Stationary Source Enforcement Series
EPA 340/1-76-008b
NOVEMBER 1976
SUMMARY OF PARTICULATE AND SULFUR OXIDE
EMISSION REDUCTIONS ACHIEVED NATIONWIDE FOR
SELECTED INDUSTRIAL SOURCE CATEGORIES
1970- 1975
VOLUME 2: CALCULATIONS
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Enforcement
Division of Stationary Source Enforcement
Washington, D.C. 20460
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SUMMARY OF PARTICULATE AND SULFUR OXIDE EMISSION
REDUCTIONS ACHIEVED NATIONWIDE FOR
SELECTED INDUSTRIAL SOURCE CATEGORIES, 1970-1975
Volume II
by
Martin F. Massoglia
Prepared for:
Division of Stationary Source Enforcement
Environmental Protection Agency
under
Task Order No. 66, Contract No. 68-02-1325
and
Purchase Order No. DA-6-99-5332J
Center for Technology Applications
August 1976
(revised)
-------
This report is issued by the Office of Enforcement, Environmental Protection
Agency. Copies are available - as supplies permit - from Air Pollution
Technical Information Center, Library Services Division, Environmental Pro-
tection Agency, Research Triangle Park, North Carolina 27711, or may be obtained,
for a nominal cost, from the National Technical Information Service, 5285
Port Royal Road, Springfield, Virginia 22161. The opinions expressed in
this report are those of the producing contractor and not necessarily
those of the U.S. Environmental Protection Agency.
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SUMMARY OF PARTICULATE AND SULFUR OXIDE EMISSION
REDUCTIONS ACHIEVED NATIONWIDE FOR
SELECTED INDUSTRIAL SOURCE CATEGORIES, 1970-1975
Volume II
by
Martin F. Massoglia
Prepared for:
Division of Stationary Source Enforcement
Environmental Protection Agency
under
Task Order No. 66, Contract No. 68-02-1325
and
Purchase Order No. DA-6-99-5332J
EPA Project Officer: Robert Marshall
Center for Technology Applications
Research Triangle Institute
August 1976
(revised)
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FOREWORD
This research was performed for the Division of Stationary Source Enforcement
(DSSE), Environmental Protection Agency under Purchase Order No. DA-6-99-5332J and
Task Order No. 66, Contract No. 68-02-1325 with the Environmental Protection
Agency/Durham. Mr. Robert Marshall, Compliance Monitoring Branch, Division of Sta-
tionary Source Enforcement was the EPA Project Officer. His suggestions and comments
during the conduct of this research were most helpful.
This research updates the nationwide emission data on total suspended particulates
and sulfur oxides from selected source categories for 1975, and the associated analyses to
determine the progress made, nationwide, in meeting the ambient air quality standards
for the two pollutants under study. The initial inventories and analyses were developed
by the Research Triangle Institute under Task Order No. 21, Contract No. 68-02-1325
and reported to EPA in June 1975.* The analyses and inventories developed in the June
1975 studies are updated to reflect changes in SIP requirements proposed or promulgated
since the initial study, use of actual 1975 production data in place of projections, and use
of compliance status data available in the DSSE Compliance Data System.
This report is published in two volumes. Volume I presents a summary of the
emission inventory data and the analyses; Volume II, the detailed calculations, in
appendix form, upon which nationwide emission inventories—actual, potential, and com-
pliance—were based.
'Massoglia, Martin F., Summary of Emission Reductions Achieved Nationwide by Select-
ed Industrial Source Categories, Volumes I and II, Research Triangle Institute, June
1975.
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TABLE OF CONTENTS
Page
FOREWORD ii
SUMMARY 1
APPENDIX A: Coal-Fired Steam-Electric Plants
Oil-Fired Steam-Electric Plants A-l
APPENDIX B: Industrial/Commercial Coal-Fired Boilers B-l
APPENDIX C: Portland Cement Plants C-l
APPENDIX D: Petroleum Refineries D-l
APPENDIX E: Municipal Refuse Incinerators E-l
APPENDIX F: Sulfuric Acid Plants F-l
APPENDIX G: Phosphate Fertilizer Plants G-l
APPENDIX H: Primary Smelters H-l
APPENDIX I: Iron and Steel Industry 1-1
APPENDIX J: Ferroalloy Plants J-l
APPENDIX K: Asphalt Concrete Plants K-l
APPENDIX L: Coal Cleaning Plants L-l
APPENDIX M: Kraft and Sulfite Pulp M-l
APPENDIX N: Grey Iron Foundries N-l
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SUMMARY
The calculations for the fourteen selected source
categories are summarized in table 1.
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Table 1
ESTIMATED POTENTIAL AND ACTUAL EMISSIONS (1970, 197S)
103 tons
1970
Source Categories
Coal-Fired Steam Electric
Power Plants
Oil-Fired Steam-Electric
Power Plants
Coal-Fired Industrial/
Commercial Boilers
Integrated Iron and Steel
Mills and Coke Plants
Petroleum Refineries3
Primary Smelters
Portland Cement Plants
Municipal Refuse Incinerators
Sulfuric Acid Plants
Phosphate Fertilizer Plants
Ferroally Plants
Asphalt Concrete Plants
Coal-Cleaning Plants
Kraft and Sulfite Pulp Plants
Grey Iron Foundries
Subtotal Selected Source
Categories
All Sources
Other Sources
Particulates
197
Potential1
34.S33
54
4.501
15.259
283
1.637
10.643
184
-
172
366
6.998
671
3.133
1.320
79,754
98,479'
18.7254
D
Actual
4.188
54
2.545
2,346
136
190
906
105
_
24
71
526
217
288
156
11.752
27.500s
16,748'
Potential
49,352
80
3,959
12.760
324
1,553
9,604
203
-
167
313
7.088
372
3.789
899
90.463
110,339'
19.876*
975
Actual
3.760
80
1.287
1,469
148
145
305
73
-
14
34
203
35
146
62
7.761
17.000'
9.239'
Compliance2
756
80
401
386
146
100
66
16
-
12
29
120
11
38
46
2.207
9,798'
7.591 10
1970
Potential1
15.439
1.618
5.529
197
1.537
4.845
733
-
581
-'
-
-
.
-
-
30,479
39,580"*
9.107'
Actual
15.439
1.618
5,529
180
1,537
3.580
733
-
581
-
-
-
-
-
-
29.197
34.300s
5.381'
Sulfur Oxides
U
Potential
20.971
2.022
5.131
173
1,759
4.629
661
-
626
-
-.
-
-
-
-
35.972
45.639'
8.667*
75
Actual
13,536
1,692
3,530
110
1.498
2,965
661
-
350
-
-
-
-
-
-
24,342
32.900*
8.5S81
Compliance2
11,481
1.555
2.788
25
1.312
603
661
-
183
-
-
-
-
18.608
26.568'
7.960' '
ro
Note: Footnotes appear on the following page.
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1 Massoglia, Martin. F., Summaiy of Emissions Reductions Achieved Nationwide by Selected Industrial Source Categories, Volume 1. Final Report. Research Triangle Institute (Tach No. 2 I. EPA Contract 68-02-135).
except petroleum refinery SOj emissions. This figure is from Appendix D. this irpoit.
1 Based on 1975 Activity Factors.
3 For the purposes of this study, petroleum refinery emissions included the following:
a. Uncontrolled — Emissions from catalytic cracking regenerators, boilers and process heaters, and flaring or burning all of these off-gases without prior desulfurizatinn.
b. Contracted — All off-gases, and combustion products processed through a sulfur recovery unit with a 99.5 percent effective sulfur recovery.
c. Actual — Emission from alt operations including sulfur recovery units at level of control estimated to be In effect in 1970 and 1975.
4 Calculated from data in OAQPS Data File of National Emission, 1970and1971.
5 NAOB internal paper. Air Pollutant Emission Estimates 1970-1974, undated.
'Preliminary 1975 data provided by NAD8.
7 By difference (all sources minus Selected Source Categories).
* Projected from 1970 based on population growth.
' By addition (Other Sources plus Selected Source Categories).
1 ° Estimated assuming area source emissions are relatively uncontrolled and process emissions included in other sources all at 91 percent control. Process emissions in other sources are assumed to he from industrial
processes. Combustion emissions in other sources are assumed to be area emissions. Calculations follow.
1975 emissions from other sources (estimated from data in OAQPS Emission Data File and activity factors provided by C. Mann, NADB) are:
Total 19.876 tons
Area 6,435 tons
Process 13.441 tons
Assuming process emissions included in other sources are from small plants with an average throughput of 15 tons per hour and process emissions in the selected source categories are from larger plants • average
hourly throughput of 75 tons, an estimate of degree of control at compliance with emission limitations can be made using the process rate emission curves.
Large plants E = 55I750-'1) - 40
= 48.4 pounds per hour
CO Small plants E - 4.1(15067I
= 25.2 pounds per hour
Under compliance with emission limitations average degree of control for industries in the selected source categories (combustion sources excluded) Is 97.6 percent.
1 -(963/29,2711 = 0.976
This represents an uncontrolled emission rate of 1,467 pounds per hour.
48.4/11 -0.967)
Assuming the same emission rate per unit throughput for small plants potential emissions are estimated to be 293 pounds per hour.
1.467(15/75)
Under compliance with emission limitations process emissions included in other sources will be 1.156 tons per year.
13,441(5.2/293)
Total other source emissions at compliance are 7,591 tons per year.
6,435+ 1.156
1' Estimated assuming area sources are relatively uncontrolled and process emissions included in other sources are at the same degree of control as emissions from selected source categories less combustion sources.
Analysis of state emission regulations indicate that SOX emission limitations for industrial sources are not dependent on plant size.
Data in OAQPS Emission Data File indicate that approximately 25 percent of emissions in other sources are from industrial processes and remainder from area sources. Potential 1975 emissions from other
sources can be distributed as follows:
Total 9,504 tons
Area 7,128 tons
Process 2,376 tons
At compliance, emissions from selected source categories, less combustion sources would be at 65 percent control.
1 - 2,784/7.848
At compliance with emission limitations other source emissions would be:
Area 7.128
Process 832 (2,376 X (1 - 0.65)
Total 7.960 103 tons
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APPENDIX A
COAL-FIRED STEAM-ELECTRIC PLANTS
OIL-FIRED STEAM-ELECTRIC PLANTS
(Participates and SOJ
1970
Baseline year data (1970) are as calculated in initial study.
Estimated actual emissions for 1970 are (Ref.l, p.A-l5).
10 Tons
Coal Oil
Particulates 4,188 54
SO, 15,439 1,618
1975
Estimated Actual Emission Factors
Oil and Coal-Fired Steam-Electric capacity in 1975 was under three
degrees of control. Plants coming onstream were subject to NSPS and can be
assumed to be in compliance therewith. Some of the 1972 plants in place
were in compliance with SIP emission limitations. The remainder were
emitting at the average 1970 rate. The following emission factors are
applicable.
lb/10D Btu
Coal
1970-level [Ref.l, pp.A-11, A-12]
PM
S0
[Ref.3, pp.24878/9]
[See table A-l for calculations]
NSPS
SIP-level
Oil
1970
NSPS
SIP CONTROL [See table A-2 for calculations]
Uncontrolled particulate emissions from oil combustion are less than
the estimated actual emissions under SIP control. Therefore, controlled
particulate emissions will be assumed to be the same as uncontrolled or
0.054 lb/106 Btu [Ref.l, p.A-5].
A-l
[Ref.l, p.A-12]
[Ref.2, pp.24878/9]
1.18
0.10
0.16
lb/1
PM
1.18
0.10
0.14
4.35
1.2
2.48
I06 Btu
so2
1.61
0.8
1.06
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I
PO
Table A-l. Allowabl'e Emission Factors, Coal-Fired Steam-Electric Plants Based on Regulations
for States Accounting for over 70 percent of Coal Consumption for Electric Generation
State
Alabama
Georgia
Illinois
Indiana
Kentucky
Michigan
Missouri
North Carolina
Ohio
Pennsylvania
Tennessee
West Virginia
Wisconsin
Total
US Total
%
19721 Coal
Consumption
103 Tons
16,286
10,937
29,069
26,033
22,291
20,212
12,527
18,696
39,768
35,051
17,155
19,758
10,120
277,903
348,694
79.7
2
Allowable,Emissions
lb/105 Btu
Particulates
0.12
0.10
0.10
0.30
0.10
0.22
0.30
0.22
0.12
0.11
0.22
0.05
0.15
so2
1.8
6.0
1.8
6.0
1.2
3.2
2.0
2.3
1.0
2.1
2.8
2.7
1.2
Allowable Emissions
Weighted by Coal Consumption
Particulates
1 ,954
1 ,094
2,907
7,810
2,229
4,447
3,758
4,113
4,772
3,856
3,774
998
1,518
43,220
so2
29,314
65,622
52,324
156,198
26,749
64,678
25,054
43,001
39,768
73,607
48,034
53,347
12,144
689,840
Allowable Emissions
Particulates
SO,,
,43.220
277,903
689.846
277,903
= 0.16 lb/10° Btu
2.48 lb/10Q Btu
Electric Plant Air and Water Quality Control Data for the Year Ended December 31, 1972.
Based on FPC Form No. 67. Summary Report FPC5-246 Washington, D.C.: Federal Power Commission, p. 1.
2Based on an average size unit 500 x 106 Btu/lb and State Regulations as published in the Environmental
Reporter.
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Table A-2. Allowable Emissions, Oil-Fired Steam-Electic
Plants Based on Regulations for States
Accounting for over 70 percent of Oil Consumption
for Electric Generation
State
California
Connecticut
Florida
Massachusetts
New Jersey
New York
Pennsylvania
Virginia
TOTAL
U.S. TOTAL
%
19721
Oil
Consumption
103bbl
41,352
27,618
62,347
45,238
42,867
78,232
23,773
24,528
345,955
458,390
75.5
2 6
Emissions , lb/10 Btu
Parti culates
0.333
0.20
0.10
0.05
0.10
0.10
0.11
0.20
so2
2.584
0.55
1.1
0.56
0.30
0.80
2.1
1.06
Allowable Emission
Weighted by Oil Consumption
Parti culates
13,646
5,524
6,235
2,262
4,287
7,823
2,615
4,906
47,298
so2
106,688
15,190
68,582
25,333
12,860
62,586
49,923
26,000
367,162
Particulate Material
47,298
345,955
=0.14 lb/10°Btu
SO,
367,162 _
345,955
= 1.06 lb/10°-Btu
Steam Electric Plant Air and Water Quality Control Data for the Year Ended
December 31, 1972. Based on FPC Form No. 67. Summary Report FPC5-246
Washington, D. C.: Federal Power Commission, p 1.
fi
Based on an average size unit 500 x 10 Btu/lb and State Regulations as
published in the Environmental Reporter.
Based on 0.2 gr/scfm
Based on 0.2% by volume
A-3
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The synthesized SIP controlled emission factors for Coal and Oil are different
from those contained in the previous study [Ref. 1], because of changes to
State regulations since the original study and the use of 1972 consumption
data in place of 1971.
