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 ------- 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. ------- 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. ------- 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 ------- 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 ------- |