United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EPA-450/3-80-024
December 1980
Air
Organic Chemical
Manufacturing
Volume 2:  Process
Sources

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                                 EPA-450/3-80-024
Organic Chemical  Manufacturing
   Volume 2:  Process Sources
          Emission Standards and Engineering Division
          U.S. ENVIRONMENTAL PROTECTION AGENCY
             Office of Air, Noise, and Radiation
          Office of Air Quality Planning and Standards
          Research Triangle Park, North Carolina 27711

                  December 1980

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                                       Ill
     This report was furnished to the  Environmental  Protection Agency  by  IT  Enviro-
     science,  9041  Executive  Park Drive,  Knoxville,  Tennessee  37923, in fulfillment
     of Contract No. 68-02-2577.   The  contents  of this  report  are  reproduced herein
     as received from IT Enviroscience.   The  opinions,  findings, and conclusions
     expressed are  those of the authors  and not necessarily those  of the  Environmen-
     tal Protection Agency.  Mention of  trade names  or  commercial  products is not
     intended to constitute endorsement  or recommendation for  use.  Copies of this
     report are available,  as supplies permit,  through  the Library Services  Office
     (MD-35),  U.S.  Environmental Protection Agency,  Research Triangle  Park,  North
     Carolina  27711, or from National Technical Information Services,  5285  Port
     Royal Road, Springfield, Virginia 22161.
D124R

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                                CONTENTS
                                                            Page
1.    CARRIER GAS GENERIC STANDARD APPROACH                   1-i


2.    EMISSION PROJECTIONS FOR CARRIER GAS PRODUCING
     REACTIONS                                               2-i


3.    AIR OXIDATION EMISSION PROJECTIONS                      3-i

4.    VACUUM SYSTEM EMISSION PROJECTIONS                      4-i


5.    UPSET RELEASES                                          5-i

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                                      REPORT  1
                            THE GENERIC  STANDARD APPROACH
                                   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
                                     March 1981
D127G

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                              CONTENTS OF REPORT 1
THE GENERIC STANDARD APPROACH                                       1-1
A.  CONCEPT DEVELOPMENT                                             1-1
B.  STANDARD SUPPORT                                                1-2
C.  PROJECTION OF VOC EMISSIONS                                     1-3
    1.  Total Flow                                                  1-3
    2.  VOC Concentration                                           1-6

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                                          1-1
                          I.  THE GENERIC STANDARD APPROACH

A.   CONCEPT DEVELOPMENT
     The synthetic organic chemicals industry is estimated to produce 350 to 400
     chemicals by about 600 processes.   For processes used to manufacture the same
     products, differences in the catalysts, reaction conditions,  separations,
     product purity, reactant type and purity,  types of storage,  waste treatment,
     and company process design philosophy all affect the specific design,  perfor-
     mance, and emissions at the individual production site.

     The standard approach to the control of volatile organic compounds (VOC) in the
     organic chemicals industry consists of identification of the major emission-pro-
     ducing processes and generation of industry-wide regulations for manufacturers
     of specific products, e.g., VOC regulations for manufacturers of formaldehyde,
     acrylic acid, and others.  This is the standard approach normally required by
     EPA for the collection of emission and control-device performance data to
     generate support documents for VOC New Source Performance Standards (NSPS).  In
     this approach the major advantages are that the emission sources common to all
     manufacturers of that product are highlighted and investigated.  Data from this
     effort allow the regulatory agency to estimate the volume and composition of
     the emissions from plants producing a common chemical and to estimate the cost
     effectiveness of various control devices on that common emission.

     Unfortunately, the many plant-to-plant variations that exist can still cause
     significant variations in the organic emissions of existing plants.  Some 400
     to 600 product regulations would be necessary to completely cover the industry,
     and sensitive data are required to assure that the regulation applies to all
     the manufacturers of a specific product.  If regulations could be developed for
     existing products, more of them would be needed for the steady stream of new
     products; also, technology changes in the forthcoming years would make many of
     these current product standards obsolete.

