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Interoffice Communication To VCM Plant Employees From J. A. DeBernardi Date Subject February 1, 1980 Removal of Plant Property (conoco) It has come to my attention that some confusion apparently exists related to company employees removing company property from the plant premises. Therefore, the purpose of this letter is to again communicate plant policies governing removal of company property from the plant premises by plant employees. It is our policy to allow permanent plant employees to borrow tools for their"own personal use outside of the plant premises provided the loan of the tools does not hamper the efficient completion of plant maintenance work and the tools are returned promptly and in good condition. The procedure to be used by employees borrowing tools: 1) Contact the appropriate Maintenance Supervisor to request the use of tools and receive his approval. Shift Supervisors may approve the loan of tools outside of normal working hours. 2) Complete the appropriate paper work to document the approved loan of the tools. 3) Return the tools promptly following their use to the tool room and document the return of the tools. In the same light, our policy allows permanent employees to bid on obsolete piping, grating, and other miscellaneous scrap material specified in the bid notices. This policy is specifically intended to allow the employees to obtain the scrap material for their own personal use and is not intended to allow employees to resell the material for personal profit. Special points to remember regarding this policy: 1) Notices listing the scrap material for bid are posted. Following the close of the bid, a list of successful bidders on the items is posted. 2) Items made of exotic metals (such as copper, nickel, tantalum titanium, chromium) or alloys of these metals are not for employee bidding. 3) A gate pass is required for any material removed from the plant premises. Employees should not assume that because an item is obviously obsolete, whether it is in the scrap pile or not, it can be removed from the plant without obtaining a gate pass. CCR 000079979 VCM Plant Employees Page 2 February 1, 1980 4) Only employees may load scrap for removal from the plant. Non-employees (including family members, relatives, friends, etc.) may not help load scrap. Both of the policies described above have been established and administered for the benefit of our plant employees. Therefore, policing of these policies and procedures is the responsibility of all employees. Deviations from the policies and procedures outlined above could jeopardize the con tinuance of these benefits for all employees. Unauthorized removal of tools, scrap, etc. from the plant must be considered as theft of company property and dealt with accordingly. Your adherence to the proper procedures related to these policies is ex pected and appreciated. Distribution Bulletin Boards Supervisors Department Heads CCR 000079980 r7<7?Ts3.V GATE PASS FOR SCRAP OF PURCHASED MATERIAL REMOVED FROM VCM PLANT Name_____________ Employee Items Approved: __________________ ___________________ Supervisor _______ Date Approved: ____________________________________________ Department Head Date Rev. 9/80 CCR 000079981 LOAN TOOL ISSUE SLIP ITEM Subject item is being loaned to me for the following dates: to I understand that I will assume full responsibility for returning this item in same condition as when borrowed. Signed Employee APPROVED: ___________ _____________________________ Mechanical Maintenance Supervisor Instrument-Electrical Supervisor Issued By: _______________________________________ Tool Room Attendant Instructions: This form is to be filled out in duplicate, one copy to be given to employee borrowing tool, the other retained by Tool Crib Attendant. Upon return of tool, employee will return his copy which will be matched with copy held by Tool Room Attendant. These copies will be filed in employee's tool crib file. Any tool not returned within alloted time will be brought to the immediate attention of the Mechanical Maintenance Supervisor or Instrument-Electrical Supervisor. Rev. 9/80 USE PLEASE DO NOT ABUSE CCR 000079982 Lake Charles VCM Plant CERTIFIED MAIL #316131 RETURN RECEIPT REQUESTED September 9, 1980 Conoco Chemicals Company A Oivision of Conoco Inc. P.O. Bo* 605 Westlake. Louisiana 