N
N

Len
8
8
8.1
8.1
8.1
8.1
8.1
8.5
8.5
8.5
8.5
8.5
8.5
8.1
7
8.7
5.1
8
8
8.7
7
8.7
8.7
8.7
8.7
8.2
8.1
8
.1
8.1
8.1
8.2
8.2
8
a
8
8.2
a
8.2
8.3
8.2
8.2
8

Fieldname
flow rate
temp"
o2
moisture
pres
hap_conc
mw
cpa
cpb
cpc
SG
boil joint
refr_index
hvap
ad_type
cv_ratio
remove_eff
no_ad_beds
no_de_beds
st'vel bed
mode
ct_adsorp
ct_regen
ct_drycool
steam_rat
duct_cost
len_duct
stack cost
eqpt_li?e
olabor_req
mlabor_req
olaborwage
mlaborwage
op_hrs_yr
site_cost
bldg_cost
int_rate
eqpt_fact
carb_cost
steam_cost
water_cost
value prod
dampers

Range Values

77













(def














HORIZTL/VERTICL
0.25-0.40 (0.
0 - 100 (90)
(1)
(1)
(85)
333)




CONTINU/BATCH
(2)
(2)
(0.25)
(0.30)



(10)
(0.5)
(0.5)
(12.96)
(14.26)
(6000)


(10)
1 - 10 (1)
(2.00)
(0.006)
(0.20)
























                                                    A-3

-------
MESSAGES TO USER

   Condition             Variable         Message

   S < 97                Sf lag            "Calculated value for S is beyond equation accuracy -- Consult Manual
   S > 2110              Sf lag            "Calculated value for S is beyond equation accuracy -- Consult Manual
   Bf > 4                Bflag            ***Carbon bed  is fluidized --  Recheck steam ratio or regeneration
theta a <                Tflagl,
(NA *~theta_reg)/MO      Tflag2           **** Ads. Cycle time changed to  [<«* * th*tsyr*9?/li»] to allow for
                                          continuous operation.


INTERMEDIATE CALCULATED RESULTS

      Dtot      = density of HAP pollutants
      Mhap      = inlet HAP loading
      Uc        = adsorptive capacity
      Creq      = carbon requirement
      Ov        = vessel diameter
      Lv        = vessel length
      S         = vessel surface area
      Qs        = steam rate
      Ocw       = cooling water flow rate
      Bf        = bed fluidization
      Pb        - pressure drop
      hpsf      = system fan power
      theta dcf = power for drying/cooling fan
      FRdcf"    = bed gas flow rate
      Pdef      = electricity requirement for drying/cooling fan
      hpcwp     = horsepower required for cooling water pump


CAPITAL COSTS

      Spc   s site preparation
      Bldg  = building cost
      PEC   = purchased equipment cost
   +  DC    = direct installation costs
      Tdc   = total direct costs
   •••Tic   = total indirect costs

      Tec   = total capital costs

OPERATING COSTS

      AEC   - electricity cost
      Ccw   = cooling water cost
      Olc   = labor
      Svc   = supervisory cost
      Mlc   = maintenance labor cost
      Mtc   = maintenance materials cost
   +   CS   = steam cost

      Tdac  = total direct annual costs (operating costs.)


      OH    = overhead
      adm   = administrative cost
      Pt    = property taxes
      In    = insurance
   +  CRC   = capital  recovery cost

      Tiac  = total indirect annual costs

   -  VRP   = value of recovered product

      * total annual costs
      Tac   - Tdac + Tiac - VRP


                                                    A-9

-------
PACKED COLUMN SCRUBBER (STRIPPER)
INPUT PARAMETERS
   Note:  Only one of the following stream types can be specified

   Emission Stream Input Parameters:
   ORGANIC VAPOR
      Maxinun Flow Rate (scfm)
      Stream Temperature (deg F)
   *  Oxygen Content (X)
   *  Moisture Content (X)
   *  Stream Pressure (mmhg)
   INORGANIC VAPOR
      Maximum Flow Rate (scfm)
      Stream Temperature (deg F)
   *  Moisture Content (X)
   *  Stream Pressure (mmhg)
   *  Are Halogens Present? (Y/N)
   *  Are Metals Present? (Y/N)

