^ ^ U.S. EPA Region III
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1C50 Arch Street (3PM52)
Philadelphia, PA 19103
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Philadelphia. PA 19101
VOLATILE ORGANIC COMPOUND EMISSION CONTROLS
FOR WITCO CHEMICAL CORPORATION PLANT
IN TRAINER, PENNSYLVANIA
by
PEDCo Environmental, Inc
1006 N. Bowen Road
Arlington, Texas 76012
Contract No. 68-02-3512
Task Order No. 43
Project Officer
Eileen Glen
U.S. ENVIRONMENTAL PROTECTION AGENCY
REGION III
PHILADELPHIA, PENNSYLVANIA 19106
March 1984
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CONTENTS
Tables iii
Summary iv
1. Introduction 1
1.1 Source Description and Types of VOC Emissions 1
2. Emission Control Techniques 4
2.1 Current Witco Practices 4
2.2 Proposed Control Systems 4
3. Cost Analysis 6
3.1 Plant Parameters 6
3.2 Nitrogen Credit 6
3.3 Incineration 6
3.4 Carbon Adsorption 7
3.5 Refrigeration 8
3.6 Combined Refrigeration and Carbon Adsorption 9
3.7 Cost-Effectiveness 9
4. ' Regulatory Analyses 12
4.1 Draft Regulation 12
4.2 Regulations in Other Areas 15
4.3 Compliance and Monitoring Techniques 15
4.4 Potential Problem Areas 15
References 17
Appendix
A Outline of Calculations for Incinerator
Performance and Heat Recovery A~l
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TABLES
Number Page
1 Cost Comparison of VOC Control Systems for Witco Chemical v
2 Nitrogen Recovery 7
3 Capital Costs, Annual Costs, and Cost-Effectiveness for VOC
Control Systems 10
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SUMMARY
The Witco Chemical Corporation plant in Trainer, Pennsylvania, produces
oil-soluble sulfonic acids and sulfonate salts by treating hydrocarbons and
phenols with oleum (a solution of sulfur trioxide in 100 percent sulfuric
acid) and neutralizing the acid. The reactions take place in a proprietary
solvent solution. Although most of the solvent that evaporates is recovered
via a system that includes refrigeration and a condenser, a material balance
indicates that the plant emits 1200 tons of VOC per year.
Five systems were evaluated for additional VOC control at this plant:
0 Incineration without heat recovery
0 Incineration with heat recovery
0 Carbon adsorption
0 Refrigeration
0 Refrigeration combined with carbon adsorption
All of these systems are technically feasible. The nonincineration systems
also offer the possibility of recovery and reuse of nitrogen in the process
for additional cost savings. Table 1 presents the comparative costs of the
five systems. Except for the first option (incineration without heat recov-
ery), all of the systems would result in a net annual savings to the company.
The absence of any significant fugitive VOC sources at the plant should
be verified, as no costs for controlling fugitive emissions are included in
the estimates. Compliance can be monitored via solvent purchases and inven-
tory.
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SECTION 1
INTRODUCTION
Over the past several years the U.S. Environmental Protection Agency's
(EPA's) Office of Air Quality Planning and Standards (OAQPS) has developed a
series of Control Techniques Guidelines (CTGs) for volatile organic compounds
(VOC) to assist state and local agencies in developing regulations for VOC
control. Although the CTGs cover major VOC source categories from an overall
nationwide perspective, several VOC source categories that are not covered by
CTG documents are major contributors to the ozone problem within given areas.
Air pollution control agencies in the Philadelphia Air Quality Control
Region (AQCR) have requested guidance in determining whether VOC controls are
available for these non-CTG sources. The agencies have requested information
for use in the development of appropriate regulations. This evaluation of
potential VOC controls for the Witco Chemical Corporation plant at Trainer,
Pennsylvania, is in response to that request.
1.1 SOURCE DESCRIPTION AND TYPES OF VOC EMISSIONS
Witco produces oil-soluble calcium, magnesium, and sodium sulfonates1
for use as lubricant additives. The process has two steps. In the first
step, the sulfonic acid is made by reacting a high-molecular-weight aromatic
hydrocarbon or phenol with oleum (a solution of sulfur trioxide in 100 percent
sulfuric acid). After the sulfonation reaction has taken place, the solvent
is removed by distillation and condensation. In the second step, the sulfonic
acid is reacted with the appropriate base (calcium, magnesium, or sodium
hydroxide) and then dried to produce sulfonate salt. The reaction takes place
in a volatile organic compound solution; most of the VOCs from this process
are routed through the condenser system (SOI), and the rest are vented through
a separate stack (S08). A flow diagram of this process is presented in Fig-
ure 1. Witco considers the identity of this solvent to be proprietary; it is
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a water-insoluble, flammable VOC with a density of about six pounds per gal-
lon.
