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&EPA United States Environmental Protection Agency Office vf Air Quality Planning and Standards Research Triangle Park NC 277T1 EPA-450/4-84-007d March 1984 Locating And Estimating Air Emissions From Sources Of Ethylene Dichloride - X9 CMA. 051406 EPA-450/4-84-007d March 1984 Locating And Estimating Air Emissions From Sources Of Ethylene Dichloride U.S. ENVIRONMENTAL PROTECTION AGENCY Office Of Air And Radiation Office Of Air Quality Planning And Standards Research Triangle Park, North Carolina 27711 CMA, 051407 This report has been reviewed by the Office Of Air Quality Planning And Standards, U.S. Environmental Protection Agency, and has been approved for publication as received from GCA Technology, Approval does not signify that the contents necessarily reflect the views and policies of the Agency, neither does mention of trade names or commercial products constitute endorsement or recommendation for use. ii QA 051408 This report has been reviewed by the Office Of Air Quality Planning And Standards, U.S. Environmental Protection Agency, and has been approved for publication as received from GCA Technology. Approval does not signify that the contents necessarily reflect the views and policies of the Agency, neither does mention of trade names or commercial products constitute endorsement or recommendation for use. ii CMA 051409 CONTENTS Figures.............................................................................................................................. iv Tables.............................................................................................................................. vi 1. Purpose of Document ............................................................................... 1 2. Overview of Document Contents .......................................................... 3 3. Background....................................................................................................... 5 Nature of Pollutant.......................................................................... 5 Overview of Production and Uses.................................................8 4. Ethylene Dichl.oride Emission Sources............................................... 11 Ethylene Dichloride Production............................................... 11 Vinyl Chloride Monomer Production...........................................22 Methyl Chloroform Production................................................... 26 Ethyleneamines Production........................................................... 32 Trichloroethylene Production................................................... 36 Perchloroethylene Production................................................... 43 Vinylidene Chloride Production...............................................49 Ethyl Chloride Production............................................................52 Polysulfide Rubber Production................................................... 55 Liquid Pesticide Formulation................................................... 56 Use of Ethylene Dichloride in Grain Fumigation ... .61 EDC Use in Leaded Gasoline....................................................... 72 EDC Use in Paints, Coatings, and Adhesives...................... 76 EDC Use as an Extraction Solvent...........................................80 # EDC Use in Cleaning Solvents...................................................80 ' Miscellaneous EDC Uses............................................................... 81 - -Volatilization from Waste Treatment, Storage and Disposal Facilities....................................................................81 5. Source Test Procedures.................................. 83 References......................................................................................................................85 iii CMA. 051410 FIGURES Number Page 1 Chemical use tree for ethylene dichloride..................... 10 2 Basic operations that may be used for ethylene dichloride production by the balanced process, with air-based oxychlorination................................................................... 12 3 Basic operations that may be used for ethylene dichloride production by the oxygen process (oxychlorination step) ........................................................................ 15 4 Basic operations that may be used for vinyl chloride production by ethylene dichloridedehydrochlorination. . . 23 5 Basic operations that may be used for methyl chloroform production by the vinyl chloride hydrochlorination/ 1,1-dichloroethane chlorinationprocess........................................ 27 6 Basic operations that may be used for methyl chloroform production by the vinylidene chloride hydrochlorination process................................................................... 29 7 Basic operations that may be used in the production of ethyleneamines ........................................................................................ 33 8 Basic operations that may be used for trichloroethylene (TCE) and perch!oroethylene (PCE) production by ethylene dichloride chlorination ................................................... 37 9 Basic operations that may be used for trichloroethylene (TCE) and perch!oroethylene (PCE) production by ethylene di chloride oxychlorination.............................................. 39 10 Basic operations that may be used for the production of perchloroethylene by hydrocarbon chlorinolysis ..................... 44 11 Basic operations that may be used for the production of vinyl idene chloride................................................................................ 50 12 Basic operations that may be used in the production of ethyl chloride by ethylene hydrochlorination ......................... CONTINUED 53 iv CMA 051411 FIGURES Number Page 1 Chemical use tree for ethylene dichloride..................................... 10 2 Basic operations that may be used for ethylene dichloride production by the balanced process, with air-based oxychlorination.................................................................. 12 3 Basic operations that may be used for ethylene dichloride production by the oxygen process (oxychlorination step) ...................................................................... 15 4 Basic operations that may be used for vinyl chloride production by ethylene dichloride dehydrochlorination. . . 23 5 Basic operations that may be used for methyl chloroform production by the vinyl chloride hydrochlorination/ 1,1-dichloroethane chlorination process................................... 27 6 Basic operations that may be used for methyl chloroform production by the vinylidene chloride hydrochlorination process.................................................................. 29 7 Basic operations that may be used in the production of ethyleneamines ....................................................................................... 33 8 Basic operations that may be used for trichloroethylene (TCE) and perch!oroethylene (PCE) production by ethylene dichloride chlorination ................................................. 37 9 Basic operations that may be used for trichloroethylene (TCE) and perch!oroethylene (PCE) production by ethylene dichloride oxychlorination.............................................. 39 10 Basic operations that may be used for the production of perchloroethylene by hydrocarbon chlorinolysis ..................... 44 11 Basic operations that may be used for the production of vinyl idene chloride.............................................................................. 50 12 Basic operations that may be used in the production of ethyl chloride by ethylene hydrochlorination ......................... CONTINUED 53 iv CMA 051412 FIGURES (continued) Number Page 13 Basic operations that may be used for liquid pesticide formulation............................................................................... 57 14 Method 23 sampling train........................................................................... 84 v CMA 051413 TABLES Number Page 1 Physical Properties of Ethylene Dichloride.................................. 6 2 Ethylene Dichloride Emission Factors for a Hypothetical EDC Production Plant (Balanced Process) .............................................. 17 3 Production of Ethylene Dichloride ................................................... 21 4 Production of Vinyl Chloride Monomer.............................................. 25 5 Production of Methyl Chloroform ....................................................... 31 6 Production of Ethyleneamines............................................................... 35 7 Production of Trichloroethylene ....................................................... 42 8 Production of Perchloroethylene ....................................................... 48 9 Production of Ethyl Chloride............................................................... 54 10 ' Companies Which Hold Registrations on Pesticide Formulations Containing Ethylene Dichloride ............................. 58 11 Ethylene Dichloride Pesticide Brand Names .................................. 62 12 Fumigant Application Rates.............................................. 66 13 On-Farm Grain Storage ............................................................................ 68 14 Off-Farm Grain Storage............................................................................ 71 15 EDC Emissions from Bulk Loading, Storage, and Transportation of Leaded Gasoline .................................................. 73 16 EDC Emissions from Service Stations .............................................. 75 17 Petroleum Refineries................................................................................ 77 vi CMA 051414 TABLES Number Page 1 Physical Properties of Ethylene Dichloride................................. 6 2 Ethylene Dichloride Emission Factors for a Hypothetical EDC Production Plant (Balanced Process) ........................................... 17 3 Production of Ethylene Dichloride .................................................. 21 4 Production of Vinyl Chloride Monomer............................................. 25 5 Production of Methyl Chloroform ...................................................... 31 6 Production of Ethyleneamines.............................................................. 35 7 Production of Trichloroethylene ...................................................... 42 8 Production of Perchloroethylene ...................................................... 48 9 Production of Ethyl Chloride.............................................................. 54 10 ' Companies Which Hold Registrations on Pesticide Formulations Containing Ethylene Dichloride ............................. 58 11 Ethylene Dichloride Pesticide BrandNames ................................... 62 12 Fumigant Application Rates......................................... _. .... .... 66 13 On-Farm Grain Storage .......................................................................... 68 14 Off-Farm Grain Storage.......................................................................... 71 15 EDC Emissions from Bulk Loading, Storage, and Transportation of Leaded Gasoline . . ........................................ 73 16 EDC Emissions from Service Stations .............................................. 75 17 Petroleum Refineries.............................................................................. 77 vi CMA 051415 SECTION 1 PURPOSE OF DOCUMENT EPA, States and local air pollution control agencies are becoming increasingly aware of the presence of substances in the ambient air that may be toxic at certain concentrations. This awareness, in turn, has led i to attempts to identify source/receptor relationships for these substances and to develop control programs to regulate emissions. Unfortunately, very little information is available on the ambient air concentrations of these substances or on the sources that may be discharging them to the atmosphere. To assist groups interested in inventorying air emissions of various potentially toxic substances, EPA is preparing a series of documents such as this that compiles available information on sources and emissions of these substances. This document specifically deals with ethylene dichloride. Its intended audience includes Federal, State and local air pollution personnel and others who are interested in locating potential emitters of ethylene dichloride and making gross estimates of air emissions therefrom. Because of the limited amounts of data available on ethylene dichloride emissions, and since the configuration of many sources will not be the same as those described herein, this document is best used as a primer to inform air pollution personnel about 1) the types of sources that may emit ethylene dichloride, 2) process variations and release points that may be expected within these sources, and 3) available emissions information indicating the potential for ethylene dichloride to be released into the air from each operation. The reader is strongly cautioned against using the emissions information contained in this document to try to develop an exact assessment of emissions from any particular facility. Since insufficient data are available to develop statistical estimates of the accuracy of these emission 1 CMA. 051.416 factors, no estimate can be made of the error that could result when these factors are used to calculate emissions from any given facility. It is possible, in some extreme cases, that orders-of-magnitude differences could result between actual and calculated emissions, depending on differences in source configurations, control equipment and operating practices. Thus, in situations where an accurate assessment of ethylene dichloride emissions is necessary, source-specific information should be obtained to confirm the existence of particular emitting operations, the types and effectiveness of control measures, and the impact of operating practices. A source test and/or material balance should be considered as the best means to determine air emissions directly from an operation. 2 CMA. 051417 factors, no estimate can be made of the error that could result when these factors are used to calculate emissions from any given facility. It is possible, in some extreme cases, that orders-of-magnitude differences could result between actual and calculated emissions, depending on differences in source configurations, control equipment and operating practices. Thus, in situations where an accurate assessment of ethylene dichloride emissions is necessary, source-specific information should be obtained to confirm the existence of particular emitting operations, the types and effectiveness of control measures, and the impact of operating practices. A source test and/or material balance should be considered as the best means to determine air emissions directly from an operation. 2 CMA 051418 SECTION 2 OVERVIEW OF DOCUMENT CONTENTS As noted in Section 1, the purpose of this document is to assist Federal, State and local air pollution agencies and others who are interested in locating potential air emitters of ethylene dichloride and making gross estimates of air emissions therefrom. Because of the limited background data available, the information summarized in this document does not and should not be assumed to represent the source configuration or emissions associated with any particular facility. This section provides an overview of the contents of this document. It briefly outlines the nature, extent and format of the material presented in the remaining sections of this report. Section 3 of this document provides a brief summary of the physical and chemical characteristics of ethylene dichloride, its commonly occurring forms and an overview of its production and uses. A chemical use tree summarizes the quantities of vinylidene chloride consumed In various end use categories in the United States. This background section may be useful to someone who needs to develop a general perspective on the nature of the substance and where it is manufactured and consumed. Section 4 of this document focuses on major industrial source categories that may discharge ethylene dichloride air emissions. This section discusses the production of ethylene dichloride and its use as an industrial feedstock. For each major industrial source category described in Section 4, example process descriptions and flow diagrams are given, potential emission points are identified, and available emission factor estimates are presented that show the potential for ethylene dichloride emissions before and after controls employed by industry. Individual companies are named that are reported to be involved with either the production or use of ethylene dichloride, based primarily on trade pub!ications. 3 CMA 05X419 The final section of this document summarizes available procedures for source sampling and analysis of ethylene dichloride. Details are not prescribed nor is any EPA endorsement given or implied to any of these sampling and analysis procedures. At this time, EPA generally has not evaluated these methods. Consequently, this document merely provides an overview of applicable source sampling procedures, citing references for those interested in conducting source tests. This document does not contain any discussion of health or other environmental effects of ethylene dichloride, nor does it include any discussion of ambient air levels or ambient air monitoring techniques. Comments on the contents or usefulness of this document are welcomed, as is any information on process descriptions, operating practices, control measures and emissions information that would enable EPA to improve its contents. All comments should be sent to: Chief, Source Analysis Section (MD-14) Air Management Technology Branch U.S. Environmental Protection Agency Research Triangle Park, N.C. 27711 4 CMA. 051420 The final section of this document summarizes available procedures for source sampling and analysis of ethylene dichloride. Details are not prescribed nor is any EPA endorsement given or implied to any of these sampling and analysis procedures. At this time, EPA generally has not evaluated these methods. Consequently, this document merely provides an overview of applicable source sampling procedures, citing references for those interested In conducting source tests. This document does not contain any discussion of health or other environmental effects of ethylene dlchloride, nor does it include any discussion of ambient air levels or ambient air monitoring techniques. Comments on the contents or usefulness of this document are welcomed, as is any information on process descriptions, operating practices, control measures and emissions information that would enable EPA to improve its contents. All comments should be sent to: Chief, Source Analysis Section (MD-14) Air Management Technology Branch U.S. Environmental Protection Agency Research Triangle Park, N.C. 27711 4 CMA. 051421 SECTION 3 BACKGROUND NATURE OF POLLUTANT Ethylene dichloride (EDC) is a clear, colorless oily liquid with a pleasant chloroform-like sweet odor and taste. The chemical name for ethylene dichloride is 1,2-dichloroethane, the molecular formula is ClCH^CHgCl, and the structure is as follows: HH Cl - C - C - Cl HH Ethylene dichloride should be distinguished from 1,2-dichloroethylene which has double-bonded carbon atoms and the molecular formula C1CH=CHC1. Ethylene dichloride is soluble in hydrocarbon solvents, miscible with other chlorinated solvents, and has a high solvency for fats, greases, and waxes. However, it has only a limited solubility in waterJ Physical properties of EDC are listed in Table 1. Dry EDC is stable at room temperature but decomposes slowly when exposed to air, moisture, and light, forming hydrochloric acid and other corrosive products. The decomposing liquid becomes darker in color and progressively acidic. It can thus corrode iron or steel containers. Decomposition can be prevented by adding a small amount of alkyl amine. EDC that is sold as a solvent is normally treated in this manner; however, as an intermediate chemical, EDC is usually not stabilized. 2 Both of the chlorine atoms in the ethylene dichloride molecule are reactive and can be removed by heat or replaced by other substituents. The economic importance of ethylene dichloride is based in part on the ease with which hydrogen chloride can be removed to form vinyl chloride with the application of heat. The chemical nature of EDC also makes it useful in the manufacture of condensation polymers and ethylene dlamineJ 5 CMA 051422 TABLE 1. PHYSICAL PROPERTIES OF ETHYLENE DICHLORIDE3,4 Synonyms: 1,2-Dichloroethane, EDC, glycol dichloride, ethylene chloride, sym-dichloroethane, brocide, borer sol, destruxol borer-sol, di-chlor-mulsion, dutch liquid, ent 1,656, freon 150, NCI-C00511 Chemical Formula CAS Registry Number Molecular Weight Boiling Point, C Melting Point, C Density at 20C, g/1 Refractive Index at 2QaC, for Sodium Light Viscosity at 20C, mPa*s Surface Tension at 20C, mN/m Specific Heat at 20C, J/(g*K) liquid gas Latent Heat of Vapor at 20C, J/g Latent Heat of Fusion, J/g Critical Temperature, aC Critical Pressure, MPa Critical Density, g/L Flash Point, C closed cup open cup Explosive Limits in Air at 25C, % by Vol. Autoignition Temperature in Air, C Thermal Conductivity, liq. at 20C, W/(m*K) Heat of Combustion, kJ/g Heat of Formation, kJ/(g*mol) . liquid vapor C1CH2CH2C1 107-06-2 98.97 83.7 -35.3 1.2529 1.4451 0.84 31.38 1.288 1.066 323.42 88.36 290 5.36 0.44 17 21 6.2-15.6 413 0.143 12.57 157.3 122.6 CONTINUED 6 CMA 051423 TABLE 1. PHYSICAL PROPERTIES OF ETHYLENE DICHLORIDE3,4 Synonyms: 1,2-DichIoroethane, EDC, glycol dichloride, ethylene chloride, sym-dichloroethane, brocide, borer sol, destruxol borer-sol, di-chlor-mulsion, dutch liquid, ent 1,656, freon 150, NCI-C00511 Chemical Formula CAS Registry Number Molecular Weight Boiling Point, C Melting Point, C Density at 20C, g/1 Refractive Index at 20C, for Sodium Light Viscosity at 20C, mPa*s Surface Tension at 20C, mN/m Specific Heat at 20C, J/(g-K) 1iquid gas Latent Heat of Vapor at 20oC, J/g Latent Heat of Fusion, J/g Critical Temperature, C Critical Pressure, MPa Critical Density, g/L Flash Point, C closed cup open cup Explosive Limits in Air at 25C, % by Vol. Autoignition Temperature in Air, C Thermal Conductivity, 11q. at 20C, W/(m*K) Heat of Combustion, kJ/g Heat of Formation, kJ/(g-mol) . 1iquid vapor C1CH2CH2C1 107-06-2 98.97 83.7 -35.3 1.2529 1.4451 0.84 31.38 1.288 1.066 323.42 88.36 290 5.36 0.44 17 21 6.2-15.6 413 0.143 12.57 157.3 122.6 CONTINUED 6 CMA 051424 TABLE 1. (continued) Dielectric Constant liquid, 20C vapor, 120C Dipole Moment, C*m Coefficient of Cubical Expansion, mL/g, 0-30C Vapor Pressure, kPa 10C 20C 30C Solubility at 20C, g 1,2-dichloroethane in 100 g H20 H20 in 100 g 1,2-dichloroethane , Azeotropes, bp, C with 19.5% H20 with 5% H20 and 17% ethanol 10.45 1.0048 5.24 x 10'30 0.00116 5.3 8.5 13.3 0.869 0.160 72 66.7 7 CMA 051425 OVERVIEW OF PRODUCTION AND USES Since the mid-l940s, ethylene dichloride has been used principally as a raw material in the synthesis of other compounds, particularly vinyl chloride, methyl chloroform, trichloroethylene, perchloroethylene, vinylidene chloride, and ethyleneaminesJ Ethylene dichloride is produced in the United States C mainly by 12 manufacturers in 19 production facilities. The production of EDC from these plants is flexible and highly responsive to economic conditions. The combined annual capacity of these plants in 1983 was estimated to be c 9,205,700 Megagrams while actual production in 1982 was estimated at a level of 3,451,488 Megagrams.6 Exports of EDC in 1981 were estimated at 277,000 Megagrams/ Ethylene dichloride is manufactured in the United States by direct chlorinatii. of ethylene, oxychlorination of ethylene, or a combination of these methods. In the direct chlorination process ethylene is treated with chlorine in the presence of a catalyst to produce EDC. Either vapor- or liquid-phase reactions may be used, but undesirable side products are obtained unless conditions are controlled carefully. In one vapor-phase procedure, product yields of 96 to 98 percent are obtained by treating ethylene at 40C to 50C with chlorine containing traces of ethylene dibromide, which acts as a catalyst. Other direct chlorination procedures exist that differ primarily in reaction conditions and catalyst. Catalysts mentioned most often in the patent literature include ferric, aluminum, cupric, and antimony chlorides. In 1974 the direct chlorination of ethylene accounted for 58 percent of the U.S. production of ethylene dichloride.