   ORGANIC PARTICIPATE
      Maximum Flow Rate (scfm)
      Stream Temperature (deg F)
      Moisture Content (X)
   *  Mean Particle Diameter (Ug)
   *  Particulate Content (gr/scf)
   HAP Input Parameters:
      Inlet HAP Concentration (ppmv or X)
      Molecular Weight (Ib/lb mole)
      Specific Heat Equation Constant A
      Specific Heat Equation Constant B
      Specific Heat Equation Constant C
      Antoine Equation Constant A
      Antoine Equation Constant B
      Antoine Equation Constant C
      Heat Vaporization (BTU/lb mole)
   Design Related Input Parameters:

      Removal Efficiency (X)
   *  What Solvent is used?
      Slope of the Equilibrium Curve
      Absorption Factor
      Schmidt number for HAP/Emission Stream
      Schmidt number for HAP/Solvent
      Density of the Emission Stream (Ib/ft3)
      Density of the Solvent  (Ib/lb  mole)
      Average Mole Wt of the  Stream  (Ib/lb mole)
      Mole Ut of the Solvent  (Ib/lb  mole)
      Solvent Viscosity (centipoise)
   *  Packing Material
      Packing Constant  a
      Packing Constant  b
      Packing Constant  c
      Packing Constant  d
      Packing Constant  Epsilon
      Packing Constant  Y
      Packing Constant  s
      Packing Constant  g
      Packing Constant  r
      Fraction Flooding Velocity
      Number of Beds
HAP
Manual
Qe
Te



Qe
Te




Qe
Te
Rhum


HAPe








RE

m
AF
Scg
Scl
Dg
Dl
MUstm
MUsol
mu

F
F
F
F
e
F
F
F
F
f
Nbed
Data
Type
N
N
N
N
N
N
N
N
N
C
C
N
N
N
N
N
F
F
F






N
C
F





F
F
F
C
8
8
8
3
F
8
8
3
8
8
N

Len Fieldname
8 flow rate
8 temp"
5.1 o2
5.1 moisture
8.1 pres
8 flow_rate
8 temp"
5.1 moisture
8.1 pres
1 halogens
1 metals
8 flowjrate
8 temp"
5.1 moisture
8.3 diameter
8.3 part_cont
8.1 hap cone
8.1 mw
8.5 cpa
8.5 cpb
8.5 cpc
8.5 ante
8.5 antb
8.5 ante
8.1 hvap
5.1 remove_eff
13 solvent
8.7 slope_curv
8.7 absorption
8.7 schdt_strm
8.7 schdt_solv
8.7 dnsty_strm
8.7 dnsty_solv
8.7 avg_mw_stm
8.7 avg_mw_sol
8.7 solv^visc
1 packjnat
.7 packing_a
.7 packing_b
.7 packing_c
.7 packing_d
8.7 packing_e
.7 packing_y~
.7 packing_s
.7 packing_3
.7 packing r
.7 flood_vel
8 no beds

Range Values

(77)
0 - 100
0 - 100
(760)

(77)
0 - 100

Y,(N)
Y,(N)

(77)
0 - 100











0 - 100 (95)
(water)
(2)
(1.6)


(62.4)

(29)
(18)

1 - 3 (1)









(0.60)
1
                                                   A-10

-------
   Cost Related Input Parameters:

      Cost of Packing Material ($/ft3)
      Cost of Fans and Motors ($)
      Duct Cost (Vlinear ft)
      Length of Duct (ft)
      Stack Cost ($)
      Average Equipment Life (yr)
      Operator Labor Requirements  (hrs/shift)
      Maintenance Labor Requirements (hrs/shift)
      Operator Labor Wage ($/hr)
      Maintenance Labor Wage ($/hr)
      Operating Hours (hrs/yr)
      Site Preparation Cost ($)
      Building Cost ($)
      Interest Rate (X)
      Damper Cost ($)
      Steam Cost ($/lb)
      Cooling Water Cost ($/1000 gals)