70669 (318) 491-521 1 Barbara Brand TRW Environmental Engineering Division 1509 Main Street Suite 720 '* Dallas, TX 75201 ? ** ; Dear Ms. Brand: The following is provided in response to your request for more information regarding Conoco Chemicals Company's permit application for construction of modifications to the Conoco VCM Plant in Westlake, Louisiana. Specifically, we wish to clarify the point of emissions potential in the VCM Plant's Vent Gas Incineration Unit (Point Source I.D. No. V-A). The Plant has identified this point as the flue gas vent stack downstream of the Incineration Unit. The Incinerator is not listed as a control device for hydrocarbon reduction since National Emission Standard for Hazardous Air Pollutants (NESHAP) regulations require reduction of vinyl chloride emissions from the vents from the Plant process. Therefore, the Incinerator is .required for compliance with NESHAP regulations and is considered an integral partof the process. The Incineration Unit is also defined as a production unit since muriatic (hydrochloric) acid is produced in its operation. The flue gas immediately exiting the incinerator cannot be considered a source of emission potential either, even though the flue gas enters scrubbing towers tHCl Absorber and Caustic Scrubber) immediately downstream of the Incinerator. The HC1 Absorber and the Caustic Scrubber form an integral unit with the Incinerator. The Incinerator cannot be operated without the HC1 Absorber and the Caustic Scrubber. Also, the HC1 Absorber is the equipment in which the product muriatic acid is re covered and thus it also constitutes a production unit. Therefore, the vent stack \ downstream of the Caustic Scrubber is the only source of emission potential in the Incinerator Unit. Also enclosed is a copy of a letter sent to Randall Brown of the EPA confirming the approval of our State Construction Permit by the Louisiana Department of Natural Resources. Revisions to the permitted emissions are included, and these revised emissions should be used in PSD determinations. If you have any questions or require further information concerning this letter, please contact G. L. Foshee, Chief Process Engineer, at (318) 491-5062. Sincerely iSc: REL-CRH-HJN-VAM-GLF-PLF-DLD-J WW-JCL-DLD OCR 000079983 lak Charles VCM Plant CERTIFIED MAIL #315690 RETURN RECEIPT REQUESTED (cor-^co) Conoco Chemicals Company A Division of Conoco Inc. P 0. Box 605 Westlake. Louisiana 70669 <3181 491 -5211 September 8, 1980 Mr. Randall E. Brown Environmental Protection Agency 6AAHAT Technical Support `Section First International Building 1201 Elm Street Dallas, TX 75270 i Dear Mr. Brown: Attached is the revised Section IV of the Appendix of the Prevention of Significant Air Quality Deterioration (PSD) permit application which was submitted to your office on February 14, 1980 by the Conoco VCM Plant. These revisions reflect an updating of information as the engineering on the plant expansion continues. These revisions constitute a decrease in permitted emissions. A copy of the revised Emissions Inventory Questionnaire (EIQ) which was sent to the State of Louisiana is also included. This EIQ is considered by the State to be the permit. Since the revisions reflect an emissions decrease, the State does not require that the revisions be placed before the commission. However, by submission of the revised EIQ to the Technical Secretary, the new EIQ becomes the enforceable permit. A copy of the letter confirming the approval of the original State Construc tion and Operating Permit by the Louisiana Environmental Control Commission on March 25, 1980 is attached. The revised EIQ that was submitted to the State now supersedes the EIQ in the original permit and is considered the enforceable permit. If there are any questions, please contact Gary Foshee at (318) 491-5062. Sincerely, di Plant Manager is Enc CC: Kathy Bell Barbara Brand BCC: REL-CRH-HJN-VAM-GLF-PLF-DLD-JWW-OCL-JGC CCR 000079984 APPENDIX SECTION IV EMISSION CALCULATIONS CCR 000079935 TABLE I SUMMARY OF EMISSIONS TONS/YR. Incremental ID Potential to Emit Hydrocarbons Total Point Source VCM Point Source Other Hydrocarbon Point Source Particulates Carbon Monoxide Nitroaen Oxide Sulfur Dioxide 5.59 6.78 1.62 19.2V 9.57 22.17 59.3&". Expanded Plant Total A1lowable Existing Plant . To tal Allowable Total Net Change 23.39 11.18 12.2186183 17.73 