DEQ-CFW_00088171

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DEQ-CFW 00088171

Form D: Process Information (Page 1 of 2) Facility ID# 0900009
North Carolina Department of Environment and Natural Resources
Division of Air Quality
Calendar 2000 Air Pollutant Point Source Emissions Inventory
1. Source ID No. (same as in permit) BS-7 (Insig-B8 in Title V)
2. Process Description: Butacite® Extruder Vacuum System
4. Maximum Process Rate: 4. CY 2000 Process Throughput:
(Ex: gaUhr, mmcf/hr) Confidential (Ex: lb, gal) Confidential
include units include units
5. Normal Operating Schedule:
Hours per Days per Weeks Hours per
Day Week per Year Year Confidential
6. Typical Start & End Times For Process: Start: Continuous End:
7. Percentage Annual Throughput:
Dec -Feb 25 Mar -May 25 June -Aug 25 Sept -Nov 25
8. Capture Efficiency (% of Emissions from this Process Vented Through Control Device): 100%
9. Control Device Descriptions Primary Venturi Condenser BCD-7
Secondary:
10. Combined (Net) Control Device Efficiency (%): PM
(Control efficiency is pollutant -specific)
PM-10
PM-2.5
SO2
NOx
VOC 74%
11. ANNUAL FUEL USAGE For This Process (Coal. oil. wood. natural gas. etc.) -Use additional sheets as needed.
Type of Fuel Used in This Process/Source Amount (gal, tons, mmcf/year) % Sulfur % Ash
If you do not provide annual throughput your inventory will be deemed incomplete and returned to you
0 To review instructions or get a new copy, go to web page: httv://dag.state.nc.us/OtTices/Planninp-/Attainment/est.html or
httn://daa.state.nc.us/Offices/Planninp-/Attainment/1999/99forms.html
DEQ-CFW 00088172

Form D: Process Information (Page 2 of 2)
CY 2000 Facility ID# 0900009 Source ED# BS-7
Alctual Emissions aer Pollutant Listed for Source/Process Identified Above:
Alik Attach calculations and documentation of emission factors or other estimation methods used.
"Per Ton" Pollutan
t:
PM
PM-10
PM-2.5
S02
NOx
VOC
CO
Actual Emissions: Tons/year
0.24
***All Other HAPs/TAPs Per Instructions (use additional sheets if necessary)***
Pollutant
CAS #
Emitted
lbs./ r.
Comments
Chlorine
7782-50-5
Fluorine
7782-41-4
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 (Not a VOC, by rule)
71-55-6
Methylene Chloride (Not a VOC, by rule)
75-09-2
Ozone (Not expected as a facility emission)
10028-15-6
Perchloroethylene (Not a VOC, by rule)
127-18-4
Phosphine
7803-51-2
List all other HAP/TAPs below IN ALPHABETICAL
ORDER, Per
Instructions. Use more sheets, as needed
E,
Information on Form D cannot be held confidential.
DEQ-CFW 00088173

•
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ENGINEERING ANALYSIS OF EMISSIONS
Emission Unit ID: Insig-B8
Emission Source Desc. Butacite Extruders
Emission Estimation Approach:
Emissions from the Butacite extruders are calculated using a mass balance approach.
Based on the vapor pressure exerted by organic material in the extruder and the flow rate out
of the extruder, material flowrates throughout the entire extruder process are calculated.
There are a total of 6 extruders in the extruder operation.
The extruder process consists of the extruder unit followed by a knock -out pot, and the
steam jet vacuum system (see attached flowchart). Material flowrates into and out of each of these
process steps are calculated below.
General Steps for Quantifying Emissions:
The primary purpose of the extruders is to remove water from the extruder feed material. This is
accomplished by heating the feed material and operating the extruders under vacuum conditions.
Vacuum is pulled on the extruder by a 2-stage steam jet vacuum system. The vacuum jet system
consists of a 1st condenser followed by the 1st vacuum jet, 2nd condenser, 2nd vacuum jet, and
lastly a final condenser. The purpose of the first condenser is to remove condensable substances
so as to maximize efficiency of the steam jet. The purpose of the 2nd condenser is to condense
steam injected into the 1 st vacuum jet in order to maximize efficiency of the 2nd vacuum jet. The
purpose of the final condenser is to condense the steam that is injected into the 2nd vacuum jet.
The general steps for quantifying emissions are as follows:
STEP 1: Estimate VOC's vented from the extruder unit based on water and noncondensables that are
vented, total system pressure, and approximate vapor pressure of organics.
STEP 2: Calculate amount of VOC that passes through the first condenser based on temperature out
of the first condenser, noncondensable flow, and system pressure.
STEP 3: Calculate amount of VOC that passes through the second condenser based on temperature
of the second condenser, noncondensable flow, and system pressure.
STEP 4: Calculate amount of VOC that passes through the final condenser based on temperature
of the final condenser, noncondensable flow, and pressure which will be at atmospheric.
For Steps 1 and 2, VOC flowrates are calculated on a per extruder basis. For Steps 3 and 4, VOC
flowrates are calculated per extruder and for all six extruders combined.
BS•7.x1s. nonconf 06/08/2001 Page 1 of 5
DEQ-CFW 00088174

