### ·

. , , 

## RADIAN
CORPORA"'ON MEMORANDUM
TO: David Markwardt, EPA/CPB (MD-13) FROM:

. Daryl J. Whitt, Radian DATE: 5 June 1991 SUBJECT: Impacts from the Control of VHAP Emissions from Equipment Leaks in Non-SOeM! Process Units for HON

The purpose of this memorandum is to present and document the impacts from the control of Volatile Hazardous Air Pollutant (VHAP) emissions from equipment leaks for select process units which are not included in the Synthetic organic Chemical Manufacturing Industries (SOCM!) impacts for the Hazardous organic NESHAP (HON). These impacts apply to process units using the designated VHAPs in the seven source categories listed in paragraph (c), section XX.XQ of the National Emission standard for Equipment Leaks (also known as the Equipment Leaks Negotiated RegUlation or Reg Neg). The seven source categories and designated VHAPs are: (1) styrene-butadiene rubber production (butadiene and styrene); (2) Polybutadiene production (butadiene); (3) Chlorine production (carbon tetrachloride); (4) Pesticide production (carbon tetrachloride, methylene chloride, and ethylene dichloride); (5) Chlorinated hydrocarbon use (carbon tetrachloride, methylene chloride, tetrachloroethylene, chloroform, and ethylene dichloride); (6) Pharmaceutical production (carbon tetrachloride, and methylene chloride); and (7) Miscellaneous butadiene use (butadiene). This memorandum presents the baseline emissions, emission reductions, and cost impacts attributable to implementation of the Reg Neg for these seven source categories.The methodology used for this impacts analysis was divided into three steps. The procedure and results of each of these steps are discussed in greater detail below. These steps were:

• step 1. section**11~site** survey response letters from select facilities within the seven source categories
were reviewed. These response letters had been obtained under a previous work assignment and new information gathering was not required.

• step 2. Federal "and state regulations were reviewed to determine if any equipment leak emission "controls requirements are already in place for these source categories.

• step 3. Based on information gathered during the first two steps, control costs, baseline emissions, and emission reductions, were estimated using the equipment count based algorithms which were developed for evaluation of SOCHI processes. 1,2 The impacts presented in this memorandum are based exclusively on the responses to the Section 114 survey. The responses included equipment counts for the facilities but may not represent a complete accounting of all equipment in VHAP service. Further, this is only a sub-set of the actual number of facilities within the seven non-SOCMI industries. Impacts for the entire industries have not been estimated because the number of process units within each industry is unknown. It is assumed that the process units evaluated here are representative of the
seven industries, but this cannot be determined from the available data.

SECTION 114 SURVEY RESPONSE LETTERS Response letters to surveys authorized under Section 114 of the Clean Air Act were reviewed for 86 facilities believed to be included in the seven non-SOCMI source categories. The process units at these facilities were then checked to ensure applicability of the Reg Neg and prevent overlap with process
jkb.076 VlIAP .1lIeIft 2· , -,' units included in the SOCMI impacts already evaluated under HON. Any process units not covered by the Reg Neg or included in the soeMI impacts were removed from this analysis. The final list of facilities included a total of 60 process units. The survey response for each process unit included in the final list was reviewed to determine geographic location and equipment counts. The information gathered from the survey responses of the 60 process units is presented in Table 1. The geographic location of each process unit was used to determine if the unit is in a state which already has regulations in place requiring equipment leak emissions controls. This was later used to assign the costing and emissions algorithms which
use different baseline emission factors for process units in states with control regulations and in states without control regulations. The baseline emission factors used for units in states without equipment leak regulations are the Ituncontrolledll factors presented in Table 2, while the factors used for units in states with equipment leak regulations are the llCTG controlledl ' emission factors. 2 The "CTG controlled" emission factors are used to estimate equipment leaks emissions from equipment controlled to the level specified in the SOCMI CTG for Equipment Leaks. 3 Table 2 also presents the MACT controlled emission factors, which
are used to estimate equipment leak emissions after Reg Neg controls are in place. The emission reductions are then estimated as the difference between baseline emissions and Reg Neg controlled emissions. The equipment counts for each process unit were used in the algorithms developed for the SOCMI impacts analysis. These algorithms are used to estimate baseline emissions, emission reductions, and cost impacts for each process unit as a function of the equipment counts contained in the section 114 responses. Some of the information contained in the section 114 survey response letters required clarification. First, the surveys

, listed pumps as having packed seals, mechanical seals, or double mechanical seals. Pumps with double mechanical seals are exempt

jltb.076 VHAP .1IlellI 3TABLE 1. NON-SOCMI PROCESS UNIT LOCATIONS AND EQUIPMENT COUNTS

Section

114 File

No. Facil ity Name location PUIlJ Seals (a)

