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                                           PB88 196027
 AIR POLLUTION  CONTROL  ALTERNATIVES
FOR SHALE OIL PRODUCTION  OPERATIONS
                            By:

                        H.  J. Taback
                       R. J. Goldstick

                         KVB, INC.
               Engineering and Research Division
                      Irvine, CA  92714

                  EPA Contract No. 68-03-3166
                       Project Officer

                       Edward R. Bates
          Air and Energy Engineering Research Laboratory
              U.S. Environmental  Protection Agency
               Research Triangle Park, NC  27711
                       Prepared For:

              U.S. Environmental Protection Agency
               Office of Research and Development
                   Washington, D.C.  20460
                       December 1987

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                                    NOTICE
        The information in this document has been funded wholly  or  in  part  by
the United States Environmental Protection Agency under Contract Number  EPA
No. 68-03-3166 to Metcalf & Eddy, Wakefield, MA.  It has been  sub-ject  to the
Agency's peer and administrative review, and it has been approved for
publication as an EPA document.  Mention of trade names or  commercial  products
does not constitute endorsement or recommendation for use.
                                       ii

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                                   FOREWORD

        When energy and material resources are extracted, processed,  converted
and used, the related pollution impacts on our environment and even on  our
health often require that new and increasingly more efficient pollution
control methods be used.  The EPA's Air and Energy Engineering Research
Laboratory (Research Triangle Park, NC) assists in developing and
demonstrating new and improved methodologies that will meet these needs both
efficiently and economically.

        This report is a compilation of air pollution control technology
specifically applicable to the various processes employed in the production of
shale oil, along with a forecast of air pollutant emission rates achievable
using that technology.  The results should assist developers and permit
writers in selecting controls and predicting emissions for any future oil
shale projects.
                                Frank Princiotta, Director
                                Air and Energy Engineering Research Laboratory
                                U.S. Environmental Protection Agency
                                Research Triangle Park, NC 27711
                                      iii

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                                   ABSTRACT

        The available air emission data and air pollution control technology
relevant to the production of shale oil are consolidated, evaluated and pre-
sented in a manner to be useful to project developers in preparing environ-
mental impact statements and permit applications under the Clean Air Act as
well as to their respective regulatory approval agencies.  The processes
covered include subsurface and surface mining; raw shale sizing and handling;
all of the various retorting schemes, both in—situ and above—ground; spent
shale combustion; spent shale disposal and product upgrading.  The air
pollution control technology covered includes most of the traditional
processes for nitrogen oxide (NO), sulfur compounds, particulate, volatile
organic compounds (VOC) and carbon monoxide (CO) control.  However, some
recently-developed processes and processes not discussed elsewhere in the oil
shale literature are included; such as catalytic mufflers for NOX, VOC and CO
control on surface and subsurface vehicles; a new wet scrubbing process
(caustic/charcoal/sodium hypochlorite solution) for organic sulfur compounds,
staged combustion for NO  control of high nitrogen fuels; spent shale
absorption for sulfur oxides; improved filter bag materials, moving bed
granular filters and dry Venturis for fine particulate control; and dry sor-
bent injection for sulfur oxide control.

        Data extracted from PSD permit applications from seven different shale
oil projects are analyzed and compared.  Data consistencies and inconsis-
tencies are noted for future reference.  Finally, five shale oil recovery
processes, considered to be the best of the state of the art, are analyzed at
three levels of emission control.  The baseline is comparable to that used in
the PSD permit applications.  The first improvement level represents the use
of existing proven technology used commonly in other industries.  The second
and greater improvement level represents the additional use of technology that
may still require some development before committing it to a full scale shale
oil production application.

        The interesting conclusion is made that if the second level of
improved control technology is applied, the overall emission levels in terms
of weight of emissions per unit of oil produced will be essentially the same
whether the oil is produced in either in—situ or above—ground retorts and
whether the retorts are either directly or indirectly heated.

        Based on this highest degree of control, the emissions that might be
expected from a shale oil production plant under the best conditions are
approximately:
                                        Kg/1000m3.0il  Produced
                    CO                            200
                    VOC                           100
                    NOX                           700
                    SOX                           200
                    TSP                           200
                                     iv

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                               TABLE OF CONTENTS

Section

    Foreword
    Abstract
    Figures
    Tables
    Acronyms and Abbreviations
    Conversion Factors

    1.0     EXECUTIVE SUMMARY
            1.1   Introduction
                  1.1.1   Background
                  1.1.2   Objective
                  1.1.3   Approach
            1.2   Overview
            1.3   Retort Process Review
                  1.3.1   Retort Gas
                  1.3.2   Sulfur Gases
                  1.3.3   Nitrogen Gases
                  1.3.4   Specific Process Review
            1.4   Air Pollution Control Technology Review
                  1.4.1   Dry Venturi
                  1.4.2   Fugitive Dust
                  1.4.3   Staged Combustion
                  1.4.4   Activated Carbon and  Hypochlorite
                  1.4.5   SO  Absorption on Spent Shale
                  1.4.6   Catalytic Mufflers
            1.5   Prevention of Significant Deterioration  (PSD)
                  Permit Applications
                  1.5.1   Total Facility Emissions
                  1.5.2   Individual Unit Operations
            1.6   Retort Process Evaluation
                  1.6.1   Shale Oil Recovery  Plant
                  1.6.2   Methodology
                  1.6.3   Mining, Solids Handling and Upgrading
                          Emissions
                  1.6.4   Retort Gas Emissions
                  1.6.5   Retort Gas Combustion and End-of-Pipe
                  1.6.6   Emissions from Retort Gas Combustion

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Section
    2.0     RETORT PROCESS REVIEW                                          2-1
            2.1   Background                                       ~        2-4
                  2.1.1   Chemistry                                        2-5
            2.2   Formation and Fate of Pollutants                        2-14
                  2.2.1   Criteria Pollutants (SOX, NOX)                  2-14
                  2.2.2   Trace Elements                                  2-25
            2.3   Retort Processes                                        2-27
                  2.3.1   Above-Ground Retorts                            2-31
                  2.3.2   In-situ Retorts                                 2-33
            2.4   Process Descriptions                                    2-35
                  2.4.1   Paraho Retort Process                           2-35
                  2.4.2   Hvtort Oil Shale Retorting                      2-37
                  2.4.3   T3 Oil Shale Retorting                          2-39
                  2.4.4   Lurgi Retorting Process                         2-40
                  2.4.5   Tosco II Oil Shale Retorting                    2-42
                  2.4.6   Union A, B, C and SGR                           2-46
                  2.4.7   Circular Grate Retort                           2-49
                  2.4.8   Fluidized-Bed (Chevron STB Oil Shale            2-51
                          Retorting)
                  2.4.9   Cascading-Bed Retort and Combustor              2-55
                  2.4.10  Occidental Vertical Modified In-situ            2-55
                          (VMIS)
                  2.4.11  Horizontal In-situ Retorting (Geokinetics)      2-59

    3.0     AIR POLLUTION CONTROL TECHNOLOGY REVIEW                        3-1
            3.1   Particulate Emission Controls                            3-6
                  3.1.1   Point Source Technologies                        3-6
                  3.1.2   Fugitive Dust Technologies                      3-50
            3.2   Nitrogen Oxides Control                                 3-96
                  3.2.1   Staged Combustion                               3-98
                  3.2.2   Exhaust Gas Treatment                          3-115
            3.3   Sulfur Compound Control                                3-134
                  3.3.1   Stretford Process (H2S)                        3-135
                  3.3.2   Lo-Cat Process (Reduced Sulfur                 3-143
                          Compounds)
                  3.3.3   Unisulf Process (H2S)                          3-151
                  3.3.4   Alkaline Scrubbing                             3-157
                  3.3.5   Activated Carbon and Hypochlorite              3-160
                          Process
                  3.3.6   Claus Process (H2S)                            3-179
                  3.3.7   Operating Requirements for Claus               3-188
                          Process
                  3.3.8   Flue Gas Desulfurization (Wet and Dry)         3-199
                  3.3.9   SOX Absorption in Spent Shale (ASSP)           3-217
            3.4   Engine Emissions of CO and HC                          3-223
                                        VI

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Section                                                                  Page

    4.0     PSD PERMIT APPLICATION ANALYSIS                                4-1
            4.1   Particulate Emissions                           ~      4-22
                  4.1.1   Mining - Below-Ground  (Primary                 4-23
                          Category 1)
                  4.1.2   Above-Ground Mining Emissions                  4-24
                          (Primary Category 2)
                  4.1.3   Retort Operations and  Retort                   4-25
                          Gas Combustion
                  4.1.4   Upgrading and Miscellaneous                    4-26
            4.2   Total Facility Gaseous Emissions                       4-27
            4.3   Emission Source Breakdown                      ,        4-31
                  4.3.1   Carbon Monoxide                                4-31
                  4.3.2   Hydrocarbons                                   4-34
                  4.3.3   Nitrogen Oxides                                4-38
                  4.3.4   Sulfur Oxides                                  4-42
            4.4   PSD Application Data Inconsistencies                   4-45
                  4.4.1   Carbon Monoxide                                4-45
                  4.4.2   Sulfur Oxides                                 .4-47
            4.5   Actual Permitted Emission Rates                        4-48

    5.0     PROCESS ANALYSIS                                               5-1
            5.1   Methodology                                              5-3
                  5.1.1   Mining                                           5-4
                  5.1.2   Retort                                           5-5
                  5.1.3   Gas Utilization and End-of-Pipe                5-11
            5.2   Results                                                5-14
                  5.2.1   Direct Combustion - Case #1                    5-14
                  5.2.2   Direct Combustion - Circular Grate             5-20
                          Case #2
                  5.2.3   Indirect Combustion -  Gas Recycle              5-23
                          Case #3
                  5.2.4   Indirect Combustion -  Solids Recycle           5-26
                          Fluidized Bed Spent Shale Combustor
                          Case #4
                  5.2.5   Modified In-situ with  Indirect Combustion      5-30
                          Gas Recycle Above-Ground Process
                          Case #5
                  5.2.6   Summary                                        5-33

    6.0     REFERENCES                                                     6-1

APPENDICES

    A.  Trace elements                                                     A—1
    B.  Codisposal emissions                                               B-l
    C.  Summary of PSD permit application emissions                        C-l
                                        vii

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                                 FIGURES

Number                                                                  Page

1-1      Total Facility Emissions Summary                               1-16
1-2      Carbon Monoxide Emissions                                      1-18
1-3      Hydrocarbon Emissions                                          1-18
1-4      Nitrogen Oxides Emissions                                      1-19
1-5      Sulfur Oxides Emissions                                        1-19
1-6      Particulate Emissions                                          1-20
1-7      Particulate Emissions from Retort Gas  Combustion               1-30
         for Five Cases
1-8      Nitrogen Oxide Emissions Summary for Five  Cases                1-30
1-9      Sulfur Oxide Emissions Summary for Five  Cases                  1-31
1-10     Nitrogen Oxide Emissions for Five Cases                        1-33
1-11     Particulate Emissions for Five Cases                           1-34
1-12     Sulfur Oxide Emissions for Five Cases                          1-34
2-1      In-situ Retort Processes - General                              2-2
2-2      Above-Ground Retort Processes - General                         2-3
2-3      Carbonate Reaction Scheme                                       2-9
2-4      Sulfur Reactions in Recycled Shale Process                     2-11
2-5      Nitrogen Reactions During Char Combustion                      2-13
2-6      Partitioning of Sulfur During Retorting                        2-18
2-7      Nitrogen Conversion Mechanisms                                 2-20
2-8      Nitrogen Distribution During Retorting                        2-22
2-9      Ammonia Evolved from Fischer Assay                             2-23
2-10     Schematics of Above-Ground Retorting Processes                 2-29
2-11     Schematics of Established In-Situ Retorting  Processes          2-30
2-12     Paraho Retort                                                  2-36
2-13     Simplified Schematic of the Hytort Process                     2-38
2-14     Schematic of the T3 Process                                    2-41
2-15     Lurgi-Ruhrgas Retorting Process                                2-43
2-16     Fines Type Tosco II Retort                                     2-44
2-17     Union Processes                                                2-47
2-18     Superior Direct-Heated Process                                 2-50
2-19     Schematic of a Fluidized-Bed Retort System                     2-52
2-20     Two-Stage Fluidized-Bed Retort                                 2-53
2-21     Concept for Cascading-Bed Retorting System                     2-56
2-22     Cascading-Bed Oil Shale Combustor                              2-57
2-23     Soak Tank Portion of Cascading-Bed Retort                      2-58
2-24     Occidental Vertical Modified In-situ Process                   2-60
2-25     An Example of a Geokinetics Horizontal In-situ Retort          2-61
3-1      Test Sheet                                                      3-2
3-2      Isometric View of a Two-Compartment Pulse-Jet                   3-8
         Fabric Filter
3-3      Predicted and Observed Result for Bench  Scale Fabric           3-11
         Filter Tests
3-4      Fabric Filter Field Test Results for Different                 3-12
         Bag Materials
3-5      Filter Pressure Drop for Reverse Air-Jet Operation             3-13
                                   Vlll

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Number

3-6      Costs for Pressure Flow, Intermittent Duty, Mechanical         3-16
         Shaker Standard Construction Baghouses
3-7      Costs for Continuous Duty, Pulse Jet Standard                  3-17
         Construction Baghouses
3-8      Costs for Continuous Duty, Pressure Flow, Mechanical           3-18
         Shaker Standard Construction Baghouses
3-9      Costs for Continuous Duty, Pressure Flow, Reverse              3-19
         Air Standard Construction Baghouses
3-10     Costs for Continuous Duty, Reverse Air Custom                  3-20
         Construction Baghouses
3-11     Standard Venturi Scrubber                        ,              3-24
3-12     Efficiency Performance of Venturi Scrubbers                    3-25
3-13     Cut Diameter for Gas-Atomized Spray Scrubbers                  3-29
3-14     Venturi Cut Diameter vs Liquid-to-Gas Ratio                    3-30
3-15     Schematic Arrangement of Wire/Plate and Wire/Tube              3-33
         Precipitators
3-16     Drop in Precipitation Rate Wg with Increasing                  3-38
         Fly Ash Resistivity for a Representative Group
         of Precipitators
3-17     Relation of W  to Coal Sulfur Content for Flue Gas             3-38
  ;       Temperatures In the Neighborhood of 420K as
         Determined by Several Investigators
3-18     Theoretical Precipitator Collection Efficiencies               3-39
         at Different Migration Velocities
3-19     Capital Investment for Collectors on 500 MW (Net)              3-45
         Power Plants
3-20     Purchase Price of Dry-Type Electrostatic Precipitators         3-46
3-21     Dry Venturi                                                    3-48
3-22     Sources of NOX Emissions Using Western Kentucky               3-106
         Coal and a Divergent Injector with 600ฐF Preheat
3-23     Low NOX Combustor for Sewage Sludge                           3-108
3-24     Emissions from Isothermal Combustion of Retorted              3-111
         Shale
3-25     Arrhenius Plot of Rate Data for Nitric Oxide                  3-112
         Reduction by Retorted Oil Shale
3-26     NO Reduction Variation with Temperature                       3-113
3-27     Exit NO and NH3 Concentrations for Laboratory                 3-116
         Test with Simulated Flue Gas
3-28     Effect of Temperature on NO Reductions with                   3-117
         Ammonia Injection
3-29     Effect of Initial NO Level with NH3 Injection                 3-119
3-30     Coal Firing with Ammonia Flue Gas Injection, 80 hp Boiler     3-121
3-31     Ammonium Bisulfate/sulfate Equilibrium with Field             3-124
         Operating Conditions Overplotted
3-32     Simplified Flow Diagram of the Stretford Pilot Plant          3-137
3-33     Stretford Capital Investment Cost                             3-142
3-34     Flow Scheme for Conventional Lo-Cat Unit                      3-145
3-35     Unisulf Process                                               3-153
3-36     Centrifuge Capacity for Separating Sulfur from                3-155
         Aqueous Feed Slurry


                                   ix

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Number                                                                  Page

3-37     Alkaline Scrubbing Process Schematic for H2S Removal          3-158
3-38     Removal Efficiency vs Selectivity for Alkaline                3-161
         Scrubber
3-39     Two-Stage Alkaline Scrubber                                   3-162
3-40     Tray Tower Scrubber with Isolated Liquid Inlets               3-163
3-41     Teller System Flow Sheet                                      3-164
3-42     Equilibrium H2S Concentration in Flue Gas                     3-167
3-43A    Schematic Diagram of One Version of PPRIC/BCRC                3-171
         Scrubbing Process Using a TESI  Cross-Flow  Scrubber
3-43B    Schematic Diagram of the PPRIC/BCRC Scrubbing Process         3-171
         in a Packed Counter-Current Scrubber
3-44     Kraft Recovery Boilers TRS Removal Data                       3-173
3-45     TRS Emissions Inlet vs Outlet Condition 2                     3-174
3-46     TRS Emissions Inlet vs outlet Condition 1                   -  3-175
3-47     Kraft Boiler with Direct Contact Evaporation                  3-177
3-48     Straight-Through Glaus Process                                3-182
3-49     Glaus Plant Installed Costs                                   3-189
3-50     Estimated Glaus Plant Capital Investment Cost                 3-190
3-51     Shell Glaus offgas Treating (SCOT) Process                   3-192
         Schematic Flow Diagram
3-52     Capital Investment Cost for Scot Units                        3-198
3-53     Typical Process Flow Diagram for Lime/Limestone               3-201
         Scrubbing
3-54     Schematic of a Coal-Fired Power Plant with Dry-               3-209
         Sodium Injection for SO^ Control
3-55     S02 Removal as a Function of Normalized Stoichiometric       3-212
         Ratio
3-56     Sodium Utilization as a Function of NSR and Particle          3-214
         Size
3-57     ASSP Process Flow Diagram                                     3-218
3-58     Effect of Flue Gas Oxygen on S02 and NOX Emissions            3-222
3-59     Effect of Flue Gas Oxygen on CO and Trace                     3-222
         Hydrocarbon Emissions
3-60     Catalyst Efficiency for Oxidation of CO vs                   3-227
         Exhaust Temperature, Engine 1-Various
         Speeds and Loads
3-61     Catalyst Efficiency for Oxidation of CO vs                   3-227
         Exhaust Temperature, Engine-2 Various Speeds and Loads
3-62     Effect of Load and Catalyst on  Exhaust Odor                  3-230
         Intensity                                         ,
5-1      Possible Processing Combinations                                5-2
5-2      Case #1 - Direct Heat                                          5-15
5-3      Case #2 - Circular Grate                                       5-22
5-4      Case #3 - Indirect Heat, Gas Recycle                           5-25
5-5      Case #3 - Solids Recycle                                       5-27
5-6      Case #3 - Modified In-situ                                     5-31
         (Indirect Heat Above-Ground)
5-7      Nitrogen Oxide Emissions from Retort Gas Combustion           5-35
5-8      Sulfur Oxide Emissions from Retort Gas Combustion             5-36
5-9      Particulate Emissions from Retort Gas Combustion              5-37

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Number                                                                 Page

5-10     Particulate Emission for Total Facility                       5-39
5-11     Nitrogen Oxide Emission for Total Facility             "       5-40
5-12     Sulfur Oxide Emissions for Total Facility                     5-41
                                   XI

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                                 TABLES

Number

1-1      Principal Air Emission Sources                                  1-4
1-2      Retort Gas Production Rates                                     1-7
1-3      Partitioning of Nitrogen in Retort                              1-9
1-4      Retort Processes Reviewed                                      1-11
1-5      Air Pollution Control Technologies                             1-12
1-6      PSD Permit Applications in Data Base                           1-15
1-7      Five Processes for Analysis                                    1-22
1-8      Design Parameters Used in Analysis                             1-24
2-1      Retort Gas Compositions (Solids Recycle)                        2-7
2-2      Chemical Analysis for Various Oil Shales                       2-14
2-3      Sulfur Gases from Three Raw Shales                             2-16
2-4      Distribution of Raw  Shale Sulfur in Products                   2-17
2-5      Nitrogen Concentration in Oil Shale Components  and            2-21
         other Fuels
2-6      Nitrogen Partitioning from PSD  Permit  Applications            2-24
2-7      Nitrogen-Containing  Species in  Retort  Off-gas                  2-25
2-8      Untreated Retort Gas Characteristics                           2-31
3-1      Characteristics of Selected Filter  Fabrics                      3-9
3-2      Approximate Guide to Estimate Gross Cloth Area                 3-21
3-3      Bag Prices                                                     3"22
3-4      Typical Pressure Drops for Venturi  Scrubbing                   3-27
         Systems
3-5      Typical Value of Design Variables  for  Commercial              3-35
         ESPs
3-6      Typical Average Migration Velocities                           3-41
         Encountered in Commercial ESP  Systems
3-7      Typical Application  Data  for Electrostatic                     3-42
         Precipitators
3-8      Commonly Encountered Precipitator  Problems                     3-43
3-9      Performance Characteristics  of  the  Dry Venturi-               3-51
         Baghouse System
3-10    Soil Movement Dust  Suppressants                               3-55
3-11    Summary of Results                                             3-58
3-12    Exposed Area  and  Storage  Pile  Dust  Suppressants               3-62
3-13    Test Plots Application Data                                    3-71
3-14    Weed Growth Quantification                                     3-73
3-15    Proper  Size Gradation  for Unpaved  Road Surface                 3-78
3-16    Improper  Size Gradation                                        3-78
3-17    Unpaved Road  Dust  Suppressants                                 3-81
3-18    Assumptions for  Cost-Effectiveness  Analysis                   3-88
3-19    Preliminary Cost-Effectiveness  Comparison to                  3-89
         Achieve  50  Percent  Control
3-20    Comparison  of Measured  Control Efficiencies                   3-92
3-21    Total  Capital  Investment  and Annual Revenue                  3-126
         Requirements  for Improved Thermal  DeNOx Applied
         to Coal-Fired  Boilers
                                    xii

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Number

3-22     Cost Effectiveness  for  Improved  Thermal  DeNO
         Applied  to  Coal-Fired Boilers
3-23     Total Capital  Investment  for Thermal  DeNOx
         and Selective  Catalytic Reduction for a
         Coal-Fired  500 MW Boiler
3-24     Cost Effectiveness  Comparison  of Improved                     3-129
         Thermal  DeNOx vs Kawasaki  Industries  SCR
         for a Coal-Fired 500 MW Boiler
3-25     SCR Costs                                                     3-133
3-26     Design Data for a Stretford Unit Treating                     3-140
         Rectisol Offgas at  El Paso Natural Gas Burnham
         Coal Gasification Facility
3-27     Typical  Compositions of Stretford Absorber                   3-140
         Offgas in Beavon Sulfur Removal  Plants
3-28     Operating Requirements  for the Stretford Process              3-143
3-29     Chemical Costs for  Lo-Cat                                     3-148
3-30     Capital  Costs for Lo-Cat  Plant                               3-150
3-31     Cost Basis for Lo-Cat                                         3-151
3-32     Commercial Nucleation Process  Applications                   3-178
3-33     Teller Recovery Boiler  System  Performance                     3-180
3-34     Sulfur Recovery Variation Relative to Acid                   3-185
         Gas Feed Composition and Number  of Catalytic
         Stages
3-35     Reported Glaus Plant Operating Data                          3-187
3-36     Operating Requirements  for the Glaus  Process                 3-188
3-37     Typical  Compositions of Gas Streams in Glaus                 3-195
         and Scot Units
3-38     Sulfur Concentration in Scot Offgas                          3-196
3-39     Sodium Reagent Materials                                      3-210
3-40     Costs of S02 Control for 90 Percent Removal                   3-216
3-41     Cost Comparison for ASSP                                      3-220
3-42     Catalytic Converters                                          3-224
3-43     Engines Tested                                                3-225
3-44     Fuel Properties                                               3-225
3-45     Emission Rates of CO and HC                                   3-228
3-46     Acceptable Maximum Emission Rates                             3-229
3-47     Exhaust Odor Intensity                                        3-231
3-48     Aldehyde Emissions                                            3-233
3-49     Sulfate Emissions                                             3-234
4-1      Sources and Controls for PSD Applications                       4-2
4-2      Controlled Particulate  Emissions                               4-23
4-3      Controlled Below-Ground Particulate Emissions                  4-23
4-4      Controlled Above-Ground Mining and  Material                    4-25
         Handling Particulate Emissions
4-5      Controlled Particulate  Emissions  from Retort Operation         4-25
4-6      Controlled Particulate  Emissions  from Upgrade  and              4-27
         Miscellaneous Above-Ground Operations
4-7      Total Facility Controlled Gaseous  Emissions  Summary            4-27
4-8      Increase in NOX Emissions from Fuel Nitrogen    •              4-29
4-9      Effect of Organic Sulfur in Retort  Gas on                      4-30
         Sulfur Oxide Emission                                    Continued


                                   xiii

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Number   ,                                                              Page

4-10     Controlled Carbon Monoxide Emissions                          4-31
4-11     Controlled Carbon Monoxide Emissions for                      4-32
         Below-Ground Mining
4-12     Controlled Carbon Monoxide Emissions from Retort and          4-33
         and Gas Combustion
4-13     Carbon Monoxide Emissions from Upgrading Operations           4-34
4-14     Controlled Hydrocarbon Emissions                              4-35
4-15     Controlled Hydrocarbon Emission from Below-Ground Mining      4-36
4-16     Controlled Hydrocarbon Emission from Retort and Gas           4-36
         Combustion
4-17     Controlled Hydrocarbon Emissions from Upgrading Operations    4-37
4-18     Controlled Nitrogen Oxide Emissions                           4-38
4-19     Controlled Nitrogen Oxide Emissions from                      4-39
         Below-Ground Mining and Material Handling
4-20     Controlled Nitrogen Oxide Emissions from Retort               4-40
         and Other Gas Combustion
4-21     Controlled Nitrogen Oxide Emissions from                      4-41
         Upgrading Operations
4-22     Controlled Sulfur Oxide Emissions                             4-42
4-23     Controlled Sulfur Oxide Emissions from                        4-43
         Below-Ground Mining
4-24     Controlled Sulfur Oxide Emissions from Retort and Other       4-44
         Gas Combustion
4-25     Controlled CO Emissions from White River and Syntana          4-45
4-26     Comparison of Permit Application and Actual                   4-49
         Permitted Emission Rates.                                        ,
5-1      Design Parameters                                               5-4
5-2      Controlled Emission Rates for Mining                            5-5
5-3      Retort Gas Production Rates                                     5-5
5-4      Effect of Organic Sulfur on Sulfur Emission                     5-7
5-5      Summary of Estimated SOx Emission Rates                         5-8
5-6      Estimated Emission of Nitrogen Oxide from                     5-10
         Combustion of Retort Gas
5-7      Controlled Particulate Emissions                              5-16
5-8      Controlled Sulfur Oxide Emissions from                        5-17
         Retort Gas Combustion
5-9      Controlled Nitrogen Oxide Emission                            5-18
5-10     Total Facility Controlled Emissions                           5-19
         Case 1 - Direct Combustion
5-11     Total Facility Controlled Emissions                           5-21
         Case 2 - Direct Combustion
5-12     Total Facility Controlled Emissions                           5-24
         Case 3 - Indirect Combustion
5-13     Total Facility Controlled Emissions                           5-28
         Case 4 - Indirect Combustion
5-14     Total Facility Emissions                                      5-32
         Case 5 - Modified In-situ
                                   xiv

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                      LIST OF ABBREVIATIONS AND ACRONYMS




ACGIH      American Conference of Government Industrial Hygienists.




APC        Air Pollution Control.



ASSP       Adsorption on Spent Shale Process - a SOX control.




BACT       Best Available Control Technology.



BAF SET    Baffled Settling - a dust suppression technique.




BCRC       British Columbia Research Council.




BERC       Bartlesville Energy Research Center.




COS        Carbonyl Sulfide.



DeNO       Exxon's N0__ control involving  ammonia injection.
    X                X



EDTA       Ethylene diamine tetra acetic  acid.




EPA        Environmental Protection Agency (U.S.)




EPRI       Electric Power Research Institute.



ESP        Electrostatic Precipitator




FBN        Fuel  Bound Nitrogen




FEL        Front end  loader.



FGD        Flue  Gas Desulfurization.




FGR        Flue  Gas Recirculation.




HC        Hydrocarbon.



KVB        Authors of this  report.



 LBL        Lawrence  Berkeley Laboratories.




 LLNL       Lawrence  Livermore National Laboratory




 MIS        Modified In-situ




 MW        Megawatts




 MeSH       Methyl mercaptan.



 NAAQS      National Ambient Air Quality Standards





                                      xv

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N0_        Nitrogen oxides - air pollutants.
  li.                      .         '                                           i

NSPS       New Source Performance Standards - EPA's allowable new source
           emissions.                                 .

NSR(l)     New Source Review - a Clean Air Act designation for the permitting
           requirements for an area not in compliance with the NAAQS.

NSR(2)     Normalized Stoichiometric Ratio.

NTU        Number of Transfer Units - a mass transfer concept.

PCTM       Pollution Control Technical Manual.

PM         Particulate matter - an air pollutant.

ppmV       Parts per million on a volumetric basis.

PPRC       Pulp & Paper Research Institute of Canada.

PSD        Prevention of Significant Deterioration - a Clean Air Act
           designation for the permitting requirements for an area in
           compliance with the NAAQS.

SCA        Specific collection area.

SCOT       Shell Glaus Offgas Treating

SCR        Selected Catalytic Reduction - a NOX reduction technique using
           ammonia and a catalyst.

SGR        Steam - Gas Recirculation - a retorting process.

SNG        Synthetic Natural Gas.

SOX        Sulfur oxides - air pollutants.

STB        Stage Turbulent Bed - a type of fluid bed combustor.

TESI       Teller Environmental Services, Inc.

TLV        Threshold Limit Value.

TRS        Total Reduced Sulfur

TRW        TRW, Incorporated

UEF        Uncontrolled Emission Factor.

VMIS       Vertical modified in-situ - a retorting process.

VOC        Volatile Organic Compound.
                                     xvi

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                                  SECTION 1.0
                               EXECUTIVE SUMMARY

 1.1     INTRODUCTION
        For over  ten years,  the  EPA has  supported research on the control of
 air pollutants from shale  oil  production.   This report is a culmination of
 that effort.
 1.1.1   Background
        Production of  oil  from oil  shale has  been on the verge of becoming a
 commercial reality a number  of times in  the last  thirty years.  However, the
 barrier of economic uncertainty,  related primarily to the availability and
 price of conventional  crude  oil,  has resulted in  limited commercial
 development efforts.   The  recent  (1986)  collapse  in the price of crude oil
 (from $28/bbl to  $12/bbl)  illustrates the volatile nature of the crude oil
 market and further enhances  the  uncertainty and risk associated with the major
 capital investment required  to construct and  operate a shale oil recovery
 plant.
        The economics  of shale oil  recovery are complicated further by the
 environmental concern  associated  with oil shale recovery.  The mining and
 processing of oil shale to produce  a refined  shale oil product can produce a.
 variety of air pollutants, many  of  which may  have adverse environmental
 impacts if not properly managed.
        Under the Clean Air  Act  (PL 95-95)  shale  oil project developers must:
 (a) employ Best Available Control Technology  (BACT),  (b) insure that National
Ambient Air Quality Standards  (NAAQS)  are not  violated,  (c) avoid violating
 the prevention of significant deterioration (PSD) ambient air quality
 increments, (d) refrain from significant degradation of visibility in
                                 X1*3*"'    •'   " '"":  ..... „-  - ,—""'
mandatory Class I areas and  (e) obtain up to  one  year of baseline data before
 applying for a PSD permit to construct and  operate.   These requirements can
add substantial costs  and complexity to  the design and construction of an oil
 shale recovery plant.
                                      1-1

-------
        Currently, the most significant aspect of the Clean Air Act to oil
shale development is the PSD program.  The energy rich oil shale region of
Colorado, Utah and Wyoming enjoys some of the cleanest air in the United
States.  The maximum size of an oil shale project in Colorado may be limited
by the emissions of sulfur dioxide, nitrogen dioxide and particulates
resulting from that specific project and possibly also by visibility
impacts.  The Air and Energy Engineering Research Laboratory, which is part of
EPA's Office of Research and Development, has conducted an on-going research
program to provide technical support to EPA's Program Offices, EPA Regional
Offices, other federal and state agencies, and industry.  The major efforts in
this research program have been directed towards quantifying the air
emissions, waste water discharge and solid wastes associated with the various
types of recovery facilities.
        This program has consisted of a combination of laboratory and field
tests to determine actual waste stream quantities and compositions from
retorting processes and engineering studies to evaluate various pollution
control techniques.
        The EPA's engineering study series titled Pollution Control Technical
Manuals (PCTM) in particular provides a comprehensive analysis of the air,
water and solid emissions from specific shale oil recovery plants.  (These
PCTMs are cited later in the report.)
1.1.2   Objective
        The objective of this report is to consolidate available air emissions
data and air pollution control (APC) technology relevant to oil shale
processing operations for use by proponents (i.e., PSD, or NSR applicants) and
their respective approval agency.  Five basic questions are answered in this
report:
           What shale oil production processes are available and how do
           they function?
        .  What are the specific sources of air pollutants from those
           processes?
           What APC technology options are applicable to each source;
           how do they function; what removal efficiency can be

                                      1-2

-------
           expected; what do  they  cost;  and what  rationale  should be
           used to select the most effective  one?
         .  What mass emissions per unit  of throughput  (e.g.,  kg/1000 m^
           of oil) will be released  by the various  processes?
           What answers to the above questions  have been  proposed in
           actual PSD permit  applications?
1.1.3   Approach
        In preparing this report,  the authors have  reviewed and  summarized the
pertinent literature.  A comprehensive bibliography is  included  as  Section 6
and key design manuals (such  as the  EPA's PCTMs)  are extensively referenced
and summarized rather than completely reproduced.   Interviews with  key
industry and government agency personnel were held  to gain  their latest
experiences, impressions of process  performance,  and their  intentions with
regard to future developments.  An evaluation was then  made of the  emission
factors for mining, retorting, and upgrading processes.   A  matrix is presented
summarizing APC options for each unit process of  certain  selected shale oil
production schemes.  Each of the standard APC techniques  identified in  the
matrix is synopsized while the newer and more innovative  APC  techniques are
discussed more extensively.  Performance and cost data  are  presented along
with all known limitations.
        Finally, as an example of specific case studies,  the  APC alternative
for five shale oil production processes are presented along with their
associated mass emission rates:  (1) direct heated  (e.g.  Paraho); (2) circular
grate (e.g. Superior, Allis-Chalmers, Dravo); (3) indirect  heated (e.g.  Union
B); (4) recycled solids (e.g. Chevron, Lurgi); and  (5) modified  in-situ (e.g.,
Occidental).

1.2     OVERVIEW
        A shale oil recovery facility consists of many varied unit
operations.  The raw shale is mined and then retorted to  produce  gas, oil  and
spent shale.  The spent shale is conveyed to a solid waste  disposal  site.   The
retort gas may be treated to remove nitrogen and sulfur-gases and then  burned
to produce steam and electricity.  The recovered oil is treated  to  remove
                                      1-3

-------
sulfur and nitrogen and then stored.  The primary  sources  for  air  emissions
from these processes are shown in Table  1-1.

                  TABLE 1-1.  PRINCIPAL  AIR EMISSION  SOURCES
Process
Principal
Emissions*
Source
Mining
Retort Gas
  Combustion
Spent Shale Disposal
Upgrade
PM
                             CO
                             NO,,
PM, NOX, SOX
PM
HC
Drilling, blasting,
materials handling,
crushing, vehicles
blasting, vehicles
Vehicles
Retort gas
Materials handling,
erosion
Storage
*PM  = particulate matter
 CO  = carbon monoxide
 NOX = nitrogen oxides
 SOX = sulfur oxides
 HC  = hydrocarbon (volatile organic compounds)
        The potential (i.e., uncontrolled) emissions from retort gas
combustion are determined by the composition of the raw shale, the type of
retort used to separate the oil and gas from the raw shale, and the retort gas
combustion process.  The retorting process determines the quantity of retort
gas produced, its heating value, the concentration of sulfur and nitrogen
gases.  These factors (retort gas quantity, heating value, and concentration
of sulfur and nitrogen gases) determine the applicability and effectiveness of
the various air pollution control (APC) schemes that might be used.
        The chemistry of the retort process, source and type of sulfur and
nitrogen gases, a generic description of the types of retort processes
developed and a discussion of eleven specific processes being considered for
full scale application are described in Section 2.0.
                                      1-4

-------
        Emissions from mining,  spent  shale  disposal  and  upgrading operations
are similar to other mining and oil refining  operations.  A technology review
of all air pollution controls that are  applicable  to an  oil shale recovery
facility is presented in Section  3.0.   Included  are  process descriptions,
application experience or development status,  and  economics.
        The developers who have proposed  full-scale,  oil  shale  recovery
facilities have submitted Prevention  of Significant  Deterioration (PSD) Permit
Applications.  These PSD applications represent  a  significant data base of
emission sources, controls and controlled air  emissions.  Information  from
these sources was computerized and sorted to  determine typical  emissions from
each specific unit operation in a complete  shale oil  recovery facility. The
results from this analysis are presented  in Section  4.0.
        In Section 5.0 the retort process information from  Section 2.0,  the
air pollution control technology information in  Section  3.0 and the unit
operation emission data from Section  4.0  are used  to  evaluate five types of
retort processes.  For each process three scenarios are considered.  The first
scenario (base case) uses air pollution controls proposed in PSD permit
applications.  The reader should note that  the PSD permit finally issued often
called for more stringent controls than proposed in  the original permit
application.  The second scenario (Alternate  1)  uses  either additional,
improved or more appropriate control technology.  The third scenario
(Alternate 2) uses a further improvement  in control technology  where
available.  The major conclusion from these five analyses is that, although
the base case emissions can vary for the  individual process configurations by
as much as one order of magnitude, the  application of appropriate  controls
essentially results in air emissions being  similar for each of  the five
processes considered.

1.3     RETORT PROCESS REVIEW
        The type of retorting process determines the  subsequent  emissions of
sulfur (SOX) and nitrogen (NOX) from the  combustion of the  retort  gas.   The
following is a summary of the findings  of this study.
                                      1-5

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         Oil  shale contains organic material, (kerogen and bitumen) associated
 with various minerals including sulfur [(organic and FeS2) and nitrogen
 [organic and inorganic (in the form of buddingtonite — an ammonium alumina
 silcate)].   To  recover the organic content in the form of oil and gas, the raw
 shale is heated to 500 C to 800 C, decomposing the high molecular weight
 organics to  oil and gas.  This may leave a "carbonaceous residue (char) on the
 retorted (spent)  shale.
         Two  types of processes have been developed — above-ground and
 in-situ.  The above-ground process requires  mining, crushing, screening and
 transfer of  the raw shale to the retort and  then removal and disposal of the
 spent  shale.  The true in-situ process provides heat to the oil shale directly
 by feeding oxygen to burn part of the organic content (the carbonaceous
 char).   The  hot combustion.gases heat the remaining shale bed to decompose the
 kerogen  and  bitumens.   The modified in-situ  process (MIS) is a hybrid of the
 above-ground and  in-situ processes.   Approximately 25 percent of the  shale is
 mined  and retorted  above-ground.   The remaining shale is rubblized and
 retorted in  place.
         In the  above-ground  process,  heat can be provided to the retort either
 directly or  indirectly.   The direct-heated retort is  similar to an in-situ
 retort in that  the  heat  is provided  by feeding air (oxygen)  to combust the
 carbonaceous char.   The  resulting hot  combustion gases  flow through the raw
 shale, heating  it to  the  retorting temperature.
         In the  indirectly  heated  process,.heat  is provided  to the  retort  by
heating either  a gas  or  a  solid which  is  recycled to  the retort.   Since no
combustion takes place within  the  retort,  the  retort  gas  is  not  diluted by
combustion air  and,  consequently,  lower volumes  of  high  Btu  content gas are
produced.
1.3.1   Retort Gas
        The emissions from the combustion  of the  retort  gas  are  determined by
the:
           volume and heating value of the retort gas
           presence of sulfur in the gas
                                      1-6

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         .   presence  of  nitrogen as ammonia or organic nitrogen compounds

         The retort gas  flow rates  for the three basic types of retorts are
 shown  in Table  1-2.
                    TABLE 1-2.  RETORT GAS PRODUCTION RATES
                         (Taback, H. J., et al., 1986)
Type Gas Produced
Retort m3 of gas/m3 of Oil
In-situ 7000
Direct combustion 1800
Indirect combustion 180
Heating Value
gram-calories/liter
9000
9000
90,000
        The in-situ process produces  the highest  retort  gas  flow rate  due to
the combined effect of the higher retort temperatures  converting more  of  the
kerogen to gas and the higher dilution gas  flow required to  provide  adequate
oxygen to burn the shale.  The direct combustion  retort  has  similar  conditions
(i.e. high temperatures and requirement for adequate oxygen  for  combustion)
but to a lesser degree than the in-situ retort  and, consequently, has  lower
retort gas flow rates.  The indirect  combustion process  has  the  lowest retort
gas flow rate due to the lower retort temperatures and low gas flow  rate  with
no reduction from combustion air.
        The heating value of the retort gas is  determined by the amount of
combustion air.  In-situ and direct combustion  retorts produce low heating
value gas at 9000 gram-calories/liter (100 Btu/scf) and  the  indirect
combustion retort produces high heating value gas at 90,000  gram-
calories/liter (1000 Btu/scf).
        The retort gas flow and heating value determine  the  net  exhaust gas
flow after combustion.  Since air pollution control performance  is often
determined by a pollutant exit concentration (ppm or g/m3),  high gas flow
rates can result in comparatively higher pollutant emissions.
                                      1-7

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 1.3.2   Sulfur Gases
        During retorting,  sulfur  in  the  raw shale  is  partitioned to the spent
shale  (60 percent), oil  (10 percent)  and retort  gas  (30  percent).   The
significant variations in  raw  shale  sulfur  content,  percentage  of  sulfur
partitioned to the gas phase and  the  chemical  structure  of  these sulfur gases
result in the sulfur gas clean-up strategy  being quite difficult.
        Sulfur emissions can be reduced  either by  removing  the  sulfur  prior  to
combustion or by adding a  flue gas desulfurization process  after combustion.
Because the combustion process reduces the  pollutant  concentrations and
increases the gas flow rate, the  more cost-effective  technique  often is sulfur
removal prior to combustion.
        The form of the sulfur in the gas is extremely important when
considering sulfur removal processes.  Sulfur  recovery processes that  have
been considered for cleaning the  retort  gas prior  to  combustion are not
effective in removing the organic sulfur compounds, which can amount to as
much as 16 percent of the total sulfur in the  retort  gas.   Consequently,  the
effectiveness of these clean-up processes is dependent on the amount of
organic sulfur relative to H2S.   Even high  efficiencies  of  H2S  removal (99%)
may not be sufficient to meet the Colorado  standard on sulfur emissions below
850 kg/1000 m3 of oil (0.3 Ib/bbl).
        To avoid the costly alternative  of  adding  an  "end of pipe"  flue gas
desulfurization, two alternatives can be considered.  The first, the activated
carbon and hypochlorite H2S removal process, is  an improvement  on the  H2S
scrubbing process, because it also removes  organic sulfur species.  Therefore,
this process is effective for removal of the sulfur gases prior  to  combustion,
and eliminates the need for more expensive post-combustion  control.  The
activated-carbon and hypochlorite process can  remove  99+% of H2S and 90-98+%
of the organic sulfur gases.  This results in  a net sulfur  removal  efficiency
of 99% and a sulfur emissions (SOX) of 500 kg/1000 m3 oil (0.17  Ib/bbl) even
when the organic sulfur gases are 15% of the total sulfur.
        The second alternative to the use of post-combustion SO  control is
                                                               x
the indirect combustion-solids recycle retort process, which limits sulfur gas
                                      1-8

-------
emissions  by  the  chemistry  of  the  retort  and combustion process.   The sulfur
contained  in  the  retort  gases  from the  recycle solids process represent only
one percent of  the  total sulfur  content in the feed.   [The remaining sulfur is
partitioned to  the  oil (10%) and the  spent shale  (89%)].  Therefore, the
amount of  organic sulfur is minimal,  and  the H2S  removal processes alone are
sufficient to reduce  the sulfur  emissions below the  regulatory limit.
1.3.3   Nitrogen  Gases
        The removal of nitrogen  gases also is difficult to predict due to the
degree of variability in nitrogen  content in shale,  partitioning  between gasi,
oil and spent shale and  chemical form of  the gaseous  nitrogen species.
        Using the data reported  in the  PSD permit applications and the EPA's
Pollution Control Technical Manuals,  the  partitioning of nitrogen was
estimated as shown in Table 1-3.
              TABLE 1-3.  PARTITIONING OF NITROGEN  IN  RETORT
                         (Taback, H.J., et al.,  1986)
Process
In-situ (MIS)
Solids Recycle
Direct Combus'n
% (
Spซ

(Lurgi)
(Chevron)
(Paraho)
Df Raw Sh
int Shale
21
5
33
ale Nitrogen
Oil
25
55
37
in Product
Retort Gas
54
10*
30
        * remaining nitrogen content in the spent shale after retorting
          is burned in the lift pipe or fluidized combustor and exits
          with the flue gas.

        The nitrogen content of the retort gas consists primarily of ammonia
with smaller amounts of other nitrogen compounds.  In an investigation of
nitrogen-containing species from an in-situ and above-ground retort process,
hydrogen cyanide, various nitriles, pyridine, methyl and diethyl aniline and
other nitrogen gas species were identified.  The organic nitrogen content of
the retort gas was found to be as much as 1 - 2% of the"ammonia content.
                                      1-9

-------
         The  presence  of  organic nitrogen species presents the same problem for
 limiting fuel  related NOX emissions  as that described above for the SO
 emissions; namely  that the removal processes generally considered are not
 effective in reducing the organic nitrogen content of the retort gas.
         The  primary nitrogen  removal technique considered is removal of
 ammonia  from the retort  gas by  a water wash absorption tower followed by an
 ammonia  recovery stripper.  The outlet ammonia concentration is determined by
 the effectiveness  of  the ammonia absorber.   At atmospheric pressure, the
 equilibrium  exit partial pressure for  ammonia at 50 C is  0.5 mm Hg.
         The  nitrogen  content  of the  treated retort gas and the  subsequent NO
                                                                             X
 emissions from combustion of  the retort gas is determined by:
           the exit gas  ammonia concentration
           the amount  of retort gas  produced by the retort
           the amount  of nitrogen partitioned to the retort  gas
           the percentage  of  nitrogen  present as organic  nitrogen
           compounds
         The  processes  that use  the combustion of high-nitrogen-content  spent:
 shale for energy recovery  can produce  high  NOX emissions  if  proper  staging of
 the combustion is  not  used.  The PSD permit applications  NOX emissions  were
 based on a high estimate of 15% for  the  conversion of  the  nitrogen  in the
 spent shale  to NOX in  the  combustor.   This  level  of conversion  also was
 determined by Lawrence Berkeley Laboratory  investigators who did  not attempt
 to stage the combustion.
        The principle  of NO reduction  in a  staged  combustor  can be  applied to
reduce these excessive NOX emissions to approximately  3% nitrogen conversion.
to NOX.
1.3.4   Specific Process Review
        A description of the retort processes listed in Table 1-4 also is
provided in Section 2.0.
                                      1-10

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                     TABLE 1-4.  RETORT PROCESSES REVIEWED
Developer/
Process Name
Paraho
Hytort
T3
Lurgi
Tosco II
Union A
Union B
Union SGR
Union C
Superior,
Dravo, Allis-
Chalmers
Chevron
Lawrence
Livermore
Modified In-
Situ
Flow Pattern
Counter-current ,
gas up, solids
down
Counter-current ,
gas up, solids
down
Batch
Solids recycle
mixer
Solids mixer
Counter-current
gas down, solids
up
Travelling grate,
cross-flow
Fluidized bed,
recycle solids
Cascading bed,
Below-ground ,
semi -batch
Heat
Direct
Indirect
Direct
Indirect
Indirect
Direct/
Indirect
Indirect
Indirect
Direct/
indirect
Indirect
Indirect
Direct
Fines
No
No
No
Yes
Yes
No
No
Yes
Yes
No
Yes
No
NA
Spent
Shale
Comb.
Partial
No
Yes
Yes
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Comment

Hydrogenation
Two vessels

Ceramic balls
provide heat




In-situ
  cross-flow
above-ground
  any of above

Semi-batch
                                      Direct
NA     Yes
                                      1-11

-------
 1.4
AIR POLLUTION CONTROL TECHNOLOGY REVIEW
         Descriptions of the air pollution control technologies that can be
 applied to oil  shale facilities are provided in Section 3.0.  The technologies
 presented  are listed in Table  1-5.   The technologies indicated by an asterisk
 have  been  recently developed and have potential application for oil shale
 processing.  For  these  technologies,  the descriptions are extensive, providing
 as  much design  information as  available.  The remaining technologies have been
 previously presented extensively in the oil shale literature,  and the
 descriptions are  meant  more as an overview than a detailed analysis.
                TABLE  1-5.  AIR  POLLUTION CONTROL TECHNOLOGIES
        Pollutant

        Particulate
        (Point Sources)
        (Fugitive Sources)
        Nitrogen Oxides
        Sulfur Oxides
        CO and HC
                                Control Technology

                                Baghouse
                                Venturi scrubber
                                Electrostatic precipitator
                             *  Dry Venturi

                             *  Surfactants
                             *  Liners
                             *  Wind screens
                             *  Chemicals
                             *  Water spray

                                Staged combustion
                                Ammonia injection
                                Selective catalytic reduction

                                Stretford
                                Lo-Cat
                                Unisulf
                                Alkaline scrubber
                                Activated carbon and hypochlorite
                                Glaus
                                Scot (Shell-Glaus Offgas Treating)
                                Flue Gas desulfurization (wet & dry)
                                SOX Absorption  on spent  shale

                                Catalytic mufflers
*
*
*Indicates systems given greater emphasis in this report because they are not
 covered in other shale oil documents.
                                      1-12

-------
1.4.1   Dry Venturi
        The dry venturi scrubber is similar to a wet venturi  scrubber  except
that the dry venturi is based on the principle of providing the  targets
necessary for sub-micron particle removal as a dry  solid  particle  rather  than
as a liquid droplet.  In a standard wet venturi, particles are captured by
inertial impact; the liquid targets are created within  the venturi by
transferring velocity energy into shearing action.
        The capture of the particles in the dry venturi is only  the first step
in the removal processes.  The particles still have to be removed  from the gas
stream.  In a completely dry process, i.e., no downstream processing after the
venturi, a solids capture device (baghouse or ESP)  is required to  remove  the
solid particles [captured particulate and targets]  from the gas  stream.
1.4.2   Fugitive Dust
        Oil shale recovery that uses above-ground retorting requires extensive
mining and spent shale disposal.  These mining and  disposal operations require
storage piles for raw shale feed.  They also include soil removal  and  storage,
spent shale hauling, and disposal sites for spent shale and raw  shale  fines.
These processes are standard mining operations and  the fugitive  dust emissions
and control techniques have been defined in detail.  To provide  the reader
with access to this information, it is presented in Section 3.1.2.
1.4.3   Staged Combustion
        The high nitrogen content of the retort gas and the spent  shale result
in high NOX emissions when either is burned.  Staged combustion  is  the control
technology that converts the fuel nitrogen to N2 rather than  NO  and maintains
a flame temperature low enough to prevent the reaction of the oxygen and
nitrogen in combustion air.  Staging the combustion (fuel-rich zones followed
by fuel-lean zones) can eliminate the need for end-of-pipe controls and
essentially requires a comprehensive design and prototype testing  program to
determine optimum operating conditions.  This control technology is discussed
in Section 3.2.1.
                                      1-13

-------
Io4.4   Activated Carbon and Hypochlorite
        As discussed above, the presence of organic sulfur compounds  decreases
the effectiveness of sulfur removal processes to the point where  additional
end-of-pipe controls (flue gas desulfurization) is required.   In  processes
like Stretford, Lo-Cat, etc., the I^S is scrubbed but the reduced organic
sulfur compounds are not.  The activated-carbon and hypochlorite  process
removes the organic sulfur species as well as the ^S, which eliminates the
need for further controls.  These systems have been installed  in  the  pulp and
paper industry on black liquor recovery boilers, but there is  no  operating
experience on oil shale retort gas.  A description including process
performance is presented in Section 3.3.5.
1.4.5   SOV Absorption on Spent Shale
          2t
        The energy content of the carbonaceous residue on the  spent shale
(char) represents approximately four percent of the total recoverable energy,
and most developers are considering recovery of this energy by combustion.   In
addition, the presence of carbonates in the spent shale results in the
absorption of any S02 present on the spent shale.  Consequently,  the  retort
gas and the spent shale can be burned together in a fluidized  or  cascading bed
combustor with minimal SOX emissions (10-20 ppm exit concentration).  This
process is discussed in Section 3.3.9.
1.4.6   Catalytic Mufflers
        A significant source of carbon monoxide (CO) and hydrocarbon  (HC)
emissions from a complete facility are the vehicle and engine  emissions
associated with below-ground mining and above-ground transportation,  grading,
hauling, etc.  Catalytic converters have been developed to reduce these CO and
HC emissions by as much as 90 percent.  This catalytic conversion process is
discussed in Section 3.4.

1.5     PREVENTION OF SIGNIFICANT DETERIORATION (PSD) PERMIT  APPLICATIONS
        Seven developers have submitted PSD Permit Applications to state
agencies in Utah and Colorado with extensive information on emission  sources,
controls and permitted emission rates.  To evaluate controlled emission rates,
                                      1-14

-------
particularly from operations other than retort gas combustion, this PSD
information was computerized and sorted to determine average emissions and
relative percentages of emissions for each unit process.  The seven PSD

permits analyzed are listed in Table 1-6.
                 TABLE 1-6.  PSD PERMIT APPLICATIONS IN DATA BASE
Project
Cathedral
Bluffs
Location
Rio Blanco County,
CO
bbl/
day
12,000
Oil
Product .
m3/Day
1,900
Retort Process
Modified in-situ with
Union above-ground
Clear Creek
Grand Valley, CO
Utah Cottonwood  Green River Basin
  Wash           Basin, UT
Paraho - Ute     Uinta Basin, UT

Syntana          Uinta County, UT
100,000  15,900



31,500    5,000



42,000    6,700

57,200    9,100
Union Facility   Parachute Creek, CO   10,000     1,590
 Phase I-Union B
White River
 Project
Vernal, UT
106,000  16,900
retort

Chevron - fluidized
bed with solids re-
cycle

T3 retort with fluid-
dized bed combustion
of retort gas & fines

Paraho/direct heated

Superior - retort
indirect heat with
Tosco II retort for
fines

Indirect combustion
gas recycle

Superior-direct heated
Union B-indirect
heated
Tosco II-fines retort
1.5.1   Total Facility Emissions

        The total facility emission for the five criteria pollutants  are  shown
in Figure 1-1.   There is wide variation in these emiss-ion rates directly
dependent on the type of retort process used.
                                       1-15

-------
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              1-16

-------
 1.5.2    Individual  Unit  Operations
         The  data provided in the  PSD permit applications were evaluated to
 determine  typical emission rates  for the various unit operations.  The
 emission rates  from individual  sources in the various facilities for the
 criteria pollutants are  shown in  Figures 1-2 through 1-6.  For this analysis,
 all emissions associated with combustion of the retort gas (i.e. upgrade
 heater,  retort  heater) are considered as part of the emissions from the retort
 operation.   In  actual practice, the  retort gas may not be burned on site
 depending  on the price and availability of alternate fuels (oil or coal) or
 the use  of a high Btu retort  gas  as  a source of hydrogen for the upgrading
 process.
         The  carbon  monoxide emission sources (Figure 1-2) are blasting, below
 ground vehicles,  above-ground vehicles,  and the combustion of retort gas in
 the retort and  upgrading process.  The hydrocarbon emission sources
 (Figure  1-3) are primarily mining  vehicles,  oil storage  and fugitive emissions
 in the upgrading and retort gas combustion.   Nitrogen oxide emission sources
 (Figure  1-4) are primarily from retort  gas combustion and mining vehicles.
 The only significant sulfur oxide  emissions source (Figure 1-5) is combustion
 of the retort gas,  with  mining and upgrading adding a relatively small  amount.
        The  reader  should  note that  nitrogen and sulfur  oxide emission
 estimates provided  by the  developers  in  their  PSD permit  applications were
 based on assumptions with  regard to  the  percentage of organic sulfur and
 nitrogen gases.   Consequently, the actual  emission rates  could be  much  higher
 than the estimates  presented  in the  PSD  applications.
        The particulate  emission sources  (Figure  1-6)  are  those associated
with below-ground mining (drilling,  blasting,  conveying,  crushing,  engines),
above-ground mining (surface  soils removal,  second and third  degree  crushing,
 conveying,  storage  and spent  shale disposal),  retort  gas  combustion  (steam
generator,  retort heater and upgrade heaters)  and  above ground  vehicles  and
                                         fe        '      -            .
 fugitive emissions  from  truck traffic.
                                      1-17

-------
      BLASTING
 MINING
VEHICLES
 RETORT
PROCESS
UPGRADE
SURFACE
VEHICLES
   Figure 1-2.  Carbon monoxide emissions  (Taback, H.J.,  et al.,  1986)
100
    MINING  RETORT  RETORT    QAS  UPGRADE FUGmvpsTORAOF
   VEHICLES  HEAT  (TOSCO) COMBUST* BEATERS FUGITIVE STORAGE

                              PROCESS
   Figure 1-3.  Hydrocarbon emissions  (Taback, H.J., et al., 1986).
                              1-18

-------
 600
      BLASTING
 MINING  '    GAS   "  RETORT
VEHICLES  COMBUST'N   HEATER

             PROCESS
                                               UPGRADE '  SURFACE
                                               HEATERS   VEHICLES
      Figure 1-4.  Nitrogen oxides emissions (Taback, H.J., et al. , 1986)
250 T
  0
    MINING VEHICLES   RETORT GAS ^RETORT HEATER1   UPGRADING
                               PROCESS


     Figure 1-5.  Sulfur oxides emissions  (Taback, H.J., et  al., 1986).

                             1-19

-------
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                PROCESS
• drilling
• blasting
El conveying (mine)
EH crushing
D engines
CD surface soils
@ 2nd & 3rd crush
^ conveying (retort)
El feed  storage
@ fines storage
E3 spent shale
0 steam generator
H retort heater
E2 upgrade heater
Figure 1-6.   Particulate eiru'.ssions  (Taback, K.J. , et al. ,  1986)
                           1-20

-------
1.6     RETORT PROCESS EVALUATION
        Development of oil shale production processes have  led  to  a variety  of
retort designs.  The total facility emissions as reported in  the PSD permit
applications for seven potential shale oil recovery plants  were shown  in
Figure 1-1.  The degree of variation in total facility emissions is
considerable with complicating tradeoffs.  For example,  the Clear  Creek
facility with a Chevron solids recycle retort has very high NOV and CO
                                                              • *>
emissions.  Conversely, the Union facility with a gas recycle retort has much
lower CO and NO  emissions but higher SO,, emissions.
               •*ป                        X
        The purpose of the analysis in Section 5.0 is to evaluate  these
various processing schemes and determine the effect of improved air pollution
controls.  The information developed indicates that, with the proper selection
of air pollution control techniques, the air emissions for  each of these-
processes can be held to essentially equivalent values.             •
1.6.1   Shale Oil Rcovery Plant
        A shale oil recovery plant is quite complex, involving many varied
operations.  The unit operations required to recover the oil from  the  shale
include:
     - mining
          - below-ground
          - above-ground
     - retorting
     - product recovery
     - removal of nitrogen (ammonia and organic nitrogen gases) from the
             retort gas
     - removal of sulfur (hydrogen sulfide and organic sulfur gases) from the
             retort gas
     - gas utilization (retort gas combustion)
     - end of pipe controls
     - upgrading
     - spent shale disposal                            -
                                      1-21

-------
        Within each of these unit operations, there can be a number of process
alternatives.  The shale can be mined in an open pit mine, a room and pillar
mine or the oil recovered without mining with an in-situ process.  The retort
heat can be provided by combustion of the spent char within the retort or with
a recycled stream, which can be either gas or solid.  Each of these variations
can affect the emission rates.  Consequently, consideration of all the
potential processing schemes can be extensive.
        The specific process combinations, analyzed in Section 5.0, are
summarized below in Table 1—7.

     TABLE 1-7.  FIVE PROCESSES'FOR'ANALYSIS (Taback, H.J., et al., 1986)

        Case T "      Mining      '          Retort                    ~
         1            open pit           direct combustion heat
                                            (e.g. Paraho)
         2          room & pillar        direct combustion heat -
                                            circular grate
                                            (e.g. Superior, Dravo,
                                            Allis Chalmers)
         3          room & pillar        indirect combustion gas
                                            recycle
                                           (e.g. Union)
         4          room & pillar        indirect combustion solids
                                            recycle
                                            (e.g. Lurgi, Chevron)
         5          modified in-situ     in-situ and indirect heat
                                             gas recycle above ground
        For each analysis, a base case scenario representative of  the process
configuration proposed by the developers is presented and  the criteria
pollutant emissions are determined.  Then two alternative  processing schemes
to reduce these emissions to their lowest levels are considered.
1.6.2   Methodology
        For this analysis, the oil recovery facility was divided into three
basic categories: mine, retort and upgrade.  The emissions associated with
mining and solids handling (primarily particulates, carbon monoxide and
                                       1-22

-------
nitrogen oxides) are  similar  to  other mining  operations.   The data provided in
the PSD permit applications was  used to  develop  emission  rates for each type
of unit operations  (i.e. blasting,  drilling,  vehicles,  conveying,  crushing,
etc.).  The emissions associated with the upgrading  process  (hydrocarbons from
storage and fugitive  sources), other than those  from the  combustion of the
fuel gas, are similar to other oil  refining operations  and,  again, the PSD
permit applications were used to develop estimated emission  levels.
        The combustion of the retort gas can  be  the  principal source of
emissions from a facility and the source most affected  by the particular
retort process and gas clean-up  scheme used.
        The primary concerns of  this analysis are emissions  of nitrogen and
sulfur oxides and particulates.  Emissions of carbon monoxide and  hydrocarbons
generally are consistent for all processes with  a few exceptions.   The
combustion of the spent shale can produce very high  carbon monoxide emissions',
and this will be discussed below for that particular process.   High
hydrocarbon emission rates can result from certain types  of  retort processes
(i.e., Tosco II) that involve direct contact  heating of raw  shale  or a heat
carrier with flue gas.  However, this process was not included in  this
analysis.
        To evaluate the many process variations  and  develop  the data necessary
to estimate emission levels, it  was first necessary  to determine what  process
combinations are feasible.  The  basic design  parameters that  affect the pollu-
tant emissions for each process  were defined.  These  design parameters are
shown in Table 1-8.
        For each of the unit operations, the  design  parameters were applied  as
indicated by either the retort process conditions, performance of  the
pollution control equipment or the reported emissions from the PSD
applications.   The following discussion presents the rationale for  choosing
the specific design parameters used in the analysis.
                                      1-23

-------
                TABLE  1-8.  DESIGN PARAMETERS USED IN ANALYSIS
                         (Taback, H.J., et al.,  1986)
        Unit Operation
        Mining
        Retort
        Product Recovery
        NHo Removal
            Removal
        Gas Utilization
        End of Pipe Controls
          Design Parameter
           Type of Mining
              open pit
           room and pillar
               in-situ
                        o  o
.  Retort Gas Produced, m/m  of oil
.  Heating Value of Retort Gas, kJ/m3
.  Partitioning of sulfur and nitrogen
.  None- The product recovery process
  has no significant effect on emissions
.  NHg exit concentration, ppm
.  Organic nitrogen content of retort gas
.  ^S exit concentration, ppm
.  Organic sulfur content of retort gas
.  Organic sulfur gas removal efficiency /
.  Boiler-dilution ratio (dry gas/fuel)
.  Spent shale combustion exit
  concentrations for NO , SO  & CO
  Particulate - Baghouse - exit loading,
  g/m3
.  Sulfur - FGD - exit SOX, ppm
.  Nitrogen
    Ammonia injection - exit NO
    Staged Combustion - exit NOV & CO
                               X
1.6.3   Mining, Solids Handling and Upgrading Emissions
        The values from the PSD permit applications presented for mining and
upgrading emissions were used in the overall facility emission estimates.  The
emissions from retort gas combustion were calculated based on retort and
controls used.
                                      1-24

-------
         The  choice  of mining technique determines the emission rates.  The
 values  used  were  developed  from the PSD analysis for room and pillar mining
 and  from the literature  for open pit mining.
 1.6.4    Retort  Gas  Emissions
         The  emissions from  the combustion of  the retort gas are determined by
 the:
           volume and heating value of the retort gas
           presence  of sulfur in the gas
           presence  of nitrogen as  ammonia or organic nitrogen compounds
         The  retort  gas flow rates for three types of retorts were shown in
 Table 1-2.
         The  design  conditions used  for the t^S removal process determines the
 residual H2S and organic sulfur in  the retort gas that eventually is emitted
 as sulfur oxides.  The processes considered are:
         1. Direct or  indirect conversion of the sulfur (e.g. Stretford,
           Lo-Cat, Unisulf,  alkaline or amine scrubbing)
             . lELjS exit concentration = 50 ppm
             . organic  sulfur  assumed at 5% of total  sulfur  in retort gas
               - no removal
         2. activated carbon-hypochlorite process
             . H^S exit concentration = 10 ppm
             . organic  sulfur  - 90%  removal
        Two process operations  result  in the  direct  emission of sulfur  oxides
from the retort; the circular  grate  direct heated retort  and the  fluidized bed
combustion of the spent shale.   The  design conditions  for these two  processes
were taken from the literature.
        Circular Grate Retort  - SOX  =  175 ppm in  retort gas  (White River
        Shale Project, 1981)
        Fluidized Bed Spent Shale Combustor Flue  Gas -
          SOX = 20 ppm (Chevron  Shale  Oil  Co.,  1982)
                                      1-25

-------
         The  primary  nitrogen removal technique considered is removal of
 ammonia  from the  retort  gas  by a water wash absorption tower followed by an
 ammonia  recovery  stripper.   The outlet ammonia concentration is determined by
 the effectiveness of the ammonia absorber.   At atmospheric pressure the
 equilibrium  exit  partial pressure for ammonia at 50 C is 0.5 mm Hg.
         The  nitrogen content of the  treated retort gas and the subsequent NO
                                                                             X
 emissions  from combustion of the retort gas is determined by:
         .  the exit  gas  ammonia concentration (660 ppm)
         .  the amount  of retort gas  produced by the retort
           the amount  of nitrogen partitioned to the retort gas
         .  the percentage of nitrogen present as organic nitrogen
           compounds
         The  processes  that utilize the combustion of high-nitrogen-content
 spent shale  for energy recovery can  produce high NOX emissions if proper
 staging  of the combustion is not used.   The PSD permit applications NO
                ;     .             . -     --....:       -    .    .    . .   Jฃ
 emissions were based on  a high estimate of  15% for the conversion of the
 nitrogen in  the spent  shale  to -N0_ in the combustor.   This level  of conversion
                                  J\,
 also was determined  by Lawrence  Livermore Laboratory investigators (Taylor,  R.
W., et al.,  1985) who  did not  attempt to stage the combustion.
         The  principle  of  NO  reduction in a  staged combustor can be applied to
 reduce these excessive NOX emissions  to approximately 3% nitrogen conversion
 to NO .
     X

 1.6.5   Retort Gas Combustion  and  End-of-Pipe
        The End-Of-Pipe  controls  are  those  either added  after  combustion of
 the retort gas to remove particulate, NOX and  SOX or  incorporated as part  of
 the combustion process as in  staged combustion for  NO control.
                                                     • X
A.      Particulate—
        For particulate control,  two  alternatives were considered.   The  first
is the base case using a standard  baghouse.  The  second  control technique  is
the combined dry venturi-baghouse.
                                      1-26

-------
        The dry venturi-baghouse combination provides  for particulate  control
that is somewhat independent of type of particulate.   The applicants for  PSD
permits all considered a minimum particulate exit loading of  0.07  g/m   (0.03
gr/scf) which was based on standard technology within  the limits of the
unknowns associated with oil shale particulate.  By capturing the  small
particles on larger target particles of specified physical, properties,  the  dry
venturi eliminates the major uncertainties in designing baghouses  with respect
to particulate type and size.
B.      Sulfur Oxides—
     ,   If the IL^S (and organic sulfur) removal is not sufficient  to reduce
the sulfur emissions to an acceptable level, a post combustion flue gas
desulfurization system must be added.  This could be either a wet  or dry
scrubber.                                              •
        The second sulfur control technique is the use of a spent  shale
combustor.  The combustion of the spent shale has two  important advantages:
        1. recovery of the energy value of the char, and
        2. reduction of the sulfur oxide emissions due to the scrubbing
           nature of the spent shale.
However, the spent shale combustion also has two distinct disadvantages:
        1. high emissions of NOX from the nitrogen in  the spent shale,
           and
        2. high emissions of CO due to incomplete combustion.
These emissions (NOX and CO) will be discussed in the following section.
        The design conditions for SOV emissions used in the analysis are:
                                    X.
        1. Flue Gas Desulfurization  - 50 ppm SOX exit concentration
        2. Combustion of spent shale with retort gas
                                 - 10 ppm S0v
                                            X
                                 - 300 ppm NOV
                                             X
                                 - 1000 ppm CO
                                      1-27

-------
C.      Nitrogen Oxides—
        Two controls were considered for reducing post-combustion  NO
                                                      s     . .         X
emissions.  The first is ammonia injection; this technique has  been  applied
successfully in utility boilers and could be used when  the retort  gas  is
burned in a conventional boiler for steam and electrical generation.
        The second NOX control considered is staged  combustion  which has
particular advantages for spent shale combustion due  to the ability  to
adequately control the fuel related NO,,.  The staged  combustion could  be
                                      A.
applied to either the conventional boiler or the spent  shale  combustor.
        The use of selective catalytic reduction (SCR)  was not  considered  due
to the potential for poisoning the catalyst.  The retort gas  particulates
contain a wide variety of heavy metals which have a  deleterious effect on
catalyst life.  In addition, there are still a number of unknown factors which
can effect the long term catalyst performance that have not been completely
identified.  For example, it had been assumed that the mercury  associated  with
the retort gas was in the form of elemental mercury  and would be substantially
removed prior to combustion during the standard gas  cleaning  (ammonia  and
hydrogen sulfide removal) processes.  However, it has been shown that  the
mercury may be present primarily as methyl mercury which is volatile and is
present in the retort gas during combustion.  Consequently, any post-
combustion control processes must be capable of handling these  emissions of
elemental and oxides of mercury.  This is only one instance where  unknown
factors could have a negative affect on catalyst performance.   Consequently,
due to the inherently variable nature of the retort gas from  an oil  shale
retort and the known presence of many catalyst poisons, the use  of SCR was not
considered a viable alternative.
        There is a tradeoff between the NOX and CO emissions  in the  spent
shale combustor.  As indicated above, the NOV and CO emissions  are
                                            X        •    '
approximately 300 and 1000 ppm, respectively.  Tests by J&A Associates (Van
Zanten and Haas, 1986) indicate that the excess 02 has a dramatic  effect on
NOX and CO.  As the 0^ level increases from one percent, the  NOX rises and the
CO drops.  Because shale combustors operate at low temperatures, approximately
700 C, the effects of temperature were found to be negligible.
                                      1-28

-------
         In  addition,  the  staged combustion technique for control of the fuel
 related  NOX,  depends  on low excess  oxygen (actually sub-stoichiometric
 combustion) which  further increases the CO emissions.
         The fluidized-bed combustor has limitations in process control which
 result in the inability to provide  conditions that result in adequate staging
 for NOX  control.   However,  the  cascading-bed combustor is designed as a staged
 device.  Consequently,  combustion conditions can be controlled at each stage
 of the process, alternating between fuel rich and fuel lean zones to reduce
 the NO formed to N2 and complete  the combustion of the CO formed to C02.
         There are  no  specific test  results of the staged combustion with  spent
 shale to support this hypothesis; however, the reaction kinetics of the
 reduction of  NO to N2 with  spent  shale  have been investigated (Taylor, R.  W.,
 et al.,  1985)  and  the engineering design of the cascading-bed combustor is
 ideal for a staged system with  easy means  for controlling the process
 conditions.   Consequently,  it is  the opinion of the authors that proper design
 and development would result in minimal NOX and CO emissions.
         The design conditions for post-combustion NO  control are:
         1. NH.j injection  -  20 ppm NOX exit concentration
         2. cascading-bed  combustor  - 50 ppm NOx
                                    - 50 ppm CO
 1.6.6    Emissions  from  Retort Gas Combustion
         The emissions from  combustion of the retort gas  for particulates,
nitrogen and  sulfur oxides  also are  shown  in Figures 1-7,  1-8, and  1-9.
         These figures indicate  that  there  is wide variation in emission levels
for the  five processes  based on the  technology proposed  in  the PSD  permit
applications  (Base Case conditions).  For  particulates,  the emission levels
vary from 200 to 800 kg/1000 m3 of  oil; for  nitrogen oxides the  emission
levels vary from 1000 to  8000 kg/1000 m3 of  oil;  for sulfur oxides  the
emission levels vary from 350 to 3000 kg/1000  m3  of oil.
        The first alternative considered was  the  use of  the activated  carbon
enhanced H2S removal process, an acid wash for  improved  ammonia  removal and
                                      1-29

-------
                                                CASEfl


                                                CASEK


                                                CASEI3


                                              E3CASE*4


                                              DCASEfS
                           BASE CASE
ALTERNATE

    ซM
ALTERNATED
 Figure 1-7.   Particulate emissions from retort gas combustion for  five cases

               (Taback,  H.J., et al., 1986).
                      8000 T


                      7000


                  g ? 6000




                  lซ sooฐ
                  2 E

                  I o 400ฐ
                  111 o

                   Kฐ 3000

                  0-

                  z 5 2000


                      1000
                          BASE CASE ALTERNATE  ALTERNATE

                                      •1      *2
Figure 1-8.  Nitrogen oxides emissions summary for five cases

               (Taback, H.J., et al.,  1986).
                                          1-30

-------
                  3000
                       BASE CASE  ALTERNATE  ALTERNATE
                                       #1        f2
Figure 1-9.   Sulfur oxides  emissions summary  for five cases
              (Taback, H.J.,  et al., 1986).
                                   1-31

-------
 the  addition of a dry venturi - baghouse for post combustion particulate
 control.   Referring to Figures 1-7,  1-8, and 1-9, the emission levels for
 alternate  #1 show considerably less  variation,  particularly for sulfur oxides
 (range  from 100 to 250 kg/1000 m3 of oil) and particulates (range from 50 to
              f\                                      .
 200  kg/1000 mj  of oil).   The variation of nitrogen oxide emissions is still
 considerable, ranging from 1000 to 4000 kg/1000 m3 of oil.  Essentially, the
 acid wash  only  removes the residual  ammonia without reducing the organic
 nitrogen content and has  no effect on the thermal NOX;  therefore, there is
 relatively little improvement in the NO,,,, emission rate.
                                        2t
        The second alternative considered was the use of ammonia injection for
NO.
  x
control from boiler and/or furnace combustion, the use of  staged
combustion for  control  of NOX emissions  from the  spent shale combustor and the
dry venturi-baghouse with an  increased space velocity which improves
collection performance  at the expense  of increased pressure drop.   Again,
referring to Figures 1-7, 1-8,  and  1-9,  it  is apparent that the addition of
these controls  essentially  levels the  performance  of  all  five processes.
        The particulate, nitrogen oxide  and sulfur oxide  emission  levels for
alternate #2 conditions along with  the total facility emissions are shown  in
Figures 1-10, 1-11, and 1-12.   The  particulate emissions  (Figure 1-10) still
show variation  from 4 to 12 kg/1000 m3 of oil. However,  the absolute  value is
considerably less than  the  particulate emissions  from the mining and solids
handling operations and the total facility  is essentially equivalent for all
five cases ranging from 180 to 200  kg/1000  m3 of  oil.
        The nitrogen oxide emissions,  Figure 1-11,  range  from 75 to 500
         O
kg/1000 mj of oil.  While this  is still  a significant  variation, again the
absolute magnitude of the values is such that the  net  variation in  the total
NOX emissions for the five  facilities  is less than 2  to 1 ranging  from 400 to
800 kg/1000 m3  of oil.
        The sulfur oxide emissions  (Figure  1-12) range from 100 to  250 kg/1000
 o
m  of oil and are essentially  the same for  the  total facility as there are no
other significant sources of  sulfur emissions.            '           '
                                      1-32

-------
       900 T
                   CASE *1
                   CASE *2
                   CASE 13
                 El CASE #4
                 D CASEfS
                ALTERNATE
                 RETORT GAS
                 COMBUSTION
 TOTAL
FACILITY
Figure 1-10.   Nitrogen oxides emissions for five cases
             (Taback, H.J., et al., 1986).
                          1-33

-------




CO ~
Z^J

2*5
8ซ
5 *
m O
o

QC ^
2 5"



200-
Cซ V \S
180-
160-
140-

120-
100-


80-

60-
40-
20-
n-
• CASE 41
E3 CASE ซ2
E CASE ซ3
M CASE *4
D CASE *5

t








m 	 1;!ฃ3 I,
Figure 1-11
          ALTERNATE
           RETORT GAS
           COMBUSTION

Particulate emissions for five
 (Taback,  H.J., et al., 1986).
                                                TOTAL
                                               FACILITY
                                         cases
                300 T
                      ALTERNATE
                       RETORT GAS
                       COMBUSTION
                                  TOTAL
                                 FACILITY
Figure 1-12.
Sulfur oxides emissions for five cases
(Taback, H.J., et al., 1986).
                              1-34

-------
        The basic conclusion derived from  the above  analysis  is  that,  although
the air emission levels for the different  retort processes with  controls
proposed in PSD permit applications can vary considerably, sometimes by as
much as two orders of magnitude, the application of  control techniques that
are either improvements over proposed technology or  more suitable  for  a
specific application, result in similar emission levels for all  five processes
considered.  This statement needs to be qualified by the fact that some of the
control techniques considered have not been applied  specifically to the shale
oil recovery process, and therefore might  not be considered as BACT.  However,
these techniques have been proven at the full scale  level in various other
difficult control applications.
                                      1-35

-------

-------
                                  SECTION 2.0
                             RETORT PROCESS REVIEW

        A complete shale oil processing facility consists of the following
eight operations:
        .  mining,
        .  retorting,
        .  spent shale disposal,
           oil recovery,
        .  retort gas treatment,
        .  retort gas utilization,
        .  raw shale oil upgrading, and
        .  oil storage.

        Although this report addresses the air pollution control techniques
for all aspects of shale oil production, this section deals primarily with the
retorting process, retort gas treatment, and retort gas utilization, since
these are the areas where the type of retorting process can have a significant
effect on the air emissions.  The mining and spent shale disposal emissions
are similar to those from other solids handling operations; the upgrading and
storage facilities are similar to other oil refining operations.
        The shale retort converts the raw shale solids to crude shale oil,
retort gas, and spent shale.  There are many different retorting processes
ranging in size and complexity from an in-situ retort where the retort
operation takes place within the shale formation with subsequent limitations
on process control and operation, to the above-ground cascading-bed retort-
combustor, which has considerable advantages in both process control and
reduced emission rates, but requires mining of large amounts of raw shale.
Schematics for the two general types of retort processes, underground (in-
situ) and above-ground are shown in Figures 2-1 and 2-2, respectively.
                                       2-1

-------
Combustion
   Air
     I
  Rubblized Shale
                                .Retort Gas + Oil Mist
Crude Shale Oil,

 Characteristics
 . High gas flow
. Limited mining
.  Semi-batch  process
    Figure 2-1.   In-situ retort processes - general.
                                 2-2

-------
                        Combustion Air  or
                      Heated  Recycle  Gas
n  n
n  n
              Transfer
                                 1
                                Retort
  Mine
   .^.Retort Gas + Oil Mist
  Crude Shale Oil
Spent Shale to Disposal
                                                     Characteristics
                                                     . Requires mining
                                                     . Lower gas flows
                                                     . Higher product recovery
                                                     . Continuous process
          Figure 2-2.   Above-ground retort processes - general.
                                         2-3

-------
          The type of retort process can have a considerable effect on air
  emissions.  These process differences can limit the sulfur emissions due to
  direct contact of the retort gas with oxidized spent shale; they can affect
  the relative amounts of organic sulfur to H2S by varying steam concentration,
  or they can affect the quantities of gas and the.concentrations-of pollutants
  in that gas.  Many of these different processes and their respective effects
  on the air pollution control strategy are described in this section.

.2.1     BACKGROUND

         Recovery  of  oil  from oil  shale involves  the process of  heating  the  raw
  shale  to approximately 500  C to break down the organic  content  into  its  oil
  and gas components.   This process is  referred to as "retorting".   Differences
  in  processes involve  variations in the  techniques of transferring  of heat to
  the raw shale.  This  background section presents information on various
  process configurations with particular  emphasis on  their respective pollution*
  sources and emissions of criteria pollutants.

         In direct-heated retorts, heat is provided to the shale by combustion
 within the retort to produce shale oil, retort gas, and spent shale.  Then,
 the produced gases are scrubbed to remove ammonia and sulfur compounds.   The
 gaseous emissions of SOX and NOX are determined primarily by the performance
 of the clean-up processes.  The chemistry of  the individual process and  the
 method of heating the shale affect the generation of H2S, organic sulfur, NH3,
 and organic nitrogen in the retort and the resulting concentrations of these
 pollutants  in the gas stream.  These  conditions  significantly affect the gas
 clean-up process  selected.   The discussion in Section 4.0,  PSD  Permit
 Application Analysis,  and Section  5.0, Process Analysis, reviews and evaluates
 these  emission  control design considerations.
         In  indirect heated retorts, heat is applied  to a recycle stream  of
 either  gas  or solids outside  the retort.   When gas is used as the recycle
 heating medium, the main  effect is to  eliminate the  presence of  combustion air
 within  the  retort which results in a lower retort gas volume of high  Btu
 content gas.
                                       2-4

-------
        When recycled solids are the heating medium, the solids are heated by
combustion of the char which, in addition to recovering the energy value of
the char and minimizing the SOX emissions (Section 2.1.1.B), also oxidizes FeS
to Fe203.  The recycle of Fe203 to the retort has the effect of reducing the
formation of H2S within the retort, thereby reducing the necessary controls
for limiting S0_ emissions.
               A.
        The following section describes the major chemical reactions occurring
in the retort and spent shale combustor.
2.1.1   Chemistry
        The following discussion presents information on the specific chemical
reactions that pertain to the generation and transformation of criteria
pollutant emissions.
A.      Retort—
        Oil shale consists primarily of varying amounts of organic material
(kerogen and bitumen), dolomite, calcite, quartz, analcime, feldspars, illite,
Mg-siderite, pyrite (inorganic sulfur), and nitrogen (organic and inorganic)
as well as trace amounts of many elements.  During the retorting process, the
organic material decomposes to oil, hydrocarbon (HC) gases (including hydrogen
and CO), water, carbon dioxide, hydrogen sulfide, ammonia, a carbonaceous
residue (char) and numerous minor components.  Some of the major reactions
occurring in the retort at the typical retort temperature of 500 C are:
        1. Kerogen and Bitumen •	> HC(gas) + oil(liquid) + H2S(gas) +
           organic S (gas) + C02 (gas) + H20 (gas) + char (solid)
        2. FeS2 + H2 	> FeS + H2S (gas) + oil S (liquid)
        3. Organic S 	> H2S (gas) + organic S (gas) + oil S + char S
           (solid)
        4. 2H2S + Fe203 + H2 —> 2FeS + 3H20
        5. Buddingtonite (NH4AlSI3Og) ---> NH3 (gas) + organic N (gas)
        6. Organic N 	> NH3 (gas ).+ organic N (gas)
                                       2-5

-------
         Reaction 1 is the primary reaction occurring in the retort and is the
 pyrolysis of kerogen and bitumen to form CpCy hydrocarbons which comprise the
 oil and gas.  The thermal efficiency of the processes (i.e., the relative
 amount of oil and gas produced per unit of energy input) can vary
 considerably.  However,  most of the candidate processes for commercial
 application have process efficiencies of approximately 78 percent in the form
 of oil and gas with an additional 4 percent contained in char remaining with
 the spent shale.

         In reactions 2 and 3 sulfur gases (H2S and organic sulfur gases) are
 formed from inorganic sulfur (FeS2) and organic sulfur material in the raw
 shale.   Since FeS is stable under retort conditions,  as much as 50-60 percent
 of the inorganic sulfur  remains with the retorted shale.
         In the direct heated and indirect heated with gas recycle processes,
 i.e.,  without external combustion and recycle  of hot  solids,  organic  sulfur
 gases  are produced  with  the H2S significantly  complicating gas  clean-up.   In
 indirect  heated solids recycle  processes,  recycled shale  is present,  which
 contains  iron oxides  and,  as Reaction 4 indicates,  some H2S is  removed from
 the gas phase by reaction  with  iron  oxides  to  form the  stable FeS.  A major
 concern of  air pollution control  process design is  kinetic and  thermodynamic
 requirements  to  maximize the H2S  removal.
        In  reactions  5 and 6 nitrogen-containing gases, primarily NHo  with
 other organic nitrogen gases, are produced  from inorganic  nitrogen
 (buddingtonite)  and organic  nitrogen  in the shale.
        The gas  formed in  the retort  is  a mixture of the gaseous  components
 listed in Reaction 1  to 6  plus N2, CO,  and H20.  Typical retort gas
compositions  are shown in  Table 2-1.  A  breakdown of the sulfur gases  (H2S,
thiophenes, carbonyl  sulfide, etc.) and  the nitrogen gases  (NH3,  etc.) are
presented in  Section  2.2.
                                       2-6

-------
             TABLE 2-1.  RETORT  GAS  COMPOSITIONS  (SOLIDS  RECYCLE)
                                    (Mole  %)
             (Adpated from Dept.  of Energy,  1979,  and  Ondich,  1983)

H2
CO
co2
N2
CH4
CnHo
C2H4
C2H6
C3H6
C3H8
H2S
NH3
Water
In-Situ
6.5
1.2
17.3
42.0
1.1
—
0.1
0.2
0.1
0.1
0.12
0.40
30.8
Union B
Indirect Heat
16.2
3.9
11.9
1.9
15.5
0.1
1.2
5.3
2.6
2.3
2.01
0.13
31.52
Lurgi
8.2
0.8
7.4
0.8
3.9
—
1.4
1.4
1.2
0.6
0.12
0.37
55.03
Paraho
Direct Heat
3.5
1.6
17.6
51.3
1.9
—
0.7
0.8
0.4
0.4
0.24
0.57
19.2
B.      Spent Shale Combustion—
        In some processes, spent shale is burned to recover energy associated
with with residual char.  The resulting energy can be used to produce energy
for either the retort or cogeneration of electricity.  The reactions occurring
in spent shale combustion are numerous and have significant effects on both
the process performance and emission rates, as presented below.
   I-   Process efficiency— The thermal efficiency of the overall retorting
process is improved by spent shale combustion, primarily due to the energy
value of the char, but also from any unretorted kerogen present after
pyrolysis.  At the typical combustion temperature range of 500-800 C, the
major reactions are:
        7.  Kerogen + 02 	> C02 + H20 + S02 + NOX        .
        8.  Char + 02 	> C02 + H20 + S02 + NOX
        9.  Char + NO 	> N2 + C02 + H20
                                       2-7

-------
        The reaction of char with NO can be used to  limit NOX emissions  by
using staged combustion.  Limiting the combustion temperature also  limits the
thermal NOX formation.  See Section 3.2.I.B.
        Combustion of the spent shale can have a negative effect on the  energy
recovery if the combustion conditions are not adequately controlled.  At
elevated temperatures, carbonate decomposition can occur resulting  in
endothermLc reactions that consume available energy.  These reactions are:
                                                           Heat" of "Reaction
        10. CaC03 — > CaO + C02                              -420 cal/g
        11. CaMg(C03)2 --- > CaO + MgO + 2C02                  -400 cal/g
        12. 2CaC03 + Si02 -- > Ca2SiO^ + C02                  -270 cal/g
        13. CaMg(C03)2 + 2Si02 --- > CaMgSi206 + 2C02          -200 cal/g
        If allowed to occur, these reactions result in a loss of thermal
efficiency.  Figure 2-3a shows the detailed reaction mechanism for these
reactions and Figure 2-3b shows the C02 evolution rate as a function of
temperature.  At temperatures below 700 C, the C02 evolution and the energy
loss from carbonate decomposition is minimal.
   2.   Sulfur reactions — The use of a spent shale combustor limits the SO
emissions due to reactive elements in the spent shale.  The principal sulfur
reactions in the combustor are:
        .   spent shale combustion
        14. 4FeS + 702 - — > 2Fe203 + 4S02
        15. 2S02 + 02 + 2MC03 — > 2MS04 + 2C02,
            where M = Ca or Mg
        .   recycled spent shale combustion
        16. MS + 202 --- > MS04
        17. 4Fe304 + 1/202 ---
                                       2-8

-------
 Dolomite
      MgCa(CO3).
 Calcite
     CaCO.
                -c
         (Si02)
                  MgO + CaCO3 + CO2
                               (Si02)
                                 CaO + CO2
CaO + CO2
                      CaOซySiO2 > CO2
                             CaOxSiO2 + C02
                                           ฉ
        Figure 2-3a.
500   600   700   800    900
        Temperature (ฐC)
        Figure 2-3t>.
                                        K =
                                         c
                          KEY
                       Decomposition rate constant
                       Calcination rate constant
                     = Reverse calcination rate constant
                       Indiate temp, at which corres-
                       ponding reactions take place.
   Figure 2-3.  Carbonate reaction scheme (Burnham, 1985).
                                 2-9

-------
 Dolomite
      MgCa(CO3)2
 Calcite
     CaCO,
                -c
         (SiO,)
                  MgO + CaCO3 + CO2
                               (Si02)
                                 CaO + CO.
CaO + CO2
                      CaO'78102+002
                             CaO-xSiO2
                                                                  ฉ
        Figure 2-3a.
CM
500   600   700   800    900
        Temperature (ฐC)
        Figure 2-3b.
                                        K,  =
                                         d
                                        K  =
                 QB)
                 ฉ
                          KEY
                       Decomposition rate constant
                       Calcination rate constant
                       Reverse calcination rate constant
Indiate temp, at which corres-
ponding reactions take place.
   Figure 2-3.   Carbonate reaction scheme  (Burnham, 1985).
                                 2-9

-------
        Calcium and magnesium carbonate are present in both the raw and spent
shale and react with the sulfur dioxide according to Reaction 15 thereby
removing the sulfur from the flue gas.
        Reaction 14 shows the oxidation of FeS to Fe20o and SC^, the primary
source for the sulfur in the spent shale.  It is this reaction combined with
Reaction 4 (the reaction of ^^2^3 with H2S) that produces the synergistic
effect of the recycled solids processes.  Figure 2-4 illustrates this
effect. , Combusting the spent shale converts the FeS sulfur to SO? and
Fe203.  The S(>2 is removed from the gas phase (Reaction 15) and the ~P&2ฐ3 is
recycled with the solids to the retort.  In the retort the Fe20o removes BUS
from the gas phase (Reaction 4).  The sulfur is essentially contained in a
closed loop within the retort and combustor, exiting only as FeS on the
combusted shale and sulfur in the oil.
        The combustion of the spent shale therefore not only increases the
thermal efficiency of the process, but also removes the gaseous sulfur from
the flue gas eliminating the need for additional flue gas controls for the
portion of the energy generated in the combustor.  Since the concentration of
calcium and magnesium carbonates is considerably greater than the amount of
sulfur in the spent shale, the spent shale has additional capacity to remove
SC>2 from retort offgas and from combustion of raw shale (which also contains
carbonates).  Because spent shale combustion has the potential for also
burning both raw shale fines and retort gas, it also can be used for limiting
SOX emissions from these energy conversion processes.
   3.   Nitrogen reactions — The combustion of the spent shale results in the
following reactions for nitrogen containing species:
        18. Char .+ 02 —.-> NO + NH3 + C02 + H20 + CO
        19. Char + NO 	> N2 + C02 + H20
        20. NO + NH3 	> N2 + H20 + H2 (with & without catalyst)
        21. NO 	> N2 + 02 spontaneous decomposition
        22. NH3 	> N2 ฑ H2 (catalyzed)
        23. NH3 + 02 —> N2 + H20 + NO
                                       2-10

-------
               Hot  Solids  for  Recycle
                      with
               i
Retort

Spent Shale

                                               Combustor
              (Fes,  Char  with  Sulfur) I——Oxygen
Sulfur Production
  FeS  + H —ป- FeS + H S
    ฃ,   ฃ         ฃ,


Sulfur Consumption
Combustion Reactions


FeS + O  —•ป• Fe O3


MS + O^—i
1/2 H2 + 1/2 Fe20


   FeS + 3/2 HO
 ,            A
Char + O -ป-'CO_ + HO + SO  + NO
       ฃ    ฃ    2.     2

      M == Ca, Mg
                                      SO  + O + MCO -*>MSO  + CO0
                                       ฃ    ฃ     j     4c    
-------
         24.  Buddingtonite  (NH4AlSi3Og)  	> NO + NH3
         Reactions  18,  23 and  24,  the  combustion of  the  char,  ammonia and
mineral Buddingtonite,  respectively,  form NO.   The  relative importance  of  the
contribution from  inorganic Buddingtonite at normal combustion temperatures
has  been shown  to  be minimal  (Burnham,  1985).
         The  NO  then can react with  char in accordance with a  carbon reduction
reaction:
         25.  C + 2NO —> N2 + C02
and  with any ammonia present according  to Reaction  20.  These reactions are
shown in Figure 2-5.   In kinetic  studies  to determine the mechanism for NO
reduction (Taylor, 1983),  found that  the  C02 evolution  rate was not consistent
with Reaction 25 and proposed that  hydrogen in  the  char was the actual
reducing agent.
         The  application of these  reactions  to reduce NO is actually the
application  of  staged combustion, the principal  of  Reaction 25, and ammonia
injection, Reaction 20.  Since there are  a  number of sources  of each
component, (e.g.,  carbon can come from  retorted  shale as char or raw shale
fines as  kerogen,  ammonia from reactions  18 and  23  or externally from the
retort  offgas), there are many variables  that can affect the net NO
formation.   Consequently, the potential exists to limit NO emissions by proper
process  design.  The cascading combustor  described  below is suitable for
staged  control  of  operating conditions  (excess oxygen percent, temperature) as
combustion proceeds and should therefore  be  suitable for designing to minimal
NO levels.
        As an example of how effective  combustion staging can lower NO
                                                                      X
emission rates when burning high Nฃ fuel, consider  the experiments conducted
on sewage sludge by Haug, et al (1981).   The digested sewage sludge fuel was
dried thoroughly and was in powder form.  It had a heating value of
approximately 2.8 kcal/g, an ash content  of approximately 50 percent and a
nitrogen content of approximately three percent.  This was burned in a
conventional fluidized-bed reactor first  in an incineration mode with 30
percent excess air then in a pyrolysis mode  (i.e., starved air)  with 30
                                       2-12

-------
                         CHKNy •_•-*
                                  H2O + H2


                                   + CO + CO2 + H2O
                             O2 •* N2 * H2O + NO
Secondary reactions
                 1   _r
CH  N (char) + O2 -* NO + NH3 + CO2 + H2O + CO      Char combustion
                        Mป~ N2 + H2
                       -*-  N2 + O2
                                        Spontaneous
                                      '  decomposition (catalyzed?)
Figure  2-5. Nitrogen reactions during  char combustion (Taylor,  et al., 1985b).
                              2-13

-------
percent excess air added to the gases in stages  downstream of  the  bed.   In  the
incineration mode the NOX ranged from 500 to  1200 ppmV  (at 5.5 percent  02).
In the optimum staging configuration, the NOX was lowered  to the range  of 50-
75 ppmV (at 5.5 percent 02), a reduction of over 90 percent.
2.2
FORMATION AND FATE OF POLLUTANTS
2.2.1   Criteria Pollutants-('SO-j NO  >
        	_^^_.	^^^^_^i_.	,	      t X    3v
        The pollutants emitted from an oil shale  recovery process  (no  solids
recycle) are directly related to the  composition  of the oil shale.   The
analyses of various oil shales is shown in Table  2-2.
        The sulfur and nitrogen weight percent varies considerably,  from  0.12
percent to 1.2 percent for nitrogen and 0.23 percent to 1.4 percent  for
sulfur.  The wide variation in the concentration  of the source material
requires that process and emission controls be designed to limit subsequent
pollutant emissions.
             TABLE 2-2.  CHEMICAL ANALYSIS FOR VARIOUS OIL SHALES
                            (Dept.  of Energy,  1979)
_> . . . ซ ..ii n ., . ,. ,„,,--- ---IT
Location
Tract
Tract
Anvil
Anvil
Anvil
Anvil
Ca
Ca
Points
Points
Points
Points
Co Core #3
Naval
Anvil
Resrv.l
Points
Geokinetics
Horse
Draw Co
Oil Yield
(gal/ton)
34
24
61
30
22
8
22
1
25
4
25
.3
.8
.0
.6
.4
.1
.0
.9
.0
.7
.0
Chemical Composition,
C C02 C H
acid org. .
21.
16.
30.
19.
15.
10.
12.
4.
15.
6.
19.
9
6
4
6
6
0
6
7
6
5
2
16.0
19.7
12.3
20.6
17.5
21.4
12.3
11.4
17.1
15.2
.29.5
17.5
11.2
27.0
14.0
10.8
4.1
9.2
1.5
11.0
2.4
11.1
2.4
1.7
3.6
1.8
1.6
0.6
1.7
0.5
1.6
0.5
2.0
wt%
S
NA
1.1
0.84
NA
0.63
0.23
1.4
0.87
0.69
NA
0.60
% Inorg.
N N
0.61
0.54
0.95
0.43
0.41
0.12
1.2
0.54
0.47
0.20
0.45
21
43
2.2
10
27
13
78
92
35
67
..32 _
                                       2-14

-------
A.      Sulfur—
        Raw oil shale contains a significant amount  of  sulfur.  During
retorting, the sulfur is converted to various organic and inorganic compounds
and partitioned to the retort gas, oil and spent shale.  The use of the retort
gas (combustion or shale) and oil dictates that these sulfur compounds be
recovered and/or controlled to prevent excessive emissions of reduced and
oxidized sulfur species.
    **  F_Qrmation — oil shale from the Mahagony basin  contains up to 2
percent sulfur (by weight), with the average sulfur  concentration being nearly
one percent.  Approximately 73 percent of the sulfur in raw shale is found as
pyrite (FeS2) (Williamson and Mechior, 1980) and approximately 23 percent as
organic sulfur with the remaining 4 percent in the form of sulfates.
        The disposition of sulfur during processing depends on both the
original form of the sulfur and retort operating conditions.  The primary
concern when evaluating retort processes with respect to removal of sulfur
gases is the composition and chemical structure of these sulfur compounds.
The results from determining the composition of the sulfur gases from
retorting three raw shales are shown in Table 2-3.
                                       2-15

-------
                TABLE  2-3.   SULFUR GASES FROM THREE RAW SHALES
                              (Wong,  et  al.,  1985)

Sulfur Gas
Hydrogen sulfide
Methanethiol
Ethane thiol
Propanethiol
Dimethyl disulfide
Carbonyl sulfide
Carbonyl disulfide
Thiophene
Methyl thiophene
Total raw shale S, %
Conversion of S
to S gases, %
Tract Ca
18 gal /ton
mole %
90.3
0.38
0.26
0.01
0.005
1.71
6.92
0.21
1.11
1.7

20.2
Anvil Points
24 gal /ton
mole %
86.2
0.55
0.47
0.02
0.01
2.66
6.39
0.39
3.27
0.7

7.9
Geokinetics
56-57'(4.7)
5 gal/ton
. mole %
84.2
1.5
0.67
0.08
0.03
4.57
0.24
1.37
7.40
0.1

1.8
        The dominant inorganic sulfur reaction has been  shown to  be:
        FeS2 + H2 	> FeS + H2S  (gas) + organic S (gas) + oil  S
        Since the FeS is not easily reduced to Fe at temperatures below  900 C,
this reaction is consistent with  the observation that over 60 percent of the
inorganic sulfur remains in the retorted shale.
        Reactions of organic sulfur compounds in raw shale have not been
determined.  However, the evolution temperatures and source of  sulfur for
individual gaseous species has been investigated (Wong et al, 1985).  Raw
shale and acid treated raw shale  were pyrolized and evolved gas species  were
measured.  Treating the raw shale with acid removes FeS2, leaving only organic
sulfur.  Consequently, by comparing the results from the raw shale and the
acid-treated shale, the specific  source of the sulfur gases can be determined.
        The H2S evolves from the  organic sulfur at temperatures of 250 to
400 C and from the FeS2 at 500 C.  The CS2 evolves from the FeS2 at

                                       2-16

-------
 temperatures  greater than 500  C.   Thiophenes  come  from the  organic sulfur at:
 temperatures  of  300  to  450 C.   The methanethiol, ethanethiol and propanethiol
 are generated from both the  organic  sulfur  compounds at 250 to 400 C and from
 the pyrite  (FeS2)  at temperatures  greater than 500 C.
        The reactions can be summarized as:
        26. FeS2 + 2H2  	>  FeS (solid) + H2S (gas) +  CS2 (gas) +
                             methanethiol +  ethanethiol  + propanethiol
        27. organic  S -—> H2S  (gas) + thiophenes + methanethiol + ethanethiol
                           + propanethiol
    2.   Partitioning of sulfur during pyrolysis— In  the pyrolysis of oil
 shale, the  sulfur  is  distributed between the gas, oil and spent shale.  The
 results of  the distribution  analysis for various samples are shown in
 Table 2-4.
           TABLE 2-4.  DISTRIBUTION OF RAW SHALE SULFUR IN PRODUCTS
                            (Dept.  of  Energy,  1979)
Sample
Site
Anvil Points
Anvil Points
Anvil Points
Geokinetics
Tract C-a
Tract C-a
Colony
Avg. Sulfur
Content, wt.%

0.6
1.29
0.6
0.5
1.4
1.4
0.8
% of Raw Shale
Spent Shale
69
78
74
86
60
66
69
Sulfur
Oil
11
8
15
7
8
5
15
in Product
Gas
20
14
11
7
32
28
19
        The amount of sulfur partitioned to the gas phase varies from 7 to
32 percent of that contained in the raw shale.   Figure 2-6 shows the partition
data from Table 2-4.                                            '
                                       2-17

-------
    o
    H
    EH
    H

    -S

    gi
30
        20
        10
           Qoil
                      D
                                   1.0


                        WT %  SULFUR IN SHALE
                                         Gas
                                                  Oil
                                                  2.0
Figure  2-6.   Partitioning of  sulfur during retorting (Table 2-4 data)
                                  2-18

-------
B.       Nitrogen Oxides—
         Nitrogen oxides emissions (NOX) from oil shale retorting are due to
both  fuel  nitrogen (i.e., nitrogen compounds originating in the raw shale and
released during the retorting process) and thermal N0_ from combustion of
                                                      X
either  the retort gas  or the carbonaceous spent shale.  In this section, only
fuel-related  nitrogen  emissions are discussed.   Thermal NO  emissions are
discussed  in  Section 3, Air Pollution Control Technology,  and Section 5,
Process Analysis.
   J-    Formation— The fuel-related nitrogen emissions are determined by the
nitrogen content  of the raw shale,  the chemical form of the nitrogen, the
partitioning  of the nitrogen to the gas,  oil and spent shale and the chemical
form of  the gaseous nitrogen species.   The composition of  a number of raw
shales  from the Mahagony zone western states were presented previously in
Table 2-2.  The average nitrogen composition is 0.5  weight percent with values
ranging  from  0.1  to 1.2 weight percent.   The nitrogen is present as both
inorganic nitrogen compounds,  primarily buddingtonite, and organic nitrogen
compounds associated with the organic  kerogen and bitumen.
        The nitrogen conversion mechanisms are  shown in Figure  2-7.   Organic
nitrogen is either deposited  in the oil or forms  HCN and NH3 in the gas phase.
Inorganic nitrogen decomposes  to NH3.   The NH3  formed can  be oxidized to NO or
reduced to N2.  The retorting process  redistributes  the nitrogen from the
kerogen and shale  rock  to  the  shale oil and char.  Typical nitrogen
concentrations  for  shale  and  other  fuels  are shown in Table 2-5.
                                       2-19

-------
                 OIL  SHALE  NITROGEN
              ORGANIC
   N  in  OIL
INORGANIC
                        +CHAR
                   NO—	Np
                        NHit CO
  •—- PYROLYSIS

  	 COMBUSTION
Figure 2-7.  Nitrogen conversion mechanisms (Oh, et al., 1985).
                         2-20

-------
          TABLE 2-5.  NITROGEN CONCENTRATION IN OIL SHALE COMPONENTS
                      AND OTHER FUELS (Oh, et al., 1985)
Component
Raw shale
Kerogen
Oil shale char
Shale oil
Other fuels:
Crude oil
Coke
Coal
wt % N
0.5
3.0
7.0
2.0

0.1
1.0
1.5
   2.   Partitioning— Nitrogen is distributed into four components:  oil,
gas, spent shale and condensed water.  Figure 2-8 shows the relative
distribution.  At retort temperatures of 500 C and 700 C, the nitrogen
distribution is:
                    Component                 % of nitrogen
                                          (data from Fig. 2-8)
                                           at 500 C    700 C
                    Spent shale                60       40
                    Oil    ,                    33       30
                    Water                       4       15
                    Gas                         3       10
        The rapid increase in nitrogen (primarily ammonia) in the gas phase
with temperature is also indicated by the ammonia evolution rate which varies
with temperature shown'in Figure 2-9.  At 500 C, ammonia evolution is minimal
with rapid increases between 500 and 700 C (Oh, 1985).
        Using the data reported in the PSD permit applications presented in
Section 4, the partitioning of nitrogen for the modified in-situ (MIS), Lurgi
solids transfer and Paraho direct combustion was calculated and the results
are shown in Table 2-6.
                                       2-21

-------
100
 0
   350
                                                         750
                                           650




                         PEAK TEMPERATURE, C




Figure 2-8.  Nitrogen distribution during retorting  (Oh,  et al. , 1985)
                              2-22

-------
CD
tH
td

CO
bO
•H
J-i
o,

M-l
O
I
M

1
    1200,
    1000-
     800_
I.   600-
     400-
    200
    100.
         300
400          500


        PEAK TEMPERATURE, C
                                                T—
                                                600
700
                 •20%


                J. 8%


                JL6%


                 •14%


               JJ.2%


                 10%


                  8%


                 ' 6%


                  4%


                - 2%


                 0%
        Figure 2-9.   Ammonia evolved  from Fischer Assay  (Oh,  et  al.,  1985).
                                      2-23

-------
        TABLE  2-6.  NITROGEN PARTITIONING FROM PSD PERMIT APPLICATIONS
% of Raw Shale Nitrogen

Tract
Tract
Paraho

C-b
C-b
Site

(modified
(Lurgi


in-situ)
solids
recycle)
(direct combustion)
Spent shale
21
5(35*)
33
Oil
25
55
37
Water/Gas
54
10
30
in Product
Retort
1000
500
500-700
Temp.
High
Low
C


Medium
*Much of the nitrogen content  in the  spent  shale,  after Lurgi retorting,  (as
 shown in parentheses) is burned in the  lift  pipe  combustion and exits with
 the flue gas.