FNr,INFFRING ANAI YSIS OF EMISSIONS
4P Emission Unit ID: Insig-B8
Emission Source Desc. Butacite Extruders
STEP 1: VOC's vented from extruder:
Mass in extruder off -gas (excluding organics):
Water 175.5 Ibs/hr Equals Total Feed times water fraction removed (CONFID)
Noncondensables 20 Ibs/hr Based on vacuum jet performance curves
Moles in extruder off -gas (excluding organics):
Water
9.75 lb-moles/hr
Based on 18 pounds per lb -mole
Noncondensables
0.71 lb-moles/hr
Based on 28 pounds per lb -mole
TOTAL:
10.46 lb-moles/h r
Mole fraction of organics:
VOC
0.56%
Calculated as vapor pressure of organics
(0.5 mmHg) divided by sys. pressure (90 mmHg)
Thus, total moles:
10.52 lb-moles/hr
Calculated as moles in offgas (excluding org.)
divided by 1 minus VOC mole fraction
Moles VOC:
0.058 lb-moles/hr
Calculated as total moles minus moles
excluding organics
Mass VOC
24.44 lb/hour
Calculated as moles VOC times plasticizer
molecular weight (it is assumed all VOC is
plasticizer).
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06/08/2001
Page 3 of 5
DEQ-CFW 00088175

•
Emission Unit ID:
Emission Source Desc
ENGINEERING ANALYSIS OF EMISSIONS
Insig-B8
Butacite Extruders
Process Parameters Used in the Calculations:
Total Feed:
Fraction Water in Feed:
Fraction Water in Output Stream:
System Pressure up to the first vacuum jet:
Avg. Ext. Vap. Space Temp.
Organic Vapor Pressure @ 150 deg. C'
Condenser Outlet Temperatures
Organic Vapor Pressure @ 35 deg. C'
System Pressure between 1 st and 2nd jets:
Noncondensable flow through system:
Water vapor pressure @ 35 deg. C
Plasticizer Molecular Weight
CONFIDENTIAL Ibs/hr per extruder
CONFIDENTIAL
CONFIDENTIAL
90 mmHg
150 degrees Celsius
0.5 mmHg
35 degrees Celsius
0.05 mmHg
225 mmHg
20 Ibs/hour
42.2 mmHg
418 lb/lb-mole
' The vapor pressure is based on a plasticizer which is added to the polyvinyl butyral (PVB)
product. This plasticizer is called "4G7" and is tetra ethylene glycol di-heptanoate and has a
molecular weight of 418 Ib/Ib-mole. The Butacite product contains approximately 28% 4G7.
As is normally the case for compounds with high molecular weights, 4G7 has a very low vapor
pressure. According to the MSDS, the vapor pressure of 4G7 is 0.5 mmHg at 200 deg. C
and less than 0.01 mmHg at ambient conditions. Other materials are added to PVB to give
it various properties; however all of these materials have negligible vapor pressures and are
added in very small amounts (0..1 % or less). Nevertheless, to be conservative and to account
for overall organic vapor pressure, it is assumed that the organics exert a pressure of 0.5 mmHg
at 150 degrees C (this is equal to the vapor pressure of 4G7 at 200 degrees C and allows for some
pressure to be exerted by trace constituents) and 0.05 mmHg at 35 degrees C (this accounts
for the fact that the vapor pressure of 4G7 which is less than 0.01 mmHg at ambient conditions
will be slightly higher at 35 degrees C and also allows for some pressure to be exerted by trace
constituents). These vapor pressure values are conservative because it is expected that they
overestimate actual vapor pressures primarily because they do not account for mole fractions in the
extruder feed (i.e. Raoult's Law), and furthermore, they do not account for molecular level interactions
that resist volatilization (this is why all of the water is not removed even though the extruders
operate in excess of the atmospheric boiling point temperature of water and under vacuum).
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06/08/2001
Page 2 of 5
DEQ-CFW 00088176