••••••
----- •••• Compressor

LL HL Seals SlIq)le Open Valves (a) Pressure Connections Ended lines

-- •••••••
----- ••••••••• Relief ••••••••
---- •••••••••••••
- •• Flanges Gas LL Nl Devices Gas liq Gas liq
STYRENE'BUTADIENE RUBBER PRODUCTION ====:========================:c;==========c=============c======_==e:=================:==:_==::::===::==:============:::=:::::=:======:==========:===========: EQ051 American Synthetic Rubber Corp. louisville KY 10 2 450 3 120 10 40 EQ054 BF Goodrich Co. Port Neches TX 10 30 6837 732 740 EQ056 Copolymer Rubber & Chemical Baton Rouge LA 28 2661 30 1225 11 73 EQ065 BASF (formerly Polysar) Chattanooga TN 17 1 950 131 128 16 2 1 18 EQ065 BASF (formerly Polysar) Chattanooga TN 14 7 1343 87 162 35 6 36 2 163 EQ075 Goodyear Tire &Rubber Co. Houston TX 35 15 1600 100 2100 1 5 20 5 EQ076 Goodyear Tire &Rubber Co. Calhoun GA 7 3 350 142 164 30 12 2 10 EQ084 Gencorp, Inc. Odessa TX 20 4 2409 221 697 19 16 16 63 83 EQ085 Gencorp, Inc. Mogadore OH 7 1 650 12 130 32 2 20 8 oC>o EQ086 \I.R. Grace & Co. Owensboro KY 5 1 105 14 36 16 7 16 5

..... 

### --_ --------- 

### -------- _-------- _-----_ 

### -.---_ _------ 

### ---- _-----_ _---- -- _--_ 

### _---- ---
POLYBUTADIENE PRODUCTION**====================================================== ====;=========;========================~=======c=c=====================aa=c==a==c================a~==ac**  EQ051 American Synthetic Rubber Corp. Louisville ICY 34 6 2250 545 55 70 EQ052 ARCO Chemical Co. ChaMel View TX 31 150 300 4 28 60 EQD66 Phillips Petroleum Co. Borger TX 18 91 173 34 EQ067 Polysar Limited Orange TX 34 5 3200 50

. 502 58 EQ071 Union Carbide Corp. Institute W 0 80 30 15 2 EQ073 Goodyear Tire &Rubber Co. Beaunont TX 18 4 708 239 103 15 30 EQ073 Goodyear Tire & Rubber Co. Beaunont TX 23 2 892 417 71 26 EQ082 Firestone Orange TX 42 2 2376 398 2517 8 26 68 708 EQ083 firestone lake Charles LA 14 1 46 248 3 ••...........

__ _ .. 

### -- _--------_.- - _._ .••••....••...••..

_ _....••.••••...........•• _.- _----

__ .. _------ 

### _- (a) Pump seals and valves are divided Into equipment in light liquid service (LL) and heavy liquid service (Nl) where data are available.



# , L

## (

TABLE 1. 

## (
(Continued) 

### (

Section

114 File

No. Facil ity Name Location PUlp Seals (0)

II Hl COII'pressor Seals SBq)le Open Valves (a) Pressure Connections Ended lines ••••..••••.•••••••••••• Relief ••••••.•••.••••••••••••••••. Flanges Gas II Hl Devices Gas liq Gas liq
CHLORINE PRODUCTION ====;=:=================================================c=======:=====:=====::=:::==:=====:=:=:====::=:=========_:;==============_:::::===:===::==:=:===:=::: EQ033 D I amend Shamrock Deer Park TX 2 140 34 EQ033 Diamond Shamrock BattlegrOUld TX 0 5 402 80 222 13 48 EQ033 Diamond Shamrock Mobil AL 3 42 37 EQ033 Diamond Shamrock Muscle Shoals AL 3 140 51 2 16 18 EQ033 Diamond Shamrock Delaware City DE 5 356 83 19 EQ038 Du Pont Corpus Christi TX 0 29 8

PESTICIDE PRODUCTION =============:m=============c==========================e===::::::::====::::=:==::===:::::::=:::::=::=:=====::==========:===================================== 01 EaOD1 Buckman laboratories, Inc. Cadet MO 4 48 14 9 4 EQD01 Buckman laboratories, Inc. Meqlhis TN 16 0 124 42 46 0 0 13 1 0 EQ002 Chevron Chemical Corp. Richmond CA 29 264 296 735 18 2 26 25 110 Ea002 Chevron Chemical Corp. Maryland Heights MO 1 2 2 Ea003 DuPont La Porte TX 13 2 1043 92 167 11 10 38 46 EQ004 FHC Corp. Baltimore HO 0 445 112 12 6 14 Ea005 Hobey Chemical Corp. Kansas City HO 6 46 6 Ea007 Monsanto Agricultural Prod. Amiston Al 5 6 200 20 80 8 4 2 2 EQ008 Union Carbide Agrig. Prod. Co. Institute W 8 678 590 5 EQ008 Union Carbide Agria. Prod. Co. Institute W 7 1128 623 17 Ea009 Union Carbide Agrig. Prod. Co. \loodblne GA 20 S 9

CHLORINATED HYDROCARBON USE**=================0================================:;:: :::=====:==::=:==:::======c======c=~==================** **=================================================** EQOOS Hobey Chemical Corp. EQ035 General Electric Co. Baytown MO\.nt Vernon TX IN 48 94 1750 75 4 11053 212 811 1700 2 71 27 40 125 15 188 43

....... -_ .. 

