EPA-450/3-76-031
September 1976
                          REPORT
      OF FUEL REQUIREMENTS,
                   CAPITAL COST
     AND OPERATING EXPENSE
                 FOR CATALYTIC
                 AFTERBURNERS
  U.S. ENVIRONMENTAL PROTECTION AGENCY
      Office of Air and Waste Management
    Office of Air Quality Planning and Standards
   Research Triangle Park, North Carolina 27711

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                                    EPA-450/3-76-03I
REPORT OF FUEL REQUIREMENTS,
               CAPITAL COST
      AND OPERATING EXPENSE
 FOR CATALYTIC AFTERBURNERS
                          by

                      CE Air Preheater
                 Industrial Gas Cleaning Institute
                  Stamford, Connecticut 06904
                    Contract No. 68-02-1473
                       Task No. 13
                EPA Project Officer: Frank Bunyard
                       Prepared for

              ENVIRONMENTAL PROTECTION AGENCY
                Office of Air and Waste Management
              Office of Air Quality Planning and Standards
              Research Triangle Park, North Carolina 27711

                      September 1976

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This report is issued by the Environmental Protection Agency to report
technical data of interest to a limited number of readers. Copies are
available free of charge to Federal employees, current contractors and
grantees, and nonprofit organizations - in limited quantities - from the
Library Services Office (MD35), Research Triangle Park, North Carolina
27711; or,  for a fee, from the National Technical Information Service,
5285 Port Royal Road, Springfield, Virginia 22161.
This report was furnished to the Environmental Protection Agency by
CE Air Preheater, Industrial Gas Cleaning Institute, Stamford, Connecticut,
in fulfillment of Contract No. 68-02-1473,  Task No.  13.  The contents
of this report are reproduced herein as received from CE Air Preheater.
The opinions, findings, and conclusions expressed are those of the
author and not necessarily those of the Environmental Protection Agency.
Mention of company or product names is not to be considered as an endorse-
ment by the Environmental Protection Agency.
                    Publication No. EPA-450/3-76-031
                                    11

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                                 CONTENTS
                                                                         Page
SUMMARY. .	    v
CASE 1, INCINERATION WITH NO HEAT RECOVERY .  .	    1
CASE 2, INCINERATION WITH PRIMARY HEAT RECOVERY	   65
CASE 3, INCINERATION WITH PRIMARY AND SECONDARY HEAT RECOVERY	129
CASE 4, INCINERATION WITH DIRECT REUSE OF EXHAUST GASES	193
APPENDIX:  CAPITAL COSTS FOR AFTERBURNERS	203
                                    ill

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                                     SUMMARY





     This report presents the results and conclusions of an investigation in



accordance with the Environmental Protection Agency's Contract Number 68-02-1473.



     The scope of this study is to develop fuel consumption data, capital costs



and annual operating costs for direct flame and catalytic incineration of light



hydrocarbon solvents.  The following combinations of operating parameters were



investigated:



     a)  Catalytic and thermal afterburners for three cases;  1) no heat recovery;



         2) 357, primary heat recovery; and 3) 35% primary heat recovery and 55%



         secondary heat recovery.



     b)  Inlet flow rates to the afterburners of 5,000, 15,000, and 30,000 scfm.



     c)  Inlet stream temperature of 70°F and 300°F for all three cases.



     d)  Inlet stream LEL's of 0%, 5%, 15% and 25%.



     e)  A Case 4 situation is investigated in which a thermal afterburner with
                                                              -v-


         357<> primary heat recovery is used in conjunction with an oven that uses



         a portion of the incinerated gases to supply oven heat.





     The following assumptions were utilized in developing costs:



     a)  Afterburners designed for oil operation only  (gas only for Case 4).



     b)  Thermal afterburners capable of 1500°F operation with a 0.5 second



         residence time.



     c)  Catalytic afterburners capable of 800°F operation below 6% LEL; 1200°F



         design capability for operation from 6% to 25% LEL.



     d)  Three-year catalyst life before replacement is necessary - replacement



         cost annualized with a 7.570 inflation factor and added to yearly fuel cost,



     e)  Costs based on outdoor location.



     f)  Rooftop installation requiring structural steel.

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     g)   Installation costs  developed  for  weight  and complexity of unit,  rather




         than a fixed percentage of capital investment  for equipment.




     h)   Fuel cost  of 1.50 $/MM Btu (gross).




     i)   Electricity at .03  $/KWH.




     j)   Yearly maintenance  4% of capital  investment.




     k)   Yearly tax 1% of capital investment.




     1)   Yearly insurance 0.57, of capital  investment.




     m)   Yearly building overhead 2.5% of  capital investment.




     n)   Yearly depreciation 12% of capital investment.




     o)   Yearly interest 57o  of capital investment.




     p)   Annualized expenditure 2570 of capital investment (summation items j thru o) .




     q)   Direct labor assessed at .5 hrs/shift x  730 shifts/year x 8.00 $/hr. =




         2920 $/year direct  labor expense.




     r)   Operation time:  2  shifts/day x 9 hrs/shift x 365 days/year = 5840 hrs/year.







     The direct flame incinerator (thermal afterburner) utilized was based on




standard designs for oil firing incorporating  the following features:




     a)   0.5 seconds residence time.




     b)   Nozzle mix burner capable of #2 thru  #6  oil firing.




     c)   Forced mixing of the burner products  of  combustion using a slotted




         cylinder mixing arrangement.   This cylinder allows the burner flame




         to establish itself before radial entry  of the effluent thru slots in




         the far end of the  cylinder.




     d)   A portion of the effluent  to be incinerated is ducted to the  burner to




         serve as combustion air -  this allows the burner to  act as a  raw gas




         burner - thus, saving fuel over conventional nozzle  mix burners  - can only




         be used however when the 0« content of the oven exhaust is 1770 b.v. or above,







                                        vi

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     e)   The incinerator for Case 4 uses a line burner, such as the Maxon




         Combustifume, which is a gas fired secondary air (raw gas) burner.




         Minimum 0.3 second retention time at 1500°F operation.






     The catalytic afterburner was costed for two design points, 800°F and 1200°F.




The higher temperature design is required for LEL levels exceeding 670 (at 600°F




into the catalyst and a 67, LEL, the outlet temperature of the catalyst is approx-




imately 800°F - at a 25% LEL condition and a minimum initiation temperature of 500°F,




the catalyst reaches an outlet temperature of around 1200°F.)




     The catalyst unit requires a burner to preheat the oven effluent to a minimum




initiation temperature of 500°F, with 600°F required for some of the slower oxidizing




hydrocarbons (generally, the acetate family and the C-l, and C-2 hydrocarbons).  The




catalyst element will operate successfully in an oil fired environment, however,




only the clean oils  (Nos. 1 and 2) can be employed as the heavier oils contain




metallics which will shorten the life of the catalyst.




     A catalytic element is poisoned (deactivated) by heavy metals such as mercury,




lead and arsenic.  However, if these elements are in heavy enough concentrations to




severely shorten the catalyst life, then the elements themselves would represent an




environmental hazard when discharged to the atmosphere.




     The catalytic element may be blinded by any particulate matter in the exhaust




to be incinerated.  This blinding reduces effectiveness since the catalyst contact




area has been decreased.  Effectiveness can be nearly fully restored by cleaning




via air lancing or possibly washing in a detergent solution.
                                      vn

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     Temperature wise the catalyst can operate at approximately 1200°F and




still give normal (2-3 years) service life.  However, sustained operation at




temperatures higher than 1200°F can severely shorten life.  In general, catalyst




manufacturers will limit their applications to streams with concentrations no




higher than 257» LEL.
                                     vm

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Case 1




     The Case 1 system is a straight afterburner concept using no heat




recovery.




     An analysis of our generated cost, fuel rates, and expenses shows that




the catalytic unit is attractive for use in low LEL exhausts with the direct




flame afterburners a better proposition for the higher LEL concentrations.