     The growing realization that it is impossible to apply the normal product
     standard approach to regulating process emissions from SOCMI substantiates the
     belief that the generic approach is the only approach that is applicable and
     sustainable.  The starting point for this study is that the generic approach

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                                         1-2
     has been accepted as the only logical procedure for developing regulations for
     fugitive emissions or for storage.   Industry study reports have been issued
     that establish a basis for these regulations,  based on the equipment,  the
     operating conditions, and the physical properties of the chemicals involved.
     To generate generic process-emission standards, a procedure is developed that
     relates unit processes,  unit operations,  and physical properties consistent
     with the approach used for fugitive and storage emissions.

     In this study the applicability of a generic regulatory approach to unit proc-
     esses (reactions) and to unit operations  is investigated.   Priorities  were
     determined by use of established survey and ranking data to identify the unit
     processes and unit operations associated with the greatest emissions.   The
     survey and ranking program established that 140 compounds  account for  an esti-
     mated 86% of the SOCMI VOC emissions and identified the unit processes and unit
     operations associated with the production of each compound.

B.   STANDARD SUPPORT
     The generic standard methodology is comprised of three parts.  The first part
     consists of projecting the emissions involved through establishing the VOC
     emission range to be expected and defining the method that will best estimate
     the ranges of total flow and VOC concentration for the particular process group
     being considered (i.e.,  air-oxidation processes, vacuum systems).  Maximum and
     minimum flow and VOC concentrations are established.  Therefore since  all
     possible emissions from the concerned generic grouping are described,  the most
     appropriate control method or methods can be identified.  It is important to
     mention that the emission projection is not intended to be an exact predictive
     method for forecasting emission data.  Although this would be desirable, it is
     sufficient for the emission projection to generate data for a reasonable range
     of flow and composition.  This range then allows application of the control-
     device evaluation and costs to determine the corresponding range of cost and
     energy impacts that will cover the reasonable scope of emissions in SOCMI.

     The second part of the generic standard methodology consists of an evaluation
     of applicable control devices.  An assessment must be made of the applicability
     of the control device to the emission ranges concerned.  The control-device

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                                     1-3
design criteria must be established,  and the emission variables  having signifi-
cant impact on control device design  must be identified.   This will  lead to  a
set of specific designs,  utilizing the proper design equations and procedures,
that will adequately represent the application of the control device to the
control of VOC emissions  within the specified emission ranges.   Control-device
capital costs and operating costs are generated for various key  flows and com-
positions.  Control-device evaluation reports have been prepared for the EPA on
thermal oxidizers, high-temperature thermal oxidizers, catalytic oxidizers,
carbon adsorbers, absorbers, condensers, and flares and the use  of emissions as
fuel in which the technical and economic applicability of each  control device
to various organic emissions is assessed.

The third part of the methodology consists of an impact assessment.   The cost
and energy effectiveness  must be determined for each control device evaluated
over the appropriate range of flows and composition based on information from
the emission projection and control device evaluation reports.

Knowledge of the emission range control technology and costs of control will
lead to the development of an optimal standard for each generic area.

PROJECTION OF VOC EMISSIONS

Total Flow
To satisfy the first part of the generic standard support approach, methods
must be defined to estimate the emissions total flow and VOC concentration
range (thereby the total VOC flow) for the generic area being developed.  In
order to accomplish this, a common factor between most air emissions  is sought.
In this study it is assumed that an organic air emission can result  from chemi-
cal process equipment if a gas is purged from the equipment into  the  atmosphere
and if the gas contacts liquid or solid organics within the equipment.  This
gas is called the carrier gas, which  is defined as an organic or  inorganic
compound that exists as a vapor or gas at the temperatures and  pressures
existing at the emission point.  If a chemical process vessel does  not generate
a carrier gas, it cannot have an organic emission.   (This  analysis  does not

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                                         1-4
     include air emissions arising from liquid- or solid-waste streams such as some
     fugitive or secondary emissions.   In some fugitive emissions,  leaking liquids
     or solids evaporate to generate an organic emission.   In some  secondary emis-
     sions, liquid or solid streams are exposed to the atmosphere and the organics
     evaporate, generating organic emissions.)

