CD A U.S. Environmental Protection Agency Industrial Environmental Research
^« Office of Research and Development Laboratory
Research Triangle Park, NC 277V
EPA-600/7-76-012
September 1976
INVENTORY OF
COMBUSTION-RELATED
EMISSIONS FROM
STATIONARY SOURCES
Interagency
Energy-Environment
Research and Development
Program Report
-------
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S.
Environmental Protection Agency, have been grouped into seven series.
These seven broad categories were established to facilitate further
development and application of environmental technology. Elimination
of traditional grouping was consciously planned to foster technology
transfer and a maximum interface in related fields. The seven series
are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
This report has been assigned to the INTERAGENCY ENERGY-ENVIRONMENT
RESEARCH AND DEVELOPMENT series. Reports in this series result from
the effort funded under the 17-agency Federal Energy/Environment
Research and Development Program. These studies relate to EPA's
mission to protect the public health and welfare from adverse effects
of pollutants associated with energy systems. The goal of the Program
is to assure the rapid development of domestic energy supplies in an
environmentallycompatible manner by providing the necessary
environmental data and control technology. Investigations include
analyses of the transport of energy-related pollutants and their health
and ecological effects; assessments of, and development of, control
technologies for energy systems; and integrated assessments of a wide
range of energy-related environmental issues.
REVEVV NOTICE
This report has been reviewed by the participating Federal
Agencies, and approved for publication. Approval does not
signify that the contents necessarily reflect the views and
policies of the Government, nor does mention of trade names
or commercial products constitute endorsement or recommen-
dation for use.
This document is available to the public through the National Technical
Information Service, Springfield, Virginia 22161.
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EPA-600/7-76-012
September 1976
INVENTORY
OF COMBUSTION-RELATED EMISSIONS
FROM STATIONARY SOURCES
by
Owen W. Dyke ma and Vernon E. Kemp
Th^Aerospace Corporation
Environment and Energy Conservation Division
El Segundo, California 90245
Grant No. R803283-01
ROAPNo. 21ADG-089
Program Element No. 1AB014
EPA Project Officer: Robert E. Hall
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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ABSTRACT
This report describes the first year of a study performed by The
Aerospace Corporation to satisfy the Emissions Inventory phase of a federal
grant entitled "Analysis of NO Control in Stationary Sources." The grant de-
ji
fines a three-year program covering the period 15 July 1974 to 14 July 1977.
The purpose of this phase of the program is to assist the Environmental Protec-
tion Agency in establishing priorities for detailed studies of techniques for the
control of combustion-related emissions from stationary sources. To develop
the proper perspective, it was necessary that the inventory include emissions
of (1) oxides of nitrogen, (2) unburned hydrocarbons, (3) carbon monoxide, and
(4) particulate matter, not only from recognized major stationary combustion
sources but also from other stationary source categories in which combustion
plays a secondary role. During the first year of this study, Remissions were es-
tablished for 1975 and projected to 1980 from boilers, internal combustion en-
gines, chemical manufacturing, and petroleum refining A In the second year
comparative combustion-related emissions data will be obtained for selected
industries, including evaporation and primary metals, and the third year will
cover mineral products, secondary metals, and wood products. This report
identifies approximately 90 percent of all nitrogen oxide emissions and from 30
to 50 percent of unburned hydrocarbons, carbon monoxide, and particulate mat-
ter for stationary point sources.
This report is submitted by The Aerospace Corporation under
sponsorship of the Environmental Protection Agency in partial fulfillment of
Grant Number R803283. The remainder of the grant is fulfilled by the Aerospace
report entitled "Analysis of Test Data for NO Control in Coal-Fired Utility
J^
Boilers," prepared by Owen W. Dykema, Aerospace Report No. ATR 76(7549)-2,
January 1975 (to be published as an EPA report).
111
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ACKNOWLEDGMENTS
Robert E. Hall, the Environmental Protection Agency (EPA)
Project Officer, Combustion Research Branch, is acknowledged for his
guidance during this study and for his assistance in the data collection process,
The efforts of EPA personnel Jacob Summers and Martha Abernathy of the
National Air Data Branch are acknowledged for providing magnetic tapes con-
taining point source emission data from the National Emissions Data
Systems (NEDS).
The following personnel of The Aerospace Corporation made
valuable contributions to the performance of this study:
Keith W. Aaron
Siumay Cheung
Otto Hamberg
Norman E. Kogen
Robert B. Laube
Patricia L. Merryman
Elliot K. Weinberg
Herbert M. White
The overall emissions inventory project was managed
by Owen W. Dykema, and the project coordination and
organization of this report was accomplished by
Vernon E. Kemp.
Office of Stationary Systems
Environment and Energy
Conservation Division
Itzer, General Mai
Snvironment and Energy
Conservation Division
Civil Operations
rer
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CONTENTS
ABSTRACT "i
ACKNOWLEDGMENTS v
PART I. SUMMARY OF STUDY AND EMISSION DATA
ES. EXECUTIVE SUMMARY ES-1
ES. 1 Introduction ES-1
ES. 2 Study Summary ES-4
IS. INVENTORY SUMMARY IS-1
PART II. BASIC INVENTORY
1, DATA HANDLING 1-1
1. 1 Data Acquisition 1-1
1. 2 Data Handling and Storage 1-7
1.3 References 1-12
2. EXTERNAL COMBUSTION IN BOILERS 2-1
2. 1 Introduction 2-1
2.2 Summary 2-3
2.3 Approach 2-3
2.4 Data Analysis from Literature 2-25
2. 5 NEDS Data Analysis 2-32
2.6 References 2-36
Vll
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CONTENTS (Continued)
3. STATIONARY INTERNAL COMBUSTION ENGINES
3. 1 Introduction .............................. 3-1
3.2 Summary ................................ 3-2
3.3 Point Sources ............................. 3-2
3.4 Area Sources ............................. 3-15
3.5 References ............................... 3-20
4. CHEMICAL MANUFACTURING ...................... 4-1
4. 1 Introduction .............................. 4-1
4. 2 Summary ................................ 4-1
4.3 Emission Analysis .......................... 4-9
4.4 References ............................... 4-31
5. PETROLEUM REFINERIES ......................... 5-1
5. 1 Introduction .............................. 5-1
5.2 Summary ................................ 5-1
5.3 Approach. ................................ 5-1
5.4 Statistics ................................ 5-10
5.5 Processes Evaluated ........................ 5-12
5.6 Results and Discussion ....................... 5-16
5.7 References ............................... 5-17
APPENDIX 5. A. DISCUSSION OF PETROLEUM REFINERY
PRACTICES ........................... 5.A-1
CONVERSION FACTORS .............................. CF-1
GLOSSARY ........................................ G-l
Vlll
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TABLES
ES-1. Stationary Source Emissions ES-5
ES-2. Distribution of Point Source Emissions ES-7
ES-3. Uncertainties in Point Source Emission Rates ES-8
IS-1. Definition of Modified Source Classification Codes IS-2
IS-2-a. Summary of 1975 Emissions and Charge Rates IS-4
IS-2-b. Summary of 1975 Emissions and Charge Rates
Uncertainty IS-9
IS-3-a. Summary of 1980 Emissions and Charge Rates IS-15
IS-3-b. Summary of 1980 Emissions and Charge Rates
Uncertainty IS-20
1-1. Study List of Emissions 1-2
2-1. Definition of External Combustion (Boiler) Processes 2-4
2-2-a. 1975 External Combustion Emissions and Charge Rates .... 2-8
2-2-b. 1975 External Combustion Uncertainties 2-11
2-3-a. 1980 External Combustion Emissions and Charge Rates .... 2-16
2-3-b. 1980 External Combustion Uncertainties 2-19
3-1. Definition of Internal Combustion Processes 3-3
3-2-a. 1975 Internal Combustion Emissions and Charge Rates .... 3-4
3-2-b. 1975 Internal Combustion Uncertainties 3-5
3-3-a. 1980 Internal Combustion Emissions and Charge Rates .... 3-7
IX
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TABLES (Continued)
3-3-b. 1980 Internal Combustion Uncertainties 3-8
3-4. Internal Combustion Engine Distribution: Number
Versus End Use 3-13
3-5. 1980 Projection of Total Internal Combustion Engine
Emissions 3-16
3-6. 1980 Projection of Area Source Internal Combustion
Engine Emissions 3-17
4-1. Definition of Chemical Manufacturing 4-2
4-2-a. 1975 Chemical Manufacturing .Emissions and Charge
Rates 4-3
4-2-b. 1975 Chemical Manufacturing Uncertainties 4_4
4-3-a. 1980 Chemical Manufacturing Emissions and Charge
Rates 4-6
4-3-b. 1980 Chemical Manufacturing Uncertainties 4.7
4-4. Nationwide Point Source Emissions 4-10
4-5. Industrial Process Emissions 4-11
4-6. Producers of Greatest Emissions in Chemical
Manufacturing 4-12
4-7. Producers of Greatest HC Emissions in Chemical
Manufacturing 4-13
4-8. Producers of Greatest CO Emissions in Chemical
Manufacturing 4-14
4-9. Summary of Chemical Manufacturing Emissions
and Charge Rate 4-17
5-1. Definition of Petroleum Industry Processes 5_2
5-2-a. 1975 Petroleum Industry Emissions and Charge Rates 5,3
5-2-b. 1975 Petroleum Industry Uncertainties 5.4
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TABLES (Continued)
5-3-a. 1980 Petroleum Industry Emissions and Charge Rates 5-6
5-3-b. 1980 Petroleum Industry Uncertainties 5-7
5-4. 1973 Distribution of Petroleum Products 5-11
XI
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FIGURES
ES-1 Emissions from Stationary Sources ES-6
3-1 Electric Utility Gas Turbine Fuel Demand 3-12
4-1 Emissions from Chemical Manufacturing 4-18
4-2 Synthetic Ammonia Production 4-21
4-3 Total Carbon Black Production 4-26
4-4 Breakdown of Carbon Black Production 4-27
xn
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PART I
SUMMARY OF STUDY AND EMISSION DATA
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SECTION ES
EXECUTIVE SUMMARY
ES. 1 INTRODUCTION
ES. 1.1 Background
A cost-effective approach to nationwide reduction of air pollution
requires an accurate assessment of the air pollutants being discharged into the
atmosphere by combustion-related processes and other related activity. Since
there is a long lead time between the recognition of a large source of air pollu-
tion and the implementation of control methods, it is further required that the
magnitude of these emissions be estimated for an appropriate time in the future.
Studies of specific industries have been and are being con-
ducted. Because the sources of air pollution are numerous and geographically
scattered, few studies have involved the gathering of significant samples of
original emission data. Most tend to review, analyze, summarize, and pro-
ject the same data.
The National Emissions Data System (NEDS) of the U.S.
Environmental Protection Agency (EPA) has generated a large volume of
detailed, original emission data, covering a wide range of industries. Most
of these data were gathered in the 1970 through 1972 time period. Efforts
to update the data base are continuing. However, as of 1975, the NEDS data
were incomplete, contained some errors, and represented data from an
average time period of about 1971. The NEDS contains no system for pro-
jecting the data beyond the acquisition period. Despite these drawbacks, the
NEDS has the largest, most comprehensive, and detailed sample of original
emission data available.
ES-1
-------
The other studies containing original data surveys serve as a
check on the completeness of the NEDS data and provide the rationale for
projection of the data into the future.
ES. 1.2 Scope
The purpose of this study, which is part of a three-year program,
is to assist the EPA in establishing priorities for combustion-related detailed
air pollution control studies. The atmospheric pollutants of interest are oxides
of nitrogen (NO ) unburned hydrocarbons (HC), particulate matter (PART), and
Ji
carbon monoxide (CO). The study utilizes the NEDS original emission data
base, as well as original data obtained from individual studies, to generate
a detailed inventory of emissions, with projections to the year 1980.
The nationwide emissions inventory compiled by this study is
limited to atmospheric point source emissions. Point sources are defined as
stationary sources contributing more than 100 tons per year of pollutant.
Area sources, i.e., stationary sources of pollution exclusive of point sources,
are considered only in cases where a point source is likely to develop.
The industries from which the emissions of interest emanate
are referred to as process or source categories and are classified under the
NEDS source classification code (SCC). A detailed breakdown of these source
categories is further defined by a modified SCC (MSCC) developed by The
Aerospace Corporation for this study. The emissions inventoried during the
first year of the study, reported here, are from the following major source
categories: external combustion in boilers, internal combustion, chemical
manufacturing, and petroleum refineries. Evaporation and primary metals
emissions will be studied in the second year of the program; emissions from
mineral product, secondary metal, and wood product industries will be
investigated in the third year.
Uncertainty values are given for the current emission
estimates and for emission projections to the year 1980. The variables
determining these values are process usage rates, emission factors, control
applications, and time derivatives or trends. Statistical engineering
ES-2
-------
estimates, current and potential legislative controls, and several independent
sources of data were considered in calculating the uncertainty of each of the
emissions inventoried.
ES. 1.3 Objectives
The objectives of this study are as follows:
a. Establish current and future five-year estimates of signifi-
cant nationwide atmospheric stationary point source emis-
sions, particularly from industries involving combustion.
b. Determine the uncertainty of current and future
emission rates.
ES. 1.4 Approach
The objectives of the study were accomplished by the perfor-
mance of the following tasks:
a. Establish a list of processes which yield a significant
quantity of atmospheric emissions. The selection of
processes and subprocesses is described in Sections
1.1.1 and 1.1.2.
b. Determine a data base (starting point) and slopes for
time-dependent variables from which current and future
emissions can be calculated. Accomplishment of this
task for each process is described in Sections 2 through 5.
c. Establish and code equations, for computer usage, which
allow emissions and their uncertainties to be estimated
for the year of interest. Sections 1.2.1 and 1. 2. 2
describe these equations.
d. Calculate and publish emissions for the current year and
to the year 1980. The detailed results of these calculations
are listed for each process in Sections 2 through 5. The
summarized results are published in Section IS.
ES. 1.5 Organization of This Report
The results of this study are reported in three fundamental
areas of this document, grouped into two major parts:
ES-3
-------
Part I. Summary of Study and Emission Data
Executive Summary
Inventory Summary
Part II. Basic Inventory
The Executive Summary section of Part I presents an overview of the study
and a concise review of the significant results, while the Inventory Summary
presents the 1975 and 1980 emissions, charge rates, and the uncertainties
for the three broadest categories of the process studies. In Part II, Basic
Inventory, there are two subgroupings: data handling and process studies.
The data handling section describes fundamental assumptions and approaches
to the development of the entire emissions inventory. This includes descrip-
tions of data acquisition techniques and methods used to perform computational
analysis of these data. The process studies are presented in separate sections
for each of the four major processes studied in the emissions inventory. Each
section is independently oriented. The overall study is a three-year effort
scheduled to continue to July 1977. Each year, a selected industry, process,
or group of sources will be studied and reported in separate sections of this
report. Also, during the third year, the inventory of the previous two years
will be updated. The basic report, then, is bound such that subsequent
inventories and updates of previous inventories can be easily incorporated.
Metric equivalents for English units used in this report are
listed in the conversion table at the back of the document. A glossary of
terms is also provided.
ES.2 STUDY SUMMARY
A summary of the stationary point source emissions inventory
conducted in the first year of this program is given in Table ES-1 for 1975
and 1980; a summary of all stationary source emissions is shown in Fig-
ure ES-1. The general trend of reduced emissions or, at worst, small
increasesbetween 1975 and 1980, is attributed to increased compliance with
new standards during this period even though industrial production is ex-
pected to increase appreciably. The most noteworthy emission rate deter-
mined is the 1975 CO value from petroleum refineries, which is 17 million
ES-4
-------
Table ES-1. STATIONARY SOURCE EMISSIONS
Source Category
2^
Steam. Boilers:
1975
1980
Internal Combustion Engines:
1975
1980
Chemical Manufacturing:
1975
1980
Petroleum Refineries:
1975
1980
b
Internal Combustion Engines:
1980
Emissions, million tons/yr
N0x
7.59
6.22
0.60
0.57
NegC
Neg°
0.56
0.38
2.96
HC
0.15
0.19
0.35
0.42
1.08
1.13
0.41
0.45
0.99
CO
0.37
0.44
Negc
NegC
2.63
2.76
17.04
11.61
13.57
PART
5.58
5.68
Negc
Negc
Negc
Negc
0.30
0.24
Neg
source: more than 100 tons per year of pollutant.
bArea source: all stationary sources exclusive of point sources.
GNeg is defined as less than 1% of the NEDS 1975 stationary source
emissions.
ES-5
-------
* LESS THAN 1% OF NEDS 1975
STATIONARY SOURCE EMISSIONS
_
-
-
' 1
$
'" "."H
;,-,,
OXIDES OF NITROGEN
Hi! * * ISSi BBSS: BRSI ill
£ 4
Q_
Z O
e 2
o 0
HYDROCARBONS
oo
z
o
16
- 12
LO
C/1
5 4
CARBON MONOXIDE
-
^
HWW"»
PARTI CULATE MATTER
* * * *
f
1975 1980 1975 1980 1975 1980 1975 1980 1975 1975
STEAM INTERNAL CHEMICAL PETROLEUM OTHER POINT AREA SOURCES
BOILERS COMBUSTION MANUFACTURING REFINERIES SOURCES
ENGINES
Figure ES-1. Emissions from stationary sources
ES-6
-------
tons per year. This number is approximately four times that reported in any
of the recent NEDS nationwide emission summary reports. The difference
is attributed partially to a small emission factor used in computing emissions
from fluid catalytic cracking processes, but the exact cause for the difference
is unresolved at this writing.
As shown in Table ES-2, which identifies the contribution of
the inventoried emissions to the total point source emissions, approximately
98 percent of the NO and 40 to 50 percent of the HC, CO, and PART are
accounted for in this initial inventory. Most of the remainder will be inven-
toried during the second and third years of this program, which will be con-
cerned with evaporation and primary metal, mineral product, secondary
metal, and wood product emissions.
The uncertainties of point source emissions were computed and
are presented in Table ES-3. As shown, significant uncertainties in emission
rate predictions exist for CO from petroleum refineries. Expressed as a
percentage of the nominal value of the predicted emissions, the uncertainty
of 1975 CO emissions from refineries is approximately 35 percent. This
large uncertainty is due to the lack of substantiated emission factor data for
fluid catalytic cracking facilities. Refinements in data are expected to sig-
nificantly reduce this uncertainty in the updates planned for the third year
of the study.
Significant quantities of NO , HC, and CO emissions are pre-
Jt
dieted for stationary area source internal combustion (1C) engines which far
exceed the emissions attributed to present point source 1C engines.
The difference in emissions is attributed to 1C engines whose
usage, emission factor, or size is too small to qualify them as point source
emitters and consequently are classified as area source emitters. The four
highest polluting 1C engines contributing to area source emissions were studied
because many are in a standby installation and, with a modest increase in
ES-7
-------
Table ES-2. 1975 DISTRIBUTION OF POINT SOURCE EMISSIONS
Percent of Total Point Source Emissions
Source Category
NO
HC
CO
PART
Steam Boilers
Internal Combustion Engines
Chemical Manufacturing
Petroleum Refineries
81
6
2
6
2
5
15
6
1
Nega
7
45
41
Nega
2
2
Total Initial Inventory
Other Point Sources
Total Point Sources
95
5
100
28
72
100
53
47
100
46
54
100
aNeg is less than 0. 5%
ES-8
-------
Table ES-3. UNCERTAINTIES IN POINT SOURCE
EMISSION RATES
Emissions, million tons/yr
Source Category
NO
HC
CO
PART
Steam Boilers
1975
1980
Internal Combustion Engines
1975
1980
Chemical Manufacturing
1975
1980
Petroleum Refineries
1975
1980
+0.42
-0.42
+0.85
-0.81
+0.39
-0.14
+0.42
-0. 18
Nega
Nega
+0.03
-0.03
+0.03
-0.03
+0. 10
-0.02
+0. 12
-0.03
+0.18
-0.08
+0.26
-0. 11
+0. 10
-0.10
+0. 11
-0. 11
+0.04
-0.04
+0.05
-0.05
+0.08
-0.05
+0. 10
-0.07
Nega
Nega
+0.37
-0.37
+0.43
-0.43
+5.89
-5.89
+6.72
-6.72
+0.47
-0.47
+0.87
-0.87
Nega
Nega
Nega
Nega
+0.01
-0.01
+0.02
-0.02
Neg corresponds to the nominal emission equaling less than 1% of total
stationary source emissions.
ES-9
-------
usage, could become point sources of significant quanties of emissions.
These four offenders are (1) distillates, (2) crude-oil-fueled turbines (3)
diesel engines, and (4) gasoline-fueled reciprocating engines. A detailed
description of these area source emissions is presented in Section 3.4. The
gasoline engine contributes the largest amount of NOX, HC, and CO, particu-
larly CO whose rate of 13 million tons per year is two orders of magnitude
greater than that of any other area source emission from 1C engines. Since
the primary objective was to establish an inventory of point source emissions,
area source emissions are not included in the basic inventory as summarized
in Section IS.
ES-10
-------
SECTION IS
INVENTORY SUMMARY
The categories studied are classified and summarized under
the processes contributing the stationary source emissions of interest. In
Table IS-1, the major process categories investigated are listed and defined
according to the NEDS modified source classification code (MSCC) and charge
rate unit. The 1975 and 1980 emissions are similarly summarized by major
process category in Tables IS-2-a and IS-3-a, respectively. The respective
uncertainties for these emissions are given in Tables IS-2-b and IS-3-b.
In these tables, three levels of summarization are defined by
the NEDS nine-digit MSCC number. The first, most general, summary level
is indicated by the first digit of the MSCC. The emissions listed in the first-
level summary categories in Tables IS-2-a and IS-3-a are the sum of those
in the second-level summary, and those in the second level are the sum of
those in the third level. Second-level categories are indicated by the second
and third digits in the MSCC, and the third-level summary categories by the
numbers in the fourth, fifth, and sixth digits.
No charge rates are listed for the first- and second-level sum-
mary categories because these categories represent different types of pro-
cesses with different units of measure. For example, the second-level sum-
mary category 101000000 represents all external combustion for boilers used
in electric generation including those burning coal in tons per year, oil in
thousands of gallons per'year, and natural gas in millions of cubic feet per
year. In some cases, third-level summaries involve a single process type
with the same unit, e.g., 101002000, bituminous coal in tons per year. In
such cases, the appropriate MSCC unit of measure is shown in Table IS-1,
and a charge rate for this unit is listed in Tables IS-2-a and IS-3-a.
The major source categories summarized here are further
classified and detailed in Sections 2 through 5.
IS-1
-------
Table IS-i. DEFINITION OF SUMMARY CATEGORIES
MSCC
Source Category
Charge Rate Unit
100000000
External Combustion (Boiler)
101000000
101002000
101004000
101005000
101006000
101007000
102000000
Electric Generation
Bituminous coal
Residual oil
Distillate oil
Natural gas
Process gas
Industrial
202000000 Industrial 1C Engines
202001000 Distillate oil turbine
202002000 Distillate oil reciprocating
202003000 Natural gas turbine
202004000 Natural gas reciprocating
202999000 Miscellaneous fuelsb
Tons burned/yr
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
102002000
102004000
102005000
102006000
102007000
200000000
201000000
201001000
201002000
201003000
201999000
Bituminous coal
Residual oil
Distillate oil
Natural gas
Process gas
Internal Combustion
Electric Generation
Distillate oil
Natural gas
Diesel
Miscellaneous fuel
Tons burned/yr
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
1000 gal/yr
Million cu ft/yr
1000 gal/yr
N.A.a
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
300000000
Industrial Processes
301000000 Chemical Manufacturing
301002000 Ammonia production with
methanator
Tons/yr
IS-2
-------
Table IS-1. DEFINITION OF SUMMARY CATEGORIES (Continued)
MSCC
Source Category
Charge Rate Unit
301003000 Ammonia production with CO
absorber
301005000 Carbon black production
301999000 Miscellaneous chemical
manufacturing
306000000 Petroleum Industry
306001000 Process heater
306002000 Fluid catalytic crackers
306003000 Moving bed catalytic crackers
306008000 Miscellaneous leakage
306012000 Fluid coking
Tons/yr
Tons /yr
Tons/yr
N. A. a
1000 bbl/yr
1000 bbl/yr
1000 bbl
capacity/yr
1000 bbl feed/yr
aN.A. (not applicable) is listed under "Charge Rate Unit" where the MSCC
number is made up of two or more MSCCs whose charge rates are different.
bAlthough this category is made up of two MSCCs whose units are different.
only one (202999970) was studied.
IS-3
-------
Table IS-2-a. SUMMARY OF 1975 EMISSIONS AND CHARGE RATES
ANNUAL CHARGE
EXTERNAL
RATES AND EHISS
COMBUST ION, BOILER CATEGORY
IONS PROJECTED TO 1975 RUN
PAGE 1
DATE-JUNE 24,1976
KODIHED
sec
100COOCGO
1C1CGGCOO
U1G02000
1C1L04COC
IGlC-bSUG
1MOG6CUC"
1G1007GOC
UZOUCIOO
1G2002000
1G2C04GOO
1G20G5CGG
1C2CU6CGU
1C2007000
TACRP EMISSIONS
(SCC UNITS) NOX
7.591
6.237
369250000. 4. 897
1821COOO. .667
0. C.OOG C
2993400. .673
9C390. .000 NEGL
1.354
572340GO. .592
12100000. .290
70600CO. .169
3520000. .303
1749300. .CCO NEGL
MSCC Source Category
100000000 External Combustion (Boiler)
101000000 Electric Generation
101002000 Bituminous coal
101004000 Residual oil
101005000 Distillate oil
101006000 Natural gas
101007000 Process gas
102000000 Industrial
102002000 Bituminous coal
102004000 Residual oil
102005000 Distillate oil
102006000 Natural gas
102007000 Process gas
(MILLIONS DF TONS / >
HC CO
.147 .371
09C .252
.07C .199
.018 .027
.OOC 0.000
IGIBLE NEGLIGIBLE
C57 .119
.023 .051
.018 .024
Oil .014
.005 .030
IGIBLE NEGLIGIBLE
Charge Rate Unit
Tons burned/yr
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
Tons burned/yr
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
'EAR)
PART
5.579
4.301
4.205
.073
C.GOC
.022
NEGLIGIBLE
1.279
1.055
.139
.053
.032
NEGLIGIBLE
-------
Table IS-2-a. SUMMARY OF 1975 EMISSIONS AND CHARGE RATES (Continued)
INTERNAL COMBUSTION ENGINES
ANNUAL IHARGE RATES AND EMISSIONS PROJECTED TO 1975
PAGE la
RUN DATE-JUNE 24*1976
MODIFIED
sec
2CCCOCCOC
2C1COOGC-C
2C1C01COC
2C1C02COC
2C1C030CC
201S991CC
TACRP
(SCC UNITS)
1066100.
336860.
75159.
EMISS1
NOX
.60*
.244
.12C
.096
.Cll
.017
ONS (HILLION5
HC
.348
.086
.002
.001
.001
.063
ur iuNi i T
CO
.067
.016
.010
.000
.005
.002
C »K *
PART
.017
.011
.006
:8&i
.001
Ul
MSCC
200000000
201000000
201001000
201002000
201003000
201999000
Source Category
Internal Combustion
Electric Generation
Distillate oil
Natural gas
Diesel
Miscellaneous fuel
Charge Rate Unit
1000 gal/yr
Million cu ft/yr
1000 gal/yr
N.A.a
aN.A. (not applicable) is listed under "Charge Rate Unit" where the MSCC
number is made up of two or more MSCCs whose charge rates are different.
-------
Table IS-2-a. SUMMARY OF 1975 EMISSIONS AND CHARGE RATES (Continued)
INTERNAL COMBUSTION ENGINES
ANNUAL CHARGE RATES AND fcMlSSIONS PROJECTED JO 1975
RUN
MODIFIED
SCC
2C2GOGGCO
2C2GG1GGG
2C2CC2CC.C
2C20U3CCC
2G2GG4LLU
2C29990GC
TACRP
(SCC UNITS)
65953.
97396C.
3470.
26201.
23326.
NOX
.360
.004
.348
CGC
.OG5
.003
EMISSIONS
(MILLIONS OF
HC
.261
.000
.089
.000
.000
.172
PAGE
DATE-JUNE 24,1976
/ YEAR)
lb
TONS
CO
.051
.002
.044
.003
.002
.001
PART
.006
.001
OCA
GOO
.000
.COO
MSCC
202000000
202001000
202002000
202003000
202004000
202999000
Source Category
Industrial 1C Engines
Distillate oil turbine
Distillate oil reciprocating
Natural gas turbine
Natural gas reciprocating
Miscellaneous fuels
Charge Rate Unit
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Although this category is made up of two MSCCs whose units are different,
only one (202999970) was studied.
-------
Table IS-2-a. SUMMARY OF 1975 EMISSIONS AND CHARGE RATES (Continued)
INDUSTRIAL PROCESS* CHEMICAL MANUFACTURING PAGE 1
ANNUAL CHARGE RITES AND EMISSIONS PROJfcCTED TO 1975 RUN DATE-JUNE 2*»1976
YEAR)
MODIFIED
SCC
3CKOCCCO
3C1CG2CCC
301999GGO
TACRP
(SCC UNITS)
61C6000.
2443000.
60S4400.
15U800CO.
EMISSIONS IMILLIONS OF TONS /
NOX HC CO
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
1.080
.209
.031
.322
.516
2.625
.003
.336
PART
NEGLIGIBLE
NEGLIGIBLE
MEGLIGIBLE
EGLIGIBLE
NEGLIGIBLE
MSCC
Source Category
Charge Rate Unit
300000000
Industrial Processes
301000000 Chemical Manufacturing
301002000 Ammonia production with Tons/yr
methanator
301003000 Ammonia production with CO Tons/yr
absorber
301005000 Carbon black production Tons/yr
301999000 Miscellaneous chemical Tons/yr
manufacturing
-------
Table IS-2-a. SUMMARY OF 1975 EMISSIONS AND CHARGE RATES (Continued)
oo
INDUSTRIAL PROCESS, PETROLEUH INDUSTRY PAGE 1
ANNUAL CHARGE RATES AND EMISSIONS PROJECTED TO 1975 RUN DATE-JUNE 24*1976
YEAR)
PART
.302
.095
NEGLIGIBLE
NEGLIGIBLE
.027
MODIFIED
sec
306GGGOGO
306C01GCU
3C6GG2GOO
366U3CCG
306CC6000
306012000
TACRP
(SCC UNITS)
26250000.'
110000.
MSCC
306000000
306001000
306002000
306003000
306008000
306012000
EMISSIONS
NQX
.557
.507
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE NEGL
Source Category
(MILLIONS OF
HC
.407 17
.045
Il67 NEGL
IGIBLE NEGL
coN
.044
.034
IGIBLE
IGIBLE
Charge Rate Unit
Petroleum Industry
Process heater
Fluid catalytic crackers
Moving bed catalytic crackers
Miscellaneous leakage
Fluid coking
N.A.a
1000 bbl/yr
1000 bbl/yr
1000 bbl
capacity/yr
1000 bbl feed/yr
aN.A. (not applicable) is listed under "Charge Rate Unit" where the MSCC
number is made up of two or more MSCCs whose charge rates are different.
-------
Table IS-2-b. SUMMARY OF 1975 EMISSIONS AND CHARGE RATES UNCERTAINTY
en
EXTERNAL COMBUSTION,
1ACR AND EMISSION UNCERTAINTIES PROJECTED
BOILER CATEGORY PAGE Id
TO 1975 RUN DATE-JUNE 24,1976
KODlf-IED
sec
1COCCCCCO
icicotccc
1C1002000
101GG4CGO
1C1GG51GG
1C10C6COO
1UGU7CGO
1
4
.
4
.
4
_
4
..
4
TACRP
;scc UNITS)
11708000.
1 1 708000 .
21113 CO.
2111300.
0.
C.
590090.
59C090.
15220.
15220.
+
t
4-
4-
.
