United States
                     Environmental Protection
                     Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park NC 27711
                    Research and Development
EPA/600/S7-86/009 May 1986
6EPA         Project  Summary
                    Evaluation  of  Control
                    Technologies  for  Hazardous
                    Air  Pollutants

                    Robert Y. Purcell and Gunseli Sagun Shareef
                      The purpose of this manual is to help
                    EPA regional, state, and local air pollu-
                    tion control agency technical personnel
                    to select, evaluate, and cost air pollu-
                    tion control techniques for reducing or
                    eliminating the emission of potentially
                    hazardous air pollutants (HAPs) from
                    industrial/commercial  sources. The in-
                    formation provided by this manual will
                    be useful for reviewing permit applica-
                    tions or for informing interested parties
                    as to the type, basic design, and cost of
                    available HAP control  systems.
                      Since the definition  of a HAP is very
                    broad and, thus, encompasses poten-
                    tially thousands of specific compounds,
                    it is not possible for this manual to de-
                    velop an all-inclusive  list of HAP com-
                    pounds and compound-specific control
                    techniques. However, the number of
                    generic air pollution control techniques
                    available is small, and the factors affect-
                    ing the cost and performance of these
                    controls as applied to many noncriteria
                    pollutants have been identified and dis-
                    cussed in the literature. Therefore,  the
                    main focus of this manual is to provide
                    sufficient guidance to select the appro-
                    priate air pollution control system(s) for
                    an emission stream/source containing
                    HAPs.
                      The manual will help the  user per-
                    form three distinct functions: (1) to se-
                    lect  the  appropriate control tech-
                    nique(s) that can  be  applied to each
                    HAP emission stream generated at a
                    specific facility, (2) to determine the
                    basic design parameters of the selected
                    air pollution control device(s) and  ac-
                    companying auxiliary  equipment, and
                    (3) to estimate order-of-magnftude con-
                    trol system  capital  and annualized
                    costs.
  This Project Summary was developed
by EPA's Air and Energy Engineering
Research Laboratory, Research Triangle
Park, NC, to announce key findings of the
research project that is fully documented
in two separate volumes of the same title
(see Project Report ordering information
at back).

Introduction
  The objective of this manual is to
present a methodology for determining
the performance and cost of air pollu-
tion control techniques for reducing or
eliminating the emission of potentially
hazardous air pollutants (HAPs) from in-
dustrial/commercial sources. [Note:
The term "hazardous" in this manual is
very broad. It does not reflect the
specific compounds listed under cur-
rent regulations (i.e., the Clean Air Act,
the Resource Conservation and Recov-
ery Act, and the Toxic Substances Con-
trol Act).] This manual is to be used by
EPA regional, state, and local air pollu-
tion control agency technical personnel
for two basic purposes: (1) to respond
to inquiries from interested parties (e.g.,
prospective permit applicants) regard-
ing the HAP control  requirements that
would be needed at a specified process
or facility,  and (2) to evaluate/review
permit applications for sources with the
potential to emit HAPs. Note that this
manual provides general technical
guidance on controls; it does not pro-
vide  guidance for compliance with
specific regulatory  requirements for
HAPs. Specifically, the manual does not
specify design requirements necessary
to achieve compliance with standards
established under specific programs;
e.g., Section 112 of the Clean Air Act or

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standards  established under the  Re-
source Conservation and Recovery Act.
Such requirements vary with the HAP
emitted and with the emission source;
thus, regulatory-specific detailed speci-
fications are beyond the scope of this
manual.

Contents of the Manual

  Chapter  1 discusses the  use of the
manual.
  Chapter 2 assists the user in identify-
ing HAPs and their respective emission
sources. Information on potential HAP
emissions is provided for the following
source categories: solvent usage opera-
tions, metallurgical industries, the Syn-
thetic Organic Chemical Manufacturing
Industry (SOCMI), the inorganic chemi-
cal manufacturing industry, the chemi-
cal products industry, the mineral prod-
ucts  industry,  the wood products
industry, petroleum related industries,
and combustion sources. Potential
HAPs are identified as organic vapors,
inorganic vapors, or participates. Both
point source and fugitive emissions are
covered. Chapter 2 also identifies the
key emission  stream characteristics
necessary to select appropriate control
techniques.
  Chapter 3 provides  additional infor-
mation to assist the user in the control
technique selection process for  each
HAP emission source/stream. Control
techiques applicable to the following
types of sources are discussed: organic
vapor emissions from point sources, in-
organic vapor emissions from point
sources, organic/inorganic vapor emis-
sions from process fugitive sources,  or-
ganic/inorganic vapor emissions  from
area fugitive sources, particulate emis-
sions from  point sources, and particu-
late emissions from fugitive sources.
  Chapter 4 presents  simple step-by-
step procedures to determine basic de-
sign parameters  of the specific control
devices and auxiliary  equipment. The
following control technologies are cov-
ered: thermal incinerators, catalytic in-
cinerators, flares, carbon adsorbers, ab-
sorbers/scrubbers, condensers, fabric
filters, electrostatic precipitators, and
venturi scrubbers.
  Chapter  5 provides the  necessary
data  and procedures to determine
order-of-magnitude estimates (-60 to
-1-30 percent) for the capital and annual-
ized costs of each control  system.
  Several appendices provide pertinent
information not found  in the main text.
The appendices are divided into  three
groups. Appendices in Group A present
supplementary data that clarify/expand
the information discussed. (For exam-
ple, Appendix A.1  contains the "New
York State Air Guide -  1," which illus-
trates some of the  methods that might
be used when developing a HAP pro-
gram.) Group B appendices contain
derivations of equations, calculation
procedures, and unit conversion tech-
niques for emission stream  physical
characteristics. Blank worksheets to be
used for performing the functions of
this manual are in the Group C appen-
dices.

