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PRESENTED BY
SCREENING OF VOC CONTROL TECHNOLOGIES
TECHNOLOGY OPTIONS AND COMPARATIVE COSTS
PRESENTED AT
DOD/DOE INTERNATIONAL WORKSHOP ON SOLVENT SUBSTITUTION
PHOENIX, ARIZONA
DECEMBER 6, 1990
DR. VICTOR S. ENGLEMAN SCIENCE APPLICATIONS INTERNATIONAL CORPORATION
PROCESS TECHNOLOGY DIVISION
SAN DIEGO, CA 92121 10240 SORRENTO VALLEY ROAD #204
UNDER SPONSORSHIP OF
U.S. DEPARTMENT OF ENERGY CONSERVATION AND RENEWABLE ENERGY OFFICE OF INDUSTRIAL TECHNOLOGIES
SCREENING OF VOC CONTROL TECHNOLOGIES: TECHNOLOGY OPTIONS AND COMPARATIVE COSTS. Dr. Victor S. Engleman, Science Applications International Corporation, 10240 Sorrento Valley Road #204, San Diego, CA 92121.
ABSTRACT
This presentation provides an overview of control technologies for emissions of volatile organic compounds and a discussion of the parameters that influence the cost of these control technologies. The comparative economics of a specific example of a solvent emission control is also presented.
The opportunities for solvent control technologies in representa- tive industries are discussed. Both recovery and destruction technologies are presented and explained. Recovery technologies represent an opportunity to save both energy and money, since solvent recovered may be reused in the same or a similar applica- tion. Each specific case requires separate evaluation because of the specific requirements of the individual application. In order to assist in the initial evaluation of control technologies for specific cases, a screening model is under development. The results of calculations from this screening model are presented in graphical form to illustrate the regions where control technologies are cost-competitive for the specific case of toluene emissions.
The model under development is currently capable of handling twenty-five volatile organic compounds (see Table 1) and fourteen control technology variations (see Table 2). The user can input the concentrations and recovery values of any of the volatile organic compounds in the emissions stream. The user also input stream conditions, such as flow rate, temperature, pressure, operating time, and percent recovery required. The user can also set supply and utility costs such as catalyst, carbon, electricity, steam, and fuel. Labor costs can also be varied. The outputs include capital costs (equipment and installation), operating costs (labor, energy, maintenance, supplies, taxes/insurance, overhead, and solvent recovery credit). Total annualized costs are also calculated. Since this is a screening model, results are expressed as ranges rather than as absolute numbers. The ranges represent the uncertainty of the calculations, based on site-specific factors not considered.
The model is still under development and interested parties are encouraged to contact the author at the above address or by phoning (619) 587-9071 ext 169. Input for cost information, suggestions for inclusion of additional features, case studies for calibration, and general interest are solicited.