*
_
4
_
1
EMISSIONS (MILLIONS OF TONS / YEAR)
NOX HC CO PART
.417 * .099 4- .077 4- .471
.418 - .020 - .052 - .471
.386 4 .097 + -.071 * .431
.386
.348
.348
.094
.094
O.OOC
O.CCC
.139
.139
.OCC
.000
- .015
4 .097
~ .014
4. ~ «00 8
- .CC6
4 0.000
- Q.OOO
4 .001
- .001
NEGLIGIBLE
NEGLIGIBLE
» _ fg M H
4 .069
- .046
.012
- .008
+ 0.000
* C . 000
4- .012
- .009
NEGLIGIBLE
NEGLIGIBLE
,*31
+ .431
- .431
4- .008
.008
* 0.000
Q , CCO
4- .004
- .004
NEGLIGIBLE
NEGLIGIBLE
MSCC
Source Category
Charge Rate Unit
100000000
101000000
101002000
101004000
101005000
101006000
101007000
External Combustion (Boiler)
Electric Generation
Bituminous coal
Residual oil
Distillate oil
Natural gas
Process gas
Tons burned/yr
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
-------
Table IS-2-b.
SUMMARY OF 1975 EMISSIONS AND CHARGE RATES UNCERTAINTY
(Continued)
EXTERNAL COHBUSTIClN* BOILER CATEGORY
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 1975 RUN DATE-JUNE
JJUIHED
SCL
1G2GCOCCO
U20C2CCG
1C20040C.I/
102C05GOC
1C2006GOG
1G2CC7GGO
TACKP
-------
Table IS-2-b. SUMMARY OF 1975 EMISSIONS AND CHARGE RATES UNCERTAINTY (Continued)
INTERNAL COMBUSTION ENGINES
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 1975
RUM
PAGE 1Q
DATE-JUNE 24,1976
MODIFIED
sec
200000GOO
2CICOCCOO
201001000
2C10C2CCO
2C10C300C
2C1999CCO
4
_
4
4
_
TACRP
(SCC UNITS)
3320600.
1088HU.
41767C.
11C20G.
14799.
14799.
4
4
-
«.
_
4
+
_
4
EMISS
NOX
.393
.137
.376
.122
.369
.12C
.C72
.C22
.003
.CC2
.003
.CC3
IONS
+
4
4
_
4
4
4
(MILLIONS
HC
.178
047
.013
.012
.005
.002
.002
.001
.000
.000
.012
.012
OF
4.
4
+
1
4
4
TONS /
CO
.038
.013
.029
.010
.029
.010
.003
.000
.002
001
000
.000
YEAR)
4
4
4
4
4
4
PART
.025
009
.024
.008
.024
.008
.001
.000
.001
.001
.001
.001
MSCC Source Category
Charge Rate Unit
200000000 Internal Combustion
201000000 Electric Generation
201001000 Distillate oil
201002000 Natural gas
201003000 Diesel
201999000 Miscellaneous fuel
1000 gal/yr
Million cu ft/yr
1000 gal/yr
N.A.a
aN.A. (not applicable) is listed under "Charge Rate Unit" where the MSCC
number is made up of two or more MSCCs whose charge rates are different.
-------
Table IS-2-b. SUMMARY OF 1975 EMISSIONS AND CHARGE RATES UNCERTAINTY (Continued)
INTERNAL COMBUSTION ENGINES
PAGE lb
TACK ANU EMISHfJN
I* JLIFIEC
2C2001COU
2C20C100C
2C2C02CLC
2C2C03CCC
ZOZC04CGC
202999000
UNCERTAINTIES PROJECTED TO 1975 RUN DATE-JUNC
TACkP EMISSIONS (hILLIONS OF TONS / YE
(SCC UMTS)
4
«
4
_
4
.
4
4
22224.
22224.
61674C.
1749CO.
1172.
1172.
26055.
260*5.
5925.
5925.
NOX
4
-
4
~
4
>_
4
_
4
!
.112
.061
.001
. OC1
.111
.C61
.OOC
.000
.005
.005
.001
.001
hC
4
-
4
«
4
4
4
4
.177
045
.000
.OOC
.030
.016
.000
OOC
.OOC
.OOC
.175
.043
CO
4
4
4
4
4
4
.024
008
88}
.001
.024
.008
.002
.001
002
.002
.000
.000
24,1976
Aft)
PART
4
~
4
4
4
4
4
005
.004
COO
.000
.005
°9i
.000
.coo
000
.000
000
coo
MSCC
Source Category
Charge Rate Unit
202000000 Industrial 1C Engines
202001000 Distillate oil turbine
202002000 Distillate oil reciprocating
202003000 Natural gas turbine
202004000 Natural gas reciprocating
202999000 Miscellaneous fuels a
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
1 Although this category is made up of two MSCCs whose units are different,
only one (202999970) was studied.
-------
Table IS-2-b. SUMMARY OF 1975 EMISSIONS AND CHARGE RATES UNCERTAINTY (Continued)
INDUSTRIAL PROCESS* CHEMICAL MANUFACTURING PAGE 1
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 1975 RUN DATE-JUNE 24*1976
MODIFIED
3C1CCCCCO
301002000
301003CCC
3G100iC>CG
3CL999GOO
TACRP EMISSIONS
(SCC UNITS) NOX
NEGLIGIBLE 4-
NEGLIGIBLE
4 22911C. NEGL GIBLE +
229110. NEGLIGIBLE
4 54487. NEGLIGIBLE +
54487. NEGL GIBLE
4 22654C. NEGL GIBLE 4-
226540. NEGL GIBLE -
4 17464000. NEGL GIBLE +
1746400C. NEGL GIBLE
MSCC Source Category
300000000 Industrial Processes
301000000 Chemical Manufacturing
301002000 Ammonia production with
methanator
301003000 Ammonia production with CO
absorber
301005000 Carbon black production
301999000 Miscellaneous chemical
manufacturing
(MILLIONS OF TONS / YEAR)
HC CO
.101 + .365 NEG
.101 - .365 NEG
.028 4- ,001 NEG
.028 - .001 NEG
.004 4- .031 NEG
.004 - .031 NEG
.072 + .340 NEG
.072 - .340 NEG
.065 + .129 NEG
.065 - .129 NEG
Charge Rate Unit
Tons/yr
Tons/yr
Tons/yr
Tons/yr
PART
LIGIBLE
LIGIBLE
IGIBLE
IG BLE
IGIBLE
IG BLE
IG BLE
IGIBLE
IGIBLE
IGIBLE
-------
Table IS-2-b. SUMMARY OF 1975 EMISSIONS AND CHARGE RATES UNCERTAINTY (Continued)
INDUSTRIAL PROCESS* PETROLEUM INDUSTRY
PAGE 1
TACR AKD EMIS.SION UNCERTAINTIES PROJECTED TO 1975
hODIFUD
SCC
3C600COCC
3C6CC1COC
3C6002CCO
306003000
3CbC08COC
30bCl2UGO
TACRP
(SCC UNITS)
3COOC.
30000.
-------
Table IS-3-a. SUMMARY OF 1980 EMISSIONS AND CHARGE RATES
en
>-*.
in
ANNUAL CHARGE
EXTERNAL COMBUSTION* BOILER CATEGORY
RATES AND EMISSIONS PROJECTED TO I960 RUN DATE-JUNE 24,1976
MODIFIED
SCC
100000COO
101GOOOOO
101002COO
1 CIO 0*i COO
lOlCCbOOG
1C1GQ6COO
102000000
1C2G02COG
1C2004COO
1C2C050GO
1C2006COO
1G2C07CCG
TACRP EM
(SCC UNITS) HOX
6.217
5.057
459910000. t*6.?*
26860000. «'£5§
0. O.OOD
1.160
93319000. .793
ll?!8888: :JIS
mm: :M?
I551UCO iniLLiuni ur «"* '
.187 ««
,110 «292
.063 «234
027 .040
OIOCO °*017
NEGLIGIBLE NEGLIGIBLE
.077 .151
.037 .082
013 '018
NEGLIGIBLE NEGLIGIBLE
PART
5.675
4.123
4.001
.107
0.000
NEGLIGIBLE
1.552
1.287
.177
.067
NEGLIGIBLE
MSCC Source Category Charge Rate Unit
100000000 External Combustion
101000000 Electric Generation
101002000 Bituminous coal
101004000 Residual oil
101005000 Distillate oil
101006000 Natural gas
101007000 Process gas
102000000 Industrial
102002000 Bituminous coal
102004000 Residual oil
102005000 Distillate oil
102006000 Natural gas
102007000 Process gas
(Boiler)
Tons burned/yr
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
Tons burned /yr
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
-------
Table IS-3-a. SUMMARY OF 1980 EMISSIONS AND CHARGE RATES (Continued)
ANNUAL CHARGE RATES AND
INTERNAL COMBUSTION ENGINES
EMISSIONS PROJECTED TO 1980
RUN DATE
PAGE la
JUNE 2
-------
Table IS-3-a. SUMMARY OF 1980 EMISSIONS AND CHARGE RATES (Continued)
INTERNAL COMBUSTION ENGINES
ANNUAL CHARGE RATES AND EMISSIONS PROJECTED TO 1980
PAGE
RUN DATE-JUNE 2*»1976
lb
MODIFIED
sec
2C2000COO
202C010UO
2C2COZCCC
2C2C03CUC
2C2004000
2G2999<.GO
TACRP
(SCC UNITS!
79753.
624330.
4627.
35626.
32923.
EMISSIONS
NOX
.313
.005
.297
.001
.006
.005
(MILLIONS
HC
.314
.OOC
.076
CC1
OCO
.237
OF TONS / H
CO
.047
.002
.037
.004
.003
.001
'EAR)
PART
COS
G01
.CC4
COO
.000
.000
MSCC
Source Category
Charge Rate Unit
202000000
202001000
202002000
202003000
202004000
202999000
Industrial 1C Engines
Distillate oil turbine
Distillate oil reciprocating
Natural ga's'turb.ine
Natural gas reciprocating
Miscellaneous fuels
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
___ ~~~~~~~~
aAlthough this category is made up
only one (202999970) was studied.
-------
Table IS-3-a. SUMMARY OF 1980 EMISSIONS AND CHARGE RATES (Continued)
oo
INDUSTRIAL PROCESS, CHEMICAL MANUFACTURING PAGE 1
ANNUAL CHARGE RATES AND EMISSIONS PROJECTED TO 1980 RUN DATE-JUNE 2<*>1976
YEAR)
PART
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
MODIFIbO
sec
3G1GUGCOC
301002000
301003000
3G1U-HCO
3C1999L-CC
TACRP EMISSIONS
(SCC UNITS) NOX
NEGLIGIBLE
7083000. NEGLIGIBLE
2832500, NEGLIGIBLE
6217000* NEGLIGIBLE
15118COCO. NEGLIGIBLE
MSCC Source Category
300000000 Industrial Processes
301000000 Chemical Manufacturing
301002000 Ammonia production with
methanator
301003000 Ammonia production with CO
absorber
301005000 Carbon black production
301999000 Miscellaneous chemical
manufacturing
(MILLIONS OF TONS /
HC CO
1.126 2.761
.243 .003
.036 .054
.328 2.369
.518 .336
Charge Rate Unit
Tons/yr
Tons/yr
Tons/yr
Tons/yr
-------
Table IS-3-a. SUMMARY OF 1980 EMISSIONS AND CHARGE RATES (Continued)
en
!-».
NO
INDUSTRIAL PROCESS* PETROLEUM INDUSTRY PAGE 1
ANNUAL CHARGE RATES AND EMISSIONS PROJECTED TO 1980 RUN DATE-JUtfE 24,1976
MODIFIED
SCC
30600000C
306C01000
306CC2COC
3C6GG3CCU
306C081CC
306012000
TACRP
EMISSIONS (MILLIONS OF TONS / YEAR)
(SCC UNITS)
2985COOC?
120000.
MSCC
306000000
306001000
306002000
306003000
306008000
306012000
NOX HC
.382 .454
.326 .055
NEGLIGIBLE Io"C3
NEGLIGIBLE .215
NEGLIGIBLE NEGLIGIBL
Source Category
Petroleum Industry
CO
11.609
.038
NEGLIGIBLE
E NEGLIGIBLE
Charge Rate Unit
Process heater N.A.a
Fluid catalytic crackers
Moving bed catalytic crackers
Miscellaneous leakage
Fluid coking
1000 bbl/yr
1000 bbl/yr
1000 bbl
capacity/yr
1000 bbl feed/yr
PART
.239
.082
NEGLIGIBLE
.029
N.A. (not applicable) is listed under "Charge Rate Unit" where the MSCC
number is made up of two or more MSCCs whose charge rates are different.
-------
Table IS-3-b. SUMMARY OF 1980 EMISSIONS AND CHARGE RATES UNCERTAINTY
to
o
EXTERNAL COMBUSTION* BOILER CATEGORY PAGE la
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 1980 RUN DATE-JUNE E4>1976
H°^1E° mPSKlSI NOX EMISSI°NS AS111""" °F ?8NS ' '""'ART
"ooowo i :in - :iii i :81? i :UI
ioicoooc» i JH« * :jij i :8|| ! :l}f
1GUU2CGG
1G1G0400G
U1C05GOO
lOiCOtCCO
101CG7CCO
4 3C5770GO.
4616700?
4 0.
0.
4 202V50C.
11158GG.
4 15220.
1522C.
MSCC
100000000
101000000
101002000
101004000
101005000
101006000
101007000
+ .771 +
- 1094 -
0.000 + 0
- O.CCO - C
4- .136 *
- .071
4- .000 NEGL
- .LOG NEGL
Source Category
External Combustion (Boiler)
Electric Generation
Bituminous coal
Residual oil
Distillate oil
Natural gas
Process gas
.118
IOC9
COO
.000
4- .oe
" .0!
4 . 0
- .0
4 O.Oi
- o.oc
.001 * .0:
CGI - .01
IGIBLE NEGLIG
IGIBLE NEGLIG
!*
0
0
9
9
BLE
BLE
.812
- .810
+ .016
- .018
0.000
- 0.000
.015
- .008
NEGLIGIBLE
NEGLIGIBLE
Charge Rate Unit
Tons burned/yr-
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
-------
Table IS-3-b. SUMMARY OF 1980 EMISSIONS AND CHARGE RATES UNCERTAINTY (Continued)
EXTERNAL COMBUSTION,
TACft AND EMISSION UNCERTAINTIES PROJECTED
BOILER CATEGORY
TO 1980 RUN
PAGE lb
DATE-JUNE 24,1976
Crt
r"j£l-H£ D
SCC
102COCOOO
10200^0.00
102CU4000
102CG5COO
1C20060GO
102C07CGO
(
4
4
4
4
4
TACPP
SCC UMTS)
126110CO.
12611000.
16R66CO.
1686600.
2072900.
20724CC.
26461CO.
1330900.
142990.
142990.
EMISSIONS CHILLIONS
KOX HC
« .303
.210
* .171
- 1 060
* .096
- .041
1 -177
4> 1 000
- .000
* .023
- .C20
+ .017
- .017
+ .013
- .009
4- .009
- .006
« .014
NEGLIGIBLE
NEGLIGIBLE
OF TONS / YEAR)
CO PAkT
.046
.031
* .03**
* *016
* :8H
- .006
* .025
NEGLIGIBLE
NEGLIGIBLE
.304
- .3C4
4 .302
7 1016
- .Olb
t\ ^ A.
.014
NEGLIGIBLE
NEGLIGIBLE
MSCC
Source Category
Charge Rate Unit
102000000
102002000
102004000
102005000
102006000
102007000
Industrial
Bituminous coal
Residual oil
Distillate oil
Natural gas
Process gas
Tons burned/yr
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
-------
Table IS-3-b.
SUMMARY OF 1980 EMISSIONS AND CHARGE RATES UNCERTAINTY
(Continued)
INTERNAL COMBUSTION ENGINES
TACR AND.EMISSION UNCERTAINTIES PROJECTED TO 1980
EMISSIONS (MILL
S) NOX HC
PAGE la
RUN DATE-JUNE 24,1976
OF
2COOOOCCO
2C100CLCO
IClGOlCOb 4 34720CO.
1275600.
201002000 4 419680.
109070.
2C10C3CCC 4 i§£35'
18635.
+ .418
- .17t
4- .394
- .143
4- .387
- .141
* .074
+ I003
- .OC3
4- .005
- .005
+ .261
- .113
4- .027
- .026
4- .005
- .002
+ .OC2
- .000
4- .000
- .000
4- .026
- .026
* .040 + .026
- .017 - .010
+ .031 4- .C26
- .011 - .005
4 .03C
: :tti
- fioj
4- ,00i
- *2s;
4- .00!
- .001
> 4 .025
- .009
> .001
- .000
4- .001
- .001
4 .001
- .001
MSCC Source Category
200000000 Internal Combustion
201000000 Electric Generation
201001000 Distillate oil
201002000 Natural gas
201003000 Diesel
201999000 Miscellaneous fuel
Charge Rate Unit
1000 gal/yr
Million cu ft/yr
1000 gal/yr
N.A.a
aN.A. (not applicable) is listed under "Charge Rate Unit" where the MSCC
number is made up of two or more MSCCs whose charge rates are different.
-------
Table IS-3-b. SUMMARY OF 1980 EMISSIONS AND CHARGE RATES UNCERTAINTY (Continued)
INTERNAL COMBUSTION ENGINES
TACP. AND EriS5IDN UNCfcRl AlMTIfcS PROJECTED TO 1<»80
RUN
PAGE
OATE-JUNt 2«.,197o
lb
J'JiMU-
5CC
2C20CCCOG
202001000.
2C2CC2CCC
202003000
202004000
202999000
TACRP
(SCC UN US)
4 49437.
49437.
4 662170.
-
4
4
4
-
27*270.
2311.
2311.
26452;
26452.
14345 .
14845.
NOX
4 .
~" .
* .
" .
4 .
_ 9
4 .
.
4" .
~ .
tlISS
139
102
OG3
102
coc
ecu
005
005
002
002
IC-^S (KILLIGNS OF TONS / Yt
HC CO
4 .26C 4 .026
- ;no - .013
4 .000 4 .001
- .CCC - .001
4 .037 4 .026
4
4
+
.026
.OCC
.OCO
.OCO
.OCO
.258
.107
AR)
PART
4 .005
- .009
4 .001
- .001
4 .COS
- .013
4 .003
4
+
,0(
.0
.0
.01
>2
)Z
91
4
4
"
+
- .001
.003
CUO
.OCC
.000
.000
coo
ooc
IN)
MSCC
Source Category
Charge Rate Unit
202000000
202001000
202002000
202003000
202004000
202999000
Industrial 1C Engines
Distillate oil turbine
Distillate oil reciprocating
Natural gas turbine
Natural gas reciprocating
Miscellaneous fuels a
1000 gal/yr
100.0 gal/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Although this category is made up of two MSCCs whose units are different,
only one (202999970) was studied.
-------
Table IS-3-b.
SUMMARY OF 1980 EMISSIONS AND CHARGE RATES UNCERTAINTY
(Continued)
INDUSTRIAL PROCESS. CHEMICAL MANUFACTURING
PAGE
TACR AND EMISSION UNCERTAINTIES PROJECTED TO I960
RUN DATE-JUNE 24,1976
hODlFIED
sec
aoicococc
301C02000
301C03CCO
3C1C05000
301999000
TACRP
(SCC UNITS)
» 288470«
288470.
* 68686.
68686.
I 237320.
237320.
4 17464000.
17464000.
EMISSIONS
NOX
NEGLIGIBLE +
NEGLIGIBLE
REGLIGIBL
EGL1G1BL
NEGLIGIBL
NEGLIGIBL
NEGLIGIBL
NEGLIGIBL
NEGLIGIBL
NEGLIGIBL
f
! 4
| *
(HILLIO
HC
IllS
,032
.032
OCb
.005
.087
.087
.065
.065
NS OF
1
4_
1
*
TONS /
CO
.432
.432
.001
.001
.036
.036
il
YEAR)
PART
NEGLIGIBLE
NEGLIGIBLE
NEGL1
NEGL
NT
N
N
N
N
N
EGLJ
;GL
:GL
;GL
:GL
EGLI
LG1
G
G
G
G
G
G
G
[BLE
BLE
BLE
BLE
BLE
BLE
BLE
BLE
IN)
MSCC
Source Category
Charge Rate Unit
300000000 Industrial Processes
301000000 Chemical Manufacturing
301002000 Ammonia production with Tons/yr
methanator
301003000 Ammonia production with CO Tons/yr
absorber
301005000 Carbon black production Tons/yr
301999000 Miscellaneous chemical Tons/yr
manufacturing
-------
Table IS-3-b.
SUMMARY OF 1980 EMISSIONS AND CHARGE RATES UNCERTAINTY
(Continued)
INDUSTRIAL PROCESS, PETROLEUM INDUSTRY PAGE 1
1ACR AND EMISSION UNCERTAINTIES PROJECTED TO 1960 RUN DATE-JUNE 24*1976
ro
MODIFIED
sec
306000000
3C6001CCO
316002000
306003CCC
306008000
3060120CO
(
4
.
4
4
4
TACRP
SCC UNITS)
166980.
166980.
21002.
21002.
1375200.
1375200.
11998.
11998.
EMISSIONS (MILLIONS OF TONS / YEAR)
NOX HC CO PART
4 .033 4 .046 4 6.723 4 .016
- .033 - .046 - 6.723 - .016
4 .032 4 .006 4 .006 4 .006
.032
4 .006
- . 006
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
- .OC7
4 .020
- .02C
4 .001
- .001
4 .041
- .041
BEGLIGIBLE
EGLIGIBLF
- .006
4 6.723
- 6.723
.040
NEGLIGIBLE
NEGLIGIBLE
KiGLI^IBL§
- .006
4 .01
- .0
H EGLIG
EGLIG
NEGLIG
NEGLIG
4
4
BLE
BLE
OLE
BLE
- IOC4
MSCC Source Category
306000000 Petroleum Industry
306001000 Process heater
306002000 Fluid catalytic crackers
306003000 Moving bed catalytic crackers
306008000 Miscellaneous leakage
306012000 Fluid coking
Charge Rate Unit
N. A. a
1000 bbl/yr
1000 bbl/yr
1000 bbl
capacity/yr
1000 bblfeed/yr
1N.A. (not applicable) is listed under "Charge Rate Unit" where the MSCC
number is made up of two or more MSCCs whose charge rates are different.
-------
PART II
BASIC INVENTORY
-------
SECTION 1
DATA HANDLING
1.1 DATA ACQUISITION
1.1.1 Data Selected for Study
It was determined at the outset, by the EPA Project Office,
that this study would be restricted to stationary sources of emissions and
that the emissions of interest were oxides of nitrogen (NO ), carbon
monoxide (CO), hydrocarbons (HC), and particulate matter (PART). It was
also agreed that only point sources (as opposed to area sources) of emissions
would be studied. A point source, as defined by the National Emissions Data
System (NEDS), is a single stack or geographical point from which more
than 100 tons of a given identified air pollutant are discharged annually into
the atmosphere. The NEDS is described in detail in Ref. 1-1. The pro-
cesses which contribute to the atmospheric emissions studied and reported
here are described in Refs. 1-2 and 1-3.
The categories of emission sources initially selected for
study were determined from the NEDS nationwide emissions report (Ref.
1-4). The order of priority was based largely on the desire to study as
many stationary sources of the four emissions in as little time as possible.
Table 1-1 shows the emissions from the categories selected for study. The
values are as reported in the NEDS Nationwide Emissions Summary,
January 10, 1975 (Ref. 1-4).
1-1
-------
Table 1-1. STUDY LIST OF EMISSIONS'
Source Category
Utility Boilers
Industrial Boilers
Process Gas Combustion
Stationary 1C Engines
Petroleum Industry
Chemical Manufacturing
Evaporation
Primary Metals
Mineral Products
Secondary Metals
Wood Products
Point Source Emissions Selected
for Study
Remaining Point Source Emissions
Total Area Source Emissions
Total Stationary Source Emissions
Percent of Total Stationary
Source Emissions
NO
X
48.4
9.6
0.9
2.6
22.6
1.1
-
0.1
1.4
0.1
0.1
86.9
-
13.1
100.0
HC
0.8
0.9
0.5
9.7
22.3
30.8
1.1
0.1
-
0.2
66.4
3.6
30.0
100.0
CO
0.8
1.0
0.1
13.9
18.4
-
24.3
0.1
4.1
2.8
65.5
18.0
16.5
100.0
PART
23.1
9.8
0.1
0.1
6.6
1.5
0.1
10.1
25.4
1.1
2.9
80.8
4.7
14.5
100.0
aData extracted from Ref. 1-4,
Internal combustion (1C) engines.
1-2
-------
Table 1-1 shows that stationary area sources represent
from 13 to 30 percent of the emissions of interest. The categories studied
in the first year, under study in the second year, and planned for the third
year represent from 78 to 100 percent of the four point source emissions
identified in Ref. 1-4.
Of the categories inventoried in the first year of this study,
utility and industrial boilers and process gas combustion were studied
together and are reported in Section 2 under the more general category
"external combustion (boiler)." The process gas combustion category was
included in this study because an earlier NEDS nationwide emissions
summary (emissions as of December 19, 1973) indicated that nearly 20 per-
cent of all NO from stationary sources originated from process gas com-
Jt
bustion. This information was supported by the large process gas combus-
tion rates listed in Ref. 1-4. Study of the actual data stored in the NEDS
(from a data tape) showed that large errors in the original data for two users
of process gases accounted for nearly all of the previously reported nation-
wide process gas usage rates and, therefore, for nearly all of the reported
NO emissions in this category. These errors were reported, checked, and
confirmed by the NEDS personnel, and greatly reduced NO emissions are
Ji
now as reported in Table 1-1.
The stationary internal combustion engines category, although
contributing only small quantities of emissions (Ref. 1-4), was chosen
because the NO emissions could be very large, depending on the usage
Jv
rates of a large population (Ref. 1-5) of gasoline-fueled engines, each of
which is too small to be classed as a point source. Although emissions from
point sources in this category are small, the data are summarized, along
with a .discussion of this critical area source problem, in Section 3.
The chemical manufacturing and petroleum refinery cate-
gories were selected because of the high emissions of NO , CO, and HC.
Ji
These categories are reported in Sections 4 and 5, respectively.
1-3
-------
Although the categories tinder study have been referred to
as NEDS categories, the NEDS was not the only source, or even in' some
cases the major source, of original data. Extensive reviews of the litera-
ture were also conducted to obtain other original data as well as the
rationale for projection of the data into the future. The data obtained, con-
sisting of necessary calculations, sources, and results, are different for
each of the general categories studied, and discussions of these data are
contained in each of the following sections of this report. The NEDS data
acquisition and evaluation techniques were generally common to all
categories studied.
1.1.2 Preliminary NEDS Data Evaluation
In each study, a computer tape of all point source data
stored in the NEDS for the categories of interest were requested from the
NEDS. Initially, the data contained on the tape were analyzed (by computer)
to determine the significant source classification code (SCO). The NEDS
source classification codes are listed and described in Appendix A.Z of
Ref. 1-1.) This summary of emissions by the NEDS SCC was reviewed to
determine those categories containing the bulk of the four emissions. In
most cases it was found that a small number of SCC categories accounted
for nearly all of the emissions of each type in the general category chosen
for study. Therefore, the total of emissions of some types for the entire
general category chosen for study was comparatively insignificant. Con-
sidering the rather large ranges of uncertainty in the emissions from other
major categories, it was not considered cost-effective to study these small
categories. A general measure used to rule out study of certain emissions
within a general category or to rule out study of certain SCCs altogether
was based on one percent of jbhe total stationary point source emissions.
If the sum of any one of the four selected air pollution emissions over the
entire general category was less than one percent, emissions of that pollu-
tant were neglected. In certain groups of SCCs, none of the four emissions
exceeded one percent, and these SCCs were neglected.
1-4
-------
Reference 1-1 lists all the SCCs represented on the NEDS
data tape in each of the general categories selected for study. Each data
section in this report shows those SCCs studied. The SCCs listed in the
appropriate category in Ref. 1-1 but not listed in the corresponding data
section of this report were neglected for the above reasons. In cases
where any of the four air pollutants were negligible, the data printout
indicates "negligible."
The SCCs which were considered significant for one or more
of the emissions were then reviewed for data entries indicating excessive
process charge rates or emissions. The most commonly used technique to
check charge rates was to review the process state of the art, select a
large processing plant, and execute a computer search for point sources
with listed charge rates greater than this expected maximum. If such cases
were discovered, all of the data for that plant and point source were printed
for further review. Many cases were found, in this manner, where the
listed charge rates were 100 to 1000 times that considered reasonable for a
large plant (in some cases even larger than the entire national capacity). In
most categories, no equivalent reliable check could be devised, however,
for charge rates listed too low. After correction of the data for charge rates
listed too high, the corrected total was compared with other original data
from the literature.
Erroneously recorded emissions were checked by comparing
emission factors calculated from the NEDS tape data on emissions and
charge rates against the latest emission factors recorded in Ref. 1-2.
Some errors in the listed emissions were uncovered in this manner. A more
common error, however, resulted from the accepted practice of calculating
the emissions from the -best estimate of emission factors and the charge
rate, instead of from actual measurements. Since most of the data currently
stored in the NEDS was entered in the 1970 through 1972 time period,
emission factors were approximately those listed in Ref. 1-3. Corrections
in emission factors between the Ref. 1-3 listing and the subsequent listing
1-5
-------
in Ref. 1-2 in some cases increased or decreased the emission factors by
factors of as much as 75 and 40, respectively.
1.1.3 Data Coding
The NEDS data categories are identified by an eight-digit
number called the SCC. Where possible and where one or more emissions
in a given SCC were large, a further detailed breakdown of the data in that
SCC was effected. To facilitate handling of this more detailed data and yet
maintain close correspondence with the established NEDS SCC data coding
system, a modified SCC (MSCC) system was initiated for this study. A
ninth digit was added to all of the eight-digit NEDS SCCs to form the MSCCs
used in this study. All of the NEDS SCCs, then, appear in this study with
an additional zero in the last place of a nine-digit code number. Where
additional breakdown of data in a NEDS SCC was possible and desirable, the
last place in the nine-digit code of this study shows a nonzero digit. For
example, the NEDS SCC category 10-10-02-02 identifies raw, original data
stored for the category: external combustion, boiler (Ix-xx-xx-xx);
electric generation (10- Iz-xx-xx); bituminous coal (10-10-02-xx); fired as
pulverized coal in dry-bottom boilers of capacity greater than 100 million
Btu/hr (10-10-02-02). This same general category is identified in this
study by the MSCC 101002020. This MSCC, in this study, however, is con-
sidered a fourth-level summary because the additional breakdowns
101002021 through 101002024 have been included to divide those data into
the boiler firing types: tangential, opposed, single-wall, and vertical,
respectively. These are now the data levels, and the MSCC 101002020
represents the sum of the emissions and charge rates of the four data SCCs.
Again, although the data coding system used in this study
closely parallels that of the NEDS system, the data actually stored and used
in this study were acquired from a number of sources (including NEDS). The
original data base being accumulated in the data storage and handling pro-
gram at The Aerospace Corporation, then, represents a careful and
judicious sum from other sources as well as NEDS.
1-6
-------
1.2 DATA HANDLING AND STORAGE
The sheer volume of data being generated in this study
immediately dictates the use of a computer system for storage and handling.
After only the first year of study, 102 MSCC categories have been defined
for storage of significant data. In each of the MSCCs, 40 separate
bits of information must be entered into storage. In any particular MSCC,
a particular storage location may contain data either in the form of a
number or an indication that the particular data are negligible. Thus, a
total of 4080 data entries have already been entered into the program.
The general form of the data storage and handling program
is based on two major considerations:
a. The data acquired from various sources represent
different points in .time. Particularly because of the
rapidly changing energy picture, much of those data
may have changed considerably between the time of
acquisition and the time of this study. Data acquired
and stored in general categories at the beginning of
this study will be three years older at the time of
the first planned update. Users of the data need to
have available an estimate of emissions in the time
period of implementation of control systems (i.e.,
in the future) rather than at the time of planning.
b. Complete and accurate original data are difficult to
acquire. As a result, little good data are available,
and data from several sources are often widely
discrepant. As estimates of future emissions are
highly desirable, it is important to know how uncer-
tain these projections are.
