OAR Box 1851 

Prepped by Keeia Richards 

Document Number: 

33) ll-A-7 

Docket Number: 

A-90-19 

Printed 11/19/2008 11:19:51 AM Sheet 33 of 41 

P.1 
P.2 

A-90-19 

ll-A-7 

EPA450/3-73-006-d 

ENGINEERING 

AND COST STUDY 

OF AIR POLLUTION CON 

FOR THE 

PETROCHEMICAL INDUS|T®_m£22-S 

VOLUME 4: FORMALDEHYDE 

MANUFACTURE 

WITH THE SILVER 

CATALYST PROCESS 

by 

R. B. Morris, F. B. Higgins, Jr . , 

J. A. Lee, R. Newirth, and J. W. Pervie r 

Houdry Division 

Air Products and Chemicals, Inc . 

P.O . Box 427 

Marcus Hook, Pennsylvania 19061 

Contract No. 68-02-0255 

EPA Project Officer: Leslie B.. Evans 

A;7_T_; : P6 

Prepared for 

ENVIRONMENTAL PROTECTION AGENCY 

Office of Air and Waste Management 

Office of Air Quality Planning and Standards 

Research Triangle Park , N. C. 27711 

March 1975 *'"•"' 
P.3 

« 

This report is issued by the Environmental Protection Agency to report 

technical data of interest to a limited number of readers. Copies are 

available free of charge to Federal employees, current contractors and 

grantees, and nonprofit organizations - as supplies permit - from the Air 

Pollution Technical Information Center, Environmental Protection Agency, 

Research Triangle Park , North Carolina 27711; or, for a fee , from the 

National Technical Information Service , 5285 Port Royal Road, Springfield, 

Virginia 22161. 

This report was furnished to the Environmental Protection Agency by 

the Houdry Division of Air Products and Chemicals, Inc . , in fulfillment 

of Contract No. 68-02-0255. The contents of this report are reproduced 

herein as received from the Houdry Division of Air Products and Chemicals, 

Inc. The opinions, findings, and conclusions expressed are those of 

the author and not necessarily those of the Environmental Protection 

Agency. Mention of company or product names is not to be considered 

as an endorsement by the Environmental Protection Agency. 

Publication No. EPA-45O/3-73~006-d 

n 
_ 

EPA Code Number 

Date on-stream 

Capacity - Tone of 37% HCHO/Yr. 

Average Production - Tons o f 377. HCHO/Yr. 

Range in Production - 1 o f Max. 

Emissions t o Atmosphere 

Stream 

Flov - lbs./hr . 

Flov Characteristi c - Contlnuoua or Intermitten t 

if Intermittent - hrs/yr . 

Composition - Tons/Ton o f 37% HCHO 

Formaldehyde 

Methanol 

Methyl Formate 

Di-methyl Ether 

Methylal 

Oxygen 

Nitrogen 

Carbon Monoxide 

Carbon Dioxide 

. * Methane 

Water 

Hydrogen 

• Sample Tap Location 

Date or Frequency o f Sampling 

Type of Analysis 

Odor Problem 

Vent Stacks 

Flov - SCFM per stack 

Number 

Height - Feet (elev . @ <tip) 

Diameter - Inche s 

feSit uaB aCiapSiSitii c - F" 

Emission Control* Device s 

Type - Vater Scrubber 

Incinerato r 

Catalog I. D. No. 

Total Hydrocarbon Emissions - Ton/Ton HCHO (377.) 

Tota l Particulat e 6, Aerosol Emissions - Ton/Ton HCHO (377.) 

Total N0X - Ton/Ton HCHO (37%) 

Total SOjj - Ton/Ton HCHO (37%) 

Totsl CO - Ton/Ton HCHO (37%) 

' 

TABLE FS-5 

NATIONAL EMISSIONS INVENTORY 

Mi * # 

FORMALDEHYDE VIA SILVER CATALYST PROCESS paRe 1 of b * *• 

14- 1 

154,00 0 

17 

Abaorber Vent 

Not Specifie d 

Continuous 

+ 

+ 

None 

Never 

No 

Yes 

1 

43. 8 

42 

Yes 

X 

FS-1 

Not Specifie d 

o 

Converter Emergency Vent 

Not Specifie d 

Intermitten t 

0.1 0 

+ 

+ 

+ 

None 

Never 

Not Specifie d 

»500 ° 

No 

14-3 

4 7.500 

4 7,500 

0 

Converte r Start-u p Vent 

2620 

Intermi tten t 

5 

.00011 

.00003 

. < *•* 

None 

Never 

9 

Not Specifie d 

No 

.00489 

0 

0 

0 

.00159 

, 

• • ' • ' 

] 

1 | 

i 

Absorber Vent 

Not Speci fied 

Cont i nuous j 

'• 

.00114 

.00364 

+ 

+ 

.00159 

+ 

.01193 

.00755 

Yes 

•s- T / i 

718 

1 

6 '68 ) 

.67 

8 2 ° 

No 

T3 
TABLE FS-5 

NATIONAL EMISSIONS INVENTORY 

EPA Code No. 