Activity Factors, 1975
Coal 405.95 x 106 tons [Ref. 3]
Oil 468.46 x 106 bbl [Ref. 3]
It should be noted that some of this activity is subject to NSPS. Assuming
that any increase in 1975 activity over 1972 is in new facilities an estimate
of this capacity can be obtained by comparing 1972 and 1975 activity data.
Coal (IP6 tons) Oil (IP3 bbl)
1975 Activity Factor 405.95 468.46
1972 Activity Factor [Ref. 4, p.l] 348.69 458.,39
Capacity subject to NSPS 57.26 10.07
Estimated Actual 1975 Emissions
EPA Division of Stationary Source Enforcement compliance data indicates
the following compliance states of coal and oil-fired steam-electric pi tints
in 1975 [Ref. 5].
Percent of Facilities in Compliance
Particulates S02
Coal-fired 41 78
Oil-fired 92 83
Some of the plants in compliance are meeting NSPS emission limitations,
others SIP emission limitations. The plants not in compliance are assumed
to have the same degree of control as in 1970. These data and 1970, NSPS,
and SIP emission factors can be used to estimate actual emissions for 1975.
First the distribution of fuel by type of control must be determined.
Coal, Particulates:
1970 level (1- 0.41) (405.95) = 239.51 x 106 tons
SIP 348.69 - 239.51 = 109.18 x 106 tons
NSPS 405.95 - 348.69 = 57.26 x 106 tons
A-4
-------
Coal, S02:
1970 level (1 - 0.78) (405.95) = 89.31 x 106 tons
SIP 348.69 - 89.31 = 259.38 x 106 tons
NSPS 405.95 - 348.69 = 57.26 x 106 tons
Oil, Particulates:
Because the NSPS (0.1 lb/106 Btu) and 5.0 (0.14 lb/106 Btu)
emission limitations are greater than uncontrolled (0.054 lb/10 Btu),
all oil combustion for 1975 is assumed to result in emissions of 0.054
lb/106 Btu.
Oil, S02:
1970 level (1 - 0.83) x (468.46) = 79.64 x 106 bbl
SIP 458.39 - 79.64 = 378.75 x 106 bbl
NSPS 468.46 - 458.39 = 10.07 x 106 bbl
Actual 1975 emissions are estimated to be:
1970-Control iSIP-Control NSPS-Control
Coal-Fired
Particulates
Activity Factor (106 tons) 239.51 109.18 57.26
Emission Factor (Tb/106 Btu) 1.18 0.16 0.10
Emissions (103 tons)* 3,476 214 70
Total Particulate Emissions 3,476 + 214 + 70 = 3,760 x 103 tons.
oUo
Activity Factor (106 tons) 89.31 259.38 57.26
Emission Factor (lb/106 Btu) 4.35 2.48 1.2
Emissions (103 tons)* 4,779 7,91.2 845
4,779 + 7,912 + 845 = 13,536 x 103 tons
Calculated using 24.6 x 106 Btu/ton
Oil-Fired
Particulates ALL
Activity Factor (106 bbl) 468.46
Emission Factor (Ib/lO^ Btu) 0.054
Emissions (103 tons)* 80
1970-Control SIP-ControT NSPS-GontrQl
Activity Factor (106 bbl) 79.64 .378.75 10.07
Emission Factor (Ib/lO^ Btu) 1.61 1.06 0.8
Emissions (103 tons)* 403 1,264 25
Total S02 emissions 403 + 1,264 + 25 = 1,692 x 103 tons
alculated 'using 6.3 x 106 Btu/bbl
acuae usng . x
A-5
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1975 Potential Emissions
Coal-Fired
Activity Factor (10 tons)
Uncontrolled Emissions Factor (lb/10
[Ref. 1, p. A-5] 3
Uncontrolled Emissions (10 tons)
(Assumed 24.6 x 106 Btu/ton)
Particulates S02
405.95 405.95
Btu) 9.92 4.20
49,532 20,971
Oil -Fired
Activity Factor (10 bbl)
Uncontrolled Emission Factor (lb/10
[Ref. 1, p. A-5] 3
Uncontrolled Emissions (10 tons)
(Assumed 6.3 x 106 Btu/bbl )
Btu)
468.46
0.054
80
468.46
1.37
2,022
Compliance Emissions
Coal-Particulates
Activity Factor (10 tons) g
Compliance Emission Factor (lb/10 Btu)
Emissions (103 tons)
Total Particulates
Coal-S02
Activity Factor (106 bbl) g
Compliance Emission Factor (lb/10 Btu)
Emissions (103 tons)
Total SO,
OIL-SO,
Activity Factor (106 bbl) fi
Compliance Emission Factor (lb/10 Btu)
Compliance Emissions (103 tons)
Total SOo
SIP Control NSPS
348.69 57.26
0.16 0.10
686 70
756 x 103 tons
348.69 57.26
2.48 112
10,636 845
11,481 x 103 tons
458.39 10.07
1.06 0.08
1,530 25
1,555 x 103 tons
A-6
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References
Coal-Fired Steam-Electric Power Plants
1. Massoglia, Martin F., Summary of Emission Reductions
Achieved Nationwide by Selected Industrial Source
Categories, Volume II: Research Triangle Park, N.C.;
Research Triangle Institute, June 19715 (Task No. 21,
EPA Contract 68-02-1325).
2. Standards of Performances for New Stationary Sources.
36 FR 247, December 23, 1971.
3. Personal Communication with Mr. M. Johnson. Federal
Power Commission, Washington, D.C. May 21 1S76.
4. Steam Electric Plant Air and Water Quality Control Data
for the Year Ended December 31, 1972. Based or FPC Form
No. 67, Summary Report FPC 5-246. Washington, D.C.:
Federal Power Commission.
A-7
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APPENDIX 3
INDUSTRIAL/COMMERCIAL COAL-FIRED BOILERS
1970
Baseline year data (1970) are as calculated in the initial study.
Estimated actual emissions for 1970 are [Ref.l, p. B-7, B-8].
10 tons
Industrial Commercial
•- Particulates 2,435 110
S02 4,754 775
1975
Estimated Actual Emission Factors
Coal-fired industrial/commercial boilers were under two levels of
control in 1975; 1970-level and SIP-level. The SIP control level has been
reevaluated to reflect SIP changes in 1974. The following emission factors
are applicable.
Emission Factor (Ib/ton)
Industrial Commercial
Parti cul ate SO,, Parti cul ate S02
1970 level [Ref.l, pp. B-4, B-5] 58.4 114 16.2 114
SIP level (See tables B-l, B-2) 8.64 52.9 8.9 67.3
Activity Factors 1975
Coal consumption in industrial and commercial boilers is expected to
remain constant through 1980 at 70-75 x 10 tons and 15-20 x 10 tons
respectively (Ref. 2, p.2). Midpoint data will be used.
Industrial Boilers 72.5 x 10 ton
Commercial Boilers 17.5 x 10 ton
Estimated Actual 1975 Emissions
EPA Division of Stationary Source Enforcement compliance data indicate
that in 1975 fifty-two percent of coal-fired boilers, other than electrical
generation units, were in compliance with emission limitations for particu-
late emissions and sixty-one percent for S02 emissions [Ref. 3]. The data
are not broken down by commercial and industrial units. Therefore, this
compliance data is assumed to be equally applicable to both commercial and
B-l
-------
Table B-l. Estimated Nationwide Allowable Emissions.
Coal-Fired Industrial Boilers.
STATE
New York
Pennsylvania
Virginia
West Virginia
Michigan
Ohio
Indiana
Illinois
Wisconsin
TOTAL
TOTAL US
%
1970
Coal1
Consumption
103 tons
5,659.6
7,711.9
4,000.9
4,936.1
7,922.6
14,601.1
6,418.4
7,741.3
4,096.7
63,088.6
83,447.4
75.6%
Particulates
Allowable*
lb/106 Btu
0.37
0.27
0.29
0.17
0.30
0.20
0.80
0.10
0.15
Weighted
Allowable
2,094
2,082
1,160
839
2,377
2,920
5,135
774
615
17,996
so2
Allowable^
lb/106 Btu
1.20
2.67
1.06
2.30
2.20
'1.00
6.00
1.20
1.20
Weighted
Allowable
6,792
20,591
4,241
11,353
17,430
14,601
38,510
9,290
4,916
127,724
Particulates:
17.996
63,088.6
0.29 lb/10° Btu
S02:
26.2 x 0.33 = 8.64 Ib/ton coal1
127.724 = 2.02 lb/106 Btu
63,088:6
26.2 x 2.02 = 52.9 Ib/ton coal'
1
Projection of the Effectiveness and Costs of a National Tax on Sulfur
Emissions. Research Triangle Institute, November 1973, pp. 96-98.
2 fi •
Based on a 100 x 10 Btu/hr plant and State regulations as published
in Environmental Reporter
Assumes 26.2 x 10 Bfu/ton (Background Information for Establishment
of National Standards of Performance for New Sources—Industrial Size
Boilers. Wai den Research Corporation, June 1971, p.4-2)
B-2
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Table B-2. Estimated Nationwide Allowable Emissions.
Coal-Fired Commercial Boilers.
'ennsylvania
Virginia
North Carolina
Michigan
Ohio
Indiana
Illinois
Wisconsin
Minnesota
Kentucky
Tennessee
TOTAL
TOTAL U.S.
%
1970
Coal1
Consumption
103 tons
600
500
500
900
1,500
600
2,800
1,600
900
500
600
11,000
13,567
81%
Parti culates
Allowable2
lb/106 BTU
0.4
0.3
0.7
0.3
0.4
0.8
0.1
0.15
0.6
0.56
0.6
Weighted
Allowable
240
150
350
270
600
480
280
240
540
280
360
3,790
S02
Allowable2
lb/106 BTU
3.0
1.06
2.3
2.2
1.0
6.0
1.8
1.2
2.5
4.0
4.0
Weighted
Al 1 owabl e
1,800
530
1,150
1,980
1,500
3,600
5,040
4,640
3,600
2,000
2,400
28,240
Particulates:
3.790 = 0.34 lb/106 BTU
SO,
11,000
26.2 x 0.34
26,240
11,000
= 8.91 Ib/ton coaV
= 2.57 lb/106 BTU
26.2 x 2.57 = 67.3 Ib/ton3
1
Projections of the Effectiveness of a National Tax on Sulfur
Emissions. Research Triangle Institute, November 1973, pp. 96-98.
o c
Based on a 10 x 10 BTU/hr plant and State Regulations as published
in The Enivronmental Reporter.
o c
Assumes 26.2 x 10 BTU/ton (Background Information for Establishment
of National Standards of Performances for New Sources—Industrial
Size Boilers, Walden Research Corporation, June 1971, p. 4-2).
B-3
-------
industrial boilers. Distribution of fuel in 1975 by type of control is
determined to be:
Particulat.es
1970-level
SIP-Tevel
SO,
1970-1 eve!
SIP-Tevel
Commercial
8.4
9.1
6.8
10.7
tons
Industrial
34.8
37.7
28.3
44.2
Actual 1975 emissions are estimated to be:
Industrial Boilers
Particulates
Activity Factor (10b tons)
% Emission Factor (lb/ton)
Emissions (103 tons)
Total particulates
Activity Factor (10° tons)
Emission Factor (lb/ton)
Emission (103 tons)
Total SOp emissions
SO,
Commercial Boilers
Particulates
Activity Factor (10 tons)
Emission Factor (lb/ton)
Emissions (103 tons)
Total particulates
Activity Factor (106 tons)
Emission Factor (lb/ton)
Emissions (103 tons)
Total SOo emissions
SO,
1970 Control SIP Control
34.8
58.4
1,016
37.7
8.64
163
1,016 + 163 = 1,179 x 10-* tons
28.3
114
1,613
44.2
52.9
1,169
1,613 + 1,169 = 2,782 x 10"3 tons
1970 Control SIP Control
8.4 9.1
16.2 8.91
68 40
68 +40 = 108 x 103 tons
6.8
114
388
10.7
67.3
360
388 + 360 = 748 x 10° tons
B-4
-------
1975 Potential Emissions
Particulates
Industrial Boilers
Activity Factor (106 tons Coal) 72.5 72.5
Errlssion Factor (lb/ton) 105.3 114.0
[Ref. 1, p. B-4]
Emissions (103'ton) 3,817 4,133
Commercial Boilers
Activity Factor (106 tons Coal) 17.5 17.5
Emission Factor (lb/ton) 16.2 114
[Ref. 1, p. B-4]
Emissions (103 ton) 142 998
Total:
Particulates 3,817 + 142 = 3,959
S02 4,133 + 998 = 5,131
Compliance Emissions
Particulates
Industrial Boilers
Activity Factor .(106 tons coal) 72.5 72.5
Compliance Factor (lb/ton) 8.91 60.0
[Ref. 1, p. B-7]
Emissions (103 tons) 323 2,175
Commercial Boilers
Activity Factor (106 tons coal) 17.5 17.5
Compliance Factor (lb/ton) 8.91 70
[Ref. 1, p.,B-8]
Emissions (lO^tons) 78 613
Total: o
Particulates 323 + 78 = 401 x 10 tons
S09 2,175 + 613 = 2,788 x 103 tons
B-5
-------
Industrial/Commercial Coal-Fired Boilers
List of References
1. Massoglia, Martin F., Summary of Emission Reductions
Achieved Nationwide by Selected Industrial Source
Categories, Volume II: Research Triangle Park, N.C.;
Research Triangle Institute, June 1975 (Task No. 21,
EPA Contract 68-02-1325).
2. Background Information on Coal-Fired Industrial Boilers,
Washington, D.C.: Division of Stationary Source Enforcement,
Environmental Protection Agency, September 5, 1974.
3. Provided by the EPA Project Monitor.
B-6
-------
APPENDIX C
PORTLAND CEMENT PLANTS
1970
Baseline year data, 1970, are as calculated in the initial study.
Estimated actual particulate emissions for 1970 are estimated to be
[Ref.l, p. C-8].
Particulates 906 x TO3 tons
S02 733 x 103 tons
1975
Estimated Actual Emission Factors
Portland cement plants were under three levels of control in 1975.
Plants coming onstream since 1972 were subject to NSPS and can be assumed
to be in compliance therewith. Some of the 1972 plants in place were in
compliance with SIP emissions limitations. The remainder were emitting at
the average 1970 rate.
SIP control level has been recalculated to reflect SIP changes since
1974 and more current production data. The following emission factors are
applicable.
+ Ib/ton
Particulates SO?
1970 [Ref.l, p. C-8] 23.67 19.15
NSPS [Ref.2] 0.60 None
SIP Control (See table C-l) 1.92 19.15
*Includes 0.96 Ibs. from kilns and 0.96 Ibs. from clinker coolers.
C-l
-------
?
i-o
Table C-l. Allowable Particulate Emissions, Portland Cement Industry,
Based on States having over 75 Percent of 1973 Capacity.