### ----------.---- .. 

### _----- _.----------_.-------------- 

### _--- .. _--_ 

### _--- - _--.--_ _- --_ _.--- 

### -.--- (a) Pump seals and valves are divided Into equipment in light liquid service (ll) and heavy liquid service (HL) where data are available.TABLE 1. (Continued)

Section

114 File

No. Facil ity Name Location PUlP Seals (a) .•••••.•••••••. Compressor

LL HL Seals SIIII'ple Open Valves (a) Pressure connections Ended Lines ••....•••••.•.....•..•• Relief ••••••....•••••••••••••••••• flanges Gas LL HL Devices Gas liq Gas liq
PHARMACEUTICAL PRODUCTION :====================================;======================================================================================================================= EQ011 :The UpJOOn Co. Kalamazoo MI 185 2550 2275 240 270 760 EQ012 The UpJOOn Co. Barceloneta PR 7 450 7 53 ·15 7 15 EQ013 Eli Lilly & Co. lafayette IN 54 4500 EQ013 Eli Li lly & Co. Cl inton IN 31 EQ014 Eli Lilly & Co. Indianepol is IN 2 4 38 4 EQ015 Abbott Laboratories Abbott Park IL 1 12 6 12 3 3 EQ016 Abbott Laboratories CNC 0 8 50 8 8 3 EQ017 Abbott Laboratories PPR 

# ,. 10 5 3 3 EQ018 Abbott Laboratories North Chicago IL 13 165 34 26 9 1 4 EQ019 Abbott Laboratories CNC 11 50 24 6 9 3 6 5 2 0\ EQ020 Abbott Laboratories CPR 3 76 49 7 4 EQ021 Merck Chemical Co. Barceloneta PR 56 500 3 40 4 5 6 EQ022 Merck Chemical Co. Rahway NJ 39 698 114 266 43 42 3 4 EQ023 Merck Chemical Co. Danville PA 47 2200 396 44 44 44 EQ024 Merck Chemical Co. Albany GA 27 2165 193 348 31 48

........... _------.---- -_._-------.-

__ 

### ---------- _------------ 

### ------- _---------- _------_ 

### _------- _----- --- . MISCELLANEOUS BUTADIENE USE**================~===================================== ==================================================================;:====================::=============**  EQ066 Phillips Petroleun Co. Borger TX 3 95 38 68 1 3 4 7 EQ066 Phillips Petroleun Co. Borger TX 0 2 10 3 EQ068 Room and HaaS Kentucky Louisville ICY 4 1 143 10 45 8 4 EQ069 SOOio Lilll8 OH 1 1 6 4 2 3 4 9 EQ070 Uniroyal Painesville OH 11 7 490 40 196 16 12 24 21 EQOn Monsanto Polymer Prod. Muscatine IA 3 1 136 19 69 1 0 5 2 9 EQ074 Goodyear Tire & Rubber Co. Akron OH 1 3 992 190 304 ••...........

### _- -.--- _---------_.---- 

### _-- --------- _-_ _----- -----.- _------- ----._--.-._--- (a) Pump seals and valves are divided into equipment in light**liq~id** service (lL) and heavy liquid service (HL) where data are available.TABLE 2. SUMMARY OF EQUIPMENT LEAK VOC EMISSION FACTORS

jkb.D76 VHAP.llIeIlI 7from the Leak Detection and Repair (LDAR) requirements of the Reg Neg, provided they are equipped with a heavy liquid barrier fluid system**wh~ch** is operated at a pressure above the stuffing box pressure or are controlled with a closed-vent or closed-purge system. To be exempt from the routine leak detection and repair requirements for pump seals, the barrier fluid system must also have a sensor to detect seal failure. It was assumed that pumps 

### in existing process units would not meet all of these exemption requirements and, therefore, were included 

### in this analysis. Second, whether the pumped fluid was heavy liquid or light liquid was not stated. To be used 

### in this analysis, a determination of heavy liquid or light liquid service would be required. Pump seals 

### in heavy liquid and light liquid service
use different emission factors and are controlled differently by the Reg Neg. Therefore, the designated VHAPs of concern for each
source category were evaluated. All of the VHAPs (butadiene, styrene, carbon tetrachloride, methylene chloride, ethylene dichloride, tetrachloroethylene, and chloroform) are light liquids. Therefore, all pumps were assumed to be 

### in light liquid service and the total number of pumps was used. Further, this represents the worst case high cost for the process units. Third, the section 114 survey responses listed separate equipment counts for equipment in gas service and in liquid service for sample connections and open-ended lines. The equipment counts for each of these equipment types were summed for this analysis since the Reg Neg requires identical controls for all equipment of these types, regardless of service.

EXISTING REGULATIONS

Federal and state regulations for six states were reviewed ) to determine which process units are located in areas with applicable equipment leak control regUlations. This information
was used to determine which baseline emission factors and algorithms should be applied to each process unit. Process units in areas without regUlations , were evaluated using the

jkb.076 VHAP.mem 8"uncontrolled" emission factors and algorithms which estimate impacts based on a process unit with no regulatory-driven program in place for reducing emissions from equipment leaks. Process units 

### in areas with regulations were evaluated using the "CTG controlled" emission factors and algorithms which estimate impacts based on a process unit with controls meeting the guidance contained in the SOCHl CTG.

