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MEMORANDU

M TO : Plasti c Composite s NESHA P Pre-MAC T Teamand/o r Wor k

Grou p Member s FROM : Gre g LaFla m Pacifi c Environmenta l Services , Inc . (PES ) DATE : Jun e 28 , 199 5

L:\N30 8 SUBJECT : Summar y o f Vendo r Teleconferenc e Enclose d wit h thi s memorandu mi s a summary o f th e pre-MAC T teleconferenc e hel d o n Ma y 24 , 1995 . Tw o attachment s ar e included . On e i s th e technica l "fac t sheet " materia l fro m Grac e Te c Systems , whic h w e wer e no t abl e t o includ e i n th e packag e sen t ou t befor e th e meeting . Th e othe r summarize s writte n comment s receive d o n variou s aspect s o f th e pre-MAC T developmen t fromth e Februar y 7 , 199 5 meeting . An y additiona l comment s regardin g th e pre-MAC T proces s woul d b e welcom e a t an y time . Athir d meetin g i s planne d fo r the * en d o f Jul y t o discus s th e dat a bas e fo r som e o f th e fabricatio n processe s and t o explor e approache s fo r determinin g MAC T contro l levels . Yo u wil l b e notifie d o f th e dat e an d provide d wit h an

y additiona l informatio n neede d fo r th e meetin g a s soo n a s i t become s avail

able . Attachment s



## - a vr 

# W*. * f V' !P. 3

MEMORANDU

M TO : Madeleine Stru m U.S . Environmenta

l Protectio n Agency FROM : Kennet

h R . Meardo n an

d Greg LaFla

m Pacifi c Environmenta

l Services , Inc . DATE : Jun e 28 , 199 5 SUBJECT : Vendor

Pre-MAC T Teleconferenc e o n Ma y 24 , 199 5 I . Purpos e Th e purpos e of

thi s meeting wa s to brin g together fiv e vendor s of

contro l equip

men t t o receiv e informatio n o n their contro l system s an d t o discus s how thes e system s ma y b e applicabl e to th e reinforce d plasti c composite s industry . II . Locatio n o

f Teleconferenc e an

d Participant s Place : Date : U.S . Environmenta l Protectio n Agenc y N.C . Mutua

l Building , Roo

m63 8 Durham , Nort

h Carolin a Ma y 24 , 199 5 Participants : Bija n Etaian , Sout

h Coas t Air Qualit y Managemen

t Distric t (SCAQMD ) Moha n Balagopalan , SCAQM

D (909 ) 396-2704 Nanc y Pat e (fo r Jan e Caldwel

l EPA/AQSSD) * (919 ) 541-032 8 Lis aConner , OAQPS/AQSS D (919 ) 541-506 0 Bo b Fegley , EPA/ORD * (202 ) 260-048 4 Christin e McPhee , Ohi o EPA * (216 ) 963-120 5 Nor mKaplan , EPA/ORD * (919 ) 541-255 6 Stev e McNally , Composit

e Fabricator s Association * (703 ) 524-333 2 Arnol d Medbery , EPA/OSDBU * (703 ) 305-517 1 Richar d Nielson , Clar

k County , Nevada * (702 ) 383-127 6 Carlo s Nunez , EPA/ORD * (919 ) 541-115 6 Joh n Schweitzer , Composite s Institut e (313 ) 668-470 3 Jorda n Spooner , OPPT/PPD * (202 ) 260-441 8 Pau l Blystone , Purus , Inc . (408 ) 955-102 9 Magnu s Danielsson , Weatherly Inc . (404 ) 873-503 0P. 4

Dr . Madeleine Stru

m Jun e 28 , 199 5 Pag e 2
Ander s Munters , AMT , Inc . (813 ) 540-000 6 Lor i Coenen , Grac e Te c System s (414 ) 339-278 9 Ronald Sundberg , SETC O Inc . (612 ) 824-109 3 Da n Boyd , industr

y consultant

(410 ) 827-624

4 Joh n Glunn , Florid aDE P (904 ) 488-011 4 Bet h Harden , Florid aDEP Cleav e Holiday , Florid aDEP Gedde s Ramsey , EPA/OR D (919 ) 541-796 3 Madeleine Strum , EPA/ESD * (919 ) 541-238 3 WanitaDunston , EP

A inter n (919 ) 541-230 6 Mar k Banner , RT

I (919 ) 541-601 6 Emor y Kong , RT

I (919 ) 541-596 4 Gre g LaFlam , PE S (919 ) 941-033 3 Ke n Meardon , PE S (919 ) 941-033 3 Indicate s apre-MAC T tea

mand/o r EP A Wor k Grou p member . III . Discussio n Ms . Stru masked Joh

n Schweitzer , Composite s Institute , and Stev e McNally , Composit e Fabricator s Association , t o review th e segment s o f th e industr

y tha t their respectiv e association s represent . Mr . Schweitze r stated tha t their member s are associate d witii compressio n molding , pultrusion , an d fabrication of

corrosion-resistin g resin equip

ment . Mr . McNall

y state d tha

t their member s are associate d wit h filamen t winding , ope

n molding , han

d layup , an

d corrosio n work . He als o offere d t o arrang e plan t

tour s a t subject facilitie s fo

r an y membe r of th e pre-MAC T tea

mto se e ho w th e regulatio n migh

t affec t actua l processes . Nor

mKapla n expresse d interest , an

d Mr . McNall

y sai d tha t h e will contac t Mr . Kapla

n fo r aplan t visi t somewher

e i n centra l Nort h Carolina . Mr . Schweitzer/Mr . McNall y noted tha

t the Clea n Ai r Managemen

t Partnership , comprise d o

f fou r trad e associations , wa s forme d abou t 4 o r 5 year s ag o in respons e to th e 199 0 Clea n Ai r Act Amendment s to hel

p th e EP A in th e developmen

t of th e MAC T standard s affectin

g reinforce d plasti c composite s manufacturing . Mr . Schweitze r estimate d tha t the Composite s Institut

e an d th e CF A includ e probably a

t leas t 1 5 percent

of al l fabricator s a s members , and provid e agoo d representatio n o f th e entire industry .P. 5

Dr . Madeleine Stru

m Jun e 28 , 199 5 Pag e 3

MAGNUS DANIELSSON . WEATHERL Y INC . Mr . Danielsso n state

d tha t their company' s technolog y wa s develope d i n Sweden i n th e lat e 1970's/earl y 1980's . The y us e auniqu e adsorbent , Bonopore , develope d an d patente d by our

Swedish subsidiary , Chematu r Engineerin g an

d Nobe l Chemicals . Th e proces s ca n b e use d eithe

r a s apre-concentrato r

o r fo r solven t recovery . Th e equipment i s composed of

fou r t o si x fluidize d beds , an

d i s abl e to utiliz e 10

0 percent of th e adsor

bent' s capacit

y (rathe r tha n partia l capacity) . Th e adsorben t i s fe d t o adesorber

where th e capture d VOC s are released . I n th e pre-concentratio n mode , th e temperatur e use d t o desor b i s approximately 300° F an d th e reduce d ai r

volum e goe s to acatalyti c oxidize r fo r destructio n o

f th e VOCs . Whe

n th e equipmen

t i s use d fo

r solven t recovery , amovin g be d desorbe r i s used . W

e developed the solven

t recover y uni t first an d the n di e pre-concentra tor . Mr . Danielsso n note d tha t the y currentl y hav e installation s i n Europ e runnin g o f styrene emission s ~ one pre-concentrator and fou r solven t recovery . Th e firs t

wa s installe d i n 198 9 an d i s still operating , wit

h n o changeout

o f th e adsorbent

to date . The operatin g cost s o

f the system s essentially include onl y th e electricit

y require d t o pul l the wast e ga s strea mthroug h the adsorber . Fo r

20,00 0 cfm , thi s cos t

i s les s tha

n $60,00 0 pe

r year , assuming 2

4 hour s per

day , 36 5 day s per

yea r of operation . Question s an

d Answer s Carlo s Nunez : Ho

w muc h attritio n i s there per

yea r fo r th e fluidized bed ? Magnus : Approximately 5 % pe r year . Thi s i s asmal