Reactions that form sulfonate salts also take place in this solvent
medium. The bulk of the VOC from this process is routed to the condenser,
which is used in sulfonic acid manufacturing. After the sulfonic acid has
been manufactured, most of the solvent is removed by distillation.
Total VOC emissions amount to about 400 pounds per hour or 1200 tons per
year. Because the solvent is flammable, all distillation and evaporation
takes place in a nitrogen atmosphere. The nitrogen flow rate is about 1425
scfm.
The VOC emission rates were obtained from a report that Witco submitted
to the Pennsylvania Department of Environmental Resources, and they are based
on a material balance.2 All the solvent from sulfonation and salt production
and about 75 percent of the solvent from salt drying is sent first to the con-
denser, and then through a 100-ft stack (emission point SOI). The other 25
percent of the solvent from salt drying is routed through a caustic scrubber
to the 125-ft dryer stack (emission point SOS) for uncontrolled emissions. It
is assumed that no fugitive emissions occur and that all VOC emissions come
from one of the two identified emission points.
The plant uses natural gas and fuel oil with a 0.5 percent maximum sulfur
content to provide process heat and steam. Natural gas is sold to Witco on an
interruptible service basis. It is the cheaper of the two fuels and thus is
used whenever available. Heat produced by combustion of the VOC used in the
plant process could replace fuel as a source of process heat and steam. This
would be equivalent to about 10 per cent of the output from one of the process
boilers.
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SECTION 2
EMISSION CONTROL TECHNIQUES
2.1 CURRENT WITCO PRACTICES
The VOC emissions from the process reactor are controlled first by a
chilled-water condenser that operates at a maximum temperature of 35° to 40°F
(2° to 4°C). The water is chilled by cooling towers and a refrigeration sys-
tem. The gas stream from the condenser, which contains about 98 percent
nitrogen and 2 percent VOC, then passes through a refrigeration system, where
it is cooled to below 10°F (-12°C). Most of the solvent from the sulfonate
salt dryers is routed through the condenser system, but about 25 percent is
vented through a separate stack.
2.2 PROPOSED CONTROL SYSTEMS
Improved VOC control can be achieved by incineration, incineration with
heat recovery, additional refrigeration, or a combination of refrigeration and
carbon adsorption, all of which are technically feasible. Each of these sys-
tems is evaluated in the following subsections.
2.2.1 Incineration
Incineration of the gas streams from the condenser and dryer is technic-
ally feasible. The solvent concentration in the gas stream appears to be
large enough so that supplemental fuel would not be required for incineration.
Because the stream contains very little oxygen, however, combustion air would
have to be added.
2.2.2 Incineration With Heat Recovery
It is estimated that about 65 percent of the heat content of the solvent
could be recovered for use in the plant.
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2.2.3 Carbon Adsorption
Additional VOC emission control could be obtained by routing the gas
streams from the condenser and dryer through a bed of activated carbon. Be-
cause solvent is insoluble in water, it can be recovered from the carbon by
steam stripping and then reused in the plant. The adsorber would have two
carbon beds; this allows one bed to be regenerated while the other one is on
1 ine.
2.2.4 Refrigeration
Additional refrigeration of the gas stream could further reduce emis-
sions. Cooling to -110°F (-79°C) should achieve at least a 90 percent reduc-
tion in VOC emissions (E. Pijanowski, Trane Thermal, Inc., personal communica-
tion, February 23, 1983). A large refrigeration unit would be required 'to
handle the volume of nitrogen that would have to be cooled.
2.2.5 Combined Refrigeration and Carbon Adsorption
A combination system that incorporates both refrigeration and carbon
adsorption is less expensive to install than a system that uses only one con-
trol device. Both components in such a system are much smaller than would be
required for a single corresponding control system capable of achieving the
same overall control efficiency.
2.2.6 Other Control Methods Considered
Catalytic incineration is not feasible because sulfonate metal salts are
formed in the plant process.3 Metal compounds tend to deposit on the catalyst
surface and render it inactive. Although the same problem might apply to a
carbon adsorber, replacement of all or part of the carbon is relatively easy
and inexpensive.
