DEQ-CFW_00087844

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DuPont - Fayetteville Works - Butacite® Date: April 28, 2005
2004 SARA Title III Report Page No. 18 of 33
Form D: Process Information (Page 2 of 2)
CY 2001 Facility ID# 0900009 Source ID# BS-1
Actual Emissions per Pollutant Listed for Source/Process Identified Above:
Attach calculations and documentation of emission factors or other estimation methods used.
"Per Ton" Pollutant:
Actual Emissions: Tons/year
PM
PM-10
MP-2.5
SO2
Nox
VOC
1.17
CO
***All Other HAPs/TAPs Per Instructions use additional
sheets if necess ***
Pollutant
CAS #
Emitted
bs./ r.
Comments
Chlorine
7782-50-5
Fluorine
7782414
Hydrazine
302-01-2
Hydrogen Chloride As weight of HCl in solutions
7647-01-0
Hydrogen Fluoride As weight of HF in solutions
7664-39-3
Hydrogen Sulfide
7783-06-4
Lead As metal or compounds — mass of total
LEADCPDS
Methyl Chloroform of a VOC, by rule
71-55-6
Methylene Chloride of a VOC, by rule
75-09-2
Ozone (Not expected as a facility emission)
10028-15-6
Perchloroeth lene of a VOC, by rule
127-18-4
Phos hire
7803-51-2
List all other HAP/TAPs below IN ALPHABETICAL ORDER, Per Instructions. Use more sheets as needed.
DEQ-CFW 00087844

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DuPont - Fayetteville Works - Butacite® Date: April 28, 2005
2004 SARA Title III Report Page No. 19 of 33
2004 AIR EMISSIONS INVENTORY
BUTYRALDEHYDE STORAGE TANK
S-1
EMISSIONS SUMMARY
VOC
VOC EMISSIONS
EMISSIONS
PROCESS EMISSIONS:
(lb. / year)
(TYP)
BA Condenser
751
0.38
VOC
VOC
VOC
EMISSIONS
EMISSIONS
EMISSIONS
Worst case
With 67%
With 67%
scenario based
Reduction for
Reduction for
on AP-42
"Good" control
"Good" control
FUGITIVE EMISSIONS:
(lb. / year)
(lb. / year)
(TYP)
Unloading System
2750
908
0.45
Recirculation System
126
42
0.02
BA Storage Tank
1917
633
0.32
TOTAL EMISSIONS 1
1
2334 1
1.17
DEQ-CFW 00087845

DuPont - Fayetteville Works - Butacite® Date: April 28, 2005
2004 SARA Title III Report Page No. 20 of 33
2004 AIR EMISSIONS INVENTORY
BUTYRALDEHYDE STORAGE TANK
(BS-1)
EMISSIONS DETERMINATION
Butyraldeh dY a (BA) emissions from Storage Tank Condenser (BCD-1):
BA (breathing losses ) to condenser = 24821bs. / year
BA Vapor Pressure at 71.37 °F = 1.844 psi
BA Vapor Pressure at 32 °F = 0.558 psi
BA emissions from condenser = [2482 lb x 0.558 psi = 751 lb.
yr. [-1.844 psi yr.
0 (See information from Title V — Form D6 on the following pages.)
Butyraldehyde (L3A) fugitive emissions from BA Storage Tank:
(See information on the following pages.)
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DEQ-CFW 00087846

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DuPont - Fayetteville Works - Butacite® Date: April 28, 2005
2004 SARA Title III Report Page No. 21 of 33
2004 EMISSIONS AIR INVENTORY
SECTION D - FORM D6
ENGINEERING ANALYSIS TO SUPPORT PERMIT APPLICATION
Emission Unit ID: BS-1
Emission source Description: Butyraldehyde Storage Tank
A. Emission Estimation Approach
Emissions from this unit are based on EPA Publication AP-42 (using EPA -
developed Tanks 2.0 software). Actual working losses are zero because when being
loaded, the tank is vented back to the railcar. Breathing losses are calculated form
the ambient temperature changes in the tank, and are controlled by an 70% efficient
brine cooled condenser. Thus control on working losses is 100% and control on
breathing losses is 70%, and as shown by the calculations below, this gives an
overall control efficiency of approximately 92 — 94%.
Actual Emission Calculations
BA (Breathing Losses) to Condenser 2482 Lbs. / year
Uncontrolled Working Losses 1 (Actual 2004) 7438 Lbs. 1 year
Uncontrolled Working Losses 1 (Potential) 9905
Total Uncontrolled Emissions 2 (Actual 2004) 9920 Lbs. / year
Total Uncontrolled Emissions 2 (Potential) 12387 Lbs. / year
Vapor Pressure 3 at 71.37 °F (21.87 °C) 1.844 Psi
Vapor Pressure 3 at 32 °F (0 °C) 0.558 Psi
Condenser efficiency 4 70% Or greater
BA Emissions From Condenser 5 (Annual) 751 Lbs. / year
BA Emissions From Condenser 5 (Hourly Average) 0.086 Lbs. / hour
Actual Working Loss Emissions 0 Lbs. / year
Overall Control Efficiency 6 (Based on Actual 2004 Emissions) 92% Or greater
Overall Control Efficiency 6 (Based on Potential Emissions) 94% Or greater
DEQ-CFW 00087847