Federal Regulations

The review of federal regulations revealed that equipment leak emissions from equipment in VHAP service for these seven source categories are not currently regulated by the federal government. Therefore, the impacts for each process unit were estimated based on state equipment leaks control regulations. Existing process units in states which adopt federal NSPS requirements were assumed to have no applicable regulations and
were evaluated using the "uncontrolled" baseline emission factors and algorithms which estimate impacts based on a process unit with no existing controls.

state Regulations Regulations for six states (Illinois, Louisiana, New Jersey, Ohio, Texas, and West Virginia) which had been initially reviewed for all of HON were rechecked for this analysis. Based on the equipment leak regulations found in these six states, assumptions
were made to extend the analysis to cover the seven source categories in alISO states. Regulations for alISO states were not reviewed. Originally these six states were chosen for the review because 61 percent of the SOeMI facilities are located

••. 4 w1th1n these states. The assumptions made to extrapolate this data are discussed in greater detail below. A summary of the final determination of regulatory status for each source category in each state is presented in Table J.

jkb.076 VHAP

..... 9by-step for the SOCKI equipment leaks cost impacts and are discussed in more detail in the April 15, 1991 memorandum from Daryl Whitt to David Markwordt'. The algorithms were compressed into two series of eight equations for this analysis. The results of these equations are:

• Equation 1. Capital Costs;

• Equation 2. Annualized Capital Costs;

• Equation 3. Annualized Operating Costs;

• Equation 4. Total Annualized Costs;

• Equation 5. Baseline Emissions (Mg Voc/yr);

• Equation 6. Emissions Reduction (Mg Voc/yr);

• Equation 7. Net Annual Cost; and,

• Equation 8. Cost Effectiveness ($/Mg HAP). One series of these equations was developed based on the "uncontrolled" baseline emission factors and the purchase of control equipment to meet the requirements of the Reg Neg. The second series of these equations was developed based on the "CTG controlled" baseline emission factors and the purchase of control equipment to improve a process unit from meeting the recommended control levels of the SOCMI CTG for Equipment Leaks to meeting the requirements of the Reg Neg. The procedure used to develop these equations is discussed in Attachment 1. It should be noted that these equations have been developed based on the same costs, monitoring frequencies, leak frequencies, and other assumptions used for the SOCMI impacts analysis. However, the results of this analysis are based on the equipment counts reported for specific process units and not model units. Therefore, the results for anyone process unit in this analysis may vary greatly from the results of anyone model unit in the SOCMI analysis, but the average of the results for a source category in this analysis should be similar to the results of using the SOCMI model units.

jkb.076 VHAP.1lIeIIl 14TABLE 3. (Continued)

Equipment Leaks Unlssions Control Regulations for Existing Units in Place?

State StyreneButadiene

Rubber Production PolyButadiene Production Chlorine Pesticide Production Production Chlorinated Hydrocarbon Use Pharmaceut IcaI Production Miscellaneous Butadiene Use
South Dakota No No No No No No No Tennessee No No No No No No No Texas Yes Yes No No Yes No Yes Utah No No No No No No No Vermont No No No No No No No Virginia No No No No No No No Washington No No No No No No No West Virginia No No No No No No No Wisconsin No No No No No No No Wyoming No No No No No No No (1) In Kentucky, regulations apply only in Boone, Boyd, Campbell, Jefferson, and Kenton counties. (2) In Michigan, regulations apply only in Kent, Lapeer, Livingston, Macomb, Monroe, Muskegon, Oakland, Ottowa, St. Clair, Washnetaw, and Wayne counties. (3) In Missouri. regulations apply only in Jefferson. St. Charles, Franklin. and St. Louis counties and in the city of St.Louis.

11TABLE 3. SUMMARY OF REGULATORY STATUS ASSUMED FOR EQUIPMENT LEAKS 

# ..; NON-SOCMI SOURCE CATEGORIES .. EMISSIONS CONTROLS FOR
Equipment Leaks Emissions Control Regulations for Existing Units in Place?

------------------------------------------------------------------------------------------

StyreneButadiene Poly· Chlorinated Miscellaneous

Rubber Butadiene Chlorine Pesticide Hydrocarbon PharmaceutIca 1 Butadiene State Production Production Production Production Use Production Use**======Gaaaa=aa=========~ccc=a===========ca8eaa==~z==~c=ee====aaaa============~=======a===cDceee==========** Alabama No No No No No No No Alaska No No No No No No No Arizona No No No No No No No Arkansas No No No No No No No California No No No No No No No Colorado No No No No No No No Connecticut No No No No No No No Delaware Yes Yes No No Yes No Yes Florida No No No No No No No Georgia No No No No No No No Hawai i No No No No No No No Idaho No No No No No No No 111 inois Yes Yes No No Yes No Yes Indiana No No No No No No No Iowa No No No No No No No Kansas No No No No No No No 

# -J Kentucky (1) Yes Yes No No Yes No Yes Louisiana Yes Yes No No Yes No Yes Maine No No No No No No No Maryland No No No No No No No Massachusetts Yes Yes No No Yes No Yes Michigan (2) Yes Yes No No Yes No Yes Minnesota No No No No No No No Mississippi No No No No No No No Missouri (3) Yes Yes No No Yes No Yes Montana No No No No No No No Nebraska No No No No No No No Nevada No No No No No No No New Hampshire No No No No No No No New Jersey Yes Yes No No Yes No Yes New Mexico No No No No No No No New York No No No No No No No North Carolina Yes Yes No No Yes No Yes North Dakota No No No No No No No Ohio Yes Yes No No Yes No Yes Oklahoma No No No No No No No Oregon No No No No No No No Pennsylvania Yes Yes No No Yes No Yes Rhode Island No No No No No No No South Carolina No No No No No No No

