-------
H
I
C»
Table II-l. (continued)
Product
Procesa
114. MIMlithTRI.ETim. MIKE
115. OUKOMXTIC ItU
114. KVZOPtCMWE
117. KTHTl HOHI1E
118. nan M.COOL
in. PWYI MUM.
u*. sum. MINES
120. ETHTL dirnmi rno
121. ram wiics (MhD
121. MPa MINES (M-T)
122. atOTMMUEWK
in. isoocin. ILCML
124. ramtc ACID
123. nwuic area itnm. ETHTI FTKJ MXTME
124. UICM MXn
127. ISOKCMML
127. ISOKCMO.
ia. nun. MXOHCL
121. MlYlDLCna
m. MJ.TL «uaa
121. ISOCMPn. «t»TE
130. icnm. Mzrtn
Hi. cramcTMiEK
132. ICMdlORaiEXZEK
133. «-IUTTl ACET«TE
134. wmic «ci»
134. MlTTflC ACID
13S. DHUTMPHEML
loci nwwo. ,v9«(arsis •
1001 MZI1C Kit CM.CKIMTIW
1001 (GOBC/CMIMW THIMaiailK
tool (crawoumt Ntt MOUIC
871 0X0 PMCESS
I3Z PMPMC OIIMTIW
lOOt WTTMUEIfflE HYMtCKIMTIlK
lOOtETHMa
MI IHNtlPTl M.COML
501 HHB>n CIUMK
1MI N.M MOKSS
m H-IVTNC IHIMTIIM
1001 ETHOOCT ETNMd ESTER
1001 Utl SUJHMTIM
471 «un auxiic HTIMLISIS
47i nv tune i
ton
IMI «TIC tcit/nrnwa.
100Z WTUIEK IHRIZAIim
1001 HEMCHLOMCTOOCUC
1001 ESTtllFIMlIW
331 tUmnUCCTDE OXIMTIIW
671 »-!«:«£ OXIDATION
1001 DUITMTIW OF PcCNit.
;CO* ETHTLEW OXIK
-------
Table II-l. (continued)
. . Product0 Process d
137. craocxYiArti* soz ANILINE
137. craoHEXTLMfiic soz crcuKXANONE
138. rtLtOC SULfWIC ACIDS 1001 TOLUDC SULFONATION
13?. KNZTI. KMZOATE SOZ KNTALDEfmiE
139. wcti KWQATI soz KKZYL WCOHOL/ACIB
140. KNZOTL CHL«i8£ 1WZ KMZOIC ACID
Based on an IT Envirosciencc survey and ranking study.
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»nd "B-, etc. More than one A ior a product indicates that the product is made by acre than
and Ranking study and are based upon total estimated 1982 emissions for that process and the
xcentages indicate the percentage of 1982 estimated production for that product nada by that process.
one unit
toxicity
-------
11-10
Table II-2. Estimated Total VOC Emissions from Process,
Fugitive, and Storage and Secondary Sources for Major Unit Processes
Based on Early ITE Ranking Studies !
Unit Process
Oxidation
Ammoxidat ion
Esterification
Chlorination
Pyro lysis (chlorinolysis)
Dehydrochlorination
Oxychlorination
Alkylation
Hydrolysis
Hydration
Saponification
Reforming
Hydrogenation
Hydrochlorination
Condens at ion
Isomerization
Oxyacetylation
Dehydrogenation
Hydro cyanation
Dehydration
Sulfo nation
Nitration
Carbonylation
Phosgenation
Hydrofluorination
Oximation
Neutralization
Hydro formylation
Ammonolysis
Peroxidation
1982 Estimated
Production
(M* Ib/yr)
37,300
3,420
7,700
16,100
56,100
9,500
6,030
14,400
1,900
10,800
2,960
9,370
7,210
2,020
14,300
1,590
1,930
10,900
1,670
12,200
3,710
2 , 380
1,080
1,630
1,000
1,080
1,480
1,620
1,380
1,360
1982 Estimated
Total VOC Emissions
(M Ib/yr)
528
301
182
175
173
91
72
59
56
52
50
39
31
22
20
19
17
13
12
10
9
8
7
7
5
5
5
4
4
3
-------
11-11
Table II-2. (Continued)
1982 Estimated 1982 Estimated
Production Total VOC Emissions
Unit Process (M Ib/yr) (M Ib/yr)
Hydrodealkylation
Addition esterification
Bromination
Alcoholysis
Cleaving
Acidification
Fusion
Reduction
4,030
290
220
1,110
25
220
84
45
3
2
1
<1
<1
<1
<1
-------
11-12
The data presented in Tables II-l and II-2 are based on the total emissions
from the 140 products surveyed by IT Enviroscience. These data, however, do
not indicate the relative importance of the emissions from one reaction over
that from another reaction. Data from nearly 200 trip reports and letter
responses to EPA requests for information, given in Appendix B, were generated
through the IT Enviroscience study and led to a data base of chemical reaction
emissions. These data have been analyzed and organized to show the most signi-
ficant reactions from a VOC-emission standpoint from the available data (no new
data were collected specifically for this report because of time and budget
constraints). Figure II-l is a summary of the organic emissions from reactions
on which real data are available. The emissions are based on the pounds of VOC
emitted per million pounds of product produced; this ratio is based on the
emissions actually entering the atmosphere as reported by industry and there-
fore represents a mixture of uncontrolled and controlled emissions for the unit
processes from data collected from 1975—1979. These data sources are given in
Appendix B. Unit processes designated with an asterisk indicate that less than
four items of emission data were available. The dots designate the average
values for all the data available, with the maximum and minimum values also
shown. As would be expected, the ranges of emissions vary greatly because of
the difference in the processes and because both controlled and uncontrolled
plants exist in nearly every category.
A crude estimate of the emissions arising from reactors in each unit process
can be made by multiplying the median value as shown in Fig. II-l and by the
total production of chemicals using that unit process, and is given in
Table II-3.
Air-oxidation processes are clearly the leading emitters based on both the
annual production and the estimated VOC emission ratio. A report specifically
pertaining to air oxidation processes has been prepared.
The chlorination process, which is widely used throughout the industry, is the
second highest emitter source (this catagory includes chlorohydrination). The
chlorination reactions are analyzed later in this report.
-------
11-13
ilIT_PROCESS *
IIR OXIDATION
IHEMICAL OXIDATION
(using air)
MLORINATION
STERIFICATION
KDROFLUORINATION
[LECTROCHEMICAL
REDUCTION
EHYDROC.ENATION
KDROLYSIS
flfDROGZNATION
PTRATION
J1KGEN OXIDATION
CVANATION
BEHYDROCHLORINATION
INFORMING
ILKYLATION
JESULFURIZATION
DEHYDRATION
IXIMATION
i
ttROLYSIS
XEAVAGE
'HOSGENATION
IMMONOLYSIS
Less than
ID'1 xo-1
10
10
10"
io4 io5
**
**
**
.**
**
**
**
^
\—9
**
*Unit processes are shown only
for processes on which data
are available and are organized
as shown in those data.
**Based on less than four examples.
1 I 11UJ
I MIL
Less than 10~ 10 1
1 10 10 10 10
Organic Emissions from Reactions (Ib of VDC/M Ib of Chemical Produced)
Fig. II-l. Actual VDC Reaction Emission Data
-------
11-14
Table II-3. Estimated Annual VOC Emissions from Reactions
Based on Actual Emission Data Received from Industry
Type of Reactor
Air oxidation
Chlorination
Esterification
Chemical oxidation using
airc
Dehydroge nat ion
Hydrogenat ion
Dehydrochlorination
Oxygen oxidation
Hydro fluorination
Nitration
Hydrolysis
Pyrolysis (chlorinolysis)
Alkylation
Dehydration
Reforming
Hydrocyanation
Phosgenation
Ammonolysis
Oximation
Hydrodimerization/electro-
chemical reduction
Cleavage
Estimated 1982
Production
(M Ib/yr)
44,900
16,100
7,700
1 , 850
10,900
7,210
9,500
3,950
1,000
2,380
1,900
56,100
14,400
12,200
9,370
1,670
1,630
1,380
1,080
126
25
Estimated Annual VOC Emissions
a
Ratio
24,800
2,360
2,300b
7,760
910
580
230b
510
l,540b
530b
610b
b
b
b
b
b
b
b
b
Rate
(5 lb/yrj
1,100
38
18
14
10
4
2
2
2
1
1
<1
<1
<1
<1
<1
<1
<1
<1
<1
<1
Ib of VOC per million pounds of product produced.
Ratios based on less than four examples.
•^
'This category includes oxidation reactions in which a chemical oxidant is used and air
is used, sometimes in other reactors to re-oxidize the chemical oxidant.
-------
11-15
The esterification processes, the third highest source of emissions (see
Table II-3), typically have no reaction-related carrier gases associated with
them. The emission ratio is based on only three items of data and may reflect
the fact that inert carrier gases have been used in the reactor to prevent
decomposition or operations in the explosion range. Further specific data are
required on esterification processes to confirm the emission ratio in this
widely used reaction.
Chemical oxidations using air are also significant emitters. This category is
also covered in the Air Oxidation Emission Projection report in this volume.
Dehydrogenation has a relatively low emission ratio but has significant VOC
emissions because of the large amount of products annually produced. In 1982
styrene production will account for 87% of the chemicals produced by dehydro-
genation.
Hydrogenation is estimated to account for 4 million Ib of VOC emitted per year.
Most hydrogenation emissions are now burned as fuel or are controlled with a
flare. The moderate emission ratio is caused by two factors: producers of
hexamethylenediamine and caprolactam have low levels of VOC control, and flares
and fuel burners are assumed to have a VOC destruction efficiency of 99%
(emitting 1% of the VOC).
Dehydrochlorination reactions emit an estimated 2 million Ib of VOC per year.
However, only one item of data was available on this type of reactor and it
relates to a product responsible for only 3% of 1982 production. Nearly 90% of
the chemicals produced by dehydrochlorination reactors are from vinyl chloride
manufacture. Regulations for this chemical have already been promulgated.
Oxygen oxidations, which are primarily used to make vinyl acetate and ethylene
oxide, are also estimated to be significant emitters. All the actual data on
these plants obtained by trip reports and EPA information requests indicate
that the uncontrolled emissions are being sent to flares or are being used for
fuel. The emission ratio estimated is therefore primarily based on 99% VOC
destruction efficiency in the combustion control devices. It is felt that the
bulk of these plants may already be controlled.
-------
11-16
Hydrofluorination (sometimes referred to as fluorination) is used exclusively
in the manufacture of fluorocarbons. Emissions from this category could be
reduced through the requirement of higher levels of control. However, as
stated in the product report on fluorocarbons, the bulk of the emissions in
this industry results from distillation operations. Generic standards under
development for distillations may require control devices to which the reactor
emissions may also be routed.
The emissions ratio from nitration reactions is based upon only three data
points. One has a large VOC emission with a relatively low level of control,
whereas the other two have nearly negligible emission ratios. Further real
data on nitration reactions should be collected before a generic standard for
it is undertaken.
The hydrolysis reaction emission factor is based on two items of data. It is
likely that these data overstate the estimated emission ratio and that the
annual VOC emissions from hydrolysis reactions are less than 1 million Ib/yr.
All the remaining reactions are projected to result in VOC emissions of less
than 1 million Ib/yr. However, these projections are often based on limited
real data, and it is possible that plants in these groups exist that emit
significant quantities of VOC. A different method is needed to estimate the
potential magnitude of VOC emissions from processes on which there is limited
information. In the next two sections a method is discussed that can be used
in subsequent EPA projects to estimate other chemical reactions with poten-
tially severe VOC emissions. Time and budget constraints prohibit the applica-
tion of this method in this report. The method will be demonstrated with
chlorination reactions used as an example.
-------
III-l
III. EMISSIONS
A. INTRODUCTION
The next two chapters present a technique for estimating the likely range of
organic emissions being generated by chemical reactions; the technique is based
on the propensity for a given reaction to generate or use carrier gases. These
carrier gases can be organic or inorganic gases and can arise from the reac-
tants or products of the reaction or from nonreaction-related sources. In
chapter IV, chlorination reactions are discussed as an example of this
approach.
B. CARRIER GASES ESTIMATION OF TOTAL FLOW
Carrier gases an be organized in two ways: according to their chemical class
or by the method in which they are generated. The next two subsections deal
with carrier-gas classification by chemical class. The subsections following
the classification by chemical class deal with carrier-gas classification by
functional source, that is, reaction-related and nonreaction-related carrier
gases.
1. Inorganic Carrier Gases
Carrier gases are chemical compounds that exist as a gas at the temperature and
pressure existing at the emission point. Inorganic gases are nearly always
carrier gases, because their normal boiling points are significantly less than
the temperatures at the emission point. Table III-l1* gives some examples of
these various classes of inorganic carrier gases. Inorganic carrier gases can
be nonreactive or inert, prone to conversion by oxidation, prone to conversion
by reduction, or easily converted to a water-soluble ionized or salt form.
Totally nonreactive gases are the noble gases in the Periodic Table and nitro-
gen. Other common gases (C02) are said to be inert in the sense that they do
not react with oxygen or other organics, but from a carrier-gas viewpoint they
can be converted by salt formation (carbonates) or other reactions. Gases
prone to thermal or chemical oxidation can be converted to other gases (carbon
monoxide to carbon dioxide) or to nongaseous compounds (hydrogen to steam and
then condensed). This group can often be considered as candidates for combus-
tion control or energy recovery as fuel if the combustion or control device can
remove or recover nitrogen oxides or sulfur compounds from the flue gas.
*See Sect. VI for references cited in this report.
-------
III-2
Table III-l. Classification of Inorganic Carrier Gases
Classification
Some Inorganic
Carrier Gases
Characteristics
Nonreactive
Prone to conversion by
oxidation
Prone to conversion by
reduction
High water solubility
or forms salts
Nitrogen
Argon
Helium
Hydrogen
Carbon monoxide
Sulfur dioxide
Hydrogen sulfide
Some NO
x_
Oxygen
Ozone
Chlorine
Bromine
Some NO
x_
Carbon dioxide
Sulfur dioxide
Sulfur trioxide
Hydrogen chloride
Hydrogen bromide
Hydrogen fluoride
Ammonia
Inert; will not undergo
chemical reaction or conver-
sion
Can be thermally or chemically
oxidized, forming another
carrier gas or a nongaseous
compound
Can be thermally or chemically
reduced, forming another
carrier gas or a nongaseous
compound
Easily ionizes in water or
converts to form saOLt with
a high water solubility
Some NOV
-------
III-3
Inorganic carrier gases that are prone to conversion by chemical reduction can
be chemically or thermally reduced into nongaseous compounds. Chlorine can be
removed by reacting it with a reducing agent such as a sodium bisulfite solu-
tion. Compounds that have a high water solubility (usually because they are
easily ionized) or form soluble salts at certain pHs can be converted to non-
gaseous compounds in an acid, base, or neutral-pH water absorber. This classi-
fication allows identification of the chemical processes most likely to form
and emit a carrier gas. Processes into which nitrogen, argon, or helium is fed
or generated will likely lead to a carrier-gas emission (therefore a VOC) since
these compounds are not converted to nongaseous compounds. Other inorganic
gases may be emitted as carrier gases only if they are not converted by oxida-
tion, reduction, or salt reactions to nongaseous compounds.
2. Organic Carrier Gases
Organic compounds can also be carrier gases if they exist as gases at the
conditions of the emission. It is obvious that some organics are gases at
ambient conditions (e.g., methane, ethane) but most organic compounds are
liquids or solids at these conditions. Ambient conditions selected for this
analysis are atmospheric pressure and temperatures that range from 16 to 32°C.
Compounds that have a boiling point of less than, say, 32°C at atmospheric
pressure are potential carrier gases. Compounds that have a normal boiling
point in excess of 32°C usually cannot be carrier gases although they can exist
as an organic component in another carrier-gas emission. Figure III-l shows
the normal boiling points for many classes of organic compounds as a function
of the number of carbon atoms in each molecule. The curves shown in Fig. III-l
are based on homologs of one compound in each series. For instance, the alkane
series show the boiling points of methane (1 carbon atom), ethane (2 carbon
atoms), propane (3 carbon atoms), n-butane (4 carbon atoms), n-pentane (5
carbon atoms), and so on. Isomers of butane and pentane are not included. The
curves therefore represent a typical but not comprehensive presentation of the
boiling points of members of the different organic classes.
For the organic classes studied it becomes apparent that alkenes with 5 carbon
atoms and less can be carrier gases; alkanes and alkynes with 4 carbon atoms
and less can be carrier gases; ethers, chlorinated hydrocarbons, epoxides,
amines and aldehydes and esters with 2 carbon atoms and less can be carrier
-------
III-4
o
o
•rl
£
Cn
•H
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AMBIENT TEMPERATURE RANGE
•180
2345
Number of Carbon Atoms per Molecule
Fig. III-l. Organic Compound Normal Boiling Points
-------
Table III-2. Organic Compounds Likely To Be Carrier Gases
Chemical Class
Alkenes and dienes
Alkanes
Alkynes
Ethers
Compounds with Indicated Number
One TWO
Ethylene
Methane Ethane
'
Acetylene
Dimethyl ether
of Carbon Atoms in
Three
Propylene
Propane
Propyne
Methylethyl
ether
Each Molecule
Four
Butylene, bu-
tadiene, and
isomers
Butane and
isomers
Butyne and
isomers
Five
Pentene and
isomers
Chlorinated "hydrocarbons
Brominated hydrocarbons
Fluorinated hydrocarbons
Epoxides
Amines
Aldehydes
Esters
Mercaptans
Nitriles
Methyl chloride3/b
Methyl bromide '
Trichlorofluoromethane,
dichlorodifluoromethane,
chlorodi fluoromethane
Methyl amine
Formaldehyde
Methyl mercaptan
Hydrogen cyanide
a,b.
Ethyl chloride
vinyl chloride
Dichlorotetrafluoro-
ethane
Ethylene oxide
Ethyl aminea
Acetaldehyde
Methyl formate
i
m
aCan be removed or partly removed by water absorption at the appropriate pH.
Secondary emissions from the absorber liquid effluent are likely.
-------
III-6
gases; and mercaptans and nitriles with 1 carbon atom can be carrier gases.
Organic compounds that cannot be carrier gases are acetals, ketones, sulfides,
acid chlorides, alcohols, nitriles (except HCN), nitro-compounds, carboxylic
acids, and acid anhydrides. Since the compounds that can be carrier gases are
few in number and most often have the fewest numbers of carbon atoms in the
series, a listing of many of the actual compounds can be presented. Table III-2
gives the specific organic compounds likely to be carrier gases.
All organic carrier gases are prone to oxidation and therefore may be candi-
dates for burning for fuel or control. Many of the potential organic carrier
gases have significant water solubilities and therefore can be physically
removed by water absorption. Compounds that can be removed or controlled by
water absorption are designated in Table III-2. Compounds that cannot be
removed by water absorption can often be removed by an oil or hydrocarbon
absorption process. Condensation may be possible if refrigerated condensers
are used.
Reaction-Related Carrier Gases
Reaction-related carrier gases can arise from gaseous impurities in the reac-
tants, excess gaseous reactants, and unrecovered gaseous products or by-products.
The reaction-related carrier-gas flows can be estimated if the reaction
stoichiometry, reactant purities, and amount of excess reactants are known or
can be estimated.
The 140 products ranked for VOC emission potential (further discussed in
Appendix B of Volume 1) have been studied and catagorized so as to identify the
existence of inorganic and organic reaction-related carrier gases. Tables III-3
and III-4 represent a compilation of these data. Carrier gases that originate
because of reactants are listed in Table III-3 and carrier gases that originate
because of reaction products or by-products are given in Table III-4. Organic
gases are denoted by type and carbon number, whereas inorganic gases are
designated as to whether they are always or sometimes used or produced.
Products that are given in Tables III-3 and III-4 were organized to indicate
which each group uses or produces a certain class of carrier gases, as shown in
Appendix C. For instance all products that use or produce alkenes can be
-------
Table III-3.
Reaction-Reactant-Related
Carrier Gases for 140
Synthetic Organic Chemicals
Product
procesa
Reaction-Rejetant-Reiated Carrier Gases
Inoraanii:
WINYL CHLCSIBE
VINYI CHLORIDE
ACRYLONITRILE
ETHTLEtlE BICHLORIDE
ETHYLENE DICHI.ORIDE
KALE 1C UNHYDRIDE
KALEIC ANHYDRIDE
F.THYIFHE OXIDE
ETHYLEKE OXIDE
IIHETHYL TEREPHTHALATE (DHT)
BIKETHYL TEREPHTHftLAIf. (DHT)
DIKETHYL TEREPHTHALATE
ETHTLLNE
ETHYLEHE
F.THTLBEN7.ENE
ETHYUENZEKE
HYDROBFN CYANIDE (HCM)
MYDROGEN CYANIDE (HCN)
STYRENE
1.1.1. TRICHLOROETHAKE
1. III. TRKHLORURTHANE
1.1.1. TRICHLOROETHANE
CARBON TrTMCHIOSIDE
CARBON TETRACHLOftUE
!'.AR6HH TFTRACHI ORtDE
FOftMi DEHYDE
Fnf:«A!.DEHY(E
1% ACETYLENE
9*Z ETHYLEHE
1001 FROfYLEKF
S4X DIRECT rHI.OfclKftTION
851 IEKZENE OXIDATION
15Z BUTAKE OXIDATION
*41 AIR UXIDATIIlN/ETHa.ENE
34Z 02 OXIDATIOK/ETHYI.ENE
23Z AMOCO VIA TFREPHTHALIT ftCIB
3SI DUPMT
171 EASTMAN VIA TFRFPHTHAL1C ACID
Kl HERCULES
4«Z KftPTHA GAS Oil PYKOtYSIS
Til NATURAL GAS l.IUUIBS PYROLYSIS
21 REFINERY BY-PROPUtT
f8Z BENZENE ALKYLATION
2Z HUF.O XYLENF EXTRACT
50t ACRYLOHITftlLE CUPROOUCT
SOZ ANDRUSSOU PROCFSS
100Z ETHYL BENZENE
10Z ETHANE CHLORIKATIOK
74Z VINYL CHLORIDE
HI VINYLIDEUE CHLORIDE
3«t CARtON BISULFIDE
42X CHLOROPARAFFIN CHLPRIHOLVSIS
70Z HFTHANE
231 HETAl OX1K/NEYHANOI
7/1 SILVER CArAl.rST/HFTHANOL
tt
-------
Table III-3. (continued)
Product Process
4. HFWI. NF.THACRVI.Arr (UNA) 190Z ACFTONF i: iftdOHftiRIN
S. FROPYLENE OXIDE oOl' CHLORONYBKIN
5. PROPYLENE OXIDE 40% PEKl>X(»AnOK
6. PROPYLENE S4Z NAPTHA/GAE OH PVRtll YSIS
.6. PROPYLENE UZ NATURAL GAS LIQUIDS PYRQLVSIS
16. PROPYLENE 301 REFINERY iY-PROWT
.7. NITROBENZENE 100J! &ENZFNF NITRATION
18. ETNYLHIE 6LYCOL 1001 FTNYIENF CIXIIlE
19. CrCt.OHEXANflL/CYC(.OHEXANONE 75Z C'/CLQHEXANE
19. CYCLOHEXANOL/CYCLOHEXANONE 25* PHENOL
20. CIWENE 100* BENZENE
21. HETHANDL (NETWL ALCOHOL) 100Z HETHANE
22. PHENOL 3Z CHLOR08ENZF.NE
22. PHENOL • 2t BFNZFNE SULFOKAT1DN
22. PHENOL 9JI CUKENE
22. PHENOL 21 TOLUENE OXIDATION
23. ANILINE 10QZ NITROBENZENE HYOROGENATION
24. FLUOKOCARIONS 1601 Cn.4/r2CL6 Fl.UORIKATJDN
25. PERCHLOROETHYI.ENE Ml ETHVLENE CICNI OSIOE
25. PERCNLOROETHYLENE 341 ETHANE CHLORINOIYSIS
2«. TEREPKTNALIC ACID (TPA) J9Z AnOCO
26. TEREPHTHALIC ACID . «PT(»ANOL
:». iCETIC ACID 4J. OTHFR?
Reaction-Reactant-Related Carrier Gases
Org
§
3
L Carbon 1
A
A
A
A
i
i
BC
BC
BC
6
BC
CD
I
anic
f
«J
! Carbon 1
HC
K
K
BC
Rt
tr
1
2
I Carbon 1
ft
sc
BC
K
p.r
,
41
> Carbon I
C
r.
c
i
1
4*
2
S
A
A
A
A
A
A
A
S
S
|
c
A
ft
A
1
a
[ Carbon Hoi
#
A
A
3
s
[ sulfur Die
£
S
3
| Hydrogen S
c
A
A
A
A
A
A
A
A
,1
A
•H
A
A
A
A
. b
lorQanic
| Bromine
a
X
Q
1
u
A
A
A
|
S
\ sulfur Tri
A
loride
g
A
V
m
I
uoride I
*•*
Hydrogen I
A
Anemia
g
S
Milcellam
1
I
00
-------
Table III-3. (continued)
Product Process
30. CHI.nt-OPRFHF 1"07 VIA tillfAOfEHE
31. A'.KVL LEAPS 5'. ELECTROLYSIS
31, ALK.'i I EABS v'.iz FTHYL CHLORIDE
31. ACETONE 692 CUHFNE
35, ACFTONE 7. 1 Z ISOF'ROPANOL
33. ETHYL CHLORHiE • 45. ETHAKOl /ETHANE
33, FTHYi. CHLORIDE »*Z FTH.iFHf i:HL.ORIHAT ION
34. ETHANOIAMINES 1001 tTHYLENE P. N-IlUTENE
38. VlHYLiriCMF CWOP.I6E 301 1.1.1 TfUCHUiRUF.THCI.FNE
38. WIKYLJDENE CHLORIBE 50% 1.1.? TRICHLnRaETMYLENE
39. TOLUEHF Til ISOC fAKATF. iTI'I) 1'VIZ DI AHIHO IOLIIEKE
40. CMIORUFGRR 611 «ETHANE CHLnklNATION
40. CHlfiRDFORfi 391 HFTHAHUL CHlOftlHATlON
41. PHTHALIC AHHYIiftlSE 30X NAPTHALEKE
41. FHTHA..IC AMHYDRIBE 70Z 0-"CL.ENE
42. IsOPF'OFAML (I50PROPY1. tLCOHOLi 100Z PROPYLEHE/Sill.FURIC ACIli
43. ACETIC MHIIlf.lK tOOZ ACCTIC AC III
44. SLYCERCL iSYKTHETIC DFLYi 14X ACRDI E1H
44. '',! iCFRnl. (SYHTHFl.t!: ONUV I'll !(Hfl. Ai.CllHOL
44. GLYCFP'OL iSf*iTHET!C OWL') 71Z EPItrHLOKOHYIiPIK
45. hIT'"'"4FiiOL '•''"'- PHFKOI HUK/,TIO»
Reaction-Reactant -Related Carrier Gases
. a
Oraanic
']~~\
U
^
3,
ri
F
A
F
A
<•
I
4J
c
5
,N
F
tr
BC
C-
cc
t(C
PC
fC
0)
s
c
,->
PC
ir
HC
I
n
C
8
a
„
r.
pr.
B
r
1
4J
fi
|
^
C
c
. b
Inorqanic
c.
Si
f,
s
s
S
A
A
a
A
A
c
| Hydroge
S
*
u
•o
X
o
o
[carbon :
A
o
•o
X
o
[sulfur
3
3
C
[ Hydroge
1
o
A
S
.'
S
A
A
V
1 Chlorln
A
«
A
A
A
A
A
A
A
A
I Bread no
1
X
-H
a
[carbon
01
•o
X
M
H
[Sulfur
o
3
^
C
| Hydroge
«
1
u
CQ
C
Hydroge
QJ
•o
"-i
3
fc
C
1
as
[ Ammonia
s
3
8
S
JMiBCell
V
3
H
I
-------
Table III-3.
Product
CYCLOHEXANE
C.YCLl)HFXA*E
PISF-HEMOL A
CELI.UI OSF. ftr.FTATE
CAPROLACTAH
PFNTftERYTHRITOL
KOKYL PHENOL
ACRYLAHIDE
1IETHYLENE. TRIETHYLEME GLYCOLS
FUHARIC ACID
PROPYLENE GLYCOLS (MOKO.BI.TRI)
FflCHLOROHYDKIN
ALLYL CHLORIDE
ft01Pi,.NtTRUt/H«D«
ADIPOHITRILE/HHBA
ADrPUNITRlLE/HNDA
TRICHLOOOETHTLEKE
TRICHLOROETH/LENE
HETHYl ISOBUTYL KETONE (HIBKI
HR[ BINE
IEKZENE
It.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
58.
58.
59.
59.
>0.
61.
62.
62.
63.
64.
65.
66.
67. FIIRFIIKAL
68. 6LTCOL F^hERS
68. >>UVCOI. ETHERS
ETMAKOL (FTHYL ALCOHOL >
UREA
ACETALIiEHYDE
(continued)
Process
841 BEH2ENE HYSKriGEhATION
16J PFTSillFlM IiISriLLflTlCN
100: PHEHOL/ACETOHE
1'WZ CELLULOSE FSIFRlFITftTION
IOOZ TYCLOHEXANOKF
t.MZ FflRrtALDEHYDE/ACETALtiEh^E
IOOZ PHENOL AlKlLf.TION
1007. fti:K'L UKITR ;LE
100J COPRODWTS U/ETH\LENE 01 YCClL
100Z HALFIC AC10/ISOHERUATION
100Z PRDPYLENE 0-XICF HYORATTON
IOOZ ALLY!. CHLORIDC/MCL
IOOZ PROPYLEKE CH4.0RIKATION
HZ ACRrumiTRlLE
24X ADIPIC ACIP
A5I WTABlEtt
91 ArEIYLENE
VIZ ETHYLFHE DICHI.IIRIDE
IOOZ ACFTOKE
IOOZ FORrtALRFHYCK/ACf TAttlFHYIiE
80Z HOT IN PROJECT SCOPf
?l>7 TIH1IEI1F. HYnRaPiALi(rl.nTIOH
IOOZ ETHYLEKF
)'>OZ ArtHONIA/CARMN DTllXIPE
IOOZ ETHYLE«
«7Z C« H«ROCARSONS
33Z ISOAHYLEKE EXTRi^rTION
1MZ PUl fSACCHAHIlFS HfORIUYSIS
97Z ETHHENE 0>.IDF
3Z PROPYLCWE MIDE
;
c
'C
1
s
CJ
T
I
I
Ore
t
"i
|
\
u
r*
\
G
1
BC
BC
C
cm
•j)
g
c
S
U
o
*
u
r^
G
BC
LC
0]
*J
eC
tr
^
3
V
r.
RE
a
e
S
s
1
1
U1
act
tC
M
4J
•H
2
S
S
ior
I
-K€
c
«
1
X
A
A
A
A
A
A
?ct
o
T3
-H
X
1
1
a
o
ant
4!
•H
1
a
!
•3
Ul
-Re
V
•D
dS6
«
3
S
£
o
S
I
A
b
1
0
14
n
i
i
•3
-H
rH
fu
C
-------
Table III-3. (continued)
Process
69.
70.
71.
72.
73.
74.
74.
75.
76.
74,
77.
77.
->f.
79.
80.
81.
81.
82.
83.
81.
85.
80.
86.
87,
87.
98.
89.
?( .
•»l.
DIHITROT01UEHE
SEC-BIITANOL
LINEAR ALKYL BEHZEKE
ACROI.EIN
BIPHEKYLAHINE
HF.THfl. 5TYRENE
HETHYL STYREKE
FTHYLF.NE HIAHINK/TRtFTHaFHP. TETRAHINE
ETHYL ACRYLATE
F.THYL ACRYLATE
HETHYL CHLORIDE
HF.THYI. CHLORIDE
HETHYLENE BIPHENYLENE DIISOCYAKATE
H-WTYRAI.OEHYDE
NITROANILIME
ACF.TOPHENONE
ACETOPHENONE
ISOPHTHALIC ACID
BEKZ8IC ACID
KIISOOCTYI. PHTHAI.ATf
2-ETHYL 1-HEXAKOL
H-»IITAM){. (BIITV. mCQriOL)
K-BUTANOL r:fT
-------
Table III-3. (continued)
Product
93.
92.
93.
94,
94.
94.
91.
95.
96.
96.
94.
97.
98.
?8.
99.
100.
lOt.
102.
103.
104.
105.
105.
104.
107.
108.
109.
110,
111.
113.
tjlCHI.OROPHEHOL
MCHlORnFHEKOL
ISOBUTYRftLDF.HfDE
CRESYLIC ACIDS (SYK)
rRFSYI 1C ACIDS iSlNI
CRESYLIC ACII'S (SY*i)
CRF-SYI.IC ACI&S (SYN)
N-N DIHETHYL ANILIKE
ACETYLENE
ACETYLENE
ACETYLENE
PHOSGENE
T-8UTANOL
T-BUTANOL
SALICYLIC ACID
DIHETHYL HYDRAZIKE
OODECENE
DIISOLBCYL PHTHALATE
BUTYL ACRCLATE
CHLDROSULFONIC ACID
HFTHYI. ETHYI. KETOHF (NEK)
METHYL ETHYL f.ETONE IhEK)
ISMIITANQI. (ISOBIITfl ALCOHOL)
HYDROQUINONE
T
-------
Table III-3. (continued)
114.
115.
114.
117.
118.
118.
119.
120.
121.
121.
122.
123.
124.
125.
124.
127.
127.
128.
128.
12R.
129.
130.
131.
132.
133.
134.
13-1.
13f.
13'..
product
rtON&FDT.TRIfETHYI. MINE
Process
1001
CHLOROACETIC ACID 100Z
BENZOPHEHONE IOOZ
METHYL BROMIDE 100Z
PROPYI. ALCOHOL 877.
PROPY1 ALCOHOL • 131
BUTYI. AMINES 100Z
ETHYL (DIETHYL) ETHER 100Z
PROPYL AJUHF.S (H-B-T) 50Z
PROPYL AHINES (H-D-T) 501
CRQTONALBEHYDE 100Z
ISOOCTYL ALCOHOL 1001
FORMIC ACID »8Z
ETHYLENE 6LYCOL METHYL ETHYL ETHER ACETATE 100X
LINEAR ALKYL BENZF.HF. SULFONATE tOOZ
ISODECAMOL 251
ISODF.CAMOL • 7SZ
ALLYl ALCOHOL 471
ALLYl. ALCOHOL «
ALLYL ALCOHOL 47Z
ISOPROPYI. Af.ETATE 1001
METHYL ACETATE 100Z
r.YCI.OOCTADIE« 1'MZ
HEXACHLORO!>EK2EtC
BC
BC
BC
BC
»C
Inorqanle
I
I-1
CO
-------
Table III-3.
(continued)
product
Process
137. CYCLOHEXVLAHINE
137. CYCUIHEXYI AHINE
138. TOLUENE SHLfOWIC AC I fir.
137. lEHZri. HfNZDATE
139. BENZYL »EHZOATE
140. SENZOYL CHLORIDE
501 AtULiKE
30* CltLQHEXANOHE
1001 TOLUEHE SULFONATJOK
501 EFH/f.i DEHYDE
soi BENZYL ALCOHOL/ACID
100Z BEHZOIi: ACH
Re action-Re actant-Related Carrier Gases
Organic'
inorganic
'organic Carrier Gases
A - MBtllane
B - Mkanes
C - iltenea, dienes
D - Alkynes
E - Ethers
P - Chlorinated hydrocarbons
G - Epoxldei
Inorganic Carrier Gases
A - Always f oond
S - SoBetines found
H
H
I
I - Aldehydes
J - Esters
K - Mercaptans
L - lltrlles
M - BroniAated hydrocarbons
• - Flnorinated hydrocarbons
1. Nitrogen oxides
2. Phosgene
3. Ketene
4. HydroxylaBine
5. Baron triruluoride
-------
Table III-4. Reaction-Product-Related
Gases for 140 Synthetic
Organic Chemicals
I. VINYL CHLORIDE 1* ACETYLENE
1. VINO. CHLORIDE "X FTHYLENE BICHLORIDE
2. ACRYLONITRILE 100* PROPYLENE OXIMTION
3. ETHYLENE DICHLORIHE 50X DIKEC.T CHLOR1NATION
3. ETMYIENE BICHLORIDE . 501 OXYCHLORINATIOK
4. MAI.EIC ANHYDRIDE »SX BENZENE OXIDATION
4. KALEIC ANHYDRIDE 1SZ BUTANE OXIDATION
S, ETHYLENE OXIDE "* ftls OXiDATION/ETMYLME
5. ETHYLENE OXIDE 341 02 OXIDATJON/ETHYLENE
0. DIMETHYL TEKEPHTHALATE (DMT) 23Z AMOCO VIA TERF.PHTHAUC ACID
6. DIMETHYL TEREPHTHALATE (DMT) 35Z DUPONT
.. DIMETHYL TFREPHTHALATE
Trioxida
M
z
•+
2
01
n Chlorid
8.
1
I-
A
A
A
A
A
A
n Bromide
|
^
w
•0
1
1
=
c
*
aneoua
,-«
V
u
3
£
H
M
-------
Table III— 4. (continued)
Product Process
14. METHYL HETHACRYLATE (HttA) 100Z Af.FlOnt r.YANOHf DRIN
15. PROPYLENE OXIDE 60% CHLOF.OHYDRIN
15. PROPYI.ENF, OXIDE 40Z PERllXjnftTION
U. PROPYLENE 54% NAPTHA/BAS OIL PVROI.YSIS
14. PROPYI.E^E HZ NATURAL fi.lS LIOIUPS P/RIII.YSIS
It. PROPYIENE 30Z REFIHERY BY-PRODUCT
17. NITROSEWENE 1'WZ BF.N7ENF NITRATION
IB. ETHYLENE 6LYCOL 100Z ETHYLENF. OXIDE
1?. CYCLOHEXANOL/CYCLOHEXAHONE 731 CYCl.OHFXANE
19. CYCLOHEXANOL/CYCLOHEXANONE 25Z PHFKOl
20. CUHENE 100Z BEN7ENE
11 f HETHANOL (HETHYL ALCOHOL) 100Z HErHANE
22. PHENOL 3Z CHl.OROBEHZENE
22. PHENOL 2Z BENZENE SULFONATION
22. PHENOL 93Z CUKENE
22. PHENOL 2Z TOIUFNE OXICATION
23. ANILINE 101Z MnKOM.K7.t.Hf HYDKOfiEHATION
24. FLUOROCARBONS 100Z CCL4/C?fL* FLUORINAT10N
25. PERCHLOROETHYLENE «AZ FTHY1.FNF IHCH10RISE
25. PERCHLOROFTHYLENE 34X ETHANE CHLORINOLYS IS
24. TF.REPHTHAI.IC ACID (TPA) 39Z ,1HOCO
26. TEREPHTHALIC ACID (TPA) 47% EASTHAN
24. TEREPHTHALIC ACID (TPA) HZ rlllBIL
27. CHLOROBENZENE 100Z PEXZEKE CHLnRIKATinN
28. ACRYLIC ACID «Z HllBIKIEB KFPPE
28. ACRYLIC A(;IB 77Z FROPYLENE 0>.IHftTIOI*
29. ACFTK ACIB 3.fr ACF (Ai nFH HE
29, ACETIC ACID 44% 6UTAf!E OXIIATION
29. w.nir. Ar.u. '*:• ,-~«^
Reaction-Product-Related Carrier Gas
§
c
u
I
A
A
A
N
Or
v
a
u
Bf
BC
BC
N
anic4
n
!
