# Polyvinyl Chloride and Copolymers (PVC) Production

MACT Floor, Baseline Emissions, and Emission Reductions Analyses Equipment Leaks April 8, 2011

Worksheet Name Description Data Table Section 114 Survey Response Data LDAR Cost Worksheet Summary of Baseline Emissions and Costs for Equipment Leaks Cost tables for Memos Summary of Baseline Emissions and Costs for Equipment Leaks Using Protocol Baseline Emissions Analysis for Equipment Leaks factors- EPA sprdsht, emissionsEmisison Factors

# Section 114 Survey Data

Company Facility Process Unit ID Has

LDAR LDAR 1 LDAR 2 LDAR 3 LDAR 4
Formosa Delaware City P-1 Yes 40CFR63 UU Formosa Delaware City P-2 Yes 40CFR63 UU

Formosa Baton Rouge P-1 Yes 40 CFR 61 Subpart F LAC 33:III.2122, LAC 33:III.5109 Formosa Point Comfort P-1 Yes 40CFR61 VOLD MACT 28CNTQ Formosa Point Comfort SPVCP-2 Yes 40CFR61 V 28 MID Georgia GulfAberdeen 1Yes 40CFR61 V Georgia GulfPlaquemine P-1 Yes 40CFR63 UU40CFR61 V 2122 OxyVinyls Pedricktown P-1 Yes 40CFR61 V N.J.A.C. 7:27-16.18(h) OxyVinyls Pedricktown P-2 Yes 40CFR61 V N.J.A.C. 7:27-16.18(h) OxyVinyls Pedricktown P-3 No OxyVinyls Pedricktown P-4 Yes 40CFR61 V N.J.A.C. 7:27-16.18(h) OxyVinyls Pedricktown P-5 Yes 40CFR61 V NJAC 7:27-16.18(h) OxyVinyls Pedricktown P-6 No OxyVinyls Pedricktown P-7 No Shintech Plaquemine P-1 Yes 40CFR61 V LAC33:III.2122 Shintech Addis P-1 Yes 40CFR61 V LAC 33:III.2122 Shintech Freeport U-35 Yes 40CFR63 UU40CFR61 V 30 TAC 115 Certain TeedLake Charles P-1 Yes 40CFR61 V Certain TeedLake Charles P-2 Yes 40CFR61 V OxyVinyls Deer Park sitewide Yes 40CFR61 V 30 TAC 115 Sub. D OxyVinyls Pasadena sitewide Yes 40CFR61 V 28 LAER PolyOne Pedricktown P-1 Yes 40CFR61 V40 CFR Part 61, Subpart F PolyOne Henry P-1 Yes 40CFR61 V40 CFR Part 61.65 b 8 ii PolyOne Henry P-11 Yes 40CFR61 V40 CFR Part 61.65 b 8 ii PolyOne Henry P-12 Yes 40CFR61 V40 CFR Part 61, Subpart F PolyOne Henry P-2 Yes 40CFR61 V40 CFR Part 61.65 b 8 ii PolyOne Henry P-3 Yes 40CFR61 V40 CFR Part 61.65 b 8 ii PolyOne Henry P-4 Yes 40CFR61 V40 CFR Part 61.65 b 8 ii PolyOne Henry P-5 Yes 40CFR61 V40 CFR Part 61.65 b 8 ii PolyOne Henry P-7 Yes 40CFR61 V40 CFR Part 61.65 b 8 ii PolyOne Henry P-9 Yes 40CFR61 V40 CFR Part 61.65 b 8 ii Dow Midland Vinyl TrainYes 40CFR61 VSubpart H Dow Texax City P-1, P-2, P-3Yes 40CFR61 V63 EEEE (OLD MACT) 28 VHP and 30 TAC 115 Westlake Calvert City P-1 Yes 40CFR61 V Westlake Geismar P-1 Yes 40CFR61 V LAC 51

### LDAR Process Subject to 40CFR63UUSubject to

40CFR61V?Subject to

other Federal Federal LDAR

Regulation Yes Yes
N/A No No Yes 40 CFR 61 Subpart F No Yes Yes OLD MACT

Yes Yes Yes Yes No

Yes Yes Detected by daily operator inspections and maintenance notifications Yes Yes Ammonia sensor alarms, operator rounds; repaired via work orders Leaks detected on operator rounds and repaired via work orders No Yes No 40 CFR 61.65 No Yes No 40 CFR 61.65 Yes Yes No No Yes No No Yes No No Yes No No Yes No No Yes Yes 40 CFR Part 61, Subpart F No Yes Yes 40 CFR Part 61.65 b 8 ii No Yes Yes 40 CFR Part 61.65 b 8 ii No Yes Yes 40 CFR Part 61, Subpart F No Yes Yes 40 CFR Part 61.65 b 8 ii No Yes Yes 40 CFR Part 61.65 b 8 ii No Yes Yes 40 CFR Part 61.65 b 8 ii No Yes Yes 40 CFR Part 61.65 b 8 ii No Yes Yes 40 CFR Part 61.65 b 8 ii No Yes Yes 40 CFR Part 61.65 b 8 ii No Yes Yes Subpart H No Yes Yes 63 EEEE (OLD MACT)

