US €IWIftONM€NTfll PROTECTION RG€NCV
OFFICE of ENFORCEMENT
OFFK€ of GENERRIENFORCEMENT
UJflSHINGTON, D.C. 20460
REVISED TECHNICAL GUIDE
FOR REVIEW AND EVALUATION
OF COMPLIANCE SCHEDULES
FOR AIR POLLUTION SOURCES
EPA-340/1-77-017
May 1977
Stationary Source Enforcement Series
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EPA-340/1-77-017
REVISED TECHNICAL GUIDE
FOR REVIEW AND EVALUATION
OF COMPLIANCE SCHEDULES
FOR AIR POLLUTION SOURCES
by
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-01-3150
Tasks No. 24 and 25
EPA Project Officers: J. Casey, S. Karacki, and J. Flood
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Division of Stationary Source Enforcement
Washington, D.C. 20460
May 1977
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The Stationary Source Enforcement series of reports is issued by
the Office of General Enforcement, Environmental Protection Agency,
to assist the Regional Offices in activities related to enforcement
of implementation plans, new source emission standards, and hazardous
emission standards to be developed under the Clean Air Act. Copies of
Stationary Source Enforcement Reports are available - as supplies permit -
from the U. S. Environmental Protection Agency, Office of Administration,
General Services Division, MD-35, 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 22151.
This report has been reviewed by the Environmental Protection Agency and
approved for publication. Approval does not signify that the contents
necessarily reflect the views and policies of the Agency, nor does mention
of trade names or commercial products constitute endorsement or recommenda-
tion for use.
PUBLICATION NO. EPA-340/1-77-017
ii
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ACKNOWLEDGMENT
This report was prepared by Messrs. Fred Hall, Lario
Yerino, Vishnu Katari, and Yatendra Shah under the direction
of Mr. Richard W. Gerstle. Project Officers for the Environ-
mental Protection Agency were Mrs. S. Karacki and Messrs. J.
Casey and J. Flood. The authors appreciate the contribution
made to this study by the project officers and other members
of the Division of Stationary Source Enforcement.
111
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IV
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TABLE OF CONTENTS
Page
1.0 INTRODUCTION 1-1
2.0 COMPLIANCE SCHEDULE DEVELOPMENT 2-1
2.1 Compliance Schedule Format 2-1
2.2 Summary Schedules by Control Device 2-8
2.2.1 Simplified Control Device Schedules 2-8
2.2.2 Critical Path Method 2-38
2.3 Contingencies Affecting Compliance Schedules 2-42
2.3.1 Normal Variation in Time Requirements 2-49
2.3.2 Contingencies in Project Time
Requirements 2-54
2.3.3 Conclusions 2-56
3.0 COMPLIANCE SCHEDULES FOR SELECTED INDUSTRIAL
SOURCES 3-1
3.1 Stationary Combustion 3-1
3.1.1 Coal-Fired Utility Boilers 3-1
3.1.2 Coal-Fired Industrial Boilers 3-15
3.2 Waste Disposal 3-22
3.2.1 Municipal Incinerators 3-22
3.2.2 Sludge Incinerators 3-29
3.2.3 Liquid Waste Incinerators 3-33
3.2.4 Waste Disposal in Existing Boilers 3-36
3.2.5 Sanitary Landfill 3-39
3.3 Evaporation Sources 3-42
3.3.1 Surface Coating 3-42
3.3.2 Petroleum Storage 3-51
v
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TABLE OF CONTENTS (Cont'd)
Pa^e
3.4 Chemical Processes 3-54
3.4.1 Nitric Acid 3-54
3.4.2 Phosphoric Acid 3-60
3.4.3 Sulfuric Acid 3-66
3.4.4 Paint and Varnish 3-76
3.4.5 Soap and Detergents 3-80
3.4.6 Chlorine Manufacture by the Mercury
Cell Process 3-87
3.4.7 Carbon Black Industry 3-93
3.4.8 Ammonium Nitrate 3-101
3.4.9 Urea Manufacturing Process 3-106
3.4.10 Plastics 3-112
3.5 Agricultural Products 3-121
3.5.1 Grain Handling and Processing 3-121
3.5.2 Grain Drying 3-131
3.5.3 Phosphate Fertilizer 3-135
3.5.4 Cotton Ginning 3-141
3.5.5 Alfalfa Dehydrating 3-146
3.6 Primary Metallurgical Processes 3-154
3.6.1 Metallurgical Coke 3-154
3.6.2 Primary Aluminum 3-168
3.6.3 Ferroalloys 3-176
3.6.4 Primary Copper, Lead, and Zinc 3-183
3.6.5 Iron and Steel 3-195
3.7 Secondary Metallurgical Processes 3-233
3.7.1 Aluminum 3-233
3.7.2 Brass and Bronze 3-241
3.7.3 Steel 3-245
3.7.4 Gray Iron 3-250
3.7.5 Lead Smelting 3-255
3.7.6 Zinc Smelting 3-261
3.7.7 Magnesium Smelting 3-265
3.7.8 Core Making, Casting Shakeout, and
Sand Handling 3-269
3.7.9 Metallurgical Chlorination 3-276
VI
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TABLE OF CONTENTS (Cont'd)
Page
3.8 Mineral Industries 3-279
3.8.1 Portland Cement 3-279
3.8.2 Lime 3-286
3.8.3 Phosphate Rock 3-291
3.8.4 Glass 3-295
3.8.5 Fiber Glass 3-302
3.8.6 Asphalt Batching 3-309
3.8.7 Asphalt Roofing 3-314
3.8.8 Concrete Batching 3-319
3.8.9 Coal Preparation Plants 3-323
3.9 Petroleum Industry 3-327
3.9.1 Petroleum Refining 3-327
3.10 Pulp and Paper 3-338
3.10.1 Kraft Process 3-338
3.10.2 Sulfite Pulping 3-344
3.10.3 Wood Waste (Hog) Boilers 3-349
4.0 SUPPORTING DATA 4-1
4.1 Information from Equipment Suppliers 4-1
4.2 Information from Industrial Gas Cleaning
Institute 4-6
APPENDIX A BASIC CONVERSION FACTORS A-l
Vll
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Vlll
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LIST OF FIGURES
No. Page
2-1 Compliance Schedule Chart 2-2
2-2 Schedule for Installation of an Electrostatic
Precipitator with Capacity Under 300,000 acfm 2-9
2-3 Schedule for Installation of an Electrostatic
Precipitator with Capacity Over 300,000 acfm 2-12
2-4 Schedule for Installation of a Fabric Filter
with Capacity Under 200,000 acfm 2-14
2-5 Schedule for Installation of a Fabric Filter
with Capacity of 200,000 acfm or More 2-15
2-6 Schedule for Installation of a Low-Energy Wet
Scrubber with Capacity Under 150,000 acfm 2-17
2-7 Schedule for Installation of a High-Energy Wet
Scrubber with Capacity Under 150,000 acfm 2-19
2-8 Schedule for Installation of a High-Energy Wet
Scrubber System with Capacity of 150,000 acfm
or More 2-20
2-9 Schedule for Installation of an Afterburner 2-22
2-10 Schedule for Installation of a Packaged
Adsorption System, Including Field-Erected
Distillation Unit 2-24
2-11 Schedule for Installation of a Field-Erected
Adsorption System, Including Distillation Unit 2-25
2-12 Schedule for Installation of a High-Energy Air
Filter Unit 2-27
2-13 Schedule for Installation of a Multiple Cyclone 2-28
IX
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LIST OF FIGURES (Cont'd)
No. Page
2-14 Schedule for Installation of a Mist Eliminator
System 2-30
2-15 Schedule for Installation of a Wet Electrostatic
Precipitator 2-32
2-16 Schedule for Installation of a Package CO
Boiler 2-33
2-17 Schedule for Installation of a Field-Erected
CO Boiler 2-35
2-18 Schedule for Installation of a Combination Wet
Mechanical Collector 2-37
2-19 Critical Path Schedule for Scrubber Installation 2-40
2-20 Critical Path Schedule for Baghouse Installation 2-43
2-21 Critical Path Schedule for a Limestone Scrubbing
System 2-44
2-22 Critical Path Schedule for Installation of Two
Electrostatic Precipitators 2-45
2-23 Example Compliance Program 2-47
2-24 Precompliance Plan Activities 2-48
3-1 Steam Generation at a Coal-Fired Utility 3-2
3-2 Schedule for Installation of an Electrostatic
Precipitator on a 500-MW Coal-Fired Boiler 3-6
3-3 Schedule for Installation of a Fabric Filter on
Utility-Sized Coal-Fired Boilers 3-7
3-4 Schedule for Installation of a Wet Scrubber for
Particulate Control on a Coal-Fired Utility
Boiler 3-8
3-5 Schedule for Installation of an FGD System on a
Boiler with Capacity Less Than 500 MW 3-9
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LIST OF FIGURES (Cont'd)
No. Page
3-6 Schedule for Installation of an FGD System on a
Boiler with Capacity of 500 MW or More 3-10
3-7 Compliance Schedule for Flue Gas Desulfurization
on a Utility-Size Boiler 3-12
3-8 Schedule for Installation of a Dry Multiple
Cyclone for Particulate Control on Industrial
and Utility-Sized Coal-Fired Boilers 3-17
3-9 Schedule for Installation of a Fabric Filter for
Particulate Control on a Coal-Fired Industrial
Boiler 3-18
3-10 Schedule for Installation of an Electrostatic
Precipitator for Particulate Control on a Coal-
Fired Industrial Boiler 3-19
3-11 Schedule for Installation of a Wet Scrubber for
Particulate Control on a Coal-Fired Industrial
Boiler 3-20
3-12 Municipal Incineration Process 3-23
3-13 Schedule for Installation of a Wet Scrubber for
Particulate Pollutant Control on a Municipal
Incinerator 3-25
3-14 Schedule for Installation of an Electrostatic
Precipitator for Particulate Control on a
Municipal Incinerator 3-26
3-15 Sludge Treatment System 3-29
3-16 Liquid Incineration Process 3-34
3-17 Refuse Processing Plant 3-37
3-18 Union Electric Co. Facilities for Receiving,
Storing, and Burning Refuse 3-37
3-19 Surface Coating Operation with Afterburner
Control System 3-43
XI
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LIST OF FIGURES (Cont'd)
No. Page
3-20 Surface Coating Operation with Adsorption
Control System 3-44
3-21 Schedule for Installation of a Field-Erected
Adsorption System, Including Distillation Unit,
for Hydrocarbon Control on a Surface Coating
Operation 3-47
3-22 Schedule for Installation of a Packaged
Adsorption System, Including Field-Erected
Distillation Unit, for Hydrocarbon Control
on a Surface Coating Operation 3-48
3-23 Schedule for Installation of an Afterburner
for Hydrocarbon Control on a Surface Coating
Operation 3-49
3-24 Schedule for Installation of an Internal Floater
for Hydrocarbon Control on an Existing Storage
Tank of Diameter Less Than 150 ft. 3-52
3-25 Nitric Acid Manufacture by the Pressure Process,
with Catalytic Tail Gas Control System 3-55
3-26 Schedule for Installation of a Catalytic
Reduction Unit with Waste Heat Recovery for
Nitrogen Oxide Control on a Nitric Acid Plant 3-57
3-27 Tentative Schedule for Installation of a
Molecular Sieve Adsorption System for Nitrogen
Oxide Control on a Nitric Acid Plant 3-58
3-28 Manufacture of Phosphoric Acid by Wet Process 3-60
3-29 Manufacture of Phosphoric Acid by Thermal
Process 3-61
3-30 Schedule for Installation of a Wet Scrubber
System for Gaseous and Particulate Fluoride
Control on a Phosphoric Acid Plant 3-63
3-31 Schedule for Installation of a High-Pressure
Mist Eliminator Unit for Acid Mist Control on
a Phosphoric Acid Plant 3-64
Xll
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LIST. OF FIGURES (Cont'd)
No. Page
3-32 Contact Process Single Adsorption Sulfuric Acid
Plant Burning Elemental Sulfur 3-67
3-33 Schedule for Modifying a Sulfuric Acid Plant to
the Dual Adsorption Process 3-70
3-34 Schedule for Installation of a Sodium Sulfite
Scrubbing System on a Sulfuric Acid Plant 3-71
3-35 Schedule for Installation of an Ammonia Scrub-
bing System, Including Mist Eliminator, for
Sulfur Oxides Control on a Sulfuric Acid Plant 3-72
3-36 Tentative Schedule for Installation of a
Molecular Sieve Separation Process for Sulfur
Oxides Control on a Sulfuric Acid Plant 3-73
3-37 Schedule for Installation of a Mist Eliminator
for Acid Mist Control on a Sulfuric Acid Plant 3-74
3-38 Paint Mixing Process 3-77
3-39 Schedule for Installation of an Afterburner for
Hydrocarbon Control on Paint or Varnish Opera-
tions 3-79
3-40 Soap Manufacture 3-81
3-41 Detergent Manufacture 3-82
3-42 Schedule for Installation of a Wet Scrubber
Electrostatic Precipitator for Particulate
Control on a Spray Drying Tower 3-84
3-43 Schedule for Installation of a Fabric Filter for
Particulate Control on Blending and Packaging
Operations 3-85
3-44 Chlor-Alkali Mercury-Cell Operation 3-88
3-45 Schedule for Installation of a High-Energy
Venturi Scrubber on Chlor-Alkali Plant 3-91
3-46 Typical Furnace Carbon Black Process 3-94
XI11
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LIST OF FIGURES (Confd)
No. Paqe
3-47 Schedule for Installation of a Field-Erected
CO Boiler 3-97
3-48 Schedule for Installation of a Packaged CO
Boiler 3-98
3-49 Ammonium Nitrate Manufacturing Process 3-102
3-50 Schedule for Installation of a Shroud, Wet
Scrubber, and Mist Eliminator on an Ammonium
Nitrate Prill Tower 3-104
3-51 Urea Manufacturing Process 3-107
3-52 Urea Prill Tower Without Control System 3-108
3-53 Schedule for Installation of a Shroud, Wet
Scrubber, and Mist Eliminator on a Urea Prill
Tower 3-110
3-54 Simplified Plastics Manufacturing Process 3-113
3-55 Schedule for Installation of a High-Energy Air
Filter Unit on Plastics Manufacturing Operations 3-116
3-56 Schedule for Installation of a Low-Energy Wet
Scrubber on Plastics Manufacturing Operations 3-117
3-57 Schedule for Installation of a Mist Eliminator
on Plastics Manufacturing Operations 3-118
3-58 Schedule for Installation of an Afterburner on
Plastics Manufacturing Operations 3-119
3-59 Terminal Grain Elevator 3-122
3-60 Soybean Processing 3-123
3-61 Flour Milling 3-124
3-62 Wet Corn Milling 3-125
3-63 Feed Manufacturing 3-127
xiv
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LIST OF FIGURES (Cont'd)
No.
3-64 Schedule for Installation of a Baghouse or a
Self-Cleaning Screen Filter on Grain Handling
and Processing Sources 3-129
3-65 Schedule for Installation of a High-Energy
Cyclone on Grain Handling and Processing Sources 3-130
3-66 Column and Rack Grain Dryers 3-132
3-67 Schedule for Installation of a Self-Cleaning
Screen on Grain Drying Process 3-134
3-68 Normal Superphosphate Plant 3-135
3-69 Triple Superphosphate Plant 3-136
3-70 Diammonium Phosphate Plant 3-137
3-71 Schedule for Installation of a Wet Scrubber on
Phosphate Fertilizer Operation 3-140
3-72 Cotton Ginning Process 3-142
3-73 Schedule for Installation of a Small Packaged
Fabric Filter on a Cotton Ginning Plant 3-145
3-74 Alfalfa Dehydration Process 3-147
3-75 Schedule for Installation of a Low-Energy Wet
Scrubber on an Alfalfa Dehydration Process 3-150
3-76 Schedule for Installation of a Small Fabric
Filter on an Alfalfa Dehydration Process 3-151
3-77 Schedule for Installation of a High-Energy Air
Filter on an Alfalfa Dehydration Process 3-152
3-78 Metallurgical Coke Manufacturing 3-156
3-79 Schedule for Larry Car Modifications Required
for Staged Charging on a Coke Oven Battery 3-160
3-80 Schedule for Installation of a Closed Car System
for Controlling Coke-Pushing Emissions 3-161
xv
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LIST OF FIGURES (Cont'd)
No. Page
3-81 Schedule for Installation of a Shed for Control-
ling Coke-Pushing Emissions 3-162
3-82 Schedule for Installation of a Traveling Hood to
Control Coke-Pushing Emissions 3-163
3-83 Schedule for Installation of a Coke Oven Gas
Desulfurization System 3-164
3-84 Schedule for Converting to Vented Doors to
Control Coke Oven Emissions 3-166
3-85 Schedule for Installation of a Wet or Dry ESP
to Control Particulate Emissions from Coke Oven
Battery Stacks 3-167
3-86 Aluminum Reduction Process 3-169
3-87 Schedule for Installation of a Wet Scrubber on a
Primary Aluminum Reduction Operation 3-173
3-88 Schedule for Installation of a Fabric Filter on
a Primary Aluminum Reduction Operation 3-174
3-89 Schedule for Installation of an Electrostatic
Precipitator on a Primary Aluminum Operation 3-175
3-90 Ferroalloy Production Process 3-177
3-91 Schedule for Installation of a High-Energy Wet
Scrubber on a Ferroalloy Furnace 3-179
3-92 Schedule for Installation of a Fabric Filter
with Pre-cooler on a Ferroalloy Furnace 3-180
3-93 Schedule for Installation of an Electrostatic
Precipitator on a Ferroalloy Furnace 3-181
3-94 Primary Copper Smelting Flow Diagram 3-184
3-95 Primary Lead Smelter 3-186
3-96 Flow Diagram of Primary Zinc Production 3-187
xvi
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LIST OF FIGURES (Cont'd)
No.
3-97 Schedule for Installation of a Dry Electrostatic
Precipitator on a Nonferrous Smelter 3-191
3-98 Schedule for Installation of a High-Energy Wet
Scrubber System on a Nonferrous Smelter 3-192
3-99 Schedule for Installation of an Acid Plant on a
Primary Nonferrous Metallurgical Process 3-193
3-100 Typical Blast Furnace 3-196
3-101 Schedule for Installation of Hoods and Ducting
to a Fabric Filter on the Cast House of a Blast
Furnace Operation 3-199
3-102 Simplified Sintering Process 3-202
3-103 Schedule for Installation of a Dry Electrostatic
Precipitator on a Sinter Plant 3-205
3-104 Schedule for Installation of a Wet Electrostatic
Precipitator on a Sinter Plant 3-206
3-105 Schedule for Installation of a Fabric Filter on
a Sinter Plant t 3-207
3-106 Schedule for Installation of a High-Energy Wet
Scrubber System on a Sinter Plant 3-208
3-107 Open Hearth Furnace 3-211
3-108 Schedule for Replacement of Open Hearth with
BOF or QBOF 3-213
3-109 Schedule for Replacement of Open Hearth with
Electric Arc Furnace 3-214
3-110 Basic Oxygen Furnace 3-217
3-111 Schedule for Installation of Secondary Hooding
and Ducts for Charging of a Basic Oxygen Furnace 3-219
xvi i
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LIST OF FIGURES (Cont'd)
No. page
3-112 Schedule for Installation of Movable Hood and
Fabric Filter for Control of Hot Metal Transfer
at a Basic Oxygen Furnace 3-220
3-113 Schedule for Installation of a Secondary Hood
to New Fabric Filters for Control of Tapping of
a Basic Oxygen Furnace 3-221
/
3-114 Direct-Arc Electric Furnace 3-224
3-115 Schedule for Installation of Canopy Hoods and
Fabric Filter on an Electric Arc Furnace 3-227
3-116 Schedule for Installation of a Large Fabric
Filter for Building Evacuation Around an
Electric Arc Furnace 3-228
3-117 Schedule for Installation of a Canopy Type
Swing-Away Hood and ESP or Scrubber on a
Scarfing Operation 3-231
3-118 Secondary Aluminum Process 3-234
3-119 Schedule for Installation of a Fabric Filter or
Fabric Filter/Afterburner Control System on a
Secondary Aluminum Process 3-236
3-120 Schedule for Installation of a Wet Scrubber or
a Wet Scrubber/Afterburner Control System on a
Secondary Aluminum Process 3-237
3-121 Schedule for Installation of an Afterburner on
a Scrap Cleaning Furnace in Aluminum Production 3-239
3-122 Schedule for Installation of a Custom-Designed
Fabric Filter on a Secondary Aluminum Process 3-240
3-123 Brass/Bronze Reverberatory Furnace 3-242
3-124 Schedule for Installation of a Fabric Filter on
a Brass and Bronze Foundry 3-244
xvi 11
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LIST OF FIGURES (Cont'd)
NO.
Page
3-125 Schedule for Installation of a Fabric Filter on
a Steel Foundry Furnace . 3-246
3-126 Schedule for Installation of a Wet Scrubber on
a Steel Foundry Furnace 3-247
3-127 Schedule for Installation of a Custom-Designed
Fabric Filter on a Steel Foundry Furnace 3-249
3-128 Gray Iron Foundry Process 3-251
3-129 Schedule for Installation of a Fabric Filter/
Afterburner Control System on a Gray Iron
Foundry Furnace 3-253
3-130 Schedule for Installation of a High-Energy Wet
Scrubber System on a Gray Iron Foundry Furnace 3-254
3-131 Lead Reverberatory Furnace 3-256
3-132 Schedule for Installation of a Wet Scrubber
System on a Lead Smelting Furnace 3-258
3-133 Schedule for Installation of an Afterburner/
Baghouse System on Lead Smelting Furnace 3-259
3-134 Melting Furnace for Producing Secondary Zinc 3-262
3-135 Schedule for Installation of a Fabric Filter on
a Zinc Smelting Furnace 3-264
3-136 Schedule for Installation of a Fabric Filter
on a Magnesium Smelting Furnace 3-266
3-137 Schedule for Installation of a Wet Scrubber
System on a Magnesium Smelting Furnace 3-267
3-138 Core Making, Casting Shakeout, and Sand Handling 3-270
3-139 Schedule for Installation of an Afterburner on
a Core Baking Oven 3-272
xix
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LIST OF FIGURES (Cont'd)
No. Page
3-140 Schedule for Installation of a Fabric Filter
on a Casting Shakeout and Sand Handling System 3-273
3-141 Schedule for Installation of a Low-Energy Wet
Scrubber on a Casting Shakeout and Sand Handling
System 3-274
3-142 Schedule for Installation of a Wet Scrubber
System for Control of Emissions from Metallur-
gical Chlorination 3-278
3-143 Cement Manufacture 3-280
3-144 Schedule for Installation of a Fabric Filter on
a Cement Kiln 3-282
3-145 Schedule for Installation of an Electrostatic
Precipitator on a Cement Kiln 3-283
3-146 Manufacture of Lime and Limestone Products 3-287
3-147 Schedule for Installation of a Wet Scrubber on
a Lime Kiln 3-288
3-148 Schedule for Installation of a Fabric Filter on
a Lime Kiln 3-289
3-149 Phosphate Rock Processing 3-292
3-150 Schedule for Installation of a Fabric Filter on
a Phosphate Rock Processing Operation 3-293
3-151 Soda-Lime Glass Manufacture 3-296
3-152 Schedule for Installation of a Custom-Designed
Fabric Filter on a Glass Furnace 3-299
3-153 Schedule for Installation of a High-Energy
Venturi Scrubber on a Glass Furnace 3-300
3-154 Fiber Glass Production 3-302
xx
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LIST OF FIGURES (Cont'd)
No. Page
3-155 Schedule for Installation of a High-Energy Wet
Scrubber on Fiber Glass Forming and,Curing
Operations 3-304
3-156 Schedule for Installation of a High-Energy Air
Filter (HEAF) Unit on Fiber Glass Forming and
Curing Operations 3-305
3-157 Schedule for Installation of a Wet Electrostatic
Precipitator on Fiber Glass Forming and Curing
Operations 3-.306
3-158 Schedule for Installation of an Afterburner on
Fiber Glass Forming and Curing Operations 3-3'07
3-159 Asphalt Batch Process 3-310
3-160 Schedule for Installation of a Wet Scrubber on
an Asphalt Batch Plant 3-312
3-161 Schedule for Installation of a Fabric Filter on
an Asphalt Batch Plant 3-313
3-162 Manufacture of Asphalt Roofing Materials 3-315
3-163 Schedule for Installation of an Afterburner
on an Asphalt Roofing Operation 3-317
3-164 Schedule for Installation of a HEAF Unit on
an Asphalt Roofing Operation 3-318
3-165 Wet-Concrete Batch Loading Operation 3-320
3-166 Schedule for Installation of a Fabric Filter
on a Concrete Batch Plant 3-321
3-167 Schedule for Installation of a High-Energy Wet
Scrubber on a Coal Preparation Thermal Dryer 3-325
3-168 Intermediate Refinery 3-328
3-169 Complete Refinery 3-329
xxi
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LIST OF FIGURES (Cont'd)
No. page
3-3.70 Schedule for Installation of an Amine-Treater-
Sulfur Plant at a Petroleum Refinery 3-334
3--171 Schedule for Installation of a Tail Gas
Desulfurization Unit at a Petroleum Refinery 3-335
TJ-172 Schedule for Installation of an Amine Treater,
a Sulfur Plant, and a Tail Gas Desulfurization
Unit at a Petroleum Refinery 3-336
3-173 Schedule for Installation of an Electrostatic
Precipitator on a Catalytic Cracking Unit 3-337
3-174 Kraft Process 3-339
3-175 Schedule for Installation of an Electrostatic
Precipitator on a Recovery Boiler in a Pulp Mill 3-341
3-176 Schedule for Installation of a Wet Scrubber on a
Lime Kiln and Smelt Dissolving Tank in a Kraft
Mill 3-342
3-177 Spent Sulfite Liquor Recovery System 3-345
3-178 Schedule for Installation of a Spent Sulfite
Liquor Recovery System in a Pulp Mill 3-347
3-179 Schedule for Installation of a Wet Scrubber on
a Wood Waste (Hog) Boiler 3-351
3-180 Schedule for Installation of an Electrostatic
Precipitator on a Wood Waste (Hog) Boiler 3-352
xxi i
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LIST OF TABLES
No. Page
2-1 Description of Compliance Schedule Activities 2-3
2-2 Explanation of' Compliance Schedule Activities 2-6
2-3 Critical Path Network Terminologies 2-39
i
2-4 Effect of Contingencies on Compliance Plan
Activities 2-50
2-5 Effect of Contingencies on Precompliance Plan
Activities 2-51
3-1 Emission Factors for Primary Copper Smelters
Without Controls 3-188
3-2 Emission Factors for Primary Lead Smelting
Processes Without Controls 3-188
3-3 Emission Factors for Primary Zinc Smelting
Without Controls 3-189
4-1 Vendor Delivery Schedule for Installation of
Large Electrostatic Precipitators (weeks) 4-2
4-2 Vendor Delivery Schedule for Installation of
Small Electrostatic Precipitators (weeks) 4-3
4-3 Vendor Delivery Schedule for Installation of
Wet Scrubbers (weeks) 4-4
4-4 Vendor Delivery Schedule for Installation of
Multiple Cyclones (weeks) 4-5
4-5 Vendor Delivery Schedule for Installation of
Fabric Filter Systems (weeks) 4-7
4-6 Vendor Delivery Schedule for Installation of
Molecular Sieves (weeks) 4-8
xxi 11
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LIST OF TABLES (Cont'd)
No. Pagj3
4-7 Vendor Delivery Schedule for Installation of
Afterburners (weeks) 4-9
4-8 Vendor Delivery Schedule for Installation of
a Mist Eliminator on an Industrial Operation
(weeks) 4-10
4-9 Vendor Delivery Schedule for Installation of
a Dual Absorption System for Sulfuric Acid
Production (weeks) 4-11
4-10 Summary of Compliance Schedule Data from IGCI
Survey 4-12
xxiv
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1.0 INTRODUCTION
On August 14, 1971, the Administrator of the Environ-
mental Protection Agency promulgated regulations in the
Federal Register, 40 CFR Part 51, specifying minimum re-
quirement? for the State Air Quality Implementation Plans
required by Section 110 of the Clean Air Act. As mandated
by Section 110 and specified in these regulations, imple-
mentation plans must include emission limitations adequate
to attain and maintain national ambient air quality stan-
dards and must require compliance schedules from all sources
subject to the emission limitations. For sources in air
quality control regions where the national primary standards
are being exceeded, the schedules must provide for com-
pliance as expeditiously as practicable; for sources in
regions where only the secondary air quality standards are
being exceeded, the schedules must provide for compliance
within a reasonable period of time.
In July 1973 the Environmental Protection Agency,
Division of Stationary Source Enforcement, published the
first edition of a Technical Guide for Review and Evaluation
of Compliance Schedules for Air Pollution Sources (Publica-
tion EPA-340/l-73-001a). The material presented herein has
been prepared to update that publication. Certain schedules
presented earlier have been modified, and schedules are
included for new industries and control systems.
Manufacturers and users of air pollution control equip-
ment supplied most of the information used to develop these
schedules. Preliminary schedules based on PEDCo staff
1-1
-------
experience and manufacturers' data were subjected to engi-
neering evaluation by the Industrial Gas Cleaning Institute.
On the basis of these reviews, the schedules presented
herein were developed.
As with the first edition, it is emphasized that these
schedules should be considered as guidelines. Many factors
may mitigate the proposed time scales. These can include
on-site problems such as space limitations, inclement weather,
and lack of needed utilities; logistical problems such as
delays in equipment delivery caused by special orders,
backlog of orders, or unavailability of large motors and/or
fans; and design problems caused by lack of engineering data
for some applications. To the limited extent possible, such
factors were considered in preparation of the schedules.
Section 2.0 describes the compliance schedule format,
presents summary schedules by type of control device, and
describes the technical and economic contingencies that can
affect control device installations. Section 3.0 presents
brief process descriptions and describes emission sources
and emission characteristics of the various industries. The
types of control systems commonly used are identified; some
of the problems encountered in achieving reliable, high-
efficiency emissions control are briefly discussed; and
sources of additional information are also listed. Time
schedules are presented for installation of selected control
systems. Section 4.0 describes the study approach and
summarizes the supporting data on which the schedules are
based.
1-2
-------
2.0 COMPLIANCE SCHEDULE DEVELOPMENT
2.1 COMPLIANCE SCHEDULE FORMAT
Figure 2-1 depicts the chart used in this manual to
identify the various steps generally required to complete
installation of a control system and the time required for
completion of such steps. The increments of progress
(milestones) presented on this chart are the same as those
defined in 40 CFR, Part 51:
1) Date of submittal of the final control plan to the
appropriate air pollution control agency;
2) Date by which contracts for emission control
systems or process modifications will be awarded;
or date by which orders will be issued for pur-
chase of component parts to accomplish emission
control or process modification;
3) Date of initiation of on-site construction or in-
stallation of emission control equipment or pro-
cess change;
4) Date by which on-site construction or installation
of emission control equipment or process modifica-
tion is to be completed; and
5) Date by which final compliance is t:o be achieved.
The major activities required for achieving these
milestones, also shown on these compliance schedules, are
described in Table 2-1.
In development of the time schedules, i't was assumed
that the steps prior to Milestone 1 are essentially com-
plete. These very important preliminary steps may require a
lengthy period of time, depending on the nat.ure and com-
2-1
-------
to
i
N)
D
Milestones
•Activity and duration in weeks
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R.-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 2-1. Compliance schedule chart.
-------
Table 2-1. DESCRIPTION OF COMPLIANCE SCHEDULE ACTIVITIES
Activity
code
NJ
I
U)
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity
description
Conduct source tests
Perform preliminary
investigation
Evaluate control
alternatives
Commit funds for total
program
Prepare control plan and
compliance schedule for
agency review
Agency reviews and
approves the plans
Finalize plans and
specification
Procure control device bids
Evaluate control device
bids
Award control device
contract
Prepare assembly drawings
Details of activity
Emissions are estimated or measured to define need for control. Rate of emission,
chemical composition, particle size, and other characteristics are determined to
provide engineering design data.
Feasibility studies are made to determine the best method for reducing emission?.
Alternative methods of control are evaluated, budget estimates made, and a control
plan is selected.
Budget estimates are submitted and funds are applied for.
Preliminary plans for controlling emissions are submitted to appropriate agencies
for review.
Control agency reviews plan and prepares comments. Recommended changes are made
and agency approves plan.
The control system is specified in sufficient detail for suppliers and contractors
to prepare bids. A final control plan summarizing this information is prepared for
submittal to the agency.
Specifications for the control device are disseminated and bids from suppliers are
requested.
Bids are evaluated and suppliers are selected.
•j.'i?..
The successful bidder is notified and a contract is signed.
The vendor prepares assembly drawings for the control device. For the smaller and more
common types <5f devices, standard shop drawings applicable to several size ranges may
be used with the appropriate dimensions underlined or otherwise indicated. For larger
devices, it may be necessary to prepare drawings specifically for the project. The
assembly drawings are mailed to the client for his approval before fabrication
drawings are started.
-------
Table 2-1 (Cont'd.). DESCRIPTION OF COMPLIANCE SCHEDULE ACTIVITIES
Activity
code
NJ
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5j
Activity
description
Review and approve
assembly drawings
Prepare fabrication
drawings
Fabricate control device
Prepare engineering
drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site
construction
Install control device
Complete construction and
system tie-in
Perform startup, shakedown
and emission testing
Details of activity
The client reviews the assembly drawings and gives approval to begin fabrication
drawings. The client uses the assembly drawings to prepare engineering drawings.
Upon receipt of approval from client to proceed with construction of the-control
device, the vendor prepares fabrication or shop drawings for use in manufacturing
and assembling the control equipment.
Based on fabrication drawings, the supplier fabricates major components of the
device for shipment to the site. If the device is not too large, it can be
completely fabricated and shipped as a package unit.
Based on data from the vendor's drawings and on earlier engineering studies, the
client (or his consultant) prepares architectural and mechanical drawings for any
modifications and additions to the plant that are required to accommodate the emission
control system.
The bid package is mailed to selected contractors. This package specifies the scope
of work and the materials and includes the drawings. During this period, the con-
tractors prepare bids for materials and labor to construct all duct work, piping, and
utilities and for installation of the control device.
The client or his consultant evaluates the bids and -selects the contractor.
The selected contractor is notified and the contract is negotiated and signed.
Using the architectural and mechanical drawings, the contractor begins field work.
He usually subcontracts various specialties such as electrical or duct work.
The control device (or the components) arrives on site. The contractor should be
prepared for installation and tie-in with other piping, duct work, and electrical
switchgear. Field assembled units will arrive in sections for erection at the site.
Internals .such as catalysts, activated carbon, and bag filters are also installed
during this time.
Tying the control device into the system requires shutdown of the process, scheduled
for minimum disturbance of the operation. The contractor's responsibility usually
ends'when the client and the vendor's representative accept the construction as
complete.
The process is brought back on-line and any unforeseen problems with the control
system are resolved. Emissions testing may be performed to determine whether per-
formance of the system is acceptable.
-------
plexity of the control problem. Because many emission
regulations have been in force for some time, however, it is
assumed that much of this preliminary investigation is now
complete. Where pilot plant investigations or further
technology development are required, this phase of the work
may still be under way.
During these initial steps the process owner must first
determine the need for reducing emissions; this need may be
evidenced by plant inspection, denial of an operating per-
mit, or notice of violation. The owner must then evaluate
the emissions and their relationship to the process to
develop the information needed for an engineering evaluation
of control alternatives. Feasibility studies of various
control alternatives will include consideration of energy
needs, potential additional environmental impacts (water,
sludge, noise), and costs. On the basis of the feasibility
studies the owner may select one or two control systems for
further study and more exact cost estimates. He will then
make budget appropriations and submit the control plan to
the appropriate pollution control agency for review. Guided
by agency comment, the owner can finalize the plans and
initiate the control program.
The time schedules presented in this manual start at
the point of finalizing control system plans and specifi-
cations for submission to the appropriate air pollution
control agency (Activity G-l).
Table 2-2 identifies typical time increments required
to complete the various activities on the schedule and the
factors that influence these time requirements. The time
ranges can vary considerably and are of limited usefulness
in application to specific cases.
2-5
-------
Table 2-2. EXPLANATION OF COMPLIANCE SCHEDULE ACTIVITIES
Activity
Comments
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
K-L
Preliminary investigations require 1 to 10 weeks
to determine which sources require control. The
time range depends on the number of vents, number
and type of pollutants, and the methods for
determining control needs.
An evaluation of emission parameters requires 2 to
8 weeks, depending on the need for and complexity
of source testing.
Feasibility studies of alternative emission
reduction plans require from 4 weeks to as much as
10 to 20 weeks, depending on the type of source,
the number of alternatives studied, and the infor-
mation available on control.
Time required for committing funds varies with the
amount of money involved and the corporate approval
steps required; typical increments are 2 to 10
weeks.
Proposing a preliminary control plan and scheduling
review by the control agency typically requires 2
to 4 weeks. The time required will vary with the
agency's needs.
Review by the control agency will require 2 to 8
weeks, depending on their backlog, staff avail-
ability, and complexity of the schedule.
Finalizing plans and specifications requires 2 to
6 weeks, depending on the magnitude and com-
plexity of the project and the agency's comments.
A minimum of 4 weeks is required to procure bids
on small jobs. A maximum of 12 weeks is allowed
for large non-standard units, since initial
vendor quotations frequently do not match bid
specifications and further contacts with each
bidder are required.
Evaluation of bids requires 2 to 5 weeks. Small,
privately owned firms will require little time; in
large corporations, bid evaluation often involves
several departments and thus requires more time.
A minimum of 2 weeks is allocated for preparing
final control plans and awarding contracts for the
control device and major components. This activity
takes longer in large corporations that require
examination and approval of the contract by several
departments.
Depending on the complexity and originality of the
design, the time required by the vendor to submit
assembly drawings showing dimensions, orientations,
and loads could vary widely. Consultation with
equipment suppliers indicates a range of 2 to 6
weeks.
Review and approval of assembly drawings requires
1 or 2 weeks. The longer period is required for
any delay in approval as a result of revisions and
modifications.
2-6
-------
Table 2-2 (Cont'd.). EXPLANATION OF COMPLIANCE
SCHEDULE ACTIVITIES
Activity
Comments
L-M
N-R
M-N
L-O
O-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Normal time requirement for the vendor to prepare
shop drawings for fabrication and assembly of the
control device is 3 to 8 weeks. These figures are
based on information supplied by control equipment
suppliers.
For this activity, time is allocated primarily for
installation of a shop-assembled (or modular)
control device. For a field-erected unit, it
represents1 the time required to complete the
installation of components as they arrive on site.
The.se installation times are based on data supplied
by suppliers and substantiated by users.
,
On small control devices that can be shop-assembled,
this activity represents fabrication, assembly of
components, and delivery of the control unit to the
site. On large field-erected control devices,
time shown for this activity indicates fabrication
and delivery of the first components to the site.
Delivery of remaining components continues through-
out the construction phase. Duration given for
this activity, based on consultation with manufac-
turers of control devices, ranges from 14 to 30 weeks.
In this activity the client (or his consultant)
prepares engineering drawing packages for use by
the construction company for pouring foundations,
installing structures, ductwork, electrical equip-
ment, and any other items not supplied with the
control device. These drawings also show the
location and tie-in of the control device.
Estimated engineering times range .from 6 to 10
weeks.
Engineering drawings and specifications constitute
the bulk of the construction bid document. A
minimum of 2 weeks is allocated for obtaining bids
from the contractors.
Construction bids are evaluated and the successful
bidder selected; 2 weeks is allowed for this
activity.
Construction contract is prepared. In large
corporations, it is reviewed and approved by
several departments before submission to the
contractor. The procedure requires 2 to 3 weeks.
This activity consists primarily of site preparation;
pouring of the foundation; erection of structural
members; and installation of ductwork, controls, and
auxiliary equipment. Typical requirement is 4 to
12 weeks.
For this activity, time is allocated primarily for
installation of a shop-assembled (or modular)
control device. For a field-erected unit, it
represents the time required to complete installation
of components as they arrive on site.
Tie-in requires 2 to 6 weeks. In large installations,
where the process cannot be conventionally shut
down at the end of the construction phase, longer
times may be required to phase in the control
device.
Time required for start-up, shakedown, and emission
testing ranges from 2 weeks for a small and simple
installation to about 6 to 10 weeks for a large,
complicated system.
2-7
-------
2.2 SUMMARY SCHEDULES BY CONTROL DEVICE
2.2.1 Simplified Control Device Schedules
Schedules for the expeditious installation of commonly
used air pollution control devices are shown in Figures 2-2
through 2-18. These device-specific schedules supplement
the process-specific schedules shown in Section 3.0.
Although these schedules are necessarily more general than
those presented in Section 3.0, they provide guidelines for
evaluating or developing compliance schedules for processes
not described in Section 3.0. The range of time shown for
each increment indicates the expected variations. The
schedule presents only the shortest time period for each
increment.
These schedules are based on several sources of infor-
mation. Delivery and installation times stated by control
device suppliers are modified by personal experience and
judgment and at times by comparison with the times required
for recent installations. As discussed more fully in
Section 2.3, many contingencies affect the compliance sched-
ule, and delivery schedules must often be modified. Data
developed from case histories also require qualification,
since they often do not reflect expeditious schedules,
either because the owner or the contractor does not vigor-
ously pursue prompt installation or because the specifica-
tions are changed. In view of these types of delays, in
addition to those caused by weather, labor problems, and the
like, the schedules should be considered solely as guide-
lines.
These device-specific schedules are based on somewhat
arbitrary breakpoints with respect to capacities; within
each category of size range, (or capacity), significant
variations in elapsed time can occur. Moreover, certain
2-8
-------
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G, WEEKS
3
12
30
59
62
ELAPSED TIME
FROM A, WEEKS
16
25
43
72
75
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-6
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
3
4
5
3
4
4
4
5
4
3
5
Duration
range,
weeks
2-4
2-5
3-8
2-5
3-7
3-7
3-7
4-8
3-6
2-5
4-7
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
Ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction, and system
tie-in
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
3
6
35
6
5
2
2
8
6
4
4-
Duration
range,
weeks
2-5
4-8
30-42
4-8
4-7
2-4
2-4
6-10
4-7
3-5
3-5
Figure 2-2. Schedule for installation
with capacity under
of an electrostatic precipitator
300,000 acfm.
-------
factors influencing delivery and construction may have more
effect on the final schedule than size of the control
device. These factors include (a) special designs that
require new fabrication drawings and procedures; (b) special
materials of construction; (c) space limitations that
necessitate unusual control system configurations or re-
location of process equipment; (d) extensive modifications
of the process; (e) type of contract — erected, nonerected,
or turnkey; and (f) type of unit — shop-fabricated modular,
or field-erected. These factors are described further in
Section 2.3.
These schedules include time estimates for phases A to
G of the overall compliance schedule. The time estimates
are provided in the generalized schedules as approximations
of the range of time requirements. The time range for each
activity indicates the minimum and maximum time required for
that activity.
2.2.1.1 Small Electrostatic Precipitator - Figure 2-2
shows the compliance schedule for installation of a small
electrostatic precipitator with a capacity under 300,000
actual cubic feet per minute.a The minimum installation
time is approximately 75 weeks, including a preliminary
investigation period of 16 weeks.
Control device fabrication requires the longest time
increment of from 30 to 42 weeks. This is followed by on-
site construction time requirements of 6 to 10 weeks. These
large time ranges result from order backlog, different size
units, and different site conditions.
Installation of multiple units requires additional
erection time and additional on-site construction time
(activities N-R and 3-N). Additional time requirements for
other activities are insignificant. Assuming the consecu-
The values in this report are expressed in British system
of units. Appendix A presents the basic metric conver-
sion factors.
2-10
-------
tive erection of units and allowing for the increased on-
site construction period, an additional time increment of 9
to 12 weeks is estimated for each additional unit. This
estimate includes the added time requirements for other
activities.
The upgrading of a precipitator would mainly involve
improvements in gas distribution or sectionalization, addi-
tion of new collector plates, modification of the rapping
system, etc. The time required depends on the degree of
upgrade. Time for preliminary investigation and vendor
selection may not be needed for minor modifications. A
major precipitator upgrade might require an entire new
section in parallel or in series with the existing unit.
2.2.1.2 Large Electrostatic Precipitator - Figure 2-3
shows the compliance schedule for installation of a large
electrostatic precipitator with capacity 300,000 cubic feet
per minute or above. The minimum installation time is 123
weeks, including a preliminary investigation period of 22
weeks. A similar schedule would apply to either a conven-
tional or hot (450-700°F) precipitator.
The longest time increment is control device fabrica-
tion which requires from 48 to 60 weeks. On-site construc-
tion requires 16 to 25 weeks. These large time ranges are
due to different size units and to different site conditions.
Installation of multiple large precipitator units
requires additional erection time and additional on-site
construction time (activities N-R and 3-N). Additional time
requirements for other activities are insignificant. Assum-
ing the consecutive delivery and erection of multiple units
and allowing for the increased on-site construction period,
an additional time increment of 18 to 24 weeks is estimated
for each additional unit. This estimate also includes the
minor additional time requirements for other activities.
2-11
-------
D
I
H-
r-o
Milestones
•Activity and duration 1n weeks
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
4
4
4
2
6
6
5
12
5
4
7
Duration
range,
weeks
3-5
4-6
3-5
2-4
5-7
4-7
4-6
6-14
4-7
4-6
6-9
ELAPSED TIME
FROM G, WEEKS
4
18
44
99
105
ELAPSED TIME
FROM A, WEEKS
22
36
62
117
123
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-1n
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
3
7
56
10
5
3
3
18
17
8
8
Duration
range,
weeks
2-4
6-9
48-60
8-11
4-6
3-5
3-5
16-25
14-19
5-9
6-12
Figure 2-3. Schedule for installation
with capacity over
of an electrostatic precipitator
300,000 acfm.
-------
The upgrading of a precipitator would generally involve
improvement of flow distribution, addition of collector
plates, or modification of the ash handling facility. Total
time requirement depends on the extent of upgrading; exten-
sive modifications may entail more time than that required
for the original installation.
2.2.1.3 Small Fabric Filter - Figure 2-4 shows the com-
pliance schedule for installation of a small fabric filter
with a capacity under 200,000 cubic feet per minute. The
minimum installation time is approximately 55 weeks, in-
cluding a preliminary investigation period of 16 weeks.
The installation of multiple fabric filter units re-
quires additional erection time and additional on-site
construction time (activities N-R and 3-N). Additional time
requirements for other activities are insignificant. Assum-
ing the consecutive erection of units and allowing for the
increased on-site construction period, an additional time
increment of 6 to 8 weeks is estimated for each additional
unit. This estimate also includes the minor additional time
requirements for other activities.
The upgrading of a fabric filter would mainly involve
changes in fabric or cleaning mechanism. Time required
depends on the degree of upgrade; in minor upgrading time
may not be needed for preliminary investigation and vendqr
selection.
2.2.1.4 Large Fabric Filter - Figure 2-5 shows the com-
pliance schedule for installation of a large fabric filter
with a capacity of 200,000 cubic feet per minute or above.
The minimum installation time is approximately 72 weeks,
including a preliminary investigation period of 19 weeks.
The initial period may be longer for new or novel applica-
tions of a fabric filter system or for applications re-
quiring extensive preconditioning of the vent gases.
2-13
-------
D
to
I
Milestones
•Activity and duration in weeks
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
3
4
5
3
4
4
4
5
4
3
3
Duration
range,
weeks
2-4
2-5
3-8
2-5
3-7
3-7
3-7
4-8
2-6
2-5
2-5
ELAPSED TIME
FROM G, WEEKS
3
12
27
40
43
ELAPSED TIME
FROM A, WEEKS
16
25
40
53
56
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
3
4
17
5
5
2
2
8
6
4
4
Duration
range,
weeks
2-5
3-6
13-22
3-7
4-7
2-4
2-4
6-10
4-7
3-5
3-5
Figure 2-4. Schedule for installation of a fabric filter
with capacity under 200,000 cfm.
-------
I I Milestones^
»• Activity and duration In weeks
10
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
3
13
34
53
56
ELAPSED TIME
FROM A, WEEKS
19
29
50
69
72
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-6
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
4
6
3
3
8
4
4
5
3
4
6
Duration
range,
weeks
2-5
4-9
2-6
2-3
5-10
3-7
3-6
4-8
3-7
3-6
4-8
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
3
6
30
10
4
3
2
10
8
4
•
4
Duration
range,
weeks
2-4
5-8
20-50
8-12
3-5
2-4
2-3
8-13
6-10
3-5
3-8
Figure 2-5. Schedule for installation
with capacity of 200,000 cfm
of a fabric filter
or more.
