United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EPA-450/3-88-003
October 30 1986
Air
Summary of Emissions
Associated with
Sources of Naphthalene
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EPA-450/3-88-00;
Summary of Emissions
Associated with
Sources of Naphthalene
Emission Standards Division
U.S. r.nyiro'-;;;.,,-^: ,-•
.
••' '••' "•: Jack;:' ••'••<
thic , !L of
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Radiation
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
October 30, 1986
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This report has been reviewed by the Emission Standards Division of the Office of Air
' ^ """ °
d rae "»™ °
intended to constitute endorsement or recommendation for use Copies of this
the Library Services Offices (MD-35), U.S. Env.ronmenta, Protectio'n A e^^ a n
2771 1 , or from National Technical Informat.on Serv.ces, 5285 Port Royal Road, Sprmgf.eld VA 221 61
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TABLE OF CONTENTS
Section " Pa5e
LIST OF TABLES V
LIST OF FIGURES vi i
1.0 INTRODUCTION AND SUMMARY 1-1
2.0 NAPHTHALENE PRODUCTION AND END USES 2-1
2.1 Introduction 2-1
2.2 Naphthalene Production Processes .... 2-1
2.2.1 Naphthalene from Coal Tar .... 2-1
2.2.2 Naphthalene from Petroleum .... 2-7
2.3 Naphthalene Usage 2-8
2.3.1 Phthalic Anhydride 2-11
2.3.2 Carbamate Insecticides 2-13
2.3.3 2-Naphthol 2-16
2.3.4 Synthetic Tanning Agents 2-16
2.3.5 Surface Active Agents 2-16
2.3.6 Moth Repellant . . 2-21
2.3.7 Miscellaneous Uses 2-23
3.0 NAPHTHALENE EMISSION SOURCES AND ESTIMATES ... 3-1
3.1 Naphthalene Emission Sources 3-1
3.2 Air Impacts 3-2
3.2.1 Emissions from Handling and
Production of Naphthalene 3-2
3.2.2 Emissions from Naphthalene End
Uses 3-2
3.2.3 Naphthalene Emissions from
"Inadvertent Sources" 3-5
3.2.4 Naphthalene Emission Summary . . . 3-5
iii
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TABLE OF CONTENTS
(concluded)
Section Page
3.3 Water Impacts 3-5
3.4 Solid Waste Impacts 3-10
4.0 REGULATIONS AFFECTING THE ENVIRONMENTAL
RELEASE OF NAPHTHALENE 4-1
4.1 Toxic Substances Control Act 4-1
4.2. NSPS for SOCMI Equipment Leaks 4-1
5.0 AMBIENT AIR MONITORING DATA FOR NAPHTHALENE. . . 5-1
6.0 REFERENCES 6-1
Appendix A Documentation for Human Exposure
Model Input DAta A-l
Appendix B Procedures for Estimating Naphthalene
Emissions from Coke By-Product Recovery
Plants B-l
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LIST OF TABLES '
Table Title Page
2-1 U.S. Coke By-product Recovery Plants Handling/
Processing Naphthalene 2-2
2-2 Current and Potential U.S. Naphthalene
Producers and Capacities, 1985 2-5
2-3 U.S. Naphthalene Consumption, 1983 2-10
2-4 Producers of Synthetic Tanning Agents 2-18
2-5 Producers of Surface Active Agents from
Naphthalene Derivatives 2-22
2-6 Miscellaneous Naphthalene Derivatives and
Producers 2-24
3-1 Naphthalene Emissions from Coke By-product
Recovery Plants 3-3
3-2 Naphthalene Emissions from Production of
Chemical-grade Naphthalene 3-4
3-3 Naphthalene Emissions from Major Users .... 3-6
3-4 Summary of Naphthalene Emissions from All
Sources 3-9
A-l Modeling Parameters for Naphthalene Emissions
from Coke By-product Recovery Plants A-27
A-2 Modeling Parameters for Naphthalene Emissions
from Naphthalene Production A-29
A-3 Modeling Parameters for Naphthalene Emissions
from Phthalic Anhydride Production A-31
A-4 Modeling Parameters for Naphthalene Emissions
from Carbamate Insecticides A-32
A-5 Modeling Parameters for Naphthalene Emissions
from 2-naphthol Production A-33
A-6 Modeling Parameters for Naphthalene Emissions
from Production of Synthetic Tanning Agents . . A-34
A-7 Modeling Parameters for Naphthalene Emissions
from Production of Surface Active Agents --
1-naphthalenesulfonic Acid A-35
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LIST OF TABLES
(concluded)
Table Title Page
A-8 Modeling .Parameters for Naphthalene Emissions
from Production of Surface Active Agents —
2-naphthalenesulfonic Acid A-37
A-9 Modeling Parameters for Naphthalene Emissions
from Production of Moth Repellant A-39
A-10 Modeling Parameters for Naphthalene Emissions
from Production of Miscellaneous Organic
Chemicals A-40
VI
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LIST OF FIGURES
Figure Title Page
2-1 Final cooler with naphthalene sepa'ration .... 2-4
2-2 Naphthalene production from coal tar 2-6
2-3 Production of naphthalene from petroleum
fractions 2-9
2-4 End uses of naphthalene 2-12
2-5(a)Flow diagram for oxidation process in production
of phthalic anhydride 2-14
2-5(b)Fow diagram for refining process in production
of phthalic anhydride 2-15
2-6 Flow diagram for carbaryl production using
naphthalene 2-17
2-7 Selected paths to naphthalenesulfonic acids. . . 2-20
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1.0 INTRODUCTION AND SUMMARY
The purpose of this document is to identify and quantify, on a
preliminary basis, all emission sources of naphthalene. These esti-
mates will be used to estimate public exposure to naphthalene using
EPA's human exposure model (HEM). Information used to assemble this
document came from existing information sources, including previously
published EPA documents and reports, general chemical and engineering
references, current literature and periodicals, and State agency files.
In addition, information was obtained through telephone conversations
with State air pollution control personnel and/or visits to State
agenci es.
In most cases there was little information available for indi-
vidual producers and users of naphthalene. The scope and purpose of
this project did not allow, in many instances, the desired investiga-
tion or follow up to fill information gaps. Therefore, where informa-
tion was not available, assumptions were made.
SUMMARY
There are 17 producers of crude and/or refined naphthalene in the
U.S. Twleve of these producers are coke by-product recovery plants
that may refine naphthalene or manufacture a coal tar product containing
naphthalene. Two of the 17 producers use coal tar as a raw material to
manufacture chemical-grade naphthalene, and three other producers use
petroleum as a raw material to produce chemical-grade naphthalene.
Naphthalene is used primarily as an intermediate in the production of
organic chemicals, including phthalic anhydride (mainly), carbamate
insecticides, surface active agents, synthetic tanning agents, and
miscellaneous organic chemicals. The only direct use of naphthalene is
for moth repellant. Koppers in Follansbee, WV, which manufactures
naphthalene from coal tar, is the only producer that uses some of the
naphthalene it produces on-site for the production of an end-use
chemical, namely, phthalic anhydride. All other producers sell naphthalene
to various customers for the manufacture of other end-use chemicals.
Emission sources from the production and use of naphthalene are
primarily from distillation unit vents, equipment leaks from pump seals
1-1
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and flanges, and naphthalene storage tanks. Process emissions
may be vented to a flare or other control device, although informa-
tion was not usually available to indicate what emission controls, if
any, are used. Total naphthalene process emissions from production
and use are estimated to be about 85 Mg/yr. Fugitive emissions of
naphthalene are approximately 43 Mg/yr, and total storage emissions of
naphthalene are estimated to be about 84 Mg/yr. Naphthalene emissions to
the atmosphere from all sources are about 213 Mg/yr. The largest
contributors of naphthalene emissions are coke by-product recovery
plants and naphthalene users, emitting about 38 and 35 percent of total
naphthalene emissions, respectively. Naphthalene producers contribute
about 25 percent of the total. Less than 3 percent of naphthalene
emissions originate from combustion processes, primarily residential
wood and coal heating.
1-2
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2.0 NAPHTHALENE PRODUCTION AND END USES
2.1 INTRODUCTION
Naphthalene is produced from either coal tar or petroleum as raw
materials. Approximately 55 percent of the total annual capacity of
chemical-grade naphthalene is recovered from coal-tar-based
feedstocks, while the remainder is from petroleum refinery streams.
Crude naphthalene from coal tar may be produced at one of twelve coke by-
product recovery plants in the U.S. Five U.S. companies currently
produce chemical-grade naphthalene from either coal tar or petroleum at
facilities operating with a total annual capacity of 184 gigagrams (Gg),
based on a January 1985 estimate.1 In addition, two other companies,
U.S.S. Chemicals and Ashland Chemical Company, have a total of three
facilities to produce chemical naphthalene; however, all three are closed
due to market conditions.1>2
Since the early 1970's, naphthalene production as a whole has
decreased at an average rate of about 3 percent per year, from 326 Gg
in 1970 to 184 Gg in 1985.1'^ The decline in naphthalene production
primarily resulted from competition with ortho-xylene as the feedstock
for phthalic anhydride, the major chemical derivative of naphthalene.^
Since ortho-xylene is currently the preferred raw material for
phthalic anhydride manufacture, only about one-fourth to one-third
of phthalic anhydride produced in the United States is based on
naphthalene feed.
2.2 NAPHTHALENE PRODUCTION PROCESSES
2.2.1 Naphthalene from Coal Tar
2.2.1.1 Coke By-product Recovery Plants. Coal-tar naphthalene
may be recovered as a crude by-product from the coking of coal at
some coke-oven by-product plants. Table 2-1 lists the twelve U.S.
coke by-product recovery plants that handle and/or process naphthalene.
Naphthalene, which is present as a constituent of coke oven gas, is
removed from the gas stream after the coke oven gas leaves the ammonia
adsorber. The naphthalene-containing gas is cooled in a tower scrubber
(called a final cooler) by direct contact with water to condense most
2-1
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Table 2-1. U.S. COKE BY-PRODUCT RECOVERY PLANTS
HANDLING/PROCESSING- NAPHTHALENE*
Plant
Empire Coke
Republic Steel
National Steel
Interlake
Indiana Gas & Chemical
U.S. Steel
Rouge Steel Co.
National Steel
Bethlehem Steel
Chattanooga Coke &
Chemical
Lone Star Steel
J&L Steel
(LTV Steel )
Location
Holt, AL
Gadsden, AL
Granite City, IL
S. Chicago, IL
Terre Haute, IN
Gary, IN
Dearborne, MI
Detroit, MI
Bethlehem, PA
Chattanooga , TN
Lone Star, TX
Pittsburgh, PA
Coke Production
Capacity
(1,000 Mg/yr)
161
758
570
582
132
4,228
778
1,397
2,253
130
507
1,792
Reference 5.
2-2
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of the naphthalene and any entrained tar and vapors, thus separating
naphthalene from the gas stream before the gas is processed further.6
The condensed naphthalene floats to the top of the water in the final
cooler, is skimmed and collected in open sumps as an impure, yellow-brown
slurry containing about 50 to 60 percent water.5»7 Separation may be
enhanced with a froth flotation separator or similar equipment. The
naphthalene slurry may be pumped into a tank where water is removed by
gravity separation, which crystallizes the product. The resulting
crude naphthalene may be dissolved in coal tar after physical separation
and sold as a commercial feedstock. A typical dry coal tar processed
in the United States contains approximately 8 to 10 weight percent
naphthalene.4>8 Although crude naphthalene has little market value,
about 40 percent of coke by-product recovery plants handle and/or
process naphthalene in some manner.
If the crude naphthalene is further refined on-site, the
crystallized product may be refined through drying when the crystals
are melted in a separate rectangular tank equipped with coils for
either cold water or steam circulation.5 After 24 hours in the vessel,
an upgraded (chemical-grade) naphthalene (>78°C crystallization point)
is generated. Figure 2-1 is a flow diagram of a final cooler and
recirculating water Circuit with naphthalene collected by physical
separation at a typical coke by-product recovery plant that handles
and/or processes naphthalene.
2.2.1.2 Coal-tar Naphthalene Producers. As discussed above, the
naphthalene product that is dissolved in coal tar at coke by-product
recovery plants may be sold as a commercial feedstock to companies that
produce chemical-grade naphthalene as an intermediate product for
various end uses. Coal-tar naphthalene accounts for about 55 percent
of the total annual chemical naphthalene capacity. There are only two
U.S. producers of chemical naphthalene in operation that use coal tar
as a raw material, namely, Allied Chemical in Ironton, Ohio, and Koppers
Company in Follansbee, West Virginia. These plants and their location
and capacities are listed in Table 2-2.
Figure 2-2 depicts a general process for the production of chemical
naphthalene from coal tar. To recover naphthalene from coal tar, the
crude tar is distilled and fractionated. The crude coal tar is generally
2-3
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RECIRCULATING WATER
COKE OVEN GAS
50-60*C
FINAL
COOLER
20-30»C
NAPHTHALENE
SEPARATION
CRUDE NAPHTHALENE TO
FURTHER PROCESSING
COOLED COKE OVEN
GAS TO LIGHT OIL
SCRUBBER
SATURATED AIR
ATMOSPHERIC
COOLING
TOWER
T
AMBIENT AIR
WATER
SLOWDOWN
Figure 2-1. Final cooler with naphthalene separation.
2-4
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Table 2-2. CURRENT AND POTENTIAL U.S. NAPHTHALENE
PRODUCERS AND CAPACITIES, 1985
Producer
Location
Capaci ty
(Mg/yr)
Raw Material Used/Remarks
Coal-tar naphthalene
Al 11 ed Chemical
Koppers Co.
U.S.S. Chemicals
Petroleum naphthalene
Chemical Exchange
Industries (Advanced
Aromatics Chemical Co.)
DuPont
Texaco Chemical
Ashland Chemical
Ironton, OHa
Follansbee, WVa
Clairton, PAC
Gary, INC
34,000b Coal tar/product is sold.
68,000b Coal tar/product is both sold
and captively consumed.
90,000d'e Coal tar.
~e Coal tar.
Baytown, TXa
Chocolate Bayou, TXa 41,000b
14,000° Petroleum naphtha stream/
product is sold.
Delaware City, OEa 27,000b
Ashland, KYC 41,000d
Petroleum (ethylene by-product)/
product is sold.
Petroleum/product is sold.
Petroleum/product is sold.
Total capacity (plants operating)
(plants not operating)
184,000 Mg/yr
131,000 Mg/yr
aCurrent producer - plant in operation, based on information obtained in Reference 1.
bSRI International estimates as of January 1, 1985 (Reference 1).
cPlant not operating. This plant is on standby and can be restarted if market conditions
warrant (Reference 9).
dEstimates as of October 1984 (Reference 2).
eCombined capacity for facilities in Clairton, PA, and Gary, IN.
2-5
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Middle Oil
Coal
tar
Waste
Crystallizing
pan
Creosote
oil
Centri f uge
Anthracene
oil
Tar acids
and bases
to recovery
Waste
To cresol
and phenol
plant
Crude
Naphthalene
Cooling
Pan
Refined
Naphthalene
Figure 2-2. Naphthalene production from coal tar.
10
2-6
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distilled in pipe stills in either a batch or continuous process. The
tar is discharged into a flash tank from which the vapors pass to con-
densers; the still bottom and the pitch are sent to receiving tanks.
If the total distillate is condensed, the distillate is fractionated
in four fractions: light oil, middle oil, heavy oil, and anthracene
oil. The middle oil fraction contains most of the naphthalene and tar
acids.
The middle oil fraction, containing naphthalene, phenols, and
cresols, is pumped hot into shallow pans where it is cooled, allowing
the naphthalene to crystallize. After draining, the crystalline coke
is then broken up and charged into batch centrifuges. The mother
liquors are combined and sent to phenol and cresol recovery units.
The naphthalene coke is washed with hot water to increase its purity
before it is discharged as crude naphthalene. This material is suit-
able for phthalic anhydride manufacture and is graded and sold according
to its melting point.
For refined naphthalene, the crude material is further distilled.
The distillate is first washed with a hot caustic soda solution to
remove phenolic compounds and then washed with concentrated sulfuric
acid to remove basic substances. To yield a refined product, the washed
naphthalene is redistilled. The distillate from the final still is
either cast into forms or is cooled and subsequently .crushed. The
refined material is suitable for manufacture of flakes or pellets for
insecticide use (i.e., mothballs or flakes).^ However, the production
of refined naphthalene from coal tar essentially has ceased in the
United States due to costs of refining and costs of disposing signifi-
cant amounts of waste sludge that is generated by the process.^
2.2.2 Naphthalene from Petroleum
There are three U.S. producers of naphthalene in operation that
use petroleum as a raw material, namely, Chemical Exchange Industries,
Baytown, Texas; duPont, Chocolate Bayou, Texas; and Texaco Chemical,
Delaware City, Delaware. One potential producer, Ashland Chemical
Co. in Ashland, Kentucky, is not currently operating, but may restart
if market conditions warrant. These plants and their capacities are
listed in Table 2-2.
2-7
-------
The production of naphthalene from petroleum involves two principal
steps. The first is the production of an aromatic fraction in the
naphthalene-al kylnaphthalene boiling range, usually by hydroaromatiza-
tion or cyclization. The second step is the dealkylation of the aromatic
fraction either thermally or catalytical ly. The naphthalene that is
produced is recovered as a high quality product, usually by fractional
distil lation. 4 Suitable feedstocks may be the bottoms distilled from
catalytic reformate or a narrow cut distilled and concentrated from
refractory cycle oils. Figure 2-3 presents a general process used to
produce petronaphthalene.
The feedstock and a hydrogen-rich gas are pumped to a dealkyla-
tion reactor. The reactor product is quenched and is then sent to a
separator from which part of the hydrogen-rich gas is recycled and
part burned as fuel. The liquid product is distilled to separate
naphthalene, gasoline, and fuel oil. The naphthalene produced by this
process is usually better than 99 percent pure and is low in sulfur
content. Naphthalene may also be recovered from the stream of
naphthalene-methyl naphthalene formed in the cracking of heavy liquids
for ethylene production.^
2.3 NAPHTHALENE USAGE
Naphthalene is used almost exclusively as an intermediate in the
manufacture of organic chemicals. The only direct use of naphthalene
is as a moth repellant. The U.S. naphthalene consumption by end use
(based on 1983 data) is presented in Table 2-3. Demand for naphthalene
and consumption patterns are not expected to change significantly
through 1988, according to October 1984 estimates.2
Naphthalene derivatives are numerous and can be classified as
follows;11
Al kylnaphthalenes
Chlorinated naphthalenes
Hydrogenated naphthalenes
Naphthalenecarboxylic acids
Naphthalenesul fonic acids
Nitronaphthalenes and nitronaphthalenesulfonic acids
Naphthylamines
2-8
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Hydrogen make-up
^_ Fuel gas
Gasoline
Naphthalene
or other
feedstocks
Figure 2-3. Production of naphthalene from petroleum fractions.
10
2-9
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Table 2-3. U.S. NAPHTHALENE CONSUMPTION, 1983a
Use
Phthalic anhydride
Carbamate insecticides
Surface-active agents
Synthetic tanning agents
Moth repellent
Miscellaneous organic
chemicals
2-naphthol
Total
Naphthalene
consumption
(Gg)
233
23
23
18
13
5
ob
315
% of Total
74
7
7
6
4
2
0
100
aReference 9.
^American Cyanamid, Willow Island, WV, the sole U.S. producer of
2-naphthol, ceased production in 1982 (Reference 9). All 2-naphthol
consumed in the U.S. is now imported.
2-10
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Aminonaphthalenesulfonic acids
Naphthols
Hydroxynaphthal enesul fonic acids
Aminonaphthols
Aminohydroxynaphtha!enesulfonic acids
The three major uses of naphthalene, which represent 88 percent of
naphthalene consumption, are as feedstocks for the production of phthalic
anhydride, carbarnate insecticides, and surface-active agents. The
remaining 12 percent of naphthalene consumption is used in a variety of
applications, including usage as a feedstock in the production of
synthetic tanning agents, in moth repellant, and in the manufacture of
miscellaneous organic chemicals. Figure 2-4 presents a general diagram
of naphthalene use. A brief description of each of the major uses and
its processes is presented below.
2.3.1 Phthalic Anhydride
Seventy-four percent of naphthalene produced is consumed in the
manufacture of phthalic anhydride. Phthalic anhydride is derived from
one of two raw materials, naphthalene or ortho-xylene. For many
years coal tar naphthalene was the only raw material used for phthalic
anhydride production. However, ortho-xylene has gradually replaced
naphthalene as the principal feedstock for phthalic anhydride manufacture;
only about 25 to 35 percent of phthalic anhydride is derived from
naphthalene. Koppers Company, Cicero, Illinois, operates the only
naphthalene-based phthalic anhydride plant in the U.S., with an
annual production capacity'of 20,400 Mg.^2 Koppers shut down its
Bridgeville, Pennsylvania, plant upon restarting its Cicero unit in
1985. The Cicero unit was idle while more than one-half of its
capacity was converted from orthoxylene to naphthalene feedstock. Two
other phthalic anhydride producers, Monsanto and USS, closed their New
Jersey and Pennsylvania units in early 1986 and fall of 1983, respectively.