The use of the gas stream as fuel for an existing process boiler is also
impractical. The large volume of inert gas (nitrogen) that would have to be
routed through the boiler could adversely affect the operation of the burner
by causing incomplete combustion, deposition of tars and resins on heat trans-
fer surfaces, and tube fouling.4
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SECTION 3
COST ANALYSIS
Some of the data presented in this section has been combined or is ap-
proximated to avoid revealing information that Witco considers confidential.
Calculations performed with these approximations represent actual plant condi-
tions reasonably well and do not materially affect the conclusions of this
study.
3.1 PLANT PARAMETERS
The combined flow rate from the sulfonic acid and sulfonate salt units is
90,000 scf per hour; most of the flow comes from the sulfonic acid unit.
About 1600 scf per hour of the stream is solvent, and the balance is nitrogen.
The 400 pounds of solvent per hour has a recovery value of $67 (16.7 cents per
pound) as solvent and it has a heat content of 8 x 106 Btu/h.
3.2 NITROGEN CREDIT
The plant currently exhausts a solvent-contaminated nitrogen stream that
could be recycled to the process if the solvent were removed. The estimated
capital cost for equipment to recycle the nitrogen is $120,000. The annual
cost for operating this equipment would be $29,600; however, this equipment
would produce an annual nitrogen credit of $454,500, which reduces the annual
cost to a credit of $424,900 (as shown in Table 2). This credit is based on a
nitrogen price of $30 per ton (W. Reiger, Union Carbide Corporation, personal
communication, March 3, 1983) and an 80 percent net recovery efficiency (90
percent control device efficiency with 10 percent blowdown to maintain nitro-
gen quality).
3.3 INCINERATION
The 1500-scfm VOC-nitrogen stream would be burned in 26 percent excess
air. No incremental fuel would be required. About 65 percent of the 8 x 106
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TABLE 2. NITROGEN RECOVERY
(September 1982 dollars)
CAPITAL COST
Installed equipment 120,000
ANNUAL COST
Capital recovery factor 14,100
Operating and maintenance 5,700
Property taxes and insurance 4,800
Utilities 5,000
Total annual cost 29,600
Nitrogen recovery credit (454,500)
Net annual credit (424,900)
Btu/h would be recoverable, based on an incineration temperature of 2000°F and
a stack exhaust temperature of 400°F. An incinerator without heat recovery
would cost about $60,000. Adding a waste heat boiler would increase the
equipment cost by about $100,000. Installation costs would be about equal to
equipment costs. Credits for recovered heat are based on a price of $4.08/106
Btu paid for natural gas by Pennsylvania utilities in September 1982.5 This
would be $127,300 per year. If the recovered heat displaced No. 6 fuel oil,
the credit would be $4.847/106 Btu.5
A capital recovery factor of 14.67 percent of the total capital invest-
ment (based on a 12-year equipment life and a 10 percent interest rate) was
used.6 Property taxes and insurance were estimated to be 4 percent of total
capital costs and maintenance costs were estimated to be 4.75 percent of total
capital costs.
3.4 CARBON ADSORPTION
Vic Manufacturing Company and Hoyt Manufacturing Company provided separ-
ate cost estimates for a carbon adsorber to handle the VOC stream at Witco
(N. Shaw, Vic Manufacturing Company, personal communication, March 14, 1982
and V. Nayak, Hoyt Manufacturing Company, personal communication, March 15,
1983). The respective estimated equipment costs from the two vendors were
$95,000 and $145,000; in both cases, installation costs were estimated to be
-------
an additional 50 percent. Equipment and installation costs are site-specific,
but it was estimated that the cost of the necessary duct work and blowers
would amount to 50 percent of the carbon adsorber equipment cost. The two
estimates were averaged together to obtain an estimate $120,000 for the equip-
ment cost and $180,000 for the installed equipment cost.
The capital recovery factor for carbon adsorber systems is based on a
20-year life and a 10 percent interest rate. The capital recovery factor,
nonvariable operating and maintenance costs (estimated at 4.75 percent), and
property taxes and insurance (estimated at 4.0 percent) add up to 20.5 percent
of the total capital cost. Low pressure steam is estimated to cost $3.50 per
thousand pounds. (L. Nisbet, PEDCo, Inc. , personal communication, December 1,
1982). Vic estimated that 5 pounds of steam would be required to strip 1
pound of solvent (N. Shaw, Vic Manufacturing Company, personal communication,
March 14, 1982). Properties and prices of the solvent were obtained from
standard references.7'8
The sulfonic acid manufacturing process operates 5940 hours per year, and
the sulfonate salt manufacturing process operates 6720 hours per year.2 The
carbon adsorber was assumed to operate an equivalent of 6000 hours per year
because sulfonic acid manufacturing produces most of the VOC emissions. Sol-
vent credits are based on 90 percent recovery of 400 pounds per hour and a
price of 16.7 cents per pound.