        These data are consistent with the  trend of  the curves in
Figure 2-8.  The higher temperature retort, modified in situ, has the  highest
percentage of nitrogen in the  gas phase, while  the lower temperature direct
combustion retort has lower nitrogen  and the  solids  transfer Lurgi,  with  the'
lowest retort temperature, has the lowest amount of  nitrogen in the  gas phase.
   3-   Nitrogen species — The  trace nitrogen  species  in retort offgas are
primarily ammonia with small amounts  of other nitrogen  compounds.  In  an
investigation of nitrogen-containing  species  from  an in-situ and an  above-
ground retort process, Sklarew (1984) identified the compounds  in Table 2-7.
                                       2-24

-------
            TABLE 2-7.  NITROGEN-CONTAINING SPECIES IN RETORT OFFGAS
                                 (Sklarew,  1984)

                              Compound            ppm
                       HCN                      6-39
                       Acetonitrile            17-58
                       propionitrile           16-26
                       isobutyronitrile         7-16
                       pyrrole or pyridine      6-45
                       butanenitrile              *
                       pentanenitrile             *
                       pyrrolidine                *
                       benzylamine                *
                       N-methylaniline            *
                       o-toluidine                *
                       N,N-diethylaniline          *
                       ammonia                   1-3%

         *Detected but  below limit of  quantification  (approx.  1 ppm)
2.2.2    Trace Elements
         The principal  source  of  gaseous trace element emissions at an oil
shale facility is the  retort  itself.  The elevated temperatures, from 500 to
750 C in surface retorts and  up  to 1200 C in in-situ retorts, mobilize trace
elements associated with kerogen  and mineral phases and redistribute them
among product gases, oil, process  water, and retorted shale.
        The quantity of trace elements volatilized during retorting has been
studied by making direct, gas-phase measurements and by mass balances in which
gas phase emissions are calculated by difference.  These studies have revealed
that trace element emissions during retorting are controlled primarily by
retorting temperature and configuration and operation of the bed of raw shale
and secondarily, by shale source, heating rate,  and retorting atmosphere.
        The type of process determines the effective retorting temperature.
Thus, higher temperature in-situ retorts will revolatilize greater amounts of

                                       2-25

-------
 trace elements than will the lower temperature processes.  However, the
 relative trace element concentrations using the in-situ processes will be
 lower due to the high amount of dilution gas.
         The flow configuration of the retort gas also effects the trace
 element concentration.  Trace elements volatilized within the retort may be
 adsorbed onto raw shale or retorted shale,  thus reducing and/or retarding
 their release from the retort.  Thus, whether the bed is stationary or mobile
 and whether the gas flow is co-current or counter-current with the bed will
 affect the release of trace elements.
         In-situ retorts are stationary beds of shale with a moving reaction
 zone.   Some trace elements volatilized in the reaction zone may be deposited
 ahead of the reaction zone on cool raw shale and are not released from the
 retort until late in a run when the bottom of the bed is sufficiently hot.
 These volatile trace elements are release'd  to the off gases in pulses towards
 the end of  a run.

         In  surface retorts,  which have moving shale beds with stationary
 reaction zones,  volatilized  trace elements  are continuously released into the
 reaction zone with organic vapors and can be partially deposited either on  the
 retorted shale or  raw shale,  depending on whether co-current  or  counter-
 current gas  flow is used.   Trace  element  emissions from above-ground
 continuous  retorts  are  relatively uniform throughout  a run, with variations
 due primarily to changes in  raw shale feed  composition.
         At pyrolysis  temperatures  of  500  C,  typical of  above-ground,
 indirectly heated  retorts, the  only  trace elements  that  are volatilized in
 significant quantitites are mercury and cadmium.  At higher temperatures
 typical  of above-ground, direct-combustion  retorts  (up  to  750 C  ) and all in-
 situ processes  (up  to 1200 C), other  trace  elements, notably arsenic and
 selenium, also may  be volatilized.  Certain other trace  elements (e.g., the
halides  and volatile organometallic compounds, such as nickel carbonyl) may
also be  released.  However, there are no  definitive data currently available.
         The reader is referred to Appendix B, Trace Elements from Oil Shale
Retorts, for a more thorough discussion of  the individual trace elements and
                                       2-26

-------
their distribution during  the retorting process.   It  should  be noted  that the
majority of this work has  been performed using  small  laboratory retorts or at
pilot-scale, demonstration facilities without control technology  for  the
criteria pollutants.  Therefore,  the applicability of this information to a
commercial oil shale plant with control technology in place  is uncertain.
Retort gases at a commercial plant will be variously  compressed,  heavier
hydrocarbons removed, sulfur and  perhaps N0_ may be reduced, and  the  gases may
be mixed with natural gas  and burned.  Thus, the information presented in the
Appendix should be considered to  be uncontrolled emission data.

2.3     RETORT PROCESSES
        Retort processes can be categorized with respect to both  location,
above-ground or in-situ (underground), and heating method, direct or
indirect.  The above-ground retorting steps include:
            mining and handling shale —• removal of the raw shale,
            crushing and screening, conveying to retort, feeding  retort,
            discharge from retort
            retorting - heating the raw shale to produce oil and  gas
        •   product recovery - separation of oil from gas stream
            product upgrading - removing sulfur, nitrogen and trace
            elements from  the oil product, improve oil quality
            offgas clean-up - removal of I^S (and  organic sulfur) and
            NHg (and organic nitrogen) from retort gas prior to
            combustion or  sale
            spent shale disposal
        Emissions associated with the raw shale mining, crushing,  handling and
spent shale disposal are primarily particulates from solids handling and CO
and NOX from vehicles and other combustion engines.  As these emissions are
similar to those from other ore mining processes the reader is referred to
Section 3.0,  Control Technology Review,  and the EPA's publication AP-42 (1985)
of emission factors for additional background on these techniques and their
emissions.   Also,  the discussions in Section 4.0,  PSD Permit  Application
                                       2-27

-------
Analysis, and Section 5.0, Process Analysis, provide detailed information on
the various emission sources and control techniques.
        Emissions associated with the upgrading process are N0_, CO and SO
                                                              X           X
from boilers, heaters and other combustion devices plus hydrocarbons from
product handling and storage.  These processes and emission sources are
similar to those in the petroleum refining industry, and the reader is again
referred to Section 2 and the EPA's publication AP-42 for a detailed
discussion.  The discussions in Section 4.0, PSD Permit Application Analysis,
and Section 5.0, Process Analysis, also provide detailed information on the
various emission sources and control techniques.
        The following discussion will focus primarily on the retorting
processes, their variations and the effect of the type of process on the
retort gas volume, pollutant concentration and subsequent ease of control.
        Essentially, the following four techniques have evolved to provide
efficient retorting processes:  (These process are shown in Figures 2-10 and
2-11.)
        .   direct heating - above ground with combustion in a
            countercurrent retort
            direct heating - above ground with combustion in a crossflow
            moving grate retort
            indirect heating - above ground with recycled solids or gas
            in-situ - below ground - direct heating with combustion
The approximate retort gas flow rates and pollutant concentrations for each of
these process types is shown in Table 2-8.
                                       2-28

-------
   Raw Shale
 Retort
    Zone


Combustion.
 Zone
	—^ Retort Gas S
       Oil Mist

Combustion
I	 Air


   Spent Shale
A.  Direct heated
    e.g. Paraho
     Raw Shala-
                              Heated .Recycle
                              Gas or Solids
ppop-f- C"ha1 Q^



~n
                                 Retort Gas.
                           Oil
                          Air
                             Char Combustion
                              Retorting
                             Retort Gas
                            & Oil
                                                              Heat
                                                   B.
                                Indirect heated
                                e.g. Union B - recycle gas
                                Lurgi, Chevron-recycle .
                                              solids
                            C.
       Circular grate
       e.g.  Superior

       Either direct or
       indirect heated
      Figure  2-10.   Schematics  of above-ground  retorting processes  (KVB, Inc.).
                                    2-29

-------
                             Oil
         Exit Gas
                                                                Inlet Air
Crille?t   Flame Front |
 Siimn
                                                     Rubbliz   Shale
                                                            T
                                                             I
                              A.  Geokinetics Horizontal/ In-situ Retort.

                                                             I
                                                             I

                                                             I
                      Input Air
                                            Exit Gas
Rubblized
                        "|C"	^Oil                0        500      1000
                         	                            TEMPERATURE, C
                          B.  Occidental Modified In-situ.

          Figure 2-11.   Schematics of established in-situ retorting processes
                        (J&arwal,  1986).
                                         2-30

-------
               TABLE  2-8.  UNTREATED  RETORT GAS  CHARACTERISTICS
Type of Heat
direct-combustion
direct-combustion
direct-combustion
indirect-no comb.
m3 Retort Gas/
Location m Oil Produced
in-situ
above ground
(circular grate)*
above ground
(Paraho)
above ground
(Union, Chevron, etc.]
7000
2000
2000
200
)
H2S
ppm
1200
0
4000
40000
so2
ppm
0
80
• 0
0
*Circular grate operates with excess air— others are starved air.
        The gas production rate varies from a minimum of 200 m3 retort gas/m3
of oil for the indirect heating mode to a maximum of 7000 m  retort gas/m3 of
oil in-situ direct combustion mode, or a 35:1 increase.  This is the same 35:1
ratio which appears in the pollutant concentration.
2.3.1   Above-Ground Retorts
        Surface retorts are moving-bed, continuous reactors.  Various types
involve cocurrent or countercurrent flows, and examples in which the gas sweep
is up, down, or horizontal may be found.
A.      Direct Heating - Countercurrent Flow —
        In the direct heating mode (Figure 2-10a) combustion air is introduced
into the retort to burn the residual carbon and provide the heat necessary for
the retort process.  Raw shale and hot combustion gas flow countercurrently,
the shale is heated and retorted producing oil and retort gas.  However, the
internal combustion results in the dilution of the retort offgas producing a
large quantity (2,000 in-situ, m3/m3 of oil) of low heating value [9 kJ/kmole
(100 Btu/scf)] gas with a relatively low pollutant concentration (1500 to 4000
ppm H2S).  Consequently, it is difficult to condition and use the retort
offgas.
                                       2-31

-------
 B.       Indirect Heating—
         In  the  indirect-heating mode (Figure 2-10b),  the retort heat is
 provided by either  recycled retort gas  or recycled solids.   Due to the absence
 of  combustion in the  retort,  this process produces a  low quantity of retort
 gas (200 m3/m3  of oil)  of  high heating  value [90 kJ/kmole (1000 Btu/scf)]  with
 relatively  high pollutant  concentrations  (e.g.,  35,000 to 40,000 ppm H2S).
 However,  the heat for retorting must be supplied by burning some source of
 fuel, either the offgas, part of the produced oil,  natural  gas  or the carbon
 residue  in  the  spent  shale.
         Since the spent shale from an indirect heated retort contains about
 four percent carbon,  it is feasible to  burn  it to recover the additional
 energy content.  The  spent shale is conveyed to  a combustion reactor where
 oxygen is introduced  and the  char is burned.   A  spent shale combustor also can
 be  used  to  burn unprocessed raw shale fines  and  low Btu gas,  again with
 minimal  sulfur emissions due  to the chemical  nature of the  spent  shale.
 Combining the spent shale  combustion with recycle solids heating  results in
 the low H2S  and SOX emissions  discussed above in Section 2.1.1.4.
 C.      Direct Heat - Cross Flow Moving Grate Retort—
        The  moving grate is a  continuous  above-ground retorting method  that
 uses a cross flow between  the  shale and the heating gas.  The cross  flow
 pattern provides improved  control of the  relative gas  flow  rates  and  various
 zone temperatures compared with the countercurrent  direct heating mode.  The
 moving grate approach also provides for easy  transfer  of  the  spent shale
 solids from  the retorting  zone  to the spent shale combustion  zone.
        The  process utilizes a  moving bed  retort  (Figure  2-10c).   Raw shale is
 fed onto a moving grate where it  is first  preheated with exhaust  gases.  The
 shale then moves into the  retorting zone where it is heated to retorting
 temperature  and oil is evolved  and  carried away with the circulating  gas
heating media.  Variations of the process  involve multiple retorting  zones
with individual temperature control  to  produce specific oil products  (heavy,
light, etc.).  The retorted shale is then  passed  through the  carbon recovery
zone where residual carbon is partially oxidized, a portion of the low heating
                                       2-32

-------
value retort gas  is  burned  and  oil  evolution  is  completed.   The  spent  shale
then continues into  the  shale cooling  zone. Recycle  gas  is  heated  in the  shale
cooling  zone by recovering  sensible heat  from the  hot  retorted shale.   The
shale is further  cooled  by  ambient  air which  is  heated for  use in  the  direct
fired burners or  alternately in the indirect  heater.
         The retort offgas and combustion  flue gas  are  combined prior to oil
recovery.  The oil and water are removed  from the  circulating gas  which is
then divided into a  recycle stream  for spent  shale combustion and  a low
heating  value gas for steam generation.
         This system  can  be  operated in either the  direct or indirect heating
mode.  However, the  development  work and  proposed  plants are all based on the
direct heating mode  that produces a relatively large quantity of retort gas
with a low pollutant concentration.  As this  process includes the  combustion
of the spent shale with  the low Btu gas,  the  reactions described above for
spent shale combustion are  applicable.  Therefore, the sulfur present  in  the
retort gas is removed and the exit  gas SOX concentration is  low  (50 to 100 ppm
S02).  However, since the combusted solids are not recycled  to the retort, the
reactions limiting ^S formation do  not apply.
2*3*2    In-Situ Retorts
        Above-ground processing  of  oil shale  requires mining large amounts of
solids and the subsequent disposal  of approximately 80 percent of the  material
mined.  This large amount of solid handling and  disposal is  costly.  An
alternative to above-ground processing is in-situ retorting which recovers the
energy content of the oil shale without requiring solids removal, handling and
disposal.  In-situ processing also allows consideration of low quality shale
(10 gal/ton) which would be uneconomical by above-ground techniques.   The
solids handling emissions are decreased, however, the increased gas flow rates
required for in-situ retorts can result in increased pollutant emissions from
the gas conditioning and combustion processes.
        The various direct combustion processes for in-situ oil shale
retorting are basically similar with regard to the reactions that take place,
although they differ in geometry and flow configuration.   Each may be
                                       2-33

-------
characterized as a semi-batch, fixed-bed reactor in which reaction zones,
commonly called fronts, are swept through the bed by a stream of injected
gas.  The sweep contains oxygen to sustain the combustion and inert gases,
steam or recycled produced-gas to control it.  Differences exist principally
in the flow patterns that prevail.
        Two processes that have been developed for commercialization are the
horizontal in-situ retort and the modified in-situ retort (Figure 2-11).  In a
vertical modified in-situ (VMIS) retort, the major dimension of the bed is
vertical, the fluids flow downward, and gravity and pressure forces are
parallel.  This may be considered most likely to produce uniform, one-
dimensional flows with nominally flat, horizontal fronts.  An upward-flow,
vertical retort might exhibit reduced yields owing to the tendency of the
produced fluids to drain back into the reaction zones.  A horizontal retort,
with both its major dimension and flow oriented horizontal is characterized by
nominally one-dimensional flow, however, gravitational forces act
perpendicularly to the imposed flow.  Generally, vertical plane fronts would
be preferred, but because of the gravitational effects, the fronts may tend to
tilt or override and be more difficult to control.
        The behavior of an in-situ retort is"most easily illustrated by
considering the reactions occurring in various sections in an in-situ
retort.  After an initial startup period, the combustion retorting process
reaches a quasi—steady state characterized by a slowly moving temperature wave
which moves progressively through the retort.  The temperature distribution
defines the reaction zones depicted schematically in Figure 2-11.
        Near the exit, there is relatively cool, raw shale, and the dominant
process is water condensation.  Except for a period near the end of a run, the
gas will therefore exit at close to the dew point temperature.  Somewhat
higher temperatures exist in the next higher levels of the retort where oil
may condense and the water originally in place will vaporize.  As the fronts
move through the retort, the oil is condensed ahead and revaporized
repeatedly.  Kerogen decomposition occurs in the next higher levels of the
retort. Conversion rates become appreciable as the shale approaches 300 C
(570ฐF), and decomposition is essentially complete at 500 C (900CF).
                                       2-34

-------
        The highest temperatures in the retort occur in the combustion zone,
the region next upstream from the retorting zone, where the injected oxygen is
consumed in burning the carbon residue within the particles and the coke
deposited on their surfaces.  This normally supplies all the heat necessary to
sustain retorting.  Produced gas and oil will also burn if present in the
oxygen-containing region.  Optimum control will therefore aim at separating
the combustion and retorting zones as much as possible.
        It is this region of high temperature combustion plus the variation in
bed temperature in the retorting zone due to localized heating that results in
higher sulfur, nitrogen and trace element gas emissions from in-situ retorts.
        The region near the inlet of the retort is the gas heating zone where
the spent shale is cooled as heat is transferred from the solids to the
incoming gas.  The combustibles in any produced gas that is recycled will burn
in this region when they reach their ignition temperature.

2.4     PROCESS DESCRIPTIONS
        The following discussion covers brief descriptions of eleven specific
processes being considered for full scale commercial retorting.  This
information was obtained primarily from previous reviews of oil shale retort
processes.  The reader is referred to references Agarwal, A. (1985), Shih,
C. C. (1979), TRW (1979), and LLNL (1985), for more detailed description of
each process as well as other processes that have been considered.
2.4.1   Paraho Retort Process
        The Paraho retort (Figure 2-12) is a continuous vertical kiln for
retorting oil shale.  Crushed shale flows downward and is contacted with a
countercurrent stream of hot gases which provide sufficient heat content to
pyrolyze the kerogen in the shale.  The oil is carried out of the top of the
retort as a stable mist with the gas stream, and the retorted shale is removed
from the bottom.
A.      Directly Heated Mode—(Figure 2-12a)
        Raw shale is distributed evenly across the top of the bed. Shale flows
downward and is warmed by ascending hot gas in the mist formation zone.   Next,

                                       2-35

-------
                   Raw Shale
                  A
Mist
Formation
Retorting
Combustion
Cooling


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Cooling Gas
^ Retort
W' Gas
Recycle Gas
                            Retorted Shale
A.  direct combustion
                    Raw Shale
                 A
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Retorting
Heating
Cooling
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   Figure 2-12.   Paraho  retort  (adapted  from Agarwal,  1985).

                                 2-36

-------
 the preheated shale passes through the retorting zone where the kerogen is
 decomposed into oil, gas,  and char.  The char remaining on the retorted shale
 serves as fuel for the process in the combustion zone.  Air for combustion is
 distributed evenly across  the bed in an air-gas mixture by at least two levels
 of distributors.  In the lower section of the retort, the shale is cooled by
 bottom recycle gas and this gas,  in turn, is preheated before entering the
 combustion zone.  The cooled,  retorted shale passes through a rotary seal and
 is conveyed to a shale disposal area.  Oil,  as a stable mist,  is swept out the
 top of the retort through  the offgas collector and is separated from the gas
 in a coalescer-electrostatic precipitator system.
 B.      Indirectly Heated  Mode—(Figure 2-12b)
         In the indirect mode the  retort heat is provided by heating the
 recycle gases  in an external heater.   The offgas product is not diluted by
 combustion gases and has a high energy content [78 kJ/kmole (885 Btu/scf)].
 However,  the spent shale contains two to four percent carbon residue
 representing an energy loss  and decreased efficiency.
         The principal zones  within the retort are  essentially  the same as  the
 direct  mode, except  that in  the indirect  mode,  the combustion  zone  becomes the
 heating zone.
         Because of  changes  in  the nature  and flows of  the recycle gas,  the
 temperatures of  both  the offgas and retorted shale  are somewhat hotter  for the
 indirect mode.   Both  the retorted shale and  the  offgas temperatures  average
 approximately  150 C  (300ฐF).
 2.4.2   Hytort  Oil Shale Retorting
        Eastern  shales produce  a much  lower  yield of oil plus gas than western
 shales despite the fact  that the organic carbon content is similar.  This is
 due to the lower hydrogen-carbon ratio present in Eastern shale as well as
 structural differences.  The Institute of Gas Technology has found that
retorting in the presence of high partial pressure of hydrogen greatly
increases the yield of oil and gas and has developed the HYTORT process.
        The HYTORT Retort (Figure 2-13) consists of an indirect heated moving-
bed-type retort with countercurrent contacting of hydrogen and shale.  Crushed

                                       2-37

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  Raw
Shale
    H
-D
        PEEHEATER
                         .Oil/Gas Recovery
                        PREHYDROGENATION REACTOR
Shale
                      PREHEATER
                                                Oil/Gas Recovery
                                        GASIFICATION RETORT
                                                     Shale
                 Figure 2-13. Simplified schematic of the Hytort process
                              (KVB. Inc.).
                                   2-38

-------
shale is first heated with recycle hydrogen to about  425  C (800ฐF)  for shale
prehydrogenation.  This prehydrogenation stage allows  for greater recovery of
the carbon content of the shale.  The shale then  is contacted  concurrently
with hot reactant hydrogen increasing its temperature  to  650 C (1200ฐF)
resulting in shale gasification.  The pressures used  have been from (1400 to
3400 kPa (200 to 500 psi) and average temperatures from 650 to 800  C (1200 to
1475ฐF).  In the bottom of the retort, the spent  shale is cooled by
countercurrent contact with warm (preheated) hydrogen  which carries that  heat
upward to effect the retorting.  For Western shales,  the  retort would operate
at 1700 kPa (250 psig).
        Spent shale is removed from the reactor through liquid sealed
lockhoppers.  Product gas is scrubbed to recover  water and shale oil and  then
treated to remove acid gases.  A bleed stream of  the  clean gas is sent to the
steam reformer where hydrocarbons are converted into  hydrogen. All the make
up hydrogen requirements of hydroretorting and catalytic  hydrotreating are to
be produced in this fashion and it is expected that no hydrogen will need to
be purchased.
        HYTORT shale oils from both eastern and western shales have relatively
low viscosities and pour points.  They can be pumped  through pipelines in the
raw state, in contrast to most shale oils from thermal retorting processes.
HYTORT shale oil from Colorado shale is lighter in color  and contains 30
percent less sulfur than oils from conventional retorting, because  of the high
pressure hydrogen treatment.  However, like all shale  oils, HYTORT  oil
requires catalytic hydrotreating to reduce its sulfur  and nitrogen  to
acceptable levels.
2.4.3   T3 Oil Shale Retorting
        The NTU/T3 consists of the NTU batch retorting process with
significant improvements based on recent technology development including the
vertical modified in-situ oil shale process.
                o
        In the T  process a mixture of air and steam  instead of air and
recycled gas is used for retorting. The use of steam  results in an  increase  in
                                       2-39

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 the retorting rate,  control of maximum retort temperature, and the water gas
 shift  reaction,
                             CO + H20 —-> C02 + H2
 The net  result of  this  reaction is to increase the combustion rate of residual
 carbon in spent  shale,  increase the hydrogen production per ton of oil shale,
 and reduce the oil loss due to thermal cracking.
              o
         The T retort process  is a semi-batch process where the two reaction
 vessels  alternate  between  retorting and retorted shale combustion and cooling
 (Figure  2-14).   The  process operates in the following manner.   At the end of a
 cycle, the Vessel  A  that had been functioning as the  retorted  shale combustion
 and cooling vessel has  been filled with raw shale and will now function as the
 retort vessel.   No shale is added during the retorting process and the retort
 heat is  provided by  the air-steam mixture from Vessel B.   As  the raw shale is
 retorted,.the  retorted  shale front moves down the vessel,  much in the same way
 that the front moves down  the  vertical in-situ retort.  The retorting is
 complete when  the  vessel is filled with hot,  retorted shale.
         While Vessel A  is  functioning as the retort,  Vessel B  is functioning
 as  the retorted  shale combustion and cooling vessel.   Air  and  water are
 introduced to  the  bottom of the  vessel,  which contains  hot, retorted shale
 from the previous  cycle, and the water is  vaporized to  steam while  cooling the
 hot  shale.  The  air-steam  mixture flows  up the vessel  and  burns  the residual
 carbon char on the retorted shale.   The  heat  released  is contained  in the.air-
 steam mixture which then flows to Vessel A where  the  gas flow  provides  the
 heat for  retorting the  raw shale  in Vessel  A.
        As the lower section of  the hot  shale  is  cooled, it is discharged  and
 an equal volume of raw  shale is  introduced  in  the top of Vessel  B.  At  the
 completion of the cycle, Vessel  B  is  filled with preheated  raw shale  ready  to
 be retorted and Vessel A is filled  with  hot, retorted shale ready to  be burned
for  its  char value and  then cooled  and discharged.
2.4.4   Lurgi Ruhrgas Retorting Proces s                      '
        The Lurgi Ruhrgas Retorting Process is an indirectly heated continuous
process in which a fine-grained heat carrier is circulated from a combustion

                                       2-40

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                         Raw Shale
     Air  S  Steam
Vessel

   A

(Retort
 Mode)
 To
 Oil/Gas
 Recovery
                       Vessel

                         B

                       (Cooling
                        Mode)
       Combustion of Char


       Cooling


       4—Air
       4—Water

Cooled Spent Shale
Figure 2-14.  Schematic of the T  process  (KVB,  Inc.)
                 ,2-41

-------
zone to a retorting zone to supply the retort heat  (solids  recycle heating).
Heat is transferred from the hot recirculated solid to  shale  feed in a
horizontal screw mixed retort  (Figure 2-15).
        Raw oil shale (including fines) is mixed with six to  eight times as
much hot spent shale.  The raw shale feed is rapidly heated to about 450 to
600 C (840 to 1100ฐF) where retorting occurs.  The  retorted shale mixture
passes to the lift pipe where  preheated combustion  air  is introduced to burn
residual carbon from the spent shale.  The combustion gas and heated shale
residue are separated at about 600 to 700 C (1100 to 1300ฐF).  The heated
spent shale is recycled to provide the heat for the retorting process.
        The volatile gas stream contains oil product, retort  offgas containing
H2S and NHg and entrained dust.  Cyclones are used  to remove  the bulk of the
entrained dust.  The gas is then scrubbed with oil  in a series of absorption
units for product -recovery.  The retort gas is then treated to remove the NHo'
and l^S and burned to produce  steam and/or electricity.
        Combustion gas leaving the collection bin enters the  primary cyclone
where most of the dust is removed.  The gases are passed through the heat
recovery train, secondary cyclone, humidifier, and  finally  an electrostatic
precipitator before being discharged to the atmosphere.  The  spent shale
combustion results in the reaction of the sulfur gases reducing the SO  to a
concentration of 70 to 100 ppm.
2.4.5   Tosco II Oil Shale Retorting
        The process is indirectly heated and employs a solid-to-solid heat
exchange (between hot ceramic balls and raw shale)  as a means for providing
the heat of retorting.  While this process could be  termed  a  solids recycle
heater, the solid material being recycled is not spent shale  so the reduction
of H2S evolution is not obtained.  The integral parts of the TOSCO II
retorting system are:  retort and accumulator; product fractionator;  processed
shale removal system; ceramic ball system; and raw  shale preheat system
(Figure 2-16).
        The raw shale is fed into a slightly inclined,  rotating drum where it
is preheated to approximately 500ฐF.  Ceramic balls, at 1.5 times the shale
                                       2-42

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                                           2-43

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                                                          FINES TYPE TOSCO II RETORT
7igure 2-16.  Fines  type Tosco II retort  (Quintana Minerals Corp.-PSD
              Permit Application, 1982).
                                       2-44

-------
mass flow rate, and previously heated  to  about  800 C  (1300ฐF), are also added
to the retort.  The rotating, mixing action results in pulverization of the
raw shale.  Heat transfer  from the  ceramic balls raises  the shale temperature
to approximately 500 C  (900ฐF), and pyrolysis,  or retorting, of the kerogen in
the shale occurs.  The  pyrolysis vapors and the mixture  of balls and pyrolyzed
shale are then taken to an accumulator vessel.  This  accumulator consists of a
rotating, perforated screen or trommel which retains  the balls but allows the
pulverized shale to pass through, thus affording a separation of the two.  The
pyrolysis vapors are removed from the vapor dome at the  top of the accumulator
and sent to a fractionator for oil  recovery, while the ceramic balls are sent
for recycling and the processed shale is  eventually sent for disposal.
        In the oil recovery section the pyrolysis vapors are separated by the
fractionator into gas,  naphtha oil, gas oil, bottom oil, and gas condensate,
or foul water.  Each stream is sent to its respective processing unit for
appropriate treatment.
        Processed shale dust, contained with the ceramic balls as they emerge
from the accumulator, is removed by hot flue gas from the steam superheater.
The particulate matter  is  subsequently converted to a sludge in the venturi
wet scrubber and sent to the disposal area.  The clean flue gas is emitted to
the atmosphere through  the scrubber stack.  The clean ceramic balls are then
transported by a bucket elevator to the ball heater for heating and recycling
back to the retort.  In the ball heater,  treated fuel gas and shale oil are
burned by atomizing the fuels with air in a vertical combustion chamber at the
top of the vessel.  Hot flue gas thus generated passes downward,  concurrently
with the balls, thereby heating them.  The flue gas is separated from the
balls in the gas disengagers and the hot balls are returned to the retort.
        The hot spent shale from the accumulator is taken to rotating drum
steam generator/cooler where it is  cooled to about 150 C (300ฐF)  by indirect
heat transfer to the feedwater to generate some process steam.  The cooled
spent shale is then taken  to another rotating drum and processed shale
moisturizing water is added.  Steam incidentally produced during  the
moisturizing operation  entrains some processed shale dust which is removed in
the venturi wet scrubber;  the steam, along with a little particulate matter,
                                       2-45

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 is released to the atmosphere through the scrubber stack.  The spent shale,
 cooled to below 100 C (200ฐF) is moisturized to approximately 14 percent water
 by weight (to aid compaction and dust control) and then transported to the
 disposal area.

         The disengaged hot flue gas is used to preheat the raw shale feed,
 thereby recovering most of the waste heat.  The preheating system consists of
 a series of three lift pipes (or preheat zones),  a thermal oxidizer
 (incinerator), cyclones and wetscrubbers.   The flue gas is introduced at the
 bottom of the last lift pipe (first preheat zone),  where the raw shale stream
 from the second lift pipe  (second preheat zone) is  also received.   The solids
 are lifted pneumatically and heat transfer  from the gas to the shale occurs.
 The preheated shale is accumulated in a collecting  bin at the top  of the lift
 pipe and sent to the retort.   Residual dust in the  flue gas is separated by a
 cyclone and added to the feed going to the  retort.
         Since the flue gas temperature is at its  highest when introduced to
 the last lift pipe (first  preheat  zone), it partially  retorts the  very fine
 shale,  which results in hydrocarbon vapor release into the flue  gas.
 Therefore,  the flue  gas  is  introduced to a  thermal  oxidizer (located  between
 the first and second preheat  zones)  to burn the hydrocarbons  so  that  the
 hydrocarbon emission to  the atmosphere is not  excessive.   Some shale  oil,
 liquids,  and air are also  added  to the oxidizer to  sustain combustion.   The
 resulting flue gas is  cooled, and  then introduced to the  bottom  of the other
 two lift pipes.   At  this point,  the  temperature of  the  flue gas  is low enough
 so  that  the  extent of  retorting  of the  fine  shale is less  than in the  first
 preheat  zone.   Hydrocarbons released in these  two lift  pipes  are emitted with
 the  flue  gas, without  incineration.
 2.4.6    Union A,  B,  C  and SGR
        All  four  of  the processes  developed by Union Oil Company are
variations of an upflow vertical kiln retort using a rock-pump shale feeding
mechanism  (Figure 2-17).  The retorts  are known as Retort A, Retort B, Retort
C and SGR-3.   In all three processes, ,the oil shale is pushed upward through
the  retort while the gas flow is downward.  The Union Retort A is a direct-
heated retort where the heat for pyrolysis is generated by internal combustion

                                       2-46

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Spent
Shale
                  Combustion Air
Shale cooling/preheat combustion air
 char combustion
                               Oil/gas to recovery
                                         Union A
                                         Direct heat
                 Raw Shale
 Spent
 Shale
                            Recycle Gas
                                                         Flue Gas
                                  _.  Oil/Gas to Recovery
                                                                       Heater
                                                                     —    ,
                                                   Fuel
                     Raw Shale
                                                                    Union B
                                                                    Indirect heat
                                                                    with recycle  gas
                                                           Recycle  Gas  (or Steam
                                                                      and Gas)
                          Raw Shale
                                  Spent  Shale

                                            Union C
                                            SGR With
                                       (Items  in parenthesis
                       Combustion Air   for SGR only).
                                        , product

                     Figure 2-17.   Union processes  (KVB,  Inc.).

                                        2-47

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 of  residual carbon on the  spent  shale.   In  Retorts  B  and  C  and -SGR,  the heat
 is  supplied indirectly by  externally heated hot  gases.
 A.      Union A—
        In the  Ifaion  A process,  air is  introduced at  the  top of  the  retort to
 support combustion of residual carbon on retorted shale fragments in the upper
 portion of the  retort.  This  combustion provides the  heat necessary  to retort
 the upward-moving shale.
        As the  shale  enters the  retort,  it  is  contacted by  a countercurrent
 flow of hot gases leaving  the combustion and/or  retorting zones  above.  In
 this lower zone,  the  gas-cooling zone,  heat is transferred  from  the  hot gases
 to the cool incoming  shale.  The feed is preheated, and the oil  vapors are
 condensed while the gases  are cooled.   Passing up through the retort, the
 preheated shale enters  the retorting or  pyrolysis zone.   The gases passing
 downward in this  area heat the shale to  a temperature such  that  organic
 material is pyrolyzed,  producing shale  oil  vapor, product gas, and residual
 carbon on the surface of the shale.  As  the gaseous products of  pyrolysis are
 evolved, they are swept downward by the  flow of  combustion gases.  The
 downward sweep  of pyrolysis to the cooler region of the retort helps limit
 product degradation (cracking and coking).
        The retorted  shale fragments then enter  the combustion zone where they
 encounter preheated combustion air passing  down  through the retort.  This air
 sustains the combustion of the residual  carbon that remains on the surface of
 the shale after retoring.  Excessive temperatures must be avoided to limit
 fusion of the shale and formation of clinkers.
        The hot spent shale leaves the combustion zone and enters the top most
 zone, the air preheat zone.  In  this area,  heat  from  the spent shale is
 transferred to the  cool incoming combustion air,  thus preheating the air
 before entry into  the combustion zone.  Upon leaving  this zone,  the shale is
pushed up over the  top of  the retort and falls into the ash disposal chute.
B.      Union B—                                     -             -    .
        The Union B is an  indirect retorting process based on the upflow of
shale.   The process is similar to the directly heated retort described  above

                                       2-48

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 with the exception that the retort heat is supplied by externally heated gas
 resulting in lower retort gas volumes with high pollutant concentrations.
 C.       Union C and SGR--
         The Union C and Steam-Gas Recirculation Retort (SGR-3) are similar to
 the Union B retort (downward gas flow with indirect heat) but also provide for
 the combustion of the residual carbon in a separate vessel thus producing
 enough hot flue gas to supply all of  the retort heat requirements.  The spent
 shale combustion results in energy recovery and reduction of sulfur
 emissions.   In the SGR system the addition of steam increases the retorting
 rate and energy recovery due to the water/gas shift reaction as used in the T3
 process.
 2.4.7   Circular Grate Retort
        The circular grate  is a  continuous moving  bed  above-ground  retort.
The doughnut-shaped retort  is divided  into five  separately  enclosed
sections:  a loading zone,  a retorting zone,  a residual  carbon  recovery  zone,
a cooling zone, and finally an unloading zone (Figure  2-18).  The ability to
control the process conditions as the  solids  move  through the retort allows
for variations in retort and combustion conditions to  provide specific
results.
        The raw shale is fed to  the traveling grate so that the finest
material is at the bottom and coarsest on top.   The prepared bed of shale
passes first into the retorting  zone where it contacts a stream of hot gases,
and retorting occurs as the hot  gases pass down  through the bed of shale.  The
oil and gas mixture passes to a  separator/condenser system where shale oil is
recovered, and the cooled recycle gases then pass through the retorted shale
bed in the cooling zone of the retort to cool the processed shale before
dumping and provide heat for the recycle gas.
        The shale is cooled further by ambient air which is heated for use in
the direct fired burners or alternately in the indirect heater.   This energy
recovery improves thermal efficiency.  The rotating grate is sealed between
stationary hoods on top of the bed and the windboxes underneath by water
troughs on both sides of the shale bed.
                                       2-49

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                 MOT
               RECYCLE
                 GAS
SHALE
FEED
                             SPENT SHALE DISCHARGE
       A. Isometric view
     HOT RECYCLE GAS
                                                EQUIVALENT TO AN
                                                ADMBATC RETORT
                                                FIXED BCD SECTION
                                        COOL RECYCLE  GAS
  SHALE
   FEED
                         DIRECT I
                         HEATING
                         BURNERS
                                      PREHEATED COMBUSTION AIR
                                         AIR IN
                                GAS
"ICOOLING"
 | BY AIR
 I
                        CARBON
                       RECOVERY
                                                         PROC-
                                                         ESSED
                                                         SHALE
                                                          LIQUID
                                                          SEAL
                                            GAS  BLOWER
                                                    GAS COMPRESSOR
                                                   ^SURPLUS RETORT
                                                          GAS
                                •>OIL 81 WATER
B. Straight  Path Representation              .
   (The circular path of the solids bed  is
    pictured as a straight path for clarity)
  Figure 2-18.  Superior  direct-heated process  (Agarwal,  1986).

                                   2-50

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        Preheated recycled gas from the shale cooing zone is further heated by
mixing with hot combustion gases of 1370 to  1650 C  (2500 to 3000ฐF).  The
resulting gas mixture, at 680 to 815 C (1250 to 1500ฐF) is introduced into the
shale heating zone completing its cycle.
        Product gas is taken as a slip stream from  the recycling heating media
gas.  A high Btu gas of 14,900 to 22,400 kJ/m3 (400 to 600 Btu/scf), depending
on grade of feed shale) is produced by using the indirect heating mode.  The
gas produced from direct heating is diluted by combustion gases (COo and No)
and has a heating value of 3000 to 4200 kJ/m3 (80 to 130 Btu/scf) depending on
shale grade.
        This process takes advantage of the chemistry of spent shale
combustion to limit the SOX emissions from this portion of energy
generation.  The moving grate process also has the  capability to control the
combustion conditions for staging and N0_ emission  control.
                                        X
2.4.8   Fluidized-Bej (Che^r^gn_^TB_qil_Shale Retorting)
        The Staged Turbulent Bed (STB) retort is a  small-particle indirectly
heated retorting process in which retorted shale is burned in a separate
combustor and recycled to the retort to supply the  process heat requirement.
The flow scheme for the core of the process is shown schematically in
Figure 2-19.
        The environment in the retort section, Figure 2-20, can best be
described as a staged, moving bed of particles, in which a portion of the
particles are "fluidized."  Solids first move downward through the retort.
The internal design creates a staging effect approaching a plug flow pattern
with countercurrent gas flow thereby minimizing the residence time required to
assure complete retorting.  The solids then flow upward in the second stage
with co-current gas flow.  The two-stage approach provides for equal residence
times for large and small particles.  During the downflow, the heavier
particles drop quickly, however, during the upflow, the larger particles rise
more slowly.
        Within each stage, conditions have all the appearances of fluidized
state, although the superficial gas velocity is far below the minimum
                                       2-51

-------
  CflS
PRODUCTS   t     O1
         u
         M
         z
         u
         O
         z
         O
         u
FOUL UBTER
    ,
PRODUCTS
                                      RflU SHALE
                                            STflGED

                                         FLUII1I2ED-BED
                                            RETORT
                       SOLIDS
                      RECYCLE
F1HES
                     RECYCLE CflS
                                                            BURN

                                                            SOLI
                     SOLIDS
                                           FLUE CflS
ฃ

O


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  Figure  2-19.   Schematic of  a fluidized-bed retort system (Diaz  & Braun,

                  1985).
                                        2-52

-------
     Top of baffle
Hot shale i
    Raw shale in
    Bottom of baffle
   Gas distributor^ r
   plate         *"t
                                  Shale put
                                    _ Fluidizing
                                    gas
                                                     Burned
                                                     shale -
                                                                      Baffle
                                                                        Spent
                                                                        shale
                                                              Raw shale
Figure 2-20.  Two-stage  fluidized-bed retort (Mallon,  1985),
                                       2-53

-------
 fluidization velocity of many of the particles.   Rapid local mixing and a high
 rate of heat transfer keep  the temperature profile in the retort very nearly
 isothermal.
        The retort  can be operated with a stripping gas consisting of either
 recycled product gas,  steam,  or an inert gas.
        The fresh shale throughput for  this process is 5-10 times that of most
 other retorting processes.  The use of  small shale particles,  the excellent
 heat transfer conditions in the retort,  and the  "staging" effect in the retort
 make the residence  time required for complete  retorting quite  low.  The
 extremely low residence time  required in the combustor is a consequence of the
 high reactivity of  the  carbonaceous residue.
        The combination of  thermal shock experienced by the fresh shale on
 entering the retort,  removal  of the binding kerogen,  and turbulent conditions
 within the retort causes some breakup of the shale.   The finest  particles
 ซ200 mesh) are swept overhead from the  retort with the product  vapors.   Most
 of the elutriated particles are recovered from the vapor stream  before
 condensation of the oil.  The recovered  particles,  collected by  primary and
 secondary devices,  contain  carbonaceous  residue;  and they are, therefore,  sent
 to the combustor section for  recovery of  their fuel  value.
        In the product  recovery section,  the product  vapors are  condensed in
 stages producing several  oil  fractions and  foul water.   The initial
 condensation stage has  to be  capable  of  handling  some  solids, as  the  fines
 removal equipment is never  100 percent efficient.  The  non-condensible  gases
 are either produced directly  or  a  portion is recycled  to the retort for
 stripping.  With very le.an shales,  some  or  all of  the product gas  can  be  used
 as a supplemental fuel  in the  combustor.
        The combustion  section  receives  coarse retorted  shale withdrawn  from
 the bottom of the retort  and  retorted shale  fines  removed  from the product
vapors.  Air injected at  the  bottom of the  combustor both  transports the  shale
pneumatically and combusts the  carbonaceous  residue.  The  temperature  of  the
solids rises rapidly.  At the outlet of the  combustor, a solid separator
splits the stream once again  into  fine and  coarse  fractions.  Most of  the hot,
                                       2-54

-------
 coarse fraction is recycled to the retort to provide the necessary process
 heat.  The excess coarse shale is sent on to the heat recovery section, from
 which it eventually discharges as wet coarse spent shale.  The fine fraction
 exits the separator with the flue gas.  This stream is also sent to the heat
 recovery section where it is cooled and then separated into a wet fine spent
 shale stream and a flue gas stream.  The SOX content of the flue gas is
 claimed to be unusually low ซ20 ppm) because of the scrubbing action of the
 shale itself.
 2.4.9   Cascading-Bed Retort and Combustor
         The Cascade-Bed Reactor has been developed by Lawrence Livermore
 National Laboratory (LLNL)  to take advantage of the significant performance
 improvement inherent in retorts employing the solids recycle heating and spent
 shale combustion process while making significant improvements in various
 portions of the process.
         The Cascade-Bed system is shown in Figure 2-21.   Raw shale and hot
 burned shale are mixed by gravity flow in a series of inclined planes
 (Figure 2-22).   The mixed shale is then retorted on a moving packed-bed
 pyrolyzer (Figure 2-23). The retort  gas  is removed at several locations to
 prevent fluidization of the solids.
         A lift  pipe,  sized  for optimum pneumatic transport (a significant
 advantage of this system over the combined lift pipe-combustor in the
..fluidized bed system)  conveys the retorted shale to the  top of a cascading-bed
 combustor (Figure 2-22).  Gravity-delayed fall  of the shale through this
 combustor yields sufficient residence time for  burning the char to reach the
 burned-shale temperature required for retorting.  Low pressure drop and  low
 elutriation of  fines  are major advantages of using a cross-flow of air.
         An additional  advantage is that cross-flow combustion  allows  for easy
 control of the  operating conditions (excess  oxygen and temperature)  on each
 stage  which can be  used  to  reduce NC>   emissions.
                                    X
 2.4.10  Occidental  Vertical  Modified  In-situ (VMIS)
         The Occidental Vertical Modified  In-situ (VMIS) process is  a
 combination of  above-ground  and in-situ processing.   True  in-situ processing,

                                       2-55

-------
Air
Raw shale
Pyrolysis products
Waste shale
                                  Recycle shale
                          i
                      Combustor
1
              Flue gas
                            Burned shale
   Mixer
    and
 pyrolyzer
       Retorted shale
       Recycle shale
                        Surge
                         bin
                                   Flue gas
                             II
                                                   V
                                                   Q.
                          |        Recycle shale   f f        Air
  Figure 2-21.. Concept for cascading-bed retorting system  (Braun, et al,  1985),
                                2-56

-------
              Air plenum^.
               Air orif i
                                       Incoming  shale
-Gas discharge
 plenum

-Gas discharge
 port

•Baffle
                                      -Discharge shale
Figure 2-22.   Cascading-bed oil shale  combustor  (Cena,  1985),
                                 2-57

-------
               Level detector
                & controller
                                          (7=*
 To oil
collectors
                         Rotary/'
                          valve [    o
Figure  2-23.   Soak  tank portion of cascading-bed retort  (Cena, 1985)
                                     2-58

-------
i.e., processing all of the shale without mining, is difficult to control and
consequently presents serious limitations on the recovery of the total
potential energy source.  {The primary considerations in maximizing yield and
minimizing operating costs in in-situ processing are the gas flow rate,
temperature profile and gas pressure drop.]  The Occidental process is based
on the fact that a greater degree of predictability and hence control of both
the initial retort bed conditions and the operating parameters can be obtained
when the degree of rubblization to prepare the shale for retoring is closely
controlled.  The method of achieving this control is to first remove 20-30
percent of the shale rock by "room and pillar" mining and then rubblize the
remaining shale into the complete volume.  The concept is illustrated in
Figure 2-24.  This technique results in more uniform gas flow rates and easier
control over retort conditions to improve yield.
        A complete Occidental MIS retort facility consists of both an above-
ground retort to recover the oil and gas from the 20-30 percent of the raw
shale mined to prepare the in-situ retort.  Occidental Shale Oil Corporation
has considered various above-ground processes for their Cathedral Bluffs
facility, however, they have not made a final decision as to which process
they will use.                                  v
2.4.11  Horizontal In-Situ Retorting (Gepkinetics)
       • In the GKI horizontal in-situ retorting process, a specific pattern of
blast holes is drilled from the cleared surface through any overburden and
into the oil shale bed.  Explosives are placed in these holes and detonated by
use of a carefully timed and planned blast system.  The blast yields a well-
fragmented mass of shale with high permeability and also produces a slightly
sloping (approximately four deg) bottom surface that allows the produced oil
to drain into a sump for collection.  The fragmented zone constitutes the in-
situ retort.  The void space in the fragmented zone comes from lifting the
overburden, producing a small uplift of the surface as shown in Figure 2-25,.
Submerged-type oil well pumps are used to lift the recovered oil to surface
storage tanks.                                           •
        Burning charcoal is introduced into drilled holes at the upper end of
the rubblized zone to ignite the retort.  Air inlet piping is also installed

                                       2-59

-------
               STEP A
                                                           STEPB
GAS TO
PURIFICATION
ON. SHALE
OUTCROP
                           LEAN SHALE
                           REMOVED f OR
                           SURFACE
                           RETORTING
                           OR DISPOSAL
Figure 2-24.   Occidental vertical modified in-situ  process.
                (Sladek, 1975.   Reprinted by permission of  Colorado  School
                of Mines, Golden,  CO).
                                   2-60

-------

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2-61

-------
at this end of the retort.  The burn front, consisting of a vertical wall
approximately 30-ft high, travels toward the deep or low end of the retort.
The objective is to retort the shale from one end to the other in a plug-flow
fashion by maintaining a burn front that occupies the entire cross section of
the bed.  Typically the front travels at speed of one foot per day.  At normal
production with two retorts operating, the GK1 plant produced approximately
400 barrels/day of shale oil.
                                       2-62

-------
                                  SECTION 3.0
                   AIR POLLUTION CONTROL TECHNOLOGY REVIEW

        This section is concerned with those air pollution control (APC)
methods identified as applicable to the various shale oil production processes
and those aspects of its upgrading and refining performed in the vicinity of
the production sites.  Extensive detailed information is available in the
literature on most of these methods.  All of those  relevant documents and the
test references that are especially appropriate for a given method are listed
in the bibliography.  The objective of this section is to provide the reader
with information regarding the alternatives which are available, the expected
emission reduction efficiency, the associated cost, descriptions of the method
and other decision-making information, such as how  extensively the method has
been used in the same application and what, if any, problems have been
experienced.  The reader is also referred to Section 4.0 where the PSD permit
applications for a number of shale oil projects are reviewed and the APC
methods are identified.
        The level of detail for  this section is such that a process designer
could, on the basis of  the information presented, select candidate APC
measures (and alternative) to be confirmed in the detailed design.  Where the
EPA or other agency has a comprehensive  report on the subject, this will be
noted and the level of  detail in this report will be less than for a more
recently developed process that  may not  be as well  documented in the
literature.  Certain shale oil specific  problems (such as scrubbing organic.
sulfur from the retort  offgas) are specifically addressed in this report.
        To help focus  on the various APC processes  as applied to oil shale, a
matrix (Figure 3-1) was prepared matching each step in the shale oil recovery
process with the various APC technologies considered.  The matrix serves as an
index indicating the section of  this report where the technology is presented
and also indicating an approximate control efficiency possible with that
measure.
                                       3-1

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3.1     PARTICULATE EMISSION CONTROLS
3.1.1   Point Source Technologies
A.      Baghouse—
        The broad terminology for this technology is fabric filtration.
However, in most practical applications particulate collection is performed
using an array of fabric bags with a suitable positioning and holding device
inside of an enclosure called a baghouse.  While the general principles of
operation are similar to a household vacuum cleaner, the industrial version
requires bag materials which will collect submicron particles and withstand
the process gas temperature and the wear and tear associated with collection
of the trapped particles.  Another critical matter is the design of the bag
attachment.  It must clamp the bag to prevent leakage of the particles under
the joint (called sneakage) while avoiding adverse stress on the bags which
cause early failure.  A properly designed baghouse provides for continuous air
flow through the unit while the bags are cleaned sequentially.  The bags often
are compartmentalized and cleaned a compartment at a time.  Often an extra
compartment or two are provided to allow for bag replacement or other
maintenance while the unit remains in operation.
        Baghouse technolpgy has improved rapidly.  Except for gases with high
temperature, condensed moisture, or certain corrosive constituents it is the
preferred point-source control technology.  This is especially true since a
fine particulate emission standard is in existence.  Baghouses achieve a high
removal efficiency.  Their actual efficiency is a matter of the dust loading;
i.e., the higher the dust loading, the higher the removal efficiency.
Practically, the baghouse can be characterized better by its outlet dust
loading in grains per dry standard (g/dscf) cubic feet or grams per dry cubic
meter.  Typical performance efficiencies exceed 99.99 percent for particle
sizes down to 0.5 micrometers and 99.9 percent below 0.5 micrometer.  Dust
                               o                      .
loadings of less than 0.002 g/m  (approx. 0.001 gr/dscf) can be achieved.
    1.  Process Description—Fabric filter systems typically consist of cloth
bags or envelopes, suspended or mounted in such a way that the collected par-
ticles fall into a hopper/bin for disposal when dislodged from the fabric.
Bags usually have the conveying gas flow from inside the bag to the outside;
                                      3-6

-------
 envelopes,  from the  outside  in.   The  accumulated material  is dislodged by such
 devices  as  bag  shakers,  a  pulse-jet reverse  gas-flow (which reverses  total air
 flow in  a bag),  and  a  reverse-jet, ring-slit device (which moves  along the
 bag).  The  sieving action  of the  dust layer  accumulating on the fabric surface
 predominates  shortly after the cleaning operation.   However,  the  slight pass-
 age  of material  through  and  around the bag attachment  during the  cleaning
 cycle is felt to contribute  most  of the exhaust  dust loading.
         With  shakers or  the  pulse-jet equipment,  removal occurs on a  scheduled
 basis when  the  flow  in a bag or a series of  bags  is reversed momentarily.
 Only those  bags  being  cleaned at  any  moment  are  out of use;  the rest  of the
 unit keeps  operating.  An  isometric view of  a two-compartment  pulse-jet fabric
 filter is provided in  Figure 3-2.  The reverse-jet  ring-slit  device works
 continuously  to  remove the collected  particulates as it travels along the  bag
 during filtration.   In this  technique,  bags  remain  in service  while being
 cleaned.  Because it removes most of  the accumulation, tightly felted fabric
 works best, and  the  initial  particulate layer  becomes less  significant.
         Fabric filters can be categorized as  to  the type of  service and
 frequency of  bag cleaning.   Intermittent fabric  filters are cleaned after
 filtering is  completed (i.e., after the process stream is secured  or  shutdown)
 usually  at  the end of  each day.  These  fabric  filters operate  with low dust
 loadings since they  cannot be cleaned while on stream.  In  continuous  duty
 fabric filters,  cleaning of  a portion of  the filters occurs at periodic
 intervals while  the  remainder continue  to process gases.  These filters are
more expensive than  the intermittent  types due to the accessories  required in
 the  cleaning process and the  additional  filter area  required for continuous
 operations.
        A variety of fabrics  are available for use in filtration systems.  A
 selected listing of materials and their properties is presented in
Table 3-1.   Tabulated air permeabilities reflect fresh fabric performance and
will decrease upon use.  Other fabrics which are available include graphitized
fiber, and polyethylene.   Cotton and nylon,  although the least expensive
fabrics listed,  have poor resistance to acid attack.  Orion, Dacron, and
polypropylene resist attack by acids and may be suitable at low
temperatures.  Fiberglass and Teflon offer higher temperature acid resistance

                                      3-7

-------
Clean Air Outlet


Branch Header


        Nozzle
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                                                                            Access Plates
                                                                             Solenoid Valves
                                                                              Compressed Air
                                                                              Manifold
Dirly Air Inlet
                                                                                Baffle Plate
                                                                         Access Door
   Figure 3-2.    Isometric view of a two-compartment pulse-jet fabric filter
                   (Ondich, 1983).
                                             3-8

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-------
 — although Teflon is  more costly.   A Teflon or a Teflon-Orion mixture called
 MTI may be used when significant  concentrations of fluorides are present.
 With the exception of  wool and fiberglass,  most listed materials provide good
 resistance to  attack by alkaline  substances.  A recently-developed bag
 material,  GORE-TEX membrane,  is a micro-porous membrane of expanded
 polytetrafluoroethylene (PTFE) laminated to the surface of various fabric
 substrates.  It has been found to exhibit excellent filtration properties.
 The special  property of this  bag  material is that it has high membrane surface
 filtration and does not depend on the buildup of a filter cake.   Thus, the
 removal efficiency remains high immediately after the cleaning cycle  and
 before  a new filter cake has  been formed.   This material is a proprietary
 product of W.L.  Gore & Associates,  Inc.,  Elkton,  MD.
         The  applicability of  fabric filters depends upon the emission limi-
 tations, temperature,  moisture content,  the bag replacement schedule  of  the
 fabric  filter,  and other aspects.   Temperature of the gas imposed limitations
 upon usable  materials  of construction for bags,  as well  as  affecting  system
 size with  regard to volumetric flow.   Moisture or other  condensibles  can
 affect  performance of  the fabric  filter  and may render it inoperative.
         Laboratory studies  with fabric filters have demonstrated a strong
 correlation  between outlet  concentration and face velocity  (air-to-cloth
 ratio)  for a given loading  and type  of fabric.  Predicted and  observed outlet
 concentrations  for bench scale tests  indicate  that  outlet concentration
 increases  to a  certain  extent  and then tapers  off as air-to-cloth ratio  (face
 velocity or  fabric loading) is  increased.   The  results of these  tests  are
 presented  in Figure  3-3.  This  effect  has also  been substantiated by field
 pilot studies  (refer to  Figure  3-4) although there  are some  inconsistencies
 which could  be due  to control  problems in field experimentation.
        The pressure drop across the baghouse generally varies as  the  square
 of the  face velocity (air-to-cloth ratio) at constant dust  loadings.  However,
 it is difficult  to  relate pressure drop directly  to  the collection efficiency
 of the unit.  The  filter pressure drop is influenced by the frequency and
 completeness of bag cleaning.  The effects of cleaning frequency on the filter
 pressure drop for a reverse air-jet type of cleaning mechanism are shown in
Figure 3-5.  At the lower dust loading value of 1 g/am3, this curve indicates

                                      3-10

-------
                           INLET CONC (g/mฐ)   (m/min)  (ft/min)
 10
                             60       80      100      120

                           Fabric Loading  (W/,  g/nT
140
Figure 3-3.   Predicted and observed results for bench scale fabric
              filter tests.  GCA fly ash  and Sunbury fabric (Ondich,  1983)
                                  3-11

-------
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           Penetration = 1 - fractional  collection efficiency
O"
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           MEMBRANE
                                9
                                   Teflonฎ
     J	L
                  J	L
                    0.91
             1.83
2.74
                                                              3.66
                               Air-to-Cloth Ratio, m/min


        Nomexฎ and Teflonฎ are registered trademarks of E. I. duPont de Nemours  '.
          & Co., Inc.


        GORE-TEXฎ MEMBRANE is a registered trademark of W.L. Gore & Associates,Inc.
        Figure 3-4.  Fabric filter field test results for different bag materials
                     (Ondich, 1983).
                                     3-12

-------
        70
        60
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           0
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             dust at  1 g/m3
             20
60
80     100
                  Cleaning Frequency,  %
Figure 3-5.   Filter pressure drop for reverse air-jet operation

             (Ondich, 1983).
                              3-13

-------
that operating the cleaning mechanism only  30  percent  of  the  time  causes  an
increase in pressure drop of only  10  percent.   Because of the wear on most
fabrics imposed by cleaning, these values indicate  the desirability of
accepting minimal pressure drop  increase while reducing bag maintenance.  The
need for more frequent cleaning  at higher dust loadings also  is  indicated by
the data shown in Figure 3-5.
        The design of a baghouse requires careful consideration  and analysis
of the above factors along with  the information and advise of reliable equip-
ment suppliers who will ultimately warrant  the unit's  performance.   A smaller
air-to-cloth ratio results in a  large and more expensive  unit.   However,  this
is offset by lower energy and bag  replacement  cost  because of the  lower pres-
sure drop and bag cleaning frequency.  Cleaning frequency involves  a tradeoff
of bag wear versus pressure drop.  This is  somewhat subjective and depends on
the equipment supplier's recent  experience  with his attachment design and
selected cleaning method.  Acid  and moisture conditions in the gas  must be
considered in selecting case material.
        Since most users prefer  to purchase a  unit  on  a competitive basis, it
is advisable to allow as much design  freedom as possible  consistent  with
obtaining the desired performance  guarantees backed up by demonstrated
achievements.  Failure to achieve  a performance guarantee may be as  much  of a
hardship on the user as the supplier  if the entire  process is down  due to a
malfunctioning baghouse.
        The time to isolate a broken  bag can be reduced drastically  if detec-
tors are placed on the outlet of each compartment.  These  detectors  actually
indicate the opacity of the gas  stream from the compartment and allow opera-
tors to isolate quickly the faulty compartment for  repair.
        Leaks through bypass dampers also affect performance  since  leakage can
approach five percent.  Leakage  can be reduced essentially to zero by includ-
ing two louvered dampers with a  continuous  purge of clean  reverse air to block
uncleaned gas.
                                      3-14

-------
   2.   Process Economics — Costs of fabric filter baghouses depend upon:
(1) type of fabric, (2) air-to-cloth ratio, (3) intermittent or continuous
duty, (4) pressure or suction type construction, (5) standard or custom
design, (6) type of cleaning mechanism, and (7) materials of construction.
        Costs for mechanical shaker, pulse-jet, reverse-air, and custom bag-
houses are presented in Figures 3-6 though 3-10.  The prices are based on net
cloth area which is determined from the specified air-to-cloth ratio.  The net
cloth area is the average filter area seen by the air flow.  This may differ
from the gross cloth area (which is the total cloth area in the baghouse) due
to the need to isolate cloth area when continuous cleaning is used.  For an
intermittent system, the net and gross cloth areas are the same, since the
baghouse is cleaned after a filtering cycle.  For continuous filters, factors
to calculate gross cloth area are provided in Table 3-2.  Using this
calculated gross area and type of filter desired, bag costs can be determined
from Table 3-3.
        Baghouse prices are flange-to-flange, including the basic baghouse
without bags, three meter support clearance, and inlet and exhaust manifold.
Pressure baghouses are designed for three kPa gauge pressure and suction
fabric filters are designed for a negative pressure of five kPa gauge.  Custom
baghouse prices are more a function of specific requirements than of pressure
or suction construction, so prices do not differentiate between pressure or
suction.  Custom baghouses are designed for continuous operation and normally
use reverse air cleaning.  All baghouses except custom baghouses are generally
factory-assembled.  The operating requirements for fabric filters primarily
consist of labor, .replacement bags, and power.  Labor requirements include two
to four man-hours per shift for operations and one to two man-hours per shift
for maintenance.  Bag life is estimated at 0.3 to 5 years with an average of
1.5 years.  Power requirements for shaker and blower motors are given as
                         r\
approximately 4 kW/1000 m  of cloth area.  Power usage will depend on dust
loading and cleaning cycle.
B.      Venturi Scrubber—
    1.  Process Description—A Venturi scrubber is one of several types of wet
scrubbers and is the most commonly used for large scale control of particu-
lates.  It uses the venturi effect to create water droplets in the high

                                      3-15        • '

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3-20

-------
TABLE 3-2.  APPROXIMATE GUIDE TO ESTIMATE GROSS CLOTH AREA
                      (Ondich, 1983)
Net Cloth Area.
m3
1 -
370 -
1100 -
2200 -
3300 -
4400 -
5600 -
6700 -
7800 -
8900 -
10,000 -
12,300 -
16,700
370
1100
2200
3300
4400
5600
6700
7800
8900
10,000
12,300
16,700
On Up
Gross Cloth Area
m •
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Multiply
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by
by
by
by
by
by
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2
1.5
1.25
1.17
1.125
1.11
1.10
1.09
1.08
1.07
1.06
1.05
1.04
                          3-21

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velocity gas stream.  These droplets coalesce and collide with and scrub the
particulates.  Use of baffles and mist eliminators in conjunction with the
velocity decrease returns the droplets with entrained particulates to the
liquid phase.
        In venturi type scrubbers (Figure 3-11) mixing is achieved by using
fans to accelerate the incoming gas stream to velocities in the range of 46 to
120 m/second in the converging venturi section.  As high velocity gas enters
the throat of the venturi, it encounters a stream of scrubbing liquor flowing
down the walls of the chamber.  The liquor is introduced by flooding, sprays,
or weirs, and a spray of atomized liquid is directed into the gas stream ahead
of the venturi throat.  As the thin sheet of liquid reaches the venturi
throat, it is sheared off by the gas stream to become a mass of droplets
entrained in the atomized sprays.  Typically these droplets are 25 to 100 nn
in size. , In the turbulent zone just beyond the entrance to the throat, these-
relatively massive droplets move much more slowly than dry particulates in the
gas stream.  As a result, collisions between droplets are frequent, so most
particles are captured by the scrubbing liquor.
        As droplets with their burden of particulates move through the
venturi, the gas/droplet mixture decelerates, and the droplets collide with
each other to form even larger and heavier drops.  When they enter the next
stage, these are separated from the gas in a cyclonic (or other) separation
device.
        Inertial impaction is the most important mechanism for collection of
fine particulates.  As particle size decreases, theory indicates that a higher
pressure drop is required to maintain a given particle removal efficiency.
For a given dust, as the pressure drop is increased, finer water droplets are
atomized to interact with the dust particles through impingement and agglomer-
ation with a consequent increase in removal efficiency.  Increasing the
pressure drop can be accomplished by either increasing the gas stream throat
velocity, increasing the scrubber liquor flow rate, or both.  The relationship
between particle size and pressure drop is shown in Figure 3-12.  The rela-
tionship between pressure drop and collection efficiency is the same for all
types of venturi scrubbers irrespective of the size,  shape, or general con-
figuration of the scrubber.  Venturi scrubbers normally are operated at

                                      3-23

-------
                 DIRTY GAS
                   INLET
         LIQUOR
         INLETS
 ALTERNATE
LIQUOR INLETS
                                          CLEAN GAS
                                            OUTLET

          FLOODED
           ELBOW
                 TANGENTIAL
                    INLET
 CYCLONIC
SEPARATOR
                                          LIQUOR
                                          OUTLET
           Figure 3-11.    Standard Venturi Scrubber
                           (Ondich, 1983).
                                   3-24

-------
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1.0 -
         0.5 -
           0
            0    50    100   150  200   250  300



               PRESSURE DROP REQUIRED, cm WG
"Figure 3-12.  Efficiency performance of venturi scrubbers.

              (Ondich, 1983).
                                  3-25

-------
pressure drops of between 1.5 and 20 kPa, depending on the characteristics
of the dust, and at liquor flow rates of 0.4 to 2.7 L/min per gas flow of
   o
1 m /min.  The collection efficiencies range from 99+ percent for one un
(micron) or larger sized particles to 90 to 99 percent for particles below one
urn size.
        A separator for removal of the agglomerates from the gas stream is
provided downstream of the scrubber.  These separators are usually of the
cyclone type in which the gas stream and agglomerates are given a cyclonic
motion which forces the liquid and particles to impinge on the walls of the
separator by centrifugal force.  The separator normally consists of a
cylindrical tank with a tangential inlet located at the lower side of the tank
and an exhaust outlet located at the top of the tank on the centerline axis<>
A cone bottom with outlet is provided to collect the liquid slurry.  The col-
lected particles settle to the bottom of the cone and are sent to the water
treatment facility while the cleaner liquid above the sediment is removed and
recycled to the scrubber.
        For hot processes, a considerable amount of water is vaporized in the
scrubber and upstream equipment (e.g., quencher) which must be handled by the
fan.  Although the gas volume is reduced, a large portion remains as water
vapor which results in higher horsepower requirements and in higher operating
costs.  To alleviate this condition, a gas cooler can be incorporated into the
separator to cool and dehumidify the gas stream.  Several types of gas coolers
are used for this purpose; one type employs spray banks of cooling water fol-
lowed by impingement baffles while a second type utilizes flooded plates or
trays with either perforated holes or bubble caps to permit passage of the gas
stream through the cooling water bath.  Several plates or trays can be used in
sequential stages to provide the necessary cooling and contact time.
        Scrubber selection for particulate emission control depends upon the
particulate loading, particle size distribution, and required removal effi-
ciency.  Generally, venturi scrubbers are used in those process areas where
wet collection is necessary or appears desirable due to the characteristics of
the gas stream such as the presence of tar, gums and other materials that tend
to blind or plug bag filters.  Table 3-4 gives typical values of pressure
drops for selected processes and equipment where venturi scrubbers are
utilized for particulate control.
                                      3-26

-------
  TABLE  3-4.  TYPICAL PRESSURE DROPS FOR VENTURI SCRUBBING SYSTEMS
                            (Ondich, 1983)
   '	Process	^^	   Pressure Drop, kPa

Basic oxygen furnaces                            10.0-15.0
Brick manufacturing                               0.7-8*7
Clay refractories                                    2.7
Coal-fired boilers                                   3.7
Detergent manufacturers                          2.5-10.0
Ferroalloy plants                                10.0 -  19.9
Glass manufacturing                                  16.2
Gray iron foundaries      t                       6.2-14.9
Kraft recovery furnaces                          3.7-7.47
Lime kilns                   ,                    3.0 - 10.0
Petroleum catalytic cracking                         10.0
Phosphate fertilizer                             3.7 - 7.47
Phosphate rock crushing                           2.5 -  5.0
Secondary aluminium                                  7.5
                              3-27

-------
        Venturi scrubbers produce a significant quantity of liquid waste which
may be discharged to a settling pond or to a water treatment plant after
solids removal.  The quantities of wastewater discharged are difficult to
predict since systems use different L/G ratios as well as. different degrees of
recirculation.  A venturi scrubber on a pulverized coal boiler operating at an
L/G ratio of 0.9 L/m3 with no recirculation will discharge about 2000 L/min.
Usually this discharge is pumped to a settling pond where the fly ash settles
                                                       /   • . .
to the bottom and the liquid is either discharged, evaporated, or recycled.
Pond liners may be used to prevent leaching of any metals or chemicals into
the soil and surrounding water table.  Although intrusion upon a local water
body or supply is always possible, good operating procedures can minimize this
potential impact.  Since the properties of pond discharge waters are dependent
upon the process particulate and gas composition, it is not possible to
specify average values.
   2.   Process Performance-—Collection performance of venturi scrubbers is
affected by the following parameters:  (1) pressure drop, (2) liquid-to-gas
ratio (L/G), (3) gas velocity, and (4) particle size distribution.
        Particle cut diameter is the diameter of the particle which will be
collected by the scrubber at 50 percent efficiency.  Particle-cut diameter is
a frequently used parameter for describing the particle collection efficiency
of venturi scrubbers.  One reason for this is that plots of collection
efficiency versus particle diameter tend to be rather steep in the region
where inertial impaction is the predominant collection mechanism.  A plot of
cut diameter versus pressure drop for a gas-atomized spray scrubber is
provided in Figure 3-13.  This plot is based on experimental data from large
Venturis, orifices, and rod-type units, plus mathematical model.  A plot of
particle size vs pressure drop has been illustrated earlier in Figure 3-12.
        The relationship between liquid-to-gas ratio and cut diameter for
Venturis has been plotted (Ondich, 1983) with a liquid density of water,
1000 kg/m3, and a gas viscosity of 1.8 x 10~5 Pa's (equal to the viscosity of
air at one atmosphere and 298 K).  Plots of liquid-to-gas-ratio versus cut
diameter with gas velocity and pressure drop as parameters are presented in
Figure 3-14.  The factor f, the ratio of relative velocity between gas and
liquid droplet to gas velocity, is approximately 0.25 for fly ash and

                                      3-28

-------
 M
 Ol
 4-1
 
-------
a

ij
3
   3.0


   2.0
   1.0
   0.5
   0.1
                  or   relative gas-particle velocity
                                gas velocity
                  I   i   1  I  I I  I
                                              i   i
      0.2
                                1.0

                    Liquid-to-Gas  Ratio,
                                                    4.0
Figure 3-14.  Venturi cut diameter vs  liquid-to-gas ratio
              (Ondich, 1983).
                                  3-30

-------
hydrophobia aerosols and significantly higher for hydrophilic  (water
attracted) aerosols.  This figure may be used to determine approximate
operating conditions once the required cut diameter has been estimated.  Care
must be used to ensure that adequate liquid is supplied to provide good gas
sweeping; a minimum liquid-to-gas ratio of approximately 1 liter/nr
recommended.
        It has been shown that the pressure drop across a venturi is propor-
tional to the square of gas velocity and directly proportional to the liquid-
to-gas ratio.  Therefore, within limits, increasing gas velocity will result
in increasing pressure drop and decreasing the device cut diameter, other
things being equal.  Velocity data are not available for survey sites equipped
with Venturis, although typical gas velocities employed commercially are 30 to
120 m/s.  The low end of this range, 30 to 45 m/s, is typical of power plant
applications while the upper end of the range has been applied to lime kilns
and blast furnaces.
   3.   Process Reliability—Maintenance is critical in venturi scrubbing sys-
tems when corrosive gases (such as sulfur oxides) are present.  In additions,
handling of large amounts of water containing potentially corrosive or abra-
sive materials causes more problems than those found in dry systems.  Hence,
frequent and thorough inspection of equipment is essential for reliable
operation.
   4.   Process Economics—Costs of venturi scrubbers depend upon:  (1)
volumetric flow, (2) operating pressure, and (3) materials of construction.
For venturi scrubbers constructed of 3.2mm carbon steel and gas capacities up
                      O
to about 5700 actual m /rain, ventrui scrubber costs can be estimated with the
following equation (Vatavik & Neveril, 1981):

        C = 7117 + 14.4 V - 0.0011 V2                                    (3-1)

where:
                                           o
        C is the venturi scrubber cost, $10  and
                                              o
        V is the inlet gas flow rate, actual m /min.
                                      3-31

-------
These costs are flange-to-flange costs  (December  1977 dollars) and  Include the
venturi, elbow, separator, pumps, and controls.   Correlations for adjusting
these costs for different vessel thicknesses, materials of  construction, and
internal coolers are presented by Vatavik & Neveril, 1981.
C.      Electrostatic Precipitator—
   !•   Process Description—Electrostatic precipitators use electrical rather
than mechanical forces for the removal  of suspended particulates in a gas
stream.  The process encompasses three  basic functions:  the charging of
particles, the collection of the charged particles on an electrode  of opposite
polarity, and the removal of the collected particles.  Particles suspended in
the gas stream are charged by passing through a high voltage direct-current
corona established between a discharge  electrode, usually a small diameter
wire which is maintained at high voltage, and a grounded collecting surface
(collecting electrode).  As the particles pass through the corona,  they are
bombarded by negative ions emanating from the discharge electrode and charged
within a fraction of a second.  The charged particles, influenced by electric
field forces, migrate toward the grounded collecting surface where  they are
deposited and held by electrical, mechanical, and molecular forces.  Part-
iculates adhering to the collecting surface are periodically dislodged by
mechanical rappers, acoustical horns or by flushing with water and  fall to a
hopper from which they are subsequently removed.
        A majority of the industrial electrostatic precipitators (ESPs) used
today are the single-stage, wire and plate type.  Charging and collection take
place in the same section of the ESP.  The collecting surface consists of flat
parallel plates spaced from 15 to 30 cm apart with wire or rod discharge elec-
trodes located between the plates.   The plates usually range from  4 to 12 m
in height and 4 to 7 m in length.  Plate-type precipitators are typically used
for dry particulate collection.  In tube-type ESPs, the collecting  surface
consists of a cylinder with the discharge electrode centered along  its
longitudinal axis.  They are generally used for wet gas cleaning.  With either
type, a complete precipitator consists of many units in parallel and in
series.  A schematic arrangement of wire/plate and wire/tube ESPs is shown in
Figure 3-15.
                                      3-32

-------
         DischO'je
         electrodes
             Wire/Plate Type
             Discharge
             electrodes

                                Ground
                               electrodes
 Ground *.
electrodes
                                         T
                  T
                                                       I
T
                                                                T
                     Gas flow


                 Wire/Tube  Type
Figure 3-15.     Schematic arrangement of wire/plate and
                   wire/tube precipitators   (Ondich,  1983).
                                 3-33

-------
        In both ESP types, there are four main components:  electrode system,
precipitator casing, collected material removal system, and power supply.
        In the single-stage wire/plate ESP the discharge electrodes may be
round wire, square twisted rods, ribbons, etc.  The choice of construction
material is a function of the corrosive service.  The most common collection
electrode in the wire/plate design is a smooth plate with vertical inter-
locking baffles.  These baffles provide strength and also produce near-zero
velocity conditions as the gas flows in a normal direction to them.  Other
special plate electrode configurations are rod curtains, zigzag plates, and
various hollow electrodes with pockets on the outside surfaces for discharging
the collected dust to the hopper from quiescent gas zones.  As in the case of
the discharge electrodes, the plates are fabricated from a wide choice of
construction materials, depending upon the degree of corrosive service.  The
high-voltage discharge electrodes are suspended vertically between each pair
of collection electrodes.  They are carefully centered between the collection
electrodes to ensure proper corona gaps.  Typical design parameters for com-
merical wire/plate precipitators are shown in Table 3-5 (Ondich, 1983).
        The precipitator casing may be fabricated from a wide selection of
materials including mild steel, lead-lined steel, brick, and concrete.  The
ESP may include several fields in the direction of the gas flow.  Each field
section can be treated as a separate unit module so that additional fields can
be tied easily into the system as the need for increased collection efficiency
arises.  The entire casing is supported on a steel base that rests on support
steel.  Main support columns, attached to the steel base, support structural
members near the top of the precipitator from which the grounded electrodes
are suspended.  The casing roof also is supported from these structural
members.  The discharge electrodes are hung from high-voltage insulators
located on and supported by the roof.  These insulators, together with gas
seals and rapper mechanisms, are enclosed in an attic space above the casing
roof.  The storage hoppers for the wire/plate ESP are located under the
collection electrodes and are a structural continuation of the casing.
        Collected dust from the ESP is removed by mechanical or acoustical
rapping and washing.  Mechanical rapping methods usually consist of mechanical
actuated "hammers", which are driven electrically or pneumatically.  The

                                      3-34

-------
 TABLE  3-5.  TYPICAL  VALUE  OF  DESIGN VARIABLES FOR COMMERCIAL ESPs
                           (Ondich, 1983)
       Design Variable
   Normal Range  of Values
Plate spacing

Gas velocity

Vertical height of plates

Horizontal length of plates

Applied voltage

Gas temperature



Treatment time

Draft loss

Efficiency


Corona current

Field Strength
        0.20  to  0.28 m

       0.61 to 2.4 m/s

         3.7  to  7.3 m

      0.5 to 1 x height

         30 to 75 kV

    Up to 643 K; standard
    810  K high temperature
        977 K; special

          2 to 10 s

         25 to 125  Pa

Up to 99.9%,  although usually
          90 to 98%

  0.033 to 3.3 mA/m of wire

       276 to 590 kV/m
                               3-35

-------
impact blow from the hammer is transmitted vertically  to the  freely  suspended
collection electrode so that the dust is released in the direction of gravity.
Rappers are provided for the discharge electrodes as well.  In  certain
installations particles have collected in peripheral areas and  built up to
impede gas flow.  Conventional rapping is ineffective.  If the  material col-
lected is friable (ie. dry and powdery), it can be dislodged  by directing
acoustical frequency sound at the mass.  In the case of some  viscid  dusts the
removal of collected material can be accomplished by washing  down the plate.
Periodic water sprays are used, and by proper cycling  of these  sprays to
maintain a wetted electrode, reentrainment can be completely  eliminated.
        The electrical energy requirement for an electrostatic  precipitator is
that necessary to produce an effective corona.  The power supply must deliver
a unidirectional negative current to the discharge electrodes at a potential
very close to that which will produce arcing across the electrodes.  The value
of the potential difference used in the single-stage precipitator is usually
in the range of 20,000 to 100,000 volts.  The current  delivered may vary from
20 to 500 mA.  Power requirements are relatively low since only the dust is
treated rather than the total gas flow.  Solid state rectification is used in
most new ESPs.  Selenium and silicon rectifiers provide reliable service with
long life.  The ESP potential is maintained at the optimum value by a spark
counter or current-sensing feedback circuit.
        The single-stage wet wire/tube precipitator design is better suited
for wet collection applications.  This type of precipitator is  built in a
cylindrical shell.  The collection electrodes consist of nested pipes which
are connected and sealed to header sheets attached to the shell.  The dis-
charge electrodes are supported above the header sheet and are  suspended
axially in the collection electrode pipes.  Water is introduced above the
header sheet and flows over carefully leveled weirs at the tops of the pipes
to form a water film on the inner walls of the pipes.  The charged particles
are collected in the water film, where their charge is neutralized, and
drained off from the bottom of the ESP with the water.  Because wet collection
is involved, materials of construction are usually corrosion resistant.
                                      3-36

-------
        The power supply is similar to that for the plate  type EPS.  However,
it is simpler in concept because the vertical gas flow pattern eliminates  the
need for sectionalization.
        Electrostatic precipitators are used extensively on  large volume
applications where the fine dust and particulate matter is less than 10 to
20 urn in size with a predominant portion in the sub iซn range.  The
precipitators can achieve high efficiencies (in excess of  99 percent)
depending on the resistivity of the particulate matter and the characteristics
of the gas stream.  Wet or dry particulate can be collected  including highly
corrosive materials if the units are suitably constructed.  Precipitators  can
be used at temperatures up to 810 K but are normally operated at temperatures
below 650 K.  The static pressure drop through the units is  low, usually up to
12 kPa for units operating at gas velocities of 0.6 to 2.4 m/sec.  Safety
precautions are always required since the operating voltages are as high as
100,000 volts.  The overall size of electrostatic precipitators is comparable
to fabric filters (baghouses).  Space requirements are an  important factor in
the layout and design of the facilities.
   2.   Process Performance—The three most important design criteria for  ESPs
are the precipitation rate (We), the specific collection area (SCA), and the
gas velocity (QQ)ซ  Because precipitation rate can vary with resistivity,
particle size distribution, gas velocity distribution, rapping, and electrical
factors, an effective rate parameter or migration velocity usually is adopted.
Variation of this parameter with fly ash resistivity and coal sulfur content:
is shown in Figures 3-16 and 3-17.  Particulate resistivities of over 109  to
10   ohm-cm were found to decrease collection efficiency.  This loss results
since some high resistivity particles are not able to dissipate their charge
as they attach to the collector electrode.  Eventually, an electric potential
can build up at the surface of the collected particulates giving rise to tuft-
like discharges of polarity opposite to that of the collector.  Subsequent13%
arriving particles are repelled rather than collected at these sites (Ondich,
1983).
        The relationship of gas flows to theoretical collection efficiency as
a function of migration velocity is represented in Figure 3-18.  Migration
                                      3-37

-------
                0.6
              .V) 0.5
              LU
                0.4
                0.3
              P 0.2
              CL

              LU 0.1 f-
              CC
              a.
                    10IU      10"
                 RESISTIVITY, ohm-cm
                                        1*ง
                                          LU
                                              12
                                            10
                                                 CC
                                                 z
                                       6  g
                                          Q.
                                          O
                                       3  LU
                                          CC
                                          a.
                                       0
                                       12
Figure 3-16.
                     Drop in precipitation rate W  with
                     increasing  fly  ash resistivity for a
                     representative  group of precipitators,
                     (Ondich, 1983).
'
1 0.6
^0
S 0.5
LU
1—
CC 0.4
Z
O
(- 0.3
H-
Q.
o ฐ-2
LU
CC
ฐ- 0.1
0
I I I I 1
- RAMSDELL CURVE /-
420K "^^7
_ / _
BARRETT REGRESSION /
ANALYSIS CURVE ^C^^
^^^^^*~~ "*™ ™"
^
ซ^X<^^
^^•^"^s TVA DATA
430K


— • —
I i I I I
21
18 -2
E
0
15 uj"
1-
cc
12 z
g
i —
9 <
a_
6 uj
CC
Q.
3
0
                 0   0.5   1.0   1.5  2.0   2.5  3.0
                        COAL SULFUR, %
Figure 3-17.  Relation of We to coal sulfur content  for flue
              gas  temperatures in the neighborhood of  420K as
              determined by several investigators.(Ondich, 1983)
                                 3-38

-------
    100
 o

 S   90
•H
 U
•H
W

 c
 o
.•H

 u   80
 OJ
f—I
1—I
 o
     70
                                         cm/s
                                         1    I   I   I   i
                     (las Velocity, m/s
                                                  8   10
 Figure  3-18.  Theoretical precipitator collection efficiencies

              at different migration velocities. (Ondich,  1983),
                                3-39

-------
velocity is an empirical constant used  for  sizing  ESPs  in  certain applica-
tions.  Suggested values of migration velocities for  some  of  these applica-
tions are tabulated in Table  3-6.
        It should be noted that migration velocity is directly  proportional
to particle size.  Therefore, the larger the particle size, the larger  the
migration velocity and the higher the particulate  collection  efficiency.  Gas
velocity in the ESP is extremely important  since collection is  highly sensi-
tive to velocity variations.  The gas velocity at  which maximum efficiency can
be attained depends on such factors as  plate configuration, precipitator  size,
and the judicious use of flow distributors  required to  minimize velocity
gradients.  The design velocity limit for high efficiency  fly ash
precipitators is about 1.5 to 1.8 m/s.
        In general, the performance of  a given ESP unit is a  function of  "the
size of the box" (plate area  and depth), the particle resistivity and size
distribution, the electrical  parameters defining particle  charge and field
strength, and proper operation and maintenance of  equipment.  Typical collec-
tion efficiencies that can be achieved  by ESPs in  various  applications  are
listed in Table 3-7.
        There are two types of reliability problems encountered with ESPs:
mechanical and operational.  Mechanical problems include misalignment of
electrodes, breakage of corona wires by fatigue or by electrical  burning, and
air in-leakage into the hoppers.  Operational problems  commonly encountered
include poor electrical set adjustments, shorted corona sections  (e.g., caused
by broken wires), overloading the precipitator by  excessive gas  flow, and
failure to empty hoppers of collected dust.  A more complete  list  of the
problems most frequently encountered is given in Table  3-8.
        ESP reliability can be improved by increased  sectionalization; pre-
cipitators can have as many as 100 independent electrical sections.  To
minimize the effect of ash-valve failures or plugged  hoppers,  the  trend is
toward locating a hopper under each section.  A well-designed ESP may have 5
to 25 percent of the bus sections out of service during the operational year.
The loss in efficiency must be offset by additional collection areas beyond
the plate area added for performance efficiency contingencies.  Commonly, this
                                      3-40

-------
               TABLE  3-6.  TYPICAL AVERAGE MIGRATION VELOCITIES
             ENCOUNTERED IN COMMERCIAL ESP SYSTEMS  (Ondich,  1983)
               Application
Migration Velocity (w),
         m/s
Pulverized coal (fly ash)

Paper mills

Open-hearth furnace

Secondary blast furnace (80% foundry iron)

Gypsum

Hot phosphorous

Acid mist (^804)

Acid mist (TiOฃ)

Flash roaster

Multiple hearth roaster

Portland cement manufacturing (wet process)

Portland cement manufacturing (dry process)

Catalyst dust

Grey iron cupola (iron to coke ratio - 10)
     0.10 to 0.13

         0.076

         0.057

         0.12

     0.16 to 0.19

         0.027

    0.057 to 0.076

    0.057 to 0.076

         0.076

         0.079

     0.10 to 0.11

    0.057 to 0.070

         0.076

    0.030 to 0.036
                                  3-41

-------
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-------
    TABLE 3-8.   COMMONLY ENCOUNTERED  PRECIPITATOR PROBLEMS  (Ondich,  1983)
Fundamental Problems
        1.  High resistivity particles
        2.  Reentrainme'nt of collected particles
        3.  Poor gas flow
        4.  Insufficient or unstable rectifier equipment
        5.  Insufficient number of corona sections
        6.  Improper or incompatible rapping
        7.  Gas velocity too high
        8.  Aspect ratio too small
        9.  Precipitator size too small

Mechanical Problems
        1.  Poor electrode alignment
        2.  Distorted or skewed collecting plates
        3.  Vibrating or swinging corona wires
        4.  Excess dust deposits on corona electrodes and/or collecting
            plates (sometimes cemented on)
        5.  Formation of dust mountains in precipitator inlet and outlet ducts
        6.  Gas turning vanes and/or gas distribution screens plugged with
            dust
        7.  Air inleakage into hoppers, shells, or gas ducts
        8.  Gas leakage around precipitation zones and/or through hoppers

Operational Problems
        1.  Full or overflowing hoppers
        2.  Shorted corona sections (e.g., broken wires)
        3.  Rectifier sets or controls poorly adjusted
        4.  Precipitator overloaded by excessive gas flow
        5.  Precipitator overloaded by excessive dust concentration
        6.  Process upsets (e.g., poor combustion, steam leaks)
                                3-43

-------
extra area is expressed in terms of extra fields.  For instance, a precipi-
tator that could meet guarantees with four fields may have a fifth field
installed to account for normal deterioration and contingency.
   3.   Process Economics—Costs for ESPs are given in Figure 3-19 (Ondich,
1983).  This figure illustrates capital investment costs for precipitators
used on 500 MW  pulverized coal fired power plants.  These costs are based on
20 different designs and estimates.  Included in the estimates are material
and labor costs for the installation of the collectors and associated
equipment.  Added to these costs are differential and indirect field costs,
engineering costs, fee at 3 percent, and contingency and miscellaneous costs
at 10 percent.
        Costs for ESPs increase significantly as emission limits become more
restrictive.  Note that capital investment increases about 20 percent when the
outlet emission is halved.  Costs also vary depending upon the type of coal
and properties of the fly ash.  To meet NSPS standards for electric utilities
of 13 ng/J requires a capital investment from $42/kW to $57/kW (1978 dollars)
depending upon the type of coal being fired.  Costs also increase with
increase in size as shown in Figure 3-20 for a dry ESP.  Although these costs
(no data given) may be substantially lower than current market costs, they
provide a relative cost vs. size factor.  Many items influence costs, and for
wet precipitators, the cost may be 2 to 10 times higher than for dry ESPs
(Ondich, 1983).
        Annual operating and maintenance costs for ESPs are generally composed
of maintenance labor and materials, maintenance supervision, plant general and
administration, and electrical power costs.  Maintenance labor and material
costs are approximately 2 percent of the total capital investment.  Mainten-
ance supervision and plant general and administrative costs are approximately
5 percent and 15 percent of maintenance labor and material costs, respec-
                                                         O
tively.  Electrical power requirements average 0.012 kW/m  for high efficiency
ESPs and 0.009 kW/m3 for other ESPs.  High efficiency ESPs are those units
which have collection efficiencies of over 99 percent.
                                       3-44

-------
 10
   0.01       002           0.05

     PARTICULATE EMISSION LIMIT, Ib/IO6 BTU
                   I
                  0 1
                                              100
                                               90
                                               80
                                               70
                                               60
                                            z
                                            uj
                                            >
                                            z
                                              10 -
                                                •it
I

\ NORTH DAKOTA
    LIGNITE
                               0 01       0.02          0.05        0.1

                                 PARTICULATE EMISSION LIMIT. lb/1Q6BTU
10
   001       002          005

    PARTICULATE EMISSION LIMIT, lb/106 BTU
                                   0 1
                                              10
                               0.01       0.02          0.05       0.1

                                PARTICULATE EMISSION LIMIT, lb/106 BTU
             •1 20-COMPARTMtNl FABRIC FILTER WITH 2 Yt AH SAG-REPLACEMENT
             •2. 20-COMPARTMENT FABRIC FILTER WITH 4. YE AR SAG-REPLACEMENT
             •3 40-COMPARTMENT FABRIC FILTER WITH 2-YEAR BAC;.REPLACEMENT


            Notes:   1 lb/10b  Btu  = 430 ng/J.   Costs  are
                      in  1978  dollars.
Figure 3-19.
Capital investment for collectors  on  500 MW  (net)
power plants  (Ondich,  1983).
                                         3-45

-------
   10C
V)
o
u
a
to
   10s
   10"
     100
1000
10.000
                                 Plate Area, m
100,000
     Figure  3-20.  Purchase price  of  dry-type electrostatic  precipitators.
                    (Ondich, 1983).
                                          3-46

-------
D.      Dry Venturi Scrubber —
        The dry venturi scrubber is based on the principal of providing the
targets necessary for sub-micron particle removal as dry solid particles
rather than as liquid droplets.
        In a standard wet venturi, particles are captured by inertial impact;
the liquid targets are created within the venturi by transfering velocity
energy into shearing action.
        The capture efficiency for a venturi can be represented by the
equation:

                                       f ( Vr Dp)
            Efficiency of capture  =    ---------  =  f (Ng)
where V_ = relative velocity between particles and targets
       D  = pollutant particle diameter
       Dt = target droplet (or solid) diameter
       Ng = separation number
        The diameter of the target droplets in a wet venturi is inversely
proportional to the gas velocity.  Therefore, high velocities, and the
resulting high pressure drop, are required to achieve the small diameter
targets necessary for a high capture efficiency.
        In the dry venturi system developed by Teller Environmental Systems
shown in Figure 3-21, the targets are supplied to the system as a dry
powder.  The required gas velocity is reduced because the targets already have
been created, both gas velocity and the energy input are reduced. Small solid
targets in the range of 5 to 25 microns permit high capture efficiencies with
only a few percent of the power required for a high energy wet venturi.
        The dry venturi introduces the target material  in a dispersed state at
a high velocity relative to the gas stream.  The target size, population
density and velocity can be varied for specific applications to improve
capture efficiency.  Existing systems use a separation  function number (Ng) of
1.2 to capture 0.5 urn size particles with a 20  im size  target.

