P.1 

OAR Box 1770 

Prepped by Keeia Richards 

Document Number: 

34) XII-B-2 

Docket Number: 

A-79-15 

Printed 10/28/2008 10:20:28 AM Sheet 34 of 93 
P.2 

4 DocJcetNo.A-79 J5 

ItemNo.XU-B-2 

Draft Post-MACT Screening Risk Assessment for the Coke Oven Source Category 

Q^m^ycayj 

APPENDIX B 

Facility Emission Calculations 

D.?.j^ rep- 4* T-if,Ls 

B-1 
P.3 1 

Sources for Coke Oven Emissions Data: 

Batteries: 

Revised battery emissions estimates provided by Roy Huntley (EPA, OAQPS). 9/7/2000. 

Pushing/Quenching/Combustion/By-Product Chemical Plant (Process Equipment): 

Revised Emissions for Coke Oven Facilities, ICF Memorandum dated 8/21/2000, Table: Summary of 

Allowable Emissions from Coke Oven Facilities. 

By-Product Plant (Fugitive Equipment Leak): 

Revised Fugitive Emission Calculations, ICF Memorandum dated 8/31/2000, Table: Fugitive 

Equipment Leak Emissions from By-Product Chemical Plants. Based on telephone conversation with 

Roy Huntley and Ted Palma on 9/12/2000, average emission factors (column 3) were used for all 

facilities except Ashland. Monitored emissions data area available for Ashland (column 4). 

V 

\ 
P.4 

Revised Battery Emissions Estimates 

Provided by Roy Huntley. (EPA, OAQPS), 9/7/00 
BSO Emission Rates for Doors, Lids, Offtakes, and Charging 

Allowable Emissions 

Facility 

AK Steel, Middletown 

AK Steel, Ashland 

Erie Coke, Erie 

Gulf States Steel, Gadsden 

New Boston, Portsmouth 

Tonawanda, Buffalo 

Battery 

3 

3 

4 

A 

B 

2 

3 

2 

2 

No, 

Of 

Ovens 

n 

76 

70 

23 

35 

49 

63 

70 

60 

Charging 

'lime 

s/chg (1) 

11.00 

12.00 

12.00 

12.00 

12.00 

12.00 

12.00 

12.00 

12.00 

f ercent Leaks (&) 

PLD 

5.50 

5.50 

5.50 

5.50 

5.50 

5.50 

5.50 

5.50 

^.50 

PLL 

0.60 

0.60 

0.60 

0.60 

0.60 

0.60 

0.60 

0.60 

0.60 

PLO 

3.00 

3.00 

3.00 

3.00 

3.00 

3.00 

3.00 

3.00 

3.00 

Max s/chg 

9.34 

50.10 

50.10 

20.83 

20.83 

7.84 

7.84 

18.27 

14.42 

Max PLD 

5.41 

5.33 

5.33 

10.87 

11.43 

6.00 

4.69 

9.42 

9.17 

Max PLL 

0.48 

0.97 

0.97 

1.71 

2.26 

0.87 

4.69 

2.27 

1.39 

NOTE: 

For allowable emissions, emission limits for existing by-product batteries was used. ' oj 

(1) Allowable charging time in December 1995 MACT track limit. 

(2) Erie and Tonawanda are foundry ovens. The rest are furnace ovens. December 1995 MACT track limits were used. None of these ovens have tall doors. 

\y- n M« ^y^f •UVi c A/V 0- U: W.'i l/A/J < »\fA/ • Aj. !-e>A7-\ f> '<&>..<! 

Provided by: Dib Paul/ICF 

batter~r.xls - Battery Leaks-Allowable 

11/8/2000-9:32 AM 

<y 

XI 

bi 
BSO Emission Rates for Doors, Lids, Offtakes, and Charging 

Allowable Emissions 

Facility 

AK Steel, Middletown 

AK Steel, Ashland 

Erie Coke, Erie 

Gulf States Steel, Gadsden 

New Boston, Portsmouth 

Tonawanda, Buffalo 

Battery 

3 

3 

4 

A 

B 

2 

3 

2 

2 

ADSOIUte LOWi 

lb/hr of BSO 

Visible Door 

0.3344 

0.3344 

0.3080 

0.1012 

0.1540 

0.2156 

0.2772 

0.3080 

0.2640 

Lower Hound t__stimates ot amissions 

lb/hr of BSO 

Visible Door NVLD Totals 

0.3344 0.4309 0.7653 

0.3344 

0.3080 

0.1012 

0.1540 

0.2156 

0.2772 

0.3080 

0.2640 

0.4309 

0.3969 

0.1304 

0.1985 

0.2778 

0.3572 

0.3969 

0.3402 

0.7653 

0.7049 

0.2316 

0.3525 

0.4934 

0.6344 

0.7049 

0.6042 

Lower nest tstimate 

lb/hr of BSO 

Visible Door NVLD 

0.3428 0.5746 

0.3428 

0.3157 

0.1037 

0.1579 

0.2210 

0.2841 

0.3157 

0.2706 

0.5746 

0.5292 

0.1739 

0.2646 

0.3704 

0.4763 

0.5292 

0.4536 

DOORS" 

0.9173 

0.9173 

0.8449 

0.2776 

0.4225 

0.5914 

0.7604 

0.8449 

0.7242 

Visible 

0.41 oO 

0.4180 

0.3850 

0.1265 

0.1925 

0.2695 

0.3465 

0.3850 

0.3300 

NOTE: 

For allowable emissions, emission limits for e; 

(1) Allowable charging time in December 199: 

(2) Erie and Tonawanda are foundry ovens. Tl 

Provided by: Dib Paul/ICF 

batter~r.xls - Battery Leaks-Allowable 

11/8/2000 -9:32 AM 
BSO Emission Rates for Doors, Lids, Offtakes, and Charging 

Allowable Emissions 

Facility 

AK Steel, Middletown 

AK Steel, Ashland 

Erie Coke, Erie 

Gulf States Steel, Gadsden 

New Boston, Portsmouth 

Tonawanda, Buffalo 

Battery 

3 

3 

4 

A 

B 

2 

3 

2 

2 

UPl* lAKt a 

Best Lstimate 

lb/hr of BSO 

0.0171 

0.0171 

0.0158 

0.0052 

0.0079 

0.0110 

0.0142 

0.0158 

0.0135 

CHAKljrl. Lr 

Best Lstimate 

Lower Bound lb/hr of BSO 

0.0005 0.0471 

0.0005 0.0471 

0.0005 0.0434 

0.0002 0.0143 

0.0002 0.0217 

0.0003 0.0304 

0.0004 0.0391 

0.0005 0.0434 

0.0004 0.0372 

Upper Bound 

0.0912 

0.0912 

0.0276 

0.0420 

0.0588 

0.0756 

0.0840 

0.0720 

Lower Bound 

lb/hr of BSO 

0.3657 

0.3657 

0.1107 

0.1684 

0.2358 

0.3031 

0.3368 

0.2887 

NOTE: 

For allowable emissions, emission limits for e; 

(1) Allowable charging time in December 199: 

(2) Erie and Tonawanda are foundry ovens. Tl 

Provided by: Dib Paul/ICF 

batter-r.xls - Battery Leaks-Allowable 

11/8/2000 -9:32 AM 

s 
^ 

BSO Emission Rates for Doors, Lids, Offtakes, and Charging 

Allowable Emissions 

Facility 

AK Steel, Middletown 

AK Steel, Ashland 

Erie Coke, Erie 

Gulf States Steel, Gadsden 

New Boston, Portsmouth 

Tonawanda, Buffalo 

Battery 

3 

3 

4 

A 

B 

2 

3 

2 

2 

nates ot ttmiss 

gram/sec BSO 

0.2959 

0.2959 

0.0896 

0.1363 

0.1908 

0.2453 

0.2726 

0.2336 

NOTE: 

For allowable emissions, emission limits for e; 

(1) Allowable charging time in December 199: 

(2) Erie and Tonawanda are foundry ovens. Tl 

Provided by: Dib Paul/ICF 

batter-r.xls - Battery Leaks-Allowable 

11/8/2000 - 9:32 AM 

00 
P.9 

^ & ' • 

/ 

CONSULTIN G 

August 21,2000 

Mr. Ted Palma 

USEPA 

Emission Standards Division 

Risk & Exposure Assessment Group 

MD-13 

RTP, NC 

Re: Revised Emissions Estimates for Coke Oven Facilities 

Dear Mr. Palma: 

ICF Consulting (ICF) appreciates the opportunity to support EPA's residual risk 

assessment project for the coke oven source category. Enclosed are the revised 

calculations of emission rates and modeling parameters. The revisions reflect throughput 

changes and other site-specific parameters obtained from COETF/ACCCI. The revisions 

also reflect our discussions during the June 14th and August 16th meetings. 

The following are enclosed: 

• Facility-wide emissions 

• Summary of emissions from batteries 

• Summary of pushing/quenching/combustion emissions 

• Summary of byproduct chemical plant emissions 

• Modeling parameters 

• Supporting documentation 

I am e-mailing you all disk files used for the above calculations. If you have any 

questions, please do not hesitate to call me at (919) 233-0382. 

Sincerely, 

rv /' oA 

:V_ y-yy-' 

DibPaul, P.E. 

Project Manager 

End 

dp 

9300Lee Highway — — Fairfax, VA 22031-1207 USA— 703-934-3000—- 703-934-3740 fax — www.icfconsulting.com 
EMISSIONS SUMMARY 

P.10 

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SUMMARY OF ALLOWABLE EMISSIONS FROM COKE OVEN FACILITIES 

All Emissions are in lb/hr 

Facility 

AK Steel, Middletown 

AK Steel, Ashland 

AK Steel, Ashland 

Erie Coke, Erie 

Erie Coke, Erie 

Gulf States Steel, Gadsden 

Gulf States Steel, Gadsden 

New Boston, Portsmouth 

Tonawanda, Buffalo 

Indiana Harbor, E. Chicago 

Battery 

3 

3 

4 

A 

B 

2 

3 

2 

2 

A/B/C/D 

Emissions from 

Batteries (1) 

Visible & 

Nonvisible 

BSO 

1.7134 

1.7134 

1.5782 

0.5185 

0.7891 

1.1047 

1.4203 

1.5782 

1.3527 

NA 

Visible 

Only 

BSO 

0.4207 

0.4207 

0.3875 

0.1273 

0.1937 

0.2712 

0.3487 

0.3875 

0.3321 

NA 

Emissions from Pushing /Quenching 

/Combustion (2) 

Pushing 

BSO 

0.9132 

0.8219 

1.2785 

0.137 

0.2055 

0.4338 

0.5708 

0.6849 

0.4338 

1.0502 

Quenching 

BSO 

0.4795 

0.4338 

0.6621 

0.0685 

0.0913 

0.2511 

0.3425 

0.4338 

0.2283 

NA 

Combustion 

BSO 

1.21 

0.411 

1.484 

0.2968 

NA 

0.7306 

0.9361 

0.4566 

0.7534 

NA 

By-product Chemical Plant 

Process Equipment (3) 

Benzene 

0.2370 

1.0461 

0.0375 

0.5303 

0.3585 

0.2054 

NA 

Toluene 

0.0142 

0.0628 

0.0022 

0.0318 

0.0215 

0.0123 

NA 

Xylenes 

0.0071 

0.0314 

0.0011 

0.0159 

0.0108 

0.0062 

NA 

Fugitive 

Equipment 

Leak (4) 

Benzene 

0.0000 

0.2292 

0.0000 

0.0055 

0.0023 

0.0001 

NA 

NOTE: 

(1) See spreadsheet Battery_Emissions-Battery Leaks-Summary 

(2) See spreadsheet P-Q-C emissions 

(3) See spreadsheet byproduct_emissions. Actual emissions = allowable emissions. 

There is one by-product chemical plant per facility. 

(4) See spreadsheet fugitive_emissions. Actual emissions = allowable emissions. 

There is one by-product chemical plant per facility. 

NA = not available/not applicable 

Dlb Paul 

ICF Consulting 

Facility-Summary 

8/21A30-3:12 PM 
P.12 

Summary of BSO Emission Rates for Doors, Lids, OfTtakes, and Charging 

Actual and Allowable Emissions 

Recovery Ovens 

V 

Facility 

AK Steel, Middletown 

AK Steel, Ashland 

Erie Coke, Erie 

Gulf States Steel, Gadsden 

New Boston. Portsmouth 

Tonawanda, Buffalo 

Battery 

3 

3 

4 

A 

B 

2 

3 

2 

2 

Total Actual Emissions, lb/hr (1) 

Visible & Nonvisible Door 

Leaks 

1.4837 

1.4913 

1.3736 

0.4488 

0.6732 

0.9381 

1.2240 

1.4146 

1.1892 

... 

Visible Door 

Leaks Only 

0.1434 

0.1528 

0.1408 

0.0429 

0.0527 

0.0705 

0.1136 

0.1890 

0.1372 

Total Allowable Emissions, lb/hr (2) 

Visible & Nonvisible Door 

Leaks 

1.7134 

1.7134 

1.5782 

0.5185 

0.7891 

1.1047 

1.4203 

1.5782 

1.3527 

Visible Door 

Leaks Only 

0.4207 

0.4207 

0.3875 

0.1273 

0.1937 

0.2712 

0.3487 

0.3875 

0.3321 

NOTE: 

(1) Total actual emissions from doors, lids, offtakes, and charging. 

Actual emissions are based on Method 303 inspection data. 

(2) Total allowable emissions from doors, lids, offtakes, and charging. 

Allowable emissions are based on MACT emission limits for existing by-product batteries. 