^ Ethylene dichloride is also manufactured commercially by treating ethylene with anhydrous hydrogen chloride and oxygen (or air) in a fluidized bed of finely divided particles containing cupric chloride. Typically, the reactive pressure and temperature are maintained at 20 to 70 psig and 200C to 315C, respectively.^ 8 CMA 051426 OVERVIEW OF PRODUCTION AND USES Since the mid-1940s, ethylene dichloride has been used principally as a raw material in the synthesis of other compounds, particularly vinyl chloride, methyl chloroform, trichloroethylene, perchloroethylene, vinylidene chloride, and ethyleneaminesJ Ethylene dichloride is produced in the United States mainly by 12 manufacturers in 19 production facilities.6 The production of EDC from these plants is flexible and highly responsive to economic conditions. The combined annual capacity of these plants in 1983 was estimated to be 5 9,205,700 Megagrams while actual production in 1982 was estimated at a level of 3,451,488 Megagrams.6 Exports of EDC in 1981 were estimated at 277,000 Megagrams.7 Ethylene dichloride is manufactured in the United States by direct chlorinatic of ethylene, oxychlorination of ethylene, or a combination of these methods. In the direct chlorination process ethylene is treated with chlorine in the presence of a catalyst to produce EDC. Either vapor- or liquid-phase reactions may be used, but undesirable side products are obtained unless conditions are controlled carefully. In one vapor-phase procedure, product yields of 96 to 98 percent are obtained by treating ethylene at 40C to 50C with chlorine containing traces of ethylene dibromide, which acts as a catalyst. Other direct chlorination procedures exist that differ primarily in reaction conditions and catalyst. Catalysts mentioned most often in the patent literature include ferric, aluminum, cupric, and antimony chlorides. In 1974 the direct chlorination of ethylene accounted for 58 percent of the U.S. production of ethylene dichlorideJ Ethylene dichloride is also manufactured commercially by treating ethylene with anhydrous hydrogen chloride and oxygen (or air) in a fluidized bed of finely divided particles containing cupric chloride. Typically, the reactive pressure and temperature are maintained at 20 to 70 psig and 200C to 315C, respectively.^ 8 CMA, 051427 Where EDC is produced for use in the manufacture of vinyl chloride, the oxychlorination and direct chlorination processes are often used together in what is know as the balanced process. In the balanced process, EDC is synthesized by the direct chlorination process and is then dehydrochlorinated, resulting in the production of vinyl chloride monomer and byproduct HC1. Manufacturers take advantage of the byproduct HC1 by using it in the oxychlorination process to produce more EDC. Ethylene dichloride is used primarily as a chemical Intermediate in the synthesis of other compounds. The current uses of EDC are listed in Figure 1, along with the percentage of the total product devoted to each use. Synthesis of vinyl chloride accounts for 81 percent of the annual United States consump tion of EDC while the synthesis of methyl chloroform (1,1,1-trichloroethane), ethyleneamines, perchloroethylene, trichloroethylene, and vinylidene chloride (1,1-dichloroethene) accounts for another 14 percent of consumption.^ Ethylene dichloride is also used as a scavenger for lead in gasoline. The EDC decomposes during combustion, with the chlorine atoms binding to the lead in the gasoline to form gaseous lead species. Thus, engine fouling with lead oxides or other solid lead species is prevented. The use of EDC as a lead scavenger in gasoline accounted for about 1 percent of the 1980 production. However, this use declined by 30 percent in 1980 and is expected to decline further because of the decreasing production of leaded gasolines.^ Minor uses of ethylene dichloride are in textile cleaning and processing, in formulations of acrylic-type adhesives, as a product intermediate for polysulfide elastomers, as a constitutent of polysulfide rubber cements, in the manufacture of grain fumigants, and as a cleaning and extraction solvent. Of the estimated consumption of EDC by minor uses, about 28 percent is used in the manufacture of paints, coatings, and adhesives. Extracting oil from seeds, treating animal fats, and processing pharmaceutical products account for 23 percent. An additional 19 percent is consumed in cleaning textile products and polyvinyl chloride manufacturing equipment. Nearly 11 percent is used in the preparation of polysulfide compounds. Grain fumigation requires about 10 percent. The remaining 9 percent is used as a carrier for amines in leaching copper ores, in the manufacture of color film, as a diluent for pesticides and herbicides, and for other miscellaneous purposes.^ 9 CMA. 051428 CMA. 0 5 1 4 2 9 ETHYLENE (ch2ch2) CHLORINE (ci2) CATALYST ETHYLENE DICHLORIDE (cich2ch2ci) i ETHYLENE (ch2ch2) HYDROGEN CHLORIDE + OXYGEN CATALYST HEAT (2HC1) (i02) USE VINYL CHLORIDE METHYL CHLOROFORM ETHYLENEAMINES PERCHLOROETHYLENE TRICHLOROETHYLENE VINYLIDENE CHLORIDE LEAD SCAVENGER METAL DEGREASING ORE FLOTATION ORGANIC SYNTHESIS PAINT, VARNISH, AND FINISH REMOVER SOAPS AND SCOURING COMPOUNDS SOLVENT WETTING AND PENETRATING AGENTS Figure 1. Chemical use tree for ethylene dichloride.4 PERCENT - 81% - 3% - 3% - 3% - 3% - 2% - 5% 100% ETHYLENE (ch2ch2) CHLORINE (ci2) CATALYST ETHYLENE DICHLORIDE (cich2ch2cij o ETHYLENE (ch2ch2) HYDROGEN CHLORIDE + OXYGEN CATALYST HEAT (2HC1) (i02) USE VINYL CHLORIDE METHYL CHLOROFORM ETHYLENEAMINES PERCHLOROETHYLENE TRICHLOROETHYLENE VINYLIDENE CHLORIDE LEAD SCAVENGER METAL DEGREASING ORE FLOTATION ORGANIC SYNTHESIS PAINT, VARNrSH, AND FINISH REMOVER SOAPS AND SCOURING COMPOUNDS SOLVENT WETTING AND PENETRATING AGENTS PERCENT - 819! - 39! - 39! - 39! - 39! - 29! - 52 1009! Figure 1. Chemical use tree for ethylene dichloride.4 oin uo> SECTION 4 ETHYLENE DICHLORIDE EMISSION SOURCES This section discusses ethylene dichloride (EDC) emissions from direct sources such as production of EDC, production of chemicals using EDC as a feedstock, and miscellaneous uses of EDC. Process and emissions- information are presented for each source for which data were available. ETHYLENE DICHLORIDE PRODUCTION Ethylene dichloride (EDC) is produced from ethylene and chlorine by direct chlorination, and from ethylene and hydrogen chloride (HC1) by oxychlorination. At most production facilities, these processes are used together in what is known as the balanced process. This section discusses EDC emissions from this process. The balanced process generally is used wherever EDC and vinyl chloride monomer (VCM) are produced at the same facility. As noted in Section 1, about 81 percent of the EDC produced domestically is used in the manufacture 4 of VCM. In VCM production, EDC is dehydrochlorinated to yield VCM and byproduct HC1. In the balanced process, byproduct HC1 from VCM production via the direct chlorination/dehydrochlorination process is used in the oxychlorination/dehydrochlorination process. Process Description The balanced process consists of an oxychlorination operation, a direct chlorination operation, and product finishing and waste treatment operations. The raw materials for the direct chlorination process are chlorine and ethylene. Oxychlorination involves the treatment of ethylene with oxygen and HC1. Oxygen for oxychlorination generally is added by feeding air to the reactor, Q although some plants use purified oxygen as feed material. Basic operations that may be used in a balanced process using air for the oxychlorination step are shown in Figure 2. Actual flow diagrams for production facilities will vary. The process begins with ethylene (Stream 1) 11 CMA 051431 IX) NOTE: The lumbers In this figure refer to process streams, as discussed in the text, and tlu* letters designate process vents. The heavy lines represent final product strums through the process. Figure 2. Basic operations that may be used for ethylene dichloride production by the balanced process, with air-based oxychlorination.8 CMA 0 5 1 4 3 2 CMA. 0 5 1 4 3 3 MIE: The nuabers In this flyure refer to process streams, as discussed In the teat, and the letters desIgnite process vents. The heavy lines represent final product streams tbrouyli the process. Figure 2. Basic operations that may be used for ethylene dichloride production by the balanced process, with air-based oxychlorination.8 being fed by pipeline to both the oxychlorination reactor and the direct chlorination reactor. In the oxychlorination reactor the ethylene, anhydrous hydrogen chloride (Stream 2), and air (Stream 3) are mixed at molar proportions of about 2:4:1, respectively, producing 2 moles of EDC and 2 moles of water. The reaction is carried out in the vapor phase at 200 to 315C in either a fixed-bed or fluid-bed reactor. A mixture of copper chloride and other O chlorides is used as a catalyst. The products of reaction from the oxychlorination reactor are quenched with water, cooled (Stream 4), and sent to a knockout drum, where EDC and water (Stream 5) are condensed. The condensed stream enters a decanter, where crude EDC is separated from the aqueous phase. The crude EDC (Stream 6) is transferred to in-process storage, and the aqueous phase (Stream 7) is recycled to the quench step. Nitrogen and other inert gases are released to the atmosphere (Vent A). The concentration of EDC in the vent stream is reduced by absorber and stripper columns or by a refrigerated condenser (not shown in Figure 2). 2 ' 8 In the direct-chlorination step of the balanced process, equimolar amounts of ethylene (Stream 1) and chlorine (Stream 8) are reacted at a temperature of 38 to 49C and at pressures of 69 to 138 kPa. Most commercial plants carry out the reaction in the liquid phase in the presence of a ferric p chloride catalyst. Products (Stream 9) from the direct chlorination reactor are cooled and washed with water (Stream 10) to remove dissolved hydrogen chloride before being transferred (Stream 11) to the crude EDC storage facility. Any inert gas fed with the ethylene or chlorine is released to the atmosphere from the cooler (Vent B). The waste wash water (Stream 12) is neutralized and sent to the wastewater steam stripper along with neutralized wastewater (Stream 13) from the oxychlorination quench area and the wastewater (Stream 14) from the drying column. The overheads (Stream 15) from the wastewater steam stripper, which consist of recovered EDC, other chlorinated hydrocarbons, and water, are returned to the process by adding them to the crude EDC (Stream 10) going 0 to the water wash. Crude EDC (Stream 16) from in-process storage goes to the drying column, where water (Stream 14) is distilled overhead and sent to the wastewater steam stripper. The dry crude EDC (Stream 17) goes to the heads column, which 13 CMA 051434 removes light ends (Stream 18) for storage and disposal or sale. Bottoms (Stream 19) from the heads column enter the EDC finishing column, where EDC (Stream 20) goes overhead to product storage. The tars from the EDC finishing Q column (Stream 21) are taken to tar storage for disposal or sale. Two domestic EDC producers use oxygen as the oxidant in the oxychlorination reactor. The process details are considered to be confidential by both producers. Although conceptual descriptions of such processes are given in the literature, it is not known how the actual processes compare with those described in the literature. One producer has released data showing that the plant is not truly balanced; that is, the ratio of EDC from oxychlorination and direct chlorination differs from that of a balanced plant. However, because both producers have direct chlorination, EDC purification and cracking, and VCM purification steps at the same site, both plants probably can be O considered to have integrated processes. Another producer uses only the 2 oxychlorination process and does not use direct chlorination. Figure 3 shows basic operations that may be used in an oxygen-based Q oxychlorination process as presented in the literature. For a balanced process plant, the direct chlorination and purification steps are the same as those shown in Figure 2, and, therefore, are not shown again -in Figure 3. Ethylene (Stream 1) is fed in large excess of the amount used in the air oxychlorination process, that is, 2 to 3 times the amount needed to fully consume the HC1 feed (Stream 2). Oxygen (Stream 3) Is also fed to the reactor, which may be either a fixed bed or a fluid bed. After passing through the condensation step in the quench area, the reaction products (Stream 4) go to a knockout drum, where the condensed crude EDC and water (Stream 5) produced by the oxychlorination reaction are separated from the unreacted ethylene and the inert gases (Stream 6). From the knockout drums the crude EDC and water (Stream 5) go to a decanter, where wastewater (Stream 7) is separated from the crude EDC (Stream 8), which goes to in-process storage as in the air-based process. The wastewater (Stream 7) is sent to the steam stripper in the direct chlorination step for recovery of dissolved organics. 8 - The vent gases (Stream 6) from the knockout drum go to a caustic scrubber for removal of HC1 and carbon dioxide. The purified vent gases (Stream 9) are then compressed and recycled (Stream 10) to the oxychlorination reactor as 14 CMA. 051435 removes light ends (Stream 18) for storage and disposal or sale. Bottoms (Stream 19) from the heads column enter the EDC finishing column, where EDC (Stream 20) goes overhead to product storage. The tars from the EDC finishing Q column (Stream 21) are taken to tar storage for disposal or sale. Two domestic EDC producers use oxygen as the oxidant in the oxychlorination reactor. The process details are considered to be confidential by both producers. Although conceptual descriptions of such processes are given In the literature, it is not known how the actual processes compare-with those described in the literature. One producer has released data showing that the plant is not truly balanced; that is, the ratio of EDC from oxychlorination and direct chlorination differs from that of a balanced plant. However, because both producers have direct chlorination, EDC purification and cracking, and VCM purification steps at the same site, both plants probably can be g considered to have integrated processes. Another producer uses only the 2 oxychlorination process and does not use direct chlorination. Figure 3 shows basic operations that may be used in an oxygen-based Q oxychlorination process as presented in the literature. For a balanced process plant, the direct chlorination and purification steps are the same as those shown in Figure 2, and, therefore, are not shown again -in Figure 3. Ethylene (Stream 1) is fed in large excess of the amount used in the air oxychlorination process, that is, 2 to 3 times the amount needed to fully consume the HC1 feed (Stream 2). Oxygen (Stream 3) Is also fed to the reactor, which may be either a fixed bed or a fluid bed. After passing through the condensation step in the quench area, the reaction products (Stream 4) go to a knockout drum, where the condensed crude EDC and water (Stream 5) produced by the oxychlorination reaction are separated from the unreacted ethylene and the inert gases (Stream 6). From the knockout drums the crude EDC and water (Stream 5) go to a decanter, where wastewater (Stream 7) is separated from the crude EDC (Stream 8), which goes to in-process storage as in the air-based process. The wastewater (Stream 7) is sent to the steam stripper in the Q direct chlorination step for recovery of dissolved organics. The vent gases (Stream 6) from the knockout drum go to a caustic scrubber for removal of HC1 and carbon dioxide. The purified vent gases (Stream 9) are then compressed and recycled (Stream 10) to the oxychlorination reactor as 14 CMA 051436 IN-PHOCESS STORAGE NOTE: The nuabers In this figure refer to process streams, as discussed tn the text, and llie letters designate process vents. The heavy lines represent final product streams through Lite process. Figure 3. Basic operations that may be used for ethylene dichloride production by the oxygen process {oxychlorirtation step).8 CMA. 0 5 1 4 3 7 part of the ethylene feed. A small amount of the vent gas (Vent A) from the knockout drum is purged to prevent buildup of the inert gases entering with O the feed streams or formed during the reaction. Emissions Uncontrolled EDC emission factors for the balanced process are listed in Table 2. Also listed in this table are potentially applicable control techniques and associated emission factors for controlled emissions. The emission factors were developed for a hypothetical plant with a total EDC production capacity of 400,000 Mg/yr, based on 8760 hours of operation annually. Of the total production capacity, 215,000 Mg/yr is produced by direct chlorination and g 185,000 Mg/yr by oxychlorination. Because of variations in process design, age of equipment, and so on, actual emissions vary for each plant. Process Emissions -- Ethylene dichloride process emissions originate from the purging of inert gases from the oxychlorination vent (Vent A, Figures 2 and 3) and the direct chlorination vent (Vent B, Figure 2). The level of EDC in the oxychlori nation vent gas is reduced by either an absorber/stripper combination or a g refrigerated condenser. Average EDC emission rates of 3.24 and 3.58^ kg/Mg of EDC produced have been reported from the absorber column. Emissions from the refrigerated condenser of one EDC producer were calculated 2 to be 2.40 kg/Mg of EDC produced. These emission factors are presented in the "uncontrolled EDC emission factor" column in Table 2 because the use of either the absorber/stripper combination or the refrigerated condenser is considered an integral part of the process design of some EDC production facilities. Somewhat higher oxychlorination and chlorination pressures are also reported to help lower EDC emissions. Many plants incinerate vent gases from the oxychlorination and direct chlorination reactors to reduce atmospheric emissions of EDC and VCM. This includes plants using the air-based as well as the oxygen-based oxychlorination processes,^ although in air units a much larger incinerator must be used 2 because of high levels of nitrogen in the oxychlorination vent. Thermal oxidation is estimated to reduce EDC emissions by 98 percent or more. Incineration destruction efficiency varies with emission stream properties 16 CMA 051438 part of the ethylene feed. A small amount of the vent gas (Vent A) from the knockout drum is purged to prevent buildup qf the inert gases entering with O the feed streams or formed during the reaction. Emissions Uncontrolled EDC emission factors for the balanced process are listed in Table 2. Also listed in this table are potentially applicable control techniques and associated emission factors for controlled emissions. The emission factors were developed for a hypothetical plant with a total EDC production capacity of 400,000 Mg/yr, based on 8760 hours of operation annually. Of the total production capacity, 215,000 Mg/yr Is produced by direct chlorination and g 185,000 Mg/yr by oxychlorination. Because of variations in process design, age of equipment, and so on, actual emissions vary for each plant. Process Emissions -- Ethylene dichloride process emissions originate from the purging of inert gases from the oxychlorination vent (Vent A, Figures 2 and 3) and the direct chlorination vent (Vent B, Figure 2). The level of EDC in the oxychlori nation vent gas is reduced by either an absorber/stripper combination or a g refrigerated condenser. Average EDC emission rates of 3.24 and 3.58^ kg/Mg of EDC produced have been reported from the absorber column. Emissions from the refrigerated condenser of one EDC producer were calculated 2 to be 2.40 kg/Mg of EDC produced. These emission factors are presented in the "uncontrolled EDC emission factor" column in Table 2 because the use of either the absorber/stripper combination or the refrigerated condenser is considered an integral part of the process design of some EDC production facilities. Somewhat higher oxychlorination and chlorination pressures are 2 also reported to help lower EDC emissions. Many plants incinerate vent gases from the oxychlorination and direct chlorination reactors to reduce atmospheric emissions of EDC and VCM. This includes plants using the air-based as well as the oxygen-based oxychlorination processes,^ although in air units a much larger incinerator must be used 2 because of high levels of nitrogen in the oxychlorination vent. Thermal oxi*dati.on is estimated to reduce EDC emissions by 98 percent or more. 12 Incineration destruction efficiency varies with emission stream properties 16 CMA. 051439 TABLE 2. ETHYLEME DICHLORIDE EMISSION FACTORS FOR A HYPOTHETICAL EDC PRODUCTION PLANT (BALANCED PROCESS)3 k Emission source Oxychlorination Air process Absorber/strtpper, or Refrigerated condenser Oxygen process Direct chlorination vent Column vents Storage vents In-process Product Process fugitive Secondary Wastewater biotreatment Source . designation A aJ B C D E F G Uncontrolled t)C mission factor^ (kg/Mg) Potentially applicable control technique 3Me'f 23.-4S08ee,ff 0.462d 1.0Bd 3.0Qd 0.0149d 0.0733 0.265d 0.002-0.061*" Thermal oxidizer Catalytic oxidizer Thermal oxidizer Thermal oxidizer Refrigerated condenser Thermal oxidizer Refrigerated condenser Thermal oxidizer Thermal oxidizer Refrigerated condenser Thermal oxidizer Refrigerated condenser Detection & correction of major leaks Hone" 1 reduction 9B+9 92.21 9B9 989 salt 98 *9 86^ 98 r9 9B+9 BSk 98 *9 ask 72* * Controlled EOC emission factor^ (kg/Hg) <0,064Bh <0.2B0fh <O.04B0n <0.0092*' 0.0693",0.17* <0,0216h 0.162", 0.26* 0.0600h 0.000 0.0022r <0.0015" 0.0110 0.106*1 0.002-0.06^ * *Any given EDC production plant atay vary to configuration and level of control from this hypothetical facility. The reader It encouraged to contact plant personnel to confirm the existence of emitting operations and control technology at a particular facility prior to estimating emissions therefrom. bLetters refer to vents designated in Figure 2. cEinlsslon factors in terms of kg/Hg refer to kilogram of EDC emitted per Megagram of fOC produced by balanced process. In cases where a particular source designation applies to multiple operations, these factors represent combined emissions for all (not each) of these operations within the hypothetical facility. ^Reference 8, p. IV-3. eThe use of the absorber/stripper combination or refrigerated condenser is sometimes used for EOC recovery as an integrated part of the process. Per reference 2, one producer reports uncontrolled EDC emissions of 40 kg/Hg. Emissions from newer plants are generally significantly lower. ^Reference 10. 