The phthalic anhydride plant at Koppers in Cicero, Illinois, is
broken down into two operational areas, oxidation and refining. Each
of these sections has a dedicated heat transfer oil system used to
regulate temperature during the process. The facility can use either
naphthalene or ortho-xylene as a raw material.13
2-11
-------
ro
i
Coal-tar
(60*)
Petroleum
(402)
Naphthalene
Phthallc anhydride
(1.2,3.4-)
Tetrahydronaphthalene
Decahydronaphthalene
Plastlclzers
Alkyd resins
Polyester resins
^- 1-naphthol
Naphthalene sulfonlc add
Chloronaphthalenes
Alkylnaphthalenes
carbaryl
2-naphthol
1-naphthol ~|_
1-n1tronaphthaleneJ
-Dyes & dye Intermediates
-Antloxldants for rubber,
fats, and oils
-Pharmaceuticals
.Fungicides, rodentlcldes
Perfumes
Synthetic tanning agents
Dyes
Pharmaceuticals
Rubber chemicals
Rodentlcldes
Perfumes
Mono- and dl-
alkylnaphthalene sulfonlc acids & salts
Surface-active agents
_ Naphtha]eneacetlc acid
_Moth repel 1 ant
*_ Miscellaneous organic chemicals
Figure 2-4. End uses of naphthalene.
14-16
-------
The oxidation section consists of four production trains, two of
which are deactivated. This operation is bro.ken down into seven
subsections: air compressing and heating, ortho-xylene and naphtha-
lene feed systems, reaction and gas cooling, condensing, scrubbing
and incineration, and Mobil therm oil system. A diagram of the oxida-
tion operation is presented in Figure 2-5(a). In the oxidation process,
coal tar naphthalene and/or o-xylene is vaporized, mixed with air
and fed to the reactors. The catalytic oxidation reactors convert
the feedstock to phthalic acid and other by-products. Reactor off
gases are cooled and sent to a bank of six switch condensers which
capture and solidify the product. According to a preset cycle, one of
the condensers is taken out of line and heated to melt out the crude
acid which is then transferred to storage. Condenser off gases are
then scrubbed using venturi and packed-bed scrubbers before release
to the atmosphere. The phthalic anhydride section also has seven sub-
sections consisting of crude storage, decomposing, predistillation,
stripping, refining, refined storage and marlotherm heat transfer oil
system. A diagram of the refining section is presented in Figure
2-5(b). Crude phthalic anhydride feed is sent to a series of four
decomposers where some by-products are removed and the acid converted
to phthalic anhydride. This then goes to predistillation where nonvolatile
by-products are removed. Light ends are removed in the stripping and
the product polished in the refining step. Phthalic anhydride (99.8 percent
pure) is then sent to storage until sold or used in polyester production.^
Approximately 50 percent of current phthalic anhydride production is
used for plasticizers, 25 percent for al kyd resins, 20 percent for unsatura-
ted polyester resins, and 5 percent for miscellaneous and exports.17
2.3.2 Carbamate Insecticides
The second largest use of naphthalene is as a raw material for
the manufacture of carbarmate insecticides, of which carbaryl (Sevin©)
is the most important. Carbaryl is used as a substitute for DDT and
other chlorinated compounds that have become environmentally unaccept-
able. It is registered for use on about 70 crops and is used chiefly
in the South and West.18 Union Carbide at Institute, West Virginia,
is the only domestic producer of carbaryl. 1
2-13
-------
ro
i—•
-P.
REACTION
AND
GAS COOLING
SCRUBBING
AND
INCINERATING
l Am dim
Nlplhilinl (Ulldul '
Figure 2-5(a). Flow diagram for oxidation process in production of phthalic anhydride.
13
-------
llol Uiilmhum ON
ro
i
Slum
I Innl GII
..... J_L
j x
CRUDE
STORAGE
1 I
Cmidoollll Vinltd lltlejw
Ciudt Plllhilic ii>h|diillt
Ciudi Phllulic Anhydlldt
Pilllllh
{jicloi
IllllUll
Slum
Intil Gil i
T 1 '
_K
loilei Ficd WiUi i
C.^undAI, »'l« «»*•'« 1
— - ^ il|
— J
Rllldu.
l|Klo< [ihlull
Sciubbll
Iihiuil
Cult
Innl
Gil
Sltira
REFINED
STORAGE
AND
LOADING
(Sludgi)
Figure 2-5(b). Flow diagram for refining process in production of phthalic anhydride.
13
-------
Crude or semirefined coal tar or petroleum naphthalene can be
used for carbaryl manufacture. Production involves the following
steps: (1) hydrogenation of naphthalene to produce 1,2,3,4-tetrahydro-
naphthalene; (2) oxidation of this compound to produce 1-haphthol ; and
(3) reaction of 1-naphthol with methyl isocyanate to produce 1-naphthyl-
n-methyl carbamate (carbaryl). Intermediate products of this process
-- 1,2,3,4-tetrahydronaphthalene and 1-naphthol -- are also used as
insecticides. Figure 2-6 depicts the production process for carbaryl.
2.3.3 2-Naphthol
A third major use of naphthalene is for the manufacture of 2-
naphthol (beta-naphthol or 2-naphthalenol ). It is an intermediate
primarily used in the manufacture of a variety of dyes or dye interme-
diates. Other applications include its use as insecticides; antioxi-
dants for rubber, fats, and oils; and in the synthesis of fungicides,
Pharmaceuticals, and perfumes.19 American Cyanamid Company in Willow
Island, West Virginia, the only U.S. producer .of 2-naphthol , closed
in 1982. All 2-naphthol consumed in the U.S. is now imported.9
The production process uses high quality petroleum naphthalene
as a feedstock, which is reacted with sulfuric acid. The sodium salt
of the resulting 2-naphthalenesulfonic acid is treated with sodium
hydroxide. The product is then distilled and sub!imed.9.19
2.3.4 Synthetic Tanning Agents
Synthetic tanning agents (syntans) are primarily derivatives of
1- and 2-naphthalenesulfonic acids, their salts, and the sodium
salts of the reaction products of the sulfuric acid and formal dehyde.20
Approximately 6 percent of the U.S. naphthalene supply is consumed in
the manufacture of these compounds. Synthetic tanning agents are used
for both vegetable and chrome tanned leather.IS producers of synthetic
tanning agents and their locations are listed in Table 2-4.
2.3.5 Surface Active Agents (Naphthalenesulfonic acids)
Surface active agents (also known as surfactants) are naphthalene-
sulfonate compounds consisting primarily of 2-naphthalenesulfonic acid,
its alkyl derivatives, and their salts. Naphthalene derivatives, how-
ever, represent a small portion (less than 0.5 percent) of the total
production of surface active agents. The products are used as wetting
2-16
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Hydrogen
Naphthalene
ro
i
Tetrdl in
hydrogenation
unit
Crude
naphthol
dehydrogendtton
unit
1-naphthol
refining
unit
Naphthalene
Naphthalene
Carbaryl
unit
I = Pri
= Primary naphthalene emission point
p I
Figure 2-6. Flow diagram for carbaryl production using naphthalene.
-------
Table 2-4. PRODUCERS OF SYNTHETIC
TANNING AGENTS1'18
Producer Location
Morflex, Inc. Greensboro, NC
(formerly Ciba-Geigy
Dyes tuff Division)
Diamond Shamrock Carlstadt, NJ
Cedartown, GA
Georgia Pacific Corp. Bellingham, WA
Rohm and Haas Co. Philadelphia, PA
2-18
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agents and dispersants in paints, dyes, pigments, coatings, polymeri-
zation emulsi fiers, and concrete additives, as well as in a variety
of pesticides and cleaner formulations.20 The application of naphtha-
lenesulfonate compounds as surface active agents is expected to continue
as a low-growth item; however, recent use of these products as
concrete additives (i.e., plasticizers) may alter, this pattern.20
These products, primarily from the sodium and calcium derivatives of
naphthalenesul fonic acid, formaldehyde condensates, increase the f 1 ow
of concrete without decreasing its strength.
Naphthalene sufonation leads to a mixture of products. When the
process is controlled at less than about 100°C, 1-naphthalenesul fonic
acid is predominantly produced. Sulfonation of naphthalene at above
150°C yields 2-naphthalenesulfonic acid as the main product.H At one
time naphthalenesul fonic acid production technology included only batch
operations but now emphasizes continuous processes, removal of excess
sulfonating agent by stripping under vacuum, and the use of chloro-
sulfonic acid or sulfur trioxide to minimize the need for excess
sulfuric acid. The improved analytical methods have contributed to the
success of process optimization.
A schematic diagram of the main naphthalene sulfonation pathways
is presented in Figure 2-7.
1-Naphthalenesulfonic acid. The sulfonation of naphthalene with
excess sulfuric acid at less than 80°C gives some 1-naphthalenesulfonic
acid, while the majority is 2-naphthalenesul fonic acid.H Older methods,
however, have been replaced by methods which require less, if any,
excess sulfuric acid. For example, sulfonation of naphthalene can be
carried out in tetrachloroethane solution, followed by separation of
the precipitated 1-naphthal enesulfonic acid; the filtrate can be reused
as the solvent for the next batch.
1-naphthalenesul fonic acid can be converted to 1-naphthalenethiol
by reduction of the related sulfonyl chloride; this product is used as
a dye intermediate, and is converted by reaction with al kyl isocyanates,
to S-naphthyl-N-alkylthiocarbamates which are used in pesticides and
herbicides.
2-Naphthalenesulfonic acid. The standard manufacture of 2-
naphthalenesulfonic acid involves the batch reaction of naphthalene
2-19
-------
SO,H
SO3H
N-l,3,5-tri-SA
S03H
SO,H
N-l,3,5.7-tetra-SA
Figure 2-7. Selected paths to naphthalenesulfonic acids
Key: N = naphthalene
SA = sulfonic acid
yld = yield
11
2-20
-------
with sulfuric acid at about 160°C for approximately 2 hours. The
product contains the 1- and 2-isomers in about a 15/85 ratio.H
Sulfonation can be conducted with a mixture of naphthalene and
sulfuric acid with staged acid addition at 160°C over 2.5 hours to give
a 93 percent yield of the desired product. Continuous monosulfonation
of naphthalene with sulfuric acid in a cascade reactor at about 160°C
gives 2-naphthalenesulfonic acid and small amounts of by-product naphtha-
lenedisulfonic acids.
Alkylnaphthalenesulfonic acids and naphthalenesulfonic acid-formal-
dehyde condensates. The alkylnaphthalenesulfonic acids can be made by
sulfonation of al kylnaphthalenes, e.g., with sulfuric acid at 160°C, or
by alkylation of naphthalenesulfonic acids with alcohols or olefins.H
These products, as the acids or their sodium salts, are commercially
important as textile auxiliaries, surfactants, wetting agents, dispers-
ants, and emulsifying aids, (e.g., for dyes, wettable powder pesticides,
tars, and clays). The sodium salts of the condensation products of
naphthalenesulfonic acid with formaldehyde constitute the most important
class of synthetic tanriing agents for hides, which were discussed in
Section 1.3.4. The naphthalenesulfonic acid-formaldehyde condensation
products are also used as plasticizers for concrete, as stated earlier.
Release of naphthalene from the use of surface active agents occurs
indirectly, possibly from their degradation. 18 since 2-naphthalene-
sul fonic acid hydrolyzes to naphthalene in the presence of steam,
naphthalene detected in paint, textile, and ink discharge streams is
most likely a degradation product formed when vats and tanks are
cleaned by injecting steam. These industries use both surface active
agents and naphthalene-containing dyes; it is difficult to determine
from which product the naphthalene arises.
A partial listing of producers of surface active agents and their
locations is given in Table 2-5.
2.3.6 Moth Repel 1 ant
Moth repellant accounts for about 4 percent of the U.S. naphthalene
consumption. The production of naphthalene-based moth repellant is
decreasing, however, due to the availability of para-dichlorobenzene
and the increased use of synthetic fibers.^ Moth repellant is the
only consumer product manufactured directly from naphthalene. The
2-21
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Table 2-5. PRODUCERS OF SURFACE ACTIVE AGENTS
FROM NAPHTHALENE DERIVATIVES11'0
Producer
Location
Chemical
Al lied Chemical
American Cyanamid
Ciba-Geigy
Morflex, Inc.
DeSoto, Inc.
Diamond Shamrock
DuPont
Emkay Chemical Co,
Georgia Pacific
Claymont, DEa
Linden, NJa
Marietta, OHb
Toms River, NJa
Greensboro, NCa
Fort Worth, TXa
Carlstadt, NJa»c
Cedartown, GAa
Deepwater, NJa
Elizabeth, NJa
Bellingham, WAa
2-naphthalenesulfonic acid
1- and 2-Naphthalenesulfonic acids
2-naphthalenesulfonic acid
1-naphthalenesulfonic acid
1-naphthalenesulfonic acid
1- and 2-Naphthalenesulfonic acids
1-naphthalenesulfonic acid
1-naphthalenesulfonic acid
1- and 2-Naphthalenesulfonic acids
1- and 2-Naphthalenesulfonic acids
1-naphthalenesulfonic acid
Reference 22.
bReference 18.
cReference 23.
2-22
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product is manufactured as a solid flake, powder, or ball, and repackaged
for shipment. All of the naphthalene contained in moth repel -lant 'is
emitted to the atmosphere.
There is one U.S. producer of moth repellant from naphthalene,
Morflex, Inc. (formerly Ciba-Geigy), in Greensboro, NC.^3 Kincaid
Enterprises in Nitro, UV, is believed to be shut down or no longer
uses naphthalene in the production of moth repellant.24
2.3.7 Miscellaneous Uses
Approximately 2 percent of naphthalene consumption is used in the
manufacture of various organic chemicals and intermediates. These
chemicals, some of which are listed below, are produced in relatively
small amounts and cannot be separately quantified. Process descrip-
tions are not available for most of these compounds. Table 2-6 lists
the miscellaneous chemicals and producers.
1-naphthol. 1-naphthol (1-naphthalenol, alpha-naphthol) is used
as an intermediate in the manufacture of several agricultural chemicals,
i.e., Carbaryl (Sevin®), napropamide (Stauffer's Devrinol®), and 1-
naphthoxyacetic acid).^ In addition, several drugs are derived from
1-naphthol. For example, the magnesium salt of 3- (4-methoxy -1-
naphthoyl) propionic acid (Hepalande®) is used as a choleretic; pro-
pranolol (Inderal®) is an important adrenergic blocking agent used in
the treatment of angina and cardiac arrhythmias; and 1-naphthyl sal icy-
late (Aphol®) has been used as an antiseptic and antirheumatic.
1-naphthol is also used in the preparation of dyes and dye interme-
diates and as an antioxidant for gasoline. Some of its alkylated deriva-
tives are stabilizers for plastics and rubber. It is an intermediate
in the manufacture of synthetic perfumes.25 -
Union Carbide, the only U.S. producer of 1-naphthol, manufactures
X
the chemical by the oxidation of 1,2,3,4-tetrahydronaphthalene (tetralin)
in the presence of a metal catalyst to an intermediate product which is
dehydrogenated and aromatized to 1-naphthol.^
1,2,3,4-tetrahydronaphtha!ene. This naphthalene derivative (also
called Tetralin) is used as an insecticide and as a specialty solvent.
It is a powerful solvent for oils, resins, waxes, rubber, asphalt, and
aromatic hydrocarbons. Its high flash point and low vapor pressure
make it useful in the manufacture of paints, lacquers, and varnishes;
2-23
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Table 2-6. MISCELLANEOUS NAPHTHALENE DERIVATIVES AND PRODUCERS
Chemical
Producer
Location
Naphthalenols
• 1-naphthol
• Napropamide
1,2,3,4-tetrahydronaphthalene
Decahydronaphthalene
Naphthaleneacetic acids
• 1-naphthaleneacetic acid
Naphthylamines
t 1-rraphthylamine
• Naptalam
1-bromonaphthalene
Alkylnaphthalenes
• 1-methylnaphthalene
• methylnaphthalene
1-naphthaleneacetamide
Chloronaphthalenes"^
• Dichlone
Nitronaphthalenes
• 1-nitronaphthalene1
• 2-nitronaphthalene1
Ni tronaphthalenesul fonic acids
Aminonaphthalenesulfonic acids1
Hydroxynaphthalenesul fonic acids'"
Naphthalenecarboxylic acids1
Union Carbide3
Stauffer Chemical Co.1
DuPonta
Union Carbide3
DuPont3
Rorer-Amchem'3
Greenwood Chemical0
Union Carbide0
Sigma Chemical Co.e
Uniroyal , Inc.c
RSA Corp.f
Chemical Exchange9
Koppers Co.S
Crowley Chemicals
Greenwood Chemical Co.c
Union Carbide0
—d
Uniroyal , IncJ
..d
..d
Ciba-Geigy Corp.S
..d
..d
..d
Institute, WV
..d
Deepwater, NJ
Institute, WV
Deepwater, NJ
Greenwood, VA
Ambler, PA
St. Louis, MO
Gastonia, NC
Ardsley, NY
Houston, TX
Follansbee, WV
Kent, OH
Greenwood, VA
Ambler, PA
..d
..d
Toms River, NJ
—d
__d
..d
2-24
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Table 2-6. MISCELLANEOUS NAPHTHALENE DERIVATIVES AND PRODUCERS
(concluded)
Chemical
Producer
Location
Anthraquinone^
Sebacic acid-J
Reference 25.
^Reference 26.
cReference 27.
^Not available.
eReference 23.
fReference 28.
9Reference 29.
"Reference 20.
^Reference 11.
JReference 30.
^Reference 31.
1 Reference 32.
2-25
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for cleaning printing ink from rollers and type; in the manufacture of
shoe creams and floor waxes; as a solvent in the textile industry; and
for the removal of naphthalene deposits in gas-distribution systems.33
Tetrahydronaphthalene is produced by the catalytic treatment of
naphthalene with hydrogen. Nickel or modified nickel catalysts gen-
erally are used commercially; however, they are sensitive to sulfur,
and only naphthalene that has very low sulfur levels can be used. Thus,
sodium treatment and catalytic hydrodesulfurization processes have been
used to remove the sulfur from naphthalene; the latter treatment is
preferred because of the hazardous nature of sodium treatment.33
Decahydronaphthalene. Decahydronaphthalene (also called Decalin)
is used as a solvent for resins and coatings.26 It is produced commer-
cially by the catalytic hydrogenation of naphthalene or 1,2,3,4-
tetrahydronaphthalene. Decahydronaphthalene can be converted to
naphthalene by heating with platinum, palladium, or nickel catalyst at
300°C.33
Naphthaleneacetic acid (naphthylacetic acid). This naphthalene-
derived chemical is used as a plant growth regulator to induce rooting
of plant cuttings, as a germination suppressor for potatoes, and an
intermediate for drug manufacture.26,34 i-naphthaleneacetic acid
(NAA®) can be produced by side-chain chlorination of 1-methyl-
naphthalene to 1-chloromethylnaphthalene and formation of naphthalene-
acetonitrile.34 Alternatively, the chemical may be produced by the
reaction of naphthalene with chloroacetic acid in the presence of
potassium bromide as a catalyst.32
Naphthylamines. Naphthylamines and their derivatives (e.g., 1-
naphthylamine) are used in the manufacture of azo dyes, diazo compo-
nents, and coupling components.H 1-naphthylamine is a dye inter-
mediate and is used as a raw material in the manufacture of rodenticides,
insecticides, miticides, herbicides, and rubber antioxidants. 1-
naphthylamine can be made from 1-nitronaphthalene by reduction with
iron-dilute HC1 , or by catalytic hydrogenation. Naptalam (Alanap®), a
herbicide, is a derivative of 1-naphthylamine, prepared by reacting
phthalic anhydride with 1-naphthylamine.32
2-naphthylamine is recognized as a human carcinogen, producing
bladder cancer from prolonged exposure.H Therefore, this chemical is
2-26
-------
no longer commercially produced or used in the U.S. It was used at one
time in the production of dyes and rubber antioxidants.
1-bromonaphthalene. This is a specialty chemical used to cali-
brate refractometers.35 It is produced by mixing sodium bromate and
water with naphthalene at room temperature. It is usually batch pro-
duced (as needed) in relatively small quantities (50 to 250 kg).
Alkylnaphthalenes. Methyl- and dimethylnaphthalenes are contained
in coke-oven tar and in certain petroleum fractions in significant
amounts. A methylnaphthalene-rich fraction is usually extracted and
used as solvents for pesticides, sulfur, and various aromatic compounds.
They can also be used as low freezing, stable heat-transfer fluids.
Mixtures rich in monoethylnaphthalene content have been_used as dye
carriers for color intensification in the dyeing of synthetic fibers.
They also are used as the feedstock to make naphthalene in dealkylation
processes. Phthalic anhydride can also be made from methylnaphthalene
mixtures by an oxidation process that is similar to the one used for
naphthalene.34
A mixed monomethylnaphthalene-rich material can be produced by
distillation and can be used as feedstock for further processing. By
cooling this material to about 0°C, an appreciable amount of 2-
methylnaphthalene crystallizes leaving a mother liquor consisting of
about equal quantities of 1- and 2-methylnaphthalene. Pure 2-
methylnaphthalene is used primarily as a raw material for the produc-
tion of vitamin K preparations.3^
•1-methylnaphthalene can be used as a general solvent because of
its low melting point. It also is used as a test substance for the
determination of the cetane number of diesel fuels. In addition, as
described earlier, 1-methylnaphthalene is used in the production of
1-naphthaleneacetic acid,-a pla"nt growth regulator and an interme-
diate for drug manufacture.24
1-naphthaleneacetamide. This naphthalene derivative is used as a
pesticide. Two producers of the compound were identified, Greenwood
Chemical Company, Greenwood, VA, and Union Carbide, Ambler, PA.30
However, no information on the chemical, including process descriptions,
was available in state permit files.56,37
2-27
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Chioronaphthalenes. There are 77 possible chloronaphthalenes, but
not all are known or precisely identified materials.31 Some past
commercial uses of this class of compounds have included electrical
insulating materials (mixtures containing tri- to hexachloronaphthalene)
and fungicides, algicides, bactericides, and colorants for plastics
(from mixtures containing octachloronaphthalene). Technical
octochloronaphthalene has been recommended as an additive in grinding-
wheel media and cutting-oil coolants. Monochloronaphthalene and
mixtures of mono- and dichloronaphthalene have been used or recommended
for chemical-resistant gage fluids and instrument seals, as heat exchange
fluids, high-boiling specialty solvents, for_color dispersions, as engine
crank case additives to dissolve sludges and gums, and as ingredients
in motor tuneup compounds. In addition, monochloronaphthalene has been
used as a raw material for dyes and as a wood preservative with fungi-
cidal and insecticidal properties.