^
u
nn
K
BC
I
X
o
to
|
0
no
1
s
1
rt
1
A
ft
A
A
Monoxide
Carbon ^
A
A
A
A
dioxide
Sulfur I
a
V:
I
O
kl
•0
>
3:
c
1
c
Chlorine
S
1
a)
b
aanic
Carbon Dioxide
A
A
A
A
A
S
Sulfur Trioxide
A
Hydrogen Chloride
A
A
A
A
A
o
•D
a
1
•S
1
fc
1
I
ft
•H
C
Miscellaneous I
1
H
H
CTi
-------
Table III-4. (continued)
Product process
30. CHLOROPRENE 100Z VIA PUTAOIFKE
31. ALKYI. LEADS '•>! ELtCTROLYSIS
31. ALKYL LEADS «* E™VL CHLORIDE
32. ACETONE *v* CUNENE
32. ACETONE »* ISOPROPANOL
33. ETHYL CHLORIDE « ETHANOL/E THANE
33. ETMYL CHLORIDE »« ETHYIENE CHLORINATION
34. ETHANOLAHINES I™* ETNYLENE OXIDE
35. VINYL ACETATE (VA) U* ACETTLEKE VAPOR PHASE
35. VINYL ACETATE oz fHfMl NITRATION
Reaction-Product-Related Carrier Gas
Ora
g
u
I 1 Carton 1
1
1 2 Carton J
F
F
I
I
anic*
|
§
1 3 Carton i
I
1 4 Carton j
C
C
C
n
S
1 S Carton .
Inor an
C
4-
z
!
|
s
A
A
a
•a
•rt
x
1 Carbon Mo
S
5
o
1
| Sulfur Di
4)
•U
•H
3
1
3
X
o
1 Chlorine
j Broming
1
1 Carton Di
A
A
A
A
A
A
A
b
4)
13
X
O
1 Sulfur Tr
a
t<
S
g
1
ft
A
A
A
A
A
A
A
A
A
A
u
1
«
I
3
S
(H
1
I
r
n
-H
I
.
O
1 Hiseellan
•
1
-------
Table III-4. (continued) |
Product Process
46. CYCUIHEXANE «Z BEKZENF. HYDROGF.NAT10N
46. CYCLOHEXAWE lei PETROLEUM DISTILLATION
47. 8ISPHENOL A 1007. PHFNIH./ACETUNE
48. CELLULOSE ACETATE IOOZ CELLULOSE ESTERIF1CATION
49. CAPROLACTAM IOOZ CYCI OHEXAHONE
50. PE-TAERYTHRITOL IOOZ FORHALDEHYBE/AfiFTAl BFHYPF
51. NONYL PHENOL IOOZ PHFHOL ALKYI.ATION
52. ACRYLAN1DE IOOZ ACRYLONURILE
Si. OIETHYLENE. TRIETHYLENE GLYCOLS IOOZ COPROmiriS y/ETHYLENE fiLYCOL
54. FUNARIC ACIt IOOZ NALEIC AriD/ISONERIZATION .
55. PROPYLF.NE GLYCOLS (HONO.OI.TRI ! IOOZ PROPYLENE OXIBE HYDRATION
56. EPICHLOROHYtRIN IOOZ ALLYI. CHLORIflE/HCl
57. ALLYI. CHLORIDE IOOZ PROPYLFHE CHLORINATION
58. ADIPOKITRILE/HHBA HZ ACRY1 OKlTRILt
58. ADIPOHtTRILE/HMDA 24Z ADIPIC ACID
58. ADIPONITRILE/HftVA 45Z BUTADIENE
5». TRICHLORDETHYLENE « ACETYLENE
59. TRICHLOROETHYLEME 91Z ETHYLEKE DICHLORIDE
40. HETHYL ISOIIITYI. KtrOME (MI»K) IOOZ ACETONE
41. PYRIDINE IOOZ FDRHALDEHYDE/ACETALDEHYDE
67. (ENZEME 80Z NOT IN PROJECT SCOPE
42. BENZENE 20Z TOLUENE HYBRODFALKYLATTON
4J. F.THANOL (ETHYl. ALCOHOL) tOOZ ETHYLCNE
64. UREA IOOZ ANHOKIA/CARbOM niPXU't
45. ACETAI.8EMYDE IOOZ FTMYtENE
46. ISOPREKE "I C4 HYDROCARKlNS
66. !SOP*Eȣ MI ISOAMfLFNt EXTRACTION
47. FURFURAL 1001 POLYSACCH«RIPES HYDRnL^SIS
68. I5LYCW. ETHERS *« ETH«.ENf. IIXIDE
48. COC.OL l\*tK H fP.OPlLENE OXHiF
Reaction-Product-Selated Carrier Gas
Org
S 1
> *J
C •<
i 1
> O
•» rx
A
I
a
anic
1
i i
& a
<
|
S
<
I
B
0
I
<
1
5
!
i
S
Z
I
i
1
A
A
A
S
g
*
u
s
X
o
M
3
«H
r-t
y
to
•o
p
(A
•
£
C
S
I
?
•rl
g
S
noraanic
V
c
1
14
at
§
1<
5
o
c
u
o
3
X
•jj
y
HI
s
w
5
£
u
c
s
1
A
A
A
.8
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i
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s
g
I
«
i
§
s
5
Hisca
4
5
H
H
I
00
-------
Reacticn-Produet-Rtlated Carrier Gas
Table HI— 4. (continued)
Product ^ Process
69. DIMITROTUIUENE ™"Z TUUIENF DIWITRMION
70. SEC-BUTANOL 100* BWTYLENES
71. LINEAR ALKYL BENZENE »»« BENZENE AIKYLAT10N
72. ACROLEId 10°z PRW'fLENE OXIDATION
73. DIPHENYLAHINE .»<*>« AHILIKK AHINATIOII
74. HETHYL STYRENE 15Z CUNEKE DEHYIIR06EKATION
74. MFTHYL STYRENE 85Z CtDtFNE PROCESS BY-PRODUCT
75. ETHYLEHE DIAHIKE/TRIETHYLEKE TETRAHIKE 1001 EnC AHHOHOI.YSIS
74. ETHYL ACRYLATE *>* ACETYLENE (REPPE)
76. ETHYL ACRYLATE «* »"*« ESTERFICATIUN
77. HETHYI. CHLORIDE « HFTHANF. CHLORINAflON
77. METHYL CHIORIBE ?8Z NETHANOL HYDROCHLORINATION
78. HETr.rLEHE OIPHENYI.EHF. DUSOCYANATE IOOZ DPrtDA/PHOSGEHE
7?. N-BUTYRALBEHYDE »«OZ 0X0 PROCESS
80. NITROAN11.INE »<>OZ NITRO CHLORBEN/ENE
81. ACETOPHFNONE 60Z CUKENE PEROXIBATION .
81. ACETOPHEHONE 40Z ETHYL BFH7EHE OXIDATION
82. ISOPHTHALIC ACID IOOZ H-XY1 EKE OXIDATION
83. BENZOIC ACID IOOZ TULUFNF. AIR OXIDATION
84. DIISOOCTYL PHTHALATE (BI2-ETHYLHEXYL) IOOZ PHTHALIC ANHVDRIllf./ALCOHOt
85. 2-ETHYL 1-HEXANOL IMZ CONDENSATION
86. N-BUTAKOL (BUTYL ALCOHOL) 20Z ACETAl OEHYDF
St. N-BIJTANOL (BUTYL ALCOHOL) 80Z QXO PROCESS
87. PROPIOKIC ACID 71 OTHERS
87. PROPinNIC ACIB »3Z 0X0 PROCESS
88. ETHYL .ACETATE IOOZ ACETIC ACHl
89. ETHYLEHE tUSROMIOF. IOOZ ETH/LENf. BROHlXf.TION
90. ACETOttE CTA«iHYiFRIf IOOZ ACETONE CYANAMOK
91 trn7n. r.HiM.im t*** TiiniFKt: CHLORINATIOK
Ora
§
«J
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ia
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s
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loride
S
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VO
-------
Table III-4.
(continued)
Product
92. DICHLOROPHENOL
92. DICHLOROPHENOL
93. ISOIUTVRAIDEHYgE
94, CRESYLIC ACIDS
94. CRESYLIC ACIDS (SYN)
94. CRFSYLIC ACIDS (SYN)
94. CRESYLIC ACIDS (SYN)
95. N-N DIHETHYL ANILINE
?'. ACETYLENE
It, ACETYLENE
94. ACETYIENE
97. PHOSGENE
98. Y-tUTANOL
98. T-IUTANOl
99. SALICYLIC ACID
100. DIMETHYL HYDRAZINE
101. D01CCENE
102. BIISOIDCYI. PHTMALATE
103. tUTYl ACRYLATE
104. CHLRROSULFONIC ACID
105. METHYI ETHYL KETONE (HEX)
IK, METHYL ETHYL KETQNE (MEK>
104. ISOIUTANOL (ISOIUTYL ALCOHOL)
107. HYOROaUIMONE
108. HONOftI>TRI.METHYL AMNES
109. ADIPIC ACID
110. CHLOROKITROIENZENE
111. CARtliN tllSHLFIPE
112.
Procegg
45X PHENOL CHLORIKATION
55Z TRITHLOROSEMZEHE
100Z 0X0 PROCESS
4Z CYHfHF. OXIDATION
80Z NATURAL COAL TAR
8* PHFHDL/METHANOL
81 TOLUENE SULFOKATIOK
1001 ANILINE ALCOHPLYSIS
30Z CALCIUM CARIIDE
81 ETHYLENE BY-PRODUCT
621 HYPROCARION OXIDATION
1001 CARtON HOmXIOE/CHLORIIIE
211 ISOHUTYl.EKE
m PROPYLENE OXIDE CO-PRODUCT
100Z SODIUM PHENATE
100Z NITROSODIMETHYL AHINE
100Z NQNENE CO-PRPtUTT
lOOr. PHTHALIC ANHYDRIDE/ISODECANOL
100Z ACRYLIC ACID ESTERIFICATION
IDOZ S03 HYDROCHLORINATION
25Z 1UTANE OXIDATIOK
7SZ StC-DUTAMOL
100Z OXR PROCESS
100Z ACETOME CO-PRODIJCI
100Z METHANOL AKMONOLYSIS
tOOZ CYC1.0HEXANE
100Z CHLOROKEN7ENE NITRATION
100Z METHANK/SIILFUR VAPOR
100Z TOtUFKE HYDKODFALKYLATIOM
\IHll SOftlUH
Reaction-Product-Rclated Carrier Gas
Organic
ID
.norganic
I
NJ
o
-------
Table III-4. (continued)
Product
Proceaa
11'.. NONDtDIiTKItETHlTL AD1KE
115. CHLOROArfTIC ACID
114. tEKZOFHENONE
117. HCTHYI. BRrtHtJE
118. PROPYL ALCOHOL
118. K.OHI. M.COHOI
119. turn AMINES
120. ETHYL (DIETHYL) f THE It
121. PROP»L AMINES
171. PSOPYL AMINES
122. CROTOMALDFHTDE
123. ISCOr.IYL ALCOHOL
124. FORMIC MID
125. ETHYLENE DI.YCOL METHYL ETHYL ETHER ACETATE
126. LINEAR ALKYL BENZENE SULFOKATE
127. (SOKCAMOL
127. ISOtECANOL
12«. ALLYL ALCOHOL
128. ALLYL ALCOHOL
128. ALLYL ALCOHOL
12?. ISOFftOPVL ACETATE
130. METHYL ACETATE
131. CTCLOOCTAPIEKE
132. HEXACHLOROBEMZENE
133. N-tUTYL ACETATE
134. 1llirtt.lt. ttfllt
134. BUTYRIC ACIP
13S. OtKTTRllPHF.NOL
134. *M!
1001 ETHANOl AhHONOI YSIS
100Z ACETIC ACID CHtURINATION
1001 »ENZEKE/CAR>ON TETRACHLORIDE
1001 HETHANOL/HBD ANA BROMINE
87Z 0X0 PROCESS
1JI PROPANt OXICftTIOH
1001 (UTYRALriEHYHF HYDR06ENATION
1001 ETHANOL
501 N-PROPYL ALCOHOL
SOI H-PROPTt CHLORIDE
1001 ALBO PROCESS
tOflt 020 PROCESS/HYDKOBENATtON
m M-BUTANE OXIMTION
1001 ETHOXY ETHANOL ESTER
1001 LAI SULFOKATION
2SI N-PARAfFIN OXIMTION
751 0X0 PROCESS
47Z ALLYL CHLORItC HYDROLYSIS
61 PROP 6LYCOL >EHY»RATION
471 PROP OXIDE ISOMCRIZATION
1001 ISOPROPANOL ESTF.RIFICATION
tWZ ACETIC ACIB/METHAMOL
1001 BUTABIFKE BIKERIZATIOK
1MI HEMCHLOR04:/CLUHEXAME
100Z ESURIFICATION
33Z BUTYRALIEHYOF OXIDATION
47Z N-BUTAME OXIBATION
1001 DINITRATION OF PHENOL
100Z ETHTLENE OXIDE
Reacticn-Pix>diict.-tel«ted Carrier da
H
H
M
I
NJ
-------
Table III-4. (continued)
Product Process
137. CVCI.DHEXrl AHINE 50X AN11.INE
137. CYCLOHEKYLAHIKE 50Z CYCLOHEXANONE
139. TUI.HENF SUI.FONTP ACIDS 140Z TflLUEKf. SlUFUMftUON
13?. BENZYL BEHZOATE 501 BEH7ALUEHYDE
13?. 'BENZYL BFNZOATE soz BENZYL ALCOHOL/ACID
140. BENZOYL CHLORIDE 1001 CEKZQIC ACIC
•"
§
1 Carbon ;
Reaction-Product-Related Carrier Gas
Ore
w
2 Carbon J
anica
,
*J
3 Carbon 1
I
4 Carbon 1
I
I uoqx*3 5
j
e
•H
IS
^
c
1
9
Carbon Mor
•
•d
K
Sulfur Die
i
I
X
Oxygen
•r4
u
noraan
«
1
X
Carbon Die
icb
«
•«4
C{
h
H
a
IM
M
3
CO
loride
-c
A
V
s
t4
1
1
t<
!?
c
a:
Anvnonia
E9
0
Kiscellane
to9and
Carrier Gases
A - Matbane
B - Mfrf">*«
C - Alkenaa, diene*
D - Xlkynai
E - Bthara
F - Oilorinatad hydrocarbon*
G -
I - JOtehydea
J - Bctars
K - Marcaptana
L - MitrllM
H - Bxominatod bydxocarbona
• - riaorinatad bydrocartens
Inorganic Carrier Gaa«s
A - Alw«ys found
S - SoaattmM found
H
1. Bitroqan oxidas
2. Phoaotn*
J.
4.
5. Boron trifluoride
-------
111-23
categorized. The tables in Appendix C are useful for locating reactions with
common carrier gases.
Carrier gases generated by reaction reactants or products are not the sole
source of reaction-related carrier gases. Another source of reaction-related
carrier gases is gases introduced with liquid or solid reactants or generated
through decomposition of liquid or solid products.
Carrier gases introduced with liquid or solid reactants are dissolved in, are
adsorbed on, or exist in an ionized or salt form in the liquid or solid re-
actant. Table III-5 gives data on the gas flow resulting from 100% of the
gases dissolved in several organic liquids. These flow rates are based on
100 million Ib of the liquid being introduced into the reactor per year and on
the liquid being saturated with gas. It is evident that carrier gases intro-
duced in this fashion are normally not significant contributors to the total
carrier-gas flow.
Water can also introduce dissolved gases into a reactor. Table III-62 gives
the amount of carrier gas that can be expected when water is fed at various
temperatures into a system. Although it is possible for reactions to use more
than 1000 gpm of water, this is a fairly high flow. For these flows the
absorbed gas represents a carrier-gas flow contribution of low significance.
Gases adsorbed on solids can be a significant contribution to carrier-gas flow
only under certain circumstances. A solid that adsorbs a great deal of gas,
such as activated carbon, can carry 0.1 to 5 scf of gas/lb of solid, and if
this solid is fed to a reactor that has had the appropriate conditions to
desorb the gases from the carbon (higher temperatures or lower pressures), the
gas can be released as a carrier gas.3 Normal chemical solids, however, have
much less capacity to adsorb gases and are normally not significant sources of
carrier gases.
Gases that can be generated by chemical conversion of an ionic or salt form can
be significant sources of carrier gases. Sodium carbonate, for instance, that
is acidified can generate about 3.4 scf of C02/lb of dry Na2C03 fed. Acidifi-
cation of sodium sulfide can generate about 4.6 scf of H2S/lb of dry sodium
-------
111-24
Table III-5. Contribution of Carrier Gases from
Dissolved Gases in Organic Liquids3
Organic Liquid
n-Perfluoroheptane
n-Heptane
Carbon tetrachloride
Carbon disulfide
Acetone
Gas
H2
0.25
0.47
0.14
0.13
0.27
Flowb [scfm/(100 M
N2
0.68
0.28
0.20
0.70
Ib of liquid/yr) ;
CH4
1.45
1.26
1.18
2.63
]
CO 2
3.68
8.26
4.75
2.95
Adapted from ref 1.
At 25°C and atmospheric pressure.
-------
111-25
Table III-6. Contribution of Carrier Gases from Gases
Dissolved in Water Fed to a Reactora
Water Temperature (°F)
40
50
60
70
80
90
100
Gas Flow
(lb/hr)
16.8
14.9
13.2
11.8
10.7
9.7
8.8
for 1000-gpm Water
(scfm)
3.47
3.07
2.72
2.43
2.21
2.00
1.82
ref 2.
-------
111-26
sulfide fed. Reactions operating under conditions to free acid or basic gases
from solids or liquids are not that common in SOCMI but can lead to carrier-gas
formation.
Reaction-related carrier gases can result from the decomposition of liquid or
solid products that form gases. The estimation of flow from this source re-
quires specific information concerning the potential of decomposition in each
case. However, the following simple order-of-magnitude case can be estimated
for gases generated by chemical decomposition: a chemical with a molecular
weight of 100 is being processed in vacuum equipment at the rate of 1 to
1000 lb/hr; 10 mole % of this material is decomposed to a gas. The number of
moles of gas produced is equal to the number of moles of chemical decomposed.
The data from the calculation are presented in Table III-?.4 Carrier-gas
generation resulting from chemical decomposition becomes significant only for
very large plants or when more than 10 mole % of the chemical is being decom-
posed.
4. Nonreaction-Related Carrier Gases
Nonreaction-related carrier gases arise from either the planned or the unavoid-
able introduction of carrier gases into process equipment. If these gases are
not converted to nongaseous compounds or if they change state through condensa-
tion, solution, or other physical process, they are emitted as carrier gases.
Nonreaction-related carrier gases can be classified into three areas: gases
introduced to control conditions, gases introduced to control the chemical
atmosphere, and gases related to reduced pressure.
Some of the gases introduced to control conditions are air, nitrogen, carbon
dioxide, or methane fed to process equipment to increase or control pressure or
temperature. A common example of this type of carrier gas is the air or nitro-
gen bled into a vacuum distillation unit fjr the purpose of controlling the
vacuum. An evaluation of the emissions from vacuum equipment is presented in
the vacuum system emission projections report. A special case of this classi-
fication is the use of gases to control the process-equipment pressure, result-
ing in fluid transfer operations. The gases introduced or removed to form
slightly elevated or reduced pressure often result in an air emission. Al-
-------
111-27
Table III-7. Gas Flow from Chemical Decomposition
(Equimolar Gas Evolving from 10 mole % of the Feed Decomposed)
Feed Rate
(Ib-moles/hr)
0.01
0.1
1.0
10.0
(Ib/hr) a
1
10
100
1000
Decomposition Gas
(Ib-mole/hr)
0.001
0.01
0.1
1.0
Rate
(scfm)
0.006
0.06
0.6
6.0
on a molecular weight of 100.
-------
111-28
though the carrier-gas flow from the sources is small, it can be a significant
fraction of the flow.
Gases introduced to control the chemical atmosphere are fed to chemical process
equipment in order to modify the chemical composition of the gas or vapor phase
in the equipment. This is done to promote specific reactions, to control
chemical decomposition, or to prevent the hazards of operating chemical equip-
ment in the flammable range (organic-oxygen ratio such that detonation or
deflagration can occur). Inert gases such as nitrogen and carbon dioxide (C02
is inert to oxidation) and organic carrier gases such as methane are often used
for this purpose. Table III-8 gives some data on the concentrations of inert
gases required to completely prevent flammable conditions in process equipment.
Since the amount of inert gas required depends on the amount of air or oxygen
present, the ratio of inert gas volume to air volume can be calculated. Ranges
for this ratio are listed in Table III-9. This source of carrier gases can be
significant.
Gases related to reduced-pressure operation are involved in the operation of
vacuum equipment. This type of carrier gas is introduced as the result of air
leaking into the equipment under reduced pressure. Even though leakage can be
minimized through appropriate design, it is very difficult to eliminate air
leakage in vacuum equipment. Since air leakage introduces oxygen into the
process vessel, sometimes inert gases must be used to prevent product decomposi-
tion or operation in the explosion range. Further information on carrier-gas
flow from vacuum equipment may be found in the vacuum system emission projec-
tion report. In general carrier-gas flow from reduced pressure can be a signi-
ficant fraction of the total emission.
C. VOC CONCENTRATION
Once a carrier gas is generated and reaches the emission point without being
reduced through reaction or physical change, a VOC emission will occur only if
the carrier gas is organic and is considered to be VOC and/or the carrier gas
contacts volatile organic liquids or solids before they are emitted. In the
latter case the significance of the emission depends on the mole fraction of
the volatile organics in the emission, which, in turn, depends on the vapor
pressure of the organics, the temperature and pressure in the process equip-
-------
.
o
::
I
8
J
o.oi
0:001
-ZO'C -IO O*C 10* 20* 10' 40* • 50" «/• 70* »0* SO' IOO*
TEMPERATURE (°C)
ISO* HO* l«0*
1. Methanol
2. Chloroform
3. Formic acid
4. Dichloromethane
5. Trichloroethylene
6. Acetonitrile
7. Acetic acid
8. Ethanol
9. Monoethancrlamine
10. Allyl alcohol
11. Butyric acid
12. Phenol
13. Methyl phenyl ether
14. o-Cresol
Fig. III-2 . Composition of Gases Saturated with Various Compounds
-------
111-30
Table III-8. Minimum Inert-Gas Concentration for
Operation To Be Entirely Out of the Flammability Envelope
Compound
Methane
Ethane
Propane
Butane
n-Pentane
n-Hexane
Higher paraffins
Ethylene
Propylene
Isobutylene
1-Butene
3-Methyl-l-butene
Butadiene
Acetylene
Benzene
Cyclopropane
Methanol
Ethanol
Dimethyl ether
Diethyl ether
Methyl formate
Isobutyl formate
Methyl acetate
Acetone
Methyl ethyl ketone
Hydrogen sulfide
Hydrogen
Carbon monoxide
b
Inert-Gas Concentration
(mole %)
CO 2
23
31
28
28
29
29
28
39
28
26
31
31
35
53
29
30
32
33
33
34
33
26
29
28
34
30
56
41
N2
37
44
43
40
42
42
42
49
42
40
44
44
48
65
43
41
46
45
48
49
45
40
44
43
45
72
58
See ref 4.
Does not include the inert gas related to the air concentration. Values
expressed are for mixture at 25°C and 760 mm Hg. Operation under vacuum will
not require as high inert concentration as those expressed.
-------
111-31
Table III-9. Inert-Gas-Flow Estimates to Prevent
Operation in the Flammability Range
Volume of Inert Gas
Required for Each Volume of Air
At 25 °C At 100 to 150 °C
Organic gases and vapors 0.25—1 3—10
Flammable inorganic gases and acetylene 0.8—3 5—10
a
From ref 4 for use in estimating emission rates only; not to be used for
equipment design.
-------
111-32
ment, and the degree to which the VOC achieves saturation. This is more
completely descussed in the next chapter.
Estimation of the VOC concentration requires specific process details and is
very difficult to generalize. In addition the vapor pressure of organic com-
pounds varies greatly. Figure III-2 shows the saturation concentration of
several organic components in a carrier gas. It is clear that VOC concentra-
tions can vary from nearly zero to 100%.
It is not always necessary to know the exact VOC concentration. The generic
approach accepts the inherent physical variability in the emission through the
reality that, for a given class of reactions, the VOC concentration could be
very high, moderate, or low, depending on the reaction and the specific proc-
ess. Regulations covering this class of reactions would reflect this varia-
bility.
-------
IV-1
IV. CHLORINATION REACTIONS
In this chapter the development of a technique for estimation of the likely
range of organic emissions from chemical reactions is concluded. This tech-
nique will be developed with chlorination reactions used as an example. The
same approach should be applicable in the estimation of organic emissions from
other chemical reactions.
Chlorination reactions are widely used in SOCMI. They make use of gaseous
chlorine, aqueous hypochlorous acid solutions, or other chlorinating agents to
substitute chlorine for other functional groups. Table IV-1 lists the products
that use chlorination reactions in the group of 140 products ranked.
A. ESTIMATION OF TOTAL FLOW
The general equation for chlorination is
aR + bC!2 5- cRCl + dHCl (IV-1)
The minimum amount of chlorine used is dependent on the reaction stoichiometry
although excess chlorine can be used. In many reactions hydrogen chloride gas
is generated. In reactions that operate in the aqueous phase hydrochloric acid
or a chloride salt is formed. The molar chlorine ratio (MCR) of chlorine
reactant to chlorinated product can be written as the ratio of b to c or b/c.
The molar ratio of HCl formed (MHCR) to product is d/c. These two ratios then
give a measure of the chlorine fed and the hydrogen chloride generated in a
chlorination reaction as functions of the chlorinated product produced. All
these ratios are shown in Table IV-2. In addition some of the chlorination
reactions use gaseous organic reactants or generate gaseous organic products;
they are expressed as a/c (the molar ratio of gaseous organic reactant to
product, or MGRR) for the cases of organic reactants and c/c (the molar ratio
of gaseous organic product to product manufactured, or MGPR), or 1 for organic
products (c/c can be a low fraction if gaseous by-products are generated), and
are also shown in Table IV-2.
Once the stoichiometric relationships are known, estimation of the total
carrier-gas flow from the reaction depends on knowledge of the purity of the
-------
IV-2
Table IV-1. Products That Use Chlorination Reactions
Product
Processes
3. Ethylene dichloride
11. 1,1,1-Trichloroethane
11. 1,1,1-Trichloroethane
12. Carbon tetrachloride
12. Carbon tetrachloride
12. Carbon tetrachloride
15. Propylene oxide
25. Perchloroethylene
25. Perchloroethylene
27. Chlorobenzene
30. Chloroprene
33. Ethyl chloride
36. Methylene chloride
36. Methylene chloride
40. Chloroform
40. Chloroform
44. Glycerol (synthetic only)
57. Allyl chloride
59. Trichloroethylene
77. Methyl chloride
91. Benzyl chloride
92. Dichlorophenol
97. Phosgene
113. Acetyl chloride
115. Chloroacetic acid
132. Hexachlorobenzene
50% Direct chlorination
74% Vinyl chloride
10% Ethane chlorination
42% Chloroparaffin chlorinolysis
20% Methane
38% Carbon disulfide
60% Chlorohydrin
34% Ethane chlorinolysis
66% Ethylene dichloride
100% Benzene chlorination
100% Via butadiene
4% Ethanol/ethane
65% Methanol/methyl chloride
35% Methane chlorination
39% Methanol chlorination
61% Methane chlorination
71% Epichlorohydrin
100% Propylene chlorination
9% Acetylene
2% Methane chlorination
100% Toluene chlorination
45% Phenol chlorination
100% Carbon monoxide/chlorine
100% Sodium acetate
100% Acetic acid chlorination
100% Hexachlorocyclohexane from
benzene
Percentages listed indicate the
manufactured by that process.
estimated portion of the domestic production
-------
Table IV-2.
Stoichiometric Ratios of Potential Carrier Gases
to the Chlorination Product
:
Product
Ethylene dichloride
1,1, i-Trichloroethane
Carbon tctrachloride
Propylcne oxido
pf-rcliloroethyli no
(JiloroLienzenc
Chloroptene
Ethyl chloride
Mcthylene chloride
Chloroform
Glycerin (epichlorohydrin)
Allyl chloride
Trichloroethylene
Methyl chloride
Benzyl chloride (s)
Dichlorophcnol
I lior.ijone
Acct.yl chloride
Chloroacetic acid
]lox.T.liloroljorizcne
Maior Organic Reactant
Ethylene
Vinyl chloride
Ethane
Propane -propy le ne
Methane
Carbon disulfide
Propylene (chlorohydrin)
Propane-propylene
Benzene
Butadiene
Ethanol-ethane
Mcthanol — methyl chloride
Methane
Methane
Acetone
Allyl chloride
Propylene
Acetylene
Methane
Toluene
Phenol
Carbon monoxide
Sodium acetate — acetic acid
Acetic acid
Molar Chlorine
Ratio
(MCR)
1
1
3
_ Oc
7 — 8
4
2
1
7/2 — 8
1
1
1/2 — 1
1/2 — 1
2
3
39
I9
1
2
1
1—3
2
1
«
1
Hexachlorocyclohexane from benzene 3
Molar Hydrogen
Chloride Ratio
(M1ICR)
0
b
1 — 3
-__pC
4
0
1
4 — 8
1
0
0 1
0 1
2
3
0
0
1
h
0—1
1
IT— 3
2
0
0
1
0
Molar Gaseous
Reactant Ratio
(MGRR)
1
O
1
1
1
0
1
1
0
1
e
1/2—1
1/2— lf
1
1
0
0
1
1
0
0
1
0
0
0
Molar Gaseous
Product Ratio
(MGPR)
0 (0.1)a
0
t /I
1/3
a
0 (0.1)
0
0
0
Q
0
0
1
0
-d
0
d
0
0
0
0 (0 • 1)
0
1
0
0
1
0
0
H
^
U)
ar«t<:ntial for formation of ethyl chloride by-product.
bDepcnding on ethylene hydrochlorination side reaction.
CDei*iiding on propane-propylene ratio.
dl-otcntial for formation of methyl chloride by-product.
eDcpending on ethane-ethanol feed ratio.
fDopending on methyl chloride—methanol feed ratio.
9Used as an aqueous bleach solution.
hI!Cl formed through dchydrochlorination reaction has MHCR of 1.
i«sos pJxini-horus trichloride ns a chlorinating
-------
IV-4
reactants, the extent of separation of the product and excess reactants, and
the existence of other carrier-gas mechanisms. The molar ratio of total reac-
tion-related carrier-gas flow to production rate is given by Eq. (IV-2):
G=C+H+R+P
where
G = the molar ratio of total reaction-related carrier-gas flow from the
reactor after any separation- recovery equipment to the production rate,
C = the molar ratio of chlorine-related carrier-gas flow to the produc-
tion rate,
H = the molar ratio of hydrogen chloride — related carrier-gas flow to
the production rate,
R = the molar ratio of gaseous organic reactants carrier-gas flow to
the production rate,
P = the molar ratio of gaseous organic products carrier-gas flow to
the production rate.
In turn the molar ratio of chlorine related carrier gases, C, is expressed as
c =[MCR x (FC - i) x (i - sc)J+rMCR x (i - PC) x FC x (iv-3)
* <> - Sln>]
(FC - i = o if FC < i),
where
MCR = the molar ratio of chlorine to product,
P = the molar purity of the chlorine,
F = the molar ratio of total chlorine feed to the stoichiometric
requirement,
S = the separation efficiency of chlorine in the separation-recovery
equipment following the reaction,
S = the separation efficiency of the gaseous impurities in the chlorine
in the separation-recovery equipment following the reaction.
-------
IV-5
The molar ratio of hydrogen chloride—related carrier gases, H, is
H = MCHR X (1 - SH) , (iv-4)
where MCHR = the molar ratio of hydrogen chloride to product, and Su is the
n
separation efficiency of hydrogen chloride in the separation-recovery equipment
following the reaction.
The molar ratio of gaseous organic reactant carrier gases, R, is
R = MGRR X FGR X (1 - YGR) X (1 - SGR) , (IV-5)
where
MGRR = the molar ratio of gaseous organic reactant to product,
FGR = the molar ratio of total gaseous organic reactant to the stoichio-
metric requirement,
YGR = the molar overall reaction yield on the gaseous organic reactants,
SGR = the seParati°n efficiency of the gaseous organic reactants in the
separation-recovery equipment following the reaction.
The molar ratio of gaseous organic product carrier gases, P, is given as
P = MGPR X (1 - SGp) , (IV-6)
where MGPR is the molar ratio of gaseous organic product to product manufac-
tured, and SGP is the separation efficiency of the gaseous organic products in
the separation-recovery equipment following the reaction.
The estimation or development of all these specific variables is a major task,
since many of them are defined only with specific knowledge of the design and
operation of each production facility. However, since the requirements of the
generic standard approach are to estimate the range of emissions from a type of
reaction (i.e., the maximum and minimum carrier-gas flow from a chlorination
reaction), generalization of the ranges of these variables is acceptable. The
rationale for these generalizations follows: Chlorine purity (P ) depends on
whether the chlorine used is merchant chlorine or is produced and used captive-
ly at a plant site. Merchant chlorine is purified to large extent to remove
-------
IV-6
gaseous impurities such as carbon dioxide, oxygen, and nitrogen. The purity of
merchant chlorine varies from producer to producer but ranges from 97.5—99.4
mole % or better.5'6 Purities for captive use are normally confidential to the
companies. The purity of captive chlorine could range from 90 to 99 mole %.
Chlorine used captively could also undergo significant purification.
The excess chlorine fed to a reactor, F , is also sensitive information.
Chlorination reactors may recycle their gaseous products except for a purge to
eliminate HCl, inert gases introduced with chlorine, and the products. FC is
based on all the products, co-products, and by-products produced. If the
recycle ratio is very high (as in the case of chlorination of liquid reactants
to make liquid products) or if the chlorine reacts with very high conversion to
the main product, F approaches 1. If the recycle ratio is very low or zero or
if the conversion of chlorine to the major product is low, with co-products or
byproducts produced, the value of F would be greater than 1. If chlorine can
be introduced from another source (say a chlorinated hydrocarbon feed), it is
also possible for F to be less than 1. Values presented in Table IV-3 are
based on these guidelines and also on other references.7—17 [The term F_, - 1
in Eq. (IV-3) is restricted to zero or positive numbers since it is not reason-
able for the first term in this equation to be negative, physically represent-
ing a negative carrier-gas production.]
The separation of unreacted chlorine, as represented by S is usually accom-
plished in water or caustic absorbers. Design of these absorbers can vary
greatly. However, a chlorine separation efficiency of 95 to 99.9% is assumed
in this report.
Inert gases entering with the chlorine are difficult to remove by absorption in
the HCl or chlorine absorbers. These gases (carbon dioxide, oxygen, and nitro-
gen) would have a low separation efficiency, S ; 10 to 50% removal is assumed.
The removal efficiency of HCl, Su, depends on whether HCl is recovered as a
n
concentrated acid solution or is converted to sodium chloride in a caustic
absorber,- 90 to 99% removal is assumed.
-------
Table IV-3. Important Variables for Estimating Organic
Emissions from Chlorination Reactions
Product
Ethylene dichloride
1 ,1, 1-Trichloroethane
Carbon tetrachloride
Propylene oxide (chlorohydrin)
Perchloroutl.ylene
Chlorobenzene
Chloroprene
Ethyl chloride
Hethylene chloride
Chloro form
Glycerin
Allyl chloride
Trichloroethylene
Methyl chloride
Benzyl chlorides
Dichlorophenol
phosgene
Acetyl chloride
Chloroacetic acid
Hexachlorobeni.ene
Organic Reactant
Ethylene
Vinyl chloride
Ethane
Prop ane -propy lene
Methane
Carbon disulfide
Propylene
Propane-propylene
Benzene
Butadiene
Ethanol-ethane
Methanol — methyl chloride
Methane
Methane
Acetone
Allyl chloride
Propylene
Acetylene
Methane
Toluene
Phenol
Carbon monoxide
Sodium acetate — acetic acid
Acetic acid
Benzene
Captive
0.9—0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9—0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
O.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9—0.99
0.9 — 0.99
1'C
Merchant
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975— 0. 994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
0.975 — 0.994
FC
1.0 — 1.1
0.9 — 1.1
1.0 — 1.3
0.7—1.0
1.0 — 1.01
1.0 — 1.3
1.0 — 2.0
0.7 — 1.0
1.0 — 1.4
1.0 — 1.4
1.0 — 1.1
1.0 — 1.01
1.0 — 1.01
1.0 — 1.01
1.0
1.0 — 1.22
1.0 — 1.5
1.0—1.1
1.0 — 1.01
1.0 — 1.1
1.0 — 1.4
1.0 — 1.004
1.0 — 1.08
1.0 — 1.4
FGR
1.01 — 1.1
0.9—1.0
0.8 — 1.0
1.0 — 1.6
1.0 1.1
0.8 — 1.1
1.0 — 1.1
1.0 — 1.1
1.0 — 1.1
1.0 — 1.6
1.0 — 1.6
1.0 — 1.4
1.0 — 1.1
1.0 — 1.6
1.0
So
0.95 — 0.999
0.95 — 0.999
0.95 — O.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95—0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
0.95 — 0.999
sln
0.1 — 0.5
0.1 — 0.5
0.1 — O.S
0.1 — 0.5
0.1 — 0.5
0.1 — 0.5
0.1 — 0.5
0.1 — 0.5
0.1 — 0.5
0.1 — 0.5
0.1 — 0.5
0.1—0.5
0.1—0.5
0.1—0.5
0.1 — 0.5
0.1—0.5
0.1 — O.S
0.1 — 0.5
0.1 — 0.5
0.1 — 0.5
0.1 — 0.5
0.1 — 0.5
0.1 — 0.5
0.1 — 0.5
Su
"
0.9 — 0.99
0.9—0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9 — 0.99
0.9—0.99
Sr.r< £t_;i' v, ,
0.1 — 0.9 0.1— O.'J O.'.T-,I.T
0.1 — O.i
0.1—0.9 0.1—0.9 o.a -,)..,.
0-1 — 0.9 0.1 — O.'J (J.b - n.y.
0.1—0.9 0.5 -i,..,
0.1—0.9 o.u vj.-,
0.1—0.9 o.i, -u..,.
0.1—0.9 O.'j-'ii.'..'
0.1 — 0.9 O.'j — U.Vi u.u u.-j...
0.1 — 0.9 0.9- O.y.
0.1—0.9 0.5--0.-K.
0.1—0.9 0.5--O..J...
0.1 — 0.9 0.1 — o.'j (.i.a'j -,).•):,
O.i — 0.9 0.1 — o.yy 0.5 D..I.J
0.1 — 0.9 0.5 o.'j-J
0.1—0.9 O.'JS — U.'« u.j'i o.'»
-------
IV-8
The molar ratio of total gaseous organic reactant to the stoichometic require-
ment, F__, depends on the purity of the gaseous reactant. Most organic gases
GR
that are purchased have a purity in excess of 99 mole %, including ethylene,
propylene, butadiene, and others. Acetylene has a somewhat lower purity (97
mole %) but can be purified to greater than 99 mole %. The purity of methane
(natural gas) can vary widely (46 to 96.9% mole %), and purification processes
can increase its purity. Ethane may have lower purity (94 mole %). Companies
that manufacture organic gases can design chlorination processes to accept
gases of much lower quality than those cited here. They can also choose to
pretreat gases to increase their purity. Therefore a wide range was used to
calculate the organic reactant carrier gases shown in Table IV-3.18—23 The
yields of the organic feed gases also depends on the reactant purity. Ethylene
with high levels of ethane will have a lower yield (Y ) if the ethane does not
GR
take part in the reaction. These values are also shown in Table IV-3.
The separation efficiency of the unreacted gaseous reactants (S ) varies,
CjK
depending on the type of organic recovery process equipment available. Re-
actants with high water solubilities may have a high value for S , whereas
(jK
organics with low water solubilities will have a low S_ value unless a special
GR
hydrocarbon absorber (for example) is included. Values assumed for S are
from 10 to 90%.
The separation efficiency for the gaseous products and by-products (SGp)
depends on whether recovery of the product or by-product is economically fea-
sible. Values for S^^ vary from 10 to 99%.
GF
Chlorinated products normally have a low tendency to form flammable mixtures
and are not expected to require inert gases to prevent explosions. (However,
diluents can be added for other reasons.) They are also relatively stable to
oxidation and probably do not require blanketing to prevent decomposition. No
chlorinated reactions in the products studied are known to operate under
reduced pressure. Transfer operations might introduce carrier gases, but the
volume of gas is expected to be small. Carrier-gas contribution from all these
sources is assumed to be negligible for chlorination reactions. Carrier-gas
flows for chlorination reactions are presented in Table IV-4.
-------
Table IV-4. Projected Uncontrolled VOC Emission Ranges from Chlorination Reactors
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12
13.
14.
15.
16.
17.
18.
19.
2O.
21.
22.
23.
24.