-------
The installation of multiple units requires an addi-
tional erection time and additional on-site construction
time (activities N-R and 3-N). Additional time requirements
for other activities are insignificant. Assuming the con-
secutive erection of units and allowing for the increased
on-site construction period, an additional time increment of
8 to 10 weeks is estimated for each additional unit. This
estimate also includes the minor additional time require-
ments of other activities.
The upgrading of a fabric filter would mainly involve
addition of filtration area (more bags) or modification of
the bag cleaning system. The time requirement could vary
widely depending on the nature and extent of modifications.
2.2.1.5 Low-Energy Scrubber - Figure 2-6 shows the com-
pliance schedule for installation of a low-energy wet
scrubber with capacity under 150,000 cubic feet per minute.
The minimum installation time is approximately 46 weeks,
including a preliminary investigation period of 12 weeks.
The time range for each activity indicates the lower
and upper extremes for that increment. The relatively
shorter span between the two limits for a wet scrubber
indicates a small variation in installation time of differ-
ent size low-energy wet scrubbers.
The installation of multiple units requires an addi-
tional erection time and additional on-site construction
time (activities N-R and 3-N). Additional time requirements
for other activities are insignificant. Assuming the con-
secutive erection of units and allowing for the increased
on-site construction period, an additional time increment of
6 to 8 weeks is estimated for each additional unit. This
estimate also includes the minor additional time require-
ments of other activities.
2-16
-------
D
Milestones
•Activity and duration In weeks
to
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G, WEEKS
2
10
24 -
33
36
ELAPSED TIME
FROM A, WEEKS
12
20
34
43
46
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
0-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
3
3
3
1
3
5
3
5
2
2
3
Duratioji
range,
weeks
2-4
2-5
2-5
1-2
2-5
3-7
2-5
4-8
2-4
2-4
2-4
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-slte construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
3
7
15
8
4
2
2
7
3
3
4
Duration
range,
weeks
2-4
4-9
12-24
4-10
2-5
2-3
2-3
6-10
2-6
1-6
3-5
Figure 2-6. Schedule
with
for installation of a low-energy wet scrubber
capacity under 150,000 cfm.
-------
The upgrading of a scrubber would mainly involve improve-
ment of the auxiliary systems (fan or water supply system)
or modification of scrubber internals. The erection pro-
cess for upgrading will probably require less time than the
erection of a new unit, depending on site limitations and
the extent of the modifications. The time requirement
could range from a few weeks to many months.
2.2.1.6 Small High-Energy Scrubber - Figure 2-7 shows the
compliance schedule for installation of a high-energy wet
scrubber with capacity under 150,000 cubic feet per minute.
The minimum installation time is 59 weeks, including a
preliminary investigation period of 12 weeks.
The installation of multiple units requires an addi-
tional erection time and additional on-site construction
time (activities N-R and 3-N). Additional time requirements
for other activities are insignificant. Assuming the con-
secutive erection of units and allowing for the increased
on-site construction period, an additional time increment of
8 to 10 weeks is estimated for each additional unit. This
estimate also includes the minor additional time require-
ments of other activities.
The upgrading of a scrubber would mainly involve improve-
ment of the auxiliary systems such as fans or water spray
nozzles. The time required to upgrade the system depends on
the nature and extent of modifications; it should be con-
siderably less than that for installation of a new system if
existing ductwork and water treatment facilities are not
replaced.
2.2.1.7 Large High-Energy Scrubber - Figure 2-8 shows the
compliance schedule for installation of a high-energy wet
scrubber with capacity of 150,000 cubic feet per minute or
above. The minimum installation time is approximately 66
weeks, including a preliminary investigation time of 14 weeks.
2-18
-------
D
to
M
VO
Milestones
•Activity and duration 1n weeks
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
2
10
24
45
48
ELAPSED TIME
FROM A. WEEKS
12
20
34
55
58
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-6
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
3
3
3
1
3
5
3
5
2
2
3
Duration
range,
weeks
2-4
2-5
2-5
1-2
2-5
3-7
2-5
4-8
2-4
2-4
2-5
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
Ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
3
6
2
6
4
2
2
10
7
4
4
Duration
range,
weeks
2-4
4-8
18-28
4-10
2-5
2-3
2-3
8-15
6-9
3-5
3-5
Figure 2-7
Schedule for installation of a high-energy wet scrubber
with capacity under 150,000 cfm.
-------
D
N5
O
Milestones
Activity and duration in weeks
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
3
3
4
2
3
5
3
5
4
2
4
Duration
range,
weeks
2-4
2-4
3-5
2-3
2-5
3-7
2-5
3-8
3-5
2-4
3-5
ELAPSED TIME
FROM G, WEEKS
2
10
29
50
54
ELAPSED TIME
FROM A, WEEKS
14
22
41
62
66
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
3
6
28
9
4
2
2
12
10
15
4
Duration
range,
weeks
2-5
5-8
17-48
8-12
2-5
2-3
2-3
10-15
8-15
3-8
4-6
Figure 2-8. Schedule for installation of a high-energy wet scrubber system
with capacity of 150,000 cfm or more..
-------
The installation of multiple units requires an addi-
tional erection time and additional on-site construction
time (activities N-R and 3-N). Additional time requirements
for other activities are insignificant. Assuming the con-
secutive erection of units and allowing for the increased
on-site construction period, an additional time increment
of 8 to 10 weeks is estimated for each additional unit.
This estimate also includes the minor additional time
requirements of other activities.
The upgrading of a scrubber would mainly involve
replacement of throat sections, or installations of new
water sprays and pumps, entrainment separators, or fans.
The time required to upgrade the system could range from a
few weeks to many months.
2.2.1.8 Afterburner - Figure 2-9 shows the compliance
schedule for installation of an afterburner. The minimum
installation time is 48 weeks, including a preliminary
investigation period of 12 weeks.
The installation of multiple units requires an addi-
tional erection time (activity N-R) and also an additional
on-site construction time (activity 3-N). Additional time
requirements for other activites are insignificant. Assum-
ing the consecutive erection of units and allowing for the
increased on-site construction period, an additional time
increment of 8 to 10 weeks is estimated for each additional
unit. This estimate also includes the minor additional time
requirements of other activities.
The upgrading of an afterburner would mainly involve
capability for operation at higher temperature or installa-
tion of parallel units. The time required to upgrade the
system cannot be predicted accurately without definition of
the modification.
2-21
-------
D
Milestones
•Activity and duration 1n weeks
to
I
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G, WEEKS
2
10
22
36
38
ELAPSED TIME
FROM A, WEEKS
12
20
32
46
48
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
3
3
3
1
3
5
3
5
2
2
3
Duration
range,
weeks
2-4
2-5
2-5
1-2
2-5
3-7
2-5
4-8
2-4
2-4
2-4
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
3
3
14
4
4
2
2
6
8
3
3
Duration
range,
weeks
2-4
2-5
12-18
2-5
2-5
2-3
2-3
4-7
6-10
2-4
2-4
Figure 2-9. Schedule for installation of an afterburner.
-------
2.2.1.9 Package Adsorption System - Figure 2-10 shows the
compliance schedule for installation of an adsorption system.
The minimum installation time is 76 weeks, including a
preliminary investigation period of 15 weeks.
The installation of multiple units requires an addi-
tional erection time (activity N-R) and also an additional
on-site construction time (activity 3-N). Additional time
requirements for other activities are insignificant.
Assuming the consecutive erection of adsorption units and
allowing for the increased on-site construction period, an
additional time increment of 10 to 12 weeks is estimated for
each additional unit. This estimate also includes the minor
additional time requirements of other activities.
Upgrading may involve replacement of the adsorbent or
installation of more beds to increase capacity. Installa-
tion times could range from a few weeks to about 15 weeks.
2.2.1.10 Adsorption System, Field-Erected - Figure 2-11
shows the compliance schedule for installation of a field-
erected adsorption system. The minimum installation time is
85 weeks, including a preliminary investigation time of 15
weeks.
The installation of multiple units requires an addi-
tional fabrication and erection time and additional on-site
construction time. Additional time requirements for other
activities are insignificant. Assuming the consecutive
erection of units and allowing for the increased on-site
construction period, an additional time increment of 16 to
22 weeks is estimated for each additional unit. This esti-
mate also includes the minor additional time requirements of
other activities.
Time required for upgrading an adsorption system would
be similar to that for package systems and would of course
depend on the modification.
2-23
-------
to
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
1
in control
il equip-
ELAPSED TIME
FROM G, WEEKS
3
11
30
60
64
- *AiV \£S
ELAPSED TIME
FROM A, WEEKS
15
23
42
72
76
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-6
6-1
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
3
3
4
2
3
5
4
6
3
3
6
Duration
range,
weeks
2-4
2-4
3-5
2-3
2-5
3-7
3-6
4-7
2-5
2-5
4-7
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
4
10
30
8
4
2
2
7
5
5
5
Duration
range,
weeks
3-6
8-12
26-32
6-9
2-5
2-3
2-3
6-9
4-7
4-6
4-6
Figure 2-10. Schedule for installation of a packaged adsorption system,
including field-erected distillation unit.
-------
D
to
I
N)
Ul
Milestones
•Activity and duration 1n weeks
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G, WEEKS
3
11
30
69
73
ELAPSED TIME
FROM A, WEEKS
15
23
42
81
85
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-6
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
3
3
4
2
3
5
4
6
3
3
3
Duration
range,
weeks
2-4
2-4
3-5
2-3
2-5
3-7
3-6
4-7
2-5
2-5
4-7
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
4
10
40
8
4
2
2
9
4
5
5
Duration
range,
weeks
3-6
8-12
36-42
6-9
2-5
2-3
2-3
7-12
3-5
4-6
4-6
Figure 2-11.
Schedule for installation of a field-erected adsorption
system, including distillation unit.
-------
2.2.1.11 High Energy Air Filter - Figure 2-12 shows the
compliance schedule for installation of a fibrous mat type
high-energy air filter. The minimum installation time is 44
weeks, including a preliminary investigation period of 12
weeks.
The installation of multiple units requires an addi-
tional erection and on-site construction time (activities N-
R and 3-N). Additional time requirements for other activi-
ties are minor. Assuming the consecutive erection of units
and allowing for the increased on-site construction period,
an additional time increment of 3 to 4 weeks is estimated
for each additional unit.
These air filter units may be upgraded by replacing the
filtering medium or mat, installing water sprays, or changing
the mat speed. These modifications do not require much time
after initial planning has been completed.
2.2.1.12 Multiple Cyclone - Figure 2-13 shows the compli-
ance schedule for installation of a multiple cyclone.
The minimum installation time is approximately 69 weeks,
including a preliminary investigation time of 22 weeks.
The installation of cyclones on multiple units requires
an additional erection time and additional on-site construc-
tion time (activites N-R and 3-N). Additional time require-
ments for other activites are insignificant. Assuming the
consecutive erection of units and allowing for the increased
on-site construction period, an additional time increment of
6 to 8 weeks is estimated for each additional unit. This
estimate also allows for the added time requirements of
other activities.
The upgrading of a multiple cyclone system would mainly
involve replacement or repair of the internal tubes and
would require 1 to 4 weeks in addition to equipment delivery.
2-26
-------
n
to
I
to
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance Is achieved.
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration.
weeks
3
3
3
1
3
5
3
5
2
2
3
Duration
range,
weeks
2-4
2-5
2-5
1-2
2-5
3-7
2-5
4-8
2-4
2-4
2-4
ELAPSED TIME
FROM G, WEEKS
2
10
22
32
34
ELAPSED TIME
FROM A, WEEKS
12
20
32
42
44
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-In
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
2
3
14
4
4
2
2
6
3
3
3
Duration
range,
weeks
2-4
2-5
12-18
2-5
2-5
2-3
2-3
4-7
2-4
2-4
2-4
Figure 2-12. Schedule for installation of a high-energy
air filter unit.
-------
I
NJ
00
Milestones
•Activity-and duration In weeks
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
4
6
3
2
8
4
4
4
4
3
7
Duration
range,
weeks
2-5
4-9
2-6
2-3
5-10
3-7
2-6
2-6
3-6
2-5
5-10
1
m control
il equip-
ELAPSEO TIME
FROM G, WEEKS
2
9
28
43
45
*vi/ viv
ELAPSED TIME
FROM A, WEEKS
18
25
44
59
61
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
3
7
20
6
4
3
2
10
6
4
3
Duration
range,
weeks
2-4
5-9
15-28
5-9
3-7
2-4
2-3
8-15
5-8
2-7
2-5
Figure 2-13. Schedule for installation of a multiple cyclone.
-------
Final system shakedown and checking would require 2 to 5
weeks.
Installation time for a multiple cyclone is fairly
independent of the flow of gas to be cleaned. Although
installation of the larger units requires use of a higher-
capacity crane and other larger-scale erection equipment,
the total installation time remains unchanged.
2.2.1.13 Mist Eliminator - Figure 2-14 shows the compliance
schedule for installation of a mist eliminator. The minimum
installation time is approximately 62 weeks, including a
preliminary investigation period of 14 weeks.
The installation of multiple units requires an addi-
tional erection time and additional on-site construction
time (activities N-R and 3-N). Additional time requirements
for other activities are insignificant. Assuming the con-
secutive erection of units and allowing for the increased
on-site construction period, an additional time increment of
5 to 7 weeks is estimated for each additional unit. This
estimate also allows for the added time requirements of
other activites.
The upgrading of a mist eliminator system would mainly
involve installation of additional eliminator sections in
series. Time required to upgrade the system naturally
depends on the degree of modification. Time for preliminary
investigation and vendor selection may not be needed for
minor modifications.
Installation time for a mist eliminator is fairly
independent of the gas volume. Although installation of
larger units requires the use of larger-capacity erection
equipment, the total installation time remains unchanged.
2-29
-------
n
to
I
Milestones
•Activity and duration in weeks
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date by which final compliance Is achieved.
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-6
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
3
3
4
1
5
5
3
5
4
3
5
Duration
range,
weeks
2-4
2-5
2-8
1-2
4-7
3-7
2-5
4-8
3-6
2-5
4-7
ELAPSED TIME
FROM G, WEEKS
2
11
31
47
50
ELAPSED TIME
FROM A, WEEKS
14
23
43
59
62
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-In
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
3
6
22
7
5
3
2
7
5
3
4
Duration
range,
weeks
2-5
4-8
20-26
6-9
4-8
2-5
2-4
6-9
4-7
2-4
3-7
Figure 2-14. Schedule for installation of a mist eliminator system.
-------
2.2.1.14 Wet Electrostatic Precipitator - Figure 2-15
shows the compliance schedule for installation of a wet
electrostatic precipitator. The minimum installation time
is approximately 106 weeks, including a preliminary investi-
gation period of 22 weeks.
Installation of multiple units requires an additional
time for erection (activity N-R). In case of multiple units
of different sizes and designs, vendor selection and pre-
liminary investigation will require additional time, depend-
ing on site conditions, unit sizes, and control efficiencies.
Time requirement for installation of identical multiple
units depends on the availability of erection resources.
Assuming the consecutive erection of units, an additional
time increment of 6 to 8 weeks is estimated for each addi-
tional identical unit.
The upgrading of a wet precipitator would mainly
involve improvement of flow distribution, addition of
collector plates, change of spray nozzles, or modification
of the sludge removal system. The time requirement naturally
depends on the extent of upgrading. Upgrading involving
extensive modifications may require more time than a normal
project, since it may entail some dismantling.
The installation of larger wet electrostatic precipi-
tators involves an additional field assembly and erection
time as well as the use of higher-capacity erection equip-
ment. The various time increments may approach those shown
in Figure 2-3 for a large conventional precipitator.
2.2.1.15 Package CO Boiler - Figure 2-16 shows the com-
pliance schedule for installation of a package or shop-
assembled CO boiler. The minimum installation time is
approximately 66 weeks, including a preliminary investiga-
tion period of 15 weeks.
2-31
-------
D
Milestones
•Activity and duration in weeks
I
U)
to
MILESTONES
1
Z
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
Activity
designation
A-B
A-C
C-0
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
4
6
3
2
8
4
7
10
5
4
10
Duration
range,
weeks
2-5
4-9
2-6
2-3
5-10
3-7
6-9
8-12
4-7
3-5
7-15
ELAPSED TIME
FROM G, WEEKS
6
21
46
86
90
ELAPSED TIME
FROM A, WEEKS
22
37
62
102
106
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
2
13
35
10
5
3
3
14
16
7
6
Duration
range,
weeks
2-4
10-17
30-40
8-11
4-9
2-5
2-5
11-22
10-18
6-10
4-10
Figure 2-15. Schedule for installation of a wet electrostatic precipitator.
-------
D
10
,l*»
u>
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Date of submittal of final control plan, to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G, WEEKS
3
12
31
51
54
ELAPSED TIME
FROM A, WEEKS
15
24
43
63
66
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
3
3
4
1
5
5
4
5
4
3
6
Duration
range,
weeks
2-4
2-5
2-8
1-2
4-7
3-7
3-7
4-8
3-6
2-4
4-7
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
4
6
7
6
5
3
2
7
3
4
4
Duration
range,
weeks
3-5
4-8
3-30
4-8
4-7
2-4
2-4
6-9
2-4
3-5
3-5
Figure 2-16. Schedule for installation of a package CO boiler.
-------
The installation of multiple package units requires an
additional erection time and additional on-site construction
time (activities N-R and 3-N). Additional time requirements
for other activities are insignificant. Assuming the
consecutive erection of units and allowing for the increased
on-site construction period, an additional time increment of
4 to 5 weeks is estimated for each additional unit. This
estimate will also allow for the added time requirements of
other activities.
The upgrading of a package boiler system would mainly
involve modifications of the burner system. Time required
to upgrade the system depends on the degree of modification.
If only burner tips are changed, the delivery time would
determine the time schedule. Time for preliminary investi-
gation and vendor selection would be greatly reduced for
minor modifications.
Installation time for a package boiler is independent
of the unit size. Even though installation of the larger
units requires use of large capacity erection equipment, the
total installation time remains unchanged.
2.2.1.16 CO Boiler, Field-Erected - Figure 2-17 shows the
compliance schedule for a field-erected CO boiler. The
minimum installation time is approximately 149 weeks,
including a preliminary investigation period of 24 weeks.
The installation of multiple units requires additional
time for fabrication and erection (activities M-N and N-R)
and for on-site construction time (activity 3-N). Addi-
tional time requirements for other activities are insigni-
ficant. The additional time requirement for each additional
unit depends on the availability of fabrication and erection
resources. Assuming the consecutive erection of units, an
additional time increment of 8 weeks will be required for
2-34
-------
D
to
CO
en
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
6-1
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
4
6
7
2
7
6
7
9
10
3
12
Duration
range,
weeks
2-5
4-9
4-10
2-3
5-10
3-9
6-10
6-12
9-14
2-4
10-16
ELAPSED TIME
FROM G, WEEKS
6
23
74
127
131
ELAPSED TIME
FROM A. WEEKS
24
41
92
145
149
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
Ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on- site construction
Install control device
Complete construction and system '
t1e-1n
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
5
16
65
23
9
5
4
42
10
9
6
Duration
range,
weeks
4-8
14-20
62-76
21-29
8-12
4-7
4-6
39-50
8-13
6-10
4-9
Figure 2-17. Schedule for installation of a field-erected CO boiler.
-------
each additional unit. The estimate of 12 to 14 weeks for
each additional unit incorporates the added time require-
ments for fabrication, erection, and other project activities.
Time required to upgrade an existing unit depends on
the amount of fabrication and sitework involved. Time
needed for preliminary investigation and for vendor and
contractor selection may remain unchanged. The erection
time for upgrading may be more than that for new installa-
tions, since removal of old equipment and limitation of
working space may cause delays.
Installation of larger CO boilers will require more
time; the erection sequence and procedures may also be
different for these units. Times for preliminary investi-
gation and vendor selection may remain unchanged.
2.2.1.17 Combination Wet Mechanical Collector - Figure
2-18 shows the compliance schedule for installation of a
combination wet mechanical collector. The minimum installa-
tion time is 74 weeks, including a preliminary investigation
time of 22 weeks.
The installation of multiple units requires additional
erection time and additional on-site construction time
(activities N-R and 3-N). Additional time requirements for
other activities are insignificant. Assuming the consecu-
tive erection of units and allowing for the increased on-
site construction period, an additional increment of 6 to 8
weeks is estimated for each additional unit. This estimate
also allows for the minor additional time requirements of
other activities.
The upgrading of a combination wet mechanical collector
system would mainly involve modification of auxiliary
systems such as water sprays or fans. The time required to
upgrade the system naturally depends on the degree and
2-36
-------
n
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment. ^
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
6
17
36
56
58
ELAPSED TIME
FROM A, WEEKS
22
33
52
72
74
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Typical
duration,
weeks
3
6
3
2
7
4
7
8
4
3
6
Duration
range,
weeks
2-3
4-6
2-4
2-3
5-8
3-6
6-9
6-10
3-6
2-5
5-8
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on- site construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
Typical
duration,
weeks
3
7
24
6
4
3
2
12
6
3
4
Duration
range,
weeks
2-4
5-9
20-28
5-9
3-7
2-4
2-3
8-15
5-8
2-4
2-7
Figure 2-18. Schedule for installation of a combination wet mechanical collector.
-------
extent of modification. Preliminary investigation time may
not be needed for minor modifications.
Installation time for a combination wet mechanical
collector is independent of the gas flow to be treated.
Although installation of larger units requires use of high-
capacity erection equipment, the total installation time
remains unchanged.
2.2.2 Critical Path Method
The Critical Path Method (CPM) is based on the concept
of network logic. By use of this logic any project can be
represented in a network form. The network identifies the
relationships among activities and the logical sequence in
which they can be performed. The network thus becomes a
basis for project planning and scheduling and a means of
monitoring progress.
Development of the network consists of the following
steps:
0 Develop the project structure. Visualize and list the
different activities to be performed and the sequence
in which they can be performed.
0 Construct the activity network representing the se-
quence and relationship of activities.
0 Determine and assign time estimates for each activity.
0 Determine the Critical Path - Identify the activities
that are crucial to the timely completion of the
project (i.e. the next step cannot be completed until
the previous one is done). These critical activities
form a small percentage of the total number of acti-
vities in the entire project. Any delay or accelera-
tion of these activities will affect the completion
date of the project.
The activity network is constructed by use of network
logic and some simple conventions, such as arrows for
activities and circles for events; the interrelationships
2-38
-------
and the sequences of activities are represented in the form
of a network. Construction of a critical path network is
illustrated by the network for a scrubber installation in
Figure 2-19. The terminologies of the critical path net-
work are defined in Table 2-3.
Table 2-3. CRITICAL PATH NETWORK TERMINOLOGIES
Event: This is an inexplicitly identifiable point in
time at which something has happened or a situ-
ation has come into existence. Some amount of
work or operation may be involved in reaching an
event, but the event itself takes no time. An
event shows only the starting or end point of any
activity. Events are numbered for reference
purposes.
Events are represented by circles; the network in
Figure 2-19 has 24 events. Events are also called
nodes, milestones, or benchmarks.
Activity: This is a clearly definable task to which a known
quantity of manpower and other resources must be
applied. An activity requires effort applied over
a period of time and is therefore bounded by two
events. These events are referred to as prede-
cessor and successor events for the activity.
An activity is represented by an arrow directed
toward the successor event.
Dummy: A dummy is a dotted arrow that represents an inter-
relationship but involves no time. Dummies are
used for completion of a logic in a network.
Early The early start date or earliest expected time of
Start an event is the date when all the activities con-
Date: straining the starting of the event in question
are completed.
The early start time for an event in Figure 2-19
is indicated in the lower left quarter of the
event circle.
2-39
-------
I
^
O
^T^il^/TN
\r_y~ 3 "V^lv
. CTITICAl ACTIVITT
T ACTIVITY
SPECIFY AKO PROCURE 1
10!
111
L2J
F1HALIIC PIA1S AOT
HBYAU PUTS AIO PITOt
m
PROCURE ELECTRICALS
IhSTALL ELECTWULS
[10J
CT AinillAKlES
ki
. COWISSIOFI SCR-JSEB1 __
PRKURE AND EVALUATE X*TN. AWARD SCRUBBED X N FABRICATE tan DELIVERY X7""\ / *\ /%TT\ opEWTICf( A«o ACHIEVE f*T?^
5c»vmR fliss ^/ 9 \ C:\TRJ:T ^ I 10 > SCRUBBER o!i SITE ^ I 14 ^ IIOTALL scRusaEiwf 22 > TIST urn Bfyji TBC SYSTEIL^ 23 > COTLHICE ^ / 2*
. >. PREPARE UTtlUT XTTN /C^N E»ECT SUPPORTIKG/1, _ •,
4 A ORAMIHGS Y 11 A procure sreueTuaAis_/ \2\ STRUCTUIES I 13
L5J
• .- -\ FAtRI«TE WO OELIVE«. / .„•»
15 \ OUCTIM OT SITE .( 19 A mST«lL HUCTIK8
^ SO|71/ Q]
SPECIFY A»D.
nxaa SITOE DISPOSAL tmipreHT
SUIMC msnsn. EOUIPBBIY
Figure 2-19. Critical path schedule for scrubber installation.
-------
Late The late start date or latest allowable time is
Start that by which an event should occur if slippage of
Date: the event schedule is to be avoided.
The late start date for an event in Figure 2-19 is
indicated in the lower right quarter of the event
circle.
Slack: The slack or float is a difference between
the earliest expected time and latest allowable
time; it represents flexibility. This is a range
of time over which an activity can take place
without influencing the project completion date.
Critical The longest time path through a network is called
Path: the critical path, which represents the least
time for achieving the objective without crashing.
The activities on the critical path are called
critical activities. The critical activities have
no slack and are generally shown by a heavy line.
Each event circle in the diagram contains the event
number and the time limits. The event number is in the
upper half of the circle; the early start date is in the
lower left quarter, and the late start date is in the lower
right quarter. The difference between these two limits
gives the float or slack for the activity/activities pre-
ceding the event.
Event 1 in the diagram represents the start of the
*
project, and event 24 represents completion of the project.
Various activities occur between these two events in a
definite sequence. The network explains the relationship
between various activities for the project.
An activity begins and ends with an event. Activities
are represented by solid arrows joining the events, with
the arrowhead at the ending event. The description of an
activity is written above the arrow, and the estimate of
time for an activity is indicated below the arrow. The
dotted arrow or dummy represents an interrelationship but
2-41
-------
requires no time; dummies are introduced to indicate the
technological relationship of the activities.
The heavier line formed by activities joining events 1
and 24 through events 2, 3, 4, 9, 10, 14, 22, and 23, is the
critical path; any change in the time required for an acti-
vity on this path will affect the project duration by the
same amount. Activities on the critical path have no slack.
The size of a network for a given project may vary
according to requirements of different organizational levels.
Senior management may use a macro network consisting of
major representative activities. Department heads or project
managers may require an intermediate network incorporating
more details than those presented in the macro network.
Project personnel (the on-site staff) will use a detailed
micro network with activities exploded for execution of the
project on site.
Figures 2-20 through 2-22 exemplify critical path
networks for installation of a baghouse, limestone S02
scrubber system, and electrostatic precipitators. These
schedules illustrate the complexity of the projects and the
time increments involved in their completion.
2.3 CONTINGENCIES AFFECTING COMPLIANCE SCHEDULES
The compliance schedules compiled in this report rep-
resent "expeditious as practicable" control programs. These
represent the minimum time required to achieve compliance,
taking into account the lead times required for engineering
design, equipment fabrication, field installation, and
related activities. Successful completion of the projects
in the indicated time periods requires minimizing the normal
time variation in each of the component activities and
avoiding major delays caused by unforeseen contingencies.
2-42
-------
PROCURE aECTRICALS
AW OTHBt AUXILIARIES/
INSTALL AUHLIAMP
, mm CONNECT AUHLIARIO MB atcnicAL*
to
I
PREPARE PRELIMINARY OBTAIN AGENCY FINALIZE PLANS
CCHTS31. PLAN AND __ ..wnu.i • ^^ AKD ^
/T\ SCHEDULE /2\ *rra»H- /T\ SPECIFICATIONS (I
^jjo/ LU V«ly LU \2£x LU '**!!
( iKrza. \
LU
/i
y LU ^«y ^
i
_ | FABRICATE AND DaiVER . v
\ I DUCTING ON SITE /1?S INSTALL DUCTING
1
1
1
i
/'UN INSTALL ID FAN ./TsN
omission BAG
.TEST AND DEM ._. MOUSE t ACHIEVE ^^^
Figure 2-20. Critical path schedule for
baghouse installation.
-------
PP.fPARE PRELIMINARY
CT.:?(!' PLA'I 8 COHPU
vl'.CE SCHEDULE/"^1
IEPARE PRELIMINARY
:1V!L DRAWINGS 1 x
IIU OF MATERIAL
EXCAVATE 1 PREPARE
FOUNDATIONS FOR , „
TAHKS i PUMPS ' z9
INDICATES CRITICAL ACTIVITY
INDICATES DIMff AUIVITY
EXCAVATE S PREPARE
FOUNDATIONS FOR
EQUIPMENT
i_FABRICATE 1 INSTALL
DUCTING ON SITE
DUaiNG FABRICATION
BIDS.
INSTALL I.D. FAN i
CONNECT DUCTING
DESIGN I SPECIFY
IIELECTP.ICAL EQUIP.
FINALIZE LONG. TERN
CONTRACT FOR LIMESTONE
AHD CHEMICALS
I—INSTALL CONTROL PANEL
' AND COMPLETE HIRING
!_ INSTALL 1 ERECT
| LIMESTONE EQUIPMENT
Figure 2-21. Critical path schedule for a limestone scrubbing system.
-------
MOCME I EVALUATE OUCTII
'•FABRICATION
INSTALL ELECTRIC*,
EOUIPHERT AW
COMPLETE VIRM
to
I
£»
en
INDICATES OtMIT ACTHITT
INDICATES CRITICAL ACTIVITY
Figure 2-22. Critical path schedule for installation of
two electrostatic precipitators.
-------
A statistical approach is used here to generally
identify those elements of a control program for which
assignment of additional manpower or other actions would be
most beneficial in reducing overall elapsed-time require-
ments for the project. The potential impacts of normal time
variance and unforeseen contingencies were evaluated by use
of standard PERT probability calculations as applied to a
generalized compliance schedule. The results are useful in
determining the impact of contingencies on the expected mean
time of project completion and on the variability of the
predicted completion date. It should be noted that the
generalized compliance schedule used in this discussion is
somewhat longer than the average project involving air
pollution control devices. Furthermore, the nonspecific
characteristics of the schedule inherently introduce more
variability than would be encountered in a typical schedule.
The precision of this approach could be improved by com-
piling data specific to each industry or to each control
device.
The generalized compliance schedule presented earlier
in Section 2 is divided and expanded to illustrate activities
subject to normal and abnormal schedule variation. Activi-
ties denoted by dotted lines represent contingencies that
may be important in certain control programs. Figure 2-23
includes all activities that comprise the formal compliance
schedule; Figure 2-24 is limited to precompliance schedule
review and negotiation. Estimates of variation in time
requirements for each activity are based on engineering
experience and a limited survey of equipment vendors and
other engineering companies. The expected mean time require-
ment (tg) for each activity is calculated by use of equation
1, which is based on an assumed beta distribution. Beta
2-46
-------
K>
Activity
1-H,
H1-H2
H2-H3
H3-H
I-H
H-J
J-2
2-K
K-L
L-O
0-P
P-Q
Q-3
3-N
L-M
M-M!
M-M2
Ml-«3
Action Taken
Contact Vendors
Prepare Specifications
Procure Subcontractor Bids
Submit Formal Bids
No Revisions Necessary
Evaluate Bids
Award Contract
Vendor Assembly Drawings
Client Approval
Client Prepares Ste. Drawings
Procure Construction Bids
Evaluate Bids
Award Contract
Site Preparation
Vendor Fabrication Drawings
Vendor Acquires Std. Equipmt.
Vendors Acquires Spec. Matrls
Dummy
fce
2.17
4.5
3.83
2.17
0
5.17
2.17
6.67
4.33
15.0
2.17
2.17
2.17
6.5
12.7
2.17
23.2
0
a2
0.56
1.56
5.06
0.56
0
5.06
0.56
4.0
2.25
56.2
0.56
0.56
0.56
18.1
9.0
1.56
100
0
fcmi,
1
3
1
1
0
3
1
4
2
6
1
1
1
3
8
0
10
0
fcp
2
4
3
2
0
4
2
6
4
12
2
2
2
4
12
2
20
0
ma>
4
8
10
4
0
12
4
12
8
36
4
4
4
20
20
5
50
0
Vctivitj
M2-M3
M3-N
N-R
R-4
4-S,
Sl-?, -
S,-5
S,-S,
S3-S4
S4-5
Action Taken
Dummy
Fabricate Control Device
Field Installation
Tie-in
Start-up
Acceptance Test
Certify Compliance
Adjust and Modify
Re test
Certify Compliance
fce
0
17.7
36.7
4.3
9.0
4.3
4.3
20.7
4.3
4.3
a2
0
132
600
2.25
20.2
2.25
2.25
121
2.25
2.25
min
0
6
6
2
2
2
2
8
2
2
fcp
0
12
26
4
8
4
4
16
4
4
•nuyi
0
52
|104
8
20
8
8
52
8
8
NOTE: Dotted lines indicate possible contingencies in
schedule, arrows indicate "normal" critical path.
t = expected mean time, weeks
t = most probable time, weeks
fcmin = mini-raum completion time, weeks
t = maximum completion time, weeks
IHaX
a2 = completion time variance
Figure 2-23. Example compliance program.
-------
(£$
I
**
00
fcctivitj
*-Al
R!-B
k-A2
^-B
^-A,
^-B
B-B,
B^Bj
B,-B,
33-C
3"B4
f-B5
P,'C
VC
:-D
Action Taken
Source Test Preparation
Perform Test & Submit Report
Obtain Consultant
Consultant Evaluation
Obtain Chemical/Physical Data
Evaluate Operating Conditions
Contact Equipment Vendors
Prepare Control Device Specs
Procure Subcontractor Bids
Vendors Submit Bids
Evaluate Fuel/Feedstk Changes
Evaluate Proc. Design Changes
Duisny
Dairary
Evaluate Control Alternative:
fc*
4.7
4.3
2.2
6.0
2.2
2.2
2.2
4.5
5.1
2.2
30.3
30.3
0
0
5.2
a2
4.0
2.2
0.6
4.0
0.6
0.6
0.6
1.6
3.8
0.6
600
600
0
0
S.I
Snin
2
2
1
2
1
1
1
3
1
1
2
2
0
0
3
fcp
4
4
2
6
2
2
2
4
3
2
20
20
0
0
4
max
10
8
4
10
4
4
4
8
10
4
100
100
0
0
12
•ctivity
D-EI
EI-F
D-E
E-F
F-G
G-l
Action Taken
Legal Negotiations
Dummy
Reserve Funds
Prepare Preliminary Plan
Agency Approval and Review
Finalize Control Plans
%
18
0
0.7
2.2
6.3
4.3
°2
156
0
4.0
0.6
6.3
2.2
fcmir
0
2
1
•>
2
1
S
8
0
4
2
6
4
fcma>
52
0
10
4
12
E
NOTE:
t =
Dotted lines indicate possible contingencies in
schedule, arrows indicate "normal" critical path.
expected mean time, weeks
most probable time, weeks
= minimum completion time, weeks
•= maximum completion time, weeks
completion time variance
Figure 2-24. Precompliance plan activities
-------
distribution is.biased toward longer time periods and has
been useful in a variety of engineering and construction
projects.
t = tmin ^ * tmost Probable) + 'Snax Equation 1
e 6 ^
2 t - t
a = max min Equation 2
4
where
t = expected mean time, weeks (completion time with
a probability of 50 percent),
t . = minimum time, weeks,
t _„ = maximum time, weeks,
luciX
t „„. „ , V1 = time of greatest statistical probability
most probable , , ~=>. . ,...... »
c (peak of beta distribution),
2
a = variance of completion time.
Variance is calculated according to equation 2. Because of
the limited sample population, a denominator of 4 is used
instead of the more common value of 6. The overall comple-
tion time estimates for the project are calculated by summa-
tion of the elements along the critical path. The resulting
completion probabilities for a "normal" project are indi-
cated in the first columns of Tables 2-4 and 2-5 for the
compliance program and preschedule activities, respectively.
2.3.1 Normal Variation in, Time Requirements
Inspection of the data included in Figure 2-23 in-
dicates that half of the total time requirement and most of
the variance is introduced in the fabrication (M. to N) and ~
field installation (N to R) activities (see elements along
critical path). Following are some of the factors that con-
tribute to normal variation.
2-49
-------
Table 2-4. EFFECT OF CONTINGENCIES ON
COMPLIANCE PLAN ACTIVITIES
Probability
of completion in
time specified,
•%
95
90
80
70
60
50
40
30
Time required for project completion, weeks3
Normal
160
147
133
124
116
109
103
95
Revised
bids
168
158
147
136
129
122
115
107
Special
materials and/or
equipment
180
171
159
150
141
133
126
118
Noncompliance
190
180
166
156
147
139
132
123
The time estimates are illustrative only; they do not necessarily
apply to a specific type of control device or a specific industry,
2-50
-------
Table 2-5. EFFECT OF CONTINGENCIES ON
PRECOMPLIANCE PLAN ACTIVITIES
Probability of
completion in
time specified/
%
90
80
70
60
50
40
Time required for plan development, weeks
Normal
52
49
47
45
44
43
Process research
74
66
61
56
51
47
Legal negotiations
100
87
77
70
62
47
2-51
-------
Type of Control Device
The complexity of the common air'pollution control
devices varies substantially- Fabrication of electrostatic
precipitators, for example, requires more time than fabri-
cation of mechanical collectors or fabric filters. The data
presented in this report indicate that complexity of the
control device is responsible for 25 to 50 percent of the
total variation.
Scale of Installation
Field erection time and, to some extent, fabrication
i
time are proportional to the scale of the control facility.
Installation of multiple units requires considerable site
preparation, duct construction, electrical connection, and
related work. Space requirements can also impede expeditious
installation.
Retrofit Difficulty
Installation of large air pollution control devices at
existing facilities can require substantially greater time
periods than incorporation of similar controls into new
facilities. Site preparation could be more difficult
because of underground tanks, overhead power lines, or
existing structures. Restricted access can dictate the type
of equipment used to erect the support structure and to
install the control device.
Availability of Skilled Labor
Backlogs can affect both fabrication and field erec-
tion. The susceptibility of projects to availability of
skilled labor is roughly proportional to the complexity of
the control device and the scale of the installation.
Geographical distribution of skilled personnel must some-
times be considered. Strikes can result in substantial
delays.
2-52
-------
Other normal factors that influence the length of time
required to achieve compliance include availability of
engineering and drafting personnel (activities 2-k, L-M, and
L-0), difficulty of start-up (activity 4-S,), and acceptance
testing (activity S,-S2). Tie-in of the control device to
an already operating process can require lengthy periods if
temporary shutdown of the process would result in severe
economic loss. In such cases, it is conceivable that tie-in
would be delayed until a scheduled process maintenance
period. Tie-in time can be minimized by installing blinded
tie-in flanges and ductwork during the construction phase.
If normal weather patterns are considered, severe weather
should not be a major delaying factor. Obviously, sche-
duling of construction during midwinter in northern areas
should be avoided, and the site should be protected from
water accumulations.
The variation in time requirements shown in Table 2-4
accounts for these contingency factors. The estimated
variation data show a 95 percent probability that all of
the project will be completed in 160 weeks and a 30 percent
probability of completion within 95 weeks. The expected
mean time (50 percent probability) is 109 weeks, barring
such unusual factors as revised bids, special material, or
extra shakedown time. The precision of the estimates could
be improved by factoring in the type of control device and
the difficulty of field erection.
In projects subject to normal variation only, the
fabrication and field erection activities require greatest
attention to minimize time requirements. Time requirements
can be reduced by ensuring the availability of adequate
skilled labor, by reducing tie-in delays, and by minimizing
effects of adverse weather.
2-53
-------
2.3.2 Contingencies in Project Time Requirements
A number of contingencies can substantially delay
compliance work. The impact of these factors on the proba-
bility of completion has also been estimated by use of PERT
calculation procedures.
Special Materials and Accessories
Certain installations require special materials of
construction to withstand severe conditions. Delays in
receipt of stainless steels or nickel alloy steels are not
unusual. Figure 2-23 indicates that this factor has a
direct impact on the critical path (see activity M-M_).
Acquisition of special components such as fans, pumps, and
electrical parts may involve similar delays; these are
usually less severe, however, since fabrication can gener-
ally proceed without these components. As shown in column 2
of Table 2-4, this problem could increase the expected mean
time from 109 to 133 weeks and could increase the vari-
ability slightly. Except for avoiding any unnecessary use
of special materials or hard-to-get accessories, very little
can usually be done to compress the time requirement for
such contingencies.
Revised Bids
Depending on the elapsed time involved in compliance
plan development, it is occasionally necessary to obtain
updated bids from equipment vendors. Such bids are gen-
erally valid for only 60 or 90 days. As indicated in the
dotted line l-H^-E^E^-E on Figure 2-23, this process adds
approximately 12 weeks to the project time requirement. It
causes only a minor shift in the completion probability
estimates. Since haste in the design stage can cause major
problems at a later stage, compression of the schedule for
this activity is seldom prudent.
2-54
-------
Noncompliance
In certain cases it is impossible to achieve perforj-
mance guarantees and compliance through normal adjustment of
the control device. Evaluation of the operational problems
can include airflow studies in models, extensive on-site
inspection, and redetermination of pollutant characteristics
(particle size, particle composition, resistivity, pollutant
concentration, gas flow variation, etc.). Minor modifica-
tions of the control equipment require most of the time
listed in activity S2 to 83. Adjustment and modification
work increases the expected mean time from 109 to 139
weeks. This factor exerts the greatest impact of any factor
identified and obviously deserves careful attention. In
view of the extensive potential time delay and costs, the
activities of equipment selection, design, and installation
should not be accelerated unnecessarily.
Development of Final Compliance Plan
The work discussed thus far involves the actual design,
fabrication, and installation of equipment. Obviously none
of this work can be initiated until a formal plan has been
developed by the owner and approved by regulatory authorities,
Several factors can delay the plan development. A control
device is generally selected only after the owner has
determined that changes in process design or feedstock/fuel
are not economical or technically feasible. Evaluation of
the control alternatives can require a lengthy period,
depending primarily on the complexity of the process. As
shown in Table 2-5, these preliminary studies can shift the
expected mean time for generating a final plan from 44 weeks
to 51 weeks and can substantially increase the variability.
After completing a preliminary review of the control
alternatives and costs, the owner may choose to challenge
2-55
-------
the need for control or the extent of .control required.
Such a challenge could result in substantial delays, de-
pending on the legal action involved. The potential delay
is roughly estimated as 18 .weeks.
On the basis of the completion probability data in
Table 2-4, it is estimated that delays in developing a
formal compliance schedule could delay achievement of
compliance by 6 to 12 months.
2.3.3 Conclusions
The completion probability estimates suggest several
activities that can facilitate expeditious compliance.
Development of the formal compliance plan should be done in
the minimum of time that allows adequate evaluation of
control alternatives. The regulatory requirements should be
stated clearly to prevent or minimize the use of time in
legal negotiations. Emphasis should be placed on acquisi-
tion of representative data on pollutant loads and charac-
teristics to avert noncompliance problems. Time require-
ments for procuring special materials of construction should
be incorporated into schedules to provide realistic compli-
ance dates.
2-56
-------
3.0 COMPLIANCE SCHEDULES FOR SELECTED INDUSTRIAL SOURCES
3.1 STATIONARY COMBUSTION
3.1.1 Coal-Fired Utility Boilers
Process Description - Individual coal-fired utility boilers
range in size from small units generating about 20 MW of
power to units generating over 1000 MW. The smaller units
are usually operated for peak loading (i.e. to generate the
additional power needed during peak power usage hours),
whereas the larger boilers are usually operated continously
to provide the base load. At large power generating stations
with several boilers, generating capacities can reach several
thousand megawatts.
The overall process for power generation at a coal-
fired utility is shown schematically in Figure 3-1. Coal is
usually received by barge or rail, sized, and then fired
into the furnace; the heat from combustion is used to pro-
duce steam for generating power. Most coal-fired utilities
use either pulverized coal or cyclone-fired boilers, the
pillverized-coal-fired units vastly predominating. Almost
all units in current use are equipped with some type of
device for fly ash control.
Atmospheric Emissions - Sources of particulate emission
include the coal receiving and handling operations, the
furnace flue gases, and the ash disposal operations. Of
these, the fly ash contained in the flue gases represents
the largest particulate emission source. The flue gases
also can contain substantial amounts of sulfur oxides and
nitrogen oxides.
3-1
-------
U)
I
CO C02 02 N2
NOV SOV PARTICULATE
X X
GASES TO ATMOSPHERE
AIR POLLUTION
rnniTDrti ncwtrc r\ rnMfiiiT ^ rftMTPrti
tUNIKUL Ut-VILL ILbnNUU 1 ^*
UNBURNED COAL DUST
t
STEAM •* —
1
1
DEVICE
^ — ^ CONDENSED STEAM AND
^ 1 I i.ni-rn ^
I L
AIR HEATER
^"* ECONOMIZER
SUPER HEATER
V
HOPPER CAR 1 HOPPER
BARGE OR *- CRUSHER -*• CONVEYOR -*• BUNKER -V AND -*• FIRE BOX
STORAGE PILE 1 FEEDER
! *
WATER ^^
1
DRY SYSTEM WET{;|S]
ASH HOPPER n,?X
UloV/tl
1
1
CONVEYING
SYSTEM
| V DRUM 1
i . • -^JMiin nrciiMi
v /
FLYASH X — i— "^
REINJECTION BLOWDOWN ^ f?"
* ' LINE HEAT
"*~ AIR
'STEM
Va ^ WATER
ARGE
LIQUID OR SOLID WASTE
TO ASH STORAGE,
WASTE TREATMENT, OR LAGOON
Figure 3-1. Steam generation at a coal-fired utility.
-------
Pulverized-coal-fired boilers generally emit, as fly
ash, between 75 and 85 percent of the ash content of the
coal. For example, a unit burning coal having 10 percent
ash content emits approximately 160 pounds of fly ash per
ton of coal burned. Cyclone-fired units emit considerably
less, approximately 10 percent of the total ash content of
the coal; a unit burning coal having 10 percent ash content
emits approximately 20 pounds fly ash per ton of coal burned.
Nationwide, particulate emissions from coal-fired
boilers may increase during the next few years. Two fac-
tors, available fuels and controls, will contribute to this
emission increase. The limited availability of oil and gas
fuels will result in the conversion back to coal-firing of
some oil- and gas-fired boilers that formerly burned coal.
Oil- or gas-fired boilers that have never burned coal cannot
be converted to coal firing without equipment modification
or capacity reduction because of physical size and general
design. To comply with S02 regulations some utilities may
switch from high-sulfur to low-sulfur coal. The change in
resistivity of the fly ash can decrease the efficiency of
an electrostatic precipitator for particulate control.
The addition of precipitator sections can prevent an increase
in particulate emissions.
Control Systems - Electrostatic precipitators have been used
almost exclusively for high-efficiency particulate control.
These devices are capable of operating with collection effi-
ciencies of more than 99 percent. In design of the precipi-
tator, particular attention must be paid to the properties
of the coal and the expected precipitator operating tempera-
ture; both parameters influence fly ash resistivity, which
in turn directly affects collection efficiency.
3-3
-------
Flue gas conditioning is sometimes used when fly ash
resistivity prevents efficient particulate removal by exist-
ing precipitators. Conditioning involves injecting SO-,
ammonia, or other chemicals into the flue gas to improve fly
ash resistivity and in turn increase the fly ash collection
efficiency. The degree of improvement in collection effi-
ciency depends on the resistivity of the dust before flue
gas treatment and the operating condition of the precipi-
tator. Increases in efficiency of up to 40 percent have
been reported, but a 10 percent increase would be more
typical.
Fabric filters can also be used to control particulate
emissions from coal-fired boilers. Although they have been
used to only a very limited extent, their use may increase
in the future because of their ability to control fine
particulate emissions. Particulate collection efficiencies
of over 99 percent can be expected. Fly ash resistivity has
no effect on collection efficiency of fabric filters but
flue gas temperatures must be high enough to prevent conden-
sation on the fabric even at low loads.
Within the last few years, wet scrubbers have also been
installed to control particulate emissions from coal-fired
boilers. Usually such installations are made in anticipa-
tion of converting the scrubber system to collect both SO-
and particulate.
Some plants are using flue gas desulfurization (FGD)
systems for control of S02. These S02 absorption systems
are located downstream of the particulate collection device
and typically remove about 85 percent of the SO- in the gas
stream. The systems are classified as either nonregenerable
or regenerable. Nonregenerable systems (for example the
lime, limestone, and double-alkali systems) produce a non-
usable sludge that must be disposed of by landfill, whereas
3-4
-------
regenerable systems (for example the Wellman-Lord and mag-
nesium oxide systems) recover the collected SO,, which is
ultimately used to produce sulfur or sulfuric acid.