One example of a dichloronaphthalene is dichlone (Phygon®), a
fungicide.32 Dichlone may be manufactured by chlorinating 1,4-
naphthoquinone in a single step in the presence of a catalyst at a
temperature of 80-120°C. Alternatively, naphthalene may be used as the
starting material. The chlorination of naphthalene produces a chlori-
nated tetrahydronaphthalene intermediate, which is hydrolyzed and then
oxidized by nitric acid to a chlorinated naphthaquinone, which is
further chlorinated to the final product.
The trichl oronaphthalenes and higher products have been used as
impregnants for condensers and capacitors as well as dipping compounds
in electronic and automotive applications; as temporary binders in the
manufacture of ceramic components; in paper coating and impregnation;
in precision ca-sting of alloys; in electroplating stop-off compounds;
as additives in gear oils and cutting compounds; as flame retardants;
as moisture-proof sealants; and as separators in batteries.
Chlorinated naphthalenes are currently used only as refractive
index oils and as impregnants for capaci tors.38 Refractive index oils
are produced by mixing monochloronaphthalene with mineral oils to yield
testing oils with various high refractive indices. These refractive
index oils are used in small amounts during the preparation of slides
2-28
-------
for observation in crime and petrographic laboratories. Chi oronaphtha-
lenes are still used in some capacitors, primarily for military appli-
cations.
Commercial chloronaphthalenes are manufactured by the metal halide-
catalyzed chlorination of molten naphthalene to the desired chlorination
stage at a temperature slightly above the melting point of the desired
product.31 The hydrogen chloride produced in the reaction must be
treated when used for hydrochloric acid manufacture due to the possible
presence of unreacted chlorine and entrained or vaporized organics.
Crude chloronaphthalenes are treated with soda ash or caustic soda,
fractionated under reduced pressure, and purified with activated clay.
Since the 1920's the use of chlorinated naphthalenes has declined
steadily. Domestic production of chloronaphthalenes ceased in 1980.38
Only about 13.6 Mg of these compounds are imported and processed
annually, the largest percentage of which (about 70;percent) is for use
in refractive index oils. The decline of chloronaphthalenes in the
U.S. has been attributed to rising costs, competing products, shifting
markets, and increasingly stringent industrial health and safety regu-
lations.
Certain manufacturers and importers of 19 chlorinated naphthalenes
are required under Section 8(a) of the Toxic Substances Control Act, 15
U.S.C. 2607(a), to notify EPA of current and prospective manufacture or
import of the compound.38 The rule requires current and prospective
manufacturers and importers to notify EPA of any current or prospective
manufacture or import of chlorinated naphthalenes. The notice must
state whether a person is manufacturing these compounds, or is
importing or is proposing to import chloronaphthalenes. Reporting
requirements include information on intended or expected uses, produc-
tion quantities, chemical composition, and wastes.
Nitronaphthalenes. Many of the nitronaphthalene compounds are not
formed by direct nitration of naphthalene but are made by indirect
methods, such as nitrite displacement of diazonium halide groups in the
presence of a copper catalyst, decarboxylation of nitronaphthalene-
carboxylic acids, or decontamination of nitronaphthalene amines.H
1. 1-nitronaphthalene. This compound has been used as a
deblooming agent for petroleum and oils, for the manufacture of dyes
2-29
-------
and i ntennediates, and as a component of commercial explosives.H
1-nitronaphthalene is important for the manufacture of 1-naphthylamine.
It is manufactured by nitrating naphthalene with nitric and sulfuric
acids at 40-50°C.
2. 2-nitronaphthalene. This naphthalene derivative is present
in 1-nitronaphthalene (about 3-10 percent by weight). It is metabolized
to the carcinogenic 2-naphthylamine in the human body.^ In making
this compound as a by-product, respirators, protective clothing, proper
engineering controls, and medical monitoring programs for workers
should be used.
Nitronaphthalenesulfonic acids. These chemicals are primarily
used in the preparation of dye intermediates. Nitronaphthalenesulfonic
acids are prepared by sulfonization of 1-nitronaphthalene with oleum
at a low temperature.il
Aminonaphthalenesulfonic acid's. Many of these naphthalene deriva-
tives are used in the manufacture of azo dyes or used to make interme-
diates for azo acid dyes, direct, and fiber-reactive dyes.^ The
aminonaphthalenesulfonic acids are generally made by either sulfonation
of naphthylamines, nitration-reduction of naphthalenesulfonic acids,
amination of naphtholsulfonic acids, or desulfonation of aminonaphthalene
di- or tri-sulfonic acid.
Hydroxynaphthalenesulfonic acids. Hydroxynaphthalenesulfonic
acids are important as intermediates either for coupling components for
azo dyes or azo components and for synthetic tanning agents.^ Hydroxy-
naphthalenesulfonic acids can be manufactured either by sulfonation of
naphthols or hydroxynaphthalenesulfonic acids, by acid hydrolysis of
aminonaphthalenesulfonic acids, by fusion of sodium naphthalenepoly-
sulfonates with sodium hydroxide, or by desulfonation or rearrangement
of hydroxynaphthalenesulfonic acids.
Naphtha!enecarboxylic acids. These compounds are generally used
as intermediates for azo dyes, pigments, and synthetic tanning.agents.H
The 1- and 2-naphthalenecarboxylic acids are prepared readily by the
oxidation of 1- or 2-alkylnaphthalenes with dilute nitric acid, chromic
acid, or permanganate. Some of these acids are useful as herbicides,
plant growth regulators and insecticides. Tetrahydrozoline (Visine®,
Tysine®), a nasal decongestant, is a derivative of these acids.
2-30
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Anthraquinone. One new use of naphthalene that could potentially
be produced in significant quantities is the manufacture of anthraqui-
none.20 it -js usecj as a dyes tuff intermediate and in the wood pulp
industry. In addition, a by-product of anthraquinone is phthalic
anhydride. At present, almost all anthraquinone worldwide is made by
the oxidation of anthracene, an expensive chemical recovered from coal
tar. The first attempt (joint venture of Bayer and Ciba-Geigy) to
operate the world's first naphthalene-based anthraquinone plant (in
Japan) failed, however, due to clogging of a scaled-up commercial
unit.39 After considering process changes that would have required 3
more years of study and a costly new investment, the company closed the
plant and planned to use the equipment elsewhere.
In the process, coal-tar naphthalene is oxidized with air to
naphthoquinone and phthalic anhydride using a vanadium oxide catalyst.20
Without prior separation, the naphthoquinone reacts with butadiene to
form tetrahydroanthroquinone, which is dehydrogenated to anthraquinone.
Subsequent separation and purification yield the main product,
anthraquinone, and phthalic anhydride as- a by-product. This
naphthalene-based process is more economical than the conventional
anthracene-based process, reducing production costs by 50 percent
because of lower feedstock costs despite more complex processing and
a higher investment than the conventional process.20,39
Sebacic acid. Another potential market for naphthalene may be
in the production of sebacic acid. The process uses naphthalene as
a raw material along with hydroperoxide.30 Decalin hydroperoxide (HPO)
is obtained by autoxidation, and the cleavage reaction of HPO and
subsequent dehydration reaction results in 5-cyclodecen-l-one.
By reducing and reoxidizing it, sebacic acid is produced. A Japanese
chemical company has applied for a patent for this new industrial
process for manufacturing sebacic acid. Sebacic acid is used in high-
quality plasticizers, engineering plastics, etc. Other methods have
been proposed to synthesize sebacic acid from naphthalene, but these
processes have either caused problems in operation and equipment or
have been unable to manufacture sebacic acid on an industrial scale.
2-31
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3.0 NAPHTHALENE EMISSION SOURCES AND ESTIMATES
This chapter discussed the types of emission sources that release
naphthalene to the environment and also presents estimates of naphthalene
emissions to the atmosphere. Section 3.1 describes the general types
of emission sources (process, fugitive, and storage) of naphthalene.
Section 3.2 discusses naphthalene emissions to the atmosphere from pro-
duction and various end uses; Section 3.3 presents estimates of naphth-
alene discharged to water; and Section 3.4 discusses solid waste impacts
from naphthalene.
3.1 NAPHTHALENE EMISSION SOURCES
Naphthalene emissions may be released to the environment from
numerous sources. As discussed in Section 2.2.1.1, naphthalene emis-
sions from coke by-product recovery plants originate primarily from
naphthalene separation and handling in open sumps and naphthalene
melting/drying tanks. The bulk of naphthalene emissions to the atmos-
phere from production processes is expected from distillation unit
vents, pump seals and flanges, and naphthalene storage tanks.40 For
processes that use a catalyst, catalyst decoking operations can be
expected to release particulates that may contain naphthalene. In
addition, waste streams resulting from cooling water treatment may
contain naphthalene. Spent catalyst and acid-treated clay used in
purification may also contain traces of naphthalene, and these solid
wastes are usually land disposed.
Little or no information is available on naphthalene emission
sources from the production of phthalic anhydride, carbamate insecti-
cides, or other naphthalene derivatives. The major contributor of
phthalic anhydride emissions from the naphthalene-based process is the
reactor and condenser effluent, which is vented from the condenser
unit.16 other emision sources of the naphthalene-based phthalic anhy-
dride process include the control catalyst and product storage in the
liquid phase. Naphthalene storage emissions are small and are presently
not controlled.
In addition, there are emissions from "inadvertent" sources such
as combustion sources, largely due to residential wood and coal heating,
3-1
-------
and aquatic discharges from cooling water treatment and various
industries, including wood preserving, paint, ink, and textile.10»41
3.2 AIR IMPACTS
3.2.1 Emissions from Handling and Production of Naphthalene
Only crude estimates of naphthalene from production sources are
available from the literature. According to one source, nationwide
production of naphthalene accounted for approximately 34 Mg annually
(1976 estimate) to the atmosphere, which may be attributed primarily
to distillation unit vents (process emissions), leaks from pump seals
(fugitive emissions), and flanges.10 Other estimates indicate that 40 Mg
of naphthalene are released annually to the atmosphere (1975 estimate).41
This section presents estimated atmospheric emissions from the
handling and production of naphthalene based on limited data from State
permit files and from January 1985 production capacity estimates from
Reference 1. Table 3-1 summarizes process, fugitive, and storage
emissions of naphthalene from coke by-product recovery plants that
handle and/or process crude naphthalene. Approximately 80 Mg/yr of
naphthalene are emitted to the atmosphere from coke by-product recovery
plants that process crude naphthalene. Table 3-2 summarizes process,
fugitive, and storage emissions of naphthalene from the five current
U.S. producers of chemical-grade naphthalene. Naphthalene emissions
from the production of chemical-grade naphthalene are about 50 Mg/yr.
Appendix A, Sections A.2 and A.3, presents the methods and assumptions
used to estimate emissions from coke by-product plants and naphthalene
production facilities, respectively. Appendix B includes a memorandum
describing two procedures for estimating naphthalene emissions specifically
from coke by-product plants. The procedure that was selected is
included in Appendix A.
3.2.2 Emissions from Naphthalene End Uses
Naphthalene emissions to the atmosphere originate from its uses in the
manufacture of phthalic anhydride, carbamate insecticides, synthetic tanning
agents, moth repellant, surface active agents, and miscellaneous organic
chemicals. In the manufacture of phthalic anhydride and miscellaneous
organic chemicals, it has been reported that naphthalene may be emitted
to the atmosphere from leaks in column vents, pump seals, and flanges.42
3-2
-------
TABLE 3-1. NAPHTHALENE EMISSIONS FROM COKE BY-PRODUCT
RECOVERY PLANTS
Plant3
Empire Coke
Republic Steel
National Steel
Interlake
Indiana Gas &
Chemicals
U.S. Steel
Rouge Steel
National Steel
Bethlehem Steel
Chattanooga Coke
& Chemical s
Lone Star Steel
J&L Steel
(TLV Steel)
Location
Holt, AL
Gadsden, AL
Granite City, IL
S. Chicago, IL
Terre Haute, IN
Gary, IN
Dearborne, MI
Detroit, MI
Bethlehem, PA
Chattanooga , TN
Lone Star, TX
Pittsburgh, PA
TOTAL
Emissions
Process
330
1,700
1,000
1,000
330
10,000' '
1,600
2,700
3,300
330
1,000
3,300
26,600
by Type (kg/y
Fugitive
330
1,700
1,000
1,000
330
10,000
1,600
2,700
3,300
330
1,000
3,300
26,600
r)b
Storage
330
1,700
1,000
1,000
330
10,000
1,600
2,700
3,300
330
1,000
3,300
26,600
Plant
Total
(kg/yr)
1,000
5,000
3,000
3,000
1,000
30,000
5,000
8,000
10,000
1,000
3,000
10,000
80,000
Reference 5.
See Appendix A, Section A. 2, for discussion of the method used to estimate emissions
from handling and/or processing crude naphthalene at coke by-product recovery plants.
3-3
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Table 3-2. NAPHTHALENE EMISSIONS FROM PRODUCTION OF
CHEMICAL-GRADE NAPHTHALENE*
Emissions by Type (kg/yr)
Plant Location Process Fugitive Storage
Coal-Tar Naphthalene
Allied Ironton, OH 8,100 580 770
Koppers Co. Follansbee, WV 19,300 580 1,540
Petroleum Naphthalene
Chemical Exchange Baytown, TX 3,300 340 320
Industries
DuPont Chocolate Bayou, TX 9,800 340 930
Texaco Chemical Delaware 'city, DE 6,400 340 610
TOTAL 46,900 .2,180 4,170
Plant -
Total
9,450
21,420
3,960
11,070
7,350
53,200
*S.ee appendix A, Section A.3, for discussion of the method used to estimate
emissions.
3-4
-------
This section presents estimates of process, fugitive, and storage
emissions from naphthalene end uses based on an apportioning technique
and limited data from State permit files. A discussion of the methods
and assumptions used to calculate these emissions is presented in
Appendix A, Sections A.4 through A.10. Table 3-3 summarizes process,
storage, and fugitive emissions from production of naphthalene end use
compounds. Total naphthalene emissions from production of these com-
pounds are about 75 Mg/yr.
3.2.3 Naphthalene Emissions from "Inadvertent Sources"
No estimates are available for atmospheric naphthalene emissions
from inadvertent sources, such as combustion processes. One report
indicates, however, that combustion sources account for most of the
annual atmospheric emissions of naphthalene (5,100 Mg), primarily
attributed to residential wood and coal heating.43 Other inadvertent
sources, such as wood preserving, paint, ink, and textile industries
use naphthalene-containing products (i.e., creosote, dyes, surface
active agents), release traces of naphthalene to waste streams instead
of to the atmosphere.44
3.2.4 Naphthalene Emission Summary
Total naphthalene emissions from all-sources (i.e., coke by-product
recovery, naphthalene production, naphthalene end uses, and inadvertent
sources) are approximately 213 Mg/yr, This emission summary is pre-
sented i n Table 3-4.
3.3 WATER IMPACTS
Only crude estimates of naphthalene discharges to water are avail-
able from the literature. Annual discharges from naphthalene production
are estimated to be 4.5 Mg, primarily from coal tar production (extrac-
tion and wash tank effluents), distillation, and water treatment.10»43>4b
Large amounts of naphthalene discharged to surface waters are expected
to volatize to the atmosphere and, to a lesser extent, removed to the
sediment by adsorption.43
The only available estimate of water impacts from naphthalene end
uses is for its use as carbamate insecticides, from which 2640 Mg of
naphthalene is discharged (1976 estimate).26 Water impacts from other
naphthalene uses are expected to be negligible (i.e., less than 1 Mg per
year), based on EPA descriptions of waste treatment practices and EPA
3-5
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Table 3-3. NAPHTHALENE EMISSIONS FROM MAJOR USERSC
Naphthalene
End-Use Compound
Phthalic anhydride
Carbamate insecticides
2-naphthol
Synthetic tanning agents
(from l- and i:-napntnaienesul fonic
acids)
Surface active agents
1-naphthalenesulfonic acid
(1-NSA)
2-naphthalenesulfonic acid
(2-NSA)
Plant
Koppers
Union Carbide
American Cyanamid
Morflex, Inc.
Diamond Shamrock
Georgia Pacific
Rohm S Haas
Subtotal Synthetic
American Cyanamid
Ciba-Geigy
OeSoto, Inc.
Diamond Shamrock
Diamond Shamrock
duPont
Emkay Chemicals
Morflex, Inc.
Georgia Pacific
Subtotal 1 - NSA
Allied Chemicals
American Cyanamid
American Cyanamid
OeSoto, Inc.
duPont
Emkay Chemicals
Location
Cicero, IL
Institute, WV
Willow Island, WV
Greensboro, NC
Carlstadt, NJ
Cedartown, GA
Bellingham, WA
Philadelphia, PA
Tanning Agents
Linden, NJ
Toms River, NO
Fort Worth, TX
Carlstadt, NJ
Cedartown, GA
Deepwater, NJ
Elizabeth, NJ
Greensboro, NC
Bellingham, WA
Claymont, DE
Marietta, OH
Linden, NJ
Fort Worth, TX
Deepwater, NJ
Elizabeth, NJ
Emissions
Process
0
1,402
Ob
430
430
430
430
430
2,130
41
41
41
41
41
41
41
41
41
370
350
350
350
350
350
350
by Type
Fugitive
8,470
1,250
0°
430
430
430
430
430
2,130
41
41
41
41
41
41
41
41
41
370
350
350
350
350
350
350
(kg/yr)
Storage
46,300
1,905
Ob
430
430
430
430
430
2,130
41
41
41
41
41
41
41
41
41
370
350
350
350
350
350
350
Plant
Total (kg/yr)
54,770
4,557
0°
1,300
1,300
1,300
1,300
1,300
6,400
120
120
120
120
120
120
120
120
120
1,100
1,050
1,050
1,050
1,050
1,050
1,050
Subtotal 2 - NSA
2,100 2,100
2,100
6,300
3-6
-------
Table 3-3. NAPHTHALENE EMISSIONS FROM MAJOR USERS'
(concluded)
Naphthalene
End-Use Compound
Moth repel 1 ant
Miscellaneous Chemicals
1-naphthol
1 ,2 ,3 ,4-tetrahydronaphthalene
(tetralin)
Qecahydronaphthalene (decalin)
1-naphthaleneacetic acid
1-naphthylamne
Naptalam
1-oromonaphthal ene
1-methylnaphthalene
nethylnaphthalene
1 -napnt ha leneacet amide
Nitronapnthalenesulfonic acids
Plant
Morflex, Inc.
Kincaid Enterprises
Union Carbide
DuPont
Union Carbide
DuPont
Greenwood Chemical
Union Carbide
Sigma Chemical Co.
Uniroyal , Inc.
RSA Corp.
Chemical Exchange
Koppers Co.
Crowley Chemical
Crawl ey Chemical
Greenwood Chemical Co.
Union Carbide
Ciba-Geigy Corp.
Subtotal Miscellaneous
Emissions by Type (kg/yr)
Location Process Fugitive Storage
Greensboro, NC
Nitro, WV
Institute, WV
Deepwater, NJ
Institute, WV
Oeepwater, NJ
Greenwood, VA
Ambler, PA
St. Louis, MO
Gastonia, NC
Ardsley, NY
Houston, TX
Follansbee, WV
Kent, OH
Oklahoma City, OK
Greenwood, VA
Ambler, PA
Toms River, NJ
Chemicals
0"
Oe
50
of
50
09
50
50
50
0.13
50
50
0"
O1
09
50
50
450
Oc
0^
Qe
50
of
50
09
50
50
50
0.13
50
50
O1
09
50
50
450
' Oc
50
of
50
09
50 .
50
50
0.13
50
50
50
50
09
50
50
550
Plant
Total !'
-------
TABLE 3-3. NAPHTHALENE EMISSIONS FROM MAJOR USERS9
(concluded)
FOOTNOTES
aSee Appendix A for discussion of procedur-es used to calculate emissions
from production of each naphthalene end-use compound.
^Z-naphthol is no longer produced in the U.S. All 2-naphthol consumed
in the U.S. is now imported (Reference 9). American Cyanamid closed
its Willow Island, WV, facility in mid-1982 (Reference 46). When it
was in operation, 1981 emissions of naphthalene were reported to be
about 17 Mg/yr (Reference 47).
cNaphthalene emissions from production and handling of moth repellant
at Morflex, Greensboro, NC, are included in estimates for general
production of naphthalene (Table 3-2). The product is made directly
from the production of naphthalene at one of the five naphthalene
producers in Table 3-2 as a solid flake, powder, or ball, and is then
usually repackaged as a consumer product at another facility (Reference
17, p. .26). PES assumes that the Morflex facility only repackages the
naphthalene product that is already manufactured in a crystallized
form by one of the naphthalene producers. Therefore, no emissions of
naphthalene are expected from the facility.
dBased on information from the West Virginia Air Pollution Control
Commission that the facility is either no longer in production or does
not use naphthalene to make moth repel!ant (References 24 and 48), PES
assumes no emissions of naphthalene from Kincaid Enterprises.