10

### Chlorine, Pesticide, and Pharmaceutical Production units. The review of regulations for the six states listed above indicated that there are currently no regulations controlling VHAP emissions from equipment leaks for chlorine production units, pesticide production units, and pharmaceutical production units. Therefore it was assumed that equipment leaks emissions for these industries are not controlled by regulations in any state. For this analysis, all process units in these three
source categories were evaluated using the "uncontrolled" baseline emission factors and algorithms which**es~imate** 

### impacts based on a process unit with no existing controls. styrene-Butadiene Rubber Production, Polybutadiene Production, Chlorinated Hydrocarbon Use, and Miscellaneous Butadiene Use. The remaining four source categories, styrene-butadiene rubber production, polybutadiene rubber production, chlorinated hydrocarbon use, and miscellaneous butadiene use are all considered to be polymer production units for this analysis. This assumption was made since all of

### ~hese categories primarily produce polymers according to the

## ~efinitions in the Reg Neg. The chlorinated hydrocarbon use and miscellaneous butadiene use categories are not exclusively polymer production processes. However, all of the compounds covered by these categories are polymers, polymer additives, monomers, or, in the
case of chlorinated hydrocarbon use, pesticides (which are covered above). Further, the only two process units listed under chlorinated hydrocarbon use for this analysis are polycarbonate production units. In all six of the states reviewed, polymer production units had the same regulatory requirements as SOeMI process units. Illinois, Louisiana, New Jersey, Ohio, and Texas require VHAP equipment leak emissions from both SOeMI and polymer production units to be controlled. West Virginia regulations adopt the federal NSPS requirements and, therefore, do not require controls for existing SOeMI units or existing polymer production units. Based on these findings, styrene-butadiene rubber production, polybutadiene rubber production, chlorinated hydrocarbon use, and

jkb.076 VHAP.lIIelll 12miscellaneous butadiene use process units in Illinois, Louisiana, New Jersey, Ohio, and Texas were evaluated using "CTG controlled" baseline emission factors and algorithms which estimate impacts based on a process unit with controls meeting the SOCMI CTG recommendations. Process units in West Virginia were evaluated using the "uncontrolled" baseline emission factors and algorithms which estimate impacts based on a process unit with no existing controls. It was assumed that polymer processing units were controlled to the CTG level in all states which had been assumed to be controlled to the CTG level for SOCMI units. Therefore, styrenebutadiene rubber production, po1ybutadiene rubber production, chlorinated hydrocarbon use, and miscellaneous butadiene use process units in Michigan, Pennsylvania, Kentucky, Delaware, Massachusetts, and Missouri were also evaluated using "CTG controlled" baseline emission factors algorithms which estimate impacts based on a process unit with controls meeting the SOCMI CTG recommendations. Process units in all other states were evaluated using the "uncontrolled" baseline emission factors and algorithms which estimate impacts based on a process unit with no existing controls. The designation of these states is based on the July 13, 1990 memorandum from Lee Gabele to Fred Crane, Bennett King, and Ed Moretti regarding HON Equipment Leaks-States with CTG Level of Control for Existing sources. 5 For those states which specify counties as being controlled, it was assumed that other counties did not have regulatory controls. The county location of process units in the seven source categories in the affected states were then checked to determine if regulations applied.

CONTROL COSTS AND EMISSION REDUCTIONS
The control costs and emissions reductions were estimated as a function of unit equipment counts using algorithms developed for monthly valve monitoring for the SOCMI equipment leaks**.~** impacts analysis under HON. The algorithms were developed stepjkb.076 VHAP.menI 13RESULT AND CONCLUSIONS

For each of the 60 process units included in the seven nonSOCMI source categories the capital cost, annual costs, baseline emissions, emission reductions, net annual costs, and cost effectiveness were estimated using the equations. These results
are presented in Table 4. The average costs, emissions, and emission reductions were calculated for each source category. The costs, emissions, and emission reductions were then summed for each source category. The average cost effectiveness for each source category was calculated based on these source category sums. The average values for each source category are presented in Table 5. The costs, emissions, and emission reductions for the 6 SOCHI model units are also presented in Table 5 for comparison. As can be seen in Table 5, the results of the impacts analysis for non-SOCMI source categories are similar to the results of the impacts analysis for SOCMI process units. The average capital costs range from $25,800 for the chlorine production source category to $201,000 for the chlorinated hydrocarbon use source category. The average net annual costs range from a savings of $52,900/yr for the chlorinated hydrocarbon use source category to a cost of $8,500/yr for the polybutadiene production source category. The average cost effectiveness values range from a savings of $430/Mg HAP for the chlorinated hydrocarbon use source category to an expense of $430/Mg HAP for the miscellaneous butadiene use source category. In all cases, the average capital costs, average net annual costs, and the average cost effectiveness for the non-SOCMI source categories falls within the range of the 80CMI model units. Some differences can be noted between the seven non-SOCHI
source categories and the SOCMI model units in Table 5. For the chlorine production, pesticide production, and miscellaneous butadiene use source categories the average annual operating costs and average total annual costs are below the lowest value

jkb.076 VHAP.Mem 15TABLE 4. IMPACTS FOR NoN-soeMI EQUIPMENT LEAKS CONTROLS

Amual ized Annual ized Total Net Section Capitol Capital Operating Amual Basel ine Emissions Annual Cost