l cos t an d i s include d i n th e estimate o f operatin g cost s abov e (i.e. , $60,00 0 pe r yea r fo r a20,00 0 cf

msystem) . Carlos : Wha

t i s th e concentratio n range ? Magnus : Fo r

th e preconcentrator , les s tha n 30 0 pp ma s styrene . I t

handle s avariet

y o f flow s an d i s mos t cos t effective wit

h flow s greater

tha n 10,00 0 cfm . Nor mKaplan : Wha

t are th e cos t

effectivenes s number s fo

r th e system ? Magnus : Around $70 0 pe r ton fo r 8,76 0 hour s per

yea r o f operatio n and aroun d $1,50 0 pe r ton fo r 3,00 0 hour s pe

r yea r o f operation .P. 6

Dr . Madeleine Stru

m Jun e 28 , 199 5 Page 4
Carlos : Wha

t i s th e capita

l investmen

t cost ? Magnus : Aroun d $2 5 pe

r cf mfo r a20,00 0 cf

munit , fo r instance . Fro mthere , th e cos t per cf mgoe s u p fo r smalle r unit s an d goe s down fo

r large r units . Norm : Wha

t capitalizatio n facto

r wa s use d to annualiz e the costs ? Magnus : Around 0.16 3 (1 0 percent interest , 1 0 year s life) . Gre g LaFlam : Whic

h processe s i

n th e categor

y could thi s syste

mb e used on ? Magnus : An y operatio n fro mwhich styren e emission s nee d to b e controlled . Typ e o f operatio n i s not

important . W

e recommen

d preconcentratio n followed by oxidation . Da n Boyd : O n wha

t type s of processe s hav e preconcentrator s bee n installed ? Magnus : Thos e tha

t manufactur

e septi c tank s - ope

n spra y bo x wit h apolyester

resi n an d fiberglass . Flo w i s around 10 0 ppma t 12,50 0 cfm , operatin g 1 shif t pe r day , 8 hour s per day . Thi s syste

muse d t o b e asolven

t recover y system , but

wa s modified to no w b e a preconcentrato r

followe d b y combustion . Th e efficiency o f th e syste mincrease d following the chang e fro

maround 90 % to 97% . No downtim e ha s occurre d wit

h th e syste

myet . Dan : Ar e an y system s bein g considere d fo r installatio n i n th e Unite d States ? Magnus : Yes , quit

e afew . Cannot

tell yo u wher e a t thi s time , but

should b e abl e t o provid e informatio n i

n afe w months . Stev e McNally : Fo r

the preconcentrato r

system , doe s th e incineratio n uni t ad d mor e cost ? Magnus : Th e cos t

o f the incineratio n uni t

wa s include d i

n th e capita

l cos t state d earlier . I t run s between 1 5 an

d 2 0 percen

t o f th e tota l capita l costs . Mar k Banner : Fo r

the syste mtha t treat s 12,50 0 cfm , wha

t i s th e flo w to th e incinerator ? Magnus : Around 50 0 cf

mi s goin g t

o th e incinerato r

afte r the preconcentrator . Dan : Th e plastic s composit e industr y ha s facilitie s wit

h flows of severa l hundre d thousan d cfm . I s thi s aproblemfo

r you r system ?P. 7

Dr . Madeleine Stru

m Jun e 28 , 199 5 Pag e 5 Magnus : No t

really . Bu

t tha t i s alarg e flow t o handle . Th e facilitie s shoul d first se e if ther e i s anythin g tha

t could b e done to reduc e the flow . T o handl e 200,00 0 cfm , w e woul d probably install fiv

e o r si x adsorber s i

n parallel . Dan : Occupationa

l exposur e limit s requir

e tha t larg e flow rate s b e maintaine d i n th e wor k area . Madeleine Strum : Wha

t are th e workplac e styren e concentratio n leve l standard s i n Sweden ? Magnus : I

n Swede n i t i s abou t 2 5 pp mpossibly . Concentration s fro mth e spra

y booth s are aroun d 10

0 ppm . Moha n Balagopalan : Wha

t i s th e efficiency o

f th e uni t handlin g 10

0 ppm ? Magnus : 9 7 percent

a t 10 0 pp minlet concentration . Richar d Nielson : Wha

t i s di e larges t

strea mo n which on e o f

you r system s ha s bee n installed ? Magnus : 35,00 0 cf

ma t thi s time ; it s concentratio n i s aroun d 100 ppm . John : Yo u hav e fiv e unit s i n operatio n i

n Europe . Wh

y not more ? Magnus : Goo d question ; I do no t know . Carlos : Ho

w are the bed s regenerated ? Magnus : I

n afluidized bed wit

h war mair , heate d wit

h ai r fro mth e oxidizer , a t

aroun d 300°F . Pulle d through the bed , th e VOC i s release d int o th e smalle

r ai r stream . Carlos : I s there an

y polymerizatio n i

n th e bed ? Magnus : W

e hav e neve

r see n any . Carlos : Ho

w wa s efficienc

y measured i

n thes e systems ? Magnus : Carbo n tube , Tedla r bags , GC , FID . Mohan : Wha

t are th e condition s of

th e oxidizer ?P. 8

Dr . Madelein

e Strum Jun e 28 , 199 5 Pag e 6 Magnus : Th e oxidizer

used i s astandar

d one availabl e o n th e market . I f i t i s arecupera tiv e system , th e residenc e time i s > 1 second . Norm : Ther

e i s a199 2 uni t

installe d i n Denmark . Wh

y hav e yo u focuse d o n th e 12,50 0 cf munit ? Magnus : Th e uni t

i n Denmar k i s asolven

t recover y uni t tha t i s undergoin g modificatio n t o apreconcentratio n unit . They hav e no t been abl e t o re-us e th e recovere d solvent . Norm : I s th e flo

w to th e adsorbe

r constant ? Magnus : Th e flo

w i s constant , but

the concentratio n i s not

constant . Th e flo

w and concentratio n to th e oxidizer are constant , however . Emory : Wha

t about th e adsorbe

r being abl e to handl e non-constan t flows? Magnus : Capacit

y o f th e adsorbe

r i s designed to handl e pea

k flow. S o i

f i t i s designe d correctly , there i s n o problem . Carlos : I s ther

e abuffe r to equaliz e the concentratio n t o th e adsorber ? Magnus : There i s no buffe r to smoot h out th e concentratio n peaks . Th e syste muse s fou

r t o si x beds . Norm : For

th e solven t recover y systems , wh

y can' t th e solven

t b e reused ? Magnus : I

n th e adsorber , w e us e air instea d of nitrogen . A s aresult , ther e i s som e oxidatio n o

f styrene . Thi s create s som e discoloratio n o f

th e recovere d solvent . Madeleine : Wha

t i s th e siz e o f

th e facilitie s o n which you hav e thes e systems ? Magnus : I do not

know . I ca

n researc h tha t and get bac k t o you . Rich : I understand tha

t you hav e ru

n som e test s i n either Nort h Carolin ao r

Sout h Carolina . Ca

n yo u summariz e th e highlight s of thos e tests , th e goo d an

d di e bad ? Magnus : Yes , w e ra

n som e test s i n Novembe

r 1992 . We only ha

d recover y unit s at tha t time . Positiv e highlight s included : syste mreact s slowl

y to up s an

d down s an

d aroun d 9 5 % efficiency wit

h recover y system .P. 9

Dr . Madeleine Stru

m Jun e 28 , 199 5 Pag e 7
Rich : Wha

t wa s th e cos t

effectivenes s of

th e unit ? Magnus : Should b e i

n the report . Simila

r number s t

o thos e tha

t I noted earlier . Dan : I thin

k the tes t wa s a t Wilson, ' N

C fo r ableed syste

mwidi low cfm . Magnus : Tha

t i s correct . It

wa s asli p strea mfro maspra y booth . John : I jus t

wanted to point

out a t dii s time tha

t industr y ha s alo t

o f informatio n o n uies e topics , an d tha t silenc e o n ou

r par t should not

b e interprete d a s agreement wit h wha t i s bein g said . Carlos : Whe

n wil l industr y provide thi s information ? John : Whe

n appropriate . W

e wil l shar e i t wit h the vendors , and welcom e furthe r opportunit y t o discus s thes e technologies . PAU L BLYSTONE . PURU S INC . Th e PURU S syste