One thing that must be remembered in comparing fuel rates between the two




principles is that for the same efficiency the direct flame unit will operate




at temperatures lower than the 1400°F used for an incineration temperature in




the study.  Assuming 907o reduction on a straight hydrocarbon destruction basis,




the direct flame unit would operate at 1200°F.  If CO concentrations are taken




into account  (such as LA Rule 66), the. incineration temperature would be in the




1360°F region.
                                    IX

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Case 2




     The Case 2 system uses a straight afterburner section with either a




catalyst or direct flame incineration, and incorporates a shell and tube




heat exchanger of 3570 nominal efficiency to preheat the effluent before




introduction to the oxidation section.




     This size heat exchanger, which is about the smallest efficiency practical




on a commercial basis, reduces the fuel rate significantly at all inlet




temperatures and LEL conditions.  However, at the higher LEL condition, it




presents problems for the catalytic unit in terms of burner turndown, operation




within the 1200°F high temperature limit, etc.




     As  shown, at 21-25% LEL  conditions and 70°F  inlet process gas temperature




the catalytic unit must use a lower  initiation temperature in order  to  keep




the catalytic outlet  temperature  at  a  1200°F  level.  And when the  inlet




temperature  is raised to 300°F, the  unit  can  only handle an LEL  of approx-




imately  167o  and  still maintain  a  minimum  burner condition and not  go over a




1200°F catalyst  outlet  temperature.




     The direct  flame unit, has  the same problem,  only at a higher LEL rate.




The problem  may  be solved  by  using a bypass around  the primary heat  exchanger,




in effect  creating a  heat  recovery unit  of variable efficiency.   This is  done




in this  study for the 300°F inlet condition and an LEL of 20 to 25%.

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Case 3




     The Case 3 system consists of a Case 2 unit with the addition of a




secondary heat exchanger to indirectly recover incinerator heat for use in




the process.  The secondary heat exchanger is a two-pass shell and tube design




with a nominal efficiency of 55%.




     Fuel rates for the incinerators re.main the same as before for Case 2.




Secondary heat recovery represents various levels which correspond to the LEL




concentration for catalytic units - whereas the direct flame incinerator has




a constant secondary recovery.  It is interesting to note that with the catalytic




unit the fuel rate remains the same and secondary recovery increases with LEL




concentration - as compared to the direct flame, unit where secondary recovery




remains the same and the fuel rate decreases as the LEL increases.




     As in Case 2,  the direct flame units are costed with:.a  heat  exchanger by-




pass for operating  conditions of 300°F and 20-25% LEL.
                                  XI

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                                   .  CASE 4






     The Case 4 system is based on an oven design developed by Wagner Litho




Machinery Division, National Standard Company, Secaucus, New Jersey.  This oven




uses the exhaust gases of a fume incinerator to supply heat.  Approximately 80%




of the incinerated exhaust is used, half to the baking zones and half to preheat




the conveying racks (wickets) before they receive the coated sheet to be transported




through the oven.




     The recirculation of incinerated gases causes the 02 level to decrease to




around 177, b.v.  This figure tends to decrease the flamability "of the solvent air




mixture yet provide adequate oxygen for stable flame propagation at the raw gas




burner as well as an over sufficiency of Q£ for complete oxidation of the solvents.




     The heat recovery oven system using the recirculated exhaust gases of the




incinerator will require less fuel overall than the same oven without recirculation




when the LEL of the oven exhaust is in the 5 to 10 percent range.  This is important




if natural gas is in limited supply.




     Another consideration is that the addition of the incinerator can be of economic




benefit dependent upon the hours of operation, the size of the system, and the price




of the fuel.




     The concept of recirculating incinerator exhaust back to the process would work




equally as well for catalytic incinerators.  The temperature of the recirculated gases




should be in the 800-1000°F temperature range, consequently a primary heat exchanger




would probably not be required.




     The recirculation concept is applicable to all ovens which use large quantities of




hot gases to perform the drying operation.  It is most economical and effective when




the incinerator is an integral part of the oven.





                                     xii

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 CASE 1, INCINERATION




WITH NO HEAT RECOVERY

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NOZZLE MIX BURNER-
      FUEL
      OIL
    40.6 G PH.
    5.32 X 10 BTU/HR
INCINERATION
CHAMBER
                                     PROCESS  GAS   INLET
                                     5000 SCFM  70°F
                                     SOLVENT LOADING  15/6 LEL
                                        PROCE&S GAS FAN
                                       PROCESS
                                                                       INCINERATED  GAS
1400 °F
                                     TYPICAL CASE  I
                                     /NO HEAT  RECOVERY^
                                     \AND NO CATALYST J

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  FUEL
22.5 GPH
2 95 X icf BT U
                                                             600°F
                                    PROCESS GAS  INLET
                                    5000  SCFM-70°F
                                    SOLVENT  LOADING  15% LEL
                                       PROCESS  GAS FAN
                                      PROCESS
                                                                         CATALYST
INCINERATED  GAS
22664
IOOO°F
                                TYPICAL   CASE  I
                              /NO HEAT RECOVERY^
                              V^WITH CATALYST )

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        CASE I
   NO HEAT EXCHANGER
      NO CATALYST
70°F INLET TEMPERATURE
PROCESS
GAS FLOW
IN
ACFM
5,000
5,000
5,000
5,000
i
15,000
15,000
15,000
15,000
30,000
30,000
30,000
30,000
PROCESS
GAS FLOW
IN
#/HR.
22,500
. 22,500
22,500
22,500
67,500
67,500
67,500
67,500
135,000
135,000
135,000
135,000

INCINERATED
GAS FLOW
#/HR.
22,945
22,895
22,796
22,698
68,835
68,685
68,389
68,093
137,670
137,371
136,780
136,187

INLET
TEMPERATURE
°F
70
70
70
70
70
70
70
70
70
70
70
70

OUTLET
TEMPERATURE
op
1,400
1,400
1,400
1,400
1,400
1,400
1,400
1 , 400
iUoo
1,400
1,400
1,400
HEAT
RELEASE HEAT
LEL BTU/CF RELEASE
% (NET) 106 BTU/HR.
00 0
5 2.83 0.85
15 8.47 2.54
25 14.11 4.23
0 00
5 2.83 2.54
15 8.47 7.62
25 14.11 12.71
00 0
5 2.83 5.08
15 8.47 15.23
25 14.11 25.40
BURNER
REQUIREMENTS
106 BTU/HR. 106 BTU/HR.
(NET) (GROSS)
8.00
7.10
5.32
3.56
24.00
21.31
15.98
10.66
48.00
42.63
32.00
21.34
8.50
7.56
5.66
3.79
25.50
22.67
17.00
11.34
51.00
45.36
34.05,
22.71

-------
        CASE I
   NO HEAT EXCHANGER
      NO CATALYST
300°F INLET TEMPERATURE
PROCESS
GAS FLOW
IN
SCFM
5,000
5,000
5,000
5,000
15,000
15,000
15,000
15,000
30,000
30,000
30,000
30,000
PROCESS
GAS FLOW
IN
ACFM
7,170
7,170 '
7,170
7,170
21,509
21,509
21,509
21,509
43,019
43,019
43,019
43,019
PROCESS
GAS FLOW
IN
#/HR.
22,500
22,500
22,500
22,500
67,500
67,500
67,500
67,500
135,000
135,000
135,000
135,000

INCINERATED
GAS FLOW
#/HR. .
22,875
22,824
22,725
22,627
68,120
68,472
68,176
67,880
137,240
136,944
136,352
137,670

INLET
TEMPERATURE
OF
300
300
300
300
300
300
300
300
300
300
300
300

HEAT
OUTLET RELEASE HEAT
TEMPERATURE LEL BTU/CF RELEASE
°F % (NET) 106 BTU/HR.
1,400
1,400
1,400
1,400
1,400
1,400
1,400
1,400
1,400
i , 4oo'
1,400
1,400
00 0
5 2.83 0.85
15 8.47 2.54
25 14.11 4.23
00 0
5 2.83 2.54
15 8.47 7.62
25 14.11 12.71
00 0
5 2.83 5.08
15 8.47 15.23
25 14.11 25.40
BURNER
REQUIREMENTS
106 BTU/HR. 106 BTU/H
(NET) (GROSS)
6.71
5.82
4.05
2.28
20.13
17.48
12.16
6.83
40.27
34.95
24.31
13.66
7.13
6.20
4,30
2 . 4.3
21.43
18.59
12.93
7.27
42.85
37.19
25.86
14.54