How to Use the Manual

  Figure 1 is  a flowchart of the steps
performed when  responding  to in-
quiries; Figure 2 presents the same type
of flowchart for use when reviewing
permits. These figures show that these
two functions are basically the  same;
the only substantive  difference is that
the review process also compares the
determined/calculated parameters with
the corresponding parameters stated in
the permit application to ensure that the
control system(s) proposed by the ap-
plicant will provide the  required reduc-
tion of HAP emissions.
  When an inquiry or permit application
is received, determine the HAPs appli-
cable to the source category in question
(Section 2.1). The HAPs are in four cate-
gories: organic vapor, organic particu-
late, inorganic vapor, and inorganic par-
ticulate. [Note: For each HAP  group, a
list of potentially or suspected  haz-
ardous compounds that may be emitted
as a HAP from the source category is
provided. This list is neither all-inclusive
nor a declaration that the compounds
presented are hazardous.] Next, identify
the potential emission sources for each
HAP group (Section 2.1). The HAP emis-
sion sources are listed under one of the
three classifications:  process point
sources, process fugitive sources, and
area fugitive sources. After determining
each emission source,  identify the key
HAP emission stream characteristics
(e.g., HAP concentration, temperature,
flow rate, heat content, particle size)
needed to select the appropriate control
technique(s) (Section 2.2). Obtain the
actual  values for these characteristics
from the owner/operator or from avail-
able literature. If two or more  emission
streams are combined prior to entry
into an air pollution control system, de-
termine the characteristics of the com-
bined emission stream  (Appendix B.2).
  Depending on the specific regulation j
and the type/characteristics of the HAP I
emission source/stream, the remaining
steps in the methodology will differ.
There are four basic formats for a regu-
lation: (1) a particular control device
may be required, (2) a numerical limit
may be specified, (3) a technology forc-
ing requirement may be imposed, and
(4) a specific work practice or other re-
lated practice may be required. The reg-
ulation format will define the steps that
lead to the selection of the appropriate
control technique(s). The control device
and other formats specify the appropri-
ate control  technique(s). A numerical
limit format requires the determination
of the HAP removal efficiency before the
appropriate control technique(s) can be
identified. Lastly, the  technology forc-
ing format has two paths: one where
the cost of the control system is a  factor
in the decision, and one where cost is
not a factor. If control system cost is a
factor, the agency must determine the
cost constraints that will be imposed on
the control technique selection  process.
The steps that occur in defining the HAP
control requirements will  depend on
each agency's regulatory policies.
  The HAP emission stream character-
istics,  in conjunction  with the limita-
tions imposed by the applicable regula-
tions, are used to select the appropriate
control techniques (Chapter 3) for each
HAP emission source/stream.  General
guidelines are provided  that match
specific control devices with specified
emission stream properties (e.g., HAP
content, temperature, moisture, heat
content,  particle size,  flow  rate).  Basic
design parameters are then determined
to provide  general design condition:
tha should be met or exceeded for each
selected control technique to  achieve
the specified HAP removal efficiency
(Chapter 4). This exercise also identifiet
which  of the  selected control  tech
niques will not achieve the  desired HAI
control requirements. The basic desigi
parameters also can be used to obtaii
an order-of-magnitude cost estimate fo
each control device  (Chapter 5). A
noted above, this cost information cat
be an integral  part of the  HAP contrc
system selection  process.  After  corr
pleting the  above process, a HAP cor
trol program can  be recommended  c
evaluated.

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                     Manual Location to
                        Perform Step
                       'Section 2.1
                       ^Section 2.2
                       3None
                       'Appendix B.2
                       sNone
                       ^Chapter 3
                       ''Chapter 4
                       'Chapters
                                                    Information Requested
                                                      on HAP Control for
                                                       a Specific Facility
                                                       Obtain Available
                                                      Plant-Specific Data
      Define HAP s'
  Define Emission Sources
     Generating HAP s1
   Define Characteristics
   Needed for Each HAP
     Emission Stream3
\   Combine HAP Streams3  |*-j  Inquirer Assistance    |
                                                     Define Characteristics
                                                     of Combined Streams4
Control
Device •


[Select Appropriate
Control Technique(s)*
t
/ Afe \
/Basic Design Parameters}
\ Requested /
i Yes
Determine Basic Design
Parameters for
Control System(s)7