     The assumption in the preceding paragraph allows chemical processes to be
     classified and ranked through an analysis of the possibility that each process
     will generate a carrier gas.   Chemical reactions generate carrier gases because
     of the reactions themselves and because of mechanisms unrelated to the reac-
     tion.

a.   Reaction-Related Carrier Gases	Chemical reactions generate carrier gases in
     several ways.  The reactants  for a specific reaction may contain gaseous
     impurities or may have an excess amount of a gaseous reactant  for that parti-
     cular reaction.  A product or by-product from a reaction can also be a poten-
     tial carrier gas.

     In every case two additional  conditions must be satisfied for  a potential
     carrier gas to actually be emitted from the equipment:  the potential carrier
     gases must not disappear as a result of reacting to nongaseous chemicals before
     being emitted and they must not have a net change in physical  state from gases
     to liquids or become adsorbed on solids.  In other words once  gases are formed
     or introduced in the equipment, they must remain gases up to the point of dis-
     charge or be stripped or desorbed from any liquids or solids at the point of
     discharge.  For example, carbon dioxide may be generated in an oxidation reac-
     tion but if it is scrubbed in a caustic scrubber, much of it can be converted
     to nongaseous inorganic carbonates and thus prevent an emission.  Some organic
     compounds with normal boiling points greater than the ambient  temperature may
     exist as gases inside the chemical equipment but are normally condensed before
     being emitted.  These compounds are not carrier gases.

b.   Nonreaction-Related Carrier Gases	Potential carrier gases are introduced into
     chemical process equipment for reasons unrelated to reactions; one reason is to
     control the physical conditions (temperature, pressure) in process equipment,
     another is to control the chemical atmosphere in process equipment, and the
     third one is uncontrolled leakage into equipment under reduced pressure.

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                                    1-5
Gases used to control physical conditions	Gases such as air,  N2/  C02,  and
others are sometimes introduced into process equipment to cause cooling,  heat-
ing, or elevated pressures or to control the pressure of vacuum systems.   For
processes operating under high pressure the amount of gases introduced can be
significent.  Slightly elevated pressures may be required for control of fluid
flow or for transfer operations.  Ultimately, gases used to achieve elevated
pressures are released as potential carrier gases when the process  streams
return to atmospheric pressure at the end of the process train.  This may be a
continuous emission in continuous equipment or a periodic emission  in batch or
continuous equipment.  Unexpected depressurization results in an upset emis-
sion.

Gases used to control the chemical atmosphere	Sometimes flammable or reactive
chemicals are handled in chemical equipment, often requiring that the gaseous
atmosphere in the equipment be controlled so as to prevent detonation, deflagra-
tion, or decomposition.  Inert gases (gases that do not react under the condi-
tions in the equipment being used) or organic gases are used to ensure that
detonation, deflagration, or decomposition does not occur.  Inert gases can
also be used to sweep away gaseous reaction by-products that cause  corrosion,
decreased reaction rates, or other deleterious effects on the equipment per-
formance .

Gases resulting from leakage because of reduced pressure	The two  preceding
cases (gases introduced to control conditions and the chemical atmosphere) are
usually under some control by the plant designers or operating personnel.
However, this case of leaks introducing gases into vessels under vacuum is
largely beyond the control of plant personnel.  This carrier gas results from
air leaking into vacuum equipment through small seal imperfections  and discon-
tinuities caused by a pressure drop between the environment and the vacuum.
Air that leaks into the equipment is normally emitted from the vacuum devices
as a carrier gas.

Sources with Multiple Types of Carrier Gases	All chemical processes can be
analyzed in terms of the gas sources mentioned above.  Very few chemical proc-
esses generate carrier gases from only one mechanism.  However, sometimes  one
mechanism from a source will override all the other mechanisms.  Air-oxidation

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                                          1-6
     processes, for instance, generate carrier gases because of the inert nitrogen
     and unreacted oxygen introduced with the air,  the carbon monoxide,  and the car-
     bon dioxide generated in the reaction.   Some vapor-phase air oxidations also
     generate vapor-phase organic products that are potential carrier gases.  With
     some air oxidations an inert gas is used for control of the reaction conditions
     or of the chemical atmosphere.