1.2.1 Data Projections
In response to the need for current and future emissions
estimates as well as a set of values upon which these estimates and projec-
tions can be evaluated as to their accuracy, a data storage and handling
program was developed. As in the NEDS summary system, emissions of
each of the four air pollutants NO , CO, HC, and PART are calculated
from charge rates and emission factors:
1-7
-------
Emissions = Emission Factor X'Charge Rate (1-1)
For all four of the emissions in a single SCC, the charge
rate'is the same and is fundamental data in itself. For that reason, storage
space is.available for-three values of the charge, .rate (with the appropriate
year of the data) for each'MSCC.
For NO , CO, and HC emissions, the appropriate emission
"Jt
factors are entered directly and used with the charge rates as in Eq. (1-1)
to calculate emissions. As such, these emission factors directly reflect
the average degree of control of emissions in all processes represented by
the MSCC. 'Since'the degree .of control may change with time, either because
of more-effective control or more widespread application of the same degree
of control, the emission .factor must be projected into the future indepen-
dently of the charge rates.
PART emissions, however, are.normally controlled by
special hardware. Since these are recognizable pieces of hardware with
relatively well-established PART collection. efficiencies, both the
collector efficiency and the degree of> application of such collectors to
processes .represented in the .MSCC can be determined. The emission
factors in Eq. (1-1) for PART emissions, -then, are calculated from an
uncontrolled emission factor for the process, a function of the average
collector efficiency, and the average degree of application of this average
collector:
PART Emission Factor = Uncontrolled Emission Factor x
(1 - Collector Efficiency) X
Fraction-of-Application of the
Collector (1-2)
1-8
-------
It is assumed that the uncontrolled PART emission factor is fundamental
to the process and will not change with time. Both the average collector
efficiency and the degree of application of this average collector, however,
can change with time, and both must be projected independently into the
future.
Thus, six time-dependent variables must be entered into the
program storage in order to calculate emissions of the four air pollutants
of interest: the latest charge rate, the three controlled emission factors,
the PART collector efficiency, and the degree of application of the PART
collector. Because of the widely varying sources of these data, they hardly
ever represent the same period in time. Therefore, the original data
cannot be meaningfully combined directly to calculate emissions. The data
storage and handling program allows for three separate years of record for
(1) the latest charge rate, (2) all three controlled emission factors and the
PART control efficiency,, and (3) the degree of PART control application.
Whenever emissions are calculated, according to Eqs. (1-1) and (1-2),
these time-dependent variables must be projected from their individual
years of record to the same date.
The projection of these six time-dependent variables into
the future required a time-dependent projection equation. In light of the
large uncertainties in the original data and the usual uncertainties of the
future, no more sophisticated equation than a straight line is justified.
Thus, for each of the six time-dependent variables, a linear slope with time
(a time derivative) must also be determined from appropriate rationale
(e.g., control equation'efficiency and degree of application) and stored in
the data storage and handling program. All calculations of emissions thus
start with the original data for the six time-dependent variables, use the
six appropriate linear slopes to project these variables to some common
time, and then calculate emissions from the projected values according to
Eqs. (1-1) and (1-2). In this report, the charge rate and emission raw data
base are generated by projecting all of the data to the current year. A fur-
ther projection is made for five years into the future.
1-9
-------
1.2.2 Data Uncertainties
The second major consideration in the development of the
data storage and handling program relates to the uncertainties in the data.
As related in Section 1.1.1, data have been found that were in error by two
and three orders of magnitude. Differences between independent original
sources of the same data are often as large as factors of two. The recent
wide variations in charge rates with time, resulting first from the impact
of environmental considerations and from the energy shortage, make projec-
tions into the future uncertain. If users of the data reported here intend to
give weight to certain emissions projected for different sources, then it
becomes important that the user have values of the uncertainty in those
emissions.
Even an estimate of the uncertainties in the data is difficult
because of the lack of data. Adequate data are not available from a suffi-
cient number of original sources that a reasonable statistical estimate of
uncertainty can be made. The use of small data sample statistics results
in unrealistically large uncertainties. In most cases, only two sources
(and sometimes only one source) are available.
Usually, however, certain engineering methods can be
followed in estimating realistic bounds on some given data or time-dependent
slope from better-known data. For example, current levels of total elec-
trical demand and total installed electric-generating capacity are reasonably
widely studied and well documented. By using engineering judgment to set
various realistic upper and lower bounds on less well-documented data,
such as a breakdown of electric-generating capacity into fuels, firing types,
and plant sizes, an engineering estimate of a reasonable uncertainty range
around the data on charge rates in large pulverized coal-fired, electric-
generating boilers can be obtained. It may also be possible, from a descrip-
tion of a particular study or survey, to make an engineering estimate of the
degree of completeness and accuracy of the results. Some cases remain
where no data other than a single estimate from the literature and the
1-10
-------
corresponding NEDS data are available. In such cases, there is no
alternative other than to take the data as the average of the two available
estimates and the uncertainty range as the difference between the two.
Some fairly clear limits exist, or are defined here, on
projections into the future. In most cases, Aerospace familiarity with the
basic processes generating or controlling emissions is sufficient that lower
limits on emission factors can be estimated with reasonable confidence, at
least for the near future. These lower limits are stored in the data storage
and handling program, and the program will not allow the NOx, CO, or HC
emission factors (minus the uncertainty) to drop below these limits.
Similarly, upper limits are set on PART collector efficiencies. The degree
of application of a collector cannot exceed 1.0. Because of the social
pressure in all areas to reduce air pollution, the assumption was made in
this program that the maximum value of a projected emission factor (the
projected nominal value plus the projected uncertainty) cannot exceed the
current maximum value (i.e., no increase in emission factors). Of course,
no charge rates or emissions, including uncertainties, are allowed to be
negative. Limits such as those discussed in this paragraph can result in
unsymmetrical uncertainties in projected data levels. For example, the
1975 NO emission for MSCC 101002000 is
The above discussion outlines the methods used and problems
encountered in generating engineering estimates of uncertainty in the data
shown in this report. The fact that it is so difficult to generate these esti-
mates underlines the need to provide the user with the documentation of the
uncertainty of these data. These uncertainties are not statistical quantities.
It is necessary, however, to combine the uncertainty estimates of charge
rate, emission factor, collector efficiency, control equipment application
1-11
-------
data, and the derivatives of these with time slopes, to establish the
uncertainties of emission data projected into the future.. In the data storage
and handling program, these are treated as statistical quantities.(standard
deviation.).-.. The resulting.uncertainties in the projected emissions.are
considered engineering estimates.
1.3 REFERENCES
1_1. Guide for Compiling a Comprehensive Emission Inventory,
'revised, APTD-1135-, U..S;? Environmental Protection
Agency, Research Triangle Park, North Caroline
(March 1973).
1_2. Compilation of Air Pollutant Emission Factors, 2nd ed.,
AP-42, U.S. Environmental Protection Agency, Research
Triangle Park, North Carolina (April 1973).'
1_3. Compilation of Air Pollutant Emission Factors, AP-42,
U.S. Environmental Protection Agency, Research Triangle
Park, North Carolina (February 1972).
1_4. Nationwide Emissions Summary, National Emissions Data
System, U.S. Environmental Protection Agency, Resea-rch
Triangle Park, North Carolina (January 10, 1975).
1_5. W.. U. Roessler, et al., 'Assessment of the Applicability of Auto-
motive-Emission Control .Technology to Stationary Engines,
EPA-65012-74-051, The Aerospace Corporation, El Segundo,
-California (July 1974).
1-12
-------
SECTION 2
EXTERNAL COMBUSTION IN BOILERS
2.1 INTRODUCTION
The external combustion (boiler) category of stationary
emission sources includes all of the fuels burned in stationary boilers for
the purpose of generating steam for electric generation and various other
industrial purposes. According to the National Emissions Data System
(NEDS) nationwide emissions report of January 10, 1975 (Ref. 2-1), this
category, at least in the 1970 to 1973 time period, represented the largest
single stationary source of both oxides of nitrogen (NO ) and particulate
(PART) emissions. NO emissions of over 8 million tons per year repre-
H
sented about 59 percent of NO emissions from all stationary sources and
about 36 percent of NO emissions from all sources inventoried by the NEDS.
Ji.
PART emissions of over 5 million tons per year represented about 33 per-
cent of PART emissions from all stationary sources and 31 percent of this
air pollutant emitted from all sources. Hydrocarbon (HC) and carbon mon-
oxide (CO) emissions from sources in this category represented less than
two percent, each, of those from all stationary sources. The external com-
bustion (boiler) category was the first to be studied in this continuing inven-
tory because of the large NOX and PART emissions.
A wide range of fuels is burned in external combustion boilers,
including the following:
a. Coal: anthracite, bituminous, and lignite
b. Oil: residual and distillate
2-1
-------
c. Gas: natural and processed
d. Wood
e. Bagasse
f. Coke
g. Liquified petroleum gas
h. Other minor fuels
Of the NO and PART generated from the external combustion of these fuels,
3t
for electric generation and various industrial purposes, in single sources
emitting more than 100 tons per year of these air pollutants (point sources),
the combustion of bituminous coal is by far the largest fuel source. More
than 58 and 88 percent of the NO and PART, respectively, from the exter-
nal combustion, boiler category result from the combustion of bituminous
coal. Other fuel combustion which contributes 'significantly to the emission
of NO and PART includes that of natural gas and oil.
7£
At the time that the fuels to be studied in this portion of the
inventory were selected, the then existing NEDS emission summary (Ref. 2-2,
dated December 19, 1973) indicated that process gas combustion in industrial
boilers and heaters was the source of 2. 6 million tons per year of NO and
13
resulted from the annual combustion of more than 2 X 10 cu ft/year of such
gaseous fuels. This fuel category, therefore, was included in those to be
studied. During the study, it was found that large errors in the fuel usage
(annual charge rate) data submitted by two companies accounted for over
90 percent of the listed annual process gas combustion and more than 80 per-
cent of the listed NO emissions from process gas combustion. These errors
have subsequently been corrected in the NEDS data bank. The NEDS emis-
sions inventory of January 10, 1975 (Ref. 2-1) indicates only about 11,000
tons per year of NO from combustion of process gas. Since this fuel cate-
X
gory was studied, however, it is included in the projections in this section
even though the emissions are small or negligible. No significant effort was
made to estimate future changes in process gas usage rates or emission
factors.
2-2
-------
The fuels selected for study in this inventory were bituminous
coal, residual and distillate oil, natural gas, and process gas. These five
fuels account for 96 and 92 percent, respectively, of the NOx and PART gen-
erated from external combustion, electric generation, and industrial point
sources. All other fuels except lignite and wood represent sources of less
than one percent of these pollutants. Lignite represents the source of just
over one percent of the pollutants from this category and was neglected.
Wood combustion represents the source of nearly two percent and more than
four percent of the NO and PART, respectively, from this category. The
7C
more general category of wood products, including wood combustion, also
represents a significant source of CO emissions. As a result, study of the
more general categories related to wood use was not neglected but was
deferred to a later date.
2.2 SUMMARY
The NEDS source classification code (SCC) for external com-
bustion (boiler) point source categories was modified according to the fuels
utilized in utility and industrial boilers and inventoried by this study.
Table 2-1, therefore, identifies the source categories studied according to
the Aerospace-developed modified source classification code (MSCC) and
presents the total annual charge rate projected (TACRP) for each.
A summary of the 1975 and 1980 emissions and TACRP units
for the external combustion (boiler) categories was compiled and is given in
Tables 2-2-a and 2-3-a, respectively. The uncertainties in the emission
and charge rate data for 1975 and 1980 are given in Tables 2-2-b and 2-3-b,
respectively.
2.3 APPROACH
i
Study of fuel usage, emission factors, and projection data in
the external combustion (boiler) category was initiated in this study solely
from the available literature. In many areas, however, the available data
did not provide a sufficient breakdown of firing types nor sufficient multiple
sources to evaluate data accuracy (or uncertainty). As a result, a computer
(Continued on page 2-24)
2-3
-------
Table 2-1. Definition of External Combustion (Boiler) Processes
MSCC
101000000
101002000
101002010
101002020
101002021
101002022
101002023
101002024
101002030
101002040
101002050
101002060
101002070
101002080
101002090
101002100
101002110
101002120
101004000
101004010
101004011
101004012
Source Category
Utility Boilers
Bituminous coal
>100 MMBtu/hr pulverized wet
>100 MMBtu/hr pulverized dry
Tangential firing
Opposed firing
Single -wall firing
Vertical firing
>100 MMBtu/hr cyclone
>100 MMBtu/hr spreader stoker
>100 MMBtu/hr overfeed stoker
10 to 100 MMBtu/hr pulverized wet
10 to 100 MMBtu/hr pulverized dry
10 to 100 MMBtu/hr overfeed stoker
10 lo 100 MMBtu/hr underfeed stoker
<10 MMBtu/hr overfeed stoker
<10 MMBtu/hr underfeed stoker
<10 MMBtu/hr pulverized dry
Residual oil
>100 MMBtu/hr general
Tangential firing
Opposed firing
TACRP Unit
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
1000 gal/yr
1000 gal/yr
1000 gal/yr
1000 gal/yr
-------
Table 2-1. Definition of External Combustion (Boiler) Processes (Continued)
to
in
MSCC
101004013
101004014
101004020
101004030
101005000
101005010
101005020
101005030
101006000
101006010
101006011
101006012
101006013
101006014
101006020
101006030
101007000
101007010
101007020
101007030
Source Category
Single-wall firing
Vertical firing
10 to 100 MMBtu/hr generala
<10 MMBtu/hr general
Distillate oil
>100 MMBtu/hr general
10 to 100 MMBtu/hr general
<10 MMBtu/hr general
Natural gas
>100 MMBtu/hr general
Tangential firing
Opposed firing
Single wall firing
Vertical firing
10 to 100 MMBtu/hr general
<10 MMBtu/hr general
Process gas
>100 MMBtu/hr general
10 to 100 MMBtu/hr general
<10 MMBtu/hr general
TACRP Unit
1000 gal/yr
1000 gal/yr
1000 gal/yr
1000 gal/yr
1000 gal/yr
1000 gal/yr
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
-------
Table 2-1. Definition of External Combustion (Boiler) Processes (Continued)
ts)
MSCC
102000000
102002000
102002010
102002020
102002030
102002040
102002050
102002060
102002070
102002080
102002090
102002100
102002110
102002120
102002130
102004000
102004010
102004020
102004030
Source Category
Industrial Boilers
Bituminous coal
>100 MMBtu/hr pulverized wet
>100 MMBtu/hr pulverized dry
>100 MMBtu/hr cyclone
>100 MMBtu/hr spreader stoker
10 to 100 MMBtu/hr overfeed stoker
10 to 100 MMBtu/hr underfeed stoker
10 to 100 MMBtu/hr wet pulverized
10 to 100 MMBtu/hr dry pulverized
10 to 100 MMBtu/hr spreader stoker
<10 MMBtu/hr overfeed stoker
<10 MMBtu/hr underfeed stoker
<10 MMBtu/hr dry pulverized
<10 MMBtu/hr spreader stoker
Residual -oil-fired
>100 MMBtu/hr residual-oil-fired
i to 10 MMBtu/hr residual-oil-fired
<10 MMBtu/hr residual-oil-fired
TACRP Unit
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
Tons/yr
1000 gal/yr
1000 gal/yr
1000 gal/yr
1000 gal/yr
-------
Table 2-1. Definition of External Combustion (Boiler) Processes (Continued)
to
i
MSCC
102005000
102005010
102005020
102005030
102006000
102006010
102006020
102006030
102007000
102007010
102007020
102007030
Source Category
Distillate-oil-fired
>100 MMBtu/hr distillate-oil-fired
10 to 100 MMBtu/hr distillate-oil-fired
<10 MMBtu/hr distillate-oil-fired
Natural-gas-fired
>100 MMBtu/hr natural-gas-fired
10 to 100 MMBtu/hr natural-gas-fired
<10 MMBtu/hr natural-gas-fired
Process gas-fired
>100 MMBtu/hr process gas-fired
10 to 100 MMBtu/hr process-gas-fired
<10 MMBtu/hr process-gas-fired
TACRP Unit
1000 gal/yr
1000 gal/yr
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million cu ft/yr
Million British thermal units (MMBtu).
-------
Table 2-2-a. 1975 EXTERNAL COMBUSTION EMISSIONS AND CHARGE RATES
EXTERNAL COMBUSTION, BOILER CATEGORY
PAGE
ANNUAL CHARGE RATES AND EMISSIONS PROJECTED TO 1975
I
00
MODIFIED
SCC
101C02CCO
1C1004U10
1C10C2C2G
1C1CC2C21
1CUC2C22
K1GG2C23
10UV2C24
01002030
:81
0
c:
c:
0
c
0
10]
L002C40
002050
Cv.2060
002070
CO 2 CSC
002090
002100
002110
L002120
IGlCftCOC
10U04G10
1G1GG4G11
101004012
U-1C04113
1C1CL4C14
1G1CG4C2C
1G1CU4C30
101G05CCO
1010C5UO
1C1CC5C20
101105030
TACRP
CSCC UNITS)
389250000.
4583000C.
277100000.
14606UOOO.
58780000,
5790000G.
1436COOO.
54080000.
4200000.
1810000.
190COO.
1567200.
440000.
235COOO.
30000.
0.
.1655800.
18210000.
1796COOO.
71840CO.
5200000,
520COOO.
376010.
2400CO.
10000.
NOX
EMISSIONS
4.897
.573
2.716
.974
,781
.769
.191
1.509
0.
>
IT \
&:
.13
.002
.015
.003
.017
.000
0.000
.016
.667
.656
.160
.232
.232
.C34
.009
.000
C.OCO
0.000
0.000
o.tcc
(MILLIONS
HC
.070
.007
,050
.022
RUN DATE-JU^E 24*1976
OF TONS / YEAR)
OC9
.011
.008
.000
.GCC
CCO
.001
.000
o.coc
occ
.016
.018
.007
.ccc
.ooc
.ooc
o.occ
0.000
o.coo
0.000
TONS
CO
.199
.023
.139
.073
.029
.029
.007
.027
:tt*
1000
.002
.000
0.000
.001
.027
.027
.011
008
.008
.001
.OOC
.000
0.000
0.000
0.000
0.000
PART
4.205
.8Z6
2.940
.073
.072
.029
.021
.021
.002
CC1
.000
0.000
0.000
0.000
0.000
-------
Table 2-2-a. 1975 EXTERNAL COMBUSTION EMISSIONS AND CHARGE RATES (Continued)
i
vO
EXTERNAL COMBUSTION, BOILER CATEGORY PAGE 2
ANNUAL CHARGE RATES AND EMISSIONS PROJECTED TO 1975 RUN DATE-JUNE 24*1976
EMISSIONS (MILLIONS OF TONS / YEAR)
MODIFIED
SCC
1010G6COO
1C1006UO
1C1CC6C11
K1U6C12
101CC6C13
ltUC6tl4
1C1C06C20
1G1L06030
IClOuTOCG
1C1C07010
K1CC7G20
1CICC7C30
102002000
102CC2C1C
02C02C20
C2002C30
C2C02C40
02002050
02CU2060
102C02070
102002080
102002090
102002100
1C2CL211U
1C2C02120
102002130
1C2004COO
102CC4C10
1C2C04020
TACRP
(SCC UNITS)
29934GO.
2936000.
7760CO.
1206000.
86
-------
Table 2-2-a. 1975 EXTERNAL COMBUSTION EMISSIONS AND CHARGE RATES (Continued)
ANNUAL CHARGE
EXTERNAL
RATES AND EHISS
COMBUSTION* BOILER CATEGORY PAGE 3
IONS PROJECTED TO 1975 RUN DATE-JUNE 24,1976
MODIFIED
StC
1G2GG4C30
1020G&000
1C2GG5C1G
!G2GOb02G
102GC3C30
1020C6COO
102006010
102006020
N> 1C2G06C30
i
o 1G2GG7CGU
1C20C7G10
102G07020
IC2G07G30
TACRP
(SCC UNITS)
530000.
706COOO.
5186000.
1684000.
19COOO.
3520000.
2C60GOO.
924000,
536000.
1749300.
1257000.
28260.'
EKISS
NOX
.013
.169
.124
.040
.005
.303
.177
.079
.046
.000
.CCO
.000
.COG
IONS (MILLIONS
HC
.001
Oil
.006
.003
.OCO
.005
.003
.001
.001
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
OF TONS /
CO
.001
014
.010
.003
.000
.030
.018
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
YEAR)
PART
.006
.053
.039
.013
.001
.032
.019
.008
.005
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
-------
Table 2-2-b. 1975 EXTERNAL COMBUSTION UNCERTAINTIES
EXTERNAL COMBUSTION* BOILER CATEGORY
PAGE 1
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 1975
RUN DATE?JUNE 24*1976
MODIFIED
sec
U1002CCO
1C1002C10
101002020
101C02021
111C02022
1C1CU2123
101002024
1010C2030
101GG2C4G
101G02C50
101002.060
1C10U2C70
1C1C02080
101002090
1G1CC2100
101002110
101G021J-0
TACRP
(SCC UNITS)
4 11708000.
11708000.
4 4651900.
4651900.
4 9643300.
9643300.
4
4
«
4
»
4
4
4
4
4
4
4
4
4
4
4
B3650CO.
83650GO.
336C300.
3360300.
3324500.
3324500.
C2219U.
622190.
46861GO.
468610C.
632460.
632460.
172050.
172050.
29732.
29732.
761C2.
76102.
63245.
63245.
156200.
156200.
8:
^r
0.
0.
1013CO.
10(300.
4
4
4
4
4
4
4
4
4
4
4
4
4
4
_
4
4
4
EMISSIONS (MILLIONS OF TONS / YEAR]
NOX HC CO
.348 4- .097 4 .069 4
.346 - .014 - .046
.099 4 .005 4 .017 4
.099 - .OG4 - .012
,253 4 .097 4 .063 4
.253 - .CIS - .042
.166
.166
.134
.134
.132
.132
.033
.033
.218
.218
.006
.006
.002
.002
.001
.001
.003
.003
.001
.001
.002
.002
.OOC
.OOC
c.ooo
0.000
.C03
.003
4
4
4
4
4
4
4
4
4
4
4
_
4
4
4
.017
.011
.068
004
.067
.004
ooe
»OG1
.006
OC4
002
.002
loci
"occ
.000
.000
.000
GOO
.000
.001
.001
.000
.occ
o.coc
o.ooc
.ooc
.ccc-
4-
4
4
4
4
4
4
4
4
4
4
4
4
4
.055
037
.022
01 5
022
.015
.005
.004
020
.014
003
.002
:88i
:888
001
.000
.000
.000
.002
.001
000
.000
0.000
0.000
.001
.000
4
4.
4
4
4
4
4
4
4
4
4
4
4
4
1
PART
.431
.431
.271
.271
.325
.325
.282
.282
113
1» i
13
.112
112
028
.028
.063
063
027
.027
Oil
Oil
.004
.004
' .003
.003
.002
.002
C09
009
OOC
.000
8.000
.000
.042
C42
-------
Table 2-2-b. 1975 EXTERNAL COMBUSTION UNCERTAINTIES (Continued)
ro
i
H*
ts)
EXTERNAL COMBUSTION* BOILER CATEGORY PAGE 2
TACR AMD EMISSION UNCERTAINTIES PROJECTED. TO 1975 RUN DATE-JUN.E 24*1976
MODIFIED lACRP EMISSIONS (MILLIONS OF TONS / YEAR)
sec
101CC4COO
(SCC UNITS)
4 2111300.
4
NOX
2111300.
1G1004C1G
1C1C04C11
1C1004G12
101GG4C13
1G10C4U4
1G1C04C20
101004G30
1C1C05COO
U1COC10
101005020
1C1C05C30
1C1006COO
101CC6010
1C1006C11
4 2111300.
4
21113LC.
4 1464800. 4
_
4
«
4
4
4
-
4
~
4
-
4
-
4
4
-
4
-
4
-
4
-
L4648CO.
oeocco.
080000.
0663CC.
L068300.
63245:
63245.
0.
0.
0.
0.
C.
0.
0.
0.
0.
0.
C.
0.
590090.
59009G.
589870.
589870.
265350.
265350.
4
4
4
4
4
~
4
-
4
4
4
4
4
4-
G
0
0
0
C
0
0
G
.094
.094
.094
.094
.041
C41
.060
.060
.059
.059
.008
.008
.001
.001
.000
.000
.000
.OOC
.000
.000
.000
.000
.COG
.coo
.139
.139
.139
.139
.C34
.C34
4
4
4
_
4
4
4
-
4
4
4
4
4
4
4
4
4
-
HC
.008
oct
.008
OG6
.006
.004
.004
.OC3
.004
.003
.000
.GCO
.000
.000
.000
.OOC
O.COG
O.OCC
c.occ
0.000
0.000
o.occ
O.COO
O.OOG
.001
.OC1
.001
OC1
.ccc
.ceo
4
4
-
4
^.
4
4
V
4
4
4
4
4
4
4
4
4
4.
CO
.012
.008
012
.008
.009
.006
.006
4004
.006
.004
.000
.000
.000
.000
000
000
0.000
c.ooo
0.000
0.000
0.000
c.ooo
0.000
0.000
.012
.009
.012
.009
.005
.004
4
4
4
_
4
4
0
4
4
4
4
4
4
«
4
-
4
4
4
PART
.008
.006
.008
.008
.006
.006
.004
.004
.004
.004
.000
.OOC
0.000
0*000
8.0UG
.000
O.COO
O.OOG
O.OOC
c.coc
O.COO
O.OuG
0.000
O.GOO
.004
.C04
.004
.CC4
.102
.U02
-------
Table 2-2-b. 1975 EXTERNAL COMBUSTION UNCERTAINTIES (Continued)
EXTERNAL COMBUSTION, BOILER CATEGORY
PAGE
ISJ
I
TACP AND EMISSION UNCERTAINTIES PROJECTED TO 1975
RUN DATE-JUKE 24,lVfO
MODIFIED
sec
101006012
101006013
161006014
1C10C602C
101006030
101C07CLC
101CG7C10
101007C20
101007030
1C2CC2COO
1020U2C10
102002020
1C2C02C30
1020C2C40
1C20C2C50
U20U2C60
4
.
4
_
4
-
4
4
-
4
4
4
4
4
4
4
4
4
TACRP
(SCC UNITS)
427930..
427930.
305750.
305750.
30594.
3C594.
16000.
16000.
1400.
1400.
15220.
15220.
1522C.
15220.
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
64316CO.
64316CO.
796490.
796490.
4091400.
4091400;
14S66CO.
1486600.
4049500.
4C49500.
106300.
106300.
884080.
884080.
EMISS
NOX
4 .109
- .109
4 .078
- .078
4- .016
- .016
4 .004
- .004
* .OOC
- .OOC
4 .COO
- .000
4 . OCt
- iOOO
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
4 .075
- .075
4 .014
- .014
4 .041
- .041
4 .046
- .046
4 .035
- .035
4 .CC1
- .001
* .007
- .007
IONS (MILLIOI
HC
4 .OC1
- .ooc
4 .OOC
-i C (' P
4 .OCO
- .oco
4 .000
- .000
4 .OCO
- .ccc
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
4- .010
r .01C
4 .001
- .000
4 .001
- .OC1
4 .CC1
- .001
4- .009
- .OC9
4 .000
- .01 c
4 .OC2
- .CC2
NS OF TONS / 1
CO
4- .009
- -006
4 .006
"" ^5$)
4 .001
- .000
4 .000
- .000
4 .000
000
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGL GIBLE
NEGLIGIBLE
NEGL GIBLE
NEGLIGIBLE
4 .020
- .014
4- .002
- .001
4 .003
- .003
* .002
- .C02
4 .018
~ .012
i :S81
4- .003
'EAR)
% * ** ^
PART
4 .003
- .003
_ f\ A 1
4 .002
*4\ j\ /\
000
- .OOC
4 .000
- ,000
.000
- .000
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
4 .190
- .190
4 .020
- .020
4- .089
- .089
«k «
4- .011
- .011
4 .141
- .141
4- .005
- .005
4- .022
- .022
-------
Table Z-Z-b. 1975 EXTERNAL COMBUSTION UNCERTAINTIES (Continued)
EXTERNAL COMBUSTION, BOILER CATEGORY PAGE 4
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 1975 RUN DATE-JUNE £',1976
CN)
I
MODIFIED
sec
K2CC2C7C
1020C2080
1C2C02090
102002100
102002110
102002120
102002130
1C2CC4C.OO
102004010
1C20C4C20
1G2004C30
1020050GO
102CC5C1C
1G2CU5C20
1C2C05030
1C2006000
TACRP
(SCC UNITS)
4
.
4
_
4
.
4
_
4
*
4
-
4
4
4
4
4
4
«.
4
4
4
-
34409.
34409.
417610.
417610.
2C95900;
2099900.
344C9.
3 4 4u9 .
12000.
12000.
0.
0.
59464;
59464.
114C10C.
1140100.
1C62900.
10628GG.
4091<*0.
40914C.
53073.
53073.
836110.
836110.
807220.
807220.
223730.
223730.
27724.
27724.
9C2520.
902520.
4
«»
4
4
4
_
4
4
4
4
4
4
4
1
4
_
*
4
+
EMIS
NOX
.001
.001
.004
.004
.017
.017
.000
.GOO
.OCO
.001
0.000
O.OCC
.001
.001
.093
.093
.083
.083
.042
.042
.006
.OC6
.060
.060
.057
.057
.018
.018
.C02
.GC2
.084
.089
SIONS
4
4
"4
4
4'
4
4
4
4
4
1
4
4
1
4
+
(MILLIONS OF TONS 7
HC
.OOC
.000
.OOC
.OCO
.004
.004
.000
.OCC
.000
.occ
O.OGO
o.ccc
.occ
.occ
.010
.OC7
.009
.006
.*OC3
.001
.ccc
?OC4
.CC6
;oc4
CO 2
.001
.OOC
.000
.OC3
.CC2
4
4
4
4
4
4
4
~
4
4
4
4
4
4
1
4
4
CO
.000
000
888
.000
COB
.005
.001
.001
.000
.000
0.000
0.000
.001
.001
.012
.009
Oil
.008
88?
.004
.001
.001
.008
.006
.007
.005
.002
.002
.000
000
.017
.012
YEAR)
4
4
4
4
4"
4
4
"
4
4
4
4
4
4
4
"4
4
PART
.C04
.004
.010
i * A
010
C85
.085
.001
.001
.001
.001
o.coo
O.GOO
.OGc
,002
.013
.013
.012
.012
.005
.005
.001
.001
.006
OOb
.006
.006
.002
.002
.000
.COO
.008
.006
-------
Table 2-2-b. 1975 EXTERNAL COMBUSTION UNCERTAINTIES (Continued)
Ul
EXTERNAL COMBUSTION* BOILER CATEGORY
PAGE 5
TACK AND EMISSION UNCERTAINTIES PROJECTED TO 1975
RUN DATE-JUN.E 24*1976
MODIFIED
sec
102C06010
1C2G06C20
U 2 DC b l3C
1C2CC7CCO
102CC7C10
1G2U7C2C
1C2C07C30
4
4
.
4
-
4
«
4
.
4
-
TACRP
(SCC UMTS)
826010.
826010.
310540.
310540.
180280.
180280.
142990.
14299C.
125700.
125700.
66100.
68100.
2800.
2800.
4-
+
4-
+
+
.
+
.
4.