Annual costs include a capital recovery charge of 11.75 percent of the
capital investment, based on a 20-year life and a 10 percent interest rate;
operating and maintenance costs are estimated to be 4.75 percent of capital
costs; and property taxes and insurance charges are estimated to be 4 percent
of capital costs.
3.5 REFRIGERATION
Capital and operating costs for VOC control by refrigeration were ob-
tained from a published report9 and updated to September 1982 dollars by use
of cost indices published in Chemical Engineering. To achieve 90 percent
control would require cooling to about -110°F (-79°C).9 The installed cost
for a refrigeration system would be $1.29 million.
-------
The capital recovery charge is 14.67 percent of the total capital invest-
ment; this is based on a 10 percent interest rate and a 12-year equipment
life.6 Operating and maintenance costs are estimated to be 2.4 percent of
capital costs, and property taxes and insurance are estimated to be 4 percent
of capital costs. Estimated annual power requirements are 3.21 million kilo-
watt-hours (E. Pijanowski, Trane Thermal, Inc., personal communication, Febru-
ary 23, 1982). At a cost of $0.0484/kWh, this would be $155,400 per year. As
in the case of the carbon adsorber, refrigeration would recover the solvent
and possibly enable the plant to recycle the nitrogen to the process.
3.6 COMBINED REFRIGERATION AND CARBON ADSORPTION
A combination of refrigeration and carbon adsorption seems to be the most
economical VOC control method. Refrigeration would lower the VOC vapor pres-
sure and condense out much of the VOC. This would reduce the VOC loading on
the carbon adsorber and allow the use of a smaller unit. The prospect of
using sufficient refrigeration to halve the VOC pressure and halve the size of
the carbon adsorber was analyzed. This approach would reduce capital costs
and related annual costs. It would also reduce overall utility costs because
the reduction in steam requirements to strip the carbon adsorber would more
than offset the cost of electricity for the refrigeration unit.
Actual costs would be site-specific; optimization of the trade-off be-
tween increased refrigeration and decreased carbon adsorption would require a
more detailed engineering evaluation of the Witco facility. Capital costs
would be $22,200 for incremental refrigeration (E. Pijanowski, Trane Thermal,
Inc., personal communication, February 23, 1983) and $118,800 for a carbon ad-
sorber, for a total installed equipment cost of $141,000. Annual costs are
estimated to be $50,800. With a VOC recovery credit of $360,700, the net
annual credit would be $309,900. This amount, plus an annual nitrogen credit
of $454,500, yields a net credit of $764,400 for this system .
3.7 COST-EFFECTIVENESS
Table 3 summarizes capital cost, annual cost, and cost-effectiveness
determinations for carbon adsorption, incineration, refrigeration, and com-
bined refrigeration-carbon adsorption. Incineration with heat recovery would
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result in an annual credit of $89,800 on a $160,000 capital investment. Car-
bon adsorption would result in an annual credit of $285,900 on a $180,000
capital investment. The refrigeration-carbon adsorption combination would
result in an annual credit of $309,900 on a $141,000 capital investment. All
of these control options appear to be attractive investments, with credits
ranging from $83 to $287 per ton on VOC controlled. Incineration without heat
recovery would cost $13 per ton of VOC controlled, and vapor recovery would
cost $62 per ton of VOC controlled.
The economics of VOC emission control by carbon adsorption, vapor recov-
ery, and the refrigeration-carbon adsorption combination are improved greatly
if all or part of the nitrogen can be recovered and recycled. An annual
credit of $424,900 on a $120,000 capital investment is obtainable, based on
recycling 80 percent of the nitrogen and a nitrogen cost of $30 per ton
(W. Reiger, Union Carbide, personal communication, March 3, 1983). Costs and
credits for nitrogen recycling are shown in Table 1 (in the Summary).
Witco's emissions are based on a material balance and on the assumption
that all VOCs are emitted through the two stacks (no fugitive emissions).
Some plant testing may be necessary to verify this assumption.
11
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4. REGULATORY ANALYSIS
This section contains a draft regulation, applicable compliance and moni-
toring techniques, and a discussion of potential problem areas.