244.97 68.45 4636.0 60.1 4575.9 67.62 1784.16 223.9 9.13 -4612.61 - 48.92 -4563.69 + 19.21 -1766.43 + 21.07 + 59.32 c ') *-The "Potential to Emit" was calculated from a base of existing allowable emissions v- ' and, therefore, only represents the potential to emit above the present permit J conditions. CCR 000079986 o o X) 00079987 Source Oxychlorination Vent Stack 1.0. No. IV-4 No. 1 Cracking Furnace 1.0. No. 1I-A Pollutant i| Particulates , Hydrocarbons - Total Carbon Monoxide j/litrogen Oxides Sul fur Dioxide VCM Particulates Hydrocarbons Total Carbon Monoxide Nitrogen Oxides Sul fur Dioxide No. 2 Cracking Furnace I.D. No. I1-B Particulates Hydrocarbons - Total Carbon Monoxide Nitrogen Oxides Sul fur D.ioxide TABLE II POINT SOURCE EMISSIONS - EXISTING. AND EXPANDED CASE Existing Permit Tons/Vr. 0 4610.0 1776.0 0 0 55.8 3.81 0.634 3.6 48.7 4.48 Expanded Potential to Emit^ Tons/Yr. 0 0 0 0 0 0 0 0 0 0 0 Expanded Actual Tons/Yr. 0 0 0 0 0 0 3.81 0.634 3.6 48.7 4.48 3.81 0.634 3.6 ' 48.7 4.48 0 3.81 0 0.634 0 3.6 0 48.7 0 4.48 Expanded^ Allowable Tons/Yr. 0 0 0 0 0 0 3.81 0.634 3.6 48.7 4.48 3.81 0.634 3.6 48.7 4.48 Net Change to Expanded A Tons/Yr 0 -4610.0 -1776.0 0 0 - 55.0 0 0 0 0 0 0 0 0 0 0 1) Expanded allowable represents the emission values based upon the emission permit application submitted to the Stateof Louisiana, 2) Potential to Emit addresses only the emissions which are over the existing permits. Source Propylene Vent Stack l.D. No. IV-C No. 3 Cracking Furnace 1.0. No. n-c Oock EOC Tank l.D. No. 1V-J Pollutant Particulates . Hydrocarbons - Total Carbon Monoxide Nitrogen Oxides Sul fur Dioxide TABLE H (Cont'd.) POINT SOURCE EMISSIONS - EXISTING AND EXPANDED CASE Existing Permit Tons/Yr. Expanded Potential to Emit^ Tons/Yr. Expanded Actual Tons/Yr. 0 8.2 *0 0 0 0 0 0 0 0 0 0 0 0 0 Particulates Hydrocarbons - Total Carbon Monoxide Nitrogen Ox ides Sul fur Dioxide .0 0 0 0 0 3.24 1.62 8.10 22.17 57.47 3.24 1.62 8.10 22.17 57.47 Particulates Hydrocarbons - Total Carbon Monoxide nitrogen Oxides Sulfur Dioxide 0 7.33 Q 0 0 00 0 7.33 00 00 00 Expanded^ Allowable Tons/Yr. 0 0 0 0 0 3.24 1.62 8.10 22.17 57.47 0 7.33 0 0 0 Net Change - Existing to Expanded Allowable Tons/Yr. 0 -0.2 0 0 0 + 3.24 + 1.62 + 8.10 +22.17 +57.47 0 0 0 0 0 1) Expanded allowable represents the emission values based upon the emission permit application submitted to the State.of Louisiana. 2) Potential to Emit addresses only the emissions which are over the existing permits. CCK 000079983 .CJL Dock VCM Vent Recovery I.D. No. 1V-K Pollutant \Particulates Hydrocarbons - Total Carbon Monoxide Nitrogen Oxides Sulfur Dioxide Vent Incinerator I.D. No. V-A Total Particulates Hydrocarbons - Total Carbon Monoxide Nitrogen Oxides Sul fur Dioxide VCM Particulates ' Hydrocarbons - Total Carbon Monoxide Nitrogen Oxides Sulfur Dioxide VCM TABLE II (Cont'd.) POINT SOURCE EMISSIONS - EXISTING AND EXPANDEO CASE Existing Permit Tons/Yr. 0 0.1 0 0 0 Expanded Potential to Emit^ Tons/Yr,______ 0 0 0 0 0 Expanded Actual Tons/Yr. 0 0.1 0 0 0 60.0 9.1 0.96 126.5 0.166 4.3 67.62 4636.0 1784.16 ' 223.9 9.13 60.1 15.97 3.97 1.47 0 1.85 6.78 19.21 5.59 9.57 22.17 59.32 6.78 75.97 13.07 2.43 125.40 2.02 11.08 86.83 23.39 17.73 244.97 68.45 11.18 Expanded^ Allowable Tons/Yr. 0 0.1 0 0 0 75.97 13.07 2.43 125.40 2.02 11.08 86.83 23.39 17.73 244.97 68.45 11.18 Net Change - Existing to Expanded Allowable Tons/Yr. _____ -0 0 0 0 0 + 15.97 + 3.97 + 1.47 -1.1 + 1 .85 + 6.78 + 19.21 -4612.61 -1766.43 + 21.07 + 59.32 - 49.02 1) Expanded allowable represents the emission values based upon the emission permit application submitted to the State of Louisiana. 2) Potential to Emit addresses only the emissions which are over the existing permits. CCR 000079989 SAMPLE EMISSION CALCULATIONS EXPANDED VCM PLANT New EDC Cracking Furnace Description The calculations for the emissions for the new cracking furnace are done as follows: 1. Determine required heat duty. 2. Select the fuel. 3. Determine the fuel firing rate based on the lower heating value (LHV). 4. For all pollutants, except N0X, the emissions are then M gallons fuel burned times the emission factor obtained from the EPA Publication AP-42. 