DEQ-CFW_00088452

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DEQ-CFW 00088452

Form D: Process Information (Page 1 of 2) Facility ID# 0900009
•
•
North Carolina Department of Environment and Natural Resources
Division of Air Quality
1998 Annual Air Pollutant Emissions Inventory
1. Source ID No(s): NS-11 (NS- H in Title V)
2. Permit Item No(s): 3(a)
3. Process Description: "Nafion" Resin Membrane Treatment Process
4. Operational Schedule:
Hour per
Day
Day per
Week
5. Start Hour of Process: Semi -continuous
6. Percentage Annual Throughput:
Dec -Feb 25
Mar -May 25
Weeks per
Year
June -Aug 25
7. Maximum Process 8. Annual Process
Rate per Hour: (ex: Throughput:
gal/hr, mmcf/hr) CONFIDENTIAL (ex: lb/yr, gal/yr)
include units
9. Capture Efficiency (% of Process Emissions Vented Through Control Device): n/a
10. Control Device Descriptions Primary None
Secondary
11. Combined Control Device Efficiency (%): n/a
Hours per CONF.
Year
Sept -Nov 25
CONFIDENTIAL
12. ANNUAL FUEL USAGE (e.g. Coal, oil, wood, natural gas, etc.) - Use additional sheets if necessary
include units
DEQ-CFW 00088453

Form D: Process Information (Page 2 of 2) Facility ID# 0900009
Source ID # NS-11
•
Actual Emissions per Pollutant Listed for Source Described Above:
Attach calculations and documentation of emission factors or other estimation methods used.
Per Ton" Pollutant:
TSP
PM-10
SO2
NOx
VOC
CO
n/a
Actual Emissions: Tons/year
7.74
***All Other HAPs/TAPs as listedinAppendix C or Appendix D (use additional sheets if necessary)***
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Chlorine
7782-50-5
Fluorine
7782-41-4
Hydrazine
302-01-2
Hydrogen Chloride
7647-01-0
Hydrogen Fluoride
7664-39-3
48.8
Hydrogen Sulfide
7783-06-4
Lead Compounds
LEADCPDS
Methyl Chloroform
71-55-6
Methylene Chloride
75-09-2
Ozone
10028-15-6
Perch Ioroethylene
127-18-4
Phosphine
7803-51-2
Acetic Acid
64-19-7
41.5 Ibs
Information on Page 2 of Form D cannot be held confidential.
DEQ-CFW 00088454

1998 Nafion Products Air Emissions
i Jim Lisi
11
Nafion Resin Membrane Treatment Process
NS-11
Operational Schedule
Nafion Film Extrusion and Hydrolysis operational schedule (hours per year) is
obtained from the NICS system with the help of Molly Meadowcroft. The operational
schedule for the Membrane Treatment Process is calculated as the combined hours of
operation of the extrusion and hydrolysis processes.
Maximum Process Rate
The maximum process rate is calculated from the multiplying the maximum film
thickness by the film speed and maximum die width to yield a maximum volumetric rate
of film on the extruder line. This is converted to kg/hr by multiplying by the conversion
factor 0.00136144 which includes the density of the film.
Annual Process Throu"hput
The annual process throughput is equivalent to the total polymer resin consumed
annually during the film extrusion process. This is calculated as the weight of XR, SR
and CR Resin consumed during the year. XR, SR and CR consumption information is
obtained from John Clark. He uses cost sheets 051135, 051136 and 051145 and excludes
resin which is shipped offsite.
DMSO Emissions
DMSO Emission is calculated as the amount of DMSO consumed in the
Hydrolysis Area subtracting the DMSO shipped offsite as waste. DMSO consumption is
estimated as
DMSO drums received + DMSO drums Jan I" — DMSO drums Dec 31Sc
DMSO drums received and DMSO drum inventory information is obtained from Brenda
Streble. DMSO shipped as waste is calculated by multiplying the total waste shipped
from the waste shipping tank by the DMSO wt% in the waste solution. The total waste
shipped is obtained from Catherine Bass. The DMSO content of the waste is estimated as
11 % DMSO.
Acetic Acid Emissions
Acetic Acid Emissions are calculated as the surface treatment run time multiplied
by the acetic acid emission rate during the surface treatment process. Production surface
treatment run time is based on process line speed and membrane roll length.
DEQ-CFW 00088455

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Additionally, 12 hours is added to each surface treatment run, representing process start-
up. The emission rate is based on filed test conduct by Lee Ann Kessler in 1996.
Nitric Acid Emissions
Field tests conducted in 1996 indicate that Nitric Acid solution used in Hydrolysis
(14 wt% and ambient temperature process conditions) yield negligible emissions over the
course of the year.
Dieftlene Glycol (DEG) Emissions
Due to the low vapor pressure of DEG (1 mmHg @ 91.8'C), the ambient process
temperature, and the 30 wt % DEG operating condition, the air emissions for DEG are
negligible.
HF Emissions
HF emissions are based on formation during the extrusion process. The
calculations for HF formed at 200'C and 300'C are based on tests conducted by D. E.
Curtin. This information is documented in a letter to Gerry Mozena, dated 21-Jun-1991.
The letter is located in Nafion Files, Folder 5704 (Located in Mary Phillips office.) Since
films are extruded from resin process at 275'C, the HF formation at this temperature has
been estimated by interpolating from the data at 200'C and 300'C. The HF formed is
calculated as the estimated HF formation rate (@275'C) multiplied by the resins
processed in film extrusion over the past year. The HF formed for each resin is added to
yield the total annual HF Emissions.
VOC Emissions
Annual VOC Emissions are calculated as the added DMSO and Acetic Acid
Emissions for the year. Nitric acid and DEG are not included as their emissions are
negligible.
DEQ-CFW 00088456