Emissions of naphthalene from 1-naphthol production at Union Carbide,
Institute, WV, are included in naphthalene emissions from carbaryl
production (Reference 21): .process emissions from 1-naphthol produc-
. tion = 0.82 kg/yr; fugitive emissions = 249 kg/yr; and storage emis-
sions = 17.3 kg/yr. Total naphthalene emissions from 1-naphthol
production = 270 kg/yr.
^Emissions of naphthalene from tetralin production (tetralin hydrogena-
tion and oxidation) at Union Carbide, Institute, WV, are included in
naphthalene emissions from carbaryl production (Reference 21): process
emissions = 1,400 kg/yr; fugitive emissions = 963 kg/yr; and storage
emissions = 1,844.7 kg/yr. Total naphthalene emissions from tetralin
production = 4,207.7 kg/yr, or 4.2 Mg/yr, which represents 92% of
total emissions from carbaryl production.
9No longer in operation due to explosion and fire destroying facility
in April 1985; no plans to rebuild (Reference 49).
hStorage emissions only (Reference 50).
^Storage emissions only (Reference 51).
3-8
-------
TABLE 3-4. SUMMARY OF NAPHTHALENE EMISSIONS FROM ALL SOURCES
Emission
Source
Coke by-product recovery
Naphthalene production
Coal tar
Petroleum
Naphthalene end uses
Inadvertent sources*
Total All Sources
Source
Process
26.6
27.4
19.5
6.5
5.1
85.4
Total by Type,
Fugitive
26.6
1.16
1.02
14.8
--
43.0
Mg/yr
Storage
26.6
2.31
1.86
53.4
—
84.2
Source
Total, Mg/yr
79.8
30.8
22.4
74.6
5.1
212.7
NOTE: Totals may not sum due to rounding.
*Naphthalene emissions from combustion processes, primarily residential wood and
coal heating (Reference 43). For the purposes of this analysis, these emissions
are classified as process emissions.
3-9
-------
effluent guidelines.18 Discharges to POTW's are estimated to be about
2 Mg (1976 and 1979 estimates) from the leather tanning industry.18,52
Less than 0.1- Mg is directly dicharged from this industry (1979 esti-
mate) .18 These direct dischargers treat wastewater streams primarily
by activated sludge or aerated lagoons.
Traces of naphthalene contained in creosote, dyes, surface active
agents, etc. have also been detected in wastewater streams from
"inadvertent" sources, such as the woodpreserving, paint, ink, and
textile industries. Detection in these waste streams is most likely
attributed to the degradation of these compounds.44 Naphthalene losses
to water from oil spills represents another "inadvertent" source. An
estimated 12 Mg (1976 estimate) of naphthalene was reported to be
released to the aquatic environment through crude oil spills.53
3.4 SOLID WASTE IMPACTS
Solid waste from naphthalene production originates from spent
catalyst, acid treated clay (from petroleum purification processes),
process sludge, and onsite wastewater treatment sludge.40,45 /\n esti-
mated 32 Mg of naphthalene is generated as solid waste from production
processes.10
Solid waste generated from naphthalene end uses is estimated to be
20,240 Mg (1976 estimate).26 Some solid waste containing traces of
naphthalene is expected to originate from process purification activi-
ties.42
No estimates are available for solid waste generated from
"inadvertent" sources of naphthalene. However, an estimated 5 Mg (1976
estimate) of naphthalene is reported lost to the land from crude oil
spills.53
3-10
-------
4.0 REGULATIONS AFFECTING THE ENVIRONMENTAL
RELEASE OF NAPHTHALENE
Two environmental regulations are known to be in effect specifically
to control emissions of naphthalene derivatives. The Toxic Substances
Control Act specifies certain reporting and recordkeeping requirements
for current and future production or import of chloronaphthalene com-
pounds. In addition, emissions of a number of naphthalene derivatives
are regulated under the New Source Performance Standards (NSPS) for
Equipment leaks of VOC in the Synthetic Organic Chemical Manufacturing
Industry (SOCMI). These environmental regulations pertaining to naphth-
alene derivatives are discussed below. In addition the Occupational
Safety and Health Administration (OSHA) has set limits for occupational
exposure to naphthalene. No water criterion has been established;
however, a Health Advisory is currently being developed.
4.1 TOXIC SUBSTANCES CONTROL ACT
Section 8(a) of the Toxic Substances Control Act, 15 U.S.C. 2607(a),
requires certain manufacturers and .importers of 19 chlorinated naphtha-
lenes to notify EPA of current and prospective manufacture or import of
the compounds.38 These manufacturers and importers are required to
report to EPA and keep records of information on intended or expected
uses, production quantities, chemical composition, and wastes.
4.2 NSPS FOR SOCMI EQUIPMENT LEAKS
Equipment leaks of certain naphthalene derivatives are regulated
under Subpart VV of the NSPS for Equipment Leaks of VOC in SOCMI .54
Naphthalene itself'is not regulated by this standard because it is not
a synthetic organic chemical. Equipment subject to the standards
include valves, pumps, compressors, pressure relief devices, sampling
systems, and open-ended lines in VOC service. The standards require:
(1) a leak detection and repair program for valves in gas/vapor and
light-liquid service and for pumps in light-liquid service; (2) equip-
ment for compressors, sampling systems, and open-ended lines; and
(3) no detectable emissions (500 ppm as determined by Reference Method
21) for pressure relief devices in gas/vapor service during normal
operation. Naphthalene derivatives listed in Section 60.489 that are
4-1
-------
subject to the standards include alkylnaphthalene, anthraquinone,
bromonaphthalane, chloronaphthalene, 1- and 2-naphthalenesulfonic acids,
1-naphthol, 2-naphthol, phthalic anhydride, and tetrahydronaphthalene.
4-2
-------
5.0 AMBIENT AIR MONITORING DATA FOR NAPHTHALENE
Few ambient air monitoring data for naphthalene are available. In
one study data were compiled for quarterly naphthalene concentrations
in 13 cities across the United States.55 No annual estimates are avail-
able. The highest reported quarterly mean for naphthalene is 12.0
Hig/m3 (2.09 ppb) at Upland, California.
Other monitoring data show that ambient air concentrations of •
naphthalene are 3.5 x 10~4 p.g/m3 (6.1 x 10"5 ppb) in an urban area and
5.0 x 10'5 |J.g/m3 (8.7 x 10~6 ppb) in a rural area.43 it was not stated,
however, whether these readings were hourly, daily, quarterly, or annual
averages.
5-1
-------
6.0 REFERENCES
1. 1985 Directory of Chemical Producers, United States. SRI Inter-
national . p. 728.
2. "Chemical Profile," Chemical Marketing Reporter, October 19, 1984.
p. 54.
3. Gerry, R.T., J. Bakker, and 0. Kamatari. Chemical Economics
Handbook, SRI International. CEH Product Review - Naphthalene.
June 1981, p. 300.7600F.
4. Kirk-Othmer. Encyclopedia of Chemical Technology. Third
Edition. John Wiley & Sons. New York, NY. Vol. 15, 1981.
p. 706-709.
5. Benzene Emissions from Coke By-Product Recovery Plants. Background
Information for Proposed Standards, EPA-450/3-83-016a. U.S.
Environmental Protection Agency, Office of Air Quality Planning
and Standards. Research Triangle Park, N.C. May 1984. p. 3-31.
6. Lankford, W.T., ed. The Making, Shaping, and Treating of Steel,
10th edition. U.S. Steel Corporation. 1985. pp. 242-243.
7. Van Osdel1, et. al. Environmental Assessment of Coke By-product
Recovery Plants, EPA-600/2-79-016, Research Triangle Institute,
Research Triangle Park, NC. For U.S. Environmental Protection
Agency, IERL, Research Triangle Park, NC. January 1979. pp. 40,
93, 95.
8. Kirk Othmer, Encyclopedia of Chemical Technology, Vol. 22, 1983.
p. 572.
9. C. Hughes, et. al. Chemical Economics Handbook, SRI Interna-
tional. CEH Product Review - Naphthalene. March 1985, pp.
300.7600A-300.7600Z.
10. Production and Use of Naphthalene. Versar, Inc., Springfield, VA.
For U.S. Environmental Protection Agency, Office of Water Planning
and Standards, Washington, D.C. Contract No. 68-01-3852, Task 22,
Subtask 1. January 30, 1980. pp. 7-11.
11. Reference 4, pp. 720-746.
12. "Chemical Profile," Chemical Marketing Reporter, July 7, 1986.
p. 50.
13. Letter with attachments from L. Carlson, Koppers Co., Inc.,
Chicago, IL, to C. Mata, Illinois EPA, Maywood, IL. July 10,
1986.
14. Reference 9, p. 13.
6-1
-------
REFERENCES (continued)
15. Synthetic Organic Chemical Manufacturing Industry: Inputs and
Product Uses. Research Triangle Institute. For U.S. Environ-
mental Protection Agency, Strategies and Air Standards Division,
Research Triangle Park, NC. EPA Contract No. 68-02-3071.
February 1980.
16. Year End Report - Synthetic Organic Chemical Manufacturing Indus-
try Study. U.S. Environmental Protection Agency, Office of Air
Quality Planning and Standards, Chemical and Petroleum Branch.
December 1977. p. 158.
17. Compilation of Air Pollutant Emission Factors - Volume 1: Sta-
tionary Point and Area Sources. Chapter 5, Chemical Process
Industry. Section 5.12. AP-42. Fourth Edition. U.S. Environ-
mental Protection Agency, Office of Air Quality Planning and
Standards, Research Triangle Park, NC. September 1985. p. 5.12-1
through 5.12-4.
18. Polycyclic Aromatic Hydrocarbons - An Environmental Materials
Balance. Acurex Corporation, Rosslyn, VA. For U.S. Environ-
mental Protection Agency, Monitoring and Data Support Division,
Washington, D.C. EPA Contract No. 68-01-6017. January 1981.
pp. 41-50.
19. Reference 9, pp. 15-16.
20. Reference 4, p. 715.
21. 1984 Emission Inventory Summary by Process, Union Carbide,
Institute, WV. West Virginia Air Pollution Control Commission,
Charleston, WV.
22. Reference 1, pp. 728 and 900.
23. Chem Sources, USA, 1985.
24. Telecon. C. Beard, West Virginia Air Pollution Control Commission,
with D. Cole, PES, Inc. September 22, 1986.
25. Reference 1, p. 729.
26. Reference 9, p. 17.
27. Reference 1, p. 766.
28. Reference 1, p. 457.
29. Reference 1, p. 720.
30. "New Process for Sebacic Acid," Hydrocarbon Processing, October
1985. p. 83.
6-2
-------
REFERENCES (continued)
31. Kirk-Othmer. Encyclopedia of Chemical Technology. Third Edition.
John Wiley & Sons. New York, NY. Vol. 5, 1979. pp. 838-843..
32. Pesticide Manufacturing and Toxic Materials Control Encyclopedia.
Marshall Sittig, editor. Noyes Data Corporation, Park Ridge, NJ .
1980. pp. 277-279, 550-554.
33. Reference 4, p. 704.
34. Reference 4, p. 716.
35. Telecon. T. McGillick, New York State Department of Environ-
mental Conservation, White Plains, NY, with D. Cole, Pacific
Environmental Services, Inc., Durham, NC. August 26, 1986.
36. Letter from D.L. Lesher, Pennsylvania Bureau of Air Quality Control,
Harrisburg, PA, to D.G. Cole, Pacific Environmental Services,
Inc., Durham, NC. August 15, 1986.
37. Letter from K. Chaudhari,.Virginia State Air Pollution Control
Board, Richmond, VA, to D.G. Cole, Pacific Environmental Services,
Inc., Durham, NC. August 20, 1986.
38. 49 FR 33649, August 24, 1984. Final Rule.
39. "A Naphthalene-based Process Bites the Dust," Chemical Week.
September 26, 1984. p. 41.
40. U.S. Environmental Protection Agency. Industrial Process Profiles
for Environmental Use: Chapter 5. Basic Petrochemicals Industry.
January 1977. pp. 98-101.
41. Reference 17, pp. 35-36.
42. Reference 9, p. 18.
43. An Exposure and Risk Assessment for Benzo[a]pyrene and Other
Polycyclic Aromatic Hydrocarbons. Volume 1. Summary. Final
Draft Report. EPA Contract No. 68-01-6160. U.S. Environmental
Protection Agency, Monitoring and Data Support Division, Office of
Water Regulations and Standards, Washington, D.C. July 1982.
p. 2-20, 2-21.
44. Reference 17, p. 36.
45. Reference 17, p. 35.
46. Letter from J.L. Noe, American Cyanamid, Willow Island, WV, to C.
Beard, West Virginia Air Pollution Control Commission, Charleston,
WV. September 9, 1985.
6-3
-------
REFERENCES (concluded)
47. West Virginia Air Pollution Control Commission, 1981 Air Emission
Inventory Summary by Process.
48. West Virginia Air Pollution Control Commission (WVAPCC), Permit
Files, Charleston, WV. Information obtained from visit to WVAPCC
office by K. Meardon, PES, Inc., Durham, NC. October 1-2, 1986.
49. Letter from K. Chaudhari, Virginia Air Pollution Control Board,
Richmond, VA, to D.G. Cole, PES, Inc., Durham, NC. August 20, 1986,
50. Telecon. L. Malcolm, Ohio State Air Pollution Control Agency,
Akron, OH, with D.G. Cole, Pacific Environmental Services, Inc.,
Durham, NC. August 7, 1986.
51. Telecon. C. Goeller, Oklahoma City Health Department, Oklahoma
City, OK, with D.G. Cole, PES, Inc., Durham, NC. August 7, 1986.
52. Reference 9, p. 5.
53. Reference 9, pp. 31-32.
54. 48 FR 48328, October 18, 1983. Final Rule.
55. W.F. Hunt, R.B. Faora, and G.M. Duggan, Compilation of Air Toxics
and Trace Metal Summary Statistics. U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards. Research
Triangle Park, NC. EPA-450/4-84-015. July 1984. pp. 7, 112.
6-4
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APPENDIX A
DOCUMENTATION FOR HUMAN EXPOSURE MODEL INPUT DATA
A.I INTRODUCTION
This appendix documents the Human Exposure Model (HEM) input
parameters for naphthalene. For each naphthalene source category,
these parameters include:
SIC code
plant name
latitude and longitude
stack release height (meters)
cross-sectional downwash area (meters2)
gas exit velocity (meters/second)
vent type/diameter (meters)
gas temperature (degrees, Kelvin scale)
emission rate (kilograms/year
The sections below cite the references or provide the basis for the
modeling parameters and describe the methods used to calculate naphthalene
emissions from a given source category (i.e., naphthalene production or
end use). The source categories are included in the following sections:
A.2 Naphthalene from Coke By-product Recovery Plants
A.3 Naphthalene Production
A.4 Phthal.ic Anhydride End Use
A.5 Carbamate Insecticides End Use
A.6 2-naphthol End Use
A.7 Synthetic Tanning Agents End Use
A.8 Surface Active Agents End Use
A.9 Moth Repellant End Use
A.10 Miscellaneous Organic Chemicals End Use
Tables A-l through A-10 present the modeling parameters described in
this appendix.
A.2 NAPHTHALENE FROM COKE BY-PRODUCT RECOVERY PLANTS
A. SIC Code
Reference 1.
R. Plant Name
Reference 15, Table 3-3 (revised since proposal), is the basis for
the list of coke by-product recovery plants, which include only
facilities that produce coal tar naphthalene.
C. Latitude/Longitude
Reference 15, Table E-l (revised since proposal).'
A-l
-------
D. Urban
All plants are located >n urban areas for modeling purposes.
E. City, State
Locations of coke by-product recovery plants from Reference 15,
Table 3-3 (revised since proposal).
F. Emission Type
Process (P), storage (S), and fugitive (F) emission points were
based on information in References 15 and 16. Process emissions are
considered to be emitted from a stack or vent. Most naphthalene
emissions from coke by-product recovery plants originate from naphtha-
lene processing, specifically separation and drying, which usually
occur in partially open, but vented, tanks; therefore, some emission
points may be both fugitive and process emission sources. Storage
emissions of naphthalene originate from naphthalene storage tanks and
some coal tar storage tanks (containing a mixture of coal tar and
naphthalene).
G. Stack Number
Corresponds to an emission point, either process, fugitive, or
storage. When stack parameters for different emission points are
identical, they are assigned one number and emissions from these
points are combined.
H. Stack Parameters
Reference 15, Table E-2. Stack parameters for the naphthalene
drying tank were selected for modeling purposes. Storage tank release
height is based on height of tar storage tank (containing naphthalene)
also from Table E-2. For cross-sectional downwash area (fugitive
"emission points) areas of 200m x 100m for large plants (coke capacity
greater than 1 million Mg/yr), 100m x lOQm for middlesized plants (coke
capacity between 500,000 Mg/yr and 1 million Hg/yr), and 75m x 65m for
smaller plants (coke capacity less than 500,000 Mg/yr) are used.
I. Emissions
A plant-wide naphthalene emission factor is developed for naphthalene-
handling coke by-product recovery plants. This factor is based on a
material balance of a representative coke by-product recovery plant and
the amount of naphthalene estimated in coal tar production. -A naphthalene
emission factor is needed on a "kilogram (kg) of naphthalene per megagram
(Mg) of coke produced" basis because coke production rates are available
for each coke by-product plant. To derive this factor, the following
procedure is used.
1. Estimate annual coal tar production based on (1) the amount of
naphthalene in coal tar produced (1978 estimate) and (2) the weight
percent of naphthalene in dry coal tar:
A-2
-------
1978 coal-tar npahthalene production = 230,000 Mg
(Reference 10, pp. 27-28)
Average Weight % naphthalene of dry tar (U.S.) = 8.80%
(Reference 11, p. 572).
Coal,Tar Production = 230,000 Mg = 2.6 Tg
0.088
2. Estimate relative amount of coal tar produced per megagram of coke
from material balance of a representative coke by-product recovery
plant:
380 Mg Coal Tar = 0.052 Mg Coal Tar per Mg Coke (Reference 16,
7370 Mg Coke p. 23)
3. Estimate annual coke production based on steps (1) andf (2) above:
2.6 Tg coal tar = 50 Tg coke production, U.S.
0.052 Mg coal tar/Mg coke (1978 estimate)
Note: This estimate approximates 1979 U.S. coke production figure
(48.0 Tg) from Reference 41.
4. Calculate naphthalene emission factor from estimate of total
naphthalene emissions to atmosphere from coal tar production
(Reference 10) and total U.S. coke production from step (3) above:
300 Mg naphthalene = 6 Mg naphthalene per Tg coke produced,
50 Tg coke produced or 0.006 kg naphthalene per Mg coke produced.
A plant-specific emission total was calculated using the above
method. The total was divided by three to allocate emissions to process,
fugitive, and storage vents.
A.3 NAPHTHALENE PRODUCTION
A. SIC Code
Reference 1.
B. Plant Name
Plants 1-5 from References 2, 3, 4 represent U.S. producers of
naphthalene from both coal tar and petroleum.
Plants 6-9 are on standby or not operating due to market conditions
based on information from References 2, 3, and 4. Therefore, plants
6-9 are not modeled.
C. Latitude/Longitude
Plant 1 - Reference 5.
Plants 2,3 - Reference 6.
Plant 4 - Reference 7.
Plant 5 - Reference 8.
A-3
-------
D. Urban
This information is not available from State Permit files or other
available sources. All plants are assumed to be located in urban
areas.
E. City, State
Location of plant numbers 1-9 from References 2, 3, 4.
F. Emission Type
Process (P), storage (S), and fugitive (F) emission points were
based on information in Reference 9.
G. Stack Number
Corresponds to an emission point, either process (P), fugitive (F),
or storage (S). When stack parameters for different emission points
are identical within a given type, they are assigned one number, and
emissions from those points are combined.
H. Stack Release Height
A stack release height of 13m from all process stacks at naphthalene
production facilities was used based on average of stack heights from
Reference 9. Other assigned values are as follows:
Plant 1 - Release height of 3m for fugitives; release height of
7.6m for each of 5 storage tanks (estimated average
of heights of 7 tanks from Reference 9).
Plant 2 - Three meters for fugitives; 2 storage tanks both
having a height of 7.6m (based on average height of
storage tanks, Reference 9).
Plant 3 - Three meters for fugitives; release height of 7.6m for
6 storage tanks (based on Reference 9).
Plant 4 - Three meters for fugitive releases; storage release
height based on 7.6m from storage tank height (Refer-
ence 9).
Plant 5 - Three meters for fugitives. Three storage tanks, all
having a height of 7.6m (based on Reference 9).
I. Cross-Sectional Oownwash Area
For fugitive emissions, a cross-sectional downwash area of 20,000m2
was used for all naphthalene production facilities, based on model input
parameters for xylene reported in Reference 40.
A-4
-------
J. Vent Type
Vertical (0) for process and storage emission points, and nonvertical
(1) for fugitive emissions are assumed.
K. Vent .Diameter
For process emissions, Reference 9 (average of stack diameter).
For storage emissions, unless assigned plant-specific infor-
mation was available, a storage tank is assigned a diameter of
0.076m, based on vent diameters of 0.17 ft, 0.25 ft, and 0.33 ft.
reported in Reference 40, Table 29-20, for xylene vent parameters.
