SERA
                    United States
                    Environmental Protection
                    Agency
                                   Air and Energy Engineering
                                   Research Laboratory
                                   Research Triangle Park NC 27711
                    Research and Development
                                   EPA/600/S7-85/022 Aug. 1985
Project Summary
A  Model  for  Evaluation  of
Refinery and  Synfuels VOC
Emission  Data
                    R. G. Wetherold, G. E. Harris, F. D. Skinner, and L P. Provost
                      Estimates of the emissions of volatile
                    organic compounds (VOCs) from
                    petroleum refineries and synfuel plants
                    are of considerable interest to EPA, in-
                    dustry, and the public. Such estimates
                    are needed in the preparation and re-
                    view of Environmental Impact State-
                    ments (EIS) and permits required by the
                    Clean Air Act. In response to this need,
                    several studies have been made of VOC
                    emissions, particularly from refineries.
                    Methods for estimating VOC emissions
                    and the results of VOC emissions tests
                    have been published in various journals
                    and at numerous forums. A need has
                    developed to define a consistent  and
                    comprehensive approach for estimat-
                    ing VOC emissions from refineries and
                    synfuel plants.
                      This study has resulted in the devel-
                    opment of a model for performing such
                    estimates. A modular technique was
                    developed in which the entire spectrum
                    of potential VOC emissions sources
                    was defined in a number of process and
                    utility modules. Each module repre-
                    sents a process or auxiliary unit.  The
                    user  of the model provides emission
                    source counts and other process infor-
                    mation, or uses default values pro-
                    vided. Emissions are calculated, using
                    emission factors for each source type.
                    Detailed examples of the application of
                    the model to both refineries and syn-
                    fuels  plants are presented.
                      This Project Summary was devel-
                    oped by EPA's Air and Energy Engineer-
                    ing Research Laboratory, Research Tri-
                    angle Park, NC, to announce key
                    findings of the research project that is
                    fully  documented  in two separate
                    volumes (see Project Report ordering
                    information at back).
                                   Introduction

                                    Over the past several years, volatile
                                   organic compound (VOC) emissions
                                   from petroleum refineries and synfuel
                                   plants have been of considerable inter-
                                   est to the EPA, industry, and the general
                                   public. The preparation and review of
                                   Environmental Impact Statements (EIS)
                                   and  permitting requirements of the
                                   Clean Air Act depend on emission esti-
                                   mates. In response to this need, several
                                   studies have been made of VOC emis-
                                   sions, particularly from  refineries.
                                   Methods for estimating VOC emissions
                                   and the results of VOC emissions tests
                                   have been published in various journals
                                   and at numerous forums. A need has
                                   developed  to define a consistent and
                                   comprehensive approach for estimating
                                   VOC emissions from refineries and syn-
                                   fuel plants. This study was performed to
                                   fulfill this objective.
                                    A literature search was conducted to
                                   obtain all available information on VOC
                                   emissions  from petroleum refineries
                                   and synfuel plants. The types of synfuel
                                   plants included in the search were coal
                                   gasification (excluding in-situ gasifica-
                                   tion), coal liquefaction (direct and indi-
                                   rect), and oil shale processing.
                                    Four major sources of emissions
                                   were included in the search: process
                                   emissions, product storage, baggable
                                   fugitive emissions, and  nonbaggable
                                   fugitive emissions. Both controlled and
                                   uncontrolled sources were considered;
                                   if the source was controlled, any avail-
                                   able information on the degree and type
                                   of control and the rationale for control
                                   application was included.
                                    Process operating parameters and
                                   physical data were included if they per-