9The control efficiency for thermal oxidation (t.e. Incineration) varies depending on the design of the Incinerator and the compound which is burned. The 98 percent level Is an estimate of the control efficiency of an Incinerator with a residence time of about 0.75 seconds and a temperature of about B70'C. for a compound which is difficult to incinerate. Incinerators operating at longer residence times and higher temperatures may achieve higher efficiences. Reference 12. ^Calculated by applying the control efficiency to the uncontrolled emission factor. 'Reference 2. 3See Figure 3 for this vent source; see Figure 2 for all others. ''Reference 13. ^Detection and correction of major leaks is estimated to achieve emission reductions of 75 percent for pumps, 90 percent for vapor-service valves, 70 percent for liquid service valves, and 62 percent for relief valves, for an overall reduction of 72 percent. Emission reductions of up to 100 percent can be achieved for pumps and relief valves by installing double mechanical sealed pumps and rupture disks on relief va1ves. "[missions data are not available for deep well injection or neutralization. Reference 2. Steam stripping is sometimes used as an integrated part of the EDC production process for the recovery of EDC from wastewater, as shewn In Figure 2. Information was not available on the use of controls beyond steam stripping. CMA 0 5 1 4 4 0 and incinerator operating parameters. The 98 percent efficiency level is based on incinerator operation at 870C and 0.75 second residence time for a compound which is difficult to incinerate. 12 The emission reduction may be greater than 98 percent for incineration of EDC with these operating parameters. In addition, the efficiency may be higher for longer residence times or higher operating temperatures. Catalytic incineration is used by one plant to reduce EDC emissions from reactor vents by 92.2 percent.^ Refrigerated vent condensers may also be used to control direct chlorination vent emissions, 2 as reported by one EDC producer. In an oxygen process, the purge gas can be dried and the contained ethylene can be chlorinated in a separate direct chlorinator to produce additional EDC. The small vent from this direct chlorinator can be combined with the vent from the other direct chlorinator and other vents from the process and incinerated. This treatment is reported to essentially eliminate 2 all emissions of EDC and VCM. Process emissions of EDC also result from the release of gases from the column vents (Vent C, Figure 2). Column vents include vents from the wastewater steam stripper, the drying column, the heads column, and the EDC finishing column. 9 Incineration reduces EDC emissions by at least 98 percent. 12 Storage Emissions -- Ethylene dichloride emissions result from the storage of EDC during in-process and final product stages. Sources for the hypothetical plant are shown in Figure 2 (Sources D and ). The emissions in Table 2 are based on 0Q fixed-roof tanks, half full, and 11 C diurnal temperature variation. Emissions may be controlled by use of refrigerated vent condensers. The control efficiency for a refrigerated condenser is dependent on the properties of the uncontrolled emission stream and on the condenser operating parameters. The 85 percent efficiency level for storage vents is based on an uncontrolled emission temperature of 20C and a condenser operating temperature of -15C. Greater efficiency can be achieved by using a lower operating temperature. 13 Handling Emissions -- No handling emissions occur in the hypothetical plant, as all raw materials, product, and waste byproducts are transported by pipeline. This may not be the case in existing plants, where loading and unloading operations could g result in additional emissions. 18 CMA 051441 and incinerator operating parameters. The 98 percent efficiency level is based on incinerator operation at 870C and 0.75 second residence time for a compound which is difficult to incinerate. 12 The emission reduction may be greater than 98 percent for incineration of EDC with these operating parameters. In addition, the efficiency may be higher for longer residence times or higher operating temperatures. Catalytic incineration is used by one plant to reduce EDC emissions from reactor vents by 92.2 percent.^ Refrigerated vent condensers may also be used to control direct chlorination vent emissions, 2 as reported by one EDC producer. In an oxygen process, the purge gas can be dried and the contained ethylene can be chlorinated in a separate direct chlorinator to produce additional EDC. The small vent from this direct chlorinator can be combined with the vent from the other direct chlorinator and other vents from the process and incinerated. This treatment is reported to essentially eliminate 2 all emissions of EDC and VCM. Process emissions of EDC also result from the release of gases from the column vents (Vent C, Figure 2). Column vents include vents from the wastewater steam stripper, the drying column, the heads column, and the EDC finishing column. 9 Incineration reduces EDC emissions by at least 98 percent. 12 Storage Emissions -- Ethylene dichloride emissions result from the storage of EDC during in-process and final product stages. Sources for the hypothetical plant are shown in Figure 2 (Sources D and E). The emissions in Table 2 are based on fixed-roof tanks, half full, and 11 QC diurnal temperature variation. Q Emissions may be controlled by use of refrigerated vent condensers. The control efficiency for a refrigerated condenser is dependent on the properties of the uncontrolled emission stream and on the condenser operating parameters. The 85 percent efficiency level for storage vents Is based on an uncontrolled emission temperature of 20C and a condenser operating temperature of -15C. Greater efficiency can be achieved by using a lower operating temperature. 13 Handling Emissions -- No handling emissions occur in the hypothetical plant, as all raw materials, product, and waste byproducts are transported by pipeline. This may not be the case in existing plants, where loading and unloading operations could g result in additional emissions. 18 CMA. 051442 Fugitive Emissions -- Fugitive emissions of EDC and other volatile organics result from leaks in process valves, pumps, compressors, and pressure relief valves. The plant is estimated to have 38 pumps handling EDC or other light liquids. There are an estimated 40 pressure relief valves in volatile organics service and 900 9 process valves handling EDC or other liquids. Fugitive emission quantities for specific production facilities are dependent on age of equipment, level of preventative maintenance, and leak detection programs. Secondary Emissions -- Secondary emissions can result from the handling and disposal of process waste-liquid streams (Source 6 in Figure 2). Wastewater treatment at an EDC production plant may consist of neutralization and steam stripping followed by either deep well injection or biotreating. Use of an open-pit neutralization 2 system may result in substantial EDC air emissions. Handling of wastewater prior to deep well injection may also result in EDC emissions; however, emissions after injection are negligible. Emissions of EDC from a biotreater are affected strongly by the biotreater process configuration, temperature of ambient air and wastewater, type of aeration device used, degree of aeration, and hydraulic retention time of the system. 2 ' l n EDC wastewater to a biotreater originates from several sources, as designated in Figure 2, as well as from spills, drips, stormwater runoff from concrete pads under process equipment and washing down of equipment. 2 ' 10 In an activated sludge biotreating system, EDC is not a readily biodegradable 2 compound. Most biotreater activated sludge systems consist of an open tank with surface mixers for aeration and mixing. The removal of EDC by air stripping in these systems can be extremely high (over 99 percent). The emisssion factor range in Table 2 is from biotreater emission data reported by two EDC 2 production facilities. The emission factors were based on production rates 3 of approximately 1.1 x 10 Mg/day. Emission data were not available for neutralization or deep well injection. 19 CMA. 051443 Source Locations Major EDC producers and production locations are listed in Table 3. In addition, the Chemical Division of 01in Corporation is listed as a producer of EDC by the U.S. International Trade Commission.^ 20 CMA 051444 Source Locations Major EDC producers and production locations are listed in Table 3. In addition, the Chemical Division of 011n Corporation is listed as a producer of EDC by the U.S. International Trade Commission, 14 20 CMA. 051445 TABLE 3. PRODUCTION OF ETHYLENE DICHLORIDE 2,5 Manufacturer Location Atlantic Richfield Co. ARCO Chem. Co., div. Diamond Shamrock Dow Chem. U.S.A. E.I. duPont de Nemours 4 Co., Inc. Conoco Inc., subsid. Conoco Chems. Co. Div. Ethyl Corp. Chems. Group Formosa Plastics Corp., U.S.A. Georgia-Pacific Corp. Chem. Div, The BF Goodrich Co. BF Goodrich Chem. Group PPG Indust., Inc. Indust. Chem. Div. Shell Chem. Co. Union Carbide Corp. Ethylene Oxide Derivatives Div. Vulcan Materials Co. Vulcan Chems., div. Port Arthur, TX Deer Park, TX Freeport, TX Oyster Creek, TX Plaquemine, LA Lake Charles, LA Baton Rouge, LA Pasadena, TX Baton Rouge, LA Point Comfort, TX Plaquemine, LA La Porte, TX Calvert City, KY Convent, LA Lake Charles, LA Deer Park, TX . Taft, LA Texas City, TX Geismar, LA Note: This listing is subject to change as market conditions change, faci lity ownership changes, plants are closed down, etc. The reader should verify the existence of particular facilities by consulting current listings and/or the plants themselves. The level of EDC emissions from any given facility is a function of variables such as capacity, throughput and control measures, and should be determined through direct contacts with plant personnel. 21 CMA. 051446 VINYL CHLORIDE MONOMER PRODUCTION Vinyl chloride monomer (VCM) is produced domestically by the dehydrochlorination of ethylene dichloride (EDC). It is used primarily in the production of polyvinyl chloride (PVC). Vinyl chloride has the following structure: Cl / H Process Description A typical flow diagram for EDC dehydrochlorination is shown in Figure 4. Ethylene dichloride (Stream 1) is introduced into the pyrolysis furnace where it is cracked in the vapor phase at temperatures of 450 to 620C and pressures of 450 to 930 kPa. About 50 percent conversion of EDC to VCM is achieved in the reaction. 15 The product gas stream from the furnace (Stream 2), containing VCM, EDC, and HC1 is quenched with liquid EDC, and fed to a condenser. Hydrogen chloride is removed from the condenser in the gas phase, and is recovered for use on site, generally in EDC production. The liquid stream from the condenser (Stream 4) is fed to a distillation column, where it is separated into VCM product, unreacted EDC, and heavy ends. The unreacted EDC (Stream 5) is recycled either to the quench column or to the finishing section of an EDC plant (generally onsite). Vinyl chloride product is used either on-site or sold, and heavy ends are incinerated. 15 Emissions In the EDC dehydrochlorination process, losses of EDC to the environment can occur in the heavy ends from the vinyl chloride separation unit (Source A in Figure 4). Uncontrolled EDC emissions from the heavy ends stream are reported as 0.6 - 0.8 kg/Mg.^'^ 22 CM* 051447 VINYL CHLORIDE MONOMER PRODUCTION Vinyl chloride monomer (VCM) is produced domestically by the dehydrochlorination of ethylene dichloride (EDC). It is used primarily in the production of polyvinyl chloride (PVC). Vinyl chloride has the following structure: H Cl HH Process Description A typical flow diagram for EDC dehydrochlorination is shown in Figure 4. Ethylene dichloride (Stream 1) is introduced into the pyrolysis furnace where it is cracked in the vapor phase at temperatures of 450 to 620C and pressures of 450 to 930 kPa. About 50 percent conversion of EDC to VCM Is achieved in the reaction. 15 The product gas stream from the furnace (Stream 2), containing VCM, EDC, and HC1 is quenched with liquid EDC, and fed to a condenser. Hydrogen chloride is removed from the condenser in the gas phase, and is recovered for use on site, generally in EDC production. The liquid stream from the condenser (Stream 4) is fed to a distillation column, where it is separated into VCM product, unreacted EDC, and heavy ends. The unreacted EDC (Stream 5) Is recycled either to the quench column or to the finishing section of an EDC plant (generally onsite). Vinyl chloride product is used either on-site or sold, and heavy ends are incinerated.^ Emissions In the EDC dehydrochlorlnation process, losses of EDC to the environment can occur in the heavy ends from the vinyl chloride separation unit (Source A in Figure 4). Uncontrolled EDC emissions from the heavy ends stream are reported as 0.6 - 0.8 kg/Mg.^ 22 CMA 051448 NOTE: The nrabers In this figure refer to process streams, as discussed In the text, and the letters designate process vents. The heavy lines represent final product streaas through the process. Figure 4. Basic operations that may be used for vinyl chloride production by ethylene dichloride dehydrochlorination.15 The heavy ends usually are incinerated along with other solid wastes generated by the VCM manufacturing process. Assuming that a removal 12 efficiency of at least 98 percent is achieved by incineration, the controlled emission factor for EDC would be < 0.016 kg of EDO per Mg of vinyl chloride produced. Fugitive and process vent emissions of EDO from VCM production are expected to be minor because of control measures which are taken to prevent emissions of vinyl chloride. 15 VCM production plants may vary in configuration and level of control. The reader is encouraged to contact plant personnel to confirm technology at a particular facility prior to estimating emissions therefrom. Source Locations A list of vinyl chloride production facilities, and locations is presented in Table 4. 24 CMA 051450 The heavy ends usually are incinerated along with other solid wastes generated by the VCM manufacturing process. Assuming that a removal efficiency of at least 98 percent is achieved by incineration, 12 the controlled emission factor for EDC would be < 0.016 kg of EDO per Mg of vinyl chloride produced. Fugitive and process vent emissions of EDC from VCM production are expected to be minor because of control measures which are taken to prevent emissions of vinyl chloride. 15 VCM production plants may vary in configuration and level of control. The reader is encouraged to contact plant personnel to confirm technology at a particular facility prior to estimating emissions therefrom. Source Locations A list of vinyl chloride production facilities, and locations is presented in Table 4. 24 CMA 051451 TABLE 4. PRODUCTION OF VINYL CHLORIDE MONOMER2,5 Manufacturer Borden Inc. Borden Chem. Div. Petrochems. Div. Dow Chem. U.S.A. Location Geismar, LA Oyster Creek, TX Plaquemine, LA E.I. duPont de Nemours & Co., Inc. Conoco Inc., subsid. Conoco Chems. Co. Div. Ethyl Corp. Chems. Group Formosa Plastics Corp. U.S.A. Georgia-Pacific Corp. Chem. Div. The BF Goodrich Co. BF Goodrich Chem. Group PPG Indust., Inc. Chems. Group Chem. Division-U.S. Shell Chem. Co. ----- Lake Charles, LA Baton Rouge, LA Baton Rouge, LA Point Comfort, TX Plaquemine, LA Calvert City, KY La Porte, TX Lake Charles, LA Deer Park, TX Note: This listing is subject to change as market conditions change, facility ownership changes, plants are closed down, etc. The reader should verify the existence of particular facilities by consulting current listings and/or the plants themselves. The level of EDC emissions from any given facility is a function of variables such as capacity, throughput and control measures, and should be determined through direct contacts with plant personnel. 25 CMA. 051452 METHYL CHLOROFORM PRODUCTION Methyl chloroform (Cl,C-CHO, also known as 1,1,1-trichloroethane, is *J 16 used predominantly as a metal-cleaning solvent. It is produced in the United States by three processes. It has been estimated that about 60 percent of the methyl chloroform produced in the U.S. is derived from vinyl chloride and about 30 percent is made from vinylidene chloride. The remaining 10 percent of methyl chloroform produced is derived from ethaneJ7 Because there are no documented EDC emissions from the production of methyl chloroform from ethane, this process is not discussed in this section. Methyl chloroform may be produced from vinyl chloride by a two-step process involving the hydrochlorination of vinyl chloride to form 1,1-dichloroetha and the thermal chlorination of this intermediate to produce methyl chloroform. In the vinylidene chloride process, vinylidene chloride is hydrochlorinated in the presence of a catalyst to form methyl chloroform. 18 Process Description Vinyl Chloride Hydrochlorination/1,1-Dichloroethane Chlorination Process- Basic operations that may be used for production of methyl chloroform from vinyl chloride are presented in Figure 5. Vinyl chloride, hydrogen chloride (HC1), recycled methyl chloroform, and ferric copper catalyst are combined in a tower-type reactor. In the reactor, a hydrochlorination reaction between vinyl chloride and HC1 takes place at temperatures of 35 to 40C, producing 1,1-dichloroethane. 18 After being cooled in a condenser, the reaction products (Stream 1) are fed to a purification column. The dichloroethane fraction is removed as an overhead stream (Stream 2) from the column, and fed to a chlorination reactor. There, the dichloroethane is reacted with chlorine gas at atmospheric pressure and about 400C to produce methyl chloroform and byproduct hydrogen chloride. The entire product stream from the chlorination reactor, containing methyl chloroform, HC1, and a small amount of unreacted 1,1-dichloroethane, is recycled to the hydrochlorinator reactor (Stream 3). 18 26 CMA 051453 METHYL CHLOROFORM PRODUCTION Methyl chloroform (C13C-CH3), also known as 1,1,1-trichloroethane, is used predominantly as a metal-cleaning solvent.16 It is produced in the United States by three processes. It has been estimated that about 60 percent of the methyl chloroform produced in the U.S. is derived from vinyl chloride and about 30 percent is made from vinylldene chloride. The remaining 10 percent of methyl chloroform produced is derived from ethane. Because there are no documented EDC emissions from the production of methyl chloroform from ethane, this process is not discussed in this section. Methyl chloroform may be produced from vinyl chloride by a two-step process involving the hydrochlorination of vinyl chloride to form 1,1-dichloroethane and the thermal chlorination of this Intermediate to produce methyl chloroform. In the vinylidene chloride process, vinylidene chloride is hydrochlorinated ]Q in the presence of a catalyst to form methyl chloroform. Process Description Vinyl Chloride Hydrochlorination/1,1-Dichloroethane Chlorination Process- Basic operations that may be used for production of methyl chloroform from vinyl chloride are presented in Figure 5. Vinyl chloride, hydrogen chloride (HC1), recycled methyl chloroform, and ferric copper catalyst are combined in a tower-type reactor. In the reactor, a hydrochlorination reaction between vinyl chloride and HC1 takes place at temperatures of 35 to 40C, producing 1,1-dichloroethane. 18 After being cooled in a condenser, the reaction products (Stream 1) are fed to a purification column. The dlchloroethane fraction is removed as an overhead stream (Stream 2) from the column, and fed to a chlorination reactor. There, the dichloroethane is reacted with chlorine gas at atmospheric pressure and about 4Q0C to produce methyl chloroform and byproduct hydrogen chloride. The entire product stream from the chlorination reactor, containing methyl chloroform, HC1, and a small amount of unreacted 1,1-dichloroethane, is recycled to the hydrochlorinator reactor (Stream 3). 18 26 CMA. 051454 CMA. 051455 NOTE: The numbers In this figure refer to process streams, as discussed In the text. end the letters designate process vents. The heavy lines represent final product streams through the process. Figure 5. Basic operations that may be used for methyl chloroform production by the vinyl chloride hydrochlorination/1,1-dichloroethane chlorination process.18 The recycled methyl chloroform is removed in the purification column as a high boiling fraction (Stream 4), and is sent to a stripper column where it is steam-stripped and distilled to yield a purified product (Stream 5). The product yield is over 95 percent. One company reports that it does not use a steam stripper, eliminating Vents B and C, but has a solids dump (not shown 2 in Figure 5) from the hydrochlorinator filter. Vinylidene Chloride Hydrochlorination Process-- Figure 6 shows basic operations that may be used for the production of methyl chloroform from vinylidene chloride. Vinylidene chloride, hydrochloric acid, and small quantity of ferric chloride catalyst are fed to the hydro chlorination reactor. The reaction is conducted in the liquid phase at 25 to 35C. Crude methyl chloroform product is withdrawn continuously from the hydrochlorination reactor (Stream 1) and purified by fractional distillation. The purified product (Stream 2) is treated to remove moisture and is combined with appropriate stabilizers to make the material suitable for commercial use. The yield of product is over 98 percent. 18 Emissions Figure 5 shows possible sources of gas and liquid wastes (Sources A, B, and C) for the methyl chloroform production process from the vinyl chloride method. The two major sources of EDC emissions to the atmosphere from the vinyl chloride method are: (1) the hydrochlorinator vent (Vent A), and (2) the steam stripper gas effluent vent (Vent B). The emissions of EDC may result from the presence of EDC as an impurity in vinyl chloride or the production of EDC in the hydrochlorination and chlorination reactions. The emission factors for EDC emissions from the hydrochlorinator vent condenser and the steam stripper vent condenser are 8.5 kg/Mg and 0.5 kg/Mg, respectively. 17 The emission factors refer to kg of EDC emitted per Mg of methyl chloroform produced. One methyl chloroform producer is reported to incinerate gases in the 7 12 hydrochlorinator vent. This would reduce EDC losses by at least 98 percent, resulting in an emission rate of < 0.17 kg/Mg, and insome facilities below 0.001 kg/Mg. No information was available on techniques used by industry to control emissions from the stream stripper gas vent. 28 CMA 051456 The recycled methyl chloroform is removed in the purification column as a high boiling fraction (Stream 4), and is sent to a stripper column where it is steam-stripped and distilled to yield a purified product (Stream 5). The 1Q product yield is over 95 percent. One company reports that it does not use a steam stripper, eliminating Vents B and C, but has a solids dump (not shown 2 in Figure 5) from the hydrochlorinator filter. Vinylidene Chloride Hydrochlorination Process- Figure 6 shows basic operations that may be used for the production of methyl chloroform from vinylidene chloride. Vinylidene chloride, hydrochloric acid, and small quantity of ferric chloride catalyst are fed to the hydro chlorination reactor. The reaction is conducted in the liquid phase at 25 to 35C. Crude methyl chloroform product is withdrawn continuously from the hydrochlorination reactor (Stream 1) and purified by fractional distillation. The purified product (Stream 2) is treated to remove moisture and is combined with appropriate stabilizers to make the material suitable for commercial use. The yield of product is over 98 percent. 