-
EMISS
NOX
.077
.081
.C3U
.032
.017
.018
.000
.000
.000
.000
.001
. OOC
.000
.000
IONS (MILLIONS
HC
.003
- .OC2
+ .001
- .001
.001
- .ceo
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLI.GIBLF
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
OF TONS /
CO
* .015
- .011
.006
,005
+ .004
.003
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
YEAR)
PART
.007
C07
.003
. V
.002
NEGLIGIBLE
NEGLIGIBLE
NEGL
NEGL
NEGL
NEGL
NEGL
BLE
BLE
BLE
BLE
BLE
NEGLIGIBLE
-------
Table 2-3-a. 1980 EXTERNAL COMBUSTION EMISSIONS AND CHARGE RATES
EXTERNAL COMBUSTION, BOILER CATEGORY PAGE 1
ANNUAL CHARGE RATES AND EMISSIONS PROJECTED TO 198C RUN DATE-JUNE £4*1976
/ YEAR)
MODIFIED
SCC
1CUC2GOO
101002010
1C1GC2120
1C1GG2C21
101002022
1C1LJ2C23
1C10C2024
1011C2U30
101002G4C
C1CC2L5C
C1CG20CC
G1GU2C7G
01GU2G80
C1C02G90
!U10021GG
G1G02110
1GICC2120
101GN.4CCL
1C1CU4C10
!GlGO
-------
Table 2-3-a. 1980 EXTERNAL COMBUSTION EMISSIONS AND CHARGE RATES (Continued)
EXTERNAL COMBUSTION, BOILER CATEGORY
PAGE 2
IS)
l-t
-J
ANNUAL CHARGE RATES AND EMISSIONS PROJECTED TO I960
RUN .DATE-JUNE 24*1976
MODIFIED
SCC
ICiOlfcCGO
101CC6C10
1C1D06C11
1C1CD6G12
1C1CC6C13
101006020
1C1CC6G3G
101C07('CO
1C1UU7C10
1010U7020
101007030
102002CCO
.102002010
.02002020
02002030
: C20L2040
i C2GG2C5C
C20G2C6C
0200207C
02COZ080
1C2UG2G9G
1C2G02K.G
1G2CG2110
1G2GU212G
102002130
1C21U4000
102004010
102C04C20
TACRP
(SCC UNITS)
1986900.
1951GCO.
SlbOCC.
803000.
580CO.
33000.
2900.
90390.
90390.
iGLIGIBLE
IGLIGIBLE
93319000.
81900CO.
1133CUCO.
10600000.
40220000.
1780000.
7620000.
410000.
11700CO.
10769000.
470000.
170000.
0.
590000.
15350000.
9700000.
497COOC.
EMISSIONS (MILLIONS OF TONS / YEAR)
NOX HC CO PART
.122
.618
.056
.041
.008
.C02
.000
.000
.coo
.001
CC1
.000
.000
.OCC
.OCO
.000
.OCC
NEGLIGIBLE
NEGLIGIBLE
.793
.C82
.091
.24C
.242
.011
.046
.004
.009
.065
.037
.GC1
.000
C.OOO
.003
.138
.087
.045
.020
.001
.004
.000
OOC
.005
.001
.000
o.oco
.001
.023
.015
.CC7
.017
.017
.004
.007
.005
.000
.000
.000
BEGLIGIBLI
EGLIGIBLI
.082
.004
.006
.005
.040
.002
.002
.001
0.000
.003
.031
.019
.010
.015
.015
.004
.006
OC4
COO
.OOC
.000
NEGLIGIBLE NEGLIGIBLE
NEGLIGIBLE NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
1.287
.102
.192
.040
.638
.031
.092
G14
.022
.149
:88!
.177
.112
.057
-------
Table 2-3-a. 1980 EXTERNAL COMBUSTION EMISSIONS AND CHARGE RATES (Continued)
EXTERNAL COMBUSTION, BOILER CATkGORY
ANNUAL CHARGE
MODIFIED
sec
1C2C04C30
1C2CG5COO
1C2CC5010
1C2CC5C2G
10200^030
1C2C06CCO
1G2CG6C10
1020C6G20
iv 1G2GG6C30
So 102C07CCC
10200701C
1C20U7G2G
1G2G0713G
RATES. AND EMISSIONS
TACRP
(SCC UNITS)
68COGO.
896COOO.
65860CO.
2134CGG.
240000.
2320000.
136COCU.
S??888:
1749300.
1257000^
464000.
28260.
PROJECTED
EMISS
NC!X
.006
.081
.059
C19
.002
.147
.086
.000
.000
.000
.OOC
TO 1980
RUN DATE-JUNE
IONS (MILLIONS OF TONS / YE
HC CO
.001
.013
01C
CC3
.OCC
.003
.002
NEGLIGIBLE
NEGLIGIBLE
R EGLIGIBLE:
EGLIGIBLE
.001
.018
.013
.004
.000
.020
.012
NEGLIGIBLE
NEGLIGIBLE
M EGLIGIBLE
EGLIGIBLE
PAGE 3
24,1976
AR)
PART
.008
.067
.049
.021
.012
:88i
NEGLIGIBLE
NEGLIGIBLE
R EGLIGIBLE
EGLIGIBLE
-------
Table 2-3-b. 1980 EXTERNAL COMBUSTION UNCERTAINTIES
EXTERNAL COMBUSTION* BOILER CATEGORY PAGE 1
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 1980 RUN DATE-JUNE 24/1976
IS)
I
h«*
vO
MODIFIED
sec
101002000
1C1CC2C10
1C1002020
101CC2C21
101002C22
lClG02t>23
101CC2C24
1C1C02C3C
1010U2C40
1C1C02050
ltlCo2C6C
1C1CC2C70
101002080
U10C2G9C
101CL21CC
101002110
1010C212C
4
-
4
4
-
4
_
4
.4
-
4
-
4
4
4
»
4
_'
4
.
4
_
4
_
4
i
4
.
4
TACRP
(SCC UNITS)
30577000.
30577000.
1483500C.
14d35000.
23282000.
23282000.
2019400C.
20194000.
3108100.
8108100,
8032200.
8032200.
1989100.
19891CO.
12952000.
12952000.
2109500.
21095CO,
500100.
50010C.
98508.
98508.
215870.
215870.
210950.
21095C.
431740.
43174C .
0.
0.
0.
0.
-288620.
286620.
4
4
4
4
«
4
4
4
4
4
4
4
_
4
4
4
_
4
_
4
-.
4
EMISS
NOX
.771
.771
.218
.216
.486
.486
.321
.321
.256
.256
.253
.253
.063
.063
.556
.556
.015
.015
.005
.005
.001
.001
.005
.005
.002
.002
.015
.005
.COO
.000
O.OOC
C.COC
.006
.006
IONS
4
+
4
~
4
4
4
4
+
4
4
4
4
4
4
_i
4
^
4.
4
(MILLIONS
HC
.118
.017
.OC6
OC4
.118
.016
021
.014
.082
.OC6
.081
.005
.010
.001
.008
.005
OC2
CC2
.C01
.001
OCO
.OCC
.CCC
.000
.000
.ccc
.OC1
.C01
.coc
.OCO
O.GOC
o.occ
.ccc
.ccc
OF
4
4
4
~
4
4
4
4
4
4
4
"
4
4
4
4
4
_
4
«-
4
TONS /
CO
.084
.057
.019
.014
.078
.053
.068
.046
.027
.018
027
S1^
.007
.004
.025
.017
.004
.003
. 001
. 00 1
.000
.000
801
00
.000
.000
.002
.001
.000
.000
0.000
0.000
:88i
YEAR)
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
PART
.812
.810
.321
.321
.739
.737
.641
.640
.258
557
5 4
.254
.063
.063
.078
.078
.042
.042
RH
Oil
.004
.004
.006
.006
.003
OC3
.008
01C
.000
.ccc
0.000
o.oco
.035
.037
-------
Table 2-3-b. 1980 EXTERNAL COMBUSTION UNCERTAINTIES (Continued)
EXTERNAL
TACR AND EMISSION UNCERTAINTI
COMBUSTION* BOILER CATEGORY
ES PROJECTED TO 19BC
PAGE
RUN DATE-JUNE 24*1976
tODIFIFD
sec
1G1004COO
1C1C04C10
1C1L04C11
1C1G04C12
U10C1C13
ts) IClCuAGIA
i
ro
° 1G1CC4C20
1010C4C30
1G1GC5COC
101005010
1G1CG5G20
1G1CC5030
101006000
1C10C6G10
1C1CG6C11
I
4
4
4
«_
4
_
4
4
4
4
4
4
4
4
4
-
4
4
-
TACRP
SCC UNITS)
46187GC.
46187U.
itlfflS:
3175500.
31755CO.
2A030CO.
24030CO.
2337900.
23379CC.
92195.
92195.
0.
0.
0.
0.
0.
c.
0.
0.
0.
0.
0.
G.
2C295CC.
1115800.
2028700.
1115300.
91154C.
516COO.
EMISSIONS
1
1
+
f
1
+
4-
+
~
4-
-
4-
4-
+
1
4-
NOX
.155
.194
:JK
.Otb
.027
.098
.C63
.098
.063
.CIA
.Cll
:ffl
.000
.000
C.GOG
C.OCO
G.CGG
0.000
G.OGO
G.COO
c.ooc
C.OCG
.136
.071
.136
.071
.033
.016
4-
I
4-
_
4-
t
4-
4>
+
^
+
4-
4-
*
4-
4-
0
0
0
0
0
0
0
0
(MILLIONS OF TONS /
HC
.012
OC9
.012
.GC9
.009
.006
.006
00 £
OC6
OG5
.000
.occ
.occ
OGC
ceo
OtU
.oco
.coo
.occ
..000
.oco
.000
.ccc
ccc
.OC1
OC1
.001
.001
.ore
.oco
4-
1
4-
^
4-
4-
4
1
4-
**
f
i
4
4-
4
4
+
CO
.019
.013
019
.013
.013
.009
.010
.007
.010
.007
.001
coo
.000
.000
000
coo
O.COO
0.000
0.000
0.000
0.000
8:888
0.000
.019
.009
.019
.009
.008
.004
YEAR
+
+
4-
-
4-
4-
4-
+
4
*"
f
4
4-
4-
+
4-
4-
^
)
PART
.018
.018
C18
G18
.013
.013
QIC
ulG
.009
SR2
.000
GOC
O.COC
o.cco
o.ooc
O.GOC
O.CGC
O.COC
0.000
0.000
0.000
0.000
G.OGO
0.000
.015
.008
.015
.OOfc
.C07
.004
-------
Table 2-3-b. 1980 EXTERNAL COMBUSTION UNCERTAINTIES (Continued)
EXTERNAL COMBUSTION, BOILER CATEGORY
PAGE 3
ts)
I
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 198C
RUN DATE-JUNE 24,1976
MODIFIED
sec
1010C6C12
1C10C6C13
1C1006C1*
101006020
101C06C30
1C1CC7CCO
!CltC7C10
1C1C07C20
101007030
1C20C20GC
102CG2C1C
102C02C20
102CU203C
1020020*0
102C0205C
102002060
4
4
4
4
4
4
4
4
-
4
_
4
4
4
_
4
.
4
TACRP
(SCC UNITSI
14723CO.
803000.
1051700.
57*000.
58000?
56000.
33000.
290C!
1522C.
15220.
15220.
15220.
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
12611COC.
12611000.
2226900.
2226900.
5006000.
5006000.
39778CO.
3977800.
9981500.
9981500.
288620.
286620.
201*500.
2015500.
EMISSIONS (MILLIONS OF TONS / YEAR)
NOX HC CO PART
4 .106 + .001 + .01* * .011
- .056 - .000 - .007 - .006
4 .076 4 .001 4 .010 * .008
- .0*0 - .OCO - .005 r -00*
4 .C15 4 .OOC + .001 * .001
- .COB - .000 - .000 - .000
4 .OC* * .OCO * .001 * .000
- .002 - .OCO - .000 - .OCO
4 .000 4- .000 + .000 + .000
- .000 - .OCC - .000 - .000
4 . )00
- .000
4 .001
- .OCO
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
4 .171
- .171
4 .036
- .036
4- .0*9
4 Il20
- .120
4 .10l/
- .100
- loo*
4 .019
- .019
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
4 .017
- .017
4 .ori
.001
4 .C02
- iOOl
4 .OC1
- .OC1
4 .016
.016
4 .001
- .001
4 .003
- .003
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
4 .03*
- .02*
4- .003
.002
4 .005
- iOO*
4 .00*
- .003
4 .032
.022
4 .001
- .001
NEGLIGIBLE
NEGLIGIBLE
N
N
N
N
N
N
EGLIG1BLE
1GLIGIBLE
GLIGIBLE
LGLIGIBLE
iGLIGIBLE
EGLIGIBLE
* .302
- .302
t .039
.039
4 .10*
- .10*
4 .021
- .021
4 .260
«
~ . c o\»
4- .011
.012
4 .006 * .041
- .00* .0*3
-------
Table 2-3-b. 1980 EXTERNAL COMBUSTION UNCERTAINTIES (Continued)
EXTERNAL COMBUSTION, BOILER CATEGORY
PAGE 4
to
I
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 1980
RUN DATE-JUNE 24,1976
MODIFIED
sec
102C02C70
1020U2CUO
102CC2C90
1C2002100
1C2C02110
102002120
102CC2130
H20u4LoG
1C20C4010
U2GC4C20
1G2C04C30
1C20G5COO.
102CC5C1C
1G2CGI>020
102005C30
102C06CCO
(
4
4
-
4
4
.
4
_
4
4
-
4
-
4
4
4
-
4
-
4
.
4
.
4
-
4
-
TACRP
SCC UNITS)
100020.
100020.
580000.
580000.
3002900.
3002900.
10C020.
100C20.
42000.
42000.
0.
0.
197020.
197920.
16866CC.
1686600.
1608600.
1608600.
&OC6CO.
5006UO.
79862.
79882.
207290C.
2072900.
19830CC.
1983COO.
600050.
600050.
7C113.
70113.
26481CO.
153090C.
FMISSIQNS (MILLIONS OF TONS /
4
4
4
4
«.
4
_
4
_
4
4
4
4
4
4
4
4
_
4
4
NOX
.OC2
.002
.005
CC5
.026
.026
.CC1
.001
.000
.000
O.OCC
0.000
.CC3
.OC2
.148
.060
.132
.054
.067
.027
.009
.CG4
.096
.041
.091
.039
.U29
.013
.003
.001
.177
.097
4
4
4
4
4
4
-.
4
4
4
4
4
4
4
4
4
-
4
HC
ccc
.000
oco
.000
.or. 4
.004
.ore
.000
.occ
.coo
C.OOf
0.000
OC1
.OC1
.013
.000
.011
.CCB
OC6
.004
.001
.OC1
.009
.006
OC8
.006
,Ct3
C02
.OCC
.OCO
.OC4
.002
4
4
4
4
4"
4
4
4
4
4
4
-
4
4
4
4
4
CO
.000
.000
.001
.000
.009
.006
.001
.001
.000
.000
0.000
0.000
.002
.002
.016
.011
.014
. 0 10
007
. 005
.001
.001
.011
.008
.010
.008
.003
.002
.000
.000
.025
.013
YEAR]
4
4
4
4
>
4
_
4
4
4
-
4
4
4
-
4
-
4
4
4
4
1
PART
.007
.007
.012
.012
.C92
.093
.002
.002
.001
.001
0.000
O.COO
OC4
.003
.(19
.019
.018
.018
.006
.006
.001
.001
.016
.016
.015
.015
.005
.005
.001
.001
.024
.014
-------
Table 2-3-b. 1980 EXTERNAL COMBUSTION UNCERTAINTIES (Continued)
EXTERNAL COMBUSTION* BOILER CATEGORY
PAGE
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 198C
RUN DATE-JUNE 24*1976
MODIFIED
sec
1020G6C1G
1C2C0602C
1C2C06C30
1G20U7COO
102CU71LO
U20U702C
102007030
4
m
4
m.
«
-
4
4
4
4
TACRP
(SCC UNITS)
2363500.
136COOO.
IC33600.
609CCO.
598020.
351CCC.
142990.
142990.
1257CO.
12570C.
68100.
6B1GG.
28CO.
28GO.
4-
4
4-
4-
4>
4-
4-
EMISS
NOX
.158
.086
.069
.039
.040
.022
.000
.100
.000
.000
.000
COO
.000
.000
IONS (MILLIONS
HC
4 .004
- .002
.002
- .OC1
4- .001
- .001
KEGLIGIBLE
EGLIGIBLE
NEGL1
»EGL
:GL
NEGL
NEGL
NEGL
GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
GIBLF
OF TONS /
CO
t .022
012
.010
i
00?
4- .006
YEAR)
PART
.021
012
* .009
* *v f
OC5
4- .
- .003 - «
NEGLIGIBLE
NEGLIGIBLE
NEGL
NEGL
NEGL
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NEGL
NEGL
[GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
UU3
*V f. 4
.003
NEGLIGIBLE
EGLIGIBLE
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
-------
tape was obtained from the NEDS data bank containing card images of all
stored point source data for utility and industrial boilers, SCC 1-01-001-01
through 1-02-999-99 (see Ref. 2-3 for definition of terms and SCC categor-
ies). It was necessary to write computer programs to extract, summarize,
and check the data contained on this tape. Much of the literature search and
literature data.analyses were completed by the time the NEDS tape data be-
came one in which complete data acquisition and projection was first accom-
plished from existing sources in the published (and some unpublished) litera-
ture. The'NEDS tape data was used as a second data source, both to accom-
plish a further breakdown of some of the larger source categories into more
detailed firing types and to provide a means of estimating the accuracy, or
uncertainty, of the data.
In the special case of process gas combustion, the situation
was reversed in that little or no data existed in the literature but the NEDS
data indicated large fuel usage rates and NO emissions. In that case,, only
the NEDS tape data were examined in detail, and uncertainties were derived
from that data analysis alone. As discussed in Section 2. 1, the errors found
were sufficiently large to reduce that category to negligible proportions.
The SCC external combustion (boilers) category was subdivided
according to the fuels selected for study within this category, which are rep-
resented by 58 MSCC categories. In order-to accomplish the type of linear
projections into the future, with cited uncertainties, as describedin Section 1, a
total of 39 distinct input numbers had to be generated for each MSCC. Thus, for
this category alone, a total of 2,262 separate data entries had to be Considered.
In general, initial efforts were made, from data in the litera-
ture, to estimate current values of fuel usage rates and emission factors.
The NEDS data were used to improve and confirm these estimates, provide
further breakdowns into finer categories, and estimate uncertainties in cur-
rent data levels. Methods of projecting data into the future could only be
derived from the literature and other unpublished data sources. All data
sources were also used to estimate uncertainties in the projection methods
and the resulting levels projected to 1980. The resulting data level
2-24
-------
estimates and uncertainties were then used to derive the linear slopes and
the uncertainties in these slopes.
Since the literature search and analyses of data from the liter-
ature provided a major source of current data and the only source of projec-
tion data and methods, these data and analyses are discussed in depth in Sec-
tion 2. 3. In most cases, the data finally used in the projections were reviewed
and somewhat modified (or established)by subsequent comparison with NEDS
tape derived data. A discussion of the NEDS data is contained in Section 2. 4.
2.4 DATA ANALYSIS FROM LITERATURE
Data in the literature can be divided into the source categories
of utility boilers and industrial boilers. Data concerning these two sources
are sufficiently different, both in depth and type, that separate data sources
and analyses were necessary to derive the desired data. Further, PART
control equipment efficiency and degree of application data represented a
special effort. Therefore, studies in these three areas were generally con-
ducted separately.
2.4.1 Fuel Usage, NOy, HC, and CO Emissions in and
from Utility Boilers
An Edison Electric Institute (EEI) survey (Ref. 2-4) of several
hundred utility steam generator units provided data on boiler firing type, fuel
type, and unit megawatt electrical design capacity. This survey provided the
basis for a proportional breakdown of burner firing types categorized as fol-
lows: tangential, opposed wall, front or back wall, cyclone, and vertical.
The sample contained'in the EEI survey was sufficiently large to be deemed
representative of the overall utility industry.
Since many utility stations were shown to have multifuel oper-
ating capability, a further time-related refinement was required. Annual
fuel usage statistics for multifuel-fired plants were sampled (Ref. 2-5). The
sample size chosen for analysis of these data was arbitrarily limited to utili-
ties with power capability exceeding ~400 MW. This was done for reasons of
manageability. The average proportions of annual usage of each fuel as
2-25
-------
reported for these stations (coal/oil, oil/gas, coal/oil/gas) were acquired.
In the analysis, data were weighted to account for differences in fuel heating
values. The proportional statistics for adjusted fuel consumption and break-
down by firing type were then used to develop a summary breakdown ex-
pressed as the percent of total energy output.
The total estimated 1973 electrical energy output of the United
States was 1.88 X 1012 kW-hr (Ref. 2-6). The fossil-fueled steam electric
energy value of 1. 43 X 1012 kW-hr is about 76 percent of the total annual
output (Refs. 2-7 and 2-8). An average plant net heating rate of 10, 350 Btu/
kW-hr was selected as representative of the industry (Refs. 2-9 and 2-10).
This equals an electrical conversion efficiency of 33 percent, a figure which
is somewhat below the most efficient of recently installed large units but which
conservatively accounts for many of the older units still in operation.
With these factors, tables were derived for electrical and heat
energy generation by firing type. The heating values for coal, oil, and gas,
taken as 25 X 10 Btu/ton, 142,800 Btu/gas, and 1050 Btu/cu ft, respectively,
enabled the determination of fuel consumption by firing type.
Emission factors published by the Environmental Protection
Agency (EPA) (Ref. 2-11) are given in pounds of pollutants per unit fuel
usage and are categorized by source. Additional data on tangential-fired
furnace emissions were obtained from other sources. (Refs. 2-12 and 2-13).
The product of fuel usage multiplied by the appropriate emission factor (CO,
HC, NO ) provided the detailed data breakdown for the stationary power plant
emission inventory by boiler firing type.
Projections of emissions for 1980 involved establishment of
expected fuel usage figures for that year (Ref. 2-8). However, current
drastic changes in socioeconomic conditions may strongly affect actual over-
all electric energy demand in 1980 as well as the fuel mix used to supply
that demand. The differences between current fuel usage and the 1980 usage
estimates represent new construction.
Boiler construction figures by firing type were not readily
obtainable in the short time span of the study. Speculative consideration
2-26
-------
was given to recent trends showing that Combustion Engineering, supplier
of tangential furnaces, has shown increasing market penetration and is cur-
rently reported (Ref. 2-14) to be controlling about 43 percent of the new
boiler market. In addition, multifuel firing capability, already in common
practice, tends to favor a shift in this direction with coal remaining as the
predominant fuel, especially in view of uncertainties in the future availability
of oil and gas. Thus, the 1980 fuel usage breakdown, reflecting these
considerations, is based on the assumption that one half of the new con-
struction for fuel consumption (coal, oil, and gas) will be allocated to
tangential-fired units, and the remaining one half will be proportioned as
in 1973. The incremental fuel usage values were summed to the 1973
usages to obtain 1980 projections.
The new construction is expected to fulfill the EPA national
emissions requirements already legislated (Ref. 2-15). It is further antici-
pated that improvements in existing units will be forthcoming. Exploratory.
efforts concerning the feasibility of reduced NOx by means of combustion
modifications have shown promise in several investigations (Refs. 2-12,
2-16, and 2-17). Therefore, slightly lower emission factors were assumed
for NO emitted from existing facilities.
For all coal-fired furnaces, it was assumed that the 1980 NOx
emission factors could be reduced by 25 percent from the 1973 factors listed
in Ref. 9. NO emission factors estimated for coal in 1980, were
13. 5 Ib/ton for all pulverized firing and 41 Ib/ton for cyclone furnaces. The
1973 NO emission factors for gas and oil, converted to parts per million
(PPM) in the flue gas, are 273 for oil and 238 for gas in tangential-fired
boilers and 572 for oil and 476 for gas in other firing types. Recent efforts
to reduce NO emissions in utility boilers indicate that simple, practical
combustion modifications can reduce NO emissions in both1 gas- and oil-
fired utility boilers at least to 200 parts per million. On the assumption
that this technology is currently available and will be widely implemented
o ^L
by 1980, NO emission factors of 36 lb/10 gal of oil and 250 lb/10 cu ft
of gas in all firing types were estimated.
2-27
-------
Although there is little well-documented information in the
technical literature, the popular media and personal observation of some
public and private utilities indicate that natural gas may disappear.as a fuel
for electric generation well before 1980. Many utilities are already experi-
encing'long seasonal periods during which natural gas fuels are not available.
Even the highly publicized Alaskan natural gas supply, when fully developed,
is expected to deliver less than 10 percent of the current demand in utility
and industrial boilers'alone. For these reasons, projected natural gas usage
in utility and industrial boilers was estimated to decrease at a slope (and
slope uncertainty) which indicates zero usage as early as 1978. Consider-
ing the unsubstantiated quality of this type of popular data, however, the
uncertainty in this negative slope is large. The projected electrical demand
which would have been supplied by natural gas combustion was shifted to coal-
burning utilities and coal- and oil-burning industrial boilers.
In general, HC and CO emissions from external combustion
boilers are low and usually well below the limits of any foreseen regulations.
For this reason, no effort was made to project changes in HC and CO emis-
sion factors. In all cases in this category, HC and CO slopes were con-
sidered equal to zero.
2.4.2 Fuel Usage, NO , HC, and CO Emissions in and from
3C ^^^^^^^^^^^^i^^i^^^^^^^^^^^^^^»'~«^"^-^^^^^^^^^^^^^^
Industrial Boilers
The three major pieces of information needed to calculate the
industrial boiler emissions are the installed boiler capacity, the consump-
tion of each type of fuel, and the emission factors. Within the time con-
straints of this study, only a limited literature search and a survey of poten-
tial information sources were possible. For boiler capacity data, the only
source located was Ref. 2-18, in which were several tables based on infor-
mation in Ref. 2-19 (the latter report, by Ehrenfeld, could not be obtained
by the Aerospace library). In those tables, industrial boiler capacities were
given for 1967, with projections to 1975 and 1980, in terms of total steam
generation in pounds per hour. An estimate was made of the breakdown of
the 1967 total capacity into three size categories: 10 to 100, 100 to 250, and
2-28
-------
250 to 500 KPPH.* Sales data from Ref. 2-20 were used to project how the
total capacity would be divided into these three size ranges in 1973 and 1980.
The Ehrenfeld 1967 data given in Ref. 2-18 also included coal,
oil, and natural gas annual consumption for the industrial boilers. Using
heating values for the coal (25 X 10 Btu/ton), oil (6 X 10 Btu/bbl), and gas
(1050 Btu/cu ft) and assuming 1000 Btu/lb heat content of steam, it was pos-
sible to relate capacity data in heat output per hour to the annual heat input.
A factor of 3800 was derived, an average factor, in hours per year at rated
capacity operation. Lacking any later data along these lines, this factor was
used for all subsequent year calculations to relate boiler capacities to heat
input and thus to total annual fuel consumption.
Next, the total fuel consumption derived for 1973 and 1980
was divided among coal, oil, and gas. The boiler population data in Ref. 2-20
(for 1972) were used to estimate the 1973 fuel usage split. Although these
data are boiler number percentages rather than capacity percentages, there
are sufficient size categories that the two percentages should not be widely
different. For 1980, Battelle is currently working on such an estimate,
taking into account the energy supply situation; however, results were not
available in time for this study. Therefore, a best estimate was made on
the basis that the use of coal would show a sharp rise, both from new boilers
and conversion of existing units, with a smaller rise in oil consumption and
a decrease in natural gas use. A rough guideline was the fuel breakdown
given in Ref. 2-20 for 1950 when coal was widely used in industrial boilers.
A further consideration was the greater tendency toward coal in large units
compared to the smaller sizes.
With boiler capacities and fuel consumption estimates in hand,
the emissions of NO , CO, and HC for 1968 and 1973 were calculated using
the emission factors of Ref. 2-11. Emission factors for NO from gas-fired
boilers, given.in Ref. 2-11 for industrial boilers, range from 120 to 230 lb/
10 cu ft from the smallest to the largest boilers. Rather than trying to
KPPH = thousands of pounds of steam per hour.
2-29
-------
interpolate and use multiple factors, an arithmetic average of 175 was applied
to the total gas consumption. Since NO emissions from natural gas combus-
3k
tion represent only about 20 percent of the total, an error in using an average
emission factor should not significantly affect the total emissions.
In estimating probable NO emission factors for 1980, it-was
JL
noted that there are currently no NO regulations for industrial boilers
other than for new units larger than 250 million Btu/hr heat input but that
some sort of control appears likely in the near future. Much of the NO
ji
control technology developed for utility boilers should be directly applicable,
but the larger question concerns the degree to which new regulations will be
met in industrial boilers by 1980. For the 1980 projections, it was assumed
that the NO .emission factors for coal firings will be reduced by 25 percent
(as in the case of utility boilers) but that NO emissions from gas and oil-
firings will be reduced by 50 percent, rather than the 58 to 65 percent re-
duction which appears likely for utility boilers. A summary of the 1973 NO
Ji
emission factors and those assumed in this study for 1980, for both utility
and industrial boilers, is as follows:
Emission Factor
Oil
Natural Gas
Emission
Factor
Unit
Ib/ton
Ib/ton
Ib/ton
lb/1000 gal
lb/1000 gal
Ib/million cu ft
lb/million cu ft
Cyclone
Stoker
Tangential
Other
Tangential
Other
Utilities
1973
18
55
-
50
105
300
600
1980
13.5
41
-
36
36
250
250
Industrial
1973
18
55
15
40
80
180
180
1980
13.
41
11.
20
40
90
90
5
25
As in the utility boiler category, HC and CO emissions were considered cur-
rently satisfactory, and the 1980 emissions factor used were unchanged from
those of Ref. 2-11.
2-30
-------
2.4.3
PART Emissions from Utility and Industrial Boilers
The PART emission category is different from those of NG>x>
CO, and HC in that PART emissions are not only a function of the fuel type
but are also strongly dependent on the PART control equipment used. PART
emissions from gas- and oil-fired utility and industrial boilers represent
less than seven percent of the total from these sources. As a result, only
PART emissions from coal-fired boilers were examined in detail. For these
coal-fired boilers, the PART emission factors can be classified in the gen-
eral pulverized coal category and the more specific firing categories of stoker
and cyclone. For each of these categories, the annual PART emissions can
be calculated from the product of five factors: (1) coal usage rates, (2) aver-
age weight percent of ash in the coal, (3) ash factors, (4) average collector
efficiencies, and (5) fraction of total plants using the collectors to control
PART emissions. Data for each of these factors were obtained, respectively,
from (1) the reference sources and analyses discussed in the previous sections
plus Refs. 2-22 through 2-25 in the utility boiler area, (2) Ref. 2-21, (3) Ref.
2-11, (4) Ref. 2-21, and (5) Ref. 2-25 for utility boilers and Ref. 2-21 for
industrial boilers. The values of percent ash, ash factors, collector effi-
ciencies and control application [factors (2) through (5)] used to calculate 1967
to 1973 PART emissions in this analysis were as follows:
Utility Boilers
Boiler
Type
Pulverized
Stoker
Cyclone
Ash
Factora
16
13
3
%
Ash
11.9
11.2
11.8
Collector Control
Efficiency Application
0.92 0.97
0.80
0.91
0.87
0.79
Net
Control
0.89
0.70
0.72
Industrial Boilers
Pulverized
Stoker
Cyclone
16
13
3
10.6
10.2
10.3
0.85
0.85
0.82
0.95
0.62
0.91
0.81
0.53
0.75
aThe ash factor multiplied by the percent of ash yields the uncontrolled
emission factor.
2-31
-------
For projections to 1980 in the utility boiler area, the
assumption, based on data in Ref. 2-Z3, was that new construction would
be 85 percent of the pulverized category, 15 percent of the cyclone firing
type, and no new stoker construction. Application of control equipment to
new construction was assumed to be 100 percent.
In the industrial boiler area, EPA standards of perform-
ance for new stationary sources (Ref. 2-26) require control efficiencies of
about 0.988 (based on allowable emissions of 0.1 Ib/millionBtu and an average
coal ash content of 10. 4 percent), but these standards currently apply only
to boilers with a capacity greater than 250 million Btu/hr heat input. It was
assumed, therefore, that all new construction of boilers greater than 250
million Btu/hr capacity would be 100 percent controlled by the efficiency
rate of 0.988. No regulations for industrial boilers of smaller capacity are
currently forecast, and the control efficiencies and application (net control)
therefore, were assumed to be the same in 1980 as in 1973.
Since PART emissions from gas- and oil-fired boilers, both
utility and industrial, together represent a small fraction of those from coal-
fired boilers, little effort was made to estimate changes in control efficien-
cies or control applications. Even on the assumption of 100 percent uncon-
trolled gas- and oil-fired utility and industrial boilers, the PART emissions
from gas- and oil-firing projected to 1980 represent less than 7 percent of
the projected total from these sources. PART emissions from gas- and oil-
fired utility boilers were considered uncontrolled in all time periods. Con-
trols for industrial boilers were treated the same except that new construc-
tion in the capacity range greater than 250 million Btu/hr were assumed to
meet the EPA standards of performance for new stationary sources as given
in Ref. 2-26.