4.1 DRAFT REGULATION
A. Definitions
1. For the purpose of this regulation, the general definitions apply.
2. For the purpose of this regulation, the following definitions also
apply.
a. "Control system" means any number of control devices that are
designed and operated to reduce the quantity of VOC emitted to
the atmosphere.
b. "Carbon adsorber" means a device that adsorbs VOC on activated
carbon in such a manner that at least a 90 percent reduction in
VOC emissions to the atmosphere is achieved.
c. "Incinerator" means a device that burns VOC in such a manner
that at least a 90 percent reduction in VOC emissions to the
atmosphere is achieved.
d. "Vapor recovery unit" means a device that removes VOC from gas
streams by any combination of refrigeration and compression in
such a manner that at least a 90 percent reduction in VOC emis-
sions to the atmosphere is achieved.
e. "Refrigeration" means cooling of a VOC-containing gas in such
a manner as to lower the partial vapor pressure of the VOC.
f. Equipment normally used in manufacturing (e.g., condensers)
shall not be considered to be part of any "control system" and
shall not be used to claim credits for VOC emission reduc-
tions.
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B. Applicability
1. This regulation applies to manufacturers of surface active agents,
finishing agents, sulfonated oils, and assistants as defined by
Standard Industrial Classification 2843. This includes, but is
not limited to, the manufacture of sulfonic acids, metal sulfonate
salts, sulfonated phenols, and metal phenate salts.
2. This regulation applies to the control of VOC emissions in manufac-
turing processes in which VOC can be employed as a solvent, reactant,
product, or intermediate.
3. VOC sources that emit less than 10 tons (9091 kilograms) per year
or 55 pounds (25 kilograms) per day shall be exempt from this
regulation. The most stringent requirement will apply.
C. Provision for Specific Processes
1. Carbon adsorbers, vapor recovery units, incinerators, refrigera-
tion, or any combination of these controls shall be used.
2. Equivalent controls may be used, but they must reduce VOC emissions
by at least as much as the control devices cited in C-l.
3. The owner or operator of a facility subject to this regulation
shall reduce the VOC emissions from all process equipment:
a. By at least 90 percent if VOC emissions are equal to or
more than 550 pounds (250 kilograms) per day; or
b. To 55 pounds (25 kilograms) per day or less if VOC emissions
are less than 550 pounds (250 kilograms) per day.
D. Compliance Schedules
1. The owner or operator of a facility subject to this regulation must
meet the applicable increments of progress shown in the following
schedule:
a. Submit final plans for all emission control systems and pro-
cess equipment within 5 months after this regulation is in
effect.
b. Award contracts or purchase orders for all emission control
systems and process equipment within 8 months after this
regulation is in effect.
c. Initiate onsite construction or installation of all emission
control and process equipment within 12 months after this
regulation is in effect.
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d. Complete onsite construction or installation of the emission
control and process equipment within 18 months after this
regulation is in effect.
e. Achieve final compliance, demonstrated as specified in Sec-
tion E, within 24 months after this regulation is in effect.
2. The owner or operator of a facility subject to this regulation may
submit to the Director a proposed alternative compliance schedule,
and the Director may approve such a schedule, provided:
a. The proposed alternative compliance schedule is submitted
within 3 months after this regulation is in effect.
b. The owner or operator provides information showing the need
for an alternative schedule.
c. The alternative compliance schedule contains increments of
progress.
d. The owner or operator of the facility submits sufficient
documentation and certification from appropriate suppliers,
contractors, manufacturers, or fabricators to justify the
dates proposed for the increments of progress.
e. Final compliance is achieved as expeditiously as possible and
before the photochemical oxidant attainment date.
3. The owner or operator of a facility subject to a compliance sched-
ule of this section shall certify to the Director within five days
after the deadline for each increment of progress whether the required
increment of progress has been met.
E. Determining Compliance
1. The owner or operator of a VOC source subject to this regulation
shall demonstrate compliance by:
a. Certifying that the appropriate control equipment is in place
and in use.
b. Providing the Director with certified analyses of all VOC in
place and in use. Analyses may be provided by the owner-
operator of the source, the manufacturer of the VOC, or an
independent laboratory acceptable to the Director.
c. Maintaining VOC purchasing, inventory, and consumption records
in such a manner that the Director can determine compliance.
d. Maintaining the appropriate control equipment in a manner
consistent with manufacturer's recommendations.
14
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e. Maintaining operating and maintenance records on the appro-
priate control equipment in such a manner that the Director
can determine compliance.