     This one type of reaction,  air  oxidation, can generate carrier gases from a
     variety of mechanisms, but  the  overriding mechanism of emission formation is
     the inert nitrogen fed in the air as an impurity.  Since the nitrogen is a
     function of the reaction stoichiometry, the range of carrier gas flow and ulti-
     mately the VOC emission can be  projected.  On the other hand in vacuum equip-
     ment the major carrier gas  is largely generated by the leakage of air into the
     equipment although carrier  gases can arise from the control of pressure, tem-
     perature, or chemical atmosphere or from reactions.  Specific generic standard
     reports have been prepared  that illustrate emission projection for both air-
     oxidation processes (a reaction-based approach) and vacuum systems (a nonreac-
     tion-based approach).  These reports are contained in this volume.

     Sometimes organic emissions arise when a process upset or runaway reaction
     causes a rapid buildup of carrier gas,  which is released for safety reasons.
     These upset releases arise  from the mechanisms mentioned above.  Liquids that
     volatilize more rapidly than they can be condensed or stored in existing equip-
     ment can create an organic  carrier gas from a chemical that is normally a
     liquid at atmospheric conditions.  For example, a reactor with, say, liquid
     benzene could experience a  rapid increase in temperature or decrease in pres-
     sure, causing the benzene to boil inside the equipment.  This benzene vapor
     could become a carrier gas  if insufficient cooling capacity existed before the
     emission was discharged. Benzene vapor could escape through equipment vents as
     a carrier gas and immediately dissipate in the atmosphere before it would be
     able to condense.  A separate report on upset releases is included in this
     volume.

2.   VOC Concentration
     The concentration of VOC in the emission must be estimated in order to  calcu-
     late the total amount of VOC emitted.  It is difficult to generalize about  this

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                                    1-7
concentration.  If the carrier gas flow is much larger than the VOC flow can
possibly be, a maximum can be set on the VOC concentration.  For example,  air-
oxidation processes generate so much carrier gas that even if the entire plant
chemical production was VOC, the VOC concentration would be less than 5 mole %.
In this special case VOC emissions are likely to be very large, whereas the VOC
concentration will be very small.  In other cases the chemicals being processed
must be known in order for the VOC concentration to be calculated.

When the VOC normal boiling points are greater than the ambient temperature
(organics that are liquids or solids at normal conditions) and the chemicals
are known, the VOC content can be estimated by assuming saturation at the emis-
sion temperature.  Although this will normally be a high estimate, it is suffi-
cient to yield a VOC emission range and therefore enable control devices to be
selected and cost estimates to be developed.  If the normal boiling point of
the VOC is less than the ambient temperature, then the VOC itself can be an
organic carrier gas and can be the overriding VOC contributor  for that emis-
sion.  VOC for this case can be estimated from the techniques  given in the
report in this volume entitled Emission Projections for Carrier-Gas-Producing
Reactions.

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                                         2-i
                                     REPORT 2


              EMISSION  PROJECTIONS FOR CARRIER-GAS-PRODUCING REACTIONS

                                  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
                                     March 1981
D127A

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                                         2-iii
                                 CONTENTS  OF  REPORT 2
  I.   THE GENERIC STANDARD APPROACH                                         1-1
 II.   CARRIER-GAS-GENERATING PROCESSES IN THE SYNTHETIC ORGANIC            II-l
      CHEMICALS MANUFACTURING INDUSTRY
III.   EMISSIONS                                                           III-l
      A.   Introduction                                                   III-l
      B.   Carrier Gasses	Estimation of Total Flow                      III-l
      C.   VOC Concentration                                              111-28
 IV.   CHLORINATION REACTIONS                                               IV-1
      A.   Estimation of Total Flow                                        IV-1
      B.   Estimation of VOC                                               IV-11
      C.   Actual Chlorination Reaction Emissions                          IV-12
  V.   CONTROL OPTIONS FOR CHLORINATION REACTORS                             V-l
      A.   In-Process Control                                               V-l
      B.   Add-On Controls                                                  V-3
 VI.   REFERENCES                                                           VI-1
                                APPENDICES OF REPORT 2

