p. 1



# OAR Box 1413 Prepped by Ollie Stewart



## Document

Number: 

# 33 ) 11-1-3 3
Docket Number: 

# A-94-5 2

Printed 7/9/2008 3:11:21 PM

Sheet 33 of 114s*f^:rfii;">r.S^Jil?;" : P. 2

"**:*** ' -«_ . 

# 94-RA111.0 3 Demonstratio n o f

Captur e an d Contro l Efficiency fo r a Styren e Emissio n Sourc e

Avinas h N . Patkar an d Joann e M . Reinhol d

Radia n Corporatio n Mason , Ohi o
Gerar d Henderso n I T Corporatio n Cincinnati , Ohi o

^T^^W^WT^^^ ^ 

## AI R& WASTE MANAGEMEN T ASSOCIATIO N

• SINC E 190 7 

### Fo r Presentatio n atth e 87t h Annua l Meetin g & Exhibitio n Cincinnati,Ohi o June 19-24,199 4

.. . \P. 3

, . _..->:*r-T7vrs.>^>»7<>_>.-;.. . _. . :;-i-g*>::*c-$M-^-5S*i>S?:-**-; :

94-RA111.0 3

INTRODUCTIO N Thi s pape r describe s th e design an

d compliance demonstratio n o f a coUectio

n an d contro l syste m for styrene-lade

n ai r firo m a manufacturin

g facility . Catalytic oxidation was selected t

o b e th e contro l syste m base d o n a technica

l an d economi c feasibilit

y stud y o f severa l options . Specifications were writte n fo r the captur

e an d contro l systems , an

d th e systems were installed . Th e pape r present s the strateg

y use d for demonstratio

n o f captur e an d oontro i efficiency value s resulting in a n overall reduction i

n emission s o f

85 % a s require

d b y the state . DESCRIPTIO N O F OPERATIO N «-•-...•__
_ Th e compan

y manufacture

s side-wall panel s used for trailer s an d recreational vehicles . A styrene-base

d gelcoati s use

d alon g wit

h a styrene-base

d resin in th

e manufacturin

g process . Thi s pape

r discusse s onl y th e gelcoatoperation . Th e gelcoatapplicatio

n proces s atomizes th e resin wit h a hig h volum e lo w pressur

e spra y system . The gelcoa

ti s applie d t o a myla r sheetwhic

h i s unrolle

d an d fe d unde r th e nozzl e an

d the n continuously conveye d dow n th e lengt

h o f th e tabl e b y a chain . Afle r the entir

e shee ti s coated , i

ti s allowed t o cure befor

e bein g transferre

d t o the laminatio n area. COLLECTIO N SYSTE M Th e styrene coUectio

n syste m fo r the gelcoatarea oonsist s o f a n enclosure aroun

d the atomization are

a (AT-1) , an

d diree hoods ove r th e entire lengdi o f th e tabl e (GC-1 , GC- 2 an d GC-3) . Figur

e 1 i s a schematic diagra

m o f th e gelcoa tan

d atomization hoods . Th e atomizatiot

\ enclosure capture

s th e styrene emission s du e t o th e atomization an

d overspra

y o f th e gelcoa

tb y th e spra

y nozzle . Th e three hoods ove r the tabl e captur

e the styrene emission s ftom th e myla r a s the curing proces s take s place . Th e atomizatio

n hoo d i s a stationaiy enclosure wit h a doo r a

tth e operator station . Th e doo r i s raised t

o se tu p a ne w shee tan d lowere d befor

e startin g th e spray . The gelcoathoods ar

e lowere d i n place b

y a pneumati

c system fro

m thei r inclined resting



### \94-RA1U.0 3 94-RA111.0 3

Electio n an d ttalytic oxidatio n ni c feasibilit

y an d control -g y used fo r overa U

nationa l resin i n th e oo . telo w pressur

e le d an d fe d unde

r ibl e b y a chain , insfetrcd t o th e

dosur e aroun d th e th e tabl e (GC-l , id atomization uetoth e thre e hood s ove r 5 proces s take s perato r station , g th e spray . Th e a r incline d resting position . Th e spra y i s starte d an d th e sheetcure s unde

r th e hood s fo r 8-1 0 minutes . Th e emission s ar

e capture d an d ducted t o th e catalyti c oxidizer . CONTRO L SYSTE M Th u projec