-------
                                                       CASE 1
                                                  NO HEAT EXCHANGER
                                                    WITH CATALYST
                                               70°F INLET TEMPERATURE
PROCESS
GAS FLOW
IN
SCFM
5,000
5,000
5,000
5,000
-j
15,000
•15,000
15,000
15,000
30,000
30,000
30,000
'I!
30,000
PROCESS
GAS FLOW
IN
ACFM
5,000
5,000
5,000
5,000

15,000
15,000
15,000
15,000
30,000
30,000
30,000
30,000
PROCESS
GAS FLOW
IN
#/HR.
22,500
22,500
22,500
22,500

67,500
67,500
67,500
67,500
135,000
135,000
135,000
135,000
GAS FLOW
THRU
CATALYST
#/HR.
22,664
22,664
22,664
22,632

67,992
67,992
67,992
67,896
136,984
136,984
136,984
136,792
GAS IN
TEMPERATURE
IN
OF
70
70
70
70

70
70
70
70
70
70
70
70
TEMPERATURE
INTO
CATALYST
°F
600
600
600
500

600
600
600
500
600
600
600
500
TEMPERATURE
LEAVE
CATALYST
op
600
740
1,000
1,208

600
740
1,000
1,208
600
740
1 , 000
1,208

LEL
%
0
5
15
25

0
5
15
25
0
5
15
25
RELEASE
FROM
CATALYST
106 BTU/HR.
0
0.815
2.34
4.06

0
2.44
7.31
12.20
0
4.88
14.62
24.39
BURNER

REQUIREMENTS
106 BTU/HR. 10^ BTU/HR.
(NET) (GROSS)
2.95
2.95
2.95
2.53

8.85
8.85
8.85
7.12
17.69
17.69
17.69
14.24
3.14
3.14
3.14
2.53

9.41
9.41 .
9.41
7.56
18.82
18.82
18.82
15.15
*Heat release based on 96% conversion of solvents by catalyst.

-------
                                                      CASE  1
                                                 NO HEAT EXCHANGER
                                                   WITH CATALYST
                                               300°F INLET TEMPERATURE

PROCESS
GAS FLOW
IN
SCFM
5,000
5,000
5,000
5,000
00
15,000
15,000
15,000
15,000
30,000
30,000
30,000
30,000

PROCESS
GAS FLOW
IN
ACFM
7,170
7,170
7,170
7,170

21,509
21,509
21,509
21,509
43.01.9
43,019
43,019
43,019

PROCESS
GAS FLOW
IN
#/HR.
22,500
22,500
22,500
22,500

67,500
67,500
67,500
67,500
135,000
135,000
135,000
135,000

GAS FLOW
THRU
CATALYST
#/HR.
22,594
22,594
22,594
22,562

67,982
67,982
67,982
67,686
135,564
135,564
135,564
135,372
PROCESS
GAS IN
TEMPERATURE
IN
°F
300
300
300
300

300
300
300
300
300
300
300
300
GAS
TEMPERATURE
INTO
CATALYST
op
600
600
600
500

600
600
600
500
600
600
600
500
GAS
TEMPERATURE
LEAVE
CATALYST
oF
600
740
1,000
1,208

600
740
1,000
1,208
600
740
1,000
1,208


LEL
0
5
15
25

0
5
15
25
0
5
15
25
*HEAT
RELEASE
FROM
CATALYST
106 BTU/HR.
0
0.815
2.34
4.06

0
2.44
7.31
12.20
0
4.88
14.62
14.24

BURNER


REQUIREMENTS
10& BTU/HR. lO5" BTU/HR.
(NET) (GROSS)
1.69
1.69
1.69
1.12

5.07
5.07
5.07
3.35
10.14
10.14
10.14
6.69
1.80
1.80
1.80
1.19

5.39
5.39
5.39
3.56
10.79
10.79
10.79
7.12
*Heat release based on 96% conversion of  solvent  by  catalyst.

-------
ENyiRCN.MENTAL
                                                  PBQ
                                                  NO. 68-02-
                                                   NO. 13
       XiNTKACT
            i TASK
                              'NO CATAL'
                    PROCESS GAS TE**1 DTr
                                  TEM^ RATU RE
                                     30
                                     7.2|96#/Gal.
                     HEATING VALUE   19[l20 Btu/#
                     HEATING VALUE  139;eo
                     11E ATING VAL4»'E   4 7 980
                     HEATING VALUE  131300 Btu/Cal
	8 	t-	61:5

-------
                        ENVIRONMENTAL
                               CONTRACT
                                 '   ' TASF
                 PROTECTION AGENCY
                 NO. 618-02-H73  !
                 NO. J13
                                       CJ
                                NO HEAT
                                    NO CATALYST
                                 GAS
                        INCINERATION TEJMPERATUFE
                 iSE I
                                         RECOVERY
PROCESS
                iJMI
                              ,  IN ->3000 F
                                 - 1400° F
                                    FUELi
|	335. 5
                     A-Pt-
                                          - 02 OIL
DENSITY       ;   7.
HEATING \^ALUE
                     HEADING "
                     HEATING tALUE
                                         1960/Qal,
                                        19130 ftu/ill
                           HHV)j
               139680
                     Btu/Gsl
                     Btn/Ga
                                        10

-------
                                                       c
                                               NO JHEATI
                                                 WITH
                                               70°F
                                               ,YS1J OUT
. 0
                                                      11

-------
12

-------
NVIKCJNMENTAI. PROT
     CONTRACT .NO.
     :     I TASK NO.
              CASE [
       NO
       70° H PROCESS
           !NO CATAU

-------

-------
                         CONTRACT NO.  68-02-
                                TAS&NO. !I3
CASK I
                                    15

-------
iOO'F PROCESS GAS INLET
    WITH CATALYST
        16

-------
                                 O  %
        0/U
               SHES/SH/FT X
SUPPLIES:
,
                    .25
             M/
                              17
                                           2120
                                         Cosrj

-------
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            $000    SCPM    • -5" % JL£L  Pcocess li^p
                       -  2
       o/u
MRS
8.1
                                                      2^20
SUPPLIES :

                             18

-------
                                          LEL
        o/u
•5ro/io<" 67dx 5-7  < \o"/ne. x £5>k> KIRS
              * -
                                                     HP.
SUPPLIES-.
                             73odMirrs/«/_: x 8A°/ He.
                                           2120
                                                         79,**?
                                19

-------
                              LEL
o/u
                                       HP.
       s
     •  \
                     20

-------
SCPM     O
                                            Peocess TEMP ?&*
                       - 2
        o/u
              *
D/tSCT
SUPPLIES;

                    .25
                             21
                                                HP.
                                                    _

-------
                      -  2
       O/U
,
                                                HP.
SUPPLIES;

                              22

-------
\  ,
                                             L£L
   STC/JM
            o/u
.^ xio!Xi4e x
                    SHes/sH/FT x 73osHiPr&/fe x
                  \
                                    23
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-------
                                          /.EL
Process  O/>&e/97-//v<$ T/MC? -
                                        - 3G*s
  PU6L OIU
SUPPLIES:

                                                         _
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                                             Cosr/
                                 24

-------
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                                                        .
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-------
3O, OOP   5CFM
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-------
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                             27

-------
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                      - 2
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-------
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-------
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-------
                          SCFM
                                          LEL
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                                32

-------
SCFM
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   A/0
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                                                     ? 28,373
                               33

-------
          scrM
                                        Lt=L  Process
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                               34

-------
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-------
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                              36

-------
            3&,Q0£>   SCFM     &    LGL  Pcocess  TEMP
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        l£HP.
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                                                      37390
                              37

-------
/%//r-
                              /* JLEL
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                                                          2120
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-------
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                               39

-------
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                               40
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-------
                       SCPM     O     LGL  Peoc«?ss  IJMp  70
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67
-------
                                    LEL
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                       X 730 SHIFTS /«jg  X
SUPPLIES;

                           42
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-------
            SOOO    SCFM    IS    L£L Pcocess Tii^p  ?0
                       -  2
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                             43

-------
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                                46
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41
                                       2120
              or
      .2S
                48