Product
Ethylene dichloride
1 , 1 , 1-Trichloroethane
Carbon tetrachloride
b
Pei chloroethy lene
Methyl chloride
Methylene chloride
Chloroform
Carbon tetrachloride
Carbon tetrachloride
propylene oxide (chlorohydrin)
Chlorobenzene
Chloroprene
Ethyl chloride
Methylene chloride
Chloroform
Glycerin
Allyl chloride
Trichloroethylene
Benzyl chloride (s)
Dichlorophenol
Phosgene
Acetyl chloride
Chloroacetic acid
Hexachloro benzene
Major Organic Reactant
Ethylene
vinyl chloride
Ethane
Propane-propylene
Propane-propylene
Methane
Methane
Methane
Methane
Carbon disulfide
Propylene
Benzene
Butadiene
Ethanol-ethane
Methanol — methyl chloride
Acetone
Allyl chloride
propylene
Acetylene
Toluene
Phenol
Carbon monoxide
Sodium acetate — acetic acid
Acetic acid
Benzene
Most Volatile
Liquid Organic
Ethylene dichloride
1,1, 1-Trichloroethane
1 , 1 , 1-Trichloroethane
Carbon tetrachloride
Carbon tetrachloride
Methylene chloride
Methylene chloride
Methylene chloride
Methylene chloride
Carbon diaulf ide
Propylene chlorhydrin
Benzene
Chloroprene
Ethanol
Methylene chloride
Acetone
Allyl chloride
Allyl chloride
Trichloroethylene
Toluene
phenol
(tone
Acetic acid
Acetic acid
Benzene
Carrier-Gas Flow
[scfm/(S lb/yr)]a
Min Max
0.056 — 2.02
0.014 — 0.53
0.272 — 6.02
0.33: — 7.94
0.198 — 6.99
0.325 — 13.68
0.217 — 8.86
0.230 — 7.43
0.235 — 6.59
0.027—1.17
0.153—6.22
0.079—1.49 H
<
0.023—1.89 |
0.127-4.27 *>
0.01S— 2.33
0.05J— 1.55
0 — 0.90
0.161 — 4.81
0.037 — 4.19
0.070 — 3.30
0.109—2.06
0.151—2.53
0
0.094 — 1.45
0.021 — 1.03
^Ranges continued on next page.
Co-producto.
-------
Table IV-4. (Continued)
Organic Carrier Gas
Product
1.
2.
2 t
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
10.
20.
21.
22.
23.
24.
Flow
Iscfm/(M lb/yr)]
Min Max
0.005 — 1.30
0
0.175 — 2.45
0.004 — 1.20
0.003 — 0.741
0.149 — 11.1
0.008 — 5.79
0.006 — 4.13
O.O04 3.19
0
0 — 2.33
0
0 — 0.764
0.111—2.11
0.004 — 0.796
0
O
0.045 — 2.49
0.005 — 2.58
O
0
0.108 — 1.08
0
0
0
Emission
(Ib/fi Ib)
Min Max
1,600 — 88,600
0
16,200 181,000
230 — 10,500
200 47,700
10,600 — 527,400
350 — 254,000
250 — 181,000
2OO 140,000
0
0 — 150,000
0
0 — 62,600
10,300 — 143,000
300 — 59,000
0
0
2,900 — 185,000
200 — 106,000
0
0
10,000 — 100,000
0
0
0
Concentration
(mole fraction)
0.087
0.137
0.137
0.127
0.127
0.493
0.493
0.493
0.493
0.405
0.002
0.105
0.040
0.062
0.493
0.257
0.408
0.408
0.082
O.O31
0.003
0
0.016
0.016
0.105
Liquid Organic VOC
Flow
(scfnt/(M lb/yr)]
Min Max
0.005 — 0.193
0.002 — 0.084
0.093 — 0.956
0.049 — 1.16
0.029 — 1.02
0.316 — 13.3
0.211 — 8.62
0.224 — 7.22
O.229 — 6.41
0.018 — 0.796
0.0003 — 0.013
0.009 — 0.175
0.001 — 0.079
O.OOB O.2B2
0.016 2.27
0.018 — 0.536
0 — 0.620
0.111 — 3.32
0.003 — 0.374
O.OO2— O.106
0.00003 — 0.0006
0
0
0.002 — 0.024
0.003 — 0.121
Total VOC
Emission
(Ib/M Ib)
Min Max
770 27,900
430 — 16,400
8,400 186,000
11,000 — 260,000
6,500 — 229,000
39,300 — 1,650,000
26,200 — 1,070,000
27,800 — 898,000
28,4OO 797,000
2,000 — 88,500
40 — 1 , 700
1,100 — 19,900
100 — 10,200
560 19,000
1,900 282,000
1,500 — 45,600
0 69,400
12,400 — 371,000
600 — 71,700
300 14,200
4 — 85
0
0
130 — 2,100
280 — 13,800
Flow
Iscfm/(M lb/yr))
Min Max
0.061 2.21
0.016 — 0.614
0.315 — 6.98
0.384 — 9.10
0.227 — 8-01
0.641 — 27.0
0.428 — 17.5
0.454 — 14.7
0.464 13. 0
0.045 — 1.97
0.153 — 6.23
0.088 — 1.67
0.024 — 1.97
0.135 4.55
0.032 4.60
0.070 — 2.09
0 — 1.52
0.272 — 8.13
0.040 — 4.56
0.072 3.41
0.109 — 2.06
0.151 — 2.53
0
0.096 — 1.47
0.024 — 1.15
Emission
(Ib/S Ib)
Min Max
2,400—117,000
430 — 16,400
24,600 — 367,000
11,200 271,000
6,700 — 277,000
49,900 — 2,177,000
26,600 1,324,000
28,100 — 1,079,000
28,600 937,000
2,000 88,500
40 — 152,000
1,100 — 19,900
100 — 72,800
10,900 — 162,000
2,200 — 341,000
1,500 46,600
0 69,400
15,300 — 556,000
800 — 178,000
300 14 , 200
4 — 85
10,000 — 100,000
0
130 — 2,100
280 — 13,800
^Numbers refer to products listed on preceding page.
^D.iscd on pure saturated compound at 21°C and 760 r.».i
Hg.
-------
IV-11
With the information given here the carrier gases from the various reactions
can be estimated. Sample calculations are shown in Appendix D. The total flow
from a reaction is equivalent to the carrier-gas flow plus the flow related to
VOC from other organic liquids and solids.
B. ESTIMATION OF VOC
The VOC in an organic emission comes from those carrier gases that are organic
and from evaporation into the carrier gases of organics that are liquid or
solid at ambient conditions. If the equipment design and operation is well
known, the partial pressures of the liquid and solid organics present are
easily estimated. The maximum VOC concentration would be calculated as the
total of the organic liquid or solid partial pressures at the extreme emission
conditions (highest ambient temperature and atmospheric pressure). If the
gas-liquid (solid) contact surface is small or if the contact time is short,
saturation may not be achieved. Prediction of the fraction of saturation
requires knowledge of the specific equipment and engineering judgement.
The VOC composition can be estimated as the summation for all the individual
components of each component's vapor pressure divided by the total pressure
times each component's liquid-phase molar concentration. This sum is then
multiplied by the fractional approach to saturation that the system has
attained; this product is the estimated VOC composition, yvnr-
The equation for the estimation VOC from organic liquids or solids is shown
below:
n ^
;r (iv-7)
where
= A
i = i
yvnp = the mole fraction of organic vapors (VOC) arising from gas contacting
liquid or solid organic compounds,
A = the fractional approach to saturation (A = 1 for a saturated vapor),
n = the number of organic compounds present in the liquid or solid,
x. = the mole fraction of organic component i in the liquid,
-------
IV-12
p*
i = the vapor pressure of the ith organic compound at the temperature
of the emission,
TT = the total pressure (normally atmospheric) at the emission point.
Since we are interested in the range for VOC emissions, yunr is calculated for
the single most volatile liquid present in the chlorination reaction as if it
were the only organic present. Saturation is also assumed. Therefore equa-
tion IV-7 is simplified to
P* (mm Hg)
Y = — IV-8
VOC 760
Once the VOC concentration from liquids and solids is known, the total flow
from the emission and the total VOC content (VOC from carrier gases and from
liquids and solids) can be easily calculated.
Table IV-4 gives the carrier-gas flow range, the organic carrier-gas emission,
the VOC emission from organic liquids and solids, and the total emission flow
range. An example calculation is shown in Appendix D.
C. ACTUAL CHLORINATION REACTION EMISSIONS
Emissions for chlorination reactions reported to the EPA during the IT Enviro-
science study are shown in Table IV-5. The information sources are included in
Appendix B. The actual data show good agreement with the projections from
Table IV-4. The uncontrolled data from Table IV-5 compare with the ranges
given in Table IV-4. Many of the real emissions fall at the low end of the
ranges predicted. Some of the emission data lie below the minimum values
expressed in Table IV-4. These comparisons indicate that assumptions used to
develop the emission projections could lead to emission projections higher than
realistic ones.
If more sophisticated projections are necessary, further identification or
refinement of the factors in Table IV-3 may be necessary. This could be done
through a more thorough literature search than was permitted by the available
time or funds in this contract or through additional solicitation of industrial
data. Better estimates of separation efficiencies could be developed through
mass-transfer calculations.
-------
Table IV-5. VOC Emissions from Chlorination Reactors Based on Industry Information
Product
Ethylene dichloride
1,1, l-Trichloroethane
Ethylene dichloride
Chlorinated methanes
Chlorinated methanes
Methyl chloride
Propylene oxide
Propylene oxide
Chlorobenzene
Chloroprenc
Allyl chloride
Trichloroethylene
Total Flow
Uncontrolled
n.r.
n.r.
n.r.
2.57
n.r.
n.r.
n.r.
5.02
0.067
n.r.
n.r.
n.r.
Rate [scfm/CM
Controlled
0.22
0.41
10.0°
n.r.
0.094 — 0.28
n.r.
n.r.
0.008
0.0037
n.r.
0.031
Ib of product/yr) ]
Emitted
0.22
(To incinerator)
10.0°
2.57
n.r.
(To flare)
n.r.
n.r.
0.008
0.0037
n.r.
0.031
VOC
Uncontrolled
n.r.
n.r.
n.r.
28,700
n.r.
n.r.
n.r.
104,200
3,130
n.r.
9
n.r.
Emissions (Ib/M Ib of
Controlled
2,280
16,800
n.r.
n.r.
7,450 22,400
10 , 300
n.r.
88
290
n.r.
200
product)
Emitted
2,280
(To incinerator)
n.r.
28,700
n.r.
(To flare)
10,300
n.r.
88
290
9
200
Control Li'jvico
Condenser
Condenser (-1'C)
thon incinera-
tion
Incineration
Compressed and
condensed
Condenser
(27-33"C! ;
then flared
Absorber (16°C)
Incineration
Absorber (30°C)
Absorber
Refrigerated
condenser
3Not reported.
bMany VOC emissions estimated by assuming molecular weight of VOC.
clnoludes combustion gases.
-------
V-l
V. CONTROL OPTIONS FOR CHLORINATION REACTORS
The carrier-gas method described in two earlier chapters allows the preliminary
selection of control devices that would probably be applicable. Large poten-
tial flows, high levels of organic carrier gases, low or high VOC concentra-
tions, and other parameters projected from the carrier-gas method allow rejec-
tion of inappropriate control devices without requiring detailed emission in-
formation. The following section on add-on controls is an example of how
information generated with the carrier-gas method can be used to assess the
viability of a control device at a very early stage. One of the potentially
applicable control devices has been identified; the best choice can be achieved
with the use of cost-effectiveness parameters
The emissions from chlorination reactions range widely from process to process,
and it is likely that the control technology for each process will vary. Con^
trol for all chlorination reactions include in-process control elements and
add-on control devices.
A. IN-PROCESS CONTROL
Clearly, any approach that lowers the amount of carrier gas in the reaction
will reduce the emission. This is particularly true of chlorinations that use
gaseous organic reactants. In these cases higher organic reactant purities and
high chlorine purities may lower the organic emission if the carrier gases from
these sources are significant.
Plants incorporating higher separation efficiencies for equipment separating
the reaction waste gases will have lower carrier-gas flows and lower organic
emissions. High-efficiency chlorine and HCl removal may be significant but
often the removal of organic reactants and products is the limiting factor in
minimizing the carrier gas. Normally the absorbers used to separate HCl and
chlorine are ineffective in removing the unused gaseous organic reactants and
products, and separate removal equipment is needed.
Emissions containing large levels of HCl can sometimes be used directly in
hydrochlorination reactions at the same plant. This eliminates the chlorina-
tion emission but can increase the carrier-gas flow from the hydrochlorination
-------
Table V-l. Possible Add-on Control Devices for
VOC Emissions from Chlorination Reactors
Possible Control Technolocry
Oraanic Carrier Gases
Product
Ethylene dichloride
1 ,1 , 1-Trichlorofcthane
Carbon tetrachloride
Perchloroethylene
Carbon tetrachloride
Methylene chloride
Chloroform
Methyl chloride
Carbon tetrachloride
Propylene oxide (chlorohydrin)
Chlorobenzene
Chloroprene
Ethyl chloride
Methylene chloride
Chi oro f orm
Glycerin
Allyl chloride
Trichloroethylene
Benzyl chloride (s)
Dichlorcphenol
Phosgene
Acetyl chloride
Chlor«cetic acid
Htxachlorobtnzene
Major Orajnic Peactant
Ethylene
Vinyl chloride
Ethane
Propane-propylene
Propane-propylene
Methane
Methane
Methane
Methane
Carbon disulfide
Fropylene
Benzene
Butadiene
Ethanol -ethane
Meth^.iol — methyl chloride
Acetone
Allyl chloride
Propylene
Acetylene
Toluene
phenol
Carbon monoxide
acid
Acetic acid
Benzene
s Never.
Most Volatile
Liouid Oraanic
Ethylene dichloride
1 ,1 , 1-Trichloroe thane
1 ,1 ,1-Trichloioethane
Carbon tetrachloride^
Carbon tetrachloride J
Methylene chloride ~-\
Methylene chloride 1
Methylene chloride J
Methylene chloride J
Carbon disulfide
Propylene chlorohydrin
Benzene
Chloroprene
Ethanol
Methylene chloride
Acetone
Allyl chloride
Allyl chloride
Trichlcroethylene
Toluene
Phenol
None
Acetic acid
Acetic acid
benzene
Hydrocarbons
Yes
No
Yes
Yes
Yes
No
Yes
No
Yes
Yes
No
No
No
Yes
Yes
No
No
Yes
No
No
No
Chlorinated
Hydrocarbons
Yes
No
Yes
Yes
Yes
No
No
No
No
Yes
Yes
No
No
Yes
No
No
No
No
No
No
No
HC1 Present
No
No
Yes
Yes
Yes
No
Yes
Yes
No
Yes
Yes
No
No
Yes
Yes
Yes
Yes
No
No
Yes
Yes
Condensers
sa
f
A
a
S
Af
A£
f
A
a
E
f
A
a
A
a
£
f
S
f
A
f
A
f
A
A H f
sa,b,f
f
A
f
A
N
^
f
A
Absorbers
b
A
a.b
S '
ftb,f
Ab>f
b.f
A
b
A
A '
b
A
b,f
A
b.f
A
f
A
f
A
b f
A '
h f
AB>t
b.f
A
f
A
f
A
^
b.f
A '
Carbon
Adsorbers
sc
f
E
c
S
EC
sc
f
S
sc
f
s
sc
c
s
f
s
f
s
f
f
s
sc
s
f
s
f
£
c
s1
f
s
Flares
d
N
d
N
Nd
Nd
Q
S9
d
N
H
N
A
N
d
N
Q
E9
d
N
»»
Nd
d
N
d
N
Nd
£9
d
N
Thermal
Oxidation
N£
NC
N'
Ke
Ne
S9
Q
S9
S9
f
A
A
N
116
S9
Q
S9
s?
s9
s9
s9
s9
s9
s9
Q
S9
High-
Teirp^r at ure
Thermal
Oxidation
A
A
A
ft
S
S
s
s
A
A
S
s
s
£
S
S
S
£
E
E
f
to
'product recovery or pretreatment for other control devices. Kill not significantly reduce VOC enuss.on.
Using hydrocarbon solvent.
CLo»-level VOC concent, at ion. Kill not siqr.i f leant ly reduce VOC emission.
Noxious gases formed.
"lU^h-temperature oxidation required.
'significant VOC reduction possible.
'Defending on chloiinated hydrocarbon Cl^ and HC1 level.
-------
V-3
reactor. This is not a universal control technique, since all chlorination
plants may not manufacture products using HC1.
B. ADD-ON CONTROLS
Since the organic concentrations vary so greatly in chlorination reactions, the
choice of an effective control depends on the reaction and the equipment design
and operation. However, generalizations can be made by examining the data in
Table IV-4. The potential use of add-on controls is summarized in Table V-l.
The control device evaluation reports mentioned later are contained in
Volumes IV and V.
1 - Condensers
Condensers and refrigerated condensers can be used when the concentration of
VOC from organic liquids (or solids) is high. VOC resulting from organic
carrier gases cannot be removed by condensers. Therefore the overall reduction
efficiency in condensers even with high-VOC feeds can be poor. For further
information on condensers, consult the condensation control device evaluation
report.
2. Absorbers
Absorbers for C12 and HC1 recovery have already been included in the carrier-
gas calculations. Additional absorbers could be effective on emissions if a
solvent with a high affinity for hydrocarbons or chlorinated hydrocarbons is
used. One increasingly popular control is the use of a refrigerated liquid to
absorb the same liquid and other hydrocarbons from the emission. Further
information about the use of absorption as a control technique can be found in
the gas absorption control device evaluation report.
3. Adsorption
Because of safety and operating considerations, carbon adsorption may be used
for control only if the total VOC concentration is less than about 1 mole %. A
few waste gases from chlorination reactors could achieve this requirement if
low levels of organic carrier gases, high levels of nonorganic carrier gases,
and low-volatility organic liquids are present. Streams can be diluted with
air but the cost of control increases to a large extent. Also, carbon has
relatively low efficiency for streams whose VOC is composed mostly of organic
-------
V-4
carrier gases. Further information on carbon adsorption control can be found
in the carbon adsorption control device evaluation report.
4. Combustion
Combustion control can be achieved in a wide variety of burners. Flares and
fuel gas can be considered only if the percentage of non-chlorine-containing
carrier gas is high and that of HCl, chlorine, and chlorinated hydrocarbons is
low since the chlorine released in combustion would form noxious flue gases
(C12 and HCl). Chlorinated hydrocarbons also have low levels of heat content
and therefore are relatively poor fuels. Burners that are not specifically
designed to accept chlorine-containing compounds can also suffer severe corro-
sion problems.
Streams with very low levels of chlorinated hydrocarbons and moderate levels of
HCl and nonchlorinated VOC (reactant- or product-related organic carrier gases)
can be burned in low-temperature thermal oxidizers equipped for removal of
halogen from the flue gas. Streams with high levels of chlorinated hydrocar-
bons and moderate to high levels of HCl and chlorine can be controlled with
high-temperature thermal oxidizers equipped for removal of halogen from the
flue gas. Further information on these control technologies can be found in
the following control device evaluations reports:
1. Flares and the Use of Emissions as Fuels
2. Thermal Oxidation
3. Thermal Oxidation Supplement (VOC Containing Halogens or Sulfur)
Catalytic oxidation is normally not acceptable since the chlorine in the waste
gas can poison the catalyst. Further information on catalytic oxidation can be
found in the catalytic oxidation control device evaluation report.
-------
VI-1
VI. REFERENCES
1. R. C. Reid, J. M. Prausnitz, and T. K. Sherwood, The Properties of Liquids
and Gases, 3d ed., McGraw-Hill, New York, 1977.
2. "Steam Ejectors for Vacuum Service," chap. 15, p 257, in Applied Chemical
Process Design, F. Aerstein and G. Street, editors, Plenum Press, New York,
1978.
3. R. J. Grant, Milton Manes, and S. B. Smith, Adsorption of Normal Paraffins
and Sulfur Compounds on Activated Carbon, AIChE Journa1 8(3), 403—406 (July,
1962).
4. M. G. Zabetakis, Flammability Characteristics of Combustible Gases and Vapors,
Bulletin 627, Bureau of Mines, Dept. of Interior (nd).
5. Hooker Chemical Corp., Hooker Chlorine, Product Literature, 1965.
6. G. C. White, Handbook of Chlorination, pp 10—20, Van Nostrand Reinhold, New
York, 1972.
7. F. D. Hobbs and C. W. Stuewe, IT Enviroscience, Chloromethanes (November 1980)
(EPA/ESED report, Research Triangle Park, NC).
8. S. S. Gelfand, "Chlorocarbons, -Hydrocarbons (Benzyl)," p 831 in Kirk-Othmer
Encyclopedia of Chemical Technology, 3d ed., vol 5, edited by M. Grayson e_t
al., Wiley-Interscience, New York, 1979.
9. R. c. Ahlstrom, Jr., and J. M. Steele, "Chlorocarbons, -Hydrocarbons (ChaCl),"
ibid., p 681.
10. H. D. DeShon, "Chlorocarbons, -Hydrocarbons (Chloroform)," ibid., p 693.
11. P. R. Johnson, "Chlorocarbons, -Hydrocarbons (Chloroprene)," ibid., p 773.
12. F. A. Lowenheim and M. K. Moran, editors, p 434 in Faith, Keyes and Clark's
Industrial Chemicals, 4th ed., Wiley-Interscience, New York, 1975.
13. Ibid., p. 254.
14. Ibid., p 258.
15. Ibid., p 606.
16. Ibid., p 836.
17. Ibid., p 844.
18. Gulf Oil Co., Ethylene, Product Information Sheet No. EHP.64-12+, New York.
19. Sunolin Chemical, Ethylene Product Bulletin, Claymont, Delaware.
-------
VI-2
20. I. Kirshenbaum and R. P. Cahn, "Butadiene," p 807 in Kirk-Othmer Encyclopedia
of Chemical Technology, 2d ed., vol 3, edited by Standen e_t al., Wiley-Inter-
science.
21. H. C. Ries, New York, 1964: Acetylene, p 355 in Report No. 16, A private
report by the Process Economics Program, Stanford Research Institute, Menlo
Park, CA (September 1966).
22. C. M. Detz and H. B. Sargent, "Acetylene," p 195 in Kirk-Othmer Encyclopedia
of Chemical Technology, 3d ed., vol 1, edited by M. Grayson, Wiley-Inter
science, New York, 1978.
23. J. E. Lane, "Natural Gas," p 450 in Kirk-Othmer Encyclopedia of Chemical
Technology, 2d ed. , vol 10, edited by A. Standen e_t al. , Wiley-Interscience,
New York, 1966.
-------
APPENDIX A
PRODUCTS ORGANIZED BY UNIT PROCESSES
-------
A-3
Table A-l. Products Organized by Unit Processes
Product
Process
22. Phenol
22. Phenol
99. Salicylic acid
Acidification Reactions
3% Chlorobenzene
2% Benzene sulfonation
100% Sodium phenate
Addition Esterification Reactions
35. Vinyl acetate (VA)
68. Glycol ethers
68. Glycol ethers
95. n,n-Dimethyl aniline
8. Ethylbenzene
20. Cumene
31. Alkyl leads
51. Nonyl phenol
71. Linear alkyl benzene
74. Methyl styrene
94. Cresylic acids (SYN)
116. Benzophenone
34. Ethanolamines
58. Adiponitrile/HMDA
61. Pyridine
75. Ethylene diamine/triethylene
tetramine
108. Mono-, di-, trimethyl amines
114. Mono-, di-, triethyl amine
119. Butyl amines
121. Propyl amines (M-D-T)
121. Propyl amines (M-D-T)
136. Amino ethylethanolamine
137. Cyclohexylamines
aRefers to rank-order number in Table Il-l.
13% Acetylene vapor phase
Alcoholysis Reactions
97% Ethylene oxide
3% Propylene oxide
100% Aniline alcoholysis
Alkylation Reactions
98% Benzene alkylation
100% Benzene
95% Ethyl chloride
100% Phenol alkylation
100% Benzene alkylation
85% Cumene process by-product
8% Phenol/methanol
100% Benzene/carbon tetrachloride
Ammonolysis Reactions
100% Ethylene oxide
24% Adipic acid
100% Formaldehyde/acetaldehyde
100% EDC ammonolysis
100% Methanol ammonolysis
100% Ethanol ammonolysis
100% Butyraldehyde hydrogenation
50% jn-Propyl chloride
50% ri-Propyl alcohol
100% Ethylene oxide
50% Cyclohexanone
-------
A-4
Table A-l. (Continued)
Product Process
Ammoxidation Reactions
2. Acrylonitrile 100% Propylene oxidation
9. Hydrogen cyanide (HCN) 50% Andrussow process
9. Hydrogen cyanide (HCN) 50% Acrylonitrile co-product
Bromination Reactions
89. Ethylene dibromide 100% Ethylene bromination
117. Methyl bromide 100% Methanol/HBR and bromine
Carbonylation Reactions
28. Acrylic acid 23% Modified Reppe
29. Acetic acid 19% Methanol
76. Ethyl acrylate 61% Acetylene (Reppe)
99. Salicylic acid 100% Sodium phenate
Cleaving Reactions
107". Hydroquinone 100% Acetone co-product
Chlorination Reactions
3. Ethylene dichloride 50% Direct chlorination
11. 1,1,-Trichloroethane 74% Vinyl chloride
11. 1,1,-Trichloroethane 10% Ethane chlorination
12. Carbon tetrachloride 42% Chloroparaffin chlorinolysis
12. Carbon tetrachloride 20% Methane
12. Carbon tetrachloride 38% Carbon disulfide
15. Propylene oxide 60% Chlorohydrin
25. Perchloroethylene 34% Ethane chlorinolysis
25. Perchloroethylene 66% Ethylene dichloride
27. Chlorobenzene 100% Benzene chlorination
30. Chloroprene 100% Via butadiene
33. Ethyl chloride 44% Ethanol/ethane
36. Methylene chloride 65% Methanol/methyl chloride
36. Methylene chloride 35% Methane chlorination
40. Chloroform 39% Methanol chlorination
40. Chloroform 61% Methane chlorination
44. Glycerol (synthetic only) 71% Epichlorohydrin
57. Allyl chloride 100% Propylene chlorination
59. Trichloroethylene 9% Acetylene
-------
A-5
Table A-l. (Continued)
Product
Process
59.
77.
91.
92.
97.
98.
113.
115.
132.
140.
15.
47.
50.
60.
64.
73.
85.
86.
131.
64.
85.
20.
22.
28.
1.
30.
38.
38.
44.
60.
92.
Trichloroethylene
Methyl chloride
Benzyl chloride
Dichlorophenol
Phosgene
i-Butanol
Acetyl chloride
Chloroacetic acid
Hexachlorobenzene
Benzoyl chloride
91% Ethylene dichloride
2% Methane chlorination
100% Toluene chlorination
45% Phenol chlorination
100% Carbon monoxide/chlorine
79% Propylene oxide co-product
100% Sodium acetate
100% Acetic acid chlorination
100% Hexachlorocyclohexane
100% Benzoic acid
Condensation Reactions
Propylene oxide
Bisphenol A
Pentaerythritol
Methyl isobutyl ketone (MIBK)
Urea
Diphenylamine
2-Ethyl 1-hexanol
ri-Butanol (butyl alcohol)
Cyclooctadiene
40% Peroxidation
100% Phenol/acetone
100% Formaldehyde/acetaldehyde
100% Acetone
100% Ammonia/carbon dioxide
100% Aniline amination
100% Condensation
20% Acetaldehyde
100% Butadiene dimerization
Dehydration Reactions
Urea 100% Ammonia/carbon dioxide
2-Ethyl 1-hexanol 10o% Condensation
Ethyl (diethyl) ether 100% Ethanol
Crotonaldehyde 100% Aldo process
Allyl alcohol 6% Propylene glycol dehydration
Dehydrochlorination Reactions
Vinyl chloride
Chloroprene
Vinylidene chloride
Vinylidene chloride
Glycerol (synthetic only)
Methyl isobutyl ketone (MIBK)
Dichlorophenol
99% Ethylene dichloride
100% Via butadiene
50% 1,1,2-Trichloroethylene
50% 1,1,-Trichloroethylene
71% Epichlorohydrin
100% Acetone
55% Trichlorobenzene
-------
A-6
Table A-l. (Continued)
Product Process
Dehydrogenation Reactions
10. Styrene 100% Ethyl benzene
32. Acetone 31% Isopropanol
66. Isoprene 33% Isoamylene extraction
74. Methyl styrene 15% Cumene dehydrogenation
105. Methyl ethyl ketone (MEK) 75% sec-Butanol
132. Hexachlorobenzene 100% Hexachlorocyclohexane
Esterification Reactions
6. Dimethyl terephthalate (DMT) 23% Amoco via terephthalic acid
6. Dimethyl terephthalate (DMT) 25% Hercules
6. Dimethyl terephthalate (DMT) 17% Eastman via terephthalic
acid
6. Dimethyl terephthalate (DMT) 35% Du Pont
14. Methyl methacrylate (MMA) 100% Acetone cyanohydrin
49. Cellulose acetate 100% Cellulose esterification
76. Ethyl acrylate 39% Direct esterification
84. Diisooctyl phthalate (di-2-ethylhexyl) 100% Phthalic anhydride/alcohol
88. Ethyl acetate 100% Acetic acid
102. Diisoldcyl phthalate 100% Phthalic anhydride/isodec-
anol
103. Butyl acrylate 100% Acrylic acid esterification
125. Ethylene glycol methyl ethyl 100% Ethoxy ethanol ester
ether acetate
129. Isopropyl acetate 100% Isopropanol esterification
130. Methyl acetate 100% Acetic acid/methanol
133. n-Butyl acetate 100% Esterification
139. Benzyl benzoate 50% Benzaldehyde
139. Benzyl benzoate 50% Benzyl alcohol/acid
Fluoronation Reactions
24. Fluorocarbons 100% CC1./C Cl fluorination
Fusion Reactions
22. Phenol 2% Benzene sulfonation
94. Cresylic acids (syn) 8% Toluene sulfonation
-------
A-7
Table A-l. (Continued)
Product Process
Hydration Reactions
18. Ethylene glycol 100% Ethylene oxide
42. Isopropanol (isopropyl alcohol) 100% Propylene/sulfuric acid
44. Glycerol (synthetic only) 71% Epichlorohydrin
44. Glycerol (synthetic only) 15% Allyl alcohol
44. Glycerol (synthetic only) 14% Acrolein
53. Diethylene, triethylene glycols 100% Co-products w/ethylene
glycol
55. Propylene glycols (mono- di- tri~) 100% Propylene oxide hydration
63. Ethanol (ethyl alcohol) 100% Ethylene
70. sec-Butanol 100% Butylenes
96. Acetylene 30% Calcium carbide
Hydrocyanation Reactions
58. Adiponitrile/HMDA 65% Butadiene
90. Acetone cyanolhydrin 100% Acetone cyanation
119. Butyl amines 100% Butyraldehyde hydrogenation
121. Propyl amines (M-D-T) 50% n-Propyl alcohol
Hydrochlorination Reactions
11. 1,1,1-Trichloroethane 74% Vinyl chloride
11. 1,1,1-Trichloroethane 16% Vinylidene chloride
33. Ethyl chloride 96% Ethylene chlorination
77. Methyl chloride 98% Methanol hydrochlorination
104. Chlorosulfonic acid 100% SO hydrochlorination
Hydrodealkylation
62. Benzene 20% Toluene hydrodealkylation
79. ii-Butyraldehyde 100% Oxo process
112. Biphenyl 100% Toluene hydrodealkylation
Hydrodimerization Reactions
58. Adiponitrile/HMDA 11% Acrylonitrile
Hydroformylation Reactions
86. n-Butanol (butyl alcohol) 80% Oxo process
87. Propionic acid 93% Oxo process
93. Isobutyraldehyde 100% Oxo process
106. Isobutanol (isobutyl alcohol) 100% Oxo process
-------
A-8
Table A-l. (Continued)
Product Process
Hydroformylation Reactions (Continued)
118. Propyl alcohol 87% Oxo process
123. Isooctyl alcohol 100% Oxo process/hydrogenation
127. Isodecanol 75% Oxo process
Hydrogenation Reactions
19. Cyclohexanol/cyclohexanone 25% Phenol
23. Aniline 100% Nitrobenzene hydrogenation
44. Glycerol (synthetic only) 14% Acrolein
46. Cyclohexane 84% Benzene hydrogenation
58. Adiponitrile/HMDA 65% Butadiene
60. Methyl isobutyl ketone (MIBK) 100% Acetone
63. Ethanol (ethyl alcohol) 100% Ethylene
85. 2-Ethyl 1-hexanol 100% Condensation
86. n-Butanol (butyl alcohol) 20% Acetaldehyde
119. Butyl amines 100% Butyraldehyde hydrogenation
137. Cyclohexylamine 50% Aniline
Hydrolysis Reactions
14. Methyl methacrylate (MMA) 100% Acetone cyanohydrin
22. phenol 3% Chlorobenzene
52. Acrylamide 100% Acrylonitrile
56. Epichlorohydrin 100% Allyl chloride/HCL
67. Furfural 100% Polysaccharides hydrolysis
116. Benzophenone 100% Benzene/carbon tetrachloride
128. Allyl alcohol 47% Allyl chloride hydrolysis
135. Dinitrophenol 100% Dinitration of phenol
Isomerization Reactions
30. Chloroprene 100% Via butadiene
49. Caprolactam 100% Cyclohexanone
54. Fumaric acid 100% Maleic acid/isomerization
128. Allyl alcohol 47% Propylene oxide isomerization
Neutralization Reactions
22. Phenol 2% Benzene sulfonation
49. Caprolactam 100% Cyclohexanone
98. t-Butanol 21% Isobutylene
-------
A-9
Table A-l. (Continued)
Product
Process
Nitration Reactions
17.
45.
69.
80.
110.
4.
4.
5.
5.
6.
6.
6.
6.
13.
13.
19.
22.
22.
26.
26.
26.
28.
29.
29.
32.
32.
41.
41.
43.
65.
72.
Nitrobenzene
Nitrophenol
Dinitrotoluene
Nitroaniline
Chloronitrobenzene
Oxidation
100% Benzene nitration
100% Phenol nitration
100% Toluene dinitration
100% Nitro chlorobenzene
100% Chlorobenzene nitration
Reactions
Maleic anhydride
Maleic anhydride
Ethylene oxide
Ethylene oxide
Dimethyl terephthalate (DMT)
Dimethyl terephthalate (DMT)
Dimethyl terephthalate (DMT)
Dimethyl terephthalate (DMT)
Formaldehyde
Formaldehyde
Cyclohexanol/cyclohexanone
Phenol
Phenol
Terephthalic acid (TPA)
Terephthalic acid (TPA)
Terephthalic acid (TPA)
Acrylic acid
Acetic acid
Acetic acid
Acetone
Acetone
Phthalic anhydride
Phthalic anydride
Acetic anhydride
Acetaldehyde
Acrolein
85% Benzene oxidation
15% Butane oxidation
34% 02 oxidation/ethylene
66% Air oxidation/ethylene
17% Eastman via terephthalic acid
25% Hercules
23% Amoco via terephthalic acid
35% Du Pont
23% Metal oxide/methanol
77% Silver catalyst/methanol
75% Cyclohexane
2% Toluene oxidation
93% Cumene
39% Amoco
14% Mobil
47% Eastman
77% Propylene oxidation
33% Acetaldehyde
44% Butane oxidation
31% Isopropanol
69% Cumene
70% o-Xylene
30% Naphthalene
100% Acetic acid
100% Ethylene
100% Propylene oxidation
-------
A-10
Table A-l. (Continued)
Product
Process
Oxidation Reactions
81. Acetophenone
82. Isophthalic acid
83. Benzoic acid
94. Cresylic acids (ayn)
96. Acetylene
100. Dimethyl hydrazine
105. Methyl ethyl ketone (MEK)
107. Hydroquinone
109. Adipic acid
111. Carbon disulfide
118. Propyl alcohol
124. Formic acid
127. Isodecanol
134. Butyric acid
134. Butyric acid
139. Benzyl benzoate
40% Ethyl benzene oxidation
100% m-Xylene oxidation
100% Toluene air oxidation
4% Cumene oxidation
62% Hydrocarbon oxidation
100% Nitrosodimethyl aiaine
25% Butane oxidation
100% Acetone co-product
100% Cyclohexane
100% Methane/sulfur vapor
13% Propane oxidation
98% ri-Butane oxidation
25% n-Paraffin oxidation
33% Butyraldehyde oxidation
67% ri-Butane oxidation
50% Benzaldehyde
Oximation Reactions
49. Caprolactam
35.
35.
1.
3.
15.
44.
44.
59.
81.
39.
78.
Vinyl acetate (VA)
Vinyl acetate (VA)
Vinyl chloride
Ethylene dichloride
100% Cyclohexanone
Oxyacetylation Reactions
72% Ethylene vapor phase
15% Ethylene liquid phase
Oxychlorination Reactions
1% Acetylene
50% Oxychlorination
Peroxidation Reactions
Propylene oxide 40% Peroxidation
Glycerol (synthetic only) 15% Allyl alcohol
Glycerol (synthetic only) 14% Acrolein
Trichloroethylene 91% Ethylene dichloride
Acetophenone 60% Cumene peroxidation
Phosgenation Reactions
Toluene diisocyanate (TDI) 100% Diaminotoluene
Methylene diphenylene diisocyanate 100% DPMDA/phosgene
-------
A-ll
Table A-l. (Continued)
Product Process
Pyrolysis (Chlorinolysis) Reactions
7. Ethylene 46% Naphtha/gas-oil pyrolysis
7. Ethylene 52% Natural-gas liquids pyrolysis
12. Carbon tetrachloride 42% Chloroparaffin chlorinolysis
16. Propylene 16% Natural-gas liquids pyrolysis
16. Propylene 54% Naphtha/gas-oil pyrolysis
21. Methanol (methyl alcohol) 100% Methane
25. Perchloroethylene 34% Ethane chlorinolysis
37. 1,3-Butadiene 13% n-Butane
37. 1,3-Butadiene 80% Ethylene co-product
37. 1,3-Butadiene 7% n-Butene
Reforming Reactions
21. Methanol (methyl alcohol) 100% Methane
Reduction Reactions
31. Alkyl leads 5% Electrolysis
139. Benzyl benzoate 50% Benzaldehyde
Saponification Reactions
15. Propylene oxide 60% Chlorohydrin
98. i-Butanol 79% Propylene oxide co-product
122. Crotonaldehyde 100% Aldo process
Sulfonation Reactions
22. Phenol 2% Benzene sulfonation
42. Isopropanol (isopropyl alcohol) 100% Propylene/sulfuric acid
70. sec-Butanol 100% Butylens
94. Cresylic acids (SYN) 8% Toluene sulfonation
104. Chlorosulfonic acid 100% SO hydrochlorination
126. Linear alkyl benzene sulfonate 100% Lab sulfonation
138. Toluene sulfonic acids 100% Toluene sulfonation
Separations
7. Ethylene 22% Refinery by-product
8. Ethylbenzene 2% Mixed xylene extract
16. Propylene 30% Refinery by-product
-------
A-12
Table A-l. (Continued)
Product Process
Separations (Continued)
46. Cyclohexane 16% Petroleum distillation
62. Benzene 80% Not in project scope
66. isoprene 67% C4 hydrocarbons
94. Cresylic acids (SYN) 80% Natural coal tar
96. Acetylene 8% Ethylene by-product
98. _i-Butanol 21% Isobutylene
101. Dodecene 100% Nonene co-product
-------
APPENDIX B
EPA INFORMATION SOURCES
-------
B-3
Trip Reports Surveyed for the Organic Emission Data Base
1. Acetaldehyde
Texas Eastman
Celanese Chemical Co.
2. Acetic Acid
Monsanto Chemical Co.
Borden, Inc.
Union Carbide Corp.
3. Acetic Anhydride
Celanese Chemical Co.
Tennessee Eastman Co.
4. Acrolein-Glycerin
Shell Oil Co.
Dupont
Vistron Corp.
5. Acrylic Acid and Acrylate Esters
Union Carbide Corp.
Rohm & Haas Co.
6. Allyl Chloride—Epichlorohydrin
Shell Oil Co.
7. C2 Chlorinated Hydrocarbon
Dow Chemical
8. Chlorobenzenes
Monsanto Chemical Co.
PPG Industries
9. Chloromethanes
Vulcan Materials Co.
10. Cyclohexane
Phillips Puerto Rico Core, Inc.
Exxon Chemical Co.
-------
B-4
11. Cyclohexanol/Cyclohexanone and Caprolactam
Nipro, Inc.
Allied Chemical
Monsanto Textiles Co.