      Key for PACKING MATERIAL

         1 = rachig rings
         2 = pall rings
         3 = flexisaddles
Pcost
Pfan


Pstack
n
olr
mlr
olur
mlwr
HRS
spc
bldg
i
Pdamp
PS
Ccw
N
N
N
N
N

N
N
N
N
N
N
N
N
N
N
N
8.2
8
8.2
8.1
8
8.1
8.1
8.1
8.2
8.2
8
8
8
8.2
8
8.3
8.2
pack_cost
fan_cost
duct cost
lenJJuct
stack cost
eqpt_life
olabor_req
mlabor_req
olaborwage
mlaborwage
op_hrs_yr
site_cost
bldg~cost
int_rate
dampers
steam_cost
water_cost





(10)
(0.5)
(0.5)
(12.96)
(14.26)
(6000)


(10)

(0.006)
(0.20)
MESSAGES TO USER

   NONE


INTERMEDIATE CALCULATED RESULTS

      ABS  - flooding correlation
      Garea = gas stream flow rate
      Gmol = gas stream flow rate (Ib mole/hr)
      ImoI = liquid stream flow rate (Ib mole/hr)
      Igat = liquid stream flow rate (gals/min)
      Acol = column area
      DeoI - diameter
      HAPo = HAP outlet concentration
      Nog = no of gas transfer units
      Hg = ht. of gas transfer unit
      HI = ht. of liquid transfer unit
      Hog = ht. of overall gas transfer unit
      Httot - total ht. of column
      Vpack = packing volume
      Pa = column pressure drop
      Ptot = total colum pressure drop
      Fp = electricity requirement

CAPITAL COSTS

      Spc   = site preparation
      Bldg  = building cost
      PEC   = purchased equipment cost
   +  DC    = direct installation costs

      Tdc   = total direct costs
   +  Tic   = total indirect costs

      Tec   = total capital costs
                                                   A-11

-------
OPERATING COSTS

      AEC   * electricity cost
      Olc   - labor
      Svc   = supervisory cost
      Mlc   = maintenance labor cost
      Mtc   = maintenance materials cost
   +  ASC   = annual solvent cost

      Tdac  = total direct annual costs (operating  costs)

      OH    = overhead
      adm   = administrative cost
      Pt    = property taxes
      In    = insurance
   +  CRC   * capital recovery cost

      Tiac  = total indirect annual costs

      * total annual costs
      Tac   = Tdac + Tiac
                                                   A-12

-------
CONDENSER
INPUT PARAMETERS

   ORGANIC VAPOR ONLY

   Emission Stream Input Parameters:

      Naxioun Flow Rate (scfm)
      Stream Temperature (cleg F)
   *  Oxygen Content (X)
   *  Moisture Content (X)
      Stream Pressure (mmhg)


   HAP  Input Parameters:
       Inlet HAP Concentration (ppmv or X)
       Molecular Weight (Ib/lb mole)
       Specific Heat Equation Constant A
       Specific Heat Equation Constant B
       Specific Heat Equation Constant C
       Antoine Equation Constant A
       Antoine Equation Constant B
       Antoine Equation Constant C
       Heat Vaporization (BTU/lb mole)
   Design Related Input Parameters:

      Removal Efficiency (X)
   *  Coolant Used
      Condensation Temp (*F)
      Overall Heat Transfer Coeff (BTU/hr-ft2-"F)
      Avg Specific Heat for Coolant (BTU/lb/'F)
      Heat Cap. of Air (Btu/lb/mol'F)
      Heat Cap. of HAP (Btu/lb mol'F)
      Condenser Type
      Length of Tube (in)

   Cost Related Input Parameters:

      Value of Recovered Product ($/lb)
      Duct Cost (Vlinear ft)
      Length of Duct (ft)
      Cost of Fans and Motors ($)
      Damper Cost ($)
      Stack Cost ($)
      Total Pressure Drop (in H20)
      Average Equipment Life (yr)
      Operator Labor Requirements (hrs/shift)
      Maintenance Labor Requirements (hrs/shift)
      Operator Labor Wage ($/hr)
      Maintenance Labor Wage ($/hr)
      Operating Hours (hrs/yr)
      Site Preparation Cost ($)
      Building Cost ($)
      Interest Rate (%)

