EPA
United States
Environmental Protection
Agency
Region 7
726 Minnesota Ave.
Kansas City, KS66101
EPA 907/9-86-005
September 1986
Air Branch
Assessment of the
Monsanto Acrylonitrile
Solution in Muscatine, Iowa
-------
ASSESSMENT OF THE
MONSANTO ACRYLONITRILE SOLUTION
IN MUSCATINE, IOWA
Prepared by
Thomas C. Ponder, Jr., PE, CCE
George Schewe
John E. Spessard, Ph.D.
PEI Associates, Inc.
11499 Chester Road
P.O. Box 46100
Cincinnati, Ohio 45246-0100
Contract No. 68-02-3890
Work Assignment No. 37
PN 3655-37
Project Officer
Deann K. Hecht
U.S. Environmental Protection Agency
Region VII
726 Minnesota Avenue
Kansas City, Kansas 66101
September 1986
-------
DISCLAIMER
This report was furnished to the United States Environmental Protection
Agency by PEI Associates, Inc., 11499 Chester Road, Cincinnati, Ohio 45246, in
fulfillment of Work Assignment 37, Contract Number 68-02-3890. The opinions,
findings, and conclusions expressed are those of the authors and not neces-
sarily those of the U.S. EPA or those of cooperating agencies. Similarly,
mention of company or product names should not be considered as an endorsement
of the U.S. EPA.
-------
CONTENTS
Disclaimer . ii
Figures iv
Tables v
Executive Summary vi
1. Introduction 1
2. Emission Control Systems 2
2.1 Monsanto's Proposal 2
2.2 Monsanto's Proposed Alternate Control Methods 4
2.3 PEI's Proposed Control System 6
2.4 Alternate Controls Considered 7
3. Exposure Calculations 9
3.1 Description of Human Exposure Model 9
3.2 HEM Calculations and Results 10
4. BACT Determination 21
Appendix A - Summary and Outline of Calculations and A-l
Cost Estimates
Appendix B - HEM Model Grid Map for Exposure to Acrylonitrile
Under Scenario No. 4 ' B-l
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FIGURES
Number Page
1 Anticipated SGL-15 Treatment Train . 3
2 Anticipated SGL-16 Treatment Train 5
IV
-------
TABLES
Number Page
1 Exposure Results Summary for AN, BD, and ST at Monsanto's vi
Muscat!ne, Iowa Plant
2 VOC Control Costs at Monsanto's Muscatine, Iowa Plant ix
3 Alternate Control Cases of the AN Emissions at the 11
Monsanto Muscatine Facility
4 Source Characteristics for Emissions of Acrylonitrile, 12
1,3 Butadiene, and Styrene from Monsanto
5 Emission Rates for Acrylonitrile for each Control Case 13
at Monsanto in Muscatine, Iowa
6 Emission Rates for 1,3 Butadiene for each Control Case 14
at Monsanto in Muscatine, Iowa
7 Emission Rates for Styrene for each Control Case at 15
Monsanto in Muscatine, Iowa
8 Exposure Calculation Results for Acrylonitrile at the 16
Monsanto Muscatine Facility
9 Exposure Calculation Results for 1,3 Butadiene at the 17
Monsanto Muscatine Facility
10 Exposure Calculation Results for Styrene at the Monsanto 18
Muscatine Facility
11 Definition of Parameters Used in Human Exposure Calcula- 20
tions
-------
EXECUTIVE SUMMARY
Monsanto Corporation's (Monsanto) Muscatine, Iowa plant produces acry-
lonitrile butadiene styrene (ABS) resins through the polymerization of acry-
lonitrile (AN), 1,3 butadiene (BD) and styrene (ST). The state of Iowa has
required Best Available Control Technology (BACT) for volatile organic com-
pound (VOC) emissions. Acrylonitrile (AN) has been classified as a probable
human carcinogen, and AN emissions are of particular concern.
Monsanto has proposed process revisions that would reduce annual AN emis-
sions from 391 megagrams (metric tons) to 44 metric tons. The U.S. EPA asked
PEI Associates, Inc. (PEI) to evaluate Monsanto's proposal; if appropriate,
propose an alternate BACT program; and review the health risk assessments of
the various proposals.
For the health risk assessments, PEI ran the Human Exposure Model (HEM)
which gave exposures in terms of people and concentrations within a 50-km ra-
dius of the plant. PEI evaluated four scenarios. The first one is Monsanto's
current operation with controls only on storage tanks. The second case is
Monsanto's proposed controls to combine emissions from SGL-9 through SGL-14
into two new sources, SGL 15 and SGL 16. The third case is the second case
plus control on emissions from SGL 6, SGL 15, and SGL 16. The fourth case is
the third case plus control on emissions from SGL-4. The exposure results
summary is in Table 1.
PEI's proposed BACT program requires augmenting Monsanto's proposed pro-
gram by controlling emissions from three process vents by incineration. The
combined flow rate from these three vents is about 100 cubic feet per minute
(cfm) out of a 51,300 cfm flow rate from all process vents. Total VOC emis-
sions are reduced from 121 to 57 metric tons, and AN emissions are reduced
from 44 to 29 metric tons. The average risk or probability in 106 of con-
tracting cancer from AN over a lifetime to the average exposed individual is
reduced from 0.88 to 0.56 cancer per lifetime per million persons. The AN
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TABLE 1. EXPOSURE RESULTS SUMMARY FOR AM, BD, AND ST AT MONSANTO'S MUSCATINE, IOWA PLANT
Population
exposed,
persons
Total emissions,
kg/yr
Maximum risk,
cancers/
lifetime/106
persons
Annual ^
incidence,
cancers/yr
Repeat
interval ,
yrs/cancer
Average
risk,c
cancers/
lifetime/106
persons
ACRYLONITRILE
Current
314,000
391,082
2,050
0.034
29
7.68
Monsanto
proposal
314,000
42,505
457
0.0039
250
0.88
PEI
proposal
314,000
27,716
256
0.0025
400
0.56
More
stringent
proposal
314,000
12,184
184
0.0012
870
0.26
1,3 BUTADIENE
Current
314,000
42,100
2.06
2.56 E-5
39,000
5.76 E-3
Monsanto
proposal
314,000
41,700
3.32
1.70 E-5
37,000
6.08 E-3
PEI
proposal
314,000
13,840
0.67
8.33 E-6
120,000
1.90 E-3
More
stringent
proposal
314,000
11,751
0.59
7.14 E-6
140,000
1.62 E-3
STYRENE
Current
314,000
„••
323,000
3.76
1.16 E-4
8,600
2.58 E-2
Monsanto
proposal
314,000
32,800
1.29
1.30 E-5
77,000
2.89 E-3
PEI
proposal
314,000
11,806
0.26
4.35 E-6
230,000
9.84 E-4
More
stringent
proposal
314,000
5,935
0.12
2.22 E-6
450,000
5.00 E-4
Maximum risk is the probability in 106 of contracting cancer over a lifetime to the maximum exposed individual.
Annual incidence is cancers per year per lifetime expected to occur over the actual population.
Average risk is the probability in 106 of contracting cancer over a lifetime to the average exposed individual.
-------
control cost is $440 per metric ton, and the total VOC control cost is $100
per metric ton.
PEI evaluated VOC emission controls on two other streams, SGL-14 and
SAN-5, and on all process vents. Incremental control costs ranged from $3,230
to $16,500 per metric ton of VOC controlled. PEI concluded that these costs
were too high for practical implementation.
Monsanto estimated that VOC control by incineration in lieu of its pro-
posed control system would cost $2,400 per metric ton of VOC controlled. PEI
estimated that VOC control by catalytic incineration in lieu of Monsanto's
proposed control system would cost $1,200 per metric ton of VOC controlled.
These costs are summarized in Table 2.
vm
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TABLE 2. VOC CONTROL COSTS AT MONSANTO'S MUSCATINE, IOWA PLANT
Vents
Controlled
SGL 6,15 & 16
SGL 6,15 8 16
SGL 6,15 & 16
SGL 4,6,15 & 16
SGL4.6.15 & 16
SAN 5
All vents with
Monsanto 's
control
All vents with-
out Monsanto's
controls (PEI
estimate)
All vents with-
out Monsanto's
controls (Mon-
santo's esti-
mates)
Control
Method,
Route to
Boiler
Incinerator
Refrigerated
condensers
Catalytic
incinerator
Catalytic
incinerator
Catalytic
incinerator
Catalytic
incinerator
Incinerator
Capital
Cost, $
5,000
30,000
34,200
270,000
870,000
1,400,000
2,200,000
1,100,000
Annual
O&M
Cost, $
[2430 credit]3
6,560
20,760
82,820
338,420
644,000
873,400
1,820,000
Incremental
O&M Cost, $
Base case
Base case
Base case
76,260
255,600
306,380
Quantity of VOC
Controlled,
metric tons
64
64
33
87.6
103.4
121
753
753
Incremental
Quantity of VOC
Controlled,
metric tons
-
-
-
23.6
15.8
17.6
Control Costs,
$ per metric
ton of VOC
[38]a
104
630
955
3,300
5,300
1,200
2,400b
Incremental
Control Cost,
$ per metric
ton of VOC
-
-
-
3,230
16,300
16,500
X
uCredits shown in brackets
Monsanto presents a control cost of $4,860 per metric ton based upon acrylonitrile only.
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1. INTRODUCTION
Monsanto Corporation's (Monsanto) Muscatine, Iowa plant produces acry-
lonitrile butadiene styrene (ABS) resins. The July 1, 1985 Chemical Marketing
Reporter estimated the production capacity at 52,200 megagrams (metric tons)
per year. Monsanto classifies much of the production process as confidential
and/or proprietary and has provided very few details concerning the production
methods and procedures. However, ABS resins are made by the copolymerization
of varying proportions of acrylonitrile (AN), 1,3 butadiene (BD), and styrene
(ST). All three compounds are potential volatile organic compound (VOC) emis-
sions. Since AN has been characterized as a probable human carcinogen, AN
emissions are of particular concern.
The Monsanto plant started up in 1976. At that time, annual AN emissions
were 652 metric tons. Since then process modifications, reduction of process
and fugitive emissions, and installation of an internal floating roof on a
large AN storage tank have reduced annual AN emissions from 652 to 391 mega-
grams. Iowa has responsibility for control of AN and VOC emissions and has
required that Monsanto implement Best Available Control Technology (BACT) at
the Muscatine plant. Monsanto has proposed process modifications where most
of the AN, BD, and ST are recovered and recycled. Monsanto has estimated that
annual AN emissions would be reduced to 44 megagrams. The United States En-
vironmental Protection Agency (EPA) asked PEI Associates (PEI) to determine
whether or not Monsanto's proposed program satisfies BACT requirements and to
review the health risk assessment.
-------
2. EMISSION CONTROL SYSTEMS
2.1 MONSANTO'S PROPOSAL
Monsanto's proposed control system consists of a two stage spray conden-
ser, a flash tank, and a stripping column. Monsanto has classified the system
"proprietary technology" but submitted a two page schematic to the Iowa De-
partment of Water, Air, and Waste Management on May 29, 1986. The two page
schematic is included in this report as Figures 1 and 2. Monsanto labeled
each of the two sheets as Figure 1.
