# OAR Box 1107
Prepped by Ollie Stewart



### Document

Number: 

# 47 ) IV-E-3
Docket Number: 

# A-81-2 1

Printed 4/11/2008 3:03:46

PM Sheet 47 of 90 P. 1P. 2 

# A-8I-2 I

IV-E- 3

MEMORANDU M
DATE : Januar y

10 , 198 5 TO : Lesli e B . Evans , Chemical s an d Petroleu m Branc h FROM : Kare nK . Fidler , Radia n SUBJECT : Meetin g Repor t - Incinerato r Bypas s Discussio nwit h

B F Goodric hRepresentative s

I . PURPOS E Representative s o f B F Goodric hprovide d infonnatio non incinerato r operation s an d incinerato r bypas s occurrence s a t thei r two ethylen e dichloride/viny l chlorid e (EDC/VC ) facilitie s and si xpolyviny l chlorid e (PVC ) facilities . Thi s informatio nwil l b e use d t o stud y th e nee d fo r a contro l devic e bypas s provisio nfo r th e V C standard . Th e purpos e o f th e meetin g wa s t o gai nfamiliarit y wit hth e desig nand operatio no f contro l device s use db

y th e EDC , «

C and PVC industries . II . PLAC E AN D DAT E U.S . Environmenta l Protectio nAgenc y Nort hCarolin a Mutua l Buildin g Durham , Nort hCarolin a Januar y 7 , 198 5
III . ATTENDEE S Fre dDimmick , EPA/OAQPS/ESED/SD B Lesli e Evans , EPA/OAQPS/ESED/CP B Bo bRosensteel , EPA/OAQPS/ESED/CP B Gi l Wood , EPA/OAQPS/ESED/SD B Susa nWyatt , EPA/OAQPS/ESED/CP B Kare nFidler , Radia nCorporatio n Jef f Shumaker , Radia nCorporatio n Ji m Fannin , B F Goodric h W.C . Holbrook , B F Goodric h
IV . DISCUSSIO N Prio r t o th e meeting , EPA provide d th e B F Goodric hrepresentative s wit h a lis t o f informatio nneed s t o serv e a s th e basi s fo r th e meetin g discussion . (Se e lette r fro

m Evans , L . t o Holbrook , W. , Decembe r 5 , 198^^Docke t No .

. ) Informatio npresente d o n B F Goodrich' s tw

o EDC/VC facilitie s an d si xPV C facilitie s i s summarize d below .

Progres s Center/320 0 E

. Chape l Hil l Rd./Nelso n Hwy./P.O

. Bo x13000/Researc h Triangl e Park , N.C

. 27709/(919)541-910 0P. 3

1 . EDC/VC - L

a Porte , Texa s B F Goodrich' s LaPort e facilit y produce s V

C fro m ethylen e b

y an air-base dprocess . Th e plan t wa s purchase d from Diamon dShamroc k in1982 . Th e facilit y

wa s starte dupin1978 . 1. 1 Incineratio nSyste m Desig nand Operatio n Two identica l JohnZin c incinerator s wer e include d a s origina l equipmen t inth e LaPort e facility . Eac hincinerato r i s equippe d wit ha wast e hea t boile r an dHC l scrubber . On e o f th e system s ha s steam turbin e drive ncombustio nai r blower s and boile r wate r pump s and a cylinde r suppl y o f instrumen t ai r s o tha t i t ca nb e operate ddurin g a powe r failure . Desig nandoperatin g parameter s fo r th e tw o incinerator s ar e a s follows : Desig ncapacit y

Hea t inpu t rat e - [Confidential ] Wast e ga s loa d- [Confidential ] Temperatur e Operatin g - 1,800° F Hig hshutdow

n- 2,100° F Low shutdow n- 1,470° F Residenc e time - 3 se c Th e tw o incinerator s ar e operate d simultaneousl y unles s on e i s dow

nfo r maintenanc e o r repair . Althoug heac hincinerato r i s capabl e o f handlin g al l o f th e ven t gase s generate dunde r norma l proces s operatin g condition s wit h spar e capacity , th e ven t gase s ar e typicall y spli t betwee nth e tw o incinera tors . I nth e absenc e o f wast e ga s load , th e incinerator s ca nb e maintaine d a t thei r operatin g temperatur e b y firin g natura l ga s a t abou t 1 5 t o 2 0 percen t o f th e desig nhea t inpu t rate . Th e incinerator s ar e capabl e o f burnin g liqui dwastes , bu t usuall y ar e no t use d fo r thi s application . 1. 2 Incinerato r Bypasse s Thre e header s (the dr y vent , th e we t ven t an dth e oxyvent headers ) transpor t ven t gase s t o th e incinerator . Manua l valve s positione dremotel y fro m th e contro l roo