2.5 NEDS DATA ANALYSIS
The NEDS data are stored in a large number of SCC by type
of source (external combustion boiler, electric generation and industrial),
by fuel (e. g. , bituminous coal, lignite), and to some degree by firing types
2-32
-------
(e.g., pulverized wet, cyclone, stoker) (Table A. 2 of Ref. 2-3). These
data represent a more detailed breakdown than was available in the litera-
ture for the boilers of this study. The NEDS data also contain a large amount
of detail on primary and secondary PART control equipment, categorized by
control equipment identification codes (Table A. 3 of Ref. 2-3), which does
not appear to be available anywhere else. For these reasons, it was con-
sidered desirable to obtain a magnetic tape of data stored in the NEDS sys -
tem for analysis. The availability of these in-house data on tape allowed
extensive computer analysis and represents a powerful tool for emis-
sion inventories and other studies. A comparison of some of the totals,
such as fuel usage and emissions, with data from other sources indicated
that the NEDS data were considerably more comprehensive. In all cases,
totals from various sources agreed as well as can be expected with the NEDS
data. The NEDS data were initially accumulated and stored over the time
period from about 1969 to 1972. Data available from other sources tend to
represent time periods from about 1968 to 1973. Comparing the NEDS data
with interpolated data for the same time period and considering the probable
accuracies of these other sources, the NEDS data appear to be in good
agreement.
Two significant problems with the NEDS tape data were found
during this study. Significant errors of unknown origin can exist in some of
the stored data. It appears that a single individual can submit data that are
grossly in error and this error can enter into and remain in the NEDS data
bank, undetected, grossly affecting all summary uses of the data. Annual
CO emissions from coal-fired utility boilers were found to be more than a
factor of five (more than 3 X 106 tons) too high. Two individuals submitting
data in the process gas combustion area may have entered fuel usage data
(total of several point sources within their plant) which were too high by fac-
tors of as much as 1000 (a total error of more than 2 X 10 cu ft/yr). Such
excessively high values can be detected with relative ease by screening the
data for charge rates (fuel usage) larger than that of a very large plant. For
2-33
-------
excessively small values, however, Aerospace was unable to develop
reliable, consistent methods for detecting errors or even to assure that
zero values were not valid. The best overall checks found in this study
involved correcting excessively high values and comparing the corrected
totals against data from other sources, if available. These problems led
to rather large estimates of the uncertainty of the final data.
The data stored in the NEDS were generated by many primary
sources over a period of several years. In many cases, the emissions re-
corded were calculated from fuel usage rates and the then-current listing of
emission factors. Most of the emission factors used in compiling the NEDS
data are listed in the 1972 compilation (Ref. 2-27). From the 1972 compila-
tion to the 1973 compilation (Ref. 2-11), there were some very large changes.
Those important to this study are listed below:
Emission Factor Ratio,
Fuel Plant Type Emission 1973/1972
Coal
Oil Utility CO 75.0
20.0
Natural Gas Utility NOV 1.538
0.025
42.5
0.075
42.5
The changes in emission factors between these two compilations do not
represent real changes in emissions but are more likely errors in the 1972
compilation, the first of its kind ever issued. In some cases, the emissions
found in the NEDS tape data analyses could be brought into line with data
from other sources by applying the above emission factor corrections. In
the case of CO from all fuels, however, the emission totals from the NEDS
tape analysis could not be brought into agreement with either the other sources
in the literature or the NEDS nationwide emissions reports, even when these
corrections were made.
2-34
Plant Type
None
Utility
Industrial
Utility
Utility
Utility
Industrial
Industrial
Emission
_
CO
CO
NOX
HC
CO
HC
CO
-------
Because of these problems, only the NEDS data which could
be roughly verified by some other source were used. Similarly, because of
the questions concerning the proper emission factors, the. recorded NEDS
emission data were not used as such. Instead, the NEDS fuel usage data
were multiplied by 1973 emission factors obtained from Ref. 2-11. A check
of resulting emissions totals calculated in this manner showed reasonably
good agreement with direct NEDS emissions data, except as discussed in the
CO and the process gas category.
A further complication in using the NEDS point source data
(NEDS tape) results from the use of a number of fuels, concurrently or at
different times, in the same facility. The emissions, operating times,
PART control equipment, and compliance data (card nos. 3 through 5) are
combined, listed, and stored as single values for the facility, while fuel and
fuel usage data are listed separately by fuel (multiple cards no. 6). There
appears to be no way to .determine those emissions or fractions of operating
time associated with each fuel. To generate total emissions data from the
NEDS tape, this study utilized data from facilities using only one fuel (single
card no. 6) to determine an effective emission factor for that SCC. Total
emissions for that fuel were then calculated from the total usage of that fuel
in that SCC. This procedure assumes that the emission factor for a given
fuel in a given facility is the same whether or not the facility operates with
multiple fuels. For example, there is some evidence in the literature that
NO emissions during gas firing may be higher for a significant period of
H
operation if it was preceded by a period of oil firing. No solution for this
possible source of error was found.
One of the greatest values of the NEDS tape analysis is in the
extremely detailed breakdown of PART control equipment usage and perform-
ance. No other source of such detail in the use of PART control equipment
was identified. The data on the NEDS tape are such that further valuable
information such as collector efficiencies, degree of application, and use of
secondary collectors could also be developed. While such data were not of
interest to the current study, it appears that a powerful tool for further data
analysis is available.
2-35
-------
2.6 REFERENCES
2-1. Guide for Compiling a Comprehensive Emission Inventory,
Revised, APTD-1135, U.S. Environmental Protection Agency,
Research Triangle Park, North Carolina (March 1973).
2-2. Nationwide Emissions Summary, National Emissions Data
System, U.S. Environmental Protection Agency, Research
Triangle Park, North Carolina (January 10, 1975).
2-3. Guide for Compiling a Comprehensive Emission Inventory,
U.S. Environmental Protection Agency, Research Triangle
3-
Park, North Carolina (March 1973).
2-4. Unpublished Edison Electric Institute tabulation of utility boilers
by firing type, fuels, and megawatt capacity (May 1973).
2-5. Keystone Coal Industry Manual, McGraw Hill Book Co.,
Inc., New York (1973).
2-6. Semi-Annual Electric Power Survey, Nos. 53 and 54,
Edison Electric Institute, New York (1973).
2-7. "Annual Statistical Report, " Electrical World (March 15, 1973).
2-8. The 1970 National Power Survey, Federal Power Commission,
Washington, D. C. (December 1971).
2-9. "The 18th Steam Station Cost Survey, " Electrical World
(November 1, 1973).
2-10. "The 1973 Annual Plant Design Report, " Power (November 1973).
2-11. Compilation of Air Pollutant Emission Factors, 2nded.,
U.S. Environmental Protection Agency, Research
Triangle Park, North Carolina (April 1973).
2-12. Systems Study of Nitrogen Oxide Control Methods for
Stationery Sources, GR-2-NOS-69, Esso Research and
Engineering Co. ^November 1969).
2-13. "Controlling NOX Emissions from Steam Generators, "
Journal of the Air Pollution Control Association,
23 (1) 37 (1973).
2-36
-------
2- 14. "New Generating Capacity, " Power Engineering, TT_ (4),
40 (April 1973).
2-15. Federal Register, j6, Part II (December 1971).
2_ 16. "Utility Boiler Operating Modes for Reduced Nitric
Oxide Emissions. " Journal of the Air Pollution
Control Association, 21 (11) (November 1971).
2.17. "Operation of Scattergood Steam Plant Unit 3 Under Los Angeles
County Air Pollution Control District Rule 67 for Nitrogen
Oxides Emissions, " Intersociety Energy Conversion Engineering
Conference Proceedings, Society of Automotive Engineers,
New York (1971).
2-18. G. A. Cato, Survey of Industrial Boilers, 60-17, KVB, Inc., Tus-
tin, California (October 31, 1973), EPA Contract No. 68-02-1074.
2-19. J. R. Ehrenfeld, et al., Systematic Study of Air Pollution
from Intermediate Size Fossil Fuel Combustion Equipment,
PB20Y110, Walden Research Corporation, Cambridge,
Massachusetts (July 1971).
2-20. D. W. Locklin, et al., Design Trends and Operating Problems
in Combustion Modification of Industrial Boilers, Battelle
Memorial Institute, Columbus, Ohio; EPA Report No. EPA-
650/2-74-032; NTIS No. PB235-712/AS (April 1974).
2-21. Particulate Pollutant System Study, Vol. 1 - Mass Emissions,
Midwest Research Institute, Kansas City (1 May 1971),
Contract CPA 22-69-104.
2-22. Technical and Economic Factors Associated with Fly Ash
"Utilization, TOR-0059(6781)-1. The Aerospace Corporation,
El Segundo, California (July 1971).
2-23. Minerals Yearbook, Vols. I and II, U.S. Department of
The Interior, Washington, D. C. (1967).
2-24. Keystone Coal Industry Manual, McGraw-Hill Book Co.,
Inc. , New York (1970).
2_25. "llth Survey on Steam Station Design, " Electric World
(October 1970).
2-26. "Standards of Performance for New Stationary Sources,
EPA," Federal Register. .36 (247) (December 23, 1971).
2-27. Compilation of Air Pollutant Emission Factors, U.S.
Environmental Protection Agency, Research Triangle
Park, North Carolina (1972).
2-37
-------
SECTION 3
STATIONARY INTERNAL COMBUSTION ENGINES
3.1 INTRODUCTION
Stationary internal combustion (1C) engines include those used
for (1) electrical power generation, (2) industrial use, (3) commercial and
institutional application, and (4) engine testing. The fuels used in these
engines range from natural gas to crude oil. The types of engines include
diesel and spark ignition reciprocating engines and gas turbines.
Since by definition point source engines are those where one
or more of the common emissions exceed 100 tons per year, it is to be
expected that many stationary engines fall into the area source category (all
stationary sources of pollution other than point sources). These engines fail
to qualify as point source engines because of (1) a smallness in size, (2) a low
usage rate, (3) a low emission factor, or (4) a combination of these factors.
Although the emissions total (point source plus area source)
for most types of stationary engines is not much large* than point source
only, four engine-fuel combinations were identified where area source emis-
sions are estimated to be significantly large simply because their populations
are enormous. These four engines are distillate-fueled and crude-oil-fueled
turbines and gasoline-fueled and diesel-fueled reciprocating engines.
This study concentrates on point sources of air pollution as
described in Section 3. 3; Section 3. 4 describes the assessment of the engine
categories that make significant contributions to both area and point source
emissions.
3-1
-------
3.2 SUMMARY
The point source stationary 1C engines studied along with their
modified source classification code (MSCC) numbers and MSCC charge rate
units are listed in Table 3-1. The 1975 point source charge rates and emis-
sions used as a data base are shown in Table 3-2-a and their uncertainties in
Table 3-2-b. The 1980 estimated charge rates and point source emissions
are shown in Table 3-3-a, with uncertainties in Table 3-3-b,
Point source 1C engines in 1980 will contribute about one-half
million tons per year of nitrogen oxides (NO ) and hydrocarbons (HC) and
3£
about 60,000 tons of carbon monoxide (CO) annually. The annual area source
emissions for the four previously mentioned engines are estimated to be
about 3 million tons of NO , 1 million tons of HC, and about 13. 5 million
3C
tons of CO. The largest contributor to stationary 1C engine pollution is the
conventional gasoline engine.
3.3 POINT SOURCES
This category includes fixed installations of diesel and spark
ignition reciprocating engines and gas turbine engines. These engines are
used for electrical power generation and for industrial use such as pumps
for fuels, water, and sewage and compressors for gaseous fuels and air.
The three basic types of engines may be further subdivided into subtypes
such as two and four stroke, direct and indirect injection, and carburetion.
However, obtaining emissions from such breakdowns is
frustrated by a lack of a breakdown in annual fuel consumption and emission
factors by engine subtype. Thus, it is not possible to establish the effect
on the environment of variations in engine configuration, state of repair, or
specific application. Significant pollution contributors in this category are
listed in Table 3-1.
3.3.1 Diesel Engines
Diesel engines are used-for electrical generation in oil and
gas pipelines, oil and gas exploration, and pumping water and sewage.
(Continued on page 3-10)
3-2
-------
Table 3-1. DEFINITION OF INTERNAL COMBUSTION PROCESSES
MSCC
201000000
201001010
201002010
201002020
201003010
201999970
201999980
202000000
202001010
202002010
202002020
202003010
202004010
202999970
Source Category
Internal Combustion
(Electrical Generating)
Distillate -oil-fueled turbine
Natural-gas-fueled turbine
Natural -gas -fueled reciprocating
Diesel-fueled reciprocating
Other,, not classified
Other (not classified)
Internal Combustion (Industrial)
Distillate -oil -fueled turbine
Natural gas turbine
Natural gas reciprocating
Gasoline reciprocating
Diesel reciprocating
Other (not classified)
Charge Rate Unit
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
1000 gal/yr
Million cu ft/yr
1000 gal/yr
1000 gal/yr
Million cu ft/yr
Million cu ft/yr
1000 gal/yr
1000 gal/yr
Million cu ft/yr
3-3
-------
Table 3-2-a. 1975 INTERNAL COMBUSTION EMISSIONS AND CHARGE RATES
INTERNAL COMBUSTION ENGINES
ANNUAL CHARGE
MUDIFIFD
sec
2C10C1COO
2010C1010
201C02CIO
2C1CC2C10
2G1CG2G20
2G1GC3COO
211CG3G10
2C1999COO
201999970
2C19999PO
202001 COG
2C200i010
2C2G02UI.O
2G2C02C10
2U2C02C20
202003COO
202G03010
2C2C04GCG
202004010
2G2999CCO
2C2S9997C
RATES AND EMISSIONS
TACRP
(SCC UNITS)
1088100.
1G8810C.
338860.
11564C.
223C2G.
75159.
75159.
7259.
115600.
65953.
65953.
973960.
69322.
904640.
3470.
347C.
26201.
26201.
23628.
23828.
PROJECTED
EMISS
NOX
.120
.120
.096
.020
.C76
.011
.011
.017
.011
.006
.004
.004
,3
-------
Table 3-2-b. 1975 INTERNAL COMBUSTION UNCERTAINTIES
Ul
INTERNAL COMBUSTION ENGINES
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 1975
PAGE 1
RUN DATE-JUNE 24*1976
MODIFIED
sec
2G10G1CGC
2C10G1C10
2C1CC2GOC
201002010
201CG2G20
201103000
201003010
2C19990CO
20199997C
201999960
2C2CG1COO
2C2001C10
2C2C02COO
TACRP
(SCC UNITS)
4
4
4
4
4
4
4
4
4
4
4
332060G.
108B100.
332C600.
1088100.
417670.
1182CC.
417010.
115840.
23532.
23532.
14799.
14799.
14799.
14799.
1804.
1804.
18027.
18027.
22224.
22224.
22224.
22224.
61674G.
174900.
EMISSIONS (MILLIONS OF TONS /
NDX HC CO
4
4
4
4
4
4
4
4
4
4
4
4
4
.369
.120
.369
.120
.072
.022
.072
.020
.008
.006
.003
.002
.CC3
.002
.003
.003
.CC3
.003
.001
.001
.001
.001
.001
CGI
.111
.061
4
4
4
4
4
4
4
4
4
mm
4
4
4
4
OC5
.002
005
.002
.002
.001
.002
0:8? t
o.coc
.000
.000
ccc
.000
.012
.012
. .CC3
.003
.011
.011
.CCC
.occ
oco
.occ
.030
.016
f
4
4
4
4
4
4
4
4
4
4
4
4
.029
010
:§io
.003
.000
.003
.000
0.000
0.000
.002
.001
.002
001
000
.000
0.000
0.000
.000
.000
.001
.001
.001
.001
.024
.008
YEAR]
4
4
4
4
4
4
4
4
4
4
4
4
4
PART
.024
.008
G24
.(.08
.001
.000
.001
.000
O.OCO
O.OGG
.001
.001
.001
.001
.001
CC1
c.ooo
Icoi
.000
.000
.000
.000
.005
.004
-------
Table 3-2-b. 1975 INTERNAL COMBUSTION UNCERTAINTIES (Continued)
INTERNAL COMBUSTION ENGINES
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 1975
PAGE 2
RUN DATE-JUNE 24,1976
MODIFIED
sec
2C2002C10
202GU2C2G
2C20030CC
2G2003010
2L-2004GGO
OJ
o- 2C2C04C10
2G2999GOC
202999970
TACRP
ISCC UNITS)
4
4
4
4
4
4
4
4
595470.
69322.
16C580.
160580.
1172.
1172.
1172.
1172.
26055.
26055.
26C55.
26055.
5925.
5925.
5925.
5925.
EMISSIONS
NOX
4
4
1
4-
*
*
4
4
.011
.oto
.060
.COC
.COG
.000
.ICC
.005
.005
.005
C05
.001
.001
.CGI
.001
4
4
1
4-
+
4
'4-
(MILLIONS OF
HC
.024
OC3
.018
.015
CCt
.000
.000
.000
.000
.000
.OCO
.000
.175
.043
.175
.043
4-
4-
4-
4-
1
+
TONS /
CO
.022
.003
.008
.007
.002
.001
.002
.001
.002
.002
.002
.002
.000
.000
.000
.000
YEAR)
PART
4- .OG4
- .000
+ .004
- .004
4 .000
- .000
4 .000
- .000
* .COO
- .000
4 .000
- .000
4 .OOC
- .000
4 .000
- .000
-------
Table 3-3-a. 1980 INTERNAL COMBUSTION EMISSIONS AND CHARGE RATES
INTERNAL COHBUS1 ION ENGINES
ANNUAL CHARGE
MODIFIED
sec
2C1001GOO
2C'1(JG1C10
2C1C020CC
211002C1C
2C100202C
2C10030GC
201CC3C1G
2C199900C
2C199997C
201999980
2C2CC1COC
2CZGG1L10
2C2GG2CGC
20200ZC10
202002C20
2G20G3CCC
2G20G3C1G
2L21C41GC
2G2C04G1G
2G29990GC
20299V97C
RATES AND. EH
TACRP
(SCC UNITS)
12756CO.
1275600.
29C630.
98582.
192050*
B2909.
82909.
8089.
1406CO.
79753.
79753.
824330.
48187.
776140.
4627.
4627.
35626.
35626.
32923.
32923.
ISSIONS PROJECTED
EHISS
NLX
.141
.141
.083
.C17
.066
.012
.012
.019
.012
.007
.005
.005
.297
.008
.289
.001
.001
,0t6
.006
.005
.005
TO 19BC
IONS (HILL
HC
.002
CC2
.OCf
.OOC
O.OOC
.001
.001
.ICC
.013
.0*7
000
.OOC
.O7e
.oca
.074
.001
.001
.coc
.000
.237
.237
RUN DATE "JUNE
IONS OF TONS / YE
CO
Oil
.011
.COO
.000
0.000
.005
.005
.002
0.000
.002
.002
.002
.037
.002
.035
.004
004
.003
OC3
.001
.001
PAGE 1
24,1976
AR)
PART
.009
.OC9
COO
.OOC
O.OCO
.002
.002
.002
C.COC
.002
.001
OC1
.014
.000
.003
.OOC
.OCO
.000
ceo
.coc
.000
-------
Table 3-3-b. 1980 INTERNAL COMBUSTION UNCERTAINTIES
00
INTERNAL COHBUSTIQN ENGINES
TACR AND EMISSION UNCERTAINTIES.PROJECTED TO 1980
RUN DATE
PAGE 1
JUN.E 24* 1976
MODIFIED
sec
2C1C01COO
201001010
2010020UO
2tlCc2tlO
201C02C20
2U1C03COO
201C03C10
201999COC
201999970
2C199998C
2C2CC1COO
202CCU10
2C2C02CCC
TACRP
(SCC UNITS)
4
4
4
4
4
4
4
4
4
4
4
4
3472000.
12756CO.
3472COO.
12756CO.
41968C.
109070.
417070.
98582.
46677.
46677.
18635.
18635.
18635.
18635.
3163.
3163.
41231.
41231.
49437.
49437.
49437.
49437.
66217C.
276270.
EMISSIONS (MILLIONS OF TONS /
NOX HC CO
4
1
4
mm
4
4
4
4
4
4
4
4
4
4
.387
.141
.387
.141
.074
,C23
.072
.017
.003
.003
.003
.COS
CCS
.005
.COS
.005
.002
.002
.003
.(03
.003
.003
.139
.102
4
4
4
4
4
1
:
4
4
4
4
4
4
.005
.002
.CC5
.002
.002
.000
.002
.OCO
8 .000
.000
.000
.occ
ooc
.000
.026
.026
oct
.005
.026
.026
.000
.ccc
.ccc
.coc
.037
.026
1
4
4
4
4
4
4
4
4
4
4
.030
Oil
:8i?
.003
.000
.003
.000
C .000
0 000
.002
.001
.002
001
OC1
.001
c.ooo
o.oco
.001
.001
.001
.001
.001
.001
.026
.013
YEAR)
4
4
4
4
4
4
4
4-
4
4
4
4
4
PART
C25
.009
.025
.009
.001
000
.001
.OCO
.001
C01
.001
001
OC1
.001
o.ooc
o.ooc
001
.001
.001
C01
.001
.001
.COS
.003
-------
Table 3-3-b. 1980 INTERNAL COMBUSTION UNCERTAINTIES (Continued)
I
vO
INT
TACR AND EMISSION UNCERTAINTI
ERNAL COMBUSTION ENGINES
ES PROJLCTEO TO 1960
PAGE 2
RUN DATE-JUNE 24*1976
MODIFIED
sec
202002C10
2C2G02020
202C03LCO
2C2C03G1G
2G2CC41GG
2C2CG4C1G
2G2999GGO
2C299997C
TACRP
(SCC UNITS)
4
4
4
4
4
4
4
4
603710.
46187.
272030.
272030.
2311.
2311.
2311.
2311.
26452.
26452.
26452.
26452.
14845.
14845.
14B45.
14845.
EMISSIONS
NOX
4-
4-
t
1
*
4-
1
.09?
.006
.101
.101
.000
COG
.COO
.000
GCb
.005
.005
.005
.002
CC2
.002
.002
4
4-
4
4
4
4-
1
4
(MILLIONS OF
HC
.025
.002
.027
,026
.OCC
.OOC
.OCC
.000
.OOC
.CCC
.OOC
.OOC
.258
.107
.25F
.1C7
+
4-
4-
4-
4-
4-
4
TONS /
CO
.022
.002
.013
.012
.003
.002
.003
.002
.002
.002
.002
.002
.001
.001
.001
.001
YEAR)
4-
4-
+
4-
I
4-
1
PART
OO4
.000
.003
.003
.000
.000
.000
.000
.000
.GOO
.000
.000
oco
.000
.000
.ccc
-------
For electrical generation, dies el engines represent on the
order of 1. 2 percent of the 1970 total electrical generating capacity in the
United States and only about 0'. 3 percent of the total power generated,', for an
average utilization of about 12 percent. These- engines are used for elec-
trical peaking power and also standby installation. The projected utilization
factor for 1980 drops to eight percent.
Diesel engines represent about four percent of the installed
horsepower in pipelines and about five percent of the power generated. For
oil and gas''exploration, about 75 percent of the power used is generated by
diesel engines. For municipal water and sewage pumping about 50 percent
is diesel-powered, while agricultural water pumping is done almost exclu-
sively by diesel engines.
3.3.2 Gas Turbines
The main applications for stationary gas turbines include
electric power generation for utilities and for-industrial and pipeline use.
Gas turbines have low initial costs, short delivery times, small space re-
quirements, flexible fuel needs, and high thermal efficiency. For these
reasons, turbines are being installed in electrical plants to replace steam
plants or to add capacity.
Gas turbine engines vary greatly in size and configuration.
Turbines have single- or two-shaft designs., Both types can be operated in
simple cycles, regenerative cycles, or combined cycles. The simple-cycle
engines operate at 25 to 30 percent efficiency. Regenerative cycles utilize a
heat exchanger which uses turbine exhaust gases to heat the air as it passes
from the compressor into the combustor. Efficiency of these, engines runs
about 34 to 38 percent. In the combined cycle, turbine exhaust gas is used
to generate steam which drives a second generator or other device. Effi-
ciencies of 40 to 42 percent are realized with these units.
3. 3. 3 Spark Ignition Engines
The spark ignition internal combustion engine is the most
widely used powerplant in- the world today. These engines range from small
3-10
-------
single-cylinder units producing as little as a fraction of a horsepower to
large multicylinder units with power ratings of several thousand horsepower.
The large units are predominantly used in stationary power applications.
Medium-sized gasoline engines (50 to 200 hp) are used for
commercial and construction site compressors, pumps, blowers, and elec-
tric power generators. Medium-large spark ignition engines (200 to 1000 hp)
are generally operated on gaseous fuels to power gas compressors or standby
power generators. Large spark ignition engines (greater than 1000 hp) always
operate on gaseous fuels and are used for gas-well recompression, gas plant
compressors, refinery process compressors, water and sewage pumping,
and continuous electrical power generation.
3.3.4 Charge Rate
The NEDS was used as the primary source of data. Annual
charge rates (fuel consumption), as of the year of record, formed the start-
ing point for the charge rate projections..
The 'rate of change of charge rate for electric utility turbines
is based on the fuel demand data shown in Figure 3-1. The total rises every
year for all fuels except natural gas, reflecting the increased dependence on
turbine power. Lacking fuel consumption projections on gas turbines for
industrial use, the assumption was made that"charge rate trends for these
turbines are equal to those for electrical power demand. For turbines used
in the handling of petroleum products in such services as pumping and pres-
surization, it is also reasonable to assume that the same trends exist as for
the electric utility consumers.
For reciprocating engines, it was necessary to use less direct
methods of estimating charge rate changes. Table 3-4 shows data on the
number of 1C engines versus end use for gasoline and diesel fuels. Only
those listed in the source (Ref. 3-4) for construction, generator sets, or
general industrial use were considered in this part of the study. Of the
engines produced (Table 3-4), many were probably for replacement of
3-11
-------
THOUSANDS OF
BARRELS PER DAY
1,320. TOTAL FUEL DEMAND
RESIDUAL
CRUDE
JET/ KEROSENE
DISTILLATE
NATURAL GAS
(1000 barrel equivalent)
(1972) 1973 1975 1977 1979
CALENDAR YEAR
Figure 3-1. Electric utility gas turbine fuel demand
3-12
-------
Table 3-4. INTERNAL COMBUSTION ENGINE DISTRIBUTION:
NUMBER VERSUS END USE
Engine Type Number of 1C Engines Distributed
and End Use*
1973 1974
Gasoline
Construction 1,172,836 1.306,153 1,192.112 1.239.276 1,424,790 1,225.742 1.174,173 975,637 1,399.800 1.272.551
and General
Industrial Use
Generator 67,769 76,678 67,930 67,798 90.760 86,264 104,142 146.270 165.183 176,014
Sets
Total Gasoline 1.240,605 1.382,831 1.260.042 1.307.074 1.515.550 1,312,006 1.278,320 1,121,907 1,564,983 1,448,565
Diesel
Construction 130,185 140,021 134,665 139,577 156,329 142,266 130.216 150.823 175,071 200.054
and General
Industrial Use
Generator 13.209 12,746 5,564 6,070 8,535 10.201 8,400 9.661 13,327 15,212
Sets
Total Diesel 143,394 152,767 140,299 145,647 164.864 152,467 138,616 160.484 188.398 215.266
Total 1C 1,383.999 1.535,598 1.400,271 1.452.721 1.680.414 1,464,473 1,416,936 1,282.991 1.753,381 1,663.831
Engines
aRe£. 3-4.
Represents total number of engines shipped or produced and incorporated into products at the same establishment during the time
period 1965 through 1974.
-------
worn-out engines or were exported, with perhaps only 10 percent of
production going into new installations. Hence, the assumption of a change
of charge rate based on 10 percent of the annual production seems conserva-
tive, but the uncertainty of this slope is rather large. Comparison of several
sources of predicted consumption for electrical generation shows variations
in slopes of from 3 to 22 percent per year. Thus, a 10 percent slope with
10 percent uncertainty in the slope was assumed.
3.3.5 Emission Factors
The emission factors were derived from the NEDS data by
dividing the emissions by the charge rate. Other sources of emission fac-
tors (Refs. 3-1 through 3-3) were used to determine the uncertainty of the
NEDS data. It was assumed that emission factors would not change with the
passage of time. The only factor that would change that assumption would
be the imposition of clean air standards on all of the users of this equipment.
This factor was ignored in the data input; thus, the data represent emissions
with no controls imposed.
3.3.6 Results
Table 3-3-a shows the 1980 projections of annual charge rates
and emissions for point sources. The data show that about one-half million
tons per year of NOx and HC are produced by stationary 1C engines. Of this
amount, about 50 percent of the NOv and 20 percent of the HC are from elec-
2v
trical generating plants, with the remainder from industrial sources. In the
electrical generating category, the worst offender is the distillate-fueled gas
turbine. With a charge rate of over 1. 25 billion gal/year, it contributes
about 140, 000 tons/year of NOx< In the industrial use classification, natural
gas reciprocating engines contribute about 300,000 tons/year of NO from
about 780 billion cu ft/year of gas. The uncertainty in 1980 charge rates
and emissions are shown in Table 3-3-b.
3-14
-------
3.4 TOTAL EMISSIONS FROM SELECTED STATIONARY 1C
ENGINES (POINT AND AREA SOURCES)
3. 4. 1 Introduction
As reported in Section 3. 1, four stationary 1C engine-fuel
combinations were identified whose'total (area plus point source) emissions
far exceed the estimated point source emissions reported in Section 3.3.
The four offenders are distillate-fueled and crude-oil-fueled turbines, and
gasoline-fueled and diesel-fueled reciprocating engines. Identification of
the engine types responsible for these large area source emissions was pos-
sible through analysis of the data extracted from Refs. 3-1, 3-4, and 3-5.
This section reports the rationale and results of estimating the total emis-
sions for those four types of engines.
3.4.2 Summary
Four engine-fuel combinations were found to contribute poten-
tially significant amounts of area source pollution: distillate-fueled and
crude-oil-fueled turbines and gasoline-based and diesel-fueled reciprocating
engines. Table 3-5 shows the total emissions for these engines in 1980.
Table 3-6 gives the 1980 projection of pollutants from these four sources in
excess of the point sources data reported in Section 3. 3.
3. 4. 3 Discussion
3.4.3.1 Turbines
In 1971, the installed horsepower for gas turbines was about
38 million. About 29 million of that was for electrical power generation, and
the remainder was for pipelines and natural gas processing. For power gen-
eration, gas turbines provide the repowering when old and less efficient
plants are retired and also fill the need for increased power. In 1970,
approximately 5 percent of the power generated was by gas turbines; by 1980,
it is estimated that as much as 12 percent of the power capacity will be from
gas turbines. Projected electrical generation use is about 12u-million hp in
3-15
-------
Table 3-5. 1980 PROJECTION OF TOTAL INTERNAL
COMBUSTION ENGINE EMISSIONS*
Source Category
Emissions, million
tons/yr
NO.
HC
CO
Charge Rate,
1000 gal/yr
Distillate-Fueled Turbines
Crude -Oil-Fueled
Turbines
Gasoline -Fueled
Reciprocating Engines
Diesel-Fueled
Reciprocating Engines
0.459 0.011 0.060 6.70X10
0.884 0.022 0.116 12.90X10*
1.345 0.924 13,273 12.75X106
0.432 0.032 0.142 2.40 X 106
Total
3.120 0.989 13.591 34.75X10*
aPoint source and area source emissions.
3-16
-------
Table 3-6. 1980 PROJECTION OF AREA SOURCE INTERNAL
COMBUSTION ENGINE EMISSIONS
Emissions, million
_ tons /yr _ Charge Rate,
Source Category 1000 gal/yr
Distillate -Fueled Turbines 0.313 0.009 0.047 5.34X10
Crude -Oil-Fueled 0.884 0.022 0.116 12.90X106
Turbines
Gasoline -Fueled 1.344 0.923 13.269 12.74X106
Reciprocating Engines
Diesel-Fueled 0.414 0.031 0.134 2.28X106
Reciprocating Engines
Total 2.955 0.985 13.566 33.26X10
3-17
-------
1980. Similar growth rates for other uses 'can be expected. By 1980,
therefore, total gas turbine installed horsepower will be on the order of
ISO million.