      Key for CONDENSER TYPE:

         1  = fixed tubesheet
         2 = floating head
HAP
Manual
Oe
Te


Pe
HAPe
MWhap



anta
antb
ante

RE

Tcon
> U
CPcool
Cpair
CPhap
CON type
tubelen
VRPC


Pfan
Pdamp
Pstack
P
n
olr
mlr
olwr
mlwr
HRS
spc
bldg
i
Data
Type
N
N
N
N
N
F
F
F
F
F
F
F
F
F
N
C
F
F
F
F
F
C
F
N
N
N
N
N
N
N
8.
N
N
N
N
N
N
N
M

Len
8
8
5.1
5.1
8.1
8.1
8.1
8.5
8.5
8.5
8.5
8.5
8.5
8.1
5.1
13
8.7
8.7
8.7
8.7
8.7
1
8.7
8
8.2
8.1
8
8
8
8.1
1
8.1
8.1
8.2
8.2
8
8
8
3.2

Fieldname
f low_rate
temp"
o2
moisture
pres
hap cone
DM ~f
cpa-
cpb
cpc
anta
antb
ante
hvap
removl_eff
coolant
t_coolant
heat_coeff
ag_sh_cool
heat_air
cphap
contype
tubelen
value_prod
duct cost
len_duct
fan_cost
dampers
stack_cost
pres_drop
eqpt_life
olabor_req
mlabor_req
o labor wage
m labor wage
op_hrs_yr
site_cost
bldg_cost
int_rate

Range Values

(77)












0 - 100 (90)
(water)

(20)



(D,2
(8), 12,16






(5)
(10)
(0.5)
(0.5)
(12.96)
(H.26)
(6000)


(10)
MESSAGES TO USER

     NONE
                                                   A-13

-------
INTERMEDIATE CALCULATED RESULTS
      Otlm
      Ppart
      Tcon
      Hload
      Aeon
      Qcool
      Ref
      Qrec
log mean temp difference
partial pressure
condenser temp
condenser heat load
condenser size
coolant flow rate
refrigeration capacity
recovered product
CAPITAL COSTS
      Spc
      Bldg
      PEC
   +  DC
      Tdc
     Tref
   +  Tic
site preparation
building cost
purchased equipment cost
direct installation costs
total direct costs
refrigerant capital costs
total indirect costs
      Tec   = total capital costs


OPERATING COSTS

      AEC   * electricity cost
      Olc   = labor
      Svc   * supervisory cost
      Mlc   * maintenance labor cost
   +  Mtc   = maintenance materials cost

      Tdac  * total direct annual costs (operating costs)


      OH    * overhead
      adffl   = administrative cost
      Pt    » property taxes
      In    = insurance
   +  CRC   = capital recovery cost

      Tiac  = total indirect annual costs

      RC    = value of recovered product

      * total annual costs
      Tac   * Tdac + Tiac - RC
                                                   A-14

-------
FABRIC FILTERS
INPUT PARAMETERS

   INORGANIC PARTICIPATE ONLY

   Emission Stream Input Parameters:

      Naxinun Flow Rate (scfm)
      Stream Temperature (deg F)
      Moisture Content (X)
      Mean Particle Diameter (Ug)
      Particulate Content (gr/scf)
   *  Drift Velocity (ESPs only,  ft/s)
      S03 Concentration (ppmv)


   HAP Input Parameters:

      Inlet HAP Concentration (ppmv or  %)
   *  Molecular Weight (Ib/lb mole)
   *  Specific Heat Equation Constant A
   *  Specific Heat Equation Constant B
   *  Specific Heat Equation Constant C
   *  Antoine Equation Constant A
   *  Antoine Equation Constant B
   *  Antoine Equation Constant C
   *  Heat Vaporization (BTU/lb mole)
 HAP   Data
Manual Type  Len
Qe 1
Te 1
Me 1
Dp 1
Partcon 1
1
S03 1
HAPcon f