TABLE 1 VOLATILE ORGANIC COMPOUNDS INCLUDED IN THE MODEL
ACETIC ACID ACETONE BENZENE CARBON TETRACHLORIDE CHLOROBENZENE p-DICHLOROBENZENE ETHYLENE ETHYLENE DICHLORIDE FORMALDEHYDE HEPTANE METHANOL METHYL CHLORIDE METHYL CHLOROFORM METHYL ETHYL KETONE METHYL ISOBUTYL KETONE METHYLENE CHLORIDE PERCHLOROETHYLENE TOLUENE TRICHLOROETHYLENE TRICHLOROFLUOROMETHE TRICHLOROTRIFLUOROETHANE VINYL CHLORIDE m-XYLENE 0-XYLENE p-XYLENE
TABLE 2
CONTROL TECHNOLOGIES INCLUDED IN THE MODEL
THERMAL INCINERATION THERMAL INCINERATION WITH HEAT RECOVERY REGENERATIVE INCINERATION CATALYTIC INCINERATION ADSORPTION WITH OFF-SITE REGENERATION ADSORPTION WITH ON-SITE STEAM REGENERATION ADSORPTION WITH ON-SITE STATIONARY RANKINE REGENERATION ADSORPTION WITH ON-SITE STATIONARY BRAYTON REGENERATION ADSORPTION WITH ON-SITE DECOUPLED BRAYTON REGENERATION REVERSE BRAYTON CYCLE CONDENSATION REVERSE RANKINE CYCLE CONDENSATION CRYOGENIC LIQUID CONDENSATION (being implemented) ABSORPTION/SCRUBBING (not yet implemented) FINE MIST SCRUBBING (not yet implemented)
CONTROL TECHNOLOGIES ARE A PORTION OF THE SOLUTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i . . . i : 'REUSE:: i : i : ; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
p j!!.. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
An Employee-Owned Company
-Science Applications International corporaton
OPPORTUNITIES FOR SOLVENT CONTROL TECHNOLOGIES
Based on 1988 Study Sponsored by Southern CalEfornia EdIson
MILLIONS OF POUNDS OF SOLVENT
eeEXEMPT" CONTROL NEW INDUSTRY SOLVENTS TECHNOLOGY TECHNOLOGY ----------. ----------- ---------.- ----------- PAlNTS AND 100 172 393
COATINGS
SEALANTS ADHESIVES AND 34 55 174
PRINTING INKS 33 86 31
METAL CLEANERS 52 69 58
AEROSOL 18
PESTICIDES 29 PROPELLANTS
MERCHANT ALKYD 13
DRY CLEANING 6
RUBBER PRODUCTS 11
RESINS
FLUIDS
0
0
39
23
91
5 1
58
39
18
17
NATURAL OILS 0 12 4
BLOWING AGENTS 5 15 5
WOOD 3 PRESERVATIVES
0 2 0
OIL FIELD 0 . 2 2 CHEMICALS
OTHER 168 307 48 1
TOTAL 472 87 1 1351
An Employee-Owned Company
- - s c i e u n ; e A j @ c a & ~ e m a t ~ I ~ t h
EXAMPLES OF CONTROL OPTIONS FOR VOLATILE ORGANIC COMPOUNDS
TREATMENT APPROACH METHOD ----------- ----------- RECOVERY CONDENSATION
ADSORPTION
ABSORPTION
SEPARATION
DESTRUCTION INCINERATION
BIODEGRADATION
TREATMENT TECHNIQUE
OPEN-CYCLE BRAYTON
CRYOGENIC LIQUID
CLOSED-CYCLE RANKINE
CLOSED-CYCLE BRAYTON
CARBON/OTHER
-----------
SCRUBBING
MEMBRANE SEPARATION
THERMAL
CATALYTIC
BlOFlLTRATlON
RECYCLING / REGENERATION
COLLECT
COLLECT
COLLECT
COLLECT
INERT GASIBRAYTON
INERT GAWRANKINE
STEAM/DISTILLATION
STEAM/DECANT
DISTILLATION
CONDENSE
W/O HEAT RECOVERY
W/ HEAT RECOVERY
REGENERATIVE
W/O HEAT RECOVERY
W/ HEAT RECOVERY
NONE
-----------
An Employee-Owned Company
PREHEATED AIR
. . . . . . . . . . . . . . : . : . : . : . : . : . : . : . : . : . I . . . . . .......................
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&@+j$$jfiHE@ ;- . . ::c?Mb&j?aR::: ........ . . . . . . . . * . . , . . : .: .: .: .::i: .: .: .: .: .: .: . ..... . . . . . . . . . . : i i ;(QpRiQN&$ i i i .......................... . . . . . . . . . . . . . . . . . . . . . . . . i : i : i : pa jMh~$i: i i i : .,.:.:.:. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . I(, i : i : i : : : i:: :: :.: i:.: : : : : : :: ::*- : i ie*eHA(j&&# i i e EXHAUST . . . . . . . . . ... . . . . . . . . . . . . . . . .