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tained to a  process stream for which
emission  data were  expected to be
available or if they pertained to any ex-
isting emission model.  Emission  data
could include  measurements of emis-
sion rates, measurements  of parame-
ters that could correlate  with or predict
emission rates, or composition data.
  Because of Radian's involvement
with EPA  in VOC  emissions activities
over the past 7 years, it was expected
that very  little information of signifi-
cance would be found of which EPA and
Radian were  not already aware. A
search of the DOE ENERGY data  base
using the DIALOG Information Retrieval
Service bore this  out. The search in-
cluded the last 5 years.  Therefore, the
bulk of the  information was gathered
through the  Radian library. Particularly
in the refinery area, a  great deal of the
available information  on emissions is
the result of EPA/Radian testing efforts.
  Refinery emission data were obtained
from  a  few  major sources which had
been identified from past studies. These
sources are tabulated  in the full report.
Some of these references also provided
additional data (e.g.,  emission  source
distributions and process and operating
parameters)  needed to develop a model
for estimating  refinery VOC emissions.
  Much less information on VOC emis-
sions from synfuels plants is available
than for refineries. The full report sum-
marizes the literature surveyed.  Source
types and frequencies for a number of
synfuel  processes, together with a lim-
ited amount of emission factor data (pri-
marily for Lurgi  gasification plants),
were located.
  There are thousands of potential VOC
emission sources in a refinery or syn-
fuel plant, but this variety of sources
falls into one of the following general
categories:
  •  Process  fugitive emissions. These
    are  the  result  of  leakage of  VOC
    from the piping and fittings  with
    which a process unit is constructed.
    Sources  of process  fugitive emis-
    sions and their uncontrolled emis-
    sion factors are given  in Tables  1
    and 2. Note that the emission fac-
    tors are presented by industry, and
    that there are significant differences
    between industries.  The full report
    describes how VOCs may be emit-
    ted  from each source type,  how
    such emissions may be controlled,
    and the effectiveness of these con-
    trol measures.
Table 1.    Process Fugitive Emission Factors
Emission Factors,
Ib/day/source
Source
Type
Pump Seals
Pump Seals
Compressor Seals
Compressor Seals
Valves
Valves
Valves
Valves
Connections
Relief Valves
Relief Valves
Open End Lines
Process Drains
Service
Category
Light Liquidb
Heavy Liquid'
Hydrocarbon Gas
Hydrogend
Hydrocarbon Gas
Hydrogen
Light Liquid
Heavy Liquid
All
Gas
Liquid
All
All
Refineries
6.0
7.7
34.0
2.6
1.4
0.43
0.58
0.012
0.013
8.6
0.37
0.12
1.7
SOCMI'
2.6
1.1
12.0
-
0.30
-
0.38
0.01 2e
0.044
5.5
0.37e
0.09
-
'The Synthetic Organic Chemical Manufacturing Industry. These emission factors may be more appropria
 for petrochemical units associated with refineries or synfuel plants.
bAny organic material more volatile than kerosene.
cAny organic material with a volatility equal to or less than kerosene.
dA stream with greater than 50 percent (by volume) of hydrogen.
eFrom refinery data since there were not enough heavy liquid sources found in the SOCMI testing to warrai
 the development of separate emission factors.
  •  Process combustion emissions.
    Many refinery or synfuel processes
    require a great deal of heat input,
    which may be provided directly by a
    fixed process heater, or indirectly
    by steam, generated in a boiler. In-
    complete fuel combustion and/or
    reactions between the products of
    combustion may  result  in VOC
    emissions.  Emission factors from
    combustion sources are given in
    Table 3.
  •  Process point source emissions.
    Point sources of VOC emissions are
    present in some process units,  and
    emissions must of necessity be esti-
    mated for each  individual process
    unit. Data obtained  in this study
    were used to identify  the point
    sources occurring  in various pro-
    cess units and to develop emission
    factors for each.
  •  Slowdown and  flare system emis-
    sions.  Flares are used  to handle
    large emergency releases  from re-
    finery and  synfuel plant  process
    units and for combusting  continu-
ous, low flows of VOC that are trans
ported in closed vent systems. Flar
destruction efficiencies may rang
from 91 to 100 percent; a  mean eff
ciency of 98 percent is normally as
sumed.

Wastewater treatment system emit
sions.  Primary sources of VOi
emissions from  wastewater treat
ment systems are evaporative emis
sions from oil/water separators am
dissolved air flotation units. Con
trolled and uncontrolled emissioi
factors are given in Table 4.

Sludge/solid waste treating emis
sions.  Atmospheric VOC  emission
can result from the land disposal o
refinery and synfuel plant  oil'
wastes. No  well-established emis
sion factors exist for any  of the im
portant disposal  methods (land
farming, landfilling,  and surfaci
impoundment), but the full repor
presents several predictive emis
sion models which have  been pro
posed  in the literature.