Provided by. Dib Paul/ICF 

BaneryEmissions - Battery Leaks-Summary 

8/21/00-11:53 AM 
Summary of BSO Emission Rates for Pushing, Quenching, and Combustion Stack 

Allowable Emissions 

Battery 

AK Steel, Middletown, OH, Battery 3 

AK Steel, Ashland, KY, Battery 3 

AK Steel, Ashland. KY, Battery 4 

Erie Coke, Erie, PA Battery A 

Erie Coke, Erie, PA Battery B 

Gulf States, Gadsden, AL, Battery 2 

Gulf States, Gadsden, AL, Battery 3 

New Boston Coke, Portsmouth, OH, Battery 2 

Tonawanda Coke, Tonawanda, NY, Battery 2 

Indiana Harbor, East Chicago, IN 

Allowable Emissions 

Pushing 

4 

3.6 

5.6 

0.6 

0.9 

1.9 

2.5 

3 

1.0 

4.6 

Quenching 

2.1 

1.0 

2.9 

0.3 

0.4 

1.1 

1.5 

1.9 

1 

NA 

,tpy(D 

Combustion 

5.3 

1.8 

6.5 

1.3 

Note (3) 

3.2 

4.1 

2 

3.3 

NA 

Allowable Emissions, lb/hr (2) 

Pushing 

0.9132 

0.8219 

1.2785 

0.1370 

0.2055 

0.4338 

0.5708 

0.6849 

0.4338 

1.0502 

Quenching 

0.4795 

0.4338 

0.6621 

0.0685 

0.0913 

0.2511 

0.3425 

0.4338 

0.2283 

NA 

Combustion 

1.2100 

0.4110 

1.4840 

0.2968 

Note (3) 

0.7306 

0.9361 

0.4566 

0.7534 

NA 

NOTE: 

(1) Allowable emissions based on methylene chloride extractables data. 

This information was prepared by Marvin Branscome of RTI. 

(2) lb/hr = tpy * 2000 lb/ton / (8760 hr/yr) 

(3) One combustion stack serves both batteries. 

NA = not applicable, as non-recovery oven is less likely to produce green coke, and HAP data is not available. 

Provided by: Marvin Branscome/RTI 

Prepared by: Dib Paul/ICF 

P-Q-C_emisslons Sheetl 

8/18ADO-11:06 AM 

TJ 
Summary of Actual BTX Emissions 

Process Equipment At By-Product Chemical Plant 

Company 

AK Steel 

AK Steel 

Erie Coke 

Gulf States Steel 

New Boston Coke 

Tonawanda Coke 

Location 

Middletown, OH 

Ashland, KY 

Erie, PA 

Gadsden, AL 

New Boston, OH 

Tonawanda, NY 

Actual Emissions, lb/yr 

Benzene (1) 

2.076 

9,163 

328 

4,645 

3,141 

1,799 

Toluene (2) 

125 

550 

20 

279 

188 

108 

Xylenes (3) 

62 

275 

10 

139 

94 

54 

Actual Emissions, lb/hr (4) 

Benzene 

0.2370 

1.0461 

0.0375 

0.5303 

0.3585 

0.2054 

Toluene 

0.0142 

0.0628 

0.0022 

0.0318 

0.0215 

0.0123 

Xylenes 

0.0071 

0.0314 

0.0011 

0.0159 

0.0108 

0.0062 

NOTE: 

(1) Revised estimates based on updated throughput rates. 

98% control efficiency was assumed for tar intercepting sump. 

(2) Toluene emissions at 0.06 times benzene emission rate. 

The factor is based on information in ESD files. 

(3) Xylene emissions at 0.03 times benzene emission rate. . 

The factor is based on information in ESD files. 

(4) lb/hr = lb/yr* 1/8760 

ICF Consulting 

Dlb Paul 1of1 

byproduct_emlsslons 

8/21/DO- 2:59 PM 

V 
Table 5.5-1 (Revised) 

Coal and Coke Throughput Calculation 

Company 

AK Sleel 

AK Steel 

AK Steel 

Erie Coke 

Erie Coke 

Gulf States Steel 

Gulf States Sleel 

New Boston Coke 

Tonawanda Coke 

Inland Steel 

Inland Steel 

Inland Steel 

Inland Steel 

Location 

Middletown, OH 

Ashland, KY 

Ashland, KY 

Erie, PA 

Erie, PA 

Gadsden, AL 

Gadsden, AL 

New Boston; OH 

Tonawanda, NY 

Indiana Harbor, IL 

Indiana Harbor, IL 

Indiana Harbor, IL 

Indiana Harbor, IL 

Battery 

3 

3 

4 

A 

B 

2 

3 

2 

2 

A 

B 

C 

D 

No. of 

ovens (1) 

76 

76 

70 

23 

35 

49 

63 

70 

60 

67 

67 

67 

67 

Annual coke 

production, 

tons/yr (2) 

423,252 

376,341 

588,636 

65,083 

99.040 

226.671 

291,433 

353,091 

219,439 

360.000 

360.000 

360,000 

360,000 

Annual coal 

throughput, 

(1.000 tpy) 

(2) 

592.00 

533.00 

833.00 

79.00 

120.00 

315.00 

438.00 

530.00 

275.00 

570.00 

570.00 

570.00 

570.00 

Hourly coal 

rate, tons/hr 

per oven (3) 

0.9 

0.8 

1.4 

0.4 

0.4 

0.7 

0.8 

0.9 

0.5 

1.0 

1.0 

1.0 

1.0 

NOTE: 

(1) From cokesurvey.xls received from EPA. 

(2) Site-specific data from COETF/ACCCI. Throughput data are for 1998. 

The data was verified, and changes were made where necessary, following discussions with individual sites and Marvin Branscome of RTI. 

(3) See sample calculation. 

Sample Calculation: 

Houriy coal rate per oven = (annual coal rate, "000 tpy) * 1.000 / (no. of ovens) / 8.760 hr/yr 

For Indiana Harbor, the coal rate was divided equally among the four batteries. 

ICF Consulting 

Dlb Paul 1 of 1 

throughput.add 

8/21/00- 12:17 PM 

TJ 

Ol 
Combustion Stack Parameters (Revised) 

Site 

Ak Steel Middletown 

AK Steel Ashland 

AK Steel Ashland 

Erie Coke 

Gulf States Steel No. 2 

Gulf States Steel No.3 

New Boston 

Tonawanda 

Indiana Harbor 

Battery 

3 

3 

4 

A/B 

2 

3 

2 

2 

A/B/C/D 

Dia 

(m) 

4.27 

2.9 

3.8 

2.44 

3.35 

3.79 

2.74 

2.74 

5.49 

Area (m2) 

14.31 

6.60 

11.34 

4.67 

8.81 

11.28 

5.89 

5.89 

23.66 

Area 

(ft2) 

153.98 

71.03 

121.95 

50.28 

94.78 

121.31 

63.40 

63.40 

254.54 

Flow 

(acfm) 

156,274 

54,220 

190,925 

37,900 

96,246 

123,189 

60,700 

97,000 

560,000 

exit vel 

(m/s) 

5.16 

3.88 

7.95 

3.83 

• 5.16 

5.16 

4.86 

7.77 

11.18 

exit vel 

(ft/s) 

16.91 

12.72 

26.09 

12.56 

16.92 

16.92 

15.95 

25.49 

36.66 

Height 

(m) 

76.2 

56.08 

67 

57.91 

76.2 

76.2 

64.01 

54.86 

91.44 

Temp 

(oK) 

518 

505 

553 

513 

518 

518 

478 

478 

339 

NOTE: 

Stack'flow data was not available for Gulf States Steel. 

AK Steel Middletown data based on similarities. 

Used engineering judgement and 

Stack flow data was not available for New Boston. Used engineering judgement and 

Tonawanda data based on similarities. 

Indiana Harbor data is based on dscfm. 

Sample Calculation: 

Exit velocity, m/s = flow, acfm/(area, ft2)/60 * 0.3048 

ICF Consulting 

Ed Carr/Dib Paul 1 of 1 

con.bustion_stack_now 

8/21/00-9:04 AM 

Tl 
P.17 

Summary of Actual Benzene Emissions 

Fugitive Equipment Leak At By-Product Chemical Plant 

Company 

AK Steel 

AK Steel 

Erie Coke 

Gulf States Steel 

New Boston Coke 

Tonawanda Coke 

Location 

Middletown, OH 

Ashland, KY 

Erie, PA 

Gadsden, AL 

New Boston, OH 

Tonawanda, NY 

Actual Benzene 

Emissions, lb/yr 

0 

2,007 

0.06 

48 

20 

1 

Actual Benzene 

Emissions, lb/hr 

0.0000 

0.2292 

0.0000 

0.0055 

0.0023 

0.0001 

NOTE: 

Revised emissions estimates based on screening factors in "Protocol for Equipment Leak 

Emission Estimates", EPA-453/R-95-017, November 1995, Table C-3. 

For Ashland, detailed monitoring report was available by month, quarter, semi-annual, and annual. 

For components that leaked above 500 ppmv, it was assumed leak occurred for the entire 

monitoring period. 

For Gulf States Steel, revised emissions estimates are from the COETF field study report. 

For other facilities, emissions estimates were based on one cycle of monitoring only. 

lb/hr = lb/yr/8760 

ICF Consulting 

Dib Paul 

fugitive_emissions 

8/21A30-3:02 PM 
P.18 

MODELING PARAMETERS 

77l-

UiUiftym;. 

• A-: ':&>27' 

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'''y2'c.-Ay--r;^y^pyi''-^7.Vp:l. • '••• ' •••' 
P.19 

Summary of Buoyancy Flux Calculations 

Company 

AK Steel 

AK Steel 

AK Steel 

Erie Coke 

Erie Coke 

Gulf States Steel 

Gulf States Steel 

New Boston Coke 

Tonawanda Coke 

Inland Steel 

Inland Steel 

Inland Steel 

Inland Steel 

Location 

Middletown, OH 

Ashland, KY 

Ashland, KY 

Erie, PA 

Erie, PA 

Gadsden, AL 

Gadsden, AL 

New Boston, OH 

Tonawanda, NY 

Indiana Harbor, IL 

Indiana Harbor, IL 

Indiana Harbor, IL 

Indiana Harbor, IL 

Battery 

3 

3 

. 4 

A 

B 

2 

3 

2 

2 

A 

B 

C 

D 

Total Buoyancy Flux, 

m4/s3 

Previous 

Estimate (1) 

305 

637 

976 

46 

62 

242 

340 

192 

135 

246 

246 

246 

246 

Revised 

Estimate (2) 

304 

297 

432 

38 

54 

172 

252 

191 

128 

245 

245 

245 

245 

NOTE: 

(1) Emissions estimates submitted by ICF in May 2000. 

(2) Emissions estimates revised by ICF based on throughput changes. 

See Appendix B for revised estimates of buoyancy flux. 

ICF Consulting 

Dib Paul 1 of 1 

flux_summary 

8/90)-_11:36AM 
Quench Tower Parameters (Revised) 

Company 

AK Steel, Middletown 

AK Steel, Ashland 

AK Steel, Ashland 

Erie Coke 

Gulf States Steel 

New Boston 

Tonawanda 

Tonawanda 

Indiana Harbor A/B 

Indiana Harbor C/D 

Battery 

3 

3 

4 

A/B 

2/3 

2 

2 

2 

A/B 

C/D 

Height, ft 

100 

68 

68 

50 

56.5 

50 

40 

60 

60 

60 

Width, ft 

14 

14 

21 

18 

15 

14 

20 

21 

21 

Length, ft 

55 

78 

37 

37.5 

45 

51 

51 

72 

72 

Dia, ft 

14 

Temp, oF 

220 

220 

220 

220 

220 

220 

220 

220 

220 

220 

Duration 

of 

Quench, 

s 

82 

73 

110 

108 

90 

75 

80 

80 

70 

70 

Quench 

Flow, gal 

5,200 

7,000 

9,500 

5.000 

5.000 

1,800 

10,000 

10,000 

10,000 

10,000 

Make-up, 

gal 

2,250 

3,500 

4,750 

2,500 

2.500 

900 

2.000 

10.000 

5.000 

5,000 

Velocity, 

ft/s 

20 

7 

5 

3 

5 

2 

4 

14 

5 

5 

Note 

1. Site data was used where available. 

2. Lula Melton's spreadsheet was used where site data was not available. 

3. Make-up water was not available for all quench towers from sites or Lula Melton's spreadsheet. 

4. Per Lula Melton's spreadsheet, there are two quench towers at Tonawanda and two at Indiana Harbor. 

See attached spreadsheet "quench_flow.xls" for sample calculations. 

Dib Paul 

ICF Consulting 

quench_parameters 

8/21/00- 10:30 AM 
P.21 

Quench Tower Flow Calculation 

AK Steel, Middletown/OH 

Water flow per quench 

Time per quench 

Make-up water 

% of make-up water to steam 

Quench temperature 

Diameter of quench tower 

Quench tower stack flow 

Quench tower velocity 

5,200 gal 

82 sees 

2,250 gal 

50% 

1,125 gal 

220 deg F 

14 ft 

189,244 acfm 

20 ft/s 

Note 1 

Note 1 

Note 2 

Note 3 

Note 4 

Notel 

Sample calculation 1 

Sample calculation 2 

Note5 

NOTE: 

1. From site data or Lula Melton's spreadsheet titled "cokesurvey.xls". 

2. Use 50% of quench flow where not available. 

3. Engineering assumption. 

4. Assumed slightly superheated vapor, based on discussion with ACCCI representatives. 

To simplify calculations, assumed ideal gas. 

5. Use length x width where quench tower is rectangular. 

Sample calculation: 

1. 1,125 gal* 1/82s • 60s/min * 8.34 lb/gal * lbmole/18 lb * 359 ft3/lbmole * (460 + 220)/(460 + 32) 

2. 189,244 acfm / (3.14 * 14*2 ft2/4)/(60 s/min) 

ICF Consulting 

Dib Paul 

quench_f)ow - Middletwon-OH 

8/21/00-10:27 AM 
P.22 

SUPPORTING DOCUMENTATION FOR 

BATTERY EMISSIONS 

T$tfeifei&&;

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v..OOf$£-|^ 
BSO Emission Rates for Doors, Lids, OfTtakes, and Charging 

Allowable Emissions 

Facility 

AK Steel. Middletown 

AK Steel, Ashland 

Erie Coke, Erie 

Gulf States Steel, Gadsden 

New Boston, Portsmouth 

Tonawanda. Buffalo 

Battery 

3 

3 

4 

A 

B 

2 

3 

2 

2 

No. 