tinitiaU y involve d estimatin g th e amoun to f styrene bein g emitte d fro m th e gelcoa toperation . Th e styrene use d i n th e gelcoa tactuaU y has a dua

l purpose . I

t serve s a s a solventt o keep th e gelcoa tfluid , buti tals o serve s a s a polymerizin g agent whe n combine

d wit h a catalyst . Therefore , som e portion o f th e styren e i n th e gelcoa t i s los tt o atmospher

e du e t o it s solven trole, buta larg e portion o f th e styrene reacts an d polymerizes , causing th e gelcoatt o cure onc e i ti s spraye d onto th e mylar . Detenninin g th e amoun

to f styrene emitted t o th e atmosphere , therefore , wa s no ta simpl e materia

l balanc e calculation . Emissio n factor s wer e develope d an

d ar e discusse d i n th e nex

tsection . Once thes e value s wer e determined , a desig n baa s wa s establishe d fo r controllin g th e styrene emission s throug

h add-on contro

l equipmen tA s par

to f th e project , alternativ e coating material

s wit h lowe r styrene contento r othe r solvents were evaluated . Thes e alternativ e product s di d no tachiev e hig h enough produc tqualit y t o allo w th e facilit

y t o mak e a produc

tsubstitution . Severa l add-o n control system s wer e evaluate d includin g adsorption , absorption , condensatio n an d catalyti c oxidation . Eac h add-o n oontro i syste m wa s evaluate

d based o n technica

l feasibilit y an d economi c criteria . Catalytic oxidation wa s selecte d fo r severa l reasons . Th e facilit

y di d no t wan tt o recover an

d reuse th e styren e becaus e o f degraded qualit

y during th e recovery proces s wit

h adsorption . Other contro l system s woul d b e costl y and creat e a secondar y styren e wast e strea m requiring furthe

r treatmen

to r disposal . Th e catalyti c oxidize r i s designe d t o operat e a t600-700° F wit

h a recuperative hea

t exchange r t o recover hea

tfro m th e exhaus tan

d us e i tt o prehea

tth e inle tair . Thi s hea trecovery reduces th e amoun to f fuel (natura

l gas ) required t o kee p th e oxidize r at th e required temperatur

e fo r destruction . Th e oxidize r has a capacit y o f approximatel

y 500 0 acfm . EMISSIO N FACTO RDEVELOPMEN T Thi s sectio n summarize

s a gravimetri c procedur

e use d t o generat

e th e styrene emissio n factor

s fo r th e gelcoa tprocess . Th e tota l emission s fro

m tiu s proces s ar

e divide d int

o tw o components , atomization losse s an d curin g losses . Emissio n factor s fo r each o f

thes e tw o component

s were determined b y conductin g gravimetri c testing . Th e gravimetri

c testing fo r th e atomization are a involve d weighin g th e dru m o f resin before an d afte r sprayin g an d coUecting a

U th e spraye

d resin s o tha

ti tcoul d b e wdghed . Losse s were determine d b y calculatin g th e differenc e betwee n spraye d resin



### \ \ 

# >3i>*^r-^"£i!"{«!$-^ ^ #>>: . * : :>St. . >: : : : -S : >^fe-7i:^^>:s^^:_:*y^^_^-:^_^:-_;; : P. 5


# • r •^r^:**:^^ ^ • - , - i,| | _•_- • i-_i

- :-:-_ J -_-___-.____«___-____________ _

94-RA I 11.0 3
an d collecte d resin. Gravimetri c testin g fo r th e curin g losse s involve d weighin g a spraye d shee timmediatel y afte r bein g spraye d and weighin g i tafle r curing . Th e differenc e wa s determine d t o b e di e styren e losses . Thes e emissio n factor s wer e determine d t o b e 0.04 2 an d 0.08 8 lb s styrene/l b o f gelcoa tuse d fo r th e atomizatio n an d curin g losses , respectively. Thus , di e tota l emissio n facto r (Eg ) wa s 0.1 3 lb s styrene/l b o f

gelcoa tused . Thi s facto r i s fo r di e baselin e gelcoat . A "hig h performance " gelcoa tmateria l wa s als o use d tha tcure s a ta faste r rate tha n th e baselin e gelcoat . I