Figure 3-1 shows distillate consumption for gas turbines for
electrical generation growing to 350, 000 bbl (14.7-million gal/day in 1979).
Projecting this to 1980, fuel consumption can be expected to be 5.6-billion
gal/year for electrical generation alone. Adding consumption for other
uses increases this number by 20 percent to 6.7-billion gal/year. The
1979 crude oil demand from Figure 3-1 is 560,000 bbl (23.52-million gal/
day). Projecting the growth rate to 1980 and adding 20 percent for uses
other than electrical generation, the estimated consumption of crude oil in
gas turbines will be 12.9-billion gal/year in 1980.
Emission factors used to estimate total emissions are the
average of emission factors derived from the NEDS data and from Refs. 3-1
through 3-3. Crude oil emission factors were assumed to be the same as
the distillate emission factors, in the absence of any other information.
3.4.3.2 Diesel Engines
In Ref. 3-1, the total estimated installed horsepower of sta-
tionary diesel engines was about 16-million bhp (brake horsepower) in 1971.
Of this total, 5.2-million bhp were used for electrical generation, and the
remainder was for industrial uses.
Table 3-4 indicates that about 215,000 diesel engines for in-
dustrial construction and generator sets were shipped in 1974. Total horse-
power was about 42 million for engines of greater than 50 hp. To estimate
fuel consumption, it was necessary to make the following assumptions:
a. Twenty percent of the engines shipped were new installa-
tions. The remainder were replacement engines or were
exported (nine percent were exported in 1974).
b. Engines will be operated on an average of 1170 hr/year.~
NEDS data for 1970 indicate an average of 1888 hr/year
for electrical generation and 5282 hr/year for industrial
use. The estimated 1980 operation is 8 percent for elec-
trical generation and 15 percent for industrial use.
3-18
-------
c. Specific fuel consumption is 0. 40 Ib/bhp-hr. (According to
Ref. 3-1, an average specific fuel consumption is 0.403 for
diesels of this class. ) Using data from Ref. 3-4 and the
1974 growth rate, it is estimated that diesel horsepower will
be about 36 million in 1980; fuel consumption will be 2.40-
billion gal/year (7. 0 Ib/gal). Emission factors were derived
as for gas turbines (Section 3. 3. 5).
3.4.3.3 Spark Ignition Engines
Spark ignition engines, both liquid- and gaseous-fueled, are
by two orders of magnitude the most common engines in the country today.
The 1971 total installed horsepower is estimated at 800-million (Ref. 3-1).
These engines are used for everything from small power tools to 1000-hp
and greater compressors, pumps, and electrical power installations.
Table 3-4 shows the number of 1C engines shipped in the years
1965 to 1974. Gasoline engines for construction, general industrial use, and
electrical generator sets number well over one million in each of those years.
Assuming that the engines in these categories are the larger horsepower
rated engines, this represents about 50-million hp/year. Of the 800-million
hp in 1971, it is estimated that about 50 percent was devoted to these
categories.
Using the same assumptions as were made for diesel engines,
namely, that 20 percent were new installations, but now assuming the aver-
age engine is used for 300 hr/year, the 1980 estimated installed horsepower
is 490 million and the annual fuel consumption (at 0. 52 Ib/bhp-hr) is 12.75-
billion-gal/year. Gasoline density of 6.0 Ib/gal was used in this computation.
Emission factors were derived by the same method used for
gas turbines (Section 3. 3. 5).
3.'4. 3.4 Results and Conclusions
From charge rates and emission factors, the 1980 total emis-
sions were estimated and are presented in Table 3-5. The data indicate that
about 3-million tons of NO , 1-million tons of HC, and 13. 6-million tons of
JL
CO (mainly from gasoline engines) will be emitted from these engines.
Table 3-6 is the same data minus the point source data in Table 3-3-a. This
shows an estimate of the area source pollution.
3-19
-------
The uncertainty of the data is large. Although the
assumptions made are thought to be conservative, the real contribution of
these engines could be much higher.
The conclusions to be drawn from this study are that a large
number of stationary 1C engines are being produced in this country every
year and that information as to the application and utilization rates of these
engines is lacking. Therefore, a potentially large source of air pollution is
going undetected. Efforts to trace these engines to the user and to estimate
numbers of engines, use rate, and emissions are recommended.
3.5 REFERENCES
3-1. W. U. Roessler, et al., Assessment of the Applicability of
Automotive Emission Control Technology to Stationary
Engines, EPA-650/2-74-051, The Aerospace Corporation,
El Segundo, California (July 1974).
3-2. C. R. McGowin, Stationary Internal Combustion Engines
in the United States, EPA-R2-73-210, Shell Development
Company, Houston, Texas (April 1973).
3.3. NEDS Source Classification Codes and Emission Factor
Listing (SCC Listing), Office of Air and Waste Material,
Office of Air Quality Planning and Standards, U.S.
Environmental Protection Agency, Washington, D. C.
(July 1974).
3-4. "Internal Combustion Engines: 1965 through 1974,"
Current Industrial Reports Series, MA-35L (65 through 7.4)-1,
U.S. Bureau of the Census, Washington, D. C. (1975).
3.5. V. DeBiasi, "Double Standard on Fuel Oils Would Favor
Steam over Gas Turbine Plants, " Gas Turbine World
(September 1973).
3-20
-------
SECTION 4
CHEMICAL MANUFACTURING
4.1 INTRODUCTION
The emission sources discussed in this section are classified
under the general process category of chemical manufacturing and the more
specific categories of carbon black and ammonia manufacturing. The emis-
sions under consideration are oxides of nitrogen (NO ), hydrocarbons (HC),
3C
carbon monoxide (CO), and particulate (PART) matter.
This section describes the development of the data base used
to calculate emissions from chemical manufacturing. The development of
emission equations is described in Section 1, Data Handling. Chemical
manufacturing processe's studies are defined according to the National
Emissions Data System (NEDS) source classification codes (SCC) and, in
Table 4-1, by the NEDS modified source classification code (MSCC) devel-
oped by The Aerospace Corporation for this study.
4.2 SUMMARY
Chemical manufacturing production rates and emissions are
defined for 1975 and estimated for 1980. These data are respectively listed
in Tables 4-2-a and 4-3-a. The uncertainties in the production and emission
data are listed in Tables 4-2-b and 4-3-b for 1975 and 1980, respectively.
Table 4-1 describes the process and production rate (charge rate) unit for
each MSCC for which emissions were determined.
(Continued on page 4-9)
4-1
-------
Table 4-1. DEFINITION OF CHEMICAL MANUFACTURING PROCESSES
MSCC
Source Category
Charge Rate
Unit
301002010 Purge gas in ammonia plant with methanator Tons/yr
301002020 Storage and loading in ammonia plant with
methanator
301003010 Regenerator exit in ammonia plant with CO
absorber
301003020 Purge gas in ammonia plant with CO absorber
301003030 Storage and loading in ammonia plant with CO
absorber
301003990 Miscellaneous processes in ammonia plant with
CO absorber
301005010 Channel process carbon black production
301005020 Thermal processes carbon black production
301005030 Gas-fired furnace process carbon black
production
301005040 Oil-fired furnace process carbon black
production
301005050 Gas- and oil-fired furnace process carbon
black production
301005991 SIC 2952 sector of miscellaneous carbon black
processes
301005992 SIC 3624 sector of miscellaneous carbon black
processes
301005993 SIC 3999 sector of miscellaneous carbon black
processes
301005994 SIC 2899 sector of miscellaneous carbon black
processes
301005995 All other SICs of sector of miscellaneous
carbon black processes
301999991 SIC 2818 sector of miscellaneous chemical
manufacturing
301999992 SIC 3999 sector of miscellaneous chemical
manuf a ctu ring
301999993 All other SICs of sector of miscellaneous
chemical manufacturing
aStandard industrial classification (SIC). The product description
corresponding'to each SIC is given in Ref. 4-1.
4-2
-------
Table 4-2-a.
1975 CHEMICAL MANUFACTURING EMISSIONS
AND CHARGE RATES
ANNUAL CHARGE
INDUSTRIAL
RATES AND ENISS
PROCESS* CHEMICAL MANUFACTURING PAGE 1
IONS PROJECTED TO 1975 RUN DATE-JUNE 24,1976
MODIFIED
SCC
301C02000
301C02C1C
301L02C?0
301003(00
3010C3010
3C10C3C20
301C03030
3C1CC3990
3G1C05GCG
3C1CC5C10
3C1C05030
301CC5C40
301C05050
301COL99L
3010059Y1
3010C5992
301005993
3010C5994
301CC5995
301999000
3C199999C
3C1999991
301999992
3C1999993
TACRP
(SCC UNITS)
6106000.
52350GO.
871000.
2443000.
769000.
743000.
555000.
376GOO.
6054400.
1267CC.
216810.
31BOC.
491400.
641100.
4546600.
4C03COO.
4254CU.
2433C.
44550.
49290.
151180COO.
151180000.
70000000.
1815(0.
8100CCCO.
EHISS
NOX
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGL GIBLE
NEGL GIBLE
NtGL GIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
IONS (MILLIONS
HC
.209
.2C9
0.000
.031
.001
.030
O.OCO
.000
.322
.112
.000
.027
.1C3
.071
.009
O.OOC
OC4
.005
.CCO
C.OCC
.518
.518
.276
.016
.224
OF TONS /
CO
.003
.003
0.000
.046
.046
0.000
8.000
.000
2.241
.508
.003
.084
.552
1.040
.055
0.000
.009
.045
.COO
0.000
.336
.336
.067
YEAR)
PART
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGL GIBLE
NEGL GIBLE
NEGL GIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
-------
Table 4-2-b. 1975 CHEMICAL MANUFACTURING UNCERTAINTIES
INDUSTRIAL PROCESS, CHEMICAL MANUFACTURING
PAGE 1
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 1975
EMISSIONS
MODIFIED
SCC
3C1CC2COO
3Q1CC2C1C
3C1CC212G
301GG3000
3G1CU3010
301CC3C20
301CC3030
3010U399C
3CICG5CCG
3GUG501G
301C05C20
301005030
3tlOCi»C4G
301G05G50
3UC05990
4
4
1
4
«
4
4
4
4
4
4
4
4
4
301CC5991
TACRP
(SCC UNITS)
229110.
229110.
226000.
226000.
37599.
37599.
54487.
54487.
33199.
33199.
3208C.
320HO.
2396C.
.23960.
16230.
16230.
226540.
Z2t54G.
79830.
79830.
17799.
17799.
2550.
2550.
39400.
39400.
51400.
514CO.
201070.
20107C.
20GOOC.
200000.
NOX
RUN DATE-JUNE 24*1976
/ YEAR)
NEGLIGIBLE +
NEGL1
[GIBLE
NEGLIGIBLE +
NEGL1
[GIBLE
NEGLIGIBLE 4-
NEGLIGIBLE
NEGLIGIBLE *
NEGLIGIBLE
NEGL]
NEGL:
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL]
GJ
G
G
G
G
G
G
61
BLE 4-
BL
OL
BL
BL
BL
BL
BL
+
f
|
4-
NEGLIGIBLE +
NEGL1
NEGL1
[GIBLE
[GIBLt 4-
NEGLIGIBLE
NEGLIGIBLE +
NEGL1
NEGL
[G
[GJ
NEGLIG1
NEGLIG
NEGLIG
NEGLIG
NEGLIG]
NEGL1
BLE
BLE +
BLE
BL
BL
BL
BL
[GIBL
NEGLIGIBL
4-
'
; +
': 4-
.028
.028
.028
.028
O.COC
O.OCC
.004
.004
.000
.000
.004
.004
O.OCO
O.OCO
.ooc
.000
.072
.072
.071
.071
.000
.OGO
.003
OC3
.019
.OC9
.007
.006
.001
.001
NEGLIGIBLE
NEGLIGIBLE
(MILLIONS OF TONS
HC CO
* .001
- .001
.001
- .001
4- 0.000
- 0.000
.031
- .031
4- .031
- .031
4- 0.000
- o.ooo
4- C.OOO
. C.OOO
* 0.000
- 0.000
- .340
4 .321
- .321
4- .000
- .000
4- .007
- .007
.052
- .051
» .098
- .098
4- .005
- .005
4- 0.00,0
. 0.000
PART
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGL1
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
[GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
GIBLt
GIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
IGIBLE
IGIBLE
IGIBLE
IGIBLE
IGIBLE
IGIBLE
1G
IG
IG
IG
IG
IG
faLE
BLE
BLE
BLE
BLE
BLE
4- 0,000
- C.CCO
NEGLIGIBLE
NEGLIGIBLE
-------
Table 4-2-b. 1975 CHEMICAL MANUFACTURING UNCERTAINTIES (Continued)
INDUSTRIAL PROCESS* CHEMICAL MANUFACTURING
PAGE
Ul
TACR AMD EMISSION UNCERTAINTIES PROJECTED TO 1980
RUN DATE-JUNE 24,1976
MODIFIED
SCC
3C1005992
3C1CC5993
3C10C5594
3C1C15995
301999COC
3C1999990
3C1999991
301999992
301999993
TACRP
(SCC UNITS)
4
_
»
.
«
-
4
1
4
4
4
4
-
19999.
19999.
1000.
1000.
2000.
2000.
4999.
4999.
17464000.
174640CC.
17464COO.
17464000.
7000000.
7000000.
19999.
19999.
IbOOCOCG.
16000000.
NOX
NEGL
NEGL
NEGL
NECL
NEGL
NEGL
NEGL
NEGL
IG
IG
IG
IG
E M I S S
IBLE
IBLE
IBLE
IbLE
IONS
4
;
UIBLE +
IG
IG
IG
IBLE
IBLE
IBLE
*
(MILLIONS
HC
.COC
.000
.001
.001
.occ
.000
o.ooc
o.ooc
OF
4.
+
4-
4-
TONS
CO
.001
RSI
.005
.005
.000
.000
0.000
c.ooo
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGL1
NEGL
NEGL
NEGL
NEGL
NEGL
GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
4-
4-
+
4-
4-
.065
.065
.065
.065
.039
.039
.011
.011
.Ob(
.050
/ YEAR)
PART
4- .129
- .129
+ .010
- .010
t .126
.126
+ .026
- .026
NEGLIGI
Nl
Nl
Nl
Nl
EGL
EGL
EGL
EGL
NEGL
NEGL
NEGL
Nl
Nl
GI
Gl
Gl
GJ
Gl
-GI
GI
EGLIG1
EGL1G1
NEGLIGI
NEGLIGI
NEGLIGI
N
N
N
N
N
EGL
;GL
;GL
EGL
iGL
GJ
G
G
G
IG
BLE
BLE
BLE
BLE
BLh
BLE
-BLE
BLE
.BLE
BLE
[BLE
[BLE
[BLE
6LE
BLE
BLE
BLE
BLE
-------
Table 4-3-a.
1980 CHEMICAL MANUFACTURING EMISSIONS
AND CHARGE RATES
ANNUAL CHARGE
MODIFIED
SCC
361002000
301002010
3C100202C
3C1CC3GOO
3C1003010
3010C3C20
3C1C03030
301003990
3010C5CoC
3C1005C10
3C1C0512G
301005030
3010C5C4C
3010U5050
301C05990
301005991
3G1CU5992
301COt«,93
301005994
301005995
3C1999CIC
301999990
301999991
301999992
301999993
INDUSTRIAL
RATES AND EMISS
TACRP
(SCC UMTS)
7083000.
6073000.
101COOO.
2632500.
892000.
661500.
643500.
4355CO.
6217000.
PROCESS, CHEMICAL MANUFACTURING PAGE 1
IONS PROJECTED TO 196C RUN DATE-JUME 24*1976
EMISSIONS (MILLIONS OF TONS / YEAR)
NOX
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
(MILLIONS
HC
.243
.243
0.000
.036
.001
.034
0.000
CCO
.328
105960.
254010.
35795.
553100.
721600.
4546600.
4003010.
4254CC.
24330.
44550.
49290.
151180000.
15118COOO.
70000000.
16150C.
81000000.
NEGL]
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL]
Gl
G
G
G:
G
G
G]
G
G
G
G
BLE .094
BLE .OOC
BLE .031
BLE .116
BLE .079
BLE .009
[BLE O.OCO
BLE .OC4
BLE .005
BLE .000
BLE 0.000
NEGLIGIBLE .518
NEGLIGIBLE .518
NEGLIGIBLE .276
NEGLIGIBLE .018
NEGLIGIBLE .224
TONS
CO
.003
.003
0.000
.054
.054
8; ooo
.000
0.000
2.369
PART
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
EGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
.425
.004
.094
.621
1.170
.055
0.000
.009
.045
.000
0.000
.336
.336
NEGL]
NEGL
NEGL
NEGL
NEGL
NEGL1
NEGL1
NEGL
NEGL
NEGL
NEGL]
Gl
G
G
G
G
Gl
BLE
BLE
BLE
BLE
BLE
BLE
GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
NEGLIGIBLE
NEGLIGIBLE
.067 NEGLIGIBLE
.153 NEGLIGIBLE
.116 NEGLIGIBLE
-------
Table 4-3-b. 1980 CHEMICAL MANUFACTURING UNCERTAINTIES
INDUSTRIAL PROCESS* CHEMICAL MANUFACTURING
PAGE
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 1980
MODIFIED
SCC
301C02COO
301GC2U1G
3C10L2020
301C03000
3CU03CIC
3C100302C
3C1CG3C3G
301003990
3C1CC5000
3GUC5C10
3CIU5C2C
301CC503C
3C1U5C40
3010C-5C50
301005990
4
4
4
4
4
4
4
4
4
4
4
*
4
4
3C1C05991
TACRP
(SCC UNITS)
288470.
288470.
2B458C.
284580.
47180.
4718U.
68686.
68666.
41862.
41862.
4C365.
40365.
30270.
30270.
20485.
20485.
237320.
237320.
96857.
96957.
2C185.
20185.
3070.
3070.
47482.
47482.
61941.
61941.
201070.
201070.
20CGOO.
200000.
EMISSIONS (MILLIONS OF TONS
NOX MC CO
4 .001
- .001
4 .001
- .001
4 0.000
- 0.000
4 .036
- .036
4 .036
- .036
4 0.000
. 0.000
coo
.000
RUN DATE-JUNE 24*1976
/ YEAR)
NEGLIGIBLF
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGL G BLE
NEGL G BLE
NEGLIGIBLE
NEGL GIBLE
NEGL GIBLE
NEGL G BLE
NEGLIG BLF
NEGLIGIBLE
NEGLIGIBLF
NEGLIGIBLE
NEGLIGIBLF
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLF
NEGLIGIBLE
4
4
4
"
+
+
4
4
4
+
4
+
4
4
4
4
«
4"
.032
.032
.032
.032
0.000
0.000
.005
.005
.000
.OOC
,CC5
.005
C.OCO
0.000
.OOC
.ceo
.087
.067
.086
.086
.ore
.oco
CC3
.003
.011
.011
.008
.CC7
.001
.001
O.CCO
O.ocr
w <
i8;
4
4
4
~
4
4
4
.389
.389
.000
.000
.006
.008
.062
.061
.116
.116
.005
.005
4 0.000
- C.OOO
PART
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGL1
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
GIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
N
N
N
N
N
N
N
EGLIGIBLE
;GLIG;
:GLIG
iGLIGl
;GL
iGL
EGL
NEGL
NEGL
61
G
G
G
[G
NEGLIG
BL
BL
BL
BL
BLI
BLI
BLI
BLI
BLI
NEGLIGIBLE
NEGLIGIBLE
-------
Table 4-3-b. 1980 CHEMICAL MANUFACTURING UNCERTAINTIES (Continued)
INDUSTRIAL PROCESS* CHEMICAL MANUFACTURING PAGE Z
TACR AND.EMISSION UNCERTAINTIES PROJECTED TO 1975 RUN DATEOUNE 24,1976
MODIFIED
SCC
301005992
301005993
00
311005995
301999UOO
301999990
3C1999991
301999992
301999993
TACRP
(SCC UNITS)
4 19999.
19999.
4 1000.
1000.
4 2000.
20UO.
4 4999.
4999.
4 17464000.
17464000.
4 17464000.
17464000.
4 700COOO.
70000CO.
» 19999.
19999.
4 160COCOO.
1600COOO.
NOX
EMISSIONS
N
N
N
B
N
N
N
EGLIG]
GLIG
GLIG
GLIG
IGLIG
GLIG
GLIG
EGLIG
BL
BL
BL
BL
BL
BLI
BLE
[BLE
N!
Nl
Nl
Nl
GLIGIBLE
ELIGIBLE
GLIGIBLE
GLIGIBLE
NEGLIG
4EGL1G
NEGLIG
LIG
LIG
E
E
F
LE
NEGLIGIBLE
INS
t
4.
_
+
+
*
1
4-
f
«
+
i (MILLIONS
HC
.000
.000
.001
.001
.etc
.000
o.oco
0.000
.065
.065
.065
.065
.039
.039
.011
.011
.050
CSC
OF
4,
V
*
V
4-
*
~
f
1
4
f
f
TONS
CO
.001
.001
.005
.005
.000
.000
0.000
0.000
.129
.129
.129
.129
.010
.010
.126
.126
.026
/ YEAR)
PART
NEGL]
NEGL
NEGL
NEGL
NEGL
NEGL
NEGL
Gl
G
G
G
G
G
G:
[BLE
BLt
BLE
BLE
BLfc
BLE
.BLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
GIBLE
GIBLE
GIBLE
GIBLE
GIBLfc
N
N
N
N
N
EGLI
iGL
iGL
iGL
EGL
-------
4.3 EMISSION ANALYSIS
The NEDS categorizes chemical manufacturing as a
member of the industrial process family of stationary sources of emissions
(Ref. 4-2). Industrial process emissions are compared to other point
sources in Table 4-4. Industrial process emissions for chemical manu-
facturing (SCC 3-01-xxx-xx) are compared in Table 4-5 with emissions
from the petroleum industry and other members of the industrial process
group. The PART and NO emissions from chemical manufacturing repre-
sent a small fraction, approximately three percent and four percent,
respectively, of total industrial process emissions. Since the PART
and NO emissions from chemical manufacturing processes represent
x
such small fractions of the totals from stationary sources, these pollutants
were largely neglected in this study.
The charge rate, emissions, and other pertinent data were
extracted from the NEDS point source data for each of the 143 SCC process
categories in the chemical manufacturing group. Table 4-6 ranks the cate-
gories with the highest charge rates. Tables 4-7 and 4-8, respectively,
list the most significant chemical manufacturing emitters by SCC category
and product for HC and 'CO emissions. In comparing the process categories
that produce the most emissions (Tables 4-7 and 4-8) to those having the
highest charge rates (Table 4-6), it is seen that the miscellaneous synthetic
rubber production (3-01-026-99) and the ammonium nitrate prilling tower
cooler (3-01-027-03) categories have high charge rates, but are not producers
of the largest amount of pollutants.
As a check against erroneous data, the effective emission
factors from the NEDS data (emissions and charge rate) were compared
with data published elsewhere. Although little data were available (data
were obtained only from Refs. 4-4 and 4-5), good agreement existed where
comparisons could be made. These comparisons plus a general knowledge
4-9
-------
Table 4-4. NATIONWIDE POINT SOURCE EMISSIONS*
_ Emissions, ~tons/yr
Source _ | _ 7
Category pART NQ HC CQ
Fuel
Combustion 5,414,4Z7 8,922,937 239,403 645,880
Industrial
Processes 8,427,012 3,728,717 7,033,590 21,132,667
Other Point
Sources 150,847 29,725 165,847 5,455,023
Total 13,992,286 12,681,379 7,438,840 27,233,570
aRef. 4-3.
4-10
-------
Table 4-5. INDUSTRIAL PROCESS EMISSIONS'
Source
Category
Chemical
Manufacturing:
SCC 3-01-xxx-xx
Petroleum
Industry:
SCC 3-06-xxx-xx
Other Industrial
Processes0
Total Industrial
Processes
PART
Total Industrial
232,886
(2.76%)
1.036,281
(12.30%)
7, 157,845
(84. 94%)
8.427,012
(100%)
NOX
Process Emissions.
155,068
(4.16%)
3,264,812
(87.56%)
308,837
(8.28%)
3.728,717
(100%)
HC
tons/yr
2,319,544
(32. 98%)
1,012, 131
(14.39%)
3,701,915
(52.63%)
7,033, 590
(100%)
CO
5,992,262
(28.36%)
4,524,476
(21.41%)
10,615,929
(50.23%)
21, 132,667
(100%)
Total Nationwide Point Source Emissions, %
Chemical
Manufacturing
Petroleum
Industry
Other
Industrial
Processes
Total Industrial
Processes
1.7
7.4
.51.2
60.2
1.2
25.7
2.4
29.4
31.2
13.6
48.8
94.6
22.0
16.6
39.0
77.6
Ref. 4-3.
Includes such processes as food, agriculture, primary metals,, and secondary metals.
4-11
-------
Table 4-6. PRODUCERS OF GREATEST EMISSIONS
IN CHEMICAL-MANUFACTURING
Number Annual
Rank "SCC of .Point Source Category Production
Sources Rate,
'tons/yra
1 3-01-999-99 1944 Miscellaneous .1S1.-Z9 x 10
chemical
manufacturing
2 3-01-026-99 189 .Miscellaneous 13.63 x id6
synthetic .rubber
production
3 3-01-021-99 ' 40 .Miscellaneous '11.67xl06
sodium carbonate
production
4 3-01-018-99. 225 Miscellaneous . 5.30 x 10
plastics production
5 3-01-005-99 74 Miscellaneous 4.75x10
carbon black
production
6 3-01-002-01 33 Ammonia pro- 4.62x10
duction with
methanator
7b 3-01-027-03 41 Ammonium nitrate 4.25x10
with prilling
tower
aAlso known as annual charge rate (ACR).
These categories were not among the five categories yielding the greatest
emissions in the chemical manufacturing group.
4-12
-------
Table 4-7. PRODUCERS OF GREATEST HC EMISSIONS IN
CHEMICAL MANUFACTURING
Rank by Emissions
Rank SCC
1 3-01-999-99
2 3-01-005-01
3 3-01-002-01
4 3-01-005-04
5 3-01-018-99
Source Category
Miscellaneous chemical
manufacturing
Carbon black, channel
Ammonia with methanator
Carbon black, furnace oil
Miscellaneous plastics
production
Effective Emission
Emission R
FKa;;tora tons/yr
lb/tona '
6.86 519 X
1767. 227 x
69.2 160 x
425. 82 x
30.6 81 X
10J
103
103
103
103
Rank by Product
Rank Product
1 Carbon black
2 Ammonia
3 Plastics
4 Other
Total
Production Rate
Tons /yr %
0.634X106 0.4
4.622X 106 2.9
5.296 x 106 3.3
151.3 x 106 93.5
161.85 x 106 100
Emission Rate
Tons/yr %
309 X 103 29
160 x 103 15
81 x 103 8
519 x 103 49
1069 x 103 100
aEffective emission factor is the emission rate (Ib/yr) divided by the
production rate (tons/yr).
4-13
-------
Table 4-8.. PRODUCERS OF GREATEST CO-EMISSIONS IN
CHEMICAL MANUFACTURING
Rank by Emissions
Rank SCC
1 3-01-005-01
2 3-01-005-05
3 3-01-005-04
4 3-01-999-99
5 3-01-005-03
6 3-01-005-99
'Source.- Category
Carbon black, channel
Carbon black, furnace
oil and gas
Carbon black, furnace oil
Miscellaneous chemical
Carbon black, furnace gas
Carbon black, miscella-
neous processes
Effective
Emission
Fa'ctor,
lb/tona
8031.
3246.
21.37
4.44
5000
24.44
Emission
Rate,
tons /yr
1032-.X 103
797 x 103
403 x 103
336 x 103
60 x 103
58 x 103
Rank by Product
1 Carbon black
2 Miscellaneous
chemical
manufacturing
Total
Production Rate
Tons/yr .%
5.90X106 3.8
151.29 x 106 96. 2
157.19X 106 100
Emission
Tons/yr
2350 x 103
336 x 103
2686 X 103
Rate
%
87
13
100
aEffective emission factor is the emission rate (Ib/yr) divided by the
production rate (tons/yr).
4-14
-------
of the subject process resulted in the elimination of synthetic rubber
and ammonium nitrate manufacturing as major contributors of the four
emissions of interest.
4.3.1 Chemical Manufacturing Processes Studied
As mentioned, only unburned HC and CO emissions were
examined when forming the list of products and SCCs for which future charge
rate and emission forecasts were to be made. All SCC categories related
to an offending product were studied regardless of the magnitude of the
current emissions represented by any one SCC. Table 4-7 shows that cer-
tain carbon black, ammonia, and miscellaneous chemical manufacturing
emissions represent 93 percent of the HC emitted by the five largest pro-
ducers in the chemical manufacturing category. Table 4-8 shows that
certain carbon black manufacturing processes produce the most CO emis-
sions in the chemical manufacturing group.
The chemical manufacturing products and SCC categories
for which future emissions and production rates were projected are as
follows:
SCC Product
3-01-0002-xx Ammonia made with methanator
3-01-003-xx Ammonia made with CO absorber
3-01-005-xx Carbon black
3-01-999-99 Miscellaneous chemical manufacturing
These four broad categories were divided into 19 MSCC
categories, and a current data base and 1980 projection were made for each.
More detailed definitions of these processes, as well as charge rates, are
listed in Table 4-1.
4.3.2 General Observations
In the course of the chemical manufacturing emissions study,
certain errors and discrepancies were noted in the NEDS point source
4-15
-------
emission data. Most of these observations were trivial, but two were
believed sufficiently significant to be reported here.
4.3.2.1 Summary of Point Source Comparison
The charge rate (production) and emissions as extracted from
the NEDS point source data (Ref. 4-6) are shown in Table 4-9 for the chemi-
cal manufacturing group. Although the years of record vary from 1969 to
1973 for the NEDS data, the preponderance of SCC data is for 1971. The
emissions from Refs. 4-3, 4-6, and 4-7 are summarized in the following
table and are-presented graphically in Figure 4-1.
Emissions, million tons/yr
Data Source PART NcTHC CO
NEDS Tape:
1971 0.28 0.33 1.42 2.92
NEDS Nationwide Emis-
sion Summary Report:
December 1973 0.22 0.15 2.37 6.01
January 1975 0.23 0.16 2.33 5.99
A discontinuity appears to exist between the 1971 and the
1974-75 data shown in Figure 4-1, indicating an inconsistency in ground
rules or methods of establishing the two sets of data. Two known factors
which may have contributed to the inconsistency are listed here. Their
exact effects are unknown, but are believed to be significant.
a. Emissions listed on the NEDS tape are based frequently
on preliminary (sometimes inaccurate) emission factors
(Ref. 4-4) or in some cases simply a guess. A com-
parison of emission factors published in Refs. 4-4 and
4-5 reflects the size of certain data errors. These
could cause either high or low emissions to be entered
on the NEDS tape.
4-16
-------
Table 4-9. SUMMARY OF CHEMICAL MANUFACTURING
AND EMISSIONS REPORTED IN NEDSa
sec
3-01-002-01
3-01-002-02
3-01-002-99
3-01-002
3-01-003-01
3-01-003-02
3-01-003-03
3-01-003-99
3-01-003
3-01-005-01
3-01-005-02
3-01-005-03
3-01-0.05-04
3-01-005-05
3-01-005-99
3-01-005
3-01-999-99
3-01-008
3-01-033-01
3-01-900-99
Other
3-01
Total
Annual ,
Charge Rate
4,621,676
766. 500
679,793
651.996
486. 877
330,000
257,163
24,381
376,731
491.484
4.745,552
151.288,357
248.813
(100 tons/yr)
3.000
(gal/yr)
747
(million cu ft/yr)
182,696,930
aExtr acted from Ref. 4-6.