5. For N0X, a stack gas calculation is made based on 15% excess air. N0X emitted is then calculated based on information provided by John Zink Company for its Lo N0X burner and the particular fuel type. This calcula tion was used for the expanded actual and expanded allowable categories of Table II. The expanded potential to emit category of N0X on Table II was calculated by multiplying the M gallons fuel burned times the emission factor obtained from the EPA Publication AP-42. 6. Stack gas concentrations are calculated from the emissions and the stack gas flow rate. Sample Calculations 1. Heat release required--51.314 MM BTU/Hr. 2. Use purchased No. 2 fuel oil with a LHV of 126,788.1 BTU/Gal. and a sulfur content of 0.25 wt. %. 3. Fuel firing rate-- Firinq rate = 51.314 x 106 BTU/Hr. = 404.723 Gal. of No. 2 Fuel Oil 126,788.1 BTU. Hr. Gal. CCR 0Q007999Q 4. Emission Calculations (except NO^)-- AP-42 Emission Factors Pol 1utant Particulates Hydrocarbons Carbon Monoxide Sulfur Dioxide Factor (Lb./M Gals.) 2 1 & 142 (wt. % sulfur) Particulates 404.723 Gals, x 2 Lb. x M Gals. x Ton x 8,000 Hr. Hr. M Gals. 1,000 Gals. 2,000 Lb. Yr. = 3.24 Tons/Yr. Hydrocarbons 404.723 Gals, x 1 Lb. x M Gals. x Ton x 8,000 Hr. Hr. M. Gals. 1,000 Gals. 2,000 Lb. Yr. - = 1.62. Tons/Yr. Carbon Monoxide 404.723 Gals, x 5 Lb. x M Gals x Ton x 8,000 Hr. Hr. M Gals. 1,000 Gals. 2,000 Lb. Yr. = 8.10 Tons/Yr. Sulfur Dioxide 404.723 Gals, x 142 (0.25) Lb. x M Gals. x Ton x 8,000 Hr. Hr. M Gals. 1,000 Gals. 2,000 Lb. Yr. = 57.471 Tons/Yr. Emission Calculations for NQX-- AP-42 Emission Factor'' Pol 1utant Factor (Lb./M Gals.) N0X 22 John Zink Co. Lo NO* Burner Factor Pol 1utant Factor (Lb./MM BTU) N0X 0.108 CCR 000079991 Uncontrolled NQV 404.723 Gals, x 22. Lb. x M. Gals. x Ton 8,000 Hr. Hr. M~ GaTsT 1,000 Gals. 2,000 Lb. x Yr. = 35.62 Tons/Yr. Controlled N0y 51.314 MM BTU x 0.108 Lb. x 8,000 Hr. Ton Hr. MM BTU Yr. x 2,000 Lb. = 22.168 Tons/Yr. Stack Gas Concentrations--based on the maximum possible flowrates. Particulates 0.97 Lb. of Particulates x Lb,-Mole Hr. 12 Lb. of Particulates x ,, . 737.231 ft.3______ x Min. x Hr. Lb.-Mole of Stack Gas 22,375 ft.3 60 Min. x 1 x 106 = 44.5 PPM (parts per million) Million Hydrocarbons 0.49 Lb. of Hydrocarbons x ________ Lb.-Mole Hr. 66 Lb. of Hydrocarbons x __________ 737.231 ft.3 x Min. _ x Hr. Lb.-Mole of Stack Gas 22,375 ft.3 60 Min. x 1 x 106 = 4.1 . PPM Mi 11 ion Nitrogen Dioxide 6.65 Lb. of Nitrogen Dioxide - x ______Lb.-Mole Hr. 46 Lb.-of" Nitrogen Dioxide x 737.231 ft.3______ x Min. Lb.-Mole of Stack Gas 22,375 ft. x Hr. 60 Min. x 1 x IT)6 = 79.3 PPM Mi 11 ion OCR 000079992 Sulfur Dioxide - 17.24 Lb. of Sulfur Dioxide X Lb.- Mole Hr. 64 Lb. of Sulfur Dioxide x 737.231 ft.3 x Min. X Hr. Lb.-Mole of Stack Gas 22,375 ft 3 60 Min. x 1 x 106 = 147.9 PPM Million Carbon Monoxide 2.43 i_b. of Carbon Monoxide X Lb. -Mole Hr. 26 Lb. of Carbon Monoxide x 737.231 ft.3 Lb.-Mole of Stack Gas x Min. 22,375 ft.3n x Hr. 60 Min. x 1 x 106 = 47.7 PPM Million 000079993 cca Vent Incineration Unit Description The calculations for the emissions for the vent incineration unit are done as follows:. 1. Determine the incineration unit exhaust gas rate. 2. Determine the applicable emission factors for the incineration unit. 3. For all pollutants, the emissions are then calculated by multiply ing the exhaust gas flow rate times the applicable emission factor. 4. Stack gas concentrations are calculated from the emissions and the exhaust gas flow rate. Sample Calculations 1. Exhaust gas rate--1,536,900 DSCF/Hr., based on the firing of the vents and the waste liquid streams from the expanded plant with 80% excess air. 2. "The incineration unit vent stack was tested by Kemron Environmental Services during a recent test run of the incineration unit. The data calculated from this test run were used as a basis for the emission factors to be used for the expanded plant. See the attached data sheet. At the expanded operating rate of the revised plant, the scrubbers will operate near the limit of their capacity for the efficient control of pollutants, therefore, a linear extrapolation of the test run data is not considered to be valid at the expanded operating rate of the revised plant. In our best judgement, the scrubbing efficiency will be nonlinear in this operating range and we have determined the emission factors to be as follows: Emission Factors Pollutant Particulates Sulfur Dioxide Nitrogen Dioxide Hydrocarbons Carbon Monoxide Factor (Lbs./DSCF) 1.1315 x IQ"5 2.993 x 10-7 1.868 x 10-5 2.9507 x 10-7 3.6098 x IQ"7 Seethe Air Pollution Engineering Manual, (Second Edition), Part I, Pages 208-216 for an explanation of the effects of increased flow rates on the operation and efficiency of packed scrubbers. This manual was prepared for the EPA. CC* ooqo 79994 The emission factor for VCM ..emissions from this source was based on the allowable emission of 10 ppm VCM in the exhaust gas of the incinerator. Emission Calculations-- Particulates 1,536,900 DSCF x 1.1315 x 10"5 Lb. 