State
Al abama
California
Florida
Illinois
Indiana
Iowa
Kansas
Michigan
Missouri
New York
Ohio
Pennsylvania
Tennessee
Texas
Total
U.S. Total
.2
19731
Production
103 Tons
2,393
9,262
2,182
1,419
2.1185
2,436
1,930 )
4,805
4,154
5,354 .
3,074
8,294
1 ,660
7,853
56,934
78,212
72.7
Number'
of
Plants
7
13
4
3
65
5
5
6
7
10
8
17
6
18
115
166
69.3
Process Rate
Average-Plant 2
Tons/hr •
65.0
135.6
103.8
90.0
67.2
92.7
73.4
152.4
112.9
101.9
73.1
92.8
52.6
83.0
Allowable-
Emissions
Ib/hr
33.8
47. 24
36.4
50.2
123.0
51.6
50.5
55.6
52.5
'56.3
41.2
64.0
32.6
90.3
Total
Allowable
Ib/hr
236.6
613.6
145.6
T50.6
738.0
258.0
252.5
333.6
367.5
563.0
329.6
1,088.0
195.6
1,625.4
6,897.6
Total Process
Rate
tons/hr
455.0
1,762.8
415.2
270.0
403.2
463.5
367.0
914.4
790.3
1,019.0
584.8
1,577.6
315.6
1,494.0
10,832.4
Allowable Emissions
6,897.6
(10,832,4 t 1.5)
0.96 Ib/ton
Minerals Yearbook, U.S. Bureau of Mines, 1973, p. 255.
^Based on ratio of fuel to product of 1.5 as calculated from EPA data (Background Information for Proposed New
Source Performance Standards. Environmental Protection Agency, August 1971) and 7,884 hours per year operation.
o
From State Regulations as reported in The Environmental Reporter.
Average of Los Angeles and San Francisco Process Rate Regulations.
Estimated from data in reference 1 above.
-------
Activity Factors, 1975
68,993 x TO3 tons [Ref. 4].
It should be noted that some of this activity is subject to NSPS.
Assuming that any increase in 1975 activity over 1973 was new facilities.
An estimate of this capacity can be obtained by comparing activity levels
for these two years.
1975 Activity Factor 68.993 x TO3 tons [Ref.4]
1972 Activity Factor . 78.212 x 103 tons [Ref.3, p. 255]
Under NSPS None
Estimated Actual 1975 Emissions
EPA Division of Stationary Source Enforcement compliance data indicates
that 68 percent of the Portland cement plants were in compliance with emission
limitations in 1975 [Ref.5]. Applying this figure to the 1975 reported prod-
uction results in the following distribution by level of control
1970-level (1-0.68) (68,993) = 22,07.8 x 103 tons
SIPHevel (0.68) (68,993) = 46,915 x TO3 tons
Actual 1975 emissions are estimated to be:
1970 Control SIP Control
Particul.ates
Activity Factor (103 tons) 22,078 46,915
Emission Factor (Ib/ton) 23.67 1.92
Emissions (103 ton) 261 45
Total particulate emissions 261 +45 = 305 x 103 tons
SO,
All Activity is considered uncontrolled for S02
Total S02 emissions 68,993 x 19.15 * 2000 = 661 x 103 tons
1975 Potential Emissions
Uncontrolled Emission Factors - Particulates 278.4 lb/ton[Ref.1, p.C-4]
S02 11.9 lb/ton[Ref.l, p.C-4]
Particulates 68,993 x 103 x 278.4 * (2000) = 9,604 x 103 tons
S02 68,993 x 103 x 19.15 - (2000) = 661 x 103 tons
C-3
-------
Compliance Emissions
Participates
3
Activity Factor 68,993 x 10 tons
Emission Factor 1.92 Ib/ton
Emissions 68,993 x 1.92 * 2,000 = 66 x 103 tons
3
Activity Factor 68,993 x 10 tons
Emission Factor 19.15 Ib/ton
68,993 x 19.15 x 2,000 = 661 x 103 tons
C-4
-------
PORTLAND CEMENT PLANTS
List of References
1. Massoglia, Martin F., Summary of Emission Reductions
Achieved Nationwide by Selected Industrial Source
Categories, Volume II: Research Triangle Park, N.C.;
Research Triangle Institute, June 1975 (Task No. 21,
EPA Contract 68-02-1325).
2. 36 FR 24 880, December 23, 1971.
3. Minerals Yearbook 1972. Washington, D.C.: U.S. Bureau
of Mines.
4. Personal communication with Mr. Avery Reed, U.S. Bureau
of Mines, May 11, 1976.
5. Provided by EPA Project Monitor.
C-5
-------
APPENDIX D
PETROLEUM REFINERIES
(Particulates and SC^)
Major sources of particulate and SC^ emissions from petroleum refinery
operations are from catalytic cracking operations and combustion operations
[Ref.l, p.31]. Claus sulfur recovery units using refinery gases as feed-
stocks are also a significant source of S0? emissions.
For the purposes of this analysis, petroleum refinery operations will
include any associated Claus sulfur recovery units. The reduction in SOp
emissions that would otherwise occur if the refinery off-gases were flared,
is not considered a reduction resulting from emission limitations required
under Federal and State programs. Recovery of sulfur from off-gases is
profitable if the price of sulfur is greater than $5.88 per long ton
[Ref.2, p.130]. For the purposes of this analysis, it is assumed that
during 1970-1975, with the exception of small independent refineries, Claus
capacity at petroleum refineries was sufficient to process all off-gases gen-
erated during refinery operations.
It should be noted that emission from Claus units are subsumed under
chemical processes in the NEDS inventories rather than under petroleum
refineries. Fluid coking operations can also result in particulate and SO^
emissions. However, this process is not economically attractive unless the
fuel oil market is weak. [Ref.l, p.20]. Increased demands for energy will
most likely result in an increased demand for residual fuel oil with sup-
pression of fluid coking. Therefore, for the purposes of this analysis,
fluid coking processes will not be considered.
D-l
-------
EMISSION FACTORS
Uncontrolled
Particulates [Ref.3, p.9.1-3]
Boilers and Process Heaters 840 lb/103 bbl oil burned
Fluid Catalytic Cracking . 242 .lb/103 bbl fresh feed
Moving Bed Catalytic Cracking 17 lb/103 bbl fresh feed
S0? [Ref.3, p. 9.1-3; p. 5.18-3]
o
Boilers and Process Heaters 6,720 S lb/10 bbl oil burned
Fluid Catalytic Cracking 493 lb/103 bbl fresh feed
Moving Bed Catalytic Cracking 60 lb/103 bbl fresh feed
Claus Sulfur Recovery Units
(average of two stage unit) 280 Ib/ton sulfur recovered
o
These factors can be converted to a basis of 10° bbl crude processed.
1. Boilers and Process Heaters
In 1967 1,160.677 x 1012 Btu from oil combustion were used in the
petroleum industry [Ref.4] to process 3,582.6 x 106 bbl of crude [Ref. 5,
p.166]. Using a heat content of 6,000 x 106 Btu/103 bbl of oil, 2nd sulfur
o
content of 1.0% [Ref. 1, p. 4], uncontrolled emissions per IQ'3 bbl crude
processed are calculated as being: •
Particulates:
840x 1,160.677 x IP12 x 103 = 45.4 ib/lO3 bbl crude
6,000 x 106 x 3,582.6 x 106
SO:
6,720 x 1 x 1 160.677 x IP12 x 1Q3 = 363 lb/1Q3 fabl cnjde
6,000 x 10° x 3.582.6 x 10b
2. Catalytic Cracking
In 1970 and 1971 86.6 percent of production was by the fluid bed system
[Estimated from data in Ref. 6, p.69, and Ref. 7, p. 81]. This same ratio will
be used through 1975. Approximately 45 percent of crude is processed by cata-
lytic cracking [Ref.l, p.14].
Particulates:
[(242 x 0.886) + (17 x 0.114)] x 0.45 =97.4 lb/103 bbl crude
S02:
[(493 x 0.886) + (60 x 0.114)] x 0.45 = 198 lb/103 bbl crude
D-2
-------
Emissions from existing coking operations, .and sulfur in solid and
liquid wastes;could amount for a.t .least part.i.of the .unaccounted for sulfur.
The validation .by the sulfuric balance is considered adequate for the
purposes of this analysis. • ...
5. Recapitulation
Uncontrolled Emission Factors
Tb/10 bbl crude processes
Particulates S02
Catalytic Crackers -.97.4 363
Boilers and Process Heaters 45.4 198
Claus Recovery Systems — 214
Total 142.8 775
Controlled Emissions
Particulates
Synthesized nationwide allowable emission factors for catalytic cracking and
fuel combustion based on'regulations for states having 70% of national
refinery capacity are calculated ~as ;being Xtable D-l)
Catalytic cracking 19.1 l:b/106 bbl crude
Combustion 0.31 lb/106 Btu
Using the same data as used for uncontrolled emissions, the emission factor
3
for combustion sources.converts to 100.4 lb/10 bbl crude.
0.31 x 1,16.0,677,000
.. a 100,. 4
3,582,600
This is larger than the uncontrolled remissions factor. Controlled factor is
assumed to be the same as uncontrolled for combustion processes.
All sources 45.4 + 19.1 = 64.5 lb/103 bbl crude
New sources performance standards for partlculate emissions from catalytic
D-4
-------
Table D-l. Allowable Particulate Emissions, Petroleum Refinery
Operations. Based on regulations for States having
over 70 percent of national crude capacity.
State
California
Illinois
Indiana
Louisiana
Ohio
Oklahoma
Pennsylvania
Texas
TOTAL
U.S. TOTAL
%
1975
Capacity
bbl/day
1,903,935
1,176,050
561,160
1,753,095
589,770
545,775
575,020
5,966,330
11,253,135
15,074,845
74.6
Catalytic Cracking
Allowable,,
Emissions
Ib/hr
49.3
58.5
58.5
58.5
58.5
58.5
33. T
91.14
Weighted
by 5
Capacity
9,386
6,880
3,282
10,256
3,450
3,193
2,506
36,133
75,087
Combustion Processes
Allowableg
Emissions
106/Btu
0.27
0.1
0.4
0.6
0.2
0.35
0.27
0.3 8
Weighted
by 5
Capacity
38.08
11.77
22.45
105.19
11.80
19.10
20.44
118.99
347.82
Catalytic Cracking
75,087 xlO x 24 y n ?8 = 1Q l
11 253.135 x 31.8
"
Combustion Process
^47 ft? v in
347'82 X 10
11,253,135
= 0.31 lb/10 Btu
Summary of Operating Capacities in the U.S.," The Oil and Gas Journal.
Vol. 79, No. 13, March 29, 1976, p. 129.
2
Based on an average throughput of 31,800 bbl/day (Petroleum Refinery Back-
ground Information for Establishment of Federal Standards for the Performance
of Stationary Sources. Process Research Inc., August 1974, p. 19) and
regulations as published in The Environmental Reporter.
3
Average Los Angeles and California Process Rate Curves.
Based on 90,000 scfm and temperature 600° F (calculated from Background
Information for Proposed New Source Performance Standards, Environmental
Protection Agency, June 1973, p. 18).
(bbl/calendar day) x (allowable emissions) * 10 .
Based on average boiler size, 100 x 10 Btu hr. and regulations as
published in The Environmental Reporter.
7
Estimated from previous RTI work on PRMS.
Analyses of Final State Implementation Places—Rules and Regulations.
APTD-1334 Environmental Protection Agency, July 1972.
D-5
-------
converters and combustion processes were promulgated in March 1974. It will
be assumed that the NSPS will not be applicable to new refinery capacity
until after 1975.
so2
NADB considers SOp emissions from refinery operations to be relatively uncon-
trolled. Claus plants are considered as control techniques for S02 emissions
for off-gases from other than catalytic crackers and combustion process [Ref.9].
Analysis of State regulations for S02 emissions from catalytic crackers and
combustion processes indicates that no controls are required for these processes
For sulfur recovery units, EPA estimates that reasonable available control
technology will permit limitation of S02 emissions to 0»01 pound per pound of
sulfur processed (1,300 ppm) [Ref. 1, p.50]. This figure, assumed to
represent SIP requirement, converts to crude input as follows:
0.01 x 1.1 x 2,000
0.01 x 1.1 x 2,000 x 103 = 17 pound/103bb/crude
pounds S02/ton of S recovered
1,310
Total controlled S02 Emission
Claus Plants
Catalytic Crackers
Boilers and Combustion Processes
Total
lb/10° bbl crude
17
363
198
578
ACTIVITY FACTORS
1970
1975
DEGREE OF CONTROL
Particulates
SO 2 Process and Combustion
3,967.5 x 106 bbl crude [Ref.4, p.166]
4,539.14 x 106 bbl crude [Ref. 10]
1970
68.4 lb/106 bbl crude [Ref.11, p.0-8]
532 lb/103 bbl crude Uncontrolled [Ref. 9]
D-6
-------
1970
Particulate emissions in 1970 are estimated to be:
Actual Potential
Activity Factor (106 bbl crude) 3,967.5 3,967.5
Emission Factor (lb/103 bbl) 684 [Ref.ll, 142.8
, p.12-8]
Emissions (10J tons) 136 283
emissions in 1970 are estimated to be:
Actual Potential
Activity Factor (106 bbl crude) 3,967.5 3,967.5
Emission Factor (lb/103 bbl) 775 775
Emissions (103 ton) ' 1,537 1,537
1975
EPA Division of Stationary Source Enforcement compliance data indicates
that 81 percent of petroleum refineries as a source were in compliance with
emissions regulations as in 1975 [Ref.l] . It is assumed that these compli-
ance data are equally applicable to particulates and SOp- Actual 1975 emission
factors can be estimated as follows:
Particulates:
(1-0.81)(68.4) + (0.81)(64.5) = 65.2 lb/103 bbl crude
S09: .
c , (l-0.8l)(l,007) + (0.81)(578) = 660 lb/10J bbl crude (Assumes all
off gases processed through sulfur recovery units.)
1975 actual emissions are estimated to be:
Particulates S02
Activity Factor (106 bbl crude) 4,539.14 4,539.14
Emission Factor (lb/103 bbl crude) 65.2 660
Emissions (103 tons) 148 1,498
1975 potential emissions are estimated to be:
Particulates SO
2
Activity Factor (10^ bbl crude) 4,539.14 4,539.14
Emission Factor (lb/103 bbl crude) 142.8 775
Emissions (103 tons) 324 1,759
D-7
-------
Compliance Emissions
Participates SO
2
Activity Factor (106 bbl crude) 4,539.14 4,539.14
Emission Factor (lb/103 bbl crude) 64.5 578
Emissions (103 tons) 146 1,312
D-8
-------
PETROLEUM REFINERIES
List of References
1. Atmospheric Emissions from The Petroleum Refining Industry.
Research Triangle Park, N.C.: Environmental Protection Agency,
August 1973. EDA
2. Russell, Cliford S., Residuals Management in Industry: A Case
Study of Petroleum Ref lining. Baltimore: The Johns Hopkins
University Press, 1973 (Published for Resources for the
Future, Inc.).