m ar e availabl e t o direc t th e flow ineac hheade r betwee nth e tw

o incinerators . However , th e valve s ar e normall y open . I

n th e even t on e incinerato r trips , anautomatic contro l valv e a t th e incinerato r inle t close s thu s divertin g th e portio no f th e ven t gase s goin g t o tha t incinerato r t o th e othe r incinerator . (Thi s ca nbe don e withou t upsettin g th e secondincinerato r inpar t du e t o th e larg e exces s capacit y o f bot hP. 4

systems. ) I f bot hincineratio nsystem s g o down , eac ho f th e header s ar e equippe dwit hmanua l contro l valve s whic hca nb e activate d remotel y fro m th e contro l roo

m t o bypas s th e ven t gase s t o th e atmosphere . Suc hbypasse s d o no t occu r automaticall y bu t requir e operato r activation . (I nadditio nt o th e manua l bypas s control , th e system include s pressur e relie f valve s wit h ruptur e disc s t o ensur e system safety. ) Bypasse d ven t gase s ar e discharge d withou t scrubbin g t o th e atmospher e a t stac k elevation . Condition s whic hautomaticall y resul t inshutdow

no f a nincinerato r and automati c diversio no f ven t gase s t o th e second incinerato r include :

Fue l ga s pressur e to o hig ho r low ; Combustionai r pressur e to o low ; Flame sensor ; Low wate r leve l i nsteam drum ; Hig hwate r leve l inscrubber ; Hig htemperature ; Low temperature ; an

d
Low pressur e i natomizin g steam whe nburnin g liquids . 1. 3 Metho dfo r Estimatin g V C Emission s Durin g Bypas s T o estimat e th e amoun t o f VC emission s inincinerato r bypasses , flow volum e durin g th e bypas s i s note d b y flow measuremen t device s inth e header(s ) anda gra bsampl e i s take no f th e bypas s stream(s) . Determinatio n o f V C emission s inthi s wa y i s considere d t o b e mor e reliabl e tha nestimate s base donbypas s duratio nand typica l ven t stream characteristics . Ga s sample s o f bypasse dstream s ar e take ndurin g o r a s soona s practica l followin g a bypas s event . Th e operator' s firs t priorit y i s t o regai nsystem operation . 1. 4 VC Emission s Durin g Startup/Shutdown A specia l techniqu e use d b y thi s plan t enable s th e oxychlorinatio n reacto r t o star t u pandshu t dow nwithou t ventin g t o th e atmospher e (a s do othe r "ai r based " oxychlorinatio nprocesses) . Detail s o nthi s procedur e ar e no t available . Th e remainde r o f th e plan t wa s designe dfo r norma l startup / shutdow noperation s withou t ventin g t o th e atmosphere . Unplanne do r "crash " shutdown s similaril y

d o no t requir e incinerato r bypas s unde r mos t circumstances .P. 5

1. 5 Impac t o f Oxychlorinatio nVen t Th e oxyven t make s u

p94. 8 percen t b

y weigh t o f th e ven t gase s burne di n th e incinerators . However , becaus e o f th e exces s capacit y availabl e fo r th e two incinerators , oxyven t surge s ar e easil y handled . A s a result , n o incinerato r bypasse s hav e occurre dove r th e pas t tw o year s (198 3 - 1984 ) becaus e o f oxyven t surges . 1. 6 Incinerato r Bypas s Histor y Th e followin g informatio no n1 0 pp m exceedence s andincinerato r bypasse s durin g 198 3 and198 4 wa s provided : 198 3 198 4 1 0 pp m exceedence s 2 h r 0 h r Cumulativ e bypas s tim e 1. 2 h r 4 h r Th e B F Goodrich/LaPort e facilit y ha s experience da tota l o f fiv e incinerato r bypas s incident s durin g th e two-yea r perio d198 3 throug h1984 . Informatio nonth e bypas s incident s i s summarize da s follows :