Unless otherwise specified, charge
Emissions, ~ tons/yr
PART
118
118
(-%)
40
119
159
(0. 1%)
22, 146
3,614
901
7,168
8,079
41,908
(15.27.)
69,015
(25.0%)
343
(0. 1%)
(-)
4,667
(1.7%)
159.870
(57.9%)
276,080
(100%)
rate units are
N0x
3.259
3,259
(1.0%)
65
65
(-%)
HC
160,008
160,008
(11.3%)
772
2,510
331
3,613
(0.3%)
227, 337
19.997
435 82,204
10 54,013
68 8, 967
513 392,518
(0.2%) (27.7%)
44, 054
(13.3%)
55,730
(16.8%)
(-)
146
(-)
228. 523
(68.8%)
332. 290
(100%)
in tons of
518,506
(36.5%)
(-)
5,801
(0.4%)
(-)
338, 554
(23.9%)
1.419.000
(100%)
product per year.
CO
2,777
2.777
(0. 1%)
10.995
10,995
(0.4%)
1,031,710
63.469
402,659
797,087
57, 506
2,352,431
(80.7%)
335, 500
(11.5%)
144
(-%)
(-)
18.850
(0.6%)
194,503
(6.7%)
2.915,200
(100%)
4-17
-------
0.28
0.26
0.24
0.22
0.20
0.34
§ 0.30
£ 0.26
1 0.22
LL.
S 0.18
o
=j 0.14
S. 2.6
0=REF.4-6 &=REF.4-3and4-7
OXIDES OF NITROGEN
UNBURNED HYDROCARBONS
1971
1972
1973
CALENDAR YEAR
1974
1975
Figure 4-1. Emissions from chemical manufacturing
4-18
-------
b. Emissions listed in the summary reports (Refs. 4-3
and 4-7) are based on the product of charge rate and
known emission factors. Where the emission factors
are not known, zero emissions are entered. This
characteristic can only cause the summary report
emissions to be low.
4.3.2.2 Lack of Thermal Carbon Black Data
No data were reported under SCC 3-01-005-002 thermal
carbon black production. Reference 4-8 shows a steady growth from 47,000
tons in 1950 to 137,000 tons in 1965. Approximately 170,000 tons should
have been reported in 1970 according to the trend reported in Ref. 4-8.
Total carbon black production in 1970 as extracted from the NEDS falls on
the trend line established from Ref. 4-8 only if some production other than
that reported in the SCC categories 3-01-005-01, -03, -04, and -05 existed.
The difference is close to the forecast production of thermal black in the
Ref. 4-8 data. Either thermal carbon black was not reported or it was
erroneously reported in SCC 3-01-005-99. Normally, this SCC would be used
to report carbon black handling or the manufacturing of some product where
carbon black is a principal ingredient. That portion of SCC 3-01-005-99
corresponding to SIC 2895 is close to the deficit. Of the nine SICs compris-
ing SCC 3-01-005-99, SIC 2895 is the only one identified as carbon black.
4.3.3 Ammonia Production
4.3.3.1 Process Description
Two principal methods of ammonia (NHg) production exist:
a. Methanator process
b. CO absorber process
Both processes combine nitrogen (N) from the atmosphere with hydrogen
(H-) from some HC feed stock such as natural gas. The difference in the
two techniques is centered on how the large amounts of CO are handled.
The CO results when H_ is extracted from the HC feed stock. While the
CO emissions in the main process of ammonia production are substantially
4-19
-------
less in the CO absorber technique, the CO efflux from the absorber when
it is being rejuvenated tends to be quite high. An extensive water scrubber
and incinerator system can considerably reduce the CO emissions during
absorber regeneration.
Unburned HC emissions (usually methane) from the purge
gas stream are of the same concentration whether the methanator or CO
absorber system is used. Scrubbers have a modest effect on HC emissions.
Although beyond the scope of this study, another noteworthy
emission is ammonia vapor. This emission can be reduced to almost any
level of insignificance through repeated water scrubber application.
4.3.3.2 ' Data Research and Analysis
*
Production rates of synthetic ammonia are recorded in
Refs. 4-6 and 4-9. The charge rate history is graphically presented in
Figure 4-2. Several straight lines were derived by least square fit tech-
niques from various combinations of the data points on Figure 4-2. The
straight line obtained when 19,64 and 1965 data were excluded yielded the
best correlation. Its. equation was used when estimating future ammonia
production. The uncertainty in baseline production is simply the standard
error of estimate obtained with the straight line derivation. The uncertainty
of the production slope is the difference in slope for the adopted line and the
line derived using the six da.ta points in-Figure 4-2. This number is
approximately 21 percent of the baseline value.
The total production reflected in Figure 4-2 is considered to
be apportioned among the six SCC categories for all years in the same per-
centage as that listed by the NEDS for the 1970-72 era. Emission factor
data are found in three areas:
The term "production rate" as used here refers to the charge rate
associated with the particular operation; e.g., SCC 3-01-002-02 is related
to storage and loading, and the ammonia charge rate was actually produced
or created under 3-01-002-01 for methanator systems. The production
SCC for CO absorption systems is 3-01-003-02.
4-20
-------
10
LU
Qi
Lkl
C-
o
o
8 2
a. i
O REF. 4-9
A REF. 4-6
0
1940
I
I
LEAST SQUARE FIT TREND
(excluding 1964 and 1965 data)
1945 1950 1955 1960
CALENDAR YEAR
1965
1970
1975
Figure 4-2. Synthetic ammonia production
4-21
-------
a. Reference 4-5
b. Reference 4-10
c. Quotient of emissions and charge rate from Ref. 4-6
data.
Where emission factor data exist in Ref. 4-10, they are considered to
supersede Ref. 4-5 data. In the following discussion, that which prevails
between Refs. 4-5 and 4-10 will be referred to as the "EPA emission
factor."
Where reasonable agreement (i.e., less than 15 percent
difference) exists between the EPA emission factor and that derived from
the NEDS data, the average of the two was established as the baseline value.
Where the difference was great, a third source was enlisted as a referee;
where no third source was available, engineering judgment was exercised on
the basis of knowledge of the process in question. The uncertainty in the base-
line emission factor is simply the difference between the baseline value and
the nearest source value which contributed to its derivation.
As mentioned, PART and NO emissions from chemical
1L
manufacturing were so small (Table 4-5) in comparison to the total indus-
trial process that no time was spent in establishing their emission factors
(or related variables like slope, or uncertainties); these emissions'were
defined as negligible for all future years.
The literature survey described ammonia production
processes as having remained essentially unchanged since 1953, and no
substantial changes in controls or process are forecast for the immediate
future. As a result, the slope and the slope uncertainties for ammonia
emission factors were set to zero.
4.3.3.3 Projections of Ammonia Activity
The total HC emission from ammonia production in 1980 is
estimated to be Z79,000 tons ± 32,000. The majority (243,000 tons) of these
emissions is from methanator-type production. The total estimated CO
4-22
-------
emissions from ammonia industries in 1980 is 57, 000 tons ± 36,000. The
NO and PART emissions are expected to be negligible in 1980 (as is the
2£
case presently) compared to other point source industrial processes
emissions.
4.3.4 Carbon Black Industry
4.3.4.1 Processes and Uses
Carbon black is an oil-free ultrafine soot. Although it is
used in the paint and printing industry as a pigment, the prominent use is
in the rubber industry as a reinforcing agent. Tires, for example, roll
three to five times farther with carbon black than without.
Three principal techniques of carbon black production exist:
a. Impingement process
b. Thermal process
c. Furnace process
The furnace process, which accounts for most carbon black production, is
subdivided further according to fuel type: oil. natural gas, and oil-enriched
natural gas.
The impingement and thermal processes involve incomplete
combustion of HC fuel, whereas the thermal process involves thermal
decomposition (or cracking) of natural gas by exposing it to heated (2400°
to 2800°F) brick work. The impingement process (also called channel
process) involves natural gas-fueled flames impinging on surfaces of steel
(usually channel cross section) and depositing carbon black. The carbon
black is periodically scraped off the channels before pelietizing (to increase
the density for more economical shipment) for packaging and shipment.
Channel black is one of the finest (20 to 50 nm particle size) grades made.
Furnace black particle size is 25 to 160 nm. Although the thermal process
produces a much larger particle size (150 to 500 nm) and consequently
facilitates control of particulate-type HC emissions, many users of carbon
bla'ck, such as tire manufacturers, simply cannot use this product. The
4-23
-------
furnace process employs refractory-lined furnace combustion chambers
where the natural gas and oil is burned with insufficient air. The process
is continuous in nature, whereas the thermal and impingement processes
are cyclic. Furnace reactors have grown to be sophisticated efficient
plants compared to the channel black burner houses. The latter are
normally temporarily set up at the source of cheap natural gas and involve
few controls (except for air flow). Gas furnaces yield 12 to 16 Ib of carbon
black per 1000 cu ft of gas compared to a yield of 2 to 3 lb/1000 cu ft from
the channel black process. The theoretical yield is approximately 32 Ib/
1000 cu ft.
By its nature, carbon black production is a high emitter of
HC and CO. Although much of the following practice was implemented to
improve efficiency, pollution control benefits are inherent. Since most HC
emission are in the form of soot particulate. Hie most common forms of
alleviation are cyclone separators; water scrubbers; bag filters; and, more
recently, electrostatic percipitators. Also some consideration has been
given to burning HC emissions. This would alleviate the flow of gaseous
emissions such as methane as well as the fine particulate soot. CO emis-
sions are left essentially uncontrolled in carbon black production.
4.3.4.2 Data Research and Analysis
4.3.4.2.1 Carbon Black Production
Production rates of carbon black are listed in Ref. 4-8 for
selected years from 1925 to 1965. Production rates for 1970 are recorded
in Ref. 4-6. With some difficulty, the data from Ref. 4-8 for the years
1950, 1955, I960, and 1965 were merged with the Ref. 4-6 data to establish
a modern-day trend. Two problems were encountered:
a. The Ref. 4-8 furnace data were not broken down by
type, i.e., oil, gas, or oil and gas.
b. No production rates were recorded in Ref. 4-6 for
thermal black.
4-24
-------
Problem a. was disposed of by assuming Ref. 4-8 furnace charge rates
were apportioned among the three processes on a percentage basis the same
as the Ref. 4-6 data.
The trend of total carbon black production for 1970 follows
the same curve as Ref. 4-8 data only if some carbon black production exists
other than that reported in Ref. 4-6 under the SCC categories 3-01-005-01,
-03, -04, and -05. As seen in Figure 4-3, the deficit closely matches the
charge rate reported under SIC 2895 of SCC 3-01-005-99. These observa-
tions (plus the fact that corporations listed in the NEDS point source data
were involved in other carbon black production) led to defining the 1970
production as the sum of the charge rate for the four previously mentioned
SCC categories and the portion of SCC 3-01-005-99 allocated to SIC 2895.
Products corresponding to SIC. classifications are defined in Ref. 4-1.
Figure 4-4 shows the production rate of carbon black for the five processes
under these ground rules.
Trend curves were established for the production rate of
each process by deriving the least square fit straight line using various
combinations of the 1955 to 1970 data. Figure'4-4 shows the curve which
used all five sets of data between 1950 and 1970. Even though the 1950-65
data resulted in a better fit (higher correlation coefficient), it was decided
to use (for future black production estimates) those curves derived from all
five points (1950 to 1970). The rationale was as follows:
a. The inclusion of the latest data (1970) adds credence
to future estimates.
b. Use of data from several sources offsets errors in
individual data where checking for validity is not
possible.
These trend curves were used to establish baseline production in the year
1975. The uncertainty in baseline production is equal to the standard error
of estimate obtained in deriving the straight line. The uncertainty of the
baseline slope (change in production rate per year) was defined as the dif-
ference in slope of straight lines using all five points and that excluding the
1970 data.
4-25
-------
o
(/I
o
o
oo
o
CO
ce.
o
LL.
o
o
o
REF.
4-6
1950
O SUM OF 3-01-005 xx SCCs
O SAME AS O LESS SIC 2952 OF SCC 3-01-005-99
D SAME AS O LESS ALL SICs OF SCC 3-01-005-99 EXCEPT SIC 2895
& SAME AS O LESS ALL OF SCC 3-01-005-99
0 SCC 3-01-005-01 ONLY
V REF. 4-7 DATA
SCC = SOURCE CLASSIFICATION CODE
SIC = STANDARD INDUSTRIAL CLASSIFICATION
THERMAL
FURNACE
>CHANNEL
1955 1960 - 1965
CALENDAR YEAR
1970
Figure 4-3. Total carbon black production
4-26
-------
UJ
tx.
LlJ
0
z
o
0.5
0.4
0.3
0.2,
0
0.4
0.3
0.2
0
0.025
^ 0.020
g 0.015
£ 0.010
g 0
£. 0.20
DO
O
00
Of.
O
0.15
0.10
0
0.3
0.2
0.1
0
0 = REF. 4-3 A - REF4-6
h- O
O
o
I
(gas/oil)
FURNACE
THERMAL
CHANNEL
I
1950 1955 1960 1965
CALENDAR YEAR
1970
1975
Figure 4-4. Breakdown of carbon black production
4-27
-------
Emission factors for carbon black production are reported
in Refs. 4-5 and 4-10 and also can be calculated by dividing the pounds of
emissions by the tons of carbon black produced from Ref. 4-6. Data in
Ref. 4-10 for a particular process were considered an update of Ref. 4-5
data. Reference 4-5 or 4-10 data (whichever prevail) is referred to as
the "EPA emission factor." The other source is called the "NEDS emis-
sion factor." Where reasonable agreement (i.e., < 15 percent difference)
exists between the EPA and NEDS emission factors, the average of the
two values was established as baseline and its uncertainty was the difference
between the baseline value and the parent data.
Three cases were encountered where the EPA emission factor
differed substantially from the one based on the NEDS data:
a. Hydrocarbon emission factor for channel process
b. Carbon monoxide emission factor for channel
process
c. Carbon monoxide emission factor for oil- fed
furnace .
It was reasoned that the emission factors should be inversely proportional
to the percent theoretical product yield.
The theoretical maximum yield of carbon black is 32 lb/
1000 cu ft of natural gas. However, according to Ref. 4-11, approximately
40 percent of this HC is needed to' raise the temperature sufficiently to
separate the carbon. Therefore, if none of the 32 lb of carbon black were
collected, approximately 19 lb would escape to the atmosphere, and the
remainder would be consumed to heat the gas. Stated mathematically, the
hypothesis is as follows:
(1.0 - 0.4- 1)1
(1.0 - 0.4-
4-28
-------
where
EF = emission factor
T\ = decimal fraction of 32 Ib that the process yields of
carbon black
Since the emission factor for furnace process with gas was known (i.e.,
good agreement between the EPA emission factor and the one derived from
the NEDS), it was used as a basis to establish the three discrepant emis-
sion factors. This approach yielded values so close to the ones derived
from the NEDS data that the latter was selected for channel baseline
emission factors.
In the case of the oil-fired furnace process, the baseline
CO emission factor was defined as five percent higher than the one based
on NEDS data.
4.3.4.2.2 Miscellaneous Carbon Black Processes
Data were prepared to allow projections to be made in the
five MSCC categories of the miscellaneous carbon black industry
(MSCC 3-01-005-99). These MSCC categories were based on the SIC
classifications listed below and their corresponding products and comprised
the point sources under SCC 3-01-005-99 in Ref. 4-6 of the NEDS data:
MSCC SIC Product
3-01-005-99-1 2952 Asphalt, felts, and coatings
3-01-005-99-2 3624 Carbon and graphite products
3-01-005-99-3 3999 Manufacturing industries NEC
3-01-005-99-4 2899 Chemical preparation NEC
3-01-005-99-5 3334 Primary aluminum
3069 Fabricated rubber products
3991 Brooms and brushes
2999 Petroleum and coal products
aNot elsewhere classified (NEC).
4-29
-------
The baseline charge rate was set equal to the NEDS (1970)
value. Uncertainties were set at 5 percent of the base value for cate-
gories MSCC 3-01-005-99-1 through 3-01-005-99-4 and to 10 percent for
MSC'C 3-01-005-99-5,,'which is a bigger uncertainty since it is comprised
of a broad collection of activities. Typical uncertainty of the carbon black
production is eight percent.
The baseline emission factors were set e'qual to the NEDS'
emissions divided by the charge rate.. The emission factor uncertainty was
i
set tb 10 percent of baseline value, which' was typical of the primary carbon
black production SCC categories.
Since little is known about the production and processes in
this miscellaneous manufacturing group, no attempt was made to establish
a finite slope .(trend)- or slope'uncertainty of any of the data leading to'
projections of the 3-01-005-99 SCC categories.
4.3.4.3 Projections of Carbon .Black Activity
i i
The estimated HC emissions in 1980 carbon black industries
are 328,000 tons ± 87,000. Although the channel process is by far the
dirtiest (high emission factor), its.HC emissions are down-both trend-wise
and process-wise. The 1980 channel black production is 94,000 tons com-
pared to 116,000 for the oil-fired furnace process. The estimated channel
black HC emissions in 1975 are 112,000 tons.
The estimated CO emissions from carbon black in 1980 are
2.37-million tons ± 411,000 tons. The oil-enriched natural gas-fired
furnace technique leads CO emissions with 1. 17-million tons in 1980.
4.3.5 Miscellaneous Chemical Manufacturing
4.3.5.1 Products
Some 78 separate products (SIC classifications) at 1944
point sources comprised the miscellaneous chemical manufacturing
(SCC 3-01^999-99) categories in the NEDS data tape. Entriesmade under
4-30
-------
SIC 2818 and 3999, respectively, constituted approximately 50 percent of
the HC and CO emissions. The 76 other SIC products combined represented
only 43 percent of the HC and 35 percent CO emissions. Emission projec-
tions were made for three subdivisions of miscellaneous chemical manu-
facturing: (1) SIC 2818, (2) SIC 3999, and (3) remainder (other than SIC 2818
and 3999). SIC 2818 was not defined in Ref. 4-1, but such a classification
would be a member of the industrial inorganic chemicals under SIC 281x.
SIC 3999 designates manufacturing industries NEC.
4.3.5.2 Data Definition
The baseline charge rates and emission factors for each
category were set equal to the value calculated from the NEDS data
(Ref. 4-6). The uncertainties in charge rates and emission factors were
based on other chemical manufacturing (ammonia and carbon black).
Slopes and slope uncertainties were set to zero since little
is known about the collage of industrial activity.
4.3.5.3 Projections of Miscellaneous Chemical
Manufacturing
The estimated 1980 HC and CO emissions from miscellaneous
chemical manufacturing are 518,000 ± 65,000 tons and 336,000 ± 129,000
tons, respectively.
4.4 REFERENCES
4_1. Standard. Industrial Classification Manual, Executive Branch
of The Federal, Government, Statistical Policy Division,
Washington, D. C. (1972).
4_2. Guide for Compiling a Comprehensive Emission Inventory,
Revised, APTD-1135, U.S. Environmental Protection
Agency, Research Triangle Park, North Carolina
(March 1973).
4.3. NEDS Nationwide Emissions Report as of January 10, 1975
(with New York and West Virginia Supplement), U.S. Environ-
mental Protection Agency, Research Triangle Park, North
Carolina (February 12, 1975).
4-31
-------
4_4. Compilation of Air Pollutant Emission Factors, AP-42, U.S.
Environmental Protection Agency, Research Triangle'Park,
North Carolina (February 1972).
4.5. Compilation of Air Pollutant Emission Factors, 2nd ed.,
AP-:42, U.S. Environmental Protection Agency, -Research
Triangle .Park, North-Carolina (April 1973).
4_6. "Industrial Processes', Chemical Manufacturing Category, "
NEDS Data, The Aerospace Corporation Tape Analysis, The
Aerospace Corporation, El Segundo, California (February 25,
1975).
4.7. NEDS Nationwide Emissions Repo.rt as of December 10, 1973,
U.S. Environmental Protection Agency, Research Triangle
Park, North'Carolina (January i'2, 1974).
4_8. I. Drogin, "Carbon Black," Journal of Air Pollution Control
Association, Informative Report No. 9, j* (4) .(April 1968).
4.9. R. Shreve, Chemical Process Industries, 3rd ed., McGraw
Hill Book Co., Inc., New .York (1967).
4_10. NEDS Source Classification Codes and Emission Factor
Listing (SCC Listing), U.S. Environmental Protection
Agency, Research Triangle "Park, North Carolina
(July 1974).
4.11. T. Cox, Jr., '"High.Quality-High Yield Carbon Black, "
Chemical-Engineering Journal (June 1950).
4-32
-------
SECTION 5
PETROLEUM REFINERIES
5. 1 INTRODUCTION
This section develops data for the petroleum refining industry,
in terms of several important source classification codes (SCC), for emis-
sions of particulate (PART) matter, nitrogen oxides (NOx), unburned hydro -
carbons (HC), and carbon monoxide (CO).
The purpose is to provide a general overview of the petroleum
refining industry, assess the importance of specific major process sources
of atmospheric emissions, estimate current and projected levels, provide the
rationale used in making the projections, and present the data sources.
Table 5-1 describes the process and charge fate units for each SCC studied.
5.2 SUMMARY
Petroleum industry annual charge rates and emissions were
established for 1975 and estimated for i960. These data are reported in
Tables 5-2-a and 5-3-a, respectively. Uncertainty data are listed in
Tables 5-2-b and 5-3-b for 1975 and 1980. respectively.
5.3 APPROACH
Developing and forecasting emission inventories requires
knowledge or judgment about a combination of factors. Technological gen-
eralities are discussed in Appendix 5-A. Two important elements are total
annual charge rates and emission factors. Judgments have been made about
expected changes in these parameters resulting from technology advancements,
(Continued on page 5-9)
5-1
-------
Table 5-1. DEFINITION OF PETROLEUM INDUSTRY PROCESSES
MSCC
Source Category
Charge Rate Unit
306001(010 Process heater (oil-fired, major
quantities)
306001020 Process heater (gas-fired, minor
quantities)
306001030 Process heater (oil-fired, minor
quantities)
306001040 Process heater (gas-fired, major
quantities)
306002010 Fluid catalytic cracking
306003010 Moving bed catalytic cracking
306008010 Miscellaneous leakage (pipe, valve,
flange)
306008020 Miscellaneous leakage (vessel
relief valves)
306008030 Miscellaneous leakage (pump seals)
306008040 Miscellaneous leakage (compressor
seals)
306008050 Miscellaneous leakage (other,
general)
306012010 Fluid coking
1000 bbl burned/yr
1000 cu ft burned/yr
1000 gal burned/yr
Million cu ft burned/yr
1000 bbl fresh feed/yr
1000 bbl refined/yr
1000 bbl refined/yr
1000 bbl refined/yr
1000 bbl refined/yr
1000 bbl refined/yr
1000 bbl fresh feed/yr
5-2
-------
Table 5-2-a. 1975 PETROLEUM INDUSTRY EMISSIONS AND CHARGE RATES
0)
ANNUAL CHARGE
INDUSTR
RATES AND EMI
IAL PROCESS* PETROLEUH INDUSTRY PAGE 1
SSIONS PROJECTED TO 1975 RUN DATE-JUNE 24*1976
MOD1FILD
SCC
3C60C101G
306001010
306001020
30600U3G
306001040
306002000
306002010
3C60C300C
3C6C03C1C
3060UBGOO
3C600B010
30tOC8C20
306COOC30
3C6006040
306006050
3G6CltGCC
306012010
TACRP
(SCC UNITS)
160600.
2200000000.
5867CO.
NEGLIGIBLE
150COOO.
1500000.
106500.
1065CO.
26250000.
52500GO.
525&OCO.
52500CO.
525COOO.
525COGO.
110000.
110000.
Ni
N(
NI
NE
N
N
N
N
NI
NI
NOX
.507
.233
.254
.121
NEGLIGIBLE
.050
.05C
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
EGLIGIBL
GLIGIBL
GLIGIBL
IGLIGIBL
NEGLIGIBLE
NEGLIGIBLE
EMISSIONS
(MILLIONS
HC
.045
OF
TONS
CO
.034
/ YEAR)
Cll
.033
.OC1
NEGLIGIBLE
.019
.001
NEGLIGIBLE
PART
.095
.067
.022
.OCb
NEGLIGIBLE
E
E
E
E NEGL
E NEGL
.170
.170
.005
.COS
.187
.074
«029
.045
.013
.026
IGIBLfc
IG1BLE
16.800
16. BOO
.210
.210
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
.180
.180
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
N
N
4
4
N
EGLIGIBLE
iGLIGIBLE
iGLlGIBLE
GLIGIBLE
EGLIGIBLE
.027
.027
-------
Table 5-2-b. 1975 PETROLEUM INDUSTRY UNCERTAINTIES
01
I
INDUSTRIAL PROCESS* PETROLEUM INDUSTRY
1ACR AKD EMISSION UNCERTAINTIES PROJECTED TO 1975 RUN DATE-JUNE
PAGE
MODIFIED
SCC
TACRP
fSCC UNITS)
NOX
EMISSIONS
(MILLIONS OF
HC
NS / YEAR)
PART
306001000
306GC1010 4
4 .
025 4 .006 4 .005 4 .005
- .025 - .OC6 - .005 - .005
8CGO. 4 .
8000. - .
3C6001G20 4 11000COOO. 4 .
- llOOOOOOo. - .
306CCll<3C 4
016 4 .OC6 4 .00
G16 - .OCfc - .00
3 4 .005
*% ~ rt f* C
3 - .005
018 4 .002 4 .004 4 .002
018 - .OC2 - .004 - .002
29COO. 4 .007 * .000 4 .000 4 .00?
29000. - .007 - .OGO - .000 - .002
306001040 NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE
NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE
3C60C2Ctb 4
3C6C02010 4
306CG30GO 4
3C6CG3C1C 4
3COGC. 4 .
003 4 .OC9 4 5.P90 4 .010
30000. - .003 - .OG9 - 5.890 - .010
30000. 4 .
30000. - .
003 4 .CC9 4 5.890 4 .010
003 - .OC9 - 5.890 - .010
2169. NEGLIGIBLE 4 .OCC 4 .011 NEGLIGIBLE
2169. NEGLIGIBLE: ~ .000 - .011 NEGLIGIBLE
2169. NEGLIGIBLE 4 .000 4 .011 NEGLIGIBLE
2169. NEGLIGIBLE - .000 - .011 NEGLIGIBLE
306CC80CO 4 234790. NEGLIGIBLE 4 .034 NEGLIGIBLE NEGLIGIBLE
234790. NEGLIGIBLE - .034 NEGLIGIBLE NEGLIGIBLI
3C60C8C10 4 105000. NEGLI
1050GO. NEGL)
306CC8C20 4 105000. NEGL]
105000, NEGL
3C6008C30.. 4 105000. NEGLI
306008040 4 :
3060UB05C 4 I
L05000. NEGLI
05000. NEGL
05000. NEGL
05000. NEGL
05000. NEGLI
GIBLb 4 .026 NEGLIGI
GIBLE - .026 NEGLIGI
GIBLE 4 .010 NEGL G
GIBLE - .010 NEGL G
GIBLE 4 .016 NEGLIG
GIBLE - .016 NEGLIG
GIBLE 4 .OC£ NEGLIG
GIBLE - .005 NEGLIG
elBLE 4 .009 NEGLIG
BLE - .Of 9 NEGLIGI
BLE NEGLIGIBLE
BLE NEGLIGIBL
BLE NEGLIGIBL
ILE NEGLIG BL
BLE NEGLIGIBL
KEGLIGIBL
EGLIGIBL
BLE NEGLIGIBL
LE NEGLIGIBL
BLE NEGLIGIBL
-------
Table 5-2-b. 1975 PETROLEUM INDUSTRY UNCERTAINTIES (Continued)
INDUSTRIAL PROCESS* PETROLEUM INDUSTRY PAGE 2
TACR AND EMISSION UNCER1A1NTIES PROJECTED TO 1975 RUN DATE-JUNE 24*1976
MODIFIED TACRP (MISSIONS (MILLIONS OF TONS / YEAR}
SCC (SCC UMTS) NOX HC CO PART
3C6C12CCO 4 2199. NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE + .002
2199. NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE - .002
306012010 « 2199. NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE « .002
2199. NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE - .002
U1
-------
Table 5-3-a. 1980 PETROLEUM INDUSTRY EMISSIONS AND CHARGE RATES
o^
INDUSTRIAL PPOCESSt PETROLEUM INDUSTRY
ANNUAL CHARGE
MODIFIED
sec
3C6001COO
306001010
306GClw2C
3G6GG1030
306001040
3C6G02COO
3G6C02010
306GC3COO
3G6CC3C10
306008000
306008010
316CG802C
3G60G803G
3G6008Q40
306012GCO
3Q6012G10
RATES AND EMISS
TACRP
(SCC UNITS)
112410.
NEGLIGIBLE*
1690000.
1690000.
70000.
7COOG.
29B50GOO.
6150000.
61500UO.
6150000.
5250000.
61510CO.
12GOCO.
1200GO.
IONS PROJECTED
EMISS
NDX
.326
.062
.234
.G1C
NEGLIGIBLE
.C56
.056
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
TO 1980
IONS (MILL
HC
.055
.008
,047
. loci
NEGLIGIBL
.180
.180
.C03
.003
.215
.087
.033
.C52
.013
.030
NEGLIGIBL
NEGLIGIBL
RUN DATE-JUNE
IONS OF TONS / YE
CO
.038
.010
.027
.001
E NEGLIGIBLE
11.441
11.441
.130
.130
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
EGLIGIBLE
E NEGLIGIBLE
E NEGLIGIBLE
PAGE 1
24*1976
PART
.082
.047
.031
.004
NEGLIGIBLE
,12b
.126
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
NEGLIGIBLE
EGLIGIBLE
.029
.029
-------
Table 5-3-b. 1980 PETROLEUM INDUSTRY UNCERTAINTIES
INDUSTRIAL PROCESS, PETROLEUM INDUSTRY
PAGE
Ul
-o
UCR AND EMISSION UNCERTAINTIES PROJECTED TO 1980
RUN DATE-JUNE 24*1976
MODIFIED TACRP
SCC (SCC UNITS)
3C6C01000
4
EMISSIONS (MILLIONS C
NOX
HC
IF T
ONS / YEAR)
CO PART
f .032 * .006 4- .
- .032 - .007
006 4- .
.006 -
306C01010 4 11243. + .012 4- .004 + .002 *
11243.
- .012 - .OC4
.002 - .
3C60ul02C 4 31016000C. * .030 * .005 + .006 + .
- 31C16COCO.
- .030 - .005
OO6 - .
3C6U.1C3C 4 58e668e. * .007 * .000 * .000 t
306C01040 NEGLIGIBLE NEJL IG^IBLE N|GLIGIBLE N|
30bH.2C»;C » 168980.
168980.
3C6GC2C1U 4 16R98C.
166960.
006
006
005
005
003
003
001
C01
GLIGIBLE NEGLIGIBLE
IGLIGIBLE NEGLIGIBLE
4- .006 4- .020 4- 6.723 4- .
- .006 - .020
- 6.723 - .
014
C14
* .006 + .020 4- 6.723 * .C14
- .006 - .C20
- 6«
7Z3 - .
014
306C03COC 4 21002. NEGLIGIBLE 4 .001 4- .040 NEGLIGIBLE
21002. NEGLIGIBLE - .001 - .040 NEGLIGIBLE
3C6UL3C1C 4 21CC2. N
21002. N
EGLlGIbLE + .001 + .040 NEGLj
EGLIGIBLE - .001 - .040 NEGL1
.GIBLE
GIBLF
30600800C 4 1375200. NEGLIGIBLE 4 .041 NEGLIGIBLE NEGLIGIBLE
13752CO. NEGLIGIBLE - .C41 NEGLIGIBLE NEGLIGIBLE
306C08C1C 4 blg030. N
615030. N
306C08U2C 4 615030. N
615030. N
3C6CC6C30 4 615030. h
615030. J1
306008040 4 615030. ^
615030. t
3060U8050 4 615030. £
615030. N
EGLIGIBLE 4 .031 NEGL
IGLIGIBLE - .032 NEGL]
IGLIGI
GLIGI
GL1G
EGLIGI
EGL G
EGL GI
EGLIG
EGLIG
BLE 4 .012 Nl
)LE - .012 N
JLE 4 .019 N
JLE - .019 N
HE 4- .CC5 N
JLE - .005 N
HE + .011 N
HE - .011 N
EGL1
EGL
:GL
;GL
&
lit
GIBLE NEGL1
GIBLE NEGL
GIBLE NEGL
G BLE NEGL
G BLE NEGL
G BLE NEGL!