FUEL .,:,.:.*.*.
WASTE .......................... . . .:.:.;::::::::.:::::::::::::. . . : e .
GAS
AIR ~ ~ ~ ~ ~ ~ _ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ - - ~ ~ - - - - - ~ ~ - ~ ~ ~ - ~ ~ - ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ CATALYTIC INCINERATION
PREHEATED AIR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ...................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : a :CHAMBER:::::: -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . * . ; H E ~ ~ i : i : i : i : ; . . eA+A;c*s+;:: : : gxehfi(j:&ij i i :
* : .:;pREAg&;Fj:i:f:; . . . . . . . . e * . * . :.:@gb:;::::i::::: . . . . . . . . . . . . . . . . . . . . . - :.
... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................... .:::.:.:.:.: :: #o#??roN&C)t i ; i
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I . . . . . EXHAUST . . . . . :.::.:::I: . . . . . .
. . . . * . . . . . . . .
. . . . . .......... ....... . . . . . . . . . . . . . . a .
FUEL
WASTE GAS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......................... . . . . . . . . . . . . ............................. .:.:.:.:.
AIR
An Employee-Owned Company
REGENERATIVE INCINERATOR
I I
INLET < - -
I I I I I I I I I I
EXHAUST
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : ........ . . . . CoMabSTj:QN f : ! : f : :: : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
: . . . . . . . . . .'.'.CHkMBER:.fir:!it:fif . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
I
An Employee-Owned Company
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INDIRECT RANKINE OR BRAYTON
AIR AND I I
I I 1 RESIDUAL VAPOR
WATER RECO~ERED voc
An Employee-Owned Company
TO OR
PROCESS EXHAUST
TO I I I
ADSORBER i I
I
I
I
RECUPERATOR
RECOVERED SOLVENT
DIRECT BRAYTON
An Employee-Owned Company
EXAMPLES OF RANGES FOR CONTROL TECHNOLOGIES
RANGES REPRESENT ECONOMIC FEASIBILITY FOR A SPECIFIC APPLICATION TECHNICAL FEASIBILTY CAN COVER A BROADER RANGE
OTHER FACTORS AFFECTING VOC CONTROL SELECTION o VALUE o REACTIVITY o * COMPONENTS o CONDENSATION TEMP o MISCIBILITY
o WATER CONTENT
100,000
U 10,000 3
i s I- w 2 1,000
10 100 1,000 10,000 100,oo 0
VOC CONCENTRATION (PPM)
An Employee-Owned Company . .
EXAMPLES OF RANGES FOR CONTROL TECHNOLOGIES RANGES REPRESENT ECONOMIC FEASIBILITY FOR A SPECIFIC APPLICATION TECHNICAL FEASIBILITY CAN COVER A BROADER RANGE
OTHER FACTOR AFFECTING VOC CONTROL SELECTION o VALUE o REACTIVITY o a# COMPONENTS o CONDENSATION TEMP o MISCIBILITY
o WATER CONTENT
100,000
10,000 a - 4
1,000
100 10 100 1,000 - 10,000 100,000
VOC CONCENTRATION (PPM)
I r a -- An Employee-Owned Company
I \
..
EXAMPLES OF RANGES FOR CONTROL TECHNOLOGIES RANGES REPRESENT ECONOMIC FEASIBILITY FOR A SPECIFIC APPLICATION TECHNICAL FEASIBILITY CAN COVER A BROADER RANGE
OTHER FACTOR AFFECTING VOC CONTROL SELECTION
o VALUE o REACTIVITY o # COMPONENTS o CONDENSATION TEMP o MISCIBILITY
o WATER CONTENT
100,000
10,000 9
4 1,000 w > i
' 0 v)
100
I DIRECT I
I' I I I I
10 100 1,000 10,000 100,000
VOC CONCENTRATION (PPM)
An Employee-Owned Company