Yes No Yes No

### Subject to

other stateState LDAR Regulation Total LDAR Cost ($) 10,000.00 $10,000.00 $

Yes LAC 33:III.2122,

LAC 33:III.5109 CBI Yes 28CNTQ 43,675.00 $ 28 MID

Yes 2122 155,000.00 $ Yes N.J.A.C. 7:27-16.18(h) 5,800.00 $ Yes N.J.A.C. 7:27-16.18(h) 5,800.00 $

Yes N.J.A.C. 7:27-16.18(h) 3,400.00 $ Yes NJAC 7:27-16.18(h) 1,000.00 $

Yes LAC33:III.2122 17,000.00 $ Yes LAC 33:III.2122 14,000.00 $ Yes 30 TAC 115 cost incurred internally No 20,000.00 $ No 6,000.00 $ Yes 30 TAC 115 Sub. D 29,093.94 $ Yes 28 LAER 85,277.00 $20,000.00 $ No 240.00 $ No 240.00 $ No 240.00 $ No 240.00 $ No 240.00 $ No 240.00 $ No 240.00 $ No 240.00 $ No 240.00 $ No 20,000.00 $ Yes 28 VHP and 30 TAC 115 105,000.00 $ No 10,000.00 $ Yes LAC 51 16,525.00 $

# Attachment E1 - Baseline Emissions Analysis for Equipment Leaks

Company Facility LDAR Program Type (by Survey) Facility Type Baseline Emissions (TPY) [1] Certain TeedLake Charles 40CFR61 V Bulk 16.5 Formosa Baton Rouge 40CFR61 V Other 59.29 Formosa Delaware City 40CFR63 UU Dispersion 8.1 Formosa Point Comfort 40CFR61 V Other 59.29 Georgia GulfAberdeen 40CFR61 V Other 59.29 Georgia GulfPlaquemine 40CFR63 UU Other 8.1 OxyVinyls Deer Park 40CFR61 V Other 59.29 OxyVinyls Pasadena 40CFR61 V Other 59.29 OxyVinyls Pedricktown 40CFR61 V Other 59.29 PolyOne Henry 40CFR61 V Other/Dispersion 59.29 PolyOne Pedricktown 40CFR61 V Dispersion 59.29 Shintech Addis 40CFR61 V Other 59.29 Shintech Freeport 40CFR63 UU Other 8.1 Shintech Plaquemine 40CFR61 V Other 59.29 Dow Midland 40CFR61 V Other 59.29 Westlake Calvert City 40CFR61 V Other 59.29 Westlake Geismar 40CFR61 V Other 59.29
[1] 59.29 from "PVC_eqlk_baseline_er_estimate_102610" Worksheet "Using Protocol" For subpart V, medium /small complexity plant. 8.1 from Worksheet "factors-EPA sprdsht, emissions" US, Level 2, medium/small complexity plant

## Attachment K - Equipment Leaks

Company Facility LDAR Program Type (by Survey) Facility

Reported LDAR Cost ($) 2006

Capacity 1,000 US Tons Facility LDAR

Cost $/1,000Ton Facility LDAR

Cost by Using Average Cost of 40CFR61V x 2006Facility LDAR Cost

by Using A

verage Cost of 40CFR63UU x 2006Increase in LDAR Cost from V to UU PRV Cost

Reduction TAC [1] PRV Cost

Reduction TCI [1] TCI per

Facility ($) TAC per

Facility ($/year) Certain TeedLake Charles40CFR61 V $26,000 240.3 108 $ $55,860 $64,595 $8,736 16,105 $ 113,116

$ 113,116

$ $24,841 Formosa Baton Rouge40CFR61 V

- 458.6

- $106,595 $123,265 $16,670 26,897 $ 188,913

$ 188,913

$ $43,567 Formosa Delaware City 40CFR63 UU $20,000 71.7 279 $ $16,655 $19,260 $0 26,897 $ 188,913