twa s show n t o hav e a tota l emissio n facto r (Eg ) o f 0.09 1 lb s styrene/l b o f

gelcoa tused . ANALYTICA L AN D TES T PROCEDURE S Th e overa U contro l efficienc y i s th e produc to f di e destructio n an d captur e efficienc y values . Th e procedure s an d calculation s associate d wit h destructio n an d captur e efficienc y detenninatio n ar e describe d i n dii s section . Figur e 1 show s di e sampl e location s a tdi e inle tand outle to f di e oxidizer . Semi-QiiaatiUtiv e Captur e Efficienc y Demoustratio a *"*•--•»

_ Th e EP A requires dia tdi e sourc e owner/operato r demonstrat e adequat e captur e efficiency . I n orde r t o demonstrat e tha tth e captur e efficienc y required b y th e syste m wa s bein g achieved , a tes tprotoco l usin g smok e tests , organi c vapo r analyze r (OVA ) readings, an d velocit y measurement s nea r eac h styren e coUectio n poin twa s developed . Smok e testin g wa s use d t o visibl y demonstrat e effectiv e captur e o f styren e emission s fro m th e controlle d proces s area . A n aspirato r bul b an d ventilatio n smok e tube s (Min e Safet y Appliance s Company , Par tNo . 458480 ) wer e use d to generat e smok e withi n di e zon e o f

influenc e (approximatd y 1 to 2 inche s outsid e eac h hoo d ai r inlet ) o f eac h o f di e styren e collectio n hoods . Eac h ventilatio n smok e tub e contain s tw o ampule s containin g ethylenediamin e an d aceti c acid . Whe n th e glas s ampoule s ar e manuaU y crushed , di e released vapor s reactformin g a fum e compose d o f aeroso l particle s tha ti s visibl e a s a whit e vapor . Thi s whit e smok e ha s a vapo r densit y tha ti s ver y mod i large r tiian tha to f styren e an d henc e i s a conservativ e indicato r o f th e syste m captur e perfonnanc e wid i respectto styrene . A n OV A wa s als o use d to monito r backgroun d concentratio n o f styren e i n th e are a aroun d eac h o f

th e collectio n hoods . B y takin g intermitten treadings wid i di e OV A durin g nonna l productio n operations , i twa s show n dia tdier e wa s n o chang e i n th e backgroun d level s o f

styren e cause d b y di e controlle d processes . Thi s provide d anothe r semi-quantitativ e demonstratio n tha tth e captur e o f styren e b y th e contro l syste m i s nea r 9 5 percent .

\ 

# AP. 6

94-RA1U.0 3 I weighin g a uring . Th e ictor s wer e i e atomization ra s 0.1 3 lb s "hig h : tha n th e T 0.09 1 lb s

ptur e efficiency i d captur e s th e sampl e

t e captur e s d b y th e system analyzer (OVA ) i twas raptur e o f styren e ntilatio n smoke d t o generat

e id e eac h hoo d ai r e tub e contain s las s ampoules ar

e do f aerosol JO T densit y dia ti s icatoro f di e
si e i n di e area wit h di e OVA change i n th e • provide d i r di e control 94-RA111.0 3 Velodty measurement

s wer e mad

e nea r eac h o f th e opening s leadin g int o di e contro l hoods . Thes e vdodt y measurement s wer e shown t o b e greater tha n th e minimu

m value recommende

d b y goo d engineering practic e fo r industria

l ventilation . Captur e Efficiency Demonstratio n I n additio n to di e semi-quantitativ

e captur e efficiency demonstration , di e stat e als o required a quantitativ

e mediod fo r demonstratin g captur e efficienc y b e conducted . Captur e effidenc y wa s determine d using EP

