EMB Report No. 78-OCM-12D
December 1979 '
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SOCMI - Fugitive Emissions
Chloromethanes Production
Stauffer Chemical Company
Louisville, Kentucky
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Emission Measurement Branch
Research Triangle Park. North Carolina
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EMB Report No. 78-OCM-12D
Emission Test Report
SOCMI-Fugitive Emissions Chloromethanes Production
Stauffer Chemical Company
Louisville, Kentucky
December 1979
-------
Table of Contents
I. Introduction
II. Summary of Results
III. Process Description
IV. Sampling and Analytical Procedures
Appendix
A. Field Data Sheets
B. Test Log
C. Project Participants
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I. Introduction
Under the Clean Air Act, as amended, the Environmental Protection
Agency is required to develop standards of performance for new stationary
sources. These standards are based on the best systems of emission
reduction (considering costs) that have been demonstrated. EPA is currently
developing a standard for fugitive emissions from synthetic organic chemical
manufacturing processes, and testing was performed at this facility to gather
data for this study.
Testing was performed at Stauffer Chemical Company's chlorinated methanes
unit at the Louisville, Kentucky, facility during January 3-4, 1979.
Emission Standards and Engineering Division, EPA personnel performed the
testing.
The purpose of the field study was to perform a complete individual
component survey with a portable VOC analyzer to measure the local VOC
concentration around the component's potential leak source, and based on
that data, compute the frequency of occurrence of leaks based on
different concentration-limit criteria. Unit walkthrough surveys with a
portable analyzer were also conducted for comparison of leak detection
effectiveness.
II. Summary of Results
The results of the individual component surveys at the potential leak
source interface (0 cm) are summarized in Table I. Data are presented
for different equipment types as well as for the total equipment tested.
The walkthrough data will be analyzed in a separate report. All field
data sheets are included in Appendix A.
Two programs at Stauffer may have an impact on the amount of fugitive
emissions. The first is an inspection program conducted by the laboratory
personnel, called an ambient air survey. Monitoring is conducted with
Drager tubes in 10 to 15 areas of the plant at least once per week. The
action level for the Drager tubes is generally 1/2 of the TLV for the
individual chemicals. After a leak is detected, the production personnel
then take action to locate the source and repair the leaking equipment.
The surveys require about 4 hours per week on the part of the laboratory
personnel. Further, if a problem is found, the laboratory personnel
retest periodically until the problem is solved. In addition, a personnel
monitoring program is conducted to evaluate employee exposure specifically.
The second major program involves the replacement of several pieces
of equipment with more reliable equipment. This has occurred over the last
three years. The purpose of the program was to improve the overall plant
reliability and thus, in effect, increase annual production capacity.
The program has resulted in decreased downtime. Several pumps and compressors
have been replaced, as well as a good deal of piping. In particular, the
company has found that Durco plug-cock valves do not leak as much as other
valves, and these have been installed where possible. Further, the company
is using more teflon-lined pipe to improve reliability.
-------
Table I - Summary - Number of Readings Versus VOC Concentration at<0 cm from the Source; Stauffer
Chemical Company, Louisville, Kentucky
VOC
Concentration
(ppm methane
calibration)
<_ 200
201 - 1000
1001 - 10000
> 10000
Total
Pumo
#
29
7
2
1
39
Seals
%
74
18
5
3
Equipment Type
G°
-------
III. Process Description
Stauffer Chemical Company produces chloromethanes at their Louisville,
Kentucky, facility, through hydrochlorination of methanol and chlorination
of methyl chloride. The ratios of co-products produced is flexible,
depending on the desired end products. The process was operating normally
throughout the test period.
Table II is a list of process pumps provided by Stauffer. In this
table, the pump I.D., seal type, and approximate molar composition of the
fluids being pumped are provided.
IV. Sampling and Analytical Procedures
The instrument used to conduct surveys at this facility was a
Century Systems Corporation OVA-108 organic vapor analyzer. The instrument
was calibrated in EPA laboratories in Durham, N.C. prior to shipment to the
test site. Methane in air standards were used.
Unit walkthrough surveys were performed by first identifying a
proposed path so that the unit perimeter would be traversed, and all
pumps and control valves at ground level would be surveyed within a
distance of 1 meter. The instrument was then carried through the unit
along this path with concentrations and location notations recorded on a
strip chart recorder.
Individual component surveys were performed by traversing at the
surface of the potential leak interface to determine local VOC concen-
trations. The highest observed concentration was recorded on a field
data sheet.
The testing was successfully completed, even though weather
conditions were less than ideal. Cold weather did not appear to affect
the instrument or to seriously impair the testing.
-------
TABLE II
COMPONENTS IN MOLB-PER CENT
LOCATION
CA-3
AA-1
AA-2
PA-3
PA-5
PA-6
T*7V A
PA 9
PA-8
PA-4
PA-7
PA-10
PA-11
PA-12
PA-51
PB-2
PB-3
Tk Yt 1 *\
PB-12
V^T^ 1 O
PB-13
PA-60
SEAL CH3Cl
Mech. 82.6
NA 54
NA 24
Mech. 13
Mech. 23
Meeh.
1uT*t«>«T* A
Mecn. A
Pack B
Mech. A
Pack B
Mech.
Mech.
fiMech. A
Pack B
Mech. A
Pack B
Mech.
Mech.
Mech. H2SO4 :
Pack H2SO4
« _ , T~ 1 f\ r\
Mecn. ... . J.UU
m»_ _i, T f\f\
Mecn. JLUU
Pack
CH2C12
5
16
30
63
76
44
i nf\
J.UU
100
___
. .-
'
88%
96%
II
CHC13 CCl4 HC1 N2 , C12
.5 .2 2. 10
3 .6 23 4
10 2 32 2 i
21 3 '«. _._
1 ' .
48 8 -
' _
85 13 1
86 14
100 _:._ .... _: _.
100 _ -
100 -
100
100
-------
APPENDIX A
FIELD DATA SHEETS
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-------
Appendix B
Test Log
1/3/79 1040-1107 Unit Walkthrough
1300-1530 Unit-OVA
1/4/79 1604-1635 Unit Walkthrough
0830-? Unit OVA
-------
Appendix C
Project Participants
Dan Bivins EMB/ESED.EPA
Robert Weber CPB/ESED.EPA
------- |