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Table 2.    Process Fugitive Emission Factors Used in the Gasification, Acid Gas Removal,
          and Wastewater Extraction Modules
Source Type
Pump Seals - Aqueous
Pump Seals - Hydrocarbon Liquid
Compressor Seals - Hydrocarbon Gas
Compressor Seals - Hydrogen Gas
Valves - Hydrocarbon Gas
Valves - Hydrogen Gas
Valves - Hydrocarbon Liquids
Valves - Aqueous
Connections - Hydrocarbon Gas
Connections - Hydrocarbon Liquid
Connections - Aqueous
Relief Valves - Gas •
Relief Valves - Liquid
Open End Lines
Process Drains
Sample System Purging
VOC Emission Factor,
lb/day/sourcea
0.0026
0.011
34.0
2.6
0.0042
0.43
0.0057
0.0026
0.0005
0.0011
< 0.00007
0.34
0.0037
0.12
1.7
0.79
"There is some concern over the accuracy of these numbers, since they represent only the
 gaseous portion of the leak (i. e., they do not include the potential contribution of liquid leaks).
 A number of liquid leaks were noted, although most were in aqueous stream service. These
 factors were included because they are the only source of gasification specific data, but the use
 of refinery factors may be more accurate if liquid leaks are suspected to be significant.
  • Emissions from storage tanks.
    Emission models have been devel-
    oped for the most commonly  used
    types of tanks used to store crude
    oil and liquid products or byprod-
    ucts. These models are quite com-
    plex; details are given in the full re-
    port.
  • Emissions for cooling towers.  VOC
    emissions from cooling towers typi-
    cally occur as a result of leaks in
    shell-and-tube heat exchangers
through which cooling water circu-
lates. An  emission factor  of 6 Ib
VOC/106 gal. of cooling water circu-
lated is used.
Emissions from product loading op-
erations. VOC emissions result
from evaporation of products dur-
ing loading operations.  Emission
factors for several different stocks,
means of transport,  and style of
loading are given in  Table 5. For
other products, emissions may be
Table 3. Emission Factors
Fuel Type
Natural Gas
Fuel Oil
Coal (Bituminous or Lignite)
Coal (Anthracite)
for Heaters and Boilers
Emission Factors,
Industrial Heaters and Boilers
(< 100 x 106 Btu/hr) '
0.0029
0.0667
1.0 Ib/ton
negligible

lb/106 Btu
Utility Boilers
(> 100 x 10s Btu/hr)
0.001
0.0667
0.3 Ib/ton
negligible
   estimated by  using the factors for
   the product listed whose volatility is
   closest to the  product of interest.
  Refineries and synfuel plants may be
thought of as consisting of a number of
process units and auxiliary operations.
To provide a VOC emission model, a
number of such process and auxiliary
units were selected. Process and auxil-
iary modules were developed to repre-
sent the process units and auxiliary op-
erations in their generic form. Modules
were assigned to those processes
which may potentially  make a  signifi-
cant contribution to VOC emissions.
The refinery and synfuel modules con-
sidered in the VOC emission model de-
veloped as a result  of this study are
listed in Tables 6 and 7. Note that there
is some overlap; a number of the refin-
ery modules will be found in most syn-
fuel  plants. The full report describes
each module so that the user may select
those which are applicable to his refin-
ery or synfuel plant.
  Information  on the numbers and
types of VOC emission sources  occur-
ring  in each  module was used  to de-
velop various levels  of default  values.
These defaults provide useful informa-
tion  to  users of the model who may
have different amounts of detailed data
regarding a specific refinery or synfuels
plant for  which an  estimate of VOC
emissions is desired.

Results
  The VOC emission  model is pre-
sented  in a workbook format in  appen-
dices to the full report. The model con-
sists of  calculation sheets and module
default sheets. The basic emission cal-
culations for all emission sources are
done on the calculation sheets. If the
person using the model has complete
descriptive information about the plant
in question, then the calculation sheets
will provide everything else necessary
to estimate the VOC emissions. In most
cases, however, the  calculation sheets
will require some input data that the
user does not  have, and the default
sheets  were designed to  provide  rea-
sonable estimates for .such missing
data.
  The logic flow of the emission  model
is illustrated in  Figure 1. The user first
characterizes the  plant to be modeled
by selecting .appropriate  process  and
auxiliary modules. Process modules are
the model's representation of process
units (such as a Fluid Catalytic Cracker,
a Naphtha Hydrotreater, or a Lurgi Gasi-
fier). Auxiliary modules are the repre-