A.    PRODUCTS ORGANIZED BY UNIT PROCESSES                                 A-l
B.    EPA INFORMATION SOURCES                                              B-l
C.    PRODUCTS ORGANIZED BY CARRIER GASES                                  C-l
D.    SAMPLE CALCULATIONS                                                  D-l

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                                          2-v


                                  TABLES OF REPORT 2

Number
 II-l   Unit Process Used to Manufacture Organic Chemicals                 II-2
 II-2   VOC Emissions from Major Unit Processes                            11-10
 II-3   VOC Emissions from Reactions                                       11-14
III-l   Classification of Inorganic Carrier Gases                         III-2
III-2   Organic Compounds Likely To Be Carrier Gases                      III-5
III-3   Reaction-Reactant-Related Carrier Gases                           III-7
III-4   Reaction-Product-Related Carrier Gases                            111-15
III-5   Carrier Gases from Dissolved Gases in Organic Liquids             111-24
III-6   Carrier Gases from Gases Dissolved in Water Feed                  111-25
III-7   Gas Flow from Chemical Decomposition                              111-27
III-8   Flammability Envelope Inert-Gas Concentration                     111-30
III-9   Flammability Range of Inert-Gas Flow                              111-31
 IV-1   Products That Use Chlorination Reactions                           IV-2
 IV-2   Ratios of Carrier Gases to Chlorination Products                   IV-3
 IV-3   Variables for Estimating VOC Emissions from Chlorination           IV-7
        Reactions
 IV-4   Projected Uncontrolled VOC Emissions from Chlorination Reactors    IV-9
 IV-5   VOC Emissions from Chlorination Reactors                           IV-13
  V-l   Possible Control Devices for Emissions from Chlorination Reactors   V-2
  A-l   Products Organized by Unit Processes                                A-3
  C-l   Various Reactant Carrier Gases                                      C-3
  C-2   Various Product Carrier Gases                                       C-15
                                   FIGURES OF  REPORT 2

  II-l   Actual VOC Reaction Emission Data                                 11-13
 III-l   Organic  Compound  Boiling Points                                   III-4
 III-2   Saturation Concentration of Specific  VOC  in Gas                   111-29

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                                     1-1
                     I.   THE GENERIC STANDARD APPROACH

For a discussion of the  basis for the generic standard concept see Report 1
in this volume entitled  The Generic Standard Approach. The reader is advised to
read this report since the concept and essential terminology are explained
therein.

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                                    II-l
               II.  CARRIER-GAS-GENERATING PROCESSES IN THE
            SYNTHETIC ORGANIC CHEMICALS MANUFACTURING INDUSTRY

The synthetic organic chemicals industry is comprised of a wide variety of unit
processes.  Table II-l gives the relative VOC emission ranking developed by IT
Enviroscience for 140 different chemicals manufactured in the industry.  This
ranking is based on the total VOC emissions from storage, fugitive,  secondary,
and process emissions, as well as on an estimate of the severity of the VOC
being emitted from the standpoint of quantity and toxicology.  In addition the
process emission can arise from all process operations-reactions, distilla-
tions, crystallizations, etc.  This ranking was used to target 64 products and
97 processes that have been specifically addressed in 39 product reports pre-
pared as part of this program.  These reports cover over 85% of the VOC emis-
sions initially projected for 1982.  Further discussion of this ranking may be
found in Appendix B of Volume 1.

Table II-l also presents a ranked listing of products and the unit processes or
reactions used to manufacture them.  More than one process can be used to
manufacture a product and more than one type of reaction can be used.  For
example, ethylene dichloride can be manufactured by either the oxychlorination
or the direct chlorination process.  In the production of methyl methacrylate a
series of different reactions are used to convert the reactants to methyl
methacrylate.  The first reaction in a series for a particular product is
designated "A" and the next "B."  More than one "A" for a product indicates
that the product is made by more than one unit process, but was not assigned
additional processes.  The unit processes (reactions) identified in the table
are based on a rather specific classification of processes.  For instance, oxy-
acetylation, oxychlorination, and ammoxidation are listed but are all special
cases of oxidation.  The specificity is required because the actual reaction
chemistry and stoichiometry are often needed to develop emission projections.