There are four process streams which Monsanto identifies as Streams A, B,
C, and D and the two emission points which Monsanto identifies as SGL-15 and
SGL-16. Stream A consists primarily of steam at 200°C with some AN, BD, and
ST. This stream is introduced into a spray condenser where chilled water is
circulated. The system is under vacuum, and the vapors exit through a three-
inch diameter stack identified as SGL-15. These vapors are at 75°C and pro-
bably are saturated with water vapor. The condensate is recirculated except
for a slipstream which is sent to the plant's wastewater treatment facility.
Stream B consists mostly of steam at 200°C with AN, BD, and ST also pre-
sent. This is introduced into a second spray condenser through which chilled
styrene is introduced. The condensate goes to a separator where the organic
layer floats on top of the water layer. The organic layer is chilled to be-
tween 3 and 5°C. Most of the organic layer is recirculated to the spray con-
denser facility. Monsanto provides no indication as to the relative volumes
of these two streams. The schematic for this part of the treatment system is
shown in Figure 1 which Monsanto labels "Figure 1 - Anticipated SGL-15 Treat-
ment Train."
The overheads from the flash tank go to a steam stripping column. The
vapor from the steam stripping column is condensed and collected in a water
separator. The organic layer floats on top of the water layer. It is col-
lected and reused in the plant. The water layer is recycled to the steam
-------
^v
VACUUM
PUMP
SGL-15
•IVHR. H?0
•IVHR.ACRYLONITRILE
•
-------
stripping column. Uncondensed vapor is vented through a four-inch diameter
stack identified as SGL-16. The condensate from the steam stripping column is
sent to the wastewater treatment facility.
The schematic for this part of the treatment system is shown in Figure 2
which Monsanto labels "Figure 1: Anticipated SGL-16 Treatment Train.."
Monsanto projects that annual AN emissions will be reduced from the pre-
sent 391 metric tons to 44 metric tons. Annual ST emissions are projected to
be reduced from 325 to 35 metric tons. BD emissions will remain at 42 metric
tons. AN emissions are reduced by 93 percent from the emission rate at the
time of the 1976 startup and by 89 percent from present operating conditions
which includes the internal floating roof in the AN storage tank. ST emis-
sions are projected to be reduced by 89 percent from present operating con-
ditions. BD emissions will be essentially unaffected. Monsanto has not pro-
vided the bases for these emission estimates.
Monsanto projects that the AN control cost through the proposed control
system is $160 per metric ton. This estimate is presented as a single large
solid black dot on a graph showing control cost as a function of percent emis-
sion reduction. There is no supporting evidence or information that could
serve as a basis for evaluating this cost estimate. Cost estimates for alter-
nate control methods are presented as other large solid black dots on the same
graph. This cost does not take into account a reduction of ST emissions from
324 to 36 megagrams. If both AN and ST emission reductions are taken into
accounts, the control cost is $87 per metric ton of VOC controlled, a very
nominal cost.
2.2 MONSANTO'S PROPOSED ALTERNATIVE CONTROL METHODS
Monsanto evaluated the following alternate AN emission control strate-
gies:
Incineration or condensation of the largest AN process sources.
Monsanto's estimated control cost is $2100 per metric ton of AN.
Monsanto estimates that AN emissions would be reduced to 21 percent
of 1976 levels or 137 metric tons per year.
Additional particulate control and recycling of major off-gas
streams with all off-gas streams incinerated in the coal-fired plant
boiler. Monsanto's estimated control cost is $4900 per metric ton.
Monsanto estimates that AN emissions would be reduced to 5 percent
-------
en
STREAM C
o IVHR. H20
oZVHR. ACRYLONITRILE
oTWHR. STYRENE
o4VHR. 1,3-BUTADlENE
o 3-5° C
STREAM D »
•36600VHR. H?0
olOOVHR. ACRYLONITRILE
olCVHR. STYRENE
o< IVHR. 1,3-BUTADIENE
o200° C
FLASH TANK
TO RECYCLE ««-
STEAM •
-*• TO W.T.P.
STRIPPING
COLUMN
CONDENSER
SGL-16
° IVHR. H?0
• 3VHR. ACRYLONITRILE
o3VHR. STYRENE
-4VHR. 1,3-BUTADIENE
H60 C
SEPARATOR
MONOMER LAYER
WATER LAYER
J
TO W.T.P.
—>-TO RECYCLE
FIGURE I:
ANTICIPATED SGL-16 TREATMENT TRAIN
(REVISED 7/H/86)
Figure 2. Anticipated SGL-16 Treatment Train. -
-------
percent of 1976 levels or 33 metric tons per year. Monsanto ex-
pressed misgivings about this control method since a similar system
at its plant near Cincinnati, Ohio, has been the cause of fires and
downtime.
2.3 PEI'S PROPOSED CONTROL SYSTEM
Monsanto's proposed emission control system appears to be technically
feasible and can provide good controls of AN and other VOC emissions at an
acceptable cost. This conclusion is based upon Monsanto's cost and perfor-
mance estimates. However, better control can be achieved and at an acceptable
cost for some of the process vents. Five process vents comprise most of the
remaining VOC emissions.
Emission Point
SGL-15 (Spray condenser
vent)
SGL-16 (Water separator
vent)
SGL-6 (Unidentified)
Subtotal
SGL-4 (Unidentified)
SAN-5 (Unidentified)
Total all emission
points
Annual Emissions (Metric tons or megagrams)
Acrylonitrile
3.6
10.9
0.4
14.9
15.6
4.8
44
Butadiene
11.9
15.9
0.2
28
2.1
8.0
42
>
Styrene
4.0
10.9
6.2
21.1
5.9
2.9
35
Flow rate,
scfm
2.1
9.0
78
89
3770
26,640
51,336
SGL-15, SGL-16, and SGL-6 have a combined flow rate of less than 100
standard cubic feet per minute (scfm). These streams could be ducted to and
incinerated in the new plant boiler or the existing boiler. The air require-
ments for the new boiler are about 917 cfm, so this stream easily could be
incinerated without upsetting either of the boilers. PEI estimates the capi-
tal and annual costs of ducting these streams to the boiler to be $5,000 and
$1,320, respectively. However, the annual fuel value of the three streams is
about 2500 million Btu. At $1.50 per million Btu, this provides a net credit
of $2,430 as well as control emissions of 14.9 metric tons of AN, 28 metric
tons of BD, and 21 metric tons of ST. Even if an incinerator must be provid-
ed, 14.9 metric tons of AN and 64 metric tons of VOC can be controlled at an-
nual costs of $440 and $100 per metric ton, respectively.
-------
Additionally, the SGL-15 stream is 27.6 percent VOC and the SGL-16 stream
is 11.9 percent VOC. These stream concentrations are probably above the upper
explosion limit (UEL); but as they leave the vents and mix with air, they
would become potentially ignitable. Safety considerations probably will re-
quire some type of control for these two streams.
PEI evaluated AN and VOC control by refrigerated condensation for these
three streams. PEI assumed a standard refrigeration unit, heat exchanger,
dehumidification equipment, instrumentation, engineering, fans, and ductwork
for each stream. The capital and annual costs for each stream will be $11,400
and $6,920, respectively. The units would cool to -30PF which does not
provide any BD control. Achievable control levels and control costs are:
Stream
SGL-15
SGL-16
SGL-6
Total
Annual
metric tons
AN
3.6
10.9
0.4
14.9
ST
4.0
10.9
6.2
21.1
Percent
controlled
AN
90.5
85.8
0
85.2
ST
99.7
99.5
88.8
96.2
Control cost
per metric ton
AN
2100
740
No control
1630
VOC
950
340
1260
630
PEI contacted firms that provide refrigerated condensers that cool to
-100°F and -150°F. These lower temperatures would provide additional AN and
ST control as well as control BD emissions. However, each unit would cost
$200,000 which is excessive.
2.4 ALTERNATE CONTROLS CONSIDERED
The SGL-4 stream has a 3770 cfm flow and annually contains 15.6 metric
tons of AN, 2.1 metric tons of BD, and 5.9 metric tons of ST. This stream has
183 ppm VOC and can be controlled with a catalytic incinerator. With 60
percent heat recovery, fuel requirements will be about one million Btu per
hour. The VOC stream can supply about 10 percent of this; so net fuel re-
quirements are about 0.9 million Btu per hour.
PEI estimates the capital cost at $240,000 and the annual cost at
$76,260. This corresponds to an incremental control cost of $4,890 per metric
ton for AN and $3,230 per metric ton for VOC.
-------
An alternative control method is a non-catalytic incinerator without heat
recovery. Higher fuel costs would be offset by lower capital costs. The cap-
ital cost would be $165,000, and annual costs would be $83,540. This corre-
sponds to an incremental control cost of $5,360 per metric ton of AN and
$3,540 per metric ton of VOC. Hence, catalytic incineration is cheaper.
The combined costs of controlling streams SGL-15, SGL-16, and SGL-6 by
ducting to the boiler and of controlling stream SGL-4 by catalytic incinera-
tion are a capital cost of $245,000 and an annual cost of $73,830. Control
costs per ton of AN and per ton of VOC are $2420 and $840, respectively.
SAN-5 is the fifth major AN and VOC source of emissions. The calculated
flow rate is 26,640 cfm, and the VOC content is 18 ppm. This renders control
very expensive. Capital costs and annual costs are $600,000 and $255,600,
respectively. This corresponds to incremental control costs of $53,300 per
metric ton of AN and $16,300 per metric ton of VOC.
PEI evaluated incinerating VOC emissions-from all process vents. A
55,000 acfm incinerator would be required at a capital cost of $1,400,000;
annual costs would be $644,800. This corresponds to incremental VOC control
costs of $16,500 per metric ton.
The bases for (1) the calculation of AN,BD, and ST concentrations and
volumes in vent streams, (2) total flow rates from vent streams, (3) capital
costs of AN and VOC controls, (4) annual costs of AN and VOC controls, and (5)
costs per metric ton of AN and VOC controlled are shown in Appendix A. Cost
data is presented in Table 1.
Carbon adsorption is widely used to control VOC emissions and is often
technically and economically superior to incineration because the controlled
VOC can be recovered and recycled. However, carbon adsorption does not work
well if the VOC stream has (1) a relative humidity above 50 percent, (2) a
temperature above 40°C (104°F) or, (3) a tendency to polymerize. For these
VOC streams, all three conditions prevail and carbon adsorption is considered
unfeasible.
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3. EXPOSURE CALCULATIONS
Exposure calculations for the Monsanto facility at Muscatine, Iowa, were
made using the results obtained from the Human Exposure Model (HEM). The
overall resulting exposures are given in terms of people and concentrations
(person-yg/m3) within a 50-km radius of the facility. In addition, the maxi-
mum ambient impact of the emission sources was estimated at a receptor outside
of the plant boundary and is reported.
