# OAR Box 1870

Prepped by Ollie Stewart



## Document

Number: 

# 13 ) ll-A-1 8
Docket Number: 

# A-90-1 9

Printed 11/28/20087:05:04 AM Sheet 13 of 67 P. 1P. 2 

## i ' * > 

# A-90-1 9 ll-A-1 8 bHA-450/3-80-02 6



# Organi c Chemica l Manufacturin g Volum e 4 : Combustio n Contro l Device s 

# 5j r 

# i_iU_j_li

EP A AI R DOCKE

T

Emissio n Standard s an d Engineerin g Divisio n

U.S
. ENVIRONMENTA L PROTECTIO N AGENC Y Offic e o fAir , Noise , an d Radiatio n Offic e o f Ai r Qualit y Plannin g an d Standard s Researc h Triangl e Park . Nort h Carolin a 2771 1

Decembe r 198 0P. 3

il l

Thi s repor t wa s furnishe dt o th e Environmenta l Protectio nAgenc y b y I T Enviro science , 904 1 Executiv e Par k Drive , Knoxville , Tennesse e 37923 , i nfulfillment o f Contrac t No . 68-02-2577 . Th e content s o f thi s repor t ar e reproduce

dherei n as receive

dfro m I T Enviroscience . Th e opinions , findings , an dconclusion s expresse

dare thos e o f th

e author s an

dno t necessaril y

thos e o f th

e Environmen ta l Protectio

nAgency . Mentiono f trad e name s o

r commercia l product s i s not intende dt o constitut e endorsement o r recommendatio

nfo r use . Copie s o f thi s repor t are available , a s supplie s permit , throug hth e Librar

y Service s Offic e (MD-35) , U.S . Environmenta l Protectio nAgency , ResearchTriangl e Park , Nort h Carolin a 27711 , or fro

m Nationa l Technica l Informatio nServices , 528 5 Por t Roya l Road , Springfield , Virgini a 22161 .

D124RP. 4

1- i

REPOR T 1

CONTRO L DEVIC E EVALUATIO N THERMAL OXIDATION

J . W . Blackbur n

I T Enviroscienc e 904 1 Executiv e Par k Driv e Knoxville , Tennesse e 3792 3

Prepare d fo r Emissio n Standard s and Engineerin g Divisio n Offic e o f Ai r Qualit yPlannin g and Standard s ENVIRONMENTAL PROTECTIONAGENC Y Researc h Triangl e Park , Nort h Carolin a <

Jul y198 0

D75 GP. 5

III- l

III . BASI S FOR THERMAL OXIDIZE R DESIG N

Afte r the desig n consideration s describe d i n th e precedin g sectio n wer e evaluated , thos e sensitiv e desig n variable s tha t woul d hav e an effec t o n cos t and energ y wer e identifie d and ar e describe d below
.



## a A

EFFECT O F SENSITIV E DESIG NVARIABLE S ONCOS T AND ENERGY Adistinctio n mus t b e mad e betwee n thos e desig n variable s which , i f change d b y a smal l amount , woul d caus e significan t change s i n capita l annua l o r energ y costs . Thes e ar e calle d sensitiv e variables , and th e cos t curve s give n late r in the repor t generall yinclud e thema s parameters . Othe r variable s mayb e quit e importan t fo r a n individua l systemdesig n bu t hav e mino r effect s o n economi c o r energ yimpac t conclusions
.
The approac h use d i n thi s stud ywa s t o determin e th e sensitivit yo f certai n variable s b

ymean s o f computerize d hea t and materia l balanc e calculations
. Through thi s process , estimate s o f th e relationship s betwee n th e variable s an d eguipmen t desig n and operatin g cost s ma yb e derived
. Primar yvariable s tha t ar e a functio n o f th e wast e ga s ar e th e wast e ga s temperature , pressure , flo w rate , VO C compositio n and VO C averag e molecula r weight , VO C carbon , oxygen , an d hydroge n (an