L. Gas Exit Velocity
No plant-specific information was available. Therefore, PES used
an estimate of 6.3 m/s from Reference 9 is used as a representative exit
velocity for process stacks at naphthalene production facilities, and
0.01 m/sec for fugitive and storage emission points.
M. Gas Temperature
An estimate of 320°K from Reference 9 is selected as a representa-
tive exit gas temperature for process stacks at naphthalene production
facilities, and 293°K (ambient) for fugitive and storage emission
points.
N. Emissions
Plant 1 - Allied Chemical, Ironton, OH.
No plant-specific information was available to calculate
naphthalene emissions (Reference 12).
Naphthalene Distillation Process - Process, fugitive, and storage
emissions are based on plant-specific information from the Koppers
facility in Follansbee, WV (Reference 9). Since no process description
was available for Allied, the process is assumed to be identical to the
one at Koppers. Like Koppers, the facility uses coal tar as a raw
material.
a. Process Emissions
A naphthalene emission factor for process emissions was
derived from the polycyclic organic matter (POM) emissions reported in
the 1984 Emissions Inventory submitted by Koppers Co., Follansbee, WV
(Reference 9). The factor is expressed in terms of kilograms of
naphthalene per megagram of naphthalene produced. Based on 20.6 ton
POM/yr and based on an estimate from Reference 10 that 87% of POM
emissions from naphthalene production are assumed to be naphthalene,
the following emission factor for process emissions is calculated:
ton_ 2,000 Ib 0.454 k£ 1 0.239 kg naphtha!ene/Mg produced
0.87 x 20.6 yr x ton x Ib x 68 x 10-5 Mg/yr =
A-5
-------
Using this emission factor, process emissions of naphthalene from the
Allied facility with production rate of 34,000 Mg (Reference 13) are
calculated as:
0.239 J<£ x 34,000 Mg_ = 8,100 kg/yr
J<£
Mg
b. Fugitive Emissions
yr
No information was available on the number of components
containing or contacting naphthalene at the Allied facility.
Therefore, fugitive emissions at Allied are estimated to be
580 kg/yr as reported for the fugitive emissions .from naphthalene dis-
tillation and desulfurization at the koppers facility (Reference 9).
c. Storage Emissions
Storage emissions of naphthalene from the Allied facility were
based on storage emissions from the Koppers, Follansbee, WV, facility
(Reference 9), and the 1985 production capacity for the Allied facility
from Reference 13. Storage emissions factor is calculated as follows:
1,545 kg
68,000 Mg
0.0227 k£
Mg
Therefore, storage emissions from the Allied facility are:
0.0227 kg Mg kg
ftg X 34,000 yf = 770 yf
Therefore, total emissions from the Allied facility are 9,450 kg/yr,
or 9.4 Mg/yr. As a basis of comparison, nationwide estimates of naphtha-
lene emissions from production (Reference 14) can be apportioned among
the five naphthalene producers. Reference 14 reports that from 0.0004
to 0.07% of the annual U.S. production of naphthalene is lost from the
plant during its manufacture, and that 48% of these emissions are
released to the atmosphere. Using a conservative estimate of 0.0336%
(0.0007 x 0.48) as the percentage of naphthalene production emitted
and the total naphthalene production of 184,000 Mg/yr (Reference 4),
naphthalene emissions to the atmosphere can be calculated as:
0.000336 x 184,000 Mg/yr = 61.8 Mg/yr.
Apportioning this total among the five naphthalene producers based on
production rate, naphthalene emissions are the following:
A-6
-------
Plant 1 - Allied 11.4 Mg
Plant 2 - Chemical Exchange 4.7 Mg
Plant 3 - DuPont 13.8 Mg
Plant 4 - Koppers 22.8 Mg
Plant 5 - Texaco Chemical 9.1 Mg
Total 61.8 Mg
Plant 2 - Chemical Exchange Industries, Baytbwn, TX.
No plant-specific information was available from State permit
files from which to calculate naphthalene emissions (Reference 6).
This plant uses a petroleum-based feedstock (e.g., heavy refor-
mate) in the production of naphthalene. In a comparison of coal
tar and petroleum-based processes, certain steps are similar, such as
distillation and fractionation. In addition, some petroleum naphthalene
producers may also process coal-derived material (Reference 33, p. 25).
Although admittedly there are differences in naphthalene contents between
coal tar and petroleum, no information is available on the relative
percentage of naphthalene in petroleum streams or the percentage of
naphthalene emissions of total polycyclic organic matter. Therefore, the
only basis for estimating emissions from a petroleum-based naphthalene
process is the estimating procedure used above to estimate coal tar-based
naphthalene emissions.
a. Process Emissions
A naphthalene emission factor (0.24 kg naphthalene/Mg napth-
alene produced) derived from the Koppers- facility, Follansbee, WV
(Reference 9) was used to estimate'process emissions from the Chemical
Exchange faci.lity. The same procedure was followed as in Plant 1,
assuming 87% of POM emissions are naphthalene (based on Reference 10);
and based on a production rate of 14,000 Mg/yr for the Chemical Exchange
facility.
Process emissions of naphthalene are calculated as:
0.239 kg/Mg x 14,000 Mg/yr = 3,300 kg/yr.
b. Fugitive Emissions
No information was available on the number of components
containing or contacting naphthalene at the Chemical Exchange Facility.
Since there is no desul furization section in the petroleum-based process,
only the distillation process information from the Koppers facility
(Reference 9) is used.
Fugitive emissions af heavy liquid coal tar distillate = 1.26 Ib/hr
(Reference 9)
Weight of naphthalene in dry coat tar, (Reference 11) = 8.8%
Hours of Operation per year, (Reference 44) = 6,745
A-7
-------
0.088 x 1.26 Ib/hr x 6,745 x 0.454 k£ = 340 k£
lb yr
c. Storage Emissions
-Same procedure as Plant 1, Storage Emissions.
Storage emissions from the Chemical Exchange facility are:
0.0227 kg 14,000 Mg
MJJ- x yf = 320 kg/yr.
Total naphthalene emissions from Chemical Exchange Industries
are 3,960 kg/yr, or 4.0 Mg, which compares favorably with the emissions
estimate of 4.7 Mg based on the apportioning technique described above.
Plant 3 - E.I. DuPont de Nemours, Chocolate Bayou, TX.
No plant-specific information was available from State permit
files from which to calculate naphthalene emissions (Reference 6).
The plant uses a petroleum-based feedstock in the production of
naphthalene. The same basis that was used to calculate emissions from
the other facilities was used here, based on plant-specific information
from Reference 9.
a. Process Emissions
Same procedure as Plant 1, Process Emissions.
Process emissions from the DuPont facility are calculated as:
0.239 kg 41,000 Mg
^ x — = 9,800 Kg/yr
b. Fugitive Emissions
Same procedure as Plant 2, Fugitive Emissions.
Fugitive emissions from the OuPont facility are calculated as:
0.0084 k£ 41,000 M£ k£
Mg x yr = 34° yr
c. Storage Emissions
Same procedure as Plant 1, Storage Emissions.
Storage emissions from the OuPont facility are calculated as:
0.0227 kg 41,000 Mg kg
Mj x y* = 930 J^
A-8
-------
Naphthalene emissions from the DuPont facility total 11,070
kg/yr, or 11.1 Mg/yr. This approximates the estimate of 13.8 Mg/yr from
the apportioning technique described above.
Plant 4 - Koppers, Follansbee, WV.
1. Process #230 (Naphthalene Distillation)
a. Process Emissions
20.6 tpy POM emitted from distillation process (Reference 9).
87 percent of POM emissions from naphthalene production
assumed to be naphthalene (Reference 10, p. 27), based on an estimate
that 87% of POM emissions to air is naphthalene in coal tar production.
ton 2,000 Ib 0.454 kg kg
0.87 x 20.6 -yf x tfon" * Tb = 16,200 yp
b. Fugitive Emissions
Fugitive emissions of heavy liquid coal tar distillate = 1.26 Ib/hr,
Reference 9.
Ueight percent naphthalene in dry coal tar, = 8.8%
Reference 11.
Hours of operation per year (1984), Reference 9. = 7,490
1.26 Ib 7,490 hr 0.454 kg kg
0.088 x "hf x yf x J£ = 380 yr
c. Storage Emissions
2 naphthalene oil storage tanks for naphthalene distillation
process (each 60-65% naphthalene Reference 11); the 65% value is used for
calculations. Tank 1 corresponds to S-l at Koppers in Table A-2 of this
appendix, and tank 2 corresponds to S-2 at Koppers.
Tank 1 (S-l) = Ib 0.454 kg
547 yf x Tb x 0.65 = 160 kg/yr
Tank 2 (S-2) = Ib 0.454 kg
590 yf x Tb x 0.65 = 170 kg/yr
Total = 330 kg/yr
A-9
-------
2. Process 300 - Naphthalene Oesulfurization
a. Process Emissions
Based on (1) POM emissions from naphthalene desulfurization process
of 3.9 ton/yr (Reference 9) and (2) 87% of POM is naphthalene
(Reference 10), naphthalene process emissions are calculated as:
ton 2,000 Ib 0.454 kg
0.87 x 3.9 ~y7 x ton" x Tb = 3,100 kg/yr
b. Fugitive Emissions
Based on:
(1) Fugitive emissions of total heavy liquid = 0.77 J_b_ (Refer-
ence 9); hr
(2) Weight % of naphthalene in dry coal tar = 8.8% (Reference 11); and
(3) Hours of operation per year (1984) = 6,336 (Reference 9);
naphthalene fugitive emissions are calculated as:
0.77 1-b 6,336 hr 0.454 kg
0.088 x Tfp x 7F x Tb = 20° k9/yr
c. Storage Emissions
5 naphthalene storage tanks for naphthalene desulfurization process
(Reference 9):
Tank H(m) D(m) Emissions
1 (S3) 10.9 6.1 575 Ib 0.454 kg
7F x Tb"= 261 k9/yp
2 (S4) 9.1 7.6 610 Ib 0.454 kg
yf x TF = 277 kg/yr
3 (S5)* 6.1 7.3 393 jb_ 0.454 k£
yr x 15 = 178
4 (S5)* 6.1 7.3 393 jb_ 0.454 kg, _
V P ID"" J./O
5 (S6)* 12.8 13.7 697 ]b_ 0.454 k£
yr x Ib = 2L6—
Total = 1,210 kg/yr
A-10
-------
*Note: Tanks 3 and 4 are modeled as one tank since parameters are
identical, and emissions for the two tanks are combined.
Total naphthalene emissions from the Koppers plant are 21,420 kg/yr,
or 21.4 Mg/yr, which closely approximates the estimate (22.8 Mg) based
on a nationwide apportioning technique discussed in Plant 1 emissions
documentation above.
Plant 5 - Texaco Chemical, Delaware City, DE.
No plant-specific information was available from State permit
files from which-to calculate naphthalene emissions (Reference 8).
The plant uses a petroleum-based feedstock in the production of
naphthalene. The same procedure as used in other facilities was used
to calculate naphthalene emissions from Texaco Chemical, based on
plant-specific information from Reference 9.
a. Process Emissions
Same procedure as Plant 1, Process Emissions.
Process emissions from the Texaco Chemical facility are
calculated as:
0.239 kg_ 27,000 Mg_ _ 6,400 k_g
Mg x yp = yr
b. Fugitive Emissions
Same procedure as Plant 2, Fugitive Emissions.
c. Storage Emissions
Same procedure as Plant 1, Storage Emissions.
Storage emissions from the Texaco Chemical facility are
calculated as:
0.0227 kg_ 27,OOOMg 610 l<£
Mg x yr = yr
Naphthalene emissions from the Texaco Chemical facility
total 7,350 kg/yr, or 7.3 Mg/yr, compared to 9.1 Mg/yr using the appor-
tioning technique based on Reference 14.
Total emissions of naphthalene from production at the ahove
five facilities are 53.2 Mg.
A.4 PHTHALIC ANHYDRIDE END-USE
A. SIC Code
Reference 1.
A-ll
-------
B. Plant Name
References 18 and 19. Plant restarted.during May 1985 after
modification to use naphthalene as a feedstock as well as orthoxylene.
C. Latitude/Longitude
Derived from zip code conversion to DIM coordinates using computer
program from Office of Toxic Substances.
D. Urban
The location of the facility is assumed to be in an urban area.
E. City, State
Location of facility from Reference 19.
F. Emission Type
Reported as process (P), fugitive (F), or storage (S) based on
information in References 17-19.
G. Stack Number
Corresponds to an emission point, either process, fugitive, or
storage. When stack parameters for different emission points are
identical, they are assigned one number, and emissions from these
points are combined.
H. Stack Release Height
A height of 3 m is selected for fugitive emissions; release height
for storage emissions is based on storage tank height from Reference 20.
I. Cross-Sectional Oownwash Area
For -fugitive emission points, 100 m x 200 m is selected from
(Reference 40).
J. Vent Type
Vertical (0) for storage emission points and nonvertical (0) for
fugitive emissions are chosen.
K. Vent Diameter
Process emissions - Reference 20, p. 15.
Storage emissions type: same as documentation for naphthalene
production, Section A.3, subsection K.
A-12
-------
L. Gas Exit Velocity
A gas exit velocity of 0.01 m/sec for fugitive and storage emission
points is used.
M. Gas Temperature
An ambient temperature of 68°F, or 293°K is chosen.
N. Emissions
Plant 1 - Koppers Co., Bridgeville, PA - not operating.
Plant 2 - Monsanto Co., Bridgeport, NJ - not operating.
Plant 3 - Koppers Co., Stickney, IL - restarted May 1985 (Reference 19).
The facility uses either orthoxylene or naphthalene as feedstock
for production of phthalic anhydride. The bulk of total emissions
originate from the catalytic oxidation reactor (Reference 17). Emis-
sions from other equipment (e.g., switch condensers, distillation
columns, and heat treaters) are negligible.
a. Process Emissions from Phthalic Anhydride Formation Process
One-hundred percent of naphthalene used in the manufacture of
phthalic anhydride is converted to phthalic anhydride in the reactor.
Therefore, 0 process emissions of naphthalene are assumed (Reference
10, p. 41). This is supported by raw material and product informa-
tion from Reference 20, p. 9-10, which states that 4,386 Ib/hr naphtha-
lene is raw material fed to process and 4,386 Ib/yr is production rate
for crude phthalic anhydride vapor from naphthalene, indicating that
all naphthalene as raw material is used in the process.
b. Fugitive Emissions
VOC emission factors from Reference 24 for equipment leaks
from synthetic organic chemical manufacturing plants (SOCMI) are used.
All VOC is assumed naphthalene to estimate conservatively.
Number of pumps, valves, and other equipment per process unit
is based on SOCMI process unit counts in Reference 24. Only equipment
in heavy liquid or gas vapor service is included since naphthalene is
considered a heavy liquid on the basis of its Reid vapor pressure
(0.007 kPa at 20°C).
Equipment component counts and emission factors for an aver-
age SOCMI unit are used to estimate emissions (Reference 24, pp. 1-4,
3-2, 3-6) as follows:
A-13
-------
Equipment
Component
Component
Count
Average SOCMI
Emission Factor
(kg/hr/source)
Opera-
ting hrs
per year3
VOC Emis-
sions'^
(kg/yr)
Heavy Liquid Pumps
0.0214
8,232
881
Heavy Liquid Valves
Heavy Liquid Safety/
Relief Valves
Heavy Liquid Open-
84
0.00023 8,232
Not avilable 8,232
160
ended Valves A Lines
Compressor Seals
Sampling Connections
Flanges
48
1
12C
500
0.0017
0.228
0.0150
0.00083
TOTAL
8,232
8,232
8,232 -
8,232
670
1,880
- 1,480
3,400
8,470
Footnotes from table, previous page:
aOperating hours from Reference 20.
^Assumed to have single mechanical seals.
C25% of open-ended lines used for sampling, based on Reference 24,
p. 3-4.
dVOC assumed to be 100% naphthalene for conservative estimate.
c. Storage Emissions
Emissions of naphthalene from phthalic anhydride production
at the facility are primarily from one storage tank (Reference 10).
It is assumed that EPA emission factors from AP-42 (Reference
21) apply for uncontrolled stor.age tank losses of naphthalene at phthalic
anhydride plants. Emissions from naphthalene storage are presently not
controlled.
The facility has one naphthalene storage tank.
Emission equations for estimating breathing (Lg) and working
losses (Lu) from fixed-roof tanks storing volatile organic liquids are
calculated as follows (PES assumes all organics in tank are naphthalene):
A-14
-------
Total Loss • LB + Lu 0_M
LB . 2.26 x ID"2 HV P^T Bl-» H°-» T'-5° Fp CKC
where:
LB = fixed roof breathing loss (Ib/yr)
MV = molecular weight of vapor in storage tank (Ib/lb mole)
PA = average atmospheric pressure at tank location (psia)
P = true vapor pressure at bulk liquid conditions (psia)
D = tank diameter (ft)
H = average vapor space height, including roof volume
correction (ft)
T = average ambient diurnal temperature change (°F)
Fp = paint factor (dimensionless)
C = adjustment factor for small diameter tanks .(dinension-
less)
KC = product factor (dimensionless).
Fixed-roof tank working losses can be estimated from:
Lw = 2.40 x 1(T5 Mv PVNKN Kc
where:
LW = fixed-roof working loss (Ib/year)
Mv = molecular weight of vapor in storage tank (Ib/lb mole)
P = true vapor pressure at bulk liquid temperature (psia)
V = tank capacity (gal)
N = number of turnovers per year (dimensionless)
N = Total throughput per year (gal)
Tank capacity, V (gal)
KN = turnover factor (dimensionless)
Kp = product factor (dimensionless)
A-15
-------
From References 20 and 21, the following variables for the equations
are given:
Fixed-roof breathing loss, LR (Ib/yr):
Mv = 128.19 (Reference 22)
PA = 14.7 psia (Reference 23)
P = 1.84 (Reference 25) true vapor pressure at 60°F
D = 66.5 ft (Reference 20)
H = 16 ft (assume H = 1/2 tank height, Reference 21)
T = 20°F (assumed as typical value, Reference 23)
Fp = 1.26 (aluminun tank, based on average of several aluminum
tank paint factors, Reference 21)
C = 1 (Reference 23, p. 3-26)
KC = 1.0 (Reference 21, p. 4.3-8)
LB = 25,500 Ib 0.454 kg
yf x Tb = 11.600 kg/yr
Fixed-roof working loss, LU (Ib/yr):
Mv = 128.19 (Reference 22)
P = 1.84 psia (same assumptions as for breathing loss above)
V = 835,000 gal (Reference 20)
N = 16.17 (Reference 21)
KN = 1.0 (Reference 21)
Kc = 1.0 (Reference 21)
I 76,400 Ib 0.454 kg
W = 7F x Tb = 34,700 kg/yr
LB + LW = 46,300 kg/yr.
Total Naphthalene Emissions from Phthalic Anhydride Production = 54,754 kg/yr
= 54.8 Mg/yr .
A.5 CARBAMATE INSECTICIDES END USE
A. SIC Code
Reference 1.
A-16
-------
8. Plant Name
Only one plant, Union Carbide, Institute, WV, produces carbamate
insecticides (chiefly carbaryl) from naphthalene (References 4 and 9).
One other Union Carbide facility,. St. Louis, MO, is reported to dilute
the carbaryl product it receives from another plant, but it does not
produce carbaryl directly and there is no naphthalene storage (Reference
26).
Corresponds to an emission point, either.process, fugitive, or
storage. Uhen stack parameters for different emission points are
identical, they are assigned one number, and emissions from these
points are combined.
H. Stack Parameters
Reference 9 unless indicated otherwise.
1. Process emissions from Unit Number 250 corresponds to Stack
Number P-l in Table A-4. Stack parameters from Reference 9.
2. Process emissions from Unit Number 251 correspond to Stacks P-2,
P-3, and P-4 in Table A-4. Stack P-3 represents 2 identical
4.6-meter stacks with reported average velocity of 0.22 m/sec
Stack P-4 represents 5 15-meter stacks with average
temperature of 317°K and an average velocity of 2.4 m/sec.
Total emissions from Process [251] were apportioned among the
stacks based on stack sampling data given in Reference 9.
3. Process emissions from Unit No. 252 correspond to Stack Number
P-5 in Table A-4. Stack parameters from Reference 27.
4. Process emissions from Unit No. 253 correspond to Stack Number
P-6 in Table A-4. Stack parameters from Reference 9.
5. Fugitive emissions from all process units are reported under
one "stack number." Assumptions include a release height of
3 meters above ground, a cross-sectional downwash area of
100 x 200 meters, a velocity of 0.01 m/sec, and temperature of
293°K (ambient). Values of 0.01 m/sec for velocity and 293°K
for temperature were assumed.
C. Latitude/Longitude
Reference 43.
D. Urban
Plant assumed to be located in an urban area.
E. City, State
Reference 4.
A-17
-------
F. Emission Type
Process (P), Fugitive (F), or Storage (S) emission points
are based_on information in Reference 9.
G. Stack Number
6. Storage emissions:
Unit 250 - 3 tanks H = 12m, D = 15m (S-l in Table A-4)
1 tank H = llm, D = 21m (S-2 in Table A-4)
Unit 251 - Estimated 1 tank, H = 3m, 0 = 3m (S-3 in Table A-4)
Unit 252 - 3 tanks, H = 9.1m, D = 7.6m (S-4 in Table A-4)
Unit 253 - 1 tank, H = 3.4m, D = 3.5m (S-5 in Table A-4)
Values of 0.01 m/sec assumed for velocity and 293°K (ambient) for
temperature. Vent diameter of 0.076 m is based on average diameter
of xylene storage tank vents from Reference 40.