3. Compilation of Air Pollutant Emission Factors, AP-42, Second
Edition (with changes 1-5). Research Triangle Park, N.C.:
Environmental Protection Agency, December 1975.
4. An Analysis of the Materials and Natural Resources Requirements
and Residuals Generation of Personal Consumption Expenditures.
Draft Final Report. Research Triangle Park, N.C.: Research Triangle
Institute, April 1975 (For EPA Office of Solid Waste Management under
Contract 68-01-2448).
5. 1971 Business Statistics, U.S. Department of Commerce.
6. OAQPS Data File of Nationwide Emissions, 1970. Research Triangle
Park, N.C.: Environmental Protection Agency, April 1973.
7. OAQPS Data File of Nationwide Emissions, 1971. Research Triangle
Park, N.C.: Environmental Protection Agency, May 1973.
8. Petroleum Refinery Background Information for Establishment of
Standards of Performance for Stationary Sources, Process Research,
Inc., August 1974.
9. Personal communication with Mr. C. Mann, EPA/Durham, June 1, 1976.
10. Personal communication with Mr. D. Lange, Oil and Gas Journal,
May 14, 1976.
11. Massoglia, Martin F., Summary of Emission Reduction Achieved Nation-
wide by Selected Source Categories, Volume II. Research Triangle
Park, N.C.: Research Triangle Institute, June 1975 (Prepared for
DSSE under Task 21, Contract 68-02-1325).
12. Unpublished EPA Data Provided RTI in conjunction with work under
Task Order 15, Contract 68-02-0607).
13. Provided by EPA Project Monitor.
D-9
-------
APPENDIX E
MUNICIPAL REFUSE INCINERATORS
(Particulates Only)
1970
Baseline year data (1970) are as previously calculated in the initial
study and are estimated as being 105 x 10 tons [Ref. 1, p. E-3].
1975
Estimated Actual Emission Factors
Municipal incinerators in 1975 were under two levels of control:
1970-level and SIP-level. The emission factors used in the initial study
are considered to represent the most current SIP data and are used herein.
1970-level [Ref.l, p. E-6] 17.2 Ib/ton
SIP-level [Ref.l, p. E-6] 2.4 Ib/ton
Activity Factor
1975 13.5 x 106 tons [Ref. 2]
Estimated Actual 1975 Emissions
EPA Division of Stationary Source Enforcement compliance data indicate
that 43 percent of municipal incinerators were in compliance with emission
limitations in 1975. Activity can be distributed to level of control as
follows:
1970-level [1-0.43][13.5] = 7.7 x 106 tons
SIP-level [0.43] [13.5] = 5.8 x 106 tons
Actual 1975 emissions are estimated to be:
1970-level SIP-level
Activity Factor (106 tons) 7.7 5.8
Emission Factor (Ib/ton) 17.2 2.4
o
Emissions (10 tons) 66.2 7.0
Total: 73.2 x 103 tons
E-l
-------
1975 Potential Emissions
Activity Factor (TO6 tons) 13.5
Emission Factor (lb/tonj[Ref .3, p. 2.1-3] 30
Emissions (TO3 tons) 203
Compliance Emissions
Activity Factor (106 tons). 13.5
Emission Factor (Ib/toir) 2.4
Emissions (10 tons) 16
E-2
-------
MUNICIPAL REFUSE INCINERATORS
List of References
1. Massoglia, Martin F., Summary of Emission Reductions
Achieved Nationwide by Selected Industrial Source
Categories, Volume II: Research Triangle Park, N.C.;
Research Triangle Institute, June 1975 (Task No. 21,
EPA Contract 68-02-1325),
2. Personal communication with Mr. S. Hitte, Office of
Solid Waste Programs, Environmental Protection Agency,
May 17, 1976.
3. Compilation of Air Pollutant Emission Factors AP-42
(with changes 1-5). Research Triangle Park, N.C.:
Environmental Protection Agency, December 1975.
E-3
-------
APPENDIX F
SULFUR1C ACID PLANTS
(S02 Only)
1970
Baseline year data (1970) are as previously calculated in the initial
study. Estimated actual emissions for 1970 are 581 x 10 tons S02 [Ref. 1
p. F-3].
1975
Estimated Actual Emission Factors
Sulfuric acid production in 1975 was under four levels of control:
1970-level; SIP level, SIP new source level for plants coming onstream
1970-1972, and NSPS level for plants coming onstream after 1972.
The following emission factors are applicable.
S02/ton 100% acid
1970-level [Ref. 1, p. F-6] 40
SIP-level [Table F-l] 12.0
SIP-level, New Plants [Table F-l] 8.8
NSPS [Ref. 2] 4.0
The SIP emission factor has been recalculated to reflect SIP changes since
the initial study.
Activity Factors
IP6 tons 100% acid
1970 [Ref.3, p. 125] 29.0
1972 [Ref.4, p. 125] 31.0
1975 [Ref.5] 31.3
6 *
Thus 2.0 x 10 tons were produced under SIP new source controls and
0.3 x 106 tons under NSPS.
F-l
-------
Table F-l. Allowable SCL Emission Factors, Sulfuric Acid Plants. Based on
Regulations for States Having over 75 Percent of National Capacity
\
State
Arizona
California
Florida
Idaho
Illinois
Louisiana
New Jersey
North Carolina
Pennsylvania
Tennessee
Texas
Total
US
%
1973
Capacity
103 tons
2,573
2,332
15,323
1 ,489
1,570
6,361
1,915
2,257
937
1,260
4,274
40,291
42,878
94.0
2
Allowable Emissions
Existing
Plants
4.0
6.5
10.0
28.0
4.0
6.5
6.53
27.0
6.5
6.5
30.0
New
Plants
4.0
6.5
4.0
4.0
4.0
6.5
6.53
27.0
6.5
4.0
30.0
Weighted by Capacity
Existing
Plants
TO, 292
15,158
153,230
41 ,692
6,280
41 ,347
12,448
60,939
6,091
8,190
128,220
483,887
New
Plants
10,292
15,158
61 ,292
5,956
; 6,280
41,347
12,448
60,939
6,091
5,040
128,220
353,063
-n
ro
= 8.76 Ib/ton
Existing Plants ^fffffy = 12.00 Ib/ton New Plants
Chemical Economics Handbook, Stanford Research Institute, February 1976, pp. 780, 1003B-U.
Based on State Regulations as published in The Environmental Reporter.
o
Analyses of Final State Implementation Plans—Rules and Regulations
APTD 1334. Environmental Protection Agency, July 1972.
-------
Estimated Actual 1975 Emissions
EPA Division of Stationary Source Enforcement compliance data indicate
that 62 percent of the sulfuric acid plants were in compliance with emission
limitations in 1975 [Ref. 6]. Some of the plants in compliance are meeting
NSPS or SIP new source standards. The remainder SIP existing source require-
ments. The plants not in compliance are assumed to have the same degree of
control as in 1970. Following is the distribution of 1975 production by level
of control.
1970-level (1-0.62)(31.3) = 11.9xl06tons
SIP-new source level 2.0 x 10 tons
NSPS 0.3 x 106 tons
SIP-existing sources level 17.1 x 10 tons
Actual 1975 emissions are estimated to be:
1970
Activity
Emission
Emissions
Factor
Factor
(103
(106
tons)
(Ib/ton)
tons)
Total Emissions
1975
238.0 +
Potential
11.
40
238.
8.8 + 102.
Emissions
9
0
6
SIP
2.
•8.
8.
+ 0.6
New SIP
0
8
8
=
17.
12.
102.
350 x
1
0
6
103
NSPS
0.
4.
0.
3
0
6
tons
Activity Factor (106 tons) 31.3
Uncontrolled Emission Factor 40
(Ib/ton) [Ref.7, p. 5.17-5]
Potential Emissions (103 tons) 626
Compliance Emissions
SIP-existing SIP-new NSPS
Activity Factor (106 tons) 29.0 2.0 0.3
Emission Factor (Ib/ton) 12.0 8.8 4
Emissions (103 tons) 174.0 8.8 0.6
Total 174.0 + 8.8 + 0.6 = 183.4 x 103 tons
F-3
-------
SULFURIC ACID PLANTS
List of References
1. MassogTia, Martin F., Summary of .Emission Reductions
Achieved Nationwide by Selected INdustrial Source
Categories, Volume II: Research Triangle Park, N.C.;
Research Triangle Institute., June 1975 (Task No. 21,
EPA Contract 68-02-1325).
2. 36 FR 24881, December 23, 1971.
3. 1971 Business Statistics, U.S. Department of Commerce.
4. 1973 Business Statistics, U.S. Department of Commerce.
5. Chemical Economics Handbook. Stanford .Research
Institute, February 1976.
6. Provided by EPA Project Monitor.
7. Compilation of Air Pollutant Emission Factors, AP42,
Second Edition (with changes 1-5), Research Triangle
Park, N.C.: Environmental Protection Agency,
December 1975.
F-4
-------
APPENDIX G
PHOSPHATE FERTILIZER PLANTS
(Particulate Emissions Only)
1970
Baseline year data (1970) are as calculated in the initial study.
Estimated actual particulate emissions for 1970 are [Ref. 1, pp. G-9,
Diammonium Phosphate (Process) 10
Normal Super Phosphate (Process) less than 1
Rock Pulverization 14
1975
Estimated actual emission data
Phosphate fertilizer plants in 1975 were under two levels of control,
1970-level and SIP-level. SIP-level has been recalculated to reflect
changes in SIP regulations since 1974 and more current production data
[Table G-l]. The following emission factors are applicable:
Emission Factors (Ib/Ton PO^C)
1970-level SIP-level
Diammonium Phosphate (Process) 8.2 [Ref.l, p.G^-7] 1.41 [See table G-l]
Normal Superphosphate 0.9 [Ref.l, p.G-7] 6.09 [Ref.l, p. G-4]
Rock Pulverization 4.3 [Ref.l, p.G-7] 3.19 [Ref.l, p. G-6]
Activity Factors 1975
Diammonium Phosphate 2.552 x 106 Tons P205 [Ref. 2]
Normal Superphosphate 0.484 x 106 Tons P205 [Ref. 2]
Rock Pulverization 6.72 x 106 Tons P205
Rock pulverization activity factor estimated by scaling up 1970 data by
ratio of diammonium phosphate production 1975 to 1970.
1970 Diammonium phosphate production 2.43 x 106 tons P205 [Ref.3,Table 1.1]
1975 Diammonium phosphate production 2.52 x 106 tons P205 [Ref.2]
1970 Rock Pulverization Activity 6.4 x 106 tons P205 [Ref.3, Table 1.1]
Estimated 1975 Rock Pulverization Activity
5 toi
G-l
6.4 x 2.552 _ f. 79 In6 .nne
2 aq = 6.72 x 10 tons
-------
Estimated Actual 1975 Emissions
EPA Division of Stationary Source Enforcement Compliance data indicates
that 87 percent of the phosphate fertilizer sources were in compliance'with
emission limitations in 1975 [Ref. 4]. The data are not broken down by
process. It will be assumed that the compliance data are applicable to all
operations. Applying this compliance figure to 1975 activity data results
in the following distribution of activity by control level.
106 Tons P205
SIP-level 1970-1evel
Diammonium Phosphate 2.221 0.331
Normal Superphosphate 0.421 0.063
Rock Pulverization 5.85 0.87
Actual 1975 emissions are estimated to be:
n- • u u ^ 1970 Control SIP Control
Diammonium phosphate •• - • *
Activity Factor (106 tons P205) 0.331 2.221
Emission Factor (Ib/ton P205) 8.2 1.41
Emissions (103 tons) 1 2
Total particulate emissions 3 x 10 tons
Normal Superphosphate
Activity Factor (106 tons P205) 0.063 0.421
Emission Factor (Ib/tons PgO,-) <1 <1
Total particulate emissions
-------
1975 Potential Emission
Activity Factors
Diammonium phosphate 2.252 x 10 tons P^Or
fi ^ 5
Normal Superphosphate . 0.484 x 10 tons P20c
Rock Pulverization 6.72 x 106 tons P20g
Uncontrolled Emission Factors
Diammonium phosphate 82 Ib/ton P20g [Ref. 5, p.6.10-1-2]
Normal superphosphate 9 Ib/ton PgOg [Ref. 5, p.6.10-1]
Rock Pulverization 21.5 Ib/ton P205 [Ref.l, p.G-4]
Potential Emissions
fi 3
Diammonium phosphate 2.25 x 10 x 82 •* (2,000 x 1,000) = 92.3 x 10 tons
Normal Superphosphates 0.84 x 106 x 9 * (2,000 x 1,000) = 2.2 x 103 tons
Rock Pulverization 6.72 x 106 x 21.5 4 (2,000 x 1,000) = 72.4 x 103 tons
Total 166.9 x 103 tons
Compliance Emissions
Activity Factors •
Diammonium phosphate 2.252 x 10 tons P20g
Normal Superphosphate 2.484 x 106 tons P205
Rock Pulverization 6.72 x 10 tons P205
Compliance Emission Factors
Diammonium phosphate 1.51 Ib/ton P20c
Normal Superphosphate 0.09 Ib/ton P205
Rock Pulverization 3.19 Ib/ton P205
Emissions
Diammonium Phosphate 2.252 x 106 x 1.41 * (2,000 x 1,000) = 1.6 x 103 tons
Normal Superphosphate 0.484 x 106 x 0.09 * (2,000 x 1,000) = neg.
Rock Pulverization 6.72 x 106 x 3.19 •*. (2,000 x 1,000) = 10.7 x 103 tons
Total 12.3 103 tons
G-3
-------
Table G-l. Allowable Emissions, Diammonium Phosphate Based on State Re-
gulations for States having 75 Percent of National Production Capacity
State
Florida
Idaho
Illinois
Louisiana
Texas
TOTAL
US TOTAL
%
Annual
Capacity
1Q3 tons
3,520
525
530
1 ,630
1,240
7,445
9,910
75
Number
of
Plants
8
3
3
4
5
23
2
Allowable
Emissions
Ib/hr
;22,85
21,44
22.38
29.85
35.53
i
Allowable
Emissions, all plants
Ib/hr
182..80
64.32
67.14
119.40
177.65
611.31
"
SIP Emissions:
611.31 x 8,760
7,445,000 x 0.73
Diammonium phosphate contains 70% P90K (calculated)
0.985 Ib/ton DAP
0.985
0.70
1.41 Ib/ton P00C
c. b
1
1974 Directory of Chemical Producers, Stanford Research Institute,
pp. 424-425
"Average of all plants calculated on a plant by plant basis, using
State Regulations as published in The Environmental ^Reporter, using
operation at 43 percent capacity.. (Calculated from data in
Engineering and Cost Study of Emission Control in The Phosphate
Industry, Chemical Construction Corporation, December 1970, p.6.3;
and Emission Standards for the Phosphate Rock Processing Industry,
Chemical Construction Corporation, July 1971, Table 1.).