A Methods 2 5 an

d 2S A atdi e oxidize r inlet(Location 1) . Th e gdcoa tusag e rates an d predicted styren e emissio n rates wer e monitore d an d calculate

d durin g th e tes tprogra

m an d compared t o th e Metho d 2 5 an d 25 A results. Medio d 2 4 analyse s wa s conducte d o n coatin g sample s fro

m th e gelcoa tareas . One sample wa s collecte d a

tdi e spra y statio n ever y 4 hour s fo r a tota

l o f 3 samples . Analyses b y Mediod 2 4 includes : volatil e matte r content , wate r content , density , volum e solids , an

d wdgh tsolids . Captur e effidenc y wa s determine d usin g th e followingieqtetion : . C E « M i EF g M , (Locatio n 1 ) = Styrene measure d a tincinerato r inlet , I

b pe r period . EF g •= • Predicte d styren e emitte d fro

m gelcoa toperation , l b pe r period . Destructio n Efficiency DHrrmlnatlo n Destructio n effidenc y wa s determine d usin g EP

A Medio d 2 5 a tth e inle tan d oude to f th e oxidizer . Location 1 an d 2 (se e Figure 1 ) representdi e inle tand outle tsampl e locations . A tdi e destructio n effidenc y required to demonstrat e a n overa U control efficiency o f

85% , di e outletconcentration wa s expecte d to b e clos e t o o r les s tiian 5 0 pp m styrene measure

d a s organi c caibon . Thi s woul d hav e create d uncertaint y i n di e outle tmas s rate o f

nonmethan

e organi c carbo

n calculate d b y Medio d 25 . Therefore , a tota

l hydrocarbo

n analyze r (EP

A Medio d 25A ) wa s use d i n conjunction wid i di e Medio d 2 5 tests to verif y an y apparen tMedio d 2 5 outlier s an

d to estabUs

h di e mas s flow rate o f

styrene ban g collecte d fro m th e proces s areas (se e Captur e Efficienc y Detennination) . Volumetric ga s flow rates an d compositio n were determined a tcad i sit e usin g EP A Method s 1-4 . On e measuremen

twa s conducted during each sampl e run . Moistur e conten twa s determine

d ateac h locatio n usin g di e we tbulb/dr y bul b technique . Gas molecula r weigh twa s determine

d usin g Fyrit

e gra b samples .



### \ \ 

# 5>-- "P. 7 

# ^^'.•y*^** ^ 

# T

94-RA l 11.0 3

.-yv. Destructio n effidency was determine d using th e followin g equation : DE « fM, - M,. x 10 0

M , where : D E = destruction efficiency , %

M , 

### M , mass o f

nonmethan

e organic carbo

n a toxidize r inlet , I

b per give n perio

d (M , i s Location 1 o n diagram)
mas s o f nonmethan

e organi c carbo

n a toxidize r outlet , I

b pe r give n period (M , i s Location 2 o n diagram) Three on e hou

r test s were conducted an

d th e destructio

n efficiency value s wi

U b e calculated . Overa U Contro l Efficienc

y Determinatio n **• .--___ Stat e regulations require

d di e source t o have a

n overall contro

l efficiency o f

8 5 percent. A contro

l efficienc y equa l t o o r greate

r tha n the required lev d wa s demonstrate

d durin g th e tes tprogram . Th e overa U contro l effidenc y wa s calculated b y a combinatio

n o f the captur

e an d destructio

n efficienc

y values , b y usin g di e foUowin g equation : OC E - (C D x (DE ) x 10 0 100 10 0 where : OC

E = C E - DE - overa

U control efficiency , % captur e efficiency , % destruction effidency , % Overa U contro l efficienc y value s were calculated for di e dire e on e hou r tests . RESULT S Fo r variou s testruns , di e captur e an d destructio

n effidencie s wer e determined . Th e results are summarize

d i n Tabl e 1 . Eac

h spra y i s calle d a

n even tan

d di e time between tw o spray

s i s calle d eventtime. Th e dat a showe d dia tdi e captur

e efficiency varied fro

m 9 0 t o 9 7 percen

tbase d o n even ttime . Th e tota

l eventtim e indude s di e tim e required t o spra y an d cure th e



### \ 

# CoP. 8

94-RA111.0 3

oxidize r inlet , l b diagram ) oxidize r oudet , I

b diagram ) 94-RA111.0 3 sheet , lif tth e hood s up , mov

e di e she d to th e transfer table , brin g the hoods down , an d setu p th e new sheet . Th e captur

e efficiency can b e improve d b y leaving th

e hood dow n for a longe r period , bu

tdii s woul d lowe r th e productio n rate. Th e destmctio n efficiency wa s ver y dos e t o 98 % fo r al l th e runs . Thi s proves tha t th e catalyti c oxidize r wa s no tsensitiv e t