Of 

Ovens 

76 

76 

70 

23 

35 

49 

63 

70 

60 

Charging 

Time 

s/chg (t) 

12.00 

12.00 

12.00 

12.00 

12.00 

12.00 

12.00 

12.00 

12.00 

Percent Leaks (2) 1 

PLD 

5.50 

5.50 

5.50 

5.50 

5.50 

5.50 

5.50 

5.50 

5.50 

PLL 

0.60 

0.60 

0.60 

0.60 

0.60 

0.60 

0.60 

0.60 

0.60 

PLO 

3.00 

3.00 

3.00 

3.00 

3.00 

3.00 

3.00 

3.00 

3.00 

DOORS 

Best Estimate 

lb/hr of BSO 

Visible ion-visible 

0.3428 

0.3428 

0.3157 

0.1037 

0.1579 

0.2210 

0.2841 

0.3157 

0.2706 

1.2928 

1.2928 

1.1907 

0.3912 

0.5954 

0.8335 

1.0716 

1.1907 

1.0206 

Totals 

1.6355 

1.6355 

1.5064 

0.4950 

0.7532 

1.0545 

1.3558 

1.5064 

1.2912 

Lros 

Best Estimate 

lb/hr of BSO 

0.0137 

0.0137 

0.0126 

0.0041 

0.0063 

0.0088 

0.0113 

0.0126 

0.0108 

OFFTAKES 

Best Estimate 

lb/hr of BSO 

0.0171 

0.0171 

0.0158 

0.0052 

0.0079 

0.0110 

0.0142 

0.0158 

0.0135 

CHARGING 

Best Estimate 

lb/hr of BSO 

0.0471 

0.0471 

0.0434 

0.0143 

0.0217 

0.0304 

0.0391 

0.0434 

0.0372 

NOTE: 

For allowable emissions, emission limits for existing by-product batteries was used. 

(1) Allowable charging time in December 1995 MACT track limit. 

(2) Erie and Tonawanda are foundry ovens. The rest are furnace ovens. December 1995 MACT track limits were used. None of these ovens have tall doors. 

Provided by: Dib Pnul/ICF 

Battery Emissions - Battery Leaks-Allowable 

8/18/00-9:43 AM 
BSO Emission Rates for Doors, Lids, OfTtakes, and Charging 

Actual Emissions 

Facility 

AK Steel, Middletown 

AK Steel, Ashland 

Erie Coke, Erie 

Gulf Slates Steel, Gadsden 

New Boston, Portsmouth 

Tonawanda, Buffalo 

Battery 

3 

3 

4 

A 

B 

2 

3 

2 

2 

No. 

Of 

Ovens 

76 

76 

70 

23 

35 

49 

63 

70 

60 

Charging 

Time 

Avg s/chg 

2.97 

3.07 

3.07 

3.78 

3.78 

1.60 

1.60 

6.39 

2.32 

Percent Leaks 

Avg PLD 

2.03 

2.16 

2.16 

1.97 

1.50 

1.64 

2.08 

2.73 

2.59 

Avg PLL 

0.08 

0.12 

0.12 

0.04 

0.06 

0.00 

0.02 

0.12 

0.04 

Avg PLO 

0.63 

0.64 

0.64 

0.60 

0.80 

0.18 

0.14 

1.25 

0.39 

DOORS 

Best Estimate 

lb/hr of BSO 

Visible 

0.1262 

0.1344 

0.1238 

0.0371 

0.0432 

0.0658 

0.1074 

0.1568 

0.1275 

ion-visible 

1.3403 

1.3385 

1.2328 

0.4059 

0.6205 

0.8676 

1.1104 

1.2256 

1.0520 

Totals 

1.4665 

1.4729 

1.3566 

0.4430 

0.6637 

0.9333 

1.2178 

1.3823 

1.1795 

LIBS 

Uesi Estimate 

lb/hr of BSO 

0.0019 

0.0027 

0.0025 

0.0002 

0.0006 

0.0001 

0.0003 

0.0026 

0.0007 

OFFTAKES 

Best Estimate 

lb/hr of BSO 

0.0036 

0.0037 

0.0034 

0.0010 

0.0021 

0.0006 

0.0007 

0.0066 

0.0018 

CHARGING 

Best Estimate 

lb/hr of BSO 

0.0117 

0.0120 

0.0111 

0.0045 

0.0068 

0.0040 

0.0052 

0.0231 

0.0072 

NOTE: 

This data was provided by Ron Myers of EPA. 

Provided by: Ron Myers/EPA 

Revised by: Dib Paul/ICF 

Battery_Emissions - Battery Data 

8/18/00-8:53 AM 
P.25 

SUPPORTING DOCUMENTATION FOR 

BY-PRODUCT CHEMICAL PLANT 

PROCESS EQUIPMENT EMISSiiON^^^^^^f^ ^ 

-iKhfeJp&'O'. '•••: 

$p£pA: 

#£» ' O 

W&7L 

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P.26 

Ak Steel, Middletwon/OH 

Process Equipment Emissions from By-Product Plant 

7 

Source 

Tar decanter 

Tar intercepting 

sump 

Tar dewatering 

tank 

Tar storage tank 

Flushing liquor 

circulation tank 

Excess 

ammonia liquor 

tank 

Wash oil 

decanter 

Total (lb/yr) 

No. of 

Units'1' 

2 

2 

2 

1 

1 

4 

1 

Gas 

Blanketing 

(Yes/No) 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Source Height (ft)12' 

See next page 

11 

10 

40 

10 

See next page 

10 

' 

Source Dia or 

Length/Width 

(ftf 

See next page 

47x1 0 

10 dia x 22 

56.5 dia 

10 dia x 35 

See next page 

10 dia x 32 

Tank 

Orientation 

(Horiz/Vert) 

Horiz 

Horiz 

Horiz 

Vert 

Horiz 

Vert 

Horiz 

Calculated 

Benzene 

Emissions 

(lb/yr)"' 

1304 

1524 

7 

53 

0 

152 

64 

3,104 

Method of 

Calc."' 

Mass Transfer 

AP-42 

TANKS 

TANKS 

No benzene 

data 

AP-42 

AP-42 

V' 

Calculated 

Benzene 

Emissions 

(lb/yr)14' AP 

42 factors 

931 

161 

356 

322 

220 

24 

63 

L^OKAP-42 

Emission 

Factor 

(lb/ton)w 

0.002200 

0.000380 

0.000840 

0.000760 

0.000520 

0.000056 

0.000150 

NOTE: 

1) Multiple units are assumed to be operating in parallel. 

2) Diameter if cylindrical tank; lenflth and width if rectangular tank. See attached sheet for dimensions of multiple units. 

3) Benzene emission rate calculated by site using TANKS or AP-42. 

4) Benzene emission rate calculated by ICF using Furnace Plant Draft AP-42 dated Feb'99, Table 12.2-19. 

For tar intercepting sump with pas blanketing, 98% control efficiency was used per Ron Myers' recommendation. 

Actual facility throughput for operating year 1998 423.252 tons/yr 

Sample calculation: 

Benzene emissions = AP-42 factor, lb/ton of coke pushed * actual facility coke throughput, tons/yr 

ICF Consulting 

Prepared by. Site 

Updated ty. Dib Paul 1 of1 

Middletown_Byproducl-rev 

8/18/00-11-2 AM 
Table 4.3-1 (Revised) 

A k Steel, Ashland/KY 

Process Equipment Emissions from By-Product Plant 

Source 

Light oil storage tank 

Tar decanter 

No. of 

Units'1' 

Gas 

Blanketing 

(Yes/No) 

Yes 

Yes 

Source 

Height 

(«)'" 

19 

12 

Source Dia or 

Length/Width 

(ft) U) 

20 dia 

12 dia x 50 

Tank 

Orientation 

(Horiz/Vert) 

Vert 

Horiz 

Calculated 

Benzene 

Emissions 

(lb/yr)1" 

282 

2,972 

Method of 

Calc.'" 

TANKS 

Mass 

Transfer 

Calculated 

Benzene 

Emissions 

(lb/yr)'4' AP42 factors 

232 

2.123 

AP-42 

Emission 

Factor 

(lb/ton)

 ,4» 

0.00024 

0.0022 

Tar intercepting sump Yes 12 12 dia x 50 Horiz 3.474 AP-42 367 0.00038 

Tar dewatering tank Yes 10 10 dia x 30 Horiz 

TANKS 

/Mass 

Transfer 

1*7 

<

=joe) Wash oil decanter 

811 0.00084 

Tar storage tank Yes 50 33 dia Vert 17 TANKS 733 0.00076 

Light oil condenser vent Yes 53 3 x 6 Vert 3,435 AP-42 3.474 0.0036 

Light oil sump Yes 10 10 dia x3 0 Horiz 579 AP-42 579 0.0006 

Flushing liquor circulation tank Yes 10 10 dia x 30 Horiz TANKS 502 0.00052 

Excess ammonia liquor tank Yes 34 30 dia Vert TANKS 54 0.000056 

Yes 10 10 dia x 30 Horiz 147 TANKS 

Wash oil circulation tank 1 Yes 10 10 dia x 30 Horiz 56 TANKS 

145 

145 

0.00015 

0.00015 

Total emissions, lb/yr 10,967 

^7^ 7 V3> o 

NOTE: 

1) Multiple units are assumed to be operating in parallel. 

2) Diameter if cylindrical tank; length and width if rectangular tank. See attached sheet for dimensions of multiple units. 

3) Benzene emission rate calculated by site using TANKS or AP-42 (older than Feb'99 draft). 

4) Benzene emission rate calculated by ICF using Draft AP-42 dated Feb'99, Table 12.2-19, benzene emission factors for Furnace Plant. 

For tar intercepting sump with gas blanketing, 98% control efficiency was used per Ron Myers' recommendation. 

9^163 

Actual facility throughput for operating year 1998 964,977 tons/yr 

Sample calculation: 

Benzene emissions = AP-42 factor, lb/ton of coke pushed * actual facility coke throughput, tons/yr 

Prepared by. Site 

Updated by: Dlb Paul 

Ashland Byproducl.rev - Process Equipment 

8/18/00- 11:24 AM 
Tonawanda Coke Corporation 

Process Equipment Emissions from By-Product Plant 

Source 

Light oil storage lank 

Tar decanter 

Tar storage tank 

Light oil condenser vent 

Flushing liquor circulation tank 

r 

Excess ammonia liquor tank 

Wash oil decanter 

Wash oil circulallon tank 

Total (lb/yr) 

No. of 

Unlts m 

Gas 

Blanketing 

(YesffJo) 

1 No 

1 

2 

1 

1 

1 

2 

1 

. 

suction 

suction 

sealed 

suction 

No 

sealed 

sealed 

Source Height (ft) m 

10 

10 

10 

50 

10 

30 

10 

10 

Source Dia or 

Length/Width 

9 dia 

30x10 

10 dia 

2 dia 

10 dia 

40 dia 

8 dia 

Tank 

Orientation 

(Horlz/Vert) 

Horiz. 

Horiz. 

Horiz. 

Vert. 

Horiz. 

Vert. 

Horiz. 

Horiz. 

Calculated 

Benzene 

Emissions 

(lb/yr)'" 

589 

0 

0 

0 

0 

0.4 

0 

0 

589 

Method of 

Calc.m 

TANKS 

Testing 

Testing 

Testing 

Testing 

TANKS 

Testing 

Testing 

Calculated 

Benzene 

Emissions 

(lb/yr)'" AP42 factors 

1,361 

0 

0 

0 

0 

439 

0 

0 

'' 1J799 . 

AP-42 Emission 

Factor1" 

(lb/ton) 

0.006200 

NA 

NA 

NA 

NA 

0.002000 

NA 

NA 

NOTE: 

1) Multiple units are assumed to be operating In parallel. 

2) Diameter if cylindrical tank; length and width if rectangular tank. See attached sheet for dimensions of multiple units. 

3) Benzene emission rate calculated by site using TANKS or testing data. 

4) Benzene emission rate calculated by ICF using Draft AP-42 dated Feb'99. Table 12.2-19. benzene emission factors for foundry plant. 

5) Emissions from sealed units or those wilh suction are zero or negligible. 

Actual facility throughput for operating year 1998 219.439 tons/yr 

Sample calculation: 

Benzene emissions, lb/yr = AP-42 factor, lb/ton of coke pushed * actual facility coke throughput, tons/yr 

Prepared by: Site 

Updated by: Dlb Paul 

1 of 1 

Tonawenrfe hvprtx..iet_rsv - Process Equipment 

8/tB/OO- 11:33 AM 

ro 

oo 
Erie Coke Corporation 

Process Equipment Emissions from By-Product Plant 

Source 

-

Tar decanter 

Tar dewatering tank 

Tar storage tank 

Flushing liquor circulation tank 

Excess ammonia liquor tank 

Total (lb/yr)

 >:' 

No. of 

Units'1' 

2 

1 

1 

1 

1 

Gas 

Blanketing 

(Yes/No) 

suction 

suction 

suction 

suction 

No 

Source Height (ft)'" 

10.0 

12.0 

22.0 

15.0 

20.0 

Source Dia or 

Length/Width 

(ft)'* 

30x1 0 

8.0 

30.0 

10.0 

15.0 

Tank 

Orientation 

(Horlz/Vert) 

Horizontal 

Horizontal 

Vertical 

Horizontal 

Vertical 

Calculated 

Benzene 

Emissions 

(lb/yr)'" 

270 

0 

0 

0 

0 

270 

Method of 

Calc.'" 

Testing & 

Estimate 

Testing 

Testing 

Testing 

Calculation 

Estimate 

Calculated 

Benzene 

Emissions 

(IWyr)'" AP42 factors 

0 

0 

0 

0 

328 

*«*H8SO 

AP-42 Emission 

Factor'4' 

(lb/ton) 

NA 

NA 

NA 

NA 

0.002000 

NOTE: 

1) Multiple units are assumed to be operating In parallel. 

2) Diameter if cytindricai tank; length and width if rectangular tank. See attached sheet for dimensions of multiple units. 

3) Benzene emission rate calculated by site using test data or other estimates. 

4) Benzene emission rate calculated by ICF using Draft AP-42 dated Feb'99, Table 12.2-19, benzene emission factors for foundry plant. 

5) Emissions from sealed units or those with suction are aero or negligible. 

Actual facility throughput for operating year 1998 164,123 tons/yr 

Sample calculation: 

Benzene emissions, lb/yr = AP-42 factor, lb/ton of coke pushed * actual facility coke throughput, tons/yr 

Prepared by: Site 

Updated by: Dib Paul 

Page 1 of 1 

Erie byproduct-rev - Process Equipment 

8/18/00-11:27 AM 
New Boston Coke Corp. 

Process Equipment Emissions from By-Product Plant 

Source 

Light oil storage tank 

Tar decanter 

Tar intercepting sump 

Tar dewatering tank 

Tar storage tank 

Light oil condenser vent !':'. 