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sentation of non-process operations
(such as wastewater treating,  cooling
towers, and product storage). If the user
does not know which modules should
be included, several typical refineries
and synfuel  plants are fully defined.
These "generic plants" may be  used as
is or simply as a guide in selecting the
modules for a particular plant.
  The emissions are calculated on a
module-by-module basis, using emis-
sion calculation sheets and  default
sheets (as necessary). When all  the pro-
cess modules have been calculated, a
similar procedure is followed  for the
auxiliary modules. The results  may be
displayed in at least two useful ways.
First, the emission estimates on a
module-by-module  basis  will show
which modules are producing the most
emissions; control efforts can  be con-
centrated where they will accomplish
the greatest emissions reductions. Sec-
ond, adding together the  emissions
from like sources (e.g., light liquid pump
seals) can facilitate comparisons of po-
tential  reductions which may  be
achieved by control programs aimed at
all sources of a given type, such as leak
detection  and repair programs or im-
proved equipment specifications.
  Several examples of the  use of the
VOC emission model are detailed in the
full report. One of the example plants
was a small refinery.  Table 8 lists the
modules used to  represent the small re-
finery, and Figure 2 is a block diagram.
The results of the model VOC estimate
are summarized in  Table 9.  As de-
scribed previously, the VOC model has
multiple levels of defaults to allow the
user to take advantage of whatever data
is  available. Table 10 compares the
model results, using three levels of de-
faults.

Conclusions and
Recommendations
  This report presents a mathematical
model for estimating VOC emissions
from refineries and several types of syn-
fuel plants. All significant VOC emission
sources have been included in the emis-.
sions model. A modular technique was
developed in which the entire spectrum
of potential VOC emissions sources was
defined in a  distinct number of  process
and utility modules. This model is con-
venient, flexible,  and functional for de-
veloping VOC emissions estimates  for
very diverse petroleum  refineries and
synfuel plants.
  The model developed in this study
Table 4.    Emission Factors for Wastewater Treating Slowdown Systems, Flares, and
          Cooling Towers
     Source Type
    Emission Control
 Emission Factor
Wastewater Treating

  Oil/Water Separator

  Oil/Water Separator

  Oil/Water Separator

  Dissolved Air Flotation

Slowdown and Flares

Cooling Towers
       Uncovered

       Covered

Covered and vented to flare

          NA

          NA

          NA
1.88 lb/103 gal. WV\

0.38 Ib/W3 gal. WV\

0.06 lb/103 gal. WU

0.09 lb/103 gal. WV\

0.8 lb/103 bbl crudt

6 lb/106 gal. CW
Table 5.    Emission Factors for Product Loading
                                        Emission Factor, lb/103 gal.
Vehicle
Tank Trucks/
Tank Cars



Barges

Ocean Barges


Marine Tankers



Loading
Style
Submerged-
normal
Splash-
normal
Submerged-
balanced
Splash-
balanced
Clean-vapor
free
Uncleaned-
dedicated
Average
condition
Clean-vapor
free
Uncleaned-
dedicated
Ballasted
Clean-Vapor
free
Ballasted
Uncleaned-
dedicated
Average
condition
Gasoline
5.0
12.0
8.0
8.0
1.2
4.0
4.0
1.3
3.3
2.1
1.0
1.6
2.4
1.4
Jet No. 2 No. 6
Naphtha Kerosene Fuel Oil Fuel Oi
1.5 0.02 0.01 0.0001
4.0 0.04 0.03 0.0003
2.5 NA NA NA
2.5 NA NA NA