12. Dimethyl Terephthalate
Hercofina Hanover
13. Ethyl Acetate
Celanese Chemical Co.
14. Ethylbenzene and Styrene
Dow Chemical Co.
Cosden Oil & Chemical Co.
15. Ethylene and Butadiene/1591 and 1592 Olefin Processes
Arco Chemical Co.
Petro-Tex Chemical Corp.
Gulf Oil Chemical Co.
16. Ethylene Dichloride
Dow Chemical Co.
Borden Chemical Co. - Stauffer
17. Ethylene Oxide
BASF Wyandotte Corp.
Celanese Chemical Co.
Union Carbide Corp.
18. Fluorocarbons
Allied Chemical Co.
19. Formaldehyde
Celanese Chemical Co.
Borden, Inc.
20. Glycol Ethers
Union Carbide
Dow Chemical Co.
21. Linear Alkylbenzene
Union Carbide Corp.
Monsanto Co.
-------
B-5
22. Maleic Anhydride
Amoco Corp.
Denka Chemical Corp.
Monsanto Chemical Co.
Reichhold Chemicals, Inc.
23. Methanol
Borden, Inc.
Celanese Chemical Co.
Monsanto Co.
24. Methyl Methacrylate
Rohm & Haas
Dupont
25. Nitrobenzene/Aniline
Du Pont
Rubicon Chemical
26. Phenol/Acetone
Monsanto Chemical Co.
27. Propylene Oxide
Dow Chemical Co.
Oxirane Chemical Co.
28. Terephthalic Acid
Amoco Chemical Corp. - Standard
29. Toluene Diisocyanate
Allied Chemical Co.
30. Vinyl Acetate
Celanese Chemical Co.
Union Carbide Corp.
31. Waste Acid Recovery (Sulfuric Acid)
Dupont
-------
B-6
Letter Responses to EPA Requests for Information
1. Acetic Acid
Tennessee Eastman Co., Kingsport, TN
2. Acetone
Tennessee Eastman Co., Kingsport, TN
Exxon Chemical Company USA,
Bayway Chemical Plant, NJ
Shell Oil Co., Houston, TX
Union Carbide Corp.,
Cumene at Ponce, Puerto Rico
3. Acrolein
Union Carbide Corp., Taft, LA
4. Acrylic Acid and Esters
Celanese Chemical Co., Inc.,
Clear Lake plant, TX
5. Adipic Acid
E. I. du Pont de Nemours & Co., Victoria, TX
E. I. du Pont de Nemours & Co., Orange, TX
Mobay Chemical Corp., Pittsburgh, PA
6. Adiponitrile—Hexamethylenediamine
E. I. du Pont de Nemours & Co., Orange, TX,
Sabine River Works and Victoria plant
Celanese Chemical Co., Inc., Bay City, TX
Monsanto Co., Pensacola, FL
J. C. Edwards
J. C. Edwards
C. R. Ball
J. A. Mullins
F. D. Bess
F. D. Bess
C. R. DeRose
D. W. Smith
D. W. Smith
Lee P. Hughes
J. R. Cooper
R. H. Maurer
F. T. Osborne
7. Aniline
E. I. du Pone de Nemours & Co., Gibbstown, NJ D. W. Smith
8. Carbon Tetrachloride
E. I. du Pont de Nemours & Co., Corpus
Christi, TX
9. Catalytic Oxidation
Diamond Shamrock, Cleveland, OH
Notes on meeting, EPA, Durham NC
Rhone-Poulenc S.A., Neuilly-sur-Seine
D. W. Smith
W. R. Taylor
J. A. Key
J. C. Zimmer
5/15/78
9/25/78
10/13/78
10/25/78
9/21/78
4/21/78
4/21/78
4/20/78
9/28/78
1/31/78
2/9/79
10/3/78
10/27/78
2/3/78
3/23/78
10/3/77
8/23/79
5/29/79
-------
B-7
10. Chlorinated Methanes - Methyl Chloride
General Electric Co., Waterford, NY
Allied Chemical, Moundsville, WV
Union Carbide Corp.
Ethyl Corp., Baton Rouge, LA
Diamond Shamrock, Belle, WV
E. I. du Pont de Nemours & Co.,
Niagara Falls, NY
Dow Chemical USA, Texas Division
11. Chlorobenzene
Dow Chemical USA, Michigan Division
Montrose Chemical Corp. of California,
Henderson, NV
12. Chloroprene
Denka Chemical Corp., Houston, TX
Petro-Tex Chemical Corp. (sold to Denka)
E. I. du Pont de Nemours & Co., La Place, LA
13. Cyclohexanol/Cyclohexanone
Union Carbide Corp., Taft, LA
Celanese Chemical Co., Inc., Bay City, TX
14. Cyclohexane
CORCO Cyclohexane, Inc.
Cosden Oil & Chemical Co., Big Spring, TX
Champlin Petroleum Co., Corpus Christi, TX
Sun Petroleum Products Co., Tulsa, OK
Gulf Oil Company, Port Arthur, TX
15. Cumene
R. L. Hatch
J. V. Muthig
F. D. Bess
W. C. Strader
S. G. Lant
D. W. Smith
J. Beale
J. Beale
H. J. Wurzer
A. J. Meyer
H. A. Smith
F. D. Bess
C. J. Schaefer
Bob Fuller
R. L. Chaffin
W. W. Dickinson
M. P. Zanotti
8/8/78
3/31/78
8/3/78
a/2/78
4/3/78
3/23/79
4/28/78
3/14/78
3/7/78
3/26/79
11/28/78
5/5/78
4/21/78
1/24/78
1/24/78
1/25/78
1/26/78
1/26/78
Ashland Petroleum Co., Catlettsburg, KY
Sun Petroleum Products Co., Corpus Christi,
TX
Gulf Oil Company, Port Arthur, TX
Shell Oil Company, Deer Park, TX
Monsanto Chemical Intermediates Co., Alvin,
TX
0. J. Zandona
J. R. Kampfhenkel
M. P. Zanotti
M. A. Pierle
9/25/78
9/12/78
9/19/78
16. Chlorinated C2-Methyl Chloroform, Perchloroethylene, Trichloroethylene,
Trichloroethane
Dow Chemical USA, Freeport, TX
Ethyl Corporation, Baton Rouge, LA
Dow Chemical USA, Louisiana Division
PPG Industries, Inc., Lake Charles, LA
Vulcan Materials Co., Geismar, LA
F. E. Homan
W. C. Strader
J. S. Beale
F. C. Dehn
T. A. Leonard
1/20/78
11/28/78
12/5/78
3/14/79
3/8/79
-------
B-8
17. Dimethyl Terphthalate/Terephthalic Acid
Tennessee Eastman Co., Kingsport, TN
Hoechst Fibers Industries, Spartanburg, SC
Amoco Chemicals Corp., Joliet, IL
E. I. du Pont de Nemours & Co., Cape Fear,
NC, and Old Hickory, TN
18. Ethanolamines
Dow Chemical USA, Plaquemine, LA
Texaco Petrochemicals, Port Neches, TX
Olin Chemicals, Brandenburg, KY
19. Ethyl Acetate
Tennessee Eastman Co., Kingsport, TN
Monsanto, Trenton, MI, Springfield, MA
Texas Eastman Co., Longview, TX
20. Ethylene
Texas Eastman Co., Longview, TX
Exxon Chemical Co. USA, Baton Rouge, LA
Phillips Petroleum Co., Sweeny, TX
Shell Oil Co., Deer Park, TX
21. Ethylene Dichloride
Allied Chemical, Baton Rouge, LA
B. F. Goodrich Chemical Co., Calvert City, OH
Conoco Chemicals, Lake Charles, LA
PPG Industries, Lake Charles, LA
PPG Industries, Lake Charles, LA
PPG Industries, Lake Charles, LA
Shell Oil Co., Norco, LA, Deer Park, TX
Vulcan Materials, Co., Geismar, LA
22. Ethylene Glycol
Calcasieu Chemical Corp., Lake Charles, LA
Shell Oil Co., Geismar, LA
BASF Wyandotte Corp., Geismar, LA
23. Ethylbenzene-Styrene
American Hoechst Corp., Baton Rouge, LA
Atlantic-Richfield Co., Port Arthur, TX,
and Beaver Valley, PA
El Paso Products Co., Odessa, TX
Gulf Oil Chemicals Co., St. James, LA
Monsanto Chemical, Texso City, TX
Union Carbide Corp., TX, and Puerto Rico
Sun Oil Co. of PA, Corpus Christi, TX
J. C. Edwards
R. M. Browning
H. M. Brennan
D. W. Smith
8/31/78
8/14/78
8/16/78
10/20/78
J. S. Beale
J. F. Cooper
L. B. Anziano
J. C. Edwards
N. B. Galluzzo
G. Prendergast
G. Prendergast
J. P. Walsh
L. A. McReynolds
A. G. Smith
W. M. Reiter
W. C. Holbrook
J. A. DeBernardi
R. J. Samelson
F. C. Dehn
A. T. Taetzsch
R. E. Vanlngen
P. M. Ableson
J. A. Mullins
T. R. Kovacevich
L. T. Bufkin
W. G. Kelly
C. R. Kuykendall
F. E. Berry
H. M. Keating
F. D. Bess
9/15/78
2/9/79
5/17/78
8/11/78
1/26/79
2/21/78
2/10/78
1/27/78
2/22/78
4/18/75
4/7/75
5/16/78
6/2/78
4/15/75
6/21/74
4/10/75
4/23/75
12/20/7*
1/11/79
11/27/78
1/26/78
2/23/78
1/31/78
1/27/78
4/28/78
5/5/77
-------
B-9
24. Flares
Exxon Chemical Co. USA, Bayway, NJ
Dow Chemical USA
Shell Oil Co., Houston, TX
Phillips Petroleum Co., Bartlesville, OK
Allied Chemical
Gulf Oil Chemicals Co., St. James, LA
25. Fluorocarbon
E. I. du Pont de Nemours & Co., Louisville,
KY
E. I. du Pont de Nemours & Co., Deepwater,
NJ
26. Formaldehyde
Georgia Pacific Corp., Lufkin, TX
Reichhold Chemicals, Inc., Moncure, NC
27. Formic Acid
Rockland Industries, Inc., Middlesboro, MA
Sonoco Products Co., Hartsville, SC
28. Fugitive
Monsanto Textiles Co., Pensacola, FL
29. Glycerine
FMC Corporation, Bayport, TX
30. Linear Alkylbenzene
Witco Chemical, Wilmington, CA
Conoco Chemicals, Baltimore, MD
31. Maleic Anhydride
Monsanto Chemical, St. Louis, MO
32. Fumaric Acid
Pfizer Inc., Vigo plant, Terre Haute, IN
Hooker, Puerto Rico
33. MethanoI/Methyl Ethyl Ketone
IMC Chemical Group, Inc., Sterlington, LA
Rohm and Haas Texas Inc., Deer Park, TX
E. I. du Pont de Nemours & Co., Beaumont, TX
R. R. Schirripa
S. L. Arnold
J. A. Mullins
J. J. Moon
E. J. Shields
F. E. Berry
D. W. Smith
D. W. Smith
V. J. Tretter, Jr.
P. S. Hewett
Mrs. C. Glass
C. N. Betts
J. J. Vick
C. B. Hopkins
E. A. Vistica
D. J. Lorine
M. A. Pierle
T. W. Cundiff
L. F. Wood, Jr.
R. E. Jones, Jr.
D. A. Copeland
D. W. Smith
5/1/79
5/15/79
4/12/79
5/4/79
4/30/79
8/17/78
8/21/78
6/7/78
7/19/78
7/21/78
9/18/78
10/10/78
8/3/78
2/6/79
2/6/78
2/17/78
3/22/78
4/16/79
2/9/79
4/26/78
5/19/78
5/25/78
-------
B-10
34. Methyl Methacrylate
CY/RO Industries, Avondale, LA
Texas Air Control Board
Exxon Chemical Co. USA, Bayway, TX
ARCO Chemical, Lyondell plant
Shell Oil Co., Martinez plant
Shell Oil Co., Deer Park, TX
35. Nitrobenzene-Aniline
U.S.E.P.A. First Chemical Corp.,
Pascagoula, MS
36. Olefins
Mobil Chemical Co., Beaumont, TX
37. Toluene Diisocyanate
Union Carbide Corp., Charleston, WV, plant
38. Vinylidene Chloride
Dow Chemical USA, Plaquemine, LA
39. Vinyl Acetate
E. I. du Pont de Nemours & Co., Houston, TX
National Starch & Chemical Corp., Long
Mott, TX
U.S. Industrial Chemicals Co., Deer Park, TX
Celanese Chemical Co., Clear Lake, TX
40. Waste Acid Recovery (Sulfuric Acid)
Celanese Chemical Co., Inc., Corpus
Christi, TX
Texas Eastman Co., Longview, TX
Colgate-Palmolive Co., Berkeley, CA
Amoco Chemicals Corp., Texas City, TX
Allied Chemical, Richmond, CA
Stauffer Chemical Co., Baytown, TX
Purex Corporation, Edgewater, NJ
Shell Oil Co., Deer Park, TX
Mobay Chemical Corp., Baytown, TX
Exxon Chemical Co., Baton Rouge, LA
ARCO Chemical Co., Lyondell plant
Exxon Chemical Co., Baton Rouge, LA
ARCO Chemical Co., Lyondell plant
Olin Chemicals Group, Beaumont, TX
D. H. Gold
C. R. Barden
B. L. Taranto
C. N. Hudson
J. A. Mullins
J. A. Mullins
D. A. Beck
P. B. Mullin
J. C. Ketcham
J. Beale
D. W. Smith
E. W. Bousquet
K. G. Carpenter
C. R. DeRose
J. M. Mullins
G. Prendergast
T. M. Casey
H. M. Brennan
W. M. Reiter
J. W. Call
K. E. Blackwell
J. A. Mullins
L. P. Hughes
J. P. Walsh
C. N. Hudson
J. P. Walsh
C. N. Hudson
H. T. Emerson
5/4/78
11/7/72
6/7/78
5/15/78
5/1/78
6/22/78
2/3/78
1/26/78
5/16/78
10/25/78
9/18/78
8/22/78
8/17/78
8/14/78
3/29/79
4/17/79
4/16/79
4/2/79
5/8/79
8/6/79
3/28/79
5/4/79
4/10/79
4/27/79
4/30/79
4/27/79
4/30/79
5/14/79
-------
APPENDIX C
PRODUCTS ORGANIZED BY CARRIER GASES
-------
C-3
Table C-l. Various Reactant Carrier Gases'
_ Product
7. Ethylene
7. Ethylene
7. Ethylene
9. Hydrogen cyanide (HCN)
12. Carbon tetrachloride
16. Propylene
16. Propylene
16. Propylene
21. Methanol (methyl alcohol)
31. Alkyl leads
36. Methylene chloride
36. Methylene chloride
37. 1,3-Butadiene
40. Chloroform
50. Pentaerythritol
58. Adiponitrile/HMDA
61. Pyridine
77. Methyl chloride
90. Acetone cyanyohyrin
96. Acetylene
96. Acetylene
111. Carbon disulfide
119. Butyl amines
3. Ethylene dichloride
3. Ethylene dichloride
5. Ethylene oxide
5. Ethylene oxide
7. Ethylene
7. Ethylene
7. Ethylene
8. Ethylbenzene
11. 1,1,1-Trichloroethane
Process
1-Carbon-Atom Reactants
46% Naphtha/gas-oil pyrolysis
2% Refinery by-product
52% Natural-gas liquids pyrolysis
50% Andrussow process
20% Methane
54% Naphtha/gas-oil pyrolysis
16% Natural-gas liquids pyrolysis
30% Refinery by-product
100% Methane
5% Electrolysis
35% Methane chlorination
65% Methanol/methyl chloride
80% Ethylene co-product
61% Methane chlorination
100% Formaldehyde/acetaldehyde
65% Butadiene
100% Formaldehyde/acetaldehyde
2% Methane chlorination
100% Acetone cyanation
62% Hydrocarbon oxidation
8% Ethylene by-product
100% Methane/sulfur vapor
100% Butraldehyde hydrogenation
2-Carbon-Atom Reactants
50% Direct chlorination
50% Oxychlorination
34% O2 oxidation/ethylene
66% Air oxic'ation/ethylene
2% Refinery by-product
46% Naptha/gas oil pyrolysis
52% Natural-gas liquids pyrolysis
98% Benzene alkylation
10% Ethane chlorination
Carrier Gas
Methane
Methane
Methane
Methane
Methane
Methane
Methane
Methane
Methane
Methyl chloride
Methane
Methyl chloride
Methane
Methane
Formaldehyde
Hydrogen cyanide
Formaldehyde
Methane
Hydrogen cyanide
Methane
Methane
Methane
Hydrogen cyanide
Ethane, e thyle ne
Ethane, ethylene
Ethane, ethylene
Ethane, ethylene
Ethane, ethylene
Ethane, ethylene
Ethane, ethylene
Ethyl chloride
Ethane
See Table III-3.
o
Refers to rank-order number in Table III-3.
-------
C-4
Table C-l. (Continued)
Product
Process
Carrier Gas
1. Vinyl chloride
2. Acrylonitrile
7. Ethylene
7. Ethylene
7. Ethylene
9. Hydrogen cyanide (HCN)
12. Carbon tetrachloride
15. Propylene oxide
15. Propylene oxide
16. Propylene
16. Propylene
16. Propylene
3-Carbon-Atom Reactants
1% Acetylene
100% Propylene oxidation
2% Refinery by-product
52% Natural-gas liquids
pyrolysis
46% Naphtha/gas-oil pyrol-
ysis
50% Acrylonitrile co-pro-
duct
42% Chloroparaffin chlori-
nolysis
40% Peroxidation
60% Chlorohydrin
30% Refinery by-product
54% Naphtha/gas-oil pyrol-
ysis
16% Natural-gas liquids
pyrolysis
28. Acrylic acid
37. 1,3-Butadiene
42. Isopropanol (isopropyl alcohol)
44. Glycerol (synthetic only)
57. Allyl chloride
72. Aerolein
79. n-Butyraldehyde
86. n-Butanol ( utyl alcohol)
93. Isobutyraldehyde
96. Acetylene
98. t-Butanol
101. Dodecene
106. Isobutanol (isobutyl alcohol)
118. Propyl alochol
124. Formic acid
77% Propylene oxidation
80% Ethylene co-product
100% Propylene/sulfuric
acid
71% Epichlorohydrin
100% Propylene chlorination
100% Propylene oxidation
100% Oxo process
80% Oxo process
100% Oxo process
8% Ethylene by-product
79% Propylene oxide
co-product
100% Nonene co-product
100% Oxo process
13% Propane oxidation
98% n-Butane oxidation
Propylene, propyne
Propane, propylene
Propane, propylene
Propane, propylene
Propane, propylene
Propane, propylene
Propane, propylene
Propane, propylene
Propane, propylene
Propane, propylene
Propane, propylene
Propane, propylene
Propane, propylene
Propane, propylene
Propane, propylene
propylene
propylene
propylene
propylene
propylene
propylene
propylene
propylene
Propane,
Propane,
Propane,
Propane,
Propane,
Propane,
Propane,
Propane,
Propane,
Propane, propylene
Propane, propylene
Propane, propylene
-------
C-5
Table C-l. (Continued)
Product
Process
Carrier Gas
16. Propylene
16. Propylene
16. Propylene
18. Ethylene glycol
20. Cumene
28- Acrylic acid
29. Acetic acid
31. Alkyl leads
33. Ethyl chloride
33. Ethyl chloride
34. Ethanolamines
35. Vinyl acetate (VA)
35. Vinyl acetate (VA)
35. Vinyl acetate (VA)
37 • 1,3-Butadiene
50• Pentaerythritol
53• Diethylene, triethylene
glycols
61• Pyridine
63. Ethanol (ethyl alcohol)
&5. Acetaldehyde
68- Glycol ethers
74. Methyl styrene
76. Ethyl acrylate
2-Carbon-Atom Reactants (Continued)
30% Refinery by-product
54% Naptha/gas-oil pyrolysis
16% Natural-gas liquids pyrolysis
100% Ethylene oxide
100% Benzene
23% Modified Reppe
33% Acetaldehyde
95% Ethyl chloride
4% EthanoI/ethane
96% Ethylene chlorination
100% Ethylene oxide
13% Acetylene vapor phase
15% Ethylene liquid phase
72% Ethylene vapor phase
80% Ethylene co-product
100% Formaldehyde/acetaldehyde
100% Co-product w/ethylene glycol
100% Formaldehyde/acetaldehyde
100% Ethylene
100% Ethylene
97% Ethylene oxide
85% Cumene process by-product
61% Acetylene (Reppe)
86. n-Butanol (butyl alcohol) 20%
87. Propionic acid 93%
89. Ethylene dibromide 100%
96. Acetylene 8%
118. Propyi alcohol 87%
118. Propyi alcohol 13%
120. Ethyl (diethyl) ether 100%
122. Crotonaldehyde 100%
124. Formic acid 98%
136. Amino ethylethanolamine 100%
Acetaldehyde
Oxo process
Ethylene bromination
Ethylene by-product
Oxo process
Propane oxidation
Ethanol
Aldo process
n-Butane oxidation
Ethylene oxide
Ethane, ethylene
Ethane, ethylene
Ethane, ethylene
Ethylene oxide
Ethane, ethylene
Ethylene, acety-
lene
Acetaldehyde
Ethyl chloride
Ethane, ethylene
Ethane, ethylene
Ethylene oxide
Ethylene, acety-
lene
Ethane* ethylene
Ethane, ethylene
Ethane, ethylene
Acetaldehyde
Ethylene oxide
Acetaldehyde
Ethane, ethylene
Ethane, ethylene
Ethylene oxide
Ethane, ethylene
Ethylene, acety-
lene
Acetaldehyde
Ethane, ethylene
Ethane, ethylene
Ethane, ethylene
Ethane, ethylene
Ethane, ethylene
Ethane, ethylene
Acetaldehyde
Ethane, ethylene
Ethylene oxide
-------
C-6
Table C-l. (Continued)
Product
Process
Carrier Gas
4. Maleic anhydride
7. Ethylene
7. Ethylene
7. Ethylene
15. Propylene oxide
16. Propylene
16. Propylene
16. Propylene
29. Acetic acid
30. Chloroprene
37. 1,3-Butadiene
37. 1,3-Butadiene
37. 1,3-Butadiene
58. Adiponitrile/HMDA
96. Acetylene
98. t-Butanol
105. Methyl ethyl ketone (MEK)
118. Propyl alcohol
119. Butyl amines
124. Formic acid
134. Butyric acid
7. Ethylene
7. Ethylene
7. Ethylene
16. Propylene
16. Propylene
16. Propylene
37. 1,3-Butadiene
96. Acetylene
4-Carbon-Atom Reactants
15% Butane oxidation
2% Refinery by-product
52% Natural-gas liquids
pyrolysis
46% Naphtha/gas-oil pyrolysis
40% Peroxidation
54% Naphtha/gas-oil pyrolysis
16% Natural-gas liquids
pyrolysis
30% Refinery by-product
44% Butane oxidation
100% Via butadiene
80% Ethylene co-product
7% ji-Butene
13% n-Butane
65% Butadiene
8% Ethylene by-product
21% Isobutylene
25% Butane oxidation
13% Propane oxidation
100% Butyraldehyde hydrogenation
98% n-Butane oxidation
67% ri-Butane oxidation
5-Carbon-Atom Reactants
46%.Naphtha/gas-oil pyrolysis
2% Refinery by-product
52% Natural-gas liquids
pyrolysis
16% Natural-gas liquids
pyrolysis
30% Refinery by-product
54% Naphtha/gas-oil pyrolysis
80% Ethylene co-product
8% Ethylene by-product
Butane ,
Butane, butylen6
Butane, butylen6
Butane,
Butane
Butane, butylefl6
Butane, butylene
Butane,
Butane, butyls*^
Butadiene
Butane, butylefle
Butene
Butane, butyl®11*
Butadiene
Butane, butylefl6
Isobutylene
Butane, butylePe
Butane,
Butylene
Butane,
Butane,
Pentene
Pentene
Pentene
Pentene
Pentene
Pentene
Pentene
Pentene
-------
C-7
Table C-l. (Continued)
Product
Process
Carrier Gas
1. Vinyl chloride
2. Acrylonitrile
3. Ethylene dichloride
4. Maleic anhydride
4. Maleic anhydride
5. Ethylene oxide
6. Dimethyl terephthalate (DMT)
6. Dimethyl terephthalate (DMT)
6. Dimethyl terephthalate (DMT)
6. Dimethyl terephthalate (DMT)
9. Hydrogen cyanide (HCN)
9. Hydrogen cyanide (HCN)
13. Formaldehyde
13. Formaldehyde
15. Propylene oxide
19. Cyclohexanol/cyclohexanone
22. phenol
22. Pehnol
26. Terephthalic acid (TPA)
26. Terephthalic acid (TPA)
26. Terephthalic aicd (TPA)
28. Acrylic acid
29. Acetic acid
29. Acetic acid
32. Acetone
32. Acetone
34. Ethanolamines
37. 1,3-Butadiene
41. Phthalic anhydride
41. Phthalic anhydride
58. Adiponitrile/HMDA
Nitrogen-Containing Reactants
1% Acetylene
100% Propylene oxidation
50% Oxychlorination
15% Butane oxidation
85% Benzene oxidation
66% Air oxidation/ethylene
23% Amoco via terephthalic acid
17% Eastman via terephthalic acid
35% Du Pont
25% Hercules
50% Acrylonitrile co-product
50% Andrussow process
77% Silver catalyst/methanol
23% Metal oxide/methanol
40% Peroxidation
75% Cyclohexane
2% Toluene oxidation
93% Cumene
39% Amoco
14% Mobil
47% Eastman
77% Propylene oxidation
44% Butane oxidation
33% Acetaldehyde
31% isopropnol
69% Cumene
100% Ethylene oxide
7% ri-Butene
70% jo-Xylene
30% Naphthalene
65% Butadiene
-------
C-8
Table C-l. (Continued)
Products Process CarrierGaS
Nitrogen-Containing Reactants (Continued)
b
65. Acetaldehyde 100% Ethylene
72. Acrolein 100% Propylene oxidation
81. Acetophenone 40% Ethylbenzene oxidation
81. Acetophenone 60% Cumene peroxidation
82. Isophthalic acid 100% rn-Xylene oxidation
83. Benzoic acid 100% Toluene air oxidation
94. Cresylic acids (SYN) 4% Cumene oxidation
94. Cresylic acids (SYN) 80% Natural coal tar
96. Acetylene 62% Hydrocarbon oxidation
100. Dimethyl hydrazine 100% Nitrosodimethyl amine
105. Methyl ethyl ketone (MEK) 25% Butane oxidation
107. Hydroquinone 100% Acetone co-product
118. Propyl alcohol 13% Propane oxidation
124. Formic acid 98% ri-Butane oxidation
127. Isodecanol 25% n-Paraffin oxidation
134. Butyric acid 33% Butyraldehyde oxidation
134. Butyric acid 67% ri-Butane oxidation
Argon-Containing Reactants
5. Ethylene oxide 34% 02 oxidation/ethylene
35. Vinyl acetate (VA) 15% Ethylene liquid phase
35. Vinyl acetate (VA) 72% Ethylene vapor phase
Hydrogen-Containing Reactants
19. Cyclohexanol/cyclohexanone 25% Phenol
21. Methanol (methyl alcohol) 100% Methane
23. Aniline 100% Nitrobenzene hydrogenation
37. 1,3-Butadiene 13% n-Butane
44. Glycerol (synthetic only) 14% Acrolein
46. Cyclohexane 84% Benzene hydrogenation
58. Adiponitrile/HMDA 11% Acrylonitrile
58. Adiponitrile/HMDA 65% Butadiene
58. Adiponitrile/HMDA 24% Adipic acid
60. Methyl isobutyl ketone (MIBK) 100% Acetone
62. Benzene 20% Toluene hydrodealkylation
79. ri-Butyraldehyde 100% Oxo process
-------
C-9
Table C-l. (Continued)
Products
Process
Carrier Gas
81.
85.
86.
86.
87.
93.
106.
112.
118.
119.
123.
127.
137.
137.
21.
28.
29.
39.
76.
79.
85.
86.
86.
87.
93.
97.
106.
118.
123.
127.
Acetophenone
2-Ethyl 1-hexanol
ji-Butanol (butyl alcohol)
ri-Butanol (butyl alcohol)
Propionic acid
Isobutylraldehyde
Isobutanol (isobutyl alcohol)
Biphenyl
Propyl alcohol
Butyl amines
Isooctyl alcohol
Isodecanol
Cyclohexylamine
Cyclohexylamine
Hydrogen-Containing Reactants (Continued)
40% Ethylbenzene oxidation
100% Condensation
80% Oxo process
20% Acetaldehyde
93% Oxo process
100% Oxo process
100% Oxo process
100% Toluene hydrodealkylation
87% Oxo process
100% Butraldehyde hydrogenation
100% Oxo process/hydrogenation
75% Oxo process
50% Cyclohexanone
50% Aniline
Carbon Monoxide—Containing Reactants
Methanol (methyl alcohol)
Acrylic acid
Acetic acid
Toluene diisocyanate (TDI)
Ethyl acrylate
ri-Butyraldehyde
2-Ethyl 1-hexanol
ri-Butanol (butyl alcohol)
ri-Butanol (butyl alcohol)
Propionic acid
Isobutyraldehyde
Phosgene
Isobutanol (isobutyl alcohol)
Propyl alcohol
Isooctyl alcohol
Isodecanol
100% Methane
23% Modified Reppe
19% Methanol
100% Diaminotoluene
61% Acetylene (Reppe)
100% Oxo process
100% Condensation
80% Oxo process
20% Acetaldehyde
93% Oxo process
100% Oxo process
100% Carbon monoxide/chlorine
100% Oxo process
87% Oxo process
100% Oxo process/hydrogenation
75% Oxo process
-------
C-10
Table C-l. (Continued)
Products
Process
Carrier
2. Acrylonitrile
4. Maleic anhydride
4. Maleic anhydride
5. Ethylene oxide
5. Ethylene oxide
6. Dimethyl terephthalate (DMT)
6. Dimethyl terephthalate (DMT)
6. Dimethyl terephthalate (DMT)
6. Dimethyl terephthalate (DMT)
9. Hydrogen cyanide (HCN)
9. Hydrogen cyanide (HCN)
13. Formaldehyde
13. Formaldehyde
15. Propylene oxide
19. Cyclohexanol/cyclohexanone
22. Phenol
22. Phenol
26. Terephthalic acid (TPA)
26. Terephthalic acid (TPA)
26. Terphthalic acid (TPA)
28. Acrylic acid
29. Acetic acid
29. Acetic acid
32. Acetone
32. Acetone
35. Vinyl acetate (VA)
37. 1,3-Butadiene
41. Phthalic anhydride
41. Phthalic anhydride
58. Adiponitrile/HMDA
65. Acetaldehyde
72. Acrolein
Oxygen-Containing Reactants
100% Propylene oxidation
15% Butane oxidation
85% Benzene oxidation
34% 0.2 Oxidation/ethylene
66% Air oxidation/ethylene
23% Amoco via terephthalic acid
35% Du Pont
25% Hercules
17% Eastman via terephthalic acid
50% Acrylonitrile co-product
50% Andrussow process
77% Silver catalyst/methanol
23% Metal oxide/methanol
40% Peroxidation
75% Cyclohexane
93% Cumene
2% Toluene oxidation
14% Mobil
39% Amoco
47% Eastman
77% Propylene oxidation
44% Butane oxidation
33% Acetaldehyde
31% Isopropanol
69% Cumene
72% Ethylene vapor phase
7% ri-Bv.c.ene
30% Naphthalene
70% £-Xylene
65% Butadiene
100% Ethylene
100% Propylene oxidation
-------
C-ll
Table C-l. (Continued)
Products
Processes
Carrier Gas
81. Acetophenone
81. Acetophenone
82. isophthalic acid
83. Benzoic adid
94. Cresylic acids (SYN)
94. Cresylic acids (SYN)
96. Acetylene
100. Dimethyl hydrazine
105. Methyl ethyl ketone (MEK)
107. Hydroquino ne
118. Propyl alcohol
124. Formic acid
127. isodecanol
134. Butyric acid
134. Butyric acid
1. Vinyl chloride
3. Ethylene dichloride
3. Ethylene dichloride
11. 1,1,1-Trichloroethane
11. 1,1,1-Trichloroethane
12. Carbon tetrachloride
12. Carbon tetrachloride
12. Carbon tetrachloride
15. Propylene oxide
25. Perchloroethylene
25. Perchloroethylene
27. Chlorobenzene
30. Chloroprene
33. Ethyl chloride
33. Ethyl chloride
35. Vinyl acetate (VA)
Oxygen-Containing Reactants (Continued)
40% Ethyl benzene oxidation
60% Cumene peroxidation
100% m-Xylene oxidation
100% Toluene air oxidation
4% Cymene oxidation
80% Natural coal tar
62% Hydrocarbon oxidation
100% Nitrosodimethyl amine
25% Butane oxidation
100% Acetone co-product
13% Propane oxidation
98% iv-Butane oxidation
25% n-Paraffin oxidation
33% Butyraldehyde oxidation
67% £i-Butane oxidation
Chlorine-Containing Reactants
1% Acetylene
50% Oxychlorination
50% Direct chlorination
74% Vinyl chloride
10% Ethane chlorination
38% Carbon disulfide
42% Chloroparaffin chlorinolysis
20% Methane
60% Chlorohydrin
66% Ethylene dichloride
34% Ethcine chlorinolysis
100% Benzene chlorination
100% Via butadiene
4% Ethanol/ethane
96% Ethylene chlorination
15% Ethylene liquid phase
-------
C-12
Table C-l. (Continued)
Products
Processes
Carrier
Chlorine-Containing Reactants (Continued)
36.
36.
40.
40.
44.
44.
56.
57.
59.
77.
91.
92.
97.
113.
115.
132.
82.
89.
117.
21.
28.
29.
64.
76.
94.
99.
Methylene chloride
Methylene chloride
Chloroform
Chloroform
Glycerol (synthetic only)
Glycerol (synthetic only)
Epichlorohydrin
Allyl chloride
Trichloroethylene
Methyl chloride
Benzeyl chloride
Dichlorophenol
Phosgene
Acetyl chloride
Chloroacetic acid
Hexachlorobenzene
Isophthalic acid
Ethylene dibromide
Methyl bromide
Methanol (methyl alcohol)
Acrylic acid
Acetic acid
Urea
Ethyl acrylate
Cresylic acids (SYN)
Salicylic acid
65% Methanol/methyl chloride
35% Methane chlorination
61% Methane chlorination
39% Methanol chlorination
15% Allyl alcohol
71% Epichlorohydrin
100% Allyl chloride/HCl
100% Propylene chlorination
91% Ethylene dichloride
2% Methane chlorination
100% Toluene chlorination
45% Phenol chlorination
100% Carbon monoxide/chlorine
100% Sodium acetate
100% Acetic acid chlorination
100% Hexachlorocyclohexane
Bromine-Containing Reactants
100% m-Xylene oxidation
100% Ethylene bromination
100% Methanol/HER and bromine
Carbon Dixide—Containing Reactants
100% Methane
23% Modified Reppe
19% Methanol
100% Ammonia/carbon dioxide
61% Acetylene (Reppe)
80% Natural coal tar
100% Sodium phenate
-------
C-13
Table C-l. (Continued)
Products Process Carrier Gas
Sulfur Trioxide-Containing Reactants
22. Phenol 2% Benzene sulfonation
126. Linear alkyl benzene sulfonate 100% Lab sulfonation
138. Toluene sulfonic acids 100% Toluene sulfonation
Hydrogen Chloride-Containing Reactants
11. 1,1,1-Trichloroethane 10% Ethane chlorination
11. 1,1,1-Trichloroethane 16% Vinylidene chloride
11. 1,1,1-Trichloroethane 74% Vinyl chloride
22. Phenol 3% Chlorobenzene
59. Trichloroethylene 9% Acetylene
73. Diphenylamine 100% Aniline amination
75. Ethylene diamine/triethylene 100% EDO ammonolysis
tetramine
77. Methyl chloride 98% Methanol hydrochlorination
99. Salicylic acid 100% Sodium phenate
116. Benzophenone 100% Benzene/carbon tetrachloride
Hydrogen Bromide-Containing Reactant
117. Methyl bromide 100% Methanol/HBR and bromine
Hydrogen Fluoride-Containing Reactants
24. Fluorocarbons 100% CC14/C2C16 fluorination
71. Linear alkyl benzene 100% Benzene alkylation
Ammonia-Containing Reactants
2. Acrylonitrile 100% Propylene oxidation
9. Hydrogen cyanide (HCN) 50% Andrussow process
9. Hydrogen cyanide (HCN) 50% Acrylonitrile co-product
34. Ethanolamines 100% Ethylene oxide
49. Caprolactam 100% Cyclohexanone
52. Acrylamide 100% Acrylonitrile
58. Adiponitrile/HMDA 24% Adipic acid
61. Pyridine 100% Formaldehyde/acetaldehyde
64. Urea 100% Ammonia/carbon dioxide
75. Ethylene diamine/triethylene 100% DC ammonolysis
tetramine
80. Nitroaniline 100% Nitro chlorobenzene
100. Dimethyl hydrazine 100% Nitrosodimethyl amine
-------
C-14
Table C-l. (Continued)
Products
Process
Carrier Gas
Ammonia-Containing Reactants (Continued)
108. Mono-, di-, trimethyl amines
114. Mono-, di-, trimethyl amine
119. Butyl amines
121. Propyl amines (M-D-T)
121. Propyl amines (M-D-T)
137. Cyclohexylamine
17. Nitrobenzene
39. Toluene diisocyanate (TDI)
100% Methanol ammonolysis
100% Ethanol ammonolysis
100% Butryaldehyde hydro-
genation
50% ri-Propyl alcohol
50% n-Propyl chloride
50% Cyclohexanone
Miscellaneous Gaseous
100% Benzene nitration
100% Diaminotoluene
43. Acetic anhydride
49. Caprolactam
78. Methylene diphenylene diisocynate
109. Adipic acid
110. Chloronitrobenzene
100% Acetic acid
100% Cyclohexanone
100% DPMDA/phosgene
100% Cyclohexane
100% Chlorobenzene nitra-
Nitrogen oxides
Nitrogen oxides/
phosgene
Ketene
Hydroxylamine
Phosgene
Nitrogen oxides
Nitrogen oxides
-------
C-15
Table C-2. Various Product Carrier Gases'
Product
Process
Carrier Gas
2. Acrylonitrile
7. Ethylene
7. Ethylene
7. Ethylene
9. Hydrogen cyanide (HCN)
9. Hydrogen cyanide (HCN)
12. Carbon tetrachloride
13. Formaldehyde
13. Formaldehyde
14. Methyl methacrylate (MMA)
16. Propylene
16. Propylene
16. Propylene
24. Fluorocarbons
62. Benzene
77. Methyl chloride
77. Methyl chloride
96. Acetylene
97. Phosgene
108. Mono-, di-, trimethyl
amines
112. Biphenyl
117. Methyl bromide
1. Vinyl chloride
1. Vinyl chloride
3. Ethylene dichloride
3. Ethylene dichloride
5. Ethylene oxide
5. Ethylene oxide
7. Ethylene
1-Carbon-Atom Products
100% Propylene oxidation
2% Refinery by-product
52% Natural gas liquids pyrol-
ysis
46% Naphtha gas-oil pyrolysis
50% Acrylonitrile co-product
50% Andrussow process
20% Methane
77% Silver catalyst/methanol
23% Metal oxide/methanol
100% Acetone cyanohydrin
54% Naphtha/gas-oil pyrolysis
30% Refinery by-product
16% Natural-gas liquids pyrol-
ysis
100% CC14/C2C16 fluorination
20% Toluene hydrodealkylation
2% Methane chlorination
98% Methanol hydrochlorination
8% Ethylene by-product
100% Carbon monoxide/chlorine
100% Methanol ammonolysis
100% Toluene hydrodealkylation
100% Methanol/HBR and bromine
2-Carbon-Atom Products
1% Acetylene
99% Ethylene dichloride
50% Oxychlorination
50% Direct chlorination
66% Air oxidation/ethylene
34% 02 oxidation/ethylene
46% Naphtha gas-oil pyrolysis
Hydrogen cyanide
Methane
Methane
Methane
Hydrogen cyanide
Hydrogen cyanide
Methyl chloride
Formaldehyde
Formaldehyde
Hydrogen cyanide
Methane
Methane
Methane
Fluorinated methanes
Methane
Methyl chloride
Methyl chloride
Methane
Methyl chloride
Methyl amine
Methane
Methyl bromide
Vinyl chloride
Vinyl chloride
Ethyl chloride
Ethyl chloride
Ethylene oxide
Ethylene oxide
Ethane, ethylene
See Table III-4.
o
Refers to rank-order number in Table III-4.