'x. 365 Days Hr. DSCF Yr. x 24 Hrs. x Ton = 75.97 Tons/Yr. Day 2,000 Lb. Sulfur Dioxide 1,536,900 DSCF x 2.993 x TO'7 Lb. x 24 Hrs. x 365 Days Hr. DSCF Day Yr. x Ton ~ 2.02 Tons/Yr. 2,000 Lb. - Nitrogen Dioxide 1,536,900 DSCF x 1.868 x 10'5 Lb. Hr. DSCF x 24 Hrs. Day x 365 Days Yr. x Ton = 125.40 Tons/Yr. 2,000 Lb. Hydrocarbons (Excluding VCM) 1,536,900 DSCF x 2.9507 x 10"7 Lb. x 24 Hrs. x 365 Days Hr. DSCF Day Yr. x Ton = 1.99 Tons/Yr. 2,000 Lb. Carbon Monoxide 1 ,536,900 DSCF x 3.6093 x 10"7 Lb. Hr. - DSCF x 24 Hrs. Day x 365 Days Yr. x Ton = 2.43Tons/Yr. 2,000 Lb. CCR 000079995 VCM 1 ,536,900 DSCF x 10 DSCF x 62.5 Lb. of VCM Hr. 1 "x TO6" DSCF Lb.-Mole x Lb.-Mole x 24 Hr. x 365 Day x Ton 379.565 SCF* Day Yr. 2,000 Lb. = 11.08 Tons/Yr. * 379.565 SCF/Lb.-Mole at 60F, 1 atm. 4. Stack Gas Concentrations--based on the maximum possible flowrates Particulates 21.61 Lb. of Particulates x ________ Lb.-Mole Hr. 12 Lb. of Particulates x 427.01 ft.3 x Min. ,, x Hr. Lb.-Mole of Stack Gas 28,817 ft. 60 Min. x 1x10^ = 444.8 PPM (parts per million) Million Total Hydrocarbons 3.70 Lb. of Hydrocarbons x ________ Lb.-Mol e Hr. 28 Lb. of Hydrocarbons x 427.01 ft.3 x Min. Hr. Lb.-Mole of Stack Gas . 28,817 ftr x 60 Min. x 1 x 106 = 32.7 PPM Million Nitrogen Dioxide 35.68 Lb. of Nitrogen Dioxide x ___________ Lb.-Mole Hr. 46 Lb. of Nitrogen Dioxide x 427.01 ft.3 Lb.-Mole of Stack Gas xMin. x Hr. 28,817 ft.3 60 Min. x 1 x 106 = 191.5 ppm Million CCft 000079996 Sulfur Dioxide 0.57 Lb. of Sulfur Dioxide x Lb.-Mole Hr. 64 Lb. of Sulfur Dioxide x 427.01 ft.3 x Min. Lb.-Mole of Stack Gas 23,817 ft. x Hr. 60 Min* x 1 x 10^ = 2.2 ppm Mi 1 lion Carbon Monoxide 0.69 Lb. of Carbon Monoxide x __________Lb*-Mole Hr. 28 Lb. of Carbon Monoxide x 427.01 ft.^ x Min. ,, x Hr. Lb.-Mole of Stack Gas 28,817 ft.3 60 Min. x 1x10^ = 6.1 ppm Million CCR 000079997 COMBUSTION EQUATIONS OF INCINERATION FUEL Process Vents C2H4C12(EDC) + C2H3CL(VCM) + CjjH^CI(Ethyl Chloride) + CHC13 + H20 + CC14 + 2H20 ch4 c2h4 + C2H6 h2 + + CO + 2.5 2.5 2 roo ------ > ------ > 3.0 2 -------- > 0.5 2 -------- > 2.0 2 3.0 2 3.5 2 0.5 2 0.5 02 ------ > ------ > --> ------ > ------ > ------ > 2Z0Z 2C02 2C2 co2 co2 co2 2C02 2C02 co2 + H20 + H2 + 2H20 + 2H20 + 2H20 + 3H20 + h2o + + + + + 2HC1 HC1 HC1 3HC1 4HC1 CCR 000079998 By-Product Liquids 1. Light Ends C2H4C12 (EDC) C2H3C1 (VCM) + 2.5 02 + 2.5 02 C2H5CI (Ethyl Chloride) + CHC13 + H20 + 3.0 02 0.5 02 CCI4 + 2H20 c2h4 + 3.0 02 C2H2C12 + 2.0 02 2. Tars (elemental equations) C (Carbon) + 02 H (Hydrogen) + 0.25 02 Cl (Chlorine) + 0.5 H20 -------> 2C02 -------> 2C02 -------^ 2C02 ------ > co2 -------> co2 ------ => 2C02 -------^ 2C2 + h2o + h2o + 2H20 + 2h2 + + + + + + ------ > co2 ------ > 0.5 H2 0 ------ > HC1 + 0.25 2 Supplemental Fuel ch4 + 2.0 02 ------- ^ co2 + 2H2 2HC1 HC1 HC1 3HC1 4HC1 2HC1 The following tables itemize the sources and flowrates of the vent feed to the incinerator and the components and flowrates of the exhaust gases from the in cinerator firebox. OOOOl^" cc* TABLE III INCINERATOR VENT FEED MOLES/HOUR EDC VCM Et. Cl. CHC13 CC14 CH4 C2H4 CzH6 h2 2 N2 CO C02 HCT Loadinq .. 6.00 -- -- -- -- -- -- -- -- 148.30 ---- Direct Chlorination Header 0.56 0.80 0.47 -- -- 21.56 6.17 1.07 4.34 25.11 61.59 2.79 31.18 15.86 Subtotal 154.30 Auxiliary Fuel (CH4) 171.50 Subtotal Stoichiometrie Combustion Air Excess Combusti on Air TOTAL Wet Vent Header 3.89 7.39 40.26 4.77 2.39 5.42 17.51 0.85 -0.89 43.18 0.41 2.77 -- 129.73 02 _ 325.68 281.34 Ng 1225.18 1058.39 Total 4.45 14.19 40.73 4.77 2.39 26.98 23.68 1.92 4.-34 26.00 253.07 3.20 33.95 15.86 455.53 22.50 478.03 1550.86 1339.71 3368.6 ccr ooooaoooo TABLE IV ' COMBUSTION OF VENTS MOLES/HOUR Vent Component Component Vent Rate EDC VCM Et. Cl. CHC13 CC3 4 ch4 c2h4 c2h6 h2 2 N2 CO C02 HCT Subtotal Auxiliary Fuel (CH4) TOTAL 4.45 14.19 40.73 4.77 2.39 26.98 23.68 1.92 4.34 26.00 253.0? 