3.1 DESCRIPTION OF HUMAN EXPOSURE MODEL
Health risk assessment of an airborne pollutant requires computation of
the ambient concentrations of the pollutant and summation of the products of
the concentrations of the pollutant and the population exposed to the concen-
tration within the region of study. Ambient concentration estimates were ob-
tained using the SHEAR submodel of HEM. The concentrations obtained were then
supplied as input concentrations to HEM. Other HEM inputs included the fol-
lowing:
Card 1
Number of concentration rings input (10 in this case)
Two logical variables controlling printed output options
The number of sources included
Optional concentration correction factor (not used)
Optional unit risk estimate (not used)
Card 2
Distances from the plant centroid to each ring
Card 3
Pollutant name for title output
Card 4
Concentration units for title output
-------
Card 5
Title
Card 6
Latitude and longitude of the plant centroid
Making use of the latitude and longitude for the approximate center of
the Monsanto facility, HEM extracted site-specific population data from the
U.S. Census Bureau files using data at the Enumeration District/Block Group
(ED/BG) level. All accessed files contain 1980 population statistics. The
population data were used in combination with the input concentration arrays
by HEM to develop patterns of exposure, risk, and hazard. These were summed
over the 50-km region around the plant to produce areawide control scenario
specific exposure totals. Exposure is defined by HEM as the occurrences of
contact between humans and pollutants.
3.2 HEM CALCULATIONS AND RESULTS
Exposures to acrylonitrile, 1,3 butadiene, and styrene were obtained for
each of four control scenarios for a region encompassing 50 km at 10 downwind
distances.
The four control scenarios include: the current operation at the facil-
ity with storage emission controls; a proposed Monsanto control strategy to
combine emissions from SGL-9 through SGL-14 and controlling with a two stage
spray condenser, a flash tank, and a stripping column; and two PEI control
scenarios. These control scenarios are described in Table 3.
Each vent, stack, or other emission point was detailed in terms of the
effluent release characteristics for the purposes of modeling. Table 4 de-
scribes each vent and the associated stack parameters. For each control sce-
nario emissions of acrylonitrile, 1,3 butadiene, and styrene vary according to
the type and degree of control. The emissions associated with each source are
listed in Tables 5 through 7 along with the total for each scenario.
Tables 8 through 10 present the risk and exposure to humans in the vari-
ous HEM formats. The results show that as emissions decrease the various max-
imum and overall cumulative exposures and risks decrease. Only in Case 2 of
1,3 butadiene do the exposure levels increase slightly. This is due to little
10
-------
TABLE 3. ALTERNATE CONTROL CASES OF THE AN EMISSIONS
AT THE MONSANTO MUSCATINE FACILITY
Case
Identification
Current
Monsanto antic-
ipated post-
project
Proposed PEI
control
More stringent
proposed PEI
control
No.
1
2
3
4
Comment
Only controls are on storage
tanks; all other emissions as
in pre-1986 cases
Emissions from'SGL-9 through
SGL-14 are combined and two
new sources SGL-15 and SGL-16
result
Emissions from SGL-6, SGL-15,
and SGL-16 may be incinerated
in a new or existing boiler
Emissions from SGL-4 may be
incinerated in a catalytic
incinerator
Sources
affected
Storage
SGL-9
through
SGL-16
SGL-6
SGL-15
SGL-16
SGL-4
SGL-6
SGL-15
SGL-16
Percent
control
98.6
96. Oa
99.5
99.5
99.5
99.5
Represents overall control comparing the old emissions of SGL-9 through
SGL-14 of 363,077 kg/yr to the proposed SGL-15 and SGL-16 emissions of
14,500 kg/yr.
11
-------
TABLE 4. SOURCE CHARACTERISTICS FOR EMISSIONS OF ACRYLONITRILE,
1,3 BUTADIENE AND STYRENE FROM MONSANTO
Vent
description
SGL-1
SGL-5
SGL-6
SGL-4
SGL-9
SGL-10
SGL-11
SGL-12
SGL-13
SGL-14
SGL-15
SGL-16
SGL-7
SGL-8
SGL-2
SGL-3
SAN-1
SAN-4
LNIC-1
LNIC-2
LNIC-3
LNIC-4
LNIC-5
LNIC-6
LNIC-7
LNIC-8
SAN-5
SAN-2
SAN-3
Fugitive
Storage
Stack
height,
m
20
20
20
20
13.7
13.7
12.1
13.7
16.7
18.9
15.0
15.0
13.5
13.5
13.5
13.5
25
13.5
.20
20
20
20
20
13.5
13.5
15
21.0
13.5
13,5
7
14.2
Stack
diameter,
m
0.051
0.051
0.076
0.616
0.267
0.610
0.102
0.203
0.607
1.06
0.076
0.102
0.210
0.210
0.210
0.210
0.051
0.603
0.051
0.025
0.051
0.051
0.051
0.321
0.321
0.337
1.16
0.406
0,406
50*
0.1
Gas
velocity,
m/s
0.79
0.76
8.14
5.96
20.2
6.46
1.13
15.0
30.6
21.1
0.218
0.523
1.22
1.22
1.22
1.22
2.63
26.5
0.015
0.037
0.052
0.23
0.19
0.23
0.23
21.2
11.9
1.33
1.33
0.1
O.la
Gas
temperature,
°K
294.1
294.1
294.1
299.7
343
301.9
308.6
326.2
326.8
307.6
299.7
290
294.7
294.7
295.8
295.8
295.8
335.2
294.1
295.2
293
301
293.6
334.1
334.1
335.2
290.2
351.9
351.9
293
293
Assumed.
12
-------
TABLE 5. EMISSION RATES FOR ACRYLONITRILE FOR EACH
CONTROL CASE AT MONSANTO IN MUSCATINE, IOWA
Vent
l C 1 1 U
identification
SGL-1
SGL-5
SGL-6
SGL-4
SGL-9
SGL-10
SGL-11
SGL-12
SGL-13
SGL-14
SGL-15
SGL-16
SGL-7
SGL-8
SGL-2
SGL-3
SAN-1
SAN-4
LNIC-1
LNIC-2
LNIC-3
LNIC-4
LNIC-5
LNIC-6
LNIC-7
LNIC-8
SAN- 5
SAN-2
SAN-3
Fugitive
Storage
Acrylonitrile emission rates (kg/yr)
Case 1
0.165
5.13
363
15,610
110,410
23,340
687
12,780
34,930
180,930
a
a
370
370
99.3
99.3
3.48
1,870
11.8
1.32
90.5
2.15
62.2
11.6
11.6
377
4,780
133
133
2,600
1,000
Total 391,081.545
Case 2
0.165
5.13
363
15,610
b
b
b
b
b
b
3,600
10,900
370
370
99.3
99.3
3.48
1,870
11.8
1.32
90.5
2.15
62.2
11.6
11.6
377
4,780
133
133
2,600
1,000
42,504.545
Case 3
0.165
5.13
1.82
15,610
b
b
b
b
b
b
18.0
54.5
370
370
99.3
99.3
3.48
1,870
11.8
1.32
90.5
2.15
62.2
11.6
11.6
377
4,780
133
133
2,600
1,000
27,715.865
Case 4
0.165
5.13
1.82
78.5
b
b
b
b
b
b
18.0
54.5
370
370
99.3
99.3
3.48
1,870
11.8
1.32
90.5
2.15
62.2
11.6
11.6
377
4,780
133
133
2,600
1,000
12,184.365
Proposed new source.
Eliminated with proposed controls.
13
-------
TABLE 6. EMISSION RATES FOR 1,3 BUTADIENE FOR EACH
CONTROL CASE AT MONSANTO IN MUSCATINE, IOWA
Vent
identification
SGL-1
SGL-5
SGL-6
SGL-4
SGL-9
SGL-10
SGL-11
SGL-12
SGL-13
SGL-14
SGL-15
SGL-16
SGL-7
SGL-8
SGL-2
SGL-3
SAN-1
SAN-4
LNIC-1
LNIC-2
LNIC-3
LNIC-4
LNIC-5
LNIC-6
LNIC-7
LNIC-8
SAN-5
SAN-2
SAN-3
Fugitive
Storage
Total
1,3 Butadiene emission rates (kg/yr)
Case 1
a
a
200
2,100
12,800
3,800
700
600
1,600
8,700
c
c
600
600
1,200
1,200
a
a
a
a
a
a
a
a
a
a
8,000
a
a
d
a
42,100
Case 2
a
a
200
2,100
b
b
b
b
b
b
11,900
15,900
600
600
1,200
1,200
a
a
a
a
a
a
a
a
a
a
8,000
a
a
d
a
41,700
Case 3
a
a
1.0
2,100
b
b
b
b
b
b
59.5
79.5
600
600
1,200
1,200
a
a
a
a
a
a
a
a
a
a
8,000
a
a
d
a
13,840
Case 4
a
a
1.0
10.5
b
b
b
b
b
b
59.5
79.5
600
600
1,200
1,200
a
a
a
a
a
a
a
a
a
a
8,000
a
a
d
a
11,750.5
Not emitted.
Eliminated with proposed controls.
c Proposed new source.
Not determined.
14
-------
TABLE 7. EMISSION RATES FOR STYRENE FOR EACH
CONTROL CASE AT MONSANTO IN MUSCATINE, IOWA
Vent
identification
SGL-1
SGL-5
SGL-6
SGL-4
SGL-9
SGL-10
SGL-11
SGL-12
SGL-13
SGL-14
SGL-15
SGL-16
SGL-7
SGL-8
SGL-2
SGL-3
SAN-1
SAN-4
LNIC-1
LNIC-2
LNIC-3
LNIC-4
LNIC-5
LNIC-6
LNIC-7
LNIC-8
SAN-5
SAN-2
SAN-3
Fugitive
Storage
Total
Styrene emission rates (kg/yr)
Case 1
a
b
6,200
5,900
24,400
7,700
600
5,100
53,500
213,800
d
d
b
b
a
a
b
1,300
b
b
b
b
b
b
b
1,400
2,900
100
100
e
e
323,000
Case 2
a
b
6,200
5,900
c
c
c
c
c
c
4,000
10,900
b
b
a
a
b
1,300
b
b
b
b
b
b
b
1,400
2,900
100
100
e
e
32,800
Case 3
a
b
31
5,900
c
c
c
c
c
c
20
54.5
b
b
a
a
b
1,300
b
b
b
b
b
b
b
1,400
2,900
100
100
e
e
11,805.5
Case 4
a
b
31
29.5
c
c
c
c
c
c
20
54.5
b
b
a
a
b
1,300
b
b
b
b
b
b
b
1,400
2,900
100
100
e
e
5,935
Not emitted.
Less than 100 kg/yr and assumed equal to 0.0 kg.
c Eliminated with proposed controls.
d n
Proposed new source.
e Not emitted.