Date on-stream 

Capacity - Tons of 377. HCHO/Yr. 

Average Production - Tons of 377. HCHO/Yr. 

Range In Production - % of Max. 

Emissions to Atmosphere 

Stream 

Flov - lbs./hr. 

Flov Characteristic - Continuous or Intermittent 

if Intermittent - hrs./yr. 

Composition - Tons/Ton of 377. HCHO 

Formaldehyde 

Methanol' 

Methyl Formate 

Di-methyl Ether 

Methylal 

Oxygen 

Nitrogen 

Carbon Monoxide 

Carbon Dioxide 

Methane 

Water 

Hydrogen 

Sample Tap Location 

Date or Frequency of Sampling 

Type of Analysis 

Odor Problem 

Vent' Stacks 

Flov - SCFM per stack 

Number 

Height - Feet (elev. @ tip) 

Diameter - Inches 

Exit Gas Temperature - F° 

Emission Control Devices 

Type - Water Scrubber 

Incinerator 

Catalog I. D. No. 

Totsl Hydrocarbon Emissions - Ton/Ton HCHO (377.) 

Total Particulate & Aerosol Emissions - Ton/Ton HCHO (377.) 

Total N0X - Ton/Ton HCHO (377.) 

Total SO, - Ton/Ton HCHO (377.) 

Total CO - Ton/Ton HCHO (37%) 

FORMALDEHYDE VIA SILVER 

Absorber #1 

Vent 

4040 

Continuous 

.00035 

.00111 

.00269 

.25569 

.00238 

.03354 

.00946 

.00523 

None 

Never 

Calc. 

No 

Yes 

1090 to 1152 

1 

60 

.9 

104° to 140° 

No 

CATALYST PROCESS 

Absorber 

Vent 

1350 

14 

52 

52 

-4 

,500 

500 

0 

#2 

Continuous 

.00012 

.00037 

.00090 

.08523 

.00080 

.01115 

.00315 

.00174 

Never 

Celc. 

No 

Yes 

363 to 384 

1 

50 

.6 

104° to 

No 

140° 

.00348 

0 

0 

0 

.00556 

PaBe 2 of 6 

Absorber 

Vent 

4040 

•<3 

Cont i nuous 

.0003 5 

.00111 

.00269 

.25569 

.00238 

.03354 

.0094b 

.00523 

None 

Never 

Cslc 

No 

Yes 

1090 to 

1 

65 

9 

104° to 

No 

1152 

140° 

St r i pper 

Overhead Vent 

Con t i nuovis 

.00002 

.0000D 

+ .003 72 

+ 

.00038 

None 

Never 

Est imat e 

No 

Yes 

5 to 20 

1 

65 

4 

78" to 110° 

FS-8 
• ' • 

EPA Code Number 

Date on-stream 

Capacity - Tons of 37% HCHO 

Average Production - Tons o f 37% HCHO ° 

Range in Production - % o f Max. 

Emissions t o Atmosphere 

Stream 

Flov - lbs./hr . 

Flov Characteristi c - Continuous or Intermitten t 

if Intermittent - hrs./yr . 

Composition - Tons/Ton of 37% HCHO 

Formaldehyde 

Methanol 

Methyl Formate 

Dl-methyl Ether 

Methylal 

Oxygen 

Nitrogen 

Carbon Monoxide 

Carbon Dioxide 

Methane 

Water 

Hydrogen 

Sample Tap Location 

Date or Frequency o f Sampling 

Type of Analysis 

Odor Problem 

Vent Stacks 

Flov - SCFM per stack 

Number 

Height - Feet (elev . @ tip ) 

Diameter - Inche s 

Exit Gas Temperature - F° 

Emission Control Device s 

Type - Water Scrubber 

Incinerato r 

Demlster 

Other 

Catalog I. D. No. 