3.20 33.95 15.86 455.53 22.50 478.03 Oxygen Required 11.13 35.48 122.19 2.39 -- 53.96 71.04 6.72 2.17 (26.00) -- 1.60 ___ -- 280.68 45.00 325.68 Incinerator Firebox Effluent (1) C02 HC1 h2o 8.90 28.38 81.46 4.77 2.39 26.98 47.36 3.84 --___ 3.20 33.95 -- 241.23 22.50 263.73 8.90 14.19 40.73 14.31 9.56 -___ -- -- ___ __ .... 15.86 103.55 103.55 4.45 14.19 81.46 (4.77) (4.78) 53.96 47.36 5.76 4.34 __ __ ___ -- 201.97 45.00 246.97 (1) The incinerator firebox effluent also includes 281.34 moles/hour of excess oxygen and 2283.57 moles/hour of nitrogen. ccr ooooaoooi SAMPLE CALCULATIONS FOR DETERMINING THE INCINERATOR FIREBOX EFFLUENT FROM PROCESS VENTS Example -- EDC at 4.45 moles/hour C2H4C12 (EDC) + 2.5 02 ______ ^ 2C02 + H20 + 2HC1 Oxygen consumed (4.45 Mol. EDC/Hr.)(2.5 Mol. 02/Mol- EDC) = 11.13 Mol./Hr. C02 Produced (4.45 Mol. EDC/Hr.)(2.0 Mol. C02/Mol. EDC) = 8.9 Mol./Hr. H20 Produced (4.45 Mol. EDC/Hr.)(1.0 Mol. H20/Mol. EDC) = 4.45 Mol./Hr. HC1 Produced (4.45 Mol. EDC/Hr.)(2.0 Mol. HCl/Mol. EDC) = 8.9 Mol./Hr. Oxygen Balance Total Oxygen consumed 11.13 + 35.48 + 122.19 + 2.39 + 53.96 + 71.04 + 6.72 + 2.17 + 1.60 + 45.00 351.68 Mol./Hr. Stoichiometric Oxygen Oxygen consumed minus oxygen supplied in the vent * 351.68 - 26.00 * 325.68 Mol./Hr. Excess Oxygen Percent excess oxygen times oxygen consumed (80%)(351.68 Mols./Hr.) = 281.34 Mol./Hr. Nitrogen Balance Stoichiometric Air Excess Air Nitrogen (Air = 21.0 Mol. % 79.0 Mol. % N2) Stoichiometric oxygen divided by 21.0% = 325.68 * 21% = 1550.86 Mol./Hr. 79% of Stoichiometric Air * (79% x 1550.86 Mol./Hr.) = Excess oxygen divided by 21% 1225.18 Mol./Hr. * (281.34 Mol. 02/Hr.) * 21% = 1339.71 Mol./Hr. (79% x 1339.71 Mol./Hr. = 1058.37 Mol./Hr. CCR 000080002 The following table itemizes the components and flowrates of the light ends byproduct liquid stream and the oxygen required for combustion. The incinerator firebox effluent components and flow rates are also shown. Component EDC VCM Et. Cl. CHCT 3 CC14 c2h4 CTV Subtotal Stoichiometric Air Excess Air TOTAL TABLE V LIGHT ENDS BYPRODUCT LIQUID FIRING Mol./Hr. Oxygen Feed Rate Required 2.10 0.83 10.90 3.60 1.02 0.47 2.15 5.25 2.08 32.70 1.80 -- 1.41 4.30 Incinerator Firebox Effluent n2 co2 HC1 h2q __ 4.20 4.20 2.10 1.66 0.83 0.83 -- 21.80 10.90 21.80 -- 3.60 10.80 (1.80) -- 1.02 4.08 (2.04)* -- 0.94 -- 0.94 -- 4.30 4.30 -- 21.07 47.54 -- 37.52 35.11 21.83 Oxygen Supplied 226.38 47.54 178.84 -- -- -- 181.10 38.03 143.07 428.50 85.57 321.91 37.52 35.11 21.83 000080003 CCR SAMPLE CALCULATIONS FOR DETERMINING THE INCINERATOR FIREBOX EFFLUENT FROM LIGHT ENDS BYPRODUCT LIQUIDS Example: EDC at 2.10 Moles/Hour C2H4C12 (EDC) + 2.5 02 _______ ^ 2C02 + H0 + 2HC1 Oxygen consumed = (2.10 Mol.EDC/Hr.)(2.5 Mol. 02/Mol. EDC) 5.25 Mol./Hr. C02iproduced = (2.10 Mol.EDC/Hr.)(2.0 Mol. C02/Mol. EDC) 4.20 Mol./Hr. HC1 produced = (2.10 Mol. EDC/Hr.){2.0 Mol.HCl/Mol. EDC) 4.20 Mol./Hr. H2O produced Oxygen Balance (2.10 Mol. EDC/Hr.)(1.0 Mol. H20/Mol. EDC) 2.10 Mol./Hr. Stoichiometric Oxygen = 5.25 + 2.08 + 32.70 + 1.80 + 1.41 + 4.30 = 47.54 Mol. /Hr. Excess Oxygen = (8Q%)(47.54 Mol./Hr. Stoichiometric Oxygen) = 38.03 Mol./Hr Nitrogen Excess Air * (79%)(226.38 Mol./Hr. Stoichiometric Air) = 178.84 Mol./Hr = (38.03 HCl/Hr. Excess Oxygen)* (21%Oxygen)= 181.10 Mol./Hr Nitrogen = (79%)(181.10 Mol./Hr. Excess Air) = 143.07 Mol./Hr OCR 000080004 The following table.itemizes the elements and flowrates of the tar byproduct liquid stream and tfie oxygen required for combustion, The incinerator firebox effluent components and flowrates are also shown, Element Carbon Hydrogen Chlorine Subtotal TABLE VI TAR BYPRODUCT LIQUID FIRING Mol ,/Hr Flowrate Oxygen Required Incinerator Firebox Affluent N2 CCJ2 HCl' a2o 59,68 78.13 47.32 59,68 19,53 01.83) -- 59:. 68 - -- 39., 0.6 - 47,32 23.66 185.13 67.38 59., 68 47,32 15,40 Stoichiometric Air Excess Air Total 320.86 256.69 762.68 Oxygen Supplfed 67.38 53.91 121,29 253.48 2Q2.78 456.26 59.68 47.32 _ 15.40 CCR 000080005 SAMPLE CALCULATIONS FOR DETERMINING THE INCINERATOR FIREBOX EFFLUENT FROM TAR BYPRODUCT LIQUIDS Oxygen Consumed = (59.68 Mol. C./Hr.) (1.0 Mol. O^/Mol.C.) + (78.13 Mol. H./Hr.) (0.25 Mol.02/Mol.H) (47.32 Mol, Cl/Hr.) (0.25 Mol. Cl./Mol.Cl) = 67.38 Mol./Hr. C02 Produced = (59.68 Mol.C./Hr.) (1.0 Mol. COj/Mol.C.) = 59.68 Mol. C02/Hr. HC1 Produced = (47.32 Mol. Ci./Hr) (1.0 Mol. HCl/Mol. Cl.) = 47.32 Mol. HCl/Hr. HgO Produced (78.13 Mol. H./Hr.) (0.5 