18 Emissions Figure 5 shows possible sources of gas and liquid wastes (Sources A, B, and C) for the methyl chloroform production process from the vinyl chloride method. The two major sources of EDC emissions to the atmosphere from the vinyl chloride method are: (1) the hydrochlorinator vent (Vent A), and (2) the steam stripper gas effluent vent (Vent B). The emissions of EDC may result from the presence of EDC as an Impurity in vinyl chloride or the production of EDC in the hydrochlorination and chlorination reactions. The emission factors for EDC emissions from the hydrochlorinator vent condenser and the steam stripper vent condenser are 8.5 kg/Mg and 0.5 kg/Mg, respectively.^ The emission factors refer to kg of EDC emitted per Mg of methyl chloroform produced. One methyl chloroform producer is reported to incinerate gases in the hydrochlorinator vent. 2 This would reduce EDC losses by at least 98 percent, 12 resulting in an emission rate of < 0.17 kg/Mg, and in some facilities below 2 0.001 kg/Mg. No information was available on techniques used by industry to control emissions from the stream stripper gas vent. 28 CMA. 051457 HYDROCHLORINATION METHYL CHLOROFORM INJ to HEAVY ENOS FRACTIONATOR WASTE COLUMNS NOTE: The numbers In this figure refer to process strews, as discussed In the text. The heavy lines represent final product streams through the process. Figure 6. Basic operations that may be used for methyl chloroform production by the vinylidene qhloride hydrochlorination process.*8 CMA. 0 5 1 4 5 8 Information on EDC emissions from the vinylidene chloride-based production process of methyl chloroform is not available. It is thought that EDC may be present in the heavy ends waste stream and the aqueous effluent waste stream discharged by the vinylidene chloride-based process.^7 Data are not currently available to quantify atmospheric discharges from the handling of these waste streams. Methyl chloroform production plants may vary in configuration and level of control. The reader is encouraged to contact plant personnel to confirm the existence of emitting operations and control technology at-a particular facility prior to estimating emissions therefrom. Source Locations A list of methyl chloroform production facilities and locations is presented in Table 5. Manufacturing processes used in each of the facilities are not listed in the available literature. 30 CMA, 051459 Information on EDC emissions from the vinylidene chloride-based production process of methyl chloroform is not available. It is thought that EDC may be present in the heavy ends waste stream and the aqueous effluent waste stream discharged by the vinylidene chloride-based process.^ Data are not currently available to quantify atmospheric discharges from the handling of these waste streams. Methyl chloroform production plants may vary in configuration and level of control. The reader is encouraged to contact plant personnel to confirm the existence of emitting operations and control technology at a particular facility prior to estimating emissions therefrom. Source Locations A list of methyl chloroform production facilities and locations is presented in Table 5. Manufacturing processes used in each of the facilities are not listed in the available literature. 30 CMA. 051460 2,5 TABLE 5. PRODUCTION OF METHYL CHLOROFORM Manufacturer Location Dow Chem. U.S.A. PPG Indust., Inc. Indust. Chem. Div. Vulcan Materials Co. Vulcan Chems., Div. Freeport, TX Lake Charles, LA Geismar, LA Note: This listing is subject to change as market conditions change, facility ownership changes, plants are closed down, etc. The reader should verify the existence of particular facilities by consulting current listings and/or the plants themselves. The level of EDC emissions from any given facility is a function of variables such as capacity, throughput and control measures, and should be determined through direct contacts with plant personnel. 31 CMA 051461 ETHYLENEAMINES PRODUCTION Ethyleneamines are used in the production of carbamate fungicides, chelating agents, dimethyl ethylene urea resins, and diaminoethylethanol. 19 Process Description The only reported process used in the production of ethyleneamines is shown in Figure 7. Ethyleneamines may be produced by reacting EDO with ammonia in either the liquid phase or the vapor phase. The major product of both of these reactions is ethylenediamine. Byproducts of the reactions include diethylenetriamine, triethylenetetramine, tetraethylenepentamine, pentaethylenehexamine, and higher polymers. 20 In the vapor phase reaction, EDO and an excess of anhydrous ammonia are reacted at 150C and 9.0 MPa. Anhydrous ethylenediamine hydrochloride is formed, which, on treatment with caustic soda at 100C, yields free ethylene diamine (NHgCHgCHgNHg). Ethylenediamine vapors, steam, and unreacted ammonia are fed to a dehydrating column (not shown) where the diamine is dried and condensed.^ In the liquid phase process, EDO is treated with excess aqueous ammonia at 100C and 1.0 MPa. The aqueous product solution containing ethylenediamine hydrochloride, ammonium chloride, and ammonia is heated with caustic soda and fractionated. The ethylenediamine is drawn off and the ammonium chloride is recycled to the reaction vessel. 20 The ethyleneamines are separated into a number of marketable products, the composition of which varies from producer to producer.^ Emissions Reactor pressure vents, dehydration columns, and fractionating (distillation) columns are possible sources of unreacted EDO emissions. Waste water streams from dehydrochlorination and drying operations may contain quantities of unreacted EDC. 20 Emissions of EDC from ethyleneamine production facilities using typical -controls have been estimated at 600 Megagrams for 1976. 19 Typical control techniques used by industry in the production of ethyleneamines are not 32 CM& 051462 ETHYLENEAMINES PRODUCTION Ethyleneamlnes are used in the production of carbamate fungicides, chelating agents, dimethylethylene urea resins, and diami noethyl ethanol. 19 Process Description The only reported process used in the production of ethyleneamines is shown in Figure 7. Ethyleneamines may be produced by reacting EDC with ammonia in either the liquid phase or the vapor phase. The major product of both of these reactions is ethylenedlamine. Byproducts of the reactions include diethylenetriamine, triethylenetetramine, tetraethylenepentamine, pentaethylenehexamine, and higher polymers. 20 In the vapor phase reaction, EDC and an excess of anhydrous ammonia are reacted at 150C and 9.0 MPa. Anhydrous ethylenediamine hydrochloride is formed, which, on treatment with caustic soda at 100C, yields free ethylenediamine (NHgCHgCHgN^). Ethylenediamine vapors, steam, and unreacted ammonia are fed to a dehydrating column (not shown) where the diamine is dried and condensed.^0 In the liquid phase process, EDC is treated with excess aqueous ammonia at 100C and 1.0 MPa. The aqueous product solution containing ethylenediamine hydrochloride, ammonium chloride, and ammonia is heated with caustic soda and fractionated. The ethylenediamine is drawn off and the ammonium chloride is recycled to the reaction vessel. 20 The ethyleneamines are separated into a number of marketable products, the composition of which varies from producer to producer.^ Emissions Reactor pressure vents, dehydration columns, and fractionating (distillation) columns are possible sources of unreacted EDC emissions. Waste water streams from dehydrochlorination and drying operations may contain quantities of unreacted EDC. 20 Emissions of EDC from ethyleneamine production facilities using typical -controls have been estimated at 600 Megagrams for 1976. 19 Typical control techniques used by industry in the production of ethyleneamines are not 32 CMX 051463 RECYCLE AMMONIA EDO AMMONIA '' * REACTOR ETHYLENE DIAMINE CAUSTIC SODA + CO CO FRACTIONATING COLUMN OTHER *> ETHYLENE AMINES Figure 7. Basic operations that may be used in the production of ethyleneamines. 19 051464 discussed in the published literature. The total production of ethyleneamines in 1976 was estimated at a level of 66,012 Megagrams. 19 From these two -values, average EDC emissions per unit ethyleneamine production are estimated at 9.09 kg per Mg. Data are not available on the derivation of the total nationwide emissions estimates, nor are data available to break down EDC emissions between specific sources. Ethyleneamine production plants may vary in configuration and level of control. The reader is encouraged to contact plant personnel to confirm the existence of emitting operations and control technology at a particular facility prior to estimating emissions therefrom. Source Locations A list of major ethyleneamine production facilities and locations is presented in Table 6. 34 CMA. 051465 discussed in the published literature. The total production of ethyleneamines in 1976 was estimated at a level of 66,012 Megagrams. 19 From these two -values, average EDC emissions per unit ethyleneamine production are estimated at 9.09 kg per Mg. Data are not available on the derivation of the total nationwide emissions estimates, nor are data available to break down EDC emissions between specific sources. Ethyleneamine production plants may vary in configuration and level of control. The reader is encouraged to contact plant personnel to confirm the existence of emitting operations and control technology at a particular facility prior to estimating emissions therefrom. Source Locations A list of major ethyleneamine production facilities and locations is presented in Table 6. 34 CMA. 051466 TABLE 6. PRODUCTION OF ETHYLENEAMINES2,5,a,b Manufacturer Location Dow Chem. U.S.A. Union Carbide Corp. Ethylene Oxide Derivatives Div. Freeport, TX Taft, LA aEthylenediamine is the principal product, although a mixture of various ethyleneamines is obtained. bThis listing is subject to change as market conditions change facility ownership changes, plants are closed down, etc. The reader should verify the existence of particular facilities by consulting current listings and/or the plants themselves. The level of EDC emissions from any given facility is a function of variables such as capacity, throughput and control measures, and should be determined through direct contacts with plant personnel. 35 CMA 051467 TRICHLOROETHYLENE PRODUCTION Trichloroethylene (TCE) is used primarily as a metal-cleaning solvent and is produced domestically by either chlorination or oxychlorination of EDC or other chlorinated ethanes. Trichloroethylene, C12C=CHC1, can be produced separately or as a coproduct of perchloroethylene (PCE), Cl-C = CC1, by varying raw material ratios. 21 cc TCE was once manufactured predominantly by the chlorination of acetylene. However, because of a decrease in the supply of acetylene, EDC. chlorination became the preferred method for producing TCE. The last acetylene-based TCE plant was shut down in late 1977. 22 Process Descriptions Ethylene Dichloride Chlorination Process -- The major products of the EDC chlorination process are TCE, PCE, and hydrogen chloride (HC1). Basic operations that may be used in the production of TCE and PCE by EDC chlorination are shown in Figure 8. EDC (Stream 1) and chlorine (Stream 2) vapors are fed to a chlorination reactor. The chlorination is carried out at a high temperature (400 to 450C), slightly above atmospheric pressure, without the use of a catalyst. Other chlorinated C- hydrocarbons or recycled chlorinated hydrocarbon byproducts may be fed to the cchlorinator. 21 The product stream from the chlorination reaction consists of a mixture of chlorinated hydrocarbons and HCl. Hydrogen chloride (Stream 3) is separated from the chlorinated hydrocarbon mixture (Stream 4) and used in other processes. The chlorinated hydrocarbon mixture (Stream 4) is neutralized with sodium hydroxide solution (Stream 5) and is then dried. Spent caustic is transferred to a wastewater treatment plant. 21 The dried crude product (Stream 7) is separated by a PCE/TCE column into crude TCE (Stream 8) and crude PCE (Stream 9). The crude TCE (Stream 8) is fed to a TCE column, where light ends (Stream 10) are removed overhead. Bottoms from this column (Stream 11), containing TCE and heavies, are sent to the finishing column, where TCE (Stream 12) is removed overhead and sent to TCE storage. Heavy ends (Stream 13) are combined with light ends (Stream 10) from the TCE column and stored for eventual recycling. 21 36 CMA 051468 TRICHLOROETHYLENE PRODUCTION Trichloroethylene (TCE) is used primarily as a metal-cleaning solvent and is produced domestically by either chlorination or oxychlorination of EDC or other chlorinated ethanes. Trichloroethylene, ClgC^HCl, can be produced separately or as a coproduct of perchloroethylene (PCE), C17C = CCl,, by 21 c c varying raw material ratios. TCE was once manufactured predominantly by the chlorination of acetylene. However, because of a decrease in the supply of acetylene, EDC chlorination became the preferred method for producing TCE. The last acetylene-based TCE 2? plant was shut down in late 1977. Process Descriptions Ethylene Dichloride Chlorination Process -- The major products of the EDC chlorination process are TCE, PCE, and hydrogen chloride (HC1). Basic operations that may be used in the production of TCE and PCE by EDC chlorination are shown in Figure 8. EDC (Stream 1) and chlorine (Stream 2) vapors are fed to a chlorination reactor. The chlorination is carried out at a high temperature (400 to 450C), slightly above atmospheric pressure, without the use of a catalyst. Other chlorinated C9 hydrocarbons or recycled chlorinated hydrocarbon byproducts may be fed to the cchlorinator. 21 The product stream from the chlorination reaction consists of a mixture of chlorinated hjdrocarbons and HC1. Hydrogen chloride (Stream 3) Is separated from the chlorinated hydrocarbon mixture (Stream 4) and used in other processes. The chlorinated hydrocarbon mixture (Stream 4) is neutralized with sodium hydroxide solution (Stream 5) and is then dried. Spent caustic is transferred 2i to a wastewater treatment plant. The dried crude product (Stream 7) Is separated by a PCE/TCE column into crude TCE (Stream 8) and crude PCE (Stream 9). The crude TCE (Stream 8) is fed to a TCE column, where light ends (Stream 10) are removed overhead. Bottoms from this column (Stream 11), containing TCE and heavies, are sent to the finishing column, where TCE (Stream 12) is removed overhead and sent to TCE storage. Heavy ends (Stream 13) are combined with light ends (Stream 10) from the TCE column and stored for eventual recycling. 21 36 CMA 051469 ORGANICS FROM OTHER PROCESSES NOTE: The matters In this figure refer to process strews, as discussed In the text, and the letters designate process vents. The heavy lines represent final product stream through the process. Figure 8. Basic operations that may be used for trichloroethylene (TCE) and perchloroethylene (PCE) production by ethylene dichloride chlorination.21 CMA 051470 The crude PCE (Stream 9) from the PCE/TCE column is fed to a PCE column, where PCE (Stream 14) goes overhead to PCE storage. Bottoms from this column (Stream 15) are fed to a heavy ends column. Overheads from the heavy ends column (Stream 16) are recycled and bottoms, consisting of tars, are incinerated. These bottoms, called "hex wastes", may be processed further or heated to recover more volatilizable materials, with the resulting tars sent to disposal, often by incineration. This additional step recovers 80 to 90 percent of the bottoms.^ Ethylene Dichloride Oxychlorination Process -- The major products of the EDC oxychlori nation process are TCE, PCE, and water. Side reactions produce carbon dioxide, hydrogen chloride (HC1), and several chlorinated hydrocarbons. Figure 9 shows basic operations that may be used for EDC oxychlorination. The crude product contains 85 to 90 weight percent PCE plus TCE and 10 to 15 weight percent byproduct organics. Essentially all byproduct organics are recovered during purification and are recycled to the reactor. The process is very flexible, so that the reaction can be directed toward the production of either PCE or TCE in varying proportions. 21 EDC (Stream 1), chlorine or hydrogen chloride (Stream 2), oxygen (Stream 3) and recycled byproducts are fed to a fluid-bed reactor in the gas phase. The reactor contains a vertical bundle of tubes with boiling liquid outside the tubes to maintain the reaction temperature at about 425C. The reaction takes place at pressures slightly above atmospheric. Copper chloride catalyst is added continuously to the tube bundle. The reactor product (Stream 4) is fed to a water-cooled condenser and then a refrigerated condenser. Condensed material and catalyst fines drain to a decanter. The noncondensed inert gases (Stream 5), consisting of carbon dioxide, hydrogen chloride, nitrogen, and a small amount of uncondensed chlorinated hydrocarbons, are fed to a hydrogen chloride absorber, where HC1 is recovered by absorption in process water to make byproduct hydrochloric acid. The remaining inert gases are purged (Vent A). 21 38 CMA 051471 The crude PCE (Stream 9) from the PCE/TCE column is fed to a PCE column, where PCE (Stream 14) goes overhead to PCE storage. Bottoms from this column (Stream 15) are fed to a heavy ends column. Overheads from the heavy ends column (Stream 16) are recycled and bottoms, consisting of tars, are incinerated. 21 These bottoms, called "hex wastes", may be processed further or heated to recover more volatilizable materials, with the resulting tars sent to disposal, often by incineration. This additional step recovers 80 to 90 percent of the bottoms.^ Ethylene Dichloride Oxychlorination Process -- The major products of the EDC oxychlorination process are TCE, PCE, and water. Side reactions produce carbon dioxide, hydrogen chloride (HC1), and several chlorinated hydrocarbons. Figure 9 shows basic operations that may be used for EDC oxychlorination. The crude product contains 85 to 90 weight percent PCE plus TCE and 10 to 15 weight percent byproduct organics. Essentially all byproduct organics are recovered during purification and are recycled to the reactor. The process is very flexible, so that the reaction can be directed toward the production of either PCE or TCE in varying proportions. 21 EDC (Stream 1), chlorine or hydrogen chloride (Stream 2), oxygen (Stream 3) and recycled byproducts are fed to a fluid-bed reactor in the gas phase. The reactor contains a vertical bundle of tubes with boiling liquid outside the tubes to maintain the reaction temperature at about 425C. The reaction takes place at pressures slightly above atmospheric. Copper chloride catalyst is added continuously to the tube bundle. The reactor product (Stream 4) is fed to a water-cooled condenser and then a refrigerated condenser. Condensed material and catalyst fines drain to a decanter. The noncondensed inert gases (Stream 5), consisting of carbon dioxide, hydrogen chloride, nitrogen, and a small amount of uncondensed chlorinated hydrocarbons, are fed to a hydrogen chloride absorber, where HC1 is recovered by absorption in process water to make byproduct hydrochloric acid. The remaining inert gases are purged (Vent A). 21 38 CMA 051472 NOTE: The numbers In this figure refer to process streams, as discussed in the text, and the letters designate process vents. The heavy lines represent final product streams through the process. Figure 9. Basic operations that may be used for trichloroethylene (TCE) and . perchloroethylene (PCE) production by ethylene dichloride oxychlorination. ZLV1 SO >0 In the decanter the crude product (Stream 7) is separated from an aqueous phase. The aqueous phase, containing catalyst fines (Stream 8), is sent to a waste treatment plant (G). Crude product is fed to a drying column where dissolved water is removed by azeotropic distillation. The water (Stream 9) from the drying column is sent to the waste treatment plant (G) and the dried crude product (Stream 10) is separated into crude TCE (Stream 11) and crude PCE (Stream 12) in a PCE/TCE column.^ Crude TCE (Stream 11) is sent to a TCE column, where the light ends (Stream 13) are removed overhead and stored for recycle. The bottoms (Stream 14) are neutralized with ammonia and then dried to produce finished TCE (Stream 15), which is sent to storage. 21 The crude PCE (Stream 12) from the PCE/TCE is fed to a heavy ends column where PCE and light ends (Stream 16) are removed overhead. Heavy ends (Stream 17), called "hex wastes", are sent to an organic recycle system, where the organics that can be recycled (Stream 18) are separated from tars, which are incinerated. The PCE and light ends (Stream 16) from the heavies column are fed to a PCE column, where the light ends (Stream 20) are removed overhead and sent to the recycle organic storage tank. The PCE bottoms (Stream 21) are neutralized with ammonia and then dried to produce finished PCE (Stream 22) which is sent to storage. 21 Emissions Potential sources of EDC process emissions for the EDC chlorination process (Figure 8) are the neutralization and drying area vent (Vent A), which releases inert gases from the chlorine and EDC feeds, and the distillation column vents (Vents B), which release noncondensable gases. Storage emission sources (Vents C) include raw material storage and recycle storage. Fugitive emissions (D) occur when leaks develop in valves or in pump seals. When process pressures are higher than the cooling-water pressure, VOCs can leak into the cooling water and escape as fugitive emissions from the quench area. Secondary emissions can occur when wastewater containing VOCs is sent to a wastewater treatment system or lagoon and the VOCs evaporate (E). Another source of secondary emissions is the combustion of tars in the incinerator where VOCs are emitted with the flue gases (F). 21 40 CMA 051474 In the decanter the crude product (Stream 7) is separated from an aqueous phase. The aqueous phase, containing catalyst fines (Stream 8), is sent to a waste treatment plant (G). Crude product is fed to a drying column where dissolved water is removed by azeotropic distillation. The water (Stream 9) from the drying column is sent to the waste treatment plant (G) and the dried crude product (Stream 10) is separated into crude TCE (Stream 11) and crude PCE (Stream 12) in a PCE/TCE column.^ Crude TCE (Stream 11) is sent to a TCE column, where the light ends (Stream 13) are removed overhead and stored for recycle. The bottoms (Stream 14) are neutralized with ammonia and then dried to produce finished TCE (Stream 15), which is sent to storage. 21 The crude PCE (Stream 12) from the PCE/TCE is fed to a heavy ends column where PCE and light ends (Stream 16) are removed overhead. Heavy ends (Stream 17), called "hex wastes", are sent to an organic recycle system, where the organics that can be recycled (Stream 18) are separated from tars, which are incinerated. The PCE and light ends (Stream 16) from the heavies column are fed to a PCE column, where the light ends (Stream 20) are removed overhead and sent to the recycle organic storage tank. The PCE bottoms (Stream 21) are neutralized with ammonia and then dried to produce finished PCE (Stream 22) which is sent to storage. 21 Emissions Potential sources of EDC process emissions for the EDC chlorination process (Figure 8) are the neutralization and drying area vent (Vent A), which releases inert gases from the chlorine and EDC feeds, and the distillation column vents (Vents B), which release noncondensable gases. Storage emission sources (Vents C) include raw material storage and recycle storage. Fugitive emissions (D) occur when leaks develop in valves or in pump seals. When process pressures are higher than the cooling-water pressure, VOCs can leak into the cooling water and escape as fugitive emissions from the quench area. Secondary emissions can occur when wastewater containing VOCs is sent to a wastewater treatment system or lagoon and the VOCs evaporate (E). Another source of secondary emissions is the combustion of tars in the incinerator where VOCs are emitted with the flue gases (F).