-------
           30.000
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,
             VJf
                               49
                                                       34*27
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-------
3O,0OO
                                         L£L  Peoc
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                                     L£L Peaces* TEMP ?O
                      ~ 2
SUPPLIES;
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                             51

-------
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                       - 2
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                                                      2120
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                    .as
                              52

-------
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279?  -n
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      2120
,
                         x
                              53

-------
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                              54
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                                  2120

-------
                                      LEL  Peocess
                  -    A/*
- 2
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                                                      27
                  Costs
                             55

-------
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                        - 2
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MRS
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                                         2120
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-------
                                              Peoc«=ss TEMP $00°?
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- 2
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-------
                                Cos
erux ..s.4xto
                                              r

-------
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X SSM-o
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                                  59



-------
S/ze-
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                              60
                               3I.S-60  —
                  Costs
                                             
-------
                         S.CFM

    e>
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Process
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                                 61

-------
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67tfX

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          £014,410
                              62

-------
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                        - 2
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                     .25
                                63

-------
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3o. 00 o
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                        - 2
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                               64

-------
    CASE 2, INCINERATION




WITH PRIMARY HEAT RECOVERY
               65

-------
                                            PREHEATED  PROCESS  CAS
  FUEL

  2  OIL
  18.4 GPH
  2 A X I06BTU/HR
o
-j
                                                      580 F
ZLE
NER
»

MIX
-


1

r
INCINERATION
CHAMBER
                                                        I400°F
                                                                           1
PRIMARY
 HEAT
EXCHANGER
                                                                                              INCINERATED  !CAS
      PROCESS GAS   0
      5000   SCFM-70F
      SOLVENT  LOADING—15/LEL
                                                                           •PROCESS GAS
                                                                              FAN
                     PROCESS
                                            TYPICAL  CASE  2
                                           /PRIMARY  HEAT  RECOVER^
                                           V  AND  NO CATALYST    )

-------
                                              PREHEATED  PROCESS  CAS
oo
                                                    404°F
INU (.L LC
BURN El?
FUEL ^ 	
2 GIL
£.5 GPH
1.1 1 X !0*BTU/HR
\
>
WIA


1
1
f INCINERATION
. CHAMBER

/-CATALYS1
' n
600°F i 1000° F
i
i i
LJ
' 4
PRIMAPY
HEAT
EXCHANGER
J
i PROCESS
5000 SCf
SOLVENT
^\
                                                                                               INCINERATED GAS
                                                                                               22560 "
                                      TYPICAL  CASE   2
                                     /PRIMARY HEAT RECOVERY\
                                     V   WITH CATALYST      )
                                                                         PROCESS GAS
                                                                            FAN
                                                                                            PROCESS

-------
           CASE  2
      WITH HEAT EXCHANGER
          NO  CATALYST
    70°F INLET TEMPERATURE
1400T INCINERATION TEMPERATURE
                                                                                BURNER
                                                                                                     HEAT
1



1 1
i
0"
vD
3

. ^


PF.OCESS
GAS FLOW
IK
SCFM
5,000
5,000
5,000
5,000
15,000
15,000
15,000

15,000
30,000
30,000
30,000
30,000
PROCESS
GAS FLOW
IS
ACFM
5,000
5,000
5,003
5,000
15,000
15 , 000
>5,000

15,000
30,000
30,000
30,000
30,000
PROCESS
GAS FLOW
IN
Jt/HR. .
22 , 500
22,500
22,500
22,500
67,500
67,500
67,500

67,500
135,000
135,000
135,000
135,000
PROCESS
GAS FLOW
INCINERATED
GAS FLOW
#/HR.
22,782
22,733
22,635
22,538
68,356
68,207
67,908

67,609
136,691
136,398
135,808
135,218
PROCESS
GAS FLOW
INLET
TEMPERATURE
•F
70
70
70
70
70
70
70
•
70
70
70
70
70
PREHEAT
TEMPERATURE
"T
582
581
580
579

582
581
580
579

582
581
580
579

INCINERATION
TEMPERATURE
°F
1,400
1,400
1,400
1,400

1,400
1,400
1,400
1,400

1,400
1,400
1,400
1,400

HEAT
nirrl™ RELEASE HEAT
<™ - sr
942 0 0 0
941 5 2.83 0.85
940 15 8.47 2.54
939 25 14.11 4'23
_ n
942 0 0
r •> fl* 2.S4
941 5 2.83
ic R 47 7.62
940 15 8.«<
939 25 14.11 "-71

_ o
942 0 0 0
941 • .5 2.83 ' 5.08
940 15 8.47 15-23
939 25 14-11 25'40

REpUIREMENTS
106 BTU/HR. 10° BrU/HR.
NET GROSS .
5.07
4.19
2.42
0.68
15.40
12.71
7.34
1.96

30.41
25.13
14.54
3.92

5.39
4.46
2.58
" 0.73
16.38
13.52
7.81
2.09

32.35
26.74
15.46
4.17

EXCllrv^ -jEF
EFFICII;:;CV
%
3S.5 .
38.4
38.4
3«.4
3B.S
38.4
38.4
3B.3

38.5
38.4
38.4
38.3


-------
                                                                                 CASE  2
                                                                           WITH HEAT EXCHANGER
                                                                               NO CATALYST
                                                                          300°F INLET TEMPERATURE
                                                                      1400T  INCINERATION TEMPERATURE
j PROCESS
\ GAS FLOW
.' IN
1 SCFM
! 5,000
1
5 5 , 000
J . 5-, 000
! 5 , 000

' 15,000
-J 15,000
O
{ " IS.OtlO
1 15,000
30,000
30,000
30,000
30,000

PROCESS
GAS FLOW
IM
_ACFM
7,170
7,170
7,170
7,170

21,509
21,509
21,509
21,509
43,019
43,019
43,019
43,019

PROCESS
GAS FLOW
IN
t/HR. .
22,500
22,500
22,500
22,500

67,500
67,500
67,500
67,500
135,000
135,000
135,000
135,000

INCINERATED
GAS FLOW
ft/HR.
22,734
22,685
22,587
22,500

68,210
68,061
67,763
67,464
136,406
136,111
135,521
135,000

PROCESS
GAS FLOW
INLET
TEMPERATURE
300
300
300
300

300
300
300
300
300
300
300
300
bvoassed arou
PROCESS
GAS FLOW
PREHEAT INCINERATION
TEMPERATURE TEMPERATURE '
.F «F
725 1.40°
725 L400
724 1,400
723 1.400

725 L400
725 1,400
724 1,400
723 1.400
725 ' 1,400
725 L400
724 1,400
723 1.400
nd primary heat exchanger.
HEAT
OUTLET RELEASE HEAT
PEMPERATURE LEL BTU/CF REiEASE/HB
oF % (NET) 106 BTU/HR.
1,013 00 0
, ., _ c 2 83 0.85
1,012 3 *.oj
1,011 15 8.47 2.54
1,010 25 14.11 4.23

1,013 0 0 0
1,012 5 2.83 2.54
1,011 15 8.47 7.62
1,010 25 14.11 12.71
1,013 0 0.0
1,012 5 2.83 5.08
1,011 15 8.47 15.23
1,010 25 14-11 25.40
_
BURNER
REQUIREMENTS
106 BTU/HR. 10° BTU/HR
NET GROSS
4.21
3.32
1.56
* .42
12.77
10.09
4.73
•1.31
25.28
19.97
9.38
•2.53