1.2 0.13 0.012 0.0000&




0.5 0.005 0.005 0.00004


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 has several unique and valuable fea-
 tures. The modules lend themselves
 readily to individual updating, improve-
 ment, and  expansion, without disturb-
 ing the integrity of the remaining mod-
 ules. The model  is capable  of
 developing emissions estimates from
 various levels of information. In the ex-
 treme, VOC emission estimates for  re-
 fineries and synfuel plants can be devel-
 oped when only the plant type and
 capacity are known. The results of these
 "maximum default" cases are pre-
 sented as Table 10.
   Several areas for further work could
 enhance the model developed in this
 study. The  most obvious is computeri-
 zation of the model. The modular form
 of this model is ideal for computeriza-
 tion. A computerized version of the
 model would allow rapid estimation of
 VOC emissions and optimization of pro-
 cessing and control techniques for min-
 imizing VOC emissions.  Different levels
 of control could be quickly evaluated
 under different scenarios.  Summaries
 of emissions from particular sources
 across modules could be prepared with
 minimal effort.
   VOC emissions from fugitive process
 sources (valves, pumps, flanges, etc.)
 represent  a significant  percentage  of
 total  VOC emissions. Emissions from
 these sources are best controlled by a
 leak detection and repair program. This
 VOC emissions  model could ultimately
 incorporate EPA's leak detection (LDAR)
 model to allow additional evaluation
 and emission minimization  studies  to
 be performed rapidly. The LDAR model
 is currently in computer form.
   The accuracy of the VOC emission es-
 timate is  not evaluated  by  the current
 model. An assessment of accuracy
 would require information on the accu-
 racy of the emission source data as well
 as the equipment counts and loading
 levels. This information  is available (in
 the form of confidence intervals, stand-
 ard errors, and other types of error
 bounds) for some of the data used  in
 developing the model.  For other
 sources,  new data  are currently being
 developed which should include an ac-
 curacy assessment.  The level of accu-
 racy in using the model will also depend
 on the level of information that the user
 has available (e.g.,  equipment  counts
versus unit capacity levels). The current
model could be  updated  to include lev-
els of accuracy for  all default values.
These values could then be summarized
 by appropriate error propagation meth-
 Table 6.    Refinery Modules

           Module Name
               Comments
  1. Atmospheric Crude Distillation




  2, Vacuum Crude Distillation

  3. Naphtha Hydrotreating


  4. Middle Distillate Hydrotreating

  5. Gas Oil Hydrotreating


  6. Vacuum Resid Hydrodesulfurization

  7. Catalytic Reforming



  8. Aromatics Extraction

  9. Catalytic Cracking
 10, Hydrocracking

 7 1. Thermal Cracking & Visbreaking

 12. Delayed Coking

 13. Fluid Coking

 14. Light Ends Recovery and Fractiona-
    tion

 15. Other Miscellaneous Fractionation
    Units

 16. Alkylation

 17. Polymerization


 18. Isomerization

 19. Lubes Processing - Volatile Organic
    Solvents
20.  Other Lube Oil Processing
Includes desalting, heat exchange network, at-
mospheric column, and side stream strippers.
Does not include facilities for processing LPG
in non-condensible OH gases (see # 14).
For sulfur reduction in straight-run or cracked
naphthas.

For sulfur reduction in jet fuels and kerosene.

For low sulfur fuel oils, cracking feed pretreat-
ment, and lube oil hydroprocessing.
Includes Platforming, Rheniforming, and
Powerforming. Does not include naphtha hy-
drotreating (see #3).

Includes Udex, Sulfolane, and Tetra.

Includes fluid and moving bed crackers such
as the FCC, HCC, and TCC. Includes reactor,
regenerator, main fractionater, and heat ex-
change. Light ends recovery and fractionation
are not included (see # 14).
27. Asphalt Production
22.  Hydrogen Production
Includes fluid coking and flexicoking.

Includes circulating oil absorption/stripping
and fractionation of recovered light ends.

Independent naphtha splitters, rerun stills,
stabilizers, etc.

Includes both HF and H^SO4 alkylation.

Production of polymer gasoline from propy-
lene and LPG mixtures.

Includes both C4 and Cs/C6 isomerization.

Includes propane deasphalting, propane de-
resining, propane dewaxing, solvent dewax-
ing, Duo Sol, solvent deasphalting, MEK de-
waxing, and MEK-toluene dewaxing.

Includes phenol extraction, furfural extraction,
acid treating, SO2 extraction, white oil manu-
facture, centrifuge and chilling, naphthenic
lube oils, clay contacting, wax deoiling, wax
sweating, wax neutral separation, and com-
pounding.

Includes asphalt oxidizing, asphalt emulsify-
ing, Dubbs pitch, and 200°F softening point
unfluxed asphalt.