o di e inle tconcentration . Aldioug h di e inle t concentratio

n averaged 24 0 ppm, ther e wer e peak s o f

u p to 80 0 pp

m withi n 2 minute

s o f completing di e spray . Th e destructio n efficiency wa s 98 % bot h a tdi e lowes tan

d a tdi e pea k concentrations . Th e overa U contro l effidenc y varie

d fro m 8 8 t o 95% . Th e syste m was , dierefore , capable o f

demonstratin

g compUanc

e wit h th e 85 % requirement. value s wi n b e REFERENCE S

aenc y o f 8 5 lev d was • y wa s calculate

d i y usin g th e 1 . "Result s o f Gravimetri

c Testing fo

r Emission s fro

m Gdcoa tOperatio

n Usin g BaseUn e an d CT-76-H

P Resin, " Tests conducted b y Radia n Corp , Apri

l 30 , 1993 . ** • -i t 2 . Industria

l Ventilation : A Manua

l o f Recommende

d Practice . Committe

e o n Industria l Ventilation , America

n Conference o f

Governmenta

l Industria l Hygienists . Vol . 17 , 1991 .

tou r tests .

determined. Th e i d th e time

scen tbased o n ran d cur e di e

\ . ..... .

\ 

# •3--~ "P. 9

94-RA111.0 3

Tabl e 1 . Styren e Capture , Contro l an d Overal l Efficiencie s (a )

Ro n No . I 

# 1 Oeleo-t

f (lb. ) 46. 8 44. 5 47. 2 49. 3 49. 6 S1. 2 SI. S S4. 2 Ever t Time

(minXb ) I S 1 8 2 0 2 1 2 1 2 0 2 1 1 9 Inl*.<c )

(Ib/eveot ) S. 6 J J S. S 6. 1 6. 1 6. 2 6. 3 6. 4 Oml* . (d )

(Ib/awst ) 0.1 1 0.0 9 0.1 0 0.1 0 0.1 0 0.1 1 O. U 0.1 2 Bfficieacie i <* )

Captur e Do* . 92. 1 98. 0 91. 6 98. 3 9 4 J 98. 3 9S. 1 98. 4 94. 7 98. 4 93. 2 98. 4

« • « ^! 4 90. 8 98. 2 Tota l

90. 3 90. 0 92. 9 93. 6 93. 2 91. 7 92. S 88. 6

a : Test s o n Ma

y 19 , 1993

. BaseUn

e gelcoat

. EP

A Metho d 2S A modified , b : Event time i s di e duratio n betwee n tw o spray s i n minutes , c : Inl d mas s i s base d o n 505 5 scf mmeasured

. Rang e o f

cone . 210-27 0 ppm . d : Outle t mas s i s base d o n 515 4 scf mmeasured

. Rang e o f

cone . 3- 5 ppm .

\94-RAM1.0 3 P.1 0

94-RA I 11.0 3

ure . Contro l and Overal l Effidencie s (a ) Figur e I . Geioool CoUectio

n Hood s and Samplin g Location i

5 4 S J 5. 1 6. 1 6. 1

* J

« J •. 4 Onchi . ( 0

0.1 1 OJ0 9 0.1 0 0.1 0 0.1 0 0.1 1 0.1 1 0.1 2 BmOamdm (« ) Caf-t-tr a DM . n. i »lj » 94_ S •S. l W. 7 W J •4. 1 •0. 1 fS. 0

W J W J W. 4 W. 4 •t. 4 M J W. 2 Tota l W J *M > «2. t WJ » W J 91. 7 ns M. « locatio n 2 OuOa t

18*1 0

isetifie gdcoo L EP

A Method 2S A modified . «twee n tw o quay s i n minutes , acf m measured . Range o f

cone . 210-27 0 ppm . > 4 acf m measured . Range o f

cone . 3- 5 ppm . 1 / T i T i T i T T / \MO*I D \»iori o oitri o IMOM D Locatio n »V / *V /

" / »V

_ 1 20*1 0 "

AfexiUzaflonHco d

(90 0 dm ) 3 Gelcoat Collectio n Hood s (00 0 d m each )



# s : j 

# MV * .+_3_; > < A, .



# * 7