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

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          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

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                                  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.

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                                   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

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                                    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

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                               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.

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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.

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                         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

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^v

VACUUM
PUMP



                                                                                  SGL-15
                                                                                   •IVHR. H?0
                                                                                   •IVHR.ACRYLONITRILE
                                                                                   •
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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

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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.   -

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          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.

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     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.

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     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

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          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

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       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

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  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

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         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

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           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

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               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

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          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

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          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

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             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

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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

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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

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                            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

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            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

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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

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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
                                                          I
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MAP OF POPULATION    BY SUB-PflTCH OUTER RADIUS
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MAXIMUM RADIUS =   50.0 KB
LEVEL  CONCENTRATION  POPULATION     EXPOSURE
1
2
3
4
5
6
7
8
9
10
11
12
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2,700
22,600
34,200
217,000
304,003
314,000
9.88E-03
1.91E-02
1.25E-01
1.81E-01
2.B2E-01
6.08E+00
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
1.00E-05
5.00E-&
2.50E-06
1.00E-8&
5.MIE-37
<1
U
<1
<1
1
58
598
11,000
27,500
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

-------
 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:)

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                                   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)

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