G-4
-------
PHOSPHATE FERTILIZER PLANTS
List of References
1. Massoglia, Martin F., Summary of Emission Reductions
Achieved Nationwide by Selected Industrial Source
Categories, Volume II: Research Triangle Park, N.C.;
Research Triangle Institute, June 1975 (Task No. 21,
EPA Contract 68-02-1325).
2. Personal Communication with Ms. Gloria Cable, U.S.
Department of Commerce.
3. Emission Standards for The Phosphate Rock Processing
Industry, New York: Chemical Construction Corporation,
July 1971.
4. Provided by EPA Project Monitor.
5. Compilation of Air Pollutant Emission Factors, AP-42,
Second Edition (with changes 1-5). Research Triangle
Park, N.C.: Environmental Protection Agency,
December 1975.
G-5
-------
APPENDIX H
PRIMARY SMELTERS
1970
Baseline year data (1970) are as calculated in the initial study.
Estimated actual emissions for 1970 are [Ref.l, App. H]:
103 Tons
Particulates
Primary Copper Smelters 42 3,184
Primary Lead Smelters 1 217
Primary Zinc Smelters 2 179
Primary Aluminum Smelters 145
Total 190 3,580
1975 (Primary Copper, Lead, and Zinc Smelters).
Emissions data for primary smelters are summarized in Table H-l
for Copper, H-2 for Lead, and H-3 for Zinc Smelters. These data are developed
on an individual smelter basis. Summary emissions for 1975 and under full
compliance are: •,
10J Tons
Particulates SO
Copper
1975 Potential 423 3,751
1975 Actual 31 2,661
Compliance 8 512
Lead
1975 Potential 57 321
1975 Actual 1 240
Compliance 1 55
Zinc
1975 Potential 69 557
1975 Actual 1 64
Compliance 1 36
H-l
-------
Table H-1. Emissions Data, Primary Copper Smelters
NAME/LOCATION
1. ASARCO/Tacoma, Washington
2. ASARCO/Hayden, Arizona
3. ASARCO/E1 Paso, Texas
4. Phelps Dodge/Douglas, Arizona
5. Phelps Dodge/Morenci , Arizona
6. Phelps Dod^e/Ajo, Arizona
7. Magma/San Manuel, Arizona
8. Kennecott/Hurley, N.M.
9. Kennecott/McGill, Nevada6
0. Kennecott/Hayden, Arizona
11. Kennecott/Garfield, Utah
2. Anaconda/Anaconda, Montana
3. White Pine/White Pine, Michigan
14. Cities Service/Copperhill ,Tenn
5. Inspiration/Miami, Arizona
Capacity
Tons/Day
Cone
1,200
2,000
700
2,260
2,113
680
1,700
767
750
1,050
2,200
1,710
700
300
840
Metal
300
366
260
365
470
197
310
234
185
220
750
500
220
50
300
1975
Compliance
Status2
PM
out
out
in
out
out
out
out
out
out
in
out
out
in
out
in
so2
out
out
out
out
out
out
out
out
out
out
out
out
(7)
out
out
1972 ,
Emissions
Tons/Day
PM
2.04
1.5
3.5
48
15.5
0.7
2.33
3.55
13.0
1.1
4.79
22.5
2.4
~0
Unk
so2
383.0
311.8
400
1,394
T.,294
380
1,080
596
560
199
355
790
97
Unk
37.4
Compliance
Emissions
Tons/Day
PM
1.13
0.42
1.05
0.61
0.60
0.47
0.58
0.53
0.50
0.52
4.7911
0.58
0.47
0.27
0.37
so2
75.0'
58. 18
205
156.58
176. 98
61. 48
153. 68
74. 49
121. 81(
43. 98
72. 412
240.0
97. 013
1.3
14. 38
1975
Estimated
Emissions
Tons/Day
PM
2.04
1.5
1.05
48
15.5
0.7
2.33
355
13.0
0.52
so2
383.0
311.8
400
1,394
1,294
380
1,080
596
560
199
4.7910 355
0.58
0.47
~0
0.37
790
97
18714
37.4
1975 |
Potential |
Emissions5 j
Tons/Day j
PM
81
135
47.3
152.6
142.6
45.9
114.8
51 .8
50.6
70.9
148.5
115.4
47.3
20.3
56.7
so2 !
750 |
1,250 |
438 I
1,413 i
1,321 !
425 '
1,063 ;
479 1
469 |
656 1
1,375 1
1,069 |
97 !
187 i
374 !
_.. 18,9704,727 120.91 24.20 94.4 1,280.7 1
Iota1s 7,877.2 1,551.6 8,064.2 11, 366 j
IE
ro
1. Background Information for Proposed New Source Performance Standards for Primary Copper, Zinc, and Lead
Smelters, Volume I. EPA-450/2-74-002a, Environmental Protection Agency, October 1974, pp. 5-3, 5-4.
2. Memorandum, Subject: Smelter Compliance Status, March 22, 1976, Grubbs to Duprey, Division of
Stationary Source Enforcement, EPA, Washington, D.C.
-------
3. Calculated using control requirements in applicable SIP's and EPA proposed or promulgated regulations.
Assumption is made that EPA promulgated regulations will be sustained in any current litigations.
Actual production data for each smelter is estimated by applying the ratio of reported 1975 production/
total capacity to individual plant capacities.
4. Compliance emissions used for smelters reported to be in compliance with SIP requirements and 1972
emissions for smelters reported out of compliance.
5. Massoglia, Martin F. Summary of Emission Reduction achieved nationwide by Selected Industrial Source
Categories, Volume II: Appendixes. Research Triangle Park, N.C. Research Triangle Institute, June,
1975. (Task Order No. 21, EPA-Contract 68-02-1325).
6. Company announced intention of shutting down facility in June 1976. (Source, Reference 2, above).
7. No S02 Regulation. Emissions assumed to be uncontrolled.
8. EPA Proposed 40 FR 49365, .October 22, 1975.
9. EPA Proposed, 40 FR 19213, May 2, 1975.
10. EPA promulgated. 40 FR 5512, February 6, 1975.
11. Reported actual emissions. EPA promulgated rules permit 16.1 tons particulate matter per day.
!2. EPA promulgated 40 FR 54786, November 20, 1975.
13. No regulation. Compliance emissions assumed same as reported actual.
14. No data available, assumed to be uncontrolled.
-------
Table H-2. Emission Data, Primary Lead Smelters
NAME/LOCATION
1. Bunker Hill/Kellogg, Idaho
2. AMAX/Boss, Missouri5
3. St. Joe/Herculaneum, Missouri
4. ASARCO/Helena, Montana
5. ASARCO/Glover, Missouri
6. ASARCO/E1 Paso, Texas
Totals
Capacity
Tons/Day
Cone.
515
810
745
400
260
220
Metal
350
380
550
105
222
150
2,950
1,757
1975
Compliance
Status2
PM
in6
in
in
out
in
in
so2
out
out
in
in
out
out
1972 ,
Emissions
PM
0.85
0.25
0.48
1.56
0.18
0.20
so2
29.5
71.0
200.0
447.8
387.0
217.0
3.52
1,352.3
Compliance
Emissions J
Tons/Day
PM
0.39
0.49
0.49
0.33
0.25
0.34
so2
81. 47
12. 08
12.08
9.9
12. 08
38.4
2.29 165.7
1975
Estimated
Emissions4
Tons/Day
PM
0.39
0.259
0.489
1.56
0.189
0.209
so2
29. 59
71.0
12.0
9.9
387
217
3.06 7,265
1975
Potential 5
Emissions
Tons/Day
PM
32.2
50.6
46.6
12.4
16.3
13.8
so2
170.0
267.3
245.9
132.0
85.8
726
71.2 973.6
1. Background Information for Proposed New Source Performance Standards for Primary Copper, Zinc, and Lead
Smelters, Volume I. EPA-450/2-74-002a, Environmental Protection Agency, October 1974, pp 5-30.
2. Memorandum, Subject: Smelter Compliance Status, March 22, 1976, Grubbs to Duprey, Division of
Stationary Source Enforcement, EPA Washington, D. C.
3. Calculated using control requirements in applicable SIP's and EPA proposed or promulgated regulations.
Assumption is made that EPA promulgated regulations will be sustained in any current litigations.
Actual production data for each smelter is estimated by applying the ratio of reported 1975 production/
total capacity to individual plant capacities.
4. Compliance emissions used for smelters reported to be in compliance with SIP requirements and 1972
emissions for smelters reported out of compliance.
-------
5. Massoglia, Martin F., Summary of Emission Reductions Achieved Nationwide by Selected Industrial
Source Categories, Volume II: Appendices. Research Triangle Park, N.C.,'Research Triangle
Institute, June, 1975. (Task Order No. 21, EPA-Control 68-02-1325).
6. DSSE Compliance data indicates smelter is in violation of fugitive emission regulations. Implies
compliance with process emission regulations. Fugitive emissions not included in these data.
7. Calculated using 317,000 Scfn (from reference in note above) and EPA promulgated limitations of
2,000 ppm for weak gas streams. Strong gas streams are trended at H2S04 recovery plant at the
collocated zinc smelter. Total compliance emissions from the combined Zn/Pb smelters do not
exceed the EPA promulgated limitation of 680 tons per seven day period.
8. Missouri Regulations S-X,D specifies fenceline requirements, as such they are unenforceable.
However, Regulation S-X,E limits emissions to 1,000 Ib/hour. Compliance emissions are calculated
on the latter.
9. Compliance emissions are greater than reported in 1972 emissions. The latter emissions are used.
en
-------
Table H-3. Emission Data, Primary Zinc Smelters
NAME/LOCATION6
1. ASARCO/Corpus Christy, Texas
2. ASARCO/Col umbus , Ohio
3. ASARCO/Amarillo, Texas
4. National Zinc/Bartlesville,
Oklahoma 8
5. Bunker Hill/Kellogg, Idaho
6. St. Joe/Monaca, Pennsylvania
7. New Jersey Zinc/Pal merton, Pa.
8.; GMAX/Blackwell, Oklahoma10
9. New Facility 1]
Totals
Capacity
Tons/Day
Cone.
250
200
270
250
550
875
520
490
Metal
300
60
135
140
300
640
315
275
150
1975
Compliance
Status2
PM
in
in
out
out
in9
in
out
out
so2
in
out
out
(15)
out
out
out
out
1972
Emissions
Tons /Day
PM
~0
~0
4.4
0.45
^,
1.79
0.12
0.25
so2
4.9
2.9
162
20.4
14.4
53
20
324
Compliance
Emissions 3
Tons/Day
PM
0.44
0.22
__
0.26
0.43
0.12
0.09
__
0.22
1.78
so2
2.6
2.9
_.
20. 412
15. 73
31.4
8.5
_«.
28. O14
109,5
1975
Estimated.
Emissions
Tons/Day
PM
0.44
0.22
2.2
0.45
0.43
0.12
0.12
0
0
3.98
so2
2.6
2.9
81
20.4
14.4
53
20
0
0
194.3
1970
Potential
Emissions5
Tons/Day
PM
15.0
12.0
8.0
16.0
57.8
91.9
80?6
__
18. 01
299.3
so2
137.5
110.0
68.8
137.5
302.5
481.3
286.0
__
616516
1,688.
1. Background Information for Proposed New Source Performance Standards for Primary Copper, Zinc, and Lead
Smelters, Volume I. EPA-450/2-74-002a, Environmental Protection Agency, October 1974, pp 5-20.
2. Memorandum, Subject: Smelter Compliance Status, March 22, 1976, Grubbs to Duprey, Division of
Stationary Source Enforcement, EPA, Washington, D.C.
3. Calculated using control requirements in applicable SIP's and EPA proposed as promulgated regulations.
Assumption is made that EPA promulgated regulations will be sustained in any current litigations.
Actual production data for each smelter is estimated by applying the ratio of reported 1975 production
total capacity to individual plant capacities.
4. Compliance emissions used for smelters reported to be in compliance with SIP requirements and 1972
emissions for smelters reported out of compliance.
-------
5. Massoglia, Martin F., Summary of Emission Reductions Achieved Nationwide by Selected Industrial Source
Categories, Volume II: Appendices. Research Triangle Park, N.C. Research Triangle Institute, June,
1975. (Task Order No. 21, EPA-Contract 68-02-1325).
6. Does not include ASARCO/E1 Paso vacility. This smelter uses slag from ASARCO's primary copper
smelter as raw materials. S0~ emissions from the zinc primary process are relatively small and
are not included.
7. Shut down by State order May 31, 1975. Will be replaced by electrolytic refinery in 6 months,
assumed to meet emission limitations on startup. One-half of 1972 emissions used for.1975 actual
and potential emission.
8. Will be shut down when replacement smelter is completed. Replacement smelter assumed to be same
capacity as existing one.
9. DSSE compliance data indicates smelter is violation of fugitive emission regulations. Implies
compliance with process emission regulations. Fugitive emissions not included in these data.
10. Shut down by State order. December 1973. According to EPA (EPA-450-74-002a, p.5-26) AMAK
the American Zinc Company electrolytic zinc plant in St. Louis. Full capacity of 84,000 tons :
electrolytic zinc to be reached in 1975. No date available to permit inclusion of the St. Louis
facility in this table.
11. EPA (EPA-452-74-002a, pp. 5-26, 5-27) reports that ASARCO plans to replace the capacity of the
shutdown Amarillo facility with a 150 ton/day electrolytic zinc plant near Stephensport, Kentucky.
Plant start-up scheduled for 1976. Emissions from this facility included in compliance emissions
based on new source emission limitations.
12. No regulations. Smelter is in a priority III AQCR. 1972 actual emissions used for compliance
emissions.
13. Combined with emissions from stack at associated Pb smelters, total S0£ emissions do not exceed the
EPA promulgated limitations or 680 tons/7 days.
14. Based on NSPS requirements.
15. No SIP regulations. In a priority III AQCR. Reported 1972 emissions used for compliance and 1972
actual.
16. Estimated using AP-42 emissions factors.
-------
1975 (Primary Aluminum Smelters, Partial lates only)
Estimated Actual Emission Factors
Primary aluminum production in 1975 was under two levels of control:
1970-level, and SIP-level. The SIP control level calculated in reference 1
(the initial study) has been refined to reflect SIP changes that have been
made since the initial calculations. The following emission factors are
applicable:
1970-level, all processes [Ref.l, p. H-4-5] 72.7 Ib/tons
1975-level, all processes [Calculated below]
SIP allowable emission factors for reduction process as calculated in
table H-4 is 2.9 Ib/hr. This is the same as 2.9 Ib/hr. calculated in the
initial study [Ref.l, p. H-4-4]. Therefore the SIP emissions factor of
46.2 Ib/ton previously calculated for all processes in aluminum smelting
is considered to be valid iRef.l, p. H-4-3].