^ 40 CMA. 051475 In the EDC oxychlorination process (Figure 9), the hydrogen chloride asbsorber vent (Vent A), which releases the inert gases from the oxygen, chlorine, and hydrogen chloride feeds, is a potential source of EDC process emissions. Other potential sources of EDC process emissions are the drying column vent (Vent B) and the distillation column vents (Vents C), which release primarily noncondensable gases, and the TCE and the PCE neutralizer vents (Vents D), which relieve excess pressure of the nitrogen pads on the systems. Storage emission sources (Vents E) are raw material storage and recycle storage. Fugitive emissions (F) occur when leaks develop in valves or in pump seals. Secondary emissions (G and H) occur as described above for the chlorination process (see Vents E and F In Figure 8). 21 Atmospheric emissions of EDC in 1977 from the TCE production processes were estimated at 610 Mg. 23 The total domestic production of TCE in 1977 was estimated at 135,000 Mg, of which 90 percent was from EDC. 23 The emission factor for the controlled EDC emissions from the production of TCE can be calculated by dividing the EDC emissions by 90 percent of the total TCE production quantity. From these values, the controlled emission factor is about 5.0 kg of EDC per Mg of TCE produced. Data are not available on the derivation of the total annual EDC emissions estimate, nor are sufficient data available to break down EDC emissions between various sources. One reference states that EDC emissions for the process as a whole are practically zero when volatiles are recovered from the hex wastes and since EDC conversion 2 is 100 percent in the reactor. TCE production plants may vary in configuration and level of control. The reader is encouraged to contact plant personnel to confirm the existence of emitting operations and control technology at a particular facility prior to estimating emissions therefrom. Source Locations A list of trichloroethylene production facilities and locations is presented in Table 7. 41 CMA. 051476 TABLE 7. PRODUCTION OF TRICHLOROETHYLENE5 Manufacturer Dow Chem. U.S.A. PPG Indust., Inc. Indust. Chem. Div. Location Freeport, TX Lake Charles, LA Note: This listing is subject to change as market conditions change, facility ownership changes, plants are closed down, etc. The reader should verify the existence of particular facilities by consulting current listings and/or the plants themselves. The level of EDC emissions from any given facility is a function of variables such as capacity, throughput and control measures, and should be determined through direct contacts with plant personnel. 42 CM* 051477 TABLE 7. PRODUCTION OF TRICHLOROETHYLENE5 Manufacturer Location Dow Chem. U.S.A. PPG Indust., Inc. Indust. Chem. Div. Freeport, TX Lake Charles, LA Note: This listing is subject to change as market conditions change, facility ownership changes, plants are closed down, etc. The reader should verify the existence of particular facilities by consulting current listings and/or the plants themselves. The level of EDC emissions from any given facility is a function of variables such as capacity, throughput and control measures, and should be determined through direct contacts with plant personnel. 42 CMA 051478 PERCHLOROETHYLENE PRODUCTION Perch!oroethylene (PCE) is used primarily as a dry-cleaning and textile-processing solvent. It is also used as a metal-cleaning solvent.16 PCE is produced domestically by three processes. Two of the processes involve the chlorination and oxychlorination of EDC or other chlorinated hydrocarbons having two carbon atoms. PCE and trichloroethylene (TCE) are manufactured separately or as coproducts by the chlorination or oxychlorination process with the raw material ratios determining the proportions of PCE and 01 TCE. PCE is also manufactured as a coproduct with carbon tetrachloride by the chlorinolysis of hydrocarbons such as propane and propylene. 24 PCE was once manufactured predominantly by the chlorination of acetylene. However, as acetylene production declined, EDC chlorination and hydrocarbon chlorinolysis became the preferred methods of production. The last acetylene-based PCE plant was shut down in late 1977. 25 Process Descriptions Ethylene Dichloride Chlorination Process -- A discussion of the EDC direct-chlorination process for producing PCE and TCE Is presented in the subsection titled TRICHLOROETHYLENE PRODUCTION. Ethylene Dichloride Oxychlorination Process -- A discussion of the EDC oxychlorination process for producing PCE and TCE is presented in the subsection titled TRICHLOROETHYLENE PRODUCTION. Hydrocarbon Chlorinolysis Process -- The major products of the hydrocarbon chlorinolysis process are PCE, carbon tetrachloride, and hydrogen chloride (HC1). Basic operations that may be used in this process are shown in Figure 10. Preheated hydrocarbon feed material (Stream 1) and chlorine (Stream 2) are fed to a chlorinolysis reactor, which is a fluid-bed reactor maintained at about 50QC.^ The reaction products, consisting of carbon tetrachloride, PCE, HC1, and chlorinated hydrocarbon byproducts, (Stream 3) pass through a cyclone for removal of entrained catalyst and then on to a condenser. Uncondensed materials (Stream 4), consisting of hydrogen chloride, unreacted chlorine, and some 43 CMA. 051479 CATALYST CHLORINE mixed yy FEED <> CHLORMOLYSIS REACTOR CARBON TETRACHLORIDE FROM METHANOL HY DROCHLOR tNATION AND METHYLCHLOAIDE --FF** CHLORINATION PROCESS HCI d Cl? REMOVAL COLUMN 1 CRUDE storage CARBON tetrachloride DISTILL AT ION\ CARBON TETRACHLORIDE STORAGE jeS* jt [_f===* r Hg0 <8> (?& STABILIZER f HLTrT^i Te 1 Yheawes to LOADING DISPOSAL RCE DISTILLATION PCE STORAGE IIOTHER SOURCES Ji CAUSTIC CAUSTIC SCRUBBER CHLORINE ABSORPTION COLUMN T HCI ABSORBER BY-PRODUCT HCI STORAGE NOTE: The nuabers In this figure refer to process streams, 'as discussed In the text, and the tetters designate process vents. The heavy lines represent final product streams through the process. CMA 051480 Figure 10. Basic operations that may be used for the production of perchloroethylene by hydrocarbon chiorinolysis. 1^ NOTE: The mabers I* this figure refer to process stream, ts discussed In the test, end the letters designate process vents. The heavy lines represent final product stream through the process. Figure 10. Basic operations that may be used for the production of perchloroethylene by hydrocarbon chlorinolysis. ^ CMA 051481 carbon tetrachloride, are removed to the hydrogen chloride purification system. The condensed material (Stream 5) is fed to a hydrogen chloride and chlorine removal column, with the overheads (Stream 6) from this column going to hydrogen chloride purification. The bottoms (Stream 7) from the column are fed to a crude storage tank. Material from crude storage is fed to a distillation column, which recovers carbon tetra chloride as overheads (Stream 8). The bottoms (Stream 10) from the carbon tetrachloride distillation column are fed to a PCE distillation column. The overheads (Stream 11) from the PCE distillation column are taken to PCE storage and loading, and the bottoms are incinerated. 24 These bottoms, called "hex wastes", may be processed further or heated to recover more volatilizable materials, with the resulting tars sent to disposal, often by incineration. This additional step recovers 80 to 90 percent of the bottoms.^ The feed streams (Streams 4 and 6) to hydrogen chloride purification are compressed, cooled, and scrubbed in a chlorine absorption column with chilled carbon tetrachloride (Stream 9) to remove chlorine. The bottoms and condensable overheads (Stream 12) from this column are combined and recycled to the chlorlnolysis reactor. Uncondensed overheads (Stream 13) from the chlorine absorption column are contacted with water to produce a hydrochloric acid solution. This solution is stored for eventual reprocessing and use in a separate facility. Overheads from the absorber and vented gases from byproduct hydrochloric acid storage are combined (Stream 14) and passed through a caustic scrubber for removal of residual hydrogen chloride. Inert gases are vented from the scrubber. 24 Emissions Potential emission sources for the EDC chlorination and oxychlorination processes are shown in Figures 8 and 9, respectively, and discussed in the TRICHLOROETHYLENE PRODUCTION subsection. It is estimated that 910 Mg of EDC were released to the atmosphere from the PCE production 45 CM&. 05lA82 process in 1977. The majority of these emissions were from EDC oxychlorination and chlorination. The total domestic production of PCE in 1977 was 279,000 Mg, of which 65 percent of PCE production was from EDC. 26 Thus, the nationwide emissions estimate corresponds to a controlled EDC emission factor for EDC chlorination and oxychlorination of about 5.0 kg of EDC per Mg of PCE produced. Data are not available on the derivation of the nationwide annual EDC emissions estimate, nor are sufficient data available to break down EDC emissions between specific emission points. One reference states that EDC emissions for the process as a whole are practically zero when the volatiles are recovered from the hex wastes 2 and since EDC conversion is 100 percent in the reactor. Potential emission sources for the hydrocarbon chlorinolysis process are shown in Figure 10. Since EDC is not used as a feedstock in this process, as it is in the EDC chlorination and oxychlorination processes, the only emissions of EDC can result from the handling and disposal of hex wastes from the PCE distillation column (Source A in Figure 10). The EDC is produced in the chlorinolysis reaction. The uncontrolled EDC emission factor for the hex waste handling is about 0.026 kg of EDC per Mg of PCE and carbon tetrachloride produced. 27 Hex wastes may be processed further or heated to recover more volatilizable materials, with the resulting tars sent to disposal. This additional step recovers 80 to 90 percent of the bottoms,^ and the EDC 2 emissions from the dumping of the hex wastes are essentially zero. Alternatively, a vapor-balance system and refrigerated condenser have been used to control emissions from hex wastes with an emission reduction of approximately 99 percent. 28 Thus, the controlled EDC emission factor for the secondary emissions is 0.00026 kg of EDC per Mg of PCE and carbon tetrachloride produced. These EDC emission factors were developed for a hypothetical plant with the capacity to produce 50,000 Mg/yr PCE 29 and 30,000 Mg/yr carbon tetrachloride operating 8760 hours per year. PCE production plants may vary in configuration and level of control. The reader is encouraged to contact plant personnel to confirm the existence of emitting operations and control technology at a particular facility prior to estimating emissions therefrom. 46 CMA. 051483 process in 1977. 26 The majority of these emissions were from EDC oxychlori nation and chlorination. The total domestic production of PCE in 1977 was 279,000 Mg, of which 65 percent of PCE production was from EDC. 26 Thus, the nationwide emissions estimate corresponds to a controlled EDC emission factor for EDC chlorination and oxychlorination of about 5.0 kg of EDC per Mg of PCE produced. Data are not available on the derivation of the nationwide annual EDC emissions estimate, nor are sufficient data available to break down EDC emissions between specific emission points. One reference states that EDC emissions for the process as a whole are practically zero when the volatiles are recovered from the hex wastes 2 and since EDC conversion Is 100 percent in the reactor. Potential emission sources for the hydrocarbon chlorlnolysis process are shown In Figure 10. Since EDC is not used as a feedstock in this process, as It is in the EDC chlorination and oxychlorination processes, the only emissions of EDC can result from the handling and disposal of hex wastes from the PCE distillation column (Source A in Figure 10). The EDC is produced in the chlorinolysis reaction. The uncontrolled EDC emission factor for the hex waste handling Is about 0.026 kg of EDC per Mg of PCE and carbon tetrachloride produced. 27 Hex wastes may be processed further or heated to recover more volatilizable materials, with the resulting tars sent to disposal. This additional step recovers 80 to 90 percent of the bottoms,^ and the EDC 2 emissions from the dumping of the hex wastes are essentially zero. Alternatively, a vapor-balance system and refrigerated condenser have been used to control emissions from hex wastes with an emission reduction of approximately 99 percent. 28 Thus, the controlled EDC emission factor for the secondary emissions is 0.00026 kg of EDC per Mg of PCE and carbon tetrachloride produced. These EDC emission factors were developed for a hypothetical plant with the capacity to produce 50,000 Mg/yr PCE and 30,000 Mg/yr carbon tetrachloride operating 8760 hours per year. 29 PCE production plants may vary in configuration and level of control. The reader is encouraged to contact plant personnel to confirm the existence of emitting operations and control technology at a particular facility prior to estimating emissions therefrom. 46 CMA. 051484 Source Locations A list of perchloroethylene production facilities and locations is presented in Table 8. 47 CMA. 051485 TABLE 8. PRODUCTION OF PERCHLOROETHYLENE 2,5 Manufacturer Location Diamond Shamrock Corp. Indust. Chems. and Plastics Unit Electro Chems. Div. Dow Chem. U.S.A. E.I. duPont de Nemours & Co., Petrochems. Dept. Freon Products Div. PPG Indust., Inc. Indust. Chem. Div. Vulcan Materials Co. Vulcan Chems., Div. Deer Park, TX Pittsburg, CA Plaquemine, LA Corpus Christi, TX Lake Charles, LA Geismar, LA Wichita, KS Note: This listing is subject to change as market conditions change, facility ownership changes, plants are closed down, etc. The reader should verify the existence of particular facilities by consulting current listings and/or the plants themselves. The level of EDC emissions from any given facility is a function of variables such as capacity, throughput and control measures, and should be determined through direct contacts with plant personnel. 48 CMA. 051486 TABLE 8. PRODUCTION OF PERCHLOROETHYLENE2,5 Manufacturer Location Diamond Shamrock Corp. Indust. Chems. and Plastics Unit Electro Chems. Div. Dow Chem. U.S.A. E.I. duPont de Nemours & Co., Petrochems. Dept. Freon Products Div. PPG Indust., Inc. Indust. Chem. Div. Vulcan Materials Co. Vulcan Chems., Div. Deer Park, TX Pittsburg, CA Plaquemine, LA Corpus Christi, TX Lake Charles, LA Geismar, LA Wichita, KS Note: This listing is subject to change as market conditions change, facility ownership changes, plants are closed down, etc. The reader should verify the existence of particular facilities by consulting current listings and/or the plants themselves. The level of EDC emissions from any given facility is a function of variables such as capacity, throughput and control measures, and should be determined through direct contacts with plant personnel. 48 CMA. 051487 VINYLI DENE CHLORIDE PRODUCTION Process Description Vinylidene chloride, or 1,1-dichloroethene, is used primarily in the production of polyvinylidene copolymers such as Saran and some modacrylic fibers.^ It is manufactured domestically by a two step process as shown in Figure 11. The first step involves the chlorination or oxychlorination of EDC to produce 1,1,2-trichloroethane. The second step is dehydrochlorination of 1,1,2-trichloroethane to produce vinylidene chloride. Little data are available on the specific steps used in the production of 1,1,2-trichloroethane; however the process used to produce vinylidene chloride from 1,1,2-trichloroethane is described extensively in published literature. 30 Most 1,1,2-trichloroethane is made by chlorination of EDC. The reaction is carried out in the liquid phase at 120C and 345 kPa. The major products are hydrogen chloride (HC1) and 1,1,2-trichloroethane. Where 1,1,2-trichloroethane is made by oxychlorination the reactants are EDC, HC1, and oxygen. Reaction conditions vary from one process to another. Water and 1,1,2-trichloroethane are the major products of this reaction. 31 After 1,1,2-trichloroethane is produced, it is dehydrochlorinated with aqueous sodium hydroxide at about 70C. Major products of the reaction are vinylidene chloride, sodium chloride, and water. Emissions The primary source of emissions from the EDC chlorination process are the waste streams from the HC1 scrubber. Waste water streams may contain chlorine, HC1, spent caustic, and various chlorohydrocarbons, including EDC, trichloroethane and reaction byproducts. Hydrogen chloride and a number of organic chlorides are probably present in the waste gas. 31 Emissions from the EDC oxychlorination process originate from waste water and vent gases from the separator which contain a number of chloro hydrocarbons, including EDC, trichloroethane, and byproducts. Scrubbing of the crude product to remove unreacted acid is another source of waste water which may contain EDC.^ 49 CMA. 05X488 EOC Cl: CHLORINAT. REACTOR 1,1,2-TRICHLOROETHANE PRODUCT PURIFICATION MCI RECYCLE NoOH SOLUTION RECYCLE I A fSTORAGE 1 VINYLIDENE^XN. PRODUCT CHLORIOE aiRIFICATIO PHASE SEPARATION TO USERS atOcn OXYCHLORI. 1,1,2-TRICHLORO ETHANE _ PRODUCT STORAGE DEHYDROCHLORINATION REACTOR T1 WASTEWATER omitL REACTOR PURIFICATION ' HCI SOLUTION RECYCLE NOTE: The heavy lines represent final product streams through the process. CMA. 051489 Figure 11 Basic operations that may be used for the production of vinylidene chloride. EDC Clj CHLORINAT. REACTOR 1,1,2 -TRICHLOROETHANE PRODUCT PURIFICATION -HCI RECYCLE NaOH SOLUTION RECYCLE f a(b) STORAGE 1 VINYLIDENE^\ PRODUCT CHLORIOE FURIFICATlOh PHASE SEPARATION TO USERS STORAGE DEHYDROCHLORINATION Ul fo 1,1,2-TRtCHLOROETHANE _ REACTOR WASTEWATER OXYCHLORI. PRODUCT oxysen REACTOR WJRIFICATION MCI SOLUTION RECYCLE NOTE: The hewy Hut represent MmI product strews through the process. Figure 11 Basic operations that may be used for the production of vinylidene chloride.30.31 o Ul vot>^ Potential sources of F.DC emissions for the dehydrochlorination of 1,1,2-trichloroethane are the dehydrochlorination reactor purge vent (Ain Figure 11) and the distillation column vents (B), which release noncondensable gases- Secondary EDC emissions can occur from desorption of VOCs during wastewater treatment.^ It is estimated that 600,000 kg of EDC were released to the atmosphere from the production of vinylidene chloride in 1977. 32 The total U.S. production of vinylidene chloride in 1977 was estimated at 105,000 Mg. 32 From these values, the controlled EDC emission factor for vinylidene chloride production is calculated to be 5.7 kg of EDC per Mg of vinylidene chloride produced. Data are not availabe on the derivation of the annual EDC emissions estimate for vinylidene chloride production, nor are sufficient data available to break down EDC emissions between specific emission points. Vinylidene chloride production plants may vary in configuration and level of control. The reader is encouraged to contact plant personnel to confirm the existence of emitting operations and control technology at a particular facility prior to estimating emissions therefrom. Source Locations Major vinylidene chloride production facilities and their locations 5 are listed below. Dow Chemicals U.S.A. Freeport, TX Plaquemine, LA PPG Industries, Inc. Industrial Chemicals Div. Lake Charles, LA This listing is subject to change as market conditions change, facility ownership changes, plants are closed down, etc. The reader should verify the existence of particular facilities by consulting current listings and/or the plants themselves. The level of EDC emissions from any given facility is a function of variables such as capacity, throughput and control measures, and should be determined through direct contacts with plant personnel. 51 CMA. 05149% ETHYL CHLORIDE PRODUCTION About 90 to 95 percent of ethyl chloride produced domestically is manufactured by the hydrochlorination of ethylene. This reaction takes place in the presence of EDC and a catalyst such as aluminum chloride. Ethyl chloride is also produced by the thermal chlorination of ethane or by a combination of ethane chlorination and ethylene hydrochlorination. EDC is a by-product of ethyl chloride production by both of these processes. 33 Process Description Basic operations that may be used in the production of ethyl chloride by the hydrochlorination of ethylene are presented in Figure 12. Ethylene gas and hydrogen chloride are mixed in equimolar proportions before being fed to a reactor which contains EDC or a mixture of EDC and ethyl chloride. Hydro chlorination of ethylene occurs in the presence of an aluminum chloride catalyst. The gaseous reaction products are charged to a separation column or flash drum to remove heavy polymer bottoms and then to a fractionation column for final product purification. 34 Emissions There is little information available in the published literature on EDC emissions from ethyl chloride production. Emissions may occur from process air vents. EDC emissions from ethyl chloride production via ethylene hydrochlorination were estimated to be 2313 x 103 kg in 1978. 35 From this total emission estimate and the level of ethyl chloride production for 1978 (244,800 Mg), the EDC emission factor for ethyl chloride production was calculated to be 9.45 kg/Mg. Ethyl chloride production plants may vary in configuration and level of control. The reader is encouraged to contact plant personnel to confirm the existence of emitting operations and control technology at a particular facility prior to estimating emissions therefrom. Source Locations Major ethyl chloride producers and locations are listed in Table 9. 52 CMA. 051492 ETHYL CHLORIDE PRODUCTION About 90 to 95 percent of ethyl chloride produced domestically is manufactured by the hydrochlorination of ethylene. This reaction takes place in the presence of EDC and a catalyst such as aluminum chloride. Ethyl chloride is also produced by the thermal chlorination of ethane or by a combination of ethane chlorination and ethylene hydrochlorination. EDC is a by-product of ethyl chloride production by both of these processes. 33 Process Description Basic operations that may be used in the production of ethyl chloride by the hydrochlorination of ethylene are presented in Figure 12. Ethylene gas and hydrogen chloride are mixed in equimolar proportions before being fed to a reactor which contains EDC or a mixture of EDC and ethyl chloride. Hydro chlorination of ethylene occurs in the presence of an aluminum chloride catalyst. The gaseous reaction products are charged to a separation column or flash drum to remove heavy polymer bottoms and then to a fractionation column for final product purification. 34 Emissions There is little information available in the published literature on EDC emissions from ethyl chloride production. Emissions may occur from process air vents. EDC emissions from ethyl chloride production via ethylene hydrochlorination were estimated to be 2313 x 103 kg In 1978. 35 From this total emission estimate and the level of ethyl chloride production for 1978 {244,800 Mg), the EDC emission factor for ethyl chloride production was calculated to be 9.45 kg/Mg. Ethyl chloride production plants may vary in configuration and level of control. The reader is encouraged to contact plant personnel to confirm the existence of emitting operations and control technology at a particular facility prior to estimating emissions therefrom. Source Locations Major ethyl'chloride producers and locations are listed in Table 9. 