Conversion from coal to oil or gas as fuel also effec-
tively reduces particulate and S02 emissions.
Compliance Schedules - Figures 3-2 through 3-4 illustrate
expeditious schedules for installation of an electrostatic
precipitator, fabric filter, and wet scrubber for particu-
late control. Schedules for installation of FGD systems for
boilers larger and smaller than 500 MW are shown in Figures
3-5 and 3-6. Differences in the compliance schedules of
regenerable and nonregenerable FGD systems are too slight to
warrant separate schedules.
Figure 3-2 shows a typical compliance schedule for
controlling a large utility boiler. With an ESP control
device, fabrication requiring approximately 48 weeks con-
stitutes the longest time increment, followed by a control
device installation time of 14 weeks. Total compliance time
is 105 weeks. As shown in Figure 3-3, the longest time
increment required for compliance with a fabric filter is
the 52 weeks necessary for control device fabrication,
with a total time of 106 weeks. As shown in Figure 3-4,
a scrubber can be installed on a coal-fired utility boiler
in approximately 83 weeks. This interval is from the time
an agency grants approval of compliance plans until comple-
tion of control device shakedown and the preliminary source
test. The longest time increment is 20 weeks for control
device fabrication.
FGD systems require water treatment facilities, sludge
handling equipment, and (for a regenerable system) a chemical
processing plant. Schedules for installation of FGD systems
on a small and large (greater than 500 MW) boilers are shown
in Figures 3-5 and 3-6, respectively. Total times required
3-5
-------
Milestones
-Activity-and duration 1n weeks
U)
I
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
18
44
99
105
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Figure 3-2.
Perform startup, shakedown, and
emission testing
Schedule for installation of an electrostatic precipitator
on a 500-MW coal-fired boiler.
-------
D
Milestones
•Activity and duration In weeks
CO
MILESTONES
1
2
3
/
4
5
Refer to Chapter 2 for time
•Increments A to G.
Date of submtttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
12
37
83
89
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device btds
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Figure 3-3.
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-slte construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Schedule for installation of a fabric filter on
utility-sized coal-fired boilers.
-------
OJ
I
00
n
Milestones
•Activity and duration 1n weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
20
44
65
70
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
6-1 Finalize plans and specifications
1-H Procure control device hids
H-J Evaluate control device bids
0-2 Award control device contract
2-K , Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
1nps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Figure 3-4.
Perform startup, shakedown, and
I emission testing
schedule for installation of a wet scrubber for particulate
control on a coal-fired utility boiler.
-------
D
Milestones
•Activity and duration In weeks
U)
vo
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
Increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. KEEKS
22
71
136
156
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Figure 3-5.
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-H Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
K-4 Complete construction and system
tie-In
4-5 Perform startup, shakedown, and
emission testing
Schedule for installation of an FGD system on a boiler
with capacity less than 500 MW.
-------
LO
I
Milestones
Activity and duration 1n weeks
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
71
151
171
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
inos
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-6.
Schedule for installation of an FGD system on a boiler
with capacity of 500 MW or more.
-------
for compliance by use of FGD are approximately 156 and 171
weeks.for coal-fired boilers of capacities less than and
greater than 500 MW respectively. The longest time incre-
ment is for control device fabrication, approximately 60 and
75 weeks for the small and large boilers, respectively.
Regenerable and nonregenera'ble FGD systems require approxi-
mately the same installation time. Construction and in-
stallation of chemical' process equipment and scrubber equip-
ment can normally be done concurrently.
The elapsed time of these schedules may increase as a
result of delays in control device fabrication, staggering
the installation of several devices at one site, retrofit
difficulty, and start-up problems. The time delay, if any,
caused by backlogs of orders or delivery scheduling can
be estimated by the manufacturer. Approximately 12 to 24
weeks is usually required for installation of each additional
precipitator after the first unit has been completed, because
utilities must stagger the down times of the various boilers
to meet power generation requirements. Although this addi-
tional time can be shortened, the schedules must be con-
sidered on an individual basis for each utility. The variety
of start-up problems encountered with large control devices
can entail more than 6 months delay unless both the utility
and control system manufacturers make an intensive effort
to rectify the difficulties promptly.
Installation time of a flue gas conditioning system
ranges from approximately 6 weeks to 8 months, depending on
the chemical used to treat the gas, the equipment require-
ments, and the boiler configuration. Properties of the fly
ash and plant economics will determine which flue gas
conditioning system is best for each plant. An expeditious
compliance schedule for a flue gas conditioning system is
shown in Figure 3-7. Specialty chemical systems reportedly
3-11
-------
OJ
i
M
NJ
D
Milestones
•Activity and duration in weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
_22_
_33_
35
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G ' Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
inas
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-7,
Compliance schedule for flue gas conditioning
on a utility-size boiler.
-------
require as little as 6 weeks for installation and shakedown,
but operating costs may be much higher than those of other
systems.
Sources of Additional Information
Type of
Source information*
1. Particulate Pollutant System Study. P, E, C
Volume III. Handbook of Emission
Properties. Prepared by Midwest
Research Institute for the U.S.
Environmental Protection Agency,
Durham, North Carolina. NTIS No.
PB 203 522. May 1971. 613 p.
2. Oglesby, S. and G.B. Nichols. A C
Manual of Electrostatic Precipitator
Technology. Part II - Application
Areas. Prepared by Southern Research
Institute for the National Air
Pollution Control Administration,
Cincinnati, Ohio. NTIS No. PB
196-381. August 1970. 875 p.
3. Steam, Its Generation and Use. P
Babcock and Wilcox Co., New York,
1963.
4. Smith, W.S. and C.W. Gruber. P, E
Atmospheric Emissions from Coal
Combustion, An Inventory Guide.
U.S. Public Service, Cincinnati,
Ohio. Publication No. AP-24.
April 1966. 114 p.
5. Feazel, C.E., ed. Symposium on P, E, C
Electrostatic Precipitators for the
Control of Fine Particles. Prepared
by Southern Research Institute for
the Office of Research and Develop-
ment, U.S. Environmental Protection
Agency, Washington, D.C. Publication
No. EPA-650/2-75-016. January 1975.
489 p.
3-13
-------
6. Proceedings: Symposium on Flue Gas P, E, C
Desulfurization - Atlanta, November
1974, Volume II. U.S. Environmental
Protection Agency, Washington, D.C.
Publication No. EPA-650/2-74-126b.
December 1974. 531 p.
7. Green, G.P. and W.S. Landers. P, E, C
Operating Experience with Gas
Conditioned Electrostatic Precipi-
tators. Public Service Company of
Colorado. January 1974. 5 p.
8. Inspection Manual for the Enforce- P, E, C
ment of New Source Performance
Standards: Fossil-Fuel-Fired Steam
Generators. Prepared by PEDCo
Environmental Specialists for the
U.S. Environmental Protection Agency,
Washington, D.C. Publication No.
EPA 340/1-75-002. January 1975.
140 p.
*P = Process description
E = Emission rates
C = Control devices
3-14
-------
3.1.2. Coal-Fired Industrial: Boilers
Process Description - Coal-fired industrial boilers are
generally distinguished from large utility boilers by their
size, coal-firing method, and operating steam pressure.
Capacities of industrial boilers are lower, ranging from
1000 to 500,000 pounds per hour of steam. Pulverized-coal-
fired boilers are used for generating steam loads of 300,000
pounds per hour or higher. The smaller boilers are often
operated with wide variations in loads, and stoker-fired
furnaces are uniquely suited to this fluctuating demand.
Atmospheric Emissions - Sources of atmospheric emissions
from industrial boilers are identical to those from utility
boilers: the coal receiving and handling operations, the
furnace flue gases, and the ash disposal operations. Fly
ash in the flue gas represents the major particulate emis-
sion source. The quantity emitted depends upon the ash
content of the coal, the method of combustion, and the
control equipment. Uncontrolled pulverized-coal-fired
boilers burning coal with 10 percent ash generally emit
about 160 pounds of fly ash for each ton of coal burned.
Emissions from stoker-fired furnaces burning bituminous coal
containing 10 percent ash are about 130 pounds per ton of
coal, but these emissions vary widely.
Sulfur dioxide emissions from industrial boilers are
also of concern. The quantity emitted depends upon the
sulfur content of the coal.
Control Systems - Electrostatic precipitators have been used
almost exclusively for high-efficiency particulate emission
control. Their use on industrial size boilers has not been
widespread, however; most controlled installations are
equipped only with multiple cyclones. Electrostatic preci-
pitators can attain efficiencies of more than 99 percent.
3-15
-------
In precipitator design, particular attention should be given
to the coal composition and the expected operating precipita-
tor temperature, since both factors affect collection
efficiency.
Multiple dry high-efficiency cyclones are also used to
collect particulate emissions., Cyclones are also used as a
precleaner to reduce the dust loading on a secondary control
device, usually an electrostatic precipitator. High-effi-
ciency cyclones typically collect 65 to 75 percent of the
fly ash when applied to pulverized-coal-fired boilers.
Some facilities are installing wet scrubbers for fly
ash control because of the possibility of modifying the
control system at a later date for collection of sulfur
oxides.
Compliance Schedules - Figures 3-8 through 3-11 illustrate
expeditious schedules for installation of a multiple cy-
clone, a fabric filter, an electrostatic precipitator, and a
wet scrubber for fly ash control. The time required for
installation of additional units on the same site after
completion of the first unit can add 3 months to the sched-
ule. No schedule is shown for S0~ and NO control, since
2 x '
these systems are not widely used on industrial boilers at
this time.
3-16
-------
n
Milestones
•Activity and duration in weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment Is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G. WEEKS
28
45
47
Activity
designation
A-B
A-C
C-D
D-E
E-F
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Figure 3-8. Schedule for installation of a
control on industrial and utility-
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
dry multiple cyclone for particulate
•sized coal-fired boilers.
-------
CO
I
M
CO
Milestones
Activity and duration in weeks
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G. WEEKS
13
35
56
59
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-6 Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Figure 3-9. Schedule for installation
control on a coal-fired
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-H Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
of a fabric filter for particulate
industrial boiler.
-------
vo
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
Increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
23
49
84
89
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Figure 3-10. Schedule for installation of an electrostatic precipitator
for particulate control on a coal-fired industrial boiler.
-------
Milestones
• Activity and duration in weeks
U)
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G. WEEKS
17
41
62
66
Activity
designation Activity description
x
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-11. Schedule for installation of a wet scrubber for particulate
control on a coal-fired industrial boiler.
-------
Sources of Additional Information
Type of
Source information*
1. Oglesby, S. and G. B. Nichols. C
A Manual of Electrostatic
Precipitator Technology. Part
II - Application Areas. Prepared
by Southern Research Institute
for the National Air Pollution
Control Administration, Cincinnati,
Ohio. NTIS No. PB-196-381.
August 1970. 875 p.
2. Smith, W.S. and C.W. Gruber. P, E
Atmospheric Emissions from Coal
Combustion, An Inventory Guide.
U.S. Public Health Service.
Cincinnati, Ohio. Publication
No. AP-24. April 1966. 114 p.
3. Steam, Its Generation and Use. P
Babcock and Wilcox Co., New
York, 1963.
4. Background Information for Pro- E, C
posed New-Source Performance
Standards: Steam Generators,
Incinerators, Portland Cement
Plants, Nitric Acid Plant, and
Sulfuric Acid Plants. U.S.
Environmental Protection Agency,
Research Triangle Park, North
Carolina. NTIS No. PB 202-459.
August 1971. 50 p.
*P = Process description
E = Emission rates
C = Control devices
3-21
-------
3.2 WASTE DISPOSAL
3.2.1 Municipal Incinerators
Process Description - Capacities of municipal incinerators
range from approximately 50 to 1000 tons of refuse per day.
In the incineration process, as shown in Figure 3-12, refuse
is brought to the unloading/charging area. It is then fed
to the incinerator, either in batches or continuously, and
the combustible fraction of the refuse is burned. In multi-
ple-chamber units, air may be added in mixing or secondary
chambers to complete the combustion of the volatile materials
driven off in the primary refuse-burning chamber.
The ash residue from the furnace is periodically
removed, quenched, and disposed of, usually in a landfill.
Atmospheric Emissions - Sources of particulate emissions
include combustion gases from the furnace and fugitive dust
emissions from the handling and disposing of ash from
furnace and control device hoppers. Odors can also be a
problem if proper housekeeping procedures are not strictly
followed. Of these sources, the furnace combustion gases
represent the largest emission potential. The particulate
emission rate is highly variable, depending upon such fac-
tors as furnace design, operating conditions, and type
and characteristics of the refuse. Particulate emissions
from an uncontrolled incinerator typically range between 8
and 70 pounds per ton of refuse burned.
Control System - Many incinerators are designed with a
settling chamber and water spray or baffle as an integral
part of the incinerator system. Although these are con-
sidered air pollution control systems, their collection
efficiencies are generally very low on a weight basis. They
do not provide sufficient control to meet most emission
regulations.
3-22
-------
»
GASES AND
ENTRAINED
SOLIDS
ni *UTC I.ITTUrtllT
CONTROL AIR POLLUTION CONTROL -_..„
ODOR, DUST, i
LITTER f
TimoT (AUXILIARY FUEL) «" '
| LIV | AIR 1
TIPPING, WASTE! 1 ' ""
MLTn Ufl-Tr >» STORAGE, AND | , DRYING AND 1 r .......... .„„ a rnc
uOLIDWA^TC » CRAR6ING »| | * IGNITION 1 COMBUSTION *' GAS
ADCB S*T \ *
"" /
SHREDDER (OPTIONAL)
1 1
IND/OR WATER TR^
\ (WATER) 1 MSES
-V.TH- FLUEGASEi ATPPONMTinN
l'UUL1|1'u CONTROL DEVICE
FLY ASH FLY ASH
, (WATER) , (WATER)
1 WATER—, RESIDUE
NO w II
00 T
RESIDUE
QUENCHING
''
RESIDUE (WA*
1 !
LAND SB
DISPOSAL
(FLY ASH
& WATER)
WATER WATER
TREATMENT
PER)
[Mi
«IER EFFLUENT SLUDGE FLY ASH
WATER (FLY ASH)
Figure 3-12. Municipal incineration process.
-------
Wet scrubbers are the most common high-efficiency air
pollution control devices installed on municipal incinera-
tors. Scrubber systems normally operate with pressure drops
ranging from 15 to 50 inches of water. Electrostatic
precipitators are also being installed to control emissions.
A venturi scrubber should achieve 80 to 95 percent particu-
late removal, and an ESP should control particulates by 90
to 95 percent.
A very limited number of fabric filters have been
/
applied to municipal incinerators. Although they can
achieve particulate collection efficiencies greater than 98
percent, operational problems are caused by the high tempera-
ture and the moisture content of the exhaust gases.
Compliance Schedules - Figures 3-13 and 3-14, respectively,
illustrate expeditious schedules for installation of a wet
scrubber and an electrostatic precipitator for control of
incinerator combustion gases. The schedule for the wet
scrubber system shows a total time of 57 weeks and includes
the time required for installation of associated equipment
for wastewater treatment. Installation of an ESP on a
municipal incinerator requires approximately 111 weeks.
Control device fabrication, requiring 48 weeks, is the
longest time increment.
3-24
-------
Co
to
Ul
D
Milestones
•Activity and duration 1n weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
10
34
53
57
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-f Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
1nos
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-13. Schedule for installation of a wet scrubber for particulate
pollutant control on a municipal incinerator.
-------
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-s1te construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
20
46
105
111
to
Activity
designation
A-8
A-C
C-D
D-E
E-F
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Figure 3-14. Schedule for installation
for particulate control on a
Activity
designation Activity description
K-L Review and approve assembly draw-
1nps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
H-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
of an electrostatic precipitator
municipal incinerator.
-------
Sources of Additional Information
Type of
Source information*
1. Systems Study of Air Pollution from P, E, C
Municipal Incinerators. Volume I,
II and III. Prepared by Arthur D.
Little, Inc., for the U.S. Environ-
mental Protection Agency, Washington,
D.C. Publication No. APTD-1283,
1284, 1285. March 1970. 920 p.
2. Oglesby, S. and G.B. Nichols. C
A Manual of Electrostatic Precipi-
tator Technology- Part II-Appli-
cation Areas. Prepared by Southern
Research Institute for the National
Air Pollution Control Administration,
Cincinnati, Ohio. NTIS No. PB
196-381. August 1970. 875 p.
3. Stear, J.R. Municipal Incineration: P, E, C
A Review of Literature. Environmental
Protection Agency, Research Triangle
Park, North Carolina. Publication
No. AP-79. June 1971. 94 p.
4. Air Pollution Aspects of Emission E, C
Sources: Municipal Incineration.
Environmental Protection Agency,
Research Triangle Park, North
Carolina. Publication No. AP-92.
May 1971. 101 p.
5. Refuse Incineration. In: Compila- P
tion of Air Pollutant Emission
Factors, 2nd edition. U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina.
Publication No. AP-42. February
1976. p. 2.1-4.
3-27
-------
6. Axetell, K. et al. Inspection Manual P, E, C
for the Enforcement of New Source
Performance Standards: Municipal
Incinerators. Prepared by PEDCo
Environmental Specialists for the
U.S. Environmental Protection Agency,
Washington, D.C. Publication No.
EPA 340/1-75-003. February 1975.
98 p.
*P = Process description
E = Emission rates
C = Control devices
3-28
-------
3.2.2 Sludge Incinerators
Process Description - Sludge incinerators reduce by about 90
percent the volume of sludge generated by municipal waste-
water treatment plants by burning the combustible content.
Incineration destroys the organic matter in the sludge and
leaves only an odorless, sterile ash suitable for landfill.
Figure 3-15 is a generalized schematic of a sludge
treatment system.
NATURAL STACK
GAS GASES
DIRTY
WATER
THICKENING
OR
SETTLING
TANK
(OPTIONAL)
DIGESTING
TANK
(OPTIONAL)
DEWATERING
DEVICE
SLUDGE
CAKE
AIR POLLUTION
CONTROL
DEVICE
INCINERATOR
ASH RESIDUE
J
CLEAN
WATER
FLOCCULENT
AIDS
Figure 3-15. Sludge treatment system.
3-29
-------
The most prevalent types of sludge incinerators are
multiple hearth and fluidized bed units. Capacities gen-
erally range up to 8000 pounds per hour of dry sludge. In
multiple hearth units, the sludge enters the top of the
furnace and is dried by the hot rising combustion gases.
Then the sludge burns as it moves down through the lower
hearths. Temperatures range from 600°F on the lower ash
cooling hearth to 2000°F on the combustion hearths. In
fluidized bed reactors, combustion takes place in a hot
suspended bed of sand. Temperatures generally range from
1250 to 1500°F. An auxiliary fuel may be required in both
types of furnace during start-up or when the moisture con-
tent of the sludge is too high to support combustion.
Atmospheric Emissions - Odors and particulate are the major
emissions from a sludge incineration facility. Most of the
odors emanate from pretreatment stages from the accumulation
of grit, screenings, and skimmings and from raw sludge
thickening, storage in tanks, and vacuum filtration of raw
sludge. From a multiple hearth incinerator,- odors are given
off as a result of the evaporation of volatiles. Odors are
not generally a problem in fluidized bed incinerators since
temperatures are usually high enough for complete combustion
of the volatile compounds.
Particulates are generated because of the upward
movement of combustion gases with respect to the burning
sludge. Uncontrolled particulate emissions from sludge
incinerators are estimated to be about 194 pounds per ton of
dry sludge. Particulate emissions into the atmosphere are
almost entirely a function of control device efficiency.
Emissions will increase if design temperatures are not
maintained or if excess sludge is charged. Mercury and
other more volatile metals may also be emitted if they are
present in the sludge.
3-30
-------
Other products of•combustion (i.e. carbon monoxide,
carbon dioxide, sulfur oxides, and nitrogen oxides) are not
emitted in sufficient quantities to warrent concern.
Control Systems - Sludge incinerators are generally subject
to particulate and opacity standards. Although odors are
sometimes a problem, they are not typically regulated. A
well-operated sludge incinerator will yield little odor if
proper housekeeping procedures are practiced.
Water scrubbing'is the most effective method for
cleaning exhaust gases from sludge incinerators. Venturi,
baffle plate, impingement, orifice, and cyclone type scrub-
bers are potentially effective for controlling particulate
emissions. Venturi scrubbers with pressure drops of 20 to
30 inches water gauge and impingement towers have been used
successfully to control particulate emissions. Normally a
particulate removal efficiency of at least 97 percent is
required to meet applicable regulations.
Compliance Schedules - Figure 3-13 illustrates an expedi-
tious schedule for installation of a venturi scrubber.
Water treatment facilities should already be available at
the sludge incinerator site. If a water treatment system is
needed, the treatment facility and scrubber can be installed
concurrently within the same time interval. The total time
requirement is estimated to be 57 weeks, including a 20-week
increment for control device fabrication.
3-31
-------
Sources of Additional Information
Type of
Source information*
1. Devitt, T.W. and N.J. Kulujian. P, E, C
Inspection Manual for the Enforce-
ment of New Source Performance
Standards: Sewage Sludge Incinera-
tors. Prepared by PEDCo-Environmental
Specialists, Inc. for the U.S.
Environmental Protection Agency,
Washington, D.C. Publication No.
EPA 340/1-75-004. February 1975.
pp. 3-1 to 3-5.
2. Hecht, N.L. et al. Characteriza- P
tion and Utilization of Municipal
and Utility Sludges and Ashes.
Volume II - Municipal Sludges.
Prepared by University of Dayton
Research Center for U.S. Environmental
Protection Agency, Research Triangle
Park, North Carolina. Publication
No. EPA 670/2-75-033b. May 1975.
pp. 164-177.
3. Compilation of Air Pollutant E
Emission Factors, 2nd edition.
U.S. Environmental Protection
Agency, Research Triangle Park,
North Carolina. Publication No.
AP-42. February 1976.
*P = Process description
E = Emission rates
C = Control devices
3-32
-------
3.2.3 Liquid Waste Incinerators
Process Description - Liquid waste incinerators burn liquids
such as paint sludges, off-quality paints and inks, waste
lubricating and cutting oils, partially polymerized plastic
resins, cleanup solvents, pickling liquors, plating wastes,
and degreaser bottoms. Generally, these liquids are de-
stroyed on a load-by-load basis and are not blended to
produce a feed having constant heating value and solids
content. Figure 3-16 is a schematic of a typical liquid
waste incineration process.
After the liquid wastes are screened or filtered to
remove large solids, the liquids are injected with com-
bustion air into a refractory-lined combustion chamber.
Combustion of some low-Btu wastes may require supplementary
fuel. Complete combustion of organic materials requires
temperatures above 1600°F and retention times greater than
0.5 second.
Solids removed by filtration and ash removed from the
incinerator are disposed of by landfill.
Atmospheric Emissions - Emissions from liquid waste in-
cinerators depend on the type of liquid waste being burned
and the completeness of combustion. Particulate emissions
have been estimated to range from 0.075 to 0.37 pound per
1 2
gallon burned. Because the sulfur content of most liquid
wastes is low, emissions of S02 are not a problem. Hydro-
carbon emissions can be significant if the incinerator
temperature is below 1600°F or retention times are less than
2
0.5 second. Hydrogen chloride emissions can be generated
by burning of materials such as chlorinated solvents and
pickling liquors.
3-33
-------
STACK GASES
J
AIR POLLUTION
CONTROL
DEVICE
LIQUID
WASTE ""
U)
1
OJ
SCREEN
FILTERS
STORAGE
TANKS
i
\
i
i
I
MIXING
TANKS
(OPTIONAL)
INCINERATOR
FUEL
Figure 3-16. Liquid incineration process.
-------
Control Systems - Wet scrubbing is the most effective
method for controlling partioulate emissions from a liquid
waste incinerator. If a venturi is used, pressure drops of
over 40 inches water gauge may be required to meet appli-
cable particulate regulations.
Hydrocarbon emissions can be reduced by increasing the
efficiency of combustion through* use of lower feed rates and
higher operating temperatures. If hydrogen chloride emis-
sions are a problem, the incineration facility may be
required to stop burning the liqu.ids containing excess
chlorides.
Compliance Schedules - Figure 3-13 shows an expeditious
schedule for installation of a wet scrubber on any type of
incinerator. Concurrent installation of associated equip-
ment for wastewater treatment would :,not significantly
change this schedule. An estimated 54 weeks is required for
compliance, including 20 weeks for control device fabrica-
tion.
Sources of Additional Information
Type of
Source information *
1. Ponder, T.C. Particulate Emission P, E, C
Control - Robert Ross & Sons, Inc. ,
Grafton, Ohio. Prepared by PEDCo-
Environmental Specialists, Inc. for
Ohio Environmental Protection
Agency. June 1974. 19 p.
2. Hall, F.D. and T.C. Ponder. P, E, C
Report on Emission Controls at the
Liquid Disposal Company, ISIorwalk,
Ohio. Prepared by PEDCo-Environmental
Specialists, Inc. for Ohio Environ-
mental Protection Agency. July
1974. 18 p.
*p = Process description
E = Emission rates
C = Control devices
3-35
-------
3.2.4 Waste Disposal in Existing Boilers
Process Description - Many companies in the United States
are considering combustion of relfuse along with other fuel
in existing boilers. In Europe, where several boilers are
designed to accommodate refuse, this technique has been used
successfully since 1965.
For burning in an existing boiler, the refuse must
first be separated and classified. A typical processing
plant is shown in Figure 3-17 . After separation, the
shredded combustible materials are sent to the boiler, the
ferrous metals are hauled to a steel mill, and the nonmag-
netic metals, glass, and other waste are further separated
or sent to a landfill. Fig/ure 3-18 shows a schematic of
refuse being fed to a boiler. The refuse can supply 10 to
15 percent or more of the total fuel burned in industrial or
utility boilers. The heat content of dry refuse ranges from
6000 to 8000 Btu per pound.
Atmospheric Emissions - Tests performed at a demonstration
plant of Union Electric .in St. Louis indicated no signifi-
cant changes in gaseous or particulate concentration levels
when refuse and coal vjere fired together in the utility
boiler. However, the resistivity and the chloride content
of the particulate had increased slightly.
Control Systems - Currently marketed control systems will
generally be adequate for boilers burning a combination of
refuse and coal. Scrxabbers, ESP's or baghouses are all
applicable. However, modifications to existing boiler
control equipment may be necessary because of the increased
resistivity and the change of chemical properties of the
flyash.
Compliance Schedules - If controls are needed, the installa-
tion times will be -the same as those determined for utility
and industrial boilers, discussed in Section 3.1.
3-36
-------
COMBUSTIBLES
REFUSE
HAMMERMILL
CYCLONE
SEPARATOR
FERROUS METALS
TO STEEL MILL
STORAGE
COMBUSTIBLES
TO BOILER
MAGNETIC
SEPARATOR
NONMAGNETIC METALS,
•GLASS. AND WASTE TO
FURTHER SEPARATION OR LANDFILL
Figure 3-17. Refuse processing plant.
UNLOADING OPERATION
Receiving Bin
Trailer Truck t
Blower
FIRING SYSTEM
Blower Ulr Feeder
Tangentially-fired Boiler
Figure 3-18. Union Electric Co. facilities for
receiving, storing, and burning refuse.
3-37
-------
Sources of Additional Information
Type of
Source information*
1. Lowe, R.A. Energy Recovery from P
Waste. U.S. Environmental Pro-
tection Agency. Publication No.
SW-36. 1973.
2. Shannon, L.J. et al. St. Louis/ P, E, C
Union Electric Refuse Firing
Demonstration, Air Pollution Test
Report. Prepared by Midwest
Research Institute for the U.S.
Environmental Protection Agency,
Washington, D.C. Publication No.
EPA 650/2-74-073. August 1974.
108 p.
*P = Process description
E = Emission rates
C = Control device
3-38
-------
3.2.5 Sanitary Landfill
Process Description - Sanitary landfilling is a method of
disposing of solid wastes on land by spreading them in thin
layers, compacting them to the smallest practical volume,
and covering them with soil each working day in a manner
that protects the environment. No wastes are burned at a
sanitary landfill. Wastes are brought to landfill sites in
trucks and dumped in designated areas. Thes
-------
Control Systems - Good landfill design and proper operation
are the best methods for control of emissions from landfills.
Generally, accumulation of decomposition gases present no
problems if the cover material is more permeable than the
surrounding soil, allowing dispersal of the gases over a
large area. If the cover soil is relatively impermeable,
gases can be vented to a safe area by use of gravel or pipe
vents. Fugitive dust can be minimized by wetting of roadways
and cover soils. Planting of trees and shrubs along the
landfill boundaries will help contain dust and litter
within the site. Litter can also be controlled by cleaning
the site frequently and by erecting fences to retain the
blowing paper.
Compliance Schedules - A properly designed and operated
landfill should be in compliance with applicable regulations
from the beginning of operation until landfilling is com-
pleted. Any problems can be resolved within 2 weeks of
notification by improving site cleanup and maintenance
practices.
3-40
-------
Sources of Additional Information
Type of
Source information*
1. Brunner, D.R. «md D.J. Keller. P, E, C
Sanitary Landfill Design and
Operation. U.S. Environmental
Protection Agemcy. Publication
No. SW-65ts. 1972. 59 p.
2. Residual Wast;e Best Management P
Practices: A Water Planner's
Guide to Land Disposal. Prepared
by PEDCo-Environmental Specialists/
Inc. for the Water Planning Divi-
sion, U.S. Environmental Protection
Agency, Washington, D.C. Publication
No. EPA 440/9-76-022. August 1976.
238 p.
*P = Process description
E = Emission rates
C = Control dlevices
3-41
-------
•3.3 EVAPORATION SOURCES
3.3.1 Surface Coating
Process Description - Surface coating operations consist of
applying a coat of paint or varnish to an object, evapo-
rating the solvent by application of heat'., and finally
hardening the coated surface by subjecting it to high
temperatures. Coating operations range from small, manually
operated units to large facilities for spr.aying and dipping
auto bodies. This classification also includes coating and
decorating of cans.
Large-scale solvent evaporation and baking operations
are conducted inside an oven, where heat is s-upplied by
banks of infrared lamps or by direct or indirect combustion
of natural gas or fuel oil. During the surface coating and
drying operation, most of the volatile constituents of the
coated material evaporate and are released to "the atmosphere
if air pollution controls are not applied.
Simplified schematics of surface coating operations,
with direct-fired afterburner and adsorption systems to con-
trol hydrocarbon emissions, are shown in Figures; 3-19 and
3-20. Freshly coated pieces enter the oven, in which the
pressure is maintained slightly below atmospheric to prevent
leakage of solvent vapors into the room and to draw in
enough room air to prevent the formation of explosive mix-
tures. Most of the volatile components of the coating are
released shortly after the object enters the oven. This
mixture of hydrocarbons and air is withdrawn from the oven
by means of a blower.
Atmospheric Emissions - Hydrocarbons generated in the
coating and drying processes are the primary emissions of
concern. The paint spraying operations generate some par-
ticulate emissions, but these are generally controlled near
3-42
-------
FLUE
GAS
U)
COATED
WORK
IN
-EVAPORATION
RECIRCUUTED AIR
-BAKING-
OVEN
VVVVVVVVVWVVVVVVVW
HEAT
EXCHANGER
WORK
OUT
\
AFTER-
BURNER
AMBIENT
AIR
NATURAL
GAS
Figure 3-19. Surface coating operation with afterburner control system.
-------
OJ
I
WORK
IN
VENT
GAS
ADSORBENT
VESSEL
V V
OVEN ,
vvvvvvv wvvv
ADSORBENT
VESSEL
WORK!
OUT i
FUEL OR HEATED AIR
STEAM
DECANTER
-^
v___,
^^
r-^
-------
the point of application by fiberglass filters and/or a
water curtain built into the exhaust system.
The type and quantity of hydrocarbon emissions vary
directly with the type and quantity of solvent in the
coating. The solvent content often amounts to about 50
percent of the total weight of the coating material.
Overall process emissions can be estimated by material
balance calculations, since all of the solvent must evapo-
rate in some phase of the process. In direct-fired ovens,
however, some solvent vapor is burned.
Control Systems - Hydrocarbon emissions can be minimized by
using control equipment or by reducing the solvent content
of the coating. Process changes that reduce emissions
include the use of "exempt" solvents and water-base coatings,
and the setting or drying of coatings by application of
other types of energy (e.g. infrared, ultraviolet) instead
of heat, supplied by direct firing. Where process changes are
unfeasible, emissions can be reduced by use of control
equipment such as direct-fired afterburners, catalytic
afterburners, and adsorption systems. Selection of an air
pollution control system depends on several factors, in-
cluding the value of the recovered solvent and the avail-
ability and cost of fuel oil or natural gas for incinera-
tion. Generally, in small operations where the flow rate of
vented gas is less than 5000 scfm emissions are controlled
with direct-fired afterburners without heat recovery. In
large operations, some of which generate emissions in the
tens of thousands of scfm control is achieved by direct-
flame incineration with heat recovery, or catalytic burners.
When the solvent is worth recovering, an adsorption system
may be incorporated into the process.
3-45
-------
Compliance Schedule - Figures 3-21 and 3-22 illustrate ex-
peditious schedules for installation of a field-erected
adsorbtion system and a skid-mounted "package" adsorption
system, respectively, on a surface coating operation.
Selection of a system depends upon such factors as nature of
the recovered solvent and volume of vented gas. Figure
3-23 represents an expeditious schedule for installation of
an afterburner on a surface coating operation.
A compliance schedule for switching to an exempt sol-
vent is highly variable. Testing to determine alternative
solvents compatible with the process could take several
weeks. After an acceptable alternative solvent has been
determined and a supplier has been found, the changeover can
be made within a week of receiving the new solvent. Shortages
of many exempt solvents could delay the changeover for
several weeks.
3-46
-------
Milestones
-Activity and duration In weeks
U)
i
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s1te construction or installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date fay which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
12
36
82
87
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
i nps
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-21. Schedule for installation of field-erected adsorption
system, including distillation unit, for hydrocarbon
control on a surface coating operation.
-------
u>
I
*>
00
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
12
38
68
73
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evalua'te control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R.-4 Complete construction and system
t1e-in
4-5
Perform startup, shakedown, and
emission testing
Figure 3-22. Schedule for installation of a packaged adsorption system, including
field-erected distillation unit, for^hydrocarbon control on a surface coating operation.
-------
U)
I
II Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
Increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
10
27
43
45
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-1
1-H
H-J
J-2
2-K
Figure 3-23.
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
Ings
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
Schedule for installation of an
ner for hydrocarbon
control on a surface coating operation.
-------
Sources of Additional Information
Type of
Source information*
1. Surface Coating Operations. In: P, E, C
Air Pollution Engineering Manual,
2nd ed., Danielson, J.A. (ed.).
U.S. Environmental Protection
Agency, Research Triangle Park,
North Carolina. Publication No.
AP-40. May 1973. pp 855-871.
2. Rolke, R.W. et al. Afterburner C
Systems Study. Prepared by Shell
Development Company for the U.S.
Environmental Protection Agency,
Research Triangle Park, North
Carolina. NTIS No. PB 212 560.
August 1972. 512 p.
3. Gadomski, R.R. et al. Evaluations P, E, C
of Emissions and Control Technolo-
gies in the Graphic Arts Industries.
Prepared by Graphic Arts Technical
Foundation for the U.S. Public
Health Service, Cincinnati, Ohio
NTIS No. PB 195-770.
*P = Process description
E = Emission rates
C = Control devices
3-50
-------
3.3.2 Petroleum Storage
Process Description - Storage vessels can be classified as
either closed-storage or open-storage tanks. Pressure
vessels used for storage of volatile hydrocarbons are most
commonly cylinders, spheres, or spheroids. Fixed-roof tanks
or lifted-roof conservation tanks are used for storage of
low-volatility liquids. 'Floating-roof tanks and diaphragm
conservation tanks minimize the vapor space and are normally
used for storage of-volatile fractions or of hydrocarbons
that present potential hazards for fire or explosion.
Open-storage vessels, found in a variety of shapes, are
now used infrequently because of safety and product conser-
vation considerations.
Atmospheric Emissions - Hydrocarbon vapors are emitted as a
result of volatilization of the stored material. Since
cylindrical flat-roof tanks operate at only a very slight
positive pressure, the diurnal atmospheric temperature
changes cause expansion and contraction of the tank vapor
space, and hence emissions or "breathing." Emissions are
particularly significant in fixed-roof tanks, since filling
also causes breathing.
Control Systems - Effective control methods include the use
of floating roofs, use of devices such as plastic blankets
and spheres to reduce the exposed surface area or the tank
volume, and use of vapor recovery systems. Installation of
an internal floating roof is the most commonly used control
technique for existing tankage.
Compliance Schedules - Figure 3-24 represents an expeditious
schedule for installation of a floating-roof with a double
deck on an existing storage tank.
3-51
-------
14
U)
I
ui
NJ
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (HEEKS)
4
10
24
29
31
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction Including process tie-Ins.
4-5 Perform equipment startup and source testing
Note: For tanks 150 to ^00 ft. in diameter, add 10 weeks to Steps 3-4.
Figure 3-24. Schedule for installation of an internal floater for hydrocarbon
control on an existing storage tank of diameter less than 150 ft.
-------
Sources of Additional Information
Type of
Source information*
1. Danielson, J.A., ed. Air Pollution P, E, C
Engineering Manual. U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina.
Publication No. AP-40. May 1973.
987 p.
2. Nelson, W.L. Petroleum Refinery P, C
Engineering. McGraw-Hill, New
York. 1958. 960 p.
3. Atmospheric Emissions from Petroleum E
Refineries. A Guide for Measurement
and Control. U.S. Public Health
Service, Cincinnati, Ohio. NTIS No.
PB 198-096. 1960. 64 p.
*P = Process description
E = Emission rates
C = Control devices
3-53
-------
3.4 CHEMICAL PROCESSES
3.4.1 Nitric Acid
Process Description - All nitric acid produced commercially
is manufactured by the ammonia oxidation process. Despite
many variations in operating details, three basic steps are
common to all plants producing nitric acid: (1) oxidation
of ammonia to nitric oxide, followed by (2) oxidation of
nitric oxide to the dioxide, and finally (3) absorption of
nitrogen dioxide in water to produce nitric acid with the
release of additional nitric oxide.
A schematic flow diagram for production of nitric acid
by the ammonia oxidation pressure process is shown in Figure
3-25. In this process ammonia vapors are mixed with pre-
heated compressed air and passed over a platinum catalyst to
form nitrogen oxide and water. The heat content of the gas,
primarily due to the exothermic reaction, is recovered by
preheating the absorber tail gases and the process air, and
finally by passing the gas through a waste heat boiler to
generate steam. The gases are then filtered to recover the
valuable platinum catalyst dust and are further cooled in a
water cooler. The successive oxidations and hydrations of
the nitric oxide are conducted with continuous water cooling
in a stainless steel absorption tower.
The tail gas leaving the absorption tower normally
contains 0.2 to 0.3 percent nitrogen oxides by volume. In
an uncontrolled plant these gases are vented after passing
through an expander turbine for energy recovery.
Atmospheric Emissions - Emissions of nitrogen oxides from
nitric acid plants are estimated to be about 43 pounds per
ton of acid produced. This value corresponds to about 3000
ppm NO (by volume) in the exit gas stream. Nitrogen
X
dioxide, distinguished by its opaque reddish-brown color,
3-54
-------
COMPRCSWH
PROUIlCr 55*1* .
UNO,
Figure 3-25. Nitric acid manufacture
by the pressure process, with catalytic
tail gas control system.
3-55
-------
makes up approximately 50-percent of this emission. The
remainder of the gas is the colorless nitric oxide compound.
Control. Systems - Techniques for nitrogen oxides control
include catalytic reduction and use of molecular sieve
adsorption systems and caustic scrubbers. Catalytic reduc-
tion can reduce emissions by 36 to 99 percent (80 percent
average) depending on design1, fuel input, and operating
temperatures. The molecular sieve system provides effi-
ciency of over 99 percent, but has only recently been
applied to full-size systems. Caustic scrubbers are used
only under special circumstances (e.g. where a market is
available for recovered by-products).
Compliance Schedules - Figures 3-26 and 3-27 illustrate
expeditious schedules for installation of a catalytic
reduction unit with heat recovery and a molecular sieve
adsorption system. At present, molecular sieve systems are
being installed on two nitric acid plants. Because no
nitric acid plant is operating with molecular sieves, the
schedule is tentative.
3-56
-------
00
Ul
D
Milestones
•Activity and duration 1n weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submfttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
12
32
56
60
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
Inps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Figure 3-26. Schedule for installation of a catalytic reduction unit with
waste heat recovery for nitrogen oxide control on a nitric acid plant.
-------
20
48
CO
I
U1
00
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
4
29
77
85
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process tie-ins.
4-5 Perform equipment startup and source testing
Figure 3-27. Tentative schedule for installation of a molecular sieve
adsorption system for nitrogen oxide control on a nitric acid plant.
-------
Sources of Additional Information
Type of
Source information*
1. Kirk-Othmer Encyclopedia of Chemical P
Technology, 2nd ed. Volume 13.
Interscience Publishers, New York,
1967. p. 796-814.
2. Atmospheric Emissions from Nitric Acid P, E, C
Manufacturing Processes. National
Center for Air Pollution Control,
Cincinnati, Ohio. Publication No.
AP-27. 1966. 96 p.
3. Background Information for Proposed E, C
New-Source Performance Standards:
Steam Generators, Incinerators,
Portland Cement Plants, Nitric Acid
Plants, and Sulfuric Acid Plants.
U.S. Environmental Protection Agency,
Research Triangle Park, North
Carolina. NTIS No. PB 202-459.
August 1971. 50 p.
4. Air Pollution Aspects of Emission E, C
Sources: Nitric Acid Manufacturing.
U.S. Environmental Protection Agency,
Research Triangle Park, North
Carolina. Publication No. AP-93.
May 1971. 37 p.
*P = Process description
E = Emission rates
C = Control devices
3-59
-------
3.4.2 Phosphoric Acid
Process Description - Phosphoric acid is produced by two
basic methods, the wet process and the thermal process. In
the wet process, phosphate rock is treated with sulfuric
acid. The ensuing chemical reactions result in the forma-
tion of phosphoric acid and the precipitation of calcium
sulfate. The latter is filtered off, and the acid is
concentrated from about 32 percent P2°s to a^out 54 percent
P2°5" A simplified flow diagram is shown in Figure 3-28.
OVPtUM
MHD »AT««
I ay I a?..™ aa,. isiy] "•"» I ">SH I' •"* I uou°; I
"J«0.
10 V«CWM •
**AND HOT VILL
UNGLE'TANK I I *
• tACTOtl HOT
I »tLI
*-o
•TO 1CHU1HK
HirOKOfLUOKLICIC ACIO
Figure 3-28. Manufacture of phosphoric acid by
wet process.
3-60
-------
In the thermal process/ phosphoric acid is produced
from elemental phosphorous. Three basic steps are involved:
(1) burning the molten phosphorus in a suitable chamber to
produce phosphorus pentoxide; (2) hydrating the phosphoric
acid mist; (3) removal of the phosphoric acid mist from the
gas stream. A simplified flow diagram of the major steps in
the manufacture of phosphoric acid by the thermal process is
shown in Figure 3-29.
STACK
EFftuENT
(AIR » HjP04 HIST)
BLOWER
ACID TREATING PLANT
STACK EFFLUENT
(AIR * HS)
HYDROGEN SULFIOE,
SODIUM MYOROSULFIDE.
OR SODIUM SULFIOE
IURNIM AND HtTORATION SECTION
I ACID TO
STORAGE
BLOWER PUMP
ACID TREATING SECTION
(USED IN THE MANUFACTURE OF ACID
FOR FOOD AND SPECIAL USES)
Figure 3-29. Manufacture of phosphoric acid by
thermal process.
Atmospheric Emissions - Emissions of most concern in the wet
process are the fluoride compounds liberated from the rock
by the sulfuric acid. These consist of hydrogen fluoride,
silicon tetrafluoride and various products of reaction and
decomposition of the latter. Most phosphate rock contains
3.5 to 4 percent fluorine, and half of this may be volatil-
ized in the processing. Fluorides may be emitted from
3-61
-------
exposed surfaces of reaction slurry, from aqueous solutions
of fluoride compounds, and from, evaporation processes.
The major atmospheric contaminant from the thermal
'process is phosphoric acid mist discharged in the absorber
exit gas. This gas stream also contains water vapor and
trace amounts of nitrogen oxides. Another important emis-
sion is the discharge gas from the acid-treating tank.
These emissions are intermittent and range from 10 to 2500
parts per million of hydrogen sulfide.
Control Systems - Because the principal atmospheric con-
taminants generated in the wet process are gaseous fluorides,
scrubbing is universally employed to control emissions.
Devices for control include venturi scrubbers, impingement
scrubbers, and various kinds of spray towers. These con-
trols are applicable to the five NSPS categories of wet
process phosphoric acid plants, superphosphoric acid plants,
diammonium phosphate plants, triple superphosphate plants,
and granular triple superphosphate storage facilities. (The
recommended method of control is with a spray cross flow
packed scrubber).
For the thermal process, primary control devices for
control of emissions of acid mist include high-pressure
wire-mesh eliminators and high-efficiency glass-fiber mist
eliminators.
Compliance Schedules - Figure 3-30 illustrates an expeditious
schedule for installing a wet scrubber system on a wet
process or thermal process plant. An expeditious schedule
for installation of a high-efficiency mist eliminator is
shown in Figure 3-31.
3-62
-------
U)
i
cr>
D
Milestones
•Activity and duration 1n weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
Increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
19
40
59
61
Figure 3-30.
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-6
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device 'contract
Prepare assembly drawings
0. Schedule for installation
Activity
designation
K-L
l-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
of a wet
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
a wet scrubber system for gaseous
and particulate fluoride control on a phosphoric acid plant.
-------
12
I
CT>
MILESTONES
1
2
3
4
5
Date of subtnittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which bn-s1te construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance 1s achieved.
ELAPSED TIME (WEEKS)
4
10
22
30
32
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications.
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process t1e-1ns.
4-5 Perform equipment startup and source testing
Figure 3-31. Schedule for installation of a high-pressure mist eliminator
unit for acid mist control on a phosphoric acid plant.
-------
Sources of Addition. Information
Type of
Source information*
1. Atmospheric Emissions from P/ E, C
Wet-Process Phosphoric Acid
Manufacture. Prepared by
Manufacturing Chemists' Associa-
tion, Inc. and Public Health
Service for National Air Pollution
Control Administration, Raleigh,
North Carolina. Publication
No. AP-57. April 1970. 98 p.
2. Atmospheric Emissions from P, E, C
Thermal-Process Phosphoric Acid
Manufacture. Prepared by
Manufacturing Chemists' Associa-
tion, Inc. and Public Health
Service for National Air Pollution
Control Administration, Raleigh,
North Carolina. Publication No.
AP-48. October 1968. 72 p.
*P = Process description
E = Emission rates
C = Control devices
3-65
-------
3.4.3 Sulfuric Acid
Process Description - Essentially all sulfuric acid is
produced by the contact p'rocess shown schematically in
Figure 3-32 for a single absorption type sulfur burning
plant. Sulfur or sulfur-containing raw materials (e.g.
spent acid) are burned to form S02, which is then catalyt-
ically oxidized in a converter to SO.,. The heat liberated
in the converter reaction is removed in several stages by
intermediate gas cooling. The exit gas from the converter
is cooled, and the SO- is absorbed in a circulating stream
of 98 percent H2S04.
Variations in the contact process are due primarily to
differences in the sulfur feedstock. Units operating with
spent acid, sludge, H2S or smelter tail gas are more com-
plicated than sulfur-burning plants since these feed streams
are contaminated. After burning the feed stock in these
"wet gas" plants, or when testing smelter gases, the re-
sulting SO2 gas or S02 rich gas stream requires additional
cleaning and cooling to remove particulate, acid mist, and
excessive water vapor.
Atmosheric Emissions - SO2 emissions vary inversely with the
SOp-to-SO, conversion efficiency. For older sulfur-burning
plants with three-stage converters, conversion efficiencies
are typically 95 to 96 percent, which correspond to emis-
sions of 55 to 70 pounds of S02 per ton of acid produced.
Conversion efficiencies of four-stage converters range from
96 to 98 percent, with S02 emissions between 26 and 55
pounds per ton. Dual absorption plants, discussed in this
section under Control Systems, can achieve conversion effi-
ciencies in excess of 99 percent; the resulting SO2 emis-
sions usually range between 1 and 4 pounds per ton of acid
on plants subject to new source performance standards. For
3-66
-------
tlltll *IUM
new COWN
•ItINC
IOWII
(lOVII
iieni*
•9
IHIIIM
titan
i . * °
Aii
tumid IOIXI 1OIUI COMVIItll
• em • "i* *»'••
1
HI
ICONOMIIK
•lie«»tlON
tew 11
JlVi >*•
»«>•>
r
toon •
>IO*VCI
Figure 3-32.•-Contact process single absorption sulfuric
acid plant burning elemental sulfur.