Duratio nAmoun t Dat e (min ) (l bVC ) Cause 12/8 3 - 0. 4 Froze nboile r fee dwate r line . 5/8 4 14 8 16 6 Steam pressur e los t durin g powe r failure . Problem

wa s a t adjacen t Diamon dShamroc k facilit y fro m whic h powe r i s received . Powe r faile d twic e i nsuccession ; bypas s occurre d durin g secondfailure . 5/8 4 2 0 - Hig hhea t conten t i nven t ga s cause d b y fault y liquid/vapo r interfac e indication . Instrumen t failur e i s attribute dt o th e earlie r powe r failure . 7/8 4 7 1 5 Ven t heade r bypasse dt o atmospher e whil e investigatin g tw o leak s i nth e incinerato r fee dline . Th e firs t lea k wa s stoppe dan

dth e second reduced ; th e secon dlea k wa s repaire d durin g th e nex t bypas s below . 7/8 4 4 6 11 4 Ven t heade r bypasse dt o atmospher e whil e repairin g sectio no f incinera to r fee dline .



# <+P. 6

12/8 4 1 7 - Plan t stea m boiler s shu t down , triggerin g ga s lin e pressur e surg e and hig hstea

m demandfrom

incinera to r hea t recover y

system . Incinera tor s trippe d du e t o eithe r pressur e surg e o r lo

w wate r leve l i nhea t recover y steam drum . 2 . EDC/V C - Calver t City , Kentucky B F Goodrich' s Calver t Cit y facilit y

currentl y

produce s ED C an

d V C in severa l productio nunits . Th e newes t uni t wa s adde din1982 . 2. 1 Incineratio nSystem Desig nan d Operatio n Thre e incinerator s ar e availabl e t o bur nven t gase s a t th e Calver t Cit y facility . Th e "primary " and "secondary " incinerators , manufacture d b y John Zinc , wer e adde dt o th e olde r EDC/VC productio nuni t t o mee t th e V C standar d regulations . Th e "oxy " incinerator , manufacture d b y McGill , wa s constructe d wit hth e newes t ED C uni t in1982 . Th e primar y and ox y incinerator s ar e equippe dwit hwast e hea t boiler s an dHC l scrubbers ; th e secondar y incinerato r vent s directl y t o th e atmosphere . Desig nan doperatin g parameter s fo r th e thre e incinerator s ar e a s follows : Desig nhea t inpu t rat e

Primar y - [Confidential ] Secondar y

- [Confidential ] Ox y - [Confidential ] Desig nwast e ga s loa d Primar y - [Confidential ] Secondar y

- [Confidential ] Ox y - [Confidential ] Operatin g temperatur e Primar y - 1800° F Secondar y

- 2000° F Ox y - 1800° F Residenc e time Primar y - 2 se c Secondar y

- 2 se c Ox y - 1 se c



## 4 fP. 7

Turndowncapabilit y

( % o f desig nhea t input ) Primar y - 30 % Secondar y

- 20 % Ox y - 25 % Th e oxy incinerato r wa s size d t o handl e th e oxychlorinatio nven t from th e ne w plan t i nadditio nt o th e othe r proces s vent s fro m bot hproductio n units . (Th e oxyven t from th e olde r plan t i s no t require d t o b e incinerate d fo r V C o r hydrocarbo ncontro l purpose s and i s therefor e vente d t o th e atmosphere. ) Th e primar y incinerato r ca nbur nal l vent s from bot hunit s wit hth e exceptio no f th e new oxyvent . Normally , th e primar y and ox y incinerator s ar e operate da t al l time s wit hth e secondar y incinerato r on col dstandby . Th e primar y incinerato r ca nb e maintaine d a t operatin g temperatur e b

y burnin g natura l ga s only . I f eithe r o f th e primar y o r ox y incinerator s trips , th e ven t gase s (excep t th e ox y vent ) ar e manuall y diverte dt o th e operabl e incinerato r fro m th e contro l room . I f eithe r o f th e primar y

o r ox y incinerator s i s down , th e secondar y incinerato r i s brough t upt o ho t standby an d operate d a s needed . (Startu p o f th e col d incinerato r require s 1 day. ) Th e secondar y incinerato r i s use donl y ona n a s neede dbasis . 2. 2 Incinerato r Bypasse s Fiv e ven t header s (tw o dr y ven t headers , tw

o we t ven t header s an d on e decommissionin g line ) carr y ven t gase s fro

m th e tw o productio nunit s t o th e primar y incinerator . Thes e ven t stream s canb e manuall y switche d fro