2. The Director may require that the owner or operator of a VOC source
subject to this regulation demonstrate compliance by conducting
emission tests in a manner consistent with U.S. EPA standards. All
tests shall be made by, or under the direction of, a person quali-
fied by training and/or experience in the field of air pollution
testing. The Director shall receive at least 30 days' advance
notice of such testing so that the Director and/or his authorized
representative(s) may witness the test.
A source emitting 550 pounds per day 365 days per year would be a 100-ton
per year source. The regulation would require VOC emission reduction to 55
pounds per day or 10 tons per year.
4.2 REGULATIONS IN OTHER AREAS
No BACT/LAER determinations, New Source Performance Standards, or regula-
tions applicable to this industry were found.
4.3 COMPLIANCE AND MONITORING TECHNIQUES
Emissions can be accurately estimated from solvent inventories and pur-
chasing records, and they can be verified by spot inspections. The plant may
also demonstrate compliance by submitting monthly material balances.
4.4 POTENTIAL PROBLEM AREAS
Control equipment has been sized and economic evaluations have been made
on the basis of 1980 data Witco submitted to the Pennsylvania Department of
Environmental Resources.2 The timeliness of this information would have to be
verified before any control equipment could be mandated.
If purchasing and inventory records indicate that VOC emissions are still
excessive after control equipment has been installed, it may be necessary for
the agency to examine production and operating schedules to determine whether
the control equipment is adequate to comply with regulations. This will en-
tail obtaining the following information:
1. Operating schedules for all equipment connected to the control
device(s).
15
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2. VOC quantities potentially routed to the control device(s).
3. Operating capacity and schedule of the control device(s).
If the question is still unresolved, VOC emission testing may be necessary.
16
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REFERENCES
1. Stanford Research Institute. 1982 Directory of Chemical Producers.
Chemical Information Services.
2. Witco Chemical Corporation. Emission Data for the 1980 Calendar Year.
Report submitted to the Pennsylvania Department of Environmental Re-
sources.
3. Neveril, R. B. Capital and Operating Costs of Selected Air Pollution
Control Systems. EPA-450/5-80-002, December 1978, pp. 5-65 to 5-72.
4. Air Pollution Control District, County of Los Angeles. Air Pollution
Engineering Manual. 2d Ed. John A. Danielson, ed. AP-40, May 1973.
pp. 183 to 189.
5. U.S. Department of Energy, Cost and Quality of Fuels for Electric Utility
Plants, September 1982. DOE/EIA-0075.
6. U.S. Environmental Protection Agency. Control Technique Guidelines for
the Control of Volatile Organic Emissions From Wood Furniture Coating.
(Draft) Office of Air and Waste Management, Office of Air Quality Plan-
ning and Standards, Research Triangle Park, North Carolina. April 1979.
7. Chemical Engineers' Handbook. 4th ed. Robert H. Perry, Cecil H. Chil-
ton, and Sidney D. Kirkpatrick, eds. McGraw-Hill Book Company, 1963.
8. Chemical Marketing Reporter. Price of Witco's Solvent. February 21,
1983.
9. U.S. Department of Energy. Monthly Energy Review. September 1982.
17
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APPENDIX A
OUTLINE OF CALCULATIONS FOR
INCINERATOR PERFORMANCE AND HEAT RECOVERY
A-l
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APPENDIX A
OUTLINE OF CALCULATIONS FOR
INCINERATOR PERFORMANCE AND HEAT RECOVERY
C6H14 + 1202 + 48N2 -> 6C02 + 7H20 + 2.502 + 48N2
Hexane = 393 pounds per hour in 26% excess air
Process nitrogen = 1425 scfm = 85,500 scfh = 6309 pounds
Carbon dioxide = 393 XJ X 44 = 1206 pounds
OD
Water = 393 XJ x 18 = 576 pounds
Oxygen = 393 x gg5 X 32 = 366 pounds
Nitrogen from air = ^ = 6142 pounds
ob
Total nitrogen = 6309 + 6142 = 12,451 pounds
To heat to 1500°F = (1206 x 377.6) + (576 x 717.6) + (366 x 350.8) +
(12,451 x 378.7) = 5,712,311 Btu
To heat to 2000°F = (1206 x 531.4) + (576 x 1003.1) + (366 x 84.5) +
(12,451 x 523.0) = 7,761,454 Btu
Fuel value of hexane = 20,771 Btu/lb
393 x 20,771 = 8.163 million Btu
2000°F is attainable
A-2
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