d othe r component ) ratios , VO C heat s o f combustion , and the nitroge n (an d othe r iner t gases) , oxygen , an dwate r contents , and th e presenc e o f specia l contaminant s (particulates , halogens , hig h level s o f sulfur)
.
Th e wast e ga s temperatur e i s assume d t o b e 100° F fo r th e bas e case , bu t a n increas e o r decreas e withi n reasonabl e boundarie s wil l hav e littl e effec t upo n the capita l
o r operatin g cost s and i t i s therefor e no t a significan t variable
. Sensibl e hea t carrie d b yth e wast e ga s i s smal l compare d t o tha t require d t o rais e it s temperatur e t o th e combustio n conditions
. Abou t 3. 5 Btu/sc f i s require d t o increas e th e temperatur e o f nitroge n from80° F t o 260°F
. Thi s compare s wit h fue l hea t requirement s o n th e orde r o f 6 0 t o 8 0 Btu/sc f t o rais e th e wast e ga s t o combustio n temperatures . Wast e ga s temperatur e difference s withi n thi s rang e coul d no t chang e th e tota l hea t requirement s b y mor e tha n abou t 6%
. Wast e ga s pressur e i s assume d t o b e 1. 5 psig . Pressur e change s withi nreasonabl e limit s o f 1. 5 psi g als o wil l hav e no significan t effec t o ncapita l or operatin g costs .III- 2

Flo w rat e i s a ver

y significant variabl e fo r bot hcapita l an

doperatin

g costs . Th e wast e ga s flow

s show ninth e figure s throughou t thi s repor t are translate d t o scf m o f wast e ga s to th e therma l oxidizer .

Hea t content o f th

e wast e ga s i s a significant variable . VO C mola r concentra tion ; average molecula r weight ; carbon , hydrogen , an doxyge nratios ; an

dheat s o f combustio

n(Btu/l bo f VOC ) are al l expressedi nth e variabl e o f th

e hea t content o f th

e wast e ga s (Btu/scf) . B y assessin

g th e hea t o f combustio no f th e VOC bein

g destroyedan

dth e mol e % VOC concentratio ni nth e wast e gas , th

e hea t content ca

nbe determined(Btu/scf ) a s show nb y th e family

o f compoun

dline s o

n Fig . III-l . Multicomponen t VO C system s ma y b e describedwhenth e mol e fraction s o f eac hcomponent are known . Th e contributio

no f carbo

nmonoxide to th

e tota l hea t conten t ma

y als o be analyzedi nthi s way . Tabl e III- l give s VO C mola r heat s o f combustion. 1 3

I f th e actua l flu

e ga s compositio

ni s needed , a component materia l balanc e mus t b e performed , fo

r whic hcarbon , hydrogen , an doxygenratio s ar e required . I n order to estimat e "typical " value s fo r thos e ratios , 21 9 organi c compound s con tainin g C , H , 0 , N , an

dC l wer e surveyed. 1 4 Tabl e III- 2 summarize s thi s informa tio nbase do

ngrouping s o f differen t classes . The VO C componen t average s o f 68.3 % carbon , 11.4 % hydrogen , an d20.3 % oxygenwer e use dto establis hhea t value plu s hea t an

dmateria l balanc e fo r thi s evaluation . Compound s containin g chlori i
or sulfu

r ar e no t includedi nth e impac t assessmen t o f thi s stud y bu t covered inth e Contro l Devic e Evaluation , Therma l OxidationSupplemen t (VO C containin

g halogen s or sulfur) .
Th e leve l o f oxygeni nth e wast e ga s i s important becaus e compound s containin g hig hanoint s o f oxygenlessenth e leve l o f combustio nai r requiredan

dreduc e th e tota l therma l oxidize r flu e gas , whic haffec t bot hcapita l an doperatin

g costs . No additiona l combustio nai r i s requiredwhe nth e oxygeninth

e flu e ga s exceed s 3 mol e % . Thi s lead s t o a smalle r uni t an dlower capita l an doperati n costs . Althoug

hsom e designer s wil l us e variou s level s o f oxygent o determine combustio

nrequirements , th e valu e o f 3 mol e % i s base donacceptedpractic e an dwil l b e constan t for al l th e desig i calculations - in . thi s evaluation . I n orde r t o generat e a conservativ e desis t andimpac t analysis; , th e wast e ga s i n thi s repor t i s assumedt o hav e n o oxygen . MaxiaM i combustionai r i a therefor e