G BLE NEGL:
G BLE NEGL
[GIBLt
GIBL
GIBL
GIBL
GIBL
GIBLI
:GIBL!
EGIBL!
-------
Ul
I'
00
Table 5-3-b. 1980 PETROLEUM INDUSTRY UNCERTAINTIES (Continued)
INDUSTRIAL PROCESS* PETROLEUM INDUSTRY PAGE 2
TACR AND EMISSION UNCERTAINTIES PROJECTED TO 198C RUN DATE-JUNE 24*1976
fOOIFIFO TACRP EMISSIONS (MILLIONS OF TONS / YEAR)
SCC (SCC UNITS) NOX HC CO PART
306012CCO * 11996. NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE t .004
4 - 11998i NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE * iOC4
306012010 « 11998. NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE + .004
11998* NEGLIGIBLE NEGLIGIBLE NEGLIGIBLE - .004
-------
regulatory impacts, economic considerations, and other matters. Development
of emission factors for the more important SCCs was primarily based upon
data provided in Ref. 5-1. The major sources of petroleum refinery emissions
stem from combustion-generated emissions resulting from process heating
and catalyst regeneration, while HC discharges result mainly from sources
of leakage or evaporation.
In certain instances, revisions of CO factors were made for
consistency with other firing equipment using similar fuels or known data.
For example, the CO emission factor for oil-fired process heaters in SCC
3-06-00i-01 is indicated as zero. The corresponding CO emission factor for
external combustion boilers (SCC 1-02-004-xx and 1-02-005-xx) indicates
4-lb CO/1000 gal burned, which is equivalent to 168 lb/1000 bbl. The factor
used in this instance was accordingly taken as 170 for equipment in this SCC.
In a similar way, it can be determined that CO variation in
fluid catalytic cracking introduces uncertainty in the emission factor for
SCC 3-06-002-01. The factor given for this effluent in Ref. 5-1 is 13, 700-lb
CO/SCC. Coke formation ranges between 4 and 10 percent of fresh feed
charge. The amount of CO produced varies with the stoichiometry within the
regenerator, but a range may be assessed in a simple way by assuming that
the CO2/CO ratio in the off gases is 1.5, which is typical (Ref. 5-2). On
the basis of an 8 percent coke formation and a feed gravity of 300 Ib/bbl, we
have
5C + 4O2 = 2CO + 3CO2
8-lb coke v 56 -lb CO 300 lb 1000 bbl _ ._ 4QQ .. co/SCc
100 -lb fresh feed X 60-lb coke X HST X SCC ' 22' 4°°-lb CO'SCC
Slightly different assumptions can be made to show even mpre severe emission
factors, which merely makes the uncertainty range greater.
5-9
-------
5.4 GENERAL REFINERY STATISTICS
Statistical data from several data sources served as the basis
for obtaining detailed information concerning crude charging rates, produc-
, i
tion capacities, product yields, and past production trends-. Most refiners
try to maximize gasoline and fuel production,, although some operators.
concentrate on other specialty products as well. Average yields and other
statistics of U.S. refineries are periodically published by the American
Petroleum Institute (API) and also in industry journals- such as The Oil and
Gas Journal (Ref. 5-3). Percentage-yields of various petroleum products for
1973 are represented in Table 5-4. As shown, gasoline represents the major
product of the industry; the yield of gasoline relative to crude input is nearly
one-half the total volume. This is a composite statistic; some refiners can
obtain gasoline yields in excess of 60 percent.
Petroleum refinery statistics dating back to 1956 are given in
Ref. 5-2. Few changes in refinery yields have occurred. Average gasoline
yields have increased from 43.4 to 45.6 percent. The- annual growth rate in
crude runs to stills for the entire time period of Ref. 5-2 is 2.7 percent and
3.6 percent over the last 10 years. Gasoline production growth over this
same time period has been nearly 4 percent and approximately 3 percent
over the entire time period. Thus, refiners have been concentrating their
efforts on producing ever increasing amounts of gasoline from crude. The
most recent estimates for gasoline production in 1974 is about 6.5 X 10 bbl/
day or nearly 10 gal/year. Although kerosene production in Ref. 5-4
appears to have declined, it has been replaced by jet fuels. Total kerosenes
therefore, are increased. A considerable decline in residual fuel oil yield
from -14.7 percent in 1956 to 7.7 percent in 1973 is indicative of further
processing of these "heavy ends."
Recent data on a state-by-state basis show that in early 1974
there were 247 refineries operating imthe United States, with a daily stream
crude capacity of 14.9 X 10 bbl/day, running at 96 percent capacity (Ref. 5-3).
For 1975, the daily runs were estimated at 15 X 10 bbl, which when annu-
alized on 350 days results, in 5.25 X, 10' bbl. Although this appears to be an
5-10
-------
Table 5-4. 1973 DISTRIBUTION OF PETROLEUM PRODUCTS
Product Percent of Refinery Yield
Gasoline 45.61
Distillate Fuel Oil Z2.46
Residual Fuel Oil 7.74
Jet Fuel (Kerosene) 5.41
Kerosene 1.73
Jet Fuel (Naphtha) 1-44
Lubricants 1 50
Other 14.11
5-11
-------
exceptional rise in..the two-year interim following the last tabulated values of
Ref. 5-2, it seems in line with present market demand patterns and industry
construction.
A number of reference sources can be cited in forecasting
energy demands, sources of supply, or projected growth rate of U.S. con-
sumption (Refs. 5-5 through 5-11). Such issues as .-economics and industrial
activity, population grpwth, domes.tic governmen^policies,. and related inter-
national politics lead to considerable uncertainty in forecasts. In this study,
considering an overall oil requirement in the vicinity of 22 to 23 million
bbl/day by 1980, refinery runs have been estimated to be in the range of 17
to 18.5 million bbl/day. On an annual charge rate basis,, the values are from
6. 0 X 109 to 6.3 X 109 bbl/year. When a SCC is.measured in terms of 1000
bbl/year, these figures represent projected levels of6.Oto6.3XlO SCC/
year and compare favorably with the long-term and recent-term trends
discussed earlier.
5.5 PETROLEUM REFINERY PROCESSES EVALUATED
5.5.1 Process Heaters
Energy consumption requirements of typical refineries were
determined to establish the emissions, from combustion equipment. Energy
used in refining, as in other industrial practices, is governed by fuel price.
Nelson (Ref. 5-12) has shown that, for an average refinery, net energy con-
sumption varies with refinery complexity, but for many years has generally
remained in the range of 10 to 12 percent of processed crude. Newer refin-
eries tend to have lower energy consumption because refiners have installed
more efficient systems, enabling better overall heat utilization. In this study,
the net energy consumption level was therefore assumed as 10 percent of
0.63 X 106 Btu/bbl oil processed. About two thirds of this heat is obtained in
some plants by the burning of refinery .process gases and about one third from
the firing of salable liquids or residual fuel (Ref. 5-13). A further breakdown
of process heater firing was obtained from a NEDS data tape printout which
showed that 92 percent of the oil-fired process heater charge rate is in
SCC category 3-06-001-01 versus 8 percent in SCC 3-06-001-03 (Ref. 5-14).
5-12
-------
In forecasting to 1980, it was assumed that refineries will
continue to increase in complexity (as they have for many years). There are
several reasons why this should occur. A large portion of the industry lacks
the capability to process high-sulfur crude oil (Ref. 5-15). Therefore, the
industry will develop the flexibility to handle such crudes and at the same time
will be upgrading production facilities to meet new environmental demands
for pollution control and to produce lead-free and low-lead gasoline products.
These factors will tend to be offset by certain energy conservation measures;
hence, it was assumed that the energy required to operate refineries in 1980
will still be 10 percent of the total product processed by these refineries.
The overall energy consumed by oil-fired heaters will tend to
decline as fuel-firing strategies will tend toward selection and use of process
gaseous fuels having a low sulfur content. This is dictated by recently pro-
mulgated regulations (Refs. 5-16 and 5-17) which limit atmospheric sulfuric
oxide (SO-) emissions from process heaters. It has been estimated that a
6
reduction of up to 30 percent of current energy values in SCC 3-06-001-01 can
be realized. The implication of this is that future needs for process heat
from this SCC will consume only about 25 percent of refinery fuel require-
ments, with greater implementation of refinery-process gas-fired equipment.
At the same time, improved firing techniques will enable reductions in NOx
emission factors.
5.5.2 Fluid Catalytic Cracking
The fluid catalytic cracking capacity of an average refinery is
about 30 percent of crude capacity, with larger companies tending to have
higher fractions (approximately 34 percent) and smaller companies having
lower fractions (24 percent)(Ref. 5-15). The largest fluid catalytic cracking
plants operate in the range of 120, 000 bbl/day, and there are eight plants of
this size range (Ref. 5-3). The total annual charge rate of this SCC is
presently 1.5 x 109 bbl/year. Over the past few years, the growth trend has
been a fairly consistent 2.4 percent annually, so that by 1980 the expected
q
new additions will account for 1.69 X 10 bbl/year, if no perturbations occur.
According to Conn (Ref. 5-18), the attributes of fluid catalytic cracking are
that fluid crackers (1) may be constructed in very large sizes, (2) are rela-
tively free of mechanical problems, and (3) have proven flexible in operation.
5-13
-------
As mentioned, several important advances have taken place in fluid catalytic
cracking. These include improved catalysts and improved operating and
regeneration techniques (such as riser cracking and two-stage regeneration)
resulting in improved capacities and yields (Ref. 5-19), lower coke make;
and lower .emissions (Ref. 5.-20). The .rising :trend-in fluid cracking capacity
is expected to continue.
However, the new. standards of performance which Became
effective in 1974 limit the emissions-fro.m fluid- catalytic crackers (Ref. 5-16).
The promulgated standards apply to PART and CO emissions from new or
modified catalyst regenerators. Essentially, an operator is prohibited from
discharging (1) PART matter in excess-of 1 kg/1000 kg (1 lb/1000 Ib) of coke
burnoff in the catalyst regenerator and (2) gases which contain CO in excess
of 0.050 percent by.volume (500 parts per million).
Background information contained in Ref s. 5-21 and 5-22 shows
that compliance with the new-standards, may be achieved by use of'more than
one type of control technique. Emissions of CO from fluid cracking regen-
erators are also discussed .in Ref. 5-20.
Since the regulations apply to new plants and existing plants
which were modified in a way that increased their emissions, it became
necessary to assess the expected degree of modernization which can'occur
between the present and 1980. In other words, to forecast the emissions one
must evaluate the expected rapidity of plant replacement and the fraction of
controlled emission production' levels which would b'e in effect by 1980.
Information concerning refinery abandonments, replacements, enlargement,
and modernization is scarce. As reported by Nelson (Ref. 5-23), a refinery
that is to operate profitably must adhere to certain rules:
a. Grow in crude capacity so that the refiner retains his share
of the growing market
b. Be constantly repaired and maintained
c. Grow in downstream1 technology to meet product and
quality requirements
d. Grow technologically-so that it'remains competitive
5-14
-------
Thus, not only does crude and downstream capacity increase, but whole
process units (e.g., crude, cracking, and reforming) are replaced from time
to time so that the larger refinery is not simply an accumulation of small units.
It has also been shown that on average a refinery can be kept competitive
with respect to crude capacity and downstream facilities by doubling every
12 to 13 years, or at an annual rate of 5.7 percent. In addition, during recent
years, now operating refineries of major companies have been below 0. 4 per-
cent of existing capacity. The approach taken was to assume that these
criteria apply also to fluid catalytic cracking, and on this basis an analytical
assessment was made on 1980 charge rates.
5.5.3 Moving Bed Cracking
This form of catalytic cracking appears to be of diminishing
importance in terms of overall charge rates. Recent trends according to
Ref. 5-15 show that daily capacity receded from 0.5 X 10 bbl/day in 1972 to
0. 3 X 10 bbl/day in 1975. At this rate of decline (roughly 16 percent annu-
ally), the daily charge rate would be about 0.13 X 10 bbl/day, but it is not
known how the new regulations will affect refiners plans. The approach used
was to assume the decline would continue at approximately half this rate so
that by 1980 the daily throughput would be 0.2 x 10 bbl/day. The annual
charge rate becomes 0.07 X 109 bbl/year or 0.07 X 10 SCC/year. The
uncertainty in charge rate is thus relatively high. The emission factors used
were those in Ref. 5-1.
5.5.4 Coking and Miscellaneous Categories
These categories include particulate dispersions resulting
from coke making and various other HC losses. No special approach was
necessary for SCCs based upon total annual charge rate. For coking, annual
charge rates were based on the assumption that two percent of capacity is
used in coke making. According to Ref. 5-3, coke capacity of 43,410 tons
5-15
-------
is obtained from a daily feed capacity of 14.2 X 10 bbl. At 300 Ib/bbl,
we obtain
43f 410 ton/day _ X.100.= 2.0%
14.216 x 10°.bbl/day X 300.1b/bbl x.
5.6 RESULTS AND DISCUSSION
Tables.5-2-a and 5-3-a summarize -the results of the inventory
studies for process heaters, catalytic cracking, and the miscellaneous cate-
gories of fluid coking and equipment leakage.
Emission factor levels are generally found to be declining
gradually. This is expected to result'from higher monetary values for fuel
and more stringent control of. emissions through expansion and modernization.
The new.ruling especially in regard to fluidccatalytic cracking is estimated
Q
to affect.0.67 X 10 bbl/year .of fresh feed charge rates out of a'total of
q ' Q
1.69 X 10 bbl/year by 1980. In other words, of the current 1.5 X 10 , nearly
-one third.of the total charge will either have-.been replaced or modernized
and will therefore be in compliance.
However, .as seen in Tables ,5-2-b and 5-3-b, large uncertain-
ties can exist.in charge1 rate data, emissions, and other data. It is therefore
necessary to periodically re view, industry-production trends, technology
achievements, and consumer demands which can impact the resulting year-to-
year data.
It was originally intended to compare emission level results
from the NEDS data. However, because of significant discrepancies found in
the past, this was not attempted here. The most-recent NEDS data error
.showed that total annual charge rate in fluid, catalytic cracking was approxi-
mately a factor of 20 too'high (Ref. 5-4). This error was acknowledged and
corrected.in Ref. 5-24.
5-16
-------
5.7 REFERENCES
5-1. NEDS Source Classification Codes and Emission Factor
Listing (SCC Listing), U.S. Environmental Protection
Agency, Washington, D.C. (July 1974).
5-2. Energy Statistics, Department of Transportation,
Washington, D.C. (August 1974), p. 57.
5-3. A. Cantrell, "Annual Refining Survey, " The Oil and Gas
Journal (1 April 1974).
5-4. E. J. Cahill and A. L. Grossberg, Current and Future
Trends in United States Gasoline Supply, SAE Paper
No. 730516, Society for Automotive Engineers, New York
(1973).
5-5. W. G. Dupree, Jr. and J. A. West, United States Energy
Through the Year 2000, U.S. Department of the Interior,
Washington, D.C. (December 1972).
5-6. W. B. Bryant, "Trends in the Oil Industry, " Chemical
Engineering Progress, 70 (8) (August 1974).
5-7. "The Energy Outlook for the United States," The Oil and
Gas Journal, 59 (16 September 1974).
5-8. M. W. Nichols, "Balancing Requirements for World Oil
and Energy, " Chemical Engineering Progress, 70 (10)
(October 1974).
5-9. A. L. Aim, "Energy and the Environment: Choices
for the Future, " Chemical Engineering Progress, J70 (12)
(December 1974).
5-10. "News Features. . .Oil Price Drop?, " Chemical Engineering,
34 (February 3, 1974).
5-11. W. W. Reynolds and H. S. Klein, "Petrochemical and
Energy in Perspective, " Chemical Engineering Progress,
7J_, (3) (March 1975).
5-12. "Fuel and Steam Required in Average U.S. Refinery, "
The Oil and Gas Journal (April 21, 1958).
5-17
-------
5-13. "Industrial Processes, Petroleum Industry Category, "
NEDS Data, The Aerospace Corporation Tape .Analysis,
The Aerospace Corporation,.'El,Segundo, California
(February 25, 1975).
5_14. L. R. Aalund, "Refining Capacity Registers Largest
'Nickel, and-Dime1 Jump in History, " The Oil and "Gas
Journal (April 1974).
5_15. "Air Programs; Standards.of Performance for New
Stationary Sources-Additions and Miscellaneous
Amendments, " 'Federal Register, ^9 (47),. Part II
(8 March 1974).
5_l6. Journal-6f the Air Pollution Control Association, 24 (4),
362-364 (April 1974).
5_17. A. L. Conn, "Developments in Refining Processes for
Fuels, ".Chemical Engineering Prog.ress, £9 .(12)
(De cember 1973).
5_18. "Striking Advances Show Up in.Modern FCC Design, "
The Oil and Gas Journal (October 30, 1972).
5_19. "NPRA Q&C - 3, Answers for .Process Questions of
FCC Units, " The Oil and Gas Journal (March 11, 1974).
5_20. Background Information for Proposed New Source Per-
formance Standards. Vol. 1. Main Text, U-.S. Environ-
mental Protection Agency, .'Washington,. D.C. (June 1973).
5-21. Background Information for' New Source Performance
Standards, Environmental Protection Agency, Vol. 3,
Promulgated Standards, U.S. Environmental Protection
Agency, Washington, D.C. (February. 1974).
5-22. "Question on Technology," The Oil and Gas Journal
(February 5, 1973).
5-23. E. K. WeinbergtoO. Dykema, The Aerospace Corporation
Memo No. 75-.5124.31-16, "Data Error in EPA National
Emissions Data Systems (NEDS)" (13 May .1975).
5-24. O. W. Dykema to J. G.r Summers, U.S. Environmental
Protection Agency Memo (September 1975).
5-18
-------
APPENDIX 5.A
DISCUSSION OF PETROLEUM REFINERY PRACTICES
5.A.I BACKGROUND
Familiarization with overall refinery technology (Ref. 5.A-1)
is prerequisite to understanding the refinery industry practices which con-
stitute important sources of atmospheric emissions. The raw feedstocks,
consisting mainly of crude oil but including, also, natural gas and asphalt,
are subjected to thermal or chemical treatments leading to a broad variety
of intermediate and finished products.
A single refinery may not produce all petroleum products,
even in the most diverse of the major composite refineries. Significant dif-
ferences occur in chemical composition and physical properties of the crude
liquid feedstocks that are available to an individual plant. For example, some
crudes are highly amenable to the economical production of lubricants and
waxes, whereas others may be less so. The fundamental determinant defining
which products will be produced at a given refinery is economics. Economics
includes not only such factors as equipment capitalization, operating costs,
and product values, but also feedstock costs and variability.
5.A.2 REFINERY PROCESSING OVERVIEW
It is desirable to recognize certain types of similar refinery
processes and operations from a chemical engineering aspect. The more
5.A-1
-------
important manufacturing procedures that may be associated with atmospheric
emissions are identified as follows:
a. Topping
b. Crude distillation
c. Gasoline stabilization
d. Vacuum flash operation
e. Cracking (thermal and catalytic)
f. Catalytic reforming
g. Hydroprocessing
h. Alkylation
i. Isomerization
5.A.2.1 Topping
The basic operation in all refineries is atmospheric pressure
distillation. This operation, known as topping, represents the first step in
the fractionatiqn of crude oil feedstock into various, boiling range components
such as gasoline, kerosene, distillates., .lubricants, and fuels. Crude-oil
distillation normally requires preheating the feedstock in a heat exchanger
train and/or direct-fired heaters before being fed to the distillation tower
units. The o'verhead stream condensate (raw.straight-run gasoline) goes to a
stabilizer column for pro pane-butane removal, yielding stabilized straight -
run gasoline for later treatment.and.octane upgrading. The side streams,
which boil at intermediate temperatures, yield naphtha, kerosene, diesel oil,
and gas oil. The bottom stream, also called reduced crude, may be vacuum.-
fractionated for lube manufacture or r,un (with gas oil) into cracking units for
conversion into lower moleeula-r weight products, particularly gasoline.
5.A.2.2 Cracking
The major forms-of cracking are thermal and catalytic pro-
cesses. At one time during. World War II,-' overall gasoline yield from crude
was less than 40 percent, and thermal cracking accounted for more than
20 percent of total gasoline yield from crude. Thermal processes are now
mainly used for viscosity breaking (visbreaking) of reduced crudes and for
5.A-2
-------
coke production. Catalytic cracking is used mostly with gas oil but may
sometimes be used on various fractions, including naphtha and residuals.
The process takes one of several forms, depending upon the method of hand-
ling the catalyst. Fluidized bed catalytic cracking represents the largest
overall capacity in the United States, followed by Thermofor and Houdriflow
moving bed processes. Cracking causes decomposition of the higher molecu-
lar weight constituents of petroleum, which produces products in lower boiling
ranges. These include large amounts of olefinic gases, gasoline, and recycle
oil. Coincident with the disintegration mechanisms, coke deposits on the
catalyst. The amount and rate of coke formation varies with the type of feed
and catalyst, system design, and operating conditions. Generally, the
coking laydown ranges between 4 and 10 percent of the fresh feed charge
(Ref. 5.A-1).
Since catalyst activity declines with coke deposition, reactiva-
tion is required and is accomplished by periodic burnoff of the coke with air.
Modern systems operate continuously by recirculating finely divided catalyst
beads between the reactor and the regenerator. Regenerator off gases contain
the usual combustion products of HC, but complete combustion of carbon is
seldom accomplished during regeneration. Concentrations of CO in the flue
gases, therefore, are also variable but generally 8 to 10 percent by volume.
Further combustion of these gases in flares or CO boilers may be accom-
plished to recover heat energy and to minimize emissions. Cyclone sepa-
rators are the means'used to retain the solids in the circulating system.
Additional separation equipment in the form of electrostatic precipitators
can be used to further recover catalyst fines.
Recent advances have occurred in fluid catalytic cracking,
including the use of highly active zeolitic catalysts, higher pressures and
temperatures, more efficient equipment, and improved construction materials.
Higher equipment capacities, improved conversion and energy utilization,
higher octane products, and greater operating flexibility have resulted. Des-
criptions of several modern catalytic cracking processes as practiced by major
refiners are provided in Ref. 5. A-2. Considerable study effort was devoted
5.A-3
-------
to catalytic cracking practices because of the overall impact of these practices
on atmospheric emissions.
5.A.2.3 Catalytic Reforming
Catalytic reforming causes rearrangement of HC molecules,
primarily-accompanied by hydrogen abstraction (dehydrogenation) or addition
(hydrogenation). The process is used to upgrade low-octane naphtha to high-
octane gasolines and to produce aromatics such as benzene, toluene, and
xylene (BTX). Reforming was developed.in the late 1940s and early 1950s
with a platinum catalyst on a ceramic substrate. One of the main advantages
of the so-called platforming process at that time was the great improvement
in catalyst lifetime relative to existing cracking catalysts. In catalytic crack-
ing, about 10-gal oil/lb catalyst could be processed before regeneration.was
needed while the reforming processes could treat 1000-gal oil/lb catalyst. By
1956, as much as 10,000-gal oil/lb catalyst could be-ireated. Other advan-
tages of reforming included resistance to permanent catalyst poisoning, ability
to achieve multiple reactions simultaneously (e.g., dehydrogenation, dehydro-
isomerization, dehydrocyclization, isomerization, and hydrodesulfurization).
In short, the process was used to produce a high quality gasoline known as
reformate and a high yield of aromatics (for which there existed a high market
demand at the time). More recently, catalytic reforming processes have
become a valuable source of byproduct hydrogen. As in the case of catalytic
cracking, newer catalysts (some including nonnoble materials) are being
developed. The processes are variously referred to as platforming, magna-
forming, houdriforming, powerforming, rheniforming, and ultraforming
(Ref. 5.A-2).
A particular type of reforming process involving rearrange-
ment of a HC molecular structure is known, as isomerization. Originally,
isomerization involved the vapor-phase conversion of HC from one structure
to another by an acid catalyst '(e.g.,- butane to isobutane, C4 isomerization;
pentane to isopentanes, C- isomerization). Now, more modern plants.
such as Butamer, Pehex, and Hysomer process reactants in the presence of
highly active and selective fixed-bed noble catalysts. Such plants are often
5.A-4
-------
operated in conjunction with alkylation facilities. The clear octane ratings
of isomerization products is significantly improved. Unconverted reactants
are often recycled.
5.A.2.4 Hydroprocessing
The rapid increase in catalytic reforming capacity during the
past 25 years and the consequent availability of large amounts of hydrogen
produced therefrom has stimulated the development of refinery processing
in which the low-cost hydrogen is consumed or used within a particular
process. The general terms hydroprocessing, hydrotreating, and hydro -
refining are used to describe a multitude of production systems. The most
usual applications are for desulfurization (also called hydrosulfurization) of
various petroleum fractions in which many of the more stable sulfur-containing
compounds, such as mercaptans, are destroyed catalytically into HC rem-
nants. The liberated sulfur combines with the hydrogen to form hydrogen
sulfide gas which requires removal to avoid emission to the atmosphere.
This may be accomplished in several ways, often leading to recovery of
marketable byproduct sulfur compounds.
Some of the more commonly known processes are Gulfining,
HDS, RDS, VRDS, and ultrasweetening. Besides desulfurization treatments,
hydrogen processing includes selective hydrogenation treatment of certain
olefin or aromatic stocks and lube oil improvement. Finally, there are
combination processes such as ultrafining. A number of hydroprocessing
plant descriptions are contained in Ref. 5.A-2.
5.A.2.5 Rebuilding Processes
Several processes are used to rebuild various types of low
molecular weight of hydrocarbons into higher molecular weight species.
Alkylation and polymerization are processes in which unsaturated two-,
three-, and four-carbon atom gases are reacted in order to form high-octane
branched chain hydrocarbons for gasoline. The olefinic feedstocks are
usually cuts obtained from catalytic cracking. When olefins are added to
olefins, the product is called polymer gasoline. When an olefin is connected
5.A-5
-------
to a saturated molecule such as isobutane, the product is called alkylate.
Alky late finds extensive use in aviation gasoline.
5.A.2.6 Other Processes
Several other refinery processes were examined but do not
appear at this time to be significant factors relating to atmospheric emissions
in terms of volatile HC, CO, CO2> or NOx except, perhaps, from the stand-
point of requiring boiler-produced steam or direct-fired thermal energy.
These include the following:
a. Light oil treating
b. Lube, oil processing
c. Asphalt manufacture
d. Sulfur recovery
e. Wax forming operations
Coking processes involve relatively severe cracking for converting heavy
components (such as pitch and tar) into lighter products (such as gas oil and
coke) for fuel and other specialty uses. Two major processes are delayed
coking and fluid coking, the latter being a continuous fluidized bed circulation
flow process. In withdrawing the coke product from the system, some
entrainment of particulates does occur as the gases pass through the cyclone
separators and disperse to the atmosphere.
5.A.3 REFERENCES
5.A-1. W. L. Nelson, Petroleum Refinery Engineering,
4th ed. , McGraw Hill Book Co. , Inc., New York
(1958).
5.A-2. Hydrocarbon Processing, (1974 Refining Process
Handbook Issue) (September 1974).
5.A-6
-------
CONVERSION FACTORS
To Convert From
To Multiply By
Barrel (42 gallons) Cubic meters 1.590x10
British thermal unit Joules 1.055x10
Fahrenheit (temperature) Kelvin TK ^(TF + 459-
foot Meters 3.048 X 10" '
_3
gallon (U.S. liquid) Cubic meters 3.785 X 10
horsepower (sSO ^^} Watts 7.457 X 102
\ sec / a
inch Meters 2.54X10'2
lbf (pound force) Newtons 4.448 X 10°
lb (pound mass) Kilograms 4.536x10
m -2
Ton (short, 2000 pounds) Kilograms 9.072X10
2
lb per gallon Kilogram per cubic meters 1. 198 X 10
m -2
Cubic feet Cubic meters 2. 832 X 10
lb per cubic foot Kilograms per cubic meter 1.602x10
m r
Btu per ton Joules per kilogram 1. 163 X 10°
Btu per gallon Joules per cubic meter 2.787 X 10
4
Btu per cubic foot Joules per cubic meter 3.726 X 10
aExact.
CF-1
-------
GLOSSARY
ACR annual charge rate
API American Petroleum Institute
bhp brake horsepower
BTX benzene, toluene, xylene
CO carbon monoxide
EEI Edison Electric Institute
EPA Environmental Protection Agency
H_ hydrogen
HC hydrocarbons
1C internal combustion
KPPH thousands of pounds per hour
MMBtu/hr millions of British thermal units per hour
MSCC modified source classification code
N nitrogen
NEC not elsewhere classified
NEDS National Emissions Data System
nm nanometer (formerly millimicron)
NH, ammonia
NO oxides of nitrogen
G-l
-------
PART
PPM
SCC
vSIC
SO,
b
TACRP
particulate matter
parts per million
source classification code (NEDS),
standard industrial classification
sulfur dioxide
total annual charge rate projected
temperature, degree Fahrenheit
temperature, Kelvin
G-2
-------
TECHNICAL REPORT DATA
(Please read iHitnicnom on ike rc\ cnc be/ore completing)
1 REPORT NO
EPA-600/7-76-012
3 RECIPIENT'S ACCESSION'NO.
4 TITLE AND SUBTITLE
INVENTORY OF COMBUSTION-RELATED EMISSIONS
FROM STATIONARY SOURCES
5 REPORT DATE
September 1976
6. PERFORMING ORGANIZATION CODE
7 AUTHOR(S)
Owen W. Dykema and Vernon E. Kemp
8 PERFORMING ORGANIZATION REPORT NO.
ATR-76(7549)-l
9 PERFORMING OROANIZATION NAME AND ADDRESS
The Aerospace Corporation
Environment and Energy Conservation Division
El Segundo, California 90245
10 PROGRAM ELEMENT NO.
1AB014; ROAP 21ADG-089
11. CONTRACT/GRANT NO.,
Grant R803283-01
12 SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Phase: 7/74-7/75
14. SPONSORING AGENCY CODE
EPA-ORD
15.SUPPLEMENTARY NOTES iERL_RTp pr()ject officer for this report is R.E. Hall, Mail
Drop 65, 919/549-8411, Ext 2477.
. ABSTRACT The report describes the first year of a study covering the combustion-
related emissions inventory phase of a 3-year program entitled, "Analysis of NOx
Control in Stationary Sources." The study is aimed at assisting in the establishment
of priorities for detailed studies of techniques for the control of combustion-related
emissions from stationary sources. To develop the proper perspective, it was neces-
sary that the inventory include emissions of oxides of nitrogen, unburned hydrocarbons
carbon monoxide, and particulate, not only from recognized major stationary combus-
tion sources, but also from other stationary source categories in which combustion
plays a secondary role. During the first year of the study, emissions were established
for 1975 and 1980 from boilers, internal combustion engines, chemical manufacturing,
and petroleum refining. In the second year, comparative combustion-related emis-
sions data will be obtained for selected industries including evaporation and primary
metals. The third year will cover mineral products, secondary metals, and wood
products. This report identifies approximately 90 percent of all nitrogen oxide emis-
sions and from 40 to 50 percent of unburned hydrocarbons, carbon monoxide, and
particulate matter for stationary sources.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c COSATI Field/Group
Air Pollution
Exhaust Gases
Nitrogen Oxides
Carbon Monoxide
Dust
Hydrocarbons
Chemical Industry
Coal
Fuel Oil
Natural Gas
Boilers
Internal Combustion
Engines
Petroleum Refining
Air Pollution Control
Stationary Sources
Emissions Inventory
Particulate
13B
21B
07B
11G
07C
07A
21D
13A
21G
13H
18 DISTRIBUTION STATEMENT
Unlimited
19 SECURITY CLASS (ThisReport)
Unclassified
21 NC Or PAGES
180
20 SECURITY CLASS (Thispage)
Unclassified
22 PRICE
EPA Form 2220-1 (9-73)
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