3-67
-------
acid plants testing smelter tail gas, variations in SO2
inlet concentrations make it difficult to reduce emissions
to less than -650 ppm.
Acid mist emissions are also significant, especially
for plants producing oleum or using sulfur feedstocks other
than elemental sulfur. If uncontrolled, emissions range
between 0.5 and 5 pounds per ton of acid produced at sulfur-
burning plants, and about 1 to 10 pounds per ton at spent
acid plants.
Control Systems - S02 emissions can be controlled by use of
a dual absorption process, sodium sulfite scrubbin.g, lime/
limestone solution scrubbing, ammonia solution scrubbing, or
molecular sieves. Dual absorption and ammonia scrubbing are
the more popular control methods. In the dual absorption
process, SO2 emissions are decreased by increasing the SO^-
to-S03 conversion efficiency. The SO_ formed iru the initial
converter stages is removed in a primary absorber, and the
remainder of the gas is returned to the convert.er. The
additional SO., formed is absorbed in a secondary absorber.
The dual absorption configuration can reduce SO- emissions
to a range of about 1 to 4 pounds per ton of cicid produced.
However, for acid plants treating smelter gas , the range may
be greater due to SO2 concentration variations.
Sodium sulfite or ammonia scrubbing of absorber off-gas
can reduce S02 emissions to between 1.5 and 4 pounds per ton
of acid. The recovered S02 is normally recycled to the acid
plant. Either process can reduce SO- emissions to approxi-
mately 100 ppm. Spent ammonia scrubbing Liquor is either
used to produce ammonium sulfate or therma.lly decomposed to
recycle SO2 to the acid plant. A multistctge scrubber and a
high-efficiency particulate collection device are normally
required to minimize ammonia losses and to prevent formation
of a visible plume caused by ammonium saJits..
3-68
-------
Molecular sieve separation is capable of reducing SO2
emissions to between 50 and 100 ppm. The recovered S02 is
recycled to the acid plant.
Acid mist emissions are usually controlled by use of
electrostatic precipitators or various designs of fiber type
mist eliminators. Tubular fiber type mist eliminators are
frequently used for plants producing oleum or using virgin
nonsulfur feedstocks because their collection efficiency is
slightly higher than the horizontal dual fiber pad type or
vertical fiber panel type mist eliminator. Properly selected,
a fiber type mist eliminator can operate with zero visible
emissions.
Compliance Schedules - Figure 3-33 illustrates an expedi-
tious schedule for modifying an existing plant to use the
dual absorption process. Figures 3-34 and 3-35 illustrate
expeditious schedules for installation of sodium sulfite and
ammonium solution scrubbing processes, respectively; the
schedule for the ammonium solution scrubbing process incor-
porates the time required for simultaneous installation of a
high-efficiency particulate control device. An approximate
time schedule for installation of a molecular sieve separa-
tion process is shown in Figure 3-36.
Figure 3-37 illustrates an expeditious schedule for
installation of a mist eliminator for controlling acid mist
emissions.
3-69
-------
40
OJ
I
MILESTONES
1
2
3
4
5
Date of submUtal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME (HEEJCSl
4
16
30
70
74
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications.
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process t1e-1ns.
4-5 Perform equipment startup and source testing
Figure 3-33. Schedule for modifying a sulfuric acid plant to the
dual absorption process.
-------
13
21
29
U)
l
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance 1s achieved.
ELAPSED TIME (WEEKS)
13
34
65
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications.
.construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process tie-ins.
4-5 Perform equipment startup and source testing
Figure 3-34. Schedule for installation of sodium sulfite scrubbing
system on a sulfuric acid plant.
-------
12
26
J2
u>
I
^j
NJ
MILESTONES
1
2
3
4
5
ELAPSED TIME (WEEKS)
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
12
38
50
54
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction Including process tie-ins.
4-5 Perform equipment startup and source testing
Figure 3-35. Schedule for installation of an ammonia scrubbing system,
including mist eliminator, for sulfur oxides control on a sulfuric acid plant.
-------
20
48
CO
I
-j
u>
MILESTONES
1
-7
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date Of Initiation of on-sKe construction or Installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed. "~: •—-
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
4
29
77
85
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process tie-ins.
4-5 Perform equipment startup and source testing
Figure 3-36. * Tentative schedule for installation of a molecular
sieve separation process for sulfur oxides control on a sulfuric acid plant.
-------
12
MILESTONES
1
2
3
Date of submlttal of final control plan to appropriate agency.
Date of award of control Device contract.
Date of iniH.Stion of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME (WEEKS)
4
10
22
30
32
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process t1e-1ns.
4-5 Perform equipment startup and source testing
* 52 weeks 1f booster blower required.
Figure 3-37. Schedule for installation of a mist eliminator for
acid mist control on a sulfuric acid plant.
-------
Sources of Additional Information
Type of
Source information*
1. Engineering Analysis of Emissions P, E, C
Control Technology for Sulfuric
Acid Manufacturing Processes.
Prepared by Chemical Construction
Corp. for U.S. Public Health
Service, Cincinnati, Ohio. NTIS
No. PB 190-393. March 1970. 337 p.
2. Background Information for Proposed P, E, C
New-Source Performance Standards:
Steam Generators, Incinerators,
Portland Cement Plants, Nitric Acid
Plants, and Sulfuric Acid Plants.
U.S. Environmental Protection Agency,
Research Triangle Park, North
Carolina. NTIS No. PB 202-459.
August 1971. 50 p.
3. Atmospheric Emissions from Sulfuric P, E, C
Acid Manufacturing Processes. Public
Health Service, Cincinnati, Ohio.
Publication No. AP-13. 1965. 136 p.
4. Duecker, W.W. and J.J. West. P
Manufacture of Sulfuric Acid.
A.C.S. Mono. 144. Reinhold
Publishing Co., New York. 1959.
5. Air Pollution Aspects of Emission E, C
Sources: Sulfuric Acid Manufac-
turing. U.S. Environmental Protec-
tion Agency, Research Triangle Park,
North Carolina. NTIS No. PB 200-079.
May 1971. 64 p.
*P = Process description
E = Emission rates
C = Control devices
3-75
-------
3.4.4 Paint and Varnish
Process Description - The manufacture of paint involves
dispersing a colored oil or .pigment into a vehicle that can
be applied to a surface, usually a resin or oil, and adding
either a hydrocarbon solvent or water to lower the viscosity
of the paint for ease of application. Only physical pro-
cesses are involved; no chemical reactions take place.
Figure 3-38 presents a simple flow diagram of a paint mixing
process.
The manufacture of varnish also involves the mixing and
blending of vario'iis ingredients. In this process, however,
chemical reactions are initiated by cooking the varnish in
open or closed gas-fired kettles for 4 to 16 hours at tem-
peratures between 200 and 650°F.
Atmospheric Emissions - Particulates can be emitted from the
handling of dry pigments. The quantities vary with the care
taken in handling and with the method of transferring the
dry materials. Typical emission values range from 0.5 to
1.0 percent of the pigment handled.
Emissions of hydrocarbons, the pollutants of primary
concern, are due to the use of organic solvents. Depending
on the cooking time and temperature, type of solvent, and
type of enclosure, hydrocarbon emissions from varnish cook-
ing range from 20 to 160 pounds per ton of product. The
corresponding hydrocarbon emission rate for paint manufac-
ture is approximately 30 pounds per ton of paint produced.
Control Systems - Catalytic oxidation and direct-flame
incineration are used to control hydrocarbon emissions from
paint and varnish plants. With catalytic units, the col-
lected process off-gases and vapors are heated by combustion
of fuel to approximately 600 to 800°F. They are then passed
through the catalyst bed, where oxidation of the hydrocarbons
3-76
-------
U)
I
-J
-J
TINTS &
THINKERS
RESINS
ATI C
PIGMENTS
*
t
1 "
\
WEIGHT TA
F
^^
.
SCAL
1
:ED
uc'
/
f
()
• i
TAN
\
>
(I
1
" 1
/
1
J
Figure 3-38. Paint mixing process.
-------
further increases the temperature. In thermal incineration
units, the temperature is raised to 1200 to 1500°F for
residence times between 0.25 and 0.5 second. In both types
of units, the hydrocarbons are oxidized to C02 and water
vapor.
Compliance Schedules - Figure 3-39 illustrates an expedi-
tious schedule for installation of an afterburner.
Sources of Additional Information
Type of
Source information*
1. Kirk-Othmer Encyclopedia of Chemical P, C
Technology, 2nd ed., Volume 14. Inter-
science Publishers, New York, 1967.
p. 462-485.
2. Exhaust Gases from Combustion and E
Industrial Processes. Prepared by
Engineering-Science, Inc. for the
U.S. Environmental Protection Agency,
Research Triangle Park, North
Carolina. NTIS No. 204 861. October
1971. 440 p.
3. Danielson, J.A., ed. Air Pollution P, E, C
Engineering Manual. Publication No.
AP-40. May 1973. 987 p.
*P = Process description
E = Emission rates
C = Control devices
3-78
-------
D
Milestones
•Activity and duration In weeks
MILESTONES
1
Refer to Chapter 2 for time
Increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
10
27
45
47
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
Ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-39. Schedule for installation of an afterburner for hydrocarbon
control on paint or varnish operations.
-------
3.4.5 Soap and Detergents
Process Description - Present commercial methods for the
manufacture of soap consist primarily of catalytic hydrolysis
of various fatty acids with sodium or potassium hydroxide to
form a glycerol-soap mixture. This mixture undergoes separa-
tion through distillation, followed by neutralization and
blending to produce different grades of soap. Soap is
finished in many forms, such as bars, flakes, granules,
liquids, and powders.
In the manufacture of soap in powder form, the material
is spray dried. Prior to spray drying, additives to com-
plete the formulation are suspended or dissolved in the hot
soap and the mixture is then pumped through nozzles near the
top of a spray tower. Circulation of hot air through the
tower evaporates water from the spray, forming the powdered
soap. A schematic flow diagram for the manufacture of soap
is shown in Figure 3-40.
In the manufacture of synthetic detergents, fatty
alcohols or linear alkylate compounds are first treated with
sulfuric acid. The sulfonated compounds are then neutral-
ized with caustic solution, and various dyes, perfumes, and
other compounds are added. The resulting paste or slurry is
pumped to the top of a drying tower and sprayed through
nozzles to form small droplets. As the droplets descend,
the moisture content is reduced by the countercurrent flow
of hot air. The dried detergent is then cooled and packaged.
A simplified flow diagram for the manufacture of detergent
granules is shown in Figure 3-41.
Atmospheric Emissions - Odors are the emissions of primary
concern from soap manufacture. The severity of odorous
emissions depends upon the type of feed material used. Low-
grade stocks obtained from rendered grease and fats tend to
3-80
-------
CONTROL DEVICE
FATTY ACIDS
CATALYST
(NoOH or KOH)
HYDKOLYZtK
1
CRUDE GLYCERINE
VACUUM
STILL
BOTT'OMS
CAUSTIC SODA
M^»
NtUIKALIZtR
SPRAY
DRYER
1
POWDER
'BARS
CHIPS
FLAKES
. LIQUID
Figure 3-40. Soap manufacture.
3-81
-------
EXIT GASES
ALKYLBENZENE
OLEUM
OLEUM-
FATTY
ALCOHOLS
BUILDERS &
ADDITIVES
CYCLONE
FINES TO PROCESS
(HEAT EXCHANGERS
I SECONDARY
I j PARTICULATE
1 (COLLECTOR
nrmrm
SEPARATOR
SPRAY
DRYER
SECONDARY
COLLECTOR
• FINES RETURNED
TO PROCESS
-HEATED AIR
DRY PRODUCT STREAM
I PRODUCT
& PACKAGING
AIR CONVEYOR
HIGH PRESSURE
PUMP
Figure 3-41. Detergent manufacture.
3-82
-------
be odoriferous. Local dust emissions can also occur during
blending, mixing, and packaging of the finished soap.
Uncontrolled spray dryers can be a major source of particu-
late emissions.
Emissions from synthetic detergent manufacture can be
classified as those resulting from preparation of the
synthetic feed compounds from petrochemical stock and those
resulting from the final detergent-making operation. The
former are essentially hydrocarbons emitted from relief
valves, from storage vessels, and from atmospheric and
vacuum fractionation operations. The latter come primarily
from the spray drier. Uncontrolled particulate emissions
from the spray drier are approximately 90 pounds per ton of
product. Particulates can also be emitted from various
handling and packaging operations, although these are
usually controlled because of the product's value.
Control Systems - Emissions of particulate and odors from
the spray drying of soap or detergent are commonly controlled
by a wet scrubber followed by an electrostatic precipitator,
if necessary. The stack gases are sometimes reheated to
prevent formation of a visible plume.
Dust from blending, mixing, and packaging operations
can be controlled by collection in a fabric filter. Hydro-
carbon emissions from relief valves and fractionation towers
can be controlled by incineration.
Compliance Schedules - Figures 3-42 and 3-43 illustrate,
respectively, expeditious schedules for installation of a
wet scrubber/electrostatic precipitator system on a spray
drying tower and a fabric filter on blending and packaging
operations.
3-83
-------
15
20
1}-
32
CO
I
00
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (HEEKS)
4
19
39
71
77
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process tie-ins.
4-5 Perform equipment startup and source testing
Figure^ 3^-42. Schedule for installation of a wet scrubber electrostatic
precipitator for particulate control on a spray drying tower.
-------
U)
i
CO
en
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
Increments A to 6.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plin to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. KEEKS
14
30
47
50
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-6 Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
Inps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-slte construction
N-R Install control device
R-4 Complete construction and system
tie-In
4-5 Perform startup, shakedown, and
emission testing
Figure 3-43. Schedule for installation of fabric filter for particulate
control on blending and packaging operations.
-------
Sources of Additional Information
Type of
Source information*
1. Danielson, J.A., ed. Air Pollution P, E, C
Engineering Manual. U.S. Environ-
mental Protection Agency,, Research
Triangle Park, North Carolina.
Publication No. AP-40. May 1973.
987 p.
2. Kirk-Othmer Encyclopedia of Chemical P
Technology, 2nd edition. Volume 18.
Interscience Publishers, New York,
1967.
*P = Process description
E = Emission rates
C = Control devices
3-86
-------
3,. 4.6 Chlorine Manufacture by the Mercury Cell Process
Process Description - Approximately 30 percent of all manu-
factured chlorine is produced electrolytically by the
mercury cell process. The balance is produced by the
diaphragm cell process.
Sodium chloride in the form of brine is normally used
as the feedstock. Salt solutions used in mercury cells
require more extensive treatment than those used in diaphragm
cells since such heavy metal impurities as vanadium, chromium,
and molybdenum will cause hydrogen evolution at the cathode
and undesirably increase the amount of hydrogen in the
chlorine.
Figure 3-44 illustrates a typical mercury cell. A
mercury cell consists of two sections, the electrolyzer and
the decomposer. In the electrolyzer, mercury, which is the
lower layer, acts as the cathode and carbon (graphite)
anodes are placed in the stream of brine, which flows on top
of the mercury. During electrolysis, chlorine is evolved at
the anodes and sodium ions are drawn into the mercury to
form an amalgam. The amalgam, which contains between 0.1
and 0.3 percent sodium, is removed from the cell and reacted
with water in the decomposer to yield hydrogen, caustic soda
and mercury. The mercury is then recycled.
The hot chlorine gas evolved from the anodes is collected
in common headers, which connect as many as 70 to 75 cells.
The gas is cooled in a water spray chamber, passed through a
demister, and then dried with sulfuric acid in a packed
tower. After drying, the chlorine is distilled and com-
pressed.
Atmospheric Emissions - Chlorine emissions from electrolytic
chlor-alkali plants can occur from:
1. Cell operation
3-87
-------
BASIC TREATMENT CHEMICALS
(SODA ASH, CAUSTIC LIME, CHLORINE
ACID, CaCL2, ETC.)
PRODUCT
CHLORINE
SOLID
NaCL FEED
OTHER
1
MAIN
STREAM
RECYCLE
1
BRINE
DECHLORINATOR
SPENT BRINE
TREATED
MAIN BRINE
SATURATION,
PURIFICATION, AND
FILTRATION
BRINE
INLET
END-BOX
END-BOX
VENTILATION SYSTEM
AQUEOUS
LAYER
STRIPPED
AMALGAM
END-BOX
VENTILATION SYSTEM
1
COOLING,
DRYING,
COMPRESSION, AND
LIQUEFACTION
OUTLET END-BOX
END-BOX
VENTILATION SYSTEM
AQUEOUS LAYER
HYDROGEN GAS
BYPRODUCT
WATER COLLECTION
SYSTEM
END-BOX
"VENTILATION-SYSTEM
Hg PUMP
AQUEOUS LAYER
* PROPRIETARY TREATMENT CHEMICALS INCLUDE PRECIPITATORS,
FLOCCULANTS, POLYELECTROLYTES, AND SIMILAR MATERIALS
DECOMPOSER
(DENUDER)
AMALGAM
CAUSTIC SODA
SOLUTION
»-TION, AND »-CAUSTIC
PRODUCT
Figure 3-44. Chlor-alkali mercury-cell operation.
3-88
-------
2. Acidifying, air blowing, and vacuum treating of
the depleted brine.
3. The chlorine liquefaction process (as "blow gas").
4. Losses through vents from storage tanks, process
transfer tanks, tank cars, and shipping containers,
5. Leaks or spills due to corrosion, wear, and
accidents.
Quantitative emission data are not available.
Emissions of mercury to the atmosphere occur from:
1. The hydrogen by-product stream.
2. The end-box ventilation system.
3. The cell room ventilation air.
The hydrogen by-product stream leaving the decomposer
is saturated with mercury vapor (1.0 grain of mercury vapor
per cubic foot at 210°F). Cooling the hydrogen stream to
110°F along with partial mist elimination reduces emissions
to about 50 pounds for each 100 tons of chlorine produced.
Mercury emissions from an untreated or inadequately
treated end-box ventilation system range from 2 to 15 pounds
for each 100 tons of chlorine produced.
The volumetric flow rate of the cell room ventilation
stream ranges from 100,000 to 1,000,000 cubic feet per
minute for each 100 tons of daily chlorine capacity- A
higher flow of air may be needed in old plants, where mer-
cury concentrations are more likely to be high. On the
basis of data obtained from operating plants, it is esti-
mated that mercury emissions from the cell room ventilation
system range from 0.5 to 5.0 pounds per day per 100 tons of
daily chlorine capacity.
3-89
-------
Control System - Wet caustic scrubbers are the preferred
method of collecting chlorine gas released from acidulating
of the depleted brine. The chlorine from the cells is
collected in packed towers with sulfuric acid.
Mercury emissions can be eliminated by switching to the
diaphragm cell process. This change, however, requires a
major modification of the brine handling systems.
Since mercury is very volatile, emissions can be
reduced by cooling the exit gas streams, either with direct
contact scrubbers or with refrigeration systems using brine.
Adsorption on impregnated activated carbon or molecular
sieves also will reduce emissions.
Compliance Schedule - Figure 3-45 illustrates the compliance
schedule for installation of high-energy venturi scrubbers.
This system would reduce both chlorine and mercury emissions
by absorption and cooling, respectively. Wastewater would
be treated and recycled. The schedule shows an overall time
period of 68 weeks, exclusive of installation of a waste-
water treatment facility. The on-site construction period,
which is the longest single interval on this schedule, is
required to accomodate the installation of corrosion-resis-
tant piping, pumps, ducts, and controls.
3-90
-------
i
vo
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
Increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
16
42
65
68
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
6-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-H Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-45. Schedule for
venturi scrubber on
installation of a high-energy
chlor-alkali plant.
-------
Sources of Additional Information
Type of
Source information*
1. Control Techniques for Chlorine and P, E, C
Hydrogen Chloride Emissions. Pre-
pared by PEDCo Environmental for
the U.S. Environmental Protection
Agency under Contract No. CDA-70-96.
March 1971.
2. Engineering Guide for Processing P, E, C
OEPA Air Pollution Permits. Indus-
trial Pollution Section, OEPA
Division of Waste Management and
Engineering. July 1973.
3. Compilation of Air Pollution Emission E
Factors, 2nd ed. U.S. Environmental
Protection Agency, Research Triangle
Park, North Carolina. Publication
No. AP-42. February 1976. pp. 5-5
to 5-6.
4. Atmospheric Emissions from Chlor- P, E
Alkali Manufacture. U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina.
Publication No. AP-80. January 1971.
116 p.
5. Stahl, Q.R. Preliminary Air Pollu- P, E
tion Survey of Chlorine Gas. U.S.
Environmental Protection Agency,
Raleigh, North Carolina. Publica-
tion No. APTD 69-33. October 1969.
pp. 25-35.
6. Control Techniques for Mercury Emis- E, C
sions from Extraction and Chlor-Alkali
Plants. U.S. Environmental Protection
Agency, Research Triangle Park, North
Carolina. Publication No. AP-118.
February 1973. pp. 3-19 to 3-33.
*P = Process description
E = Emission rates
C = Control devices
3-92
-------
3.4.7 Carbon Black Industry
Process Description - The carbon black industry processes
hydrocarbon feedstocks (mainly heavy oils) into finely
divided carbon black particles for use largely in manufac-
ture of tires, and to a lesser extent, pigments, cement, and
cosmetics. Carbon black products are distinguished by the
particle size of the unagglomerated particles, ranging from
5 to 500 millimicrons. Most carbon black plants produce 25
to 75 thousand tons per year of product.
Carbon black is made by three processes - the furnace,
thermal, and channel processes. The channel process is
being phased out, and only one plant is in operation. The
furnace process currently accounts for about 90 percent of
production, and the thermal process for the remaining 10
2
percent. A flow sheet for the furnace process is presented
in Figure 3-46.
The furnace process basically involves the incomplete
combustion and thermal cracking of a liquid hydrocarbon
feedstock under controlled conditions in a reactor at a
temperature of approximately 2550°F to produce a finely
2
divided carbon particulate. The gaseous effluent from the
reactor is quenched with water to approximately 1000°F to
stop the cracking reactions and then is further cooled to
2
about 450°F. The particulate (raw carbon black) is then
removed from the gas stream by passage through a fabric
filter system. A number of reactors are normally connected
by a manifold and served by a single quench chamber and
product collection system.
In the thermal process, decomposition of a natural gas
is produced by thermal cracking at a temperature of 2400 to
2800°F in the absence of air to yield carbon and hydrogen.
The product stream is then filtered to remove carbon black
3-93
-------
vo
PRIMARY QUENCH
PARALLEL SET
OF REACTORS
IR HEAT
NATURAL GAS
SECONDARY QUENCH
AIR
HWjt \
>
^
k /
>h
».
P
Jr Jr
i i
i i
i . i
ROCESS
Jr A-
BAGHOUS
f\
ENTRAINED BLACK
'TO BAGHOUSE
NATURAL GAS
MICROYPULVERIZER
STORAGE
OFF SPEC
TANK
Figure 3-46. Typical furnace carbon black process.
-------
and the exit gas is burned to generate heat for additional
cracking.
Raw carbon black leaving the filtration step is pul-
verized by a micropulverizer to break up any agglomerates,
pelletized to facilitate handling, and finally dried in a
rotary drum dryer prior to storage and shipment.
Atmospheric Emissions - Atmospheric emissions of carbon
monoxide, gaseous and condensible hydrocarbons, particulate,
and hydrogen sulfide are the primary pollutants associated
with carbon black manufacture; these pollutants are generated
by the high-temperature cracking of the hydrocarbon feed-
stocks.
At thermal process plants the off-gases are recycled to
the reactor, and emissions rates are very low. Some partic-
ulate emissions occur when the reactors are switched from
the cracking to the heating cycle. At furnace process
plants, however, CO emissions are roughly 100 percent of
product weight. Hydrocarbon emissions from the furnace
process consist of methane and acetylene; these are largely
nonreactive in photochemical processes. Emissions of H2S
are directly related to sulfur content of the feed, amounting
to approximately 0.01 times the percent sulfur in the feed
on a weight basis. Emissions of NO are very low because of
2£
lack of air in the reactor. Particulate emissions depend
mainly on product size and process fabric filter efficiency-
The purge gas from the dryer contains particulate.
Average emission rate is 0.08 pound per ton of product after
the product recovery filter.
Control Systems - Control of particulate from the furnace
and thermal processes is generally very good. Poor control
results in product loss and low yield. Fabric filter
systems are widely used to ensure high collection efficiency
3-95
-------
(99+ percent). These filters function both as process
equipment and emission controls. Some companies use cy-
clones ahead of the filter to improve the removal efficiency
of the fabric filter.
Cyclones, scrubbers, and fabric filters are used to
control exhausts of the dryer purge gas stream. If a
scrubber is used, the liquid effluent is used in the pellet-
izer and no liquid waste occurs.
The CO in the furnace off-gas stream can be controlled
by off-gas incineration or use of a CO boiler. Although
there is limited use for steam at carbon black plants, some
furnace process plants combust the off-gas and export steam.
Others use incineration without heat recovery to reduce
odors from H2S emissions. To obtain CO removal efficiencies
of greater than 95 percent, firebox temperatures should
range from 1400 to 1600°F with residence times of about 0.4
second.
Compliance Schedule - Figures 3-47 and 3-48 show expeditious
schedules for installation of a field-erected and a packaged
CO boiler, respectively. Installation time for a field-
erected unit is 131 weeks, whereas installation of a package
CO boiler requires approximately 68 weeks. These schedules
include control device fabrication times of 62 and 23 weeks
for the field-erected and packaged CO boiler, respectively.
3-96
-------
D
Milestones
•Activity and duration 1n weeks
u>
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. KEEKS
23
74
127
131
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-6 Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
Inos
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-47. Schedule for installation of a field-erected CO boiler,
-------
U)
I
vo
00
Milestones
•Activity and duration in weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of subroittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
17
46
65
68
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
0-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves .plans
6-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-4?. Schedule for installation of a packaged CO boiler.
-------
Sources of Additional Information
Type of
Source information*
1. Background Information - Best Systems P, E, C
of Emission Reduction for Furnace
Type Carbon Black Plants. Prepared by
PEDCo Environmental Specialists, Inc.
for U.S. Environmental Protection
Agency, Research Triangle Park, North
Carolina. Contract No. 68-02-1321.
Task No. 9. December 1975. 209 p.
2. Gerstle, R.W. Carbon Black Industry. P, E, C
Environmental Catalog of Industrial
Processes. Prepared by PEDCo Environ-
mental Specialists, Inc. for U.S.
Environmental Protection Agency,
Research Triangle Park, North Carolina.
Contract No. 68-02-1321. Task No. 21.
May 1975. 25 p.
3. Schwartz, W.A., et al. Engineering P, E, C
and Cost Study of Air Pollution for
the Petrochemical Industry. Volume I:
Carbon Black Manufacture by the Furnace
Process, Houdry Division, Air Products.
Environmental Protection Agency,
Raleigh, North Carolina. Publication
No. EPA-450/3-73-006a. June 1974.
127 pp.
4. Compilation of Air Pollutant Emission E
Factors, 2nd edition. U.S. Environmental
Protection Agency, Research Triangle Park,
North Carolina. Publication No. AP-42.
February 1976. pp. 5.13-1 and 5.13-2.
5. Cheremisinoff, P.N. and R.A. Young. C
Pollution Engineering Practice Handbook.
Ann Arbor Science Publishers, Inc.
Ann Arbor, Michigan. 1975. pp. 177-180.
3-99
-------
6. Danielson, J.A., editor. Air Pollution P, E, C
Engineering Manual. U.S. Environmental
Protection Agency, Research Triangle
Park, North Carolina. Publication No.
AP-40. May 1973. pp. 704-711.
*P - Process description
E - Emission rates
C - Control devices
3-100
-------
3.4.8 Ammonium Nitrate
Process Description - Ammonium nitrats is .made by Neutral-
izing nitric acid with ammonia gas. The .neutralization is
generally carried out in a batch reaction according to*the
reaction:
NH-(g) + HNO-(l) -> NH.NO,(1)'' '" •'•*>* ' '
Tt J -. ;_• i
Figure 3-49 illustrates the commercial production of ammonium
nitrate prills.
In this process the ratio of ammonia and acid is auto-
matically controlled. The heat of neutralization evaporates
/
a part of the water and gives a solution of 83 percent
ammonium nitrate. Final evaporation to above 99 percent is
accomplished in a falling film evaporator. The resultant
melt flows through spray nozzles and downward through a
prill tower countercurrent to ambient air. The melt is
cooled and solidified to form round pellets or prills.
The prills are continually removed from the bottom of
the tower and fed to a rotary cooler. Fines from the cooler
are typically collected in a wet cyclone and returned to the
neutralizer. After cooling, the prills are screened to
size; the over- and undersize prills are sent to a sump and
returned to the neutralizer. Intermediate or product-size
prills are dusted with a coating material, usually diato-
maceous earth, in a rotary coating drum and sent to a
bagging operation.
Atmospheric Emissions - Emissions of particulate and ammonia
from the top of the prill tower constitute the major atmos-
pheric emissions. This discharge air contains from 0.1 to
0.3 percent ammonium nitrate, most of which is under 0.5
micron diameter, as shown below:
3-101
-------
U)
I
H
O
NJ
EVAPORATOR
NITRIC
ACID
AHMONIA
NEUTRALIZER
FAN
-' LT
WEAK LIQUOR
PUMP
SHORT
PRILL
TOWER
FAN
CYCLONE I ATD
1? I
SCREEN
COOLER
COATING DRUM
PRODUCT TO
"BAGGING
Figure 3-r49. Ammonium nitrate manufacturing process.
-------
Particle size, Test No. 1 Test No. 2
microns % %
<0.3 00 •
0.3-0.5 39 74
0.5-1 54 20
1-2 7 6
>2 00
The grain loading in these tests ranged from 0.07 to 0.26
grain per cubic foot at 65,000 scfm and 120°F. Plume
opacity was approximately 60 percent.
Control Systems - Exhaust air is drawn through a shroud in
the top of the prill tower and sent to a high-energy wet
scrubber and mist eliminator. The captured ammonium nitrate
is recycled. Emissions of ammonium nitrate and ammonia can
reportedly be reduced to 1.0 and 0.15 pound per ton of
product, respectively. Another control system for ammonia
nitrate prill towers utilizes a spray scrubber system inside
the prill tower and recirculates the scrubbing solution to
the neutralizer.
Compliance Schedule - Figure 3-50 illustrates an expeditious
schedule for installing a shroud, wet scrubber, and mist
eliminator on an ammonium nitrate prill tower. This sched-
ule shows an overall time period of 68 weeks, which could be
reduced by a few weeks if on-site construction and equipment
activity could be further expedited. This control system
requires a high-pressure fan, which, together with the fan
motor, is a long-delivery item. The scrubber must be con-
structed of corrosion-resistant material, either stainless
steel or glass-reinforced plastic. Because such scrubbers
are built only to order, delivery time is somewhat longer
than normal.
The spray scrubber system installed in the prill tower
requires an overall time period of 30 to 45 weeks. This
3-103
-------
I
i-1
o
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-s1te construction or Installation of emission control equip-
ment is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G, WEEKS
J6_
35
65
68
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R.-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Figure 3-50. Schedule for installation of a shroud, wet scrubber, and mist
eliminator on an ammonium nitrate prill tower.
-------
installation proceeds more quickly because the system
requires no large fans and ductwork.
Sources of Additional Information
, Type of
Source information*
1. Shreve, R. The Chemical Process P
Industries, 2nd edition. McGraw-
Hill, New York. 1956. 1004 p.
*P = Process description
3-105
-------
3.4.9 Urea Manufacturing Process
Process Description - Urea is synthesized by reacting
ammonia (NH.J with carbon dioxide (C02) at approximately
4500 psig and 390°F to form ammonium carbamate, and simul-
taneously dehydrating the ammonium carbamate to urea, as
*
shown in Figure 3-51. The following equations show the
chemical reations:
2 NH3 + CO- -»• NH' COONH. (Ammonium carbamate)
NH2 COONH4 -> NH2 CONH2 + H20 (Urea)
The urea synthesis reactor always contains unreacted
carbamate and excess ammonia, depending upon the composition
of the feeds. This material is removed from the urea solu-
tion and reused. Depending on how the unreacted material is
reused, the commercial urea synthesis processes are grouped
into the following main categories:
° Once-through urea process
0 Solution recycle urea process
0 Internal carbamate recycle urea process.
Product urea normally obtained from the synthesis
section as a 70 to 90 weight percent aqueous solution is
usually further processed to solid urea by evaporation or by
crystallization with crystal remelt. In both cases the
product is molten pure urea. The molten urea is sprayed and
solidified into small spherical particles (prills) in a
prill tower as shown in Figure 3-52.
Atmospheric Emissions - Carryover from the urea prill tower
ranges from 0.04 to 0.22 grain per cubic foot with an
updraft velocity of 1200 feet per minute. Measurements at
one plant showed the following particle size distribution:
3-106
-------
LO
I
RECYCLE
, C02, H20. GAS _
JO NEUTRALIZER
WATER
STEAM
DECOMPOSER
SYSTEMS
LIQUID NH3 PUMP
1
I
C02 COMPRESSOR
GAS
LIQUID
SEPARATOR
85-90 WT X
UREA SOLUTION
Figure 3-51. Urea manufacturing process.
-------
EXHAUST FANS
TRANSFER CONVEYOR
TO PRODUCT COOLING
AND SHIPPING
Figure 3-52. - Urea prill tower without control system.
3-108
-------
Particle size, microns % by weight
0 - 2.5 44.9
2.5 - 5 16.6
5-10 17.2
>10 21.4
Because of the high percentage of fines/ a highly visible
plume was produced. Upward air flow through the tower was
80,000 scfm.
Control Systems - To capture particulate emissions, a shroud
is placed around the spray to sieve section in the top of
the tower. The exhaust air is then ducted to a wet scrubber
followed by vane-type mist eliminators, passes through the
fan, and is discharged to the atmosphere. Some towers are
equipped with refrigerant coolers, and the air is recircu-
lated up the tower. The scrubbing liquor is recycled to the
process.
Compliance Schedule - Figure 3-53 illustrates an expeditious
schedule for installing a shroud, wet scrubber.- and mist
eliminator on a urea prill tower. This schedule shows an
overall time period of 68 weeks, which could be reduced by a
few weeks if on-site construction and equipment activity
could be further expedited. One long-delivery item is the
high-pressure fan and motor. Because the scrubber must be
built to order of corrosion-resistant material, either
stainless steel or glass-reinforced plastic, delivery time
is longer than normal.
3-109
-------
Milestones
•Activity and duration In weeks
oo
I
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G, WEEKS
16
35
65
68
Activity
designation
A-B
A-C
C-D
D-E
E-F
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Activity
designation
K-L
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings 4-5
Figure 3-53. Schedule for installation of a
and mist eliminator on a urea prill
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R.-4
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-s1te construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
shroud, wet scrubber,
tower.
-------
Source of Additional information
Type of
Source information*
1. Shreve, R. Norris. The Chemical P
Process Industries, 2nd , edition.
McGraw-Hill, New York, 1956.
1004 p.
2. Kirk-Othmer Encyclopedia of P
Chemical Technology, 2nd edition.
Volume 21. Interscience Publishers,
New York. 1967. p. 37-56.
*P = Process description
3-111
-------
3.4.10 Plastics
Process Description - Plastics manufacturing generally
'consists of polymerizing an organic compound, drying it, and
finally treating and forming the plastic product. Polymer-
ization is mostly done in an indirectly heated reaction
vessel that is jacketed and lined with glass or stainless
steel. The vessel is normally completely enclosed; it is
equipped with a stirring mechanism and may contain a reflux
condenser. The reactants required to form plastic resins
differ for various plastics. For example, polyester resins
are formed by the condensation reaction between a polyhydric
alcohol and a polybasic acid. Polyvinyl resins are generally
produced by polymerization of vinyl acetate and vinyl
chloride.
After the polymerization reaction is complete, the
resin is separated from unwanted products of reaction,
washed, and dried. Compounding (addition to the polymer of
such ingredients as stabilizers, colorants, plasticizers,
and flame retardants) is done after drying. The specific
additives depend on the end use of the plastic. Compounding
may be done by a two-roll mill, an extruder, or a mixer.
After compounding, the plastics may be dried and
crushed if they are used for molding or they may be thinned
with solvent and stored if the plastic is used for protec-
tive coating. Sometimes the polymers are stored in latex
form as they come from the reaction vessel. Figure 3-54
shows a simplified flow diagram of typical plastics manu-
facturing.
Atmospheric Emissions - Major emissions from this industry
are raw materials or monomers, solvents or other volatile
liquids emitted during the reaction, sublimed solids such as
phtalic anhydride emitted in alkyd production, and solvents
3-112
-------
CO
U)
REFLUX
CONDENSER
REACTANTS
CRUSHING
PELLETIZINS
SOLVENT
THINNING
STORAGE
Figure 3-^54* Simplified plastics manufacturing process.
-------
emitted during storage and handling of thinned resins.
These emissions leave the stack as gaseous and condensed
hydrocarbons. Other particulates are generated during
pelletizing or crushing of the solidified plastic resin.
Quantities of emissions vary with the type of plastic
product. Estimated emission factors for uncontrolled
plastics manufacturing are as follows:
Particulates, Gases,
Type of plastic Ib/ton Ib/ton
a
Polyvinyl chloride 35 17
Polypropylene 3 0.7
General 5 to 10
a As vinyl chloride.
As propylene.
Control Systems - Control systems used to recover a reactant
or product are considered a basic part of the process equip-
ment. These include floating-roof or gas-tight storage
2
tanks and vapor recovery systems (adsorption or condensation).
Emissions of particulate and condensible hydrocarbons can be
controlled by use of high energy air filters, scrubbers, or
mist eliminators. Afterburners can be used to eliminate
gaseous hydrocarbon emissions. High-energy air filters have
been applied to plastic extruders to collect particulates
and condensible hydrocarbons from exhausts at flow rates up
to 60,000 acfm. For effective removal of condensible hydro-
carbons the exhaust stream must be cooled to less than
150°F. High-energy air filters typically have pressure
drops of about 28 inches water gauge and air-to-cloth ratios
of 500/1 to 1500/1. The collected pollutants are not
recycled but are disposed of with the fabric roll.
3-114
-------
Various types of scrubbers can be used to control the
plastics process. One type is a settling chamber partially
filled with water followed by water sprays. A spray cham-
ber precleaner followed by a venturi scrubber is also
4
effective. These scrubbers will not collect significant
amounts of gaseous hydrocarbons.
Fiber-bed mist eliminators remove plasticizer droplets
by trapping them in a bed of fibers. For proper collection
efficiency with this device, the gas inlet temperature
should be a maximum of 90 to 120°F. The collected liquid
can be disposed of or used for plasticizer reclamation.
Afterburners are used to incinerate hydrocarbons from
plastics manufacturing. The exhaust must be heated to
temperatures often exceeding 1500°F to reduce 90 percent of
the organics to carbon dioxide and water. This technique
should not be used when the plasticizers contain such
elements as phospherous, sulfur, chlorine, and nitrogen,
since the products of combustion can be worse than the
organics.
Compliance Schedules - Figures 3-55 through 3-58 show
expeditious schedules for installing a high-energy air
filter, a typical low-pressure wet scrubber, a mist elimina-
tor, and an afterburner. Installation times range from 41
weeks for a high-energy air filter unit to 50 weeks for a
mist eliminator. Fabrication requires the greatest time
increment in all cases. The high-energy air filter unit and
afterburner require approximately 14 weeks for fabrication
and the fabrication duration for mist eliminator and low-
energy scrubber is about 15 and 20 weeks, respectively.
3-115
-------
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
10
29
39
41
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
1nps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-55.
Schedule for installation of a high-energy air filter unit
on plastics manufacturing operations.
-------
U)
i
n
Milestones
•Activity and duration 1n weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
Increments A to G.
Date of submfttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
12
30
45
49
Activity
designation
A-B
A-C
C-0
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
1 nos
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate On-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-56,
Schedule for installation of a low-energy wet scrubber
on plastics manufacturing operations.
-------
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
OJ
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-s1te construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
n
31
47
50
CO
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-s1te construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-57. Schedule for installation of a mist eliminator
on plastics manufacturing operations.
-------
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of- Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
12
29
44
46
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-H Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
' tie-in
4-5
Perform startup, shakedown, and
emission testing
Schedule for installation of an afterburner
Figure 3-58.
on plastics manufacturing operations.
-------
Sources of Additional Information
Type of
Source information*
1. Compilation of Air Pollutant E
Emission Factors, 2nd edition.
U.S. Environmental Protection
Agency, Research Triangle Park,
North Carolina. Publication
No. AP-42. February 1976.
pp. 5.13-1 and 5.13-2.
2. Danielson, J.A., editor. Air P, E, C
Pollution Engineering Manual.
U.S. Environmental Protection
Agency, Research Triangle Park,
North Carolina. Publication
No. AP-40. May 1973. pp. 704-711.
3. HEAF/CHEAF Brochure and Installation C
List. Bulletins 112 5/75 and 113 5/75.
Anderson 2000, Inc. Atlanta, Georgia.
May 1975.
4. Engineering Guide for Processing P, E, C
OEPA Air Pollution Permits. Ohio
Environmental Protection Agency,
Columbus, Ohio. July 1973.
pp. 5-14-1 to 5-14-13.
5. Cheremisinoff, P.N. and R.A. Young. C
Pollution Engineering Practice Handbook.
Ann Arbor Science Publishers, Inc.,
Ann Arbor, Michigan. 1975.
pp. 177-180.
*P = Process description
E = Emission rates
C = Control devices
3-120
-------
3.5 AGRICULTURAL PRODUCTS
3.5.1 Grain Handling and. Processing
Process Description - Grain handling and processing encom-
pass a variety of operations from the initial receipt of the
grain at either a country or terminal elevator to the
delivery of such finished products as flour, livestock feed,
soybean oil, and corn syrup. Primary operations in this
industry include: (1) grain handling and transferring; (2)
milling of dry corn, wet corn, soybeans, rice, durum, and
wheat; and (3) feed manufacturing.
Grain is handled and transferred at country and ter-
minal elevators. Country elevators receive grain from farms
by truck for future delivery to terminal elevators. At a
typical terminal elevator, the grain is unloaded, cleaned,
dried, stored, turned periodically, and eventually shipped
to another elevator or processed at an adjacent facility.
Figure 3-59 illustrates the basic operations of a terminal
elevator.
Milling of dry and wet corn, soybeans, rice, durum, and
wheat involves several steps: (1) grain receiving; (2)
cleaning and drying; (3) grinding or milling; (4) sifting,
separating, and mixing; and (5) final loading of the finished
products and by-products. Unloading and loading operations
are similar to those of a terminal elevator. The by-products
of the milling industries are frequently shipped to feed
mills for further processing. Figures 3-60, .3-61, and 3-62
illustrate general operations for soybean processing, flour
milling, and wet corn milling. Grain drying is discussed in
Section 3.2.
Processing of grains into mixed feed involves grinding
the grain, mixing it with the other ingredients of the
formula, and forming the feed into the desired shape and
3-121
-------
LEG VENTS
OJ
I
\->
to
GONDOLA SHIPPING
SPOt-T
GONDOLA & CAR
RECEIVING &
SHIPPING
VENT
GARNER & SCALE
VENT
SHIPPING CONVEYOR
SHIPPING SPOUT
SHIPPING BUCKET
ELEVATOR LEG
VjtiT LOADERS x
TUNNEL BELTS
CAR RECEIVING CONVEYOR •
•-CAR REC'G & SHIPPING LEG
• EMISSION K>INT
Figure 3-59. Terminal grain elevator.
-------
I BARGE |
TRUCK
CONVEYOR
(DIRECTION OF f LOW)
EMISSION POINT
Figure 3-60. Soybean processing,
3-123
-------
«
ELEVATOR
,
PRODUCT CONTROL
r
SEPARATOR
*
ASPIRATOR
DISC SEPARATOR
«
r
1 SCOURER
1
• EMISSION POINT
|
MAGNETIC SEPARATOR
WASMER-STONER
1
TEMPERING
. 1
TEMPERING BINS
ENTOLETER
» 1
GRINDING BIN
e>
FIRST BREAK
*
r
r
•
»
SIFTER
«
PURIFIER
BRAN ANI
REDUCING ROLLS
.
SHOJ
SIFTER
1
:
V
r
>s
TS
J
LOUR
HORT'S
J
9
PURIFIER
.
®
REDUCING ROLLS
SIFTER
1
®
PURIFIER
4 FLOUR
PURIFIERS
BLEACHING
BULK STORAGE
'-
.
GERM ROLLS
-*- SHORTS
^» FLOUR
"^ FLOUR
SIFTER
ENRICHING
r
*
PACKER BULK DELIVERY
Figure 3-51. Flour milling.
3-124
-------
--..
P$ SHELLED CORN-Si*?
E^teraayi'&ra^ig •IS*-''
STEEPWATER
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STEEPWATER
EVAPORATORS
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pi^CpNC ENTRATE ^ ^ |
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few* STEEPWATER i iv>
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fe*FOR SHIPMENT £3 Ji
GLUTEN
f \
| FEED DRIERS fii^!^!|
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KiCORN jJUfTEN FEED;'" j CQT.N GLyTCN MEAL :
FIRST CORN CLEANERS
i m
STORAGE BINS
» &
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» 6
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DEGERMINATORS '
|
GERM SEPARATORS .
, GERM WASHING AND DRY
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GRINDING MILLS
CRUDE OIL .,
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* t
WASHING SCREENS
FILTERS |
1 1
CENTRIFUGAL
SEPARATORS
(CENTRIFUGAL r , ,
•SEPARATORS
t t
STARCH WASHING
FILTERS^
1. BLEACHING AND- 1
WINTERIZING I
f f
' I_STARCH""/;;'
.^ 3
|— 1 STARCH DRIERS — i
1 1 .
t- DRY STARCHES .• 1 1 DEXTRIN ROASTERS
I ' •'• •*.. - 1 1
I> „ ,KXRINS |
IcpRN SYRUP ££.>;•..$.
SYRUP AND SUGAR
ENZYME OR
ACID CONVERTERS
I DEODORIZERS 1
\
\ FILTERS
1
[ 'REFINED'CORN.OIL. |
t
DECOLORIZING AND
EVAPORATING-
® *
DRUM OR SPRAY
DRIERS
SUGAR I
CRYSTALLIZERS 1
f 1
:*S-B.:CORN SYRUPiS?;?*
?•::%£ SOLIDS '™SS?-
n PRODUCTS AND INTERMEDIATE POINTS
BETWEEN PROCESSES
| | EQUIPMENT AND PROCESSES
CENTRIFUGALS I— ^lgOR
t
1' DEXTRpSE -p-|
-(
-c
Mz
NG
T
}IL EXTRACTORS U
SOAP STOCKS
; CORN GERM^a-iiL
MEAL Imj"^
"YDROL 1
;; 30GAR MOLASStsJ
: LACTIC ACID
ISORBITOL.
\
MANNITOL
METHYL ••• . .
GLUCOSIDET:' '-
• EMISSION POINT
Figure 3-62. Wet corn milling.
3-125
-------
consistency. The basic forms'of finished feed are mash,
pellets, and crumbles.
Grinding and mixing are the two basic operations in
each feed mill. Extrusion and cooling are additional opera-
tions in the manufacture of pellets. If pellets are broken
into "crumbles" or "granules", the crumbling operation and
screening follow the pelletizing operation. Figure 3-63
illustrates the flow diagram for a typical feed mill.
Atmospheric Emissions
Particulate emissions are of primary concern in most
grain industry operations. The emission rates are highly
variable, depending upon such factors as cleanliness of
grain, process design, and operating practices. Emissions
from the various processes generally range between 2 and 8
pounds of particulate per ton of material handled or pro-
cessed. Fugitive dust emissions can be a major problem in
grain unloading or loading. Control requires the use of
adequate enclosures and hooding systems in conjunction with
emission control devices.
Control Systems
Fabric filters and mechanical collectors (cyclones) are
the most commonly used control devices. Fabric filters
operate with efficiencies greater than 99.9 percent, with no
visible emissions. Air-to-cloth ratios generally range
between 10/1 and 15/1 (cubic feet per minute per square foot
of filter area); the higher ratios are used for intermittent
operations and in relatively dry climates. Fabric filters
are not used on streams having high moisture content because
of the tendency of the fabric to "blind".
Because of the relatively large size of the emitted
particulates, the collection efficiency of mechanical col-
lectors is high. For example, cyclones on pneumatic con-
veying systems can operate with efficiencies above 99
3-126
-------
• (MISSION K>INT
SHIPPING
Figure 3-63. Feed manufacturing.
3-127
-------
percent. At most emission sources, however, mechanical
collectors allow a visible discharge even though collection
efficiencies are relatively high.
Grain drying emissions and controls are discussed in
Section 3.2.