4.48
3.54
1.66
* .45 "
13.58
10.73
5.03
•1.40
26.90
21.25
9.97
•2.7

HFAT
EXCHANGER
EFFICIENCY
t
33.7
38.6
_ 38.5
33.4
33.7
38.6
38.5
33.4
35.7
33.6
38.5
38.4

"Burner at mininuni

-------
'1
                                                                                            CASE  2
                                                                                 WITH  PRIMARY  HEAT  EXCHANGER
                                                                                         WITH CATALYST
                                                                                    70°F  INLET  TEMPERATURE
j PROCESS
| GAS FLOW
j SCFM
• 5 , 000
5,000
i 5,000
5,000
, 15,000
•! 15,000
i
i 15,000
15,000
]
j
j 30,000
j 30,000
30.0CO
30,000
PROCESS
GAS FLOW
#/HR.
22,500
22,500
22,500
22,500
67,500
67,500
67,500
67,500
135,000
135,000
135,000
135,000
PROCESS
GAS FLOW
THRU
CATALYST
#/HR.
22,606
22,590
22,560
22,507
67,820
67,772
67,685
67,520
135,638
135,545
'135,370
135,040
PROCESS
GAS
TEMPERATURE
IN
°F
70
70
70
70
70
70
70
70
70
70
70
70
PROCESS
GAS
PREHEAT
TEMPERATURE
°F
260
310
404
479
260
310
404
479
260
310
404
479
GAS
TEMPERATURE
INTO
CATALYST
°F
600
600
600
515
600
600
600
515
600
600
600
515
GAS
TEMPERATURE
LEAVE
CATALYST
°F
600
' 740
1,000
•1,210
600
740
1,000
•1,210
600
740
1,000
•1,210
GAS
TEMPERATURE
LEAVE
HEAT
EXCHANGER
Op
416
506
675
806
416
506
675
806
416
506
675
806
HEAT
EXCHANGER
EFFICIENCY
35.9
35.9
36.0
36.2
35.9
35.9
36.0
36.2
35.9
35.9
36.0
36.2
LEL
0
5
15
25
0
5
15
25
0
5
15
25
HEAT
RELEASE
FROM
CATALYST
106 BTU/HR.
0
0.815
2.34
4.06
0
2.44
7.31
12.20
0
4.88
14.62
24.39
BURNER
REQUIREMENTS
10b BTU/HR.
NET
1.91
1.G3
1.11
* .19
5.73
4.89
3.32
* .57
11.46
9.80
6.65
•1.15
106 BTU/HR.
GROSS
2.03
1.72
1.19
• .2
6.10
5.02
3.54
* .61
12.20
10.43 •
7.08
*1.22
           • Bui'ner is at minimum fire.
           Gas  temp, into catalyst is lower than tfhat is generally recommended.
           Gas  ter.p. leaving catalyst is higher than what is generally recomnended.

-------
          CASE 2
WITH PRIMARY HEAT EXCHANGER
       WITH CATALYST
  300°F INLET TEMPERATURE
1

PROCESS
GAS FLOW
SCFM
f 5,000

5,000
•i
! 5 , 000
1
': 5,000
i
! 15,000
15,000
| 15,000
' 15,000
30,000
j 30,000
i
J
1 '3U,000
' 30,000
•Preheat


PROCESS
GAS FK)W
#/HR.
22,500

22,500

22,500

22,500

67,500
67,500
67,500
67,500
• 135,000
135,000
135,000
135,000
Temperature
**No burner required
'
i

PROCESS
"GAS FLOW
THRU
••CATALYST
#/HR.
22,563

22,590

22,540

22,500

67,690
67,632
67,543
67,500
135,377
135,265
135,086
135,000
higher than
due to high

PROCESS PROCESS
GAS
GAS
TEMPERATURE PREHEAT
IN
op
300

300

300

300

300
300
300
300
300
300
300
300
minimum
preheat

TEMPERATURE
Op
400

460

555

*635

400
460
555
•635
400
460
555
•635
required temperature
temperature.

GAS
TEMPERATURE
INTO
CATALYST
°F
600

600

600

635

600'
600
600
635
600
600
600
635
into catalyst.


GAS
GAS
TEMPERATURE
TEMPERATURE LEAVE
LEAVE
CATALYST
Op
600
1
740
*
1,000

1,315

600
740
1,000
1,315
600
740
liOOO
1,315
gas temp.


HEAT
EXCHANGER
°F
493

583

750

910

493
- 583
750
910
493
583
750
910
leaving catalyst



HEAT
EXCHANGER
EFFICIENCY
%
36.5

36.6

36.8

36.9

36.5
36.6
36.8
36.9
36.5
36.6
36.8
36.9
is higher than





LEL
*
0

5

15

25

0
5
15
25
0
5
15
25
good


HEAT
RELEASE
FROM'
CATALYST
106 BTU/HR.
0

0.815

2.34

4.06

0
2.44
7.31
12.20
0
4.88
14.62
24.39
design.




BURNER
REQUIREMENTS
106 BTU/HR.
NET
1.13

0.79

0.26

**

3.39
2.38
.77
**
6.78
4.76
•1.54
**



10b BTU/HR.
GROSS
1.21

0.84

0.27

**

3.62
2.53
.82
• *
7.21
5.07
1.65
**





-------
                          ENVIRONMENTAL
             .rtTA
             :RAC
      •ROT
       CTIC 'N. AG:
                     :NCY
                                 CONTRACT
                                      'TASK
     tNO.
      NO.
     68
           -os-
          is: -
 47;8
32
       -244-.-6
                                     HEAT BECOVERY
                                  :HANGER
                                  GAS
 HEAT EX
 PROCESS
-JNCQUE
 NOICATAJLYST
TEMPERA
                               Bji.TIQ5l
                                            SE 2
                       VEI
TrFFTCJI
FERATtt
     FF1C41EIS1C
          URE:
TEMJPERAlrUBE
     38%~
N-|  70°F
     1400°F
                                         73

-------
HEAT RECOVERY ;
HEAT EXdHANGER
INCINER/TION
NO CATA1YST
                                            '  12/7?

-------
EWIROlttENTAL
    CONTRACT Np.  68-02-1478
          TASK! NQ. IB
   HEAT EXCHANGER E
   WITH CATALYST
                   7.296 ffl/GAL
                   19130 BTU/#(HHV>
                   139660 BTU/GAL(HHV)
                   17980 BTU/#(LHV)
                   131300 BTU/GAL(LHV)
HEATING
HEATING I
            75

-------
                                               ENVIRC NM^NTAL PR01 ECtlCBf AGElfl^V
                                                   CCNtftACI  NO.  (8-02-1478
                                                        TASK MO.
                                                                ta-
                                                       -itetr
                                                           CASE 2
                                                                3VERY
                                                •HBAT
                                                mow ss
                                                    EXCHAIfGER EFFICIEIfCY  _
                                                           TBMPHRA2U8B IH
                       36 J
                       300
                                                     CATALXST
                                                          1FUHL
                                                                 -«-
                                                                      30
                                               -DBMS-
                                                     nr	1	
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-------
ENVIRONMENTAL
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-------
    CASE 3,  INCINERATION




WITH PRIMARY AND SECONDARY




       HEAT RECOVERY
              129

-------
    NCZZLE  MIX
  2.4 X I06BT
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                    INCULPATION
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-------
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-------
                                                                                                                   CA3E 3
                                                                                                         «TM ?MHARY HEAT EXCHANGER
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t— '
00
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PROCESS
GAS PLOW
1.1
SCTK
5*&CO
5.000
5.000
5.OOO
15.000
15,000
15.900
15,750
10,000
10,000
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JO. CCO
PJOXXSS
GAS PLOW
19
t/HR.
32,500
32.500
22.5OO
22.500
67,500
67,500
67,500
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135.000
115.000
115. COO
1)5,000

InClftEftATBD
GAS FLOW

22.762
22,71)
22.O5
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68.156
68.307
67,908
67,609
116.691
116,198
1)6.808
115,218
PROCESS
GAS IN
TEMPERATURE
•p
70
70
70
70
70
70
70
70
70
70
70
70
PROCESS
GAS
INCINERATED
PREHEAT GAS in
TEMPERATURE TEMPERATURE
•p
5S2
581
580
579
582
581
580
579
592
581
580
579
•p
1,400
1,400
1,400
1,400
1,400
1,400
1,400
1,400
1,400
* 1,400
1,400
1,400
GAS
TEHPCRATOaZ
OUT
•P
942
941
940
9)9
943
941
940
919
942
941
940
919
PRIMARY
HEAT
EXCHANGER
ErriciENci
% 	
18.5
18.4
18.4
18.4
18.3
18.4
18.4
18.1
18.5
18.4
38.4
M.I
CECOKDASY SECONDARY
IN TEMPERATURE
t/HR.
15.000
15,000
15.OOO
15,000
1 45,000
45.000
45.000
• 45,000
90,000
90,000
90,000
90,000
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70
70
70
70
70
70
70
70
70
70
70
70
SECONDARY
TCMPCRATURI
•P
549
546
548
548
549
S48
548
548
S44
544
541
Ml