                                      3-47

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3-48

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        The capture of  the particles  in  the  dry venturi  is  only the first step
in the removal processes.  The  dry venturi is  used  primarily as an
augmentation device to  improve  the particulate collection efficiency,  to
facilitate the removal  of the collected  particulate matter  from the collector
surface and possibly to provide a degree of  acid gas control.
        Commercial systems have demonstrated a total power  consumption for the
dry venturi and baghouse/ESP of 0.35  to  0.5  kW/1000 m3/hr of gas (Teller,
1985).  If additional processing is required,  e.g.  acid  gas removal with a wet
scrubber, the wet scrubber can  also serve as a particulate  removal system
since the particulate diameter  of the particulates  has been increased  from the
original particulate diameter (i.e. 0.5  um)  to the  target diameter
(i.e. 20 inn).
   !•   Dry Venturi - Baghouse/ESP — The use  of the dry venturi followed  by a
baghouse permits collection of  deliquescent, cohesive, adhesive submicron,  and
combustible particulates where  the use of a  baghouse was previously restricted
or where ESP collector  plates could not  be continuously  cleaned.   These
devices now can function with submicron  particles and hydrophilic or cohesive
particulates without blinding or high pressure  drops.  It also  functions
safely with combustible particulates.  In systems where  SO   or  other acid
                                                          X
gases as well as particulate control is  required, the use of SOo-reactive
powder (like Nahcolite  or Trona) as the  target  material  can serve a dual
purpose.  The use of dry sorbent for SOX control  is  discussed further  in
Section 3.3.8D.
        The use of crystalline  targets results  in exceedingly low pressure
drops in the baghouse even when capturing submicron  particulates.   As  a
result, the bag cleaning cycle  can be extended  from  the  normally  anticipated 5
to 30 minutes to 4 to 36 hours.  This results in extended bag life  from
decreased shaking requirements and from  the  elimination  of  the  permeation of
the submicron particles into the interstices of the  cloth.
        Residence time of the cake on the cloth is increased by  a  factor of
approximately 30.  As a result, where a  system  is providing the  dual service
of particulate and acid gas removal,  residual unreacted  reagent .is  accumulated
in the cake which increases the residence time  for the acid gas  reaction.
                                      3-49

-------
         Performance  characteristics - Performance data for the dry venturi -
 baghouse combinations  is  shown in Table 3-9.
    2ซ    Dry Venturi  -  Wet Scrubber — The use of the dry venturi followed by a
 wet scrubber  results in the  scrubber functioning as both a particulate removal
 device and gas  absorption unit,.   While wet scrubbing will remove large
 diameter particulate from a  gas  stream,  it is generally not effective in
 removing particles less than 5 nn.   However,  by increasing the particle size
 from 0.5 .urn to  20  urn,  the use of dry venturi  upstream of the wet scrubber
 results  in effective particulate removal.
         This  combination  can be  particularly  effective for oil shale
 processing in that a wet  scrubber for gas clean-up is required and its dual
 use for  particulate  control  can  eliminate the need for an end-of-pipe baghouse
 or  ESP.   The  reader  is referred  to  Section 3.3.5 for additional discussion of
 this combination.
 3.1.2    Fugitive Dust  Technologies
         Dust  is generated from the  detonation of explosives;  the loading,
 handling, crushing,  screening, and  stockpiling of  raw shale;  the handling  and
 disposing of  spent shale;  and the moving  of transport vehicles over  unpaved
 and paved roads.  In an underground mine,  the generation of  dust is  of concern
 for workers'  health, safety  and  comfort.   But the  dust that  escapes  the mine
 must traverse the mine vents  where  it  can  be  readily collected in conventional
 filters  (electrostatic precipitators,  baghouses  or granular  filters).   Above
 ground,  the normal handling,  stockpiling  and  disposal are  the  subject  of
 special  procedures to  be  discussed  below.  Where open pit  mining is  employed,
 other special controls are employed since  the blasting is  unconfined.
         The following  discussion  of  fugitive  dust  emission controls  is
 presented in  relationship  to  the  operations in which dust  is produced:   (1)
material  handling, (2) wind erosion,  (3) vehicle traffic,  and  (4)
miscellaneous processes.
A.       Shale and Overburden Handling—
         The movement of raw shale,  spent shale and  occasionally  overburden
material  is performed  by bulldozers, front-end loaders  and conveyors.
                                      3-50

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                                    3-51

-------
Particulate emissions from bulldozers come  from  two points,  the  bulldozer
tracks and the bulldozer blade.  The bulldozer tracks  reentrain  dirt much  the
same as wheels, except probably with additional  grinding action.  The
bulldozer blade top and sides are emissions points as  dirt slides off  the
blade.  This is particularly true of the top of  the blade where  thin layers  of
dirt can easily be carried off by the wind.
        Emissions from front-end loaders come off the  tracks or  wheels as  well
as the loader bucket.  With the loader bucket, the usual source  of emissions
is spillage from the bucket as the bucket is being raised.
        Both the bulldozer and loader drop  their loads of shale  into a truck
bed or into a conveyor. Dust is emitted by  two mechanisms as the material  is
dropped.  First, the wind picks up shale particles from the edges of the mass
of material being dropped.  Second, the air turbulence caused by the displace-
ment of air up out of the truck or conveyor bed  caused by the mass of  dirt
moving downward, brings up soil already in  the bed and soil from the edge  of
the dirt mass being dropped.
        Emissions from conveyors loaded are caused primarily by wind and can
be controlled by proper screening or enclosing.
   1.   Quantification of Emissions—An emission factor was developed  for
bulldozing activity on overburden in coal mines where silt values ranged from
3.8 to 15.1 percent, and moisture ranged from 2.2 to 16.8 percent.  The
emission factor includes emissions from both the tracks and the blade  and  is
(PEDCo 1981):

                   •S 7  1-2
             TSP =    ,%                                            (Eq.  3-2)
                     M
where       TSP = emissions of total suspended particulate in Ib/hour
              s = silt, percent
              M = Moisture, percent

        The emission factor for front-end loader operations appearing  in EPA's
Compilation of Air Pollutant Emission Factors (1982) was developed based on
                                      3-52

-------
 material  handling operations within a steel mill.  All sources (track, tires,
 bucket, dump)  are represented by the factor which is given as:
                    "  ". '    s.  U.  H.
             E = (0.0013)   5  5  5                                   (Eq. 3-3)
                            M     Y U*JJ
                            26
 where        E  = TSP emission factor, Ib/ton
             s  = material silt content,  (%)
             U  = mean  wind  speed,  m/s (mph)
             H  = drop  height,  m (ft)
             M  = material moisture content, (%)
             Y  = dumping device capacity,  m^ (yd^)

 The silt  and moisture terms describe the  general  dustiness of the material
 being moved.   Three of the variables deal with  the material dump  cycle.
 Emissions  increase with increased wind  speed (blowing of  dirt from the dirt
 mass edges), increased drop height (greater turbulence caused by  material
 drop), and decreased  bucket size  (more  dirt mass  edge per unit of volume).
        2.   Principles of  Control—Because the  movement of shale  continually
 exposes new  material,  the  control measure also  must be continuous.   For
 emissions  from bulldozers  or  front-end  loaders, the only  method to control
 dust emissions  is to  spray the area being worked  at frequent  intervals of
 30 minutes to  2-3 hours.   The spray can be water  or surfactant (to minimize
 the amount of  water used),  and can be sprayed from a mobile tower.   Spraying
 moistens the shale particles  on the surface but not all the shale being
 moved.  However, the  material  below the surface is  frequently more  moist  than
 that on the  surface.  The  surface spray reduces emissions  from the track  or
 wheels, as well as emissions  from the bucket and  material  being dropped.
        There have been limited experiments on attaching  sprays directly  to
 bulldozers or front-end loaders (PEI, 1985).  Several  operational  problems
 develop.  The machine either must  be outfitted with a  large tank  or with  an
 umbilical cord to a tank --neither  is  desirable.   The  spray  nozzles must  be
 attached to the blade/bucket or on  arms reaching  over  the  blade/bucket.
Maintenance is difficult with  either approach.  Lastly, machine operators
 don't like to work in the misty conditions.

                                      3-53                          ,

-------
        Area spraying does seem to reduce  the dust  emissions  from material
being dropped despite the fact that most of  the material  is never treated with
the spray, and significant emissions are still present.   The  basic methods  of
control are (1) to induce moisture into the  drop  cycle  (increasing the
moisture term in Equation 3-3) and (2) to  decrease  windspeed  around  the  drop
receptacle (decreasing the windspeed in Equation  3-2).  Neither  of these
practices is used widely by the mining industry for truck loading, although
they are commonly used in the aggregate industry  when dumping material into
bins.  The most efficient method of spraying moisture on  material being  dumped
is to construct a mobile frame under which a truck  can  be driven.  The truck
bed is thus positioned under a series of nozzles  which  produce a curtain of
water across the horizontal surface of the bed.   The spray is operated only
during the dumping.  The system either can be activated by the truck driver,
or remotely by the front-end load operator,  but is  not  operated
continuously.  Water, surfactant, or foam  may be  used.  As the material  is
dumped through the spray curtain, the edges  of the  soil mass  are moistened.
More importantly, as the upward turbulence of air brings  dirt upward out of
the bed, the dust is caught in the spray curtain  and falls back  into the
bed.  Portable windscreens also may be used  to control emissions from the dump
cycle.  The windscreen can be positioned to  shield  the  dump area as  well as
the loading operation.  The screen height  should  be at  least  one foot above
the height of the front-end loader bucket  drop height.  The screen should be
two screen heights wider than the width of the area being worked.  Screen
porosity should be 50 percent.  The screen will shelter a down-wind  distance
of about 7 to 10 screen heights with as much as a 50 percent  reduction in
windspeed at the surface.
        Wind screens do not reduce the formation  of  dust  by the  material
handling operation.  However, the diminished wind velocity causes  the dust  to
drop back to the ground sooner.  If the plume from  the material  drop rises
above the height of the screen, there is no  control  on that portion  of the
plume.  In fact, wind eddies from the windscreen  may carry the dust  farther.
   3.   Products—'Products available are mainly surfactants,  which can be used
for the area spray and for the spray curtain, foams  which can be used for the
spray curtain, and windscreens.  Data on these products are shown  in
Table 3-10.

                                      3-54

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-------
        Suppliers of these products often  sell  spray  nozzles,  masts  and  spray
curtains.
   4.   Effectiveness—The only testing  the effectiveness  of  dust  control
measures effectiveness was performed by  PEDCo Environmental,  Inc.  (1984).  Four
control measures were evaluated.  Control  Measure  1 consisted  of spraying  the
active working area of the Front End Loader (FEL)  and dump truck with water  at
     O            f)
4 L/m  (0.9 gal/ydz).  Control Measure 2 was identical to  Measure  1  but  a
surfactant was added to the water to form  a 1:1000 dilution of surfactant  to
water.  It was found that somewhat less  water was  needed for  these tests,  only
3.4 L/m2 (0.75 gal/yd2).
        Control Measure 3 consisted of an  array of 12 spray nozzles  on the
sides of the dump truck emitting a spray curtain of the water/surfactant
mixture at a rate of 6.8 L/m2 (1.5 gal/yd2).  This method  was  used to control
emissions only during dumping.  Control  Measure 4  consisted of four  spray
nozzles at the corners of the truck bed  to disperse a foam spray curtain at  a
               r\            ry
rate of 1.8 L/nr (0.4 gal/ydz).  As in Method 3, the  foam  spray was  actuated
only during dumping.
        The results are summarized in Table 3-11.  Water spraying  over the
area being worked by the FEL and truck controlled  efficiencies for the fine
particles ซ2.5 micrometers), more effectively  (64 percent) than it  controlled
on the larger particles ซ30 micrometers)  (42 percent).  Adding surfactant to
the water increased control efficiencies while  allowing the quantity of water
used to be reduced.
        Both the spray curtain control measures were  less  effective  than the
area spray with the water/surfactant mixture.   The water curtain was somewhat
better for control of dust from the dump cycle  than the foam curtain.  It  is
believed that higher efficiencies could  be achieved with the water spray by
redesigning the spray system.  If this dumping  control was used in conjunction
with the water/surfactant area spray, the  resulting overall control  efficiency
would probably be significantly greater  than for either one alone.
B.      Wind Erosion—
   !•   Dust Producing Mechanisms—Wind  erosion from  exposed areas or piles
includes shale particle transport by surface creep, saltation,  and

                                      3-57

-------
                  TABLE 3-11.   SUMMARY OF RESULTS  (PEI,  1985)
                                                          Control Efficiency
Operation
PEL travel and
scraping

PEL dump

Control Measure
Area Spray-Water 4 L/m3 (0.9 gal/yd2)
Area Spray-Water/Surfactant 3 L/m2
(0.75 gal/yd2)
Water Curtain 7 L/m2 (1.5 gal/yd3)
Foam Curtain 2 L/m2 (0.4 gal/yd3)
FP
65
70

56
41
TSP
42
63

50
46
 FP = Fine particles




TSP = Total Suspended Particles




PEL = Front End Loader
                                     3-58

-------
 suspension.   Surface creep describes the rolling and sliding movement of
 particles across a surface.  These particles generally have a diameter in
 excess  of 1,00.0 urn.   Saltation is a term used to describe the hopping and
 bouncing movement of a particle.   These particles are lifted by the wind but
 are too heavy to remain airborne.  Particles moved by saltation have diameters
 ranging from 80 to 1,000 urn.   Particles smaller than 80 nn are generally
 suspended.   PEI (1985) reported that from 3 to 40 percent by weight of the
 total soil particle  loss from exposed areas may be attributed to suspension,
 from 50 to 75 percent of particle loss to saltation, and 5 to 25 percent of
 the loss to  surface  creep.
         Wind erosion is largely an intermittent activity that occurs above a
 threshold wind velocity.   Estimates of this threshold velocity have varied,
 and range from about 10 to 20 mph across different soil types, aggregates and
 meteorological conditions.
         2.   Quantification of Emissions—Various researchers have attempted to
 quantify emissions from exposed areas and from piles.   None are totally
 satisfying.
         The  emission factor most  commonly used to estimate emissions from
 exposed  areas  is  (EPA 1974):

             Eg = AIKCL'V                                            (Eq.  3-4)

 where:        Eg = suspended  particulate fraction of  wind erosion losses
                 of  tilled  fields,  tons/acre/year
             A  = portion of total wind erosion losses  that  would be
                 measured as  suspended particulate,  estimated  to be  0.025
             I  = soil  erodibility,  tons/acre/year
             K  = surface roughness  factor,  dimensionless
             C  = climatic factor, dimensionless
             L' = unsheltered  field  width  factor,  dimensionless
             V = vegetative cover factor,  dimensionless
 Values from  this equation can  range from  .001  to  8.25 tons/acre-year, but more
 generally range from  .05 to .75 tons/acre-year.   The equation  is  based on the
 premise  that wind erosion varies with  the  soil particle size  (A), soil
 characteristics (I and K), moisture and windspeed (C),  field width (L') and
vegetative cover (V).
                                      3-59

-------
        The most commonly used emission  factor  equation  for  wind erosion from
storage piles is (EPA  1979):
             E = 1.7   O-)  :<-.)   <)   (Ib/day/acre)             (Eq.3-5)
where:      E = total suspended particulate emission  factor
            s = silt content of aggregate  (%)
            p = number of days with 2. 0. 01 in.  of  precipitation  per  year
            f = percentage of time that the unobstructed wind  speed  exceeds
                12 mph at the mean pile height
The premise of the equation is that wind erosion emissions vary  with soil
particle size, mositure and windspeed.
   3.   Principles of Control— Control systems  work in one of  two ways:  (1)
By reducing windspeed on the soil surface; or (2)  By  forming a new,  less
erodible soil surface.
        Methods to reduce windspeed at the soil surface are:
        1.  Cover pile with wind impervious fabric or vinyl
        2.  Erect windscreen
        3.  Pile orientation and pile shape
These control methods have the effect of reducing  the "C" term in Equation 3-4
(measures 1 and 2), or reducing the area exposed to maximum windspeeds
(measure 3) which influences the "C" and "Lf" terms in Equation  3-4.
        Methods to form a new, less erodible surface, are:
        1.  Water spraying which compacts and weights soil particles
        2.  Chemical dust suppressant application  which forms  a  crust
            over the existing soil, or binds the top soil particles
            together.
        3.  Establish vegetation.  The roots bind  the soil together,
            while the stems reduce windspeed at the surface.
These methods change the I, K, C, and V  factors in Equation 3-4.
   4.   Product-Types, Application Rates, Availability and Costs — Products for
dust control of exposed areas and undisturbed storage piles are  the same.
Product categories are:
                                      3-60

-------
         1.  Liners and fabrics that are impermeable to the wind.  Some
             are impermeable to liquids
         2.  Windscreens which decrease windspeed on the downwind side.
         3.  Spray systems and foams which are sprayed every few hours to
             cover or moisten the soil
         4.  Liquid chemicals which form a soil admixture.  These
             products are sprayed on every few weeks.  Liquids can be
             bitumens, adhesives, salts, or binders with grass seed.
 Product name,  address, phone number, application method and cost are shown in
 Table 3-12.
         Liners will not allow water or many chemicals to pass.  Fabrics will
 allow liquids  to pass, and may not be tolerant of certain chemicals.  Because
 fabrics are  more commonly used for prevention of soil erosion, chemical
 compatibility  testing has not been performed.  The spray systems and foams are
 intended for small areas as a temporary dust control measure.  The control
 would last only for a period of hours.
         The  greatest diversity of products occurs under the category of liquid
,chemicals.  Listed first are oil-based products, many of which are primarily
 marketed for haul road control.  Next listed are adhesives which encompass a
 wide  range of  products.  For example, Bio Cat 300-1 is marketed as a soil
 enzyme.   Some  are lignons such as Flambinder, Lignosite,  and Norlig A.  Others
 are polymers of various sorts such as AMSCO-RES 4281 (Carboxylated Styrene-
 Butadiene Copolymer),  Curasol (Synthetic Resin), Genaqua (Vinyl Acetate Resin)
 and Soil Seal  (Latex Acrylic Copolymer).  The polymers are applied as a water
 soluble  liquid,  but supposedly cure from a non-water soluble material.
         Terra  Tack I,  Terra Tack III, Terra Tack AR and Sherman Mulch can be
 impregnated  with grass seed.   The products contain a binder to hold the soil
 while the grass grows.   Other similar products are available and are routinely
 used  to  vegetate highway excavations after construction.   A detailed Handbook
 for use  of materials to quickly revegetate soils of low productivity is
 available (EPA 1975).
   5.    Effectiveness —
        (a)  Exposed Areas—Wind erosion control from the  standpoint  of stabilizing
 mineral  wastes  and soil stabilization in connection with  construction projects

                                       3-61

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 have been examined in several studies.  None has been performed in conjunction
 with improvement of air quality,  or control of dust emissions from hazardous
 waste sites.   Testing has consisted of compressive strength testing,
 resistance to water erosion and weatherability.  Weathering tests consists of
 placing a weighted amount of soil of known moisture content in a sheet pan,
 spraying the  soil with a dust-suppressant, exposing the sample to weather, and
 reweighing the pan with moisture  correction.   The soil loss is the loss in
 weight through the period.   These tests give  qualitative results, but are
 several abstractions away from a  large exposed area for the following reasons.
         1.  The soil is not naturally compacted in the baking pan.
         2.  The soil is not of the same thickness as would be found in
            place.   The sample soil is less then two inches thick.
            Moisture probably behaves differently in this circumstance.
         3.  Using a hand spray bottle for  suppressant application may
            not simulate the use  of a high-powered sprayer on a large
            exposed area.
         4.  The before  and  after  weights are  compromised by dust and
            organic matter  falling onto the test sheet.

         None  of  the tests have involved ambient air sampling.   References  are
 Bureau  of Reclamation  (1977);  Bureau  of Reclamation (1982);  U.S.  Army Engineer
 Waterways Experiment Station (1977).
         The only  testing with ambient  air  measurements was  performed  by PEDCo
 Environmental,  Inc.  (1984a).   A chemical tracer (zinc oxide)  was  applied to
 50 x  50  foot  test plots.  Dust suppressants then were applied.   Sampling was
 performed for several weeks  with  passive air  samplers.   The  dust  collected
 from  the ambient  air was analyzed  with atomic absorption spectroscopy to
 determine the presence  of zinc.   Zinc  concentrations  above  the  natural
 background level  occurring  in  the  soil  (75 ppm)  indicated failure  of  the dust
 suppressant formed  crust.
        Materials tested, dilution, and application rates are shown in
Table 3-13.   Selection  of the  products  shown for  testing did not mean they
were worse or better than other products available.   These same products are
listed in Table 3-12.
                                      3-70

-------
               TABLE 3-13.  TEST PLOTS APPLICATION DATA (PEI, 1985)
Dust Suppressant
      Name
   Formulation
Appli.
Cone.
Application
   Rate
Soil seal
AMSCO-RES 4281

Fiber mat
Flambinder
Genaqua
Curas ol
M166/M167

CRF
Sherman process
 (no grass seed)
Sherman process
 (with grass seed)
Terra Tack I
Latex acrylic copolymer     3%
Carboxylated styrene-       20%
  butadiene copolymer
Non-woven geotextile     8 oz/yd2
Lignon sulfanate            17%
Vinyl acetate resin         10%
Synthetic resin             3%
Latex                   7% (M166)+
                        0.2%  (M167)
Petroleum resin             25%
Straw mulch bound with      —
  emulsified asphalt
Straw mulch bound with      —
  emulsified asphalt
Vegetable gum              0.3%
            4 L/m2 (1.0 gal/yd2)
            3 L/m2 (0.6 gal/yd2

            3-12 ft rolls
            2 L/m2 (0.5 gal/yd2)
            0.9 L/m2 (0.2 gal/yd2)
            1.3 L/m2 (0.3 gal/yd2)
            2 L/m2 (0.5 gal/yd2)

            2 L/m2 (0.5 gal/yd2)
            6 L/m2 (1.4 gal/yd2)
                                     3-71

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        After  16  to  30 days from application,  all crusts remained intact.
After  30  to  44 days  from application,  only the M166/M167 crust was intact.
The  zinc  tracer values increased with  time,  representing the progressive
failure of the crust over time.
        Visual examination of  the plots  during the course of the tests
revealed  almost immediate plant  growth on the  initially bare plots.   The
vegetation eventually overran  all of the test  plots,  totally destroying the
dust controlling  crusts and rendering  the test plots  indistinguishable from
the  surrounding study area.  Even the  fiber  mat covering Plot 3 was  overtaken
by vegetation  growing through  the mat.   This necessitated the use of a
preemergent  herbicide on most  of the subsequent test  plots.   The use of the
preemergent  herbicide marked by  decreased the  amount  of vegetation although a
few plants still  appeared on each plot.
        Weed growth  is quantified in Table 3-14.   The presence of zinc in
various segments,  of  the test plot on July 20 is shown in this table.   The
first  column indicates the saltation (ambient  air)  catch sample.   Values range
from 55 to 121  ppm.   Of course the crust was very rich  in zinc,  since  that  is
where  the tracer  had been added.   (Values  ranged  from 163 to 544  ppm.)  Below
the crust, values were at or near background.   The  soil around the weed stems,
however, apparently  was composed of destroyed  crust,  because zinc levels
ranged to 546 ppm — very nearly the same  as in the crust levels.  The  loose
soil around  the weed stems was crumbly,  had  a  very  erodible  texture, and would
be highly subject to wind erosion.
        An alternate procedure to eliminating  vegetative  growth would be to
encourage it.   Products  are  available that are  temporary  soil  binders
impregnated  with grass  seed.  While grass  was  beginning to grow,  the same
problem described above  would occur.  Assuming  a  thick  stand  of grass did
grow, control probably  would not  be 100  percent since there  could  always be
some loose dirt between  grass stems.  Chemical  dust suppressants  sprayed on
thick grass  stands would  not be  effective  because the suppressant  would stick
to the stems and little would penetrate  the  soil.
        It is apparent  that  100  percent  effective control of wind  eroded
particulates will require higher  dust suppressant concentrations and/or
                                      3-72

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TABLE 3-14.  WEED GROWTH QUANTIFICATION (PEI, 1985).

              Initial 8 Plots, July 20
                        (ppm)
Saltation
Product Sample
1 85
2 121
4 55
5 90
6 67
7 67
8 72
Crystal
Sample
544
413
291
433
366
190
163
Sub-crust
Sample
47
79
50
46
69
71
91
Soil Around
Plant Stems
499
546
263
546
239
193
108
                        3-73

-------
multiple applications beyond the measures  tested  in the  field  study.
Considerations must also be made for the effects  of weather  and  vegetation.
Precipitation is detrimental to those suppressants that  are  water  soluble
(i.e., lignon sulfonate).  Control of plant growth is essential  if the  crust
formed by a dust suppressing product is to remain intact.
      (b)   Storage Piles—Various studies were located  that evaluated  the effec-
tiveness of dust suppressants or windscreens  in controlling  fugitive  dust from
storage piles.
        The use of chemical dust suppressants have been  evaluated  in  two
studies.  The first study used a wind tunnel placed over a coal  pile  for the
evaluation (Midwest Research Institute 1983).  Because coal  is a very
different material than contaminated soil, results are only  partially
applicable.  Control techniques studied were:  (1) a 17  percent  solution of
Coherex in water applied at an intensity of 3.4 L/m2 (0.74 gal/yd2),  and (2) a
2.8 percent solution of Dow Chemical M-167 Latex  Binder  in water applied at an
average intensity of 6.8 L/m2 (1.5 gal/yd2).  The control efficiency  of
Coherex applied at the above intensity to  an undisturbed steam coal surface
approximately 60 days before the test, under a wind of 15.0  m/s  (33.8 mph) at
15.2 cm (6 in.) above the ground, was 89.6 percent for total particulate (TP)
and approximately 62 percent for <15 (IP)  and <2.5 (FP)  micrometer size
particles.  The control efficiency of the  latex binder on a  low  volatility
coking coal two days after application, under a 14.3 m/s (32.0 mph) wind speed
at 15,2 cm (6 in.) above the ground, was 37 percent for  TP and near zero for
IP and FP.  However, when the wind speed was increased to 17.2 m/s (38.5 mph),
the control efficiency increased to 90 percent for TP, 68.8  percent for IP,
and 14.7 percent for FP.  The efficiency under the same wind speed, 17.2 m/s,
decayed four days after application to 43.2 percent for TP,  48.1 percent for
IP, and 30.4 percent for FP (PEI, 1985).
        Another study evaluated the use of chemical dust suppressants on a
topsoil pile (PEDCo 1984c).  Measurements were made with the RAM-1, a light-
scattering instrument.  Control efficiencies of more than 50 percent were
estimated.  Plots of emission rates indicated a lower rate of wind erosion
than for an untreated pile, and wind erosion was not initiated until a higher
threshold windspeed.  The report concluded that the use of a chemical dust

                                      3-74

-------
suppressant was superior to a windscreen in controlling  dust,  in  terms  of
effectiveness, cost, and mobility around the pile.

     In conclusion, on chemical  dust suppressants applied to inactive
piles, control efficiencies of at least 50 percent  are achieved./ However,
data indicate that dust suppressants cannot approach 100 percent
effectiveness.  Data reported are for an undisturbed pile and  material  being
added or removed would necessitate retreatment.  However, material  cost is
quite low, and only the distrubed area would need to be retreated.   For piles
with vehicle travel on them, control measures suitable to controlling vehicle
reentrainment would need to be used as opposed to the materials listed  in this
section.

     PEDCo (1984c) studied windscreens using RAM-1  aerosol monitors and
windspeed sensors interfaced with a portable computer to give  real-time data
results.  The analysis indicated that the windscreen did not produce
significant reductions in concentrations in the less than 10 mmicrometer
respirable size range.  The screen did reduce windspeeds by the amount
anticipated, but this did not result in commensurate reductions in particulate
concentrations coming from the pile.

     An explanation for the windscreen's performance is that wind erosion
emission rates in the less then 10 micrometer size range are fairly constant
at windspeeds above the threshold of about seven mph (hourly average).   The
additional emissions associated with high wind erosion losses at high
windspeeds are larger particles that are not detected by the RAM-l's.  The
windscreen may be effective in stopping or reducing the movement of these
large particles, but many of them do not stay airborne because of their
relatively large size, so they present less of a threat of off-site exposure.

      In summary, the results of all studies of reductions in windspeed caused
by windscreens are  in fair  agreement.  Reductions in total dust concentrations
are  achieved  but reductions in concentrations of the smaller re~spirable sizes
are  questionable.   A PEDCo  study of particles in the less than 10 micrometer
size respirable  range shows no consistent benefit from the windscreen, but
acknowledge that positive control efficiencies of larger  size particles is

                                       3-75

-------
likely.  However, control of the smaller size particles is more important
because they are in the respirable range and because their small size will
allow the wind to transport them far off-site.
C.      Vehicle Emissions —
        Dust from vehicles is produced by the action of the tire on the road
which grinds the road surface and forces particles backwards and up.  It also
is produced by wind currents created by the moving vehicle which lift the dust
from the roadway and the shoulder.  Thus, both the road and the road shoulder
are involved in this problem.  If the road is unpaved, it should be as
compacted (no loose particles) as possible.  If the road is paved, it should
be clear of windblown dust and spills.  Road shoulders should be as compacted
as possible to make it difficult for wind currents to lift particles.
   1.   Quantification of Emissions — For unpaved roads, the emission factor
for an uncontrolled road (PEI Assoc. 1985) is:
                                     0.7    0.5
             E = k(5.9) (-fj) (|^) (|)    (|)                         (Eq. 3-6)

where   E = Emissions, Ib of _<30 micrometer particulate
        k = particle size multiplier (dimensionless) = 0.80
        s = silt content of road surface material, percent
        S = mean vehicle speed, mph
        W = mean vehicle weight, tons
        w = mean number of wheels
For paved roads the emission factor (PEI Assoc. 1985) is:
             E = k(0.90) I  <>  ()  (-)  ()ฐ'7               (Eq. 3-7)
where   E = Emissions, Ib of _<30 micrometer particulate
        I = industrial augmentation factor (dimensionless),
              ranging from 1.0 to 7.0, usually 3.5
        n = number of traffic lanes
        s = surface material silt content, percent
        L = surface dust loading, Ib/mile
        W = average vehicle weight, tons
Particles _<30 micrometers are likely to stay in the air at distances greated
than several hundred yards from the source.  Particles greater than
100 micrometers usually settle out within 20 to 30 feet of the edge of the
                                      3-76

-------
road.  Particles 30 to 100 micrometers probably will settle out within a few
hundred feet of the road.
        By examining the variables in the equation, the factors influencing
dust emissions can be analyzed.  For unpaved roads, emissions increase with
increases in silt content in the road surface material, vehicle speed, vehicle
weight and number of wheels.  For paved roads, emission increase with an
increase in silt content of the surface material, the quantity of material on
the road, and vehicle weight.  (It would seem that speed should be a factor
for paved roads, as it was for unpaved, but apparently speed did not meet the
statistical requirements to be entered into the equation.)
        2.  Principles of Control—The effect of dust suppressants on unpaved
roads is to aid in compacting the dust particles.  The ability of a road
material to be compacted is highly dependent on the size gradation of that
material.  A proper size gradation for a roadway surface is shown in
Table 3-15.  The results of an improper size gradation are shown in
Table 3-16.  With too much gravel, there will be relatively little dust (until
tires grind the gravel creating silt size particles), but the aggregate will
be pushed to the side of the road.  Any dust suppressant will pass through the
top roadway surface and provide little control.  If there is too much sand,
bearing capacity will be poor, and any dust suppressant that attempts to from
a crust will not work due to rutting.  The most common of these conditions is
excess silt and clay.  For this condition, the dusting rate is high, since
dust suppressants do not effectively penetrate the surface.  In the rain, the
road becomes muddy, rutted, and slippery.  The dust suppressant will aggrevate
these conditions.
        For each unpaved road where dust control is required, roadway samples
should be taken and a size gradation obtained.  If the roadway aggregate does
not meet the specifications on Table 3-15, additional material of the missing
sizes should be added to the roadway.  Without the proper size gradation of
particles no chemical dust suppressant or watering, will be satisfactory.
        The method of control on paved roads is to sweep, vacuum or flush the
dust from the paved road surface (i.e., reduce the "L" term in Equa. 3-7).
These methods tend to remove coarse particles more effectively than fine
                                      3-77

-------
TABLE 3-15.  PROPER SIZE GRADATION FOR UNPAVED ROAD SURFACE (PEI,  1985)









Material
in Excess
Gravel
Sand
Silt/Clay
Sieve Size
1"
3/4"
3/8"
#4
#10
#40
#200
TABLE 3-16.
Bearing
Capacity
Good
Poor
Very
Poor
Percent Passing
100
85-100
65-100
55-85
40-70
25-45
10-25
IMPROPER SIZE GRADATION
Amount
of Dust When Wet
Little OK
Some Soft
Great Mud /Ruts/
Slippery
Soil Type
Gravel
••
••
••
Sand
it
Clay, Silt
(PEI, 1985)
Action of Dust
Suppressant
Drain through top level
of soil. Little control.
Drain through top level
of soil. Little control.
May not penetrate. Will
aggravate mud, ruts and
slippery conditions.
                                 3-78

-------
particles, i.e., the silt term in Equation  3-3.  Any  paved  road  dust  control
program must concentrate on removing the  fine material  from the  street.
        Water is the most commonly used dust suppressant  for unpaved  roads.
The quantity and frequency of application depend on the road material, the
traffic level and the weather conditions.   Chemical dust  suppressants can be
more effective than water alone and are sometimes more  cost-effective than
water where usable water is not readily available at  the  site, which  is
commonly the case in oil shale projects.
        A comprehensive questionnaire survey indicated  that  about 40
manufacturers marketed various products for unpaved road  dust suppression.
Available products were divided into the  following four categories:
        Salts—Hygroscopic compounds that extract moisture  from  the
        atmosphere and dampen the road surface, e.g., calcium chloride,
        magnesium chloride, hydrated lime,  sodium silicates,  etc.
        Surfactants—Compounds capable of reducing liquid surface
        tension thereby allowing available moisture to  wet more  dust
        particles per unit volume, e.g.,  soaps, detergents,  Dust-set,
        Monawet, etc;
        Adhesives^-Compounds that are mixed with native soils to form a
        crust-like new surface, e.g., calcium lignon  sulfonate,  sodium
        lignon sulfonate, ammonium lignon sulfonate,  etc.
        Bitumens—Compounds derived from  petroleum that are  mixed with
        native soils to form a cohesive surface, e.g.,  Coherex,  asphalt,
        oils, etc.

        Salts, adhesives, and bitumens can be applied topically  (sprayed on
the road surface) or mixed in place (blade mixed with the top four to
six inches of the roadbed) at intervals of weeks or months.   Surfactants are
routinely added to the water in water wagons and applied  at  intervals of
hours.  In selecting a chemical dust suppressant type,  the type  of roadway
aggregate should be considered as shown in Table 3-15.
   3.   Product Availability and Cost—Names of commercial products,  their
application method, dilution, rate and cost are shown in  Table 3-15.  Also
shown is a telephone number for the main office where each of the products is
manufactured.  .      .  .
                                      3-79

-------
        The products  shown  in  Table  3-17  represent  suppressants  available in
 1984.  Some products  may  be no longer  available  while  some  new products  may
not be listed.  Products  listed are  not endorsed over  products not  listed.
The results of control efficiency  evaluations  are described in the  next
section.
        The cost elements involved in  dust  suppression include labor  and
material associated with  road  surface  preparation,  the dust suppressant  used,
application, and road maintenance  (grading, watering,  and aggregate).  A
recent study (PEI Assoc.  1985)  cited total  costs of applying specific types of
dust suppressants at  a rate and frequency to achieve a 50 percent control
level in a coal mine.  These data  are  directly applicable to an  oil shale
mine.  Assumptions used for the analysis  are shown  in  Table 3-18.   These
assumptions are based on  the following.
            Product costs were  obtained from each vendor and represent
            the least expensive per  gallon  cost  available shipped to
            both a Wyoming  and  an  Illinois  destination.
        .   Labor and machinery values are  industry averages obtained
            from mine personnel by PEI.   Rates vary by mine depending on
            local labor contracts, machinery type and  age.
            The water was assumed  to be free.  The  reader should adjust
            these figures for actual water  costs  in his area.
            Activity  parameters (miles graded  per hour, etc.)  are
            industry  averages and  vary by mine.   Actual time to  apply
            the suppressants for the tests  was not  used since  the
            relatively short test  segments  did not  facilitate  optimum
            application procedures.  Identical parameters were used for
            all chemicals mixed in place, with a  second set  of activity
            parameters for  all  topical applications.

These assumptions were used to  calculate  costs associated with the  use of
chemicals and water for dust suppression.   The analysis of  chemical dust
suppressants was limited to calcium  chloride (mixed  and topical  applications)
and lignon (mixed in place  only).
        The results of the  comparison of  cost  effectiveness  to achieve a
minimum 50 percent control  level are shown  in  Table  3-19.   The limited results
show that the topically applied salt or the mixed in place  adhesive is more
                                      3-80

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     TABLE 3-18.  ASSUMPTIONS FOR COST-EFFECTIVENESS ANALYSIS  (PEI, 1985)


Cost Item
Application
Surface Prep
Application
Hours/Mile
Chemicals
$/h Mixed Topical Water Frequency

75-16 80 I/application
45 8 2 0.15 I/application
Grading Cost
75
Water, 1/wk
Chemicals, I/
  application
Remaining Watering    95     0.15
                    0.15      0.15     Water,  1.5/h
                                       Chemicals,  I/
                                         shift
                                    3-88

-------
           TABLE 3-19.   PRELIMINARY COST-EFFECTIVENESS COMPARISON TO
                    ACHIEVE 50 PERCENT CONTROL  (PEI,  1985)
Cost of
Chemi cal
Application/
Mile, $<1>
Control*" ' East West
Salt
Mixed 7240 11,300
Topical 3260 5,100
Adhesive
Mixed 4800 7,600
Water
Applications
Cost of Grading Required to
Watering/Week, $ Average 50%
Grading Water Control

0 143 1/4 weeks
0 143 1/4 weeks

0 143 1/4 weeks
375 1710 I/week
Cost Per
Week
East West

1950 2970
960 1420

1340 2040
2100 2100
    Includes surface preparation, material cost, and application.  Material
    cost is delivered cost in East (southern Illinois) and West (Rock
    Springs, WY).  Material cost is:  Liquidow, $0.36/gallon East,
    $0.47/gallon West; Flambinder $0.33/gallon East, $0.47/gallon West.
    Assumes 50-ft and 60-ft wide road in East and West.
(2)
    The application intervals required could not be estimated for adhesive—
    topical, surfactant,  or bitumens.  Comparative costs could not be
    calculated.
                                  3-89

-------
 cost-effective  than watering.   However,  the choice of dust suppressant
 strategies  also should include other considerations related to road
 construction  and spillage as explained in the next section.
         Reapplications of the  chemicals  probably would result in higher
 control  efficiencies than the  initial application because of residual traces
 of  the material.   Therefore, this  analysis based on initial applications may
 overestimate  the cost of  a long-term chemical program.  Conversely, watering
 displays no such cumulative control  effects.   The analysis was performed for
 the mine and  for  the haul road.  The heavy vehicles and high speeds make dust
 suppiressions  more difficult on the haul  road  where more frequent application
 would be required.
         Equation  3-6 has  a factor  of S/30 to  describe the effect of speed on
 emissions.  For example,  a change  in speed from 30 to 20 mph would result in a
 33  percent  reduction in emissions.   While this factor may overestimate
 emission reductions  with  reduced speed,  the principle holds.   The cost of
 speed control is  increased labor and equipment time to haul material.
         The base  emission factor for an  unpaved road versus a paved road given
 in  Equation 3-2 and  3-3 is  5.9  Ibs/mile  traveled versus 0.09  Ibs/mile
 traveled, a reduction of  98.5  percent.   This  control is far more efficient
 than water, chemicals  speed control  or housekeeping.   However,  to maintain
 that control efficiency,  the paved street  must be  continually cleaned.
         Costs vary between  area of the country and the thickness of pavement
 required to support  truck weight.  The average cost  to blacktop  a road
 suitable for over-the-road  trucks  is  about  $140,000  per mile  of  2-lane road,
 plus street cleaning  costs.
        Paved roads, which  become dirt-laden  due to  spills, track-on and
windblown dust, must be cleaned to remove  all  loose  dirt, particularly the
fine particles.  Manual cleaning may  be  adequate for  short  sections  of  road.
However,  it is very  labor intensive.  Street  sweeping  is most  common.
However,  street sweeping  is relatively ineffective at  removing fine
particles.   In one series of tests, material  74 to  177  microns in  size  was
applied to a paved street at a loading of  600  grains per square  foot.   Removal
efficiency was 46 to 63 percent.  Silt size particles,  the particle  size most

                                      3-90

-------
likely to be entrained, are less than 74 micron in size.  Removal efficiency
of this size particle is probably less than 46 percent.  In addition, street
cleaning itself makes dust due to tires rolling on the road, brushing dry
pavement, and wind turbulence caused by exhaust and vehicle movement.  As will
be discussed in the next section, the net cleaning impact on improving ambient
air will be small or negative unless the street is very dirty.
        Vacuum sweeping is more efficient than sweeping.  In the above
experiment, collection efficiencies of 90 to 92 percent were noted.  Again,
collection of silt particles would probably be less, and again, some dust
emissions are caused by the sweeper itself.
        Street flushers hydraulically move street debris from the street
surface to the gutter.  Often flushing is used as an aid to sweeping, and not
the sole method of cleaning.  Flushing before sweeping washes street dirt to
the curb for collection by motorized sweepers.  This type of flushing
ordinarily employs smaller quantities of water and lower nozzle pressures.
The benefits of flushing after sweeping are that the entire pavement is made
cleaner and that only small quantities of dirt are washed into inlets and
catch basins.  Again, however, flushing is more effective at removing larger
particles.
        4.  Effectiveness—Watering test results are shown in Table 3-20.   In
general, watering once per hour will have a control effectiveness of
50 percent.  Watering twice per hour, or once every two hours, will have an
effectiveness of about 75 and 30 percent respectively.  Greater effectiveness
may be realized during evening hours and during humid periods.
        No surfactant tests were conducted.  Efficiencies at the same level of
water use should exceed plain watering.  Although the objective of using a
surfactant is to reduce water use, the effectiveness of decreased watering
with a surfactant has not been tested.
        To obtain the nearly 100 percent control needed at some sites,  it is
                                                                  ?
recommended that watering be initially applied at 0.125 gallons/yd  every
20 minutes.  If muddy  conditions develop, reduce to 30 minutes or more  as
possible to achieve near  total dust control.
                                       3-91

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3-94

-------
        Data for the effectiveness of chemical dust suppressants also is shown
in Table 3-20.  Data vary widely depending on days since application,
application rates, traffic volumes, vehicle size, the receiving surface, and
testing methodologies.  In the first week after application, efficiencies of
80 percent or greater can be achieved.  After one month, values of 40 to
60 percent are common under heavy duty vehicle use.  These data are for
initial applications.  Almost no data are available for chemical
reapplications.  Higher efficiency values could reasonably be expected.
        From an air quality perspective, the relative merits of topical
application versus mixed in place application are unclear.  It appears that
salt and bitumen generally performs better when topically applied.
Conversely, lignon was better when mixed in place.
        In light of the greatly higher cost involved with mixed-in-place
application as opposed to topical application, these test results suggest that
the CaCl2 and bitumens be applied topically.  At any rate, mixed-in-place
application is usually only recommended at the time of initial application.
        To achieve the total control of dust when necessary, it is recommended
that a second chemical dust suppressant application be made 4 to 10 days after
the initial application.  The time should be based on observation.  Time
between applications can be gradually lengthened to near 30 days assuming
spillage and track-on are being controlled.
        When hourly watering is compared with application of chemical dust
suppressants (and once/shift watering), every four weeks costs and control
efficiencies are similar (see Section 3.2), depending on the chemical used.
Other considerations can impact the selection as indicated in Table 3-20.
Chemicals often may be the material of choice, since containment of
contaminated water runoff from the road may be problematical.
        However, chemical dust suppressants are not feasible at sites where
road construction is so poor that the road must be regraded or rebuilt with
new aggregate after all major storms.  Regrading or rebuilding almost totally
destroys chemical effectiveness.  Thousands of dollars of chemicals could
conceivably could be wasted within days of application.
                                      3-95

-------
        Control effectiveness testing of paved roads has dealt primarily with
the effectiveness of sweeping on city streets in lowering ambient air
quality.  City streets are relatively clean to begin with as compared to paved
industrial roads which would be more similar to streets at an oil shale site
used for material hauling.
        Results on the effect of cleaning non-industrial streets are virtually
all in agreement.  Based on results from several cities, it appears that
street cleaning of unpaved roads makes no significant difference in ambient
air quality, and may make air quality slightly worse.  A frequent explanation
is that more dust is generated during the sweeping, than fines are removed
from the road.
        Street sweeping of industrial roads is much more limited.  Based on
four exposure profiler tests per control (MRC 1983) in a steel mill, the
highest measured values for the control efficiency of vacuum sweeping,
occurring 2.8 hr (midpoint of test) after vacuuming, were 69.8 percent for
TP.  Another test 4.1 hours after vacuuming showed a control efficiency of
16.1 percent.  The control efficiency for water flushing at 2.2 L/m2
            f\
(0.48 gal/yd ), approximately 40 minutes after application, was 54.1 percent
for total particulates.  A subsequent test after 3.6 hours showed a value of
44.1 percent.  The control efficiency for flushing and broom sweeping
approximately 40 minutes after application with water applied at 2.2 L/m2
            o
(0.48 gal/yd^), was 69.3 percent for TP.  After 2.8 hours, the control
efficiency was 34.6 percent.  Control efficiency decay on a paved road is more
a function of how much material is being deposited on the road from spilling
and windblown dust, than actual decay in control efficiency (assuming control
measurements are made under dry road conditions).  However, because some of
the steel plant tests were performed immediately after flushing, portions of
the levels of control being measured are probably the effect of moisture.

3.2     NITROGEN OXIDES (NOX) CONTROL
        In a shale oil plant, NOX is produced by the various combustion pro-
cesses associated with retorting and the generation of heat and-power.  N0_ is
                                                                          X
formed by the oxidation of nitrogen (N2) in the combustion air or in the fuel.
"Thermal NOX" is the term used for the NOX produced from the ^ in the air and

                                      3-96

-------
"fuel NOX" is the term used for that produced from the nitrogen bound into the
fuel.
        The control of thermal NOX is accomplished best by combustion design
which prevents the formation of NOX rather than destroying it.  If combustion
designs (or modifications in the case of existing equipment) techniques are
not effective, there are two exhaust gas cleanup processes which can be
employed:  thermal DeNOx and selective catalytic reductions.  Combustion
design is always the most cost effective NCL. control on new equipment; but,
                                           A.
sometimes, is subject to certain process limitations such as requirements to
produce a high gas temperature or a high heat release rate.
        One of the combustion design concepts which produces low NO  emissions
                                                                   X
is called "staged combustion."  Stage combustion involves a sequencing of the
addition of combustion air to the fuel system.  This lengthens the flame (or
combustion reaction zone) and provides time for certain combustion chemical
reactions to take place in a sequence that will avoid NOV formation.  It also
                                                        X
provides an opportunity to control the temperature of the reaction zone which
is important in NOX prevention.  Certain processes cannot accommodate the
staged combustion characteristics; and, therefore, exhaust gas cleanup con-
cepts must be employed on these processes.
        Both of the exhaust gas NOX removal processes available involve the
use of ammonia or urea to reduce the NO  to N? and 1^0.  One process (Thermal
DeNOx*) involves the injection of ammonia in the exhaust gas stream at a
precise temperature of 950ฐ ฑ 30ฐC.  Typically, 50 percent control efficiency
can be achieved with this medium cost process.  The use of urea to reduce the
NOX is in the development and evaluation stages.  A California utility
currently is experimenting with the use of urea in this application.  The
other NOX removal technique involves the use of a catalyst which lowers and
widens the temperature range over which the ammonia is effective.  This
process, referred to generically as selective catalytic reduction (SCR), is
available from several manufacturers who feature, among other things,
different structural forms of the catalyst.  The catalyst is expensive.  In a
dirty gas stream, especially one containing trace metals, the catalyst life

*Patented by Exxon Corp., New Jersey
                                      3-97

-------
X
 could be prohibitively short.  SCR systems can achieve approximately
 85 percent removal when the catalyst is uncontaminated.
         NOX removal by wet scrubbing is not effective for combustion gases
 because the NOX is predominately NO which is relatively insoluble in water.
 NC>2 is relatively soluble in water and can be successfully scrubbed.  There-
 fore,  if the exhaust has high N02, a wet scrubber could be considered for NO
 reduction.   But no process to first oxidize NO to N02 then scrub it has been
 applied on a significant commercial basis.
         This presentation on NOX controls is concerned primarily with
 combustion staging and provides  only summary and reference material on Thermal
 DeNOv  and SCR.
     A                               .                        •              .     .
 3.2.1    Staged  Combustion
         The mechanisms involved  in the formation and emission abatement of  NO
                                                                              X
 are extremely complicated and only beginning to become understood by the
 researchers in  the field.   Most  of the recent NO^ research has dealt with
                                                 X
 coal,  primarily with pulverized  coal  burners.  Many  experiments have been
 conducted to quantify physical and chemical reaction rates in order to develop
 a  consistent model.   One thing has been apparent from this research,  i.e.,  the
 NOX that  is produced is  dependent  on  the broad parameters  of  time,  temperature
 and stoichiometry.   The  time  phasing  of volatilization, mixing,  and chemical
 reaction  are critical.   These rates can change by orders of magnitude with
 only a  100  C temperature change.   The  local fuel/air ratio is  a critical
 factor  in the formation  of  NO .  It is  difficult to  design a  low NO
                                                                    X
 combustion  system  that will work every  time for  every fuel.   Scaling  up  from
 pilot  sizes  to  full  scale  can change results  significantly.
        In  the  coal-burning utility industry,  manufacturing firms build
 boilers to  meet a  size specification and must  guarantee the NO  emission
                         *        •     " -                        X
 level.  Their basic  approach  has been  to use  discrete burner modules  in  which
 the combustion and NOX level  have  been  established before  the  hot gas  is
discharged  to the heat exchange section.  Whether the  boiler has  10 or 20
burners,  each of them is the  same  and the NOV which  is emitted can  be
                                            X
predicted by burning the specified coal in  a  subscale  boiler in  the
manufacturer's plant.
                                      3-98

-------
        The modular  technique  is  not  so readily adaptable to an oil shale
 retort  because  shale oil  retorting itself  is  still in a state of evolution.
 Nevertheless, it  is  possible to apply the  staged combustion principles early
 in  the  retort design and  then  test and adjust them throughout the pilot plant
 and semi-works  stages.  Because the staged combustion principles still are
 evolving,  it is important that any design  team include a staged combustion
 researcher who  keeps up with the  current state-of-the-art.
        The principles discussed  below are simplified and philosophical rather
 than rigorous.  They are  intended to  inform the retort designer of the com-
 plexities, not  to provide a design procedure.   For standard combustion equip-
 ment (boilers,  heaters, incinerators,  etc.) that may  be acquired for  a shale
 oil  project, the discussion which follows  should provide some advice  on what
 features to expect and what NOX emission levels to anticipate.
 A.      Thermal NO —                                                       .
        In a conventional  combustor burning gas,  oil  or coal  with excess
 air  in  the range of  30 percent, the flame  temperature is 1600 C (3000ฐF) or
 higher.  At these temperatures, a fraction of  the oxygen and  nitrogen present
 in  the  combustion air will form NOY in  the thermal  fixation reaction:
                                   A.

                               N2  + ฐ2  ^ 2NO>

 This phenomenon is well known.  In the  early  1970s  the  first  NO  reduction
 techniques addressed this phenomenon.
        It was  reasoned that the  rate determining mechanism for NO  formation
                                                                  X
was the reaction:
                                  + 0    NO + N
which is highly temperature dependent and occurs to an appreciable extent only
at temperatures above 1600 C (Hayhurst and Vince, 1980).  The principal source
of oxygen atoms for this reaction is the dissociation pf molecular 02,
although other reactions probably contribute oxygen atoms.
                                      3-99

-------
        The free nitrogen  further  reacts with  molecular  oxygen:

                                N + 02 * NO + 0

Even in fuel rich flames where hydroxal radicals,  OH,  are  present, NO  can  be
formed from the reaction:

                                N + OH * NO + H

Thus, early NOX control involved schemes to produce  lower  flame tempera-
tures.  This approach is still essentially valid for nitrogenless fuel.  The
research in this area continues.   The early theory failed  to account for
experimentally derived NO  formation rates in the flame region.  It is  not  the
purpose here to explain the many theories now  found  in the literature.
However, to illustrate the complexity of the combustion  chemistry in thermal
NO formation and to help indicate  why an emperical approach to N0__ control is
                                                                 X
taken by combustion hardware designers, the following equation proposed by
Bartok, et. al. (1972) is  given:
             d[NO]            2 ko
             ~dF~~ = kj  [02]  + k4 [NO]  + k4 [OH]e   k3k5 tN2]  [ฐ2]

                                                 k  k  [NO]2 [H]  n
             + k3 k7 [N2]  [OH]eq ' k4 k6 [Nฐ]   ~      k  [0 ]     '
                                                       o   2
where the various kj are equalibrium constants for the N2, 02, N, 0
dissociation and recombination reactions and the symbol,  [ ]   , indicates
equilibrium concentrations of the species inside the brackets.
        Based on this general understanding of the thermal NOX formation
mechanisms, various control concepts involving modifications to both hardware
and operating procedures have been identified and evaluated to reduce NO
emissions from boilers, heaters, etc.
                                      3-100

-------
         In  principle,  thermal-NOx can be minimized using the following
 techniques:
            Reduce  the peak temperature
         .   Lower the  local N2 concentrations  at peak temperature
            Reduce  the residence  time at peak  temperature,  and
            Decrease the  local 02 concentrations at peak temperature

         Lowering the N2 levels requires the  use of oxygen-enriched air,  which
 is not considered cost-effective.   Therefore,  efforts in the field have
 focused  on  the decreasing of 02 levels, peak temperature, and residence  time
 in the Npx~producing regions of a furnace.   On a macroscopic scale,  techniques
 such as  low-excess-air (LEA) combustion and  off-stoichiometric combustion
 (OSC) have  been used to lower local 02 concentrations in utility  and
 industrial  boilers.  In addition,  flue-gas recirculation (FGR), water
 injection,  load reduction,  and reduction of  air preheat  have been used in
 boilers  to  control  thermal  NOX by  lowering the peak flame temperatures.  FGR
 also decreases combustion-gas  residence time and local 02 levels,  but its
 primary  effect is to lower  peak temperatures.
         Thermal NOX formation  is  largely a burner  phenomenon,  since  the
 temperature and availability of oxygen in the  bulk gas downstream is usually
 too low  to support  NO  formation.   To  a large measure,  the amount  of NO formed
 is dependent upon the  design of the burner.  A burner that  is  efficient  in
 promoting complete  mixing and  combustion close  to  the burner will  have com-
 bustion  products that will  experience  a subsequent  high  temperature time
history.  Hence, the rate of NOX formation is high.   In  contrast,  a burner
 that promotes a delayed mixing  of  the  primary and  secondary  air streams will
 result in a long, low-turbulent flame  with reduced  peak  flame  temperatures.
Similarly, a burner that can operate at  reduced  excess air levels  will have
lower emissions than a  burner  that  requires  a higher  levels of excess air.
        It has been demonstrated through numerous  studies on existing on-line
units that modifications to  the combustion process  can be implemented using
existing equipment.   This is accomplished in several ways.
                                      3-101

-------
        A relatively simple technique is to use the flexibilities  in  combus-
tion air damper position and degree of swirl which exist on nearly every
burner.  The local fuel arid air distribution at each individual burner  can
thereby be affected to various degrees and operation of the unit optimized
with regard to NCL. emissions and minimum excess air level.
                 A.
        An OSC approach involves staging the combustion process by operating
the burners at fuel-rich conditions and introducing the remaining  air required
to complete combustion in the bulk gas region.  This can be accomplished
either by using existing "NOX ports", where present, or by operating  with less
than a full complement of burners in service.  In this manner, the fuel is
distributed to fewer burners whereas the air supply, which is maintained
through the out-of-service burners, remains fixed.  The local fuel/air  ratio
at the in-service burners is therefore higher.  Using this technique, the
formation rate of NO is lowered by reducing the availability of oxygen  in the
primary combustion zone.  It also maintains a lower flame temperature because
the final air addition takes place in a portion of the combustion  chamber
where heat removal occurs.  This technique requires a field test program to
optimize the burner out-of-service pattern to be used.  Since each unit (even
units of identical design and construction) operate differently, this
generally requires that a program be conducted on each unit to minimize the
formation of NOX.
        In an FGR system, the recirculated flue gases are inert materials
which absorb a part of the energy released during the combustion process and
thereby reduce the peak temperatures achieved.  This technique, however,
requires the existence of a windbox flue gas recirculation system  which is not
always available on industrial boilers of the size used for shale  oil
projects.
        Another relatively simple approach involves the adjustment of com-
bustion air preheat temperature.  However, this technique, however, causes
several practical operational problems and reduces the fuel use efficiency.
        Although NOX formation is a burner phenomenon, the furnace design can
have a substantial influence on the amount of N()  produced.  This  influence is
                                                X
manifested in several ways.  The temperature of the bulk gas, which controls
                                      3-102

-------
the rate of temperature decay of the combustion products and thus the rate of
decrease in NOX formation, is fixed by the heat release rate per unit volume
and is effected locally by circulation patterns and the promixity of cold
surfaces.  Bulk gas recirculation into this primary combustion zone following
cooling by the furnace walls can affect NOX formation by reducing peak  flame
temperature.  The existence of "NOX ports" allows greater flexibility in the
implementation of staged combustion operation.
B.      Fuel NO --
               A.        '                                             ,
        Fuel NOX is the principal form of NOX to be controlled in a shale oil
project.  While there may be conventional boilers firing natural gas or light
oils where thermal NOX is a concern, the major concern is with the retoring
process or any combustor using the shale, the shale oil, other nitrogen
containing oil or coal as fuel.
        There are several extensive documents treating fuel NOX controls as
associated with coal firing primarily in utility boilers [Thompson, et  al,
1985; Huang, 1981; and KVB, 1977].  This discussion will acquaint the reader
with some of the technical factors and suggest certain approaches that  might:
be incorporated into any new system involving the burning of shale, shale oil,
etc.  These principles may also suggest modifications to R&D burners as test
data are obtained.
        Two mechanisms for the formation of NOX from fuel-nitrogen have been
proposed.  The combustion of the fuel yields volatile matter released from the
fuel particles and char.  Fuel-N0x can be created in combusting both forms of
fuel as either volatile-NCT. or char-NO_...  These two reactions are interrelated
                          A           A
(as are thermal-NOx and fuel-NOx), because any fuel-nitrogen not emitted as
volatiles must remain as part of the char.
                                      3-103

-------
        The fate of fuel nitrogen is shown schematically  in  the  diagram which
indicates the complex manner in which combustion takes place.

Coal Nitrogen
Compounds
. 1
r -
Volatiles

••.'

*
Cha
1

Burned
Char

r

t
Unburned
Char (Ash)
                                                N2 and Others
        The first step in the process, the pyrolysis of the fuel, determines
the fractions of fuel-nitrogen to be associated with volatiles and char.  The
manner in which the volatiles evolve depends on the time-and-temperature
history of the fuel particles.  Tests by Pohl and Sarofim (1977) have demon-
strated that about 10 percent (by weight) of coal is volatilized before any
fuel-nitrogen is released.  It is believed that this reflects the time
required to break down the structures of the nitrogen-containing compounds.
After the initial delay, fuel-nitrogen is released at a rate higher than, but
proportional to, the rate of incremental changes in weight of the coal par-
ticles.
        The precise form in which fuel-nitrogen is released is not known.
Similarly, no complete reaction mechanisms for the combustion of the volatile
fuel-nitrogen components have been developed, although it has been postulated
that ammonia and hydrogen cyanide are the major intermediates for NO  forma-
                                                                    X
tion.  (In burning the retorted shale the fuel is principally char.  Thus the
nitrogen may not be in the form of hydrogen compounds.)  Laboratory studies
                                      3-104

-------
have demonstrated that the conversion of fuel nitrogen to NO  is strongly
affected by the local stoichiometry.  However, contrary to the trends for
thermal NO, the effects of temperature on the formation of volatile NO  are
small, because of two opposing phenomena.  An increase in the pyrolysis tem-
perature will generally increase the rate of release of volatile hydrocarbons
as well as of nitrogen compounds.  Therefore, the local fuel fraction will
increase, resulting in more fuel-rich combustion and a decrease in the con-
version rate of volatile nitrogen to NOX.  The combined effect produces the
relative independence of volatile NO  on temperature.
        As the fuel particles leave the flame zone, the combustion of the
volatiles essentially is complete; the remainder of the combustibles, as well
as fuel nitrogen, can be oxidized via surface reactions on the char material.
The rate of conversion of the char's fuel nitrogen is determined by the
stoichiometry at the surface and in the pores of the char.  Low conversion
rates of char nitrogen compounds are attributable to local oxygen depletion
(and, possibly to the chemical reduction of the fuel NOV on the char's
                                          . :       .     X
surface).
        Based on Pershing and Wendt's (1976 a,b and 1977) work with coal,
there probably is a weak dependence of char NO formation on temperature.
Because both volatile NO and char NO are considered to be relatively
temperature-independent, fuel NO formation is considered to be relatively
temperature-independent as well.  This relatively independence is in contrast
to the strong temperature dependence of thermal NO formation.
        The magnitude of the fuel-NOx can be expressed by both the quantity of
NO  emitted and the fraction of fuel-nitrogen converted to fuel-NOv.  It has
  A                   •                                            X
been experimentally determined that approximately 80 percent of the total NO
formed from coal combustion can be attributed to fuel-nitrogen, depending upon
combustion conditions.  Pershing and Wendt's (1976, b) method of determination
is to compare the quantity of NO emitted for a coal/air flame as opposed to a
coal/oxygen (plus non-nitrogen inert gas) flame.  In this procedure, the
source of nitrogen for thermal NO is eliminated, and fuel"NO alone is
determined.  As illustrated in Figure 3-22,  the bulk of the fuel NO is
generated from volatile fuel components (Pershing and Wendt, 1977, b).
                                      3-105

-------
      1200
   o.
   Q.
c/i
o
+J
•r—
•o
C
o

u
tl
O)
o
•f—
u
•I—
o
to

1C
o
      1000
       800
       600
       400
       200
         .1.0
             A   Total  NO
             O   Fuel  NO (Ar/02/C02)
             D   Calculated — NO Addition
             O   Calculated -- NH3 Addition
                  O	D
                                    Volatile NO
                                                       TT
                                                                    -QCr
                                       Char NO
                                         I,
                           1.10                 1.20
                          Stoichiometric Ratio
1 .30
Figure 3-22.
            Sources of NOX emissions (baseline conditions) using western
            Kentucky coal and a divergent injector with 600ฐF preheat
            (Wendt, 1980).  Reprinted by permission of J.O.L. Wendt,
            Dept. of Chemical Eng., Univ. of Arizona, Tucson, AZ.
                                     3-106

-------
        Pershing and Wendt  (1976, a) have recorded  coal-nitrogen  conversions
of 15 to 30 percent in tests using a variety  of  coals and  burners.   Although
the conversion rate is low, the amount  of fuel NO produced is  high  because  of
the large quantity of fuel  nitrogen contained in coal.  These  experiemental
findings, obtained using small-scale laboratory  burners are higher  than
obtained in some coal-burn-ing utility and industrial boilers.
        While most NOX reduction research has been  performed on coal,  the Gity
of Los Angeles conducted some interesting experiments with dried  sewage  sludge
[Haug, 1981].  Los Angeles  plans to initiates operation of the Hyperion  Energy
Recovery Systems (HERS) in  1986.  The plant uses a  multiple effect  evaporation
process to produce a bone dry fuel in powder  form yield approximately
3000 Cal/gm (5500 Btu/lb).  This fuel has approximately 3  percent bound
nitrogen.  It will be burned in a substoichiometric fluidized  bed combustor
followed by a two stage air addition in an afterburner.  In designing  their
combustion system, an extensive NOX reduction program was  conducted on a
subscale system.  Beginning with an unstaged  incineration  mode in the
fluidized-bed, the NOX emissions ranged from  500 to 1200 ppmv  at an excess  On
level of approximately 5 percent.  After testing several staging
configurations, a NOX emission level of 50 ppmv  at  5.5 percent Oo (60  to
90 ppmv at 3 percent 02) was achieved on a continuous basis.   This  is  a
reduction of over 90 percent compared with the incineration mode.
        The low NOX configuration consisted of substoichiometric combustion in
the fluidized bed (gasification mode) followed by injection of secondary air
into the freeboard of the fluidized-bed reactor  and then injection  of
additional air at two locations in an after-burner  section.  A schematic of
the essential elements of the system is shown in Figure 3-23.
        In the evaluation of this configuration  measurements were made of the
NOX and ammonia contents of the pyrolosis gas emitted from the fluidized bed.
NOX values measured by TECO chemiluminescence analyzer indicated levels  of  2
to 15 ppmv.  Some concern was expressed regarding accuracy  of  this  instrument
in a reducing atmosphere.  Nevertheless, these data indicate that the NO
concentration 'at that point was comparatively low.  The ammonia measurements
(by wet chemistry) at a point where the air supplied was only  60 to  63 percent
of stoichiometric ranged from 1700 to 2700 ppmv.  When the  air supplied  was
83 percent of stoichiometric, the ammonia concentration was 230 ppm.

                                      3-107

-------
                                                        I
rฑuia Bea
Combustor

Air 	 ป
21%
(0.005_____L
NnrVsec) f
Bed Depth
'"1
(0

1
950C
Bed Temp.
0.76 m/sec
Space Vel.
t 1
Fuel Air
100% 63%
. 5Kg/min) (0.

Air
•?&^ 	 	 „
(0.0062
Nm3/sec)
mi
26%
(0.0062
Nm3/sec)
015 N m /sec)
J
After-
Burner

t
Separation
i"
T

—



Fuel :
Exhaust Excess Air
  36 Percent
(5.5 Percent O )

 NO  Emissions:
   x
  50 ppmV Avg.
  at 5.5% CL
                                                           Digested sewage
                                                           sludge with 3.2%
                                                           nitrogen (ult.
                                                           analy) and HHV =
                                                           3000 cal/gm
                                                           (5500 Btu/lb)
Figure 3-23.  Low NO  combustor for sewage sludge  (Haug, 1981).
              Reprinted by permission of T.  Haug,  City of Los
              Angeles,  CA.
                                  3-108

-------
        The presence of NHo in the pyrolysis gas is consistent with the fact
that starved air conditions in the fluidized bed should limit the availability
of oxygen to oxidize fuel-bound nitrogen to nitrogen gas or NOX.  Thus, a
fraction of the fuel bound nitrogen (FBN) would be expected to leave the
reactor in the reduced NHo form.  Furthermore, the concentration of NHo, is
inversely proportional to the fraction of stoichiometric air supplied.  If
excess air were supplied to the FBR, very little NHo would be expected in the
exhaust gas.  The concentration of NHo, increased to several hundred ppm at
83 percent of stoichiometric air and several thousand ppm at 60 to 63 percent
of stoichiometric air.  It is interesting to note that if all fuel nitrogen
were converted to ammonia, the resulting concentration in the pyrolysis gas
would be on the order of 20,000 ppmv [Haug, 1981].  Thus, a relatively small
percentage of fuel nitrogen leaves in the NHo, form when the fluidized bed air
supply is 60 percent of stoichiometric or above.
        An estimated nitrogen balance about the fluidized bed when operated in
a gasification mode at about 60 to 65 percent stoichiometric was made by Haug
(1981).  Ammonia and ML. concentrations were assumed to be 2300 and 10 ppmv,
                       X
respectively.  Organic nitrogen in the pyrolysis gas was estimated from the
measurement of the quantity and nitrogen content of tars and oils.  This
analysis indicated that approximately 10 percent of the fuel nitrogen will
appear as ammonia, 0.5 percent as organic nitrogen in tar and oil, and only
0.05 percent as NO .  The remaining 90 percent will be'released as N9.  As
indicated above, the increase in total air supply to 80 percent of stoi-
chiometric reduces the ammonia to 1 percent.
        An interesting result was that the expected "thermal DeNOx reaction
did not occur.  As discussed in Section 3.2.2., the injection of ammonia into
NO  bearing combustion gas will lower the NO  emissions.  This process is
characterized by a narrow temperature window of approximately 900 to  1000 C.
This would suggest that the afterburner temperature could have a critical
effect on NO  emissions since there are ammonia—like species in the pyrolosis
            X
gas.  Tests were run between 760 and 920 C with an approximately constant
level of 100 to 120 ppmV.  At the higher temperatures, the CO and hydrocarbon
burnout was improved.  Raising the temperature to  1000 C caused some  NOX
increase to 150 ppmV.  However, no distinct window was observed.
                                      3-109

-------
         In a series of  laboratory  tests where  retorted  Colorado  oil  shale was
burned in both the cascading bed and  fluidized bed combustor,  it was found
(Taylor, et al.  1985 a) that the fraction  of total nitrogen  which is released
as NO was lower  than expected for  this high-nitrogen  fuel.   In investigating
the kinetics of  the NO  formation,  it  was found that the NO is  released  well
after the C02 from the  oxidation of carbon.  This  is  shown in  Figure 3-24.
This phenomenon  indicates that it  is  quite possible to  burn  the  char to C02
while limiting the NO emissions from  the combustion of  the fuel-bound
nitrogen.  The temperature dependence of the nitric oxide reduction  by
retorted oil shale is shown as an  Arrhenius plot in Figure 3-25  (Taylor,  et al
1985, b).  The reaction for the nitric oxide reduction  is:

                           char +  NO  —-> CO  + N2ซ
        The effects of  this temperature dependence  are  such  that  at  400-500 C
this reaction is quite rapid and results in an effective reduction of NO  in
the combustor.  These results are  shown in Figure  3-26  (Taylor, et.al 1985 b),
where it is indicated that NO concentration greater than 150 ppm would  result
at low combustion temperatures, but that the NO decreases to below 50 ppm at
temperatures above 400 C.  This test  indicates that the potential for limiting
the NO emissions from the retorted shale combustor exists and appears to  be
primarily dependent on proper design  of the combustor to provide adequate
staging (fuel-rich zones followed by  oxygen rich zones).
        The following statements summarize the staged-combustion strategy for
controlling fuel NOX from shale oil processing:
            For standard items of combustion equipment (boiler, heaters,
            etc.) where nitrogen bearing fuels are planned:
            -   select units equipped with proven low-NOx burner systems
            -   insist on experimental evidence to substantiate
                manufacturer's warranted NO  level
            -   provide manufacturers with detailed fuel composition
                data for their analyses
                if possible,  provide sufficient quantity of  the proposed
                fuel to allow the manufacturer(s) to test  their burner
                systems with the proposed fuel.  NO^ emissions are
                                                 :  X

                                      3-110

-------
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                               3-111

-------
  05
  T3


ฃ ง
M O
H 0)
O CO

5^ ^^


S^
ctj 53
e> o
  St-l
  H
            500
      Temperature,  C

      4UO          300
      -1
         1.2
                          I
                    I
1.4
1.6
1.8
               103/T, (Degrees Kelvin)"1
                    200
2.0
    Figure 3-25.  Arrhenius  plot of rate data for nitric

                  oxide  reduction by retorted oil shale

                   (Taylor, et al.,  1985b).
                              3-112

-------
                     250
                     200
                     150
NO concentration (ppm)
                     100
                      50
                            200
                                                      I            I
                                                  100 g retorted shale
                                       4.9 L/min
 300         400
Temperature ( C)
500
           Figure 3-26.  NO reduction variation with temperature
                         (Taylor, et al. , 1985b).
                                         3-113

-------
    primarily a function of the fuel/burner system provided
    that the bulk gas temperature in the remainder of the
    system does not exceed 1400 C.

For customized systems (shale and shale oil burner, etc),
where the system is designed and developed for a specific
process:

-   First, design the system to provide a substoichiometric
    combustion (or pyrolysis) process to release the
    volatile nitrogen in the fuel in an atmosphere where the
    released nitrogen will take the ^ form rather than
    oxidize to NO .

-   Provide sufficient residence time for this process to
    take place before injecting secondary air to complete
    combustion.

-   When introducing the secondary air, let the bulk gas .
    temperature increase only as high as necessary to
    achieve CO and hydrocarbon burnout or to meet any other
    process requirements.  (Limit the temperature to 1400ฐC
    if possible).

-   Bulk temperature control can be achieved by heat removal
    or by recirculating cooled exhaust.  (In systems with
    gases containing abrasive particles that could erode
    steam tubes or refractory, recirculated exhaust gas is a
    proven technique).

-   Subscale and pilot plant test are essential to determine
    the achievable levels of NOX control.  Many of the NOX
    producing processes take place in localized zones.  It
    is important to appreciate these phenomena in scaling
    the combustion process up or down.

-   At every level of design including the full scale unit,
    it. is essential to provide as much leeway as possible
    for combustion modifications during startup.  Equally
    important is to provide gas sampling ports throughout
    the unit for diagnostic purposes.

-   The achievable NOX emissions from a procedure of this
    type can only be predicted in broad terms.  There is no
    reason to expect any correlation between the level of
    fuel nitrogen and the NO  emissions.  The level will
    depend on the skill of the designer and the patience
    (i.e., funding available) of the owner.  With this in
    mind, the authors feel the range of emissions that can
    be expected is as follows:
                          3-114

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                   NOX Emission              Probability of Achieving
                   ppmV @ 3% 02                 This Level  or Lower
                        200                              95
                        100                              50
                        75                              25

        .   The cost impact of the above procedure will be difficult
            to separate from the overall development costs.   Since all
            process development goes through subscale, pilot  plant,
            semi-works and full scale development, these NOX  control
            procedures are just an added concern that would be difficult
            to price.  Undoubtedly the best investment in this regard is
            to secure services of combustion scientists and engineers
            who are most current on NOX abatement technology  especially
            those involved in coal combustion research.

3.2.2   Exhaust Gas Treatment

A.      Ammonia Injection (Thermal DeNOv)—
                                       A

   1.   Process Description— Ammonia has been the most widely investigated
NO 'reducing agent and the process patent for ammonia injection is held by
  A     .
Exxon Research and Engineering as Thermal DelSK)  (Patent No. 3,900,554).   It
                                              A
involves a chain reaction mechanism between NO,, and the radicals produced by
                                              A.
the decomposition of ammonia.  The overall reaction is [KVB,  Inc.  1977]:

                       NH3 + NO +1/4 02 = N2 + 3/2 H20

        Laboratory tests of ammonia injection using simulated flue gas and a
gas/oil-fired combustion tunnel experiment are shown in Figures 3-27 and  3-28,
respectively [KVB, 1977].  Dramatic NO reductions occur in the temperature
range of 870 to 1040 C for NH-j to NO molar ratios near 1.0 or greater.  At
temperatures below 870 C, NHg and NO concentrations remain near their original
levels which indicate that the reaction activity level is low (Figure 3-28).
After a peak reduction of NO, in the temperate range of 930 to 980 C, the

                                      3-115

-------
350-
                                                       = [NH]/[NO] = 1.7
                           [NH]  - 382 ppm
                           [NO]   = 225 ppm
                                                  [   ]   = concentration,
                                                              ppm
       1200    1300   1400   1500    1600    1700   1800   1900
                            TEMPERATURE, ฐF
        650
760           870
     TEMPERATURE,  C
                                                  980
                                        I
                                      1100
      Figure  3-27.   Exit NO and NH3 concentrations for laboratory test with
                     simulated flue gas (KVB, 1977).

                                           3-116

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      1.0
      0.8
      0.6
  M
  53
  H
I
H
      0.4
 a   0.2
                                                      1.1
                                                      1.6
           1200       1400
                                1600         1800        2000        2200
         650         760
                            TEMPERATURE, ฐF

                                 I             I
                               870         980

                            TEMPERATURE, C
1100        1200
Figure  3-28.  Effect of temperature on NO reductions with ammonia injection
              (excess oxygen 4%, initial [NO] 300 ppm) (KVB, 1977).
                                          3-117

-------
emission of NO begins to rise.  At the same time, the ammonia carryover
remains at the minimum level.  A reaction of ammonia and oxygen occurs at
these higher temperatures, competes with the NO and NHo_ reaction for the
ammonia, and prevents effective NO reduction.  The overall reaction of ammonia
and oxygen is:
                          NH3 + 5/4  02 * NO + 3/2 HZO

In extreme cases, the final NO level  can be higher than the initial, due to
the production of NO from the reaction of NHg with 02ซ  Because of the two
competing reactions, the selective reduction of NO with ammonia is a very
temperature-sensitive process.
        The effect of a variation of  the NH^/NO ratio is shown in
Figure 3-28.  For a constant reaction temperature, the NO emission decreases
as the concentration of NH-j which is  available to react with NO increases.  At
the optimum temperature and a NHg/NO  ratio of approximately 2, there is very
little room for further improvement.  For the laboratory scale data presented,
the maximum reduction efficiency achieved is approximately 95 percent of the
original NO concentration (Figure 3-28).
        The variation in reduction with the initial NO concentration is shown
in Figure 3-29 for the injection temperature of 960 C.  The dependence of NO
reduction efficiency upon both NO and NHo concentration points to the need
of a well designed injection system.  A well designed system would provide
thorough mixing, efficient use of ammonia, and minimum ammonia carryover.
        Oxygen levels between two percent and six percent were investigated by
KVB (1977) and were found to have only a small effect on NO reduction.  Very
little effect was noted at peak reduction temperatures, but increases in Dฃ
level increased NO removal at lower temperatures  (approximately 870 C).
Increases in oxygen levels also decreased the ammonia carryover for all
temperatures.
        Although most of the laboratory tests have been performed with gas and
oil-fired systems, a brief series of  tests was performed on an 80 hp firetube
boiler burning bituminous coal to evaluate the applicability of NHo injection
on coal-fired systems.  These preliminary tests allow comparison with the
                                      3-118

-------
      1.0 Q
      I            I
Initial Nitric Oxide Concent.
Q  100 ppm
                                             200 ppm
                                             400 ppm
                                         O   680 ppm
                                         O   1050 ppm
Figure 3-29.  Effect of initial NO level with NH- injection (960 C,  2%
              excess oxygen) (KVB, 1977):
                                        3-119

-------
 natural gas combustion tunnel experiments, and  show  a  good  similarity  in  NH3
 injection effectivenesss (Figure 3-30).
    2.   Application Experience
         Thermal DeNOx can be a viable control measure  for certain applications
 with removal efficiencies in the range of 50 to 70 percent.  The system is
 readily applied to a low-sulfur low-particulate gas  stream at a constant  and
 uniform gas temperature of 950 C.  Since there are few of these applications,
 problems arise in using the system in retrofit shifting load and sulfur
 bearing fuel applications.   However, in the twelve years since it was
 patented,  the process has evolved to a point where it  is a highly-developed
 and pratical means of achieving NOX reduction in all types of stationary
 firing equipment (Hurst,  1985).
         The problems in the past have involved the design of an injection
 system to  distribute the  ammonia to the gas where the temperature was the
 critical 950 C.   In constant-load systems,  this was achieved by careful
 temperature probing and the use  of  an injection grid.  A full scale  system
 was installed on a 235  megawatt  oil and gas fired utility boiler by  the Los
 Angeles (California)  Department  of  Water and  Power (Dziegiel et al,  1983).
 The system startup was  in May  1982.   The initial NOY  reduction  observed was
                                                    Ji
 40  to  50 percent with ammonia  breakthrough  less  than  65 ppm.
         Ammonia  breakthrough is  a problem because  of  odor  and the  formation of
 ammonia bisulfate  and other  ammonia  salts which  condense  in  the  exhaust stream
 causing fouling  plus  visibility  and  fine  particulate  emission problems.
         The more recent technology involves the  use of  novel  injector designs
 and the development of  a kinetic model which  together may  substantially
 improve the system performance and lower  costs.  The  kinetic  model has  been
 successful in assessing the process capability through  a more precise calcu-
 lation  of the interaction of flue gas constituents and  physical  conditions
 including temperature, time, initial NOX, NH3/NOX ratio, 02,  H20 and  free
 radicals.  This technology has enabled extension of the temperature window to
 over 1200ฐC under  certain conditions of the other kinetic parameters.  The
model can be used to determine the optimum amount of  NH3 which should be
injected in a given location.  Also the model permits accurate prediction  of
                                      3-120

-------
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                                               60
3-121

-------
the quantity of unreacted ammonia.  The kinetic model calculations represent:
kinetic limit performance for the process and this may be lowered in a real
system due to one or more of the engineering design or unit specific
parameters including mixing, carrier rate, flue gas temperature and velocity
gradients, and staged injection.  The influence of each of these parameters
has been the subject of considerable research and development and some work in
this area is being continued.  Mixing effectiveness of grid injectors has been
increased such that it is possible to achieve 95 to 100 percent of the kinetic
limit performance. Wall injector mixing can now be optimized for a specific
geometry by utilizing a field-validated three-dimensional flow modeling
technique (Hurst, 1985).
        The field testing of wall injectors was performed on a 100 x 10
kcal/hr gas and oil fired boiler in Kawasaki, Japan.  In this boiler, it was
desirable to optimize performance in the range of 30 to 50 percent DeNO., since
 •                       ~                      •                         *ป
it is unnecessary to achieve high NO  reduction except during pollution emer-
                                    X
gencies.  The modeling results were verified by field testing with a maximum
variation between calculation and data of ฑ7 percent.  Thus, in the 80 to
100 percent load range, this boiler may operate with a single zone of injec-
tors making adjustments to carrier and NH^ rate as required to meet emission
targets (Hurst, 1985).
        The subject of ammonia breakthrough with the Thermal DeNO,. process Is
                                                                 X
extremely complicated because it depends upon the interaction of numerous
factors such as flue gas concentrations of NOX, H20, 02, SOg, HC1, particu-^
lates, the time-temperature relationship of the flue gas, the effectiveness of
mixing NHg with flue gas, high temperature materials which the flue gas con-
tacts within and downstream of the injection zone, the type of flue gas heat
recovery equipment, and the type of flue gas scrubbing equipment.  Because of
its complexity, ammonia breakthrough must be evaluated for a particular firing
system, and there are very few generalizations which can be made. Since
breakthrough is linked to a certain degree to DeNOx performance, fired
equipment in which the time-temperature relationship is favorable to achieving
high DeNOx performance will also typically exhibit low NHg breakthrough.  In
any case, the placement of the injectors for a given time-temperature rela-
tionship and their mixing effectiveness are of primary importance in
                                      3-122

-------
minimizing NH3 breakthrough, and this is within the control of the DeNOx
system design.  In some cases, factors not under the control of  the DeNO
                                     -                       -            X
system design combine to make high removal efficiency with low NH3 break-
through incompatible.

        Laboratory experiments have  shown that in the lower temperature flue
gas, S03 combines with H20 to produce sulfuric acid starting at  a flue gas
temperature as high as 430 C.  Above 430 C the sulfur is present as S02

only.  When the flue gas temperature drops to the region of approximately 320
C, ammonia combines with sulfuric acid to form ammonium bisulfate in the
reaction:



                     .       ^3 +H2S04 tm4 HS04


As flue gas temperature is further reduced, the ammonia bisulfate reacts with
additional ammonia to form ammonium  sulfate in the reaction:
                          NH3  + NH4 HS04


Equlibrium data for each of these reactions are plotted in Figure 3-31.  The

following conclusions can be drawn from these curves (Hurst, 1985).

        .   First, the curves intersect at high NH3 concentrations, one
            would conclude that at high NH3 concentrations, in the flue
            gas relative to S03, the problem of bisulfate formation can
            be significantly curtailed.

        .   Second, as the NH3 concentration is reduced, the curves
            diverge and thus show that the bisulfate compound exists
            over a wider temperature difference before moving to the
            sulfate.  Therefore, lower breakthrough in the case of NH3
            injection processes is actually more detrimental to fouling/
            corrosion from bisulfate except in the limit when very
            little or no NH3 breakthrough occurs.  In such case, the
            amount of deposit is curtailed simply by the unavailability
            of NH3.

            Third, the initial formation temperature of bisulfate
            increases with increases of NH3, S03 and H^O '
            concentrations.  This is consistent with previous data.
            However, the equilibrium temperature between the sulfate and
            bisulfate also increases with increases in these constituent
            concentrations, but at a faster rate.


                                      3-123

-------
    1.6
 c

U   1-7
co

8   1.8


bO
0)
ฃ


 .  1.9
    2.0
    2.1
o
o
o
   2.2
   2.3
     Reactions Assumed:


     NH, + H2SO4 = NH4HSO4


     NH4HSO4 + NH, -•= (NH4)aSO4
                   <9^
.NH, + H,SO4 = NH4HSO




         Sป*
         ^
     0.1
                                          10
                                                            100
                                                                              1000
                                            ppnV
   Figure 3-31.  Ammonium bisulfate/sulfate  equilibrium with field operating

                 conditions overplotted  (Hurst,  1985).
                                             3-124

-------
         In most cases,  severe  fouling  clearly  occurs  in a region where sig-
nificant bisulfate formation would  be  expected as  a result of  the concentra
tions of NHg and SOg and the flue gas  temperature.  Low fouling cases
generally satisfy one or more  of the following four criteria:
         1.  Excess NHg  so that NH^HSO^ formation is curtailed  at any
            temperature, i.e., operating  condition falls below the
            equilibrium curve  between  bisulfate and sulfate.
         2.  Temperature at the outlet  of  the air heater is at  or above
            temperature where  significant NH^HSO^  is  formed.
         3.  Temperature at the point of NH3 injection is lower than  for
            mation temperature of
        4.  Excess NHg is very low so that deposit amount  is
            insufficient to cause a fouling problem.

Use of the data from Figure 3-31 and the low fouling assessment  criteria
permits the accurate design of features in the boiler and  NHo injection system
to eliminate or minimize the problem of sulfate fouling air emissions.
   3.   DeNOx Costs - Based on statements by Exxon (Hurst, 1985), the latest
version of thermal DeNOx technology requires much lower investment than the
older technology and is substantially less expensive than  catalyzed ammonia
injection (SCR) processes.  At the same plant in Kawasaki, Japan; a boiler was
equipped with Thermal DeNOx, the performance of which was  discussed above, and
a fired heater of similar heat input was equipped with SCR.  The cost of the
SCR facility was approximately $2M and the cost of the Thermal DeNOx facility
was approximately $0.4M or 20 percent of the SCR cost.
        Cost information for the improved Thermal DeNO  process applied to
utility boilers is summarized in Tables 3-21 and 3-22 and  compared to previous
estimates using the older technology.  In Table 3-21 note  that investment
costs for the improved technology are only 45 to 55 percent of the older tech-
nology.  The annual revenue requirements have been calculated in accordance
with the standard U.S. utility procedures.  The lower costs here reflect lower
NH-j consumption and a much lower carrier air requirement.  In addition, lower
capital investment results in lower indirect costs.
                                      3-125

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TABLE 3-21.  TOTAL CAPITAL INVESTMENT AND ANNUAL REVENUE REQUIREMENTS
             FOR "IMPROVED" THERMAL DeNO  APPLIED TO COAL-FIRED
             BOILERS (Hurst, 1985)
                                     Older Technology
  500 MW
  NOi = 300 ppmv

  500 MW
  NOi = 600 ppmv
  500 MW
  NOi = 300 ppmv

  500 MW
  NOi = 600 ppmv


  NOi = Initial NO,,
                        Inves tment
                            k$
11792
 6526
 7755
            $/kW
          Annual Requirements
           k$      Mills/kWh
23.58     4577
13.05     3159
15.51     4712
1.31
17157       34.31     8125        2.32

         Improved Technology	
0.90
1.35
                                3-126

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 TABLE 3-22.  COST EFFECTIVENESS FOR "IMPROVED" THERMAL
              APPLIED TO COAL-FIRED BOILERS (Hurst, 1985)
          \
500 MW
NOi = 300 ppmv

500 MW
NOi = 600 ppmv
500 MW
NOi = 300 ppmv

500 MW
NOi =600 ppmv
                                    Older Technology
                           Mills/kWh
 3.07
                 $/lb NO,, Removed
0.97
 5.26                   0.83

	Improved Technology
 2.03
 2.94
0.57
0.41
NOi = Initial NO.
                x
                              3-127

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        Cost effectiveness results shown  in Table  3-22 have  been  provided on
two bases, mills/kWh and $/lb NOX removed.  The removal efficiency  is  70 per-
cent for the "older" technology and 80 percent for the "improved" technology.
        The NOX emission levels of 300 and 600 ppmv (0.4 and 0.8  Ib/MBtu) used
in Tables 3-21 and 3-22 span the range of most coal-fired boilers using other
than the recently developed low-M)  burners.  Thermal DeNO^  is more cost
                                  • A.    .                   X  '
effective ($/lb NO  removed) on boilers which have higher initial NOV  levels.
                  "         ,                                         X
        The investment costs developed for the "older" technology compare
favorably with 1982 cost estimates prepared by the Electric  Power Research
Institute which are also based on "older" technology.  These estimates are
presented in Table 3-23 along with estimates from  the same reference for two
SCR processes.  The two SCR processes include the  Kawasaki Heavy  Industries
(KHI) process and the Hitachi-Zosen process.  The  KHI process is  the least
costly of the two, but is still approximately three times the cost  of  Thermal
DeNOx.  If the published annual operating cost for the KHI process  are
escalated to a 500 MW plant, this amounts to $15M  for NO  =  300 ppmv and
$19.3M for NOX = 600 ppmv at 90 percent NOX reduction.  Using the investment:
and operating cost data for KHI, it is possible to calculate the  cost
effectiveness.  The results of such calculations are presented in
Table 3-24.  A comparison between these cost effectiveness data and those for
the "improved" Thermal DeNOv process reveals that  Thermal DeNO^ is
                           •*ป•                                  X         .
approximately four to five times more cost effective than SCR.
B.      Selective Catalytic Reduction (SCR)—
   1.   Process Description— The SCR concept is  similar to Thermal DeNOv but
        •^••(^•^••M^HB^^MMBMBIHMK^HHB^.MM^B                               .               jฃ
the critical temperature window is eliminated, the process can take place at a
lower temperature and therefore is less affected by load changes.   Offsetting
these advantages is the cost of a catalyst system  which is subject  to trace
metals contamination which can shorten its lifetime and add  significantly to
system cost.  This can pose a serious limitation in  shale oil combustion
systems where trace metal content is high.
        In this process, gaseous ammonia diluted through either air (i.e.,
below the flammabillty limit) or steam is injected, through  a grid  system,
into the flue gas stream at the exit of the boiler  or other  combustor.  The
                                      3-128

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          TABLE  3-23.   TOTAL CAPITAL INVESTMENT FOR THERMAL DeNO  AND
                       SELECTIVE CATALYTIC REDUCTION FOR A COAL-FIRED
                       500 MW BOILER (Hurst,  1985)
                                               Investment $/kW
      Thermal
                  X

      Kawasaki, Heavy  Ind.  (SCR)

      Hitachi-Zosen  (SCR)


      NOi = Initial  NO,,
                      NOi  = 300 ppmv

                            19

                            69

                           101
      NOi  =  600  ppmv

             25

             83

           109
    TABLE 3-24.  COST EFFECTIVENESS  COMPARISON OF  IMPROVED THERMAL DeNO
                 VS KAWASAKI INDUSTRIES  SCR  FOR A  COAL-FIRED 500 MW BOILER
                                   (Hurst,  1985)
Thermal DeNO.,
KHI (SCR)
                                    Cost Effectiveness
                       NOi = 300 ppmv
Mills/kWh   $/lb NO^ Removed

   2.03          0.57

   9.86          2.43
NOi = Initial NO.
                                        NOi =600  ppmv
Mills/kWh  $/lb NO,, Removed

  2.94         0.41

 12.53         1.54
                x
                                     3-129

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ammonia/flue gas mixture then travels to catalytic reactors where  the  ammonia
and NOX interact resulting in a substantial NOX reduction at  the exit  of  the
reactor.  The primary reactions are:

                      NO + NH3 +  1/4 02  -v N2 + 1  1/2 H2 1 1/2  NZ + 3H20

        As can be seen in the above equations, the stoichiometric  NHo:N()  mole
                                                                     •j   X
ratio is approximately 1:1 considering that NC>  at the boiler outlet is gener-
                                              A.
ally assumed to be 95 percent NO  and 5 percent NOo.  In actual practice this
ratio may be 0.9 to  1.0 for a 90  percent removal  efficiency based  on the  inlet
NO  concentration, assuming that  a suitable catalyst volume has been provided
  X
to achieve this efficiency.  If adequate catalyst volumes are not  provided  to
achieve high efficiencies, the result of increasing the NHo:NO mole ratio
will be ammonia slip or breakthrough which is simply the flow of excess
ammonia past the reactor(s) and on to the downstream equipment.
        The ideal process temperature range is generally limited to  310 C to
400 C.  Below the lower temperature there is danger of the formation of
ammonium sulfates and bisulfates  which can attack the catalyst surface.   If
the low temperature  operation is  continuous (i.e., 12 hours or more),  this
attack can permanently damage the catalyst.  An economizer flue gas  bypass  is
typically provided to raise the economizer exit flue gas temperate at  low
loads to an acceptable level and  thereby overcome this problem in  boiler
applications. The economizer outlet temperature rarely exceeds 400 C at full
load conditions.  However, if exceeded,  the NH^ may disassociate and NOX
reduction process will be impaired; if temperatures exceed 500 C to  550 C the
catalyst may sinter  and be permanently damaged.
        The NO., reduction efficiency of  this process is dependent  upon the
              •*ป•                '            ...         .    .
space velocity selected for the catalyst.  The space velocity is basically  the
total flue gas volume per hour divided by the bulk volume of  the catalyst,
noting that the flue gas and catalyst volumes are generally stated in  standard
cubic feet or normal cubic meters for this purpose.  The units of  space
velocity are reciprocal hours.  In general, reasonably low space velocities
                                      3-130

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and/or area velocities are required for high process efficiencies.   This means
that increased catalyst quantities are required for high NCL.  reduction
                                                            A.
efficiencies (e.g., 90 percent).  It is important  to note  that  increased
quantities of catalyst are also required to control ammonia breakthrough.
That is, not only must a sufficient quantity of catalyst be provided to
achieve the required NOX reduction efficiency, but additional catalyst is
generally required to insure the oxidation of excess ammonia  used in the
process to prevent excessive ammonia slip (i.e., typically less  than
10 ppm).  The specific relationship of these indices and NC>  reduction
                                                            X
efficiency is related to the proprietary catalyst  used by  the various SCR
manufacturers.
        The catalyst used in these processes is either solid  or  surface coated
catalyst on a substrate.  Both are subject to erosion damage  from fly ash in
coal fired power plant flue gases, and the efficiency of the  catalyst can be
impacted over the long term (1 to 3 years).  The loss of catalyst
effectiveness will probably require the use of an  excess of catalyst to
maintain the required process efficiency over an extended  period of  time.  If
this is the case, the capital and operating costs  for the  SCR process will be
increased accordingly.
        These catalysts also have the tendency to  oxidize  S02 to SOg which
tends to react with the NHg carryover and the form ammonium bisulfate at the
exit of the reactor in the reaction:

                          NH3  + SO   + HO  •*• NH HSO,

        As mentioned in the Thermal DeNO_ discussions, ammonium  bisulfate has
                                        X
the tendency to condense in the intermediate baskets of a  standard regenera-
tive air preheater.  This makes their removal by conventional soot blowing
difficult.  The result, particularly on high sulfur fuels,  can be significant
fouling of these preheaters which will cause high draft losses and possibly
unit load limitations.  Frequent air heater water washings  may be required.
Japanese experience with SCR systems has led to the development  of combined
intermediate/cold end air heater baskets which have a heat  transfer  surface
configuration which is conducive to cleaning by soot blowing.  This  combined

                                      3-131

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section is longer than its conventional counterparts (the separate
intermediate and cold end baskets in a standard regenerative air heater).  The
result is more expensive air heaters which may reduce the ammonium bisulfate
fouling.  However, on high sulfur fuels, the effectiveness of this
accommodation is still questionable.
   2.   System Experience — A number of gas and oil fired boilers in Japan
have been equipped with SCR.  In the U.S., by 1983, only the Southern
California Edison Plant at Huntington Beach, CA had been equipped with a
system.  The full scale Kawasaki SCR system was attached to one of two exhaust
ducts from the 215 MW Bacock & Wilcox unit.  It was designed for a removal
efficiency of 90 percent and a maximum ammonia slip of 10 ppmv and a pressure
drop of 30 cm water column.  After more than two years of testing, pperating
results have shown that the desired NO  removal and pressure drop performances
were obtained.  The ammonia breakthrough constraint has not been satisfied but
there were uncertainties in the measurements (Kerry and'Weir, 1985).
Operation of the system showed that the catalytic reaction of ammonia plus NO
                                                                             X
behaved as a first order reaction with removal dependent on ammonia
addition.  Thus, NOX removal.was controlled by ammonia addition.  As ammonia
addition was increased to increase removal, ammonia slip increased.  Operation
also showed that ammonia was adsorbed by the catalyst.  The amount appeared to
be a function of the ammonia flow rate.  The unit has been run 70 percent of
the time on gas and 30 percent on 0.25 percent sulfur oil.  After 11,000 hours
of activity, only a 5 percent loss of catalyst activity was reported.
        The overall SCR operational experience on coal fired utility boilers
is minimal.  In Japan, Takahara Unit 1 (250 MW) is now testing the SCR process
on coal.  In the U.S., three coal fired pilot plants are in operation, these
are:
            The EPRI Arapahoe Test Facility at the Arapahoe Power Plant
            of the Public Service Company of Colorado.
            Size - 5000 scfm (2.5 MW)
            Supplier - Kawasaki Heavy Industries
            The U.S. EPA Pilot Plant at the Mitchell Station,
            Georgia Power Company
            Size - 0.5 MW
            Supplier ^- Hitachi Ship Building and Engineering Company
                                       3-132

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            The U.S. EPA Pilot Plant at  the Big Bend  Station  of  the
            Tampa Electric Company
            Size - 0.6 MW (Combined SO /NO  Removal)
            Supplier - UOP Inc.

   3.   SCR Costs — A comprehensive study of  SCR economics for  coal  fired
utility boilers was made by Damon et al.  (1985).  The results of  three  other
studies conducted for the EPA, EPRI and  TVA were analyzed and placed  on an
identical basis for a 500 MW net capacity.  The results are shown in
Table 3-25 (Damon et al., 1985).
                 TABLE  3-25.   SCR COSTS (Damon, et  al.,  1985)*

Report
EPRI/Stearns-Rogers
EPRI/U.S. EPA/TVA
U.S. EPA/TVA

$/Net/kW
94
79
65

$/ACFM $/Nm3/min
15.93 560
15.97 560
13.21 410
First Year
Mills/kWhr*
6.87
6.14
5.11
Levelized
Mills/kWhr*
12.59
11.44
9.53
* Based on a one year catalyst guarantee life
t Costs are in 1983 dollars.
        As can be seen, the capital costs developed for the EPRI reports on a
$/kW (net) basis are somewhat different.  The reason for this variation is the
difference (approximately 19 percent) in the adjusted flue gas flows used for
                                O     .  -                       '
these reports.  However, on $/Nm /min basis, the two EPRI reports show
identical costs.  The two TVA reports use nearly identical flue gas flows but
have significantly different capital costs.  This results in the significantly
reduced catalyst requirements assumed in the U.S. EPA/TVA report.  All three
of these studies used Hitachi-Zosen's catalyst NOXNON 500 Type 3 in their cost
analyses.  The lower costs of this latter report could only be accepted when
this reduced catalyst loading is demonstrated to be viable in achieving a
90 percent NOX reduction efficiency while at the same time controlling NH3
slip to 10 ppm or less.
        The Southern California Edison plant described above shows a similar
result of 11.3 mils/kWhr (Kerry and Wier, 1985) at 100 percent capacity.  In
                                      3-133

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terms of cost effectiveness, $/ton NO  (as N02) removed, the cost ranges from
$16,700/ton at a 30 percent capacity factor to $6,400/ton at 100 percent capa-
city factor.

3.3     SULFUR COMPOUND CONTROL
        Sulfur from shale oil processing operations is emitted in three basic
forms:
           Inorganic reduced - t^S
           Inorganic oxidized - 802/803 (sox)
           Organic reduced - CS2, COS, MeSH, thiophenes, etc.