### III- 3 P. 7

1000. 0

l e



### m g 100. 0

Li . o c o


### m i - 

## z U J 

### O o U J X C O < <_> U J
r - c o < 1. 0 -/- ,

0. 1 _ . . I 1 

### I

i i "BENZEN E 1,404,00 0 Btu/L B M0LE


### I I I I ' 1,000.00 0 Btu/L B MOL E

/ - / ^ 

### y<C^.

y^r y ^—y/^^' 

## / /l//J/> / 

# iv// 7\////

I— / I 25 ° I.LE L 

## vy v / / 

## X
4 ( D% LE L 

### A1 1 ^ >^ 

# ^4C"L ^

y-^ ^

100 % LE L ^>- —

\ --— ' | | | j

2,000,00 0 Btu/_ B MOLE " l^^^^-p-r r
. _^2—- ~

—-—J" " J—•—

7 

# 1 -^ETHYLEN E 607,00 0 Btu / v—pROpv i piv p | | 882,00 0 Btu/L B MOL E \—730.25 0 Btu/L B MOL E 

# k * " _ B MOL E

100,00 0 Btu/L B MOL E

^ ^ ^ ^ -
-

6ARBO N TETRACHLORIDE : 6 7 14 0 Rtu/ I R MO I F

(P A O F RAM

. CO M ITE R BUS T= M0 L IO N C A R H ) F V O EAT C ) 10. 0 —

4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 

### VO C COMPOSITIO N (MOL E % )
Fig . III-l . Relationshi p Betwee n Waste Ga s Hea tContent , VO C Composition , and VO C MolarHea to f

Combustio nP. 8 

# t

III- 4

Tabl e III-l
. VO C Mola r Heat s o f Combustion *

Compound Methan e Ethan e Hexan e Benzen e Toluen e Ethylen e Propylen e Acetylen e Methano l Ethano l Aceti c aci d Pheno l Methy l chlorid e Methylen e chlorid e Chloroform Carbo n tetrachlorid e Ethy l chlorid e Hexachloroethan e Dichlorobenzen e Hexachlorobenzen e Carbo n disulfid e Carbony l sulfid e fttiophene Methy l amine Anilin e Ure a Uri c aci d Ammoni a Nitromethan e Nitrobenzen e Trinitrobenzen e Molecula r Weigh t 1 6 3 0 8 6 7 8 9 2 2 8 4 2 2 6 3 2 4 6 6 0 9 4 50. 5 8 5 119. 5 15 4 64. 5 23 7 111. 5 28 5 7 6 6 0 8 4 3 1 9 3 6 0 16 8 1 7 6 1 12 3 21 3 Gros s o r High-Hea t o f Combustio n

(Btu/lb ) 23,90 0 22,40 0 20,80 0 18,00 0 18,30 0 21,70 0 21,00 0 21,50 0 9,77 0 12,80 0 6,27 0 14,00 0 5,85 0 2,26 0 1,34 0 43 6 8,84 0 83 5 8,23 0 3,22 0 5,84 0 3,92 0 14,40 0 14,70 0 15,70 0 4,53 0 4,93 0 8,30 0 5,00 0 10,80 0 5,61 0 (Btu/lb-mole )

382,40 0 672,00 0 1,788,80 0 1,404,00 0 1,683,60 0 607,60 0 882,00 0 559,00 0 312,60 0 588,80 0 376,20 0 1,316,00 0 295,40 0 192,10 0 160,10 0 67,14 0 570,20 0 197,90 0 917,60 0 917,70 0 443,80 0 235,20 0 1,209,60 0 455,70 0 1,460,10 0 271,80 0 828,20 0 141,10 0 305,00 0 1,328,40 0 1,194,90 0
*Se e re f 12 .P. 9

III- 5

Tabl e III-2
. Summaryo f Organi c Compound Component s Surveye d

Clas s Carbon , hydroge n compound s onl y

Carbon , hydroge n com pound s an

d carbon , hydrogen , oxyge n compound s Carbon , hydrogen , and chlorin e compound s onl y Carbon , hydrogen , oxygen , an d nitroge n compound s an d carbon , hydrogen,and nitroge n compound s Al l compound s Lowvalue * Mea n

. Hig h value * Lo wvalu e Mea n High valu e Lo wvalu e Mea n High valu e Lo wvalu e Mea n High valu e Lo wvalu e Mea n Hig h valu e C