Includes steam reforming and partial oxida-
tion.

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Table 6.   Refinery Modules (Cont)

           Module Name
               Comments
23.  Gasoline Treating
24.  Other Product Treating
25.  Olefins Production
26.  Other Volatile Petrochemicals
27.  Other Low Volatility Petrochemicals
28.  Boilers


29.  Slowdown System and Flares

30.  Wastewater Treating


31.  Sludge/Solids Handling


32.  Crude and Product Storage

33.  Cooling Towers

34.  Product Loading Operations
Includes Merox, inhibitor sweetening, mercap-
fining, Petreco Locap, Linde, caustic treating,
and Doctor treating.

Includes clay treating, Linde, salt treating, and
blending for middle distillates and fuel oils.

Production of mixed olefins from gas, naph-
tha, and/or oil feedstocks.

Includes butadiene, alpha olefins,  aromatics,
cumene, cyclohexane, aliphatics, linear paraf-
fins, heptene, MEK, MIBK, ethyl amyl ketone,
tertiary amylenes, acetone, isobutylene,
hydrodealkylation of aromatics.

Includes naphthalene, xylenes, mineral spirits,
octyl formal alkylate, styrene, phthalic anhy-
dride, nonene, diallylamine, poly isobutylene
chloride, oxalcohol, phenol, cresylic acid,
naphthenic acid, butyl alcohols, pentoxone,
sodium sulfonates, tertiary butyl toluene,
polymers, carbon black, furfural, catalysts,
mesityl oxide, isophorone, gasoline additives,
lubricant additives, and oxidates.

Independent combustion units for production
of steam and/or electricity.
Includes oil/water separators (OWS) and dis-
solved air flotation (DAF) units.

Includes any on-site treatment such as land-
farming, landfilling, and ponding.

Includes fixed roof and floating roof tanks.
Includes loading facilities for tank trucks, tank
cars, barges, ocean barges, and marine
tankers.
ods to estimate the accuracy of emis-
sion estimates generated by the model.
  Obviously,  it would be desirable to
update the modules periodically as ad-
ditional emission data become avail-
able.  Additional  emission  data from
synfuel facilities  should  be available
during the next 5 years. As the model is
employed, users will  undoubtedly find
additional needs which have not been
addressed by or included in  the current
model. These needs should  be cata-
logued for future model improvement
efforts.
  This VOC emissions model has been
evaluated in  a preliminary  fashion  by
applying the model to some specific fa-
cilities and comparing the emissions es-
timates to  results obtained indepen-
dently (e.g., through  permit  proce-
  dures). Field tests would be more thor-
  ough and objective. Emissions could be
  estimated using the  model and then
  measured using transect  techniques.
  The  results from this effort could  be
  used to  refine, calibrate, and validate
  the model.

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Table 7.    Synfuel Modules

           Module Name
                Comments
Coal Preparation (Thermal Drying)

Slurry Drying

Coal Gasification



Methanol Synthesis

Fischer-Tropsch Synthesis

Mobil M-Gasoline Synthesis

Direct Liquefaction

Above-Ground Oil-Shale Retorting

Acid Gas Removal

Oil-Soluble Arsenic Removal


Wastewater Solvent Extraction
Used in EDS process.

Includes gas cooling. Fugitive emissions from
some gasifiers negligible because they do not
provide significant hydrocarbons.
Includes product separation.
No default values developed due to lack of pro-
cess information.

Example: Phenosolvan process
           Menu of
           Process
             and
           Auxiliary
           Modules
                                                 Repeat for Next Module
                                                    Repeat for Next Module
                                              User
                                              Input
                                                        Process
                                                        Module
                                                        Defaults
       Process
       Module
       Emission
     Calculations
                              Facility
                              Definition
                              By Module
                              Selection
                                                                               No
— te,
u
Ini
i
ser
->ut
"i
Auxiliary
Module
Defaults
T '
Auxiliary
Module



Yes
 Emission
Calculations
                                                                     Store
                                                                     Results
                                                                                                                       No
Complete
   ?  /Yes
                                                                       Store
                                                                       Results
                                  Baseline Emmisions Summary
                                                                                            Control Efficiency
                                                                                                Defaults
                                                                                                                   User
                                                                                                                   Input
                                                                           Controlled Emissions Summary
Fjpurt  1.    Logic flow diagram.