The principal source of reduced sulfur emissions is the retort off-gas in
which the organic fraction of the total sulfur content ranges from one to
fifteen percent as discussed in Section 2.0.  Most sulfur removal systems are
unable to adequately scrub the organic sulfur compounds which are insoluble in
water.  This is a serious concern which has not as yet been adequately
addressed by project proponents.  The activated carbon-hypochlorite process,
as presented in Section 3.3.5, appears to provide for the removal of organic
sulfur.  Claims of organic sulfur removal have also been made for the Lo-Cat
process, but there is minimal experience in long term application of either of
these technologies on removal of organic sulfur species.
        The oxidized sulfur is emitted by primarily combustion processes
including incinerators of the retort tailgas.  Using conventional flue gas
desulfurization (FGD) on the incinerator off-gas is another way to ensure the
removal of the organic sulfur.
        The EPA has detailed many sulfur removal processes in their Control
Technology Appendices for Pollution Control Technical Manuals (Ondich,
1983).  In this section, those processes that are relevant to shale oil
processes are presented.  Since those technologies are included in the EPA
Appendices, they will be summarized with any pertinent comments regarding
applicability.  Processes not appearing in the EPA Appendices will be pre-
sented in greater detail, where information is available.
                                      3-134

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3.3.1   Stretford Process (H2S)                                    ;
A.      Process Description—
        The process chemistry of the Stretford  technology  is  based  on  the
absorption of H2S in an alkaline scrubbing solution and subsequent  liquid-
phase oxidation of the captured H2S to elemental sulfur.   The Stretford  liquor
is a dilute solution of sodium carbonate  (Na2COo), sodium  metavanadate
(NaV03), and sodium salts of the 2:6 and  2:7 isomers of anthraquinone
disulfonic acid (ADA).  The solution is maintained at a pH range of  8.5  to  9.5
and at a temperature of approximately 43  C.  Citric acid is used as  a
complexing agent to keep quadravalent vanadium  dissolved in the alkaline
solution.  Anti-fearning agents are used when required usually as the result of
condensed hydrocarbon in the solution.
        The process chemistry is complex  and poorly understood.  However, in a
simplified manner, the process of removing H2S  and converting  it to  elemental
sulfur is a six step process as follows:
        1. The H2S is absorbed in the alkaline  Stretford solution in a
         *  suitable gas/liquid contactor.
        2. The H2S reacts with the sodium carbonate to form sodium
           hydrosulfide and sodium bicarbonate:
            H2S + Na2C03 + NaHS + NaHCC>3                                 (R-ll)
        3. The hydrosulfide reacts with sodium metavanadate to form
           elemental sulfur,  a quadravalent vanadium salt,  and sodium
           hydroxide:
            2NaHS + 4NaV03 + H20 —> Na^Og +  2S + 4NaOH                (
        4. The quadravalent vanadium salt reacts with ADA to regenerate
           the sodium metavanadate:
            Na2V409 + 2NaOH + H20 + 2ADA —> 4NaVC>3 + 2ADA .  2H          (
        5. The sodium hydroxide and sodium bicarbonate reaction products
           further react to form sodium carbonate:
            NaOH + NaHC03 —> Na2CC>3 + HZO               '                (
        6. The reduced ADA reacts with oxygen to regenerate the ADA:
            2ADA .  2H + 02 —> 2ADA + 2H20                              (R-15)

                                      3-135

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        The overall process reaction can be written as  the  oxidation  of H2S  to
elemental sulfur:
            2H2S + 02 —> 2S 4- 2H20                                     (R-16)

        Several side reactions that form nonregenerable compounds are possible
in the Stretford process.  These consist primarily of oxidized sulfur
compounds such as sodium sulfate and sodium thiosulfate.  The nonregenerable
compounds can build up in the system and eventually impede  the performance of
the process by interferring with the principal chemical reactions.  These
compounds must be removed from the process either by purging them from the
system or by recovering them in a regeneration system.
        The oxidized sulfur compounds form when the dissolved oxygen  in the
process liquor is too high, which occurs when the pH is too low.  H?S absorp-
tion also is reduced at low pH.  The high C02 found in retort offgas  can
reduce the pH unless the process pH level is maintained by  sodium bicarbonate
addition.  A simplified process flow diagram of an EPA pilot plant is
presented in Figure 3-32.  Reactions (13) through (15) take place in  the
reaction tank.  The air which provides the oxygen for Reaction (15) also
causes the elemental sulfur to float as a heavy froth on the liquid surface,,
        The sulfur froth overflows from the oxider to a froth tank while the
sulfur-free reactivated Stretford solution flows through a  cooling tower
before falling into a surge tank and being recirculated to  the absorber.  The
cooling tower is designed to evaporate sufficient water to maintain the system
in water balance and to control the solution temperature which is normally
kept at 305 to 314 K.  A solution heater (not shown in Figure 3-32) usually  is
provided in case additional heat is required to promote evaporation of water
to maintain the water balance.
        The sulfur can be recovered from the froth in several ways, depending
on the desired end product, total sulfur production, and utilities cost.  For
small sulfur capacities, simple filtration of the sulfur froth may be
economic.  For larger sulfur production rates, one or more stages of
centrifuging (or filtering) followed by heating may be used.  In this mode of
                                      3-136

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          To Atmosphere
Reaction
  Tank
                      Vent
                                             (Sulfur Froth)

                                      |           ft  Makeup   1
                                      1           *J   Water    I
                                                     Chemicals I
                         Oxidizer
        Air
             Compressor
                                                                    Slurry
                                                                     Tank
                                                                                        Disposal
 Figure  3-32.   Simplified flow diagram of  the Stretford pilot  plant.
                  (Taback,  H.J., et  al.,  1985a)
                                    3-137

-------
operation, the sulfur cake is reslurred with steam condensate to reduce the
Stretford reagent loss.  The slurry is pumped through a sulfur melter and then
into a steam-jacketed separator, where molten sulfur is recovered and the
remaining dilute Stretford solution is returned to the system.  Any wash water
and reslurry water provide additional water load to the cooling tower duty.
In an alternative mode of operation (i.e., direct autoclaving), the sulfur
froth is pumped through a sulfur melter into an autoclave, where the phases
are separated and the hot Stretford solution is returned  to  the surge tank.
This mode of operation has the advantages of simplicity of operation, lower
capital investment, and reduction of water evaporation load  on the cooling
tower.
B.      Process Applicability—
        Over 100 Stretford units are currently in operation  worldwide, with
                                Q             1 *?   ^
capacities ranging from 2.7 x  10  to 5.4 x  lO1'' Nnr/D and sulfur removal rates
ranging from 0.45 to 82 Mg/D (Ondich,  1983).  Applications include
purification of Glaus unit tail gases, amine regenerator  off-gases, coke oven
gases, coal gasification product streams, low Btu gas streams, oil
gasification SNG streams, reformed petroleum products, and vent gases from
geothermal steam turbines.  Stretford  sulfur  recovery units  also are  included
in the designs of at least four Lurgi  coal  gasification facilities in the U.S.
(i.e., projects sponsored by Tenneco Coal Gasification, Nokota Company, WyCoal
Gas,  Inc., and Great Plains Gasification Associates)  (Beychok & Rhodes,  1981).
        Inlet concentrations of 1198 as low  as  300 ppmv can be processed  in a
Stretford unit.  The practical upper limit  for H2S  inlet  concentration is
15 percent, although in theory a unit  could be developed  for higher concentra-
tions (Ondich,  1983).
        The serious limitation of  the  Stretford  process  is the  removal of
organic  sulfur.  Tests performed with  the EPA mobile  Stretford plant  have
shown no  organic sulfur removal  (Taback,  et al.,  1985a).   Ondich  (1983)
reports  a private  communication  indicating  90 percent  removal of methyl
mercaptan but  then states  that carbonyl  sulfide  and carboti disulfide  are not
removed  by  the  Stretford process.   It  is  the  concensus  among the  shale  oil
process  designers  that the  Stretford process  cannot be counted on  for organic
sulfur removal.
                                      3-138

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C.      Process Performance—
        When properly operated l^S removal efficiency  can be very high.  Emis-
sions of less than 1 ppmv I^S can be obtained  (Ondich,  1983).  Any hydrogen
cyanide in the feed stream is converted to sodium thiocyanate which  is a con-
taminant to the Stretford solution.
        Although there are many installations  where the Stretford process  is
employed, actual operating data are limited.   Stream characterization of most
of the effluent streams, including trace and minor constituents, are lacking.
Data from a design for a Stretford unit that would treat lean acid gas from
the Rectisol unit at an El Paso Natural Gas Burnham coal gasification facility
are shown in Table 3-26.  Typical compositions of the  Stretford absorber
offgas from several Beavon sulfur removal plants which utilize the Stretford
process are presented in Table 3-27.  The recovered sulfur normally consists
of 99,5 percent sulfur with small amounts of contaminants such as vanadium
salts and sodium thiocyanate.  Organic sulfur  compounds and the lower hydro-
carbons (e.g., containing five carbon atoms or less) essentially appear in the
purified gas stream.  Higher hydrocarbons as well as ammonia will be present
in the oxidizer vent stream, if present in the absorber feed gas.
D.      Process Reliability—•
        With so many constituents in the solution, it  is not surprising that
many Stretford users have reported startup problems such as low removal effi-
ciency, foaming, clogging, etc.  Because these problems are treated on a
confidential basis, there are little published data on their cause.
        The EPA reported foaming problems attributed to organic vapor in the
inlet gas.  Low sulfur removal efficiencies also were experienced.  These were
attributed to poor gas to liquid contact.  Both problems appeared to be
solvable (Taback, et al., 1985a).  Preliminary information from the SASOL
Lurgi coal gasification facility in South Africa indicated that biological
growth due to high carbon dioxide levels in the feed was primarily responsible
for plugging problems in the Stretford absorption towers.  Conventional
absorbers consist of packed towers.  Plugging normally occurs in the bottom 2
to 3 meters of packing after 6 to 12 months operation  [2],  The use of a
                                      3-139

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    TABLE 3-26.  DESIGN DATA FOR A STRETFORD UNIT TREATING RECTISOL OFFGAS
   AT EL PASO NATURAL GAS BURNHAM COAL GASIFICATION FACILITY (Ondich, 1983)
Component
CO, %
H2S , ppmv
COS, ppmv
CS , ppmv
HCN, ppmv
CO, %
CH4, %
C2H4, %
C2H6, %
HOI
2> /0
H20S %
Na2 S203, %
NaSCN, %
NaV03, %
ADA, %
NaHC03 + Na2C03, %
Raw Gas
96.0
7400
77
2
30
0.17
0.53
0.22
0.30
0.43
1.6





Absorber
Offgas
99.0
8
75
2
0
0.16
0.52
0.22
0.29
0.42
4.32





Solvent
Purge










80.0
10.8
4.4
0.7
1.1
3.0
        TABLE 3-27.  TYPICAL COMPOSITIONS OF STRETFORD ABSORBER OFFGAS
                IN BEAVON SULFUR REMOVAL PLANTS (Ondich, 1983)
Component Facility A
H2S, ppmv
S02 , ppmv
COS, ppmv
CS2, ppmv
CH3SH, ppmv
CO , ppmv
CH4 , ppmv
N2 H- AR, %
co2, %
H2, %
5
<20
50
20
<5
NR
NR
NR
NR
NR
Facility B
<1
<1
30
9
NR
500
200
89
7
3
Facility C
<0.1-7
<5
7-23
1
NR
565
221
NR
5.7
5.6
Facility D
<1
<0.4
5
0.5
NR .
250
NR
NR
NR
NR
Facility E

-------
venturi scrubber followed by a short conventional absorber will result in
appreciable reductions in investment and maintenance costs since plugging is
limited to the venturi scrubber which can be more easily cleaned than a
conventional absorber (Ondich, 1983).  Stretford designs with two venturi
scrubbers in parallel (one spare) followed by a short absorber can conceivably
eliminate plant shutdown for absorption equipment cleanout.  Plugging of
sulfur froth lines is greatly reduced by using long-radius elbows and flushing
the lines before shutdown.  Some provision must be made for sour gas disposal
during absorber cleanouts and any mechanical failures.
E.      Process Economics—
        Investment and operating costs are affected by operating pressure,
hydrogen sulfide content of feed gas, and disposition of sulfur products.  The
capital investment costs for a Stretford unit are presented as a function of
sulfur removal capacity in Figure 3-33.  The capital investment costs were
obtained by EPA from studies recently performed by Catalytic, Inc., Oak Ridge
National Laboratory, and Black & Veatch [Ondich, 1983].  From data provided by
J. F. Pritchard Co. to Black & Veatch, an equation was developed relating
capital cost to sulfur recovered and flow rate as follows:

              A  ฐ'6     B  ฐ'18
            36TT       37^5"        (7.8) = C

where:     A = sulfur removed, kmol/hr
                                    O
           B = feed gas flow rate, m /rain per kmol sulfur removed per hour
           C = total capital cost less interest during construction, $10^
           (1980) .

        Operating requirements for the Stretford process (presented in
Table 3-28) were extracted from information provided by the Ralph M. Parsons
Co. to Black & Veatch with respect to the Beavon sulfur removal process.
Other cost data also were reviewed (Ondich, 1983).
                                       3-141

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       1000


          7
    CO
    0)
    iH
    O
    ฃ

    t>0
    -a
    0)

    o

    I
    3
    C/3
       100
        10
         2 -
                                                        o
                                                o
                                                           o
                                      o
                  o
                        o
                            o
                         1
              j  I  1  I  I I
                   2        4       7   10        2        4
                      Capital  Investment, $106 (1980 Dollars)
                                                    7  100
Figure 3-33.
Stretford capital  investment cost (less interest during
construction.)   (Adapted from Ondich,  1983)

                        3-142

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        TABLE 3-28.  OPERATING REQUIREMENTS FOR THE STRETFORD PROCESS3
                                (Ondich, 1983)
For 36.1 kmol/hr (27 Mg/day) unit
     cooling water
     electricity
                                                  5.70 m3/min
                                                  610 kW
For 41 kmol/hr (31 Mg/day) unit
     chemicals
     steam
                                                  $350,000/year
                                                  7.30 Mg/hr (16,000 Ib/hr)
a Data extracted from information provided to Black & Veatch by the Ralph M.
  Parsons Company for the Beavon Sulfur Removal Process, Nov. 1980.
3.3.2
A.
        Process Description —
        The Lo-Cat process is similar to the Stretford process except that
chelated iron is used in place of sodium metavanadate as the principal agent
for producing elemental sulfur.  The details of the chemical scrubbing solu-
tion are proprietary with ARI Technologies, Inc. Palatine, Illinois.
        The process using ARI-310 catalytic  reagent is the third generation
of a process which was originated by Humphreys and Glasgow in London.  Their
Chelated Iron Process used ethylene diamine tetra acetic acid (EDTA) to hold
iron in solution.  The process was incorporated in an oil refinery in
Landarcy, Wales, in 1964, but was not a success because of the instability of
the chelated iron compound.
        ARI developed the second generation process which overcame the problem
of iron precipitation at high pH, by the addition of a polyhydroxylated sugar
or "Type B" chelating agent to the EDTA or "Type A" chelate.  An installation
was made at the Plateau Refining Company in Bloomfield, New Mexico in 1977.
This was followed by the installation of six small units, and two refinery
                                      3-143

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process  units  which produced 7 to 15 long tons of sulfur per day.   These units
performed  well with respect  to H2S removal,  but higher than expected
degradation  of the  organic chelating agents  was experienced.  ARI-310,
developed  in 1982,  improved  stability.
         In the Lo-Cat  process,  the chelated  iron acts as a catalyst to  the
overall  reaction:

             2H2S +  02  * 2H20 + 2S *   '

A  schematic  of the  process is shown in Figure  3-34.   In the absorber, the iron
reacts with  sulfide ions, accomplishing  the  oxidation in the electro-chemical
sense by accepting  electrons according to the  half reaction:
            2Fe    + S   -* 2Fe   +  S  *

No oxygen is involved in  the production  of  the  sulfur.
        In the oxidizer,  the iron reacts with dissolved  oxygen  and  is  regen-
erated for reuse according to the equation:

            2Fe++ + 02 +  2H20 ->• 2Fe+++ + 4(OH)~

These reactions are specific for the production of sulfur.  However, a sig-
nificant byproduct is formed whenever  sulfide ions and oxygen are brought
together.  Thiosulfate is produced when  sulfide ions  "leak" out of  the
absorber and get into the oxidizer.  This happens in  the Stretford  process
because these catalysts have low activity and finish  the reaction slowly.  The
Lo-Cat reaction is faster which eliminates this problem.  Thiosulfate  is also
produced when oxygen dissolved in the  oxidizer  is not consumed before  the
solution is carried into the absorber.   This occurs in the Lo-Cat process
because there is an equilibrium between  the oxidation state of the  iron and
the oxygen content of the solution.  (Hardison, 1984a).  Lo-Cat plants operate
with approximately 1 ppm of oxygen in  the reoxidized  solution, so there is
little byproduct thiosulfate formation.
                                      3-144

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                                                            ^~.  0)
                                                             <0  G
                                                            <* -H
                                                            00 +J
                                                            (T>  (fl
                                                            rH i-l
                                                                 (0
                                                              - P4
                                                            -H   U
                                                            •o   c
                                                             M  H
                                                             (0

                                                            >-•  tn
                                                                 (U
                                                            -P  -H


                                                             B  3

                                                            ฉ   g
                                                             I 1  J(~J
                                                             id   u
                                                            U   
-------
         The rapid reaction of the Lo-Cat solution with H2S producing elemental
 sulfur requires careful consideration in designing the gas/liquid contactor.
 A packed tower such as used for the Stretford process can become clogged with
 sulfur in a Lo-Cat process.  A venturi contactor alone, or preceding the
 packed tower (as shown in Figure 3-34) should be considered for this process.
 B.       Process Applicability—
         The Lo-Cat process is intended for the same applications as the Stret-
 ford,.   Its  only use on a shale oil retort was at Geokinetics (Hardison and
 Lekas,  1984).   The design conditions at this plant were as follows:

         Flow                                      600 Nm3/min
         Pressure                                  1 x 10~4 Pa
         Moisture                                10 to  12 vol%
         Temperature                             40 C (maximum)
         Gas  Composition                           (Dry Basis)
           H2S                             0.220 (2000 ppmV maximum)
           C02                                       22.17.
           ฐ2                                         1.97
           CO                                         5.31
           N2                                        58.76
           H2                                         9.25
           COS                                       0.008
           cs2
           cl .  •                                      1.44
           C2                                         0.41
           C3                                         0.29
           C4                                         o.io
           C5                                         0.04
           C6+                                        0.05
                                                    100.00
        The Lo-Cat system at Geokinetics was assembled from used hardware
available from an abandoned Stretford plant.  The major items of refurbished
equipment used included:
                                      3-146

-------
         Absorber Vessel .   A 23 cm x 18 m column packed with 9 m 5 cm
         diameter stainless steel pall rings, estimated to give an
         efficiency of 99.3 percent minimum.
         Two Oxidizer Vessels .   Each 4 m x 4  m vessel with an air sparger
         and 55ฐ cone bottom which were coated internally with epoxy.
         Two Air Blowers.   Each 40 Nm3/min unit.
                                          Each 750 gpm centrifugal pump.
         The  potential  suitability of  the Lo-Cat process for cleaning the gas
 and  for  production  of  elemental  sulfur  was  demonstrated.   During the first two
 months of  operation,  (February 5 through March, 1984),  H2S loading at the
 inlet averaged  1600 ppm  and was  decreased to  about  2  ppm by the Lo-Cat unit
 with gas flows  at approximately  the 400 Nm3/min "normal"  rate.   Catalyst
 solution circulation rate was maintained at approximately 6000  L/min and
 catalyst solution strength was 1000 to  2000 ppm iron  content  (Hardison and
 Lekas, 1984).
        Consumption of catalyst  concentrate (ARI-310  is furnished  in liquid
 form with  approximately  18,000 ppm of active  Fe) has  been minimal  on units
with operating melters,  but is discarded with the sulfur  when a melter is  not
used.  In  this case, the discard  rate constituted the greatest  single oper-
ating expnese, and  reached approximately 6.5  gallons  per  hour of catalyst
solution.  ARI-310M solution is a chelate-rich  concentrate which is  added  to
replace chelate compounds which degrade  slowly  by oxidation.  ARI-310SA is  a
startup additive used to bring the solution to  equilibrium conditions
quickly.   The cost  of chemicals for operation of the Lo-Cat unit from January
through September 1984 are shown in Table 3-29  (the sulfur production was not
measured but has been estimated at 240 days x 0.85 onstream factor x
1.25 metric ton/day = 256 metric tons for the project).
                                      3-147

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                     TABLE 3-29.  CHEMICAL COSTS FOR LO-CAT
                                (Hardison,  1984b)
        Chemical
  Total       Original    Operating      Operating Cost
Purchased	Fill        Supply        $/metric ton
 ARI-310
 Catalyst Concentrate
 ARI-310SA
 Startup Additive
 ARI-310M
 Makeup Solution
 ARI-400 Biochem
 Antifoam
$44,400      $23,100
$21,300
$ 83.20
  6,300        6,300

  8,500        —          8,450

  1,450        —          1,450
    290        —            290
$61,000     $29,364      $31,500
                   33.10

                    5.70
                    1.10
                 $123,00
        The initial  operation  of  the  plant  was  carried  out  with the  ammonia
absorption and stripping  towers in  operation.   During this  period, consider-
able difficulty was  experienced with  fouling of the  ammonia wash tower  by  tar
carried over from the retorts  through a marginal entrainment  separator  vessel.
The Lo-Cat absorber  operated at high  efficiency (>99 percent) without plugging
during this period.
        Because the  Lo-Cat unit is  tolerant of  high  ammonia concentrations,
the ammonia wash system was taken out  of service.  Subsequently,  the packing
in the Lo-Cat absorber was fouled repeatedly with oily  sulfur and several
shutdown periods were required to dump and clean the  packing.   The combination
of tar and condensed sulfur could not  be flushed successfully through the
two-inch pall rings.
        The scrubber was modified to include a venturi prescrubber to reduce
the tar and sulfur load on the packed column, but the venturi did not correct
the plugging problem and it was frequently necessary  to bypass  some gas around
the absorber to keep the pressure drop down to the 0.5 psi available.
                                      3-148

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        Several conclusions can be drawn with regard to packed columns in this
service:
           In general, packed columns in slurry service should have
           provision for cleaning without interfering with normal
           operation.  A spare column is recommended where 100 percent
           onstream factor is essential.
           Oil and tars must be separated from the gas stream before it
           reaches the sulfur-removing process.
           Low density packings, which have given satisfactory service
           in several other Lo-Cat units, are recommended over the
           conventional pall rings used in the Geokinetics unit.

        The plugging problem was mitigated, but not eliminated by replacing
the lower packed bed with a low pressure drop venturi.
        The Lo-Cat solution functioned well and remain active and resisting
contamination.  When the plant was operated for a period of several hours
without reoxidation, the catalyst solution turned black (normal color dark
brown or coffee color) and showed redox potentials below -300 mv, representing
totally reduced iron.  On aeration, the catalyst solution regained full
activity.
C.      Process Reliability—
        The reliability of an ARI Lo-Cat system in a retort gas application
has not be adequately stressed.  The process chemistry appears to be reason-
ably stable and resistant to the normal contaminants.  Undoubtedly, it is
desirable to rid the process gas of oil, tar, moisture and particulate matter
before it is delivered to the unit.  This is equally true for the Stretford
process.
        The chelated iron solution is corrosive to many varieties of steel.
Manufacturer's material recommendations and warranties are important in
selecting materials which contact the solution.
        The selection of a contactor may involve a tradeoff between removal
efficiency and maintenance.  Dense packed towers that achieve high removal
efficiency may clog.  Solutions to this problem include providing a second
packed tower to permit continuous operation while one tower is being cleaned

                                      3-149

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or to add one or more venturi contactors to remove most of  the sulfur before
the packed tower does the final gas polishing.
D.      Process Economics—
        The cost of a basic Lo-Cat plant similar to the one shown in
Figure 3-34 which ARI Technologies refer to as an autocirculation unit
(Hardison, 1984a) is presented in Table 3-30:

                 TABLE  3-30.  CAPITAL COSTS  FOR  LO-CAT PLANT
Capacity
Metric Ton/day
Sulfur
0.1
0.5
1.0
3.0

Design
10,000
10,000
10,000
10,000
Cost
Equipment
110,000
160,000
230,000
350,000
$
Centrifuge
.> N/A
N/A
120,000
120,000

Total
120,000
170,000
360,000
480,000
                                      3-150

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        Another  cost  basis  for  Lo-Cat  (Table 3-31)  was provided by Hydrocarbon
 Processing  (1984)  as  follows:
                      TABLE  3-31.   COST BASIS FOR LO-CAT
                         (Hydrocarbon  Processing,  1984)
Gas Flow, MMscfd
(MNM3/day)
H2S Cone. , ppmV
Sulfur Prod. Metric Ton/day
Capital Cost, $1,000
Net Op. Cost, $/MCF
($/Mm3)
2
(57)
6,000
0.5
600
0.06
(2)
5
(142)
500
0.1
350
0.008
(0.3)
100
(2,800)
1,000
3.8
3,000
0.0002
(0.007)
        A final data point is the operating cost for a Lo-Cat plant  in a
Texaco gas field processing 10 MMscfd  (280 MNm3/day) (the  sulfur  concentration
was unspecified) of gas containing 99.6 percent C02 and water (Hardison, Oil
and Gas Journal, 1984).  The annual operating costs are:

        Chemical
           Catalyst Concentrate                    $10,000
           Catalyst Makeup                           7,700
           Buffer (KOH)                              9,100
        Electrical                                  13,700
                            TOTAL                  $40,500

3.3.3   Unisulf Process (H2S)

        The Unisulf process is a homogeneous aqueous catalytic process which
converts absorbed H2S to elemental sulfur using sparged air.  In operation, it
resembles the Stretford process giving the same high sulfur yields (_> 99.9%);
                                      3-151

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however, Union Oil, its developer and only user  in  the U.S.,  claims  that the
Unisulf process has a much lower chemical consumption.  Union Oil's  shale
retort off-gas located at their Parachute Shale  Oil Project in Colorado, now
undergoing startup, utilizes the Unisulf process on the retort offgas.
A.      Process Description—
        The Unisulf process is a homogeneous catalytic process for oxidizing
H2S to sulfur which is similar to the Stretford process in concept and
application but it operates without a bleed stream.  Although it can be used
to recover sulfur from gas streams rich in H2S,  it is expected to find
broadest application in recovering over 99.9% of the sulfur from gas streams
containing less than about 10 mole percent H2S.  The Unisulf  process employs
an aqueous solution composition which absorbs H2S and converts  it to elemental
sulfur by oxidation with air.  The absorbing solution is also  regenerated and
recycled back to the absorber.  Typical components of the Unisulf solution are
as follows:
           Sodium Carbonate and Sodium Bicarbonate
        .  Vanadium Complex
           Thiocyanate Ions
           Carboxylate Complexing Aent
        .A Water Soluble Aromatic Compound
           Water
        A flow sheet of the Unisulf process is shown in Figure  3-35.  Acid gas
is fed to a venturi scrubber and absorber which operates in series to remove
over 99.9 mole percent of the H2S.  The treated acid gas leaves the  absorber
odor free, usually containing less than 1.0 ppmv H2S.   The absorber also
serves as a reaction vessel to oxidize the absorbed H2S to particles of
elemental sulfur in the reaction:

         2V+5 + HS + 2 OH~ * 2V+4 + 2H0 + S
                                      3-152

-------
             DESULFURI2ED
               FUEL GAS
                             COOLING TOWER
SHALE RETORT
  MAKE GAS
                                                 SOLID BOWL
                                                 CENTRIFUGE
                                    TO RETORT RECYCLE
                                        GAS HEATER
                                                 SOLUTION AND WASH WATER RETURN
         VENTURI
       AND CLEANUP
        ABSORBER
  SOLUTION  THREE-STAGE
  DEGASSER    OXIDIZER
AND REACTION
    TANK
                                                            d
                                             BASKET
                                           CENTRIFUGE
                                                  r
                   WASH
                   WATER
                                                                    SULFUR
                                                                   PRODUCT
  CAKE
RESLURRY
  TANK
     Figure 3-35.  Unisulf Process  (after Hass, 1984).
                                     3-153

-------
 After a short residence time in the absorber,  the slurry is transferred to an
 oxidizing vessel  which uses sparged air to oxidize the reduced vanadium ions
 from V+4 to V+5 in the reaction:

          2V+  + H20 + 1/2 02 -ป• 2V+5 + 20H~

 Simultaneously, the sulfur particles adhere to air bubbles and float to the
 surface of the aqueous solution by a froth flotation technique.  The sulfur
 froth overflows through a weir  into a receiving tank forming a slurry.   The
 solids are later  mechanically separated from the mother liquid by either
 filtering or centrifuging.   The filtrate is pumped to a balance tank which
 also  receives the regenerated solution leaving the oxidizer.   The balance  tank
 is used mainly as a inventory vessel for the regenerated solution which is
 recycled back to  the absorber and  venturi scrubber.   The properties  of  the
 unisulf absorber  solution and the  sulfur which is formed are  different  than
 those  of the Stretford process  and therefore cause an improved absorber
 operation and a more efficient  separation of sulfur  from the  regenerated
 solution than for the Stretford process.
         The  effects  of  design and  operating parameters  on the recovery  of
 sulfur  provided by  the  Unisulf  plant  are summarized  in  Figure 3-36.   It shows
 that an efficient vertical  basket  centrifuge (121.9  cm  diameter x 76.2  cm
 depth)  can process  6500 kg/day  of  sulfur  from  a  feed slurry containing  five
 percent  (wt)  sulfur  received  directly from the oxidizer.   The centrifuge cycle
 includes  alternating  washing  and dewatering steps.   To  process  greater
 quantities of  sulfur, the slurry would have to be  concentrated  above  five
 percent  sulfur.  The  entire process operates at ambient  temperature,  20  to 50
 C (70 to  120ฐF).
 B.       Process Applicability—
         The Unisulf process has been  adapted to treat shale oil retort  gas,
 Rectisol expansion gas, Glaus plant tail gas,  and other nonconventional
 gases.  The first  commercial application of the Unisulf process was made at
 the SASOL I facility located at Sasolburg, Republic of South Africa, beginning
 in December 1981.   In these facilities, the sulfur recovery plants treat a
Rectisol plant tail gas containing about 1.3 mole percent H2S in C02.  A
 typical off-gas composition includes the following percentages:
                                      3-154

-------
      20
  *18
      14
  IE




O CO


< DC
2 to   8

< O
S •-   6
  O
  EE
  H   4
  LU
  :E
      2
             BOWL: DIAMETER 121.9 cm x DEPTH 76.2 CM


             1800
            QC 1600
           O
           X
           •^.
           QC
           =>
           u_
              1400
              1200
            CO
            > 1000
            DC
            Q

            u.  800
            O

            CO
            Q  600
            2  400
               200
                        I
                             T
                                T
T
T
                           I
                                I
J_
I
I
                   0    5   10   15   20   25   30

                 SULFUR SLURRY CONCENTRATION, WT%
Figure 3-36.  Centrifuge capacity for separating sulfur from aqueous feed

           slurry-( after Hass, 1984).
                               3-155

-------
            C02                        97
            H2S                         1.3
            Saturated  ci ~  cs           1.0
            Unsaturated C,  - Cr         0.2
            co                        .,:QiA
                                     100                   .         .
plus traces (up to  50 ppmv) of HCN.   In  this  application, the Unisulf  process
recovered about 15  t/d of  sulfur.  During  a  160-day  test, over 2200  metric
tons of sulfur were recovered.  The  only major  problem encountered was the
presence of contaminant oxygen in  the feed gas.   In  the Rectisol  plant,  rich
methanol solvent is expanded  in several  stages  to release acid gases.   The
last two stages operate at subatmospheric  pressure,  thus requiring vacuum
blowers to  pump the acid gas  to the  Unisulf process.   Unless  the  seals on
these blowers are properly maintained (purged with an  inert gas),  air  can leak
into the acid gas.  Oxygen and H2S can then react under basic conditions  to
form thiosulphate.
        A processing  scheme was developed  by  Union which minimizes
thiosulphate buildup  if the contaminant  oxygen  concentration  in the  expansion
gas can be  controlled below a specified  low level.   Subsequent  operation  has
proved that with these modifications,  the  Unisulf solution can  be  used without
thiosulphate production even though  the  feed  gas  does  contain a low  level  of
contaminant oxygen.  This apparently  eliminates the need for  purge streams and
disposal of spent solution.
        The retort  offgas composition  at the  Unisulf plant in Parachute Creek
includes the following percentages (Hass,  et  al.,  1984).
            Saturated C,  - Cc          37
           H2                         24
            C02                        19
           Unsaturated C, - Cc     •    8
            CO                          6
           H2S                         5
           C6+                         0.6
           N2                          0.4

plus approximately  150 ppmV of HCN.
                                      3-156

-------
        The Bnisulf process is being used along with  the Beavon  Sulfur Removal
Process to treat Glaus plant off gas at Union's shale  oil upgrading -plant in
Colorado.  Tbe Beavon process converts all  sulfur  compounds  in the Calus
tailgas (SOX, Sx, COS, CS2, etc.) to H2S.   The inlet  gas composition to the
Unisulf plant Includes the following percentages:
CO2                        6
                                     90
                                      6
                                      3
           H2S                      _ 1_
                                     100
plus CO and saturated hydrocarbons of  500 ppmv each.
        Further applications of the  Unisulf process are expected including
recovering sulfur from sour gas streams leaving tar sands operations, sewage
disposal plants, and geothermal operations (Hass, et. al.,  1984).
C.      Process Performance and Economics —
        At this time no commercial data are available for the Unisulf process
performance or costs.  The manufacturer expects that the Unisulf process
should have the same capital costs and high sulfur recovery efficiency (99
plus percent) as reported earlier for  the Stretford process, however, the
Unisulf plant has a lower operating  cost.

3.3.4   Alkaline Scrubbing
        Based on some pilot scale tests on offgas from an in-situ shale oil
retort the concept of alkaline scrubbing of H2S appears to be viable for this
application (Taback et al., 1985a).  Much more development is required to
prove the concept and produce reliable hardware.  However, in view of the
potential economic advantages, this  process is presented here as an option to
be considered as a part of a future  oil shale process plant development.
        The process schematic for removing H2S from a gas stream that is rich
in C02 and that may also contain NH-j is shown in Figure 3-37.  The process gas
enters the alkaline scrubber where the H2S any NHg present and some C02 are
absorbed by the scrubber liquid.  This process is selective so that more H2S
is absorbed compared to its concentration than C02.  The measure of the H2S
                                      3-157

-------
                            Process Gas
                               Outlet
Process
 Gas
Inler
                ALKALINE
                SCRUBBER
          LIQUID WITH
           ABSORBED
           H2S & CO2
                        LIQUID
                       RECYCLE
                                                                    OFFGAS
                                                   H2S. CO2
 SULFUR
RECOVERY
  PLANT
•SULFUR
                                        REGENERATOR
        Figure 3-37.   Alkaline scrubbing  process  schematic for H,S removal.
                       (Taback, et al., 1985a).                  2
                                         3-158

-------
 selectivity  is  the  percent  reduction  of  H2S  divided  by the percent  reduction
 of  C02.   Depending  on the initial  concentrations  of  H2S and C02 in  the process
 gas,  selectivities  of over  40 are  desired.
        The  next  step in the  process  is  to distill off the absorbed H2S and
 C02 from  the scrubber liquid  in the regenerator.  The  gaseous  H2S~ and C02
 (with an  enriched amount of H2S) are  sent to a  sulfur  recovery process of
 which the Glaus is  probably the most  cost effective.   The  Glaus process
 prefers the  highest possible  H2S concentration.   The process might  work with
 8 percent H2S but 15 percent  is needed for confidence  and  25 percent or higher
 is  desired (Love! 1 let al., 1982-j.'
        For  a typical in-situ retort  the H2S concentration might be 1500 ppmv
 and the C02  concentration 22  percent.  The C02  concentration is 150 times
 greater than the  for H2S in the process  gas. To  enrich the H2S concentration
 the following H2S selectivities* are  required (Taback  et al.,  1985a).

             Sulfur  Plant (Glaus)                  Scrubber Selectivity*
          Inlet gas  H2S Percentage                       Required

                      8                                       12
                      15                                       23
                      25                                       38

        Thus a selectivity  of  over 40 is desired.  This  is  undoubtedly the
worst case.  If the  H2S concentration is higher,  such  as in an  indirectly
heated retort gas where it might reach 4 percent, then a much  lower selec-
tivity is acceptable.
        The alkaline  scrubber  removes the NHg as  well  and  it may be recovered
an  appropriate point  in the regeneration process.  The  recovered NH-, may be
used elsewhere in the plant for NOX reduction or  incinerated with proper
staging to prevent NOV formation.
                      A.
*Selectivity is defined rigorously by Taback, et al. (1985a).  Qualitatively,
selectivity is a measure of the preference of the process to scrub H9S over
C02.
                                      3-159

-------
         While it is important that the scrubber achieve the required selec-
 tivity to accommodate the claus plant, the importance of overall sulfur
 removal must be maintained.  Most process changes which improve selectivity
 worsen sulfur recovery.  Venturi and tray tower scrubbers were investigated in
 the EPA's pilot program.   A plot of selectivity versus removal efficiency for
 both types of scrubbers is presented in Figure 3-38.  The tower favors removal
 while,the venturi  favors  selectivity.  Taback et al. suggests a multi-stage
 scrubber.  One example presented combines a venturi and tower as shown in
 Figure 3-39.   The  result  is 95 percent H2S removal efficiency and 37
 selectivity.   Multiple tower stages where the gas passes through fresh solu-
 tion at each stage are shown in Figure 3-40.   The removal efficiency is
 estimated at  99 percent,  but the selectivity is only 22.
 3.3.5   Activated_  Carbonand Hyppchlorite Process
         A variation of the alkaline scrubbing process for H2S removal has been
 developed by  the Pulp  & Paper Research Institute of Canada (PPRIC)  and Teller
 Environmental Systems,  Inc.  (TESI)  (Prakacs,  1983,  and Teller and Amberg,
 1985).   The process consists of  alkaline  absorption of the acid gases in  the
 presence of activated  carbon and with sodium  hypochlorite added to  the
 solution to improve the solubility  of the organic sulfur gases.   The
 particular process  commercialized by  TESI includes  provision  for particulate
 nucleation which results  in  particulate removal  as  well  as absorption of  the
 acid  gases.   Unlike other  H2S  removal systems,  this one  has the  capability of
 removing organic sulfur species  (mercaptans,  thiophenes,  etc.) which  is
 important in  achieving  the low total  sulfur emissions  needed  to  comply with
 PSD regulations.  This  process has  the capability of reducing the total
 reduced  sulfur  (TRS) emissions to the level of 2-5 ppm and particulate
emissions to  the level  of  0.06 to 0.18 g/Nm3, dry.
A.       Process Design—
        A schematic of  the activated-carbon hypochlorite process is shown in
Figure 3-41.  Retort is first treated in a venturi,scrubber which serves to
wet the particulate for collection within the packed bed section.  The gas
then flows to a packed bed section where it is contacted with a caustic slurry
containing oxygenated activated carbon and sodium hypochlorite plus the
reduced sulfur species removed from the gas phase.
                                      3-160

-------
        100
                                        TRAY TOWER
                                 O N= NaOH
                                 D K = KOH
                                 O A= NH4OH
                                 OPEN SYMBOLS: VENTUR!
                                 SOLID SYMBOLS: TRAY TOWER
                       SELECTIVITY
                       40            60

                        % REMOVAL H2S
                        % REMOVAL CO2
Figure 3-38.
Removal efficiency vs. selectivity for alkaline scrubber
(Taback, et al., 1985a)........
                                    3-161

-------
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           Inlet
          Retort Gas
                                    J
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                                                        Scrubber Liquid
                                                            Outlet
HjS Cone., ppm

CO2 Cone., %

  H2 removal eff. =

  CO., removal eff. =
  Selectivity =
99
4.5
      1500-15
       1500
          Inlet
        (Assumed)

          1500

           22

       = 99%
22

22
                            m 4.5%
                                 Stage  1
                                 Exit

                                 150

                                  21.5
Scrubber
  Exit

  15

  21.0
   Figure 3-40.   Tray tower scrubber with isolated  liquid  inlets.
                 (Taback et al, 1985a)
                                   3-163

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       RECOVERY  BOILER
        FliE  CAS
PRODUCT
STREAM
TO BLACK
LIQUOR SYSTEM
                                                                                CLEAN EXHAUST
                                                                                   GAS
                       VENT6RI
                      (MULTIPLE
                       THROAT)
                                                             CARBON MAKE-UP
                                                             CAUSTIC MAKE-UP
                                                             AIR
*ปCLEAN  ROT
    WATER
        Figure 3-41.  .Teller System Flow Sheet.  20-30% Total Dissolved Solids,
                       (Teller, 1985b).   Reprinted by permission of Research-
                    ,  Cottrell, Somerville,  NJ.
                                           3-164

-------
        The spent slurry is regenerated in a separate vessel by providing
oxygen which is adsorbed on the catalyst surface for subsequent reaction in
the packed bed.  A bleed stream containing approximately 25 wt percent  solid
sodium thiosulfate (Na2S202) is removed for disposal or additional processing
and sale.
Bo      H2S Removal—
        The principal steps involved in the removal of I^S are (a) absorption
in the liquid phase, (b) partial adsorption on the surface of the activated
carbon, and (c) oxidation.
        The most important chemical reactions of the process can be  summarized
in the following simplified fashion when NaOH is used as the make-up alkali.

        2NaOH + C02   •ซ-   Na2C03 + tL^O                       (1)
        Na2C03 + C02 + H20   J 2NaHC03                       (2)
        Na2C03 + H2S   ฃ  NaHC03 + NaHS                      (3)
        NaHCO, + H,0   *  NaHS + CO, + H90                   (4)

                  2        a       2
        Reactions (1) and (2) govern the (initial) chemical composition and,
more importantly, the pH of the scrubing medium.  At  12-16 percent by volume
of C02 in .the flue gas, and the typical 70-75 C steady-state temperatures  in
the scubber, the equilibrium molar proportion of NaHC03 to Na2C03 is
approximately 70:30, resulting in a pH of 9.0 ฑ0.2.
        Reactions (3) and (4) have unfavorable equilibria for efficient
absorption of H2S.  The degree of removal of E^S by the process as a whole
depends primarily on an oxidation reaction, which can shift the equilibria of
Reactions (3) and (4) towards essentially complete absorption of the B^S:
        2NaHS + 202     * ca.r-b.ฐ-n. ->  Na2S203 + H20             (5)

        Reaction (5) takes place partly in the absorption stage of  the
process, in the presence of 2-3 percent oxygen.  Pilot studies showed that
when activated carbon in concentrations of 0.1-0.4 percent by weight is used
as the adsorbent/catalyst, 100-120 ppm of H2S can be removed  with 99 percent

                                      3-165

-------
efficiency  in  the  scrubber  itself  without  a separate aeration step.   At  higher
H2S  concentrations, aeration  of  the  scrubbing medium in a separate oxidizer is
required before  recycle  to  the scrubber.
        The residence  (aeration) time  and  the aeration rate  requirements are a
function of the  inlet  gas H2S concentration as well  as on the required H2S
concentration  in the exit gas.   The  latter can be  estimated  using the
following theoretical  correlations:

        PeH2S  =  K[(Na2S)H+]                                   (6)
where:
        PeH2S  = equil.  partial pressure of H2S, atm.
            K  = 77 x  106 at  70 C
        [Na2S] = Sodium  sulfide concentration,  g mol/L of  Na2S equiv.
        [H  ]   =  hydrogen ion  con., g mol/L

        Equation 6 can be used to  develop  plots which  provide useful
information for  the design.   For a given design, the equation can  be used for
optimizing  the scrubber  and the oxidizer.
        As  indicated by  the family of  curves  in Figure  3-42, a desired BUS
concentration  in a scrubber outlet gas can be  achieved  by  increasing the pH
(more alkali added) or by reducing the residual sulfide concentration (more
intensive aeration).  Data from both pilot- and commercial-scale installations
indicate that the theoretical correlations  represented  in Figure 3-42 can be
approached very  closely  in properly designed and operated  systems.
        As should be apparent from Reactions  (3),  (4) and  (5), the overall
efficiency of the process of removing the H2S  from the  flue gas depends on
providing:
        1.  Sufficient absorption capacity in the scrubber.
        2.  Adequate aeration capacity for oxidizing the primary
           absorption product of H2S, via., the HS~ ion, into Na2S203.
                                      3-166

-------
                              *Assuming 33% moisture an
                               flue gas scrubbing temp.:
                               70 C
            2      4     6      8     10     12      14     16
      TOTAL SULPHIDE CONG.  IN OXIDIZED SCRUBBING SOLUTION, mg/ฃ
Figure 3-42.
Equilibrium H S concentration in flue gas, as a
function of S  concentration in oxidized scrubbing
solution  (Prahacs, 1983).  Reprinted by permission
of the Pulp and Paper Research Inst. of Canada.
                         3-167

-------
        Because of  the  extremely  complicated  nature  of  the absorption and
subsequent simultaneous liquid  phase  and  catalytic solid-surface-oxidation
reactions involved, a universally applicable  predictive theoretical  model of
the overall process has not  been  developed  as yet.   The problem of providing
reliable predictive models for  the three  principal physical types and
configurations of absorption-oxidation  systems tested in a pilot-scale and/or
commercial scale is made more difficult by  the fact  that there  is a  variable
rate and degree of catalyst  contamination that occurs when scrubbing real
retort gases.
        Not withstanding the above problems in arriving at a universally
applicable predictive model of  the process, sufficient  empirical data and
correlations were obtained for  design purposes.
        The following is an illustration  of how some of the empirical design
parameters were developed.  A parameter called the Number of Transfer Units
(NTU) for the removal of H2S in the pilot-scale studies was used as  measure of
performance and is defined by the  following formula:

                                NTU =  In  pH2Si                  '
                                          pH S
where:                               .      *•  ฐ •
        pH2Si = partial  pressure of H2S in the inlet gas
        PH2So = partial  pressure ofH2S  in the  outlet gas.

        Pilot-scale studies (Prahacs, 1983) were carried  out in a turbulent
contact absorber with a  cross-section of  0.3 x 0.3 m and  three to five
absorption stages with a height of  1.5 m  each.  When calculating the  apparent
NTU/stage for various loads (at fixed gas flows but varying  inlet
conentrations of H2S) the values varied between 0.1 to  1.6/stage.  However,
when correlations between the intensity and efficiency  of oxidation vs. the
NTU/stage were reexamined, it was found that with adequate  oxidation, NTU
values of 0.95 to 1.6 could always be achieved.  This indication of the
oxidation step being the performance-limiting operation has been confirmed in
commercial installations.
                                      3-168

-------
         Within the observed range of NTU's under conditions of adequate
.oxidation and other variables kept essentially constant, the liquid-to-gas
 mass flow ratios (L/G) proved to be governing the attainable absorption
 efficiencies.  This can be particularly critical in the case of high but
 variable inlet concentrations of H2S to the absorber.  Increasing the L/G from
 10 to 16 under conditions of 400-1000 ppm of H2S inlet concentrations can
 bring about approximately proportional increase in NTU's.  In actual practice,
 packing heights (or travel path through the packing, in the case of the cross-
 flow scrubbers) in the range of 10-15 ft (providing for gas-liquid contact
 times of 1-2 seconds), were shown to be capable of absorbing HoS in
 concentrations of 600 to 1200 ppm by vol. (dry basis) with 98-99+ percent
 efficiency.  This performance could be achieved only if the other operating ,
 parameters, both in terms of the chemical composition of the scrubbing medium
 and the air supply to the oxidizer, were maintained at appropriate levels.

 Co      Organic Sulfur Gas Removal—
         Laboratory studies and limited pilot-scale tests have been conducted
 in which a dilute sodium hypochlorite solution was used as a scrubbing agent
 for efficient "polishing" removal of dimethyl sulfide and various mixtures of
 organic sulfur compounds (Teller, 1985a).  These tests were aimed at having an
 alternative process configuration (with a last hypochlorite stage) for
 achieving ซซ1 ppm total odoriferous sulfur emission levels, regardless of the
 original inlet conentrations of the organic sulfur compounds.   Removal
 efficiencies of 97-98 percent were obtained for methyl and dimethyl mercaptans
 at inlet concentrations of 10 to 20 ppm with hypochlorite dosages of 13-18
 grams/gram of organic sulfur removal.  This approach was found to be
 technically feasible, although considerably more expensive in terms of
 chemical cost than the use of alkaline suspensions of activated carbon
 alone.   Also, the possible emission of traces of chlorinated organic compounds
 might need to be checked before implementing this suplementary processing
 step.
         The removal of CHgSH is achieved in a fashion similar  to H2S,  but the
 overall reaction mechanism is less well understood.   The following represents
 an illustration of the likely principal reactions involved:
                                      3-169

-------
        CH3SH + NaHC03   +-ป•  CH3  SNa + SNa  + C02  + H20        (7)
        2CH3SNa +  1/202 +  H20  ++ (CH3)2S2  + 2NaOH            (8)
        With inlet concentrations of  2-10  ppm of  CH3SH and  0-5  ppm of
 (CH3)2S2, the general experience in the  commercial  installations  is that  both
 of these organic compounds can be removed  nearly  quantitatively.   This,
 presumably is due primarily to physical  absorption  and adsorption of these
 sulfur compounds in the scrubbing medium,  possibly  followed by  other oxidation
 reactions, e.g., to sulfonic acid.  The  removal of  (CH3)2S2,  if present in
 significant concentrations, is only partial.   Again,  it is  probably by
 physical absorption in the solution and  adsorption  on the carbon,  with the
 possibility of oxidation to sulfoxides.  The  removal  efficiency of (CH3)2S2  or
 any of the organic sulfur compounds can  be improved,  if necessary,  simply by
 the introduction of additional activated carbon.
 D.      Process Performance —
    1ป  Contactor ~ Two types of packed bed  scrubbers have been  used for his
 process: a countercurrent absorber and a cross flow absorber  (Prahacs,
 1983),  These contactors are shown in Figure  3-43.  The principal  difference
 between the two with regard to removal efficiency is  the concentration profile
 of the caustic-activated carbon slurry through the  packed bed.
        To remove the H2S from the retort  gas it is first necessary to absorb
 the H2S into the liquid phase and then react  the H2S  with C03=  to  form HS~.
The physical absorption and reaction of  H2S can be  described using  the
absorption - chemical reaction model described by the equation:

        Kia - Kja [1 + G! (q/Cai)]0'5
where s
        q   =  concentration of free caustic
        Cai = partial pressure of H2S in the gas phase
              converted to concentration in the liquid
        Kj_a = transfer coefficient for physical absorption
        K-^a = transfer coefficient for chemically enhanced absorption
                                      3-170

-------
            A.
                                                     Treated Fine
                                                     Gas to Stack
               Bleed to
               Recovery
sauiii
^BOS
                           Hot Water
              Schematic diagram of one version of the PPRIC/BCRC scrubbing
              process using a TESI cross-flow scrubber  (Prahacs, 1983).
              Reprinted by permission of the Pulp and Paper Research
              Inst. of Canada.
                                    Treated Flue
                                      to Stack
           B.
                       Heat Recovery
                       Zone
                       Scrubbing
                       Zone
                      Flue Gas'
                         Alkali t Carbon
Figure -3-43>.
Schematic diagram of the PPRIC/BCRC scrubbing process
in a packed counter-current scrubber designed by
Flakt Canada (Prahacs, 1983).  Reprinted by permission of
the Pulp and Paper Research Inst. of Canada.
                                 3-171

-------
        The crossflow contactor has  significant  advantages  over  a
countercurrent  contactor  for maximizing  the  absorption  rate of H2S  by
controlling the caustic concentration  -  H^S  gas  concentration profile.   The
countercurrent  contactor  has a high  caustic  concentration at the top of  the
tower where the H~S  concentration  is low and the concentration term (q/C i)  is
                                                         . .               3
very high.  However,  at the bottom of  the tower,  the  caustic has been consumed
by both the H2S and  C02 and the concentration term (q/Cai)  approaches zero.
The net effect  is  that the effective K-^a for the tower  is the average of a
high (top) and  low (bottom) value.   With the cross flow contactor the caustic
concentration can  be  maintained at a high value  for all concentrations of HoS
and the overall K^a  is consistently  high for the entire contactor.
        In addition  to controlling the caustic concentration, the cross  flow
contactor allows variation of the  liquid/gas ratio to provide adequate caustic
to regions of the  contactor with high H2S concentrations.   Other advantages  of
the cross flow  contactor  claimed by  the  manufacturer  are lower pressure  drop
(less than one-third  of countercurrent contactors), stable  operation (no
flooding), no build-up of solids at  gas/liquid support  plates, and  30 -  60
percent lower liquid  flow rates.
        Extensive  pilot-plant studies have been  conducted by both PPRIG  and
Teller Environmental  Systems (Prahacs, 1983  and  Teller  and  Amberg,  1985).
Test results from  two of  these pilot studies for the  crossflow contactor and a
turbulent contact  absorber (TCA) are shown in Figure  3-44.  At 100  ppm inlet
H2S concentration, the crossflow contactor resulted in  98+  percent  total
sulfur removal  efficiency while the  TCA  had  86 percent  removal efficiency
(Teller and Amberg,  1985).
        The performance of the TESI  system at inlet H2S concentrations ranging
from 100 ppmV to 1000 ppmV is presented  in Figure  3-44.  Additional test
results are shown  in  Figures 3-45 and 3-46 for high (300 -  500 ppmV H2S)  and
low (10 - 20 ppmV  H2S) inlet gases.  The  outlet  H2S concentration is stable  at
less than 4 ppmV regardless of the initial gas concentration.
   2.    A.ctiyated  Carbpn .Conce.ntratlon —- In the  contactor, the  path length
for diffusion,  and hence  the diffusion rate,  is  determined  by the bulk
concentration of the  activated carbon and the mode  of suface renewal which
determines the  carbon concentration  at the boundary layer.  The  PPRIC patents

                                      3-172

-------
C/D
C/3

ง
S3
H
        EQUIVALENT
        EFFICIENCY


         98%

         95%


         86%
65%
        40%
                                             AP  In. wg CARBON  %
             Boiler #1 - 7.5 ft. Bed Nucleator  ~10.

          C]Bhatia - TCA 5 stages              ~18

             Boiler #2 -~7.5 ft. Bed Nucleator  ~11
                                                 0.03-0.06

                                                    0.5

                                                 0.03 - 0.06
                                TRS INLET ppm, -Yj_
   Figure 3-44.
         Kraft recovery boilers TRS removal data
         (Teller, 1985a).  (Reprinted by permission  of
         Research-Cottrell, Somerville, NJ)
                              3-173

-------
                            TRS EMISSIONS
                           INLET vs. OUTLET
                            CONDITION 2
p.'
a.
CO
&
H
      700
      600
     500
     400
     300
      20
      10
          INLET
                              OUTLET
                                     2

                                    HOURS
       Figure 3-45.
TRS emissions inlet vs. outlet condition 2.
(Teller, 1985a).  (Reprinted by permission  of
Research-Cottrell, Somerville, NJ)
                              3-174

-------
                          TRS  EMISSIONS

                         INLET vs.  OUTLET

                           CONDITION  1
E
a,
a.
     70
     60
     50
     40
     30
     20
     10  _
                        OFF SCALE
                                                   INLET
                                                   OUTLET
                                HOURS
       Figure  3-46.
TRS emissions inlet vs. outlet condition 1

(Teller, 1985a).  (Reprinted by permission  of

Research-Cottrell,  Somerville, NJ)
                           3-175

-------
 using a countercurrent contactor call for 0-10 percent carbon and laboratory
 data indicate 0.5 percent is sufficient.  Tests conducted with the TESI cross
 flow scrubber indicated at 0.05 to 0.10 percent is sufficent due to the
 effective  laminar surface renewal that is inherent in the crossflow scrubber.
         The bulk concentration of carbon and surface renewal characteristics
 also determine the kinetics of adsorption of H2S or the sodium salt (NaHS) on
 the  carbon surface.
         The effect of  the carbon concentration on removal efficiency is shown
 in Figure  3-47.   There is an increase in removal efficiency from 97.2 percent
 to 99.1  percent  by increasing the carbon concentration from the range of 0.03
 - 0.07  percent to 0.08 - 0.13 percent.
   3*    garticulates — The TESI system can also include two means for
 particulate control.   The first is  a  dry venturi scrubber and the second is a
 wet  nucleation scrubber.   The reader  is referred to Section 3.1.ID for a
 description of the dry venturi  system.
         The particulate collection  of  a crossflow scrubber is due to two
 factors.   First,  the dry  venturi  increases  the  size of the particulates  by
 using solid particles  (i.e.  20  un)  as  the targets  for  the small particles
 (i.e. 0.5  urn)  resulting in  large  particles  in the  gas  stream to the  scrubber
 rather than the  initial small ones.  Consequently,  an  expected result  would be
 to increase the  particulate  removal of  any  scrubber since  removal  efficiency
 is directly related to  particle  size.
         In  addition to  the  scrubbing action  of  the  gas-liquid  contact, when
 the gas  stream contacts the  liquid, it  is cooled to  the  adiabatic  saturation.
 temperature  and  then proceeds to  condense water.  The  condensation process  is
 generally aided  by the  presence of condensation sites  and  the  large  particles
 from the dry venturi provide these condensation  (or nucleation) sites.
 Table 3-32  shows performance data for commercial systems utilizing the
nucleation  process for particulate control.  These  systems do not have a dry
venturi upstream and are processing the small diameter particles indicated
 (from 0.04 to  10  un).
                                      3-176

-------
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3-178

-------
        The kinetics of  isothermal nucleation is  highly  dependent  on the
population density of  the water molecules  with a  desirable  level above  25
percent by volume.
   4.   Operating Experience  — Teller  Environmental  Systems,  Inc.  (TESI)  has
installed eleven full  scale systems  for control of  I^S from black  liquor
recovery boilers (Teller, 1985b).  The  operating  performance for these  eleven
systems is presented in  Table 3-33.
        The TRS outlet conentrations range from 3 to  43  ppm with the majority
of installation having exit concentrations at 10  ppm  or  less.   The  exit
particulate concentrations range from 7 to 730 mg/Nm  with  most of  the
facilities having exit concentrations less than 130
   5.   Costs — The cost for a full  scale TESI  system has  been estimated  at
$8.40/kg-hr of gas  (1984 dollars) based on a gas flow  rate  of  5 x  106 kg/hr
(Teller,  1985b).
3.3.6   Glaus Process (HpS)
        The Glaus process has been used extensively for four decades  in
refineries, gas plants and coking operations where large quantities of H^S are
produced.  The feed stream to the Glaus plant should be at least 25 percent
HฃS although reliable operation is possible at as low as 15 percent concen-
tration and with great effort even lower.  The plants typically are capable of
95 percent elemental sulfur recovery.
        The EPA Control Technology Appendices for Pollution Control Technical
Manuals [Ondich, 1983] provides a comprehensive discussion of this process
including many important design and application factors.  A summary of that
discussion is presented here.
A.      Process Description —
        The Glaus sulfur removal process is a vapor-phase, dry , high tempera-
ture process in which hydrogen sulfide-rich gases from acid gas removal
processes are catalytically reacted with sulfur dioxide (produced by air
oxidation of hydrogen sulfide) to form elemental sulfur.  Modern Glaus units
produce a high-quality, salable sulfur, as well as steam.  The Glaus unit
off gas generally contains several thousand ppmv sulfur and may require further
processing to reduce emissions of sulfur species (e.g., SCOT, Beavon, or
Wellman— Lord processes).

                                      3-179

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3-180

-------
        A typical Glaus unit (Figure 3-48) consists of a thermal reaction
furnace and one or more catalytic stages, depending on the desired level of
sulfur in the treated tail gas.  The overall Glaus reaction is given by:

        3H2S + 1.502 = 3H20 + 3S

The overall Glaus reaction actually takes place in two steps.  Sulfur dioxide
is formed by oxidation of a portion of the hydrogen sulfide in the thermal
stage of a Glaus unit:

        H2S + 1.502 = S02 + H20

The prevailing combustion conditions (1370 to 1800 K and pressure slightly
above atmospheric) also result in the formation of sulfur vapor from hydrogen
sulfide and sulfur dioxide with a 50 to 70 percent yield.

        2H2S + S02 = 3 S + + 2H20

The process gas is cooled in a steam-producing waste heat boiler and the
sulfur is condensed and removed.  Additional formation of sulfur from the
remaining hydrogen sulfide and sulfur dioxide is promoted by either bauxite or
alumina catalyst in one or more catalytic stages.  Each catalytic reactor is
preceded by a process gas reheat unit and followed by a sulfur condenser.
        The Glaus process is controlled by regulating the flow of combustion
air to the reaction furnace so that only about one-third of the hydrogen
sulfide is oxidized to sulfur dioxide.  This provides the optimum quantity to
react with the hydrogen sulfide to produce elemental sulfur.  However, high
carbon dioxide contents (such as those encountered in shale oil retort offgas
often dilute the acid gas to the point where stable combustion of one-third of
the hydrogen sulfide is very difficult.  Therefore, Glaus plant designs are
generally based on one of three combustion configurations, depending on the
carbon dioxide concentration in the feed gas:  "straight-through," "split-
stream, "and the "sulfur burning" mode.
        For carbon dioxide levels below about 30 percent by volume (corres-
ponding to hydrogen sulfide levels above 40 percent by volume), the "straight-
                                     3-181 .

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 through" process is generally used (i.e., the entire feed gas stream is sent
 to the Glaus furnace, Figure 3-48).  At carbon dioxide concentrations above
 about 30 percent by volume (corresponding to hydrogen sulfide concentrations
 below about 40 percent by volume), free flame combustion with stoichiometric
 air becomes unstable and the "split-stream" process must be used.  In this
 design approximately one-third of the acid gas is completely oxidized to form
 sulfur dioxide and the remaining two-thirds is bypassed around the combustion
 chamber.  When the acid gas contains less than 5 to 10 percent by volume
 hydrogen sulfide (corresponding to very high carbon dioxide levels) combustion
 temperatures are too low to sustain the thermal sulfur reactions and side
 reactions become troublesome,  especially those involving hydrocarbons.
         At very low hydrogen sulfide levels,  the "sulfur burning" mode  may be
 used,  in which liquid sulfur is recycled to the combustion chamber to supply
 heat  and sulfur dioxide for reaction with hydrogen sulfide downstream in the
 process.
         The presence of hydrocarbons,  carbon dioxide,  ammonia,  and other
 impurities in the  feed complicate the reduction process  with the formation of
 carbonyl sulfide and carbon disulfide in the  combustion  zone and the partial
 hydrolysis of thes  compounds to hydrogen sulfide in the  catalytic reactors.
 Carbonyl sulfide and carbon disulfide are slow to react  over the Glaus
 catalyst and,  therefore,  represent sulfur that is not  totally recovered  as
 elemental  sulfur.   The presence of ammonia in the feed gas gives rise to
 secondary  reactions  which may  disturb  the operation of the units.   There are
 limited  data  available on the  maximum allowable concentration of these various
 contaminants.   However,  decreased  sulfur removal  efficiencies appear to  be due
 to decreased  hydrogen  sulfide  concentrations  rather than the presence of
 impurities  in  the acid gas  feed.   The  presence of  hydrogen cyanide  in the  acid
 gas can  lead  to  excessive equipment corrosion  and  catalyst  deactivation  via
 formation  of  thiocyanates.
 B.       Process Applicability	
        More than 15 million tons  of sulfur are recovered  annually  from  treat-
ment of acid gases by  the Glaus process.  There are at least  170 Glaus plants
 in the U.S. which are used in a wide variety of industries including
petroleum, natural gas, and coke production.  Applicability of the Glaus

                                      3-183

-------
 process  to  coal  conversion  process  gas  purification systems has not been
 entirely established.  A Glaus  plant  is featured in the design of the Hygas
 pilot  plant at Chicago,  Illinois  for  processing the acid gas stream from a
 diglycol amine unit.  A  number  of firms are experienced designers of Glaus
 plants in the U.S.  including:   Black, Sivals & Bryson,  Inc.;  Ford,  Bacon &
 Davis, Inc.; and the Ralph  M. Parsons Company.
 C.       Process  Performance—
         Modern Glaus units  are  capable  of  greater than  95 percent sulfur
 recovery.   However, the  sulfur  removal  efficiency is dependent on certain
 factors  such as:  the number of catalytic  conversion stages,  the inlet feed
 stream composition, the  operating temperatures,  catalyst, maintenance pro-
 cedures, .maintenance of  the proper  stoichiometric ratio of  hydrogen sulfide
 to sulfur dioxide, and operating  capacity  factor.
         The Glaus reaction  is reversible and is  limited by  chemical equi-
 librium.  Sulfur recovery is enhanced by removing heat  since  the  desired
 reactions in the Glaus process are  exothermic.   Operation at  the  lowest
 possible temperature in  the catalytic reactors without  condensing sulfur  vapor
 on the catalyst is desired, but adequate reaction rates  must  be maintained.
 The percentage of sulfur recovery increases  with the number of catalytic
 stages and the acid gas  feed hydrogen sulfide  concentration as indicated  in
 Table 3-34.   The addition of a fourth catalytic  stage can give recoveries
 above 99 percent.  However, the Glaus reaction rate is  significantly reduced
at high  sulfur conversion because of the lower temperatures imposed by
 thermodynamics and, especially,  the lower hydrogen sulfide and sulfur dioxide
 concentrations.   Glaus plants in the U.S. generally have two or three
catalytic stages.
                                      3-184

-------
       TABLE 3-34.    SULFUR RECOVERY VARIATION RELATIVE TO ACID GAS FEED
           COMPOSITION AND NUMBER OF CATALYTIC STAGES (Ondich, 1983)

Mole Percent I^S
In Acid Gas Feed

15
50
90
90
90

... ...
•••••••••••^•^^••^•^••••••^••••••••••••••••••••^••^^•••VVMMM
Number of
Catalytic Stages . ...

2
2
1
2
3

• - - • 	
Percent Sulfur
	 . ,. Recovery

90
93
85
94
97
" "~ ' ------ • --- ---.
        Sulfur recovery is also dependent upon catalyst performance.  Very
active catalysts which resist aging are required to maintain fast reaction
rates, especially at lower temperatures.  The formation of sulfate on the
surface of this catalyst is the most significant cause of activity loss, but
inorganic or organic deposits also lead to catalyst deactivation.  Because
sulfate formation (called sulfation) is limited by equilibrium conversion, it
increases with low hydrogen sulfide concentrations, high sulfur trioxide, high
oxygen concentrations, and low temperatures.  Thus, a catalyst in the second
and third catalytic conversion stages is more susceptible to deactivation by
sulfation, even though these later stages require a more active catalyst to
maintain reasonable reaction rates at the low temperatures.  Catalyst life
generally varies from 2 to 5 years depending on plant operation and con-
taminants in the feedstock.
        Deviation above or below the 2:1 stoichiometric ratio of hydrogen
sulfide to sulfur dioxide results in a loss of Claus plant efficiency.  At
less than stoichiometric amounts of air, the sulfur yield falls due to reduced
flame temperatures.  At greater than stoichiometric amounts of air, it
declines due to oxidation of elemental sulfur.  Operation of a Claus plant
below capacity may also impair sulfur recovery efficiency.  Although the
impact of these process variables represents, in most cases, a loss of only 1
to 3 percent efficiency, at the relatively high efficiencies typical of Claus

                                      3-185

-------
operations (95 percent), a 1 to 3 percent efficiency loss represents a 20 to
60 percent increase in uncontrolled sulfur emissions.
        Actual operating data are shown in Table 3-35.  The treated gas from
the Glaus process generally contains several thousand ppmv (dry basis) of
sulfur which is present as hydrogen sulfide, sulfur dioxide, carbonyl sulfide,
carbon disulfide, and sulfur vapor.  Depending on the exact nature of the acid
gas feed and the operating conditions, combined carbonyl sulfide and carbon
disulfide levels as high as 5000 ppmv may exist in the tail gas.
        The "split-stream" process efficiently suppresses the formation of
carbon sulfides.  However the primary reaction products in the split-stream
process are sulfur dioxide and water with virtually no elemental sulfur being
formed (Ondich, 1983).  This can be a serious limitation since an FGD system
would be required to capture the sulfur and prevent air pollution.
D.      Process Reliability—
        Available information indicates no special maintenance problems or
unusually hazardous conditions created by the Glaus process.  Principal
problems result from lack of feed or from upsets in feed rate and composition
caused by operating problems in upstream units.  Plant shutdowns generally are
due to plugging problems.  Carryover of hydrocarbons present in the acid gas
feed may lead to coke formation in the catalyst beds.  High concentrations of
carbon dioxide and ammonia in the acid feed gas (e.g., greater than 30 percent
carbon dioxide and 500 ppmv ammonia) can result in precipitation of ammonium
salts through the Glaus unit.  Hydrogen cyanide in the acid gas can produce
high molecular weight compounds that plug the Glaus unit even more severely
than the ammonium salts.  Hydrogen cyanide also can lead to excessive
equipment corrosion.
E.      Process Economics—
        The cost of a Glaus plant varies as a function of the acid gas hydro-
gen sulfide content and the daily sulfur production capacity.  The presence of
inert diluents (e.g., carbon dioxide, nitrogen, and air) and combustible
contaminants (e.g., ammonia, hydrocarbons, carbon monoxide, hydrogen cyanide,
carbonyl sulfide, and carbon disulfide) increase the initial investment cost
of the plant.  The combustible impurities also affect the operating costs.
                                       3-186

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        The Glaus  capital  investment  costs,  as  a function of  both hydrogen
 sulfide concentration  in the  Glaus  feed  gas  and the  kg moles  of  sulfur  removed
 in  the Glaus process,  are  presented in Figures  3-49  and 3-50.  Figure 3-49 is
 based on data for  Glaus feed  streams  containing 15 and 50 volume percent
 hydrogen sulfide and includes installed  costs only.   Figure 3-50 is  an  exten-
 sion of Figure  3-49 and presents  total capital  costs,  which include  installed
 costs as well as contingency  costs, engineering design costs,  and contractor's
 fees.
        The utility and labor requirements estimated for the  Glaus process are
 presented in Table 3-36.

          TABLE 3-36.   OPERATING REQUIREMENTS  FOR THE GLAUS  PROCESS
                                (Ondich,  1983)
Utilities
                         o        .                                    .
  .  Steam  (generated),  10  kg/kg mole  sulfur removed           0.10 at 0.7 MPa
                                                                0.01 at 4 MPa
                        o   -
    Boiler feedwater, m /kg mole sulfur removed                     0.125
    Electric power, kW/kg mole sulfur  removed                        3.0

jProcess Materials
    Chemicals, $ (first quarter 1980)/kg mole sulfur                0.012

Manpower
    Labor, manhours/yr                                               1577
3.3.7   SCOT (Shell Glaus Offgas Treating) Process (H2S)
        The SCOT process is designed to reduce the emissions of sulfur species
from Glaus plant tail gas.  The system process is discussed in Section
3o3.6.  The EPA Control Technology Appendices for Pollution Control Manuals
                                      3-188

-------
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Figure 3-49.  Claus plant installed costs  (Ondich,  1983).
                                     3-189

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 Figure 3-50.   Estimated Claus plant capital  investment cost
                (Ondich,  1983)
                                    3-190

-------
[Ondich, 1983] covers this process detail.  That information is summarized in
the following subsections.
A.      Process Description—
        A typical flow diagram for the SCOT process is presented in
Figure 3-51.  The process essentially consists of two sections:  a reduction
section and an alkanolamine absorption section.  In the reduction section, all
sulfur compounds and any free sulfur in the Glaus offgas are converted into
hydrogen sulfide over a cobalt-molybdate catalyst at a temperature of about
570 K in the presence of a reducing gas.  The reducing gas can be hydrogen, a
mixture of hydrogen/carbon monoxide mixtures of hydrogen/hydrocarbon mixtures
supplied from an outside source, or can be generated by substoichiometric
combustion of a fuel gas in the direct heater preceding the reduction reactor.
        In the presence of hydrogen and steam, the following reactions take
place in the reduction reactor:
        S02 + 3H2 = H2S + 2H20

        So H~ oHo = 8HoS

        COS + H20 = C02 + H2S

        CS2 + 2H20 = C02 + 2H2S

        When carbon monoxide also is present as a reducing agent, the
following additional reactions may occur:
        S02 + 3CO = COS + 2C02

        8S + SCO = 8COS

        CO +.H20 = C02 + H2

        CO + H2S = COS + H2

        The reactor effluent is subsequently cooled in a heat exchanger and a
quench tower.  The excess condensate from the quench, which contains a small

                                      3-191

-------
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3-192

-------
 amount of hydrogen sulfide and possibly NH3, is sent to a sour water stripper.
 Any H2S and NH3 present is released and recycled to the Glaus feed.
         The cooled gas, which contains up to 3 mole percent of hydrogen
 sulfide and up to 20 mole percent of carbon dioxide, is countercurrently
 scrubbed with an alkanolamine solution in an absorption column.  The treated
 gas,  containing traces  of hydrogen sulfide and carbonyl sulfide,  is burned.
 The rich amine solution is regenerated in a conventional stripper,  and the
 desorbed hydrogen sulfide is  recycled to the front of the Glaus plant for
 recovery of additional  sulfur.
         The selection of the  type of solvent used in SCOT absorbers is largely
 determined by the composition of  the Glaus tail gas, more specifically its CO,
 content.   For amine  treating  processes using MEA (monoethanolamine) or DEA
 (diethanolamine)  or  the ADIP  solvents based on DIPA (diisopropanolamine)  and
 MDEA  (methyldiethanolamine),  the  rate of H2S absorption is high and practi-
 cally  the  same,  since the absorption is gas-film-controlled.   Therefore,  to
 achieve  a  given  purity  of the treated gas the same number of  absorption trays
 is  required for  these four solvents.
         Three different  levels  of  integration of  the solvent  systems  have been
 applied, viz.  add-on, common  regeneration,  and cascaded lineup.   The  term add-
 on  refers  to  a self-contained SCOT unit with a fully independent  solvent
 system,  including  solvent  regeneration which as such can be "added-on"  to one
 or  more  Glaus  units.  Most  SCOT units  built  so far are  of  the  add-on  type.
 However, in  recent SCOT  designs there  is  a  distinct  trend  towards the appli-
 cation of  integration,  in  particular  the  cascaded  line-up.
         In  the common generation and  cascaded  line-up systems  the SCOT  solvent
 section  is  integrated with  the sovent  section  of the primary gas  treating
unit.  An  integrated  system all treating  units must use  the same  type of
 solvent.
        In the common regeneration system the  loaded SCOT  solvent is regen-
erated together with the fat solvent stream(s) from the primary gas treaters
in one common regenerator - usually considered part of the primary gas
treaters.
                                      3-193

-------
         Owing  to  the  low EU^S  partial  pressure in a SCOT absorber,  the solvent
leaving  this column is  only partly  loaded with HoS.   The loading capacity left
can  be utilized for the removal  of  H2S  from a gas with a high H2S  partial
pressure.   In  the cascaded line-up  this further loading takes place by Intro-
ducting  the SCOT  "fat"  solvent into a primary gas absorber.   From this column
the  solvent is routed to the  (again common) solvent  regenerator.
B.       Process Applicability—
         The SCOT  process is applicable  for treatment of tail  gases from Glaus
plants operating  under  a variety of conditions.   As  discussed previously^
factors  such as the Glaus tail gas  pressure and composition,  available reduc-
ing  gas, and desired  level of integration with upstream processes  influence
the  overall SCOT  design.
         The first  two commercial SCOT units began operation in the fall of
1973.  By late 1980,  32 plants in the U.S.  and 25 plants outside the  U.S. were
in operation.  Approximately  8 plants in the U.S.  and 7 plants outside the
U.S. are in various stages of planning,  design,  and  construction.   These
plants are  located mostly in  petroleum  refineries  and range in size from 3 to
2100 Mg/day of sulfur recovered  in  the  Glaus unit.   The largest  SCOT  unit in
the U.S., at 850 Mg/day of sulfur,  is located in the Shell Oil Plant  at
Eustace, Texas.
C.      Process Performance—
        The vent gas from the SCOT  absorber typically contains 200 to 500 ppmv
hydrogen sulfide.  In Table 3-37, typical  compositions  of Glaus  and SCOT unit
gas streams are presented.  For  this  example case, the  SCOT offgas  contains
300 ppmv H2S, 10 ppmv COS, and 1 ppmv CS2.   The  low  concentration  of  COS  could
be the result of the low C02/H20 ratio  (less  than  0.1)  in the  Glaus offgas,
leading to  favorable conditions  for the hydrolysis of COS in the SCOT reactor.
The calculated equilibium COS concentration  for  this  case, however, is  even
lower at 1  ppmv.  This  is in  conflict with  the observation that  the concen-
tration of  COS approaches thermodynamic equilibrium.
        Two other sets  of sulfur emission data are presented in Table  3-38.
However,  none of the data presented provides  information on the concentrations
of COS in the SCOT offgas.  Also, all three plants started up prior to  1978

                                      3-194

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TABLE 3-37.   TYPICAL COMPOSITIONS OF GAS STREAMS IN GLAUS AND SCOT UNITS
                                (Ondich, 1983)
                  (Basis:   94%  sulfur  recovery in  Glaus  unit)
Composition,
% Volume
H2S
S02
83 vapor & mist
COS
cs2
CO2
co2
HC2(MW: 30)
H2
H20
N2
ฐ2
Total
Temperature, K
Pressure, kPa
Gas quantity, mole relative
Glaus .
Intake
89.9
—
—
—
—•—
4.6
0.5
—
5.0
—
—
100.0
310
147
1
Glaus
Off gas
0.85
0.42
0.05
0.05
0.04
0.22
2.37
1.60
33.10
61.30
—
100.00
410
127
3.0
SCOT
Offgas
0.03
'
— •
10 ppm vol
1 ppm vol
3.05
0.96
7.00
88.96
— —
100.00
310
98
2.2
Incinerated
SCOT
Offgas
<10 ppm vol
0.02

—
I
4.42
.
9.84
83.94
1.78
100.00
920
98
3.5
                                    3-195

-------
       TABLE 3-38.   SULFUR CONCENTRATION IN SCOT OFFGAS (Ondich, 1983)
   Plat Location
                                   Sulfur  Concentration  in  SCOT  Offgas
Before Incineration
After Incineration
Shell/Deer Park, Texas
Gulf/Port Arthur, Texas     517 ppmv

Texaco/Port Arthur, Texas   200 to 500 ppmv t^S
                            average 300 ppmv
                         160 — 350 ppmv, average
                         200 ppmv on  the basis of
                         50% excess air

                         267 ppmv
                                    3-196

-------
and were probably not designed to meet the current New Source Perforamnce
Standards (NSPS) for petroleum refinery Glaus sulfur recovery plants.
D.      Process Reliability—
        The SCOT process is generally considered to be highly reliable and
easy to operate.  Three sets of process reliability data have been collected
(Ondich, 1983).  These data indicate that:
        .  At the Shell/Deer Park, Texas facility, the SCOT unit has
           99.5 percent on-stream time (excluding three weeks scheduled
           maintenance shutdown every three or four years).
        .  At the Gulf/Port Arthur, Texas facility, typical on-stream
           time for the SCOT unit ranges from 97.9 percent in 1977 and
           1978 to 99.9 percent in 1980.  Due to a heater tube failure
           in 1979 and a process blower failure in early 1981, the on-
           stream time during these two periods is considerably lower.
        .  At the Texaco/Port Arthur, Texas facility, on-stream time for
           the SCOT unit is 99.16 percent.  Operational problems causing
           down—time include:  (1) leaking amine exchanger, (2) high
           incinerator temperature, (3) blower failure, and (4)
           malfunction and repair of regulators, control valves, and
           emergency shut-down instruments.
E.      Process Economics—
        The capital investment cost for a SCOT unit designed to treat the tail
gas from a 150 Mg/D Glaus unit operating at 94 percent sulfur recovery was
quoted by Shell Development Company to be $4 million based on mid-1979
dollars.  In 1973 Shell provided capital investment costs for SCOT units;
$1.8 million for a 100 Mg/D unit, $3.2 million for a 200 Mg/D unit, and
$7.2 million for a 1000 Mg/D unit.  Generally the capital investment for the
add-on SCOT unit is approximately equal to the capital investment required for
the preceding Glaus unit.  For the integrated SCOT unit (sharing amine
regeneration and sour water stripping facilities), the capital investment for
the SCOT unit equals about 75 percent of that for the Glaus unit (Ondich,
1983).
        In Figure 3-52, the capital investment costs for the SCOT unit are
presented as a function of the capacity of the preceding Glaus unit.
                                      3-197

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 3.3.8    Flue  Gas  Desulfurizati_on_(Wet and Dry)
         Flue  gas  desulfurization (FGD) techniques are used widely for removing
 sulfur  oxides (SOX)  and other  acid gases from the exhaust gases of combustion
 processes.  In any shale oil recovery operation where conventional boilers,
 process heaters,  etc.  are used with fuel containing sulfur, FGD,  in one form
 or  another, can be readily employed to limit SOV emissions.  Where retorted
                                                A.
 shale is used as  fuel  in fluidized-bed combustors (FBC),  the SO  emission
                                                                X ,
 should  be low.  The  use of FGD on these FBC exhaust gases may not be cost
 effective but could  be used if the SC)  levels are excessive.
                                     - X
         Retort  offgas  with high organic sulfur content also may be treated by
 incinerating  the  organics in the offgas and then scrubbing SO  created with  an
                                                              X
 FGD system.   Any  H2S in the offgas also will be converted to SOX by the
 incineration  process.
         Incineration followed  by FGD is not usually the most cost effective
 technique for removing reduced sulfur  compound (i.e.,  H2S,  COS,  CS,  MeSH,
 etc.).   The gas volume Increases by 1.5 to  3 times  in the incineration which
 increases the scrubber size proportionally.   Therefore, the reduced  sulfur
 removal  processes, discussed in the preceding section should be employed  if
 possible.
         However,  to date,  scrubbing processes which will  remove over 90
 percent  of the reduced organic sulfuric compounds  (COS, CS2,  MeSH, etc.) have
 not been used in  full-scale operations  with retort  gas.   Therefore,  some  shale
 oil processing plants  with a high organic sulfur  content  in their  retort gas
 are being designed to  use  incineration  and  FGD.
         The alkaline/carbon/hypochlorite scrubber,  discussed  in Section 3.3.5,
 could be the  alternative  to incineration/FGD if  it  proves  to  have  the high
 reduced  organic sulfur  removal  that  is  expected,
        FGD is widely  discussed  in  the  literature.   The following  is a  brief
 recap of the  technology as  extracted from the  Pollution Control Technical
Manual Appendices  (Ondich,  1983).
A.       Calcium-Based, Wet  Systems—
        Calcium based wet FGD  systems are the most prevalent  type  of SOo
 control processes used for  coal-fired utility generating stations.  Lime,

                                      3-199

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limestone, and alkaline ash systems represent approximately 80 percent of the
FGD capacity currently operating, under construction, or being planned.
Almost all of these processes are nonregenerable or throwaway processes.  The
major impetus for the use of nonregenerable systems is economic.  The cost of
limestone is such that discarding the resulting sludge is the cheapest SC^
control mechanism available.
        The history of lime and limestone FGD systems since their initial
application in the early 1970s has not always been favorable.  Numerous
problems have plagued commercial systems throughout the development of this
technology.  One of the major causes of problems is the relatively low
solubility of most calcium compounds present in FGD systems.  Because of the
low solubility of calcium carbonate and calcium sulfite, high liquid to gas
(L/G) ratios are needed for adequate SO? removal.  The low solubility of
calcium sulfate has often caused scale formation in a system either due to
undersized reaction tanks or chemical upsets.  Another problem is the high
solubility of calcium chloride in this chemical system which results in high
liquid phase chloride concentrations that can cause corrosion.
        The  FGD system with a lime/limestone type of scrubbing solution is
the generic process offered by many different vendors.  Each vendor may have
unique features incorporated in their design; however, the overall process
chemistry and equipment are generally very similar.  Both lime and limestone
produce the same reaction products, although differences exist in the
operating parameters.  A general flow diagram is shown in Figure 3-53.
Hydrated lime (CaO) is slaked onsite to form calcium hydroxide slurry.  This
slurry reacts with S02 to form calcium sulfite and calcium sulfate.  The
limestone chemistry is similar; however, carbon dioxide is also generated.
The limestone, often gravel size or larger, is crushed in ball mills to
produce a reagent slurry.
        In the typical system, the flue gas is contacted with a slurry of
calcium sulfur salts and the reagent.  The gas may or may not contain fly ash,
depending on the absorber design.  Venturi 'and turbulent contact absorbers
(TCA) have been used for combined S02 and particulate control while spray
towers, perforated trays, and other low pressure drop contactors are often
used for just S02 removal.  A large volume of slurry (relative to the gas

                                     3-200

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                            CO
                                       O
                                       
-------
volume) is sprayed or dispersed in some manner in the contactor, saturating
                                                                   o
the flue gas and removing the S02ซ  Typical L/G ratios for 5.3-16 m  liquid
                     3
per thousand actual m  of gas.  The scrubbed gas is then passed through mist
eliminators and is often reheated to restore buoyancy before being discharged.
        The S02~rich liquor typically drains into a large tank where
neutralization and precipitation reactions occur.  The alkaline reagent is
added to this tank to maintain the desired system pH.  When lime is used as
the reagent, the feed liquor pH is typically 8-9 and the absorber effluent is
5-7.  In a limestone system, because it is buffered by the carbonate species,
the pH usually ranges between 5 and 6.  Operating at this lower pH tends to
increase the sulfite oxidation rate.  If a super-saturated condition is
reached without adequate gypsum seed crystals present in the slurry, hard
scale can form on the absorber internals, disrupting operation.  In order to
obtain scale-free operation, the reaction tank is either sized to maintain the
gypsum concentration low enough to prevent scale formation, or the oxidation
is forced to near completion, which results in adequate^crystal precipitation
sites to prevent scaling.
        A small portion of the recirculating slurry is removed to control the
suspended solids concentration.  This stream can be thicknened, filtered, or
centrifuged before it is ultimately disposed.
B.      Sodium-Based, Wet Systems—
        Approximately ten percent of commercial FGD systems are based on
sodium processes, of which there are three types, dual alkali, sodium
carbonate, and Wellman-Lord.  All of these processes absorb SCU in the same
manner.  The makeup sodium reagent typically is either caustic (sodium
hydroxide) or soda ash (sodium carbonate).  Trona, a mineral form of sodium
carbonate, also is used.
        The sodium compounds used in these processes are relatively expensive
compared to reagents such as lime or limestone.  However, sodium compounds
have certain advantages.  The primary advantage is that they are much more
soluble than their respective calcium salts.  As a result, the liquid phase
alkalinity of the absorbing liquid permits very efficient S(>2 removal at low
L/G ratios.  The predominant reactive species is the sulfite ion which
neutralizes the sulfurous acid formed.  Absorber effluent is treated with
makeup reagent to convert the bisulfites back to sulfites.
                                   ฃ>
                                     3-202

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        The high solubility of sodium salts, although good for SC>2 removal,
creates a disposal problem.  Since the salts are soluble, direct disposal can
only be accomplished economically in arid areas where evaporation ponds can be
employed.  The waste, if it is not oxidized to sulfate, also could place a
large chemical oxygen demand on any receiving waters.
        The dual alkali and Wellman-Lord systems solve the soluble effluent
disposal problem in two different manners.  In the dual alkali system, lime is
reacted with the absorber effluent to produce a sludge which is discarded.
This reaction also converts the sodium sulfite back into caustic, which is
returned to the system.  In the Wellman-Lord system,the bisulfite containing
effluent is steam stripped to form sodium sulfite and gaseous SC^.  The SC>2 is
then processed into sulfur or sulfuric acid.  The Wellman—Lord selection is
dependent on the available market for either of its byproducts.
        The dual alkali process uses alkaline sodium compounds to achieve
efficient SO^ removal, and lime to regenerate the sodium-based scrubbing
liquor.  The flue gas normally is treated for particulate removal before it
reaches the system.  A presaturator can be included to prevent chloride
buildup in the recirculating liquor when treating high chloride coals.  The
dual alkali process has two major chemical steps, absorption and
regeneration.  Sodium sulfite is the major alkaline species present in the
liquid phase.
        In the absorption step, caustic and soda ash react with SC^ to form
sodium sulfite, which, upon additional absorption of SC^, forms sodium
bisulfite.  Oxidation of the sulfite ion to sulfate also occurs.
        A portion of this recirculating clear liquor stream is sent to a
reaction tank where lime is added to precipitate the sulfur species.  The
solids are separated in a thickener and concentrated in a vacuum filter before
disposal  The regenerated sodium compounds are then recycled to the
absorber.  Alkali losses in the filter cake moisture are replaced by the
makeup sodium reagent.  Most systems include some type of filter cake washing
system to minimize the sodium loss.
        The oxidation reaction of sulfite to sulfate requires a treatment
scheme to remove the inactive sulfate from the clear liquor.  Two mechanisms
exist, the selection of which depends on the relative sulfate to sulfite
                             '         3-203

-------
concentrations.  Both calcium sulfate and calcium sulfite are relatively
insoluble compounds, although gypsum (a form of calcium sulfate) is about an
order of magnitude more soluble than calcium sulfite.  Consequently, unless
the sulfate to sulfite ion ratio in the solution is the same as the ratio of
solubility products of the two compounds, only one species should precipi-
tate.  When this ratio is high, gypsum will precipitate as lime is added.
This is called a "dilute" system because the concentration of the active
sodium sulfite is fairly low.  In a "concentrated" system, both calcium
sulfite and sulfate precipitate and the liquor is subsaturated with respect to
gypsum by a coprecipitation mechanism.  The sulfite and sulfate form a solid
solution in the crystal lattice structure.  This mechanism maintains the
subsaturated gypsum condition.
        The Wellman-Lord process uses an aqueous solution of Na2SOg to remove
SC>2.  The sulfite ion is oxidized to form sulfate.  The NaHSOo solution from
the absorber is thermally decomposed in a steam-heated evaporator to
regenerate sodium sulfite.
        Most of the water vapor from the overhead SC^-I^O mixture is
condensed, and the SC^-rich gas is further concentrated to about 85 percent
S09 by steam stripping of the condensate.  The S09-rich stream is suitable for
  ^>                      •                        ฃ. .
processing into elemental sulfur or sulfuric acid.  A slurry of Na2SOg
crystals is formed in the evaporator, redissolved with the condensate from the
evaporator overhead, and recycled to the absorber as regenerated scrubbing
solution.
        Accumulation of sulfate in the Wellman-Lord system is prevented by a
continuous purge treatment of the NaHSOo solution from the absorber.  Earlier
installations used a refrigerated purge treatment section to crystallize and
removal NaSO^.  More recent developments indicate that a high temperature
purge treatment requires less energy and capital.  Sodium losses from the
purge treatment are made up by addition of NaOH or Na2COo to the recirculating
scrubbing solution.
C.      Spray Dryer Systems—
        Wet-reagent, dry-scrubbing systems, known as spray dryers, use a
solution or slurry, which is evaporated to dryness by the flue gas, to remove
S02.

                                       3-204

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        Spray drying  is  a  relatively new FGD  process  rapidly  gaining utility
acceptance.  In  spray dryer  systems, hot flue gas  from the  boiler  or air
preheater passes into a  reaction vessel  with  a residence  time of 5 to 10
seconds.  Here it is  contacted with a  slurry,  paste,  or solution ,of alkaline
material.  The flue gas  is humidified  adiabatically to within 30ฐK of its-
saturation temperature by  evaporation  of the  slurry solution.   The slurry
generally is dried to less than one percent free moisture.  These  salts,  along
with fly ash, are entrained  in the flue  gas and carried to  the particulate
control section.  This is  typically a  baghouse, although  ESPs  can  also be
used.  Some of the solids  drop to the  floor of the dryer  and  are combined with
the baghouse catch.   Collected solids  may be  recycled through the  reagent
preparation system along with solids from the  particulate collector.   The S02
capture reactions take place both during and  following the  drying  process,
continuing even  on the particulate collector  surfaces.
        There are three  advantages of  wet-reagent, dry-scrubbing processes
over wet processes.   First, the flue gas leaving the  S02  absorber  is  not
saturated with water  vapor.  This usually prevents moisture condensation  and
subsequent corrosion  in  downstream equipment.   Second,  waste material is
handled dry, rather than in a slurry or  a liquor.  Third, particulate control
is achieved at no additional pressure  drop.  For throwaway applications,  dry
solids disposal  can be easier.  One disadvantage of these systems  is  the
somewhat lower S02 removal capabilities.  Commercial  operating experience also
is less with the dry  systems than with the wet  systems.
        There are several  types of spray dryer  system designs  being offered.
All involve the  following  four steps:
           reagent preparation
        .  atomization
        .  S02 absorption-water evaporation, and
           particulate removal

        In addition,   solids recycle is integrated into most of  the current
system designs.  During  reagent preparation, the alkaline material is
dissolved or slurried  in water.  Limestone has not been shown  to be
sufficiently reactive for this application.  Both lime and soda ash are
                                      3-205

-------
reactive and cost effective for  spray  dryer  applications.   At  this  time,
however, most spray drying systems  are lime  based.
        Atomization is accomplished in either  a  rotary atomizer  or  with
nozzles,  In a rotary atomizer,  liquid is  fed  into  a  rotating  wheel.   The
liquid is accelerated, and is atomized at  the  wheel's edge  forming  a  spray  of
droplets.  The spray leaves the  wheel  horizontally  at an angle of about
180ฐ.  Droplet size is dependent on the wheel  speed,  fluid  viscosity,  and feed
rate5, with wheel speed being the most  important  variable.
        In a nozzle atomizer, either the slurry  or  solution is fed  under high
pressure (hydraulic) or a separate  high pressure (two-fluid) medium is
supplied.  In a nozzle, the feed is ejected  from the  orifice as  a high speed
film which disintegrates into droplets.  In  a  large module, multiple nozzles
can be installed.
        SC>2 absorption and water evaporation occurs simultaneously, generally
within a second or two after the droplets  and  gas enter the dryer.  In a
properly designed system, the dried product  must be free flowing while the
chamber itself remains dry and free of  deposits.  This is achieved  by
controlling: (1) the particle size  of  the  atomized  feed, and (2) the dryer
outlet temperature.  The dry salt mixture  produced  is usually  about 70 percent
anhydrous sulfite and 30 percent anhydrous sulfate.
        Particulate removal is accomplished  either  in a baghouse or precipi-
tator.  Bag collectors offer sites  for  additional S02 removal  with unreacted
alkalinity.  Up to 10 percent of the total S02 removal occurs  in the
baghouse.  Bag fabrics can be blinded by wetting, therefore operation  must
remain well above the saturation temperature.  On the other hand, ESP
collectors do not assist with the S02 absorption; but, they are  less senstive
to condensation.  Therefore, the spray  dryer can be operated as  close  as 11 C
above the saturation temperatures which causes higher SO? removal in the
reactor.
        Some spray drying systems also  incorporate  solids recycle to increase
reactant  utilization and in some cases also take advantage of  fly ash
alkalinity.  Spent solids removed from  the bottom of the spray dryer are sent
to the sorbent preparation area  (e.g.,  slurry tank).  Most system designs
reslurry  the product solids in a loop separate from the fresh sorbent
                                      3-206

-------
preparation loop, and then combine the two slurries just upstream of the
atomizer.  This allows closer control of the recycle slurry pH, which has been
found to impact the overall system performance.
D.      Dry Sorbent Injection System—
        The newest FGD concept is to inject a dry sodium sorbent powder ahead
of the particulate collection filter (i.e., baghouse).  This system offers the
industry a potential for substantial cost savings as well as design and
operational simplicity compared to wet scrubbing systems or even compared to
spray dryers.  It also requires less water than wet or spray dry type systems,
an important consideration in regions where water is in short supply.  This
system is especially attractive for boilers firing western U.S. coals subject
to 70 percent SOX removal New Source Performance Standards.
        The system involves the injection of Trona, Nahcolite or any other
naturally-occuring forms of sodium bicarbonate and sodium carbonate.  This dry
powder is introduced into the gas stream at a point between one and two
seconds of flow time before the gas enters the baghouse.  The gas temperature
at the point of injection and in the baghouse is important to the removal
efficiency achieved.  The nominal temperature is 150 C (300ฐF) and the optimum
must be established for the specific sorbent selected.
        The sorbent selection is the most important aspect of the system
design.  Nahcolite is most effective.  It can achieve a 70 percent removal
efficiency with a normalized stoichiometric ratio (NSR) of approximately
0.75.  Trona can achieve 70 percent removal efficiency with an NSR of 1.3 and
soda ash has proven to be esssentially ineffective in tests to date (Muzio and
Sonnichsen, 1984).
        This process is still in development under sponsorship of the Electric
Power Research Institute (EPRI).  Demonstration tests on a 22 MW coal fired
boiler were conducted at the Public Service of Colorado's Cameo Unit 1 (Muzio
and Sonnichsen, 1984).
        In late 1985, EPRI was planning a project to demonstrate the process
at full scale for S02 control on coal-fired utility boilers.  The project was
to be co-sponsored by City Utilities of Colorado Springs and the FMC
Corporation.  The demonstration would be conducted on Unit 1 of the R.D. Nixon
plant of City Utilities.
                                      3-207

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        The primary disadvantage of this process is the disposal of the water-
soluble byproducts, sodium sulfite and sulfate.  Because certain areas in the
Colorado and Utah areas may have suitable disposal sites for these byproducts,
this process may have an application for shale oil processing in those states.
        Figure 3-54 is a simplified flow schematic of a coal-fired power plant
equipped with dry sodium injection for S02 control.  With the dry sodium
injection processes tested thus far, the reagent material is fed into the flue
gas stream ahead of a baghouse and downstream of the system air heater.  In
the ductwork, the reagent particles decompose to sodium carbonate (NaoCOo)
forming an open, porous microstructure, which then reacts with SO, to form
either ^ฃ$03 or Na2S04.  Unreacted sodium carbonate deposited on the fabric
in the baghouse can also react with SC>2 to provide further S02 removal.  The
decomposition process is apparently important to the efficiency of the
process, particularly at temperatures between 120 and 200 C.  Typically 70 to
80 percent of the total S02 removal occurs in the baghouse and 20 to 30
percent in the upstream ductwork, although these ratios can vary considerably
with injection temperature and, perhaps, particle size.
        From the work completed and that currently is in progress, the
following parameters have been identified as being important:
        .  Sodium sorbent type
           Sodium/sulfur injection ratio
        .  Particle size
        .  Injection method (sorbent dispersion)
        A list of sodium based reagents which have been tested, thus far, in
dry S02 removal systems is shown in Table 3-39.  Sodium sesquicarbonate is a
synthetic material normally obtained by refining Trona ore.  It results as an
intermediate step in the manufacture of soda ash.  Trona ore is dissolved in a
liquor and impurities are removed.  Crystalization then results in a pure
sodium sesquicarbonate product.  Trona is a naturally occurring sodium sesqui-
carbonate.  It is water soluble and decomposes with heat to yield sodium
carbonate, carbon dioxide, and water.   Tremendous deposits of Trona,  located
in the State of Wyoming are currently being mined and refined into soda ash
for use in a great number of commercial products.
                                       3-208

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3-210

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        In the dry sodium scrubbing process, the following  series  of  reactions
are postulated to take place to produce sodium carbonate for  the removal of
S02:

Bicarbonate (Nahcolite)
         2NaHC03  •* Na2CO_ + C(>2
Sesquicarbonate (Trona)
                    NaHC03
Tribicarbonate
         2[Na CO    3NaHCO
Then for sulfation:
                    2S02 + 02 ••--ป• 2Na2S04  + 2CO,
                                       or
        The  decomposition  step,  which for  Nahcolite at a temperature of 300ฐC
occurs  in  approximately  one half second, generally leads to an increase in the
specific surface  area  of the  sorbent.  The surface area of Nahcolite can
                               O     '          "              O
increase from about  0.5  to 5  M /g,  of Trona from 1.5 to 3 M /g, and of
                                  9
sesquicarbonate from 1.0 to 2.5  M /g  during decomposition.
        In Figure 3-55,  typical  results comparing the S02 removal achieved
with various sodium  compounds as a  function of the NSR are shown.  At an NSR
                                       3-211

-------
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               *
Nahcolite
Wyoming Trona
Owens Lake Iron
Sesquicarbonate
Soda Ash
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                 NORMALIZED STOICHIOMETRIC RATIO
        Figure 3-55.  S02 removal as a function of normalized
                     stoichiometric ratio. (KVB, Inc., 1985).
                               3-212

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 of  Ij Nahcolite  typically produces a 70 to 85 percent removal and Trona or
 sodium  sesquicarbonate 40 to 60 percent.   Soda ash (sodium carbonate) also has
 been  tried but discontinued when it produced an unacceptable removal
 efficiency of ten  percent.
         In the temperature  range normally encountered in baghouse systems used
 with  boilers  (125  C  to 170  C),  the flue gas temperature can affect sorbent
 usage although the effect can vary with reagent type.  For sodium bicarbonate,
 there is a general increase in  sorbent  utilization with increasing temperature
 at  the  point of  injection.
        This improvement  in utilization appears to be related to the rate of
 thermal decomposition  of  the sodium bicarbonate and the availability of S0? in
 the vicinity of  the  freshly decomposed  sorbent surface.   For Nahcolite the
 concern is  at low  temperatures.   At a temperature  of  130 C,  the  SOo  removal
 efficiency  using Nahcolite  can  be 50 percent lower than it is at 150 C.
        With a Trona reagent, the baghouse temperature  can be as low as 120 C
 without a  detrimental  effect on S02 removal.   The  capability of  Trona to
 remain  reactive  at low temperatures can probably be attributed to its faster
 reaction rate relative  to Nahcolite.  In  general,  with  injection of  sodium
 sesquicarbonate  or Trona, the effect of increasing the  temperature within the
 125 C to 170 C window  has been  found to have little or  no  effect (Muzio and
 Sonnichsen, 1984).
        The testing  performed thus  far has  indicated  that  the sorbent particle
 size  is important.   The influences  of particle  size is  on  the distribution  and
 dropout of  the particles  in  the  baghouse.   The  measured  effect of particle
 size on the S02  removal efficiency  is shown in  Figure 3-56.   A significant
 influence of particle size was seen, although  from this  figure it is  not  clear
 if the  influence or  particle size is due  directly  to a  change in reaction rate
 or is an indirect effect  due to  increase  particle  dropout  in  the ductwork and
 baghouse.  Current indications are  that the  decrease in  sodium utilization  for
 larger paticles  is due primarily to the dropout  of  large particles directly
into the baghouse hopper without depositing on  the  filter  bags.  This
conclusion is important when considering  injection  design  criteria, reagent
pulverization requirements and possibly baghouse inlet transition and hopper
designs.  The carrying velocity into a baghouse  compartment hopper needs to be
                                      3-213

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    100
     80
I
     60   „
     40
     20
                                      NSR
Figure 3-56.
                       Sodium utilization as a function of NSR and
                       particle size.  All bicarb materials supplied
                       by  one chemical company.   (KVB, Inc., 1985).
                                  3-214

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sufficient to keep a reagent particle  from falling  out;  and  the  reagent
distribution needs to remain somewhat  uniform across  the tubesheet.   This
underlines the importance of a good aerodynamic modeling effort  relating to
the injection system and baghouse designs,  especially at lower boiler steam
loads where flue gas flow rates are substantially lower  than design
specifications.
        On tests conducted to date, the addition of sodium sorbents  have had
no adverse effects on baghouse performance.   During the  EPRI tests at the
Public Service of Colorado, Cameo Station,  the baghouse  collection efficiency
remained at 99.96 percent when Nahcolite and  Trona  were  injected at  quantities
required for 70 percent S02 removal.   No appreciable  increase in baghouse
pressure drop characteristics or bag cleanability where  observed during
sorbent injection while operating in the pressure-  or time-initiated cleaning
modes.
        During earlier pilot tests, the only  problem  observed with increased
baghouse pressure drop when injecting  very  fine sorbents  (MMD =  8  un).  When
using this material, the cleaning frequency had to  be increased, after which
satisfactory operation could be maintained  (Bland,  1985).
E.      Process Performance and Economics—
        Two commercially available systems, limestone and Wellman-Lord, were
selected as being representative of FGD process by  Ondich  (1983).  Other FGD
processes may offer certain technical  or cost  advantages, but the two selected
processes are believed to be "state-of-the-art" as  far as achievable  levels of
S02 control are concerned.
        FGD costs for boilers in shale oil plants will depend upon the amount
of sulfur emissions control required to meet NSPS standards.  This may vary
depending upon the amount of sulfur in the fuel.  For an Illinois No. 6 type
bituminous coal having a sulfur content of 3 to 3.5 percent approximately 90
percent removal is generally required.  However, for  a lower  sulfur  fuel,  a
smaller amount of removal may be necessary.
        FGD cost data have been developed by the EPA  for electric utility
steam generating units ranging in size from 25 MW to  1000 MW  (Ondich, 1983).
The cost variations are principally governed by:  1)  size of the boiler, 2)

                                       3-215

-------
 fuel used,  3) averaging time over which the plant must meet the SO,
 limitation, and 4) level of control maintained.
         Table 3-40 presents estimated capital investments and annual operating
 costs for the limestone and Wellman-Lord FGD processes applied to a 500 MW
 boiler burning a 3.5 percent sulfur coal and achieving 90 percent S02
 control.  These estimates are in 1983 dollars.  Capital investment estimates
 include direct and indirect costs,  such as purchase of equipment, installation
 labor and material,  engineering costs,  land required for sludge, etc.  Annual
 operating costs include fuel costs, operating labor, and overhead expenses for
 safety.
            TABLE  3-40.   COSTS OF S02 CONTROL FOR 90 PERCENT REMOVAL
             Basis:  500 MW unit burning a 3.5 percent sulfur coal
                          (Adapted from Ondich,  1983)
                            Capital  Investment,       Annual  Operating Costs.
                           	1/kW                     $/kWh
Limestone Scrubber                  170                       0.005

Wellman-Lord Scrubber               160                       0.005
        In order to estimate costs for shale oil  steam and power generating
units, it can be useful to evaluate costs in terms of dollars per flue gas
flow rate.  For the limestone and Wellman-Lord FGD process, the capital costs
for a 500 MW eletric unit were both estimated to  be $1,100 per kmol/hr.
Similarly, annual operating costs for both were estimated to be approximately
$250 per kmol/hr.  When applying these costs to shale oil plants, adjustments
for size can be made based upon the six-tenths rule.  Costs for FGD units
requiring less than 90 percent control can be estimated by bypassing part of
the flue gas and treating the remainder for 90 percent removal so as to
achieve the required S02 removal.
                                      3-216

-------
3.3.9   Sg^Absprption in Spent Shale  (ASSP)
        The ability of combusted carbonate—containing spent shale to absorb
SC>2 gives zlse to a novel concept for  controlling sulfur emissions in oil
shale plants.  This concept is referred to as ASSP which stands for Absorption
on Spent Shale Process by Van Zanten and Haas (1986).
        The ASSP concept has several potential advantages over conventional
sulfur removal technologies:
        .  The sorbent is cheap and inherently abundant in oil shale
           plants.
        .  The process requires combustion of the spent shale which is
           already incorporated into several of the retorting
           technologies or which would be a useful add-on to recover
           residual carbon values.
        .  Since non-I^S compounds are converted to SOo by combustion,
           ASSP could represent a more efficient removal relative to gas
           sweetening processes which  only remove H~S.
        The ASSP concept uses a fluidized transport system to combust either
raw or retorted shale, thereby providing the vehicle for converting sulfur
compounds to S02  and absorbing the S02 in the shale matrix.  The concept
envisions either a conventional dense-phase fluidized bed or a dilute-phase
fluidized bed or a dilute-phase contactor (lift pipe).  Key elements of the
process are shown in Figure 3-57.
        In an engineering assessment of the ASSP concept, J&A Associates (Van
Zanten and Haas, 1986) evaluated three types of retorting processes:
           Direct heated
        ,  Indirect heated
        .  Indirect heated with combustion integrated into the process
                                      3-217

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                                                       3-218

-------
         Specific  retorting technologies and sites were selected as
 representative  of these  three retort  types as follows:

 Retort  Type                 Process                     Site
Direct heated            MIS  with Unishale C     Cathedral Bluffs (Tract C-b)
Indirect heated          Unishale B               Union Oil (Parachute Creek)
Integral combustor       Lurgi                    Rio Blanco (Tract C-a)
Integral combustor       Unishale C               Union Oil (Parachute Creek)

        The study assumed that  amine  absorption is used to remove acid gases
from indirect heated  retort gases and that regenerated acid gases are burned
in the ASSP combustor.  MIS gases were assumed  to be processed  in the ASSP
combustor without pretreatment.
        For comparison purposes,  conventional sulfur removal processes were
evaluated:
        .  Direct heated - Case A; Unisulf + Flue gas desulfurization on
                           combusted  modified in-situ gases
                           Case B; Unisulf + Stretford on  modified in-
                           situ gases
        .  Indirect heated - Unisulf  on Unishale  B gases
           Integral combustor - DBA + Stretford on Lurgi gases
                              - Unisulf on Unishale  C gases
        Major equipment costs were taken from EPA Pollution  Control Technical
Manuals (PCTM).  ASSP equipment was sized  and costs  factored from in-house
data and PCTM's.  Costs were factored  to the first quarter of 1985.
        The results of the cost study  showed changes  in incremental capital
and operating costs for ASSP relative  to conventional processing  in Table 3--41
below.
                                      3-219

-------
                     TABLE  3-41.   COST COMPARISON FOR ASSP
                            (VanZanten,  et  al.,  1985)
Retort Type
Retorting Process
ASSP Incremental
Cap. Cost, $106
ASSP Incremental
Ann. Oper. Cost, $106/yr
Direct Heated
Case A, Case B
MIS/Unishale C
-71.2 -63.2

+10.83 +12.07
Indirect
Heated
Uni shale B
+90.2

-19.21
Integral
Combust or
Lurgi Uni shale C
-13.0 -32.1

- 2.29 -1.56
         These  cost  comparisons  show that the best potential for application of
ASSP  are those processes  which  already have a spent shale combustor integrated
into  the retorting  process  (e.g.,  Lurgi, Unishale C,  Chevron STB,  and Tosco
HSP).   Capital and  operating  cost  savings for Unishale C and Lurgi cases are
primarily a result  of deleting  the Unisulf and Stretford plants.
         Economics for the indirect and direct heated  retorts are good to
marginal.  Factors  which  will affect  the economics  are:
         .  How effectively  combustor  heat can be  utilized (simple  steam
           raising  is the best  desirable).
         .  The  value of steam.
         .  The  use  of fast  or circulating fluid beds  to  reduce
           investment in  combustor  equipment.
         Pilot plant tests were  performed in an 46 cm  (18-in)  diameter,
bubbling  fluidized-bed combustor of the  type  which  is  integrated into  the
retort process.  A  total  of 44  individual  tests were performed.  Variables
evaluated were  combustor  temperature,  solids  residence time,  gas residence
time,  oxygen concentration,  inlet gas  sulfur  concentration,  staged combustion,
and raw shale injection.  Over  the entire range of  conditions tested,
emissions of primary pollutants were:
                                      3-220

-------
                   Component                  Range

                    S02                      1-38 ppmV

                    NOX              '        80-670 ppmV

                    CO                       0.05 - 1.80 vol%
                    Trace hydrocarbon        51-8465 ppmV


 Key findings of the tests were:

         .   S02 emissions were controlled easily to low levels at
            virtually all conditions tested, probably as a result of the
            high Ca/S ratios used.