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DuPont - Fayetteville Works - Butacite® Date: April 28, 2005
2004 SARA Title III Report Page No. 22 of 33
SECTION D - FORM D6
ENGINEERING ANALYSIS TO SUPPORT PERMIT APPLICATION
Emission Unit ID:
Emission source Description:
Note:
BS-1
Butyraldehyde Storage Tank
1. Actual 2004 uncontrolled working losses based on 34 turnover.
Potential uncontrolled working losses based on 95 turnovers.
2. Total uncontrolled emissions equal breathing losses plus working losses.
3. Vapor pressure calculated using Antoine Equation
Logp*(T°C) = A—[B/(T°C +C)]
Where p* = vapor pressure
A = 6.3854
B = 913.590
C = 185.480
4. Condenser control efficiency is calculated:
1— ( vapor pressure at 32 / vapor pressure at 71.4 )
This is based o the assumption that the condenser exit temperature will be at 32°F
(because of the low flow associated with breathing losses the gas will be completely
chilled to the coolant temperature in the condenser and 32°F is the upper value of the
condenser temperature; 71.37°F is the average surface temperature in the BA storage
tank — See Tanks 2.0 Output).
5. Emissions from condenser calculated as: Uncontrolled BA to condenser x ( 1—
control efficiency)
Hourly emissions calculated by dividing annual emissions by 8760.
6. Overall Control Efficiency = 1— [ ( annual breathing losses from condenser +
actual working loss emissions) / total uncontrolled
emissions ]
DEQ-CFW 00087848

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DuPont - Fayetteville Works - Butacite® Date: April 28, 2005
2004 SARA Title III Report Page No. 23 of 33
2004 BUTYRALDEHYDE
FUGITIVE EMISSIONS CALCULATIONS
I. FIXED LOSSES
A. Unloading System
Leak Rate = ( pump losses + liquid valve losses + gas valve losses +
flange losses ) x ( weight fraction BA ) x ( total hours)
[(1)(0.109) + (9)(0.016) + (1)(0.012) + (27 )
( 0.0018) ] ( 1.0 ) ( 8760 hours )
= [ 0.109 + 0.144 + 0.012 + 0.049 ] ( 1.0 ) ( 8760 )
= ( 0.314 lbs. / hr. ) ( 8760 hrs. / yr.)
= 2750 lbs. / year
B. Vapor Return System
Area Average Temperature = 75°F
BA Vapor Pressure = 110 mmHg (from Hercules vapor pressure curve)
BA mole fraction in vapor
= Vapor pressure of BA
Total Pressure
= Vapor Pressure of BA
Gauge Pressure + Atmospheric Pressure
_ ( 110 mmHg_)( 1 atm / 760 mmHjz)
( 4 in H2O = 406.8 in H2O ) ( 1 atm / 406.8 inch H2O )
= 0.143 mole BA / mole of gas
Leak Rate = [ gas valve losses + flange losses ] ( fraction BA )( total operating hours )
_ [ ( 2) ( 0.015) + ( 5) ( 0.0018) ] 0.143 mol BA 72 lbs. BA mole gas (8760 hr. )
mole BA 28 lbs. gas yr.
DEQ-CFW 00087849

DuPont - Fayetteville Works - Butacite® Date: April 28, 2005
2004 SARA Title III Report Page No. 24 of 33
_ (0.030) + 0.0090 0.0143 2.57 8760
= 125.6 lbs. / year
C. Storage Tank
1. Liquid Flanges / Valves
Leak Rate = ( liquid valve losses + flange losses) ( weight fraction
BA) ( total operating hours )
= [2(0.016) + (8)(0.0018)](1.0)(8760)
= [0.032 + 0.014](1)(8760)
= 406 lbs. / year
2. Vapor Flanges / Conservation Vents
Leak Rate = ( C / V losses + vapor flange losses) ( weight fraction
BA) ( total operating hours )
_ [(2)(0.224) + (12)(0.0018)](0.143) (2.57)(8760)
_ [0.448 + 0.0216 0.143 2.57 8760
= 1511 lbs. / year
3. Total Leak Rate
= 406 + 1511 = 19171bs. / year
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DEQ-CFW 00087850