United States
.Environmental Protection
Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park NC 27711
Research and Development
EPA/600/S2-90/059 May 1992
-&EPA Project Summary
Evaluation of Innovative Volatile
Organic Compound and
Hazardous Air Pollutant Control
Technologies for U.S. Air Force
Paint Spray Booths
D. Ritts, C. Garretson, C. Hyde, J. Lorelli, and G.D. Wolbach
This report gives results of an evalu-
ation of carbon paper adsorption cata-
lytic incineration (CPACI) and
fluidized-bed catalytic incineration
(FBCI) as control technologies to re-
duce volatile organic compound (VOC)
emissions from paint spray booths. Pi-
lot-scale units were tested simulta-
neously to evaluate the technical
performance of both technologies. Re-
sults showed that each technology
maintained >99% destruction and re-
moval efficiencies. Particulate emis-
sions from both pilot-scale units were
<0.08 gr/dscf. Emissions of the criteria
pollutants—SOX, NO,, and CO—were
also below general regulatory standards
for incinerators. Economic evaluations
were based on a compilation of manu-
facturer-supplied data and energy con-
sumption data gathered during the
pilot-scale tests. CPACI and FBCI are
less expensive than standard VOC con-
trols when net present costs for a 15-
year equipment life are compared.
This Project Summary was devel-
oped by EPA's Air and Energy Engi-
neering Research Laboratory, Research
Triangle Park, NC, to announce key find-
ings of the research project that is fully
documented in a separate report of the
same title (see Project Report ordering
information at back).
Introduction
The objective of this project was to
identify and evaluate innovative emission
control technologies capable of effectively
and economically reducing or eliminating
volatile organic compound (VOC) and haz-
ardous air pollutant (HAP) emissions from
atypical U.S. Air Force (USAF) paint spray
booth.
Significant quantities of VOCs and
HAPs are released into the atmosphere
during USAF maintenance operations.
Painting operations conducted in paint
spray booths are major sources of these
pollutants. Solvent-based epoxy primers
and solvent-based polyurethane coatings
are typically used by the Air Force for
painting aircraft and associated equipment.
Solvents used in these paints include:
methyl ethyl ketone (MEK), toluene, lac-
quer thinner, and other solvents involved
in painting and component cleaning.
USAF maintenance facilities have been
identified as VOC and HAP emissions
sources; as such, they are regulated by
the Clean Air Act (CAA) and related state
and local regulations. Because many USAF
bases are located in areas that have not
yet attained pollution control goals estab-
lished by the CAA, local air pollution con-
trol agencies are requesting that the USAF
decrease its VOC and HAP emissions. In
response to these regulations, the USAF
Engineering Services Center (AFESC), in
cooperation with the U.S. EPA, initiated
technology evaluation programs to mini-
mize VOC and HAP emissions through the
application of source control reductions
and system modifications to existing paint
spray booth operations.
Scope
Technical and economic evaluations,
in conjunction with a vendor survey, were
performed for 11 innovative emission con-
trol technologies. Based upon the results
of these tasks, two technologies were se-
lected for field-testing: carbon paper ad-
sorption catalytic incineration (CPACI), and
fluidized-bed catalytic incineration (FBCI).
In these evaluations, CPACI and FBCI
were compared with standard VOC emis-
Printed on Recyclecj Paper
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slon control technologies, such as regen-
erative thermal incineration (RTI).
During the field-testing, one CPACI pi-
lot-scale unit and one FBCI pilot-scale unit
were tested simultaneously, at the "Big
Bertha" paint spray booth in Building 655
at McClellan Air Force Base (AFB), Cali-
fornia.
Methodology
Reid tests of the pilot-scale CPACI and
FBCI units were conducted by using Bay
Area Air Quality Management District-
(BAAQMD-) and EPA-approved source test
methods. BAAQMD Method ST-7, and EPA
Methods 2, 3A. 4, 5, 10, and 25A were
used. Organics in the exhaust gases were
characterized using National Institute for
Occupational Safety and Health (NIOSH)-
Method 1300. Economic evaluations were
based on manufacturer-supplied data used
in conjunction with estimates provided in
EPA's EAB Cost Control Manual. This
manual and the Naval Facilities Engineer-
ing Command's Economic Analysis Hand-
book were referenced to develop the net
present cost (NPC) and treatment costs for
each technology evaluated.
Test Description
The pilot-scale units were tested over a
10-day period during which the technolo-
gies were operated under a variety of con-
ditions. The control technologies' operating
temperatures and the flow rate of exhaust
gas to be treated were controlled to meet
desired operating parameters. Operating
conditions generally fell into one of three
categories: low flow rate and high tem-
perature, high flow rate and bw tempera-
ture, and high flow rate and high
temperature. During the tests, the paint
spray booth was operated normally.
Results
Information gathered in the vendor sur-
vey indicates that certain innovative VOC
control technologies could be applied to
paint spray booths. Regenerative thermal
oxidation (RTO), RTI, membrane vapor
separation/condensation, carbon adsorp-
tion/incineration, CPACI, and FBCI might
be applied successfully to USAF paint spray
booths.. Field-tests of CPACI and FBCI-
have demonstrated that each unit can
achieve VOC destruction and removal effi-
ciencies (DREs) of 99% during normal op-
erating conditions.
An economic evaluation performed for
a CPACI device sized to treat 60,000 scfm
for 15 years resulted in an NPC of
$2,570,000.
An economic evaluation performed for
an FBCI device sized to treat 60,000 scfm
for 15 years resulted in an NPC of
$2,369,000.
Conclusions
CPACI, FBCI, and RTO appear fea-
sible based on manufacturers' literature
and reports used in the automobile and
aircraft manufacturing industries.
The ORE of 99% achieved in field tests of
the CPACI and FBCI pilot-scale units indi-
cates that these systems can effectively
control VOC emissions from USAF paint
spray booths. This ORE is equivalent to or
better than the DREs achievable with stan-
dard technologies. RTO has not yet been
tested on USAF paint booths, but its per-
formance is expected to be acceptable.
The economic evaluations of CPACI
and FBCI found that both compare favor-
able to standard treatments such as ther-
mal incineration. NPCs and treatment costs
for both CPACI and FBCI are lower than
those associated with standard VOC emis-
sion controls. Implementation of flow re-
duction techniques can further reduce the
-costs.of VOC-emission controls
Recommendations
Either CPACI or FBCI can be used
effectively and economically to control VOC
emissions from USAF paint spray booths.
Other technologies, such as RTO, may be
applicable, but they should first be field-
tested at the pilot-scale level in paint spray
booths to determine their viability.
Flow reduction technologies need to be
incorporated into existing paint spray booths
if possible. Reduction of paint spray booth
exhaust by as much as 90% is possible
with these technologies. Such a flow re-
duction is beneficial because it can sub-
stantially reduce treatment costs.
D. Ritts, C. Garretson, C. Hyde, J. Lorelli, andC.D. Wolbach
are with Acurex Corp., Mountain View, CA 94O39.
Charles H. Darvin is the EPA Project Officer, (see below).
The complete report, entitled "Evaluation of Innovative
Volatile Organic Compound and Hazardous Air Pollutant
Control Technologies for U.S. Air Force Paint Spray ___
Booths," (Order No. ADA-242508/AS; Cost: $26.00,
subject to change) will be available only from:
National Technical Information Service
5285 Port Royal Road
Springfield, VA 22161
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
^,^J\itandJ:nergyEngineering Research Laboratory
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati, OH 45268
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EPA/600/S2-90/059
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