         *   N0x emissions were primarily sensitive to oxygen
            concentration (Figure 3-58).  Reasonably good NO  control
            could be obtained with flue gas oxygen concentrations below
            about 3 volume percent.  The lowest NOX concentrations were
            seen at 02 levels approaching zero  but at the expense of
            higher CO and trace hydrocarbon emissions.

            CO and trace  hydrocarbon emissions  were primarily sensitive
            to flue gas oxygen concentration (Figure 3-59).   Good control
            of both could be obtained at 02 levels about 2 volume
            percent.

        Emissions of NOX move in a direction opposite  to S02,  CO and trace

hydrocarbon emissions.   Thus,  finding  a set of  operating conditions which

minimize all four represents a compromise.   One test was run which produced
nearly optimum results.

        Conditions for this  test were:

                   Bed temperature                  937ฐK
                   Solids  residence  time            9.4  min
                   Gas residence time               0.9  sec
                   Gas superficial velocity        1.3  m/sec
                   Flue gas  02                      2.6  vol%
                   Ca/S mole  ratio                  10.3
                   Raw shale/spent shale ratio      1:36

At these conditions, the following result were  obtained.

                   S02                              11 ppmV
                   N0x                              160  ppmV
                   co                               0.27 vol%
                   Trace hydrocarbon                388 ppmV
                   Combustion efficiency            89%
                                     3-221

-------
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           ~~~(VanZanten, et al., 1986).              X
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                                 FLUE GAS 02. VOL%
    Figure 3-59.
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             (VanZanten, et  al.,  1986).

                                      3-222

-------
        During selected tests, both combustor flue gas and retort gas were
sampled and analyzed for selected trace elements — mercury, cadmium, arsenic,
lead, beryllium and fluorine.  Solids streams also were analyzed for trace
elements in an attempt to determine where trace elements go.  One run was
performed where a spike solution of mercury and cadmium was added to the
combustor.                                                    ,
        Results of the trace element tests indicated some relative trends with
regard to emissions but because of the short duration of the sampling, no hard
conclusions can be reached which would allow extrapolation of result to long
term steady—state operations.  Some of the key observations were:
           Lead, beryllium and fluorine were found to have low
           volatility.  That is, of the amounts present in raw shale,
           only very small percentages were volatilized to the gas
           streams.
           Arsenic was found in significant concentrations in the retort
           gas (100-400 ppmV) although the amount of arsenic found
           represented less than 15 percent of that in the raw shale.
        .  So little mercury was present in the raw shale that mercury
           emissions could not be characterized with high accuracy.
           Mercury emissions were very low except during the spike
           indicating that mercury, if present in higher concentrations
           in the raw shale, could possibly pose emissions problems.
        .  Although significant amounts of cadmium was found in the
           gases at higher retort and combustor temperatures, emissions
           represented less than 10 percent of cadmium present in raw
           shale.
        There is some evidence that mercury and cadmium introduced to the
combustor during the spike test condensed within the retort equipment and
revolatilized over time.  However, because of the limited number of samples
taken, the validity of any conclusions drawn would be questionable.  Longer
term steady-state operations would have to be studied to determine the fate of
mercury and cadmium with more certainty.

3.4     ENGINE EMISSIONS OF CO AND HC
        An oil shale recovery plant using an above-ground or modified in-situ
(MIS) retort requires extensive mining.  The primary gaseous emissions from
the mining operation are carbon monoxide, hydrocarbons and nitrogen oxides
from diesel engines.
                                      3-223

-------
        One method for control of diesel emissions  in underground mines  that
has gained fairly wide acceptance is the use of  catalytic mufflers.  These
systems have been found effective in reducing emission  levels  of carbon
monoxide (CO), unburned hydrocarbons (HC), and odor.
        The results of an experimental program carried  out  by  the Bartlesville
Energy Research Center (BERC) (Marshall, et al;,  1978)  on the  effectiveness of
various catalysts on reducing CO and HC emissions are presented in this
section.
        Four noble metal catalytic converters (two  units each) and two engines
were used in these tests.  Three of the converters  are  standard production
models and are representative of a significant fraction of  those used in
underground mines; the fourth converter is a prototype.  The engines were
mounted on test stands and coupled to eddy-current  dynamometers.  The engines
                  r                                         .                  ซ
were operated over a wide range of speed and load conditions.  Converter and
engine designations are given in Tables 3-42 and 3-43,  respectively.  All fuel
used in these tests was obtained from the same supplier.  Fuel property data
are given in Table 3-44.

          TABLE  3-42.  CATALYTIC  CONVERTERS  (Marshall,  et  al.  1978)
                           ^        -- ---               *lซป*fc^fc*T • II • HAM ซ I • .• i ••• ^ || • HL| _M H|, T | |, • || || i L ji
                  Catalyst Bed
Designation       Construction           Manufacturer            Models

    A             Pelletized         Universal Oil Products   Prototypes
    B             Telletized         Oxy Catalyst             DV101,  149D
    . C             Monolithic         Oxy Catalyst             OC-4,  OC-5
    D             Monolithic         Engelhard                PTX-5DF,  PTX-6DF
                                      3-224

-------
              TABLE 3-43.  ENGINES TESTED  (Marshall,  et  al.,  1978)
      „  ,                                                        Nominal Power
      Code                         Engine Type                       bhp

       1                Direct-injection, 4-stroke cycle,            50
                        air-cooled
       2                Indirect-injection, 4-stroke cycle,         100
                        water-cooled
             TABLE 3-44.  FUEL PROPERTIES  (Marshall,  et  al.,  1978)
          Specific gravity                                     0.845
          Gravity  (ฐAPI)                                        36>0
          Sulfur  (pet)                                          0>24
          FIA analysis,  pet:
             Aromatics                                             34
             Olefins                                                2
             Paraffins                                             64
          Cetane index                                           49.7
          Distillation,  ฐF:
              10 pet evaporated                                   42Q
              50 pet evaporated                                   490
              90 pet evaporated                                   530
        The exhaust gas was continuously monitored before and after each
catalyst system for determination of CO, carbon dioxide (C02), sulfur dioxide
(S02), nitric oxide (NO), nitrogen dioxide (N02), HC (total), and smoke
(opacity).  Batch samples were collected for subsequent determination of
sulfur trioxide (S03), aldehydes, HC character, particulate mass loading, and
particulate size.
                                     3-225

-------
         The  results  of  tests  with the four catalysts showed significant
 differences  in the oxidation  efficency of various catalytic reactors.   For a
 given catalyst design,  the  reduction in CO levels was fairly consistent for
 the  two  engines (Figures  3-60,  61).   At low power modes  (low exhaust
 temperature)  the catalysts  had  minimal effect  on CO emissions.   At  high power
 modes (high  exhaust  temperature)  the catalysts exhibited a major influence on
 CO levels—  from 60 to 90  percent reduction at full load.   The exhaust
 temperature at which 50 percent of the CO was  oxidized ranged from  about 350ฐF
 for  catalysts  A to greater, than 700ฐF for catalyst C.  Although there were
 large differences in oxidation  efficiency,  all of the  catalysts effected major
 reductions in  CO levels for those engine operating modes where  the  highest
 levels of CO were produced.   Peak and average  emission rates  of CO  and  HC are
 given in Table 3-45.  Note  that the  peak CO emission rate exceeded
 5 g/hr/rated hp  (the "acceptable" maximum emission rate  of  CO)  only in  those
 cases without  any exhaust treatment.   The value of 5 g CO/hr/rated  hp is
 significant because  at  this level the quantity of ventilation air necessary to
 dilute the exhaust C02  to its threshold  limit  value (TLV)  (0.5  percent)  is
 sufficient for dilution of  CO to its  TLV (50 ppm).
        The acceptable  maximum  emission  rate can  be computed  for any toxicant
 for which an acceptable TLV level is  specified.   Values  of  acceptable maximum
 emission rate  and TLV for various toxicants are given  in Table  3-46.  The
 emission rate of C02 was selected as  the  basis upon which the acceptable
maximum emission rates are calculated  because  (1)  C02 emission  rate is
 relatable to fuel rate or power output,  (2) C02 is  the only toxicant
necessarily produced from the complete combustion  of a hydrocarbon fuel, and
 (3) the quantity of C02 is the toxicant that defines the minimum ventilation
air rate required to dilute the exhaust to acceptable levels.
                                      3-226

-------
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-------
            TABLE 3-45.  EMISSION RATES OF  CO  AND HC,  g/hr/rated hp

                            (Marshall, et al.,  1978)
Exhaust Treatment System
Peak Rates
CO    HC
Average Rates
  CO      HC
                                           1  ————————•.—.——ซ.——ซ.._ซ-. _._ซซ,
No catalyst
Catalyst A
Catalyst B
Catalyst C
Catalyst D

No catalyst
Catalyst A
Catalyst B
Catalyst C
Catalyst D
18.7
1.5
1.5
2.6
2.2

5.7
. 2.6
3.5
4.4
2.8
1.5
0.8
0.8
0.9
0.9

4.1
2.9
2.9
3.8 7
3.4
3.4
0.5
0.6
1.0
0.7

2.6
0.3
1.1
2.4
1.1
1.0
0.3
0.4
0.5
0.5

1.5
0.3
0.8
1.3
0.9
                                      3-228

-------
                TABLE 3-46.  ACCEPTABLE MAXIMUM EMISSION RATES
                            (Marshall, et al.,  1978)
                                                Acceptable Maximum
                                                 Emission Rate'1'.
         Constituent             TLV, ppm         mg/hr/Rated hp
CO
NO
N02
HCHO
'. Acrolein
so2
S03 (as H2S04
50
25
5
2
0.1
5
.) 0.25
5,000
2,500
800
200
20
1,100
80
         ^ 'Acceptable maximum emission rate, mg/hp/hr = 3.5 x TLV x
            molecular weight.
            Based on: fuel = CH2
                      brake specific fuel consumption =0.5 Ib/hp/hr
        The catalysts effected a 10- to 50-pecent reduction in peak emission
rates of HC.  The reduced efficiency (in comparison to oxidation of CO) is a
consequence of the rather high emissions of HC at light load conditions (and
correspondingly low exhaust temperatures).  The results of a detailed
examination of the hydrocarbon by gas liquid chromatography indicate that the
catalysts tend to preferentially oxidize the unsaturated hydrocarbons.  The
remaining high-molecular-weight hydrocarbons are, as a result, predominately
saturated.
        The effect of the catalysts on exhaust odor intensity as determined by
a panel of odor judges was similar to the effects on CO and HC; that is, at
light load (low exhaust temperature) the reduction in odor intensity was
significantly less than at heavy load conditions.  The effects of load and
catatyst on odor intensity are shown in Figure 3-62.  Peak and average odor
intensity data are given in Table 3-47.  The effect on peak odor intensity was
much less pronounced for Engine 2, primarily owing to the rather high odor
intensity at light loads where the catalyst had little effect.

            .                          3-229

-------
       Engine I
                           Engine 2
                                      • B oD
                                      o Untreated
                                        exhaust
   	I
30     40      0       20
        POWER ,bhp
                                                                 80
Figure 3-62.  Effects of load and catalyst on odor intensity.
             (Marshall, et al.,  1978).
                         3-230

-------
          TABLE 3-47.   EXHAUST ODOR INTENSITY (Marshall,  et al.,  1978)
         Exhaust  Treatment  System
                                        Odor  Intensity
                                        Peak   Average
(1)
(2)

No catalyst
Catalyst A
Catalyst B
Catalyst C
Catalyst D
No catalyst
Catalyst A
Catalyst B
Catalyst C
Catalyst D

9.8
3.9
5.0
4.7
4.9
-—ซ.—— PAT/"1 TMT? O
8.9
5.7
8.9
8.4
7.5

7.0
2.2
2.9
3.1
3.5
6.1
2.1
4.1
4.8
3.9
        (1)
        (2)
Dilution rate = 400/1.
Diesel intensity (DI) units.
        None of the catalytic reactors had any significant effect on emissions
of NO, N02, or particulates.  These findings with respect to N02 should not be
taken as definitive, however, because there is some question as to the
validity of the results obtained by the sampling and analytical technique
employed in this investigation.  An ambient temperature chemiluminescent
analyzer was used to determine exhaust levels of NO and N02.  To prevent
condensation of water in the detector, the exhaust sample was directed through
a water knock-out trap.  Results of other work indicate that this procedure
might yield erroneous information as to absolute levels of N02.  This
analytical technique does, however, appear to yield valid information
concerning relative levels of N02; that is, N02 levels as determined in a
system with minimum perturbation of the sample — no knockout trap — are
roughly linear with the levels determined with the system used in these
experiments.  Therefore, the conclusion that the catalysts had no major effect
on N02 levels appears to be reasonable
                                       3-231

-------
         The particulate emission rate was measured directly (by a filtration-
 gravimetric technique) and indirectly (plume opacity).  The results obtained
 by both techniques indicated that the catalysts generally had little or no
 influence on particulate emission rate.   The physical characteristics of the
 particulates (size,  size range,  and distribution) were also unaffected by the
 various catalytic reactors.   The particulate matter,  which had the appearance
 of carbon black,  had a size  median diameter (number basis) of about 0.04 to
 0.8 urn and a mass median diameter of 0.128 urn.   The particulate size was
 independent of  engine,  fuel,  speed,  and  load.
         The aldehyde emission levels were determined  by three analytical
 methods:   total aldehydes by dinitrophenyl hydrazone,  formaldehyde by
 chromotropic acid, and  acrolein  by hexyl resorcinol.   The results showed that
 total  aldehyde  (RCHO)  levels  were typically highest at light  load conditions
 and decreased with increasing load.   The formaldehyde  component accounted for
 20 to  nearly 100  percent  of  the  total.   Engine  operating conditions influenced
 acrolein  level  in the  same manner as total aldehydes —that  is,  levels  of
 acrolein  generally decreased  with increasing load.
        The  effects  of  the various  catalysts on emissions of  aldehydes were
 similar to effects on CO  and  HC  — catalyst  A showed highest  overall
 efficiency,  and catalyst  C showed the lowest.   The  results  are  summarized in
 Table  3-48.   Because peak emission  rates  of  aldehydes  occurred  at  light  load
 (low exhaust  temperature), the catalysts  had little influence,  except for one
 case.  The peak aldehyde  emission rate was reduced  to  below the acceptable
maximum (200 mg/hr/rated  hp); however, in  only  one case  (catalyst A, engine  1)
was the peak acrolein emission rate  below 20 mg/hr/rated  hp.  Average emission
rates of acroelin were reduced substantially.   The average  ambient  level  of
acrolein would be well below  its  TLV with a ventilation rate of 50  cfm/rated
hp.  This ventilation rate is approximately equal to that necessary to limit
ambient G02 level to its TLV.
                                      3-232

-------
                TABLE 3-48.  ALDEHYDE EMISSIONS, mg/hr/rated hp
                                (Marshall,  1978)
                                 Peak Rates               Average Rates
Exhaust Treatment System     RCHO   HCHOT  Acrolein    RCHO   HCHOT  Acrolein

No catalyst
Catalyst A
Catalyst B
Catalyst C
Catalyst D
No catalyst
Catalyst A
Catalyst B
Catalyst C
Catalyst D .

106
86
93
—
99
243
134
87
225
103
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32
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16
21
24
44
124
34
42
56
45

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39
40
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111
27
47
103
40

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7
15
13
14
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9
14
57
28

15
6
8
10
7
32
3
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10
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* RCHO = Total Aldehydes
t HCHO = Formaldehyde
        For all toxicants discussed thus far, the influence of the catalytic
reactors was either beneficial or not significant.  Emissions of one toxic
material, however, are adversely influenced by catalysts -— SOo or sulfric
acid (^SO^).  Diesel fuel contains significant levels of sulfur, which is
oxidized to S02 in the combustion process.  Although S02 is a toxicant,
emissions can be easily controlled to tolerable levels by limiting the level
of sulfur in the fuel.  Even with a moderately low sulfur fuel (about 0.2
percent), however, the catalyst tend to cause oxidation of the S02 to SOo.
Unfortunately, the catalysts that display the greatest efficiency for
oxidation of CO, aldehydes, and HC also tend to produce the greatest SOo
conversion to SOo,.  Moreover, the catalysts tend to "store" the sulfur during
light-load (low temperature) operating conditions and then release much as SOo,
at heavy loads.  This is evidenced by data indicating that greater quantities
of sulfur are emitted as S02 and S03 than are present in the fuel that goes
                                       3-233

-------
into the converter at a specific time.  The results of the S03 determinations
are given in Table 3-49.  The acceptable maximum value for the specific
emission rate of H2SO^ is 80 mg/hr/rated hp.  Note that for catalyst A,
ventilation air flow rate of 100 cfm/rated hp would not be sufficient to
dilute the I^SO^ to less than 0.25 ppm —even for the "average" emission
rates.  Thus, it would appear that the use of catalytic reactors for emissions
reduction is not toally satisfactory when using high-sulfur fuel.  Additional
exhaust treatment would be necessary to remove sulfates produced by the
catalysts.  Although this probably could be achieved with a water scrubber
system installed downstream of the catalyst, this aspect of emissions control
was not examined in this study.

              TABLE  3-49.   SULFATE^a) EMISSIONS,  mg/hr/rated  hp
                           (Marshall, et al., 1978)
Exhaust Treatment System

No catalyst
Catalyst A
Catalyst B
Catalyst C
Catalyst D
No catalyst
Catalyst A
Catalyst B
Catalyst C
Catalyst D
Peak Rates
— FWTWfi1 1 — _____
102
1,044
473
220
283
47
1,011
702
114
354
Average Rates

22
182
41
53
63
14
315
139
30
96
^'Almost entirely H2S04
                                      3-234

-------
                                  SECTION 4.0
                        PSD PERMIT APPLICATION ANALYSIS

        A shale oil recovery plant encompasses a large number of widely
varying types of unit operations ranging from solids crushing and handling
associated with typical mining operations to gas and liquid processing and
clean-up systems associated with refineries.  A significant source of data for
determining the environmental impact of each type of process are the
applications for Prevention of Significant Deterioration (PSD) permits filed
by the various developers.  During the investigation into the various emission
control processes for a number of the proposed facilities in the West, the
data submitted in these PSD applications were entered into a computerized data
base.
        The purpose of this task was to determine and evaluate average values
and trends for the emission rates of the criteria pollutants for each type of
process.  This task was complicated considerably by the fact that in each
permit, application a different format for presenting the essential emissions
data was used.  The data from each permit application were entered on a
standard format so that sort routines on the various performance parameters
and unit processes could be made.  These parameters were evaluated for
consistency and trends.  For example, the N0_. emissions from vehicles for
                                            *V
below ground mining should be similar for each of the facilities using similar
mining techniques and this was found to be true.  However, in other cases,
such as carbon monoxide emissions from combustion, some inconsistencies in the
reported data were obvious when the values were compared.
        The results of these analyses are shown in Tables C-l through C-4 in
Appendix C - Summary of PSD Permit Application and Unit Process Analysis.  A
summary- of the specific control techniques presented in the PSD Applications
used for each unit process is listed in Table 4-1.  To permit proper sorting
for evaluation, each process was categorized by two levels — primary and
secondary.  The primary categories are defined as:
        1.  below ground mining

                                      4-1

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        2.  above ground mining
        3.  retorting and gas utilization upgrading, and
        4.  miscellaneous
        There are 54 secondary categories and these are noted  for  each  process
listed in Table 4-1.  These categories are described in Appendix C.
        The following discussion evaluates the emission rates  for  the criteria
pollutants for each unit process reported by the seven projects included  in
this analysis.  Details of the individual processes are presented  in
Section 5.0, Process Analysis.
        It is important for the reader to note that this analysis  is based on
data presented in the PSD permit applications and is not necessarily
representative of either the final permitted emission rates  or the actual
operating emission rates.  In some cases, the final permitted  emission  rates
were obtained and a comparison made between the permit application and  the
final permit.  This analysis is presented at the end of Section 4.0.

4.1     PARTICULATE EMISSIONS
        The PSD application data for particulate emissions from each of the
seven developers are presented in Table 4-2.  The control of particulate
emissions from oil shale mining operations is similar to other mining
processes.  The reader is referred to Section 3 for a detailed analysis of
these emissions sources, emission factors and control techniques.  The
following discussion will present data analysis based on the PSD
Applications.  This information is presented to show the degree of variability
and estimated emission ranges for particulates and to emphasize particular
processes that can have a significant affect on the overall  emission rate.
                                      4-22

-------
                 TABLE 4-2.   CONTROLLED  PARTICULATE EMISSIONS*
                               kg/1000 m3  of  Oil
Mining & Material
Handling

Project
Cathedral Bluffs
Clear Creek
Cottonwood
Paraho
Syntana
Union B
White River
Average

Below
89
49
48
64
49
70
42
59

Above
190
135
104
217
98
55
56
122

Total
280
184
152
281
147
125
98
181
Process
Retort &
Upgrade
53
660
8
72
60
14
115
140

Misc.
1
11 ,
13

30
42

20

Total
54
671
21
72
90
56
115
160

Facility
330
855
173
353
237
181
213
341
*Based on  PSD  Permit  Applications

4.1.1   Mining - Below Ground  (Primary Category 1)

        Below  ground  mining  emissions  varied from 42 kg/1000 m3 of oil to 89
kg/1000 m3 with an average value  of  59 kg/1000 m3 of oil.  These emissions are

the result of  the unit operations listed in Table 4-3.


          TABLE 4-3.   CONTROLLED BELOW GROUND PARTICULATE EMISSIONS1"1"

Drilling
Blasting
Conveying and transfer
Primary & secondary -crushing
Vehicle & engine emissions
Total
Secondary
Category*
1
2
3,4,5
6,7
8
Average
kg/ 1000 m3
Of Oil
8
14
6
14
18
60
Avg. % of Total
Facility PM
Emissions
5
" 7 .
5
8
10 ,
35
 'Based on PSD Permit Applications
* See Appendix C for category definition
                                      4-23

-------
 A.      Sources—

         The major sources for below ground mining emissions are blasting,
 crushing and vehicles/engines which account for 14 - 18 kg/1000 m3 of oil each
 or 7 - 10 % of the total facility particulate emissions.  Less significant
 sources are drilling and transfer operations which account for 6-8 kg/1000 m3
 of oil and approximately 5 percent each of the total facility particulate
 emissions.
 B.      Controls—                               -

         Emission factors, control techniques and control percentages are shown
 in Table 4-1.   Typically, water sprays, wet suppression and baffled settling
 are used to control the below ground emissions from blasting and drilling.
 There are considerable differences in the assumed control percentages ranging
 from 50 to 94  percent for the baffled settling.   The primary crushing and
 transfer operations mostly used baghouses for control with 99+ percent control
 efficiency.  Other options used are a wetted fan scrubber (99 percent) and wet
 suppression  (80 percent).  The emission factors  vary from 0.02 to 1.5
 Ib/ton.   The particulate emission from below-ground  vehicles and engines are
 based on the emission factor of 22 lb/1000 gal of  diesel fuel.
 '4.1.2   Above-Ground Mining Emissions  (Primary Category 2)
         Above-ground particulate mining emissions varied from 55 kg/1000 m3  of
 oil  to  217 kg/1000  m  of oil with an average  value of  122 kg/1000 m3  of  oil.
 The  above-ground mining  emission rates  and the unit  processes  are shown  in
 Table 4-4.
 A.       Sources—

        The  major source of  above-ground  particulate emissions is  the  handling
 and disposal of spent  shale.  These unit  processes (categories 30  - 36)
 account  for  22 percent of  the total facility particulate emissions and amount
 to 54 kg/1000 m3 of oil.   The handling  of  the  raw shale  (categories 13 - 25)
 account for  18 percent of  the total facility particulate emissions and amount
 to 50 kg/m   of oil.  The  removal and hauling of surface soils account  for 7
percent of the toal facility particulate emissions and" amount to 14 kg/1000 m3
of oil.
                                      4-24

-------
       TABLE 4-4.  CONTROLLED ABOVE-GROUND MINING. AND MATERIAL HANDLING
                            PARTICULATE EMISSIONS
                                                STT

Unit Process
Surface Soils Removal,
Hauling & wind
Secondary & tertiary crushing
Conveying & screening
Storage
Fines storage
Spent shale matls. handling
Conveying, transfer, stacking,
haul, storage,
Total

Secondary
Category* . .
9,10,11,12
13, 14 .
15, 16
17-25
26,27,28,29
30-36


Average
g/1000 m3
of. Oil .
14.--
20
20
10
7
54
125
-• ' •
Percent of Total
Facility PM
. Emissions '...
7
9
9
4
3
22
44
* See Appendix C for category definition
''Based on PSD Permit Applications
4.1.3   Retort Operations and Retort Gas Combustion
        Particulate. emissions from the retort operations and gas combustion
varied from 8 kg/1000 m3 of oil to 660 kg/1000 m3 of oil with an average value
                O    -        -      •
of 140 kg/1000 nr of oil.  The major sources and emission rates are presented
in Table 4-5.

     TABLE 4-5.  CONTROLLED PARTICULATE EMISSIONS FROM RETORT OPERATION**

Unit Process
Steam generation
Retort heating
Total


Secondary
Category*,
37
40



Average
kg/ 1000 m3 of
20
25 ,-. 120
	 , , 45 - 140


Percent of
Total Facility
Oil PM Emissions
7
.10 -.25
17 - 3.2

* See Appendix C for category definitions
''Based on PSD Permit Applications
                                       4-25

-------
A.      Sources—
        The major  sources  for  particulate  emissions  from the  retort  are  from
the steam generation  (Category 37)  from burning  the  retort  off-gas and fuel
combustion to provide heat for the  retort  (Category  40).  The steam  generation
from burning the off  gas produces 20 kg/1000 m3  of oil of particulates and
averages eight percent of  the  total facility particulate emissions.
        The retort heating produces 20  - 120 kg/1000 m3  of  oil and averages  25
percent of the total  facility  particulate  emissions.  The retort heating
values are high due to the inclusion of  the Clear Creek  Fluidized bed spent
shale combustor which produces an extremely high particulate  emission of 640
         O
kg/1000 mj of oil.  The average particulate emission for  the  facilities  not
using the fluidized bed spent  shale combustor is 25  kg/1000 m3 oil,  or about
ten percent of the total facility particulate emissions.
B.      Controls—
        The controls  used  depended  on the  fuel used.  When  burning gaseous
fuel an emission factor of 0.015 Ib/MMBtu  and no controls were used.  When the
combustion processes  results in contact  between  the  flue  gas  and a solid (i.e.
burning spent shale and/or fines or a Tosco retort requiring  a ball heater)  a
baghouse was used with an  emission  factor  of 0.03 Ib/MMBtu.      :
4.1.4   Upgrading and' Miscellaneous
        Particulate emissions  from upgrading and miscellaneous above-ground
sources varied from 20 kg/1000 m3 of oil to 62 kg/1000 m3 of  oil with an
                             O
average value of 40 kg/1000 nr of oil.  The major sources are shown
in Table 4-6.
A.      Sources—
        The upgrading process produces 20 kg/1000 m3 of particulate and
averages seven percent of  the total facility particulate emissions.  The major
sources for above ground miscellaneous emissions are vehicles/engines and
fugitive dust which both produce 10 kg/1000 m3 of oil and an average of five
percent of the total facility emissions.
                                     4-26

-------
         TABLE 4-6.  CONTROLLED PARTICULATE EMISSIONS FROM UPGRADE AND

Unit Process
Upgrading heaters
Vehicles /engines
Fugitive dust
Total


Secondary
Category*
43
53
54



Average
kg/1000 m3 of Oil
20
10
10
40 -

.".• .•.'.•.• -."••.--.--. ----.-_-._
Percent of Total
Facility PM
. . Emissions
7
5
5
17

 ' Based on PSD Permit Applications
* See Appendix A for category definitions

B.      Controls—

        Controls used are primarily wet suppression to control fugitive dust.


4.2     TOTAL FACILITY GASEOUS EMISSIONS

        Total gaseous emission summaries for the criteria pollutants carbon

monoxide, hydrocarbons, nitrogen oxides and sulfur oxides are presented in

Table 4-7.  The following section discusses the variations for the facility
totals.  A discussion on the individual process emission rates follows in
Section 4.3.
       TABLE 4-7.   TOTAL FACILITY CONTROLLED GASEOUS EMISSIONS  SUMMARY^


Cathedral Bluffs
Clear Creek (fluid bed)
Cottonwood (fluid bed)
Paraho
Syntana
Union
White River
Avg.
Avg./flb ,


CO
250
11300
250
260
230
500
210
290
5800 .

. . . ....
HC
90
230
110
50
150
250
210
160


..-.--
NOX
3200
5800
4300
1700
1200
1200
1100
1700
5000 .


sox
710
550
800
650
290*
450
160'
510


TT
  Based on PSD Permit Applications
* and t Corrected values - refer to Section 4.4
                                        4-27

-------
 A.       Carbon Monoxide—
         The carbon monoxide emissions for facilities not using a fluidized bed
 combustor are fairly consistent ranging from 200 to 500 kg/1000 m3 of oil with
 an  average value of 290 kg/1000 m3 of oil.  The two facilities using the
 fluidized bed differ widely on their estimates for carbon monoxide
 emissions.   This variation is due to the different applications of the
 fluidized bed.   The Clear Creek facility uses the fluidized bed to burn spent
 shale.   It is critical to control closely the temperature in the combustor to
 limit the reactions of dolomite and calcite and the formation of both thermal
 and fuel NOX emissions.   The low combustion temperature and the low carbon
 concentration in the char result in the high CO emissions.
         The Cottonwood facility uses the fluidized bed to burn fines, spent
 char and retort  gas.   The presence of the retort gas and the raw shale with
 its relatively high carbon content result in improved control of the
 combustion  conditions  resulting in lower CO emissions.   ,
 B.       Hydrocarbons—•
         The hydrocarbon  emissions are also fairly consistent ranging from 30
 to  250 kg/1000 m3  of oil  with an average value of 160 kg/1000 m3 of oil.   The
 two low  values,  50 and 90 kg/1000 m3 of oil for Cathedral Bluffs and
 Paraho-Ute  are due to  their  low estimates for storage and above ground
 vehicles and engines.                                       ,
 C.       Nitrogen Oxides  (NOX)—
         Nitrogen oxide emissions estimates for the five facilities  without a
 fluidized bed shale combustor range  from 1100 to 3200 kg/1000 m3 of oil with
 an  average  value of  1700  kg/1000 m3  of  oil.   The highest value,
              o
 3200 kg/1000 mj of oil for Cathedral Bluffs,  is  due  to the  higher temperatures
 and higher  gas flow rate  typical of  an  in-situ retort.   Nitrogen oxide
 emissions for the  two  facilities  using  a  fluidized bed shale  combustor were
 estimated in the range from  4300 to  5800  kg/1000 m3  of oil  with an  average
value of 5000 kg/1000 m3  of  oil.   These high  emissions  are  due  to the
 combustion  of the  nitrogen in the  shale.
                                      4-28

-------
        It should be noted that these estimates from the PSD permit applica-
tion do not include provision for fuel nitrogen present after a water wash
system has been used to remove ammonia.  The fuel NOX emission rate is
determined by the efficiency of ammonia removal, presence of other nitrogen
compounds or (if fluidized bed) nitrogen content of shale fines or carbon-
aceous spent shale.  The effect of residual ammonia and organic nitrogen on
the NO  emission rate was estimated based on the analysis described in Section
5.2.2-C and the increased N0_ emissions are shown in Table 4-8*
                            •"•

           TABLE 4-8.  INCREASE IN N0_ EMISSIONS FROM FUEL NITROGEN
                               kg/1000 m3 of  Oil

Project

Clear Creek
Cathedral Bluff -
Parahute

••••-•
Type of Retort
Heating

Solids recycle
In-situ w/ union
above ground retort
Direct combustion


Thermal
x
5800
3200
... 1700...


Fuel
x
500
4500
.2700 -...


Percent
Increase

9
140
160 . .

        The effect of the fuel N0_ varies, with the type of process and the
                                 A
retort gas production.  In the case of the solids recycle process with low
retort gas production rate of high Btu gas, the fuel related NOX from
incomplete ammonia removal and organic nitrogen compounds only increase the
NO., emissions by nine percent.  The direct combustion process with higher gas
  A.
                 - :         .      " " -       •              -           o
production of low Btu gas results in an increase of 2700 kg/1000 m  of oil in
N0_ emissions for a 160 percent increase  over the expected value.  In the case
  X,   '
of the in-situ process, the higher retort temperatures and gas production
                                       o
result in an increase of 4500 kg/1000 m   of oil.  This value is based on the
relative oil production rates for the in-situ and above ground (Union) process.
        The reader also should note that  these estimates are based on a number
of assumptions including retort gas flow  rate, nitrogen partitioning to the
retort gas, organic nitrogen content of the retort gas and expected ammonia
removal rates.  Consequently, these values are rough estimates and are
presented primarily to illustrate the potential impact of the fuel related
nitrogen content of the retort gas on the facility nitrogen oxide emissions.
                                       4-29

-------
D.       Sulfur Oxides  (SOX)—
         Sulfur oxide emissions  range from 160 kg/1000 m3 of oil to 800
kg/1000  m  of oil with an  average  value  of 510 kg/1000 m3 of oil.   The two
facilities with  the lowest SOX  emissions are  White River (160 kg/1000 m3 of
oil) and Syntana (290  kg/1000 m3 of  oil),  both of  which are using  the circular
grate Superior above ground  retort.
   1.    Organic:  sulfur, —  In Section 2.2.1.A, the  concentration of organic
sulfur species in the  retort gas was described.  The  presence of these organic
sulfur species at higher concentrations  than  assumed  results in a  considerable
increase in sulfur oxide emissions.   In  all cases,  the PSD applications assume
no significant organic sulfur content in the  retort gas.   The effect  of
various  organic  sulfur levels on the facility SOX  emissions are shown in
Table 4-9.
             TABLE 4-9.  EFFECT OF ORGANIC SULFUR IN RETORT GAS ON
                            SULFUR OXIDE EMISSIONS
           Organic Sulfur          Potential Increase in SO  Emissions
            •Percent '             From Orgahic\'Sulfurt Tcg/lOOO m3 of Ol'I
               15                                7600
               10                                5200
                5                                2800         =    I
                1                  	        .   940 .   ...'.'."
        These levels of increased SOX emissions are substantial and greater
than the total estimated facility emissions even at the one percent level for
organic sulfur.  Processes that utilize a flue gas desulfurization after
combustion of the retort gas avoid this problem by burning all of the sulfur
gases to SOX prior to clean-up.
        As discussed above for the organic nitrogen effect •. on NO  emissions,
this analysis for the effect of organic sulfur levels on SOX emissions is
based on a number of assumptions including sulfur partitioning to the gas,
organic sulfur content and the limited effectiveness of an H2S cleanup system
                                     4-30

-------
on organic sulfur compounds.  The estimates are made  to  indicate  the  nature of

the problem rather than to indicate that these would  be  expected  values.


4.3     EMISSION SOURCE BREAKDOWN

4.3.1   Carbon Monoxide

        The carbon monoxide emissions for  the four  major process  categories

are shown in Table 4—10.
              TABLE 4-10.   CONTROLLED CARBON MONOXIDE EMISSIONS
                               kg/1000 m3 of Oil
                                                               tt
                             Mining & Material
                                  Handling
Processing
Below Above Total Retort
Primary
Category No.
Project
Cathedral Bluffs
Clear Creek (fluid bed)
Cottonwood (fluid bed)
Paraho
Syntana
Union B
White River
Average

1 2

150
150 8
130
180
155
120 8
120
140 8

3

60
11100
100
60
30
210
60
90
Upgrade

4

40
0
30
20
50
160
40
60
Total



250
11300
250
260
230
500
220
300
  Based on PSD Permit Applications


        The below-ground mining emissions  are  in  relatively close agreement

ranging from 120 to 180 kg/1000 m3 of oil  with an average  value of 140
         .Q     -..-=.
kg/1000 m  of oil.  The small  above-ground mining emissions are due to

vehicles involved in soil and  spent shale  removal and  hauling.


        The carbon monoxide  emissions from the retorting processes not using
                             •                                           ^
the fluidized bed spent shale  combustor vary from a low of 30 kg/1000 m  of
                                  O
oil to a maximum of 210 kg/1000 m of oil  with an average  value of 90
         *3          '               '     -       .             .
kg/1000 m  of oil.  As discussed  previously, the  wide  variation in the two
                                       4-31

-------
facilities using fluidized bed  combustion  is  due  to  the  different
applications.
        The upgrading process carbon monoxide emissions  vary from 20 to 160
kg/I000 m3 of oil.  The high value  for  the Union  facility,  160  kg/1000 m3 of
oil, is due to a higher value for above-ground vehicles  (65 kg/1000 m3 of oil)
than the other projects.  The following discussion presents data  on the
specific sources and controls for carbon monoxide emissions.
A.      Below-Ground Mining (Category 1)—
        Below-ground emissions  of carbon monoxide result from blasting and
below ground vehicles.  The data presented in the Specific  Process  Sort,
Table C-4, Appendix C were used to  determine  the  average emission rates for
each specific process.  The specific process  emission  rates of  carbon monoxide
are shown in Table 4-11.

            TABLE  4-11.   CONTROLLED CARBON MONOXIDE  EMISSIONS FOR
                             BELOW GROUND  MINING™
Process
Blasting
Vehicles
Total
Secondary
Category No.
1
8
Average
kg/ 1000 m3 of oil
70
80
150
% of Total
Carbon Monoxide
Facility Emissions
25
30
55
''Based on PSD permit applications

   1.   Sources— The primary sources are blasting (70 kg/1000 m3 of oil) and
                                   o
below ground vehicles (80 kg/1000 m  of oil).  These two sources account for
55 percent of the total facility carbon monoxide emissions (excluding the
fluidized bed facility with its large CO emission rate).

   2.   Controls — Vehicles account for 25 percent of the total reported
facility emissions for carbon monoxide.  Consequently, a substantial
improvement in vehicle controls (e.g. catalytic mufflers) could reduce these
                                      4-32

-------
estimated emission  rates.   Blasting emissions  have all been estimated at the
minimum number of blasts;  consequently,  no additional  controls are available.
B.      Above Ground Mining (Category 2)—
        Carbon monoxide emissions  from above ground mining operations are less
                 o
than  10 kg/1000 nr  of oil  and  are  not significant,  amounting to less than
3 percent.
C.      Retort & Gas Utilization (Category 3)—
        Carbon monoxide emissions  from retort  and  gas  utilization are shown in
Table 4-12.
            TABLE 4-12.  CONTROLLED CARBON MONOXIDE EMISSIONS  FROM
                          RETORT AND GAS COMBUSTION*'
                                                    Average           Percent
                                              _kg/1000 m3 of _ QiIl_^_V of Total
Standard combustion or
  fluidized bed with retort gas                          90               35
Fluidized bed for spent shale
  combustion-recycle solids	   ; 	    ...'..,..... 11000            .98

T'Based on PSD Permit Applications
        The carbon monoxide emissions from the retort  and gas combustion are
due to incomplete oxidation and are directly dependent on  the type of
combustion and amount of retort gas produced.  For processes that do not use a
fluidized-bed combustor, the CO'emissions can be expected to be approximately
            Q       .
90 kg/1000 m  of oil which represent 35 percent of the total facility carbon
monoxide emissions.
        The projects using fluidized-bed combustion vary considerably in their
estimated carbon monoxide emissions.  The Cottonwood facility uses a
fluidized-bed to burn fines and spent shale along with the retort off-gas.
The estimated CO emissions for the fluidized-bed combustor are 96 kg/1000 m3
of oil.  The Clear Creek facility uses a fluidized-bed to burn spent shale and
provide heat for the retort as recycled solids.  The estimated CO emission
rate is 11000 kg/1000 m3 of oil.  The additional high value fuel (retort gas

                                      4-33

-------
and fines) burned in the Cottonwood fluidized-bed results in more complete
combustion and hence, the lower CO emission rates.
D.      Upgrade (Category 4)—                                   :
        The carbon monoxide emissions from upgrading operations are shown in
Table 4-13.

      TABLE 4-13.  CARBON MONOXIDE EMISSIONS FROM UPGRADING OPERATIONS1't

Process
Heaters,
Vehicles



Secondary
Category No.
boilers, etc. 43
53
Total . :


Emission Rate
(kg/1000 m3 of Oil)
40
25,
... ... 65 . ..... .


Percent of Tot
CO Emissions
14
	 , 7
.'... . -1..21 ...

—
:al



''Based on PSD Permit Applications
   1.   Sources — The major sources for carbon monoxide emissions from
upgrading processes are the various combustors for heaters, boilers, hydrogen
reformers, etc. (40 kg/1000 m3 of oil) and in plant vehicles (25 kg/1000 m3 of
oil).
   2.   Controls — Promotion of complete combustion in either the furnace
heaters or vehicles will reduce carbon monoxide emissions.
4.3.2   Hydrocarbons
        Hydrocarbon emission rates are shown in Table 4-14.
                                       4-34

-------
                TABLE 4-14.
CONTROLLED HYDROCARBON EMISSIONS
  kg/IQOO m3 of Oil
                                                             tt

Mining &
Material


Handling . Process

Primary
Category No.
Project
Cathedral Bluffs
Clear Creek
Cottonwood
Paraho
Syntana
Union B
White River
Avg.
Below

1

40
20
20
30
20
20
30
25
Above Retort

2 3
i
50
0
3
10
60
10
70
35
Upgrade

4

8
210
90
10
70
220
120
100
Total



100
230
110
50
150
250
220
160
''Based on PSD Permit Applications
        The below-ground mining hydrocarbon emissions vary from  20 to 40
kg/1000 m3 of oil with an average value of 25 kg/1000 m3 of oil.  The above-
ground mining hydrocarbon emissions were not presented.  The above-ground
vehicles do emit some hydrocarbons, however.   ;
        Hydrocarbon emissions from retort and gas utilization varied from  0 to
70 kg/1000 m3 of oil with an average value of 35 kg/1000 m3 of oil.  The
facilities using a Tosco II retort, Syntana and White River, both have
                     ;                             . ,          o
relative high hydrocarbon emission rates, 60 arid 70 kg/1000 m  of oil, due to
the direct contact preheating of the raw shale.  The Cathedral Bluffs facility
has a high value due to the combustion of large quantities of low heating
value retort gas.  The facilities using retorts other than the Tosco II or in-
situ have hydrocarbon emissions from retort and gas utilization  of less than
10 kg/1000 m3 of oil.
        Hydrocarbon emissions from the upgrading process varied  from 8 to  220
kg/1000 m3 with an average value of 160 kg/1000 m3.
A.      Below-Ground Mining- (Category #1)—
        Below ground mining hydrocarbon emissions sources are shown in
Table 4-15.                               .
                                      4-35

-------
   TABLE 4-15.  CONTROLLED HYDROCARBON EMISSIONS FROM BELOW  GROUND MINING^1"
                       Secondary         Emission Rate       Percent  of  Total
Process           .    Category No. .    (kg/1000 m3 .of .oil)   .. HC.Emissions   ..
Vehicles                   .8,.-.        ..     20  . .	     . _    ..21
''Based on PSD Permit Applications
   1.   Sources^— The major source for hydrocarbon emissions from below-
ground mining are vehicles and engines.  The emission rate  is 20 kg/1000 m3 of
oil and amounts to approximately 21 percent of the total facility  hydrocarbon
emissions.
   2.   Controls^— Additional controls on the vehicles (e.g. catalytic
mufflers) could reduce these hydrocarbon emision rates.
B.      Above Ground Mining -(Category #2)—
        No significant hydrocarbon emissions result from the above-ground
mining operations.  The EPA's AP-42 emission factor for hydrocarbons from 1C
engines is approximately one hundredth of the CO emissions  from that source
type.
C.      Retort and Gas Combustion (Category #3)—
        The hydrocarbon emission rates for retort and gas combustion are shown
in Table 4-16.

TABLE  4-16.   CONTROLLED HYDROCARBON EMISSION FROM RETORT AND GAS  COMBUSTION1^
Process
Gas combustion
Retort heating
Not Tosco II
Tosco II 	

Secondary
Category No.
37

40
.40 	 ...

Emission Rate
(kg/ 1.000 m3 of oil) .
16

4
. 	 .50 	

Percent5 of Total
HC Emissions :
10

3
30

''Based on PSD Permit Applications                     .             ,  ,  ,
   1.   Sources— The major sources for hydrocarbon emission from retort and
gas combustion are the retort gas used for power generation and to provide

                                     4-36        .  ' .

-------
heat to the retort.  The gas combustion for power generation produces 16
         o
kg/1000 m  of oil amounting to 10 percent of the total facility hydrocarbon
emissions.  The hydrocarbon emissions from combustion to provide heat to the
retort is dependent on the type of retort.  Retort processes other than the
Tosco II process produce relatively low amounts (4 kg/1000 m3 of oil ) of
hydrocarbon emissions.  The Tosco II retort has two direct contact heating
processes —an "elutriator" to heat the ceramic balls and raw shale
preheater.  Fuel gas is burned and the hot combustion gases are mixed directly
with the recycled ceramic balls to provide the heat for retorting and raw
shale for preheat.  An incinerator is provided for control of the hydrocarbon
emissions; however, the HC emissions for this process are still quite high at
60 - 70 kg/1000 m3 of oil.
   2.   Controls— Controls for the combustion processes have been included
in the plant design, primarily by promoting complete combustion.  The controls
for the Tosco II process include an incinerator on the raw shale preheat
system.  Additional controls would be ineffective.
D.      Upgrading (Category #4)—
        The hydrocarbon emission rates for upgrading operations are shown in
Table 4-17.

  TABLE 4-17.   CONTROLLED HYDROCARBON EMISSIONS FROM UPGRADING  OPERATIONS1^

Process
Heaters
Fugitive
Storage
Vehicles
Total


Secondary
Category No.
43
44
46
53



Emission Rate
(kg/ 1000 m3 of Oil)
6
100
40
4
. 150


Percent of Total
HC emissions
3
50
2'0
2
.,75

        on PSD Permit Applications                                    ,
   1*   Sources^ — The major sources for hydrocarbon emission from upgrading
are heaters, fugitive emissions, storage and vehicles.  These emissions total
75 percent of the total facility hydrocarbon emission with the major

                                      4-37  '  .       •'            '•

-------
contributors being the fugitive emissions (50 percent) and storage
(20 percent).
   2.   Controls— No additional controls are available to reduce these
emissions.               „
4.3.3   Nitrogen Oxides
        The nitrogen oxide emission rates are shown in Table 4-18.
              TABLE 4-18.  CONTROLLED NITROGEN OXIDE EMISSIONS
                              (kg/1000 m3 of Oil)
                                                              tt

Mining & Material
Handling " ... procegg 	 --
Primary
Category # .
Cathedral Bluffs
Clear Creek (fluid bed)
Cottonwood (fluid bed)
Paraho
Syntana
Union B
White River
Average (no fuid bed)
(with fluid bed)
BeTow
1
500
140
270
470
300
230
340
320

Above Retort
... . .2 	 ...3. .

1400
30 5600
4000
930
400
20 570
460
25 750
4800
Upgrade
... 4

1300
10
10
300
500
350
260
390


Tofal

3200
5800
4300
1700
1200
1200
1100
1700
5500
''Based on PSD Permit Applications
                                                                    o
        Below ground mining emissions vary from 140 to 500 kg/1000 m  of oil
                                      o
with an average value of 320 kg/1000 m  of oil.  Above-ground N0_ emissions
                                                                •*V
(primarily from vehicles) are minimal and were reported by only two
facilities.
        Retort and gas combustion NOX emissions vary from 400 to 5600 kg/1000
 o
m  of oil.  The large variation is due to the difference in the processes.
The facilities that use the fluidized bed combustion of the spent shale (Clear
Creek and Cottonwood) have high NOX emission rates (4000 - 5600 kg/1000 m3 of
oil) due to the combustion of the fuel related nitrogen in the shale.  The

                                      4-38                       :

-------
other facilities have NO^. emission rates from  <400 to 1400 kg/1000 m3 of oil
                        *ป•
which are determined by the  combustion of the retort off gas and retort
heaters.  The high value for the  Cathedral Bluffs facility is due to the
higher gas production rate of the in-situ process.
        The upgrading N0_ emissions are fairly consistent with the exception
                        2v
of the Clear Creek and Cottonwood facilities.  NO^. emission rates from these
                                                  A*
                                    o
latter two facilities (10 kg/1000 m  of oil) are unexplainedly one to two
orders of magnitude lower than the other five facilities.
A.      Below-Ground Mining  (Category #1)—
        The nitrogen oxide emission rates for below-ground mining operations
are shown in Table 4-19.
   TABLE 4-19.   CONTROLLED NITROGEN OXIDE EMISSIONS FROM BELOW-GROUND MINING
                            AND MATERIAL HANDLING''
i.n	!•• •ป•	^	1—'	1	urnn™_ป	--^ _ _-^r^^a_ป_^ป_^i^^^i^.ปซaB^^ป^ซ-^^^T^n^-^ m~^ m --p--^ V^r^Vrnr IT --m •_••"••	
                        Secondary         Emission Rate       Percent of Total
Process	Category Ho.* . . Xkg/JLOOO, jnT..of. Oil)	NQ^, Emissions..,..
Blasting                    2                 20                    1
Vehicles                    8                300                   20
    Total   .         ..     ...  ... , ......   .320.	:. .   ........ 21...-. .. ....
 ''Based  on PSD Permit Applications          - _   -
*  See Appendix C for category definition
   1.    Sources— The  major  source for below ground mining emissions are
                                        o
vehicle/engines producing 300 kg/1000  m  of oil  amounting to 20 percent of the
total facility NOX emissions. Blasting is a relatively minor source for N0.x
emissions.
   2.    Controls —  Additional controls on the vehicles could reduce the
overall  plant NO  emissions.
B.       Above-Ground Mining (Category  #2)—
         Only two facilities reported NOX  emissions from above-ground mining
                                          o
operations amounting to 20 - 30  kg/1000 m  of oil or less than one percent of
the total facility NO   emissions.
                                        4-39

-------
C.      Retort and Gas Combustion (Category  #3)—
        The NOX emissions from oil shale retorting  and  other  combustion
devices in an oil shale plant are presented  in Table  4-20.
         TABLE 4-20.  CONTROLLED NITROGEN OXIDE EMISSIONS  FROM RETORT
                           AND OTHER .GAS COMBUSTION*'
                (Not Including Organic Nitrogen & Residual NH)
                       Secondary         Emission  Rate        Percent of Total
Process     	    ... Category. 2Jo**... ,(kg/10Q.Q .m3 .of. .Oil)	ND^.emtssi.ojis.
                                                                   X
Gas combustion            37                  550                     30
Retort heaters
      (no fluid bed)      40                  220                     14
      (with fluid bed)    40                4800                     95
  Total
      (no fluid bed)                          770                     44
      (with fluid bed) .	 .	540.0,..,.. .		..95ฑ... ...
'*Based on PSD Permit Applications
* See Appendix C for category definitions
   1.   Sources -— The major sources  for NO   emissions from  retort and other
gas combustion are due to the need to provide heat for the retort  or power
generation from the retort off gas.   The NOX  emission rate is determined by
the type of combustion (thermal NOX)  and the  nitrogen content of the fuel
(fuel NOX).  The PSD permit applications consistently assumed that fuel NOX
emissions are negligible based on effective fuel gas cleanup.  However, the
presence of organic nitrogen compounds reduce the  removal efficiency of the
nitrogen clean-up process (water wash for ammonia  removal).   Therefore, the
actual expected NOX emissions will be greater than calculated in the PSD
permits (See Section 4.2).
                                                                             o
        Combustion of the retort gas  produces NOX  emissions  of 550 kg/1000 m
of oil or 30 percent of the total facility N0_ emissions.  The NO  -emission
                                              X.                   X
rate for the Cathedral Bluffs Plant is high at approximately 1000  kg/1000 m-(
of oil due to the higher temperatures in an in-situ retort producing higher
quantities of retort gas.
                                      4-40

-------
NO
  X
                 emission from providing heat for the retort depends on the
 type of combustion.  The facilities not using a fluidized bed spent shale
 combustor produce NOX emissions for retort heat of approximately 220 kg/1000
  3
 m  of oil and account for 14 percent of the total facility NOV emissions.  The
                                                      •        X
 facilities using 'the fluidized bed spent shale combustor produce considerably
 more NOX (4800 kg/ 1000 m3 of oil) due to the nitrogen in the spent shale.
    2*   -QopJ^-Q-J-g- — Additional controls to reduce NOX emissions from these
 combustion processes are staged combustion or selective catalytic reduction
 (SCR).  The SCR can only be applied on relatively clean gases and would not be
 suitable  for the fluidized bed combustor flue gas.
        Staged  combustion could be applied on either the clean (gas and oil)
 fuels or  the fluidized  bed combustors.   The reader is referred to Section
 3.2.1 for a description of the application of staged combustion on the
 fluidized bed (or cascading bed) combustor.
 D.      Upgrading (Category #4) — •
        The nitrogen oxide emissions  from upgrading operations are presented
 in  Table  4-21.

 TABLE 4-21.  CONTROLLED NITROGEN OXIDE EMISSIONS FROM UPGRADING OPERATIONS*1"
               (Not Including Organic Nitrogen and Residual NHo)

Process ...
Heaters
Vehicles
Total ,


Secondary
... Category Ho.* .
43
. ' - • .53


Emission Rate
XJcg/1000, m3 of Oil) .
450
10
460


Percent of Total'
. N0_. Emissions, ..
A -
25 '
>1
26

''Based on PSD permit applications
* See Appendix C for category definitions
   !•   Sources— The major source for NOX emissions from upgrading
operations are the heaters and furnaces.  These units produce 450 kg/1000 m3
of oil and account for 25 percent of the total facility NO^ emissions.  Above-
                                                          X
ground vehicles add a minimal amount of NOX emissions amounting to less than
one percent of the total.
                                     4-41

-------
    2-   Controls— Staged combustion and ammonia injection are two controls
 that could reduce these NOX emissions.
 4.3.4   Sulfur Oxides

         The sulfur oxide emission rates are shown in Table 4-22.

                TABLE 4-22.  CONTROLLED SULFUR OXIDE EMISSIONS1"t
                               (kg/1000 m3  of  Oil)




Primary
Category No.
Cathedral Bluffs
Clear Creek
Cottonwood
Paraho
Syntana
Union B
White River
Average .

Mining & Material
.,_ Handling

Below Above
1 2
30
10 10
20
30
20
20 10
20
.20 . 10 	

,

Retort
3
330
540
780
600
270
390
130
. ,-.-.'• 430 -

Process

Upgrade
. ' 4
350


20
10
30
10
,,.:,, .1**..,,
	 ' ^ _' 	 ' .\ , ."
....

Total
-
710
550
800
650
300*
450
1601"
.,475ง ...
 TT
   Based on PSD permit  applications
 * - Corrected value - reported values for SOX emissions for the retort and
     other  gas combustion were low by a factor of 5 (see section 4.4 below).
 T - Corrected value - reported values for SOX emissions for the retort and gas
     combustion were low by a factor of 3 (see section 4.4 below).
 ง - Value  for Cathedral Bluffs upgrading emissions not included.
         Below ground mining emissions of sulfur oxides are relatively small,
 ranging  from 10 to  30 kg/1000 m3  of oil and averaging 15 kg/1000 m3 of oil.
 Above-ground mining emissions of  sulfur oxides are minimal.
         The  sulfur  oxide emissions from the retort and other gas combustion
-has.wide variation  ranging from 130 to 780 kg/1000 m3 with an average value
 of  430  kg/1000 m3.   The variation is due to the differences in the retort
                                       4-42

-------
processes  and the clean-up methods.  These will be discussed further  in
Section  4.3.4.C,  below.
         The  sulfur oxide emissions from the upgrading operations are
relatively small  (10 - 30 kg/1000 m3 of oil) for all facilities other than  the
Cathedral  Bluffs  facility.  The value of 350 kg/1000 m3 is much higher than
the other  facilities due to the fact that the facility is relying on  the flxie
gas desulfurization (FGD) unit to reduce the SOX emissions and the flue gases
from  the upgrading heaters are not included in that FGD system.  Consequently,
the sulfur oxide  emissions are considerably higher reflecting the high sulfur
level in the retort off  gas after the I^S removal.
A.       Below Ground Mining (Category #!)•—
         The  emission rates for sulfur oxides from below ground mining are
shown in Table 4-23.

    TABLE 4-23.  CONTROLLED SULFUR OXIDE EMISSIONS FROM BELOW-GROUND MINING
                            AND MATERIAL HANDLING''
                        Secondary        Emission Rate       Percent of Total
  Process    .......  Category No...... (kg/1000.m3..of,.Oil)...	J30_ Emissions. _
         - • • •    --    . .   ..    .             . 	   . L   T  .       x
Vehicles/engines   ..   ...-.&	....2.Q	 	_j 5__
•>• .•i JปJIปปMMปI---- -| - nj • • •.-i-rriTima	 r~	~ " ~ ~ I. ~ ~ ~.	r n - -'- m m —•	-* m , , r	'- - - -, ,._	.•pปaajปn_i I ._i__i • • HI n 11.111 ปir
  Based on PSD permit applications
   1*   Sgurces^—  The only  source  for  below-ground mining emissions of sulfur
oxides is vehicles  producing 20  kg/1000 m3 of  oil  of emissions which amount to
5 percent of the total facility  sulfur  Oxide emissions.
   2.   Controls— The  only control technique would be to reduce the sulfur
content of the fuel used in  the  engines.
B.      Above Ground  Mining—
        Sulfur oxide  emissions from above  ground vehicles  is minimal.
C.      Retort and  Gas Utilization—
        Emissions of  sulfur  oxides  from the retort and gas utilization are a
function of:
                                       4-43

-------
        .  type of retort
        .  gas production rate
        .  efficiency of the fuel gas cleanup
           post-combustion flue gas desulfurization
        The effect of the various process designs and clean-up systems is
discussed extensively in Section 5, Process Analysis.
        The emissions of sulfur oxides for the individual operations are
presented in Table 4-24.

          TABLE 4-24.  CONTROLLED SULFUR OXIDE EMISSIONS FROM RETORT
                          AND OTHER GAS COMBUSTION1"'

Process
Retort gas combustion
Retort heater
Total


Secondary
Category. -No..
37
40


Emission Rate
_(kg/J.OOQ. .m3. af Oi 1 ) .
230
200
. .;. ..430 	


Percent of Total
. . S0_. Emissions . .
42
35
	 ..'..77.. 	 :..

 •'Based on PSD permit applications
   1.   Sources^ — The primary sources of SO  emissions from retort and gas
utilization are the' combustion of the retort gas  (230 kg/1000 m3 of oil; 42
percent of the total facility SOX emissions) and  the retort heater (200
kg/1000 m3 of oil; 35 percent of the total facility emissions.)
   2.   Controls^— Additional controls can be used to reduce these sulfur
oxide, emissions.  .The reader is referred to Section 3 for a complete
discussion on the various sulfur oxide control techniques that can reduce
these emissions.
   3.   Organic sulfur — As discussed above, the PSD Applications do not
consider the presence of organic sulfur gases.  The effect of including the
expected emissions from combustion of these organic sulfur compounds varies
with the type of retort.  For example, sulfur oxide emissions from the solids
recycle retort used by Clear Creek would be expected to increase by nine
percent; the direct combustion retort (Paraho) emissions would increase by as
much as 150 percent.  The Cathedral Bluffs facility has included a post

                                      4-44

-------
combustion FGD and therefore, their estimated  SO,, emissions would not
                                                X                •
increase.
4.4
PSD PERMIT APPLICATION DATA INCONSISTENCIES
        During this evaluation of the PSD permit application data, a number of
inconsistencies were found in the reported facility emissions.   In some  cases
reasonable explanations were found; in other cases no explanations were
found.  The more significant of these items are discussed below  for the
purpose of informing future permit applicants in estimating their own
emissions.
4.4.1   Carbon Monoxide
        The combustion related carbon monoxide emissions for the White River
and Syntana facility as reported in their PSD permit applications are shown in
Table 4-25.

      TABLE 4-25.   CONTRpLLED CO.EMISSIONS FROM WHITE RIVER.AND SYNTANA1^


White River
Retort Tosco ball heater
Retort recycle heater
Upgrade reformer
Utility steam
Total
Syntana
Upgrade FGD
Retort Tosco ball heater
Retort Superior
Retort FGD Steam
Upgrade Hydro reformer
Total (as reported.) .

Energy
Consump .
-. MW


140
280
630
710
1760

20
83
166
285
478
. .1030. .

Reported
Emissions
kg/_LOOO m Oil


8.8
18.1
40.5
314.0
382.0

0.7
5.1
4.0
6.8
7.4
	 24.. 0

Corrected
Emissions
ks/lQOO m^ Oi'L


8.8
18.1
40.0
22.0
89.0

1.8
11.0
8.6
14.5
15.9
51.8

tt
  Based on PSD permit application
                                      4-45

-------
         Since  these  two  facilities are similar in concept, the wide variation
 in carbon monoxide emissions  (382 kg/1000 m3 of oil for White River compared
 to 24 kg/1000  m3 of  oil  for Syntana)  for the steam/generation process appeared
 suspect.  The  steam  boiler emissions  for White River seemed to be too high.,
 The high value was found to be  due to a different definition of the emission
 factor.  Generally,  the  project  applicants  used natural gas emission factors
 when estimating emissions from  retort gas combustion.   In  all cases except for
 White River, an assumption was made that the emission  factor was  actually
 based on the weight  of pollutant  per'  unit of energy consumed rather than
 weight of pollutant  per unit of volume.   The definition is  important when
 computing emissions  for burning low Btu  gas  (with 100  Btu/cubic ft)  rather
 than emissions from burning high  Btu  gas  (with  1000  Btu/cubic  ft).   In this
 instance it leads to a 10 fold difference in the  emissions.
         In this case of carbon monoxide emissions from  the  steam boiler,  the
 White River applicant used an emission factor of  17  Ib/mscf; which is the  same
 as 0.017 Ib/MMBtu for natural  gas with a heating value of 1000 Btu/scf.
 However, when burning low Btu gas the other  facilities assumed the emission
 factor would be the  same  0.017 Ib/MMBtu which is 1.7 Ib/mscf for 100 Btu/scf
 gas.   The  corrected  values  for the White River facility are shown in
 Table  4-25.

         The  problem  faced by all applicants is that there is little emission
 data on  the  combustion of low  Btu gas.  The CO emissions depend a great deal
 on the  specific burner design.   The low energy content of the gas  will usually
 result in a  lower flame temperature and probably a higher CO emission per unit
 of energy throughput.  Using the CO emission factors for 1000 Btu/mscf gas may
 result in predicted emissions  lower than actual but it  is probably a closer
 prediction than using the emission factor based on gas  volume throughput.
         In checking the difference between the White River  and Syntana
 facility, it also was discovered that  the emissions  in  the  Syntana facility
 permit application are all 1/3 of  the  value  calculated  from  the emission
 factor and the heat input rate.  This  was  true for all  emissions from the
 Syntana facility.  The  (reported and corrected)  combustion related  emissions
of CO from the Syntana facility are also  shown in  Table  4-25.
                                      4-46

-------
         Since the CO emissions from all of the gases burned except those in
 the Tosco elutriator and lift pipe were based on the same 0.026 kg/MW (0.017
 Ib/MMBtu) emission factor,  the total emissions based on energy consumption
 should  balance.   However this was  not the case.
         The  total CO emission rated (excluding the Tosco ball heater) is:
      (1030 MW total - 83 MW Tosco) x 0.026 kg/MW = 21 kg/hr = .57 ton/day
 The CO  emission  rate reported,  as  totals,  were (.239 - .052) or .187 tons/day.
         Further  investigation of the PSD application table of emissions  showed
 that, although the  values given are indicated as being totals,  they are
 actually values  per operating unit.   Where there are two units,  the "totals"
 must  be  doubled  to  arrive at  the actual  emission rate.   This type of
 presentation  is  extremely misleading.
         The corrected  carbon  monoxide  emissions  are  52  kg/1000 m3 of oil
 rather than 24 kg/1000 m3 of  oil as  indicated in the PSD application.  With
 these corrections,  both  facilities  have  CO emission  rates 0.05 kg/1000 m3 of
 oil/MW based on  the  total heat  rate.
 4.4.2    Sulfur Oxides  (SOx)
        The SOX emissions also  were  inconsistent.  The  Syntana emission data
 appeared to be 1/3 of  the proper value and  the analysis was  similar  to that
 discussed above for carbon monoxide.  The White  River project SO  value
 reported in their summary emissions  table was  1/5 of the  actual value.  This
discrepancy was determined as follows:
        The White River PSD permit states that the retort gas contains 175
ppmw sulfur in low Btu gas.   The SOX emission rate is:
                       TT,   „   „  ,  V
                   -x [Density (kg/m )] x [ppm] = kg sulfur /hr
 Heating Value MW/m

     1760 MW         .     '   3                    6
 — -- __ — __ -    (1>2 kg/m )  (175 kg sulfur/10  kg) = 172 kg sulfur /hr
 0.002140 MW-hr/m
                                      4-47

-------
  172 kg sulfur/hr = 5.4 kg moles sulfur/hr x 64 kg SO /kg mole sulfur =
                     344 kg SO /hr = 8260 kg SO /day    .
                              x                x
         Assuming that all of the fuel sulfur is converted to SO  , this would
                                          ' '         •             **
 be the proper estimate of SOX emissions.  The reported value is 1630 kg/day.
 Using the emission factor reported in the White River PSD Permit Application
 of 0.0037 kg/m3 gives the following:
         0.0037 kg/m3 x 820,000 m3/hr = 360 kg SOx/hr = 8600 kg SO /day
 which agrees with the calculation based on their reported concentration of 175
 ppm.

         These discrepancies seem to reveal a need to have a standardized
 approach for the PSD permit application to allow comparative evaluation of the
 various  processes.

 4,5      ACTUAL PERMITTED  EMISSION RATES
         The  previous discussion has focused on the emission rates: estimated by
 the developers  in their PSD permit applications.   The actual permits issued
 indicated  some  significant  variations  from the applications.
         Table 4-27 shows  the application and  actual  permitted emission
 rates.   Notable  differences  result from:
         1. Requirement for  selective catalytic  reduction  for NO   control
           on the fluidized-bed  combustor at  the  Clear Creek plant.
         2. Use of catalytic converters  for  mine vehicles  to  decrease CO
           and HC emissions at Paraho.
         3. Revision of emission  estimates at  Cathedral Bluffs and
           Cottonwood facilities.
                                                     - .                         •ป
In most  cases the permit application data was consistent  with the actual
permitted values.
                                      4-48

-------
               TABLE 4-27.   COMPARISON OF PERMIT APPLICATION AND ACTUAL
                               PERMITTED EMISSION RATES
                                  (kg/1000 m3 of Oil
                      Particulate
                   Appli-   Permit
                   cation    ted
                                       SOx
                       NOx
                                                               CO
                                                                            HC
                                                                          A
Cathedral Bluffs 330 235 710 627 3200 1300 250 250 . 90 90

Clear Creek
CD (2) (3)
855 N/A 550 550 5800 15001130011300 230 230
Cottonwood
                    173
730
(5)
                                    800   800  4300  3700   250   230   110   140
Paraho .

Syntana
Union B
White River
350

237
181
213
350

N/A
N/A
213
650
. .
290
450
160
620

N/A
N/A
160
1700

1200
1200
1100
1400
(6)
N/A
N/A
1100
260

230
500
210
150
(7)
N/A
N/A
210
50

150
250
210
20
(7)
N/A
N/A
210
N/A - Not available. •
(1) - Particulate
emissions
for sr
lent shale distribution, raw shale storage.
(2)
(3)

(4)

(5)

(6)
(7)
      spent shale  conveyor were  not  included.
    - SOX emissions  from incinerator reduced from 127 to 83 kg/1000 m3 of oil.
    - Major reduction  due to  decrease by 73.5  percent in estimated NO  emis-
      sions from retort  gas combustion in steam boilers  reformer,  recycle gas
     'heater and oil charge heat.  No explanation available.
    - NO   emissions  from retort  combustor decreased  by application SCR to
      exhaust gas.
    - Large increase due to increases in particulate emission  from blasting,
      conveying, transfer and fluidized-bed  combustor.
    - NOX reduced  by 30% for  reformer furnace.
    - Addition of  catalytic converter on mine  vehicles providing 85% control
      CO  and 90% control of HC accounts  for  major reduction.
                                     4-49

-------
                                  SECTION 5.0
                               PROCESS ANALYSIS

        A wide variety of processing schemes can be used to recover  oil  from
shale.,  The purpose of this section is to investigate  some of  the many
possible variations to determine the net effect on criteria pollutant
emissions.
        The retort processes (Section 2), air pollution control equipment
(Section 3) and the data provided by the Prevention of Significant
Deterioration (PSD) permit applications (Section 4) have been  described
previously.  In this section, the information presented in the previous
sections will be used to evaluate the overall facility emissions for various
retort processes and pollution control equipment.

BACKGROUND
        A shale oil. recovery plant is quite complex involving many varied
operations.  The possible processing combinations are presented in Figure 5—1.
        Our primary concern in this analysis is emissions of nitrogen and
sulfur oxides and particulate.  Emissions of carbon monoxide and hydrocarbons
are generally consistent for all processes with the following exceptions.  The
combustion of the spent shale can produce very high carbon monoxide emissions
and this will be discussed below for that particular process.  The only
process that results in high hydrocarbon emissions is the Tosco II retort with
its direct heating of raw shale and ceramic balls with flue gas.
        In this section the methodology used to evaluate the various processes
is presented, followed by an evaluation of the sulfur and nitrogen gases
produced by the retort for the various processes.  An analysis of the
emissions for five typical processes being considered for full scale
development is also included.
                                      5-1

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                            5-2

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        For each analysis, a base case scenario is presented to determine the
criteria pollutant emissions.  Two alternative processing schemes are then
considered to reduce these emissions to their lowest levels.

5.1     METHODOLOGY
        To evaluate the many process variations it was first necessary to
determine what process combinations are feasible.  Using the information
presented in the literature and PSD applications, the potential unit
operations for each process category was prepared.  Figure 5-1 presents these
alternatives.  The basic design parameters that affect the pollutant emissions
for each process are shown in Table 5—1.
        For each of the unit operations, design parameters were applied as
indicated by either the retort process conditions described in Section 2, the
pollution control performance as described in Section 3 or the reported
emissions from the PSD applications as described in Section 4.  The following
discussion presents the design parameters used in the analysis.
                                       5-3

-------
Operation
                         TABLE 5-1.  DESIGN PARAMETERS
                          (Taback,  H.J.,  et  al.,  1986)
Design Parameter
Mining
Retort


Product Recovery

NHg removal

H^S removal


Gas Utilization


End of Pipe Controls
5.1.1   Mining
Type of mining
   open pit
   room and pillar
   in situ
Retort Gas Produced, m^/m3 of oil
Heating Value of Retort Gas, kJ/nr
Partitioning of sulfur and nitrogen
None- The product recovery process has no
  significant effect on emissions.
NHg exit concentration, ppm
  organic nitrogen content of retort gas
H2S exit concentration, ppm
  organic sulfur content of retort gas
  organic sulfur gas removal efficiency, %
Boiler - dilution ratio (dry gas/fuel)
Spent Shale Combustion
  exit concentrations for N0_, S0_ & CO
                            X    5t
Particulate-Baghouse-exit loading, g/m3 of oil
Sulfur - FGD - exit SOX, ppm
Nitrogen
   Ammonia injection - exit NOX
   Staged Combustion - exit NO,, & CO
                              X
        The choice of mining technique determines the emission rates from the
mining operation.  The values used were developed from the PSD permit
applications analysis, Section 4, for room and pillar mining and from the
literature for open pit mining (PCTM-Lurgi-Open Pit Mining).  The emission
rates used are shown in Table 5-2.
                                       5-4

-------
              TABLE 5-2.  CONTROLLED EMISSION RATES FOR MINING
                                                               * *
Type of Mining

Open pit
Room & pillar
Room & pillar with
Catalytic converters
on Engines
Emissions, kg/1000 m3 of Oil
CO
370
150

15

EC
50
20

2

NOX
470
350

350

S0x
40
20

20

PM
410
180

; 180

1'Based on PSD permit applications
5.1.2   Retort
Ao      Gas Volume & Heating Value—
        The retort gas produced for the various  types  of  retorts  was
determined from the information presented  in  the PSD applications.   The gas
rates are shown in Table 5-3.
                   TABLE 5-3.  RETORT GAS PRODUCTION
Gas Produced
Type of Retort m3 of gas/m3 of Oil
In-situ
Direct heating
Indirect heating
7000
1800
180
Heating Value
Gram-Calories/Liter
9000
9000
90000
  Bassed on PSD permit applications
        The in-situ process  produces  the  highest  retort gas flow ^rate due to
the combined effect of  the higher retort  temperatures  converting more of the
kerogen to gas and the  higher  sweep gas flow required  to provide adequate
oxygen to burn the shale.  The direct heating retort has similar conditions
(i.e. high temperatures and  requirement for adequate oxygen for combustion)
but to a lesser degree  than  the in-situ retort and,  consequently, has lower
retort gas flow rates.   The  indirect  heating process has the lowest retort gas
flow rate due to  the lower retort temperatures and low gas flow rate with no
dilution required to provide oxygen for combustion within the retort.
                                        5-5

-------
        The heating value  of  the  retort  gas  is  determined  by  the  amount  of
dilution gas; in-situ and  direct  heated  retorts produce  low heating value gas
at 9000 gram-calories/liter  (100  Btu/scf)  and the  indirect heated retort
produces high heating value gas at  90000 gram-calories/liter  (1000 Btu/scf)*
B.      Sulfur Gases—
   1.   Species and Distribution— The  sulfur  in  the  raw  shale is partitioned
to the spent shale, oil and retort  gas.  The significant variations in raw
shale sulfur content, percentage  of sulfur partitioned to  the gas phase  and
the chemical structure of  these sulfur gases result in the gas clean-up
strategy being quite complex.
        The sulfur emission problem can  be solved  either by removing the
sulfur prior to combustion or by  addition  of a  flue gas desulfurizatipn
process after combustion.  As the combustion process dilutes  the  pollutant
concentrations and increases the  gas flow  rate,  the economically  preferred
technique is sulfur removal prior to combustion.
        The form of the sulfur in the gas  is extremely important  when
considering the sulfur removal processes.  The  sulfur  recovery processes that
have been considered for cleaning the retort gas prior to  combustion are not
effective in removing the  organic sulfur compounds which can  amount to as much
as 10 - 16 percent of the  total sulfur in  the retort gas.   Consequently, the
effectiveness of these clean-up processes  is dependent on  the relative amounts
of organic sulfur to H2S.  Even high efficiencies of H2S removal  (99%) are not
sufficient to reduce the sulfur emissions  below the 850 kg/1000 m3 of oil
(0.3 lb/bbl) regulatory level for Colorado.
        The results of the calculation to  determine the net sulfur emissions
from burning the retort gas after the sulfur (H2S) removal  are shown in
Table 5-4.  For raw shale with 1.0 wt % sulfur where 30 percent of the sulfur
in the raw shale is evolved with  the retort  gas, the net sulfur emissions
range from 1000 kg/1000 m3 oil (0.33 lb/bbl) for retort gas with  99 percent of
the total sulfur as H2S to 7600 kg/1000 m3 oil  (2.66 lb/bbl) for retort gas
with 85 percent of the total sulfur as H2S.  Even with 0.5 wt% sulfur in the
                                       5-6

-------
raw shale the retort gas must contain greater than 95 percent of  the  sulfur  as
H2S to approach the regulatory limit of 850 kg/1000 m3 oil  (0.3 Ib/bbl).

           TABLE 5-4.  EFFECT OF ORGANIC SULFUR ON SULFUR EMISSIONS

Basis: sulfur wt % = 1; raw shale at 30 gal/ton; 28 % of sulfur in retort  gas
             H9S, %                        85       90       95  :      99
Organic sulfur gas of total sulfur %
Sulfur as H2S, kg/1000 m3 oil
Organic S, kg/ 1000 m3 oil
Total S, kg/1000 m3 oil
Total S (as SOX) , kg/1000 m3 oil
15
200
3600
3800
7600
10
220
2400
2600
5200
5
230
1200
1400
2800
1
230
240
500
1000
        Essentially, the above analysis indicates that the I^S  removal process
must be capable of removing a significant amount of the organic sulfur gases
to meet the regulatory limit of 850 kg/1000 m3 of oil  0.3 Ib sulfur  (as
SOX) /bbl).  To avoid the costly alternative of adding an "end  of pipe" flue
gas desulfurization, two alternatives can be considered.  The first,  activated
carbon-hypochlorite H2S removal process, is an improvement on the H2S
scrubbing process to remove organic sulfur species.  The second is  the solids
recycle process which limits sulfur gas emissions by the chemistry  of the
retort and combustion process.
        The activated carbon-hypochlorite H2S removal process described in
Section 3 can be designed to remove the organic sulfur compounds as well as
the H2S and, therefore, is suitable for removal of the sulfur gases prior to
combustion eliminating the need for more expensive post combustion  control.
This process can remove 99+ percent of the HoS and 90-98+ percent of  the
organic sulfur gases (Teller 1985b).  This results in a net sulfur  removal
efficiency of 99 percent and sulfur emissions (SOV) of 500 kg/1000 m3 oil
                                                 X.
(0.17 Ib/bbl) even when the organic sulfur gases are 15 percent of  the total
sulfur.
        The recycle solids process controls the emissions of sulfur gases by
the chemistry of the process.  The sulfur emissions from the recycle  solids
                                       5-7

-------
process represent only one percent of  the  total  sulfur  inlet  primarily as  HioS
in the retort gas.  Therefore, the amount  of  organic  sulfur is  minimal and the
H2S removal processes alone are sufficient to reduce  the  sulfur emissions
below the regulatory limit.  The above discussion  is  summarized in Table 5-5.
              TABLE 5-5.   SUMMARY OF ESTIMATED SOX EMISSION RATES
                    Basis: 1 wt% sulfur oil  shale;
                           30% partitioned to gas phase
                   	..15% organic. .suLfur	  	
First Generation-no solids recycle
First Generation-no solids recycle


First, generation - no solids recycle
                                          Control Technique
                                             I^S removal
                                             H2S removal
                                            and flue gas
                                           desulfurization
                                            Enhanced t^S
                                          and organic sulfur
                                            gas removal
Second Generation - with solids recycle   Standard
                                                       removal
SOX, kg/1000
 m3 "of "oil"'
     7700
      850
      570
      .100
   2.   Design Conditions — The HUjS removal process determines the residual
    and organic sulfur in the retort gas.  The processes considered are:
      1 - Direct or indirect conversion - considered the same for performance
          of H2S removal:
               H^S exit concentration = 50 ppm
               organic sulfur - assumed at 5 % of
               total sulfur in retort gas — no removal
      2 — Activated carbon—hypochlorlte proc'e'ss
               H2S exit concentration = 10 ppm
               organic sulfur assumed at 5% of total sulfur in
               retort gas - 90% removal
                                       5-8

-------
      3 - Spent shale combustion
               SOX exit concentration =  20 ppm
C.      Nitrogen Gases—
   1ป   Species and Distribution — The  removal  of  nitrogen gases  is  also
difficult to predict due to the degree of variability  in nitrogen  content in
shale, partitioning between gas, oil and spent shale and chemical  form of the
gaseous nitrogen species.
        The presence of organic nitrogen species presents the  same problem for
limiting fuel related N0_ emissions as that described  above for  the SO
                            .                                           -^
emissions; namely that the removal processes generally considered  are not
effective in reducing the organic nitrogen content  of  the retort gas.
        The primary nitrogen removal technique considered is removal  of
ammonia from the retort gas by a water wash absorption tower followed by  an
ammonia recovery stripper.  The outlet ammonia concentration is  determined by
the effectiveness of the ammonia absorber.  At atmospheric pressure the
equilibrium exit partial pressure for ammonia  at 50 C  is 0.5 mm  Hg (Perry and
Green, 1984).
        The nitrogen content of the retort gas is determined by:
            The exit gas ammonia concentration (0.5 mm Hg)
            The amount of retort gas produced  by the retort  (Table 5-3)
            The amount of nitrogen partitioned to the  retort gas (Table 2-8)
            The percentage of nitrogen present as organic nitrogen compounds
                (Table 2-9)
        Based on this information, an analysis of the  effect of  organic
nitrogen on the overall NOX emissions was made for  three  types of  retorts.
These results are shown in Table 5-6.                            ;
                                       5-9

-------
            TABLE 5-6.  ESTIMATED EMISSIONS OF NITROGEN OXIDE FROM
                           COMBUSTION OF RETORT GAS
Type of Retort
'ill
o o
Retort gas, m /m oil
Nitrogen in gas, %
N from NH3, kg/1000 m3 oil
Organic N, kg/ 1000 m3 oil
Total N, kg/ 1000 m3 oil
Total NOY, kg/ 1000 m3 oil
A.
Direct
Combustion
1800
30
890
380
1300
2800
Solids
Recycle.
180
10
90
13
100
214
In-situ
7000
50
3500
640
4100
8800
        .(a) Solids recycle retort — has the lowest fuel-NO,, emissions (from
                                                           X
fuel nitrogen) due to the combined effect of the low retort gas production
      o  o                                                                  ,
(180 m /m  oil) and the low partitioning of nitrogen to the gas phase
  *.
(10 percent).  Consequently, since the exit ammonia concentration is based on
an equilibrium value partial pressure, the lower retort gas flow rates results
in less NHg in the exhaust.  The resulting fuel-NOx emissions from burning
this retort gas are 214 kg/1000 m3 oil.
        (b) Direct heated retort — This type of retort (e.g. Paraho) produces
      O      O
1800 m  gas/m  of oil and partitions 30 percent of the nitrogen to the gas
phase.  Therefore, the NHg removal process has 10 times as much gas to process
(compared to the solids heated retort) and a higher concentration of NH^ (and
associated organic nitrogen compounds).  Consequently, using the same exit
partial pressure of 0.5 mmHg NH^ the resulting fuel-NOx emissions from NH^ and
organic nitrogen combustion are 2700 kg/1000 m3 oil.
        (c) In-situ '— The in-situ retort produces the highest retort gas
            o  o
flow,, 7000 m /m  oil with the highest partitioning of nitrogen to the gas
phase (50 percent).  Therefore, the ammonia removal is least efficient and the
resulting fuel-NOx emissions from NH3 and organic nitrogen are 8800 kg/1000 m3
oil.
   2o   Combustion of Spent Shale— As mentioned previously, the combustion
of the carbonaceous shale is desirable for recovery of the energy content.
                                       5-10

-------
The nitrogen reactions resulting from spent shale combustion were described in
Section 2.1.1.
        The combustion of the spent shale to obtain the extremely low sulfur
emissions can result in large nitrogen emissions due to the fuel nitrogen.
While the inorganic nitrogen burns slowly, it does burn to some degree and any
residual organic nitrogen is also burned to NO...  In the PSD permit
                                              X.                 L
applications NOX emissions were based on the conversion of approximately  15
percent of the nitrogen in the spent shale to N0_ in the combustdr.  The
                                                X
principal of NO reduction with carbon in a staged combustor can be applied to
reduce NOV emissions.
         X
   3.   Design Conditions— The method for ammonia removal determines the
amount of fuel nitrogen in the cleaned retort gas.  Since the gas is
eventually burned, this fuel-nitrogen is emitted as NO  unless a staged
combustion burner is used.  The design parameters for considering the various
ammonia clean—up schemes are:
     1 — Water wash - NHg in exit gas based on pp = 0.5 mm Hg
                    - organic nitrogen based on 2 percent of nitrogen
                        in retort gas and no removal with water wash
                    - thermal NOX from retort gas rate,
                        heating value and 0.2 Ib/MMBtu
     2 - Acid wash - same as water wash except NHg exit cone = 10 ppm
5.1.3   Gas Utilization and End-Of-Pipe
        The End-Of-Pipe controls are those either added after combustion  of
the retort gas to remove particulate, NOX and SOX or incorporated as part of
the combustion process as in staged combustion for NO  control.
A.      Particulate—
        For particulate control, two alternatives were considered.  The first
is the base case using a standard baghouse.  The second control technique is
the combined dry yenturi-baghouse.  The dry venturi-baghouse combination
provides for particulate control that is somewhat independent of type of
particulate.  The applicants for PSD permits all considered a minimum
                                       5-11

-------
particulate exit loading of 0.07 g/m  (0.03 gr/scf) which was based on
standard technology within the limits of the unknowns associated with oil
shale particulate.  By capturing the small particles on larger target
particles of specified physical properties, the dry venturi eliminates the
major uncertainties in designing baghouses with respect to particulate type
and size.
        Two alternative design conditions were considered, based on the face
velocity in the baghouse of 0.5 and 1.5 ft/sec (see Figure 3-3).
                     particulate loading     face velocity
                           g/m 3                 m/sec
                           0.02                   0.5
                           0.001                  1.5
B.      Sulfur Oxides—
        If the t^S (and organic sulfur) removal is not sufficient to reduce
the sulfur emissions to an acceptable level, a post combustion flue gas
desulfurization system must be added.  This could be a wet or dry scrubber.
        The second sulfur control technique is the use of a spent shale
combustor.  The combustion of the spent shale has two important advantages; 1)
recovery of the energy value of the char and 2) reduction of the sulfur oxide
emissions due to the scrubbing nature of the spent shale.  However, the spent
shale combustion also has two distinct disadvatages; 1) high emissions of NO
                                                                            X
from the nitrogen in the spent shale and 2) high emissions of CO due to
incomplete combustion.  These emissions (NO  and CO) will be discussed in the
following section.
      1 - Flue Gas Desulfurization — 50 ppm S0_ exit concentration
                                               A.
      2 - Combustion of spent shale with retort gas
                                   - 10 ppm SOX
                                   - 300 ppm NOX
                                   - 1000 ppm CO
                                       5-12

-------
C.      Nitrogen Oxides—
        Two controls were considered for reducing NO  emissions.  The first is
ammonia injection which has been applied successfully in utility boilers and
could be used when the retort gas is burned in a conventional boiler for steam
and electrical generation.
        The second NOX control considered is staged combustion which has
particular advantages due to the ability to adequately control the fuel
related NOX.  The staged combustion could be applied to either the
conventional boiler or the spent shale combustor.
        There is a tradeoff between the NOX and CO emissions in the spent
shale combustor.  As indicated above, the NOX and CO emissions are quite high
at 300 and 1000 ppm, respectively.  Higher combustor temperatures increase the
NOX emissions but decrease the CO emissions.  In the range of 600 - 800 C the
NOX emissions can range from 250 ppm to over 600 ppm while the CO emissions
can vary from 200 ppm to over 1000 ppm at the lower temperatures with low
excess oxygen.
        In addition, the control of the fuel related NOX depends on low excess
oxygen (actually sub-stoichiometric combustion) which increases the CO
emissions even higher.
        The fluidized-bed combustor has limitations in process control which
result in the inability to provide adequate staging for N0_ control.  However,
                                                          X
the cascading bed combustor is designed as a staged device.  Consequently,
combustion conditions can be controlled at each stage of the process,
alternating between fuel rich and fuel lean zones to reduce the NO formed to
N2 and complete the combustion of the CO formed to C02ซ
        There are no test results to support this hypothesis; however,  the
chemistry and engineering of the cascading bed combustor indicate that  proper
design could result in minimal NOX and CO emissions.
     1 - NHg injection - 20 ppm NOx exit concentration
     2 - cascading bed combustor - 50 ppm NOx exit concentration
                                 - 50 ppm CO
                                       5-13

-------
5.2     RESULTS
        The results from the analysis for all five cases are shown for
particulates, nitrogen oxides and sulfur oxides in Tables 5-7, 5-8 and 5-9,
respectively.  The following discussion presents the individual analysis for
each case.
5.2.1   Direct Combustion - Case #1
Ao      Base Case-r-
        The base case for this process consists of open pit mining with a
Paraho type retort followed by water wash for ammonia removal and a Stretford
direct sulfur conversion plant.  The retort gas is then burned in a boiler to
produce steam and electricity followed by a baghouse for particulate control.
        The schematic for this case is shown in Figure 5-2.  The expected
emissions for this process for the base case and two alternatives are shown in
Table 5-10.

Bo      Alternate #1--
        Alternate 1 scheme uses room and pillar mining in place of an open pit
mine,, the activated carbon-hypochlorite process for l^S and organic sulfur
removal prior to combustion, an acid wash in addition to the water wash for
ammonia removal and a dry venturi/baghouse combination with a face velocity of
0.5 m/sec (1.5 ft/sec).
        The use of a room and pillar mine in place of an open pit mine reduces
CO arid HC emissions by 42 and 13 percent, respectively.  N0_ emissions from
                                                           X
mining vehicles are also reduced from 471 kg/1000 m3 of oil to 345 kg/1000 m3
of oil.                                                          !
        The activated carbon-hypochlorite process for I^S and organic sulfur
removal reduces SOX emissions from combustion of the retort gas from 2600
kg/l/)00 m3 of oil to 160 kg/1000 m3 of oil and results in an overall facility
reduction of SOX emissions of 93 percent.
                                       5-14

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-------
               TABLE 5-10.  TOTAL FACILITY CONTROLLED EMISSIONS
                          Case 1 - Direct Combustion
                             (Paraho type retort)
                         (Taback, H.J., et al.,  1986)
Base Conditions: H2S-Stretford (50 ppm), NHg-water wash
Particulate loading = 0.07 g/m3
Emissions, kg/1000 m3 of Oil

Open pit
Retort gas
Upgrade
Total
Alternate #1 SOX-H2S
NOX-NH3
PM - dry
Room and

Room and pillar
Retort gas
Upgrade .
Total
Reduction
(from Base Case)
% Reduction
CO HC NOX
370 50 471
125 35 2812
25 150
520 235 3283
S0x
38
2593

2631
removal - activated carbon and
removal - water and acid
venturi and baghouse
pillar mining
CO HC NOX
150 20 345
125 35 1156
25 150
300 205 1501
220 30 1782

42 13 54
wash


S0x
20
159

179
2451

93
, PM
410
246

656
hypoehlorite



PM
181
70

251
405

62
Alternate #2 NOX - ammonia injection
PM - dry
venturi /baghouse


HC and CO - vehicles/catalytic converter

Room and pillar
Retort gas
Upgrade
Total
Reduction
(from Alt. #1)
% Reduction
CO HC NOY
X.
15 2 345
125 35 85
2 60
142 97 430
158 108 1071

52 53 71
S0x
20
159

179
0

0
PM
181
4

185
67

27
        The use of an acid wash in addition to the water wash for ammonia
removal reduces NOX emissions from combustion of the retort gas from 2800
                                       5-19

-------
 kg/1000 m3  of  oil  to 1200  kg/1000 m3 of oil and results in an overall facility
 reduction  (combined  effect of  room & pillar mining and the acid wash for
 ammonia removal) of  54 percent.
        The dry venturi/baghouse  for an end-of-pipe particulate control
 reduces particulate  emissions  from combustion of the retort gas from 246
 kg/1000 m3  of  oil  to 70 kg/1000 m3 of oil  and the combined effect of room and
 pillar mining  and  the dry  venturi/baghouse reduces the overall facility
 particulate emissions by 62 percent.
 C.      Alternate  #2—
        The Alternate 2 scheme uses catalytic converters  on the mining
 vehicles and engines to reduce CO and HC emissions,  ammonia injection to
 reduce NOX  from combustion of  the retort gas and the dry  venturi/baghouse with
 a space velocity of  1.0 m/sec  (3.5 ft/sec) for additional particulate control.
        The catalytic converters  reduce  the CO and HC emissions from the
 mining operations  by 90 percent and result in an overall  facility reduction  of
 52 percent  for CO  and 53 percent  for  HC.
        The  use of ammonia  injection  reduces  the NOX emissions  from  1200
 kg/1000 m3  of  oil  to 85 kg/1000 m3 of  oil  for retort gas  and  results  in an
 overall facility reduction  of 71  percent.
        The  dry venturi/baghouse  with  the  higher space  velocity reduces
 particulate  emissions from  combustion  of the  retort  gas to  4  kg/1000  m3 of oil
 and results  in an  overall facility reduction  of  27 percent.
 5.2.2   Direct Combustion - Circular Grate  -  Case #  2
A.      Base Case—
        The  base case for this process consists  of room and pillar mining with
a circular grate retort (e.g., Superior, Allis Chalmers,  Dravo)  fpllowed by  a
boiler and a baghouse.  As this type of retort provides combustion of  a
portion of the retort gas,  the sulfur  is converted to sulfur  oxides prior to
the boiler and no ^S removal is proposed.  The  retort contains  a water wash
for ammonia and sulfur oxide removal as an  integral part  of the  process.
                                       5-20

-------
          The schematic for this case are shown in Figure 5-3.  The emissions

  expected for this schematic and the two alternatives are shown in Table 5-11,

                 TABLE 5-11.  TOTAL FACILITY CONTROLLED EMISSIONS
                            Case 2 - Direct Combustion
                              (Circular grate retort)
                           (Taback, H.J., et al.,  1986)
Base Case

Room and pillar
Retort gas
Upgrade
Total
Alternate #1 SO.
NO.
PM
HC

Room and pillar
Retort gas
Upgrade
Total
Reduction
(from Base Case)
% Reduction
Alternate #2 NO
2i
PM
,
Room and pillar
Retort gas
Upgrade
Total
Reduction
(from Alt. #1)
% Reduction
Emissions. kg/TOOf)
CO HC NOX
150 20 345
125 35 2812
25 150
300 205 3157
x - Flue Gas Desulfurization
X-NH3 removal - water and acid
- dry venturi/baghouse
and CO - vehicles/catalytic ci
CO HC NOY
X
15 2 345
125 35 1156
2 60
142 97 1501
158 108 1656
52 53 52
, - ammonia injection
- dry venturi/baghouse
CO HC NOX
15 2 345
125 35 85
2 60
142 97 430
0 0 1226
0 0 74
m3 of Oil
S0x
20
370

390

wash

onverter
S0x
20
106
126
264
68


S0x
20
106

126
0
0
• ,
PM
181
246

427




PM
181
70
251
176
41
^

PM
181
A

185
66
26
B.      Alternate #1-
        The first alternate scheme uses catalytic converters for the mining
engines and vehicles to reduce CO and HC, flue gas desulfurization after
                                       5-21

-------
                                51
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-------
combustion to reduce the SO  emissionss an acid wash  for additional  ammonia
removal and a dry venturi/baghouse for particulate control.
        The CO and HC emissions from mining vehicles  and engines  are reduced
by 90 percent and the overall facility emission is reduced by  52  and 53
percent, respectively.
        The acid wash reduces the NOX emissions from  retort gas combustion
from 2800 kg/1000 m3 of oil to 1200 kg/1000 m3 of oil and the  overall facility
reduction is 52 percent.
        The flue gas desulfurization reduces the SO^,  emissions from  retort gas
                                                   A.
combustion from 370 kg/1000 m  to 106 kg/1000 m  and  reduces the  overall
facility SO  emission rate by 68 percent.
        .The dry venturi/baghouse with a space velocity of 0.5  m/sec  (1.5
                                                                          o
ft/sec) reduces particulate from retort gas combustion from 246 kg/1000 m of
                   O                                             e
oil to 70 kg/1000 rsr of oil and results in an overall facility reduction  in
particulate emissions of 41 percent.
C.      Alternate #2—
        The second alternative scheme uses ammonia injection for  post
combustion NOX control and the dry venturi/baghouse with a space  velocity of
1 m/sec (3.5 ft/sec).
        The N0__ emissions from combustion of the retort gas are reduced from
              li
1156 kg/1000 m3 to 85 kg/1000 m3 of oil and the overall facility  NOX emission
is reduced by 74 percent.
        The particulate emissions from combustion of  the retort gas  are
reduced from 70 kg/1000 m3 to 4 kg/1000 m3 and the overall facility
particulate emission is reduced by 26 percent.
                                                                 s
5.2.3   Indirect Combustion - Gas Recycle- Case # 3
A.      Base Case—
        The base case for this process consists of open pit mining with an
indirect combustion - gas recycle retort followed by  a water wash for
                                        5-23

-------
ammonia removal and an direct conversion process for HoS removal.  The retort

gas is burned in a boiler followed by a baghouse for particulate control.

        The schematic for this process is shown in Figure 5-4.  The emission

rates for the three alternatives are presented in Table 5-12.