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Table 8.    Modules of Example Small
           Existing Refinery3

Process Modules:

  Atmospheric Crude Distillation
  Vacuum Crude Distillation
  Naphtha Hydrotreating
  Catalytic Reforming
  Aromatics Extraction
  Fluid Catalytic Cracking
  Light Ends Recovery and Fractionation
  Other Miscellaneous Fractionation
  Alkylation

Auxiliary Modules:

  Boiler
  Slowdown System and Flares
  Wastewater Collection and Treating
  Storage—Fixed Roof Tanks
  Storage-Floating Roof Tanks
  Cooling Towers
  Loading Racks-Trucks or Rail Cars

"Crude capacity = 50,000 bbl/day.
                    I   Slowdown    I
                    J   System and   .
                    I     Flares     \
Figun 2.    Block flow diagram for the example small refinery.

                                       8

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Table 9. Summary of Baseline Emissions
Source Type/Service
Pumps/Light Liquid
Pumps/Heavy Liquid
Compressors/Hydrocarbon Gas
Compressors/Hydrogen Gas
Valves/Hydrocarbon Gas
Valves/Hydrogen Gas
Valves/Light Liquids
Valves/Heavy Liquids
Connections/All
Relief Valves/Gas
Relief Valves/Liquid
Open-End Lines/All
Process Drains/All
Combustion Sources
Other Point Sources
Wastewater Collection and Treating
Cooling Towers
Slowdown System and Flares
Loading Racks
Fixed Roof Storage
Floating Roof Storage
Totals
Emissions,
Ib/day
522
53
238
6
4938
142
4950
60
748
1446
33
42
539
91
450
1056
1314
110
308
1485
2306
20,837
Percent
of Total
2.5
0.3
1.1
neg.
23.7
0.7
23.8
0.3
3.6
6.9
0.1
0.2
2.6
0.4
2.2
5.1
6.3
0.5
1.5
7.1
11.1
100.0
                                        Table 10.    Summary of "Maximum
                                                   Default" Emission Estimates

                                        The Type A (or topping) refinery can be es-
                                        timated by:
                                          Emissions (Ib/day) = 4,024 + (82.3)
                                          (Crude Rate in TO3 BPDa)
                                          The average Type A refinery has a crude
                                          capacity of 14,000 BPSDb.
                                        The Type B (or cracking) refinery can be es-
                                        timated by:
                                          Emissions (Ib/day) = 13,649 + (82.4)
                                          (Crude Rate in W3 BPD)
                                          The average Type B refinery has a crude
                                          capacity of 66,000 BPSD.
                                        The Type C (or petrochemicals) refinery can
                                        be estimated by:
                                          Emissions (Ib/day) = 25,339 + (83.1)
                                          (Crude Rate in W3 BPD)
                                          The average Type C refinery has a crude
                                          capacity of 150,000 BPSD.
                                        The Type D (or lubes) refinery can be esti-
                                        mated by:
                                          Emissions (Ib/day) = 24,455 + (86.0)
                                          (Crude Rate in W3 BPD)
                                          The average Type D refinery has a crude
                                          capacity of 187,000 BPSD.
                                        The Type E (or integrated) refinery emis-
                                        sions can be estimated by:
                                          Emissions (Ib/day) = 30,774 + #6.5;
                                          (Crude Rate in 103 BPD)
                                          The average Type E refinery has a crude
                                          capacity of 312,000 BPSD.

                                        aBarrels per day.
                                        bBarrels per stream day..
 R. G. Wetherold. G. E. Harris. F. D. Skinner, and L. P. Provost are with Radian
   Corporation. Austin, TX 78766.
 Robert C. Lagemann is the EPA Project Officer (see below).
. The complete report consists of two volumes, entitled "A Model for Evaluation of
   Refinery and Synfuels VOC Emissions Data:"
   "Volume!. Technical Report and Appendix A," (Order No. PB85-215 713/AS;
     Cost: $23.50)
   "Volume II. Appendices B and C," (Order No. PB 85-215 721/AS;   Cost:
   $16.00)
 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, NC27711
                                            , U.S. aCVERNUENT PRINTING OFFICE I«S 559-111/20640

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