United States
Environmental Protection
Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park NC 27711
Research and Development
EPA/600/S2-89/043 Sept. 1989
&EPA Project Summary
Source Characterization and
Control Technology
Assessment of Methylene
Chloride Emissions from
Eastman Kodak Company,
Rochester, NY
S. A. Walata III and R. M. Rehm
This report gives results of an
assessment of the application of
potential control technologies for
methylene chloride< also known as
dichloromethane or DCM) emissions
sources at Eastman Kodak Com-
pany's Kodak Park facility in
Rochester, NY. DCM is a solvent used
by Kodak in the manufacture of
cellulose triacetate film support
This work involved: (1) a plant visit
where the major DCM emission
sources were inspected, and (2)
identification and evaluation of poten-
tial control technologies that might
be applied to the emission sources.
Included are emission estimates
determined by Kodak of all emission
points greater than 8,000 lb*/yr DCM,
as well as a description of each point
observed during the visit. A cost
analysis of different add-on control
devices is provided for four of the
uncontrolled emission points.
This report characterizes emissions
and control technologies for reduc-
ing emissions of methylene chloride
(DCM) at Eastman Kodak Company's
Kodak Park facility in Rochester, NY.
This Project Summary was devel-
oped by EPA's Mr and Energy Engi-
neering Research Laboratory, Re-
"1lb = 0454 kg
search Triangle Park, NC, to announce
key findings of the research project
that is fully documented In a separate
report of the same title (see Project
Report ordering information at back).
introduction
The assessment of Control technol-
ogies for DCM emission sources at
Kodak Park was initiated by New York
State's Department of Environmental
Conservation (DEC) in order to bring the
facility into compliance with title 6,
chapter III, Part 212 of New York State's
air pollution regulations. This was due in
part to New York's reducing the accep-
table ambient level for methylene
chloride from 1167 to 0.37 iig/m3, and
Kodak's plans to increase cellulose tri-
acetate film production. DEC requested
assistance from EPA's Control Technol-
ogy Center (CTC) to independently eval-
uate control technologies which might be
applied to DCM emissions at Kodak Park.
Data provided by Kodak indicate that
DCM emissions from the Kodak Park
facility total 9.2 million Ib/yr, the largest of
any source in the U.S.
Emissions Inventory
Work on this project focused on the
evaluation of category 1 and 2 emission
points. According to Kodak, category 1
sources emit more than 100,000 Ib/yr
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DCM, while category 2 sources emit
between 8,000 and 100,000 Ib/yr. Of the
181 registered emission points at Kodak
Park, 26 (15%) are category 1 or 2.
These sources, however, emit approxi-
mately 8.4 million Ib DCM, or greater
than 90% of all DCM emissions. During
the control technology assessment, it was
determined that a substantial number of
emission sources had emission estimates
with a low confidence level. Of the 26
existing category 1 or 2 sources, emis-
sions from 11 points were estimated by
best engineering judgment. The accuracy
of such estimates can be held suspect.
Before serious consideration is given to
applying a control device to any of the
emission points which were estimated
using best engineering judgment, better
emission estimates need to be obtained.
By far, the largest source of DCM
emissions at Kodak Park is the pro-
duction of cellulose triacetate film. In this
process, triacetate pellets are dissolved
in methylene chloride and other solvents
to form "dope." The dope is then ex-
truded onto a polished surface to forma
thin sheet or web. The web is than dried
at elevated temperatures, driving off the
methylene chloride and other solvents.
This process happens within roll coating
machines which are enclosed. While
Kodak recycles greater than 95% of the
DCM used in this process, 7.38 million Ib,
or over 80% of total DCM emissions to
the atmosphere, occur from this process.
Other sources of DCM emissions include:
the Dope Department, where triacetate
pellets are dissolved in DCM; the Dis-
tilling Department, where DCM is distilled
and recovered; fugitive emissions from
pumps, valves, seals, flanges, etc., within
Kodak Park; and secondary losses from
wastewater.
The assessment also indicated that the
greatest potential for emission reduction
is controlling leaks from the roll coating
machines. Kodak has proposed to rem-
edy this situation by changing latching
devices and gasket seals, covering bear-
ing casings, and installing solid pipe
bulkhead fittings on the machine casing.
These changes were projected by Kodak
to reduce DCM emissions by 3 million
Ib/yr. This assessment found no reason
that this projection cannot be met. Kodak
projects that work in this area will be
completed in 1992.
The remaining category 1 and 2
sources at Kodak Park can be divided
into two groups. The first group consis
of emission points which are alreat
controlled, while the second group co
sists of uncontrolled sources. "Emissii
controls used by Kodak include carbi
adsorbers, dual water/methanol scru
bers, and condensers. A review of ava
able data indicates that the scrubbe
and condensers are not being operat<
efficiently, and significant emission r
duction can be achieved by more ef
cient operations.
Most of the uncontrolled emissic
points have high flow rates and low DC
concentrations, making control diffici
and expensive. Several points in th
group, however, present situations whe
Kodak could recover DCM. These incluc
combining emission sources and addii
a scrubber or carbon adsorber. In ad<
tion, emissions can also be reduced I
controlling solvent loss from ultrason
cleaning operations, and instituting a le.
detection and repair program for valve
flanges, pumps, seals, etc., in DC
services.
Table 1 summarizes potential emi
sions reduction of emission sources e
amined by this report.
Table 1. Expected Emissions Reduction from Possible Control Technologies
Emission Points)
53-85, 53-38, and
20-68
53-22
142-1
120-7
54-15
52-37 and 54-29
53-32 and 53-96
49-53
Fugitives
Description
Machine Room Exhaust
C.A. for Machine Air
Draw-off
Solvent Recovery System
Vent Scrubber
Sen System Vent
Scrubber
Building 54 Vent System
Batch Mixers Felt Wash
Process
Hopper Cleaning, Storage
Vessel Vents
Wtrasonic Cleaner
Equipment Leaks
Current
Emissions,
Iblyr
7,380.000
78,500
14,000
8,700
23,350
237,835
41,900
10,000
650,000
Emissions After
Control, Ib/yr
4,380,000
45,700
Cannot
Determine
Cannot
Determine
2,350
23,784
2,095
4,000
390,000
Percent
Reduction
40.6
41.7
89.9
90
95
60
40
Reasonable Control
Technology
Improving Seals on Rott Casting Machines
Improved Operations
Improved Operations
Improved Operations
Improved Operations
Carbon Adsorber or Scrubber
Inclusion with Flows for the 18,000 cftn*
Carbon Adsorber
Proper Freeboard Ratio, Freeboard Chiller <
C.A
Leak Detection and Repair Program
' 1 cfm = 0,00047 073/5
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S. A. Walata III and R. M. Rehm are with Alliance Technologies Corporation, Chapel
Hill, NC 27515.
Charles H. Darvin is the EPA Project Officer (see below).
The complete report, entitled "Source Characterization and Control Technology
Assessment of Methylene Chloride Emissions from Eastman Kodak Company,
Rochester, NY," (Order No. PB 89-224 471/AS; Cost: $21.95, subject to change)
will be available only from:
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/S2-89/043
CHIC Me
STBEET
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