               TABLE 5-12.  TOTAL FACILITY CONTROLLED EMISSIONS
                         Case 3 - Indirect Combustion
                         Gas Recycle Retort (Union B)
                            (Taback, et al., 1986)
Base Case
Open pit
Retort gas
Upgrade
Total
Emissions, kg/1000 m3 of
CO HC NOV SO,,
X X
370 50 471 38
125 35 2812 2593
25 150 	 No Data
520 235 3283 2631
Alternate #1 SOX-H2S removal - activated carbon and
NOx~NH.j removal - water and acid wash
PM - dry venturi and baghouse
Room and pillar mining
CO HC NO.. SOY
A. .. A.
Room and pillar 150 20 345 20
Retort gas 125 35 1156 159
Upgrade 25 150 	 No Data -
Total 300 205 1501 179
Reduction 220 30 1782 2451
(from Base Case)
% Reduction 42 13 54 93
Alternate #2 NOX
PM
HC
Room and pillar
Retort gas
Upgrade
Total
Reduction
Oil
PM
410
; 246
656
hypochlorite
PM
181
! 7ฐ
251
405
62
— ammonia injection
- dry venturi /baghouse
and CO - vehicles/catalytic converter
CO HC NOY SO^. PM
Jt X. '
15 2 345 20 181
125 35 85 159 4
2 60 	 No Data 	 —
142 97 430 179 185
158 108 1071 0 67
        (from Alt. #1)
        % Reduction            52       53       71        0       27
                                       5-24

-------
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                                    5-25

-------
B.      Alternate  #1—
        The  first  alternative consists of using an acid wash for ammonia
removal,  activated carbon  and hypochlorite process for I^S and organic sulfur
removal,  the dry venturi/baghouse for particulate control and a room and
pillar mine.
        The  NOX emissions  are reduced from 2812 to 1156 kg/1000 m3 of oil from
combustion of the  retort gas  and  the  overall  facility NC>  emissions are
                                                         X
reduced by 54 percent.
        The  SOX emissions  from combustion of  the retort gas are reduced from
2593 to 159  kg/1000 m3 of  oil and the overall facility SOX emissions are
reduced by 93 percent.
        The  particulate emissions are reduced from 246 to 70 kg/1000 m3 of oil
and the overall facility particulate  emissions are reduced by 62 percent.
C.      Alternate  #2—
        The  second alternate  process  scheme uses ammonia injection for post:
combustion NOX control and the  dry venturi/baghouse with the high space
velocity, and catalytic converters on vehicles.
        The NOX emissions  from  combustion of  the retort gas are reduced from
1156 to 85 kg/1000 m3 of oil  and  the  overall  facility NO^ emissions are
                                                         X
reduced by 71 percent.
        The particulate emissions  from combustion of  the retort gas are
reduced from 70 to 4 kg/1000  m3 of oil  for an overall  facility  reduction of 27
percent.
5.2.4   Indirect Combustion - Solids  Recycle  - Fluidized Bed Spent  Shale
        Combustor - Case # 4                                •
A.      Base Case—                                              ; .
        The base case is room and  pillar  mining  and an indirect combustion
solids recycle retort with a  fluidized bed spent  shale combustor.   The  retort
gas is burned and the flue gas is  treated  by  a baghouse.
        The schematic for this process is  shown  in  Figure  5-5.   The emission
rates for the three alternatives are  presented in Table  5-13.
                                       5-26

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-------
       TABLE 5-13.  TOTAL FACILITY CONTROLLED EMISSIONS
         Case 4 - Indirect Combustion, Solids Recycle
                   (Fluidized bed combustor)
                    (Taback, et al., 1986)
Base Case

Room and pillar
Retort gas
Combustion
Upgrade
Total
Alternate #1 SOX
Emissions, kg/1000 m3 of Oil
CO HC NO,, SO,,
X 2v
150 20 345 20
125 35 921 106
11197 3359 224


11497 205 4626 350

: PM
181
185
653


1019
HB^S removal - activated carbon and hypochlorite
NOX~ NH-j removal - water and acid wash
PM
HC

Room and pillar
Retort gas
Combustion
Upgrade
Total
Reduction
(from Base Case)
% Reduction
Alternate #2 NOX


PM

Room and pillar
Retort gas
Combustion
Upgrade
Total
Reduction
- dry venturi/baghouse
and CO - vehicles/catalytic converter
CO HC NO,, SO,,
2t X
15 2 345 20
125 35 756 8
11197 3359 224
2 60 	 No Data 	
11340 97 4460 252
158 108 166 98

1 53 4 28
- ammonia injection for retort staged


PM
181
53
187
— . 	
420
599

59

'combustion for combustor gas cascading
bed spent shale combustor
- dry venturi
CO HC NO,, SO,,
3v 2C
15 2 345 20
125 35 63 8
423 423 169


565 97 831 197
10775 0 3629 55


PM
181
3
9


193
227
(from Alt. #1)
% Reduction
95
0
81
22
54
                               5-28

-------
X
B.      Alternate #1—
        The first alternate uses an acid wash to remove ammonia from the
retort gas, activated carbon and hypochlorite process to remove H^S and
organic sulfur from the retort gas and the dry venturi/baghouse for
particulate control on the burned retort gas and the exhaust gas from the
spent shale combustion unit, and catalytic converters on mine vehicles to
reduce CO and HC levels by 90 percent.
        The acid wash reduces the NOX emissions associated with the retort gas
from 921 kg/1000 m3 of oil to 756 kg/1000 m3 of oil.  However, because the NO.
                                                                    o
emissions from the spent shale combustor are so high (3400 kg/1000 m  of oil)
the reduction in facility NOX emissions is only 4 percent.
        The activated carbon H9S removal process reduces the SO., emissions
                              ^—                     •           X
from combusting the retort gas from 106 kg/1000 m3 of oil to 8 kg/1000 m3 of
oil.  The overall facility SOX emission is reduced by 28 percent.
        The dry venturi/baghouse with a space velocity of 0.5 m/sec (1.5
ft/sec) reduces particulate from the retort gas and combustor flue gas from
838 kg/1000 m3 to 240 kg/1000 m3.  The overall facility particulate emission
is reduced by 59 percent.
C.      Alternate #2—
        The second alternative uses ammonia injection for NO  reduction from
burning the retort gas and staged combustion for N0_ reduction from the spent
                                                   X
shale combustor.
        A fluidized bed is essentially a single stage device where high
turbulence provides equal concentrations of reactants throughout the bed.
This fact makes it difficult to design a single fluidized bed unit to provide
the temperature and excess oxygen control necessary to reduce the NO formed in
the combustion process.  The staging effect could be achieved by using a
series of fluidized beds followed by combustion chambers; however, this
concept would result in multiple units requiring solids transfer and would be
quite complicated.  Therefore, to utilize this NOX control, a cascading bed
combustor as described in Section 2.4.9 is used in place of the fluidized
bed.  As the cascading bed is essentially a staged device, it provides easy
access and means for control of individual stage temperatures and
                                    5-29

-------
concentrations.  Therefore, the NO reduction can be achieved without the
excessive CO emissions that are typical of the fluidized bed combustor.
        The dry venturi/baghouse with the higher space velocity is also
applied.
        Ammonia injection for the combusted retort gas reduces the NO
                                  o
emissions from 756 to 63 kg/1000 m  of oil.  The staged combustion on the
cascading bed spent shale combustor reduces the N0_ emissions from 3359 to 423
                                                  -A
kg/1000 m  (based on an exit concentration of 50 ppm NO ).  The overall
facility N0_ emission is reduced by 81 percent.
           A.         -                                           '       -
5.2.5   Modified In-situ With Indirect Combustion, Gas Recycle Above Ground
        Process - Case # 5
A.      Base Case—
        The base case consists of a modified in-situ retort supported by an
indirect combustion - gas recycle above ground retort. The in-situ retort
produces 60 percent of the oil.
        The gas from the in-situ retort is cleaned with the standard water
wash for ammonia removal and either direct or indirect conversion of l^S for
sulfur gas control.  The combusted gas is passed through a baghouse for
particulate control.  The schematic for this process is shown in Figure 5-6.
The expected emissions for three alternatives are presented in Table 5-14.
                                       5-30

-------
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                                                  5-31

-------
TABLE 5-14.  TOTAL FACILITY CONTROLLED EMISSIONS
            Case  5  - Modified  In-situ
        Indirect Combustion Above-Ground
Base Case

Room and pillar
Retort gas in-situ
Above-ground
Upgrade
Total
Alternate #1 SOX-H2S
NOX-NH3
PM - dry
Emissions, kg /I 000 m3 of Oil
CO
150
72
53
25
300
removal
removal
HC
20
35

150
205
NOX
345
7342
369

8056
S0x
20
2033
968

3020
PM
181
739
, 74

994
- activated carbon
- water and
acid wash
venturi/baghouse
HC and CO - vehicles/catalytic converter

Room and pillar
Retort gas in-situ
Above-ground
Upgrade
Total
Reduction
(from Base Case)
% Reduction
CO
15
72
53
2
142
158

52
HC
2
35
0
60
97
108

53
NOX
345
2375
302

3022
5034

62
S0x
20
191
50

261
2760

91
PM
181
211
21

413
581

58
Alternate #2 N0_ - ammonia injection
A.
PM - dry
venturi/baghouse
HC and CO - vehicles/catalytic converter

Room and pillar
Retort gas in-situ
Above-ground
Upgrade
Total
Reduction
(from Alt. #1)
% Reduction
CO
15
72
53
2
142
0

0
HC
2
35
0
60
97
0

0
NOX
345
254
25

624
2398

79
sฐx !
20
191
50

261
0

0
PM
181
11
1

193
221

53
                        5-32

-------
B.      Alternate 1—                                            !
        The first alternate process scheme uses  catalytic  converters  for  mine
vehicles, an acid and water wash for ammonia removal, the  activated carbon-
hypochlorite process of H2S and organic sulfur removal  and the  dry
venturi/baghouse for particulate control.
        The acid wash reduces the NOX emissions  from burning  the in-situ
                                      1
retort gas from 7342 to 2375 kg/1000 nr and reduces the NO,, emissions  from
                                                           X
burning the above ground retort gas from 369 to  302 kg/1000 m3.  The  higher
effect on the in-situ retort gas is due to relatively high gas  volume  produced
by the in-situ retort which results in high ammonia emission  rates from either
the water wash or acid wash towers.  The overall facility  NO  emission is
reduced by 62 percent.
        The activated carbon-hypochlorite process reduces  the S0_ emissions
                          ,.                                     x
from 3020 to 261 kg/1000 mj of oil for a 91 percent reduction.
        The dry venturi/baghouse reduces the particulate emissions associated
with burning the retort gases (in-situ & above ground) from 813 to 230 kg/1000
 3
m  of oil.  The overall facility reduction in particulate  emissions is 58
percent.  The use of catalytic converters on mine vehicles  reduces the CO and
HC levels from mining by 90 percent, and the total CO and  HC  levels by 52 and
53 percent respectively.
C.      Alternate #2—
        The second alternate control scheme uses ammonia injection for post
combustion NOX control and the dry venturi/baghouse with the  higher space
velocity for particulate control.
        NOX emissions from combustion of the retort gas are reduced from  2677
                O
to 279 kg/1000 nr of oil for an overall facility reduction  of 79 percent.
Particulate emissions from combustion of the retort gas are reduced from  232
               o
to 12 kg/1000 nr of oil for an overall facility reduction of  53 percent.
        The above information for Case #5 is summarized in  Table 5-14.
5.2.6   Summary
        The following discussion evaluates the differences  between the five
cases and the effect on the overall facility emissions.
                                       5-33

-------
A.      Carbon Monoxide and Hydrocarbon Emissions—
        Carbon monoxide emissions for the base  case conditions  are  reasonably
consistent with the exception of case #4, the indirect  combustion,  solids
recycle with a fluidized bed spent shale combustor  which has extremely high CO
emissions.  The alternate 1 conditions reduce the CO emissions  by
approximately 90 percent due to the addition of  catalytic  converters  to  the
mine vehicles and engines.  However, this has little effect on  Case #4 CO
emissions.  The alternate 2 conditions, using a  cascading  bed spent shale
combustor with its superior means for controling combustion conditions at  each
                                                                 i        Q
stage of the combustion process reduces the CO emissions to 570 kg/1000  m   of
oil; however, the facility CO emissions for Case #4 are still considerably
higher than the other four cases. No additional  means of control seems
feasible.
        The hydrocarbon emissions are consistent for all of the cases
considered.  The addition of the catalytic converters reduce these  hydrocarbon
emissions from the mining operations by 90 percent  and no  further reduction
seems feasible.
B.      Particulates, Nitrogen and Sulfur Oxides (PM, NOX, SOX)—
   1.   Retort Gas Combustion— The emissions from combustion  of the retort
gas for particulates, nitrogen and sulfur oxides are shown in Figures 5-7,  5-8
and 5-9.
        These figures indicate that there is wide variation in  emission  levels
for the five processes based on the PSD permit application proposed technology
(Base Case conditions).  For particulates, the emission levels  vary from 200
                o
to 800 kg/1000 m  of oil; for nitrogen oxides the emission levels vary from
1000 to 8000 kg/1000 m3 of oil; for sulfur oxides the emission  levels vary
from 350 to 3000 kg/1000 m3 of oil.
        The first alternative considered was the use of the activated carbon
enhanced ^S removal process, an acid wash for improved ammonia removal  and
the addition of a dry venturi - baghouse for post combustion particulate
control.  Referring to Figures 5-7, 5-8 and 5-9, the emission levels  for
alternate #1 show considerably less variation, particularly for sulfur oxides
(ranging from 100 to 250 kg/1000 m3 of oil) and  particulates (range from 50 to
                                       5-34

-------
en
 3
 o
 o
 o
 o
 I
 M
 CO
 CO
               BASE CASE
ALTERNATE #1
ALTERNATIVE
                                                 #1 #2  #3
                                                           #4  #5
ALTERNATE #2
                                        CASE #1
                                        CASE #2
                                        CASE #3
                                        CASE #4
                                        CASE #5
      Figure 5-7.  Nitrogen oxide emissions from retort gas combustion.
                   Summary for five cases.   (Taback,  H.J.,  et  al.,  1986)
                                         5-35

-------
S

o

ง
r-l

O


CO
M
OT
cn
              BASE CASE
                                                                     • CASE #1


                                                                     H CASE #2


                                                                     B CASE #3


                                                                     H CASE #4


                                                                     D CASE #5
                                ALTERNATE #1

                                ALTERNATIVE
ALTERNATE #2
  Figure 5-8.  Sulfur oxide emissions from retort gas combustion.   Summary for

               five cases.   (Taback, H.J., et al., 1986)
                                        5-36

-------



en
o
o
o
i— i
MISSIONS K

900 •
800 •
700 •
600 •
500 •
400 •
300 •
200 •
100 •
0 •
           BASE CASE
ALTERNATE #1
ALTERNATIVE
#1 #2 #3   #4 #5
   •••••••••BSBSaE
   ALTERNATE #2
                                                                  • CASE #1
                                                                  0 CASE #2
                                                                  B CASE f 3
                                                                     CASE #4
                                                                  D CASE #5
Figure 5-9.  Particulate emissions from retort gas combustion.
             for five cases.  (Taback, H.J., et al., 1986)
                                     5-37

-------
              O                                                         -    '
 200 kg/1.000 nr of  oil).   The  variation of  nitrogen oxide emissions is still
 considerable, ranging  from 1000  to  4000 kg/1000 m3 of  oil.   Essentially,  the
 acid wash only removes the residual ammonia  without affecting the organic
 nitrogen content and has  no effect  on the  thermal  NO,,;  therefore, there  is
                                                     X
 relatively little  improvement in the NO emission  rate.           i
        The second alternative considered  was  ammonia  injection for NO
 control from  boiler and/or furnace  combustion,  staged  combustion for control
 of NOX emission from the  spent shale combustor  and the  dry  venturi - baghouse
 with an increased  space velocity which improves collection  performance at the
 expense of increased pressure drop.   Again,  referring  to Figures 5-7,  5-8 and
 5-9, it is apparent that  the  addition of these  controls  essentially levels the
 performance of all five processes.
   2.,   Total Facility Emissions — The particulate, nitrogen oxide and  sulfur
 oxide emission levels  for alternate  #2 conditions  along  with the total
 facility emissions are shown  in  Figures 5-10, 5-11 and  5-12.   The particulate
 emissions (Figure  5-9) still  show variation  from 4 to  12 kg/1000 m3 of oil.
 However, the absolute  value is considerably  less than  the particulate
 emissions from the mining and solids handling operations and the total
 facility is essentially equivalent for all five cases ranging from 180 to 200
 kg/1000 m3 of oil.
        The nitrogen oxide  emissions,  Figure 5-11,  range from 75 to 500
 kg/1000 m3 of oil.  While this is still a  significant variation,  again the
 absolute magnitude of  the values  is  such that the  net variation  in the total
 NOX emission for the five facilities  is less than  2 to 1  ranging from  400 to
 800 kg/1000 m3 of  oil.
        The sulfur oxide  emissions,  Figure 5-12, range from 100  to 250 kg/1000
 3
 m  of oil and are  essentially the same for the  total facility as  there are no
 other significant  sources  of  sulfur  emissions.
        The basic  conclusion  derived  from the above analysis  is  that,  although
 the air emission levels for the  different retort processes  with  controls
proposed in the PSD permit  applications  can vary considerably, sometimes  by as
much as two orders of magnitude,  the  application of control  techniques that
                                       5-38

-------


c
r-
o
"a
o
o
o
T— 1
a
SNOISS:
i


200
180 •

160 -
140 •
120 •
100 •
80 •
60 •
40 •
20 •
0 •
                                    #1    #2    #3
                                                    #4   #5
             ALTERNATE #2
        RETORT GAS COMBUSTION
 TOTAL
FACILITY
Figure 5-10.  Particulate emissions for total facility.  Summary for
              five cases.  (Taback, H.J., et al., 1986).
                                  5-39

-------
   900
   800
   700
ns 600-
ง 500
a 400

ง 300 •
m 200-
w
w 100-
     o-
                                                               • CASE #1
                                                               E3 CASE #2
                                                               H CASE #2!
                                                               13 CASE #4
                                                               D CASE #5
          ALTERNATE #2
     RETORT GAS COMBUSTION
                                                 TOTAL
                                                FACILITY
Figure 11.  Nitrogen oxide emissions for total facility.  Summary for
            five cases (Taback, H.J., 1986). ""
                                     5-40

-------

M
O
O
en
(3
o
0
o
t— 1
p
CO
O
H
CO
co
M
@
300 '
250 •


200 •


150 '

100 •


50 •
]
!
0 i
     #1
                     • CASE #11
                     E2 CASE mi
                     5 CASE #3
                     H CASE #4
                     D CASE #5
            ALTERNATE #2
       RETORT GAS COMBUSTION
  TOTAL
FACILITY
Figure 12.  Sulfur oxide emissions for total facility.  Summary for five
            cases (Taback, H.J., et al., 1986).
                                    5-41

-------
                   statenent d
                   q,,es  cms
ฐU .hale reeo,ery procass.
                         tb.
ซPPU-
                                  that

                                     to
5-42

-------
are either improvements over proposed technology or more suitable for a
specific application, result in similar emission levels for all five processes
considered.  This statement does need to be qualified by the fact that some of
the control techniques considered have not been applied specifically to the
oil shale recovery process.  However, these techniques have been proven at the
full scale level in various other difficult control applications.
                                        5-42

-------
                             SECTION 6.0

                             REFERENCES

Agarwal, A. K.  Assessment  of  Solid Waste  Characteristics and Control
Technology  for  Oil  Shale Retorting.  EPA-600/7-86-019,  NTIS PB86 198371,
1986.                                                        ]

Anonymous.  Parachute  Creek Shale Oil  Program.   Union Oil Company
Brochure, 1983, 12  pp.                                       :

Anonymous.  Clear  Creek Shale  Oil Project  - Joint Venture.  PSD Permit
Application for Upgrading  in Grand Valley.  Environmental Research &
Tech.,  Fort Collins, CO,  1982.                               \

Anonymous.  Permit  Application.   Paraho-UTE Facility.  Prevention of
Significant Deterioration.   Utah Air  Conservation Program.  Paraho
Development Corp.,  Grand  Junction, CO, November 1981.

Anonymous.  Perspective on the Emerging Oil Shale Industry.  EPA
Environmental Assessment,  EPA-625/9-81-005, NTIS PB83-171769, 1983.

ARCO Coal Company.   Black Thunder Haul Road Supply, 1980.

Ball,  B. C. "An  investigation into  the Potential Economics of Large-
Scale Shale Oil Production."  American Chemical Society Series.  Vol.
1981,  No. 163,  pp.  195-221, 1981.

Banks,  C. E., et  al.   "Simulated Dewatering Requirements at an Oil Shale
Surface Mine.   Piceance  Creek  Basin,  Colorado."  Mineral Industries
Bulletin, Vol.  21,  No.  2,  1978.

Barke,  W. L., et  al.   Evaluation of  Processes for Liquefaction and
Gasification of Solid  Fossil Fuels.   Volume 2 - Oil Shale and Tar
.Sands:   Mining  and Liquid Recovery.   Stanford Research Inst.iMenlo Park,
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Bartok, W., et  al., Basic Kinetic Studies  and Modeling of NO, Formation in
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Bates,  E. R., and K.  Jakobson.  "Status of EPA's Pollution Control
Guidance Document For  Oil Shale."  Fourteenth Oil Shale Symposium,
Golden, CO, 1981.                                            ',

Bates, E. R., and T.  L.  Thoem.  Environmental Perspective on the Emerging
Oil  Shale  Industry.  EPA Report No.  EPA-600/2-80-205b, NTIS PB 81  186942,
 1981.

Bates, E. R., W.  W. Liberick,  and J.  Burckle.  Oil Shale;  Potential
Environmental  Impacts  and Control Technology.  Environmental Research
 Brief, U.S. EPA Industrial Environmental Research Laboratory", Cincinnati,
 OH,  Report  No.  EPA-600/D-84-036, NTIS -No.   PB-84-190743,  1985, 14 pp.


                                   6-1

-------
Baughman, G. L., and T. A. Sladek.  "Shale Oil Recovery Methods."  Mining
Engineering, Vol. 33, No. 1,1981, pp. 43-47.

Beychok, M. R. and W. J. Rhodes. Comparison of Environmental Design
Aspects of Some Lurgl-Based Synfuels Plants, 6th Symposium on
Environmental Aspects of Fuel Conversion Technology, Denver,_CO, October
1981.

Bland, V. "Evaluation of Sodium Sorbent Utilization in Flue Gas
Desulfurization."  KVB Report 72-806930-2020, Interim Report Research
Project 1682-2 for Electric Power Research Institute, Palo Alto, CA,
1985.  Unpublished draft report.

Booker, J. D.  "Oil Shale Retorting in the First Commercial Plants."
Proceedings of the 16th Intersociety Energy Conversion Engineering
Conference.  Technologies for the Transition.  ASME Publ., Vol.  1, 1981,
pp. 47-51.

Bourcier, D. R., et al.  "Preliminary Evaluation of Heavy Metals in
Dustfall in the Intermountain West Region."  14th Annual Conference Trace
Substances in Environmental Health, Columbia, MO, 1980.

Braun, R. L., et al. Mathematical Modeling of the Cascading-Bed Retorting
System and Comparisons of Model Calculations with LLNL Pilot Retort Data,
5th Briefing on Oil Shale Research, Lawrence Llvermore National
Laboratory, October 1985.                                   :

Bureau of Reclamation, U.S. Department of Interior.  Laboratory and Field
Studies of Soil Stabilizers, Engineering Research Center, Denver, CO,  ~~~~
1982.

Burnham, A. K. Review and Comparison of Chemistry of In-Sltu and
Aboveground Processing, 5th Briefing on Oil Shale Research, Lawrence
Livermore National Laboratory, October 1985.

Calvert, S. "How to Choose a Particulate Scrubber.  Chemical Engineering.
84(18): pp. 54-68, 1977.

Calvert, S., J. Goldschmid, D. Lelth, and D. Metha.  Wet Scrubber System
Study, Volume I - Scrubber Handbook.  EPA-R2-72-118a, NTIS No. PB213016,
1976.

Capital and Operating Costs of Selected Air Pollution Control Systems.
Prepared by Card, Inc.  EPA-450/5-80-002, 1978.             !

Cathedral Bluffs Shale Oil Co.  PSD Permit Application.  Prevention of
Significant Deterioration.  (Amendment), 1982.
                                  6-2

-------
Cavanaugh, E. C., et al.  Atmospheric  Pollution  Potential  from Fossil
Fuel Resource Extraction, On-Site  Processing,  and  Transportation.   Radlan
Corporation, Austin, TX, Report  No.  EPA-600/2-76-064,  NTIS No. PB-252649
1976, 292 pp.

Cena, R. J., General Description for a One  Ton/Day Rapid Pyrelysls,  Solid
Recycle Retort. 5th Briefing on  Oil  Shale Research,  Lawrence-LIvermore
National Laboratory, October 1985.

Cha, C. Y., and D. Chazin.  "A Survey  of Current Technologies  for
Production of Oil from Oil Shale by  In-Situ Retorting  Processes:  Their
Technical and Economic Readiness and Requirements  for  Further
Developments."  AIChE Symposium  Series. Vol. 78, No. 216,  1982, pp.  1-17.

Chappell, W. R., and D. D. Runnells.   "Toxic-Trace Elements  and Oil  Shale
Production."  llth Annual Conference on Trace  Substances in  Environmental
Health:  Abstract. 1977.         ~~~~~


Chevron Shale Oil Company.  Clear  Creek Shale  Oil  Project.   Joint Venture
Mine and Retort Facilities.  PSD Permit Application.   Vol.  1,
Environmental Research & Technology, Fort Collins,  CO,  1982.

Cieslewicz, W. J.  "Selected Topics  of Recent  Estonian-Russian Oil  Shale
Research and Development."  Colorado School of Mines Quarterly.  Vol. 66,
No. 1, 1971.

Colorado School of Mines: Proceedings  of the First Five Oil  Shale
Symposia, 1964-68. Vol. 59, No.  3, 1964, 911 pp.

Committee on Synthetic Fuel Safety.  Safety Issues Related to  Synthetic
Fuels Facilities, NTIS PB82-258682,  1982.

Cooperative Inst. for Research in Environmental Science, Boulder, CO.
Environmental Chemistry of Oil Shale Development.  Interim Technical
Progress Report, January 1 - August  1, 1983.   Report No. DOE/ER/60121-1,
1983.  11 pp.

Cotter, J. E., et al.  Fugitive  Dust at the Paraho Oil Shale
Demonstration Retort and Mine.EPA-600/7-79-208, NTIS No. PB80-
122591,1979.
                                  6-3

-------
Cox, C. H., and 6. L. Baughman.  "Oil Sands:  Resource, Recovery, and
Industry."  Mineral & Energy Resources, Vol. 23, No. 4, 1980, Publ .,
Colorado School of Mines.

Damon  J. E., et al.  "Economics of SCR Post Combustion NOX Control
Processes " In Proceedings of the 1982 Joint Symposium on Stationary
Combustion NOX Control,Vol. II, EPA-600/9-85-022b, NTIS No PB85-235612,
1985.

Daum   K. A., et al.   "Analysis of Sulfur Control Strategies for the Oil
Shale  Industry."   J.  Air Pollution Control Assoc.  Vol. 32, No. 4,
1982.  pp. 391-392.                                             '.

Dennis, R., ed., Handbook on Aerosols.  TID-26608.  Technical Information
Center, Energy Research and Development Administration, Tennessee, 1976.

Denver Research  Institute, Pollution Control Technical Mannual:   Lurgi Oil
Shale  Retorting with  Open Pit  Mining,  EPA-600/8-83-005, NTIS  PB83-200204,
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Denver Research  Institute.  Pollution  Control  Technical Manual:   Modified
"In--Situ"  Oil  Shale  Retortig Combined  with  Lurgi  Surface  Retorting,  EPA
600/8-83-004,  NTIS PB83-200121,  1983.

Denver Research  Institute.  Pollution  Control  Technical Manual:  TOSCO 2
Oil Shale Retorting  with  Underground Mining,  EPA-600/8-83-003,  NTIS  PB83-
200212,  1983.

 Department of Energy, Office  of Technology  Impacts, Environmental Control
 Costs  for Oil  Shale  Processes. Washington.  DC, October 1979.    ;

 Detailed Emissions Calculations for Oil  Shale Mining and  Ore Handling and
 Construction - Related Activities Associated with the Clear Creek Shale
 OiT Project.  Appendix 2, 1982.

 Diaz  J. C. and R. L. Braun.   Mathematical  Modeling of Oil  Shale Retorting
 in a'Pluidized-Bed Pyrolyzer and Lift-Pipe Combustor, 5th Briefing on Oil
 Shale Research, Lawrence Livermore National Laboratory, October 1985.

 Domahidy, 6., et  al.  "Air Pollution control for Oil Shale
 Applications."  Proceedings from the 1983 Eastern Oil Shale Symposium,
 pp. 271-280.

 Duir, J. H., B. A. Christolini, and C. F. Griswold.  "Oil Shale'Retorting
 Technology."  Chemical Engineering Progress.  Vol. 79, No. 2, 1983. pp.
 45-50.                                                         i
                                        6-4

-------
 Duir, J. H., et al.   "Union  Oil  Shale  Retorting Technology."   Chemical
 Engineering Progress.  Vol.  6, No.  3,  1982,  p.  264.

 Dunn, D. W., T. A. Bonner, and S. C. Cheng.   Oxides  of  Nitrogen/Ammonia
 Control Technology for Oil Shale Retort  Emissions  (Final  Report).
 Monsanto Research Corp.,  Dayton, OH, Report  No.  EPA-600/2-84-078,  NTIS
 Wo. PB84-171453, 1984, 89 pp.

 Dyni, J. R.  "Lacustrine  Oil Shales and  Stratigraphy of Part  of  the
 Kishenehn Basin, Northwestern Montana."  Mineral & Energy Resources.
 Vol. 26, No. 4, 1983, Publ., Colorado  School of  Mines,  Golden, CO.

 Dziegiel, H. T., et al. The  Thermal DeNOx  Demonstration Project.   In:
 Proceedings of the 1982 Joint Symposium  on Stationary Combustion NO
 Control, Volume II, EPA-600/9-85-022b, NTIS  No.  PB85-235612,  1985. *

 Edgar, T. F., et al.  Environmental Effects  of  In-Sltu  Gasification of
 Texas Lignite.  EPA Report EPA-600/7-81-035,  NTIS  PB81-171654, 1981.

 Edward, M. S.  J3_ 2s Removal  Process for  Low-Btu  Coal Gasification.  Oak
 Ridge National Laboratory, ORNL/TM  6077, January 1979.

 Environmental Protection  Agency.  Manual for  Methods of Quickly
 Vegetating Soils of Low Productivity,  Construction Activities.  Office  of
Water Programs, Applied Technology Division,  Washington,  DC.,  1975.

 Environmental Protection  Agency.  Iron and Steel Plant  Open Dust Source
 Fugitive Emission Evaluation, EPA-600/2-79-103,  NTIS No.  PB299385, 1979.

 Environmental Protection  Agency.  Technology  Assessment Report for
 Industrial Boiler Applications:  Particulate  Collection.   EPA-600/7-79-
 178h,  NTIS No. PB80-176365, December 1979.

 Environmental Protection  Agency.  Air  Pollution  Engineering Manual,
 Second Edition.  AP-40, May  1973.

Environmental Protection  Agency.  Capital  and Operating Costs of Selected
Air Pollution Control Systems.  EPA-450/5-80-002, December 1978.

Environmental Protection  Agency.  Development of Emission  Factors for
Fugitive Dust Sources, EPA-450/3-74-037, NTIS No. PB238262, 1974.
                                  6-5

-------
Environmental Protection Agency.  Compilation of Air Pollutant Emission
Factors, AP-42, 1985.

Environmental Protection Agency.  Extended Evaluation of Unpaved'Road
Dust Suppressants in the Iron and Steel Industry.  Prepared by Midwest
Research Institute, EPA-600/2-84-027, NTIS No PB84-154350, 1984.^

Environmental Protection Agency.  Control of Emissions from Lurgi Coal
Gasification Plants.  EPA-450/2-78-012, NTIS No. PB279012, March" 1978.

Evans, R. J., et al.  "Development of a Sampling Train for Environmental
Assessment of Coal Gasification and Oil Shale Hydro Retorting
Processes."  182nd American Chemical Society National Meeting, New York,
NY, August 23-28, 1981, Paper No. 182.

Fisher, S. T.  "Electrical  Induction Heating for the In-Situ Processing
of Coal, Oil Shale and Oil  Sand."  International Electrical, Electronics
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                                      6-6

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                                  6-7

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                                  6-8

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                                  6-10

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                                  6-11

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                                  6-12

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                                  6-15

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Teller, A. J., "Simultaneous Acid Gas and Particulate Recovery,"
In: Symposium on the Transfer and Utilization of Particulate Control
Technology, Volume 2.  EPA-600/7-79-044b, NTIS PB 295227, 1979. ;

Teller Environmental Systems, Inc.  Dry Venturi (a schematic concept
drawing), Shrewsbury, MA, 1986.

Teller, A. J., Teller Environmental Systems, Inc. Incineration - Resource
Recovery Flue Gas Emission Control, presented at the Acid Gas and Dioxin
Control for Waste to Energy Facility Symposium, Washington, DC, November
1985c.

Teller, A. J., Teller Environmental Systems, Private Communication,
1985d.                                                          ;

Thompson, R. E., et al. "Retrofit NOX Control Guidelines for Coal-Fired
Utility Boilers," Research Project 2154-1, Final  Report for the Electric
Power Research Institute, Palo Alto, CA5 1985.

Tomany, J.P. Air Pollution:  the Emissions, the Regulations, and the
Controls.  American Elsevier Publishing Co., Inc., 1975.

Tosco Development Corp., PSD Permit Application, Sand Wash Shale Oil
Facility, June 1981.

Travis, C. C., et al.  Exposure Assessment Methodology and Reference
Environments for Synfuel Risk Analysis.  Oak Ridge National Laboratory,
TN, Report No. DOE ORNL/TM-8672, NTIS No. PBDE 84004128, 1983, 89 pp.

TRC Environmental Consultants.  Coal Mining Emission Factor Development
and Modeling Study, 1981a.
                                      6-16

-------
TRW Energy Systems Group, Oil Shale Data Book, prepared  for  U.S.
Department of Energy, NTIS PB 80-125636, June  1979.

Union Oil Co. of California, Union Energy Mining  Division: PSD Permit
Application for Union's Phase II Oil Shale Mining and Retort Facility,,
1982.

Union Oil Co. of California, Union Energy Mining  Division: -PSD Permit
Application for Union's Phase II Shale Oil Upgrading Plant Facility,
1982.

University of Wyoming Research Corp., Laramie, WY.  Oil  Shale  Tar  Sands,
and Underground Coal Gasification.  Quarterly  Progress Report,  July -
September 1983.  Report No. DOE/FE/60177-1534, NTIS No.  DE84008069, 1983,
92pp.                                     	             I

U.S. Army Engineer Waterways Experiment Station.  Materials  Evaluated as
Potential Soil Stabilizers.  Vicksburg, MS,  1977.

U.S. Army Corps of Engineer, Sacramento District.  Getty and Cities
Service Shale Oil Projects^  Environmental Impact Statement'  (Final
Report), 1984.                                             •

Van Zanten, K. D., et al. "Control of Sulfur Emissions from  Oil Shale
Retorting Using Spent Shale Absorption," 19th  Oil Shale  Symposium
Proceedings, Colorado School of Mines Press, Golden, CO,  1986.

Vatavik, W.M., and R. B. Neveril.  Pa.rt X:  Estimating Size  and Cost of
Venturi Scrubbers.  Chemical Engineering, 1981, pp 93-96.  :

Waples, D. W.  "C/N Ratios in Source Rock Studies."  Mineral Industries
Bulletin.  Vol. 20, No. 5, 1977, Colorado School  of Mines, Golden, CO.,

Weber, J. H.  "Oil Shale Processing Technology Above Ground  and Below
Ground, Sampling Strategy and Characterization of Potential  Emissions
from Synfuel Production."  Symposium on Sampling  Strategy and
Characterization of Potential Emissions from Synfuel Production, Austin,
TX, June 6, 1974.

Weiss, H.  "Retorting of Oil-Shale - Background,  Status  and  Potential of
the Lurgi Ruhrgas (LR) Process."  American Chemical Society  Abstracts..
Vol. 183, March 1982, p. 26.

Wendt, J.O.L.  "Fundamental Coal Combustion Mechanisms and Pollutant
Formation in Furnaces", Prog. Energy Combust.  Sci., Vol.  6,  pp. 201-222,
1980.

White, J.J.  Role of Electrostatic Precipitators  in Particle Control:  A
Retrospective and Prospective View.  Jour. Air Poll. Control Assoc. Vol.
25, No. 2., 1975.
                                  6-17

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White River Shale Project.  Prevention  of  Significant  Deterioration of
Air Quality - Oil Shale Tracts Ua  and Ub.   Bechtel  Petroleum,  Inc., San
Francisco, CA, Job #14188, August  1981.                     '-.

Wong, C. M., R. W. Crawford, A. K. Burnham,  and  P.E. Miller-. From Bench-
Top to Pilot Scale: Determination  of Sulfur  Gases by Triple.Quadripole
Mass Spectrometry (TQMS), 5th Briefing  on  Oil  Shale Research,  Lawrence"
Livermore National Laboratory, 1985.
                                  6-18

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                                   APPENDIX A
                                 TRACE ELEMENTS

        Western oil  shale  from the Green River Formation is a fine-grained,
sedimentary rock that  contains about  20 wt% organic material in a mineral
matrix composed primarily  of  dolomite and calcite.   Also present in trace
quantities are compounds of certain metals considered to be hazardous to human
health.  These may be  in the  form of  sulfides, as  substitution products in
major mineral phases,  or as organometallic compounds (Desborough et al. 1976;
Fox et al. 1982; Fish  1983).   These trace metallic  compounds are mobilized and
released to the environment when oil  shale is  processed.
        These hazardous compounds are released as dust,  in  gaseous form or as
contaminants in product or waste streams.   Fugitive dust  and particulates,
largely raw and retorted shale fines  and suspended  soil material,  are produced
by mining, crushing, screening,  haulage,  retorted shale  disposal and other
material handling operations.
        Trace elements present in the raw shale are redistributed  during
retorting among the  oil, retort  gases,  process water and  retorted  shale.   The
low to medium Btu gas produced during retorting may be subsequently used for
power generation or  as a heat  source.   Depending upon an  element's mineral
residence, the retort operating  conditions  and subsequent offgas handling,
some of the trace metals may be  emitted  from the retort plant  as gases  and
particulates.  Trace metals may  also  be  released during the  refining of the
crude shale oil.  However, such  emissions  are  expected to be  similar to those
from conventional refineries.  This source  has not  been specifically studied
for shale oil refineries and is  thus not  discussed  here.       '  i
        Table A-l summarizes and compares  emission  factors and rates for  those
operations that are unique to  the  oil  shale industry, namely,  retorting and
material handling.  The database  and assumptions explicit in  these estimates
are discussed at greater length  in  subsequent  sections.   These  same  trace
elements may also be emitted from other  conventional  emission  sources at  an
oil shale facility, including  industrial oil-  and coal-fired boilers  and
diesel engines; however, emissions  from  those  sources are expected to be  low

                              •         A-l

-------
          TABLE A-l.  SUMMARY OF TRACE ELEMENT EMISSION FACTORS AND
               EMISSION  RATES  FOR RETORTING AND SOLIDS HANDLING
Emission Rate Per

As
B
Ba
Be
Br
Cd
Cl
Co
Cr
Cu
F
Fe
Hg
Mo
Mn
Ni
Pb
Sb
Se
Th
U
V
Zn
Emission
Retorting^1)
(mg/bbl)
M3-770
—
<24-<292
—
>33
0-1070
1300
<0.3-<3
<6-151
<8
—
<1040-<4000
39-208
15-940
<1
<0.3-<2
<18
<12-<17
Factors
Materials
Handling^2'
(mg/bbl)
1.8
2.6
18
0.090
0.16
0.029
6.9
0.33
1.2
1.2
49
720
0.0032
0.90
11
0.79
0.79
0.071
0.082
0.21
0.15
4.0
2.7
10,000
Retorting'1^
(ton/yr)
>0. 05-3.1
—
<0.1-<1.2
—
>0.1
0-4.3
5.2
<0.001-<0.04
<0.02-0.6
<0.03
' —
<4.2-<16
0.2-0.8
<0. 004-0. 02
<0.02-<0.2
<0.02
<0.1
<0.004
>0.06-1.8
<0.004
<0.001-<0.008
<0.07
<0.05-<0.07
BPD Capacity
Materials
Handling^2'
(ton/yr)
0.01
0.01
0.1
0.004
0.001
0.0001
0.03
0.001
0.005
0.005
>0.2
2.9
0.0001
0.004
0.04
0.0032
0.0032
0.0003
0.0003
0.0008
0.0006
0.016
0.01

Total
| (ton/yr)
>0. 06-3.1
0.01
0.1
>0.004
>0.1
0-4.3
5.2
0.001
0.005-0.6
0.005
>0.2
2.9
0.2-0.8
0.004-0.02
; 0.04
0.0032
0.0032
0.0003
0.06-1.8
0.0008
0.0006
0.016
0.01
(1)  Assumes no trace elements are removed in criteria-pollutant control
     technology and that no special technology is installed to reduce trace
     elements.

(2)  Assumes particulate and fugitive emissions are controlled as specified
     in company permit applications.
                                     A-2

-------
compared to retorting and material handling  operations.   They would be  similar
to emissions reported for these elements  in  other  industries.   Therefore,
these conventional sources are not covered here, and  the  reader is  referred to
the following references: for boilers  (Krishnan and Hellwig  1982 and
Littlejohn 1984); for diesel emissions  (NRG  1981).
        Table A-l shows that retorting  is the principal source of; trace
element emissions, particularly of the  volatile elements  As,  Br,  Cd,  Cl, Hg
and Se.  Although no data have been reported for F, it is anticipated that  it
would be emitted during retorting because it is chemically similar  to the
other halides that have been reported in retort gases (Br, Cl  and I).
Material handling, which releases about 30 g/bbl of particles,  contributes
greater than 1 mg/bbl of As, Cl and F,  as well as  the nonvolatile elements  B,
Ba, Cr, Cu, Fe, Mn, V and Zn.
        Of those elements that are emitted in significant quantities, only  Pb,
Be, F and Hg are covered in the PSD permit applications for various
projects.  Table A-2 compares PSD emissions  with emissions calculated in this
study.
        The most striking discrepancies between the PSD permit  applications
and this study occur for Hg.  The PSD permit applications  assumed that little
or no Hg would be emitted from the retort, typically arguing  that Hg  is
released in the elemental form and therefore would condense out or be
otherwise removed in the retort system.  However,  some studies reviewed here
indicate that the majority of the retort Hg  is present as  organomercurials
that are not expected to condense or be otherwise  lost.   Therefore,  it is
possible that PSD applications, as presently filed, greatly underestimate Hg
emissions.
        This section reviews available literature on hazardous, noncriteria
trace elements released to the atmosphere during the production of crude oil
from Green River oil shale.   Emission factors are estimated and compared with
those used by industry in PSD applications.
                                      A-3

-------
   TABLE A-2.   COMPARISON OF PERMIT APPLICATIONS ESTIMATES OF Be,  F,  Hg AND
                Pb EMISSIONS  WITH THOSE  DETERMINED IN THIS  STUDY
                                   (tons/yr)
Be
PSD This
Study
(tons/yr)
Cathedral Bluffs
Clear Creek
Cottonwood
Paraho
Syntan
Union B
White River
0
(2)
• 0.001
(1)
(1)
0.0024
(1)
>0.005
>0.04
>0.02
>0.02
>0.02
>0.04
>0.04
F Hg
PSD Thls PSD This
Study Study
(tons/yr) (tons/yr)
7.8
(2)
0.93
2.9
1.45
1.45
1.8
>0.2 0.003
>2 (2)
>1 0.05
>1 (1)
>1 (1)
>2 (1)
>2 , (1)
0.2-1 ;
2-8 ;
1-5
1-3
1-4 ;
2-7
2-8 ;
Pb
PSD Thls
Study
(tons/yr)
0.15
(2)
(2)
(2)
0.03
(2)
0.46
0.004
0.03
0.02
0.01
0.01
0.03
0.03
(1)  Negligible
(2)  Not reported
                                     A-4

-------
RETORTING
        The principal source of trace element emissions at an oil shale
facility is the retort itself.  During retorting, raw shale is pyrolyzed to
release organic vapors, and retorted shale may be combusted to recover
energy.  The high processing temperatures, from 500 to 700 C in surface
                                                                 i
retorts and up to 1200 C in in-situ retorts, can mobilize some of the trace
elements in the raw shale and redistribute them among gases, oil, process
water and retorted shale.
        The majority of the trace elements are present in the gaseous state in
unprocessed retort gases, which contain very low particulate concentrations.
These gases would only reach the environment as a result of leaks or during
upset conditions.  However, most developers will generate power from the large
quantities of low Btu gas produced during retorting.  Combustion of these
gases to produce power or in a flare to control emergency gas purges can
generate significant quantities of respirable particulates that are highly
enriched in volatile trace elements, including As, Br, Hg and Se.
        The quantity of trace elements volatilized during retorting has been
                                                                 ',
studied by making direct, gas phase measurements and by mass balances in which
gas phase emissions are calculated by difference.  These studies have revealed
that trace element emissions during retorting are primarily controlled by
retorting temperature, retort configuration, and operation of the raw shale
bed.  Raw shale mineralogy, heating rate and/or retorting atmosphere may also
affect trace element partitioning.
        This section summarizes what is presently known (August 1985) about
trace element emissions from oil shale retorts.  Emphasis is placed upon Hg,
Cd, As and Se because they are volatile in oil shale retorts and may be
present in the untreated gases at relatively high concentrations.  Available
data for other less volatile elements are also summarized.
        The vast majority of the trace element data reviewed here was
developed using small laboratory retorts or pilot scale demonstration
facilities in which gases were not processed and treated as presently planned
                                       A-5

-------
for commercial facilities.  Therefore, the applicability of this information
to commercial oil shale plants is highly uncertain.
        Retort gases at a commercial plant will be processed and treated to
remove particulates, SO , NO  and hydrocarbons.  In most proposed commercial
processes, the gases are compressed, heavier hydrocarbons are removed  (the
shale oil) and treated gases are mixed with natural gas and burned.
Therefore, the information presented here is typically for uncontrolled
emissions unless otherwise noted.
        Ranges are reported for emission factors and are presumed to apply
equally to all types of processes, unless specifically excepted.

Mercury
        Because Hg and its compounds are the most volatile among the trace
elements that occur in oil shale, many studies have been conducted on  its
distribution during retorting.  These studies have demonstrated that Hg is
volatilized from the shale between 160 and 380 C, well in advance of shale
pyrolysis and oil evolution, and is redistributed among the retorted shale,
shale oil, water and gases.  From 23 percent up to 100 percent of the  Hg
originally present in the raw shale is partitioned into the gases, depending
upon raw shale mineralogy and retort operation.
                                                                    o
        Mercury concentrations of from less than 0.2 up to 8200  ijg/m  .have
been reported in retort gases, and emission rates of up to 60  ig/min have been
measured at field in-situ retorts.  Emission factors of from 39 to 208 mg/bbl
have been determined for five separate retorts based on continuous offgas
measurements.
        In uncombusted gases, the majority of this Hg is present as
organomercurials, principally dimethylmercury, while in combusted gases,
elemental Hg predominates.  Particulate Hg concentrations in uncombusted gases
are low and typically are 1-2 percent of the total Hg, while in combusted
gases, they account for over 30 percent of the total Hg.  Reported
concentrations of Hg and its compounds in shale gases typically exceed OSHA
                                       A-6

-------
and American Congress  of  Governmental  and Industrial Hygienists (ACGIH)
standards for workroom air,  and  thus may be  environmentally significant.
        Mass Balance Studies.  Most  investigations of the distribution of Hg
-in oil  shale retorts have used mass  balances in which the amount of Hg present
in retort inputs  (raw  shale) are compared with those in retort outputs
(retorted shale,  water, oil, gas).   In fact, most early evidence for the
emission of Hg  from retorts  came indirectly  from such studies by measuring all
outputs except  the  gas stream and then calculating the gas phase by
difference.  Subsequent studies  in which Hg  in the gas stream was directly
measured substantiated these earlier estimates.
        Average Hg  mass balances for four types of oil shale retorts are
summarized in Table A-3 as a percentage of raw shale Hg.  The imbalance is the
percentage of raw shale Hg that  is not recovered in the measured products and
thus  includes experimental error. The gas phase is rarely measured in such
studies, and it is  typically assumed to be equal to the imbalance.  This
approach has been validated  for  Hg in  several studies (Fox 1985a;' Hodgson
et al.  1982) by making continuous gas  phase  measurements.
        These studies  (Table A-3) demonstrate that the majority of the Hg is
mobilized from  the  raw shale and redistributed among the products.  A small
amount, from 1  percent to about  10 percent,  is nonvolatile and is retained in
the retorted shale  at  temperatures up  to 1000 C.  Although higher percentages,
from  18 to 33 percent, have  been reported in the retorted shale, these are due
to incomplete retorting and/or deposition of volatilized Hg on cool raw or
retorted shale  (Fox et al. 1977; Hodgson et  al. 1982; Fruchter et al. 1980),
as discussed later. The  majority of the Hg, from 70 percent up to
100 percent, is redistributed to the gases,  although some may be subsequently
retained on cool  retorted shale  (e.g., Paraho).  Lesser quantities are
partitioned to  the  oil and water.
        Hodson  et al.  (1982) and Olsen et al. (1985) used a 5.5 kg, externally
heated  retort to  study the effect of shale temperature, heating rate and  shale
type  on Hg partitioning.   A  typical  Hg emission profile from these studies is
shown in Figure A-l.   They found that  Hg evolution in western shale starts at
160 C,  peaks at 190 to 240 C and terminates  at 250 to 320 C, well in advance

                                        A-7

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-------
     0.6
     0.5
     0.4
     0.3
     0.2
     0.1
100
200
                                   300
                         400
                                                     500    600
                               CENTERLINE TEMPERATURE, C
Figure A-l.  Evolution of Hg into the offgas of the Battelle Pacific North-
             west  (BPNL) 5.5-Kg laboratory retort for a heating rate of
             2 C/min to 750 C for a Green River oil shale  (Olsen et al. 1985)
                                  A-9

-------
of shale pyrolysis and oil production.  This is similar to the I^S evolution
profile from organic sulfur (Wong  1983).
        They also found that from  2 percent up to  14 percent of  the Hg
originally present in the raw shale was not volatilized at 500 to 750 C and
remained in the retorted shale.  This is consistent with other studies in
which maximum retorting temperatures reached 760 to 1025 C (Fox  1985a; Fox
1980, Fruchter et al. 1978).  Therefore, a small fraction of the Hg in raw
shale is nonvolatile at retorting  temperatures and is not redistributed during
retorting or emitted to the atmosphere.
        Thus, the retorting temperature of commercial processes, which range
from 500 C to 1200 C, should have  no significant effect on the quantity of Hg
that is mobilized from the raw shale, since volatilization is essentially
complete by 320 C.  Differences in the amount of nonvolatile Hg  are probably
due to differences in raw shale mineralogy, while the amount actually present
in the gases depends on other aspects of retort operation, as discussed below.
        Concentrations.  Direct measurements of total Hg in the  offgases from
several types of retorts are summarized in Table A-4.  In the majority of
these studies, total Hg was continuously measured throughout the runs using
Zeeman atomic absorption spectroscopy (Girvin and Fox 1981).  All of the
measurements were made in uncontrolled offgas following the condensation of
heavy hydrocarbons (i.e., the shale oil).
        Mercury concentrations in  uncombusted retort shale gases range from
                             o
less than 0.2 up to 8200 vg/m .  Generally, much higher concentrations have
been measured in gases from small  laboratory retorts than from the much larger
pilot and field retorts (Table A-4).  These differences are partially due to
Hg losses by condensation and adsorption in the extensive offgas plumbing
systems of these larger field retorts (Hodgson et al. 1982, 1984) and
differences in gas flow rates.
        Laboratory retorts are carefully constructed and operated to minimize
losses by condensation and adsorption.  However, it is possible  that when a
commercial retort reaches steady state with respect to Hg, it may well behave
                                       A-10

-------








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-------
much as a laboratory retort, since Hg losses by condensation  and  adsorption
would no longer be significant.
                                                                  i
        Differences between laboratory and field Hg  concentrations  are  also
due to short duration sampling of highly variable offgas emissions, which
results in low concentrations for pilot and field in-situ  retorts;.  Laboratory
studies are also typically conducted in an inert atmosphere with  sweep  gas
volumes limited to rates required to remove the oil  product from  the  reaction
zone.
        Very little information is available on Hg concentrations in  combusted
retort gases.  The three studies reported in Table A-4 indicate that
concentrations range from 0.2 to 75 Pg/m3, typically at least a factor  of
three lower than in corresponding uncombusted gases.  Natural gas combustion
air and combustion by-products reduce stack gas concentrations, compared  with
uncombusted retort gas.  Particulate Hg is formed during combustion,  as
discussed below, and some probably settles out.
                                                                              t
        Emission Factors.  Mercury emission factors  were estimated  from the
raw data for the Hg mass balances summarized in Table A-3  and the;
concentrations presented in Table A-4.  The resulting factors (Table  A-4)
range from 39 to 208 mg of Hg per barrel of oil produced,  which scales  to 14.2
to 7-5.9 metric tons per year for a 1,000,000 bbl/day industry.  This  wide
range in emission factors is primarily due to variations in raw shale Hg
content and system losses.
        Emission Profiles.  The temporal distribution of Hg in offgases varies
for surface and in-situ processes.  Mercury is uniformly emitted  from surface
processes, while for vertical modified in-situ (VMIS) retorts (i.e.,
Occidental, Rio Blanco), it is nonuniformly emitted  in a pulse during the
final one-third of each retort burn (Figure A-2).
        The nonuniform distribution typical of VMIS  retorts is attributed to
their unique operation (Fox 1985a; Fox et al. 1978).  A VMIS  retort consists
of a stationary bed of rubblized shale through which a reaction zone  is
vertically propagated by sweep gases that are continuously introduced at  the
top of the retort.  Mercury present in the raw shale is released  at 160-320 C,
                                        A-12

-------
       10,000
        1,000
      .|5
      60
          100
          10
                   Laboratory Reto
                (Hodgson et. al 1982)
Controlled-State
Retort (Fox,
         1985a)
                       Occidental
                       Retort 6
                    20     40     60    80       100

                      PERCENT OP SHALE BED RETORTED
Figure A-2.  Mercury emissions from in-situ retorts as  a  function of percent
             burnccnmplete' (Frucheter et. al. 1983, except  as noted).
                                    A-13

-------
       10,000
       1,000
         100
      oo
      fa
          10
                   Laboratory Reto
                (Hodgson et.  al 1982)
                      Occidental
                      Retort  6
                    Rio Blanco
                    Retort 0
                     I
I
                  Controlled-State
                  Retort (Fox,
                           1985a)
              0     20     40     60    80       100

                      PERCENT OP SHALE BED RETORTED

Figure A-2.  Mercury emissions from in-situ retorts as a  function  of percent
             burnecomplete {'(Frucheter et. al. 1983, except as noted).
                                    A-13
                        KVB72 807530-2031 R#101

-------
well in advance of pyrolysis.  This Hg is carried down the bed by  the  sweep
gases and is eventually deposited on the cool shale ahead of the reaction
zone.  This deposited Hg is subsequently revolatilized when the bed heats up.
        This process of successive volatilization and deposition continues
during retorting, retarding the release of Hg from the retort.  When the shale
bed is saturated with Hg and/or the retort gets sufficiently hot,  Hg is
volatilized and swept out of the retort.  If the shale bed is saturated with
Hg before the reaction zone reaches the bottom of the retort, Hg will  be
uniformly released at a low level prior to the appearance of the pulse.  This
behavior has been observed during two field experiments  (Occidental, Rio
Blanco) and in laboratory simulations of the in-situ process (Figure A-2).
        Additional substantiating evidence (Fox 1985a) was also provided by
studying the Hg profile along a partially retorted shale bed (Figure A-3).
Individual 0.5 ft segments of the bed were separately recovered and analyzed
for Hg;, Cd and other elements.  Both Hg and Cd accumulated in cool zones below
the point at which retorting had been terminated.  Mercury accumulation is
evident in the peak at zone 17.
        The above-discussed emission profile was not observed at the
Geokirietics retort (Figure A-2), a horizontal true in-situ retort,: nor at Rio
                                                                   :
Blanco Retort 1 (Hodgson et al. 1984).  Hodgson's measurements at  Rio  Blanco
Retort: 1 were made during the latter half of the run and did not span  a long
enough time period to observe a Hg peak.  Hodgson observed large temporal
variations in the Hg emission rate, both within and between days,  presumably
due to large variations in retorting conditions used in an attempt to  control
retorting.  Additional variability is expected from natural variations in raw
shale mineralogy (Hodgson et al. 1984).
        The cause of the relatively uniform Hg emissions from the  ;Geokinetics
retort is uncertain.  Since it is a distinct technology and differs
substantially from VMIS, it is not unreasonable to anticipate a different
emission profile.  Mercury may have been deposited downstream of the exit gas
piping, in unretorted regions of the retort, or in the overburden  above the
retort.
                                        A-14

-------
         I
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         w
         ง
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             3.0
             2.0
             1.0
                     I   T
                    i    i    i    i   i   rn   TT
                  Maximum Retorting Temp. = 540 C
                  Retorting Atmosphere = N
                  Heating Rate = 1 C/min
                  Isothermal Advance Rate = 1.8 m/day

                                Retorting
                                Terminated
                                                       I   I
                             6   8    10   12  14  16

                                  RETORT ZONE
                                       18   20  22  24
Figure A-3.
Variation of Hg and Cd along the  shale bed in an interrupted
run oftfche 20-Kg controlled state retort.  Zones 'are numbered
consecutively from the top to the bottom of the retort.  Each
zone is 15 cm (0.5 ft) in length  (Fox 198.0).
                                  A-15

-------
        The nonuniform emission profile typical of most in-situ retorts
 (Figure A-2) is not expected  for suface retorts,  which are operated as plug
 flow reactors with co- or  countercurrent gas flow (i.e.,  Union B, Paraho).
 The shale bed continuously moves while  the  reaction zone  is stationary.
 Mercury emission profiles  for these  retorts are expected  to be relatively
 uniform, with minor fluctuations in  offgas  Hg concentrations due to
 differences in the Hg  content of the raw shale feed.   Although no,long-term
 monitoring has been conducted at a surface  retort,  several samples collected
 over a four-month period by Fruchter et al.  (1979)  definitely displayed this
 type of behavior.                                                 '
        However, Hg emissions from these types of processes are reduced by  a
 process similar to that occurring in in-situ retorts.   If retort gases contact
 retorted shale that is not subsequently reheated,  Hg will be deposited on the
 shale.  For example, In the Paraho process,  the shale  moves downward,
 countercurrent to recycle  gases,  which  move  upward.  Retorted shale and
 recycle gases meet near the bottom of the retort,  providing opportunity for
 adsorption of gas-phase constituents onto the solids.
        The Hg mass, balance for  the  Paraho  direct-mode process (Table  A-3)
 provides clear evidence for the  occurrence  of this  mechanism.   In that studjr,
 only 23 percent of the Hg present In the raw shale  was found in the retort
 gases, an unprecedentedly  low amount, while  72 to 100  percent  has been found
 in the gases from other retorts  (Table  A-3).   In  contrast,  33  percent  of  the
Hg was found in the retorted  shale,  while 2  to 12 percent has  been found  in
most other retorted shales.   (The high  values of  18 and 29 percent  in
Table A-3 are due to incomplete  retorting of  the  shale bed and Hg ;accumulation
in partially retorted shale in the bottom of  the  retort.)  Apparently,  Hg in
 the recycle gas in the Paraho  retort  is  deposited on cool retorted shale  in
 the bottom of the retort.  A  similar mechanism has  been postulated  to  control
offgas Hg concentrations for  the Union  B process  (UOC  1985).      '.
        Mercury Speciation.  The majority of  the Hg measured in uncombusted
shale gases exists in the gaseous state.  Hodgson et al.  (1982)  reported  that
the particulate Hg concentrations in two offgas samples from the  Lawrence
Berkeley Laboratory 5.5 kg retort were  5 and  14  Jig/m3,  contributing 1.1 and
                                       A-16

-------
1.7 percent of the total Hg.  Similarly, Fruchter et al.  (1978) reported that
the particulate Hg concentration in a single offgas sample from the
LETC 10-ton retort was 0.15 ug/m3, or 3.0 percent of the  total Hg.  Work
reported by Ondov et al. (1982) suggests that the particulate fraction is
mostly oil mist.                                                  ;
        Some of the gaseous Hg is converted into particulate Hg when  the gases
are combusted.  Mercury volatilized during retorting is converted; into
elemental and oxide forms and condenses, either homogenously or on the
surfaces of even smaller ash particles.  Similar behavior has been widely
reported for Hg from many other combustion sources  (e.g., Gladney et  al.
1976).
        Fruchter et al. (1978) found that 32 percent of the Hg in the stack
gases from an offgas burner on the LETC  10-ton retort was in the  particulate
              O          •                                         :
form (0.6 ug/m ), while only 3 percent of the Hg was in the particulate form
before the burner (0.15 ug/m ).  He also later reported (Fruchter et  al. 1979)
that Hg in dust from the Paraho thermal  oxidizer was enriched by  a factor  of
140 times, relative to retorted shale, indicating significant condensation of
Hg in the thermal oxidizer.
        The specific Hg compounds present in the gases have been  observed  to
vary in both time and by source (Table A-5).  Organomercurials dominate in
untreated gases (Hodgson et al. 1982,  1984; Olsen et al.  1985), while
elemental Hg and particulate Hg dominate in combusted stack gases (Fruchter
et al. 1978, 1979).  However, early in retorting, before  hydrocarbons are
released into the gas stream (i.e., during startup  of a commercial plant),
elemental Hg dominates.  Later, when hydrocarbon vapors are present,
organomercurials, primarily dimethylmercury and diethylmercury, predominate
(Qlsen et al. 1985); traces of elemental Hg, mercuric chloride, methylmercury
chloride, di-n-propylmercury, and methylethylmercury may  also be  present.
        These alkyl Hg compounds are widely acknowledged  to be the most toxic
Hg species  (WHO 1976; ACGIH 1983), and even small releases of untreated retort
gases, such as from process leaks or during upset conditions, could  result in
health effects.  The concentrations of alkyl Hg compounds reported by Olsen
                                        A-17

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A-18

-------
et al. (1985) greatly exceed the  threshold  limit value  of  10  Mg/m3 established
for alkyl Hg compounds in workroom air  (ACGIH 1983).
        The organomercurials in the untreated gas would"be combusted in most
commercial processes and converted into elemental Hg  and HgO,  which are
considerably less toxic.  Only traces of methylmercury  chloride  and
dimethylmercury have been observed in combusted retort  gases  (Fruchter et  al.
1978).

        Pollution Control.  The foregoing sections have demonstrated that  from
39 to 208 mg of Hg may be emitted for every barrel of oil  produced
(Table A-3).  For each 10,000 BPD of production capacity,  this corresponds to  .
an emission rate of 0.2 to 0.8 ton/yr of Hg.
        However, shale gases will be variously processed and  treated to remove
the criteria pollutants prior to discharge  to the atmosphere.  Commercial  oil
shale plants will include technology to reduce particulates,  SO,,,  NO  and
                                                               X i    X
nonmethane hydrocarbons, as discussed in other chapters of  this  report.  The
effectiveness of this technology in reducing  Hg emissions  from oil shale
retorts has not been studied experimentally.                     ,
        Some studies have used thermodynamic  calculations  to  predict the
effect of various pollution control devices on offgas Hg concentrations  (U.S.
DOE 1979; Cathedral Bluffs 1981).  These analyses, which characteristically
conclude that essentially all of the offgas Hg is removed  in  the pollution
control devices, assume that the Hg is present in its elemental  form.   In
fact, the majority is present as highly volatile organomercurials  (Table A-5)
that would not condense or precipitate out  in the pollution control devices.
        Very few studies have experimentally  determined the effect of
pollution control devices on trace element  emissions.   The  authors are not
aware of any studies that demonstrate that  gaseous Hg or very  small
particulates that are highly enriched in trace elements are removed in any of
the pollution control technologies proposed for oil shale plants.
        It is widely acknowledged that particulate reduction  technology, such
as electrostatic precipitators, do not remove  very fine combustion
                                       A-19

-------
particulates that may be highly enriched in trace elements  (e.g., Kaakinen
1974; Gladney et al. 1976; Klein et al. 1975; Krishnan and  Hellwig  1982).
Scrubbers are likewise ineffective (Mansour and Jones 1978; Kaakinen  1974).  A
sizeable (and presently unquantified) fraction of trace element emissions from
oil shale retorts may be present in this form.
        It is significant to note that all of the six proposed commercial oil
shale projects that have submitted PSD applications  (Table  A-l) have  estimated
that Hg emission rates are considerably less than discussed herein  and that no
gaseous Hg is emitted; the major source of Hg emissions in  these PSD
                                                                 i
applications is from fugitive dusts, which are primarily raw and retorted
shale fines.
        Company estimates of Hg emission rates are based on Hg measurements in
untreated gases from pilot plants and/or on the assumption  that the majority
of the Hg occurs as elemental Hg and thus would condense out in the pollution
control devices and offgas plumbing.  However, in all cases where the authors
were able to examine the supporting data, the claim  of no gaseous Hg  emissions
is unsubstantiated.  Technology conventionally used  to control Hg emissions in
other industries have been summarized and reviewed by Sittig (1976).
Cadmium      •                                              .     '
        Very few studies have been conducted on the  distribution of Cd during
oil shale retorting, primarily because Cd is difficult to accurately  measure
                                                              o
in oil shale materials.  Cadmium concentrations of from 1 Jig/m  to  over  1000
    n               -                           -     '
ug/m ' have been directly measured in retort gases.   Since these concentrations
                                                     O
greatly exceed the ACGIH recommended limit of 50 iig/m  on Cd and its  compounds
in work-room air, these concentrations may be environmentally significant.
        Mass balance studies reveal that for most commonly  encountered
retorting conditions, an average of from 12 percent  to 29 percent of  the Cd
originally present in the raw shale is lost from the retort, presumably  in the
retort gases.  If losses to the offgas plumbing system are not considered,
this corresponds to the emission of from 0 to 175 mg of Cd  per barrel of oil
produced.  Generally, Cd losses increase with increasing retorting
temperature, and thus are expected to be higher for  in-situ retorts.
                                       A-20

-------
        Mass Balance Studies.  Cadmium mass  balances  for  three  types  of oil
shale retorts are summarized in Table A-6.   None  of these studies  directly
measured Cd in the gases.  However,  the  imbalances or system losses,  which are
the percent of the raw shale Cd that was not recovered in the retorted  shale,
oil and water, provide an upper-limit estimate  of the amount of Cd that may  be
distributed to the gases.
        These studies demonstrate that the majority of the Cd is either
nonvolatile and retained in the retorted shale, or it is  lost from the  retort,
presumably to the gases.  An average of  12 to 33  percent  of the Cd was  not
recovered in these studies and was presumed  to  be volatilized from the  raw
shale.  Therefore, the potential exists  for  Cd  emission from virtually  all
commercial processes.
        However, some of the volatilized Cd  may have  a short residence  time  in
the gas.  Hodgson (1985) found that  14 percent  of the Cd  originally present  in
the raw shale had condensed in the gas sampling lines,  while in another study,
Fox (1980) found that Cd was removed from the gases at  <390 C and  deposited  on
the partially retorted shale (Figure A-3).
        In contrast, in the modified Fischer Assay retort (Goodfellow and
Atwood 1974), all of the Cd was recovered in the  retorted shale in two
separate studies using different analytical  methods (Fox  1985b;  Shrendrikar
and Faudel 1978).  This is believed to be due to  the  rapid heating rates,  from
2 to 14 C/min, and the relatively short time (20  mins)  that the retort  is  held
at its maximum temperature of 500 C.  If this is  the  correct interpretation,
then little or no Cd may be volatilized from fluidized  bed combustors,  such  as
those proposed for the Union C, Lurgi and Chevron processes.
        These studies (Table A-6), which reported Cd  losses for a  range of
retorting conditions, clearly demonstrate that  the fraction of  the Cd lost
from the retort increases with increasing retorting temperature.   The data :ln
Table A-6, except that for the Fischer Assay, is  plotted  in Figure A-4  as  a
function of maximum retorting temperature.   This  not  only demonstrates  that
the percentage of the Cd lost and presumably volatilized  increases with
temperature, but also that the magnitude of  the loss  is inversely  related  to
the capacity of the retort.

                                        A-21

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A-22

-------
        This inverse relationship is analagous to the one previously noted  for
Hg (gas concentration decreases as capacity of retort increased, Table A-4)
and likely has a common source, namely system losses.  Cadmium may  deposit
within the retort, either in the shale bed or offgas system, due to nonuniform
heating and/or sweep gas flow.  In small laboratory retorts, such as the
5.5-kg retort used by Hodgson, retorting can be precisely controlled, and
relatively uniform temperatures and sweep gas flow rates can be maintained
throughout the retort cross-section and length.  Any Cd volatilized within
such a retort would probably be released from the retort into the offgases,
and the only losses would occur in the offgas and sampling  system.  However,
as the retort is scaled up, bed heterogenities and/or poor  process  control  can
cause nonuniform bed temperatures and sweep gas flow rates, which allow the Cd
to deposit in cool regions along the bed or on the retort walls.
        Convincing evidence for the occurrence of such a trapping; mechanism in
larger retorts has been presented by Fox (1980).  Cadmium profiles  through  a
partially retorted shale bed (Figure A-3) indicate that Cd  is readily removed
from the gases at temperatures of less than 390 C and is deposited  on the
shale bed ahead of the reaction zone.  Some Cd also may be  deposited behind
the reaction zone (see peak at zone 13 in Figure A-3).
        Concentrations.  Very few direct measurements of Cd in shale gases
have been attempted, and available measurements are believed to greatly
underestimate actual offgas Cd concentrations.  However, the available
measurements do substantiate that Cd is volatilized from in-situ retorts and
emitted in the untreated gases.  Some Cd may also be emitted from surface
retorts, but the evidence is less conclusive than for in-situ retorts.
        Hodgson (1985) used an atomic absorption spectrometer equipped with a
single-slot burner to continuously measure Cd in gases from the LBL 5.5-kg
retort charged with retorted shale previously heated to 500 C.  Cadmium
         """          '             O                               •
concentrations of up to 1000  iig/m  were observed.  However, these
concentrations may be low.  The Cd mass balance demonstrated a low  recovery
and simultaneous measurements using an impinger technique were higher. . The Cd
was evolved from the shale over a temperature range of 775  to 950 C and peaked
                                       A-23

-------
at 890 C.  However, 33 percent of the Cd had been previously volatilized in an
earlier run at 500 C in which the gases were not monitored.
        Cadmium concentrations in discrete samples of offgases from two
separate in-situ retorts have also been reported (Rinaldi et al. 1981; Ondov
                                                                  I
et al. 1982).  Rinaldi et al. (1981) reported gaseous Cd concentrations of
.  •          o                          ,                          - '
about 1 ug/m  in each of three samples taken at the demister inlet and outlet
and the incinerator outlet of a Geokinetics field burn.  The concentration of
Cd in offgas particulates from the LLL 6000-kg simulated in-situ retort was
2.7 yg/g (Ondov et al. 1982).  However, neither investigator demonstrated that
his sampling and analytical methods were suitable for collecting and
                                              •         .,'.!,.
accurately quantifying Cd in shale gases.  Furthermore, a few grab samples
cannot be presumed to represent a lengthy retorting experiment, particularly
in light of the nonuniform emission profiles documented for these retorts (Fox
1985a).                                                           ;
        Emission Factors.  Cadmium emission factors were estimated from raw
data for the Cd mass balances summarized in Table A-6, adjusted for a
14 percent loss to system plumbing (Hodgson 1985).  The resulting factors,
shown in Figure A-4, range from 0 to 1070 mg/bbl and average 285 mg/bbl, which
scales to 104 metric tons/year for a 1,000,000 bbl/day industry.  \
        .There is presently inadequate information to develop factors for
specific retorting processes.  However, based on the information reviewed
here, the lower end of this range (0 to 260 mg/bbl) might be used for surface
retorts and the upper end (175 to 1070 mg/bbl) might be used with the higher
temperature in-situ processes.  It is presently uncertain whether a fluidized
bed combustor would contribute additional Cd emissions.
        Emission Profiles.  The temporal distribution of Cd in offgases has
not been measured but is expected to be similar to the Hg profiles discussed
previously and summarized in Figure A-2.  The nonuniform emission ;of Hg for
in-situ retorts is due to its accumulation along the shale bed, ahead of the
reaction zone, as shown in Figure A-3.  This retards the release of Hg,
causing a nonuniform emission profile (Figure A-2), as discussed previously.
Since Cd also accumulates along the shale bed (Figure A-3), it is also
expected to be nonuniformly emitted.

                                        A-24

-------
to
3
u
100


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 80


 70


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 50


 40


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 10
              I
               I
            T
/\ LBL 5.5-Kg Retort  (Hodgson  1985)

    LETC 20-Kg Retort  (Fox  1980)

    LLL 125-Kg Retort  (Fox  et.  al  1977;
     Fox 1980)
                                                                   /(1070mg/
                                                                   BBL) —
                          (260 mg/
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                            Cf
                           (110 mg/BBL)
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                                (175 mg/BBL)  —
              I
        I
I
                                (0 mg/BBL)
                             I
        0     100   200   300   400   500   600   700   800   900  1000

                          CENTERLINE RETORT TEMPERATURE (C)


   Figure  A-4.   Effects of maximum retorting temperature on Cd loss from oil
                shale  retorts.   Values in parentheses are Cd emission factors
                in mg  Cd volatilized per barrel of oil produced.
                                   A-25

-------
         Cadmium  Speciation.   The Cd species present in shale gases have not
been determined.   However, they are expected to include some of the same
species  reported for  Hg  since both Cd and Hg are Group lib metals and have
similar  chemistries.   In particular, both metals are known to form
organometallics  of the type  R2M and RR'M, where R and Rf  are alkyl groups and
M is the metal (Hagihara et  al.  1968).   However, the thermal stability of Cd
compounds is also the lowest among the  organometallics of the Group lib
metals,  and the  only  organocadmium compound that is stable under ambient
conditions is dimethylcadmium.
         Pollution Control.   The foregoing sections indicate that from 0 up to
1070 mg  Cd may be released to the  gases for every barrel  of shale oil produced.
(Figure  A-4).  For each  10,000  BPD of production capacity, this corresponds to
the emission of  up to 4  ton/yr  of  Cd.   The effectiveness  of criteria-pollutant
control  technology in reducing  these emissions  is unknown and cannot even be
speculated upon  due to limited  information.
         No emission or ambient  air quality standards exist for Cd,  and it is
not addressed in  any  existing oil  shale PSD permit.   Therefore, no  control
technology has been required to  remove  Cd.   However, the  potential  magnitude
of Cd emissions  and the  well-established toxicity of Cd and its compounds
indicate that further study  of  this  element  is  warranted.
Selenium
        Selenium concentrations of 4.2  Mg/m  to  over  18  yg/m^ have  been
reported in the gases from in-situ retorts.   Since these  are well  below the
                         o
OSHA. standard of 200 ug/m  on Se and its compounds in workroom  air,  these
concentrations probably are not environmentally significant.  Selenium  has not
been detected in gases from surface processes.  Emission  factors of  >15 to
940 mg/bbl have been estimated for in-situ retorts.
        However, some mass balance studies suggest that much higher  Se
concentrations could occur in gases from in-situ retorts.  For  retorting
temperatures of 900 C to over 1000 C, from 8  to 27 percent of the  Se is
unaccounted for in the products and presumed  to be lost to the  gases.
                                        A-26

-------
        Mass Balance Studies.  Selenium mass balances  for  four  types  of  oil
shale retorts are summarized in Table A-7.  These  studies  demonstrate that  the
majority of the Se, from 69 percent up to 100 percent,  is  nonvolatile and is
retained in the retorted shale.  Little or no Se is  apparently  volatilized  at
500 C since near-zero mass balances were obtained  for  both the  Paraho direct
and Fischer Assay retorts.  At temperatures greater  than about  890  C  in
in-s:Ltu retorts, from 8 percent up to 27 percent of  the Se originally present
in the raw shale (Fox 1985b) is not accounted for  in the products,  suggesting
that it is volatilized and emitted from the retort.
        Selenium behavior at temperatures from  >500  C  up to about 870 C  is
uncertain because mass balances within this range  have positive imbalances  due
to a sampling and/or analytical problem.  This  obscures any Se  losses since
the ipositive imbalance is greater than the loss.
                                                                 '          *l
        However, Ondov et al.  (1982) measured a Se concentration of•9 yg/nr in
the gases from one of the same retorts studied  by  Fox  (1980) operated at
840 C.  This corresponds to the volatilization  of  about 0.1 percent of the  raw
shale Se.  This low distribution is much too small to  detect in mass  balance
studies.          •
                                                                 [
        Concentrations.  Although Se has been directly measured in  retort
gases and particulates, the available measurements are believed to
underestimate actual offgas Se concentrations.  However, the available
measurements do substantiate that Se is volatilized  from in-situ retorts and
is present in the untreated gases.  There is currently no  evidence  that  Se  is
emitted from surface retorts.                                    i
        Ondov et al. (1982) used coconut charcoal  absorption tubes  to trap
gaseous Se emitted during a run of LLL's 6000-kg simulated in-situ  retort.
Adsorbed vapors were analyzed  by neutron activation  analysis.  Three  discrete
samples were taken during this run at 59 hr, 101 hr  and 121 hr  following
retort ignition.  The first sample was collected when  the  average  centerline
temperature was 842 C and lean shale was being  retorted; it contained 8.9
    O                               '                         •    '
Pg/m  of Se.  The next two samples were taken when the average  centerline
temperature was 945 C and rich shale was being  retorted.   The capacity of the
charcoal tube for Se was exceeded for both of these  samples, and;only minimum

                                       A-27

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                 Q           '  O
values of 18 ug/m  and  14  ug/nr were  reported.   The  actual  concentrations
could be higher.  During this  run,  Se concentrations in the particulates  were
0.1 to 2.5 iJg/g.
        In another study at  a  Geokinetics  in-situ retort, Se concentrations  of
                o
0.5 and 4.2 ug/m  were measured at  the  demister  outlet  and  the  incinerator
outlet, respectively.  Corresponding  particulate loadings at the  (demister
inlet and incinerator outlet were 5 and 10 Mg/g,  respectively.  The  accuracy
or representativeness of these samples  is  unknown.   However,  they are  of  the
same order of magnitude as those reported  by  Ondov et al. (1982)  at  the LLL
simulated in-situ retort.
        Emission Factors.  Selenium emission  factors were estimated  from  raw
data for the Se mass balances  reported  by  Fox (1980) (Table A-7)  and from the
gas measurements reported by Ondov  et al.  (1982).
        Ondov's measurements indicate that  for a retorting  temperature of 842
C in lean shale, 12 mg of Se was emitted per  barrel  of  oil  produced.  For a
retorting temperature of 945 C in rich  shale, over 9 mg of  Se was emitted per
barrel of oil.  The combined emission for  the entire run is >15 mg/bbl.   This
is estimated to be .about 0.3 percent  of the Se originally present in the  raw
shale.
        The six Se mass balances reported  by  Fox (1980)  for the LLL  simulated
in-situ retorts indicate that  from  420  to  940 mg  of  Se  was  lost from the
retort for each barrel of oil  produced.  These values are over  an order of
magnitude higher than values calculated from  Ondov's direct gas phase
measurements.  It is highly probable  that  some of  the Se lost in  Fox's studies
was deposited in cool regions  within  the retort  and  offgas  plumbing  system,  as
previously reported for both Cd and Hg, and was not  present in  the gas
                                                            \
stream.  It is also possible that Ondov's values  are very low,  due both to
nonuniform emissions from in-situ retorts  and the reported  saturation of  the
collection device.
        Thus, for in-situ retorts,  the  Se emission factor ranges  from greater
than 15 to 940 mg per barrel of oil,  based on available  data.   The emission
                                       A-29

-------
factor for surface retorts is believed to be near zero.  Additional
experimental studies are required to improve these estimates.

Arsenic
        Mass Balance Studies.  The volatility of As and its compounds  is
similar to that of Se and much less than Hg and Cd.  Mass balance studies are
not useful for estimating the amount of As volatilized and potentially emitted
because less than 1 percent of the raw shale As is lost, which is considerably
less than the experimental error in such studies.  Additionally, the As mass
balances reported in most studies (Fox 1980, Wildeman and Meglen 1978; Fox
et al. 1977) are flawed by high positive imbalances resulting from an
analytical problem.
        Concentrations and Emission Factors.  Only two studies have reported
enough information to reliably estimate the amount of As volatilized and
emitted from oil shale retorts.  In the first such study, Fruchter et  al.
(1980) completed an As mass balance for the Paraho semiworks retort.   Total As
                         o                                       •
ranged from 13 to 55 ug/m  in the thermal oxidizer stack gases and from 120 to
        o
155 ug/m  in the recycle gases.  Since these, as well as other reported As
concentrations, are well below established OSHA and ACGIH standards for
workroom air, they are not believed to be environmentally significant.  This
is equivalent to about 0.07 percent of the As present in the raw shale and
corresponds to an emission rate of 330 mg/hr and an emission factor of
65 mg/bbl.
                                                                 t
        In another study, Ondov et al. (1982) measured the total As
concentration in three samples of gas from a run of the LLL 6000-kg simulated
in-situ retort, as previously described above for Se.  Arsenic concentrations
                                       o
ranged from 5.5 to greater than 17 ug/m ; corresponding As concentrations in
particulates were 0.3 to 2.5 ug/g.  This is equivalent to an emission  factor
for the entire run of greater than 13 mg of As per barrel of oil and
corresponds to the emission of about 0.01 percent of the As originally present
in the raw shale.  This value, which is an order of magnitude or more  lower
than emission factors for the Paraho and Union B retorts, is believed  to be
                                       A-30

-------
low, as previously discussed above for Se.  The higher  temperatures  of  the  LLL
retort should result in higher emissions.
                                                      o
        Higher As concentrations, from 11 to 380  Mg/m, have  been reported  by
UOC (1985) for the Unisulf offgases from their Brea pilot  plant  (simulates  the
Union B retort).  Concentrations in Unisulf gases are reduced when natural  gas
and air are added prior to combustion, resulting  in stack  concentrations  of
              o
0.1 to 28 Vg/m .  This corresponds to an emission rate  of  12  g/hr and an
emission factor of 740 mg/bbl.  This is estimated to  be about 0.01 percent  of
the As originally present in the raw shale.
        Significantly higher concentrations of gaseous  As  were reported by
Rinaldi et al. (1980) for a Geokinetics in-situ retort.  The  As  concentration
at the demister inlet was 130 Pg/m3 while at the  demister  outlet,  it was  38
    Cl                                        Q                    ;
Pg/nT.  The concentration dropped to 0.4 Pg/m  at the incinerator stack.
These data are consistent with those reported by  Fruchter  et  al.  (1979) for
the Paraho retort.  Corresponding As concentrations in  particulates  were  401
Pg/g at the demister inlet and 140 Pg/g at the demister outlet.   Apparently,
gaseous As is converted into particulate As, as reported by Fruchter et al.
(1978) for another in-situ retort.  This is common to most combustion sources.
        Arsenic Speciation.  Fruchter has reported As speciation data for
gases from several oil shale retorts (U.S. DOE 1980;  Fruchter et al. 1983;
Fruchter et al. 1979; Fruchter et al. 1978).  These measurements i(Table A-8)
indicate that gaseous arsenic trioxide and arsine occur in all samples.
Traces of arsine have also been variously reported by the  U.S. DOE (1980) for
the Paraho direct mode retort (0.17-0.46 Pg/m3) and by Rinaldi et  al. (1981)
for a Geokinetics in-situ retort ซ5 to 5 Mg/m3).
        Traces of organoarsenic compounds, including  methylarsine  and
dimethylarsine, were reported in uncombusted stack and  recycle gases from both
in-situ and surface processes.  These compounds were  not found in  the thermal
oxidizer gases, presumably because they are combusted and  converted  into
arsenic trioxide.
        Arsenic particulate concentrations (Table A-8)  are very  low  (0.4-1.2
ug/m~) in uncombusted retort gas, constituting from 1 to 3 percent of the
                                        A-31

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-------
total As, and are somewhat higher  (2.5-19  Pg/m  )  in  flared  gases,  contributing
from 35 to 64 percent of the total As.  Arsenic volatilized during retorting
is converted into elemental and oxide forms which condense, either
homogenously or on the surface of  even  smaller  ash particles.   This is
substantiated by the enrichment of As in thermal  oxidizer ash  (Table A-9)  and
is consistent with numerous studies of  other  combustion  sources ('i.e.,  Gladney
et al. 1976).

Other Trace Elements
        Concentrations of other  trace  elements measured  in gases  from several
retorts are summarized in Table  A-9, together with  the data previously
discxissed for Hg, Cd, Se and As.  This summary indicates that  the only other
elements that have been detected in shale  gases  are the  halogens, Br (>25
yg/mj) and Cl (>980 ug/m3), and  Cr, Fe, Mo,  Pb and  Sb.   Neither of the
halogens exceed OSHA or ACGIH limits for workroom air.   Flourine  may also be
emitted from in-situ shale retorts and should be measured.
        Of the remaining elements which have been detected (Cr, Fe,  Mo, Pb,
Sb), only Sb compounds are expected to be  volatile  at retorting temperatures
(CRC 1968; Dean 1979).  The presence of the  other nonvolatile  elements is most
likely due to sample or system contamination.  Nevertheless, additional study
of these elements is probably warranted.
        Radon, a radioactive gas, has  also been  reported in gases from two
separate burns of Rio Blanco retorts (Fruchter et al. 1983).  Average Rn
concentrations during these two  runs were  6.7 pCi/L and  28.3 pCi/L.   This
corresponds to an emission factor of 6 yCi of Rn per barrel and an emission
rate of 3.3 VCi/s.
        When shale gases are combusted, many of  the above-discussed gaseous
trace elements are converted into condensed  phases, in processes  similar to
the production of ash in power plant boilers.  The  resulting fine particulates
are enriched in the volatile trace elements, notably As, Cl, Br,  Cd, Hg and
Se.  Some of these fine particulates would be removed in electrostatic
precipitators or scrubbers, but  the majority of  them will probably be emitted.
                                        A-33

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-------
        Fruchter analyzed a single sample of ash  from  the  Paraho  thermal
oxidizer and computed enrichment ratios relative  to  retorted  shale.   The  dust
composition and enrichment ratios are reported  in the  first two columns of
Table' A-9.  These data rather dramatically demonstrate this enrichment
phenomenon.  Note that As, Br, Hg and Se, all of  which were found to  be
volatilized in this review, are significantly enriched in  the oxidizer dust.
The enrichment factor for Sb also suggests that it may be  volatilized.
        Retort emission factors are summarized  and ranked  in  Table A-10.
Interestingly, when emissions are normalized to oil  yields (the emission
factor), Cl emerges as the element emitted in the greatest quantities,
followed by Cd, Se, As, Hg, Cr, Br and Mo.                        !       .

MATERIAL HANDLING
        Because oil shale is a low grade fuel source that  contains about  a
half a barrel of oil per ton of rock, large amount of  rock material must  be
handled at an oil shale plant.  For each barrel of oil that is produced in an
above-ground retort, about 2 tons of rock must  be mined, crushed, sieved,
hauled and loaded into the retort.  About 80 percent of these 2 tons  remains
after the oil has been removed.  This retorted  shale must  be  cooled,  unloaded
from the retort, hauled, placed and compacted in  a disposal pile. Additional
solid material, primarily mine overburden, soil used to reclaim the disposal
pile, and superficial material disturbed during construction  must also be
handled.  At in-situ retorts, for each barrel of  in-situ oil  that is  produced,
about 2 tons of raw shale must be mined and either disposed of on the surface
or processed in an aboveground retort.
        The handling of these enormous quantities of material generates large
amounts of fugitive dust that must be controlled.  The majority of the
fugitive dust at an aboveground retort is raw and spent shale fines and
suspended soil material.  At an in-situ retort, the  majority  is raw shale
fines and suspended soil material.
        Oil shales are enriched in some trace elements, notably As, B, Cd, Mo
and Se, compared to average crustal material.   They  also contain  'rather high
concentrations of silica.  The next two sections  summarize what is presently
                                        A-35

-------
     TABLE A-10.  SUMMARY OF UNCONTROLLED TOTAL  (GASEOUS AND  PARTICULATE)
             TRACE ELEMENT EMISSION FACTORS FOR  OIL  SHALE RETORTS
                                   (mg/bbl)
                                                        Retort    ;
                                                   Emission Factor
            Element                                  (mg/bbl oil)
Cl
Cd
Se
As
Hg
Cr
Br
Mo
Fe
Ba
Pb
Zn
V
Cu
Mn
Co
U
Ni
Sb
Th
Rn
1300
0-1070
>15-940 I
>13-770
39-208
<6-151
>33

-------
known about trace elements and silica in fugitive dusts  produced  by solid
material handling at oil shale plants.

Trace Elements
        Several investigations have reported  the  composition of  fugitive dust
at the Anvil Points site as operated by Paraho  (Cotter et  al.  1979;  Cotter
et al. 1978; Fruchter et al.  1979; Garcia et  al.  1981; Hargis  et al.  1983).
Most of these studies and other company data  are  summarized  in the  Paraho data
compendium prepared by the U.S. DOE (1980).   All  of  these  studies are
generally consistent.  The following discussion is largely based on  the
studies reported by Cotter et al. (1979), Fruchter et al.  (1979) and U.S. DOE .
(1980b) because they are the most comprehensive.
        At Anvil Points, retorting, crushing  and  retorted  shale  disposal
generated the largest quantity of fugitive dust.  The dusts  had  a bimodal
distribution, and the majority of the particles were either  >7 Mm or
<1.2 Mm.  The respirable fraction, defined as particles  less than 3.3 Mm in
diameter, generally constituted greater than  50 percent  of the fugitive  dust.
        The chemical characteristics of fugitive  dust from several  different
locations at the Anvil Points site are very similar  to those of  raw and
retorted shales.  However, As, Cr, V, Sb and  Co were enriched  in the
respirable fraction of most samples (Fruchter et  al. 1979).   This is probably
due to the presence of thermal oxidizer dust  (Table  A-9).  Tr-ace elements
associated with thermal oxidizer dust are accounted  for  in the retort emission
factors.
        Because shale-plant fugitive dusts from material handling are
primarily raw and retorted shale fines, emission  factors for this source can
be reliably calculated from raw and/or retorted shale composition data.   Trace
element emission factors for fugitive dusts produced by  material handling are
summarized in Table A-ll.  These were estimated by multiplying the  average
particulate emission rate from all material handling operations
(63.5 lb/1000 bbl) by estimated average dust  concentrations.  We estimated
dust composition by multiplying the average raw shale composition in column 1
of Table A-ll by 1.3 to convert it to a retorted  shale basis.  This  provides

-------
    TABLE A-ll.  SUMMARY  OF  CONTROLLED TRACE ELEMENT EMISSION FACTORS FOR
           FUGITIVE DUSTS GENERATED BY MATERIAL HANDLING OPERATIONS
                            AT OIL SHALE FACILITES

As
B
Ba
Be
Br
Cd
Cl
Co
Cr
Cu
F
Fe
Hg
Mo
Mn
Ni
Pb
Sb
Se
Th
U
V
Zn
Mahogany
Zone
Raw Shale^1'
(ppm or
g/106g)
48
70
478 • •
2.4 2
4.2<2>
0.77
184'2'
8.8
33
33
1,300
19,200
0.086
24
289
21
. 21
1.9
2.2
5.7
4.1
106
72
Retorted
Shale*3^
(ppm or
g/106g)
53
__
609

-. —
0.81
—
12.3
46
51
—
26,900
0.03
30
396
31
30
28
2.8
8.4
6.2
136
87
Controlled
Emissipn
Factor''4 >
(mg/bbl)
1.8
2.6
18
0.090
0.16
0.029
6.9
0.33
1.2
1.2
49
720
0.0032
0.90
11
0.79
0.79
0.071
0.082
0.21
0.15
4.0
2.7
(1) Average for 125 samples from two cores from the Naval Oil Shale Reservej,
    as reported by Giauque, et. al. (1980).

(2) Average of 12 Mahogany-zone composite samples as reported by
    Ppulson et. al. (1977).

(3) Average for 25 samples of retorted shale, as reported by Fox (1980).

(4) Computed from average particulate emissions for permitted mining and
    retorted shale disposal emissions for six plants (63.5 lb/1000 bbl) and
    Mahogany Zone raw shale composition (Column 1) converted to a retorted
    shale basis or factor = (raw shale) (1.3) (63.5) (37.48 x 10~2 g bbl/lb
    103 bbl).
                                    A-38

-------
an upper limit for dust composition and also tends to significantly
overestimate volatile trace element emissions associated with particulates.
        A process- and site-specific dust concentration could also be
estimated from a knowledge of the fraction of the dust that is raw and
retorted shale and soil.  Extensive and reliable chemical composition data
exist for raw shales (Giauque et al. 1980; Tuttle et al. 1983; Dean et al.
1981; Desborough et al. 1976), retorted shales (Fruchter et al.  1979; Fox
1980; U.S. DOE 1980) and soils (Dean et al. 1979) from oil shale regions and
can be used for such estimates.  Typical retorted shale composition data are
provided in Table 11 for convenience.                             ;

Silica
        Silica (quartz) in airborne dust is a respiratory health concern.
Some evidence exists that prolonged exposure to silica-bearing shale oil dust
can cause pneumoconiosis.                                         ;
        In an industrial hygiene study at the Anvil Points Mine  (Hargis et al.
1983), the free silica content in 10 dust samples from the crusher and retort
areas ranged from 7 to 9 percent.  A single sample taken in the mine area had
a silica content of 4 percent.  Assuming a maximum quartz content of
10 percent, the threshold limit values for total and respirable dust are 2.5
            o                     -
and 0.8 ug/m .  The majority of the dust samples in most studies have exceeded
these values.  However, it is important to realize that this was an
experimental facility with no dust control, and workers were not exposed for
long periods.
        These silica concentrations correspond to an emission rate of 25 to
57 Ibs/day of Si02 and an emission factor of 1.2 to 2.6 g/bbl of Si02.
                                       A-39

-------
                                   APPENDIX A                   •

                                   REFERENCES

 ACGIH, "Threshold Limit Values  for  Chemical Substances  and Physical, Agents  in
 the Work Environment with  Intended  Changes for  1983-84,"  American Congress  of
 Governmental Industrial Hygienists,  Cincinnati,  OH,  2nd Printing^ 93 pp.,
 1983.

' CRC, Handbook of Chemistry and  Physics, R.  C. Weast  (Ed.),  The  Chemical Rubber
 Co., Cleveland, OH, 49th Ed., 1968.

 Cathedral Bluffs Shale Oil Co., Prevention of Significant Deterioration, 1981.

 Cotter, J. E., et al. "Sampling and  Analysis Research Program at  the Paraho
 Shale Oil Demonstration Plant," U.S. EPA Report  EPA-600/7-78-065, NTIS  No.  PB
 284027,  71 pp., 1978.

 Cotter, J. E., et al. "Fugitive Dust at the Paraho Oil  Shale  Demonstration
 Retort and Mine," U.S. EPA Report EPA-600/7-79-208,  NTIS  No.  PB80122591,- 78
 pp., 1979.

 Dean, J. A., (Ed.) Lange's Handbook  of Chemistry, McGraw-Hill Book Co.,  New
 York, 12th Ed., 197"9T~^'	                 '

 Dean, W. E., et al. "Geochemical Variation  in Soils  in  the  Piceance  Creek
 Basin," Western Colorado, Geological Survey Bulletin 1479,  47 pp.,  1979.

 Dean, W. E., et al. "Geochemical and Mineralogical Analysis of U.S.  Geologic
 Survey Oil-Shale Core CR-2, Piceance Creek  Basin," Western  Colorado, U.S.
 Geological Survey Open File Report 81-596,  25 pp., 1981.

 Desborough, G.  A., et al. "Concentration and Mineralogical Residence of
 Elements in Rich Oil Shales of the Green River Formation,  Piceance Creek
 Basin,  Colorado, and the Uinta Basin, Utah  — A  Preliminary Report," Chemical
 Geology, Vol. 17, pp. 13-26,  1976.                                   	

 Donnell, J. R.  and V. E. Shaw.  "Mercury in Oil  Shale from  the Mahogany  Zone
 of the  Green River Formation, Eastern Utah  and Western  Colorado," Journal of
 Research of the U.S. Geological Survey, Vol. 5,  No.  2,  pp.  221-226,  1977.

 Fish, R.  H. "Organometallic Geochemistry, Isolation  and Identification of
 Organoarsenic and Inorganic Arsenic Compounds from Green  River Formation Oil
 Shale," in Geochemistry and Chemistry of Oil Shales, F. P. Miknis  and J. F.
 McKay (Eds.), ACS Symposium Series 230, American Chemical Society, Washington
 D.C., pp.  423-432,  1983.

 Fox,  J. P.  The  Partitioning of Major, Minor and Trace Elements During
 Simulated  In-situ Oil Shale Retorting.  Lawrence Berkeley Laboratory Report
 LBL-9062,  Berkeley,  CA,  1980.
                                         A-40

-------
 Fox, J. P., A. T. Hodgson, and D. C. Girvln. Trace Elements  In  Oil  Shale
 Materials in Energy and Environmental Chemistry, Fossil Fuels,  Vol.  1.. Keith,
 L. H. (Ed.), Ann Arbor Science Publishers, Ann Arbor, MI, p.  69-102,  1982.

 Fox, J. P. "Distribution of Mercury During Simulated In-situ  Oil :Shale
 Retorting," Environmental Science and Technology. Vol.  19, No.  4, pp. 316-322,
 1985a.                                                           ;-

_Fox, J. P. Unpublished mass balance data for the Fischer assay  retort, Fox
 .Consulting, Berkeley, CA, 1985b.

 Fox, J. P, et. al. "The Partitioning of As, Cd, Cu, Hg, Pb and  Zn During
 Simulated In-situ Oil Shale Retorting," 10th Oil Shale  Symposium Proceedings,
 Colorado School of Mines Press, Golden, CO, pp. 223-237, 1977.

 Fox, J. P., et. al. "Mercury Emissions from a Simulated In-situ Oil  Shale
 Retort," llth Oil Shale Symposium Proceedings, Colorado School  of Mines Press,
 Golden, CO, pp. 55-75, 1978.


 Fruchter, J. S., et al. "High-Precision Trace Element and Organic Constituent
 Analysis of Oil Shale and Solvent-Refined Coal Materials," in Analytical
 Chemistry of Liquid Fuel Sources. P. C. Uden, S. Siggia, and H. B. Jensen
 (Eds.), ACS Advances in Chemistry Series 170, American Chemical Society,
 Washington, D.C., pp. 255-281, 1978.

 Fruchter, J. S. et. al. Source Characterization Studies at the  Paraho
 Semi works Oil Shale Retort.  Battelle Pacific Northueat Lahnrat-m-y Popart- PNL-
 2945,  Richland, WA, 70 pp.,  1979.

 Fruchter, J. S., et al. "Elemental Partitioning in an Above-ground Oil Shale
 Retort Pilot Plant," Environmental Science and Technology.  Vol. 14, No. 11.
 pp.  1374-1381,  1980.             ~~~

 Fruchter, J.  S. et al. "Potential Air Emissions from Oil Shale Retorting," In
 Oil  Shale,  the  Environmental Challenges III.  K. K.  Peterson (Ed.), Colorado
 School of Mines Press, Golden, CO, pp.  139-164, 1983.

 Garcia,  L.  L.,  H.  F. Schulte,  and J. J.  Ettinger,  J.  J.  "Industrial Hygiene
 Study  at the Anvil Points  Oil  Shale  Facility,"  American  Industrial Hygiene
 Association Journal.  Vol.  42,  pp. 796-804,  1981~	
                                        A-41

-------
 Giauque, R. D., et al. Characterization of Two Core Holes  from the  Naval  Oil
 Shale Reserve Number  1, U.S. EPA Report EPA-600/7-81-024.  NTTS PRS1  1fi77^fi
 176 pp., 1981.

 Girvin, D. C. and J.  P. Fox.  On-line Zeeman Atomic Absorption Spectroscopy
 for Mercury Analysis  in Oil Shale Gases, U.S. EPA Report EPA-600/7-80-130  95
 pp.,, 1980.

-Girvin, D. C., et al. "On-Line Measurement of Trace Elements  in  Oil  Shale
 -Offgases by Zeeman Atomic Absorption Spectroscopy," in Energy and Environment
 Division Annual Report 1979, Lawrence Berkeley Laboratory  Report LBL-10486,
 pp. 5-29 — 5-33, 1980.

 Gladney, E. S., et al. "Composition and Size Distribution  of  In-stack
 Particulate Material at Coal-Fired Power Plant," Atmospheric  Environment, Vol.
 10, pp. 1071-1077, 1976.                               	!	

 Goodfellow, L. and M. T. Atwood. "Fischer Assay Oil Shale  Procedures of Oil
 Shale Corporation," Quarterly of the Colorado School of Mines. Vol.  69, No. 2
 pp. 205-219,  1974.                                '	   ,

 Hagihara,  N.  et al. Handook of Organometallic Compounds, W. A. Beniamin,  Inr.,
 New York,  1044 pp., 1968.	

 Hargis, K.  M., et al. "Aerosol Sampling and Characterization  in the Developing
 U.S. Oil Shale Industry, in Aerosols in the Mining and Industrial Work
 Environments,  Vol. 2, Characterization,  V. A. Marple and B. Y. H. Liu (Eds.),
 Ann Arbor  Science Publishers,  Ann Arbor, MI,  pp. 481-499,  1983.