Compliance Schedules
Figures 3-64 and 3-65 illustrate expeditious schedules
for installation of a baghouse and a high-energy cyclone,
respectively.
Sources of Additional Information
Type of
Source information*
1. Engineering and Cost Study of Emission P, E, C
Control in the Grain and Feed Industry.
Prepared by Midwest Research Institute
and PEDCo-Environmental under Contract
No. 68-02-0213. Environmental Protec-
tion Agency, Research Triangle Park,
North Carolina. December 1973. 545 p.
2. Danielson, J.A., editor. Air Pollution P, E, C
Engineering Manual. U.S. Environmental
Protection Agency, Research Triangle
Park, North Carolina. Publication No.
AP-40. May 1973. pp. 352-362.
*P = Process description
E = Emission rates
C = Control devices
3-128
-------
U)
N)
vo
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
12
30
45
48
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
Inps
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawinas
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Figure 3-64.
Perform startup, shakedown, and
emission testing
Schedule for installation of baghouse or self-cleaning screen
filter on grain handling and processing sources.
-------
OJ
I
M
U)
O
|~] Milestones
» Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
ELAPSED TIME
FROM G. WEEKS
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
22
29
30
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-65. Schedule for installation of a high-energy cyclone
on grain handling and processing sources.
-------
3.5.2 Grain Drying
Process Description:^ Drying removes moisture frQiLgrain so
that it can be stored safely. . For example, corn that may
contain 20 percent moisture or more when it is received at
a grain elevator is dried to decrease the moisture to
approximately 14 percent for storage.1
Rack or column dryers, as shown in Figure 3-66, are
normally used at grain elevators. Grain can be fed con-
tinuously through both types of dryers, and heated air is
the drying medium. From the dryer, the grain is sent for
storage or further processing (see Section 3.5.1.).
Atmospheric Emissions - The rate of particulate emissions
from grain dryers depends on the type of grain, the dusti-
ness of the grain, and the type of dryer (column or rack).
Drying of soybeans usually creates the greatest visible
emissions; in corn drying, a light, flaky material called
"beeswings", which is difficult to collect, breaks off the
corn and is emitted along with normal grain dust. Generally,
95 percent of the grain dust is in particles greater than 50
microns. Emissions from column dryers are lower than from
rack dryers, since some of the dust is trapped by the column
of grain. Dryer emissions amount to 6 and 7 pounds per ton
of grain processed at a terminal and a country elevator,
2
respectively.
Control Systems - Because of the large volumes of effluent
and its high moisture content, the seasonal nature of grain
drying, and the relatively large diameters of the partic-
ulate emissions, grain dryers are usually controlled with
relatively low cost "screen" filter systems, of four major
types:
Settling screen house
Concentrating screen house
Rotary self-cleaning screen
Sliding-bar self-cleaning screen
3-131
-------
(a) Rack Dryer
Grain
Receiving
Air
Sea
Dryer Section
Cooler
Section
,
•*—
•*—
<^—
-«—
•^^v
-*—
•*—
r
«^—
•*— i
^ 1 1
P
^f
IA^
•»*
•*
•r
JU
ri
•h
•r
Li
S
^
Garner
^ra i rii:
•*^fc ^**
— N» ^^«
-1 ^^^
n
rr
D~
(!>
M
!«•
•r
w
rt
^
•J.
_!,
^.
— *-
— »•
»
— »•
-^
— ^
-^
—*•
^^
— »>
Variable Speed Discharge
(b) Column Dryer
MOISTURE
LADEN
AIR
OUT
Figure 3-66. Column and rack grain dryers.
3-132
-------
The filter material is usually 24-, 35-, or 50-mesh wire
screens and occasionally 100-mesh Dacron.
Compliance Schedule - Figure 3-67 illustrates an expeditious
schedule for installation of a self-cleaning screen house on
a grain dryer. The time interval from agency approval until
full-time operation is estimated to be 37 weeks, including
12 weeks for fabrication and delivery of the control device.
Sources of Additional Information
Type of
Source , information*
1. Engineering and Cost Study of P, E, C
Emission Control in the Grain and
Feed Industry. Prepared by Midwest
Research Institute and PEDCo-
Environmental under Contract No.
68-02-0213. Environmental Protection
Agency, Research Triangle Park, North
Carolina, December 1973. 545 p.
2. Compilation of Air Pollutant E, C
Emission Factors, 2nd edition.
Environmental Protection Agency,
Research Triangle Park, North
Carolina. Publication No. AP-42.
February 1976. pp. 6.4-1 to 6.4-2.
*P = Process description
E = Emission rates
C = Control devices
3-133
-------
i
M
U>
D
Milestones
•Activity and duration in weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. UEEKS
10
36
37
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
M
4-5
Figure 3-67,
Schedule for installation of
on grain drying process.
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete, construction and system
tie-in
Perform startup, shakedown, and
emission testing
self-cleaning screen
-------
3.5.3 Phosphate Fertilizer
Process Description - Among the commonly produced, phosphate
fertilizers are normal superphosphate, triple superphosphate,
and ammonium phosphates. Normal superphosphate is produced
by reacting sulfuric acid with phosphate rock. Sulfuric
acid and phosphate rock are intimately mixed, dropped into a
den, held for sufficient time to allow the slurry mixture to
set, and then stored to permit the acidulation to go to
completion. Following the curing period, the solid fertil-
izer is either sold as run-of-pile (ROP) product or pro-
cessed further by (1) grinding and bagging or (2) granu-
lating and reacting with ammonia to produce a granular mixed
fertilizer. Figure 3-68 is a simplified flow diagram of a
normal superphosphate plant.
EXIT (GASEOUS FIUORIOE.PARTICUIATE AND SULFUR DIOXIDE)
EXIT (CASEOUS FLUORIDE)
EXIT (AMMONIA, PARTICULATE)
EXIT (AMMONIA, PARTICULATE,.
EXIT (PARTICULATE)
GASEOUS FLUO
DRYER
*
RIDE)
COOLER
RUN OF PILE PRODUCT ,
BAGGING PRODUCT
GRANULATED.
PRODUCT
Figure 3-68. Normal superphosphate plant.
3-135
-------
Triple superphosphate, which is also referred to as
double or concentrated superphosphate, is produced through
the reaction of phosphate rock and phosphoric acid. Unlike
production of normal superphosphate, the production of
triple superphosphate is usually a continuous operation in
large plants located near phosphate rock deposits.
Production is by two major processes. The first uses a
mixing cone to achieve' intimate contact between the acid and
rock. The resulting mix falls on a conveyor belt, which
moves the material to the curing building. After curing for
30 to 60 days, the product is sold as run-of-pile or is
granulated in separate equipment.
The second process produces granulated fertilizer
directly. Acid and phosphate rock are placed in mixing
tanks, fed through a plunger for intimate mixing and release
of some of the gases, and then dried in a rotary dryer. The
product is a directly granulated material that is rather
hard and dense and is normally not amenable to ammoniating.
Figure 3-69 is a simplified flow diagram for a triple super-
phosphate plant;
(AMMONIA. PIUOIIOE AND PAKTICUIAK)
PHOSPHATE HOCK
CXIT
(H.UOHIDE)
IXII
IPAITICUIATE. FIUOHIOE AND SUlfUl OXIDtl,
PHOSPHOIIC ACID
1
MIXED
1
LUNGEI
civil
fXII (PAITICUIATE)^
KKEN
GIANUIATCO
PIOOUCI
PHOSPHATI IOCK
Figure 3-69. Triple superphosphate plant.
3-136
-------
in production of diammonium phosphate, sulfuric and
phosphoric acids are mixed with ammonia in a reactor and the
/•* •;
product of the reactor is pumped as a slurry to a rotary
ammoniator. Ammonia is sparged underneath the mixing bed in
the ammoniator to achieve the desired ammonia level. While
the equipment is rotating, agglomeration takes place and the
ammoniation is completed. Diammonium phosphate granules are
discharged into a rotary dryer, then conveyed through a
screening station, and a rotary cooler and finally to
storage. A simplified flow diagram for a diammonium phos-
phate plant is shown in Figure 3-70.
FLUORIDES, AMMONIA, PARTICULATE
FLUORIDES, AMMONIA, fARTICULATE
EXIT
FLUORIDES, AMMONIA
FUEL DIAMMONIUM PHOSPHATE!
GRANULES
Figure 3-70. Diammonium phosphate plant.
3-137
-------
Atmospheric Emissions - The gases released from acidulation
of phosphate rock in normal superphosphate production
contain silicon tetrafluoride, carbon dioxide/ steam, and
sulfur dioxides. From 20 to 30 percent of the fluorine in
the phosphate rock is evolved during the acidulation and
curing operations. Vent gases from the granulator-ammonia-
tor may contain ammonia, silicon tetrafluoride, hydrofluoric
acid, ammonium chloride, and fertilizer dust. Emissions
from the final drying of granulated product include gaseous
and particulate fluorides, ammonia, and fertilizer dust.
In triple superphosphate production the exit gases from
plants producing nongranular products contain considerable
quantities of silicon tetrafluoride, some hydrogen fluoride,
and small amounts of particulates. Fluorides are also
emitted from the curing buildings. Emissions from run-of-
pile granulated superphosphate are mostly dust and fumes,
especially from the dryer and cooler.
The major pollutants from diammonium phosphate produc-
tion are fluorides, particulates, and ammonia. Vent gases
from the ammoniator tanks are the major source of ammonia
emissions.
Control Systems - Spray towers, grid packed towers, and
high-velocity jet scrubbers are used to control fluoride and
particulate emissions. Current practice is to scrub gases
with either water or dilute fluorosilic acid.
In triple superphosphate production, wet scrubbers are
the primary method for controlling emissions of gaseous
fluorides and particulate emissions. Packed towers, venturi
scrubbers, wet-pad scrubbers, and impingement scrubbers have
been used.
3-138
-------
Control of emissions from fertilizer granulation
involves collection of dry dust from rotary dryers and
rotary coolers, and collection of gas and dust from liquid-
solid reactor units. Various high-efficiency cyclones have
been used for removal of dust in exit gases, followed by wet
scrubbers to further reduce the dust content and to remove
the acid constituents.
These control devices are applicable to the five NSPS
categories of wet process phosphoric acid plants, super-
phosphoric acid plants, diammonium phosphate plants, triple
superphosphate plants, and granular triple superphosphate
storage facilities. (Recommended method of control is use
of a spray cross-flow packed scrubber).
Compliance Schedules - Figure 3-71 illustrates an expedi-
tious schedule for installation of a wet scrubber.
Sources of Additional Information
Type of
Source information*
1. Particulate Pollutant System Study. P, E, C
Volume III. Handbook of Emission
Properties. Prepared by Midwest
Research Institute for the U.S.
Environmental Protection Agency,
Durham, North Carolina. NTIS No.
PB 203 522. May 1971. pp. 313-338.
*P = Process description
E = Emission rates
C = Control devices
3-139
-------
I
M
*>
O
Milestones
•Activity and duration in weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-s1te construction or Installation of emission control equip-
ment is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
18
39
58
60
Activity
designation
A-B
A-C
C-0
D^'E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing .
Schedule for installation of a wet scrubber
Figure 3-71.
on phosphate fertilizer operation.
-------
3.5.4 Cotton Ginning
Process Description - Cotton ginning is the mechanical
separation of lint (cotton fibers) from trash (stems,
leaves, unopened bolls, and dirt) and cotton seeds. The
amount of trash in the seed cotton depends largely on the
harvesting method. Machine-picked seed cotton contains an
average of 172 pounds of trash for each 500-pound bale
2
produced. The quantity of trash per bale ranges from about
80 pounds for hand-picked cotton to almost 1200 pounds for
machine scrapped cotton. Along with this trash, there is
approximately 800 pounds of seeds per 500-pound bale of
2
cotton fiber. Figure 3-72 is a simplified flow diagram of
a typical cotton gin plant.
The seed cotton is generally removed from trucks with a
suction tube and is conveyed pneumatically throughout the
ginning processes. Dryers are used to maintain moisture
content of the lint within a 6.5 to 8 percent range. Each
drying step is generally followed by a cleaning step to
remove more trash. After the proper moisture content is
reached and most of the trash has been removed, the seed
cotton is fed to the gin stand. Seeds are separated from
the lint cotton and stored in a seed house until they are
sold to an oil mill for crushing or to a farmer for planting.
The lint cotton is cleaned again to remove fly lint, fine
dust, and small leaf particles and finally is condensed and
pressed into low-density bales (14 pounds per cubic foot).
Ginning plants generally operate 2 to 3 months per
year, the schedules depending on supplies of cotton and
availability of labor. Gin capacities range from less than
2
5 bales per hour to approximately 35 bales per hour.
Atmospheric Emissions - The primary emissions from cotton
gins are trash, dust, and lint. When cotton trash is
3-141
-------
•BYPASS^
UNLOADING
(TELESCOPE
SUCTION TUBE)
E)
]
STONE
TRAP
STONFS
TOWER
DRYER;
o o oo
U)
I
ro
GREEN BOLES
TRASH
TRASH
AIR
BATTERY CONDENSER
TRASH
TRASH
Figure 3-72. Cotton ginning process.
-------
incinerated, fly ash and smoke are emitted. Conical burners
are sometimes used for incineration. The major sources of
particulate from cotton gins include the unloading fan, the
4
cleaners, and the stick and burr machine. Quantity of
particulate emissions varies widely with condition of the
seed cotton and time and method of harvesting. A signifi-
cant amount of the particulates settles out in the ginning
plant. Taking this into consideration, uncontrolled emis-
4
sions are approximately as follows:
Estimated emissions
Process to atmosphere, Ib/bale
Unloading fan 5.0
Cleaner 0.30
Stick and burn machine 0.20
Miscellaneous 1.5
The particulates may contain chemicals, fungi, bacteria,
plant particles, and fly lint. The chemicals, which include
pesticides and herbicides, are potentially hazardous.
Control Systems - At present, low-pressure-drop cyclones and
lint filters are used at most gins. Particulate removal
efficiency is approximately 90 percent for the particle size
4
distribution found at cotton gins. Filters have been added
in series with cyclones to increase particulate removal
efficiencies to greater than 99.9 percent. A well-designed
baghouse alone can also control particulates with greater
than 99.9 percent efficiency.
Although scrubbers can also control cotton ginning
emissions effectively, they impose greater space and power
requirements and also generate problems of sludge and water
disposal.
3-143
-------
Compliance Schedule - Figure 3-73 shows a reasonable schedule
for installing a small packaged fabric filter. Total com-
pliance time is estimated to be 44 weeks, including 13 weeks
for control device fabrication. Installation of this device
in the off season would not interrupt production.
Sources of Additional Information
Type of
Source information*
1. Control and Disposal of Cotton P, E, C
Ginning Wastes. Public Health
Service, Cincinnati, Ohio.
Publication No. AP-31. 1967.
104 p.
2. Capital and Operating Cost Study P, C
of Model Cotton Gin Plants with
Pollution Control Systems. Prepared
by Research Triangle Institute and
PEDCo-Environmental Specialists, Inc.
for U.S. Environmental Protection
Agency. Contract No. 68-02-0607.
May 1974. 221 pp.
3. Parnell, C.B., Jr. and R.V. Baker. E
Particulate Matter Emissions by a
Cotton Gin. The Cotton Gin and Oil
Mill Press. April 17, 1971. 4 p.
4. Compilation of Air Pollutant Emission P, E
Factors, 2nd edition. U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina.
Publication No. AP-42. February
1976. p. 6.3-1.
5. What We Know About Air Pollution P, C
Control. The Texas Cotton Ginners
Association, Dallas. March 1965.
31 p.
*P = Process description
E = Emission rates
C = Control devices
3-144
-------
D
Milestones
•Activity and duration in weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or installation of emission control equip-
ment Is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G. WEEKS
13
28
41
Ul
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Figure 3-73.
Activity
designation Activity description
K-L Review and approve assembly draw-
inps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, .shakedown, and
emission testing
Schedule for installation of a small packaged fabric filter
on a cotton ginning plan-W
-------
3.5.5 Alfalfa Dehydrating
Process Description - An alfalfa dehydrating plant produces
animal feed from alfalfa. Chopped alfalfa is dried and
ground, then is either bagged and stored, or is pelletized
or blended before shipping. Figure 3-74 shows a typical
alfalfa dehydrating plant.
Moisture content of the alfalfa feed is reduced from
approximately 80 percent to 8 to 10 percent in a gas- or
oil-fired drum dryer. Drying temperatures range from 1800
to 2000°F where the alfalfa first contacts the flue gases to
between 250 and 350°F at the dryer outlet. After passing
through the dryer, the alfalfa usually is blown into a
primary cooling cyclone, which separates it from the moist
flue gases. From the primary cyclone, the alfalfa, now at
approximately 140°F, is conveyed by gas-cooled, dry air to a
secondary cooling cyclone. At the secondary cyclone exit
the alfalfa is at about 110°F and ready for grinding.
A hammermill is usually used to grind the dehydrated
alfalfa into meal. Vegetable oil or animal fat is sometimes
added during grinding to preserve the carotene content of
2
the meal. After grinding, a cyclone collects the meal for
bagging, bulk storage, or pelletizing. The meal is fre-
quently steam-extruded into pellets to minimize storage and
shipping requirements. Larger dehydrating plants also
produce formula feeds. For this process, the pellets are
reground and the meal is mixed with additives in a blender.
A typical alfalfa dehydrating plant operates 24 hours
per day, 7 days per week during the production season, which
generally lasts from May to October. Plant capacities range
from under 1000 to over 35,000 tons per year.1
Atmospheric Emissions - Particulate emissions are the pri-
mary concern of the alfalfa dehydrating industry. Sources
3-146
-------
Pellet V
Cooler | |
Cyclone I
Not.:
Secondary cyclone collectors
may not be used and in some
cases the cyclone effluents
may be ducted back to the
primary cyclone.
oonaajaflaBoaoj.
Screw Conveyor
(Mining Chamber)
Secondary
Pellet
Collector
|* | Collector
^n
Fresh Cut
Alfalfa (Green Chaps)
from the Field
A
JL
Natural
Gas
Steam
Prlle'i to Storoa.
or Cc. Loooinc
Hoi-
3-74. Alfalfa dehydration process.
-------
of particulate emissions are the cooling cyclones, the
grinder, the meal air separator, pellet meal in separator,
and blending operations.
The primary cooling cyclone is the major source of
emissions. Approximately 15 pounds of particulate is
i
emitted per ton of meal. The effluent from the cyclone
also includes combustion products, billowing clouds of
condensed steam, and odorous volatile matter from the
alfalfa meal.
Total particulate emissions from the plant probably do
not exceed 20 pounds per ton of meal. This figure does not
include emissions attributed to blenders, which are operated
only in large alfalfa dehydrating installations. Adding
vegetable oil or animal fat at the milling operation will
decrease the uncontrolled emissions associated with sub-
sequent handling and storage operations.
Control Systems - Cyclones are commonly used throughout the
industry for product recovery. A plant using no secondary
controls may lose 1 to 3.5 percent of its meal production to
2
the atmosphere. Cyclones, fabric filters, and low-energy
wet scrubbers (2 to 10 inches water gage pressure drop) have
been used as secondary control devices for the primary
cooling cyclone and the hammermill. Fabric filters or wet
scrubbers are generally required to reduce particulate
emissions below state regulations. In general, the partic-
ulate collection efficiencies of wet scrubbers with pressure
drops of 3 to 10 inches are about 60 percent. Fabric
filters can attain efficiencies greater than 99.5 percent.
The addition of vegetable oil to the alfalfa during
grinding promotes agglomeration, which in turn reduces
dustiness and increases removal efficiency of the cyclone.
The oily meal could cause plugging in most fabric filters.
3-148
-------
A high-energy air filter could be used if plugging problems
occur. A pressure drop of more than 20 inches is required
for maximum efficiency of a high-energy filter, and the unit
4
operates at air-to-cloth ratios of 500/1 to 1500/1.
Compliance Schedule - Figures 3-75 through 3-77 show com-
pliance schedules for a low-energy wet scrubber, a baghouse,
and a high-energy filter. Each control device is designed
to control a primary cooling cyclone with a typical exhaust
rate of 30,000 acfm at 225°F. Installation schedules range
from 41 weeks for the high-energy air filter to 53 weeks for
the small baghouse. A low-energy wet scrubber requires 48
weeks for installation. In all cases, fabrication repre-
sents the major time increment, totalling 14, 16, and 20
weeks for the air filter, baghouse, and scrubber, respec-
tively. Any control device could be installed in the off
season and would not interrupt production.
3-149
-------
GJ
I
h-
Ui
o
D
Milestones
•Activity and duration 1n weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
12
31
44
48
.Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Figure 3-75.
Activity
designation Activity description
K-L Review and approve assembly draw-
inps
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R.-4 Complete construction and system
tie-In
4-5 Perform startup, shakedown, and
emission testing
Schedule for installation of a low-energy wet scrubber
on an alfalfa dehydration process.
-------
UJ
i
M
Ul
D
Milestones
•Activity and duration 1n weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-s1te construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
12
31
52
55
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-6 Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-In
4-5 Perform startup, shakedown, and
emission testing
Figure 3-76.
Schedule for installation of small fabric filter
on an alfalfa dehydration process.
-------
I
M
ui
Milestones
Activity and duration in weeks
Refer to Chapter 2 for time
increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or Installation of emission control
equipment.
Date by which on-s1te construction or installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
10
29
_39_
41
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
6-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
inos
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R.-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-77. Schedule for installation of a high-energy air filter
on an alfalfa dehydration process.
-------
Sources of Additional Information
Type of
Source information*
1. Engineering and Cost Study of P, E, C
Emission Control in the Grain and
Feed Industry. Prepared by Midwest
Research Institute and PEDCo-
Environmental under Contract No.
68-02-0213. Environmental Protection
Agency, Research Triangle Park, North
Carolina. December 1973. 545 p.
2. Alfalfa Dehydrating Engineering Guide P, E, C
For Processing OEPA Air Pollution
Permits. Industrial Pollution Section,
OEPA, Columbus, Ohio. July 1973.
p. 6-1-1 to 6-1-9.
3. Particulate Emissions from Alfalfa
Dehydrating Plants - Control Costs
and Effectiveness. Prepared by
American Dehydrators Association under
Grant No. R801446. Environmental
Protection Agency, Washington, D.C.
January 1974. 122 p.
4. HEAF. Manufactures Bulletin 113 5/75.
Anderson 2000, College Park, Georgia.
May 1975. 4 p.
*P = Process description
E = Emission rates
C = Control devices
3-153
-------
3.6 PRIMARY METALLURGICAL PROCESSES
3.6.1 Metallurgical Coke
Process Description - Coke, an essential component in the
manufacture of iron and steel, is the residue from the
destructive distillation of coal. By-product coking, which
is by far the most common process in the United States, is a
batch process generally involving batteries of 50 ovens or
more. These slot coke ovens, in which coal is heated in the
absence of air, are narrow refractory channels. Gas-fired
flues between adjoining ovens keep the ovens at coking
temperature.
Initially, coal is blended to give uniform coking
characteristics, then pulverized in hammermills and trans-
*ferred to a storage silo above the battery of ovens. A
weighed portion of coal is then discharged into a larry car,
which is a wide-gauge vehicle fitted with coal hoppers. The
coal is transferred from the hoppers into three to six
opened coal-charging ports above an empty oven. The oven-
charging ports are then closed for the duration of the
coking cycle.
As the charged coal is heated, a wide range of organic
compounds are emitted, and collected in standpipes or
exhaust flues. These gases are sent to a by-product re-
covery section for separation and recovery of such by-
products as tar, light aromatic compounds, and ammonia
liquor. The remaining coke oven gas containing methane,
hydrogen, and carbon monoxide is used as fuel in the plant
or flared.
Upon completion of the coking cycle, both oven end
doors are opened and the incandescent coke is forced into a
hot-coke car at one end of the oven by a large pusher ram at
the opposite end. The hot-coke car, or quenching car, moves
3-154
-------
the coke to a quenching tower, a chimney-like structure in
which the coke is deluged with water. The damp/ quenched
coke is then deposited in a sloping wharf, in which it
drains and cools to uniform moisture content and tempera-
ture. Figure 3-78 illustrates the overall coking process.
Atmospheric Emissions - The primary pollutants from coke
manufacture are coal and coke dust, sulfur compounds, light
hydrocarbons and aromatics, carbon monoxide, nitrogen
oxides, and reduced sulfur compounds. Emissions can occur
during coal handling, charging, coking, pushing, and quenching,
The emission sources of primary concern are charging pots,
oven doors and take-offs, pushing and quenching operations,
and coke-oven gas combustion stacks.
Major emissions occur at the point of charging the coal
to the hot oven, since the rapid heating of the coal causes
volatilization of gases from the coal mass. These gases
escape to the atmosphere through the charging ports, larry
car hoppers, and drop sleeves unless controlled. Emissions
also occur in the early stages of coking because of leaks at
the charging ports, off-takes, and around the sealed end
doors.
Coke-oven gas recovered in the by-product recovery
system typically contains 3.5 to 4.5 grains per standard
cubic foot of hydrogen sulfide. Use of the coke-oven gas
for fuel in heating or underfiring the coke ovens and for
other combustion operations causes sulfur oxide emissions
unless the hydrogen sulfide has been removed.
Emissions resulting from discharge of the coke from the
ovens consist of smoke from any incompletely coked coal and
dust released as the coke is pushed into the hot-coke car.
Quenching of the hot coke results in a fine coke breeze
formed during the pushing of the hot-coke car and as water
3-155
-------
RAWCOAl STORAGE
PULVERIZER
PREPARED COAL BINS
OIL
COAL BLENDING
AND MIXING
COAL BUNKER
LARRY CAR
COKE OVEN
AIR
•
HOT -COKE
CAR
WATER,-
QUENCH
TOWER
BY-PRODUCTS
RCCOVLRY
SYSTEM
COKE OVEN
FUEL GAS
•TAR
•CHEMICALS
MISCELLANEOUS
" FU:L USAGES
COKE WHARF
COKt CRUSHER
SCREENING
MISCELLANEOUS
FUEL USAGES
• BLAST FURNACE
Figure 3-78. Metallurgical coke manufacturing.
3-156
-------
is flash-evaporated within the coke itself, in addition,
use of contaminated water for quenching can cause emissions
of ammonia and phenol vapors.
Control Systems - A procedure commonly used to reduce emis-
sions during coal charging is termed "charging on the main."
A steam ejector in the ascension pipe produces a vacuum in
the oven during the charging period and the gases are pulled
into the gas collector main. Although it has undergone some
improvements, this technique alone is generally considered
to be ineffective. Two improvements are charging on the
main with staged or sequential charging and pipeline charg-
ing. Charging on the main with staged charging can be
readily incorporated into an existing plant. Features of
this system include sequencing of larry car coal charging to
prevent a surge of pollutant-laden gases, maintaining some
portion of charge in the hopper car to prevent the escape of
gases at the port, and maintaining a steady negative pres-
sure in the oven to continually draw off the evolved gases.
Removal of gases from both ends of the oven should be
practiced because of the possibility of blockage of the free
space. Dual collecting mains or jumper pipes can be used
for this purpose.
Pipeline charging involves preheating coal to drive off
moisture and transporting it by pipeline. Although a 40 to
50 percent increase in oven productivity can be realized
with this method, it is considerably more expensive, re-
quiring far more extensive equipment changes than staged
charging. Due to these changes, pipeline charging systems
cannot be readily retrofitted. Furthermore, the capacity of
the by-product recovery system must be increased to accom-
modate the increase in oven capacity.
3-157
-------
Several systems have been considered for control of
pushing emissions. One operating system consists of an
enclosed quench car, which is attached to a second car that
carries a wet scrubber unit. During the pushing operation,
emissions are collected in the enclosed car and withdrawn
through ductwork between the cars to the wet scrubber unit.
A traveling hood system has also been used for emission
control. A hood is installed on a track so that it can be
moved to cover the oven in the battery being pushed. The
hoods are normally ducted to a stationary scrubber. Another
control technique is to install a shed enclosing the entire
coke side of the battery. The dust and smoke collected in
the shed are then exhausted through a particulate control
device such as a scrubber or a wet ESP.
During coking, the generated gases and particulate are
collected from the oven by an off-take system which maintains
a slightly positive pressure in the oven. This positive
oven pressure provides an oxygen deficient atmosphere for
coking, but leads to door and top-side leaks. Good prac-
tices for maintenance and replacement of doors can minimize
such emissions. New designs such as vented flue doors can
be utilized to reduce coking door emissions. Vented flue
doors provide a passage for gases that are generated at the
bottom of the oven during the beginning of the coking cycle
to the free space in the top of the oven. High pressures at
the base of the oven are caused by the lack of gas passages
through the coal mass early in the cycle. As coking proceeds,
fissures form in the mass and reduce the pressure in the
bottom of the oven.
Particulate emissions from the coke battery stack can
be controlled by wet and dry ESP's. Charged-droplet scrub-
bers are also being considered for particulate control.
3-158
-------
Coke oven gas, after by-product recovery, may require desul-
furization before it is used as fuel. For removal of
hydrogen sulfide from coke oven gas, the vacuum carbonate
process is the most widely accepted method applied on a
large scale. Hydrogen sulfide is absorbed by a sodium
carbonate solution and then released in a concentrated H2S
stream by steam stripping. By this method the H2S level in
the gas stream can be reduced by about 93 percent. A sul-
fur-recovery plant is normally used in conjunction with the
vacuum carbonate process to convert the recovered H2S into
elemental sulfur. Other desulfurization processes such as
the Stretford process may also be used.
Generally, quenching emissions can be controlled by
installation of baffles, with or without water sprays,
in existing quench towers. Other techniques are quenching
coke by spraying it on a controlled moving grate or rotary
table, which is ducted to a wet scrubber, and quenching the
coke with an inert gas such as nitrogen instead of water.
Compliance Schedules - Figure 3-79 illustrates a reasonable
schedule for installation of staged charging at existing
coke oven batteries. Differences in existing equipment may
alter certain parts of the schedule.
Figures 3-80 through 3-82 represent estimated schedules
for installation of a closed car system, a shed, and a
traveling hood system, respectively, for emissions control
during pushing.
Figure 3-83 illustrates a reasonable schedule for
installation of a coke oven gas desulfurization system.
When desulfurization is not used at a coke battery, particu-
late emissions can be controlled by a wet or dry electro-
static precipitator. A complete door modification may be
necessary to minimize leakage from the coke oven doors.
3-159
-------
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
Increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
26
62
70
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
0-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawlnas
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-79. Schedule for larry car modifications required for staged
charging on a coke oven battery.
-------
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
10
28
80
92
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commi t funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate'control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Schedule for installation of closed car system
Figure 3-80.
for controlling coke-pushing emissions.
-------
D
Milestones
•Activity and duration 1n weeks
U)
I
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
10
32
79
89
ro
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Figure 3-81.
Activity
designation Activity description
K-L Review and approve assembly draw-
Ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Schedule for installation of a shed for controlling
coke-pushing emissions.
-------
CT\
LJ
n
Milestones
Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submtttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment. •
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
10
27
74
89
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-82.
Schedule for installation of a traveling hood to
control coke-pushing emissions.
-------
U)
I
M
CTl
Milestones
•Activity and duration in weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G, WEEKS
2
10
34
82
106
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
0-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Figure 3-83,
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings 4-5
Schedule for the installation of
desulfurization system.
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
Perform startup, shakedown, and
emission,testing
a coke oven gas
-------
Figures 3-84 and 3-85 show expeditious schedules for door
modification and for installation of a wet or dry ESP,
respectively.
Sources of Additional Information
Type of
Source information*
1. Barnes, T.M., et al. Evaluation P, E, C
of Process Alternatives to Improve
Control of Air Pollution from
Production of Coke. Prepared by
Battelle Memorial Institute for
the U.S. Public Health Service,
Cincinnati, Ohio. NTIS No.
PB-189-266. January 1970. 178 p.
2. Kirk-Othmer Encyclopedia of Chemical C
Technology, 2nd edition. Volume 19.
Interscience Publishers, New York,
1969. p. 383
3. Control Techniques for Sulfur E, C
Oxide Air Pollutants, 2nd edition.
U.S. Environmental Protection
Agency, Research Triangle Park,
North Carolina. November 1972.
4. Coke Ovens - Particulate Emission P, E, C
Control Analysis, Empire-Detroit
Steel, Portsmouth Works. Prepared
by PEDCo-Environmental Specialists,
Inc. for Ohio Environmental Protection
Agency, Columbus, Ohio. May 1975.
53 p.
5. Kulujian, N.J. By-Product Coke P, E
Battery Compliance Evaluation.
Prepared by PEDCo-Environmental
Specialists, Inc. for U.S. Environ-
mental Protection Agency under
Contract No. 68-02-1321, Task No.
13. June 1975.
*P = Process description
E = Emission rates
C = Control devices
3-165
-------
Milestones
•Activity and duration 1n weeks
U)
I
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-s1te construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G. WEEKS
11.
36
75
85
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Figure 3-84,
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings 4-5
Schedule for converting to vented
coke oven emissions.
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing . ,
doors to control
-------
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
12
30
62
65
Activity
designation Activity description
A-B Conduct sourcg tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
i nps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Figure 3-85. Schedule for installation of a wet or dry ESP to control
particulate emissions from coke oven battery stacks.
-------
3.6.2 Primary Aluminum
Process Description - Bauxite is the principal ore of
aluminum. It consists of aluminum oxide and various impuri-
ties, such as iron oxide, aluminum silicate, and titanium
dioxide. The production of alumina, which consists of
separating it from the impurities in the bauxite ore, is
accomplished entirely by chemical means. In the Sainto-
Claire Deville process, the sodium aluminate is prepared by
calcining the bauxite with sodium carbonate at 2000°F; the
calcined material is then washed with alkali, yielding a
sodium aluminate solution from which the alumina is pre-
cipitated by carbon dioxide. In the Bayer process, a more
recent development, the separation is carried out entirely
in the aqueous phase, taking advantage of the solubility
equilibria of the alumina hydrates in a caustic soda solu-
tion.
Aluminium is produced electrolytically from alumina.
The alumina is decomposed by a continuous current that flows
through the electrolytic cell containing alumina dissolved
in molten cryolite.
The electrolyte cell consists of a carbon-lined box
containing a pad of molten aluminium that serves as a
cathode, a carbon anode, and the alumina-cryolite bath.
Usually 100 cells, commonly called reduction pots, are
connected in series to form a potline, each plant operating
three to ten potlines. Figure 3-86 illustrates a pictorial
flow chart of primary aluminum production.
Atmospheric Emissions - Emissions from the electrolyte cell
consists primarily of particulates containing fluorides. In
addition to fluorine, exhausts from the cells contain sulfur
dioxide from the sulfur impurities in the anodes, tarry
hydrocarbons, alumina and carbon particles, and oxides of
carbon.
3-168
-------
u>
I
!-•
(Ti
VO
REDUCTION
PLANT
REFINING
AND CASTING
CARBON
MIX PLANT
RAW MATERIAL
(SHIP OR RAIL)
ALUMINUM
SHIPMENT
POWER
Figure 3-86. Aluminum reduction process.
-------
Other atmospheric emissions in aluminum reduction
plants are caused by certain peripheral operations. Among
these are anode and paste manufacturing/ which emits high-
molecular-weight hydrocarbons and small carbon particles.
The molten metal purification, alloying, and casting opera-
tions cause further emissions, mainly chlorides of aluminum
and small amounts of hydrogen chloride and chlorine. A
third peripheral operation related to the manufacture of
anode and paste is the production of calcined petroleum
coke. This operation involves heating the material to drive
off moisture and volatiles, and transforming the carbon from
an insulating to a conducting carbon.
Control Systems - As noted above, the principal potential
pollutants in the electrolytic cell effluent are (1) parti-
culate solids, including solid fluorides and alumina, (2)
gaseous hydrogen fluoride, and (3) condensed hydrocarbons
(from Soderberg cells).
Because of specific problems encountered in use of each
type of electrolytic cell, the control systems for each are
discussed separately.
1) Vertical-Spike Soderberg Cell - Gases and dust
from the bath can be collected by a hood around the bottom
of the anode. The dust content of the raw gas is reduced in
the collection system by burning the tar components in
combination with the carbon monoxide with a burner located
in the collection channel. Final treatment of the gas
consists of passage through a dry cyclone to collect the
coarse particles (in some installations followed by a
filter) followed by two to three stages of wet scrubbers
that use water to recover the hydrogen fluoride. A final
stage of alkaline scrubbing may be required to remove sulfur
dioxide and the remaining fluoride.
3-170
-------
2) Horizontal-Spike Soderberg Cells - The arrangement
of the spikes in horizontal-spike soderberg cells makes it
difficult to effect a good seal around the anode, and there-
fore large quantities of diluting air enter the gas cleaning
system. The dilution is so great that combustion to destroy
the tars is neither economical nor feasible.
One installation in Canada reportedly has overcoirie the
i
problem of tar interference in the wet scrubber operation by
using a turbulent-bed scrubber. The combined action of an
upward flow of gas and the downward flow of the scrubbing
liquid maintains the spheres in a loose assembly and pro-
motes intimate mixing. Turbulence around the loose spheres
keeps them free of tars and dirt. Field tests have shown
that this type of scrubber can remove 90 percent or more of
hydrogen fluoride.
3) Prebaked Cells - When cells with prebaked anodes
are used, it is difficult to draw off furnace gases in
concentrated form directly from the cells because of the
large number of anodes. On these pots, an exhaust hood
usually encloses the active area and maintains it at a
slightly negative pressure.
Pollution control with the prebaked cell consists of a
dry cyclone or electrostatic precipitator for removal of
particulates, followed by a wet scrubber to absorb the
highly soluble hydrogen fluoride and the remaining traces of
fluoride particulates.
A more recent method for recovering gaseous fluorides
from prebaked potlines entails the use of a heavy bed of
alumina, which is continually added on the upper crust of
the cell. Contaminants are removed by filtering the gases
through the bed of alumina; stray particulates are captured
by a baghouse further downstream.
3-171
-------
Compliance Schedules - Figures 3-87, 3-88, and 3-89, illus-
trate expeditious schedules for installation of a wet scrub-
ber system, a fabric filter, and an electrostatic precipi-
tator on a primary aluminum reduction operation. The
complexity of the ductwork and hooding systems required for
effective control was considered in developing the schedules.
Additional time was included to reflect the extra work
required for design, fabrication, and installation. No
compliance schedule is shown for installation of dry cyclones
or afterburners, since these devices can be installed
relatively quickly and construction can be accomplished
within the elapsed time shown for any of the other control
devices mentioned.
Sources of Additional Information
Type of
Source information*
1. Kirk-Othmer Encyclopedia of Chemical P
Technology, 2nd edition. Volume 1.
Interscience Publishers, New York.
1967.
2. Air Pollution Control Field Operations P
Manual, Revised Edition. Volume III.
Prepared by System Development Corp.
for the U.S. Environmental Protection
Agency, Raleigh, North Carolina under
Contract No. CPA 70-122. February 1972.
3. Rush, D. et al. Air Pollution Abate- P, E, C
ment on Primary Aluminum Potlines.
Journal of the Air Pollution Control
Association, 23 (2):98-104, 1973.
*P = Process description
E = Emission rates
C = Control devices
3-172
-------
U)
D
Milestones
Activity and duration In weeks
Refer to Chapter 2 for time
Increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
18
43
72
75
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, 'and
emission testing
Figure 3-87.
Schedule for installation of a wet scrubber on a primary
aluminum reduction operation.
-------
OJ
I
D
Milestones
•Activity and duration in weeks
MILESTONES
1
Z
3
4
5
Refer to Chapter 2 for time
increments A to 6.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G, UEEKS
14
38
71
75
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-0 Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
inos
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4. Complete construction and system
tie-In
4-5
Perform startup, shakedown, and
emission testing
Figure 3-88. Schedule for installation of fabric filter on a
primary aluminum reduction operation.
-------
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-s1te construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G. WEEKS
20
49
108
114
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q • Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Figure 3-89.
Perform startup, shakedown, and
emission testing
Schedule for installation of an electrostatic precipitator
on a primary aluminum operation.
-------
3.6.3 Ferroalloys
Process Description - Ferroalloys, the generic term for
alloys consisting of iron and one or more other metals, are
used for deoxidation, alloying, and graphitization of steel.
They can be classified into three basic types according to
the major nonferrous constituent: (1) silicon-based alloys,
such as ferrosilicon; (2) manganese-based alloys, such as
ferromanganese; and (3) chromium-based alloys, such as
ferrochromium.
Blast furnaces and electric arc furnaces are both used
to produce ferroalloys. Ferromanganese is produced in blast
furnaces by the reduction of iron ore and manganese ore with
coke in the presence of limestone. Approximately 75 percent
of the ferroalloys, however, are produced in electric arc
furnaces.
Other ferroalloy manufacturing processes, used to a
much lesser extent, are the alumino silico-thermic process
and the electrolytic deposition process. Figure 3-90
presents a detailed flow diagram for a ferroalloy production
process.
Atmospheric Emissions - Particulates emitted from the fur-
nace are the primary emission problem. The chemical and
physical properties of the particulates depend upon the
alloy being produced and the type of furnace. Particle
sizes generally range from 0.1 to 1.0 micron, with a geomet-
ric mean of approximately 0.3 micron.
Particulate emissions from silicon alloy manufacture
contain a high percentage of Si02. They also contain some
tars and carbon caused by the use of coal, coke, or wood
chips in the charge. Chromium furnaces produce Si09 fume
similar to that generated in a ferrosilicon operation, with
some additional chromium oxides. Manganese operations
produce a brown fume, largely a mixture of Si09 and manganese
^
oxides.
3-176
-------
OUST
FUMES
U>
1
UNLOADING ASSORTMENT ORE STORAGE
CRUSHING SCREENING STORAGE
SHIPMENT
Figure 3-90. Ferroalloy production process.
-------
Control Systems - Blast furnace emissions are most commonly
controlled by a high-energy wet scrubber., Electric furnaces
can use either an open or closed furnace hooding design. In
open furnaces all the CO produced burns with induced air at
the top of the charge, resulting in a large volume of high-
temperature gas. In closed furnaces most or all of the CO
is withdrawn from the furnace without combustion with air.
High-energy venturi scrubbers are the most commonly
used control devices for both open and closed furnaces. The
pressure drop required for high-efficiency particulate
collection is about 60 inches water gauge for a ferrosilicon
or ferrosilicochrome operation. Substantially all of the
sulfur in the reducing agent appears in the gas phase,
creating a potential corrosion problem for liquid recycle
systems unless neutralizing agents or special materials of
construction are used.
Fabric filters can also operate effectively provided
the gas temperature is reduced below 500°F. In silica fume
collection, however, a buildup of electrostatic charge leads
to a high residual pressure drop across the bags.
Electrostatic precipitators have been used only to a
limited extent.
Compliance Schedules - Figures 3-91, 3-92, and 3-93 illus-
trate expeditious schedules for installing a high-energy wet
scrubber system, a fabric filter, and an electrostatic
precipitator on ferroalloy furnaces.
3-178
-------
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
Increments A to G.
Date of submfttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-sKe construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
16
40
60
63
vo
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
Inos
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
a-5
Figure 3-91,
Perform startup, shakedown, and
emission testing
Schedule for installation of a high-energy wet scrubber on a
ferroalloy furnace.
-------
u>
I
M
00
o
Milestones
Activity and duration 1n weeks
Refer to Chapter 2 for time
increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-s1te construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
17
41
78
82
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
6-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-H Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R.-4 Complete construction and system
tie-in
4-5
Figure 3-92.
Perform startup, shakedown, and
emission testing
Schedule for installation of a fabric filter with
pre-cooler on a ferroalloy furnace.
-------
CO
M
00
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G. WEEKS
19
42
82
87
Activity
designation
A-B
A-C
C-0
D-E
E-F
F-6
6-1
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
Inps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Schedule for installation of an electrostatic
Figure 3-93.
precipitator on a ferroalloy furnace
-------
Sources of Additional Information
Type of
Source information*
1. Particulate Pollutant System Study. P, E, C
Volume III. Handbook of Emission
Properties. Prepared by Midwest
Research Institute for U.S. Environ-
mental Protection Agency, Durham,
North Carolina. NTIS No. 203 522.
May 1971. 613 p.
2. Background Information for Standards
of Performance: Electric Submerged
Arc Furnaces for Production and
Ferroalloys. Volume 1. U.S.
Environmental Protection Agency.
Publication No. EPA 450/2-74-018A.
October 1974.
*P = Process description
E = Emission rates
C = Control devices
3-182
-------
3.6.4 Primary Copper, Lead and Zinc
Process Description - Copper, lead, and zinc are recovered
from sulfide ores. Both pyrometallurgical and electrolytic
methods are used. Each metal is recovered by oxidizing the
sulfide ores, reducing the oxides to a crude metal product,
and finally refining the metal. Electrolytic techniques are
normally used when high-purity metal is required.
Copper is recovered by four steps: roasting, smelting,
converting, and refining. The roasting of copper sulfide
ore concentrates is basically a process in which the concen-
trates are heated in air (or oxygen-enriched air) to the
temperature necessary for removing some of the sulfur as
sulfur oxides. Multiple hearth and fluid bed roasters are
used. Some copper plants charge the ore directly into the
reverberatory furnace without roasting.
The roasted product (calcine) is smelted in a rever-
beratory or electric furnace to produce copper-iron sulfide
matte and a silicious slag. This matte is treated in a
converter to product blister copper and then sent to a. hold-
ing furnace for further refining by electrolytic or fire-
refining. A flow diagram of primary copper metallurgy is
shown in Figure 3-94.
Lead concentrates are first sintered to convert the
lead sulfides into oxides, to purify the concentrate by
volatilizing some contaminants, to provide a feed with a
proper ratio of materials for subsequent smelting opera-
tions, and to produce a clinker for blast furnace feed. The
blast furnace reduces the lead oxides to metallic lead.
From the blast furnace, the bullion is drossed. The dross
is sent to a dross reverberatory furnace to recover the lead
and the lead bullion is sent to the refining process.
Refining requires many steps to remove antimony, tin, arsenic,
3-183
-------
STACK
U)
MINE
ORE
DUST
COLLECTORS/
BAGHOUSE
-LIME
-WATER
-FROTHING
-pH CONTRC
*
CONCENT
CYCLONE OR
SETTLING FLUE
'
AGENTS
L AGENTS
AT CONCENTRA1
FUE
\
»
:L
AIR
FLUXES
CONTROL DEVICE
ROASTER
CALCINE ,
t
i
WATER SPRAY OR
SETTLING CHAMBER
l
WASTE HEAT
BOILER
FLUXES
COPPER P
-CONVERTE
FLUE DUS"
BALLOON
FLUE
i
ECIPITATES
I SLAG
rFLUX
I SMELTING
FURNACE
-HOT AIR
-FUEL
MATTE
»
NVE
t
DILUTION AIR
-COLD BLISTER
-FLUXES
-AIR
-HYDROGEN
-OTHERS
„,,:,, BLISTER „ DCI-TIJCDV COPPER
COPPER" REFINERY >•
<» -i
1 1
FUEL SLIMES
Figure 3-94. Primary copper smelting flow diagram.
-------
precious metals, zinc, bismuth and other substances. A flow
diagram of primary lead smelting is shown in Figure 3-95.
Zinc production is represented in Figure 3-96. The
concentrate is first roasted to remove sulfur. Roasting is
followed by either pyrometallurgical or electrolytic pro-
cessing to recover metallic zinc. The first step in pyro-
metallurgical processing is sintering, which volatilizes
lead and cadmium and creates a hard, porous mass for retort
furnace feed. In the furnace it is reduced to zinc metal.
Three types of retorts are used at primary zinc smelters -
horizontal, vertical, and electrothermic. In electrolytic
processing, the roasted concentrate is first leached in
sulfuric acid to dissolve the zinc, then purified by various
filtration and precipitation steps before recovery of
metallic zinc by electrolysis.
Atmospheric Emissions - The major pollutants from nonferrous
smelting operations are particulate and sulfur dioxide.
Emission factors for copper, lead, and zinc smelting are
shown in Tables 3-1, 3-2, and 3-3, respectively.
3-185
-------
CO
I
!-•
00
Figure 3-95. Primary lead smelter.
-------
CONCENTRATION
ROAST
ACID
LEACH
SINTER
PURIFI-
CATION
RETORT
ELECTRO-
LYSIS
ACID
PLANT
Figure 3-96. Plow diagram of primary zinc production.
3-187
-------
Table 3-1. EMISSION FACTORSa FOR PRIMARY COPPER
SMELTERS WITHOUT CONTROLS2
Type of operation
Roasting
Smelting (reverberatory furnace)
Converting
Refining
Total uncontrolled
Particulates,
Ib/ton
45
20
60
10
135
kg/MT
22.5
10
30
5
67.5
Sulfur b
oxides,
Ib/ton
60
320
870
1250
kg/MT
30
160
435
625
a Approximately 4 unit weights of concentrate are required to
produce 1 unit weight of copper metal. Emission factors
expressed as units per unit weight of concentrated ore pro-
duced.
b
Sulfur oxides can be reduced by about 90 percent by using
a combination of sulfuric acid plants and slurry scrubbing.