Mol. H20/Mol. H.) (47.32 Mol. Cl./Hr.) (0.5 Mol. H20/Mol. Cl.) 15.40 Mol./Hr. Oxygen Balance Stoichiometric Oxygen Excess Oxygen * (80%) (67.38 Mol./Hr. Stoichiometric Oxygen) = 53.91 Mol./Hr. Nitrogen Balance Stoichiometric = (67.38 Mol./Hr. Stoichiometric Oxygen) t (21%) Air = 320.86 Mol. Hr. Nitrogen = (79%) (320.86 Mol./Hr. Stoichiometric Air) = 253-48 Mol./Hr. Excess Air = (53,91 Mol./Hr. Excess Oxygen) 4 (21%) = 256.69 Mol./Hr. Nitrogen = (79%) (256.69 Mol./Hr. Excess Air) = 202.78 Mol./Hr. CCR 000080006 2 n2 C02 HC1 h2o Total TABLE VII INCINERATOR FIREBOX EFFLUENT RATES MOLES/HOUR VENTS 281.34 2,536.64 263.73 103.55 246.97 3,432.23 LIGHT ENDS 38.03 321.91 37.52 35,11 21.83 454.40 TARS 53.91 456.26 59.68 47.32 15.40 632.57 TOTAL 373.28 3,314.81 360.93 185.98 284.20 4,519.20 TABLE VIII INCINERATOR STACK EFFLUENT RATES 01 MOLES/HOUR 2 n2 C02 Total VENTS 281.34 2,536.64 263.73 3,081.71 LIGHT ENDS 38.03 321.91 37.52 397.46 TARS 53.91 456.26 59.68 569.85 TOTAL 373.28 3,314.81 360.93 4,049.02 (1) The H20 and HC1 are removed in the scrubbers. Incinerator Stack Vent Rate (DSCF at 60F and 14.7 psia) DSCF/Mol. = RT/P = (10.73 Ft3 - psia/Mol R.) (460 + 60) R.) 7 (14 .7 psia) = 379.565 Ft3/Mol. DSCF/Hr. = (4049.02 Mol./Hr.) (379.565 DSCF/Mol.) = 1 ,536,900 DSCF/Hr. OOOOSOOOT cc* Parameter Filterable Particulates Total Particulates Sulfuric Acid Mist Sulfur Dioxide Oxides of Nitrogen. Hydrogen Chloride Total Hydrocarbons Non-Methane Hydrocarbons EMISSION TESTING FOR CONOCO Cond. I Cone. Rate GR/DSCF S/hr 0.0205 0.0319 0.08 - 0.0326 0.113 1 ppm 1.25 1.95 0.653 1.99' 6.90 1 ppm Cond. II Cone. GR/DSCF Rate S/HR 0.0395 0.0506 3.83 4* 00 10 0.00649 - 0.613 -_ 0.0285 2.73 0.110 10.5 * Dorg-Worrtef CorpOfCTiOO ccr ooooaoooa / FRANK A. ASHBY, JR. SECRETARY DEPARTMENT OF NATURAL RESOURCES OFFICE OF ENVIRONMENTAL AFFAIRS AIR QUALITY DIVISION September 2, 1980 B. JIM PORTER ASSISTANT SECRETARY Conoco Chemical Company P. 0. Box 605 Westlake, Louisiana 70669 Re: Modification of VCM Plant Dear Sir: This is to confirm that your permit request for the above referenced project at Conoco Chemicals Co., Lake Charles has been approved by the Louisiana Environmental Control Commission. The submittal was approved on the basis of emissions reported and the approval in no way guarantees the design presented will be capable of controlling the emissions to types and quantities stated. scheme the Date: March 25, 1980 Permit No. 1424 The attached 2 synopsis sheets and 3 data sheets establish the emission operating limitations which condition this certifi cate of approval. A new application must be submitted if the reported emissions are exceeded after operation begins. The permit number cited above should be referenced in future correspondence regarding this subject. Sincerely, BJP/AB/ebp B. Jim sorter Assistant Secretary Office of Environmental Affairs CCR 000080009 P.O. BOX 60630 . NEW ORLEANS, LA. 70160 . PHONE 504 568-5121 . 325 LOYOLA AVENUE LOUISIANA ENVIRONMENTAL CONTROL COMMISSION AIR QUALITY DIVISION CONOCO CHEMICAL COMPANY LAKE CHARLES VCM PLANT Westlake (Calcasieu) This permit request by Conoco Chemicals Company, a Division of Conoco Inc., is for permission to modify its existing vinyl chloride monomer pro duction facility located at Westlake in Calcasieu Parish to expand its production capacity from 700 million pounds per year to one billion pounds per year on an annualized basis. The expansion will be accomplished by adding a parallel train to the VCM system and debottlenecking existing equipment. The technology will be based on a well proven system. Process emissions will be controlled by recovering hydrocarbon as much as practical and then by incineration to meet the NESHAP Standard of less than 10 ppm VCM in any vent gas. Process incinerators will be controlled with wet scrubbers and the new heater will use LoNOx burners. Sulphur oxide emissions will be controlled by using fuel of less than 0.7% sulfur content. The debottlenecking techniques employed will result in hydrocarbon and CO being reduced by 4609 and 1768 tons per year respectively. Dispersion modeling supplied by the company indicates that ambient air quality standards will not be violated. Table I shows the effect of this plant expansion on emissions of the facility as a whole. NSPS does not apply to this facility. Recommendations ----------------- -(See Approval) JHS/ys CCR 000080010. RECO^ENGATION: CONOCO CHEMICAL COMPANY LAKE CHARLES VCM PLANT WeS tlake (Calcas ieu) Approval provided the following conditions are met. 1) The synopsis sheets and the attached data sheets establish the emission and operating limitations and are a part of the permit. The synopsis and data sheets are based on the application for approval of emissions dated Feb-runtv 5. 