 Hodgson, A. T. Unpublished data from a laboratory study of Cd partitioning In
 a  5.5-kg Fischer Assay-type retort,  Lawrence Berkeley Laboratory, Berkeley,
 CA, 1985.                                                         i

 Hodgson, A. T., et al. Mercury Mass  Distribution During Laboratory and
 Simulated  In-situ Oil Shale Retorting,  Lawrence Berkeley Laboratory Report
 LBL-12908,  39  pp., 1982.

 Hodgson, A. T.,  et al. "Mercury Emissions  from a Modified In-situ Oil Shale
 Retort", Atmospheric  Environment.  Vol.  18,  No.  2,  pp.  247-253, 1984.

 Kaakinen,  J.,  Trace Element Study in a  Pulverized-Coal-Fired Power Plant,
 Ph.D. Dissertation, University of Colorado,  Boulder, CO,  186 pp., 1974.

 Klein,  D. H.,  et al.  "Pathways of Thirty-Seven Trace Elements Through Coal-
 Fired Power Plants,"  Environmental Science  and Technology,  Vol. 9;  pp.  973-
 979,  1975.              ~	           f

 Krishnan, E. R.  and G. V.  Hellwig. "Trace  Emission from Coal and Oil
 Combustion," Environmental Progress,  Vol.  1,  No.  4,  pp.  290-295, 1982.
                                        A-42

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 Littlejohn, R. F. "Emission of Trace Elements from Coal-Fired Industrial
 Boilers.  A Survey of Relevant Literature," Energy Research, Vol. 8, pp. 375-
 386, 1984.                                  	   	

 Mansour, M. N. and D. G. Jones. Emission Characteristics of Parafio Shale Oi. 1
 as Tested in a Utility Boiler, Electric Power Research Institute-Report EPRT
 AFr709, 1978.

 National Research Council (NRC), Health Effects of Exposure to Diesel Exhaust,
"National Academy Press, Washington, D.C., 169 pp., 1981.

 Olsen,  K.  B., et al.  "Partitioning and Chemical Speciation of Volatile Trace
 Elements During Inert Gas Oil Shale Retorting," Proceedings of First Annual
 Oil Shale/Tar Sands Contractors Meeting, U.S. Dept. of Energy, Morgantown, "WV,
 1985.   !                                          •-..- .

 Ondov,  J.  M., et al.  Measurements of Potential Atmospheric Pollutants in
 Offgases from the Lawrence Ltvermore National Laboratory's 6-Tonne Retort,
 Experiment L-3, Lawrence Livermore Laboratory Report UCRL-53265, 44 pp., 1982.

 Poulson, R. E., et al.  Minor Elements in Oil Shale and Oil-Shale Products,
 Laramie Energy Research Center Report LERC/RI-77/1, 1977.

 Rinaldi, G., et al. Environmental Characterization of Geokinetics In-situ Oil
 Shale Retorting Technology.  U.S. EPA Report EPA-600/7-81-021 (NTIS PB 81-163-
 727),  1981.                                                      '

 Shendrikar, A. D. and G. B.  Faudel. "Distribution of Trace Metals During Oil
 Shale Retorting," Environmental Science and Technology, Vol. 12,'No. 3,  pp.
 332-334, 1978.                                                   :

 Sittig,  M. Toxic Metals.  Pollution Control and Worker Protection, Noyes Data
 Corp.,  Park Ridge,  NJ,  pp. 349, 1976.~~~~

 Tuttle,  M. L., et al. "Inorganic Geochemistry of Mahogany Zone Oil Shale in
 Two Cores  from the Green River Formation,"  in Geochemistry and Chemistry of
 Oil Shales, F. P. Miknis and J. F. McKay (Eds.), ACS Symposium Series 230,
 American Chemical Society, Washington,  D.C., pp. 249-267, 1983.

 Union Oil  Company,  Air  Quality Technical Report, Parachute Creek Shale Oil
 Program, Phase II, Woodward-Clyde Consultants,  Walnut Creek, CA, 1985.

 Union Oil  Company,  PSD  Permit Application for Union's Phase II Oil Shale
 Mining  and Retort Facility,  1982.                                ;

 U.S. DOE,  Environmental Control Costs for Oil Shale Processes,  U.S.  Department
 of  Energy  Report DOE/EV-0055,  Washington,  D.C.,  450 pp.,  1979.    •

 U.S. DOE,  Environmental Research on a Modified In-situ Oil Shale Process,"
 U.S. Department of Energy Report DOE/EV-0078,  Washington, D.C., .94 pp.,  1980a.
                                        A-43

-------
 U.S. DOE, Paraho Environmental Data, U.S. Department of Energy Report DOE/EV-
 0086, Washington, D.C., 1980b.                                   i

 Wildeman, T.  R. and R.R. Meglen, "Analysis of Oil Shale Materials for Element
 Balance Studies," in Analytical Chemistry of Liquid Fuel Sources; P. C. Uden,
 S. Siggia,  and H. B. Jensen (Eds.), ACS Advances in Chemistry Series 170,
 American Chemical Society,  Washington, D.C., pp. 195-212, 1978.  -

 Wong, C. M. Quantitative Analysis and Kinetics of Trace Sulfur Gas Species
-from Oil Shale Pyrolysis by Triple Quadrupole Mass Spectrometry, ;Lawrence
 Livermore Laboratory Report UCRL-89361, 1983.                    :

 World Health  Organization (WHO), Environmental Health Criteria 1. Mercury,
 Geneva, 131 pp.,  1976.            "                         ~~~~	:	
                                       A-44

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                                  APPENDIX B

                             CODISPOSAL EMISSIONS

        Codisposal is the combining of two or more waste  streams  for
disposal.  For oil shale development, it  refers  to the  simultaneous disposal
of wastewaters and low volume solid streams with the  retorted  shale.   These
materials would be blended with the retorted shale prior  to  disposal  and/or
added at the pile.  The types of materials that  have  been considered  for
codisposal and their approximate quantities are  summarized in  Table B-l.
Wastewaters and raw shale rejects together can comprise over 30 percent by
weight of the total disposed material.  The balance of  the solids would
comprise up to 1 percent by weight of the  disposed material.
        Among those materials proposed for codisposal (Table B-l), the only
ones that presently appear to be environmentally important with respect to air
emissions are the wastewaters.  Much of the present controversy surrounding
the issue of codisposal involves these waters and, in recent years, the term
"codisposal" has been used exclusively to  designate the disposal  of
wastewaters with the retorted shale (e.g.,  Persoff et al  1984; Hawthorne
1984).  These waters include the process  streams which may comprise over half
of the water codisposed with the retorted  shale.
        The principal environmental concerns attributed to codisposal  are  its
effect upon leachate composition and its  contribution to  air emissions.  The
wastewaters proposed for codisposal include process waters that contain high
concentrations of organic carbon, dissolved solids and several trace
elements.  Many of these compounds are individually unregulated,  and  they
include a number of substances that are malodorous and toxic.  Those  compounds
that are volatile could be emitted directly to the atmosphere  during  cooling
and wetting or from the pile surface, while those that are soluble may be
leached by precipitation percolating through the pile.            :
        These potential emissions and leachates may be controlled by
pretreating one or more of the wastewaters  to remove  volatile ,and/or  soluble
materials.  The design options include steam stripping and biological
treatment.  Various end-of-stream control  technologies may also be used.
                                                                  i
                                      B-l

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         TABLE B-l.  SOLID WASTE GENERATION AT A TYPICAL COMMERCIAL
                     OIL SHALE FACILITY  (Heistand  1985)
                      Material                         Weight Percent
     Retorted Shale                                           85

     Various Wastewaters                                    <5  •ป• 20

     Raw Shale Rejects (1)                                  <2  -ป-!10

     Water Treatment Sludges (2)                              0.8

     Flue Gas Desulfurization Chemicals (2)                   0.3

     Off-Specification Byproducts (3)                         0.1

     Biological Sludges (2)                                   0.05

     Oily Solids                                              0.04

     Scrap and Garbage                                        0.004

     Oil Upgrading Catalysts                                  0.003

     Fuel Gas Cleanup Chemicals                              <0.001


(1)  Includes dusts from air pollution control devices, raw shale feed
     preparation fine rejects and low-grade ores.

(2)  This material is primarily (about 90 wt. %) water.

(3)  Primarily sulfur and coke (for projects using the TOSCO II retort).
                                    B-2

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 Those that  have been proposed for codisposal air emissions include Venturi
 scrubbers and flaring of flue gases.                              ,

 B.I      CODISPOSAL OF WASTEWATERS
         The balance of this section discusses the codisposal of wastewaters
 and  retorted shale.  Relatively large volumes of water are required for
 retorted shale disposal ranging from 5 to 25 weight percent.  This water is
 used to  cool the  hot retorted shale, moisturize the retorted shale to
 facilitate  compaction and control dust at the pile surface.   Various
 wastewaters are employed for this purpose to minimize the use of fresh water.
         The codisposal of wastewaters with retorted shale is divided into
 three phases,  as  follows:
             Phase I:     Cooling of retorted shale from 500-750 C to
                         300 C;
             Phase II:    Wetting retorted  shale to optimum moisture
                         content during which the temperature is reduced
                         from 300 C to about 80 C;  and,
             Phase III:   Disposal in a landfill.
 These  three  phases  correspond to discrete periods  when  environmental  impacts
 may  occur.   The following  subsections define  and describe  Phase I  through
 Phase  III codisposal processes.                                    '

 B.I.I    Phase  I Cooling
         In most projects that have  been proposed,  cooling  and  moisturization
 are  carried  out in  separate process  units.  Following the  extraction  of oil,
 the  retorted shale  is  at pyrolysis  (500 C)  or  combustion  (>500-750 C)
 temperatures,  depending upon  the  type  of  process.   This hot material  must be
 cooled prior to disposal to permit  safe handling and to prevent  fires  in  the
pile.  This  is typically done with water  in indirect processes  (e.g.,
TOSCO II, Union B) and with flowing  gases  (i.e., air and recycle gas)  in
direct processes  (e.g., Paraho,  Superior).  Those processes that use  gas
                                      B-3

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cooling are not of interest here because water is not used for cooling and
codisposal is not involved until the moisturization phase.        '
                                                                  !
        Two types of processes for cooling hot retorted shale have been
proposed in the literature.  The first, the rotating drum steam generator, is
used, with the TOSCO II process (e.g., BLM 1975; C-b 1976; TOSCO 1982).  Hot
spent shale is introduced into conventional rotating drum coolers where its
temperature is reduced by tumbling and by water sprays.  The use and design of
such coolers has been described in the literature (Perry and Chilton 1973).
        The second, water immersion quenching, has been proposed for the
Superior and Union B retorts, which are designed with the cooler attached to
the retort to achieve a positive seal.  In the Union B retort, hot retorted
shale falls by gravity down chutes through a shaft cooler where it is cooled
by water sprays.  Steam generated during quenching and cooling is condensed,
scrubbed and returned to the shaft cooler, while noncondensable vapors are
recycled to'the retort or flared (Duir et al 1983; UNOCAL 1986; Deering et al
1984, 1985).
        Phase I cooling should not have a significant impact on the
environment so long as it occurs in a closed system.  Most of the water used
in cooling is flashed to steam, condensed and recycled.  Dust is removed by
high efficiency baghouses or scrubbers.  Condensible vapors stripped from the
pores of the retorted shale or released when the wastewaters contact the hot
retorted shale are .scrubbed from the gas stream and become part of the
recycled condensate; noncondensable vapors may be recycled to the ;retort or
flared.  Contaminants in the cooling waters that are not volatile under
cooling conditions, primarily inorganic substances and gases trapped in
retorted shale pores, may be subsequently volatilized and/or leached.

B.I.2   Phase II Moisturization
        Additional water may be added to retorted shale prior to disposal in
the pile.  This water serves to further cool the retorted shale, typically
from about 300 C to 80-90 C and to bring the codisposed solids (Table B-l) to
their "optimum moisture content".  This quantity of water, which may range
from 7 to 25 weight percent, represents the amount of water required to
                                      B-4

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compact the material to a specified dry density with  the  least  compactive
effort.
        Two processes have been proposed for moisturizing retorted  shale prior
to disposal.  The first, rotating drum moisturization, has been proposed for
the TOSCO II and Lurgi processes (RBOSC 1981; TOSCO 1982).  This process
operates similar to the rotating drum steam generator described above, except
the steam produced is not used to generate electricity.   The  second, water
immersion, has been proposed for use with the Union B process.  In  this
process, the retorted shale and other solids are blended  with wast&water in a
pug mill (UNOCAL 1986).  The gases and solids resulting from  moisturization
are typically routed through a Venturi scrubber in which  wastewaters are used
to scrub vapors and entrained solids from the flue gases.
        Phase II moisturization is not utilized in all proposed commercial
projects.  In the Paraho-Ute Project (Paraho 1982), the majority of the
retorted shale would be disposed in a relatively loose fill encased in a
blanket of highly compacted, impervious retorted shale.   The  only water used
in retorted shale disposal is added at the pile and therefore is part of the
Phase III disposal process, as discussed below.
        Phase II moisturization may lead to significant environmental
consequences if appropriate control technology is not installed.  Organic
compounds associated with the wastewaters may be volatilized  and emitted at
the scrubber.  The temperatures during Phase II moisturization  ซ300 C) are
too low to volatilize any trace elements, with the possible exception of
arsenic which has been found in volatile organic forms in process waters.

B.I.3   Phase III Disposal                                        !
        The cooled retorted shale is transferred by conveyor belt or by truck
to the disposal site where the solids are placed by traveling stacker (movable
conveyor) or truck.  Rubber-tired compaction equipment compacts the retorted
shale to the specified density, typically over 85 lb/ft3.  The pile itself
will be constructed in lifts or windrows of 6 to 24 inches.  Each individual
lift will be compacted to a specified field density, and when a portion of the
pile reaches its final configuration, the surface will be reclaimed.
                                      B-5

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        Additional water may be  sprayed on the retorted shale during transit
and as needed at the pile  to replace water lost by  evaporation and  for  dust
control.  Since retorted shale surface  temperatures are high (65  to 90  C)  on
placement and evaporation  rates  in  the  region  are high  (>50  in/yr),  up  to
30 weight percent of the moisturization water  may be evaporated during
placement and compaction and must be replaced.   Higher  quality surface  or
ground waters, rather  than wastewaters,  have been proposed for this use by
some developers due to potential worker  exposure to wastewaters.  Those
projects that do not use wastewaters for retorted shale cooling and
moisturization prior to disposal (e.g.,  Paraho  1982)  may add 5 to 10 weight
percent wastewater to  control dust  at the pile.
        The retorted shale will  cool during transport,  placement  and
compaction during which time organic compounds  may  be volatilized.   As  each
successive lift is added,  additional material may volatilize.   This
volatilization process is  expected  to continue  until the pile surface is
reclaimed.  The soil layer proposed by most developers  is expected  to sorb and
trap any volatile emissions  from underlying retorted shale.

B.2     CODISPOSAL AIR EMISSIONS
        When wastewaters contact hot retorted shale,  volatile compounds
present in the waters can  be  emitted as  gases  (Phases I  and  II).  Nonvolatile
compounds are transferred  to  the solids  and emitted with particulates.  The
moisturized solids continue  to release vapors when  disposed  in the pile
(Phase III) until the pile surface is reclaimed.  Such  emissions  are not
unique to oil shale operations,  and the  emission of organic  vapors from
disposal sites and soil surfaces has been widely reported (e.g.,  from
pesticide applications, solvent  disposal).  The  phases  referred to here  (I,  II
and III) are defined in Section  B.I.
        From an air emission  standpoint,  the compounds  of greatest  concern are
the volatile organic ones, particularly  those containing nitrogen.   These
compounds comprise over 95 weight percent  of the emissions from cddisposal,
the balance (5 weight percent) arising from codisposed organics associated
with particulates.  Most of  the  trace elements  and  inorganic ions present  in
wastewaters are not volatile  at  the temperatures involved in  codisposal.  The

                                      B-6

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 organic compounds,  however,  include many with high vapor pressures at the
 temperatures  prevalent  in codisposal (80 C-300 C),  which are malodorous (e.g.,
 alkylpyridines)  and toxic (e.g.,  nitriles).   These substances maybe emitted
 with  codisposal  flue gases and are regulated as nonmethane hydrocarbons under
 the Clean Air Act.   However,  many of the individual compounds of concern are
 not regulated.
         The nonvolatile organic compounds, which may be present on
 particulates  from codisposal  operations,  include a  number of mutagenic and
 carcinogenic  compounds,  including the polynuclear aromatic hydrocarbons (PNAs)
 and possibly  nitrated and aminated PNAs.  These substances could pose an
 inhalation hazard for workers in  the vicinity of the wetting and disposal
 operations.   Organics associated  with particulates  may  be emitted during all
 three of the  codisposal phases.

 B.2.1    Characterization of Codisposal Air Emissions
         Phase I,  II  and  III gaseous emissions have  been simulated and
 characterized in  laboratory studies  (Hawthorne 1984;  Hawthorne  et al  1985) and
 modelled (Persoff et  al  1984).
 B.2.1.1  Laboratory Studies.   Hawthorne (1984)  simulated Phase I and  II
 emissions by  heating  2 grams  of retorted  shale to four  temperatures  (80  to
 450 C) and contacting it with 0.2  mL  of  oil  shale process water.   The vapors
 were  collected in a Tenax  trap and  analyzed  and  quantitated  by  gas,
 chromatography/mass spectrometry.  All of the samples used in these
 experiments were from a  run of Laramie Energy  Technology Center's  150-ton
 simulated in  situ retort.
        The results of Hawthorne's Phase  II  simulation  are summarized in
Figure B-l,  which plots the mass concentration of total  organic  carbon in
micrograms of TOG per milliliter of process water (yg/mL)  as  a  function  of
retorted shale temperature.   Considerably more organic  carbon was volatilized
from the gas  condensate than  from  the  retort water.  Gas  condensates  have a
higher fraction of volatile compounds because  they are condensed from the gas
stream,  while retort waters are aqueous extracts of  the  oil.  Figure  B-l can
be used to estimate Phase I and II codisposal  emissions.
                                      B-7

-------
ง
8
8
u
H
K  to
o  o)
J  nJ
p  to
E-i  W
   0)
s-
1000
 900
'D800
 700
 600

 500

 400

 300



 200
CQ
100
 90
 80
 70
 60

 50

 40

 30
       20
       10
                               PHASE I AND II EMISSIONS
                      A
Condensate
•• 600 Img/L)
                                                          Retort Water
                                                               = 21tiO mg/L)
                      100
                            200
                                              300
                                                    400
                                                                      500
                              RETORTED SHALE TEMPERATURE (C)
      Figure B-l.   Mass concentration of total organic carbon as a result of cooling
                    and moisturizing retorted shale with process waters.  (Adapted
                   by  J. Fox  from  Hawthorne,  1984).
                                            B-8

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        The classes of  compounds  found by Hawthorne  In these  experiments  are
summarized in Table B-2.  The most abundant  classes  in descending, order of
concentration are:  pyridines, phenols, ketones,  anilines,  pyrroles,  nitriles
and quinolines.  These  classes contain a number of malodorous (e.g.,
pyridines) and toxic  (e.g., nitriles, phenols) compounds.   Since  many of  them
are irritants to the  eyes and upper  respiratory tract  (e.g.,  ketones,
pyridines), worker exposure should be considered.  Nonmethane hydrocarbons  are
very minor components of the emissions, contributing less than 2  percent  of
the emitted organic carbon.  The  specific compounds  volatilized during
Phase II wetting were essentially the same as those  found in  the  air  space
above oil shale process water samples (Hawthorne  and Sievers  1984; Hunter
et al 1985).
        Hawthorne also quantitated Phase III emissions  that would' occur from
an 80 C pile surface during lift  construction.  This was simulated by
measuring organic carbon emissions over time from a  14  weight percent
codisposed mixture.  An 80 C, 2g  sample of retorted  shale was contacted with
0.30 mL of process water and mixed,  and emissions were  quantitated as  the
sample cooled over a 49 hr period.   The results of this simulation are plotted
in Figure B-2 (solid lines), together with an extrapolation to 100 C  (dashed
line), based on temperature relationships from Figure B-l.  Figure B-2 can  be
used to estimate the quantity of  organic carbon emitted from  the  pile  surface
during construction.
        Hawthorne found that the  organic carbon emission rate following
moisturization decreased logarithmically with time.  At the end of 49  hours,, a
period equivalent to that required to construct a lift  in many commercial
processes, the total organic carbon  emission rate was negligible, amounting to
0.014 to O.llug C/mL/hr.                                          |
        Thus, it may be anticipated  that the emission rate from a!given area
of the pile will be cyclical.  The emission  rate will increase when each  new
lift is added and thereafter decrease logarithmically over time until  the next
lift is added, and so on.  When the  final pile depth is reached,  the surface
will be covered with top soil and reclaimed.  Emissions following reclamation
have not been studied but will probably be negligible due to:   (1) logarithmic
decay over time noted by Hawthorne (1984); and (2) sorption of vapors  by

                                      B-9                         :

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           TABLE B-2.  CLASSES OF ORGANIC COMPOUNDS EMITTED AS A RESULT
                       OF COOLING AND MOISTURIZING RETORTED SHALE WITH
                       PROCESS WATERS ( yg EMITTED/mL OF PROCESS WATER)
                       (Hawthorne et al, 1985)


                            	         MASS CONCENTRATION (yg/mL)	

                                  Gas Condensate                 Retort Water

                            Retorted Shale Temperature    Retorted Shale Temperature
COMPOUND CLASS
Total alkylpyridines
Total alkylanilines
Total alky Iquino lines
Total alkylpyrroles
Total alkylnitriles
Total alkylphenols
Total ketones
Total alkylthiophenes
Total alkylbenzenes
450
242
20
8.2
20
13
73
45
3.7
0.6
250
184
15
5.8
16
11
58
39
2.3
0.5
150
157
16
4.2
17
10
50
41
2.0
0.4
80
62
4.4
0.4
8.2
4.1
12
23
1.3
0.3
450
88
10
6.5
7.3
14
33
21
5.5
3.4
250
66 !
7.6
4:.2
5.1
9.6
24
19;
2.2
0.5
150
70
5.6
3.0
3.5
5.3
16
15
1.0
0.2
80
23
0.8
0.8
1.3
1.4
4.3
10
0.6
0.1
Total identified emitted
  compounds (Mtot)          427    332    299    1.16

% of emitted compounds
  identified                 84     87     88     85

Total emitted organic
  carbon                    295    222    201     80
191    139    119     42
 78     79'     85     82
140    100     84     31
(1)  Percent of emitted compounds identified was determined by dividing the total
     integrated area of the chromatographic peaks of the identified species by the
     total integrated area of all peaks in the flame ionization detector
     chromatogram.

(2)  Total emitted organic carbon was estimated by calculating the amount of total
     emitted species as hydrocarbons and multiplying this result by the quantity
     0.84yg of C/l.OOyg of hydrocarbon.
                                      B-10

-------
          nil      r
                           Mill!    !T
                                                                                 CO
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                                                                                    co r^io  in
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                                                   o (Ticoir--
                                                                   m
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-------
organic matter in soils  (e.g., Spencer et al  1982; Lokke  1984).  However,
microbially mediated reactions may occur within the pile, which would  release
byproduct gases (e.g., Wildung and Garland  1985; Hassler  et  al 1984).
B.2.1.2 Mathematical Model.  Emissions from Phase III codisposal operations
have also been estimated by mathematically  modelling the  major processes that
occur in the near-surface pile environment  (Persoff et al 1984). |  They divided
Phase III emissions into three processes which were separately modelled, as
follows:  (1) expulsion of gases from internal pore space during compaction]
(2) diffusion of vapors to the lift surface following compaction;  and  (3)
emission of particulates.  They used their  model to estimate the emission
rates for six nitrogen heterocycles from a  50,000 BPD facility in,which the
retorted shale was moisturized to 15 weight percent with untreated Occidental
                                        O
gas condensate and compacted to 85 Ib/ft  at  a temperature of 85 C (a  worst-
case).
        The factors that determine the actual emission rate  of a particular
compound depend on the chemical content of  the waste water,  the spent  shale,,
interaction between the water and spent shale and the partitioning of  the
compounds between the solid, liquid and gaseous phase.           '
        Persoff et al (1984) used a mathematical model to calculate the
partition coefficients and interstitial void  volumes to estimate daily
emission rates of pyridine, methyl dimethly and trimethly pyridines,
quinolines, and pyrroles.
        Many simplifying assumptions were made and research  should be
undertaken to develop actual data.  This analysis was not intended to
determine all singularly accurate values but  rather to illustrate'the
framework of the interpretation of the laboratory and field  data as they
become available.  The assumptions used are summarized in Table B-3.
A.      Removal of Volatile Solutes by Absorption j)n Spent Shale
        Nitrogen compounds can be removed from the waste water by  absorption
onto the spent shale which would decrease its concentration  and eventual
emission rate.  An evaluation was made of the absorption potential of
collidine (2,4,6-trimethylpyridine).  A simulated in-situ spent shale  from the
                                      B-12

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    TABLE B-3.  BASIC ASSUMPTIONS USED FOR PHASE II EMISSION CALCULATIONS
                (Persoff et al,  1984)
Production rates:


Moisturization:



Compacted density:

Height of compacted lift:

Active disposal area:

No sorption of solutes to solid phase.

Disposal shale temperature:
oil:          50,000 bbl/day
spent shale:  1.4 ton/bbl oil

15% moisture (i.e., 15g water/lOOg
spent shale); moisturizing water is
Oxy-6 condensate

85 lb/ft3 (1.36 metric tons/m3)

0.5m (1 lift/day)

93,000 m2
85 C
                                   B-13

-------
Laramie Research Center  (LRC)  10-ton retort was  used.   The primary data can be
fit by a Langmuir isotherm:
                             C/Q = (I/A B) + (C/A)
where:
        C = equilibrium  phase  concentration of collidine  (yg/ml)
        Q = equilibrum solid phase concentration of  collidine  (yg/g)
        A = sorption capacity  (yg/g)
        B = constant (ml/yg)
        Using values for A and B  of  0.274  y/g and 0.029 ml/g,  respectively,
for concentrations of collidine less  than  100 yg/ml, the  degree of  absorption
that would occur would be less than  1.4  yg/ml.   Therefore,  removal  of
collidine by absorption  would  be  minimal.  Similar data analyses are needed
for the other compounds  of interest  at the relevant  temperatures.   However,
for this analysis, the removal of volatile solutes by absorption on spent
shale is considered negligible.                                  ;
B.      Emission of Compounds  During  Compaction;   Expulsion of Gas  From Pore
        Space      •                                                         ~
Estimation of Gas Composition  in  Pore Space—
        To estimate emission by expulsion  of inertial air,  both the
composition of the expelled air and its volume must  be  determined.  The
expelled air will have equilibrated with defined masses of  solids spent  shale
and moisturized water.   Because solute removal by  absorption would  apparently
be minimal, as discussed above, only equilibration of air  and  moisturizing
water need be considered.  Partial pressure that would  be  exerted by each
constituent in the gas phase would be equal to the product  of  its'mole
fraction in the liquid phase,  its liquid phase activity coefficient, and the
vapor pressure of the pure compound.  These values for  the  heterocyclic
nitrogen compounds from  an Oxy-6 gas condensate  and  the resulting head space
composition are shown in Table B-4.
                                      B-14

-------
      TABLE B-4.  NITROGENOUS HETEROCYCLES IN OXY-6 GAS CONDENSATE AND
                  ESTIMATED HEADSPACE COMPOSITION (Persoff et al, 1984)
Compound
Pyridine
Methylpyridines
Diinethylpyridines
2-, 4-, 6-Trimethyl-
pyridines
Quinolines
Pyrroles
Mole
Fraction
x 106a
3.35
4.25
7.91
10.41
1.64
1.32
Activity
Coefficient1*
12.29
64.99
358.79
2054.33
1918.22
12.29d
Vapor
Pressure
of Pure
Compound
(85 C)
294
183
114
71
<4
183
Mass Concentration
in Headspacec
mg/m3
56
276
2036
10806
83
12
  Based on pooling all isomers.

  Activity coefficient calculated by UNIFAC.

c Mass concentration at standard temperature and pressure (i.e., 0 C and
  1 atm).                                                         ;

  Activity coefficient assumed to be same as pyridine.
                                    B-15

-------
Volume of Gas Expelled During  Compaction—
        Once the compoisiton of the  gas  In the  pore  spaces  has  been calculated
(for this example, head  space  over  pure waste  water was  assumed)  the
calculation of emissions by expulsion of inertial air  requires a  value for.the
volume expelled.  The volume of gas expelled can be estimated  directly from
the bulk density of spent shale during  emplacement  and after compaction (0.865
                      O                                                   - •
and 1.36 metric tons/or*, respectively)  and from the solid  density of the spent
shale (2.5 metric tons/m3).  Using  these values, it can  be shown  that 0.356 m3
of inertial gas is expelled during  compaction  of the spent shale  generated
from production of one barrel  of oil.
C.      Emission of Compound After  Compaction;  Diffusion to Surface of Lift
        After compaction it can be  assumed that the pile will  remain hot for
24 hours until the next lift is in  place.   Although each lift  will cool by
radiation and evaporation of water, such cooling is limited because the shale
is placed on a previously compacted lift which is still  above  ambient
temperature.  Spent shale that  is black (i.e.,  contains  residual  char) will
gain heat from solar radiation.  Surface temperatures  of 65 C  have been
observed on sunny summer days  for black spent  shale that has been previously
been cooled to ambient temperature.  Thus,  65  C can be taken as the lower
temperature limit for cooling  a spent shale on hot  days.   It is approriate  to
consider hot weather conditions for codisposal  scenarios studies  since air
pollution management is generally directed at  limiting severe  episodes rather
than annual average concentrations.
        For the diffusion of compounds  (e.g.,  nitrogenous  heterocycles),  the
following assumptions were made: (i)  the  surface of the disposal  pile is a
zero-concentration boundary; (ii) the concentration of nitrogenous
heterocycles is uniform throughout  the  pile immediately  after  compaction;
(iii) and the bottom of the lift is a zero-flux boundary.
        An analytical solution  based on  on a three-phase matrix to determine
an "effective diffusivity" was used to  estimate the  fraction of each  solute
that would diffuse to the surface of the pile  during 24 hours.  The results  of
these calculations are summarized in Table B-5.
                                      B-16

-------
           TABLE B-5.
ESTIMATED LOSS OF NITROGENOUS HETEROCYCLES
VIA DIFFUSION (Perspff et al, 1984)
      Compound
   Diffusivity m2/sec x 10 5
   Gas    Liquid
  Phase   Phase    Effective3
            Fraction Lost
 Henry's    From Disposal
Constant1*   Pile in 1 Day3
Pyridine

Methyipyridines

Dimethylpyridines

2-9 4-, 6-Trimethyl-
   1.36  0.000321   0.00461

   1.21  0.000283   0.0121

   1.10  0.000255   0.0325
   4.75         0.148

  14.54    !     0.231

  44.85         0.377
pyridines
Quinolines
Pyrroles
1
1
1
.01
.02
.47
0
0
0
.000233
.000247
.000355
0
0
0
.0813
.00734
.00281
135
10
2
.15 :
.35
.59
0.
0.
0.
590
181
115
a Method of calculation shown in Persoff et al (1984)

  Henry's constant = (vapor pressure of pure compound)(activity coefficient)/
                     (total pressure)
                                    B-17

-------
        Two  important  effects  are not considered in this analysis.  The first
is evaporation  of water  from the  pile.   Considerable water loss may be
expected  at  85  C.  Evaporation of water will cool a pile while also making the
remaining liquid phase more  concentrated.   The second effect that also
contributes  to  considerable  volatilization is "wicking".  As the moisture
content in the  upper region  of the pile decreases relative to he lower region
of the pile,  the resulting moisture  potential gradient causes moisture to move
upward toward the surface.   This  results from capillarity.  This flow of water
within the pile causes an advective  transport to the surface in addition to
the diffusive transport  modeled.
        The  calculated emission rates for  nitrogeneous heterocycles that would
result if  spent shale  were moisturized  with Oxy-6 is condensate (undiluted and
untreated except for ammonia removal) are  summarized in Table B-6.  Emissions
from particulates were calculated directly using the value of 2 grams of
fugitive  dust per barrel of  oil (Crawford  et al 1977) and assuming that the
                                                                   f
dust contained  15 percent moisture which in turn had the concentrations of
nitrogeneous  heterocycles  are  shown  in  Table B-6.   The emissions from the
particulates  are minimal when  compared  with those from diffusion and
expulsion.
B.2.1.,3 Comparison of  Facility Emissions.   Persoff's estimates of Phase III
gaseous emissions are  compared  in Table B-6 with those calculated from
Hawthorne's experimental data  using  the procedures detailed below.  Overall,
Persoff's model predicts TOG emission rates that  are about a factor of  two
higher than those measured by Hawthorne (1984).   Individual compound and class
emission rates  estimated from  these  two methods  deviate  by as  much as  a factor
of seven.  When one realizes that Persoff's model was not calibrated or
validated with  authentic data and  that  all  variables  were estimated from
procedures such as those presented in Lyman et  al (1982),  it is truly
remarkable that the two  sets of estimates  are as  close as  they are.
        The cause for  the discrepancy between Hawthorne's  laboratory
simulsition and Persoff's model predictions  is not  known  precisely,; but
inaccurate input data  is certainly an important  factor.   In  general,  it is
believed that both methods tend to overestimate Phase  III  emissions.
Hawthorne's estimates  are probably high because he did not  compact his
                                                                               \
                                      B-18                      • '  I

-------
       TABLE B-6.  COMPARISON OF PHASE III CODISPOSAL GASEOUS EMISSION
                   RATES CALCULATED BY TWO INDEPENDENT METHODS
COMPOUND OR CLASS
Pyridine
Methylpyridines
Dimethylpyridines
2-, 4-, 6-Trimethylpyridines
Quinolines
Pyrroles
TOTAL
MASS
(Ib/hr)
Hawthorne
(1984)
7.0
10.3
12.5
11.0
.3
2.9
43.9
EMISSION RATE
hg/1000 m3 of oil
Persoff
et al (1984)
2.2
5.2
20.2
51.0
,1.9 ;•
.6
81.0

Ratio
(P/H)
0.3
0.5
1.6
4.6
7.0
0.2
1.8
(1)  Both sets of estimates "were calculated for a 50,000 BPD facility in which
     the retorted shale is -moisturized to 15 weight percent with a gas
     condensate and compacted to 85 lb/ft3 at a temperature of 85 C.
                                    B-19

-------
samples, and he continuously flushed them with air during the experiment, both
of which would tend to increase emissions compared to the field case.
        Persoff's estimates are also probably high because his model did not
consider evaporation, which occurred in Hawthorne's simulation and which is
significant in the arid high mountain desert terrain of oil shale regions.
Free-water surface evaporation in many areas exceed 50 in/yr.  This
evaporation will cool the pile surface, reducing emissions that strongly
depend on temperature.  Gas expulsion may also not be as significant as
suggested by Persoff's model, which assumed that all of the interstitial gases
was expelled.  In fact, gases may be trapped within internal pores, and only
those pores near the surface of a lift may contribute.  Although Persoff's
model did not consider adsorption, there is presently no evidence that it is
important for nitrogen heterocycles at the pH and temperatures common in
codisposal (e.g., Zachara et al 1986; McGowan and Sorini 1985; Routson and Li
1980).

B.2.2   Summary                                                   l
        Codisposal of process waters is estimated to release about
             *%
188 kg/1000 mj of oil of organic vapors to the atmosphere.  This is greater
than the average facility (all sources) hydrocarbon emission rate of
             o                  "    .                         •     -
160 kg/1000.mฐ of oil calculated from seven oil shale PSD applications.
Codisposal of the waters would contribute an additional 5.7 kg/1000 m3 of oil
of organic material to normal particulate emissions, which average
340 kg/1000 m3 of oil for the same seven projects (Taback and Goldstick 1986).
                                      B-20

-------
                                   APPENDIX B


                                   REFERENCES                     l


 Anonymous.   Shale  Oil  Project  (C-b),  Detailed Development Plan and  Related
 Materials,  Vol.  1,  Submitted to Area  Oil Shale Supervisor,  Grand "Junction, CO
-(1976)..

 Bureau of Land Management  (BLM),  Final  Environmental Statement,  Proposed
 Development of Oil  Shale Resources by the Colony Development Operation in
 Colorado, U.S. Department  of Interior (1975).

 Crawford, K. W:-,*C; H.  Prien,  L.  B. Baboolal,  C. C., Shih,  A.  A., Lee.  "A
 Preliminary Assessment  of  the  Environmental  Impacts  from Oil Shale
 Developments."   EPA/600/7-77-069,  NTIS  PB- 272283, 1977.          '

 Deering, R.  F.,  R.  0. Dhondt,  and J.  E.  Hines.  "Process  for Cooling,
 Depressurizing and Moisturizing Retorted Oil Shale," U.S.  Patent 4,461,673
 (1984).

 Duir, J. H., C.  G. Griswold, and  B. A.  Christolini.  "Oil  Shale Retorting
 Technology," CEP, February 1983,  p. 45-50                        ,

 Hassler, R. A.,  D. A. Klein, and  R. R. Meglen,  R. R. "Microbial  Contributions
 to Soluble  and Volatile Arsenic Dynamics in  Retorted Oil  Shale," J. Environ.
 Qual., Vol.  13,  No. 3,  1984.   p.  466.

 Hawthorne,  S. B. "The Emission of  Organic Compounds  from  Shale Oil
Wastewaters," Ph.D. Thesis,  Department  of Chemistry, University  of  Colorado,
 Boulder, CO, 1984.

Hawthorne,  S. B. and R. E.  Sievers. "Emission of Organic Air Pollutants  from
 Shale Oil Wastewaters," Environ.  Sci. Technol.,  Vol. 18, No. 6,  1984.  p.  992.

Hawthorne,  S. B., R. E. Sievers, and R.  M. Barkley.  "Organic Emissions from
Shale Oil Wastewaters and  their Implications for Air Quality," Environ.  Sci.
Technol., Vol. 19, No.  10,  1985.   p. 992.                         !

Heistand, R. N.  "Estimating  Solid Wastes from Oil Shale Facilities,"
Proceedings of the Eighteenth  Oil  Shale  Symposium, Colorado  School  of  Mines,
Golden, Colorado, 1985.  p.  291.

Hunter, L., P. Persoff, P. and C.  G. Daughton.  "Identification and  Correlation
of Volatile Components in  Oil  Shale Retort Wastewaters," in  Chemistry  for
Protection of the Environment,  Leuven, Belgium,  September 10-13,  1985.

Lokke, H. "Sorption of Selected Organic  Pollutants in Danish Soils;," Ecotox.
Environ.  Safety,  Vol. 8, 1984.   p. 395.
                                      B-21

-------
 Lyman,  W.  J.,  W.  F. Reehl,  and D. H. Rosenblatt, D. H. (Eds.) "Handbook of
 Chemical Property Estimation Methods," McGraw-Hill Book Company, New York,
 1982).                                                            -

 McGowan, L.  J. and S. S. Sorini.  "The Effect of Residual Carbon-on Adsorption
 of Organic Compounds by Retorted Oil Shale," in Proceedings of the Eighteenth
 Oil Shale  Symposium, Colorado School of Mines Press, Golden, CO, 1985. p. 317.
                                                                 _i>
. Paraho  Development Corp., Paraho-Ute Project Technical Report, prepared by
-Paraho  Development Corp. for Bureau of Land Management in conjunction with the
 Uintah  Basin Synfuels Environmental Impact Statement, 1982.

 Perry,  R.  H. and  C. H. Chilton.  "Chemical Engineers' Handbook, 5th Edition,"
 McGraw-Hill  Book  Company, New York, 1973.

 Persoff, P., L. Hunter, L.  and C. G. Daughton. "Atmospheric Emissions from
 Codisposed Oil Shale Wastes, A Preliminary Assessment," Lawrence Berkeley
 Laboratory Report, LBID-890, 1984.

 Rio Blanco Oil Shale Company, Modification to the Detailed Development Plant,
 Lurgi Demonstration Project, Tract C-a, submitted to the USGS Deputy
 Conservation Manager-Oil Shale, 1981.

 Routson, R.  C. and S. W. Li. "Collidine Sorption on a Silt Loam Soil and a
 Spent Shale,"  Soil Sci., Vol. 130, No. 5, 1980.  p. 233.

 Spencer, W.  F., W. J. Farmer, and W. A. Jury. "Review:  Behavior of Organic
 Chemicals  at Soil, Air, Water Interfaces as Related to Predicting; the
 Transport  and Volatilization of Organic Pollutants," Environ. Toxic. Chem.,
 Vol. 1, 1982.   p. 17.                                            ;

 Tosco Development Corporation (TOSCO), Project Description, Technical Report,
 San Wash Shale Oil Project, Uintah County, UT, Report prepared for Utah Bureau
 of Land Management, 1982.

 UNOCAL, Draft Environmental Monitoring Plan, Phase I Project (Unishale B),
 Vols. I and  II, prepared by UNOCAL Energy Mining Division for Department of
 Treasury,  May 1986.

 Wildung, R.  E. and T. R. Garland. "Microbial Development on Oil Shale
 Wastes:  Influence on Geochemistry in Soil Reclamation Processes,
 Microbiological Analyses and Applications," R. L. Tate III and D. A. Klein
 (Eds.), Marcel Dekker, Inc., New York, 1985.  p. 107.

 Zachara, et al. "Quinoline Sorption to Subsurface Materials: Role of pH and
 Retention  of the  Organic Cation," Environ. Sci. Technol., Vol. 20, No. 6,
 1986.  pp. 620-627.                                              <
                                       B-22

-------
                                  APPENDIX C
                  SUMMARY OF PSD PERMIT APPLICATION EMISSIONS

        These are the data reported in the applications for  Prevention  of
Significant Deterioration (PSD) Permits.  The data  are presented  in  six tables
as follows:                                                  •     ;

        Table C.I - Gaseous Emissions
        The data are sorted by (1) Project,  (2) Pollutant and  (3);General
Process.  This sort provides the total emissions for each project;  i.e., total
emissions of CO from Cathedral Bluffs.  The  information is used  to  determine
and compare total facility emissions.

        Table C.2 - Particulate Emissions
        The data are sorted by (1) Project and  (2) General Process.  This  sort
provides the total particulate emissions for each project.  The information  is
used to determine and compare total facility emissions.

        Table C.3 - Gaseous Emissions
        The data are sorted by (1) Pollutant, (2) Process and  (3),Project.
This sort provides emissions for each process within the project.  The
information is used to determine and compare emission rates for each general
process category (mining, retort, etc.) within each facility;  i.e;, NOX
emissions from mining process for each project.

        Table C.4 - Particulate Emissions
                                """      ~ •" ~             '            f
        The data are sorted by.(1) General Process and (2) Project.  This  sort
provides particulate emissions for each process within the project.  The
information is used to determine and compare emission rate for each general
process category (mining, retort, etc.) within each facility.
                                      C-l

-------
        Table C.5 - Gaseous Emissions
        The data are sorted by  (1)  Pollutant,  (2)  Specific Process and (3)

Project.  This sort provides emissions  for  each  process.   The  information is

used to determine and compare average value for  specific  processes;  i.e., CO

emissions from blasting and particulate emissions  from underground:vehicles.


        Table C.6 - Particulate Emissions

        This data is sorted by  (1)  Specific Process  and (2)  Project.   This

sort provides emissions for each specific process.   The information is used to

determine and compare average values for specific  processes.

        Each category is used for the data  base  sort routines  and  is  described
below.


C.1     PROJECT    •                                                !            •

        The projects included in the data base are:                |
   Project Name
                   Process Description
Cathedral Bluffs


Clearcreek Oil Shale


Cottonwood


Paraho

Union B

Syntana

White River
Oxydental MIS/Lurgi modified in-situ with above
ground Lurgi solids recycle retort

Above ground Chevron - Fluidized Bed Retort and
spent shale combustion with solids recycle

Above ground circular grate retort with;fluidized
bed combustion of spent shale and fines

Above ground Direct Heat Retort

Above ground Indirect Heat - Gas Recycle

Above ground T 3 Process - direct heat - semi-batch

Above ground circular grate (Superior) with Union B
and Tosco II
                                      C-2

-------
C.2     POLLUTANT                                                 ;
        The pollutants included are:

        Carbon Monoxide (CO)
        Hydrocarbons (C)
        Nitrogen Oxides (NOV)
                           A.
        Sulfur Oxides (SOY)
                         A.
        Particulates (PM)

C.3     GENERAL PROCESS
        The General Process categories:

        Category Description
        1.  mining
        2.  retort
        3.  gas utilization
        4.  upgrading, storage

C.4     SPECIFIC CATEGORIES
        The Specific Categories are  described  in  Table  4-1  in the'text  and
indicated in the various tables.
                                       C-3

-------

ProjecF
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
.Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdrai Bluffs
Catherdral Bluffs
Catherdral Bluffs.
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs

Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs.
Catherdral Bluffs
Catherdral Bluffs
f". - - -
r~~ general process
fflining-beloB
utility
retort
retort
• retort
upgrade
upgrade
;: upgrade
i upgrade
i upgrade

utility
retort .
retort
retort
upgrade
upgrade
upgrade
' ' ' ' upgrade
upgrade
upgrade

aining-belos
utility
retort
retort
. ' retort
upgrade
upgrade
, upgrade
upgrade
upgrade
aining-belos
utility
. retort
retort
retort
upgrade
upgrade .
upgrade
I .upgrade
• .! ' upgrade
:"•'.: . "-TABLE; c-i. GASEOUS EMISSIONS
specific process * addition pollu t-tons/d cat!
sine shaft vents
steas boilers
flares
sponge oilreboiler
recycle gas heater
incinerator
H2 Recycle Heater
H2 Charge Heater
oil charge heater
reforaer
sine shaft vents
steas boilers
flares
sponge oil reboiler
recycle gas heater
H2 Recycle Heater
incinerator
H2 Charge Heater
oil charge heater
reforser
storage

tine shaft vents
steaa boilers
flares
sponge oil reboiler
recycle gas heater
incinerator
H2 Recycle Heater
H2 Charge Heater
oil charge heater
reforier
sine shaft vents
steas boilers
flares
sponge oil reboiler
recycle gas heater .
H2 Recycle Heater
H2 Charge Heater
oil charge heater
incinerator
reforser
	 'co
CO
CO
CO
CO
CO
CO
CO
CO
• co
HC
HC
HC
HC
HC
• • " ' HC
HC
HC
HC
HC
HC

NQx
NQx
NOx
NOx
NQx
NOx
NOx
ซ0x
NOx '
NOx
. ,
SOx
SOx
SOx
SOx
SQx
SOx
SOx
SOx
Sfls
'SOx "
,30
.05
.00
' .01
.05
.00
.00
.01
.01'
.05

.08
.08

.00
.01
.00
.00
.00
.00
.01


-• ,
.91
1.89
.00
.09
.70
.02
.02
.07
.12
2,21

.06
.28
.02
".04
.30
,01
.03
.05
• .24
.33
"8
3?
38
40
40
43
43
43
43
43

8
37
38
40
40
43
43
43
43
43
43

3
37
38
40
40
43
43
43
43 '
43

8
37
38
40
40
43
43
43
43 .
43
"cafcf
1 	 "
3
3
3 :
3
4
4
4
4
4 :

i ;
3
3 ;
3
3 :
4
4 ;
4 ,'.
4
4
4

1
3
3
3 ;
3
4
4
4 .
4 .
4 ;

1 ;
3
3
3
3
4
4 :
4
4 '•-
4 ' ;
oil
158.37
23.78
.18
3.33
25.21
.67 .
.90
2.85
4.66
28.06

39.47
42.80

.57
4.52
.14
.14
.57
.81
4.76


475.12
989.24
2.62
48.04
369.06
9.04
12.84
39.00
62.78
1159.03

29.96
147.44
8.09
20.45
S56.95
5.23
17.60
28.54
126.98
173.12
-% H • - B i*
i X total
ฃ3.86 ;
9.59 "
.07 '
1.34
10.16 '
.27
.36 " 	
1.15
.1.88 r
11.31-
: jis. :-•- •-
42.09
45.64

.61
4.82
.15 .. .
.15
.61
.86
5.07
;
,""'-
15.00
31.24
.08 . •
1.52. ,-
11.65
.29
.41
1.23
1.98
.36.60
• .*- .;-•:
4:19
20.64
1.13 i'
2.86
21.97
.73
2.46 ' i •.
3,99 .""-
17.78 ,
24.23

-------
TABLE C-l..  Continued




Project
Clear Creek
Clear Creek
.Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek.
Clear Creek
Clear Creek
Clear Creek
Clear Creek,
Clear Creek
Clear Creek

Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek

Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek

Clear Creek
Clear Creek
Clear Creek





Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale

Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale

Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale

Shale
Shale
Shale





Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil

Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil

Oil
Oil
Oil
Oil
Oil!
Oil
Oil
Oil
Oil
Oil
•Oil
Oil
Oil
mi

Oil
Oil
00

r ' v ' '

r'- • •---...-
general process
mining-above
aininq-below
iining-belos
sining-beloB
sining-above
aining-above
Bining-above
sining-above
utility
retort
retort
retort
lining-above

ffiining-belos
sining-belos
ffiining-above
aining-above
sining-above
upgrade
upgrade
ffiining-above

sining-abave
ffiining-belDซ
Bining-belos
sining-belos
sining-above
tining-afaove
sining-above
sining-above
ffiining-above
utility
retort
retort
retort
sininq-above

fiining-beloB
Bsininq-beltm
sining-above




specific process
blasting
blasting
crushing/screening
vent
top soil
top soil
raw shale haul
spent shale haul
steas superheat
char coabustion
char combustion
TE6 Concentrator
vehicles
., . . • „,".
crushing/screening
vent
top soil
raw shale haul
spent shale haul
fugative
storage
vehicles
• 	 - - - :
blasting
blasting
crushing/screening
vent
top soil
top soil
top soil
raw shale haul
spent shale haul
steai superheat
char coBBustion
char cosbustion
TE6 Concentrator "
vehicles

crushing/screening
vent
top soil

V


addition


prisary

removal
load




coal gri

road sai

priiary

reioval




road asai
, ,


prismry

reioval
load
load




coal gri

road fflai

pritary

resoval




pollu
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CQ
CO
CO

HC
HC
HC
HC
HC
HC
HC
HC
-i
NGx
NDx
SOx
NOx
NO*
NO*
NOs
NOx
iffix
m
MX
NOx
ซQx
NOs
-\
SOx
SOx
Sflx




s-tons/d
,05
.36
.72
1.23
.03
.00
.03
.06
.58
176.04
.05
.00
.01 .

.11
.17
.01
.01
.01
3.26
.13
.01

.02
.03
.75
1.30
.20
.00
.01
.19
,14
1.87
. 86.90
.15
.00
.05

.07
.12
. .01




cat!
2
2.
6
8
9
10
16
32
37
40
40
43
53

6
8
9
16
32
44
46
53

2
2
6
8
9
10
10
16
32
37
40
40
43
53

6
a
9

,ป

-
cat
1
1
1
1
2
2
2
2
3
3
3
4
4

r
i
2
2
2.
4
4
4

1
1
1
i
2
2
2
2
2
3
3 .
;3
4
4

1
1
2



- kg/IOOOt
2 oil
2.97
22.66
45.03
77.62
1.83
.17
2.11
3.94
36.41
11071.92
2.97
.11
.70

7.19
10.96
.57
.68
.51
, 204.89
i 7.99
.57

1.43
1.71
• 47.03
81.61
12.44
.06
.74
11.99
8.73
i 117.57
5465.19
9.53
.29
3.42

4.34
7.48
.86
-,- ' ..=• j
•^ ' fl? . •-

3V"r : .' -v- .: "'•"• :"
X .total
.03
.20
.40
.69
.02
,00
.02
.03
-32
98.26
.03
.00 •
.01
.! 	 pf- ;• t
3.08'- ' """ " •'
•4.70
.24
.29 . -
.22
87.80
3.42
.24
; '&'"*''>' i'''' ' ~-
.02
.03
.82
1.42
.22
.00
.01
.21
.15
2.04
94.85 '
.17
,00 :
.06
! I
it
', .78
1.35
.15

-------
TABLE  C-l.   Continued




Project               general process
specific process      addition pollu  ซ-tons/d   catl  cat2  *9/j?j0i
total
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek

Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute
Parahc-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute

Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute

Paraho-Ute
Paraho-Ute

Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute

syntana
syntana
syntana
syntana
syntana
syntana
syntana
Shale Oil lining-above
Shale Oil sining-above
Shale Oil sining-above
Shale Oil utility
Shale Oil retort
Shale Oil retort
Shale Oil retort
Shale Oil sining-abave

sining-beloB ground
nining-beloB ground
upgrade
retort
upgrading
( upgrading
eining-beloH ground
upgrade
retort
upgrading
upgrading
upgrading
upgrading
upgrading
upgrading
upgrading

aining-beloi* ground
aining-beloป ground
upgrade
retort

upgrading
upgrading

sining-beloa ground
upgrade
retort
upgrading
upgrading

flining-faeloH
sining-beloB
sining-beloB
retort
retort
retort
upgrade
top soil
raH shale haul
spent shale haul
steac superheater-soi
char coibustion
char coibustion
TE6 Concentrator
vehicles

blasting
eobile equipeent
package boiler
power generation
hydrotreater feed fur
reforier furnace
aobile equipment
package boiler
power generation
hydrotreater feed fur
reforaer furnace
storage
storage *day)
storage
storage
storage

blasting
aobile equipaent
package boiler
poser generation

hydrotreater feed fur
reformer furnace

sobile equiptent
package boiler
poser generation
hydrotreater feed fur
reforaer furnace

blasting
blasting
vehicles
F6D
F6D
Tosco ball heater & 1
F6D
load SOx
SGx
SOx
i 80s
coal gri Sflx
SOx
SOx
road aai SQx

CO
CO
CO
CO
CO
CO
HC
HC
HC
HC
HC
crude sh HC
crude sh HC
hydrotre HC
fuel oil HC
diesel & HC

NOx
NOx
NOx
NOx

NO*
KOX

SOx
SOx
SOx
SQx
SOx

CO
CO
CO
steaa bo CO
superior CO
CO
hydrotre CO
.00
.01
.01
.49
.05
8.06
.00
.00

.52
.67
.01
.39
.01
.15
.21
.00
.07
.00
.03
.01
.01
.01
.00
.00


3.17
.02
6.25

.09
2.00

.23
.05
3.97
.00
.11

.41
.41
.57
.15
.09
.05
.01
10
16
32
37
40
40
43
53

2
8
37
37
43
43
S
37
37
43
43
46
46
47
48
49

2
8
37
37

43
43

8
37
37
43
43

2
2
8
37
40
40
43
2
' 2
2
- 3
: 3
!3
; 4
4

; i
l
3
'3
4
;4
1
3
3
4
4
4
;4
4
4
4

i
|i
'3
3

;4
4

1
3
3
$
4

1
1
1
3
3
3
4
.06
.68
.51
30.82
2.97
506.80
.11
.29

77.39
99.67
.83
58.57
.98
	 22AB
30.98
.16
10.26
.16
3.91
.82
1.22
1.05
.04
.37


473.97
3.74
936.25

13.18
300.03

34.31
7.07
595,18
.03
16.65

45.76
45.76
62.58
16.14
9.51
5.17
1.53
'.01
. 12
.09
5.55
.53
91.33
.02
.05
,
29.81 I
38.39
.•32
22.-S6
.38
JJ.54 	 	
63.26
.33
20.95
.33
7.99
1.66
2.48
2.15
.08
.75
i ^

27.44
.22
54.21
i
.76
17.37

5.25
1.08
91.11
.00
2.55

24.88
24.88
34.03
8.78
5.17
2.81
.83
                                                  C-6

-------
TABLE C-i:.  Continued

it-

Project
syntana
syntana • ;' ••

syntana
syntana
syntana
syntana
syntana
syntana
syntana -.;:
syntana
syntana

syntana
• nuntans
nwnf ans
. sy 11 LQII&
syntana
syntana
syntana •'-.'.
syntana
- syntana ',
. syntana '.
syntana

syntana
syntana ;
syntana
syntana
syntana ~
syntana
syntana
syntana
syntana

Union
Union
Union
Union
Union
Union
•Union
Union
Union
Union j -
Union • " ,
•i"

/•
general process
upgrade
upgrade

iining-bsloB ,
retort
-'.-• retort
retort
upgrade
upgrade
upgrade
upgrade
upgrade

sining-belos
ffiining-faeloB
retort

utility
retort
retort
retort
upgrade
upgrade
, upgrade

aining-beloa
retort
utility
retort
retort
retort
retort
.' retort
upgrade

fiining-beloB
isining-beloB
ffiining-beloK
iining-above
tining-above
Bini rig-above
utility
.coab. -retort
retort
upgrade
, upgrade



specific process
FGD
hydrogen

vehicles
F8D
F8D ,
Tosco ball heater & 1
F6D
FGD'
hydrogen
oil storage tanks
fugitive eiissions

blasting
vehicles
FGD

steast
retort indirect heate
rep "'"," \1
Tosco ball heater & 1
FGB
FGB
hydrogen

vehicles
FGS
steas
claus plant
F6D
retort indirect heate
FSB . " ..; ; , .
Tosco ball heater & 1
FB8

drilling
blasting
raB shale resoval/sca
ras shale
spent shale
spent shale
steas - . . •
sponge oil stripper
gas recycle heater
fractionater
dearseniter



addition polls
hydrogen CO
furnace CO

HC
steaa bo HC
superior HC
HC
hydrotre HC
hydrogen HC
furnace HC
HC
HC

NOx
SOx
steaa bo NOx

NQx
HOx
superior NOx
NOx'
hydrotre NOx
hydrogen KOx
furnace N0>:

SOx
steas bo SOx
SOx
SOx
ciaus pi SQx
SOx
superior SOx
80s
hydrotre SOx

CO
CO
engines/ CO
topsoil CO
hauling CO
aroosiing CO
CO
CO
CO
reboiler CO
purge he CO
'- -- . .,.- -
- ' . • ;* ' •""' = .

i B-tons/d
.16
.23-

.18
,03
.02
,51
.00
.03
.04
.03
' .52
^
.23
2.70
r



.99
.57
.16
1.90
2.20

.20
.91


.51

.53
, .40
.09
:<
.00
1.14
.55
.01
.05
"' •'"; .01
2.66
.03
.33
.01
.00



catl
43
. 43-..

8
37
40
40
43
43
43
46
54

2
8


37
39
' 40
40 '
43
43
43

8
37
37
39
39
39
40
40
43

1
2
8
.11
32
36
37
40
' 40
43
43



cat2
4
: 4 ' .

1 •'
'• 3
3
3
4
'4
: 4.
4
4

. 1
1 1
.,___ — ___

3
3
;' 3
i 3
4
4
4

i
: 3
3
3
3
3
: 3
3
: 4

1
1
; i .
2
2
2
3
3.
,3
4
' 4" •
.

kg/1000t3
oil
17.87
25.33-

19.42
2,83
1.79
55.87
.29
3.20
4.71
3.12
57.07

25.03
297.37




108.80
62.58
17.77
210.16
242.30

21.53
100, 13


56.27

57.97
44.46
9.51

.09
79.71
38.75
.43
3.77
• ,50
185,67
'2.44
23.13"
..38.
..32
' 	 ^~~^f-.
_':.", ..'. !'-L"^^s}
V i 1. 1
A -total
9.72
13.78
: ta:.'
13.10
1.91
1.21
37.67
.20
2.16
3; 17
2J11
38.48
; Jlj%-:
2r17
25,79
; . J



9.44"
. grjjj--
1,54
18.23
21^02
i pv*
' 3.74
17,33


9.77

10,06
7.72
1.65
^"'
.02
16,09
7.82
.09
• 76 , '
.10
37,49
.49
4.67
,08
.06 ; ' '•

-------
TABLE C-l.  Continued

{•: ' -

Project
Union
Union
Union
Union
Union
Union

Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
.Union
... - j,-. j*. . ^_L, ,. - ._ , ...
.-• '-•-'- - • ,;
f
general process
— . • upgrade
upgrade
upgrade
;-.- upgrade
upgrade
sining-ahove

•- sining-beioB
1 sining-beloB
aining-beloB
oining-above
' mining-above
sining-above
\ ' . utility
coib. -retort
-•".-• retort
upgrade
upgrade
, • upgrade
upgrade
upgrade
'. •;' -• - upgrade
upgrade
upgrade
0 . .upgrade
upgrade
aining-above
upgrade
siining-belos
aining-belpB
aining-belos
sining-above
, sin ing-above
sining-above
','-". utility
ccfflb. -retort
: retort
V . upgrade
upgrade.
upgrade
upgrade
j upgrade
upgrade
.:'•'•- upgrade
i- aining-above
specific process
dearseniter
unicracker
steaa boiler
stean boi 1 er
reforffier furnace
vehicles/engines

drilling
blasting
ras shale reaoval/sca
ran shale
spent shale
spent shale
steas
sponge oil stripper
gas recycle heater
fractionater
dearseniter
dearseniter
unicracker
steam boiler
steas boiler
reforier furnace
storage tanks
oil storage
siscellaneous
vehicles/engines
fugative
drilling
blasting
raป shale reacval/sca
raB shale
. spent shale
spent shale
- "• steas
sponge oil stripper
gas recycle heater
fractionater
dearseniter
dearseniter
unicracker
steaa boiler
steal boiler
• -reforffier furnace
vehicles/engines
addition pollu s-tons/d
charge h CO
charge h CO
no air p CO
snth air CO
CO
CO
- .J
HC
HC
engines/ HC
topsoil HC
hauling HC
grooming HC
HC
HC . '
' ' "*. HC
reboiler HC
purge he HC
charge h HC
charge h HC
no air p HC
with air HC '-"
HC
HC
HC
table 4- HC
HC
HC
NOs
NOs
engines/ NOs
topsoi 1 80s
hauling NOx
grooving HOx
^SOs
NOs
'ffis
reboiler ffflx
purge he NOs
charge h Kfls
charge h fes •
no air p N0>:
si th air NOs
NOs
NOx
.02
.03
.51
.51
.26
.97

.00

.18
.00
.02
.00
.05
.00
.06
.00
.00
.00
.01
.01
' .01
.05
1.10
.02
.84
.11
1,10

.01
.29
2.97
.03
.31
.05
3.54
' .42
4.14
.05
.04
,20
.26
.56
.67
3.22
.25
'catl cat2
43
43
43
43
43
53

1
2
8
11
32
36
37
40
40
'43
43
43
43
43
43
43
46
46
46
53
54

1
2
8
1.1
32
36
37
40
40
43
43
43
43
43
43
43
53
: 4
4
,4
4
' 4
4

1
1
1
: 2
2
12
'3
3 -
3
4
4 '
,4
~4
;4
4
'4
: 4
'4
4
r4
;4
~T~" 	
1
.1
; i
2
2
2
.3
'3
;3
:4
4
'•4
;4
4
4
u
4

1 -^ ' i~" '
f ' ' *•" "" •'
k9/1^ฐ"3 I total
""'1.65'
2.09
35.38
35.38
18.01
67.57

.03

12.87
.14
1.24
.16
3.80
.30
4.26
.06
,06 ,
.32
.38
.70
.70
3.36
77.08
1.46
58.85
7.36
77.08

.42
20.23
207.74
2.31
21.46
3.42
247.31
29.22
289.16
3.30
2.79
14.14
18.07
39'. 25
47,05
225.12
17.69
,33
.42
7.14
7.14
3.64 "-"
13.64 "-"
: t
.01

5.14
,06
.49 .
.06
1,52
;12
1^70 ;
• " -^03 --
.03
.13
'.. hs
.28
i2B
1.3.4
3O1
.58
23.52
2,94
30.81
1
.04
1.70
17.48
.19
1.81
.29
20.81
2.46
24.;33
.28
.23
1.19
* 1.I52'
3.30
3.96
18.94
1.49

-------
TABLE C-l.  Continued


— "t. -' : ------- - • --
-;ซ•
Project
Union . ', •"
Union
Union i
Union ''
Union
Union
Union
Union
Union
Union
Union
Union
Union '
Union
Union '••..-
Union
Union ;
Union '......-

Utah-cottonwood
Utah-cottonsood
Utah-cottommod
Utah-cottonaood
Utah-cottonaood

ytah-cottonBood
Utah-cottonsood
Utah-cottonseed
Utah-cottonseed
Utah-cottonBcod

Utah-cottonHOod
Utah-cottonaQod
Utah-cottonBood
Utah-cottonsood

Utah-cottonseed
Utah-cottonsood

Shite River Shale Proj
Shite River Shale Proj
ihite River Shale Proj
Unite River Shale Proj
ซhite River Shale Proj
	 _ _ ._ -.. - , , . .

;- - - . - . r -
f"-*" '- 	 :'..- •>t-"
general process
aining-beloi*
sining-beloH
aining-beloB
tuning-above
Bining-above .
jiining
sining-above
utility
coab. -retort
retort
upgrade
upgrade
upgrade
upgrade
upqrade
upgrade
upgrade
sininq-abcve

siining-faeloB ground
iining-beloB ground
retort
upgrade
upgrade

aining-beloB ground
retort
upgrade
upqrade
upgrade

sining-belos ground
lining-belos ground
.retort
upqrade

tining-belos ground ..
retort

ffiining-beloB
iEininq-belos
utility
retort
retort


. . , - - --._-• . . . .
. ^ r ^..ป,, . ,_ (.- „ 1H,.^ „ J
specific process
drilling
blasting
ras* shale retoval/sca
raw shale
spent shale
dusping shale
spent 'shale
steals
sponge oil stripper
gas recycle heater
fractionater
dearseniter
.dearseniter
unicracker
steaa boiler
steaa boiler
reforier furnace
vehicles/engines

blasting
vehicles-cosbustibn e
fluid bed coabustor
fugitive
fugitive

vehicles-coabustion e
fluid bed coibustor
product storage
fuel oil storage tank
fuqitive

blasting
vehicles-combustion e
fluid bed cosbustor
fugitive

vehicles-coibustion e
fluid bed coabustor

blasting
vehicles
steaffi
Tosco bail heater & 1
recycle gas heater
•',. - ,-.. •

- - -. . ?. •

addition


engines/
topsoii
hauling

grooaing



reboiler
purge he
charge h
charge h
no air p
Bith air






on site
on site










on site
.







union b



:-v :- .
poliu s
80s
SOs
SQx
SOx
SOs
SOx
SOs
SOs
SOs
SQx
SOs
SOs
SOs
SOx
SOs
SOs
SOs
SOs

CO
CO
.CO
CO
CO

HC
HC
HC
HC
HC

HOs
KOx
HOs
SOx
-'
S0>!
80s

CO
CO
CO
CO
CO



>.iV. k
-tons/d
.00
.03
.19
.00
.02
.04
.00
2.02
.29
3.34
.01
.01
.05
.06
.11
.11
.15
.02

.40
.24
.48
.03
.13

. .07
.02 .
.11

.34

.22
1.12
20.12
.06

.08
3.91

.87
1.10
.44
.15
.32



'i "" ' "1
catl
i
2
8
11
32 :
33 ;
36
37
40
40 i
43
43 :
43
43
43 ;
43
43
53

2
8
37
53 ,
53

8 '
37 ;
46
48
54

2
8
37
53

8
37

2
8
37
40
40 ;




cat.
1
i
i
2
2
2
2
3
3
3
4
4
4
4
4
4
4
4

1
1
3
4.
4

1
3
4
4-
4

i
1
3
4.

1
3

1
1
3
3
3
\


i-kg/lOOOi3
oil L
.02
2.38
13.00
.16
1.31
2.85
.24
141.16
20.39
233.74
.76
.63
3.36
4.25
, 7.55
7.55
10.15
1.17

80.33
46.97
95.57
6.85
25.21

14.51
3.08
22.49

68.55

43.88
223.05
4020.34
11.24

16.14
781.58

51.58
65.17
26.33
8.97
18.80
t •



I total
.63
1.27
5.07
6.97
20.26
20.90
22.80
23.43
25.33
25,33
27.23
27.23
27.23
27.23
27.23
27.23
27 .'23
33.56
.me-:. -
',31*51
18.42
37.49 .
2.69
9.89

13.36
2.84
20.70

63.11
ฃ-'-.-
1.02
5.19
.93.53
.26
: f - - .
2.02
97.98
f-_. •••
24.37
30.89
12.50
4.25
8.90
                                       ; C-9

-------
TABLE C'-l.  Continued
•'.' • s-
i -.. ,- ' .:, , • • • :•- , - •-• >• ". ,
f '
Project general process
Hhite River Shale Proj upgrade

Hhite River Shale Proj stining-beloH
White' River Shale Proi utility*
Hhite River Shale Proj retort
Hhite River Shale Proj retort
Hhite River Shale Proj upgrade
Hhite River Shale Proj upgrade
Hhite River Shale Proj upgrade
ffitite River Shale Proj upgrade

Hhite River Shale Proj iining-belos
Hhite River Shale Proj eining-belos
Hhite River Shale Proj utility
Hhite River Shale Proj retort " "..
Hhite River Shale Proj retort
Hhite River Shale Proj retort
Hhite River Shale Proj upgrade

inte River Shale Proi Siininq-below
Hhite River Shale Proi utility
Hhite River Shale Proj retort
Hhite River Shale Proj retort
Hhite River Shale Proi retort
Hhite River Shale Proj retort
Hhite fiiver Shale Proj upgrade




'-'-' • • ' •' ' • '..- •' ">'- ;• •-. - --:1

specific process additio
reformer furnace

vehicles
steasi '
Tosco ball heater & 1
recycle gas heater union
reforaer furnace
- valvesjfiangesspuipss
crude storage
. crude shale oil stora •

blasting
vehicles
' steas
gas treatment plant
• Tosco ball heater It 1
recycle gas heater union
reforaer furnace

vehicles
steaa
gas treatsent-claus t
retort 1
Tosco ball heater Ic 1
recycle gas heater union
reforser furnace




? T

n pollu
CO

HC
HC
HC
HC
HC
HC
HC
HC

NOs
HOs
• NOx
ซ0x
NQx
8Bx
NO?:

80s
SDK
SOx
SOx
Sflx
SOx
SOx






a-tons/d
.69

.34
.32
.83
.06
.14
1.02
.46
. .48
/
.47
5.24
4.77
.07
1.02
2.01
4.32

.38
1.63
.36

.10
.07
.14


'I



cat!
43

8
37
40
40
43
44
46
46

2
•8
37
39
40
40
43

8
37
39
40
40
40
43




" ',• -

cat2
'4

1
3
3
3
4
4
4
4

1
1
3
3
3
3
4

; i.
3
3
, 3
3
3
4



- -•.?_
'*-• ' m
kg/1000i 3
oil
40.62

20.31
19.13
49,00
3.81
8.22
60.17
27.29
28.69

27.94
310.42
282.59
4.14
60.17
119.27
255.73

22.51
96.70
21.06

6.18
3.92
8.33



~ 	 i 	 __|^
^ t -if,- ;. kf-,~! i

total
19.23
•• ••-•,--" • '-"• •-_.. ••
9;38
8.83
' 22,62
1.76
3.79
27,78
12-60
13,24
: t "
2.63
29,28
26.65
,39
5.68
11.25
24.12
! 1
' I4!i8
60.93
13.27

- 3.89
2.47
.5.25
; ft


                                               C-10

-------
TABLE C-2.  PARTICULATE EMISSIONS

^— — --"•"' "' 1 ' *

project
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluff s
Cathedral Bluffs
• Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral 'Bluff s
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs

Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale






























Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
Oil
fliT
Oil

" " '* .
t •
general process
Eining-belov!
sining-above
Bining-abcve
aining-above
sining-above
aining-above
sining-abo
sining-abo
fflining-above
raining-abo
sining-above
tining-above
aining-abo
aining-above
sining,-abo
'aining-abo
. coib-utility
retort
cosh. -retort
cosb. -retort
cosb-upgrade
upgrade
upgrade
upgrade
fflining-abo

isining-belos
sining-helos
sining-heios
sining-belcw
fflining-beloB
sining-beloB
aining-above
aining-above
sining-above
sining-above
sining-above
mining-above
fflining-above
aining-above
sining-above
fflining-above
si fiing-above
sining-above
: sining-^above
aining-above
.sitting-above
sining-above
__ , ; . . tj -.- v^. r-_. .;'. , -v
'. .... _ ^

specific process'
sine shaft vents
reclais drashole
ras shale
raw shale
r 39 shale .
ras shale"
raซ shale storage
ras shale storage
raw shale
spent shale
spent shale
spent shale ...
spent shale
spent shale
spent shale
spent shale storag
steas boilers
incinerator
sponge oil rebel le
recycle gas heater
reforser furnace
H2 Recycle heater
H2 charge heater
Oil charge heater
fugitive ciust

drilling
drilling
blasting
blasting
priaary crushing
vehicles-vent
surface soils
surface soils
surface, soils
surface soils
surface soils.
ravs shale
, r as shale :
' rm shale
ras shale
raซ shale
int waste
int Haste
raw shale' ...
raM shale ;
r as' shale
spent shale
r '^ - y v -...:; ^ ' J ^ . ;
... . ' . ,r 	 [:

additional desc
0
0
crushing buildi
screening plant
transfer house
conveyor-stacke
5 day
5 year
conveyor -retort
stacker conveyo
conveyor
transfer house
conveyer discha
transfer
distribution
0
0
0
0
0
0
0
0
0
haul roads

inter, waste
0
inter, saste
0
0
0
resoval-drill
resoval
resoval -blast
haul
sind
crushing
crushing-2nd
crushing-3rd
conveying
conveying
dusp
haul
dusp
wind errosion
Bind
conveying



cat!
8
9
13
13
15
15
18
21
24'
30
30
31
31
31
33
34
37"
40
40
40
43
43
43
43
54

1
1
2
2
6
8
9
9
9
11
12
13
13'
14
15
15
16
16
17
19
22
30
,1 ป•
"_!,„,
.
i cat
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
4
4
4
4
4

1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2.
2
2
2:
2
2
i v.f- •--:
	 ' mjm: -^"'

s pol E
ps
ps
pit)
ps
pis
ps
ps
ps
pa
psi
pa
ps
ps
' ps
ps
ps
ps
pa
pa
ps
ps
ps
pa
ps
ps :

PH
PH
PH
PH
PR
PH
PH
PH
PH
PH
PH
PH
PH
PH
PH
PH
PH
; PH
PH
PH
PH
PH
!.'- -.^ _. " i „
,'™J, , - -r"—
, ;i: j
s-ton/d
. .17
.01
.00
-.00'
,02
' .05
; .01,
i -^
M
.05
.04
' .02
; .04
.04
; .07
: .01
'.03
.00
• .00
.03
.03
.00
.00
; .01
'".00

\ .00
.01
.10
,26
.00
.40
,01
.13
• .25
,36
l ,00
.00
.' .01
, -M
• .02
; .si
, .01
.15
.12
.00
• .04
' .18
"."„ " ~^.~. ^ --" " f
j " " __^^- • — "^sL
ig/1000ซ 3
oil
88.46
2.7.1
1.62
1.43
9.04
25.21
3.80
5.42
2.313
, 25.21
20.93
9.04
20.93
20.93
38.52
2.85 .
14.27
.38
1.90
14.74
16.98
.57
1.71
2.85
1.43

.26
.74
6.22
16.27
.21
25.34
.74
8.28
-15.58
22.83
.21
.29
.68
.91
1.13
51.03 .
.34
9.36
7.53
.02 '
2.57
11,59
x. 	 -™-
,-„ 'L •-:',_,

I tot
26,
.
•
.
2.
7.
1.
1.
.
7.
6.
2.
6.
6.
11.
1 .
4.
.
.
4.
5.
.
.
.
.

.
-
3.
8.
.
'"-13.
.
4.
8.
11.
'
*

•
•
26.
•
' - 4.
3.
.
1.
5.
T •- V* -Vi
• , i^h 	 ,- • j

al
54
81
49
43
71
56 •„ ,
14
63
71
56
28
71" "'"-"
28
28
56
86
28
11
57
42 "
09
17
51
86
43
JTIr
13 ^ '
38
19
35
11 "
01
38
25
00
72
il
15
35
47
58
23
18 '
81
87
01
32
95
               C-ll

-------
TABLE C-2.  Continued
                                                        T%
— ... . ... •-, -

project ]
Clear Creek Shale Oil
Clear Creek Shale Oil
.Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek ishsle Oil
cottonseed
cottonseed ..•••••
cottonseed ,'
cottonseed
cottonseed -;
cottonseed
cottonseed . ..
cottonseed
cottonseed
cottonseed
cottonseed
cottonseed
cottonseed
cottonwool!.
cottonseed
cottonseed. !
cottonseed
cottonseed
cottonseed ' " • :
cottonseed ;
cott'onsood
cottonseed !
cottonseed
cottonseed
cottonseed ;
cottonseed
cottonseed
cottonseed

Paraho-Ute
Paraho-Ute
Paraho-Ute ,
Paraho-Ote '
Paraho-Ute
Paraho-Ute '
Paraho-Ute \[ •
Parahe-Ute ;
-..-• . • =..,- -;---
IS
'. V ' • •
general process
iining-above
coffib-retort
coab-retort
cosb-utility
coipb-retert
coEb-retort
cosh-retort
Bining-above
sining-above
aining-beles
aining-bflow
lining-belos
sining-belos
si ning-above
aining-abovE
raining-above
Mning-above
siningtabove
iiti ning-above
'aining-above
งi ning-above
si ning-above
aining-abeve
' fining-above
fiii ning-above
aining-above
•ining-above
isining-abcve
si fling-above
'ai Ring-above
fflining-above
tinihg-above
aining-above
fflining-above
cos-retort
coib-upgrade
coab-upgrade

aining-beles
fflining-beloB
isining-beles
iining-beloป
sining-belos
fflining-faeloB
sining-above
si ning-above









ground
ground
ground
ground
ground
ground
ground
ground
ground
ground
ground
ground
ground
ground
ground
ground
ground
ground
ground










ground
ground
ground
ground
ground
ground
ground
ground
specific process
spent shale
retort gas
TE8 Concentrator
steaa superheat
char combustion
char cosbustion
char coibustion
vehicles
coal
aining
transfer
ras shale
vehicles-cosbustie
ras shale
ras shale
ran shale
ras shale
ras shale.
ras shale
Vis shale
ras shale
ras shale
ras shale
ras shale
fines
fines
fines
fines ' '".
spent shale
spent shale
spent shale-fines
spent shale-fines
spent shale
spent shale
shale fluid bed co
fugitive
fugitive

iiining
blasting
conveying
crushing/screening
crushing/screening
isobile equipment
surface soils
ras shale
additional" desc
haul
0 '. '
0
0
feed binsfsourc
coal grinding
0 " .
0
0
0
transfer points
prisary crushin
0
crusher -luap br
screening
surge bin
storage-load in
storage-reclaifi
stpr.ageUiveJsi
MerageCdeadlsi
retort feed bin
retort feed si!
retort feed. con
retort discharg
FBC discharge b
cenveyor-transf
FBC feed bin .'"
storage silo
conveyor
disposalUoad i
loading/duiaping
storage bin
disposal-sind
disposal -grooii
0
paved roads
unpaved roads

0
0
0
priaary
secondary
0
sind
tertiary crush/
'.'"": '.„ " " ' "F A"" J
catl cate pel ir-ton/d
32
37
37
37
40
40
40
53
54
1 .
5
6
8
13
13
15
18
18
18
21
'23
23-
24
25
26
26
27
27
30
33
33
34
35
36
40
53
53

1
2
4
6
7 ,
8
12
14
2
3
3
3
3
3
3
4
4
1
i
1
1
2
2
2
2
2
: 2
2 .
2
2
2
2
2
2
2
2
2
2
2
2
2 ,
2
3
4
4

1
1
1
1
1
1
2
2
,Pซ .02
•pit
PH .00
Pfi .14
PH
PH ! .09
PH 10.24
PH .17
Pfi .01
-./
pa .11
pa .05
ps , .03
ps .06
pa .02
pis .03
ps .02
pro .00
•pa ~' .00
psi i.03
pa ; .01
pa ,' .00
ps '.00
pa .00
pa ! .00
pa i .01
ps , :'.ot
P!B .01
pi : '.0!
pa
pffl , ,
pffl
ps . i .01
pa .03
ps .33
pa ; .04
pii ' .01
pi .06

pa .04
pis .17
pi .03
pa ; .08
pa .08
pa .02
Pffi ;.07
pa" '.24
. . •- '• .
._ . ^^
kg/1000ซ3'
oil
i.

.
8.

5.
643.
10.
,

21.
9.
5.
11.
4.
5.
3.
•
*
6.
2,
•
•
'•
•
. 1.
1.
1.
.1.



1.
5.
. 66.
8.
37"

23
96

71.
77
50
65!

76 :
61
26
42
8.1
60
23
30
60
8?
77
7f
79
T]
79
09
09
09
09



12
01
53
20
2.18
11."

5.
25.
5.
12.
12,
3.
10,
36.
M

7!
4i3
10
16
16
06
19
355
I total
.

•
i.

•
97.
5,
..

12.
5.
3.
6.
2,
3,
1.
•
" •
3.
1.
•
•
•
*
- • *
•
•
•



•
2.
38.
.
.1.
6.

70

03
36

37
74
39
•VlT
35
: |it
f --i .
50
52
02
56
76
22-,"
85"
1.7
34,
96
59
46
46
46
46 '
63 '
63
63
63



64
87.
23
-9 i -
71
25
46
i R
1.70
7.
1.
3.
3.
1.
2.
10.
dU
50
60
60
00
40
50
                                            C-12

-------
CABLE. C-2., Continued

_

project
Paraho-Ute
Paraho-Ute , .
Paraho-Ute '
Paraho-Uie • •
Paraho-Ute ';."..
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute '
Paraho-Ute
Paraho-Ute
•"Paraho-Ute --.
Paraho-Ute
Paraho-Ute
Paraho-Ute :
Paraho-Ute
Paraho-Ute
Parahc-Ute ;
Paraho-Ute
Paraho-Ute
Paraho-Ute

syntana ,
syntana
syntana
syntana
syntana
syntana , ,
syntana ;. .-.. ..'•
syntana
syntana ', ., . v '.
syntana • ;
syntana
syntana ,
syntana .
syntana
syntana
syntana
syntana
syntana
syntana ;
syiitana
syntana i • %
syntana
syntana
svntana
_^ 	 : 	 	 	 —

,-
general process
tining-above ground
. tining-above ground
sining-above ground
. aining-above ground
Biining-above ground
sining-above ground
fflining-above ground
raining-above ground
siining-above ground
. sining-above ground
si rung-above ground
mining-above ground
sining-above ground
sining-above ground
sining-above ground
fflining-above ground
sining-above ground
upgrade
coab-retort
upgrading
upgrading

Bining-beloB
Eining-beloB
aining-belovf
sining-above
sining-above
' 'Sining-above
fflining-above.
fflining-above
fflining-above
sining-above
(sining-above
si Ring-above
sining-above
iining-above
siining-above
utility
retort ; __.
retort
retort
, retort
retort
upgrade
, upgrade
. iainino-above
_- 	 *—.-


specific process"
raw shale
raป shale
rm shale
ras shale
rass shale
rm shale
raa shale
fines
fines
ras shale
fines
spent shale
spent shale
spent shale
spent -shale
spent" '.shale
spent shale
package boiler
poser generation
hydrotreater feed
refofaer furnace

sining
blasting
vehicles
ras shale ••
raw shale
ras shale
raw shale
raB shale
ras shale
fines transfer
fines
fines . '_
spent shale
spent shale
spent shale
steaa
FSB . .
retort indirect he
F6B
Tosco ball heater
Tosco ffioisturizer
FBB
FSB
fugative
UK- .... -,- ••'-.; ';_ .-•ซ
^•' ' ?r^'

additional desc cat!
trans, fr. live 15
convey/transfer 15
sasple & seigh 15
screening/trans 15
live storage 18
emergency stora 21
retort feed 24
conveyor-transf 26
to bin 26
fines transfer/ 26
storage 26
conveying 30
to bin ,' 30
convey ing-A 30
retort overflow 31
retort discharg Si-
storage ; 34
0 37
0" • 37
0 43
0 ' 43

o i
0 2
0 8
prisary crushin 13
secondary crush 13
storage 18
storage-Mind 22
retort feed-tos 24
conveyor feed 24
0 26
storage-Hind 27
maintenance 29
storage-load-tr 34
storage-Bind 35
storage-sainten 36
0 37
steaffl boiler 37
0 39
superior heater 40
0 : ' •'" . .40"
0 42
hydrotreater 43
hydrogen refers 43
truck traffic 53
. -r *-">' •--.- f-
,i/f J,,'.

cate pol is
2 ps
2 ps
2 po
2 pa
2 'pa.
2 ps
2 ps
2 ps
2 ps '
.-' 2 ps
2 ps
2 ps
2 ps
2 ps
2 '• ps
2 pa
2 pst
3 PH
3 PR
4 BE
4 PH
;
i ps
i ps
1 pa
2 ps
2 ps
2 . ps
2 ps
• 2 pcs
2 ps
2 ps:.
2 pa
2 ps
2 pa
2 pa
2 ps
3 ps
3 ps
3 ps
3 ps
3 pa
3 ps
4 pis
4 • ps
4 pe

!*' '!' " "
inr. /j
-ton; a
.01
.05
'.10
: .16
.00
, .11
; .04
; .01
.01
; .01
.11
; .01
.02
.03
.04
.23
; .22
[ .00
i .35
..: .01
; .is

.13
.18
.14
.01
.29
.03
.04
.00
: .00
.01
.02
.05
' .02
.16
.24

: .05

.03
''.34
.06
.00
',.06'
.28
s. :\- .•-.;.., \J—:.
-,.. /
'' -, '; - * *~T"
kg/1000ii3!
oil ^
1.77
7.34
14.27
24.60
.14
16.10
5.38
.82
1.14
1.79
16.50
1.30
2.213.
4.24
5.38,.
34.24.
33.50
.33
51.70
.82 '
19.57

13.91
19.32
15.31
1.42
32.14
3.47
4.77
.18
.35
.85
2.64
5.87
'" 1.89
17.62
26.33

5.89

3.48
37.73
6.13
.53
6.61
30.44
-~;— '^-ฃL- : ' *.
i
y fnfaj
ft {.ULCl
.50'
2.20
4.20
7.10
.04
4.70
1,60
.40 '.'
.40
.50
3.80
.37
.70
i.30
1.60
10.00
7.90
.09
15.00
.30
5.70
___— — i- 	

5.87
8.16
6.46
.60
13.57
1.47
2.01 "
.07
.15
•-r I
.06
1.12
2.48
.80
7.44
11.12

2.49

1.47
15.93
2.59
.22
2.79
12.85
                                                                                                   ?:*.
                                                C-13,

-------
TABLE C-2.  Continued



• "— -—
project
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Union
Shite
White
Shite
Shite
Shite
Shite
Shite
Shite
Shite
White
Shite
White
Shite
Shite
Shite
White
Shite

























River
River
River
River
River
River
River
River
River
River
River
Ri ver
River.
River
River
River
River
i

v'






















Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
iShale
Shale
iBhale
Shale
Shale
Shale
Shale
Shale
Shale









. /









"





Project
Project
Project
Project
Project
Project
Project
Project
Project
Project
Project
Project
Project
Project
Project
Project
Project
— , — ^ — ^^_-., — ,_
— ซ4 ..--., -. -, - ,<-• J r ,.
general process specific process
siining-beloB
sining-beioB
fflining-belos
sining-belog
siriing-beloH
aining-beloB
isining-beloH
"aining-ab'ove
fflini rig-above
mining-above
isining-afaove
irdning-above
Bining-above
mining-above
aining-above
sining-above
Bining-above
sin ing-above
ffiining-above
aining-above
Biining-above
aining-above
Biining-afaove
.utility
retort
retort
aining-above
sining-above
Bining-above
Bining-above
lining-belos
ainihg-belo*
aining-belos
aining-beloB
•aining-above
ai'ning-abDve-
sining-above
ffiining-above
nifiing-above
sining-above
isining-above
aining-above
Bining-above
sining-above
aining-above
liiining-above
sin ing-above
drilling
blasting
reoovai
. conveying
. rm shale crushing
crushing
,raป shale removal/
ras shale
r as shale
ras shale
raw shale
.. raป shale storage
storage silos
.." rass shale storage
. ras shale storage
retort pad
; spent shale convey
spent shale
spent shale
spent shale
spent shale dispos
spent shale-storag
spent shale
steat -'.•-
sponge oil strippe.
gas recycle heater
vehicles/engines
vehicles/engines
vehicles/engines
fugative dust
fining
crushing.
crushing
vehicles
conveyor surge bin
retort feed silos
ras shale stockpil
• conveyor feed-unib
conveyor feed-supe
fines reclaim conv
fines-storage
fines
spent shale discha
spent shale convey
spent shale dispos
spent shale dispos
spent shale dispos
additional desc
0 ,
0
0
priiary
priaary.
engines/vehicle
topsoil hauling
crushing/second
crushing/tertia
conveying/trans
load out
o -
load in
Bind erosion
gind errosion
0
stacking
hauling
truck dusping
0
Bind errosion
grooaing/cospac
0
0
0
light duty
road taint/acce
diesel
0 "" * '." ' '
0
prisary
secondary
0
0
three
load/groosMnd
0
transfer
0
reclait/sind/tr
storage/conveyo
un/tos/sup
0
load in
wind erosion
groosing
"catl
1
'2
3
4
6
8
ii
13
14
15
"18"
18
18
19
19
30
31
32
33
34
35
36
37
39
40
53
53
53 •"
54
1
6
7
8
$5
18
18
24
24
26
27
27
30
30
34
35
36
cate po! t-ton/d * . .
1
1
1
i
i
1
1
2
2
2
2
2
2
2
2
2
2^ '.
2
2
2
2
2
2
3
3
3
4
4
4
4
i
1
1
1
2
2
2
2
2'
2
2
2 :
2
2
2
2
2
pss .00 "
PH .01
pa .03
PH '• .17
PH ' .07
PH . ; .63
ps ,JO
pa .01
PH '.12
PH .41
PH ' ,01
P'H : .00
PH. ,'.01
PH .0!
PH ;.00
pa ' : .01
pa .08
pst ' .02
ps : .05
pa .03
Pfl
pa . .01
ps .03
ps ; .09
ps '.01 '
PH ^.10
pis \ .04
pa t .05
"•pa ' !.15
PH " !,36
; f
,'pa .26
pi .14
ps ; .04
ps .27
pa .01
pa .05
ps : .12
pB .01
pa .05
ps .00
pa ,07
ps .14
.pa .01
pa ' .05
pa .02
pi .05
pa . 36
.34
.50
2.31
11.5?
4.63
43.78
7.15
'.•49
8.61
28.7!
'.59
.06
.50
.77
.19
.36
5.55
- 1.54
3.16
1.98

.57
1.93
6.09
. .61
7.31
2.64
3.5-!
10.62
'24.95

15.31
8.4(;
2.63
15,85
.86
2.69
6.93
.51
2.6(?
.17
4.4J
8.54
.37
3.22
1.07
2.7?
21.60
'-% total
.19
.28
1.28
6.40
2.56
24.18
3.95
.27
4,76
15.85
, i'32 ' ' ' -
.04
.27
.43
.10
.20
3.07
.85
• 1.75
1.09

.32
1.07
3.36
' .34
4.03
1.46
1.96
5.86
13.78'
7J7
3.98
1.23
7.42.
.40
1,26
3.25 .
.24
1.26 : .
.08
2.06
4.00
.17
1.51
.50
1.31
10.12

                                                 c-14/:

-------
ABLE  C-2.   Continued
steals            ~0
Tosco ball heater  0
recycle gas heater  union
elutriator         0
37
40
40
41
Tosco elutriators  and  loisturizer 41
processed shale BO 0              42
reforier furnace   0              43
3
3
3
3
3
                                                                                                   pa
                                                                                                   ps
                                                                                                   pro
.72
.44
.19
.05
.13

.41
42.515
26.06
11.28
 3.0?
 7,7!?

24.513
project                   general process   ' specific p'rocess   additional  desc  call cate pol a-ton/d      oij    , X total

White River Shale Project  utility
Shite River Shale Project  retort
Hhite River Shale Project  retort
White River Shale Project  retort
White River Shale Project  retort
Shite River Shale Project  retort
Shite River Shale Project  upgrade     :
19.93
12.21
 5.29
 1.45
 3.65

11.50
                                                                                                                                        M" i- -
                                                                                                                                       • !-.'• IT
                                                                    C-15

-------
                                            GASEOUS EMISSION?

Project
Catherdral Bluffs
Clear Creek Shale
..• Clear Creek'iShale
.Clear Creek Shale
Clear Creek Shale
Paraho-Ute
Paraho-Ute
syntana
syntana
syntana :
_• i
Union
Union
Union-.
Utah-cottonttood
Btah-cottonsciod
Shite -River iihale
White River. Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale-
Clear Creek Shale
Union
Union
Union : •
Catherdral Bluffs
••-. Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Clear Creek Shale



Oil
Oil
Oil
-Oil
Projec
Projec
Oil
Oil
Oil '
Oil
Oil


general process
sining-beloซ ,
Bining-above
sining-belos
sining-belDB
sining-beloB
iining-beloB ground
tining-belos ground
sining-beloB
siining-belos ~
eining-belQB
sining-beloH
inining-beloe
sining-beloe
tining-belcs ground
sining-belos ground
sining-beloH
mining-above
mining-above
Bining-above
sining-above
mi ning-above . "
Bining-above
Bining-above
utility.
retort
retort
retort
utility
,,::,';•*. '-,;-^< ,-,",,/-:--
specific process additional
sine shaft vents
blasting
blasting
crushing/screening 'primary
vent , •
blasting
Bobile epipaent
blasting
blasting
vehicles . '- -•' '
drilling
blasting
rm shale ressval /seal engines/ve
blasting
vehicles-coibustion eq
blasting
vehicles
top soil resjoval
top soil load
ras shale haul
spent shale haul
raw shale topsoil ha
spent shale hauling
spent shale grociing/c
steaa boilers
flares
sponge oil reboiler
recycle, gas heater
steaB superheat
poliu ii-tdn/d "
CO
CO
CO
CO
CO
CO
CO
CO
co :
CO
co
CO
CO
CO
CO
CO
CO
co
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
.30
.30
.05
.36
.72
1.23
••
.52
.67

.41
- '.41
.57
j
.00
i.14
.55
•>
.40
.24

.87
1,10
,*
'.03
.00
.03
.06

.01
.05
.01
• ••
.05
.00
.01
.05
";'"•-'/ .10
.^

-
•j

i a ~ ~
cat cat ^^fV total
8
2
2
6

8

2
2
8

1
2
8

2
8 ."

2
8

9
10
16
32

11.
32
36

37
38
40
40

i
1
1
1
1

.1
1

i
i"
i

i
i
i

I
i

i
i

'.i •
2
.2
2

2
i
2

3.
3
•3 .
3

158.
158.
' 2.
22.
45.
77.

37
37
97
66
03
62

77.39
99.67

45.
45.
62.

79.
38.

80.
46.

51.
65.

1.
2.
3.

3.

23.
3.
25.
52.


76
76 '
58

09
71
75

33
97

158
57

83'
17 '
11
94

43
77'
50

78
18
33
21
30

-63^86 ' .
63.'86
.03
.20
,40
-69

\ ' f i
29.81
38.39"

24
24

26
7

31
18

24
30





9
1
21

• -*1 i
.88
.88

.02
.09
.82

.51 '
.;42

.37 ,
.'89
.. ฃ•-- '•
J02
.00
..02
.03
^ 	 f*- -g^
.09
.76;
,10
|i , _-- .
.59
.07
.34 .
.17
; r
TABLE C-3.  Continued
/ C-16 ,'

-------
TABLE C-3.  Continued,

Project
Clear Creek Shale Oil
Clear Creel; Shale Oil

ParahQ-Ute ' . '
ParahD-Ute

syntana
syntana
syntana

Union
Union , . . . .
Union

Utah-cottonaood

Shite River Shale Projec
Shite River Shale Projec
Shite River Shale Projec
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs


Clear Creel: Shale Oil
Clear Creek Shale Oil

Paraho-Ute
Paraho-Ute

syntana
syntana
syntana i

Union j •
Union
Union

general process
retort
retort

upgrade
retort

retort
retort
retort

utility
coffib. -retort
retort

retort

utility
retort
retort
upgrade
upgrade
upgrade
upgrade
upgrade


retort •
si ni no-above

upgrading
upgrading

upgrade
upgrade
upgrade ,
-
upgrade
upgrade
upgrade

specific process
char cosbustion
char cosbuEtion

package boiler
poser generation :

F6D
FGD
Tosco ball heater & li

steaa
sponge oil stripper
gas recycle heater

fluid bed cosbustor

steas
Tosco ball heater & li
recycle gas heater
incinerator
H2 Recycle Heater
H2 Charge Heater
oil charge heater
reforser


TE8 Concentrator
vehicles

hydrotreater feed furn
refprBer furnace

F8D
FBD
hydrogen

fractionater
dearseniter
dearseniter
- : — . .... -
additional
coal grind

- -

steal boil
superior h
: 	 - ---




union b



road saint



hydrotreat
hydrogen r
furnace
.' = ' '• tr= -,=
reboiler
purge heat
charge hea

pollu
CO
CO

CO
CO

CO
CO
CO

CO
CO
CO

CO

.CO
CO
CO
CO
CO
CO
CO
CO


CO
CO

CO
CO

CO
Co :
C8 .