= 8.7
'• 8.7
1 5.1
: 8.7
= 8.7
= 8.7
: 8.7
8.1
8.1
8.5
8.5
8.5
8.5
8.5
8.5
8.1
flow_rate
temp
moisture
diameter
part_cont
velocity
so3_conc
hap_conc
mw
cpa
cpb
cpc
ant a
antb
ante
hvap
Fieldname    Range Values (default)
                                (77)
Design Related Input Parameters:

   Filter Cleaning Method

   Mat. Type (polyester,  propylene etc.)
   Air to Cloth Ratio (ft/min)
*  Neg. Baghouse Operating Pressure? (Y/N)

Cost Related Input Parameters:

   Site Preparation Cost  ($)
   Building Cost ($)
   Cost of Cyclone ($)
   Cost of Bag ($/ft2)
   Life of Bag (yr)
   Waste Disposal Cost Factor ($/ton)
   Duct Cost ($/linear ft)
   Length of Duct (ft)
   Cost of Fans and Motors (S)
   Damper Cost ($)
   Stack Cost ($)
   Stainless Steel Add on (Y/N)
   Insulation Add on (Y/N)
   Total Pressure Drop (in H20)
   Average Equipment Life (yr)
   Operator Labor Requirements (hrs/shift)
   Maintenance Labor Requirements  (hrs/shift)
   Operator Labor Wage ($/hr)
   Maintenance Labor Wage ($/hr)
   Operating Hours (hrs/yr)
   Interest Rate <%)

   ** Key for CLEANING METHOD:

      MSI  - Mechanical Shaking,  Intermittent
      MSC - Mechanical Shaking, Continuous
      PJFCH - Pulse Jet Filters, Common Housing
      PJFM - Pulse Jet Filters, Modular
      RAF  - Reverse Air Filters
      C8F  - Custom Built  Filters
                                                     FCM
                   clean meth

ACrat

spc
bldg
Pcyc
Bagc
nb
Wdcf


Pfan
Pdamp
Pstack
SS
INS
P
n
olr
mlr
olwr
mlwr
MRS
i
C
F
C
N
N
N
N
N
N
N
N
N
N
N
C
C
N

N
N
N
N
N
N
13
8.7
1
8
8
8
8
8.1
8
8.2
8.1
8
8
8
1
1
8.1
8.1
8.1
8.1
8.2
8.2
8
3.2
material
air_cloth
bag_conf i g
site_cost
bldg~cost
cyc_cost
cost bag
bag_life
disp_fact
duct~cost
len_duct
fan_cost
dampers
stack_cost
stainsteel
insulation
pres_drop
eqpt_life
olabor_req
mlabor_req
olaborwage
mlaboruage
op_hrs_yr
int rate
(polyes
(2.5)
(Y), N



(.59)
(2)
(200)





(N)
(N)
(5)
(20)
(3)
(1)
(12.96)
(14.26)
(6000)
<10)
             ** (MSI),MSC,PJFCH,
                PJFM,RAF,CBF
                                                   A-15

-------
MESSAGES TO USER

   NONE


INTERMEDIATE CALCULATED RESULTS

      Anc = net cloth area
      Ate = total cloth area


CAPITAL COSTS

      Spc   * site preparation
      Bldg  = building cost
      PEC   * purchased equipment cost
   +  DC    = direct installation costs

      Tdc   = total direct costs
   +  Tic   * total indirect costs

      Tec   • total capital costs


OPERATING COSTS

      AEC   • electricity cost
      Olc   = labor
      Svc   = supervisory cost
      Mlc   * maintenance labor cost
      Mtc   = maintenance materials cost
      Wdc   = waste disposal cost
      cca   = compressed air cost
      crb   = cost of replacement bags

      Tdac  = total direct annual costs (operating costs)


      OH    = overhead
      adm   - administrative cost
      Pt    = property taxes
      In    = insurance
   +  CRC   = capital recovery cost

      Tiac  = total indirect annual costs

      * total annual costs
      Tac   = Tdac + Tiac
                                                   A-16

-------
VENTURI SCRUBBER
INPUT PARAMETERS

   ORGANIC PARTICIPATE ONLY

   Emission Stream Input Parameters:

      Maximum Flow Rate (scfm)
      Stream Temperature (deg F)
   *  Moisture Content (X)
   *  Mean Particle Diameter (Ug)
   *  Paniculate Content (gr/scf)
   *  Drift Velocity (ESPs only, ft/s)
   *  S03 Concentration (ESPs only, ppmv)
                            HAP   Data
                           Manual Type
                             Qe
                             Te
Len   Fieldname    Range Values (default)
8
8
5.1
8.7
8.7
8.7
8.7
flow_rate
temp"
moisture
diameter
part_cont
velocity
so3 cone
(77)
   Design Related Input Parameters:

      Required Collection Efficiency (X)              CE
      Sat. Moist. Content (Ibs H20/lb of dry air)     Lws
      Actual Moist. Content (Ibs H20/lb of dry air)   Lwa
      Stream Saturation Temperature (*F)             Tes
      Material of Construction                       Mat

  Cost Related Input Parameters:
      Site Preparation Cost ($)
      Building Cost ($)
      Cost of Cyclone ($)
      Duct Cost (S/linear ft)
      Length of Duct (ft)
      Cost of Fans and Motors ($)
      Damper Cost ($)
      Stack Cost (J)
      Total Pressure Drop (in H20)
      Average Equipment Life (yr)
      Operator Labor Requirements (hrs/shift)
      Maintenance Labor Requirements (hrs/shift)
      Operator Labor Wage ($/hr)
      Maintenance Labor Wage ($/hr)
      Operating Hours (hrs/yr)
      Interest Rate (X)

      Key to MATERIAL OF CONSTRUCTION:

         0 = Carbon Steel
         1 = 304 Stainless Steel
         2 = 316 Stainless Steel
MESSAGES TO USER

        Condition

        P > 80
        Oea < 10000
        Qea > 150000
                                        5.1
                                        8.7
                                        8.7
                                        8.7
                                        1
      contrl_eff
      satjnoist
      actjnoist
      sat_temp
      material
             0 - 100 (99)
             ** 0 - 3 (0)
spc
bldg
Pcyc


Pfan
Pdamp
Ps tack
P
n
olr
mlr
olur
mlwr
MRS
i
N
N
N
N
N
N
N
N
N

N
N
N
N
N
N
8
8
8
8.2
8.1
8
8
8
8.1
8.1
8.1
8.1
8.2
8.2
8
8.2
site_cost
bldg_cost
cyc_cost
duct cost
len_duct
fan_cost
clampers
stack_cost
pres_drop
eqpt_llfe
olabor_req
ml abor_req
olaborwage
mlaborwage
op_hrs_yr
int_rate








0 - 80 (40)
(10)
(2)
(1)
(12.96)
(14.26)
(6000)
(10)
Variable         Message

Pflag            **Venturi Scrubber may not be applicable with this pressure drop
Qeaflag          ***Cost Value may not be accurate for this flow rate
Qeaflag          ***Cost Value may not be accurate for this flow rate
INTERMEDIATE  CALCULATED  RESULTS

      Qea = actual  flow  rate
      Qes = saturation flow rate
                                                   A-V

-------
CAPITAL COSTS

      Spc
      Bldg
      PEC
   +  Oc
      Tec
site preparation
building cost
purchased equipment cost
direct installation costs
      Tdc   « total direct costs
      Tic   - total indirect costs
total capital costs
OPERATING COSTS
      AEC
      Olc
      Svc
      Mlc
      Mtc
   +  WCst
electricity cost
labor
supervisory cost
maintenance labor cost
maintenance materials cost
water cost
      Tdac  = total direct annual costs (operating costs)
      OH    = overhead
      adm   - administrative cost
      Pt    « property taxes
      In    = insurance
   +  CRC   = capital recovery cost

      Tiac  * total indirect annual costs

      * total annual costs
      Tac   » Tdac + Tiac
                                                   A-13

-------
ESP (Electrostatic Precipitator)
INPUT PARAMETERS
   ORGANIC PARTICULATE ONLY

   Emission Stream Input Parameters:

      Maximum Flow Rate (scfm)
      Stream Temperature (deg F)
   *  Moisture Content (X)
   *  Mean Particle Diameter (Ug)
      Participate Content (gr/scf)
      Drift Velocity (ESPs only, ft/s)
      S03 Concentration (ppmv)


   HAP Input Parameters:
      Inlet HAP Concentration (ppmv or X)
      Molecular Weight (Ib/lb mole)
      Specific Heat Equation Constant A
      Specific Heat Equation Constant B
      Specific Heat Equation Constant C
      Antoine Equation Constant A
      Antoine Equation Constant B
      Antoine Equation Constant C
      Heat Vaporization (BTU/lb mole)
   Design Related Input Parameters:

      Control Efficiency (X)
      Liquid Rate (gals/min)
      Fluid Head (ft of water)

  Cost Related Input Parameters:

      ESP Type
        Nozzles? (Y/N)
        Hopper Auxiliary?  (Y/N)
        Weather Enclosure? (Y/N)
        Structure Support? (Y/N)
        Insulation? (Y/N)
      Material of Construction
      Site Preparation Cost ($)
      Building Cost ($)
      Cost of Cyclone ($)
      Duct Cost (S/linear  ft)
      Length of Duct (ft)
      Cost of Fans and Motors  ($)
      Motor Efficiency (%)
      Damper Cost ($)
      Stack Cost ($)
      Total Pressure Drop  (in  H20)
      Average Equipment Life (yr)
      Operator Labor Requirements  (hrs/shift)
      Maintenance Labor Requirements (hrs/shift)
      Operator Labor Wage  ($/hr)
      Maintenance Labor Wage (S/hr)
      Operating Hours (hrs/yr)
      Interest Rate (X)
      Waste Disposal Cost  Factor ($/ton)
 HAP   Data
Manual Type  Len
Fieldname    Range Values (default)
Oe
Te


Partcon
Ud
S03
HAPcon








RE
01
Z
N
N
N
N
N
N
N
F
F
F
F
F
F
F
F
F
N
F
F
8
8
5.1
8.3
8.3
8.3
8.3
8.1
8.1
8.5
8.5
8.5
8.5
8.5
8.5
8.1
6.2
8.7
8.7
flow rate
temp"
moisture
diameter
part_cont
velocity
so3_conc
hap_conc
mw
cpa
cpb
cpc
ant a
antb
ante
hvap
contrl_eff
liq_rate
fluid head
                                 0 -  100 (99)
Dtyp
C
7 esp_type (PWESPB),PWESPE,FPESPB,
FPESPE , TSPESP , TSBSESP . WESP ,

C
C
C
C
C

spc
bldg
Pcyc


Pfan
nm
Pdamp
Pstack
P
n
olr
mlr
olwr
mlur
HRS
i
Wdcf






C
N
N
N
N
N
N
N
N
N
N

N
N
N
N
N
N
*
TESP
1 nozzles Y,(N) for PWESPB.FPESPB
1 hopper aux Y.(N) for PWESPB.FPESPB
1 wthr encl Y,(N) for PWESPB.FPESPB
1 stnfsupp Y,(N) for PWESPB.FPESPB
1 insulation Y,(N) for PWESPB.FPESPB
1 mat_const ** 0 - 6 (0)
8 site_cost
8 bldg~cost
8 eye cost
8.2 duct cost
8.1 len_duct
8 fan cost
5.1 motor_eff (65)
8 dampers
8 stack cost
8.1 pres drop 0 - 80 (5)
8.1 eqpt_life (20)
8.1 olabor_req (0.5)
8.1 mlabor req (0.5)
8.2 olaborwage (12.96)
8.2 mlaborwage (14.26)
8 op_hrs_yr (6000)
8.2 inl_rate (10)
8 disp_fact (200)

only
only
only
only
only



















                                                   A-19

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      ** Key for ESP TYPE
         PWESPB
         PUESPE
         FPESPB
         FPESPE
         TSPESP
         TSBSESP
         WESP
         TESP
Plate Wire ESP, Basic
Plate Uire ESP, Enhanced
Flat Plate ESP, Basic
Flat Plate ESP, Enhanced
Two Stage Packaged ESP
Two Stage Basic System ESP
Wet ESP
Tubular ESP
      ** Key for MATERIAL OF CONSTRUCTION
             Carbon Steel
             304 Stainless Steel
             316 Stainless Steel
             Carpenter 20 CB-20
             HoneI - 400
             Nickel - 200
             Titanium
MESSAGES TO USER