Activity Factors 1975
Annual production
3.879 x 10b tons [Ref. 2]
Estimated Actual 1975 Emissions
EPA Division of Stationary Source Enforcement 'compliance data indicates
that 56 percent of aluminum smelters as a source were in compliance with
emission limitations in 1975 [Ref: 3]. Production in 1975 can be distributed
over 'control level as follows:
1970-level (l-0,.56)(3v879 x 10b)
1.707 x 10° Tons
SIP-level (0.56)(3.879 x 10b) = 2..172 x 10° Tons
Activity Factor (10 tons)
Emission Factor (Ib/ton)
iEmissions -(1.00
\
1 Total
tons)
1970 Control
1.707
72.7
62.0
SIP Control
2.172
46.2
50.2
112.2 x 10 -tons
H-8
-------
Table H-4. Synthesized Allowable Emission Factor
Primary Aluminum Smelters
State
Alabama
Arkansas
Indiana
Kentucky
Louisiana
Maryland
Montana
New York
North Carolina
Ohio
Oregon
Tennessee
Texas
Washington
West Virginia
TOTAL
19701
Capacity
000 tons
221
185
225
90
260
85
175
253
100
240
228
340
561
1,016
163
3,126
2
Allowable
Emission
Ib/hr
31.83
31.83
43.60
43.60
43.60
43.60
43.60
49.38
43.60
43.60
43.60
43.60
75.74
(3)
32.60
Weighted
Allowable
Emissions
7,034
5,889
9,810
3,924
11,336
3,706
7,630
12,493
4,360
10,464
9,941
14,824
42,490
5,314
149,215
Average allowable emissions factor:
148,909
3,126
= 47.64 Ib/hr.
On an 8.760 hours/year and a nominal production of 4,000,000 tons in
28 plants, this converts to 2.9 Ib/tons of aluminum.
Air Pollution Control in the Primary Aluminum Industry, Singmeister and Breyer,
pp. 2-22, 2-23.
2
From State Regulations as published in The Environmental Reporter. Based on
average plant of 45 tons/hr. process rate (calculated from data in Singmeister
and "Breyer, pp. 2-22, 2-23) and using 2.589 tons of feed per ton of aluminum
produced (Singmeister and Breyer, p. 3.2).
4.142,000 (total capacity) x 2.589
28 (number of plants) x 8,760 (hrs./yr.)
No process rate regulation. Not included in total.
= " 45
H-9
-------
1975 Potential Emissions
Activity Factor (106 tons) 3.879
Uncontrolled Emission Factor (Ib/ton) [Ref.l, p. H-4-2] 517.7
Potential Emissions (103 tons) 1,004
Compliance Emissions
Activity Factor (106 tons) 3.879
Emission Factor (Ib/ton) 46.2
Compliance EmissionsOO tons) 89.6
iRecapitulation
o
Emissions, 10 tons
Particulates 2
75 Actual 75 Potential Compliance 75 Actual 75 Potential Compliance
Copper 31 423 8 2,661 3,751 512
lead ' ' 1 57 1 240 321 55
Zinc 1 69 1 64 557 36
Aluminum 112 1,004 90
Total 145 1,553 100 2,965 4,629 603
H-10
H-10.
-------
PRIMARY SMELTERS
List of References
1. Massoglia, Martin F., Summary of Emission Reductions Achieved
Nationwide by Selected Industrial Source Categories, Volume II:
/"Appendices. Research Triangle Park, N.C., Research Triangle
Institute, June, 1975. (Task Order No. 21, EPA-Contract 68-02-1325),
2. Personal communication with Mr. J. W. Stamper, U.S. Bureau of Mines,
May 12, 1976.
3. Provided by EPA Project Monitor.
H-ll
-------
APPENDIX I
IRON AND STEEL INDUSTRY
Processes Other Than Coke Plants (Participates Only)
1970
With the exception of emissions from Sinter Plants and Open Hearths, 1970
emissions are those calculated in the initial study [Ref. 1]. In the initial
calculations, the activity factor for sintering was estimated using a ratio
of sinter to pig iron based on average molecular weights. Subsequently, more
valid data on sinter operations were made available by NADB. In the case of
open hearth the degree of control was erroneously reported as being 95 percent.
Reference to primary data source indicated the correct degree of control to
be 40 percent. These data were used to refine the 1970 baseline emissions.
These are summarized below.
Process ' 103 tons particulate matter*
Ore Crushing 100.0
Materials Handling 445.7
Blast Furnaces 68.6
Sinter Plants 1,272.9
Open Hearths 124.8
Basic Oxygen Furnaces 16.1
Electric Furnaces 22.2
Scarfing 7.3
Storage Piles 134.5
*Reference 1, p. 1-5, except sinter plants and open hearth. (See calculations
that follow).
Sinter Plants
Activity Factor 90.6 x 106 tons sinter [Ref. 2]
Emiss-ion Factor 28.1 Ib/ton sinter [Ref. 1, p.I-11]
Emissions 1,272.9 x 10 tons (Calculated)
Open Hearth
Activity Factor 48.0 x 106 tons [Ref. 3, p.53]
Uncontrolled Emission
Factor 13 Ib/ton steel* [Ref. 7, p.75-4]
*Assumes 50 percent use of oxygen lancing.
1-1
-------
Overall Degree of
Control 40 percent [Ref. 6, p.92]
Actual Emissions 124,800 tons
(48.0 x 106 x 13 x 0.40 * 2,000)
1975
Emissions from 1975 iron and steel processes were under two levels of
control, l'97'O-level and SIP-level. While NSPS have been issued for basic
oxygen furnaces and new source standards are specified in some SIP's, they
are not applicable to 1975 production. NSPS for basic oxygen furnaces were
promulgated on 8 March 1974. As such they are applicable only to construction
started after that date. A comparison of 1970 production data for the oth.er
processes with reported 1975 data indicates no significant increase in
production that would require added capacity that would be subject to
new source emissions limitation.
Process Calculations
Ore Crushing:
Activity Factor 89.08 x 106 Tons
Scaled from 1970 data on the ratio of steel production 1970 to 1975
1970 Steel Production 131.1 x lO6 Tons [Ref.3, p.8]
1975 Steel Production 1.16.783 x 106 Tons [Ref. 4]
1970 Ore Crushing 100.0 x'TO6 Tons [Ref,5, p.66]
loo x ne.783 =. 89 08 x 10e Tons
Emission Factors: Uncontrolled 2 Ib/tons of ore [Ref.6, p.91]
SIP-level 2 Ib/tons of ore (assumed uncontrolled)
1970 Emissions 100 x 103 Tons [Ref.l, P. 1-5]
1975 Actual Emissions 89.08 x 106 x 2 * (2,000 x 1,000) = 89.1 x 103 Tons
Compliance Emissions 89.08 x 106 x 2 * (2,000 x 1,000) = 89.1 x 103 Tons
Potential Emissions 89.08 x 106 x 2 + (2,000 x 1,000) = 891 x 103 Tons
1-2
-------
Material Handling:
Activity Factor: 116.783 x 106 tons Steel [Ref. 4]
Emission Factors: 1970-level 6.8 Ib/ton Steel [Ref. 1, p.1-6]
SIP-control 1 Ib/ton steel [Ref. 1, p.1-7]
Uncontrolled 10 Ib/ton steel [Ref.6, p.91]
90 percent control is feasible [Ref.7, p.91] assuming that the 1975
compliance status for materials handling will be the same as average compliance
of all sources. An average of 40 percent (Estimated from data provided by DSSE
[Ref 8] will be used to distribute 1975 production to levels of control as
shown below ,
1970-level (1-0.40)(116.783) = 70.070 x 106 tons
SIP-level ( 0.46)(116.783) = 46.713 x 106 tons
Actual emissions for 1975 can be estimated to be
1970-level control 70.070 x 106 x 6.8 * (2,000 x 1,000) = 238.2 x 103 tons
SIP-level control 46.713 x 106 x 1 * (2,000 x 1,000) = 23.4 x 103 tons
Total . 261.6 x 103 tons
Potential 1975 emissions
116.783 x 105 x 10 f (2,000 x 1,000) = 5,831.9 x 103 tons
Compliance emissions
116.783 x 106 x 1 4 (2,000 x 1,000) = . 58.4 x 103 tons
Blast Furnaces
Activity Factor: 79.923 x 106 Tons [Ref.. 4]
Emission Factors: Uncontrolled 150 Ib/ton pig iron [Ref.6, p.7.5-1]
Controlled 0.63 Ib/ton pig iron [Table H-l]
1970-level 1.5 Ib/ton pig iron [Ref. 1, p. 1-9]
EPA Division of Stationary Source Enforcement compliance data indicate
that 64 percent of the nation's blast furnaces were in compliance with
emission limitations [Ref. 9] in 1975. This permits distribution of 1975
pig iron production as follows:
1970-level (1-0.64)(79.923) = 28.77 x 106 tons
SIP-level (0.64) (79.923) = 51.15 x 106 tons
Actual 1975 emissions can be estimated to be:
1970-level . 28.77 x 106 x 1.5 - (2,000 x 1,000) = 21.6 103 tons
SIP-level 51.15 x 106 x 0.63 •* (2,000 x 1,000) = 16.1 103 tons
Total 37.7 103 tons
1-3
-------
Table I.-l. Allowable Emission Factor, Blast Furnaces, Based on
Regulations of States accounting for over 70 percent
of 1974 pig iron production.
State
Alabama
Illinois
Indiana
Michigan
Ohio
Pennsylvania
Total
U.S. Total
%
1974 ,
Production
103 tons
3,872
7,170
16,998
7,619
17,439
22,168
75,266
95,909
78.5%
Number of
Furnaces
in9
BlastT
7
13
18
9
29
35
Throughput^
tons/per
Furnace
133.8
133.4
228.4
204.8
145.2
153.2
Allowable
Emission
Ib/ton
37.9
54.2
60.0
58.8
55.1
43.5
Total
All
Furnaces
265.3
704.6 ;
1,008.0 :
529.2
1,597.9
1,522.5
5,627.5
Allowable Emission Factor 5,627.5 x 24 x 350
75,266,000
=0.63 Ib/tons pig iron
Iron Ore 1974, Cleveland: American Iron Ore Association, p.63.
?Ibid. p. 60.
Based on 350 days operation, a ratio of 2.032 raw materials to pig iron
(Iron Ore 1979, p.61) and State regulations as published i-n The
Environmental Reporter.
1-4
-------
Potential 1975 emissions:
79.923 x 106 x 150 * (2,000)(1,000) = 5,994.2 x 103 tons
Compliance emissions:
79.932 x 106 x 0.63 * (2,000)(1,000) = 25.2 x 103 tons
Sinter Plants
1970 Emissions are recalculated as follows:
Activity Factor: 90.6 x 106 tons [Ref.10]
Uncontrolled Emission Factor: 42 Ib/ton Sinter [Ref.7, p.7.5-4]
1970 Emission Factor:: 28.1 Ib/ton Sinter [Ref., pl-ll]
Potential Emissions: 90.6 x 106 x 42 * (2,000x1,000) = 1,902.6 x 103 tons
Actual Emissions: 90.6 x 106 x 28.1 f (2,000 x 1,000) = 1,272.9 x 103 tons
1975 Data:
Activity Factor: 68.708 x 106 tons sinter [Ref. 4]
Uncontrolled Emission Factor: 42 Ib/ton Sinter
Complaince Emission Factors: 0.24 Ib/ton Sinter [table 1-2]
1970 Emission Factor: 28.1 Ib/tons Sinter [Ref. 1, p.I-11]
EPA Division of Stationary Source Enforcement compliance data indicates
that 22 percent of the sinter plants were in compliance with emission
limitations in 1975 [Ref. 9]. This permits distribution of 1975 production
to level of control as follows:
1970-level (1-0.22)(68.708) = 55.592 x 106 Tons
SIP-level (0.22) (68.708) = 15.116 x 106 Tons
1975 actual emissions are estimated to be:
1970-level 55.592 x 106 x 28.1 - (2,000 x 1,000) = 781.1 x 103 Tons
SIP-level 15.116 x 106 x 0.24 * (2,000 x 1,000) = 1.8
Total 782.9
1-5
-------
Table 1-2. Allowable Emission Factor, Sinter Plants, based on
regulation for States accounting for over 70 percent
of 1974 pig iron production (assuming Sinter produc-
tion is proportionate to pig iron production).
State
Alabama
Illinois
Indiana
Michigan
Ohio
Pennsylvania
Total
U. S. Total
%'
1974
Production
Pig Iron1
103 tons
3,872
7,170
16,998
7,619
17,439
22,168
75,266
95,909
78.5
Allowable
2
Emission
Ib/hr
39.2
47.8
47.8
47.8
47.8
22.9
Weighted
Allowable
Ib/hr
151,782
342,726
812,504
364,188
833,584
507,647
3,012,431
Allowable Emissions
40.0 x 24
4,000
3.012,431
75,266 ^
= 0.24 Ib/ton Sinter
'° lb/hr
1
Iron Ore, 1974, Cleveland: American Iron Ore Association, p.63.
"Based on average plant size - 4,000 tons/day (A Systems Analysis of the
Integrated Iron and Steel Industry, Battelle Memorial Institute, May 1969)
1-6
-------
1975 potential Emissions
68.708 x 106 x 42 v (2,000 x 1,000) = 1,442.9 x 103 tons
Compliance Emissions:
68.708 x 106 x 0.25 T (2,000 x 1,000) = 8.6 x 103 tons
Open Hearths
Activity Factor: 22.165 x 106 tons Steel [Ref. 4]
Emission Factors: Uncontrolled 13 Ib/ton Steel [Ref. 7, p.7.5-4]
Compliance 1.28 Ib/ton Steel [Ref. 1, p.1-12]
1970-level 5.6 Ib/ton Steel (40 percent average
control
EPA Division of .Stationary Source Enforcement data indicate that 27 per-
cent of open hearth in operation in 1975 were in compliance with emission limita-
tions. This permits distribtuion of 1975 production by control level as follows:
1970-level: (1-0.27)(22.165) = 16.18 x 106 tons
SIP-level: (0.27)(22.165) = 5.98 x 106 tons
Actual 1975 emissions are estimated to be:
1970-level: 16.18 x 106 x 5.6 v (2,000 x 1,000) = 48.3 x 103 tons
SIP-level: 15.98 x 106 x 1.28 - (2,000 x 1,000) = 3.8 x 103 tons
Total: 52.1 x 103 tons
1975 Potential Emissions:
22.165 x 106 x 13 T (2,000 x 1,000) = 144.1 x 103 tons
Compliance Emissions:
22.165 x 106 x 1.28 T (2,000 x 1,000) = 14.2 x 103 tons
Basic Oxygen Furnaces
Activity Factor: 71.800 x 106 tons [Ref. 4]
Emission Factors: Uncontrolled 51 Ib/ton Steel [Ref. 7, p.7.5-4]
Compliance 0.17 Ib/ton Steel [Ref. 1, p.1-14]
1970-level 0.51 Ib/ton Steel [Ref. 1,. p.1-15]
EPA Division of Stationary Source Enforcement data indicate that 28
percent of basic oxygen furnaces were in compliance with emission limita-
tions in 1975. This permits distribution of 1975 production by control
level as follows:
1970-level (1-0.28)(71.800) = 51.696 x 106 tons
SIP-level (0.28)(71.800) = 20.104 x 106 tons
1-7
-------
Actual 1975 emissions are estimated to be:
1970-1 evel: 51.696 x TO6 x 0.51 * (2,000 x 1,000) =13.2 x 103 tons
SIP -level: 20.104 x 106 x 0.17 - (2,000 x 1,000) = 1.7 x 103 tons
Total: 14.9 x 103 tons
1975 Potential Emissions.'
71.800 x 10
Compliance Emissions:
71.800 x 106 x 51 t (2,000 x 1,000) = 1,830.9 x 103 tons
71.800 x 106 x 0.17 * (2,000 x 1,000) = 6.1 x 103 tons
Electric Arc Furnaces
Activity Factor: 22.818 x TO6 tons [Ref. 4].