CO
CO
CO

s-ton/d
176.04
,05

.01
.39
i
.15
'.09
.05

2.66
.03
.33

.48
~\
~ .44
.15
.32
.00
.00
.01
.01
.05


.00
.01

,01
.15
*,
.01
,11
. .23
=-.
.01'
* '.00
"-.02

cat
40
40

37
n

37
40
40

37
40
•40

!37

37
:40
40
43
43
43
:43
:43
1

43:
53

' 43
43

:43
:43
43

43
43
;43
•J . 1-V

cat
3'
3

3;
3

3
3
3

3
3
3

3

3
3
.3
4
4
4
4
4


'4
4

4
4

4
4
4

4
.4"
4
-.*•• -, -,-• .-,, .3
Tg/1000t3
: oil
ii07i;92
2.97

.83
58.57

16.14
.9.51
5.17

185.67 ^
2.44
23.13

95.57

26.33
8.97
18.80
.67
.90
2.85
• 4.66
28.06


,11 •
.70

.98
22.18

1.53
17.87
25.33

.38
.32
1.65
.1 . . - ซr :
-| .;_!-• - r^-' t ;••-
.1 total
b-~- ••
' 98,26 	
.05
	 _jซ_vj 	 r
1 fc
s=i.-
.32
22:56
n_p - •
8J8 	
5.17 •
2,81
e
~ 37.49
'.49
4.67
; Jt";
37,49
! fr-.
i2;so
4.25
8.90
____!— ^-^1,
,_
,36
1.15:
1.88
11,31 ' . >
s . •
• l=~
,00
.01
f..
,,. ซ.-.. j
.38
8i54
; t-
,83
9.72
13.78
A •
L 	 ^" '
.08
.06
.33
                                             C-17

-------
TABLE C-3. Continued .. -.''.'. .
	 ;==.*=-— 	
Project
Union
Union
Union ...
Union ' -
Union
Utah-cottormsod
Utah-cottonsood
White River Shale
Catherdrai Bluffs
• • Clear Creek Shale
Clear Creek Shale
Paraho-Ute
syntana
Union
Union
Union
Utah-cottonseed
Shite River Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Union
Union
Union

~—t . :,-- - :..:,. ... .,'. - , . .- -
' general process specific process
upgrade
"'.' upgrade
" : upgrade
upgrade
fflining-above
upgrade ,
upgrade
Projec upgrade
sining-beloB
Oil iining-belos
Oi.l sining-beioB
sining-belos
Bining-beloB
sining-belos
tining-beloe
sining-belos
flining-beiow
Projec sining-belos
Oil sining-abeve
Oil sin ing-above
Oil • laining-above
fflining-above
aining-above
sining-above
uni cracker
" steasi boiler
. steai boiler . . .
reforier furnace
'vehicles/engines
fugitive
fugitive
reforier furnace
Bine shaft vents
crushing/screening
vent
ground Eobile equipment
vehicles
drilling
blasting
raw shale resoval/scal
ground vehicles-cosbustion eq
vehicles
top soil
raw shale haul
spent shale haul
rav* shale
spent shale
spent shale
additional pol
charge hea CO
no air pre CO
"sith air p CO
"'" ' " CO
• -'CO.
on site ve CO
on site ve CO
CO
HC
priaary HC
HC
HC
HC
HC
HC
engines/ve HC
HC
HC
retoval HC
HC
HC
topsoil ha HC
hauling HC
grooiing/c HC
?" '•- -, " '" *- '
iu s-ton/d
..03
.51
.51
.26
.97
_-
.03
.13
-i
'".69

.08
'"?'
.11
.17
--
.21
"
.18

.00
.18
ฐ
.07

.34
^
.01
.01
.01
•>
.00
.02
.00

cat
4J
43
43
43
JL
53
53

43

8

8

8

8

1
2
8

8

8

9
16
32

11
32
36
,
cat
4
4
4
4
4

4
4

4

'l

1
i

1

1

1
1
1

1

1

2
2
2

2
2
2

•

_^ 	 	 — -T— -^ ' —
"T • ; -i . > ".. ." f , i. ' -h' . "L> • / ' '
^ฐ'3,X total
*** " L,,,.,,,
2.09
35.38
35.38
18.0,1
67.!J7

6.135
25.21

40.62

39.47

7.19
10.96

30.98

19.42

.03
. 1-2.87

14.51

, 20.31

.57
.68
.51

.14
- 1.24
• .16

.42
• 7.14
7.14
13. 6J " '

2.69
9.89

19v23
i Sv
42.09
: &•*"
3.08
4.70
t-
63.26
1 M
13.10
- i If
,01
5J14 	 	
13.36
1 jv"1 "1
9.38

.24
.29
.22
K:-i,
,06
.,49
.06
*•'-
Catherdrai  Bluffs
utility
steas boilers
HC
.08   37  3      42.80     45.64
                                                        C-18

-------
TABLE C-3.  Continued

Project
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs

i
Paraho-Ute
Paraho-Ute

syntana
syntana
syntana

Union
Union
Union i
• , .
Utah -cot tonaood

Mhite River Shale
Hhite River Shale
Khite River Shale

Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Eluffs
Catherdral Bluffs

Clear Creek Shale
Clear Creek Shale
Clear Creek Shale

Paraho-Ute
Paraho-Ute ,- :
Paraho-Ute
Paraho-Ute
Paraho-Ute ;
Paraho-Ute !
Paraho-Ute
fi
. ' general process
retort
retort
retort

upgrade
retort

retort
retort
retort

utility
coab. -retort
. retort

retort

Projec utility
Projec retort
Projec retort

upgrade
upgrade
upgrade
upgrade
upgrade
upqrade

Oil upgrade
Oil upgrade
Oil iining-above

upgrading
• upgrading
upgrading
upgrading
upgrading
upgrading
upgrading

specific process
flares
sponge oil reboiler
recycle qas heater

package boiler*
poser qeneration

F6D
. FSB 	 ;
Tosco ball heater & li
V ' i'
steals ' .
sponge oil stripper
oas recycle heater

fluid bed cosbustor

steas
Tosco ball heater 4-li
recycle gas heater
	
H2 Recycle Heater
incinerator
H2 Charge Heater
oil charge heater
reforser
storage •

fugative
storage
vehicles

hydrotreater feed furn
reforaer furnace
storage
storage (day)
storage
storage
storage ,

additional poll
HC
HC
HC

! ' HC
HC

steai boil HC
superior h HC
HC

HC
HC
HC

HC

HC
HC
union HC

HC
HC
HC
HC
HC
HC

HC
HC
road iaint HC

HC
HC
crude shal HC
crude shal HC
hydrotreat HC
fuel oil HC
diesel 4 g HC

u s-ton/d
.00
.01
f
v .00
.07

.03
.02
.51
- >
.05
.00
.06
'* i
.02

.32
.83
.06

.00
.00
.00
.00
.01

3.26
.13
.01
• 4 -='
.00
.03
.01
.01
.01
.00
.00

Udl
38
,40
40

37
37

37
40
40
,
37
40
40
,
37

37
:40
40

43
43
43
-43
,33
43

44
46
53

43
43
46
46
47
48
;49

cat
3
3
3

3
3

3
3
3

3
3
3

3

3
3
3

4
4
4
4
4
4

4"
4
4

4
4
4
f
4
4
4 •
kTiooo^
oil ••?
.57
4.52

.16
10.26

2.83
1.79
55.87

3.80
.30
4.26

3.08

'19.13
49.00
3.81

.14
.14
.57
.81
4.76

204.89
7.99
.57

.16
3.91
.82
1.22
1.05
.04
.37
-:- "I' 1 — ~ 	 T-TT---'
™ r I1 ,-
total
.61
4^82
i ฃ'- •
20.95
: |l;
1.91
1.21
37.67
f*-
1.52
.12
L70
i jg*
ifc '•'''"'
S-:
8.83
22^62
1.76
: p= -"
.15
.15
.61 . ' •
.86
5.07
K
87.80
3.42
.24
: ฃ;:
.33
7.99
1.66
2.48
2.15
.08
.75
                                           C-19

-------
TABLE C-3.  Continued


Project
syntana :
syntana
syntana
syntana
syntana
Union : ;
Union '',.
Union
Union :
Union
Union
Union
Union ;
Union !;
Union, '*"'
Union
Union
Utah-cottonHood
Utah-cottonHDod
Utah-cottonseed
Unite River Shale
White River Shale
, White River Shale
Shite River Shale
Catherdral Bluffs
Clear Creek .Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Paraho-Ute !
Paraho-Ute
syntana
syntana
f. ,

general process
r , upgrade
upgrade
upgrade
upgrade
, upgrade
• .--"upgrade.
' ' " upgrade
upgrade
upgrade
upgrade
upgrade
• ; upgrade
upgrade
upgrade
upgrade • •,
isining-above
upgrade
upgrade
upgrade
upgrade
Projec upgrade
Projec upgrade
Projec upgrade
Projec upgrade
aining-beloH
Oil sining-above
Oil ffiining-belos
Oil oining-beloB
Oil sining-beloB
iiining-belos ground
sining-beloB ground
Mning-beloB
fflining-belos
specific process
F8D
F6D
hydrogen
oil storage tanks
fugitive enissions
fractionater
dearseniter
dearseniter
unicracker
steas boiler
steas boiler
reforaer furnace
"storage tanks 	 " ""
oil storage
Miscellaneous
vehicles/engines
f ugative
product storage
fuel oil storage tanks
fugitive
reforaer furnace
crude storage
crude shale oil storag
sine shaft vents
blasting
blasting
crushing/screening
vent
blasting
uobile equipaent
blasting
vehicles
additional pollu
hydrotreat HC
hydrogen r HC
furnace HC
HC
HC
reboiler HC
purge heat HC
charge hea HC
charge hea HC
no air pre HC
with air p HC
HC
; 	 " HC
HC ''
table 4-7? HC
HC
HC
ซC
HC
HC
HC
HC
HC
HC
. ffls
HOx
NO?,
priiary N0>:
HOx
NOs"
HOs
80s
ffl-ton/d
.00
.03
.04
.03
.52
. ,/
.00
.00
.00
.01
.01
.01
.05
1.10
.02
.84
.11
1,10

.11
.34

.14
1.02
.46
.48

.91
,.'
.02
.03
.75
1.30

3.17
/
.23
2.70

cat
43
,43
:43
146
54

43
43
43
43
143
43
43
46
146
46
53
54.

'46
48
54

43
44
46
46

8

2
2
6
8

2
8

2
8

cat",
4
4
4
4
4

4
4
4
4
4
4
4
4
4
4
4
4

4
4
4

4
4 .
4
4 .

1

1
1
1
1

1
1

1

'I
kg7lOOOซ 3
oil
	 .29
3.20
4.71
3.12
57.07

.06
M
.32
.38
.70
.70
3.36
77.08
1.46,
58.85
7.36
77.08

22/49
68.55

8.22
60.17
27.29
28.69

475.12

1.43
1.71
47.03
81.61

473.97

25.03
297.37

• p"
I total
.20
2,16
3.17
2.11
38.48
: f?.?:~*.
.03
.03
,13
.15
.28
^28
1.34
30,81
.58
23.52
30.81
Jft,
20JO
63.11
1 t
3.79
27.78
12.60
13.24

15.00
*,:-,;
.02
.03
.82
1.42
f. -.-
27.44
! f-
'2.17
25.79
! I"
                                           C-20

-------
TABLE C-3.  Continued
	 — • 	 — -Jt— 	 =-



Project
Union
Union
Union

Utah-cottonsood
Utan-cottonHood

Mhite River Shale Projec
Wnte PJฅDr Shale Projec

Clear Creek Shale Oil
Clear Creel; Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil

Union
Union • i „.
Union

Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs

Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil

Paraho-Ute
Paraho-Ute

syntana !.
syritana
syntana
syntana
syntana

Union
Union ,
'" 	 — r-- 	 : '- - - --—


f-
fc
general process
sining-below
sining-beioB
raining-beloB

sining-beloB ground
Biining-beloB ground

iining-beloB
Binino-faeloB

aining-above
sin ing-above
(sining-above
sining-above
aining-above

flining-above
mining-above
iining-above

utility
retort
retort
retort

utility
retort
retort

upgrade
retort .

retort
utility
retort
retort
retort

utility
cosb. -retort
„.- . • , • -- - ,--....-•.-.••..
'; -•
* . . . • 	 	 	 ---, *- -- 	 , -

specific process additional
drilling
blasting
ras shale reaoval/scal engines/ve

blasting
vehicles-coBbustion eq

blasting
vehicles

top soil retoval
top soil . load
top soil lead
rm shale haul
spent shale haul

ras shale topsoii ha
spent shale hauling
"spent shale 'groosing/c

steaB boilers
flares
sponge oil reboiler
recycle gas heater

steas superheat
char cosibustion
char cosbustion coal grind

package boiler
poser generation

FBB steas boil
steal
retort indirect heater
FSD superior h
Tosco ball heater & H

steai
sponge oil stripper


_ ^

poil
NOx
NQK
fids

NOs
KOs

ซfln
ffis

NQx
NOx
SOs
ซ0s
NOs

NOs
NOx
NOs

N0>:
NOs
NOs
NOx

NOs
NOs
NOs

NOs
NOs

NOK
WOs
NOs
NOs
NOs

NOs
NOx
= 1- -, „ ~. ' ' --5*



u a-ton/d
.01
.29
2.97
/
,22
1.12

.47
5.24
,'
.20
.00
.01
.19
.14

.03
.31
.05
-,-
LS9
.00
.09
.70
'-S
1.87
86.90
.15

.02
6.25

i.71
.99
.57
f
3.54
.42
1 • .



cat
'1
2
8

2
8

2
8

9
10
10
16
:32

11
32
:36

37
38
:40
40

,37
40
40

37
37

37
,37
,39
40
140

37
:40




. cuL
1
1
1

i
!

1
1

2
2
2
2
2

2
2
2

3
3
3
3

3
3
3

3
3

3
3
3
3
3

3
3
r. *,1 -
m
, ,,L -, .,
kg7lOOOt 3
oil
, .42
20.23
207.74

43.88
223.05

27.94 .
330.42

12.44
.06
.74
11.99
8.73

2.31
21.46
3.42

989.24
2.62
48.04
\369.06

117.57
5465.19
9.53

3.74
936.25

188.84
108.80
62.58

247.31
29.22

i ft
. - „ *.
V 1_1 n?
/. total
.04
1.70
17.48
: ' fc^.
li.02
5J9
: ft-
f-i.t
2,63
25f2S t.
rr*
^22
.00
.01
.21
.15
I
.19
1.81 .
.29
: F.
31.24
.08
1.52
11,65
r w-
2.04
94.85
.17

.22
54.21
f-
16.38
9,44
. 5;43
1*'
20.81
2.46
                                              C-21

-------
TABLE C-3.  Continued
;



Project



Utah cottonwood
White River Shale Projec
, Shite River 'Shale Projec
Hhite River Shale Projec
yttite River Shale Projec

Catherdral Bluffs
Catherdral Bluffs
.Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs

Clear Creek Shale Oil
TJoar frpofc Rh^lp fit 1

Paraho-Ute >

syntana
syntana h
cyntana '

Union
Union
Union
Union
Union
Union •'••>'
Union



Shite River Shale Projec

Catherdral SlUffs





general process
retort



utility
retort
retort
retort

upgrade
upgrade
upgrade
upgrade
upgrade

retort
si ni hg~aboฅe

upgrading
upgrading

upgrade
upgrade *
upgrade

upgrade
upgrade
upgrade
upgrade
upgrade
upgrade
upgrade
sining-above

upgrade

upgrade

raining-feeloB

/- . 	 . . . -_ :
...-.- — ...


; specific process additional poilt
gas recycle heater NOx

fluid bed coabustor NQx

steas NOs
gas treatsent plant NOx
Tosco ball heater & li NOx
recycle gas heater union NOx

incinerator NOx
H2 Recycle Heater NOx
H2 Charge Heater NOs
oil charge heater NOx
ref orser NOx

TES Concentrator NOx
vehicles road saint NOx

hydrotreater feed furn ' •' NQX
reformer furnace NOX

FSD hydrotreat SOx
FGB 'hydrogen r SOx
hydrogen furnace NOx

• ' fractionater reboiler NQx
dearseniter purge heat SOx
: ' dearseniter " charge hea N8x
unicracker charge hea NOx
steas boiler no air pre NQx
steat boiler " ปith air p NOx
reforaer furnace NOx ,
vehicles/engines NOx

fugitive on site ve NOx

reformer furnace , NOx
•--•.:-:,•
sine shaft vents SOx






4.14

20.12
^
4.77
.07
1.02
2.01
1
.02
.02
.07
.12
2.21

.00
.05

.09
2.00
X
.16
1.90
2.20
, .,-. ''-•
.05
, .04
.20
.26
.56
.67
3.22
.25 .
f ^
.06
J
4.32
-i
.06
'"'-,



cat

40

37

39
40
40

43
43
• 43
.43
43

43
53

43
43

43
43
43
f
43
43
143
43
'43
43

53

43

$




caf

3

3

3
3
3
3

4
4
4
4
4

4
4 .

4
4

4
4
4 .

4
4
4
4
4
4
4
4

4

4

i




kg/10(
	 01
289.

4020.

282.
4.
60.
119.

9.
12.
39.
62.
1159.

3.

13.
300.

17.
210.
242.

3.
2.
14.
18.
39.
47.
225.
17.

11.

255.

29.




)0ซ-
1!
16

34

59
14
17
27

04'
84
00
78
03

29
42

18
03

77
16
30

30
79
14
07
25
05
12
69

,24

;73

,96


- - -;

5rJ

24.

"93;

26.
5.
11.

1,
1.
36.

•

It
17.
i
1,
18.
21.

1,
1.
3,
; 3.
18,
1,



24.

4",


ri
_t ' •
al

33
If--- -'-
53 *_!'"'
f.
65
39
68
25
1;
29
41
23
98
60

00
06
fe ,..,
76
37
&-**
54
23 -:
02
fe;
28 '
23
19
52
30
96
:94
49
^""JL "" "
,26
iฐ" 'l-L'
12 ; "
Y**
,19
*•-.:;; •,
                                           C-22

-------
TABLE C-3.

Project
Continued


Clear Creek Shale
Clear Creek Shale
Paraho-Ute
syntana
Union ;
.Union
Union
Utah-cottonsood
Shite River Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek I3hale
Union
Union
Union
Union
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Paraho-Ute
Paraho-Ute '"
	
Oil
Oil
Projec
Oil-"
Oil
Oil
Oil
Oil
Oil
Oil
r
general proa
aining-beloB
aining-feeloii
sining-beloH
aining-beloH
aining-beloH
fflining-beioB
iining-belos
sining-belos
aining-beloB
tining-above
sin ing-above
Bining-above
pin ing-above
iining-above
sining-above
ffiining
tining-above
utility
retort
retort
retort
utility
retort
retort
upgrade
retort
.,..::;;:,;.

SEE specific process additional
crushing/screening prisary
vent ".
ground sobile equipsent
vehicles
drilling
blasting
rasi shale reioval/scal engines/ve
ground vehicles-cosbustion eq
vehicles
top soil resoval
top soil load.
rm shale haul
spent shsle haul
rm shale topsail ha
spent shale hauling
dusping shale
spent shale grooaing/c
steasi boilers
flares
sponge oil reboiler :
recycle gas heater
steaa superheater -sour
char cosbustion coal grind
char cosbustion
package boiler
poser generation
.:

• - •

pollu IB-ton /d
SOx
SQx
SQx
SQx
SOx
Sflx
SQx
SOx
SQx
SQx
SOx
SQx
SOx
SOx
SOx
SQx
SQx
SQx
SOx
SQx
SOx
SQx
SOx
SQx
SQx
SOx
,07
. 12
*•
,23
-- -?
.20
- *
.00
.03
.19

.08

,38

,01
, •. .00
.01
.01
'- y
.0*0
.02
.04
. ' ,00

.28
.02
.04
,30
- ฅ
.49
.05
8.06
•/
,05
3.97
j
•K



\< '''.= <
cat cat
6
8
1
8

8
(
1
2
8

8

8

9
10
16
32

11
32
33
"36
[
37
38
40
40
'
37
40
40

37
37
'
i
1

1

1

1
1
1

1

1

2
2
i
2

2
2
2
2

3
3
3
3

3
3
3

3
3

. - "-

8 oil * l
4.34
7.48

34.31

21.53 ":

.02
2,38
13.00 ".

16.14

22.51

.136
.06
.68
.51

.16
1.31
2.85
.24

147.44
8.09
20.45
156.95

30.82
2.97
506,80

7.07
595.18

1


: -, •;•_-. - -'~S
total
.78
l!35

5.

3.

i.
5.

2.

14.

•

6.
20.
20.
22.

20,
1.
2.
21.

5.
91.

1.
91.

, ^
25
P"
74
• "far.
IT"
63
27
07 " "
fr' ..>'
02_____.
J*
18
&-..*
15
01
Of
$?'*
97
26
90
80
f
64
13
86
97
K - ~;
55 " ;
53'
33
|; t
08
11
si''
syntana
retort
                                            FGB
steal boil SOx
.91    37  3
                                                                               100.13
                                                                                                                  17.0
                                                        C-23  [

-------
TABLE C-3.  Continued


Project
syntana
syntana ;'
syntana
syntana
syntana
syn ana
Union
Union ;
Union

Utah -cottons sod

Shite River Shale
Hhite River Shale
finite River Shale
Shite River Shale
Shite River Shale


Catherdral Bluffs
Gatherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs

Clear Creek Shale
Clear Creek Shale
Paraho-Ute "''.•
Parahn— lit P •



Union
Union
Union
Union
Union
Union
Union ;
Union
1

;.
general proces
utility
retort
, .. -. retort' . ,
retort
retort
retort

utility
coib. -retort
retort

retort

Projec utility
Projec retort
Projec retort
Projec retort
Projec retort

, •- • . . .-. •
upgrade
upgrade
upgrade
upgrade
upgrade

Oil retort
Oil isining-above
upgrading
upgrading

imnradp

upgrade
•;" upgrade
upgrade
upgrade
upgrade
upgrade
upgrade
mining-above

— : - - -- . . . ^.

E specific process
•' steaos
claus plant
F6B '' : 	
retort indirect heater
' F6B
Tosco ball heater & li

steaa ''
sponge oil stripper
gas recycle heater

fluid bed cosibustor

steaa
gas treatment -claus ta
retort li
Tosco ball heater It li
recycle gas heater
- , - /
- - , :. -. ,.;.,..ป ;,v.,:- :.t * .
H2 Recycle Heater ,
H2 Charge Heater
oil charge heater
incinerator
reformer

TE6 Concentrator
vehicles
hydrotreater feed furn
ref orser furnace

: FSB

fractionater
dearseniter
dearseniter
unicracker
steara boiler
steals boi ler
reforaer furnace
vehicles/enqines
"?" ' "- ' 1 .ป
ri- ' - ~ ~

additional pollu
;sos
80s
claus plan 80s
" . . SOs
superior h SOs
SOx
, - ',,;, — - -^
' 80s
80s
SOs '
, , , , -
SOs

SO)!
SOs
SOs
SQs
union SQx

.-'•„..'-• ii. t. .
80s
SOs
SOs
SOs
SOs

80s
road saint SQs
' ' 80s
80s ..

hvdrotreat SOs

reboiler SOs
purge teat SOs
charge hea SOs •
charge hea SOs
no air pre 80s
Bith air p SOs
80s
80s

, . -.. ,,

s-ton/d

"-- .51
.53
.40
, - i
2.02
.29
3.34

3.91

1.63
.36

.10
.07
:;2.16
,••• .01
.00
.11

.09
?
.01
.01
- .05
. .06
.11
.11
' -- .15
:'_.'*-:.: .02
;


cat
37
39
39
M
40
40

" 37
40
40

'37

37
39
40
40
40

•*-•[ •'._-
43
43
43
. 43
43
|
^53
bi
43
43
'•
43

43
43
4i
43
43
:43
53



i-zsl
3
3
3
J
3
3

3
3
3

3

3
-j
d
3
3

,ป -;
' 4
4
4
4'
4

4
4
4
4

4

4
4
4
4
4
4
4
4


:kg/10^.3
oil
	 	 	
56.27
57.97
44.46

'" 141V16"
20.39
233.74

781.58

96.70
' 21.06

6.18
3.?2
127.86
- ,;. , f . -
5.23
17.60
28.54
126.98 :
173.12
351.47
.11
.29
.40
.03
16.65

9.51

.76
.63
3.36
4.25
7.55
7.55
10.15
1.17

___4____lrv:
V * nf n 1
A tQIfil

9^77
10.06
7.72
r^^B::
23^43
25.33
25.33
i fr ;
97.98
5:- -
60,,93
13.27

3.89
2.47
80.57
-:- '-: [jf'iv - .." -.:•;
,73
2.46
3.99
17,78
24.23
49.20
,of
.05
.07
;00 '
2.55
f*
U65 "

27.23
27.23
27.23
27.23
27,23
27.23
27.23
33.56
; f
                                           1 C-24  \l-

-------
TABLE C-3.   Continued
   Project                 genera! process      specific process      additional pollu   a-ton/d   cat caf    0^{   3 total
      _—_..—	_...—	.—.._,.—— —-~	.ปซ..	——___ __—_—_.	_,_—__—_-.-.—— ——————— —-.———  —-.————   	—- ——— ^—————ซ——  —————

   Shite River Shale Projec upgrade             refoner furnace                 80s         .14   43  4      8.33      5.25
               •••.:••-:.••;•      - .  >.   .-.:  .   :, ,      r,,   ,  ,  -   .  ,   .,.    .|4.    '         8.33      5.25
                                                           "c-25  f.

-------
TABLE C-4.  PARTICIPATE EMISSIONS

project
Cathedral Bluffs

Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
;Clear Creek Shale
Clear Creek Shale
Clear Creek Shale

cottonseed
cottonseed
cottormood
cottonseed

Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute '
Paraho-Ute
Paraho-Ute

syntana
syntana
syntana t

Union
Union
Union
Union
Union
Union
Union
ffiute River Shale
White River Shale
Shite River Shale
Shite River Shale

^ Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs .
i
- general process specific process
stininq-belovj sine shaft vents

Oil aining-beloB drilling
Oil fflining-beloB drilling
Oil sin ing -be! OB blasting
Oil iBining-beloM blasting
Oil aining-below pritary crushing
Oil fflinino-below vehicles-vent

itining-beloป ground sining
ffiining-beloB ground transfer
sining-belos ground ra$ shale
sining-belos ground vehicles-coabustio
— • • • . 	 •- . •-
iining-faeioB ground ffiining
(aininq-beles ground blasting
sining-beles ground conveying
' .mining-be! OB ground crushing/screening
aininq-beloB ground crushing/screening
irdriinq-beloB ground labile equipment

sining-teloH sining
oining-beioB . blasting
fiining-beioH vehicles

sininq-beloH drilling
ffiining-beloB blasting
aininq-belos reaoval
fdning-beloB . eonveving
sininq-beleB . raw shale crushing
fflining-beloB crushing
siining-beloB raw shale resovai/
Project fiining-beloH sining
Project aining-belov) ' crushing
Project tinsnq-beioe crushing
Project isinino-belov) vehicles

sining-abcve reclais drashoie
sining-above ras shale
raininq-above rae shale
mining-above raw shale

additional desc
d

inter, saste
0
inter, easte
0
0
0

o ;
transfer points
priaary crushin
0
- --•-•-,-•-
0 '
0
0
priiary
secondary
0

0
0
0

0
0
0
0
priiaary
priisary
engines/vehicle
0 .
priaary
secondary
0

0
crushing buildi
screening plant
transfer house

catl
8

1
1
2
2
6
8

i
5
6
8
-
1
2
4
6
7
8

1 ,
2
8 -

i ;
2
3
4
6
6
8
1
6
•7 •
8

9
13
13
15

cat!
1

1
i
1
1
1 '

1
1
1
i

1"
1
1
1
1
1

1 '
i
1

1
1
1
1
i
1
1
1
1
1
1

2
2
2
2

s pel ซ-ton/d
OS ' • 1 /

PH .00
Pซ • .01
Pfi .10
PH .26
Pfi .00
PH ' .40

pa .11
ps .05
ps .03
ps ,06
j-
SSi : .04
pa .17
ps .03
ps .08
pa .08
pa : .02

ps .13
pง .1.8
ps . 14
7 r
pss .00
PH .01
pa ; .03
Pfi .17
PH . .07
PH : .63
pa ,10
pa ' .26
pia .14
pi .04
pn .27
'. 1
Pi8 ' ,01
pa .00
ps .00
'ps .02
kg/1000n3
oil
88,46
. 88.46
.26
• 74
6.22 •
16.27
.21
25.34

21.76
9.61
5.26
11.42

5.71
25,48
5.10
12.16
12.16
3.06

13.91
19.32
15,31

"" .'.34'
,50
2.31
11.59
4.63
43.78
7.15
15.31
8,49
2.63
15.85

2.71
1.62
1.43
9.04
_ j •- ซ•
I total
26.54
26.54
.13
,38
3.19
8,35
.11
13.01 -,
t-
12,50
5.52
3.02
6.56
jty.r-J
1.70 •~:
7.30
1.50 .
3.60
3.60
1.00
fe ---.;•--
5.87
8.16
6.46
'• fl::-.-
.19 '
.28
.28
.40
2.56
24.18 ..

7.17
3.98
1.23
7.42
; ฃ.
.81
.49
,43
2.71
                  C-26

-------
TABLE C-4.  Continued


project
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs

Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creel; Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
.Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear, Creek Shale Oil

cottonseed
cottonseed
cottonseed.
cottonseed . '
cottcnsood
cottonseed
cottonseed
cottonseed
cottonseed
cottonseed
cottonseed
cottonseed
cottonseed .,'
cottonsood
cottonseed :
cottonseed . ....•••
cottonseed •' ; -•

- ~ ' "L. " , 	
qeneral process specific process
iining-above ras shale
Eiining-abo ras shale storage
ffiining-abo raw shale storage
fflining-above ras shale
ffiining-abo spent shale
fiining-ahove spent shale
sining-above " spent shale
aining-abo spent shale
ffiining-afaove spent shale
iining-abo . spent shale
iining-abo spent shale storag

ffiining-above surface soils
dning-above surface soils
sining-abeve surface soils ^
ffiining-above surface soils
tsining-above surface soils
Bining-above ras shale
iining-above ras shale
.iining-above ras shale
sining-above ras shale
ffiining-above ras shale
aining-above int waste
fflining-above int saste
sining-above raw shale
iining-above r as shale
iining-above ras shale
fflining-above spent shale
sining-ahove spent shale
• • -
aining-above ground ras shale
siining-abcve ground ras shale
iining-above ground ras shale
iining-above ground ras shale
sining-above ground ras shale
sining-above ground raw shale
aining-above ground ras shale
fflining-above ground raa shale
aining-above ground ras shale
ffiining-above ground ras shale
mining-above ground ras shale
sining-above ground fines
ffiinirig-above ground fines
ffiining-above ground fines
sining-above ground fines
ffiining-above spent shale
ffiining-above spent shale
ฐ

additional desc cat;
conveyor-stacks 15
5 day 18
5 year 21
conveyor-retort 24
stacker conveyo 30
conveyor 30
transfer house 31
conveyer discha 31
transfer 31
distribution 33
0 34

reaoval-drill 9
reioval 9
resioval-blast 9
haul " 11
Bind 12
crushing 13
crushing-2nd 13
crushing-3rd 14
conveying 15
conveying 15
"duip : 16
haul / 16
duffip 17
sind err esi on 19
sind " 22 •
conveying 30
haul 32

crusher-lusp br 13
screening 13
surge bin 15
storage-load in 18
storage-reclaiB 18
storage (live) si 18
storagefdeadJsi 21
retort feed" bin 23
retort feed sil 23
retort feed con 24
retort discharg 25
FBC discharge b 26
cenveyor-transf 26
FBC feed bin 2?
storage silo 27
conveyor 30
dispesalXload i 33 ,
..

I ca
2
2
2
2
2
2
2
2
2
'.2
2

2
2
2
i
2
2
2
2
2
2
2
2
2
2
2
2
2

2
2
2
2
"2
2
*2
2
2
2
2
2
2
2
2
2 •
2


te pol
pi
psi
pa
pffi
pffi
~pa
pa
'-pi
po
pi
pa_
•'- —
PH
PH
PH
PH
PH
PH
PH
PH
Pfi
Pfi
PH
Pfi
Pfi
. PH
PH
Pfi
PH

pi
pa
pa
pa
pa
pa
. PBl
ps
:pa
PS
pa
pi
pffi
pa
pi
pi
pa


ffi-ton/d
.05
.01
.01.
: .00
, .05
.04
i .02 '
.04
.04
, .07
	 M
• 	 ' 	
.01
. .13
.25
: .36
.00
1 .00
.01
.01
.02
.81.
.01
; .15 .
.12 "
.00
• .04
.18
.02
,* '<
.02
.03
.02
.00
.00
: .03
' .01
:.00'
. .00
. ; .00
; .00
! .01
.01
.01
.01


, -, '.... .ฑ_
7g7lOOO.r
oil
~2^2i^
3.80
" 5.42
2.38
25.21
"'20.93
9.04
20.93
20.93 .
38.52
2.85

.74
.8.28
15.58
22.83
''. .21 .
, .29
.68
.91
1.13
51.08 •
- .34
. 9.36
7.53
.02
2.57 .".
11.59 "
1.37

4.81
5.60
3.23
.30
.60
6.89
2.77
.79
.79
" .79
..7?
1.09
1.09
'. 1.09
' 1.09,,'


1 M

I total
7.56
1.14
1.63
.71
7.56
6.28
2.71
6.28
6.28 '
11.56
.86
, J:;-
.38 '
4.25
8.00
11.72 '
.11
.15
.35 • "•"
.47
.58
26.23
.18 '
.4.81
3.87
4i
1.32
; 5.95
.70
*'-'
2.76
3.22
1.85
.17
.34
3.96
^1.59
'."46"
.46
.46
.46
.63
.63
.63
.63 '


                                       C-27

-------
TABLE C-4.  Continued
project
cottonseed
cottonseed ,
cottonsood
cottonseed

Paraho-Ute
Parahe-Ute •
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute , ;
Paraho-Ute , .
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute ..
Paraho-Ute ;
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute
Paraho-Ute

syntana
syntana
syntana
syntana
syntana
syntana
"• . •
syntana '
syntana
syntana .,
syntana '
syntana
syntana

Union
Union
Union
Union
Union i
Union
Union
Union
	 	 __ J . " '- i . ," """ !- " • " "'V'K
genef al" process " specific process "
sining-above spent shale-fines
aining-above " spent shale-fines
aining-above spent shale
aining-above spent shale

aining-above ground surface soils ,
aining-above ground rat? shale.
aining-above ground rats shale
aining-above ground ras shale
"sining-above ground raซ shale
aining-above ground ras shale
- aining-abcve ground raw shaie
fflining-above ground ras shale
sining-above ground ras shale.
aining-abeve ground fines ...
sining-above ground fines _
aining-above ground ran shale .
ai Ring-above ground fines
aining-above ground spent shale
aining-above ground spent shale
fflining-above ground spent shale
aining-above ground spent shale
iining-above ground spent shale
fflining-afaove ground spent shale

aining-above Lraซ shale
sining-above ras shale
aining^abeve r as shale
Bining-above ras shale
aining-above ras shale
aining-above ras shale
ฃ fflining-above fines transfer
fflining-above fines
aining-above fines
aining-above spent shale
sining-above spent shale
iining-above spent shale

sining-above raซ shale
aining-afaove ras shale
aining-above ras shale
aining-above ras shaie
raining-above . ras shale storage
sitting-above storage silos
r . iining-above . r as shale storage
fflining-above . ras shale storage
"additional desc cat!
loading/duisping 33
storage bin 34
disposal -wind 35
disposai-grooai 36

Bind : 12
tertiary crush/ 14
trans, ff. live 15
convey/transfer 15
saaple & seigh 15
screening/trans 15
live storage 18
eaergency stora 21
retort feed 24
conveyor-transf 26
;to bin 26
fines transfer/ 26
storage 26
conveying 30
to bin 30
conveying-A 30
retort everfl os 31
retort discharg 31
storage 34

prisary crushin 13
secondary crush 13
storage . 18
storage-Kind 22
r etofC f ee'd-tos 24
conveyor feed 24
0 * 26
storage-Hind 27
aaintenance'" 29
storage-load-tr 34
storage-sind 35
storage-sainten 36

topsoil hauling 11
crushing/second 13
crushing/tertia 14
conveying/trans 15
load out 18
0 '•""•" $8
load in 18
Bind erosion 19
cat
2
2
2
"2

2
2
2
2
2
2
2
2
2
2
2"
2
2
2
2
2
2
2
2

2
2
2
2
2
2
2
2'
2
2
2
2

2
2
2
2
2
2
2
2
e pol
pa
PB
pa
pa

pi
pa
pa
pa
pa
pE
pa
pa
ps
pa
pa
pa
pa
pa
pa
pa
pas
' ps
pn

pa*
.' Pซ
pt
pa •
pa
pa
pa
pa
pa
pa
pa
pa
*
pa
Pfi
PH
PH
PH
PH
Pfi
PH
s-ton/d

.01
.03
' " ,33
1
.07
' .24
' -01
.05
' ': .10
'.16
.00
.11
' .04
.01
: .01
.01
' .11
.01
.02
; .03
; .04
.23
' .22

.01
,29
,03
' .04
' .00
.00
: .01
; .02
; .05
.02
,16
_ui24_.

.01
.12
.41
! .0$
: .00
i.Ol
• .01
;.oo
./.-. 3- ' 1, ••/
oil '
• ,.-
1.12
,5.0$
66.55

$0.19
36.35
1.77
7.34
$4.27
24,6"3
.14
$6.10
5.38
.82
: 1.14
1.7?
16.50
1.30
2.28.
4.24
5.3B
34,24
33.50

^ 1.42 '
32.14
3.47
4,77
.18
.35
.85
2,64
5.87
"1.89
• 17.62
26.33

.49
'8,61
28.7$
.5?
.06
.50
.77
• 1(?
1 total

.64
2.87
38.23
! #>;
2.40
10.50
.50
2.20
4,20
7.10
.04
4.70
1.6^0
.40
.40
.50
" 3.80
.37
.70-
. i ,
$.30
1.60
10.00
7.90

"" M
$3.57
1.47
2.01
.07
.15
.36
1.12
2.48
.80
7,44
11.12
^ 	 jr
.27
4.76
15.85
.32 .
.04
.27
,43
.10
                                          C-28

-------
TABLE C-4.


project
Union
Union
Union
Union
Union
Union
Union
Union

Shite River
Shite River
Shite River
White River
White River
White River
Shite River
Shite River
White River
tthite River
Shite River
White River
White River











-i .

Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale
Shale

Continued






•^.





Project
Project
Project
Project
Project
Project
Project
Project
Project
Project
Project
Project
Project

Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs

Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek
Clear Creek


cottonsood

Paraho-Ute
Paraho-Ute

syntana
syntana
syntana
•• . •
Shale
Shale
Shale
Shale
Shsie
Shale


,'






',

Oil
Oil
Oil
Oil
Oil
Oil











t -' ? V V-
gehefal process
fflining-above
iaining-abeve
sining-above
iining-above
raining-above
Bining-above
aininu-above
aining-above

aining-above
mi nine-above
sining-above
iainihg-above
fining-above
mining-above
sining-above
aininq-above
aining-above
iining-above
sining-above
ssining-above
sining-above

coifa-utility
retort ,
cofflb, -retort
ccab. -retort

coab-retort
coab-retort
coffib-utiiity
coffib-retort
ccab-retort
cosib-retort


coffs-retort

upgrade
cosb-retort

utility
retort
retort ... . '

'specific process
retort pad
spent shale convey
spent shale
spent shale
spent shale
spent shale dispos
spent shale-storag
spent shale
..'•". . ":' - _
conveyor surge bin
retort feed silos
raซ shale stockpil
conveyor feed-unio
conveyor f eed-supe
fines reclaifi conv
fines-storage
fines
spent shale discha
spent shale convey
spent shale dispos
spent shale dispos
spent shale dispos

"steaa boilers
incinerator
sponge oil reboile
recycle gas heater

retort gas
' TE6 Concentrator
steat superheat
char coobustion
char coibustion
char coffibustion


shale fluid bed co

package boiler
poser generation

. steal
F6D
retort indirect he

^;\>vr-->>.
additional desc
snnd errosion
0
stacking
hauling
truck dustping
0
wind errosion
grooMng/coapac
- s . " ^ ; -^ ' .- ^
0
three
load/groosArind
0
transfer.
0
reclaiiMnd/tr
storage/conveyo
un/tos/sup
0
load in
Hind erosion
groaning
~ '*-' . '-ฃ . - , -: L --
6
0
0
0

0 '
0
0
feed binsCsourc
coal grinding
0
•

0

0 , .
0

o ;
steal boiler
0
?!.;.;-
>;-'-': V;v;-
?'*• ••-,: ,-'• f'. *
cat! cate pol
19
30
41
42
33
34
4b
36

15
18
18
24
24
26
27
27
30
30
34.
35
36

37
40
40
40

37
37
37
40
40
40


40

37
37

37
37
W
2 pis
2 pis
2 pia
2 pa
2 pst
2 PH
2 pffl
2 . pi

2 ps
2 ps
2 pB
2 pa
2 ps
2 pi
2 pffl
2 pฎ
2 ps
2 pง
2 ,.. Pฎ
2 pi
2 pa

3 pa
3 pa
3 ps
3 ps

3 pit
3 PH
3 Pซ
3 PH
3 PH
3 PK


3 pป

3 PH
3 PH

3 pe
3 pi
3 pB
s-ton/d
.01
.08
.02
.05
.03

i.Ol
f .03
• ;•?'
F - ,
.01
.05
.12
; .01
' .05
' .00
•;• .07
.; .14
.01
.05
.02
: .05
,36
-; -9-4
'.03
• .00
•:- .00
: .03
; .06

.00
.14

: .09
10.24
-10.47

.04
I .04
.00.
', .35
: .35
i
1 -
.05
1
•^ ' • a ' , -'i-\-:-
,~ --,- it -: h- •
;* -- ;?* "-. ".
kg7ToOOซ3
oil
.36
5,55
1.54
3.16
1.98

.57
1.9,5
55.02
.86
2.6'?
6.93
.51
2.69
.17
.: 4.41
8.54
.37
3.22
1.07
2.79
21.60
55.85
14.27
.38
1.90
'14.74
31.29

.23
8.96

5.71
643.77
658.6?

8.20
8.20
.33
51.70
52.03

' 5.89

r^
f - . ' J"-
i
•l total

3.
•
1.
1.

-
1.
30.
.
1.
3.
•
1.
ซ
2.
4.
•
1.
•
1.
10.
26,
4.
•
.
4.
9.

.
1.

.
97.
too.

. 4.
' 4.
,
15.
15.

2.
T— fr
20
07
85
75
09

32
07
38,
40
26
25
24
26
08
06
00
17
51
50
31
12
16
28'
11
57
42
39
- --•• '-- -
03
36

87
74
00
L
71
71
09
00
09 .-.

49

C-29 -^

-------
TABLE C-4.  Continued



project
syntana i
syntana
syntana . ; ' ~

, - . -, -
Union
Union i
Union ' :*
:- •••':
yhite River Shale
Mhite River Shale
•'Hhite River Shale
White River iihale
Shite River Shale
Shite River Shale

Cathedral Bluffs
Cathedral Bluffs
, Cathedral Bluffs
Cathedral Bluffs
Cathedral Bluffs

Clear Creek-. Shale
Clear Creek Shale

cottonisood
.cottomiood

Paraho-llte
Paraho-Ute

. syntana.
syntana :
syntana

Union :,
Union
Union
Union

yhite River Shale



""'Tv':. "
general process
retort
retort
retort


utility
retort
retort

Project utility.
Project retort
Project retort
Project retort
Project retort
Project retort

ccsb-upgrade
upgrade
upgrade
upgrade
fiining-abo

Oil tining-afaove
Oil aining-above

cosb-upgrade
coab-upgrade

upgrading
upgrading

upgrade
- upgrade
iining-above

sining-above
siining-above
aining-above
fining-above

Project upgrade


	 	

specific process
FSD
Tosco ball heater
Tosco aqisturizer

.' " ' -'='= i- -: ':?-
steaa " ' 	 :
sponge oil strippe
gas recycle heater

steas
Tosco hall heater
recycle gas heater
eiutriator
Tosco elutriators
processed shale so
• --• '" : •••"• -'^ "" • 	
reforaer furnace
H2 Recycle heater
H2 charge heater
8il charge heater
fugative dust

vehicles
coal

fugitive
fugitive
^ .. ... 5- f
hydrotreater feed
rsforter furnace
...
FSD
F6D -_
fugative .

vehicles/engines
vehicles/engines
vehicles/engines
fugative dust

reformer furnace
" •
fp :"
. 	 . — /. ..._..-_.
7 v ",.
additional desc
superior heater
0
o'

*"<"' " '•""• " y"ป. ">
o
0
0 -

0
0
union
0
and soi stumer
0 •
,' . ,.... . •
0
0
0
0
haul roads

0
0

paved roads
unpaved roads
i ,, : •.- ; ;;--. . ;-
0
0

hydrotreater
hydrogen refers
truck traffic

light duty
road aaint/acce
diesel
0

o .'';'.




"cat"!
40
40
42


37
39
40

37
40
40
41
41
42
, „„.,
43
43
43
43
54

53
54

53
53

"43
43

43
43
53

"53
53
53
54

43


--_,-- .- ', - ^
* i ' --_ ,;ซ '" '
'cite pol ซ•
3 pa
3 pi
3 pป

* .--'.' .-. ' -
3 ps
3 ps
3 PH

3 pa
3 pffi
3 pa
3 Pfi
3 . ps
3 pffl
*-*"• •' ' '•'" *
4 pm
4 pa
4 ps
4 p0
4 pa

4 Pfi"
4 Pfi

4 ps
4 pB

4 pa
4 PH

4 psi
4 ps
4 " ps

4 ps.
4 pa
4 ps
•4 PH

4 ps

,
1
; v| L". .;, r-
-ton/d "
.03
i l34
>06
;.48

>09
,01
• ,10
: j.20
.72
."44
.19
.05
.13

•1.53
; .03
'.00
.00
; .01
:.00
.04
.17
.01
;,ia
'. ,01
.06
,-j.07,
i
.01
i .13
...14
^.00
.06
"' .28
:,;.34"
: .04 "
!,05
.15
; .36
; ,60
-'.41
2^,78*


kg/ IOC
oi!
3,
37.
6,
53.

6.
*
7.
14.
42.
26.
11.
3.
7.

90.
16.
r
1.
2.
1.
23.
10.
•
11.
2.
11.
13.
19.
20.
c
6.
30,
37.
2.
3.
10.
24.
41.
24.
24.
2345.


-j
!
46
73 "
13
23

09
61
3!
00
5!s
06
2i5
o(;
79

77
98
57
71-
85
45.'
54
50
68
19
18
24
42
82
57
38
53
61
44
58
64
54
62
95
74
55
55'
58*


! 	
;2 tot
1.
15.
2.
"22.

3.
.
4.
7.
19.
12.
5.
1.
3.

' 42.
5.
• •
•
•
•
7.
5.
•
5.
1.
6.
7.
5.
6.
2.
12.
15,
1.
1.
5.
13.
23.
11.
11.
800.

i 'i-
-T— -„ — ^.-FTJ-"
ai
47
93
f<9 	 '
47
T .- ' '--...
36
34
03
73
93 ;
21
29
45
65

53
09
17
51
86 ':
43
06
39
35
74
25
46
71
30
70
00
22
79
85
86 ',
46 ' .
96
86
78
05
50 .
50
oo*s
                                           C-30

-------
 TABLE C-4.    Continued'

Pr~oject                 'general  process      "specific process
                       additional  poilu   a-ton/d  ' cat cat k8/1^0i  *1total
Union                    sining-below
Clear Creek 'Shale Oil    sining-above
Clear Creek I3hale Oil    aining-beloB
Paraho-Ote               tining-beloB ground
syntana  '  , •-' '  -. "      siining-belQB
syntana     '   -.         aining'-beloป
Union                    sining-belos
Utah-cottensood          aining-belos ground
tJhite.River Shale Projec  fiining-belos
Clear Creek Shale Oil    einino-beles
Catherdral  Bluffs        aining-beloB
Clear Creek Shale Oil    eining-belos
Paraho-tite  ,  , ;        iBining-below ground
syntana                  Bining-belos
drilling
blasting
blasting
blasting
blasting
blasting
blasting
blasting
blasting
crushing/screening
sine shaft vents
vent
mobile equipment
vehicles
           CO
           CO
           CO
           CO
           CO
           CO
  •         co
           CO
prisary    CO
           CO
           CO
        "  CO
       :''   CO
 ,.05
  .52
  .41
  ,41,
1.14
  .40
  .87
  .72
  .30
1.23   8
'  .67   8
  .57   8
   .09
  2.97
.22,66
 77,3?
 45.76
 45.76
 79.71
 80.33
 51.58
 45.03
158.37
 77.62
 99.67
 62.58
  .02
  .03
  .20
29,81
24.88
24.88
16.09
31.51
24.37
  .40
63.86'
  :;69
38.39
34.03
                                                               c-31

-------
	 	 "" ""• r 'TABLE C-5. GASEOUS '.

Proiect
Union
Clear Creek
Clear Creek
Paraho-Ute
syntana



Shale
Shale

union
Utah-cottonaood
Hhite River Shale
Clear Creek 'Shale
Catherdral Bluffs
' Clear Creek Shale
Paraho-Ute Y .
syntana
Union '
Utah-cottoRH0od
White River Shale
Clear Creek Shale
Clear Creek Shale
Union - r
Clear Creek Shale
Clear Creek Shale
Union i
Union
Catherdral Bluffs
Clear Creek Shale
Paraho-Ute
Paraho-Ute
syntana '•'
Union ;


Oil"
Oil

Prpjec
Oil
Oil
Projec
Oil ''
Oil
Oil
Oil
Oil

general process
aining-below
aining-above
aining-beloB
aining-beloH ground
mining-belos

iTnrng-Deioe
flining-belos ground
osining-beloB
fsining-belos
sining-beloH
sining-beloH
ffiining-belog ground
liiining-beloH
siining-beloB
mining-belcH ground
sining-belos
fflining-above
sining-above
aining-above
aining-above
aining-above
nining-above
fflining-above
utility
utility
upgrade
retort
retort
utility
specific process
drilling
blasting
blasting
blasting
blasting

Blasting
blasting
blasting
crushing/screening
sine shaft vents
vent
aobile equipaent
vehicles
rae shale resoval/sc
vehicles-coabustion
vehicles
top soil
top soil
rass shale
ras shale haul
spent shale haul
spent shale
spent shale
steas boilers
steaa superheat
package boiler
poHer generation
FSD
steaa
EMISSIONS
additional pollu is-tons/d
CO
	 •' ; 	 " to"
CO
CO
CO

- UU
CO
CO
primary CO
CO
CO
CO
CO
engines/ve CO
CO
CO
removal CO
load CO
topsoil ha CO
CO
CO
hauling CO
grocffiing/c CO
CO
C8
CO
CO
steas boil CO
CO
-:- .00
	 	 705
.36
.52
.41

1,14-
.40
.87
^~
'"'.72
,
.30
• 1.23
.67
.57
" .55
	 .24
1.10

.03

.00

" "~~- .01

.03

.06
.05
• T
.01
>
.05
.58
.01.
.39
,15
2.66
cat
1
2
2
2
'
2
2
2

v

. 8
.8
8
8
a
8'
8

9

10
'
11
;
16

32
32

36
:
: 37
37
37
37
37
37
-

. kg/lOOOi-5
cat oil
1
1 "
1
1
1

i
1
1

i

i
1
1
1
1
1
r

2

2

2

2

2
2

2

3
3
3
3
3
3
,09
.09
' :2.97
22.66
77.39
45.76

79. 71
80.33
51.58

45.03:

158.37
77.62
99.67
62,58
38.75
46.97
65.17

1.83

.17

•.'43

2.11

3.94
3.77

.50

23.78
36.41
.83
58,57
16.14
185.67
': 	
i "-ปฃ-
-r— 	 -f .--
^ total
29.
24.

16.
31.
24.



63.
38.
34.
7.
18.
30,



.



02
02
03
20
81
88
i ' &*•
:.„ ,€;
09
51
37
; ff_ '•
w 	
! fjj~
86
69
39
03
82
'42." ' '
89
-•:" •.'.,
02
fff-
00
ฃ. "j"

• fe: ;
.02


.03
.76

fiY
.10

' m - -
: 9.59-
.32
.32
22.56
8.78
37.49
j C-32

-------
TABLE C-5.   Continued

1
Project



Utah-cottonssod
Unite River Shale Projec

Catherdral
Catherdral
Catherdral
Clear Creek
Clear Creek
syntana
syntana '
Union
Union

Bluffs
Bluffs
Bluffs
Shale Oil
Shale Oil




yhite River Shale Projec
Hhite River
Catherdral
Catherdral
Catherdral
Catherdral
Catherdral
Clear Creek
ParahB-Ute
Paraho-Ute
syntana
syntana
syntana
Union
Union
Union
Union
Union,
Union
Union
White River
Clear Creek
Union
Shale Projec
Bluffs
Bluffs
Bluffs
Bluffs
Bluffs
Shale Oil




!







Shale Projec
Shale Oil

Utah-cottonssod
Utah-cottormnod

Union


i
•'-
general process
retort
utility

retort
retort
retort
retort
retort
retort .
retort
coab. -retort
retort
retort
retort
upgrade
upgrade
upgrade
upgrade
upgrade
retort
upgrading
upgrading
upgrade
upgrade
upgrade
upgrade
upgrade
upgrade
upgrade
upgrade
upgrade
upgrade
upgrade
aining-above
aining-above
upgrade
upgrade

jBining-beloH
specific process
'fluid bed coab'ustor
steaa

flares
sponge oil reboiler
recycle gas heater
char coabustion
char combustion
F6D . . .. . .
Tosco ball heater It
sponge oil stripper
gas recycle heater
Tosco bail heater &
recycle gas heater
incinerator
H2 Recycle Heater
H2 Charge Heater
oil charge heater
reformer
TES Concentrator
hydrotreater feed fu
reformer furnace
F6D
F6B
hydrogen
fractionater
dearseniter
dearseniter
unicracker
steajt boi 1 er
steas boiler
reformer furnace
reforaer furnace
vehicles
vehicles/engines
fugitive
fugitive

drilling ,
additional
• - --,- .-. -' ,:..,






coal grind
superior h




union b








hydrotreat
hydrogen r
furnace "
reboiler
purge heat
charge hea
charge hea
no air pre
with air p


road saint

on site' ve
on site ve


pollu
CO
CO

CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO '
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO

HC
i-tons/l
" "'-'-.IB
.44
4.75
.00
.-;
.01
.05
176.04
.05
.09
.05
.03
.33
. .15
.32

.00
,00
.01
.01
.05
.00
.01
.15
.01
' .16
.23
.01
.00
.02
.03
.51
.51
.26
.69
•-ซ:
.01
.97
,03
.13
1.14
.00
'• ,,-K- -"
cat
"3f
3?

38

40
40,
40
40
40
40
40
40
40
40

''43
43
43
, 43-
43-'
43
43
43
43
43
43
43
43
43
43
43
43
43
43
1
53
53
53
53
i
I-
— — — —

<_
rkg/1000t3
cat oil
3"
3

3

3
3
3
3
3
3
3
3
3
3

4
4
4
4
4
4
4
t
4
4
4
4
4
4
4
4
,4
4
4

4
4
4
4

1

	 '91,57
26.33
443.2?
.13

3.33
25.2!
11071.92
2.9?
9.51
5.17
1 .. 2.44
23.13
8,97
18.80

.67
,90
2.815
4.66
28.06
.IS
.913
22.18
1.53
17.87
25.33
.3i!
.32
-1.65
2.09
35.38
35.38
18.0$
40,62

.70-
67.57
6.815
25.21
100.32
'" "' ,n



F"i
•
I total
3?:
4V'
12.50
129.
,

1.
10.
98.
.
5.
. 2.
.
4.
4.
8.


.
1.
1.
11-
,
.
8.
.
9.
13.
.
.
.
.
7.
7.
3.
19,

".
13.
2,
9.
26.
.
1?
04
o?
i- -"
34
16
26
03
17
81
49
67
25
90
~T "" fe
,i
27
36
15
88
31
00
38
54
83
72
78
ds
06
33
42"
1,4
14
64 '" '"
23
f
01
64
69
89
22
01
i . ft';
                                                                                                            V&
                                                                                                            f-.
Union
aining-beloB
blasting
                                                                 HC
                                                            2   1
                                                  C-33

-------
TABLE C-5.  Continued
i
Project
Clear Creek Shale Oil

Catherdral Bluffs
Clear Creek Shale Oil
Paraho-Ute
syntana
Union
Utah-cottonBood .
Hhite River Shale' Projec

Clear Creek Shale Oil

; Union

Clear Creek Shale Oil

Clear Creek Shale Oil
Union

Union

Catherdral Bluffs
Paraho-Ute
Paraho-Ute
syntana
Union
Utah-cottonsood

.Catherdral Bluffs
Catherdral Bluffs
Catherdral Bluffs
syntana :
syntana
, Union
Union
Hhite River Shale Projec
Mhite River Shale Projec


general process
fiining-belos

isining-beloa
siining-belcH
iiining-below ground
sining-beicB
fiirnng-beloB
isining-beloH ground
ffiining-beloป

sining-above

Bining-above

sining-above

sining-lbove
raining-above

sining-above

utility
upgrade
retort
retort
utility
retort

retort
retort
retort
retort
retort
cosib. -retort
retort .
retort
retort


specific process
crushi no/screens nq •

sine shaft vents
vent
raobile equipment
vehicles
rm shale reaoval/sc
vehicles-coibustion
vehicles
- -
top soil

raw shale

ras shale haul
- - - - • -
spent shale haul
spent shale

spent shale ,•

steals boilers
package boiler
poser generation
FGB
steaa
fluid bed coiabustor
steas

flares
sponge oil reboiler
recycle gas heater •
F8B
Tosco ball heater &
sponge oil stripper
gas' recycle heater,
Tosco ball heater &
recycle gas heater

.**•- • ,-, '
additional poll
Driaar'y". HC

HC
HC
;HC
HC
engines/ve HC
HC
HC
1 - .U, , ft
reiovai HC

topsail ha HC

HC
	 ' •• •-• ;
: HC
hauling HC

groosing/c HC

HC
HC
HC
steas boil HC
HC
HC
HC

"' V'""HC ':
HC
HC
superior"!] HC
HC
HC
HC
.' ' HC
union HC
*

u 6-tons/d
.11

.08
.17
: .21
.18
.18
.07

.01

.00

.01

.01
' .02

.00

.08
.00
.07
.03
.05
.02
.32
~j
.00
.01
.02
.51
.00
.06
.83
.06

	 ! '
ca'
6

8
8
8
8
8
8
"8

9

11

16

32
32
'.
36
i
37
37
37
3?
37
37
37
	 ; —
' 38
40
40
40
40
40
4p
40
40
i
• ,. fc
t cat
1

1
1
i ":
i
i
i
i

2

2

2

2
2

2

3
3
3
3
3
3
3

3
3
3
3
3
3
3
3
3

g/1000ป 3
oil
7.19

39.47
10.96
30.98
19.42
12.87
14.51
20.31

.5?"

.14

.6S

.51
'1.24 "..

.16

42.80
.16
10.26
2.83
3.80
3.08
19.13

.57
4.52
1.79
55.87
.30
4.26
49.0(3
3.81


!! total
3.08 '
: jK---.-
42.09
4.7.0
" 63,26
' 13.10
5.14
13.36 ::
9.38

.24 "

.06 '

,29

.22
" .49 ::

.06 l|
•" c;J
45.64
.33
20.95
1.91
1.52.
2.84
8.83
; f
.61
4.82
1..21
37.67
.12
1.70
22,62 .
1.76"
f ' '—
                                     • C-34

-------




Project
Catherdrai Bluffs
Catherdrai Bluffs
, Catherdrai Bluffs
Catherdrai Bluffs
Cstherdral Bluffs
Catherdrai Bluffs
Psraho-Ute
Paraho-Ute
.syntana
syntana
syntana
Union
Union
Union
Union
Union
Union
Union ^~ -..''.',
Bhite River Shale

Clear Creek 'Shale
Hhite River Shale

Clear Creek Shale
Paraho-Ute :
Paraho-Ute | 	
syntana ...
Union
Union
Union
Utah-cottonmjod
Shite River Shale
8hite River Shale

Paraho-Ute

Paraho-lfte .
Utah-cottonatiod

Paraho-Ute

Clear Creek Bhale
Union




,r. '-' ' "-
general process
upgrade
upgrade
upgrade
upgrade
upgrade
upgrade
• upgrading
upgrading
upgrade
'upgrade 	
upgrade
upgrade
upgrade
upgrade
upgrade
upgrade
upgrade
upgrade
Projec upgrade

Oil, upgrade
Projec upgrade

Oil upgrade
upgrading
upgrading
upgrade '
upgrade
upgrade
upgrade
upgrade
Projec upgrade
Projec upgrade

upgrading

upgrading
upgrade

upgrading
- - -
Oil sining-above
'sining-above




':...
specific process
H2 Recycle Heater
incinerator
H2 Charge Heater
oil charge heater
reforser
storage
hydrotreater feed fu
reformer furnace
FGD '•_'
	 FSB • "- ' -
hydrogen
fractionater "_
dearseniter
dearseniter
unicracker : 	 "
steaffl boiler
steal boiler
reforser furnace
reforaer furnace
*
fugative
valves, flangeSjpuraps

storage
storage
storage (day)
oil storage tanks
storage tanks
oil storage
Biscellaneous
product storage
crude storage
crude shale oil stor

storaoe

storage
fuel oil storage tan

storage

vehicles
vehicles/engines



,

additional poll
HC
HC
HC
HC
HC
HC
HC
HC
hydrotreat HC
hydrogen r HC
furnace HC
reboiler HC
purge heat HC
charge hea HC
charge hea HC
no air pre HC
Bith air p HC
HC "
HC

HC
HC

HC
crude shaf HC
crude shal HC
HC"
HC
'*. HC
table 4-7? HC
HC
HC '
HC

hydrotreat HC

... . ,_, vฑ, ,
fuel oil HC
HC

diesel & g HC

road saint HC
HC





u fi-tons/d
.00
.00
.00
.00
.01
.00
.03
• ', - .00
:' .03
.04
.00
.00
.00
.01
.01
.01
,05
- .14;

3.26
1.02
. ' ?
,13.
.01
.01
.03
1.10
.02
-.84
.11
.46
.48

! .01
- J
.00

.00
. -_
.01
•H





cal
43
43
,43
43
43
43
43
4,3
43
43
43
•43
43
43
43
43
43
43
43
1
44
44

<
46
46
46
"46
46
46
46
46
46
46

47

48
48
i
49

53
53





: ca
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4

4
4

4
4
4
4
4
4
4
4
4
4

4

4
4

4

4
4




' kg/iOOOi •
[i oil
.14
.14
,57
.81
4.76
.16
3.91
.29
3.20
4.71
.06
.06
.32
.38
.70
.70
3,36
8.22

204.89
60.17

7.99
.82
1.22
3.12
77.08
1.46
58,85
22.49
27,29
28.69

1.05

.04

,37

.57
7.36

- , ฃ


3,
;sX total
.15
.15
.61
.86
5.07
.33
7.99
.20
2".tt "'".
3.17
.03
.03 '" .'"''
.13
~ .15
.is
",28
1.34
3.79
*-•-
87.80 .
27.78
~ -.'
3.42
1/66
2.48
"2.T1
30.81
.58
23.52 "
..20.70
12.60
13.24 '' .

2.if5" ,
•
.08
f'V'
.75
-.-
.24
, L94 "

: c-35

-------
TABLE  C-5.   Continued

'_
Project



syntana
Union
Utah-cottonsood
Union <
Clear Creek Shale
Clear Creek Shale
Paraho-Ote ;
syntana
Union
Utah-cottonwood
Mhite River Shale
, Clear Creek Shale
Catherdral Bluffs
Clear Creek Shale
Paraho-Ute
•syntana
Union
Utah-cottormaod
Shite River Shale
Clear Creek Shale
Clear Creek Shale
Clear Creek Shale
Union
Clear Creek Shale
Clear 'Creek Shale
Union
Union



Oil
Oil
Projec
Oil
Oil
Projec
Oil •
Oil
Oil
Oil
Oil


general process
upgrade
upgrade
upgrade
sining-below
eining-above
aining-belots
sining-beloB ground
sining-.beloB
sining-beloB
mining-beioB ground
sining-belos
ftining-beloB
fflining-belos
siining-beloss
sirdng-beloH ground
fflining-beloB
sining-beloB
fliining-belDB ground
sining-belos
sining-above
isining-above
sining-above
aining-above
mining-above
iining-above
fflining-above
sining-above
specific process
fugitive eaissions
fugative " ''.
fugitive
drilling
blasting
blasting
blasting
blasting
blasting
blasting
blasting
crushing/screening
sine shaft vents
vent
sobile equipsent
vehicles
raป shale reaoval/sc
vehi cl es-coibust i on
vehicles
top soil
top soil
top soil
ras shale
ras? shale haul
spent shale haul
spent shale
spent shale
'additional pel lu ra-tons/d
'•'.' 'HC '
, HC
HC
NOx
NOx
NOx
NOx
.NOx
SOx
" " '. 'NOx
NOx •
primary NOx
NOx
NOx '
NOx
NQx
engines/ve SOx
NOx
NQx
resiaval NOx
load NOx '
load NOx
topsoil ha NOx
NOx
NOx
hauling NOx
groosing/c NOx
.52
1,10
.' ..34

.01
. :*
.02
.03
.23
.29
"'.22"
,47"

... - "i.
.75
'_ _' .75
.91
"1.30
3.17
2.70
2.97
1.12
5.24

.20

.00
.01
.03

.19
.
.14
.31
... .„ ~,
.05

cat
34
54 '
54

l"

2
2;
2
2
2""
2
i
6; "
8
8
8
8,
8
s;
8;

9
1
10
10
11
i
16

32
32

36



cat k9/10j
4
4
4

1

1
1
1
1
1
1
1

i
1
r
i
i
i
i
i
2

2
2
2

2

2
2

2



|f 3X total
57.07
77.08
68.55



1
1
25
20
43
27

47
47
475
" ' 81
473
297
207
223
310

•12


2

11

8
21

3


.42

.43
.71
.03
.23
.88
.94

.03
.03
.12
.61
.97
.37
.74
.05
.42

.44

.06
.74
.31

.99

.73 .
.46

.42

. 38.48
,30.31
63.11
Ji, B~
"""".04
.F .;=-
• ' '.02 "" 	 	 *
"" .03
. 2.17
1.70
1.02 	
2.63
*• '
.82
•82
15.00
•1.42" ""
27.44
25.79
17.48
5.19
29.28
; ; ,
t -.
.22
•
,00 ;
.19 	
•,'•' 	
.21
>-
.15
1.81
V\: "
.29
Iv
Catherdral  Eiiuffs       utility
                                         steara boilers
NOx
1.89   37  3
989.24
31.24
                                                  j C-36  L „,

-------
TABLE C-5.  Continued,


Project



Clear Creek Shale
ParahQ-Ute
ParahQ-Ute
syntana
syntsna
Union





Utah-cottonseed
-Shite River Shale
Catherdrsl
syntana
White River
Gather dral
Catherdral
Bluffs

Shale
Bluffs
Bluffs
Clear Creek Shale
Clear Creek
syntana '
syntana
Union
Union
Shale

I - f


Shite River Shale
Mhite River


Catherdral
Catherdral
- Catherdral
, Catherdral
Catherdral
Clear Creek
Paraho-Ute
Paraho-Ute
syntana
syntana
syntana
Union
Union
Union
Union
Union
• Union
Union
Hhite River
Shale


Bluffs
Bluffs
Bluffs
Bluffs
Bluffs
Shale


."•" "









Shale

general process
Oil utility
upgrade
retort
retort
utility
utility
retort
Projec utility
retort
retort
Projec retort
retort
retort
Oil retort
Oil retort
retort
retort
coffib. -retort
retort
Projec retort
Projec retort


upgrade
upgrade
upgrade
upgrade
upgrade
Oil retort
upgrading
upgrading
upgrade
upgrade
upgrade ,
upgrade
upgrade
upgrade
upgrade
upgrade "
upgrade
upgrade
Projec upgrade

specific process
steai superheat
package boiler
poser generation
F6D
steai
steaii ' '
fluid' bed coabustor
steal .
flares
retort indirect heat
gas treataent plant
sponge oil reboiler
recycle gas heater
char cosbustion
char coabustion
F8D
Tosco ball heater &
• sponge oil stripper
gas recycle heater
Tosco ball heater '&
recycle gas heater


incinerator
H2 Recycle Heater
H2 Charge Heatsr
oil charge heater
reforter
TE6 Concentrator
hydrotreater feed fu
ref oraer furnace
' F80 - V
F8D
hydrogen
fractionater
dearseniter
dearseniter
unicracker
steas boiler •
•. steas boiler
reforier furnace
.reforrser furnace
additional



steai boil





.
	 .;.
.


coal grind
superior h




union

tr








hydrotreat
hydrogen r
furnace
reboiler
purge heat
charge hea
charge hea
no air pre
idth sir p

„ . . .,,
pollu s-tons/d
H0>:
NOs
NQx
ซQ>;
tfflx
ซSs
SOs
N0>:
Sflx
SOx
NOx
'HOx
SQx
ซ0x
SOx
HOx
NOx
ซ0>;
NOx
H0>:
NOx


ซ0x
NOx
NOx
NOx
N0>:
NOx
NOX
HOX
NOx
NOx
NOx.
NOx
NOx
HOx
NOx
NOx
NOx
NQx
NOx
1.87
.02
6.25
1.71

3.54
20.12
4.77

.00


.07
.09
.7,0
86.90
.15
.99
.57
.42
' 4.14
1.02
2.01


.02
.02
.07
.12
2.21
.00
.09
2.00
' .16
1.90
2.20
.05
.04
.20
.26
.56
.67
3.22
4.32

--,^Ll
' cat
37
37
3,7
37
37
37
37
37

38

39
39
40
40
40
40
40
40
40
40
40
40

'-,,
43
43
43
43
43
43
43
43
43
43
43
43
43
43
43
43
43
43
43

'cat'
3
3
3
3
3
3
3
3

3

3
3

3
3
3
3
3
3
3
.3
3
3

-.
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4 -
4
4 .
4
4

kg/lOOOi 3
oil
117.57
3.74
936,25
188.84

247.31
4020.34
282.59

2.62


4.14

48.04
369.06
5465.19
9.53
108.80
62.58
29.22
289.16
60.17
119.27


9.04
12.84
39.00
62.78
1159.03
.29
13. 18
300.03
17.77
210. 16
242.30
3.30
2.79
14.14
18.07
39.25
47.05
225.12
255.73


s_: :,
. ~~-
"r~T . • • i
'|j "total
't-atl — 1-
2.04
.22
54,21
16.38


20.81
93.53
26.65

! .tt.
.08


,

.'"W 'fl,
i,
11.
94.
•.
9.
5.
2,
24.
5.
11.


.
.
1.
1.
36.
.
. .
17.
1.
18.
21.
.
.
1.
1.
3.
3.
18.
24.

t^-

f 	 ^
!>'- --. • =.;,;-
S2
65
85
17
44
43
M
33
68
25
, "-
L "~ " LT_ " _ r
f w~ :• --
29
41
23
98
60
00
76
37
54
23
02
28
23
i
-------
TABLE C-5.  Continued



Project
Clear Creek Shale Oil
Union ,
Utah-cottomซjod

Union

Union

Clear Creek Shale Oil


Catherdral Bluffs-
Clear Creek Shale Oil
Paraho-Ute ; ,- '-...
syntana
Union'
Utah-cottonsood
Mhite fiiver Shale Projec

Clear Creek Shale Oil

Clear Creek Shale Oil

Union !

Clear Creek Shale Oil
. -
Clear Creek Shale Oil
Union

Union
' • -' ' ' • .'•-
Union i- ' ;

Catherdral Bluffs
Clear Creek Shale Oil
Paraho-Ute
Paraho-Ute- ' '
syntana ,
i . . . .
	 ,.. •-- „ , ...

general process
mining-above
iining-above
upgrade

nining-beloB

fsining-beios

iining-belos


sining-beioH
sining-belos
sining-beloB ground
iaining-below
sining-beloB
fsining-belos ground
iining-beloB

aining-above

aining-above

aining-above

sining-above

ainimj -above
sining-above

aining

iining-above
• •- --.,. *..- . i.
utility
utility-
upgrade
retort
retort
. -- - •'''- •'
..,.-., ,.--.- t -•* T. -: -

specific process additional
vehicles road saint
vehicles/engines
fugitive " on site ve

drilling

blasting
..--.. -^
crushing/screening prinary


sine shaft vents
vent
aobile equipsent
vehicles
raw shale resoval/sc engines/ve
vehicles-coibustion
vehicles

top soil reaoval

top soil load

ras shale topsoil ha

ras shale haul

'spent shale haul .
spent shale hauling

dusping shale
: .-•-- •:-,'. -:. .- : :i ::
spent shale grooaing/c
-ป-...-! ... ;-[.. -.1 r.;-. ••- ,,,, ,;u -
steas boilers
steas superheater-so
package boiler
poser generation
F8D _ steas boil



pollu 8
NOx
NOx

SOx

"SOx

Sflx
t

SOx
SOx
SOx
SOx
SOx
SOx
SOx
•- *
SOx

SOx
-V
SOx

SOx
• .',-"
SOx
SOx

SOx
;- J
SOx
. -, . . ,T<
SOx
SOx
SOx ,.
SOs
SOx



t-tons/d
.05
.25
.06

,00
..— - ^—
":" " .03'
..
.07


.06
.12
.23
.20
.19
.08
.38

.01

.00

.00

,01
-
.01
.02

.04

"'.00

.28
.49
.05
3.97
.91
- f-.-
,,- ,-.r
,-!ป.,
cat
53
^
53

t
___
2

6
[

8
8
8
B"
8
8
8

9,

10

11
1
16

32
32

33

36 '

37
37
37
37
37
i -



cat
4
4
4

1

i-

1


1
1
1
1
i
1
1

2

v

2

2

2
2

2

2

3
3
3
3
3
. ,

= kg/1000i 3
oil
3.42
17.69
11.24

.02

• ' 2.38 '

4,34


29.96
7.413
34.31
. 21.53
13.00
16.14
22.5!

.86

.06

. 16

.68'

" .51
1.31

2.815

.24 '

. 147.44 .
30.82
7.07
' -595.18
100. 13
3? _


I total
" .06
1.49
.26; '•

^63 	 I

^ • i;ir- 	 -
t- .
.78
--t

4.19
1.35
5; is
3.74
5.07
2.02
14.18
;i
.15
fc 	 -.

;*-
6.97
_ซ;
.' , i '• , - t -.
'ฃ- '-' . -. "
.09 "V"""
20.26 / "
" • f;-
20.90
ปt-
22.'80 	

20.64
5.55
1.08
91.11
17.38
                                                                                             "A
                                          -\ C-38

-------
TABLE C-!>.
-.-
Project


syntana
Union •
Utah-cottonsaod
ซhite River Shale
Catherdral
syntana
syntaua
syntana
Hhite River
Catherdral
Catherdral
Bluffs



Shale
Bluffs
Bluffs
Clear Creefe Shale
Clear Creek
syntana
syntana
Union
Union
Shite River
White River
ffiiite River
Catherdral
Catherdral
Catherdral
Shale




iihale
Shale
Shale
Bluffs
Bluffs
Bluffs
Catherdral Bluffs
Catherdral
Clear Creek
Paraho-Ute
: Paraho-Ute
• • syntana
Union
Union
Union
Union
Union
Union
Union
Shite River

Clear" Creefe
Union
Bluffs
Shale










Shale

Shale
I
Continued
*•
general process
utility
' utility
retort
Projec utility
retort
retort
retort
retort
Projec retort
retort
retort
Oil retort
Oil retort
retort
retort
coib. -retort
v •' "retort
Projec retort
Projec retort
Projec retort
upgrade
upgrade
upgrade
upgrade
upgrade
Oil retort
upgrading
upgrading
upgrade
upqrade .
upgrade
upgrade
upqrade
; upgrade
upgrade
upgrade
Projec upgrade

Oil tininq-above
sining-above
specific "process
steas
steass
fluid bed costbustor
steas
flares
claus plant
F6D
retort indirect heat
gas treataent-claus
sponge oil reboiler
recycle gas heater
char cosbustion
char coibustion
F8B
Tosco ball heater &
sponge oil stripper
gas recycle heater
retort
Tosco ball heater &
recycle gas heater
H2 Recycle Heater
H2 Charge Heater
oil charge heater
incinerator
reforier
TES Concentrator
hydrotreater feed fu
reforaer furnace
FSB
fracticnater
dearseniter
dearseniter
uni cracker
steaffl boiler
steasi boiler
reforier furnace
reforaer furnace,

vehicles
vehicles/engines
additional pcllu
SQx
SOx
SOx
SOx
SOx
SOx
claus plan SOx
SOx
SOx
" "SQx
SOx
coal grind SOx
Sflx
superior h SOx
SQx
SOx
SOY"
SOx
SOx
union SOx
SOx
SOx
SOx
SOx
SOx
SOx
SOx
SOx
hydrotreat SOx
reboiler SOx
purge heat SOx
charge hea SOx
charge hea SOx
no air pre SOx
with air p SOx
SOx
SOx

road saint SOx
SOx
a-tons/d
2,02
3.91
1,63

.02


.51

.36
*
.04
.30
.05
8.06
-.53
. .40"
.29
3.34

.10
.07

.01
.03
.05
.24
,33
.00
.00
.11
.09
.01
.01
.05
.06
.11
.11
.15
.14

.00
.02
•,f
cat
37
37
37
. 37

38

39
39
39
39
i
40
40
40
40
40
40
40
40
40
4<>
40
i
.43''
43
43
43
43
43
43
43
43
43
43
43
43
43
43
43
43
— i
53
53
•


--'
;~kg/1000ป3
cat oil
3
3
3
3

3

3
3
3
3

3-V
3
3
3
3
3
3
3
3
3
3

4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4

4
4

141.16
781,58
. 96.70


8.09


56.

21.



27

06'

-'26.45
156.
95

i 1
I total
23,43
97.98
60.93

k
1.13

—
9.

13,

2.
21.
2.97
506,
811
57.97
44.
20.
233.

6.
3.

5.
17.
28.
126,
173,
,
..
16,
9.
.
a
3.
4.
7.
7.
10.
8.


1.

46
39
74

1!)
92

23
60
54
98
12
11
03
65
51
76
63
36
25 •.
55 .
55
15
33

29
17

91,
10.
7.
25.
25.

3.
2,

:
2.
3.
17.
24.
.
.
2.
1.
27.
27.
27.
27.
27.
27.
27,
5.

.
33.

f":
•
77

27
f
86
'?
53
33
06
72
33
33

89
47
_, .^
iai "'
73
46
99
78 '; 	
23
02
00
55
65
23
23
23
23
23
23
23
2'5, " 'I'
ฃ'
05
56
: ۥ
                            415.IOS
36042.71*  3051.45*
G-39

-------
TABLE C-6.  PARTICULATE EMISSIONS

==—,-—. 	 ~- 	
project
Clear Creek Shale Oil
Clear Creek Shale Oil

cottonsood

Parsho~Ute

syntana

Union

Unite River Shale Project

Clear Creek Shale 8il
Clear Creek Shale Oil

Psraho-lite '• :
eyntana

Union ! ' '
Union

Paraho-Ute

Union

cottonseed

Clear Creel; Shale Oil

rnttonwond

v • -
general process
ssining-belcB
ai ning-bel OH

aining-belcB ground

nining-belos ground

aining-beloB

Biining-beloB

stining-beloB

Btining-beloB
oining-belGB

aining-belcB ground
aining-belos

sining-beloB
mi ning-bel OB

sining-below ground
: , . • : ..
aining-beloB

ai ning-bel os ground

sining-below

ffdninn-belos qround
*
- ^~. ,,.,-,
specific prcc
drilling
drilling

raining

aining

aining

drilling

mining

blasting :
blasting
.
biastino
blasting
. ,.;,_..,^^ .L. .....
blasting
reroval

conveying

conveying

transfer

priaary crush

raซ shale

,- .:-: .,- ,-..;
additional d
inter, waste
0

0

0

0 '

0

0

inter. Baste
0
----- -
0
0
"'••'-•' -,- ' -,
V
0

0

o .:

transfer poi

0 '

prifiary crus


cat
1
1

1

1

1

1

1

1
1

1
1
: ll
1
1

i

i

i

i

i

. *:.
cat i
1
1
_.i
1

1

1

1

1

2
2

2
2

2'
3

4

4

5

6 :

4

,;•:---
s-ton/d
.00
.01
i
.11

.04

.13

.00

.26

.10
.26

.17
.18
5 !
,01
.03

.03
i
.17

.05

.00

'.03

Vg/1000ซ 3
oil
^2ir
.74

21.76

5.71

13.9!

.34

15.31

6.22
16.27

25.413
19.32

.-".50
2.3!

"" 5.10

11.5?

9.61

.2r

.. 5.26
./ , . **.,-

total
.13
.38

12.50
ฃ - :-
1.70
f\v -,
5.87 :
&'-' -
.19
,"
7.17
ฃ . .
3.19
8.35
: J-"-': :
' 7.30 ' 'J
	 ; fe. - -'•
•5. ";- ' * '
" ,28
1.28
:" - =
1.50 '
'• - •'.
6,40 '
: .™" : "-''-
r 5.52' -
*-- "
AI
!>' - -
3.02

-------
TABLE C-6,   Continued
                                                                        ir- --H


project
Paraho-Ute

' Union
Union

Shite River

Paraho-Ute

White River

CB

Clear Creek

cottonseed

Paraho-Ute

syntana

Union

White River



Clear Creel;
Clear Creek
Clear Creek
Clear Creek

Union



.. - 	 	 — —
general process
. aining-beloH ground
. i ^
Bining-beloH
dning-beloB

Shale Project sinihg-beles?

. - fiining-belos ground

Shale Project ciining-belos

aininq-beloH

Shale Oil fiininq-faeloH

i aining-belos ground
* .r. , „ -' ... , f , :- = ^ f
ffiining-belos ground

Qininq-belos

sining-below

iihale Project mnirig-beloB

sining-above

Shale Oil aining-above
Shale Oil aini rig-above""
Shale Oil • aining-abeve
Shale Oil sining-above

jiining-above


•
r ; '•-' •
"specific proc additional d
crushing/sere pritary
" " . . --
raw:shale cru priaary
crushing priaary

crushing priaary
' ^L ~ - r - ~ L "^"
crushing/sere secondary
.. . .,-,. - -'
crushing secondary

sine shaft ve 0
-: _ , ' .- . - •
vehicles-vent 0

vehicles-coab 0
1, .-..-„-:,->"'.• : '.*-.. -•--•:. -
sobile eguips "0
•': . , •' ' •
vehicles 0

ras shale res engines/vein
•••- •--- - - 	
vehicles 0

reclais drawh 0

surface soils resoval-dril
surface soils resoval
surface soils resoval-blas
surface soils -haul

ras shale topsoilhaul

••••*.'

, • : .
cat cat i-ton/d
1 6 .08 "
i
1 6 .07;
1 6 ,63
'- . ' .' i
-i
1 6 .14
I
1 7 .08
• - ;
17 .04
i
i"'"a'"" .h

1 8 .40

18 .06
. -- - -^. - jf -
1 8* .02

18 .14
•••--- j
i 8 ,.10
. „ ,-. -; ,
1 8 .27

2 9 .01

29 .01
29 .13
29 .25
2 11 .36

2 11 .Oi:

•• :
'? ~^~~'^[
"ig/ToOOii 3 , , , ,
' oil z total
12,16 .--- 3.60
;T~
4.63 2.56
43.78 24,18
c.
K .
8.49 3.98
R-,-1,
12.16 3.60
: ;1.' -'
2.63 1.23
i fe- ,
88.46 ' 26.54"
: fi"- '
25.34 13.01
.I,-: .
11.42 6.56 '
?.:•:-' ft
- \ " '" ' ! T
"3.06" 1.00
S "t
15.31! 6.46

7.15 3.95
J*:- .-
15.85 7.42 ""
'ฃ-- -
2.7$ .81
2
,74 .38
8.28 4.25
15.58 8.00
22.83 11.72
C""T
.ฅ} .27 ":~


                                             C-41

-------
TABLE C-6.  Continued



project •--
Clear .Creek Shale Oil

Parahomte

CB • . y ;'.• '
. CB

Clear Creel; Shale Oil
Clear Creek Shale Oil

cottonseed ,
cottonปDod

syntana
syntana

Union

Clear Creek Shale Oil

Paraho-Ote

Union

CB
CB "...-.

Clear Creel; Shale Oil
Clear Creek Shale Oil

cottonseed

Paraho-ilte ."•-.-'
Paraho-Ute
".
i

.-
1 "-
general . process
siining-above

sining-above ground

'- aining-above
sining-above

sining-above
sining-above

jiining-above ground
tining-above ground

fiining-above
sining-afaove

fflining-above

fflining-above

aining-above ground

.- aining-above

sining-above
fflininq-above

si Ring-above
mining-above

ffiining-abeve ground

lining-above ground
fflining-above ground


-• --' ^ -;... -. /
specific proc
surface soils

surface soils

". r'3ป shale
., rag shale

ras shale
raw shale

raw shale ,
. rae shale

raw shale
raw shale

raป shale

ras shale

raป shale

rass shale

raw shale
ras shale

raw shale
raw shale

raw shale

raป shale
rm shale
f- _ -. . .
-...,.
' • r ' ." "•,
additional d cat
Bind 2

Bind 2

crushing faui 2
screening pi 2 ,

crushing 2
crushing-Znd 2

crusher-iusp 2
screening 2

priiary crus 2
secondary cr 2

crushing/sec 2

crushing-3rd 2

tertiary cru 2

crushing/ter 2

transfer hou 2
conveyor -st a 2

conveying 2
conveying 2

surge bin 2

trans, fr. 1 2
convey/trans 2


-
cat
12

12

13
13

13
13

13
13

13
13
i
13'

14

14

14

15
15

15
15

15

15
15,


, ":, >:•., -" ... ...
., , : _"""J[
as-ton/d
.00
I
.07
i— 1_
.00
.00

"M
.01
	 . 	 ;
.02
.03
i
	 .29
1
.12
"
.01-
|
.24 .
T ''
.41

.02
.05

.02
.81
'_
.02

.01
.05


g/lOOOi %
oil
"".21

10.1?

1.62
1.43

.2?
.6IJ

4.81
5.60

1.42
32.14

: 8.61

.91

:36.35

28.71

9.04
25.2!

1.13
51. OB

3.23

1.77
7.34
m
f\ arf"
-. . 1 f^--
-.^•••-..•:^'-^i,-2
!,X total
.31

2.40
5"
.49
.43 '
: .: :'
.15
.35
. f ,
2.76
3.22
V- - -'.
.60
13.57
r . . r" -. *"-•-
4.76 . '
"~
- „ .., j-. ,,-- ',- -,. „
.47
fe.
10:30
r •'••
15.85

2.71 " ' "
- 7.56
'':• -
.58
26.23
'• F;
1.85

.50
2.20

-------
TABLE C-6.  Continued


project
Paraho-Ute '
Parahq-Ute
Union
Shite River Shale Project
Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil
. CB '" . '
cottonseed
cettonwood
cottonseed /
Paraho-Ute . • .
•syntana
Union " ;
Union
Union ; •'""
Shite River Shale Project
finite- River Shale Project
Clear Creek Shale Oil
Union
Union
CB

. . ' 	 L_^.
general process
ftining-above ground
fftining-sbove ground
aining-above.
Bining-above
sini fig-above
sining-above
iining-above
. ffiining-abo
iining-above ground
ffiining-above ground
fiining-above ground
fiining-above ground
sining-above
sining-above
eining-above
sining-aboye
siining-above
sining-above
Bining-above
sining-above
" aining-above
aining-abo


specific proc
rm
raw
shale
shale
raw shale
conveyor surg
int saste
int waste
ras shale
raw shale sto
ran shale
raซ shale
ratf shale
raw shale
"raB shale
ran shale sto
storage silos
ras shale sto
retort feed s
raw shale sto
ras shale
ras. shale sto
retort pad
ras shale sto

additional d
saspie S: sei
screening/tr
conveying/tr
0
duip
haul
duap
5 day
storage-load
storage-reel
storageUive
live storage
storage
load out
0
load in
three
load/groosi/B
ปind errosio
wind erosion
Bind errosio
5 year
; ^ -;; ; :- \ .
cat cat s-ton/d
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2'
2
2
2
2
.15
15
15 *
f
15

16
16
17
18
18"
18
18
18
18
18
18
IS
- • ,'
18
18

"ir""'
19
21
.10
.16



;
.01
!
.01
.15
.12
;
.01
•'
.00
.00
.03

.00
i
.03
1
.00
.01
.01

.05
••12

'''~'M '
!
.00
.01
.01
.01

oil
•--•-•• n,27
24.60

"••",." ".5?

.86

.34
9.36
7.53

3.80

.30
.60
"6.8!?

.14.

3.47

.Oft
.50
.77

2.69
6.93'

^02
'.19
.36
5.42'
5.42
/ . i A
I total
' 4.20
7.10
; ...
.32.
f
'.40'
i,:;--

. • 4.8'1
3.87
; e1.;. -
1 —
1.14
' * '-Tt
.34 ;
3.96
i t -:
.04
^ jfl'J.''
1.47
1 UN 1 a
.04
.27
.43
; ,';
1.26
3.25
ฃ*,--
M' "
.10
.20
	 , 	 JJK
1.63
1.63 .
                                             C-43
                                                                                       t :x -

-------
TABLE C-6.   Continued
_____ ._ ^ 	 	 	 	 	 „., .; 	

projecf _
cottonseed ;
Paraho-Ute
Clear Creek Shale Oil
syntana
cettonHood
• cottonseed .
CB
cottonseed
Paraho-Ute •!•*-..
i
• syntana . <
syntana
Shite River Shale' Project
Hhit'e River iJhale Project
cettcnsood _ , ,
cottonHood
cottonseed i •• /
. Paraho-Ute ;
Paraho-Ute
Paraho-Ute ; •
Paraho-Ute ;
1 "
syntana




general process
aining-above
ffiinirig-abeve
sining-above
siining-above
aining-above
aining-above
tining-above
si Ring-above
mining-above
ffiining-abeve
fflining-above
ffsining-above
fflining-above
sining-above
sin ing-above
aining-above
fflining-above
atining-above
isin ing -above
sining-above
sin ing -above
ground
ground
ground
ground
ground
ground
ground
ground
ground
ground
ground
ground
ground
V •
." ." 'specific proc
rat? shale
ras shale
ravs shale
raซ shale
ra*s shale
ras shale
ras shale
raw shale
raป shale ; ,
raซ shale
rm shale
conveyor feed
conveyor feed
ras shale
fines
fines
fines
fines
raป shale
fines
fines transle
fc-4Tl-
TL: r'-" v. • • . a
additional d
storage (dead
esergency st
Bind
stor age-si nd
retort feed
retort feed
conveyor -ret
retort feed ,
retort feed
retort feed-
conveyor fee
0
transfer
retort disch
FBC discharg
conveyor-tra
convey or -tr a
to bin
fines transf
storage
cat
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
cat
21

21
22
22
23
23
24
24
24
24
24
24
24
25
26
26
26
26
26
26
26

.01

1
. .11
( f
.04

.04
X ''
.00
.00
1
,00 -

.00
;
.04

.00
.00

.01
.05

- .00
.01
.01
i
.01
.01
.01
.11
^ 1
* vo'i
,

•:.:"~ * ;~7'

kg/lOOOi 3 v . . .
• i A ZDlai
01 1
2.77 1.5^9
j.
16.10 4.70
ft-T^
2.57 1.32
jf_
4.77 2.01
#iป
.?
-------
TABLE C-6.  Continued


.project ;. ., ' .
Unite 'River Shale Project
cottonseed ".
cottomsoDd ' .
syntana
. Mhite River ' Shale Project
.White fiiver iihale Project
syntana :
CB • r - .
CB , : • ' '
Clear Creek 13hale Oil
I-
cottonseed
Paraho-Ute
ParahQ-Ute " .
Paraho-Ute i
Union
Hhite River Shale Project
tthite fiiver ishale Project
CB
: CB '"
CB ;
Paraho-Ute
Paraho-Ute ' \
|-
J"
general process
sining-above
&i Ring-shove ground
'-irdning-above ground
lining-above
Ein ing-above
ssining-above
sining-above
aining-abo
sining-above
fflining-above
. si Ring -above
ffiining-afaove ground
aining-above ground
.. iining^above ground
sining-above
inining-above
fflining-above
•Biining-above
iBJninง-abo
fiining-above
sining-above ground
iining-above ground
specific proc
fines reclaia
fines
fines ' " "
fines
fines-storage
fines
fines
spent shale
spent shale
. spent shale
spent shale
•=.-•-• . -=:
spent shale
spent shale
spent shale
spent shale c
-•• spent shale d
• spent shale c
spent shale
spent shale
spent shale
spent shale
spent shale
additional d cat
0 2
FIC feed bin 2
storage silo 2
storage-Bind 2
reclais/sind 2
storage/conv 2
aaintenance 2
stacker conv 2 "
conveyor 2
conveying 2
conveyor 2
conveying 2
to bin 2
conveying-A 2
0 ' 2
un/tos/sup 2
0 2
transfer hou 2
conveyer dis 2
transfer 2
retort overf 2
'retort disch 2





V + M -"""kg/1000t3
cat i-ton/d s oij
26
27
27
27
27
27
29
30
30
30
30
30
30
30
30
30
30
31
31
3t
31
31
.00 •
-.
.01
.01
i
.02
, :
,07
.14
-
.05
•••' :
.04
- 	 ,; :
.18
> :
, !
.02
.03
r r
.08
; ,
.01
.05
-f \
,02
.04
.04

.04
.23
,
- .17

1.09
IM

2.64

8.54

5.87

25.21
20.93

11.59

2.28
4.24

5.55

.37
3.22

9.04
20.93
20.93

5.38
34.24


X total
.08
:
.63
.63
i *' - . i
1.12 ;
r-:- .
2.06
, 4,00
|fl. .
2.48
f""
6.28
r
5.95
h_
.70
1.30
T~ |j'ft
3.07 "
ฃ,
.17
1.51
r;':;"
2.71
6.28
6.28
.*'"••'-
1.60
10.00
_ „-. "-"
                                           i..C-45_J.  s

-------
TABLE C-6.   Continued
                                                                                                                                  t
 project

 Union
 Union
 CB
 cottqnHood
 cottomsood
 Union
 CB
 cottonsood
 Paraho-Ute
 syntana
 Union
general process

Siining-above
specific proc additional  d cat  cat  t-ton/d   j^^Jjj      ?• total
 Clear Creek Shale Oil     "  nining'-above
sining-above
sining-abo
aining-absve  •
ffiining-above
aining-above


siining-abo


aining-above


ffiining-above ground


aining-above


aining-above
 Hhite River  Shale  Project   aining-above
 cottoneood
 syntana
 Union
sining-above


fflinlng-above


ffiining-above
   ite River Bhale Project    sining-above
spent shale   stacking     2   31       M
                             "spent shale"  'haul
                         '  2   32      .02
1.37       .70
spent shale   hauling      2   32
                                                                                                             3.1i      1.75
spent shale   distribution 2   53      .07        58.52	J11.56_
spent shale   disposal flea 2   33
spent shale-f loading/duip 2   33
spent shale   truck duspin  2  "33"      .05
spent shale s 0
                                                                                     2   34      .01
2.85
spent shale-f storage bin   2    34  	.01	_^	1.JJ?	 ,64
spent shale   storage      2    34       .22        33.50      7.?0
spent shale   storage-load  2   .34       .02
spent shale d 0
                                                                                     2   34
                              spent  shale d load in      2   34	'.J2	1.07
spent shale   disposal-sin 2    35  _   .03         5.01      2.fl7
spent shale   storage-Bind  2    35    	Ah	17.&2
spent shale-s Bind errosio  2    35       .01
                                                                                                              .57       .32
                              spent  shale  d wind erosion 2   35   _  .05	     2.79-
                                                           ••'•.C-46.JT

-------
TABLE C-6.  Continued
. 	 	 	


.project . '- ' : - " :.
cottonseed

syntana

Union

Shite River Shale Project

CB

Clear Creek Shale Oil
Clear Creek Shale Oil
Clear Creek Shale Oil

Paraho-Ute ; ...-.'•,-•
Paraho-Ute

syntana
syntana ,.----• , -



Shite Piver Shale Project

syntana
Union . • '"

CB
CB - '
CB

Clear Creek iShale Oil
Clear Creek Shale Oil

ฃ-•
\.
• general process
fiininq-abave
-
,-.-.- •- - _ •_ . -
sining-above

si ning-above

sining-above

cosb-utility

cosBb-retort.
coab-retort
coffib-utility

upgrade
coab-retort

utility
retort

utility

utility

retort
retort

retort
coab. -retort
cosb. -retort

cosib-retort
coiEb-retort
. _. _— -. 	 — 	 	 — 	 — 	 = .in, j.


specific proc additional d
spent shale disposal-gro
-.- - _ ;. -_
spent shale storage-sain

' spent shale grpoaing/coB

spent shale d Qrootinq

steais boilers 0

retort gas 0
TES Concentra 0
steas superhe 0

package boile 0
power generat 0

steas . 0
FBD steas boiler

steaa 0

steas 0

retort indire 0
sponge oil st 0

incinerator 0
sponge oil re 0
recycle gas h 0
._ ,"..-.' :..._.
char cosbusti feed bins?so
, char cosbusti coal grindin



cat
2:

2

2

2

3

3
3
3

3
3

3
3

3

3

3
3

3
3
3

3
3



cat
36
.: J
36

36

36
• -•
37

37
37
37

37
37

37
37

37

37

39
39

40
40
40

40
40


; - . ;
iB-ton/d
.33

.24 '
r
: .03

.36
X '
.03
f i
.00
.14

.00
.35

.05
?
.09

"' ".r
.72

.01
:-
.00
.03-
;
.09
•f. ,"-•''.-- 9 i - - Mf"**-

kg/l
-------
                                                                                                                     •:•:>$
                                                                                                                        T
TABLE  C-6.   Continued
project

syntana
general  prccesV

fflinifig-above
specific proc  additional d'cat cat m-ton/T   k8/10^ฐ*    X total
— MM — — — — — — —  — — — — —	_ — — —— — — — __ — —.—  __—-.— — ..—ป—  ^  ^,:	• — — — — ^

fugative"    truck traffi 4   53  '_.JjgJ."". ... 30."4^    ,12/fe
Union
Union
On ion
CB
Clear Creek iBhale Oil
Union
id Piing-above
iining-aijGve
lining-above
aining-abo


aining-above


aininQ-above
Vehicles/engi  Tight duty   t   53     '.t'4
vehicles/engi  road iaint/a 4   53      .05
vehicles/engi  diesel       4   53      ,15
 2.64  '    1.46
 3.54      1.96
10,62      5.86
fugative dust  haul roads   4   54      .00
                                                                                                         1.43       .43
coal
fugative dust  0
                                                                                  4   54      .01
                                                                                  4   54      .36
24.95     13,73
                                                         C-49T

-------
TABLE C-6.  Continued

1
1
project '
Clear Creek Shale
cottonseed
syntana
syntana
Union
Mhite River Shale
8hite River Shale
White River Shale
•^'" tthite River Shale
syntana
Shite River Shale
CB
- CB •.-,'.,-
CB
CB
Paraho-Ute
Paraho-Ute
syntana
syntana
Mhite River Shale
Clear Creek Shale
cottonseed
cottonseed

1 .
f
general process
Oil coiab-retort
cos-retort
retort
retort..
retort
Project retort
Project retort
Project retort
Project retort
retort
Project retort
• coisb-upgrade
- - - upgrade
upgrade
i upgrade
upgrading
upgrading
upgrade
•" --• upgrade
Project upgrade ,
Oil giining -above
coib-upgrade
coib-upqrade

specific proc
char coafausti
shale fluid b
F8D
Tosco ball he
gas recycle h
Tosco ball he
recycle gas h
elutriator
Tosco elutria
Tosco soistur
processed sha
reformer furn
H2 Recycle he
H2 charge hea
Oil charge he
hydrotreater
reformer furn
F6ป
F6D
reforaer furn
vehicles
fugitive
fugitive
additional 'd
0 .
0
superior hea
0
0
0
union '
:0
and ioi star i
0
o'
0'
0
o
0
(I
0
hydrotreater
hydrogen ref
0
paved roads
unpaved road

cat
3
3
3
3
3
3
3
3
3.
3
3
4
4
4
4
4
4
4
4
4
4
4
4
cat
40
- .-ฃ'
f
40
?
40
40
40
40
40
41
41
42
42
43
43
43
43
43
43
43
•43
43

53
53
53
;' -'/*" :,"i
B-tb?i/d
10.24
1
.04
<
.03
.34
I \
.10
. i ',
,44
.-"..19
.•13
.06
*

.03
.00
;00
.01
.0"!
.13

.00
,06
.41

.17

,06
..,,,./


kg7lOOOt3
oil
643.

8.

3.
37.

7.
26.
11.
3.
7.
6.

16.
1.
2.
19,

6.

24.

10.
2.
11.
77"

20
48
73

31 .
06
28
W
79
13

98
57
71
85
82
57

53
61

55

50
18
24



.;-• : ป ••_-•
'i total i
97.

4.

i.
15,

4.
12.
5.
1.
3.
.2.

5.
5,

2.

11.

5.
i.
6.
74 |
r €!":,;
f -, •* • +? '
71.- '•
&.-..:,.
47
93
T" - •
03 '""" "
21 . ::
29
45 ' |
65
i 	 ~~&'-*-
59
,**•- 1
09 : j
17" ' \
51
86
i 	 "~zl
T 	 •""*••',
30 ' ^ \
70 . J
i _/|
22
79'
r- .. j.,,.
50
: . t- J
39" 	 	 "T
5 I
25 :
46 1

-------
                                   TECHNICAL REPORT DATA
                            (Please read Instructions on the reverse before completing)
 1. REPORT MO.
                              2.
                                                            3. RECIPIENT'S ACCESSION NO.
 4. TITLE AND SUBTITLE

 Air Pollution  Control  Alternatives
 For Shale Oil  Production Operations
                                                           5. REPORT DATE1
                                                           6. PERFORMING ORGANIZATION CODE
 7. AUTHOR(S)

 H. J. Taback, R.  J.  Goldstick
                                                           8. PERFORMING ORGANIZATION REPORT NO
9. PERFORMING ORGANIZATION NAME AND ADDRESS

 KVB,* Inc., 18006 Skypark Boulevard, Irvine, CA   92714
                                                           10. PROGRAM ELEMENT NO.
                                                            11. CONTRACT/GRANT NO.
                                                              68-03-3166
 12. SPONSORING AGENCY NAME AND ADDRESS
 EPA, Office of Research and  Development
 Air and Energy Engineering Research Laboratory
 Research Triangle Park, NC   27711
                                                           13. TYPE OF REPORT AND PERIOD COVERED
                                                            Final Dec.1 85-Dec.87
                                                           14. SPONSORING;AGENCY CODE
01880.
                                            1S EdWard R'  BateS  (EPA'  H^ERL> Cincinnati, OH
               -7774)-  <*) Under  Subcontract to Metcalf and Eddy,  Inc., Wakefield, MA
  ..ABSTRACTThe available air emission  data and air pollution  control  technoloay data
tor  the  production of shale oil are consolidated, evaluated  and  presented in'a manner
DPrmir^nni" r,^-Pr0:ieCt d?rlop!rs i".PrePai"i"9 environmental  impact .statements and
permit applications as well as to their respective regulatory  approval  agencies   The
           covered include subsurface .and surface mining; raw shale sizing and handling;
           .VcnIntSehfii-n9 Sc!?eme5'  bo1jh 1n Sltu and above-ground;  spent shale
     ....._..,  spent shale disposal and.product upgrading.  Air pollution  control  tech-
su ?^er,CฐVe1d lnCl?de TฐSt ฐf the t^1t1onal  processes for nitrogen oxlS (NOJ
sulfur comDounds. peculate, volatile organic compounds (VOC)  and-darbon monoxide (CO)
                     icently-developed processes such a's:  Catalytic  mufflers  for
                    _  combustion for NOX;  caustic-charcoal-sodium hypochlorite scrubbing,
                  .  ion and dry sorbent  injection  for organic sulfur  and SOX;  and
3articul-te         materials,  moving bed  granular filters and dry Venturis for  fine  '
 vPn--    i'S  TChed that 1f state-of-the-art control  technology is applied   the
 verall emission  levels  per unit of oil produced will  be essentially the same  for in
 itu or above-ground retorts and for retorts that are  either  directly, or indirectly
 7.
                                KEY WORDS AND DOCUMENT ANALYSIS
                  DESCRIPTORS
                                              b.lDENTIFIERS/OPEN ENDED TERMS  C. COSATI Field/Group
 Air Pollution
 Oil  Shale
 Retorting
 Desulfurization
 NOX  Control
 Scrubbers
                                               Pollution Control
                                               Stationary Sources
                                               Air Emissions
    13B
    086
    07A
    07D
    07B
    131
 8. DISTRIBUTION STATEMEN1

 Release  to  Public
                                              19. SECURITY CLASS (ThisReportI
                                               Unclassified
21. NO. OF PAGES
    573
                                              20. SECURITY CLASS (Thispage)
                                                Unclassified
                                                                        22. PRICE
EPA Form 2220-1 (Rev. 4-77)   PREVIOUS EDITION is OBSOLETE

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