Total Hydrocarbon Emissions - Ton/Ton of 377. HCHO 

"Total Particulat e 6, Aeroso l Emissions - Ton/Ton of 377. HCHO 

Total N0X Emissions - Ton/Ton of 377. HCHO 

Total S0X Emlsalons - Ton/Ton of 37% HCHO 

Total CO Emissions - Ton/Ton o f 377. HCHO 

TABLE FS-5 

NATIONAL EMTSSIONS~~TNVENTORY 

FORMALDEHYDE VIA SILVER CATALYST PROCESS 

14-7 

50,00 0 

0 

Absorbe r Vent 

7369 

Continuous 

.0003 5 

.0034 0 

.0023 0 

.5300 0 

.0010 0 

.0385 0 

.0275 0 

.0110 0 

None 

Never 

Calc'd . ex Design 

No 

Yes 

2000 

1 

98 

8 

95 

Yes 

+ 

FS-3 

.0060 5 

0 

0 

0 

.00100 

14-8 

75,00 0 

75,00 0 

0 

Absorber Vent 

11.60 0 

Continuous 

,00067 

.5612 9 

.0052 9 

.0592 0 

.0063 4 

.0126 3 

Stack 

1972 

CLC + Titratio n 

No 

Yes 

3200 

1 

100 

16 

54 

Yes 

+ 

FS-5 

.00100 

0 

0 

0 

.00529 

rage 3 of 

.let Exhaust 

6 

Cont i nuous 

.00033 

None 

Never 

Calc'd. 

No 

Yes 

1 

43 

1.5 

200 

Yes 

+ (condenser ) 

FS-9 

6 

14-9 

30.91 9 

30,91 9 

0 

Absorbe r Emer^. Vents 

Manual/Auto 

Internii t t ent 

+ 

+ 

+ 

+ 

+ 

Process 

Random 

Orsat + ? 

No 

Yes 

1/1 

30/2 0 

8 / 8 

50°/50 ° 

No 

Not Spec i 

-

AbForber Vent 

Not Speci fied 

* 

Yes 

+ 

KS-2 

fied 

vt 

_ 
TABLE FS-5 

NATIONAL EHISSTOtrTmmNTORY 

FORMALDEHYDE VIA SILVER CATALYST PROCESS 

PA Code Number 

opacit y - .Tons of 377. HCHO/Yr. 

iverage Production - Tons of 37% HCHO/Yr. ; 

tange In Production - 7. of Max. 

mission s t o Atmosphere 

Stream 

' Flow - lbs./hr . 

Flo v Characteristi c - Continuous or Intermitten t 

If Intermitten t - hrs./yr . 

. Composition - Tons/ton of 377. HCHO 

Formaldehyde 

Methanol 

- Methyl Formate 

Dl-methy l Ether & 

Methylal 

• Oxygen 

Nitroge n 

Carbon Monoxide 

Carbon Dioxide 

Methane 

Water 

Hydrogen 

Sample Tap Location 

Date or Frequency of Sampling 

Type of Analysis 

Odor Problem 

Vent Stacks 

Flov - SCFM per stack 

Number 

Height - Feet' (elev. @ tip) 

Diameter - Inches 

Exit Gas Temperature - F° 

Emission Control Devices 

Type - Water Scrubber 

Incinerator 

Catalog I. D. Number 

Total Hydrocarbon Emissions - Ton/Ton HCHO (377.) 

Total Particulate & Aerosol Emissions - Ton/Ton HCHO (377.) 

Total NO„ - Ton/Ton HCHO (37%) 

Total S0X - Ton/Ton HCHO (377.) 

Total CO - Ton/Ton HCHO (37%) 

14-10 

240,00 0 

Absorber Vent Incinerato r 

Flue ga s 

39,72 7 

Continuous 

TR 

TR 

Page 4 Of u 

14-b 

200,00 0 

0 

tit Spec i f i ed 

.0100 5 

.4794 0 

.04269 

.18491 

TR 

Never 

CLC 

No 

Yes 

10.05 0 

1 

85 

60 

900 

Yes 

FS-7 

0 

0 

0 

0 

0 

+ Boile r 

FS-b 

Cannot Be Determined 
TABLE FS-5 

NATIONAL EMISSIONS~INVENTORY 

FORMALDEHYDE VIA SILVER CATALYST PROCESS Pa^e 5 of 6 

EPA Code No. 

Date on-stream 

Capacity - Tons o f 37% HCHO 

Average Production - Tons o f 37% HCHO 

Range in Production - % of Max. 

Emissions t o Atmosphere 

Stream 

Flov - lbs./hr . 