52 CMA 051493 MIXER REACTOR ALUMINUM SEPARATOR FRACTIONATING COLUMN ETHYL CHLORIDE cCnO CATALYST BOTTOMS WASTE CMA 051494 Figure 12. Basic operations that may be used in the production of ethyl chloride by ethlene hydrochlorination.34 TABLE 9. PRODUCTION OF ETHYL CHLORIDE5 Manufacturer Location Process Dow Chem. U.S.A. E.I. duPont de Nemours & Co., Inc. Petrochems. Dept. Freon1 Products Div. Ethyl Corp. Chems. Group Hercules Inc. Operations Div. PPG Indust., Inc. Indust. Chem. Div. Freeport, TX Deepwater, NJ Pasadena, TX Hopewell, VA Lake Charles, LA Hydrochlorination of ethylene Hydrochlorination of ethylene Hydrochlorination of ethylene Hydrochlorination of ethylene Hydrochlorination of ethylene Note: This listing is subject to change as market conditions change, facility ownership changes, plants are closed down, etc. The reader should verify the existence of particular facilities by consulting current listings and/or the plants themselves. The level of EDC emissions from any given facility is a function of variables such as capacity, through put and control measures, and should be determined through direct contacts with plant personnel. CMA. 051495 TABLE 9. PRODUCTION OF ETHYL CHLORIDE5 Manufacturer Location Process Dow Chem. U.S.A. E.I. duPont de Nemours & Co.,' Inc. Petrochems. Dept. Freon Products Div. Ethyl Corp. Chems. Group Hercules Inc. Operations Div. PPG Indust., Inc. Indust. Chem. Div. Freeport, TX Deepwater, NJ Pasadena, TX Hopewell, VA Lake Charles, LA Hydrochlorination of ethylene Hydrochlorination of ethylene Hydrochlorination of ethylene Hydrochlorination of ethylene Hydrochlorination of ethylene Note: This listing is subject to change as market conditions change, facility ownership changes, plants are closed down, etc. The reader should verify the existence of particular facilities by consulting current listings and/or the plants themselves. The level of EDC emissions from any given facility is a function of variables such as capacity, through put and control measures, and should be determined through direct contacts with plant personnel. <o Oi POLYSULFIDE RUBBER PRODUCTION Process Description Polysulfide rubber is a synthetic rubber polymer which is used in the manufacture of caulking putties, cements, sealants, and rocket-fuel. It is produced by the reaction between aliphatic halides, such as EDC, and alkali polysulfides such as Na,S,. The main products of the reaction * ^ 37 are the polysulfide rubber chain, (CHgCHg-S^, and sodium chloride. Emissions Based on yields for similar industrial chemical reactions it has been estimated that 94 percent of the EDC used during the manufacturing of polysufide rubber becomes incorporated in the end product. 37 It is estimated that 5 percent of the EDC used in the process is released to the atmosphere via leaks, spills and fugitive emissions associated with the overall polysulfide manufacturing process. The remaining 1 percent of EDC remains dissolved in the mother liquor from which the polymer is produced. The mother liquor may be discharged as solid waste and stored in landfills."^ From the stoichiometry of the polysulfide production reaction and the percentages of EDC consumed and emitted, 37 the average controlled EDC emission factor for polysulfide rubber manufacture is 33.8 kg of EDC per Mg of polysulfide rubber produced. Source Locations The Specialty Chemicals Division of Morton Thikol Incorporated in Moss Point, Mississippi is currently listed as the only producer of polysulfide rubber by the SRI Directory of Chemical Producers for 1983.^ This information is subject to change as market conditions change, facility ownership changes, plants are closed down, etc. The reader should verify the existence of this or other facilities by consulting current listings and/or the plants themselves. The level of EDC emissions from any given facility is a function of variables such as capacity, throughput and control measures, and should be determined through direct contacts with plant personnel. 55 CMA 051497 LIQUID PESTICIDE FORMULATION Ethylene dichloride is used in a number of liquid pesticide formulations. These formulations generally are mixtures of EDC and other active ingredients such as carbon tetrachloride and carbon disulfide. 38 Process Description Pesticide formulation systems are typically batch mixing operations. A typical liquid pesticide formulation unit is presented in Figure 13. Technical grade pesticide is usually stored in its original shipping container in the warehouse section of the plant until it is needed. If the material is received in bulk, it is transferred to holding tanks for storage. Solvents are normally stored in bulk tanks. Batch mixing tanks are typically closed vessels. The components of the formulation are fed into the tank, measured by weight, and mixed by circulation with a tank pump. The formulated material is then pumped to a holding tank before being put into containers for shipment. The blend tank is vented to the atmosphere through a vent dryer, which 2 prevents moisture from entering the tank. Storage and holding tanks and container-filling lines may be provided with an exhaust connection or hood to remove any vapors. The exhaust from the system may be vented to a control device or directly to the atmosphere. 39 Emissions Sources of EDC emissions from pesticide formulation include storage vessels, mixing vessel vents, and leaks from pumps, valves, and flanges. Insufficient information is available for the development of EDC emission factors for liquid pesticide formulation facilities. Source Locations Registrants and applicants for registration of pesticide products containing EDC are listed in Table 10. Some of the listed companies may buy a preformulated or prepackaged product from larger producers and therefore, may not be actual sources of emissions. In addition, this list may change as facility ownership changes or plants are closed down. 56 CMA. 051498 LIQUID PESTICIDE FORMULATION Ethylene dichloride is used in a number of liquid pesticide formulations. These formulations generally are mixtures of EDC and other active ingredients such as carbon tetrachloride and carbon disulfide. 38 Process Description Pesticide formulation systems are typically batch mixing operations. A typical liquid pesticide formulation unit is presented in Figure 13. Technical grade pesticide Is usually stored in its original shipping container in the warehouse section of the plant until it is needed. If the material is received in bulk, it Is transferred to holding tanks for storage. Solvents are normally stored in bulk tanks. Batch mixing tanks are typically closed vessels. The components of the formulation are fed into the tank, measured by weight, and mixed by circulation with a tank pump. The formulated material is then pumped to a holding tank before being put into containers for shipment. The blend tank is vented to the atmosphere through a vent dryer, which 2 prevents moisture from entering the tank. Storage and holding tanks and container-filling lines may be provided with an exhaust connection or hood to remove any vapors. The exhaust from the system may be vented to a control device or directly to the atmosphere. 39 Emissions Sources of EDC emissions from pesticide formulation include storage vessels, mixing vessel vents, and leaks from pumps, valves, and flanges. Insufficient information is available for the development of EDC emission factors for liquid pesticide formulation facilities. Source Locations Registrants and applicants for registration of pesticide products containing EDC are listed in Table 10. Some of the listed companies may buy a preformulated or prepackaged product from larger producers and therefore, may not be actual sources of emissions. In addition, this list may change as facility ownership changes or plants are closed down. 56 CM* 051499 (J1 fUMf Figure 13. Basic operations that may be used for liquid pesticide formulation.^ CMA. 051500 tar. r in COMPANIES WHICH HOLD REGISTRATIONS ON PESTICIDE hdll iu. FORMULATIONS CONTAINING ETHYLENE DICHLORIDE40 Company Location Southland Pearson & Co. Mobile, AL Vulcan Materials Co. Birmingham, AL Cardinal Chemical Co. San Francisco, CA Cooke Laboratory Products Commerce, CA Coyne Chemical Co. Los Angeles, CA Dexol Industries Torrance, CA Hacienda Enterprises San Jose, CA Hockwaldchem, Division of Oxford Chemicals Brisbane, CA James Chem Co. San Francisco, CA Master Nurseymens Assn. Concord, CA Dettelbach Chemicals Corp. Atlanta, GA Hill Manufacturing, Inc. Atlanta, GA Lester Laboratories Atlanta, GA Oxford Chemicals Atlanta, GA The Selig Chemical Industries Atlanta, GA Stephenson Chemical Co., Inc. __ College Park, GA Wool folk Chemical Works, Inc. Ft. Valley, GA Riverdale Chemical Co. Chicago Heights, IL Carmel Chemical Corp. Westfield, IN Brayton Chemicals, Inc. West Burlington, IA Industrial Fumigant Co. Olathe, KS Research Products Co. Salina, KS Central Chemical Corp. Hagerstown, MD Dow Chemical USA Midland, MIa (CONTINUED) 58 CMA 051501 tarif in COMPANIES WHICH HOLD REGISTRATIONS ON PESTICIDE IHBUt iUl FORMULATIONS CONTAINING ETHYLENE DICHLORIDE40 Company Location Southland Pearson & Co. Mobile, AL Vulcan Materials Co. Birmingham, AL Cardinal Chemical Co. San Francisco, CA Cooke Laboratory Products Commerce, CA Coyne Chemical Co. Los Angeles, CA Dexol Industries Torrance, CA Hacienda Enterprises San Jose, CA Hockwaldchem, Division of Oxford Chemicals Brisbane, CA James Chem Co. San Francisco, CA Master Nurseymens Assn. Concord, CA Dettelbach Chemicals Corp. Atlanta, GA Hill Manufacturing, Inc. Atlanta, GA Lester Laboratories Atlanta, GA Oxford Chemicals Atlanta, GA The Selig Chemical Industries Atlanta, GA Stephenson Chemical Co., Inc. _ College Park, GA Wool folk Chemical Works, Inc. Ft. Valley, GA Riverdale Chemical Co. Chicago Heights, IL Carmel Chemical Corp. Westfield, IN Brayton Chemicals, Inc. West Burlington, IA Industrial Fumigant Co. Olathe, KS Research Products Co. Salina, KS Central Chemical Corp. Hagerstown, MD Dow Chemical USA Midland, MIa (CONTINUED) 58 CMA. 051502 TABLE 10. (continued) Company Location Haertel Walter Co. E.H. Leitte Co. The Agriculture & Nutrition Co. Bartels & Shores Chemical Co. Farmland Industries, Inc. Ferguson Fumigants The Huge Co., Inc. Knox Chemical Co. Patterson Chemical Co., Inc. PBI-Gordon Corp. Stewart Sanitary Supply Co., Ltd. Falls Chemicals, Inc. Ling Fuang Industries, Inc. Rochester Midland Corp. Prentis Drug & Chemical Co., Inc Bernard Sirotta Co., Inc. Big F Insecticides, Inc. Weil Chemicals Co. J-Chem, A Division of Fumigators, Inc. The Staffel Co. Voluntary Purchasing Group, Inc. Atomic Chemical Co. Chemical Formulators, Inc. (CONTINUED) 59 Minneapolis, MN Stillwater, MN Kansas City, KS Kansas City, MO Kansas City, MO Hazelwood, MO St. Louis, MO St. Louis, MO Kansas City, MO Kansas City, MO St. Louis, MO Great Falls, MT Gardnerville, NV Rochester, NY New York, NY ' 'Brooklyn, NY Memphis, TN Memphis, TN Houston, TX San Antonio, TX Bonham, TX Spokane, WA Nitro, WV CMA 051503 TABLE 10. (continued) Note: The companies listed are registrants of pesticidal products contain ing EDC. Some of these companies may buy a preformulated or prepackaged product and, therefore may not be actual sources of emissions. In addition, the list is subject to change as market conditions change, facility ownership changes, or plants are closed down. The reader should verify the existence of particular facilities by consulting current listings or the plants themselves. The level of emissions from any given facility is a function of variables, such as throughput and control measures, and should be determined through direct contacts with plant personnel. 60 CMA 051504 TABLE 10. (continued) Note: The companies listed are registrants of pesticidal products contain ing EDC. Some of these companies may buy a preformulated or prepackaged product and, therefore may not be actual sources of emissions. In addition, the list is subject to change as market conditions change, facility ownership changes, or plants are closed down. The reader should verify the existence of particular facilities by consulting current listings or the plants themselves. The level of emissions from any given facility is a function of' variables, such as throughput and control measures, and should be determined through direct contacts with plant personnel. 60 CMA 051505 USE OF ETHYLENE DICHLORIDE IN GRAIN FUMIGATION Ethylene dichloride is used as a component of fumigant mixtures that are applied to control insect infestations in grains during storage, transfer, milling, distribution and processing. Ethylene dichloride comprises 7.1 percent of the total weight of fumigant active ingredients applied to stored grain. Annual usage of EDO in grain fumigants ranged from 870 to 1570 Mg/yr during the period from 1976 to 1979.^ Due to its flammability, EDC is used in fumigant mixtures with carbon tetrachloride, which decreases the fire and/or explosion hazard of the mixture. A product containing three parts EDC to one part carbon tetrachloride has been used widely. Other grain fumigant formulations containing EDC are: o Ethylene dichloride 64.6 percent, carbon tetrachloride 27.4 percent, ethylene dibromide 5.0 percent o Ethylene dichloride 10.0 percent, carbon tetrachloride 76.5 percent, ethylene dibromide 3.5 percent, carbon disulfide 10.0 percent o Ethylene dichloride 29.2 percent, carbon tetrachloride 63.6 percent, ethylene dibromide 7.2 percent o Ethylene dichloride 64.7 percent, carbon tetrachloride 27.4 percent, ethylene dibromide 7.9 percent o Ethylene dichloride 12.0 percent* carbon tetrachloride 83.8 percent, ethylene dibromide 1.2 percent.38 Table 11 lists brand names of pesticide products containing EDC. Process Description Liquid grain fumigants are used on approximately 12 percent of the grain grown in the United States. Fumigants are used during binning (placement in storage) and turning (shifting from one storage facility to another) operations or at any time during storage when infestation occurs. Fumigants have a period of effectiveness of only a few days. Thus, they kill existing insect populations but do not prevent later reinfestation. Newly harvested grain typically is fumigated 6 weeks after binning. Corn grown in the southern regions of the U.S. usually is fumigated immediately following binning, because of field infestation by weevils. 41 61 CMA 051506 TABLE 11. ETHYLENE DICHLORIDE PESTICIDE BRAND NAMES40 Big F "LGF" Liquid Gas Fumigant Best 4 Servis Brand 75-25 Standard Fumigant Brayton 75-25 Grain Fumigant Brayton Flour Equipment Fumigant for Bakeries Brayton EB-5 Grain Fumigant Bug Devil Fumigant Cardinal Fume Chemform Brand Bcre-Kill Cooke Kill-Bore Co-op New Activated Weevil Killer Fumigant Crest 15 Grain Fumigant De-Pester Weevil Kill De-Pester Grain Conditioner and Weevil Killer Diweevil Dowfume EB-15 Inhibited Dowfume 75 Dowfume EB-5 Effective Grain Fumigant Dowfume F Dowfume EB-59 Dynafume Excelcide Excel fume FC-7 Grain Fumigant (CONTINUED) 62 CMA. 051507 TABLE 11. ETHYLENE DICHLORIDE PESTICIDE BRAND NAMES 40 Big F "LGF" Liquid Gas Fumigant Best 4 Servis Brand 75-25 Standard Fumigant Brayton 75-25 Grain Fumigant Brayton Flour Equipment Fumigant for Bakeries Brayton EB-5 Grain Fumigant Bug Devil Fumigant Cardinal Fume Chemform Brand Bcre-Kill Cooke Kill-Bore Co-op New Activated Weevil Killer Fumigant Crest 15 Grain Fumigant De-Pester Weevil Kill De-Pester Grain Conditioner and Weevil Killer Diweevil Dowfume EE-15 Inhibited Dowfume 75 Dowfume EB-5 Effective Grain Fumigant Dowfume F Dowfume EB-59 Dynafume Excelcide Excel fume FC-7 Grain Fumigant (CONTINUED) 62 CMA 051508 TABLE 11. (continued) FC-13 Mill Machinery Fumigant Formula MU-39 Formula 635 (FC-2) Grain Fumigant Fume-O-Death Gas Nc. 3 Fumisol Gas-o-cide Grain Fumigant (Dettelbach Chemicals) Grainfume MB Hill's Hi 1 cofume 75 Hydrochlor Fumigant Hydrochlor GF Liquid Gas Fumigant Infuco 50-50 Spot Fumigant Infuco Fumigant 75 Iso-Fume J-Fume-20 J-Fume-75 KLX Koppersol Leitte Spotfume 60 Max Spot Kill Machinery Fumigant Max Kill 75-25 Max Kill Spot - 59 Spot Fumigant for Mills and Milling Machinery Parson Lethogas Fumigant Patterson's Weevil Killer (CONTINUED) 63 CMA 051509 TABLE 11. (continued) Pearson's Fumigrain P-75 Pioneer Brand Grain Fumigant Riverdale Fumigant Security Di-Chlor-Mulsion Selig's Selcofume Selig's Grain Fumigant No. 15 Selig's Grain Storage Fumigant Serfume Sirotta's Sircofume Liquid Fumigating Gas Spray-Trol Brand Insecticide Fumi-Trol Spot Fumigant Standard 75-25 Fumigant Staffel's Boraway Stephenson Chemicals Stored Grain Fumigant Vulcan Formula 635 (FC-2) Grain Fumigant Vulcan Formula 72 Grain Fumigant Waco-50 914 Weevil Killer and Grain Conditioner 64 CMA 051510 TABLE 11. (continued) Pearson's Fumigrain P-75 Pioneer Brand Grain Fumigant Riverdale Fumigant Security Di-Chlor-Mul$ion Selig's Selcofume Selig's Grain Fumigant No. 15 Selig's Grain Storage Fumigant Serfume Sirotta's Sircofume Liquid Fumigating Gas Spray-Trol Brand Insecticide Fuml-Trol Spot Fumigant Standard 75-25 Fumigant Staffel's Boraway Stephenson Chemicals Stored Grain Fumigant Vulcan Formula 635 (FC-2) Grain Fumigant Vulcan Formula 72 Grain Fumigant Waco-50 914 Weevil Killer and Grain Conditioner 64 CMA 051511 A variety of structures are used for grain storage. Farm grain storage facilities are mostly metal with some wooden bins of flat, older and loosefitting construction. Country elevators are of two types: small banked concrete silos and flat storages. At mills, banked silos are predominant. Terminal elevators are banked silos. Grain transportation vehicles include trucks, rail cars (box, freight, hopper), inland barges, ocean barges and ships. Subterminal and terminal elevators and shipholds are usually almost air tight, while farm grain storage facilities generally allow considerable air flow.38'41 On-farm facilities typically have a capacity of about 3,000 bushels, while country elevators have a capacity of about 300,000 bushels Terminal elevators have an average capacity of 4 million bushels. 42 Grain fumigants are applied primarily by the "gravity distribution" method by either surface application or layering. This method is practiced both on-farm and off-farm. A second method of fumigant application is "outside of car" application, where the fumigant is either poured from one or five gallon containers through vents located in the roof of the car or sprayed into the car with a power sprayer. 43 Equipment used to apply fumigants includes common garden sprinkling cans with spray heads removed; 3 to 5 gallon capacity compressed air sprayers from which the nozzles have been removed; high capacity motor driven pumps which apply large volumes of liquid materials directly from large drums; metering devices which treat streams of moving grain; and distribution tube and pressure reduction valve systems for discharging of liquids stored under pressure. 41 The rate of application of fumigants is dependent on the type of grain and the type of storage facility. Table 12 presents general application rates for various types of grain for both on-farm and off-farm storage. The application rates for off-farm storage are lower since these types of facilities are typically more tight-fitting than on-farm storage. 38 After application of fumigants, grain generally is left undisturbed for at least 72 hours. The usual practice is to leave the grain for a much longer period. Fumigants are often left on the grain until the normal turning procedure is undertaken. Alternatively, the grain may be aerated by 65 CMA. 051512 TABLE 12. FUMIGANT APPLICATION RATES38 Grain Wheat Corn Rice, Oats, Barley, Rye Grain sorghum Application rate (qal/103 bu) On-farm Off-farm 3-4 4-5 3-4 5-6 2-3 3-4 2-3 4-5 66 CMA. 051513 TABLE 12. FUMIGANT APPLICATION RATES 38 Grain Application rate (oal/103 bu) On-farm Off-farm Wheat Corn Rice, Oats, Barley, Rye Grain sorghum 3-4 4-5 3-4 5-6 2-3 3-4 2-3 4-5 66 CMA 051514 turning after completion of the required treatment period. In tight-fitting facilities equipped with recirculation or forced distribution blowers, the fumigant is ventilated from the grain with fresh air by operating the blowers for 3 to 4 hours. 41 Emissions Emissions of EDC from fumigant mixtures occur during fumigant application and when fumigated grain is exposed to the atmosphere, for instance, during turning or loading. The rate of emissions of EDC from fumigant use depends on a number of factors including the type of grain, the type and concentration of fumigant applied, the type of storage (whether loose or tight-fitting), the manner in which the grain is handled, and the rate of release of fumigant residues in and on the grain. Although high sorption efficiencies (84 percent) have been reported for certain cereals, it is generally concluded that by the time the grain is processed, essentially all of the retained EDC will have been dissipated to the atmosphere. 44 Source Locations The Standard Industrial Classification (SIC) code for farms at which grain may be stored are as follows: 0111 - Agricultural production of wheat 0112 - Agricultural production of rice 0115 - Agricultural production of corn 0116 - Agricultural production of soybeans 0119 - Agricultural production of other grains 0191 - General farms Table 13 lists the on-farm grain storage capacity by state and the percentage of total U.S. capacity by region. SIC codes for off-farm storage facilities, are as follows: 4221 - Grain elevators, storage only 5153 - Wholesale grain merchants (Includes country and terminal elevators and other merchants marketing grain) 4463 - Marine cargo handling (includes terminal elevators) 67 CMA 051515 Region and State Northeast: Ma i ne New Hampshire Vermont Massachusetts Rhode Island Connecticut New York New Jersey Pennsylvania Delaware Maryland Lake States: Michigan Wiscons in Minnesota Corn Belt: Ohio Indiana Illinois Iowa Missouri Northern Plains: North Dakota South Dakota Nebraska Kansas Appalachian: Virginia West Virginia North Carolina Kentucky Tennessee Southeast: South Carolina Georgia Florida Alabama TABLE 13. ON-FARM GRAIN STORAGE 42 Capacity (103 bu) 142,698 2,866 0 0 9,654 0 222 39,204 5,190 62,498 2,057 21,007 1,357,597 116,462 244,827 996,338 2,982,755 225,279 429,981 947,208 1,071,203 309,084 2,132,264 681,397 394,381 715,594 340,892 236,607 37,554 5,685 100,938 49,237 43,193 159,132 31,437 87,720 12,145 27,830 CONTINUED 68 Regional percentage _Z% 17%----- 37% 26%---- 3% _2% CMA. 051516 0 00 1 Region and State Northeast: Maine New Hampshire Vermont Massachusetts Rhode Island Connecticut New York New Jersey Pennsylvania Delaware Maryland Lake States: Michigan Wisconsin Minnesota Corn Belt: Ohio Indiana Illinois Iowa Missouri Northern Plains: North Dakota South Dakota Nebraska Kansas Appalachian: Virginia West Virginia North Carolina Kentucky Tennessee Southeast: South Carolina Georgia Florida Alabama TABLE 13. ON-FARM GRAIN STORAGE 42 Capacity (103 bu) Regional percentage 142 t698 2,866 0 0 9,654 0 222 39,204 5,190 62,498 2,057 21,007 1,357.597 116,462 244,827 996,338 2,982,755 225,279 429,981 947,208 1,071,203 309,084 2,132.264 681,397 394,381 715,594 340,892 236,607 37,554 5,685 100,938 49,237 43,193 159,132 31,437 87,720 12,145 27,830 2% _________ m-- 37^ --80 26"---- Vi 2% CONTINUED 68 CMA. 051517 Region and State Delta States: Mississippi Arkansas Louisiana Southern Plains: Oklahoma Texas Mountain: Montana Idaho Wyoming Colorado New Mexico Arizona Utah Nevada Pacific: Washington Oregon California Total TABLE 13. (continued) Capacity (103 bu) 131,593 41,588 50,095 39,910 315,160 76,685 238,472 507,357 278,783 77,960 19,519 97,216 9,136 6,404 15,220 3,119 151,622 60,011 33,552 58,059 8,116,815 Regional percentage 1% 4% 6% 2% 100% 69 CMA 05151 Table 14 lists the number of off-farm grain storage facilities and the total capacity of these facilities by State. 70 CM& 051519 Table 14 lists the number of off-farm grain storage facilities and the total capacity of these facilities by State. 