Table 3-2. EMISSION FACTORS FOR PRIMARY LEAD
SMELTING PROCESSES WITHOUT CONTROLS2
Process
Sintering (updraft)
Blast furnace
Dross reverberatory
furnace
Materials handling
Particulates , a
kg/MT
106.5
180.5
10.0
2.5
Ib/ton
213.0
361.0
20.0
5.0
Sulfur dioxide ,a
kg/MT
275.0
22.5
Neg
Ib/ton
550.0
45.0
Neg
Emission factors expressed as kilograms per metric ton (or
pounds per ton) of lead product.
3-188
-------
Table 3-3. EMISSION FACTORS3 FOR PRIMARY ZINC
SMELTING WITHOUT CONTROLS2
Type of operation
Roasting (multiple-hearth)
Sintering
Horizontal retorts
Vertical retorts
Electrolytic process
Participates,
Ib/ton
120
90
8
100
3
kg/MT
60
45
4
50
1.5
Sulfur dioxide,
Ib/ton
1100
b
kg/MT
550
b
Approximately 2 unit weights of concentrated ore are
required to produce 1 unit weight of zinc metal. Emis-
sion factors expressed as units per unit weight of concen-
trated ore produced.
Included in S02 losses from roasting.
Control Systems - Particulate emissions from nonferrous
smelter sources are controlled by electrostatic precipi-
tators, high-energy scrubbers, and fabric filters. Sulfur
oxide emissions are generally recovered by use of absorption
systems that produce sulfuric acid or elemental sulfur.
The primary copper industry typically uses particulate
controls on the roaster, smelting furnace, and converter and
sulfur oxide controls on the converter. Fabric filters are
not used on roaster effluent because of the corrosiveness of
the exit gases and the temperature limitations of the bags.
Mechanical collectors and sprays are often used upstream of
electrostatic precipitators controlling roaster and furnace
emissions to decrease dust loadings and condition the gas.
Before the converter gases pass through the absorption
system, most of the particulates are removed by high-energy
scrubbers, fabric filters, or ESP's.
3-189
-------
The primary lead industry normally controls particu-
lates from the sinter machine and dressing furnace by adding
an ESP or a fabric filter in series with a mechanical col-
lector. An ESP in series with a centrifugal collector can
be used to control blast furnace emissions. Sulfur oxides
are collected from sinter plant exhausts by an absorption
system following the particulate controls and are converted
into sulfuric acid or elemental sulfur.
As in the lead industry, primary zinc smelters collect
the S02 from the sintering exhaust gases and convert it into
sulfuric acid by the contact process. The sinter plant
gases must be precleaned by ESP's, fabric filters, or high-
energy scrubbers. Roasting and vertical hearth reduction
processes are controlled by particulate control systems.
Horizontal retorts are not controlled.
Compliance Schedules - Because of the similarities of the
primary copper, lead, and zinc industries, an expeditious
installation schedule for each type of control system would
require approximately the same time period regardless of the
applicable process or the metal industry- Figures 3-97
through 3-99 show installation schedules for an ESP, a high-
energy scrubber, and an acid plant, respectively.
3-190
-------
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
u>
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
18
44
99
105
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary-investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-6 Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-97.
Schedule for installation of a dry electrostatic precipitator
on a nonferrous smelter.
-------
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
16
35
70
74
10
to
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H,
H-j'
J-2
2-K
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
inps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Figure 3-98.
Perform startup, shakedown, and
emission testing
Schedule for installation of a high-energy wet scrubber system
on a nonferrous smelter.
-------
u>
i
M
vo
u>
D
Milestones
•Activity and duration 1n weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
20
64,
135
143
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives-**.
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
Inps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Figure 3-99.
Perform startup, shakedown, and
emission testing
Schedule for installation of an acid plant on a primary
nonferrous metallurgical process.
-------
Sources of Additional Information
Type of
Source information*
1. Devitt, T.W. et al. Trace Pollutant P, E, C
Emissions from the Processing of
Metallic Ores. Prepared by PEDCo-
Environmental Specialists, Inc. for
U.S. Environmental Protection Agency,
Research Triangle Park, North
Carolina. Publication No. EPA
650/2-74-115. August 1974.
2. Compilation of Air Pollutant Emission E
Factors, 2nd edition. U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina.
Publication AP-42. February 1976.
462 p.
3. Particulate Pollutant System Study. P, E, C
Volume III. Handbook of Emission
Properties. Prepared by Midwest
Research Institute for U.S. Environ-
mental Protection Agency, Durham,
North Carolina.1 NTIS No. 203-522.
May 1971. pp. 257-281.
4. Control Techniques for Lead Air P, E, C
Emissions. Prepared by PEDCo-
Environmental Specialists, Inc.
for U.S. Environmental Protection
Agency, Research Triangle Park,
North Carolina. October 1976.
*P = Process description
E = Emission rates
C = Control devices
3-194
-------
3.6.5 Iron and Steel
3.6.5.1 Blast Furnace
Process Description - The blast furnace reduces large
quantities of iron ore to pig iron by removing impurities
and oxygen. Iron-bearing materials (iron ore, sinter
pellets, mill scale, open hearth or basic-oxygen-process
slag, iron or steel scrap), coke, and fluxes (limestone) are
charged into the top of the furnace, and iron is tapped from
the bottom.
The heat energy required to effect the required chemical
reactions is supplied by reacting coke in the charge with
air (preheated to temperatures of 1300 to 1800 °F), which is
blown into the bottom of the blast furnace through blowpipes
known as "tuyeres". The heat of reaction maintains a pool
of molten pig iron (hot metal) in the bottom of the furnace.
The high temperature, the limited amount of air, and the
presence of large amounts of carbon in the form of coke,
produce the desired reducing atmosphere. Carbon monoxide is
formed in the high-temperature lower zone and passes up
through the solid burden. Excess carbon monoxide (diluted
with carbon dioxide, nitrogen, and moisture) passes off the
top of the blast furnace and is collected for use as a fuel
to heat the air blown into the blast furnace and for other
in-plant heating purposes. A typical blast furnace is shown
in Figure 3-100.
Periodically the hot metal produced in the blast
furnace and the liquid slag (which is a fused mixture of the
flux and impurities removed from the ore, pellets, sinter,
and coke) are removed from the blast furnace. The hot metal
is tapped or "cast", while the slag is said to be "flushed."
Hot metal from the furnace flows through troughs into tor-
pedo (submarine) cars for transfer to other steelmaking
3-195
-------
EXHAUSPGASES CONTAINING
CO AND PARTICULATES
DUCTED TO POLLUTION
CONTROL DEVICE
IRON ORE,
LIMESTONE, ,
COKE
INCOMING BLAST AIR
HEATED BY GAS BURNING
STOVES
LOWERING
OF BELL
CHARGES
FURNACE
SIMILAR TO
OPPOSITE DUCT
Figure 3-100. Typical blast furnace,
3-196
-------
processes such as the electric arc or basic oxygen furnace
(EOF). Slag flushing is not done during every hot metal
tap. When slag builds-up in the furnace it is flushed
through the cinder notch by using a water cooled nozzle or
"monkey." Since slag floats on the hot metal, the cinder
notch is located at a higher elevation than the hot metal
tap. The flushed slag is sent through runners to the oppo-
site side of the cast house from the hot metal, and trans-
ferred to a dump site or processing area.
Atmospheric Emissions - Particulate emissions from blast
furnace stoves are minimal, since a high degree of particu-
late emission control is utilized to keep the stoves (heat
exchangers) from plugging. Without controls, the furnace
emits about 150 pounds of particulate per ton of product.
Particulate emissions also occur during casting when fumes
enter the atmosphere through the open sides of the cast
house. Blast furnace slips, which create emissions that
bypass the control devices, occur rarely but can cause
2
excessive uncontrolled particulate emissions.
Blast furnace vent gases contain approximately 26
percent carbon monoxide, 16 percent carbon dioxide, and 3
percent hydrogen gas. The heating value of the raw gas is
90 Btu per cubic foot, and the moisture content is about 2
percent by volume.
Most of this gas is used for process heating purposes.
The gases leave the furnace at temperatures of 350 to 550°F
and at a flow rate of about 90,000 to 23,000 cubic feet per
ton of pig iron produced. The actual flow rate of the gases
is directly proportional to the coke feed rate.
Control systems - Cyclones are normally used as precleaners
in series with scrubbers and electrostatic precipitators to
control blast furnace emissions. Venturi-type wet scrubbers
3-197
-------
in series with a mechanical collector can reduce exhaust
grain loadings to 0.02 grain per cubic foot. In addition to
performing a significant gas-cleaning operation, the wet
scrubbers condition the gases before they enter an electro-
static precipitator. Since blast furnace gases are used
for combustion in steelmaking processes and also to preheat
the blast furnace air, the gases are usually cleaned to a
high degree and little additional control is required. No
specific compliance schedule is therefore provided for blast
furnaces. The schedules for a high-pressure-drop scrubber
presented in Chapter 2 of this report, could be used.
Cast house emissions can be reduced by total building
evacuation through a fabric filter system, or hoods over the
tap hole and runners which are vented to fabric filters.
Compliance Schedule - Figure 3-101 shows a schedule for
installation of hoods on the tapping and hot metal transfer
areas and vented enclosures over the slag pit. The con-
trolling factor in this schedule is the particulate control
device, in this case a scrubber or fabric filter.
3-198
-------
D
Milestones
Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
Increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME (
FROM G. WEEKS
4
22
52
107
113
Total duration In some
Instances Is governed by
the delivery time of
control device.
vo
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-4 Perform on-site construction
N-R Install control device
R-4 Complete system tie-In
4-5 Perform startup, shakedown,
and emission testing
Figure 3-101. Schedule for installation of hoods and ducting to a
fabric filter on the cast house of a blast furnace operation.
-------
Sources of Additional information
Type of
Source information*
1. Compilation of Air Pollutant Emis- E
sion Factors, 2nd edition. U.S.
Environmental Protection Agency,
Research Triangle Park, North
Carolina. Publication AP-42.
February 1976. pp. 75-1 to 75-6.
2. Katari, V.S. and R.W. Gerstle. P, E, C
Iron and Steel Industry. Prepared
by PEDCo-Environmental Specialists,
Inc. for U.S. Environmental
Protection Agency. Contract No.
68-02-1321, Task No. 26. December
1975. pp. 43-51.
3. Varga, J., Jr., and H.W. Lownie. P, E, C
System Analysis Study of the
Integrated Iron and Steel Industry.
Prepared by Battelle Memorial
Institute for the National Air
Pollution Control Administration,
Cincinnati, Ohio. NTIS No. PB
184-577. May 1969. 543 p.
4. McGannon, H.E., editor. The Making, P
Shaping, and Treating of Steel, 9th
edition. U.S. Steel Company.
Pittsburgh, Pennsylvania. 1971.
*P = Process description
E = Emission rates
C = Control devices
3-200
-------
3.6.5.2 Sinter Plants
Process Description - The sintering process converts the
fine-material into an agglomerated product that is suitable
for blast-furnace feed. The charge consists of iron-bearing
raw materials, recycled wastes (such as blast-furnace flue
dust, mill scale, and miscellaneous fines), flux (limestone,
dolomite, or both), coke b'reeze or coal, and water. The
charge is thoroughly mixed and placed on the sinter strand
(a continuous moving'grate), and combustion air is drawn
through the top of the bed over its active length. The
sinter bed is approximately 12 inches thick. The top
surface of the material is ignited in a gas-fired or oil-
fired combustion furnace. Once the coke breeze is ignited,
the combustion is self-supporting to the end of the sinter
bed — the flame front moving down through the bed. The
combustion temperature range is 2400 to 2700°F. Typical
heat input to the combustion furnace is approximately
150,000 Btu per ton of sinter produced. In order to provide
a uniform distribution of combustion air, the sections under
the bed are separated into a number of compartments known as
windboxes. After the combustion is complete, the sinter
cake is often crushed and screened. The undersize is
collected in the hot return fines bin for recycling on the
strand and the balance is fed to a cooler. Fines from the
cooler and the cold screening operation are also recycled.
Figure 3-102 shows a simplified schematic diagram of a sin-
tering process.
Atmospheric Emissions - The major air pollutants from
sintering are particulates, sulfur dioxide, and carbon
monoxide. Hydrocarbons, nitrogen oxide, and in some cases
fluorides are emitted in much smaller quantities.
3-201
-------
U)
1
NJ
O
ro
WINDBOX
EMISASI°NS WATER
i ,
BALLING
Y DRLW DISCHARGE
^
MAIN WIN
BOX FAN
1
MATERIAL FEED BINS
MAV
MILL V ' rrrn i A
-i H-tU T vo
"HOPPER Qzl
, , -x*s. ^ «^ig
COLLECTOR () SINTER MACHINE ( )V =£&
;v y v j \ LIJ ./^,^_
S^™,^AK[8s|^
x FINES Y Y + t 1 1 t t \ ... 1 ^
\
1 HOT 1
SCREENING
t FINES 1
COOLER)
1 \
\
1 COLD jj
SCREENINfT"
1
TO BLAST
Figure 3-1Q2. Simplified sintering process.
-------
The windbox accounts for approximately half of the
total uncontrolled particulate emissions and all of the
gaseous emissions from iron and steel sinter plants.
Emission factors for windbox emissions are 20, 0.3, and 44
pounds per net 'ton of sinter product for particulate, SO0,
2
and CO respectively. A 1975 testing program indicated
emission rates of 15, 1.8, and 57 pounds per net ton of
sinter produced for particulate, S02, and CO, respectively.
Emissions of gaseous hydrocarbons and fluorides depend on
the chemical composition of the sinter feed; emissions of
nitrogen oxides depend on combustion techniques.
Discharge particulate emissions (after the sinter
machine) are generated during sinter breaking, screening,
cooling, and conveying operations. These uncontrolled
emissions are estimated to be 22 pounds per net ton of
sinter produced.
Control Systems - Generally, windbox and discharge particu-
late emissions are controlled separately. Most plants that
effectively control windbox emissions use dry ESP's, high-
energy wet scrubbers, or gravel bed scrubbers. Fabric
filters and wet ESP's have also been used. All control
devices come after mechanical collectors that decrease the
dust loading and protect the fan. Emissions from transfer
points and discharge (including cooler) emissions are
generally controlled by fabric filters, but some plants
recycle these exhausts through the strand. When these
exhausts are recycled, the windbox control device can be
used to control transfer point and discharge particulate
emissions. A well-designed control device can provide more
than 90 percent particulate control with proper maintenance.
Most sinter plants meet regulations applicable to SO
X
and CO emissions without special controls.
3-203
-------
Compliance Schedules - Figures 3-103 through 3-106 show
expeditious schedules for installation of a dry ESP, a wet
ESP, a fabric filter and a high-energy scrubber, respec-
tively. The schedules include the installation of hoods and
ducting. Several months may be required for pilot studies
before control plans and specifications can be finalized.
Studies are needed because of the wide variation in dust
characteristics at sinter plants.
The major time increment for all systems is fabri-
cation. The times range from 20 weeks for a fabric filter
to 48 weeks for a dry ESP. Total installation times are
109, 89, 56, and 70 for a dry ESP, a wet ESP, a fabric
filter, and a high-energy scrubber, respectively.
3-204
-------
U)
i
10
O
(Jl
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
Increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
18
44
99
105
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Cornnlt funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-In
4-5 Perform startup, shakedown, and
emission testing
Figure 3-103
Schedule for installation of a dry electrostatic
precipitator on a sinter plant.
-------
U)
tO
O
J Milestones
—»-Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
21
46
90
96
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R.-4 Complete construction and system
tie-in
4-5
Figure 3-104.
Perform startup, shakedown, and
emission testing
Schedule for installation of a wet electrostatic
precipitator on a sinter plant.
-------
CO
i
ro
o
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
]
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
13
34
53
56
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
M
4-5
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-sitp construction
Install control
device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
Figure 3-105. Schedule for installation of a fabric filter
on a sinter plant.
-------
u>
I
M
O
00
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s1te construction or Installation of emission control"
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
16
35
70
74
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device-bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Figure 3-106.
Perform startup, shakedown, and
emission testing
Schedule for installation of a high-energy wet scrubber
system on a sinter plant.
-------
Sources of Additional Information
Type of
Source information*
1. Background Information - Best Systems P, E, C
of Emission Reduction For Sinter Plants
In The Iron and Steel Industry. Pre-
pared by PEDCo-Environmental Specialists,
Inc., for U.S. Environmental Protection
Agency, Research Triangle Park, North
Carolina. Contract No. 68-02-1321, Task
No. 10. June 1976.
2. Compilation of Air Pollutant Emission E
Factors, 2nd edition. U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina. Publica-
tion No. AP-42. February 1976.
3. Varga, J., Jr., and H.W. Lownie. A P, E, C
System Analysis of the Integrated
Iron and Steel Industry. Prepared
by Battelle Memorial Institute for
the National Air Pollution Control
Administration, Cincinnati, Ohio.
NTIS NO. PB 184-577. May 1969. 543 p.
*P = Process description
E = Emission rates
C = Control devices
3-209
-------
3.6.5.3 Open Hearth Furnaces
Process Description - The open hearth furnace is a rectangu-
lar unit with a comparatively shallow hearth for containing
and processing steel, as shown in Figure 3-107- Scrap,
flux, and hot metal are charged into the furnace through
several doors in the front of the furnace. The charge
materials are heated with various fuels such as oil, tar,
natural gas, and combinations of these. Steel is produced
by the addition of oxygen to the molten charge to oxidize
the carbon, manganese, and silicon contents of the feed.
The carbon passes off as carbon monoxide, and the silica and
manganese oxides dissolve in the slag. Open hearth steel-
making requires comparatively long time periods, ranging
from 8 to 10 hours down to 4 to 5 hours when oxygen lancing
is used. Many of these furnaces have been replaced by EOF
furnaces, which refine steel more quickly.
Charging and melting of the scrap requires 2 to 4
hours. When melting is complete, the molten contents of
the furnace are tapped through ports into the steel ladles.
The molten metal is poured into ingot molds of different
sizes and shapes. Slag is tapped into slag pots.2
Atmospheric Emissions - Emissions from open hearth opera-
tions consist mainly of particulates. Fluoride emissions
also occur to a much lesser extent. Uncontrolled particu-
late emissions from a furnace without oxygen lancing are
about 8.3 pounds per ton of product; with oxygen lancing,
emissions range from 9.4 to 22.0 pounds per ton and average
about 17.4 Ib/ton. These emissions include minor amounts of
gaseous and particulate fluorides.3 Tests conducted at a
major northwest Indiana steel plant showed a particulate
concentration of 0.09 grain per cubic foot in stack gas at a
flow rate of 26,200 cubic feet per minute.1
3-210
-------
Furnace Hearth
\
2
Figure 3-107. Open hearth furnace.
3-211
-------
The flow rates of gases range from 10,600 to 74,000
cubic feet per minute. Gas temperatures range from 460 to
1800°F; the gases must be cooled by waste heat boilers or
water sprays before entering any air pollution control
equipment.
Control Systems - High-energy wet scrubbers and electro-
static precipitators have been used with some degree of
success on open hearth furnaces. The steel industry is
gradually shutting down the open hearth furnaces and intro-
ducing other steel production techniques such as the EOF
shop (basic oxygen furnaces lanced above the surface of the
charge), the Q-BOF shop (basic oxygen furnace lanced below
the surface of the charge), and the EAF (electric arc
furnace).
Compliance Schedules - Open hearth steelmaking facilities
may be replaced with a EOF shop or electric arc furnaces,
which can be controlled to reduce particulate emissions.
Figures 3-108 and 3-109 show schedules for building a EOF
and an electric arc furnace, respectively. These are both
large complex installations that require more than 2 years
to complete. Each of these processes requires a particulate
control device such as a high-energy scrubber, electrostatic
precipitator, or fabric filter.
3-212
-------
u>
i
N)
I-1
U)
D
Milestones
Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
6-1
1-H
H-J
J-2
2-K
Figure 3-108,
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Schedule for replacement
ELAPSED TIME
FROM G. WEEKS
22
49
114
120
Total duration In some
Instances Is governed by
the delivery time of
control device.
Activity
designation Activity description
K-L Review and approve assembly draw-
1nos
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-4 Perform on-site construction
N-R Install control device
R-4 Complete system tie-in
4-5 Perform startup, shakedown,
and emission testing
of open hearth with EOF-or Q-BOF.
-------
U)
I
D
Milestones
•Activity and duration 1n weeks
MILESTONES
1
2
3
4
S
Refer to Chapter 2 for time
Increments A to G.
Date of submfttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. HEEKS
22
49
115
Total duration 1n some
instances is governed by
the delivery time of
control device.
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-6 Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
inos
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-4 Perform on-site construction
N-R Install control device
R-4 Complete system tie-In
4-5 Perform startup, shakedown,
and emission testing
Figure 3-109. Schedule for replacement of open hearth with electric arc furnace.
-------
Sources of Additional Information
Type of
Source information*
1. Katari, V.S. and R.W. Gerstle. P, E, C
Iron and Steel Industry. Prepared
by PEDCo-Environmental Specialists,
Inc., for the U.S. Environmental
Protection Agency. Contract No.
68-02-1321, Task No. 26, December
1975. pp. 60-65.
2. Varga, J., Jr., and H.W. Lownie. P, E, C
System Analysis Study of the Inte-
grated Iron and Steel Industry.
Prepared by Battelle Memorial
Institute for the National Air
Pollution Control Administration,
Cincinnati, Ohio. NTIS No.
PB 184-577. May 1969. 543 p.
3. Compilation of Air Pollutant E
Emission Factors, 2nd edition.
U.S. Environmental Protection
Agency, Research Triangle Park,
North Carolina. Publication No.
AP-42. February 1976. pp. 75-1
to 75-6.
4. McGannon, H.E., editor. The Making, P
Shaping, and Treating of Steel, 9th
edition. U.S. Steel Company,
Pittsburgh, Pennsylvania, 1971.
*P = Process description
E = Emission rates
C = Control devices
3-215
-------
3.6.5.4 Basic Oxygen Furnace
Process Description - The basic oxygen furnace (EOF) is a
pear-shaped vessel containing the charge materials required'
to make steel. The major materials are hot metal and scrap.
In the basic oxygen process/ no external heat is supplied to
reduce the carbon, silicon, and manganese contents. Oxygen
is blown onto the surface of the molten charge through a
probe, or in a Q-BQF, is blown under the surface of the
melt. The heat generated by oxidation of the elements is
sufficient to carry the process to completion. Flux (usually
lime) is charged into the vessel to form a slag by combining
with the oxides of iron, silicon, and manganese, and to
reduce the contents of sulfur and phosphorus in the steel to
acceptable limits. A typical EOF is shown in Figure 3-110.
Operating time per melt is approximately 50 minutes.
Refining occurs at approximately 3600°F at atmospheric
pressure. The steel is tapped into a ladle and alloying
materials are added. The slag is tapped into slag pots.
Overhead cranes then move the ladle to a line of empty ingot
molds (teeming aisle), while the slag pot is moved to the
2
dump yard.
Atmospheric Emissions - About 51 pounds of particulate and
about 0.2 pound of gaseous fluorides are produced per ton of
EOF product.
Basic oxygen furnaces also cause emission of a flaky
black material called "kish," which forms spontaneously
whenever hot metal with carbon content greater than 4.5
percent is cooled below its liquid temperature. This
results in the formation of solid Fe3C, which is unstable
and decomposes into graphite and iron. Usually the kish is
formed when the hot metal is transferred to and from the
ladle.3
3-216
-------
4
Figure 3-110. Basic oxygen furnace.
3-217
-------
Gas effluents ranging from 200,000 to 1,200,000 cubic
foot per minute are emitted, from the basic oxygen furnace at
temperatures between 2900 and, 3450°F. These gases carry 300
pounds or more of oxide dust per minute. Most of the dust
is very finely divided, the particles ranging'in size from
0.1 to 1 micron.
Control Systems - Particulate emission rates are so high
that all basic oxygen units utilize high-efficiency partic-
ulate control devices. Most of the furnace emissions are
controlled by venturi scrubbers or electrostatic precipi-
tators with approximately 98 percent collection efficiency.
About 40 to 60 pounds of particulate (largely Fe«0_) is
3
ordinarily collected per ton of steel produced.
A significant problem in the design of a control system
for a EOF installation is the potential production rate of
the EOF. EOF technology is developing so rapidly that
production can be increased by as much as 20 percent, some-
times exceeding the capacity of the pollution control equip-
ment. Existing scrubbers and ESP's often must be upgraded
to meet air pollution control regulations.
Particulate emissions generated in the transfer of hot •
metal during charging, re-ladle, and tapping can be controlled
by venting these processes to a scrubber, ESP, or fabric
filter. Use of these controls would require the design and
installation of hoods and ducts to collect the emissions.
Compliance Schedule - Figures 3-111 through 3-113 show
schedules for installation of control equipment for furnace
charging, hot metal transfer, and furnace tapping, respec-
tively. The controlling factor in many steps is related to
the fabric filter.
Tapping emissions can be reduced by use of a control
system similar to that used for charging, except that a
3-218
-------
D
Milestones
•Activity and duration In weeks:
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
.Increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
12
28
40
43
Total duration In some
Instances 1s governed by
the delivery time of
control device.
VO
Figure 3-111.
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
6-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
0-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-4 Perform on-slte construction
N-R Install control device
R-4 Complete system tie-in
4-5
Perform startup, shakedown.
and emission testing
Schedule for installation of secondary hooding and ducts for charging of a
basic oxygen furnace.
(The schedule is for secondary hooding and ducts only. The controlling factor for
installation is the particulate recovery system.)
-------
i
to
N)
O
D
Milestones
•Activity and duration 1n weeks
Refer to Chapter 2 for time
increments A to 6.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
_LL
30
Total duration 1n sonic
52 Instances is governed by
the delivery time of
65 control device.
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
1nos
L-H Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawlnas
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-4 Perform on-s1te construction
N-R Install control device
R-4 Complete system tie-In
4-5 Perform startup, shakedown,
and emission testing
Figure 3-112. Schedule for installation of a movable hood and fabric filter for
control of hot metal transfer at a basic oxygen furnace.^
-------
tSi
ro
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
Increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of
ment 1s completed.
Date by which final compliance Is achieved.
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
Prepare assembly drawings
mission control equlp-
Activlty
designation
K-L
ELAPSED TIME
FROH G. WEEKS
30
56
59
Total duration In
Instances is governed by
the delivery time of
control device.
Activity description
Review and approve assembly draw-
Inps • ^
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-4 Perform on-site construction
N-R Install control device
R-4 Complete system tie-In
4-5 Perform startup, shakedown,
and emissJon testing
2-K
Figure 3-113. Schedule for installation of a secondary hood to new fabric
filters for control of tapping of a basic oxygen furnace.
-------
larger hood system and greater exhaust flow are required.
Since the furnace tilts away from the charging side during
tapping, a separate fume enclosure system must be provided.
Many variations of ducting, fans, and final control devices
are available for control of these fumes. In some systems,
a single device controls both the furnace and tapping opera-
tions. A schedule for the basic hood and duct system for
control of tapping emissions is shown in Figure 3-113. A
fabric filter control device in this system is the con-
trolling factor in the overall schedule. If an existing
control device has sufficient capacity and can be used, the
schedule can be reduced to about 43 weeks.
The charging control system shown in Figure 3-111
utilizes an auxiliary or secondary hood over the furnace
opening when it is tilted forward for charging. Because the
hood must be high enough to clear the ladle, it draws in
large amounts of room air with the fumes. Installation of
the hooding system with fan and motor requires approximately
43 weeks. A control device installation schedule for a
large fabric filter or scrubber would thus be the control-
ling factor, as described in Section 2. If an existing
particulate control device has sufficient capacity, the hood
exhaust could be ducted into that device.
Transfer of hot metal from the torpedo car to the
charging ladle causes emission of fumes, which can be
contained in a hood and exhausted through a fabric filter.
Installation of such a system requires approximately 65
weeks, as shown in Figure 3-112.
Schedules for upgrading of an existing control device
cannot be estimated since they vary widely, ranging from a
few months to times similar to those for installation of a
new device. The amount of upgrading required directly
affects the schedule.
3-222
-------
Sources of Additional Information
Type of
Source information*
1. Katari, V.S. and R.W. Gerstle. P, E, C
Iron and Steel Industry. Prepared
by PEDCo-Environmental Specialists,
Inc., for U.S. Environmental
Protection Agency. Contract No.
68-02-1321, Task No. 26. December
1975. pp. 66-72.
•
2. McGannon, H.E., editor. The Making, P
Shaping, and Treating of Steel, 9th
Edition. U.S. Steel Company,
Pittsburgh, Pennsylvania. 1971.
pp. 473-497.
3. Compilation of Air Pollutant Emission E
Factors, 2nd edition. Environmental
Protection Agency, Research Triangle
Park, North Carolina. Publication No.
AP-42. February 1976. pp. 7.5-1
to 7.5-6.
4. Varga, J., Jr., and H.W. Lownie. A P, E, C
System Analysis Study of the Inte-
grated Iron and Steel Industry. Pre-
pared by Battelle Memorial Institute
for the National Air Pollution Con-
trol Administration, Cincinnati,
Ohio. NTIS No. PB 184-577. May
1969. 543 p.
5. Gas Cleaning and Air Pollution P, E, C
Control for Iron and Steel Pro-
cesses. Iron and Steel Engineer.
53(6):25-32, 1976.
*P = Process description
E = Emission rates
C = Control devices
3-223
-------
3.6.5.5 Electric Arc Furnace
Process Description - Electric furnaces are used to produce
both high-alloy and mild steels. In this operation, the
heat required to produce steel is supplied as electrical
energy. Hot metal from the blast furnace may also be used
as part of the charge in some large electric furnaces. An
electric arc furnace is shown in Figure 3-114.
Carbon electrodes
Port for third electrode
Slag spout
Figure 3-114. Direct-arc electric furnace.
3-224
-------
Bucket cranes move raw materials and alloying materials
into the furnace. Practically all modern arc furnaces for
steelmaking are top-charged. At the time of charging, the
electrodes are lifted and moved out of the way. After
charging of the metal, scrap, alloys, and fluxes, the
electrodes are lowered to about 2 to 3 inches above the
charge. As current is applied through the electrodes, the
charge is melted and oxidation begins. During this period
phosphorus, silicon, manganese, carbon, and other materials
are oxidized to form a slag. Oxygen lancing is often used
to decrease refining time. At the end of the melt, the
electrodes are raised. The tap hole is then opened and the
furnace is tilted so that the steel can be tapped from the
furnace into a ladle. The slag may be tapped before,
during, or after tapping of the steel. A crane moves the
ladle either to a pouring platform, where the steel is
poured into molds, or to a vacuum-degassing station.
Atmospheric Emissions - Particulate emissions from electric
furnaces consist primarily of oxides of iron, manganese,
aluminum, and silicon. Lead emissions may also be signif-
icant if the lead content of the scrap is high. The un-
controlled particulate emission rate is approximately 9.2
pounds per ton of metal without oxygen lancing and about
2
11.0 pounds per ton of metal with oxygen lancing. Particu-
late fumes also occur during tapping and hot metal charging.
About 18 pounds of carbon monoxide gas is emitted per
2
ton of metal produced.
Control Systems - Gases generated during the meltdown and
refining steps are collected by hoods at temperatures
ranging from 1200 to 1800°F. These gases are cooled by
dilution or quenching before particulate control. Fabric
filters have been successfully applied to control of emis-
sions from electric furnaces ranging up to 100 to 150 net
3-225
-------
tons capacity. Since the Design and operating character-
istics of electric furnaces can vary widely, development of
pollution controls is not straightforward. One of the major
problems is design of a hood that will completely capture
the fumes. Because most electric-arc furnaces are top-
charged, the hood must be removed during charging. As a
result, the capture and containment of emissions generated
during charging is difficult;
Control of emissions during melting and refining has
been done with canopy hoods fitted over each furnace and
ducted to a fabric filter. Fugitive emissions such as those
from charging and tapping can also be collected by hoods
that are ducted to a fabric filter. Another control tech-
nique consists of venting the entire building to a fabric
filter system.
Compliance Schedules - Figure 3-115 shows a schedule for
installation of a fabric filter, hooding, and ductwork to
control melting and refining emissions. Figure 3-116 repre-
sents a schedule for controlling emissions by evacuation of
a whole building to a fabric filter system. The schedules
assume the availability of enough space for installation of
the control systems. The canopy hood system requires more
time because of the engineering and construction involved in
fitting a movable hood and duct system around the furnace.
The building evacuation system, though much larger, handles
warm ambient air and does not involve a hood system.
Delivery time for a large motor or fan could extend the
building evacuation schedule.
Installation of controls for fugitive emissions from
tapping operations would require slightly less time than
installation of the furnace control system.
3-226
-------
U)
ro
ro
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
Increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
13
38
62
65
Activity
designation
A-B
A-C
C-D
D-E
E-F
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Figure 3-115.
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate oji-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Schedule for installation of canopy hoods and fabric
filter on an electric arc furnace.
-------
oo
I
to
M
00
[ | Milestones
> Activity and duration 1n weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-s1te construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G. WEEKS
13
34
53
56
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bi.ds
J-Z Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and •
Figure 3-116. Schedule for installation of a large^faBxfjPc filter
for building evacuation around an electric arc furnace.
-------
Sources of Additional Information
Type of
Source information*
1. Varga, J., Jr., and H.W. Lownie. A P, E, C
System Analysis Study of the Integrated
Iron and Steel Industry. Prepared by
Battelle Memorial Institute for the
National Air Pollution Control Adminis-
tration, Cincinnati, Ohio. NTIS No.
PB 184-577. May 1969. 543 p.
2. Compilation of Air Pollutant Emission E
Factors, 2nd edition. U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina.
Publication No. AP-42. February
1976. pp. 7.5-1 to 7.5-6.
3. Katari, V.S. and R.W. Gerstle. P, E, C
Iron and Steel Industry. Prepared
by PEDCo-Environmental Specialists,
Inc., for U.S. Environmental
Protection Agency. Contract No.
68-02-1321, Task No. 26. December
1975. pp. 66-72.
4. McGannon, H.E., editor. The Making, P
Shaping, and Treating of Steel,
Ninth Edition. U.S. Steel Company,
Pittsburgh, Pennsylvania. 1971.
*P = Process description
E = Emission rates
C = Control devices
3-229
-------
3.6.5.6 Scarfing
Process Description - Scarfing is the process of removing
surface defects from steel slabs and blooms; it is generally
done automatically in the rolling mill area. Any additional
scarfing is done by hand on cold steel in the conditioning
area. Milling machines and grinders are also used to finish
the billets.
In this process, oxygen is blown through a tip against
the hot steel surface causing rapid oxidation of the surface
layer and enough heat to melt and remove the oxidized
metal.
Atmospheric Emissions - The scarfing operation generates
metal oxide particulates in quantities that vary widely
depending on the depth of cut. Maximum particulate emis-
sions are 1 pound per ton of steel produced.
Control Systems - Emissions from automatic scarfing can be
controlled by an ESP or scrubber. Collection of the metal
oxide particulates in hand-scarfing areas may require
numerous hoods. A process change from hand scarfing to
grinding with conventional abrasive grinders or chipping
with hand-held hammers improves control of emissions.
Compliance Schedules - Figure 3-117 shows a typical schedule
for installation of an ESP or scrubber on a scarfing opera-
tion. Control device fabrication is the controlling factor,
requiring 29 weeks. Total installation time is 66 weeks.
3-230
-------
U)
i
N>
U)
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
increments A to 6.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Figure 3-117.
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
ELAPSED TIME
FROM G. WEEKS
13
35
63
66
Total duration In some
Instances 1s governed by
the delivery time of
control device.
Activity
designation Activity description
K-L Review and approve assembly draw-
Ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-4 Perform on-site construction
N-R Install control device
R-4 Complete system tie-in
4-5 Perform startup, shafcedown,
and emission testing
Schedule for installation of a canopy type swing-away hood and
ESP or scrubber on a scarfing operation.
-------
Sources of Additional Information
Type of
Source information*
1. McGannon, H.E., editor. The Making, P
Shaping, and Treating of Steel, Ninth
Edition. U.S. Steel Company.
Pittsburgh, Pennsylvania. 1971.
pp. 721-724.
2. Compilation of Air Pollutant Emission E, C
Factors, 2nd edition. U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina.
Publication AP-42. February 1976.
pp. 7.5-1 to 7.5-6.
3. Varga, J. , Jr., and H.W. Lownie. A P, E, C
System Analysis Study of the Integrated
Iron and Steel Industry. Prepared by
Battelle Memorial Institute for the
National Air Pollution Control Adminis-
tration, Cincinnati, Ohio. NTIS No.
PB 184-577. May 1969. 543 p.
*P = Process description
E = Emission rates
C = Control devices
3-232
-------
3.7 SECONDARY METALLURGICAL PROCESSES
3.7.1 Aluminum
Process Description - Secondary aluminum operations involve
remelting of metal alloys to make castings and ingots.
Depending on the source of the aluminum, the process may
also include removal of impurities in the melt and intro-
duction of alloying metals to obtain desired properties in
the casting. Figure 3-118 illustrates a typical secondary
aluminum process.
Impurities are usually removed by fluxing, a term
applied to any process in which materials are added to the
melt to aid in removal of gases, oxides, or other impurities
but do not remain in the final product. Alloying is accom-
plished by adding a compound containing the desired alloying
metal. For example, zinc chloride and zinc fluoride can be
used to increase the zinc content of aluminum alloys.
Demagging, which reduces the magnesium content of the
melt, is usually accomplished by injecting chlorine gas into
the molten bath. This process is discussed in Section
3.7.9.
The metal is melted in crucible, reverberatory, and
electrical induction furnaces. Crucible furnaces are
indirectly heated and are used for melting small quantities,
usually less than 1000 pounds. Reverberatory furnaces are
directly fired and are used for melting medium and large
batches of 2,000 to 20,000 pounds.
Sweat furnaces are commonly used in secondary aluminum
operations to separate the aluminum from iron and other
metals. Facilities that process borings or turnings from
fabricating operations often use gas- or oil-fired furnaces
to burn off the cutting oils and grease before the metal is
charged into the melting furnace.
3-233
-------
EMISSIONS
SCRAP ALUMINUM
CONTAINING OTHER METALS
ALUMINUM
SWEATING
FURNACE
FLUX
EMISSIONS
SCRAP ALUMINUM PARTS
LO
I
N>
UJ
ALLOYING
COMPOUNDS
EMISSIONS
ALUMINUM
BORINGS & TURNINGS
(DIRTY SCRAP)
FUEL-
SCRAP
CLEANING
FURNACE
REVERBERATORY
FURNACE
ALUMINUM
OPERATION
MOLDS
METAL
Figure 3-1181 Secondary aluminum process.
-------
The core making and sand handling systems are integral
parts of the foundry. These processes are described in
Section 3.7.8.
Atmospheric Emissions - The melting of clean aluminum pigs
and foundry returns without the use of fluxes does not
create significant atmospheric emissions. The melting of
aluminum scrap, however, requires air pollution control
equipment to prevent the discharge of excessive emissions,
consisting primarily of magnesium and aluminum chloride
fumes, which react with moisture in the air to form magne-
sium and aluminum oxides and hydrogen chloride.
Particulate emissions from the sweat furnaces amount to
approximately 15 pounds per ton of metal processed. Rever-
beratory furnaces emit from 2 to 4 pounds per ton; the
chlorination station emits about 1000 pounds of particulates
per ton of chlorine consumed (refer to Section 3.7.9).
Control Systems - Fabric filters and wet scrubbers are used
to control emissions from reverberatory and crucible fur-
naces, the fabric filters predominating. An afterburner is
also required on sweat furnaces because the effluent is oily
and combustible. In a fabric filter/afterburner combination
the exhaust gases of the afterburner must be cooled by
evaporative or radiant cooling to protect the fabric. Air-
to-cloth ratios of the filter bags are approximately 2/1.
TJ
Dacron is a commonly used fabric. High-energy venturi
scrubbers require pressure drops as high as 40 to 50 inches
water gauge to provide the required collection efficiencies.
Switching from a reverberatory furnace to an induction
furnace will eliminate products of fuel combustion and
minimize emissions caused by oxidation of the aluminum.
Compliance Schedules - Figure 3-119 illustrates an expedi-
tious schedule for installing either a fabric filter or
fabric filter/afterburner control system. Figure 3-120
3-235
-------
LO
I
N)
Milestones
Activity and duration in weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G. WEEKS
16
43
73
78
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
6-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Figure 3-119. Schedule for installation
afterburner control system on a
Activity
designation Activity description
K-L Review and approve assembly draw-
i nos
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R.-4 , Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
of a fabric filter or fabric filter/
secondary aluminum process.
-------
CO
I
fO
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
17
38
62
64
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw*
inps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R.-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Figure 3-120. Schedule for installation of a wet scrubber or wet
scrubber/afterburner control system on a secondary aluminum process.
-------
illustrates an expeditious schedule for installing either a
wet scrubber or wet scrubber/afterburner control system.
Figure 3-121 illustrates an expeditious schedule for in-
stallation of an afterburner on a scrap cleaning furnace.
Figure 3-122 illustrates an expeditious schedule for
installing a custom-designed baghouse or baghouse/after-
burner system to control emissions from secondary aluminum
production; such a system might be required because of space
limitations or unique process configurations. This schedule
can accomodate simultaneous modification of the furnace, if
required.
Sources of Additional Information
Type of
Source information*
1. Danielson, J.A., editor. Air P, C
Pollution Engineering Manual. U.S.
Environmental Protection Agency.
Research Triangle Park, North
Carolina. Publication No. AP-40.
May 1973. pp. 283-292.
2. Exhaust Gases from Combustion and P, C
Industrial Processes. Prepared by
Engineering-Science, Inc. for the
U.S. Environmental Protection Agency,
Durham, North Carolina. NTIS No.
PB 204-861. October 1971. 436 p.
3. Study of Technical and Cost Informa- P, E, C
tion for Gas Cleaning Equipment in
the Lime and Secondary Non-Ferrous
Metallurgical Industries. Prepared
by Industrial Gas Cleaning Institute
for the U.S. Environmental Protection
Agency. NTIS No. PB 198-137.
December 1970.
*P = Process description
E = Emission rates
C = Control devices
3-238
-------
NJ
U)
vo
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
Increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of'Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. HEEKS
10
27
45
47
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H. Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-H Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
'
emission testing
Figure 3-121. Schedule for installation of an afterburner on a
scrap cleaning furnace in aluminum production.
-------
15
32
26
CO
I
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME (WEEKS)
0
IS
47
73
77
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications.
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process tie-ins.
4-5 Perform equipment startup and source testing
Figure 3-122. Schedule for installation of a custom-designed
fabric filter on a secondary aluminum process.
-------
3.7.2 Brass and Bronze
Process Description - Production of brass and bronze, both
copper-based alloys, involves a wide variety of melting,
refining, and casting operations. Raw materials in the form
of ingots and/or scrap are melted in a furnace, and various
fluxes are added to refine the metal. The molten metal is
then poured into smaller pots ,and transferred to the casting
area, where it is poured into molds. After the metal cools,
the sand mold is separated from the metal in a shake-out
area. The casting is then cleaned and processed, and the
sand mold material is recycled.
The industry uses a number of melting furnaces, including
gas- and oil-fired reverberatory and rotary furnaces and
electric induction units. Figure 3-123 illustrates a
brass/bronze reverberatory furnace controlled by a fabric
filter.
The core making and sand handling systems are integral
parts of a brass and bronze foundry. These processes are
described in Section 3.7.8.
Atmospheric Emissions - The melting operation represents the
primary source of particulate emissions. Particulate com-
position depends on composition of the metals being melted
and the flux materials. Alloys containing zinc, tin, and
magnesium tend to produce higher emission levels because of
their higher volatility. The quantity of particulate
emitted depends primarily on the type^ of melting: furnace. A
direct-filled furnace, such as the reverberatory furnace,
produces higher emission levels than an indirect-fired unit.
Careful temperature control, proper flux cover, and
addition of alloying metals before the melt is started
tend to reduce emissions.
3-241
-------
JL
u>
I
to
GAS OR OIL
FUEL & AM
DOMESTIC AND
INDUSTRIAL SCRAP
REVERBERATORY
FURNACE
GAS COOLER
FABRIC FILTER
SYSTEM
-^
m*
;j;
^.*
:•:
•
FLUX
\
/
\
/
FINES
METAL
PftODOCT
SLAG
FAN
Figure 3-123. Brass/bronze reverberatory furnace.
-------
Other sources of particulate emissions include the mold
and casting handling and preparation areas. These sources
are relatively minor as compared with the furnace emissions.
Control Methods - Process changes and control systems can
reduce emissions. The use of crucible or pot furnaces,
fired externally with gas or light oil, or the use of elec-
tric induction furnaces, can greatly reduce the amount of
fume generated in the melting processes.
Particulate control is achieved by installation of
fabric filter systems. The small particle sizes and the
potential presence of hazardous metal compounds require a
highly efficient control system. Air-to-cloth ratios on the
order of 3/1 are commonly used.
Compliance Schedules - An expeditious schedule for installa-
tion of a fabric filter to control emissions from a brass
and bronze foundry is shown in Figure 3-124.
Sources of Additional Information
Type of
Source information*
1. Air Pollution Aspects of Brass and E, C
Bronze Smelting and Refining Industry.
National Air Pollution Control
Administration, Raleigh, North
Carolina. Publication No. AP-68.
March 1970. 114 p.
2. Danielson, J.A., editor. Air Pollu- P, C
tion Engineering Manual. U.S.
Environmental Protection Agency,
Research Triangle Park, North
Carolina. Publication No. AP-40.
May 1973. 987 p.
*P = Process description
E = Emission rates
C = Control devices
3-243
-------
U)
I
to
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submHtal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
14
30
46
48
Activity
designation
A-B
A-C
C-D
D-E
E-F
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
6-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Figure 3-124.
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Schedule for installation of a fabric filter on a
brass and bronze foundry.
-------
3.7.3 Steel
Process Description - Steel foundries differ from basic iron
and steel plants in that the primary raw material is scrap
steel. The foundries produce cast steel, usually for heavy
industrial uses, such as bulldozer frames and locomotive
wheels.
Three types of furnaces are in common use: direct
electric-arc, electric induction, and open hearth. Scrap,
pig iron, ferroalloys, and limestone are charged to the
furnace. Refined steel is produced in the melt by oxidizing
the impurities, reducing the iron oxide, and adding the
desired alloying constituents.
Atmospheric Emissions - Particulate emissions from steel
foundry operations include iron oxide fumes, sand fines,
graphite, and metal dust. Hydrocarbon emissions can also
occur if dirty scrap is charged. Primary factors influencing
the quantity of pollutants emitted are the quality and
cleanliness of the scrap and the amount of oxygen lancing.
Particulate emissions from an electric arc furnace
range between 4 and 40 pounds per ton, averaging about 13
pounds per ton of metal processed. Emissions from an open-
hearth furnace average about 11 pounds of particulate per
ton and from an electric induction furnace, about 0.1 pound
per ton of metal processed.
Control Systems - Fabric filters and, to a lesser extent,
wet scrubbers are the most commonly used control devices.
Air-to-cloth ratios for the fabric filter should not exceed
2.5/1. Dacron and glass fiber are the most commonly used
fabrics.
Compliance Schedules - Figures 3-125 and 3-126, respectively,
illustrate expeditious schedules for installation of a
fabric filter and a wet scrubber on a steel foundry furnace.
3-245
-------
[~~[ Milestones
»-Activity and duration 1n weeks
CO
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. HEEKS
14
38
71
75
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Figure 3-125.
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings 4-5
Schedule for installation of a
foundry furnace.
Activity
designation Activity description
K-L Review and approve assembly draw-
inos
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
Perform startup, shakedown, and
emission .testing.
fabric filter on a steel
-------
D
Milestones
•Activity and duration In weeks
OJ
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G. WEEKS
16
41
70
73
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 . Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Figure 3-126,
Perform startup, shakedown, and
emission testing
Schedule for installation of a wet scrubber on a
steel foundry furnace.
-------
Figure 3-127 illustrates an expeditious schedule for
installing a custom-designed fabric filter where it is
required by such factors as space limitations or unique
process configurations. This schedule can accommodate
simultaneous modification of the furnace, if required.
Sources of Additional Information
Type of
Source information*
1. Danielson, J.A., editor. Air P, C
Pollution Engineering Manual.
U.S. Environmental Protection
Agency, Research Triangle Park,
North Carolina. Publication No.
AP-40. May 1973. 987 p.
2. Exhaust Gases from Combustion and P, C
Industrial Processes. Prepared by
Engineering-Science, Inc. for the
U.S. Environmental Protection Agency,
Durham, North Carolina. NTIS No.