m th e contro l roo

m t o th e secondar y

o r ox y incinerator . Th e oxyven t fro m th e new uni t i s ducte di na separat e heade r t o th e oxy incinerator . Whe npressur e inon e o f th e ven t header s exceed s th e capacit y o f th e operatin g incinerators , a portio no r al l o f th e ven t gase s inth e heade r ar e automaticall y

diverte dfro

m th e incineratio nsystem . I nth e cas e o f the dr y ven t an ddecommissio nven t headers , th e diverte dven t gase s ar e burne dina flare . Diverte dwe t ven t an d oxyven t gase s ar e vente d t o th e atmosphere . Th e flar e use dt o bur ndiverte d dry ven t gase s wa s constructe d prio r t o th e V C standar dfo r safet y purpose s (i.e. , t o handl e relief s o f flammabl e materials) . Currently , th e flar e i s primaril y use d fo r V

C service . Specifi cally , th e flar e i s maintaine d a t ho t operatin g condition s (i.e. , natura l ga s continuall y

burne di

nth e flar e hea d burner ) t o combus t occasiona l VC-containin g relie f valv e discharge s an d incinerato r bypasses . Th e flar e i s equippe dwit ha smokeles s tip . Th e flar e wa s size d t o handl e sporadic , emergenc y

vents ; sufficien t capacit y i s therefor e availabl e t o handl e incinerato r bypasses . Th e V C destructio nefficienc y i nth e flar e i s unknown . B F Goodric hha s focuse dadministrativ e attentio nonincinerato r bypasse s a t th e Calver t Cit y facilit y

i nanattemp t t o minimiz e their frequenc y

an dduration . A s a result , stead y improvemen t inperformanc e ha s

<oP. 8

reportedl y

bee nachieved . Hardwar e improvement s includ e flam e arresto r replacement , additio nan dreplacemen t o f knockou t pots , and additio no f cross-connection s betwee nven t header s t o minimiz e th e effec t o f plugge d headers . Th e ne w

ox y incinerato r i s locate donth e opposit e sid e o f th e plan t fro

m th e olde r primar y

and secondar y

incinerator s an d consequentl y ha s a separat e fee dlin e system . Thi s arrangemen t ensure s tha t a fee d lin e plu g wil l rende r onl y

on e o f th e incinerator s inoperable . 2. 3 Metho dfo r Estimatin g V C Emission s Durin g Bypasse s Th e amoun t o f VC bypasse d i s calculate d onth e basi s o f th e bypas s duratio nandV

C conten t desig ndat a representativ e o f th e operatin g condition s prevailin g a t th e tim e o f th e bypass . Th e ven t header s a t thi s facilit y ar e no t equippe dwit hflow measuremen t device s and samplin g points . 2. 4 V C Emission s Durin g Startup/Shutdown Durin g startup , th e oxychlorinatio nreacto r i nth e new uni t i s vente d t o th e atmospher e fo r a perio d o f 1 5 t o 2 0 minutes . V C emission s durin g startu pd o no t excee dth e 0.2g/k g ED C standard . (Meetin g th e standar d i s onl y a proble m

i f proces s upset s occu r durin g startu p and th e proces s goe s dow nwithou t littl e o r no resultin g ED C production. ) 2. 5 Impac t o f Oxychlorinatio nVen t
B F Goodric hreport s no significan t impac t b y the oxyven t onincinerato r operation s a t thi s facility . Incinerato r on-stream time i s reportedl y

mor e affecte db

y th e ag e o f th e incineratio nsystem tha nth e presenc e o f th e oxyvent . 2. 6 Incinerato r Bypas s Histor y Th e B F Goodrich/Calver t Cit y facilit y

provide s informatio no n1 0 pp m exceedences , flar e usag e and incinerato r bypasse s t o the stat e o f Kentucky . A summar y o f th e informatio nreporte d fo r 198 3 an d 198 4 i s give nbelow . 198 3 198 4 1 0 pp m exceedence s 3 h r 4 h r Cumulativ e bypas s time 1 hr 2 hr Flar e usag e 15. 9 h r 121. 6 h r Informatio nonbypas s incident s and flar e usag e durin g 198 3 and 198 4 i s a s follows :