mi s calle d PADRE , an

d i s base d o n adsorption . Th e syste mi s smal l relativ e t o the need s of

th e plasti c composite s industry , wit h th e larges t

curren t installatio n handling around 7,00 0 cfm . Th e PADR E syste muse s fixed be d adsorbers . The y hav e around 5 0 installations , mostl y o n remediatio n technologies/processe s (e.g. , chlorinate d solvents ) a

t Superfun d sites , but

are branchin g out

into som e industria l application s (e.g. , pain

t spra y booths) . Their

syste mcoul d possibly b e use d fo r smal l flo w majo r source s i n the future , especially in th e long-ter ma s industr

y reduce s flows. Th e technology use s fixed beds , wit h one adsorbe

r on-lin e whil e th e othe r

i s either desorbin g o r

on standby . Vacuu

man d temperatur

e (_<18 0 degree s C ) ar e use d t o achiev e the desorption . The exac t "recipe " depend s on th e compound s bein g treated . They us e fou r differen t typ e of adsorbents , provide d b y Roh m& Haa s an d b y Dow . A 2-stag e condense r i s use d t o recove r the desorbe d VOC a s aliquid . There are afe w case s wher

e their customer s are routin g th e offgas t o a n oxidizer . A s acompany , Puru s strictl y sell s their unit s a s recover

y systems . The y have conducted tw o pilo t tests . On

e wa s awastewate

r stripper , which ha

d bee n a n ai r strippe r followe d b y acarbo n adsorber , a

t afacilit y ma t manufacture s styrene . Thi s pilo t tes t ra n int o cos t problem s and adsorben

t problem s (the adsorbent

los t capacit yP.1 0

Dr . Madeleine Stru

m Jun e 28 , 199 5 Pag e 8
afte r 1 o r 2 desorptio n cycles) . It

wa s treatin g asli

p strea mwit h aconcentratio n of

1 5 t o 2 0 pp mof amixtur e o f volatile s an

d wate r vapor . Fo r

thi s facility , they coul d retur n th e recovere d strea

mbac k into th e feedstock

a s qualit y contro l wa s not

a s importan

t afacto r i n th e manufactur

e of styrene . Th e secon d pilo t tes t wa s fo r acomposit

e manufacturing facilit

y an d som

e molding . A sli p strea

m[around 15 0 cf

mand 1 0 t o 10

0 pp m(spikes) ] of

f o f th e mai n strea

mwa s treated . A

t thi s pilo t test , the y measure d th e adsorptio n capacit y of th e be d ove

r time , an d sa w no dro p i

n adsorptio n capacit

y ove r multipl e desorptio n cycles . Th e recovere d produc t wa s slightly off-colo

r (du e t o water) . A secon

d recover y ste p i s likely t o b e needed befor e i t coul d b e reused . Th e abilit y t o reus e the solven

t i s stil l a n open question , an

d ma y b e th e ke y to us e o f the syste mi n thi s industr

y du e t o the high valu e of

th e recovere d styrene . Question s an

d Answer s Carlos : Wha

t i s the cos t

of the syste mi n term s o f $/cf mand $/to n o

f recovere d material ? Paul : Fo r chlorinate d solvents , aroun d $0.5 0 t o $1.00/lb to get

operatin g cos t

fo r recovery . For

large r systems , nee

d $1 5 to $25/cf

mcapita l cost . Anticipat

e tha t Puru s would fal l int o thi s range . Carlos : Ho

w muc h adsorben

t need s to b e replaced using th e fixed bed technology ? Paul : D o no

t know . Longes t

runnin g syste

mi s 3 year s ol d and s o fa r no replacemen

t ha s bee n needed . The resin use

d i n th e syste

mi s abou t lO x th e cos t fo r activate d carbon . Unde r accelerate d lif

e tests , ther

e i s stil l n o indication o

f los s of adsorben t capacity . Norm : Have the

y installe d asyste

mto contro l styrene emissions ? Paul : No . The

y have apilo t

test , however , o

f les s tha n 3 month s o n astyren e emissio n stream . Carlos : Wha

t i s the siz e of

th e particle s i

n th e bed ? Paul : The y are abou

t the siz e o f a"BB " pellet . Th e manufacturer s are tryin g to increas e th e size . Carlos : Wha

t abou t surfac e area ?P.1 1

Dr . Madeleine Strum Jun e 28 , 1995 Pag e 9 Paul : Don' t

know . Ca

n refe r t o th e technica l sheets . The

y hav e excellent

surfac e are a relativ e to carbon . There i s n o as h conten t to ac t a s acatalyst . Carlos : Wha

t about moisture ? Doe s relativ e humidit y affec t performance ? Paul : Varie s dependin g on the adsorbent . Dow , fo r example , ha s aresi n fo

r keton e recover y tha t i s mor e pola r tha n other s an

d thu s ha s ahighe

r affinit y fo r water . However , relativ e to carbon , al l o

f th e adsorbent s w e us e are hydrophobic . Carlos : Wit

h carbon , to o hig

h ahumidit

y leve l result s in moistur

e aroun d th e carbon , whic h adversely affect s adsorptio n capabilities . Paul : True , unles s tryin g to recover y methanol . Christin e McPhee : Wha

t sor t o f contro l syste

mparameter s ca

n b e monitore d t o ensure efficiency o f

th e system s bein g discussed today ? Paul : Possibl

y som e sor t o f styrene monitor . Coul d lo g desorptio n temperature s an d cycles , o r measur e styren e influen

t an d effluent . A

t th e secon d pilo t test , w e looke d at

a Foxboro analyzer , which seeme d to perfor

mwell . Other

parameter s (temperature , cycl e time , vacuu

mlevel ) coul d b e recorded . Norm : You

r cos t effectivenes s estimat

e seem s t o b e an order

o f magnitude higher

tha n reporte d b y Magnus . Paul : Th e numbe r I reporte d i s fo

r capita l cost , not operatin g cost . Magnus : I

f w e built smalle r system s lik

e Paul's , w e would probably hav e cos t effective

nes s value s i

n the sam e ballpar k a s his . Carlos : Th e contro l devic e i s onl y goo d a s th e capture efficiency . Paul : I canno t

really spea

k fo r thi s industry , but

elsewher e captur e efficiency seem s prett

y good . A t alarg e auto assembl

y plan t i n Lo s Angeles , paint

spra y booth s (250,00 0 ppm ) recirculat e 90 % o f ai r an d still maintai

n negativ e pressure an

d protectio n of

workers . Thi s reduce s flo

w b y a n order o f magnitud e befor e treating . Question : Isn' t

thi s a n unfai r comparison ?P.1 2

Dr . Madeleine Stru

m Jun e 28 , 199 5 Pag e 1 0
Paul : Yes . Thi s industr

y ma y no t hav e th e sam

e resource s to desig n suc

h recirculatio n systems . I hav e see

n other industrie s wher

e i t i s done . Mayb e SPI coul d lea d th e wa y fo r the smalle r facilities . RO N SUNDBERG . SETC Q Ou r system s (MIA