! TCMPERATum
•p
943
941
940
919
941
941
940
919
941
941
940
939

SECONDARY
HEAT
BURMER
GAS OUT BXCttANbCIl
TEMPERATURE EFFICIENCY IB.
•P
640
6)9
6)9
6)8
640
619
6)9
618
643
641
641
«40
•p
55.0
55.0
55.0
55.0
55.0
35.0
55.0
55.0
M.4
54.4
54.4
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t
0
5
15
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1
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0
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NET
5.07
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1.42
0.68
15.40
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1.96
30.41
25.11
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0.73
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11.53
7.81
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, 12.35
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1.74
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1.74
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-------
                                                                                                                  CMS I
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IN
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22,500
22,500
22.500
22.500
67.503--
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135.000
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GAS PLOW
22,714
22,685
22.587
22,500
68,210
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67,711
67,444
116. 4C6
136,111
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PROCESS
GAS IN
TEMPERATURE
•P
300
300
300
300
300
300
300
100
100
100
100
100

PROCESS
GAS
PREHEAT
TEHPERATt
•P
725
7J5
724
•690
725
725
724
•690
725
725
724
•690
bn»>»d

IBCIKE RATED
CAS IN
]R> TEMPERATURE
•P
1,400
1.400
1 1,400
1,400
1,400
1,400
1.400
1.400
1.400
1.400
1.400
1.400
•round prlMfy Iw

GAS
TEMPERATURE
OUT
•P
1,011
1.012
1,011
1,010
1,013
1,012
1,011
1,010
1,011
1,013
1,011
1,010
Hit •XChWHT*''

PRIMARY
HEAT
EXCHANGER
EFFICIENCY
%
18.7
18.6
18.5
18.4
38.7
18.6
38.5
38.4
38.7
18.6
38.5
38.4

SECONDARY
AIR PLOW
IN
15.000
15.000
15,000
15,000
45,000
45,000
45,000
45.000
90,000
90,000
•0,000
•0,000

SECONDARY
AIR IN
TEMPERATURE
•F
70
70
70
70
70
70
70
70
70
70
70
70

SECONDARY
AIR OUT
TEMPERATURE
•P 	
590
589
589
588
590
589
589
588
585
585
504
583

GAS IN
TEHPEftATUn
•P
1,013
1,012
1,011
1.010
1.011
1.012
1.011
1.010
1.011
1.012
1,011
1.010

OAS OUT
TEMPERATURE
•P
687
666
6»6
687
687
686
686
687
690
690
689
686

SECONDARY
HEAT
EXCHAHGBR
EFFICIENCY
55.2
SI. 2 .
55.2
55.1
55.3
55.2
55.2
55.3
54.7
54. 7
54. <
54. S

LEI,
»
0
S
IS
35
0
5
15
25
0
5
IS
35

BEAT
RELEASE
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0
0.85
2.54
4.21
. o
2.54
7.62
12.71
0
5.08
15.23
25.40

SDR]
10* BTU/HR.
KET
4.31
1.13
1.56
• .42
12.77
10.09
' 4.73
• 1.11
25. 2S
19.97
•.IS
' 2.51

«E»
PECS
10° BTU/NR.
CROSS
4.49
1.S4
1.66
• .45
11.58
10.7]
5.01
• 1.40
26.90
21.25
9.97
• 2.70
BT*J
RECOVERED
9T
SECONDARY
HEAT
EXCHANGER
1.9}
1.93
1.90
1.90
5.69
5.69
5.69
S.H
11.10
11.10
11.10
11.10

KET
TO
HATT
;. j;
1.43
••-;.!!
••-1.48
7.CS
4.4.s
• • - ? . 6«
••- 4.]?
n.99
e.»7
• •-i.s.-
••-6.t7
r«99**r4>4 mr 
-------
          on i
 WTO rttimiR Bar ~~"*™~
•IIH •CCONDAIW «r»T
       HIIH CATALTtT
      >  70"P IHUW
PROCESS
PF.-OCI3S
CAS rjow
CI
STt
5. COO
5.000
5. GOO
5. =00
15.000
15.000
15.0VO
IS. -.00
1 — 1
OJ
Ul 10.000
lO.ViO
30-. 0»
30.053
•fturr^r 1
-.WWCESS
GAS riOH
III
4/HR.
22. SCO
22.500
22.500
.22*500
67.500
67.SCX)
67.500
67,100 ,
135. OOO
1 15. (XX)
US, 000
135.000
4 >c •lnl»u
•*7M«t r»cov«r*4 by •
PROCESS GAS IHCINERATEO GAS
IKIBERATED GAS f» PREHEAT GA» III TBtPEMTUM
GAS rua« TEMJ-ERATUSZ TEW-CRATURB TEHP8RATUR1 OUT
./PP •' *' •* ''
22.606
22,590
22,560
22,507
67,820
67,772
67,685
, 67.520
135,638
135,545
135,370
135. 040
• Sir*, g«« t«ap
•oondkry h«*t •»
70
70
70
70
70
70
70
70
70
70
70
70
. into
elvMkgw
260
310
4O4
479
260
310
404
479
260
310
404
479
c*t«lytt !•
r !• gffMUr
600
740
' 1.000
•1,210
• 600
740
1.000
•1,210
600
740
1.000
•1,210
lower tlun what
thu h*«t input
416
506
675
806
416
506
675
806
416
506
675
•06
!• g«n«rally v«c
by buriMY.
PRIHHT
HEAT
EXCHANGE*
DTICIDKT
»
15.9
15.9
14.0
16.2
15.9
15.9
16.0
16.2
15.9
35.9
36.0
36.1
iimniHII. c



MX rUM MR III
IN TEHPERATtritl
«/HR. 	 T
15.000
15.000
15,000
15,000
45,000
45,000
45,000
45,000
90.000
90,000
90,000
9O.OOO
!•• Mp. luring

70
70
70
70
70
70
70
70
70
70
70
70
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254
102
192
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192
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504
475
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506
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441
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295
151
441
541
295
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441
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anciac* to, UUASI io4 «TO/H».
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51.1
51.1
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51.1
51.1
51.1
51.1
51.1
51.1
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11.1
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• 15 2.34
15 4.04 •
0 I 0
5 2.44
15 7.11
15 11. 20
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15 14.41
U 24.19


1.41
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106 BTu/aru
2.01
1.72
r. u
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4.10
5.02
1.54
• .41
12.20
10.41
7.04
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3.51
4.26
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7.02
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0.79
••-0.76
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J. 17
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7.44
4.74
••-0.17
"-i.n



-------
                                                                                                      iKamunr HE»T naumn
                                                                                                         •1TH CATAITST
                                                                                                          300T MUT
         5.000     22.500

         S.CSO     22,500

         5.000     22.500




        15.000    47.500

        15.000  •  -tiAoa

        15.000    67,400




        10.0CO   115.000

        10,000   115,000
h-'
UJ      10,000   115.000
•nut nco»r«4 kir MoonUcr *•**
rmCKiS PRXMIUW
™««o STS" n££« "STS™ „£;„«« OCH^B. S°£S? "001*>«f ««*»« «COHM«,
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100 ,„ • .1<000 7M ,.. isooo ^ ^ '» 1» „.. , „.„
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l-M- »•" ..oo
                                                                                                                                                                                                                     .-».,,
                                       t> tnatn Uua hMt UpM tv I

-------
    1  28
        24
 FIIMAfl?
 •SJicom
 PROCESS
-I
« lJEAr
GAS
                                                                                                                                       PR
-------
                   ..  PROVE
                      ...6
                TASK  NO.
      ACKNCY
3-02-1A73
13
                .  CASE  3
             EXCHANGER  EF
               EXCHANGER
-1CIKNCY    Q8'i
EFFTCTKNCY  54-1/2
           _3QQ°1;
            ,1400°F
        -GAS
INCINERATION
N.I CATALYST

-------

-------
    ~T~
        BWHONNENfTAL PROTECTION AGENCY
             CONTRACT NO
                  TASK NO
PRIMARJV HJJAT
SECONDARY  HB}\T
(PROCESS GAS
JITH CJATAtYSr
 EXCHANGER
   EXCJHANGER
INIJET !
     dUT OF.
             68-02
              13
                               -1473
EFFICIENCY
36. (&.
53.8%
300 °F
                                                              16
                                                              12
                                      cm.'.'