114 Facility CTG Cost Cost Cost Cost Emissions Reduction Cost Effectiveness FHe No. Name location Control (S) (S/yr) (S/yr) (S/yr) (Ng VOC/yr)(Mg VOC/yr) (S/yr) ($'"9 HAP) •.•.... --_ _------ -------- _-- _----- -----_.------ _- ..•••••••......... ---- . STYRENE-BUTADIENE RUBBER PRODUCTION**============;=============a=======c=================== =========================:c===================~~=================;~============c=============================**  EQOS1

. American Synthetic Rubber Corp. louisvil te KY Y 16571 2701 20680 23380 14.45 11.74 4,700 510 EQOS4 OF Goodrich Co. Port Neches TX Y 18n74 30526 109589 140110 131.58 99.43 (18,000) (230) EQ056 Copolymer Rubber &Chemical Baton Rouge LA y 4495 733 87117 87850 n.36 55.98 (1,200) (30) EQ06S BASf (formerly Polysar) Chattanooga TN N 78367 15074 37920 52990 40.65 36.27 (4,700) ( 170) EQ065 BASF (formerly Polysar) Chattanooga TN N 221674 39188 49213 88400 71.04 64.21 (13,700) (270) EQ075 Goodyear Tire &Rubber Co. Houston TX Y 10n82 17601 137183 154780 120.98 99.16 (2,900) (40) EQ076 Goodyear Tire &Rubber Co. Calhoun GA N 149243 26465 36621 63090 48.62 45.64 (9,500) (270) EQ084 Gencorp, Inc. Odessa TX y 112711 18988 76642 95630 70.87 57.73 3,800 80 EQ085 Gencorp, Inc. Mogadore OH y 140984 24018 30654 54670 32.06 28.91 8,700 390 t---a EQ086 W.R. Grace &Co. Owensboro KY N 80614 14351 17578 31930 18.57 17.70 3,800 280 0\

-------------- ................... _------.-- ........... 

### . _-------------- 

### .. ...... _----- 

### .....

_

### ... _------ 

### ....... .. _----- 

### ........... _-------_ ....... --------- .. 

### _--_ .. _--
POLYBUTAOIENE PRODUCTION**================~=======~_;================c=~=c=;;;_;==;~============~=~============_=================;na=============================c============;=====:======~=** EQOS1 American Synthetic Rubber Corp. louisvi lle KY Y 59928 9768 66427 76200 60.62

. 48.44 (800) (20) EQ052 ARCO Chemical Co. Channel View TX Y 1634 266 48580 488S0 22.69 19.97 17,100 1 1 100 EQ066 Phillips Petroleum Co. Borger TX Y 133612 22881 41791 64670 30.22 28.65 19,100 850 EQ067 Polys8r Limited Orange TX y 54912 8951 68358 ro10 65.88 51.25 (4,200) (110) Ea071 Union Carbide Corp. Institute W y 59763 10228 11426 21650 9.55 9.11 7,200 1.010 EQ073 Goodyear Tire &Rubber Co. Beaunont TX y 83916 14165 42788 56950 31.19 26.98 14,100 670 EQ073 Goodyear Tire &Rubber Co. Beaunont TX y 12485 2035 44509 46540 30.48 24.27 8,000 420 EQ082 Firestone Orange TX y 26378 4300 174118 178420 131.75 107.05 8,200 100 EQ083 firestone lake Charles LA Y 7468 1217 26647 27860 14.80 12.61 7,800 790

... _--_._---_ ....•..•.• -........ _------- .....•.•..•••... -_._---_ 

### ........... _--_ ........... _--- .......... _-.- 

### ........**_----~** ..........
_

### ... 

## -._- ... --- .... _-- 

### .. _- 

### ..**_--~**



# L

## (

TABLE 4. (continued) 

## (

Section

114 Fi Ie No. Facil i ty Neme Location CTG Control Capital Cost

(S) AMUal hed AlYlUal ized Capital Operating

Cost Cost (S/yr) (S/yr) Total Annual

Cost (S/yr) Net Baseline Emissions Annual Emissions Reduction Cost (Mg VOC/yr)(Mg VOC/yr) (S/yr) Cost Effectiveness

(S/Mg HAP)
CHLORINE PRODUCTION**==============================cc=============;;;========:c====c==========~;=:=====:=============;;;====:=======~==================a==;;==:===============c=====;cc;** Ea033 Diomond Shamrock Deer Park TX N 6500 1670 7927 9600 4.03 3.33 4,300 1,660 Ea033 Diamond Shamrock BattlegrOlrd TX N 108821 19139 27373 46510 45.03 41.35 (19,200) (600) Ea033 DiBmond Shamrock Mobil AL N 6500 1640 8561 10200 3.94 3.50 4,600 1,680 EQ033 Diamond Shamrock Muscle Shoals AL N 18225 3690 10480 14170 6.83 6.04 4,600 980 EQ033 Oiamond Shamrock Delaware City DE N 8432 2250 13117 15370 9.90 8.23 2,300 360 EQ038 Du Pont CorFKJS Christ I TX N 6500 1520 4953 6470 0.70 0.53 5,600 13,660

PESTICIDE PRODUCTION**=D==a==acc=c========~==================:==:========cc======c========;;========:====ccc========~=====~=~ccc=====~==========B===========m===~========================**