15
-------
TABLE 8. EXPOSURE CALCULATION RESULTS FOR ACRYLONITRILE
AT THE MONSANTO MUSCATINE FACILITY
Population exposed, persons
Total emissions, kg/yr
Maximum concentration, yg/m
Maximum exposure, person-yg/m
Maximum risk3, cancers/lifetime/
10 persons
Cumulative exposure, person-yg/m3
Cumulative hazard , cancers/
lifetime/population
Annual incidence0, cancers/yr
Repeat interval, yrs/cancer
Average risk , cancers/lifetime/
10 persons
Case
1
314,000
391,082
30.2
1.10 E-l
2,050
35,400
2.41
0.034
29
7.68
Case
2
314,000
42,505
6.72
2.46 E-2
457
4,060
2.76 E-l
0.0039
250
0.88
Case
3
314,000
27,716
3.76
1.38 E-2
256
2,570
1.75 E-l
0.0025
400
0.56
Case
4
314,000
12,184
2.70
9.88 E-3
184
1,180
8.05 E-2
0.0012
870
0.26
a Maximum risk is the probability in 10 of contracting cancer over a life-
time to the maximum exposed individual.
b The cumulative hazard is the cancers per lifetime expected to occur over
the actual population.
c Annual incidence is cancers per year expected to occur over the actual
population.
d Average risk is the probability in 10 of contracting cancer over a life-
time to the average exposed individual; it is the product of unit risk and
the areawide average concentration.
16
-------
TABLE 9. EXPOSURE CALCULATION RESULTS FOR 1,3 BUTADIENE
AT THE MONSANTO MUSCATINE FACILITY
Population exposed, persons
Total emissions, kg/yr
Maximum concentration, yg/m
Maximum exposure, person-ug/m
Maximum risk9, cancers/lifetime/
10 persons
Cumulative exposure, person-ng/m
Cumulative hazard , cancers/life-
time/population
Annual incidence0, cancers/yr
Repeat interval, yrs/cancer
Average risk , cancers/lifetime/
10 persons
Case
1
314,000
42,100
4.47
1.64 E-2
2.06
3,930
1.81 E-3
2.56 E-5
39,000
5.76 E-3
Case
2
314,000
41,700
7.06
2.58 E-2
3.32
4,070
1.91 E-3
1.70 E-5
37,000
6.08 E-3
Case
3
314,000
13,840
1.42
5.21 E-3
0.67
1,270
5.97 E-4
8.33 E-6
120,000
1.90 E-3
Case
4
314,000
11,751
1.25
4.57 E-3
0.59
1,080
5.09 E-4
7.14 E-6
140,000
1.62 E-3
a Maximum risk is the probability in 10 of contracting cancer over a life-
time to the maximum exposed individual.
The cumulative hazard is the cancers per lifetime expected to occur over
the actual population.
c Annual incidence is cancers per year expected to occur over the actual
population.
Average risk is the probability in 10 of contracting cancer over a life-
time to the average exposed individual; it is the product of unit risk and
the areawide average concentration.
17
-------
TABLE 10. EXPOSURE CALCULATION RESULTS FOR STYRENE
AT THE MONSANTO MUSCATINE FACILITY
Population exposed, persons
Total emissions, kg/yr
3
Maximum concentration, yg/m
Maximum exposure, person-yg/m
Maximum risk3, cancers/lifetime/
10 persons i
Cumulative exposure, person-yg/m
Cumulative hazard , cancers/life-
time/population
Annual incidence0, cancers/yr
Repeat interval, yrs/cancer
Average risk , cancers/lifetime/
10 persons
Case
1
314,000
323,000
13.0
1.86 E-l
3.76
27,900
8.10 E-3
1.16 E-4
8,600
2.58 E-2
Case
2
314,000
32,800
4.46
1.63 E-2
1.29
3,120
9.06 E-4
1.30 E-5
77,000
2.89 E-3
Case
3
314,000
11,806
0.90
3.29 E-3
0.26
1,070
3.09 E-4
4.35 E-6
230,000
9.84 E-4
Case
4
314,000
5,935
0.41
1.49 E-3
0.12
541
1.57 E-4
2.22 E-6
450,000
5.00 E-4
a c
Maximum risk is the probability in 10 of contracting cancer over a life-
time to the maximum exposed individual.
The cumulative hazard is the cancers per lifetime expected to occur over
the actual population.
c Annual incidence is cancers per year expected to occur over the actual
population.
Average risk is the probability in 10 of contracting cancer over a life-
time to the average exposed individual; it is the product of unit risk and
the areawide average concentration.
18
-------
change in the same emissions between Cases 1 and 2 and also due to the low
plume rise for vents in Case 2 (SGL-15 and SGL-16) compared to SGL-9 through
SGL-14. The lower plume rise and similar emissions cause higher ambient im-
pacts than the previous case.
Exposure calculation results presented in Tables 8 through 10 are for
each control case. The grid map for exposure to acryloinitrile under scenario
Number 4 is contained in Appendix B. The output for the HEM calculations is a
separate report entitled "Human Exposure Model Output for Acrylonitrile, 1,3
Butadiene, and Styrene Emissions at Monsanto in Muscatine, Iowa." Table 11
describes some of the definitions for exposure and risk used by HEM.
19
-------
TABLE 11. DEFINITION OF PARAMETERS USED IN HUMAN EXPOSURE CALCULATIONS
PfiRflffTER UNITS
Unit risk/ cancers/
Risk factor lifetime/
person/
ug/m"
Corcentraticn ug/m1
Population/
People
persons
DEFINITION DERIVATION
Probability of contracting cancer due to Fron technical literature
a constant exposure over a lifeti«e"'
to an a.ibient concentration of 1 ug/uj.
The Sfbient air iepact due to emissions
frou the source! soaetiaes presented as
«ax]»mr or cininun.
The nurber of people exposed to a con-
centration equal to or greater than a
given level; usually defined out to
58 ki frrts the source.
Dispersion iiodel results'
Bureau of Census Data, 1988
Exposure person x
Level
None
Risk/ careers/
Risk level lifeline/
person
Hazard
cancers/
lifeline
Lifetime careers/
incidence lifetine
The result of a person or persons being Concentration « population
in contact mtn ambient air containing
a pollutant that can be inhaled and
cause detrimental health effects! the
sus of ail exposures in a given region is
referred to as the cunulative exposure.
Discrete interval for performing
calculations.
)S order of ragMtuce steps be-
tween the raximus arid ainieui values
of concentration or risk
Probability of con'.ractir,; cancer due to Concentration x unit risk
a constar.t expire over a lifeline to a
given coricer.tration.
(cunulative) exposure x unit risk
OR
Risk level x population
The probable risk c.f the exposed popula-
tion contracting cancer over a lifetiae
due to the anbient concentrations pro-
duced by the modeled plant or facility!
referred to as cumulative ha:ard Htien ex-
pressing the rUt of the cuaulative
exposure.
The probable njnber of cancers resulting Exposure x unit risk
frosi lifetine exposure to a given con- OR
centrationi used in connection with the Maxinun concentration x population
raMBUi concentration. x unit risk
Br.n-jal cancers/
incidence yr
Repeat yrs/
interval cancer
The probable nuteber of annual cancers in Exposu-e x unit risk / (78 yrs per lifetime)
the population resulting from lifetime OR
exposure to the concentrations predicted Cunulative hazard/ (78 yrs per lifetime)
to occur in the 50-kB region.
The estimated nunber of years between
the occurrence of an excess cancer due
to emissions frm the Bodeied plant or
facility.
ftnnual incidence"1
(a) B lifetiie is defined as 70 years.
20
-------
4. BACT DETERMINATION
PEI has determined BACT to be the proposed Monsanto control system com-
bined with incineration of the streams from SGL-6, SGL-15, and SGL-16. The
proposed Monsanto system and complete incineration of all process vent streams
were also considered. Annual emission levels, control costs, and incremental
control costs per metric ton controlled are:
Control Method System
Monsanto 's Controls
PEI's BACT
Complete Incineration
Annual Emissions,
metric tons
AN
44
29.1
4
BD
42
14.9
4
ST
35
13.0
0.4
Total
Control
Cost. $
$55,520
$62,080
$644,800
Incremental Control
Cost, $ per metric ton
of VOC controlled
AN
$160
$440
$23,200
VOC
$87
$100
$13,000
PEI believes that $440 per metric ton is an acceptable BACT incremental
cost for AN and that $100 per metric ton is an acceptable BACT incremental
cost for VOC. Monsanto has cited unidentified EPA documents giving $1,300 per
metric ton as an acceptable upper limit control cost for benzene and $1,700
per metric ton as an upper limit control cost for VOC. PEI is aware of sit-
uations where BACT has required higher VOC control costs than those cited by
Monsanto. Monsanto's proposed control system reduces the plant to a 121 me-
tric ton per year VOC source. PEI's BACT recommendation reduces annual VOC
emissions to about 58 megagrams.
PEI evaluated incineration of all and individual process vents and con-
cluded that the incremental costs outweighed the incremental benefits.
21
-------
APPENDIX A
SUMMARY AND OUTLINE OF CALCULATIONS
AND COST ESTIMATES
A-l
-------
ni IFNT U-S. EPA _ /^•=^\\ PN _ 3655~37 Sheet No._L
mr.ATinM Monsanto-Muscatine. Iowa ( QQJ Checked By _ Date
SUR.IFP.T VOC Emissions _ x Computed Ry JES n^July 15, 1986
Monsanto's reported annual emissions are:
Emission Plant Annual Emissions (Metric Tons or megagrams)
Acrylonitrile Butadiene Styrene
SGL-15 (Spray Condenser Vent) 3.6 11.9 <4.0
SGL-16 (Water Separator Vent) 10.9 15.9 10.9
SGL-4 (Unidentified) 15.6 2.1 5.9
SGL-6 (Unidentified) 0.4 0.2 6.2
SAN-5 (Unidentified) 4.8 .8.0 2.9
Subtotal 35.3 38.1 <29.9
Total, All Emissions 44 42 35
One Pound Mole - 22.414 liters x 2731*15.5 I - fefit
convert to grams liters to
' 60°F to pounds cubic feet
For Acrylonitrile 3.6 x 2200 x 379.4 cc c-n cr, 1C
- 5O6 - = 56'630 SGL'15
10.9 ,2200 x 379.4 = SG[__16
oo. Uo
15.6 x 2200 x 379.4 _ 9.K .nn cr. ,
- 53706 -- 245,400 SGL-6
6
' = 75,510 SAN-5
For Butadiene 11.9 *nOO x 379.4 SGL_15
' = 245'360
2.1 x 2200 x 379.4 _ .„ ..n .p. .
- 54709 -- 32,410 SGL-4
0.2 x 2200 x 379.4 _ , nQn -r, -
- 54~0g -- 3,090 SGL-6
-------
r...FMT U'S- EPA x-^ 3655-37 Sheet Na_L
Monsanto-Muscatine, Iowa I QQI J checked By Date
_.,_.__. VOC Emissions ^^P/ r teia JES _ f July 15, 1986
SUBJECT v x Computed By Date i !_
Butadiene (continued)
8.0 x 2200 x 379.4
54.09
For Styrene 4.0 x 2200 x 379.4
= 123,450 SAN-5
= 32,050 SGL-15
104.16
w 770 A
- = 87,350
*'** 104°16 ' = 47>280 SGL'4
6.2 x 2200 x 379.4 _ .q ,Rn >p. ,
-- 49'680 SGL"6
2.9 x 2200 x 379.4 =
104.16
Assume that the plant operates 90 percent of the time. Then annual minutes = 365
days x 24 hours x 60 minutes x 0.9 = 473,040.