Emission Factors: Uncontrolled 10 Ib/ton Steel [Ref. 7, p.7.5-4]
Compliance 1.57 Ib/ton Steel [Ref.l, p.7-16]
1970 2.2 Ib/ton Steel [Ref.l, p. 1-17]
EPA Division of Stationary Source Enforcement data indicates that
61 percent of electric arc furnaces were in compliance with emission limita-
tions in 1975 [Ref. 9]. This permits distribution of 1975 production to
control levels as shown below.
1970-level: (1-0.61)(22.818) = 8.899 x 106 tons
SIP-Tevelt (0.61)(22.818) = 13.919 x 106 tons
Actual 1975 emissions are estimated to be:
1970-level: 8.899 x 106 x 2.2 * (2,000 x 1,000) = 9.8 x 103 tons
SIP-level: 13.919 x 106 x: 1.5.7 * (2,000 x 1,000) = 10.9 x 103 tons
Total 20.7 x 103 tons
1975 Potential Emissions:
22.818 x TO6 x 10 ^ (2,000 x 1,000) = 114.1 x 103 tons
Compliance Emissions:
22.818 x 106 x 1.57 v (2,000 x 1,000) = 17.9 x 103 tons
. *
Scarfing
Activity Factor: 40.7 x 106 tons Steel
Estimated by applying ratio of 1975 to 1970 steel production to
reported 1970 scarfing activity.
1970 Scarfing 45.7 x 106 tons Steel [Ref.5, p.66]
45.7 x 116.783 = 4Q 7
1-8
i •
»
-------
Emission Factors: 1970-level 0.32 Ib/ton [Ref.5, p.66]
SIP-level 0.32 assumed same as 1970 level
Uncontrolled 1 Ib/ton steel [Ref.7, p.7.5-4]
1975 Actual Emissions (also Compliance Emissions)
40.7 x 106 x 0.32 * (2,000 x 1,000) '= 6.5 x 103 tons
1975 Potential Emissions:
40.7 x 1 4 (2,000 x 1,000) = 20.4 x 103 tons
Storage Pile Losses
Activity Factor: 239.6 x 106 tons
Estimated by applying ratio of 1975 to 1970 steel production
to reported 1970 storage pile activity.
1970 Activity = 269.0 x 106 tons [Ref.5, p.60]
269 x 116.783
Emission Factor: 1970-level 1 Ib/ton [Ref.5, p.65]
SIP-level assumed same as 1970 level
Uncontrolled 20 Ib/ton materials [Ref.5, p.66]
Actual 1970 Emissions (also Compliance Emission) :
239.6 x 106 x 1 * (2,000 x 1,000) = 119.8 x 103 tons
1975 Potential Emissions:
239.6 x 106 x 20 t (2,000 x 1,000) = 2,396.0 x 103 tons
Coke Plants (particulates and SO,,)
1970
Baseline year data (1970) are as calculated in the initial study.
Estimated actual emissions for 1970 are [Ref.l, p.0-3]:
Particulates 153.5 x 10 tons
S00 180.3 x 103 tons
1-9
-------
1975
Estimated Actual Emission Factors
Coke ovens in operation in 1975 were subject to two levels of control,
1970-level and SIP-level. Emission factors, developed in reference 1,
as shown below, are considered to reflect current SIP requirements
[Ref.l, p.0-4, 0-5].
lb/ton Coke
1970-level SIP-level
Particulates 3.27 0.97
S02 4.2 0.6
Activity Factors, 1975 -
The U.S. Bureau of Mines reports that 82,228,000 tons of coal were
charged into Coke ovens in 1975 [Ref. 2]. Applying a ratio of coal-to-
coke of 1.43 generates the following 1975 coke production data.
88.228 * 1.43 = 57.502 x 106 tons Coke
Estimated Actual 1975 Emissions
EPA Division of Stationary Source Enforcement compliance data indicate
that nine percent of the Coke oven batteries were in compliance with
emission limitations in 1975 [Ref. q]. Because the data does not dis-
tinquish between particulate and S02 emissions, the degree of compliance
is assumed to apply to both pollutants. This indicates the following
distribution of 1975 production by level of control.
1970-level (1-0.10)(57.502) = 51.752 x TO6 tons
SIP-level (0.10)(57.502) = 5.750 x 106 tons
Actual 1975 emissions are estimated to be:
. 1970-level SIP-level
Particulates
Activity Factor (106 tons) 51.752 5.750
Emission Factor (Ib/ton) 3.27 0.97
Emissions (103 ton) 84.6 2.8
3
Total particulate emissions 84.6+2.8 = 87.4 x 10 tons
1-10
-------
so2
Activity Factor (106 tons) 51.752 5.750
Emission Factor (Ib/ton) 4.2 0.6
Emissions (103 tons) 108.7 1.7
Total S02 Emissions . 108.7 +1.7 = 110.4 x 10 tons
1975 Potential Emissions
Uncontrolled Emission Factors
Participates 3.5 Ib/ton coal charged [Ref.l, p.0-4]
S02 4.2 Ib/ton coal charged [Ref.l, p.0-4]
Participate Emissions 82,228,000 x 3.5 * (2,00a x 1,000) = 143.9 x 103 tons
S02 82,228,000 x 4.2 * (2,000 x 1,000) = 172.7 x 103 tons
Compliance Emissions
Controlled Emission Factors
o
Particulates 0.97 Ib/ton of Coal [Ref. 1]
S02 0.6 Ib/ton of Coal [Ref. 1]
Particulates 82,228.000 x 0.97 * (2,000 x 1,000) = 39.9 x 103 tons
S02 82,228.000 x 0.6 * (2,000 x 1,000) - 24.7 X 103 tons
1-11
-------
Recapitulation
Particulate Emissions 10 Tons
Process
Ore Crushing
Materials Handling
Blast Furnaces
Sinter Plants
Open Hearth
Basic Oxygen Furnace
o
Electric Arc Furnaces
Scarfing
Storage Piles
Coke Ovens
1970 Actual 1975 Potential 1975 Actual Compliance
100.0
445.7
68.6
1,272.9
124.8
16.1
22.2
7.3
134.5
153.5
89.1
583.9
5,994.2
1,442.9
144.1
1,830.9
114.1
20.4
2,396.0
143.9
89.1
261.6
33.7
782.9
52.1
14.9
20.7
6.5
119.8
87.4
89.1
58.4
25.2
8.6
14.2
6.1
17.9
6.5
119.8
39.9
2,345.6
12,759.5
1,468.7
385.7
1-12
-------
IRON AND STEEL INDUSTRY
List of References
1. Massoglia, Martin F., Summary of Emission Reductions Achieved Nationwide
by Selected Industrial Source Categories, Volume II: Research Triangle
Park, N.C.; Research Triangle Institute, June 1975 (Task No. 21, EPA
Contract 68-02-1325).
2. Provided by C. Mann, NADB, EPA/Durham.
3. Annual Statistical Report, 1973, American Iron and Steel Institute.
4. Personal communication with Ms. Betty Thompson, American Iron and Steel
Institute, May 24, 1976.
5. OAQPS Data File of Nationwide Emissions. Research Triangle Park, N.C.;
Environmental Protection Agency, April 1973.
6. Particulate Pollutant Emission Study, Volume I, Mass Emissions, Kansas
City: Midwest Research Institute, May 1971.
7. Compilation of Air Pollutant Emissions Factors, AP 42, Second Edition
(with changes 1-5). Research Triangle Park, N.C.: Environmental
Protection Agency, December 1975.
8. A Systems Analysis Study of the Integrated Iron and Steel Industry.
Columbus: Battelle Memorial Institute, May 1969.
9. Provided by EPA Project Monitor.
10. Minerals Yearbook, 1970 as cited in OAQPS data file (Ref.5 above).
11. Personal Communications with Mr. L. W. Westerstrom, U.S. Bureau of
Mines, May 14, 1976.
1-13
-------
APPENDIX 0
FERROALLOY PLANTS
(Particulate Matter Only)
1970
In the initial study [Ref. 1], the reported 1967 degree of control
was assumed to be applicable in 1970. The data developed by NADB [Ref. 2]
are considered to be based on more current data than that used in the
initial study. Consequently, 1970 estimated actual emissions used in
subsequent analysis will be 71 x 10 tons.of particulates.
1975
Emissions from 1975 Ferroalloy processes were under two levels of
control, the 1970-level and the SIP-level. The synthesized SIP emission
factor used in the initial study has been refined to reflect changes in
SIP's since 1974 and more current production data [See table J-l].
Estimated actual emission factors for 1970 have been recalculated using the
more current data mentioned above. The following emission factors are
used in subsequent analyses.
1970-level 80.2 Ibs/ton Ferroalloy
[71,000 x 2,000 (total emissions)* 1,770,000 (production, ref.2)]
SIP-level 4.74 Ib/ton Ferroalloy
1975 Activity Factors
Ferroalloy Production 1.786 x 106 tons
Latest production data available are for 1974. The Bureau of Mines
reports 1974 Ferroalloy production as 2.266 x 106 tons [Ref. 3]. The U.S.
Ferroalloy Association reports a decline of 22 percent in 1975 production
[Ref. 4].
2.266 x (1-0.22) = 1.786 x 106 tons
Estimated Actual 1975 Emissions ,
EPA Division of Stationary Sources Enforcement compliance data indi-
cate that 55 percent of the ferroalloy plants were in compliance with
emission limitations in 1975 [Ref. 5]. This indicates the following
J-l
-------
Table J -1. Allowable Emission Factor, Ferroalloy Industry Process
States
Ohio
Al abama
Tennessee
West Virginia
Kentucky
TOTAL
US TOTAL
%
Number of
Furnaces
57
12
14
25
15
123
158
77.8
Existing Plants-
Allowable
Ib/hr
25.78
19. 683
25.78
22.66
25.78
Emissions
All Furnaces
Ib/hr
1,469; 46
236.16
360.92
566,50
386.70
3,019.74
New Plants
Allowable
Ib/hr
25,78
19. .68
19.68
22.66
25.78:
Emissions
All Furnaces
Ib/hr
1,469.46
236.16
275.52
566.50
386.70
2,934.34
Allowable emissions
Existing plants
New Plants
1
3,019.74
123 x (15.55 * 3T
2,934.34 _
123 x (15.55 f"l)
4.74 Ib/ton of product
4.60 Ib/ton
Engineering and Cost Study of the Ferroalloy Industry, EPA-450/2-74-008,
Environmental Protection Agency, May 1974 p.E-3
o
Based on an average charge rate of 15.55 tons/hr (ref.l, above, p.VI-39),
and state regulations as published in the Environmental Reporter.
Based on Class 1 county allowable emission rules.
Ratio of charge to product is 3:1 (calculated from data ref. 1, above,
p. VI-39)
J-2
-------
distribution of 1975 production by level of control.
1970-1evel
SIP-level
1.786 x (1-0.55) = 0.804 x 10° tons
1.786 x 0.55
Actual 1975 emissions are estimated to be:
Activity Factor (106 tons)
Emissions Factor (Ib/ton)
Emissions (10 tons)
Total particulate emission
0.982 x 10° tons
1970-level
SIP-level
0.804
80.2
32
0.982
4.74
2
34 x 10° tons
1975 Potential Emissions
1971 Uncontrolled emissions
1971 Production
Emission Factor 377,000 * (2.151 x 10°) = 0.175 Ib/ton
377,000 Tons [Ref. 6, p.vi-19]
2.151 x 106 Tons [Ref. 6, p.vi-19]
1975 Production
1.786 x 10° tons
1975 Potential emissions (1.786)(0.175) * 1,000 = 313 x 101* tons
Compliance Emissions
From Process
1975 Production 1.786 x 103 tons
Compliance Emission Factor 4.74 Ib/ton
Compliance Emissions (1.786 x 103)(4.74) t (2,000 x 1,000) = 4.2 x 103 tons
From Raw Materials Handling (Charge to product ratio 3:1)
Emission Factor 0.29% [Ref.6, p.vi-29]
3 x 1.786 x 10J x 0.0029 * 1,000
15.5 x 10° tons
From Product Handling
Emission Factor
0.51% [Ref. 6, p.vi-31]
1.786 x 10J x 0.0051 * 1,000
Total Compliance Emissions 4.2 + 15.5 + 9.1
9.1 x 10° tons
29 x 10° tons
J-3
-------
References
Ferroalloy Plants
1. Massoglia, Martin F., Summary of Emission Reductions Achieved
Nationwide by Selected Industrial Source Categories, Volume II:
Research Triangle Park, N.C.; Research Triangle Institute, June
1975 (Task No. 21, EPA Contract 68-02-1325).
2. Provided by C. Mann, EPA/Durham.
3. Personal communication, Mr. T. Jones, U.S. Bureau of Mines,
May 12, 1976.
4. Personal communication, U.S. Ferroalloy Association, May 12, 1976.
5. Provided by EPA Project Monitor.
6. Engineering and Cost Study of the Ferroalloy Industry, EPA-450/2-74-008,
Research Triangle Park, N.C.: Environmental Protection Agency,
May 1972.
J-4
-------
APPENDIX K
ASPHALT CONCRETE PLANTS
(Particulates only)
1970
Baseline year data (1970) are as previously calculated in the initial
study. Estimated actual emissions for 1970 are 526 x 10"- tons [Ref.l, p.K-3],
1975
Estimated Actual Emission Factors
Asphalt concrete plants in 1945 were under three levels of control:
1970-level, SIP-level, and NSPS for plants becoming operational in 1975.
The following emission factors are applicable.
Ib/ton Product
1970-level [Ref.l, p.K-7] 3.38
SIP-level [Ref.l, p.K-7] 0.765
NSPS [Ref.l, p. 1-4] 0.18
Activity Factory
1974 [Ref. 2] 352 x 106 Tons
1975 [Ref. 3] 315 x 106 Tons
Because 1975 production was less than 1974 it can be assumed that
no capacity is subject to NSPS.