79. 9 85. 8 92. 3 27. 0 68. 3 92. 3 7. 8 34. 3 64. 0 26. 1 60. 1 78. 5 7. 8 62. 5 92. 3 Amoun t (w t H 7. 7 14. 2 20. 1 2. 1 11. 4 20. 4 0 4. 7 9. 8 3. 7 11. 3 15. 4 0 10. 4 20. 1 0

0 20. 3 7

0 3. 6 52. 0 0 17. 3 20. 1 % ) N

13. 0 25. 0 60. 8 0 3. 9 60. 8 C l

31. 5 60. 6 92. 2

0 5. 9 92. 2 *Lo wan d hig h value s correspond t o th e compound wit h th e lowes t an d highes t percentag e o f eac h elemen t (e.g. , carbon)
. Differen t .compound s appl yt o differen t elements ; therefor e th e value s show n wil l no t b e additive
.P.1 0



### 4- i

REPOR T 4

CONTRO L DEVIC E EVALUATIO N FLARE S AND TH E US E O F EMISSION S A S FUEL S

V . Kalcevi c

I T Enviroscienc e 904 1 Executiv e Par k Driv e Knoxville , Tennesse e 3792 3

Prepare d fo r Emissio n Standard s an d Engineerin g Divisio n Offic e o f Ai r Qualit yPlannin g and Standard s ENVIRONMENTAL PROTECTIONAGENC Y Researc h Triangl e Park , Nort h Carolin a

February198 1II- 3

15 0 M mmaygenerat e a spra yo f burnin g chemical s tha t coul d reac h ground leve l
an d presen t a safet yhazard
. Awate r sea l i s usuall ylocate d betwee n th e dis

entrainmen t dru

man d the flar e stac k t o preven t flashback s int o the system . Othe r devices , suc h a s flam e arrester s and actuate d chec k valves , maysometime s replac e a wate r sea l o r b e use d i n conjunctio n wit h it
.

Fo r safet yreason s a stac k i s use d t o elevat e th e flare
. Th e flar e mus t b e locate d s o tha t i t doe s no t presen t a hazar d t o surroundin g personne l an d facilities ; therefor e th e usua l choic e i s t o elevat e it
. Th e heigh t i s deter

mine d b ydesignin g fo r a maximu mground-leve l hea t radiatio n and possibl yals o fo r plum e dispersio n i n cas e o f emissio n ignitio n failure
. Astac k sea l i s normall yuse d jus t belo wth e flar e ti p t o imped e the incursio n o f ai r bac k int o the flar e system , whic h coul d creat e a n explosio n potential
. Th e us e o f a sea l reduce s the operatin g purge-ga s requirements
.
Th e burne r ti p i s designe d t o giv e a n environmentall yacceptabl e combustio n o f the flar e ga s ove r th e flar e system' s capacit yrange . Consideratio n i s give n t o flame stability , ignitio n reliability , effectiv e assist-steaminjection , and , possibly , nois e suppression
. Th e burne r tip s ar e normall yproprietar yi n design
. Flame stabilit yca n b e enhance d byflame holde r retentio n device s incorporate d i n the flar e ti p inne r circumference
. Wit h burne r tip s wit h moder n flame holde r design s th e flame ca n b e stabl e ove r a flare-ga s exi t discharg e velocit yrang e o f 1 t o 60 0 fps. 1 Reliabl e ignitio n i s obtaine d b y continuou s pilo t burner s designe d fo r stablilit yand positione d around th e oute r perimete r o f th e flar e tip
. Th e numbe r o f pilo t burner s require d depend s o n flar e siz e and , possibly , o n flar e ga s compositio n an d win d conditions
. Th e pilo t burner s ar e ignite d bya n ignitio n sourc e system , whic h ca n b e designe d fo r eithe r manua l o r automati c actuation
. Effectiv e assist-steaminjectio n t o promot e turbulenc e and mixin g o f ai r int o th e flar e ga s flame fo r mor e effi

cien t combustio n an d smok e suppression s i s generall yaccomplishe d byusin g high-velocit ystea mjet s positione d around th e oute r perimete r o f th e flar e tip
. Fo r th e large r flare s stea mca n als o b e injecte d concentricall yint o th e flar e tip
. Fo r some proprietar ydesign s stea m injectio n include s th e aspira

tio n o f ai r alon g wit h th e steam .