Flow in SCFM = Annual flow
473,040
Emission Point Annual Flow, SCF
Acrylonitrile Butadiene Styrene Total SCF SCFM
SGL-15
SGL-16
SGL-4
SGL-6
SAN-5
Monsanto indicates that the SGL-15 stack has a diameter of 0.076 meters and a flow
rate of 0.218 meters/second.
Flow volume in cubic meters per second = pi x radius2 x velocity = pi x 0.0382 x
0.218 = 0.000989 m3/s = cubic meters/second x 60 x 35.3 ft3/m2 =2.1 cfm
VOC concentration = ^p x 1,000,000 = 276,190 ppm
Monsanto indicates that the SGL-16 stack has a diameter of 0.102 meters and a flow
rate of 0.523 meters/second.
56,630
171,470
245,400
6,290
75,510
183,630
245,360
32,410
3,090
123,450
32,050
87,350
47,280
49,680
23,290
272,310
504,180
325,090
59,060
222,250
0.58
1.07
0.69
0.12
0.47
-------
rill_.1T U.S. EPA ^^ _.. 3655-37 ou . .. 3
CLIENT _ /X^^S. _ Sheet No._
mr.AT.nM Monsanto-Muscatine. Iowa Dl Checked By _ Date
S..R..PP.T VOC Em1SSi°nS S computed *y JES
Flow volume in cubic meters per second = pi x radius2 x velocity = pi x 0.0512 x
0.523 = 0.00427 m3/s = cubic meters/second x 60 x 35.3 ft3/m2 = 9.0 cfm
1 D7
VOC concentration = ^^ x 1,000,000 = 118,900 ppm.
Monsanto indicates that the SGL-4 stack has a diameter of 0.616 meters and a flow
rate of 5.96 meters/second.
Flow volume in cubic meters per second = pi x radius2 x velocity = pi x 0.3082 x
5.96 = 1.78 m3/s = cubic meters/second x 60 x 35.3 ft3/m3 = 3770 cfm
VOC concentration = 0.69 . nnn nnn _ .Q, nnm
3770 * l,Uuu,UUU = 183 ppm.
Monsanto indicates that the SGL-6 stack has a diameter of 0.076 meters and a
velocity of 8.14 meters per second.
Flow volume in cubic meters per second = pi x 0.0382 x 8.14 = 0.0369 m3/s =
0.0369 x 60 x 35.3 = 78 cfm
VOC concentration = 0.12 , nnn nnn _ 1K/tn nnm
jo x IjOOOjOOO = 1540 ppm.
Monsanto indicates that the SAN-5 stack has a diameter of 1.16 meters and a flow
rate of 11.9 meters per second.
Flow volume in cubic meters per second = pi x radius2 x velocity
= pi x 0.582 x 11.9 = 12.58 m3/s = cubic meters per second x 60 x 35.3 ft3/m3
= 26,640
VOC concentration = 0.47 , nnn nnn _ ,p
ye g/tn x IjOOOjUOO = 18 ppm.
26,640
The Handbook of Chemistry and Physics cites the heat of combustion of styrene as
1047.1 kilocalories per grammole.
In Btu per pound, this is 1047.1 .„ R I _ .R nQt. R.II/lh
10O6 x 453'6 x OT2520 " 18'095 Btu/lb
mol. wt. grams Btu/cal
per pound
Butadiene and acrylonitrile are also unsaturated molecules and their heats of
combustion will also be about 18,000 Btu/pound. Hence, the heat value of the
SGL-15 and SGL-16 streams - wt. in pounds x 18,000 = 2200 (3.6 + 11.9 + 4.0 + 10.9
+ 15.0 + 10.9) 18,000 = 2230 million Btu per year.
-------
CLIENT.
U.S. EPA
LOCATION Monsanto-Muscatine, Iowa
SUBJECT.
VOC Emissions
PN.
3655-37
Checked By.
. Sheet No..
Date
Computed By.
JES
Date
July 15, 1986
Air requirements for the 5,000 pounds of steam per hour boiler. This is about 5 million
Btu per hour which corresonds to about 5,000 cubic feet of natural gas per hour.
20 + 8N
2C02 + 2H20 + 8N2
One volume of gas requires ten volumes of air. Allow 10 percent extra for excess air and
higher hydrocarbons (ethane for example) in the natural gas
5,000 ft3 of natural gas requires 55,000 ft3 of air
55,000 ft3 per hour corresponds to 917 cfm.
The SGL-6 stream has a fuel value of 2200 (0.4 + 0.2 + 6.2} 18,000 = 269 million Btu
per year.
-------
CLIFNIT
-s- EPA
mr.ATinN Monsanto-Muscatine, Iowa
s..R..Pr.T VQC Emissions _
3655-37
Checked By
Computed Ry
JES
Sheet Nn
Date
16. 1986
A.
B.
Costs to route SGL-15, SGL-16, and SGL-6 to the process boiler. Installed costs
for ductwork and fans are from "Means Mechanical Cost Data, 1986".
3 inch flexible ductwork, 500 linear feet
4 inch flexible ductwork, 200 linear feet
Centrifugal fan, airfoil, motor, and drive,
0.5 HP
Connections, to vents and boiler air supply
Subtotal
Engineering and design, 50 percent
Contingencies, 30 percent
$ 900
390
1170
250
$2710
1360
810
14880
- say $5,000
Annual Costs
Capital recovery (10 years
Electricity at 6 cents per
Maintenance, 3 percent
Taxes and insurance, 2 percent
Subtotal
Fuel credit at SI
Btu, 2800 million
Net cost [credit]
12 percent)
kwh
50 per million
Btu
$ 890
180
150
100
$1320
[3750]
[$2430]
Cost of a catalytic incinerator to control SGL-4
$160,000
80,000
Catalytic Incinerator rated at 3800 cfm
with 60 percent heat recovery
Installation (50 percent)
(Vendor quotation, Metpro, Inc.,
Harleysville, Pennsylvania)
$240,000
Annual Costs
Capital recovery (10 year, 12 percent) $42,500
Electricity at 6 cents per kwh 360
Maintenance, 3 percent 7,200
Taxes and insurance, 2 percent 4,800
Fuel (0.9 million Btu/h at $2.00) 14,200
Catalyst replacement, 2 percent 7.200
Total annual cost $76,260
Control cost per metric ton of AN 76,260 «,,, onn
15.6 = $4'890
Control cost per metric ton of VOC $76.260 _
23.6 "
-------
CLIENT U'S- EPA /^^\ PM 3655-37 Sheet No_6_
IOCATION Monsanto-Muscatine. Iowa ( QQ\ ] Checked By Date
SUR.IFP.T VOC Emissions V^/ Computed Ry JES . natpJuly 17. 1986
C. Cost of a thermal incinerator to control SGL-4
Thermal incinerator rated at 3800 cfm $110,000
Installation (50 percent) 55,000
Vendor quotation (Trane Thermal, Inc., $165,000
Conshohocken, Pennsylvania)
Annual Costs
Capital Recovery (10 year, 12 percent) $ 29,200
Electricity at 6 cents per kwh 360
Maintenance (3 percent) 4,950
Taxes and Insurance (2 percent) 3,300
Fuel (2.9 million Btu/h at $2.00) 45,730
Total $ 83,540
Control cost per metric ton of AN $83,540
—TC c =
lo.b
Control cost per metric ton of VOC $83,540 _
23.6 "
D. Cost of a thermal incinerator to control SAN-5
Catalytic incinerator rated at 27,000 cfm $400,000
Installation (50 percent) 200,000
(Vendor quotation Metpro, Inc., Harlesville, $600,000
Pennsylvania)
Capital recovery (10 year, 12 percent) $106,200
Electricity at 6 cents per kwh 1,800
Maintenance, 3 percent 18,000
Taxes and insurance, 2 percent 12,000
Fuel (6.7 million Btu/h at $2.00) 105,600
Catalyst replacement, 2 percent 12,000
Total annual cost $255,600
Control cost per metric ton of AN = 255.600 _
^ n ~
Control cost per metric ton of VOC = 255.600
TV—=T~ -
-------
"•S-EPA X^x PN 3655-37 Sheet No._Z.
ir.rAT.nM Monsanto-Huscatlne, Iowa ( QQJ J Checked By _ Date _
,,, ,„,,-«, VOC Emissions ^9^^ ~ »^B JES _, Sept. 26, 1986
SUBJECT _ ^ — ' Computed By _ Date _ l _ !
E. Combined cost to control SGL-15, SGL-16, and SGL-6 by ducting to the boiler
and to control SGL-4 by catalytic incineration. (This is the sum of A and
C.)
SGL-15, SGL-16, SGL-6 Control Cost $ 5,000
SGL-4 Control Cost _ 240,000
Total Capital Cost $245,000
Annual Costs
SGL-15, SGL-16, SGL-6 Control Cost [$ 2,400] Credit
SGL-4 Control Cost _ 76,260
Total Capital Cost 573,830
Control cost per metric ton of AN = = $242°
Control cost per metric ton of VOC = = $84°
F. Cost of controlling SGL-15, SGL-16, and SGL-6 by condensation. Each vent
requires a separate unit containing a refrigeration unit, a heat exchanger,
and installation. Installation includes dehumidifi cation, instrumentation,
engineering, fan, and ductwork.
Refrigeration (Means Mechanical Cost Data) $ 1,800
Heat Exchanger (Richardson Eng. Services Cost Est. System) 2,000
Installation (Double Equipment Cost) _ 7,600
Total Capital Cost Each Unit $11,400
Annual Costs
Capital Recovery (10 year, 12 percent) $ 3,030
Electricity at 6 cents per kWh 3,320
Maintenance, 3 percent 340
Taxes and Insurance, 2 percent _ 230
Total Annual Cost Each Unit $ 6,920
Degree of Control Achieved
The refrigerant is chloro-difluoromethane (DuPont's product is called
Freon-22). It boils at -41°F. Assume that the gas stream can be cooled to
-30°F.
Vapor pressures in millimeters of mercury at -30°F are AN-3.75, BD-330, and
ST-0.12. Vapor pressures are obtained from the Handbook of Chemistry and
Physics data and by plotting log pressure versus I/temperature.
-------
U-S-EPA X^X 3655-37 Sheet Na JL
mr.AT.nM Monsanto-Muscatine, Iowa f QQ\ } Checked B Date
Checked By
VOC E"1SSi°nS computed *y JES ept. 26, 1986
Partial pressures of VOC in streams are in millimeters of mercury:
AN BD ST
SGL-15 38.8 128.1 43.1
SGL-16 26.1 38.1 26.1
SGL-6 0.07 0.03 1.07
VP at -30°F 3.7 330 0.12
VD nf AM ,-n err IK - AN in VOC cfm of VOC 7Cn
VP of AN in SGL-15 - Tota1 VQC x Total cfm x 760 =
' x x 76° = 38-8 mm H-
(3.6 + n.g + 4.0)
Other calculations are similar
Percent VOC controlled = lOOx (Partial pressure - VP at -30°F)
Partial pressure
For AN in SGL-15 = 100 x ' "0' = 90.5 pet.
oo.o
Other calculations are similar. No 1,3 butadiene is condensed since its
equilibrium partial pressure at -30°F is greater that its partial pressure in
any of these streams.