### ..... EaOOl Buckman I aboratorfes, Inc. Cadet MO N 8134 1930 8942 10810 3.85 3.59 5,200 1,860

...... Ea001 Bucklflan laboratories, Inc. Meqlhis TN N 11914 3002 21685 24690 14.45 13

...0 3,400 330 EQ002 Chevron Chemical Corp. Richmond CA N 102401 19710 79398 99110 89.35 82.96 (32,800) (510) EQ002 Chevron Chemical Corp. Maryland Heights MO N 6500 1527 5421 6950 0.61 0.61 6,000 lZ,540 EQ003 DuPont La Porte TX N 74838 14270 34686 48960 40.12 35.13 (6,900) (250) EQ004 fMC Corp. Baltimore tI) N 57532 10581 15057 25640 18.31 16.29 (300) (20) EQOO5 Mobay Chemical Corp. Kansas City KO N 6500 1700 9674 11370 3.33 2.96 6,600 2.840 EOO07 Monsanto Agricultural Prod. Amiston AL N n434 13680 19600 33280 26.98 24.62 (5,900) (310) EQ008 Union Carbide Agrig. Prod. Co. Institute W N 26149 6045 38898 44940 48.18 42.22 (22,200) (670) EaOO8 Union Carbide Agrig. Prod. Co. Institute W N 73306 14403 45037 59440 60.36 52.91 (24,700) (600) EOO09 Union Carbide Agrig. Prod. Co. Woodbine GA N 41.390 7753 23529 31280 19.80 18.40 2,000 140

CHLORINATED HYDROCARBON USE**c=ua~==~==a=====a==:==============a=c==============================;================~c===========;=;=======c=====c============~=========;=;=================c======** EQOOS EQ035 Hobey Chemical Corp. General Electric Co. Baytown MOUOlt Vernon TX IN • y N 24204 378487 4010 75798 87987 223225 92000 299020 62.63 308.44 51.16 10,700 261.31 (116.500) 270 (570)TABLE 4. (continued)

Section 114 FHe No. Facility Name location CTC Control Capital Cost

(S) Amua l i zed Annual t zed Capital Operating

Cost Cost (S/yr) (S/yr) Total Anroal

Cost (S/yr) Net Baseline Emissions Annual Emissions Reduction Cost (Mg VOC/yr)(Mg VOClyr) (S/yr) Cost Effectiveness

(S/Mg HAP)



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### .. PHARMAceUTICAL PRODUCTION**===============================;============================c~=================;====:=========a============================::c===a========:cc;=============c=======** EQ011 The UpJOOn Co. lCalamazoo HI N 1137226 202515 354560 557080 421.97 395.95 (72.500) (230) E0012 The UpJohn Co. Barceloneta PR N 69831 12841 19594 32440 19.97 18.13 3.600 250 E0013 Eli Lilly & Co. Lafayette IN N 6500 5847 60287 66130 56.06 41.26 500 20 EQ013 El i Li lly & Co. Cl i"ton IN N 6500 2380 29106 31490 13.40 12.70 11.300 1,140 EOO14 Eli Lilly & Co. Irdianapol is IN N 8134 1855 7848 9700 

### 3.n 3.50 4.100 1.500 EOO15 Abbott Laboratories Abbott Park IL N 55188 9862 10029 19890 8.58 8.50 6.400 970 EOO16 Abbott Laboratories CNC N 39164 7149 9912 17060 8.32 8.23 4,000 620 EOO17 Abbott laboratories PPR N 8031 1784 5705 1490 1.23 1.14 5,700 6,420



### .... EOO18 Abbott Laboratories North Chicago IL N 43911 8422 21179 29600 16.29 15.33 5,200 430 OJ EOO19 Abbott Laboratories eNC N 46257 8646 18239 26880 13.32 12.88 6,400 640 EQ020 Abbott laboratories CPR N 35643 6650 11795 18450 9.n 9.11 4.000 560 EQ021 Merck Chemi cal Co. Barcelonete PR N 24872 6570 53791 60360 33.64 30.66 11.600 490 E0022 Merck Chemical Co. Rahway NJ N 193352 35268 70033 105300 75.86 71.13 (7.800) (140) E0023 Merck Chemical Co. Danville PA N 201861 37839 82123 119960 93.56 83.40 (12.600) (190) Eo024 Merck Chemical Co. Albany GA N 147936 28214 67252 95410 83.75 74.20 (22,500) (390)

........................... 

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### ..... _-- ............ MISCELLANEOUS BUTADIENE USE**===============================;=========================:========:==========:=====:===::==:;==~=========c=============================c===================:;==:~=a** EQ066 Phillips Petroleum Co. Borger TX y 11807 1957 12nO 14680 7.01 5.96 5,200 1,120 EO066 Phillips Petroleum Co. Borger TX y 11789 2019 6103 8120 1.93 1.84 5,200 3,620 EQ068 Room and Haas Kentucky Louisville ICY y 39315 6668 13946 20610 9.90 8.85 6,500 940 E0069 Sohfo Lima OK y 23344 3902 n06 11610 5.08 4.82 3.900 1.040 £0070 Un; royal Painesville OK Y 121283 20288 35534 S5820 36.62 32.24 4,600 180 E0072 Monsanto Polymer Prod. Huscatint: IA N 19834 3956 12134 16090 10.n 9.64 800 110 E0074 Goodyear Tire &Rubber Co. Akron OH Y 18727 3053 30207 33260 25.49 19.80 1,800 120 .......•.....•...... --_ ....•••••......•••.......•••.•. ----_ .. 

