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 ------- 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 BULK RATE POSTAGE & FEES PAID EPA PERMIT NO. G-35 Official Business Penalty for Private Use $300 EPA/600/S2-90/059 ------- |