•*•
AA
r-~
i
Numerical
Limit i
(Each Single/Combined ^\
HAP Emission Stream J

*
Define HAP Control
Requirements5


Determine Required
Control Efficiency8
>


1


1 Technology
Forcing 1
Yes/ Cost of
r\ Decisii
Other
Requirement
Is \ Regulation Agency
Control a \No Policy Decision
? / 1
I *
Agency Determination
of Cost Constraints*

Select Appropriate
Control Technique!*)*
* i
Select Appropriate
Control Technique(s)*

t
Determine Basic Design
Parameters and Cost for
Control System(s)7*

t
Select Control System
Having Most Stringent
Level of Control Within
Given Cost Constraints

t
Recommend Appropriate
Control Technique(s)

*
/ Last \
/ HAP Emission \
Determine Basic Design
Parameters for
Control System(s)7
t
Select Control System
Having Most Stringent
Level of Control

No

\ Stream /
                                                              t Yes
                                                      Recommend HAP
                                                       Control Program
Figure 1.    Steps used when responding to inquiries.

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                                                                     Permit Application
                                                                    for Review'/Approval
                                Manual Location for
                                   Perform Step
                                  ^Section 2.1

                                  ^Section 2.2

                                  *None

                                  * Appendix B.2

                                  "None

                                  'Chapter 3

                                  7 Chapter 4

                                  'Chapter 5
                              Are
                            AIIHAPs
                          Addressed11
                               f
                                              Obtain Additional Data
                                                 from Applicant
                           Yes'T*-
                              Are
                        All HAP Emission
                       Sources Addressed*
                                              Obtain Additional Data
                                                  from Applicant
                       Are
                 All HAP Emission
              Stream Characteristics
                    Provided*
                                                      Obtain Additional Data
                                                         from Applicant
                           Yes
                              Are
                            Any HAP
                        Emission Streams
                           Combined3
                                                                                                            Are
                                                                                                      Combined Stream
                                                                                                        Characteristics
                                                                                                           Correct*
                                                                                                     	   7  	
                                                                          No
(
                                                                    Each Single/ Combined
                                                                    HAP Emission Stream
                                                                      Define HAP Control
                                                                        Requirements'
                            Control
                            Device
       Numerical
           Limit i r
                            Select Appropriate
                           Control Techniquefsf
                          Determine Basic Design
                              Parameters for
                             Control Systemfs)7
                                                                             ±
                                                      Obtain Additional Data
                                                         from Applicant
         Determine Required
          Control Efficiency"
                                        Other
                                        Requirement
                              Regulatory Agency
                               Policy Decisions'
                                        Technology
                                       , Forcing
         Is
Permit Control System
     Appropriate
                                    Is
                           Permit System Design
                               Appropriate
\No
/H
v
                                                      Recommend Appropriate
                                                        Control TechniquefsJ
Recommend Appropriate
Basic Design Parameters
                                     Yes
                                    Agency Determination
                                     of Cost Constraints'
                              Select Appropriate
                             Control TechniquefsJ'
Determine Basic Design
Parameters and Cost for
  Control Systemfs)7*
                                    Select Control System
                                    Having Most Stringent
                                   Level of Control Within
                                   Given Cost Constraints
                                      Is
                               Cost of Control a
                               Decision Factor

                                      t No
                                                          Select Appropriate
                                                        Control TechniquefsJ'
                           Determine Basic Design
                                Parameters for
                              Control Systemfs/'
                                                                                   Select Control System
                                                                                   Having Most Stringent
                                                                                      Level of Control
                                                                            Last
                                                                        HAP Emission
                                                                           Stream
                                                                      Permit Approval or
                                                                  Provide Recommendations
               Figure 2.    Steps used when reviewing permits.

                                                     4
                                                                                             T*rU. S. 60VERNMB4T PRINTING OFFICE:!986/646-116/20844

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      R. Purcellis with Pacific Environmental Services. Inc., Durham, NC 27707; and G.
        Shareef is with Radian Corporation, Research Triangle Park, NC 27709.
      Bruce A.  Tic/tenor is the EPA Project Officer fsee below).
      The complete report consists of two volumes, entitled "Evaluation of Control
        Technologies for Hazardous Air Pollutants:—"
        "Volume 1. Technical Report," (Order No. PB 86-167 020/AS; Cost: $28.95)
        "Volume 2. Appendices," (Order No. PB 86-167 038/AS; Cost: $22.95)
      The above reports will be available only from: (cost subject to change)
             National Technical Information Service
             5285 Port Royal Road
             Springfield, VA 22161
             Telephone: 703-487-4650
      The EPA Project Officer can be contacted at:
             Air and Energy Engineering Research Laboratory
             U.S. Environmental Protection Agency
             Research Triangle Park, NC 27711
United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati OH 45268
Official Business
Penalty for Private Use $300
EPA/600/S7-86/009
               0000329    PS
               t,  S  ENVIR  PROTECTION  AGENCY
                CHICAGO

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