I. Vent Type
A vertical vent (0) for process and storage emission points, and
nonvertical (1) for fugitive emissions is used.
J. Emissions . • •
Plant 1 - Union Carbide, Institute, WV.
Emissions information from 1984 Emission Inventory, Summary by
Process, Union Carbide, Institute, WV (Reference 9). The following
emission estimates are presented by emission type (process, storage,
fugitive, emergency) and by carbaryl process unit (hydrogenation,
oxidation, dehydrogenation, and refining).
a. Process'Emissions of Naphthalene from Carbaryl Production
No information to indicate emissions are controlled; therefore,
no controls are assumed to be in place. The carbaryl process units and
reported emissions are listed below:
1. #250 - Tetralin hydrogenation unit:
1,512 Ib/yr x 0.454 kg/lb = 686 kg/yr
2. #251 - Tetralin oxidation unit:
1,573.5 Ib 0.454 kg
x = 714
A-18
-------
3. #252 - Crude naphthol dehydrogenation unit:
2.8 Ib 0.454 kg
7F x Ib = 1-3
4. #253 - 1-naphthol refining unit:
1.8 Ib 0.454 kg
yjT x Tb = °-
TOTAL Process Emissions = 1,402 kg/yr
b. Fugitive Emissions of Naphthalene from Carbaryl Production
1. #250 - Tetralin hydrogenation unit:
1,279 Ib 0.454 kg
yp x TF = 581 kg/yr
2. #251 - Tetralin oxidation unit:
842 Ib 0.454 kg
y7 x TF = 382 kg/yr
3. #252 - Crude naphthol dehydrogenation unit:
83.6 Ib 0.454 kg
yp x Tb = 38-° k9/yp
4. #253 - 1-naphthol refining unit:
548 Ib 0.454 kg
yf x Tb = 249 kg/yr
TOTAL Fugitive Emissions = 1,250 kg/yr
c. Storage Emissions of Naphthalene from Carbaryl Production
1. #250 - Tetralin hydrogenation unit (4 storage tanks, 4,046.5
Ib/yr total emissions):
4,046.5 Ib 0.454 kg
7 x Tb = 1,837 kg/yr
2. #251 - Tetralin oxidation unit:
16.9 Ib 0.454 kg
= 7-67
A-19
-------
3. #252 - Crude naphthol dehydrogenation unit (3 storage tanks,
31.7 Ib/yr each):
95.1 Ib 0.454 kg
yF x Tt> = 43-2 kg/yr
4. #253 - 1-naphthol refining unit:
38.2 ]b_ 0.454 k£
\ir X Ih = 17.3
TOTAL Storage Emissions = 1,905 kg/yr.
d. Emergency Emissions of Naphthalene from Carbaryl Production
1. #250 - Tetralin hydrogenation unit:
5 ]b_ 0.454 J
-------
(Production of 1- and 2-naphthalenesulfonic acids).
A. SIC Code
Reference 1.
B. Plant Name
Five producers of synthetic tanning agents from naphthalene were
identified:
(1) Diamond Shamrock, Carlstadt, NO (Reference 4)
(2) Rohm and Haas, Philadelphia, PA (Reference 4)
(3) Morflex, Inc., Greensboro, NC (Reference 10, p. 45) (formerly
Ciba-Geigy)
(4) Georgia Pacific, Bellingham, WA (Reference in, p. 45)
(5) Diamond Shamrock, Cedartown, GA (Reference 10, p. 45)
C. Latitude/Longitude
Rased on conversion of zip code obtained from Reference 4 or
U.S. Postal Service Zip Code Directory to UTM coordinates using com-
puter program from Office of Toxic Substances.
D. Urban
All plants are assumed to be located in an urban area.
E. City, State
References 4 and 10.
F. Emission Type
Process (P), Fugitive (F), and Storage (S).
G. Stack/Vent Parameters
Sane as Section A.8, Surface Active Agents, Part H.
H. Emissions
Synthetic tanning agents are produced primarily from 1- and 2-
naphthalenesulfonic acids (NSA), both derivatives of naphthalene.
Plant-specific emissions of naphthalene from the production of 1- and
2-NSA were calculated on the basis of total naphthalene consumption by
the method described in Section A.8 for Surface Active Agents. Calculated
emissions are'based on: (1) the assumption that 0.034% of total naphthalene
consumed (315 Gg) is lost to the atmosphere (based on Reference 3,
assuming this percentage is the same for both production and consumption);
and (2) 6% of total naphthalene consumption is from production of synthetic
tanning agents (Reference 3). From the above, total naphthalene emissions
from production of synthetic tanning agents (1- and 2-NSA) are calculated as:
A-21
-------
0.06 x 0.00034 x 315 Gg = 0.0064 Gg
= 6.4 Mg.
This total was divided among the five producers of synthetic tanning
agents, or 1.3 Mg naphthalene emissions per plant.
A.8 SURFACE ACTIVE AGENTS END USE
(Production of 1- and 2-naphthalenesulfonic acids)
A. SIC Code
Reference 1.
B. Plant Name
References 4 and 31.
C. Latitude/Longitude
Based on conversion of zip codes from Reference 4 and U.S. Postal
Service Zip Code Directory to UTM coordinates using computer program
from the Office of Toxic Substances.
D. Urban
Plants are assumed to be located in an urban area.
E. City, State
References 4 and 31.
F. Emission Type
Process (P), Fugitive (F), and Storage (S) emissions.
G. Stack Number
Corresponds to an emission point, either process, fugitive, or
storage. When stack parameters for different emission points are
identical, they are assigned one number, and emissions from those
points are combined.
H. Stack Parameters
1. Process emissions - Unless a specific stack height is known,
13 m from average of stack heights was selected, Reference 9;
specific stack heights were available for some of the New Jersey
plants (Reference 32).
Vents are assumed to be vertical (0) and a stack diameter of
0.15 m (average of stack diameters from Reference 9 is used).
A-22
-------
A stack velocity of 6.3 m/sec is selected based on average
velocity from Reference 9. If stack velocities are known for
specific plants, they are reported (Reference 32).
A stack temperature of 320°K is selected based on average
temperatures for process stacks from Reference 9.
2. Fugitive emissions - A height of 3m, crosssectional area
of 200 m x 100 m (20,000 m2) for Plants 1 and 3 and 100 m x 50 m
(5,000 m2) for Plants 2 and 4 are used. Horizontal venting is
assumed; a velocity of 0.01 m/sec and a temperature of 293°K
(ambient) are assumed.
3. Storage emissions - A height of 7.7m based on average
height of tanks from Reference 9 is chosen; A vertical vent, a
vent diameter of 0.076 m (Reference 40), a velocity of 0.01 m/sec,
and a temperature of 293°K (ambient) are used.
I. Emissions
Plant-specific emissions of naphthalene from the production of
1- and 2-naphthalenesulfonic acid were calculated on the basis of total
naphthalene consumption. It is assumed that 0.034% of total naphthalene
consumed as end-use chemicals is lost to atmosphere (based on Reference
14 estimate that a maximum 0.07% of naphthalene produced is lost to the
environment and 48% of that amount is lost to atmosphere). This gross
estimating procedure is used because of the lack of usable pl-ant-
specific information. Based on: (1) 0.034% of total naphthalene
consumed (315 Gg, Reference 3) is lost to air and (2) 7% of total
naphthalene consumption is from production of surface active agents
(Reference 3), total naphthalene emissions from production of surface
active agents are calculated as:
0.07 x 0.00034 x 315 Gg = 0.0075 Gg
= 7.5 Mg
1. 1-naphthalenesulfonic acid (1-NSA) production - Naphthalene
emissions from 1-NSA production are calculated by multiplying the
above total (7.41 Mg) by 15%, the relative percentage of 1-NSA
in surface active agent compounds (estimate based on Reference 34):
0.15 x 7.5 = 1.1 Mg
This total was apportioned among the nine 1-NSA producers to obtain
a plant-specific estimate of 123 kg per plant. One-third of
the plant total (41 kg) was assigned each to process, storage, and
fugitive emissions.
A-23
-------
2. 2-naphthalenesulfonlc acid (2-NSA) production - Naphthalene
emissions from 2-NSA production are calculated by multiplying
the total emissions from NSA production (7.41 Mg) by 85%, the
relative percentage of 2-NSA in surface active agent compounds
(Reference 34):
0.85 x 7.41 = 6.3 Mg
This total was apportioned among the six 2-NSA producers to derive
a plant-specific estimate of 1,050 kg per plant. One-third of
the plant total (350 kg each) was assigned to process, storage, and
fugitive emissions.
A.9 MOTH REPELLANT END USE
A. SIC Code
Reference 1.
B. Plant Name
Plant 1 - Morflex, Inc. (formerly Ciba-Geigy Corp.), Greensboro, NC
(Reference 31).
Plant 2 - Kincaid Enterprises, Inc., Nitro, WV (Reference 31).
West Virginia Air Pollution Control Commission reports no infor-
mation on Plant 2 and that the plant may no longer be in operation or
not using naphthalene in the production of moth repellant (Reference
35).
C. Latitude/Longitude
Based on conversion of zip codes from U.S. Postal Service Zip Code
Directory to UTM coordinates using computer program from the Office of
Toxic Substances.
D. Urban
Plants are assumed to be located in an urban area.
E. City, State
Reference 31.
F. Emissions
Plant 1 - No informatioa was available on Morflex, Inc. from the
North Carolina Department of Natural Resources permit files to indicate
that the plant is manufacturing moth repellant.
It is assumed that if the plant produced moth repellent from naph-
thalene, emissions from production and handling of moth repellent would
be included in estimates for production of naphthalene because the
product is made directly from the production of naphthalene as a solid
A-24
-------
flake, powder, or ball, and is repackaged as a consumer product at
another facility (Reference 10, p. 46). It is assumed that the Morflex
facility only repackages the product that is already manufactured in a
crystallized form by one of the naphthalene producers. Therefore, no
emissions of naphthalene are expected from Morflex.
Plant 2 - Based on information from the West Virginia Air Pollu-
tion Control Commission, no emissions of naphthalene are estimated from
Kincaid Enterprises (References 35 and 42).
A.10 MISCELLANEOUS ORGANIC CHEMICALS END USE
No plant-specific information was available on miscellaneous
chemicals except one, RSA Corporation, Ardsley, New York, which produces
1-bromonaphthalene.
A. SIC Code
Reference 1.
B. Plant Name
The following organic chemicals are classified as miscellaneous
in terms of naphthalene end use:
Source
Category/Chemical
1. 1-naphthol
2. 1-naphthylamine
Plant
Name/Location
Union Carbide, Institute, WV
(Emissions included in carbaryl
production)
Sigma Chemical Co., St. Louis,
MO
3. 1,2,3,4-tetrahydronaphthalene DuPont, Deepw^ter, NJ
(tetrali n)
4. decahydronaphthalene
(decalin)
5. 1-naphthaleneacetic acid
6. 1-bromonaphthalene
Union Carbide, Institute, WV
(Emissions included in carbaryl
production)
OuPont, Deepwater, NJ
Greenwood Chemical, Greenwood,
VA
(No longer in operation)
Union Carbide, Ambler, PA
RSA Corp., Ardsley, NY
Refer-
ence
4
9
31
4
4
9
4
36
4
A-2b
-------
7. 1-methylnaphtha!ene Chemical Exchange Industries,
Houston, TX 4
8. methylna-phthalene Koppers, Follansbee, WV 4
Crowley Chemical, Kent, O.H 4
Crowley Chemical, Oklahoma City,
OK 4
9. 1-naphthaleneacetamide Greenwood Chemical, Greenwood,
VA 4
(No longer in operation) 36
10. nitronaphthalenesulfonic acids Ciba-Geigy, Toms River, NJ 4
11. naptalam Uniroyal, Gastonia, NC 4
C. Latitude/Longitude
Based on conversion of zip codes from Reference 4 and U.S. Postal
Service Zip Code Directory to DIM coordinates using computer program
from Office of Toxic Substances.
D. Urban
All plants are assumed to be located in urban areas.
E. City/State
References 4 and 31.
F. Emission Type
Reported as process (P), fugitive (F), and storage (S) emissions.
G. Stack Number
Corresponds to an emission point, either process, fugitive, or
storage.
H. Stack Parameters
1. Process emissions - Unless a specific stack height is known,
the average of stack heights, 13 m, is used, Reference 9; specific stack
heights were available from some of the New Jersey plants (Reference 32)
and from RSA Corporation (Reference 37).
Vents are vertical and a stack diameter of 0.15 m is used (average
of stack diameters from Reference 9). Stack diameter for RSA Corp. is
from Reference 37.
A stack velocity of 6.3 m/sec is used based on average velocity
from Reference 9. If stack velocities are known for specific plants,
they are based on velocities from References 32 and 37.
A-26
-------
A stack temperature of 320°K is used based on average tempera-
tures for process stacks from Reference 9. Stack temperature for RSA
Corporation-is from Reference 37.
2. Fugitive emissions - A release height of 3 m, crosssectional
downwash area of 200 m x 100 m for large plants, 50 m x 100 m for medium-
sized plants, and 50 m x 25 m for small plants. Horizontal vents are
assumed. A velocity of 0.01 m/sec and a temperature of 293°K (ambient)
are assumed.
3. Storage emissions - A height of 7.7 m is used based on average
height of tanks from Reference 9. PES assumes venting is vertical, a
vent diameter of 0.076 (Reference 40), a velocity of 0.01 m/sec, and a
temperature of 293°K (ambient).
I. Emissions
Except for RSA Corp., plant-specific emissions of naphthalene
from miscellaneous organic chemical production were calculated on the
basis of total naphthalene consumption. (RSA Corporation reported emis-
sions as "trace," which means <0.001 Ib/hr.) For other plants, it is
assumed that 0.034% of total naphthalene consumed as end-use chemi-
cals is lost to atmosphere (based on Reference 14 estimate that a maximum
of 0.07% of naphthalene produced is lost to the environment and 48% of
that amount is lost, to atmosphere). This gross estimating procedure is
used because of the lack of usable or no plant-specific information.
Based on (1) 0.034% of total naphthalene consumed (315 Gg, Refer-
ence 3) is lost to air and (2) 2% of total naphthalene is from produc-
tion of miscellaneous organic chemicals (Reference 3), total naphthalene
emissions from production of miscellaneous organic chemicals is calcu-
lated as:
0.02 x 0.00034 x 315 Gg = 0.0021 Gg
= 2.1 Mg
This total was divided among all plants for which no specific emission
was available (2.1 Mg * 14 plants = 150 kg each plant). One-third
of the total plant estimate was assigned each to process, storage, and
fugitive emissions (50 kg each).
Only storage emissions of methylnaphthalene were estimated for
Crowley Chemicals, Kent, OH, and Oklahoma City, OK, since no chemical
production occurs at either facility (References 38 and 39).
A-27
-------
Emissions from 1-naphthol production at Union Carbide, Institute,
WV, are included in naphthalene emissions from carbaryl production
(Reference 7) (see Section A.5).
Table A-2 presents the modeling parameters for naphthalene production.
After completion of the modeling, a review of the emission estimating
procedures resulted in revised emission estimates. Overall emissions for
the production category increased 0.4 percent, from 52,960 kg/yr to
53,200 kg/yr. Total fugitive emissions increased from 1,560 kg/yr to
2,180 kg/yr. Process emissions decreased from 47,200 kg/yr to 46,900 kg/yr.
Storage emissions decreased from 4,200 kg/yr to 4,170 kg/yr. EPA determined
that additional modeling was not necessary.
A-28
-------
Table A-l. MODELING PARAMETERS FOR NAPHTHALENE
EMISSIONS FROM COKE BY-PRODUCT RECOVERY PLANTS
NJ
Record*
1
2
3
4
j
6
7
a
9
id
11
12
13
14
15
16
17
16
19
20
21
22
23
24
25
26
27
23
29
30
31
32
33
34
35
36
uodate oollutaitt source_cat
10/23/66 taonthaiene Coke by-product
10/26/66
10/26/66
10/26/66
10/28/66
10/28/66
113/28/86
10/28/86
10/26/66
10/28/86
10/28/66
10/26/86
10/26/66
10/28/86
10/26/86
10/28/66
10/28/66
10/28/86
10/28/66
10/26/86
10/28/66
10/28/86
10/28/86
10/28/86
10/28/86
10/28/86
10/26/86
10/26/86
10/28/86
10/28/86
10/28/86
10/28/8b
10/28/66
10/28/66
10/26/66
10/26/86
Dlant_nuub sic_code olant_na«e
1 3312
1
1
&
2
2
3
3
3
4
4
4
5
5
5
&
6
6
7
1
7
a
a
a
9
9
' 9
id
10
10
11
11
11
12
12
12
latitude longitude urban city
Eaoire Coke
Republic Steel
National Steel
Inter lake
Indiana Gas ( Chen.
U.S. Steel
Rouge Steel Co.
National Steel
Bethlehem Steel
Chattanooga Coke t C
Lone Star Steel
J & L Steel
331425
0
0
340046
0
0
384140
0
0
413922
A
<0
0
392648
0
0
413655
0
0
421619
0
0
421516
0
0
403651
0
0
350216
0
0
325459
0
0
402534
0
0
873011
0
0
860238
0
0
900742
0
0
873732
0
872347
0
0
672003
0
0
630940
0
0
830743
0
0
752113
0
0
851811
0
0
944257
0
0
795747
0
0
• Holt
e
e
0 Gadsden
0
ft '
0 Granite City
0
0
0 South Chicago
0
0 Terre Haute
0
0
0 Gary
0
e
0 Dearborne
0
0
0 Detroit
0
0
0 Bethlehem
0
0
0 Chattanooga
0
0
0 Lone Star
0
0
0 Pittsburgh
0
0
-------
_J 0-
2
o
II
35 S
s s a 2 &
i 8 8 3 I
OJ
Q. >
is
LU
IS iS «9 iS S IS
19 IS iS IS
— IS iS —. iS IS —t
o --^
• c
a£ ca o
< u
O_ LU — »
2^
ta o
z o
19'SSisisiniSis
is r*-
is CO
O Li_
S
oo
z
• o
I— I I— I
I 1/1
-------
Table A-2. MODELING PARAMETERS FOR NAPHTHALENE
EMISSIONS FROM NAPHTHALENE PRODUCTION
Record* uotiate pollutant
1 10/28/66 Nahothalene
2 10/26/86
3 10/28/86
4 10/26/86
5 10/26/66
6 10/28/66
7 ld/26/66
8 10/28/86
9 1(9/28/86
id 10/28/86
11 10/28/86
Id 10/28/86
13 10/26/86
14 18/28/66
15 10/26/86
16 10/28/66
17 10/28/66
18 10/28/86
19 10/28/86
20 10/26/66
21 10/06/66
22 10/06/66
23 10/08/66
24 10/08/66
source_cat
Naontiialene arod.
1 2865
1
1
2 2669
2
2
3 2869
3
3
4 2865
4
4
4
4
4
4
4
5 2869
5
5
6 2669,
7 2865
6 2665
9 2865
olant_naue latitude longitude urban city
Allied Chemical Co.
Cheuical Exchange
£. I. duPont de ten.
Hoppers Coupany, Inc
Texaco Chemical
fisnland Chemical
U.S.S. Cheuicals
U.S.S. Cheaicals
Hoppers Conpany, Ire
363016
0
0
294515
0
0
291550
0
0
402013
0
0
0
0
0
0
0
393507
0
0
362736
401736
413600
415100
623942
0
0
950100
0
0
951248
0
0
803620
0
0
0
0
0
0
0
753744
0
0
623818
795230
872006
674742
• Ironton,
0
0
0 BaytoMn
0
0
0 Chocolate Bayou
0
0
0 Follansbee
0
e
0
0
0
0
0
0 Delaware City
0
0
0 Ashland
0 Clairton
0 Gary
0 Stickney
-------
Table A-2. MODELING PARAMETERS FOR NAPHTHALENE
EMISSIONS FROM NAPHTHALENE PRODUCTION
(concluded)
T
Record*
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
IB
19
20
21
22
23
24
p i ant _ name
Allied Chemical Co.
!
Chemical Exchange
£. !. duPont de Nem.
Koooers Coiaoany. Inc
Texaco Chemical
Ashland Chemical
U.S. 5. Chemicals
U.S. 5. Cneaicals
Koooers Conoany, Inc
state tyoe stack_nura
OH
TX
TX
UV
DE
KY
PA
IN
IL
P
F
S
P
F
S
P
F
S
P
F
S
S
S
5
S
S
P
f
S
1
1
1
1
1
1
1
1
1
1
1
1
2
3
4
5
6
1
1
1
0
0
0
0
height
13.~00
3.00
7.60
13.00
3.00
7.60
13.00
3.00
7.60
13.00
3.00
6.70
7.60
10.90
9.10
6.10
12. 80
13.00
3.00
7.60
0.00
0.00
0.00
0.00
area vent.type diameter velocity
0.00
20000.00
0.00
0.00
20000.00
0.00
0.00
20000.00
0.00
0.00
20000.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
20000.00
0.00
0.00
0.00
0.00
0.00
0
1
0
0
1
0
0
1
0
0
1
0
0
0
0
0
0
0
1
0
0
0
0
0
0.150
0.000
0.076
0.150
0.000
0.076
0.150
0.000
0.076
0.150
0.000
0.076
0.076
0.076
0.076
0.076
0.076
0.150
0.000
0.076
0.000
0.000
0.000
0.000
6.300
0.010
0.010
6.300
0.010
0.010
6.300
0.010
0.010
6.300
0.010
0.010
0.010
0.010
0.010
0.010
0.010
6.300
' 0.010
0.010
0.000
0.000
0.000
0.000
teno
320
293
293
320
293
293
320
293
293
320
293
293
293
293
293
293
293
320
293
293
0
0
0.