B o f Sweden ) ar e fixed be d concentrator s fo

r intermittent application s usin g acarbo n filter media . MIA

B use s carbon adsorptio n an d desorptio n wit h war mai r t o concentrate dilut

e solven t vapor s to amuc

h smalle r ai r strea mfo r efficien t destructio n i

n acatalyti c incinerator . Using thi s process , the solven t ca n als o b e recovered . MIA B ha s tw o produc t

lines , a n intermittent

dut y uni t an d acontinuou s dut

y unit . Th e intermittent

dut y MIA B F i s based o n a

n activate d carbo n fixed bed adsorber . Th e continuou s dut

y MIA B C use s afluidized bed adsorbe r wit h activate d carbo n a s th e adsorbent . MIA B F . Installation s ffl

an d # 2 o n Dat aSheet s Th e intermittent

dut y unit , the MIA

B F solven

t filter, use s afixed bed carbo n adsorber . Durin g th e wor k day , the MIA

B F solven

t filte r clean s the solven

t vapor s fro

m th e ventilatio n air . Afte

r th e wor k shif t i s complete , the solven

t filte r i s shu t dow n fo r desorption . Th e MIA

B F use s war

mai r to desor b th e carbo n bed , typically over a14-hou r period . I f mor e tha n one wor k shif t i s required , tw o MIA

B F unit s are operate d i n parallel ; whil e on e be

d i s being desorbed , th e other i s cleaning th e ai r

stream . Th e norma

l inle t concentratio n fo

r th e MIA B F i s 0. 2 g/m 3 to 0. 6 g/m 3 of solvent . Th e activate d carbo n be

d o f the MIA B F i s configured s o tha

t whe n i t i s desorbe d wit h war mair , th e solven

t vapor concentratio n in th e stri

p ga s i s a t aconstant

level , typically a t 4 t o 6 g/m 3

. Th e iniqu e configuratio n o f th e MIA B F eliminate s th e initia

l pea k i n concentratio n tha

t occur s whe

n acarbo n bed of

traditiona l desig n i s desorbe d wit

h war mair . A t th e 4 t o 6 g/

mconcentration , th e solven t ca n b e efficientl

y destroye d in a catalyti c incinerato r

without supplementa

l fuel . A constan

t concentratio n of

solven t i n th e stri p ai r strea mtha t i s treate d by th e catalyti c incinerato r i s ver y importan

t fo r safe , economica l incineratio n o

f the solvent . Tw o application s o

f the MIA B F to th e contro l of

styrene are presente d o n pag e 1 o f th e Fac t Sheet s submitted . Th e first applicatio n (#1 ) i s a

t 23,00 0 cf mwit h 96 % of th eP.1 3

Dr . Madeleine Stru

m Jun e 28 , 199 5 Pag e 1 1
solven t i n th e 23,00 0 cf

mstrea mdestroye d i

n acatalyti c incinerator . Th e uni t ha s bee n operatin g sinc e 1992 . The carbon was change d afte r 2 years . I n th e second application , 93 % o f th e styren e i s recovered . Th e MIAB F clean s 18,00 0 cf ma t aconcentratio n o

f 3 0 ppm v of styrene . I

n th e solven

t recover y process , th e MIA B F i s use d a s apre-concentrator ahea d of anothe r fixed carbo n bed . Th e MIA B F i s desorbe d wit

h war mai r int o th e secon

d bed . Th e second be d i s desorbe d b y indirec t heatin g wit

h stea man d usin g a n ai r strip gas . Usin g thi s process , aver y hig h concentra tio n of solven t ca n b e obtaine d an

d ultimately condense d fro mth e final stri p gas . Th e styren e recovere d i s destroye d an d no t reuse d sinc e th e supplie

r woul d no t

guarante e th e qualit y o f th e recovere d material . The uni t wa s installe d i

n 199 1 and i t

i s stil l operatin g wit h th e origina

l carbon . MIA

B C . Installation s 3 an

d 4 Th e continuou s dut

y MIA B concentrator

i s base d o n afluidized be d usin g activate d carbo n a s th e adsorbent . I believ e tha t MIA B i s th e only firmtha

t ha s successfull

y use d activate d carbo n i

n afluidize

d bed , an d th e onl y firmtha t seem s confiden

t i n usin g carbo n adsorptio n t

o contro l styrene vapors . The war mai r desorptio n approac h apparentl y avoid s th e problemo

f the styren e polymerizin g on th e carbon . A t present w e d o no t

hav e aful

l scal e commercia

l installatio n o

f th e MIA B C ; however , we hav e jus t complete d a3-mont

h pilo t tes t o n styren e i

n Swede n ( ates t repor t i s available) . Thi s pilo t

tes t i s th e applicatio n tha t i s presente d o n th e secon

d fac t shee t (#3) . We hav e als o include d apropose d installatio n (#4 ) t

o sho w the projecte d performanc e an d cos t of aful l scal e unit . Th e MIA B C ha s thre e majo

r components : afluidized bed adsorptio n section , a fluidize d bed desorptio n section , an d acatalyti c incinerator . Th e ai r strea menter s th e adsorptio n sectio n consistin g o f thre e fluidized stage s o f

activate d carbo n in series . Typically , th

e adsorptio n section i s designed to remov e ove r 90 % of th e solvent

fro mth e ai r stream , but

ca n b e designed fo

r highe r remova l efficiencies . Th e activate d carbon migrate s between th e adsorptio n section , where th e incomin g ai r i s purified , an

d the desorptio n section , wher e th e carbo n i s regenerated . Th e carbo n continuously passe s through the desorptio n bed an d i s recycle d bac k

to th e adsorptio n sections . Th e desorptio n section i s anothe r fluidized bed an

d use s asmall strea

mof war m strip ga s t o fluidiz e the carbon adsorbent . Th e war mstrip ga s remove s th e solvent fro m th e carbo n adsorbent . Th e carbo n i s recirculate d t o th e adsorptio n sectio n throug h a pneumati c tube . A valv e regulate s the recirculatin g flow of adsorben t withi n th e syste

m an d thu s ca n b e use d t o mak e adjustments i

n performance .P. M

Dr . Madeleine Stru

m Jun e 28 , 199 5 Pag e 1 2 Question s and Answer s Mohan : Wha

t are th e capacitie s o

f th e facilitie s o n which yo

u hav e installe d your

equip

ment ? Ron : The MIA

B F fixed bed uni t

ha s bee n installe d a

t 23,00 0 and 18,00 0 cfm . I t ha s bee n designed t

o fit a n inle t ai r flo w rang e o f u p to 50,00 0 cf

musing singl e units . Th e tw o application s cite d are a t inlet concentration s of

2 0 to 2 5 ppmv ; however , th e desig n concentratio n ca

n b e a s hig

h a s 0. 2 g/m 3 t

o 0. 6 g/m 3

. Carlos : Whe

n d o th e bed s chang e cycle ? Ron : The MIA

B F i s sized to operate ove r one shif t and desor

b ove r th e nex t 1 4 hours . Greg : Ca n yo u recommend an

y parameter s fo

r monitoring ? Ron : I assum

e yo u coul d monitor

dataon the operatio n of

th e catalyti c incinerator . Typically , an

y supplementa

l energ y neede

d fo r complet e oxidatio n i s adde d b y a

n electri c heater , or b y natura l gas . Unde

r norma l operatio n an

d afte r ashor t startup , no supplemen

ta l energy i s needed . Thus , i f th e amoun

t o f solven t i n th e strip ga s wer

e t o decreas e becaus e of los s of adsorptio n capacity , the amoun t o f supplementa

l energy needed fo

r destructio n of

th e solven

t would increase . This , of

course , assume s tha

t condition s i n th e proces s being controlle d remai n somewha t constant . Madeleine : Wha

t happen s to th e recovered styrene ? Ron : I n the cas e cited , i

t i s haule d of

f an d burned . Th e qualit

y of th e styrene coul d no t b e guaranteed . I d o not

kno w if th e recovered styren e qualifie s a s ahazardou s waste . Carlos : Could i

t b e use d a s afue l fo r the catalyti c oxidizer ? Ron : I assum

e i t coul d be . Christine : Wha

t i s the concentratio n o

f th e recovere d styrene ? Ron : I t i s al l styren e excep t

fo r moistur e fro mth e ambien

t ai r tha t i s adsorbe d o n th e carbon bed . I don' t

know th e qualit

y sinc e i t i s burned . Mohan : Wha

t i s the cos t

of replacin g the carbon ?P.1 5

Dr . Madeleine Stru

m Jun e 28 , 199 5 Pag e 1 3

Ron : Th e carbo n replacemen

t cos t i s no t included in th e cost s presente d in th e dat asheets ; however , i t