-------
C-16
Table C-2. (Continued)
Product
Process
Carrier Gas ,
7. Ethylene
7. Ethylene
16. Propylene
16. Propylene
16. Propylene
24. Fluorocarbons
33. Ethyl chloride
33. Ethyl chloride
35. Vinyl acetate (VA)
35. Vinyl acetate (VA)
65. Acetaldehyde
96. Acetylene
96. Acetylene
96. Acetylene
124. Formic acid
16. Propylene
16. Propylene
16. Propylene
37. 1,3-Butadiene
37. 1,3-Butadiene
37. 1,3-Butadiene
7. Ethylene
7. Ethylene
7. Ethylene
10. Styrene
16. Propylene
2-Carbon-Atom Products (Continued)
2% Refinery by-product
52% Natural gas liquids pyrol-
ysis
30% Refinery by-product
54% Naphtha/gas-oil pyrolysis
16% Natural-gas liquids pyrol-
ysis
100% CC1./C_C1C fluorination
4^0
4% EthanoI/ethane
96% Ethylene chlorination
72% Ethylene vapor phase
15% Ethylene liquid phase
100% Ethylene
30% Calcium carbide
62% Hydrocarbon oxidation
8% Ethylene by-product
98% ri-Butane oxidation
3-Carbon-Atom Products
54% Naphtha/gas-oil pyrolysis
30% Refinery by-product
16% Natural-gas liquids pyrol-
ysis
4-Carbon-Atom Products
80% Ethylene co-product
7% rv-Butene
13% ri-Butane
Hydrogen-Containing Products
46% Naptha gas oil pyrolysis
2% Refinery by-product
52% Natural gas liquids pyrol-
ysis
Ethylbenzene
16% Natural gas liquids pyrol-
ysis
Ethane, ethylene
Ethane, ethylene
Ethane, ethylene
Ethane, ethylene
Ethane, ethylene
Fluorinated ethanes
Ethyl chloride
Ethyl chloride
Acetaldehyde
Acetaldehyde
Acetaldehyde
Acetylene
Acetylene
Acetylene
Methyl formate
Propylene
Propylene
Propylene
Butyne, butadiene
Butyne, butadiene
Butyne, butadiene
-------
C-17
Table C-2. (Continued)
Product
Process
16.
16.
21.
29.
32.
37.
37.
61.
66.
66.
71.
74.
96.
96.
105.
107.
131.
132.
2.
4.
4.
5.
6.
6.
6.
6.
9.
21.
26.
26.
26.
Hydrogen-Containing Products (Continued)
30% Refinery by-product
54% Naphtha/gas-oil pyrolysis
100% Methane
4% Others
31% Isopropanol
80% Ethylene co-product
7% ii-Butene
100% Formaldehyde/acetaldehyde
33% Isoamylene extraction
67% C4 hydrocarbons
100% Benzene alkylation
15% Cumene dehydrogenation
62% Hydrocarbon oxidation
8% Ethylene by-product
75% Sec-butanol
100% Acetone co-product
100% Butadiene dimerization
100% Hexachlorocyclohexane
Carbon Monoxide-Containing Products
100% Propylene oxidation
15% Butane oxidation
85% Benzene oxidation
66% Air oxidation/ethylene
Dimethyl terephthalate (DMT) 17% Eastman via terephthalic acid
Dimethyl terephthalate (DMT) 25% Hercules
Dimethyl terephthalate (DMT) 23% Amoco via terephthalic acid
Dimethyl terephthalate (DMT) 35% Du Pont
50% Acrylonitrile co-product
100% Methane
39% Amoco
14% Mobil
47% Eastman
Propylene
Propylene
Methanol (methyl alcohol)
Acetic acid
Acetone
1,3-Butadiene
1/3-Butadiene
Pyridine
Isoprene
Isoprene
Linear alkyl benzene
Methyl styrene
Acetylene
Acetylene
Methyl ethyl ketone (MEK)
Hydroquinone
Cyclooctadiene
Hexachlorobenzene
Acrylonitrile
Maleic anhydride
Maleic anhydride
Ethylene oxide
Hydrogen cyanide (HCN)
Methanol (methyl alcohol)
Terephthalic acid (TPA)
Terephthalic acid (TPA)
Terephthalic acid (TPA)
-------
C-18
Table C-2. (Continued)
Product
Process
Carbon Monoxide-Containing Products (Continued)
41. Phthalic anhydride
41. Phthalic anhydride
72. Acrolein
96. Acetylene
2. Acrylonitrile
4. Maleic anhydride
4. Maleic anhydride
5. Ethylene oxide
5. Ethylene oxide
6. Dimethyl terephthalate (DMT)
6. Dimethyl terephthalate (DMT)
6. Dimethyl terephthalate (DMT)
6. Dimethyl terephthalate (DMT)
9. Hydrogen cyanide (HCN)
21. Methanol (methyl alcohol)
22. Phenol
26. Terephthalic acid (TPA)
26. Terephthalic acid (TPA)
26. Terephthalic acid (TPA)
28. Acrylic acid
30. Chloroprene
35. Vinyl acetate (VA)
35. Vinyl acetate (VA)
40. Chloroform
41. Phthalic anhydride
41. Phthalic anhydride
44. Glycerol (synthetic only)
72. Acrolein
30% Naphthalene
70% o-Xylene
100% Propylene oxidation
62% Hydrocarbon oxidation
Carbon Dioxide-Containing Products
100% Propylene oxidation
15% Butane oxidation
85% Benzene oxidation
34% 02 Oxidation/ethylene
66% Air oxidation/ethylene
23% Amoco via terephthalic acid
35% Du Pont
25% Hercules
17% Eastman via terephthalic acid
50% Acrylonitrile co-product
100% Methane
2% Toluene oxidation
14% Mobil
47% Eastman
39% Amoco
77% Propylene oxidation
100% Via butadiene
72% Ethylene vapor phase
15% Ethylene liquid phase
39% Methanol chlorination
30% Naphthalene
70% o-Xylene
71% Epichlorohydrin
100% Propylene oxidation
-------
C-19
Table C-2. (Continued)
Product
Process
22.
49.
1.
8.
11.
11.
12.
12.
15.
24.
25.
25.
27.
30.
31.
33.
33.
36.
36.
38.
38.
39.
40.
44.
57.
59.
59.
65.
91.
92.
Phenol
Caprolactam
Vinyl chloride
Ethylbenzene
1,1,1-Trichloroethane
1,1,-Trichloroethane
Carbon tetrachloride
Carbon tetrachloride
Propylene oxide
Pluorocarbons
Perchloroethylene
Perchloroethylene
Chlorobenzene
Chloroprene
Alkyl leads
Ethyl chloride
Ethyl chloride
Methylene chloride
Methylene chloride
Vinylidene chloride
Vinylidene chloride
Toluene diisocyanate (TDI)
Chloroform
Glycerol (synthetic only)
Allyi chloride
Trichloroethylene
Trichloroethylene
Acetaldehyde
Benzyl chloride
Dichlorophenol
Sulfur Trioxide-Containing Products
2% Benzene sulfonation
100% Cyclohexanone
Hydrogen Chloride-Containing Products
99% Ethylene dichloride
98% Benzene alkylation
74% Vinyl chloride
10% Ethane chlorination
42% Chloroparaffin chlorinelysis
20% Methane
60% Chlorohydrin
100% CC14/C el, fluorination
66% Ethylene dichloride
34% Ethane chlorinolysis
100% Benzene chlorination
100% Via butadiene
95% Ethyl chloride
4% Ethanol/ethane
96% Ethylene chlorination
35% Methane chlorination
65% Methanol/methyl chloride
50% 1,1,1-Trichloroethylene
50% 1,1,2-Trichloroethylene
100% Diaminotoluene
61% Methane chlorination
71% Epichlorohydrin
100% Propylene chlorination
91% Ethylene dichloride
9% Acetylene
100% Ethylene
100% Toluene chlorinaticn
45% Phenol chlorination
-------
C-20
Table C-2. (Continued)
Product
Process
Carrier Gas
Hydrogen Chloride-Containing Products (Continued)
92. Dichlorophenol
113. Acetyl chloride
115. Chloroacetic acid
116. Benzophenone
132. Hexachlorobenzene
136. Amino ethylethanolamine
140. Benzoyl chloride
55% Trichlorobenzene
100% Sodium acetate
100% Acetic acid chlorination
100% Benzene/carbon tetrachloride
100% Hexachlorocyclohexane
100% Ethylene oxide
100% Benzoic acid
Miscellaneous Gaseous Products
19. Cyclohexanol/cyclohexanone 75% Cyclohexane
43. Acetic anhydride 100% Acetic acid
45. Nitrophenol 100% Phenol nitration
51. Nonyl phenol 100% Phenol alkylation
69. Dinitrotoluene
97. Phosgene
135. Dinitrophenol
100% Toluene dinitration
100% Carbon monoxide/chlorine
100% Dinitration of phenol
Nitrogen oxideS
Ketene
Nitrogen oxides
Boron tri-
fluoride
Nitrogen oxides
Phosgene
Nitrogen oxides
-------
APPENDIX D
SAMPLE CALCULATIONS
-------
D-3
SAMPLE CALCULATIONS
The sample calculation will be for 1,1,1-trichloroethane from ethane.
1. Chlorine Carrier^ Gases
a. Merchant Chlorine
C = MCR X (Fc - 1) X (1 - Sc) + MCR X (1 - PC) X FC + 2 X (1 - SIn)
C . = 3 X 0 X 0.001 + 3 X 0.006 X 1.0 X 0.5 = 0.009
min
C = 3 X 0.3 X 0.05 + 3.X 0.025 X 1.3 X 0.9 = 0.133
max
t>. Captive Chlorine
C , = 3 X 0 X 0.001 + 3 X 0.01 X 1.0 X 0.5 = 0.015
mm
C = 3 X 0.3 X 0.05 4- 3 X 0.10 X 1.3 X 0.9 = 0.396
max
2- Hydrogen Chloride Carrier Gases
H = MHCR X (1 - Su)
H
H . = 1 X 0.01 = 0.01
mm
Hmax=3X°-10 =0'3°
3- Gaseous Organic Reactant Carrier Gases
R = MGRR X FGR X (1 - YGR) X (1 - SGR)
R . = 1 X 0.9 X 0.01 X 0.1 = 0.0009
mm
R =1X1.0X0.20 XO.9= 0.180
max
4. Gaseous Organic Product Carrier Gases
P = MGPR X (1 - SGp)
P . = 0.33 X 0.1 = 0.033
mzn
P = 0.33 X 0.9 = 0.297
max
-------
D-4
5. Total Carrier Gases
a. Merchant Chlorine
G = C. +H. + R . +P.
nun man mm mm
G . = 0.009 + 0.01 + 0.0009 + 0.033 = 0.0529
nun
G = 0.133 + 0.30 + 0.180 + 0.297 = 0.910
max
b. Captive Chlorine
G . = 0.015 + 0.01 + 0.0009 + 0.033 = 0.0589
mm
G = 0.396 + 0.30 + 0.180 + 0.297 = 1.173
max
6. Conversion to sc£m/M Ib/yr of Product (for the Merchant-Chlorine Case)
Basis: 1 M Ib/yr of product
[ _ scfm _ \ / moles of gas \ 359 scf _
min \ M Ib/yr product / ~ min \moles of product j 1 Ib-mole of gas
1 mole of product 1 X 10 Ib 1 yr
133.5 Ib yr X 525,600 min
n ?71 _r±: — = 0.0529 X 683/133.5
M Ib/yr
Merchant Clp Min
Max
Captive Cl Min
Max
7. Calculation of Carrier-Gas
Reactant or Product
/ moles of gas \
\ mole of product /
/ scfm \
\Fl Ib/yr of product y
0.272
4. .66
0.301
6.02
VOC
X 683/MW - R I -
product V M ]
(>
moles of gas \
mole of product 1
0.0529
0.910
0.0589
1.173
scfm \
Ib/yr of product /
-------
D-5
R / lb of VOC \ _ / scfm \
R _ I = R — 1 X 1463 X MW ^
\ M lb product/ \M Ib/yr of product/ voc
Total carrier-gas VOC = R | Ib of VOC \ + p /_
V M Ib of product / \ M
Ib of VOC
Ib of product
(Take the minimum case)
Reactant - 0.0009 X 683/133.5 = 0.0046 /_ scfm \
\M Ib/yr of product /
0.0046 X 1463 X 28 (assume propane) = 188 ( Ib of VOC
\ M Ib of product
Product = 0.033 X 683/133.5 = 0.170
scfm \
M Ib/yr of product /
0.170 X 1463 X 64.5 (assume ethyl chloride) = 16,030 [-—lb of voc \
\ M lb of product /
Total = 188 + 16,030 = 16,218 / lb of VOC \
\ M lb of product/
Calculation of VOC from Organic Liquids and Solids
Organic liquid [scfm/(M Ib/yr)] = Carrier-gas flow [scfm/(M Ib/yr)] X
YVOC
1 - Yvoc
(if Yyoc = 0.137 for 1,1,1-trichloroethane at 21°C)
°-043 (low) = 0.272 (low) X 0.159
°-953 (high) =6.02 (high) X 0.159
is converted to lb of VOC/M lb of product by multiplying by the VOC molecular weight
and 1463
0.043 X 133.5 X 1463 = 8398 (lb of VOC/M lb of product)
°-953 X 133.5 X 1463 = 186,130 (lb of VOC/M lb of product)
values in Table IV-3 have been rounded.
-------
3-i
REPORT 3
AIR OXIDATION EMISSION PROJECTION
J. W. Blackburn
IT Enviroscience
9041 Executive Park Drive
Knoxville, Tennessee 37923
Prepared for
Emission Standards and Engineering Division
Office of Air Quality Planning and Standards
ENVIRONMENTAL PROTECTION AGENCY
Research Triangle Park, North Carolina
December 1980
D83W
-------
3-iii
CONTENTS OF REPORT 3
Page
I. THE GENERAL STANDARD APPROACH 1-1
II. AIR-OXIDATION PROCESSES IN THE SYNTHETIC ORGANIC CHEMICALS II-l
MANUFACTURING INDUSTRY
A. Description II-l
B. Distribution of Air-Oxidation Processes in SOCMI II-2
III. EMISSIONS III-l
A. Air-Oxidation Processes III-l
B. Flow Rate III-l
C. VOC Concentration 111-10
D. Reference 111-15
IV. CONTROL OPTIONS IV-1
V. SUMMARY V-l
APPENDIX OF REPORT 3
A- LIST OF EPA INFORMATION SOURCES A-l
-------
3-v
TABLES OF REPORT 3
Unit Process Ranking
Chemicals Produced by Oxidation Processes
Common Molar Oxygen Ratios for Oxidation Processes
Air-to-Reactant Relationships for Air Oxidation Processes
Air Oxidation Absorber Off-Gas VOC Compositions
Representative Cost-Effectiveness for Organic Emission
Control Technology
II-4
II-5-
III-5
III-6
111-12
IV-2
FIGURES OF REPORT 3
III-4
Occurrence Histogram of Oxidation Products Ranked
General Air-Oxidation Process
Total Off-Gas Flow-Rate Projection for Air-Oxidation Processes
Distribution of Actual Absorber Off-Gas VOC Composition Data
Found in HI Study
Maximum Off-Gas VOC Concentration as a Function of Off-Gas
Flow Index Factor
II-6
III-2
III-9
111-13
111-14
-------
1-1
I. THE GENERIC STANDARD APPROACH
For a discussion of the basis for the generic standard concept see the
report in this volume entitled "The Generic Standard Approach." The reader
is advised to read this report since the concept and essential terminology
is explained therein.
-------
II-l
II. AIR-OXIDATION PROCESSES IN THE SYNTHETIC ORGANIC
CHEMICALS MANUFACTURING INDUSTRY
A. DESCRIPTION
Oxidation chemistry is widely practiced in SOCMI. Oxidation reactions take
many forms, including the direct addition of oxygen into another compound,
increasing the proportion of electronegative elements in a compound, removing
one or more electrons from a compound, or dehydrogenating through the action of
oxygen on a compound. Sometimes additional reactants are introduced with the
oxygen in order to create other compounds, in which a case oxidation is part of
the reaction mechanism but other types of chemical reactions also occur.
A few examples of oxidation reactions are shown below:
Ethylene Oxide
CH2=CH2
+ 1/2 02
(ethylene) (oxygen)
H2C-CH2
W
0
(ethylene oxide)
Formaldehyde
CH3OH
(methanol)
1/2 02
(oxygen)
HCHO
(formaldehyde)
H20
(water)
Maleic Anhydride
H-C - C
H-C - C'
.0
O
(benzene)
(oxygen)
(maleic anhydride) (water)
2CO.
(carbon dioxide)
Acrylic Acid (reaction simplified—actually involves acrolein as an
intermediate)
CH2=CH-CH3
(propylene)
+ 3/2 02
(oxygen)
CH2=CHcf
OH
(acrylic acid)
H20
(water)
-------
II-2
Acrylonitrlle
(propylene)
NH3
(ammonia)
3/2 02
(oxygen)
CH2=CH-CN + 3H20
(acrylonitrile) (water)
Ethylene Bichloride
2CH2=CH2 + 4HC1 + 02
(ethylene) (hydrogen chloride) (oxygen)
2C1CH2CH2C1 + 2H20
(ethylene dichloride) (water)
A wide variety of reactants can be used in oxidation processes. The starting
chemicals can be aliphatic (ethylene or propylene) or aromatic (benzene) or
they can be substituted hydrocarbons (methanol). Most oxidation processes use
air as the oxygen source, some use oxygen-carrying catalysts (such as nitric
acid in cyclohexanol-cyclohexanone), and others use purified oxygen. The
mechanism of emission generation from oxygen oxidations relates to carrier
gases introduced in trace quantities in the oxygen feed and to generation of
carrier gases (CO and C02) in the oxidation reaction. Oxygen oxidation processes
can be handled through the emission projection report on chemical reactions.
This report deals only with oxidation processes (including ammoxidation and
oxychlorination) that use air as the source of oxygen. Air-oxidation processes
correspond most closely to the emission mechanism by which carrier gases are
introduced with the reactants.
Some oxidations generate no reaction off-gases (ethylene oxide) whereas others
(formaldehyde, acrylic acid, acrylonitrile, ethylene dichloride) generate
water, and still others (maleic anhydride) generate water and carbon dioxide.
Some oxidations proceed in conjunction with other feed reactants. When ammonia
is added to propylene and oxygen, ammoxidation occurs and acrylonitrile is
produced. When hydrogen chloride is added to ethylene and oxygen, oxychlori-
nation forms ethylene dichloride. These are the two most important oxidation
related reactions; however, others could and probably do exist.
B. DISTRIBUTION OF AIR-OXIDATION PROCESSES IN SOCMI
The Survey and Ranking Program established that 140 compounds account for an
estimated 86% of the SOCMI VOC emissions and identified the unit processes and
-------
II-3
unit operations associated with each ranked compound. Even though the emissions
projected include storage and fugitive emissions, the relative values clearly
identify the highest emitters from a unit process aspect as oxidation and
ammoxidation. Oxychlorination also ranks high. The unit process ranking,
Table II-l, shows that VOC emissions associated with oxidation account for a
quarter of the total from the 140 compounds ranked and for approximately 24% of
the 141 processes classed as high emitters.
Table II-2 lists some of the chemicals produced by oxidation processes in their
order as ranked during the IT Enviroscience study. The number of sites produc-
ing this chemical and the average capacity of the individual sites are also
listed. The prominence of the oxidation process is further displayed by the
histogram of Fig. II-l, which shows that oxidation products (including ammoxi-
dation and oxychlorination) account for 40% of the top 20 products in terms of
emission severity and that they occur throughout the products ranked.1
-------
II-4
Table II-l. Unit Process Ranking'
Number of Processes Total
with High Emissions Number of
(>0.01% of Processes
Unit Process Projected Total) Ranked
Oxidation
Ammoxidation
Pyrolysis
Chlorination
Ester if ication
Oxy chlorination
Dehydrochlorination.
Alkylation
Saponification
Hydrolysis
Hydrogenation
Hydration
Oxyacetylation
Dehydration
Hydro formulation
Phosgenation
Hydrobromination
Ammonolysis
Carbonylation
Nitration
Hydrochlorination
Condensation
Sulfonation
Dehydrogenation
Addition ester
Neutralization
Bromination
Peroxidation
Hydrocyanation
Reduction, cleaving, acidi-
fication, fusion, reforming,
hydrodimerization, fluorona-
tion, alcoholysis, and
hydrodealkylation
Total
30
2
8
18
11
2
5
3
1
3
5
7
2
3
6
2
3
5
2
4
2
3
2
5
1
2
1
2
1
0
141
42
3
11
29
17
3
B
7
2
10
19
9
2
6
9
2
5
11
4
4
4
5
8
6
1
6
2
3
1
0
239
Estimated Percent
of Total Emissions
(1982 Projection)
25.29
17.00
7.74
6.74
5.59
4.18
3.77
3.20
2.76
1.86
1.51
1.44
0.97
0.47
0.45
0.43
0.41
0.39
0.38
0.37
0.32
0.31
0.25
0.17
0.14
0.08
0.07
0.06
0.03
0.00
86.03b
Based on total emissions, per HI survey and ranking program; includes estimate of
fugitive, storage, secondary, and process emissions; when more than one process is
used, the emisson estimate is proportioned.
The 140 products ranked account for 86% of the estimated SOCMI emissions.
-------
II-5
Table II-2. Chemicals Produced by Oxidation Processes
— Chemicals
Acrylonitrile9
Ethylene dichlorideb
Maleic anhydride
Ethylene oxide
Dimethyl terephthlate°
Formaldehyde
Propyiene oxide
cyclohexanol/cyclohexanone
Phenol
Terephthalic acidd
Acrylic acid
Acetic acid
Acetone (phenol process)
Phthalic anhydride
Acetaldehyde
Acrolein
Acetophenone
lsophthalic acid
Benzoic acid
propionic acid
c*esylic acids
t-Butyl alcohol
Methyl ethyl ketone
Adipic acid
Formic acid
Butyric acid
Hydroscience
Ranking
2
3
4
5
6
13
15
19
22
26
28
29
32
41
65
72
81
82
83
87
94
98
105
109
124
134
Number of
Production Sites
6
17
10
16
6
54
6
8
13
3
3
7
3
2
5
3
2
4
Average Site Capacity
(M lb/yr}
358
625
51
561
693
76
386
190
275
517
251
374
164
400
60
51
67
90
19
a
Ammoxidation process.
°xychlorination process.
Dimethyl terephthalate is an ester of terephtalic acid which is produced by air
oxidation.
Terephthalic acid reported here does not include terephthalic acid used in the
Production of dimethyl terephthalate.
-------
2 \o
1 9
u)
8
7
a
o
0
5
0
Oi
LU
Cfi
2
2
z —
40%
,(% OP EANJG»E OP ZO
5%
H
I
ZI-40 4I-G>0 fcl-60 61-100 101-110
<5R.OUPlMGj OF 140 PRODUCTS RAMKJE.D
Fig. II-l. Occurrence Histogram of Oxidation Products Ranked
- 14-0
-------
III-l
III. EMISSIONS
AIR-OXIDATION PROCESSES
With regard to the influence of air-oxidation processes on VOC emissions, the
most important feature that they have in common is the requirement that air be
contacted with organic reactants. The nitrogen in the air fed to the reactors
must ultimately be released to the atmosphere, along with any other carrier
gases. Air-oxidation processes can be liquid or vapor phase and can be carried
out over a wide range of temperatures and pressures. Reactors may be the
fixed-bed or fluidized-bed type. Single reactors or multiple reactors may be
employed, with several possible gas stream recycle options. Many of these
factors can affect VOC emissions.
In vapor-phase oxidations the gases leaving the reactor contain all of the
vapor-phase product, as well as any unreacted reactants or other carrier gases.
Chemical processing equipment must then be used to separate the product from the
other gases. Most air-oxidation processes employ water or aqueous absorption to
accomplish this separation. Some organic components may not be soluble in water,
and sometimes absorbers using nonvolatile organics as the absorption fluid are
used instead of, or in addition to, water product-recovery absorbers. Liquid-
phase air-oxidation processes normally employ condensers, absorbers, or other
devices to reduce the organic content of the gases leaving the reactors.
FLOW RATE
All air-oxidation processes have in common the ultimate atmospheric release of
the carrier gases entering with the air, excess oxygen, gases formed during the
reaction, and nonseparable organics at near-atmospheric pressure. The general
oxidation process is shown in Fig. III-l. Process details beyond this general
framework are not needed to estimate the range of flow rates from air-oxidation
processes. Emission projections by the described technical approach apply to
essentially all air-oxidation reactions without regard for process details or
operating condition variables.
The total flow of gases emitted from any air oxidation process may be divided
into three classifications: (1) One group is the gases that enter with the
-------
COUTF2.0L. DE-VICE-, OR. PROCE-SSIUG,
CATALV AKAD
^CTAUT^-
A! R. ( OXYG,
AMD A IK.
r
i
i
I
i
1
i
I
x. !.
Y ' »-
I
Z 1
\ -^
1
1
1 -^
• /O\ \t2_c. P.
1
1
R.EACTIO
— i
- 1
STK
souece.
r/*\o
OK_
L\diU\DS
DlS-SOL-V
1 1
1
1
1
LEAU 1 I
^_ 1
EQUIPMEMT '
1
1 TO PROCE.«bS
I
I OK. D\SCHA^.<=jE.
1 i^ASES
1
1
1 LIQUIDS _ H
LIQUIDS AMD (qA^GSi w
DISSOLVED AKJD i TO PROCE.SS\U(q
EMTP-AlMEO ' OR. DlSCHAE^E.
1
1
1 t
|
AMD GjAeHe i HQVJIDS ^_
7ED AMD EMTeAlKJED |
. , i
Fig. III-l. General Air-Oxidation Process
-------
III-3
air required for oxidation. Air is assumed to contain 21 mole % 0 and 79 mole
% N (trace gases are included with the N ). Some or all of the oxygen is
tt £
consumed in the reaction; then the excess oxygen and all the nonreacted gases
leave in the reactor offgas (stream 1, Fig. III-l). For convenience these gases
are called air-carrier gases. (2) Organics entering the reactor as reactants
may contain reaction inert materials that may also exit with the reactor off-
gas (stream 1) and are called reactant-carrier gases. (3) Gases may be formed
during the oxidation reaction as inorganic or organic by-products. These gases
(CO, CO , HO, and others) must also leave with the reactor off-gas (stream 1)
and are called oxidation reaction-carrier gases. Depending on solubilities,
pressures, temperatures, and the specific materials present, some of the
nitrogen and other gases may leave the reactor system with liquid streams as
soluble or entrained gases. In this study it is assumed that the quantity of
these soluble or entrained gases is relatively small. (Ultimately, these
liquid-soluble gases appear as an emission from some other part of the process.)
The reactor off-gas (stream 1) enters the separation equipment. Condensers and
other processing equipment may be used instead of, or in conjunction with,
absorbers. Soluble or entrained gases leaving with the liquid stream are
assumed to be relatively small. For a base case it is assumed that the
air-oxidation process off-gas (stream 2) is emitted from an aqueous absorber
discharging at 1.5 psig and 100°F and that it is saturated with water vapor.
The total flow of this gaseous stream, S , is equal to the air-carrier gases
not removed by the separation equipment, A; plus the reaction-carrier gases
not removed by the separation equipment, R; plus the oxidation reaction-
carrier gases not removed by the separation equipment, 0; plus the water to
saturate the gases at 100°F, W. This is expressed in the following equation:
S = A + R + 0 + W , (1)
where
A = the air-carrier gases not removed by the separation equipment,
R = the reaction-carrier gases not removed by the separation equipment,
0 = the oxidation reaction-carrier gases not removed by the separation
equipment,
W = the water to saturate the gases at 100°F.
-------
III-4
The gas stream (predominately N ) at 100°F will contain 5.97 mole % water at
saturation:
W = 0.0597 S (Ib-mole/hr) . (2)
The total off-gas stream, S , may also be represented by the equation
S = G + VOC + 0.0597 S2 (3)
where
G = the total inorganic content of S (Ib-moles/hr) (inorganic carrier
gases from air-carrier gases, reactant-carrier gases, and oxidation
reaction-carrier gases not removed by the separation equipment),
VOC = the total organic content of S (Ib mole/hr) (organic carrier gases
from reactant-carrier gases, and oxidation reaction-carrier gases not
removed by the separation equipment).
Three major factors define the flow of air-carrier gases: the chemical oxida-
tion reaction stoichiometry, the quantity of product produced, and the quantity
of excess air fed to the reactor, which is dependent on the process operation
design specific to each plant.
1. Chemical Oxidation Reaction Stoichiometry
The chemical oxidation reaction stoichiometry of the processes studied identifies
four common molar oxygen ratios (MOR). The four common molar ratios (moles of
0 reacted per mole of product produced) are listed on Table III-l.
Oxidation reactions are possible with MORs of 3/4, 5/2, 9/4, 11/4, and others.
Reactions where two or more products are generated may have total MORs varying
as the selectivity varies. For example, the reaction producing 50 mole %
cyclohexanol and 50 mole % cyclohexanone from cyclohexane would show an overall
MOR of 3/4 even though the cyclohexanone reaction has an MOR of 1 and the
cyclohexanol reaction has an MOR of 1/2. The MOR is easily determined for
every product to be regulated. The data base for this study has been developed
to cover all products with MORs ranging from 1/2 to 9/2.
-------
III-5
Table III-l. Common Molar Oxygen Ratios for Oxidation Processes
MOR Products Reactants
1/2 Acetaldehyde Methanol
Acetic acid Acetaldehyde
Cyclohexanol* Cyclohexane
1 Cyclohexanone* Cyclohexane
Acrolein Propylene
3/2 Acrylonitrile Propylene + ammonia
Acrylic acid Propylene
9/2 Maleic anhydride Benzene
Phthalic anhydride Naphthalene
*Co-products of cyclohexane oxidation.
Quantity of Product Produced
^ *
The quantity of product produced varies widely from plant to plant. A review
of the information available identified a total of 158 air-oxidation plants
producing 27 different chemicals with molecular weights ranging from 30 to 194.
The average plant capacity was 222 M Ib/yr, with capacities ranging from 6 to
1300 M Ib/yr. These ranges were used to develop the data base for this study.
Excess Air to the Reactor
3-
The third major consideration in defining the flow of air-carrier gases is the
amount of excess air fed to the reactor. This is controlled by the specific
plant operations design. The factors commonly considered when establishing the
amount of excess air to be fed to the reactor include consideration of the
flammable or explosive range, chemical conversion efficiencies, and product or
by-product selectivity. The actual air flow data shown in Table III-2 resulted
from analysis of available data from 25 specific air oxidation plants.1
As shown by Table III-2 the reactor air feed may be as high as 709% of theo-
retical. In those cases where there is less than 100% theoretical air, some
oxygen must be supplied from another source, such as a chemical oxidant, or an
error is indicated. The inconsistency could result from an error in the emission
data reported, a variance between the estimated and actual production rate, the
-------
111-6
Table III-2. Air-to-Reactant Relationships for Air Oxidation Processes
(A)
Product
Acetaldehyde
Acetaldehyde
Acetaldehyde
Acetic acid
Acrylonitrile
Acrylic acid
Cyclohexanol "1
CyclohexanoneJ
Cyclohexanol "1
CyclohexanoneJ
Maleic anhydride
Maleic anhydride
Acrylic acid
Ethylene dichloride
Ethylene dichloride
Ethylene dichloride
Ethylene dichloride
Ethylene dichloride
Ethylene dichloride
Acetic acid
Cyclohexanol ^
CyclohexanoneJ
Formaldehyde
Formaldehyde
Formaldehyde
Formaldehyde
Ethylene oxide
Cyclohexanol ^
CyclohexanoneJ
(b)
Reactant
Ethylene
Ethylene
Ethylene
Acetaldehyde
Propylene (+NH ]
Propylene
Cyclohexane
Cyclohexane
Butane
Benzene
Propylene
Ethylene
Ethylene
Ethylene
Ethylene
Ethylene
Ethylene
Acetaldehyde
Cyclohexane
Methanol
Methanol
Methanol
Methanol
Ethylene
Cyclohexane
(C)
MOR3
1/2
1/2
1/2
1/2
3/2
3/2
1/2-1
1/2-1
7/2
9/2
3/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2-1
1/2
1/2
1/2
1/2
1/2
1/2-1
(D)
stoichio-
metric
Molar Air
Flow Ratio
2
2
2
2
7
7
2
4,
2.
4,
16,
21,
7,
2,
2.
2
2.
2.
2.
2.
2.
4.
2.
2,
2,
2.
2,
2.
4.
. 38
.38
.38
.38
.14
.14
.38
.76
.38
,76
.66
.43
.14
.38
.38
,38
.38
,38
.38
,38
.38
.76
.38
.38
.38
.38
.38
.38
.76
(E)
Actual
Molar Air
Flow Ratio
2.
2.
3.
2.
16.
15.
3.
7.
2.
3.
93.
132
14.
4.
1.
4.
4.
4.
1.
2.
3.
3.
1.
16.
4.
1.
10.
0.
1.
62
57
01
87
3
4
21
31
89
39
3
02
75
72
70
72
73
59
73
14
64
73
86
31
69
06
83
33
(F)
Percent of
Theoretical
Aird
110
108
127
121
228
216
135 "1
• 77.9J6
121 >
71.2J-
709
615
196
200
72.3
198
198
199
66.8
115
132 >
76.5J6
72.7
708
181
71.0
423
34.9^1
27.9>'f
(G)
Flanyndble Lim
(moles of air
mole of react
I.F.I
37,
37.
37.
25.
50,
50,
76.
76.
55.
76.
50.
37.
37.
37.
37.
37.
37.
25.
76.
14.
14,
14,
14,
37,
76,
its (H)
per Flammable Classification
ant' „ T_ Below
DEL UEL Range LEJ._
,0
,0
,0
,0
,0
,0
9
9
6
9
,0
,0
,0
,0
,0
0
,0
,0
,9
.9
,9
.9
,9
,0
.9
2
2
2
16
9
9
12
12
e
14
9
2
2
2
2
2
2
16
12
2
2
2
2
2
12
.78 X
.78 X
.78 X
.7 X
.01 X
.01 X
.5 X
.5 X
.4 X
.1 X
.01 X
.78 X
.78 X
.7B X
.78 X
.78 X
.78 X
.7 X
. 5 X
.78 X
.78 *
.78 X
.78 X
.78 X
.5 X
aMoles of O reacted per mole of product produced.
bAasumes 4.76 moles of air per mole of 02 (Col C X 4.76).
Calculated from actual reported reactor emission data; see ref 1.
dActual air flow vs stoichiometric air flow [100 (Col E t Col D)].
"Reflects the selectivity of co-products Cyclohexanol, cyclohexanone; average value
'process uses UNO as a chemical oxidant; excess air requirements significantly les:
used for calculations.
than theoretical.
-------
III-7
assumption that stoichiometric conditions exist when calculating the air fed to
the reactor from emission off-gas data, or variances in the reaction conversion.
These errors are not particularly important since the purpose of this approach
is the development of a flow range and not of a specific value.
Table II 1-2 also lists the lower explosive limit (LEL) and upper explosive
limit (UEL) for each reactant and the apparent operating position of each reaction
in relation to these explosion limits. Analysis of the available data indicates
that 46% of the processes operate organic-rich (above the upper limit), 13%
operate organic-lean (below the lower limit), and 42% appear to operate in the
flammable or explosive range. Through the use of process variations, such as
back-mix reactors (fluidized bed, gas stream recycle), compounds added to modify
the flammable range, and sophisticated heat transfer systems, the processes
indicated to be used in the flammable range may not actually be operated in the
flammable range and the risk of explosion may be remote. To establish the
bases for design and costing for this study the range of theoretical air in
excess of 700% was used. Very few of the air-oxidation processes being used
today require theoretical air near 700%. Therefore, by setting this amount as
a limit, the flow-rate range developed should include nearly every air-oxidation
process in operation.
4- Total Off-Gas Flow
The total quantity of air-source gases in Ib-moles/hr, A, may be expressed by
the following equation:
A = 4.76 Ib-moles of air x CA£ x MOR X F (4)
where
Ib-mole of 02 MW
CAP = plant capacity (Ib/hr),
MW = product molecular weight (Ib/lb-mole of product) ,
= stoichiometric molar oxygen ratio (Ib-moles of 02/lb-mole of
MOR
product) ,
F = ratio of actual air to reactor/ theoretical stoichiometric air
requirement.
Except for specific identifiable reactions the total reactor off-gas can best
be estimated through knowledge of the excess air feed to the reactor. Within
-------
III-8
the accuracy of the design and cost projections possible for this study of air-
oxidation reactions, the percent of theoretical air listed in Table III-2,
column F, is the best factor for calculating the total reactor off-gas. By
allowing the factor F to apply to all non-VOC off-gas emissions (water vapor
from the scrubber, air-carrier gases, reactant-carrier gases, and oxidation
reaction-carrier gases), the total reactor off-gas (Ib-moles/hr) for oxidation
reactions can be estimated by Eq. (4) as follows:
, . , . ..... 4.76 Ib-moles of air „ CAP „ ..._ „ „ ,rx
total reactor off-gas = — ; ^-r X -rr- X MOR X F . (5)
y Ib-mole of 0_ MW
2 p
The F-factor ratio is not signficantly different when calculated as "actual
air to reactor/theoretical stoichiometric air required" or as "total off-gas
from reactor/ theoretical off-gas from stoichiometric air requirement". There-
fore the total offgas flow for control device design can be projected by knowledge
of the F ratio determined by either means, the molecular weight of the product
produced, and the plant production rate.
The F-ratio has been correlated with several physical parameters in vapor-phase
air oxidations. Important variables in this correlation are the average reactor
temperature, the autoignition temperature of the feedstock, and the explosive
limits of the feedstock mixture. Although the level of precision related to
the use of this mathematical correlation is not necessary to estimate the
flow-rate range for the purpose of this report, it may be useful in developing
more accurate predictions of flow from air-oxidation processes.2
The total off-gas flow rate projection for air oxidation processes, Fig. III-2,
was formed by using Eq. (5) and the data from Table III-2 plus actual plant
data available from the production of 28 air-oxidation products (see Appendix
A). A family of total off-gas index curves [combining MOR and F from Eq. (5)]
is plotted on Fig. III-2 to facilitate the projection of off-gas flow rates for
the full range of product molecular weights and plant capacities. The flow
rates have been converted to a plant capacity of scfm* per million pounds a
*Standard conditions used throughout this report are 32°F and 760 mm Hg.
-------
111-9
50 100
MOl_ecUL_AR.
ZOO 2SO 300
PRODUCT ( MWp")
Fig. III-2. Total Off-Gas Flow-Rate Projection for Air-Oxidation Processes
-------
111-10
year to allow projection of the required control device design and cost. The
off-gas flow-rate error caused by not adjusting for VOC content will normally
be less than 2% and is discussed later in this report.
C. VOC CONCENTRATION
Determination of the VOC concentration of air-oxidation reactor off-gas would
require very specific process data for every plant. Application of the absorb-
er design equation for determination of off-gas VOC concentration would require
determination of the overall number of gas-phase transfer units in the absorber,
the mass velocity of the gas, the mass velocity of the liquid, the mole
fraction of VOC in the liquid at the absorber gas exit, the slope of the
equilibrium line and, the concentration of VOC in the gas entering the absorber.
It is very clear that such a determination of VOC concentrations is impractical.
However, since the purpose of an emission projection for a generic approach is
the definition of a range of VOC compositions, assumptions may be made to ade-
quately define the needed range.
Because there appears to be no obvious single point defining the range limi-
tation and because it takes very little effort to display an expanded range,
the maximum concentration range was determined by establishing a point that
would be clearly illogical to exceed. This maximum point was established by
assuming that the greatest amount of VOC leaving in the scrubber off-gas is
equal to the total flow of product being produced. Given this assumption, the
maximum VOC concentration can be calculated by the following equations:
voc . • (6)
vor TAP PAP
VUL U* v (4.76 X ^ X MOR X F) ,
max total reactor off-gas MW MW
P P
or
Y = I (7)
max 4.76 X MOR X F '
-------
III-ll
where
VOC = total VOC in off-gas (Ib-moles/hr),
CAP = plant capacity (Ib/hr),
MW = product molecular weight (Ib/lb-mole of product),
Y = maximum VOC concentration (mole fraction),
Total reactor off-gas - [see Eq. (5)] where it is assumed that:
4.76 Ib mole air/lb-mole of 0 and
MOR X F = total absorber off-gas flow index.