70 CMA. 051520 State Alabama Arizona Arkansas California Colorado Delaware Florida Georgia Idaho Illinois Indiana Iowa Kansas Kentucky Louisiana Maryland Michigan Minnesota Mississippi Missouri Montana Nebraska Nevada New Jersey New Mexico New York North Carolina North Dakota Ohio Oklahoma Oregon, Pennsylvania South Carolina South Dakota Tennessee Texas Utah Virginia Washington West Virginia Wisconsin Wyoming Other States Total TABLE 14. OFF-FARM GRAIN STORAGE 42 Number of facilities 37,290 33,890 179,180 115,710 91,500 17,200 6,070 56,700 64,070 775,260 245,550 635,000 830,000 49,580 87,010 36,940 90,240 366,440 76,350 204,140 54,000 484,600 300 2,200 17,550 70,270 63,420 140,070 228,800 203,520 65,530 26,900 33,470 83,820 43,180 720,350 17,170 29,920 186,370 530 118,920 5,580 5,170 6,600,030 71 Capacity (103 bu) 178 76 283 226 209 27 27 344 231 1,177 804 1,141 1,086 202 131 64 351 894 183 611 298 740 4 24 27 243 465 580 713 400 238 337 177 386 106 896 55 241 324 9 428 49 80 15,065 CMA. 051521 EDC USE IN LEADED GASOLINE General Ethylene dichloride is used in conjunction with ethylene dibromide (1,2-dibromoethane) as a lead scavenger in leaded gasoline. The addition of these compounds prevents the fouling of the engine combusion chamber with lead oxides. Ethylene dichloride and ethylene dibromide react with lead during combustion to form lead chloride (PbClg) and lead bromide (PbB^) which remain in the gas phase and are expelled with exhaust gases. About 1.0 mole of EDC and 0.5 mole of ethylene dibromide are added to gasoline per mole of alkyl lead added. 45 Current EPA regulations limit lead in gasoline to 0.29 grams (.0014 moles) per liter. 0 Thus, no more than 0.0014 moles or 0.14 grams of EDC are added per liter. Higher lead and EDC levels were added in previous years. Emissions Sources of EDC emissions from its use in leaded gasoline include blending operations at refineries, bulk gasoline marketing and trans portation service stations, gasoline combustion, and evaporation from the vehicles themselves. Blending -- EDC emissions from blending operations at refineries result from evaporation during storage and handling of EDC and blended product. It is estimated in the literature that about 1 kg of EDC is emitted to the atmosphere per Mg of EDC used in blending. 47 This corresponds to an emission factor of about 0.14 mg EDC/1 of leaded gasoline produced. Bulk Marketing and Transportation -- Estimates of EDC emissions from bulk loading, storage, and trans portation of leaded gasoline are presented in Table 15. These EDC emission factors were developed based on published V0C emission factors. 48 Data were not available to calculate emissions of EDC from loading and ballasting of marine vessels, submerged loading of tank cars and trucks, and storage and loading in fixed roof tanks. Emissions of EDC from splash 72 CMA 051522 EDC USE IN LEADED GASOLINE General Ethylene dichloride is used in conjunction with ethylene dibromide (1,2-dibromoethane) as a lead scavenger in leaded gasoline. The addition of these compounds prevents the fouling of the engine combusion chamber with lead oxides. Ethylene dichloride and ethylene dibromide react with lead during combustion to form lead chloride (PbClg) and lead bromide (PbBr2) which remain in the gas phase and are expelled with exhaust gases. About 1.0 mole of EDC and 0.5 mole of ethylene dibromide are added to gasoline per mole of alkyl lead added. 45 Current EPA regulations limit lead in gasoline to 0.29 grams (.0014 moles) per liter.46 Thus, no more than 0.0014 moles or 0.14 grams of EDC are added per liter. Higher lead and EDC levels were added in previous years. Emissions Sources of EDC emissions from its use in leaded gasoline include blending operations at refineries, bulk gasoline marketing and trans portation service stations, gasoline combustion, and evaporation from the vehicles themselves. Blending -- EDC emissions from blending operations at refineries result from evaporation during storage and handling of EDC and blended product. It is estimated in the literature that about 1 kg of EDC Is emitted to the atmosphere per Mg of EDC used in blending. 47 This corresponds to an emission factor of about 0.14 mg EDC/1 of leaded gasoline produced. Bulk Marketing and Transportation -- Estimates of EDC emissions from bulk loading, storage, and trans portation of leaded gasoline are presented In Table 15. These EDC emission factors were developed based on published VOC emission factors. 48 Data were not available to calculate emissions of EDC from loading and ballasting of marine vessels, submerged loading of tank cars and trucks, and storage and loading in fixed roof tanks. Emissions of EDC from splash 72 CMA 051523 TABLE 15. EDC EMISSIONS FROM BULK LOADING, STORAGE, AND TRANSPORTATION OF LEADED GASOLINE48 Emission source Emission rate or factor Gasoline storage and loading Fixed roof tanks u Floating roof tanks Tank car/truck loading Submerged loading normal service Submerged loading balance service Splash loading normal service Splash loading balance service Marine vessel loading Ship loading Cleaned tank Ballasted tank Uncleaned tank Average tank condition Ocean barge loading Cleaned tank Ballasted tank Uncleaned tank Barge loading Cleaned tank Uncleaned tank Average tank condition Tanker ballasting a 438 g/yr a a 0.269 mg/1 transferred 0.192 mg/1 transferred a a a a a a a a a a a information was not available to calculate emissions of EDC from these sources. ihe following assumptions were made for floating roof tanks emissions: external floating roof with metallic shoe primary seal, diameter is 62 feet, height is 40 feet, shell condition is light rust, 10 turnovers/year, wind speed is 10 miles/hour, gasoline density is 6.1 lb/gallon. 73 CMA 051524 loading of tank cars and trucks, and from floating roof tanks, were calculated using the assumption that the EDC concentration in emissions is the same as that in the bulk liquid. Service Stations -- Estimates of EDC emissions from service stations are presented in Table 16. These emission factors were developed based on published emission factors for gasoline. Data was not available for estimation of EDC emissions from under ground tank filling by submerged loading and tank breathing. Emissions from splash loading of underground tanks, vehicle refueling, and spillage were developed with the assumption that emissions have the same composition as the stored liquid. Combustion in Motor Vehicles -- Most of the EDC added to leaded gasoline is destroyed during combustion, reacting with lead and oxygen to produce lead chloride, hydrogen chloride, water, and carbon dioxide. It is estimated in published literature that about 1 percent of the EDC added is not destroyed during combustion and is emitted to the atmosphere with vehicle exhaust. 47 This corresponds to an emission factor of about 1.4 mg EDC/liter of leaded gasoline burned. Motor Vehicle Evaporation -- In addition to EDC emissions from motor vehicle exhaust, evaporative emissions occur in the crankcase, carburetor, and fuel tank. Crankcase emissions result from the crankcase as the engine is running. Hot soak losses are produced as fuel evaporates from the carburetor system at the end of a trip. Diurnal changes in ambient temperature result in expansion of the air-fuel mixture in a partially filled fuel tank. As a result, gasoline vapor is expelled into the atmosphere and EDC is emitted with the vapor. 49 Evaporative EDC emission factors for motor vehicles are not available. 74 CMA. 051525 loading of tank cars and trucks, and from floating roof tanks, were calculated using the assumption that the EDC concentration in emissions is the same as that in the bulk liquid. Service Stations -- Estimates of EDC emissions from service stations are presented in Table 16. These emission factors were developed based on published emission factors for gasoline. Data was not available for estimation of EDC emissions from under ground tank filling by submerged loading and tank breathing. Emissions from splash loading of underground tanks, vehicle refueling, and spillage were developed with the assumption that emissions have the same composition as the stored liquid. Combustion in Motor Vehicles -- Most of the EDC added to leaded gasoline is destroyed during combustion, reacting with lead and oxygen to produce lead chloride, hydrogen chloride, water, and carbon dioxide. It is estimated in published literature that about 1 percent of the EDC added is not destroyed during combustion and is emitted to the atmosphere with vehicle exhaust. 47 This corresponds to an emission factor of about 1.4 mg EDC/liter of leaded gasoline burned. Motor Vehicle Evaporation -- In addition to EDC emissions from motor vehicle exhaust, evaporative emissions occur in the crankcase, carburetor, and fuel tank. Crankcase emissions result from the crankcase as the engine is running. Hot soak losses are produced as fuel evaporates from the carburetor system at the end of a trip. Diurnal changes in ambient temperature result in expansion of the air-fuel mixture in a partially filled fuel tank. As a result, gasoline4Q vapor is expelled into the atmosphere and EDC is emitted with the vapor. Evaporative EDC emission factors for motor vehicles are not available. 74 CMA. 051526 TABLE 16. EDC EMISSIONS FROM SERVICE STATIONS48 Emission source Emission factor (mg/1 transferred) Filling underground tank Submerged filling Splash filling Balanced submerged filling Underground tank breathing and emptying Vehicle refueling operations Displacement losses (uncontrolled) Displacement losses (controlled) Spillage a 0.26 a a 0.21 0.021 0.016 information was not available to calculate emissions of EDC from these sources. 75 CMA 051527 Source Location Blending of leaded gasoline generally occurs at petroleum refineries. A list of active petroleum refineries in the United States and their locations is presented in Table 17. Bulk gasoline loading facilities and service stations are too numerous to list here. Terminal and bulk stations can be found within Standard Industrial Classifications (SIC) code 5171. Gasoline service stations can be found within SIC 5541. Terminals and bulk plants are commonly identified individually as point sources in many emission inventories such as EPA's National Emissions Data System (NEDS). Service stations and other gasoline outlets are usually treated collectively as area sources in these inventories, as are mobile sources. EDC USE IN PAINTS, COATINGS, AND ADHESIVES General It is estimated that about 1,400 Mg of EDC per year are used in the manufacture of paints, coatings, and adhesives. This amounts to about 0.03 percent of total EDC consumption. Although specific uses of EDC in paints and coatings are not known, EDC is thought to be used as a solvent in paints and coatings which use vinyl polymers, particularly polyvinyl chloride. EDC use In adhesives is restricted to adhesives using acrylics. 51 Emissions Because EDC is used as a solvent in paints, coatings, and adhesives, It is estimated that all of the EDC used in these products is eventually emitted to the atmosphere. 51 Data are not available on the relative amounts of EDC emitted during formulation and use of these products. Source Locations Standard Industrial Classification (SIC) codes for manufacturing and uses of paints, coatings, and adhesives are listed below: painting, paper hanging, decorating - 172 paint and allied product manufacturing - 285 adhesives and sealants manufacturing - 2891 76 CMA, 051528 Source Location Blending of leaded gasoline generally occurs at petroleum refineries. A list of active petroleum refineries in the United States and their locations is presented in Table 17. Bulk gasoline loading facilities and service stations are too numerous to list here. Terminal and bulk stations can be found within Standard Industrial Classifications (SIC) code 5171. Gasoline service stations can be found within SIC 5541. Terminals and bulk plants are commonly identified Individually as point sources in many emission inventories such as EPA's National Emissions Data System (NEDS). Service stations and other gasoline outlets are usually treated collectively as area sources in these inventories, as are mobile sources. EDC USE IN PAINTS, COATINGS, AND ADHESIVES General It is estimated that about 1,400 Mg of EDC per year are used in the manufacture of paints, coatings, and adhesives. This amounts to about 0.03 percent of total EDC consumption. Although specific uses of EDC in paints and coatings are not known, EDC is thought to be used as a solvent in paints and coatings which use vinyl polymers, particularly polyvinyl chloride. EDC use In adhesives is restricted to adhesives using acrylics. SI Emissions Because EDC is used as a solvent In paints, coatings, and adhesives, It is estimated that all of the EDC used in these products is eventually emitted to the atmosphere. 51 Data are not available on the relative amounts of EDC emitted during formulation and use of these products. Source Locations Standard Industrial Classification (SIC) codes for manufacturing and uses of paints, coatings, and adhesives are listed below: painting, paper hanging, decorating - 172 paint and allied product manufacturing - 285 adhesives and sealants manufacturing - 2891 76 CMA. 051529 TABLE 17. PETROLEUM REFINERIES50 Company and location Company and location Alabama Hurt Oil Co.--Tuscaloosa Louisiana Land and Exploration Co.--Saraland Marion Corp.--Theodore Mobile Bay Refining Co.--Chickasaw Warrior Asphalt Co. of Alabama Inc.--Holt Alaska Atlantic Richfield Corp.--Prudhoe Bay Chevron U.S.A. Inc.-- Kenai North Pole Refining, Div. of Mapco--North Pole Tesoro Petroleum Corp.--Kenai Arizona Arizona Fuels Corp.--Fredonla Arkansas Berry Petroleum, Division of Crystal Oil Co.--Stevens Cross Oil & Refining Co. of Arkansas--Smackover Macmillan Ring-Free Oil Co.-- Norphlet Tosco Corp.--El Dorado California Anchor Refining Cl--McKIttrick Atlantic Richfield Co.--Carson Beacon Oil Co.--Hanford Chamolin Petroleum Co.--Wilmington Chevron U.S.A. Inc.--Bakersfield El Segundo Richmond Douglas Oil Co.-- Santa Maria Eco Petroleum Inc.--Signal Hill Edgington Oil Cl--Long Beach Exxon Co.--Benicia Fletcher Oil t Refining Co.--Carson Getty Refining & Marketing Co.-- Bakersfield Golden Bear Division, Wlteo Chemical Corp.--Oil dale Golden Eagle Refining Co.--Carson Gulf Oil Co.--Santa Fe Springs Huntway Refining Co.--Benicia Wilmington Independent Valley Energy Co.-- Bakersfield Kern County Refinery Inc.-- Bakersfield Marlex Oil 1 Refining Inc.-- Long Beach Mobil Oil Corp.--Torrance Newhall Refining Cl--Newhall Oxnard Refinery--Oxnard Pacific Oasis--Paramount Pacific Refining Co.--Hercules Powerine Oil Co.--Santa Fe Springs Sabre Refining Inc.--Bakersfield Shell Oil Co.--Martinez Wi Imington Sunland Refining Corp.--Bakersfield Texaco Inc.--Wilmington Tosco Corp.--Bakersfield Martinez Union Oil Co. of California-- Los Angeles Rodeo USA Petrochem Carp.--Ventura Colorado Asamera Oil U.S. Inc.-- Commerce City Conoco Inc.--Commerce City Gary Refining Co.--Fruita Delaware Getty Refining and Marketing Co.-- Delaware City Georgia Amoco Oil Co.--Savannah Young Refining Corp,--Douglasville Hawaii Chevron U.S.A. Inc.--Barber1 s Point Hawaiian Independent Refinery Inc.--Ewa Beach Illinois Clark Oil S Refining Corp.-- Blue Island Hartford Marathon Oil Co.--Robinson Mobile Oil Corp.--Joliet Shell Oil Co.--Wood River Texaco Inc.-- Lawrenceville Union Oil Co. of California--Lemont Indiana Amoco Oil Co.--Whiting Gladieux Refinery Inc.--Ft. Weyne Indiana Farm Bureau Cooperative Association Inc.--Mt. Vernon Laketon Refininq Coro.--Laketon Rock Island Refining Corp.-- Indianapolis Kansas Derby Refining Co.--Wichita Farmland Industries Inc.-- Coffeyville Getty Refining l Marketing Co.-- E1 Dorado Mobile Oil Corp.--Augusta National Cooperative Refinery Associ at i on--McPherson Pester Refining Co.--El Dorado Total Petroleum--Arkansas City CONTINUED 77 CMA. 051530 TABLE 17. (continued) Company and location Company and location Kentucky Ashland Petroleum Co.--Catlettsburg Louisville Somerset Refinery Inc.--Somerset Louisiana Atlas Processing Co.. Division of Pennioil--Shreveport Calumet Refining Co.--Princeton Canal Refining Co.--Church Point Celeron Oil & Gas-Mermentau Cities Service Co.--Lake Charles Claiborne Gasoline Co.--Lisbon Conoco Inc.'Lake Charles Cotton Valley Refinery (Kerr-MeGee Refining Corp.)--Cotton Valley CPI Refining Inc.--Lake Charles Exxon Co.--Baton Rouge Gulf Oil Corp.--Belle Chaste Hill Petroleum Co.--Krotz Springs Kerr McGee Corp.--Oubach Mallard Resources Inc.--Gueydon Marathon Oil Co.--Garyville Murphy Oil Co.--Meraux Placid Refining Co.--Port Allen Port Petroleum Inc.--Stonewall Shell Oil Co,--Norco Tenneeo Oil Co.--Chalmette Texaco Inc.--Convent Maryland Chevron U.S.A. Inc.--`Baltimore Michioan Crystal Refining Co.--Carson City Lakeside Refining Co.--Kalamazoo Marathon Oil Co.--Detroit Total Petroleum Inc.--Alma Minnesota Ashland Petroleum Co.--St. Paul Park Koch Refining Co,--Rosemount Mississiooi Amerada-Hess Corp.--Purvis Chevron U.S.A. Inc.'Pascagoula Ergon Refining Inc.--Vicksburg Natchez Refining Inc.--Natchez Southland Oil Co.--Lunberton Sandersville Montana Cenex--Laurel Conoco Inc,--Billings Exxon Co.--Billings Flying J Inc.--Cut Bank Kenco Refining Inc.--Wolf Point Simmons Refining Co.--Great Falls Nevada Nevada Refining Co.--Tonopah New Jersey Chevron U.S.A.-- Perth Amboy Exxon Co.--Linden Mobil Oil Corp, --Paulsboro Seaview Petroleum Inc.-- Thorofare Texaco Inc.--Westvllle New Mexico Giant Industries Inc.--Ciniza Farmington Navajo Refining Co.--Artesia Plateau Inc.--Bloomfield Southern Union Refining Co.-- Lovington Thriftway Co.--Bloomfield North Dakota Amoco Oil Co.--Mandan Flying J Inc.--Willisten Ohio Ashland Petroleun Co.--Canton Gulf Oil Co.--Cincinnati Standard Oil Co. of Ohio--Lima Toledo Sun Cl--Toledo Oklahoma Allied Material Corp.--Stroud Champlin Petroleum Co.--Enid Conoco Inc.--Ponca City Kerr-McGee Refining Corp.-- Wynnewood Oklahoma Refining Co.--Cyril Custer Country Sun CI--Tulsa Tonkawa Refining Co.--Arnett Tosco--Duncan Total Petroleun Corp.--Ardmore Oreoon Chevron U.S.A, Inc.--Portland Pennsylvania Atlantic Richfield Co.--Philadelphia BP Oil Corp.--Marcus Hood Gulf Oil Co.--Philadelphia Kendall'Amalie Division Witco Chemical Co.--Bradford Penzoil Co.--Rousevilie Quaker State Oil Refining Corp,--Farmers Valley Sun Cl--Marcus Hook United Refining Co.--Warren Valvoline Oil Co., Division of Ashland Oil Co.--Freedom Tennessee Delta Refining Co.--Memphis CONTINUED 78 CMA 051531 TABLE 17. (continued) Company and location Company and location Kentucky Ashland Petroleim Co.--CatlettsburgLouisville Somerset Refinery Inc,--Somerset Louisiana Atlas Processing Co., Division of Penntoi 1 --Shreveport Calumet Refining Co,--Princeton Canal Refining Co.--Church Point Celeron Oil & Gas--Mermentau Cities Service Co.--Lake Charles Claiborne Gasoline Co.--Lisbon Conoco Inc.'Lake Charles Cotton Valley Refinery (Kerr-MeGee Refining Corp.)--Cotton Valley CPI Refining Inc.--Lake Charles Exxon Co,--8*ton Rouge Gulf Oil Corp.'-'Belle Chasse Hill Petroleian Co.-- Krot2 Springs Kerr McGee Corp.--Dubach Mallard Resources Inc.--Gueydon Marathon Oil Co.--Garyville Murphy Oil Co.--Meraux Placid Refining Co.--Port Allen Port Petroleun Inc.--Stonewal 1 Shell Oil Co.--Norco Tenneco Oil Co.--Chalmette Texaco Inc,--Convent Maryland Chevron U.S.A. Inc.--Baltimore Miehioan Crystal Refining Co.--Carson City Lakeside Refining Co.--Kalamazoo Marathon Oil Co.--Oetroit Total Petroleum Inc,--Alma Minnesota Ashland Petroleim Co.--St. Paul Park Koch Refining Co.--Rosemount MIssissiODi Amerada-Hess Corp.--Purvis Chevron U.S.A. Inc.-Pascagoula Ergon Refining Inc.--Vicksburg Natehei Refining Inc.--Natchez Southland Oil Co.--Lunbtrton Sandersvillt Montana Canex--Laurtl Conoco Inc.--Billings Exxon Co.--Billings Flying J Inc.--Cut Bank Kened Rtfining Inc.--Wolf Point Sinnons Refining Co.--Great Falls Nevada Nevada Refining Co.--Tonopah New Jersey Chevron U.S.A.--Perth Amboy Exxon Co.-- Linden Mobil Oil Corp.--Paulsboro Seaview Petroleim Inc.-- Thorofare Texaco Inc.--Westvllle New Mexico Giant Industries Inc.--Ciniza Farmington Navajo Refining Co.--Artesia Plateau Inc.--Bloomfield Southern Union Rtfining Co.-- Lovington Thriftway Co.--Bloomfield North Dakota Amoco Oil Co.--Mandan Flying J Inc.--Williston Ohio Ashland Petrol tun Co.--Canton Gulf Oil Co.--Cincinnati Standard Oil Co. of Ohio--Lima Toledo Sun Cl--Toledo Oklahoma Allied Material Corp.--Stroud Champlin Petroleim Co.--Enid Conoco Inc.--Ponca City Kerr*McGee Refining Corp.-- Wynnewood Oklahoma Rtfining Co.--Cyril Custer Country Sun Cl--Tulsa Tonkawa Refining Co.--Arnett Tosco--Ouncan Total Petroleim Corp.--Ardmore Oregon Chevron U.S.A. Inc.--Portland Rtnns^lvan^a Atlantic Richfield Co.--Philadelphia BP Oil Corp.--Marcus Hood Gulf Gil Co.--Philadelphia Kendall-Amalia Division Witco Chemical Co.--Bradford Ptn2oil Co.--Rouseville Quaker State Oil Refining Corp,--Farmers Valley Sun Cl--Marcus Hook United Refining Co.--Warren Valvolint Oil Co., Division of Ashland Oil Co.--Freedom Tennessee Delta Refining Co.--Memphis CONTINUED 73 CMA. 051532 TABLE 17. (continued) Company and location Texas Amber Refining Co. --Fort Worth American Petroflna Inc.-- Big Spring Port Arthur Amoco Oil Co.--Texas City Atlantic Richfield Co.--Houston Champlin Petroleum Co.-- Corpus Christ! Charter International Oil Co.--Houston Chevron U.S.A. Inc.--El Paso Coastal States Petroleum Co.-- Corpus Christi Crown Central Petroleum Corp.-- Houston Oiamend Shamrock Corp.--Sunray Dorchester Refining Co.-- Mt. Pleasant Eddy Refining Co.--Houston Exxon Co. U.S.A.--Baytown Flint Chemical Co.--San Antonio Gulf Oil Co.--Port Arthur Howell Hydrocarbons Inc.--San Antonio Koch Refining Co.--Corpus Christi LaGloria Oil J Gas Co.--Tyler Liquid Energy Corp.--Bridgeport Marathon Oil Co.--Texas City Mobil Oil Corp.--Beajnont Phillips Petroleum Co.-- Borger Sweeny Pride Refining Inc.--Abilene Quintana Petrochemical Co.-- Corpus Christi Saber Energy Inc.--Corpus Christi Shell Oil Co.--Deer Park Odessa Signor Refining Co.--Three Rivers South Hampton Refining Co.-- Silsbee Southwestern Refining Cl-- Corpus Christi Tesoro Petroleum Corp.-- Carrito Springs Texaco Inc.--Amarillo El Paso Port Arthur Popt Neches Texas City Refininq Inc.--Texas City Uni Refining Inc. -- Ingleside Union Oil Co. of California-- (Beaumont), Nederland Company and location Utah Amoco Oil Co.--Salt Lake City Caribou Four Comers Inc.--Woods Cross Chevron U.S.A.--Salt Lake City Crysen Refining Co.--Woods Cross Husky Oil Co.--North Salt Lake City Phillips Petroleum Co.--Woods Cross Plateau Inc.--Roosevelt Virginia Amoco Oil Co.--Yorktown Washington Atlantic Richfield Co.--Femdale Chevron U.S.A. Inc.--Seattle Mobile Oil Corp.--Femdale Shell Oil Co.--Anacortes Sound Refining Inc.--Tacoma Texaco Inc.--Anacortes U.S. Oil & Refining Co.--Tacoma West Virginia Quaker State Oil Refining Corp.-- Newel 1 St. Mary's Wisconsin Murphy Oil Corp.--Superior Wyoming Amoco Oil Co.--Casper Husky Oil Co.--Cheyenne Little America Refining Co.--Casper Mountaineer Refining Cl--LaBarge Sinclair Oil Corp.--Sinclair Wyoming Refining Co.--Newcastle Note: This listing is subject to change as market conditions change, facility ownership changes, plants are closed down, etc. The reader should verify the existence of particular facilitie's by consulting current listings and/or the plants themselves. The level of EDC emissions from any given facility is a function of variables such as capacity, throughput and control measures, and should be determined through direct contacts with plant personnel. 79 CM& 051533 EDC USE AS AN EXTRACTION SOLVENT General EDC is used in a number of solvent extraction applications. Major applications include the extraction of oil from seeds, the processing of animal fats, and the processing of pharmaceutical products. It is estimated that EDC use as an extraction solvent accounts for about 1.1 Mg EDC/year or about 0.02 percent of total EDC consumption. 