i s relatively small . For

th e fluidized bed i t

woul d b e around 1 % o f

operatin g costs . W e will hav e asmal

l (1,00 0 cfm

) tes t uni t availabl e and ar e looking fo r a n applicatio n i

n th e United States . Carlos : Wha

t ca n we d o t o hel

p yo u in findin g ademonstratio n site ? Ron : W e would appreciat

e your assistance . I would lik

e to pursu e thi s furthe

r afte r th e conference . Carlos : Wha

t i s th e sourc e o f you r carbon ? Ron : I understand i

t i s astandar

d crushed carbo n mad

e fro mcocoanut

shells . Norm : Referrin g t

o your graphic , ho

w d o yo u maintai n aconstant

concentratio n o f

styren e i n the gas ? Ron : W e d o not us e buffer s t o smoot

h th e peaks . Th e unifor

msolven t concentratio n result s fro mth e physica

l configuratio n of

th e carbo n be d an d ho w th e strip ga s flow s throug h the bed . I

t woul d b e easies t

t o describ e b y sending yo

u som e patent sketches . 

### LOR I COENEN . GRAC E TE C SYSTEM S Grac e Te c System s ha s ove r 1,60 0 oxidatio n system s (catalyti c and thermal ) controllin g emission s fro

msuc h industrie s a s graphi c arts , printing , an d specialize d applications . W

e hav e bee

n i n th e oxidize

r marke t sinc e 1970 . Currently , w e d o no t hav e an y application s controllin g styren e emissions , but generall y handl e most

VOCs . Th e Enterpris e Syste

mi s atherma

l regenerativ e syste

mwit h cerami c medi afo

r th e hea t exchange . Th e syste

mi s use d fo r VOC an d odo r

control . I t

convert s organic s t o C0 2 an d water , wit

h a95 % therma

l efficiency , an

d w e will guarante e a98 % VO C destructio n efficiency . Air enter s throug

h a n inlet manifold , an d i t

i s then preheate d i n th e cerami c media , then enter s th e combustion chamber , an d exit s throug h asecond be d o f cerami c media , wit

h a n outle t temperatur

e onl y slightly higher

tha n th e inlet temperature. The minimu

mresidenc e tim

e i s 1 second .P.1 6

Dr . Madelein e Stru

m Jun e 28 , 199 5 Pag e 1 4 Question s an

d Answer s Madeleine : I understand tha t there i s apropose d unit

fo r apip e manufacture

r using moldin g processe s an

d fiberglas s reinforce d plasti c parts . Lori : Yes , i

n Texas . I

t would b e handlin g 10,00 0 cfm . The proposa l wen t out i n Novembe r and we hav e been aske d fo r are-quot e recently . The proces s emit s aroun d 2 pound s of styren e pe

r hour . Steve : Ca

n yo u revie w th e cost s of

you r units ? Lori : Fo r the 10,00 0 cf

munit , capita

l cost s woul

d b e abou t $280,00 0 o r

$28/cfm . Fo r

a 50,00 0 cf munit , the capita

l cost s would dro p t

o abou t $1 4 o r $1 5 pe r cfm . A t highe r solven t loadings , th e unit

become s self-sustaining except fo r electricity . Steve : Wha

t abou t th e cost s fo

r the uni t propose d i

n Texas ? Lori : Annua

l cost s wer

e estimate d to b e around $ 6 per hour to operate a

t 2 8 lbs/hr loadin g fo r 10,00 0 cf mflow . Thi s i s equivalen t to abou t $5.1 0 pe r cf moperatin g costs . ANDER S MUNTERS . AM T INC . Mr . Munter s represent s Bioclea n fro mSweden . The

y brought thei r biofilte r onto th e market

i n 198 9 afte

r 1 0 year s o

f research . Th e biofilte

r use s microorganism s to clea n th e air , an d i s being use

d i n avariet y of applications . Bioclea n experimente d wit

h variou s media , an

d mostl y use s amedi acomposed of peat , moss , an

d bark . A ver

y importan

t par t o f abiofilte r i s to ensur

e tha t th e moistur

e content i s correct . An

y problem s tha

t the y hav e encountere d hav e bee n th e result o f "channeling, " wher

e area s of the biofilte

r dr y out an d th e ai r wil l funne

l out of th e dr y areas . Biofilter s brea

k the VOC dow

n int o C0 2 an d water , an

d will remov e odor s an

d mos t organics . Aliphati c solvent s including ethanol , acetane , isopropy l alcohol , methy l ethy l ketone , an

d methylformiat

e are exceptionally degradable . Aromates , merkaptanes , an d other aliphati c solvent s wit

h large r molecule s tha

n 6 C-atom s degrad e a

t aslowe r rate . Som e ver y stabl e solvent s i

n hig h concentration s suc

h a s benzene ca

n b e difficult

to degrade . Stabl e solvent s sometime s brea k down mor

e easily through co-metabolis m(in conjunctio n wit

h othe r solvents) . Chlorinate d hydrocarbon s are degradabl e wit h tw o o rP.1 7

Dr . Madeleine Strum Jun e 28 , 199 5 Page 1 5
les s chlorin e atom s present . I n general , efficiencie s of

u p to 99 % ca

n b e achieved , bu t suc h system s are no

t alway s th e most economical . Question s and Answer s Question : Styren e ha s 8 carbons . Wha t kin d o f efficiencie s hav e yo

u see n fo r styrene ? Anders : Goo d results , 9 0 to 9 5 percent . Question : Wha

t type s of operation s hav e yo

u installe d th e biofilter s on ? Anders : W

e hav e application s on pharmaceutica l plants , POTWs , on e manufacture r o f top s fo r picku p trucks , an

d variou s others . Th e manufacture r o f th e truc k top s turn s ou t abou t 2,00 0 part s pe r

year . The

y us e spra y an d hand layup , operatin g 8 hour s pe r da y wit h 2 week s of

f i n th e summer . Eve

n though th e filter s are not used fo r 2 week s i n th e summer , the

y com e back , eve

n afte r a s muc h a s 4 week s o f

downtime . Thi s particula r filte r i s designe d fo

r 8 5 % efficienc

y (doing fine) fo

r 10,00 0 ppm . Mohan : Som

e bakerie s hav e purchased biofilters . Carlos : I understan d tha

t biofilter s nee

d alarg e amoun

t o f spac e to accommodat

e them . Anders : The standar

d filter i s contained i

n a20-foot

shippin g container ; they ca n b e stacked thre e high . Thi s reduce s th e amoun t of s q f t required . W e hav e apatente d combinatio n unit

(fo r 1 t o 2 shifts pe

r day ) wit h acarbo n adsorber . W

e us e th e carbo n adsorbe r first, an d i t i s the n desorbed through the biofilter . W e hav e installe d thi s combinatio n uni t

on tw o o r

thre e pain

t operations . Norm : Wha

t are th e flo

w rate s fro

mthe carbo n adsorber

t o th e biofilter ? I assume they ar e reduced ? Anders : Th e carbo n adsorbe r doe s ac t a s aconcentrator . It

basically stretche s th e time , storing th e VOC s fo

r 8 hour s an

d the n releasin g the

mt o th e biofilte

r over th e next 1 6 hours . Christine : Wha

t operatin g parameter s coul d b e monitore d t o ensur e efficiency of

th e biofilter ? Anders : Th e biofilte

r i s afairl y simple piec e of

equipment . Contro l o f

moistur e i n th e filter i s mos t importan t to it s performance . A fa

n pull s th e ai r

through th e filter. Onc e th eP.1 8

Dr . Madeleine Stru

m Jun e 28 , 199 5 Pag e 1 6 syste mpasse s it s initia

l performanc e test , ther

e i s no t muc h nee d t o check anythin g t o ensur e i t i s working correctly . Som e customer s hav e continuou s monitor s o r run check s o f moistur e content . Carlos : Wha