204-861. October 1971. 436 p.
*P = Process description
E = Emission rates
C = Control devices
3-248
-------
15
32
26
CO
10
*>.
vo
MILESTONES
1
2
3
4
5
ELAPSED TIME (WEEKS)
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract. <
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
15
47
73
77
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications.
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process tie-Ins.
4-5 Perform equipment startup and source testing
Figure 3-127. Schedule for installation of a custom-designed
fabric filter on a steel foundry furnace.
-------
3.7.4 Gray Iron
Process Description - Gray iron foundries produce a heavy,
brittle metal commonly called cast iron but also named for
its characteristic gray-white color. Three types of fur-
naces are in common use: cupolas, reverberatory furnaces,
and electric induction furnaces. Cupolas, which are used to
melt over 90 percent of the metal poured for gray iron
castings, range in capacity from 1 to 50 tons of metal per
hour. Electric furnaces are gaining in popularity, partial-
ly because of their low emission rates. Reverberatory
furnaces are used in about 2 percent of the foundries.
Figure 3-128 presents a flow diagram for a gray iron foundry
process.
Atmospheric Emissions - Emissions from cupolas consist
primarily of metallic oxides plus products of incomplete
combustion from the oils and grease adhering to the scrap.
Carbon monoxide is emitted in significant amounts because
the cupola's atmosphere is oxygen-deficient. Uncontrolled
emission rates are approximately 15 and 150 pounds of
particulates and carbon monoxide, respectively, per ton of
metal charged.
Control Systems - Afterburner/fabric filter systems are most
commonly used to control emissions. Afterburner/high-energy
wet scrubber systems are also used. Gas burners or torches
are often installed directly above the charging door to
control emissions of carbon monoxide and, to some extent,
odors. The afterburner section should be designed to allow
a residence time of approximately 0.5 second and a minimum
temperature of 1200°F. The gases from the afterburner must
be cooled by air dilution, radiant cooling, or quenching
with water to protect the fabric filter. Air dilution and
radiant cooling are usually preferred since they minimize
3-250
-------
to
Ul
Binder
Return
sand
•\iVH/-' Gas and
• '.r-Wk'l.l' nar*;^..i
Dust and gases
Dust
FINISHING
AND
SHIPPING
^^ ^"CASTING
SHAKEOUT
SAND
PREPARATION
COOLING AND
CLEANING
Core sand
and binder
CORE
MAKING
Figure 3-128. Gray iron foundry process.
-------
, the chances of fabric blinding. Air-to-cloth ratios for the
fabric filter are typically 2/1.
Compliance Schedules - Installation of a fabric filter/after-
burner system usually requires furnace modification to
reduce the volume of exhaust air that must be treated.
Figure 3-129 illustrates an expeditious schedule for instal-
ling a fabric filter/afterburner system with simultaneous
modifications of the furnace, if required. Figure 3-130
illustrates an expeditious schedule for installation of a
high-energy wet scrubber.
Sources of Additional Information
Type of
Source information*
1. Danielson, J.A., editor. Air Pollu- P, E, C
tion Engineering Manual. U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina.
Publication No. AP-40. May 1973.
987 p.
2. Systems Analysis of Emissions and P, E, C
Emissions Control in the Iron Foundry
Industry. Prepared by A.T. Kearney
and Company, Inc. for U.S. Environ-
mental Protection Agency. NTIS No.
PB 198-348. February 1971. 368 p.
*P = Process description
E = Emission rates
C = Control devices
3-252
-------
18
30
CO
to
en
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of mission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIKE (WEEKS)
0
18
54
84
89
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process tie-Ins.
4-5 Perform equipment startup and source testing
Figure 3-129. Schedule for installation of a fabric filter/afterburner
control system on a gray iron foundry furnace.
-------
co
i
NJ
Ul
D
Milestones
•Activity and duration 1n weeks
Refer to Chapter 2 for time
Increments A to G.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G, WEEKS
J9_
40
65
68
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Figure 3-130. Schedule for
wet scrubber system on a
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
installation of a high-energy
gray iron foundry furnace.
-------
3.7.5 Lead Smelting
Process Description - Three types of furnace are used to
produce the common grade of lead: the pot furnace, the
reverberatory furnace, and the blast furnace or cupola.
Pot furnaces, which are indirectly fired, are used pri-
marily for alloying and refining. Reverberatory furnaces
are used in the processing of lead scrap metal in several
ways, including burnout, sweating, melting, and purifica-
tion. The burnout operation involves incineration of com-
bustible materials in the scrap, such as plastics, rubber
insulation, wood, and paper. In lead sweating operations,
lead is separated from a mixture of materials, many having
melting points higher than that of lead. The primary use of
reverberatory furnaces is for lead melting and purifying the
lead by removal of extraneous ingredients. Figure 3-131
illustrates a lead reverberatory furnace controlled by a
fabric filter.
The lead cupola is similar to the iron cupola used in
ferrous smelting. Unlike the reverberatory furnace, the
cupola serves a very specific function: to reduce the
oxidized metal. The material charged consists of lead-
containing alloys, slag, coke, and limestone, with some
scrap cast iron. Additional charges are added at intervals
as the material melts down.
The core making and sand handling systems are integral
parts of the foundry. These processes are described in
Section 3.7.8.
Atmospheric Emissions - Particulate emissions from the
crucible furnace are usually less than 1 pound per ton of
material charge. Because this material is extremely hazard-
ous, however, the process requires a high degree of con-
trol. Particulate emissions from reverberatory and blast
3-255
-------
REVERBERATOR*
FURNACE
GAS OR
OUFUtl
COMBUSTION
AIR
IE AD
SCRAP
CHARGE
AIR
IANCE
LEAD
PRODUCT
SETTLER-
COOLERS
LEAD OXIDE TO
MAST FURNACE
STACK
DISCHARGE
FABRIC ....
COLLECTOR FAN
T
Y
W
FINES TO
BLAST
FURNACE
Figure 3-131. Lead reverberatory furnace.
3-256
-------
furnaces amount to approximately 130 and 190 pounds per ton
of metal processed, respectively.
Although particulates are usually the emission of
primary concern, emissions of sulfur oxides, carbon monox-
ide, hydrocarbons, and hydrogen chloride (from decomposition
of chlorine-containing materials) can be caused by oxidation
of the sulfur content of the materials charged to the fur-
nace (e.g. lead batteries).
Control Systems - Particulate emissions are usually con-
trolled by fabric filters operating with air-to-cloth ratios
of about 2/2. Orion fabric is frequently used. A rever-
beratory furnace burning significant amounts of scrap may
require an afterburner system to complete combustion,
followed by a fabric filter or high-energy wet scrubber to
remove particulate; the scrubber can also remove soluble
gases.
Compliance Schedules - Figures 3-132 and 3-133 illustrate
expeditious schedules for installation of a wet scrubber and
a fabric filter system, respectively, on a lead smelting
furnace. The schedule for the wet scrubber system includes
the time required to install the associated wastewater
treatment equipment.
3-257
-------
10
I
to
en
CO
D
Milestones
•Activity and duration 1n weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
16
41
65
67
Activity
designation
A-B
A-C
C-D
D-E
E-F
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device' bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Figure 3-132.
Activity
designation Activity description
K-L Review and approve assembly draw-
inps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R.-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Schedule for installation of a wet scrubber system
on a lead smelting furnace.
-------
l
to
Ul
10
o
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
Increments A to G.
MILESTONES
1
2
3
4
5
ELAPSED TIME
FROM G. WEEKS
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of- Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
47
75
80
Activity
designation Activity description
A-B Conduct source tests
A-C Perform, preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-f Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawlngs
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Figure 3-133. Schedule for installation of an afterburner/baghouse
- system on lead smelting furnace.
-------
Sources of Additional Information
Type of
Source information*
1. Danielson, J.A., editor. Air P, C
Pollution Engineering Manual. U.S.
Environmental Protection Agency,
Research Triangle Park, North
Carolina. Publication No. AP-40.
May 1973. 987 p.
2. Study of Technical and Cost Information P, E, C
for Gas Cleaning Equipment in the Lime
and Secondary Non-Ferrous Metallurgical
Industries. Prepared by the Industrial
Gas Cleaning Institute for the U.S.
Environmental Protection Agency. NTIS
No. PB 198-137. December 1970. 307 p.
*
P = Process description
E = Emission rates
C = Control devices
3-260
-------
3.7.6 Zinc Stttelting
Process Description - Secondary zinc for use in alloying,
casting, and galvanizing is made from ingots, rejected
castings, and scrap. Melting is done in a variety of
furnaces, including crucible (pot), kettle, reverberatory,
and electric induction furnaces. The melting operation is
essentially the same in all these units. The zinc is melted
and heated to its pouring temperature, between 800 and
1100°F, by addition of a fossil fuel. Before the zinc is
poured, fluxing material may be added to separate the dross
that accumulated during the melting operation. Dross is
formed by the impurities charged with the metal and by
oxidation during the melting and heating cycles. The dross
is skimmed from the surface of the metal, and the metal is
poured into molds. Figure 3-134 presents a simplified flow
diagram of the secondary zinc melting process.
The core making and sand handling systems are integral
parts of a zinc foundry. These processes are described in
Section 3.7.8.
Atmospheric Emissions - Particulates emitted in zinc smel-
ting operations consist primarily of zinc oxide fumes. The
emission rate depends on the cleanliness and quality of the
scrap and the type of furnace. With clean zinc scrap as
feed, the melting produces relatively low emissions; with
dirty scrap, the emissions are approximately 25 pounds per
ton of metal produced.
The type of flux can also affect the emission rate.
Although many fluxes now in use do not fume, a fuming flux
may be required for processing of certain batches. For
example, when an ammonium chloride flux is heated to the
temperature of the molten zinc, it decomposes into ammonia
and hydrogen chloride; these subsequently recombine to form
a submicron fume of ammonium chloride.
3-261
-------
I
N)
(Ti
NJ
FLUE GAS -
CONTAINS FUEL COMBUSTION PRODUCTS
AND METALLURGICAL PROCESS EFFLUENT
FUGITIVE EMISSIONS FROM
OPENINGS, IN FURNACE,
FOR CHARGING, FLUXING,
AND REMOVAL OF SLAG
RAW MATERIALS:
INGOT
METALLIC SCRAP, ALL TYPES
SKIMMINGS
TOP DROSS
FLUX:
Z.RC12, NH4C1
COMBUSTION CHAMBER
MELTING HEARTH
ZINC-CONTAINING METAL
(FOR DISTRIBUTION OR
ALLOYING TO SPECIFICATION)
BY-PROtJUCT RESIDUES
REVERBERATORY FURNACE
Figure 3-134. Melting furnace for producing secondary zinc.
-------
Control Systems - Process changes and control devices can
reduce emissions. Use of electric induction furnaces, clean
scrap, and nonfuming fluxes can substantially reduce emis-
sions.
Fabric filters made of Dacron fabric are the most
commonly used control devices. Gases from the furnace must
be cooled to about 250°F by quenching or radiant cooling.
Air-to-cloth ratios typically range between 2/1 and 3/1.
Compliance Schedules - Figure 3-135 illustrates an expedi-
tious schedule for installation of a fabric filter on a
secondary zinc furnace.
Sources of Additional Information
Type of
Source information*
1. Secondary Zinc Industry Emission P, C
Control Problem Definition Study.
U.S. Environmental Protection
Agency, Durham, North Carolina.
NTIS No. PB 201-739. May 1971.
150 p.
2. Exhaust Gases from Combustion and P
Industrial Processes. Prepared by
Engineering-Science, Inc. for the
U.S. Environmental Protection Agency,
Durham, North Carolina. NTIS No.
PB 204-861. October 1971. 436 p.
3. Danielson, J.A., editor. Air Pollution P, E, C
Engineering Manual. U.S. Environmental
Protection Agency, Research Triangle
Park, North Carolina. Publication No.
AP-40. May 1973. 987 p.
P = Process description
E = Emission rates
C = Control devices
3-263
-------
U)
I
CO
en
*>•
Milestones
Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G. -
Date pf submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G, WEEKS
4
14
30
47
50
Activity
designation
A-B
A-C
C-D
D-E
E-F
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Figure 3-135.
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Schedule for installation of a fabric filter on a
zinc smelting furnace.
-------
3.7.7 Magnesium Smelting
Process Description - Magnesium is smelted in steel pot
furnaces with capacities ranging between 500 and 5000 pounds
per batch. The raw material usually consists of scrap
metal, magnesium shavings and turnings, and similar materials,
The heat source is either natural gas, oil, or electric
induction. A flux covers the surface of the molten metal
because magnesium will burn in air at the pouring tempera-
tures. The molten magnesium is usually cast by pouring it
into molds, which are then annealed in ovens in an inert
atmosphere.
Atmospheric Emissions - Particulates are the emissions of
primary concern. During the first few seconds after the
charging of the furnace, particulate may be emitted as a
result of incomplete combustion of oils and other organic
materials adhering to the scrap. Submicron metal oxides and
chlorides can be emitted during the melting and refining
stages.
Particulate emissions from pot furnaces are estimated
to be approximately 4 pounds per ton.
Control Systems - Baghouses and high-energy wet scrubbers
are used for control of particulate emissions.
Compliance Schedules - Figures 3-136 and 3-137 illustrate
expeditious schedules for installation of a fabric filter
and a high-energy wet scrubber, respectively-
3-265
-------
CO
I
NJ
CTi
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
Increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
14
30
47
50
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
6-1
1-H
H-J
J-Z
2-K
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
Inps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
C-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-slte construction
N-R Install control device
R-4 Complete construction and system
tie-In
4-5
Figure 3-136.
Perform startup, shakedown, and
emission testing
Schedule for installation of a fabric filter on a magnesium
smelting furnace.
-------
U)
I
M
0\
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
17
42
66
68
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Figure 3-137.
Perform startup, shakedown, and
emission testing
Schedule for installation of a wet scruober system on a
magnesium smelting furnace.
-------
Sources of Additional Information
Type of
Source information*
1. Exhaust Gases from Combustion and P, C
Industrial Processes. Prepared by
Engineering-Science, Inc. for the
U.S. Environmental Protection Agency,
Durham, North Carolina. NTIS No.
PB 204-861. October 1971. 436 p.
*P = Process description
E = Emission rates
C = Control devices
3-268
-------
3•7•8 Core Making, Casting Shakeout, and Sand Handling
Process Description - Core making, casting shakeout, and
sand handling operations are shown schematically in Figure
3-138. Cores,are used in the molds to form the interior of
hollow castings. The cores are prepared with binders, which
usually require baking to develop the strength required to
resist erosion and deformation when the mold is filled with
molten metal. Several types of core ovens are in use,
including shelf ovens, drawer ovens, portable-rack ovens,
car ovens, and conveyor ovens. Each type is suitable for
specific applications that depend on such factors as maximum
size and quantity of the cores. Sand cores that are not
cured in an oven before use are called green sand cores.
A heavy-duty vibrating screen is commonly used for
shakeout to separate the hot casting from the sand. The
sand flows through the screen and is transported to the sand
conditioning system while the casting remains behind. Some
foundries manually separate the casting from the sand.
Molding sand is reused continuously. The simplest sand
handling system consists of a screen for removing oversize
particles and a mixer in which clay and water are added to
the sand to prepare it for remolding. Other equipment may
be used for cooling sand, crushing oversize sand, removing
fines, removing'core binders, and conveying.
Atmospheric Emissions - Emissions from core making, casting
shakeout, and sand handling are usually much less signifi-
cant than those of other foundry operations. Emissions from
the core baking oven consist primarily of condensed and
gaseous hydrocarbons from the combustibles in the sand and
binding materials. Rates are highly variable, depending on
binder composition and baking procedures. Odors may be a
problem. Emissions from the casting shakeout and sand
3-269
-------
TO ATMOSPHERE
CO
I
N)
-J
O
1
j GRINDING
r- -, '
F
Pllflljnr -.. ^ niDMUrr
UIHKUL »i rUKNALt i
BAGHOUSE
1 A 1
1 TUMBLE AND
| HAND CHIP
I '
MOLD-CORE POURING SHAKE-OUT
BAKE OVENS *| ROOM ROOM
, ROTARY SCREEN
^[HAMMER MILL
SAND
PATTERN „ CORE SHOP SAND, OIL |
SHOP MOLD SHOP BINDERS
ii ii.* i i
1 r
INSPECTION
»-SKIPPI
TO
ATMOSPHERE
i t
5 ,
BAGHOUSE
Figure 3-138. Core making, casting shakeout, and, sand handling.
-------
handling systems consist mainly of sand. Use of green cores
generates some hydrocarbons as the hot casting contacts the
moist cooler molding sand originally located away from the
mold cavity.
Control Systems - Emissions from core ovens can be controlled
by afterburners, although most ovens are not controlled.
Particulate emissions from casting shakeout and sand handling
i
systems can be controlled by low-energy scrubbers or fabric
filters. Fabric filters should be used only when sand is
dry because of potential plugging problems.
Compliance Schedules - Figures 3-139 through 3-141 illus-
trate expeditious schedules for installation of an after-
burner on core ovens and a baghouse and scrubber, respec-
tively, on the casting shakeout and sand handling opera-
tions. The major time increments for the afterburner and
fabric filter installation are control device fabrication
and on-site construction, estimated at 10 weeks each. Total
installation times are 52 and 53 weeks for the afterburner
and fabric filter, respectively. Fabrication of the low-
energy scrubber is estimated to require 20 weeks of a total
of 49 weeks for installation.
3-271
-------
i
to
^J
to
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
increments A to 6.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
10
27
.43
45
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Conrnit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
0-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Figure 3-139.
Schedule for installation
on a core baking oven.
Activity description
Review and approve assembly draw-
inps
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-in
Perform startup, shakedown, and
emission testing
of an afterburner
-------
to
N)
-J
U)
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
Increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
14
30
47
50
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
]-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
Inps
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-slte construction
N-R Install control device
R-4 Complete construction and system
tie-In
4-5 Perform startup, shakedown, and
emission testing
Figure 3-140; Schedule for installation of a fabric filter on a
casting shakeout and sand handling system.
-------
U)
to
-J
Milestones
Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date oT award of control device contract.
.Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. KEEKS
J0_
28
46
49
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-In
4-5 Perform startup, shakedown, and
emission testing
Figure 3-141.
Schedule for installation of a low-energy wet scrubber on a
casting shakeout and sand handling system.
-------
Sources of Additional Information
Type of
Source information*
1. Danielson, J.A., editor. Air Pollu- P, E, C
tion Engineering Manual. U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina.
Publication No. AP-40. May 1973.
987 p.
2. Systems Analysis of Emissions and * • P, E, C
Emissions Control in the Iron
Foundry Industry. Prepared by
A.T. Kearney and Company, Inc. for
U.S. Environmental Protection Agency.
NTIS No. PB 198-348. February 1971.
368 p.
3. Air Pollution Aspects of the Iron P, E, C
Foundry Industry. Prepared by A.T.
Kearney and Company, Inc. for U.S.
Environmental Protection Agency.
NTIS No. 204 712. February 1971.
260 p.
*P = Process description
E = Emission rates
C = Control devices
3-275
-------
3.7.9 Metallurgical Chlorination
Process" Description - Chlorination is the bubbling of
chlorine gas through molten aluminum to reduce the magnesium
content of the molten metal or to remove dissolved gases.
Typically, chlorine gas is injected beneath the surface of
the molten aluminum bath through one or more lances. The
chlorine reacts with magnesium and/or dissolved gases to
/
form chlorides, which rise to the surface where they are
removed by skimming.
Atmospheric Emissions - The rapid addition of chlorine
during demagging causes emissions of aluminum chloride,
chlorine gas, and magnesium chloride. The aluminum chloride
readily absorbs moisture from the air, with which it reacts
to form hydrogen chloride.
An uncontrolled Chlorination station emits about 1000
pounds of particulates per ton of chlorine consumed (about
2
12.5 pounds per ton of metal produced). The amounts of
specific pollutants emitted depend mainly upon the quantity
of chlorine, the magnesium content of the aluminum, and the
temperature of the molten metal. An excess of chlorine
increases emissions of aluminum chloride, hydrogen chloride,
and chlorine.
Control Systems - For the Chlorination station, a high-
energy wet scrubber followed by a gas absorption tower
should provide effective control of the submicron particu-
lates. Pressure drops of 50 to 60 inches water gauge may be
required to control particulate emissions effectively. Test
data have shown that use of a packed column scrubber with a
10 percent caustic solution can remove 99 percent of the
hydrogen chloride, 90 to 95 percent of the chlorine, and 80
to 90 percent of the particulate. In addition, careful
control of the Chlorination rate minimizes emissions.
3-276
-------
Compliance Schedules - Figure 3-142 shows an expeditious
schedule for installation of a scrubbing system for control
of particulate, hydrogen chloride, and chlorine. Total
installation time is 64 weeks, including 24 weeks for
control device fabrication.
Sources of Additional Information
Type of
Source information*
1. Danielson, J.A., editor. Air Pollu- P, E, C
tion Engineering Manual. U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina. Publica-
tion No. AP-40. May 1973. pp. 283-292.
2. Compilation of Air Pollutant Emission E
Factors. U.S. Environmental Protection
Agency, Research Triangle Park, North
Carolina. Publication No. AP-42.
February 1976. pp. 7.8-1 and 7.8-2.
3. Feasibility and Costs of Particulate P, E, C
Control Systems for U.S. Reduction
Company, Toledo, Ohio. Prepared by
PEDCo-Environmental Specialists, Inc.
for Ohio Environmental Protection
Agency, Columbus, Ohio. November
1974. 46 p.
*P = Process description
E = Emission rates
C = Control devices
3-277
-------
u>
I
to
^J
00
D
Milestones
•Activity and duration 1n weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
17
38
62
64
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award-control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
1nps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R.-4 Complete construction and system
tie-in
4-5
Figure 3-142,
Perform startup, shakedown, and;
\ emission testing
Schedule for installation of a wet scrubber system for control of
emissions from metallurgical chlorination.
-------
3.8 MINERAL INDUSTRIES
3.8.1 Portland Cement
Process Description - Portland cement is manufactured by dry
and wet processes, both of which include four major steps:
quarrying and crushing, grinding and blending, clinker
production through calcination, and finished grinding and
packaging.
In the wet process, the wet, ground material is pumped
in slurry form to large mixing tanks, from which it is sub-
sequently pumped to the kilns. In the dry process, the dry,
ground material is conveyed to storage bins and then fed to
the kilns. In the first section of the kiln, the ground
material is heated and dried. As it progresses through the
kiln it is calcined and heated until it fuses, forming
clinker. The clinker is discharged from the kiln and
cooled in a clinker cooler. Gypsum is added, and the
mixture is ground to produce finished cement.
A simplified flow diagram of cement plant operation is
shown in Figure 3-143.
Atmospheric Emissions - More than a dozen process steps in a
typical cement plant require effective emission control.
These processes encompass widely varying conditions of tem-
perature, dust load, air volumes, and particle sizes; all
require high-efficiency collection systems.
The major source of particulate emission from both dry
and wet processes is the calcining kiln. Dust is genera-
ted by the tumbling action within the kiln as well as by
volatilization of components during calcination. Secondary
sources of particulate emission are the clinker cooler and
the grinders.
Particulate emissions from the calcining kiln are esti-
mated at 228 pounds of particulate per ton of cement pro-
3-279
-------
DRY PROCESS
I GRINDING
IMIU
I AIR I
^SEPARATOR!
M
AIR
HOT AIR I
FURNACE I
SlUKRY
WATER
WET PROCESSMMIU
BLENDING
SILOS
STORAGE
Y
STORAGE
IASIN
u>
I
NJ
00
O
'
a
tkl
GYPSUM
. . J
TO
THUCK.
1OX CAX
Figure 3-143. Cement manufacture.
-------
duced by the wet process and 245 pounds per ton produced by
the dry process. Particulate emissions from clinker
coolers, dryers, and grinders are estimated to be 32 and 96
pounds per ton of cement produced by the wet and dry process
2
respectively.
Control Systems - Fabric filters and electrostatic pre-
cipitators are used to control emissions from cement kilns.
These devices are often, installed in series with multiple
cyclones. Fabric filters are more commonly used on dry pro-
cess systems because of their higher collection efficiencies
and relative insensitivity to variations in process operating
conditions; they are also used occasionally on wet process
systems. Fabric filters are also used to control emissions
from various transferring and handling operations. Electro-
static precipitators are used primarily to control emissions
from kilns on wet process plants.
Emissions from the dryers, grinders, and clinker
coolers can be controlled by fabric filters or scrubbers if
required.
Compliance Schedules - Figures 3-144 and 3-145 illustrate
expeditious schedules for installation of a fabric filter
and an electrostatic precipitator on a cement kiln. Installa-
tion of a fabric filter requires 63 weeks, including 22
weeks for fabrication. Installation of an ESP on a cement
kiln requires about 75 weeks, including 28 weeks for fabri-
cation.
3-281
-------
OJ
I
NJ
00
to
[~~] Milestones
>• Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
Activity
designation
A-B
A-C
C-D
D-E
E-F
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
ELAPSED TIME
FROM G. WEEKS
14
F-G
6-1
1-H
H-J
J-2
2-K
36
61
63
Figure 3-144
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Schedule for installation
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
of a fabric filter on a cement kiln,
-------
to
GO
D
Milestones
•Activity *nd duration In weeks
Refer to Chapter 2 for time
Increments A to 6.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM 6. WEEKS
14
37
65
69
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-0 Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
6-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation
K-L
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R.-4
4-5
Activity description
Review and approve assembly draw-
Inos
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
1
Evaluate construct*on blds
Award construction contract
Initiate on-slte construction
Install control device
Figure 3-145.
Complete construction and system
tie-in
Perform startup, shakedown, and'
emission testing
Schedule for installation of an electrostatic
precipitator on a cement kiln.
-------
Sources of Additional Information
Type of
Source information*
1. Atmospheric Emissions from the P
Manufacture of Portland Cement.
National Center for Air Pollution
Control, Cincinnati, Ohio.
Publication No. AP-17- 1967.
53 p.
2. Compilation of Air Pollutant Emission E
Factors, 2nd edition. U.S. Environ-
mental Protection Agency. Research
Triangle Park, North Carolina.
February 1976. pp. 8.6-1 through 8.6-4.
3. Particulate Pollutant System Study. P, E, C
Volume III. Handbook of Emission
Properties. Prepared by Midwest
Research Institute for the U.S.
Environmental Protection Agency,
Durham, North Carolina. NTIS No.
PB 203 522. May 1971. 613 p.
4. A Manual of Electrostatic Precipi- C
tator Technology. Part II -
Application Areas. Prepared by
Southern Research Institute for
the U.S. Environmental Protection
Agency. NTIS No. PB 196-381.
August 1970. 584 p.
5. Background Information for Proposed C
New-Source Performance Standards:
Steam Generators, Incinerators,
Portland Cement Plants, Nitric Acid
Plants and Sulfuric Acid Plants.
Environmental Protection Agency,
Research Triangle Park, North
Carolina. NTIS No. PB 202-459.
August 1971. 61 p.
6. Air Pollution Aspects of Emission E, C
Sources: Cement Manufacturing.
Environmental Protection Agency,
Research Triangle Park, North
Carolina. NTIS No. PB 200-080.
May 1971. 51 p.
3-284
-------
*P * Process description
E = Emission rates
C « Control devices
3-285
-------
3.8.2 Lime
Process Description - The principal raw materials for lime
manufacture are calcium carbonate (limestone) or calcium-
magnesium carbonate (dolomite or dolomitic limestone). The
limestone or dolomite is heated in a vertical or horizontal
(rotary) kiln to decompose the carbonate. Heating releases
CO- and leaves calcium and magnesium oxide as products. The
heating process also drives off moisture and volatile
organic matter. Figure 3-146 illustrates the lime manufac-
turing process.
Atmospheric Emissions - The major source of particulate
emission is the calcining kiln. Emissions vary with type of
kiln and composition of the limestone. Vertical kilns emit
less than rotary kilns because larger sizes of limestone are
charged, gas velocities are lower, and less attrition occurs.
In rotary kilns, abrasion of limestone produces dust, which
is entrained by the high-velocity combustion gases. Partic-
ulate emission from a rotary kiln, if uncontrolled, is about
200 pounds per ton of lime processed. Emissions from
vertical kilns are approximately 8 pounds per ton.
Control Systems - Most rotary kilns incorporate a settling
chamber or cyclone precleaner to remove coarse particles.
Wet scrubbers and fabric filters with glass or Nomex fabric
are used for high-efficiency particulate collection.
Electrostatic precipitators are also used, but not as
frequently as fabric filters or wet scrubbers.
Compliance Schedules - Figures 3-147 and 3-148 illustrate
expeditious schedules for installation of a wet scrubber and
a fabric filter on lime kilns.
3-286
-------
LIMESTONE
AND DOLOMITE
PRIMARY CRUSHER
SCREENING AND
CLASSIFICATION
6-8 IN. LIMESTONE
FOR VERTICAL KILNS
SECONDARY CRUSHING
SCREENING AND
CLASSIFICATION
1/4 - 2 1/2 IN. LIMESTONE
FOR ROTARY KILNS
CALCINATION (ROTARY AND
VERTICAL KILNS)
FUEL
COOLING
INSPECTION
FINES
SCREENING
BY-PRODUCT
LIME
PEBBLE AND
LUMP QUICKLIME
CRUSHING AND
PULVERIZING
MAX. SIZE 1/4 - 1/2 IN.
I
GROUND AND |
PULVERIZE QUICKLIME
Figure 3-146. Manufacture of lime and limestone products
3-287
-------
U)
I
to
GO
CO
D
Milestones
•Activity and duration 1n weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commi t funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
ELAPSED TIME
FROM G. WEEKS
18
_4J_
60
63
Activity
designation Activity description
K-L Review and approve assembly draw-
inps
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-In
4-5
Figure 3-147.
Perform startup, shakedown,-and
emission testing
Schedule for installation of wet scrubber on a, lime kiln.
-------
00
VQ
D
Milestones
•Activity «nd duration In weeks
Refer to Chapter 2 for time
Increments A to G.
HIIESTOHES
1
2
3
4
s
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Site by which final compliance Is achieved.
Activity
designation
A-B
A-C
C-0
D-E
E-F
F-G
G-1
1-H
H-J
J-2
2-K
ELAPSED TIME
FROM 6. KEEKS
14
36
61
63
Figure 3-148
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Schedule for installation
Activity
designation Activity description
K-L Review and approve assembly draw-
Inps
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-slte construction
N-R Install control device
R-4 Complete construction and system
tie-In
4-5
Perform startup, shakedown, and
emission testing
of fabric filter on a lime kiln,
-------
Sources of Additional Information
Type of
Source information*
1. Particulate Pollutant System Study. P, E
Volume III. Handbook of Emission
Properties. Prepared by Midwest
Research Institute for the U.S.
Environmental Protection Agency,
Durham, North Carolina. NTIS No.
PB 203 522. May 1971. 613 p.
2. Study of Technical and Cost C
Information for Gas Cleaning Equip-
ment in the Lime and Secondary Non-
ferrous Metallurgical Industries.
Prepared by the Industrial Gas
Cleaning Institute, Inc. for the
U.S. Environmental Protection
Agency, Research Triangle Park,
North Carolina. NTIS No. PB
198-137. December 1970. 307 p.
P = Process description
E = Emission rates
C = Control devices
3-290
-------
3.8.3 Phosphate Rock
Process Description Fuosphate roclc processing involves
beneficiating the ore to reduce impurities, drying to remove
moisture, and grinding to enhance reactivity during sub-
sequent processing steps, as in reaction with sulfuric acid
to produce phosphoric acid. A simplified phosphate rock
processing operation is shown in Figure 3-149.
Atmospheric Emissions - The major sources of particulate
i
emissions are the grinding and drying operation; open
storage piles can cause significant emissions of fugitive
dust. Emissions from uncontrolled phosphate rock processing
range from approximately 2 pounds per ton of rock from
transfer and conveying systems to 40 pounds per ton from
open storage piles. Drying and grinding operations emit 15
to 20 pounds per ton of rock processed.
Control Systems - Fabric filters are the most commonly used
high-efficiency control devices, operating with collection
efficiencies above 99 percent.
Compliance Schedules - Figure 3-150 illustrates an expedi-
tious schedule for installation of a fabric filter on
phosphate rock processing operations.
3-291
-------
(KMtnCUIAK).
V
WET
HATURAL OAS Oft Fill OIL
Figure 3-149- Phosphate rock processing.
3-292
-------
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
Increments A to G.
u>
I
NJ
IO
MILESTONES
1
Z
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. KEEKS
14
39
65
69
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans.
6-1 Finalize plans and specifications
1-H Procure control device bids
-H-J Evaluate control device bids
J-2 Award control device contract
fe-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
Inos
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-H Initiate on-slte construction
N-R Install control device
R-4 Complete construction and system
tie-In
4-5
Perform startup, shakedown, and
Figure 3-150. Schedule for installation or" r'afir'ic^filter on a
phosphate rock processing operation.
-------
Sources of Additional Information
Type of
Source information*
1. Handbook of Emissions, Effluents, p, E, C
and Control Practices for Stationary
Particulate Pollution Sources. NTIS
No. PB 203-522.
2. Kirk-Othmer, Encyclopedia of Chemical P
Technology 2nd Edition. Interscience
Publishers. New York, New York.
3. Air Pollution Control Field Operations P
Manual. APTD Publication No. 1164.
*P = Process description
E = Emission rates
C = Control devices
3-294
-------
3.8.4 Glass
Process Description - At a typical soda-lime glass plant,
the raw materials are glass sand, soda ash, limestone,
cullet (broken glass), and minor ingredients. These are
batch-weighed, mixed, and charged to a glass furnace, in
which the dry mixture blends with molten glass. The batch
is mixed for homogeneity and heat-conditioned to eliminate
stones. The two major types of furnace used in the glass
industry are regenerative and electric.
Capacities of regenerative furnaces range from 50 to
300 tons of glass per day. These furnaces are direct-fired
with oil or gas and are operated continuously. Some systems
incorporate an electric induction booster system to increase
furnace capacity. Electric induction is also used to melt
glass on a large scale. Although melting glass by electric-
ity is more expensive, it is more thermally efficient since
2
the heat is supplied directly.
The molten glass from the furnace is partially cooled
and worked on forming machines by such methods as pressing,
drawing, rolling, casting, and blowing in molds. The glass
articles are immediately conveyed to gas fired or electri-
cally heated annealing ovens, in which they are heat-treated
to remove strains developed during molding.
A flow diagram of a soda-lime glass plant is shown in
Figure 3-151.
Atmospheric Emissions - Particulates can be emitted during
the unloading and transferring of raw materials. Emissions
from the glass furnace, however, present the most serious
problem. The rate of particulate emission from the furnaces
varies considerably, depending upon the composition of the
glass produced and on the furnace design and operating
conditions. An estimated 2.0 pounds of particulate is
3-295
-------
SILICA SAND
S102 - 99%
SODA ASH
Na2C03
LIMESTONE
OR
BURNT LIME
FELDSPAR
BORAX OR
BORIC ACID
uous
RNACE
BATCH MIXING
i
r
MELTING
ABOUT 2,700'F
REFINING AND
HOMOGENIZING
V ABOUT 2,300°F I
\
i
FABRICATION
HOT, VISCOUS LIQUID GLASS
SHAPED BY PRESSING,
BLOWING, DRAWING, OR ROLLING
\
F
ANNEALING
\
t
FINISHING
l
INSPECTION AND
PRODUCT TESTING
\
r
PACKING
i
SHIPPING
CRUSHED GULLET OF
SAME COMPOSITION
AS THAT TO BE
MELTED
i
CULLET CRUSHING
t
i
Figure 3-151. Soda-lime glass manufacture,
3-296
-------
emitted per ton of soda-lime glass produced in a regenera-
tive furnace. No data are available on electrically heated
furnaces, but particulate emissions should be significantly
less. Emissions from production of container glass and
plate glass, both soda-lime glasses, generally are lower
than those from production of specialty glasses. Particu-
late emissions result both from entrainment of batch con-
stituents in the combustion air and from vaporization of
certain volatile components in the melt. The volatile
constituents subsequently condense to form particulates.
Sulfates, fluorides, and borates are common batch consti-
tuents causing volatilization. The great variety of com-
pounds used to produce the hundreds of specialty glasses can
create substantial emissions problems, including the poten-
tial for emitting hazardous air pollutants.
Emissions from container-glass forming operations are
due to the volatilization of the mold coating compounds,
which create a constant haze in the vicinity of the glass
forming machine. Emissions from annealing ovens are negli-
gible.
Control Systems - Fugitive dust emissions from unloading of
raw materials can be effectively controlled by use of choked
feeding and proper enclosures. Vent filters can be used on
bin filling and conveying operations. Fabric filters can be
used on mixers and weigh hoppers.
Only a few continuously operating control devices are
used on glass furnaces. The most effective systems cur-
rently used are fabric filters and wet scrubbers. High-
energy venturi scrubbers are capable of collection effi-
ciencies above 95 percent but require a pressure drop of
approximately 50 inches of water.
3-297
-------
Particulate collection efficiencies of baghouses are
higher than 99 percent, but bag failures due to acid gases
and high temperatures are a problem. Oh furnaces processing
tableware and opal glass, fabric filters have proved effec-
tive.
Whenever possible, many soda-lime glass plants are
changing batch compositions to reduce emissions and comply
with emission regulations. Emissions of volatized materials
are reduced by elimination or reduction of various refining
agents such as sulfates. Also, the fluoride content of the
batch in many plants has been reduced or eliminated to
minimize fluoride emissions.
Electric furnaces offer a much lower emissions potential
than gas- or oil-fired furnaces. Several plants have
replaced older furnaces with electric furnaces to meet
emission regulations. At many plants, however, the use of
an electric furnace in lieu of installing control devices is
not economically feasible or is precluded by the composition
of the feed, which dictates whether the change to an elec-
tric furnace would reduce emissions enough to achieve
compliance.
Compliance Schedules - Figures 3-152 and 3-153 illustrate
expeditious schedules for installation of a fabric filter
and a high-energy venturi scrubber, respectively, on a glass
furnace.
3-298
-------
_L5_
32
26
u>
l
NJ
\O
VO
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME (WEEKS)
4
19
51
77
81
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process tie-ins.
4-5 Perform equipment startup and source testing
Figure 3-152. Schedule for installation of a custom-designed
fabric filter on a glass furnace.
-------
I
to
O
o
Milestones
•Activity and duration in weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of subroittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or Installation of emission control
equipment.
Date by which on-s1te construction or installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation
K-L
ELAPSED TIME
FROM G. WEEKS
19
41
67
71
L-M
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
R-4
4-5
Figure 3-153.
Schedule for installation of high-
glass furnace.
Activity description
Review and approve assembly draw-
ings
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-In
Perform startup, shakedown, and
emission testing
-energy venturi scrubber on a
-------
Sources of Additional Information
Type of
Source information*
1. Danielson, J.A., editor. Air Pollution P, E, C
Engineering Manual. U.S. Environmental
Protection Agency, Research Triangle
Park, North Carolina. Publication
No. AP-40. May 1973. pp. 765-782.
2. Stockham, John D. The Composition E
of Glass Furnace Emissions. Journal
of the Air Pollution Control Associa-
tion. 21 (11) .-713-715, 1971.
3. Kirk-Othmer Encyclopedia of Chemical P
Technology, 2nd edition. Volume 10.
.Interscience Publishers, New York,
1969. pp. 533-604.
4. Compilation of Air Pollutant E
Emission Factors, 2nd edition. U.S.
Environmental Protection Agency,
Research Triangle Park, North
Carolina. February 1976. p. C-16.
*P = Process description
E = Emission rates
C = Control devices
3-301
-------
3.8.5 Fiber Glass
Process Description - The manufacture of fiber glass con-
sists of melting various raw materials to form molten glass,
drawing the glass into fibers, and coating the fibers with
an organic material (the binder). When the fiber glass is
to be used in textile products, the glass is often formed
into marbles before it is drawn into fiber filaments. In
the manufacture of wool products, the molten glass is
normally fed directly into the forming line.
The processes, emissions, and control methods for the
raw material handling operations and the glass melting
furnace are similar to those described in Section 3.8.4 for
production of glass products. Fiber glass, however, is
mainly borosilicate glass, whereas 90 percent of other glass
manufacturing is from soda lime.
Glass wool is formed by feeding glass through platinum
bushings to form fine fibers. The fibers are sprayed with
binders, cured at 400 to 500°F, air-cooled, and cut to
proper size. Figure 3-154 illustrates the overall fiber
glass production processes.
RAW MATERIAL
MELTING
TANK
SIEVELIKE PLATINUM BUSHINGS
HIGH PRESSURE STEAM JETS
ATTENUATE MOLTEN STREAMS
INTO FINE FIBERS
DRYING
OVEN
FIBER DEPOSITED ON CONVEYOR
Figure 3-154. Fiber glass production.
3-302
-------
Atmospheric Emissions - Furnace emissions are similar to
those discussed for glass manufacturing, with the principal
difference that spraying resins on the glass fiber in the
forming operation creates substantial volatile emissions.
Components in the resin are driven off by contact with the
hot fibers and subsequently condense to form fine particu-
lates. The emissions are increased by use of very fine
binder sprays and binders with a high percentage of volatile
components. Particulate emissions from the forming line are
estimated to be 50 pounds per ton processed.
The curing ovens also-emit volatile components from the
binder; when these condense upon cooling, visible emissions
occur. Curing oven emissions are estimated at 7.0 pounds of
particulate per ton of fiber glass wool processed.
Control Systems - The High-Energy Air Filter device (HEAF)
is a widely used emission control method for forming lines
and curing ovens. Pressure drops of over 30 inches water
gauge are required for satisfactory operation. High-energy
wet scrubbers, wet ESP's, and afterburners can also be used
to control emissions from the forming line and curing oven.
Compliance Schedules - Figures 3-155 through 3-158 illus-
trate expeditious schedules for installation of a high-
energy wet scrubber, a HEAF unit, a wet ESP, and an after-
burner on forming line and curing oven sources.
3-303
-------
U)
o
D
Milestones
•Activity and duration In weeks
Refer to Chapter 2 for time
increments A to G.
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME
FROM G. WEEKS
19
40
64
66
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Figure 3-155,
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings 4-5
Schedule for installation of a
fiber glass forming and curing operations.
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4
Complete construction and system
tie-in
Perform startup, shakedown, and
-------
—4— rr
12
19
10
00
U)
o
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME (WEEKS)
4
16
35
45
47
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications.
construction bid documents and award construction contract.
2-3
3-4
4-5
Figure 3-156.
Fabricate and deliver structural components on site.
Deliver remaining equipment and complete construction including process tie-Ins.
Perform equipment startup and source testing
Schedule for installation of a high-energy air filter (HEAP) unit
on fiber glass forming and curing operations.
-------
u>
I
u>
o
D
Milestones
•Activity and duration 1n weeks
Refer to Chapter 2 for time
Increments A to G.
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. HEEKS
21
46
90
96
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
6-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation
K-L
L-H
M-N
L-0
0-P
P-Q
Q-3
3-N
N-R
M
4-5
Figure 3-157
Schedule for installation of a wet
on fiber glass forming and curing
Activity description
Review and approve assembly draw-
Inos
Prepare fabrication drawings
Fabricate control device
Prepare engineering drawinps
Procure construction bids
Evaluate construction bids
Award construction contract
Initiate on-site construction
Install control device
Complete construction and system
tie-In
Perform startup, shakedown, and
emission testing
electrostatic precipitator
operations.
-------
22
18
oo
I
OJ
o
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of
ment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
2
10
Mission control equip-
32
50
52
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications.
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process tie-ins.
4-5 Perform equipment startup and source testing
Figure 3-158. Schedule for installation of an afterburner
on fiber glass forming and curing operations.
-------
Sources of Additional Information
Type of
Source information*
1. Kirk-Othmer Encyclopedia of Chemical P
Technology, 2nd edition. Volume 10.
Interscience Publishers, New York,
1969. pp. 533-604.
2. Danielson, J.A., editor. Air Pollu- P, E, C
tion Engineering Manual, 2nd edition.
U.S. Environmental Protection
Agency, Research Triangle Park, North
Carolina. Publication No. AP-40.
May 1973. pp. 765-782.
3. Compilation of Air Pollutant Emission E
Factors, 2nd edition. U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina.
Publication No. AP-42. February 1976.
p. C-16.
*P = Process description
E = Emission rates
C = Control devices
3-308
-------
3.8.6 Asphalt Batching
Process Description - Asphalt batch processing consists of
drying and heating various aggregates, screening, propor-
tioning, weighing, and mixing the hot dry aggregate with
molten asphalt. Both continuous and batch mix plants are in
operation. The processes are similar except for the final
weighing and mixing steps, which are done either continuously
or batchwise. Capacities of asphalt batch plants range from
50 to 300 tons per hour.
As shown in Figure 3-159, aggregate consisting of
crushed stone, slag, and gravel or sand is sized and loaded
in a storage hopper. From the hopper it flows into the
elevated end of a rotary dryer. A gas or oil burner sup-
plies heat directly at the lower or discharge end of the
dryer. After drying, the hot aggregate is screened and
mixed with hot asphalt.
Atmospheric Emissions - Conveyor belt and bucket elevator
transfer points, bin loading, and screening operations can
be sources of fugitive dust emission. The combustion gas
stream from the rotary dryer, however, is the primary source
of particulate emissions. This stream usually passes
through a cyclone precleaner to remove some particulate, but
emissions still amount to about 5 pounds per ton of product.
The particulate emission rate increases as the particle size
of the aggregate decreases.
Control System - Covering belt conveyors, elevators, screens,
bins and other handling operations, and venting the dis-
placed air through a fabric filter system will effectively
control emissions from these sources.
A cyclone precleaner followed by a fabric filter or
high-energy wet scrubber can be used to reduce particulate
emissions from the rotary dryer. Scrubber systems should
3-309
-------
I PAHKUUII IMUSION fOINTl
Figure 3-159. Asphalt batch process,
3-310
-------
provide at least 10 gallons of water per 1000 standard cubic
feet of exhaust gas. Pressure drops through the scrubber
should be in the range of 10 to 20 inches of water. Fabric
filter systems commonly use glass fiber or Nomex fabric and
operate at air-to-cloth ratios of 3.5/1 to 6.5/1 (cubic
foot per minute per square foot).
Compliance Schedules - Figures 3-160 and 3-161 illustrate
expeditious schedules for installation of a wet scrubber and
a fabric filter on a rotary kiln.
Because the industry is seasonal in the northern climates,
field construction and control system tie-in are sometimes
scheduled only during the winter and early spring to avoid
financial hardships caused by shutdown.
Sources of Additional Information
Type of
Source information*
1. Danielson, J.A., editor. Air Pollu- P, E, C
tion Engineering Manual. U.S.
Environmental Protection Agency,
Research Triangle Park, North
Carolina. Publication No. AP-40.
May 1973. 987 p.
2. Particulate Pollutant System Study. P, E, C
Volume III. Handbook of Emission
Properties. Prepared by Midwest
Research Institute for the U.S.
Environmental Protection Agency,
Durham, North Carolina. NTIS No.
PB 203 522. May 1971. 613 p.
*P = Process description
E = Emission rates
C = Control devices
3-311
-------
Milestones
•Activity and duration In weeks
U>
I
u>
I-1
to
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
12
27
42
44
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Comnit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
6-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-H Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Figure 3-160.
Perform startup, shakedown, and
emission testing
Schedule for installation of a wet scrubber on an
asphalt batch plant.
-------
u>
I
W
I-1
U)
D
HIlestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
Increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
14
30
47
50
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalise plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
1nos
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-In
4-5
Figure 3-161.
Perform startup, shakedown, and
emission testing
Schedule for installation of a fabric fliter =.on an
asphalt batch plant.
-------
3.8.7 Asphalt Roofing
Process Description - Asphalt roofings are made by impreg-
nating a felt base with asphalt on high-speed machines
called asphalt saturators. Figure 3-162 schematically
illustrates this process. The felt is fed continuously from
rolls onto the dry looper, which provides live storage of
felt so that changing rolls will not interrupt production.
From the dry looper, the felt travels to the spray section,
where liquid asphalt heated to 400 to 450°F is sprayed on
one side of the felt; this spraying drives the moisture out
of the unsprayed side and prevents blisters when the felt is
saturated. In the asphalt tank, the felt is impregnated
with asphalt maintained at the designated temperature by
continuous circulation through an asphalt heater. The
impregnated felt then enters the wet looper, where it is
cooled by traveling over sets of rollers arranged in verti-
cal loops. The impregnated felt is rolled at the discharge
end of the wet looper for use as roofing felt; alternatively,
rock granules or other materials can be added and the felt
cut for use as roofing shingles.
At some roofing plants the asphalt saturant must first
be processed. This preparation, called "blowing", consists
of oxidizing the asphalt by bubbling air through it for 8 to
16 hours.