# 1P. 9

Bypasse s Dat e
2/8 3 3/8 3 4/8 3 5/8 3 12/8 3 11/8 4

Dat e
9/8 3 9/8 3
10/8 3 10/8 3
12/8 3
12/8 3

1/8 4 1/8 4

1/8 4 1/8 4 4/8 4 Duratio n

(hr ) 0.2 3 0.0 5 0.2 5 0.1 7 0.2 5 

### 2. 0

Duratio n (hr ) 0.0 5

0.1 7 0.1 2

-



### 0. 3

• — 

### 0. 4 Amoun t V C Bypasse d (lb )

-

-

- 0.7 5

Flar e Usag e Amoun t V

C Vente d t o Flar e (lb ) 0. 1 10,40 0

- 0.1 2
1,82 5

0.1 3



### 430 0.1 6



### 0. 6 2 0. 8 Caus e

Unknow n Unknow n Unknow n Unknow n Interna l powe r failur e Interna l powe r failure ; los s o f instrumen t ai r

Caus e

Instrumen t failur e Cracke d valv e o

n relie f valv e heade r Interna l powe r failur e Highpressur e dro p i n scrubbe r Leakin g valv e o

n relie f valv e heade r Proces s - upse t highfue l con ten t i nven t stream Plugge d flam

e arrestor s Highven t load ; 1 incinerato r dow nfo r maintenanc e Liqui d i nfee d Plugge d flame arresto r Proces s upse t i

n HTD C reacto r



# tP.1 0

4/8 4

4/8 4 

### 9

6

0.0 8
5/8 4 6/8 4 6/8 4

7/8 4
7/8 4 0.0 9

0.3 7 0.0 1

0.0 7

0.0 7 9,75 0



### 2 0
5 5 16. 5 

### 35 0

0.1 3

188 0 Leve l controlle r malfunctio non V C strippin g colum n Overpressur e in VC loadin g pum

p suctio nlin e Hig hpressur e i n ven t heade r Instrumen t erro r onVC colum

n Prematur e ruptur e dis c failur e on V C crackin g colum n Proces s upse t durin g startu p o f HTD C reacto r Prematur e ruptur e dis c failur e on V C crackin g colum n 3 . PV C Plant s B F Goodric hoperate s si xPV C plant s inth e U.S . Th e plant s var y in size , ag e andresi ntype s made . Informatio nonth e desig nan d operatio no f th e contro l device s use da t th e si xplant s i s summarize d a s follows : Plan t Contro l Devic e

Primar y Backu p Incinerato r Non e

B Solven t absorbe r Incinerato r Performanc e Histor y (1983-1984 )

- no 1 0 pp

m exceedence s

- 2 2 hr cumulativ e bypas s time

- 42 9 l bV

C bypasse d

- Causes : instrumen t failure ; highiner t load ; hightemperatur e i nquenc hwate r Note : plan t ca nshu t dow nwithou t venting .

- no 1 0 pp

m exceedence s

- n o bypasse s

- backu pincinerato r operate d1.3 % o f time



# 1P.1 1

C Solven t absorbe r Incinerato r

D Solven t absorbe r Incinerato r

E Solven t absorbe r Incinerato r

F Solven t absorbe r Solven t absorbe r 1 h r 1 0 pp m exceedenc e no bypasse s backu p incinerato r operate d 3.4 % o f time 7 5 h r 1 0 pp

m exceedenc e n o bypasse s backu p incinerato r operate d 15.5 % o f time 17 1 h r 1 0 pp

m exceedenc e n o bypasse s backu p incinerato r operate d 4.6 % o f time 3 3 hr 1 0 pp

m exceedenc e no bypasse s Th e B F Goodric hrepresentative s mad e th e followin g genera l observation s abou t contro l devic e operation s a t thei r PV C plants : Plant s B throug hF hav e availabl e pressurize d storag e tank s t o temporaril y

stor e ven t gase s inth e even t o f contro l devic e failure . Capacit y

o f th e storag e vessel s var y bu t cantypicall y hol dven t gase s generate d durin g a norma l . 8 h r shift . Reporte dexceedence s o f th e 1 0 pp m standar d b

y gase s tha t ar e vente dthroug hsolven t absorber s ar e typicall y cause d b

y hig hven t flow , col dsolvent , V C monito r malfunctions . Pas t experienc e indicate s tha t absorbe r problem s ca nusuall y b e remedie dbefor e th e backu p incinerato r i s starte du p (abou t 1- 2 hours) . Operato r attentio ni s usuall y focuse doncorrectin g th e absorbe r problem

rathe r tha nonstorin g an dincineratin g ven t gases .



### /b