Percent VOC Controlled
AN BD ST
SGL-15 90.5 0 99.7
SGL-16 85.8 0 99.5
SGL-6 0 0 88.8
For SGL-15, the metric tons of AN controlled = 3.6 x 0.905 = 3.3
Control cost per metric ton of AN = ^6j92.0 = $2100
Metric tons of ST controlled = 4.0 x 0.997 = 4.0
$fi Q7D
Control cost per metric ton of VOC = 3 3+40 = $950
For SGL-16, the metric tons of AN controlled = 10.9 x 0.858 = 9.4
Control cost per metric ton of AN = *6'9^0 = $740
y • *t
Metric tons of ST controlled = 10.9 x 0.995 = 10.8
-------
rilPMT U.S. EPA —^ 3655-37 _u f.. 9
CLIENT x^--Ov PN Sheet No
Monsanto-Muscatine. Iowa ( QQ| A Checked By
Date.
am^rr VOC MSS1'°"S V^/ computed By^!L_ n.teSept. 26. 1986
Control cost per metric ton of VOC = „ ;. ™ o = $340
9.4 + 1U.8
For SGL-6, the metric tons of AN controlled = 0
Metric tons of ST controlled = 6.2 x 0.888 = 5.5
Control cost per metric ton of VOC = 55 = $1,260
Combining SGL-15, SGL-16, and SGL-6
Control cost per metric ton of AN = 33+ g 4 - $1,630
Control cost per metric ton of VOC = 7 3 +20 2 +5 5 = $630
G. Cost of a 55,000 cfm catalytic incinerator to control all process emissions
Catalytic incinerator rated at 55,000 cfm $800,000
Installation (75 percent for such a large 600,000
unit
(Extrapolation of a vendor quotation, $1,400,000
Metpro, Inc., Harleysville, Pennsylvania)
Annual Cost
Capital recovery (10 year, 12 percent) $247,800
Electricity at 6 cents per kwh 7,600
Maintenance, 3 percent 33,800
Taxes and insurance, 2 percent 28,000
Fuel (19 million Btu/h at $2.00) 299,600
Catalyst replacement, 2 percent 28,000
Total annual costs 644,800
Control cost per metric ton:
AN: $644.800 = ^ 7QQ. yoc $644,800 = $530Q
44 ' ' 121
H. Cost of small incinerator to control SGL-15, SGL-16, and SGL-6.
Skid mounted heater with automatic $20,000
operation
Installation 5,000
Ductwork and connections (See A)
(Vendor quotation, Thermoflux, Inc., 5.000
Tulsa, Oklahoma)
$30,000
-------
CLIENT_
LOCATION.
SUBJECT.
U.S. EPA
Monsanto-Muscatine, Iowa
VOC Emissions
PN.
3655-37
Checked By.
Computed By.
JES
. Sheet No.
Date
10
Date
Sept. 26, 1986
Annual Costs
Capital recovery (10 year, 12 percent)
Electricity at 6 cents per kwh
Maintenance, 3 percent
Taxes and insurance, 2 percent
Fuel
Total
Control cost per metric ton:
AN M±60 = $437; VOC
= $103.
$4,880
180
900
600
0
$67560
-------
APPENDIX B
HEM GRID MAP FOR EXPOSURE TO
ACRYLOMITRILE UNDER SCENARIO NO. 4
B-l
-------
§SYM,U $14*TEMP1£.,1,PR
9AS6,fl SftSD*STAR.
W:122333 fl WRITE KEY EXISTS ON THE FILE.
SE 12.,SflSD»STflR.
6AUSS-OUT. fi f\)
WSE 11., GAUSS-OUT.
eCOPY.fl SflSD*HEP-ABS.SHED
FURPUR 29R1C S75.38 10/81/86 11:17:40
IftBS SGu-b
3FREE SftSD*HEP-flBS.
W:128433 FILENAME NOT KNOWN TO THIS RUN.
SXQT .SHED
THE DAYTIME DECAY RATE USED WAS .80808 PER SECOND
THE NIGHTTIME DECflY RflTE USED WAS .80888 PER SECOND
MDD.PLE 6AUSS-IN.
THE RISK FACTOR TO BE USED IN THE EXPOSURE ANflLYSIS IS 6.8888-005
SHED/SftUSS - SUMMflRY OF THE INPUT DflTfl
MONSANTO MUSCATINE BASECASE
LATITUDE: 412059, LONGITUDE: 918458
STftR STATION: 0
FOR fl NON URBAN SOURCE
AMBIENT TEMPERATURE: 293. DEGREES KELVIN
CHEMICAL COMPOUND NftME: ftCRYLONITRILE
NUMBER OF EMISSION TYPES: 25
THE LftPSE RATES USED ARE
.00000 DEGREES K PER METER FOR STABILITY CLASS D
.08080 DEGREES K PER METER FOR STflBILITY CLflSS E
.00000 DEGREES K PER METER FOR STABILITY CLflSS F
THE NEAREST STAR SITE WAS CHOSEN
STAR SITE USED
STATION NUMBER 14923 AT MOLIN , IL
STARTED 70/01 ENDED 74/12 46
LflTITUDE 412659 LONGITUDE 903059
DISTANCE 48.31 KM BEARING 76
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .888805 GRftMS/SECOND
. 165800 KILOGRflMS/YEAR
STACK HEIGHT: 20. METERS
BUILDING CROSS SECTION: 0. SOUflRE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .05 METERS
EXIT VELOCITY: .8 METERS/SECOND
EXIT TEMPERATURE: 234. DEGREES KELVIN
-------
EMISSION TYPE INDEX = (H) STOCK
EMISSION RATE: .000163 SRftMS/SECOND
5.130800 KILOGRAMS/YEAR
STOCK HEIGHT: 20. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS flRE FROM fl VERTICAL STflCK
STftCK DIMETER: .05 METERS
EXIT VELOCITY: .8 METERS/SECOND
EXIT TEMPERflTURE: 294. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STflCK
EMISSION RATE: .000058 GRAMS/SECOND
1.820000 KILOGRAMS/YEAR
STACK HEIGHT: 20. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .08 METERS
EXIT VELOCITY: 8.1 METERS/SECOND
EXIT TEMPERATURE: 294. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .002489 GRAMS/SECOND
78.500000 KILOGRAMS/YEAR
STACK HEIGHT: 20. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .62 METERS
EXIT VELOCITY: 6.0 METERS/SECOND
EXIT TEMPERATURE: 380. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .000571 GRAMS/SECOND
18.0M0M KILOGRAMS/YEAR
STACK HEIGHT: 15. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .08 METERS
EXIT VELOCITY: .2 METERS/SECOND
EXIT TEMPERATURE: 2900. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .001728 GRAMS/SECOND
54.500000 KILOGRAMS/YEAR
STACK HEIGHT: 15. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .10 METERS
EXIT VELOCITY: .5 METERS/SECOND
EXIT TEMPERATURE: 300. DEGREES KELVIN
EMISSION TYPE INDEX = IH) STACK
EMISSION RATE: .011733 GRAMS/SECOND
370.000000 KILOGRAMS/YEAR
STACK HEIGHT: 14. METERS
-------
BUILDING CROSS SECTION: 9. SQUflRE METERS
EMISSIONS flRE FROM ft VERTICAL STftCK
STftCK DIftMETER: .21 METERS
EXIT VELOCITY: 1.2 METERS/SECOND
EXIT TEMPERATURE: 895. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STftCK
• EMISSION RflTE: .911733 GRftMS/SECOND
370.088090 KILOGRftMS/YEflR
STfiCK HEIGHT: 14. METERS
BUILDING CROSS SECTION: 0. SQUflRE METERS
EMISSIONS flRE FROM fl VERTICftL STflCK
STftCK DIftMETER: .21 METERS
EXIT VELOCITY: 1.2 METERS/SECOND
EXIT TEMPERflTURE: 295. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STflCK
EMISSION RflTE: .093149 GRftMS/SECOND
99.390089 KILOSRftMS/YEflR
STfiCK HEIGHT: 14. METERS
BUILDING CROSS SECTION: 9. SQUflRE METERS
EMISSIONS ftRE FROM fl VERTICflL STftCK
STfiCK DIftMETER: .21 METERS
EXIT VELOCITY: 1.2 METERS/SECOND
EXIT TEMPERflTURE: 2%. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STflCK
EMISSION RATE: .003149 GRftMS/SECOND
99.300009 KILQGRftMS/YEflR
STftCK HEIGHT: 14. METERS
BUILDING CROSS SECTION: 0. SQUflRE METERS
EMISSIONS ftRE FROM fl VERTICftL STflCK
STACK DIftMETER: .21 METERS
EXIT VELOCITY: 1.2 METERS/SECOND
EXIT TEMPERflTURE: 296. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STftCK
EMISSION RATE: .000110 GRftMS/SECOND
3.480009 KILOGRflMS/YEflR
STSCK HEIGHT: 25. METERS
WILDING CROSS SECTION: 9. SQUflRE METERS
EMISSIONS ftRE FROM ft VERTICftL STftCK
STfiCK DIftKETER: .95 METERS
EXIT VELOCITY: 2.6 METERS/SECOND
EXIT TEMPERflTURE: 2%. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STftCK
EMISSION RflTE: .059297 GRftMS/SECOND
1870.900000 KILOGRftMS/YEflR
STfiCK HEIGHT: 14. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS ftRE FROM fl VERTICAL STACK
STfiCK DIftrtETER: .69 METERS
EXIT VELOCITY: £&.5 METERS/SECOND
El IT TEMPER8TURE: 335. DEGREES KELVIN
-------
EMISSION TYPE INDEX = (H) STOCK
EMISSION RATE: .000374 GRAMS/SECOND
11.888080 KILOGRAMS/YEAR
STOCK HEIGHT: 20. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .05 METERS
EXIT VELOCITY: .0 METERS/SECOND
EXIT TEMPERATURE: 294. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .000042 GRAMS/SECOND
1.320000 KILOGRAMS/YEAR
STACK HEIGHT: 20. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .02 METERS
EXIT VELOCITY: .0 METERS/SECOND
EXIT TEMPERATURE: 295. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .002870 GRAMS/SECOND
90.500000 KILOGRAMS/YEAR
STACK HEIGHT: 20. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .05 METERS
EXIT VELOCITY: .1 METERS/SECOND
EXIT TEMPERATURE: 293. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RflTE: .000066 GRAMS/SECOND
2.150000 KILOGRAMS/YEAR
STACK HEIGHT: 20. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .05 METERS
EXIT VELXITY: .2 METERS/SECOND
EXIT TEMPERATURE: 301. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .001972 GRAMS/SECOND
62.209080 KILOGRAMS/YEAR
STACK HEIGHT: 20. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .05 METERS
EXIT VELOCITY: .2 METERS/SECOND
EXIT TEMPERATURE: 294. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .000368 GRAMS/SECOND
11.600000 KILOGRAMS/YEAR
-------
STACK HEIGHT: 14. PETERS
BUILDING CROSS SECTION: 8. SQUARE METERS
EMISSIONS ORE FROM A VERTICAL STACK
STACK DIAMETER: .32 METERS
EXIT VELOCITY: .2 METERS/SECOND
EXIT TEMPERATURE: 334. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .008368 GRAMS/SECOND
11.6eee08 KILOGRAMS/YEAR
STACK HEIGHT: 14. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .32 METERS
EXIT VELOCITY: .2 METERS/SECOND
EXIT TEMPERATURE: 334. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .011955 GRAMS/SECOND
377.000080 KILOGRAMS/YEAR
STACK HEIGHT: 15. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .32 METERS
EXIT VELOCITY: 21.2 METERS/SECOND
EXIT TEMPERATURE: 335. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .151573 GRAMS/SECOND
4780.088000 KILOGRAMS/YEAR
STACK HEIGHT: 21. METERS
BUILDING CROSS SECTION: 8. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: 1.16 METERS
EXIT VELOCITY: 11.9 METERS/SECOND
EXIT TEMPERATURE: 290. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .084217 GRAMS/SECOND
133.880080 KILOGRAMS/YEAR
STACK HEIGHT: 14. METERS
BUILDING CROSS SECTION: 0. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .41 METERS
EXIT VELOCITY: 1.3 METERS/SECOND
EXIT TEMPERATURE: 352. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .004217 GRAMS/SECOND
133.080000 KILOGRAMS/YEAR
STACK HEIGHT: 14. METERS
BUILDING CROSS SECTION: 8. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIRMETER: .41 METERS
EXIT VELOCITY: 1.3 METERS/SECOND
-------
EXIT TEMPERATURE: 352. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STOCK
EMISSION RflTE: .082445 GRflMS/SECOND
2600.008888 KILOGRAMS/YEAR
STOCK HEIGHT: 7. METERS
BUILDING CROSS SECTION: 8. SQUARE METERS
EMISSIONS flRE FROM A VERTICAL STACK
STACK DIAMETER: 58.00 METERS
EXIT VELOCITY: .1 METERS/SECOND
EXIT TEMPERATURE: 293. DEGREES KELVIN
EMISSION TYPE INDEX = (H) STACK
EMISSION RATE: .831710 GRAMS/SECOND
1080.8WM0 KILOGRAMS/YEAR
STACK HEIGHT: 14. METERS
BUILDING CROSS SECTION: 8. SQUARE METERS
EMISSIONS ARE FROM A VERTICAL STACK
STACK DIAMETER: .18 METERS
EXIT VELOCITY: .1 METERS/SECOND
EXIT TEMPERATURE: 293. DE6RES KELVIN
MONSANTO MUSCATINE BASECASE 14923MOLIN IL 48.31 76
ACRYLONITRILE
(CONCENTRATION (MICRO GRAMS/CUBIC METER))
DOWNWIND DISTANCE (KM)
DIRECTION .208 .588 1.008 2.800 5.888 10.800 20.000 30.808 40.888 58.