Estimated Actual 1975 Emissions
EPA Division of Stationary Source Enforcement compliance data
indicates that 80 percent of the asphalt concrete plants were in com-
pliance with particulate emission limitations in 1975 [Ref. 4].
Following is distribution of 1975 production by level of control:
1970-level [1-0.080][315] = 63 x 106 Tons
SIP-level [0.80][315] = 252 x 106 Tons
K-l
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Actual 1975 emissions are estimated to be:
1970-1 eve! SIP-leyel
Activity Factory (106 tons) 63 252
Emission Factor (Ib/ton) 3.38 0.765
Emissions (103 tons) 106.5 96.4
Total Emissions 106-5 + 96-4 = 202-9 x 1o3 tons
1975 Potential Emissions
Activity Factor (106 tons) 315
Emission Factor (Ib/ton) [Ref.5, p.8.1-4] 45
Emissions (103 tons) . 7,088
Compliance Emissions
Activity Factor (106 tons) 315
Emission Factor (Ib/ton) 0.765
Emissions (103 tons) 120
K-2
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ASPHALT CONCRETE PLANTS
List of References
1. Massoglia, Martin F., Summary of Emission Reductions Achieved
Nationwide by Selected Industrial Source Categories, Volume II:
Research Triangle Park, N.C.; Research Triangle Institute, June 1975
(Task No. 21, EPA Contract 68-02-1325).
2. Personal Communication, Mr. G. Goggin, National Asphalt Paving
Association, May 28, 1976.
3. Ibid, May 17, 1976.
4. Provided by EPA Project, Monitor.
5. Compilation of Air Pollutant Emission Factors, AP-42, Second Edition
(with changes 1-5). Research Triangle Park, N.C.: Environmental
Protection Agency, December 1975.
K-3
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APPENDIX L
COAL CLEANING PLANTS
(Participates Only)
1970
Baseline year data (1970) are as calculated in the initial study.
Estimated actual emissions for 1970 are 217 x 103 tons [Ref.l, p.L-3],
1975
Estimated Actual Emission Factors
Emissions from 1975 operations were under three levels of control.
Plants coming onstream in 1975 were subject to NSPS control and are assumed
to be in compliance therewith. Some of the remaining plants in place
were under the 1970 control level, the remainder in compliance with SIP
requirements. The SIP control requirements calculated in the initial
study [Ref. 1] have been refined to reflect SIP changes since 1974 and
more current production data. The following factors will be used.
Ib/ton
Thermal Drying Pneumatic Drying
1970 [Ref.l. p.L-6] 6.0 2.61
NSPS [Calculated from Ref.2] 0.11 *
SIP-contrbl [table L-l] 0.25 0.25
Pre-1975 capacity adequate for 1975 requirements.
Activity Factors 1975
Latest production data available are for 1974. Bureau of Mines reports
1974 production being [Ref. 3]:
Thermal Drying 36.1 x 10 tons
Pneumatic Drying 7.5 x 10 tons
The increasing demands of coal resulting from the energy crisis indicates that
the 1974 level of activity could prevail for 1975 [Ref. 4],
L-l
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Table L-l. Allowable Parti cul ate-. Emissions * Coal Cleaning, Thermal and
Pneumatic Drying (States accounting for over 90 percent: of" 1972 production)
State
Illinois
(entucky
3ennsylvania
Virginia
West Virginia
TOTAL
US TOTAL
%
19721
Production
000 tons
7,163
' 4,233"
5,569
4,496
27,600
49,061
53,235
92
2
Allowable
Emission
Ib/hr:
54.9
54.9-
8.2
54.9
26.1
Number
of
Plants
24
20
21
20
76
161
Total
Statewide
Ib/hr
1,317.6
1,098.0
172.2
1,098.0
1,983.6
5,669.4
Allowable Emissions:
5,669.4
161 x 143
= 0.25 Ib/ton
1
1972 Minerals Yearbook, p:. 42.
"Based on average plant 143 tons/hr (NESS, 1970) and State regulations
as published in The Environmental Reporter.
L-2
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Estimated Actual 1975 Emissions
EPA Division of Stationary Source Enforcement compliance data indicates
that 74 percent of the coal cleaning plants were in compliance with emission
limitations in 1975 [Ref. 5]. These compliance data, not broken down by
process type, are assumed to be applicable to both thermal and pneumatic
drying. Using these compliance data, the following distribution of produc-
tion by control level can be estimated. In view of the decreasing production,
experienced in 1975, no plants are considered to be under NSPS.
Thermal Drying
1970-level (1-0.74)(36.1) = 9.39 x 106 tons
SIP-level (0.74)(36.1) = 26.71 x TO6 tons
Pneumatic Drying
1970-level (1-0.74)(7.5) = 1.95xl06tons
SIP-level ' (0.74)(7.5) = 5.55 x 106 tons
Actual 1975 emissions are estimated to be:
1970-level 1975-1 eve!
Thermal Drying
Activity Factor (106 tons) 9.39 26.71
Emission Factor (Ib/ton) 6.0 0.25
Emissions (103 tons) 28.2 3.3
3
Total Emissions 32 x 10 tons
Pneumatic Drying
Activity Factor (106 tons) 1.95 5.55
Emission Factor (Ib/ton) 2.61 0.25
Emissions (103 tons) 2.5 0.7
3
Total Emissions 3 x 10 tons
L-3
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1975 Potential Emissions
Particulates
Activity Factors: Thermal Drying 36.1 x 10 Tons
: Pneumatic Drying 7.5 x 10 Tons
Uncontrolled Thermal Drying 20.0 Ib/ton [Ref.6,p.8.9-1]
Emission Factors: Pneumatic Drying 3.0 Ib/ton [Ref.6,p.8.9-1]
Emissions: Thermal Drying 36.1 x 106 x 20 * (2,000 x 1,000) = 361.0 x 10 tons
Pneumatic Drying 7.5 x 106 x 3 * (2,000 x 1,000) = 11.2 x 103 tons
Compliance Emissions
Particulates
Emission Factors, Thermal and Pneumatic Drying 0.25 Ib/ton
Emissions [36.1 + 7.5] x 106 x 0.25 * 1,000 = 11 x 103 tons
L-4
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COAL CLEANING PLANTS
List of References
1. Massoglia, Martin F., Summary of Emission Reductions Achieved
Nationwide by Selected Industrial Source Categories, Volume II:
Research Triangle Park, N.C.; Research Triangle Institute, June 1975
(Task No. 21, EPA Contract 68-02-1325).
2. Federal Register, October 24, 1974.
3. Personal communication with Mr. L. W. Westerstron, U.S. Bureau of
Mines, 12 May 1976.
4. Personal communication with Mr. L. W. Westerstron, U.S. Bureau of
Mines, December 16,.1974.
5. Provided by EPA Project Monitor.
6. Compilation of Air Pollutant Emission Factors, AP-42, Second
Edition (with changes 1-5), Research Triangle Park, N.C.: Environmental
Protection Agency, December 1975.
L-5
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APPENDIX M
KRAFT AND SULFITE PULP
(Particulate Matter Only)
1970
Baseline year date (1970) are as calculated in the initial study
[Ref. 1]. Estimated actual 1970 particulate emissions from Kraft and
Sulfite Pulp Mills are 288 x 103 tons [Ref. 1, p.M-5].
1975
Estimated Actual Emission Factors
Kraft and sulfite mill operations in 1975 were under two levels of
control, that existing in 1970 and that required by the SIP's. The
emission factors developed in the initial study are considered to reflect
the most current and valid data. These are listed below.
Ib/ton ADP
1970 Control* SIP Control**
Recovery Boilers ^ 17.64 1.96
Lime Kiln 4.50 0.41
Total 22.14 2.41
*
Reference 1, p. M-5.
**
Calculated from data in Reference 2, p.4 and uncontrolled emission
factors published in AP-42 [Ref. 3, p.10.1-5].
The American Paper Institute reports that 31.32 x 10 tons of ADP
Activity Factors
titui
were processed in 1975 [Ref. 4].
Estimated Actual Emissions
EPA Division of Stationary Source Envorcement compliance data indicates
that 65 percent of the Kraft and Sulfite Pulp emission sources were in com-
pliance with emission limitations in 1975. No breakdown by process is
M-l
-------
available. Therefore this compliance data will be assumed to be the same
for all processes. The following distribution of 1975 activity by level
of control can be calculated.
1970-level 31.32 x 106 x (1-0.65) 10.96 x 106 tons
SIP-level 31.32 x 106 x 0.65 = 20.36 x 106 tons
Actual 1975 emissions are estimated to be:
1970-level SIP-level
Activity Factor (106 tons ADP) 10.96 20.36
Emission Factor (Ib/ton ADP) 22.14 2.41
Emissions (103 tons) 121.3 24.5
Total emissions 121.3 + 24.5 = 146 x 103 tons
1975 Potential Emissions
Activity Factor 31.32 x 10 tons
Uncontrolled Emission Factor 242 Ib/ton [Ref.5, p.lO.l-J]
3
Potential Emissions . 3,789 x 10 tons
Compliance Emissions
Activity Factor 31.32 x 10 tons
Compliance Emission Factor 2.41
Compliance Emissions 38 x 10 tons
M-2
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KRAFT AND SULFITE PULP
List of References
1. Massoglia, Martin F., Summary of Emission Reductions Achieved
Nationwide by Selected Industrial Source Categories, Volume II:
Research Triangle Park, N.C.; Research Triangle Institute,
June 1975 (Task No. 21, EPA Contract 68-02-1325).
2. Particulate Pollution Control Equipments for the Pulp and Paper
Industry. EPA furnished document, undated (Probable origin is
Department of Commerce, 1974).
3. Compilation of Air Pollutant Emission Factors. AP-42, Second
Edition with changes 1-5, Research Triangle Park, Environmental
Protection Agency, December 1975.
4. Personal communication with a staff associate at
American Paper Institute, May 14, 1976.
5. Compilation of Air Pollutant Emission Factors, AP-42, Second
Edition (with changes 1-5). Research Triangle Park, N.C.:
Environmental Protection Agency, December 1975.
M-3
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APPENDIX N
GREY IRON FOUNDRIES
(Participate Matter Only)
1970
Baseline year data (1970) are as calculated in the initial study
[Ref. 1]. The estimated actual 1970 emissions are based on a produc-
tion of 17,923 x 103 tons [Ref.2, p.51]. This figure is compatible
3
with the shipment of 13,946 x 10 tons of grey iron castings in 1970
as reported by The Department of Commerce. [Ref.3, p.154]. The OAQPS
1970 data File [Ref.4, p.71] lists 1970 production as 24,000 x 103 tons.
3
However, the figure of 17,923 x 10 tons is considered more current and
will be used. Consequently, 1970 baseline particulate emissions of
3
156 x 10 tons of particulates as calculated in reference 1, will be
used in subsequent analyses.
1975
Estimated Actual Emission Factors
Grey iron foundry capacity in 1975 was under two levels of control,
1970-level and SIP-level. The following emission factors calculated in
the initial study are considered to reflect current data and will be
used.
1970 Factor 17.37 Ib/ton
SIP Factor 7.41 Ib/ton
Activity Factors, 1975
The U.S. Bureau of Mines reports 1975 production of grey iron to be
.4]
Estimated Actual 1975 Emissions
12.4 x 106 tons [Ref.4]
EPA Division of Stationary Source Enforcement compliance data
indicate that 74 percent of the grey iron foundries were in compliance
with emission limitations in 1975. This generates the following dis-
tribution of 1975 activity by control level.
1970-level (12.4 x 106)(1-0.74) = 3.2 x 106 tons
SIP-level (12.4 x 106)(0.74)- = 9.2 x 106 tons
N-l
-------
Actual 1975 emissions are estimated to be:
1970-Control SIP-Control
Activity Factor (106 tons) 3.2 9.2
Emission Factor (Ib/ton) 17.37 7.41
Emissions (103 tons) 27.7 34.1
Total Emissions 27.7 + 34.1 = 62 x 103 tons
1975 Potential Emissions
Activity Factor 12.4 x 106 tons
Uncontrolled Emission Factor 145 Ib/ton [Ref.l, p.N-4]
Compliance Emissions 899 x 10 tons
Compliance Emissions
Activity Factor 12.4 x 10 tons
Compliance Emission Factor 7.41 Ib/ton
o
Compliance Emissions 46 x 10 tons
N-2
-------
GREY IRON FOUNDRIES
List of References
1. Massoglia, Martin F., Summary of Emission Reductions
Achieved Nationwide by Selected Industrial Source
Categories, Volume II: Research Triangle Park, N.C.;
Research Triangle Institute, June 1975 (Task No. 21,
EPA Contract 68-02-1325).
2. Background information for Establishment of National
Standards of Performance for New Source (Draft)
Cincinnati: PEDCO Environmental Specialists, Inc.,
March 1971.
3. 1971 Business Statistics, Washington, D.C., Office
of Business Economics, U.S. Department of Commerce,
October 1971.
4. Personal communication with Mr. H. Reno, U.S. Bureau
of Mines, May 12, 1970.
N-3
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TECHNICAL REPORT DATA
({'lease read Instructions on the reverse before completing)
1. REPORT NO.
EPA-340/l-76-008b
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
Summary of Particulate & Sulfur Oxide Emission
Reductions Achieved Nationwide for Selected Industrial
Source Categories 1970-1975 Volume 2 Calculations
5. REPORT DATE
November 1976
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO.
Martin Massoglia
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Research Triangle Institute
Research Triangle Park
North Carolina 27711
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
12. SPONSORING AGENCY NAME AND ADDRESS
13. TYPE OF REPORT AND PERIOD COVERED
U.S. Environmental Protection Agency
Office of Enforcement
Division of Stationary Source Enforcement
401 M Street, S.W. Washington, D.C. 20460
Progress, 1975
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
This research updates the nationwide emission data on total suspended
particulates and sulfur oxides from selected source categories for 1975, and the
associated analyses to determine the progress made, nationwide, in meeting the
ambient air quality standards for the two pollutants under study. The initial
inventories and analyses were developed by the Research Triangle Institute under
Task Order No. 21,-Contract No. 68-02-1325 and reported to EPA in June 1975.* The
analyses and inventories developed in the June 1975 studies are updated to reflect
changes in SIP requirements proposed or promulgated since the initial study, use
of actual 1975 production data in place of projections, and use of compliance status
data available :'.n the DSSE Compliance Data System.
This report is published in two volumes. Volume 1 presents a summary of the
emission inventory data and the analyses; Volume 11, the detailed calculations,
in appendix form, upon which nationwide emission inventories-actual, potential,
and compliance-were based.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group
Air Pollution
State Implementation
Plans
13 b
13. DISTRIBUTION STATEMENT.
19. SECURITY CLASS (This Report)
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21. NO. OF PAGES
88
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Unclassified
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