Flushing liquor circulation tank 

Excess ammonia liquor tank 

Wash oil decanter 

Wash oil circulation tank 

Total (lb/yr) 

No. of 

Units'" 

1 

1 

1 

1 

2 

2 ' 

1 

1 

1 

1 

Gas 

Blanketing 

(Yes/No) 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Source Height (ft)'" 

25 

12.5 

8 

27 

35 

6 

18 

15 

9 

17 

Source Dia or 

Length/Width 

(ft)*" 

10 

48x1 4 

8 

10 

32 

1 

10 

6 

30x 8 

10 

Tank 

Orientation 

(Horlz/Vert) 

Horizontal 

Horizontal 

Vertical 

Horizontal 

Vertical 

Vertical 

Horizontal 

Horizontal 

Horizontal 

Horizontal 

Calculated 

Benzene 

Emissions 

(lb/yr)'3' 

35.4 

0.7 

0 

1.2 

0.8 

1271.2 

0 

0 

53 

53 

1,415 

Method of 

Calc."' 

TANKS 

TANKS 

TANKS 

TANKS 

TANKS 

AP-42 

TANKS 

TANKS 

AP-42 

AP-42 

Calculated 

Benzene 

Emissions 

(lb/yr)'" AP42 factors 

85 

777 

134 

297 

268 

1,271 

184 

20 

53 

53 

^7007 

AP-42 Emission! 

Factor"1 

(lb/ton) 

0.000240 

0.002200 

O.00O380 

0.000840 

0.000760 

0.003600 

0.000520 

0.000056 

0.000150 

0.000150 

NOTE: 

1) Multiple units are assumed to be operating In parallel. 

2) Diameter If cylindrical tank; length and width If rectangular tank. See attached sheet for dimensions of multiple units. 

3) Benzene emission rate calculated by sHe using TANKS or AP-42 (older than Feb'99 draft). 

4) Benzene emission rate calculated by ICF using Draft AP-42 dated Feb'99. Table 12.2-19, benzene emission factors for furnace plant. 

5) Emissions from sealed units or those with suction are zero or negligible. 

For tar Intercepting sump with gas blanketing. 98% control efficiency was used per Ron Myers' recommendation. 

Actual facility throughput for operating year 1998 353,091 tons/yr 

Sample calculation: 

Benzene emissions, lb/yr = AP-42 factor, lb/ton of coke pushed • actual facility coke throughput, tons/yr 

Prepared by: Site 

Updated by. Dlb Paul 

1 of 1 

NewBoslon_bypr«_uct-rev . Process Equipment 

8/18/00-11:31 AM 
Gulf States Steel 

Process Equipment Emissions from By-Product Plant 

Source 

Oi Light oil storage tank 

xi Reclaimed wash oil storage 

N/ Light oil separator tank 

\ y Light oil condensate tank 

0/ Flushing liquor circulation tank 

Tar dewaterlng tank 

V Tar decanter f... 

\ j Tar storage 

\* Excess ammonia liquor tank 

Total (lb/yr) 

No. of 

Units'" 

7 

1 

1 

1 

1 

2 

2 r! 

2 

1 

Gas 

Blanketing 

(Yes/No) 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Source Height (ft)'" 

14.0 

14.0 

7.0 

11.0 

13.5 

13.0 

14.0 

32.0 

30.0 

Source Dia or 

Length/Width 

(«)"» 

11.0 

11.0 

4.0 

8.0 

10.5 

10.0 

10.0x36.0 

40.0 

41.0 

Tank 

Orientation 

(Horlz/Vert) 

Horizontal 

Horizontal 

Horizontal 

Horizontal 

Horizontal 

Horizontal 

Horizontal 

Vertical 

Vertical 

Calculated 

Benzene 

Emissions 

(lb/yr)"' 

132.6 

0.2 

23.8 

0.0 

0.0 

0.6 

0.0 

0.8 

0.0 

158.0 

Method of 

Calc.'" 

TANKS3 

TANKS3 

TANKS3 

TANKS3 

TANKS3 

TANKS3 

TANKS3 

TANKS3 

TANKS3 

Calculated 

Benzene 

Emissions 

(lb/yr)'4' AP42 factors 

124 

78 

311 

1,865 

269 

435 

1.140 

394 

29 

;4,645 

AP-42 Emission 

Factor'4' 

(lb/ton) 

0.000240 

0.000150 

0.000600 

0.003600 

0.000520 

0.000840 

0.002200 

0.000760 

0.000056 

NOTE: 

1) Multiple units are assumed to be operating in parallel. 

2) Diameter if cylindrical tank; length and width if rectangular tank. See attached sheet for dimensions of multiple units. 

3) Benzene emission rate calculated by site using TANKS or AP-42 (older than Feb'99 draft). 

4) Benzene emission rate calculated by ICF using Draft AP-42 dated Feb'99. Table 12.2-19, benzene emission factors for furnace plant. 

5) Emissions from sealed units or those with suction are zero or negligible. 

Actual facility throughput for operating year 1998 518,104.0 tons/yr 

Sample calculation: 

Benzene emissions, lb/yr = AP-42 factor, lb/ton of coke pushed • actual facility coke throughput, tons/yr 

Prepared by: Site 

Updated by: Dib Paul Page 1 of 1 

Gulf States_byproduct-rev - Process Equipment 

8/18/0011:28 AM 
P.32 

SUPPORTING DOCUMENTATION FOR 

' ?T 

o 

•' 

• 

BY-PRODUCT CHEMICAL PLANT 

• V .

 ;

 -

FUGITIVE EQUIPMENT LEAKS 

• \ • " • i 

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P.33 

Fugitive Equipment Leak Emissions from By-Product Plants 

TOC Emission Factors (1) (2) 

Equipment Type 

Valve 

Pump 

Other 

Connector 

Flange 

Open-ended Line 

Default Zero 

Emission Rate, 

kg/hr/source (3) 

7.80E-06 

2.40E-05 

4.00E-06 

7.50E-06 

3.10E-07 

2.00E-06 

Pegged Emission Rates, 

kg/hr/source (4) 

10,000 ppmv 

6.40E-02 

7.40E-02 

7.30E-02 

2.80E-02 

8.50E-02 

3.00E-02 

100,000 ppmv 

1.40E-01 

1.60E-01 

1.10E-01 

3.00E-02 

8.40E-02 

7.90E-02 

Correlation Equation, 

kg/hr/source (5) 

2.29E-06 *(SV)0"* 

5.03E-05 *(SV)0-

610 

1.36E-05"(SV)0-

688 

1.53E-06*(SV)°-73S 

4.61E-06*(SV)a703 

2.20E-06 *(SV)U/W 

NOTE: 

(1) Emission factors are from "Protocol for Equipment Leak Emission Estimates", 

EPA-453/R-95-017, November 1995, Table C-3. 

(2) These emission factors are for refineries, marketing terminals, and oil and gas production. 

Based on a 1980 study, EPA concluded that the use of refinery data to characterize coke 

by-product fugitive emissions was reasonable. 

(3) This factor is used when the leak detection monitor consistently shows 0 readings. 

(4) These factors are used when the leak detection monitor trips due to excessive hydrocarbon 

concentration beyond the detection range of the monitor. 

(5) SV = screening value in ppmv as detected by the leak detection monitor 

ICF Consulting 

Dib Paul 

fugibve_emissions 

8/11/00-2:30 PM 
P.34 

AK Steel, Middletown/OH 

Fugitive Equipment Leak Emissions from By-Product Plant 

NOTE: 

Fugitive equipment leaks were not calculated as the plant has no light oil recovery. 

There are no components in light oil service. 

Therefore, emissions are negligible or not quantifiable. 

DlbPau l

 fugitive_emissions 

ICF Consulting 1 8/11/00-2:20 PM 
P.35 

AK Steel, Ashland/KY 

Fugitive Equipment Leak Emissions from By-Product Plant 

Total benzene emissions 

Benzene emissions from non-leaking components = 14 lb/yr 

Benzene emissions from leaking components = 1,994 lb/yr 

Total benzene emissions = *§2~d07Mb/yr 

Dib Paul fugitive_emissions 

ICF Consulting 1 8/18£0~ 12:03 PM 
AK Steel, Ashland/KY 

Fugitive Equipment Leak Emissions from By-Product Plant 

Emissions from non-leaking components 

P.36 

Stream(1) 

Light oil (liquid or vapor) 

Rich wash oil 

Lean wash oil 

Benzene Mass 

Fraction (2) 

75% 

3% 

0.14% 

Type of 

Equipment 

Pump 

Flange 

Valves 

Open End 

Pump 

Flange 

Valves 

Open End 

Pump 

Flange 

Valves 

Open End 

No. of ZeroReading 

Components 

(3) 

4 

46 

93 

30 

2 

10 

116 

21 

3 

10 

131 

19 

Default Zero 

Emission 

Rate i 

kg/hr/source 

(4) 

2.40E-05 

3.10E-07 

7.80E-06 

2.00E-06 

2.40E-05 

3.10E-07 

7.80E-06 

2.00E-06 

2.40E-05 

3.10E-07 

7.80E-06 

2.00E-06 

Benzene 

Emissions, 

lb/yr (5) 

1.39 

0.21 

10.51 

0.87 

0.03 

0.00 

0.52 

0.02 

0.00 

0.00 

0.03 

0.00 

Total Emissions, lb/yr 14 

NOTE: 

(1) For process streams in benzene service (e.g., light oil liquid, light oil vapor, etc.) 

(2) Compositions from site. 

(3) Component count, and no. of zero leaking components from site. It was assumed that a component 

with less than 500 ppmv screening value was not leaking. 

(4) Default zero emission factors for TOC are from "Protocol for Equipment Leak Emission Estimates", 

EPA-453/R-95-017, November 1995, Table C-3. 

(5) Benzene emissions = Default zero factor, kg/hr/component * 1/0.4536 kg/lb * no. of components 

* 8760 hrs/yr * wt fraction benzene 

Dib Paul 

ICF Consulting 

fugitive_emissions 

8/11/00 -2:22 PM 
P.37 

Erie Coke Corporation 

Fugitive Equipment Leak Emissions from By-Product Plant 

Stream(1) 

CO Gas 

Benzene Mass 

Fraction (2) 

1% 

Type of 

Equipment 

Valves 

Other 

No. of Zero- Default Zero Benzene 

Reading Emission Emissions, 

Components Rate, lb/yr (5) 

(3) kg/hr/source 

(4) 

42 7.80E-06 0.06 

2 4.00E-06 0.00 

Total Emissions, lb/yr 0.06 

NOTE: 

(1) For process streams in benzene service (e.g., light oil liquid, light oil vapor, etc.) 

(2) Compositions from site. 

(3) Component count, and no. of zero leaking components from site. It was assumed that a component 

with less than 500 ppmv screening value was not leaking. 

(4) Default zero emission factors for TOC are from "Protocol for Equipment Leak Emission Estimates", 

EPA-453/R-95-017, November 1995. Table C-3. 

(5) Benzene emissions = DefauH zero factor, kg/hr/component * 1/0.4536 kg/lb * no. of components 

• 8760 hrs/yr * wt fraction benzene 

Dib Paul fugitive_en.issions 

ICF Consulting 1 8/11/00-2:18 PM 
P.38 

New Boston/OH 

Fugitive Equipment Leak Emissions from By-Product Plant 

Stream(1) 

Light oil (liquid or vapor) 

Benzene Mass 

Fraction (2) 

67% 

CO Gas 10% 

Type of No. of Zero- Default Zero Benzene 

Equipment Reading Emission Emissions, 

Components Rate, lb/yr (5) 

Pump 

Flange 

Valves 

Open End 

Other 

(3) kg/hr/source 

(4) 

9 2.40E-05 

848 3.10E-07 

122 7.80E-06 

72 2.00E-06 

8 4.00E-06 

2.79 

3.40 

12.31 

1.86 

0.06 

Total Emissions, lb/yr 20 

NOTE: 

(1) For process streams in benzene service (e.g., light oil liquid, light oil vapor, etc.) 

(2) Compositions from site. 

(3) Component count, and no. of zero leaking components from site. It was assumed that a component 

with less than 500 ppmv screening value was not leaking. 

(4) Default zero emission factors for TOC are from "Protocol for Equipment Leak Emission Estimates", 

EPA-453/R-95-017, November 1995, Table C-3. 

(5) Benzene emissions = Default zero factor, kg/hr/component * 1/0.4536 kg/lb * no. of components 

* 8760 hrs/yr * wt fraction benzene 

Dib Paul 

ICF Consulting 

fugitive_emissions 

8/11/O0 -2:17 PM 
Tonawanda/NY 

Fugitive Equipment Leak Emissions from By-Product Plant 

P.39 

Stream(1) 

Light oil (liquid or vapor) 

CO Gas 

Benzene Mass 

Fraction (2) 

65% 

1% 

Type of 

Equipment 

Pump 

Flange 

Valves 

Open End 

Other 

Valves 

No. of ZeroReading 

Components 

(3) 

1 

2 

7 

1 

3 

35 

Default Zero 

Emission 

Rate, 

kg/hr/source 

(4) 

2.40E-05 

3.10E-07 

7.80E-06 

2.00E-06 

4.00E-06 

7.80E-06 

Benzene 

Emissions, 

lb/yr (5) 

0.30 

0.01 

0.69 

0.03 

0.00 

0.05 

Total Emissions, lb/yr 

NOTE: 

(1) For process streams in benzene service (e.g., light oil liquid, light oil vapor, etc.) 

(2) Compositions from site. 

(3) Component count, and no. of zero leaking components from site. It was assumed that a component 

with less than 500 ppmv screening value was not leaking. 

(4) Default zero emission factors for TOC are from "Protocol for Equipment Leak Emission Estimates", 

EPA-453/R-95-017, November 1995, Table C-3. 

(5) Benzene emissions = Default zero factor, kg/hr/component * 1/0.4536 kg/lb * no. of components 

* 8760 hrs/yr * wt fraction benzene 

Oib Paul 

ICF Consulting 

fugitive_emissions 

8/11/00-159 PM 
P.40 

CONSULTIN G 

August 31, 2000 

Mr. Ted Palma 

USEPA 

Emission Standards Division 

Risk & Exposure Assessment Group 

MD-13 

RTP.NC 

Re: Revised Fugitive Emission Calculations 

Dear Mr. Palma: 

ICF Consulting (ICF) appreciates the opportunity to support EPA's residual risk 

assessment project for the coke oven source category. Enclosed are the revised 

calculations of emission rates from fugitive equipment leaks. As suggested during our 

August 28 meeting, I have completed emission calculations for the following scenarios: 

• COETF factors 

• AP-42 factors 

• EPA average emission factors 

• EPA Leak/No-leak factors 

• EPA default/pegging/correlation factors 

• All components leaking at 250 ppmv (half of 500 ppmv leak level). 