S 1.3349+880 5.3796-881 2.1780-001 8.8477-802 2.0938-002 7.8633-803 3.1865-003 1.8465-003 1.2889-003 9.8814-
SSU 5.6843-081 2.3105-881 9.1919-802 3.3736-002 8.6866-883 3.2327-803 1.2638-003 7.4635-004 5.1854-004 3.9294-
SW 7.6718-081 3.1171-001 1.2449-001 .4.5703-002 1.1777-082 4.3712-883 1.6980-803 9.9757-084 6.9823-804 5.2128-
USW 1.5352+808 6.2634-001 2.5658-881 9.6550-002 2.5437-882 9.6371-003 3.8447-003 2.2992-883 1.6118-803 1.2298-
W 2.6989+080 1.1383+088 4.9258-801 1.9552-001 5.3979-002 2.1283-002 8.9838-083 5.4836-003 3.9248-803 3.0422-
m 1.5818+008 6.2439-801 2.6473-801 1.0339-001 2.8189-002 1.1834-002 4.5863-003 2.8149-003 2.0101-003 1.5556-
NH 1.1089+800 4.6880-0C1 1.9316-001 7.4691-082 2.8191-082 7.8279-883 3.2124-803 1.9557-003 1.3886-883 1.0699-003
NNW 1.0127+008 4.1602-881 1.7011-881 6.4281-002 1.7058-002 6.5296-003 2.6426-083 1.5954-883 1.1261-883 8.6379
N 2.4567+880 1.8894+808 4.1825-801 1.5356-801 4.8398-002 1.5356-002 6.1625-883 3.7884-003 2.6019-083 1.9988-083
NNE 1.6378+830- 6.4341-801 2.5741-00! 9.5524-002 2.4968-082 9.4655-083 3.7943-883 2.2788-803 1.6819-803 1.2253-
NE 1.8547+808 7.4515-881 3.1021-881 1.1973-881 3.2364-882 1.2597-882 5.2862-883 3.1849-803 2.2694-803 1.7533-
ENE 2.33^8+808 ?.7212-801 4.2087-881 1.6718-881 A.63*1-002 1.8436-082 7.8168-883 4.8551-803 3.4961-803 2.7223-
ww
4
4-flw
B-m
'f
9-003
79-M
J-083
3!
-------
E 2.5241+808 1.0376+008 4.3127-081 1.6529-001 4.4378-002 1.7158-082 7.0277-003 4.2744-003 3.0331-003 2.3360-003
ESE 1.7846+000 6.8976-001 2.7326-081 1.0017-001 2.5870-002 9.6517-003 3.7779-003 2.2312-003 1.5498-003 1.1741-003
SE 9.8632-001 3.9715-001 1.5829-081 5.8371-002 1.5157-002 5.7003-083 2.2591-003 1.3459-083 9.4113-004 7.1672-004
SSE 7.7142-001 3.1150-001 1.2484-001 4.5893-002 1.1844-002 4.4131-083 1.7252-003 1.0182-003 7.0699-004 5.3542-«04
0FREE 12.
§FREE 11.
WSG.fl 6flUSS-OUT.
§USE ll.,6AUSS-OUT.
§AS8,fl SftSD*HEP-POPFILE.
W:121433 FILE IS CflTflLOGUED flS fl REflD ONLY FILE.
U: 122333 fl WRITE KEY EXISTS ON THE FILE.
ftJSE 12.,SflSD*HEP-POPFILE.
(»ftS6,A SASD*H£P-1NDEX.
U: 121*33 FILE IS CflTflLOSUED flS fl REflD ONLY FILE.
U:122333 fl URITE KEY EXISTS ON THE FILE.
§USE 13.,SASD*HEP-INDEX.
frfiSG.fl SflSD*HEP-CO.
U:121433 FILE IS CflTflLOGUED AS fl REftD ONLY FILE.
U:122333 ft URITE KEY EXISTS ON THE FILE.
§USE 18.,SflSD*HEP-CO.
§COPV,fl Sfl3D*HEP-flBS.XPQSURE-ft
FU8PUR 2SR1C S75.38 10/01/86 11:18:06
1 BBS
PFREE Sft£D»H£P-ftBS.
U:120432 FILENAME NOT KNOWN TO THIS RUN.
0XOT .XPOSURE-fl
MINIPtftX RESEARCH CORP.
POPULflTION EXPOSURE PROGRflM
RflDII
.500
i.e
BINS
.100 .350 .750
Dl = 3.588, D2 = 50.000
2.000
1.500 3.500
10.000 20.000 30.1
40.000 50.
51 STflTES FOUND ON POPULflTION-FILE INDEX,
3137 COUNTIES,
293454 B6/ED'S,
1080 BG/ED'S PER PflGE IN POPFILE.
THE FOLLOWING SOURCES EMIT ftCRYLONITRILE
MONSfflTTO HUSCflTINE BflSECASE 14923WLIN
CONCENTRftTIONS ORE IN UNITS OF MICRO-+3RAHS PER CUBIC I€TER
INPUT CONCENTRflTIONS
DIR DISTANCE
IL 48.31 76
s
ssw
sw
wsw
U
UMU'
.2C!0
1.3349+000
5.8843-001
7.6718-001
1.5352+000
2.6989+00?
1.5018+000
5.
2.
3.
6.
1
i,
6.
.500
3796-001
3105-001
1171-001
2634-091
1383+eae
£439-001
1.000
2. 1700-001
9. 1919-002
1.2449-801
2.5658-001
4.9250-831
2. 6473-00!
2.008
8.0477-002
3.3736-002
4.5703-002
9.6550-802
1.9552-321
1.0339-881
5.008
2.0938-W2
8.6866-083
1.1777-002
2.5437-082
5.3979-802
2.8189-002
10.888
7.8633-003
3.2327-083
4.3712-003
9.6371-083
2. 1283-002
1.1834-882
28.088
3.1065-083
1.2638-883
1.6988-083
3.8447-883
8.9838-883
4.5863-883
38.088
1.8465-803
7.4635-084
9.9757-804
2.2992-883
5.4836-803
2.8149-883
48.888
1.2889-803
5. 1854-004
6.9023-804
1.6118-803
3.9248-803
2.0101-803
50.088
9.8814-004
3.9294-884
5.2128-084
1.2298-883
3.0422-883
1.5556-883
-------
NU
NNU
N
NNE
NE
ENE
E
ESE
SE
SSE
1.1089+008
1.8127+800
2.4587+800
1.6078+008
1.8347+000
2.3368+008
2.5241+000
1.7046+001}
9.8632-001
7.7142-801
4.6080-881
4. 1602-081
1.8094+080
6.4341-001
7.4515-001
9.7212-801
1.0376+008
6.8976-001
3.9715-001
3.1150-001
1.9316-081
1.7011-081
4. 1025-001
2.5741-081
3. 1021-801
4.2007-081
4.3127-801
2.7326-081
1.5829-801
1.2484-001
7.
6.
1.
9.
1.
1.
1.
1.
5.
4.
4691-802
4281-082
5356-881
5524-802
1973-801
6718-081
6529-001
8017-001
8371-082
5893-002
2.8191-002
1. 7058-882
4.0398-002
2.4968-802
3.2364-002
4.6341-002
4.4378-002
2.5870-882
1.5157-002
1.1844-002
7.8279-003
6.5296-803
1.5356-002
9.4655-003
1.2597-002
1.8436-002
1.7158-002
9.6517-003
5.7003-083
4.4131-003
3.2124-003
2.6426-003
6. 1625-003
3.7943-003
5.2062-003
7.8160-003
7.0277-003
3.7779-003
2.2591-003
1.7252-003
1.9557-003
1.5954-003
3.7004-003
2.2780-003
3.1849-003
4.8551-003
4.2744-003
2.2312-003
1.3459-003
1.0182-003
1.3066-003
1.1261-003
2.6019-003
1.6019-083
2.2694-003
3.4961-003
3.0331-003
1.5498-003
9.4113-004
7.0699-004
1.0699-003
8.6379-004
1.9980-003
1.2253-003
1.7533-003
2.7223-003
2.3360-003
1.1741-003
7.1672-084
5.3542-004
SOURCE LOCflTION
41 DEB, 20' 59" N. LflT. ( 41.3497 DEGREES)
91 DE6, 4' 50" U. LONG. ( 91.0886 DEGREES)
COMPUTING EXPOSURE FOR SOURCES OF ftCRYLONITRILE
HONSftNTO HUSCPTINE BflSECftSE 14923MOLIN IL 48.31 76
CONCENTRflTlONS flRE IN UNITS OF MICRO-GROWS PER CUBIC METER
SOURCE LOCflTION
41.3*97 DEGREES N. LftT.