-------

-------
     HEAT  EX
£SS GAB  IN -
  MO.CATALYS
   142

-------
ENVBRO.'WEIJTAL  PROTECTtON
   SECONDARY HKAI EXCHANGER
     143

-------
ENVIRONMENTAL PROT
    rnfrrpAC-.T MO
      144

-------
            5000
                       - 2
        OIU
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MRS
                             WES
D/^ffCT
SUPPLIES'.

                    .25 x
                             145

-------
/%/,r~ .
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                    .25
                        //?
                             146

-------
5000
                                      /5" % /.EL
             - 2
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D/ZGCT /.*&>£:•

                                  147

-------
            5000
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               '03/KWH

            ',
             M/
                                              HZ.
                             148

-------
/ 51 OOP   SCFM
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                     149

-------
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                              150

-------
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                                 151

-------
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                                152

-------
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                     153

-------
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                       .2S
                                                             a 33
                                    154

-------
                         COST
/A/, T ; S/z& 3O, OOP    scrvl    /$  7* L£L Psaoce^  TEMP ?O ^
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                               155

-------
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-------
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                                  158

-------
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-------
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-------
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                                 161

-------
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-------
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-------
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-------
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-------
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-------
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-------
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-------
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-------
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-------
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-------
  
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-------
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-------
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-------
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-------
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-------
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-------
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-------
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-------
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-------
                                  >£
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-------
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-------
         CASE 4, INCINERATION




WITH DIRECT REUSE OF EXHAUST OF GASES
                   193

-------
                                   CASE 4 GRAPHS






     Fuel Requirement for Incinerator - This is the fuel required in terms of




Btu's per hour for 5 through 15 thousand SCFM flows with LEL's of 0-25%.  Almost




identical to the Case 2 graph with process temperature of 300°.




     Fuel Required for Oven and Incinerator Combined - Adds in the fuel required




by the oven for normal operation with recirculation, e.g. for an oven exhausting




6,000 SCFM @ 300°F, approximately 8.8 MM Btu's per hour are required without re-




circulation.  With recirculation approximately 3.8 MM Btu's per hour are inputed




to the oven, consequently the oven fuel requirement is about 5 .MM Btu per hour.




     Annualized Operating Cost of Incinerator - Total fuel cost, electricity, direct




labor and 257° of capital costs for a yearly operating expense.  "Graph is very similar




to Operating Cost - Case 2 - 300°F - no catalyst.




     Annualized Operating Cost of Incinerator Including Cost of Oven Fuel - Adds in




oven fuel cost to above graph - e.g. at 6,000 SCFM exhaust at 300°F with recirculation




of incinerator exhaust gases the fuel required by the oven is approximately 5.0 MM Btu




per hour.  At 1.50 dollars per MM Btu and 5,840 hours per year operation the cost is




about 44,000 dollars per year.  Added to the incinerator operating cost of 88,000




dollars per year the total is 132,000 dollars per year.
                                        195

-------
                             FUEL REQUIREMENT FOR  INCINERATOR
                               ENVIRONMENTAL PROTECTION AGENCY
                                    CONTRACT #68-02-1473
                                         TASK #13

                                          CASE 4
                                Recirculating Incinerator
                               With Primary Heat Exchanger

                               Process Gas  In Temperature   300 °F
                               Incineration Temperature    1400°F
                               Natural Gas  Fuel
                               Density    .0458 #/CF.
                               Heating Value     1002  Btu/CF (HHV)
                               Heating Value      904  Btu/CF (LHV)
12.0
  8.0
       PQ
      vD
       O
•i-l

g-
  4.0
                                                      10

                                              Flow -  103  SCFM
                                              - 196
                                                                               15

-------
    22
     20
     18
    16
    14
vO
 O
 @  12
 06
    10
             FUEL  REQUIRED  FOR OVEN AND  INCINERATOR COMBINED
ENVIRONMENTAL PROTECTION AGENCY
    .CONTRACT #68-02-1473
          TASK #13

           CASE 4

  Recirculating Incinerator
 With Primary Heat Exchanger
                                                                        Fuel  required for
                                                                        an oven without
                                                                        benefit of recircu-
                                                                        lation
                                                      10

                                               FLOW -  103 SCFM
                                               197
                                                       15

-------
   180
   160
   140
0)
H
CO
8
   100
    80
    60
                            AHNUALIZED OPERATING COST OF INCINERATOR
   ENVIRONMENTAL PROTECTION AGENCY
        CONTRACT #68-02-1473
             TASK #13

              CASE 4
    Recirculating Incinerator
   With Primary Heat Exchanger

Process Gas In Temperature   300°F
Incineration Temperature    1400°F/
    40
                                          10
                                       FLOW -  103  SCFM

                                                198 .
                                    15

-------
    260
    240
    220
    200
 i-i
 03
 0)
m
 o
 H
 CO
    160
    140
    120
    100
     80
                     ANNUALIZED OPERATING COST OF INCINERATOR
                            INCLUDING COST OF OVEN FUEL
ENVIRONMENTAL PROTECTION AGENCY
     CONTRACT #68-02-1473
          TASK #13

           CASE 4

  Recirculating Incinerator
 With Primary Heat Exchanger
                                                    Cost of fuel required for an oven
                                                    without benefit of recirculation
                                                       10

                                             FLOW - 103 SCFM
                                                 199
                                                     15

-------
TO ATM&SPU&JSE

-------
                                      GAS)
                              : V.7- /.
'
                                   738'
TQ
      6OOO
, 000 (MOO -
                         7D
                               Cwi-

-------
                  OPERATING COST ESTIMATE

DESCRIPTION:  CASE 4 FUME INCINERATOR

PRIMARY HEAT RECOVERY - NO CATALYST

UNIT SIZE     6000 SCFM              7 to 21% LEL

PROCESS TEMPERATURE =  300°F

PROCESS OPERATING TIME - 2 Shifts/Day - 365 Days/Yr.  = 5,840 Hrs.
   ITEM
         DESCRIPTION
                                   COST ($/YR.)
Utilities:

 Water,
 Steam,
 #2 Fuel Oil,   $1.50/10° $/Btu x  (3.45 +0.95) x 10° Btu x
                                        2
                    5840 Hrs.                                       19,300

 Electricity    $ .03/KWH x 5840 Hrs. x .746 KW/HP..x"37 HP           4,840
Direct Labor:     .5 Hrs./Shift x 730 Shifts/Yrs. x:$8.00/Hr.

Supplies:
Maintenance
Building Overhead
Taxes & Insurance      \
Interest & Depreciation^
I
Use 25% of Capital Costs
 .25 x $151,900
                                               2,920
                                              38,000
                                        TOTAL OPERATING COST       $65,060
                             202

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APPENDIX:  CAPITAL COSTS




    FOR AFTERBURNERS
           203

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                              ^ENVlEWSMBNTAL-
                                     ^SNTRACTNO
  T'RACT
    'EASE !*O. 13
;Tif5
                          --}—
   CAPITA
       CA$
                                                 E I
                                                                         j. ___
HO HEAT ESCHANOER
                                   70 - 2
                                       OQtE.lPHOCESSlG&SJS LET.
            210,000
H
            220^ 000
                                                                	'J-'f
            100, 000
            HO, 000
         J  120.000
        -^—
       :     !
       •
         -.—*ee
             -8^
               -Mfl-
             60.000
             40tOOO
           —29rO99-
                                       ip
                                                 is
                   "$    :    S        3^~
            ,.c_A§.E.!.;:
                                          FLOW -
                                                 10  scfm
                                                       12/75
                                              205

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                 ENVilRONl/LENT'Vl
                                              :TIQN
     *aorW
                       CdNTRAJCT,
                             TASK
NO
 HO
                                           B8-
                                           . i;
                            :CAPITAL COST
                           ~IGAS^: 2  ,

                     WITH PRIMARY HEAT EXCI
                      70 - 300°I' PRO
                                               AS
                                                   ANGKR:
                                                              T
                                                            if
    -24erWe
                                                                              X
                                                                                 -t
-fc-
300, OOC
                                                                  X
     -iOO. 00(
     i20. OOC
      8t), 000
    	40 ope
     CASE II
                              10
                                                  20
                                                           25:
                                                    scfm
                                        206

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207

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        • •*""''       —
      C C'j;:r  £:^?-s:'~f,j?~£'

£:
                     COSTS
35,000—
       208

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7;'i?/..-v-"//£'A/ t.o^:f~'   £:^?y.^s'J s'&
/sooc>
      ?.  70
                                O7b. zs
  / /'j£vV^    \?.  / ,'*;•«••.;£.'?/.;•:> •••v.-r?/\/
 •-•• '•—'••     /   ^.,^>	-•' x /.•-*.