1980with supplemental information submitted February 8. 1980y The application and supplemental information are also considered part of this permit by reference. 2) Construction must' commence. within two years after the date of approval. 3) The permittee will submit to the Technical Secretary semiannual reports of progress defining the status of construction, noting any design changes, modifications or alterations in the construction schedule which have or may have an effect upon the emission rates or ambient air quality levels. Such reports shall continue to be submitted until such time as construction is certified as being complete. 4) ` Any emission testing performed for purposes of demonstrating compliance with the limitations set forth in Condition 1 shall be conducted in accordance with the methods described and referenced in Table- 4 of the current Louisiana Air Control Commission Regulations 5) The permittee shall, within ISO days after certifying, the completion of construction prepare and Submit to the Technical Secretary a report detailing the actual emission rates as compared to those limitations specified in Condition 1. The report shall also include, but not be limited to, malfunctions and upsets. OCR 000080011 LOUISIANA ENVIRONMENTAL CONTROL COMISSION Air Quality Data Sheet Page 1 CCNOCO CHEMICAL COMPANY Westlake ("Calcasieu) Location of plant: ^_____________________ UTM477 q Km E vufi 5_________________ _ Km N Description of location: ,2 mips northintersect-inn of Tniecdalp Rond and Old Spanish Trail______ ____________ __ _______________________________________________ Estimated starting date Estimated date opera- of construction: April 1981___________ tion will begin: November 1982 Type of Dispersion Calculations Used: _________ CRSTER Pollutant NQx Time Period Annual SO2 Ann/24/8 CO 8/1 Part Annual/24 EFFECTS OF AMBIENT AIR Calculated Maximum Ground Level Concentration 4 ug/M3 1/6/14 ug/M3 3/6 ug/M3 3/24 ug/M3 Louisiana Air Control Commission Standard 100 80/365/1300 10000/40,000 75/260 NEW OR MODIFIED [x] EMISSION SOURCES Stack I.D. # IIA Description Cracking Furnace I IB Cracking Furnace IIC Cracking Furnace IV-J Dock EDC Tank IV-K Dock VCM Vent V-A Vent Incinerator Operating Rate (Maximum) 17607 CFM 17607 CFM 22375 CFM 6 CFM 316 CFM 28817 CFM VCM Plant (Type of Source) Operating Schedule Hrs/Day Days/Wk Wks/Yr 24 7 49 24 7 49 24 7 48 24 7 52 3 1 52 24 7 52 30080012. CCR 0( ! 1 - . ! i i i i i * k j i STACK ID IV -J ' IV -K 1 V -A 1 V II >--1 t-H HH t--( nW ts3 1--* 1 O' o\ ON OOo3no on 31 TD 9n> 1 ~*0 1--1 t--* 30> 04 03 22 W no w SJ 2 3H cn fDj3^ t h- ~-0 04 03 03 1--* H- o t-* ro w H o 2 cn 3) fe n> -i ra > 53 H 32 -* 0hH-3>- 04 on | *'4 1 ON "4 M ho UD h- 2 ho O * o 03 t-3 wM m--yiJ 3 s Coo r0+3 D - A k-* 04 o 1--* H-* oo HC 3C M 03 H 03 2 a coao>>nr r+ t -4 *--< KO Ln ho hO 03 -3 H2 M OG 2 2w 21 03 DaO ts> r 03 3 o1 | -J i hO O 1--> M o 4 oO 03 f a 03 2 \ 22 15 >r CD 2 h-J t--* >--1 H' (D -J LTJ Ck CO OJ f4 cn o hJ o ho O n 2 CD <T rf H CD 1-- hO cn '-a tn cn CO cn cn O cn cn cn 3 cn T3 o o CD 2 nO 03 rh c H - M On ho oo 00 04 ts) ts> 04 l--* -4 h-' C 'sj On o* 2 3 M -*1 v- On *>4 On cn Oo "O CD 2 & M n w 3* CCR 000080013 TABLE I SUMMARY OF EMISSIONS TONS/YR. - Incremental U) Potential to Emit - Hydrocarbons Total Fugitive VCM Fugitive Other Hydrocarbon Fugitive Total Point Source VCM Point Source Other Hydrocarbon Point Source Particulates Carbon Monoxide Nitroqen Oxide Sulfur Dioxide 29.181 2.62 26.561 8.83 6.78 4.86 40.25 7.95 129.51 59.32 Expanded Plant Total Allowable 86.713 18.062 68.651 26.63 11.18 15.45 107.87 16.11 244.97 68.45 Existing Plant Total Allowable Total Net Chanqe 57.532 15.442 42.09 4636.0 60.2 4575.8 67.62 1784.16 223.9 9.13 29.181 2.62 26.561 -4609.37 - 49.02 -4560.35 + 40.25 -1768.05 + 21.07 + 59.32 1) The "Potential to Emit" was calculated from a base of existing allowable emissions and, therefore, only represents the potential to emit above the present permit conditions. CCR 000080014