I am e-mailing you disk files for the above calculations. If you have any questions, 

please do not hesitate to call me at (919) 233-0382. 

Sincerely, 

DibPaul, PE. 

Project Manager 

End 

dp 

9300 Lee Highway Fairfax, VA 22031-1207 USA . 703-934-3000 — 703-934-3740 fax www.icfconsulting.com 
Fugitive Equipment Leak Emissions from By-Product Chemical Plants 

Summary of Benzene Emissions, lb/yr 

Facility, Location 

AK Steel, Middletown 

AK Steel, Ashland 

Erie Coke 

Gulf States Steel 

New Boston Coke 

Tonawanda Coke 

Based on COETF 

Factors (1) 

147 

72 

5 

53 

95 

10 

Based on AP-42 

Factors (2) 

78 

31.949 

106 

129,531 

153.042 

2,792 

Based on Average 

Emission Factors 

(3) 

\ 

^..5 3 

25,114 

3^279 

N 7§;959 

^ 37,340 

>2;6&8 

Based on Leak-no 

Leak Factors (4) 

N, 1.414 

^,•0^5^23 9 

1,413 

5,551 

7,567 

1,732 

Based on Default 

Zero/ Pegged/ 

Correlation 

Emission Rate (5) 

0.05 

^At,^£®Q 7 

0.06 

48 

20 

1 

Based on 250 I 

ppmv Leak (6) I 

1 

484 

1 

1,847 

2,951 

39 

NOTE: 

(1) Emission factors generated by coke association based on January 2000 field study. 

(2) Draft AP-42, Table 12.2-1. 

(3) Emission factors are from "Protocol for Equipment Leak Emission Estimates", EPA-453/R-95-017, November 1995. 

These emission factors are for refineries. Based on a 1980 study, EPA concluded that the use of refinery data to characterize coke, 

by-product fugitive emissions was reasonable. 

Average emission factors for refineries from Table 2-2 of above document. 

(4) Refinery screening range emission factors from Table 2-6 of document cited under note (3). 

With the exception of Ashland, full monitoring data was not available for the other sites. 

It was assumed that emissions from leaks at Ashland were representative of each facility. 

Therefore, emissions from leaking components at Ashland were added to non-leaking emissions from each site. 

(5) Default zero, pegged, and correlation equations from Table C-3 of document cited under note (3). 

(6) It was assumed that a 250 ppmv leak (500 ppmv leak/2) represents leaks at each site. 

ICF Consulting 

Dib Paul 

fugi!ive_emlssions_summary 

8/31100- 1:40 PM 
Fugitive Equipment Leak Emissions from By-Product Plants 

Comparison of TOC Emission Factors 

Equipment Type 

Valve 

Pump 

Other 

Connector 

Flange 

Open-ended Line 

COETF 

Factors, 

kg/hr/source 

d) 

8.26E-06 

1.82E-04 

1.46E-04 

3.48E-06 

3.48E-06 

4.38E-06 

AP-42 

Factors, kg/hr/ 

source (2) 

1.08E-02 

1.13E-01 

1.49E-02 

1.08E-02 

1.08E-02 

| 2.27E-03 

Average 

Emission 

Factors, 

kg/hr/source 

(3) 

1.09E-02 

1.14E-01 

1.50E-02 

2.50E-04 

2.50E-04 

2.30E-03 

Leak-no Leak Factors, 

kg/hr/source (4) 

> 10,000 

ppmv 

8.52E-02 

4.37E-01 

3.75E-02 

3.75E-02 

3.75E-02 

1.20E-02 

<10,000 

ppmv 

1.70E-03 

1.20E-02 

6.00E-05 

6.00E-05 

6.00E-05 

1.50E-03 

Default Zero 

Emission Rate, 

kg/hr/source 

(5) 

7.80E-06 

2.40E-05 

4.00E-06 

7.50E-06 

3.10E-07 

2.00E-06 

Pegged Emission 

Rates, kg/hr/source (6) 

10,000 

ppmv 

6.40E-02 

7.40E-02 

7.30E-02 

2.80E-02 

8.50E-02 

3.00E-02 

100,000 

ppmv 

1.40E-01 

1.60E-01 

1.10E-01 

3.00E-02 

8.40E-02 

7.90E-02 

Correlation Equation, 

kg/hr/source (7) 

2.29E-06 *(SV)°",B 

5.03E-05 *(SV)oa,° 

1.36E-05 *(SV)0589 

1.53E-06 *(SV)0735 

4.61 E-06 *(SV)0703 

2.20E-06 •(SV)""'" 

NOTE: 

(1) Emission factors submitted by coke association based oh a field study. 

(2) Draft AP-42, Table 12.2-1, VOC emissions. Lb/day factors were converted to Kg/hr. 

(3) Emission factors are from "Protocol for Equipment Leak Emission Estimates", EPA-453/R-95-017, November 1995. 

These emission factors are for refineries. Based on a 1980 study, EPA concluded that the use of refinery data to characterize coke, 

by-product fugitive emissions was reasonable. 

Average emission factors for refineries from Table 2-2 of above document. 

For allowable emissions, all components were assumed to be in light liquid service. 

For "Other", sampling connection factor was assumed. 

(4) Refinery screening ranges emission factors from Table 2-6 of document cited under note (3). 

(5) This factor is used when the leak detection monitor consistently shows 0 readings. See Table C-3 of document cited under note (3). 

(6) These factors are used when the leak detection monitor trips due to excessive hydrocarbon concentration beyond the detection 

range of the monitor. See Table C-3 of document cited under note (3). 

(7) SV = screening value in ppmv as detected by the leak detection monitor. See Table C-3 of document cited under note (3). 

ICF Consulting 

Dib Paul 

fugilive_emisslons 

8/31 A30~12:25 PM 
P.43 

'7p^0M&ppp7- pyi^^^^yw^^' 

•"•••• . :••••• - ymmmmmmm^m ^ 

EMISSIONS BASED ON AVERAGE EMISSION FACTORS; 

FUGITIVE EQUIPMENT LEAKS r^3my^M^y7,-7m:

^22PP2y7^i'7y 

BY-PRODUCT CHEMICAL PLANT 
P.44 

Summary of Benzene Emissions 

Fugitive Equipment Leak At By-Product Chemical Plant 

(Based on Average Emission Factors) 

Company 

AK Steel 

AK Steel 

Erie Coke 

Gulf States Steel 

New Boston Coke 

Location 

Middletown, OH 

Ashland, KY 

Erie, PA 

Gadsden, AL 

New Boston, OH 

Tonawanda Coke Tonawanda, NY 

Benzene Emissions, 

lb/yr 

53 

25,114 

279 

73,959 

37,840 

2,698 

Benzene Emissions, 

lb/hr 

6.09E-03 

2.87E+00 

3.19E-02 

8.44E+00 

4.32E+00 

3.08E-01 

NOTE: 

Emission factors are based on Table 2-2 of "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1.995. 

lb/hr = lb/yr/8760 

ICF Consulting 

Dib Paul 

fugitive_average-factor 

8/31A0O-10:57 AM 
AK Steel, Middletown/OH 

Fugitive Equipment Leak Emissions from By-Product Plant 

Average Emission Factors 

P.45 

Type of Equipment Benzene Mass 

Fraction 

No. of 

Components 

Average Benzene 

Emission Emissions, 

Factor, lb/yr (2) 

kg/hr/source (1) 

Pump 

Flange 

Valves 

Connector 

Other 

0.14% 2 

85 

74 

3 

61 

1.14E-01 

2.50E-04 

1.09E-02 

2.50E-04 

1.50E-02 

6.1644 

0.5745 

21.8081 

0.0203 

24.7389 

53.3062 

NOTE: 

(1) Emission factors are based on Table 2-2 of "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1995. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

fugitive_average-factor 

8/31/00-10:32 AM 

 
P.46 

AK Steel, Ashland/KY 

Fugitive Equipment Leak Emissions from By-Product Plant 

Average Emission Factors 

NOTE: 

(1) Emission factors are based on Table 2-2 of "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1995. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Stream 

Light oil (liquid or vapor) 

Rich wash oil 

Lean wash oil 

Total Emissions, lb/yr 

Benzene Mass 

Fraction 

75% 

3% 

0.14% 

Type of 

Equipment 

Pump 

Flange 

Valve 

Open End 

Pump 

Flange 

Valves 

Open End 

Pump 

Flange 

Valves 

Open End 

No. of 

Components 

5 

46 

93 

30 

3 

10 

116 

21 

3 

10 

131 

19 

Emission 

Factorm, 

kg/hr/source 

1.14E-01 

2.50E-04 

1.09E-02 

2.30E-03 

1.14E-01 

2.50E-04 

1.09E-02 

2.30E-03 

1.14E-01 

2.50E-04 

1.09E-02 

2.30E-03 

Benzene 

Emissions, 

lb/yr

 m 

8,256 

167 

"^ 14,683 

999 

198 

1 

733 

28 

9 

0 

39 

1 

25,114 

V 

Dib Paul 

ICF Consulting 

fugitive_average-factor 

8/31/00-10:39 AM 
P.47 

Erie Coke Corporation 

Emissions from By-Product Plant 

Average Emission Factors 

Stream Type of No. of Emission Factor Benzene 

Benzene Mass Fraction

 E(*u i Pmen t

 Components (1), kg/hr/source Emissions, 

lb/yr (2) 

<1% 

C o Gas [Exhauster 2 1.60E-01 62 

cio . Gas <1% Valves 42 2.68E-02 217 

Total Emissions, lb/yr

 27 9 

NOTE: 

(1) Emission factors are based on Table 2-2 of "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1995. 

Factors for gas were used. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul fugitive_averaB©-f8etor 

ICF Consulting

 1 8O1/00-10:43 AM 
P.48 

Gulf States Steel 

Emissions from By-Product Plant 

Average Emission Factors 

Stream 

Benzene Mass Fraction 

Type of 

Equipment 

No. of 

Components 

Emission Factor Benzene 

(1), kg/hr/source Emissions, 

lb/yr (2) 

60% 

Liquid 

CO. Gas 

62% 

67% 

69% 

31% 

100% 

100% 

100% 

Flange 

Connector 

Valve 

Flange 

Connector 

Flange (Lea 

Valve 

king) 

Open Ended Line 

191 

181 

83 

146 

112 

9 

115 

18 

2.50E-04 

2.50E-04 

1.09E-02 

2.50E-04 

2.50E-04 

2.50E-04 

2.68E-02 

2.30E-03 

553 

542 

11,706 

627 

168 

43 

59,520 

800 

Total Emissions, lb/yr 73,959 

NOTE: 

(1) Emission factors are based on Table 2-2 of "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1995. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

fugitive_ave.age-fac.Of 

8/31/00-10:49 AM 
P.49 

New Boston Coke Corp. 

Emissions from By-Product Plant 

Average Emission Factors 

Stream Benzene Mass Fraction Type of No. of Emission Factor Benzene 

Equipment Components (1), kg/hr/source Emissions, 

lb/yr (2) 

Liquid 67% Valve 

Open End 

Flanges/connectoi 

Pumps 

CO. Gas 10% Pres. Relief 8 1.60E-01 2,472 

Total Emissions, lb/yr 37,840 

NOTE: 

(1) Emission factors are based on Table 2-2 of "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1995. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

122 

72 

848 

9 

1.09E-02 

2.30E-03 

2.50E-04 

1.14E-01 

17,206 

2,143 

2,743 

13,276 

Dib Paul tugitive_average-lactor 

ICF Consulting

 1 6/31/00 • 10:53 AM 
Tonawanda Coke Corporation 

Emissions from By-Product Plant 

Average Emission Factors 

P.50 

Stream Benzene Mass Fraction Type of No. of 

Equipment Components 

Emission Factor Benzene 

(1), kg/hr/source Emissions, 

lb/vr (2) 

Liquid 65% Pump 

Flange 

Valve 

Open End 

>7 

3_ 

1 

2 

7 

1 

1.14E-01 

2.50E-04 

1.09E-02 

2.30E-03 

1,431 

6 

958 

29 

CO. Gas <1% Exhauster 

Pres. Relief 

Valves 

2 

1 

35 

1.60E-01 

1.60E-01 

2.68E-02 

62 

31 

181 

Total Emissions, lb/yr 2,698 

NOTE: 

(1) Emission factors are based on Table 2-2 of "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1995. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

fugitive_average-factor 

8/31/00-10:56 AM 
• 

P.51 

..-,.. 

• 

EMISSIONS BASED ON AP-42 FACTORS ,? iS% '•" 7t 'r.'-, L 

I 

FUGITIVE EQUIPMENT LEAKS 

BY-PRODUCT CHEMICAL PLANT 

L2my; 

. i. , 

• 
P.52 

Summary of Benzene Emissions 

Fugitive Equipment Leak At By-Product Chemical Plant 

(Based on AP-42 Factors) 

Company 

AK Steel 

AK Steel 

Erie Coke 

Gulf States Steel 

New Boston Coke 

Tonawanda Coke 

Location 

Middletown, OH 

Ashland, KY 

Erie, PA 

Gadsden, AL 

New Boston, OH 

Tonawanda, NY 

Benzene Emissions, 

lb/yr 

78 

31,949 

106 

129,531 

153,042 

2,792 

Benzene Emissions, 

lb/hr 

8.90E-03 

3.65E+00 

1.21E-02 

1.48E+01 

1.75E+01 

3.19E-01 

NOTE: 

Emission factors are based on Draft AP-42 Table 12.2-21. 

lb/hr = lb/yr/8760 

ICF Consulting 

Dib Paul 

fugitive_AP-42_emissions 

_

8/31flO-9:17AM 
P.53 

AK Steel, Middletown/OH 

Fugitive Equipment Leak Emissions from By-Product Plant 

Stream(1) Benzene Mass Type of 

Fraction (2) Equipment 

No. of 

Components 

(3) 

AP-42 Factor, 

VOC lb/day (4) 

Benzene 

Emissions, 

Ib/vr (5) 

Lean wash oil 0.14% Pump 

Flange 

Valves 

Connector 

Other 

2 

85 

74 

3 

61 

6.00E+00 

5.70E-01 

5.70E-01 

5.70E-01 

7.90E-01 

6.13E+00 

2.48E+01 

2.16E+01 

8.74E-01 

2.46E+01 

Total Emissions, lb/yr 78 

NOTE: 

1) All components were assumed to be in lean wash oil service. 

2) Benzene stream composition is in mass basis. 

3) Component count from site. 

4) Draft AP-42, Table 12.2-21, lb/day VOC emission factors for less than quarterly inspections. 