0
en_uax
0~000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0AAA
• vw
0.000
0.000
0.000
Missions
62M.IM
V*. Mft
760.000
3400.000
120.000
320.000
9600.000
340.000
940.000
19300.000
560.000
160.000
170.000
261.000
277.000
356.000
316.000
6500.000
230.000
620.000
0.000
0.000
0.000
0.000
-------
Table A-3. MODELING PARAMETERS FOR NAPHTHALENE
EMISSIONS FROM PHTHALIC ANHYDRIDE PRODUCTION
source_cat
plant nunt) sic code olant name
latitude longituoe urban city
1
2
3
4
5
Recordl
1
2
3
4
5
10/28/86 Naofithalene
10/08/86
10/08/86
10/28/86
10/28/86
olant_riaifie
Kopoers Co. Inc.
Monsanto Co.
Koooers Co. Inc.
Withal ic finyhdriae
state type stack_ria» heignt
PA 0 0.00
MJ 0 0. 00
IL P 1 0.00
F 1 3.00
S 1 9.80
1
2
3
3
3
2869
area
0.00
0.00
0.00
20000.00
0.M
Koooers
Monsanto
KoQoers
vent_tyoe
0
0
0
1
0
Co. Inc.
Co.
Co. Inc.
diameter
0.000
0.000
0.000
0.000
076
402136
394806
415100
0
0
velocity
0.000
0.000
0.000
0.010
0.018
800700
752100
874742
0
0
team eu_
0 0.
0 0.
0 0.
293 0.
293 8.
0
8
0
0
0
•ax
000
000
000
000
808
Bridgeville
Bridgeport
St ickney
emissions
0.000
0.000
0.000
8470.000
46300.808
-------
Table A-4. MODELING PARAMETERS FOR NAPHTHALENE
EMISSIONS FROM CARBAMATE INSECTICIDES PRODUCTION
Record uoaate pollutant
1 10/14/86 Naonthalene
2 10/14/86
3 10/14/86
4 18/14/86 .
5 10/14/86
6 10/14/86
7 10/14/86
8 10/14/86
9 10/14/86
10 10/28/66
11 10/14/86
12 10/14/86
13 10/14/86
source cat
Dlant_numb sic_code Dlant_riame
latitude longitude urban city
r
LO
ftecoroi Dlant_nai,ie
1 Union Carbide Corn.
2
3
4
5
6
7
8
9
10
11
12
13 union Caroiae
Carbaryl Proa
state tyoe stacK_
W P
P
P
P
P
P
f
S
S
5
5
5
no
nun
1
^
3
4
5
6
7
8
9
10
11
12
0
height
12.20
16.80
4.60
15.20
13.70
15.20
3.00
12.20
11.00
3.00
9.10
3.40
0.40
1
1
1
1
1
1
1
1
4
'1
1
1
1
2
2879
area
0.00
0.00
0.00
0.00
0.00
0.00
20000.00
0.00
0.00
0.00
0.00
0.00
0.W
Union Carbide
Union Carbide
Corp.
vent _ type Diameter
0
0
0
0
0
0
1
0
0
0
0
0
0
0.150
0.300
0.250
0.040
0.100
0.037
0.000
0.076
0.076
0.076
0.076
0.076
0.000
382258
0
0
0
0
0
0
0
0
0
0
0
383400
velocity
1.200
14.400
0.220
2.400
19.800
0.910
0.010
0.010
0.010
0.010
0.010
0.010
0.W0
814625
0
0
0
0
0
0
0
0
0
0
0
901500
teao
339
313
313
261
313
323
293
293
293
293
293
293
0
E
0
0
0
8
0
0
0
0
0
*
0
8
0
».„»
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.0&3
0.000
Institute
i
St. Louis
euissions
686.000
571.000
72.000
71.0A2I
1.300
0.820
1250.000
1831.000
6.000
7.670
43.200
17.300
0.000
-------
Table A-5. MODELING PARAMETERS FOR NAPHTHALENE
EMISSIONS FROM 2-NAPHTHOL PRODUCTION
Record! uodate pollutant source_cat plant.nuab sic_code plant.naw latitude longitude urban city
1 10/08/86 Napthalene Beta-naphthol prod. 1 2869 flwrican Cyarwuiid Co 392048 811912 0 Willow Island
U)
Ul
Recordl plant nane
1 Aterican Cyananid Co WV
state type stack_riu« height
area vent_type dianeter velocity teao
0.00 0 0.000 0.000 0
ea vax
emssions
-------
Table A-6. MODELING PARAMETERS FOR NAPHTHALENE
EMISSIONS FROM PRODUCTION OF SYNTHETIC TANNING AGENTS
Recorcn
1
2
3
4
5
6
7
6
9
10
11
12
13
14
15
Recora«
1
2
3
4
j
6
7
6
9
10
11
12
13
14
:5
uocate Qoliutan:
10/26/66 Naontfialene
10/28/86
10/28/86
10/28/86
10/28/66
10/28/66
10/28/66
10/26/66
10/28/66
10/28/86
10/28/86
10/26/86
10/26/86
10/28/86
10/28/86
Dlant_name
Diamond SnamrocK
Ronm & Haas Co. ,
florflex. Inc.
Georsu Pacific Coro
DiiBono SnaarocK.
source cat plant.nuHti sic_code Dlantjiame
iatituoe longitude urban city
tyce stacK_nuia
?
F
S
P
r
S
P
f
5
tanning ag
id
1
1
1
1
1
1
1
1
1
1
l
1
1
i
1
heignt
13.00
3.00
7.70
13.00
3.00
7.70
13.00
3.00
7.70
13.00
3.lM
7.70
:3.0$
3.00
7.7ii
1 2869 Diamond
1
2 Rohu &
2
2
3
3
3
4
4
4
5
5
5
area
0.00
20000.00
0.00
0.00
20000.00
0.00
0.00
20000.00
0.00
0.00
2W0. 00
0.00
o*
20000.00
0.00
Morflex
Georgia
Diamond
Shamrock 405018
0
0
Haas Co. 395954
0
, Inc.
Pacific
0
360516
0
0
Coro 464548
0
0
Snamrock 340048
vent_type diameter
0
1
0
0
1
0
0
1
0
0
1
0
0
1
0
0.150
0.000
0.076
0.150
0.000
0.076
0.150
0.000
0.076
0.150
0.000
0.076
0.150
0.000
0.076
0
0
velocity teno
6.300 320
0.010 293
0.010 293
6.300 320
0.010 293
0.010 293
6.300 320
0.010 293
0.010 293
6. 300 320
0.010 293
0.010 293
6.388 32(2
0.010 293
0.010 293
740542
0
0
750400
0
0
795324
0
0
1222900
0
0
851518
0
0
eu_uax
0.000
0.000
0.08)0
0.000
0.000
0.000
0.000
0.000
0.00«l
0.000
0.000
0.000
0.000
0.000
0.000
0 Carlstadt
0
«
0 Philadelphia
0
0
0 BreensDoro
0
0
0 BeHingnan
0
ft
0 Cedar tour.
0
0
emssions
430.000
430.000
430.000
430.000
430. 000
430.0021
430. 030
430.020
430. «I0
430. Mtf
430. 00d
t30. 000
430. 000
430.000 '
430. 000
-------
Table A-7. MODELING PARAMETERS FOR NAPHTHALENE EMISSIONS FROM
PRODUCTION OF SURFACE ACTIVE AGENTS -- 1-NAPHTHALENESULFONIC ACID
Record* uadate pollutant
1 10/14/36 Naontnalene
£ 10/14/8&
3 10/14/86
4 10/14/36
5 10/14/86
6 10/14/86
7 10/14/86
8 10/14/86
9 10/14/86
10 10/14/86
11 10/14/86
12 10/14/86
13 10/14/86
14 10/14/86
15 10/14/86
16 10/14/86
17 10/14/66
18 10/14/86
19 10/14/86
£0 10/14/86
£1 10/14/86
££ 10/14/86
23 10/14/86
£4 10/14/86
25 10/14/86
£6 10/14/86
£7 10/14/86
source_cat
1-nao.sulfonic acid
Dlant_nui»d sic_coae plant_nawe
1 £843
1
£
2
£
3
3
3
4
4
4
5
5
5
6
6
6
7
7
7
6
a
8
s
9
9
latitude longituae urban city
American Cyanauud
Ciba-beigy Corp
DeSoto, Inc.
Diamond Shamrock
Diaaond Shamrock
E.I. duPont de Men.
EsiKay Chen. Co.
Morflex, Inc.
Georgia Pacific
403800
0
0
395£54
0
0
3£4448
0
0
405018
0
0
340048
0
0
394100
0
0
403912
0
0
360518
0
0
464546
0
0
741500
0
0
741048
0
0
972000
0
0
74054£
0
0
851518
0
0
7529£4
0
0
741130
0
0
7953£4
0
0
12E29W
0
0
0 Linden
0
0
0 Tons River-
0
0
0 Fort Worth
0
0
0 Carlstadt
0
0
0 Cedartown
0
0
0 Deepwater
0
0
0 Elizabeth
0
0
0 Greensboro
0
0
0 Bellinghan
0
8
-------
Table A-7. MODELING PARAMETERS FOR NAPHTHALENE EMISSIONS FROM
PRODUCTION OF SURFACE ACTIVE AGENTS — 1-NAPHTHALENESULFONIC ACID
(concluded)
Record*
1
£
3
4
5
6
7
6
9
10
11
12
13
14
15
16
17
18
19
£0
£1
££
£3
£4
£5
£b
£7
olant riase
American Cyanatnid
Ciba-Geigy Coro
DeSoto, Inc.
Diamond Snatiroch
Diaaond ShamrocK
E. I. duPont de Nera.
EaiKay Cnew. Co.
Korflex. Inc.
Georgia Pacific
state
NJ
NJ
TX
NJ
GA
NJ
NJ
NC
WA
ty
p
F
S
P
F
S
P
F
S
P
F
S
P
F
3
P
F
S
P
F
S
P
F
S
p
F
5
type stacK_nuw
P
F
S
P
F
S
P
F
S
P
F
S
P
F
3
P
F
S
P
F
S
P
f
S
P
F
5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
S
1
1
1
1
1
i
i
height
19.60
3.00
7.70
13.00
3.00
7.70
13.00
3.00
7.70
3.00
3.00
7.70
13.00
3.00
7.70
15. 80
3.00
7.70
13.00
3.00
7.70
13.00
3.00
7.70
13.00
3.00
7.70
area vent_tyoe
0.
00
£0000.00
0.
0.
£0000.
0.
00
00
00
00
0.00
5000.
0.
0.
£0000.
0.
0.
00
00
00
00
00
00
£0000.00
0.
0.
£0000.
0.
0.
5000.
0.
0.
20000.
0.
0.
£0000.
0.
00
00
00
00
00
00
00
00
00
00
00
00
00
0
1
0
0
1
0
0
1
0
0
1
0
0
1
0
0
1
0
0
1
0
0
1
0
0
1
0
diameter
0.150
0.000
0.076
0.150
0.000
0.076
0.150
0.000
0.076
0.150
0.000
0.076
0.150
0.000
0.076
0.150
0.000
0.076
0.150
0.000
0.076
0.150
0.000
0.076
0.150
0.000
0.076
velocity
17. £00
0.010
0.010
6.300
0.010
0.010
6.300
0.010
0.010
6.300
0.010
0.010
34.000
0.010
0.010
0.170
0.010
0.010
6.300
0.010
0.010
6.300
0.010
0.010
6.300
0.010
0.010
team
3£0
£93
£93
320
£93
£93
320
£93
£93
3£0
£93
£93
3£0
£93
£93
3£0
£93
£93
3£0
£93
£93
320
£93
£93
3£0
£93
£93
era_
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
max
000
000
000
000
000
000
000
000
000
000
000
0.000
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
en 155 ions
41.000
41.0*1
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
41.000
-------
Table A-8. MODELING PARAMETERS FOR NAPHTHALENE EMISSIONS
FROM PRODUCTION OF SURFACE ACTIVE AGENTS -- 2-NAPHTHALENESULFONIC ACID
Record* update pollutant
1 10/15/86 Naphthalene
2 10/15/86
3 10/15/86
4 10/14/86
5 10/15/86
6 10/15/86
7 10/15/86
8 10/15/86
9 10/15/86
10 10/15/86
11 10/15/86
12 10/15/86
13 10/15/86
14 10/15/66
15 10/15/86
16 10/15/86
17 10/15/86
18 10/15/86
source_cat
2-nao.5ulfomc acid
plant_nunb sic_code plant_nai»e latitude longitude urban city
1 2843
1
1
2 2843
2
2
3 2810
3
3
4 2843
4
4
5 2843
5
5
6 2843
6
6
Allied Corp.
Anerican Cyanamid Co
American Cyanamid
DeSoto, Inc.
E. I. duPont de New.
EmKay Chenical Co.
394818
0
0
332830
0
0
403800
0
0
324448
0
0
394100
0
0
403912
0
0
752712
0
0
812748
0
0
741500
0
0
972000
0
0
752924
0
0
741130
0
0
0 Claytnont
0
0
0 Marietta
0
0
0 Linden
0
0
0 Fort Worth
0
*
0 Deepwater
0
0
0 Elizabeth
0
•
-------
Table A-8. MODELING PARAMETERS FOR NAPHTHALENE EMISSIONS
FROM PRODUCTION OF SURFACE ACTIVE AGENTS -- 2-NAPHTHALENESULFONIC ACID
(concluded)
Record It
1
£
3
4
5
6
7
8
9
10
11
1£
13
14
15
16
17
18
plant_name
Allied Corp.
American Cyanamd Co
American Cyanamd
DeSoto, Inc.
E. I. duPont de New.
t
EiaKay Chenical Co.
state
DE
OH
NJ
TX
NJ
NJ
t)
P
F
S
P
F
S
P
F
S
P
F
S
P
F
S
P
F
S
type
P
F
B
P
F
S
P
F
S
P
F
S
P
F
S
P
F
S
stack_mui
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
height
13.00
3.00
7.70
13.00
3.00
7.70
19.80
3.00
7.70
13.00
3.00
7.70
15.80
3.00
7.70
13.00
3.00
7.70
area
0.00
20000.00
0.00
0.00
£0000.00
0.00
0.00
£0000.00
0.00
0.00
5000.00
0.00
0.00
£0000.00
0.00
0.00
5000.00
0.00
vent_type
0
1
0
0
1
0
0
1
0
0
1
0
0
1
0
0
1
0
dianeter
0.150
0.000
0.076
0.150
0.00k)
0.076
0.150
0.000
0.076
0.150
0.000
0.076
0.15ID
0.000
0.076
0.150
0.000
0.076
velocity
6.300
0.010
0.010
6.300
0.010
0.010
17. £00
0.010
0.01U
6.300
0.010
0.010
0.170
0.010
0.010
6.300
0.010
0.010
temp
3£0
£93
Z93
3£0
£93
£93
3£ti
£93
d93
3£0
£93
£93
3£0
,£93
• £93
3£0
£93
£93
en.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
max
000
000
00U
000
00m
000
000
000
00k)
000
000
000
00*
000
000
000
000
000
emissions
350.
350.
350.
350.
350.
350.
350.
350.
350.
350.
350.
350.
350.
350.
350.
350.
350.
350.
000
000
000
000
000
000
000
006
1000
000
000
000
00k)
000
000
000
IW0
000
-------
Table A-9. MODELING PARAMETERS FOR NAPHTHALENE EMISSIONS
FROM PRODUCTION OF MOTH REPELLANT
Records ideate ooilutant
1 10/14/66 Maantnalene
£ 10/14/66
3 1(2/14/66
4 / /
source_cat
."loth Reoe 11 ant
oiarit nu«iD sic coce oiant name
i £879
1
1
Morfiex, Inc.
Kincaid Enterorises
latitude longitude uroan city
.6 795324
0 0
0 0
24 615030
0 Greenooro
i
0
0 Nitre-
Secorcs Dian.
1 norflex, Inc.
state woe
NC P
i ' F
3 5
4 Mttcaici Er.terorises wV
Id:
*
0
0
0
heicnt
0.00
0.00
0.00
0.00
area vent_tyoe diameter
0. 00
0.00
0.00
0.00
0 0. 000
0 0. 000
0 0. £00
0 0.000
velocity t
0. 000
0.000
0.000
0.000
'3
0
0
0
enijnax
£.000
0. 000
0.000
0.000
emissions
0.000
0. tit
0.000
0. Mi
-------
Table A-10. MODELING PARAMETERS FOR NAPHTHALENE EMISSIONS
FROM PRODUCTION OF MISCELLANEOUS ORGANIC CHEMICALS
c £e£3 SAUIIIO Cneiiucal Co. 3b'37-Vc silclB 3 St. ^.Oui
B it.
k
IB iocs
* . Q,..- r.b
jt-Ld"iviJr-f:aj" - .i
LS \ea.
.j .iMu/00 ._„ -.
it ii/_S/ct ,\aD.-iC£::e ic.c t, Joi-a jreefiKOCu L,r.ev. _:•.
- ^./:ao: \a:.-i:ecic acic 7 £3/5 urior Carols '-oro.
.7 ^.::3L 7
t -tf -:':^/c£ ^ - ,--/ -.
£•» lB/iB.o£ I'etrv.rsmt-.o-fcr.c ii £ot5 C^Onlev Cheiiiicai "rlt'Slc: filc'ljfa
£5 .i/'ca/j; "-1
££ .£/£a'ob *'
:- -,::,.v 11 <& £
-9 ii/.i'ot -' t i
"t iii'/CJ'ci ,-.1'=tr./Iia:".".i.6ric :£• £bb'3 Cne&ucai ExcnanLe £"3'i5l5 SS^iiii
-- '"o^£ i£ ' i; ic
-7 ,-^^ jji .-.a;, aietai.-ir -J c'd/'a ureer.rtooc L.~ie:iiica. ju^-j'.c "/a'tolc
-• :- :- .-•.;- ^.-fs.- ,-s 14 2fi7'3 jr.:or, Caraice
-------
Table A-10. MODELING PARAMETERS FOR NAPHTHALENE EMISSIONS
FROM PRODUCTION OF MISCELLANEOUS ORGANIC CHEMICALS
(concluded)
CK '-Liii r.e:a.it area vetu iv'De ciair.etE
ve.ocitv temo
. .-. .:•;, _i; y. :e La j »v
£ L.ua ;r,E:,,.: = . Io. ,'j
3
^
5 £. :. c^o.'.: ce \em.
fa
7
ti L)f iOif La) Ii.Cc w-'T- *V
i
ia
:i L -. cuPcnt as \6ii\ V
, ^
.1
:* 3.-eer«zx Ire;,. Co. V^
.5 Jr.cn Lattice Cora. -H
Ic.
-7
-o i.i.-:. ;;'D. \Y
. j
£2
II .vzziErs I:.. .••:. «v
11
1,1
c^r -• _n.e/ _~r ,:GC_ ^i
i~
1L
-•; I'zn e, ;-.£• ::,. lo. 3->
_ Z'
3i ^~tr ::a. Zxi'ar := ">
Jii
^i
Ji.1 - "65 'A j,^ _ ",c , ^8* v-i
-*• -J.Criu£.'I«IZc —
-r
~L'
57 C::a-.j=!:-/ .I.-:. ',:
p
-
S
.-
r
3
;.
-
5
:
F
3
-
r
3
-'
-"
0
r'
r
b
r1
~
~.
:
5
r
r
'0
-'
r
E
r
v 0* kjt^ (^j «t'd
1 i J. $0 ^i ^'^
1 3. M 1^50. id£
: ?.?a t.m
i is.ciij a.iia
: 3. *i ca*?ai6. aa
: 7. "7$ i. uti
l i.ii '2..^
a. M 2!. ea
i a.w a.ia
is. sa i1. aa
3.?c £v22*t.i2>'
; 7.; 2i i!. i'i2i
2l c. iu^ 0. l?itf
1 J. cl? &* i.'^
: 3.w ikjjaa.if^
7. 721 2i. U
j 9. it i.i?.a
1 3.£i idSC.aa
i 7. 7*5 a. a«j
HIM a.aa
3. a2 £^2112.21. i?v?
I 7.74' «!.*ZI
i is.iw a. a*?
i 3. 2a 1258. 31?
1 7. 7tf a. £2i
i ' i.W Z.M
• 7.7S «.ei!
i3.aa j.aa
. 3. W £2'2V^. '2i
• 7.7a 2'. 24
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REFERENCES
1. Standard Industrial Classification Manual, Office of Management
and Budget, 1972.
2. "Chemical Profile," Chemical Marketing Reporter. October 29, 1984,
p. 54.
3. Hughes, et. a!. Chemical Economics Handbook, Naphthalene. SRI
International? pp. 300.7600A-300.7600Z.
4. 1985 Directory of Chemical Producers, United States. SRI Inter-
national .
5. Ohio EPA Emissions Inventory System for 1985. April 15, 1986.
6. Texas Air Pollution Control Board, Permit Files, Austin, TX.
Information obtained from visit to TACB office, Austin, TX, by
C. Clark, Pacific Environmental Services, Inc., Durham, NC.
September 8-9, 1986.
7. 1984 Emission Inventory, Summary by Process, for Koppers Co., Inc.,
Follansbee, WV. West Virginia Air Pollution Control Commission,
Charleston, WV.
8. Telecon. J. Cugnini, Delaware Department of Natural Resources
and Environmental Control, Dover, DE, with D.' Cole, Pacific
Environmental Services, Inc. September 19, 1986.