A comparison of projected maximum VOC concentrations to actual VOC concen-
trations available for this study is shown by Table III-3. The actual VOC
concentrations are also displayed by the histogram of Fig. III-3. The actual
plant data currently available for 11 plants show all off-gas emissions to
contain less than 5% VOC.1
The full range of the index of absorber off-gas flow (MOR X F) used for the
total off-gas flow-rate projections shown by Fig. III-2 has been used to cal-
culate the maximum potential VOC concentrations shown on Fig. III-4.
The significant conclusions from Fig. III-4 that affect thermal oxidation
design, size, and cost are that (1) any off-gas with a flow index (MOR X F)
greater than 2 must have a VOC concentration of less than 10 mole %, (2)
quantitative verification is provided to show that only relatively low off-gas
flows can have VOC concentrations greater than 10 mole %, and (3) the highest
off-gas VOC concentration observed from limited available data is less than
5 mole %.
Since the maximum VOC concentration indicated by Fig. III-4 is based on the
unrealistic assumption that all product might be emitted as off-gas, actual VOC
concentrations will normally be considerably lower.
-------
111-12
Table III-3. Air Oxidation Absorber Off-Gas VOC Compositions*
Actual VOC
Composition
Range
(mole %)
Less than 0.1
0.1 -'0.499
0.5 - 0.999
1.0 - 1.999
2.0 and greater
Products
Acetic acid
Acetaldehyde
Acetaldehyde
Formaldehyde
Acetaldehyde
Acetic acid
Cyclohexanol/cyclohexanone
Cyclohexanol/cyclohexanone
Maleic anhydride
Cyclohexanol/cyclohexanone
Formaldehyde
Ethylene dichloride
Acrylonitrile
Ethylene dichloride
Acrylic acid
Ethylene dichloride
Ethylene dichloride
Actual VOC
Composition
(mole %)
0.002
0.03
0.036
0.049
0.17
0.21
0.26
0.34
0.40
0.498
0.54
0.80
0.81
1.05
1.39
1.90
2.52
Maximum
voc t
Composition
(mole %)
37
39
38
58
33
35
20 - 40
20 - 40°
0.85
20 - 40°
5.9 - 23d
63
6.1
34
7.2
50
58
— •
See ref 1.
Calculated by Eq. (7).
CDepending on product mix.
Depending on degree of off-gas recycle.
-------
\f\
r
I
a.
U.
0
oi
u)
cC
2
D
2
4-
•z .
H
H
H
N»
U)
UK1DG.P.
O.I
O. I -
0-5
0.5-
i .o
1.0-
z.o
2.0-
5-0
5.0-
IO.O
OVEJ2.
IO.O
VOC COMPOSITION
( MOL-E. °/o )
Fig. III-3. Distribution of Actual Absorber Off-Gas VOC Composition Data Found in HI Study
-------
H
H
I
H
£>.
A&SOR.&&R.
FOUMD IU HI STUDY
VOC
30 32.
12. 14 10, \& 20 ZZ 2XU 2G» 2£>
OF AE>SO^fcER OFF-G^b FUOW ( MQK. x F)
XXX-4. Waxim\ffl\ Off-Gas VOC Concetvtrati.oTv as a ¥\mctiotv of Off-Gas Flow Xndex Factor
54-
-------
111-15
D - REFERENCE*
1- Site visits and letters received by EPA describing processes and emissions.
See Appendix A for a list of information sources.
2- A. Miles and B. Newman, "Statistical Analysis and Industry Profile," Energy
and Environmental Analysis draft report to the EPA, October 1979.
*When a reference number is used at the end of a paragraph or on a heading, it
usually refers to the entire paragraph or material under the heading. When,
however, an additional reference is required for only a certain portion of the
paragraph or captioned material, the earlier reference number may not apply to
that particular portion.
-------
IV-1
IV. CONTROL OPTIONS
A variety of control devices for organic emissions were reported on in control
device evaluation reports. These reports discuss the limitations of each
control device and offer costs as functions of the applicable flow and composition
ranges for each device. Table IV-1 summarizes the cost-effectiveness for each
control technology for a typical case. This table should only be used to
identify the most cost-effective technologies in a general way since other
considerations may cause the costs to change. When a control technology is
selected, the control device evaluation reports may be used to more completely
identify the costs.
Air oxidation processes generate waste gases at flows from under 1000 scfm to
100,000 scfm and are typically dilute in VOC (the highest composition found in
this study was about 2 vol %). Air oxidation processes would therefore span
the flow range presented in Table IV-1 and be in the low and medium concentration
catagories. Therefore, technologies appropriate for control of air oxidation
processes are condensation, absorption, adsorption, catalytic oxidation, thermal
oxidation, and high temperature oxidation.
Condensation is most appropriate for waste gases of flows under 5000 scfm. It
is only effective where the VOC present is condensible or in other words, not
an organic carrier gas. Since in air oxidation processes reactants and products
must be separated from the waste gas, it is likely that if condensation is
effective in reducing organic losses, it has already been utilized in the
process. Further information on condensation is available in the control
device evaluation on condensation.
Absorption is also a technology which would be expected to exist today in air
oxidation plants. In fact, aqueous absorption is assumed to be present in the
process prior to generation of the waste gas. Although in some cases adding
additional absorption equipment may be possible, it is unlikely that organic
removals above that achieved by the existing equipment could approach 90%.
Absorption is also discussed in more detail in a control device evaluation
report.
-------
Table IV-1. Representative Cost-Effectiveness for Organic Emission Control Technology
Waste Gas
Flow
(scfm) C
500—700
1000
5,000
50,000
Cost Effectiveness (per Ib of VOC) for
oncentration Condensation Absorption
Low
Medium
High
Low
Medium
High
Low
Medium
High
Low
Medium
High
$0.20
0.03
0.06
0.14
0.02
0.04
1
1
1
1
1
1
i
i
i
$0.56 — 1.07
0.06 — 0.11
i
0.20 — 0.55
0.04 — 0.08
i
0.02 — 0.18
0.10 — 0.45
i
Adsorption
i
i
i
$0.13—0.15
k
k
0.06 — 0.08
k
k
0.03 — 0.05
k
k
Flares6
j
j
i
j
j
$0.001
j
j
i
j
j
i
Catalytic
Oxidation^
$0.31 — 0.37
k
k
i
k
k
0.09 — 0.12
k
k
0.05 — 0.07
k
k
Thermal High-Temperature
Oxidation9 Oxidation*1
$0
0
0
0
0
0
0
0
0
.55 — 0.62
.09 — 0.11
.06
i
i
i
.25 — 0.29
.02 — 0.04
.01
.20 — 0.24
.01 — 0.02
.007
$0
0
0
0
0
0
0
0
0
.78 — 1
.20 — 0
.12 — 0
i
i
i
.44 — 0
.13 — 0
.09 — 0
.37
.11
.08
.29
.30
.17
.78
.19
.12
aLow s 0.5 vol % or 10 Btu/scf; medium = 5 vol % or 50 Btu/scf; high = 20 vol % or 100 Btu/scf.
b95% removal efficiency; no VOC credit.
°99% removal efficiency? Lm/mG^ = 1.4; steam ratio «= 0.2 moles of steam/mole of waste gas; no VOC credit.
^70—12 ppm effluent; 6.96 Ib of carbon/1000 scf; no VOC credit; loading - 0.1 Ib of VOC/lb of carbon, molecular weight
of VOC « 50.
6Based on 100% VOC of propylene at 100% of capacity. Flares normally operate intermittently at a low fraction of
capacity.
f90—90% destruction efficiency; no heat recovery.
9gg—gg% destruction efficiency; no heat recovery, 1400—1600°F combustion temperature.-
h99.9% destruction efficiency; no heat recovery, 2200—2600°F combustion temperature.
XCosts not available.
applicable at low concentrations.
applicable at Yxigh concentrations.
I
to
-------
IV-3
Carbon adsorption can only be applied at low-VOC concentrations. It compares
attractively to all control technologies on a cost-effectiveness basis. However,
in addition to its concentration limitations, carbon adsorption is not effective
on a number of organic compounds. Where it is applicable carbon adsorption is
expected to be highly cost-effective. A control device evaluation report on
adsorption more completely defines its limitations.
Catalytic oxidation is only applicable for low VOC concentration waste gases as
long as catalyst poisons aren't present. Catalytic oxidation can be more cost
effective than thermal oxidation if it can be applied to the waste gas. Further
information on catalytic oxidation may be found in the control device evaluation
report on catalytic oxidation.
Thermal oxidation applies to the flow range and concentration range of waste
gases from an oxidation process. In addition, all organic compounds can be
oxidized in thermal oxidation units. However, thermal oxidizers do utilize
significant quantities of fuel when burning low-concentration waste gases.
Thermal oxidation is discussed in the thermal oxidation control device evalua-
tion.
When compounds containing sulfur or other particular elements are present in
the waste gas, noxious compounds are emitted in the flue gas. Scrubbers are
then required to remove the noxious gases from the flue gas prior to discharge.
When chlorine-containing compounds are present, the combustion temperature must
be increased to convert the Cl to HCl instead of Cl2. This aids the removal of
chlorine from the flue gas. These special cases of thermal oxidation are
discussed in the thermal oxidation supplementary control device evaluation.
-------
V-l
V. SUMMARY
Air-oxidation processes are major contributers of organic emissions. A method
of estimating the range of flow and VOC concentration from air-oxidation processes
has been developed.
Control technologies technically applicable to air-oxidation organic emissions
are thermal oxidation, high-temperature thermal oxidation, catalytic oxidation,
and carbon adsorption. Condensation and absorption are assumed to be part of
the process. More detailed discussions of the technical and economic considera-
tions of these control devices can be found in the Control Device Evaluation
reports on each of these technologies. Economic, environmental, and energy
inpacts of control of air-oxidation organic emissions can be developed over the
flow and VOC concentration ranges as established in this report.
-------
APPENDIX A
LIST OF EPA INFORMATION SOURCES
-------
A- 3
J- J. Cudahy and J. F. Lawson, IT Enviroscience , Inc., Trip Report on Visit
Regarding Lonqview. TX, Plant of Texas Eastman, Nov. 16, 1977 (on file at EPA,
ESED, Research Triangle Park, NC) .
• J. Cudahy and J. F. Lawson, IT Enviroscience, Inc., Trip Report on Visit
Regarding Clear Lake. TX, Plant of Cleanese Chemical Co., Sept. 22, 1977 (
file at EPA, ESED, Research Triangle Park, NC) .
J- A. Key, IT Enviroscience, Inc., Trip Report on Visit Regarding Clear
on
> TX. Plant of Celanese Chemical Co., Oct. 12, 1977 (on file at EPA, ESED,
Research Triangle Park, NC) .
4. j ,
°- A- Key, IT Enviroscience, Inc., Trip Report on Visit Regarding
Beaumont. TX. Plant. of E. I. du Pont de Nemours & Co., Sept. 7, 1977 (on file
at EPA, ESED, Research Triangle Park, NC).
- W. Blackburn, IT Enviroscience, Inc., Trip Report on Visit Regarding
P-igJLPark. TX. Plant of Rohm and Haas Co., Nov. 1, 1977 (on file at EPA, ESED,
Research Triangle Park, NC) .
6 . W n n
• u • Bruce, IT Enviroscience, Inc., Trip Report on Visit Regarding
, FL. Plant of Monsanto Textiles Co., Feb. 8, 1978 (on file at EPA,
ESED, Research Triangle Park, NC) .
• D- Bruce, IT Enviroscience, Inc., Trip Report on Visit Regarding
^H2Hsta_, GA, Plant of Nipro, Inc., Apr. 18, 1978 (on file at EPA, ESED,
Research Triangle Park, NC) .
8. j
• F- Lawson, IT Enviroscience, Inc., Trip Report on Visit Regarding
£JH£ao;o, IL. Plant of Amoco Chemicals Corporation. Jan. 24, 1978 (on file at
EpA, ESED, Research Triangle Park, NC).
9
J- F- Lawson, IT Enviroscience, Inc., Trip Report on Visit Regarding
is^IL. Plant of Reichhold Chemicals, Inc., July 28, 1977 (on file at EPA,
EsED, Research Triangle Park, NC).
-------
A-4
10. C. R. DeRose, Celanese Chemical Co., Houston, TX, letter to L. Evans, EPA,
Apr. 21, 1978.
11. W. M. Reiter, Allied Chemical Co., Morristown, NJ, letters to D. R. Goodwin,
EPA, Apr. 18, 1975, June 18, 1975, and May 18, 1978.
12. J. A. DeBernardi, Conoco Chemicals, Westlake, LA, letter to D. R. Goodwin, EPA,
May 16, 1978.
13. W. C. Holbrook, B. F. Goodrich Co., Cleveland, OH, letter to D. R. Goodwin,
EPA, Apr. 7, 1975.
14. K. D. Konter, B. F. Goodrich Co., Cleveland, OH, letter to L. Evans, EPA, June
15, 1978.
15. R. J. Samelson, PPG Industries, Pittsburgh, PA, letter to D. R. Goodwin, EPA,
June 2, 1978.
16. F. C. Dehn, PPG Industries, Pittsburgh, PA, letter to D. R. Goodwin, EPA,
Apr. 15, 1975.
17. A. T. Raetzsch, PPG Industries, Lake Charles, LA, letter to D. R. Goodwin, EPA,
June 21, 1974.
18. R. E. Van Ingen, Shell Oil Co., Houston, TX, letters to D. R. Goodwin, EPA,
Apr. 10, 1975, and June 25, 1975.
19. J. A. Mullins, Shell Oil Co., Houston, TX, letters to D. R. Goodwin, EPA,
May 1, 1978, and June 22, 1978.
20. J. C. Edwards, Tennessee Eastman Co., Kingrport, TN, letter to D. R. Goodwin,
EPA, May 15, 1978.
21. D. W. Smith, E. I. du Pont de Nemours & Co., letter to D. R. Goodwin, EPA,
Apr. 20, 1978.
-------
A-5
5o
D- W. Smith, E. I. du Pont de Nemours & Co., letter to R. T. Walsh, EPA,
Sept. 28, 1978.
c- «*. Schaefer, Celanese Chemical Co., letter to D. R. Goodwin, EPA, Apr. 21,
1978.
24 w
v- J. Tretter, Jr., Georgia-Pacific Corp., Portland, OR, letter to D. R. Goodwin,
EpA, July 19t 1978.
25. P _ „
r- i>- Hewett, Reichhold Chemicals, Inc., Detroit, MI, letter to R. Love 11,
Hydroscience, July 21, 1978.
26 n
u- E. Gilbert, Vulcan Materials Co., Geismar, LA, letter to D. R. Goodwin, EPA,
APr- 23, 1975.
27
c- V. Gordon, Vulcan Materials Co., Geismar, LA, letter to L. Evans, EPA,
Oct- 24, 1978.
28
w- R. Taylor, Diamond Shamrock, Cleveland, OH, letter to D. R. Goodwin, EPA,
Oct- 3, 1977.
-------
4-i
REPORT 4
VACUUM SYSTEM EMISSION PROJECTIONS
J. W. Blackburn
IT Enviroscience
9041 Executive Park Drive
Knoxville, Tennessee 37923
Prepared for
Emission Standards and Engineering Division
Office of Air Quality Planning and Standards
ENVIRONMENTAL PROTECTION AGENCY
Research Triangle Park, North Carolina
December 1980
D61G
-------
4-iii
CONTENTS OF REPORT 4
Page
I. THE GENERIC STANDARD APPROACH 1-1
II- VACUUM SYSTEMS IN THE SYNTHETIC ORGANIC CHEMICALS MANUFACTURING II-l
INDUSTRY
A. Major Uses of Vacuum II-l
B. Types of Vacuum Devices II-3
C. Distribution of Vacuum Systems in SOCMI II-9
IH- DESCRIPTION OF EMISSION III-l
A. Flow Rate III-l
B. VOC Composition III-9
C. Actual Vacuum System Emissions 111-17
JV. APPLICABILITY OF CONTROL DEVICES TO VACUUM SYSTEMS IV-1
A. In-Process Control IV~1
B. Add-On Controls IV'1
V- SUMMARY V'1
v*. REFERENCES V3>1
APPENDIX OF REPORT 4
A. LIST OF EPA INFORMATION SOURCES A-3
-------
4-v
TABLES OF REPORT 4
Number
-1*-! Maximum Thermal Efficiencies of Vacuum Sources II-7
Ix~2 Estimated Number of Vacuum Processes in Chemical Processes 11-10
Studied by Hydroscience
i Leak Rates of Fittings in Vacuum Equipment III-2
2 Minimum Inert-Gas Concentration for Operation to Be III-5
Entirely Out of the Explosion Envelope
Inert-Gas Flow-Estimates to Prevent Operation in the III-6
Explosion Range
Contribution of Inert Gases from Dissolved Gases in III-7
Organic Liquids
11-5 Gas Flow from Contact Condensers or Seal Water III-7
I:~6 Steam Consumption, Water Consumption, and Steam-Ejector III-8
Gas Flow from Water-Dissolved Gases
7 Gas Flow from Chemical Decomposition III-9
*~8 Actual Emission Data from Vacuum Systems 111-18
V-1 Representative Cost-Effectiveness for Organic Emission IV-3
Control Technology
-------
4-vii
FIGURES OF REPORT 4
Page
Three-Stage Steam Ejectors with Contact Condensers II-5
and a Barometric Seal
H-2 Three-Stage Steam Ejector with Surface Condensers and a II-6
Condensate Receiver System
H-3 Some Configurations of Mechanical Vacuum Pumps II-8
II-4 Flow Diagram for a Process Utilizing Vacuum Reactors and 11-11
Absorbers (Acetic Anhydride)
II-5 Flow Diagram for a Process Utilizing Vacuum Distillations 11-12
(Glycerin)
II-6 Flow Diagram for a Process Utilizing Vacuum Crystallizers 11-14
(Adipic Acid)
III-i Estimation of a Vacuum System's Leak Rate from Equipment III-3
Dimensions
Hl-2 Vacuum Process with Surface Condensers and Condensate Receiver III-ll
III-3 Vacuum Process with Contact Condensers and Barometric Seal 111-12
III-4 Vacuum Process with Water-Sealed Vacuum Pumps 111-13
Hl-5 Vacuum Process with Oil- or Gas-Sealed Vacuum Pumps 111-15
III-6 Saturation Concentrations of Specific Organic Compounds in Gas 111-16
-------
1-1
I. THE GENERIC STANDARD APPROACH
For a discussion of the basis for the generic standard concept see the report
in this volume entitled "The Generic Standard Approach." The reader is advised
to read this report since the concept and essential terminology is explained
therein. This report is an overview of the potential organic emissions from
vacuum systems in SOCMI and was based only on existing data collected during
the beginning of the IT Enviroscience study. This report has served as the
basis of further work by other EPA contractors. Their work will improve the
available data base on vacuum systems and provide additional detail as may be
needed to form the basis for preparation of the standards.
-------
II-l
II. VACUUM SYSTEMS IN THE SYNTHETIC ORGANIC CHEMICALS MANUFACTURING INDUSTRY
A- MAJOR USES OF VACUUM
Vacuum processes in the chemical industry relate to any processes operated at
pressures below atmospheric pressure (760 mm Hg) . In reality, most vacuum
processes (such as solvent distillation) are performed at pressures greater
than 1 mm Hg although in some special cases, such as molecular distillation,
pressures as low as 0.01 mm Hg can be involved.
Advantages of Using Vacuum
Processes operated under vacuum have three advantages compared to their atmos-
pheric or elevated pressure counterparts. These advantages are associated with
thermal effects, fluid-transfer effects, or special effects.
Thermal Effects of Vacuum - Advantages related to thermal vacuum effects arise
from the chemical exerting a higher partial pressure under reduced pressure
(vacuum) than at atmospheric or elevated pressures (with the temperatures assumed
to be the same) . Consequently the boiling point of the liquid is lowered (compared
to that at atmospheric pressure). This approach has utility when the liquid or
a component in the liquid is highly reactive or is prone to decomposition.
Undesirable reactions and decompositions are often related to temperature, and
therefore processes operating at lower temperatures (because of vacuum) have
much less product loss to undesirable by-products.
Compounds for which vacuum processing is used to forestall undesirable side
reactions or decomposition include high-molecular-weight alkenes, aldehydes,
carboxylic acids, alcohols, and other compounds with reactive functional groups.
Vacuum is also used to modify the operating conditions so that lower grade
heat sources (such as 150-psi steam) can be used.
Transfer Effects of Vacuum - Fluids flow from higher pressures to lower
Pressures. Vacuum generates the low pressure into which liquids, gases, and
slurries can flow. This approach is used in those simple cases where the objective
is to transfer liquids from one vessel to another without the use of liquid
-------
II-2
pumps, since the mechanical shear generated in pumps can be deleterious to process
chemicals. More complicated applications of vacuum for fluid flow include vacuum
filtration. In those cases liquid-solid slurries flow to the filter media
surface, where the solids remain and form a cake and the liquids pass through.
The liquid flow is induced by atmospheric pressure pushing the liquid in the
direction of the vacuum.
c. Special Effects of Vacuum Vacuum is sometimes used in reactions or separa-
tions to achieve yields or separation efficiencies between components, which
are difficult or impossible to achieve at atmospheric or elevated pressures.
This often results in beneficial changes in physical properties at reduced
pressures. For instance, compounds with very similar vapor pressures at
atmospheric pressure but with divergent vapor pressures at reduced pressures
may easily be separated by distillation under vacuum, whereas distillation at
atmospheric pressure would be difficult.
2. Types of Vacuum Processes
Nearly any type of chemical process vessel may be designed to operate under
vacuum. These vessels are categorized as reactors, absorbers, distillation
units, crystallizers, and filters.
a. Vacuum Reactors Reactors are placed under vacuum primarily to take advantage
of the different thermal characteristics of the chemicals being handled, although
sometimes special vacuum effects are important. Lowered boiling points allow
chemicals to be removed by vaporization during the reaction, thus improving
conversion and decreasing undesirable side reactions and decomposition of
sensitive chemicals. Reducing the pressure can also affect conversions by
shifting reaction rates to favor the products desired. Some reactors operate at
reduced pressure to increase the selectivities or to improve reaction yields.
Physical property changes with reduced pressure improve performance compared to
that obtained at atmospheric pressure.
b. Vacuum Absorbers Vacuum absorbers may be used after a vacuum reaction in which
a component of the reaction off-gas is to be recovered by absorption. The vacuum
device is usually placed at the end of the reactor-absorber train and supplies
the motive force for gas flow through the absorbers.
-------
II-3
Vacuum Distillation Units Vacuum distillation units are used for reasons similar
to those applying to the vacuum reactors. Thermal effects of lowered boiling
points to lessen decomposition or enhanced separations because of such special
Affects as physical property changes are usually significant. Low-temperature
vacuum distillation often provides an economic advantage by allowing the use of
a lower temperature, less expensive heat supply.
Crystallizers Vacuum crystallizers often utilize the thermal effects
of lowered boiling points under reduced pressure to remove solvents, which
generates efficient cooling and also causes solute concentrations to increase
and thereby form solids. Vacuum operation is preferred when the solids
are temperature-sensitive or have low melting points or to prevent scaling of
surface heat exchangers.
Vacuum Filters The decision of whether to select vacuum filters or pressure
filters largely depends on the filtration characteristics of the slurry being
filtered and the properties of the resulting filter cake. These considerations
result from actual laboratory testing and are very specific to the stream being
filtered. Vacuum filtration is used widely in processing industries.
n
TYPES OF VACUUM DEVICES
Two major types of vacuum-generating devices exist: ejectors or eductors and
Pumps. Ejectors or eductors develop vacuum or reduced pressure when steam or
liquids flow through restricted passages or Venturis. Vacuum pumps utilize
mechanical drives and positive-displacement actions to generate vacuums.
1. „.
fcjectors or Eductors
The most common vacuum device used in past industrial operation is the steam
Rector. Eductors are similar to ejectors except that they use liquids as the
motivating fluid. Ejectors can generate pressures as low as 0.0001 mm Hg
by using five or six ejector stages. The jas-handling capacity and vacuum
developed by an ejector is strongly dependent on the throat diameter of the
venturi and other venturi design variables. Ejectors can be designed for very
large flows. For example, systems with capacities in the millions of scfm of
have been constructed in the aerospace industry. Ejectors in use in SOCMI
capacities of less than 10,000 scfm, with the majority being less than
1°00 scfm.
-------
II-4
Steam ejectors are designed with either contact or surface condensers and usually
with barometric seal legs about 35 ft long. Surface-condenser systems can be
designed with a condensate receiver and discharge pump in place of the barometric
seals. The condensers condense the steam and any condensible vapors in the
waste gas, and the barometric leg or condensate receiver seals the vacuum device
from atmospheric pressure. A three-stage steam ejector system with contact
condensers and a barometic seal is shown in Fig. II-l, and one with surface
condensers and a condensate receiver system is shown in Fig. II-2. Surface
condensers can also utilize barometric seals. Considerable water is used to
condense the steam in a contact condenser system and usually becomes a waste-
water or secondary emission source since it becomes contaminated with organics
present in the vacuum process. Although surface condensers prevent the organic
vapors from being contacted with water, thus allowing for water recycling
through cooling towers, they are more expensive to install than contact con-
densers. Surface condensers can often be more practical and economical than
contact condensers because of the possibility of recovering VOC, of the likeli-
hood of using emission control that is more cost-effective, and of VOC not having
to be separated from the cooling water.
The design of ejector systems reguires information on the the following param-
eters:1* suction temperature, capacity (rate for each constituent), component
information (molecular weight, vapor pressure, and water solubility of each
component), evacuation requirements (system volume, leak rates, initial and
final pressures, evacuation times, evaporation rates of any liguid in the
system), suction pressure, motive steam temperatures and pressures, maximum
discharge pressure, cooling water temperature, construction materials, condenser
requirements, space limitations, and other considerations.
2. Vacuum Pumps
Vacuum pumps can be classified generally as water-sealed, oil-sealed, or gas-
sealed pumps. Water-sealed pumps have the general design of a vane impeller
rotating in a casing filled with water (or another process fluid). Air is
captured at the pump suction and released at the pump discharge, thereby generating
a reduced pressure. Oil-sealed pumps utilize a principle similar to that of
water-sealed pumps except that circular, elliptical,or other complex-shaped
*See Sect. VI for references cited in this report.
-------
II-5
6TEAM
VEKIT TO
OR CCKJTROL.
DEVICE
' . ~ ^ WATER
"HOT
Fig. II-l. Three-Stage Steam Ejectors with Contact Condensers
and a Barometric seal
-------
II-6
CO01-', NIG
PUMP
Fig. II-2. Three-Stage Steam Ejector with Surface Condensers
and a Condensate Receiver System
-------
II-7
rotary pistons or vanes capture the air at the suction, and close oil-lubricated
tolerances, instead of water seals, seal the suction from the discharge. Gas-
sealed pumps (sometimes called dry pumps) use no seal liquid but depend on sur-
faces machined to close tolerances to achieve vacuums. Figure II-3 is a simplified
diagram of some configurations of mechanical vacuum pumps.
Water-sealed vacuum pumps achieve pressures of about 150 mm Hg with single-stage
design and 20 to 30 mm Hg with two-stage design. Capacities can range over
20,000 cfm. Oil-sealed pumps can achieve pressures as low as 0.0001 mm Hg, and
capacities of up to 1500 cfm are available. Gas-sealed pumps have capacities
°f up to 6600 cfm and can develop pressures as low as 0.0001 mm Hg.2'3
Design or detailed discussion of the vacuum sources is beyond the scope of this
study. Many references are available for further discussion of steam ejector
— 11 and vacuum pump selection and design.12 — 16
Usage of Vacuum Devices
Since ejectors are commonly powered by steam, considerable energy may be consumed
in maintaining the vacuum. In fact, steam ejectors are the highest energy con-
sumers of vacuum devices. Energy efficiencies for various vacuum sources are
shown in Table II -I.17
Table II-l. Maximum Energy Efficiencies of Vacuum Sources
Suction Pressure
Maximum Energy at Maximum
Efficiency Energy Efficiency
Vacuum Source (%) ^""n n<3>
Roots type blower, gas-sealed
Rotary piston, oil-sealed
Liquid ring, water-sealed
Liquid eductor
Steam ejector
68
F4
48
25
6
600
150
300
300
10
-------
II-8
IMFELUE?
USJID SEAL.
SUC T\ OKI
P^TA?^
C=;<=rrc:vj
Cl L - S£A_
'EF, VACUUM
Fig. II-3. Some Configurations of Mechanical Vacuum Pumps
-------
II-9
Vacuum pumps are presently being considered as replacements for many of the
duties traditionally performed by steam ejectors, primarily because of their
lower energy costs. The high-energy consumption of steam ejectors is leading
to increased use of vacuum pumps in SOCMI. This trend is expected to continue,
steam ejectors will probably always be found in SOCMI.
C- DISTRIBUTION OF VACUUM SYSTEMS IN SOCMI
No comprehensive detailed information is available on the exact number and use
°f vacuum devices in SOCMI . Vacuum processes can be highly confidential to the
chemical companies and will vary substantially from site to site. During the
course of the IT Enviroscience study of chemical processes a significant body
°f information was collected on emission sources . An index of products studied
by IT Enviroscience for which vacuum processes are used or believed to be used
is given in Table II-2. Product reports generated by IT Enviroscience are the
Primary sources for this information but in some cases individuals who authored
these reports suspected the use of vacuum processes even if the model plant
flowsheets do not show vacuum equipment. A list of IT Enviroscience reports
supporting Table II-2 are presented in the Appendix.
figures H-4, II-5, and II-6 show examples of processes that use vacuum reactors,
absorbers, distillation units, and crystallizers. No data on vacuum filtration
were requested or collected in the IT Enviroscience study. It is quite possible
that the filtration unit shown on some of the study flowsheets are vacuum fil-
tration units, since this type of operation is used extensively in the industry
when filtration is required.
Of the 99 distillation operations on which IT Enviroscience has data, one- third
were found to be vacuum distillation units. The average VOC emission from all
distillation units is about 10.7 Ib/hr. But the average VOC emission from vacuum
distillation units alone is about 15 Ib/hr. A study on the use of vacuum distil-
lation in petroleum refineries18 shows that 35% of the refinery capacity is
vacuum-distilled.
A variety of preliminary plant designs for 25 products and 151 processes were
surveyed19 to establish the number of vacuum distillation units and other types
of vacuum systems in operation. About 11% of the reactors, 9% of the absorbers,
-------
11-10
Table II-2. Estimated Number of Vacuum Processes in
Chemical Processes Studied by Hydrosciencea
Chemical
Acetic anhydride
Acetone (see phenol)
Acetone cyanohydrin
Acrolein
Acrylic acid and esters
Adipic acid
Alkylbenzene
Caprolactam
Chlorobenzene
Chloroprene
Dimethylterephthalate
Ethanolamines
Ethylbenzene
Ethylene glycol
Formaldehyde
Glycerin
Glycol ethers
Maleic anhydride
Methyl methacrylate
Phenol/acetone
Propylene oxide
Styrene
Sulfuric acid (recovery)
Terephthalic acid
Toluene diisocyanate
Number of Vacuum Systems in Use
Distillation
Reactors Absorbers Units Crystallizers Filters
1 3
1
I
10
2 1-5 l-5b
3-4
2 1-5 l-5b
3
4
2
4
1
4
1
5
3
3
2
1-8
3
3
I
I
5
See Appendix A for references.
Possible use of vacuum filters.
-------
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H
H
I
Fig II-4. Flow Diagram for a Process Utilizing Vacuum Reactors and Absorbers (Acetic Anhydride)
-------
Fig. II-5. Flow Diagram for a Process Utilizing- Vacuum Distillations (Glycerin)
Page 1 of 2
-------
3rs+.
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Page 2 of 2
-------
H
I
Fig. II-6. Flow Diagram^for a Process Utilizing Vacuum Crystallizers (Adipic Acid)
-------
11-15
and 31% of the distillation systems in the data base of products surveyed19
utilize vacuum. It must be emphasized that these plant designs do not neces-
sarily represent existing plants and that the selection of products in that
data base may be biased toward large-capacity products.
It appears that nearly one-third of all distillation systems operate under vacuum
and that perhaps one-tenth of the other unit operations except for filtration
operate under vacuum. No data on vacuum filtration are available, but it is
estimated that at least one-tenth and possibly much more of the continuous filtra-
tion operations in SOCMI utilize vacuum filtration equipment.
IT Enviroscience has estimated that about 3600 distillation units are used by
SOCMI. This estimate is based on actual counts of distillation equipment at
each site from data submitted early in this study and an estimate of the total
number of sites in SOCMI. If one-third are vacuum units, then about 1200 vacuum
distillation units exist. At an emission rate of 15 Ib/hr (estimated from the
IT Enviroscience data on vacuum distillations), vacuum-distillation operations
alone could represent 158 million Ib of VOC emissions per year at the present
level of control. Another EPA contractor is collecting more data on distillation
emissions and will be able to improve the organic emission estimate.
-------
III-l
III. DESCRIPTION OF EMISSION
A- FLOW RATE
The flow from a vacuum device is determined by the noncondensed vapors and
gases that pass through the contact or surface condensers or liquid seals (if
any) in the vacuum device. These carrier gases enter the system through leaks,
through blankets, as dissolved gases in liquid or solid feeds, and/or as gases
or vapor generated in the equipment or in the vacuum-device condensers or seals.
Inorganic carrier gases are discussed here; the organic carrier gases and other
VOC are discussed in Section B.
1- Leaks
An operation under vacuum will have a tendency to leak. Any seal imperfections,
or other discontinuities will allow air to enter the system under vacuum. A
designer of the vacuum system must include the noncondensable gas load from the
leaks into the vacuum device design before the process unit is constructed.
Until recently there were two approaches to this estimate. The first approach
may be used when a detailed design of the vacuum equipment is known; then each
flange, fitting, and seal may be categorized and the total leak rate of the
equipment estimated from published factors.20 Table III-l lists these leak
factors.
The second approach for leak rate estimation depends on the approximate size of
the vacuum vessel.20 With a vacuum distillation unit used as an example, the
diameter of the distillation equipment depends mostly on the vapor flow up
through the column, which in turn is dependent on the vapor density, feed rate,
and reflux ratio. The height depends on the vapor-liquid equilibrium data and
the compositions of the feed, distillate, and bottoms (highly specific to the
application). The volume of the vessel cannot easily be predicted simply through
knowledge of the plant capacity and product. The same is true for reactors and
other unit operations. The approach requires quite detailed knowledge of the
volumes and sizes of each vacuum process unit.
-------
III-2
Table III-l. Leak Rates of Fittings in Vacuum Equipment*
Estimated Average Leak Rate
Fittings
Screwed connections to 2 in.
Screwed connections above 2 in.
Flanged connections to 6 in.
Flanged connections from 6 to 24 in.,
including manholes
Flanged connections 24 in. to 6 ft
Flanged connections above 6 ft
Packed valves to 1/2 in. in stem diameter
Packed valves above 1/2 in. in stem diameter
Lubricated plug valves
Petcocks
Sight glasses
Gage glasses including gage cocks
Liquid-sealed stuffing box for shafts
(per in. of shaft diameter)
Ordinary stuffing box
(per in. of shaft diameter)
Safety valves and vacuum breakers
(per in. of nominal size)
(lb/hr)
0.1
0.2
0.5
0.8
1.1
2.0
0.5
1.0
0.1
0.2
1.0
2.0
0.3
1.5
1.0
(scfm)
0.02
0.04
0.10
0.17
0.23
0.41
0.10
0.21
0.02
0.04
0.21
0.41
0.06
0.31
0.21
From ref 20.
b
As air with a molecular weight of 29.
Figure III-l (bottom chart) shows the relationship of system volume to diameters
and heights. Zones for typical dimensions of process equipment are shown. If
realistic dimensions of distillation systems and reactors or crystallizers can
be estimated, the system volume can be approximated and Fig. III-l (top chart)
can be used to approximate the leak rate. This rate should be multiplied by 0.5
to 0.75 for a tightly run plant with minimum leaks or by a factor of 2 to 3 for a
plant without good leak control.9'21
With enough maintenance and effort, any vacuum vessel may be made essentially
leak free. However, there is an optimum effort at which the cost of leak
-------
UI-3 ,
J * ••
1000
1000
Fig. III-l. Estimation of a Vacuum System's Leak Rate from Equipment Dimensions
-------
III-4
elimination exceeds the savings gained by using smaller, more energy-efficient,
and less costly vacuum equipment. Ryans 17 has proposed a design procedure for
vacuum systems that results in a lower value for the leak rate than was previously
used. The leak rate for each vessel is specified during design, and the leak
rate specification that is written must be met by the vessel fabricator through
a testing and leak plugging program. The vacuum source specified is therefore
sized closer to the real vessel leak rate. Lower energy costs and lower leak
rates result. This procedure, however, requires knowledge of both the size of
the unit and the number of valves, fittings, etc., in order to estimate the
leak rate.17
Oversizing of vacuum devices may lead to higher emission rates since artificial
purges or leaks into the systems are sometimes used to maintain the design vacuum.
Thus for a given vacuum operation whose real leak rate is one-third of the design
leak rate, the remaining two-thirds may be bled-in so that the vacuum system
does not operate at a lower vacuum than is required. Inert gas bleeds to provide
pressure control are usually placed between the process equipment and the vacuum
device to prevent the inert gas from contacting process organics and increasing
VOC emissions.
2. Blankets
Inert-gas blankets are introduced into vacuum systems to prevent chemical decomposi'
tion or to prevent a process from operating in the explosion range. Table III-2
presents data on the minimum concentration of inert gas that must be established
to prevent any subsequent air leak from forming a gas mixture that falls within
the explosive range.
At 25°C and atmospheric pressure, hydrogen, carbon monoxide, and acetylene require
the highest percentages of inert gases to ensure operation outside the explosive
range. Higher temperatures radically increase the inert-gas requirements so
that 5 to 10 times the usual volume of inert gas may be required in equipment
operating near 100°C. Reducing the pressure generally reduces the inert-gas
requirement.22
The factors in Table III-3 can be used to estimate the contribution of inert
gases to the total gas flow. These factors may be used with the air leak rate
-------
III-5
Table II1-2. Minimum Inert-Gas Concentration for Operation
to Be Entirely Out of the Explosion Envelope*
Compound
Methane
Ethane
Propane
Butane
N-Pentane
N-Hexane
Higher paraffins
Ethylene
Propylene
Isobutylene
1-Butene
3-Methyl-l-butene
Butadiene
Acetylene
Benzene
Cy c lopropane
Methanol
Ethanol
Dimethyl ether
Di ethyl ether
Methyl formate
Isobutyl formate
Methyl acetate
Acetone
Methyl ethyl ketone
Hydrogen sulfide
Hydrogen
Carbon monoxide
Inert-
CO?
23
31
28
28
29
29
28
39
28
26
31
31
35
53
29
30
32
33
33
J4
33
26
29
28
34
30
56
41
-Gas Concentration
(mole %)
N?
37
44
43
40
42
42
42
49
42
40
44
44
48
65
43
41
46
45
48
49
45
40
44
43
45
72
58
aSee ref 22.
Does not include the inert gas related to the air concentration.
Values expressed are for mixture at 25°C and 760 mm Hg. Operation
under vacuum will not require as high inert concentration as those
expressed.
-------
III-6
to estimate emission rates from vacuum operation when inert-gas blankets are
used to prevent operation in the explosion range.
Table III-3. Inert-Gas-Flow Estimates to Prevent
Operation in the Explosion Range
Volume of Inert Gas ,
Required for Each Volume of Air
At 25°C At 100 to 150°C
Organic gases and vapors 0.25—1 3—10
Flammable inorganic gases and acetylene 0.8—3 5—10
aFrom ref. 22; for use in estimating vacuum system emission rates only; not used
equipment design.
Can be used with leak rate prediction procedure.
The use of blanketing to prevent chemical decomposition usually implies that
the decomposition is related to the presence of oxygen in the process. Although
the oxygen restriction required to prevent decomposition may differ from that
required to prevent explosion, the inert-gas ratios shown in Table III-3 can be
considered as minimum levels of inert gas required for either purpose.