   NONE

INTERMEDIATE CALCULATED RESULTS

      Qea = actual flow rate
      SCA = specific collection area
      Ap = overall collection area


CAPITAL COSTS

      Spc   * site preparation
      Bldg  = building cost
      PEC   = purchased equipment cost
   +  DC    = direct installation costs

      Tdc   = total direct costs
   +  Tic   = total indirect costs

      Tec   = total capital costs


OPERATING COSTS

      AEC   = electricity cost
      Olc   = labor
      Svc   = supervisory cost
      Mlc   = maintenance labor cost
      Mtc   = maintenance materials cost
      Wdc   = waste disposal cost
      CS03  = S03 cost
      Wtcst - water treatment cost
   +  West  = water cost

      Tdac  = total direct annual costs (operating costs)

      OH    = overhead
      adm   = administrative cost
      Pt    = property taxes
      In    = insurance
   +  CRC   = capital recovery cost

      Tiac  = total indirect annual costs

      * total annual costs
      Tac   = Tdac + Tiac


                                                   A-20

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                                          APPENDIX B
                                   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, Control
Technologies for Hazardous Air Pollutants (June 1991)(EPA 625/6-91/014). The possible control devices include
thermal incinerators, catalytic incinerators, flares, carbon adsorbers, packed column scrubbers, condensers,
fabric filters, venturi scrubbers, and ESPs. AH 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
                                               3-1

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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 substracting the solvent recovery credit, where it applies.
                                                3-2

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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing.)
1 REPORT NO 2.
EPA-453/B-94-038
4 TITLE AND SUBTITLE
HAP-PRO User's Manual, Version 1.2
7 AJTHOR(S)
Joseph E. Steigerwald
9 PERFORMING ORGANIZATION NAME AND ADDRESS
Control Technology Center (CTC)
Emission Standard Division, MD-13
U.S. EPA
Research Triangle Park, NC 27711
12 SPONSORING AGENCY NAME AND ADDRESS
Emission Standard Division, MD-13
Office of Air Quality Planning and Standards, U.S. EPA
Research Txiangle Pajik, NC 27711
3 RECIPIENTS ACCESSION NO
S REPORT DATE
May, 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 CODE
15 SUPPLEMENTARY NOTES
16 ABSTRACT
The primary purpose of the Hazardous Air Pollutant I
permit engineers in reviewing applications for control o
the capital and annual costs for up to six different vol<
and three participate control devices, including selectee
Calculations used by the program mirror those presented
Technologies for Hazardous Air Toxics (June 1991) (EPA-62!
purpose of HAP-PRO is to generate reports that list all 1
specified pollutant in thoir emiacion ctrcam(c or 2) at
stream (e.g., organic or inorganic vapors and particular
Version 1.2 includes the addition of an expert revi«
thermal incinerators, catalytic incinerators, and carbon
gram will review the design results generated, make recor
allow for design sensitivities to be easily evaluated.
3rogram (HAP-PRO) is to atii^t
E air toxics by calculating
atile organic compound (vOc.i
i engineering parameters .
.n the EPA Handbook, Control
5/6-91/014) . A secondaiy
Facilities containirui 1} n
.specified typo of eniift.'iuii
ss) .
sw system for the desian of
adsorber systems. The pro-
nmendations for changes, and
17 • KEY WORDS AND DOCUMENT ANALYSIS

1
4
a DESCRIPTORS b iOEflTieiERS/OPEN BJDEiD "ESMS c .,:-••, , • > .. ;
i
Hazardous Air Pollutants Air Pollution
Tontrol Technology Canter Control j
Air Pollution Control Equipment Design
•.
i
1
i
i
4
                              Avaliable  f rnm
                                                                   Un c 1 ac o i f i c; "I
EPA Form 2220-1 (R«v 4-77)   PREVIOUS EDITION 'S OBSOLETE

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