9. 1984 Emission Inventory, Summary by Process, for Union Carbide,
Institute, WV. West Virginia Air Pollution Control Commission,
Charleston, WV.
10. Polycyclic Aromatic Hydrocarbons - An Environmental Materials
Balance. Acurex Corporation, Rosslyn, VA. For U.S. Environ-
mental Protection Agency, Monitoring and Data Support Division,
Washington, D.C. EPA Contract No. 68-01-6017. January 1981.
p. 27.
11. Kirk-Othmer, Encyclopedia of Chemical Technology, 3rd edition,
Vol. 22. John Wiley & Sons, New York, NY. 1983. pp. 572,584.
12. Letter from D.R. Cavote, Portsmouth Local Air Agency, Portsmouth,
OH, to D.G. Cole, Pacific Environmental Services, Inc., Durham,
NC. September 8, 1986.
13. 1985 Directory of Chemical Producers, United States. SRI Inter-
national .
14. Brown, S.L., et. al. Research Program on Hazard Priority Ranking
of Manufactured" Cfiemicals (Chemicals 61-79). Stanford Research
Institute, Menlo Park, CA. For National Science Foundaton,
Washington, D.C. PB-263 164. April 1975.
A-44
-------
15. Benzene Emissions from Coke By-Product Recovery Plants. Back-
ground Information for Proposed Standards, EPA-450/3-83-016a.
U.S. Environmental Protection Agency, Office of Air Quality Plan-
ning and Standards, Research Triangle Park, NC. May 1984.
16. Van Osdell, et. al. Environmental Assessment of Coke By-Product
Recovery PlaTvE"s,~TPA-600/2-79-016, Research Triangle Institute,
Research Triangle Park, NC. For U.S. Environmental Protection
Agency, IERL, Research Triangle Park, NC. January 1979.
17. Project Summary for Construction Permit for Modification to a
Phthalic Anhydride Plant (from Illinois EPA permit files).
18. "Chemical Profile," Chemical Marketing Reporter. July 7, 1986.
p. 50.
19. Memo to S. Levine, Illinois Environmental Protection Agency, from
C. Mata, Illinois EPA. June 10, 1986. (Inspection of Koppers
Company, Stickney, IL).
20. Letter and permit application from H.A. Hegeman, Koppers Company,
Inc., Chicago, IL, to J.D. Cobb, Illinois Environmental Protection
Agency, Springfield, IL. April 1982.
21. U.S. Environmental Protection Agency. Compilation of Air Pollu-
tion Emission Factors. Report No. AP-42, Fourth edition. Research
Triangle Park, NC. September 1985. pp. 4.3-5 through 4.3-8.
22. Handbook of Chemistry and Physics. 54th edition, 1973-74. CRC
Press: Cleveland, p. C-375.
23. VOC Emissions from Volatile Organic Liquid Storage Tanks - Back-
ground Information for Proposed Standards, EPA-450/3-81-003a.
U.S. Environmental Protection Agency, Office of Air Quality
Planning and Standards, Research Triangle Park, NC. July 1984.
p. 3-25.
24. Fugitive Emission Sources of Organic Compounds - Additional Infor-
mation on Emission Reductions and Costs, EPA-450/3-82-010. U.S.
EPA, Office of Air Quality Planning and Standards, Research
Triangle Park, NC. April 1982. p. 3-6.
25. Perry and Chilton, Chemical Engineer's Handbook. Fifth edition.
McGraw-Hill, 1973. Table 3-8, p. 3-57.
26. Telecon. D. Knapp, St. Louis Air Quality Office. St. Louis, MO,
with D.G. Cole, Pacific Environmental Services, Inc., Durham, NC.
August 8, 1986.
27. Letter from Boggs, F.L., Union Carbide, Institute, West Virginia,
to C. Beard, West Virginia Air Pollution Control Commission,
Charleston, WV. May 8, 1986.
28. Hughes, et. al. Chemical Economics Handbook, Naphthalene.
SRI InteTnatTonal. March 1985. pp. 300-7600A - 300-7600Z.
A-45
-------
29. Letter from J.L. Noe, American Cyanamid, Willow Island, WV, to
C. Beard, West Virginia Air Pollution Control Commission,
Charleston, WV. September 9, 1985.
30. West Virginia Air Pollution Control Commission, 1981 Air Emission
Inventory Summary by Process.
31. Chemical Sources USA, 1985.
32. Specific Contaminant Report, dated September 9, 1986. New Jersey
Department of Environmental Protection, Bureau of Air Pollution
Control, Air Pollution Enforcement Data System.
33. Production and Use of Naphthalene. Versar, Inc., Springfield, VA.
Contract No. 68-01-3852, Task 22. Prepared for U.S. Environmental
Protection Agency, Office of Water Planning and Standards,
Washington, D.C. January 1980.
34. Kirk-Othmer. Encyclopedia of Chemical Technology. Third edition,
Vol. 5. John Wiley & Sons, New York, NY. 1979.
35. Telecon. C. Beard, West Virginia Air Pollution Control Commission,
Charleston, WV, with D.G. Cole, Pacific Environmental Services,
Inc., Durham, NC. September 22, 1986.
36. Letter from K. Chaudhari, Virginia 'Air Pollution Control Board,
Richmond, VA, to D.G. Cole, Pacific Environmental Services, Inc.,
Durham, NC. August 20, 1986. Subject: Greenwood Chemical Company
no longer in operation as manufacturing or emitting source due to
explosion and fire destroying facility April 1985; no plans to
rebuild.
37. Telecon. T. McGillick, New York State Department of Environmental
Conservation, White Plains, NY, with D.G. Cole, Pacific Environ-
mental Services, Inc., Durham, NC. .August 20, 1986.
38. Telecon. L. Malcolm, Ohio State Air Pollution Control Agency,
Akron, OH, with D.G. Cole, Pacific Environmental Services, Inc.,
Durham, NC. August 7, 1986.
39. Telecon. C. Goeller, Oklahoma City Health Department, Oklahoma
City, OK, with D.G. Cole, Pacific Environmental Services, Inc.,
Durham, NC. August 7, 1986.
40. Human Exposure to Atmospheric Concentrations of Selected Chemicals,
Volume II, SAI. 1982.
41. Energy Information Administration, U.S. Department of Energy.
Coke and Coal Chemicals in 1979. Energy Data Report. Washington,
D.C. October 31, 1980. pp. 4-5.
42. West Virginia Air Pollution Control Commission (WVAPCC), Permit
Files, Charleston, WV. Information obtained from visit to WVAPCC
office by K. Meardon, PES, Inc., Durham, NC. October 1-2, 1986.
A-46
-------
43 Memorandum. R. Pandullo, Radian Corp., to File. Documentation of
HEM Inputs for Emissions Associated with Chlorinated Hydrocarbons
Use in Pesticide Monitoring. June 3, 1986.
44 Distillation Operations in Synthetic Organic Chemical Manufacturing -
Background Information for Proposed Standards, FPA-450/3-83-005a.
U.S. Environmental Protection Agency, Office of Air Quality Planning
and Standards, Research Triangle Park, NC. December 1983. pp. 8-13.
A-47
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APPENDIX B
PROCEDURES FOR ESTIMATING NAPHTHALENE EMISSIONS
FROM COKE BY-PRODUCT RECOVERY PLANTS
-------
K E M 0 R A N D U M
October 7, 1986
TO: Bob Lucas, EPA:ESED:CPB
FROM: David Cole, PES, Inc.
THRU: Ken Meardon, PES,
SUBJECT: Procedures for Estimating Naphthalene Emissions from Coke
By-Product Recovery Plants (EPA Contract No. 68-02-3887,
Assignment 43)
This memorandum describes two procedures for estimating
naphthalene emisions from coke by-product recovery plants. The
first method uses coke and coal tar production figures coupled
with a coal tar materials balance to derive a plant-wide naphthalene
emission factor. The second method is based on a process-specific
approach that is derived from limited data from one coke by-product
recovery plant. Following the descriptions of these methods, an
example calculation is presented to estimate naphthalene emissions
from a specific plant. Emissions are calculated by using each method
as a basis for comparison.
Method 1: Development of a Plant-wide Naphthalene Emission Factor
A plant-wide naphthalene emission factor is developed based on
a material balance of a representative coke by-product recovery
plant and the amount of naphthalene estimated in coal tar production.
A naphthalene emission factor is needed on a "kilogram (kg) of
naphthalene per megagram (Mg) of coke produced" basis because coke
production rates are available for each coke by-product plant. To
derive this factor, PES used the following procedure:
1. Estimate annual coal tar production based on (1) the amount of
naphthalene in coal tar produced (1978 estimate) and (2) the
weight percent of naphthalene in dry coal tar:
1978 coal-tar naphthalene production = 230,000 Mg (Reference I'
Average Weight % naphthalene of dry tar (U.S.) = 8.80% (Reference 2\
Coal Tar Production = 230,000 Mg = 2.614 Tg
0.088
B-l
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2. Estimate relative amount of coal tar produced per megagram of
coke from material balance of a representative coke by-product
recovery plant:
380 MCJ Coal Tar = 0.05156 Kg Coal Tar per t-ig Coke (Reference 3)
7370 Kg Coke
3. Estimate annual coke production based on (1) and (2) above:
2.614 Tg coal tar = 50.7 Tg coke production, U.S.
0.05156 Mg coal tar/Mg coke (1978 estimate)
Note: This estimate approximates 1979 U.S. coke production
figure (48.0 Tg) from Reference 4.
4. Calculate naphthalene emission factor from estimate of total
naphthalene emissions to atmosphere from coal tar production
(Reference 1) and total U.S. coke production from (3) above:
300 Mg naphthalene 5.92 Mg naphthalene per Tg coke produced,
50.7 Tg coke produced = or 0.00592 kg naphthalene per Mg coke produced
Method 2: Development of a Process-Specific Emission Estimation Procedure
Eight specific naphthalene emission sources have been identified at
coke oven by-product recovery plants. Naphthalene emission factors are
developed as described below for most of these sources based on limited
data from a screening study at one coke by-product plant:
1. Coke Oven Doors
A naphthalene emission factor of 0.73 g/hr/oven is reported
in Reference 1, based on EPA estimates (1977).
2. Tar Processing
a. Decanting
Based on estimate of 4.1 g/Mg coal for emissions of polynuclear
aromatic compounds (PNA) (Reference 3, p. 4) of which the major
component is naphthalene (Reference 1, p. 28) (PES estimates 70%),
and based on ratio of 1.42 Mg coal to 1 Mg coke (Reference 3),
the following naphthalene emission factor is calculated:
0.70 x 4.1g/Mg coal x 1.42 Mg coal = 4.1 g naphthalene
Mg coke per Mg coke produced
b. Dewateri ng/storage
Naphthalene emissions are negligible based on total PNA
compound estimates for this source (Reference 3, p. 4)
B-2
-------
3. Final Cooler Unit
No air emissions of naphthalene are expected since the
unit is a closed system (Reference 5, p. 3-32).
4. Naphthalene Separation Tank
This step involves the separation of naphthalene from
water by gravity separation (indirect water final cooling
process), in open basins. Therefore, fugitive emissions of
naphthalene are expected. A total vapor rate of 33.8 vapor
per sm3 was measured directly above the tank surface in a
screening study (Reference 3, p. 93-94), but no vent stream
was at a rate sufficient to be measured. The total exposed
surface area was about 1000 ft^, but the actual surface exposed
to the wind by the naphthalene slurry was not known nor was
the rate of entrained air flow in the tank available. Con-
sequently, because of the lack of data to quantify naphthalene,
no emission factor was developed from the naphthalene separation
tank. Subjectively, however, the odor of naphthalene in this
area was reported to be quite strong.
5. Naphthalene processing (Drying/Melting)
Each drying tank may have a vent stack which extends
about 5m above the tank. From Reference 3 (pp. 95-96), the
vent rate from the tank from one plant was estimated to be 2.9
sm3 vapor/Kg coke by measuring the rate of air entering a
hatch of a tank due to the chimney effect. A-naphthalene
concentration of 533 g/snP was found, or 1.56 kg naphthalene
per Mg coke. Since this concentration represented about twice
the plant's total naphthalene production, the sample was not
representative of the average emission rate (Reference 3, p. 95,
99). However, assuming a worst-case and for the lack of other
data, naphthalene emissions can be estimated to be the following:
533 y/sm3 x 2.9 sm3/Mg coke = 1546 g/Mg coke'
6. Tar Storage Tanks (containing naphthalene)
A VOC emission factor of 281 g/Mg coke production is
based on Reference 5, p. 7-5, for tar storage. Assuming that
the percentage of naphthalene in the primary coke tar storage
tank is between 18 to 32 percent (PES assumes 25% for calculating
emission factors) from Reference 6, and applying that percentage
to the VOC emission factor, then the naphthalene emission factor
can be estimated to be: 0.25 x 281g/Mg coke = 70.25 g/Mg coke
7. Naphthalene Storage Tanks
No throughput data are available for naphthalene storage
tanks at coke by-product recovery plants. If data were available,
then the fixed-roof tank equations from EPA Publication AP-42
for calculating breathing and working losses could be applied,
assuming 96% of contents of tank is naphthalene (Reference 6).
B-3
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8. Equipment Leaks
Equipment leaks of naphthalene are assumed to originate from
exhausters, pump seals, valves, relief valves, sampling connections,
and open-ended lines. VOC emission factors from coke by-product
plants (Reference 5, p. 3-43) are used to approximate naphthalene
emissions. Naphthalene constitutes about 96% of crude naphthalene
produced and 70% of coal tar produced. Assuming the naphthalene
concentration increases as the coke by-products are recovered
(which is certainly the case when refining the naphthalene), PES
has assumed that naphthalene emissions throughout the plant represent
75% of total VOC fugitive emissions. Number of pieces of equipment
per model plant is based on number of units in Reference 5, p.
6-13.
B-4
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Example Calculation of Plant-Specific and Nationwide Emissions of
Naphthalene
I. USS-Fairfleld Coke Plant
Naphthalene emissions from the USS-Fairfield coke plant in
Fairfield, Alabama, were calculated based on each of the above
methods for comparison. Specific data from this plant (e.g.,
number of ovens) are used in the calculations when available.
Using Method 1, the naphthalene emissions are calculated as follows:
0.00592 kg naphthalene x 4324 Me, coke x 365 days x 1 Mg
Mg coke day yr j x 103|
-------
Pump seal emissions are based on VOC emission factor of
2.7 kg/source/day (Reference 5, p. 3-43):
9 pumps x 0.75 x 2.7 kg VOC/pump/day x 365 days = 6,652 kg/yr
yr = 6.7 Hg/yr
Valves
Assume total of 105 valves (Reference 5, p. 6-13); 75% of
VOC is naphthalene:
105 valves x 0.75 x 0.26 kg VOC/valve/day x 365 days = 7473 kg/yr
yr
=7.5 Hg/yr
Re!ief Valves
Assume 5 relief valves (Reference 5, p. 6-13), 75% of VOC is
naphthalene:
5 relief valves x 0.75 x 3.9 kg VOC/relief valve/day x 365 days
= 5338 kg/yr
= 5.3 Mg/yr
Sampli ng connecti ons
Assume 10 sampling connections (Reference 5, p. 6-13), 75%
of VOC is naphthalene:
10 sampling connections x 0.75 x 0.36 kg VOC/sampling connection/day
x 365 days = 986 kg/yr
= 1.0 Mg/yr
Open-ended 1ines
Assume 22 open-ended lines, (Reference 5, p. 6-13), 75% of VOC is
naphthalene:
22 open-ended lines x 0.75 x 0.055 kg VOC/open-ended line/day x
365 days = 331 kg/yr
= 0.33 Mg/yr
Exhausters
Assume 6 exhausters, 75% of VOC is naphthalene:
6 exhausters x 0.75 x 1.2 kg VOC/exhauster/day x 365 days
yr
= 1971 kg/yr
B-6
-------
= 2 Mg/yr naphthalene
Therefore, equipment leaks of naphthalene at the plant total
about 23 Mg/yr.
Total naphthalene emissions from the Fairfield plant = 2,583 Mg/yr.
II. Nationwide Naphthalene Emissions from Coke By-Product Plants
Total nationwide estimate may be calculated by each method as follows:
Method 1:
0.00592 -kg naphthalene Mg coke nationwide
Mg coke x 51,377 ,jay x
days 1 Mg_
365 -yf- x i x iQ3 ky =111 Mg/yr.
Method 2:
Using all of the above emission factors for the emission sources
described in Method 2, nationwide totals are the following:
Nationwide
Source Estimate, Mg/yr
Coke Oven Doors 28.2
Tar Decanting 76.9
Naphthalene Processing 28,991
Tar Storage Tanks 1,313
Equipment Leaks 540.7a
Total = - 30,949.8 Mg/yr (with naphthalene
processing)
or 1,958.8 Mg/yr (without naphthalene
processing)
Summary and Conclusions
Emissions of naphthalene from the Fairfield plant based on Method 1
total about 9.34 Mg/yr compared to 2,583 Mg/yr for Method 2. Even sub-
tracting out the naphthalene processing emissions (which are obviously
overstated), the total naphthalene emissions from the plant based on
Method 2 are 143 Mg.
aFrom Reference 5, calculation of nationwide equipment leaks was based on
a model plant approach in which the percent naphthalene in VOC (75%) was
multiplied by the appropriate VOC emission factor, the number of pieces of
equipment per model plant, and the total number of model plants based on
coke production.
B-7
-------
The nationwide estimates of naphthalene from coke by-product plants
calculated above are much higher than two other nationwide estimates found
in the literature (i.e., 34 and 40 Mg/yr from total naphthalene production,
References 1 and 8, respectively). Process-specific emissions derived from
Method 2 are based in most cases on total organics or vapor emissions due
to the fact that naphthalene was difficult, or impractical to sample,
particularly when naphthalene processing tanks were sampled. In addition,
the relative percentage of naphthalene in a VOC stream is difficult to
quantify in the case of equipment leaks because naphthalene is prevalent
throughout most of the coke by-product plant. Therefore, process-specific
emissions are based on data and assumptions that may overstate emissions.
Since both plant-specific and nationwide emissions from Method 1 more
closely approximate the estimates found in the literature than Method 2,
Method 1 appears to be a more reasonable procedure for quantifying naphtha-
lene emissions from coke by-product plants.
B-8
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REFERENCES
1. Polycyclic Aromatic Hydrocarbons - An Environmental Materials
Balance. Acurex Corp., Rosslyn, VA, for U.S. Environmental
Protection Agency, Monitoring and Data Support Division,
Washington, DC. EPA Contract 68-01-6017. January 1981.
p. 27-28.
2. Kirk-Othmer, Encyclopedia of Chemical Technology. Third
edition, volume 22. John Wiley and Sons: New York. 1983.
p. 572.
3. VanOsdell, D.W., et. al. Environmental Assessment of Coke By-
product Recovery "pTants. Research Triangle Institute, Research
Triangle Park, NC. For U.S. Environmental Protection Agency,
Industrial Environmental Research Laboratory, Research Triangle
Park, NC. EPA-600/2-79-016. January 1979. p. 23.
4. Energy Information Administration, U.S. Department of Energy.
Coke and Coal Chemicals in 1979. Energy Data Report.
Washington, D.C. October 31, 1980. pp. 4-5.
5. Benzene Emissions from Coke By-Product Recovery Plants - Background
Information for Proposed Standards. EPA-450/3-83-016a. U.S.
Environmental Protection Agency, Office of Air Quality Planning
and Standards, Research Triangle Park, NC. May 1984. p. 3-1.
6. Letter from A.A. Spinola, USS; Pittsburgh, PA, to D.R. Goodwin,
U.S. Environmental Protection Agency, Office of Air Quality
Planning and Standards, Research Triangle Park, NC. July 23, 1979.
Information at Clairton and Gary Coke plants. EPA Docket No.
A-79-16, II-D-3.
7. Letter from A.A. Spinola, USS, Pittsburgh, PA, to D.R. Goodwin,
EPA. August 1, 1979. Emissions from Fairfield, AL, plant. EPA
Docket No. A-79-16, II-D-4.
8. Production and Use of Naphthalene. Versar, Inc., Springfield,'
VA. For U.S. EPA, Office of Water Planning and Standards,
Washington, D.C. Contract No. 68-01-3852, Task 22, Subtask
1. January 1980. p. 30.
B-9
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1 REPORT NO.
EPA-450/3-88-003
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
Summary of Emissions Associated
with Sources of Naphthalene
5. REPORT DATE
October 30, 1986
6. PERFORMING ORGANIZATION CODE
7 AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO
9 PERFORMING ORGANIZATION NAME AND ADDRESS
Air Quality Planning and Standards
Office of Air and Radiation
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
10 PROGRAM ELEMENT NO.
11 CONTRACT/GRANT NO.
12. SPONSORING AGENCY NAME AND ADDRESS
DAA for Air Quality Planning and Standards
Office of Air and Radiation
U.S. Environmental Protection Agency
Research Triangle Park. NC 27711
I 13. TYPE OF REPORT AND PERIOD COVERED
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
This report contains information on naphthalene emissions sources and current emission
rates.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
8. DISTRIBUTION STATEMENT
b.IDENTIFIERS/OPEN ENDED TERMS
c. COSATI 1 icId/Group
13B
19 SECURITY CLASS jThis Reportl 21. NO OF "AGES
^Unclassified
20 SECURITY CLASS . r/
Unclassified
115
EPA Form 2220-1 {Rev. 4-77) PREVIOUS EDITION is OBSOLETE
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