3. Dissolved Gases
Liquids and solids introduced into a vacuum process may carry noncondensable
gases with them. Under vacuum these gases will be released and will contribute
to the vacuum-device emission. A brief summary of a few gases dissolved in
some compounds is presented in Table III-4.23 Although not comprehensive, these
data show the magnitude of the flow of gases originating from gases dissolved
in liquids. For those cases where the pressures of the feeds are near-atmospheric
the contribution of carrier gases from this source ranges from 0.1 to 10 scfm/
100 million Ib of feed per year to the vacuum system. Except when the systems
have a very large capacity or when the liquids come directly from high-pressure
operation, this source is insignificant.
-------
III-7
Table III-4. Contribution of Carrier Gases from
s&
Dissolved Gases in Organic Liquids
Gas Flowb (scfm/100
Organic Liquid
n-Perfluoroheptane
n-Heptane
Carbon tetrachloride
Carbon disulfide
Acetone
H,
0.25
0.47
0.14
0.13
0.27
N,
0.68
0.28
0.20
0.70
MM lb of liquid/yr)
CH4
1.45
1.26
1.18
2.63
CO,
3.68
8.26
4.75
2.95
aAdapted from ref 23.
At 25°C and atmospheric pressure.
Vacuum devices sometimes utilize contact condensers or water seals. The water
introduced to the vacuum also can contain dissolved carrier gases. Table I1I-5
gives the range of gas flow from this source.
Table III-5. Carrier Gas Flow from Contact Condensers or Seal Water*
Water Temperature (°F)
40
50
60
70
80
90
100
Gas
(Ib/hr)
16.8
14.9
13.2
11.8
10.7
9.7
8.8
Flow for 1000-gpm Water
(scfm)
3.47
3.07
2.72
2.43
2.21
2.00
1.82
ref 11.
Water consumption may be estimated from the steam consumption rate for a steam
ejector. The steam consumption (in Ib/hr) times 0.06 is the approximate water
consumption in gpm.
-------
III-8
The ranges of steam consumption and therefore the water consumption and dissolved
gas flow for various types of ejector systems are given in Table III-6. Except
for five- or six-stage systems operating at low pressures, carrier gases
absorbed in the cooling water are less than 10% of those that leak in the
system.9—11
Table III-6. Steam Consumption, Water Consumption, and
Steam-Ejector Gas Flow from Water-Dissolved Gases
Type of
System
Single stage
Two stage
Three stage
Four stage
Five stage
Six stage
Steam Consumption
(Ib of steam/lb of air)
1 . 5 — 30
7 — 40
1 — 40
20 — 100
50 — 175
200 — 1000
Water Consumption
(gal of H2O/lb of air)
5 — 108
25 — 144
4—144
72—360
180 — 630
720 — 3600
Gas Flow
(scf of gas/scf of air,
0.001 — 0.022
0.005 — 0.030
0.001 — 0.030
0.015—0.074
0.037 — 0.130
0.149 — 0.743
a
From refs 9 and 11.
Water temperature, 70°F.
4. Chemical Decomposition
Some compounds undergo reactions that result in the formation of potential carrier
gases in chemical equipment and, as was noted earlier, is one of the reasons
why process equipment is operated under vacuum. Lower pressures usually mean
lower temperatures and less chemical decomposition. Gases formed by chemical
decomposition are highly specific and difficult to predict without specific
data about the process concerned. If, for instance, carbon is being oxidized to
CO or C02, then at least 1 mole of gas will be generated for each carbon atom
in the feed molecule. In other words, oxidation of a ten-carbon molecule could
form 10 moles of gas and probably 10 moles of water vapor for each mole of feed
oxidized. In a vacuum process the water vapor is condensed and does not increase
the flow rate of the final emission.
-------
III-9
The decomposition rate is probably not a function of throughput. In, say,
oxidation the oxygen required to oxidize the organic molecules may be available
only at the liquid-gas interface. This surface area may be constant and inde-
pendent of feed rate for any single piece of equipment but may increase as equip-
ment size increases. Therefore decomposition rates cannot be estimated on the
basis of product and plant capacity. Further complicating the problem, potential
carrier gases generated during decomposition may undergo further reactions, which
result in no net change in total gas volume.
The following simple case will be assumed to estimate the order-of-magnitude
range for gases generated by chemical decomposition. A chemical with a molecular
weight of 100 is being processed in vacuum equipment at the rate of 1 to 1000 lb/hr;
10 mole % of this material is decomposed to a gas. The number of moles of gas
produced is equal to the number of moles of chemical decomposed. The data from
the calculation are presented in Table III-7.
Table III-7. Carrier Gas Flow from Chemical Decomposition
(equimolar gas evolving from 10 mole % of the feed decomposed)
Feed Rate
ilb-moles/hr)
0.01
0.1
1.0
10.0
100.0
(lb/hr)*
1
10
100
1000
10,000
Decomposition
(Ib-mole/hr)
0.001
0.01
0.1
1.0
10.0
Carrier Gas Rate
(scfm)
0.006
0.06
0.6
6.0
60.0
*Based on a molecular weight of 100.
B- VOC CONCENTRATION
The maximum concentration of VOC for a single organic component under ideal
conditions can be given by a combination of Dalton's and Raoult's laws:
xp
y -
* n
(1)
where y is the mole fraction of the component in the vapor, x is the mole fraction
of the component in the liquid, p is the vapor pressure of the component at the
-------
111-10
system temperature, and re is the total pressure of the system. In this expression
thermodynamic equilibrium or saturation of the component in the vapor is assumed.
Depending on a variety of considerations the gases leaving a vacuum device may
or may not be saturated. This analysis will not apply exactly to multicomponent
organic systems, but analogous effects will be assumed.
Figure III-2 shows a vacuum operation with steam ejectors and surface condensers.
The cooling water to the condenser does not contact the condensed steam nor the
carrier gases. Liquids that form are separated from the carrier gases in the
condenser. Organics that condense with the steam condensate will either
separate as a second phase from the condensed liquid or remain soluble in the
water. If a second phase is formed with a single component, Eq.(l) should
apply. The mole fraction in the liquid (second phase) would equal 1 and the
vapors should be saturated at condenser outlet conditions. If there is only an
aqueous phase, then x would be less than 1 and y should be considerably less
than saturation.
A vacuum operation with steam ejectors and contact condensers is shown in
Fig. III-3. This system differs from a steam ejector with a surface condenser
in that water is added directly to the steam discharge from the ejector. The
water intimately contacts and cools the vapors, which are condensed. Organics
can generate two phases in this type of unit, but, since the added water con-
siderably dilutes the mixture, a single aqueous phase is much more likely.
Typically, then, the organic concentration in the gas stream from the separation
chamber (hot well) may be less than that in a steam ejector with a surface condenser-
However, organics leaving in the aqueous liquid must be treated and could be a
source of secondary emissions. Surface condensers have the advantage over contact
condensers of potential recovery of the organic from a smaller volume of liquid
discharge.
Figure III-4 shows a vacuum process with water-sealed vacuum pumps. Water-sealed
vacuum pumps use water or other liquids for the sealant, which is flushed once
through the device or is recirculated through a small seal tank. In the case
of a seal tank a certain amount is then discharged on either a batch or a con-
tinuous basis. Since no steam is used in vacuum pumps, the cooling require-
ments are lower and the ratio of the water fed to the organics condensed can be
-------
ACC.S.C. !=C
:
-------
VAC U UK PROCESS
Fig. III-3. Vacuxun Process with Contact Condensers and Barometric Seal
-------
UEAtVb
1UEKT &*
ADD£O FOR
IX. COM PO •= ITI OK.
VACUUM PROCESS
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'=/-t Aoceo '
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OWIULATE.
PRODUCT
i
•WAT=?. •
P'^Sl?
TO T?5=:
S= e^A'^ LIQUID
TO
I
M
U)
VJATE.P, - 6EAV_=.O VACUUM
P'JMP WITH
LJ&OI O TO
Fig. III-4. Vacuum Process with Water-Sealed Vacuum Pumps
-------
111-14
very low. Organic phases can be formed but are usually prevented by the water
flow rate being increased since high levels of organics reduce the vacuum potential
of the device.
For all cases where x is less than 1 the condensing or seal system also may act
as an absorber; that is, highly soluble organics will tend to partition with
the liquid and not with the noncondensable gases. This has the effect of
lowering potential air emissions and increasing liquid treatment needs and poten-
tial secondary emissions. In these cases the vacuum device can be thought of
as an air emission control device; but the organic content of the wastewater or
the water pollution potential increases.
A vacuum process with oil-sealed and gas-sealed vacuum pumps is shown in Fig. III-5.
Oil-sealed vacuum pumps can generate oil mists because of the gas flow through
the system. Mist-eliminating devices can be installed to reduce this emission
impact. Gas-sealed pumps have no impact on the VOC concentration since the
gases do not contact seal fluids. VOC concentrations in the discharge of
gas-sealed pumps would be the same as those at the suction unless some VOC is
condensed by virture of the pressure change. However, gas-sealed pumps are not
often selected for use in this type of application.
The problem of estimating VOC concentrations is further complicated by variation,
over several orders of magnitude, of the vapor pressures of various organics
[crucial to Eq.(l)]. Even the vapor pressure of a single organic can vary widely
over differing temperatures within the reasonable operating range of vacuum
devices (10 to 60°C). Figure III-6 shows this phenomenon with a variety of
organic compounds. The variation in vapor concentration (mole fraction) is
given as a function of temperature over a pure liquid at atmospheric pressure
as calculated by Eq.(l). Within certain temperature limits, 10 to 60°C, the
mole fraction can vary between essentially 100% to less than 0.1%. In fact,
there are may compounds that would lie to '.he left of dichloromethane and to
the right of o-cresol, which could be found in vacuum processes.
VOC concentrations in vacuum device emissions can vary from very low (approaching
zero) to very high (approaching 100 mole %). VOC concentrations from specific
-------
LEAK'S
VACUUM
C.W--
OCbTILJ-ATE
PRODUCT
TO
TO
H
I
- •£=AL=:a VACUUM
±±]
Vacuum Process with Oil- or Gas-Sealed Vacuum Pumps
-------
u.
)
Hi
i '', i I j i ; ;'[ . i i'i I j'Tjl *"ii ;ljJill!l_i_
! il I i , i ;T TTTt! rn| i i i l| 'i :i" jiThi hi <
.
10 20 30 40 iO 6<-' 70 8O 90 100
EMPERATURe (°C)
1. Methanol
2. Chloroform
3. Formic acid
4. Dichloromethane
5. Trichloroethylene
6. Acetonitrilo
7. Acetic acid
8. Ethanol
9. Monoethancrlamine
10. Allyl alcohol
11. Butyric acid
12. Phenol
13. Methyl phenyl ether
14. o-Cresol
Fig. III-6. Saturation Concentrations of Specific Organic Compounds in Gas
-------
111-17
sources can be defined only if components, temperatures, vapor pressure, and
other physical property data are known for that specific emission.
ACTUAL VACUUM SYSTEM EMISSIONS
Actual data for VOC emissions from vacuum systems are given in Table III-8;
the data were obtained from the sources cited in the Appendix. Both uncontrolled
and controlled data are given and the control device is noted. The emission
flow rates range from less than 1 scfm to 1300 scfm, whereas concentrations
range from nearly zero to nearly 100 mole %, and shows relatively good agreement
with the flow and concentrations developed in this report. It is not possible to
verify the relationship between flow and equipment size since information on
the latter was not collected during the IT Enviroscience study.
-------
Table III-8. Actual Emission Data from Vacuum Systems
Uncontrolled
Controlled
VOC Emissions (Ib/hr)
FJow VOC Concentration Temperature FJow VOC Concentration Temperatxir& Control Eaii-t d
fyte of Equipment (scfn) (mole ») CO (scfm) (mole \) (°C) Device Uncontrolled Controlled AtnoRi hr
-ryotallizcr 330 49
L2S2 0.11 38
Evaporator
Distillation 8.47 8.0 30
0.6
140Bb 0.36 99
(3 units) 85 32 41
(6 units) 255 52.2 49
80
2.95b ^100 100
216 0.45 30
100
loo
100
100
100
60
42.7 0.2
42.9 0.7 35
42.9 0.7 35
355b 0.66 96
Condenser 11.4
3.3 0.7 35 Condenser
0.01 100 38 Condenser
Caustic Scrubber 11.2
1.67 22.9 Condenser
a
Condenser
148 18.9 Condenser then flare 76.1
55 1.3 Condenser 401
130 2B.2 1 Condenser 1460
^100 Condenser
a
13.4
13.7
a
60 Scrubber 16,7
6O Scrubber 2.1
60 Scrubber 4.2
60 Scrubber 0.21
0.42
2
44.5 1.62 45 Manifold-condenser 6
6
30. 6
11.4
0.29 0.29
o.oa o.oa
0-11 0.11
4.1 J.I
0.%
2-45 2.45
18.9 18.9 (to
6.2 6.2
33b 325
14 14
13.4
13.7
8.3 8.3
0.42
14 14
c 30.5
tr>
re
flare)
M
1— j
H
I—1
CO
3.55 0.92 35-40 3.5 0.34 35 Condenser 0.44 0.17 0.17
54.8 4.2 35-40 52.7 200 ppm 35-40 Condenser 29.9
73.4 4.5 35-40 70.1 40 ppm Condenser 44.2
3.1 31.2 30-40 2.31 7.5 20-30 Condenser 13.0
0.13 O.S3
0.1 0.1
2.3 2.3
Level of control is unknown.
High temperature reported indicate flow may contain ejector stream.
""Controls planned.
-------
IV-1
IV. CONTROL OPTIONS FOR VACUUM SYSTEMS
IN-PROCESS CONTROL
Both in-process and add-on control techniques or devices have been used for
vacuum systems. Carrier-gas flow can be reduced by not oversizing the vacuum
device by as large a factor as is presently used. This design is more energy
efficent, and the lower flows that result may also result in lower organic emissions.
Emissions from processes in which gases are bled into the system for preventing de-
composition or explosion or for control of the vacuum may be partly controlled
through the recycle of exhaust gases from the vacuum source to the bleed line. This
approach cannot entirely eliminate the emission since the leak rate will continue
regardless of the recycle. Therefore the flow of the vacuum source emission can be
reduced to the level of the leak rate but no further. This, however, can result in
a significant emission reduction.
Design of vacuum systems incorporating surface condensers may provide for the
recovery of organic chemicals and the reduction of total water and air pollution.
However, in some cases the systems may tend to increase the concentration of
the air emissions since the noncondensed gases may come into contact with
essentially pure organic compounds. In this case water pollution (treatment
loads or potential secondary emissions) may diminish at the expense of increasing
air losses.
ADD-ON CONTROLS
Control devices added to ejector-type vacuum devices must be capable of handling
relatively large variations in flow rate at low pressure drops. The flow rate
from ejectors changes quickly if the suction pressure changes. Increased leaks
due to equipment aging or thermal cycling can increase the flows significantly.
A control device that generates significant back-pressure can reduce the capacity
of vacuum sources. In new plants this may be accounted for by appropriate
sizing of the vacuum device. In existing plants, however, this effect may
require a booster device to overcome the increased discharge pressure drop
related to the control.
Vacuum devices utilizing water seals or contact condensers will produce emissions
saturated with water at the temperature of the exhaust. This water vapor can
significantly affect the design of add-on control devices. For instance.
-------
IV-2
carbon adsorption loadings may be lowered if the emission is not dehumidified
prior to control. Water vapor may limit the temperature at which an aftercon-
denser may be operated since ice could form and plug the condenser.
A variety of control devices for organic emissions have been reported in various
control device evaluation reports. These reports describe the limitations of
each control device and offer costs as functions of the applicable flow and
composition ranges for each device. Table IV-1 summarizes the cost effectiveness
for each control technology for a typical case. This table should be used only
to identify the most cost-effective technologies in a general way since other
considerations may cause the costs to change. When a control technology is
selected, the control device evaluation reports may be used to more completely
identify the costs.
Vacuum systems can generate waste gases with flows of from less than 1 scfm to
10,000 scfm and with VOC concentrations of from nearly zero to nearly 100 mole %.
All control devices could therefore be applied, depending on the specifics for
each stream.
Condensation is most appropriate for waste gases with flows of under 5000 scfm.
It is effective only when the VOC present is condensible, or in other words not
an organic carrier gas. After-condensers and refrigerated condensers are
widely used to control vacuum system emissions. Further information on con-
densation is available in the control device evaluation report on condensation.
Absorption is also used for control of vacuum systems emissions and is also
discussed in more detail in a control device evaluation report.
Carbon adsorption can be applied only at low-VOC concentrations. It compares
attractively to all control technologies ou a cost-effectiveness basis. However,
in addition to its concentration limitations, carbon adsorption is not effective
on a number of organic compounds. When applicable, carbon adsorption is expected
to be highly cost-effective. A control device evaluation report on adsorption
more completely defines its limitations.
-------
Table IV-1. Representative Cost-Effectiveness for Organic Emission Control Technology
Waste Gas
Flow
(scfm) C
500 — 700
1000
5,000
50,000
Cost Effectiveness (per Ib of VOC) for
VOC be
oncent ration3 Condensation Absorption0
Low
Medium
High
Low
Medium
High
Low
Medium
High
Low
Medium
High
$0.20
0.03
0.06
0.14
0.02
0.04
1
1
1
1
1
1
i
i
i
$0.56 — 1.07
0.06 — 0.11
i
0.20 — 0.55
0.04 — 0.08
i
0.02 — 0.18
0.10 — 0.45
i
Adsorption
i
i
i
$0.13 — 0.15
k
k
0.06 — 0.08
k
k
0.03—0.05
k
k
Flares6
j
j
i
j
j
$0.001
j
j
i
j
j
i
Catalytic
Oxidationf
$0 . 31 — 0 . 37
k
k
i
k
k
0.09 — 0.12
k
k
0.05 — 0.07
k
k
Thermal High-Temperature
Oxidation5 Oxidation11
$0
0
0
0
0
0
0
0
0
.55 — 0.62
.09 — 0.11
.06
i
i
i
.25 — 0.29
.02 — 0.04
.01
.20 — 0.24
.01 — 0.02
.007
$0
0
0
0
0
0
0
0
0
.78 — 1.
.20 — 0.
.12 — 0.
i
i
i
.44 — 0.
.13 — 0.
.09 — 0.
.37
.11
.08
29
30
17
78
19
12 '
Low s 0.5 vol % or 10 Btu/scf; medium = 5 vol % or 50 Btu/scf; high ~ 20 vol % or 100 Btu/scf.
95% removal efficiency; no VOC credit.
99% removal efficiency;
1.4; steam ratio = 0.2 moles of steam/mole of waste gas; no VOC credit.
d70 _ 12 Ppm effluent; 6.96 Ib of carbon/1000. scf; no VOC credit; loading - 0.1 Ib of VOC/lb of carbon, molecular weight
of VOC = 50.
6Based on 100% VOC of propylene at 100% of capacity. Flares normally operate intermittently at a low fraction of
capacity.
fgg — 90% destruction efficiency/ no heat recovery.
99Q _ 9g% destruction efficiency; no heat recovery, 1400 — 1600°F combustion temperature.-
h99.9% destruction efficiency; no heat recovery, 2200 — 2600°F combustion temperature.
^Costs not available.
•'wot applicable at low concentrations.
'Slot applicable at high concentrations.
Not applicable at high flow rates.
-------
IV-4
Catalytic oxidation is applicable only for low-VOC-concentration waste gases as
long as catalyst poisons aren't present. Catalytic oxidation can be more cost
effective than thermal oxidation if it can be applied to the waste gas. Further
information may be found in the control device evaluation report on catalytic
oxidation.
Thermal oxidation applies to the flow range and concentration range of waste
gases from vacuum systems. In addition, all organic compounds can be oxidized
in thermal oxidation units. This type of control is discussed in the thermal
oxidation control device evaluation.
When compounds containing sulfur or other particular elements are present in
the waste gas, noxious compounds are emitted in the flue gas. Scrubbers are
then required to remove the noxious gases from the flue gas prior to discharge.
When chlorine-containing compounds are present, the combustion temperature must
be increased to convert the Cl to HCl instead of to C12. This aids the removal
of chlorine from the flue gas. These special cases of thermal oxidation are
discussed in the thermal oxidation supplementary control device evaluation.
-------
V-l
V. SUMMARY
Vacuum operations are widespread in SOCMI and account for significant levels of
VOC emissions. The emissions from vacuum devices can be characterized according
to their flow and VOC concentration.
The total emission flow from a vacuum device is related to the sum of the flows
from equipment air leakage, inert-gas blankets provided for safety or product
decomposition reasons, dissolved gases in liquid or solid feeds, and gases
generated because of chemical decomposition or reaction. The emissions resulting
from the leak rate and inert gases added for safety considerations are quite
significant when the total emission flow is to be estimated. Normally, gases
dissolved in liquids and solids and those evolved because of chemical decomposi-
tion are insignificant. Reactions in which gases are formed may be significant
but are highly specific and are discussed in other reports.
The VOC concentration in vacuum device emissions varies from almost zero to
almost 100 mole % and is primarily a function of the specific chemicals being
processed, their vapor pressures, and their water solubilities.
Control devices to be applied to vacuum source emissions should have low pressure
drops and not be affected by high levels of water vapor. Existing control
devices are generally aftercondensers (with or without refrigeration), scrubbers,
adsorbers, and combustion devices such as flares, boilers, or thermal oxidizers.
-------
VI-1
VI. REFERENCES
1. E. F. Newman, "How to Specify Steam-Jet Ejectors," Chemical Engineering, p. 203
(Apr. 10, 1967).
2. F. K. D'Ambra and Z. C. Dobrowolski, "Pollution Control for Vacuum Systems,"
Chemical Engineering, p. 95 (June 25, 1973).
3. B. B. Dayton, "Vacuum Technology," Kirk-Othmer Encyclopedia of Chemical Technology,.
2d ed., vol. 21, pp. 123—157, Anthony Stanley et al., editors, Wiley-Interscience,
Ney York, 1970.
4. G. A. Huff, Jr., "Selecting a Vacuum Producer," Chemical Engineering 83(6), 83
(Mar. 15, 1976). —
5. R. B. Power, "How to Specify, Evaluate and Operate Steam Jet Ejectors," Hydrocarbon
Processing and Petroleum Refiner 43(3), 138 (March 1964).
6. C. G. Blatchley, "How to Get the Most.from Ejectors," Petroleum Refiner 37(12), 106
(December 1958). —
7. V. V. Fondrk, "Figure What an Ejector Will Cost," Petroleum Refiner 37(12),
101 (December 1958). —
8. F. Berkeley, "Ejectors Have a Wide Range of Uses," Petroleum Refiner 37(12), 95
(December 1958). —
9. "Ejector and Vacuum Systems," Chapter 6 in Applied Process Design for Chemical
and Petrochemical Design, vol. 2, E. Ludwig, Gulf Publishing, Houston, TX, 1977.
10. W. D. Mains and R. E. Richenburg, "Steam Jet Ejectors in Pilot and Production
Plants," Chemical Engineering Progress 63(3). 84 (March 1967).
11. "Steam Ejectors for Vacuum Service," chap. 15, p. 257, in Applied Chemical
Process Design, F. Aerstein and G. Street, Plenum Press, New York, 1978.
12. P. W. Patton and C. F. Joyce, "How to Find the Lowest Cost Vacuum System,"
Chemical Engineering, p. 84 (Feb. 2, 1976).
13. R. G. P. Kusay, "Vacuum Equipment for Chemical Processes," British Chemical
Engineering 16(1), 29 (January 1971).
14. C.F.A. Green, "Liquid-Ring Vacuum Pumps," British Chemical Engineering 16(1),
37 (January 1971). —
15. A. A. Chambers and F. R. Dube, "Vacuum Pumps and Systems," Plant Engineering,
p. 141 (June 9, 1977).
16. B. Ebdale, "Capabilities and Limitations of Pumps, Steam Ejectors and Liquid
Ring Pumps," Vacuum 28(8/9), 337 (August/September 1978).
-------
VI-2
17. J. L. Ryans, Application of Basic Energy Conservation Principles to the Design of
Rough Vacuum Systems, ASME Publication 76, WA/PID-17 (1977).
18. T. E. Ctvrtnicek, Z. S. Khan, J. L. Delaney, and D. E. Barley, Screening Study
for Vacuum Distillation Units in Petroleum Refineries, EPA Report EPA-450/3-76-40
(December 1976).
19. Private reports on specific chemicals by the Process Economics Program, Stanford
Research Institute, Menlo Park, CA. The following chemicals were studied:
styrene, acrylic acid and acrylic esters, glycerin, acetaldehyde, acrylonitrile,
vinyl chloride, acetylene, propylene oxide and ethylene oxide, fatty acids,
formaldehyde, acetic acid, acetic anhydride, terephthalic acid and dimethyl-
terephthalate, methanol, maleic anhydride, methacrylic acid and esters, acetone,
methyl ethyl ketone, methyl isobutyl ketone, vinyl acetate, hydrofluoric acid,
and fluorocarbons.
20. D. H. Jackson, "Selection and Use of Ejectors," Chemical Engineering Progress,
vol. 44(5) (May 1948).
21. Standards for Steam Ejectors, 3d ed., Heat Exchange Institute, 1956 (cited in
ref 8).
22. M. G. Zabetakis, Flammability Characteristics of Combustible Gases and Vapors,
Bulletin 627, Bureau of Mines, Dept. of Interior (nd).
23. R. C. Reid, J. M. Prausnitz, and T. K. Sherwood, The Properties of Liquids and
Gases, 3d ed., McGraw-Hill, New York, 1977.
-------
APPENDIX A
LIST OF EPA INFORMATION SOURCES
-------
A-3
LIST OF EPA INFORMATION SOURCES
1. D. W. Smith, E. I. du Pont de Nemours & Co., letter to D. R. Goodwin, EPA,
Apr. 20, 1978.
2. C. J. Schaefer, Celanese Chemical Co. Inc., letter to D. R. Goodwin, EPA,
Apr. 21, 1978.
3. F. D. Bess, Union Carbide Corp., letter to D. R. Patrick, EPA, May 5, 1977.
4. C. R. Kuykendall, El Paso Products Co., letter to D. R. Goodwin, EPA, Jan. 31,
1978.
5. W. G. Kelly, Atlantic Richfield Co., letter to D. R. Goodwin, EPA, Feb. 23, 1978.
6. H. M. Keating, Monsanto Chemical Intermediates Co., letter to L. Evans, EPA,
Apr. 28, 1978.
7. W. C. Holbrook, B. F. Goodrich Chemical Co., letter to D. R. Goodwin, EPA,
Apr. 7, 1975.
8. K, D. Konter, B. F. Goodrich Chemical Co., letter to L. Evans, EPA, June 15,
1978.
9. W. M. Reiter, Allied Chemical Co., letter to D. R. Goodwin, EPA, May 16, 1978.
10. J. P. Walsh, Exxon Chemical Co. USA, letter to D. R. Goodwin, EPA, Feb. 10, 1978.
11. F. D. Bess, Union Carbide Corp., letter to L. B. Evans, EPA, May 5, 1978.
12. J. Beale, Dow Chemical Co. USA, letter to L. B. Evans, EPA, Mar. 14, 1978.
13. H. J. Wurzer, Montrose Chemical Corp. of California, letter to D. R. Goodwin,
Mar. 7, 1978.
-------
A-4
14. D. W. Smith, E. I. du Pont de Nemours & Co., letter to D. R. Goodwin, EPA,
Feb. 3, 1978.
15. D. W. Smith, E. I. du Pont de Nemours & Co., letter to D. R. Goodwin, EPA,
May 17, 1978.
16. C. W. Stuewe, IT Enviroscience, Inc., Trip Report on Vist Regarding Beaumont, TX,
Plant of E. I. du Pont de Nemours & Co., Sept. 7, 8, 1977 (on file at EPA, ESED,
Research Triangle Park, NC).
The following reports by IT Enviroscience personnel were prepared during
the IT Enviroscience study and will be issued in final form during 1980—1981:
17. R. W. Helsel, Acetic Anhydride.
18. C. Stuewe, Phenol Acetone.
19. J. W. Blackburn and H. S. Basdekis, Methyl Methacrylate.
20. C. A. Peterson, Jr. Glycerin and Its Intermediates.
21. J. W. Blackburn, Acrylic Acid and Esters.
22. W. D. Bruce, J. W. Blackburn, and H. S. Basdekis, Adipic Acid.
23. C. A. Peterson, Jr., Linear Alkylbenzene.
24. H. S. Basdekis, Caprolactam.
25. S. W. Dylewski, Chlorobenzenes.
26. S. W. Dylewski, Chloroprene.
-------
A-5
27. S. W. Dylewski, Crude Terephthalic Acid and Dimethyl Terephthalate and Purified
Terephthalic Acid.
28. T. L. Schomer, Ethanolamines.
29. F. D. Hobbs and J. A. Key, Ethylbenzene and Styrene.
30. R. J. Lovell, Ethylene Glycol.
31. R. J. Lovell, Formaldehyde.
32. T. L. Schomer, Glycol Ethers.
33. J. F. Lawson, Maleic Anhydride.
34. C. A. Peterson, Jr., Propylene Oxide.
35. J. A. Key, Waste Sulfuric Acid Treatment for Acid Recovery.
36. D. M. Pitts, Toluene Diisocyanate.
-------
5-i
REPORT 5
UPSET RELEASES
R. L. Standifer
IT Enviroscience
9041 Executive Park Drive
Knoxville, Tennessee 37923
Prepared for
Emission Standards and Engineering Division
Office of Air Quality Planning and Standards
ENVIRONMENTAL PROTECTION AGENCY
Research Triangle Park, North Carolina
February 1981
D111A
-------
5-iii
CONTENTS OF REPORT 5
I. INTRODUCTION 1-1
A. Definition 1-1
B. Elements That Determine VOC Emissions 1-1
II. INITIATING CAUSES II-l
A. General II-l
B. External Causes II-l
C. Internal Causes II-5
III. CHARACTERISTICS THAT DETERMINE THE CAPABILITY OF PROCESSES TO III-l
ABSORB OR ADJUST TO DISTURBANCES
A. General III-l
B. System Holdup III-l
C. Multiple Parallel Equipment vs Single-Train Equipment III-l
D. Intermediate Storage Capacity III-2
E. Emergency/Spare Equipment III-3
F. Process Controls III-5
G. Operation III-6
IV. PROCESS CHARACTERISTICS THAT DETERMINE THE POTENTIAL FOR VOC IV-1
UPSET EMISSIONS
A. General IV-1
B. Characteristics of Raw Materials, Intermediates, Products, IV-1
and By-Products
C. Process/System Characteristics IV-3
V. EMISSIONS V-l
A. Introduction V-l
B. Estimation Criteria V-l
VI. APPLICABLE CONTROLS VI-1
A. General VI-1
B. Add-On Controls VI-1
C. Elimination of Initiating Disturbances VI-2
D. Improvements in Capability to Absorb or Adjust to Disturbances VI-2
VII. ASSESSMENT VII-1
A. Summary VII-1
B. Data Assessment VII-1
-------
5-v
APPENDIX OF REPORT 5
FIGURES OF REPORT 5
A. UPSET EMISSION ESTIMATE CALCULATIONS A-l
TABLES OF REPORT 5
Number Page
1-1 Elements Determining the Frequency and Severity of Process 1-2
Upsets and the Resulting Quantity of Emissions
II-l Initiating Causes of Upset Emissions Reported to TACB by II-2
Organic Chemical Plants in Texas Region 7
V-l Estimated Annual Upset Emissions from Organic Chemical Plants V-2
in Texas Air Control Board Region 7
V-2 Estimated Annual Upset Emissions from SOCMI Plants in the U.S. V-3
IV-1 Boiling Point as a Function of Carbon Atoms in Compound IV-2
-------
5-vii
ABBREVIATIONS AND CONVERSION FACTORS
EPA policy is to express all measurements used in agency documents in metric
units. Listed below are the International System of Units (SI) abbreviations
and conversion factors for this report.
To Convert From
Pascal (Pa)
Joule (J)
Degree Celsius (°C)
Meter (m)
Cubic meter (m3)
Cubic meter (m3)
Cubic meter (m3)
Cubic meter/second
(m3/s)
Watt (W)
Meter (m)
Pascal (Pa)
Kilogram (kg)
Joule (J)
To
Atmosphere (760 mm Hg)
British thermal unit (Btu)
Degree Fahrenheit (°F)
Feet (ft)
Cubic feet (ft3)
Barrel (oil) (bbl)
Gallon (U.S. liquid) (gal)
Gallon (U.S. liquid)/min
(gpm)
Horsepower (electric) (hp)
Inch (in.)
Pound-force/inch2 (psi)
Pound-mass (Ib)
Watt-hour (Wh)
Multiply By
9.870 X 10~6
9.480 X 10"4
(°C X 9/5) + 32
3.28
3.531 X 101
6.290
2.643 X 102
1.585 X 104
1.340 X 10"3
3.937 X 101
1.450 X 10~4
2.205
2.778 X 10"4
Standard Conditions
68°F = 20°C
1 atmosphere = 101,325 Pascals
PREFIXES
Prefix
T
G
M
k
m
M
Symbol
tera
giga
mega
kilo
milli
micro
Multiplication
Factor
1012
109
106
103
10'3
io"6
Example
1 Tg =
1 Gg =
1 Mg =
1 km =
1 mV =
1 pg =
1 X 10 12 grams
1 X IO9 grams
1 X 10s grams
1 X IO3 meters
1 X IO"3 volt
1 X IO"6 gram
-------
1-1
I. INTRODUCTION
A. DEFINITION
Upset emissions as used in this report are defined as intermittent volatile
organic chemical (VOC) emissions that occur when normal process operation or
the operation of emission control devices is disturbed by abnormal internal or
external conditions or events. Intermittent emissions that normally occur
during planned and scheduled startup/shutdown operations at predictable fre-
quencies and rates and for predictable time intervals are considered as normal
process emissions,- however, abnormal emissions caused by unanticipated condi-
tions or events occurring during scheduled startup/ shutdown operations are
considered to be upset emissions.
B. ELEMENTS THAT DETERMINE VOC EMISSIONS
The total quantity of VOC upset emissions from a process is determined by the
frequency and duration of initiating disturbances or causes, by the capability
of the process to absorb or adjust to disturbances, by the characteristics of
the process that determine the quantity of VOC discharged when an upset does
occur, and by the efficiency of terminal control devices when such controls are
applicable. Table 1-1 illustrates the relationship between the elements de-
scribed and itemizes (1) the most common sources of initiating disturbances,
(2) the process factors that affect the potentiality of an upset, and (3) the
characteristics that determine the potential for VOC emissions when upsets do
occur. Item (1) is discussed in detail in Sect. II, item (2) in Sect. Ill, and
item (3) in Sect. IV. Applicable emission controls are discussed in Sect. VI.
-------
Table 1-1. Elements Determining the Frequency and Severity of
Process Upsets and the Resulting Quantity of Emissions
Frequency and
Severity of Initiating
Disturbances
Capability of Process
to Absorb or Adjust
to Disturbances
Process Characteristics
Emission Potential
Add-On
Control Device
Efficiency
Initiating Causes
Factors Affecting
Upset Potential
Emission-Controlling
Process Characteristics
External
Utilities interruption
Electrical power
Steam
Cooling water
Compressed air
Feed sources
Flow disturbance
Composition change
Consuming units
Flow interruption
Inte rna1
Rotary equipment outages
Compressors
Pumps
Miscellaneous
Flow restrictions
Piping
Equipment
Control problems
Instruments
Operator error
Direct material release
Rupture/leaks
Pressure-relief device failure
Holdup
Parallel or single-
train equipment
Intermediate storage
Emergency equipment
Installed spare equipment
Controls
Response time
Stability
Fail-safe features
Operation
Procedures
Training
Properties of materials (feeds,
products, by-products)
Physical properties
Vapor pressure
Chemical properties
Mutual reactivity
Heats of reaction
Potential for reactions that
increase gas volume
Process/system properties
Volume
Throughput
Pressures
Temperatures
State (gas, liquid)
Inert-gas flow
I
10
-------
II-l
II. INITIATING CAUSES
A. GENERAL
Process upsets may be initiated either by external occurrences (e.g., interrup-
tions or variations in utilities, raw material supplies) or by disturbances
within the process itself (e.g., mechanical equipment failure, control malfunc-
tions). Specific causes are discussed in detail in the following sections.
Table II-l summarizes the common initiating causes, the processes responsible,
and the frequency of upsets in each category that were reported by the SOCMI in
Texas State Region 7 (Houston area) to the Texas Air Control Board* (TACB) for
the periods of January—April 1978 and May—December 1979. As approximately 30
to 50% of the total SOCMI production occurs within this region, the predominant
sources and causes shown are probably reasonably representative of the major
industry sources of upset emissions.
The reported incidents that resulted in the release of only such inorganic pol-
lutants as S0_, NO , and inorganic particulates were excluded; however, those
incidents that resulted in the release of particulate emissions were included
when the emissions were caused by incomplete combustion (in flares, incinera-
tors, or boilers) of VOC released as a result of process upsets. Since upset
incidents are required to be reported only when emissions are potentially in
excess of regulatory requirements, many upset incidents were probably not
reported because the VOC released was satisfactorily controlled by terminal
control devices.
B. EXTERNAL CAUSES
1. Interruptions in Utilities
a. Electrical Power—Electrical power failure is the most significant source of
externally caused process upsets. In addition to electrical power being
required for process pumps, process gas compressors, instruments, controls, and
*The state of Texas requires that those incidents which may result in emissions
in violation of regulations be reported.
-------
II-2
Table II-l. Initiating Causes of Upset Emissions Reported to
TACB by Organic Chemical Plants in Texas Region 7*
a v
ti c
a i
1
O 3
m &
m u
2
£ JS
Process Q g
Entire plant
Acet aldehyde
Acetic acid
Acetone
Acetylene
Alcohols
Acrylates
(unspecified) i
1
Number of Incidents for Sources Listed
Internal Sources External
n
i 2
§ 1 *
11 1 s 3
c .3 S * £ » 3
•Ha> • > y o
^ s a •al -3 «
Si. S1 H S ^ "5 45 S
las1 -a s « •a6- a -
.H4j>j gi *; u ^j 0 Tj
» 4J C U 7
Is Is*. -s
A O 3 ." ij «H
^ a, m o H «
* E C W -U JJ
mo o * o o
K u u v» ^ ^
.3
1 2
1 2
1 1
8 9
1 2
2 6
1 2
Adipic acid
Allyl chloride
Butadiene
n-Butanol
Carbon tetrachloride
Chlorinated hydrocarbons 3 2
(unspecified)
Cyclohexane 1
Epoxy
Ethanol
Ethylene
1
(olefins) 6O 2
Ethylene dichloride (EDO
Ethylene diamine (EDA)
Ethylene oxide 2
1
11 11
1
211 1
11 551.41
2
1
63 7 13 1 11 4 8
2 2
1 3
1 1
Ethylene glycol
Ether
Glycerin
Isopropanol
Maleic anhydride 2
Oxo process
Propylene
oxide
Phenol/acetone
Polyethylene 3 4
Polypropylene 4
Polyvinyl
chloride (WC)
Styrene/ethyl benzene 2
1
1
3 1
2
2 1
1
1 1
11 121
1 21
11 2392
1
Vinyl acetate 2 1
Vinyl chloride (monomer) 3 7
Xylenes
Total
78 24
15 86931
1
16 23 12 43 17 35 22 13
1
4 8
1
2 ,7
22 45
3
1
1 68
1 4 39 159
1 S
1 5
4
1 1
1
2 3
4
1 5
3
2 3
1 3
3 6 22
1 9
1 4 23
3
3 6
9 52
1 2
7 4 120 414
•Includes the incidents that occurred from January—April 1978 and from May—December 1979.
-------
II-3
lighting, a plant-wide electrical power failure may result in outages of cool-
ing water, steam, and compressed air, which require electrically operated
pumps, compressors, and controls. Because of the widespread effects of plant-
wide electrical power outages and because they can occur instantly and fre-
quently without warning, the resulting process upsets are usually severe.