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## (

TABLE 5. NON-SOCMI SOURCE CATEGORY AVERAGE IMPACTS AND COMPARISON TO SOCMI MODEL UNITS 

## (

Amual ized Amual ized Total Net Capital Capital Operating Amual Basel ine Emissions AMual Cost Source Cost Cost Cost Cost Emissions Reduction Cost E ffecti veness Category (S) (S/yr) (S/yr) (S/yr) (Hg VOC/yr)(Hg VOC/yr) (S/yr) (S/Hg HAP)

.... 

### ----_ .... -- ... ---- .... _--- ..... _--- ... 

### -----_ ............. _-- ...... - ........ --- ....... --- ...... ---- ......... 

### --- ........ -. STYRENE-BUTADIENE RUBBER PRODUCTION 109,971 18,964 60,320 79,283 62.12 51.68 (2,900) (10) POLYBUTADIENE PRODUCTION 48;900 8,201 58,294 66,494 44.13 36.48 8,500 300 CHLORINE PRODUCTION 25,830 4,985 12,069 17,053 11.74 10.50 367 40



### .... PESTICIDE PRODUCTION 44,191 8,600 27,448 36,048 29.58 26.65 (6,321) (300) \D CHLORINATED HYDROCARBON USE 201,345 39,904 155,606 195,510 185.54 156.23 (52,900) (430) PHARMACEUTICAL PRODUCTION 134,960 25,056 54,764 79,820 57.30 52.41 (3,501) (90) MISCELLANEOUS BUTADIENE USE 35,157 5,9n 16,907 22,884 13.83 11.88 4,000 430
Model A 20983 5238 38650 43890 41.52 36.53 (14,200) (500) Model B 224459 42830 129211 172040 167.40 149.18 (65,200) (560) Hodel C 441517 844n 247870 332350 354.52 306.16 <154,400) (650) Hodel D 11128 1819 38650 40530 26.37 21.37 6,500 390 Model E 203625 34650 129211 163860 110.81 92.59 16,600 230 Hodel F 391913 66346 247870 314220 236.34 187.99 15,300 100 

### --_ ...... - .... _-- ...... - ... ----.- ...... - ........ _--- .... 

### --- .... 

### _- ... _--- .... 

### _----- ........ 

### _--- .... -- ........ ------ ..........for the SOCKI model units. The average baseline emissions and emission reductions for chlorine production and miscellaneous butadiene use source categories are also below the lowest value for the SOCKI model units. These low values are a result of lower equipment counts in the non-SOCKI source categories for those components requiring LOAR in the Reg Neg, and generally lower equipment counts overall. This indicates that these source categories will be impacted less .than the SOCKI units by implementation of the Reg Neg. None of the average source category value exceeded the highest SOCKI model unit value indicating that none of these
source categories will be excessively burdened by implementation of the Reg Neg.

jkb.076 VHAP.Mem 20

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Equipment

Valves
Pump Seals Compressor Seals Pressure

Relief Devices Connectors 1 Open-ended Lines Sampling Connections MACT Controlled Baseline Emission Factors Emission 

# ------------_._-. Factors Service Uncontrolled CTG (kg/hr) (kg/hr) Controlled (kg{hr) Gas 0.0056 0.002 0.0001216 Light Liquid 0.0071 0.004 0.000717 Heavy Liquid 0.00023 0.00023 0.00023 Light Liquid 0.0494 0.0331 0.00248 Heavy Liquid 0.0214 0.0214 0.0214 Gas/Vapor 0.228 0.153 0.0223 Gas/Vapor 0.104 0.0582 0.0

All 0.00083 0.00083 0.000345 All· 0.0017 0.0 0.0 All 0.015 0.015 0.0

1eonnectors include flanges and screwed connections.

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# RADIAN CORPORATION
Progress Center 3200 E. Chapel Hill Rd.lNelson Hwy. P.O. Box 13000 Research Triangle Park. N.C. Tl709 (919) 541-9100 Mr. David Markwordt 

## u. S. Environmental Protection Agency Office of Air Quality Planning and Standards Chemical and Petroleum Branch (MD-13) Research Triangle Park, North Carolina 27711 5 June 1991

Dear Dave: Enclosed are three copies of the memorandum describing impacts from the control of 

### VHAP emissions from equipment leaks in nonSOeMI process units. At the request of Bob Rosensteel, a copy of this memorandum is being sent to Randy McDonald. A copy of the May 28, 1991 memorandum from Larry Sorrels documenting emission reduction and control costs for fugitive emissions from polybutadiene production and styrene-butadiene production has been received and reviewed. Those impacts were developed based on different equipment counts and a different costing procedure. The information presented in this memo has been developed independently and does not reflect the values presented in Larry Sorrels' memorandum. Please feel free to contact me or Ken Hausle if you have any questions or comments on the enclosed memorandum. Sincerely,

# f::;K~ Associate Engineer /jkb.076

cc: R. Colyer, EPA (MD-13) J. Crenshaw, Radian J. Meyer, EPA (MD-13) R. McDonald, EPA K. Hausle, Radian J. Stelling, Radian M. Stockton, Radian B. King, Radian