For flanges, the factor for valves was used. 

5) Benzene emissions, lb/yr = AP-42 factor, lb/day VOC * benzene mass fraction 

* no. of components * 365 days/yr 

Oib Paul 

ICF Consulting 

fugitive_AP-42_emissions 

~8/31AD0-9:59AM 
AK Steel, Ashland/KY 

Fugitive Equipment Leak Emissions from By-Product Plant 

(Using AP-42 factors with no monitoring data) 

P.54 

Stream(1) 

Light oil (liquid or vapor) 

Rich wash oil 

Lean wash oil 

Benzene Mass Type of 

Fraction(2) Equipment 

75% Pump 

Flange 

Valves 

Open End 

3% Pump 

Flange 

Valves 

Open End 

0.14% Pump 

Flange 

Valves 

Open End 

No. of 

Components 

(3) 

5 

46 

93 

30 

3 

10 

116 

21 

3 

10 

131 

19 

AP-42 Factor, Benzene 

VOC lb/day (4) Emissions, 

lb/yr (5) 

6 

0.57 

0.57 

0.12 

6 

0.57 

0.57 

0.12 

6 

0.57 

0.57 

0.12 

8,213 

7,178 

14,511 

986 

197 

62 

724 

28 

9 

3 

38 

1 

Total Emissions, lb/yr 31,949 

NOTE: 

1) For process streams in benzene service (e.g., light oil liquid, light oil vapor, etc.) 

2) Benzene stream composition is in mass basis. 

3) Component count from site. 

4) Draft AP-42, Table 12.2-21, lb/day VOC emission factors for less than quarterly inspections. 

For flanges, the factor for valves was used. 

5) Benzene emissions, lb/yr = AP-42 factor, lb/day VOC * benzene mass fraction 

* no. of components * 365 days/yr 

Oib Paul 

ICF Consulting 

fugttive_AP-42_emissions 

8/31/00~10:17AM 
P.55 

Erie Coke Corporation 

Emissions from By-Product Plant 

(Using AP-42 factors with no monitoring data) 

Stream11' 

CO. Gas 

CO. Gas 

Total Emissions, lb/yr 

Benzene Mass 

Fraction'2' 

<1% 

<1% 

Type of 

Equipment 

Exhauster 

Valves 

No. of 

Components'3' 

2 

42 

AP-42 Factor

 m

, 

VOC, lb/day 

2.6 

0.57 

Benzene 

Emissions, 

Ib/vr « 

19 

87 

106 

NOTE: 

1) For process streams in benzene service (e.g., light oil liquid, light oil vapor, etc.) 

2) Benzene stream composition is in mass basis. 

3) Component count from site. 

4) Draft AP-42, Table 12.2-21, lb/day VOC emission factors for less than quarterly inspections. 

For flanges, the factor for valves was used. 

5) Benzene emissions = AP-42 factor, lb/day VOC * benzene mass fraction * no. of components * 365 days/yr 

Dib Paul 

ICF Consulting 

fugitive AP-42_emissions 

~8/3CK»- 4:28 PM 
P.56 

Gulf States Steel 

Emissions from By-product Plant 

(Using AP-42 Factors with no-monitoring data) 

Stream11' 

Liquid 

CO. Gas 

Total Emissions, lb/yr 

Benzene Mass 

Fraction11' 

60% 

62% 

Type of Equipment 

Flange 

Connector 

67% | Valve 

89% 

31% 

100% 

100% 

100% 

Flange 

Connector 

Flange (Leaking) 

Valve 

Open Ended Line 

(leaking) 

No. of 

Components'1' 

191 

181 

83 

146 

112 

9 

115 

18 

AP-42 Factorw, 

VOC, lb/day 

0.57 

0.79 

0.57 

0.57 

0.79 

0.57 

0.12 

Benzene 

Emissions, lb/yr 

(5) 

23,843 

32,359 

11,570 

27,034 

10,012 

-

23,926 

788 

129,531 

NOTE: 

1) For process streams ih benzene service (e.g., light oil liquid, light oil vapor, etc.) 

2) Benzene stream composition is in mass basis. 

3) Component count from site. 

4) Draft AP-42, Table 12.2-21, lb/day VOC emission factors for less than quarterly inspections. 

For flanges, the factor for valves was used. 

5) Benzene emissions = AP-42 factor, lb/day VOC * benzene mass fraction 

* no. of components * 365 days/yr 

Dib Paul 

ICF Consulting 

fugitive_AP-42_emissions 

~8/30/00-4:36 PM 
P.57 

New Boston Coke Corp. 

Emissions from By-Product Plant 

(Using AP-42 factors with no monitoring data) 

Stream(1) Benzene Mass Type of No. of AP-42 Factor Benzene 

Fraction(2) Equipment Components (3) (4), VOC, Emissions, 

Ib/dav Ib/vr (5) 

Liquid 67% Valves 

Open End 

Flanges/connectt 

Pumps 

10% Pres. Relief 

122 

72 

848 

9 

8 

0.57 

0.12 

0.57 

6 

8.6 

17,006 

2,113 

118,206 

13,206 

CO. Gas 2,511 

Total Emissions, lb/yr 153,042 

NOTE: 

1) For process streams in benzene service (e.g., light oil liquid, light oil vapor, etc.) 

2) Benzene stream composition is in mass basis. 

3) Component count from site. 

4) Draft AP-42, Table 12.2-21, lb/day VOC emission factors for less than quarterly inspections. 

For flanges, the factor for valves was used. 

5) Benzene emissions = AP-42 factor, lb/day VOC • benzene mass fraction * no. of components * 365 days/yr 

D i b Paul fugitive_AP-42_emissions 

ICFConsulting 1 8/3OC0 - 4:26 PM 
Tonawanda Coke Corporation 

Emissions from By-Product Plant 

(Using AP-42 factors with no monitoring data) 

Stream(1) Benzene Type of 

Mass Equipment 

Fraction(2) 

No. of 

Components 

(3) 

AP-42 Factor 

(4). VOC, 

lb/day 

Benzene 

Emissions, 

lb/yr (5) 

Liquid 

CO. Gas <1% 

65% Pump 

Flange 

Valve 

Open End 

Exhauster 

Pres. Relief 

Valves 

1 

2 

7 

1 

2 

1 

35 

6 

0.57 

0.57 

0.12 

2.6 

8.6 

0.57 

1,424 

270 

947 

28 

19 

31 

73 

Total Emissions, lb/yr 2,792 

NOTE: 

1) For process streams in benzene service (e.g., light oil liquid, light oil vapor, etc.) 

2) Benzene stream composition is in mass basis. 

3) Component count from site. 

4) Draft AP-42, Table 12.2-21, lb/day VOC emission factors for less than quarterly inspections. 

For flanges, the factor for valves was used. 

5) Benzene emissions = AP-42 factor, lb/day VOC * benzene mass fraction 

* no. of components * 365 days/yr 

Dib Paul 

ICF Consulting 

fugrtive_AP-42_emissions 

~8/3CM30-4:38 PM 
P.59 

0.. 

7. '-,\j 

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~i-.?--.liH?ii$.*A"~: 

yp^yyyy^Ky 

• •f;*«**.»:,,»i,*«-.*Uwi 

FUGITIVE EQUIPMENT LEAKS 

^^fpii^^^^^^'^HV::;!^-; 

.!'-._ £$;.'.: 

-;3='^--_ •<»:-;^feV^^"7^--^.^S-. :. ^TiS:V\:-^? VU3'V- _i*-.':-?^"-vi^::-!:

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7L;LA:$A^£7A&7iy7y-yr:?A7---' 
P.60 

Summary of Benzene Emissions 

Fugitive Equipment Leak At By-Product Chemical Plant 

(Based on COETF Factors) 

Company 

AK Steel 

AK Steel 

Erie Coke 

Gulf States Steel 

New Boston Coke 

Tonawanda Coke 

Location 

Middletown, OH 

Ashland, KY 

Erie, PA 

Gadsden, AL 

New Boston, OH 

Tonawanda, NY 

Benzene Emissions, 

lb/yr 

147 

72 

5 

53 

95 

10 

Benzene Emissions, 

lb/hr 

1.68E-02 

8.18E-03 

5.86E-04 

6.05E-03 

1.08E-02 

1.14E-03 

NOTE: 

Emission factors are based on COETF field study performed in January 2000. 

lb/hr = lb/yr/ 8760 

ICF Consulting 

Dib Paul 

fugitive_COETF_emissions 

~ 8/31*30-8:53 AM 
P.61 

AK Steel, Middletown/OH 

Fugitive Equipment Leak Emissions from By-Product Plant 

COETF Factors 

Type of Equipment No. of 

Components 

COETF Factor Benzene 

for Benzene, Emissions, 

kg/hr/source (1) lb/yr (2) 

Pump 

Flange 

Valves 

Connector 

Other 

2 

85 

74 

3 

61 

1.27E-04 

2.40E-06 

5.84E-06 

2.40E-06 

1.10E-04 

4.9053 

3.9397 

8.3459 

0.1390 

129.5847 

146.9146 

NOTE: 

(1) COETF factors are from field study conducted in January 2000. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr 

Dib Paul 

ICF Consulting 

f ugitive_C O ETF_emissions 

" 8/30/00 - 2:30 PM 
P.62 

AK Steel, Ashland/KY 

Fugitive Equipment Leak Emissions from Eiy-Product Plant 

(Using COETF Factors) 

Stream 

Light oil (liquid or vapor) 

Rich wash oil 

Lean wash oil 

Total Emissions, lb/yr 

Benzene Mass 

Fraction 

75% 

3% 

0.14% 

Type of 

Equipment 

Pump 

Flange 

Valve 

Open End 

Pump 

Flange 

Valves 

Open End 

Pump 

Flange 

Valves 

Open End 

No. of 

Components 

5 

46 

93 

30 

3 

10 

116 

21 

3 

10 

131 

19 

Emission 

Factor

 n

, 

benzene, kg/hr 

1.27E-04 

2.40E-06 

5.84E-06 

2.39E-06 

1.27E-04 

2.40E-06 

5.84E-06 

2.39E-06 

1.27E-04 

2.40E-06 

5.84E-06 

2.39E-06 

Benzene 

Emissions, 

lb/yr

 w 

12 

2 

10 

1 

7 

0 

13 

1 

7 

0 

15 

1 

72 

NOTE: 

(1) COETF factors are from field study conducted in January 2000. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr 

Dib Paul 

ICF Consulting 

tugitive_COETF_emissions 

~ 8/31/00-8:50 AM 
Erie Coke Corporation 

Emissions from By-Product Plant 

(Using COETF Factors) 

Stream Type of 

Equipment 

No. of 

Components 

Emission Factor Benzene 

(1), benzene, 

kg/hr 

Emissions, 

lb/yr (2) 

P.63 

C O. Gas Exhauster 2 1.02E-05 0.394 

CO. Gas Valves 42 5.84E-06 4.737 

Total Emissions, lb/yr 5.131 

NOTE: 

(1) COETF factors are from field study conducted in January 2000. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr 

Dib Paul fugitive_COETF_emissions 

ICF Consulting

 1 8/31/00-852 AM 
P.64 

Gulf States Steel 

Emissions from By-Product Plant 

(Using COETF Factors) 

Stream Type of 

Equipment 

No. of Emission Factor Benzene 

Components (1), benzene, Emissions, 

kq/hr lb/yr (2) 

Liquid 

CO. Gas 

Flange 

Connector 

Valve 

Flange 

Connector 

Flange (Leaking) 

Valve 

Open Ended Line 

191 

181 

83 

146 

112 

9 

115 

18 

2.40E-06 

2.40E-06 

5.84E-06 

2.40E-06 

2.40E-06 

2.40E-06 

5.84E-06 

2.39E-06 

9 

8 

9 

7 

5 

0 

13 

1 

Total Emissions, lb/yr 53 

NOTE: 

(1) COETF factors are from field study conducted in January 2000. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr 

Dib Paul 

ICF Consulting 

fugitive_COETF_emissions 

~ 8/31/00-8:54 AM 
New Boston Coke Corp. 

Emissions from By-Product Plant 

(Using COETF Factors) 

P.65 

Stream Type of No. of Emission Factor Benzene 

Equipment Components (1), benzene, Emissions, 

kg/hr lb/yr (2) 

Liquid 

CO. Gas 

Valve 

Open End 

Flanges/connecto 

Pumps 

Pres. Relief 

122 

72 

848 

9 

8. 

5.84E-06 

2.39E-06 

2.40E-06 

1.27E-04 

1.10E-04 

14 

3 

39 

22 

17 

Total Emissions, lb/yr 95 

NOTE 

(1) COETF factors are from field study conducted in January 2000. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr 

Dib Paul 

ICF Consulting 

fugithfc^COETF^emissions 

~ 8/31^0-855 AM 
P.66 

Tonawanda Coke Corporation 

Emissions from By-Product Plant 

(Using COETF Factors) 

Stream Type of 

Equipment 

No. of 

Components 

Emission Factor Benzene 

(1), benzene, Emissions, 

kg/hr lb/yr (2) 

Liquid 

CO. Gas 

Total Emissions, lb/yr 

Pump 

Flange 

Valve 

Open End 

Exhauster 

Pres. Relief 

Valves 

1 

2 

7 

1 

2 

1 

35 

1.27E-04 

2.40E-06 

5.84E-06 

2.39E-06 

1.02E-05 

1.10E-04 

5.84E-06 

2 

0 

1 

0 

0 

2 

4 

10 

NOTE 1-K.LJ I C : 

(1) COETF factors are from field study conducted in January 2000. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr 

n 

Dib Paul 

ICF Consulting 

fugitive_COETF_emissions 

" 8/31/00-8:59 AM 
P.67 

' '•' " • .' ^..'V*S'#''^V/ ^ '•',1•

,

••^ •yP.yP::72;'.y 

EMISSIONS BASED ON LEAK NO-LEAK F^T Q 

4^^^^0^^:^v5n>^!at:'r.; '.' 7 /:P

:

7

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- $. 