ENGINEERING ANALYSIS OF EMISSIONS
Emission Unit ID: i -B Ins g 8
Emission Source Desc. Butacite Extruders
STEP 2: VOC's aassina through the first condenser:
Note: Much of the VOC in the extruder off -gas is expected to be captured in the knock -out pot.
However, for the purposes of these calculations, it is assumed that all of the VOC enters into
the 1 st condenser.
All of the noncondensables pass through the first condenser. Most of the water and most of the
VOC are condensed. The vapor pressure of water and VOC at the condenser outlet are used
to calculate their overall mole fraction. Based on this and the known moles of noncondensables
passing through the condenser, the mass of VOC and water passing through the condenser is
calculated.
Mole fraction of Water 46.89% mole fraction
•
Mole fraction of VOC 0.056%
Mole fraction of 53.06% mole fraction
noncondensables
Total Moles 1.346 lb-moles/hr
Mass of VOC in 0.313 lb/hour
condenser outlet
Calculated as water vapor pressure (42.2 mmHg)
divided by system pressure (90 mmHg)
Calculated as VOC vapor pressure (0.05 mmHg)
divided by system pressure (90 mmHg)
Calculated as 1 minus mole fraction of water and VOC
Calculated as lb -moles of noncondensables (0.71 lb/moles
per hour) divided by noncondensable mole fraction.
Calculated as mole fraction of VOC (0.056%) times total
moles (1.346) times molecular weight (418).
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DEQ-CFW 00088177

0 ENGINEERING ANALYSIS OF EMISSIONS
Emission Unit ID: Insig-B8
Emission Source Desc. Butacite Extruders
Pi
STEP 3: VOC's passing through the second condenser:
In general the same approach used in Step 2 is applied here with the only difference being that the
system pressure is slightly higher which results in a slightly lower VOC mole fraction.
Mole fraction of Water 18.76% mole fraction Calculated as water vapor pressure (42.2 mmHg)
divided by system pressure (225 mmHg)
Mole fraction of VOC 0.022% Calculated as VOC vapor pressure (0.05 mmHg)
divided by system pressure (225 mmHg)
Mole fraction of 81.22% mole fraction Calculated as 1 minus mole fraction of water and VOC
noncondensables
Total Moles 0.879 lb-moles/hr Calculated as lb -moles of noncondensables (0.71 lb/moles
per hour) divided by noncondensable mole fraction.
Mass of VOC in 0.082 lb/hour per Calculated as mole fraction of VOC (0.022%) times total
condenser outlet extruder moles (0.879) times molecular weight (418).
Total Potential Emis. 4,294 lb/year Calculated as 0.082 Ib/hr per extruder times 6 extruders
before final cond. times 8,760 hours per year.
STEP 4: VOC's passing through the final condenser:
In general the same approach used in Steps 2 and 3 is applied here with the only difference being that
the system pressure is atmospheric at the condenser outlet which results in a lower VOC mole fraction.
Mole fraction of Water
Mole fraction of VOC
Mole fraction of
noncondensables
Total Moles
Mass of VOC in
condenser outlet
Total Extruder
Potential Emissions
5.55% mole fraction Calculated as water vapor pressure (42.2 mmHg)
divided by system pressure (760 mmHg - atmospheric)
0.0066% Calculated as VOC vapor pressure (0.05 mmHg)
divided by system pressure (760 mmHg)
94.44% mole fraction Calculated as 1 minus mole fraction of water and VOC
0.756 lb-moles/hr Calculated as lb -moles of noncondensables (0.71 lb/moles
per hour) divided by noncondensable mole fraction.
0.021 lb/hour per Calculated as mole fraction of VOC (0.0066%) times total
extruder moles (0.756) times molecular weight (418).
1,093 lb/year Calculated as 0.021 Ib/hr per extruder times 6 extruders
times 8,760 hours per year.
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DEQ-CFW 00088178