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Home My WebLink AboutDEQ-CFW_00087415General explanation: Semi -works is a research & development area that operates under a wide range of conditions. Emissions are calculated for each individual campaign. These campaigns fall into two categories. One is polymerization campaigns and the other is slurry reclaim campaigns. In both cases, material balance is used to determine emissions. Since all emissions occur within the semi -works facility, there are all assumed to be point source emissions via the process stack SWA. The only emissions calculated for SW-2 are acid fluoride emissions associated with running melt flow samples under the lab hood. Polymerization Campaign Emissions Determination: The production and raw material information is entered for each campaign on a worksheet. The individual sheets in this workbook are copies of the completed worksheets for each campaign. Data in green fields is entered when applicable for the polymerization campaign. The other cells are calculated cells. The emissions for the campaign are calculated at the bottom of the worksheet. For the annual emissions calculations, the emissions from these campaigns are totaled onto a summary sheet. In this workbook, that is called "Campaign Summary". A summary by month is found on "Year End Summary". Example Mass Balance Calculations for polymerization campaigns: (using 5-SXF-1.1 worksheet for example) The emissions are determined by mass balance around the system. Data used in the calculation is obtained from production records and entered into the worksheet. The following is entered into the worksheet after each campaign: 1) Enter the starting material at the beginning of the campaign. This would include any material in the recovery tank and condensate tank. The composition of the material in each tank is determined by lab analysis and/or on-line GC. 2) Enter the amount of initiator added to the system, based on integrator on initiator feed. The concentration of initiator is determined by lab analysis. 3) Enter the amount of TFE added to the system, based on the integrator for TFE feed. 4) Enter the amounts of solvent (E2, F113) and monomer (PSEPVE) added to the system during the campaign. Drum weights before and after the campaign are used to determine this. is Enter starting and addition data as described in steps 1-4 above in the green shaded areas. Spreadsheet sums all inputs for each component in right hand column (column M)....see embedded comments for details A-Aft 7777- Item Recovery Monomer Condensate Initiator Addition Addition Addition Addition Tank Tank Tank Tank (TFE) (E2) (PS) (F1 13) Weight (Kg): Compositions: %E2 f)�11 "F 5 0 OV"" AV) %PSEPVE . . . . . . . . . . "S " 4 %TFE A:- . ... . %F1 13 %Initltlatoa. N-t-C 4 "F'R Is Weights E2 0.00 0.00 0.00 19.28 0.00 0.00 0.00 0.00 0.00 A PSEPVE 0.00 0.00 0.00 0.00 0.00 0.00 97.00 0.00 0.00 TFE 0.00 0.00 0.00 0.00 114.39 0.00 0.00 0.00 0.00 F1 13 0.00 0.00 0.00 0.00 0.00 0.00 0.00 666.00 0.00 Inititlator 1 0.00 0.00 0.00 0.80 0.00 0.00 0.00 0.00 0.00 5) Enter the amount and composition of material in the recovery tank, condensate tank, in collection drum, or held up in the system at the end of the campaign. Spreadsheet sums all inputs for each component in right hand column (column M)....simllar to above Item Recovery Condensate Drained Tank E2 tank Holdup Tank to drum Tank level Oet off) . Weight (Kg): 0.00 Compositions %E2 'z M" %PSEPVE T"'I "P? R1 ��-a O/oTFE 0F113 %inititiato Weights E2 7.78 0.00 5.02 0.00 3.99 0.00 0.00 PSEPVE 15.00 0.00 7.40 0.00 5.88 0.00 0.00 TFE F1 13 0.00 0.00 0.00 0.00 0.00 0.00 0.00 175.58 0.00 94.37 0.00 74.97 0.00 0.00 Inititlator 0.00 0.00 0.00 0.00 0.00 0.00 0.00 6) Enter total weight of polymer produced, and average EW. 7) Enter approximate weight (5 kg) of adhesions on vessel walls and in piping. with an EW of 1700. 8) Enter amount and composition of slung left over at the end of the campaign. saturation of initiator and limited TFE present during shutdown conditions. The adhesions are assumed to be pTFE The EW is assumed to be 1080 as a result of over LIP",PE Item L Polymer Adhesion Slurry s Weight (Kg): Compositions;; EW p /aPolyme �^�-d ,kw u+l�� q . ��rrry %E2 %PSEPVE %TFE %F11344 777� Weights I Polymer 138.30 5.00 0.00 E2 0.00 0.00 0.00 PSEPVE 41.96 1.31 0.00 TFE 96.34 3.69 0.00 F113 0.00 0.00 0.00 VE in PoIM 41.96 1.31 0.00 The total for each component added, remaining, and production output as calculated in column M for each section of the spreadsheet above is duplicated in the table below. Emissions are difference between amount consumed and amount in product. ..___.. ... Com ound Added Remaining Used Production Other, � E2 19.3 16.8 2.5 0.0 PSEPVE 97.0 28.3 68.7 43.3 2 TFE 114.4 0.0 114.4 100.0 F113 666.0 344.9 321.1 0.0 S'R� Inititiator 0.8 0.0 0.8 0.0 ,�, � • The final section of the spreadsheet summarizes the reportable emissions in pounds for SW-1. Refer to embedded comments for details. Lb$ t�. rrti ions - - SW-9 VOC's 94.8lbs F-113 706.4lbs AF's 2.766lbs 9) Enter in the number of melt flow samples processed in the semi -works lab during the campaign. This is entered in the green box under SW-2. If all samples are sent to the mfg lab, this will be zero. SW-2 # of MF samples grams emissions 0 g Ibs of emissions 0.0000 lb Example Mass Balance Calculations for slurry reclaim campaigns: The slurry reclaim process is used to recover valuable solvent and monomer from drums of polymer slurry. The semi -works flash dryer Is used to flash off the solvent and monomer liquid into a vapor state, so that the solids can be collected in a bag filter. The vapors are then condensed back into liquid which can be reclaimed. Due to a high nitrogen (noncondensible) flow, some of the solvent and monomer escapes the condenser as vapor to the SWA stack. A mass balance approach is used to determine how much vapor has been lost, so that this can be included in annual air emissions summary. Here is a summary of the material balance calculation. 1) Weight of drums processed through the system are recorded. The reported composition of the drums is used to determine VOC and F113 content. Solids and other non -recoverable waste are backed out, based on a material balance on solids (polymer and waste collected). 2) Any fresh E2 solution used for startup of the flash drying system is accounted for in the balance. 3) Outputs include weight of reclaimed liquid collected in drums, weight of solid polymer collected, and weight of solid waste in drums. 0 0 0 Campaign Starts: 4/21/2005 5/3/2005 6/15/2005 7/25/2005 8/23/2005 2/2/2005 Campaign Ends: 4127/2005 5/14/2005 6/2012005 7/2812005 9/1/2005 2/11/2005 TA 05 15i0r�y6� � tk�'a»3i'.� ifrPy'G1 `kCa lbs 94.82 316.37 240.45 281`.01 228.44 0.00 yy...Fq 1 r1.a�,.cr . lbs 706.37 730.29 738.66 35.79 13.56 0.00 a4 e 00 0.00 lbs 2.77 8.36 4.11 0.00 0. K ✓�n b r ra: lbs 0 0 0 0 0 0.2904 r lbs 0 0 0 0 0 0 0 m p C� n I 0 0 0 0o 14 c.