FUGITIVE EQUIPMENT LEAKS 

BY-PRODUCT CHEMICAL PLANT 

^^t^iiS^^^i^^ill 

oM_$|&&$-' 

:'i:':;s:S.i^._'"^;i!f-. :

7

:

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P.68 

Summary of Benzene Emissions 

Fugitive Equipment Leak At By-Product Chemical Plant 

(Based on leak/no-leak factors) 

Company 

AK Steel 

AK Steel 

Erie Coke 

Gulf States Steel 

New Boston Coke 

Tonawanda Coke 

Location 

Middletown, OH 

Ashland, KY 

Erie, PA 

Gadsden, AL 

New Boston, OH 

Tonawanda, NY 

Benzene Emissions, 

lb/yr 

1,414 

5,239 

1,413 

5,551 

7,567 

1,732 

Benzene Emissions, 

lb/hr 

1.61E-01 

5.98E-01 

1.61E-01 

6.34E-01 

8.64E-01 

1.98E-01 

NOTE: 

Emission factors are based on screening factors in "Protocol for Equipment Leak 

Emission Estimates", EPA-453/R-95-017, November 1995, Table 2-6. 

Emissions estimates based on screening range emission factors 

For Ashland, detailed monitoring report was available by month, quarter, semi-annual, and annual. 

For components that leaked above 500 ppmv, it was assumed leak occurred for the entire 

monitoring period. 

For Gulf States Steel, revised emissions estimates are from the COETF field study report. 

For other facilities, emissions estimates were based on one cycle of monitoring only. 

ASHLAND IS THE ONLY SITE THAT SHOWED LEAKS ABOVE 10,000 ppmv. 

EMISSIONS FROM LEAKING COMPONENTS AT ASHLAND WERE ADDED TO THE 

EMISSIONS FROM NON-LEAKING COMPONENTS FOR EACH SITE. 

lb/hr = lb/yr/8760 

ICF Consulting 

Dib Paul 

fugitiveJeak_noleak_emissions 

8/31/00-12:55 PM 
P.69 

AK Steel, Middletown/OH 

Fugitive Equipment Leak Emissions from By-Product Plant 

Stream Benzene Mass Type of No. of Emission Benzene 

Fraction Equipment Components Factor, Emissions, 

kg/hr/source lb/yr (2) 

(1) 

Lean wash oil 0.14% Pump 

Flange 

Valves 

Connector 

Other 

2 

85 

74 

3 

61 

1.20E-02 

6.00E-05 

1.70E-03 

6.00E-05 

1.50E-03 

0.6489 

0.1379 

3.4013 

0.0049 

2.4739 

Total Emissions, lb/yr 6.6668 

NOTE: 

(1) Emission factors are based on Table 2-6 of "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1995. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

fugitive_leak_noleak_emissions 

8/31 KxP n :28 AM 
P.70 

AK Steel, Ashland/KY 

Fugitive Equipment Leak Emissions from By-Product Plant 

Total benzene emissions 

Benzene emissions from non-leaking components = 3,831 lb/yr 

Benzene emissions from leaking components = 1,407 lb/yr 

Total benzene emissions = 5,239 lb/yr 

Dib Paul fugitive_leak_noleak_emissions 

ICF Consulting 1 ~ ~8/30£O - 8:03 PM 
P.71 

AK Steel, Ashland/KY 

Fugitive Equipment Leak Emissions from By-Product Plant 

Emissions from non-leaking components 

Stream 

Light oil (liquid or vapor) 

Benzene Mass 

Fraction 

75% 

Type of 

Equipment 

Pump 

Flange 

Valves 

No. of Emission Benzene 

Components Factor, Emissions, 

kg/hr/source lb/yr (2) 

(D 

4 1.20E-02 695 

46 6.00E-05 40 

93 1.70E-03 2,290 

Open End 30 1.50E-03 652 

Rich wash oil 3% 

Lean wash oil 0.14% 

Pump 

Flange 

Valves 

Open End 

Pump 

Flange 

Valves 

Open End 

2 

10 

116 

21 

3 

10 

131 

19 

1.20E-02 

6.00E-05 

1.70E-03 

1.50E-03 

1.20E-02 

6.00E-05 

1.70E-03 

1.50E-03 

14 

0 

114 

18 

1 

0 

6 

1 

Total Emissions, lb/yr 3,831 

NOTE: 

(1) Emission factors are based on Table 2-6 of "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1995. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

fugitiveJeak_noleak_emissions 

8/31/00-" 11:30 AM 
P.72 

AK Steel, Ashland/KY 

Fugitive Equipment Leak Emissions from By-Product Plant 

Emissions from leaking components 

Component Type/ Screening Emission Factor, Benzene 

Monitoring Level, ppmv (1) kg/hr/source (2) Emissions, lb/yr 

Frequency (3) 

Valve (difficult to 

reach-annual) 10000 8.52E-02 1234.05 

Other 10000 1.20E-02 86.54 

(semi-annual) 

10000 1.20E-02 86.54 

Total benzene emissions, lb/yr) 1407.13 

NOTE: 

(1) It was assumed that a component was leaking if monitoring indicated 500 ppmv or greater. 

All leaking components were assumed to be in light oil service. 

(2) From "Protocol for Equipment Leak Emission Estimates",EPA-453/R-95-017, November 1995. 

(3) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb 

* benzene mass fraction * month or quarter or semi-annual or annual in hrs 

Dib Paul fugitive_teak_noleak_emissions 

ICF Consulting 1 ~ 8/31/D0~ 11:53 AM 
P.73 

Erie Coke Corporation 

Fugitive Equipment Leak Emissions from By-Product Plant 

Stream Benzene Mass Type of No. of Emission Benzene 

Fraction Equipment Components Factor, Emissions, 

kg/hr/source lb/yr (2) 

(1) 

CO Gas 1% Valves 42 6.00E-04 4.87 

Other 2 1.50E-03 0.58 

Total Emissions, lb/yr 5.45 

NOTE: 

(1) Emission factors are based on Table 2-6 of "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1995. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb • no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul * fugitive_leak_noleak_emissions 

ICF Consulting 1 8/31/00-11:56 AM 
P.74 

Gulf States Steel 

Emissions from By-Product Plant 

(Using AP-42 factors with no monitoring data) 

Stream 

Liquid 

Benzene Mass 

Fraction 

60% 

Type of 

Equipment 

Flange 

No. of 

Components 

Emission 

Factor, 

kg/hr/source 

(1) 

191 0.00006 

Benzene 

Emissions, 

lb/yr (2) 

133 

CO. Gas 

62% 

67% 

89% 

31% 

Connector 

Valve 

Flange 

Connector 

100% Flange (Leakinj 

100% Valve 

100% Open Ended Lir 

Total Emissions, lb/yr 

181 

83 

146 

112 

9 

115 

18 

6.00E-05 

1.70E-03 

0.00006 

6.00E-05 

6.00E-05 

0.0006 

0.0015 

130 

1,826 

151 

40 

10 

1,333 

521 

4,144 

NOTE: 

(1) Emission factors are based on Table 2-6 of "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1995. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb • no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

fugitiveJeak_noleak_emissions 

8/31/00-12:15 PM 
P.75 

NewBoston/OH 

Fugitive Equipment Leak Emissions from By-Product Pjant 

Stream 

Light oil (liquid or vapor) 

Benzene Mass 

Fraction 

67% 

Type of No. of Emission Benzene 

Equipment Components Factor, Emissions, 

kg/hr/source lb/yr (2) 

(1) 

Pump 

Flange 

Valves 

Open End 

9 

848 

122 

72 

1.20E-02 

6.00E-05 

1.70E-03 

1.50E-03 

1,397 

658 

2,684 

1,397 

CO Gas 10% Other 1.50E-03 23 

Total Emissions, lb/yr 6,160 

NOTE: 

(1) Emission factors are based on Table 2-6 of "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1995. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

fugitiveJeak_noleak_en.issions 

8/31/00-12:17 PM 
P.76 

Tonawanda/NY 

Fugitive Equipment Leak Emissions from By-Product Plant 

(Based on leak/no-leak factors) 

Stream 

Light oil (liquid or vapor) 

CO Gas 

Benzene Mass 

Fraction 

65% 

1% 

Type of 

Equipment 

Pump 

Flange 

Valves 

Open End 

Other 

Valves 

No. of 

Components 

1 

2 

7 

1 

3 

35 

Emission Benzene 

Factor, Emissions, 

kg/hr/source lb/yr (2) 

d) 

1.20E-02 151 

6.00E-05 2 

1.70E-03 149 

1.50E-03 19 

. 1.50E-03 1 

6.00E-04 4 

Total Emissions, lb/yr 325 

NOTE: 

(1) Emission factors are based on Table 2-6 of "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1995. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

fugitiveJeak_noleak_emissions 

8/31/00"l2:18PM 
'.••-. :r':_;

:'l .:•-£<£: j^i ^ '!-•',•• V • 

EMISSIONS BASED ON ZERO/PEGGED/CORRELATION 

.s.itb:_s.nyie_jv. FACTORS 

P.77 

.:•.; iv<A>. '.W-;..ii.d;.> -'.Vi 

FUGITIVE EQUIPMENT LEAKS 

BY-PRODUCT CHEMICAL PLANT 

,;<•*. v ?V^/^« % ," 
P.78 

Summary of Benzene Emissions 

Fugitive Equipment Leak At By-Product Chemical Plant 

(Based on default zero, pegged emission, and correlation equation) 

Company 

AK Steel 

AK Steel 

Erie Coke 

Gulf States Steel 

New Boston Coke 

Tonawanda Coke 

Location 

Middletown, OH 

Ashland, KY 

Erie, PA 

Gadsden, AL 

New Boston, OH 

Tonawanda, NY 

Benzene Emissions, 

lb/yr 

0.05 

2007.40 

0.06 

48.00 

20.43 

1.07 

Benzene Emissions, 

lb/hr 

5.25E-06 

2.29E-01 

7.40E-06 

5.48E-03 

2.33E-03 

1.23E-04 

NOTE: 

Emissions estimates based on default zero emission rate factors for non-leaking components, 

correlation equation for components leaking at <10,000 ppm, and pegged emission rates for 

components leaking at or > 10,000 ppmv. 

Emission factors are based on screening factors in "Protocol for Equipment Leak 

Emission Estimates", EPA-453/R-95-017, November 1995, Table C-3. 

For Ashland, detailed monitoring report was available by month, quarter, semi-annual, and annual. 

For components that leaked above 500 ppmv, it was assumed leak occurred for the entire 

monitoring period. 

For Gulf States Steel, revised emissions estimates are from the COETF field study report. 

For other facilities, emissions estimates were based on one cycle of monitoring only. 

lb/hr = lb/yr/8760 

ICF Consulting 

Dib Paul 

fugitive_emissions 

8/31 EO~- 11:19 AM 
P.79 

AK Steel, Middletown/OH 

Fugitive Equipment Leak Emissions from By-Product Plant 

Total benzene emissions 

Benzene emissions from non-leaking components = 0.0248 lb/yr 

Benzene emissions from leaking components = 0.0212 lb/yr 

Total benzene emissions = 0.0460 lb/yr 

Dib Paul fug'rtive_emissions 

ICF Consulting

 1 8/30/00 - 2:04 PM 
P.80 

AK Steel, Middletown/OH 

Fugitive Equipment Leak Emissions from By-Product Plant 

Emissions from non-leaking components 

Stream(1) Benzene Mass Type of No. of Zero-Default Zero Benzene 

Fraction (2) Equipment Reading Emission Emissions, 

Component Rate, lb/yr (5) 

s (3) kg/hr/source 

(4) 

Lean wash oil 0.14% Pump 

Flange 

Valves 

Connector 

Other 

2 

85 

74 

3 

61 

2.40E-05 

3.10E-07 

7.80E-06 

7.50E-06 

4.00E-06 

0.0013 

0.0007 

0.0156 

0.0006 

0.0066 

Total Emissions, lb/yr 0.0248 

NOTE: 

(1) and (2) All components were assumed to be in lean wash oil service. 

(3) Component count, and no. of zero leaking components from site. It was assumed that a 

component with less than 500 ppmv screening value was not leaking. 

(4) Default zero emission factors for TOC are from "Protocol for Equipment Leak Emission 

Estimates", EPA-453/R-95-017, November 1995, Table C-3. 

(5) Benzene emissions = Default zero factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * wt fraction benzene 

Dib Paul fugitive_emissions 

ICF Consulting 1 8I3OIO0- 2:01 PM 
P.81 

AK Steel, Middletown/OH 

Fugitive Equipment Leak Emissions from By-Product Plant 

Emissions from leaking components 

Component Type/ Screening Correlation Benzene 

Monitoring Level, Equation, Emissions 

Freguencv ppmvd) kg/hr/source (2) , lb/yr (3) 

Other (Quarterly) 1000 1.36E-05 "(SV)0589 0.0053 

Total for 4 components 0.0212 

NOTE: 

(1) It was assumed that a component was leaking if monitoring indicated 500 ppmv or greater. 

All leaking components were assumed to be in light oil service. 

(2) From "Protocol for Equipment Leak Emission Estimates",EPA-453/R-95-017, November 1995. 

(3) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb 

* benzene mass fraction * month or quarter or semi-annual or annual in hrs 

Dib Paul fugitive_emissions 

ICF Consulting 1 B/31/00~ 11:44 AM 
P.82 

AK Steel, Ashland/KY 

Fugitive Equipment Leak Emissions from By-Product Plant 

Total benzene emissions 

Benzene emissions from non-leaking components = 14 lb/yr 

Benzene emissions from leaking components = 1,994 lb/yr 

Total benzene emissions = 2,007 lb/yr 

Dib Paul fugitive_emissions 

ICF Consulting

 1 8/18/00-12:03 PM 
AK Steel, Ashland/KY 

Fugitive Equipment Leak Emissions from By-Product Plant 

Emissions from non-leaking components 

P.83 

Stream(1) 

Light oil (liquid or vapor) 

Rich wash oil 

Lean wash oil 

Benzene Mass 

Fraction (2) 

75% 

3% 

0.14% 

Type of 

Equipment 

Pump 

Flange 

Valves 

Open End 

Pump 

Flange 

Valves 

Open End 

Pump 

Flange 

Valves 

Open End 

No. of ZeroReading 

Components 

(3) 

4 

46 

93 

30 

2 

10 

116 

21 

3 

10 

131 

19 

Default Zero 

Emission 

Rate • 

kg/hr/source 

(4) 

2.40E-05 

3.10E-07 

7.80E-06 

2.00E-06 

2.40E-05 

3.10E-07 

7.80E-06 

2.00E-06 

2.40E-05 

3.10E-07 

7.80E-06 

2.00E-06 

Benzene 

Emissions, 

lb/yr (5) 

1.39 

0.21 

10.51 

0.87 

0.03 

0.00 

0.52 

0.02 

0.00 

0.00 

0.03 

0.00 

Total Emissions, lb/yr 14 

NOTE: 

(1) For process streams in benzene service (e.g., light oil liquid, light oil vapor, etc.) 