                              COSTS
                                7 /
                                                 7*00
              209

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/7
                 JT
         "' 30,000
/  i  So.ooo
               X
                        .71
                          !





                          I







                         J
                     210
                              COSTS
                                             1
                                         £0,000

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 :,	.
C Q'\
                                        .-o V
                                  7
                                     &'S T
                                                 ///r
                    211

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  •& &£
~

             COSTS
             7
                r T
  212 ,
35, ooo

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 X'

213

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'o.'\/ <- e>^

          7°
       JZ  ^/^rjfC
            ' ••.. •-• <
     214

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                 JT"

                  *Z £>£-*
30,000
         jz

C) £ &t'C/~ t\/0.<*
                                     &3rj0 V
                                 COSTS
                                  7
                   215

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            _rL^^
3Oj OOP
                            
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i

                                                (       (T <5 5 7"..
                                                         7
                                   217

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  C <•_'•'I/-,' £2 */£/"/orJ '-- O^'s"  ,^r^"s",'S~,fs;•?'•£'
£-'  Sooo
                                                    Let
WO

                     (r-
                                    COSTS
                   ^^r A^.
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WO
 2.v7:;
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/s,ooo
                             0 -
               -"•
WO
              220

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30,000
                      .
                         (&:
                                   ZS
/

3O.OOQ
          /
                    221;
                             COSTS
                           <•-  'I

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30,000
              222i
                         COSTS

                                     V

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   /
'W y^'c>,\; j£
                                   COSTS
                                         ? 7"
                  223

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                          /£tM£&J
              224
                      SS/fW^dr/e.
                    I     COSTS
                              •~7~
                                       22 /^  —

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 /
                     "§
70
                       COSTS
          225

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i
                   *
                 j£ ~'*-
                      226
                                  COSTS
                                                ^; 7*

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     /
•3O, ooo
               221
                         COSTS
                              7"

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          COSTS

                      £$000
228

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        /'
229

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                                                              /'
              /
C. i-'""- •'J s~C -:•'." /'•;•<---'.••!../   (
                                             230

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   S"""  S,—r,>  ,   —
/-
                                            M
x, ;••'-»' i'

                    -Sf/V-'f
                 r J2Z

                          231
I
s
                                                    76
           .
          .>.
                    -••  -                         /    t
                     "/•".' V3 .....—  f ••••'• ,—,,r ,<~^.  O    'V

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                                       /•
                                                 <•/
                                                 •
                            L y
                                              COSTS
^
                          232


/ — f f V.- ,. -^,
*
i • • • i
j — -, ;
"/•zTrtt Cl^-fj^//"!'?'. <^~&z~ /"" /^•Zw^'li ~~*

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30.000
         7k
                         76
•'
I
                     C
          233

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/
                  234

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         .XttVT
                 To
AMP  c#z*(*y$r 8*0
    ^X^ //<2-/y
COSTS
                 235 :
                                         2630 —

-------
£> esc/2/ t>r/o*/ —
           .* .. .

                                               :._ fc/.ev> r
                                      To
            .<.f
            /
                                          __ /

i  e/7.0/0/
                                                        74

                                                                V
                                          236 ;

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     C ojr



j£ J^i
                COSTS
     237

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                   To

              j£ ^tsAS&A
                                 COSTS
Ct>*JSr£i,Kr/e>*J
7%
                                              #0000
                     238

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       ft i« ....
  --  30,000
A/
  0zz£L

i >*"
 '
                           !   /,-.,. _ / .




                          (    COSTS
                          \

                    239

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.JEtej.M/jftAi ....£/ ..seco»o.DAR«...	tJ'<
                                  COSTS
                      240

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                 CONSTRUCTION COST ESTIMATE

DESCRIPTION:  CASE 4 FUME INCINERATOR

PRIMARY HEAT RECOVERY - NO CATALYST

UNIT SIZE     6000 SCFM             7 to 21% LEL

PROCESS TEMPERATURE =  300 °F



  QUANTITY	ITEM & DESCRIPTION	EST . COST

     1          6000 SCFM Fume Incinerator                60,500
                Skid mounted, In-Line Burner
                for Natural Gas Fuel
                Including Unit Mounted Controls,
                Piping, Stub (10') Stack, and
                Primary Heat Exchanger of 357<,
                Efficiency.  Unit to be completely
                Shop Insulated


                Auxiliary Equipment - Fan & Motor          3,600

                Excavation & Foundations

                Piping & Ductwork

                Insulation                ^              85,000

                Electrical

                Painting
                Interest on Investment During
                Construction  (Three Months @ 7-1/2%        2,800
                Prime Rate)
                                 TOTAL CAPITAL COST     $151,900
                             241

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                                   TECHNICAL REPORT DATA
                            (Please read Instructions on the reverse before completing)
1. REPORT NO.
 EPA-450/3-76-031
                              2.
                                                            3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
 Report  of Fuel  Requirements,  Capital Cost and  Operating
 Expense for Catalytic and  Thermal  Afterburners
                                          5. REPORT DATE
                                              September  1976
                                          6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
                                                            8. PERFORMING ORGANIZATION REPORT NO.
        C-E  Air Preheater
9. PERFORMING ORGANIZATION NAME AND ADDRESS

         C-E Air Preheater
         Wellsville, New York
                                                            10. PROGRAM ELEMENT NO.
                                           11. CONTRACT/GRANT NO.

                                             EPA 68-02-1473
 12. SPONSORING AGENCY NAME AND ADDRESS
                                                            13. TYPE OF REPORT AND PERIOD COVERED
   Environmental  Protection Agency
   Office  of Air  Quality Planning  and Standards
   Emission  Standards & Engineering Div. (MD/13)
                      R,ark  North  Carolina  27711
                                           14. SPONSORING AGENCY CODE
*
15. SUPPLEMENTARY NO
16. ABSTRACT

   The purpose of this manual  is  to provide capital  and operating costs  and fael
   consumption of direct flame  and  catalytic incinerators for volatile organics.
   Three  flow rates (5,000,  15,000  and 30,000 scfm),  two inlet temperatures
   (7Q°F  and  300°F), four concentration levels of  organics (0%:, 5%,  15%  and 25% of
   the lower  explosive limit) and four heat recovery  options (no recovery,  primary
   heat recovery, primary and secondary heat recovery,  and direct reuse  of
   incinerator exhaust) are  evaluated.  Cost estimates  are detailed  to enable easy
   updating or estimation using any set of assumptions.
17.
                                KEY WORDS AND DOCUMENT ANALYSIS
                  DESCRIPTORS
                                              b.IDENTIFIERS/OPEN ENDED TERMS
                                                        c.  COSATI Field/Group
   Industrial  Emission Sources
   Costs
  M anual
   Incinerators
                             Cost Estimation
                             fechniques
                             Capital Costs
                             (\nnualized Costs
                             <\ir Pollution  Control
                             Systems
18. DISTRIBUTION STATEMENT


   Unlimited
                             19. SECURITY CLASS {ThisReport)
                                Unclassified
21. NO. OF PAGES
 258
                             20. SECURITY CLASS (This page)
                                Unclassified
                                                        22. PRICE
EPA Form 2220-1 (9-73)
                                             242

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