t factor s ar e critica

l to monitor

performance ? Anders : I d

o no t know . I f yo u hav e th e correc t

moisture , th e biofilte

r works . W

e hav e a built-i n PL

C tha t monitor s and control s the moistur e content . Christine : Wha

t els e d o customer s loo

k for ? Anders : The

y chec k pressur e dro p ove

r the filters , pH , an

d ca n tak e asimpl e bacteri a count . Norm : Wha

t abou t temperature ? Anders : Ther

e i s som e temperature rise . Yo

u coul d monitor

that . I f you put les s in , though , yo

u ge t asmalle r temperatur

e rise , but th e biofilte

r i s stil l workin g properly . Oftentime s yo

u ca n smel l whethe r o r no t the biofilte

r i s working . Paul : For bioremediation , on e ca

n measur e flow rat e t o ensur e retention , bio-uptak

e (C O monitoring) . Bet h Harden : Wha

t about monitorin g porosit

y an d th e temperatur

e rang e fo r th e bacteria ? Anders : I wil

l nee d one o f m y technica l peopl e t o addres s thos e questions . Question : Wha

t would upset

th e system ? Anders : Hav

e no t ha d an y upset s s o fa

r wher e th e bacteri ahav e died . Carlos : Ho

w frequentl

y hav e yo u ha d t o chang e the media ? Anders : The be

d need s t o b e regenerate d ever y 3 t o 5 years . Bu

t sinc e 1989 , none hav e bee n changed yet . Lowe

r pH will consum

e th e bio-be d media . Carlos : Ho

w i s th e materia l dispose d of

? I s i t ahazardou s waste ? Anders : No , i

t i s no t considere d ahazardou s waste . Th e Swedish governmen t i s ver y critica l an d looke d a t th e ol d filter

medi aan d determine d tha

t i t coul d b e used a s compost .P.1 9

Dr . Madeleine Stru

m June 28 , 199 5 Pag e 1 7 Emory : How d o th e bacteri areac t to seasona

l temperatur

e changes ? Anders : Th e filter s i

n Swede n are insulated , an

d operat e ove r awid e temperature rang e (-20° F to 100°F) . Greg : Wha

t ar e th e source s o

f th e microorganisms ? Anders : I t varies . Fo r

example , loca

l sludg e ma

y b e used . In som

e case s i t i s bette r t o us e specially grow n bacteria . John : Wh

y i s i t tha t Swede n i s a"hotbed " of

contro l technology ? Anders : Th e Swedish governmen t want s to clea

n up th e air . A lo t

of government subsidies , bu t

th e regulation s are o n th e books . John : Ar e an y o f th e cost s offse

t by th e government ? Ron : I do not

believ e the

y are . Anders : Som

e o f the first one s wer e subsidize d i n order

t o get th e technolog y out ; bu t today , no . There wer

e initially variou s governmen t grant s t o develop biofilters . Magnus : None o

f our installation s ha s been subsidize d by th e government . ADDITIONA

L DISCUSSIO

N Carlos : Regardin g governmen t assistance , in OR

D ther e i s th e Federa

l Technolog y Transfe r Assistanc e progra

mwhic h work s wit

h industr y t o develop technologies . John : Nee

d to loo k int o governmen

t subsidies ; I will loo

k into mor e closely . Investment cost s i n Europea n countrie s are ver

y different . Wil l see if

I ca n get more information . Rich : Fo r Anders . Cos t

effectivenes s number s of

$92 9 pe r to n o f styren e controlled . D o yo u get muc h resistanc e t

o thi s numbe

r in thi s country ? Anders : Basically , we ar

e jus t startin g out

i n thi s country . W

e trie d t o sell t o som

e companies , but

the y fel t EP A would not

b e affecting the

mfo r th e nex t 1 0 years , s o th e interes t wa s not there .P.2 0

Dr . Madeleine Stru

m Jun e 28 , 1995 Pag e 1 8

Dan : I n evaluatin g thes e technologies , do no t jus t loo k a t th e $/to n o

f pollutan t removed , but als o loo k a t the capita l cos t versu s th e facility' s profitability . Emory : Ar

e ther e an y other technologie s tha

t coul d b e used b y th e industry ? Answer : Sourc e reductio n technologie s are i n us e in the industry . Mohan : Pre-coate d carbo n filters t o adsor b styrene . Lori : Catalyti c system s usin g platinum-palladiumo n abea d (preciou s metal , no t

mono lith) . Florid aDEP : Th e EPA' s Contro l Technology Cente r (CTC ) evaluate d styren e remova l contro l technologies . Chec k wit h Bo b Blascza k o r Chuc k Darvin . Madeleine : Polya

d wa s on e of

the technologie s evaluated . Th e result s wer e positive . Carlos : A Qua

d scrubbe r wa s th e othe

r technolog y evaluated . Th e test s ma y no t b e finished . Th e Qua

d scrubbe r i s aver y differen t technology , base d o n a

n aci d o r bas e liqui d chemica

l scrubber . Ma

y hav e achieved a50 % reductio n in the evaluation . Steve : Generally , th e applicabl e contro l technologie s are al l variation s on atheme : adsorben t an d the n purg e an

d control . Ver

y fe w offe r straight oxidation . Paul : Has industr

y lowere d the VO

C conten t o f the ra w material s use

d i n th e industry ? Steve : Unlik

e othe r industries , styren e i s areactiv e diluent tha t create s th e plasti c materia l an d i s no t simpl y acarrie r

tha t evaporates . Paul : Ha s industr

y looke d a

t catalyst s to spee

d u p th e reactio n and thereb y reduc e volatility ? Steve : Th e industr

y i s lookin g a

t this . Th e abilit y to d o thi s varie s fro

mproces s t o proces s - i

t i s proces s specifi c an

d produc t specific . W

e ca n get promoter s into th e material ; thi s optio n i s currentl y available . Ho w muc h VO C emission s are controlle d i s no t addresse d a

t thi s time . Mark : OR

D an d RT I are lookin g a

t reduction s fro

mpollutio n preventio n and sourc e reductio n ~ styren e suppressant s an d applicatio n equipment . A tes t protoco l wa s issue dP.2 1

Dr . Madeleine Stru

m Jun e 28 , 1995 Pag e 1 9

an d comment s have bee

n receive d an

d addressed . A tes t

a t Reichol d Chemica

l i s sched

ule d fo r Jun e 5 , 1995 . Dan : Ca n th e protoco l b e mad

e available ? Carlos : Yes . Anders : On

e ke y t o effective contro l i s reducin g th e amoun t o f flow t o th e syste

m(no t th e amoun t o f VOC) . Manage

d ai r usin g lamina

r flo w techniques. Ron : Wil l alis t o f meetin g participant s b e provided ? Madeleine : Yes . It

will b e par

t o f th e minute s t o thi s meeting . Carlo s Nunez aske

d th e representative s of

th e industr

y trad e group s whethe

r they coul d provid e th e vendor s wit h proces s parameter s fo

r actua l plant s s o tha

t th e vendor s coul d provid e accurat

e cos t estimates . Industr

y pointe d out

tha t there ar e fe

w commonali

tie s between facilities , an

d suc h atas k woul d b e ahug e undertakin g (costly) , an d th e vendor s themselve s woul

d incu r larg e costs . Th e vendor s basically agree d tha t t o get goo d cos t estimate s would requir

e considerabl e time an

d money . Mr . Schweitze

r pointe d out tha t th e industr

y ha d bee n frustrated i

n pas t attempt s to establis h model plant s du e to th e diversit y o f individua l facilities . Also , aconsiderabl e fractio n of th e tota l contro l cos t would b e fo

r acaptur e system , which varie s dramatically fo r differen t facilities . Industr

y suggeste d tha

t EP A d o asensitivit

y analysi s o f

strea mparameters , which woul d probabl y b e a s representativ e o

f th e industr y a s an y specifi c datatha

t the y provided . They als o noted tha t EP A ha d surveyed abou

t 1,00 0 facilitie s fo

r thi s informatio n in 1992 . I t wa s pointe d out

b y EP A tha t the information obtaine d wa s not strea mparameter

informatio n becaus e collectio n information constraint s require d tha t amuc h mor e genera l questionnair