Atmospheric Emissions - The relatively high temperature at
which the asphalt is applied to the felt causes the lower-
boiling-point components of the asphalt to vaporize. In
addition, moisture in the felt vaporizes, resulting in steam
distillation of the asphalt. The vaporized components
subsequently condense as very fine particulate matter and
create a highly visible plume. Emissions from the asphalt
saturation operation without controls range from 1 to 3
pounds of particulate per ton of saturated felt produced.
3-314
-------
t»
Figure 3-162. Manufacture of asphalt roofing materials,
3-315
-------
The asphalt blowing operation is another significant
source of air pollution. Uncontrolled emissions are approx-
imately 2.5 pounds and 1.5 pounds of particulate and hydro-
carbons, respectively, per ton of saturated felt produced.
Control Systems - A common method of control at asphalt
saturating plants is complete enclosure of the spray and
saturator area, with ventilation through one or more control
devices.
The two most effective control devices are direct-flame
afterburners and High-Energy Air Filters (HEAF). The HEAF
is a disposable, once-through, moving filter pad of glass
fiber through which the process exhausts pass. Generally,
HEAF units are used on existing plants where heat recovery
is not practical. Most new installations are equipped with
afterburners with heat-recovery systems.
Compliance Schedules - Figures 3-163 and 3-164 illustrate
expeditious schedules for installation of a direct-fired
afterburner and a high-energy air filter, respectively, on an
asphalt roofing operation.
Sources of Additional Information
Type of
Source information*
1. Danielson, J.A., editor. Air Pollution P, E, C
Engineering Manual. U.S. Environmental
Protection Agency, Research Triangle
Park, North Carolina. Publication No.
AP-40. May 1973. 987 p.
*P = Process description
E = Emission rates
C = Control devices
3-316
-------
U)
to
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
Increments A to 6.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
10
27
43
45
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Coimnlt funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
A Q-3 Award construction contract
3-N Initiate on-slte construction
N-R Install control device
K-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
Figure 3-163. Schedule for installation of an afterburner
on an asphalt roofing operation.
-------
CO
I
U)
H
00
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G, WEEKS
10
_29_
39
41
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and*
emission testing
Figure 3-164. Schedule for installation of a HEAF unit
on an asphalt roofing operation.
-------
3.8.8 Concrete Batching
Process Description - Three types of concrete batching
plants are in use: wet-batch plants, central mix plants,
and, to a much lesser extent, dry-mix plants. In wet-batch
plants the raw materials consisting of sand, aggregates, and
cement are mixed in specified propprtions and dropped into
a transit-mix truck while water is added simultaneously-
(See Figure 3-165). In central mix plants the raw materials
are mixed at the plant and wet concrete is delivered to the
job site in open trucks. In dry-mix plants the sand, aggre-
gate, and cement are mixed dry; the dry mix is transported
to the job site, where water is added and the concrete is
mixed.
Atmospheric Emissions - Particulates can be emitted in
significant quantities from the receiving and conveying of
cement, sand, and aggregates, and from load-out of the
concrete. Factors affecting the emission rate include the
amount and particle size of the materials handled and the
type of handling systems. Particulate emissions from an
uncontrolled wet-batch plant are approximately 0.2 pound per
cubic yard of concrete. The emission potential of dry-mix
plants is much higher.
Control Methods - Enclosure of dumping areas and of con-
veyors and elevators, together with the use of bin vent
filters will substantially reduce particulate emissions.
Use of wet scrubbers can entail- operational difficulties
such as plugging of spray nozzles, corrosion, and waste-
water disposal problems.
Compliance Schedules - Figure 3-166 illustrates an expedi-
tious schedule for installation of a fabric filter on a
concrete batch plant.
3-319
-------
WATER
GATHERING
HOPPER
COMPRESSED-AIR
CYLINDER!;
METAL PLATE
FOAM RUBBER
TRANSIT-MIX
TRUCK
Figure 3-165. Wet-concrete batch loading operation.
3-320
-------
u>
I
U)
to
D
Milestones
•Activity and duration 1n weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-s1te construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
14
30
47
50
Activity
designation
A-B
A-C
C-D
D-E
E-F
Activity description
Conduct source tests
Perform preliminary Investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Figure 3-166.
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Schedule for installation of a fabric filter on a
conerete batch plant.
-------
Sources of Additional Information
Type of
Source information*
1. Danielson, J.A., editor. Air Pollution P, E, C
Engineering Manual. U.S. Environmental
Protection Agency, Research Triangle
Park, North Carolina. Publication No.
AP-40. May 1973. 987 p.
2. Exhaust Gases from Combustion and Indus- P, C
trial Processes. Prepared by Engi-
neering-Science, Inc. for the U.S.
Environmental Protection Agency, Durham,
North Carolina. NTIS No. PB 204-861.
October 1971. 436 p.
*P = Process description
E = Emission rates
C = Control devices
3-322
-------
3.8.9 Coal Preparation Plants
Process Description - Coal preparation includes'crushing,
screening, cleaning, and blending the coal. Some plants
only crush and screen the coal and prepare to a specific
size. Other preparation plants also clean the coal to
reduce the amounts of undersirable materials such as sulfur
or ash. Both wet and dry coal cleaning methods are used.
Wet cleaning is based on the differences in specific
gravities of the coal and the undesirable materials. Wet
separation is done with jigs, dense-medium processes, and
concentration tables. After the coal has been separated by
a wet technique it is dewatered by screens, followed by
centrifuges or vacuum filters. Often, thermal drying by
fluidized bed, flash, or multilouvered dryers is required.
In dry separation a pulsating air table stratifies the
crushed feed into two layers. The coal, being lighter, is
removed from the top and sent to storage bins, while the
refuse from the bottom is sent to a refuse pile.
Atmospheric Emissions - Thermal dryers and pulsating air
tables are the major sources of coal dust emission at coal
preparation plants. Crushing, screening, and handling of
coal are minor sources of dust emission. Fugitive dust
emissions from crushing and screening operations are 0.1
pound*of particulate per ton of coal processed. Fluidized
bed, multilouver, and flash dryers emit approximately 20,
25, and 16 pounds of particulate, respectively, per ton of
coal dried.2 Approximately 1.3 percent of the dried coal is
burned in the thermal dryer.1 This burning generates
combustion gases, which are also emitted to the atmosphere.
Cleaning by pulsating air table eliminates the drying
step. The air tables release to the atmosphere approxi-
mately 3 pounds of particulate per ton of coal feed.
3-323
-------
Refuse piles are a source of combustion gas and partic-
ulate emissions. Fires can be caused by spontaneous com-
bustion, carelessness, or sabotage. These piles are nor-
mally located off-site.
Control Systems - Thermal dryer emissions are normally
controlled by mechanical collectors, water sprays, and wet
scrubbers. Baghouses are not used because of the danger of
a coal dust explosion. High-energy scrubbers with demisters
can reduce exhaust grain loadings approximately 99 percent.
Water sprays can reduce crushing emissions approxi-
mately 80 percent. Controls are normally not needed on
secondary grinding operations because the coal has been
completely wetted by water sprays.
For control of emissions from refuse piles, safety
measures include proper construction of the pile by compac-
tion and sealing to prevent air circulation and ignition.
The refuse pile is not needed if the reject material is used
to backfill underground mine tunnels. Proper sealing of the
mine eliminates any potential refuse burning.
Compliance Schedules - Figure 3-167 shows an installation
schedule for a high-energy wet scrubber. A coal preparation
plant may have multiple thermal dryers, located so that more
than one scrubber is needed. About 8 weeks is required for
each additional scrubber. Installation of one high-energy
scrubber will require approximately 64 weeks, including 24
weeks for control device•fabrication.
3-324
-------
00
OJ
ro
Ul
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
17
38
63
66
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
H-N Fabricate control device
L-0 Prepare engineering drawings
0-F Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-In
4-5
Figure 3-167.
Perform startup, shakedown, and
emission testing
Schedule for installation of a high-energy wet scrubber on a
coal preparation thermal dryer.
-------
Sources of Additional Information
Type of
Source information*
1. Cavanaugh, F.C., et al. Atmospheric P, E, C
Pollution Potential from Fossil Fuel
Resource Extraction, On-Site Process-
ing, and Transportation. Prepared by
Radian Corporation for ^.S. Environ-
mental Protection Agency under
Contract No. 68-02-1319, Task 19.
March 1976. p. 293.
2. Compilation of Air Pollutant Emission E
Factors, 2nd edition. U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina.
Publication AP-42. February 1976.
pp. 8.9-1 and 8.9-2.
3. Environmental Assessment of Coal P, E, C
Transportation. Draft report pre-
pared by PEDCo-Environmental
Specialists, Inc. for U.S. Environ-
mental Protection Agency, Research
Triangle Park, North Carolina under
Contract No. 68-02-1321, Task 40.
October 1976.
P = Process description
E = Emission rates
C = Contol devices
3-326
-------
3.9 PETROLEUM INDUSTRY
3.9.1 Petroleum Refining
Process Description - Capacities of petroleum refineries
normally range from under 20,000 barrels per day to more
than 200,000 barrels per day at a complete modern refinery.
Crude oil is initially separated by distillation into
boiling-range fractions (e.g., gas, naphtha, kerosene,
middle distillates, and heavy bottoms). Since these frac-
tions seldom conform to either product demand or quality
requirements, the less desirable fractions are converted to
more marketable products. Conversion normally consists of
splitting, uniting, or rearranging the original molecular
structure. The subsequent separation and conversion prod-
ucts are then treated for removal of undersirable components
and are blended with each other and a variety of additives
to meet product specifications.
The conversion processes consist of hydro, catalytic-,
and thermal-cracking, which function principally to produce
smaller, lower-boiling-point hydrocarbons. Catalytic re-
forming produces higher-quality gasoline mainly by isomeriz-
ing and aromatizing naphtha. Polymerization combines two or
more gaseous olefins, and alkylation combines an olefin with
an isoparaffin to form gasoline-range hydrocarbons. An
isomerization unit increases the formation of molecular
branch chains and improves gasoline quality. The most
common treating processes, such as caustic treating, hydro-
treating, and desulfurization, are used to reduce the prod-
uct's sulfur content.
Figures 3-168 and 3-169 illustrate processing plants
for intermediate and complete refineries, respectively.
Atmospheric Emissions - Refinery operation^ entail a number
of emission sources, including storage tanks, wastewater
3-327
-------
Wet gas
Crude oil
A
Amospheric topping unit
Stroight run
naphtho
Raw kerosine
Middle distillate
Heavy gas oil
f, fTT
ate
• GuspiuMi • Ifllr.y^.u,,, SR gasoline '_
-»-|Catolytic reformer!
I"
Hydrotrealing plant
Reformate
rnMi-iir r,^*. Crocked goso. _ u ... 1
Ivac gc
s oil L'9h' f"
U 1
el oil
Cat
^-x
(U
st — *~
s
alytic gasoline
Reduced
crude
g1
Lube stocks
Res duum
| Lube processing!]
-^Asphalt sliMs|-
Figure 3-168. Intermediate refinery.
U'G
Motor gas
Aviation gasoline
Kerosine
Light fuel oil
and
diesel fuel
_»_ Lube stocks
-+- Wan stocks
-*- Asphalt
Heavy fuel on
3-328
-------
Dry gos
Wet gos
Residuum
^ICoker
Motor gasoline
*- Aviation gasoline
Olefins to
chemical
•Hvy hydro -
cracked
gasoline
Hydrogen
--Coker gasoline
— •-[Asphalt
1 still
Lube
processing
i
FT
Kerosine
*- Light fuel oil
Diesel fuel
*- Sulfur
Lubes
Waxes
Greases
»- Heavy fuel oil
*- Asphalt
*- Coke
Figure 3-169. Complete refinery.
3-329
-------
sewer systems, pumping systems, blowdown systems, boilers
and process heaters, and catalytic regeneration units.
Emissions from many of these sources can be effectively
controlled by proper design and maintenance.
Storage tanks are significant potential sources of
hydrocarbon emissions, particularly those storing crude oil
and light distillates. Vapor is lost mainly from direct
evaporation and displacement during filling. Hydrocarbon
losses can be minimized by the use of pressure tanks, vapor-
recovery systems, or floating-roof tanks, as described in
Section 3.3.2.
The wastewater sewer system can also cause significant
hydrocarbon emissions unless it is properly designed and
maintained. The front end of the wastewater gravity separa-
tor can be covered. Use of liquid seals on catch basins,
use of manhole covers, and other good housekeeping practices
will reduce vapor losses from drainage systems.
The complex network of piping and valves is a large
potential source of hydrocarbon emissions, which also can be
controlled by good maintenance practices. Hydrocarbon
emissions from pumps and compressors can be reduced by
proper maintenance and the use of mechanical seals in light
hydrocarbon service.
Blowdown systems are used during start-up and shutdown
of process units to vent hydrocarbon vapors and during
routine operation to capture various hydrocarbon leaks and
vented materials from relief valves. Condensable hydro-
carbons are recovered and the noncondensibles are flared.
Emissions can be minimized by use of a properly designed
smokeless flare with steam or air injection.
Boiler and process heaters burning heavy fuel oil are a
major source of particulates, nitrogen oxides, and sulfur
oxides. They can also emit significant quantities of hydro-
carbons and aldehydes.
3-330
-------
The catalyst regeneration system of the catalytic-
cracking unit is a major source of carbon monoxide, sulfur
and nitrogen oxides, hydrocarbons, and particulate emis-
sions. In the fluid catalytic cracking unit, the most
common type in larger refineries, the catalyst is regen-
erated in a continuous moving bed to maintain unit heat
balance and burn off the coke that is formed on the catalyst
surface.
Regeneration of catalyst from fixed bed reforming,
hydrotreating, and hydrocracking is normally done in batches
during a shutdown. The regeneration consists of burning
coke and other deposits off the catalyst with a circulating
inert gas stream containing a controlled amount of oxygen.
Regeneration of reforming catalyst emits CO2 and some
halides as acid mist. Regeneration of hydrotreating and
hydrocracking catalyst emits CO-r SO?' ammoni-a' an^ other
minor impurities.
Control Systems - As mentioned earlier, many emissions may
be effectively reduced by proper maintenance or by venting
to a vapor recovery or flare system.
Sulfur-laden hydrocarbon vapor streams are normally
treated by amine treaters, which yield a recoverable hydro-
carbon stream and a stream high in H-S. Vapor streams rich
in H-S can be controlled by a sulfur plant (Glaus Unit) that
recovers elemental sulfur; sulfur removal efficiencies of
Claus plants are 93 to 99 percent. Several processes are
available to reduce the sulfur content of the tail gas from
a Claus Unit, some of which treat the tail gas before incin-
eration and some after incineration. The product stream is
either elemental sulfur or S02. Among the processes avail-
able that appear acceptable are the Beavon Sulfur Removal
Process, the Clean Air Sulfur Process, the Shell Flue Gas
3-331
-------
Desulfurization Process, and the Wellman-Power Gas SO2
Recovery Process.
Carbon monoxide and hydrocarbon emissions from a fluid
catalytic cracking unit can be controlled by waste heat
boilers, and particulate emissions, by electrostatic pre-
cipitators. Waste heat boilers are normally used on all
large units for heat recovery- Multistage cyclones, which
are an integral part of the cracking unit, will also reduce
the particulate load to the precipitator.
Emissions from regeneration of fixed bed catalyst can
be controlled by passing regeneration gases through a caus-
tic scrubber and venting the wet gas to a firebox.
Compliance Schedules - Figures 3-170 through 3-173 illus-
trate expeditious schedules for installation of an amine
treater-sulfur plant, a tail gas desulfurization unit, a
package amine treater-sulfur plant, and an electrostatic
precipitator. The schedules for tail gas desulfurization
represent an average time requirement for the several pro-
cesses available.
3-332
-------
Sources of Additional Information
Type of
Source Information*
1. Danielson, J.A., editor. Air P, E, C
Pollution Engineering Manual.
U.S. Environmental Protection
Agency, Research Triangle Park, III
N.C. Publication Number AP-40.
May 1973. 987p.
2. Elkin, H.F. Petroleum Refinery P, C
Emissions. In: Air Pollution,
Volume III, Stern, A.C. (ed.).
Academic Press, New York, 1968.
pp. 97-122.
3. Nelson, W.L. Petroleum Refinery P, C
Engineering. McGraw-Hill, New
York, 1958.
4. Atmospheric Emissions from Petroleum E
Refineries. A Guide for Measurement
and Control. Public Health Service,
Cincinnati, Ohio. NTIS No. PB 198-096.
1960. 64p.
P = Process description
E = Emission rates
C = Control devices
3-333
-------
22
12
28
LO
I
U)
CO
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance 1s achieved.
ELAPSED TIME (UEEKS)
4
26
38
66
69
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award construction contract. -
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process tie-ins.
4-5 Perform equipment startup and source testing
Figure 3-170.
Schedule for installation of an amine-treater-sulfur
plant at a petroleum refinery.
-------
22
14
20
OJ
U)
U1
MILESTONES
1
2
3
4
5
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME (WEEKS)
4
26
38
60
62
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications.
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process t1e-1ns.
4-5 Perform equipment startup and source testing
Figure 3-171,
Schedule for installation of a tail gas desulfurization
unit at a petroleum refinery.
-------
24
16
32
I
U)
MILESTONES
1
2
3
4
5
Date of subrolttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME (UEEKS)
4
28
44
76
80
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications.
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction including process tie-Ins.
4-5 Perform equipment startup and source testing
Figure 3-172. Schedule for installation of an amine treater, a sulfur plant,
and a tail gas desulfurization unit at a petroleum refinery.
-------
u>
i
U)
D
Milestones
•Activity and duration 1n weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
19
42
82
86
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-6
G-1
1-H
H-J
J-2
2-K
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R.-4 Complete construction and system
tie-in
4-5
Figure 3-173.
Perform startup, shakedown, and
emission testing
Schedule for installation of an electrostatic precipitator
on a catalytic cracking unit.
-------
3.10 PULP AND PAPER
3.10.1 Kraft Process
Process Description - In the Kraft process, shown schemati-
cally in Figure 3-174, an aqueous solution is mixed with
wood chips in a large pressure vessel, the digester, to
dissolve the lignin that binds the wood fibers. This solu-
tion, the "white liquor", consists of sodium hydroxide or
sodium hydroxide and sodium sulfide.
The mixture is cooked in the digester with steam for
several hours. When the cooking is completed, the contents
of the digester are forced into a blow tank. The pulp is
then separated from the spent "black" liquor, washed in
several stages, and bleached before it is sent to a paper
mill for further processing.
The spent black liquor together with the water from the
pulp washer is initally concentrated in a multiple-effect
evaporator. It is usually further concentrated by direct
contact evaporation with the flue gas from the recovery
boiler. The combustible, concentrated black liquor from the
direct contact evaporator is injected into the recovery
boiler and burned. Heat is recovered in the form of steam,
and the inorganic chemicals in the spent liquor fall to the
floor of the furnace in a molten state.
The melt, which consists essentially of a mixture of
sodium sulfide and sodium carbonate, is withdrawn from the
furnace and dissolved in water and weak liquor from the
causticizing plant. The "green" liquor thus produced is
further treated with calcium hydroxide to convert the sodium
carbonate to sodium hydroxide. The carbonate precipitates
from the solution and is collected and sent to the lime
kiln. There it is calcined to calcium oxide, which is
slaked and converted back to calcium hydroxide. This treat-
ment of the "green" liquor produces the "white" cooking
liquor used in the digester.
3-338
-------
WOOD CHIPS
RELIEF
GASES
STEAM
CO
I
CO
CO
FRESH
MAKE UP
LIQUOR
FLUE GAS
TO STACK
BLOW GASES
BLOW TANK
KNOTTER
H
WASHING
BLEACHING
COMPENSATE
MULTIPLE
EFFECT
EVAPORATOR
DIRECT
CONTACT
EVAPORATOR
CAUSTICIZER
TANK
t I
TO PAPER
MILL
RECOVERY
FURNACE
WATER
S LAKER
WATER
DISSOLVING
TANK
Figure 3-174. Kraft process
-------
Atmospheric Emissions - The major sources of particulate
emission from the Kraft pulp mill, in decreasing order of
importance, are 1) the recovery furance, 2.) the lime kiln,
and 3) the smelt dissolving tank.
It is estimated that 150 pounds of particulates would
be emitted from an uncontrolled recovery furnace for every
ton of air-dried pulp produced. The corresponding figures
for the lime kiln and the smelt dissolving tank are 45
pounds per air-dried ton and 2 pounds per air-dried ton,
respectively.
Odors can be a serious emission problem, especially if
direct contact evaporation is used or the recovery boiler is
improperly operated. Sulfur oxides can also be emitted from
the recovery boiler.
Control Systems - Electrostatic precipitators are commonly
used to control emissions from recovery furnaces, and wet
scrubbers to control emissions from lime kilns and smelt
dissolving tanks.
Compliance Schedules - Figures 3-175 and 3-176 illustrate
expeditious schedules for installation of an electrostatic
precipitator and a wet scrubber, respectively, for particu-
late emission control on a recovery boiler in a pulp mill.
3-340
-------
i
U)
n
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter Z for time
Increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment 1s completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
20
48
108
114
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Conrit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Figure 3-175,
Perform startup, shakedown, and
emission testing
Schedule for installation of an electrostatic precipitator on a
recovery boiler in a -pulp mill.
-------
Ul
I
U)
**
NJ
Milestones
•Activity and duration in weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME
FROM G. WEEKS
14
38
70
74
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary investigation
C-D Evaluate control alternatives
0-E Commit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids.
J-2 Award control device contract
2-K Prepare assembly drawings
Activity 9
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5
Perform startup, shakedown, and
emission testing
Figure 3-176. Schedule for installation of a wet scrubber on a
lime kiln and smelt dissolving tank in a Kraft mill.
-------
Sources of Additional Information
Type of
Source Information*
1. Particulate Pollutant System Study. P, E, C
Volume III. Handbook of Emission
Properties. Prepared by Midwest
Research Institute for the U.S.
Environmental Protection Agency,
Durham, North Carolina. NTIS No.
PB 203 522. May 1971. 613p.
2. A Manual of Electrostatic Precipitator C
Technology. Part II - Application
Areas. Prepared by Southern Research
Institute for the U.S. Environmental
Protection Agency, Research Triangle
Park, North Carolina. NTIS No.
196-387. August 1970. 584p.
3. Kirk-Othmer Encyclopedia of Chemical P
Technology, 2nd edition. Volume 16.
Interscience Publishers. New York.
1969.
4. Control of Atmospheric Emissions in P, E, C
the Wood Pulping Industry. Volumes
I, II, and III. Prepared by
Environmental Engineering, Inc. for
the U.S. Environmental Protection
Agency. NTIS No. PB 190-351, 190-352,
and 190-353. March 1970.
P = Process description
E = Emission rates
C = Control devices
3-343
-------
3.10.2 Sulfite Pulping
Process Description - Pulp mills operating with acid cooking
liquor and incorporating no recovery system for spent liquor
initially pose a problem of water pollution. Restrictions
on the discharge of the spent liquor to surface waters will
make mandatory the installation of spent liquor recovery
systems at plants that have not already installed such a
system. This solution to the water pollution problem, how-
ever, can create an air pollution problem. For this reason
a control system designed for water treatment also must
include air pollution control.
The several commercial systems for treatment of spent
sulfite liquor follow basically the same steps: 1) concen-
tration of the dilute spent liquor to a point where it can
sustain combustion; 2) burning of the concentrate and
recovery of the base chemical and heat; and 3) flue gas
quenching and control of sulfur dioxide by scrubbing the gas
with a solution containing the recovered base chemical. A
simplified flow diagram of the process is shown in Figure
3-177.
Dilute spent sulfite liquor from the pulp washer is
sent to a multiple-effect evaporator, where water is driven
off and the liquor is concentrated to about 50 percent
solids. Some volatile hydrocarbons, such as acetic acid,
are also driven off and leave the evaporators with the
condensate to enter a water treatment system. The concen-
trated liquor is combusted in the primary recovery furnace,
and steam is generated from the heat of combustion. The
recoverable chemical base, such as magnesium, is collected
through a multicyclone dry collector or an electrostatic
precipitator. If the base is not recoverable, as with
ammonia, then no ash collector is needed, since the ammonia
3-344
-------
STEAM
STACK
BOILER FEED WATER —
SPENT SULF1TE
L1OUCR FROM
PULP WASHER
MULTIPLE
EFFECT
EVAPORATOR
I
OJ
£*
Ul
SO2
PRIMARY
RECOVERY
FURNACE
ASH
COLLECTOR
BASE CHEMICAL MAKE UP
WATER
S02
SECONDARY
RECOVERY
SYSTEM
BASE
CHEMICAL
RECOVERY
COOKING
LIQUOR
FORTIFIC-
ATION
sc2
MAKE UP
COOKING
LIQUOR
TO DIGESTER
CONDENSATE TO SECONDARY
WATER TREATMENT SYSTEM
WASH WATER
TO SEWER
Figure 3-177. Spent sulfite liquor recovery system.
-------
is also combusted in the furnace and emitted as nitrogen and
NO compounds. The recoverable base, in, the form of an
Jk
oxide,-is washed to remove soluble impurities such as the
sulfates, then slaked to form the hydroxide, which is then
used as the chemical base in the SO2 secondary recovery
system to scrub the SO, from the gas and form a weak sulfite
liquor. This weak liquor is fortified by injection of S02
under low pressure to form rich cooking liquor, which is
sent back to the digester.
The gases from the secondary system leave the stack es-
sentially as inerts and moisture, with traces of S02 and
NOX.
A poorly designed or improperly operated spent liquor
recovery system can be a source of air pollution.
Compliance Schedules - A compliance schedule for construc-
tion and startup of a properly designed spent liquor re-
covery system is shown in Figure 3-178. This compliance
schedule can accommodate the simultaneous installation of
any associated water treatment system that may be required.
3-346
-------
16
10
87
U)
MILESTONES
1
2
3
4
5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-site construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ELAPSED TIME (KEEKS)
0
16
26
113
119
DESIGNATION ACTIVITY
1-2 Prepare detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award construction contract.
2-3 Fabricate and deliver structural components on site.
3-4 Deliver remaining equipment and complete construction Including process t1e-1ns.
4-5 Perform equipment startup and source testing
Figure 3-178. Schedule for installation of a, spent sulfite liquor
recovery system in a pulp mill.
-------
Sources of Additional Information
Type of
Source Information*
1. Particulate Pollutant System Study. P, E, C
Volume III. Handbook of Emission
Properties. Prepared by Midwest
Research Institute for the U.S.
Environmental Protection Agency,
Durham, North Carolina. NTIS No.
PB 203 522. May 1971. 613p.
2. Kirk-Othmer Encyclopedia of Chemical P
Technology, 2nd edition. Volume 16.
Interscience Publishers, New York,
1969.
3. Control of Atmospheric Emissions in P, E, C
the Wood Pulping Industry. Volumes
I, II, and III. Prepared by
Environmental Engineering, Inc. for
the U.S. Environmental Protection
Agency. NTIS No. PB 190 351.
190 352, and 190 353. March 1970.
*
P = Process description
E = Emission rates
C = Control devices
3-348
-------
3.10.3 Wood Waste (Hog) Boilers
Process Description - Wood waste (hog) boilers are used to
dispose of bark and wood scraps and to produce steam.
Typically these boilers produce steam at rates of 20,000 to
150,000 pounds per hour. Steam capacities are highly
variable, however, and can range from 1000 to 800,000 pounds
per hour. The most common hog boilers are spreader stokers;
older Dutch oven furnaces and new suspension burning systems
are also used to burn the wood waste from Kraft mills. Some
wood waste boilers use natural gas, oil, or coal as an
auxiliary fuel to maintain or improve combustion and to
2
supplement the wood waste fuel during rapid load transients.
The flyash from hog boilers is primarily unburned car-
bon and is often reinjected to increase thermal efficiency.
Atmospheric Emissions - Atmospheric discharges from a wood
waste boiler contain the gaseous products of combustion and
particulate. SO2 emissions occur only if an auxiliary fuel
containing sulfur is used. Except for the sulfur oxide
content, the exhaust gas composition is similar to that of a
coal-fired boiler. It will contain less moisture and less
flyash, depending on the type of bark fired.
Uncontrolled particulate emissions from hog boilers
with no flyash reinjection are estimated to be 30 to 50
pounds per ton of bark burned, assuming an as-fired moisture
content of 50 percent. Particulate emissions from boilers
using flyash reinjection are estimated to be 45 to 75 pounds
per ton of fuel.
A major factor affecting uncontrolled particulate emis-
sions from boilers using reinjection is the completeness of
separation of the sand and other noncombustibles from the
flyash before reinjection.
Carbon monoxide and hydrocarbons may be emitted in
significant amounts under poor operating conditions.
3-349
-------
Control Systems - Most bark boilers are equipped with
multiple cyclones with collection efficiencies ranging from 85
to 95 percent. Because this range of efficiencies is not
sufficient to meet most state regulations, secondary control
devices must be added. Scrubbers, electrostatic precipita-
tors, and fabric filters are capable of attaining the re-
quired efficiencies. Fabric filters are not used exten-
sively because of high operating costs, fire hazards, and
danger of boiler shutdowns due to tearing and blinding of
bags. Although ESP's are used to control hog boilers,
the resistivity properties of the flyash may prevent ade-
quate collection unless chemical conditioning agents are
added. Scrubbers can provide the required particulate
collection efficiency (95 to 98 percent) and are not affected
by flyash resistivity-
There is no requirement for absorption of gaseous
pollution in a well-operated boiler because the bark feed
contains little sulfur and most boilers use natural gas as
an auxiliary fuel.
Compliance Schedules - Figures 3-179 and 3-180 illustrate
expeditions schedules for installation of a wet scrubber and
electrostatic precipitator for control of wood waste (hog)
boilers. If water treatment facilities are needed, they can
be installed concurrently with the scrubber within the same
time interval.
3-350
-------
u>
Ul
Q
Milestones
•Activity ind duration In iweks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
Increments A to 6.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-site construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of Mission control equip-
ment Is completed.
Date by which final compliance Is achieved.
ftAPSED TIME
FROM G. HEEKS
12
35
54
58
Activity
designation Activity description
A-B Conduct source tests
A-C Perform preliminary Investigation
C-D Evaluate control alternatives
D-E Connrit funds for total program
E-F Prepare control plan and compliance
schedule for agency
F-G Agency reviews and approves plans
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Prepare assembly drawings
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-slte construction
N-R Install control device
R-4 Complete construction and system
tie-In
4-5
Figure 3-179,
Perform startup, shakedown, and
emission testing
Schedule for installation of a wet scrubber on a
wood waste (hog) boiler.
-------
U)
u>
D
Milestones
•Activity and duration In weeks
MILESTONES
1
2
3
4
5
Refer to Chapter 2 for time
increments A to G.
Date of submlttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of Initiation of on-slte construction or Installation of emission control
equipment.
Date by which on-slte construction or Installation of emission control equip-
ment Is completed.
Date by which final compliance 1s achieved.
ELAPSED TIME
FROM G. WEEKS
20
42
70
75
Activity
designation
A-B
A-C
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Figure 3-180.
Activity description
Conduct source tests
Perform preliminary investigation
Evaluate control alternatives
Commit funds for total program
Prepare control plan and compliance
schedule for agency
Agency reviews and approves plans
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Prepare assembly drawings
Schedule for installation
wood waste (hog)
Activity
designation Activity description
K-L Review and approve assembly draw-
ings
L-M Prepare fabrication drawings
M-N Fabricate control device
L-0 Prepare engineering drawings
0-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N Initiate on-site construction
N-R Install control device
R-4 Complete construction and system
tie-in
4-5 Perform startup, shakedown, and
emission testing
of electrostatic precipitator on a
boiler.
-------
Sources of Additional Information
Type of
Source information*
1. Compilation of Air Pollutant Emission E
Factors, 2nd edition. U.S. Environ-
mental Protection Agency/ Research
Triangle Park, North Carolina. Pub-
lication No. AP-42. February 1976.
2. Junge, David C. Boiler Fired P, E, C
with Wood and Bark Residues. Prepared
by Forest Research Laboratory, Oregon
State University for Plywood Research
Foundation. November 1975. 59 p.
3. Hardison, L.C. and C.A. Greathouse. P, E, C
Air Pollution Control Technology and
Costs in Nine Selected Areas. Prepared
by Industrial Gas Cleaning Institute
for U.S. Environmental Protection
Agency. September 1972. pp. 317-348.
P = Process description
E = Emission rates
C = Control devices
3-353
-------
3-354
-------
4.0 SUPPORTING DATA
Information on compliance schedules was obtained from
control equipment suppliers, equipment users, and from a
survey conducted by the Industrial Gas Cleaning Institute
(IGCI). Supplementary information was also obtained from
compliance schedules submitted to control agencies by vari-
ous companies. These data sources were then combined into
the generalized schedules presented in this document.
Obviously a wide range of time increments were encountered
due to the size variations in the control equipment and the
many site specific conditions encountered in past installa-
tions. A great deal of judgement was thus required to
arrive at a single schedule.
4.1 INFORMATION FROM EQUIPMENT SUPPLIERS
Tables 4-1 and 4-2 summarize information obtained from
equipment suppliers or vendors for large and small electro-
static precipitators. The largest variations in individual
time increments occur in the fabrication and engineering
drawing phase and the actual fabrication and erection
phases.
Table 4-3 presents similar information for wet scrub-
bers of various sizes. "Field erection is the most variable
single factor. Smaller sized package units require con-
siderably less time in all activities.
Multiple cyclones are relatively uncomplicated devices
and thus require less time to fabricate and install. Table
4-4 presents the time ranges estimated by 5 equipment sup-
pliers.
4-1
-------
Table 4-1. VENDOR DELIVERY SCHEDULE FOR INSTALLATION
OF LARGE ELECTROSTATIC PRECIPITATOR
(weeks)
Vendor
1
2
3
4
5
Equipment
size,a
cfm
up to
500,000
500,000 to
1,000,000
Proposal
preparation
4-6
6-7
6
6-8
4
Assembly
drawings
4-6
4
4
Fabrication
drawings
1 f\ 1 Ci
6-
20
28
6 — 1 ft
Engineering
drawings
8
20
28
Fabrication
65-:
18
44
25
40
16-32
Erection
04
26-52
26-52
30
52
8-52
Debugging
Initial
operation
and testing
For any size unless indicated.
-------
Table 4-2. VENDOR DELIVERY SCHEDULE FOR INSTALLATION OF
SMALL ELECTROSTATIC PRECIPITATORS
(weeks)
Vendor
3
9
10
Equipment
size,*
cfm
up to
200,000
more than
200,000
Proposal
preparation
4-5
8
8
6
Assembly
drawings
4-6
4-8
4-8
6-8
Fabrication
drawings
16-20
16-20
11-12
Engineering
drawings
12-16
12-16
11-12
Fabrication
35-44
35-44
24-30
Erection _
18-26
26-52
12-20
Debugging
2-6
4-8
3
Initial
operation
and testing
2
4
1
*>.
I
to
For any size unless indicated.
-------
Table 4-3. VENDOR DELIVERY SCHEDULE FOR INSTALLATION OF WET SCRUBBERS
(weeks)
Vendor
7
15a
8
Equipnent
size,b
cfm
up to
200,000
200,000 to
1,000,000
up to
50,000C
Proposal
preparation
8
8
1-4
1-3
Assembly
drawings
4-6
4-6
3-8
1-3
Fabrication
drawings
18-22
18-22
Engineering
drawings
16-18
16-18
Fabrication
18-22
30-34
10-12
8-16
Erection
26
40-52
6-18
2-6
Debugging
4
4
0-4
Initial
operation
and testing
4
4
0-12
a Industrial operations only.
For any size unless indicated.
° Standard equipment.
-------
Table 4-4. VENDOR DELIVERY SCHEDULE FOR INSTALLATION OF MULTIPLE CYCLONES
(weeks)
Vendor
11
6a
12
13
14
Equipment
size,b
cfm
Proposal
preparation
1-2°
4-8
1
1-2
Assembly
drawings
2-6
3-6
1
0.2
Fabrication
drawings
3-4
8-10
2
0.2
Engineering
drawings
2-4
2
1
Fabrication
5-10
8-10
6-24
6-8
1-3
Erection
1-4C
3
1-4
Debugging
1
Initial
operation
and testing
0.5
in
* For coal fired boiler applications.
For any size unless indicated.
° For custom-made equipment to handle large volume*.
-------
Fabric filter installation time supplied by two sup-
pliers are summarized in Table 4-5. The larger systems
require considerably more fabrication and erection time, but
the other time increments do not vary greatly with equipment
size.
Information on molecular sieve installations for gas-
eous emission controls was supplied as shown in Table 4-6.
Considerable variations in time increments, especially in
fabrication and erection is evident.
Afterburner delivery and installation schedules as
shown in Table 4-7 are fairly consistent between various
suppliers.
Mist eliminators for industrial operations are largely
shop assembled units and thus do not require extensive
engineering or assembly drawing times as shown in Table 4-8.
Schedules for installing a double absorption system at
a sulfuric acid plant are shown in Table 4-9. Time varia-
tions in the early phases of the work involve different
degrees of detail in the planning steps. The balance of the
design, fabrication, and installation times are relatively
consistent between the two suppliers.
4.2 INFORMATION FROM INDUSTRIAL GAS CLEANING INSTITUTE
Through a separate contract with the Industrial Gas
Cleaning Institute, Inc. (IGCI)+, EPA obtained information
from selected air pollution control equipment manufacturers
on the time schedules involved in designing and installing
control devices. The results of this survey are summarized
in Table 4-10 which shows both typical time increments and
the range associated with each increment.
This survey was conducted after other compliance sched-
ule information had been obtained, and was used to check
this previous information. In most cases, the overall
+ EPA Contract 68-02-1473, Task No. 24.
4-6
-------
Table 4-5. VENDOR DELIVERY SCHEDULE FOR INSTALLATION OF FABRIC FILTER SYSTEMS
(weeks)
Vendor
16
17
17
Equipment
size,*
cfm
up to
200,000
200,000
to 500,000
Proposal
preparation
2 A
3
4
Assembly
drawings
2 ID1* »
4-5
4-5
Fabrication
drawings
« ? inb
16-20
16-20
Engineering
drawings
26-30
26-30
Fabrication
8-10b
14-16
40-44
Erection
4-10b
4
14-18
Debugging
1-2
2
Initial
operation
and testinf
1
1
For any size unless indicated.
Use upper range for custom made equipment.
-------
Table 4-6. VENDOR DELIVERY SCHEDULE FOR INSTALLATION OF MOLECULAR SIEVE
(weeks)
Vendor
18
19
20
Equipment
size,*
cfm
Proposal
preparation
2
3-4
Assembly
drawings
3-4
Fabrication
drawings
14
4
Engineering
drawings
14-18
Fabrication
' 5^
8-10
Erection
14
Debugging
4
Initial
operation
and testing
1
00
a For any size unless indicated.
-------
Table 4-7. VENDOR DELIVERY SCHEDULE FOR INSTALLATION OF AFTERBURNER
(weeks)
Vendor
21b
OO
23b
24
Equipment
size,a
cfm
Proposal
preparation
2_o
2_A
1-2
2
Assembly
drawings
3
Fabrication
drawings
6_ O
7 ft
Engineering
drawings
10
1
Fabrication
1 A — 1 £
1 3_9£
13-16
i £_3n
Erection
2-3
Debugging
1-2
Initial
operation
and testing
i
vo
a For any size unless indicated.
Vendor does not provide customer with fabrication drawings.
-------
Table 4-8. VENDOR DELIVERY SCHEDULE FOR INSTALLATION OF MIST ELIMINATOR
ON AN INDUSTRIAL OPERATION
(weeks)
Vendor
25b
26
27
27
28
Equipment
size,a
cfm
2,000 or
below
4,200
(31 dia.,
6 " mesh
pad)
47,000
(101 dia.,
6" mesh
pad)
Proposal
preparation
3
1
Assembly
drawings
2
1
Fabrication
drawings
3
1
Engineering
drawings
3
1
Fabrication
8
2
d
d
6
Erection
c
c
0.2
1
c.
Debugging
Initial
operation
and testing
I
M
o
For any size unless indicated.
Time schedules do not vary with size.
Vendor does not provide installation and erection services.
Vendor does not manufacture equipment..
-------
Table 4-9. VENDOR DELIVERY SCHEDULE FOR INSTALLATION OF
DUAL ABSORPTION SYSTEM FOR SULFURIC ACID PRODUCTION
(weeks)
Vendor
29
30
Equipment
size,*
cfra
'
Proposal
preparation
1 2b
« c oc
« ..10 *>n ......
12-146
Assembly
drawings
Fabrication
drawings
13
Engineering
drawings
43
Fabrication
40-52
Erection
52
Debugging
2
Initial
operation
and testing
2
I
M
M
For any size unless indicated.
For providing cost estimations with a variation of 20 percent.
For providing cost estimations with a variation of 15 percent.
For providing cost estimations with a variation of 5'percent.
For providing cost estimations with a variation of 10 percent.
-------
Table 4-10. SUMMARY OF COMPLIANCE SCHEDULE DATA FROM IGCI SURVEY
to
Desig- Activity
nation Description
G-l Finalize plans and
specif ications
1-H Procure control device
bids
H-J Evaluate control device
bids
J— 2 Award control device
contract
2-K Prepare assembly
drawings (vendor)
K-L Review and approve
assembly drawings
L-M Prepare fabrication
drawings (vendor)
M-N Fabricate control device
L-O Prepare engineering
drawings for system
O-P Procure construction
bids
P-Q Evaluate construction
bids
Q-3 Award construction
contract
3-N Perform on-site
construction
N-R Install control device
R-4 Complete construction
(system tie-in)
4-5 Start-up, shake down
prel. source-test
Total time via fabrication path
Electrostatic Precipitators
< 300 ,000 acfm gas flow
Typical
time.
weeks
4
4
4
3
7
5
17
23
10
6
2
2
21
5
2
3
77
Total time via construction path 78
Range ,
weeks
3-7
3-4
3-8
2-4
4-10
4-6
8-24
10-52
-
-
-
-
16-24
2-8
1-2
1-4
38-120
36-86
Mile-
stone,
weeks
4
11
32
28
3
78
>300,000 acfm gas flow
Typical
time,
weeks
5
7
10
3
10
6
20
43
22
6
3
2
67
19
4
8
135
172
Range,
weeks
4-6
6-8
10-12
2-4
6-14
4-8
14-24
20-104
15-30
-
-
-
24-125
1-70
1-4
3-10
71-264
87-302
Mile-
stone,
weeks
5
20
49
90
8
172
Fabric Filters
<200,000 acfm gas flow
Typical
time.
weeks
5
6
3
2
4
2
5
11
6
2
2
1
6
4
2
3
47
48
Range,
weeks
3-6
2-6
1-4
1-2
2-8
2-4
1-12
4-24
1-12
2-4
1-2
1-2
1-12
2-10
1-6
1-4
20-86
21-82
Mile-
stone,
weeks
5
11
17
12
3
41
>200,000 acfm gas flow
Typical
time,
weeks
5
6
4
4
7
3
11
22
10
4
3
2
13
12
5
4
83
82
Range ,
weeks
2-6
2-8
2-6
2-4
4-8
2-6
4-20
12-36
8-16
2-6
1-6
1-4
6-24
6-20
3-6
2-8
39-128
43-121
Mile-
stone,
weeks
5
14
29
30
4
•2
-------
Table 4-10 (continued). -SUMMARY OF COMPLIANCE SCHEDULE DATA FROM IGCI SURVEY
Desig- Activity
nation Description
G-l Finalize plans and
specifications
1-H Procure control device
bids
H-J Evaluate control device
bids
J-2 Award control device
contract
2-K Prepare assembly
drawings (vendor)
K-L Review t approve
assembly drawings
L-M Prepare fabrication
drawings (vendor)
H-N Fabricate control device
L-0 Prepare engineering
drawings for system
O-P Procure construction
bids
P-Q Evaluate construction
bids
Q-3 Award construction con-
tract
3-N Perform on-site
construction
N-R Install control device
R-4 Complete construction
(system tie-in)
4-5 Start up, shake down
prel. source test
Total time via fabrication path
Total tine via construction .pat
Wet Scrubbers
Low-Energy
<150,000 acfm gas flow
Typical
time.
weeks
3
4
2
2
3
3
6
IS
8
4
2
1
7
3
3
4
48
49
Range,
weeks
2-5
2-6
2-4
2-4
2-6
2-4
3-7
12-24
4-10
2-5
1-3
1-3
6-10
2-6
1-6
2-5
32-77
31-77
Mile-
stone ,
weeks
3
8
21
13
4
49
High -Energy
<150,000 acfm gas flow
Typical
time,
weeks
3
4
3
2
4
3
6
22
7
4
2
1
10
7
4
4
61
58
Range,
weeks
2-5
2-6
2-4
2-4
2-10
2-4
4-8
12-40
4-12
2-5
1-3
1-3
8-15
1-14
1-6
3-5
33-106
33-96
Mile-
stone ,
weeks
3
9
21
21
4
58
High -Energy
>150,000 acfm gas flow
typical
time,
weeks
3
5
4
2
5
4
6
28
9
4
2
2
13
10
5
4
76
72
Range,
weeks
2-5
2-8
2-5
2-4
2-10
2-5
5-8
17-48
8-12
2-5
1-3
2-3
10-18
4-20
2-8
3-6
43-127
44-112
Mile-
stone,
weeks
3
«
11
26
28
4
72
Plue Gas
Oesulfurization System '
Limestone Scrubbing
Typical
time.
weeks
6
10
7
2
21
5
21
58
20
5
5
2
55
10
8
6
156
162
Range,
weeks
2-10
6-20
2-26
1-8
6-39
2-10
8-34
8-79
3-52
2-12
2-12
1-5
l«i-90
4-30
2-26
2-20
60-242
77-286
Miler
stone,
weeks
6
19
58
73
6
162
-------
schedules were in the range obtained in the IGCI survey.
Individual activities did not always agree with the IGCI
estimates and adjustments were made in the previously ob-
tained information.
4-14
-------
APPENDIX A
BASIC CONVERSION FACTORS
APPENDIX A. BASIC CONVERSION FACTORS
Length
Units
1 in.
1 ft
1 yd
1 mile
Area
Units
1 in.2
1ft2
1 yd2
1 mile2
Volume
Units
1 in.3
1ft3
1 qt
1 gal (U.S.)
Mass
Units
1 oz (avdp) =
1 Ib (avdp)
1 ton
Energy
Units
1 cal =
cm
2.54
30.48
91.44
1.609344 x
CIP
6.4516
929.0304
8361.273
2.589988 x
cm
16.38706
28316.85
946.353
3785.412
g
28.34952
453.5924
907184.7
Btu
3.965667
x 10"3
m
0.0254
0.3048
0.9144
105 1.609344 x 103
m2
6.4516 x 10"4
0.09290304
0.8361273
lo10 2.589988 x 106
liter
0.01638706
28.31685
0.946353
3.785412
kg Metric ton
0.02834952
0.4535924
907.1837 0.9071847
kWh
1.1622222...
x 10"6
A-l
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
REPORT NO.
EPA-^0/1-77-017
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
Revised Technical Guide for Review and
Evaluation of Compliance Schedules for Air
Pollution Sources
5. REPORT DATE
MY 1977
6. PERFORMING ORGANIZATION CODE
Date of Issue: May 1977
7. AUTHOR(S)
Richard Gerstle, Fred Hall, and Yatendra Shah
8. PERFORMING ORGANIZATION REPORT NO
3210-2-X, 3210-2-Y
9. PERFORMING ORG "vNIZATION NAME AND ADDRESS
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-01-3150
Tasks 24 and 25
12. SPONSORING AGENCY NAME AND ADDRESS
Division of Stationary Source Enforcement
U.S. Environmental Protection Agency
Washington, D.C. 20460
13. TYPE OF REPORT A\O PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
DSSE Project Officers: J. Casey, S. Karacki, J. Flood
16. ABSTRACT
Compliance schedules previously"presented in the first edition of
a Technical Guide for Review and Evaluation of Compliance Schedules
(Publication EPA 340/1-73-OOla), have been reviewed and up-dated
where required. Schedules for new industries are included and
control systems are reviewed and evaluated based on information
supplied by the manufacturers. Also included is a description of
the compliance schedule format, summary schedules by type of control
device, and an explanation of various factors which affect installa-
tions. Process descriptions, emission sources, emission charac-
teristics, and commonly used control equipment are given for each
industry studied.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
Air Pollution, Compliance Schedules,
Control Equipment,
Emission Factors
b.lDENTIFIERS/OPEN ENDED TERMS C. COSATI I'icld/GtOUp
Emission Limitations
Implementation Plans
Air Quality Standards
13B
18. DISTRIBUTION STATEMENT
Unlimited
19. SECURIT
CURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
454
20. SECURITY CLASS
Unclass
5S (This page)
if led
22. PRICE
EPA Form 2220-1 (9-73)
A-2
------- |