Table II-2 is a compilation of the major unit processes and their total 1982
estimated production and emissions as developed in the ranking process men-
tioned above.  Products that make up the unit processes are grouped and shown
in Appendix A.

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Table II-l. Unit Processes

Used for the
Manufacture of 140
Synthetic Organic
Chemicals '
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-------




Table II-l. (continued)





Product Process
30. CHlKOP1i£»E 1001 »!A WTAirlENE
31. dKTL LEADS 5! ELECTROLYSIS
31. ALIOTl. LEADS «I ETH1L CW.ORIK
32. ACETWE 49Z ClUtK
32. ACETONE 31Z IStHttPANO.
33. ETHYL M.OPIOE 4Z ETWMX/ETIwe
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J5. Vim. ACETATE  72Z [THTLDS WTO1 PH6SE
35. VINYl ACETATE (Ml 152 ETHTIDC UOUtB P*S£
34. ICTHTUK DUKIK 331 ICTHMC CHLKHATIOII
It. CWYIEK CH.OSIK 451 KETHAWl/ltTHYi. W-OtltC
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37. 1.3 IUTA8IEK I3Z H-WTAIC
37. 1.3 BUTUIDK 71 H-WTEIC
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44. ftrCERtt. (SYNTHETIC 0*ri 141 WKJLEIK
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-------


Table II-l. (continued)





product Proc«M
44. CYClOttXA* MI KOSX. KYIMSHAUW
«4. CltLOfUK !4I PETMLBH IKTIIUTIW
47. HSPtCML It 1001 FXMUtaiUf
48. CEU.ll.Mf ACETATE 1»W CHilUK BTEMFICATIOH
47. CtfCOLACTM 1001 CTaaCIWOt
50. PE»TAE»YT)*ITOL ' 1001 FOWLI0me/A(IT»t.»f«
51. MWYl PHEW. 100Z PICO. Njnu'IW
52. ACmailK 1»OZ IWrUMIISM
53. HETHtiEK. TmnimBe areas loot OWMUCTS vmnx area.
54. FUWIIC ACID lOOt MLEIC ACUVISOf»I7ATIW
55. PHPYUK areas iwni.ti.ni) 1001 PMRIBC OIK munm
s«. EPtCHU*am»iii ion tun cnwiBtym
57. «Un QLOUBE 1001 PSOPTLDe OUK1MTIIW
58. Miranneiii/wiM uz tatruMiTiiu
58. MHPWITliIL£/H(M 241 MIPIC »CH
58. MIPWITIIIII/WM 451 KITMIEX
57. TBiotDwrmnDt n WTTLEK
St. mcnoKirmruie fii rraruie HOUKIK
M. irraa ISOWTYI KETONE («*) tool «TM
41. PTIItlK 1001 F!WtMJO
-------



Table II-l. (continued)