Without adequate protective measures, catastrophic incidents such as fires,
explosions, and equipment rupture can result. Such critical situations are
normally avoided by provisions for alternative emergency power supplies to
essential equipment and/or other emergency alternatives (e.g., alternative
steam-driven pumps, supplies of emergency cooling water in overhead storage
tanks).
b. Steam—Plant steam required in large, multiprocess plants is usually primarily
supplied by a number of centrally located boilers but is frequently supple-
mented by steam generated by the recovery of heat from various process sources,
such as exothermic reactions, process furnaces, and incinerators. Because of
the common multiplicity of sources and uses, steam supplies are generally less
subject to sudden and total outages than are electrical power supplies; how-
ever, fluctuations in steam supply pressure, which are relatively common, can
cause significant process upsets. Common steam-consuming equipment that is
vulnerable to upsets includes turbines, compressors, pumps, and jet ejectors,
heated reactors, evaporators, preheaters, feed vaporizers, and distillation
column reboilers.
c. Cooling Water—Interruptions in the supply of cooling water are usually caused
by either the failure of cooling water pumps or cooling tower fans or by elec-
trical power outages and can result in severe process upsets. Critical re-
quirements for cooling water may include the control of exothermic reactions
and the quenching of high-temperature effluent streams from process furances.
Distillation column condensers, compressor interstage and after-coolers, and
refrigeration cycle condensers are commonxy vulnerable to the loss of cooling
water, with the subsequent release of VOC likely.
d. Compressed Air—Interruptions in compressed-air supplies usually result from
outages of air compressors either because of mechanical problems or because of
electrical power or steam outages. Common uses of compressed air include
-------
II-4
oxidation reactions and pneumatic instruments and controls. Although compressed-
air requirements for pneumatic instruments are relatively small compared to
direct-process requirements, the consequences of interruption in the supply are
usually severe.
2. Disturbances in Feed Supplies
a. General—Process upsets can result both from interruptions or variations in
feed supply rates and from variations in feed composition or purity. In
general process upsets resulting from variations in feed flow rates are more
likely for gaseous feed streams than for liquids or solids because the storage
of large quantities of gases is usually more difficult and costly. Frequently
there is little or no intermediate storage of gaseous materials between
producing and consuming units, and an upset in a producing unit may result in
an almost immediate corresponding disturbance in the consuming units.
Variations in feed composition or purity usually occur more gradually than rate
variations; however, the time required to re-establish normal stream composi-
tions in both the producing and consuming units may be extensive, and signifi-
cant quantities of off-specification materials may be vented when gaseous mate-
rials are produced.
3. Disturbances in Product Consumption
a. General—A cutback or shutdown of a unit that consumes gaseous materials can
cause an upset in the feed producing unit if the unit that suddenly goes down
is one that consumes a large part or all of the producing unit's output. As is
discussed in Sect. II-B.2, intermediate storage capacity for gaseous materials
is frequently very limited, and when a consuming unit suddenly reduces consump-
tion, the producing unit must either make a corresponding cutback or vent its
output until normal operation can be re-established. Continued normal produc-
tion rates with the venting of output from the producing unit usually occurs
only for short periods of time (i.e., a short-duration cutback by the consuming
unit or until the output of the producing unit can be reduced).
-------
II-5
C. INTERNAL CAUSES
1. Rotating Equipment Outages
a. Compressors and Blowers—The outage of compressors is the most significant
single cause of upsets from the standpoint of the number of incidents reported
and from the standpoint of the quantity of VOC that is vented. Compressors are
particularly vulnerable to upset situations because maintenance or repair re-
quirements are generally relatively high; operating problems, when they
develop, frequently require immediate shutdown; installed spare capacity is
usually minimal due to high capital costs; and temporary storage of the process
gas (at compressor suction conditions) is usually not feasible.
b. Pumps—Pump failure can be a significant cause of direct process upsets, as
well as the initiating cause of interruptions in essential utilities (e.g.,
failure of cooling water pumps, boiler feedwater pumps, and boiler fuel oil
pumps) and of interruptions in emission control devices.
c. Miscellaneous Mechanical Equipment—The failure of other items of mechanical
equipment, such as agitators, vacuum pumps, solids transfer equipment, is less
significant as causes of upsets with the potential for VOC emission.
2. Restrictions in Equipment and Piping
A significant cause of process upsets is the sudden development of restrictions
to flow (plugging) or heat transfer in piping and equipment. Most of these
restrictions occur when solids are formed or are deposited in piping and equip-
ment that normally contain liquid or gaseous materials. Frequent causes of
such solids formation include the partial pyrolysis of organic compounds, poly-
merization, precipitation of contained inorganic compounds that have limited
solubility, accumulation of ice or hydrates in low-temperature equipment caused
by abnormal concentrations of water in feed streams, and freezing of piping and
equipment subjected to abnormally low atmospheric temperatures.
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II-6
3. Control Problems
a. General—Control malfunction and improper operating performance can directly
cause process upsets. Also, controls and operator performance can affect the
severity and duration of upsets resulting from other causes. The importance of
controls and operator response in minimizing the effects of process
disturbances is discussed in more detail in Sect. III-E.
b. Process Instrumentation and Control—An automatic process control system
usually consists of a primary sensing element, a measuring element, the con-
troller proper, a power unit, and a final control element. Although process
upsets can result from malfunctions of any of the control elements, problems
with primary sensing elements and final control elements are the most frequent
ones.
In addition to problems directly attributable to the control elements, control
malfunctions may be caused by interruptions or fluctuations in power supplies
to the control systems. Control systems are almost always either electrically
or pneumatically powered (or a combination of the two) and therefore depend on
an uninterrupted supply of electrical power or compressed gas (usually dry
compressed air). Consequently, the reliability of power sources for control
systems is of primary importance.
c. Operating Personnel—Operator error or inattention is a frequent cause of
process upsets. Most operating errors occur during periods of nonroutine plant
operation (startups, shutdowns, maintenance, upsets from other causes). Lapses
or errors in communication are frequent sources of operational errors.
4. Direct Material Releases
a. General—The development of severe leaks, the*rupture of process equipment and
piping, and the failure or malfunctioning of pressure-relief devices are
significant sources of VOC emissions. In addition to the immediate and direct
release of VOC such incidents may also cause significant process upsets that
may result in additional emissions.
-------
II-7
b. Severe Leaks—Major leaks in piping and equipment that occur suddenly and that
require immediate isolation of the affected parts from adjoining piping or
equipment are considered as process upset causes and are sources of upset emis-
sions. Emissions from leaks that are predictable and that occur either con-
tinually or with high frequency but at low rates and are therefore considered
to be fugitive emissions. Fugitive emissions are discussed in a separate
report.1
Major leaks most frequently result from the failure of welds, gaskets, flanges,
or other fittings or from the failure of pump and compressor mechanical seals
and packing.
c. Rupture of Equipment_or'Piping—Sudden rupture of equipment and piping, explo-
sions, and fires are considered to be catastrophic incidents. Although they
are actually upset incidents, they are considered to be outside the scope of
this report because the emissions are usually of secondary importance compared
to safety considerations,- the incidents are very infrequent; the resulting
emissions are not predictable; and the control of the emissions is not usually
feasible.
d. Failure of Pressure-Relief Devices The premature activation of relief devices
can cause significant process upsets. The normal activation of pressure-relief
devices, which occurs when normal operating pressures are exceeded, is usually
the result of process upsets and not a primary cause,- however, emissions result-
ing from the activation of pressure-relief devices when the releases occur at
normal operating pressures or below the set or design pressures of the devices
are considered to be upset emissions.
^D~G.Erikson and V. Kalcevic, IT Enviroscience, Fugitive Emissions (September
1980) (EPA/ESED report, Research Triangle Park, NC).
-------
III-l
III. CHARACTERISTICS THAT DETERMINE THE CAPABILITY OF
PROCESSES TO ABSORB OR ADJUST TO DISTURBANCES
A. GENERAL
This section covers some of the characteristics of processes that determine the
severity and duration, and ultimately the potential for VOC emissions, of
upsets resulting from the initiating disturbances discussed in Sect. II.
B. SYSTEM HOLDUP
The holdup of a process system is the ratio of volume or capacity to the mate-
rial throughput rate. Generally, the greater the holdup of the system the less
sensitive it is to minor fluctuations or deviations in process parameters.
However, once an upset occurs, the duration of the upset is usually greater in
higher-holdup systems. Systems or equipment in which material is in the liquid
phase generally have greater holdup than vapor-phase systems.
C. MULTIPLE PARALLEL EQUIPMENT VS SINGLE-TRAIN EQUIPMENT
The trend in many of the SOCMI plants that produce large volumes of organic
chemicals by continuous processes has been toward the use of very large equip-
ment and single process trains and away from the use of multiple, parallel
items of equipment. Large single-train systems often have a number of distinct
advantages over smaller, parallel systems. The primary advantage is generally
lower unit costs. Unit capital costs generally decrease as capacity is in-
creased. Most instrumentation/control requirements (not including control
valves) and the resulting costs are virtually independent of production capac-
ity. Operating labor costs are generally virtually independent of equipment
capacity, and maintenance costs are also usually substantially lower for one
large item of equipment than for two or more smaller items with the same total
capacity.
Upsets resulting from the internally caused disturbances discussed in Sect. II
are generally more severe and of greater duration with single-train processes
than with processes that utilize multiple, parallel equipment, with the sever-
ity and duration of upsets tending to diminish as the number of parallel equip-
ment items increases. The number of internally caused disturbances will, how-
ever, increase because of the greater number of possible sources. The net
-------
III-2
effect is usually a lower potential for upset emissions from systems with
parallel equipment.
The use of parallel systems will usually not reduce the potential for upset
emissions caused by external disturbances (e.g., electrical power failure)
because they will usually simultaneously affect all parallel systems. This is
not necessarily true when parallel items are supplied by separate utility
sources such as separate electrical power supplies, or when one compressor is
steam-driven and a parallel compressor is electrically driven.
D. INTERMEDIATE STORAGE CAPACITY
A common characteristic of most continuous processes is the tendency for an
upset in one operation to be rapidly transmitted to other operations in the
process or to other process units within an integrated plant that either supply
the affected unit with feed material or consume products from it. Frequently
the effects of the secondary upsets are more severe and of greater duration
than the effects of the initial disturbance. The severity of the upset can
therefore be minimized if its effect can be confined to the initially disturbed
operation.
The primary means of preventing or minimizing the effects of secondary disturb-
ances is by providing adequate storage capacity for intermediate feed materials
or products, permitting the adjacent operations or units to continue to operate
in a normal fashion until normal operation in the affected unit is restored or
at least providing the secondary operations with sufficient time for orderly
shutdowns or cutbacks.
The cost of providing intermediate-storage capacity for a specific application
must be balanced against the potential for interruption and the severity of the
effects of an interruption. The intermediate storage of liquids is generally
more feasible than that for gases; however, gas storage may be provided by
atmospheric gas holders or by condensing the gases at elevated pressure and/or
low temperature (refrigeration), with subsequent storage as liquids.
Underground salt domes are commonly used for the storage of large quantities of
ethylene and propylene in the gaseous state at elevated pressures. Such under-
-------
III-3
ground storage provides sufficient capacity to permit the balancing of ethylene
production and consumption during relatively long-term shutdowns required for
major maintenance to the producing/consuming units. Salt-dome storage is
limited primarily to the Gulf Coast.
E. EMERGENCY/SPARE EQUIPMENT
1. General
Because of the capital requirements for equipment that is used only a small
fraction of the time the installation of emergency and/or other spare equipment
can usually be justified only for critical areas in which sudden outages can
cause severe or catastrophic occurrences or where poor reliability of equipment
and the need for frequent maintenance are a problem. Some of the situations in
which emergency/spare equipment is commonly provided are discussed in this sec-
tion.
2. Electrical Power
Since the total outage of electrical power can frequently result in critical or
even catastrophic situations, most plants have emergency electrical power
supplies for critical equipment. The normal power supply to most processing
plants is from public utility sources. The public power companies sometimes
provide processing plants with power supplied from two totally separate gener-
ating sources.
When generators located in the processing plant provide the emergency power
supply, they are usually sized to provide power to critical equipment only and
are not adequate to supply all normal plant requirements. Items commonly
supplied from plant emergency power sources include critical process compres-
sors and pumps, cooling-water pumps, boiler-feed-water pumps, cooling-tower
fans, air compressors that supply pneumatic instruments and controls, electri-
cally powered instruments, control-room lighting, and water pumps required for
fire fighting purposes. Emergency power supply systems are generally not
designed to prevent all process upsets from occurring but to prevent serious or
catastrophic upset incidents.
-------
III-4
3. Cooling Water
In addition to emergency power supplies provided for cooling-water pumps criti-
cal supplies of cooling water may also be protected with alternative steam-
driven spare pumps or with overhead water storage tanks that will provide cool-
ing long enough to shut down such critical equipment as exothermic reactors or
high-temperature pyrolysis furnaces. When closed cooling water systems using
forced-draft cooling towers are used to provide essential cooling water, the
cooling-tower fans may also be provided with emergency electrical power.
4. Steam
For critical steam requirements standby or emergency boilers may be provided.
Control systems that automatically shut off the steam supplies to noncritical
users in the event of partial steam supply outages (e.g., loss of one of two or
more boilers) can usually prevent the loss of supply or insufficient pressure
for critical uses.
5. Compressed Air
As is discussed in Sect. Ill D-2, when compressed air is needed to operate
pneumatic instruments and controls, the air supply is safeguarded with spare
compressor capacity and an emergency power supply.
6. Installed Spare Process Equipment
Spare equipment items are frequently installed in parallel with the items that
they are intended to replace, with the necessary valves provided to permit
rapid diversion to the spare equipment.
The primary advantage of providing installed spares is that the upsetting
effects caused by equipment outages can be minimized. Frequently, if the
outage can be anticipated and the switch to the spare item is made smoothly, no
significant process upset will occur.
Installed spares are frequently provided for pumps in critical service or in
services where outages are frequent because of high maintenance requirements.
Because of generally much higher capital costs for compressors than for pumps
the installation of spare compressors is not as common except in critical
services. The installation of spare equipment can generally be more easily
-------
III-5
justified if the spare item can be used as a replacement for any one of several
items (i.e., multiple, parallel systems) rather than as a replacement for a
single item.
p. PROCESS CONTROLS
The effectiveness of automatic controls can have significant impact on the capa-
bility of processes to adjust to certain disturbances without serious upsets
resulting. A detailed discussion of instrumentation and process control is
outside the scope of this report; however, several of the most significant
factors are discussed briefly below:
I. Response Time
The elapsed time between the initiation of a process disturbance and the appli-
cation of corrective action by an automatic control system can have a signifi-
cant impact on the control stability and the severity of process upsets caused
by disturbances. Control loops that have extensive time lag tend to be un-
stable, with resultant significant cycling of the controlled variables. The
primary sources of time lag are the times required for the controlled variable
to respond to the disturbance, for the sensing element to detect a change in
the controlled variable, and for the control system to apply corrective action.
Time lag caused by the control system itself is usually minor compared to the
time lag caused by delays in process response.
2. System Holdup
The effects of holdup are discussed in Sect. III-B.
3 Fail-Safe Features
In the design of automatic controls consideration must be given to the conse-
quences of the malfunctioning or total failure of the sensing elements. The
options normally available when failures occur are that the final control ele-
ment will assume the fail-open or fail-closed position or in some cases will
maintain the same position it was in at the time that the failure occurred.
The option selected will normally be the one that best guards against the
development of hazardous situations. If failure of the control system does not
create a potentially hazardous situation, the fail-safe position selected is
normally the one that minimizes the severity of any resulting upset.
-------
III-6
G. OPERATION
Most of the SOCMI plants that produce the bulk of organic chemicals utilize
continuous processes that rely primarily on automatic controls during normal
operation,- however, the ability of process operators and supervisory personnel
to respond quickly and effectively during startups, shutdowns, or upsets
largely determines the efficiency with which normal operation is re-established
and the corresponding severity and duration of upsets. Important aspects of
effective operation during abnormal situations include effective communication,
preplanned procedures to be used during abnormal situations, and advance
training in diagnosing the causes of abnormal situations and applying the cor-
rect procedures.
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IV-1
IV. PROCESS CHARACTERISTICS THAT DETERMINE THE POTENTIAL FOR
VOC UPSET EMISSIONS
A. GENERAL
The frequency and severity of the initiating disturbances (Sect. II) and the
characteristics that determine the capabilities of processes to absorb or ad-
just to disturbances (Sect. Ill) determine the frequency, duration, and sever-
ity of the resulting process upsets; however, process upsets, alone, will not
necessarily result in VOC emissions. The potential for VOC emissions during
process upsets is determined by the process characteristics discussed in this
section. An assessment of these characteristics is probably of greater value
for identification of processes with very low potential for VOC upset emissions
than for estimation of the quantities of emissions.
B. CHARACTERISTICS OF RAW MATERIALS, INTERMEDIATES, PRODUCTS, AND BY-PRODUCTS
1. Physical Properties
The vapor pressure is the most significant physical property of an organic
process material from the standpoint of its potential for VOC emission.
Figure IV-1 shows the atmospheric boiling points (vapor pressure = 760 mm Hg)
of groups of organic compounds that are frequently present in the SOCMI proc-
esses. The compounds with boiling points above ambient temperatures are not
normally released as VOC emissions unless they are transported by a carrier
gas, are released as vapor at temperatures above their boiling points, or are
discharged as liquids and subsequently evaporate. The potential for VOC emis-
sions from processes containing only compounds with low vapor pressures is
generally much less than that for processes containing compounds with higher
vapor pressures.
2. Chemical Properties
Important chemical properties include the mutual reactivity of process mate-
rials, the exothermic heats of reaction, and the potential for volumetric in-
creases resulting from increases in the number of moles of gas present. These
properties are significant not only for the organic compounds present but also
for the inorganic compounds, as well. Heat evolved from the reaction of both
organic and inorganic compounds can cause the temperatures of organic gases to
-------
IV-2
AMBIENT FEMPEBATUBF RANGE
2 3 * 5
Number of Carbon Atoms in Compound
Fig. iv-1. Boiling Point as a Function of Carbon Atoms in Compound
-------
IV-3
increase, thereby causing the pressures to increase. Similarly the generation
of inorganic gases such as CO can cause the pressure to increase and ultimate-
ly lead to the release of VOC.
C. PROCESS/SYSTEM CHARACTERISTICS
1. Volume/Throughput
The volume of equipment and piping and the throughput rates (combined with VOC
concentration) determine the quantity of VOC present in the system during an
upset and therefore establish the upper limit on the emissions that can occur
as the result of a process upset.
2. Pressure
Operations that occur at elevated pressure generally have greater potential for
upset emissions than operations conducted at or below atmospheric pressure.
The potential for emissions increases with the pressure-volume energy that can
be released during an upset.
3. Temperature
The effects of temperature on the potential for upset emissions are not as
clearcut as pressure effects are. Both high- and low-temperature operations
may have significant potential for upset emissions. Organic compounds whose
vapor pressures are not significant at lower temperatures may be present as
vapor in significant concentrations at elevated temperatures to present a
potential for VOC emissions. On the other hand low-temperature operations, in
which organic compounds with low boiling points are normally maintained as
liquids, are susceptible to upset situations that result in their vaporization.
In both cases emissions of VOC are most apt to occur in upset situations in
which the normal rate of heat addition is excessive; or, if heat is normally
removed, the rate of heat removal is less than normal, causing either abnormal
temperature increases or abnormal vaporization of liquid.
Operations in which low-boiling organic compounds are maintained as liquids by
refrigeration are particularly susceptible to upset emissions caused by
mechanical equipment (compressors) failure or power outages.
-------
IV-4
4. Carrier Gas Flow
Normal process emissions frequently result from the venting of non-VOC gases
that were introduced as feed impurities (e.g., nitrogen in air oxidation proc-
esses) or were formed as by-products. The vented gas will frequently contain
some VOC, the concentration being dependent on process conditions and on the
effectiveness of control devices.
Processes that vent significant quantities of carrier gas are often vulnerable
to process upsets, and relatively small upsets in process or control device
conditions can cause significant increases in the VOC concentration of the
vented gas.
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V-l
V. EMISSIONS
A. INTRODUCTION
Upset emissions are estimated to account for approximately 4—11 million Ib
annually, or only about 0.3—0.7% of the total VOC emissions from the SOCHI in
1978. Estimates of upset emissions, together with the corresponding initiating
causes, for 32 significant organic chemicals produced in TACB region 7 are
given in Table V-l. Estimates of upset emissions for the total SOCMI are given
in Table V-2. The estimates given in Table V-2 were obtained by prorating the
estimates from Table V-l (TACB region 7) to total industry production and from
separate estimates of emissions caused by ethylene plant compressor outages
(not included in Table V-l). Calculations of ethylene plant compressor-outage
emissions are given in Appendix A.
The estimates of upset emissions given in Tables V-l and V-2 are based on very
limited data and should be considered as order-of-magnitude estimates only.
The primary conclusion that may be drawn from those estimates is that upsets
are a relatively minor source of VOC emissions compared to fugitive, storage,
handling, and normal process emissions (see Appendix A, p A-6, for calcula-
tions).
B. ESTIMATION CRITERIA
Upset emissions are difficult to measure because they are intermittent and be-
cause emissions from specific sources are generally unpredictable as to fre-
quency, rate, and duration. The estimates for the industry were developed
primarily from data on upset incidents reported to the Texas Air Control Board
(TACB) by the SOCMI plants located in TACB region 7 (Houston area) from
January— April 1978 and from May—December 1979. These periods were selected
because specific information from the upset reports received by TACB during
those periods had been incorporated in a computerized data collection system
and were available in summary form. These summary data were supplemented with
additional information extracted from the relevant report logs maintained by
TACB during the periods.
Although the geographic area encompassed by TACB region 7 represents only a
small fraction of the total area in the United States, more than one-third of
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V-2
Table V-l. Estimated Annual Upset Emissions from
Organic Chemical Plants in Texas Air Control Board Region 7e
Initiating Cause
Number of Average VDC Emissions
Incidents per Incident (Ib)
Total Estimated
Emissions (M Ib)
Miscellaneous compressor outages
(ethylene plant compressors
not included)
Miscellaneous mechanical
equipment
18
24
3200
720
57.6
17.3
Major leaks
Restrictions (plugging/freezeup)
Control malfunction
Operator error
Relief-device failure
Electrical power. .failure
Other causes
Total
23
12
43
17
35
22
144
338
5700
900
600
1400
4460
2680
1160
131..1
10.8
25.8
23.8
156.1
59.0
167.0
648.5
Estimates were developed primarily from data on upset incidents reported to the Texas
Air Control Board by the SOCMI plants located in TACB Region 7 (Houston area) from
January—April 1978 and from May—December 1979.
Emissions resulting from major accidents, including the rupture of major equipment, fires,
and explosions, are not included in this table nor in the estimate of total upset emis-
sions.
"Estimated emissions resulting from 60 ethylene plant compressor outages are not
included in this table but were estimated separately to develop Table V-2.
Emissions estimated from power failures that were reported by TACB were for relatively
minor or localized power outages. No emission estimates were given for three plant-
wide power failure incidents reported during this.period.
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Table V-2. Estimated Annual Upset Emissions from SOCMI Plants in the U.S.;
(M = 1000)
Source
Current VOC
Losses from
Processes (m Ib)
Percent
Currently
Controlled
Emissions After Flares
fa Ib)
Estimated Reduction Attainable if
Currently Uncontrolled Vents from
Relief Devices are Flared (m Ib)
With 90% Control
Efficiency*3
With 98% Control
Efficiency*3
With 90% Control
Efficiency*3
With 98% Control
Efficiency*3
Ethylene plant
compressor
outages
82,100
98
9690
3250
1480
1610
Major leaks
Other upset
sources
Total
390
1,550
84,040
0
50
390
850
_ 10,930
390
790
4430
0
. 700
2180
0
760
2370
Estimates were based on upset incidents reported by plants in TACB region 7 and on the following criteria:
1. An estimated 5C? of ethylene production and 30% of other SOCMI production is in TACB region 7.
2. Emissions are proportional to production rates.
3. Ethylene plant compressor-outage emission calculations given in Appendix A.
4. Emissions from flares were estimated for flare efficiencies of 90% and 98%.
5. Ethylene plant compressor-outage emissions were assumed to be entirely discharged to flares.
6. 50% of other emissions from relief devices were assumed to be discharged to flares.
Actual emissions may be significantly greater_because estimates of emissions resulting from total plant power-failure
incidents are not included and because some upset incidents may not have been reported if the emissions were flared
smokelessly.
kplare efficiencies have not been satisfactorily documented except for specific designs and operating conditions.using
standard fuels. Efficiencies used are for tentative comparision purposes.
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V-4
the total quantity of chemicals produced by the SOCMI and more than half of the
ethylene and ethylene-based chemicals are produced in this region. It was
therefore concluded that a reasonable order-of-magnitude estimate of upset
emissions for the entire SOCMI could be obtained by prorating the upset emis-
sions estimated for TACB region 7 to the total, according to the relative
quantities of organic chemicals produced.
The information available from the TACB upset incident reports was quite com-
plete with respect to upset sources, initiating causes, and duration of upsets.
Information on the estimated quantities of VOC emitted was not included in many
of the reports, probably because in most cases the quantities were not known.
The estimated emissions shown in Table V-l were determined by averaging the
estimates for those sources that were included in the upset-incident reports to
TACB.
Estimates of upset emissions caused by ethylene-plant compressor outages were
not generally included in the upset information reported to TACB. The esti-
mates of emissions from these sources were developed from the number of ethylene-
plant compressor outage incidents reported to TACB (Table II-l), from an esti-
mate of the average material lost per compressor outage (based on the expe-
rience of one large ethylene manufacturer1), and from estimates of the average
efficiency of the final emission control devices (flares). (See Appendix A)
Because of the differences in estimating procedures and source data for
ethylene plant compressor outage emissions and other upset emission sources,
the separate estimates are not directly comparable. The separate estimates
were primarily used to develop order-of-magnitude estimates of total upset
emissions from the SOCMI.
*R. P. Paveletic, A. C. Skinner, and D. Stewart, "Why Dual Ethylene Unit
Compressors?" Hydrocarbon Processing 55(10), 135—138 (1976).
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VI-1
VI. APPLICABLE CONTROLS
GENERAL
Flares are the devices most frequently used for the terminal control of upset
emissions. Because upset emissions are usually relatively infrequent and of
short-term duration and because they can occur at extremely high and variable
rates, incineration, carbon adsorption, gas absorption, etc., are less fre-
quently applicable.
Often the most effective methods of reducing upset emissions are by eliminating
or reducing the frequency or severity of the initiating disturbances that cause
the upsets (Sect. II) or by improving the capability of the process to absorb
or adjust to disturbances (Sect. III).
Control methods are generally not applicable when emissions are caused by the
direct release of VOC resulting from the unpredictable and sudden rupture or
severe leakage of piping or equipment; however, if such incidents occur fre-
quently, a need is indicated for improvement in process design, operating and
safety procedures, equipment and piping specifications, or preventive mainten-
ance procedures.
ADD-ON CONTROLS
Flares
Elevated flares that utilize steam injection to provide smokeless emissions are
most commonly used to control upset emissions. Additional information on
flares is presented in a separate control device evaluation report.1
Because scrubbing devices are not adaptable to flares, flares are not normally
suitable for the control of emissions that contain significant concentrations
of inorganic acids, halogens, sulfur, or other inorganic components that will
cause objectionable emissions.
iy. Kalcevic, IT Enviroscience, Control Device Evaluation. Flares and the Use
of Emissions as Fuel (in preparation for the EPA, ESED, Research Triangle Park,
NC).
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VI-2
2. Other Add-On Controls
Flares may not be a suitable upset emission control method in some situations
and the use of other add-on controls (e.g., incineration, gas absorption) may
be required. Because the rapid relief of process equipment during upsets is
frequently necessary to prevent potentially hazardous situations, safety and
loss prevention must be a major consideration in the selection of upset emis-
sion controls.
C. ELIMINATION OF INITIATING DISTURBANCES
1. General
The common initiating disturbances that cause upset emissions and the methods
of reducing the number and severity of such disturbances are discussed in
Sects. II and III.
D. IMPROVEMENTS IN CAPABILITY TO ABSORB OR ADJUST TO DISTURBANCES
1. General
The factors that commonly determine the capabilities of processes to absorb or
adjust to disturbances are discussed in Sect. III.
The retrofitting of single-train equipment to dual or multiple, parallel sys-
tems is usually not feasible in existing plants; however, the impact of single-
train vs parallel equipment on upset emissions can be considered in the design
of new process facilities.
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VI I-1
VII. ASSESSMENT
SUMMARY
Upset emissions are defined as intermittent VOC emissions that occur when
normal process operation is disturbed by abnormal internal or external condi-
tions or events, excluding emissions that normally occur during scheduled
startup, shutdown, and maintenance periods. Upset emissions are relatively
minor compared to the other sources of VOC emissions (i.e., normal process
vents, fugitive, and storage and handling), accounting for only about 0.3 to
0.7% of the total and the impact of controlling those sources that are feasible
to control but are currently uncontrolled would be relatively minor. An esti-
mated reduction of about 2—2.5 million Ib of VOC/yr is projected if emissions
from all relief devices that are currently vented without control were flared.
The most significant sources of upset emissions are the processes that produce
and consume ethylene, with upsets caused by ethylene plant compressor outages
predominating.
The quantities of VOC that are released as upset emissions by specific proc-
esses are determined by the frequency and severity of initiating disturbances;
the capability to adjust to disturbances; the emission potential when upsets do
occur,- and the effectiveness of terminal control devices.
Flares are the control devices primarily used for the terminal control of upset
emissions. The general characteristics of upset emissions (i.e., intermittent,
unanticipated, infrequent, high and widely varying rates) generally exclude
other types of terminal control devices.
DATA ASSESSMENT
Because of their eratic nature upset emissions are very difficult to measure,
and very little direct emission data are available.
The conclusions presented in this report are based on order-of-magnitude esti-
mates of emissions for the total SOCMI, which were developed primarily from
upset-incident reports submitted to Texas Air Control Board (TACB) from the
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VII-2
SOCMI plants in region 7 (Houston area); estimates of material losses resulting
from ethylene-plant compressor outages, based on the reported operating experi-
ence of one large ethylene manufacturer,- and estimates of the degree of control
and the VOC removal efficiency of the flare systems currently used to control
compressor outage emissions from existing ethylene plants.
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APPENDIX A
UPSET EMISSION ESTIMATE CALCULATIONS
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A-3
UPSET EMISSION ESTIMATE CALCULATIONS
I. SUMMARY OF CRITERIA FOR EMISSION ESTIMATES
Following is a summary of the criteria used as the basis for the estimates of
upset emissions caused by ethylene plant compressor outages.
1. The average material loss per compressor outage (trips and checks only)
from a plant producing 1 billion Ib of ethylene per year is 1,800,000 Ib
with single compressor trains and 135,000 Ib with dual trains (Table V-2).
2. Material losses caused by compressor outages are proportional to ethylene
production.
3. The average capacity of plants using gas liquid feedstocks (primarily
ethane and propane) is 513.6 million Ib of ethylene per year.1
4. The average capacity of plants using heavy-liquid feedstocks (primarily
naphthas and gas oils) is 1107.5 million Ib of ethylene per year.1
5. Distribution of single and dual compressor trains:
Plants using ethane/propane (E/P) feedstocks, 50% with single com-
pressor trains; 50% with dual trains.1
Plants using naphtha/gas-oil (N/G) feedstocks, 90% with single com-
pressor trains; 10% with dual compressor trains:1
6. Distribution of plants using E/P and N/G feedstocks:1
Plants using E/P feedstocks
Plants using N/G feedstocks
Total
Number of Plants
39
18
57
% of Total
68.4
31.6
100
7. Compressor outages in ethylene plants with dual compressor trains occur
twice as frequently as in plants with single trains.
8. An average of 98% of the material lost because of compressor outages is
controlled by flares2 operating within their smokeless capacities.
XR. L. Standifer, IT Enviroscience, Ethylene (February 1981) (EPA/ESED
report, Research Triangle Pork, NC).
2V. Kalcevic, IT Enviroscience, Control Device Evaluation. Flares
and the Use of Emissions as Fuel (in preparation for EPA, ESED, Research
Triangle Park, NC).
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A-4
II. ESTIMATED ANNUAL UPSET EMISSIONS FROM ETHYLENE-PLANT COMPRESSOR OUTAGES IN
REGION 7 (HOUSTON AREA)
A. BASIS (SEE SECT. V)
1. Number of ethylene plant compressor outage incidents: 60 (see Table II-l)
2. Average material loss per incident for plant producing 1 billion Ib of
ethylene per year: single-train processes, 1.8 million Ib; dual-train
processes, 135,000 Ib.
3. Average annual capacity (million Ib of ethylene): plants using ethane/
propane (E/P) feed, 513.6; plants using naphtha/gas-oil (N/G) feed,
1107.6.
4. Breakdown of number of single- vs dual-train plants; E/P vs N/G plants:
E/P process plants, 68.4%.
N/G process plants, 31.6%.
E/P/ process plants, 50% with single trains; 50% with dual trains.
N/G process plants - 90% with single trains,- 10% with dual trains.
The above breakdown converts into the following values:
Single-train E/P plants: 0.5 X 68.4% = 34.2
Dual-train E/P plants: 0.5 X 68.4% = 34.2
Single-train N/G plants: 0.9 X 31.6% = 28.4
Dual-train N/G plants: 0.1 X 31.6% = 3.2
100%
B. CALCULATIONS
1. Breakdown of Compressor Outage Incidents
The following calculations are based on the assumption that the frequency of
incidents in dual-train plant is twice that in single-train plants:
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A-5
Single-train plants (E/P and N/G): 34.2 + 28.4 = 62.6%.
Dual-train plants (E/P and N/G): 34.2 + 3.2 = 37.4%.
Single- train plant incidents: &&
62 5 +(2X 37 4) '
Dual-train plant incidents: ^^t^'^vj *\ = 54.4%.
oZ.b T {£ X o/.4y
34 2
Number of single-train E/P plant incidents: 45.6% X ' „ X
60 incidents = 14.95.
28 4
Number of single-train N/G plant incidents: 45.6% X 34 2+28 4 X
60 incidents = 12.41.
Number of dual-train E/P plant incidents: 54.4% X '-> X
•J^X • fc T i3 * ^
60 incidents = 29.85.
Number of dual-train N/G plant incidents: 54.4% X ' X
jfr • 4« T* O • b
60 incidents =2.79
Total 60.0
2. Estimated Material Losses
From single-train E/P plants: 14.95 incidents/yr X 1.8 X 106 Ib
lost/incident X 513-6 x 10 - 13 82 x 106 Ib/yr
1000 X 106
From dual-train E/P plants: 29.85 incidents/yr X 1.35 X 10s Ib
lost/incident X 513-6 x 10 = 2.07 X 106 Ib/yr
1000 X 106
From single-train N/G plants: 12.41 incidents/yr X 1.8 x 106 Ib
1107.6 X 1C
1000 X 10s1
1 1 07 fi V 1fl6
lost/incident X 11U/'6 x 1° = 24.74 X 106 Ib/yr
aAverage plant capacity (E/P--513.6 X 106 Ib/yr, N/G--1107.6 X 106 Ib/yr)
bplant capacity basis for estimated material losses (1000 X 106 Ib/yr).
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A-6
From dual-train N/G plants: 2.79 incidents/yr X 1.35 X 10s Ib
lost incident X 1107-6 x 10s = 0.42 X 106 Ib/yr
1000 X 106
Total annual material losses from ethylene plant compressor outages in
TACB Region 7 = 41.05 X 106 Ib/yr.
3. Estimates of VOC Emissions from Ethylene Plant Compressor Outages Based on 98%
of VOC Material Losses Being Controlled by Flares and on 98% and 90% Flare
Efficiencies
At 98% flare efficiency: 41.05 X 106 X [0.02 + (0.98)(0.02)] = 1.625 X 106 Ib/yr
At 90% flare efficiency: 41.05 X 106 X [0.02 + (0.98)(0.10)] = 4.844 X 106 Ib/yr
III. ESTIMATED ANNUAL UPSET EMISSION FOR ENTIRE SOCMI INDUSTRY IN THE UNITED STATES
A. BASES
1. Upset emissions are proportional to production.
2. 50% of ethylene production is in TACB region 7.
3. 33.3% of other SOCMI production is in TACB region 7.
4. Flare efficiencies are 90 and 98%.
5. 98% of ethylene plant compressor-outage losses are flared.
6. Upset losses from leaks are released without control.
7. 50% of all other losses from upsets are flared.
8. Estimated emissions in Table V-l do not include flare inefficiencies.
c
Flare efficiencies have not been satisfactorily documented except for specific
designs and operating conditions using standard fuels. Efficiencies used are
for tentative comparison purposes.
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A-7
B. CALCULATIONS
1. Total Annual Upset Emissions from Ethylene Plant Compressor Outages
At 98% flare efficiency: 1-625 *Q10S& lb/yr = 3.250 X 106 Ib/yr = 3250 M Ib/yr
At 90% flare efficiency: 4-844 x 10—ik/ZI = 9.688 x 106 Ib/yr = 9688 M Ib/yr
0.5
2- Total Annual Upset Emissions from Major Leaks (See Table V-l)
131. la M lb ...
O33 = 393 M lb/yr
3. Total Annual Upset Emissions from All Other Sources
Emissions not flared:
= 776 M lb nOt flared
Emissions from flares:
At 98% flare efficience 776 M lb X 0.02 = 15.5 M lb
At 90% flare efficience 776 M lb X 0.10 = 77.6 M lb
alncludes ethylene plant emissions. The use of the general production factor
(33.3%) for the total rather than the ethylene production factor (50%) for the
respective portion of this minor source does not significantly affect the over-
all estimate.
Includes all ethylene plant emissions except those resulting from compressor
outages. The use of the general production factor (33.3%) rather than the
ethylene production factor (50%) for the ethylene industry portion of these
minor sources does not affect the overall estimate significantly.
cFrom Table V.
From Table V.
e.
'50% not flared.
General product:
TACB Region 7).
General production factor (33.3% of total SOCMI production estimated to be in
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A-8
4. Total Annual Upset Emissions from SOCMI
98% Flare Efficiency 90% Flare Efficiency
Ethylene plant compressor
outages 3250 M Ib 9688 M Ib
Major leaks 393 M Ib 393 M Ib
Other emissions not flared 776 M Ib 776 M Ib
Other emissions from flares 16 M Ib 78 M Ib
Total 4435 M Ib 10935 M Ib
IV. ESTIMATED IMPACT OF UPSET EMISSIONS ON TOTAL SOCMI EMISSIONS OF VOC
The total annual VOC emissions are estimated to be 1.5 X 109 Ib (1979).a The
estimated contribution of upset emissions is as follows:
(1) At 98% flare efficiency:
4.4 X 106 Ib/yr upset emissions _
1.5 X 10a Ib/yr total emissions A 1UU
(2) At 90% flare efficiency:
10.9 X 106 Ib/yr upset emissions in_ n 7,0
1.5 X 109 Ib/yr total emissions X 10U *'°
aBased on preliminary estimates of VOC emissions for the SOCMI made at the beginning
of this program. Revised estimates, based on information obtained during the
course of the program, will be included in a forthcoming summary report.
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-450/3-80-024
RECIPIENT'S ACCESSION NO.
4. TITLE ANDSUBTITLE
Organic Chemical Manufacturing
Volume 2: Process Sources
. REPORT DATE
December 1980
PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
J. W. Blackburn
R. L. Standifer
3. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
IT Enviroscience, Inc.
9041 Executive Park Drive
Suite 226
Knoxville, Tennessee 37923
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
.68-02-2577
12. SPONSORING AGENCY NAME AND ADDRESS
DAA for Air Quality Planning and Standards
Office of Air, Noise, and Radiation
U.S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
13. TYPE OF REPORT AND PERIOD COVERED
14. SPONSORING AGENCY CODE
EPA/200/04
IE. SUPPLEMENTARY NOTES
16. ABSTRACT
EPA is developing new source performance standards under Section 111 of
the Clean Air Act and national emission standards for hazardous air pollutants
under Section 112 for volatile organic compound emissions (VOC) from organic
chemical manufacturing facilities. In support of this effort, data were gathered
on chemical processing routes, VOC emissions, control techniques, control costs,
and environmental impacts resulting from control. These data have been analyzed
and assimilated into the ten volumes comprising this report.
This volume covers the following process emission sources within organic
chemical plants: air oxidation reactions, reactions involving carrier gases,
vacuum producing systems, sulfuric acid recovery operations, and process upsets.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b. IDENTIFIERS/OPEN ENDED TERMS
COSATi Field/Group
13B
•,B. DISTRIBUTION STATEMENT
Unlimited Distribution
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
245
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 (Rev. 4-77) PREVIOUS EDITION >s OBSOLCTE
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