(2) Compositions from site. 

(3) Component count, and no. of zero leaking components from site. It was assumed that a component 

with less than 500 ppmv screening value was not leaking. 

(4) Default zero emission factors for TOC are from "Protocol for Equipment Leak Emission Estimates", 

EPA-453/R-95-017, November 1995, Table C-3. 

(5) Benzene emissions = Default zero factor, kg/hr/component * 1/0.4536 kg/lb * no. of components 

* 8760 hrs/yr * wt fraction benzene 

Dib Paul 

ICF Consulting 

fugitive_emissions 

8/11/00-2:22 PM 
P.84 

AK Steel, Ashland/KY 

Fugitive Equipment Leak Emissions from By-Product Plant 

Emissions from leaking components 

Component Type/ Screening Correlation Equation, Benzene 

Monitoring Level, ppmv (1) kg/hr/source (2) Emissions, lb/yr 

Frequency (3) 

Valve (Quarterly) 5000 2.29E-06 *(SV)0746 4.70 

500 2.29E-06 *(SV)0746 0.84 

Flange (Quarterly) 700 4.61 E-06 *(SV)0703 1.65 

Other (Quarterly) 700 1.36E-05 *(SV)°-5M' 2.30 

Valve (difficult to 

reach-annual) 10000 6.40E-02 926.98 

Other 10000 7.30E-02 528.67 

(semi-annual) 

10000 7.30E-02 528.67 

1,994 

NOTE: 

(1) It was assumed that a component was leaking if monitoring indicated 500 ppmv or greater. 

All leaking components were assumed to be in light oil service. 

(2) From "Protocol for Equipment Leak Emission Estimates",EPA-453/R-95-017, November 1995. 

(3) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb 

* benzene mass fraction * month or quarter or semi-annual or annual in hrs 

Dib Paul fugrtive_emissions 

ICF Consulting 1 8/31 AX) - 11:45 AM 
P.85 

Erie Coke Corporation 

Fugitive Equipment Leak Emissions from By-Product Plant 

Stream(1) 

CO Gas 

Benzene Mass 

Fraction (2) 

1% 

Type of 

Equipment 

Valves 

Other 

No. of Zero- Default Zero Benzene 

Reading Emission Emissions, 

Components Rate, lb/yr (5) 

(3) kg/hr/source 

(4) 

42 7.80E-06 0.06 

2 4.00E-06 0.00 

Total Emissions, lb/yr 0.06 

NOTE: 

(1) For process streams in benzene service (e.g., light oil liquid, light oil vapor, etc.) 

(2) Compositions from site. 

(3) Component count, and no. of zero leaking components from site. It was assumed that a component 

with less than 500 ppmv screening value was not leaking. 

(4) Default zero emission factors for TOC are from "Protocol for Equipment Leak Emission Estimates", 

EPA-453/R-95-017, November 1995, Table C-3. 

(5) Benzene emissions = Default zero factor, kg/hr/component * 1/0.4536 kg/lb * no. of components 

* 8760 hrs/yr * wt fraction benzene 

Difc

 P3"

1

 fugitive_emissions 

ICF Consulting 1 8/11£0- 2:18 PM 
P.86 

New Boston/OH 

Fugitive Equipment Leak Emissions from By-Product Plant 

Stream(1) 

Light oil (liquid or vapor) 

CO Gas 

Benzene Mass 

Fraction (2) 

67% 

10% 

Type of 

Equipment 

Pump 

Flange 

Valves 

Open End 

Other 

No. of ZeroReading 

Components 

(3) 

9 

848 

122 

72 

8 

Default Zero 

Emission 

Rate 

kg/hr/source 

(4. 

2.40E-05 

3.10E-07 

7.80E-06 

2.00E-06 

4.00E-06 

Benzene 

Emissions, 

lb/yr (5) 

2.79 

3.40 

12.31 

1.86 

0.06 

Total Emissions, lb/yr 20 

NOTE: 

(1) For process streams in benzene service (e.g., light oil liquid, light oil vapor, etc.) 

(2) Compositions from site. 

(3) Component count, and no. of zero leaking components from site. It was assumed that a component 

with less than 500 ppmv screening value was not leaking. 

(4) Default zero emission factors for TOC are from "Protocol for Equipment Leak Emission Estimates", 

EPA-453/R-95-017, November 1995, Table C-3. 

(5) Benzene emissions = Default zero factor, kg/hr/component * 1/0.4536 kg/lb * no. of components 

* 8760 hrs/yr * wt fraction benzene 

Dib Paul 

ICF Consulting 

fugitive_emissions 

8/11/00-2:17 PM 
P.87 

Tonawanda/NY 

Fugitive Equipment Leak Emissions from By-Product Plant 

Stream(1) 

Light oil (liquid or vapor) 

CO Gas 

Benzene Mass 

Fraction (2) 

65% 

1% 

Type of 

Equipment 

Pump 

Flange 

Valves 

Open End 

Other 

Valves ' 

No. of ZeroReading 

Components 

(3) 

1 

2 

7 

1 

3 

35 

Default Zero 

Emission 

Rate 

kg/hr/source 

(4i 

2.40E-05 

3.10E-07 

7.80E-06 

2.00E-06 

4.00E-06 

7.80E-06 

Benzene 

Emissions, 

lb/yr (5) 

0.30 

0.01 

0.69 

0.03 

0.00 

0.05 

Total Emissions, lb/yr 

NOTE: 

(1) For process streams in benzene service (e.g., light oil liquid, light oil vapor, etc.) 

(2) Compositions from site. 

(3) Component count, and no. of zero leaking components from site. It was assumed that a component 

with less than 500 ppmv screening value was not leaking. 

(4) Default zero emission factors for TOC are from "Protocol for Equipment Leak Emission Estimates", 

EPA-453/R-95-017, November 1995, Table C-3. 

(5) Benzene emissions = Default zero factor, kg/hr/component * 1/0.4536 kg/lb * no. of components 

* 8760 hrs/yr * wt fraction.benzene 

Dib Paul 

ICF Consulting 

fugitive_emissions 

8/11/00-1:59 PM 
P.88 

EMISSIONS BASED ON 250 ppSrf 

FUGITIVE EQUIPMENT LEAKS 

BY-PRODUCT CHEMICAL PLANT 

:'_;if»:S___!ifi; 

3;3'~^PvS:"RjO* 

,.;;•« ,? rj^g:^-: ^ ^;g^-£^^-?j^rM: ;i/^ • s^4::vy>.'.;.;.jr. * _ 
P.89 

Summary of Benzene Emissions 

Fugitive Equipment Leak At By-Product Chemical Plant 

(Based on 250 ppmv leak) 

Company 

AK Steel 

AK Steel 

Erie Coke 

Gulf States Steel 

New Boston Coke 

Tonawanda Coke 

Location 

Middletown, OH 

Ashland, KY 

Erie, PA 

Gadsden, AL 

New Boston, OH 

Tonawanda, NY 

Benzene Emissions, 

lb/yr 

1 

484 

1 

1,847 

2,951 

39 

Benzene Emissions, 

lb/hr 

1.67E-04 

5.53E-02 

1.46E-04 

2.11E-01 

3.37E-01 

4.43E-03 

NOTE: 

All components are assumed to leak at half the leak level (500 ppmv/2) 

Emission Estimates are based on "Protocol for Equipment Leak Emission 

Estimates," EPA-453/R-95-017, November 1995, Table C-3. 

Emissions estimates are based on correlation equation. 

lb/hr = lb/yr/8760 

ICF Consulting 

Dib Paul 

fugitive_250ppmv_emissions 

8/31/00-8:42 AM 
AK Steel, Middletown/OH 

Fugitive Equipment Leak Emissions from By-Product Plant 

P.90 

Stream Benzene Mass Type of No. of 

Fraction Equipment Components 

Lean wash oil 0.14% Pump 

Flange 

Valves 

Connector 

Other 

ts 

2 

85 

74 

3 

61 

Correlation 

Equation, 

kg/hr/source (1) 

5.03E-05 *(SV)0610 

4.61 E-06 *(SV)0703 

2.29E-06 *(SV)0748 

1.53E-06*(SV)0735 

1.36E-05*(SV)0589 

Benzene 

Emissions, 

lb/yr (2) 

0.0789 

0.5138 

0.2818 

0.0072 

0.5797 

Total Emissions, lb/yr 1.4614 

NOTE: 

(1) Emission Estimates are based on "Protocol for Equipment Leak Emission 

Estimates," EPA-453/R-95-017, November 1995, Table C-3. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

fugitive_250ppmv_emissions 

8/31/00-8:20 AM 
AK Steel, Ashland/KY 

Fugitive Equipment Leak Emissions from By-Product Plant 

P.91 

Stream Benzene Mass Type of No. of Correlation Equation, Benzene 

Fraction Equipment Components kg/hr/source (1) Emissions, 

lb/yr (2) 

Light oil (liquid or vapor) 75% 

Rich wash oil 3% 

Lean wash oil 0.14% 

Pump 

Flange 

Valves 

Open End 

Pump 

Flange 

Valves 

Open End 

Pump 

Flange 

Valves 

Open End 

4 

46 

93 

30 

2 

10 

116 

21 

3 

10 

131 

19 

5.03E-05 *(SV)0-

610 

4.61 E-06 •(SV)0703 

2.29E-06 •(SV)0-

7

*

8 

2.20E-06 *(SV)07M 

5.03E-05 •(SV)0810 

4.61 E-06 *(SV)0703 

2.29E-06 *(SV)0748 

2.20E-06 *(SV)07W 

5.03E-05 *(SV)oe10 

4.61 E-06 *(SV)0703 

2.29E-06 *(SV)°TM 

2.20E-06 •(SV)0704 

84.58 

148.97 

189.70 

46.62 

1,69 

1.30 

9.46 

1.31 

0.12 

0.06 

0.50 

0.06 

Total Emissions, lb/yr 484.36 

NOTE: 

(1) Emission Estimates are based on "Protocol for Equipment Leak Emission 

Estimates," EPA-453/R-95-017, November 1995, Table C-3. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

fugitive_250ppmv_emissions 

8/31*30-8:22 AM 
P.92 

Erie Coke Corporation 

Fugitive Equipment Leak Emissions from By-Product Plant 

Stream Benzene 

Mass 

Fraction 

Type of No. of Correlation Equation, Benzene 

Equipment Components kg/hr/source (1) Emissions, 

lb/yr (2) 

CO Gas 1% Valves 

Other 

42 2.29E-06 *(SV)0748 

2 1.36E-05*(SV)0589 

1.14 

0.1358 

Total Emissions, lb/yr 1.28 

NOTE: 

(1) Emission Estimates are based on "Protocol for Equipment Leak Emission 

Estimates," EPA-453/R-95-017, November 1995, Table C-3. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

fugitive_250ppmv_emissions 

8/31/00-8:24 AM 
Gulf States Steel 

Emissions from By-Product Plant 

P.93 

Stream 

Liquid 

Benzene Mass 

Fraction 

60% 

Type of 

Equipment 

Flange 

No. of 

Components 

191 

Correlation Equation, 

kg/hr/source (1) 

Benzene Emissions, 

lb/yr (2) 

4.61 E-06 -(SV)' ,0.703 

CO. Gas 

62% Connector 

67% Valve 

89% Flange 

31% Connector 

100% Flange (Leaking 

100% Valve 

100% Open Ended Lin 

181 

83 

146 

112 

9 

115 

18 

1.53E-06 •(SV)0735 

2.29E-06 '(SV)0746 

4.61 E-06 •(SV)0703 

1.53E-06*(SV)CTM 

4.61 E-06 *<SV)0703 

2.29E-06 •(SV)0746 

2.20E-06 •(SV)0704 

495 

192 

151 

561 

59 

39 

313 

37 

Total Emissions, lb/yr 1,847 

NOTE: 

(1) Emission Estimates are based on "Protocol for Equipment Leak Emission 

Estimates," EPA-453/R-95-017, November 1995, Table C-3. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

fugitive_250ppnw_emi8iiont 

8/31/00 - 859 AM 
NewBoston/OH 

Fugitive Equipment Leak Emissions from By-Product Plant 

P.94^ 

Stream Benzene Mass Type of No. of Correlation Equation, Benzene Emissions, 

Fraction Equipment Components kg/hr/source (1) lb/yr (2) 

Light oil (liquid or vapor) 67% 

CO Gas 10% 

Pump 

Flange 

Valves 

Open End 

Other 

9 

848 

122 

72 

8 

5.03E-05 *(SV)0610 

4.61 E-06 '(SV)0705 

2.29E-06 *(SV)0746 

2.20E-06 •(SV)0704 

1.36E-05 *(SV)0SM 

170 

2,453 

222 

100 

Total Emissions, lb/yr 2,951 

NOTE: 

(1) Emission Estimates are based on "Protocol for Equipment Leak Emission 

Estimates," EPA-453/R-95-017, November 1995, Table C-3. 

(2) Benzene emissions = emission factor, kg/hr/component* 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

hjgitive_250ppmv_emiasiona 

8/31/00 - 8:31 AM 
P.95 

• 

Tonawanda/NY 

Fugitive Equipment Leak Emissions from By-Product Plant 

(Based on 250 ppmv leak) 

Stream Benzene Mass Type of No. of 

Fraction Equipment Components 

Light oil (liquid or vapor) 65% Pump 1 

Correlation Equation, Benzene 

kg/hr/source (1) Emissions, lb/yr (2) 

5.03E-05 •(SV)0-

610' 18.33 

— 'i 

rV 

Flange 

Valves 

Open End 

2 

7 

1 

4.61 E-06 *(SV)0703 

2.29E-06 *(SV)074e 

2.20E-06 •(SV)0704 

5.61 

12.37 

1.35 

CO Gas 1% Other 

Valves 

3 

35 

1.36E-05 »(SV)05M 

2.29E-06 *(SV)0746 

0.2036 

0.95 

Total Emissions, lb/yr 38.82 

NOTE: 

(1) Emission Estimates are based on "Protocol for Equipment Leak Emission 

Estimates," EPA-453/R-95-017, November 1995, Table C-3. 

(2) Benzene emissions = emission factor, kg/hr/component * 1/0.4536 kg/lb * no. of 

components * 8760 hrs/yr * benzene wt fraction 

Dib Paul 

ICF Consulting 

fugitive_250ppmv_emis3ions 

8/31/00"-8:33 AM