Product rrocesa
69. DIHITROTOLUCKE 100Z T3LUEie PlftinteTIO*
70. SK-JUTiW-JL 100Z WTYLE*S
71. UHEAS SLKT-L &E»ZE« 1001 KUlDf. «.KYUTI»
72. (OOLEIK 100Z P80PYLEKE OXIMTIOH
73. UPHOnUMNE IOOZ MIUK MHIMTKM
74. HETHYL STYRENE 15Z CUMEKt KHYWOKWUIOM
74. KTHYL STYREKE 851 CUKE* FKOKSS SY-fSOWCT
75. ETHYLEKE [IMIIKE/THETHYIENE TETSMHUE 100Z EJC MHOfOLYSlS
76. ETHYL ftCSYUTE 611 dCEPfLEIS !R£PP£I
74. ETHYL (OYLATE 37Z DIRECT ESTESflMTIW
77. KETHYL CHLORIIi 21 KTHUKE CAfflilWITIOK
77. STHYl M.WIDC ?8Z nETWUM. HYKOCHLOKWA7IOK
78. It '"'EM tlPHEKYLE* DIISOCYAWTE 1001 DP«ft/PICS6£«
7?. K-WTm«.;tHYDE 100Z 0«0 PROCESS
80. NITROAHILIKE 100Z HITiiO CHLOKKK71NE
81. «££TOPHE)IOKE 6CZ OlfX PEMXIB*T!0«
81. MXTOPHEJWIE UZ ETHYL BUZUE OXIMTIIW
82. ISOPHTHM.IC ACID 100Z K-XYLEJK OXIMTION
83. KKMIC DCIB IMZ TOLUQC SID OXIMTIOH
84. tUSOOCTYL WTWtLATE (DI2-ETHYLHCXYL) 10CZ PHTHAlIC (WMYtSIDE/ALCOHOL
K. 2-ETHYl 1-HEXAWL 100Z CW»(S«TI(W
86. K-IUTAM1L (KJTTL ALCOHOL ) 20Z MXTAUXHTK
86. IHIUTAML (NJTYL H.WW.I 801 HO PROCESS
87. PWIOKIC Kit 71 OTHFRS
87. PKOflOHIC «CHi 93Z 0X0 PROCESS
SS. ETHYL HCETA^E 100Z ACETIC Kit
B». ETHYUNE tlSRWu'E 1001 ETHTLE* MMHWTIW
90. dCtTCDS CY.'.lWrWIII 1001 OCETCWE CYM«TIO«
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-------
Table II-l. (continued) 5 Sic S3
o *> c o cc w + -3 c we-
2 S 2 S 3 ; ! 1 1 1 ! 1 < S 1 , 1 i i
product Proce.8 ssssl-BuofSsScacil.*;
92. UOUWtCIM. «I hCWL CHLORHM1IIM
92. 1IOUMPICML 551 HICH.«MaZE«E A
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93. ISOHirrtM-ICHrK 1001 0X0 fWCESS
94, OKSYIIC KIK (SHI) « CTIBC CXIMTIft,
94. cttsnic HUBS 
-------
H
 I
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           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
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 130. icnm. Mzrtn
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132. ICMdlORaiEXZEK
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134. wmic «ci»
134. MlTTflC ACID
13S. DHUTMPHEML
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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
                                                   \\\\\\\\\\
                                                    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

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f
«J
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sc
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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
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<•









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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





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t

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u
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BC



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cm
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g
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o
*
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eC
tr
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V















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RE


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e
S
s
1
1
U1






























act





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M
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S





ior






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c
«
1
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A












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A
A


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a
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i

































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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
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8.
1
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A




A
A


A
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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
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A
A
A











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v

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Carbon ^












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Sulfur I






























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A
A
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A















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A
A



A





o
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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
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A
A









A
A
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a
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A
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A
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-------



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
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-------
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
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-------
                   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
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,
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u






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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.

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                                         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

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                                          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).

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                                         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.

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                                          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.

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                                         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

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                                         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

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                                          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

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                                         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

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                                     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.

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                                            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

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                                            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.

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                                             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.

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                           II-5
                 6TEAM
                                                            VEKIT TO
                                                          OR CCKJTROL.
                                                            DEVICE
                                   ' .  ~	^ WATER
           "HOT
Fig. II-l.  Three-Stage  Steam Ejectors with Contact Condensers
                   and a Barometric seal

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                          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

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                                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

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                                            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,

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                                            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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                                                            ACETIC.
                                                                                           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+.
}T
                                  -±  Vitsr
                                   Cotsa. To
                                  O»^-~
                                                            c w.

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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.

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                                      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
                                LZD
A.'.R OR ^E.PT
'=/-t Aoceo  '
FGf VACUUM  I
C-MT^-C-
                                   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.

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                                  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.

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                                         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.

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                                         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

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                                         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

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                                         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

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                                    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.

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                                  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

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                                         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.

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                                               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).

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                                         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.

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                                         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).

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                                         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

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                                         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-

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                                         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.

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                                         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

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                                         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.

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                                         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

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                            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

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                                        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.

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                                         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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