e b e use d to gathe r information . N

o resolutio n of

thi s discussio n wa s reached . Carlos : Stev e an

d John . Ca

n w e hav e industr

y through th e association s provid e EPA/ven

dor s wit h prospectiv e problem s an d prospectiv e solution s an

d costs . Thi s woul d giv e u s th e "facts " o n all th

e option s availabl e t

o us . John : We hav e hire d a

n environmenta

l engineer t o follow EP

A procedure s for

case-by

cas e (Tie r 1 an d Tier 2) . Once completed , w e will shar e the result s wit

h EP A in th e coming months .P.2 2

Dr . Madeleine Stru

m Jun e 28 , 199 5 Pag e 2 0 Carlos : A numbe

r of vendor s toda

y hav e shown technologie s a t areasonabl e cost . I f

they have thi s poo l of

plan t informatio n fro

myou , ca n yo u giv e m e you r bes t sho t a s t o whethe

r yo u ca n contro l o r

no t control ? Industry : Collectin g emission s fo r ducting t o contro l device s i s abi g issue . Mos t facilitie s do no t hav e stacks . Steve : Th e EP

A need s to conside

r the "hidden " cost s in regulatio n - transpor t gase s t o contro l devices , permittin g cost s fo r contro l devices , etc . Christine : I

t depend s o n ho

w permit s are implemente d i n th e States . I n Ohio , th e contro l devic e doe s no t

requir e apermit . Greg : T o date , we hav e receive d onl y afe w comment s fro

mth e tea mmembers . Every

on e i s encourage d t

o loo k bac k a t the origina

l materia l o r today' s discussion . Pleas e write u p an d submi t an y comment s to EPA . Madeleine : I would lik

e to hav e ateleconferenc e late r thi s summe

r t o discus s pollutio n preventio n and t

o have a n industr y proposa l durin g the nex

t call . Dan : I thin

k we los e alot

by no t interactin g directl y wit

h tea mmembers . Ca

n w e meet somewhere ? Madeleine : Du e t

o budget constraints , no

t likely . However , yo

u are alway s mor

e tha n welcom e t o travel t o Durha mto meet .P.2 3

FAC T SHEE

T Informatio n o n Grac e TE C System s VO C abatemen t technologies : Manufacture n Grac e TE C System s

Industna l Emissio n Contro l Product s W.R . Grac e & Co . - Conn . 83 0 Prospe r Road , P.O . Bo x 3 0 DePere.W ! 54115-003 0 (414 ) 336-571 5 FA X (414 ) 337-158 5 Nam e o f Technology :

Enterpris e Therma l Regenerativ e Oxidize r Descriptio n o f Technology :

Th e Enterpris e I s a therma l oxidize r fo r VO C an d odo r control . I t combine s hig h temperature therma l oxidatio n wit h regenerative hea t exchang e t o efficientl y conver t VOC s an d othe r odo r causin g organi c compound s t o carto n dioxid e an d water . I t come s standar d wit h a 95 % hea t exchange r efficienc y an d a 98 % VO C destructio n efficiency . Th e uni t consists o f a n exhaus

t fa n wit h A C drive , inle t manifold , two cerami c fille d energ y recovery columns , a combustio n chamber , a nozzl e mi x burne r wit h ga s train , a n outle t manifold , an d PL C contro l system. . Ai r fro m th e proces s i s fe d int o th e first be d o f cerami c medi a throug h th e inlet manifol d b y th e exhaust fan , an d i s preheate d t o nearl y th e combustio n chambe r temperature . Bumers i n th e combustio n chambe r rais e th e temperatur e o f th e ai r t o th e operatin g setpoin t an d th e oxidatio n proces s i s completed . Retentio n tim e i n th e combustio n chambe r i s a minimu m o f on e second . Ho t purifie d ai r the n enter s th e secon d colum n an d passe s dow n throug h th e cerami c medi a an d i s cooled . Th e purifie d ai r the n passe s throug h th e outle

t valv e an d manifold , a t a temperatur e onl y slightl y highe r tha n tha t o f th e inle t stream . Industria l Application s

Grac e TE C System s i s th e leade r i n oxidatio n technology , wit h ove r 1,60 0 oxidatio n system s installe d throughou t th e world . Grac e TE C System s offer s catalytic , therma l recuperativ e an d therma l regenerativ e oxidizers . Application s includ e th e Graphi c Arts , Flexographic/Rotogravure printin g industries , a s wel l a s man y specialize d application s i n th e packaging , coating , healthcare , an d textil e industries . Ou r oxidizer s hav e bee n o n th e marke t i n industria l us e since 1970 . Thre e typica l application s fo r th e Enterpris e ar e liste d below , includin g sel l pric e an d operatin g costs . Th e first i s a uni t recentl y proposed t o a plasti c pip e manufacturer , an d th e othe r tw

o units hav e bee n sol d t o a graphi c art s printer , an d a foo d packagin g company , respectively .P.2 4

riHY-^j-iyy ^ a ? "5 4 GRAC E EM1551O NCONTROL P

R 41 4 33 9 278 4 P . 0 3

Enterpris e 1000 0 (Proposed ) Application : Exhaus t Flow : Exhaus t Temperature : Solven t (VOC) : VO C emissions : Destructio n efficiency : 98 % Capita l Cost : S282.950.0 0 Operatin g costs : Natura l ga s usag e @ S.45/therm : Electricity ®

$.06/kW h Annua l operatin g cost/cf m Enterpris e 2000 0 Application : Exhaus t Flow : Exhaus t Temperature : Solven t (VOC) : VO C emissions : Pip e manufacturin g mold s 1043 0 scf m 14 0 deg . F Styren e 28LB/h r

$3.20/h r $2.91/h r $5.1 3 Graphi c Art s Printin g Operatio n 22,00 0 scf m 32 5 deg . F Magleso l 151#to r Destructio n efficiency : 98 % Capita l Cost : $397,370.0 0 Operatin g costs : Natura l ga s usag e @ $.45/therm : Electricit y @ $.06/kW h Annua l operatin g cost/cf m Enterpris e 5000 0 Application : Exhaus t Flow : Exhaus t Temperature : Solven t (VOC) : VO C emissions : Destructio n efficiency : 98 % Capita l Cos t $742,148.0 0 Operatin g costs : Natura l ga s usag e @ $.45/thenm : Electricity ®

$.06/kW h Annua l operatin g cost/cf m $0.00/h r (self-sustainin g a t VO C loading ) $8.28/h r $3.3 0

Foo d packagin g 5000 0 scf m 10 0 deg . F Toiuene.hexane.propanol.lBA.ME K 437LB/h r

$0.0Q/h r (self-sustainin g a t solven t loading ) $U.94/h r $2.6 2

THTQ I P OH.P.2 5

Enterpris e 1000 0 (Proposed ) Application : Exhaus t Flow : Exhaus t Temperature : Solven t (VOC) : VO C emissions : Destructio n efficiency : 98 % Capita l Cost : $282,950.0 0 Operatin g costs : Natura l ga s usag e @ $.45Aherm : Electricity ®

$.Q6/kW h Annua l operatin g cost/cf m Enterpris e 2000 0 Application : Exhaus t Flow : Exhaus t Temperature : Solven t (VOC) : VO C emissions : Pip e manufacturin g mold s 1043 0 scf m 14 0 deg . F Styren e 28LB/h r

$3.20/h r $2.91/h r $5.1 3 Graphi c Art s Printin g Operatio n 22,00 0 scf m 32 5 deg . F Magleso i 151-Wh r Destructio n effidency : 98 % Capita l Cost : $397,370.0 0 Operatin g costs : Natura l ga s usag e ®