$ 188,913

$ $26,897 Formosa Point Comfort40CFR61 V $43,675 782.6 56 $ $181,929 $210,380 $28,451 26,897 $ 188,913

$ 188,913

$ $55,348 Georgia GulfAberdeen 40CFR61 V

- 500.4

- $116,332 $134,524 $18,193 26,897 $ 188,913

$ 188,913

$ $45,090 Georgia GulfPlaquemine40CFR63 UU $155,000 599.7 258 $ $139,393 $161,192 $0 26,897 $ 188,913

$ 188,913

$ $26,897 OxyVinyls Deer Park40CFR61 V $29,094 275.6 106 $ $64,059 $74,077 $10,018 26,897 $ 188,913

$ 188,913

$ $36,915 OxyVinyls Pasadena40CFR61 V $85,277 1050.5 81 $ $244,194 $282,383 $38,189 26,897 $ 188,913

$ 188,913

$ $65,086 OxyVinyls Pedricktown40CFR61 V $16,000 175.3 91 $ $40,742 $47,113 $6,371 26,897 $ 188,913

$ 188,913

$ $33,268 PolyOne Henry 40CFR61 V $2,160 62.8 34 $ $14,606 $16,890 $2,284 26,897 $ 188,913

$ 188,913

$ $29,181 PolyOne Pedricktown40CFR61 V $20,000 65.0 308 $ $15,118 $17,482 $2,364 26,897 $ 188,913

$ 188,913

$ $29,261 Shintech Addis 40CFR61 V $14,000 312.0 45 $ $72,515 $83,856 $11,340 26,897 $ 188,913

$ 188,913

$ $38,237 Shintech Freeport 40CFR63 UU

- 1598.3

- $371,544 $429,649 $0 26,897 $ 188,913

$ 188,913

$ $26,897 Shintech Plaquemine40CFR61 V $17,000 650.4 26 $ $151,180 $174,823 $23,642 26,897 $ 188,913

$ 188,913

$ $50,539 Dow Midland2 40CFR61 V $20,000 10.8 1,852 $ $2,511 $2,903 $393 26,897 $ 188,913

$ 188,913

$ $27,290 Westlake Calvert City40CFR61 V $10,000 400.1 25 $ $93,014 $107,560 $14,546 26,897 $ 188,913

$ 188,913

$ $41,443 Westlake Geismar 40CFR61 V $16,525 286.6 58 $ $66,622 $77,040 $10,419 26,897 $ 188,913

$ 188,913

$ $37,316 Total 446,457

$ 3,135,724

$ 3,135,724

$ 638,073

$ [1] EPA supplied cost factors from "PVC_PRV_Cost_reductions_110310" option 4, average facility 40CFR61 V 232.5 [2] Non CBI production data - Capacity information not available 40CFR63UU 268.8 Average $/KTon

### Attachment E2 - Baseline Emissions Analysis for Equipment Leaks

Factors from protocol

simplemediumcomplex Control Factor Control Factor Subpart V US, Level 2Subpart V US, Level 2 Pump Seals * Light-liquid service 15 40 56 0.0199Monthly (10,000ppm)0.00617Monthly (1,000ppm)0.00488 2.28 1.81 0.86 0.68 0.48 0.18 * Heavy-liquid service 0 5 36 0.00862 none 0.00862 none 0.00862 0.40 0.40 0.00 0.00 0.00 0.00
Valves * Gas/vapor service 77 414 1,3790.00597Monthly (10,000ppm)0.00078Quarterly (500 ppm)0.00035 2.97 1.33 0.55 0.25 1.64 0.31 * Light-liquid service 380 1,179 1,980 0.00403Monthly (10,000ppm)0.00084Quarterly (500 ppm)0.00038 9.16 4.14 2.95 1.33 5.02 1.62 * Heavy-liquid service 0 71 1,272 0.00023 none 0.00023 none 0.00023 0.15 0.15 0.00 0.00 0.00 0.00
Connectors * Flanges - gas/vapor 0.00183 * Flanges - light liquid 731 2,6627,410 0.00183 None 0.00180annual (500) 0.00013 44.33 3.20 12.17 0.88 41.13 11.29 * Flanges -heavy liquid 0.00183
Pressure Relief Devices * Disks 2 45 76 0.104 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00 * Disk holders, valves,etc. 2 45 76 0.104 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00 Open-ended Valves 33 141 424 0.0017 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00 Sampling Connections 8 35 106 0.015 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00 Compressor Vent 0 2 8 0.228 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Total 59.29 11.03 16.53 3.14 48.27 13.40