52 Emissions The solvent used in extraction processes is generally recovered by low pressure distillation. Some solvent is lost to the atmosphere from valves, pumps, and compressors; in spills; and during transfer operations. It is estimated that in published literature that about 95 percent of the EDC consumed in solvent extraction processes is emitted to the atmosphere, while about 5 percent is discharged with solid wastes. These solid wastes are generally incinerated. 52 Source Locations* Standard Industrial Classification (SIC) codes for uses of extraction solvents are listed below: Manufacturing of fats and oils - 207 Manufacturing of pharmaceutical preparations - 2834 EDC USE IN CLEANING SOLVENTS General Solvents containing EDC are used in cleaning equipment in the polyvinyl chloride and textile manufacturing industries. It is estimated that this use accounts for about 910 Mg/year or about 0.02 percent of total EDC consumption. 53 Data are not available on the equipment cleaned, the specific nature of the cleaning operations, or the compositions of the solvents used. Emissions Although no emissions data are available for solvent cleaning uses of EDC, it is estimated in the literature that about 95 percent of the EDC consumed is ultimately emitted to the atmosphere, while the remaining 5 percent i.s di.scharged with solid wastes. 53 These solid wastes are generally incinerated. 80 CMA. 051534 EDC USE AS AN EXTRACTION SOLVENT General EDC is used in a number of solvent extraction applications. Major applications include the extraction of oil from seeds, the processing of animal fats, and the processing of pharmaceutical products. It is estimated that EDC use as an extraction solvent accounts for about 1.1 Mg EDC/year or about 0.02 percent of total EDC consumption. 52 Emissions The solvent used in extraction processes is generally recovered by low pressure distillation. Some solvent is lost to the atmosphere from valves, pumps, and compressors; in spills; and during transfer operations. It is estimated that in published literature that about 95 percent of the EDC consumed in solvent extraction processes is emitted to the atmosphere, while about 5 percent is discharged with solid wastes. These solid wastes are generally incinerated. 52 Source Locations Standard Industrial Classification (SIC) codes for uses of extraction solvents are listed below: Manufacturing of fats and oils - 207 Manufacturing of pharmaceutical preparations - 2834 EDC USE IN CLEANING SOLVENTS General Solvents containing EDC are used in cleaning equipment in the polyvinyl chloride and textile manufacturing Industries. It is estimated that this use accounts for about 910 Mg/year or about 0.02 percent of total EDC consumption. 53 Data are not available on the equipment cleaned, the specific nature of the cleaning operations, or the compositions of the solvents used. Emissions Although no emissions data are available for solvent cleaning uses of EDC, it is estimated in the literature that about 95 percent of the EDC consumed is ultimately emitted to the atmosphere, while the remaining 5 percent is discharged with solid wastes.^ These solid wastes are generally incinerated. 80 CMA. 051535 Source Locations Standard Industrial Classification (SIC) codes for uses of cleaning solvents are listed below: Manufacturing of plastics materials and synthetics - 282 Manufacturing of textile mill products - 22 Manufacturing of apparel and other textile products - 23 MISCELLANEOUS EDC USES General EDC is used in the manufacture of color film, as a diluent in pesticides and herbicides, and as an amine carrier in the leaching of copper ores. The total amount of EDC used in these applications is 460 Mg/year or about 0.01 percent of total domestic consumption. 54 Very little information is available in published sources regarding the details of these processes. Emissions It is estimated in published literature that all of the EDC used in the manufacture of pesticides, herbicides, and color film is emitted to the atmosphere, while nearly all of the EDC used in copper leaching is either consumed in the leaching process or emitted with waste water. 54 Source Locations* Standard Industrial Classification (SIC) codes for miscellaneous uses of EDC are listed below: Photographic equipment and supplies manufacturing - 3861 Agricultural chemicals manufacturing - 287 Copper ores mining - 102 VOLATILIZATION FROM WASTE TREATMENT, STORAGE AND DISPOSAL FACILITIES Considerable potential exists for volatile substances, including EDC, to be emitted from hazardous waste treatment, storage and handling facilities. A study in California 55 shows that significant quantities of EDC may be contained in hazardous wastes, which may be expected to volatilize within 81 CMA. 051536 hours, days, or months after disposal by landspreading, surface impoundment or covered landfill, respectively. Volatilization of EDC and other substances was confirmed in this study by significant ambient air concentrations of EDC over one site. Reference 56 provides general theoretical models for estimating volatile substance emissions from a number of generic kinds of waste handling operations, including surface impoundments, landfills, landfarming (land treatment) operations, wastewater treatment systems, and drum storage/handling process. If such a facility is known to handle EDC, the potential should be considered for some air emissions to occur. Several studies show that low levels of EDC may be emitted from municipal wastewater treatment plants. In a test at a small municipal treatment plant (handling 40% industrial and 60% municipal sewage), EDC emission rates from the aeration basins were measured at levels ranging from 5 to 10 grams/hour. 57 Tests at a larger municipal treatment plant (handling about 50 percent industrial sewage) show that less than 92 to 184 grams/day of EDC are emitted, primarily from air stripping as part of the activated sludge treatment process. This emission rate was calculated from the EDC content of the Influent to the plant, and assuming 50 to 100 percent volatilization as part of the overall treatment process, which is the range of removal observed for other volatiles. 58 Too little data are available to extrapolate these test results to other wastewater treatment plants. 82 CMA. 051537 hours, days, or months after disposal by landspreading, surface Impoundment or covered landfill, respectively. Volatilization of EDC and other substances was confirmed in this study by significant ambient air concentrations of EDC over one site. Reference 56 provides general theoretical models for estimating volatile substance emissions from a number of generic kinds of waste handling operations, including surface impoundments, landfills, landfarming (land treatment) operations, wastewater treatment systems, and drum storage/handling process. If such a facility is known to handle EDC, the potential should be considered for some air emissions to occur. Several studies show that low levels of EDC may be emitted from municipal wastewater treatment plants. In a test at a small municipal treatment plant (handling 40% industrial and 60% municipal sewage), EDC emission rates from the aeration basins were measured at levels ranging from 5 to 10 grams/hour. Tests at a larger municipal treatment plant (handling about 50 percent industrial sewage) show that less than 92 to 184 grams/day of EDC are emitted, primarily from air stripping as part of the activated sludge treatment process. This emission rate was calculated from the EDC content of the influent to the plant, and assuming 50 to 100 percent volatilization as part of the overall CQ treatment process, which is the range of removal observed for other volatiles. Too little data are available to extrapolate these test results to other wastewater treatment plants. 82 CMA. 051538 SECTION 5 SOURCE TEST PROCEDURES Ethylene dichloride emissions can be measured using EPA Reference Method 23, which was proposed in the Federal Register on June VI, 1980. 59 EPA has validated the method for ethylene dlchloride in the laboratory60 as well as in the field.6^ In Method 23, a sample of the exhaust gas to be analyzed is drawn into a Tedlaror aluminized Mylar bag as shown in Figure 14. Tedlar is considered a more reliable bag material than Mylar for EDC.6"* The bag is placed inside a rigid leak proof container and evacuated. The bag is then connected by a Teflon sampling line to a sampling probe (stainless steel, Pyrex glass, or Teflon) at the center of the stack. Sample is drawn into the bag by pumping air out of the rigid container. The sample is then analyzed by gas chromatography (GC) coupled with flame ionization detection (FID). Analysis should be conducted within one day of sample collection. The recommended GC column is 3.05 m by 3.2 mm stainless steel, filled with 20 percent SP-2100/0.1 percent Carbowax 1500 on 100/120 Supelcoport. This column normally provides an adequate resolution of halogenated organics. (Where resolution interferences are encountered, the GC operator should select the column best suited to the analysis.) The column temperature should be set at 100C. Zero helium or nitrogen should be used as the carrier gas at a flow rate of approximately 20 ml/min. The peak area corresponding to the retention time of ethylene dichloride is measured and compared to peak areas for a set of standard gas mixtures to determine the ethylene dichloride concentration. The range of the method is 0.1 to 200 ppm; however the upper limit can be extended by extending the calibration range or diluting the sample. The method does not apply when ethylene dichloride is contained in particulate matter. 83 CM& 051539 FLOW METER CHARCOAL TUBE Figure 14 Method 23 sampling train 59 84 CM* 051540 FLOW METER CHARCOAL TUBE Figure 14. Method 23 sampling train.^ 84 CMA 051541 REFERENCES 1. Drury, J.S. and A.S. Hammons. Investigation of Selected Environmental Pollutants: 1,2-Dichloroethane. U.S. Environmental Protection Agency. Washington, D.C. Publication No. EPA-560/2-78-006. April 1979. 2. Cox, G.V., Chemical Manufacturers Association, Washington, DC. Letter to Tom Lahre, Office of Air Quality Planning and Standards, U.S. Environ mental Protection Agency, August 18, 1983. 3. Encylcopedia of Chemical Technology, Kirk Othmer, 3rd Edition, Volume 5. Wiley Interscience Publication, New York, New York. 1979. p. 724-740. 4. Chemical Producers Data Base System - 1,2-Dichloroethane. U.S. Environ mental Protection Agency. Cincinnati, Ohio. July 1981. 5. 1983 Directory of Chemical Producers, United States of America. SRI International. Menlo Park, California. 1983. 6. Synthetic Organic Chemicals, United States Production and Sales, 1982. U.S. International Trade Commission. Washington, D.C. 1983. p. 261. 7. Chemical Products Synopsis - Ethylene Dichloride. Mannsville Chemical Products. Cortland, New York. June 1981. 8. Hobbs, F.D. and J.A. Key. Report 1: Ethylene Dichloride. In: Organic Chemical Manufacturing Volume 8: Selected Processes. U.S. Environmental Protection Agency. Research Triangle Park, N.C. Publication No. EPA-450/3-80-28c December 1980. pp. III-l to II1-9. 9. Reference 8, pp. IV-1 to IV-11. 10. Shah, Hasmukh, Chemical Manufacturers Association, Washington, DC. Letter to D.C. Misenheimer, GCA Corporation, December 21, 1983. 11. Gasperecz, Greg, Louisiana Air Quality Division, Baton Rouge, LA. Personal communication with D.C. Misenheimer, GCA Corporation, September 30, 1983. 12. "Thermal Incinerator Performance for NSPS," Memo and addendum from Mascone, D., EPA, to Farmer, J., EPA. June 11, 1980. 13. Reference 8, p. V-2. 14. Reference 6, p. 294. 15. Bryson H., K. Durrell, E. Harrison, V. Hodge, L. Phuoc, S. Paige and K. Slimak. Materials Balance: 1,2-Dichloroethane. U.S. Environmental Protection Agency, Washington, D.C. Publication No. EPA-560/13-80-002. February 1980. pp. 3-1 to 3-6. 85 CMA. 05X542 16.. Standifer, R.L. and J.A. Key. Report 4: 1,1,1-Trichloroethane and Perch!oroethylene. Trichloroethylene,, and Vinylidine Chloride. In: Organic Chemical Manufacturing Volume 8: Selected Processes. U.S. Environmental Protection Agency. Research Triangle Park, N.C. Publication No. EPA-450/3-80-28C. December 1980. p. II-3. 17. Reference 15, pp. 3-23 to 3-30. 18. Reference 16, pp. 111-1 to 111-8. 19. Reference 15, pp. 3-30 to 3-34. .20 Liepins, R. and F. Mixon. Industrial Process Profiles for Environ mental Use. Chapter 6 - The Industrial Organic Chemicals Industry. U.S. Environmental Protection Agency. Cincinnati, Ohio. Publication No. EPA-600/2-77-023f. February 1977. pp. 353-355. 21. Reference 16, pp. 111-8 to 111-14. .22 Chemical Products Synopsis - Trichloroethylene. Mannsville Chemical Products. Cortland, New York. November 1979. 23. Reference 15, pp. 3-8 to 3-12. 24. Hobbs, F.D. and C.W. Stuewe. Report 2: Carbon Tetrachloride and Perch!oroethylene by the Hydrocarbon Chlorinolysis Process. In: Organic Chemical Manufacturing Volume 8: Selected Processes. U.S. Environmental Protection Agency. Research Triangle Park, N.C. Publication No. EPA-450/3-80-28c. December 1980. pp. II1-1 to 111-4. 25. Chemical Products Synopsis - Perch!oroethylene. Mannsville Chemical Products. Cortland, New York. October 1979. 26. Reference 15, pp. 3-12 to 3-18. 27. Reference 24, p. IV-2. 28. Reference 24, p. V-2. 29. Reference 24, p. IV-1. 30. Reference 16, pp. 111-15 to III-17. 31. Reference 20, pp. 359-363. 32. Reference 15, pp. 3-18 to 3-22. 33. Encyclopedia of Chemical Technology, 3rd Edition, Volume 5. Wiley Interscience Publication, New York, New York. 1979. p. 717-719. 34. Faith, W.L., D.B. Keyes, and R.L. Clark. Industrial Chemicals, 3rd Edition. John Wiley and Sons, New York. 1965. p. 356-357. 86 CMA. 05X543 16- Standifer, R.L. and J.A. Key. Report 4: 1,1,1-Trlchloroethane and Perchloroethylene, Trichloroethylene,, and Vinylidine Chloride. In: Organic Chemical Manufacturing Volume 8: Selected Processes. U.S. Environmental Protection Agency. Research Triangle Park, N.C. Publication No. EPA-450/3-80-28c. December 1980. p. II-3. 17. Reference 15, pp. 3-23 to 3-30. 18. Reference 16, pp. III-l to II1-8. 19. Reference 15, pp. 3-30 to 3-34. .20 Liepins, R. and F. Mixon. Industrial Process Profiles for Environ mental Use. Chapter 6 - The Industrial Organic Chemicals Industry. U.S. Environmental Protection Agency. Cincinnati, Ohio. Publication No. EPA-600/2-77-023f. February 1977. pp. 353-355. .21 Reference 16, pp. II1-8 to III-14. 22. Chemical Products Synopsis - Trichloroethylene. Mannsville Chemical Products. Cortland, New York. November 1979. 23. Reference 15, pp. 3-8 to 3-12. 24. Hobbs, F.D. and C.W. Stuewe. Report 2: Carbon Tetrachloride and Perchloroethylene by the Hydrocarbon Chlorinolysis Process. In: Organic Chemical Manufacturing Volume 8: Selected Processes. U.S. Environmental Protection Agency. Research Triangle Park, N.C. Publication No. EPA-450/3-80-28c. December 1980. pp. III-l to III-4. 25. Chemical Products Synopsis - Perchloroethylene. Mannsville Chemical Products. Cortland, New York. October 1979. 26. Reference 15, pp. 3-12 to 3-18. 27. Reference 24, p. IV-2. 28. Reference 24, p. V-2. 29. Reference 24, p. IV-1. 30. Reference 16, pp. III-15 to III-17. 31. Reference 20, pp. 359-363. 32. Reference 15, pp. 3-18 to 3-22. 33. Encyclopedia of Chemical Technology, 3rd Edition, Volume 5. Wiley Interscience Publication, New York, New York. 1979. p. 717-719. 34. Faith, W.L., D.B. Keyes, and R.L. Clark. Industrial Chemicals, 3rd Edition. John Wiley and Sons, New York. 1965. p. 356-357. 86 CMA. 051544 35. Eimutis, E.C., R.P. Quill, and G.M. Rinaldi. Source Assessment: - Noncriteria Pollutant Emissions (1978 Update). U.S. Environmental Protection Agency. Research Triangle Park, N.C. Publication No. EPA-600/2-78-004t. July 1978. p. 58. 36. U.S. International Trade Commission. Synthetic Organic Chemicals, U.S. Production and Sales, 1978. U.S. Government Printing Office, Washington, D.C. 1979. p. 313. 37. Reference 15, pp. 3-47 to 3-48. 38. Holtorf, R.C. and G.F. Ludvik. Grain Fumigants: An Overview of Their Significance to U.S. Agriculture and Commerce and Their Pesticide Regulatory Implications. U.S. Environmental Protection Agency, Washington, DC, September 1981. 39. U.S. Environmental Protection Agency. Development Document for Effluent Limitations Guidelines for the Pesticide Chemicals Manufacturing Point Source Category. EPA-440/l-78/060-e, Washington, DC, April 1978. 40. Salzman, V., U.S. Environmental Protection Agency, Washington, DC. Letter with attachments to E. Anderson, GCA Corporation, July 21, 1982 , concerning pesticide registrants. 41. Ludvik, G.F. Fumigants for Bulk Grain Protection: Biological Aspects and Relevant Data. U.S. Environmental Protection Agency, Washington, DC, August 1981. 42. Development Planning and Research Associates, Inc. Preliminary Benefit Analysis: Cancellation of Carbon Tetrachloride in Fumigants for Stored Grain. U.S. Environmental Protection Agency, Washington, DC, April 1980. 43. U.S. Environmental Protection Agency. Carbon Tetrachloride; Pesticide Programs; Rebuttable Presumption Against Registration and Continued Registration of Certain Pesticide Products. Federal Register 45(202): 68534-68584, October 15, 1980. 44. Reference 15, p. 3-49. 45. GCA Corporation. Survey of Substitutes of 1,2-D1chloroethane as a Lead Scavenging Agent in Motor Fuel. Draft Final Report. Prepared for the U.S. Environmental Protection Agency Under Contract Number 68-01-5960, Technical Directive No. 7. Bedford, MA. p. 3. 46. U.S. Environmental Protection Agency. Regulation of Fuels and Fuel Additives. Federal Register 47(210): 49322, October 29, 1982. 47. Reference 15, pp. 3-35 to 3-43. 87 CMA 051545 48. Transportation and Marketing of Petroleum Liquids. In: Compilation of Air Pollution Emis'sion Factors, Third Edition - Supplement 9. AP-42, Research Triangle Park, NC. July 1979. 49. Compilation of Air Pollutant Emission Factors: Highway Mobile Sources. U.S. Environmental Protection Agency, Office of Mobile Source Air Pollution Control, Ann Arbor, MI. Publication No. EPA-460/3-81-005. March 1981. p. 4. 50. Cantrell, A. Annual Refining Survey. Oil and Gas Journal. March 21, 1983, pg. 128. 51. Reference 15, pp. 3-43 to 3-44. 52. Reference 15, pp. 3-44 to 3-45. 53. Reference 15, p. 3-46. 54. Reference 15, p. 3-51. 55. Scheible, Mike, et al. An Assessment of the Volatile and Toxic Organic Emissions from Hazardous Waste Disposal in California. Air Resources Board, State of California, February 1982. 56. GCA Corporation. Evaluation and Selection of Models for Estimating Air Emissions from Hazardous Waste Treatment, Storage and Disposal Facilities. Revised Draft Final Report. Prepared for the U.S. Environmental Protection Agency Under Contract Number 68-02-3168. Assignment No. 77. Bedford, MA. May 1983. 57. Pellizzari, E.D. Project Summary - Volatile Organics in Aeration Gases at Municipal Treatment Plants. EPA-600/52-82-056, U.S. Environmental Protection Agency, Cincinnati, OH, August 1982. 58. Fate of Priority Pollutants in Publicly Owned Treatment Works. U.S. Environmental Protection Agency, Washington, DC. Publication No. EPA 440/ 1-82-302. July 1982. 59. Method 23: Determination of Halogenated Organics from Stationary Sources. Federal Register. 45(114)39776-39777, 1980. 60. Knoll, J.E., M.A. Smith, and M.R. Midgett. Evaluation of Emission Test Methods for Halogenated Hydrocarbons: Volume 1, CC14, C2H2CI2, C2C14, C2HC13. EPA-600/4-79-025. U.S. Environmental Protection Agency, Research Triangle Park, NC, 1979. 61. Field Validation of EPA Reference Method 23. Prepared for U.S. Environmental Protection Agency by Scott Environmental Services under Contract 68-02-3405. February 1982. 88 CM* 051546 48. Transportation and Marketing of Petroleum Liquids. In: Compilation of Air Pollution Emission Factors, Third Edition - Supplement 9. AP-42, Research Triangle Park, NC. July 1979. 49. Compilation of Air Pollutant Emission Factors: Highway Mobile Sources. U.S. Environmental Protection Agency, Office of Mobile Source Air Pollution Control, Ann Arbor, MI. Publication No. EPA-460/3-81-005. March 1981. p. 4. 50. Cantrell, A. Annual Refining Survey. Oil and Gas Journal. March 21, 1983, pg. 128. 51. Reference 15, pp. 3-43 to 3-44. 52. Reference 15, pp. 3-44 to 3-45. 53. Reference 15, p. 3-46. 54. Reference 15, p. 3-51. 55. Scheible, Mike, et al. An Assessment of the Volatile and Toxic Organic Emissions from Hazardous Waste Disposal In California. Air Resources Board, State of California, February 1982. 56. GCA Corporation. Evaluation and Selection of Models for Estimating Air Emissions from Hazardous Waste Treatment, Storage and Disposal Facilities. Revised Draft Final Report. Prepared for the U.S. Environmental Protection Agency Under Contract Number 68-02-3168. Assignment No. 77. Bedford, MA. May 1983. 57. Pellizzari, E.D. Project Summary - Volatile Organics in Aeration Gases at Municipal Treatment Plants, EPA-600/52-82-056, U.S. Environmental Protection Agency, Cincinnati, OH, August 1982. 58. Fate of Priority Pollutants In Publicly Owned Treatment Works. U.S. Environmental Protection Agency, Washington, DC. Publication No. EPA 440/ 1-82-302. July 1982. 59. Method 23: Determination of Halogenated Organics from Stationary Sources. Federal Register. 45(114)39776-39777, 1980. 60. Knoll, J.E., M.A. Smith, and M.R. Mldgett. Evaluation of Emission Test Methods for Halogenated Hydrocarbons: Volume 1, CC14, C2H2C12, C2C14, C2HC13. EPA-600/4-79-025. U.S. Environmental Protection Agency, Research Triangle Park, NC, 1979. 61. Field Validation of EPA Reference Method 23. Prepared for U.S. Environmental Protection Agency by Scott Environmental Services under Contract 68-02-3405. February 1982. 88 CMA. 051547 TECHNICAL REPORT DATA (Please read Instructions on the reverse before completingj 1. REPORT NO. EPA-45Q/4-34-007d 2. 3. RECIPIENT'S ACCESSION NO. # 4. TITLE AND SUBTITLE LOCATING AND ESTIMATING AIR EMISSIONS FROM SOURCES OF ETHYLENE DICHLORIDE 5. REPORT DATE March 1984 6. PERFORMING ORGANIZATION CODE 7 AUTHORISl GCA Corporation 213 Burlington Road, Bedford, MS 01730 9 PERFORMING ORGANIZATION NAME AND AOORESS 8. PERFORMING ORGANIZATION REPORT NO. 10. PROGRAM ELEMENT NO. 11. CONTRACT/GflANT NO. 12. SPONSORING AGENCY NAME AND AOORESS Office Of Air Quality Planning And Standards U. S. Environmental Protection Agency MD 14 Research Triangle, NC 27711 15. SUPPLEMENTARY NOTES 13. TYPE OF REPORT AND PERIOD COVERED 14. SPONSORING AGENCY CODE EPA Project Officer: Thomas F. Lahre 16. ABSTRACT To assist groups Interested in inventorying air emissions of various potentially toxic substances, EPA is preparing a series of documents such as this to compile available information on sources and emissions of these substances. This document deals specifically with ethylene dichloride. Its intended audience includes Federal, State and local air pollution personnel and others interested in locating potential emitters of ethylene dichloride and in making gross estimates of air emissions therefrom. This document presents information on 1) the types of sources that may emit ethylene dichloride, 2) process variations and release points that may be expected within these sources, and 3) available emissions information Indicating the potential for ethylene dichloride release into the air from each operation. 17. KEY WORDS AND DOCUMENT ANALYSIS a. DESCRIPTORS b. I0ENT1FI6RS/GPEN ENDED TERMS l. CCSati Field/Group Ethylene Dichloride Air Emission Sources Locating Air Emission Sources Toxic Substances is, O'striSuticn statement 19. SECURITY CLASS , This Report, E?ApOPrTi2223 -- 1 ( R v. 4-7?) 20. SECURITY CLASS /This page, --i ...J - fc v , C _ ECIT^N S 09!CLt 21 NO. OF PAGES 92 22. ?PlC CMA. 051548 CMA 051549 tInited Stales Fm'ironmpnlol Prnlecdon Aqrorv Ollioal Business siooPnnaltv lor Private Use Office of Air and Radiation Office of Air Quality Planning and Standards Research Triangle Park NC 27711 CMA 051550 tf your address is incorrect, pleasechange on the above fabnl tear nMr and fpUirn lo the above address tf you do not desire toconimue receivrng thisiechnicat report serips, CHECK HERE n tear off label, and return it to tho alujve address