$.4S/therm : Electricity ®

S.06/kW h Annua l operatin g cost/cf m Enterpris e 5000 0 Application : Exhaus t Flow : Exhaus t Temperature : Solven t (VOC) : VO C emissions : Destructio n efficiency : 98 % Capita l Cost : $742,148.0 0 Operatin g costs : Natura l ga s usag e ®

$.45/therm : Electricity ®

$.06/kW h Annua l operatin g cost/cf m $0.0Q/h r (self-sustainin g a t VO C loading ) $8.28/h r $3.3 0

Foo d packagin g 5000 0 scf m 10 0 deg . F ToIuene.hexane,propanol,IBA.ME K 437|_B/h r

$0.00/h r (self-sustainin g a t solven t loading ) $14.94/h r $2.6 2

TRTO I P onP.2 6

Attachmen t Jun e 28 , 199 5
SUMMARY O F COMMENT S RECEIVE D O NPRE-MAC T TOPIC S Durin g th e firs t pre-MAC T tea mteleconferenc e o n Februar y 7 , 1995 , Madelein e Stru mprovide d informatio n o n th e plasti c composite s fabricatio n industry an d raise d severa l issue s concernin g thi s rulemakin g effort . Sh e requeste d feedbac k from th e teamo n suc h topic s a s potentia l format s o f th e standar d an d th e dat a neede d b

y th e tea

m t o mak e th e pre-MAC T decisions . Th e reques t fo r inpu t wa s repeate d durin g th e second teamconferenc e cal l o n Ma y 24 , 1995 . Writte n response s hav e bee n receive d from thre e member s o f th e teamand th e OR D contractor . Th e question s and th e tea m response s ar e summarize d below . Commenter s ar e numbere d accordin g t o th e cod e a t th e en d o f thi s attachment . Questio n 1 . Shoul d th e teammeeting s b e opene d t o industr y trad e associatio n group s a*n d intereste d environmenta l groups ? Response : I t wa s agree d amon g participant s a t th e firs t meetin g t o includ e industry an d environmenta l representative s o n th e team . Th e thre e commenter s o n thi s questio n (1 , 2 , 3 ) acknowledge d th e team' s decisio n an d agree d tha t thes e interest s shoul d b e represented . Questio n 2 . Wha t additiona l dat a analyse s ar e necessary ? Wha t dat a coul d industry provide ? Response : On e commente r (4 ) cite d thre e desirabl e type s o f dat a analyses : 1 ) determin e emissio n factor s b y proces s usin g availabl e dat a an

d recen t studies ; 2 ) estimat e th e numbe r o f source s an

d tota l emissions , attemptin g t o reduc e th e 2 7 percen t o f emission s fo r whic h th e proces s i s "unknown" ; an d 3 ) obtai n additiona l dat a o n add-o n controls , considerin g cos t effectiveness , bot h fo r U.S . an d Europea n systems . Asecond commente r (3 ) suggeste d tha t th e analysi s o f EPA' s 199 3 screenin g surve y response s shoul d b e completed , bu t believe d tha t anothe r surve y migh t b e necessar y t o determin e "baseline " an d pollutio n preventio n (P2 ) measure s i n use . On e commente r (2 ) fel t tha t informatio n o n th e cos t effectivenes s o f U.S . an d Europea n contro l system s wa s needed , a s wel l a s opinion s fro mregulator s o n ho w effectiv e thes e system s are . Anothe r (1 ) believe d tha t dat a o n reduction s achievabl e usin g readil y availabl e P 2 technologie s an d practice s woul d b e beneficial . Athir d commente r (3 ) though t tha t industr y coul d suppl y bette r dat a i f another , mor e detaile d surve y wa s develope d an d sen t out .P.2 7

Attachmen t Jun e 28 , 199 5 Questio n 3 . D o yo u hav e an y idea s o n th e MAC T "bi g picture" ? Response : Tw o o f th e commenter s (3 , 4 ) fel t tha t Sout h Coas t Rul e 116 2 migh t b e a goo d startin g point , a t leas t fo r existin g source s (wit h wor k practice s adde d t o reduc e th e smalle r emissio n points) . Effort s shoul d b e concentrate d o n th e processe s wit h th e highes t emissions . On e (3 ) pointe d ou t tha t th e Sout h Coas t rul e probabl y doe s no t represen t th e contro l leve l o f th e to p 1 2 percen t fo r th e ge l coatin g process . Anothe r tea mmembe r (2 ) though t tha t a MAC T floo r shoul d b e develope d base d o n th e 1 2 percen t criterion , an d tha t "filler " technique s (addin g soli d filler s t o decreas e th e styren e percentag e i n th e resi n mix ) shoul d no t b e allowe d t o tak e th e plac e o f tru e emissio n reductions . Th e fourt h commente r (1 ) stresse d th e nee d t o encourag e P 2 innovation . Fo r ne w sourc e MACT , thi s commente r state d tha t add-o n control s shoul d b e explored . Questio n 4 . Wha t woul d b e a goo d forma t fo r th e standard ? Response : Fiv e possibl e format s wer e suggeste d b y Dr . Stru

m fo r discussion : 1 ) plant-wid e limi t ( g styrene/ mcoated) ; 2 ) limi t o n styren e fro mresi n use d (as-supplie d b y vendo r o r as applied ) (g/ m) ; 3 ) plant-wid e ( g styrene/k g resi n used) ; 4 ) limi t o n resi n use d (g/k g resin) ; an

d 5 ) semi-quantitativ e POIN T systembase d o n th e tota l o f technique s use d (flexibility) . Tw o commenter s (1 , 2 ) favore d th e plant-wid e limi t i n g/k g resi n used , whil e a thir d (4 ) fe^ t tha t ther e woul d b e uncertaintie s i n developin g monitorin g protocol s an d determinin g mean s o f complianc e fo r thi s format . On e (2 ) sai d tha t thi s limi t coul d b e determine d b y takin g Sout h Coast' s 6 0 g/m 2 rul e an d applyin g a MAC T reductio n o f 3 3 percent , s o fina l emission s woul d represen t a 3 3 percen t reductio n ove r existin g Rul e 116 2 uncontrolle d emissio n levels . Allo w flexibilit y i n choic e o f control s t o achiev e th e limit . On e commente r (3 ) fel t tha t th e bes t forma t woul d depen d o n th e result s o f ongoin g testing . Th e standar d currentl y shoul d includ e a numerica l emissio n limi t plu s a lis t o f P 2 measure s o r control s tha t wil l achiev e th e limi t (example : g/m 2 limit , plu s add-o n controls , styren e conten t limit , HVL P spra y guns , etc.) . Th e numerica l limi t i s neede d becaus e i t woul d allo w reductio n method s no t specificall y mentione d i n th e standard . Specifi c measure s ar e neede d becaus e thi s wil l allo w plant s t o avoi d testin g i f the y us e thos e measures . Th e standar d shoul d allo w substitutio n o f mas s balanc e calculation s fo r testing . Questio n 5 . I s i t reasonabl e t o us e dat a fro mcontro l system s bein g use d i n Europ e fo r evaluatin g feasibility ?P.2 8

Attachmen t Jun e 28 , 199 5 Response : Tw o tea

mmember s (1 , 2 ) fel t tha t th e Europea n contro l technologie s shoul d b e factore d in . Anothe r (3 ) believe d tha t industry ma y challeng e thi s approach , an d tha t th e CAA

Ad o no t appea r t o indicat e tha t foreig n technologie s shoul d b e considered . Questio n 6 . Ho w shoul d "similar " processe s b e groupe d togethe r fo r purpose s o f ne w sourc e MAC T floo r determination ? Response : On e commente r (3 ) state d tha t onl y processe s tha t hav e "nearl y th e same " emission s an d potentia l reductio n measure s shoul d b e groupe d togethe r (example : don' t combin e th e ge l coatin g proces s wit h continuou s laminatio n an d pultrusio n processe s du e t o thei r differen t emissio n factor s and likel y contro l measures) . Commenter s 1 . Jorda n Spoone r 2 . Richar d Neilso n 3 . Mar k Bahne r 4 . Mari a Malav e