Flov Characteristi c - Continuous or Intermitten t 

i f Intermitten t - hrs./yr . 

Composition - Tons/Ton of 37% HCHO 

Formaldehyde 

Methanol 

Methyl. Formate 

Dl-methyl Ether 

Methylal 

Oxygen 

Nitrogen 

Carbon.Monoxide 

Carbon Dioxide 

Methane 

Water 

Hydrogen 

Sample Tap Location 

Date or Frequency of Sampling 

Type of Analysis 

Odor Problem 

Vent Stacks 

Flov - SCFM per stack 

Number 

Height .- Feet (elev . @ tip ) 

Diameter - Inche s 

Exit Gas Temperature - F° 

Emission Control Device s 

Type - Water Scrubber 

Incinerato r 

Demlster 

Other 

Catalog I. D. No. 

Total Hydrocarbon Emissions - Ton/Ton of 37% HCHO 

Total Particulat e & Aeroso l Emissions - Ton/Ton o f 37% HCHO 

Total N0„ Emissions - Ton/Ton of 377. HCHO 

Total SO, Emissions - Ton/Ton of 377. HCHO 

Total CO Emissions - Ton/Ton of 377. HCHO 

14-12 

35,00 0 

35,00 0 

0 

Absorber Vent 

5,855 

Continuous 

.00041 

.00082 

.00276 

.00191 

.01390 

Dally 

Calc'd. 

Yes 

.460 

1 

73 

IS 

80 

Yes 

FS-4 

.00123 

0 

0 

0 

.00276 

14-18 

20,000 

20,000 

0 

Jet Exhaust 

1000 

Continuous 

.18519 

None 

Never 

No 

Yes 

1 

22 

1 

200 

No 

0 

0 

0 

0 

.00292 

Absorber Vent 

3360 

Cont i nuous 

.00250 

.54828 

.00292 

.05856 

.00167 

.00989 

Top of Tower 

Bi-annua 

Orsat + 

No 

Yes 

891 

1 

44 

6 

50 

No 

I 

? 

_ 

.51016 

.00104 

.03b88 

.02b5b 

.01040 

Random 

Calc'd 

No 

Yes 

1 

)95 

132 

95 

No 

14-20 

') 0.000 

50.000 

0 

Absorber Vent 

738b 

Cont i nuous 

.00035 

.0032b 

.00224 

Distillation Tover 

Overhead Vent 

30 

Cont inuous 

.00120 

.00120 

Never 

Not Specified 

No 

1 

95 

132 

No 

.00825 

0 

0 

0 

.00104 

00 
TABLE FS-5 

NATIONAL EMISSION INVENTORY 

FORMALDEHYDE VIA SILVER CATALYST PROCESS Page 4 of 

EPA Code Number 

Capacity - Tons of 377. HCHO/Yr. 

Average Production - Tons of 37% HCHO/Yr. 

Range in Production - 7. of Max. 

Emissions t o Atmosphere 

Stream 

tflov. - lbs. /hr . 

Flov Characteristi c - Continuous or Intermitten t 

i f Intermitten t - hrs./yr . 

Composition - Tons/to n o f 37% HCHO 

> Formaldehyde 

* Methanol 

Methyl Formate ' 

Dl-methyl Ether 

Methylal 

Oxygen 

Nitrogen 

Carbon Monoxide 

Carbon Dioxide 

Methane 

Water 

Hydrogen 

Sample Tap Location 

Date or Frequency of Sampling 

Type of Analysis 

Odor Problem 

Vent Stacks 

Flov - SCFM per stack 

Number 

Height - Feet (elev . @ tip ) 

Diameter - Inche s 

Exit Gas Temperature - F° 

Emission Control Device s 

Type - Water Scrubber 

Incinerato r 

Catalog I. D. Number 

Tota l Hydrocarbon Emissions - Ton/Ton HCHO (377.) 

Tota l Particulat e & Aeroso l Emissions - Ton/Ton HCHO (377.) 

Tota l N0„ - Ton/Ton HCHO (37%) 

Tota l 30 x - Ton/Tor. KCHO (37%) 

Tota l CO - Ton/Ton HCHO (377.) 

14-10 

240.000 

Absorber Vent Incinerator 

Flue gas 

39,727 

Continuous 

TR 

TR 

I14-b 

200,00 0 

Not Specifie d 

.01005 

.•47940 

.04269 

.18491 

TR 

Never 

CLC 

No 

Yes 

10,050 

1 

85 

60 

900 

Yes 

+ Hoile r 

FS-b 

Cannot Be Determined 

-