91.0886 DEGREES U. LONG.
STfilE 17808 BEING flCCESSED flT THE COUNTY LEVEL. 102 COUNTIES IN THIS STflTE.
COUNTY 17871 BEING flCCESSED flT THE BG/ED LEVEL. 28 BG/ED'S IN THIS COUNTY. 6ROUTH FflCTOR = 1,
COUNTY 17131 BEING flCCESSED flT THE BG/ED LEVEL.
52 BG/ED'S IN THIS COUNTY. GROWTH FflCTOR = 1.00000
COUNTY 17161 BEING flCCESSED flT THE BG/ED LEVEL.
284 BG/ED'S IN THIS COUNTY. GROWTH FflCTOR = 1.00000
COUNTY 17187 BEING ftCCESSED flT THE BG/ED LEVEL.
35 BG/ED'S IN THIS COUNTY. GROWTH FflCTOR = 1.00000
STflTE 19800 BEING flCCESSED flT THE COUNTY LEVEL.
COUNTY 19031 BEING flCCESSED flT THE BG/ED LEVEL.
99 COUNTIES IN THIS STflTE.
34 BG/ED'S IN THIS COUNTY. GROWTH FftCTOR = 1.
COUNTY 19057 BEING flCCESSED fiT THE BG/ED LEVEL.
79 BG/ED'S IN THIS COUNTY. GROWTH FflCTOR = 1.
COUNTY 19087 BEING ftCCESSED flT THE BG/ED LEVEL.
38 BG/ED'S IN THIS COUNTY. GROWTH FftCTOR = 1.00000
COUNTY 19103 BEING flCCESSED ftT THE BG/ED LEVEL.
122 BG/ED'S IN THIS COUNTY. GROWTH FftCTOR = 1.00000
COUNTY 19115 BEING flCCESSED flT THE BG/ED LEVEL.
25 BG/ED'S IN THIS COUNTY. GROWTH FflCTOR = 1.00000
COUNTY 19139 BEING flCCESSED flT THE BG/ED LEVEL.
112 BG/ED'S IN THIS COUNTY. GROWTH FflCTOR = 1.00000
COUNTY 19163 BEING flCCESSED flT THE B5/ED LEVEL.
205 BG/ED'S IN THIS COUNTY. GROWTH FflCTOR = 1.08800
-------
COUNTY 19183 BEING ftCCESSED flT THE BG/ED LEVEL.
27 BG/ED'S IN THIS COUNTY. GROWTH FACTOR = 1.80088
(CONCENTRATION,POPULflTION) PflIRS MERE GENERflTED.
MAXIMUM RADIUS = 50.0 KB
HONSflNTO MUSCftTINE BflSECRSE 14923MOLIN
CONCENTRflTIONS ORE IN UNITS OF MICRO-GRAMS PER CUBIC METER
IL 48.31 76
LEVEL CONCENTRATION POPULflTION EXPOSURE
1
2
3
4
5
6
7
B
9
10
11
12
13
2.70E+00
2.50E+00
1.00E+00
5.00E-01
2.58E-01
1.00E-01
5.00E-02
2.5&E-02
1.00E-02
5.00E-03
2.50E-03
1.00E-03
3.93E-04
(1
(1
(1
(1
56
346
2,700
22,600
34,200
217,000
304,000
314,000
MAXIMUM CONCENTRATION TO WHICH ANY
2.70E+00 (1
MINIMUM CONCENTRATION TO WHICH ANY
4.5SE-04
314,000
9.88E-03
1.91E-02
1.25E-01
1.81E-01
2.82E-01
6.0BE+00
2.54E+01
9.53E+01
3.97E+02
4.83E+02
1.02E+03
1.18E+03
1.1BE+03
PEOPLE ARE ACTUALLY EXPOSED
9.B8E-03
PEOPLE ARE ACTUALLY EXPOSED
1.1BE+03
USING A RISK FACTOR OF 6.B0E-05
LEVEL RISK LEVEL POPULATION EXPOSURE
1
2
3
4
5
6
7
8
9
10
11
12
1.84E-04
1.08E-04
5.00E-05
2.50E-05
1.00E-05
5.00E-06
2.50E-06
1.00E-06
5.00E-07
2.50E-07
1.00E-07
2.67E-08
U
<1
<1
(1
1
58
598
11,000
27,500
44,900
269,000
314,000
6.72E-07
4.53E-06
9. 12E-06
1.54E-05
3.21E-05
4.24E-04
2.40E-03
1.70E-02
3.01E-02
3.60E-«2
7.72E-02
8.05E-02
MAXIMUM RISK LEVEL TO WHICH ANY PEOPLE ARE ACTUALLY EXPOSED
1.B4E-04 (1 6.72E-07
MINIMUM RISK LEVEL TO WHICH ANY PEOPLE ARE ACTUALLY EXPOSED
3.11E-08 314,000 8.05E-02
MAP OF POPULATION BY CONCENTRATION RADIUS
MONSANTO MUSCflTINE BftSECASE 14923MOLIN
CONCENTRATIONS ARE IK' UNITS OF MICRO-GRAMS PER CUBIC METER
IL 48.31 76
-------
DIR RADIUS
10. 000
20.000
40.000
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MONSflNTO WSCflTIt€ BflSECflSE 14923MOLIN
CONCENTRATIONS flRE IN UNITS OF MICRO-GRRMS PER CUBIC METER
DIR RADIUS .200 .588 1.000 2.000
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SUB-PflTCH OUTER RflDIUS
HONSflNTO HUSCflTINE BflSECflSE 14923MOLIN
CONCENTRflTIONS fiRE IN UNITS OF KICRO-GRftMS PER CUBIC HETER
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MONSANTO MUSCflTINE BASECASE 14923MOLIN IL 48.31 76
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MAP OF POPULATION BY SUB-PflTCH OUTER RADIUS
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CONCENTRATIONS
DIR 30.000
BASECASE
ARE IN UNITS OF MICRO-GRAMS
40.000
14923MOLIN
PER CUBIC METER
50.000
IL 48.31 76
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OVERftLL SUMMARY
SUW1ARY FOR BCRYLONITRILE
MAXIMUM RADIUS = 50.0 KB
LEVEL CONCENTRATION POPULATION EXPOSURE
1
2
3
4
5
6
7
8
9
10
11
12
13
2.70E+00
2.50E+e0
1.00E+80
5.00E-«1
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1.00E-01
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(1
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2.54E+01
9.53E+01
3.97E+02
4.B3E+02
1.02E+03
1.1BE+03
1.18E+03
USING A RISK FACTOR OF 6.B0E-05
LEVEL RISK LEVEL POPULATION
HAZARD
1
2
3
4
5
6
7
B
S
1.84E-04
1.00E-04
5.00E-85
2.50E-85
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5.00E-&
2.50E-06
1.00E-8&
5.MIE-37
<1
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<1
<1
1
58
598
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3.21E-05
4.24E-04
2.40E-03
1.70E-02
3.01E-02
-------
10 2.50E-07 44,900 3.60E-02
11 1.00E-07 269.M0 7.72E-02
12 2.67E-08 314,000 8.05E-82
SUMMARY FOR ACRYLONITRILE PAGE 1
UITH fl WIT RISK OF 6.B0E-05
-MAXIMUM- --MINIMUM--
LIFETIME fitMJAL REPEflT
COtC PEOPLE EXPOSURE INCIDENCE MAX RISK CONC PEOPLE EXPOSURE INCIDENCE INTERVAL SOURCE
2.70E+00 (1 9.88E-03 6.72E-07 1.84E-04 4.58E-04 314,000 1.18E+03 0.0012 870. HQNSANTO MUSCATINE BAfl,A<
E
314,000 1.18E+03 0.0012 870. OVERALL
SUMMARY FOR ACRYLONITRILE PAGE 1 OF
WITH A UNIT RISK OF 6.B0E-05
-MAXIMUM- --MINIMUM--
LIFETIME ANNUAL REPEAT
COIC PEOPLE EXPOSURE INCIDENCE MAX RISK CONC PEOPLE EXPOSURE INCIDENCE INTERVAL SOURCE
2.70E+08 U 9.88E-03 6.72E-B7 1.84E-04 4.5BE-04 314,000 1.18E+03 0.0012 870. MONSANTO MUSCATINE
E
314,000 1.18E+03 0.0012 870. OVERALL
SUMMARY FOR flCRYLONITRILE PAGE 1 fl
UITH A UNIT RISK OF 6.80E-05 "
-MAXIMUM- --MINIMUM--
LIFETIME ANNUAL REPEAT
CONC PEOPLE EXPOSURE INCIDENCE MAX RISK CONC PEOPLE EXPOSURE INCIDENCE INTERVAL SOURCE
2.70E+00 (1 9.88E-03 6.72E-07 1.84E-04 4.58E-04 314,000 1.18E+03 0.0012 870. MONSANTO MUSCATINE BASRA
E
314,000 1.16E+03 0.0012 870. OVERALL
1 SOURCES PROCESSED.
1 HAS THE GREATEST NUMBER OF SOURCES PER CHEMICAL. 1
0BRKPT PRINT*
EOF:940
0:)
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA 907/9-86-005
2.
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
Assessment of the Monsanto Acrylonitrile Solution
in Muscatine, Iowa
5. REPORT DATE
September 1986
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Thomas C. Ponder, Jr., George Schewe,
John E. Spessard, Ph.D.
8. PERFORMING ORGANIZATION REPORT NO.
PN 3655-37
9 PERFORMING ORGANIZATION NAME AND ADDRESS
PEI Associates, Inc.
11499 Chester Road
P. 0. Box 46100
Cincinnati, Ohio 45246-0100
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
6P-02-3890
12. SPONSORING AGENCY NAME AND ADDRESS
U.S. Environmental Protection Agency
Region VII, Air Branch, 726 Minnesota Avenue
Kansas City, Kansas 66101
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
Monsanto Corporation's Muscatine, Iowa plant produces acrylonitrile butadiene
styrene resins. The State of Iowa requires Best Available Control Technology for
volatile organic compound emissions. Monsanto proposed process revisions that
would reduce annual acrylonitrile emissions from 391 to 44 megagrams. PEI evalu-
ated Monsanto's solution and proposed a BACT program that augments Monsanto's pro-
posal by controlling emissions from three process vents by incineration. Total
VOC emissions are reduced from 121 to 57 megagrams, and acrylonitrile emissions
are reduced from 44 to 29 megagrams. The average risk or probability in 106 of
contracting cancer from acrylonitrile over a lifetime to the average exposed indi-
vidual is reduced from 0.88 to 0.56 cancer per lifetime per million persons.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Croup
Air Toxics
Acrylonitrile
Butadiene
Styrene
Hazardous Air Pollutants
13. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (THil Report/
Unclassified
21. NO. OF PAGES
57
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
------- |