Equipment counts from Subpart VV analysis provided by EPA Emission reduction (simple complexity) (tpy) Type of Component Number of Components Emission Factors From Protocol (kg/hr/source) Emissions, medium complexity (tpy) Emission reduction (medium complexity) (tpy) Uncontrolled Baseline (subpart V) US, Level 2 Emissions, simple complexity (tpy)

Using Protocol 7Factors from "emissions" tab of EPA spreadsheet (A7:C11) or "final estimates" tab

simplemediumcomplex Control Factor Control Factor Subpart V US, Level 2Subpart V US, Level 2 Pump Seals * Light-liquid service 15 40 56 0.0199Monthly (10,000ppm)0.00251Monthly (1,000ppm)0.000695 0.93 0.26 0.35 0.10 0.67 0.25 * Heavy-liquid service 0 5 36 0.00862 none 0.00862 none 0.00862 0.40 0.40 0.00 0.00 0.00 0.00
Valves * Gas/vapor service 77 414 1,3790.00597Monthly (10,000ppm)0.000352Quarterly (500 ppm)0.00020 1.35 0.78 0.25 0.14 0.57 0.11 * Light-liquid service 380 1,179 1,980 0.00403Monthly (10,000ppm)0.00039Quarterly (500 ppm)0.00023 4.25 2.53 1.37 0.82 1.72 0.56 * Heavy-liquid service 0 71 1,272 0.00023 none 0.00023 none 0.00023 0.15 0.15 0.00 0.00 0.00 0.00
Connectors * Flanges - gas/vapor 0.00183 * Flanges - light liquid 731 2,6627,410 0.00183 None 0.00031 annual (500) 0.000162 7.56 3.99 2.08 1.10 3.57 0.98 * Flanges -heavy liquid 0.00183
Pressure Relief Devices * Disks 2 45 76 0.104 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00 * Disk holders, valves,etc. 2 45 76 0.104 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00 Open-ended Valves 33 141 424 0.0017 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00 Sampling Connections 8 35 106 0.015 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00 Compressor Vent 0 2 8 0.228 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Total 14.64 8.10 4.05 2.15 6.54 1.89

Equipment counts from Subpart VV analysis provided by EPA Emission reduction (simple complexity) (tpy) Type of Component Number of Components Emission Factors From Protocol (kg/hr/source) Emissions, medium complexity (tpy) Emission reduction (medium Uncontrolled Baseline (subpart V) US, Level 2 Emissions, simple complexity (tpy)

Using Protocol 8Using Protocol 9Using Protocol 10simplemediumcomplex Control Factor Control Factor Subpart V US, Level 2Subpart V US, Level 2

Pump Seals * Light-liquid service 15 40 56 0.0199Monthly (10,000ppm)0.00251Monthly (1,000ppm)0.000695 0.93 0.26 0.35 0.10 0.67 0.25 * Heavy-liquid service 0 5 36 0.00862 none 0.00862 none 0.00862 0.40 0.40 0.00 0.00 0.00 0.00
Valves * Gas/vapor service 77 414 1,3790.00597Monthly (10,000ppm)0.000352Quarterly (500 ppm)0.00020 1.35 0.78 0.25 0.14 0.57 0.11 * Light-liquid service 380 1,1791,9800.00403Monthly (10,000ppm)0.00039Quarterly (500 ppm)0.00023 4.25 2.53 1.37 0.82 1.72 0.56 * Heavy-liquid service 0 71 1,2720.00023 none 0.00023 none 0.00023 0.15 0.15 0.00 0.00 0.00 0.00
Connectors * Flanges - gas/vapor 0.00183 * Flanges - light liquid 731 2,6627,4100.00183 None 0.00031 annual (500) 0.000162 7.56 3.99 2.08 1.10 3.57 0.98 * Flanges -heavy liquid 0.00183
Pressure Relief Devices * Disks 2 45 76 0.104 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00 * Disk holders, valves,etc. 2 45 76 0.104 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00 Open-ended Valves 33 141 424 0.0017 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00 Sampling Connections 8 35 106 0.015 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00 Compressor Vent 0 2 8 0.228 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Total 14.64 8.10 4.05 2.15 6.54 1.89

Equipment counts from Subpart VV analysis provided by EPA Factors from "emissions" tab of EPA spreadsheet (A7:C11) or "final estimates" tab Emission reduction (simple complexity) (tpy) Type of Component Number of Components Emission Factors From Protocol (kg/hr/source) Emissions, medium complexity (tpy) Emission reduction (medium complexity) (tpy) Uncontrolled Baseline (subpart V) US, Level 2 Emissions, simple complexity (tpy)

factors- EPA sprdsht, emissions 11